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Weil-McLain Gold CGa manual

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Table of contents for the manual

  • Page 1

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  • Page 2

    Boiler Manual Par t Number 550-1 1 0-593/1 099 5 Failure t o adhere to the guidelines on this pag e can result in sever e personal injury , death or substantial property damage. Please read before proceeding and/or pro per ty may result. • Continual fresh mak eup water will r educe boiler life. Mineral build up in sections re duces heat transfer [...]

  • Page 3

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  • Page 4

    GOLD CGa Gas-F ired Water Boiler 2 Par t Number 550-1 1 0-593/1 099 Ho w it w orks . . . ① Control module The contr ol module (used on spar k-ignited pilot boilers ) responds t o signals from the r oom thermostat and boiler limit circuit t o operate the boiler cir culator , pilot b urner , gas valve and ve nt damper . W hen room thermostat calls [...]

  • Page 5

    GOLD CGa Gas-F ired Water Boiler 4 Par t Number 550-1 1 0-593/1 099 Contents Hazard def initions The follo w ing defined terms are used thr oughout this manual to bring attention to the prese nce of hazards of various risk le v els or to important information conc erning the life of the product. Indicates pr esence of hazards that will cause sever [...]

  • Page 6

    GOLD CGa Gas-F ired Water Boiler 6 Par t Number 550-1 1 0-593/1 099 • L ocal, state, provincial, and nat ional codes, laws, regulations and or dinances. • National Fuel Gas Code, ANSI Z223.1–latest e dition. • Standard fo r Controls and Safety Dev ices for A utomatically Fired Bo ilers, ANSI/ASME CSD-1, wh en req uired. P repare boiler loca[...]

  • Page 7

    Boiler Manual Par t Number 550-1 1 0-593/1 099 7 P repare boiler location — clearances 1b S er vice clearances 1. Provide the following clearances for cleaning and serv icing the boiler and for ac cess to c ontrols and components: Flooring and foundation Flooring The CGa boiler is appro ved for installation on comb ustible flooring , b ut must ne[...]

  • Page 8

    GOLD CGa Gas-F ired Water Boiler 8 Par t Number 550-1 1 0-593/1 099 P repare boiler location — vent system 1c Failur e to follow all instructions can result in flue gas spillage and carbon mono xide emissions, causing severe personal injury or death. When removing boiler from e xisting common vent system: At the time of removal of an existing boi[...]

  • Page 9

    Boiler Manual Par t Number 550-1 1 0-593/1 099 9 P r epare boiler location — air contamination T able 1 Corrosive contaminants and likely locations 1d T o prev ent potential of se v ere personal injury or death, check fo r products or areas list ed below before installing boiler . If any o f these contaminants ar e found: • remo ve co ntaminant[...]

  • Page 10

    GOLD CGa Gas-F ired Water Boiler 10 Par t Number 550-1 1 0-593/1 099 Combustion air and v entilat ion openings must co mply with Section 5.3, Air for Combustion and V entilat ion, of N ational Fuel Gas Code ANSI Z223.1-latest edition, or applicable local building c odes. Canadian installations must compl y w ith B149.1 or B149.2 Installation Codes.[...]

  • Page 11

    Boiler Manual Par t Number 550-1 1 0-593/1 099 11 Special considerations Tight construction ANSI Z223.1 defines unusually tight construction whe r e: a . W alls and ceilings exposed to the outside atmosphere hav e a continuous wat er vapor retarder with a r ating of 1 perm or less with op enings gasketed, and . . . b . W eather-stripping has b een [...]

  • Page 12

    GOLD CGa Gas-F ired Water Boiler 12 Par t Number 550-1 1 0-593/1 099 P repare boiler — placement and setup T able 2 Manifold orifice sizing 2a Inspect orifices and burners 1. Re move fr ont jack et door . Remo ve base ac cess panel (See Figure 32 , item 4 , pag e 62). 2. Check for c orrectly-sized manifold o r ifices. See T able 2 below for sizin[...]

  • Page 13

    Boiler Manual Par t Number 550-1 1 0-593/1 099 13 P repare boiler — pressure test P erform hydrostatic pressure test Press ure test boiler befor e atta ching water or gas piping or electrical supply (ex cept as noted below). 3. When wat er flows from sh utoff valv es, close boiler drain valv e. 4. Close shutof f valves. 5. Slowly reopen boile r d[...]

  • Page 14

    GOLD CGa Gas-F ired Water Boiler 14 Par t Number 550-1 1 0-593/1 099[...]

  • Page 15

    Boiler Manual Par t Number 550-1 1 0-593/1 099 15 P repare boiler — v ent damper installation These systems ar e used on gas-fired b oilers with vent damper s as shipp ed from facto r y . Boiler will not operate without vent damper installed. Only vent damper s listed in the Replacement parts list on page 61 are c ertified for use with CGa boiler[...]

  • Page 16

    GOLD CGa Gas-F ired Water Boiler 16 Par t Number 550-1 1 0-593/1 099 W ater piping — general inf ormation 3a Boiler model To system From system 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 suppl[...]

  • Page 17

    Boiler Manual Par t Number 550-1 1 0-593/1 099 17 Expansion tank Diaphragm-type or bladder -type expansion tank — Figure 9 1. Ensure expansion tank size will handle boiler and system water v olume and temperature. T ank must be located in boiler return piping as close to b oiler as possible, before inlet side of circulator . See tank manufacturer[...]

  • Page 18

    GOLD CGa Gas-F ired Water Boiler 18 Par t Number 550-1 1 0-593/1 099 W ater piping — multiple z ones Failu re to preve nt low r e turn water t emperature to the boiler c ould cause corr osion of the boiler sections o r burners, resulting in seve re personal injury , death or substantial pro pert y damage. Radiant heating systems Pr e ferably , us[...]

  • Page 19

    Boiler Manual Par t Number 550-1 1 0-593/1 099 19 T ypical piping — multiple-z one installations Figure 1 1 Zoning with circulators — return water 130 °F or higher . Figure 12 Zoning with zone valves — return water 130 °F or higher . 1 Boiler isolation (balancing) valves 2 Flow/che ck valve 3 Syste m or zone circulator 5 Zone valv e 6 Drain[...]

  • Page 20

    GOLD CGa Gas-F ired Water Boiler 20 Par t Number 550-1 1 0-593/1 099 W ater piping — lo w temp systems Failure to prevent lo w retur n water t emperatur e to the boiler could cause co r rosion of the boiler sections o r burners, resulting in seve re personal injury , death or substantial pro pert y damage. Radiant heating system piping should inc[...]

  • Page 21

    Boiler Manual Par t Number 550-1 1 0-593/1 099 21 P rimar y/secondar y (preferred) piping — f or radiant heating or con v er ted gravity systems 1 Boiler isolation (balancing) valves 2 Flow/che ck valve 3 Syste m or zone circulator (cir culator should cycle with zone valv e and switches, using cir culator valv e or zone c ontrol panel) 4 System t[...]

  • Page 22

    GOLD CGa Gas-F ired Water Boiler 22 Par t Number 550-1 1 0-593/1 099 W ater piping — lo w temp systems Failure to prevent lo w retur n water t emperatur e to the boiler could cause co r rosion of the boiler sections o r burners, resulting in seve re personal injury , death or substantial pro pert y damage. Radiant heating system piping should inc[...]

  • Page 23

    Boiler Manual Par t Number 550-1 1 0-593/1 099 23 1 Boiler isolation (balancing) valves 2 Flow/che ck valve 3 Syste m or zone circulator 4 System te mpe ra ture gau ges 5 Zone valv e 6 Drain valve 7 Syste m temperature valv es (see instruct ions to the left for adjusting valves) 8 Blend t emperature gauge 9 Relie f valve 10 A utomatic air vent (wit[...]

  • Page 24

    GOLD CGa Gas-F ired Water Boiler 24 Par t Number 550-1 1 0-593/1 099 W ater piping — lo w temp systems Failure to prevent lo w retur n water t emperatur e to the boiler could cause co r rosion of the boiler sections o r burners, resulting in seve re personal injury , death or substantial pro pert y damage. Radiant heating system piping should inc[...]

  • Page 25

    Boiler Manual Par t Number 550-1 1 0-593/1 099 25 3 Sy stem or zone circulat or 7 Sy stem temperature va lves (see instructions to the left for adjusting valv es) 8 Blend t emperature g auge 9 Relief valve 10 A utomatic air ve nt (with diap hragm-t y pe expansion tank), o r connect to tank fitting (closed-ty pe expansion tank). DO NO T use an autom[...]

  • Page 26

    GOLD CGa Gas-F ired Water Boiler 26 Par t Number 550-1 1 0-593/1 099 Gas piping Natural Gas: 1. Refer t o T able 4 f or pipe length and diameter . Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). T able 4 is only for gas w ith specific gra vity 0.60, with a pressur e drop thr ough the gas piping of 0.30" w .c. For ad[...]

  • Page 27

    Boiler Manual Par t Number 550-1 1 0-593/1 099 27 Field wiring For y our safet y , tur n off electrical po wer supply at service entrance panel bef ore making an y electrical connections to av oid possible electric sho ck hazard. Failur e to do so can cause severe per sonal injur y or death. Electrical installation must comply with: 1. N ational El[...]

  • Page 28

    GOLD CGa Gas-F ired Water Boiler 28 Par t Number 550-1 1 0-593/1 099 Start -up — preparation 6a Determine if water treatment is needed Verify water chemistry Cons ult local water treatment companies for unus ual ly hard wate r areas (above 7 grains hardness) or lo w pH water c onditions (below 7.0). Boiler wat er pH of 7.0 to 8.5 is recomme nded.[...]

  • Page 29

    Boiler Manual Par t Number 550-1 1 0-593/1 099 29 Fill the system with water Inspect system water piping After filling the boiler and system with water , inspect all piping throughout the system for leaks. If found, repair immediately . R epeat this inspection after the boile r has b een started and the system has heated up . Do not use petroleum-b[...]

  • Page 30

    GOLD CGa Gas-F ired Water Boiler 30 Par t Number 550-1 1 0-593/1 099 Start -up — operate boiler 6b DO NO T proceed with boiler operation unless boiler and syste m have been filled w ith water and all instructions and proc edures of previous manual sections have been completed. Failur e to do so could res ult in severe personal injury , death or s[...]

  • Page 31

    Boiler Manual Par t Number 550-1 1 0-593/1 099 31 Start the boiler Start -up — if boiler doesn ’t start . . . 6c Check for: 4. Gas not turned on at meter or boiler? 5. Inc oming gas pressure less than: 5" w .c. for natural gas? 11" w .c. for pr opane gas? 6. If none of the ab ov e corrects the p roblem, refer t o T roubleshooting , se[...]

  • Page 32

    GOLD CGa Gas-F ired Water Boiler 32 Par t Number 550-1 1 0-593/1 099 Star t-up — verify operation 6d The boiler model suffix will b e “ SPD ” . F or spark-ignited pilot boilers (suffix “ PID ”), see Section 8 or 9 for operation and light ing/operating information. Figure 22 T ypical main burner flame Figure 21 T ypical pilot burner flame[...]

  • Page 33

    Boiler Manual Par t Number 550-1 1 0-593/1 099 33 Check - out procedure — checklist 7 ❏ Boiler and heat distribution units filled with water? ❏ A utomatic air ve nt, if used, open one full turn? ❏ Air purged from syst em? ❏ Air purged from gas piping? Piping check ed for leaks? ❏ Correctly siz ed manifold orifices installed? Ref er to T[...]

  • Page 34

    GOLD CGa Gas-F ired Water Boiler 34 Par t Number 550-1 1 0-593/1 099 Operation — s tanding pilot boiler s 8a Figure 23 Wiring diagram — Standing pilot system 4 2 5 3 6 1 CIRCULA TOR 120 V .A.C. H N CR2 SER VICE SWITCH (BY OTHERS) EQUIPMENT GROUND THERMOST A T OR EMCS (NOTE 5) RELA Y COIL CR CABLE TO DAMPER DAMPER CONNECTOR CR1 SPILL SWITCH ROLL[...]

  • Page 35

    Boiler Manual Par t Number 550-1 1 0-593/1 099 35 Lighting instructions — CGa-25 to CGa-8 8b FOR Y OUR SAFETY READ BEFORE LIGHTING LIGHTING INSTRU CTIONS T O TURN OFF GAS T O THE APPLIANCE • Do not tr y to light any applianc e. • Do not touch any electric switch; do not use any p hone in your building. • Imme diately call your gas supplier [...]

  • Page 36

    GOLD CGa Gas-F ired Water Boiler 36 Par t Number 550-1 1 0-593/1 099 FOR Y OUR SAFETY READ BEFORE LIGHTING LIGHTING INSTRU CTIONS T O TURN OFF GAS T O THE APPLIANCE • Do not tr y to light any applianc e. • Do not touch any electric switch; do not use any phone in your building. • Imme diately call your gas supplier fr om a neigh bor’ s phon[...]

  • Page 37

    Boiler Manual Par t Number 550-1 1 0-593/1 099 37 Figure 24 Ignition control module sequence of operation — status light indications Follo w all procedur es g iv en in this manual and operat ing instructions when operating the boiler . Failur e to do so could result in sev ere personal injur y , death or substantial pro p erty damage. Operation ?[...]

  • Page 38

    GOLD CGa Gas-F ired Water Boiler 38 Par t Number 550-1 1 0-593/1 099 Figure 25a Sc hematic wiring diagram — Spark-ignited pilot system Operation — spark-ignited pilot system continued 9a Plug-in connectors Red White O FF O N[...]

  • Page 39

    Boiler Manual Par t Number 550-1 1 0-593/1 099 39 Figure 25b Ladder wiring diagram — Spark-ignited pilot system 59347a Honeywell VR8204 Honeywell VR8304 Rober tshaw 7200 White-Rodgers 36C * T erminals 2–4 are factory-jumpered on the White-Rodgers 36C gas valve. MV/PV MV/PV C 2–4 * MV MV M 1 PV PV P 3 T able G : Gas valve terminals and anticip[...]

  • Page 40

    GOLD CGa Gas-F ired Water Boiler 40 Par t Number 550-1 1 0-593/1 099 FOR Y OUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRU CTIONS T O TURN OFF GAS T O THE APPLIANCE • Do not tr y to light any applianc e. • Do not touch any electric switch; do not use any phone in your building. • Imme diately call your gas supplier fr om a neigh bor’ s [...]

  • Page 41

    Boiler Manual Par t Number 550-1 1 0-593/1 099 41 FOR Y OUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRU CTIONS T O TURN OFF GAS T O THE APPLIANCE • Do not tr y to light any applianc e. • Do not touch any electric switch; do not use any p hone in your building. • Imme diately call your gas supplier fr om a neighbor’ s phone. Follo w the [...]

  • Page 42

    GOLD CGa Gas-F ired Water Boiler 42 Par t Number 550-1 1 0-593/1 099 FOR Y OUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRU CTIONS T O TURN OFF GAS T O THE APPLIANCE • Do not tr y to light any applianc e. • Do not touch any electric switch; do not use any phone in your building. • Imme diately call your gas supplier fr om a neigh bor’ s [...]

  • Page 43

    Boiler Manual Par t Number 550-1 1 0-593/1 099 43 FOR Y OUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRU CTIONS T O TURN OFF GAS T O THE APPLIANCE • Do not tr y to light any applianc e. • Do not touch any electric switch; do not use any p hone in your building. • Imme diately call your gas supplier fr om a neighbor’ s phone. Follo w the [...]

  • Page 44

    GOLD CGa Gas-F ired Water Boiler 44 Par t Number 550-1 1 0-593/1 099 S er vice and maintenance — sc hedule 10a Fo llow the Service and maintenance pr ocedures giv en throughout this manual and in component lite rature shipped with the b oiler . Fail ure to perform the service and maintenance c ould result in damage to the boiler or system. F ailu[...]

  • Page 45

    Boiler Manual Par t Number 550-1 1 0-593/1 099 45 Service & maintenance — annual start -up 10b The boiler should be inspected and star ted annually , at the beg inning of the heat ing season, only by a qualified service te chnician . In addition, the maint enance and care of the boiler designated in T able 6 and explained on the following pag[...]

  • Page 46

    GOLD CGa Gas-F ired Water Boiler 46 Par t Number 550-1 1 0-593/1 099 Service & maint. — annual start -up continued 10b ❏ Service . . . . . . . . . . ❏ Inspect . . . . . . . . . . Oiled-bearing circulators Boiler heating surfaces 1. Disconnect the v ent pipe at the boiler draft hood and remov e draft hood after turning off power to the boi[...]

  • Page 47

    Boiler Manual Par t Number 550-1 1 0-593/1 099 47 ❏ Start-up . . . . . . . . . 1. P erform start-up procedur es section 6 , pages 28-32, including proc edure to v erify op eration of burners and vent damper on page 32. 2. V erify cold fill pressur e is correct and that fill syst em is working pr operly . 3. V erify antifreez e leve l (if used) is[...]

  • Page 48

    GOLD CGa Gas-F ired Water Boiler 48 Par t Number 550-1 1 0-593/1 099 Service & maint. — annual start -up continued 10b ❏ Check/test . . . . . . . Figure 27 Relief valve, typical 59343 circulation of air-saturated tank water back to the system and pr events the air fr om bubbling up through the water as it r eturns from the sy stem. • Do n[...]

  • Page 49

    Boiler Manual Par t Number 550-1 1 0-593/1 099 49 1. Review the User’ s Inf ormation Manual with the ow ner. 2. Emphasize the need to perfo rm the maintenanc e schedule specifie d in the User ’ s Infor mation Manual (and in this manual as well). 3. Remind the o wner of the need to call in a licensed ❏ Review with o wner . . . . . . . . ❏ Cl[...]

  • Page 50

    GOLD CGa Gas-F ired Water Boiler 50 Par t Number 550-1 1 0-593/1 099[...]

  • Page 51

    Boiler Manual Par t Number 550-1 1 0-593/1 099 51 Is 24VAC present across transformer terminals C & Y ? Is damper harness securely plugged in at both ends? Secure connections. 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 t[...]

  • Page 52

    GOLD CGa Gas-F ired Water Boiler 52 Par t Number 550-1 1 0-593/1 099 T roubleshooting — spark -ignited pilot boilers 11 c Make sur e gr ound wiring is installed per w iring diagr am. Good grounding is extremel y impor tant for pro p er operation. Control indicator lights — non-lockout modes FLAME light flashing alone U sually indicates pilot fl[...]

  • Page 53

    Boiler Manual Par t Number 550-1 1 0-593/1 099 53 Figure 30 Control module connections 1 2 3 4 Indicator lights POWER TST A T CIRC LIMIT DAMPER FLAME 120 V AC IN 120 V AC to transformer High voltage to spark electrode 24 V AC from transformer 24 V AC control circuits 120 V AC to circulator Sense wire to flame sensor 24 V AC vent damper connections [...]

  • Page 54

    GOLD CGa Gas-F ired Water Boiler 54 Par t Number 550-1 1 0-593/1 099 T roubleshooting — spark -ignited pilot boilers 11 c 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. Problem is with incomi[...]

  • Page 55

    Boiler Manual Par t Number 550-1 1 0-593/1 099 55 Electrical shock hazard — Wherever yo u se e ▲ TURN OFF POWER ▲ , follow the instructions. Failure to fo llow instructions could result in severe personal injury, death or substantial prop erty damage. No Yes Did you find a voltage across the two external thermostat cir cuit wires? No Yes • [...]

  • Page 56

    GOLD CGa Gas-F ired Water Boiler 56 Par t Number 550-1 1 0-593/1 099 T roubleshooting — spark -ignited pilot boilers 11 c • 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 c[...]

  • Page 57

    Boiler Manual Par t Number 550-1 1 0-593/1 099 57 continued • 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. Is pi[...]

  • Page 58

    GOLD CGa Gas-F ired Water Boiler 58 Par t Number 550-1 1 0-593/1 099 T roubleshooting — spark -ignited pilot boilers 11 c • ▲ TURN OFF POWER ▲ to boiler at service switch or breaker. • Remove base access panel (see Figure 32 , page 62 for location). • Verify inlet gas pressure at gas valve: Natural gas — 5.0" w.c. min/14.0" [...]

  • Page 59

    Boiler Manual Par t Number 550-1 1 0-593/1 099 59 continued 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. • Reset spill switch, or replace rollout switch. • Boiler is in standby. • Set t[...]

  • Page 60

    GOLD CGa Gas-F ired Water Boiler 60 Par t Number 550-1 1 0-593/1 099 Replacement parts 12a Section assembly ............................................... 61 Base assembly .................................................... 62 Jack et assembly ................................................. 63 T rim assembly ....................................[...]

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  • Page 66

    GOLD CGa Gas-F ired Water Boiler 66 Par t Number 550-1 1 0-593/1 099 Dimensions 13a Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES R IGHT SIDE L EFT SIDE T OP VIEW F RONT 19 19 13¹¹₁₆ 28³⁄₈ 1⁵⁄₈ 4³⁄₄ 4³⁄₄ 13¹⁄₄ 6¹⁄₄ Boiler circulator is shipped loose. Cir culator may be mounted on either boiler su[...]

  • Page 67

    Boiler Manual Par t Number 550-1 1 0-593/1 099 67 Ratings 13b 1 .S e e T able 7 for available pilot sy stems. The suffix sho w n in the table is added to the boiler model number . (N ot available for milliv olt systems.) 2. Based on standard test proced ures prescribed by the U nited States Department of Energy . 3. Net I=B=R ratings are based on n[...]

  • Page 68

    GOLD CGa Gas-F ired W ater Boiler — Boiler Manual 68 Par t Number 550-1 1 0-593/1 099[...]