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Weil-McLain CGa 2 Series Manual

Gas-fired water boilers
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Beginning Serial Number:
CP7540456
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 550-142-900/1016
• Maintenance
• Parts
Before installing
, read all

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Summary of Contents for Weil-McLain CGa 2 Series

  • Page 1 Beginning Serial Number: CP7540456 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: How It Works

    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 Part Number 550-142-900/1016...

  • 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

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Write in the CP number in the space provided on manual and all other information shipped with the the Installation certificate on page 33 if not already boiler, before installing.
  • Page 6 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — codes & checklist Installations must follow these codes: ws, regulations and ordinances. – latest edition. local codes. other performance criteria when boiler underwent tests specified Before locating the boiler, check the following: tem water piping trical power...

  • Page 7: Prepare Boiler Location

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances Recommended SERVICE clearances Required MINIMUM clearances 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 Please review the following information on potential 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 2 Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings Air openings to interior spaces ✷ Check the boiler placement compared to ✷ Figure 1a, page 7. , apply the sizing and placement of openings given on pages 10 and 11.
  • Page 11 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings Unusually tight construction of openings — the minimum areas FREE AREA given in this manual are free area (equals the area, buildings in which: length times width of opening, after deduction for a.
  • 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- until installa- age.
  • 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 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 as shown in Figure 7.
  • Page 15 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Prepare boiler — vent damper installation These systems are used on gas-fired boilers with vent Installation without vent damper installed. 1. Install vent damper horizontally or vertically as one boiler and so damper blade indicator is visible other vent damper installed could cause severe personal to the user.

  • Page 16: Water Piping

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water piping — general information General piping information Circulator The circulator is shipped loose (wiring pre-attached to ditional is needed. Install control in supply piping boiler) to allow you to locate it either in the return or between boiler and isolation valve.
  • Page 17 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water piping — single-zone system Diaphragm-type or bladder- Closed-type expansion tank type expansion tank (Figure 9) (Figure 10) system water volume and temperature. See tank system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possible, before inlet side of circulator.
  • Page 18 CGa Series 2 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 16 and 17 to install near- systems boiler or single-zone piping. (Also refer to below, if applicable.) Converted gravity (or steam) systems , page 19, to complete in-...
  • Page 19 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones (continued) Zoning with circulators — return water Zoning with zone valves — return water 130°F or higher. 130°F or higher. Automatic air vent (with diaphragm-type expansion tank), or connect valves to tank fitting (closed-type expansion tank).
  • 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 on all systems to assure the return water temperature is accurately set for a minimum of bypass piping is preferred because 130°F.
  • Page 21 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water piping — low temperature systems (continued) Primary/secondary piping Primary/secondary piping Zoning with circulators Zoning with zone valves Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expan- Flow/check valve sion tank).
  • 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) 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) Figures 13 and 14) Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion Flow/check valve...
  • Page 24 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water piping — low temperature systems (continued) SYSTEM-bypass piping 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 This piping method ( , page 25) is called a...
  • Page 25 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Water piping — low temperature systems (continued) 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 2 Gas-Fired Water Boiler — Boiler Manual Gas piping Connect gas supply piping to boiler Natural Gas: to pipe gas to boiler. on rated boiler input (divide by 1,000 to obtain cubic at inlet of gas connection to boiler. Where local utility requires drip leg to be extended to the floor, use appropri- feet per hour).

  • Page 27: Field Wiring

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Field wiring For your safety, the wiring diagram shown in , page 37. tions. Wiring diagram on boiler gives setting for to avoid possible electric shock hazard. Failure control module and gas valve. Also see instructions to do so can cause severe personal injury or death.

  • 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 Do not use in boiler system. Severe damage to boiler initial operation, smell near the floor will occur, resulting in substantial property damage. and around the boiler for gas odorant or any unusual odor.
  • Page 29 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Start-up — preparation (continued) Fill the system with water Inspect system water piping 1. Close manual and automatic and boiler drain cock. After filling the boiler and system with water, throughout the system for leaks. If found, repair Correct pressure will vary with each application.
  • Page 30 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler 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 starting the boiler, do the following: and the procedure (see , below).
  • Page 31 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) Start the boiler from note the gas valve manufacturer and model number. Continual fresh makeup water this gas valve (see , page 30). (The operating can build up in sections, reduc- instruction label on the boiler provides the same ing heat transfer, overheating cast information.)
  • Page 32 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Start-up — verify operation for operation and operating information. Check burner flames Typical pilot burner flame Pilot burner flame ( PROPER pilot flame 2. Inner cone engulfing pilot flame sensor (spark- ignited pilot).

  • Page 33: Check-Out Procedure

    CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist ❏ ❏ quirements. Adjust balancing valves and controls to provide ❏ design temperature to system. ❏ ❏ ❏ ❏ For multiple zones, adjust flow so it is about the same in ❏...

  • 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 (thermostat circuit opens) — Pilot and Control module monitors pilot flame current. If signal to closed position. Circulator is shut off. is lost, main valve closes, spark generator activates and sequence returns to step 4.
  • 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 550-142-900/1016...
  • 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 550-142-900/1016...
  • Page 38 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-8 Part Number 550-142-900/1016...
  • Page 39 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-6 Part Number 550-142-900/1016...
  • Page 40 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-6 Part Number 550-142-900/1016...
  • Page 41 CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-7 to CGa-8 Part Number 550-142-900/1016...

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