™
®
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
Part Number 550-101-009/0107
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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.
s
s
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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.
s
s
#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.
s
#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 —
s
$O NOT ADD COLD WATER TO HOT BOILERꢀ 4HERMAL
shock can cause sections to crack.
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$O NOT BLOCK mOW OF COMBUSTION OR VENTILATION AIR
to boiler.
Glycol — potential fire hazard —
s
3HOULD OVERHEATING OCCUR OR GAS SUPPLY FAIL TO SHUT
off, do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
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:
s
$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.
s
.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.
s
$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
Part Number 550-101-009/0107
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual
Prepare boiler location — codes & checklist
1a
Installations must follow these codes:
s
s
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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
s
s
.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:
s
#HECK FOR NEARBY CONNECTION TOꢇ
s
s
s
s
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.
s
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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.
s
,OCATE OR PROTECT THE BOILER so it cannot be damaged
by a moving vehicle.
7
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual
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.)
ꢉ
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual
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
Part Number 550-101-009/0107
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual
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:
s
7OOD LOUVERS 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 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
s
4HE TOP OF THE AIR OPENING MUST BE WITHIN ꢆꢄ INCHES OF THE CEILINGꢀ
Opening size
Motorized air dampers
s
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.
s
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
Part Number 550-101-009/0107
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual
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 ꢎ, 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 ꢍ, 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 ꢆv 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 ꢆv NIPPLEꢁ ꢆv 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 ꢆv 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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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 SYSTEMS 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.
ꢌ
ers only, install PLUG WITH /ꢋv DIAMETER HOLE in vent
damper hole.
3PARKꢀIGNITED PILOT SYSTEMS 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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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&ꢂ 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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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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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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3d
Piping — low temperature systems
the water temperature being supplied to the radiant
tubing.
Primary/secondary (preferred)
Bypass piping method
'AUGE ꢋ 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 ꢋ 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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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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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 ꢋ 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 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 ꢋ 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 ꢋ 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 ꢋ.
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
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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 ꢋ 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 ꢌ), 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
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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
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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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GOLD CGa Gas-Fired Water Boiler — Boiler Manual
27
Part Number 550-101-009/0107
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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 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
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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 ꢇ, 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.
$O NOT USE PETROLEUMꢀBASED
CLEANING OR SEALING COMPOUNDS
in boiler system. Severe damage
to boiler will occur, resulting in
substantial property damage.
4. #HECK AROUND THE BOILER for gas odor following the
procedure of Section ꢇA of this manual.
5. 6ERIFY OPERATION per Section ꢇD. Perform check-out
procedure in Section ꢍ and fill in the )NSTALLATION
AND SERVICE CERTIlCATE on the same page.
6c
Start-up — if boiler doesn’t start . . .
Check for:
1. Loose connections, blown fuse or
ꢈꢀ 'AS NOT TURNED ON AT METER OR BOILERꢔ
5. Incoming gas pressure less than:
SERVICE SWITCH OFFꢔ
ꢄꢀ (IGH LIMIT SWITCH SET BELOW BOILER
WATER TEMPERATUREꢔ
ꢑv WꢀCꢀ FOR NATURAL GASꢔ ꢆꢆv WꢀCꢀ FOR PROPANE GASꢔ
3. Thermostat set below room tem-
6. If none of the above corrects the problem, refer to 4ROUBLESHOOTꢀ
ing, Section ꢅꢅ of this manual.
PERATUREꢔ
31
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GOLD CGa Gas-Fired Water Boiler — Boiler Manual
6d
Start-up — verify operation
4HE BOILER MODEL SUFlX WILL BE h30$vꢀ &OR SPARKꢂIGNITED PILOT BOILERS ꢋSUFlX h0)$v ꢁ SEE
3ECTION ꢋ or ꢏ 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 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 9ELLOW TIPPING ON mAMES
(sooting will occur).
Check vent damper operation
1. 2AISE ROOM THERMOSTAT TO CALL FOR HEAT 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 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 ꢋ or Section ꢏ 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 ꢇ).
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 #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
Part Number 550-101-009/0107
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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
Part Number 550-101-009/0107
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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
Part Number 550-101-009/0107
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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)
0ILOT AND MAIN GAS VALVES ARE CLOSED 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
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-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 ꢎ 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 ꢎ, 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 ꢌ 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
ONTHEBOILERPRESSUREꢃTEMPERATUREGAUGEꢀ6ERIFYTHAT
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 ꢌ.
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 ꢌ 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 ꢇ 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 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 #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
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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
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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
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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
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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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|