Part Number
550-110-290/0107
3
GOLD CGt Gas-Fired Water Boiler — Boiler Manual
CGt Gas-Fired Water Boiler with tankless heater
Страница 1: ...l 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 proper...
Страница 2: ...as long as there is a call for heat Boiler circulator Theboilercirculatorcirculateswaterthroughtheexternal system piping The circulator is shipped loose and must be mounted a supply to system b retur...
Страница 3: ...Part Number 550 110 290 0107 GOLD CGt Gas Fired Water Boiler Boiler Manual CGt Gas Fired Water Boiler with tankless heater...
Страница 4: ...al 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 o...
Страница 5: ...r 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 u...
Страница 6: ...to keep boiler area clear and free of com bustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage Boiler must be i...
Страница 7: ...s shown in Figure 2 to provide proper air flow around the boiler The free area of each opening after deducting for louvers must be at least one square inch per 1 000 Btuh of boiler input If the buildi...
Страница 8: ...size as determined using the appropriate tables in Part 11 of that code Canadian installations must comply with B149 1 or B149 2 Instal lation Code Chimney or vent require ments 1 Venting must be ins...
Страница 9: ...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 inju...
Страница 10: ...personal injury death or substantial property damage caused by flue gas spillage and carbon monoxide emissions Air opening options Two openings Air supply from inside the building 1 If the building is...
Страница 11: ...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...
Страница 12: ...an only be inserted one way See Figure 35 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 i...
Страница 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 b...
Страница 14: ...23 1 latest edition or in Canada B149 1 or B149 2 Installation Code 2 To prevent downdrafts chimney should extend at least 3 feet above the highest point where it passes through a roof and at least 2...
Страница 15: ...the same vent manufacturer Do not mix components Table 4 Vent system components Obtain vent components Description Saf T Vent StaR 34 Z Vent II FasNSeal Weil McLain part number Saf T Vent part number...
Страница 16: ...r as the vent components Do not mix components from different systems The vent system could fail causing flue gas spillage resulting in severe personal injury or death 3 Follow all applicable national...
Страница 17: ...ommon vent pipe Figure 12 Vent termination minimum clearances 12 Canadian installations See B149 1 or B149 2 Installation Code Terminate vent no less than 6 feet from another combustion air inlet 3 fe...
Страница 18: ...termination coupling with screen not available for StaR 34 6 Do not seal vent pipe slip connector for Saf TVent to inside or outside plate 7 If passing through noncombustible wall provide hole diamete...
Страница 19: ...0107 19 GOLD CGt Gas Fired Water Boiler 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 subs...
Страница 20: ...lex connector into mating connector on 3 way valve Make sure that valve body is in correct position as shown in Figure 39 The circulator is shipped loose wiring pre attached to boiler Pipe the circula...
Страница 21: ...ing sizes Table 5 Water pipe size based on 20 F rise System water piping See Figure 16 and Table 5 for near boiler piping and piping for single zone systems designed for return water at least 130 F Se...
Страница 22: ...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 inFigures 20 or...
Страница 23: ...ent 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 13 Air separa...
Страница 24: ...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 circu...
Страница 25: ...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...
Страница 26: ...oiler water pressure is limited to maximum 30 psig by approved water relief valve If boiler is installed in a closet it is recommended to insulate the supply piping of domestic hot water to lower clos...
Страница 27: ...with the heating boiler Use appropriate valves to prevent chilled medium from entering boiler See Figure 23 for typical installation of balancing valve and check valve If boiler is connected to heati...
Страница 28: ...ly piping during 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 inju...
Страница 29: ...ly with 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Wiring connections Bo...
Страница 30: ...r 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 Fill the system with water 1 C...
Страница 31: ...instructions from Section 9c 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...
Страница 32: ...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 prima...
Страница 33: ...n 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...
Страница 34: ...urge then starts a new cycle b If pilot does light and control module senses flame current spark generator is turned off and main valve opens 5 During main burner operation a Control module monitors p...
Страница 35: ...Part Number 550 110 290 0107 35 GOLD CGt Gas Fired Water Boiler Boiler Manual Operation wiring diagram 9b Figure 29 Schematic and ladder wiring diagram...
Страница 36: ...GOLD CGt Gas Fired Water Boiler Boiler Manual 36 Part Number 550 110 290 0107 9c Operating instructions Spark pilot Natural or propane gas Gas valve Honeywell VR8204 VR8304...
Страница 37: ...Part Number 550 110 290 0107 37 GOLD CGt Gas Fired Water Boiler Boiler Manual Operating instructions 9c Spark pilot Natural or propane gas Gas valve White Rodgers 36E...
Страница 38: ...GOLD CGt Gas Fired Water Boiler Boiler Manual 38 Part Number 550 110 290 0107 Operating instructions Spark pilot Natural or propane gas Gas valve White Rodgers 36C 9c...
Страница 39: ...tenance 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 Failu...
Страница 40: ...nditions 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...
Страница 41: ...he 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...
Страница 42: ...crewed one turn to allow air to escape 3 See Figure 31 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...
Страница 43: ...njury may result If no water flows valve is inoperative Shut down boiler until a new relief valve has been installed 2 Diaphragm or bladder type expansion tanks These tanks are welded gas tight with a...
Страница 44: ...res If using antifreeze in system do not drain 2 Follow shutdown procedure 3 Remove venting system connection to boiler 4 Remove top jacket panel Turn back insulation 5 Remove collector box transition...
Страница 45: ...checker d U tube manometer 2 Check for 120 VAC minimum 102 VAC to maximum 132 VAC to boiler 3 Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Chec...
Страница 46: ...auses 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 block...
Страница 47: ...njury death or substantial property damage Make sure ground wiring is installed per wiring diagram Good grounding is extremely important for proper operation Control indicator lights LOCKOUT modes See...
Страница 48: ...GOLD CGt Gas Fired Water Boiler Boiler Manual 48 Part Number 550 110 290 0107 Troubleshooting components continued 11b Figure 35 Control module connections...
Страница 49: ...SWITCH light flashing FLAME light flashing For insufficient heat or no heat problem go to Chart 7 page 55 if POWER light is on steady with no other light flashing No Yes On steady not flashing No Yes...
Страница 50: ...hermostat 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...
Страница 51: ...age 46 Replace if necessary Retest Try reseating plug in module receptacle and restart If inducer still does not work replace inducer assembly Retest No Yes Wait 45 seconds Does inducer motor operate...
Страница 52: ...n on power to boiler Restart boiler following Operating instructions in this manual Section 9c Do FLAME and POWER lights still flash Boiler should now operate normally Original flashing FLAME light ca...
Страница 53: ...the ohmmeter indicate the switch is closed Inspect and check wire harness from control module to pressure switch Reseat connector in control module receptacle If harness is intact and properly seated...
Страница 54: ...or breaker Check flame signal Detach sense lead from ignition control Figure 35 item 8 page 48 Connect negative lead of MICROAMMETER to control sense terminal Figure 35 item 8 page 48 Connect positive...
Страница 55: ...are set and operating correctly Is vent piping free of blockage No Yes Correct conditions and recheck operation See Figure 28 page 34 for normal sequence of operation Check heat loss calculation versu...
Страница 56: ...GOLD CGt Gas Fired Water Boiler Boiler Manual 56 Part Number 550 110 290 0107 Troubleshooting common problems 11d...
Страница 57: ...Part Number 550 110 290 0107 57 GOLD CGt Gas Fired Water Boiler Boiler Manual Troubleshooting common problems continued 11d...
Страница 58: ...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 McLai...
Страница 59: ...Part Number 550 110 290 0107 59 GOLD CGt Gas Fired Water Boiler Boiler Manual Replacement parts section assembly 12b Figure 36 Section assembly...
Страница 60: ...GOLD CGt Gas Fired Water Boiler Boiler Manual 60 Part Number 550 110 290 0107 Replacement parts base 12c Figure 37 Base assembly...
Страница 61: ...5 Base 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 Rea...
Страница 62: ...GOLD CGt Gas Fired Water Boiler Boiler Manual 62 Part Number 550 110 290 0107 Replacement parts jacket 12d Figure 38 Jacket assembly...
Страница 63: ...41 3 Jacket panel right side with insulation 431 223 311 4 Jacket panel top front with insulation 381 355 420 5 Jacket panel top rear with insulation 381 355 742 6 Jacket panel door 381 355 742 7 Jack...
Страница 64: ...il 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 wir...
Страница 65: ...36 266 511 044 381 511 044 381 2 Pilot kit w orifice aluminum pilot gas tubing Weil McLain 511 330 080 3 Control module United Technologies 1107 1 511 330 090 4 Air pressure switch 1 53 w c Tri Delta...
Страница 66: ...GOLD CGt Gas Fired Water Boiler Boiler Manual 66 Part Number 550 110 290 0107 Dimensions 13a Figure 41 Dimensional drawing...
Страница 67: ...are based on a piping and pickup allowance of 1 15 An additional allowance should be made for unusual piping and pickup loads 3 Direct exhaust CGt boilers require special venting consistent with Cate...
Страница 68: ...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 imm...
