Weil McLain Boiler CGA25SPDN User Manual

®
GOLD CGa  
Gas-Fired Water Boilers  
s )NSTALLATION s -AINTENANCE  
Boiler Manual  
s 3TARTUP  
s 0ARTS  
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 damage.  
Part No. 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
GOLD CGa Gas-Fired Water Boiler  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
Contents  
How is works....................................................2-3  
Hazard definitions ............................................... 4  
Please read before proceeding............................ 5  
1 Prepare boiler location...................................6–11  
2 Prepare boiler...............................................12-15  
3 Waterpiping.................................................16-25  
4 Gas piping ......................................................... 26  
5 Field wiring ....................................................... 27  
6 Start-up........................................................28-32  
7 Check-outpr ocedure......................................... 33  
8 Operation – standing pilot boilers.................34-36  
9 Operation – spark-ignited pilot boilers..........37-43  
10 Service and maintenance .............................44-49  
11 Troubleshooting:  
Standing pilot boilers .............................49-50, 51  
Spark-ignited pilot boilers .................49-50, 51-59  
12 Replacement parts .......................................60-65  
13 Dimensions and ratings................................66-67  
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.  
Indicates presence of hazards that WILL CAUSE SEVERE personal injury, death or substantial  
property damage.  
Indicates presence of hazards that CAN CAUSE SEVERE personal 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 or maintenance that are important but  
not related to personal injury or property damage.  
4
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
Please read before proceeding  
Installer  
User  
2EAD ALL INSTRUCTIONS BEFORE INꢀ  
stalling. Follow all instructions in  
proper order to prevent personal  
injury or death.  
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4HIS MANUAL IS FOR USE ONLY BY YOUR QUALIlED  
HEATING INSTALLERꢁSERVICE TECHNICIANꢂ  
0LEASE REFER TO THE 5SERꢃS )NFORMATION -ANUAL for  
your reference.  
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#ONSIDER PIPING AND INSTALLATION when determining  
boiler location.  
7E RECOMMEND REGULAR SERVICE BY A QUALIlED  
SERVICE TECHNICIANꢄ AT LEAST ANNUALLY.  
!NY CLAIMS FOR DAMAGE OR SHORTAGE IN SHIPMENT  
must be filed immediately against the transportation  
company by the consignee.  
The boiler contains ceramic fiber and fiberglass materials. Use care when handling these  
materials per instructions on page 68 of this manual. Failure to comply could result in severe  
personal injury.  
When calling or writing about the boiler— Please have the boiler model number from the  
BOILER RATING LABEL AND THE #0 NUMBER FROM THE BOILER JACKETꢀ 9OU MAY LIST THE #0 NUMBER IN  
the space provided on the )NSTALLATION AND SERVICE CERTIlCATE found on page 33.  
Failure to adhere to the guidelines on this page can result in severe personal injury, death  
or substantial property damage.  
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#ONTINUAL FRESH MAKEUP WATER WILL REDUCE  
boiler life. Mineral buildup in sections re-  
duces heat transfer, overheats cast iron, and  
causes section failure. Addition of oxygen  
and other gases can cause internal corrosion.  
Leaks in boiler or piping must be repaired  
at once to prevent makeup water.  
When servicing boiler —  
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4O AVOID ELECTRIC SHOCKꢁ DISCONNECT ELECTRICAL SUPPLY  
before performing maintenance.  
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4O AVOID SEVERE BURNSꢁ ALLOW BOILER TO COOL BEFORE  
performing maintenance.  
Boiler operation —  
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$O NOT ADD COLD WATER TO HOT BOILERꢀ 4HERMAL  
shock can cause sections to crack.  
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$O NOT BLOCK mOW OF COMBUSTION OR VENTILATION AIR  
to boiler.  
Glycol — potential fire hazard —  
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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.  
All glycol is flammable when exposed to high  
temperatures. If glycol is allowed 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:  
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$O NOT USE THIS BOILER IF ANY PART HAS BEEN UNDER  
water. Immediately call a qualified service techni-  
cian to inspect the boiler and to replace any part of  
the control system and any gas control that has been  
under water.  
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.EVER STORE GLYCOL OF ANY KIND NEAR THE BOILER  
or any potential ignition source.  
Boiler water —  
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-ONITOR AND INSPECT THE SYSTEM AND BOILER  
regularly for leakage. Repair any leaks im-  
mediately to prevent possible accumulation  
of glycol.  
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$O NOT USE PETROLEUMꢂBASED CLEANING OR SEALING  
compounds in boiler system. Water seal deterioration  
will occur, causing leakage between sections. This can  
result in substantial property damage.  
s
.EVER USE AUTOMOTIVE ANTIFREEZE OR ETHYLENE  
glycol in the system. Using these glycols can  
lead to hazardous leakage of glycol in the  
boiler system.  
s
$O NOT USE hHOMEMADE CURESv OR hBOILER PATENT MEDI-  
CINESvꢀ 3ERIOUS DAMAGE TO BOILERꢁ PERSONNEL ANDꢃOR  
property may result.  
5
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Prepare boiler location — codes & checklist  
1a  
Installations must follow these codes:  
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,OCALꢁ STATEꢁ PROVINCIALꢁ AND NATIONAL CODESꢁ LAws, regulations and ordinances.  
.ATIONAL &UEL 'AS #ODEꢁ !.3) :ꢄꢄꢅꢀꢆnLATEST EDITIONꢀ  
3TANDARD FOR #ONTROLS AND 3AFETY $EVICES FOR !UTOMATICALLY &IRED "OILERSꢁ !.3)ꢃ  
!3-% #3$ꢂꢆꢁ WHEN REQUIREDꢀ  
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.ATIONAL %LECTRICAL #ODEꢀ  
&OR #ANADA ONLYꢇ "ꢆꢈꢉꢀꢆ OR "ꢆꢈꢉꢀꢄ )NSTALLATION #ODEꢁ #3! #ꢄꢄꢀꢆ #ANADIAN  
%LECTRICAL #ODE 0ART ꢆ AND ANY LOCAL COdes.  
4HE #'A BOILER GAS MANIFOLD AND CONTROLS MET SAFE LIGHTING AND  
other performance criteria when boiler underwent tests specified  
IN !.3) :ꢄꢆꢀꢆꢅnLATEST EDITIONꢀ  
Before locating the boiler,  
check the following:  
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#HECK FOR NEARBY CONNECTION TOꢇ  
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3YStem water piping  
6ENTING CONNECTIONS  
'AS SUPPLY PIPING  
%LECtrical power  
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#HECK AREA AROUND BOILERꢀ 2EMOVE ANY COMBUSTIBLE MATERIALSꢄ GASOLINE AND  
OTHER mAMMABLE LIQUIDSꢄ OR OTHER CONTAMINANTS.  
Failure to keep boiler area clear and free of COMBUSTIBLE MATEꢀ  
RIALSꢄ GASOLINE AND OTHER mAMMABLE LIQUIDS AND VAPORS can  
result in severe personal injury, death or substantial property  
damage.  
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"Oiler must be installed so that gas control system components are protected  
from dripping or spraying water or rain during operation or service.  
)F New boiler will replace existing boiler, check for and correct system problems,  
such as:  
1. System leaks causing oxygen corrosion or section cracks from hard water  
deposits.  
2. Incorrectly-sized expansion tank.  
3. Lack of antifreeze in boiler water causing system and boiler to freeze and  
leak.  
6
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
Prepare boiler location — clearances  
1b  
&IGURE ꢅB Required MINIMUM clearances  
$O NOT INSTALL BOILER ON CARPETING EVEN  
if foundation is used. Fire can result,  
causing severe personal injury, death  
or substantial property damage.  
)F ANY CLEARANCE IS LESS THAN IN &IGURE 1aꢄ  
PROVIDE OPENINGS FOR COMBUSTION AND  
VENTILATION AIR located on the wall or door  
opposite the boiler FRONT (see Figure 1b).  
These openings must be located as shown in Figure 1b to provide  
proper air flow around the boiler. The free area of each opening  
Foundation  
(after deducting for louvers) must be at least ONE SQUARE INCH  
PER ꢅꢄꢈꢈꢈ "TUH of 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.  
1. Provide a solid brick or minimum 2-inch thick concrete  
foundation pad if any of the following is true:  
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mOOR CAN BECOME mOODEDꢀ  
THE BOILER MOUNTING AREA IS NOT LEVELꢀ  
If clearances are equal to or greater than Figure 1a, see pages 10  
and 11 for location and sizing of combustion air openings.  
2. Minimum dimensions are ꢉꢊv LENGTH by:  
Minimum foundation width:  
Failure to comply can result in severe personal injury, death or  
substantial property damage and reduced boiler life.  
CGa-25/3  
CGa-4  
CGa-5  
12"  
15"  
18"  
CGa-6  
CGa-7  
CGa-8  
21"  
24"  
27"  
.EVER INSTALL THE BOILER IN A SPACE WITH CLEARꢀ  
ANCES LESS THAN THE MINIMUM CLEARANCES SHOWN  
IN &IGURE ꢅB. Failure to comply can result in severe  
personal injury, death or substantial property  
damage and reduced boiler life.  
Residential garage installations  
Take the following special precautions when installing the  
boiler in a residential garage. If the boiler is located in a  
RESIDENTIAL GARAGEꢁ PER !.3) :ꢄꢄꢅꢀꢆꢇ  
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-OUNT THE BOILER A MINIMUM OF ꢅꢋ INCHES ABOVE THE  
mOOR of the garage to assure the burner and ignition  
devices will be no less than 18 inches above the floor.  
1. (OT WATER PIPESꢆ AT LEAST 56O INCH from combustible material.  
2. 3INGLEꢀWALL VENT PIPEꢆ AT LEAST ꢇ INCHES from combustible mate-  
rial.  
3. 4YPE " DOUBLEꢀWALL METAL VENT PIPE: refer to vent manufacturer’s  
recommendation for clearances to combustible material.  
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,OCATE OR PROTECT THE BOILER so it cannot be damaged  
by a moving vehicle.  
7
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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.  
Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause  
severe personal injury or death.  
$O NOT ALTER BOILER DRAFT HOOD OR PLACE ANY OBSTRUCTION OR NONꢂAPPROVED VENT DAMPER IN BREECHING OR VENT SYSTEMꢀ  
#3! CERTIlCATION WILL BECOME VOIDꢀ &LUE GAS SPILLAGE AND CARBON MONOXIDE EMISSIONS WILL OCCUR CAUSING SEVERE  
personal injury or death.  
When removing boiler from an Chimney or vent require-  
existing common vent system: ments  
At the time of removal of an existing boiler, the following  
steps shall be followed with each appliance remaining  
connected to the common venting system placed in op-  
eration, while the other appliances remaining connected  
to the common venting system are not in operation.  
ꢆꢀ 6ENTING MUST BE INSTALLED ACCORDING TO 0ART ꢊꢁ 6ENT-  
ING OF %QUIPMENTꢁ OF .ATIONAL &UEL 'AS #ODEꢁ !.3)  
:ꢄꢄꢅꢀꢆꢂLATEST EDITION AND APPLICABLE BUILDING CODESꢀ  
#ANADIAN INSTALLATIONS MUST COMPLY WITH "ꢆꢈꢉꢀꢆ OR  
"ꢆꢈꢉꢀꢄ )NSTALLATION #ODESꢀ  
a. 3EAL ANY UNUSED OPENINGS in the common venting  
2. See Ratings table on page 67 for minimum chimney  
or vent sizes. A chimney or vent WITHOUT A LISTED  
CAP should extend AT LEAST ꢌ FEET ABOVE THE HIGHEST  
POINT where it passes through a roof of a building  
and AT LEAST ꢉ FEET HIGHER than ANY PORTION OF A  
BUILDING WITHIN A HORIZONTAL DISTANCE OF ꢅꢈ FEET.  
A chimney or vent must not extend less than the  
distances stated above.  
system.  
b. 6ISUALLY INSPECT THE VENTING SYSTEM for proper  
size and horizontal pitch and determine there is no  
blockage or restriction, leakage, corrosion or other  
deficiencies which could cause an unsafe condi-  
tion.  
c. 4EST VENT SYSTEM — Insofar as is practical, close all  
building doors and windows and all doors between  
the space in which the appliances remaining con-  
nected to the common venting system are located  
and other spaces of the building. Turn on clothes  
dryers and any appliance not connected to the com-  
mon venting system. Turn on any exhaust fans, such  
as range hoods and bathroom exhausts, so they will  
OPERATE AT MAXIMUM SPEEDꢀ $O NOT OPERATE A SUM-  
MER EXHAUST FANꢀ #LOSE lREPLACE DAMPERSꢀ  
3. A lined chimney is preferred and must be used when  
required by local, state, provincial and national  
CODESꢁ LAWSꢁ REGULATIONS AND ORDINANCESꢀ 6ITREOUS TILE  
linings with joints that prevent retention of moisture  
and linings made of noncorrosive materials are best.  
Advice for flue connections and chimney linings can  
be obtained from local gas utility. 4YPE " double-  
wall metal vent pipe or single-wall vent pipe may  
be used as a liner.  
d. 0LACE IN OPERATION the appliance being inspected.  
Follow the lighting/operating instructions. Adjust  
thermostat so appliance will operate continuously.  
ꢈꢀ #OLD MASONRY CHIMNEYSꢁ ALSO KNOWN AS OUTSIDE  
chimneys, typically have one or more walls ex-  
posed to outside air. When any atmospheric gas-  
fired boiler with automatic vent damper is vented  
through this type of chimney, the potential exists for  
CONDENSATION TO OCCURꢀ #ONDENSATION CAN DAMAGE  
a masonry chimney. Weil-McLain recommends the  
following to prevent possible damage.  
e. 4EST FOR SPILLAGE at draft hood relief opening after  
5 minutes of main burner operation. Use the flame  
of a match or candle.  
f. After it has been determined that EACH APPLIANCE  
remaining connected to the common venting system  
properly vents when tested as outlined above, return  
doors, windows, exhaust fans, fireplace dampers,  
and any other gas-burning appliance to their previ-  
ous conditions of use.  
a. Line chimney with corrosion-resistant metal  
LINER SUCH AS !,ꢄꢉꢂꢈ#® SINGLEꢂWALL STAINLESS  
STEEL OR "ꢂVENTꢀ 3IZE LINER PER .ATIONAL &UEL  
'AS #ODE !.3) :ꢄꢄꢅꢀꢆꢂLATEST EDITIONꢀ  
Any improper operation of common venting system  
should be corrected so the installation conforms with  
THE .ATIONAL &UEL 'AS #ODEꢁ !.3) :ꢄꢄꢅꢀꢆꢂLATEST EDITIONꢀ  
#ORRECT BY RESIZING TO APPROACH THE MINIMUM SIZE AS  
determined using the appropriate tables in Part 11 of  
THAT CODEꢀ #ANADIAN INSTALLATIONS MUST COMPLY WITH  
"ꢆꢈꢉꢀꢆ OR "ꢆꢈꢉꢀꢄ )NSTALLATION #ODEꢀ  
b. Provide drain trap to remove any condensate.  
5. Where two or more gas appliances vent into a  
common chimney or vent, equivalent area should  
be AT LEAST EQUAL to area of vent outlet on largest  
appliance PLUS ꢊꢈ PERCENT of vent outlet area on  
additional appliance.  
8
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Prepare boiler location — air contamination  
1d  
Please review the following information on potential Refer to 4ABLE ꢅ for products and areas which may cause  
combustion air contamination problems.  
contaminated combustion air.  
To prevent potential of severe personal injury or death, check for products or areas listed  
below before installing boiler. If any of these contaminants are found:  
s REMOVE CONTAMINANTS PERMANENTLY  
— OR —  
s ISOLATE BOILER AND PROVIDE OUTSIDE COMBUSTION AIRꢀ 3EE NATIONALꢁ PROVINCIAL OR LOCAL CODES  
for further information.  
4ABLE ꢅ Corrosive contaminants and likely locations  
Products to avoid  
Areas likely to have contaminants  
Spray cans containing chloro/fluorocarbons  
Permanent wave solutions  
Dry cleaning/laundry areas and establishments  
Swimming pools  
Chlorinated waxes/cleaners  
Metal fabrication plants  
Chlorine-based swimming pool chemicals  
Calcium chloride used for thawing  
Sodium chloride used for water softening  
Refrigerant leaks  
Beauty shops  
Refrigeration repair shops  
Photo processing plants  
Auto body shops  
Paint or varnish removers  
Plastic manufacturing plants  
Furniture refinishing areas and establishments  
New building construction  
Remodeling areas  
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  
Garages with workshops  
Adhesives used to fasten building products and  
other similar products  
Buildings under construction (where air is  
contaminated with particulates)  
Airborne particulates (drywall dust, fiberglass  
particles, road or gravel dust, lint, etc.)  
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Prepare boiler location — air openings  
1e  
#OMBUSTION AIR OPENING LOCATION AND SIZING  
REQUIREMENTS DEPEND ON THE CLEARANCES AROUND  
THE BOILERꢂ #HECK THE BOILER PLACEMENT COMPARED  
to Figure 1a, page 7.  
)F ALL CLEARANCES ARE AT LEAST EQUAL TO &IGURE ꢅAꢄ  
PAGE ꢍ, apply the sizing and placement of openings  
given on pages 10 and 11.  
)F !.9 CLEARANCE IS LESS THAN &IGURE ꢅAꢄ PAGE ꢍ,  
you must provide air openings sized and located as  
shown in Figure 1b, page 7. $/ ./4 apply the sizing  
and location information shown on page 10 or 11.  
Air openings must be provided  
#OMBUSTION AIR AND VENTILATION OPENINGS MUST COMPLY THE .ATIONAL &UEL  
'AS #ODE !.3) :ꢄꢄꢅꢀꢆꢂLATEST EDITIONꢁ OR APPLICABLE LOCAL BUILDING CODESꢀ  
#ANADIAN INSTALLATIONS MUST COMPLY WITH "ꢆꢈꢉꢀꢆ OR "ꢆꢈꢉꢀꢄ )NSTALLATION  
#ODESꢀ  
Provide adequate combustion and ventilation air to  
assure proper combustion and reduce the risk of severe  
personal injury, death or substantial property damage  
caused by flue gas spillage and carbon monoxide  
emissions.  
10  
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Unusually tight construction  
FREE AREA of openings — the minimum areas  
5NUSUALLY TIGHT CONSTRUCTION MEANS ꢋPER !.3) :ꢄꢄꢅꢀꢆ  
given in this manual are free area (equals the area,  
buildings in which:  
length times width of opening, after deduction for  
louver obstruction).  
a. Walls and ceilings exposed to the outside atmo-  
sphere have a continuous water vapor retarder with  
a rating of 1 perm or less with openings gasketed,  
and . . .  
b. Weather-stripping has been added on openable  
windows and doors, and . . .  
Cꢀ #AULKING OR SEALANTS ARE APPLIED TO AREAS SUCH AS  
joints around windows and door frames, between  
sole plates and floors, between wall-ceiling joints,  
between wall panels, at penetrations for plumbing,  
electrical, and gas lines, and in other openings.  
Use the free area information provided by the louver manufacturer.  
When this information is not available, assume:  
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7OOD LOUVERS ˆ ASSUME FREE AREA IS ꢄꢌꢍ OF TOTALꢎ SO THE ACTUAL AREA  
of each opening with wood louvers would be 5 times the required  
free area.  
-ETAL LOUVERS ˆ ASSUME FREE AREA IS ꢏꢌꢍ OF ACTUAL AREAꢎ SOꢁ FOR WOOD  
louvers, the actual area of each opening must be 1.67 times the  
required free area.  
s
For such construction cases, if appliances use inside air  
for combustion, PROVIDE AIR OPENINGS INTO THE BUILDING  
FROM OUTSIDE. Size and locate these openings per the  
appropriate case in &IGURE ꢌꢄ ꢎ OR ꢊ on page 10.  
Single air opening option  
A single combustion air opening can be used in lieu of the two-opening  
options on page 10, provided:  
7
Clearances from boiler to walls  
s
4HE BOILER MUST HAVE CLEARANCES OF AT LEAST THOSE SHOWN IN &IGURE ꢆAꢁ  
page 7.  
Exhaust fans and air movers  
Opening must be directly to outside  
The appliance space must never be under a negative  
pressure, even if the appliance(s) are installed as direct  
vent. Always provide air openings sized not only to the  
dimensions required for the firing rate of all appli-  
ances, but also to handle the air movement rate of the  
exhaust fans or air movers using air from the building  
or space.  
s
4HE OPENING MUST CONNECT DIRECTLY TO THE OUTDOORS OR TO A SPACE THAT  
communicates directly to the outdoors (not to an interior space).  
s
4HE AIR CAN BE PROVIDED THROUGH A DIRECT OPENING OR THROUGH A HORIZONTAL  
or vertical duct.  
Opening placement  
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4HE TOP OF THE AIR OPENING MUST BE WITHIN ꢆꢄ INCHES OF THE CEILINGꢀ  
Opening size  
Motorized air dampers  
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4HE FREE AREA OF THE OPENING MUST BE AT LEAST EQUAL TO THE SUM OF THE  
area of all equipment vent connectors in the space, and . . .  
If the air openings are fitted with motorized dampers,  
electrically interlock the damper to:  
s
4HE FREE AREA OF THE OPENING MUST BE AT LEAST ꢆ SQUARE INCH PER ꢅꢁꢌꢌꢌ  
"TUꢃHR INPUT RATING OF ALL EQUIPMENT LOCATED IN THE SPACEꢀ  
s
0REVENT THE BOILER FROM lRING IF THE DAMPER IS NOT  
fully open.  
Exception for large spaces  
7
s
3HUT THE BOILER DOWN SHOULD THE DAMPER CLOSE DUR-  
ing boiler operation.  
.O COMBUSTION AIR OPENINGS ARE NEEDED WHEN THE BOILER ꢋAND OTHER AP-  
pliances) are installed in a space with a volume AT LEAST ꢊꢈ CUBIC FEET PER  
ꢅꢄꢈꢈꢈ "TUH of all installed appliances, provided:  
To accomplish this interlock, wire an ISOLATED CONTACT  
(proving the damper open) in series with the thermo-  
stat input to the boiler. The boiler will not start if this  
contact is open, and will shut down should it open  
during operation.  
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THE BUILDING MUST NOT HAVE UNUSUALLY TIGHT CONSTRUCTION (see defini-  
tion, this page)  
s
ALL CLEARANCES AROUND THE BOILER MUST MUST BE NO LESS THAN SHOWN IN  
Figure 1a, page 7.  
To determine if the space is large enough to qualify:  
s
s
s
!DD THE TOTAL INPUT OF ALL APPLIANCES IN -"( ꢋꢆꢁꢌꢌꢌꢐS OF "TUH ꢀ  
-ULTIPLY THIS NUMBER TIMES ꢑꢌ TO DETERMINE MINIMUM ROOM VOLUMEꢀ  
%XAMPLEꢇ &OR A TOTAL INPUT OF ꢆꢌꢌ -"( ꢋꢆꢌꢌꢁꢌꢌꢌ "TUH ꢁ MINIMUM  
volume is 50 x 100 = 5,000 cubic feet. At a ceiling height of 8 feet, the  
space must have at least 5,000 ÷ 8 = 625 square feet (25 feet x 25 feet,  
for instance).  
11  
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Prepare boiler — placement and setup  
2a  
#ORRECTLYꢂSIZED MANIFOLD ORIFICES  
Place boiler/crate near  
position  
must be used. Failure to do so will  
result in severe personal injury,  
death or substantial property dam-  
age.  
1. ,EAVE BOILER IN CRATE AND ON PALLET until installa-  
tion site is ready.  
2. Move entire crate and pallet next to selected loca-  
tion.  
3. Level and straighten burners.  
"URNERS MUST BE PROPERLY SEATED IN  
slots in burner rest with their open-  
ings face up. Main burner orifices  
must inject down center of burner.  
Failure to properly seat burners  
will result in severe personal injury,  
death or substantial property dam-  
age.  
3. Remove crate. ,EAVE BOILER ON PALLETꢂ  
4. Remove boiler from pallet as follows:  
a. Tilt left side of boiler up and place a board under  
left legs.  
b. Tilt boiler the other way and place a board under  
right legs.  
c. Slide boiler backwards off pallet and into posi-  
tion.  
$O NOT DROP BOILER OR BUMP JACKET  
ON mOOR OR PALLETꢀ $AMAGE TO BOILER  
can result.  
4. Reinstall access panel.  
$O NOT OPERATE BOILER WITHOUT AC-  
cess panel secured in place. Failure  
to comply could cause momentary  
flame rollout on ignition of main  
flame, resulting in possible fire or  
personal injury hazard.  
ꢑꢀ #HECK LEVELꢀ  
a. Shim legs, if necessary.  
Bꢀ $O NOT ALTER LEGSꢀ  
Inspect orifices and burners  
1. Remove front jacket door. Remove base access panel  
(See &IGURE ꢌꢉ, item , page 62).  
Orifice replacement procedure  
ꢄꢀ #HECK FOR CORRECTLYꢂSIZED MANIFOLD ORIlCESꢀ 3EE  
4ABLE ꢉ below for sizing. (The orifice size is stamped  
on the orifice spud barrel.)  
(when required)  
1. Remove access panel.  
2. On gas manifold, mark location of main burner with  
attached pilot assembly.  
4ABLE ꢉ Manifold orifice sizing  
Location  
U. S.  
Natural gas  
3. Remove main burner with attached pilot assembly  
from manifold. Remove all remaining burners.  
0-2,000 ft  
over 2,000 ft  
(Note 1)  
4. Remove and discard all main burner orifices in gas  
manifold.  
2.00 mm  
0-2,000 ft  
2.00 mm  
Canada  
2,000-4,500  
1.90 mm  
5. Apply a small amount of pipe dope to each of the  
new orifices and install in the manifold. Make sure  
the orifices are aligned correctly, not cross-threaded  
in the manifold tappings.  
Location  
U. S.  
Propane gas  
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.  
0-2,000 ft  
1.30 mm  
0-2,000 ft  
1.30 mm  
over 2,000 ft  
(Note 1)  
Canada  
2,000-4,500  
1.20 mm  
6. Reinstall main burner with attached pilot assembly  
at location marked on gas manifold. Reinstall all  
remaining burners.  
Note 1: For elevations above 2,000 feet, contact your  
local Weil-McLain sales office for details.  
7. Follow check-out procedure, Section , page 33.  
12  
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Prepare boiler — pressure test  
2b  
ꢈꢀ #LOSE SHUTOFF VALVESꢀ  
5. Slowly reopen boiler drain valve until test pressure  
Hydrostatic pressure test  
Pressure test boiler BEFORE attaching water or gas piping  
of not more than 45 psi is reached on the pressure/  
or electrical supply (except as noted below).  
temperature gauge.  
6. Test at no more than ꢎꢊ PSI FOR NO MORE THAN ꢅꢈ  
Prepare boiler for test  
MINUTESꢂ  
ꢆꢀ 2EMOVE THE SHIPPING NIPPLE ꢋFROM #'A SUPPLY  
tapping) and remove the boiler relief valve. 4EMPOꢀ  
RARILY PLUG THE RELIEF VALVE TAPPING WITH A Ðv .04  
pipe plug.  
$O NOT LEAVE BOILER UNATTENDED.  
A cold water fill could expand and  
cause excessive pressure, resulting  
in severe personal injury, death or  
substantial property damage.  
ꢄꢀ 2EMOVE ꢆv NIPPLEꢁ REDUCING TEE AND DRAIN VALVE  
from accessory bag. Install in boiler return con-  
nection as shown on page 3 or in &IGURE ꢌꢎ, item  
3, page 64. Install circulator on either the return or  
supply.  
7. Make sure constant gauge pressure has been main-  
TAINED THROUGHOUT TESTꢀ #HECK FOR LEAKSꢀ 2EPAIR IF  
found.  
ꢅꢀ 2EMOVE ꢆv NIPPLEꢁ ꢆv TEEꢁ BUSHING AND PRES-  
sure/temperature gauge from accessory bag. Pipe  
to boiler supply connection as shown in &IGURE ꢌꢎ,  
page 64. (Use pipe dope sparingly.)  
,EAKS MUST BE REPAIRED AT ONCE.  
Failure to do so can damage boiler,  
resulting in substantial property  
damage.  
ꢈꢀ #ONNECT A HOSE TO BOILER DRAIN VALVEꢁ THE OTHER END  
connected to a fresh water supply. Make sure hose  
can also be used to drain boiler after test.  
$O NOT USE PETROLEUMꢀBASED clean-  
ing or sealing compounds in boiler  
system. Severe damage to boiler  
will occur, resulting in substantial  
property damage.  
ꢑꢀ #ONNECT A NIPPLE AND SHUTOFF VALVE TO SYSTEM SUPPLY  
CONNECTION ON THE ꢆv TEEꢀ 4HIS VALVE WILL BE USED  
TO BLEED AIR DURING THE lLLꢀ ꢋ6ALVE AND NIPPLE ARE  
not included with boiler.)  
ꢏꢀ #ONNECT A NIPPLE AND SHUTOFF VALVE TO SYSTEM  
return connection (at circulator flange if circula-  
tor installed on return). This valve will be used to  
BLEED AIR DURING THE lLLꢀ ꢋ6ALVE AND NIPPLE ARE NOT  
included with boiler.)  
Drain and remove fittings  
ꢆꢀ $ISCONNECT lLL WATER HOSE FROM WATER SOURCEꢀ  
ꢄꢀ $RAIN BOILER AT DRAIN VALVE OR OUT HOSEꢁ WHICHEVER  
provides best access to drain. Remove hose after  
draining if used to drain boiler.  
Fill and pressure test  
1. Open the shutoff valves you installed on supply and  
return connections.  
3. Remove nipples and valves unless they will remain  
for use in the system piping.  
2. Slowly open boiler drain valve and fresh water sup-  
ply to fill boiler with water.  
4. Remove plug from relief valve tapping. See Section ꢌ  
3. When water flows from shutoff valves, close boiler  
drain valve.  
to replace relief valve.  
13  
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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.  
Spill switch installation  
1. Fasten spill switch to draft hood as shown in &IGURE ꢇ  
and &IGURE ꢍ.  
2. See Wiring diagram to connect wires:  
2. Secure draft hood to outlet at top of boiler with sheet metal screws.  
a. Standing pilot boiler — see PAGE ꢌꢎ.  
ꢅꢀ "OTTOM OF DRAFT HOOD OR hSKIRTv MUST HAVE CLEARANCE DIMENSION ABOVE  
b. Spark-ignited pilot boiler —  
jacket top panel as indicated on draft hood.  
see PAGES ꢌꢋ and ꢌꢏ.  
$O NOT ALTER BOILER DRAFT HOOD OR PLACE ANY OBSTRUCTION OR  
non-approved vent damper in breeching or vent system.  
#3! CERTIlCATION WILL BECOME VOIDꢀ &LUE GAS SPILLAGE AND  
carbon monoxide emissions will occur causing severe  
personal injury or death.  
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  
ꢆꢀ #ONNECT FROM DRAFT HOOD OR VENT DAMPER OUTLET TO CHIMNEY OR VENT  
with same size vent connector.  
Long horizontal vent connector,  
excessive number of elbow or  
tees, or other obstructions that  
restrict the flow of combustion  
gases should be avoided. Severe  
personal injury, death or sub-  
stantial property damage could  
result.  
2. Where possible, vertical venting to the outside from the draft hood or  
vent damper outlet will offer best performance.  
ꢅꢀ 7HERE HORIZONTAL VENT CONNECTOR IS USEDꢁ SLOPE UPWARD AT LEAST v PER  
lineal foot toward chimney or vent and support with hangers to prevent  
sagging.  
ꢈꢀ "REECHING MUST NOT be connected to any portion of a mechanical draft  
system that can operate under positive pressure.  
14  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
2e  
Prepare boiler — vent damper installation  
These systems are used on gas-fired boilers with vent  
Installation  
DAMPERS AS SHIPPED FROM FACTORYꢀ "OILER WILL NOT OPERATE  
without vent damper installed.  
1. Install vent damper horizontally or vertically as  
shown in vent damper manufacturer’s instructions.  
Only vent dampers listed in the Replacement parts list  
ON PAGE ꢏꢆ ARE CERTIlED FOR USE WITH #'A BOILERSꢀ !NY  
other vent damper installed could cause severe personal  
injury or death.  
6ENT DAMPER MUST BE INSTALLED SO THAT IT SERVES ONLY  
one boiler and so damper blade indicator is visible  
to the user. See &IGURE ꢋ.  
2. Screws or rivets used to secure the vent damper to  
the draft hood must not interfere with rotation of  
Damper blade  
the damper blade.  
3TANDING PILOT IGNITION SYSTEMSˆ Refer to vent  
3. Install damper harness between damper actuator  
manufacturer’s instructions to install plug (shipped  
and knockout in jacket top panel. Use strain relief  
with damper) in damper hole. For standing pilot boil-  
connectors and locknuts to secure both ends of  
damper harness.  
ers only, install PLUG WITH /v DIAMETER HOLE in vent  
damper hole.  
3PARKꢀIGNITED PILOT SYSTEMSˆ Refer to vent man-  
ufacturer’s instructions to install plug (shipped with  
damper) in damper hole. For spark-ignited pilot boilers  
only, install PLUG WITH NO HOLE in vent damper hole.  
Keep wiring harness clear of all hot  
surfaces.  
Minimum clearances  
0ROVIDE A MINIMUM OF ꢏv BETWEEN THE VENT DAMPER AND  
any combustible material. (Provide a minimum of 36 "  
between jacket top and combustible ceiling.)  
$O NOT modify draft hood or vent damper, or make an-  
other connection between draft hood and vent damper  
OR BOILER EXCEPT AS NOTED BELOWꢀ 4HIS WILL VOID #3!  
certification and will not be covered by Weil-McLain  
warranty. Any changes will cause severe personal injury,  
death or substantial property damage.  
4. Read and apply the harness plug warning label  
(shown above) so that it is visible after installa-  
tion.  
Figure 8 Vent damper assemblies  
5. Plug damper harness receptacle into damper harness  
plug.  
"YPASSING ꢋJUMPERING VENT DAMPER  
will cause flue products such as  
carbon monoxide to escape into  
the house. This will cause severe  
personal injury or death.  
After boiler has operated once, if ei-  
ther end of harness is disconnected,  
the system safety shutdown will oc-  
cur. The boiler will not operate until  
harness is reconnected.  
%FlKAL OR &IELD #ONTROLS DAMPER—  
$AMPER HOLD OPEN SWITCH MUST BE  
in !UTOMATIC /PERATION position  
for system to operate properly.  
15  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
3a  
Water piping — general information  
General piping information  
Circulator  
)F INSTALLATION IS TO COMPLY WITH !3-% OR #ANADIAN REQUIREMENTSꢁ AN AD- The circulator is shipped loose (wiring pre-attached to  
ditional HIGH TEMPERATURE LIMIT is needed. Install control in supply piping boiler) to allow you to locate it either in the return or  
between boiler and isolation valve. Set second control to minimum 20°F supply piping, as desired. See page 3 for a typical instal-  
above setpoint of first control. Maximum allowable setpoint is 240°F. See lation. Pipe the expansion tank to the suction side of the  
page 34 or 38, for wiring.  
circulator whenever possible. Install an air separator in  
THE SUPPLY PIPINGꢀ #ONNECT THE EXPANSION TANK TO THE AIR  
separator only if the separator 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. &IGURES ꢏ and ꢅꢈ show typical near-boiler  
piping connections.  
A LOW WATER CUTOFF DEVICE is required when boiler is installed above ra-  
diation level or by certain state or local codes or insurance companies. Use  
low water cutoff designed for water installations. Electrode probe-type is  
recommended. Purchase and install in tee in supply piping above boiler.  
Use BACKmOW CHECK VALVE in cold water supply as required by local  
codes.  
System water piping  
Pressure/temperature gauge  
Install pressure/temperature gauge in tee on supply piping (as shown in  
drawing on page 3).  
See &IGURE ꢏ (diaphragm-type or bladder-type expan-  
sion tank) or &IGURE ꢅꢈ (closed-type expansion tank),  
and 4ABLE ꢌ below, for near-boiler and single-zone  
systems designed for return water at least 130°F.  
3EE PAGES ꢆꢒꢂꢆꢉ TO COMPLETE MULTIPLEꢂZONE PIPING OR  
pages 20-25 to complete piping for radiant heating  
systems or converted gravity systems (large-volume  
systems originally designed for circulation by natural  
convection rather than a pump). See page 25 for boilers  
used with refrigeration systems.  
Relief valve  
)NSTALL RELIEF VALVE VERTICALLY IN Ðv TAPPING ON SIDE OF BOILERꢀ 3EE &IGURE ꢏ  
OR ꢅꢈ, page 17, and the tag attached to the relief valve for manufacturer’s  
instructions.  
Table 3 Water pipe size (based on 20°F rise)  
To avoid water damage or scalding due to relief valve  
operation:  
Boiler model  
To  
From  
system  
system  
s
$ISCHARGE LINE MUST BE CONNECTED TO RELIEF VALVE OUTLET AND RUN TO A  
SAFE PLACE OF DISPOSAL. Terminate the discharge line to eliminate  
possibility of severe burns should the valve discharge.  
CGa-25  
CGa-3, 4, 5  
CGa-6, 7  
CGa-8  
¾"  
1"  
¾"  
1"  
s
s
$ISCHARGE LINE MUST BE AS SHORT AS POSSIBLE AND BE THE SAME SIZE AS  
THE VALVE DISCHARGE CONNECTION throughout its entire length.  
1 ¼"  
1 ½"  
1 ¼"  
1 ½"  
$ISCHARGE LINE MUST PITCH DOWNWARD from the valve and terminate  
AT LEAST ꢏv ABOVE THE mOOR DRAIN WHERE ANY DISCHARGE WILL BE CLEARLY  
visible.  
Note: The boiler supply and return connections, the return/  
drain tee and the supply/gauge tee supplied with the  
boiler are 1¼” NPT. One of the circulator flanges sup-  
plied with the boiler is 1¼”. The other circulator flange  
is the size of the recommended system piping shown  
above.  
s
s
s
4HE DISCHARGE LINE SHALL TERMINATE PLAINꢄ NOT THREADED, with a mate-  
rial serviceable for temperatures of 375°F or greater.  
$O NOT PIPE THE DISCHARGE TO ANY PLACE WHERE FREEZING COULD  
OCCURꢂ  
#HILLERS OR AIR HANDLING UNITS:  
Install boiler such that —  
.O SHUTOFF VALVE shall be installed between the relief valve and boiler,  
OR IN THE DISCHARGE LINEꢀ $O NOT PLUG OR PLACE ANY OBSTRUCTION IN THE  
discharge line.  
s
s
#HILLED MEDIUMꢁ IF USEDꢁ IS PIPED IN PARALLEL WITH  
heating boiler. Use appropriate valves to prevent  
CHILLED MEDIUM FROM ENTERING BOILERꢀ #ONSULT  
)ꢓ"ꢓ2 )NSTALLATION AND 0IPING 'UIDESꢀ  
)F BOILER IS CONNECTED TO HEATING COILS LOCATED IN  
air handling units where they can be exposed to  
refrigerated air, use flow control valves or other au-  
tomatic means to prevent gravity circulation during  
COOLING CYCLEꢀ #IRCULATION OF COLD WATER THROUGH THE  
boiler could result in damage to the heat exchanger,  
causing possible severe personal injury, death or  
substantial property damage.  
s
s
&AILURE TO COMPLY with the above guidelines could result in failure of  
the relief valve to operate, resulting in possibility of severe personal  
injury, death or substantial property damage.  
4EST THE OPERATION OF THE VALVE after filling and pressurizing system  
by lifting the lever. Make sure the valve discharges freely. If the valve  
fails to operate correctly, replace it with a new relief valve.  
16  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
3b  
Water piping — single-zone system  
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.  
Diaphragm-type or bladder-  
type expansion tank (Figure 9)  
Closed-type expansion tank  
(Figure 10)  
1. Ensure expansion tank size will handle boiler and  
system water volume and temperature. See tank  
manufacturer’s instructions for details.  
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 tank ꢄꢀ #ONNECT TANK TO v .04 TAPPING LOCATED BEHIND  
manufacturer’s instructions for details.  
SUPPLY OUTLETꢁ USING v .04 PIPINGꢀ 0ITCH ANY  
horizontal piping up towards tank 1 inch per 5 feet  
of piping.  
2. Install an AUTOMATIC AIR VENT as shown.  
Use &IGURE ꢏ or &IGURE ꢅꢈ only for single-zone systems designed for RETURN WATER AT LEAST  
ꢅꢌꢈ—&For systems with low return water temperature possible, such as converted gravity  
systems and radiant heating systems, refer to the special piping suggestions of pages 20-25.  
Failure to prevent low 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.  
&IGURE ꢏ  
Diaphragm- or bladder-type expansion  
tank — Single-zone system using dia-  
phragm-type or bladder-type expansion  
tank. See Table 3 for piping sizes.  
&IGURE ꢅꢈ  
Closed-type expansion tank — Single-  
zone system using closed-type expan-  
sion tank. See Table 3 for piping sizes.  
17  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
3c  
Water piping — multiple zones  
Piping multiple zones  
Piping for radiant heating  
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 SYSꢀ  
TEMSꢄ below, if applicable.)  
systems or converted gravity  
systems  
Converted gravity (or steam) systems  
See &IGURE ꢅꢅ or &IGURE ꢅꢉꢁ PAGE ꢆꢉꢁ TO COMPLETE IN-  
stallation.  
Whenever possible, use the primary/secondary piping  
shown in &IGURES ꢅꢌ or ꢅꢎ on page 21. This piping de-  
sign allows changing boiler flow rate without affecting  
primary circuit flow rate.  
Zoning with circulators (Figure 11)  
(return temp over 130°F)  
1. Size each circulator to individual circuit require-  
ments.  
If &IGURES ꢅꢌ or ꢅꢎ cannot be used, use the boiler-bypass  
piping shown in &IGURE ꢅꢊ or &IGURE ꢅꢇ ON PAGE ꢄꢅꢀ 9OU  
can also use the piping shown in &IGURE ꢅꢍ on page 25  
(system-bypass), if the reduced flow rate in the heating  
system will not cause heat distribution problems.  
ꢄꢀ $O NOT INSTALL CIRCULATOR ON BOILER ꢋEXCEPT FOR PRI-  
mary/secondary piping).  
Failure to prevent low return water  
temperature to the boiler could  
cause corrosion of the boiler sec-  
tions or burners, resulting in severe  
personal injury, death or substantial  
property damage.  
3. Install isolation (balancing) valves to adjust flow to  
distribute heat to all zones.  
4. Install and wire a separate relay for each zone cir-  
culator.  
Zoning with zone valves (Figure 12)  
(return temp over 130°F)  
1. Install isolation (balancing) valves to adjust flow to  
distribute heat to all zones.  
Radiant heating systems  
Preferably, use primary/secondary piping, as shown  
in &IGURES ꢅꢌ or ꢅꢎ on page 21. Alternatively, use the  
method of either &IGURE ꢅꢊ or &IGURE ꢅꢇ on page 23.  
$O NOT USE THE PIPING OF &IGURE ꢅꢍ (system-bypass),  
because this method does not control radiant system  
supply temperature.  
2. Provide a separate 24-volt transformer to power the  
zone valves. Size the transformer to handle the total  
rated load of all connected zone valves.  
If radiant system tubing has no oxygen barrier, a HEAT  
EXCHANGER must be used.  
Radiant heating system piping should include a means of regulating the boiler return water  
temperature and the system supply temperature (such as provided by an injection pumping  
CONTROL ꢀ "OILER RETURN WATER TEMPERATURE WILL BE ADEQUATELY CONTROLLED USING THE METHODS  
shown in this manual provided the system supply temperature is relatively constant.  
$/ ./4 apply the methods in this manual if the system is equipped with an OUTDOOR RESET  
CONTROL. Instead, provide controls and piping which can regulate the boiler return water  
TEMPERATURE AT NO LESS THAN ꢆꢅꢌ—& REGARDLESS OF SYSTEM SUPPLY TEMPERATUREꢀ #ONTACT YOUR  
Weil-McLain representative for suggested piping and control methods. Failure to prevent  
cold return water temperature to the boiler could cause corrosion damage to the sections  
or burners, resulting in possible severe personal injury, death or substantial property dam-  
age.  
18  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
3c  
Water piping — multiple zones  
(continued)  
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 ꢅꢌ n ꢅꢍ, as applies. Failure to prevent sustained low return water temperature to  
the boiler could cause corrosion of the boiler sections, resulting in severe personal injury,  
death or substantial property damage.  
ꢆꢉ  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
3d  
Piping — low temperature systems  
the water temperature being supplied to the radiant  
tubing.  
Primary/secondary (preferred)  
Bypass piping method  
'AUGE is REQUIRED on all systems to assure the return  
water temperature is accurately set for a minimum of  
130°F. If this gauge is not available however, adjust the  
valves such that the boiler-mounted temperature/pres-  
sure gauge reads at least 150°F when the system return  
water is cold (approximately 60°F water temperature).  
0RIMARYꢁSECONDARY bypass piping is preferred because  
the flow rate and temperature drop in the heating  
circuit(s) is determined only by the heating circuit  
circulator(s). So adjustment of the bypass valves in  
the boiler circuit will not cause a change in the heating  
circuit rate and temperature distribution.  
Figures 13 and 14, page 21, show suggested bypass  
arrangements using PRIMARYꢁSECONDARY bypass piping  
(preferred) for low temperature systems such as RADIANT  
HEATING SYSTEMS or CONVERTED GRAVITY SYSTEMS. For  
alternatives, see pages 22 through 25.  
Valve adjustment  
(Figures 13 and 14 only)  
1. Set the valves while the system is cool, setting for the  
coldest expected water temperature (usually 60°F  
since the system will often drop to room tempera-  
ture between cycles).  
The bypass valves (items ꢍA and ꢍB) provide mixing of  
hot boiler outlet water with cooler system return water  
— set to assure a minimum return water temperature  
(at least 130°F) to the boiler. Set the valves as explained  
below.  
2. Start with valve ꢍA fully closed and ꢍB fully open.  
ꢅꢀ 'RADUALLY OPEN VALVE ꢍA while closing valve ꢍB until  
the temperature at gauge reads 130°F when gauge  
ꢎA reads 60°F.  
Temperature gauges  
ꢈꢀ .OTE THAT VALVE ꢍA regulates the amount of hot wa-  
ter from the boiler supply which mixes with return  
WATERꢀ 6ALVE ꢍB regulates the amount of system water  
flowing through the boiler secondary loop.  
'AUGE ꢎA is suggested, but optional on any system.  
'AUGE ꢎB is optional on converted gravity systems,  
but REQUIRED on radiant heating systems — to display  
Failure to PREVENT LOW 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 REGULATING THE BOILER RETURN  
WATER TEMPERATURE and the SYSTEM SUPPLY TEMPERATURE (such as provided by an INJECꢀ  
TION PUMPING CONTROL).  
"OILER RETURN WATER TEMPERATURE WILL BE ADEQUATELY CONTROLLED USING THE METHODS SHOWN  
in this manual provided the SYSTEM SUPPLY TEMPERATURE is RELATIVELY CONSTANTꢂ  
DO NOT apply the methods of this manual if the system is equipped with an OUTDOOR  
RESET CONTROLꢂ Instead, PROVIDE CONTROLS AND PIPING which can REGULATE THE BOILER REꢀ  
TURN WATER TEMPERATURE at NO LESS THAN ꢅꢌꢈ—& regardless of system supply temperature.  
#ONTACT YOUR 7EILꢂ-C,AIN REPRESENTATIVE FOR SUGGESTED PIPING AND CONTROL METHODSꢀ  
Failure to PREVENT COLD RETURN WATER TEMPERATURE to the boiler could cause corrosion  
damage to the sections or burners, resulting in possible severe personal injury, death or  
substantial property damage.  
20  
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3d  
Piping — low temperature systems  
(continued)  
10 Automatic air vent (with diaphragm-type expansion  
tank), or connect to tank 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.  
1
2
3
"OILER ISOLATION ꢋBALANCING VALVES  
Flow/check valve  
System or zone circulator (circulator should cycle  
with zone valve and switches, using circulator valve  
or zone control panel)  
11 Fill valve  
4
5
6
7
System temperature gauges  
:ONE VALVE  
12 $IAPHRAGMꢂTYPE OR BLADDERꢂTYPE EXPANSION TANKꢁ  
if used (For closed-type expansion tank, pipe from  
top of air separator to tank fitting as in &IGURE ꢅꢈ,  
page 17.)  
$RAIN VALVE  
System temperature valves (see instructions to the  
left for adjusting valves)  
13 !IR SEPARATOR AND AUTOMATIC VENTꢁ IF USED ꢋ.OTE THAT  
the fill valve must always be connected to the expan-  
sion tank, regardless of location of expansion tank,  
circulator or air separator.)  
8
9
"LEND TEMPERATURE GAUGE  
Relief valve  
21  
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3d  
Piping — low temperature systems  
(continued)  
to the boiler. (When setting the valves without gauge  
ꢎA installed — using cold or room temperature water  
— assume the return water temperature to be 60°F. Set  
the valves so gauge reads at least 120°F.  
BOILER-bypass piping  
method  
This piping method (&IGURE ꢅꢊ or ꢅꢇ, page 23) is called  
a BOILERꢀBYPASS because part of the circulator flow is  
bypassed around the boiler (through valve ꢍA). This  
method reduces the flow rate throughout the boiler, in  
order to raise the average water temperature in the boiler  
ENOUGH TO PREVENT mUE GAS CONDENSATIONꢀ "OILERꢂBYPASS  
PIPING IS EFFECTIVE FOR SOME BOILERS ˆ INCLUDING THE #'A  
— provided the flow rates are adjusted according to the  
instructions following.  
'AUGE ꢎB is optional on converted gravity systems,  
but REQUIRED on radiant heating systems — to display  
the water temperature being supplied to the radiant  
tubing.  
'AUGE is REQUIRED on all systems to assure reliable  
adjustment of the bypass valves. The boiler-mounted  
temperature/pressure gauge can be used if a separate  
temperature gauge is not installed.  
&IGURES ꢅꢊ and ꢅꢇ 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 ꢅꢍ,  
page 25, is another alternative, using system bypass in  
place of boiler-bypass piping. &IGURE ꢅꢍ however, is  
not suitable for radiant heating applications because it  
does not protect the radiant system from possible high  
water temperature.)  
Valve adjustment  
1. Start with valve ꢍA fully closed and ꢍB fully open.  
ꢄꢀ 'RADUALLY OPEN VALVE ꢍA while closing valve ꢍB  
until the temperature at gauge reads 60 °F higher  
than gauge ꢎA. A minimum 60°F temperature rise  
through the boiler assures a low enough flow rate  
and high enough average temperature to prevent  
condensation even with low system return water  
temperature.  
"OILERꢂBYPASS PIPING KEEPS SYSTEM mOW RATE AS HIGH AS  
possible and temperature drop as low as possible, help-  
ing to equalize the building heat distribution.  
ꢅꢀ 6ALVE ꢍA regulates the system flow rate, while valve  
ꢍB regulates the boiler flow rate.  
Temperature gauges  
'AUGE ꢎA is optional if the bypass valves will be ad- 4. The boiler-mounted temperature/pressure gauge  
justed using cold (or room temperature) return water may be used in place of a separate gauge .  
Failure to PREVENT LOW 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 REGULATING THE BOILER RETURN  
WATER TEMPERATURE and the SYSTEM SUPPLY TEMPERATURE (such as provided by an INJECꢀ  
TION PUMPING CONTROL).  
"OILER RETURN WATER TEMPERATURE WILL BE ADEQUATELY CONTROLLED USING THE METHODS SHOWN  
in this manual provided the SYSTEM SUPPLY TEMPERATURE is RELATIVELY CONSTANTꢂ  
DO NOT apply the methods of this manual if the system is equipped with an OUTDOOR  
RESET CONTROLꢂ Instead, PROVIDE CONTROLS AND PIPING which can REGULATE THE BOILER REꢀ  
TURN WATER TEMPERATURE at NO LESS THAN ꢅꢌꢈ—& regardless of system supply temperature.  
#ONTACT YOUR 7EILꢂ-C,AIN REPRESENTATIVE FOR SUGGESTED PIPING AND CONTROL METHODSꢀ  
Failure to PREVENT COLD RETURN WATER TEMPERATURE to the boiler could cause corrosion  
damage to the sections or burners, resulting in possible severe personal injury, death or  
substantial property damage.  
22  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
3d  
Piping — low temperature systems  
(continued)  
1
2
3
4
5
6
7
"OILER ISOLATION ꢋBALANCING VALVES  
Flow/check valve  
10 Automatic air vent (with diaphragm-type expansion  
tank), or connect to tank 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.  
System or zone circulator  
System temperature gauges  
:ONE VALVE  
11 Fill valve  
12 $IAPHRAGMꢂTYPE OR BLADDERꢂTYPE EXPANSION TANKꢁ IF  
used (For closed-type expansion tank, pipe from top  
of air separator to tank fitting as in &IGURE ꢅꢈꢂ)  
$RAIN VALVE  
System temperature valves (see instructions  
to the left for adjusting valves)  
13 !IR SEPARATOR AND AUTOMATIC VENTꢁ IF USED ꢋ.OTE THAT THE  
fill valve must always be connected to the expansion  
tank, regardless of location of expansion tank, circulator  
or air separator.)  
8
9
"LEND TEMPERATURE GAUGE  
Relief valve  
23  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
3d  
Piping — low temperature systems  
(continued)  
$/ ./4 apply system-bypass piping if the reduced  
flow in the system could cause poor heat distribution.  
That is, system-bypass piping reduces the flow in the  
system and increases the water temperature supplied to  
the system. This can cause increased heat from radiators  
at the beginning of the system and reduced heat from  
radiators near the end of the system.  
SYSTEM-bypass piping  
method  
This piping method (&IGURE ꢅꢍ, page 25) is called a SYSꢀ  
TEMꢀBYPASS because part of the circulator flow bypasses  
the system (through valve ꢍA). This bypassed hot water  
from the boiler outlet mixes with cooler system return  
water temperature in order to provide minimum 130°F  
RETURN WATER TO THE BOILERꢀ 6ALVE ꢍB 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 ꢍA.  
Valve adjustment  
1. Start with valve ꢍA fully closed and ꢍB fully open.  
&IGURE ꢅꢍ is an alternative piping method that provides  
return water temperature control for boilers installed  
on CONVERTED GRAVITY SYSTEMS (large water content  
or steam systems).  
ꢄꢀ 'RADUALLY OPEN VALVE ꢍA while closing valve ꢍB until  
the temperature at gauge reads at least 130°F at all  
times.  
$/ ./4 apply the piping of &IGURE ꢅꢍ on RADIANT  
HEATING SYSTEMS. It provides no method of regulat-  
ing the water temperature provided to the system and  
could result in excessive water temperature in the radi-  
ant tubing.  
ꢅꢀ 6ALVE ꢍA regulates the amount of boiler supply water  
MIXED WITH RETURN WATERꢀ 6ALVE ꢍB causes a pressure  
drop in the system needed to balance flow through  
valve ꢍA and the system.  
System-bypass piping as shown in &IGURE ꢅꢍ can be used  
with either zone valve or circulator zoning. When used  
with circulator zoning however, the boiler circulator  
(item ), must be piped as shown. It cannot be used as  
one of the zoning circulators.  
4. The valve adjustment should be done with the  
system at the coldest expected temperature (60°F  
for converted gravity systems or high mass radiant  
systems).  
Failure to PREVENT LOW 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 REGULATING THE BOILER RETURN  
WATER TEMPERATURE and the SYSTEM SUPPLY TEMPERATURE (such as provided by an INJECꢀ  
TION PUMPING CONTROL).  
"OILER RETURN WATER TEMPERATURE WILL BE ADEQUATELY CONTROLLED USING THE METHODS SHOWN  
in this manual provided the SYSTEM SUPPLY TEMPERATURE is RELATIVELY CONSTANTꢂ  
DO NOT apply the methods of this manual if the system is equipped with an OUTDOOR  
RESET CONTROLꢂ Instead, PROVIDE CONTROLS AND PIPING which can REGULATE THE BOILER REꢀ  
TURN WATER TEMPERATURE at NO LESS THAN ꢅꢌꢈ—& regardless of system supply temperature.  
#ONTACT YOUR 7EILꢂ-C,AIN REPRESENTATIVE FOR SUGGESTED PIPING AND CONTROL METHODSꢀ  
Failure to PREVENT COLD RETURN WATER TEMPERATURE to the boiler could cause corrosion  
damage to the sections or burners, resulting in possible severe personal injury, death or  
substantial property damage.  
24  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
3d  
Piping — low temperature systems  
(continued)  
3e  
Water piping — refrigeration systems  
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 valve.  
If boiler is connected to heating coils located in air han-  
dling units where they can be exposed to refrigerated  
air, use flow control valves or other automatic means to  
prevent gravity circulation during cooling cycle.  
25  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
4
1. Remove jacket front panel and refer to &IGURE ꢅꢏ to pipe gas to boil-  
Gas piping  
Connect gas supply piping to boiler  
Natural Gas:  
1. Refer to 4ABLE ꢎ FOR PIPE LENGTH AND DIAMETERꢀ "ASE  
er.  
on rated boiler input (divide by 1,000 to obtain cubic  
a. )NSTALL DRIP LEG at inlet of gas connection to boiler. Where local  
utility requires drip leg to be extended to the floor, use appropri-  
ate length of pipe between cap and tee.  
feet per hour). 4ABLE ꢎ is only for gas with SPECIlC  
GRAVITY ꢈꢂꢇꢈꢄ WITH A PRESSURE DROP THROUGH THE  
GAS PIPING OF ꢈꢂꢌꢈv WꢂCꢂ For additional gas pipe  
SIZING INFORMATIONꢁ REFER TO !.3) :ꢄꢄꢅꢀꢆ ꢋOR "ꢆꢈꢉꢀꢆ  
OR "ꢆꢈꢉꢀꢄ FOR #ANADIAN INSTALLATIONS ꢀ  
b. )NSTALL GROUND JOINT UNION for servicing, when required.  
c. )NSTALL MANUAL SHUTOFF VALVE in gas supply piping outside boiler  
jacket when required by local codes or utility requirements.  
2. Inlet pressure required at gas valve inlet:  
d. )N #ANADA — When using manual main shutoff valve, it MUST BE  
IDENTIlED by the installer.  
s
s
s
-AXIMUMꢇ ꢆꢅv WꢀCꢀ  
-INIMUMꢇ ꢑv WꢀCꢀ  
2. 3UPPORT PIPING with hangers, not by boiler or its accessories.  
3. 0URGE ALL AIR from gas supply piping.  
-ANIFOLD GAS PRESSUREꢇ ꢅꢀꢑv WꢀCꢀ  
ꢅꢀ )NSTALL ꢆꢌꢌꢍ LOCKUP GAS PRESSURE REGULATOR IN SUPPLY  
line IF INLET PRESSURE EXCEEDS ꢅꢌv WꢂCꢂ Adjust for  
ꢆꢅv WꢀCꢀ MAXIMUMꢀ  
ꢈꢀ "EFORE PLACING BOILER IN OPERATIONꢁ CHECK BOILER AND ITS GAS CONNECꢀ  
TION FOR LEAKS  
.
a. #LOSE MANUAL MAIN SHUTOFF VALVE during any pressure testing at  
LESS THAN ꢆꢅv WꢀCꢀ  
b. $ISCONNECT BOILER AND GAS VALVE FROM GAS SUPPLY PIPING dur-  
ING ANY PRESSURE TESTING GREATER THAN ꢆꢅv WꢀCꢀ  
Propane Gas:  
ꢆꢀ #ONTACT GAS SUPPLIER TO SIZE PIPESꢁ TANKS AND ꢆꢌꢌꢍ  
$O NOT CHECK FOR GAS LEAKS WITH AN OPEN mAME  
Use bubble test. Failure to use bubble test or check for  
gas leaks can cause severe personal injury, death or  
substantial property damage.  
lockup gas pressure regulator.  
2. Adjust propane supply regulator provided by gas  
SUPPLIER FOR ꢆꢅv WꢀCꢀ MAXIMUM PRESSUREꢀ  
5. 5SE PIPE DOPE COMPATIBLE WITH PROPANE GASESꢂ Apply sparingly  
only to male threads of pipe joints so that pipe dope does not block gas  
flow.  
3. Inlet pressure required at gas valve inlet:  
s
s
s
-AXIMUMꢇ ꢆꢅv WꢀCꢀ  
&AILURE TO APPLY PIPE DOPE as detailed above can result  
in severe personal injury, death or substantial property  
damage.  
-INIMUMꢇ ꢆꢆv WꢀCꢀ  
-ANIFOLD GAS PRESSUREꢇ ꢆꢌv WꢀCꢀ  
Table 4 Pipe capacity for 0.60 specific gravity natural gas  
&IGURE ꢅꢏ Gas supply piping  
Capacity of pipe for pipe size of:  
(Capacity in cubic feet gas per hour)  
Gas pipe  
length  
(feet)  
½"  
132  
92  
¾"  
278  
190  
152  
130  
115  
93  
1"  
1¼"  
1050  
730  
590  
500  
440  
360  
305  
250  
1½"  
1600  
1100  
860  
760  
10  
20  
520  
350  
285  
245  
215  
175  
150  
120  
30  
73  
40  
63  
50  
56  
670  
545  
460  
380  
75  
45  
100  
150  
38  
79  
31  
64  
26  
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27  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
6a  
Start-up — preparation  
Check for gas leaks  
Determine if water treatment is needed  
"EFORE STARTING THE BOILERꢁ AND DUR-  
$O NOT USE PETROLEUMꢀBASED CLEANING OR SEALING  
COMPOUNDS in boiler system. Severe damage to boiler  
will occur, resulting in substantial property damage.  
ing initial operation, smell near the  
floor and around the boiler for gas  
ODORANT OR ANY UNUSUAL ODORꢀ $O  
not proceed with start-up if there is  
any indication of a gas leak. Repair  
any leak at once.  
%LIMINATE ALL SYSTEM LEAKSꢀ #ONTINUAL FRESH MAKEUP  
water will reduce boiler life. Minerals can build up in  
sections, reducing heat transfer, overheating cast iron,  
and causing section failure.  
0ROPANE BOILERS ONLY ˆ 9OUR PRO-  
pane supplier mixes an odorant with  
the propane to make its presence  
detectable. In some instances, the  
odorant can fade and the gas may  
no longer have an odor.  
Verify water chemistry  
#ONSULT LOCAL WATER TREATMENT COMPANIES FOR UNUSUALLY HARD WATER AREAS  
ꢋABOVE ꢊ GRAINS HARDNESS OR LOW P( WATER CONDITIONS ꢋBELOW ꢊꢀꢌ ꢀ "OILER  
WATER P( OF ꢊꢀꢌ TO ꢒꢀꢑ IS RECOMMENDEDꢀ  
s 0ROPANE GAS CAN ACCUMULATE  
at floor level. Smell near the  
floor for the gas odorant or any  
unusual odor. If you suspect a  
leak, do not attempt to light the  
pilot.  
Freeze protection (when used)  
Use antifreeze made especially for hydronic systems. Inhibited propylene  
glycol is recommended.  
$O NOT USE ETHYLENE GLYCOLꢄ AUTOMOTIVE OR UNDILUTED  
ANTIFREEZE. Severe personal injury or death can result.  
s 5SE CAUTION WHEN ATTEMPTING  
to light the propane pilot. This  
should be done by a qualified  
service technician, particularly  
if pilot outages are common.  
ꢆꢀ $ETERMINE ANTIFREEZE QUANTITY according to system water content.  
"OILER WATER CONTENT IS LISTED ON PAGE ꢏꢊꢀ 2EMEMBER TO INCLUDE EXPAN-  
sion tank water content.  
s 0ERIODICALLY CHECK THE ODORANT  
level of your gas.  
2. Follow antifreeze manufacturer’s instructions.  
s )NSPECT BOILER AND SYSTEM AT LEAST  
yearly to make sure all gas piping  
is leak-tight.  
ꢅꢀ ! ꢑꢌꢍ SOLUTION OF PROPYLENE GLYCOLꢃWATER PROVIDES MAXIMUM PROTEC-  
tion to about -30°F.  
4. Local codes may require BACK mOW PREVENTER or actual disconnect from  
s #ONSULT YOUR PROPANE SUPPLIER  
regarding installation of a gas  
leak detector. There are some  
products on the market intended  
FOR THIS PURPOSEꢀ 9OUR SUPPLIER  
may be able to suggest an appro-  
priate device.  
city water supply.  
5. When using antifreeze in a system with automatic fill, install a water  
METER TO MONITOR WATER MAKEUPꢀ 'LYCOL 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.  
28  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
6a  
Start-up — preparation  
(continued)  
Fill the system with water  
Inspect system water piping  
ꢆꢀ #LOSE MANUAL AND AUTOMATIC AIR VENTS and boiler drain cock.  
After filling the boiler and system with water, INSPECT ALL  
PIPING throughout the system for leaks. If found, repair  
immediately. Repeat this inspection after the boiler has  
been started and the system has heated up.  
2. &ILL TO CORRECT SYSTEM PRESSUREꢂ #ORRECT PRESSURE WILL VARY WITH EACH  
application. Typical cold water fill pressure for a residential system is  
12 psi.  
,EAKS MUST BE REPAIRED AT ONCEꢂ  
Failure to do so can damage the  
boiler, resulting in substantial prop-  
erty damage.  
3. 0URGE AIR from system:  
Aꢀ #ONNECT A HOSE TO THE PURGE VALVE ꢋSEE drain valves, item , in sug-  
gested piping diagrams on pages 17 through 23, &IGURE ꢏ through  
&IGURE ꢅꢇ). Route hose to an area where water can drain and be  
seen.  
Bꢀ #LOSE THE BOILER OR SYSTEM ISOLATION VALVE BETWEEN THE PURGE VALVE  
and fill connection to the system.  
Cꢀ #LOSE ZONE ISOLATION VALVESꢀ  
d. Open quick-fill valve on cold water makeup line.  
e. Open purge valve.  
$O NOT USE PETROLEUMꢀBASED  
CLEANING OR SEALING COMPOUNDS  
in boiler system. Severe damage to  
boiler will occur, resulting in sub-  
stantial property damage.  
f. One zone at a time, open the isolation valves. Allow water to run  
through the zone, pushing out the air. Run until no noticeable air  
mOW IS PRESENTꢀ #LOSE THE ZONE ISOLATION VALVES AND PROCEED WITH THE  
next zone. Follow this procedure until all zones are purged.  
Gꢀ #LOSE THE QUICKꢂlLL WATER VALVE AND PURGE VALVE AND REMOVE THE  
hose. Open all isolation valves. Watch that system pressure rises to  
correct cold-fill pressure.  
h. After the system has operated for a while, eliminate any residual air  
by using the manual air vents located throughout the system.  
i. If purge valves are not installed in system, open manual air vents in  
SYSTEM ONE AT A TIMEꢁ BEGINNING WITH LOWEST mOORꢀ #LOSE VENT WHEN  
water squirts out. Repeat with remaining vents.  
Inspect base insulation  
The boiler contains ceramic fiber  
and fiberglass materials. Use care  
when handling these materials per  
instructions on PAGE ꢇꢋ of this  
manual. Failure to comply could  
result in severe personal injury.  
&AILURE TO REPLACE damaged insu-  
lation or reposition insulation can  
result in a fire hazard, causing severe  
personal injury, death or substantial  
property damage.  
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.  
#HECK TO MAKE SURE BASE INSULATION IS SECURE against  
all four sides of the base. If insulation is damaged or  
displaced, DO NOT operate boiler. Replace or reposition  
insulation.  
6. Refill to correct pressure.  
ꢄꢉ  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
6b  
Start-up — operate boiler  
$/ ./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 injury, death or substantial property damage.  
"EFORE STARTING THE BOILERꢁ DO THE FOLLOWINGꢇ  
s
2EAD MANUAL 3ECTION ꢋꢁꢏ and the ,IGHTINGꢁ/PERATING INSTRUCTION  
procedure (see 4ABLE ꢊ, below).  
s
s
6ERIFY THE BOILER AND SYSTEM ARE FULL OF WATER.  
6ERIFY THE 3TARTꢀUP PREPARATION procedures of 3ECTION ꢇ have been  
completed.  
4ABLE ꢊ Lighting/Operating instruction location guide  
Models Standing pilot  
Gas  
Page Spark-ignited pilot Gas  
Page  
Natural or  
Propane  
Honeywell VR8200/VR8300  
35 Honeywell VR8204/VR8304 Natural  
40  
CGa-25  
to  
CGa-6  
Robertshaw 7200  
Natural  
Natural  
41  
42  
Robertshaw 7200  
Natural  
36  
White-Rodgers 36E  
Natural or  
Propane  
CGa-7  
to  
CGa-8  
Honeywell VR8200/VR8300  
Robertshaw 7200  
35 Honeywell VR8204/VR8304 Natural  
36 White-Rodgers 36C Natural  
40  
43  
Natural  
30  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
6b  
Start-up — operate boiler  
(continued)  
Start the boiler  
s
&OLLOW THE ,IGHTINGꢁ/PERATING )NSTRUCTIONS from  
3ECTION ꢋ OR ꢏ to start the boiler. Remove boiler  
jacket door and note the gas valve manufacturer  
and model number. Use only the lighting/operat-  
ing instruction which applies to this gas valve (see  
4ABLE ꢊ, page 30). (The lighting instruction label on  
the boiler provides the same information.)  
%LIMINATE ALL SYSTEM LEAKSꢂ  
#ONTINUAL FRESH MAKEUP WATER  
will reduce boiler life. Minerals  
can build up in sections, reduc-  
ing heat transfer, overheating  
cast iron, and causing section  
failure.  
s
3EE 3ECTION ꢇC if boiler fails to start.  
Check system and boiler  
1. #HECK SYSTEM PIPING FOR LEAKSꢂ If found, shut  
If you discover evidence of any  
gas leak, shut down the boiler  
at once. Find the leak source  
with bubble test and repair im-  
MEDIATELYꢀ $O NOT START BOILER  
again until corrected. Failure to  
comply could result in severe  
personal injury, death or sub-  
stantial property damage.  
down boiler and repair immediately.  
2. 6ENT AIR FROM SYSTEM using manual vents. Air in  
the system will interfere with circulation and cause  
heat distribution problems and noise.  
3. )NSPECT VENT SYSTEM thoroughly for signs of  
deterioration from corrosion, physical damage or  
SAGGINGꢀ 6ERIFY THAT MASONRY CHIMNEY LINERS ARE IN  
good condition, with no obstructions, and there are  
no openings into the chimney.  
$O NOT USE PETROLEUMꢀBASED  
CLEANING OR SEALING COMPOUNDS  
in boiler system. Severe damage  
to boiler will occur, resulting in  
substantial property damage.  
4. #HECK AROUND THE BOILER for gas odor following the  
procedure of Section ꢇA of this manual.  
5. 6ERIFY OPERATION per Section ꢇD. Perform check-out  
procedure in Section and fill in the )NSTALLATION  
AND SERVICE CERTIlCATE on the same page.  
6c  
Start-up — if boiler doesn’t start . . .  
Check for:  
1. Loose connections, blown fuse or  
ꢈꢀ 'AS NOT TURNED ON AT METER OR BOILERꢔ  
5. Incoming gas pressure less than:  
SERVICE SWITCH OFFꢔ  
ꢄꢀ (IGH LIMIT SWITCH SET BELOW BOILER  
WATER TEMPERATUREꢔ  
ꢑv WꢀCꢀ FOR NATURAL GASꢔ ꢆꢆv WꢀCꢀ FOR PROPANE GASꢔ  
3. Thermostat set below room tem-  
6. If none of the above corrects the problem, refer to 4ROUBLESHOOTꢀ  
ing, Section ꢅꢅ of this manual.  
PERATUREꢔ  
31  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
6d  
Start-up — verify operation  
4HE BOILER MODEL SUFlX WILL BE h30$vꢀ &OR SPARKꢂIGNITED PILOT BOILERS ꢋSUFlX h0)$v ꢁ SEE  
3ECTION ꢋ or for operation and lighting/operating information.  
Check burner flames  
&IGURE ꢉꢅ Typical pilot burner flame  
Pilot burner flame (&IGURE ꢉꢅ)  
PROPER pilot flame  
ꢆꢀ "LUE mAMEꢀ  
2. Inner cone engulfing thermocouple (standing pilot)  
or pilot flame sensor (spark-ignited pilot).  
3. Thermocouple or pilot flame sensor glowing cherry  
red.  
IMPROPER pilot flame  
1. Overfired — Large flame lifting or blowing past pilot  
flame sensor.  
2. Underfired — Small flame. Inner cone not engulfing  
pilot flame sensor.  
ꢅꢀ ,ACK OF PRIMARY AIR ˆ 9ELLOW mAME TIPꢀ  
4. Incorrectly heated pilot flame sensor.  
Main burner flame (&IGURE ꢉꢉ)  
&IGURE ꢉꢉ Typical main burner flame  
PROPER main burner flame  
ꢆꢀ 9ELLOWꢂORANGE STREAKS MAY APPEAR ꢋCAUSED BY  
dust).  
IMPROPER main burner flame:  
1. Overfired — Large flames.  
2. Underfired — Small flames.  
ꢅꢀ ,ACK OF PRIMARY AIR ˆ 9ELLOW TIPPING ON mAMES  
(sooting will occur).  
Check vent damper operation  
1. 2AISE ROOM THERMOSTAT TO CALL FOR HEAT ˆ 6ENT  
damper actuator will slowly open vent damper.  
5. Return thermostat to normal setting.  
2. 7HEN VENT DAMPER IS FULLY OPEN — Main gas valve  
will open and main burners will ignite. (Spark-ig-  
nited pilot controls will first light pilot, then allow  
main burners to ignite.)  
6. Set thermostat heat anticipator setting indicated on  
wiring diagram.  
6ENT DAMPER MUST BE FULLY OPEN  
before main burners light. If vent  
damper does not fully open, flue  
products such as carbon monoxide  
will escape into house, causing se-  
vere personal injury or death.  
Check vent system operation  
ꢆꢀ #HECK VENT SYSTEM AT LEAST ONCE A MONTH DURING  
heating season. With boiler firing, hold candle or  
MATCH BELOW LOWER EDGE OF DRAFT HOOD hSKIRTvꢀ )F  
flame does not blow out, but burns undisturbed,  
vent system is functioning properly. If flame blows  
out or flickers drastically, inspect vent system for  
obstructions or other causes of improper venting  
(such as exhaust fans in boiler room).  
3. ,OWER THERMOSTAT SETTING — Main burner flames  
will go out, then vent damper will close.  
4. 2EPEAT 3TEPS ꢉ THROUGH ꢎ several times to verify  
operation.  
32  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
7
Check-out procedure — checklist  
Adjust balancing valves and controls to provide design  
temperature to system.  
O
O
O
O
O
"OILER AND HEAT DISTRIBUTION UNITS lLLED WITH WATERꢔ  
!UTOMATIC AIR VENTꢁ IF USEDꢁ OPEN ONE FULL TURNꢔ  
!IR PURGED FROM SYSTEMꢔ  
O
O
For multiple zones, adjust flow so it is about the same in  
each zone.  
!IR PURGED FROM GAS PIPINGꢔ 0IPING CHECKED FOR LEAKSꢔ  
#ORRECTLY SIZED MANIFOLD ORIlCES INSTALLEDꢔ 2EFER TO 4ABLE ꢉ,  
page 12 to check size and fuel type.  
6ERIFY THERMOSTAT HEAT ANTICIPATOR ꢋIF AVAILABLE SET PROP-  
ERLYꢔ 2EFER TO &IELD WIRING, manual Section 5, page 27,  
4HERMOSTATꢐS .  
#ORRECTLY SIZED MANIFOLD ORIlCES MUST BE USEDꢀ  
Failure to do so will cause severe personal in-  
jury, death or substantial property damage.  
O
O
#YCLE BOILER WITH THERMOSTAT ˆ 2AISE TO HIGHEST SETTING AND  
verify boiler goes through normal start-up cycle. Lower to  
lowest setting and verify boiler goes off.  
O
O
O
Followed lighting/operating instructions on boiler or in  
manual Section or Section FOR PROPER STARTꢂUPꢔ  
0ROPERBURNERmAMEOBSERVEDꢔ 2EFERTO#HECK BURNER mAME,  
manual Section ꢇD.  
Test limit control — While burners are operating, move  
indicator on limit control below actual boiler water tem-  
PERATUREꢀ "URNERS SHOULD GO OFF WHILE CIRCULATOR CONTINUES  
to operate. Raise setting on limit control above boiler water  
temperature and burners should reignite.  
Measure natural gas input:  
a. Operate boiler 10 minutes.  
b. Turn off other appliances.  
c.  
At natural gas meter, measure time (in seconds) re-  
quired to use one cubic foot of gas.  
O
Test additional field-installed controls — If boiler has a low  
water cutoff, additional high limit or other controls, test for  
OPERATION AS OUTLINED BY MANUFACTURERꢀ "URNERS SHOULD BE  
operating and should go off when controls are tested. When  
controls are restored, burners should reignite.  
Dꢀ #ALCULATE GAS INPUTꢇ  
3600 x 1000  
number of seconds from step c  
= Btuh  
O
O
"UTTON ON SPILL SWITCH PUSHED INꢔ  
Test ignition system safety device:  
Eꢀ  
"TUH CALCULATED SHOULD APPROXIMATE INPUT RATING ON  
boiler rating label.  
a.  
3TANDING PILOT — Turn gas cock knob to 0),/4 posi-  
tion and extinguish pilot flame. Pilot gas flow should  
stop in less than 3 minutes. Put system back into op-  
eration (see Section ).  
O
#HECK MANIFOLD GAS PRESSURE BY CONNECTING MANOMETER TO  
downstream test tapping on main gas valve. Manifold pres-  
sure for natural gas should be 3.5" w.c. and for propane gas  
should be 10" w.c.  
b. 3PARKꢀIGNITED PILOT ˆ #ONNECT MANOMETER TO OUTLET  
side 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 VALVEꢀ "URNERS SHOULD GO  
off. Open manual main shutoff gas valve. Manometer  
should confirm there is no gas flow. Pilot will relight,  
flame sensing element will sense pilot flame and main  
burners reignite.  
O
O
O
O
Observe several operating cycles for proper operation.  
Set room thermostat to desired room temperature.  
&ILL IN )NSTALLATION AND SERVICE CERTIlCATE BELOWꢔ  
Review all instructions shipped with this boiler with owner  
or maintenance person. Return instructions to envelope  
and give to owner or place in pocket inside front panel in  
boiler.  
O
Set limit control(s) to system temperature requirements.  
Installation and service certificate  
"OILER MODEL ??????????????????  
3ERIES ??????????  
#0 NUMBER ???????????  
$ATE INSTALLED ???????????  
-EASURED "TUH INPUT ????????????????????  
O Installation instructions have been followed.  
O #HECK OUT SEQUENCE HAS BEEN PERFORMEDꢀ  
O Above information is certified to be correct.  
O Information received and left with owner/maintenance person  
)NSTALLER ????????????????????????  
????????????????????????????????  
(address)  
????????????????????????  
(company)  
(phone)  
)NSTALLERꢐS SIGNATUREꢇ ?????????????????????????????????????  
33  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
8a  
Operation — standing pilot boilers  
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  
substantial property damage.  
4HIS PROVIDES GAS TO THE MAIN BURNERSꢀ "URNERS RE-  
main ignited until thermostat circuit or limit circuit  
OPENSꢀ "URNERS AND CIRCULATOR ARE DEꢂENERGIZED WHEN  
CALL FOR HEAT STOPSꢀ "URNERS ARE DEꢂENERGIZEDꢁ BUT  
circulator remains on, if the limit circuit opens.  
1. 3TANDBY MODEꢆ After pilot is manually lit, the gas valve provides pilot  
gas and maintains pilot as long as the thermocouple is satisfied. If ther-  
mocouple signal drops for any reason, pilot must be manually lighted,  
following the ,IGHTING )NSTRUCTIONS IN THIS MANUAL AND ON BOILERꢀ 6ENT  
damper will remain closed.  
3. ,IMIT OPERATIONꢆ When a limit control opens, the  
main gas valve is de-energized, but circulator con-  
tinues to run. When the limit circuit closes again,  
the main gas valve is energized if there is still a call  
for heat.  
2. #ALL FOR HEATꢆ When thermostat circuit closes, the boiler circulator and  
vent damper are energized. The vent damper drives open. When the 4. 4HERMOSTAT HEAT ANTICIPATORꢆ Set heat anticipator  
vent damper is fully open, its end switch energizes the main gas valve.  
as shown on wiring diagram, &IGURE ꢉꢌ.  
Figure 23 Wiring diagram — Standing pilot system  
34  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
s 3TANDING PILOT  
s .ATURAL OR PROPANE GAS  
8b  
Lighting instructions  
CGa-25 to CGa-8  
s 'AS VALVEꢆ (ONEYWELL 62ꢋꢉꢈꢈꢁ62ꢋꢌꢈꢈ  
35  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
s 3TANDING PILOT  
s .ATURAL GAS  
8b  
Lighting instructions  
CGa-25 to CGa-8  
s 'AS VALVEꢆ 2OBERTSHAW ꢍꢉꢈꢈ  
36  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
9a  
Operation — spark-ignited pilot boilers  
4. -AIN BURNER OPERATIONꢆ  
Follow all procedures given in this manual and operating  
instructions when operating the boiler. Failure to do so  
could result in severe personal injury, death or substantial  
property damage.  
Aꢀ #ONTROL MODULE MONITORS PILOT mAME  
current. If signal is lost, main valve closes,  
spark generator activates and sequence  
returns to step 4.  
1. 3TANDBYꢆ With no call for heat, the vent damper and circulator are de-energized.  
.O GAS mOWS TO PILOT OR MAIN GAS VALVEꢀ  
2. #ALL FOR HEAT (thermostat circuit closes):  
b. If power is interrupted, control system  
shuts off pilot and main gas valves and  
restarts at step 1 when power is restored.  
Aꢀ 6ENT DAMPER AND CIRCULATOR ENERGIZED IF PILOT STATUS ACCEPTABLEꢀ 6ENT  
damper drives open. When vent damper end switch makes circuit, igni-  
tion control begins pilot ignition attempt.  
b. Ignition control checks for false flame signal: If ignition control senses  
pilot signal when no pilot gas should be present, control will lockout,  
requiring reset procedure as given in &IGURE ꢉꢎꢂ  
c. In the event the limit control shuts down  
the boiler — The control module closes  
the main gas valve, but keeps the circula-  
tor operating and the vent damper open.  
5. 4HERMOSTAT SATISlED (thermostat circuit opens)  
ˆ 0ILOT AND MAIN GAS VALVES ARE CLOSED ˆ 6ENT  
damper is de-energized, and cycles to closed posi-  
TIONꢀ #IRCULATOR IS SHUT OFFꢀ  
3. 0ILOT IGNITIONꢆ #ONTROL MODULE SPARKS THE PILOT AND OPENS PILOT VALVE IN MAIN  
gas valve.  
a. If pilot does light and control module senses flame current, spark  
generator is turned off and main valve opens.  
b. If pilot does not light within 15 seconds, pilot valve is closed and  
SPARK GENERATOR IS TURNED OFFꢀ #ONTROL MODULE WAITS ꢑ MINUTESꢁ THEN  
attempts to ignite pilot again. This cycle will continue indefinitely if  
pilot ignition control does not sense pilot flame.  
ꢏꢀ "OILER IS NOW IN THE STANDBY MODEꢀ  
7. Thermostat anticipator setting: Set thermostat  
heat anticipator as instructed in &IGURE ꢉꢊB, page  
ꢅꢉꢀ  
Figure 24 Ignition control module sequence of operation — status light indications  
37  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
9a  
Operation — spark-ignited pilot system  
(continued)  
Figure 25a Schematic wiring diagram — Spark-ignited pilot system  
38  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
9a  
Operation — spark-ignited pilot system  
(continued)  
Figure 25b Ladder wiring diagram — Spark-ignited pilot system  
ꢅꢉ  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
s 3PARK PILOT  
s .ATURAL GAS  
9b  
Operating instructions  
CGa-25 to CGa-8  
s 'AS VALVEꢆ (ONEYWELL 62ꢋꢉꢈꢎꢁ62ꢋꢌꢈꢎ  
40  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
s 3PARK PILOT  
s .ATURAL GAS  
9b  
Operating instructions  
CGa-25 to CGa-6  
s 'AS VALVEꢆ 2OBERTSHAW ꢍꢉꢈꢈ  
41  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
s 3PARK PILOT  
s .ATURAL GAS  
9b  
Operating instructions  
CGa-25 to CGa-6  
s 'AS VALVEꢆ 7HITEꢀ2ODGERS ꢌꢇ%  
42  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
s 3PARK PILOT  
s .ATURAL GAS  
9b  
Operating instructions  
CGa-7 to CGa-8  
s 'AS VALVEꢆ 7HITEꢀ2ODGERS ꢌꢇ#  
43  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
10a  
Service and maintenance — schedule  
VERIFY PROPER OPERATION AFTER SERVICING  
4ABLE ꢇ 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)  
s #HECK BOILER AREA  
Inspect:  
s #HECK AIR OPENINGS  
Daily  
s 2EPORTED PROBLEMS  
s "OILER AREA  
s #HECK BOILER PRESSUREꢁ  
TEMPERATURE GAUGE  
s !IR OPENINGS  
s &LUE GAS VENT SYSTEM  
s 0ILOT AND MAIN BURNER FLAMES  
s 7ATER PIPING  
s #HECK BOILER INTERIOR PIPING  
s #HECK VENTING SYSTEM  
s #HECK AIR VENTS  
Monthly  
s "OILER HEATING SURFACES  
s "URNERS AND BASE  
Service:  
s #HECK BOILER RELIEF VALVE  
s #HECK AUTOMATIC AIR VENTS ꢂIF  
USED  
s /ILEDꢀBEARING CIRCULATORS  
Start-up:  
Periodically  
s 4EST LOW WATER CUTOFF ꢂIF USED  
s 0ERFORM STARTꢀUP PER MANUAL  
Check/test:  
Every 6 months s /PERATE RELIEF VALVE  
s 'AS PIPING  
s #OLD FILL AND OPERATING PRESSURES  
s !IR VENTS AND AIR ELIMINATION  
s ,IMIT CONTROLS AND CUTOFFS  
s %XPANSION TANK  
End of season  
s 3HUT DOWN PROCEDURE  
s "OILER RELIEF VALVE  
Review:  
s 2EVIEW WITH OWNER  
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 system. Failure to follow the directions in this manual  
and component literature could result in severe personal injury, death or substantial property  
damage.  
44  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
10b  
Service & maintenance — annual start-up  
of the CONTAMINANTS listed in 4ABLE ꢅ ON PAGE ꢉ OF  
this manual. If any of these are present in the boiler  
intake air vicinity, they must be removed. If they  
cannot be removed, install combustion air piping  
to the boiler in accordance with national, provincial  
The boiler should be inspected and started annu-  
ally, at the beginning of the heating season, only  
by a qualified service technician. In addition, the  
or local codes.  
maintenance and care of the boiler designated in  
Table 6, page 44, and explained on the following  
Air openings  
pages must be performed to assure maximum  
boiler efficiency and reliability. Failure to service  
and maintain the boiler and system could result  
in equipment failure.  
ꢆꢀ 6ERIFY THAT COMBUSTION AND VENTILATION AIR OPEN-  
ings to the boiler room and/or building are open  
and UNOBSTRUCTEDꢀ #HECK OPERATION AND WIRING OF  
automatic combustion air dampers, if used.  
Eliminate all system or boiler leaks. #ONTINUAL  
fresh makeup water will reduce boiler life. Miner-  
als can build up in sections, reducing heat transfer,  
overheating cast iron, and causing section failure.  
Leaking water may also cause severe property  
damage.  
ꢄꢀ 6ERIFY THAT BOILER VENT DISCHARGE AND AIR INTAKE ARE  
CLEAN AND FREE OF OBSTRUCTIONS.  
Flue gas vent system  
1. 6ISUALLY INSPECT ENTIRE mUE GAS VENTING SYSTEM  
for blockage, deterioration or leakage. Repair any  
joints that show signs of leakage in accordance with  
vent manufacturer’s instructions.  
$O NOT USE petroleum-based cleaning or sealing  
compounds in boiler system. Severe damage to  
boiler will occur, resulting in substantial property  
damage.  
ꢄꢀ 6ERIFY THAT MASONRY CHIMNEYS ARE LINEDꢁ LINING IS IN  
good condition, and there are not openings into the  
chimney.  
Electrical shock hazard — Turn off power to  
the boiler before any service operation on the  
boiler except as noted otherwise in this instruction  
manual. Failure to turn off electrical power could  
result in electrical shock, causing severe personal  
injury or death.  
&AILURE TO INSPECT for the above  
conditions and have them repaired  
can result in severe personal injury  
or death.  
Pilot and main burner flames  
O Inspect . . .  
Reported problems  
Inspect any problems reported by owner and correct  
before proceeding.  
ꢆꢀ 6ISUALLY INSPECT PILOT BURNER AND MAIN BURNER  
flames as directed under Section ꢇD, page 32 of this  
manual.  
Water piping  
Boiler area  
ꢆꢀ 6ERIFY THAT BOILER AREA IS FREE OF ANY COMBUSTIBLE  
MATERIALS, gasoline and other flammable vapors  
and liquids.  
ꢆꢀ #HECK THE BOILER INTERIOR PIPING AND ALL SYSTEM PIP-  
ing for signs of leaks.  
ꢄꢀ 6ERIFY THAT BOILER AREA ꢋAND AIR INTAKE IS FREE OF ANY 2. Repair any leaks before proceeding.  
45  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
10b  
Service & maintenance – annual start-up  
(cont.)  
2. Inspect burners and all other components in the  
boiler base.  
O Inspect . . .  
3. 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.  
#AREFULLY REPLACE ALL BURNERSꢁ MAKING SURE BURNER  
with pilot bracket is replaced in its original position  
and all burners are upright (ports up).  
Boiler heating surfaces  
ꢆꢀ $ISCONNECT THE VENT PIPE AT THE BOILER DRAFT HOOD  
and remove draft hood after turning off power to  
the boiler.  
2. Use a bright light to inspect the boiler flue collector  
and heating surfaces.  
3. If the vent pipe or boiler interior surfaces show  
evidence of soot, follow #LEANING BOILER HEATING  
SURFACES in this manual section. Remove the flue  
collector and clean the boiler if necessary after closer  
inspection of boiler heating surfaces.  
4. Inspect the base insulation.  
a. Pay attention to the 7!2.).'3 on page 68  
regarding working with insulation materials.  
Bꢀ 6ERIFY THAT THE INSULATION IS INTACT AND SECURE  
4. If there is evidence of rusty scale deposits on boiler  
surfaces, check the water piping and control system  
to make sure the boiler return water temperature is  
properly maintained (per this manual).  
against all four sides of the base.  
O Service . . .  
5. Reconnect vent and draft hood. Replace all boiler  
components before returning to service.  
Oiled-bearing circulators  
ꢏꢀ #HECK INSIDE AND AROUND BOILER FOR EVIDENCE OF ANY  
leaks from the boiler. If found, locate source of leaks  
and repair."URNERS AND BASE  
ꢆꢀ 4HE CIRCULATOR SHIPPED WITH THE #'A BOILER IS WATERꢂ  
LUBRICATEDꢀ .O OILING IS REQUIREDꢀ  
ꢄꢀ #HECK OTHER CIRCULATORS IN THE SYSTEMꢀ /IL ANY  
circulators requiring oil, following circulator man-  
ufacturer’s instructions. Over-oiling will damage the  
circulator.  
The boiler contains ceramic  
fiber and fiberglass materials.  
Use care when handling these  
materials per instructions on  
PAGE ꢇꢋ of this manual. Fail-  
ure to comply could result in  
severe personal injury.  
O Start-up . . .  
1. Perform all start-up procedures given in Section ꢇ  
of this manual.  
If insulation is damaged or  
displaced, do not operate  
the boiler. Replace or reposi-  
tion insulation as necessary.  
Failure to replace damaged  
insulation can result in a fire  
hazard, causing severe person-  
al injury, death or substantial  
property damage.  
ꢄꢀ 6ERIFY COLD lLL PRESSURE is correct and that fill  
system is working properly.  
ꢅꢀ 6ERIFY ANTIFREEZE LEVEL (if used) is at the right con-  
centration and that inhibitor level is correct.  
4. #HECK GAS PIPING, per manual Sections and 6,  
verifying no indications of leakage and all piping  
and connections are in good condition.  
5. Read the ,IGHTING OR /PERATING INSTRUCTIONS  
(manual Section ꢋ OR ꢏ) applying to the boiler.  
1. After turning off power to the boiler, remove the  
jacket door and base access panel (&IGURE ꢌꢉ, item , 6. Start the boiler following appropriate ,IGHTING OR  
page 62).  
/PERATING INSTRUCTIONS (manual Section ꢋ OR ꢏ).  
46  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
10b  
Service & maintenance – annual start-up  
(cont.)  
Expansion tank  
O Check/test  
1. Expansion tanks provide space for water to move in  
an out as the heating system water expands due to  
temperature increase or contracts as the water cools.  
Tanks may be open, closed or diaphragm or bladder  
type. See Section of this manual for suggested best  
location of expansion tanks and air eliminators.  
Gas piping  
1. Sniff near floor and around boiler area for any in-  
dication of a GAS LEAK.  
2. 4EST GAS PIPING USING BUBBLE TESTꢄ per Section ꢎ  
/PENꢀTYPE — located above highest radiator or  
BASEBOARD UNITꢁ USUALLY IN THE ATTIC OR CLOSETꢀ (AS A  
gauge glass and overflow pipe to a drain.  
of this manual, if there is any indication of a leak.  
Cold fill and operating pressures  
#LOSEDꢀTYPE — welded gas tight and located above  
boiler. Tank is partially filled with water, leaving an  
air cushion for expansion.  
1. While the system is cold, note the PRESSURE READING  
ONTHEBOILERPRESSUREꢃTEMPERATUREGAUGE6ERIFYTHAT  
cold fill pressure is correct.  
2. 7ATCH THE PRESSURE as the boiler and system heat  
up to ensure pressure rise is normal. Too high a rise  
would indicate a waterlogged or undersized expan-  
sion tank.  
s
-AKE SURE THIS TYPE OF TANK IS lTTED WITH A TANK  
lTTINGꢁ SUCH AS THE " ꢕ ' Tank-Trol or Taco  
Taco-Trol. This fitting reduces gravity circula-  
tion of air-saturated tank water back to the  
system and prevents the air from bubbling up  
through the water as it returns from the sys-  
tem.  
Air vents and air elimination  
1. Inspect automatic air vents (if used). Also inspect  
air separators to ensure they are operational.  
s
$O NOT USE AUTOMATIC AIR VENTS IN SYSTEMS  
WITH CLOSEDꢀTYPE TANKSꢂ The air will escape  
from the system instead of returning to the tank.  
Eventually, the tank will waterlog and no longer  
control pressurization. The boiler relief valve  
will weep frequently.  
2. The cap must be unscrewed one turn to allow air to  
escape.  
3. See &IGURE ꢉꢇ. If the air vent is leaking, remove cap  
! and briefly push valve " and then release to clean  
the valve seat.  
$IAPHRAGMꢀ OR BLADDERꢀTYPE — welded gas tight  
with a rubber membrane to separate the tank pres-  
surizing air and the water. May be located at any  
point in the system, but most often found near the  
boiler.  
4. Replace cap ! by twisting all the way onto valve "  
and then unscrewing one turn.  
&IGURE ꢉꢇ  
Automatic air vent, typical  
s
3YSTEMS WITH THIS TYPE OF EXPANSION TANK REQUIRE  
at least one AUTOMATIC AIR VENT, preferably lo-  
cated on top of an air eliminator, as shown in  
examples in manual Section .  
2. If relief valve has tended to weep frequently, the ex-  
pansion tank may be waterlogged or undersized.  
#LOSEDꢀTYPE TANK — tank is most likely water-  
logged. Install a tank fitting if not already installed.  
Then check fill level per fitting manufacturer’s  
instructions. If fill level is correct, check tank size  
against manufacturer’s instructions. Replace with  
a larger tank if necessary.  
$IAPHRAGMꢀ OR BLADDERꢀTYPE — first, check tank  
size to be sure it is large enough for the system. If  
size is too small, add additional tank(s) as neces-  
sary to provide sufficient expansion. If tank size is  
large enough, remove tank from system and check  
charge pressure (usually 12 psig for residential ap-  
plications). If tank won’t hold pressure, membrane  
has been damaged. Replace tank.  
Limit controls and cutoffs  
ꢆꢀ )NSPECT AND TEST THE BOILER LIMIT CONTROLꢀ 6ERIFY OP-  
eration by turning control set point below boiler  
TEMPERATUREꢀ "OILER SHOULD CYCLE OFFꢀ 2ETURN DIAL TO  
original setting.  
2. Inspect and test additional limit controls or low  
water cutoffs installed on system.  
47  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
10b  
Service & maintenance – annual start-up  
(cont.)  
O Check/test (continued)  
Safety relief 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 to ensure that the  
valve and discharge line have not  
been altered or tampered with  
ILLEGALLYꢀ #ERTAIN NATURALLY OC-  
curring conditions may corrode  
the valve or its components over  
time, rendering the valve inop-  
erative. Such conditions are not  
detectable unless the valve and  
its components are physically  
removed and inspected. This in-  
spection must only be conducted  
by a plumbing contractor or au-  
thorized inspection agency — not  
by the owner. Failure to reinspect  
the boiler relief valve as directed  
could result in unsafe pressure  
buildup, which can result in  
severe personal injury, death or  
substantial property damage.  
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 MANUFACTURERꢐS WARNING LABELꢀ "EFORE  
operating any relief valve, ensure that it is piped  
with its discharge in a safe area to avoid severe scald  
potential. Read manual Section before proceeding  
further.  
2. After following the above warning directions, if the  
relief valve weeps or will not seat properly, replace  
the relief valve. Ensure that the reason for relief valve  
weeping is the valve and not over-pressurization of  
the system due to expansion tank waterlogging or  
undersizing.  
&IGURE ꢉꢍ  
Following installation, the valve  
LEVER MUST BE OPERATED !4  
,%!34 /.#% !9%!2 to ensure  
THAT WATERWAYS ARE CLEARꢀ #ERTAIN  
naturally occurring mineral de-  
posits may adhere to the valve,  
rendering it inoperative. When  
manually operating the lever, wa-  
ter will discharge and precautions  
must be taken to avoid contact  
with hot water and to avoid water  
DAMAGEꢀ "EFORE OPERATING LEVERꢁ  
check to see that a discharge line  
is connected to this valve direct-  
ing the flow of hot water from the  
valve to a proper place of disposal  
otherwise severe personal injury  
may result. )F NO WATER FLOWSꢄ  
VALVE IS INOPERATIVEꢂ Shut down  
boiler until a new relief valve has  
been installed.  
O Review with owner  
1. Review the 5SERꢃS )NFORMATION -ANUAL with the  
owner.  
2. Emphasize the need to perform the maintenance  
schedule specified in the 5SERꢃS )NFORMATION  
-ANUAL (and in this manual as well).  
3. Remind the owner of the need to call in a licensed  
contractor should the boiler or system exhibit any  
unusual behavior.  
4. Remind the owner to follow the proper shutdown  
procedure and to schedule an annual start-up at the  
beginning of the next heating season.  
48  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
10b  
Service & maintenance – annual start-up  
(cont.)  
O Cleaning boiler heating surfaces  
The boiler contains ceramic fiber and fiberglass materi- ꢊꢀ 2EMOVE BURNERS FROM BASEꢀ "RUSH AND VACUUM  
als. Use care when handling these materials per instruc-  
tions on PAGE ꢇꢋ of this manual. Failure to comply  
could result in severe personal injury.  
BURNERS TO REMOVE ALL DUST AND LINTꢀ 6ERIFY THAT ALL  
burner ports are free of debris.  
8. Place newspapers in base of boiler to collect soot.  
ꢉꢀ #LEAN BETWEEN SECTIONS WITH WIRE mUE BRUSHꢀ  
1. Shut down boiler:  
ꢆꢌꢀ 2EMOVE NEWSPAPER AND SOOTꢀ 6ACUUM OR BRUSH BASE  
s
&OLLOW h4O 4URN /FF 'AS TO !PPLIANCEv IN-  
structions on boiler and ,IGHTING OR /PERATING  
INSTRUCTIONS.  
and surrounding area.  
11. Reinstall radiation plates.  
12. Replace collector box/transition assembly. Seal with  
sealant. Obtain gas-tight seal to prevent flue gas  
spillage and carbon monoxide emissions, resulting  
in severe personal injury or death.  
s
$O NOT DRAIN BOILER UNLESS IT WILL BE EXPOSED  
to freezing temperatures. If using antifreeze in  
system, do not drain.  
2. Follow shutdown procedure.  
13. Replace insulation and jacket top panel.  
3. Remove venting system connection to boiler.  
4. Remove top jacket panel. Turn back insulation.  
14. Start up boiler following Section of this manual  
and the boiler ,IGHTING OR /PERATING INSTRUCTIONS  
(Section ꢋB or ꢏB). Excessive sooting indicates  
improper gas combustion. If found, check for proper  
combustion and make any necessary adjustments.  
ꢑꢀ 2EMOVE mUE COLLECTORꢀ #LEAN SEALANT FROM ASSEMBLY  
and sections.  
6. Remove radiation plates hanging between sections.  
11a  
Troubleshooting — procedure  
Label all wires prior to disconnection when servic-  
ing controls. Wiring errors can cause improper  
and dangerous operation.  
Before troubleshooting:  
ꢆꢀ (AVE THE FOLLOWING ITEMSꢇ  
Aꢀ 6OLTMETER THAT CAN CHECK ꢆꢄꢌ 6!# AND  
ꢄꢈ 6!#ꢀ  
b. Microammeter with a minimum scale  
range of 0-25.  
Cꢀ #ONTINUITY CHECKERꢀ  
d. U-tube manometer.  
.EVER JUMPER ꢋBYPASS ROLLOUT THERMAL FUSE ELE-  
ment or any other device except for momentary  
testing as outlined in 4ROUBLESHOOTING #HARTS.  
Severe personal injury, death or substantial prop-  
erty damage can result.  
ꢄꢀ #HECK FOR ꢆꢄꢌ 6!# ꢋMINIMUM ꢆꢌꢄ 6!# TO  
MAXIMUM ꢆꢅꢄ 6!# TO BOILERꢀ  
3. Make sure thermostat is calling for heat and  
contacts (including appropriate zone controls)  
ARE CLOSEDꢀ #HECK FOR ꢄꢈ 6!# BETWEEN THERMO-  
stat wire nuts and ground.  
"URNER ACCESS PANEL MUST BE IN POSITION DURING  
boiler operation to prevent momentary flame  
rollout on ignition of main flame. Severe per-  
sonal injury or substantial property damage will  
result.  
3EE PAGES ꢑꢌ THROUGH ꢑꢉ FOR ADDITIONAL TROUBLE-  
shooting information.  
ꢈꢉ  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11a  
Troubleshooting — procedure  
(continued)  
Check the following:  
1. Wire connectors to control module are securely  
plugged in at module and originating control.  
ꢄꢀ 'AS PRESSURESꢇ  
Aꢀ 7ITH BOILER OFF ˆ ꢆꢅv WꢀCꢀ MAXIMUM NATURAL  
or propane gas pressure upstream of gas valve.  
b. With boiler on:  
s
ꢑv WꢀCꢀ MINIMUM NATURAL GAS PRESSURE OR  
ꢆꢆv WꢀCꢀ PROPANE GAS PRESSURE UPSTREAM OF  
gas valve.  
s
ꢅꢀꢑv WꢀCꢀ MINIMUM NATURAL GAS PRESSURE OR  
ꢆꢌv WꢀCꢀ PROPANE GAS PRESSURE DOWNSTREAM  
TAPPING ON GAS VALVE ˆ #AN BE ADJUSTED BY  
regulator on gas valve.  
In event of vent damper  
failure:  
Failure to turn off power to boiler  
can result in severe personal injury,  
death or substantial property dam-  
age.  
Effikal or Field Controls damper  
2. Refer to vent damper manufacturer’s instructions  
for procedure to fix vent damper in open position.  
If troubleshooting chart recommends replacing actua-  
tor and actuator is not immediately available, damper  
blade can be fixed in an open position to allow boiler  
operation. Manually turning blade can cause actuator  
damage. Follow these instructions only in case of no  
heat or damper actuator malfunction.  
3. Turn on power to boiler.  
4. Using wrench or pliers on flat shaft section, manu-  
ally rotate damper blade until green light turns on.  
"OILER WILL lREꢀ ꢋ&IGURE ꢉꢋ)  
1. Move damper service switch to (OLD $AMPER /PEN  
POSITIONꢀ !PPLY CALL FOR HEAT TO BOILERꢀ $AMPER BLADE  
should then rotate to open position and boiler will  
fire.  
ꢑꢀ $O NOT LEAVE VENT DAMPER PERMANENTLY IN THIS POSI-  
tion. Replace actuator immediately. If vent damper  
is left in open position, boiler will not operate at  
published efficiencies.  
2. If step 1 does not open damper, manually rotate  
s 6ERIFY PROPER OPERATION AFTER SERVICINGꢀ s 3EE VENT DAMPER MANUFACTURERꢐS INSTRUCTIONS PACKED WITH VENT DAMPER  
for additional information. Failure to comply could result in severe personal injury, death or substantial property  
damage.  
50  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11b  
Troubleshooting — standing pilot boilers  
CHART 1 Standing pilot — Boiler will not fire  
Is damper harness securely plugged in at both ends?  
Secure connections.  
No  
Yes  
Check for loose wire connections or bad relay on  
transformer.  
Is 24VAC present across transformer terminals C & Y?  
No Yes  
Check for open thermostat, LWCO, high limit, spill switch or  
rollout thermal fuse element contacts or check for loose wire  
connections.  
Is 24VAC present across transformer terminal C and  
yellow wire on vent damper connector?  
No  
Yes  
If LWCO, spill switch or rollout thermal fuse  
element contacts are open, determine cause  
and correct condition. Failure to do so will  
cause severe personal injury, death or  
substantial property damage.  
Is vent damper rotated open?  
No  
Yes  
Check/repair out of round stack section. Does vent damper  
rotate open?  
Is 24VAC present across gas valve terminals?  
No  
Yes  
No  
Yes  
Replace actuator.  
Retest.  
Is main flame on now?  
No  
Yes  
Open thermostat contacts for 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?  
Retest  
Is gas valve cock turned to ON position?  
No  
Yes  
No  
Yes  
Check continuity of each wire in damper harness. Does  
continuity exist for each wire? See Table below.  
Turn gas valve cock to  
ON position. Retest.  
Replace gas valve.  
Retest.  
No  
Yes  
Remove damper harness from  
damper harness plug.  
TEMPORARILY install jumper  
between terminal 2 and  
Replace damper  
wiring harness.  
Retest.  
terminal 5 on damper plug in  
boiler wiring harness. See  
figure, right. Does boiler fire?  
No  
Yes  
Replace gas valve.  
Retest.  
Replace damper  
actuator. Retest.  
51  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — spark-pilot boilers  
The information on this page and  
Control module  
PAGES ꢑꢅ THROUGH ꢑꢉ APPLY ONLY TO  
Solder or watersplatter between plugs and circuit board  
SPARKꢂIGNITED PILOT #'A BOILERSꢀ  
These boilers are equipped with an  
ignition control module that has in-  
dicator lights to show control status.  
can cause improper operation of control module. Place a  
shield over the boiler internal controls and components  
during installation. Failure to comply could result in  
severe personal injury, death or substantial property  
damage.  
Make sure ground wiring is installed per wiring  
DIAGRAMꢀ 'OOD GROUNDING IS EXTREMELY IMPORTANT FOR  
proper operation.  
Control indicator lights —  
LOCKOUT modes  
See Charts 1 through 7 in this section for detailed troubleshooting procedures.  
4O RESET CONTROL AFTER A LOCKOUTꢁ TURN OFF POWER AT THE ꢆꢄꢌ 6!# SERVICE SWITCH OR TURN  
down all thermostats. Wait 45 seconds. Then restore power or call for heat.  
POWER light flashing alone  
5SUALLY INDICATES REVERSED POLARITY OF ꢆꢄꢌ 6!# POWER WIRESꢀ  
POWER and TSTAT CIRC lights flashing  
Usually indicates stray voltage on external thermostat circuit wires (usually due to  
miswired 3-wire zone valve).  
POWER and DAMPER lights flashing  
Usually indicates damper circuit is closed when it should not be, or damper failed  
to close within 5 minutes.  
POWER and FLAME lights flashing  
Usually indicates false flame sense or flame sensed when it shouldn’t be there.  
Control indicator lights —  
NON-LOCKOUT modes  
POWER light on and FLAME light flashing  
Usually indicates pilot flame was not established within 15 seconds from application  
OF SPARKꢀ #ONTROL WILL mASH LIGHTꢁ BUT WILL CONTINUE TO CYCLE INDElNITELY UNTIL mAME  
is established or problem is corrected.  
POWER light on and DAMPER light flashing  
Usually indicates the damper circuit opened during the run cycle.  
Troubleshooting the control module  
See Figure 30 , page 53, for location of harness plug receptacles and plugs on the  
control module.  
52  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — spark-pilot boilers  
(continued)  
Part Numbe
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — spark-pilot boilers  
(continued)  
CHART 2 Spark-ignited pilot — Troubleshooting POWER light status  
— Usually indicates reversed 120 VAC polarity if POWER light flashes by itself —  
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.  
Is POWER light off?  
Make sure service switch or circuit breaker is on or  
fuses are good.  
No  
Yes  
Remove 120 VAC IN plug (Figure 30, Item 3,  
page 53) on control module.  
Using voltmeter, check across top and bottom pins  
of 120 VAC IN plug.  
Is POWER light...  
Does voltmeter indicate 120 VAC?  
On steady  
(not flashing)  
Flashing with  
another light  
Flashing  
alone  
No  
Yes  
TSTAT CIRC  
Chart  
3
Problem is with incoming  
electricity. Have licensed  
electrician repair circuit.  
light flashing  
DAMPER  
light flashing  
Chart  
4
FLAME  
Chart  
5
Chart  
6
Reconnect 120 VAC IN plug.  
light flashing  
Remove 120 VAC transformer PRIMARY plug  
(Figure 30, Item 2, page 53) on control module.  
Using voltmeter, check across top and bottom pins  
of PRIMARY receptacle.  
For insufficient heat or no heat problem, go to  
Chart 7, page 59, if POWER light is on steady,  
with no other light flashing.  
Does voltmeter indicate 120 VAC?  
No  
Yes  
Usually indicates polarity on incoming 120 VAC power  
line is wrong.  
Replace control module.  
Retest.  
TURN OFF POWER at service switch or breaker,  
then reverse the HOT and NEUTRAL wires entering  
the boiler in the J-box.  
Reinstall 120 VAC transformer PRIMARY plug.  
Remove 24 VAC transformer plug (Figure 30, Item 5,  
page 53) on control module.  
Restore POWER at service switch or breaker.  
Is POWER light flashing now?  
Using voltmeter, check across pins of receptacle.  
No  
Yes  
Does voltmeter indicate 120 VAC?  
No  
Yes  
Have system checked by a  
licensed electricain.  
If problem persists, call your  
local Weil-McLain sales  
representative.  
Boiler should now  
operate normally.  
Replace transformer.  
Retest.  
Replace control module.  
Retest.  
54  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — spark-pilot boilers  
(continued)  
CHART 3 Spark-ignited pilot TSTAT CIRC & POWER lights flashing  
— Usually indicates 48 VAC on thermostat circuit (stray voltage) —  
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.  
• Disconnect the two external wires connected to the boiler  
thermostat leads (two black low voltage leads in J-box).  
• If a voltage does occur under any condition, check and  
correct the external wiring. (This is a common problem  
when using 3-wire zone valves.)  
• 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 voltmeter reading  
across the wires.  
• 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.  
• There should NEVER be a voltage reading.  
Did you find a voltage across the two external thermostat circuit wires?  
Yes  
No  
• If no voltage is found under any condition of the external  
thermostat circuit, connect the two boiler thermostat  
connection leads together (or jumper the boiler aquastat  
T-T terminals).  
• Leave external boiler thermostat connection wires  
disconnected from boiler.  
• Troubleshoot the external thermostat circuit until you find  
the source of the stray voltage. (Pay close attention to  
the wiring connections to 3-wire zone valves.)  
• Turn off power to the boiler for 1 minute.  
• Turn on power and allow boiler to cycle.  
Do the TSTAT and POWER lights still flash?  
• Correct the problem and repeat the voltmeter test above,  
verifying there is no longer a voltage reading under any  
condition in the external thermostat circuit.  
No  
Yes  
• Boiler should now operate per the normal sequence of  
• Replace control module.  
• Retest.  
operation shown in Figure 24, page 37.  
55  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — spark-pilot boilers  
(continued)  
CHART 4 Spark-ignited pilot DAMPER light flashing  
— If POWER light is flashing: Usually indicates vent damper failed to prove open within 5 minutes —  
— If POWER light is steady: Usually indicates vent damper closed during run cycle —  
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 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 come on.  
Does vent damper operate?  
No  
Yes  
• Wait 45 seconds.  
Does vent damper operate?  
No Yes  
• Remove DAMPER plug (Figure 30, Item 6, page 53)  
from plug receptacle of control module.  
• Place voltmeter leads across the top two pins (1 and 4)  
of the DAMPER receptacle.  
• Wait 5 minutes.  
Is PRESS SWITCH light flashing?  
No  
Yes  
Does the voltmeter indicate 24 VAC?  
No  
Yes  
• Try reseating plug in  
module receptacle and  
restart.  
• Boiler should be in  
normal operating  
sequence.  
• If vent damper still does  
not work, replace vent  
damper assembly or  
actuator.  
• Observe operation until  
thermostat is satisfied.  
Does vent damper actuator  
indicator show damper is  
open?  
• Retest.  
No  
Yes  
Are the TSTAT CIRC and LIMIT lights on steady?  
Yes  
No  
• Remove damper wiring  
plug at damper and firmly  
reconnect.  
• Recheck boiler operation.  
• If problem persists,  
replace vent damper  
assembly or actuator.  
• Replace vent damper  
assembly or actuator.  
• Retest.  
• Make sure thermostat is  
calling for heat. If lights  
still don't come on, see  
Chart 7, page 59.  
• Replace control  
module.  
• Retest.  
56  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — spark-pilot boilers  
(continued)  
CHART 5 Spark-ignited pilot FLAME & POWER lights flashing  
— Usually indicates flame sensed when it shouldn't be there —  
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.  
Are manual main shutoff valve and gas valve open?  
No  
Yes  
• Leave main manual gas valve closed.  
• Turn off power to boiler at service switch or breaker.  
• Wait at least 45 seconds.  
• Turn off power to the boiler at service switch or breaker.  
• Wait at least 45 seconds.  
• Turn on power to boiler.  
• Turn on power to boiler.  
• Restart boiler, following Operating instructions in this  
manual (Section 9b) or on boiler label.  
• Look through the pilot inspection port to see if the pilot is  
burning.  
• Restart boiler, following Operating instructions in this  
manual (Section 9b) or on boiler label.  
Do FLAME and POWER lights still flash?  
Is pilot burning?  
No  
Yes  
No  
Yes  
• Replace control module.  
• Retest.  
• Replace gas valve.  
• Retest boiler.  
• Allow boiler to continue cycling.  
Are FLAME and POWER lights flashing?  
Are FLAME and POWER lights flashing?  
No  
No  
Yes  
Yes  
• Boiler may now be  
operating  
• Replace control  
module.  
• Boiler should now  
operate normally.  
• Replace control  
module.  
TURN OFF POWER  
to boiler at service switch  
or breaker.  
normally.  
• Retest.  
• Original flashing  
FLAME light  
• Retest.  
• Open main manual gas  
valve.  
• Turn on power to boiler  
at service switch or  
breaker.  
• Restart boiler per  
operating instructions.  
• Perform start-up  
procedures in boiler  
manual to verify proper  
operation.  
• Perform start-up  
procedures in  
boiler manual to  
verify proper  
caused by gas  
valve not  
operating properly.  
operation.  
• See normal  
sequence of  
operation,  
Figure 24,  
page 37.  
57  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — spark-pilot boilers  
(continued)  
CHART 6 Spark-ignited pilot FLAME light flashing and POWER light on steady  
ALSO — Troubleshooting failure to establish main flame  
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.  
Are main manual shutoff valve and boiler gas valve open?  
No Yes  
Is pilot flame visible through inspection port?  
No  
Yes  
sTURN OFF POWERs to boiler at service switch or breaker.  
Open main manual shutoff valve and boiler gas valve (per  
Operating instructions in this manual). Wait at least 45  
seconds.  
Turn on power at service switch or breaker. Allow boiler to cycle.  
Does FLAME light flash now?  
Check the voltage across  
main gas valve terminals of  
the gas valve.  
Make sure ground wire  
terminal is securely fastened  
to control module mounting  
screw.  
Is 24 VAC present there?  
Yes  
No  
No  
Yes  
Verify inlet gas pressure at gas  
valve:  
Check the voltage across  
main gas valve terminals of  
the gas valve.  
If the wiring from the  
Boiler should be in  
normal operating  
sequence.  
control module to gas  
valve is intact, replace the  
control module.  
Natural gas — 5.0" w.c. min/14.0"  
w.c. max  
Is 24 VAC present there?  
No  
Retest.  
Observe operation  
until thermostat is  
satisfied and blower  
has completed its  
post-purge cycle.  
Yes  
Propane — 11.0" w.c. min/14.0"  
w.c. max  
Is gas present at gas valve inlet and  
within above range?  
Verify inlet gas pressure at gas valve:  
Yes  
No  
Natural gas — 5.0" w.c. min/14.0" w.c. max  
Propane — 11.0" w.c. min/14.0" w.c. max  
TURN OFF POWER to  
boiler at service switch or  
breaker.  
Remove base access panel  
(see Figure 32, item 4,  
page 62 for location).  
Is gas present at gas valve inlet and within above range?  
No Yes  
Contact gas supplier to correct  
pressure or gas supply.  
TURN OFF POWER to  
boiler at service switch or  
breaker.  
Remove base access panel (see  
Figure 32, item 4, page 62 for  
location).  
TURN OFF POWER to boiler at service switch or breaker.  
Check flame signal — Detach sense lead from igntion control  
(Figure 30, item 8, page 53).  
Connect negative lead of MICROAMMETER to control sense  
terminal (Figure 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.  
Verify pilot gas line is not  
kinked, obstructed or damaged  
and is correctly attached to  
pilot and gas valve.  
Verify pilot ignition electrode,  
electrode ceramic and spark  
lead wire from control are in  
good condition. Spark gap  
should be approximately 1/8".  
Correct any above problems,  
replacing pilot if burner or  
wiring is damaged.  
Reinstall base access panel to  
operate boiler for retest after  
any changes or corrections.  
If none of the above corrects  
problem, then replace the  
control module, reinstall base  
access panel, and retest.  
Verify pilot burner is securely  
attached to pilot bracket, bracket  
is securely attached to cross tie,  
and there is no corrosion on the  
parts which would affect the  
ground path for flame sense.  
Verify that pilot flame rod, flame  
rod ceramic and lead wire from  
control module to flame rod are in  
good condition.  
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  
If none of the previous steps  
(including replacing pilot)  
corrects problem, then replace  
the control module, reinstall  
base access panel and retest.  
If the wiring from the  
Correct any above problems,  
replacing pilot if burner or wiring  
is damaged.  
control module to gas  
valve is intact, replace the  
control module and retest.  
58  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — spark-pilot boilers  
(continued)  
CHART 7 Spark-ignited pilot — Insufficient heat or no heat (POWER light on steady)  
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.  
• Has it been at least 5 minutes since setting thermostat to  
call for heat? If not, wait 5 minutes. Is system heating?  
• Is thermostat set to call for heat? Remove thermostat  
wires at boiler and check continuity across the two wires.  
If circuit isn't closed, check external thermostat (zone  
valve, relay, etc.) wiring. Correct problems and retry.  
• Reconnect external thermostat wiring at boiler.  
Is boiler System circulator operating?  
No Yes  
• Remove CIRCULATOR harness plug from  
CIRCULATOR plug receptacle (Figure 30,  
Item 7, page 53). Check with voltmeter across  
pins of control module receptacle.  
Is thermostat circuit closed (continuity across wires)?  
Does voltmeter show 120 VAC across pins?  
No  
Yes  
No  
Yes  
• Boiler is in standby.  
• Set thermostat to call for  
heat and recheck  
operation.  
• Verify Sequence of  
operation, Figure 24,  
page 37.  
Are all red lights off?  
• Repair/replace  
circulator. Retest.  
• Repair/replace  
wiring. Retest.  
• Replace control  
module.  
• Retest.  
No  
Yes  
Wait 30 seconds.  
Are all red lights off?  
• Wait 5 minutes.  
No  
Yes  
Is FLAME light on?  
Yes  
No  
Replace control module.  
Retest.  
• If you have sufficient heat — boiler should be in normal  
operating sequence. (See normal sequence of operation,  
Figure 24, page 37.)  
Is LIMIT light on?  
No  
Yes  
• If you have less than sufficient heat —  
Is vent or combustion air piping free of blockage?  
• Check limit switch  
contacts with continuity  
checker.  
• Replace control module.  
• Retest.  
No  
Yes  
• Correct conditions and  
recheck operation.  
• See Figure 24, page 37  
for normal sequence of  
operation.  
Contact your Weil-McLain  
sales representative.  
Are limit switch contacts  
closed?  
Check spill switch and  
rollout switch continuity —  
are switches closed?  
No  
Yes  
No  
Yes  
• Wait for boiler water to cool to temperature 20 to 30 °F  
lower than temperature set on limit switch.  
• Reset spill switch, or replace  
rollout switch.  
Are limit switch contacts closed?  
No  
Yes  
• Check any other  
limit controls wired  
into the limit  
circuit. If all are  
OK, then replace  
control module.  
• Retest.  
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  
• Boiler water temperature exceeded  
setting on limit switch with thermostat  
calling for heat. Boiler is OK.  
• Replace  
limit switch.  
• Retest.  
• Also check setting on limit switch (should  
be above 140°F.).  
substantial property damage.  
ꢑꢉ  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
12a  
Replacement parts  
Section assembly ..............................................61  
Base..................................................................62  
Jacket...............................................................63  
Trim...................................................................64  
Controls ............................................................65  
Replacement parts must be purchased through a local Weil-McLain  
distributor. When ordering, specify boiler model and size 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-McLain part numbers are found in 7EILꢀ-C,AIN "OILERS AND  
#ONTROLS 2EPAIR 0ARTS ,ISTS.  
The boiler contains ceramic fiber and fiberglass materials. Use care when  
handling these materials per instructions on PAGE ꢇꢋ of this manual.  
Failure to comply could result in severe personal injury.  
60  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
12b  
Replacement parts — section assembly  
Item  
number  
Description  
Weil-McLain  
part number  
Item  
number  
Description  
Weil-McLain  
part number  
311-103-830  
1
2
3
End section, left hand, 51124  
End section, right hand, 51128  
Intermediate section, 51125  
9
High limit, 30°  
differential, with well  
Honeywell  
L4080D1036  
White-Rodgers  
11B81-3  
510-312-250  
311-103-821  
311-103-818  
not  
shown  
Replacement section  
assembly  
CGa-25 & CGa-3  
321-114-345  
321-114-346  
321-114-347  
321-114-348  
321-114-349  
321-114-350  
10  
Draft hood  
CGa-25  
CGa-3  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
450-021-240  
450-021-241  
450-021-242  
450-021-243  
450-021-244  
450-021-245  
450-021-246  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
not  
shown  
Section replacement kit, includes seals and  
sealant for 1 joint  
381-354-527  
11  
Spill switch (210°F)  
Spill switch (240°F)  
CGa-25  
CGa-3 through -8  
510-300-013  
510-300-014  
4
Tie rod, ꢀꢁꢂꢃ" without nut CGa-25 & CGa-3  
(3 per boiler):  
560-234-500  
560-234-501  
560-234-502  
560-234-503  
560-234-504  
CGa-4  
CGa-5  
CGa-6  
CGa-7 & CGa-8  
12  
Vent damper  
4"  
5"  
6"  
7"  
381-800-474  
381-800-475  
381-800-476  
381-800-477  
5
6
7
Nut, ꢀꢁꢂꢃ" (2 per tie rod)  
561-928-235  
562-248-684  
460-003-700  
13  
14  
Vent damper actuator  
Vent damper harness  
Effikal RVGP  
Johnson M35BE-1C  
510-512-337  
510-312-255  
Washer, ꢀꢁꢂꢃ" (1 per tie rod)  
Radiation plate (1 per joint)  
591-391-795  
8
Collector hood CGa-25  
381-354-625  
381-354-626  
381-354-627  
381-354-628  
381-354-629  
381-354-630  
381-354-631  
CGa-3  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
61  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
Replacement parts — base  
12c  
ers  
Item  
Description  
Weil-McLain  
part number  
number  
Base assembly kit  
CGa-25  
CGa-3  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
381-354-355  
381-354-356  
381-354-357  
381-354-358  
381-354-359  
381-354-360  
381-354-361  
(includes base panels items 1, 2,  
3, 4, 5, 6, and 7, plus insulation,  
air box gaskets, and hardware)  
1
2
3
4
5
6
7
8
Base side panel (in Base assembly)  
Base front cross-tie assembly (in Base assembly)  
Base back cross-tie assembly (in Base assembly)  
Access panel (in Base assembly)  
Base pan angle, left side (in Base assembly)  
Base pan angle, right side (in Base assembly)  
Base pan (in Base assembly)  
Burner rest  
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  
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  
(includes insulation for all base  
parts above plus gasket material  
needed between block assembly  
and base)  
10  
11  
Boiler leg kit  
Manifold  
590-424-253  
CGa-25  
CGa-3  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
591-126-615  
591-126-616  
591-126-617  
591-126-618  
591-126-619  
591-126-556  
591-126-557  
12  
Main burner orifice — Natural gas, sea level  
Main burner orifice — Propane gas, sea level  
560-528-997  
560-528-998  
13  
14  
Burner, stainless steel  
512-200-077  
512-200-079  
512-200-078  
Burner with pilot bracket  
(not shown)  
Standing pilot  
Spark-ignited  
pilot  
15  
16  
Screw, 10-32 x 1/8 STP type D hx, washer head  
available at  
local supply  
house  
slot ZP  
Rollout thermal fuse element  
512-050-230  
62  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
12d  
Replacement parts — jacket  
&IGURE ꢌꢌ Jacket assembly  
1
2
3
4
Junction box, 2 x 4  
Jacket panel, left side, with insulation  
Jacket panel, right  
side, with insula-  
tion  
Jacket panel,  
top front  
Natural Gas  
Propane Gas  
Standing Pilot  
Natural Gas  
Spark Pilot  
Standing Pilot  
Boiler  
Model  
Boiler  
Model  
Weil-McLain part number  
CGa-25  
CGa-3  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
(Available at local  
supply house)  
381-355-400  
381-355-407  
381-355-410  
381-355-417  
381-355-424  
381-355-431  
381-355-438  
381-355-445  
381-355-448  
381-355-451  
381-355-454  
381-355-457  
381-355-460  
381-355-463  
381-355-466  
381-355-470  
381-355-473  
381-355-477  
381-355-481  
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  
CGa-3  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
5
6
7
8
9
10  
Jacket panel,  
Jacket panel,  
Jacket cross tie,  
Jacket panel,  
Jacket panel,  
Not shown — gold  
top rear  
door  
bottom front  
interior  
rear  
touch-up paint  
Boiler  
Model  
Boiler  
Model  
Weil-McLain part number  
CGa-25/3  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
381-355-404  
381-355-414  
381-355-421  
381-355-428  
381-355-435  
381-355-442  
381-355-406  
381-355-416  
381-355-423  
381-355-430  
381-355-437  
381-355-444  
431-223-325  
431-223-326  
431-223-327  
431-223-328  
431-223-329  
431-223-330  
381-355-405  
381-355-415  
381-355-422  
381-355-429  
381-355-436  
381-355-443  
431-223-300  
431-223-301  
431-223-302  
431-223-303  
431-223-304  
431-223-305  
592-000-000  
CGa-25/3  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
63  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
12e  
Replacement parts — trim  
&IGURE ꢌꢎ Trim assembly  
Item  
number  
Description  
Manufacturer  
Manufacturer’s  
part number  
Weil-McLain  
part number  
1
Pressure relief valve, ASME, 30 PSIG, ¾" male inlet  
Conbraco  
Watts  
Conbraco  
Watts  
10-407-10  
M330  
10-408-05  
335  
511-546-920  
511-546-924  
Pressure relief valve, ASME, 30 PSIG, ¾" female inlet  
(Fittings shown are factory-installed on boiler.)  
2
3
Combination pressure-temperature gauge, 3ꢀꢁꢂ" diameter,  
short shank (Fittings shown are shipped loose with boiler.)  
Weil-McLain  
380-000-000  
511-210-423  
Drain valve, ¾"  
(Fittings shown are included with boiler.)  
Conbraco  
Hammond Valve  
Matco-Norca  
Watts  
31-606-01  
710  
205F04  
BD-2C  
4
5
Circulator  
Bell & Gossett NRF-22-103253 511-405-118  
(Fittings shown are shipped loose with boiler.)  
Taco  
007  
511-405-113  
Circulator gasket, universal (2 per boiler)  
Weil-McLain  
Weil-McLain  
590-317-535  
not shown Circulator hardware kit, includes:  
1 flange, 2 nuts, 2 screws, 1 gasket:  
¾” NPT — CGa-25- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 381-354-530  
1" NPT — CGa-3 through CGa-5 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 381-354-525  
1¼" NPT — CGa-6 through CGa-7 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 381-354-526  
1½” NPT — CGa-8- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 381-354-531  
6
Circulator wiring harness, standing pilot ignition  
Circulator wiring harness, spark-ignited pilot (with Molex)  
Weil-McLain  
591-319-793  
381-354-528  
not shown Mate-N-Lock connector (red), spark-ignited pilot only  
Amp  
1-480698-2  
563-210-632  
64  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
12f  
Replacement parts — controls  
&IGURE ꢌꢊ 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 through CGa-6  
Honeywell  
Robertshaw  
Honeywell  
VR8200A2116  
7200ER  
VR8300C4050  
511-044-360  
Gas valve, 3/4" x 3/4", CGa-7 and CGa-8  
Pilot assembly kit with orifice  
Tubing, pilot, aluminum  
511-044-256  
510-811-644  
560-742-860  
511-724-254  
2
3
4
Weil-McLain  
Tubing, thermocouple  
Propane gas components  
1
Gas valve, 1/2" x 1/2", CGa-25 through CGa-6  
Honeywell  
Honeywell  
VR8200C1074  
VR83004068  
511-044-258  
511-044-257  
Gas valve, 3/4" x 3/4", CGa-7 and CGa-8  
2
3
4
Pilot assembly kit with orifice  
Tubing, pilot, aluminum  
Tubing, thermocouple  
Weil-McLain  
510-811-646  
550-742-860  
511-724-253  
Natural gas and propane gas components  
Transformer relay  
not shown Wiring harness  
5
510-312-167  
591-391-862  
Spark ignition  
6
Gas valve, 1/2" x 1/2", CGa-25 through CGa-6  
Honeywell  
VR8204A2001  
36E36-266  
7200 IPER  
VR8304P4348  
36C74-474  
511-044-381  
511-044-382  
White-Rodgers  
Robertshaw  
Honeywell  
Gas valve, 3/4" x 3/4", CGa-7 and CGa-8  
White-Rodgers  
7
8
9
Pilot assembly kit with orifice and aluminum pilot gas tubing  
Control module  
Control transformer  
Weil-McLain  
United Technologies  
511-330-218  
511-330-079  
511-842-370  
591-391-905  
1107-2  
not shown Wiring harness, controls to control module  
Pilot gas pressure regulator — Natural gas and propane gas, CGa-25 and CGa-3  
not shown Pilot gas pressure regulator 4.0" w.c. outlet  
Maxitrol  
SLP  
RV-12  
SL-50N  
510-933-126  
not shown Tubing, from gas valve to regulator  
not shown Adapter, male 1/8" x 7/16" – 24, from regulator to pilot gas line  
Weil-McLain  
Weil-McLain  
560-742-859  
562-302-017  
65  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
13a  
Dimensions  
Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES  
Boiler  
model  
number  
Supply  
tapping  
(inches NPT)  
Return  
Gas connection  
“A”  
Vent  
location  
(inches)  
“D”  
Vent  
diameter  
(inches)  
“W”  
Jacket  
width  
(inches)  
“H”  
tapping & manifold size  
(inches NPT)  
Damper  
height  
(inches)  
(Note 3)  
(inches NPT)  
1
CGa-25  
CGa-3  
CGa-4  
CGa-5  
CGa-6  
CGa-7  
CGa-8  
Note 3:  
11/4  
11/4  
11/4  
11/4  
11/4  
11/4  
11/4  
11/4  
11/4  
11/4  
11/4  
11/4  
11/4  
11/4  
/
2
2
2
2
2
4
4
5
5
61/2  
4
4
5
6
6
7
7
10  
10  
13  
16  
19  
22  
25  
453/8  
523/8  
543/8  
577/8  
607/8  
621/8  
647/8  
1
/
1
/
1
/
8
1
/
91/2  
11  
121/2  
3
/
3
/
Size gas piping from meter to boiler per local utility requirements.  
66  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
13b  
Ratings  
DOE  
Boiler  
model  
number  
Input  
(Btuh)  
DOE  
0–2,000 feet  
altitude  
2,000–4,500 feet  
altitude  
Net  
I=B=R  
ratings content  
(Btuh) (gallons)  
Boiler  
water  
DOE  
Chimney  
and  
breeching  
size  
Heating  
capacity  
(Btuh)  
Seasonal efficiency  
(% A.F.U.E)  
Input Output Input Output  
(Btuh) (Btuh) (Btuh) (Btuh)  
SPDN SPDL  
PIDN  
(Note 1)  
(Note 2)  
(Note 3)  
CGa-25 52,000  
44,000 52,000 44,000 46,800 39,000 38,000  
59,000 70,000 59,000 63,000 53,000 51,000  
88,000 105,000 88,000 94,500 79,000 77,000  
117,0 0 0 140,000 117,0 0 0 126,000 105,000 102,000  
146,000 175,000 146,000 157,500 131,000 127,000  
175,000 210,000 175,000 189,000 157,000 152,000  
204,000 245,000 204,000 220,500 183,000 177,000  
1.5  
1.5  
2.1  
2.7  
3.3  
3.8  
4.4  
81.5  
81.6  
81.7  
81.8  
81.9  
82.0  
82.1  
83.3  
83.7  
83.7  
83.7  
83.6  
83.6  
83.6  
84.0 4"I.D. x 20’  
84.0 4"I.D. x 20’  
84.0 5"I.D. x 20’  
83.5 6"I.D. x 20’  
83.2 6"I.D. x 20’  
83.0 7"I.D. x 20’  
82.7 7"I.D. x 20’  
CGa-3  
70,000  
CGa-4 105,000  
CGa-5 140,000  
CGa-6 175,000  
CGa-7 210,000  
CGa-8 245,000  
1. See Table 7 for available pilot systems. The suffix shown in the table is added to the boiler model number. (Not  
available for millivolt systems.)  
Notes  
2. Based on standard test procedures prescribed by the United States Department of Energy.  
3. Net I=B=R 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 additional allowance should be made for unusual piping and pickup loads.  
Pilot ignition system  
Standing pilot  
Natural gas  
SPDN  
Propane gas  
SPDL  
Table 7 Ignition system model suffixes  
Spark-ignited pilot  
PIDN  
Not available  
)NSTALL #'A BOILERS FOR RESIDENTIAL RADIANT PANEL SYSTEMSꢁ CONVERTED GRAVITY HEATING SYSTEMS OR OTHER LOW WATER  
temperature applications per instructions in this manual to avoid damage due to condensation.  
#'A BOILERS ARE #3! DESIGN CERTIlED FOR INSTALLATION ON COMBUSTIBLE mOORINGꢀ  
#'A BOILERS ARE !3-% RATED FOR ꢑꢌ PSIG WORKING PRESSUREꢀ  
67  
Part Number 550-101-009/0107  
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual  
Handling ceramic fiber and fiberglass materials  
REMOVAL OF COMBUSTION CHAMBER  
LINING OR BASE PANELS  
REMOVAL OF FIBERGLASS WOOL  
or  
The combustion chamber lining or  
base insulation panels in this prod-  
uct contain ceramic fiber materials.  
#ERAMIC FIBERS CAN BE CONVERTED TO  
cristobalite in very high temperature  
applications. The International Agency  
FOR 2ESEARCH ON #ANCER ꢋ)!2# HAS  
CONCLUDEDꢁ h#RYSTALLINE SILICA INHALED IN  
the form of quartz or cristobalite from  
occupational sources is carcinogenic to  
HUMANS ꢋ'ROUP ꢆ ꢀvꢇ  
INSTALLATION OF FIBERGLASS WOOL,  
COMBUSTION CHAMBER LINING OR  
BASE PANELS:  
This product contains fiberglass  
jacket insulation and ceramic fiber  
materials in combustion chamber  
lining or base panels in gas fired  
products. Airborne fibers from these  
materials have been listed by the State  
OF #ALIFORNIA AS A POSSIBLE CAUSE OF  
cancer through inhalation.  
Precautionary measures  
O Avoid breathing fiberglass dust and contact with skin  
Precautionary measures  
or eyes.  
s
5SE .)/3( CERTIlED DUST RESPIRATOR ꢋ.ꢉꢑ ꢀ  
This type of respirator is based on the  
/3(! REQUIREMENTS FOR lBERGLASS WOOL AT THE  
time this document was written. Other types of  
respirators may be needed depending on the  
JOB SITE CONDITIONSꢀ #URRENT .)/3( RECOMMEN-  
DATIONS CAN BE FOUND ON THE .)/3( WEB SITE  
.)/3( APPROVED RESPIRATORSꢁ MANUFACTURERSꢁ AND  
phone numbers are also listed on this web site.  
7EAR LONGꢂSLEEVEDꢁ LOOSE lTTING CLOTHINGꢁ GLOVESꢁ  
and eye protection.  
O Avoid breathing fiberglass dust and contact with skin  
or eyes.  
s
5SE .)/3( CERTIlED DUST RESPIRATOR ꢋ.ꢉꢑ ꢀ  
This type of respirator is based on the  
/3(! REQUIREMENTS FOR lBERGLASS WOOL AT THE  
time this document was written. Other types  
of respirators may be needed depending on  
THE JOB SITE CONDITIONSꢀ #URRENT .)/3( RECOM-  
MENDATIONS CAN BE FOUND ON THE .)/3( WEB  
HTMLꢀ .)/3( APPROVED RESPIRATORSꢁ MANUFAC-  
turers, and phone numbers are also listed on  
this web site.  
s
O Apply enough water to the combustion chamber lining  
or base insulation to prevent airborne dust.  
s
7EAR LONGꢂSLEEVEDꢁ LOOSE lTTING CLOTHINGꢁ GLOVESꢁ  
and eye protection.  
O Remove combustion chamber lining or base insula-  
tion from the boiler and place it in a plastic bag for  
disposal.  
O Operations such as sawing, blowing, tear out, and  
spraying may generate airborne fiber concentration  
requiring additional protection.  
O Wash potentially contaminated clothes separately from  
other clothing. Rinse clothes washer thoroughly.  
O Wash potentially contaminated clothes separately  
from other clothing. Rinse clothes washer thor-  
oughly.  
NIOSH stated First Aid.  
O Eye: Irrigate immediately.  
O "REATHINGꢇ &RESH AIRꢀ  
NIOSH stated First Aid.  
O Eye: Irrigate immediately.  
O "REATHINGꢇ &RESH AIRꢀ  
®
68  
Part Number 550-101-009/0107  
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