Weil-McLain CGA Series 2 Manual
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Weil-McLain CGA Series 2 Manual

Weil-McLain CGA Series 2 Manual

Gas-fired water boilers
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Table of Contents

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 2
Gas-Fired Water Boilers
• Installation
• Startup
Part Number 550-142-900/0519
• Maintenance
• Parts
Before installing
, read all

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Summary of Contents for Weil-McLain CGA Series 2

  • Page 1 Series 2 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, and any related supplements. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 2 CGa Series 2 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 2 Gas-Fired Water Boiler — Boiler Manual CGa Series 2 Gas-Fired Water Boiler 09002 Part Number 550-142-900/0519...

  • Page 4: Table Of Contents

    CGa Series 2 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 2 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 2 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

    CGa Series 2 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.
  • Page 9 CGa Series 2 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.
  • Page 10 CGa Series 2 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 2 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,...
  • Page 12 CGa Series 2 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-...
  • Page 13 CGa Series 2 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 2 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 CGa Series 2 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.

  • Page 16: Water Piping

    CGa Series 2 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 high temperature limit ditional is needed.
  • Page 17 CGa Series 2 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.
  • 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 2 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 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water piping — low temperature systems water temperature being supplied to the radiant tubing. Primary/secondary (preferred) Bypass piping method required Gauge on all systems to assure the return water temperature is accurately set for a minimum of...
  • Page 21 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water 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...
  • Page 22 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water 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 60°F. Set the valves so gauge reads at least 120°F.
  • Page 23 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water 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 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water 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...
  • Page 25 CGa Series 2 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 26: Gas Piping

    CGa Series 2 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 boiler. Table 4 1. Refer to for pipe length and diameter. Base...

  • Page 27: Field Wiring

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Field wiring For your safety, turn off electrical power supply at ser- the wiring diagram shown in Figure 25b , page 37. vice entrance panel before making any electrical con- For other devices, refer to manufacturer’s specifica- tions.

  • Page 28: Start-Up

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Check for gas leaks Determine if water treatment is needed petroleum-based cleaning or sealing Do not use Before starting the boiler, and during compounds in boiler system. Severe damage to boiler initial operation, smell near the floor will occur, resulting in substantial property damage.
  • Page 29 CGa Series 2 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.
  • Page 30 CGa Series 2 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 2 Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) Start the boiler Operating Instructions Section • Follow the from to start the boiler. Remove boiler jacket door and Eliminate all system leaks. note the gas valve manufacturer and model number.
  • Page 32 CGa Series 2 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.

  • Page 33: Check-Out Procedure

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist ❏ Boiler and heat distribution units filled with water? ❏ Set Boiler Temp adjustment knob to system temperature re- quirements. Adjust balancing valves and controls to provide ❏...

  • Page 34: Department Of Energy Compliance

    CGa Series 2 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 2 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 2 Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25a Schematic wiring diagram — Spark-ignited pilot system Part Number 550-142-900/0519...
  • Page 37 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25b Ladder wiring diagram — Spark-ignited pilot system Part Number 550-142-900/0519...
  • Page 38 CGa Series 2 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 550-142-900/0519...
  • Page 39 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-25 to CGa-6 • Gas valve: Robertshaw 7200 Part Number 550-142-900/0519...
  • Page 40 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-25 to CGa-6 • Gas valve: White-Rodgers 36E Part Number 550-142-900/0519...
  • Page 41 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural gas CGa-7 to CGa-8 • Gas valve: White-Rodgers 36C Part Number 550-142-900/0519...

  • Page 42: Service And Maintenance

    CGa Series 2 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 2 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...
  • Page 44 CGa Series 2 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 2 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 2 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...
  • Page 47 CGa Series 2 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.
  • Page 48 CGa Series 2 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 position. ( Figure 28 1.

  • Page 49: Troubleshooting: Spark-Ignited Pilot Boilers

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers Control indicator lights — The information on this page and pages 50 through 56 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...
  • Page 50 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) Figure 30 Control module connections White Pink or Blue 120 VAC H 24 VAC Brown or Yellow Black 120 VAC N High voltage to pilot spark electrode...
  • Page 51 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 1 –– 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.
  • Page 52 CGa Series 2 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 2 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 2 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 2 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 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 6 –– 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 57 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) Troubleshooting Sensor Ground 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

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Replacement parts Section assembly ..........59 Base ..............60 Jacket ............... 61 Trim ..............62 Controls ............63 Replacement parts must be purchased through a local Weil-McLain distribu- tor. When ordering, specify boiler model and size and include description and part number of replacement part.
  • Page 59 CGa Series 2 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...
  • Page 60 CGa Series 2 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 381-354-355 CGa-25 (includes base panels 381-354-356 CGa-3 items 1, 2, 3, 4, 5, 6 and 7,...
  • Page 61 CGa Series 2 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...
  • Page 62 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Replacement parts — trim Figure 34 Trim assembly Item Manufacturer’s Description Weil-McLain Manufacturer part number number part number Pressure relief valve, ASME, 30 PSIG, ¾” male inlet Conbraco 10-407-05 511-546-920 Watts M330 Pressure relief valve, ASME, 30 PSIG, ¾”...
  • Page 63 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Replacement parts — controls Figure 35 Gas control assembly Item Description Boiler model Manufacturer Manufacturer’s Part number number part number Natural gas components 511-044-381 Gas Valve, ½” x ½” CGa-25 through CGa-6...
  • Page 64 CGa Series 2 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...
  • Page 65 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Ratings AHRI Certiified Ratings Chimney Boiler Boiler Seasonal water breeching Efficiency Heating model 0 - 2,000 feet 2,000 - 4,500 feet content size number Altitude Altitude Capacity Ratings PIDN-PIDL Input Output...
  • Page 66 CGa Series 2 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 2 Gas-Fired Water Boiler — Boiler Manual Notes Part Number 550-142-900/0519...
  • Page 68 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Part Number 550-142-900/0519...

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