Weil-McLain CGA25SPDN - Manuals

Page 2 - GOLD CGa Gas-Fired Water Boiler — Boiler Manual; SPARKIGNITEDPILOTBOILERS; Other boiler components:

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 2 Part Number 550-101-009/0107 How it works . . . x Control module The control module (used on SPARKIGNITEDPILOTBOILERS ) responds to signals from the room thermostat and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve an...

Page 3 - GOLD CGa Gas-Fired Water Boiler

Part Number 550-101-009/0107 3 GOLD CGa Gas-Fired Water Boiler — Boiler Manual GOLD CGa Gas-Fired Water Boiler

Page 4 - Contents; Hazard definitions

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 4 Part Number 550-101-009/0107 Contents Hazard deﬁnitions The following deﬁned terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. In...

Page 5 - Please read before proceeding; Glycol — potential fire hazard —; Installer; User

Part Number 550-101-009/0107 5 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage. Please read before proceeding s #ONTINUAL FRESH MAKEUP WATER WILL REDUCE boiler life. Mineral bu...

Page 6 - Prepare boiler location — codes & checklist; Installations must follow these codes:

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 6 Part Number 550-101-009/0107 Prepare boiler location — codes & checklist 1a Installations must follow these codes: s ,OCALSTATEPROVINCIALANDNATIONALCODESLA ws, regulations and ordinances. s .ATIONAL&UEL'AS#ODE!.3):nLATESTEDITIONs 3TANDARDFOR#...

Page 7 - Prepare boiler location — clearances; Foundation

Part Number 550-101-009/0107 7 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances 1b &IGUREB Required MINIMUM clearances .EVER INSTALL THE BOILER IN A SPACE WITH CLEARANCESLESSTHANTHEMINIMUMCLEARANCESSHOWNIN&IGUREB . Failure to comply can result in severe pe...

Page 8 - Prepare boiler location — vent system

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 8 Part Number 550-101-009/0107 Prepare boiler location — vent system 1c Failure to follow all instructions can result in ﬂue gas spillage and carbon monoxide emissions, causing severe personal injury or death. When removing boiler from an existing comm...

Page 9 - Prepare boiler location — air contamination

Part Number 550-101-009/0107 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air contamination 4ABLE Corrosive contaminants and likely locations 1d Please review the following information on potential combustion air contamination problems. Refer to 4ABLE for products and ar...

Page 10 - Prepare boiler location — air openings; Air openings must be provided

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 10 Part Number 550-101-009/0107 Prepare boiler location — air openings 1e Air openings must be provided #OMBUSTIONAIRANDVENTILATIONOPENINGSMUSTCOMPLYTHE.ATIONAL&UEL'AS#ODE!.3):LATESTEDITIONORAPPLICABLELOCALBUILDINGCODES#ANADIAN INSTALLATIONS MUST C...

Page 11 - Unusually tight construction; Motorized air dampers; Exhaust fans and air movers; Single air opening option; Exception for large spaces

Part Number 550-101-009/0107 11 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Unusually tight construction 5NUSUALLYTIGHTCONSTRUCTIONMEANSPER!.3): buildings in which:a. Walls and ceilings exposed to the outside atmo- sphere have a continuous water vapor retarder with a rating of 1 perm or less wit...

Page 12 - Prepare boiler — placement and setup; Inspect orifices and burners; Orifice replacement procedure

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 12 Part Number 550-101-009/0107 Prepare boiler — placement and setup 2a Inspect oriﬁces and burners 1. Remove front jacket door. Remove base access panel (See &IGURE , item , page 62). #HECK FOR CORRECTLYSIZED MANIFOLD ORIlCES 3EE 4ABLE below for s...

Page 13 - Prepare boiler — pressure test; Hydrostatic pressure test; Prepare boiler for test; Fill and pressure test; Drain and remove fittings

Part Number 550-101-009/0107 13 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test Pressure test boiler BEFORE attaching water or gas piping or electrical supply (except as noted below). Prepare boiler for test 2EMOVE THE SHIPPING NIPPLE FROM #'A...

Page 14 - Prepare boiler — draft hood & spill switch; Draft hood installation; Spill switch installation; Prepare boiler — install vent piping

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 14 Part Number 550-101-009/0107 Prepare boiler — draft hood & spill switch Draft hood installation 1. Orient draft hood with spill switch mounting holes to front of boiler as shown in Figure 7. 2. Secure draft hood to outlet at top of boiler with s...

Page 15 - Prepare boiler — vent damper installation; Installation; Minimum clearances

Part Number 550-101-009/0107 15 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — vent damper installation 4. Read and apply the harness plug warning label (shown above) so that it is visible after installa-tion. 5. Plug damper harness receptacle into damper harness plug. "YPASSIN...

Page 16 - Water piping — general information; General piping information

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 16 Part Number 550-101-009/0107 Water piping — general information 3a Boiler model To system From system CGa-25 ¾" ¾" CGa-3, 4, 5 1" 1" CGa-6, 7 1 ¼" 1 ¼" CGa-8 1 ½" 1 ½" Note: The boiler supply and return connections, t...

Page 17 - Closed-type expansion tank; Water piping — single-zone system

Part Number 550-101-009/0107 17 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Diaphragm-type or bladder-type expansion tank (Figure 9) 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possib...

Page 18 - Water piping — multiple zones; Piping multiple zones; Radiant heating systems

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 18 Part Number 550-101-009/0107 Water piping — multiple zones Piping multiple zones Follow instructions on pages 16 and 17 to install near-boiler or single-zone piping. (Also refer to 0IPING FOR RADIANT HEATING SYSTEMS OR CONVERTED GRAVITY SYSTEMS belo...

Page 20 - Bypass piping method; Temperature gauges; Piping — low temperature systems

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 20 Part Number 550-101-009/0107 Failure to PREVENTLOWRETURNWATERTEMPERATURE to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage. Radiant heating system piping ...

Page 24 - Valve adjustment

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 24 Part Number 550-101-009/0107 Failure to PREVENTLOWRETURNWATERTEMPERATURE to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage. Radiant heating system piping ...

Page 25 - Water piping — refrigeration systems

Part Number 550-101-009/0107 25 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — refrigeration systems 3e Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 18 for typical...

Page 26 - Gas piping; Connect gas supply piping to boiler

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 26 Part Number 550-101-009/0107 Gas piping Natural Gas: 1. Refer to 4ABLE FORPIPELENGTHANDDIAMETER"ASE on rated boiler input (divide by 1,000 to obtain cubic feet per hour). 4ABLE is only for gas with SPECIlC GRAVITY WITH A PRESSURE DROP THROUGH TH...

Page 27 - Field wiring; Wiring connections

Part Number 550-101-009/0107 27 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Field wiring For your safety, TURN OFF ELECTRICAL POWER SUPPLY AT SERVICEENTRANCEPANELBEFOREMAKINGANYELECTRICALCONNECTIONS to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or dea...

Page 28 - Start-up — preparation; Check for gas leaks; Verify water chemistry

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 28 Part Number 550-101-009/0107 Start-up — preparation 6a Check for gas leaks "EFORESTARTINGTHEBOILERANDDUR - ing initial operation, smell near the ﬂoor and around the boiler for gas ODORANT OR ANY UNUSUAL ODOR $O not proceed with start-up if there...

Page 29 - Inspect system water piping

Part Number 550-101-009/0107 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Fill the system with water #LOSEMANUALANDAUTOMATIC AIRVENTS and boiler drain cock. 2. &ILLTOCORRECTSYSTEMPRESSURE #ORRECTPRESSUREWILLVARYWITHEACH application. Typical cold water ﬁll pressure for a residential system is ...

Page 30 - Start-up — operate boiler

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 30 Part Number 550-101-009/0107 Start-up — operate boiler 6b $/./4 proceed with boiler operation unless boiler and system have been ﬁlled with water and all instruc-tions and procedures of previous manual sections have been completed. Failure to do so ...

Page 31 - Start the boiler

Part Number 550-101-009/0107 31 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — if boiler doesn’t start . . . 6c Check for: %LIMINATE ALL SYSTEM LEAKS #ONTINUAL FRESH MAKEUP WATER will reduce boiler life. Minerals can build up in sections, reduc-ing heat transfer, overheating cast iron, a...

Page 32 - Start-up — verify operation; Check vent system operation; Pilot burner flame; Main burner flame; Check vent damper operation

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 32 Part Number 550-101-009/0107 Start-up — verify operation 6d 4HEBOILERMODELSUFlXWILLBEh 30$ v&ORSPARKIGNITEDPILOTBOILERSSUFlXh 0)$ v SEE 3ECTION or for operation and lighting/operating information. &IGURE Typical main burner ﬂame &IGURE T...

Page 33 - Installation and service certificate; Check-out procedure — checklist

Part Number 550-101-009/0107 33 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Installation and service certiﬁcate "OILERMODEL??????????????????3ERIES??????????#0NUMBER???????????$ATEINSTALLED??????????? -EASURED"TUHINPUT???????????????????? )NSTALLER????????????????????????????????????????...

Page 34 - Operation — standing pilot boilers

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 34 Part Number 550-101-009/0107 Operation — standing pilot boilers 8a Figure 23 Wiring diagram — Standing pilot system Follow all procedures given in this manual and light-ing instructions when operating the boiler. Failure to do so could result in sev...

Page 37 - Operation — spark-ignited pilot boilers

Part Number 550-101-009/0107 37 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Figure 24 Ignition control module sequence of operation — status light indications Operation — spark-ignited pilot boilers 9a Follow all procedures given in this manual and operating instructions when operating the boile...

Page 38 - Operation — spark-ignited pilot system

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 44 - Service and maintenance — schedule; Service technician; NNNUAL; VERIFY PROPER OPERATION AFTER SERVICING

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 ...

Page 46 - Boiler heating surfaces

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 46 Part Number 550-101-009/0107 Service & maintenance – annual start-up (cont.) 10b O Inspect . . . Boiler heating surfaces $ISCONNECT THE VENT PIPE AT THE BOILER DRAFT HOOD and remove draft hood after turning off power to the boiler. 2. Use a brig...

Page 47 - Limit controls and cutoffs

Part Number 550-101-009/0107 47 GOLD CGa Gas-Fired Water Boiler — Boiler Manual O Check/test Gas piping 1. Sniff near ﬂoor and around boiler area for any in- dication of a GASLEAK . 2. 4ESTGASPIPINGUSINGBUBBLETEST per Section of this manual, if there is any indication of a leak. Cold ﬁll and operati...

Page 48 - Boiler relief valve; Review with owner

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 48 Part Number 550-101-009/0107 Service & maintenance – annual start-up (cont.) 10b O Check/test (continued) Boiler relief valve 1. Inspect the relief valve and lift the lever to verify ﬂow as in the following warnings, excerpted from ARELIEFVALVEM...

Page 49 - Cleaning boiler heating surfaces; Before troubleshooting:; Troubleshooting — procedure

Part Number 550-101-009/0107 GOLD CGa Gas-Fired Water Boiler — Boiler Manual O Cleaning boiler heating surfaces 1. Shut down boiler: s &OLLOW h 4O4URN /FF 'AS TO !PPLIANCE v IN - structions on boiler and ,IGHTINGOR/PERATING INSTRUCTIONS . s $O NOT DRAIN BOILER UNLESS IT WILL BE EXPOSED to freezi...

Page 50 - Effikal or Field Controls damper

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 50 Part Number 550-101-009/0107 Troubleshooting — procedure (continued) 11a Check the following: 1. Wire connectors to control module are securely plugged in at module and originating control. 'ASPRESSURES A 7ITHBOILEROFFvWCMAXIMUMNATURAL or propane g...

Page 51 - CHART 1; Standing pilot; — Boiler will not fire; Troubleshooting — standing pilot boilers

Part Number 550-101-009/0107 51 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Is 24VAC present across transformer terminals C & Y ? Is damper harness securely plugged in at both ends? Secure connections. Check for open thermostat, LWCO, high limit, spill switch or rollout thermal fuse element ...

Page 52 - Troubleshooting — spark-pilot boilers; Control module; Control indicator lights —

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 52 Part Number 550-101-009/0107 Troubleshooting — spark-pilot boilers 11c The information on this page and PAGES THROUGH APPLY ONLY TOSPARKIGNITED PILOT #'A BOILERS These boilers are equipped with an ignition control module that has in-dicator lights t...

Page 54 - CHART 2; POWER; light status

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 54 Part Number 550-101-009/0107 11c Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. Problem is with incomi...

Page 55 - CHART 3

Part Number 550-101-009/0107 55 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. No Yes Did you find a volt...

Page 56 - CHART 4; DAMPER; light flashing

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 56 Part Number 550-101-009/0107 • Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds.• Thermostat should call for heat and appropriate zone valves open. The TSTAT CIRC and LIMIT lights should ...

Page 57 - CHART 5

Part Number 550-101-009/0107 57 GOLD CGa Gas-Fired Water Boiler — Boiler Manual • Turn off power to the 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. • Look t...

Page 58 - CHART 6; FLAME; light flashing and; light on steady; ALSO; — Troubleshooting failure to establish main flame

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 58 Part Number 550-101-009/0107 • TURN OFF POWER to boiler at service switch or breaker. • Remove base access panel (see Figure 32, item 4 , page 62 for location). • Verify inlet gas pressure at gas valve: Natural gas — 5.0" w.c. min/14.0" w.c....

Page 59 - CHART 7

Part Number 550-101-009/0107 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. • Reset spill switch, or repl...

Page 60 - Replacement parts

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 60 Part Number 550-101-009/0107 Replacement parts 12a Section as sembly .............................................. 61 Base .................................................................. 62 Jacket ...................................................

Page 61 - Replacement parts — section assembly

Part Number 550-101-009/0107 61 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — section assembly 12b Item number Description Weil-McLain part number 1 End section, left hand, 51124 311-103-830 2 End section, right hand, 51128 311-103-821 3 Intermediate section, 51125 311-103-818 ...

Page 62 - Replacement parts — base

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 62 Part Number 550-101-009/0107 Replacement parts — base 12c &IGURE Base assembly, manifold, oriﬁces and burners Item number Description Weil-McLain part number Base assembly kit(includes base panels items 1, 2, 3, 4, 5, 6, and 7, plus insulation, ...

Page 63 - Replacement parts — jacket

Part Number 550-101-009/0107 63 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — jacket 12d &IGURE Jacket assembly Boiler Model 1 2 3 4 Boiler Model Junction box, 2 x 4 Jacket panel, left side , with insulation Jacket panel, right side , with insula- tion Jacket panel, top fro...

Page 64 - Replacement parts — trim

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 64 Part Number 550-101-009/0107 Replacement parts — trim 12e &IGURE Trim assembly Itemnumber Description Manufacturer Manufacturer’s part number Weil-McLainpart number 1 Pressure relief valve, ASME, 30 PSIG, ¾" male inlet Pressure relief valve,...

Page 65 - Replacement parts — controls

Part Number 550-101-009/0107 65 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — controls 12f &IGURE Gas control assembly Itemnumber Description Manufacturer Manufacturer’spart number Weil-McLain part number Standing pilot — Natural gas components 1 Gas valve, 1 / 2 " x 1 ...

Page 66 - Dimensions

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 66 Part Number 550-101-009/0107 Dimensions 13a Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES Boilermodelnumber Supply tapping (inches NPT) Return tapping (inches NPT) Gas connection& manifold size (Note 3) (inches NPT) “A” Vent location ...

Page 67 - Ratings; DOE

Part Number 550-101-009/0107 67 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Ratings )NSTALL#'ABOILERSFORRESIDENTIALRADIANTPANELSYSTEMSCONVERTEDGRAVITYHEATINGSYSTEMSOROTHERLOWWATER temperature applications per instructions in this manual to avoid damage due to condensation. #'ABOILERSARE#3!DESIGN...

Page 68 - Handling ceramic fiber and fiberglass materials

GOLD CGa Gas-Fired Water Boiler — Boiler Manual 68 Part Number 550-101-009/0107 Handling ceramic ﬁber and ﬁberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this prod-uct contain ceramic ﬁber materials. #ERAMIC FIBERS CA...