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Weil-McLain CGA25SPDN manual

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Table of contents for the manual

  • Page 1

    P ar t No . 550-101-009/0107 This manual must only be used by a qualified heating installer/service technician. Before installing , 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 substantial property da[...]

  • Page 2

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 2 P ar t Number 550-101-009/0107 How it works . . . x Control module The control module (used on SPARKIGNITED PILOTBOILER S ) responds to signals from the room thermostat and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and vent damper. When room thermosta[...]

  • Page 3

    P ar t Number 550-101-009/0107 3 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual GOLD CGa Gas-Fir ed W ater Boiler[...]

  • Page 4

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 4 P ar t Number 550-101-009/0107 Contents Hazar d 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. Indicates presence of hazards that WILL[...]

  • Page 5

    P ar t Number 550-101-009/0107 5 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage. Please r ead befor e pr oceeding s #ONTINUAL FRESH MAKEUP WATER WILL REDUCE boiler life. Mineral buildup in sections re-[...]

  • Page 6

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 6 P ar t Number 550-101-009/0107 Pr epar e boiler location — codes & checklist 1a Installations must follow these codes: s ,OCALSTATEPROVINCIALANDNATIONALCODESLA ws, regulations and ordinances. s .ATIONAL&UEL'AS#ODE!.3):?[...]

  • Page 7

    P ar t Number 550-101-009/0107 7 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — clearances 1b &IGUREB Required MINIMUM clearances .EVER INSTALL THE BOILER IN A SPACE WITH CLEAR  ANCES LESS THAN THE MINIMUM CLEARANCES SHOWN IN &IGUREB . Failur[...]

  • Page 8

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 8 P ar t Number 550-101-009/0107 Pr epar e 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 r emoving boiler from an existing common vent system: At the time of removal[...]

  • Page 9

    P ar t Number 550-101-009/0107  GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — air contamination 4 ABLE Corrosive contaminants and likely locations 1d Please review the following information on potential combustion air contamination problems. Refer to 4A B L E   for products and areas which may ca[...]

  • Page 10

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 10 P ar t Number 550-101-009/0107 Pr epar e boiler location — air openings 1e Air openings must be pr ovided #OMBUSTIONAIRAND VENTILATIONOPENINGSMUSTCOMPLY THE.ATIONAL&UEL 'AS #ODE !.3) :LATEST EDITION OR APPLICABLE [...]

  • Page 11

    P ar t Number 550-101-009/0107 11 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Unusually tight construction 5NUSUALLY TIGHT CONSTRUCTION MEANS PER !.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[...]

  • Page 12

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 12 P ar t Number 550-101-009/0107 Pr epar e boiler — placement and setup 2a Inspect orifices and bur ners 1. Remove front jacket door. Remove base access panel (See &IGURE , item  , page 62).   #HECK FOR CORRECTLYSIZED MANIFOLD ORIlCES 3EE 4 ABLE?[...]

  • Page 13

    P ar t Number 550-101-009/0107 13 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler — pr essure test Hydr ostatic pressur e test Pressure test boiler BEFORE attaching water or gas piping or electrical supply (except as noted below). Prepar e boiler for test  2EMOVE THE SHIPPING NIPPLE FROM #'A?[...]

  • Page 14

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 14 P ar t Number 550-101-009/0107 Pr epar e 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 sheet metal screws.  "OTTOM?[...]

  • Page 15

    P ar t Number 550-101-009/0107 15 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Pr epar e 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.  "YPASSING JUMPERING VENT DAM[...]

  • Page 16

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 16 P ar t Number 550-101-009/0107 W ater 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 retur n connections, the return/ drain tee and th[...]

  • Page 17

    P ar t Number 550-101-009/0107 17 GOLD CGa Gas-Fired W ater 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 possible, before inlet side of circulator. See ta[...]

  • Page 18

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 18 P ar t Number 550-101-009/0107 W ater 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 SYS TEMS below, if appl[...]

  • Page 19

    P ar t Number 550-101-009/0107  GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 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 suggestions of &IGURES n  , as applies. Failure to prevent sustained [...]

  • Page 20

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 20 P ar t Number 550-101-009/0107 Failure to PREVENTLO WRETURNWATER TEMPERATURE 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 should include a means of REGUL[...]

  • Page 21

    P ar t Number 550-101-009/0107 21 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 1  "OILERISOLATIONBALANCINGVALVES 2 Flow/check valve 3 System or zone circulator (circulator should cycle with zone valve and switches, using circulator valve or zone control panel) 4 System temperature gauges 5  :ONEVALVE 6  $RAIN?[...]

  • Page 22

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 22 P ar t Number 550-101-009/0107 Failure to PREVENTLO WRETURNWATER TEMPERATURE 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 should include a means of REGUL[...]

  • Page 23

    P ar t Number 550-101-009/0107 23 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 1  "OILERISOLATIONBALANCINGVALVES 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges 5  :ONEVALVE 6  $RAINVALVE 7 System temperature valves (see instructions to the left for adjusting valves) 8  "LE[...]

  • Page 24

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 24 P ar t Number 550-101-009/0107 Failure to PREVENTLO WRETURNWATER TEMPERATURE 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 should include a means of REGUL[...]

  • Page 25

    P ar t Number 550-101-009/0107 25 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual W ater 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 installation of balancing valve and check[...]

  • Page 26

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 26 P ar t Number 550-101-009/0107 Gas piping Natural Gas: 1. Refer to 4 ABLE  FORPIPE LENGTHAND DIAMETER"ASE on rated boiler input (divide by 1,000 to obtain cubic feet per hour). 4 ABLE is only for gas with SPECIlC GRAVITY   WITH [...]

  • Page 27

    P ar t Number 550-101-009/0107 27 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Field wiring For your safety, TURN OFF ELECTRICAL POWER SUPPLY AT SERVICE ENTRANCE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or de[...]

  • Page 28

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 28 P ar t Number 550-101-009/0107 Start-up — pr eparation 6a Check for gas leaks  "EFORESTARTINGTHEBOILERANDDUR - 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 t[...]

  • Page 29

    P ar t Number 550-101-009/0107  GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Fill the system with water  #LOSEMANUALANDAUTOMATIC AIRVENTS and boiler drain cock. 2. &ILLTO CORRECTSYSTEMPRESSURE #ORRECT PRESSUREWILLVARY WITHEACH application. Typical cold water fill pressure [...]

  • Page 30

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 30 P ar t 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 could result in severe personal inj[...]

  • Page 31

    P ar t Number 550-101-009/0107 31 GOLD CGa Gas-Fired W ater 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, and causing sect[...]

  • Page 32

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 32 P ar t Number 550-101-009/0107 Start-up — verify operation 6d  4HEBOILER MODELSUFlX WILLBEh 30$ v &ORSPARKIGNITED PILOTBOILERS SUFlXh 0)$ vSEE 3ECTION or  for operation and lighting/operating information. &IGURE[...]

  • Page 33

    P ar t Number 550-101-009/0107 33 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Installation and service certificate "OILERMODEL??????????????????  3ERIES??????????  #0NUMBER???????????  $ATEINSTALLED??????????? -EASURED"TUHINPUT??????[...]

  • Page 34

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 34 P ar t 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 severe personal injury, death or substa[...]

  • Page 35

    P ar t Number 550-101-009/0107 35 GOLD CGa Gas-Fired W ater 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 W ater Boiler — Boiler Manual 36 P ar t Number 550-101-009/0107 Lighting instructions CGa-25 to CGa-8 8b s3TANDINGPILOTs.ATURALGAS s'ASVALVE 2OBER TSHA W[...]

  • Page 37

    P ar t Number 550-101-009/0107 37 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Figure 24  Ignition contr ol 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 boiler. Failure to do so could result in [...]

  • Page 38

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 38 P ar t Number 550-101-009/0107 Figure 25a  Schematic wiring diagram — Spark-ignited pilot system Operation — spark-ignited pilot system (continued) 9a[...]

  • Page 39

    P ar t Number 550-101-009/0107  GOLD CGa Gas-Fired W ater 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 W ater Boiler — Boiler Manual 40 P ar t 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

    P ar t Number 550-101-009/0107 41 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 9b Operating instructions CGa-25 to CGa-6 s3PARKPILOTs.ATURALGAS s'ASVALVE 2OBER TSHA W[...]

  • Page 42

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 42 P ar t Number 550-101-009/0107 9b Operating instructions CGa-25 to CGa-6 s3PARKPILOTs.ATURALGAS s'ASVALVE  7HITE2ODG ER S%[...]

  • Page 43

    P ar t Number 550-101-009/0107 43 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 9b Operating instructions CGa-7 to CGa-8 s3PARKPILOTs.ATURALGAS s'ASVALVE  7HITE2ODG ER S#[...]

  • Page 44

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 44 P ar t Number 550-101-009/0107 Service and maintenance — schedule 10a Follow the 3ERVICE ANDMAINTENANCE 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 sy[...]

  • Page 45

    P ar t Number 550-101-009/0107 45 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Service & maintenance — annual start-up 10b O Inspect . . . Reported problems Inspect any problems reported by owner and correct before proceeding. Boiler area  6ERIFY THAT BOILER AREA IS FREE OF ANY COMBUSTIBLE MATERIALS ,[...]

  • Page 46

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 46 P ar t 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 bright lig[...]

  • Page 47

    P ar t Number 550-101-009/0107 47 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual O Check/test Gas piping 1. Sniff near floor and around boiler area for any in- dication of a GASLEAK . 2. 4 EST GASPIPING USING B UBBLETEST per Section  of this manual, if there is any indication of a leak. Cold fill and operating pressur [...]

  • Page 48

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 48 P ar t 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 ARELIEF VALVE MANUFACTURERSWARNING L[...]

  • Page 49

    P ar t Number 550-101-009/0107  GOLD CGa Gas-Fired W ater Boiler — Boiler Manual O Cleaning boiler heating surfaces 1. Shut down boiler: s &OLLOW h 4 O 4 URN /FF 'AS TO !PPLIANCE v IN - structions on boiler and ,IGHTING OR /PERATING INSTRUCTIONS . s $O NOT DRAIN BOILER UNLESS IT[...]

  • Page 50

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 50 P ar t Number 550-101-009/0107 T r oubleshooting — pr ocedur e (continued) 11a Check the following: 1. Wire connectors to control module are securely plugged in at module and originating control.  'ASPRESSURES A 7ITHBOILEROFFvWCMAXIMUM[...]

  • Page 51

    P ar t Number 550-101-009/0107 51 GOLD CGa Gas-Fired W ater 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 contacts or check for loose wire connections.[...]

  • Page 52

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 52 P ar t Number 550-101-009/0107 T r oubleshooting — spark-pilot boilers 11c The information on this page and PAGES  THROUGH  APPLY ONLY TO SPARKIGNITED PILOT #'A BOILERS  These boilers are equipped with an ignition control module that has [...]

  • Page 53

    P ar t Number 550-101-009/0107 53 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — spark-pilot boilers (continued) 11c[...]

  • Page 54

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 54 P ar t 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, dea th or substantial property damage. Problem is with incoming electricity. Have licensed electrician [...]

  • Page 55

    P ar t Number 550-101-009/0107 55 GOLD CGa Gas-Fired W ater 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 voltage across the two external thermostat circ[...]

  • Page 56

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 56 P ar t Number 550-101-009/0107 • Reset boiler control by turning off power at service switch or turning down the rmostat for at least 45 seconds. • Thermostat should call for heat and appropriate zone valves open. The TSTAT CI RC and LIMIT lights should come on. Does vent damper operate? Ele[...]

  • Page 57

    P ar t Number 550-101-009/0107 57 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual • Turn off power to the boiler at service switch or breaker. • Wait at least 45 seconds. • Turn on power to boile r. • Restart boiler, fo llowing Operating instructions in this manual (Section 9b) or on boiler label. • Look through the pilot inspection po[...]

  • Page 58

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 58 P ar t 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. max Propane — 11.0" w.c. mi[...]

  • Page 59

    P ar t Number 550-101-009/0107  GOLD CGa Gas-Fired W ater 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 replace rollout switch. • Boiler is [...]

  • Page 60

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 60 P ar t Number 550-101-009/0107 Replacement parts 12a Section as sembly .............................................. 61 Base .................................................................. 62 Jacket ............................................................... 63 T rim ....................[...]

  • Page 61

    P ar t Number 550-101-009/0107 61 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Replacement parts — section assembly 12b Item numbe r Description Weil-McLain part number 1 End section, left hand, 51 124 31 1-1 03-830 2 End section, right hand, 51 128 31 1-1 03-821 3 Intermediate section, 51 125 31 1-1 03-818 not shown Replacement section ass[...]

  • Page 62

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 62 P ar t 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, air box g ask ets, and har[...]

  • Page 63

    P ar t Number 550-101-009/0107 63 GOLD CGa Gas-Fired W ater 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 front Natural Gas Standing Pilot P[...]

  • Page 64

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 64 P ar t Number 550-101-009/0107 Replacement parts — trim 12e &IGURE T rim assembly Item numbe r Description Manufa cturer Manufacturer’ s par t number We il - M c La i n part number 1 Pressure relief valv e, ASME, 30 PSIG, ¾" male inlet Pressure relief valv e, ASME, 30 P[...]

  • Page 65

    P ar t Number 550-101-009/0107 65 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Replacement parts — contr ols 12f &IGURE Gas control assembly Item number Description Manufacturer Manufacturer’ s part number Weil-McLain part number Standing pilot — Natural gas components 1 Gas valve, 1 / 2 " x 1 / 2 ", CGa-25 thr[...]

  • Page 66

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 66 P ar t Number 550-101-009/0107 Dimensions 13a Figure 36  Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler model number Supply tapping (inches NPT) Return tapping (inches NPT) Gas connection & manifold size (Note 3) (inches NPT) “A” Vent location (inches) “D” Vent diameter ([...]

  • Page 67

    P ar t Number 550-101-009/0107 67 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Ratings  )NSTALL #'A BOILERS FOR RESIDENTIAL RADIANT PANEL SYSTEMS CONVERTED GRAVITY HEATING SYSTEMS OR OTHER LOW WATER temperature applications per instructions in this manual to avoid damage due to conden[...]

  • Page 68

    GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 68 P ar t Number 550-101-009/0107 Handling ceramic fiber and fiber glass materials REMOV AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The combustion chamber lining or base insulation panels in this prod- uct contain ceramic fiber materials. #ERAMIC FIBERS CAN BE CONVERTED TO[...]