Weil-McLain GOLD CGa-25 Manual
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Weil-McLain GOLD CGa-25 Manual

Gold cga gas-fired water boilers
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See also: User's Information Manual , Installation and Maintenance Manual
™
GOLD CGa
®
Gas-Fired Water Boilers
Boiler Manual
Before installing
Part No. 550-101-009/0107

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Summary of Contents for Weil-McLain GOLD CGa-25

  • Page 1 ™ GOLD CGa ® Gas-Fired Water Boilers Boiler Manual Before installing Part No. 550-101-009/0107...

  • Page 2: How Is Works

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual How it works . . . Control module Transformer Draft hood Spill switch Water temperature limit switch Boiler circulator NOTE Vent damper Other boiler components: Part Number 550-101-009/0107...
  • Page 3 GOLD CGa Gas-Fired Water Boiler — Boiler Manual GOLD CGa Gas-Fired Water Boiler Part Number 550-101-009/0107...

  • Page 4: Table Of Contents

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

  • Page 5: Please Read Before Proceeding

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User stalling page 68 When servicing boiler — Boiler operation — Glycol — potential fire hazard — Boiler water — Part Number 550-101-009/0107...
  • Page 6 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — codes & checklist Installations must follow these codes: Before locating the boiler, check the following: Part Number 550-101-009/0107...

  • Page 7: Prepare Boiler Location

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances Required MINIMUM clearances located on the wall or door opposite the boiler FRONT (see Figure 1b) Foundation Minimum foundation width: CGa-25/3 12" CGa-6 21" CGa-4 15" CGa-7 24"...

  • Page 8: Prepare Boiler

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — vent system When removing boiler from an Chimney or vent require- existing common vent system: ments Part Number 550-101-009/0107...
  • Page 9 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air contamination — OR — Corrosive contaminants and likely locations Products to avoid Areas likely to have contaminants Spray cans containing chloro/fluorocarbons Dry cleaning/laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes/cleaners Metal fabrication plants...
  • Page 10 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings Air openings must be provided Part Number 550-101-009/0107...
  • Page 11 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Unusually tight construction FREE AREA Single air opening option Clearances from boiler to walls Exhaust fans and air movers Opening must be directly to outside Opening placement Opening size Motorized air dampers Exception for large spaces Part Number 550-101-009/0107...
  • Page 12 Location Propane gas 0-2,000 ft over 2,000 ft U. S. 1.30 mm (Note 1) Canada 0-2,000 ft 2,000-4,500 1.30 mm 1.20 mm Note 1: For elevations above 2,000 feet, contact your local Weil-McLain sales office for details. Part Number 550-101-009/0107...
  • Page 13 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test Prepare boiler for test Drain and remove fittings Fill and pressure test Part Number 550-101-009/0107...
  • Page 14 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — draft hood & spill switch Draft hood installation Spill switch installation Prepare boiler — install vent piping Part Number 550-101-009/0107...
  • Page 15 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — vent damper installation Installation Damper blade Minimum clearances Figure 8 Vent damper assemblies — Part Number 550-101-009/0107...

  • Page 16: Water Pi Ping

    General piping information Circulator System water piping Pressure/temperature gauge Relief valve Table 3 Water pipe size (based on 20°F rise) Boiler model From system system CGa-25 ¾" ¾" CGa-3, 4, 5 1" 1" 1 ¼" 1 ¼" CGa-6, 7 CGa-8 1 ½"...
  • Page 17 GOLD CGa 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) Diaphragm- or bladder-type expansion Closed-type expansion tank — Single- tank — Single-zone system using dia- zone system using closed-type expan- phragm-type or bladder-type expansion sion tank.
  • 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 systems Converted gravity (or steam) systems Zoning with circulators (Figure 11) (return temp over 130°F) Zoning with zone valves (Figure 12) (return temp over 130°F) Radiant heating systems Part Number 550-101-009/0107...
  • Page 19 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones (continued) Part Number 550-101-009/0107...
  • Page 20 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems Primary/secondary (preferred) Bypass piping method Figures 13 Valve adjustment (Figures 13 and 14 on ly) Temperature gauges DO NOT Part Number 550-101-009/0107...
  • Page 21 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) DO NOT Part Number 550-101-009/0107...
  • Page 22 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) BOILER-bypass piping method Valve adjustment Temperature gauges DO NOT Part Number 550-101-009/0107...
  • Page 23 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) DO NOT Part Number 550-101-009/0107...
  • Page 24 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) SYSTEM-bypass piping method Valve adjustment DO NOT Part Number 550-101-009/0107...

  • Page 25: Water Piping

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Water piping — refrigeration systems Part Number 550-101-009/0107...

  • Page 26: Gas Piping

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Gas piping Connect gas supply piping to boiler Natural Gas: Propane Gas: Table 4 Pipe capacity for 0.60 specific gravity natural gas Gas supply piping Capacity of pipe for pipe size of: Gas pipe (Capacity in cubic feet gas per hour) length...

  • Page 27: Field Wiring

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Field wiring Installation must comply with: Wiring connections Part Number 550-101-009/0107...

  • Page 28: Start-Up

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Check for gas leaks Determine if water treatment is needed Verify water chemistry Freeze protection (when used) Part Number 550-101-009/0107...
  • Page 29 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — preparation (continued) Fill the system with water Inspect system water piping drain valves Inspect base insulation Part Number 550-101-009/0107...
  • Page 30 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler Lighting/Operating instruction location guide Models Standing pilot Page Spark-ignited pilot Page CGa-25 CGa-6 CGa-7 CGa-8 Part Number 550-101-009/0107...
  • Page 31 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) Start the boiler Check system and boiler Start-up — if boiler doesn’t start . . . Check for: ing , Part Number 550-101-009/0107...

  • Page 32: Start-Up

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — verify operation Check burner flames Typical pilot burner flame Pilot burner flame PROPER pilot flame IMPROPER pilot flame Main burner flame Typical main burner flame PROPER main burner flame IMPROPER main burner flame: Check vent damper operation Check vent system operation Part Number 550-101-009/0107...

  • Page 33: Check-Out Pr Ocedure

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist 3600 x 1000 = Btuh number of seconds from step c Installation and service certificate Part Number 550-101-009/0107...

  • Page 34: Operation - Standing Pilot Boilers

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — standing pilot boilers Figure 23 Wiring diagram — Standing pilot system Part Number 550-101-009/0107...
  • Page 35 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Lighting instructions CGa-25 to CGa-8 Part Number 550-101-009/0107...
  • Page 36 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Lighting instructions CGa-25 to CGa-8 Part Number 550-101-009/0107...

  • Page 37: Operation - Spark-Ignited Pilot Boilers

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot boilers Figure 24 Ignition control module sequence of operation — status light indications Part Number 550-101-009/0107...
  • 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 CGa-25 to CGa-8 Part Number 550-101-009/0107...
  • Page 41 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-6 Part Number 550-101-009/0107...
  • Page 42 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-6 Part Number 550-101-009/0107...
  • Page 43 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-7 to CGa-8 Part Number 550-101-009/0107...

  • Page 44: Service And Maintenance

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING 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) Inspect: Daily Monthly...
  • Page 45 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance — annual start-up inspected and started annu- ally only by a qualified service technician Table 6 Air openings Eliminate all system or boiler leaks. Flue gas vent system petroleum-based cleaning or sealing compounds Turn off power to the boiler before any service operation...
  • Page 46 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Inspect . . . Boiler heating surfaces Service . . . Oiled-bearing circulators Start-up . . . Part Number 550-101-009/0107...
  • Page 47 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Check/test Expansion tank Gas piping Cold fill and operating pressures Tank-Trol Taco-Trol Air vents and air elimination Automatic air vent, typical Limit controls and cutoffs Part Number 550-101-009/0107...
  • Page 48 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Check/test (continued) Boiler relief valve Relief valve, typical valve Review with owner Part Number 550-101-009/0107...

  • Page 49: Service And Maintenance

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Cleaning boiler heating surfaces Troubleshooting — procedure Before troubleshooting: Part Number 550-101-009/0107...
  • Page 50 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure (continued) Check the following: In event of vent damper failure: Effikal or Field Controls damper Part Number 550-101-009/0107...

  • Page 51: Troubleshooting: Standing Pilot Boilers

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — standing pilot boilers CHART 1 Part Number 550-101-009/0107...
  • Page 52 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers Control module Solder or water ground wiring Control indicator lights — LOCKOUT modes Charts 1 POWER light flashing alone POWER and TSTAT CIRC lights flashing POWER and DAMPER lights flashing POWER and FLAME lights flashing Control indicator lights —...
  • Page 53 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) Part Number 550-101-009/0107...
  • Page 54 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 2 Is POWER light off? Is POWER light... Does voltmeter indicate 120 VAC? Does voltmeter indicate 120 VAC? Is POWER light flashing now? Does voltmeter indicate 120 VAC? Part Number 550-101-009/0107...
  • Page 55 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 3 Did you find a voltage across the two external thermostat circuit wires? Do the lights still flash? Part Number 550-101-009/0107...
  • Page 56 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 4 Does vent damper operate? Does vent damper operate? Figure 30, Item 6, page 53 light flashing? Does the voltmeter indicate 24 VAC? Does vent damper actuator indicator show damper is open? Are the...
  • Page 57 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 5 Are manual main shutoff valve and gas valve open? lights still flash? Is pilot burning? lights flashing? lights flashing? Part Number 550-101-009/0107...
  • Page 58 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 6 Is 24 VAC present there? Does light flash now? Is 24 VAC present there? Is gas present at gas valve inlet and within above range? Is gas present at gas valve inlet and within above range? Figure 30, item 8, page 53 Figure 30, item 8, page 53...
  • Page 59 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 7 Is boiler System circulator operating? Figure 30, Item 7, page 53 Is thermostat circuit closed (continuity across wires)? Does voltmeter show 120 VAC across pins? light on? light on? Is vent or combustion air piping free of blockage?

  • Page 60: Replacement Parts

    GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts Section assembly ..........61 Base ..............62 Jacket ............... 63 Trim ..............64 Controls ............65 Part Number 550-101-009/0107...
  • Page 61 311-103-830 High limit, 30° Honeywell 510-312-250 differential, with well L4080D1036 End section, right hand, 51128 311-103-821 White-Rodgers Intermediate section, 51125 311-103-818 11B81-3 Replacement section CGa-25 & CGa-3 321-114-345 Draft hood CGa-25 450-021-240 shown assembly CGa-4 321-114-346 CGa-3 450-021-241 CGa-5 321-114-347...
  • Page 62 Replacement parts — base 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, CGa-4 381-354-357 air box gaskets, and hardware)
  • Page 63 Jacket panel, side, with insula- top front Natural Gas Propane Gas Natural Gas tion Standing Pilot Standing Pilot Spark Pilot Boiler Boiler Model Weil-McLain part number Model CGa-25 (Available at local 381-355-400 381-355-445 381-355-466 381-355-699 381-355-403 CGa-25 CGa-3 supply house) 381-355-407...
  • Page 64 1 flange, 2 nuts, 2 screws, 1 gasket: ¾” NPT — CGa-25 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 381-354-530 1"...
  • Page 65 1107-2 511-330-079 Control transformer 511-842-370 not shown Wiring harness, controls to control module 591-391-905 Pilot gas pressure regulator — Natural gas and propane gas, CGa-25 and CGa-3 not shown Pilot gas pressure regulator 4.0" w.c. outlet Maxitrol RV-12 510-933-126 SL-50N...

  • Page 66: Dimensions And Ratings

    (inches NPT) (inches NPT) (Note 3) location diameter width height (inches NPT) (inches) (inches) (inches) (inches) CGa-25 CGa-3 CGa-4 CGa-5 CGa-6 CGa-7 CGa-8 Note 3: Size gas piping from meter to boiler per local utility requirements. Part Number 550-101-009/0107...
  • Page 67 (Btuh) (gallons) size Input Output Input Output SPDN SPDL PIDN (Btuh) (Btuh) (Btuh) (Btuh) (Note 1) (Note 2) (Note 3) CGa-25 52,000 44,000 52,000 44,000 46,800 39,000 38,000 81.5 83.3 84.0 4"I.D. x 20’ CGa-3 70,000 59,000 70,000 59,000 63,000...
  • Page 68 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 INSTALLATION OF FIBERGLASS WOOL, COMBUSTION CHAMBER LINING OR BASE PANELS: Precautionary measures Precautionary measures NIOSH stated First Aid.

This manual is also suitable for:

Gold cga-5Gold cga-3Gold cga-4Gold cga-6Gold cga-7Gold cga-8

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