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Weil-McLain GOLD CGa-4 User Manual

Weil-McLain GOLD CGa-4
68 pages
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Part No. 550-101-009/0107
This manual must only be used by a qualified heating installer/service technician. Before installing, read all
instructions, including this manual, the burner manual and any related supplements. Perform steps in the order
given. Failure to comply could result in severe personal injury, death or substantial property damage.
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Weil-McLain GOLD CGa-4 Specifications

General IconGeneral
ModelGOLD CGa-4
CategoryBoiler
Vent TypeChimney
Fuel TypeNatural Gas
Water Connection Size1.25 inches
Efficiency82.0%
Heating Capacity Range60, 000 BTU/hr

Summary

Hazard Definitions

DANGER

Indicates hazards causing severe personal injury, death, or substantial property damage.

WARNING

Indicates hazards that can cause severe personal injury, death, or substantial property damage.

Please Read Before Proceeding

Prepare Boiler Location - Codes & Checklist

Prepare Boiler Location - Clearances

Prepare Boiler Location - Vent System

Prepare Boiler Location - Air Contamination

Corrosive Contaminants and Locations

Identifies products and areas that can contaminate combustion air, requiring removal or isolation.

Prepare Boiler Location - Air Openings

Prepare Boiler - Placement and Setup

Prepare Boiler - Pressure Test

Hydrostatic Pressure Test

Describes the procedure for performing a hydrostatic pressure test on the boiler before connecting utilities.

Prepare Boiler - Vent Damper Installation

Water Piping - Single-Zone System

Water Piping - Multiple Zones

Piping - Low Temperature Systems

Gas Piping

Field Wiring

Start-up - Preparation

Check for Gas Leaks

Emphasizes the critical importance of checking for gas leaks before and during start-up.

Start-up - Operate Boiler

Pre-Start Checks

Lists essential checks before operating the boiler, including water levels and preparation procedures.

Lighting/Operating Instructions

Directs users to specific lighting and operating instructions based on boiler model and gas valve type.

Start-up - Boiler Doesn't Start

Troubleshooting Checklist

Provides a checklist of common issues to check if the boiler fails to start, guiding to further troubleshooting.

Start-up - Verify Operation

Burner Flame Verification

Details how to inspect pilot and main burner flames for proper operation and visual cues.

Vent Damper Operation Check

Describes how to verify the vent damper opens and closes correctly during the heating cycle.

Vent System Operation Check

Explains how to check the vent system's proper function by observing flame behavior at the draft hood.

Check-out Procedure - Checklist

Installation and Service Certificate

Guides on completing the installation and service certificate, confirming procedures were followed.

Operation - Standing Pilot Boilers

Lighting Instructions CGa-25 to CGa-8

Safety Before Lighting

Provides critical safety warnings and instructions to follow before attempting to light the pilot.

Lighting Instructions

Step-by-step procedure for lighting the pilot, including safety checks and gas control knob operation.

Operation - Spark-Ignited Pilot Boilers

Operation - Spark-Ignited Pilot System (Continued)

Lockout Mode Indicator Lights

Explains the meaning of flashing indicator lights indicating a lockout condition and reset procedures.

Operating Instructions CGa-25 to CGa-8

Safety Before Operating

Crucial safety warnings and instructions about gas leaks and appliance submersion.

Operating Instructions

Step-by-step guide for operating the spark-ignited pilot boiler, including gas control and thermostat settings.

Turning Off Gas

Procedures for safely turning off the gas supply to the appliance.

Service and Maintenance - Schedule

Verify Proper Operation After Servicing

Outlines checks required to ensure proper boiler operation after maintenance is performed.

Service & Maintenance - Annual Start-Up

Boiler Inspection

Details critical inspections for the boiler area, air openings, and flue gas vent system.

Pilot and Main Burner Flames

Instructions for visually inspecting pilot and main burner flames for proper operation.

Service & Maintenance - Annual Start-Up (Cont.)

Check Gas Piping

Procedures for checking gas piping for leaks and verifying pressure.

Boiler Relief Valve Check

Explains how to inspect and test the boiler relief valve, including safety warnings.

Start-Up Procedures

Directs users to perform start-up procedures and verify gas piping and lighting instructions.

Service & Maintenance - Annual Start-Up (Cont.)

Troubleshooting - Procedure

Before Troubleshooting

Lists essential tools and initial checks required before starting troubleshooting procedures.

Troubleshooting - Procedure (Continued)

Vent Damper Failure

Provides troubleshooting steps for vent damper failures, including temporary fixes and component replacement.

Troubleshooting - Standing Pilot Boilers

Chart 1: Boiler Will Not Fire

A diagnostic chart to troubleshoot why a standing pilot boiler will not fire, guiding through component checks.

Troubleshooting - Spark-Pilot Boilers

Control Indicator Lights - Lockout Modes

Explains the meaning of flashing indicator lights indicating a lockout condition and reset procedures.

Troubleshooting the Control Module

Refers to diagrams for control module connections and further troubleshooting steps.

Troubleshooting - Spark-Pilot Boilers (Continued)

Chart 2: Power Light Status

A diagnostic chart for troubleshooting issues related to the POWER light status on the control module.

Chart 3: TSTAT CIRC & POWER Lights Flashing

A diagnostic chart for troubleshooting when TSTAT CIRC and POWER lights flash, indicating potential stray voltage.

Chart 4: Damper Light Flashing

A diagnostic chart for troubleshooting damper light flashing issues, whether the POWER light is steady or flashing.

Chart 5: Flame & Power Lights Flashing

A diagnostic chart for troubleshooting when both FLAME and POWER lights flash, indicating flame sensing issues.

Chart 6: Flame Light Flashing and Power Light Steady

A diagnostic chart for troubleshooting when the FLAME light flashes and POWER light is steady, indicating main flame establishment issues.

Troubleshooting - Spark-Pilot Boilers (Continued)

Chart 7: Insufficient Heat or No Heat

A diagnostic chart for troubleshooting issues leading to insufficient heat or no heat, with the POWER light steady.

Replacement Parts - Controls

Gas Control Assembly Components

Details components of the gas control assembly, including gas valves, pilot assemblies, and control modules, with part numbers.

Ratings

Boiler Model Ratings

Lists boiler models with input, output, efficiency, and chimney size ratings based on altitude.

Handling Ceramic Fiber and Fiberglass Materials

Combustion Chamber Lining Removal

Provides safety precautions and procedures for removing combustion chamber lining or base panels containing ceramic fiber.

Fiberglass Wool Handling

Details safety precautions for handling fiberglass wool, including respirator use and personal protective equipment.

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