GOLD CGa Gas-Fired Water Boiler — Boiler Manual How it works . . . Control module Transformer Draft hood Spill switch Water temperature limit switch Boiler circulator NOTE Vent damper Other boiler components: Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual GOLD CGa Gas-Fired Water Boiler Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Contents How is works ............ 2-3 Hazard definitions ..........4 Please read before proceeding ......5 Prepare boiler location ........6–11 Prepare boiler ..........12-15 Water pi ping ..........16-25 Gas pi ping ............26 Field wiring ............
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User stalling page 68 When servicing boiler — Boiler operation — Glycol — potential fire hazard — Boiler water — Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — codes & checklist Installations must follow these codes: Before locating the boiler, check the following: Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances Required MINIMUM clearances located on the wall or door opposite the boiler FRONT (see Figure 1b) Foundation Minimum foundation width: CGa-25/3 12" CGa-6 21" CGa-4 15" CGa-7 24"...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — vent system When removing boiler from an Chimney or vent require- existing common vent system: ments Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air contamination — OR — Corrosive contaminants and likely locations Products to avoid Areas likely to have contaminants Spray cans containing chloro/fluorocarbons Dry cleaning/laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes/cleaners Metal fabrication plants...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings Air openings must be provided Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Unusually tight construction FREE AREA Single air opening option Clearances from boiler to walls Exhaust fans and air movers Opening must be directly to outside Opening placement Opening size Motorized air dampers Exception for large spaces Part Number 550-101-009/0107...
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Location Propane gas 0-2,000 ft over 2,000 ft U. S. 1.30 mm (Note 1) Canada 0-2,000 ft 2,000-4,500 1.30 mm 1.20 mm Note 1: For elevations above 2,000 feet, contact your local Weil-McLain sales office for details. Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test Prepare boiler for test Drain and remove fittings Fill and pressure test Part Number 550-101-009/0107...
General piping information Circulator System water piping Pressure/temperature gauge Relief valve Table 3 Water pipe size (based on 20°F rise) Boiler model From system system CGa-25 ¾" ¾" CGa-3, 4, 5 1" 1" 1 ¼" 1 ¼" CGa-6, 7 CGa-8 1 ½"...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — single-zone system Diaphragm-type or bladder- Closed-type expansion tank type expansion tank (Figure 9) (Figure 10) Diaphragm- or bladder-type expansion Closed-type expansion tank — Single- tank — Single-zone system using dia- zone system using closed-type expan- phragm-type or bladder-type expansion sion tank.
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones Piping multiple zones Piping for radiant heating systems or converted gravity systems Converted gravity (or steam) systems Zoning with circulators (Figure 11) (return temp over 130°F) Zoning with zone valves (Figure 12) (return temp over 130°F) Radiant heating systems Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones (continued) Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems Primary/secondary (preferred) Bypass piping method Figures 13 Valve adjustment (Figures 13 and 14 on ly) Temperature gauges DO NOT Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) DO NOT Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) BOILER-bypass piping method Valve adjustment Temperature gauges DO NOT Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) DO NOT Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) SYSTEM-bypass piping method Valve adjustment DO NOT Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Water piping — refrigeration systems Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Gas piping Connect gas supply piping to boiler Natural Gas: Propane Gas: Table 4 Pipe capacity for 0.60 specific gravity natural gas Gas supply piping Capacity of pipe for pipe size of: Gas pipe (Capacity in cubic feet gas per hour) length...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Check for gas leaks Determine if water treatment is needed Verify water chemistry Freeze protection (when used) Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — preparation (continued) Fill the system with water Inspect system water piping drain valves Inspect base insulation Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler Lighting/Operating instruction location guide Models Standing pilot Page Spark-ignited pilot Page CGa-25 CGa-6 CGa-7 CGa-8 Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) Start the boiler Check system and boiler Start-up — if boiler doesn’t start . . . Check for: ing , Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — verify operation Check burner flames Typical pilot burner flame Pilot burner flame PROPER pilot flame IMPROPER pilot flame Main burner flame Typical main burner flame PROPER main burner flame IMPROPER main burner flame: Check vent damper operation Check vent system operation Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist 3600 x 1000 = Btuh number of seconds from step c Installation and service certificate Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — standing pilot boilers Figure 23 Wiring diagram — Standing pilot system Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Lighting instructions CGa-25 to CGa-8 Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Lighting instructions CGa-25 to CGa-8 Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot boilers Figure 24 Ignition control module sequence of operation — status light indications Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25a Schematic wiring diagram — Spark-ignited pilot system Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25b Ladder wiring diagram — Spark-ignited pilot system Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-8 Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-6 Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-6 Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-7 to CGa-8 Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING Service and maintenance schedules (service technician and user) Service technician Owner maintenance (see following pages for instructions) (see CGa User’s Information Manual for instructions) Inspect: Daily Monthly...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance — annual start-up inspected and started annu- ally only by a qualified service technician Table 6 Air openings Eliminate all system or boiler leaks. Flue gas vent system petroleum-based cleaning or sealing compounds Turn off power to the boiler before any service operation...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Inspect . . . Boiler heating surfaces Service . . . Oiled-bearing circulators Start-up . . . Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Check/test Expansion tank Gas piping Cold fill and operating pressures Tank-Trol Taco-Trol Air vents and air elimination Automatic air vent, typical Limit controls and cutoffs Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Check/test (continued) Boiler relief valve Relief valve, typical valve Review with owner Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Cleaning boiler heating surfaces Troubleshooting — procedure Before troubleshooting: Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure (continued) Check the following: In event of vent damper failure: Effikal or Field Controls damper Part Number 550-101-009/0107...
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — standing pilot boilers CHART 1 Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers Control module Solder or water ground wiring Control indicator lights — LOCKOUT modes Charts 1 POWER light flashing alone POWER and TSTAT CIRC lights flashing POWER and DAMPER lights flashing POWER and FLAME lights flashing Control indicator lights —...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 2 Is POWER light off? Is POWER light... Does voltmeter indicate 120 VAC? Does voltmeter indicate 120 VAC? Is POWER light flashing now? Does voltmeter indicate 120 VAC? Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 3 Did you find a voltage across the two external thermostat circuit wires? Do the lights still flash? Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 4 Does vent damper operate? Does vent damper operate? Figure 30, Item 6, page 53 light flashing? Does the voltmeter indicate 24 VAC? Does vent damper actuator indicator show damper is open? Are the...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 5 Are manual main shutoff valve and gas valve open? lights still flash? Is pilot burning? lights flashing? lights flashing? Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 6 Is 24 VAC present there? Does light flash now? Is 24 VAC present there? Is gas present at gas valve inlet and within above range? Is gas present at gas valve inlet and within above range? Figure 30, item 8, page 53 Figure 30, item 8, page 53...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 7 Is boiler System circulator operating? Figure 30, Item 7, page 53 Is thermostat circuit closed (continuity across wires)? Does voltmeter show 120 VAC across pins? light on? light on? Is vent or combustion air piping free of blockage?
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts Section assembly ..........61 Base ..............62 Jacket ............... 63 Trim ..............64 Controls ............65 Part Number 550-101-009/0107...
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311-103-830 High limit, 30° Honeywell 510-312-250 differential, with well L4080D1036 End section, right hand, 51128 311-103-821 White-Rodgers Intermediate section, 51125 311-103-818 11B81-3 Replacement section CGa-25 & CGa-3 321-114-345 Draft hood CGa-25 450-021-240 shown assembly CGa-4 321-114-346 CGa-3 450-021-241 CGa-5 321-114-347...
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Replacement parts — base Base assembly, manifold, orifices and burners Item Description Weil-McLain number part number Base assembly kit CGa-25 381-354-355 (includes base panels items 1, 2, CGa-3 381-354-356 3, 4, 5, 6, and 7, plus insulation, CGa-4 381-354-357 air box gaskets, and hardware)
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Jacket panel, side, with insula- top front Natural Gas Propane Gas Natural Gas tion Standing Pilot Standing Pilot Spark Pilot Boiler Boiler Model Weil-McLain part number Model CGa-25 (Available at local 381-355-400 381-355-445 381-355-466 381-355-699 381-355-403 CGa-25 CGa-3 supply house) 381-355-407...
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1107-2 511-330-079 Control transformer 511-842-370 not shown Wiring harness, controls to control module 591-391-905 Pilot gas pressure regulator — Natural gas and propane gas, CGa-25 and CGa-3 not shown Pilot gas pressure regulator 4.0" w.c. outlet Maxitrol RV-12 510-933-126 SL-50N...
(inches NPT) (inches NPT) (Note 3) location diameter width height (inches NPT) (inches) (inches) (inches) (inches) CGa-25 CGa-3 CGa-4 CGa-5 CGa-6 CGa-7 CGa-8 Note 3: Size gas piping from meter to boiler per local utility requirements. Part Number 550-101-009/0107...
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS INSTALLATION OF FIBERGLASS WOOL, COMBUSTION CHAMBER LINING OR BASE PANELS: Precautionary measures Precautionary measures NIOSH stated First Aid.
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