Weil-McLain GOLD CGa Installation And Maintenance Manual
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Weil-McLain GOLD CGa Installation And Maintenance Manual

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  • Page 2: Please Read Before Proceeding

    Boiler Manual Please read before proceeding Installer User • Read all instructions before This manual is for use only by your qualified Follow all instructions in installing. heating installer/service technician. proper order to prevent personal • Please refer to the User’s Information Manual injury or death.

  • Page 4: How It Works

    GOLD CGa Gas-Fired Water Boiler How it works . . . ① Control module The control module (used on ) responds to signals from the room thermostat and spark-ignited pilot boilers boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and vent damper. When room thermostat calls for heat, the control module starts the system circulator and activates the vent damper (causing it to drive open).

  • Page 5: Table Of Contents

    GOLD CGa Gas-Fired Water Boiler Contents Standing pilot Spark-ignited pilot How it works 2–3 Hazard definitions Please read before proceeding 1. Prepare boiler location 6–11 2. Prepare boiler 12–15 3. Water piping 16–25 4. Gas piping 5. Field wiring 6. Start-up 28–32 7.

  • Page 6: Prepare Boiler Location

    GOLD CGa Gas-Fired Water Boiler Prepare boiler location — codes & checklist Installations must follow these codes: • Local, state, provincial, and national codes, laws, • National Electrical Code. regulations and ordinances. • For Canada only: B149.1 or B149.2 Installation •...

  • Page 7: Flooring And Foundation

    Boiler Manual Prepare boiler location — clearances Flooring and foundation Service clearances Flooring 1. Provide the following clearances for cleaning and servicing the boiler and for access to controls and The CGa boiler is approved for installation on components: combustible flooring, but must never be installed on carpeting.

  • Page 8: Vent System

    Test for spillage for condensation to occur. Condensation can 5 minutes of main burner operation. Use the flame damage a masonry chimney. Weil-McLain of a match or candle. recommends the following to prevent possible f. After it has been determined that each appliance damage.
  • Page 9 Boiler Manual Prepare boiler location — air contamination Please review the following information on potential Refer to for products and areas which may cause Table 1 combustion air contamination problems. contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler.

  • Page 10: Air Openings

    GOLD CGa Gas-Fired Water Boiler Prepare boiler location — air openings ir directly from outside to boiler room Combustion air and ventilation openings must comply with Section 5.3, Air for Combustion and Ventilation, of National Fuel Gas Code ANSI Z223.1-latest edition, or applicable local building codes.
  • Page 11 Boiler Manual Special considerations Figure 4 Air from outdoors — vertical ducts Outside or ventilated attic Tight construction Each opening free area = ANSI Z223.1 defines unusually tight construction 1 sq. inch per 4,000 Btuh where: boiler a. Walls and ceilings exposed to the outside Other atmosphere have a continuous water vapor retarder appliances...

  • Page 12: Prepare Boiler

    2.00 mm (Note 1) 1.30 mm (Note 1) 0-2,000 ft 2,000-4,500 0-2,000 ft 2,000-4,500 Canada 2.00 mm 1.90 mm 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 550-110-593/1099...

  • Page 13: Perform Hydrostatic Pressure Test

    Boiler Manual Prepare boiler — pressure test Perform hydrostatic pressure test 3. When water flows from shutoff valves, close boiler drain valve. Pressure test boiler attaching water or gas piping before or electrical supply (except as noted below). 4. Close shutoff valves. 5.
  • Page 14 GOLD CGa Gas-Fired Water Boiler Prepare boiler — draft hood & spill switch Draft hood installation Spill switch installation 1. Secure draft hood to outlet at top of boiler with sheet 1. Fasten spill switch to draft hood as shown in metal screws.
  • Page 15 Boiler Manual Prepare boiler — vent damper installation These systems are used on gas-fired boilers with vent dampers as shipped from factory. Boiler will not operate without vent damper installed. Only vent dampers listed in the parts list on page 61 are certified for use with CGa boilers. Any Replacement other vent damper installed could cause severe personal injury or death.

  • Page 16: Water Piping

    GOLD CGa Gas-Fired Water Boiler Water piping — general information General piping information Circulator If installation is to comply with ASME or Canadian requirements, an The circulator is shipped loose (wiring pre-attached to additional is needed. Install control in supply piping high temperature limit boiler) to allow you to locate it either in the return or between boiler and isolation valve.

  • Page 17: Expansion Tank

    Boiler Manual Water piping — single-zone system Expansion tank Closed-type expansion tank — Figure 10 Diaphragm-type or bladder-type expansion tank — Figure 9 1. Ensure expansion tank size will handle boiler and system water volume and temperature. See tank 1. Ensure expansion tank size will handle boiler and manufacturer’s instructions for details.
  • Page 18 130 °F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 19 Boiler Manual Typical piping — multiple-zone installations Figure 11 Figure 12 Zoning with circulators Zoning with zone valves — return water 130 °F or higher. — return water 130 °F or higher. ZONE 2 ZONE 2 ZONE 1 ZONE 1 Alternate circulator location...
  • Page 20 Contact your temperature no less than 130 °F Weil-McLain representative for suggested piping and control methods. Failure to to the boiler could cause corrosion damage prevent cold return water temperature to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 21 Boiler Manual Primary/secondary (preferred) piping — for radiant heating or converted gravity systems Figure 13 Figure 14 Zoning with circulators Zoning with zone valves ZONE 2 ZONE 2 ZONE 1 ZONE 1 12" 12" MAX. MAX. Alternate circulator location Alternate circulator location Cold...
  • Page 22 Contact your temperature no less than 130 °F Weil-McLain representative for suggested piping and control methods. Failure to to the boiler could cause corrosion damage prevent cold return water temperature to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 23 Boiler Manual Boiler-bypass (alternate) piping — for radiant heating or converted gravity systems Figure 15 Boiler-bypass piping Figure 16 Boiler-bypass piping Zoning with circulators Zoning with zone valves (Alternative to primary/secondary piping (Alternative to primary/secondary piping Figures 13 and 14) Figures 13 and 14) ZONE 2 ZONE 2...
  • Page 24 Contact your temperature no less than 130 °F Weil-McLain representative for suggested piping and control methods. Failure to to the boiler could cause corrosion damage prevent cold return water temperature to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 25 Boiler Manual System-bypass piping — alternate) for converted gravity (or steam) systems From system To system Figure 17 System-bypass piping Zoning with zone valve or circulators, return water 130 °F or higher. (Alternative to boiler-bypass piping Figures Alternate 15 and 16) circulator location System or zone circulator...

  • Page 26: Gas Piping

    GOLD CGa Gas-Fired Water Boiler Gas piping Connecting gas supply piping to boiler Natural Gas: 1. Refer to for pipe length and diameter. Base Table 4 1. Remove jacket front panel and refer to to pipe gas to boiler. Figure 19 on rated boiler input (divide by 1,000 to obtain cubic at inlet of gas connection to boiler.

  • Page 27: Field Wiring

    Boiler Manual Field wiring Thermostat For your safety, turn off electrical power supply at service entrance panel before making any electrical 1. Connect thermostat as shown on wiring diagram to avoid possible electric shock hazard. connections on boiler. Failure to do so can cause severe personal injury or 2.

  • Page 28: Check For Gas Leaks

    GOLD CGa Gas-Fired Water Boiler Start-up — preparation Check for gas leaks Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if there is any indication of a gas leak.
  • Page 29 Boiler Manual Fill the system with water 1. Close manual and automatic and boiler drain cock. air vents Correct pressure will vary with each application. Typical Fill to correct system pressure. cold water fill pressure for a residential system is 12 psi. from system: Purge air a.
  • Page 30 GOLD CGa Gas-Fired Water Boiler Start-up — preparation continued Inspect base insulation The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on of this manual. Failure page 68 to comply could result in severe personal injury. damaged insulation or reposition insulation can result Failure to replace in a fire hazard, causing severe personal injury, death or substantial property...

  • Page 31: Start The Boiler

    Boiler Manual Start-up — operate boiler continued Start the boiler • Follow the from , page 30). (The lighting instruction label on the Lighting/Operating Instructions to start the boiler. Remove boiler boiler provides the same information.) Section 8 or 9 jacket door and note the gas valve manufacturer and model number.

  • Page 32: Start-Up

    GOLD CGa Gas-Fired Water Boiler Start-up — verify operation The boiler model suffix will be “ ”. For spark-ignited Figure 21 Typical pilot burner flame pilot boilers (suffix “ ”), see Section 8 operation and lighting/operating information. Inner Spark cone electrode Check burner flames Pilot burner flame...

  • Page 33: Check-Out Procedure

    Boiler Manual Check-out procedure — checklist ❏ Boiler and heat distribution units filled with water? Open manual main shutoff gas valve. Manometer should confirm there is no gas flow. Pilot will relight, ❏ Automatic air vent, if used, open one full turn? flame sensing element will sense pilot flame and main ❏...

  • Page 34: Operation

    EMCS INSTALLATION/OPERATING MANUAL. Standing Pilot 6. L.W.C.O., ADDITIONAL HIGH LIMIT, ETC., WIRED IN SERIES. A United Dominion Company DENOTES FIELD INSTALLED CHASSIS GROUND. Natural Or Propane Gas Weil-McLain 500 Blaine St. Michigan City, IN 46360-2388 25 thru 8 Forced Hot Water 550-225-009/0999...

  • Page 35: Lighting Instructions

    Boiler Manual Lighting instructions — CGa-25 to CGa-8 • Standing pilot • Gas valve manufacturer — Honeywell • Gas valve model(s) — VR8200/VR8300 • Natural/Propane gas FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

  • Page 36: Natural Gas

    GOLD CGa Gas-Fired Water Boiler Lighting instructions — CGa-25 to CGa-8 • Standing pilot • Gas valve manufacturer — Robertshaw • Gas valve model(s) — 7200 • Natural gas FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

  • Page 37: Operation

    Boiler Manual Operation — spark-ignited pilot boilers Follow all procedures given in this manual and operating is closed and spark generator is turned off. Control instructions when operating the boiler. Failure to do so module waits 5 minutes, then attempts to ignite could result in severe personal injury, death or pilot again.
  • Page 38 GOLD CGa Gas-Fired Water Boiler Operation — spark-ignited pilot system continued Figure 25a Schematic wiring diagram — Spark-ignited pilot system 120 VAC — Neutral THERMOSTAT THERMOSTAT • The control module is polarity-sensitive to the incoming 120 VAC power. If polarity is reversed, FIELD SERVICE control will flash the...
  • Page 39 Boiler Manual Figure 25b Ladder wiring diagram — Spark-ignited pilot system Neutral Electrical shock hazard — can cause severe injury or death. Disconnect 120 VAC SERVICE power before installing or servicing. SWITCH Legend for ladder wiring diagram 120 VAC field wiring Low voltage field wiring CONTROL HIGH...

  • Page 40: For Your Safety Read Before Operating

    GOLD CGa Gas-Fired Water Boiler Operating instructions — CGa-25 to CGa-8 • Spark pilot • Gas valve manufacturer — Honeywell • Gas valve model(s) — VR8204/VR8304 • Natural gas FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 41 Boiler Manual Operating instructions — CGa-25 to CGa-6 • Spark pilot • Gas valve manufacturer — Robertshaw • Gas valve model(s) — 7200 • Natural gas FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 42 GOLD CGa Gas-Fired Water Boiler Operating instructions — CGa-25 to CGa-6 • Spark pilot • Gas valve manufacturer — White-Rodgers • Gas valve model(s) — 36E • Natural gas FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 43 Boiler Manual Operating instructions — CGa-7 to CGa-8 • Spark pilot • Gas valve manufacturer — White-Rodgers • Gas valve model(s) — 36C • Natural gas FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

  • Page 44: Service And Maintenance

    GOLD CGa Gas-Fired Water Boiler Service and maintenance — schedule Table 6 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) • Check boiler area Inspect: •...
  • Page 45 Boiler Manual Service & maintenance — annual start-up The boiler should be , at the beginning of the heating season, inspected and started annually only by a qualified . In addition, the maintenance and care of the boiler designated in and explained on the service technician Table 6...
  • Page 46 GOLD CGa Gas-Fired Water Boiler Service & maint. — annual start-up continued ❏ Inspect ..components before returning to service. 6. Check inside and around boiler for evidence of any Electrical shock hazard — Turn off power to the boiler leaks from the boiler.
  • Page 47 Boiler Manual ❏ Start-up ..1. Perform start-up procedures section , pages 28-32, , per manual sections Check gas piping including procedure to verify operation of burners verifying no indications of leakage and all piping and vent damper on page 32.
  • Page 48 GOLD CGa Gas-Fired Water Boiler Service & maint. — annual start-up continued ❏ Check/test ..that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally.

  • Page 49: Review With Owner

    Boiler Manual ❏ Review with owner ..1. Review the with the contractor should the boiler or system exhibit any User’s Information Manual owner. unusual behavior. 2. Emphasize the need to perform the maintenance 4.
  • Page 50 GOLD CGa Gas-Fired Water Boiler Troubleshooting — procedure continued 2. If step 1 does not open damper, manually rotate Check the following: damper blade to open position using wrench or pliers on flat shaft between damper and actuator. 1. Wire connectors to control module are securely Boiler will fire.
  • Page 51 Boiler Manual Troubleshooting — standing pilot boilers Chart 1 — Standing pilot — Boiler will not fire Is damper harness securely plugged in at both ends? Secure connections. Check for loose wire connections or bad relay on Is 24VAC present across transformer terminals C & Y? transformer.
  • Page 52 GOLD CGa Gas-Fired Water Boiler Troubleshooting — spark-ignited pilot boilers Control indicator lights — The information on this page and pages 53 through 59 lockout modes apply only to spark-ignited pilot CGa boilers. These boilers are equipped with an ignition control module through , pages 54-59 in this section, for Charts 2...
  • Page 53 Boiler Manual Figure 30 Control module connections Black Black 120 VAC H 120 VAC H Green Entrance ground High voltage to White pilot spark electrode Green Chassis SJO cable 120 VAC N ground to J-box 120 VAC to White transformer 120 VAC N Red wire to gas valve MV...

  • Page 54: Troubleshooting

    • Using voltmeter, check across pins of receptacle. Does voltmeter indicate 120 VAC? Have system checked by a licensed electricain. If problem persists, call your local Weil-McLain sales Boiler should now Replace transformer. Replace control module. representative. operate normally. Retest.
  • Page 55 Boiler Manual continued Chart 3 — Spark-ignited pilot — TSTAT CIRC & POWER lights flashing — Usually indicates 48 VAC on thermostat circuit (stray voltage) — ▲TURN OFF Electrical shock hazard — Wherever you see POWER▲, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 56 GOLD CGa Gas-Fired Water Boiler Troubleshooting — spark-ignited pilot boilers Chart 4 — Spark-ignited pilot — DAMPER light flashing — If POWER light is flashing: Usually indicates vent damper failed to prove open within 5 minutes — — If POWER light is steady: Usually indicates vent damper closed during run cycle —...
  • Page 57 Boiler Manual continued Chart 5 — Spark-ignited pilot — FLAME & POWER lights flashing — Usually indicates flame sensed when it shouldn't be there — ▲TURN OFF Electrical shock hazard — Wherever you see POWER▲, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 58 GOLD CGa Gas-Fired Water Boiler Troubleshooting — spark-ignited pilot boilers Chart 6 — Spark-ignited pilot — FLAME light flashing and POWER light on steady ALSO — Troubleshooting failure to establish main flame ▲TURN OFF Electrical shock hazard — Wherever you see POWER▲, follow the instructions.
  • Page 59 • Check limit switch • Replace control module. contacts with continuity • Retest. checker. • Correct conditions and Contact your Weil-McLain Are limit switch contacts recheck operation. sales representative. closed? Check spill switch and • See Figure 24, page 37 rollout switch continuity —...

  • Page 60: Replacement Parts

    Gas control assembly — standing pilot ....Gas control assembly — spark-ignited pilot ..Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size and include description and part number of replacement part. Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation.
  • Page 66 GOLD CGa Gas-Fired Water Boiler Dimensions Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES Supply piping ( note 1 6¹⁄₄ Return piping ( note 1 Do not cut or alter draft hood in any way. Relief valve, ¾" NPT Boiler combustion will be affected, causing ½"...
  • Page 67 Boiler Manual Ratings Boiler Input 0–2,000 feet 2,000–4,500 feet Boiler Chimney model (Btuh) Heating altitude altitude I=B=R water Seasonal efficiency number capacity ratings content (% A.F.U.E) breeching (Btuh) (Btuh) (gallons) size Input Output Input Output SPDN SPDL PIDN (Btuh) (Btuh) (Btuh) (Btuh) (Note 1)

  • Page 68: Handling Ceramic Fiber And Fiberglass Materials

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).": ■...

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