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Boiler Manual Please read before proceeding Installer User Read all instructions before • This manual is for use only by your qualified installing. Follow all instructions in heating installer/service technician. proper order to prevent personal • Please refer to the User’s Information Manual for injury or death. your reference. • Consider piping and installation when • We recommend regular service by a qualified determining boiler location. service technician, at least annually. •Any claims for
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GOLD CGa Gas-Fired Water Boiler How it works . . . Control module ① The control module (used on spark-ignited pilot boilers) responds to signals from the room thermostat and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and vent damper. When room thermostat calls for heat, the control module starts the system circulator and activates the vent damper (causing it to drive open). When the vent damper has opened completely, the control module opens the pilot valve an
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GOLD CGa Gas-Fired Water Boiler Contents Standing pilot Spark-ignited pilot How it works 2–3 Hazard definitions 4 Please read before proceeding 5 1. Prepare boiler location 6–11 2. Prepare boiler 12–15 3. Water piping 16–25 4. Gas piping 26 5. Field wiring 27 6. Start-up 28–32 7. Check-out procedure 33 8. Operation — standing pilot boilers 34–36 9. Operation — spark-ignited pilot boilers 37–43 10. Service and maintenance 44–49 11. Troubleshooting 49–50, 51 49–50, 51–59 12. Replacement parts 60–6
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GOLD CGa Gas-Fired Water Boiler 1a Prepare boiler location — codes & checklist Installations must follow these codes: • Local, state, provincial, and national codes, laws, • National Electrical Code. regulations and ordinances. • For Canada only: B149.1 or B149.2 Installation • National Fuel Gas Code, ANSI Z223.1–latest edition. Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when re
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Boiler Manual 1b Prepare boiler location — clearances Service clearances Flooring and foundation Flooring 1. Provide the following clearances for cleaning and servicing the boiler and for access to controls and The CGa boiler is approved for installation on components: combustible flooring, but must never be installed on carpeting. Clearance from: Minimum Do not install boiler on carpeting Top (for cleaning flueways) 35" even if foundation is used. Fire can Front (for access to controls and comp
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GOLD CGa Gas-Fired Water Boiler 1c Prepare boiler location — vent system 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. Do not alter boiler draft hood or place any obstruction or non-approved vent damper in breeching or vent system. CSA certification wil
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Boiler Manual 1d Prepare boiler location — air 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 provide outside combustion air. See
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GOLD CGa Gas-Fired Water Boiler 2a Prepare boiler — placement and setup burner. Failure to properly seat Place boiler/crate near position burners will result in severe personal 1. Leave boiler in crate and on pallet until installation injury, death or substantial property site is ready. damage. 2. Move entire crate and pallet next to selected 4. Reinstall access panel. location. Do not operate boiler without access 3. Remove crate. Leave boiler on pallet. panel secured in place. Failure to 4. Re
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Boiler Manual 2b Prepare boiler — pressure test Perform hydrostatic pressure test 3. When water flows from shutoff valves, close boiler drain valve. Pressure test boiler before attaching water or gas piping or electrical supply (except as noted below). 4. Close shutoff valves. 5. Slowly reopen boiler drain valve until test pressure of not more than 45 psi is reached on the pressure/ temperature gauge. Prepare boiler for test 6. Test at no more than 45 psi for no more than 10 1. Remove the shippi
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Boiler Manual 3b Water piping — single-zone system Expansion tank Closed-type expansion tank — Figure 10 Diaphragm-type or bladder-type expansion tank — Figure 9 1. Ensure expansion tank size will handle boiler and system water volume and temperature. See tank 1. Ensure expansion tank size will handle boiler and manufacturer’s instructions for details. system water volume and temperature. Tank must be located in boiler return piping as close to boiler 2. Connect tank to ½" NPT tapping located be
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Boiler Manual Typical piping — multiple-zone installations Figure 11 Figure 12 Zoning with circulators Zoning with zone valves — return water 130 °F or higher. — return water 130 °F or higher. ZONE 2 ZONE 2 ZONE 1 ZONE 1 1 1 1 1 2 5 3 2 11 13 13 6 6 6 6 11 Alternate circulator location 9 10 9 10 11 Cold 11 Cold water water fill fill GOLD GOLD CGa CGa 12 12 59309 59308 1 Boiler isolation (balancing) valves 11 Fill valve 2 Flow/check valve 12 Diaphragm-type or bladder-type expansion tank, if used
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GOLD CGa Gas-Fired Water Boiler 3d Water piping — low temp systems Primary/secondary Primary/secondary bypass piping is preferred because the flow rate and temperature drop in (preferred) bypass the heating circuit(s) is determined only by the heating circuit circulator(s). So adjustment of piping method the bypass valves in the boiler circuit will not cause a change in the heating circuit rate and temperature distribution. Figures 13 and 14 show suggested bypass arrangements using primary/secon
