Weil-McLain Gold CGa User Manual

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Page 1

Page 2

Boiler Manual

Please read before proceeding

Installer

Read all instructions before installing.

proper order to prevent personal injury or death.

• Consider piping and installation when determining boiler location.

•Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

When calling or writing about the boiler— Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket. You may list the CP number in the space provided on the Installation and service certificate found on page 33.

Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage.

When servicing boiler —

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation —

• Do not block flow of combustion or ventilation air to boiler.

• Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

• Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water.

Follow all instructions in

User

• This manual is for use only by your qualified

heating installer/service technician.

• Please refer to the User’s Information Manual for your reference.

• We recommend regular service by a qualified

service technician, at least annually

and/or property may result.

• Continual fresh makeup water will reduce boiler

life. Mineral buildup in sections reduces heat transfer, overheats cast iron, and causes section failure. Addition of oxygen and other gases can cause internal corrosion. Leaks in boiler or piping must be repaired at once to prevent makeup water.

• Do not add cold water to hot boiler. Thermal

shock can cause sections to crack.

Glycol — potential fire hazard —

All glycol is flammable when exposed to high temperatures. If glycol is allowed to accumulate in or around the boiler or any other potential ignition source, a fire can develop. In order to prevent potential severe personal injury, death or substantial property damage from fire and/or structural damage:

Boiler water —

• Do not use petroleum-based cleaning or sealing compounds in boiler system. Water seal deterioration will occur, causing leakage between sections. This can result in substantial property damage.

• Do not use "homemade cures" or "boiler patent medicines". Serious damage to boiler, personnel

Part Number 550-110-593/1099 5

• Never store glycol of any kind near the boiler or any potential ignition source.

• Monitor and inspect the system and boiler regularly for leakage. Repair any leaks immediately to prevent possible accumulation of glycol.

• Never use automotive antifreeze or ethylene glycol in the system. Using these glycols can lead to hazardous leakage of glycol in the boiler system.

Page 3

Page 4

GOLD CGa Gas-Fired Water Boiler

How it works . . .

①

②

③

Control module

The control module (used on spark-ignited pilot boilers) responds to signals from the room thermostat and 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).

When the vent damper has opened completely, the control module opens the pilot valve and activates pilot ignition spark.

The control module allows up to 15 seconds to establish pilot flame. If flame is not sensed within 15 seconds, the control module will turn off the gas valve, flash the Flame light, and immediately start a new cycle. This will continue indefinitely until pilot flame is established or power is interrupted. Once pilot flame is proven, the control module opens the gas valve to allow main burner flame.

When the room thermostat is satisfied, the control module turns off the gas valve and deactivates the vent damper (causing it to close).

The control module indicator lights show normal sequence when the lights are on steady. When a problem occurs, the control module flashes combinations of lights to indicate the most likely reason for the problem. See page 52 for details.

Standing pilot boilers (controls not shown) use the pilot thermocouple to prove flame. If the thermocouple is

satisfied, the gas valve and vent damper will open on a call for heat and close afterwards.

Transformer

The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit.

Draft hood

The draft hood provides a minimum draft for the boiler, assuring adequate air for combustion if installed in accordance with manual and not modified in any way.

④

⑤

⑦

Spill switch

The spill switch will shut down the boiler (requiring manual reset of the switch reset button) if the vent system becomes blocked.

Water temperature limit switch

The water temperature limit switch turns off the gas valve if the temperature in the boiler goes above its setting. (The circulator will continue to run as long as there is a call for heat.)

Boiler circulator

The boiler circulator circulates water through the external (system) piping. The circulator is shipped loose, and can be mounted on either the boiler supply or return piping. The factory-installed circulator wiring harness provides ample length for either location. NOTE — The control module provides a pump exercising routine. If the boiler is not operated for 30 days, the control module will power the circulator for 30 seconds, then turn off.

Vent damper

The vent damper closes during off cycles to reduce heat loss from the house up the vent.

Other boiler components:

a supply to system b return from system c flue outlet d burner manifold e gas valve

f pressure/temperature gauge g relief valve h air vent connection i flame rollout switch j burner orifice

k pilot burner, typical l stainless steel burners m cast iron boiler sections n flue collector o junction box

2 Part Number 550-110-593/1099

Page 5

GOLD CGa Gas-Fired Water Boiler

Contents

Standing pilot Spark-ignited pilot

How it works 2–3

Hazard definitions 4

Please read before proceeding 5

1. Prepare boiler location 6–11

2. Prepare boiler 12–15

3. Water piping 16–25

4. Gas piping 26

5. Field wiring 27

6. Start-up 28–32

7. Check-out procedure 33

8. Operation — standing pilot boilers

9. Operation — spark-ignited pilot boilers 37–43

10. Service and maintenance 44–49

11. Troubleshooting

12. Replacement parts 60–65

13. Dimensions and ratings 66–67

34–36

49–50, 51 49–50, 51–59

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

Indicates presence of hazards that will cause severe personal injury, death or substantial property damage.

Indicates presence of hazards that can cause severe personal injury, death or substantial property damage.

Indicates presence of hazards that will or can cause minor personal injury or property damage. Indicates special instructions on installation, operation or maintenance that are important but

not related to personal injury or property damage.

4 Part Number 550-110-593/1099

Page 6

GOLD CGa Gas-Fired Water Boiler

Prepare boiler location —

codes & checklist

Installations must follow these codes:

• Local, state, provincial, and national codes, laws, regulations and ordinances.

• National Fuel Gas Code, ANSI Z223.1–latest edition.

• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

• National Electrical Code.

• For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Before locating the boiler, check the following:

• Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids.

Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

• Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

• If new boiler will replace existing boiler, check for and correct system problems, such as:

1. System leaks causing oxygen corrosion or section cracks from hard water deposits.

2. Incorrectly-sized expansion tank.

3. Lack of antifreeze in boiler water causing system and boiler to freeze and leak.

Figure 1

Minimum clearances (see page 7)

Top view

6 Part Number 550-110-593/1099

Fresh air opening

59305

Side elevation

Page 7

Boiler Manual

Prepare boiler location — clearances1b

Service clearances

1. Provide the following clearances for cleaning and servicing the boiler and for access to controls and components:

Clearance from: Minimum

Top

(for cleaning flueways)

Front

(for access to controls and components)

Back 7" Left side Right side 7"

(for cleaning and servicing)

35" 18"

24"

2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to provide at least screwdriver clearance, install unions and shutoff valves in system so boiler can be moved for servicing.

Small space installations

1. Provide the following clearances to combustible material for small space installations.

(See Figure 1, page 6):

Clearance from combustible materials (closet installations):

Top

(for cleaning flueways)

Front

(provide means of access)

Back 7" Left side Right side 2"

(provide means of access)

Minimum

35" 3"

Flooring and foundation

Flooring

The CGa boiler is approved for installation on combustible flooring, but must never be installed on carpeting.

Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage.

Foundation

1. Provide a solid brick or minimum 2-inch thick concrete foundation pad if any of the following is true:

• floor can become flooded.

• the boiler mounting area is not level.

2. The minimum foundation size is:

Boiler model

CGa-25 25" 12" CGa-3 25" 12" CGa-4 25" 15" CGa-5 25" 18" CGa-6 25" 21" CGa-7 25" 24" CGa-8 25" 27"

Minimum foundation length

Minimum foundation width

Residential garage installation

Take the following special precautions when installing

Hot water pipes must be at least ¹⁄₂" from

2. combustible material.

the boiler in a residential garage. If the boiler is located in a residential garage, per ANSI Z223.1, paragraph

5.1.9:

3. Single-wall vent pipe must be at least 6 inches from combustible material.

• Mount the boiler a minimum of

the floor

of the garage to assure the burner and

18 inches above

ignition devices will be no less than 18 inches above

4. Type B double-wall metal vent pipe — refer to vent manufacturer’s recommendation for clearances

to combustible material.

Part Number 550-110-593/1099 7

the floor.

• Locate or protect the boiler so it cannot be damaged by a moving vehicle.

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GOLD CGa Gas-Fired Water Boiler

Prepare boiler location — vent system1c

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death.

Do not alter boiler draft hood or place any obstruction or non-approved vent damper in breeching or vent system. CSA certification will become void. Flue gas spillage and carbon monoxide emissions will occur causing severe personal injury or death.

When removing boiler from existing common vent system:

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

Seal any unused openings in the common venting

system.

Visually inspect the venting system for proper

size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

c. Test vent system — Insofar as is practical, close all

building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

Place in operation the appliance being inspected.

Follow the lighting/operating instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at draft hood relief opening after

5 minutes of main burner operation. Use the flame of a match or candle.

f. After it has been determined that

remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1-latest edition. Correct by resizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code. Canadian installations must comply with B149.1 or B149.2 Installation Code.

each appliance

Chimney or vent requirements

1. Venting must be installed according to Part 7, Venting of Equipment, of National Fuel Gas Code, ANSI Z223.1-latest edition and applicable building codes. Canadian installations must comply with B149.1 or B149.2 Installation Codes.

2. See Ratings table on page 67 for minimum chimney or vent sizes. A chimney or vent

should extend at least 3 feet above the highest

cap

where it passes through a roof of a building

point

and at least 2 feet higher than any portion of a

building within a horizontal distance of 10 feet

A chimney or vent must not extend less than the distances stated above.

3. A lined chimney is preferred and must be used when required by local, state, provincial and national codes, laws, regulations and ordinances. Vitreous tile linings with joints that prevent retention of moisture and linings made of noncorrosive materials are best. Advice for flue connections and chimney linings can be obtained from local gas utility. wall metal vent pipe or single-wall vent pipe may be used as a liner.

4. Cold masonry chimneys, also known as outside chimneys, typically have one or more walls exposed to outside air. When any atmospheric gas-fired boiler with automatic vent damper is vented through this type of chimney, the potential exists for condensation to occur. Condensation can damage a masonry chimney. Weil-McLain recommends the following to prevent possible damage.

a. Line chimney with corrosion-resistant metal

liner such as AL29-4C® single-wall stainless steel or B-vent. Size liner per National Fuel Gas Code ANSI Z223.1-latest edition.

b. Provide drain trap to remove any condensate.

5. Where two or more gas appliances vent into a common chimney or vent, equivalent area should

at least equal to area of vent outlet on largest

be appliance plus 50 percent of vent outlet area on additional appliance.

without a listed

Type B double-

8 Part Number 550-110-593/1099

Page 9

Boiler Manual

Prepare boiler location — air contamination

Please review the following information on potential combustion air contamination problems.

To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler. If any of these contaminants are found:

• remove contaminants permanently

— OR —

• isolate boiler and provide outside combustion air. See national, provincial or local codes for further information.

Table 1 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

Refer to contaminated combustion air.

Table 1 for products and areas which may cause

Chlorinated waxes/cleaners Metal fabrication plants

Chlorine-based swimming pool chemicals Beauty shops

Calcium chloride used for thawing Refrigeration repair shops

Sodium chloride used for water softening Photo processing plants

Refrigerant leaks Auto body shops

Paint or varnish removers Plastic manufacturing plants

Hydrochloric acid/muriatic acid Furniture refinishing areas and establishments

Cements and glues New building construction

Antistatic fabric softeners used in clothes dryers Remodeling areas

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Garages with workshops

Adhesives used to fasten building products and other similar products

Part Number 550-110-593/1099 9

Page 10

GOLD CGa Gas-Fired Water Boiler

MODEL

CGi

Prepare boiler location — air openings1c

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. Canadian installations must comply with B149.1 or B149.2 Installation Codes.

Provide adequate combustion and ventilation air to assure proper combustion and reduce the risk of severe personal injury, death or substantial property damage caused by flue gas spillage and carbon monoxide emissions.

Air from inside building

(boiler in interior room - Figure 2)

1. Tightly constructed buildings must be provided with openings to outside for combustion and ventilation air. These openings must be sized to handle all fuel burning appliances, exhaust or ventilation fans and fireplaces.

2. When openings to boiler room are taken to interior spaces, provide two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling.

Air directly from outside to boiler room

1. Tightly constructed buildings must be provided with combustion and ventilation air openings to boiler room, which are adequate to handle the boiler needs plus the needs of all other fuel burning appliances, exhaust or ventilation fans and fireplaces.

2. When combustion air is supplied to the boiler space

directly through outside walls (Figure 3): Provide

two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling. Each opening must provide a minimum free area

1 square inch per 4,000 Btuh of input of all

appliances in room plus requirements for any exhaust fans in room.

Each opening must provide a minimum free area

1 square inch per 1,000 Btuh of input of all

of appliances in room plus requirements for any exhaust fans in room. The interior space supplying combustion and ventilation air must have adequate infiltration from outside.

MODEL

CGi

10 Part Number 550-110-593/1099

Page 11

Boiler Manual

Special considerations

Tight construction

ANSI Z223.1 defines unusually tight construction where:

a. Walls and ceilings exposed to the outside

atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed, and . . .

b. Weather-stripping has been added on openable

windows and doors, and . . .

c. Caulking or sealants are applied to areas such as

joints around windows and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and in other openings.

Other

appliances

CGa boiler

0 to 12"

For buildings with such construction, provide air openings into the building from outside, sized per the appropriate case in

Figure 3 if appliances are to use

inside air for combustion and ventilation.

Air

opening

Air

0 to 12"

Part Number 550-110-593/1099 11

opening

Page 12

GOLD CGa Gas-Fired Water Boiler

Prepare boiler — placement and setup

Place boiler/crate near position

1. Leave boiler in crate and on pallet until installation site is ready.

2. Move entire crate and pallet next to selected location.

3. Remove crate.

4. Remove boiler from pallet as follows:

a. Tilt left side of boiler up and place a board

under left legs.

b. Tilt boiler the other way and place a board

under right legs.

c. Slide boiler backwards off pallet and into

position.

5. Check level.

a. Shim legs, if necessary. b. Do not alter legs.

Leave boiler on pallet.

Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result.

Inspect orifices and burners

1. Remove front jacket door. Remove base access panel (See Figure 32, item 4, page 62).

2. Check for correctly-sized manifold orifices. See

below for sizing. (The orifice size is stamped on

the orifice spud barrel.)

Correctly-sized manifold orifices must be used. Failure to do so will result in severe personal injury, death or substantial property damage.

3. Level and straighten burners.

Burners must be properly seated in slots in burner rest with their openings face up. Main burner orifices must inject down center of

Table

4. Reinstall access panel.

Orifice replacement procedure

(when required)

1. Remove access panel.

2. On gas manifold, mark location of main burner with attached pilot assembly.

3. Remove main burner with attached pilot assembly from manifold. Remove all remaining burners.

4. Remove and discard all main burner orifices in gas manifold.

5. Apply a small amount of pipe dope to each of the new orifices and install in the manifold. Make sure the orifices are aligned correctly, not cross-threaded in the manifold tappings.

6. Reinstall main burner with attached pilot assembly at location marked on gas manifold. Reinstall all remaining burners.

7. Follow check-out procedure, section 7, page 33.

burner. Failure to properly seat burners will result in severe personal injury, death or substantial property damage.

Do not operate boiler without access panel secured in place. Failure to comply could cause momentary flame rollout on ignition of main flame, resulting in possible fire or personal injury hazard.

Use only pipe dope compatible with propane gas, even if boiler is to be operated on natural gas. Failure to comply could result in severe personal injury, death or substantial property damage.

Table 2 Manifold orifice sizing

Location Natural gas Propane gas

U. S.

Canada

Note 1:

12 Part Number 550-110-593/1099

For elevations above 2,000 feet, contact your local Weil-McLain sales office for details.

0-2,000 ft over 2,000 ft 0-2,000 ft over 2,000 ft

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

2.00 mm 1.90 mm 1.30 mm 1.20 mm

Page 13

Boiler Manual

Prepare boiler — pressure test

Perform hydrostatic pressure test

Pressure test boiler before attaching water or gas piping or electrical supply (except as noted below).

Prepare boiler for test

1. Remove the shipping nipple (from CGa supply tapping) and remove the boiler relief valve.

Temporarily plug the relief valve tapping with a ¾"

NPT pipe plug.

2. Remove 1¼" nipple, reducing tee and drain valve from accessory bag. Install in boiler return connection as shown on page 3 or in Figure 34, item

3, page 64. Install circulator on either the return or

supply.

3. Remove 1¼" nipple, 1¼" tee, bushing and pressure/ temperature gauge from accessory bag. Pipe to boiler supply connection as shown in (Use pipe dope sparingly.)

4. Connect a hose to boiler drain valve, the other end connected to a fresh water supply. Make sure hose can also be used to drain boiler after test.

5. Connect a nipple and shutoff valve to system supply connection on the 1¼" tee. This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

Figure 34, page 64.

3. When water flows from shutoff valves, close boiler drain valve.

4. Close shutoff valves.

5. Slowly reopen boiler drain valve until test pressure of not more than 45 psi is reached on the pressure/ temperature gauge.

6. Test at no more than 45 psi for no more than 10

minutes.

Do not leave boiler unattended. A

cold water fill could expand and cause excessive pressure, resulting in severe personal injury, death or substantial property damage.

7. Make sure constant gauge pressure has been maintained throughout test. Check for leaks. Repair if found.

Leaks must be repaired at once.

Failure to do so can damage boiler, resulting in substantial property damage.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

6. Connect a nipple and shutoff valve to system return connection (at circulator flange if circulator installed on return). This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

Fill and pressure test

1. Open the shutoff valves you installed on supply and return connections.

2. Slowly open boiler drain valve and fresh water supply to fill boiler with water.

Part Number 550-110-593/1099 13

Drain and remove fittings

1. Disconnect fill water hose from water source.

2. Drain boiler at drain valve or out hose, whichever provides best access to drain. Remove hose after draining if used to drain boiler.

3. Remove nipples and valves unless they will remain for use in the system piping.

4. Remove plug from relief valve tapping. See Section 3 to replace relief valve.

Page 14

GOLD CGa Gas-Fired Water Boiler

14 Part Number 550-110-593/1099

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 Replacement parts list on page 61 are certified for use with CGa boilers. Any other vent damper installed could cause severe personal injury or death.

Damper blade

Standing pilot ignition systems— Refer to vent

manufacturer’s instructions to install plug (shipped with damper) in damper hole. For standing pilot boilers only, install plug with hole.

Spark-ignited pilot systems— Refer to vent manufacturer’s instructions to install plug (shipped with damper) in damper hole. For spark-ignited pilot boilers only,

install plug with no hole in veper

" diameter hole in vent damper

4. Read and apply the harness plug warning label (shown above) so that it is visible after installation.

5. Plug damper harness receptacle into damper harness

Figure 8 Vent damper assemblies

plug.

Bypassing (jumpering) vent damper will cause flue products such as carbon monoxide to escape into the house. This will cause severe personal injury or death.

After boiler has operated once, if either end of harness is disconnected, the system safety shutdown will occur. The boiler will not operate until harness is reconnected.

Effikal damper — Damper hold

open switch must be in Automatic

Operation position for system to

operate properly.

Part Number 550-110-593/1099 15

Page 16

GOLD CGa Gas-Fired Water Boiler

Water piping — general information3a

General piping information

If installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. Install control in supply piping between boiler and isolation valve. Set second control to minimum 20 °F above setpoint of first control. Maximum allowable setpoint is 240 °F. See page 34 or 38, for wiring.

A low water cutoff device is required when boiler is installed above radiation level or by certain state or local codes or insurance companies. Use low water cutoff designed for water installations. Electrode probe-type is recommended. Purchase and install in tee in supply piping above boiler.

backflow check valve in cold water supply as required by local codes.

Use

Pressure/temperature gauge

Install pressure/temperature gauge in tee on supply piping (as shown in drawing on page 3). The gauge well is a self-closing valve, allowing removal of the gauge without draining the system.

Relief valve

Install relief valve vertically in ¾" tapping on side of boiler. See Figure 9 or

and the tag attached to the relief valve for manufacturer’s instructions.

To avoid water damage or scalding due to relief valve operation:

• Discharge line must be connected to relief valve outlet and run to a

safe place of disposal

possibility of severe burns should the valve discharge.

• Discharge line must be as short as possible and be the

the valve discharge connection

• Discharge line must pitch downward from the valve and terminate at least 6" above the floor drain where any discharge will be clearly visible.

• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375 °F or greater.

Do not pipe the discharge to any place where freezing could occur.

•

• No shutoff valve shall be installed between the relief valve and boiler,

or in the discharge line. Do not plug or place any obstruction in the discharge line.

• Failure to comply with the above guidelines could result in failure of

the relief valve to operate, resulting in possibility of severe personal injury, death or substantial property damage.

• Test the operation of the valve after filling and pressurizing system

by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.

. Terminate the discharge line to eliminate

same size as

throughout its entire length.

System water piping

See Figure 9 (diaphragm-type or bladder-type expansion tank) or tank) on page 21, and Table 3 below, for near-boiler and single-zone systems designed for return water at least 130 °F.

See pages 18-19 to complete multiple-zone piping or pages 20-25 to complete piping for radiant heating systems or converted gravity systems.

Refer to page 25 for boilers used with refrigeration systems.

Boiler model To

CGa-25 ¾" ¾"

CGa-3 1" 1" CGa-4 1" 1" CGa-5 1" 1" CGa-6 1¼" 1¼" CGa-7 1¼" 1¼" CGa-8 1½" 1½"

Note: Circulator flange supplied with boiler is same size as

recommended piping above.

• Chilled medium, if used, is piped in parallel with heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. Consult I=B=R Installation and Piping Guides.

• If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air, use flow control valves or other automatic means to prevent gravity circulation during cooling cycle. Circulation of cold water through the boiler could result in damage to the heat exchanger, causing possible severe personal injury, death or substantial property damage.

Figure 10 (closed-type expansion

system

From

system

Install boiler such that —

16 Part Number 550-110-593/1099

Page 17

Boiler Manual

Water piping — single-zone system

Expansion tank

Diaphragm-type or bladder-type expansion tank — Figure 9

1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possible, before inlet side of circulator. See tank manufacturer’s instructions for details.

2. Install an automatic air vent as shown.

Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve. Eventual section failure can result.

Use Figure 9 or Figure 10 only for single-zone systems designed for return water at least 130 °F. For systems with low return water temperature possible, such as converted gravity systems and radiant heating systems, refer to the special piping suggestions of pages 20-25. Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Figure 9

Diaphragm- or bladder-type expansion tank

Piping to single-zone system using diaphragm-type or bladder-type expansion tank. See Table 3 for piping sizes.

From system

Cold water fill

To DIAPHRAGM expansion tank and fittings

Closed-type expansion tank — Figure 10

1. Ensure expansion tank size will handle boiler and system water volume and temperature. See tank manufacturer’s instructions for details.

2. Connect tank to ½" NPT tapping located behind supply outlet, using ½" NPT piping. Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping.

Figure 10 Closed-type expansion tank

Piping to single-zone system using closedtype expansion tank. See Table 3 for piping sizes.

CLOSED-type expansion tank

Isolation valve

From system

Cold water fill

Isolation valve

Relief valve

To system

Circulator*

Isolation valve

To system

Relief

Automatic air vent

L O G

CGa

Drain valve

Circulator

*Alternate

59306

Part Number 550-110-593/1099 17

location

valve

Circulator

59307

*Alternate

location

Drain valve

Circulator*

L O G

CGa

Page 18

GOLD CGa Gas-Fired Water Boiler

Water piping — multiple zones

Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Radiant heating systems

Preferably, use primary/secondary piping, as shown in Figures 13 or14 on page 21. Alternatively, use the method of either

(system-bypass), because this method does not control radiant system supply temperature.

If radiant system tubing has no oxygen barrier, a

Figure 15 or Figure 16 on page 23. Do not use the piping of Figure

heat exchanger must be used.

18 Part Number 550-110-593/1099

Page 19

Boiler Manual

Typical piping — multiple-zone installations

Figure 11

Zoning with circulators — return water 130 °F or higher.

ZONE 2

ZONE 1

Cold

water

fill

CGa

GOLD

Figure 12

Zoning with zone valves — return water 130 °F or higher.

ZONE 2

ZONE 1

Cold

water

fill

Alternate circulator location

GOLD

CGa

1 2

59308

1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 5 Zone valve 6 Drain valve 9 Relief valve 10 Automatic air vent (with diaphragm-type expansion

59309

11 Fill valve 12 Diaphragm-type or bladder-type expansion tank,

if used (For closed-type expansion tank, pipe from top of air separator to tank fitting as in Figure 10.)

13 Air separator and automatic vent, if used (Note that

the fill valve must always be connected to the expansion tank, regardless of location of expansion tank circulator or air separator.

tank), or connect to tank fitting (closed-type expansion tank).

DO NOT use an automatic air vent

when using closed-type expansion tank. It would allow air to leave the system, causing waterlogging of the expansion tank.

For systems with possible low return-water temperature (such as converted gravity systems, radiant heating systems and heat pump systems), refer to the special piping suggestions of

Figures 13 – 17, as applies. Failure to prevent sustained low return water temperature to the

boiler could cause corrosion of the boiler sections, resulting in severe personal injury, death or substantial property damage.

Part Number 550-110-593/1099 19

Page 20

GOLD CGa Gas-Fired Water Boiler

Primary/secondary

(preferred) bypass

piping method

Temperature gauges

Water piping — low temp systems

Primary/secondary bypass piping is preferred because the flow rate and temperature drop in

the heating circuit(s) is determined only by the heating circuit circulator(s). So adjustment of the bypass valves in the boiler circuit will not cause a change in the heating circuit rate and temperature distribution.

Figures 13 and 14 show suggested bypass arrangements using primary/secondary bypass

piping (preferred) for low temperature systems such as radiant heating systems or converted

gravity systems

The bypass valves (items system return water — set to assure a minimum return water temperature (at least 130 °F) to the boiler. Set the valves as explained below.

Gauge 4a is suggested, but optional on any system. Gauge 4b is optional on converted gravity systems, but required on radiant heating systems —

to display the water temperature being supplied to the radiant tubing.

8 is required on all systems to assure the return water temperature is accurately set for

Gauge a minimum of 130 °F. If this gauge is not available however, adjust the valves such that the boiler-mounted temperature/pressure gauge reads at least 150 °F when the system return water is cold (approximately 60 °F water temperature).

. For alternatives, see pages 22 through 25.

7a and 7b) provide mixing of hot boiler outlet water with cooler

Valve adjustment

(Figure 13 and 14 only)

1. Set the valves while the system is cool, setting for the coldest expected water temperature (usually 60 °F since the system will often drop to room temperature between cycles).

2. Start with valve

3. Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 130 °F when gauge 4a reads 60 °F.

4. Note that valve 7a regulates the amount of hot water from the boiler supply which mixes with return water. Valve 7b regulates the amount of system water flowing through the boiler secondary loop.

Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Radiant heating system piping should include a means of

temperature pumping control

Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant.

DO NOT apply the methods of this manual if the system is equipped with an outdoor reset

control. temperature

Weil-McLain representative for suggested piping and control methods. Failure to

to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.

Instead, provide controls and piping which can regulate the boiler return water

prevent cold return water temperature to the boiler could cause corrosion damage

7a fully closed and 7b fully open.

regulating the boiler return water

and the system supply temperature (such as provided by an injection

at no less than 130 °F regardless of system supply temperature. Contact your

20 Part Number 550-110-593/1099

Page 21

Boiler Manual

Primary/secondary (preferred) piping —

for radiant heating or converted gravity systems

Figure 13

Zoning with circulators

ZONE 2

ZONE 1

Cold

water

4a 4b

fill

12"

MAX.

Alternate circulator location

GOLD

CGa

Figure 14

Zoning with zone valves

ZONE 2

ZONE 1

1 2

Cold

water

4a 4b

fill

12"

MAX.

Alternate circulator location

GOLD

CGa

59310

1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator (circulator should cycle

with zone valve and switches, using circulator valve or zone control panel)

4 System temperature gauges 5 Zone valve 6 Drain valve 7 System temperature valves (see instructions to the

left for adjusting valves)

8 Blend temperature gauge 9 Relief valve

59311

10 Automatic air vent (with diaphragm-type expansion

tank), or connect to tank fitting (closed-type expansion tank). DO NOT use an automatic air vent when using closed-type expansion tank. It would allow air to leave the system, causing waterlogging of the expansion tank.

11 Fill valve 12 Diaphragm-type or bladder-type expansion tank, if

used (For closed-type expansion tank, pipe from top of air separator to tank fitting as in Figure 10.)

13 Air separator and automatic vent, if used (Note that

the fill valve must always be connected to the expansion tank, regardless of location of expansion tank, circulator or air separator.)

Part Number 550-110-593/1099 21

Page 22

GOLD CGa Gas-Fired Water Boiler

Boiler-bypass piping

method

Temperature gauges

Water piping — low temp systems

This piping method is called a boiler-bypass because part of the circulator flow is bypassed around the boiler (through valve 7a). This method reduces the flow rate throughout the boiler, in order to raise the average water temperature in the boiler enough to prevent flue gas condensation. Boiler-bypass piping is effective for some boilers — including the CGa — provided the flow rates are adjusted according to the instructions following.

Figures 15 and16 are alternative piping suggestions for converted gravity (large water content

or steam systems) or be applied. (Figure 17 is another alternative, using system bypass in place of boiler-bypass piping. protect the radiant system from possible high water temperature.)

Boiler-bypass piping keeps system flow rate as high as possible and temperature drop as low as possible, helping to equalize the building heat distribution.

Gauge 4a is optional if the bypass valves will be adjusted using cold (or room temperature) return water to the boiler. (When setting the valves without gauge room temperature water — assume the return water temperature to be 60 °F. Set the valves so gauge

Gauge 4b is optional on converted gravity systems, but required on radiant heating systems — to display the water temperature being supplied to the radiant tubing.

Gauge boiler-mounted temperature/pressure gauge can be used if a separate temperature gauge is not installed.

Figure 17 however, is not suitable for radiant heating applications because it does not

8 reads at least 120 °F.

8 is required on all systems to assure reliable adjustment of the bypass valves. The

radiant heating system — for use when primary/secondary piping can’t

4a installed — using cold or

Valve adjustment

1. Start with valve 7a fully closed and 7b fully open.

2. Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 60 °F higher than gauge enough flow rate and high enough average temperature to prevent condensation even with low system return water temperature.

3. Valve 7a regulates the system flow rate, while valve 7b regulates the boiler flow rate.

4. The boiler-mounted temperature/pressure gauge may be used in place of a separate gauge 8.

Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Radiant heating system piping should include a means of

temperature pumping control

Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant.

DO NOT apply the methods of this manual if the system is equipped with an outdoor reset

control temperature

Weil-McLain representative for suggested piping and control methods. Failure to

to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.

and the system supply temperature (such as provided by an injection

. Instead, provide controls and piping which can regulate the boiler return water

prevent cold return water temperature to the boiler could cause corrosion damage

4a. A minimum 60 °F temperature rise through the boiler assures a low

regulating the boiler return water

at no less than 130 °F regardless of system supply temperature. Contact your

22 Part Number 550-110-593/1099

Page 23

Boiler Manual

Boiler-bypass (alternate) piping —

for radiant heating or converted gravity systems

Figure 15 Boiler-bypass piping

Zoning with circulators

(Alternative to primary/secondary piping Figures 13 and 14)

ZONE 2

ZONE 1

4a 4b

GOLD

CGa

Cold

water

fill

Figure 16 Boiler-bypass piping

Zoning with zone valves

(Alternative to primary/secondary piping Figures 13 and 14)

ZONE 2

Cold

water

fill

ZONE 1

Alternate circulator

location

GOLD

CGa

59312

1 Boiler isolation (balancing) valves

59313

10 Automatic air vent (with diaphragm-type expansion

tank), or connect to tank fitting (closed-type

2 Flow/check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve 6 Drain valve 7 System temperature valves (see instructions to the left

for adjusting valves)

8 Blend temperature gauge 9 Relief valve

expansion tank). DO NOT use an automatic air vent when using closed-type expansion tank. It would allow air to leave the system, causing waterlogging of the expansion tank.

11 Fill valve 12 Diaphragm-type or bladder-type expansion tank,

if used (For closed-type expansion tank, pipe from top of air separator to tank fitting as in

13 Air separator and automatic vent, if used (Note that

Figure 10.)

the fill valve must always be connected to the expansion tank, regardless of location of expansion tank, circulator or air separator.)

Part Number 550-110-593/1099 23

Page 24

GOLD CGa Gas-Fired Water Boiler

System-bypass

piping method

Water piping — low temp systems

This piping method is called a system-bypass because part of the circulator flow bypasses the system (through valve 7a). This bypassed hot water from the boiler outlet mixes with cooler system return water temperature in order to provide minimum 130 °F return water to the boiler. Valve 7b will most often be full open, but may need to be slightly closed on some low pressure drop systems in order to cause enough flow through valve 7a.

Figure 17 is an alternative piping method that provides return water temperature control for

boilers installed on

Do not apply the piping of Figure 17 on radiant heating systems. It provides no method of

regulating the water temperature provided to the system and could result in excessive water temperature in the radiant tubing.

System-bypass piping as shown in Figure 17 can be used with either zone valve or circulator zoning. When used with circulator zoning however, the boiler circulator (item piped as shown. It cannot be used as one of the zoning circulators.

Do not apply system-bypass piping if the reduced flow in the system could cause poor heat distribution. That is, system-bypass piping reduces the flow in the system and increases the water temperature supplied to the system. This can cause increased heat from radiators at the beginning of the system and reduced heat from radiators near the end of the system.

converted gravity systems (large water content or steam systems).

3), must be

Valve adjustment

1. Start with valve 7a fully closed and 7b fully open.

2. Gradually open valve least 130 °F at all times.

3. Valve

4. The valve adjustment should be done with the system at the coldest expected temperature

Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Radiant heating system piping should include a means of

temperature pumping control

Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant.

DO NOT apply the methods of this manual if the system is equipped with an outdoor reset

control temperature

Weil-McLain representative for suggested piping and control methods.

7a regulates the amount of boiler supply water mixed with return water. Valve 7b

causes a pressure drop in the system needed to balance flow through valve 7a and the system.

(60 °F for converted gravity systems or high mass radiant systems).

and the system supply temperature (such as provided by an injection

. Instead, provide controls and piping which can regulate the boiler return water

at no less than 130 °F regardless of system supply temperature. Contact your

7a while closing valve 7b until the temperature at gauge 8 reads at

regulating the boiler return water

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.

24 Part Number 550-110-593/1099

Page 25

Boiler Manual

System-bypass

(alternate)

piping —

for converted gravity (or steam) systems

Cold

water

59314

fill

To systemFrom system

Alternate circulator location

CGa

GOLD

Figure 17 System-bypass piping

Zoning with zone valve or circulators, return water 130 °F or higher.

(Alternative to boiler-bypass piping Figures 15 and 16)

3 System or zone circulator 7 System temperature valves (see instructions to the left for

adjusting valves)

8 Blend temperature gauge 9 Relief valve 10 Automatic air vent (with diaphragm-type expansion

tank), or connect to tank fitting (closed-type expansion tank). DO NOT closed-type expansion tank. It would allow air to leave the system, causing waterlogging of the expansion tank.

11 Fill valve 12 Diaphragm-type or bladder-type expansion tank, if used

(For closed-type expansion tank, pipe from top of air separator to tank fitting as in Figure 10.)

use an automatic air vent when using

Water piping — Refrigeration system

Figure 18 Piping refrigeration systems

System supply

Circulator

System return

59315

Water chiller

Strainer

Check valve

Expansion tank

Balancing valve

Shut-off valve

Boiler

GOLD

CGa

Prevent chilled water from entering boiler

Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See typical installation of balancing valve and check valve.

If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air, use flow control valves or other automatic means to prevent gravity circulation during cooling cycle.

Figure 18 for

Part Number 550-110-593/1099 25

Page 26

GOLD CGa Gas-Fired Water Boiler

Gas piping

Natural Gas:

1. Refer to on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 4 is only for gas with specific

gravity 0.60, with a pressure drop through the

gas piping of 0.30" w.c. For additional gas pipe

sizing information, refer to ANSI Z223.1 (or B149.1 or B149.2 for Canadian installations).

2. Inlet pressure required at gas valve inlet:

• Maximum: 13" w.c.

• Minimum: 5" w.c.

• Manifold gas pressure: 3.5" w.c.

3. Install 100% lockup gas pressure regulator in supply line if inlet pressure exceeds 13" w.c. Adjust for 13" w.c. maximum.

Propane Gas:

1. Contact gas supplier to size pipes, tanks and 100% lockup gas pressure regulator.

Table 4 for pipe length and diameter. Base

Table 4 Pipe capacity for 0.60 specific gravity natural gas

Gas pipe

length

(feet)

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 860

40 63 130 245 500 760

50 56 11 5 215 440 670

75 45 93 175 360 545

100 38 79 150 305 460

150 31 64 120 250 380

½" ¾" 1" 1¼" 1½"

Capacity of pipe for pipe size of:

(Capacity in cubic feet gas per hour)

2. Adjust propane supply regulator provided by gas supplier for 13" w.c. maximum pressure.

3. Inlet pressure required at gas valve inlet:

• Maximum: 13" w.c.

• Minimum: 11" w.c.

• Manifold gas pressure: 10" w.c.

Figure 19 Gas supply piping

Manual main shutoff gas valve (when required)

Ground joint union (when required)

Tee

Nipple

Cap

59322

26 Part Number 550-110-593/1099

Page 27

Boiler Manual

Field wiring

For your safety, turn off electrical power supply at

service entrance panel before making any electrical connections

Failure to do so can cause severe personal injury or death.

Wiring must be N.E.C. Class 1.

If rollout thermal fuse element wire as supplied with boiler must be replaced, type must be used. If other original wiring as supplied with boiler must be replaced, use only type equivalent.

Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70-latest edition.

Electrical installation must comply with:

1. National Electrical Code and any other national, state, provincial or local codes or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Wiring connections

Boiler is shipped with controls completely wired, except spill switch and vent damper. Refer to wiring diagrams shown on page 34 for standing pilot ignition boiler or page 38 for spark-ignited pilot boiler.

to avoid possible electric shock hazard.

200 °C wire or equivalent

105 °C wire or

Thermostat

1. Connect thermostat as shown on wiring diagram on boiler.

2. Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunrays or fireplaces.

3. If thermostat has a heat anticipator, set heat anticipator in thermostat to match power requirements of equipment connected to it. If connected directly to boiler, set for 0.1 amps plus gas valve current. See information on the wiring diagram shown in

Figure 25b, page 39. For other

devices, refer to manufacturer’s specifications. Wiring diagram on boiler gives setting for control module and gas valve. Also see instructions with thermostat.

Junction box (furnished)

1. Connect 120 VAC power wiring (Figure 20).

2. Fused disconnect or service switch (15 amp. recommended) may be mounted on this box. For those installations with local codes which prohibit installation of fused disconnect or service switch on boiler, install a 2 x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code.

Wiring multiple zones

Refer to zone valve manufacturer’s literature for wiring and application. A separate transformer is required to power zone valves. Zoning with circulators requires a relay for each circulator.

Figure 20

Field wiring connections —

service switch and

thermostat (or end switch)

provided by installer

Part Number 550-110-593/1099 27

Service

(not provided)

Field wiring

Factory wiring

120 VAC Hot Neutral

switch

Black White Green

Junction box,

boiler left side

Ground

Thermostat

or end switch

(not provided)

Ground screw Wire nuts

Black Black

Thermostat leads, through jacket left side

59323

Service

switch

(not provided)

Thermostat

or end switch

(not provided)

Page 28

GOLD CGa Gas-Fired Water Boiler

Start-up — preparation6a

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. Repair any leak at once.

Propane boilers only — Your propane supplier mixes an odorant with the propane to make

its presence detectable. In some instances, the odorant can fade and the gas may no longer have an odor.

• Propane gas can accumulate at floor level. Smell near the floor for the gas odorant or any unusual odor. If you suspect a leak, do not attempt to light the pilot.

• Use caution when attempting to light the propane pilot. This should be done by a qualified service technician, particularly if pilot outages are common.

• Periodically check the odorant level of your gas.

• Inspect boiler and system at least yearly to make sure all gas piping is leak-tight.

• Consult your propane supplier regarding installation of a gas leak detector. There are some products on the market intended for this purpose. Your supplier may be able to suggest an appropriate device.

Determine if water treatment is needed

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.

Verify water chemistry

Consult local water treatment companies for unusually hard water areas (above 7 grains hardness) or low pH water conditions (below 7.0). Boiler water pH of 7.0 to 8.5 is recommended.

Freeze protection (when used)

Use antifreeze made especially for hydronic systems. Inhibited propylene glycol is recommended. Do not use ethylene glycol, automotive or undiluted antifreeze. Severe personal injury or

death can result.

1. Determine antifreeze quantity according to system water content. Boiler water content is

listed on page 67. Remember to include expansion tank water content.

2. Follow antifreeze manufacturer's instructions.

3. A 50% solution of propylene glycol/water provides maximum protection to about -30 °F.

4. Local codes may require

5. When using antifreeze in a system with automatic fill, install a water meter to monitor

water makeup. Glycol will leak before the water begins to leak, causing glycol level to drop. Added water will dilute the antifreeze, reducing the freeze protection level.

back flow preventer or actual disconnect from city water supply.

28 Part Number 550-110-593/1099

Page 29

Boiler Manual

Fill the system with water

1. Close manual and automatic air vents and boiler drain cock.

2. Fill to correct system pressure. Correct pressure will vary with each application. Typical cold water fill pressure for a residential system is 12 psi.

3. Purge air from system:

a. Connect a hose to the purge valve (see drain valves, item 6, in suggested piping diagrams

on pages 17 through 23, water can drain and be seen.

b. Close the boiler or system isolation valve between the purge valve and fill connection

to the system.

c. Close zone isolation valves. d. Open quick-fill valve on cold water makeup line. e. Open purge valve. f. One zone at a time, open the isolation valves. Allow water to run through the zone,

pushing out the air. Run until no noticeable air flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.

g. Close the quick-fill water valve and purge valve and remove the hose. Open all isolation

valves. Watch that system pressure rises to correct cold-fill pressure.

h. After the system has operated for a while, eliminate any residual air by using the manual

air vents located throughout the system.

i. If purge valves are not installed in system, open manual air vents in system one at a

time, beginning with lowest floor. Close vent when water squirts out. Repeat with remaining vents.

Figure 9 through Figure 16). Route hose to an area where

4. Open automatic air vent (diaphragm-type or bladder-type expansion tank systems only) one turn.

5. Open other vents:

a. Starting on the lowest floor, open air vents one at a time until water squirts out. b. Repeat with remaining vents.

6. Refill to correct pressure.

Inspect system water piping

After filling the boiler and system with water, inspect all piping throughout the system for leaks. If found, repair immediately. Repeat this inspection after the boiler has been started and the system has heated up.

Leaks must be repaired at once. Failure to do so can damage the boiler, resulting in substantial

property damage. Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage

to boiler will occur, resulting in substantial property damage.

Part Number 550-110-593/1099 29

Page 30

GOLD CGa Gas-Fired Water Boiler

Start-up — preparation continued6a

Inspect base insulation

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 68 of this manual. Failure to comply could result in severe personal injury.

Failure to replace damaged insulation or reposition insulation can result

in a fire hazard, causing severe personal injury, death or substantial property damage.

Check to make sure insulation is secure against all four sides of the base. If insulation is damaged or displaced,

do not operate boiler. Replace or reposition insulation.

Start-up — operate boiler6b

DO NOT proceed with boiler operation unless boiler and system have been

filled with water and all instructions and procedures of previous manual sections have been completed. Failure to do so could result in severe personal injury, death or substantial property damage. Before starting the boiler . . .

• Read manual procedure (see Table 5, below).

• Verify the boiler and system are full of water.

• Verify the completed.

Table 5 Lighting/Operating instruction location guide

Models Standing pilot Gas Page Spark-ignited pilot Gas Page

Honeywell VR8200/VR8300

CGa-25

CGa-6

Robertshaw 7200 Natural 36

CGa-7

Honeywell VR8200/VR8300

CGa-8

Robertshaw 7200 Natural 36 White-Rodgers 36C Natural 43

Section 8/9 and the Lighting/Operating instruction

Start-up preparation procedures of Section 6 have been

Natural or Propane

35 Honeywell VR8204/VR8304 Natural 40

Robertshaw 7200 Natural 41

White-Rodgers 36E Natural 42

35 Honeywell VR8204/VR8304 Natural 40

30 Part Number 550-110-593/1099

Page 31

Boiler Manual

Start-up — operate boiler continued6b

Start the boiler

• Follow the Lighting/Operating Instructions from

Section 8 or 9 to start the boiler. Remove boiler

jacket door and note the gas valve manufacturer and model number. Use only the lighting/operating instruction which applies to this gas valve (see Table

Check system and boiler

Eliminate all system leaks. Continual fresh makeup

water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with bubble test and repair immediately. Do not start boiler again until corrected. Failure to comply could result in severe personal injury, death or substantial property damage.

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to boiler

will occur, resulting in substantial property damage.

1. Check system piping for leaks. If found, shut down boiler and repair immediately.

5, page 30). (The lighting instruction label on the

boiler provides the same information.)

• See Section 6c, below, if boiler fails to start.

2. Vent air from system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

3. Inspect vent system thoroughly for signs of deterioration from corrosion, physical damage or sagging. Verify that masonry chimney liners are in good condition, with no obstructions, and there are no openings into the chimney.

Check around the boiler for gas odor following the

4. procedure of section 6a, page 28 of this manual.

5. Verify operation per section 6d, page 32. Perform check-out procedure in section 7, page 33, and fill in the Installation and service certificate.

Start-up — if boiler doesn’t start . . .6c

Check for:

1. Loose connections, blown fuse or service switch off?

2. High limit switch set below boiler water temperature?

3. Thermostat set below room temperature?

Part Number 550-110-593/1099 31

4. Gas not turned on at meter or boiler?

5. Incoming gas pressure less than: 5" w.c. for natural gas? 11" w.c. for propane gas?

6. If none of the above corrects the problem, refer to

Troubleshooting, section 11, page 49 of this manual.

Page 32

GOLD CGa Gas-Fired Water Boiler

Start-up — verify operation6d

The boiler model suffix will be “SPD”. For spark-ignited pilot boilers (suffix “ operation and lighting/operating information.

PID”), see Section 8 or 9 for

Figure 21 Typical pilot burner flame

Figure 22 Typical main burner flame

32 Part Number 550-110-593/1099

Page 33

Boiler Manual

Check-out procedure — checklist7

❏ Boiler and heat distribution units filled with water? ❏ Automatic air vent, if used, open one full turn? ❏ Air purged from system? ❏ Air purged from gas piping? Piping checked for leaks? ❏ Correctly sized manifold orifices installed? Refer to Table 2,

page 12 to check size and fuel type.

Correctly sized manifold orifices must be used. Failure to do so will cause severe personal injury, death or substantial property damage.

❏ Followed lighting/operating instructions on boiler or in

manual section start-up?

❏ Proper burner flame observed? Refer to Check burner flame,

manual section 6d, page 32.

❏ Test limit control — While burners are operating, move

indicator on limit control below actual boiler water temperature. Burners should go off while circulator continues to operate. Raise setting on limit control above boiler water temperature and burners should reignite.

❏ Test additional field-installed controls — If boiler has a low

water cutoff, additional high limit or other controls, test for operation as outlined by manufacturer. Burners should be operating and should go off when controls are tested. When controls are restored, burners should reignite.

❏ Botton on spill switch pushed in? ❏ Test ignition system safety device:

Standing pilot — Turn gas cock knob to PILOT

position and extinguish pilot flame. Pilot gas flow should stop in less than 3 minutes. Put system back into operation (see section 6, pages 28-32).

b. Spark-ignited pilot — Connect manometer to outlet

side of gas valve. Start boiler, allowing for normal startup cycle to occur and main burners to ignite. With main burners on, manually shut off gas supply at manual main shutoff gas valve. Burners should go off.

8, page 34 or section 9, page 37 for proper

Open manual main shutoff gas valve. Manometer should confirm there is no gas flow. Pilot will relight, flame sensing element will sense pilot flame and main burners reignite.

❏ Set limit control(s) to system temperature requirements.

Adjust balancing valves and controls to provide design temperature to system.

❏ For multiple zones, adjust flow so it is about the same in

each zone.

❏ Verify thermostat heat anticipator (if available) set properly?

Refer to

Thermostat(s).

❏ Cycle boiler with thermostat — Raise to highest setting and

verify boiler goes through normal start-up cycle. Lower to lowest setting and verify boiler goes off.

❏ Measure natural gas input:

a. Operate boiler 10 minutes. b. Turn off other appliances. c. At natural gas meter, measure time (in seconds)

d. Calculate gas input:

e. Btuh calculated should approximate input rating on

❏ Check manifold gas pressure by connecting manometer to

downstream test tapping on main gas valve. Manifold pressure for natural gas should be 3.5" w.c. and for propane gas should be 10" w.c.

❏ Observe several operating cycles for proper operation. ❏ Set room thermostat to desired room temperature. ❏ Fill in Installation and service certificate below? ❏ Review all instructions shipped with this boiler with owner

or maintenance person. Return instructions to envelope and give to owner or place in pocket inside front panel in boiler.

Field wiring, manual section 5, page 27,

required to use one cubic foot of gas.

3600 x 1000

number of seconds from step c

boiler rating label.

= Btuh

Installation and service certificate

Boiler model __________________ Series __________ CP number ___________ Date installed _______________

❏ Installation instructions have been followed.

Measured Btuh input ____________

Installer ________________________ ________________________________ ______________________________ (company) (address) (phone)

Part Number 550-110-593/1099 33

❏ Check out sequence has been performed. ❏ Above information is certified to be correct. ❏ Information received and left with owner/maintenance person

_____________________________________

(installer’s signature)

Page 34

GOLD CGa Gas-Fired Water Boiler

Operation — standing pilot boilers8a

Figure 23 Wiring diagram — Standing pilot system

SCHEMATIC WIRING DIAGRAM

ADDITIONAL

LIMITS

(NOTE 6)

EQUIPMENT

GROUND (NOTE 7)

SERVICE SWITCH

(BY OTHERS)

CIRCULATOR

NOTES:

1. ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH: A. U.S.A. - NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL, STATE OR LOCAL

CODE REQUIREMENTS.

B. CANADA - C.S.A. C22.1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER

2. ALL CONTACTS SHOWN WITHOUT POWER APPLIED-OFF SHELF CONDITION.

3. IF ORIGINAL ROLLOUT TFE WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED,

4. REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION INFORMATION.

5. THERMOSTAT - FOR SINGLE ZONE SYSTEMS, THERMOSTAT ANTICIPATOR SETTING IS 0.40 AMPS.

6. L.W.C.O., ADDITIONAL HIGH LIMIT, ETC., WIRED IN SERIES.

7. DENOTES FIELD INSTALLED CHASSIS GROUND.

TYPE 200 C WIRE OR ITS EQUIVALENT MUST BE USED. IF OTHER ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, TYPE 105 C OR ITS EQUIVALENT MUST BE USED.

EMCS - FOR EMCS CONNECTION IN PLACE OF THERMOSTAT, REFER TO

WIRE NUT

NATIONAL, PROVINCIAL OR LOCAL CODE REQUIREMENTS.

FOR MULTIPLE ZONE SYSTEMS USING ZONE VALVES OR CIRCULATORS, REFER TO COMPONENT MANUFACTURER’S INSTRUCTIONS FOR APPLICATION WIRING AND THERMOSTAT ANTICIPATOR SETTING.

EMCS INSTALLATION/OPERATING MANUAL.

ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE INJURY OR DEATH. DISCONNECT POWER BEFORE INSTALLING AND/OR SERVICING.

SPILL

SWITCH

BK BK

THERMOSTAT

OR EMCS

(NOTE 5)

TRANSFORMER 120/24 V.A.C.

PLUG-IN DPST RELAY

JUNCTION BOX

LIMIT

CONTROL

ROLLOUT

TFE

THERMO-

COUPLE

DAMPER

CONNECTOR

GAS

VALV E

PILOT

CGa

CABLE

DAMPER

25 thru 8

R C

LADDER WIRING DIAGRAM

120 V.A.C.

SERVICE SWITCH

(BY OTHERS)

CR2

THERMOSTAT

OR EMCS

(NOTE 5)

CR1

ADDITIONAL

LIMITS

(NOTE 6)

SPILL

SWITCH

LOW VOLTAGE FIELD HIGH VOLTAGE FIELD LOW VOLTAGE FACTORY HIGH VOLTAGE FACTORY THERMOCOUPLE

Standing Pilot

Natural Or Propane Gas

Forced Hot Water

LIMIT

CONTROL

PRIMARY

24 V.A.C.

ROLLOUT

Weil-McLain

PART NUMBER

CIRCULATOR

RELAY COIL

CABLE

DAMPER

536

6315

FUSE

TFE

DAMPER

CONNECTOR

A United Dominion Company

500 Blaine St.

Michigan City, IN 46360-2388

550-225-009/0999

EQUIPMENT

GROUND (NOTE 7)

34 Part Number 550-110-593/1099

Page 35

Boiler Manual

Lighting instructions — CGa-25 to CGa-88b

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.

A. This appliance has a pilot, which must be lighted

by hand. When lighting the pilot, follow these instructions exactly.

B. Before LIGHTING, smell all around the appliance

area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

C. Use only your hand to push down the reset button or turn the gas

D. Do not use this appliance if any part has been under water.

LIGHTING INSTRUCTIONS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with place service switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with

Model M35, manually rotate damper blade in direction of

arrow to Open position indicated on damper assembly.

6. Turn gas control knob clockwise

7. When equipped with vent damper, verify damper blade is in full open position.

8. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow

"B" in the safety information above. If you don't smell gas,

go to the next step.

Effikal vent damper Model RVGP,

Johnson Controls vent damper

to OFF.

control knob. Never use tools. If the knob or reset button will not operate by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

9. Remove access panel located above burners.

10. Find pilot — follow metal tube from gas control. The pilot is between two burners behind the access panel.

11. Turn gas control knob counterclockwise to PILOT.

12. Push in red reset button and hold. Immediately light the pilot with a match. Continue to hold reset button in for about one (1) minute after the pilot is lit.

13. Release reset button. Pilot should remain lit. If pilot goes out, repeat steps 6 through 13.

• If reset button stays depressed after release, stop and

immediately call your service technician or gas supplier.

• If the pilot will not stay lit after several tries, turn the

gas control knob clockwise service technician or gas supplier.

14. Replace access panel.

15. Turn gas control knob counterclockwise

16. Turn on all electric power to the appliance.

17. When equipped with Effikal vent damper, place service switch in

18. Set thermostat to desired setting.

19. Replace front panel.

Automatic Operation position.

to OFF and call your

to ON.

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

Part Number 550-110-593/1099 35

3. Remove front panel.

4. Turn gas control knob clockwise

5. Replace front panel.

to OFF.

Page 36

GOLD CGa Gas-Fired Water Boiler

Lighting instructions — CGa-25 to CGa-88b

• Standing pilot • Gas valve manufacturer — Robertshaw

• 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.

A. This appliance has a pilot, which must be lighted

by hand. When lighting the pilot, follow these instructions exactly.

B. Before LIGHTING, smell all around the appliance

area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

C. Use only your hand to depress the selector arm. Never use tools. If the

D. Do not use this appliance if any part has been under water.

LIGHTING INSTRUCTIONS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with

Model M35, manually rotate damper blade in direction of

arrow to Open position indicated on damper assembly.

6. Depress and move selector arm left

7. When equipped with vent damper, verify damper blade is in full open position.

Position indicator

(shown in

position)OFF

59332

8. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow

"B" in the safety information above. If you don't smell gas,

go to the next step.

Johnson Controls vent damper

to OFF.

Selector arm

• Gas valve model(s) — 7200

selector arm will not move by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

9. Remove access panel located above burners.

10. Find pilot — follow metal tube from gas control. The pilot is between two burners behind the access panel.

11. Move selector arm on gas control right to SET position.

12. Hold selector arm in the pilot with a match. Continue to hold selector arm to

SET for about one-half (¹⁄₂) minute after the pilot is lit.

13. Release selector arm. If pilot does not remain lit, repeat steps 6 through 13.

• If the pilot will not stay lit after several tries, move

selector arm left to OFF and call your service technician or gas supplier.

14. Replace access panel.

15. Turn selector arm left to ON.

16. Turn on all electric power to the appliance.

17. When equipped with Effikal vent damper, place service switch in Automatic Operation position.

18. Set thermostat to desired setting.

19. Replace front panel.

SET position and immediately light

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

36 Part Number 550-110-593/1099

3. Remove front panel.

4. Depress and move selector arm left

5. Replace front panel.

to OFF.

Page 37

Boiler Manual

Operation — spark-ignited pilot boilers9a

Follow all procedures given in this manual and operating instructions when operating the boiler. Failure to do so could result in severe personal injury, death or substantial property damage.

1. Standby: With no call for heat, the vent damper and circulator are deenergized. No gas flows to pilot or main gas valve.

Call for heat (thermostat circuit closes):

a. Vent damper and circulator energized if pilot status

acceptable. Vent damper drives open. When vent damper end switch makes circuit, ignition control begins pilot ignition attempt.

b. Ignition control checks for false flame signal: If

ignition control senses pilot signal when no pilot gas should be present, control will lockout, requiring reset procedure as given in

Figure 24.

3. Pilot ignition: Control module sparks the pilot and opens pilot valve in main gas valve. a. If pilot does light and control module senses flame

current, spark generator is turned off and main valve opens.

b. If pilot does not light within 15 seconds, pilot valve

is closed and spark generator is turned off. Control module waits 5 minutes, then attempts to ignite pilot again. This cycle will continue indefinitely if pilot ignition control does not sense pilot flame.

Main burner operation:

4. a. Control module monitors pilot flame current. If

signal is lost, main valve closes, spark generator activates and sequence returns to step 4.

b. If power is interrupted, control system shuts off

pilot and main gas valves and restarts at step 1 when power is restored.

c. In the event the limit control shuts down the boiler

— The control module closes the main gas valve, but keeps the circulator operating and the vent damper open.

Thermostat satisfied (thermostat circuit opens) —

Pilot and main gas valves are closed — Vent damper is deenergized, and cycles to closed position. Circulator is shut off.

6. Boiler is now in the standby mode.

7. Thermostat anticipator setting: Set thermostat heat anticipator as instructed in

Figure 25b, page 39.

Figure 24 Ignition control module sequence of operation — status light indications

Steps

(Following step 7,cycle goes back to step 1.)

Call for

heat?

POWER TSTAT

CIRC

LIMIT

DAMPER

FLAME

Timing

1. Standby

Waiting for call for heat·

2. Call for heat

· Circulator on

3. Limit circuit

· Limit controls closed

4. Damper circuit

· Damper proven open

5. Pilot flame proven *

· Gas valve open

· Pilot remains on

· Boiler producing heat

6. Limit cycle

· Limit circuit open

· Gas valve closed

7. Flame outage *

· Flame out

· Boiler recycles

8. Thermostat satisfied

· Circulator off

9. Circulator exercise routine

· Circulator turns on for 30 seconds if boiler not operated for 30 days

* If pilot flame is not proven in 15 seconds, control module will flash the FLAME light, but will continue indefinitely with attempts to light the pilot burner.

The control module will not lockout on a failure to establish flame. It will lockout if line voltage polarity is reversed, stray voltage is sensed on thermostat line, or if flame is sensed when it shouldn’t be there. The boiler will reset after these lockouts if any of the following occurs:

• 1 hour waiting period • Opening and closing of thermostat circuit • Removal of 120 VAC power for at least 45 seconds.

YES

= "ON"

= "OFF"

—

15 sec

—

15 sec

30 sec

59340

Part Number 550-110-593/1099 37

Page 38

GOLD CGa Gas-Fired Water Boiler

Operation — spark-ignited pilot system continued9a

Figure 25a Schematic wiring diagram — Spark-ignited pilot system

White

Red

Plug-in connectors

O FF

O N

38 Part Number 550-110-593/1099

Page 39

Boiler Manual

Figure 25b Ladder wiring diagram — Spark-ignited pilot system

Electrical shock hazard — can cause severe injury or death. Disconnect power before installing or servicing.

Legend for ladder wiring diagram

120 VAC field wiring

Low voltage field wiring

120 VAC factory wiring

Low voltage factory wiring

High voltage spark ignition wiring

Ground connectors

Table G: Gas valve terminals and anticipator settings

PV PV

P 3

Anticipator

amps

0.6

0.8

0.55

0.7

Gas valve

Honeywell VR8204 Honeywell VR8304 Robertshaw 7200 White-Rodgers 36C

* Terminals 2–4 are factory-jumpered on the

White-Rodgers 36C gas valve.

"A" "B" "C"

MV/PV MV/PV

2–4 *

SERVICE

SWITCH

HIGH

VOLTAGE

PILOT

IGNITION

ELECTRODE

120 VAC

CONTROL

MODULE

120 VAC

SECTION

CIRCULATOR

120 VAC

24 VAC

POWER

GndNeutralHot

24VAC CONSTANT

1. All wiring must be installed in accordance with: A. U.S.A. — N.E.C.And any other national, state,

or local code requirements.

THERMOSTAT

TSTAT/CIRC

B. Canada — C.S.A. C22.1 C.E.C.Part 1 and any other national, provincial, or local code requirements.

2. Pilot lead wires are not field replaceable. Replace pilot assembly if necessary.

3. If any of the original wire as supplied with the appliance must be replaced,use minimum 105 °C wire or equivalent. Exception — wires to a rollout TFE must be 200 °C or equivalent.

4. Thermostat anticipator setting (single zone) — see Table G for anticipator setting, depending on which gas valve is installed in boiler.

ROLLOUT

TFE

Additional

limits

(note 7)

TEMPERATURE

LIMIT SWITCH

WATER

SPILL

SWITCH

LIMIT

CONTROL MODULE

LOW VOLTAGE

SECTION

5. For multiple zoning, use either zone valves or circulators. Refer to the component manufacturer's instructions and this manual for application and wiring suggestions.

6. Refer to control component instructions packed with the boiler for application information.

7. Wire any additional limit controls (low water cutoff, additional high limit, etc.) in series with boiler limit control as shown.

Part Number 550-110-593/1099 39

DAMPER END SWITCH

(INTERNAL TO DAMPER)

PILOT

FLAME

59347a

SENSOR

HIGH

VOLTAGE

DAMPER

FLAME

VENT

DAMPER

24VAC CALL FOR HEAT

PILOT GAS

VALVE

"C"

"A"

"B"

MAIN GAS

VALVE

See Table G

Page 40

GOLD CGa Gas-Fired Water Boiler

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.

A. This appliance is equipped with an ignition device

which automatically lights the pilot. light the pilot by hand.

B. Before

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

OPERATING, smell all around the

Do not try to

WHAT TO DO IF YOU SMELL GAS

C. Use only your hand to turn the gas control knob. Never use tools. If

D. Do not use this appliance if any part has been under water.

OPERATING INSTRUCTIONS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with Johnson Controls vent damper

Model M35, manually rotate damper blade in direction of

arrow to

6. This appliance is equipped with an ignition device which automatically lights the pilot. by hand.

7. Turn gas control knob clockwise

Open position indicated on damper assembly.

Do not try to light the pilot

to OFF.

the knob will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

8. When equipped with vent damper, verify damper blade is in full open position.

9. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas,

"B" in the safety information above. If you don't smell gas,

go to the next step.

10. Turn gas control knob counterclockwise

11. Turn on all electric power to the appliance.

12. When equipped with switch in Automatic Operation position.

13. Set thermostat to desired setting.

Effikal vent damper, place service

STOP! Follow

to ON.

14. If the appliance will not operate, follow the instructions To

Turn Off Gas To The Appliance

technician or gas supplier.

15. Replace front panel.

and call your service

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove front panel.

40 Part Number 550-110-593/1099

4. Turn gas control knob clockwise to OFF. Do not force.

5. Replace front panel.

Page 41

Boiler Manual

Operating instructions — CGa-25 to CGa-69b

• Spark pilot • Gas valve manufacturer — Robertshaw

• 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.

A. This appliance is equipped with an ignition device

which automatically lights the pilot. light the pilot by hand.

B. Before

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

OPERATING, smell all around the

Do not try to

WHAT TO DO IF YOU SMELL GAS

C. Use only your hand to depress or move the selector arm. Never use

D. Do not use this appliance if any part has been under water.

OPERATING INSTRUCTIONS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with Johnson Controls vent damper

Model M35, manually rotate damper blade in direction of

arrow to

6. This appliance is equipped with an ignition device which automatically lights the pilot. by hand.

7. Depress and move selector arm to OFF. Note: Selector arm cannot be moved to OFF unless selector arm is depressed slightly. Do not force.

Position indicator

(shown in

Open position indicated on damper assembly.

Do not try to light the pilot

Selector arm

position)OFF

• Gas valve model(s) — 7200

tools. If the selector arm will not depress or move by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

8. When equipped with vent damper, verify damper blade is in full open position.

9. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas,

"B" in the safety information above. If you don't smell gas,

go to the next step.

10. Move selector arm to

11. Turn on all electric power to the appliance.

12. When equipped with Effikal vent damper, place service switch in Automatic Operation position.

13. Set thermostat to desired setting.

14. If the appliance will not operate, follow the instructions To

Turn Off Gas To The Appliance

technician or gas supplier.

ON.

and call your service

STOP! Follow

59332

15. Replace front panel.

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove front panel.

Part Number 550-110-593/1099 41

4. Depress and move selector arm to

5. Replace front panel.

OFF. Do not force.

Page 42

GOLD CGa Gas-Fired Water Boiler

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.

A. This appliance is equipped with an ignition device

which automatically lights the pilot.

Do not try to

C. Use only your hand to turn the gas control knob. Never use tools. If

light the pilot by hand.

B. Before

appliance area for gas. Be sure to smell next to the

OPERATING, smell all around the

D. Do not use this appliance if any part has been under water. floor because some gas is heavier than air and will settle on the floor. See below.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

OPERATING INSTRUCTIONS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with Johnson Controls vent damper

Model M35, manually rotate damper blade in direction of

arrow to Open position indicated on damper assembly.

6. This appliance is equipped with an ignition device which automatically lights the pilot. by hand.

7. Turn gas control knob clockwise to OFF.

Do not try to light the pilot

the knob will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

8. When equipped with vent damper, verify damper blade is in full open position.

9. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas,

"B" in the safety information above. If you don't smell gas,

STOP! Follow

go to the next step.

10. Turn gas control knob counterclockwise

to ON.

11. Turn on all electric power to the appliance.

12. When equipped with

Effikal vent damper, place service

switch in Automatic Operation position.

13. Set thermostat to desired setting.

Position indicator

(shown in

position)ON

59333

Gas control knob

14. If the appliance will not operate, follow the instructions

Turn Off Gas To The Appliance

and call your service

technician or gas supplier.

15. Replace front panel.

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

4. Turn gas control knob clockwise force.

5. Replace front panel.

3. Remove front panel.

42 Part Number 550-110-593/1099

to OFF. Do not

Page 43

Boiler Manual

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.

A. This appliance is equipped with an ignition device

which automatically lights the pilot. light the pilot by hand.

B. Before

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

OPERATING, smell all around the

Do not try to

WHAT TO DO IF YOU SMELL GAS

C. Use only your hand to depress or turn the gas control knob. Never

D. Do not use this appliance if any part has been under water.

OPERATING INSTRUCTIONS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with Johnson Controls vent damper

Model M35, manually rotate damper blade in direction of

arrow to

6. This appliance is equipped with an ignition device which automatically lights the pilot. by hand.

7. Depress gas control knob slightly and turn clockwise to OFF. Note: Knob cannot be turned to OFF unless knob is depressed slightly. Do not force.

Open position indicated on damper assembly.

Do not try to light the pilot

use tools. If the knob will not depress or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

8. When equipped with vent damper, verify damper blade is in full open position.

9. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas,

"B" in the safety information above. If you don't smell gas,

go to the next step.

10. Turn gas control knob counterclockwise

11. Turn on all electric power to the appliance.

12. When equipped with switch in Automatic Operation position.

13. Set thermostat to desired setting.

Effikal vent damper, place service

STOP! Follow

to ON.

14. If the appliance will not operate, follow the instructions

Turn Off Gas To The Appliance

technician or gas supplier.

15. Replace front panel.

and call your service

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove front panel.

Part Number 550-110-593/1099 43

4. Depress gas control knob slightly and turn clockwise to OFF. Do not force.

5. Replace front panel.

Page 44

GOLD CGa Gas-Fired Water Boiler

Service and maintenance — schedule10a

Table 6 Service and maintenance schedules (service technician and user)

Service technician

(see following pages for instructions)

Inspect:

• Reported problems

• Boiler area

• Air openings

• Flue gas vent system

• Pilot and main burner flames

• Water piping

• Boiler heating surfaces

• Burners and base

Service:

• Oiled-bearing circulators

Start-up:

• Perform start-up per manual

Check/test:

ANNNUAL START-UP

• Gas piping

Owner maintenance

(see CGa User’s Information Manual for instructions)

• Check boiler area

Daily

Monthly

Periodically • Test low water cutoff (if used)

Every 6 months • Operate relief valve

• Check air openings

• Check boiler pressure/ temperature gauge

• Check boiler interior piping

• Check venting system

• Check air vents

• Check boiler relief valve

• Check automatic air vents (if used)

• Cold fill and operating pressures

• Air vents and air elimination

• Limit controls and cutoffs

• Expansion tank

• Boiler relief valve

End of season • Shut down procedure

Review:

• Review with owner

Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

44 Part Number 550-110-593/1099

Page 45

Boiler Manual

Service & maintenance — annual start-up10b

The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified

service technician

following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

. In addition, the maintenance and care of the boiler designated in Table 6 and explained on the

❏ Inspect . . . . . . . . . .

Reported problems

Inspect any problems reported by owner and correct before proceeding.

Boiler area

1. Verify that boiler area is free of any combustible

materials

liquids.

2. Verify that boiler area (and air intake) is free of any of the contaminants listed in Table 1 on page 9 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, install combustion air piping to the boiler in accordance with national, provincial or local codes.

Air openings

1. Verify that combustion and ventilation air openings to the boiler room and/or building are open and

unobstructed. Check operation and wiring of

automatic combustion air dampers, if used.

, gasoline and other flammable vapors and

2. Verify that boiler vent discharge and air intake are

clean and free of obstructions.

Flue gas vent system

1. Visually inspect entire flue gas venting system for blockage, deterioration or leakage. Repair any joints that show signs of leakage in accordance with vent manufacturer’s instructions.

2. Verify that masonry chimneys are lined, lining is in good condition, and there are not openings into the chimney.

Failure to inspect for the above

conditions and have them repaired can result in severe personal injury or death.

Pilot and main burner flames

1. Visually inspect pilot burner and main burner flames as directed under section 6d, page 32 of this manual.

Water piping

1. Check the boiler interior piping and all system piping for signs of leaks.

2. Repair any leaks before proceeding.

Part Number 550-110-593/1099 45

Page 46

GOLD CGa Gas-Fired Water Boiler

Service & maint. — annual start-up continued10b

❏ Inspect . . . . . . . . . .

Electrical shock hazard — Turn off power to the boiler

before any service operation

noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

Do not use petroleum-based cleaning or sealing

compounds

will occur, resulting in substantial property damage.

Eliminate all system or boiler leaks. Continual fresh

makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure. Leaking water may also cause severe property damage.

in boiler system. Severe damage to boiler

Boiler heating surfaces

1. Disconnect the vent pipe at the boiler draft hood and remove draft hood after turning off power to the boiler.

2. Use a bright light to inspect the boiler flue collector and heating surfaces.

3. If the vent pipe or boiler interior surfaces show evidence of soot, follow

surfaces

collector and clean the boiler if necessary after closer inspection of boiler heating surfaces.

4. If there is evidence of rusty scale deposits on boiler surfaces, check the water piping and control system to make sure the boiler return water temperature is properly maintained (per this manual).

5. Reconnect vent and draft hood. Replace all boiler

in this manual section. Remove the flue

on the boiler except as

Cleaning boiler heating

components before returning to service.

6. Check inside and around boiler for evidence of any leaks from the boiler. If found, locate source of leaks and repair.

Burners and base

1. After turning off power to the boiler, remove the jacket door and base access panel (Figure 32, item 4, page 62).

2. Inspect burners and all other components in the boiler base.

3. If burners must be cleaned, raise rear of each burner to release from support slot, slide forward and remove. Then brush and vacuum the burners thoroughly, making sure all ports are free of debris. Carefully replace all burners, making sure burner with pilot bracket is replaced in its original position and all burners are upright (ports up).

4. Inspect the base insulation.

a. Pay attention to the WARNINGS on page 68

regarding working with insulation materials.

b. Verify that the insulation is intact and secure

against all four sides of the base.

If insulation is damaged or displaced, do not operate the boiler. Replace or reposition insulation as necessary. Failure to replace damaged insulation can result in a fire hazard, causing severe personal injury, death or substantial property damage.

❏ Service . . . . . . . . . .

Oiled-bearing circulators

1. The circulator shipped with the CGa boiler is waterlubricated. No oiling is required.

46 Part Number 550-110-593/1099

2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator.

Page 47

Boiler Manual

59342

❏ Start-up . . . . . . . . .

1. Perform start-up procedures section 6, pages 28-32, including procedure to verify operation of burners and vent damper on page 32.

2. Verify cold fill pressure is correct and that fill system is working properly.

3. Verify antifreeze level (if used) is at the right concentration and that inhibitor level is correct.

❏ Check/test . . . . . . .

Gas piping

1. Sniff near floor and around boiler area for any indication of a gas leak.

2. Test gas piping using bubble test, per section 4, page 26 of this manual, if there is any indication of a leak.

Cold fill and operating pressures

1. While the system is cold, note the pressure reading on the boiler pressure/temperature gauge. Verify that cold fill pressure is correct.

4. Check gas piping, per manual sections 4 and 6, verifying no indications of leakage and all piping and connections are in good condition.

5. Read the Lighting or Operating instructions (manual section 8 or 9) applying to the boiler.

6. Start the boiler following the Lighting or Operating

instructions

temperature. Boiler should cycle off. Return dial to original setting.

2. Inspect and test additional limit controls or low water cutoffs installed on system.

Figure 26 Automatic air vent, typical

(manual section 8 or 9).

Watch the pressure as the boiler and system heat

up to ensure pressure rise is normal. Too high a rise would indicate a waterlogged or undersized expansion tank.

Air vents and air elimination

1. Inspect automatic air vents (if used). Also inspect air separators to ensure they are operational.

2. The cap must be unscrewed one turn to allow air to escape.

3. See Figure 26. If the air vent is leaking, remove cap

A and briefly push valve B and then release to clean

the valve seat.

4. Replace cap and then unscrewing one turn.

A by twisting all the way onto valve B

Limit controls and cutoffs

1. Inspect and test the boiler limit control. Verify operation by turning control set point below boiler

Part Number 550-110-593/1099 47

Expansion tank

1. Expansion tanks provide space for water to move in an out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See section 3, page 16 of this manual for suggested best location of expansion tanks and air eliminators.

Open-type — located above highest radiator or

baseboard unit, usually in the attic or closet. Has a gauge glass and overflow pipe to a drain.

Closed-type — welded gas tight and located above

boiler. Tank is partially filled with water, leaving an air cushion for expansion.

• Make sure this type of tank is fitted with a tank , such as the B & G Tank-Trol or Taco

fitting

Taco-Trol. This fitting reduces gravity

Page 48

GOLD CGa Gas-Fired Water Boiler

Service & maint. — annual start-up continued10b

❏ Check/test . . . . . . .

circulation of air-saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the system.

•

Do not use automatic air vents in systems with closed-type tanks.

from the system instead of returning to the tank. Eventually, the tank will waterlog and no longer control pressurization. The boiler relief valve will weep frequently.

Diaphragm- or bladder-type — welded gas tight

with a rubber membrane to separate the tank pressurizing air and the water. May be located at any point in the system, but most often found near the boiler.

• Systems with this type of expansion tank require at least one automatic air vent, preferably located on top of an air eliminator, as shown in examples in manual section pages 16-25.

2. If relief valve has tended to weep frequently, the expansion tank may be waterlogged or undersized.

The air will escape

Closed-type tank — tank is most likely

waterlogged. Install a tank fitting if not already installed. Then check fill level per fitting manufacturer’s instructions. If fill level is correct, check tank size against manufacturer’s instructions. Replace with a larger tank if necessary.

Diaphragm- or bladder-type — first, check tank

size to be sure it is large enough for the system. If size is too small, add additional tank(s) as necessary

Figure 27 Relief valve, typical

59343

48 Part Number 550-110-593/1099

Page 49

Boiler Manual

❏ Review with owner . . . . . . . .

1. Review the owner.

2. Emphasize the need to perform the maintenance schedule specified in the

Manual

3. Remind the owner of the need to call in a licensed

User’s Information Manual with the

User’s Information

(and in this manual as well).

contractor should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

❏ Cleaning boiler heating surfaces

1. Shut down boiler:

• Follow “ instructions on boiler and Lighting or

Operating instructions

• Do not drain boiler unless it will be exposed to freezing temperatures. If using antifreeze in system, do not drain.

2. Follow shutdown procedure.

3. Remove venting system connection to boiler.

4. Remove top jacket panel. Turn back insulation.

5. Remove flue collector. Clean sealant from assembly and sections.

6. Remove radiation plates hanging between sections.

7. Remove burners from base. Brush and vacuum burners to remove all dust and lint. Verify that all burner ports are free of debris.

8. Place newspapers in base of boiler to collect soot.

9. Clean between sections with wire flue brush.

10. Remove newspaper and soot. Vacuum or brush base

To Turn Off Gas to Appliance”

and surrounding area.

11. Reinstall radiation plates.

12. Replace collector box/transition assembly. Seal with sealant. Obtain gas-tight seal to prevent flue gas spillage and carbon monoxide emissions, resulting in severe personal injury or death.

13. Replace insulation and jacket top panel.

14. Start up boiler following section this manual and the boiler Lighting or Operating

instructions

gas combustion. If found, check for proper combustion and make any necessary adjustments.

. Excessive sooting indicates improper

6, pages 28-32 of

Troubleshooting — procedure11a

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Never jumper (bypass) rollout thermal fuse element or any other device except for momentary testing as outlined in Troubleshooting Charts. Severe personal injury, death or substantial property damage can result.

Burner access panel must be in position during boiler operation to prevent momentary flame rollout on ignition of main flame. Severe personal injury or substantial property damage will result.

See pages 50 through 59 for additional troubleshooting information.

Part Number 550-110-593/1099 49

Before troubleshooting:

1. Have the following items:

a. Voltmeter that can check 120 VAC and 24

VA C .

b. Microammeter with a minimum scale range

of 0-25. c. Continuity checker. d. U-tube manometer.

2. Check for 120 VAC (minimum 102 VAC to maximum 132 VAC) to boiler.

3. Make sure thermostat is calling for heat and contacts (including appropriate zone controls) are closed. Check for 24 VAC between thermostat wire nuts and ground.

Page 50

GOLD CGa Gas-Fired Water Boiler

50 Part Number 550-110-593/1099

Page 51

Boiler Manual

Damper harness Continuity Table

6 Pin Molex Pin Number

4 Pin Molex Pin Number

Pin side of connectors

1 2 3 4 5 6

1 3 4

N/C

59341

Troubleshooting — standing pilot boilers11b

Chart 1 — Standing pilot — Boiler will not fire

Secure connections.

Is damper harness securely plugged in at both ends?

No Yes

Check for loose wire connections or bad relay on transformer.

Check for open thermostat, LWCO, high limit, spill switch or rollout thermal fuse element contacts or check for loose wire connections.

If LWCO, spill switch or rollout thermal fuse element contacts are open, determine cause and correct condition. Failure to do so will cause severe personal injury, death or substantial property damage.

Check/repair out of round stack section. Does vent damper rotate open?

No Yes

Replace actuator. Retest.

Open thermostat contacts for 30 seconds. Vent damper will rotate to closed position. Close thermostat contacts. Vent damper will rotate to open position. Is 24VAC present across gas valve terminals?

Yes

Is 24VAC present across transformer terminals C & Y?

No Yes

Is 24VAC present across transformer terminal C and yellow wire on vent damper connector?

No Yes

Is vent damper rotated open?

Is 24VAC present across gas valve terminals?

No Yes

Is main flame on now?

No Yes

Is gas valve cock turned to ON position?

Yes

Retest

Yes

Part Number 550-110-593/1099 51

Check continuity of each wire in damper harness. Does continuity exist for each wire? See Table below.

Replace damper wiring harness. Retest.

Replace gas valve. Retest.

Remove damper harness from damper harness plug. TEMPORARILY install jumper between terminal 2 and terminal 5 on damper plug in boiler wiring harness. See figure, right. Does boiler fire?

No Yes

Yes

Replace damper actuator. Retest.

Turn gas valve cock to ON position. Retest.

Replace gas valve. Retest

Page 52

GOLD CGa Gas-Fired Water Boiler

Troubleshooting — spark-ignited pilot boilers11c

The information on this page and pages 53 through 59 apply only to spark-ignited pilot CGa boilers. These boilers are equipped with an ignition control module that has indicator lights to show control status. Charts through 7, pages 54-59, help you identify problems based on indicator light conditions.

Make sure ground wiring is installed per wiring diagram. Good grounding is extremely important for proper operation.

Solder or water splatter between plugs and circuit

board can cause improper operation of control module. Place a shield over the boiler internal controls and components during installation. Failure to comply could result in severe personal injury, death or substantial property damage.

Figure 29 CGa Ignition control module

Control indicator lights — lockout modes

See Charts 2 through 7, pages 54-59 in this section, for

detailed troubleshooting procedures. To reset control after a lockout, turn off power at the 120 VAC service switch or turn down all thermostats. Wait 45 seconds. Then restore power or call for heat.

POWER light flashing alone

Usually indicates reversed polarity of 120 VAC power wires.

POWER and TSTAT CIRC lights flashing

Usually indicates stray voltage on external thermostat circuit wires (usually due to miswired 3-wire zone valve).

POWER

Usually indicates vent damper failed to open within 5 minutes.

POWER

Usually indicates false flame sense or flame sensed when it shouldn’t be there.

and DAMPER lights flashing

and FLAME lights flashing

Control indicator lights — non-lockout modes

FLAME light flashing alone

Usually indicates pilot flame was not established within 15 seconds from application of spark. Control will flash light, but will continue to cycle indefinitely until flame is established or problem is corrected.

DAMPER light flashing alone

Usually indicates damper opened during run cycle. Boiler will not lockout, but won’t heat unless problem is corrected.

Troubleshooting the control module

See Figure 30, page 53, for location of harness plug

59346

52 Part Number 550-110-593/1099

receptacles and plugs on the control module.

Page 53

Boiler Manual

Figure 30 Control module connections

High voltage to pilot spark electrode

Blue wire to gas valve PV

Indicator lights

Red wire to gas valve MV

24 VAC control

circuits

FLAME

DAMPER

LIMIT

TSTAT CIRC

POWER

Black

White

120 VAC H

120 VAC N

120 VAC to

transformer

Black wires to

thermostat circuit

White wire to

gas valve MV/PV

Yellow wires to limit control

and rollout switch

123

Connector plug in vent damper

SJO cable

to J-box

24 VAC Common

Green

24 VAC call for heat

Green

120 VAC H

Entrance ground

Chassis ground

120 VAC N

Black

Green

White

120 VAC IN

Red

24 VAC

24 VAC from transformer

(Constant)

24 VAC

Black

From end switch

24 VAC to

vent damper

Red

Jumpered to pin "4"

Green

Brown

High voltage to spark electrode

120 VAC to transformer

120 VAC IN

24 VAC control circuits

24 VAC from transformer

120 VAC H

120 VAC N

Yellow

White

120 VAC to circulator

24 VAC vent damper connections

120 VAC to circulator

59345

Sense wire to flame sensor

Flame sense wire to pilot

Part Number 550-110-593/1099 53

Page 54

GOLD CGa Gas-Fired Water Boiler

Troubleshooting — spark-ignited pilot boilers11c

Chart 2 — Spark-ignited pilot — Troubleshooting POWER light status

— Usually indicates reversed 120 VAC polarity if POWER light flashes by itself —

Electrical shock hazard — Wherever you see ▲TURN OFF POWER▲, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.

Is POWER light off?

No Yes

Is POWER light...

Flashing

alone

TSTAT CIRC

light flashing

DAMPER

light flashing

FLAME

light flashing

For insufficient heat or no heat problem, go to

Chart 7 if POWER light is on steady, with no other

light flashing.

Flashing with

another light

Chart

On steady

(not flashing)

Chart

• Make sure service switch or circuit breaker is on or fuses are good.

• Remove 120 VAC IN plug (Figure 30, Item 3, page

53) on control module.

• Using voltmeter, check across top and bottom pins of 120 VAC IN plug.

Does voltmeter indicate 120 VAC?

No Yes

Problem is with incoming electricity. Have licensed electrician repair circuit.

• Reconnect 120 VAC IN plug.

• Remove 120 VAC transformer PRIMARY plug (Figure 30, Item 2, page 53) on control module.

• Using voltmeter, check across top and bottom pins of PRIMARY receptacle.

Does voltmeter indicate 120 VAC?

No Yes

• Usually indicates polarity on incoming 120 VAC power line is wrong.

• ▲TURN OFF POWER▲ at service switch or breaker, then reverse the HOT and NEUTRAL wires entering the boiler in the J-box.

• Restore POWER at service switch or breaker.

Is POWER light flashing now?

No Yes

Have system checked by a licensed electricain. If problem persists, call your

Boiler should now operate normally.

local Weil-McLain sales representative.

Replace control module. Retest.

• Reinstall 120 VAC transformer PRIMARY plug.

• Remove 24 VAC transformer plug (Figure 30, Item 5, page 53) on control module.

• Using voltmeter, check across pins of receptacle.

Does voltmeter indicate 120 VAC?

No Yes

Replace transformer. Retest.

Replace control module. Retest.

54 Part Number 550-110-593/1099

Page 55

Boiler Manual

continued

Chart 3 — Spark-ignited pilot — TSTAT CIRC & POWER lights flashing

— Usually indicates 48 VAC on thermostat circuit (stray voltage) —

• Disconnect the two external wires connected to the boiler thermostat leads (two black low voltage leads in J-box).

• Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve and relay in the external circuit one at a time and check the voltmeter reading across the wires.

• There should NEVER be a voltage reading.

Did you find a voltage across the two external thermostat circuit wires?

• Leave external boiler thermostat connection wires disconnected from boiler.

• Troubleshoot the external thermostat circuit until you find the source of the stray voltage. (Pay close attention to the wiring connections to 3-wire zone valves.)

• Correct the problem and repeat the voltmeter test above, verifying there is no longer a voltage reading under any condition in the external thermostat circuit.

• If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

• Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the boiler thermostat wires and allow the boiler to cycle.

NoYes

• If no voltage is found under any condition of the external thermostat circuit, connect the two boiler thermostat connection leads together (or jumper the boiler aquastat T-T terminals).

• Turn off power to the boiler for 1 minute.

• Turn on power and allow boiler to cycle.

Do the

TSTAT

No Yes

and

POWER

lights still flash?

• Boiler should now operate per the normal sequence of operation shown in Figure 24, page 37.

Part Number 550-110-593/1099 55

• Replace control module.

• Retest.

Page 56

GOLD CGa Gas-Fired Water Boiler

Troubleshooting — spark-ignited pilot boilers11c

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 —

• Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds.

• Thermostat should call for heat and appropriate zone valves open. The TSTAT CIRC and LIMIT lights should come on.

Does vent damper operate?

No Yes

• Wait 45 seconds.

Does vent damper operate?

No Yes

• Remove DAMPER plug ( from plug receptacle of control module.

• Place voltmeter leads across the top two pins (1 and 4) of the DAMPER receptacle.

Does the voltmeter indicate 24 VAC?

No Yes

Are the

• Replace control module.

• Retest.

TSTAT CIRC

Yes No

Figure 30, Item 6, page 53

• Try reseating plug in module receptacle and restart.

• If vent damper still does not work, replace vent damper assembly or actuator.

• Retest.

and

LIMIT

lights on steady?

• Make sure thermostat is calling for heat. If lights still don't come on, see Chart 7.

)

• Wait 5 minutes.

DAMPER

No Yes

• Boiler should be in normal operating sequence.

• Observe operation until thermostat is satisfied.

• Replace vent damper assembly or actuator.

• Retest.

light flashing?

Does vent damper actuator

indicator show damper is

open?

No Yes

• Remove damper wiring plug at damper and firmly reconnect.

• Recheck boiler operation.

• If problem persists, replace vent damper assembly or actuator.

56 Part Number 550-110-593/1099

Page 57

Boiler Manual

continued

Chart 5 — Spark-ignited pilot — FLAME & POWER lights flashing

— Usually indicates flame sensed when it shouldn't be there —

Are manual main shutoff valve and gas valve open?

No Yes

• Leave main manual gas valve closed.

• Turn off power to boiler at service switch or breaker.

• Wait at least 45 seconds.

• Turn on power to boiler.

• Restart boiler, following Operating instructions in this manual or on boiler label.

FLAME

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Open main manual gas valve.

• Turn on power to boiler at service switch or breaker.

• Restart boiler per operating instructions.

• Perform start-up procedures in boiler manual to verify proper operation.

and

POWER

lights still flash?

YesNo

• Replace control module.

• Retest.

• Allow boiler to continue cycling.

Are

FLAME

• Boiler may now be operating normally.

• Perform start-up procedures in boiler manual to verify proper operation.

and

POWER

• Turn off power to the boiler at service switch or breaker.

• Wait at least 45 seconds.

• Turn on power to boiler.

• Restart boiler, following Operating instructions in this manual or on boiler label.

• Look through the pilot inspection port to see if the pilot is burning.

lights flashing?

Yes

• Replace control module.

• Retest.

Is pilot burning?

• Replace gas valve.

• Retest boiler.

Are

FLAME

• Boiler should now operate normally.

• Original flashing FLAME light caused by gas valve not operating properly.

• See normal sequence of operation, Figure 24, page 37.

and

Yes

POWER

lights flashing?

• Replace control module.

• Retest.

Yes

Part Number 550-110-593/1099 57

Page 58

GOLD CGa Gas-Fired Water Boiler

Troubleshooting — spark-ignited pilot boilers11c

Chart 6 — Spark-ignited pilot — FLAME light flashing and POWER light on steady

ALSO — Troubleshooting failure to establish main flame

• Is pilot flame visible through inspection port?• Are main manual shutoff valve and boiler gas valve open?

No Yes

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Open main manual shutoff valve and boiler gas valve (per Operating instructions in this manual). Wait at least 45 seconds.

• Turn on power at service switch or breaker. Allow boiler to cycle.

Does

FLAME

No Yes

light flash now?

• Check the voltage across main gas valve terminals of the gas valve.

Is 24 VAC present there?

No Yes

• Make sure ground wire terminal is securely fastened to control module mounting screw.

NoYes

• Boiler should be in

• Verify inlet gas pressure at gas

normal operating sequence.

• Observe operation until thermostat is satisfied and blower has completed its post-purge cycle.

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Remove base access panel (see Figure 32, page 62 for location).

• Verify pilot gas line is not kinked, obstructed or damaged and is correctly attached to pilot and gas valve.

• Verify pilot ignition electrode, electrode ceramic and spark lead wire from control are in good condition. Spark gap should be approximately 1/8".

• Correct any above problems, replacing pilot if burner or wiring is damaged.

• Reinstall base access panel to operate boiler for retest after any changes or corrections.

• If none of the above corrects problem, then replace the control module, reinstall base access panel, and retest.

valve:

Natural gas — 5.0" w.c. min/14.0" w.c. max

Propane — 11.0" w.c. min/14.0" w.c. max

Is gas present at gas valve inlet and

within above range?

Yes

• Contact gas supplier to correct pressure or gas supply.

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Remove base access panel (see Figure 32, page 62 for location).

• Verify pilot burner is securely attached to pilot bracket, bracket is securely attached to cross tie, and there is no corrosion on the parts which would affect the ground path for flame sense.

• Verify that pilot flame rod, flame rod ceramic and lead wire from control module to flame rod are in good condition.

• Correct any above problems, replacing pilot if burner or wiring is damaged.

• If the wiring from the control module to gas valve is intact, replace the control module.

• Retest.

• Verify inlet gas pressure at gas valve:

Natural gas — 5.0" w.c. min/14.0" w.c. max

Propane — 11.0" w.c. min/14.0" w.c. max

Is gas present at gas valve inlet and within above range?

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Check flame signal — Detach sense lead from igntion control (

Figure 30, item 8, page 53

• Connect negative lead of MICROAMMETER to control sense terminal ( MICROAMMETER to sense wire.

• DISCONNECT red wire connected to man gas valve terminal of the gas valve.

• Turn on power to boiler and allow to cycle. As soon as pilot is burning, the MICROAMMETER should read at least 1.0 microamp.

• If none of the previous steps (including replacing pilot) corrects problem, then replace the control module, reinstall base access panel and retest.

Figure 30, item 8, page 53

Is flame signal at least 1.0 microamp?

No Yes

• Check the voltage across main gas valve terminals of the gas valve.

Is 24 VAC present there?

No Yes

Yes

). Connect positive lead of

• If the wiring from the control module to gas valve is intact, replace the control module and retest.

58 Part Number 550-110-593/1099

Page 59

Boiler Manual

continued

Chart 7 — Spark-ignited pilot — Insufficient heat or no heat (POWER light on steady)

• Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes. Is system heating?

• Is thermostat set to call for heat? Remove thermostat wires at boiler and check continuity across the two wires. If circuit isn't closed, check external thermostat (zone valve, relay, etc.) wiring. Correct problems and retry.

• Reconnect external thermostat wiring at boiler.

Is thermostat circuit closed (continuity across wires)?

No Yes

• Boiler is in standby.

Are all red lights off?

No Yes

Wait 30 seconds. Are all red lights off?

No Yes

Replace control module. Retest.

• If you have sufficient heat — boiler should be in normal operating sequence. (See normal sequence of operation, Figure 24, page 37.)

• If you have less than sufficient heat —

• Set thermostat to call for heat and recheck operation.

• Verify Sequence of operation, Figure 24, page 37.

Is vent or combustion air piping free of blockage?

No Yes

• Correct conditions and recheck operation.

• See Figure 24, page 37 for normal sequence of operation.

• Wait for boiler water to cool to temperature 20 to 30 ˚F lower than temperature set on limit switch.

Contact your Weil-McLain sales representative.

Are limit switch contacts closed?

No Yes

• Boiler water temperature exceeded setting on limit switch with thermostat

• Replace limit switch.

• Retest.

calling for heat. Boiler is OK. sequence of operation,

• Also check setting on limit switch (should be above 140˚F.).

(See normal

Figure 24

, p. 37.)

Is boiler System circulator operating?

No Yes

• Remove CIRCULATOR harness plug from CIRCULATOR plug receptacle (

7, page 53

control module receptacle.

). Check with voltmeter across pins of

Figure 30, Item

Does voltmeter show 120 VAC across pins?

No Yes

• Replace control module.

• Retest.

• Wait 5 minutes.

No Yes

• Check limit switch contacts with continuity checker.

• Repair/replace

FLAME

LIMIT

circulator. Retest.

wiring. Retest.

light on?

• Replace control module.

• Retest.

Are limit switch contacts

closed?

No Yes

Check spill switch and

rollout switch continuity —

are switches closed?

No Yes

• Reset spill switch, or replace rollout switch.

If rollout thermal fuse element or spill switch has opened, determine cause and correct condition. Failure to do so will cause severe personal injury, death or substantial property damage.

• Check any other limit controls wired into the limit circuit. If all are OK, then replace control module.

• Retest.

NoYes

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GOLD CGa Gas-Fired Water Boiler

Replacement parts12a

Section assembly ............................................... 61

Base assembly .................................................... 62

Jacket assembly ................................................. 63

Trim assembly .................................................... 64

Gas control assembly — standing pilot .............. 65

Gas control assembly — spark-ignited pilot....... 65

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.

Weil-McLain part numbers are found in Weil-McLain Boilers and Controls

Repair Parts Lists.

60 Part Number 550-110-593/1099

Page 61

Page 62

Page 63

Page 64

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Page 66

GOLD CGa Gas-Fired Water Boiler

Dimensions13a

Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES

6¹⁄₄

T OP VIEW

Boiler supply and return tappings are both 1¼" NPT.

Note 1:

See , page 16 for recommended system sup-

Table 3

ply and returnpiping sizes.

Boiler circulator is shipped loose. Circulator may be

Note 2:

mounted on either boiler supply or return piping. Circulator flange provided with boiler is same size as recommended pipe sizein ,page 16.Table3

13¹⁄₄

23¹⁄₄

NOTE 2

13¹¹₁₆

1⁵⁄₈

28³⁄₈

NOTE 2

2³⁄₈

4³⁄₄4³⁄₄

MODEL

CGi

F RONT

R IGHT SIDEL EFT SIDE

66 Part Number 550-110-593/1099

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Boiler Manual

Ratings13b

DOE

Boiler model

number

(Note 1) (Note 2) (Note 3)

CGa-25 52,000 44,000 52,000 44,000 46,800 39,000 38,000 1.5 81.5 83.3 84.0 4"I.D. x 20’

CGa-3 70,000 59,000 70,000 59,000 63,000 53,000 51,000 1.5 81.6 83.7 84.0 4"I.D. x 20’

CGa-4 105,000 88,000 105,000 88,000 94,500 79,000 77,000 2.1 81.7 83.7 84.0 5"I.D. x 20’

CGa-5 140,000 117,000 140,000 117,000 126,000 105,000 102,000 2.7 81.8 83.7 83.5 6"I.D. x 20’

CGa-6 175,000 146,000 175,000 146,000 157,500 131,000 127,000 3.3 81.9 83.6 83.2 6"I.D. x 20’

Input

(Btuh)

DOE

Heating

capacity

(Btuh)

0–2,000 feet

altitude

Input

(Btuh)

Output

(Btuh)

2,000–4,500 feet

altitude

Input

(Btuh)

Output

(Btuh)

Net

I=B=R

ratings

(Btuh)

Boiler water

content

(gallons)

DOE

Seasonal efficiency

(% A.F.U.E)

SPDN SPDL PIDN

Chimney

and

breeching

size

CGa-7 210,000 175,000 210,000 175,000 189,000 157,000 152,000 3.8 82.0 83.6 83.0 7"I.D. x 20’

CGa-8 245,000 204,000 245,000 204,000 220,500 183,000 177,000 4.4 82.1 83.6 82.7 7"I.D. x 20’

Notes

1.See Table 7 for available pilot systems. The suffix shown

in the table is added to the boiler model number. (Not available for millivolt systems.)

2. Based on standard test procedures prescribed by the United States Department of Energy.

3. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of

1.15. An additional allowance should be made for unusual piping and pickup loads.

Table 7 Ignition system model suffixes

Pilot ignition system Natural gas Propane gas

Standing pilot SPDN SPDL

Spark-ignited pilot PIDN Not available

Install CGa boilers for residential radiant panel systems, converted gravity heating systems or other low water temperature applications per instructions in this manual to avoid damage due to condensation.

CGa boilers are CSA design certified for installation on combustible flooring. CGa boilers are ASME rated for 50 psig working pressure.

Part Number 550-110-593/1099 67

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GOLD CGa Gas-Fired Water Boiler — Boiler Manual

Part Number 550-110-593/1099

Weil-McLain Gold CGa User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual