Weil-McLain GOLD CGa-5 User Manual

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.
GOLD CGa
s)NSTALLATION
s3TARTUP
Boiler Manual
s-AINTENANCE
s0ARTS
Gas-Fired Water Boilers
®
™

Weil-McLain GOLD CGa-5 Specifications

General

Brand	Weil-McLain
Model	GOLD CGa-5
Category	Boiler
Language	English

Summary

GOLD CGa Gas-Fired Water Boilers - Boiler Manual

Prepare boiler location

codes & checklist

clearances

Minimum clearances required for boiler placement.

vent system

Requirements and considerations for the vent system.

air openings

Requirements for combustion and ventilation air openings.

Prepare boiler - placement and setup

Water piping – general information

System water piping

Piping – low temperature systems

Primary/secondary (preferred) Bypass piping method

Piping – low temperature systems (continued)

BOILER-bypass piping method

SYSTEM-bypass piping method

Gas piping

Connect gas supply piping to boiler

Steps for connecting the gas supply piping to the boiler.

Field wiring

Start-up – preparation

Check for gas leaks

Procedure for checking for gas leaks before startup.

Start-up – preparation (continued)

Fill the system with water

Steps for filling the boiler and system with water.

Start-up – operate boiler

Before starting the boiler, do the following

Start-up – if boiler doesn't start

Check for:

Start-up – verify operation

Check burner flames

Check-out procedure – checklist

Checklist items

A comprehensive checklist of items to verify before operation.

Operation – standing pilot boilers

Lighting instructions CGa-25 to CGa-8

LIGHTING INSTRUCTIONS

Step-by-step instructions for lighting the pilot and boiler.

Operation – spark-ignited pilot boilers

Pilot ignition

Operation – spark-ignited pilot system (continued)

Operating instructions CGa-25 to CGa-8

OPERATING INSTRUCTIONS

Step-by-step instructions for operating the boiler.

Service and maintenance – schedule

VERIFY PROPER OPERATION AFTER SERVICING

Service & maintenance – annual start-up

Flue gas vent system

Service & maintenance – annual start-up (cont.)

Boiler heating surfaces

Boiler relief valve

Troubleshooting – procedure

Before troubleshooting:

Troubleshooting – procedure (continued)

In event of vent damper failure:

Troubleshooting – standing pilot boilers

CHART 1 – Standing pilot – Boiler will not fire

Troubleshooting chart for a standing pilot boiler that will not fire.

Troubleshooting – spark-pilot boilers

Control indicator lights – LOCKOUT modes

Troubleshooting – spark-pilot boilers (continued)

Figure 30 Control module connections

CHART 2 – Spark-ignited pilot – Troubleshooting POWER light status

Troubleshooting guide for POWER light status issues.

CHART 3 – Spark-ignited pilot – TSTAT CIRC & POWER lights flashing

Troubleshooting for TSTAT CIRC and POWER lights flashing.

CHART 4 – Spark-ignited pilot – DAMPER light flashing

Troubleshooting guide for DAMPER light flashing.

CHART 5 – Spark-ignited pilot – FLAME & POWER lights flashing

Troubleshooting for FLAME and POWER lights flashing simultaneously.

CHART 6 – Spark-ignited pilot – FLAME light flashing and POWER light on steady

Troubleshooting for FLAME flashing and POWER steady lights.

CHART 7 – Spark-ignited pilot – Insufficient heat or no heat (POWER light on steady)

Troubleshooting guide for insufficient heat or no heat issues.

Replacement parts

Ratings

Handling ceramic fiber and fiberglass materials

REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS