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GOLD CGa Gas-Fired Water Boiler — Boiler Manual

44

Part Number 

550-101-009/0107

Service and maintenance — schedule

10a

 Follow 

the 

3ERVICEANDMAINTENANCE

 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 could result in severe personal injury, death or substantial property 
damage.

4ABLE

Service and maintenance schedules (service technician and user)

Service technician

(see following pages for instructions)

Owner maintenance

(see CGa User’s Information Manual for instructions)

A

NNNUAL

 

STAR

T

-

UP

Inspect:

s2EPORTEDPROBLEMS

s"OILERAREA

s!IROPENINGS

s&LUEGASVENTSYSTEM

s0ILOTANDMAINBURNERFLAMES

s7ATERPIPING

s"OILERHEATINGSURFACES

s"URNERSANDBASE

Service:

s/ILEDBEARINGCIRCULATORS

Start-up:

s0ERFORMSTARTUPPERMANUAL

Check/test:

s'ASPIPING

s#OLDFILLANDOPERATINGPRESSURES

s!IRVENTSANDAIRELIMINATION

s,IMITCONTROLSANDCUTOFFS

s%XPANSIONTANK

s"OILERRELIEFVALVE

Review:

s2EVIEWWITHOWNER

Daily

s#HECKBOILERAREA

s#HECKAIROPENINGS

s#HECKBOILERPRESSURE

TEMPERATUREGAUGE

Monthly

s#HECKBOILERINTERIORPIPING

s#HECKVENTINGSYSTEM

s#HECKAIRVENTS

s#HECKBOILERRELIEFVALVE

s#HECKAUTOMATICAIRVENTSIF

USED 

Periodically

s4ESTLOWWATERCUTOFFIFUSED 

Every 6 months

s/PERATERELIEFVALVE

End of season

s3HUTDOWNPROCEDURE

VERIFY PROPER OPERATION AFTER SERVICING

Содержание GOLD CGa-25

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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