Weil-McLain CGt 2 Series Manual Download Page 56

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Part Number

550-110-290/0219

CGt

GAS-FIRED WATER BOILER — Series 2 —

Boiler Manual

Troubleshooting — common problems

12d

Common Problems

Common Causes

Possible Corrections

Rapid cycling — burner

turns on and off

frequently.

Thermostat installed where

drafts or heat affect reading.

Locate thermostat on inner wall

away from heat sources or cool

drafts.

Heat anticipator in

thermostat adjusted

incorrectly.

Adjust heat anticipator to match

current draw. Refer to boiler

wiring diagram.

Incorrect high limit setting.

Have qualified service

technician increase limit setting

to decrease cycling. Maximum

setting 220°F.

Need to frequently add

makeup water.

Leaks in boiler or piping.

Have qualified service

technician repair leaks at once

to avoid constant use of makeup

water.

Popping or percolating

noise heard in boiler.

Mineral deposits in sections

due to constant use of

makeup water, or incorrect

pH.

Have qualified service

technician repair leaks at once

to avoid constant use of makeup

water and check pH (between

7.0 and 8.5).

Black water condition.

Oxygen corrosion due to

leaks in piping.

Have qualified service

technician repair leaks at once

to avoid constant use of makeup

water and check pH (between

7.0 and 8.5).

Frequent release of

water through relief

valve.

Expansion tank sized too

small or water-logged.

Have qualified service

technician check expansion

tank operation.

Summary of Contents for CGt 2 Series

Page 1: ...ury death or substantial property damage This manual must only be used by a qualified heating installer service technician Before installing read all instructions including this manual and any related supplements Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Series 2 Gas Fired Water Boilers with Tankless Heater Boiler...

Page 2: ...ler off when the temperature at the switch reaches 135 F Control Relay Provides switching from domestic mode to heating mode 1 Control module The control module responds to signals from the room thermostat tankless heater low limit air pressure switch and boiler limit circuit to operate the boiler circulator pilot burner gas valve and inducer When room thermostat calls for heat the control module ...

Page 3: ...less heater 071001 Honeywell Honeywell Honeywell ON OFF PV PV MV MV W A RN IN G 5 10 a c p m e q b k l d h n g f i j o 1 2 3 4 9 6 7 8 H AB A B B B A A AB AB See detail upper right Actuator Connect to system return piping 3 way valve connections Connect to circulator as shown Connect to supply piping as shown r H H 11 ...

Page 4: ...that will or can cause minor personal injury or property damage Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage How it works 2 3 Hazard definitions 4 Please read before proceeding 5 1 Prepare boiler location 6 11 2 Prepare boiler 12 13 3 Venting 14 19 4 Water piping 20 27 5 Gas piping 28 6 Field wiring...

Page 5: ...red under warranty and should be replaced Electrical Damage If any electrical component or wir ing came into contact with water or was suspected to have come into contact with water replace the boiler with a new Weil McLain boiler Frozen Water Damage Hazard Residences or buildings that are unattended in severely cold weather boiler system components failures power outages or other electrical syste...

Page 6: ...ition For Canada only B149 1 or B149 2 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes The CGt boiler gas manifold and controls met safe operat ing and other performance criteriawhenboiler underwent tests specified inANSI Z21 13 latest edition Read and follow the special instructions for the Commonwealth of Massachusetts located on page 44 of this manual Before loca...

Page 7: ...on and sizing of combustion air openings Failure to comply can result in severe personal injury death or substantial property damage and reduced boiler life Flooring The CGt boiler is approved for installation on combustible flooring but must never be installed on carpeting Do not install boiler on carpeting even if foundation is used Fire can result causing severe personal injury death or substan...

Page 8: ...size as determined using the appropriate tables in Part 13 of that code Canadian installations must comply with B149 1 or B149 2 Installation Code Chimney or vent require ments 1 Venting must be installed according to Part 7 Venting of Equipment of National Fuel Gas Code ANSI Z223 1 latest edition and applicable building codes Canadian installations must comply with B149 1 or B149 2 Installation C...

Page 9: ...you must inspect the boiler at least once weekly When inspecting clean the burners if necessary using the procedure given on page 41 Failure to follow these guidelines could result in severe personal injury death or substantial property damage Products to avoid Areas likely to have contaminants Spray cans containing chloro fluorocarbons Dry cleaning laundry areas and establishments Permanent wave ...

Page 10: ... infiltration so additional air openings to the building are not required 3 See Figure 3 Provide two openings through the interior wall within 12 inches of the ceiling and the floor sized per Figure 3 Two openings Air supply directly from outside 1 Air openings must be directly through an outside wall or into a space that connects directly to the outside such as a ventilated attic or crawl space f...

Page 11: ... on page 10 provided Clearances from boiler to walls The boiler must have clearances of at least those shown in Figure 1 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 Theaircanbeprovidedthroughadirectopeningorthroughahorizontal or vertical duct Opening placement The top ...

Page 12: ... only be inserted one way See Figure 33 page 48 for location of connector on control module Inspect orifices and burners Correctly sized manifold orifices must be used Failure to do so will result in severe personal injury death or substantial property damage 1 Remove front jacket door Remove burner shield see Figure 36 item 4 page 62 2 Verify that the orifice size is 2 7mm The orifice size is sta...

Page 13: ...d nipple are not included with boiler Fill and pressure test 1 Open the shutoff valves you installed on supply and return connections 2 Slowly open boiler drain valve and fresh water sup ply to fill boiler with water 3 When water flows from shutoff valves close boiler drain valve 4 Close shutoff valves 5 Slowly reopen boiler drain valve until test pressure on the pressure temperature gauge reaches...

Page 14: ...d extend at least 3 feet above the highest point where it passes through a roof and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet 3 To vent with another appliance see National Fuel Gas Code ANSI Z223 1 latest edition or in Canada B149 2 or B149 2 Installation Code 4 Do not connect breeching to any portion of a mechanical draft system that can operate...

Page 15: ...ling to terminate run 15 Part Number 550 110 290 0219 CGt GAS FIRED WATER BOILER Series 2 Boiler Manual Max vent length feet Total number of elbows Note 1 0 1 2 3 4 5 6 CGt 40 33 26 19 12 5 Note 1 Do not include termination fitting when counting total number of elbow 1 The following special gas vent systems comply with UL 1738 and ULC S636 standards and are certified by CSA as the only systems sui...

Page 16: ...vent manufacturer Use only the vent starter of the same manufac turer as the vent com ponents Do not mix components from dif ferent systems The vent system could fail causing flue gas spillage resulting in severe personal injury or death 3 Follow all applicable national state local or provincial codes when venting the CGt boiler 4 Connect vent starter to blower hous ing outlet as shown in the Figu...

Page 17: ... formations 11 Do not connect Any other appliance to vent pipe Multiple boilers to a common vent pipe 12 Canadian installations See B149 1 or B149 2 Installation Code Terminate vent no less than 6 feet from another combustion air inlet 3 feet from any other building opening and 3 feet from any gas service regulator 13 See Figure 12 showing that the vent must terminate more than 4 feet below or to ...

Page 18: ...ctions for cleaning and sealing joints Use their specified sealant Do not use screws 3 Install vent pipe with seams on top of vent horizontal runs Follow requirements in Section 3e page 17 for vent termination 4 Maintain minimum 2 clearance from combustible materials to vent pipe 5 Vertical venting See Figure 13 Follow vent manufacturer s in structions for venting through roof Vent pipe must exten...

Page 19: ...0 0219 CGt GAS FIRED WATER BOILER Series 2 Boiler Manual Figure 15 Sidewall termination Using any termination other than one of those shown could cause nuisance outages and loss of heat resulting in substantial property damage ...

Page 20: ...rt Molex connector into mating connector on 3 way valve Make sure that valve body is in correct position as shown in Figure 38 The circulator is shipped loose wiring pre attached to boiler Pipe the circulator on the return line only as shown on page 3 and page 64 Pipe the expansion tank to the suction side of the circulator as shown in Figure 16 page 21 Install an air separator in the supply pipin...

Page 21: ...ng and piping for single zone systems designed for return water at least 130 F See pages 22 23 to for multiple zone piping for systems with return water temperature of at least 130 F See pages 24 25 for low temperature system piping i e radiant heating systems or converted gravity systems large volume systems originally designed for circula tion by natural convection rather than a pump Chillers or...

Page 22: ...age Piping for radiant heating systems or converted gravity systems 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 Converted gravity or steam systems Whenever possible use the primary secondary bypass piping shown in Figures 19 or 20 on page 25 This pipin...

Page 23: ...sion 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 13 Air separator with automatic vent if used Note that the fill valve must always be connected to the expansion tank For systems with possible low return water temperature such as converted gravity systems radiant heating systems and heat pump s...

Page 24: ...use the boiler circulator must install on the return line and be used to provide domestic water priority Adjustment of the bypass valves in the boiler circuit will not cause a change in the heating circuit flow rate or temperature distribution The bypass valves in Figures 19 and 20 items 7a and 7b provide mixing of hot boiler outlet water with cooler system return water set to assure a minimum ret...

Page 25: ...ing valves 2 Flow check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve 6 Drain valve 7 System temperature valves see instruc tions on page 24 for adjusting valves 8 Blend temperature gauge 9 Relief valve 10 Automatic air vent 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used 13 Air separator and automatic vent if used Note that the fill valve must a...

Page 26: ...ontactlocalhealth department for more information These single wall heat exchangers comply with National Standard Plumbing Code provided that Boiler water including additives is practically non toxic having a toxicity rating or class of 1 as listed in Clinical Toxicology of Commercial Products Boiler water pressure is limited to maximum 30 psig by approved water relief valve If boiler is installed...

Page 27: ...with the heating boiler Use appropriate valves to prevent chilled medium from entering boiler See Figure 22 for typical installation of balancing valve and check valve 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 automatic means to prevent gravity circula tion during cooling cycle Figure 22 Pipi...

Page 28: ... for gas leaks can cause severe personal injury death or substantial property damage Table 7 Pipe capacity for 0 60 specific gravity natural gas Figure 23 Gas supply piping 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 Failure to apply pipe dope as detailed abovecan result in severepersonalinjury death or...

Page 29: ...ditional wire if needed Thermostat 1 Connect thermostat as shown on wiring diagram on boiler 2 Install on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunrays or fireplaces 3 If thermostat has a heat anticipator set heat anticipator in thermostat to match power requirements of equipment con nected to it If connected directly to boiler set for 0 1 ...

Page 30: ... level to drop Added water will dilute the antifreeze reducing the freeze protection level 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 application 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 ...

Page 31: ...rating instructions from Section 10c to start the boiler See Section 7c if boiler fails to start Check system and boiler 1 Check system piping and domestic hot water piping for leaks If found shut down boiler and repair immediately 2 Vent air from system using manual vents Air in the system will interfere with circulation and cause heat distribution problems and noise 3 Inspect vent system thoroug...

Page 32: ... 26 PROPER main burner flame characteristics 1 Yellow orange streaks may appear caused by dust IMPROPER main burner flame characteristics 1 Overfired Large flames 2 Underfired Small flames 3 Lack of primary air Yellow tipping on flames sooting will occur Start up if boiler doesn t start 7c Check for 6 If none of the preceding corrects the problem refer to Troubleshooting Section 12 of this manual ...

Page 33: ...up cycle to occur and main burners to ignite c With main burners on manually shut off gas supply at manual main shutoff gas valve Burners should go off d Open manual main shutoff gas valve Manometer should confirm there is no gas flow e Pilot will relight flame sensing element will sense pilot flame and main burners will reignite Set limit control s to system temperature requirements Adjust balanc...

Page 34: ... to stop call for heat Pilot and main gas valves close Inducer oper ates for 15 second postpurge Circulator shuts off 8 Boiler is now in the off cycle 9 Repeat steps 1 through 6 several times to verify operation 10 Return the thermostat or tankless heater low limit to normal setting 11 Set thermostat heat anticipator setting as instructed in Figure 28 page 35 STEPS following step 8 cycle goes back...

Page 35: ...35 Part Number 550 110 290 0219 CGt GAS FIRED WATER BOILER Series 2 Boiler Manual 10b Operation wiring diagram Figure 28 Schematic and ladder wiring diagram ...

Page 36: ...Operating instructions Spark pilot Natural or propane gas Gas valve Honeywell VR8204 VR8304 36 Part Number 550 110 290 0219 CGt GAS FIRED WATER BOILER Series 2 Boiler Manual 10c ...

Page 37: ...37 Part Number 550 110 290 0219 CGt GAS FIRED WATER BOILER Series 2 Boiler Manual Operating instructions Spark pilot Natural or propane gas Gas valve White Rodgers 36E 10c ...

Page 38: ...38 Part Number 550 110 290 0219 CGt GAS FIRED WATER BOILER Series 2 Boiler Manual Operating instructions Spark pilot Natural or propane gas Gas valve White Rodgers 36C 10c ...

Page 39: ...ing Pilot and main burner flames Water piping Boiler heating surfaces Burners base and inlet air box Condensate drain system Service Inducer motor Oiled bearing circulators Start up Perform start up per manual Check test Gas piping Cold fill and operating pressures Air vents and air elimination Limit controls and cutoffs Expansion tank Boiler relief valve Review Review with owner Daily Check boile...

Page 40: ...ve condi tions and have them repaired can result in severe personal injury or death Pilot and main burner flames 1 Visually inspect pilot burner and main burner flames as directed under Start up Section 7b of this manual Water piping 1 Check the boiler interior piping and all system piping for signs of leaks 2 Repair any leaks before proceeding Boiler heating surfaces 1 Disconnect the vent pipe at...

Page 41: ...ing the burner tray to the manifold and slide the burner tray out under the manifold 2 Inspect each burner to insure that every port is completely open 3 If any port is not completely clear run a vacuum at the burner inlet while cleaning the burner ports with a wire brush The vacuum will help to draw any airborne material out of the burner 4 Reinstall components starting with the burner tray then ...

Page 42: ...ated 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 4 3 If relief valve has tended to weep frequently the expansion tank may be damaged or undersized First check tank size to be sure it is large enough for the syste...

Page 43: ...n 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 Cleaning boiler heating surfaces The boiler contains ceramic fiber and fiberglass materials Use care when han dling the...

Page 44: ...et above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BE LOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation...

Page 45: ...nuity checker d U tube manometer 2 Check for 120VAC minimum 102VAC to maximum 132VAC to boiler 3 Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Check for 24VAC between thermostat wire nuts and ground Check the following 1 Wire connectors to control module are securely plugged in at module and originating control 2 Air pressure switch hoses are ...

Page 46: ... causes blockage in hoses obstruction in inducer housing outlet loose inducer wheel on motor shaft inducer motor not in proper rpm inducer back plate not sealed properly blockage in block assembly blockage in flue pipe or termination incorrect pressure switch Return to normal operation When pressure reading is correct and air pressure switch is operating properly remove tees and reinstall hoses to...

Page 47: ...he run cycle Troubleshooting the control module See Figure 33 page 48 for location of harness plug receptacles and plugs on the control module Figure 32 Control module 3 Way valve The 3 way valve redirects water flow in the circuit Normally the valve allows water to flow through the bypass to maintain the heat in the boiler for the tankless heater The 3 way valve lever is up in the normal position...

Page 48: ...48 Part Number 550 110 290 0219 CGt GAS FIRED WATER BOILER Series 2 Boiler Manual 12b Troubleshooting components Figure 33 Control module connections Orange ...

Page 49: ... switch or circuit breaker is on or fuses are good Remove 120VAC IN plug Figure 33 Item 3 page 48 on control module Using voltmeter check across black and white wire pins of 120VAC IN plug Does voltmeter indicate 120VAC No Yes Reconnect 120VAC IN plug Remove 120VAC IN transformer PRIMARY plug Figure 33 Item 2 page 48 on control module Using voltmeter check across top and bottom pins of PRIMARY rec...

Page 50: ...hermostat 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 ...

Page 51: ...on 12b page 46 Replace if necessary Retest Clear passages and recycle boiler Recheck boiler operation Try reseating plug in module receptacle and restart If inducer still does not work replace inducer assembly Retest Boiler should be in normal operating sequence Observe operation until thermostat is satisfied and inducer has completed its post purge cycle Remove INDUCER plug Figure 33 Item 6 page ...

Page 52: ... shutoff valve and gas valve open No Yes Replace gas valve Retest boiler Are FLAME POWER lights flashing No Yes Replace control module Retest Boiler should now operate normally Original flashing FLAME light caused by gas valve not operating properly See normal sequence of operation Figure 27 page 34 Turn off power to the boiler at service switch or breaker Wait at least 45 seconds Turn on power to...

Page 53: ... control module to pressure switch Reseat connector in control module receptacle If harness is intact and properly seated but problem persists replace control module Retest Check air pressure switch per manual Section 12b page 46 Replace if necessary Retest Clear vent and recycle boiler Recheck boiler operation Replace inducer assembly Retest Boiler should be in normal operating sequence Observe o...

Page 54: ...mic and spark lead wire from control are in good condition Spark gap should be approximately 1 8 Correct any above problems replacing pilot if burner or wiring is damaged Reinstall burner shield to operate boiler for retest after any changes or corrections If none of the above corrects problems then replace the control module and retest TURN OFF POWER to boiler at service switch or breaker Remove ...

Page 55: ...Retest Replace control module Retest Repair replace circulator Retest Repair replace wiring Retest Check any other limit controls wired into the limit circuit If all are OK then replace control module Retest Correct conditions and recheck operation See Figure 27 page 34 for normal Sequence of operation Boiler is in standby Set thermostat to call for heat and recheck operation Verify Sequence of op...

Page 56: ...ng Maximum setting 220 F Need to frequently add makeup water Leaks in boiler or piping Have qualified service technician repair leaks at once to avoid constant use of makeup water Popping or percolating noise heard in boiler Mineral deposits in sections due to constant use of makeup water or incorrect pH Have qualified service technician repair leaks at once to avoid constant use of makeup water a...

Page 57: ...less heater is hot then suddenly turns cold OR Domestic water from tankless heater is always lukewarm Mineral deposits insulate internal waterways of heater Have qualified service technician delime or replace coil Boiler stop leak compound has been added to boiler water and is insulating outside of coil Have qualified service technican remove and clean coil AND drain and flush boiler to remove sto...

Page 58: ...g for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air REMOVAL OF FIBERGLASS WOOL or INSTALLATION OF FIBERGLASS WOOL COMBUSTION CHAMBER LINING OR BASE PANELS This product contains fiberglass jacket insulation and ceramic fiber materials in combustion chamber lining or ba...

Page 59: ...ze and include description and part number of replacement part Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation Weil McLain part numbers are found in Weil McLain Boilers and Controls Repair Parts Lists The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on...

Page 60: ...Jacket panel right side with insulation 381 355 793 4 Jacket panel top front with insulation 381 355 420 5 Jacket panel top rear with insulation 381 355 742 6 Jacket panel door 381 355 744 7 Jacket cross tie bottom front 431 223 327 8 Jacket panel rear with insulation 431 223 302 9 Jacket panel interior with insulation 381 355 743 NS Gold touch up paint spray can 592 000 000 13 Replacement parts j...

Page 61: ... 234 395 6 Washer 7 16 1 per tie rod 562 248 684 7 Nut 7 16 1 per tie rod 561 928 235 8 Radiation plate 1 per joint 460 003 700 Item number Description Weil McLain part number 9 Tankless heater 590 921 920 10 Gasket tankless heater 590 317 584 11 Stud and nut assembly 3 8 x 1 1 8 qty 10 560 340 577 12 High limit 30 differential with well Honeywell L4080D 1036 White Rodgers 11B81 3 510 312 250 13 T...

Page 62: ...se pan angle left side in Base assembly 6 Base pan angle right side in Base assembly 7 Base pan in Base assembly 7a Base pan air baffle in Base assembly 8a Burner mounting plate 450 003 692 8b Rear spacing strip 550 320 162 8c Nut hex 5mm Zp 550 320 170 9 Base insulation kit 381 354 332 10 Boiler leg kit 550 320 219 11 Manifold 591 126 737 12 Main burner orifice Natural gas 2 7mm 560 529 077 13 Bu...

Page 63: ...63 Part Number 550 110 290 0219 CGt GAS FIRED WATER BOILER Series 2 Boiler Manual Replacement parts base continued 13 Figure 37 Base assembly continued ...

Page 64: ...per boiler Weil McLain 590 317 535 7 Circulator wiring harness kit Molex for control end shipped loose Weil McLain 591 391 904 8 Adapter copper NPT 1 x 1 562 302 533 9 Nipple copper 1 x cut to fit 560 742 939 10 3 Way valve actuator 3 Way valve body Honeywell Honeywell 635 100 023 635 100 022 11 Main wire harness controls to module see wiring diagram for connections 591 391 950 12 Elbow copper 1 5...

Page 65: ...t kit w orifice aluminum pilot gas tubing Weil McLain 511 330 080 3 Control module United Technologies 1107 1 381 330 090 4 Air pressure switch 1 53 w c Tri Delta 511 624 542 5 Control transformer Honeywell AT140B1297 511 842 370 6 Ambient temperature switch bracket not shown 135 F automatic reset Therm O Disc 60T21 314367 540 130 401 7 Control relay DPDT 24 V Honeywell R8222D1014 510 311 019 not ...

Page 66: ...R BOILER Series 2 Boiler Manual Dimensions 14 Boiler model number Supply tapping inches NPT Return tapping inches NPT Gas connection size Note 3 inches NPT Gas manifold size Note 3 inches NPT CGt 1 1 Note 3 Gas piping from meter to boiler to be sized per local utility requirements ...

Page 67: ...oiler water content Vent size Direct exhaust Chimney draft Btuh Btuh Btuh Note 1 AFUE Btuh Note 2 gallons Note 3 CGt PIN 133 000 109 000 109 000 82 1 95 000 3 1 3 5 Notes 1 Based on standard test procedures prescribed by the United States Department of Energy 2 Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the build ing and nothing need be add...

Page 68: ...68 Part Number 550 110 290 0219 CGt GAS FIRED WATER BOILER Series 2 Boiler Manual ...

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