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GOLD CGs
Gas-Fired Water Boilers
� Installation � Maintenance
Boiler Manual
� Startup � Parts
This manual must only be used by a qualifi ed 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.
DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free air to th
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual How it works . . . Control module ① The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and inducer. When room thermostat calls for heat, the control module starts the system circulator and inducer. The control module runs the inducer long enough to purge the boiler fl ue passages, then opens the pilot valve and activates pilot ign
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual GOLD CGs Gas-Fired Induced-Draft Water Boiler 3 Part number 550-110-260/0508
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual Contents How it works ....................................................2–3 Hazard defi nitions ............................................... 4 Please read before proceeding ............................ 5 1 Prepare boiler location ...................................6–11 2 Prepare boiler ...............................................12–13 3 Water piping .................................................14–23 4 Venting & combustion air
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User • This manual is for use only by your qualifi ed Read all instructions before in- heating installer/service technician. stalling. Follow all instructions in • Please refer to the User’s Information Manual for proper order to prevent personal your reference. injury or death. • We recommend regular service by a qualifi ed • Also refer to CGs Venting Supplements. service technician, at least annually. •
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1a Prepare boiler location — codes & checklist Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223.1–latest edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1, when required. • National Electrical Code. • For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1 Canadian Electri- cal Code P
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1b Prepare boiler location — clearances Recommended SERVICE clearances Figure 2 Required MINIMUM clearances (Fig. 1) 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1 for recommenda- tions. 2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to provide at least screwdriver clearance, install
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1c Prepare boiler location — vent system Failure to follow all instructions can result in fl ue 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. DO NOT COMMON VENT — Do not install the CGs into a common vent with any other appliance. This will cause fl ue ga
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1d Prepare boiler location — contamination Please review the following information on potential Refer to Table 1 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: • remove contaminants permanently — OR — • isolate boiler and
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1e Prepare boiler location — air openings mended in Figure 3 will allow adequate ventilation and Combustion air opening location and sizing combustion air provided the boiler room is not sub- requirements depend on the clearances around jected to negative pressure due to exhaust fans or other the boiler. Check the boiler placement compared to mechanical ventilation devices. Refer to the National Figure 1, page 7. Fuel Gas Code for dealing wi
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual Figure 3 Sizing air openings for CGs installations ✷ 11 Part number 550-110-260/0508
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 2a Prepare boiler — placement & setup Inlet air box top panel must be in Place boiler/crate near position during boiler operation. position Failure to do so could result in severe personal injury, death or 1. Leave boiler in crate and on pallet until installation substantial property damage. site is ready. 2. Move entire crate and pallet next to selected loca- Orifi ce replacement procedure tion. 3. Remove crate. (when required) 4. Remove boil
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 2b Prepare boiler — pressure test 5. Slowly reopen boiler drain valve until test pressure Hydrostatic pressure test on the pressure/temperature gauge reaches no more Pressure test boiler before attaching water or gas piping than: (except as noted below) or electrical supply. • 45 psig for boilers with 30 psig relief valve. Prepare boiler for test • 75 psig for boilers with 50 psig relief valve. 1. Remove the shipping nipple (from CGs supply tap-
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3a Water piping — general information General piping information Circulator If installation is to comply with ASME or Canadian requirements, 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 f
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3b Water piping — single-zone system Diaphragm-type or bladder- Closed-type expansion tank type expansion tank (Figure 4) (Figure 5) 1. Ensure expansion tank size will handle boiler and 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must system water volume and temperature. See tank be located in boiler return piping as close to boiler manufacturer’s instructions for details. as possible, before inl
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3c Water piping — multiple zones Piping multiple zones Piping for radiant heating Follow instructions on pages 14 and 15 to install near- systems or converted gravity boiler or single-zone piping. (Also refer to Piping for systems radiant heating systems or converted gravity sys- tems, below, if applicable.) Converted gravity (or steam) systems See Figure 6 or Figure 7, page 17, to complete instal- Whenever possible, use the primary/secondary pi
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3c Water piping — multiple zones (continued) Figure 6 Zoning with circulators Figure 7 Zoning with zone valves — return water 130°F or higher. — return water 130°F or higher. 1 Boiler isolation (balancing) 10 Automatic air vent (with diaphragm-type expansion tank), or connect valves to tank fi tting (closed-type expansion tank). DO NOT use an automatic air vent when using closed-type expansion tank. It would allow air to leave the system, causing
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems the water temperature being supplied to the radiant Primary/secondary (preferred) tubing. bypass piping method Gauge 8 is required on all systems to assure the return Primary/secondary bypass piping is preferred because water temperature is accurately set for a minimum of the flow rate and temperature drop in the heating 130°F. If this gauge is not available however, adjust the circuit(s) is determined only by th
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems (continued) Figure 8 Primary/secondary piping Figure 9 Primary/secondary piping Zoning with circulators Zoning with zone valves 9 Relief valve 1 Boiler isolation (balancing) valves 10 Automatic air vent (with diaphragm-type expansion tank), or 2 Flow/check valve connect to tank fi tting (closed-type expansion tank). DO NOT use an automatic air vent when using closed-type expansion 3 System or zone circulator tank. I
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems (continued) justed using cold (or room temperature) return water BOILER-bypass piping to the boiler. (When setting the valves without gauge method 4a installed — using cold or room temperature water — assume the return water temperature to be 60°F. Set This piping method (Figures 10 and 11, page 21) is the valves so gauge 8 reads at least 120°F. called a boiler-bypass because part of the circulator Gauge 4b is opt
