Table Of Contents - Weil-McLain Gold CGa Installation And Maintenance Instructions Manual

Table of Contents

How It Works2
Boiler Overview3
Hazard Definitions4
Table Of Contents4
Installer5
User5
When Servicing Boiler5
Boiler Operation5
Please Read Before Proceeding5
Prepare Boiler Location — Codes & Checklist6
Prepare Boiler Location — Clearances7
Recommended Service Clearances7
Flooring7
Foundation7
Prepare Boiler Location — Vent System8
When Removing Boiler From Existing Common Vent System8
Chimney Or Vent Requirements8
Prepare Boiler Location — Air Contamination9
Corrosive Contaminants And Likely Locations9
Prepare Boiler Location — Air Openings10
Air Openings To Interior Spaces10
Air From Outdoors — Vertical Ducts10
Air From Outdoors — Horizontal Ducts10
Unusually Tight Construction11
Exhaust Fans And Air Movers11
Motorized Air Dampers11
Exception For Large Spaces11
Prepare Boiler — Placement And Setup12
Place Boiler/Crate Near Position12
Inspect Orifices And Burners12
Orifice Replacement Procedure12
Prepare Boiler — Pressure Test13
Hydrostatic Pressure Test13
Prepare Boiler For Test13
Drain And Remove Fittings13
Prepare Boiler — Draft Hood & Spill Switch14
Draft Hood Installation14
Spill Switch Installation14
Prepare Boiler — Install Vent Piping14
Prepare Boiler — Vent Damper Installation15
Damper Blade15
Minimum Clearances15
Vent Damper Assemblies15
Water Piping — General Information16
General Piping Information16
Circulator16
System Water Piping16
Water Piping — Single-Zone System17
Diaphragm-Type Or Bladdertype Expansion Tank17
Closed-Type Expansion Tank17
Water Piping — Multiple Zones18
Piping Multiple Zones18
Zoning With Circulators18
Zoning With Zone Valves18
Piping — Low Temperature Systems20
Bypass Piping Method20
Temperature Gauges20
Valve Adjustment20
Primary/Secondary Piping Zoning With Circulators21
Primary/Secondary Piping Zoning With Zone Valves21
Boiler-Bypass Piping Method22
Boiler-Bypass Piping Zoning With Circulators23
Boiler-Bypass Piping Zoning With Zone Valves23
System-Bypass Piping24
Water Piping — Refrigeration Systems25
Prevent Chilled Water From Entering Boiler25
Piping Refrigeration Systems25
Gas Piping26
Connect Gas Supply Piping To Boiler26
Natural Gas26
Propane Gas26
Field Wiring27
Thermostat27
Wiring Connections27
Wiring Multiple Zones27
Start-Up — Preparation28
Check For Gas Leaks28
Determine If Water Treatment Is Needed28
Freeze Protection (When Used)28
Fill The System With Water29
Inspect System Water Piping29
Inspect Base Insulation29
Start-Up — Operate Boiler30
Lighting/Operating Instruction Location Guide30
If Boiler Doesn't Start31
Start The Boiler31
Check System And Boiler31
Start-Up — Verify Operation32
Check Burner Flames32
Check Vent Damper Operation32
Typical Pilot Burner Flame32
Check-Out Procedure — Checklist33
Installation And Service Certificate33
Operation — Standing Pilot Boilers34
Wiring Diagram — Standing Pilot System34
Schematic Wiring Diagram34
Ladder Wiring Diagram34
Lighting Instructions35
To Turn Off Gas To The Appliance35
Operation — Spark-Ignited Pilot Boilers37
Ignition Control Module Sequence Of Operation37
Schematic Wiring Diagram — Spark-Ignited Pilot System38
Ladder Wiring Diagram — Spark-Ignited Pilot System39
Ladder For Ladder Wiring Diagram39
Gas Valve Terminals And Anticipator Settings39
Operating Instructions40
Service And Maintenance — Schedule44
Service & Maintenance — Annual Start-Up45
Air Openings45
Flue Gas Vent System45
Pilot And Main Burner Flames45
Start-Up46
Boiler Heating Surfaces46
Oiled-Bearing Circulators46
Check/Test47
Cold Fill And Operating Pressures47
Air Vents And Air Elimination47
Expansion Tank47
Boiler Relief Valve48
Review With Owner48
Cleaning Boiler Heating Surfaces49
Troubleshooting — Procedure49
Before Troubleshooting49
In Event Of Vent Damper Failure50
Effikal Or Field Controls Damper50
Johnson Controls Damper50
Troubleshooting — Standing Pilot Boilers51
Standing Pilot — Boiler Will Not Fire51
Troubleshooting — Spark-Pilot Boilers52
Control Module52
Control Indicator Lights52
Spark-Ignited Pilot Boilers52
Control Module Connections53
Spark-Ignited Pilot — Troubleshooting Power Light Status54
Spark-Ignited Pilot — Tstat Circ & Power Lights Flashing55
Spark-Ignited Pilot — Damper Light Flashing56
Spark-Ignited Pilot — Flame & Power Lights Flashing57
Spark-Ignited Pilot58
Insufficient Heat Or No Heat (Power Light On Steady)59
Replacement Parts60
Replacement Parts — Section Assembly61
Replacement Parts — Base62
Replacement Parts — Jacket63
Replacement Parts — Trim64
Trim Assembly64
Replacement Parts — Controls65
Gas Control Assembly65
Standing Pilot Controls65
Spark-Ignited Pilot Controls65
Dimensions66
Ratings67
Ignition System Model Suffixes67
Handling Ceramic Fiber And Fiberglass Materials68