Weil-McLain GOLD CGa Manual Download Page 63

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Part Number

550-101-009/0107

GOLD CGa Gas-Fired Water Boiler — Boiler Manual

Replacement parts — jacket

12d

&IGURE

Jacket assembly

Boiler

Model

Boiler
Model

Junction box, 2 x 4

Jacket panel,

left side

, with insulation

Jacket panel,

right

side

, with insula-

tion

Jacket panel,

top front

Natural Gas

Standing Pilot

Propane Gas

Standing Pilot

Natural Gas

Spark Pilot

Weil-McLain part number

CGa-25

CGa-3
CGa-4
CGa-5
CGa-6
CGa-7
CGa-8

(Available at local

supply house)

381-355-400
381-355-407
381-355-410
381-355-417
381-355-424
381-355-431
381-355-438

381-355-445
381-355-448
381-355-451
381-355-454
381-355-457
381-355-460
381-355-463

381-355-466
381-355-470
381-355-473
381-355-477
381-355-481
381-355-485
381-355-489

381-355-699
381-355-699
381-355-699
431-223-311
431-223-311
431-223-311
431-223-311

381-355-403
381-355-403
381-355-413
381-355-420
381-355-427
381-355-434
381-355-441

CGa-25

CGa-3
CGa-4
CGa-5
CGa-6
CGa-7
CGa-8

Boiler

Model

Boiler
Model

Jacket panel,

top rear

Jacket panel,

door

Jacket cross tie,

bottom front

Jacket panel,

interior

Jacket panel,

rear

Not shown —

gold

touch-up paint

Weil-McLain part number

CGa-25/3

CGa-4
CGa-5
CGa-6
CGa-7
CGa-8

381-355-404
381-355-414
381-355-421
381-355-428
381-355-435
381-355-442

381-355-406
381-355-416
381-355-423
381-355-430
381-355-437
381-355-444

431-223-325
431-223-326
431-223-327
431-223-328
431-223-329
431-223-330

381-355-405
381-355-415
381-355-422
381-355-429
381-355-436
381-355-443

431-223-300
431-223-301
431-223-302
431-223-303
431-223-304
431-223-305

592-000-000

CGa-25/3

CGa-4
CGa-5
CGa-6
CGa-7
CGa-8

Summary of Contents for GOLD CGa

Page 1: ...talling 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 sub...

Page 2: ...couple is satis ed the gas valve and vent damper will open on a call for heat and close afterwards y Transformer The control transformer reduces line voltage to 24 volts for the gas valve and limit ci...

Page 3: ...Part Number 550 101 009 0107 3 GOLD CGa Gas Fired Water Boiler Boiler Manual GOLD CGa Gas Fired Water Boiler...

Page 4: ...esence 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 persona...

Page 5: ...boiler s 3HOULD 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 s...

Page 6: ...ing s HECK FOR NEARBY CONNECTION TO s 3YStem water piping s 6ENTING CONNECTIONS s AS SUPPLY PIPING s LECtrical power s HECK AREA AROUND BOILER 2EMOVE ANY COMBUSTIBLE MATERIALS GASOLINE AND OTHER mAMMA...

Page 7: ...e page 11 for de nition the air openings must connect directly to outside or the building must have air openings to the outside as speci ed on page 11 If clearances are equal to or greater than Figure...

Page 8: ...iate tables in Part 11 of THAT CODE ANADIAN INSTALLATIONS MUST COMPLY WITH OR NSTALLATION ODE Chimney or vent require ments 6ENTING MUST BE INSTALLED ACCORDING TO 0ART 6ENT ING OF QUIPMENT OF ATIONAL...

Page 9: ...carbons Dry cleaning laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes cleaners Metal fabrication plants Chlorine based swimming pool chemicals Beauty shops Ca...

Page 10: ...stion and reduce the risk of severe personal injury death or substantial property damage caused by flue gas spillage and carbon monoxide emissions OMBUSTION AIR OPENING LOCATION AND SIZING REQUIREMENT...

Page 11: ...ded Clearances from boiler to walls s 4HE BOILER MUST HAVE CLEARANCES OF AT LEAST THOSE SHOWN IN IGURE A page 7 Opening must be directly to outside s 4HE OPENING MUST CONNECT DIRECTLY TO THE OUTDOORS...

Page 12: ...es and install in the manifold Make sure the ori ces 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 o...

Page 13: ...valve will be used to BLEED AIR DURING THE lLL 6ALVE AND NIPPLE ARE NOT included with boiler Fill and pressure test 1 Open the shutoff valves you installed on supply and return connections 2 Slowly op...

Page 14: ...connect wires a Standing pilot boiler see PAGE b Spark ignited pilot boiler see PAGES and Improper orientation of spill switch may cause boiler to shut down The loss of heat can result in signi cant d...

Page 15: ...instructions 6ENT DAMPER MUST BE INSTALLED SO THAT IT SERVES ONLY one boiler and so damper blade indicator is visible to the user See IGURE 2 Screws or rivets used to secure the vent damper to the dra...

Page 16: ...ERING BOILER ONSULT 2 NSTALLATION AND 0IPING UIDES s F BOILER IS CONNECTED TO HEATING COILS LOCATED IN air handling units where they can be exposed to refrigerated air use ow control valves or other a...

Page 17: ...er 5 feet of piping Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through ll valve Eventual section failure can result Water piping single zon...

Page 18: ...se the piping shown in IGURE on page 25 system bypass if the reduced ow rate in the heating system will not cause heat distribution problems Failure to prevent low return water temperature to the boil...

Page 19: ...tysystems radiant heating systems and heat pump systems refer to the special piping suggestions of IGURES n as applies Failure to prevent sustained low return water temperature to the boiler could cau...

Page 20: ...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 RADIA...

Page 21: ...vent with diaphragm type expansion tank or connect to tank tting 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 sys...

Page 22: ...RES and 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 IGURE page 25 is...

Page 23: ...or connect to tank tting 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...

Page 24: ...imum 130 F RETURN WATER TO THE BOILER 6ALVE B will most often be full open but may need to be slightly closed on some low pressure drop systems in order to cause enough ow through valve A IGURE is an...

Page 25: ...eappropriatevalvestoprevent chilled medium from entering boiler See Figure 18 for typical installation of balancing valve and check valve If boiler is connected to heating coils located in air han dli...

Page 26: ...5 100 38 79 150 305 460 150 31 64 120 250 380 4 Connect gas supply piping to boiler 1 Remove jacket front panel and refer to IGURE to pipe gas to boil er a NSTALL DRIP LEG at inlet of gas connection t...

Page 27: ...quivalent must be used If other original wiring as supplied with boiler must be replaced use only type wire or equivalent OILER MUST BE ELECTRICALLY GROUNDED as required by ATIONAL LECTRICAL ODE 3 0 L...

Page 28: ...f water treatment is needed O NOT USE PETROLEUM BASED CLEANING OR SEALING COMPOUNDS in boiler system Severe damage to boiler will occur resulting in substantial property damage LIMINATE ALL SYSTEM LEA...

Page 29: ...installed in system open manual air vents in SYSTEM ONE AT A TIME BEGINNING WITH LOWEST mOOR LOSE VENT WHEN water squirts out Repeat with remaining vents 4 Open AUTOMATIC AIR VENT diaphragm type or bl...

Page 30: ...and the IGHTING PERATING INSTRUCTION procedure see 4ABLE below s 6ERIFY THE BOILER AND SYSTEM ARE FULL OF WATER s 6ERIFY THE 3TART UP PREPARATION procedures of 3ECTION have been completed 4ABLE Lighti...

Page 31: ...SWITCH SET BELOW BOILER WATER TEMPERATURE 3 Thermostat set below room tem PERATURE Start up operate boiler continued 6b Start the boiler s OLLOW THE IGHTING PERATING NSTRUCTIONS from 3ECTION OR to sta...

Page 32: ...e sensor spark ignited pilot 3 Thermocouple or pilot ame sensor glowing cherry red IMPROPER pilot ame 1 Over red Large ame liftingorblowingpast pilot ame sensor 2 Under red Small ame Inner conenot eng...

Page 33: ...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 URNERS SHOULD GO off...

Page 34: ...S MANUAL AND ON BOILER 6ENT damper will remain closed 2 ALL FOR HEAT When thermostat circuit closes the boiler circulator and vent damper are energized The vent damper drives open When the vent damper...

Page 35: ...Part Number 550 101 009 0107 35 GOLD CGa Gas Fired Water Boiler Boiler Manual Lighting instructions CGa 25 to CGa 8 8b s 3TANDING PILOT s ATURAL OR PROPANE GAS s AS VALVE ONEYWELL 62 62...

Page 36: ...GOLD CGa Gas Fired Water Boiler Boiler Manual 36 Part Number 550 101 009 0107 Lighting instructions CGa 25 to CGa 8 8b s 3TANDING PILOT s ATURAL GAS s AS VALVE 2OBERTSHAW...

Page 37: ...PILOT AND OPENS PILOT VALVE IN MAIN gas valve a If pilot does light and control module senses ame current spark generator is turned off and main valve opens b If pilot does not light within 15 second...

Page 38: ...GOLD CGa Gas Fired Water Boiler Boiler Manual 38 Part Number 550 101 009 0107 Figure 25a Schematic wiring diagram Spark ignited pilot system Operation spark ignited pilot system continued 9a...

Page 39: ...Part Number 550 101 009 0107 GOLD CGa Gas Fired Water Boiler Boiler Manual Figure 25b Ladder wiring diagram Spark ignited pilot system Operation spark ignited pilot system continued 9a...

Page 40: ...GOLD CGa Gas Fired Water Boiler Boiler Manual 40 Part Number 550 101 009 0107 9b Operating instructions CGa 25 to CGa 8 s 3PARK PILOT s ATURAL GAS s AS VALVE ONEYWELL 62 62...

Page 41: ...Part Number 550 101 009 0107 41 GOLD CGa Gas Fired Water Boiler Boiler Manual 9b Operating instructions CGa 25 to CGa 6 s 3PARK PILOT s ATURAL GAS s AS VALVE 2OBERTSHAW...

Page 42: ...GOLD CGa Gas Fired Water Boiler Boiler Manual 42 Part Number 550 101 009 0107 9b Operating instructions CGa 25 to CGa 6 s 3PARK PILOT s ATURAL GAS s AS VALVE 7HITE 2ODGERS...

Page 43: ...Part Number 550 101 009 0107 43 GOLD CGa Gas Fired Water Boiler Boiler Manual 9b Operating instructions CGa 7 to CGa 8 s 3PARK PILOT s ATURAL GAS s AS VALVE 7HITE 2ODGERS...

Page 44: ...tion Manual for instructions A NNNUAL START UP Inspect s 2EPORTED PROBLEMS s OILER AREA s IR OPENINGS s LUE GAS VENT SYSTEM s 0ILOT AND MAIN BURNER FLAMES s 7ATER PIPING s OILER HEATING SURFACES s URN...

Page 45: ...the chimney AILURE TO INSPECT for the above conditions and have them repaired can result in severe personal injury or death Pilot and main burner ames 6ISUALLY INSPECT PILOT BURNER AND MAIN BURNER am...

Page 46: ...on al injury death or substantial property damage 1 After turning off power to the boiler remove the jacketdoor andbase accesspanel IGURE item page 62 2 Inspect burners and all other components in the...

Page 47: ...above highest radiator or BASEBOARD UNIT USUALLY IN THE ATTIC OR CLOSET AS A gauge glass and over ow pipe to a drain LOSED TYPE welded gas tight and located above boiler Tank is partially lled with wa...

Page 48: ...f valves should be REINSPECTED 4 34 6 29 4 2 9 23 by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and t...

Page 49: ...iler IGHTING OR PERATING INSTRUCTIONS Section B or B Excessive sooting indicates impropergascombustion Iffound checkforproper combustion and make any necessary adjustments Before troubleshooting AVE T...

Page 50: ...damage Follow these instructions only in case of no heat or damper actuator malfunction 1 Move damper service switch to OLD AMPER PEN POSITION PPLY CALL FOR HEAT TO BOILER AMPER BLADE should then rota...

Page 51: ...or 30 seconds Vent damper will rotate to closed position Close thermostat contacts Vent damper will rotate to open position Is 24VAC present across gas valve terminals Remove damper harness from dampe...

Page 52: ...ONTROL AFTER A LOCKOUT TURN OFF POWER AT THE 6 SERVICE SWITCH OR TURN down all thermostats Wait 45 seconds Then restore power or call for heat POWER light ashing alone 5SUALLY INDICATES REVERSED POLAR...

Page 53: ...Part Number 550 101 009 0107 53 GOLD CGa Gas Fired Water Boiler Boiler Manual Troubleshooting spark pilot boilers continued 11c...

Page 54: ...art 7 page 59 if POWER light is on steady with no other light flashing Usually indicates polarity on incoming 120 VAC power line is wrong TURN OFF POWER at service switch or breaker then reverse the H...

Page 55: ...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...

Page 56: ...reseating plug in module receptacle and restart If vent damper still does not work replace vent damper assembly or actuator Retest No Yes Wait 45 seconds Does vent damper operate No Yes Remove DAMPER...

Page 57: ...ts still flash Boiler should now operate normally Original flashing FLAME light caused by gas valve not operating properly See normal sequence of operation Figure 24 page 37 Replace gas valve Retest b...

Page 58: ...30 item 8 page 53 Connect positive lead of MICROAMMETER to sense wire DISCONNECT red wire connected to man gas valve terminal of the gas valve Turn on power to boiler and allow to cycle As soon as pi...

Page 59: ...ping free of blockage No Yes Correct conditions and recheck operation See Figure 24 page 37 for normal sequence of operation Contact your Weil McLain sales representative Replace control module Retest...

Page 60: ...size and include description and part number of replacement part Results from using modi ed or other manufactured parts will not be covered by warranty and may damage boiler or impair operation Weil...

Page 61: ...4 502 560 234 503 560 234 504 5 Nut 2 per tie rod 561 928 235 6 Washer 1 per tie rod 562 248 684 7 Radiation plate 1 per joint 460 003 700 8 Collector hood CGa 25 CGa 3 CGa 4 CGa 5 CGa 6 CGa 7 CGa 8 3...

Page 62: ...t CGa 25 CGa 3 CGa 4 CGa 5 CGa 6 CGa 7 CGa 8 450 003 742 450 003 736 450 003 737 450 003 738 450 003 739 450 003 740 450 003 741 9 Base insulation kit includes insulation for all base parts above plus...

Page 63: ...381 355 485 381 355 489 381 355 699 381 355 699 381 355 699 431 223 311 431 223 311 431 223 311 431 223 311 381 355 403 381 355 403 381 355 413 381 355 420 381 355 427 381 355 434 381 355 441 CGa 25...

Page 64: ...000 3 Drain valve Fittings shown are included with boiler Conbraco Hammond Valve Matco Norca Watts 31 606 01 710 205F04 BD 2C 511 210 423 4 Circulator Fittings shown are shipped loose with boiler Bell...

Page 65: ...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...

Page 66: ...ifold size Note 3 inches NPT A Vent location inches D Vent diameter inches W Jacket width inches H Damper height inches CGa 25 11 4 11 4 1 2 5 4 10 453 8 CGa 3 11 4 11 4 1 2 5 4 10 523 8 CGa 4 11 4 11...

Page 67: ...0 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 I 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 83 5 6 I D x 20 CGa 6 175 000 146 0...

Page 68: ...m the boiler and place it in a plastic bag for disposal O Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid O Eye Irrigate imm...

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