Weil-McLain Gold CGa Ratings13b

Boiler Manual

Part Number 550-110-593/1099 67

Ratings13b

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.)

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.

Notes

Install CGa boilers for residential radiant panel systems, converted gravity heating systems or other low water

temperature applications per instructions in this manual to avoid damage due to condensation.

CGa boilers are CSA design certified for installation on combustible flooring.

CGa boilers are ASME rated for 50 psig working pressure.

Table 7 Ignition system model suffixes

DOE

Boiler

model

number

Input

(Btuh)

DOE

Heating

capacity

(Btuh)

0–2,000 feet

altitude

2,000–4,500 feet

altitude

Net

I=B=R

ratings

(Btuh)

Boiler

water

content

(gallons)

DOE

Seasonal efficiency

(% A.F.U.E)

Chimney

and

breeching

size

Input

(Btuh)

Output

(Btuh)

Input

(Btuh)

Output

(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 1.5 81.5 83.3 84.0 4"I.D. x 20’

CGa-3 70,000 59,000 70,000 59,000 63,000 53,000 51,000 1.5 81.6 83.7 84.0 4"I.D. x 20’

CGa-4 105,000 88,000 105,000 88,000 94,500 79,000 77,000 2.1 81.7 83.7 84.0 5"I.D. x 20’

CGa-5 140,000 117,000 140,000 117,000 126,000 105,000 102,000 2.7 81.8 83.7 83.5 6"I.D. x 20’

CGa-6 175,000 146,000 175,000 146,000 157,500 131,000 127,000 3.3 81.9 83.6 83.2 6"I.D. x 20’

CGa-7 210,000 175,000 210,000 175,000 189,000 157,000 152,000 3.8 82.0 83.6 83.0 7"I.D. x 20’

CGa-8 245,000 204,000 245,000 204,000 220,500 183,000 177,000 4.4 82.1 83.6 82.7 7"I.D. x 20’

Pilot ignition system Natural gas Propane gas

Standing pilot SPDN SPDL

Spark-ignited pilot PIDN Not available

Contents

Main Please read before proceeding When servicing boiler Boiler operation Boiler water Installer Page How it works . . . Other boiler components: Boiler circulator Contents Hazard definitions Prepare boiler location codes & checklist 1a Installations must follow these codes: Before locating the boiler, check the following: Prepare boiler location clearances1b Service clearances Flooring and foundation Residential garage installation Small space installations Prepare boiler location vent system1c When removing boiler from existing common vent system: Chimney or vent requirements Prepare boiler location air contamination 1d Air from inside building Prepare boiler location air openings1c Special considerations Tight construction Prepare boiler placement and setup 2a Inspect orifices and burners Place boiler/crate near position Orifice replacement procedure 2b Prepare boiler pressure test Perform hydrostatic pressure test Page Prepare boiler vent damper installation Water piping general information3a General piping information Relief valve System water piping Pressure/temperature gauge 3b Water piping multiple zones Typical piping multiple-zone installations 3d Primary/secondary (preferred) bypass piping method Temperature gauges Primary/secondary (preferred) piping for radiant heating or converted gravity systems 3e Temperature gauges Boiler-bypass piping method Boiler-bypass (alternate) piping for radiant heating or converted gravity systems 3f System-bypass piping method System-bypass piping for converted gravity (or steam) systems 9 3g Gas piping Field wiring Electrical installation must comply with: Wiring connections Start-up preparation6a Determine if water treatment is needed Check for gas leaks Fill the system with water Inspect system water piping Start-up operate boiler6b Start-up preparation continued6a Inspect base insulation Start the boiler Start-up if boiler doesnt start . . .6c Check for: Start-up operate boiler continued6b Check system and boiler Start-up Check-out procedure checklist7 Installation and service certificate 34 Operation Standing Pilot CGa Lighting instructions CGa-25 to CGa-88b FOR YOUR SAFETY READ BEFORE LIGHTING LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING LIGHTING INSTRUCTIONS Lighting instructions CGa-25 to CGa-88b Natural gas Standing pilot Gas valve manufacturer Robertshaw Gas valve model(s) 7200 Figure 24 Ignition control module sequence of operation status light indications Operation Figure 25b Ladder wiring diagram Spark-ignited pilot system MV FLAME LIMIT DAMPER Legend for ladder wiring diagram Page Operating instructions CGa-25 to CGa-69b Natural gas Spark pilot Gas valve manufacturer Robertshaw Gas valve model(s) 7200 Page Page 44 Service and maintenance Table 6 Service and maintenance schedules (service technician and user) ANNNUAL START-UP Service technician Owner maintenance Service & maintenance annual start-up10b Reported problems Boiler area Air openings Flue gas vent system Service & maint. annual start-up continued10b Oiled-bearing circulators Boiler heating surfaces Burners and base Gas piping Service & maint. annual start-up continued10b Before troubleshooting: Troubleshooting procedure11a Page Chart 1 Standing pilot Boiler will not fire Troubleshooting standing pilot boilers11b Control indicator lights non-lockout modes Troubleshooting the control module Control indicator lights lockout modes Part Number 550-110-593/1099 53 Figure 30 Control module connections DAMPER LIMIT TSTAT CIRC Indicator lights Chart 2 Spark-ignited pilot Troubleshooting POWER light status Is POWER light... Chart 3 Spark-ignited pilot TSTAT CIRC & POWER lights flashing Did you find a voltage across the two external thermostat circuit wires? and Do the lights still flash? Chart 4 Spark-ignited pilot DAMPERlight flashing Chart 5 Spark-ignited pilot FLAME & POWER lights flashing Is pilot burning? Do Are lights flashing? Is gas present at gas valve inlet and within above range? Figure 30, item 8, page 53 Does light flash now? Is 24 VAC present there? Is gas present at gas valve inlet and within above range? Chart 7 Spark-ignited pilot Insufficient heat or no heat (POWERlight on steady) Is thermostat circuit closed (continuity across wires)? Is vent or combustion air piping free of blockage? Are limit switch contacts closed? Figure 30, Item 7, page 53 Replacement parts12a Page Page Page Page Page 66 Dimensions13a Figure 36 Dimensional drawing ALL DIMENSIONS IN INCHES Ratings13b 1 Table 7 Ignition system model suffixes Notes DOE