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Weil-McLain CGA25SPDN User's Manual

1. Is damper harness securely plugged in at both ends Secure connections lt No Yes Check for loose wire connections or bad relay on Is 24VAC present across transformer terminals C amp Y transformer s No Yes Check for open thermostat LWCO high limit spill switch or v rollout thermal fuse element contacts or check for loose wire Is 24VAC present across transformer terminal C and connections yellow wire on vent damper connector A DANGER If LWCO spill switch or rollout thermal fuse 4 No Yes element contacts are open determine cause 4 and correct condition Failure to do so will cause severe personal injury death or Is vent damper rotated open substantial property damage No Yes Check repair out of round stack section Does vent damper lt v rotate open gt Is 24VAC present across gas valve terminals No Yes No Yes Replace actuator Retest gt Is main flame on now No Yes Open thermostat contacts for 30 seconds Vent damper will 4 rotate to closed position Close thermostat contacts Vent Retest damper will rotate to open position Is 24VAC present inals across gas valve teiminals Is gas valve cock turned to ON position KES No Yes Check continuity of each wire in damper harness Does continuity exist for each wire See Table below Turn gas valve cock to Replace gas valve No a5 ON position Retest Retest Remove damper harness f
2. ON Turn onall electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To The Appliance and call your service technician or gas supplier Replace front panel HI TO TURN OFF GAS TO THE APPLIANCE M 1 Setthe thermostat to lowest setting 3 Remove front panel 2 Turn off all electric power to the appliance if service is tobe 4 Turn gas control knob clockwise to OFF Do not force performed 5 Replace front panel 550 223 041 0906 40 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 9b Operating instructions spark pilot Natural gas CGa 25 to CGa 6 e Gas valve Robertshaw 7200 NP FOR YOUR SAFETY READ BEFORE OPERATING M This appliance is equipped with an ignition device C Use only your hand to depress or move the selector arm Never use which automatically lights the pilot Do not try to tools If the selector arm will not depress or move by hand don t try to light the pilot by hand repair it call a qualified service technician Force or attempted repair BEFORE OPERATING smell all around the may resultin a fire or explosion appliance area for gas Be sure to smell nexttothe D Do not use this appliance if any part has been under water floor because some gas is heavier than air and will Immediately call a qualified service technician to inspect the appliance settle on the
3. Leave external boiler thermostat connection wires disconnected from boiler Troubleshoot the external thermostat circuit until you find the source of the stray voltage Pay close attention to the wiring connections to 3 wire zone valves Correct the problem and repeat the voltmeter test above verifying there is no longer a voltage reading under any condition in the external thermostat circuit y Boiler should now operate per the normal sequence of operation shown in Figure 24 page 37 Part Number 550 101 009 0107 e f no voltage is found under any condition of the external thermostat circuit connect the two boiler thermostat connection leads together or jumper the boiler aquastat T T terminals e Turn off power to the boiler for 1 minute Turn on power and allow boiler to cycle Do the TSTAT and POWER lights still flash No Yes y e Replace control module e Retest 55 GOLD CGa Gas Fired Water Boiler Boiler Manual 1 le Troubleshooting spark pilot boilers continued CHART 4 Spark ignited pilot DAMPER light flashing If POWER light is flashing Usually indicates vent damper failed to prove open within 5 minutes If POWER light is steady Usually indicates vent damper closed during run cycle WARNING Electrical shock hazard Wherever you see TURN OFF POWER4 amp s follow the instruction
4. type expansion tank pipe from top of air separator to tank fitting as in Figure 10 page 17 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansion tank regardless of location of expansion tank circulator or air separator For systems with possible low return water temperature such as converted gravity systems radiant heating systems and heat pump systems refer to the special piping suggestions of Figures 13 17 as applies Failure to prevent sustained low return water temperature to the boiler could cause corrosion of the boiler sections resulting in severe personal injury death or substantial property damage Part Number 550 101 009 0107 19 GOLD CGa Gas Fired Water Boiler Boiler Manual od Piping low temperature systems Primary secondary preferred Bypass piping method Primary secondary bypass piping is preferred because the flow rate and temperature drop in the heating circuit s is determined only by the heating circuit circulator s So adjustment of the bypass valves in the boiler circuit will not cause a change in the heating circuit rate and temperature distribution Figures 13 and 14 page 21 show suggested bypass arrangements using primary secondary bypass piping preferred for low temperature systems such as radiant heating systems or converted gravity systems For alternatives see pages 22 through 25 The bypass valves ite
5. It cannot be used as one of the zoning circulators DO NOT apply system bypass piping if the reduced flow in the system could cause poor heat distribution That is system bypass piping reduces the flow in the system and increases the water temperature supplied to the system This can cause increased heat from radiators at the beginning of the system and reduced heat from radiators near the end of the system Valve adjustment 1 Start with valve 7a fully closed and 7b fully open 2 Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads at least 130 F at all times 3 Valve 7a regulates the amount of boiler supply water mixed with return water Valve 7b causes a pressure drop in the system needed to balance flow through valve 7a and the system 4 The valve adjustment should be done with the system at the coldest expected temperature 60 F for converted gravity systems or high mass radiant systems Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injec tion pumping control Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system sup
6. Replace front panel 550 223 042 0906 42 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual Ob Operating instructions spark pilot Natural gas CGa 7 to CGa 8 e Gas valve White Rodgers 36C N99 FOR YOUR SAFETY READ BEFORE OPERATING M This appliance is equipped with an ignition device C Use only your hand to depress or turn the gas control knob Never use which automatically lights the pilot Do not try to tools If the knob will not depress or turn by hand don t try to repair it light the pilot by hand call a qualified service technician Force or attempted repair may BEFORE OPERATING smell all around the resultin a fire or explosion appliance area for gas Be sure to smell nexttothe D Do not use this appliance if any part has been under water floor because some gas is heavier than air and will Immediately call a qualified service technician to inspect the appliance settle on the floor See below and to replace any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Do nottry to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building e fyoucannotreach your gas supplier call the fire department EO oPERAaTING InstRucTIONS I STOP Read the safety information above on this label 7 Wait five 5
7. Zone valve Drain valve System temperature valves see instructions to the left for adjusting valves Blend temperature gauge Relief valve Part Number 550 101 009 0107 Piping low temperature systems ntinued Figure 14 Primary secondary piping Zoning with aome valses ZONE ZONE1 10 Automatic air vent with diaphragm type expansion tank or connect to tank fitting closed type expan sion tank DO NOT use an automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlogging of the expansion tank 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to tank fitting as in Figure 10 page 17 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expan sion tank regardless of location of expansion tank circulator or air separator 21 GOLD CGa Gas Fired Water Boiler Boiler Manual od Piping low temperature systems continued BOILER bypass piping method This piping method Figure 15 or 16 page 23 is called a boiler bypass because part of the circulator flow is bypassed around the boiler through valve 7a This method reduces the flow rate throughout the boiler in order to raise the average water temperature in the boiler enough to prevent flue gas condensation Boiler bypass piping is
8. and can be mounted on either the boiler supply or return piping The factory installed circulator wiring harness provides ample length for either location NOTE The control module provides a pump exercising routine If the boiler is not operated for 30 days the control module will power the circulator for 30 seconds then turn off Vent damper The vent damper closes during off cycles to reduce heat loss from the house up the vent Other boiler components a supply to system f pressure temperature gauge k pilot burner typical b return from system g relief valve l stainless steel burners c flue outlet h air vent connection m cast iron boiler sections d burner manifold i flame rollout switch n flue collector e gas valve j burner orifice o junction box Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual GOLD CGa Gas Fired Water Boiler GOLD CGa Gas Fired Water Boiler Boiler Manual Contents O 10a A BW NY 1 1 12 13 How iS WOPKS ceccssecnseeneeeseeeneeseneeeseeeessennnsenseses 270 Hazard definitions 2222222222222212222222 amp Please read before proceeding sssssssessensseeseees D Prepare boiler location ssssesssesessseeesssesesssO 1 1 Prepare boiler ssccssssscssecesssesessseeessseessseees 12 15 Water pi Ping ss222 2 16 25 Gas PIPING essncciccsnndediannstinsiensisncuwandian
9. i Refer to Table 4 for pipe length and diameter Base on rated boiler input divide by 1 000 to obtain cubic feet per hour Table 4 is only for gas with specific gravity 0 60 with a pressure drop through the gas piping of 0 30 w c For additional gas pipe sizing information refer to ANSI Z223 1 or B149 1 or B149 2 for Canadian installations Inlet pressure required at gas valve inlet e Maximum 13 w c e Minimum 5 w c e Manifold gas pressure 3 5 w c Install 100 lockup gas pressure regulator in supply line if inlet pressure exceeds 13 w c Adjust for 13 w c maximum Propane Gas Li Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Adjust propane supply regulator provided by gas supplier for 13 w c maximum pressure Inlet pressure required at gas valve inlet e Maximum 13 w c e Minimum 11 w c Manifold gas pressure 10 w c Figure 19 Gas supply piping Manual main shutoff gas valve when required Ground joint union when required 59322 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 5 Thermostat 1 Connect thermostat as shown on wiring diagram on boiler 2 nstall on inside wall away trom influences of drafts hotor cold water pipes lighting fixtures television sunrays or fireplaces 3 fthermestat has a heat anticipater set heat antici paler in th
10. minutes to clear out any gas Then smell for gas Setthe thermostat to lowest setting including near the floor If you smell gas STOP Follow B in _ Turnoffall electrical power to the appliance the safety information above If you don t smell gas go to the next step Remove front panel pei This appliance is equipped with an ignition device which 8 Turn gas control knob counterclockwise v to ON automatically lights the pilot Do not try to light the pilotby 9 Turn onall electric power to the appliance hand f Depress gas control knob slightly and turn clockwise to Set thermostat to desired setting OFF Note Knob cannot be turned to OFF unless knob If the appliance will not operate follow the instructions To is depressed slightly Do not force Turn Off Gas To The Appliance and call your service technician or gas supplier Position V Gas Replace front panel indicator A control shown in 2 K C knob ON position 5 59330 sro TURN OFF GAS 10 THE APPLIANCE M 1 Setthe thermostat to lowest setting Remove front panel 2 Turn off all electric power to the appliance if service is to be Depress gas control knob slightly and turn clockwise to performed OFF Do not force 5 Replace front panel 550 223 043 0906 Part Number 550 101 009 0107 43 GOLD CGa Gas Fired Water Boiler Boiler Manual 10a Service and maintenance sched
11. 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 9a Operation spark ignited pilot system continues Figure 25b Ladder wiring diagram Spark ignited pilot system AWARNING Electrical shock hazard can cause Hot NeutralQ GndO severe injury or death Disconnect 120 VAC power before installing or servicing SERVICE SWITCH Legend for ladder wiring diagram oo 20 VAC field wiring Low voltage field wiring HIGH CONTROL CIRCULATOR 120 VAC factory wiring VOLTAGE MODULE Low voltage factory wiring 120 VAC s SECTION High voltage spark ignition wiring PILOT IGNITION Ground connectors ELECTRODE Table G Gas valve terminals and anticipator settings 120 VAC Gas valve A pg peel Honeywell VR8204 MV PV MV PV 0 6 Honeywell VR8304 MV PV MV PV 0 8 Robertshaw 7200 Cc M P 0 55 White Rodgers 36C 2 4 1 3 0 7 24VAC Terminals 2 4 are factory jumpered on the CONSTANT White Rodgers 36C gas valve 1 All wiring must be installed in accordance with A U S A N E C And any other national state THERMOSTAT x or local code requirements 10 B Canada C S A C22 1 C E C Part 1 and any other national provincial or local code require ments ati 2 Pilot lead wires are not field replaceable Replace pi a al SPILL lot assembly if necessary note 7 SWITCH 3 If any of the original wire as supplied with the ap ieee pliance must
12. 13 w c maximum natural or propane gas pressure upstream of gas valve b With boiler on 5 w c minimum natural gas pressure or 11 w c propane gas pressure upstream of gas valve 3 5 w c minimum natural gas pressure or 10 w c propane gas pressure downstream tapping on gas valve Can be adjusted by regulator on gas valve In event of vent damper failure Effikal or Field Controls damper If troubleshooting chart recommends replacing actua tor and actuator is not immediately available damper blade can be fixed in an open position to allow boiler operation Manually turning blade can cause actuator damage Follow these instructions only in case of no heat or damper actuator malfunction 1 Move damper service switch to Hold Damper Open position Apply call for heat to boiler Damper blade should then rotate to open position and boiler will fire 2 If step 1 does not open damper manually rotate Effikal or Field Figure 28 Mariially opening the damper vert damper Wrench or pars damper blade to open position using wrench or pliers on flat shaft between damper and actuator Boiler will fire Verify that damper service switch is in Hold Damper Open position Figure 28 3 Do not leave vent damper permanently in this position Replace actuator immediately If vent damper is left in open position boiler will net oper ate at published efficiencies Johnson Controls damper
13. Circulator may be A mounted on either boiler supply or return piping Gas supply entrance right or left side Circulator flange provided with boiler is same size as dQ Pressure temperature gauge A gt recommended pipe size in Table 3 page 16 ALL DIMENSIONS IN INCHES 0 nD F lt wi F i 1 H a 1 28 5 I 19 19 1316 T tC Y j Yy Yy y Cy ct lt 12 A t 23 gt 1 59320 LEFT SIDE FRONT RIGHT SIDE Boiler Supply Return Gas connection ph DZ W A LY model tapping tapping amp manifold size Vent Vent Jacket Damper number inches NPT inches NPT _ Note 3 location diameter width height inches NPT inches inches inches inches CGa 25 1 14 Ya 5 4 10 45 CGa 3 1 1 Ya 5 4 10 52 CGa 4 1 1 V2 6 5 13 54 CGa 5 1 1 V2 8 6 16 577 CGa 6 1 1 2 9 6 19 60 CGa 7 1 1 3 4 di 7 22 62 CGa 8 14 14 Yq 12 7 25 64 Note 3 Size gas piping from meter to boiler per local utility requirements 66 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 1 3b Ratings D H DOE Boiler Input DOE 0 2 000 feet 2 000 4 500 feet Net Boiler DOE Chimney model Btuh Heating altitude altitude I B R water Seasonal efficiency and number capacity ratings content A FU E breeching Btuh Btuh gallons SPDN SPDL PIDN size Input Output Input Output Btuh Btuh Btuh Btuh Note 1
14. Frroubleshooting chart recommends replacing actuator and actuator is mot immediately available damper blade can be fixed in an open peaition to allow boiler opera tion Follow these instructions only in case of mo heat or damper actuator malfunction See Figure 28 l Turn off power to boiler Failure to turn off power to boiler can result in severe personal injury death or substantial property dam age 2 Refer to vent damper manufacturer s instructions for procedure to fix vent damper in open position 3 Turn on power to boiler 4 Using wrench or pliers on flat shaft section manu ally rotate damper blade until green light turns on Boiler will fire Figure 28 5 Do not leave vent damper permanently in this posi tion Replace actuator immediately If vent damper is left in open position boiler will not operate at published efficiencies Johnson Controls damper Closed e Verify proper operation after servicing See vent damper manufacturer s instructions packed with vent damper for additional information Failure to comply could result in severe personal injury death or substantial property damage Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 1 lb Troubleshooting standing pilot boilers
15. all system pip ing for signs of leaks 2 Repair any leaks before proceeding 45 GOLD CGa Gas Fired Water Boiler Boiler Manual 10b 46 Service amp maintenance annual start up on L Inspect Boiler heating surfaces 1 Disconnect the vent pipe at the boiler draft hood and remove draft hood after turning off power to the boiler Use a bright light to inspect the boiler flue collector and heating surfaces If the vent pipe or boiler interior surfaces show evidence of soot follow Cleaning boiler heating surfaces in this manual section Remove the flue collector and clean the boiler if necessary after closer inspection of boiler heating surfaces If there is evidence of rusty scale deposits on boiler surfaces check the water piping and control system to make sure the boiler return water temperature is properly maintained per this manual Reconnect vent and draft hood Replace all boiler components before returning to service Check inside and around boiler for evidence of any leaks from the boiler If found locate source of leaks and repair Burners and base The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 68 of this manual Fail ure to comply could result in severe personal injury If insulation is damaged or displaced do not operate the boiler Replace or reposi tion insulation as necessary Failure to replace
16. between jacket top and combustible ceiling Do not modify draft hood or vent damper or make an other connection between draft hood and vent damper or boiler except as noted below This will void CSA certification and will not be covered by Weil McLain warranty Any changes will cause severe personal injury death or substantial property damage Figure 8 Vent damper assemblies Effikal or Field Controls damper Johnson Controls damper Refer to vent manufacturer s instructions to install plug shipped with damper in damper hole Hoid open switch Effikal only Install went damper so that switch is visible and accessable to uses Part Number 550 101 009 0107 Installation 1 Install vent damper horizontally or vertically as shown in vent damper manufacturer s instructions Vent damper must be installed so that it serves only one boiler and so damper blade indicator is visible to the user See Figure 8 2 Screws or rivets used to secure the vent damper to the draft hood must not interfere with rotation of the damper blade 3 Install damper harness between damper actuator and knockout in jacket top panel Use strain relief connectors and locknuts to secure both ends of damper harness Keep wiring harness clear of all hot surfaces WARNING LINE UP KEYWAY WHEN CONNECTING PLUGS FORCING A MISMATCH CAN CAUSE A HAZARDOUS CONDITION 4 Read and apply the harness plug warning label shown a
17. damaged insulation can result in a fire hazard causing severe person al injury death or substantial property damage After turning off power to the boiler remove the jacket door and base access panel Figure 32 item 4 page 62 2 4 E Oil 1 E 1 Inspect burners and all other components in the boiler base If burners must be cleaned raise rear of each burner to release from support slot slide forward and remove Then brush and vacuum the burners thoroughly making sure all ports are free of debris Carefully replace all burners making sure burner with pilot bracket is replaced in its original position and all burners are upright ports up Inspect the base insulation a Pay attention to the WARNINGS on page 68 regarding working with insulation materials b Verify that the insulation is intact and secure against all four sides of the base Service ed bearing circulators The circulator shipped with the CGa boiler is water lubricated No oiling is required Check other circulators in the system Oil any circulators requiring oil following circulator man ufacturer s instructions Over oiling will damage the circulator Start up Perform all start up procedures given in Section 6 of this manual Verify cold fill pressure is correct and that fill system is working properly Verify antifreeze level if used is at the right con centration and that inhibitor level is corr
18. effective for some boilers including the CGa provided the flow rates are adjusted according to the instructions following Figures 15 and 16 are alternative piping suggestions for converted gravity large water content or steam systems or radiant heating system for use when primary secondary piping can t be applied Figure 17 page 25 is another alternative using system bypass in place of boiler bypass piping Figure 17 however is not suitable for radiant heating applications because it does not protect the radiant system from possible high water temperature Boiler bypass piping keeps system flow rate as high as possible and temperature drop as low as possible help ing to equalize the building heat distribution Temperature gauges Gauge 4a is optional if the bypass valves will be ad justed using cold or room temperature return water to the boiler When setting the valves without gauge 4a installed using cold or room temperature water assume the return water temperature to be 60 F Set the valves so gauge 8 reads at least 120 F Gauge 4b is optional on converted gravity systems but required on radiant heating systems to display the water temperature being supplied to the radiant tubing Gauge 8 is required on all systems to assure reliable adjustment of the bypass valves The boiler mounted temperature pressure gauge can be used if a separate temperature gauge is not installed Valve adjust
19. floor See below and to replace any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building e Ifyoucannotreach your gas supplier call the fire department DE sCOoPERATING INsTRUCTIONS 9 STOP Read the safety information above on this label 7 Wait five 5 minutes to clear out any gas Then smell for Setthe thermostat to lowest setting gas including near the floor If you smell gas STOP _ Turn offallelectrical power to the appliance Follow B in the safety information above If you don t _ Remove front panel smell gas go to the next step This appliance is equipped with an ignition device which 8 Moveselectorarmright to ON automatically lights the pilot Do not try to light the pilot by hand 9 Turnonallelectric power to the appliance Depress and move selector arm left to OFF Note Selector arm cannot be moved to OFF unless selector arm is depressed 10 Setthermostat to desired setting slightly Do not force 11 If the appliance will not operate follow the instructions acon To Turn Off Gas To The Appliance and call your oy es service technician or gas supplier Position o oO Selector indicator 3 i arm Replace front p
20. ings face up Main burner orifices must inject down center of burner Failure to properly seat burners will result in severe personal injury death or substantial property dam age 4 Reinstall access panel A CAUTION Do not operate boiler without ac cess panel secured in place Failure to comply could cause momentary flame rollout on ignition of main flame resulting in possible fire or personal injury hazard Orifice replacement procedure when required 1 Remove access panel 2 On gas manifold mark location of main burner with attached pilot assembly 3 Remove main burner with attached pilot assembly from manifold Remove all remaining burners 4 Remove and discard all main burner orifices in gas manifold 5 Apply a small amount of pipe dope to each of the new orifices and install in the manifold Make sure the orifices are aligned correctly not cross threaded in the manifold tappings Use only pipe dope compatible with propane gas even if boiler is to be operated on natural gas Failure to comply could result in severe per sonal injury death or substantial property damage 6 Reinstall main burner with attached pilot assembly at location marked on gas manifold Reinstall all remaining burners 7 Follow check out procedure Section 7 page 33 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 2b Hydrostatic pressure test Pressure test boiler before attachi
21. must be manually lighted following the Lighting Instructions in this manual and on boiler Vent damper will remain closed 2 Call for heat When thermostat circuit closes the boiler circulator and vent damper are energized The vent damper drives open When the vent damper is fully open its end switch energizes the main gas valve Figure 23 Wiring diagram Standing pilot system SCHEMATIC WIRING DIAGRAM Operation standing pilot boilers This provides gas to the main burners Burners re main ignited until thermostat circuit or limit circuit opens Burners and circulator are de energized when call for heat stops Burners are de energized but circulator remains on if the limit circuit opens Limit operation When a limit control opens the main gas valve is de energized but circulator con tinues to run When the limit circuit closes again the main gas valve is energized if there is still a call for heat Thermostat heat anticipator Set heat anticipator as shown on wiring diagram Figure 23 LADDER WIRING DIAGRAM EURCTARCAL SEHI LAZARO AN CALSE SCYTRI WUR OF DEATH DACOHHECT PIER BEFORE IMS TALLINGS AK DADA BEING SL ALARH METE ASL ACE WH A UEA ATA TEGAL GE Ae OT ATHA STETE OR LOCAL COG PREP G CREM CLA CHi NAAN PETA LEE PAAT ABC ANY OHEA PUT PLA WG Ge AUT 2 ALL COPIES SH TT PPE APP SELF DONT i FJa Ae LL H Ak PL TH BE AE T BE AA TYPE et GA TU a BE LEEU B DH
22. on pallet until installa tion site is ready Move entire crate and pallet next to selected loca tion Remove crate Leave boiler on pallet Remove boiler from pallet as follows a Tilt left side of boiler up and place a board under left legs b Tilt boiler the other way and place a board under right legs c Slide boiler backwards off pallet and into posi tion Do not drop boiler or bump jacket on floor or pallet Damage to boiler can result Check level a Shim legs if necessary b Do not alter legs Inspect orifices and burners l Remove front jacket door Remove base access panel See Figure 32 item 4 page 62 Check for correctly sized manifold orifices See Table 2 below for sizing The orifice size is stamped on the orifice spud barrel Table 2 Manifold orifice sizing Location Natural gas 0 2 000 ft over 2 000 ft U S 2 00 mm Note 1 Canada 0 2 000 ft 2 000 4 500 2 00 mm 1 90 mm 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 Correctly sized manifold orifices must be used Failure to do so will result in severe personal injury death or substantial property dam age 3 Level and straighten burners Burners must be properly seated in slots in burner rest with their open
23. openings within 12 inches of the floor and the ceiling sized per c woo Figure 5 10 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual FREE AREA of openings the minimum areas given in this manual are free area equals the area length times width of opening after deduction for louver obstruction Use the free area information provided by the louver manufacturer When this information is not available assume e Wood louvers assume free area is 20 of total so the actual area of each opening with wood louvers would be 5 times the required free area Metal louvers assume free area is 60 of actual area so for wood louvers the actual area of each opening must be 1 67 times the required free area Single air opening option x A single combustion air opening can be used in lieu of the two opening options on page 10 provided Clearances from boiler to walls The boiler must have clearances of at least those shown in Figure la page 7 Opening must be directly to outside The opening must connect directly to the outdoors or to a space that communicates directly to the outdoors not to an interior space The air can be provided through a direct opening or through a horizontal or vertical duct Opening placement The top of the air opening must be within 12 inches of the ceiling Opening size The free area of the opening must be at least equal to the sum of the
24. pilot SPDN SPDL Spark ignited pilot PIDN Not available NOTICE Install CGa boilers for residential radiant panel systems converted gravity heating systems or other low water temperature applications per instructions in this manual to avoid damage due to condensation CGa boilers are CSA design certified for installation on combustible flooring CGa boilers are ASME rated for 50 psig working pressure Part Number 550 101 009 0107 67 GOLD CGa Gas Fired Water Boiler Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or AWARNING base insulation panels in this prod uct 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 occupational sources is carcinogenic to humans Group 1 Precautionary measures 1 Avoid breathing fiberglass dust and contact with skin or eyes e Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for fiberglass wool at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommen dations can be found on the NIOSH web site at http www cdc gov niosh homepage
25. 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 Repair any leak at once AWARNING Propane boilers only Your pro pane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Propane gas can accumulate at floor level Smell near the floor for the gas odorant or any unusual odor If you suspect a leak do not attempt to light the pilot Use caution when attempting to light the propane pilot This should be done by a qualified service technician particularly if pilot outages are common Periodically check the odorant level of your gas Inspect boiler and system at least yearly to make sure all gas piping is leak tight Consult your propane supplier regarding installation of a gas leak detector There are some products on the market intended for this purpose Your supplier may be able to suggest an appro priate device 28 Determine if water treatment is needed ADANGER Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage AWARNING Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iro
26. to prevent possible damage remaining connected to the common venting system properly vents when tested as outlined above return a Line chimney with corrosion resistant metal doors windows exhaust fans fireplace dampers liner such as AL29 4C single wall stainless and any other gas burning appliance to their previ steel or B vent Size liner per National Fuel ous conditions of use Gas Code ANSI Z223 1 latest edition Any improper operation of common venting system b Provide drain trap to remove any condensate should be corrected so the installation conforms with f the National Fuel Gas Code ANSI Z223 1 latest edition 5 Where two or more gas appliances vent into a Correct by resizing to approach the minimum size as common chimney or vent equivalent area should determined using the appropriate tables in Part 11 of be at least equal to area of vent outlet on largest that code Canadian installations must comply with appliance plus 50 percent of vent outlet area on B149 1 or B149 2 Installation Code additional appliance Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 1d Prepare boiler location air contamination Refer to Table 1 for products and areas which may cause contaminated combustion air Please review the following information on potential combustion air contamination problems To prevent potential of severe personal injury or death check for products or areas listed belo
27. top of boiler with sheet metal screws Bottom of draft hood or skirt must have clearance dimension above jacket top panel as indicated on draft hood Prepare boiler draft hood amp spill switch Spill switch installation 1 Fasten spill switch to draft hood as shown in Figure 6 and Figure 7 2 See Wiring diagram to connect wires a Standing pilot boiler see page 34 b Spark ignited pilot boiler see pages 38 and 39 Do notalter boiler draft hood or place any obstruction or non approved vent damper in breeching or vent system CSA certification will become void Flue gas spillage and carbon monoxide emissions will occur causing severe personal injury or death Improper orientation of spill switch may cause boiler to shut down The loss of heat can result in significant damage due to freezing Figure amp Install spill switeh Figure 7 Spill switch wilh wire harness gt Draft hood a ee j Spill switeh a iy Spill switch Spill switeh wire harness Damper harness kreockout Draft hood 1 Connect from draft hood or vent damper outlet to chimney or vent with same size vent connector Long horizontal vent connector excessive number of elbow or 2 AWARNING Where possible vertical venting to the outside from the draft hood or vent damper outlet will offer best performance tees or other obstructions that restrict the flow of combustion gases shou
28. 09 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 12f Replacement parts controls Figure 35 Gas control assembly Standing pilot controls Spark ignited pilot controls 59354 Item Description Manufacturer Manufacturer s Weil McLain number part number part number Standing pilot Natural gas components 1 Gas valve 14 x 1 2 CGa 25 through CGa 6 Honeywell VR8200A2116 511 044 360 Robertshaw 7200ER Gas valve 3 4 x 34 CGa 7 and CGa 8 Honeywell VR8300C4050 511 044 256 2 Pilot assembly kit with orifice Weil McLain 510 811 644 3 Tubing pilot aluminum 560 742 860 4 Tubing thermocouple 511 724 254 Propane gas components 1 Gas valve 1 2 x 1 2 CGa 25 through CGa 6 Honeywell VR8200C1074 511 044 258 Gas valve 3 4 x 34 CGa 7 and CGa 8 Honeywell VR83004068 511 044 257 2 Pilot assembly kit with orifice Weil McLain 510 811 646 3 Tubing pilot aluminum 550 742 860 4 Tubing thermocouple 511 724 253 Natural gas and propane gas components 5 Transformer relay 510 312 167 not shown Wiring harness 591 391 862 Spark ignition 6 Gas valve 12 x 14 CGa 25 through CGa 6 Honeywell VR8204A2001 511 044 381 White Rodgers 36E36 266 Robertshaw 7200 IPER Gas valve 3 4 x 34 CGa 7 and CGa 8 Honeywell VR8304P4348 511 044 382 White Rodgers 36C74 474 7 Pilot assembly kit with orifice and aluminum pilot gas tubing Weil McLain
29. 1 Verify that boiler area is free of any combustible materials gasoline and other flammable vapors and liquids Verify that boiler area and air intake is free of any Part Number 550 101 009 0107 of the contaminants listed in Table 1 on page 9 of this manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed install combustion air piping to the boiler in accordance with national provincial or local codes Air openings F Verify that combustion and ventilation air open ings to the boiler room and or building are open and unobstructed Check operation and wiring of automatic combustion air dampers if used Verify that boiler vent discharge and air intake are clean and free of obstructions Flue gas vent system F Visually inspect entire flue gas venting system for blockage deterioration or leakage Repair any joints that show signs of leakage in accordance with vent manufacturer s instructions Verify that masonry chimneys are lined lining is in good condition and there are not openings into the chimney AWARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Pilot and main burner flames i Visually inspect pilot burner and main burner flames as directed under Section 6d page 32 of this manual Water piping 1 Check the boiler interior piping and
30. 13 Air separator and automatic vent if used Note that the 8 Blend temperature gauge fill valve must always be connected to the expansion tank regardless of location of expansion tank circulator 9 Relief valve or air separator Part Number 550 101 009 0107 23 GOLD CGa Gas Fired Water Boiler Boiler Manual od Piping low temperature systems ntinued SYSTEM bypass piping method This piping method Figure 17 page 25 is called a sys tem bypass because part of the circulator flow bypasses the system through valve 7a This bypassed hot water from the boiler outlet mixes with cooler system return water temperature in order to provide minimum 130 F return water to the boiler Valve 7b will most often be full open but may need to be slightly closed on some low pressure drop systems in order to cause enough flow through valve 7a Figure 17 is an alternative piping method that provides return water temperature control for boilers installed on converted gravity systems large water content or steam systems DO NOT apply the piping of Figure 17 on radiant heating systems It provides no method of regulat ing the water temperature provided to the system and could result in excessive water temperature in the radi ant tubing System bypass piping as shown in Figure 17 can be used with either zone valve or circulator zoning When used with circulator zoning however the boiler circulator item 3 must be piped as shown
31. 30 Item 3 page 53 on control module e Using voltmeter check across top and bottom pins Is POWER light of 120 VAC IN plug Flashing Flashing with On steady Does voltmeter indicate 120 VAC alone another light not flashing No Yes TSTAT CIRC Chart Problem is with incoming light flashing 3 electricity Have licensed DAMPER Chart electrician repair circuit light flashing 4 FLAME Chart Chart e Reconnect 120 VAC IN plug light flashing 5 6 Remove 120 VAC transformer PRIMARY plug For insufficient heat or no heat problem go to Figure 30 Item 2 Pager on control module Chart 7 page 59 if POWER light is on steady e Using voltmeter check across top and bottom pins with no other light flashing OLPRIMARY receptacle Does voltmeter indicate 120 VAC No Yes e Usually indicates polarity on incoming 120 VAC power line is wrong Replace control module A TURN OFF POWER at service switch or breaker Retest then reverse the HOT and NEUTRAL wires entering the boiler in the J box e Restore POWER at service switch or breaker e Reinstall 120 VAC transformer PRIMARY plug Remove 24 VAC transformer plug Figure 30 Item 5 Is POWER light flashing now page 53 on control module No EE e Using voltmeter check across pins of receptacle Does voltmeter indicate 120 VAC No Yes Have system checked by a licensed electricain If problem persists call your
32. 42 CGa 3 450 003 736 CGa 4 450 003 737 CGa 5 450 003 738 CGa 6 450 003 739 CGa 7 450 003 740 CGa 8 450 003 741 9 Base insulation kit CGa 25 381 354 518 includes insulation for all base CGa 3 381 354 518 parts above plus gasket material CGa 4 381 354 518 needed between block assembly CGa 5 381 354 518 and base CGa 6 381 354 519 CGa 7 381 354 519 CGa 8 381 354 519 10 Boiler leg kit 590 424 253 11 Manifold CGa 25 591 126 615 CGa 3 591 126 616 CGa 4 591 126 617 CGa 5 591 126 618 CGa 6 591 126 619 CGa 7 591 126 556 CGa 8 591 126 557 12 Main burner orifice Natural gas sea level 560 528 997 Main burner orifice Propane gas sea level 560 528 998 183 Burner stainless steel 512 200 077 14 Burner with pilot bracket Standing pilot 512 200 079 not shown Spark ignited 512 200 078 pilot 15 Screw 10 32 x Ys STP type D hx washer head available at slot ZP local supply house 16 Rollout thermal fuse element 512 050 230 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 12d Replacement parts jacket Figure 33 Jacket assembly a 4 6 E hi E E 1 fama a k z T fori 1 2 3 4 Junction box 2 x 4 Jacket panel left side with insulation Jacket panel right Jacket panel side with insula top front Natural Gas Propane Gas Natural Gas tion i Standing Pilot Standing Pilot Spark Pilot x Boiler Boiler Model Weil McL
33. 511 330 218 8 Control module United Technologies 1107 2 511 330 079 9 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 SLR SL50N not shown Tubing from gas valve to regulator Weil McLain 560 742 859 not shown Adapter male 1 x 7 6 24 from regulator to pilot gas line Weil McLain 562 302 017 Part Number 550 101 009 0107 65 GOLD CGa Gas Fired Water Boiler Boiler Manual l3a Dimensions Figure 36 Dimensional drawing ALL DIMENSIONS IN INCHES Supply piping note 1 Po A DANGER Return piping note 1 4 ae Yy 7 E Do not cut or alter draft hood in any way Relief valve NPT Boiler combustion will be affected causing Y2 NPT to expansion tank air vent Top VIEW4 severe personal injury death or substantial Vent connection to vent damper D property damage Draft hood 7 T e Note 1 Boiler supply and return tappings are both 114 NPT ond See Table 3 page 16 for recommended system sup Gas supply piping ply and return piping sizes Drain valve Note 2 Boiler circulator is shipped loose
34. Boiler should now local Weil McLain sales Replace transformer Replace control module operate normally representative Retest Retest 54 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual lle Troubleshooting spark pilot boilers Continued CHART 3 Spark ignited pilot TSTAT CIRC amp POWER lights flashing Usually indicates 48 VAC on thermostat circuit stray voltage Electrical shock hazard Wherever you see da TURN OFF POWER follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage Disconnect the two external wires connected to the boiler thermostat leads two black low voltage leads in J box Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the wires There should NEVER be a voltage reading If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the boiler thermostat wires and allow the boiler to cycle Did you find a voltage across the two external thermostat circuit wires Yes No
35. EN GARRAL BHE A UPPED WITE THE SPP Ud PATES a REPLACED PYPE TOMEG TE EMT MaS BENEL a REE MCDA Cii AEE TAA MEE ATH EE POR APATO Bea ihi E HEBART POR SKOLE OMG SAY TRE HEBAHAN ATCT STAD B LE AAL A MALATIA HARF SPL a MF AL A A TO GBT AAAA TLETT A APURADA WE AD Sere TG TT BEARTA PIA BM Chka Tape P PLACE F THER EEEN T FT F ALLA PEAT ML E LACO MOL HEH LMAN FTE WAE H EEEE L EMOTES MELD STALLED CSA DL Coa 25 thu 6 34 Peeped Met Virer Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual Sh Lighting instructions e Standing pilot Natural or propane gas CGa 25 to CGa 8 e Gas valve Honeywell VR8200 VR8300 E FOR YOUR SAFETY READ BEFORE LIGHTING M This appliance has a pilot which must be lighted C Use only your hand to push down the reset button or turn the gas by hand When lighting the pilot follow these control knob Never use tools If the knob or reset button will not instructions exactly operate by hand don t try to repair it call a qualified service BEFORE LIGHTING smell all around the appliance technician Force or attempted repair may result in a fire or explosion area for gas Be sure to smell next to the floor D Do not use this appliance if any part has been under water because some gas is heavier than air and will settle Immediately call a qualified service technician to inspect the appliance on the floor See below and to repla
36. Hitman GOLD CGa Gas Fired Water Boilers Bol ler Manual e Installation Maintenance e Startup e Parts CERTIFIED 1s Manual must on e use a qualine eating installer service technician Before insta Ing read a AWARNING 7 l ly be used by a qualified heating installer service technician Before installing read all instructions including this manual the burner 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 Part No 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual amp O 9 How it works Control module The control module used on spark ignited pilot boilers 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 When the vent damper has opened completely the control module opens the pilot valve and activates pilot igni tion spark The control module allows up to 15 seconds to establish pilot flame If flame is not sensed within 15 seconds the control module will turn off the gas valve flash the Flame light and immediately start a new cycle This will con tinue indefinitely until pilot flame is established or power is in
37. Note 2 Note 3 CGa 25 52 000 44 000 52 000 44 000 46 800 39 000 38 000 1 5 81 5 83 3 84 0 4 1 D x 20 CGa 3 70 000 59 000 70 000 59 000 63 000 53 000 51 000 i5 81 6 83 7 84 0 4 1 D x 20 CGa 4 105 000 88 000 105 000 88 000 94 500 79 000 77 000 2 1 81 7 83 7 84 0 5 l D x 20 CGa 5 140 000 117 000 140 000 117 000 126 000 105 000 102 000 2 7 81 8 83 7 33 Dm OnE D xe On CGa 6 175 000 146 000 175 000 146 000 157 500 131 000 127 000 3 3 81 9 83 6 83 2 6 l D x 20 CGa 7 210 000 175 000 210 000 175 000 189 000 157 000 152 000 3 8 82 0 83 6 33 0 NN Wal Dixe20 CGa 8 245 000 204 000 245 000 204 000 220 500 183 000 177 000 4 4 82 1 83 6 82 7 7 1 D x 20 1 See Table 7 for available pilot systems The suffix shown in the table is added to the boiler model number Not available for millivolt systems Notes 2 Based on standard test procedures prescribed by the United States Department of Energy 3 Net I B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 An additional allowance should be made for unusual piping and pickup loads Table 7 Ignition system model suffixes Pilot ignition system Natural gas Propane gas Standing
38. OPERATING smell all around the D Do not use this appliance if any part has been under water appliance area for gas Be sure to smell next to the Immediately call a qualified service technician to inspect the appliance floor because some gas is heavier than air and will and to replace any part of the control system and any gas control settle on the floor See below which has been under water WHAT TO DO IF YOU SMELL GAS Do nottry to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building e Ifyou cannotreach your gas supplier call the fire department EN oPERAaTING Instructions I STOP Read the safety information above on this label Setthe thermostat to lowest setting Turnoffall electrical power to the appliance Remove front panel This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Turn gas control knob clockwise Y to OFF Honeywell Position O Gas indicator control shown in i knob ON position aa 59331 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the nextstep Turn gas control knob counterclockwise v to
39. S by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally oc curring conditions may corrode the valve or its components over time rendering the valve inop erative Such conditions are not detectable unless the valve and its components are physically removed and inspected This in spection must only be conducted by a plumbing contractor or au thorized inspection agency not by the owner Failure to reinspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever must be operated AT LEAST ONCE AYEAR to ensure that waterways are clear Certain naturally occurring mineral de posits may adhere to the valve rendering it inoperative When manually operating the lever wa ter will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve direct ing the flow of hot water from the valve to a proper place of disposal otherwise severe personal injury may result If no water flows valve is inoperative Shut down boiler until a new relief valve has been installe
40. _ F u Hish valiga bo wie pilot spark electrode T Graan 50 cable Chasse 130 VAC N Ps ground lt F 120 VAC to Wia s an imava Ea i 3 fed vara to 3 gas wales 120 VAC IN lack wires to thermostat circuit a 4 Si So i Biur wire bo m White wine to gaa valve PY 1 r a gas wabe PY ll ani Yollow wires to limit control 24 VAC and rollout setich 2A VAC i i 5 0 DAMFER 5 0 LIMIT _ So TSTAT CIRC in voor daie i E ai POWER 6 H VAC to vent damper Integrated Boller Gontrol F 1 High voltage to aperk electrods 120 WAC to transtonmer 3 1 20 WAC IN 6 M VAC wont dampar connotati 120 WAC bs circulator E p e al R onse wire to fome sereor Flame sanse wire ta pilot GOLD CGa Gas Fired Water Boiler Boiler Manual 1 lc Troubleshooting spark pilot boilers continued CHART 2 Spark ignited pilot Troubleshooting POWER light status Usually indicates reversed 120 VAC polarity if POWER light flashes by itself A WARNING Electrical shock hazard Wherever you see da TURN OFF POWER follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage Is POWER light off e Make sure service switch or circuit breaker is on or No Yes p fuses are good Remove 120 VAC IN plug Figure
41. ain 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 381 355 407 381 355 448 381 355 470 381 355 699 381 355 403 CGa 3 CGa 4 381 355 410 381 355 451 381 355 473 381 355 699 381 355 413 CGa 4 CGa 5 381 355 417 381 355 454 381 355 477 431 223 311 381 355 420 CGa 5 CGa 6 381 355 424 381 355 457 381 355 481 431 223 311 381 355 427 CGa 6 CGa 7 381 355 431 381 355 460 381 355 485 431 223 311 381 355 434 CGa 7 CGa 8 381 355 438 381 355 463 381 355 489 431 223 311 381 355 441 CGa 8 5 6 7 8 9 10 Jacket panel Jacket panel Jacket cross tie Jacket panel Jacket panel Not shown gold gt top rear door bottom front interior rear touch up paint g Boiler Boiler Model Weil McLain part number Model CGa 25 3 381 355 404 381 355 406 431 223 325 381 355 405 431 223 300 592 000 000 CGa 25 3 CGa 4 381 355 414 381 355 416 431 223 326 381 355 415 431 223 301 CGa 4 CGa 5 381 355 421 381 355 423 431 223 327 381 355 422 431 223 302 CGa 5 CGa 6 381 355 428 381 355 430 431 223 328 381 355 429 431 223 303 CGa 6 CGa 7 381 355 435 381 355 437 431 223 329 381 355 436 431 223 304 CGa 7 CGa 8 381 355 442 381 355 444 431 223 330 381 355 443 431 223 305 CGa 8 Part Number 550 101 009 0107 63 GOLD CGa Gas Fired Water Boiler Boiler Manual 12e 64 Replacement parts trim Figure 34 Trim assembly xP Item Description Manufacturer Manufactu
42. aminants Failure to keep boiler area clear and free of combustible mate rials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service If new boiler will replace existing boiler check for and correct system problems such as System leaks causing oxygen corrosion or section cracks from hard water deposits Incorrectly sized expansion tank Lack of antifreeze in boiler water causing system and boiler to freeze and leak 6 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual Ib Recommended SERVICE clearances Fig 1a l Provide clearances for cleaning and servicing the boiler and tor access to controls and components See Figure la for recommen dations 2 Provide at least screwdriver clearance te jacket front panel screws for removal of front panel for inspection and minor service If unable to provide at least screwdriver clearance install unions amd di jee i Prepare boiler location clearances Figure 1b Required MINIMUM clearances Figure 1a Clearances soa WARNING Esaki F Flooring The Ca boiler is approved for installation on combustible flooring but must mever be installed on carpeting Do not install boiler on carpeting even
43. anel shown in OFF position L i 59332 DE To TURN OFF GAS TO THE APPLIANCE M 1 Setthe thermostat to lowest setting 3 Remove front panel 2 Turn off all electric power to the appliance if service is to be 4 Depress and move selector arm to OFF Do not force performed 5 Replace front panel 550 223 044 0906 Part Number 550 101 009 0107 41 GOLD CGa Gas Fired Water Boiler Boiler Manual 9b Operating instructions spark pitot Natural gas CGa 25 to CGa 6 e Gas valve White Rodgers 36E N99 FOR YOUR SAFETY READ BEFORE OPERATING P This appliance is equipped with an ignition device C Use only your hand to turn the gas control knob Never use tools If the which automatically lights the pilot Do not try to knob will not turn by hand don t try to repair it call a qualified service light the pilot by hand technician Force or attempted repair may result in a fire or explosion BEFORE OPERATING smell all around the D Do not use this appliance if any part has been under water appliance area for gas Be sure to smell next to the Immediately call a qualified service technician to inspect the appliance floor because some gas is heavier than air and will and to replace any part of the control system and any gas control settle on the floor See below which has been under water WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Immediately call your gas
44. area of all equipment vent connectors in the space and The free area of the opening must be at least 1 square inch per 3 000 Btu hr input rating of all equipment located in the space Exception for large spaces No combustion air openings are needed when the boiler and other ap pliances are installed in a space with a volume at least 50 cubic feet per 1 000 Btuh of all installed appliances provided the building must not have unusually tight construction see defini tion this page e all clearances around the boiler must must be no less than shown in Figure la page 7 To determine if the space is large enough to qualify e Add the total input of all appliances in MBH 1 000 s of Btuh Multiply this number times 50 to determine minimum room volume Example For a total input of 100 MBH 100 000 Btuh minimum volume is 50 x 100 5 000 cubic feet At a ceiling height of 8 feet the space must have at least 5 000 8 625 square feet 25 feet x 25 feet for instance Part Number 550 101 009 0107 Unusually tight construction Unusually tight construction means per ANSI Z223 1 buildings in which a Walls and ceilings exposed to the outside atmo sphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and b Weather stripping has been added on openable windows and doors and c Caulking or sealants are applied to areas such as joints around windows an
45. as technician or gas supplier including near the floor If you smell gas STOP Follow B in 12 Replace access panel the safety information above If you don t smell gas go to the 13 Turn gas control knob counterclockwise to ON next step 14 Turn on all electric power to the appliance Remove access panel located above burners 15 Set thermostat to desired setting 16 Replace front panel DI TO TURN OFF GAS TO THE APPLIANCE SR 1 Setthe thermostat to lowest setting 3 Remove front panel 2 Turn off all electric power to the appliance if service is tobe 4 Turn gas control knob clockwise x to OFF performed 5 Replace front panel 550 223 038 0906 Part Number 550 101 009 0107 35 GOLD CGa Gas Fired Water Boiler Boiler Manual Sh Lighting instructions CGa 25 to CGa 8 e Gas valve Robertshaw 7200 NN FOR YOUR SAFETY READ BEFORE LIGHTING M This appliance has a pilot which must be lighted C Use only your hand to depress or move the selector arm Never use by hand When lighting the pilot follow these tools If the selector arm will not depress or move by hand don t try to instructions exactly repair it call a qualified service technician Force or attempted repair BEFORE LIGHTING smell all around the appliance may resultin a fire or explosion area for gas Be sure to smell next to the fl
46. be replaced use minimum 105 C EN eed GS wire or equivalent Exception wires to a rollout ROLLOUT PILOT GAS TFE must be 200 C or equivalent TFE WATER CONTROL MODULE VALVE 4 Thermostat anticipator setting single zone see NMC SWITE LOW VOLTAGE Table G for anticipator setting depending on which gas valve is installed in boiler SECTION 5 For multiple zoning use either zone valves or circulators Refer to the component manufac oI o turer s instructions and this manual for applica DAMPER END SWITCH tion and wiring suggestions INTERNAL TO DAMPER 6 Refer to control component instructions packed MAIN GAS with the boiler for application information HIGH VALVE 7 Wire any additional limit controls low water cut pior VOLTAGE See Table G off additional high limit etc in series with boiler FLAME limit control as Jowi peas SENSOR Part Number 550 101 009 0107 39 GOLD CGa Gas Fired Water Boiler Boiler Manual 9b Operating instructions spark pilot Natural gas CGa 25 to CGa 8 e Gas valve Honeywell VR8204 VR8304 N99 FOR YOUR SAFETY READ BEFORE OPERATING M This appliance is equipped with an ignition device C Use only your hand to turn the gas control knob Never use tools If the which automatically lights the pilot Do not try to knob will not turn by hand don t try to repair it call a qualified service light the pilot by hand technician Force or attempted repair may result in a fire or explosion BEFORE
47. bove so that it is visible after installa tion on Plug damper harness receptacle into damper harness plug Bypassing jumpering vent damper will cause flue products such as carbon monoxide to escape into the house This will cause severe personal injury or death After boiler has operated once if ei ther end of harness is disconnected the system safety shutdown will oc cur The boiler will not operate until harness is reconnected Effikal or Field Controls damper Damper hold open switch must be in Automatic Operation position for system to operate properly N 15 GOLD CGa Gas Fired Water Boiler Boiler Manual 3a General piping information If installation is to comply with ASME or Canadian requirements an ad ditional high temperature limit is needed Install control in supply piping between boiler and isolation valve Set second control to minimum 20 F above setpoint of first control Maximum allowable setpoint is 240 F See page 34 or 38 for wiring A low water cutoff device is required when boiler is installed above ra diation level or by certain state or local codes or insurance companies Use low water cutoff designed for water installations Electrode probe type is recommended Purchase and install in tee in supply piping above boiler Use backflow check valve in cold water supply as required by local codes Pressure temperature gauge Install pressure temperature gauge in tee on supply p
48. cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injec tion pumping control Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the boiler re turn 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 20 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual od Figure 13 a vn O GO A Primarysecondary piping Zoning with circulators ai ZONE 2 ZONE 125 cod oN 2 a fill Boiler isolation balancing valves Flow check valve System or zone circulator circulator should cycle with zone valve and switches using circulator valve or zone control panel System temperature gauges
49. ce any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building e Ifyou cannot reach your gas supplier call the fire department a LIGHTING INSTRUCTIONS ESSN STOP Read the safety information above on this label 8 Find pilot follow metal tube from gas control The Setthe thermostat to lowest setting pilot is between two burners behind the access Turnoffall electrical power to the appliance panel Remove front panel Turn gas control knob counterclockwise v to le Turngas control knob clockwise to OFF PILOT ma Push in red reset button and hold Immediately light the pilot seian with a match Continue to hold reset button in for about one indicator Hon 1 minute after the pilot is lit shown in Q Gas Release reset button Pilot should remain lit If pilot goes out ON position control repeatsteps5 through 11 Red n Knob If reset button stays depressed after release stop and reset button Os l immediately call your service technician or gas supplier ceas e If the pilot will not stay lit after several tries turn the gas control knob clockwise x to OFF and call your service Wait five 5 minutes to clear out any gas Then smell for g
50. ce switch off Start up if boiler doesn t start Gas not turned on at meter or boiler ane ae i Incoming gas pressure less than 2 High limit switch set below boiler water temperature 5 w c for natural gas 11 w c for propane gas 3 Thermostat set below room tem 6 perature If none of the above corrects the problem refer to Troubleshoot ing Section 11 of this manual Part Number 550 101 009 0107 31 GOLD CGa Gas Fired Water Boiler Boiler Manual 32 6d Start up verify operation Check burner flames Pilot burner flame Figure 21 PROPER pilot flame 1 Blue flame 2 Inner cone engulfing thermocouple standing pilot or pilot flame sensor spark ignited pilot 3 Thermocouple or pilot flame sensor glowing cherry red IMPROPER pilot flame 1 Overfired Large flame lifting or blowing past pilot flame sensor 2 Underfired Small flame Inner cone not engulfing pilot flame sensor 3 Lack of primary air Yellow flame tip Incorrectly heated pilot flame sensor Main burner flame Figure 22 PROPER main burner flame 1 Yellow orange streaks may appear caused by dust IMPROPER main burner flame 1 Overfired Large flames 2 Underfired Small flames 3 Lack of primary air Yellow tipping on flames sooting will occur Check vent damper operation 1 Raise room thermostat to call for heat Vent damper actuator will slowly open
51. ch 240 F CGa 3 through 8 510 300 014 3 per boiler CGa 4 560 234 501 12 Vent damper 4 381 800 474 CGa 5 560 234 502 5 381 800 475 CGa 6 560 234 503 6 381 800 476 CGa 7 amp CGa 8 560 234 504 Ti 381 800 477 5 Nut 746 2 per tie rod 561 928 235 13 Vent damper actuator Effikal RVGP 510 512 337 6 Washer Ac 1 per tie rod 562 248 684 Johnson M35BE 1C 510 312 255 7 Radiation plate 1 per joint 460 003 700 14 Vent damper harness 591 391 795 8 Collector hood CGa 25 381 354 625 CGa 3 381 354 626 CGa 4 381 354 627 CGa 5 381 354 628 CGa 6 381 354 629 CGa 7 381 354 630 CGa 8 381 354 631 Part Number 550 101 009 0107 61 GOLD CGa Gas Fired Water Boiler Boiler Manual 12c Replacement parts base 1 i ers 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 CGa 5 381 354 358 CGa 6 381 354 359 CGa 7 381 354 360 CGa 8 381 354 361 1 Base side panel in Base assembly 2 Base front cross tie assembly in Base assembly 3 Base back cross tie assembly in Base assembly 4 Access panel in Base assembly 5 Base pan angle left side in Base assembly 6 Base pan angle right side in Base assembly 7 Base pan in Base assembly 8 Burner rest CGa 25 450 003 7
52. d I Check test continued Boiler relief valve 1 Inspect the relief valve and lift the lever to verify flow as in the following warnings excerpted from a relief valve manufacturer s warning label Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read manual Section 3 before proceeding further 2 After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing Figure 2 _J Review with owner 1 Review the User s Information Manual with the owner 2 Emphasize the need to perform the maintenance schedule specified in the User s Information Manual and in this manual as well 3 Remind the owner of the need to call in a licensed contractor should the boiler or system exhibit any unusual behavior 4 Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 10b lla AWARNING AWARNING AWARNING NOTICE Service amp maintenance annual start up on _I Cleaning boiler heating surfaces The boiler contains ceramic fiber and f
53. d door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines and in other openings For such construction cases if appliances use inside air for combustion provide air openings into the building from outside Size and locate these openings per the appropriate case in Figure 3 4 or 5 on page 10 Exhaust fans and air movers The appliance space must never be under a negative pressure even if the appliance s are installed as direct vent Always provide air openings sized not only to the dimensions required for the firing rate of all appli ances but also to handle the air movement rate of the exhaust fans or air movers using air from the building or space Motorized air dampers If the air openings are fitted with motorized dampers electrically interlock the damper to Prevent the boiler from firing if the damper is not fully open Shut the boiler down should the damper close dur ing boiler operation To accomplish this interlock wire an isolated contact proving the damper open in series with the thermo stat input to the boiler The boiler will not start if this contact is open and will shut down should it open during operation 11 GOLD CGa Gas Fired Water Boiler Boiler Manual 2a Prepare boiler placement and setup Place boiler crate near position NOTICE gt Leave boiler in crate and
54. d respirators manufac turers and phone numbers are also listed on this web site Wear long sleeved loose fitting clothing gloves and eye protection L Operations such as sawing blowing tear out and spraying may generate airborne fiber concentration requiring additional protection _1 Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thor oughly NIOSH stated First Aid Ll Eye Irrigate immediately d Breathing Fresh air Weil McLain 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com Part Number 550 101 009 0107
55. d result in severe personal injury death or substantial property damage 44 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 10b AWARNIN Service amp maintenance annual start up The boiler should be inspected and started annu ally at the beginning of the heating season only by a qualified service technician In addition the maintenance and care of the boiler designated in Table 6 page 44 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Miner als can build up in sections reducing heat transfer overheating cast iron and causing section failure Leaking water may also cause severe property damage Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death L Inspect Reported problems Inspect any problems reported by owner and correct before proceeding Boiler area
56. damper and circulator energized if pilot status acceptable Vent damper drives open When vent damper end switch makes circuit igni tion control begins pilot ignition attempt b Ignition control checks for false flame signal If ignition control senses pilot signal when no pilot gas should be present control will lockout requiring reset procedure as given in Figure 24 3 Pilot ignition Control module sparks the pilot and opens pilot valve in main gas valve a If pilot does light and control module senses flame current spark generator is turned off and main valve opens b Ifpilot does not light within 15 seconds pilot valve is closed and spark generator is turned off Control module waits 5 minutes then attempts to ignite pilot again This cycle will continue indefinitely if pilot ignition control does not sense pilot flame 4 Main burner operation a Control module monitors pilot flame current If signal is lost main valve closes spark generator activates and sequence returns to step 4 If power is interrupted control system shuts off pilot and main gas valves and restarts at step 1 when power is restored In the event the limit control shuts down the boiler The control module closes the main gas valve but keeps the circula tor operating and the vent damper open 5 Thermostat satisfied thermostat circuit opens Pilot and main gas valves are closed Vent damper is de energized and cycles to clos
57. dential garage installations ances less than the minimum clearances shown in Figure 1b Failure to comply can result in severe Take the following special precautions when installing the personal injury death or substantial property boiler in a residential garage If the boiler is located in a damage and reduced boiler life residential garage per ANSI Z223 1 1 Hot water pipes at least 7 inch from combustible material Mount the boiler a minimum of 18 inches above the 2 Single wall vent pipe at least 6 inches from combustible mate floor of the garage to assure the burner and ignition rial Type B double wall metal vent pipe refer to vent manufacturer s recommendation for clearances to combustible material Part Number 550 101 009 0107 devices will be no less than 18 inches above the floor Locate or protect the boiler so it cannot be damaged by a moving vehicle GOLD CGa Gas Fired Water Boiler Boiler Manual le 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 Do not alter boiler draft hood or place any obstruction or non approved vent damper in breeching or vent system CSA certification will become void Flue gas spillage and carbon
58. e 59 replace vent damper assembly or actuator 56 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual lle Troubleshooting spark pilot boilers continued CHART 5 Spark ignited pilot FLAME amp POWER lights flashing Usually indicates flame sensed when it shouldn t be there WARNING Electrical shock hazard Wherever you see TURN OFF POWER s follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage Are manual main shutoff valve and gas valve open No Yes e Leave main manual gas valve closed e Turn off power to the boiler at service switch or breaker Turn off power to boiler at service switch or breaker e Wait at least 45 seconds e Turn on power to boiler e Restart boiler following Operating instructions in this manual Section 9b or on boiler label Do FLAME and POWER lights still flash Wait at least 45 seconds Turn on power to boiler Restart boiler following Operating instructions in this manual Section 9b or on boiler label Look through the pilot inspection port to see if the pilot is burning Is pilot burning No Yes i No e Replace control module e Retest Yes e Replace gas valve e Retest boiler Are FLAME and POWER lights flashi
59. e boiler drain valve Part Number 550 101 009 0107 6 7 Prepare boiler pressure test Close shutoff valves Slowly reopen boiler drain valve until test pressure of not more than 45 psi is reached on the pressure temperature gauge Test at no more than 45 psi for no more than 10 minutes Do not leave boiler unattended A cold water fill could expand and cause excessive pressure resulting in severe personal injury death or substantial property damage Make sure constant gauge pressure has been main tained throughout test Check for leaks Repair if found Leaks must be repaired at once Failure to do so can damage boiler resulting in substantial property damage Do not use petroleum based clean ing or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Drain and remove fittings l 2 Disconnect fill water hose from water source Drain boiler at drain valve or out hose whichever provides best access to drain Remove hose after draining if used to drain boiler Remove nipples and valves unless they will remain for use in the system piping Remove plug from relief valve tapping See Section 3 to replace relief valve 13 GOLD CGa Gas Fired Water Boiler Boiler Manual 2C Draft hood installation 1 Orient draft hood with spill switch mounting holes to front of boiler as shown in Figure 7 Secure draft hood to outlet at
60. e pilot will not stay lit after several tries move selector arm left to OFF and call your service technician or Eea gas supplier 12 Replace access panel Wait five 5 minutes to clear out any gas Then smell for gas 13 Turn selector arm left to ON including near the floor If you smell gas STOP Follow B in i the safety information above Ifyou don t smell gas go to the 14 Turnonallelectric power to the appliance nextstep 15 Setthermostat to desired setting Remove access panel located above burners 16 Replace front panel HI TO TURN OFF GAS TO THE APPLIANCE M 1 Setthe thermostat to lowest setting 3 Remove front panel 2 Turn off all electric power to the appliance if service is tobe 4 Depress and move selector arm left v to OFF Do not performed force 5 Replace front panel 550 223 039 0906 36 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 9a Operation spark ignited pilot boilers NOTICE Follow all procedures given in this manual and operating instructions when operating the boiler Failure to do so could result in severe personal injury death or substantial property damage 1 Standby With no call for heat the vent damper and circulator are de energized No gas flows to pilot or main gas valve 2 Call for heat thermostat circuit closes a Vent
61. ect Check gas piping per manual Sections 4 and 6 verifying no indications of leakage and all piping and connections are in good condition Read the Lighting or Operating instructions manual Section 8 or 9 applying to the boiler Start the boiler following appropriate Lighting or Operating instructions manual Section 8 or 9 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 10b Service amp maintenance annual start up wn E Check test Expansion tank 1 Gas piping 1 Sniff near floor and around boiler area for any in dication of a gas leak 2 Test gas piping using bubble test per Section 4 of this manual if there is any indication of a leak Cold fill and operating pressures 1 While the system is cold note the pressure reading on the boiler pressure temperature gauge Verify that cold fill pressure is correct 2 Watch the pressure as the boiler and system heat up to ensure pressure rise is normal Too high a rise would indicate a waterlogged or undersized expan sion tank Air vents and air elimination 1 Inspect automatic air vents if used Also inspect air separators to ensure they are operational 2 The cap must be unscrewed one turn to allow air to escape 3 See Figure 26 If the air vent is leaking remove cap A and briefly push valve B and then release to clean the valve seat 4 Replace cap A by twisting all the way onto valve B and then unscrewing one t
62. ed Check out sequence has been performed Above information is certified to be correct Information received and left with owner maintenance person company Installer s signature address phone Part Number 550 101 009 0107 For multiple zones adjust flow so it is about the same in Verify thermostat heat anticipator if available set prop erly Refer to Field wiring manual Section 5 page 27 Cycle boiler with thermostat Raise to highest setting and verify boiler goes through normal start up cycle Lower to At natural gas meter measure time in seconds re Btuh Btuh calculated should approximate input rating on Check manifold gas pressure by connecting manometer to downstream test tapping on main gas valve Manifold pres sure for natural gas should be 3 5 w c and for propane gas Review all instructions shipped with this boiler with owner or maintenance person Return instructions to envelope and give to owner or place in pocket inside front panel in GOLD CGa Gas Fired Water Boiler Boiler Manual Sa Follow all procedures given in this manual and light ing instructions when operating the boiler Failure to do so could result in severe personal injury death or substantial property damage 1 Standby mode After pilot is manually lit the gas valve provides pilot gas and maintains pilot as long as the thermocouple is satisfied If ther mocouple signal drops for any reason pilot
63. ed posi tion Circulator is shut off 6 Boiler is now in the standby mode Thermostat anticipator setting Set thermostat heat anticipator as instructed in Figure 25b page 39 Figure 24 Ignition control module sequence of operation status light indications Steps Call for POWER TSTAT LIMIT DAMPER FLAME Timing heat CIRC Following step 7 cycle goes back to step 1 1 Standby f G Waiting for call for heat NO l l 2 Callfor heat YES A Circulator on S 3 Limit circuit Poa 2 T AN Limit controls closed YES ee ff l 4 Damper circuit PEN Damper proven open YES Ee 5 Pilot name proven Gas valve open ee es ea eg Pilot remains on YES FF g ie 15 sec Boiler producing heat 6 Limit cycle ex p ER Limit circuit open YES Fr TE Gas valve closed 7 Flame outage TN Flame out YES FX PF Boiler recycles 8 Thermostat satisfied ao Poa lan YS Circulator off NO fe 15 sec 9 Circulator exercise routine x pan oa EN Circulator turns on for 30 seconds NO _ fa eas 30 sec if boiler not operated for 30 days or J E ON LOTS OFF line or if flame is sensed when it shouldn t be there The boiler will reset after these lockouts if any of the following occurs If pilot flame is not proven in 15 seconds control module will flash the FLAME light but will continue indefinitely with atte
64. ed with water and all instruc tions and procedures of previous manual sections have been completed Failure to do so could result in severe personal injury death or substantial property damage Before starting the boiler do the following Read manual Section 8 9 and the Lighting Operating instruction procedure see Table 5 below Verify the boiler and system are full of water Verify the Start up preparation procedures of Section 6 have been completed Table 5 Lighting Operating instruction location guide Models Standing pilot Gas Page Spark ignited pilot Gas Page Natural or Propane 35 Honeywell VR8204 VR8304 Natural 40 CGa 25 Honeywell VR8200 VR8300 to Robertshaw 7200 Natural 41 CGa 6 Robertshaw 7200 Natural 36 RIS we White Rodgers 36E Natural 42 ceay Honeywell VR8200 VR8300 baa 35 Honeywell VR8204 VR8304 Natural 40 CGa 8 Robertshaw 7200 Natural 36 White Rodgers 360 Natural 43 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 6b Start the boiler Follow the Lighting Operating Instructions from Section 8 or 9 to start the boiler Remove boiler jacket door and note the gas valve manufacturer and model number Use only the lighting operat ing instruction which applies to this gas valve see Table 5 page 30 The lighting instruction label on the boiler provides the same information See Section 6c if boiler fails to start Check system and boile
65. er 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual le Prepare boiler location air openings AWARNING Combustion air opening location and sizing Figure Alr openings to Interior spaces requirements depend on the clearances around the boiler Check the boiler placement compared ae Esch opaning free area emp to Figure la page 7 1 ag iach par 1 000 But af If all clearances are at least equal to Figure 1a D u i page 7 apply the sizing and placement of openings ma a given on pages 10 and 11 Dee Hl ala bpi i If ANY clearance is less than Figure 1a page 7 a we 1 H you must provide air openings sized and located as E A af shown in Figure 1b page 7 DO NOT apply the sizing nil a es a and location information shown on page 10 or 11 Figure 3 Aur directi through outside wall Air openings must be provided k Combustion air and ventilation openings must comply the National Fuel ing reais pote 40000 Bi al Gas Code ANSI Z223 1 latest edition or applicable local building codes a q Canadian installations must comply with B149 1 or B149 2 Installation j h boie 3 Codes aie ali om AWARNING Provide adequate combustion and ventilation air to al 1 r assure proper combustion and reduce the risk of severe i af personal injury death or substantial property damage attr caused by flue gas spillage and carbon monoxide emissions x Figure 4 Air from outdoo
66. er manufactured parts will not be covered by warranty and may damage boiler or impair operation NOTICE Weil McLain part numbers are found in Weil McLain Boilers and Controls Repair Parts Lists AWARNING The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 68 of this manual Failure to comply could result in severe personal injury 60 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 12b Replacement parts section assembly Figure J Section assembly flue collector draft hood and vent damper pean Item Description Weil McLain Item Description Weil McLain number part number number part number 1 End section left hand 51124 311 103 830 9 High limit 30 Honeywell 510 312 250 2 End section right hand 51128 311 103 821 differential with well en te 3 Intermediate section 51125 311 103 818 Moe not Replacement section CGa 25 amp CGa 3 321 114 345 shown assembly CGa 4 321 114 346 ue Dre uecs ae ethos eel Pah cea CGa 4 450 021 242 CGa 6 321 114 348 CGa 5 450 021 243 CGa 7 321 114 349 CGa 6 450 021 244 CGa 8 321 114 350 CGa 7 450 021 245 not Section replacement kit includes seals and 381 354 527 CGa 8 450 021 246 shown _ sealant for 1 joint 11 Spill switch 210 F CGa 25 510 300 013 4 Tie rod 6 without nut CGa 25 amp CGa 3 560 234 500 Spill swit
67. ermostat to mateh ei requirements ofequipment connected to it lf connected directly to boiler set for 0 1 amps plus gas valve current See information on the wiring amp nim shown in Figure 25b page 39 For ot devices refer to manufacturers specifications Wiring diagrami on boiler gives setting for control module and gas valve Alga see instructions with thermostat Junction box furnished l Connect 120 VAC power wiring Figure 20 2 Fused disconnect or service switch 15 amp recom mended may be mounted on this box Eor thts installations with local codes which prohibit instal lation of fused disconnect or service switch on boiler install a 2 x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code Refer to zone valve manutacturer s literature for wiring and application A separate transformer is required to power zone valves Zoning with circulators requires a relay for cach circulator Figure 20 B mg Field wir tio i l emae Bld wrm Connections service switch and thermastat i l or end matah jor end switch prowided by mere installer l I T i I I l l l i J d Les a D r Viira rahe 3 Biirk Thar mod tat beac th j tkati left Part Number 550 101 009 0107 Z GOLD CGa Gas Fired Water Boiler Boiler Manual 6a Start up preparation Check for gas leaks AWARNING Before starting the boiler and dur ing initial operation
68. eturn 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 22 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual od Piping low temperature systems continuo Figure 15 B8oller bypase piping Figure 16 Boller bypace piping Zoning with circulators Zoning with zone valves Alternathre to primarnvsecondary piping Altemative to primary secondary piping Figures 13 and 14 Figures 13 and 14 ZONE 2 a 1 ZONE 2 a ZONE 1 is ZONE 1 a i z4 1 4a 4b 2 4b 5 m a 13 e 1 Tone a y cg 13 hii 1 teeter iy 7a ret a Ta a ji Th 7h T oa T 10 a Aao Cold Ti aji aa aie i 3 Bald ti 43 or a i LO 12 kri BFG 1 Boiler isolation balancing valves 10 Automatic air vent with diaphragm type expansion tank or connect to tank fitting closed type expan 2 Flow check valve sion tank DO NOT use an automatic air vent when f using closed type expansion tank It would allow air to 3 System or zone circulator leave the system causing waterlogging of the expansion tank 4 System temperature gauges 5 Zone valve 11 Fill valve 6 Dramvae 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top 7 System temperature valves see instructions of air separator to tank fitting as in Figure 10 to the left for adjusting valves
69. he return drain tee and the supply gauge tee supplied with the boiler are 114 NPT One of the circulator flanges sup plied with the boiler is 114 The other circulator flange is the size of the recommended system piping shown above AWARNING e Chilled medium if used is piped in parallel with heating boiler Use appropriate valves to prevent chilled medium from entering boiler Consult I B R Installation and Piping Guides If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air use flow control valves or other au tomatic means to prevent gravity circulation during cooling cycle Circulation of cold water through the boiler could result in damage to the heat exchanger causing possible severe personal injury death or substantial property damage Chillers or air handling units Install boiler such that Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 3b Water piping single zone system Diaphragm type or bladder type expansion tank Figure 9 1 Ensure expansion tank size will handle boiler and system water volume and temperature Tank must be located in boiler return piping as close to boiler as possible before inlet side of circulator See tank manufacturer s instructions for details 2 Install an automatic air vent as shown Undersized expansion tanks cause system water to be lost from relief va
70. he space in which the appliances remaining con required by local state provincial and national nected to the common venting system are located codes laws regulations and ordinances Vitreous tile and other spaces of the building Turn on clothes linings with joints that prevent retention of moisture dryers and any appliance not connected to the com and linings made of noncorrosive materials are best mon venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a sum mer exhaust fan Close fireplace dampers Advice for flue connections and chimney linings can be obtained from local gas utility Type B double wall metal vent pipe or single wall vent pipe may be used as a liner d Place in operation the appliance being inspected 4 Follow the lighting operating instructions Adjust thermostat so appliance will operate continuously Cold masonry chimneys also known as outside chimneys typically have one or more walls ex posed to outside air When any atmospheric gas e Test for spillage at draft hood relief opening after fired boiler with automatic vent damper is vented 5 minutes of main burner operation Use the flame through this type of chimney the potential exists for of a match or candle condensation to occur Condensation can damage a masonry chimney Weil McLain recommends the f After it has been determined that each appliance following
71. his piping de sign allows changing boiler flow rate without affecting primary circuit flow rate If Figures 13 or 14 cannot be used use the boiler bypass piping shown in Figure 15 or Figure 16 on page 23 You can also use the piping shown in Figure 17 on page 25 system bypass if the reduced flow rate in the heating system will not cause heat distribution problems Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sec tions or burners resulting in severe personal injury death or substantial property damage Radiant heating systems Preferably use primary secondary piping as shown in Figures 13 or 14 on page 21 Alternatively use the method of either Figure 15 or Figure 16 on page 23 Do not use the piping of Figure 17 system bypass because this method does not control radiant system supply temperature If radiant system tubing has no oxygen barrier a heat exchanger must be used Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injection pumping control Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant DO NOT apply the methods in this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate
72. html NIOSH approved respirators manufacturers and phone numbers are also listed on this web site Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust L Remove combustion chamber lining or base insula tion from the boiler and place it in a plastic bag for disposal L Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid _I Eye Irrigate immediately d Breathing Fresh air Um WE LAIN REMOVAL OF FIBERGLASS WOOL or INSTALLATION OF FIBERGLASS WOOL COMBUSTION CHAMBER LINING OR BASE PANELS This product contains fiberglass AWARNING jacket insulation and ceramic fiber materials in combustion chamber lining or base panels in gas fired products Airborne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation Precautionary measures d Avoid breathing fiberglass dust and contact with skin or eyes e Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for fiberglass wool at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recom mendations can be found on the NIOSH web site at http www cdc gov niosh homepage html NIOSH approve
73. iberglass materi als Use care when handling these materials per instruc tions on page 68 of this manual Failure to comply could result in severe personal injury 1 Sie eh Shut down boiler Follow To Turn Off Gas to Appliance in structions on boiler and Lighting or Operating instructions Do not drain boiler unless it will be exposed to freezing temperatures If using antifreeze in system do not drain Follow shutdown procedure Remove venting system connection to boiler Remove top jacket panel Turn back insulation Remove flue collector Clean sealant from assembly and sections Remove radiation plates hanging between sections dee 10 11 12 13 14 Remove burners from base Brush and vacuum burners to remove all dust and lint Verify that all burner ports are free of debris Place newspapers in base of boiler to collect soot Clean between sections with wire flue brush Remove newspaper and soot Vacuum or brush base and surrounding area Reinstall radiation plates Replace collector box transition assembly Seal with sealant Obtain gas tight seal to prevent flue gas spillage and carbon monoxide emissions resulting in severe personal injury or death Replace insulation and jacket top panel Start up boiler following Section 6 of this manual and the boiler Lighting or Operating instructions Section 8b or 9b Excessive sooting indicates improper gas combustion If found check for pr
74. ication Typical cold water fill pressure for a residential system is 12 psi 3 Purge air from system a Connect a hose to the purge valve see drain valves item 6 in sug gested piping diagrams on pages 17 through 23 Figure 9 through Figure 16 Route hose to an area where water can drain and be seen Close the boiler or system isolation valve between the purge valve and fill connection to the system Close zone isolation valves Open quick fill valve on cold water makeup line Open purge valve One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressure h After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system i Ifpurge valves are not installed in system open manual air vents in system one at a time beginning with lowest floor Close vent when water squirts out Repeat with remaining vents z moan 4 Open automatic air vent diaphragm type or bladder type expansion tank systems only one turn 5 Open other vents a Starting on the lowest floor open air vents one at a time unt
75. if foundation is used Fire can result causing severe personal injury death or substantial property damage AWARNING If any clearance is less than in Figure 1a provide openings for combustion and ventilation air located on the wall or door opposite the boiler FRONT see Figure 1b These openings must be located as shown in Figure 1b to provide ae air flow around the boiler The free area of each opening AWARNING Foundation Provide a solid brick or minimum 2 inch thick concrete foundation pad if any of the following is true ave air floor can become flooded after deducting for louvers must be at least one square inch per 1 000 Btuh of boiler input If the building is of unusually 1 tight construction see page 11 for definition the air Paes must connect directly to outside or the building must openings to the outside as specified on page 11 the boiler mounting area is not level If clearances are equal to or greater than Figure la see pages 10 2 Minimum dimensions are 25 length by and 11 for location and sizing of combustion air openings P p om Minimum foundation width Failure to comply can result in severe personal injury death or substantial property damage and reduced boiler life CGa 25 3 12 CGa 6 21 CGa 4 15 CGa 7 24 CGa 5 18 CGa 8 27 Required MINIMUM clearances Fig ib AWARNING Never install the boiler in a space with clear Resi
76. il water squirts out b Repeat with remaining vents 6 Refill to correct pressure Part Number 550 101 009 0107 Inspect system water piping After filling the boiler and system with water inspect all piping throughout the system for leaks If found repair immediately Repeat this inspection after the boiler has been started and the system has heated up AWARNING Leaks must be repaired at once Failure to do so can damage the boiler resulting in substantial prop erty damage A DANGER Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in sub stantial property damage Inspect base insulation AWARNING The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 68 of this manual Failure to comply could result in severe personal injury AWARNING Failure to replace damaged insu lation or reposition insulation can result in a fire hazard causing severe personal injury death or substantial property damage Check to make sure base insulation is secure against all four sides of the base If insulation is damaged or displaced do not operate boiler Replace or reposition insulation 29 GOLD CGa Gas Fired Water Boiler Boiler Manual 30 6b Start up operate boiler AWARNING DO NOT proceed with boiler operation unless boiler and system have been fill
77. iping as shown in drawing on page 3 Relief valve Install relief valve vertically in 34 tapping on side of boiler See Figure 9 or 10 page 17 and the tag attached to the relief valve for manufacturer s instructions To avoid water damage or scalding due to relief valve operation Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line to eliminate possibility of severe burns should the valve discharge Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain where any discharge will be clearly visible The discharge line shall terminate plain not threaded with a mate rial serviceable for temperatures of 375 F or greater Do not pipe the discharge to any place where freezing could occur No shutoff valve shall be installed between the relief valve and boiler or in the discharge line Do not plug or place any obstruction in the discharge line Failure to comply with the above guidelines could result in failure of the relief valve to operate resulting in possibility of severe personal injury death or substantial property damage Test the operation of the valve after filling and pressurizing system by lifting the lever Make sure the valve discharges freely Ifthe valve fails to
78. ld be avoided Severe 3 personal injury death or sub stantial property damage could result 4 Where horizontal vent connector is used slope upward at least 4 per lineal foot toward chimney or vent and support with hangers to prevent sagging Breeching must not be connected to any portion of a mechanical draft system that can operate under positive pressure 14 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 2e NOTICE AWARNING Prepare boiler vent damper installation These systems are used on gas fired boilers with vent dampers as shipped from factory Boiler will not operate without vent damper installed Only vent dampers listed in the Replacement parts list on page 61 are certified for use with CGa boilers Any other vent damper installed could cause severe personal injury or death Damper blade Standing pilot ignition systems Refer to vent manufacturer s instructions to install plug shipped with damper in damper hole For standing pilot boil ers only install plug with diameter hole in vent damper hole Spark ignited pilot systems Refer to vent man ufacturer s instructions to install plug shipped with damper in damper hole For spark ignited pilot boilers only install plug with no hole in vent damper hole Minimum clearances Provide a minimum of 6 between the vent damper and any combustible material Provide a minimum of 36
79. lve and makeup water to be added through fill valve Eventual section failure can result Closed type expansion tank Figure 10 1 Ensure expansion tank size will handle boiler and system water volume and temperature See tank manufacturer s instructions for details 2 Connect tank to NPT tapping located behind supply outlet using 42 NPT piping Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping Use Figure 9 or Figure 10 only for single zone systems designed for return water at least 130 F For systems with low return water temperature possible such as converted gravity systems and radiant heating systems refer to the special piping suggestions of pages 20 25 Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Figure 9 Diaphragm or bladder type expansion tank Single zone system using dia phragm type or bladder type expansion tank See Table 3 for piping sizes Cold From water system fill 7 F To DIAPHRAGM axpansion tank Dr and fittings Isolation valve re ies TRA Relief To system walve Circulator Automatic air vent Circulator T Alermnate cand location Part Number 550 101 009 0107 Figure 10 Closed type expansion tank Single zone system using closed type expan sion tank See Table 3 for piping sizes a CLOSED ty
80. m type or bladder type expansion tank if used For closed iype expansion tank pipe trom top ot air ma cI u separator to tank fitting as in Figure 10 page 17 3e Water piping refrigeration systems Figure 18 Piping retrigeratian systema Prevent chil led water from entering boiler im mee aera Install boiler so that chilled medium is piped in parallel md ae with the heating boiler Use appropriate valves to prevent i T r chilled medium from entering boiler See Figure 18 for Cireulstor ji Bhuto typical installation of balancing valve and check valve If boiler is connected to heating coils located in air han Water dling units where they can be exposed to refrigerated chillar t air use flow control valves or other automatic means to prevent gravity circulation during cooling cycle P Strainer Lice Boiler Ea valve ean System an return f Balancing porary valve Part Number 550 101 009 0107 25 GOLD CGa Gas Fired Water Boiler Boiler Manual 4 Connect gas supply piping to boiler 1 Remove jacket front panel and refer to Figure 19 to pipe gas to boil er Gas piping a Install drip leg at inlet of gas connection to boiler Where local utility requires drip leg to be extended to the floor use appropri ate length of pipe between cap and tee b Install ground joint union for servicing when required c Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes o
81. ment 1 Start with valve 7a fully closed and 7b fully open 2 Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 60 F higher than gauge 4a A minimum 60 F temperature rise through the boiler assures a low enough flow rate and high enough average temperature to prevent condensation even with low system return water temperature 3 Valve 7a regulates the system flow rate while valve 7b regulates the boiler flow rate 4 The boiler mounted temperature pressure gauge may be used in place of a separate gauge 8 Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injec tion pumping control Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the boiler re turn 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 r
82. monoxide emissions will occur causing severe personal injury or death When removing boiler from an Chimney or vent require existing common vent system ments At the time of removal of an existing boiler the following 1 Venting must be installed according to Part 7 Vent steps shall be followed with each appliance remaining ing of Equipment of National Fuel Gas Code ANSI connected to the common venting system placed in op Z223 1 latest edition and applicable building codes eration while the other appliances remaining connected Canadian installations must comply with B149 1 or to the common venting system are not in operation B149 2 Installation Codes a Seal any unused openings in the common venting 2 See Ratings table on page 67 for minimum chimney System or vent sizes A chimney or vent without a listed b Visually inspect the venting system for proper cap should extend at least 3 feet above the highest size and horizontal pitch and determine there is no point where it passes through a roof of a building blockage or restriction leakage corrosion or other and at least 2 feet higher than any portion of a deficiencies which could cause an unsafe condi building within a horizontal distance of 10 feet tion A chimney or vent must not extend less than the c Test vent system Insofar as is practical close all disti esatean building doors and windows and all doors between 3 A lined chimney is preferred and must be used when t
83. mpts to light the pilot burner The control module will not lockout on a failure to establish flame It will lockout if line voltage polarity is reversed stray voltage is sensed on thermostat 1 hour waiting period Opening and closing of thermostat circuit Removal of 120 VAC power for at least 45 seconds 59340 Part Number 550 101 009 0107 37 GOLD CGa Gas Fired Water Boiler Boiler Manual 9a Operation spark ignited pilot system continues Figure 25a Schematic wiring diagram Spark ignited pilot system The control module is polarity sensitive to the 120 VAC Hot Neutral Gnd ia A wy neoming 120 VAG power If polarity is reversed ip i l we control will flash the POWER light when powered SERVICE 14 FIELD and will not cycle boiler SWITCH ball i l WIRING pa All contacts shown without power applied is a T Ground Connector and status light locations orientations ton a a SHEN may vary Wire nuts ie oy Black White Green White Plug in 3 3 Items not provided Junction box a em connectors boiler lett side TRANSFORMER CIRCULATOR A i l t willy i a SPILL SWITCH Ps Honeywall VARB2O4 shown es gt al wA el p mer cS TEMPERATURE wit YAD ROLLOUT TFE si W I J ia hes Wi B r ee v Additional limits Ce Terminal block abart if used note 7 GAS VALVE See Table 38 Part Number 550 101 009
84. ms 7a and 7b provide mixing of hot boiler outlet water with cooler system return water set to assure a minimum return water temperature at least 130 F to the boiler Set the valves as explained below Temperature gauges Gauge 4a is suggested but optional on any system Gauge 4b is optional on converted gravity systems but required on radiant heating systems to display the water temperature being supplied to the radiant tubing Gauge 8 is required on all systems to assure the return water temperature is accurately set for a minimum of 130 F If this gauge is not available however adjust the valves such that the boiler mounted temperature pres sure gauge reads at least 150 F when the system return water is cold approximately 60 F water temperature Valve adjustment Figures 13 and 14 only 1 Set the valves while the system is cool setting for the coldest expected water temperature usually 60 F since the system will often drop to room tempera ture between cycles 2 Start with valve 7a fully closed and 7b fully open 3 Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 130 F when gauge 4a reads 60 F 4 Note that valve 7a regulates the amount of hot wa ter from the boiler supply which mixes with return water Valve 7b regulates the amount of system water flowing through the boiler secondary loop Failure to prevent low return water temperature to the boiler could
85. n and causing section failure Verify water chemistry Consult local water treatment companies for unusually hard water areas above 7 grains hardness or low pH water conditions below 7 0 Boiler water pH of 7 0 to 8 5 is recommended Freeze protection when used Use antifreeze made especially for hydronic systems Inhibited propylene glycol is recommended AWARNING Do not use ethylene glycol automotive or undiluted antifreeze Severe personal injury or death can result 1 Determine antifreeze quantity according to system water content Boiler water content is listed on page 67 Remember to include expan sion tank water content 2 Follow antifreeze manufacturer s instructions 3 A 50 solution of propylene glycol water provides maximum protec tion to about 30 F 4 Local codes may require back flow preventer or actual disconnect from city water supply 5 When using antifreeze in a system with automatic fill install a water meter to monitor water makeup Glycol will leak before the water be gins to leak causing glycol level to drop Added water will dilute the antifreeze reducing the freeze protection level Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual 6a Start up preparation continued Fill the system with water 1 Close manual and automatic air vents and boiler drain cock 2 Fill to correct system pressure Correct pressure will vary with each appl
86. n and extinguish pilot flame Pilot gas flow should stop in less than 3 minutes Put system back into op eration see Section 6 Spark ignited pilot Connect manometer to outlet side of gas valve Start boiler allowing for normal start up cycle to occur and main burners to ignite With main burners on manually shut off gas supply at manual main shutoff gas valve Burners should go off Open manual main shutoff gas valve Manometer should confirm there is no gas flow Pilot will relight flame sensing element will sense pilot flame and main burners reignite Set limit control s to system temperature requirements m L a Check out procedure checklist Adjust balancing valves and controls to provide design temperature to system each zone Thermostat s lowest setting and verify boiler goes off Measure natural gas input a b C Operate boiler 10 minutes Turn off other appliances quired to use one cubic foot of gas Calculate gas input 3600 x 1000 number of seconds from step c boiler rating label should be 10 w c Observe several operating cycles for proper operation Set room thermostat to desired room temperature Fill in Installation and service certificate below Coocde boiler Installation and service certificate Boiler model Series Measured Btuh input Installer CP number Date installed Installation instructions have been follow
87. n or ventilation air to boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water Immediately call a qualified service techni cian to inspect the boiler and to replace any part of the control system and any gas control that has been under water Boiler water Do not use petroleum based cleaning or sealing compounds in boiler system Water seal deterioration will occur causing leakage between sections This can result in substantial property damage Do not use homemade cures or boiler patent medi cines Serious damage to boiler personnel and or property may result Part Number 550 101 009 0107 Continual fresh makeup water will reduce boiler life Mineral buildup in sections re duces heat transfer overheats cast iron and causes section failure Addition of oxygen and other gases can cause internal corrosion Leaks in boiler or piping must be repaired at once to prevent makeup water Do not add cold water to hot boiler Thermal shock can cause sections to crack Glycol potential fire hazard All glycol is flammable when exposed to high temperatures If glycol is allowed to accumulate in or around the boiler or any other potential ignition source a fire can develop In order to prevent potential seve
88. ng e Allow boiler to continue cycling Are FLAME and POWER lights flashing No Yes No Yes t Replace control e Boiler should now TURN OFF POWER i e Boiler may now be Replace control to boiler at service switch operating module operate normally module or breaker normally e Retest Original flashing e Retest Open main manual gas Perform start up FLAME light valve procedures in caused by gas Turn on power to boiler boiler manual to valve not at service switch or breaker verify proper operation operating properly Restart boiler per e See normal operating instructions sequence of Perform start up operation procedures in boiler Figure 24 manual to verify proper page 37 operation Part Number 550 101 009 0107 57 GOLD CGa Gas Fired Water Boiler Boiler Manual 1 le Troubleshooting spark pilot boilers continues CHART 6 Spark ignited pilot FLAME light flashing and POWER light on steady ALSO Troubleshooting failure to establish main flame WARNING 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 Are main manual shutoff valve and boiler gas valve open e Is pilot flame visible through inspection port No Yes No Yes e
89. ng User This manual is for use only by your qualified heating installer service technician Installer AWARNING Read all instructions before in stalling Follow all instructions in proper order to prevent personal injury or death e Please refer to the User s Information Manual for your reference Consider piping and installation when determining Keller l cstton We recommend regular service by a qualified F i service technician at least annually Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 68 of this manual Failure to comply could result in severe personal injury When calling or writing about the boiler Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket You may list the CP number in the space provided on the Installation and service certificate found on page 33 Failure to adhere to the guidelines on this page can result in severe personal injury death AWARNING or substantial property damage When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustio
90. ng water or gas piping or electrical supply except as noted below Prepare boiler for test 1 Remove the shipping nipple from CGa supply tapping and remove the boiler relief valve Tempo rarily plug the relief valve tapping with a 34 NPT pipe plug Remove 114 nipple reducing tee and drain valve from accessory bag Install in boiler return con nection as shown on page 3 or in Figure 34 item 3 page 64 Install circulator on either the return or supply Remove 1 nipple 114 tee bushing and pres sure temperature gauge from accessory bag Pipe to boiler supply connection as shown in Figure 34 page 64 Use pipe dope sparingly Connect a hose to boiler drain valve the other end connected to a fresh water supply Make sure hose can also be used to drain boiler after test Connect a nipple and shutoff valve to system supply connection on the 11 4 tee This valve will be used to bleed air during the fill Valve and nipple are not included with boiler Connect a nipple and shutoff valve to system return connection at circulator flange if circula tor installed on return This valve will be used to bleed air during the fill Valve and nipple are not included with boiler Fill and pressure test l Open the shutoff valves you installed on supply and return connections Slowly open boiler drain valve and fresh water sup ply to fill boiler with water When water flows from shutoff valves clos
91. oor D Do not use this appliance if any part has been under water because some gas is heavier than air and will settle Immediately call a qualified service technician to inspect the appliance on the floor See below and to replace any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building e Ifyou cannot reach your gas supplier call the fire department LIGHTING INSTRUCTIONS M STOP Read the safety information above on this label 8 Find pilot follow metal tube from gas control The Set the thermostat to lowest setting pilot is between two burners behind the access Turnoffall electrical power to the appliance panel Remove front panel ight to SET Depress and move selector arm left to OFF Note a a le ESE Selector arm cannot be moved to OFF unless selector arm 59337 is depressed slightly Do not force 10 Hold selector arm in SET position and immediately light the pilot with a match Continue to hold selector arm to SET for about one half 1 2 minute after the pilot is lit Position oe Selector Release selector arm Pilot should remain lit If pilot goes out indicator arm repeatsteps5 through 11 De Siae EE e Ifth
92. oper combustion and make any necessary adjustments Troubleshooting procedure Label all wires prior to disconnection when servic ing controls Wiring errors can cause improper and dangerous operation Never jumper bypass rollout thermal fuse ele ment or any other device except for momentary testing as outlined in Troubleshooting Charts Severe personal injury death or substantial prop erty damage can result Burner access panel must be in position during boiler operation to prevent momentary flame rollout on ignition of main flame Severe per sonal injury or substantial property damage will result See pages 50 through 59 for additional trouble shooting information Part Number 550 101 009 0107 Before troubleshooting 1 Have the following items Voltmeter that can check 120 VAC and 24 VAC Microammeter with a minimum scale range of 0 25 Continuity checker d U tube manometer Check for 120 VAC minimum 102 VAC to maximum 132 VAC to boiler Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Check for 24 VAC between thermo stat wire nuts and ground 49 GOLD CGa Gas Fired Water Boiler Boiler Manual lla AWARNING 50 Troubleshooting procedure ntinuea Check the following 1 Wire connectors to control module are securely plugged in at module and originating control 2 Gas pressures a With boiler off
93. operate correctly replace it with a new relief valve 16 Water piping general information Circulator The circulator is shipped loose wiring pre attached to boiler to allow you to locate it either in the return or supply piping as desired See page 3 for a typical instal lation Pipe the expansion tank to the suction side of the circulator whenever possible Install an air separator in the supply piping Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator Always install the system fill connection at the same point as the expansion tank connection to the system Figures 9 and 10 show typical near boiler piping connections System water piping See Figure 9 diaphragm type or bladder type expan sion tank or Figure 10 closed type expansion tank and Table 3 below for near boiler and single zone systems designed for return water at least 130 F See pages 18 19 to complete multiple zone piping or pages 20 25 to complete piping for radiant heating systems or converted gravity systems large volume systems originally designed for circulation by natural convection rather than a pump See page 25 for boilers used with refrigeration systems Table 3 Water pipe size based on 20 F rise Boiler model To From system system CGa 25 Ya Sa CGa 3 4 5 ili il CGa 6 7 14 1 14 CGa 8 UB lee Note The boiler supply and return connections t
94. or normal sequence of rollout switch continuity operation p are switches closed e Wait for boiler water to cool to temperature 20 to 30 F No Yes lower than temperature set on limit switch lt n e Reset spill switch or replace x Are limit switch contacts osea rollout switch o es Yy DANGER Check any other e Boiler water temperature exceeded If rollout thermal fuse element or limit controls wired setting on limit switch with thermostat spill switch has opened determine into the limit Replace calling for heat Boiler is OK see norma cause and correct condition circuit If all are imitita SEQUENCE ci ope alor Figure 24 p 37 Failure to do so will cause severe OK then replace Retest i e Also check setting on limit switch should personal injury death or control module i be above 140 F substantial property damage Retest Part Number 550 101 009 0107 59 GOLD CGa Gas Fired Water Boiler Boiler Manual 12a Replacement parts Section assembly ccsscsseesseesseecsseecsencnseessensses 6 1 BAS A A T A E AT Y DAC KOE sinnini nce cnswiscwndeccucndsccwanshisecuawcsusssasvecteus OG Controls sack ioescsvaiaiscindicnicnes ideiaccaewduswedbasissvsierivas OD 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 Results from using modified or oth
95. pe k expansion tank wN Fa ae Cold water fill wh Isolation valve 7 H t ha ed To system Reliaf aai val ik Fram H system isolation valve Circulator Circulator 17 GOLD CGa Gas Fired Water Boiler Boiler Manual C Water piping multiple zones Piping multiple zones Follow instructions on pages 16 and 17 to install near boiler or single zone piping Also refer to Piping for radiant heating systems or converted gravity sys tems below if applicable See Figure 11 or Figure 12 page 19 to complete in stallation Zoning with circulators Figure 11 return temp over 130 F 1 Size each circulator to individual circuit require ments 2 Do not install circulator on boiler except for pri mary secondary piping 3 Install isolation balancing valves to adjust flow to distribute heat to all zones 4 Install and wire a separate relay for each zone cir culator Zoning with zone valves Figure 12 return temp over 130 F 1 Install isolation balancing valves to adjust flow to distribute heat to all zones 2 Provide a separate 24 volt transformer to power the zone valves Size the transformer to handle the total rated load of all connected zone valves Piping for radiant heating systems or converted gravity systems Converted gravity or steam systems Whenever possible use the primary secondary piping shown in Figures 13 or 14 on page 21 T
96. ply temperature is relatively constant DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the boiler re turn 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 24 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual od Piping low temperature systems continued F iiia A To system Figure i17 System bypass piping Zoning with 77b zone vahe or clrouletors return water Ta 130 F or higher Altemative to boller oe H bypass piping Figures 15 and 16 page 23 kj Akiwnrie E a a tesiei OP EGINE ioulator 8 i 10 T System temperature valves see instructions to the left for i al justing valves Cold 11 8 Blend temperature gauge water fill B Relief valve 12 a 10 Aaiemeatic air vent with diaphragii type eX jiii 5 lanki or connect to tank filing elosed type expansion ank DO NOT use an automatic air vent when using a chosed type exparon tank It weuld allow air to leave ihe systern causing waterlogging af the expansion tank 11 Fill vake 12 Diaphrg
97. r Start up E operate boiler continued Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reduc ing heat transfer overheating cast iron and causing section failure If you discover evidence of any 1 Check system piping for leaks If found shut AWARNING gas leak shut down the boiler down boiler and repair immediately at once Find the leak source y Asi with bubble test and repair im 2 Vent air from system using manual vents Air in mediately Do not start boiler the system will interfere with circulation and cause again until corrected Failure to heat distribution problems and noise comply could result in severe 3 Inspect vent system thoroughly for signs of personal injury death or sub deterioration from corrosion physical damage or stantial property damage sagging Verify that masonry chimney liners are in good condition with no obstructions and there are no openings into the chimney Do not use petroleum based cleaning or sealing compounds 4 Check around the boiler for gas odor following the in boiler system Severe damage procedure of Section 6a of this manual to boiler will occur resulting in 5 Verify operation per Section 6d Perform check out substantial property damage 6c procedure in Section 7 and fill in the Installation and service certificate on the same page Check for l Loose connections blown fuse or 4 servi
98. r retest after control module to flame rod are in any changes or corrections good condition e If none of the previous steps a i i e Ifthe wiring from the If none of the above corrects Correct any above problems including replacing pilot control module to gas problem then replace the replacing pilot if burner or wiring pe A Aa Ng valve is intact replace the control module reinstall base is damaged control module and retest access panel and retest gt base access panel and retest 58 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual lle Troubleshooting spark pilot boilers continued CHART 7 Spark ignited pilot Insufficient heat or no heat POWER light on steady Electrical shock hazard Wherever you see amp TURN OFF POWER follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage e Has it been at least 5 minutes since setting thermostat to gt Is boiler System circulator operating call for heat If not wait 5 minutes Is system heating e Is thermostat set to call for heat Remove thermostat No ve wire
99. r utility requirements d In Canada When using manual main shutoff valve it must be identified by the installer 2 Support piping with hangers not by boiler or its accessories Purge all air from gas supply piping 4 Before placing boiler in operation check boiler and its gas connec tion for leaks a Close manual main shutoff valve during any pressure testing at less than 13 w c b Disconnect boiler and gas valve from gas supply piping dur ing any pressure testing greater than 13 w c Do not check for gas leaks with an open flame Use bubble test Failure to use bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 5 Use pipe dope compatible with propane gases Apply sparingly only to male threads of pipe joints so that pipe dope does not block gas flow AWARNING Failure to apply pipe dope as detailed above can result in severe personal injury death or substantial property damage AWARNING Table 4 Pipe capacity for 0 60 specific gravity natural gas Gas pipe Capacity of pipe for pipe size of length Capacity in cubic feet gas per hour feet Y2 34 T 1 1 10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 860 40 63 130 245 500 760 50 56 115 215 440 670 75 45 93 175 360 545 100 38 79 150 305 460 150 31 64 120 250 380 26 Natural Gas
100. re personal injury death or substantial property damage from fire and or structural damage Never store glycol of any kind near the boiler or any potential ignition source Monitor and inspect the system and boiler regularly for leakage Repair any leaks im mediately to prevent possible accumulation of glycol Never use automotive antifreeze or ethylene glycol in the system Using these glycols can lead to hazardous leakage of glycol in the boiler system GOLD CGa Gas Fired Water Boiler Boiler Manual Ji a Prepare boiler location codes amp checklist Installations must follow these codes Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 latest edition Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 when required National Electrical Code For Canada only B149 1 or B149 2 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes NOTICE The CGa boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21 13 latest edition Before locating the boiler check the following Check for nearby connection to e System water piping e Venting connections Gas supply piping Electrical power Check area around boiler Remove any combustible materials gasoline and other flammable liquids or other cont
101. rer s Weil McLain number part number part number 1 Pressure relief valve ASME 30 PSIG 34 male inlet Conbraco 10 407 10 511 546 920 Waits M330 Pressure relief valve ASME 30 PSIG 34 female inlet Conbraco 10 408 05 511 546 924 Fittings shown are factory installed on boiler Watts 335 2 Combination pressure temperature gauge 3 diameter Weil McLain 380 000 000 short shank Fittings shown are shipped loose with boiler 3 Drain valve 34 Conbraco 31 606 01 511 210 423 Fittings shown are included with boiler Hammond Valve 710 Matco Norca Watts 205F04 BD 2C 4 Circulator Bell amp Gossett NRF 22 103253 511 405 118 Fittings shown are shipped loose with boiler Taco 007 511 405 113 5 Circulator gasket universal 2 per boiler Weil McLain 590 317 535 not shown Circulator hardware kit includes Weil McLain 1 flange 2 nuts 2 screws 1 gasket 34 NPT CGa 25 e 381 354 530 I NP Ces WONN COCE e ese cae me sc aj caas shaan aedo Sres 381 354 525 WA INP CCEHS inielisl Cee 2 oe oe ce oe bo ole ose ese eb ea eases eS 381 354 526 1 NPT CGa 8 381 354 531 6 Circulator wiring harness standing pilot ignition Weil McLain 591 319 793 Circulator wiring harness spark ignited pilot with Molex 381 354 528 not shown Mate N Lock connector red spark ignited pilot only Amp 1 480698 2 563 210 632 Part Number 550 101 0
102. rom Replace damper damper harness plug wiring harness TEMPORARILY install jumper Damper harness Retest between terminal 2 and Continuity Table 7 A 7 Pin side of connectors terminal 5 on damper plug in 6 Pin Molex 4 Pin Molex boiler wiring harness See Pin Number Pin Number figure right Does boiler fire 1 1 No Yes 3 3 4 i l 4 N C Replace gas valve Replace damper z ae Retest actuator Retest 59341 Part Number 550 101 009 0107 51 GOLD CGa Gas Fired Water Boiler Boiler Manual 1 le Troubleshooting spark pilot boilers NOTICE The information on this page and pages 53 through 59 apply only to spark ignited pilot CGa boilers These boilers are equipped with an ignition control module that has in dicator lights to show control status Figure 28 Ca Ignition coniral module y e GEE iria Ny 52 Control module AWARNING Solder or water splatter between plugs and circuit board can cause improper operation of control module Place a shield over the boiler internal controls and components during installation Failure to comply could result in severe personal injury death or substantial property damage Make sure ground wiring is installed per wiring NOTICE f meee diagram Good grounding is extremely important for proper operation Control indicator lights LOCKOUT modes See Charts 1 through 7 in this section for detailed troubleshoo
103. rs vertical ducts Air opening options aa na A x ae Cutak of vail ated miis haa Two openings Air supply from inside the building AEAT RAA Ifthe building is of unusually tight construction see definition next Vag inch per 4 000 Biu page the building must also be provided with air openings directly to the outelde sized and located per Figure 3 Figure 4 or Figure 5 2 Buildings of typical construction should provide adequate combustion air from natural infiltration so additional air openings to the building are mot required 3 Sec Figure 2 Provide two openings through the interior wall within 12 inches of the ceding and the floor sized per Figure 2 Two openings Alr supply directly from outside l Ar openings must be cirectly through an outside wall or into a space that conmects directly to the outside such as a ventilated attic or crawl Figure amp Air trom outdoors horizontal ducts pice for example 2 See Figure Openings directly through an outslde wall provide 3k Esch opecing Ineo arii Ti a two openings within 12 inches of the ceiling and the floor sized per ae par 2000 Etuk i af Figure 3 Ti om a 3 See Figure 4 Alr supplied through vertical ducts provide twa Z eo 4 openings terminated within 12 inches of the ceiling and the floor sized ines amp i 3 per Figure 4 mem d See Figure 5 Alr supplied through horizontal ducts provide p a af two
104. s Failure to follow instructions could result in severe personal injury death or substantial property damage e Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds Thermostat should call for heat and appropriate zone valves open The TSTAT CIRC and LIMIT lights should come on Does vent damper operate No ies e Wait 45 seconds Does vent damper operate i Mes A e Remove DAMPER plug Figure 30 Item 6 page 53 e Wait 5 minutes from plug receptacle of control module Is PRESS SWITCH light flashing e Place voltmeter leads across the top two pins 1 and 4 of the DAMPER receptacle No Yes Does the voltmeter indicate 24 VAC No Yes e Try reseating plug in Boiler should be in module receptacle and normal operating alae ia sequence eaea ee ng Observe operation until Does vent damper actuator Tep thermostat is satisfied indicator show damper is damper assembly or open actuator e Retest No Yes Are the TSTAT CIRC and LIMIT ights on steady Yes No e Remove damper wiring plug at damper and firmly ee LETETI Make sure thermostat is e Replace vent damper reconnect ae calling for heat If lights assembly or actuator e Recheck boiler operation eis still don t come on see e Retest e If problem persists etest Chart 7 pag
105. s at boiler and check continuity across the two wires v If circuit isn t closed check external thermostat zone e Remove CIRCULATOR harness plug from valve relay etc wiring Correct problems and retry CIRCULATOR plug receptacle Figure 30 e Reconnect external thermostat wiring at boiler Item 7 page 53 Check with voltmeter across Is thermostat circuit closed continuity across wires pins of control module receptacle Does voltmeter show 120 VAC across pins No WES No Yes w e Boiler is in standby Are all red lights off Set thermostat to call for lt Replace control lt Repair replace No Yes gt neat ang recheck module circulator Retest ii operation e Retest e Repair replace Verify Sequence of a A z wiring Retest Wait 30 seconds operation Figure 24 Are all red lights off page 37 1 No Yes A e Wait 5 minutes Is FLAME light on Replace control module Yes No Retest l e Ifyou have sufficient heat boiler should be in normal Is LIMIT light on operating sequence See normal sequence of operation Figure 24 page 37 No Yes e Ifyou have less than sufficient heat ii i Is vent or combustion air piping free of blockage e Check limit switch Replace control module No Yes contacts with continuity e Retest a Y checker Correct conditions and Contact your Weil McLain Are limit switch contacts recheck operation sales representative closed e See Figure 24 page 37 No Vee Check spill switch and f
106. sTURN OFF POWERS to boiler at service switch or breaker Open main manual shutoff valve and boiler gas valve per e Check the voltage across e Make sure ground wire Operating instructions in this manual Wait at least 45 main gas valve terminals of terminal is securely fastened seconds the gas valve to control module mounting Turn on power at service switch or breaker Allow boiler to cycle Does FLAME light flash now AAG Present teres ica Yes No No Yes l l e Verify inlet gas pressure at gas e If the wiring from the e Check the voltage across e Boiler should be in valve control module to gas main gas valve terminals of normal operating Natural gas 5 0 w c min 14 0 valve is intact replace the the gas valve is ab lls w c max control module Is 24 VAC present there i e Retest Observe operation Propane 11 0 w c min 14 0 4 _ Mo Yes until thermostat is We OK satisfied and blower re has completed its Is gas present at gas valve inlet and ithi post purge cycle a above range No e Verify inlet gas pressure at gas valve Natural gas 5 0 w c min 14 0 w c max JeTURN OFF POWER amp to Propane 11 0 w c min 14 0 w c max boiler at service switch or Is gas present at gas valve inlet and within above range breaker e Contact gas
107. ssurization The boiler relief valve will weep frequently Diaphragm or bladder type welded gas tight with a rubber membrane to separate the tank pres surizing air and the water May be located at any point in the system but most often found near the boiler Systems with this type of expansion tank require at least one automatic air vent preferably lo cated on top of an air eliminator as shown in examples in manual Section 3 If relief valve has tended to weep frequently the ex pansion tank may be waterlogged or undersized Closed type tank tank is most likely water logged Install a tank fitting if not already installed Then check fill level per fitting manufacturer s instructions If fill level is correct check tank size against manufacturer s instructions Replace with a larger tank if necessary Diaphragm or bladder type first check tank size to be sure it is large enough for the system If size is too small add additional tank s as neces sary to provide sufficient expansion If tank size is large enough remove tank from system and check charge pressure usually 12 psig for residential ap plications If tank won t hold pressure membrane has been damaged Replace tank 47 GOLD CGa Gas Fired Water Boiler Boiler Manual 10b 48 Service amp maintenance annual start up on AWARNING Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEAR
108. supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building e Ifyoucannotreach your gas supplier call the fire department DE oPERAaTiNG insTRUCTIYONs I STOP Read the safety information above on this label 7 Wait five 5 minutes to clear out any gas Then smell for gas Setthe thermostat to lowest setting including near the floor If you smell gas STOP Follow B in _ Tum offall electrical power to the appliance the safety information above If you don t smell gas go to the next step Remove front panel eee This appliance is equipped with an ignition device which 8 Turn gas control knob counterclockwise v to ON automatically lights the pilot Do not try to light the pilotby 9 Turn onall electric power to the appliance hand Turn gas control knob clockwise to OFF 10 Set thermostatto desired setting 11 If the appliance will not operate follow the instructions To Turn Off Gas To The Appliance and call your service Position Gas technician or gas supplier indicator 129 control shown in i knob 12 Replace front panel EH TO TURN OFF GAS TO THE APPLIANCE M 1 Setthe thermostat to lowest setting 3 Remove front panel 2 Turn off all electric power to the appliance if service is tobe 4 Turn gas control knob clockwise y to OFF Do not force performed 5
109. supplier to correct No VER Remove base access panel pressure or gas supply see Figure 32 item 4 age 62 for location A TURN OFF POWER 4k to pag boiler at serice swit h or A TURN OFF POWER to boiler at service switch or breaker e Verify pilot gas line is not breaker e Check flame signal Detach sense lead from igntion control kinked obstructed or damaged Remove base access panel see Figure 30 item 8 page 53 and is correctly attached to Figure 32 item 4 page 62 for Connect negative lead of MICROAMMETER to control sense pilot and gas valve location terminal Figure 30 item 8 page 53 Connect positive lead of e Verify pilot ignition electrode v MICROAMMETER to sense wire electrode ceramic and spark e Verify pilot burner is securely e DISCONNECT red wire connected to man gas valve terminal of lead wire from control are in attached to pilot bracket bracket the gas valve good condition Spark gap is securely attached to cross tie Turn on power to boiler and allow to cycle As soon as pilot is should be approximately 1 8 and there is no corrosion on the burning the MICROAMMETER should read at least 1 0 Correct any above problems parts which would affect the microamp replacing pilot if burner or ground path for flame sense Is flame signal at least 1 0 microamp wiring is damaged e Verify that pilot flame rod flame No Yes Reinstall base access panel to rod ceramic and lead wire from operate boiler fo
110. terrupted Once pilot flame is proven the control module opens the gas valve to allow main burner flame When the room thermostat is satisfied the control module turns off the gas valve and deactivates the vent damper causing it to close The control module indicator lights show normal sequence when the lights are on steady When a problem oc curs the control module flashes combinations of lights to indicate the most likely reason for the problem See page 52 for details Standing pilot boilers controls not shown use the pilot thermocouple to prove flame If the thermocouple is satisfied the gas valve and vent damper will open on a call for heat and close afterwards Transformer The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit Draft hood The draft hood provides a minimum draft for the boiler assuring adequate air for combustion if installed in ac cordance with manual and not modified in any way Spill switch The spill switch will shut down the boiler requiring manual reset of the switch reset button if the vent system becomes blocked Water temperature limit switch The water temperature limit switch turns off the gas valve if the temperature in the boiler goes above its setting The circulator will continue to run as long as there is a call for heat Boiler circulator The boiler circulator circulates water through the external system piping The circulator is shipped loose
111. 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 dam age 18 Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual C Water piping multiple Zones continued Figure 11 Zoning with circulators return water Figure 12 Zoning with zone valves return water i30 F of higher ZONE 2 F ZONE 1 lt i 13 j pe Ley 8 13 T il a 10 Cold 11 verter z All 412 a o sora 1 Boiler isolation balancing valves 2 Flow check valve System or cone corculatar 5 Zone valve 6 Drain valve Relic valve 1420F or higher ty Pol ZONE 2 i ty y ZONE 1 f a 1 T1 1 Zi 5 1 3 t e 13 BD ex Te 1 a Adenia i eiwishr Foortion y i 5 210 Celd TI a er ix fil T wi M MEI 10 Automatic air vent with diaphragm type expansion tank or connect to tank fitting closed type expansion tank DO NOT use an automatic air vent when wing slosed type expansion tank Lt would allow air to leave the system causing waterlogging of the expansion tank 41 Fill valve 12 Diaphragm type or bladder type expansion tank if used Por closed
112. ting procedures To reset control after a lockout turn off power at the 120 VAC service switch or turn down all thermostats Wait 45 seconds Then restore power or call for heat POWER light flashing alone Usually indicates reversed polarity of 120 VAC power wires POWER and TSTAT CIRC lights flashing Usually indicates stray voltage on external thermostat circuit wires usually due to miswired 3 wire zone valve POWER and DAMPER lights flashing Usually indicates damper circuit is closed when it should not be or damper failed to close within 5 minutes POWER and FLAME lights flashing Usually indicates false flame sense or flame sensed when it shouldn t be there Control indicator lights NON LOCKOUT modes POWER light on and FLAME light flashing Usually indicates pilot flame was not established within 15 seconds from application of spark Control will flash light but will continue to cycle indefinitely until flame is established or problem is corrected POWER light on and DAMPER light flashing Usually indicates the damper circuit opened during the run cycle Troubleshooting the control module See Figure 30 page 53 for location of harness plug receptacles and plugs on the control module Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual lle Part Numbe Troubleshooting spark pilot boilers continued Figure 50 Control module commections 120 VAC H We ry
113. tsndusdanndiene O Field wiring s ssss2222 55221 2 f Start Up cate cinecssennniccavccvedsvdnnessiudsndcimeensee 232 Check out pr ocedure ssss222222222222222222 OO Operation standing pilot boilers 34 36 Operation spark ignited pilot boilers 37 43 Service and maintenance scssssssessssssessssses 44 49 Troubleshooting Standing pilot boilers sscsssessesssss212 49 50 51 Spark ignited pilot boilers 49 50 51 59 Replacement Parts csssseessseeesseeeesnsesesesess 60 65 Dimensions and ratings sccsseeseseseeeesseenssses 66 67 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product AWARNING A caution Indicates presence of hazards that will cause severe personal injury death or substantial property damage Indicates presence of hazards that can cause severe personal injury death or substantial property damage Indicates presence of hazards that will or can cause minor personal injury or property dam age Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual Please read before proceedi
114. ule 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 Check boiler area Inspect Check air openings e Reported problems Check boiler pressure 7 Boiler area temperature gauge e Air openings Se gagventsystem Check boiler interior piping e Pilot and main burner flames Check venting system e Water piping Check air vents Monthly Boiler heating surfaces Check boiler relief valve gt Bumersand base Check automatic air vents if Service used e Oiled bearing circulators Start up Periodically Test low water cutoff if used e Perform start up per manual Check test Every 6 months Operate relief valve a P a j n l lt a Z Z Z lt e Gas piping Cold fill and operating pressures e Air vents and air elimination e Limit controls and cutoffs e Expansion tank End of season Shut down procedure Boiler relief valve Review e Review with owner AWARNING Follow the Service and maintenance procedures given throughout this manual and in com ponent literature shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failure to follow the directions in this manual and component literature coul
115. urn Figure 26 Automatic air vent typical 2 Limit controls and cutoffs 1 Inspect and test the boiler limit control Verify op eration by turning control set point below boiler temperature Boiler should cycle off Return dial to original setting 2 Inspect and test additional limit controls or low water cutoffs installed on system Part Number 550 101 009 0107 Expansion tanks provide space for water to move in an out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 3 of this manual for suggested best location of expansion tanks and air eliminators Open type located above highest radiator or baseboard unit usually in the attic or closet Has a gauge glass and overflow pipe to a drain Closed type welded gas tight and located above boiler Tank is partially filled with water leaving an air cushion for expansion e Make sure this type of tank is fitted with a tank fitting such as the B amp G Tank Trol or Taco Taco Trol This fitting reduces gravity circula tion of air saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the sys tem Do not use automatic air vents in systems with closed type tanks The air will escape from the system instead of returning to the tank Eventually the tank will waterlog and no longer control pre
116. vent damper 2 When vent damper is fully open Main gas valve will open and main burners will ignite Spark ig nited pilot controls will first light pilot then allow main burners to ignite Vent damper must be fully open before main burners light If vent damper does not fully open flue products such as carbon monoxide will escape into house causing se vere personal injury or death 3 Lower thermostat setting Main burner flames will go out then vent damper will close 4 Repeat Steps 2 through 4 several times to verify operation The boiler model suffix will be SPD For spark ignited pilot boilers suffix PID see Section 8 or 9 for operation and lighting operating information Figure 21 Typical pilot burner flame Spark electrode Pilot flame sensor spark ignited pilots Thermocouple standing pilots 59318 Figure 22 Typical main burner flame Transparent blue flame 5 Return thermostat to normal setting Set thermostat heat anticipator setting indicated on wiring diagram D Check vent system operation 1 Check vent system at least once a month during heating season With boiler firing hold candle or match below lower edge of draft hood skirt If flame does not blow out but burns undisturbed vent system is functioning properly If flame blows out or flickers drastically inspect vent system for obstructions or other causes of improper venting such as e
117. w before installing boiler If any of these contaminants are found remove contaminants permanently OR isolate boiler and provide outside combustion air See national provincial or local codes Table 1 for further information 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 Chlorine based swimming pool chemicals Beauty shops Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants Hydrochloric acid muriatic acid Furniture refinishing areas and establishments Cements and glues New building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Garages with workshops Adhesives used to fasten building products and other similar products Buildings under construction where air is contaminated with particulates Airborne particulates drywall dust fiberglass particles road or gravel dust lint etc Part Numb
118. xhaust fans in boiler room Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual Ci Boiler and heat distribution units filled with water Automatic air vent if used open one full turn Air purged from system Air purged from gas piping Piping checked for leaks Correctly sized manifold orifices installed Refer to Table 2 page 12 to check size and fuel type A DANGER Correctly sized manifold orifices must be used Failure to do so will cause severe personal in m mE m m A jury death or substantial property damage Followed lighting operating instructions on boiler or in manual Section 8 or Section 9 for proper start up Proper burner flame observed Refer to Check burner flame manual Section 6d Test limit control While burners are operating move indicator on limit control below actual boiler water tem perature Burners should go off while circulator continues to operate Raise setting on limit control above boiler water temperature and burners should reignite Test additional field installed controls If boiler has a low water cutoff additional high limit or other controls test for operation as outlined by manufacturer Burners should be operating and should go off when controls are tested When controls are restored burners should reignite Button on spill switch pushed in Test ignition system safety device Standing pilot Turn gas cock knob to PILOT posi tio

Weil-McLain CGA25SPDN User's Manual

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