Weil-McLain GOLD CGt Manual
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Weil-McLain GOLD CGt Manual

Natural gas-fired water boiler with tankless heater
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Summary of Contents for Weil-McLain GOLD CGt

  • Page 2: How It Works

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual How it works . . . ① Control module Boiler circulator The boiler circulator circulates water through the The control module responds to signals from the room external (system) piping. The circulator is shipped...

  • Page 4: Table Of Contents

    GOLD CGt 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 ............12–13 Venting ............... 14-19 Water piping .............. 20-27 Gas piping ................ 28 Field wiring ..............

  • Page 5: Please Read Before Proceeding

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User • Read all instructions before This manual is for use only by your qualified Follow all instructions in installing. heating installer/service technician. proper order to prevent personal •...
  • Page 6 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — codes & checklist Installations must follow these • Check area around boiler. Remove any combustible codes: materials, gasoline and other flammable liquids. • Local, state, provincial, and national codes, laws, Failure to keep boiler area clear and regulations and ordinances.

  • Page 7: Prepare Boiler Location

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances You must provide openings for combustion and Figure 1 Recommended clearances for ocated on the wall or door opposite the ventilation air, l service Flush to ceiling...

  • Page 8: Prepare Boiler

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — vent system CGt venting f. After it has been determined that Failure to follow all instructions can each appliance remaining connected to the common venting result in flue gas spillage and carbon...
  • Page 9 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — contamination Air contamination Please review the following information on potential Refer to for products and areas which may cause Table 1 combustion air contamination problems. contaminated combustion air.
  • Page 10 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings Combustion air and ventilation openings for all boiler installations must 3. When combustion air is supplied to the boiler comply with Section 5.3, “Air for Combustion and Ventilation,” of the...
  • Page 11 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Exception to combustion air opening 4. When combustion air is supplied to the boiler space directly from outside through horizontal rules: : Provide two permanent openings: ducts (Figure 6) combustion air openings are needed when the boiler (and other •...
  • Page 12 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Prepare boiler — placement and setup Place boiler/crate near position 1. Leave boiler in crate and on pallet until installation site is ready. 2. Move entire crate and pallet next to selected location.
  • Page 13 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Perform hydrostatic pressure test Pressure test boiler attaching water or gas piping (except as noted below) or electrical before supply. Prepare boiler for test 1. Remove the shipping nipple (from CGt supply tapping) and remove the boiler relief valve.
  • Page 14 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Venting — general information with liner approved by the National Fuel Gas CGt venting methods Code, ANSI Z223.1–latest edition, or in Canada The CGt boiler can be vented using one of the following B149.1 or B149.2 Installation Code.

  • Page 15: Venting

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Venting — direct exhaust — system components Obtain vent system components 1. The following special gas vent systems comply with 3. Refer to for maximum vent run lengths and Table 3 UL-1738 and ULC-S636 standards and are certified number of elbows.
  • Page 16 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Venting — direct exhaust — vent starter 1. Select a vent pipe manufacturer and Figure 8 FasNSeal™ vent starter Figure 9 Z-Vent II vent starter obtain all vent components needed, based on boiler location and venting FasNSeal™...
  • Page 17 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Venting — direct exhaust — vent termination Follow instructions on this page when determining 12. Canadian installations — See B149.1 or B149.2 vent location to avoid possibility of severe personal Installation Code. Terminate vent no less than 6 feet injury, death or substantial property damage.
  • Page 18 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Venting — direct exhaust......1. Do not mix types or manufacturers of vent materials. Figure 13 Direct exhaust vertical venting 2. Clean all joints before sealing. See vent manufacturer’s instructions for Follow vent manufacturer's instructions for proper installation cleaning and sealing joints.
  • Page 19 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Using any termination other than one of those shown vertical or sidewall could cause nuisance outages and loss of heat, resulting in substantial property damage. Figure 15 Sidewall termination Termination elbow or tee...

  • Page 20: Water Piping

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Water piping — general information General piping information Circulator and 3-way valve 1. See page 60, Figure 39 If installation is to comply with ASME or Canadian requirements, an additional 2. Apply pipe dope to fittings and install in boiler supply is needed.

  • Page 21: Expansion Tank

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Water piping — single-zone system Expansion tank Diaphragm-type or bladder-type Closed-type expansion tank — Figure expansion tank — Figure 16 1. Ensure expansion tank size will handle boiler and 1. Ensure expansion tank size will handle boiler and system water volume and temperature.
  • Page 22 130 °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 23 GOLD CGt Gas-Fired Water Boiler — Boiler Manual typical piping — multiple-zone installations Figure 18 Figure 19 Zoning with circulators Zoning with zone valves — return water 130 °F or higher. — return water 130 °F or higher. ZONE 2...
  • Page 24 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Water piping — low temp systems bypass Bypass piping show suggested bypass arrangements using bypass piping for low Figures 20 and 21 temperature systems such as radiant heating systems converted gravity systems Primary/secondary bypass piping is required because the boiler circulator must install on the return line and be used to provide domestic water priority.
  • Page 25 GOLD CGt Gas-Fired Water Boiler — Boiler Manual piping — for radiant heating or converted gravity systems Figure 20 Figure 21 Zoning with circulators Zoning with zone valves ZONE 2 ZONE 2 ZONE 1 ZONE 1 12" max 12" max...
  • Page 26 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Water piping — connect tankless heater Hot water can scald! To pipe tankless heater: • Consumer Product Safety Commission and some 1. Size piping no smaller than tankless heater inlet and states recommend domestic hot water temperature outlet.

  • Page 27: Water Piping

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Water piping — refrigeration system Prevent chilled water from entering boiler Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See...

  • Page 28: Gas Piping

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Gas piping Connecting gas supply piping to boiler Figure 24 Gas supply piping 1. Remove jacket front panel and refer to to pipe gas to boiler. Figure 24 Top entrance at inlet of gas connection to boiler. Where local...

  • Page 29: Field Wiring

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Field wiring Thermostat For your safety, turn off electrical power supply at service entrance panel before making any electrical 1. Connect thermostat as shown on wiring diagram connections to avoid possible electric shock hazard.

  • Page 30: Start-Up

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Check for gas leaks Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if there is any indication of a gas leak.

  • Page 31: Start The Boiler

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Start-up — preparation (continued) Inspect system water piping Inspect base insulation After filling the boiler and system with water, throughout Check to make sure against all four inspect all piping insulation is secure the system for leaks.

  • Page 32: Start-Up

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) Check burner flames View pilot and main flames through the inspection port Figure 26 Typical pilot burner flame in the base burner shield. Inner Pilot burner flame...

  • Page 33: Check-Out Procedure

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist ❏ Boiler and heat distribution units filled with water? With main burners on, manually shut off gas supply at manual main shutoff gas valve. Burners should go off.

  • Page 34: Operation

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Operation — sequence on page 36. This , main valve closes, spark generator Read Operating instructions If signal is lost information is also located on a label on the inside activates and sequence returns to step of the boiler jacket door panel.
  • Page 35 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Operation — wiring diagram Figure 29 Schematic and ladder wiring diagram Part Number 550-110-290/0501...
  • Page 36 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Operation — operating instructions Figure 30 Operating instructions FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 37 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Service and maintenance — schedule Table 8 Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see CGt User’s Information Manual for instructions) • Check boiler area Inspect: •...
  • Page 38 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Service and maintenance — annual start-up The boiler should be , at the beginning of the heating season, inspected and started annually only by a qualified . In addition, the maintenance and care of the boiler designated in...
  • Page 39 GOLD CGt Gas-Fired Water Boiler — Boiler Manual ❏ Inspect ..Burner cleaning instructions (continued) a wire brush. The vacuum will help to draw any Burners and base airborne material out of the burner.
  • Page 40 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Service and maintenance — annual start-up ❏ ❏ Start-up ..Check/test ..Gas piping 1. Perform start-up procedures in section , pages 30- 32 of this manual.
  • Page 41 GOLD CGt Gas-Fired Water Boiler — Boiler Manual (continued) ❏ Check/test ..Boiler relief valve Expansion tank 1. Expansion tanks provide space for water to move in Safety relief valves should be reinspected , by...

  • Page 42: Service And Maintenance

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Service and maintenance — (continued) ❏ ❏ Review with owner Cleaning boiler heating surfaces 1. Review the with User’s Information Manual the owner. 2. Emphasize the need to perform the 1. Shut down boiler: maintenance schedule specified in the •...

  • Page 43: Troubleshooting

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure Label wires prior 2. Check for 120 VAC (minimum 102 VAC to disconnection when servicing maximum 132 VAC) to boiler. controls. Wiring errors can cause 3. Make sure thermostat is calling for heat and contacts...

  • Page 44: Air Pressure Switch

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — components Air pressure switch Make sure boiler water temperature is 100 °F or cooler before starting procedure to obtain appropriate readings. Check pressure switch setting Return to normal operation When pressure reading is correct and air pressure 1.

  • Page 45: Way Valve

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — components (continued) POWER and PRESS SWITCH lights flashing Control module Usually indicates pressure switch is closed when it should not be, or pressure switch failed to close within 5 minutes of inducer...
  • Page 46 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — components (continued) Figure 35 Control module connections 24 VAC from Ground Brown 24 VAC Black transformer Green 120 VAC H 120 VAC H Control module receptacle Black 120 VAC N...
  • Page 47 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights CHART 1— 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 48 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (continued) CHART 2 — 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 49 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (continued) CHART 3 — PRESS SWITCH & POWER lights flashing — Usually indicates pressure switch stuck closed or failed to make within 5 minutes — 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 50 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (continued) CHART 4 — 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 51 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (continued) CHART 5 — PRESS SWITCH light flashing and POWER light on steady — Usually indicates pressure switch opened during run cycle — — May also be caused by wind gusts in excess of 40 mph for non-direct vent sidewall-vented boilers —...
  • Page 52 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (continued) CHART 6 — 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 53 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (continued) Part Number 550-110-290/0501...
  • Page 54 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — common problems Common Problems Common Causes Possible Corrections Rapid cycling — burner Thermostat installed where Locate thermostat on inner wall turns on and off drafts or heat affect reading. away from heat sources or cool frequently.
  • Page 55 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Troubleshooting — common problems (cont.) Common Problems Common Causes Possible Corrections Metal flakes found in Contaminated combustion air Remove sources of flueway. supply. hydrocarbons in or near boiler area. (Bleaches, cleaners, chemicals, sprays, fabric softeners, paint remover, etc.)

  • Page 56: Replacement Parts

    GOLD CGt Gas-Fired Water Boiler — Boiler Manual Replacement parts Section assembly ..........Base assembly ............ Jacket assembly ..........Trim assembly ............. Gas control assembly ......... 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.
  • Page 62 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Dimensions Figure 41 Dimensional drawing Supply connection, 1 ¼" NPT ( note 1 Gas supply piping Return connection, 1" NPT ( note 1 Drain valve Relief valve, ¾" NPT Gas supply entrance (top or side) ½"...
  • Page 63 For alternate piping, contact your Weil-McLain sales office. CSA design certified for installation on combustible flooring. Tested for 50 psi working pressure.
  • Page 64 GOLD CGt Gas-Fired Water Boiler — Boiler Manual Handling fiberglass and ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from...

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