Weil-McLain CGa 3 Series Manual
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Weil-McLain CGa 3 Series Manual

Gas-fired water boilers
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Boiler Manual
This manual must only be used by a qualified heating installer/service technician.
instructions, including this manual, and any related supplements. Perform steps in the order given. Failure to comply
could result in severe personal injury, death or substantial property damage.
Series 3
Gas-Fired Water Boilers
• Installation
• Startup
Now With Built In
Low Water Cut Off Functionality
Part Number 550-142-300/0520
• Maintenance
• Parts
Before installing
, read all

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Summary of Contents for Weil-McLain CGa 3 Series

  • Page 1 Series 3 Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts Now With Built In Low Water Cut Off Functionality Before installing This manual must only be used by a qualified heating installer/service technician. , read all instructions, including this manual, and any related supplements.
  • Page 2 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual How it works . . . ① Control module The control module 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).
  • Page 3 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual CGa Series 3 Gas-Fired Water Boiler Part Number 550-142-300/0520...

  • Page 4: Table Of Contents

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Contents How it works ............ 2-3 Hazard definitions ..........4 Please read before proceeding ......5 Prepare boiler location ........6–11 Prepare boiler ..........12-15 Water piping ..........16-25 Gas piping ............26 Field wiring ............

  • Page 5: Please Read Before Proceeding

    See the instructions at right. contact with water, replace the boiler with a new Weil-McLain boiler. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.
  • Page 6 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 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/NFPA 54 – latest edition. •...

  • Page 7: Prepare Boiler Location

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances Recommended SERVICE clearances Figure 1b Required MINIMUM clearances (Fig. 1a) 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1a for recommen- dations.

  • Page 8: Prepare Boiler

    Condensation can damage each appliance f. After it has been determined that a masonry chimney. Weil-McLain recommends the remaining connected to the common venting system following to prevent possible damage. properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, a.
  • Page 9 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air contamination Please review the following information on potential Refer to Table 1 for products and areas which may cause combustion air contamination problems. contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler.
  • Page 10 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings Figure 2 Air openings to interior spaces Combustion air opening location and sizing requirements depend on the clearances around ✷ the boiler. Check the boiler placement compared to ✷...
  • Page 11 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings Unusually tight construction FREE AREA of openings — the minimum areas Unusually tight construction means (per ANSI Z223.1) given in this manual are free area (equals the area, buildings in which: length times width of opening, after deduction for a.
  • Page 12 6. Reinstall main burner with attached pilot assembly CGa 3-8 at location marked on gas manifold. Reinstall all remaining burners. Note 1: For elevations above 2,000 feet, contact your Weil-McLain sales office for details. 7. Follow check-out procedure, Section , page 33. Part Number 550-142-300/0520...
  • Page 13 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test 4. Close shutoff valves. 5. Slowly reopen boiler drain valve until test pressure before Pressure test boiler attaching water or gas piping of not more than 45 psi is reached on the pressure/ or electrical supply (except as noted below).
  • Page 14 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Prepare boiler — draft hood & spill switch Draft hood installation Spill switch installation 1. Orient draft hood with spill switch mounting holes to front of boiler 1. Fasten spill switch to draft hood as shown in Figure 6 as shown in Figure 7.
  • Page 15 This will void CSA certification and will not be covered by Weil-McLain warranty. Any changes will cause severe personal injury, death or substantial property damage.

  • Page 16: Water Piping

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Water piping — general information General piping information Circulator The circulator is shipped loose (wiring pre-attached to If installation is to comply with ASME or Canadian requirements, an ad- boiler) to allow you to locate it either in the return or ditional high temperature limit is needed.
  • Page 17 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Water piping — single-zone system 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. Diaphragm-type or bladder- Closed-type expansion tank type expansion tank...
  • Page 18 . Instead, provide controls and piping which can regulate the boiler return water temperature at no less than 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 19 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones (continued) Figure 11 Zoning with circulators — return water Figure 12 Zoning with zone valves — return water 130°F or higher. 130°F or higher. Boiler isolation (balancing) Automatic air vent (with diaphragm-type expansion tank), or connect valves to tank fitting (closed-type expansion tank).
  • Page 20 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 21 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Water piping — low temperature systems (continued) Figure 13 Primary/secondary piping Figure 14 Primary/secondary piping Zoning with circulators Zoning with zone valves Automatic air vent (with diaphragm-type expansion Boiler isolation (balancing) valves tank), or connect to tank fitting (closed-type expan- Flow/check valve sion tank).
  • Page 22 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 23 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Water piping — low temperature systems (continued) Figure 15 Boiler-bypass piping Figure 16 Boiler-bypass piping Zoning with circulators Zoning with zone valves (Alternative to primary/secondary piping (Alternative to primary/secondary piping Figures 13 and 14) Figures 13 and 14) Boiler isolation (balancing) valves Automatic air vent (with diaphragm-type expansion...
  • Page 24 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 25 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Water piping — low temperature systems (continued) 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, page 23) 3 System or zone circulator 7 System temperature valves (see instructions to the left for...

  • Page 26: Gas Piping

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Gas piping Connect gas supply piping to boiler Natural Gas: 1. Remove jacket front panel and refer to Figure 19 to pipe gas to boiler. Table 4 1. Refer to for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtain cubic Install drip leg at inlet of gas connection to boiler.

  • Page 27: Field Wiring

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Field wiring turn off electrical power supply at ser- Figure 25b For your safety, the wiring diagram shown in , page 37. For other devices, refer to manufacturer’s specifica- vice entrance panel before making any electrical con- tions.

  • Page 28: Start-Up

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Check for gas leaks Determine if water treatment is needed Before starting the boiler, and during petroleum-based clean- Do not use initial operation, smell near the floor ing or sealing compounds in boiler and around the boiler for gas odorant system.
  • Page 29 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Start-up — preparation (continued) Fill the system with water Inspect system water piping 1. Close manual and automatic air vents and boiler inspect After filling the boiler and system with water, drain cock.
  • Page 30 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler 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.
  • Page 31 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) Start the boiler Operating Instructions Section • Follow the from Eliminate all system leaks. to start the boiler. Remove boiler jacket door and note the gas valve manufacturer and model number. Continual fresh makeup water Use only the operating instruction which applies to will reduce boiler life.
  • Page 32 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Start-up — verify operation Section 9 for operation and operating information. Check burner flames Figure 21 Typical pilot burner flame Pilot burner flame ( Figure 21 PROPER pilot flame 1. Blue flame. 2.

  • Page 33: Check-Out Procedure

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist ❏ Set Boiler Temp adjustment knob to system temperature re- ❏ Boiler and heat distribution units filled with water? quirements. Adjust balancing valves and controls to provide ❏...

  • Page 34: Department Of Energy Compliance

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Department of Energy – Compliance This boiler is equipped with a control system that automatically adjusts a time delay period to turn on the boiler during a call for heat. This is accomplished by circulating available hot water in the system while measuring water boiler water tempera- ture changes.
  • Page 35 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot boilers Main burner operation: 5. Thermostat satisfied (thermostat circuit opens) — Pilot and main gas valves are closed — Vent damper is de-energized, and cycles Control module monitors pilot flame current. If signal to closed position.
  • Page 36 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25a Schematic wiring diagram — Spark-ignited pilot system DO NOT connect directly from 3-wire zone valves to the T-T terminals on the CAUTION boiler. When using 3-wire zone valves, install an isolation relay. Connect the zone valve end switch wires to the isolation relay coil.
  • Page 37 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25b Ladder wiring diagram — Spark-ignited pilot system Electrical shock hazard — can WARNING Neutral cause severe injury or death. 120 VAC Disconnect power before installing SERVICE or servicing.
  • Page 38 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas • Propane gas CGa-25 to CGa-8 • Gas valve: Honeywell VR8204/VR8304 Part Number 550-142-300/0520...
  • Page 39 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-25 to CGa-6 • Gas valve: Robertshaw 7200 Part Number 550-142-300/0520...
  • Page 40 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-25 to CGa-6 • Gas valve: White-Rodgers 36E Part Number 550-142-300/0520...
  • Page 41 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-7 to CGa-8 • Gas valve: White-Rodgers 36C Part Number 550-142-300/0520...

  • Page 42: Service And Maintenance

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING Table 6 Service and maintenance schedules (service technician and user) Service technician Owner maintenance (see following pages for instructions) (see CGa User’s Information Manual for instructions) •...
  • Page 43 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Service & maintenance — annual start-up 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 The boiler should be inspected and started annu- cannot be removed, install combustion air piping...
  • Page 44 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) ❏ Inspect . . . 3. If burners must be cleaned, raise rear of each burner to release from support slot, slide forward Boiler heating surfaces and remove.
  • Page 45 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) ❏ Check/test Expansion tank 1. Expansion tanks provide space for water to move in an out as the heating system water expands due to Gas piping temperature increase or contracts as the water cools.
  • Page 46 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) 2. After following the above warning directions, if the relief valve rein- weeps or will not seat properly, replace the relief valve. Ensure Safety relief valves should be spected AT LEAST ONCE EVERY that the reason for relief valve weeping is the valve and not over- THREE YEARS...
  • Page 47 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) ❏ Cleaning boiler heating surfaces (continued) 11. Reinstall radiation plates. 6. Remove radiation plates hanging between sections. 12. Replace collector box/transition assembly. Seal with sealant. 7.
  • Page 48 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure (continued) Check the following: pliers on flat shaft between damper and actuator. Boiler will fire. Verify that damper service switch is Hold Damper Open Figure 28 position. ( 1.

  • Page 49: Troubleshooting: Spark-Ignited Pilot Boilers

    CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers The information on this page and Control indicator lights — pages 50 through 57 apply only to HARD LOCKOUT Summary (Flashing LED’s) spark-ignited pilot CGa boilers. MAY remove 120 VAC power for more than 2 seconds to clear lockout OR These boilers are equipped with ignition control will automatically restart sequence of operation after 1 hour an ignition control module that...
  • Page 50 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) Figure 30 Control module connections Part Number 550-142-300/0520...
  • Page 51 Is POWER light flashing now? Does voltmeter indicate 120 VAC ? Have system checked by a licensed electrician. If problem persists, contact Replace transformer. Replace control module. Boiler should now your Weil-McLain Technical operate normally. Retest. Retest. support. Part Number 550-142-300/0520...
  • Page 52 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 2 –– Spark-ignited pilot –– TSTAT CIRC & POWER lights flashing –– Usually indicates 48 VAC on thermostat circuit (stray voltage) –– 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.
  • Page 53 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 3 –– Spark-ignited pilot –– DAMPER light flashing –– If POWER light is flashing: Usually indicates vent damper failed to prove open within 45 seconds –– ––...
  • Page 54 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 4 –– Spark-ignited pilot –– FLAME & POWER lights flashing –– Usually indicates flame sensed when it shouldn’t be there –– 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.
  • Page 55 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 5 –– Spark-ignited pilot –– FLAME light flashing and POWER light on steady ALSO –– Troubleshooting failure to establish main flame 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.
  • Page 56 • Check temperature sensor for correct • Retest. resistance. Are resistance values • Correct conditions and correct? Contact your Weil-McLain recheck operation. Technical support. Check spill switch and • See Figure 24, page 35 rollout switch continuity – for normal sequence of Are switches closed? operation.
  • Page 57 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) Troubleshooting LWCO and POWER light Solid CHART 7 –– and/or “LCO” shown on display 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.

  • Page 58: Replacement Parts

    Jacket ............... 61 Trim ..............62 Controls ............63 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 manufac- tured parts will not be covered by warranty and may damage boiler or impair operation.
  • Page 59 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Replacement parts — section assembly Figure 31 Section assembly, flue collector, draft hood and vent damper Item Item Description Part number Description Part number number number End section, left hand, 51124 311-103-851 Temperature/LWCO sensor 511-724-305...
  • Page 60 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Replacement parts — base Figure 32 Base assembly, manifold, orifices and burners Item Description Part number number CGa-25 Base assembly kit 381-354-362 (includes base panels CGa-3 381-354-356 CGa-4 items 1, 2, 3, 4, 5, 6 and 7, 381-354-357 plus insulation, air box gaskets, CGa-5...
  • Page 61 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Replacement parts — jacket Figure 33 Jacket assembly Junction box, 2 x 4 Jacket panel, left side, with insulation Jacket panel, Jacket panel, Jacket panel, right side, top front top rear with insulation Natural Gas Propane Gas...
  • Page 62 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Replacement parts — trim Figure 34 Trim assembly Item Description Part number number Pressure relief valve, ASME, 30 PSIG, ¾” male inlet 511-546-920 Pressure relief valve, ASME, 30 PSIG, ¾” female inlet 511-546-924 (Fittings shown are factory-installed on boiler.) Combination pressure-temperature gauge, 3⅛,”...
  • Page 63 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Replacement parts — controls Figure 35 Gas control components Item Description Boiler model Part number number Natural gas components 511-044-381 Gas Valve, ½” x ½” CGa-25 through CGa-6 511-044-382 ¾ ¾ Gas valve, ”...
  • Page 64 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Dimensions Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler Supply Return Gas connection “A” “D” “W” “H” model tapping tapping & manifold size Vent Vent Jacket Damper number location diameter width height...
  • Page 65 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Ratings AHRI Certified Ratings Chimney Boiler Boiler Seasonal water breeching Heating model 0 - 2,000 feet 2,000 - 4,500 feet Efficiency content size number Altitude Altitude Capacity Ratings PIDN-PIDL Input Output Input Output Btuh...
  • Page 66 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS The combustion chamber lining or base INSTALLATION OF FIBERGLASS WOOL, insulation panels in this product con- COMBUSTION CHAMBER LINING OR tain ceramic fiber materials.
  • Page 67 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Notes Part Number 550-142-300/0520...
  • Page 68 CGa Series 3 Gas-Fired Water Boiler — Boiler Manual Part Number 550-142-300/0520...

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