Weil-McLain Gold CGa Installation And Maintenance Instructions Manual
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Weil-McLain Gold CGa Installation And Maintenance Instructions 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, the burner 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.
GOLD CGa
Gas-Fired Water Boilers
• Installation
• Startup
• Maintenance
• Parts
Before installing
, read all
Part No. 550-101-009/0107

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Summary of Contents for Weil-McLain Gold CGa

  • Page 1 GOLD CGa Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts Before installing This manual must only be used by a qualified heating installer/service technician. , read all instructions, including this manual, the burner 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. Part No. 550-101-009/0107...

  • Page 2: How It Works

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual How it works . . . ① 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 igni- tion 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 con- tinue 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 oc- curs, the control module flashes combinations of lights to indicate the most likely reason for the problem. See page 5 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. ② Transformer The control transformer reduces line voltage to 4 volts for the gas valve and limit circuit.
  • Page 3 GOLD CGa Gas-Fired Water Boiler — Boiler Manual GOLD CGa Gas-Fired Water Boiler Part Number 550-101-009/0107...
  • Page 4 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Contents How is 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 ....

  • Page 5: Please Read Before Proceeding

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User Read all instructions before in- This manual is for use only by your qualified • stalling . Follow all instructions in heating installer/service technician. proper order to prevent personal User’s Information Manual • Please refer to the...
  • Page 6 GOLD CGa 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 Z3.1–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. Installation Code, CSA C.1 Canadian Electrical Code Part 1 and any local codes. The CGa boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z1.13–latest edition.
  • Page 7 GOLD CGa 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. . 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 Figure 1a Recommended service clearances (see WARNING below) Flooring The CGa boiler is approved for installation on combustible flooring, but must never be installed on carpeting.
  • Page 8 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — vent system 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 an Chimney or vent require- existing common vent system: ments At the time of removal of an existing boiler, the following 1. Venting must be installed according to Part , Vent- steps shall be followed with each appliance remaining ing of Equipment, of National Fuel Gas Code, ANSI connected to the common venting system placed in op- Z3.1-latest edition and applicable building codes. eration, while the other appliances remaining connected Canadian installations must comply with B149.1 or to the common venting system are not in operation. B149. Installation Codes. Seal any unused openings in the common venting . See Ratings table on page  for minimum chimney...
  • Page 9 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air contamination Table 1 Please review the following information on potential Refer to 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. 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...
  • Page 10 GOLD CGa 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 ✷ Figure 1a, page . If all clearances are at least equal to Figure 1a,...
  • Page 11 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Unusually tight construction FREE AREA of openings — the minimum areas Unusually tight construction means (per ANSI Z3.1) given in this manual are free area (equals the area, buildings in which: length times width of opening, after deduction for a. Walls and ceilings exposed to the outside atmo- louver obstruction). sphere have a continuous water vapor retarder with Use the free area information provided by the louver manufacturer. a rating of 1 perm or less with openings gasketed, When this information is not available, assume: and . . . • Wood louvers — assume free area is 0% of total; so the actual area b. Weather-stripping has been added on openable of each opening with wood louvers would be 5 times the required windows and doors, and . . .
  • Page 12 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — placement and setup Place boiler/crate near Correctly-sized manifold orifices must be used. Failure to do so will position result in severe personal injury, death or substantial property dam- Leave boiler in crate and on pallet 1. until installa- age. tion site is ready. . Move entire crate and pallet next to selected loca- 3. Level and straighten burners.
  • Page 13 GOLD CGa 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). temperature gauge. 45 psi for no more than 10 . Test at no more than Prepare boiler for test minutes. 1. Remove the shipping nipple (from CGa supply Do not leave boiler unattended tapping) and remove the boiler relief valve.
  • Page 14 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — draft hood & spill switch Draft hood installation Spill switch installation 1. Fasten spill switch to draft hood as shown in Figure 6 1. Orient draft hood with spill switch mounting holes to front of boiler and Figure 7 as shown in Figure . . See Wiring diagram to connect wires: . Secure draft hood to outlet at top of boiler with sheet metal screws. a. Standing pilot boiler — see page 34 3. Bottom of draft hood or “skirt” must have clearance dimension above b. Spark-ignited pilot boiler —...
  • Page 15 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — vent damper installation Installation These systems are used on gas-fired boilers with vent dampers as shipped from factory. Boiler will not operate without vent damper installed. 1. Install vent damper horizontally or vertically as shown in vent damper manufacturer’s instructions. Only vent dampers listed in the Replacement parts list Vent damper must be installed so that it serves only on page 1 are certified for use with CGa boilers. Any one boiler and so damper blade indicator is visible other vent damper installed could cause severe personal Figure 8 to the user. See injury or death. . Screws or rivets used to secure the vent damper to the draft hood must not interfere with rotation of Damper blade the damper blade.
  • Page 16 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — general information General piping information Circulator If installation is to comply with ASME or Canadian requirements, an ad- The circulator is shipped loose (wiring pre-attached to ditional high temperature limit is needed. Install control in supply piping boiler) to allow you to locate it either in the return or between boiler and isolation valve. Set second control to minimum 0°F supply piping, as desired. See page 3 for a typical instal- above setpoint of first control. Maximum allowable setpoint is 40°F. See lation. Pipe the expansion tank to the suction side of the page 34 or 38, for wiring. circulator whenever possible. Install an air separator in the supply piping. Connect the expansion tank to the air low water cutoff device is required when boiler is installed above ra- separator only if the separator is on the suction side of diation level or by certain state or local codes or insurance companies. Use the circulator. Always install the system fill connection low water cutoff designed for water installations. Electrode probe-type is at the same point as the expansion tank connection to recommended. Purchase and install in tee in supply piping above boiler.
  • Page 17 GOLD CGa 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 (Figure 9) (Figure 10) 1. Ensure expansion tank size will handle boiler and 1. Ensure expansion tank size will handle boiler and system water volume and temperature. See tank system water volume and temperature. Tank must manufacturer’s instructions for details. be located in boiler return piping as close to boiler as possible, before inlet side of circulator. See tank . Connect tank to ½” NPT tapping located behind manufacturer’s instructions for details. supply outlet, using ½” NPT piping. Pitch any...
  • Page 18 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones Piping multiple zones Piping for radiant heating systems or converted gravity Follow instructions on pages 1 and 1 to install near- boiler or single-zone piping. (Also refer to Piping for systems radiant heating systems or converted gravity sys- tems, below, if applicable.) Converted gravity (or steam) systems Figure 11 Figure 12 See or , page 19, to complete in- Whenever possible, use the primary/secondary piping stallation.
  • Page 19 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones (continued) Figure 11 Figure 12 Zoning with circulators — return water Zoning with zone valves — return water 130°F or higher. 130°F or higher. Boiler isolation (balancing)
  • Page 20 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems the water temperature being supplied to the radiant Primary/secondary (preferred) tubing. Bypass piping method required Gauge is on all systems to assure the return Primary/secondary bypass piping is preferred because water temperature is accurately set for a minimum of the flow rate and temperature drop in the heating 130°F. If this gauge is not available however, adjust the...
  • Page 21 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Figure 13 Figure 14 Primary/secondary piping 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 DO NOT sion tank). use an automatic air vent when using closed-type expansion tank. It would allow...
  • Page 22 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) BOILER-bypass piping to the boiler. (When setting the valves without gauge installed — using cold or room temperature water method — assume the return water temperature to be 0°F. Set the valves so gauge reads at least 10°F. Figure 15 This piping method ( , page 3) is called boiler-bypass because part of the circulator flow is Gauge is optional on converted gravity systems, bypassed around the boiler (through valve ). This...
  • Page 23 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Figure 15 Figure 16 Boiler-bypass piping Boiler-bypass piping Zoning with circulators Zoning with zone valves (Alternative to primary/secondary piping (Alternative to primary/secondary piping Figures 13 and 14)
  • Page 24 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) SYSTEM-bypass piping DO NOT apply system-bypass piping if the reduced flow in the system could cause poor heat distribution. method That is, system-bypass piping reduces the flow in the system and increases the water temperature supplied to Figure 17 sys- This piping method ( , page 5) is called a the system. This can cause increased heat from radiators tem-bypass because part of the circulator flow bypasses at the beginning of the system and reduced heat from the system (through valve ). This bypassed hot water radiators near the end of the system. from the boiler outlet mixes with cooler system return water temperature in order to provide minimum 130°F...
  • Page 25 GOLD CGa Gas-Fired Water Boiler — Boiler Manual 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 26: Gas Piping

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Gas piping Connect gas supply piping to boiler Natural Gas: Figure 19 1. Remove jacket front panel and refer to to pipe gas to boil- 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. Where local Table 4 specific feet per hour). is only for gas with gravity 0.60, with a pressure drop through the utility requires drip leg to be extended to the floor, use appropri- ate length of pipe between cap and tee.

  • Page 27: Field Wiring

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Field wiring turn off electrical power supply at Thermostat For your safety, service entrance panel before making any electrical connections to avoid possible electric shock hazard. 1. Connect thermostat as shown on wiring diagram Failure to do so can cause severe personal injury or on boiler.
  • Page 28 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Check for gas leaks Determine if water treatment is needed Before starting the boiler, and dur- petroleum-based cleaning or sealing Do not use ing initial operation, smell near the compounds in boiler system. Severe damage to boiler floor and around the boiler for gas will occur, resulting in substantial property damage. odorant or any unusual odor. Do not proceed with start-up if there is Eliminate all system leaks. Continual fresh makeup any indication of a gas leak. Repair...
  • Page 29 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — preparation (continued) Fill the system with water Inspect system water piping air vents 1. Close manual and automatic and boiler drain cock. inspect all After filling the boiler and system with water, piping throughout the system for leaks. If found, repair Fill to correct system pressure. Correct pressure will vary with each immediately. Repeat this inspection after the boiler has application. Typical cold water fill pressure for a residential system is been started and the system has heated up. 1 psi. Leaks must be repaired at once.
  • Page 30 GOLD CGa 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 instruc- tions 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, do the following: • Read manual Section 8/9 and the Lighting/Operating instruction Table 5 procedure (see , below). full of water • Verify the boiler and system are Start-up preparation Section 6 • Verify the...
  • Page 31 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) Start the boiler Lighting/Operating Instructions • Follow the from Eliminate all system leaks. Section 8 or 9 to start the boiler. Remove boiler Continual fresh makeup water jacket door and note the gas valve manufacturer will reduce boiler life. Minerals...
  • Page 32 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — verify operation The boiler model suffix will be “ ”. For spark-ignited pilot boilers (suffix “ ”), see Section 8 for operation and lighting/operating information. Check burner flames Figure 21 Typical pilot burner flame Pilot burner flame ( Figure 21 PROPER pilot flame 1. Blue flame. . Inner cone engulfing thermocouple (standing pilot) or pilot flame sensor (spark-ignited pilot). 3. Thermocouple or pilot flame sensor glowing cherry red.

  • Page 33: Installation And Service Certificate

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist Adjust balancing valves and controls to provide design ❏ Boiler and heat distribution units filled with water? temperature to system. ❏ Automatic air vent, if used, open one full turn? ❏ Air purged from system? ❏ For multiple zones, adjust flow so it is about the same in each zone. ❏ Air purged from gas piping? Piping checked for leaks? ❏ Correctly sized manifold orifices installed? Refer to Table 2 ❏ Verify thermostat heat anticipator (if available) set prop- page 1 to check size and fuel type. Field wiring...
  • Page 34 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — standing pilot boilers Follow all procedures given in this manual and light- This provides gas to the main burners. Burners re- ing instructions when operating the boiler. Failure to main ignited until thermostat circuit or limit circuit do so could result in severe personal injury, death or opens. Burners and circulator are de-energized when substantial property damage. call for heat stops. Burners are de-energized, but circulator remains on, if the limit circuit opens. Standby mode: After pilot is manually lit, the gas valve provides pilot Limit operation: When a limit control opens, the gas and maintains pilot as long as the thermocouple is satisfied. If ther- main gas valve is de-energized, but circulator con- mocouple signal drops for any reason, pilot must be manually lighted, tinues to run. When the limit circuit closes again, Lighting Instructions following the in this manual and on boiler. Vent...
  • Page 35 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Lighting instructions • Standing pilot • Natural or propane gas CGa-25 to CGa-8 • Gas valve: Honeywell VR8200/VR8300 Part Number 550-101-009/0107...
  • Page 36 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Lighting instructions • Standing pilot • Natural gas CGa-25 to CGa-8 • Gas valve: Robertshaw 7200 Part Number 550-101-009/0107...
  • Page 37 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot boilers Main burner operation: Follow all procedures given in this manual and operating instructions when operating the boiler. Failure to do so a. Control module monitors pilot flame could result in severe personal injury, death or substantial current. If signal is lost, main valve closes, property damage. spark generator activates and sequence Standby: With no call for heat, the vent damper and circulator are de-energized. returns to step 4. No gas flows to pilot or main gas valve. b. If power is interrupted, control system Call for heat...
  • Page 38 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25a Schematic wiring diagram — Spark-ignited pilot system Part Number 550-101-009/0107...
  • Page 39 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25b Ladder wiring diagram — Spark-ignited pilot system Part Number 550-101-009/0107...
  • Page 40 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-25 to CGa-8 • Gas valve: Honeywell VR8204/VR8304 Part Number 550-101-009/0107...
  • Page 41 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-25 to CGa-6 • Gas valve: Robertshaw 7200 Part Number 550-101-009/0107...
  • Page 42 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-25 to CGa-6 • Gas valve: White-Rodgers 36E Part Number 550-101-009/0107...
  • Page 43 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-7 to CGa-8 • Gas valve: White-Rodgers 36C Part Number 550-101-009/0107...
  • Page 44 GOLD CGa 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 and maintenance Follow the procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance...
  • Page 45 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance — annual start-up contaminants Table 1 of the listed in 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 ally only , at the beginning of the heating season, to the boiler in accordance with national, provincial by a qualified service technician . In addition, the...
  • Page 46 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) ❏ Inspect . . . . Inspect burners and all other components in the boiler base. Boiler heating surfaces 3. If burners must be cleaned, raise rear of each burner to release from support slot, slide forward 1. Disconnect the vent pipe at the boiler draft hood...
  • Page 47 GOLD CGa 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. Tanks may be open, closed or diaphragm or bladder 1. Sniff near floor and around boiler area for any in- type. See Section of this manual for suggested best gas leak dication of a location of expansion tanks and air eliminators. Test gas piping using bubble test, per Section Open-type — located above highest radiator or...

  • Page 48: Review With Owner

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) ❏ Check/test (continued) Safety relief valves should be reinspected AT LEAST ONCE Boiler relief valve EVERY THREE YEARS , by a 1. Inspect the relief valve and lift the lever to verify...
  • Page 49 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) ❏ Cleaning boiler heating surfaces The boiler contains ceramic fiber and fiberglass materi- . Remove burners from base. Brush and vacuum als. Use care when handling these materials per instruc- burners to remove all dust and lint. Verify that all page 68 tions on of this manual. Failure to comply burner ports are free of debris.
  • Page 50 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure (continued) Check the following: damper blade to open position using wrench or pliers on flat shaft between damper and actuator. Boiler will fire. Verify that damper service switch is 1. Wire connectors to control module are securely Hold Damper Open Figure 28 position. ( plugged in at module and originating control. Do not leave vent damper permanently in this . Gas pressures:...
  • Page 51 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — standing pilot boilers CHART 1 — Standing pilot — Boiler will not fire Is damper harness securely plugged in at both ends? Secure connections. Check for loose wire connections or bad relay on Is 24VAC present across transformer terminals C &...
  • Page 52 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers Control module The information on this page and pages 53 through 59 apply only to Solder or water splatter between plugs and circuit board spark-ignited pilot CGa boilers. can cause improper operation of control module. Place a These boilers are equipped with an shield over the boiler internal controls and components ignition control module that has in- during installation. Failure to comply could result in dicator lights to show control status. severe personal injury, death or substantial property...
  • Page 53 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) Figure 30 Control module connections Part Number 550-101-009/0107...
  • Page 54 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) 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.
  • Page 55 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 3 — 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.
  • Page 56 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 4 — Spark-ignited pilot — DAMPER light flashing — If POWER light is flashing: Usually indicates vent damper failed to prove open within 5 minutes —...
  • Page 57 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 5 — 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.
  • Page 58 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 6 — 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.
  • Page 59 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 7 — Spark-ignited pilot — Insufficient heat or no heat (POWER light on steady) 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 60 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts Section assembly ..........61 Base ..............62 Jacket ............... 63 Trim ..............64 Controls ............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 Boilers and Weil-McLain part numbers are found in Controls Repair Parts Lists The boiler contains ceramic fiber and fiberglass materials. Use care when...
  • Page 61 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — section assembly Figure 31 Section assembly, flue collector, draft hood and vent damper Item Description Weil-McLain Item Description Weil-McLain number part number number part number End section, left hand, 51124 311-103-830 High limit, 30°...
  • Page 62 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — base Figure 32 Base assembly, manifold, orifices and burners Item Description Weil-McLain number part number Base assembly kit CGa-25 381-354-355 (includes base panels items 1, 2, CGa-3 381-354-356 3, 4, 5, 6, and 7, plus insulation,...
  • Page 63 GOLD CGa 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, right Jacket panel, side, with insula- top front Natural Gas Propane Gas...
  • Page 64 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — trim Figure 34 Trim assembly Item Description Manufacturer Manufacturer’s Weil-McLain number part number part number Pressure relief valve, ASME, 30 PSIG, ¾" male inlet Conbraco 10-407-10 511-546-920 Watts M330 Pressure relief valve, ASME, 30 PSIG, ¾"...
  • Page 65 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — controls Figure 35 Gas control assembly Item Description Manufacturer Manufacturer’s Weil-McLain number part number part number Standing pilot — Natural gas components Gas valve, " x ", CGa-25 through CGa-6...
  • Page 66 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Dimensions Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES Part Number 550-101-009/0107...
  • Page 67 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Ratings Boiler Input 0–2,000 feet 2,000–4,500 feet Boiler Chimney model (Btuh) Heating altitude altitude I=B=R water Seasonal efficiency number capacity ratings content (% A.F .U.E) breeching (Btuh) (Btuh) (gallons) size Input Output...

  • Page 68: Handling Ceramic Fiber And Fiberglass Materials

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS The combustion chamber lining or INSTALLATION OF FIBERGLASS WOOL, base insulation panels in this prod- COMBUSTION CHAMBER LINING OR uct contain ceramic fiber materials. Ceramic fibers can be converted to BASE PANELS: cristobalite in very high temperature applications. The International Agency...

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