Weil-McLain CGa 3 Series Manual Download

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Boiler Manual

Series 3

Gas-Fired Water Boilers

• Maintenance

• Parts

• Installation

• Startup

Part Number 550-142-300/0520

Now With Built In

Low Water Cut Off Functionality

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.

Summary of Contents for CGa 3 Series

Page 1: ...n Low Water Cut Off Functionality 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 ...

Page 2: ...ries control will lockout and flash all lights Control must be manually reset to place back into service 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 lig...

Page 3: ...Part Number 550 142 300 0520 3 CGa Series 3 Gas Fired Water Boiler Boiler Manual CGa Series 3 Gas Fired Water Boiler ...

Page 4: ...owed to accumulate in or around the boiler or any other potential ignition source a fire can develop In order to prevent potential severe 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 immediately t...

Page 5: ...t operatesduringpoweroutages senseslow temperature and initiates an effective ac tion Consult with your boiler contractor or a home security agency If any part of a boiler burner or its controls has been sprayed with or submerged under water either partially or fully DO NOT attempt to op erate the boiler until the boiler has been either replaced or completely repaired inspected and you are sure th...

Page 6: ... tests specified in ANSI Z21 13 latest edition Before locating the boiler check the following Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power Check area around boiler Remove any combustible materials gasoline and other flammable liquids or other contaminants Failuretokeepboilerareaclearandfreeof combustible materials gasoline and other flam...

Page 7: ... boiler input If the building is of unusually tight construction see page 11 for definition the air openings must connect directly to outside or the building must have air openings to the outside as specified on page 11 If clearances are equal to or greater than Figure 1a see pages 10 and 11 for location and sizing of combustion air openings Failure to comply can result in severe personal injury d...

Page 8: ... comply with Natural Gas and Propane Installation Code CAN CSA B149 1 or B149 2 Installation Code Chimney or vent require ments 1 Venting must be installed according to Part 7 Vent ing 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 Codes 2 See Ratings table on page 65 for minimum ...

Page 9: ...ns Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fast...

Page 10: ... of the ceiling and the floor sized per Figure 3 3 See Figure 4 Air supplied through vertical ducts provide two openings terminated within 12 inches of the ceiling and the floor sized per Figure 4 4 See Figure 5 Air supplied through horizontal ducts provide two openings within 12 inches of the floor and the ceiling sized per Figure 5 Prepare boiler location air openings 1e Air openings must be pro...

Page 11: ... to walls The boiler must have clearances of at least those shown in Figure 1a 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 of the air opening must be within 12 inche...

Page 12: ...es 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 pr...

Page 13: ...ir during the fill Valve 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 open boiler drain valve and fresh water supply to fill boiler with water 3 When water flows from shutoff valves close boiler drain valve Drain and remove fittings 1 Disconnect fill water hose from water source 2 Drain boiler at dr...

Page 14: ... a Spark ignited pilot boiler see pages 36 and 37 Improper orientation of spill switch may cause boiler to shut down The loss of heat can result in significant damage due to freezing Prepare boiler install vent piping 1 Connect from draft hood or vent damper outlet to chimney or vent with same size vent connector 2 Where possible vertical venting to the outside from the draft hood or vent damper o...

Page 15: ...nstall 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 an...

Page 16: ...parator 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 expansion tank or Figure 10 closed type expansion tank and Table 3 below for near boiler and single zone systems design...

Page 17: ...t of piping Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve Eventual section failure can result Water piping single zone system Figure 9 Diaphragm or bladder type expan sion tank Single zone system using diaphragm type or bladder type expan sion tank See Table 3 for piping sizes Figure 10 Closed type expansion tank Single z...

Page 18: ...g 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 temperatu...

Page 19: ... 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 s...

Page 20: ...uit 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 items 7a and 7b provide mixing of hot boiler outlet water with cooler system return water set to assure a...

Page 21: ...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...

Page 22: ...d 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 possibl...

Page 23: ...on 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 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 exp...

Page 24: ...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 ra...

Page 25: ...eparator to tank fitting as in Figure 10 page 17 Figure 17 System bypass piping Zoning with zone valve or circulators return water 130 F or higher Alternative to boiler bypass piping Figures 15 and 16 page 23 Figure 18 Piping refrigeration systems Prevent chilled water from entering boiler Water piping refrigeration systems 3e Install boiler so that chilled medium is piped in parallel with theheat...

Page 26: ...union for servicing when required c Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or 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 3 Purge all air from gas supply piping 4 Before placing boiler in operation check boiler...

Page 27: ...nts of equip ment connected to it If connected directly to boiler set for 0 1 amps plus gas valve current See information on the wiring diagram shown in Figure 25b page 37 For other devices refer to manufacturer s specifica tions Wiring diagram on boiler gives setting for control module and gas valve Also see instructions with thermostat DHW Connect DHW aquastat as shown in wiring below Economy fu...

Page 28: ...r system Severe damage to boiler will occur resulting in substantial property damage Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure Verify water chemistry Consult local water treatment companies for unusually hard water areas above 7 grains hardness or low pH ...

Page 29: ...es are not installed in system open manual air vents in system one at a time begin ning with lowest floor Close vent when water squirts out Repeat with remaining vents 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 until water squirts out b Repeat with remaining vents 6 Ref...

Page 30: ... BOILER OPERATING TEMPERATURE TO DESIRED SETPOINT BOILER ECONOMY SETTING To comply with Department of Energy regulations the control module circulates available hot water before turning on the boiler to attempt to satisfy a call for heat While attempting to satisfy the heat demand the control module also monitors the boiler temperature changes via the temperature LWCO sensor and determines whether...

Page 31: ...own fuse or service switch off 2 Boiler temperature adjustment set below boiler water temperature 3 Thermostat set below room temperature Start the boiler Follow the Operating Instructions from Section 9 to start the boiler Remove boiler jacket door and note the gas valve manufacturer and model number Use only the operating instruction which applies to this gas valve see Table 5 page 30 The operat...

Page 32: ...g past pilot flame sensor 2 Underfired Small flame Inner cone not engulfing pilot flame sensor 3 Lack of primary air Yellow flame tip 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 o...

Page 33: ... 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 Connect manometer to outlet side of gas valve Start boiler allowing for normal start up cycle to occur and ma...

Page 34: ...trol does not sense pilot flame during these trials it will lock out the boiler and require a manual reset procedure to allow further attempts Manual Reset Procedure for Propane Gas Lockout Unburned propane gas may have accumulated in combustion chamber Provide adequate ventilation to completely remove any accumulated LP gas from boiler and adjacent area before attempting to reset and light boiler...

Page 35: ... 9a STEPS following step 7 cycle goes back to step 1 Call for Heat POWER TSTAT CIRC LIMIT DAMPER FLAME LWCO Timing 1 Standby Waiting for call for heat NO 2 Call for heat Circulator on YES 3 Limit circuit Limit controls closed YES 4 Damper circuit Damper proven open YES 5 Flame proven Gas valve open Ignitor remains on Boiler producing heat YES 15 sec 6 Limit cycle Limit circuit open Gas valve close...

Page 36: ...and status light locations orientations may vary NOTICE 59374b LWCO Items not provided FIELD WIRING SERVICE SWITCH Junction box boiler left side Jacket opening boiler left side Black White Green Ground screw Wire nuts Black Black 120 VAC Neutral Hot Gnd W BK BR Y C A W W R TRANSFORMER TEMPERATURE LWCO SENSOR PILOT BURNER GAS VALVE CIRCULATOR Terminal block OFF ON W Y Honeywell VR8204 shown 80 60 7...

Page 37: ...rs 36E White Rodgers 36C Terminals 2 4 are factory jumpered on the White Rodgers 36C gas valve MV PV MV PV 2 2 4 MV MV 1 1 PV PV 3 3 Table G Gas valve terminals and anticipator settings Gas valve A B C Anticipator amps 0 6 0 8 0 64 0 7 Electrical shock hazard can cause severe injury or death Disconnect power before installing or servicing WARNING Legend for ladder wiring diagram 120 VAC factory wi...

Page 38: ... Spark pilot Natural gas Propane gas Gas valve Honeywell VR8204 VR8304 Part Number 550 142 300 0520 38 CGa Series 3 Gas Fired Water Boiler Boiler Manual 9b Operating instructions CGa 25 to CGa 8 ...

Page 39: ... Spark pilot Natural gas Gas valve Robertshaw 7200 Part Number 550 142 300 0520 39 CGa Series 3 Gas Fired Water Boiler Boiler Manual 9b Operating instructions CGa 25 to CGa 6 ...

Page 40: ... Spark pilot Natural gas Gas valve White Rodgers 36E Part Number 550 142 300 0520 40 CGa Series 3 Gas Fired Water Boiler Boiler Manual 9b Operating instructions CGa 25 to CGa 6 ...

Page 41: ... Spark pilot Natural gas Gas valve White Rodgers 36C Part Number 550 142 300 0520 41 CGa Series 3 Gas Fired Water Boiler Boiler Manual 9b Operating instructions CGa 7 to CGa 8 ...

Page 42: ...nd main burner flames Water piping Boiler heating surfaces Burners and base Condensate drain system Service Oiled bearing circulators Temperature LWCO sensor 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 boiler area Check ai...

Page 43: ...nto the chimney Failure to inspect for the above conditions 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 Section 6d page 32 of this manual Water piping 1 Check the boiler interior piping and all system pip ing for signs of leaks 2 Repair any leaks before proceeding The boil...

Page 44: ... 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 4 Inspect the base insulation a Pay attention to the WARNINGS on...

Page 45: ...e 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 Make sure this type of tank is fitted with a tank fitting such as the B G Tank Trol or Taco Taco Trol This fitting reduces gravity circula tion ...

Page 46: ...or or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve anddischarge line have notbeenaltered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inopera tive Such conditions are not detectable unless the valve and its components...

Page 47: ...een thermostat wire nuts and ground Troubleshooting components 11a Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Never jumper bypass rollout thermal fuse element or any other device except for momentary testing as outlined in Trouble shooting Charts Severe personal injury death or substantial property damage can result Burne...

Page 48: ...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 Figure 28 Manually opening the vent damper pliers on flat shaft between damper and actuator Boiler will fire Verify that damper service switch is in Hold Damper Open position Figure 28 ...

Page 49: ...t earth ground Flash code 2 Internal fault microprocessor or memory Flash code 3 Internal fault LWCO circuit Flash code 4 Unused Flash code 5 Internal fault water thermistors disagree Flash code 6 Flashes once per second Internal fault gas valve circuit Flash code pattern POWER LED flashes 2 3 etc times rapidly followed by 2 seconds off then repeats ALL LED S FLASHING Failure to establish pilot fl...

Page 50: ...Part Number 550 142 300 0520 50 CGa Series 3 Gas Fired Water Boiler Boiler Manual 11b Troubleshooting spark pilot boilers continued Figure 30 Control module connections ...

Page 51: ...ce switch or circuit breaker is on or fuses are good Remove 120 VAC IN plug Figure 30 Item 3 page 50 on control module Using voltmeter check across black and white wire pins of 120 VAC IN plug Does voltmeter indicate 120 VAC No Yes Reconnect 120 VAC IN plug Remove transformer plug Figure 30 Item 2 page 50 on control module Using voltmeter check across left side top and bottom pins of transformer r...

Page 52: ...tion 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 If no voltage is found under any...

Page 53: ...t and appropriate zone valves open The TSTAT CIRC and LIMIT lights should come on Does vent damper operate No Yes Wait 5 minutes Is Damper light flashing No Yes Remove damper wiring plug at damper and firmly reconnect Recheck boiler operation If problem persists replace vent damper assembly or actuator Wait 45 seconds Does vent damper operate No Yes Remove Damper plug Figure 30 Item 6 page 50 from...

Page 54: ...valve closed Turn off power to boiler at service switch or breaker Wait at least 45 seconds Turn on power to boiler Restart boiler following Operating instructions in this manual Section 9b or on boiler label Do FLAME and POWER lights still flash No Yes Replace gas valve Retest Are FLAME and POWER lights flashing No Yes Replace control module Retest Allow boiler to continue cycling Are FLAME and P...

Page 55: ...gas valve Turn on power to boiler and allow to cycle As soon as pilot is burning the MICROAMMETER should read at least 1 0 microamp Is flame signal at least 1 0 microamp No Yes Check the voltage across main gas valve terminals of the gas valve Is 24 VAC present there No Yes If the wiring from the control module to gas valve is intact replace the control module Retest Verify inlet gas pressure at g...

Page 56: ... Yes Reset spill switch or replace rollout switch If rollout thermal fuse element or spill switch has opened determine cause and correct condition Failure to do so will cause severe personal injury death or substantial property damage Check temperature sensor for correct resistance Are resistance values correct No Yes Replace control module Retest Replace control module Retest Repair replace circu...

Page 57: ...erty damage 11b Troubleshooting spark pilot boilers continued System is losing water Repair leak and retest Is boiler pressurized Yes No System was low on water Check system fill piping for leaks or damage Pressurize boiler to system design pressure Are lights still solid No Yes Check system for leaks Is system leaking or not maintaining pressure No Yes LWCO sensor is bad or fouled Clean LWCO sens...

Page 58: ...art Results from using modified or other manufac tured 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 66 of this manual Failure to comply could result in ...

Page 59: ...34 505 5 Nut 7 16 2 per tie rod 561 928 235 6 Washer 7 16 1 per tie rod 562 248 684 7 Radiation plate CGa 25 3 460 003 018 1 per joint CGa 4 8 460 003 017 8 Collector hood CGa 25 CGa 3 CGa 4 CGa 5 CGa 6 CGa 7 CGa 8 381 354 625 381 354 626 381 354 627 381 354 628 381 354 926 381 354 630 381 354 631 Item number Description Part number 9 Temperature LWCO sensor 511 724 305 10 Draft hood CGa 25 CGa 3 ...

Page 60: ... 003 742 450 003 736 450 003 737 450 003 738 450 003 739 450 003 740 450 003 741 9 Base insulation kit included insulation for all base parts above plus gasket material needed between block assembly and base CGa 25 CGa 3 CGa 4 CGa 5 CGa 6 CGa 7 CGa 8 381 354 518 381 354 518 381 354 518 381 354 518 381 354 519 381 354 519 381 354 519 10 Boiler leg kit 590 424 253 11 Manifold CGa 25 CGa 3 CGa 4 CGa ...

Page 61: ...59 230 381 359 230 381 359 231 381 359 232 381 359 233 381 359 234 381 359 235 381 359 236 381 359 236 381 359 237 381 359 238 381 359 239 381 359 240 381 359 241 CGa 25 CGa 3 CGa 4 CGa 5 CGa 6 CGa 7 CGa 8 Boiler Model 6 7 8 9 10 Boiler Model Jacket panel door Jacket cross tie bottom front Jacket panel interior with insulation Jacket panel rear with insulation Not shown touch up paint Part numbers...

Page 62: ...uge 3 diameter short shank Fittings shown are shipped loose with boiler 380 000 000 3 Drain valve Fittings shown are included with boiler 511 210 423 4 Circulator Fittings shown are shipped loose with boiler CGa 25 5 CGa 6 8 511 405 153 511 405 113 5 Circulator gasket universal 2 per boiler 590 317 535 not shown Circulator hardware kit includes 1 flange 2 nuts 2 screws 1 gasket NPT CGa 25 1 NPT CG...

Page 63: ...ropane gas components 1 Gas Valve x Gas Valve x CGa 25 through CGa 7 CGa 8 511 044 356 511 044 366 2 Pilot kit w orifice aluminum pilot gas tubing 511 330 273 Natural gas and Liquefied Petroleum Propane gas components 3 Control Module Natural gas Liquefied Petroleum Propane gas 381 330 039 381 330 038 not shown Wiring Harness Junction box to Control Module 591 391 975 not shown Wiring Harness Cont...

Page 64: ...apping inches NPT Gas connection manifold size Note 3 inches NPT A Vent location inches D Vent diameter inches W Jacket width inches H Damper height inches CGa 25 1 1 5 4 10 45 3 8 CGa 3 1 1 5 4 10 52 3 8 CGa 4 1 1 6 5 13 54 3 8 CGa 5 1 1 8 6 16 57 7 8 CGa 6 1 1 9 6 19 60 7 8 CGa 7 1 1 11 7 22 62 1 8 CGa 8 1 1 12 7 25 64 7 8 Note 3 Gas piping from meter to boiler to be sized per local utility requ...

Page 65: ...N for natural gas boiler PIL for Liquefied Petroleum propane gas boiler 2 Based on standard test procedures prescribed by the United States Department of Energy 3 Net AHRI 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 additi...

Page 66: ...ion from the boiler and place it in a plastic bag 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 Thisproductcontains fiberglass jacket insulation and ceramic fibe...

Page 67: ...Part Number 550 142 300 0520 67 CGa Series 3 Gas Fired Water Boiler Boiler Manual Notes ...

Page 68: ...68 CGa Series 3 Gas Fired Water Boiler Boiler Manual Part Number 550 142 300 0520 ...

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