CGa Series 3 Boiler Manual 0520

Series 3
Gas-Fired Water Boilers
Boiler Manual • Installation • Maintenance

• Startup • Parts
Now With Built In

Low Water Cut Off Functionality
This manual must only be used by a qualified heating installer/service technician. Before installing, read all
instructions, including this 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.
Part Number 550-142-300/0520

CGa Series 3 Gas-Fired Water Boiler — Boiler Manual
How it works . . .
① Control module
The control module 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 and activates pilot
ignition spark.
For natural gas, the control module allows up to 15 seconds to establish pilot flame. If flame is not sensed within
15 seconds, the control module will turn off the gas valve, flash the Flame light, and immediately start a new cycle.
This will continue indefinitely until pilot flame is established or power is interrupted. Once pilot flame is proven,
the control module opens the gas valve to allow main burner flame.
For propane gas, the control module allows up to 15 seconds to establish pilot flame. If flame is not sensed within
15 seconds, the control module will turn off the gas valve, flash the Flame light, wait 1 minute, then start a new
cycle. If flame is still not sensed after the second trial, two more attempts are made with 5 minute and 60 minute
wait periods in between. If flame is not sensed after 4 tries, control will lockout and flash all lights. Control must
be manually reset to place back into service. Once pilot flame is proven, the control module opens the gas valve to
allow main burner flame.
When the room thermostat is satisfied, the control module turns off the gas valve and deactivates the vent damper
(causing it to close).
The control module indicator lights show normal sequence when the lights are on steady. When a problem occurs,
the control module flashes combinations of lights to indicate the most likely reason for the problem. See page 49
for details.
② Transformer
The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit.
③ Draft hood
The draft hood provides a minimum draft for the boiler, assuring adequate air for combustion if installed in
accordance with manual and not modified in any way.
④ Spill switch
The spill switch will shut down the boiler (requiring manual reset of the switch reset button) if the vent system
becomes blocked.
⑤ Water temperature/ LWCO sensor

The water temperature/LWCO sensor provides a signal to the control module to turn off the gas valve if the tem-
perature in the boiler goes above its setting or if a low water condition is sensed. (The circulator will continue to
run as long as there is a call for heat.)
⑥ Boiler circulator
The boiler circulator circulates water through the external (system) piping. The circulator is shipped loose, and
can be mounted on either the boiler supply or return piping. The factory-installed circulator wiring harness
provides ample length for either location. NOTE — The control module provides a pump exercising routine. If
the boiler is not operated for 30 days, the control module will power the circulator for 30 seconds, then turn off.
⑦ Vent damper
The vent damper closes during off cycles to reduce heat loss from the house up the vent.
Other boiler components:

a supply to system f pressure/temperature gauge k pilot burner, typical
b return from system g relief valve l stainless steel burners
c flue outlet h air vent connection m cast iron boiler sections
d burner manifold i flame rollout switch n flue collector
e gas valve j burner orifice o junction box
2 Part Number 550-142-300/0520

CGa Series 3 Gas-Fired Water Boiler
Part Number 550-142-300/0520 3

Contents
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 Department of Energy Compliance .................... 34
9 Operation – spark-ignited pilot boilers........... 34-41
10 Service and maintenance.............................. 42-47
11 Troubleshooting:
Spark-ignited pilot boilers............................. 48-56
12 Replacement parts........................................ 58-63
13 Dimensions and ratings................................. 64-65
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various
risk levels or to important information concerning the life of the product.
Indicates presence of hazards that will cause severe personal injury, death or substantial property
damage.
Indicates presence of hazards that can cause severe personal injury, death or substantial property
damage.
Indicates presence of hazards that will or can cause minor personal injury or property damage.
Indicates special instructions on installation, operation or maintenance that are important but not
related to personal injury or property damage.
Glycol — potential fire hazard —

All glycol is flammable when exposed to high temperatures. If glycol is allowed to accumulate in or around the boiler or any other
potential ignition source, a fire can develop. In order to prevent potential severe personal injury, death or substantial property
damage from fire and/or structural damage:
• Never store glycol of any kind near the boiler or any potential ignition source.
• Monitor and inspect the system and boiler regularly for leakage. Repair any leaks immediately to prevent possible accumula-
tion of glycol.
• Never use automotive antifreeze or ethylene glycol in the system. Using these glycols can lead to hazardous leakage of glycol
in the boiler system.
4 Part Number 550-142-300/0520

Please read before proceeding

Installer— Read all instructions, including this Write in the Consumer Protection (CP) number in
manual and all other information shipped with the the space provided on the Installation certificate on
boiler, before installing. Perform steps in the order page 33 if not already shown.
give no prevent personal injury or death. When calling or writing about the boiler— Please
User — This manual is for use only by a qualified have the boiler model number from the boiler rating
heating installer/service technician. Refer to User’s label and the CP number from the boiler jacket.
Information Manual for your reference. Consider piping and installation when determining
User — Have this boiler serviced/inspected by a boiler location.
qualified service technician, at least annually. Any claims for damage or shortage in shipment
Failure to comply with the above could result in severe must be filed immediately against the transportation
personal injury, death or substantial property damage. company by the consignee.
If any part of a boiler, burner or its controls has Saltwater Damage — The exposure of boiler components to
been sprayed with or submerged under water, saltwater can have both immediate and long-term effects. While the
either partially or fully, DO NOT attempt to op- immediate effects of saltwater damage are similar to those of fresh-
erate the boiler until the boiler has been either water (shorting out of electrical components, washing out of critical
replaced or completely repaired, inspected, and lubricants, etc.), the salt and other contaminants left behind can lead
you are sure that the boiler and all components to longer term issues after the water is gone due to the conductive
are in good condition and fully reliable. and corrosive nature of the salt residue. Therefore, Weil‑McLain
equipment contaminated with saltwater or polluted water will no
Otherwise, by operating this boiler, you will cause
longer be covered under warranty and should be replaced.
a fire or explosion hazard, and an electrical shock
hazard, leading to serious injury, death, or substan- Electrical Damage — If any electrical component or wiring
tial property damage. See the instructions at right. came into contact with water, or was suspected to have come into
contact with water, replace the boiler with a new Weil-McLain boiler.
Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.
When servicing boiler — Boiler water — Freeze protection fluids —

• To avoid electric shock, disconnect all • Do not use petroleum-based cleaning • NEVER use automotive or standard
electrical supplies to the boiler before or sealing compounds in boiler sys- glycol antifreeze. Use only freeze-
performing maintenance. tem. Gaskets and seals in the system protection fluids made for hydronic
may be damaged. This can result in systems. Follow all guidelines given
• To avoid severe burns, allow boiler to substantial property damage. by the antifreeze manufacturer.
cool before performing maintenance. • Do not use “homemade cures” or Thoroughly clean and flush any re-
• This boiler contains ceramic fiber “boiler patent medicines”. Serious placement boiler system that has used
and fiberglass materials. Refer to damage to boiler, personnel and/or glycol before installing the new boiler
the WARNING and instructions on property may result.
page 66. • Continual fresh makeup water will Frozen Water Damage
reduce boiler life. Mineral buildup in Hazard
Boiler operation — Residences or buildings that are unat-
sections reduces heat transfer, over-
• Do not block flow of combustion or heats cast iron, and causes section tended in severely cold weather, boiler
ventilation air to boiler. failure. Addition of oxygen and other system components failures, power out-
• Should overheating occur or gas sup- gases can cause internal corrosion. ages, or other electrical system failures
ply fail to shut off, do not turn off or Leaks in boiler or piping must be could result in frozen plumbing and water
disconnect electrical supply to pump. repaired at once to prevent makeup damage in a matter of hours. For your
Instead, shut off the gas supply at a water. protection, take preventative actions such
location external to the appliance. as having a security system installed that
• Do not add cold water to a hot boiler. operates during power outages, senses low
Combustion air —
Thermal shock can cause heat ex- temperature, and initiates an effective ac-
changer to crack. tion. Consult with your boiler contractor
• DO NOT install combustion air in-
take where there is a risk of combus- or a home security agency.
tion air contamination.
Part Number 550-142-300/0520 5

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/NFPA 54 – latest edition.
• Where required by the authority having jurisdiction, the installation must conform
to the Standard for Controls and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1 –– latest edition.
• National Electrical Code, ANSI /NFPA 70 – latest edition.
• For Canada only: Natural Gas and Propane Installation Code, CAN/CSA B149.1
or B149.2 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any
local codes.
The CGa boiler gas manifold and controls meet safe operating and
other performance criteria when boiler underwent tests specified
in ANSI Z21.13 – latest edition.
Before locating the boiler,

check the following:
• Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
• Check area around boiler. Remove any combustible materials, gasoline
and other flammable liquids, or other contaminants.
Failure to keep boiler area clear and free of combustible materials,

gasoline and other flammable liquids and vapors can result in
severe personal injury, death or substantial property damage.
• Boiler must be installed so that gas control system components are protected from
dripping or spraying water or rain during operation or service.
• If new boiler will replace existing boiler, check for and correct system problems,
such as:
1. System leaks causing oxygen corrosion or section cracks from hard water
deposits.
2. Incorrectly-sized expansion tank.
3. Lack of antifreeze in boiler water causing system and boiler to freeze and
leak.
6 Part Number 550-142-300/0520

1b Prepare boiler location — clearances

Recommended SERVICE clearances
Figure 1b Required MINIMUM clearances
(Fig. 1a)
1. Provide clearances for cleaning and servicing the boiler and for
access to controls and components. See Figure 1a for recommen-
dations.
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 unions and
shutoff valves in system so boiler can be moved for servicing.
Figure 1a
Recommended
service
clearances
(see WARNING
below)
Flooring
The CGa boiler is approved for installation on combustible
flooring, but must never be installed on carpeting.
Do not install boiler on carpeting even
If any clearance is less than in Figure 1a, pro- if foundation is used. Fire can result,
vide openings for combustion and ventilation causing severe personal injury, death
air located on the wall or door opposite the or substantial property damage.
boiler FRONT (see Figure 1b).
These openings must be located as shown in Figure 1b to provide
proper air flow around the boiler. The free area of each opening Foundation
(after deducting for louvers) must be at least one square inch 1. Provide a solid brick or minimum 2-inch thick concrete
per 1,000 Btuh of boiler input. If the building is of unusually foundation pad if any of the following is true:
tight construction (see page 11 for definition), the air openings • floor can become flooded.
must connect directly to outside or the building must have air
openings to the outside as specified on page 11. • the boiler mounting area is not level.
2. Minimum dimensions are 25” length by:
If clearances are equal to or greater than Figure 1a, see pages 10
and 11 for location and sizing of combustion air openings. Minimum foundation width:
Failure to comply can result in severe personal injury, death or
CGa-25/3 12” CGa-6 21”
substantial property damage and reduced boiler life.
CGa-4 15” CGa-7 24”
CGa-5 18” CGa-8 27”
Required MINIMUM clearances (Fig. 1b)
Never install the boiler in a space with clear- Residential garage installations
ances less than the minimum clearances shown Take the following special precautions when installing the
in Figure 1b. Failure to comply can result in severe boiler in a residential garage. If the boiler is located in a
personal injury, death or substantial property dam- residential garage, per ANSI Z223.1, – latest edition:
age and reduced boiler life.
• Mount the boiler a minimum of 18 inches above the
1. Hot water pipes: at least ¹⁄₂ inch from combustible material. floor of the garage to assure the burner and ignition
2. Single-wall vent pipe: at least 6 inches from combustible mate- devices will be no less than 18 inches above the floor.
rial.
3. Type B double-wall metal vent pipe: refer to vent manufacturer’s • Locate or protect the boiler so it cannot be damaged
recommendation for clearances to combustible material. by a moving vehicle.
Part Number 550-142-300/0520 7

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 will become void. Flue gas spillage and carbon monoxide emissions will occur causing severe
When removing boiler from an Chimney or vent require-

existing common vent system: ments
At the time of removal of an existing boiler, the following 1. Venting must be installed according to Part 7, Vent-
steps shall be followed with each appliance remaining ing of Equipment, of National Fuel Gas Code, ANSI
connected to the common venting system placed in op- Z223.1-latest edition and applicable building codes.
eration, while the other appliances remaining connected Canadian installations must comply with B149.1 or
to the common venting system are not in operation. B149.2 Installation Codes.
a. Seal any unused openings in the common venting 2. See Ratings table on page 65 for minimum chimney
system.
or vent sizes. A chimney or vent without a listed
b. Visually inspect the venting system for proper cap should extend at least 3 feet above the highest
size and horizontal pitch and determine there is no point where it passes through a roof of a building
blockage or restriction, leakage, corrosion or other and at least 2 feet higher than any portion of a
deficiencies which could cause an unsafe condition. building within a horizontal distance of 10 feet.
c. Test vent system — Insofar as is practical, close all A chimney or vent must not extend less than the
building doors and windows and all doors between distances stated above.
the space in which the appliances remaining con- 3. A lined chimney is preferred and must be used when
nected to the common venting system are located required by local, state, provincial and national
and other spaces of the building. Turn on clothes codes, laws, regulations and ordinances. Vitreous tile
dryers and any appliance not connected to the com- linings with joints that prevent retention of moisture
mon venting system. Turn on any exhaust fans, such and linings made of noncorrosive materials are best.
as range hoods and bathroom exhausts, so they will Advice for flue connections and chimney linings can
operate at maximum speed. Do not operate a sum-
mer exhaust fan. Close fireplace dampers. be obtained from local gas utility. Type B double-
wall metal vent pipe or single-wall vent pipe may
d. Place in operation the appliance being inspected. be used as a liner.
Follow the operating instructions. Adjust thermostat
so appliance will operate continuously. 4. Cold masonry chimneys, also known as outside
chimneys, typically have one or more walls ex-
e. Test for spillage at draft hood relief opening after posed to outside air. When any atmospheric gas-
5 minutes of main burner operation. Use the flame fired boiler with automatic vent damper is vented
of a match or candle. through this type of chimney, the potential exists for
f. After it has been determined that each appliance condensation to occur. Condensation can damage
remaining connected to the common venting system a masonry chimney. Weil-McLain recommends the
properly vents when tested as outlined above, return following to prevent possible damage.
doors, windows, exhaust fans, fireplace dampers, a. Line chimney with corrosion-resistant metal
and any other gas-burning appliance to their previ- liner such as AL29-4C® single-wall stainless
ous conditions of use. steel or B-vent. Size liner per National Fuel
Any improper operation of common venting system Gas Code ANSI Z223.1 - latest edition.
should be corrected so the installation conforms with b. Provide drain trap to remove any condensate.
the National Fuel Gas Code, ANSI Z223.1/NFPA 54
-latest edition. Correct by resizing to approach the mini- 5. Where two or more gas appliances vent into a
mum size as determined using the appropriate tables in common chimney or vent, equivalent area should
Part 13 of that code. Canadian installations must comply be at least equal to area of vent outlet on largest
with Natural Gas and Propane Installation Code, CAN/ appliance plus 50 percent of vent outlet area on
CSA B149.1 or B149.2 Installation Code. additional appliance.
8 Part Number 550-142-300/0520

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 national, provincial or local codes
for further information.
Table 1 Corrosive contaminants and likely locations
Products to avoid Areas likely to have contaminants
Spray cans containing chloro/fluorocarbons Dry cleaning/laundry areas and establishments
Permanent wave solutions Swimming pools
Chlorinated waxes/cleaners Metal fabrication plants
Chlorine-based swimming pool chemicals Beauty shops
Calcium chloride used for thawing Refrigeration repair shops
Sodium chloride used for water softening Photo processing plants
Refrigerant leaks Auto body shops
Paint or varnish removers Plastic manufacturing plants
Hydrochloric acid/muriatic acid Furniture refinishing areas and establishments
Cements and glues New building construction
Antistatic fabric softeners used in clothes dryers Remodeling areas
Chlorine-type bleaches, detergents, and cleaning

Garages with workshops
solvents found in household laundry rooms
Adhesives used to fasten building products and other Buildings under construction (where air is contaminated
similar products with particulates)
Airborne particulates (drywall dust, fiberglass particles,

road or gravel dust, lint, etc.)
Part Number 550-142-300/0520 9

1e Prepare boiler location — air openings
Combustion air opening location and sizing Figure 2 Air openings to interior spaces
requirements depend on the clearances around
the boiler. Check the boiler placement compared to ✷
✷ Figure 1a, page 7.
If all clearances are at least equal to Figure 1a,
page 7, apply the sizing and placement of openings
given on pages 10 and 11.
If ANY clearance is less than Figure 1a, page 7,
you must provide air openings sized and located as
shown in Figure 1b, page 7. DO NOT apply the sizing
and location information shown on page 10 or 11.
Figure 3 Air directly through outside wall
Air openings must be provided

Combustion air and ventilation openings must comply with the National ✷
Fuel Gas Code ANSI Z223.1-latest edition, or applicable local building
codes. Canadian installations must comply with B149.1 or B149.2 Instal-
lation Codes.
Provide adequate combustion and ventilation air to

assure proper combustion and reduce the risk of severe
personal injury, death or substantial property damage
caused by flue gas spillage and carbon monoxide
emissions.
Figure 4 Air from outdoors — vertical ducts
Air opening options
Two openings — Air supply from inside the building ✷ ✷
1. If the building is of unusually tight construction (see definition, next
page), the building must also be provided with air openings directly
to the outside, sized and located per Figure 3, Figure 4 or Figure 5.
2. Buildings of typical construction should provide adequate combustion
air from natural infiltration, so additional air openings to the building
are not required.
3. See Figure 2. Provide two openings through the interior wall, within
12 inches of the ceiling and the floor, sized per Figure 2.
Two openings — Air supply directly from outside ✷

1. Air openings must be directly through an outside wall, or into a space
that connects directly to the outside (such as a ventilated attic or crawl Figure 5 Air from outdoors — horizontal ducts
space, for example).
2. See Figure 3 — Openings directly through an outside wall — provide
two openings within 12 inches of the ceiling and the floor, sized per
✷
Figure 3.
3. See Figure 4 — Air supplied through vertical ducts — provide two
openings terminated within 12 inches of the ceiling and the floor, sized
per Figure 4.
4. See Figure 5 — Air supplied through horizontal ducts — provide
two openings within 12 inches of the floor and the ceiling, sized per
Figure 5.
10 Part Number 550-142-300/0520

1e Prepare boiler location — air openings
Unusually tight construction

FREE AREA of openings — the minimum areas
given in this manual are free area (equals the area, Unusually tight construction means (per ANSI Z223.1)
length times width of opening, after deduction for buildings in which:
louver obstruction). a. Walls and ceilings exposed to the outside atmo-
Use the free area information provided by the louver manufacturer. sphere have a continuous water vapor retarder with
When this information is not available, assume: a rating of 1 perm or less with openings gasketed,
and . . .
• Wood louvers — assume free area is 20% of total; so the actual area
b. Weather-stripping has been added on openable
of each opening with wood louvers would be 5 times the required
windows and doors, and . . .
free area.
c. Caulking or sealants are applied to areas such as
• Metal louvers — assume free area is 60% of actual area; so, for wood
joints around windows and door frames, between
louvers, the actual area of each opening must be 1.67 times the re-
sole plates and floors, between wall-ceiling joints,
quired free area.
between wall panels, at penetrations for plumbing,
electrical, and gas lines, and in other openings.
Single air opening option ✷ For such construction cases, if appliances use inside air
for combustion, provide air openings into the building
A single combustion air opening can be used in lieu of the two-opening
from outside. Size and locate these openings per the
options on page 10, provided:
appropriate case in Figure 3, 4 or 5 on page 10.
Clearances from boiler to walls
• The boiler must have clearances of at least those shown in Figure 1a,
page 7.
Opening must be directly to outside
Exhaust fans and air movers
• The opening must connect directly to the outdoors or to a space that The appliance space must never be under a negative
communicates directly to the outdoors (not to an interior space). pressure, even if the appliance(s) are installed as direct
vent. Always provide air openings sized not only to the
• The air can be provided through a direct opening or through a horizontal dimensions required for the firing rate of all appliances,
or vertical duct. but also to handle the air movement rate of the exhaust
Opening placement fans or air movers using air from the building or space.
• The top of the air opening must be within 12 inches of the ceiling.
Opening size
• The free area of the opening must be at least equal to the sum of the Motorized air dampers
area of all equipment vent connectors in the space, and . . . If the air openings are fitted with motorized dampers,
• The free area of the opening must be at least 1 square inch per 3,000 electrically interlock the damper to:
Btu/hr input rating of all equipment located in the space. • Prevent the boiler from firing if the damper is not
fully open.
Exception for large spaces ✷ • Shut the boiler down should the damper close dur-
No combustion air openings are needed when the boiler (and other ap- ing boiler operation.
pliances) are installed in a space with a volume at least 50 cubic feet per To accomplish this interlock, wire an isolated contact
1,000 Btuh of all installed appliances, provided: (proving the damper open) in series with the thermo-
• the building must not have unusually tight construction (see defini- stat input to the boiler. The boiler will not start if this
tion, this page) contact is open, and will shut down should it open
• all clearances around the boiler must be no less than shown in Figure 1a, during operation.
page 7.
To determine if the space is large enough to qualify:
• Add the total input of all appliances in MBH (1,000’s of Btuh).
• Multiply this number times 50 to determine minimum room volume.
• Example: For a total input of 100 MBH (100,000 Btuh), minimum
volume is 50 x 100 = 5,000 cubic feet. At a ceiling height of 8 feet, the
space must have at least 5,000 ÷ 8 = 625 square feet (25 feet x 25 feet,
for instance).
Part Number 550-142-300/0520 11

2a Prepare boiler — placement and setup
Place boiler/crate near Correctly-sized manifold orifices

must be used. Failure to do so will
position result in severe personal injury,
1. Leave boiler in crate and on pallet until installa- death or substantial property dam-
tion site is ready. age.
2. Move entire crate and pallet next to selected location. 3. Level and straighten burners.
3. Remove crate. Leave boiler on pallet. Burners must be properly seated in
4. Remove boiler from pallet as follows: slots in burner rest with their open-
a. Tilt left side of boiler up and place a board under ings face up. Main burner orifices
left legs. must inject down center of burner.
b. Tilt boiler the other way and place a board under Failure to properly seat burners
right legs. will result in severe personal injury,
c. Slide boiler backwards off pallet and into posi- death or substantial property dam-
tion. age.
Do not drop boiler or bump jacket
on floor or pallet. Damage to boiler 4. Reinstall access panel.
can result.
5. Check level. Do not operate boiler without ac-
a. Shim legs, if necessary. cess panel secured in place. Failure
b. Do not alter legs. to comply could cause momentary
flame rollout on ignition of main
flame, resulting in possible fire or
personal injury hazard.
Inspect orifices and burners
1. Remove front jacket door. Remove base access panel
(See Figure 32, item 4, page 60). Orifice replacement procedure
2. Check for correctly-sized manifold orifices. See (when required)
Table 2 below for sizing. (The orifice size is stamped
on the orifice spud barrel.) 1. Remove access panel.
Table 2 Manifold orifice sizing 2. On gas manifold, mark location of main burner with
attached pilot assembly.
Location Natural gas 3. Remove main burner with attached pilot assembly
from manifold. Remove all remaining burners.
U.S. 0-2,000 ft. over 2,000 ft.
2.00 mm (Note 1) 4. Remove and discard all main burner orifices in gas
manifold.
Canada 0-2,000 ft. 2,000-4,500 ft.
5. Apply a small amount of pipe dope to each of the
2.00 mm 1.90 mm new orifices and install in the manifold. Make sure
the orifices are aligned correctly, not cross-threaded
in the manifold tappings.
Location Propane gas Use only pipe dope compatible with
U.S. 0-2,000 ft. over 2,000 ft. propane gas, even if boiler is to be
CGa 25 #61 (Note 1) operated on natural gas. Failure to
comply could result in severe per-
CGa 3-8 #56 (Note 1)
sonal injury, death or substantial
Canada 0-2,000 ft. 2,000-4,500 ft. property damage.
CGa 25 #61 .95mm
CGa 3-8 #56 #57 6. Reinstall main burner with attached pilot assembly
at location marked on gas manifold. Reinstall all
remaining burners.
Note 1: For elevations above 2,000 feet, contact your
Weil-McLain sales office for details. 7. Follow check-out procedure, Section 7, page 33.
12 Part Number 550-142-300/0520

2b Prepare boiler — pressure test
Hydrostatic pressure test 4. Close shutoff valves.

5. Slowly reopen boiler drain valve until test pressure
Pressure test boiler before attaching water or gas piping of not more than 45 psi is reached on the pressure/
or electrical supply (except as noted below). temperature gauge.
6. Test at no more than 45 psi for no more than 10
Prepare boiler for test minutes.
1. Remove the shipping nipple (from CGa supply Do not leave boiler unattended.
tapping) and remove the boiler relief valve. A cold water fill could expand and
Temporarily plug the relief valve tapping with a ¾” cause excessive pressure, resulting
NPT pipe plug. in severe personal injury, death or
2. Remove 1¼” nipple, reducing tee and drain substantial property damage.
valve from accessory bag. Install in boiler return 7. Make sure constant gauge pressure has been main-
connection as shown on page 3 or in Figure 34, item tained throughout test. Check for leaks. Repair if
3, page 62. Install circulator on either the return or found.
supply.
3. Remove 1¼” nipple, 1¼” tee, bushing and pressure/
temperature gauge from accessory bag. Pipe to Leaks must be repaired at once.
boiler supply connection as shown in Figure 34, Failure to do so can damage boiler,
page 62-. (Use pipe dope sparingly.) resulting in substantial property
4. Connect a hose to boiler drain valve, the other end damage.
connected to a fresh water supply. Make sure hose
can also be used to drain boiler after test.
5. Connect a nipple and shutoff valve to system supply Do not use petroleum-based clean-
connection on the 1¼” tee. This valve will be used ing or sealing compounds in boiler
system. Severe damage to boiler
to bleed air during the fill. (Valve and nipple are will occur, resulting in substantial
not included with boiler.) property damage.
6. Connect a nipple and shutoff valve to system
return connection (at circulator flange if circulator
installed on return). This valve will be used to
bleed air during the fill. (Valve and nipple are not Drain and remove fittings
included with boiler.) 1. Disconnect fill water hose from water source.
2. Drain boiler at drain valve or out hose, whichever
Fill and pressure test
provides best access to drain. Remove hose after
1. Open the shutoff valves you installed on supply and draining if used to drain boiler.
return connections.
2. Slowly open boiler drain valve and fresh water 3. Remove nipples and valves unless they will remain
supply to fill boiler with water. for use in the system piping.
3. When water flows from shutoff valves, close boiler 4. Remove plug from relief valve tapping. See Section 3
drain valve. to replace relief valve.
Part Number 550-142-300/0520 13

2c Prepare boiler — draft hood & spill switch
Draft hood installation Spill switch installation

1. Orient draft hood with spill switch mounting holes to front of boiler 1. Fasten spill switch to draft hood as shown in Figure 6
as shown in Figure 7. and Figure 7.
2. Secure draft hood to outlet at top of boiler with sheet metal screws.
2. See Wiring diagram to connect wires:.
3. Bottom of draft hood or “skirt” must have clearance dimension above
jacket top panel as indicated on draft hood. a. Spark-ignited pilot boiler —
see pages 36 and 37
Do not alter boiler draft hood or place any obstruction or
non-approved vent damper in breeching or vent system. Improper orientation of spill switch
CSA certification will become void. Flue gas spillage and may cause boiler to shut down. The
carbon monoxide emissions will occur causing severe loss of heat can result in significant
personal injury or death. damage due to freezing.
Figure 6 Install spill switch Figure 7 Spill switch with wire harness
2d Prepare boiler — install vent piping

1. Connect from draft hood or vent damper outlet to chimney or vent
with same size vent connector.
Long horizontal vent connector,
excessive number of elbow or 2. Where possible, vertical venting to the outside from the draft hood or
tees, or other obstructions that vent damper outlet will offer best performance.
restrict the flow of combustion 3. Where horizontal vent connector is used, slope upward at least ¼” per
gases should be avoided. Severe lineal foot toward chimney or vent and support with hangers to prevent
personal injury, death or substan- sagging.
tial property damage could result.
4. Breeching must not be connected to any portion of a mechanical draft
system that can operate under positive pressure.
14 Part Number 550-142-300/0520

2e Prepare boiler — vent damper installation

These systems are used on gas-fired boilers with vent Installation
dampers as shipped from factory. Boiler will not operate
without vent damper installed. 1. Install vent damper horizontally or vertically as
Only vent dampers listed in the Replacement parts list shown in vent damper manufacturer’s instructions.
Vent damper must be installed so that it serves only
on page 58 are certified for use with CGa boilers. Any one boiler and so damper blade indicator is visible
other vent damper installed could cause severe personal to the user. See Figure 8.
injury or death.
2. Screws or rivets used to secure the vent damper to
the draft hood must not interfere with rotation of
Damper blade the damper blade.
3. Install damper harness between damper actuator
Spark-ignited pilot systems— Refer to vent manu- and knockout in jacket top panel. Use strain relief
facturer’s instructions to install plug (shipped with connectors and locknuts to secure both ends of
damper) in damper hole. For spark-ignited pilot damper harness.
boilers only, install plug with no hole in vent damper Keep wiring harness clear of all hot
hole. surfaces.
Minimum clearances
Provide a minimum of 6” between the vent damper and

any combustible material. (Provide a minimum of 36 "
between jacket top and combustible ceiling.)
Do not modify draft hood or vent damper, or make an-

other connection between draft hood and vent damper
or boiler except as noted below. This will void CSA
certification and will not be covered by Weil-McLain
warranty. Any changes will cause severe personal injury,
death or substantial property damage.
4. Read and apply the harness plug warning label

(shown above) so that it is visible after installation.
Figure 8 Vent damper assemblies 5. Plug damper harness receptacle into damper harness
plug.
Bypassing (jumpering) vent damper

will cause flue products such as
carbon monoxide to escape into
the house. This will cause severe
After boiler has operated once, if ei-

ther end of harness is disconnected,
the system safety shutdown will oc-
cur. The boiler will not operate until
harness is reconnected.
Effikal or Field Controls damper —

Damper hold open switch must be
in Automatic Operation position
for system to operate properly.
Part Number 550-142-300/0520 15

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 for a typical instal-
above setpoint of first control. Maximum allowable setpoint is 240°F. lation. Pipe the expansion tank to the suction side of the
See page 36, for wiring. circulator whenever possible. Install an air separator in
Use backflow check valve in cold water supply as required by local codes. the supply piping. Connect the expansion tank to the air
separator only if the separator is on the suction side of
Water temperature/LWCO sensor the circulator. Always install the system fill connection
at the same point as the expansion tank connection to
A low water cutoff device is required when boiler is installed above radia- the system. Figures 9 and 10 show typical near-boiler
tion level or by certain state or local codes or insurance companies. The piping connections.
boiler has a pre-installed water temperature/LWCO sensor.
Pressure/temperature gauge System water piping

Install pressure/temperature gauge in tee on supply piping (as shown in See Figure 9 (diaphragm-type or bladder-type expansion
drawing on page 3). tank) or Figure 10 (closed-type expansion tank), and
Table 3 below, for near-boiler and single-zone systems
Isolation valves designed for return water at least 130°F.
See pages 18-19 to complete multiple-zone piping or
Isolation valves are required to enable servicing of the boiler’s temperature pages 20-25 to complete piping for radiant heating sys-
sensor. Install as shown in appropriate piping diagram. tems or converted gravity systems (large-volume systems
originally designed for circulation by natural convection
Relief valve rather than a pump). See page 25 for boilers used with
Install relief valve vertically in ¾” tapping on side of boiler. See Figure 9 refrigeration systems.
or 10, page 17, and the tag attached to the relief valve for manufacturer’s
instructions.
Table 3 Water pipe size (based on 20°F rise)
Boiler model To From
system system
To avoid water damage or scalding due to relief CGa-25 ¾” ¾”
valve operation:
CGa-3, 4, 5 1” 1”
• Discharge line must be connected to relief valve outlet and run to a
CGa-6, 7 1¼” 1¼”
safe place of disposal. Terminate the discharge line to eliminate
possibility of severe burns should the valve discharge. CGa-8 1½” 1½”
• Discharge line must be as short as possible and be the same size Note: The boiler supply and return connections, the return/
drain tee and the supply/gauge tee supplied with
as the valve discharge connection throughout its entire length. the boiler are 1¼” NPT. One of the circulator flanges
supplied with the boiler is 1¼”. The other circulator
• Discharge line must pitch downward from the valve and terminate flange is the size of the recommended system piping
at least 6” above the floor drain where any discharge will be clearly shown above.
visible.
Chillers or air handling units:
• The discharge line shall terminate plain, not threaded, with a
material serviceable for temperatures of 375°F or greater. Install boiler such that —
• Do not pipe the discharge to any place where freezing could • Chilled medium, if used, is piped in parallel with
occur. heating boiler. Use appropriate valves to prevent
chilled medium from entering boiler. Consult AHRI
• No shutoff valve shall be installed between the relief valve and Installation and Piping Guides.
boiler, or in the discharge line. Do not plug or place any obstruc- • If boiler is connected to heating coils located in
tion in the discharge line. air handling units where they can be exposed to
• Failure to comply with the above guidelines could result in fail- refrigerated air, use flow control valves or other
ure of the relief valve to operate, resulting in possibility of severe automatic means to prevent gravity circulation
personal injury, death or substantial property damage. during cooling cycle. Circulation of cold water
• Test the operation of the valve after filling and pressurizing through the boiler could result in damage to the heat
system by lifting the lever. Make sure the valve discharges freely. exchanger, causing possible severe personal injury,
If the valve fails to operate correctly, replace it with a new relief death or substantial property damage.
valve.
16 Part Number 550-142-300/0520

3b Water piping — single-zone system
Undersized expansion tanks cause system water to be lost from relief valve and makeup water
to be added through fill valve. Eventual section failure can result.
Diaphragm-type or bladder- Closed-type expansion tank

type expansion tank (Figure 9) (Figure 10)
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 inlet side of circulator. See tank 2. Connect tank to ½” NPT tapping located behind
manufacturer’s instructions for details. supply outlet, using ½” NPT piping. Pitch any
horizontal piping up towards tank 1 inch per 5 feet
2. Install an automatic air vent as shown. of piping.
Use Figure 9 or Figure 10 only for single-zone systems designed for return water at least
130°F. For systems with low return water temperature possible, such as converted gravity
systems and radiant heating systems, refer to the special piping suggestions of pages 20-25.
Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler
sections or burners, resulting in severe personal injury, death or substantial property damage.
Figure 9 Diaphragm- or bladder-type expan- Figure 10 Closed-type expansion tank — Single-

sion tank — Single-zone system using zone system using closed-type expan-
diaphragm-type or bladder-type expansion tank. See Table 3 for piping sizes.
sion tank. See Table 3 for piping sizes.
Part Number 550-142-300/0520 17

3c Water piping — multiple zones
Piping multiple zones Piping for radiant heating

Follow instructions on pages 16 and 17 to install near- systems or converted gravity
boiler or single-zone piping. (Also refer to Piping systems
for radiant heating systems or converted gravity
systems, below, if applicable.) Converted gravity (or steam) systems
See Figure 11 or Figure 12, page 19, to complete in- Whenever possible, use the primary/secondary piping
stallation. shown in Figures 13 or 14 on page 21. This piping de-
sign allows changing boiler flow rate without affecting
Zoning with circulators (Figure 11) primary circuit flow rate.
(return temp over 130°F) If Figures 13 or 14 cannot be used, use the boiler-bypass
1. Size each circulator to individual circuit require- piping shown in Figure 15 or Figure 16 on page 23. You
ments. can also use the piping shown in Figure 17 on page 25
2. Do not install circulator on boiler (except for (system-bypass), if the reduced flow rate in the heating
primary/secondary piping). system will not cause heat distribution problems.
3. Install isolation (balancing) valves to adjust flow to Failure to prevent low return water
distribute heat to all zones. temperature to the boiler could cause
corrosion of the boiler sections or burn-
4. Install and wire a separate relay for each zone
ers, resulting in severe personal injury,
circulator.
Zoning with zone valves (Figure 12)
Radiant heating systems
(return temp over 130°F) Preferably, use primary/secondary piping, as shown
1. Install isolation (balancing) valves to adjust flow to in Figures 13 or 14 on page 21. Alternatively, use the
distribute heat to all zones. method of either Figure 15 or Figure 16 on page 23.
2. Provide a separate 24-volt transformer to power the Do not use the piping of Figure 17 (system-bypass),
zone valves. Size the transformer to handle the total because this method does not control radiant system
rated load of all connected zone valves. supply temperature.
If radiant system tubing has no oxygen barrier, a heat
exchanger must be used.
DO NOT connect directly from
3-wire zone valves to the T-T termi-
nals on the boiler. When using 3-wire
zone valves, install an isolation relay.
Connect the zone valve end switch wires
to the isolation relay coil. Connect the
isolation relay contact across the boiler
T-T terminals. Failure to comply can
result in damage to boiler components
or cause unreliable operation, resulting
in severe property damage.
Radiant heating system piping should include a means of regulating the boiler return water
temperature and the system supply temperature (such as provided by an injection pumping
control). Boiler return water temperature will be adequately controlled using the methods
shown in this manual provided the system supply temperature is relatively constant.
DO NOT apply the methods in this manual if the system is equipped with an outdoor reset
control. Instead, provide controls and piping which can regulate the boiler return water
temperature at no less than 130°F regardless of system supply temperature. Contact your
Weil-McLain representative for suggested piping and control methods. Failure to prevent
cold return water temperature to the boiler could cause corrosion damage to the sections or
burners, resulting in possible severe personal injury, death or substantial property damage.
18 Part Number 550-142-300/0520

3c Water piping — multiple zones (continued)
Figure 11 Zoning with circulators — return water Figure 12 Zoning with zone valves — return water
130°F or higher. 130°F or higher.
1 Boiler isolation (balancing) 10 Automatic air vent (with diaphragm-type expansion tank), or connect
valves to tank fitting (closed-type expansion tank). DO NOT use an automatic
air vent when using closed-type expansion tank. It would allow air to
2 Flow/check valve leave the system, causing waterlogging of the expansion tank.
11 Fill valve
3 System or zone circulator
12 Diaphragm-type or bladder-type expansion tank, if used (For closed-
5 Zone valve type expansion tank, pipe from top of air separator to tank fitting as in
Figure 10, page 17.)
6 Drain valve 13 Air separator and automatic vent, if used (Note that the fill valve must
always be connected to the expansion tank, regardless of location of
9 Relief valve expansion tank circulator or air separator.
For systems with possible low return-water temperature (such as converted gravity systems,
radiant heating systems and heat pump systems), refer to the special piping suggestions of
Figures 13 – 17, as applies. Failure to prevent sustained low return water temperature to
the boiler could cause corrosion of the boiler sections, resulting in severe personal injury,
Part Number 550-142-300/0520 19

3d Water piping — low temperature systems
water temperature being supplied to the radiant tubing.

Primary/secondary (preferred)
Bypass piping method Gauge 8 is required on all systems to assure the return
water temperature is accurately set for a minimum of
Primary/secondary bypass piping is preferred because
130°F. If this gauge is not available however, adjust the
the flow rate and temperature drop in the heating
valves such that the boiler-mounted temperature/pres-
circuit(s) is determined only by the heating circuit
sure gauge reads at least 150°F when the system return
circulator(s). So adjustment of the bypass valves in
water is cold (approximately 60°F water temperature).
the boiler circuit will not cause a change in the heating
circuit rate and temperature distribution.
Valve adjustment
Figures 13 and 14, page 21, show suggested bypass
arrangements using primary/secondary bypass piping (Figures 13 and 14 only)
(preferred) for low temperature systems such as radiant 1. Set the valves while the system is cool, setting for the
heating systems or converted gravity systems. For coldest expected water temperature (usually 60°F
alternatives, see pages 22 through 25. since the system will often drop to room tempera-
The bypass valves (items 7a and 7b) provide mixing of ture between cycles).
hot boiler outlet water with cooler system return water
2. Start with valve 7a fully closed and 7b fully open.
— set to assure a minimum return water temperature
(at least 130°F) to the boiler. Set the valves as explained 3. Gradually open valve 7a while closing valve 7b until
below. the temperature at gauge 8 reads 130°F when gauge
4a reads 60°F.
Temperature gauges
4. Note that valve 7a regulates the amount of hot wa-
Gauge 4a is suggested, but optional on any system. ter from the boiler supply which mixes with return
Gauge 4b is optional on converted gravity systems, but water. Valve 7b regulates the amount of system water
required on radiant heating systems — to display the flowing through the boiler secondary loop.
Failure to prevent low return water temperature to the boiler could cause corrosion
of the boiler sections or burners, resulting in severe personal injury, death or substantial
property damage.
Radiant heating system piping should include a means of regulating the boiler return
water temperature and the system supply temperature (such as provided by an injec-
tion pumping control).
Boiler return water temperature will be adequately controlled using the methods shown
in this manual provided the system supply temperature is relatively constant.
DO NOT apply the methods of this manual if the system is equipped with an outdoor reset
Weil-McLain representative for suggested piping and control methods.
Failure to prevent cold return water temperature to the boiler could cause corrosion
damage to the sections or burners, resulting in possible severe personal injury, death or
substantial property damage.
20 Part Number 550-142-300/0520

3d Water piping — low temperature systems (continued)
Figure 13 Primary/secondary piping Figure 14 Primary/secondary piping

Zoning with circulators Zoning with zone valves
1 Boiler isolation (balancing) valves 10 Automatic air vent (with diaphragm-type expansion
tank), or connect to tank fitting (closed-type expan-
2 Flow/check valve sion tank). DO NOT use an automatic air vent when
using closed-type expansion tank. It would allow
3 System or zone circulator (circulator should cycle
with zone valve and switches, using circulator valve air to leave the system, causing waterlogging of the
or zone control panel) expansion tank.
4 System temperature gauges 11 Fill valve
5 Zone valve 12 Diaphragm-type or bladder-type expansion tank,

if used (For closed-type expansion tank, pipe from
6 Drain valve top of air separator to tank fitting as in Figure 10,
page 17.)
7 System temperature valves (see instructions to the
left for adjusting valves) 13 Air separator and automatic vent, if used (Note that
the fill valve must always be connected to the expan-
8 Blend temperature gauge
sion tank, regardless of location of expansion tank,
9 Relief valve circulator or air separator.)
Part Number 550-142-300/0520 21

BOILER-bypass piping to the boiler. (When setting the valves without gauge
4a installed — using cold or room temperature water
method — assume the return water temperature to be 60°F. Set
This piping method (Figure 15 or 16, page 23) is called the valves so gauge 8 reads at least 120°F.
a boiler-bypass because part of the circulator flow is Gauge 4b is optional on converted gravity systems, but
bypassed around the boiler (through valve 7a). This required on radiant heating systems — to display the
method reduces the flow rate throughout the boiler, in water temperature being supplied to the radiant tubing.
order to raise the average water temperature in the boiler
enough to prevent flue gas condensation. Boiler-bypass Gauge 8 is required on all systems to assure reliable
piping is effective for some boilers — including the adjustment of the bypass valves. The boiler-mounted
CGa — provided the flow rates are adjusted according temperature/pressure gauge can be used if a separate
to the instructions following. temperature gauge is not installed.
Figures 15 and 16 are alternative piping suggestions
for converted gravity (large water content or steam Valve adjustment
systems) or radiant heating system — for use when
primary/secondary piping can’t be applied. (Figure 17, 1. Start with valve 7a fully closed and 7b fully open.
page 25, is another alternative, using system bypass in 2. Gradually open valve 7a while closing valve 7b
place of boiler-bypass piping. Figure 17 however, is until the temperature at gauge 8 reads 60 °F higher
not suitable for radiant heating applications because it than gauge 4a. A minimum 60°F temperature rise
does not protect the radiant system from possible high through the boiler assures a low enough flow rate
water temperature.) and high enough average temperature to prevent
Boiler-bypass piping keeps system flow rate as high as condensation even with low system return water
possible and temperature drop as low as possible, help- temperature.
ing to equalize the building heat distribution.
3. Valve 7a regulates the system flow rate, while valve
7b regulates the boiler flow rate.
Temperature gauges
Gauge 4a is optional if the bypass valves will be ad- 4. The boiler-mounted temperature/pressure gauge
justed using cold (or room temperature) return water may be used in place of a separate gauge 8.
property damage.
water temperature and the system supply temperature (such as provided by an injec-
tion pumping control).
22 Part Number 550-142-300/0520

Figure 15 Boiler-bypass piping Figure 16 Boiler-bypass piping

Zoning with circulators Zoning with zone valves
(Alternative to primary/secondary piping (Alternative to primary/secondary piping
Figures 13 and 14) Figures 13 and 14)
1 Boiler isolation (balancing) valves 10 Automatic air vent (with diaphragm-type expansion
tank), or connect to tank fitting (closed-type expansion
2 Flow/check valve tank). DO NOT use an automatic air vent when using
closed-type expansion tank. It would allow air to leave
3 System or zone circulator the system, causing waterlogging of the expansion tank.
4 System temperature gauges
11 Fill valve
5 Zone valve
12 Diaphragm-type or bladder-type expansion tank, if
6 Drain valve used (For closed-type expansion tank, pipe from top
of air separator to tank fitting as in Figure 10.)
7 System temperature valves (see instructions
to the left for adjusting valves)
13 Air separator and automatic vent, if used (Note that the
8 Blend temperature gauge fill valve must always be connected to the expansion
tank, regardless of location of expansion tank, circulator
9 Relief valve or air separator.)
Part Number 550-142-300/0520 23

SYSTEM-bypass piping DO NOT apply system-bypass piping if the reduced

flow in the system could cause poor heat distribution.
method That is, system-bypass piping reduces the flow in the
This piping method (Figure 17, page 25) is called a system and increases the water temperature supplied to
system-bypass because part of the circulator flow by- the system. This can cause increased heat from radiators
passes the system (through valve 7a). This bypassed hot at the beginning of the system and reduced heat from
water from the boiler outlet mixes with cooler system radiators near the end of the system.
return water temperature in order to provide minimum
130°F return water to the boiler. Valve 7b will most often
be full open, but may need to be slightly closed on some Valve adjustment
low pressure drop systems in order to cause enough flow
through valve 7a. 1. Start with valve 7a fully closed and 7b fully open.
Figure 17 is an alternative piping method that provides
return water temperature control for boilers installed 2. Gradually open valve 7a while closing valve 7b until
on converted gravity systems (large water content the temperature at gauge 8 reads at least 130°F at all
or steam systems). times.
DO NOT apply the piping of Figure 17 on radiant
heating systems. It provides no method of regulat- 3. Valve 7a regulates the amount of boiler supply water
ing the water temperature provided to the system and mixed with return water. Valve 7b causes a pressure
could result in excessive water temperature in the radi- drop in the system needed to balance flow through
ant tubing. valve 7a and the system.
System-bypass piping as shown in Figure 17 can be used
with either zone valve or circulator zoning. When used 4. The valve adjustment should be done with the
with circulator zoning however, the boiler circulator system at the coldest expected temperature (60°F
(item 3), must be piped as shown. It cannot be used as for converted gravity systems or high mass radiant
one of the zoning circulators. systems).
property damage.
water temperature and the system supply temperature (such as provided by an injection
pumping control).
24 Part Number 550-142-300/0520

Figure 17 System-bypass piping — Zoning with

zone valve or circulators, return water
130°F or higher — (Alternative to boiler-
bypass piping Figures 15 and 16,
page 23)
3 System or zone circulator
7 System temperature valves (see instructions to the left for

adjusting valves)
8 Blend temperature gauge
9 Relief valve
10 Automatic air vent (with diaphragm-type expansion

tank), or connect to tank fitting (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 waterlogging of the expansion tank.
11 Fill valve
12 Diaphragm-type or bladder-type expansion tank, if used

(For closed-type expansion tank, pipe from top of air
separator to tank fitting as in Figure 10, page 17.)
3e Water piping — refrigeration systems

Figure 18 Piping refrigeration systems Prevent chilled water from
entering boiler
Install boiler so that chilled medium is piped in parallel
with the heating boiler. Use appropriate valves to prevent
chilled medium from entering boiler. See Figure 18 for
typical installation of balancing valve and check valve.
If boiler is connected to heating coils located in air han-

dling units where they can be exposed to refrigerated
air, use flow control valves or other automatic means to
prevent gravity circulation during cooling cycle.
Part Number 550-142-300/0520 25

4 Gas piping
Connect gas supply piping to boiler Natural Gas:

1. Remove jacket front panel and refer to Figure 19 to pipe gas to boiler. 1. Refer to Table 4 for pipe length and diameter. Base
a. Install drip leg at inlet of gas connection to boiler. Where local on rated boiler input (divide by 1,000 to obtain cubic
utility requires drip leg to be extended to the floor, use appropri- feet per hour). Table 4 is only for gas with specific
ate length of pipe between cap and tee. gravity 0.60, with a pressure drop through the
b. Install ground joint union for servicing, when required. gas piping of 0.30” w.c. For additional gas pipe
sizing information, refer to ANSI Z223.1 (or B149.1
c. Install manual shutoff valve in gas supply piping outside boiler
jacket when required by local codes or utility requirements. or B149.2 for Canadian installations).
d. In Canada — When using manual main shutoff valve, it must be
2. Inlet pressure required at gas valve inlet:
identified by the installer. • Maximum: 13” w.c.
2. Support piping with hangers, not by boiler or its accessories. • Minimum: 5” w.c.
• Manifold gas pressure: 3.5” w.c.
3. Purge all air from gas supply piping.
4. Before placing boiler in operation, check boiler and its gas connec- 3. Install 100% lockup gas pressure regulator in supply
tion for leaks. line if inlet pressure exceeds 13” w.c. Adjust for
a. Close manual main shutoff valve during any pressure testing at 13” w.c. maximum.
less than 13” w.c.
b. Disconnect boiler and gas valve from gas supply piping dur-
ing any pressure testing greater than 13” w.c. Propane Gas:
Do not check for gas leaks with an open flame — 1. Contact gas supplier to size pipes, tanks and 100%
Use bubble test. Failure to use bubble test or check for lockup gas pressure regulator.
gas leaks can cause severe personal injury, death or
substantial property damage. 2. Adjust propane supply regulator provided by gas
supplier for 13” w.c. maximum pressure.
5. Use pipe dope compatible with propane gases. Apply sparingly only
to male threads of pipe joints so that pipe dope does not block gas flow. 3. Inlet pressure required at gas valve inlet:
• Maximum: 13” w.c.
Failure to apply pipe dope as detailed above can result
in severe personal injury, death or substantial property • Minimum: 11” w.c.
damage. • Manifold gas pressure: 10” w.c.
Table 4 Pipe capacity for 0.60 specific gravity natural gas Figure 19 Gas supply piping
Gas pipe Capacity of pipe for pipe size of:

length (Capacity in cubic feet gas per hour)
(feet) ½” ¾” 1” 1¼” 1½”
10 132 278 520 1050 1600
20 92 190 350 730 1100
30 73 152 285 590 860
40 63 130 245 500 760
50 56 115 215 440 670
75 45 93 175 360 545
100 38 79 150 305 460
150 31 64 120 250 380
26 Part Number 550-142-300/0520

5 Field wiring
For your safety, turn off electrical power supply at ser- the wiring diagram shown in Figure 25b, page 37.
vice entrance panel before making any electrical con- For other devices, refer to manufacturer’s specifica-
nections to avoid possible electric shock hazard. Failure tions. Wiring diagram on boiler gives setting for
to do so can cause severe personal injury or death. control module and gas valve. Also see instructions
with thermostat.
Wiring must be N.E.C. Class 1.
If rollout thermal fuse element wire as supplied with boiler
DHW
must be replaced, type 200°C wire or equivalent must be Connect DHW aquastat as shown in wiring below.
used. If other original wiring as supplied with boiler must Economy function isn’t utilized with DHW input.
be replaced, use only type 105°C wire or equivalent.
Boiler must be electrically grounded as required by Junction box (furnished)
National Electrical Code ANSI/NFPA 70 – latest edition. 1. Connect 120 VAC power wiring (Figure 20).
2. Fused disconnect or service switch (15 amp. recom-
mended) may be mounted on this box. For those
Installation must comply with: installations with local codes which prohibit instal-
1. National Electrical Code ANSI /NFPA 70 – latest edition lation of fused disconnect or service switch on boiler,
and any other national, state, provincial or local codes or install a 2 x 4 cover plate on the boiler junction box
regulations. and mount the service switch remotely as required
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, by the code.
and any local codes.
Wiring connections Wiring multiple zones
Refer to zone valve manufacturer’s literature for wiring
Boiler is shipped with controls completely wired, except spill and application. A separate transformer is required to
switch and vent damper. Refer to wiring diagrams shown power zone valves. Zoning with circulators requires a
on page 36 for spark-ignited pilot boiler. relay for each circulator.
DO NOT connect directly from 3-wire
Thermostat zone valves to the T-T terminals on
1. Connect thermostat as shown on wiring diagram on the boiler. When using 3-wire zone
boiler. valves, install an isolation relay. Connect
2. Install on inside wall away from influences of drafts, hot the zone valve end switch wires to the
or cold water pipes, lighting fixtures, television, sunrays isolation relay coil. Connect the isolation
or fireplaces. relay contact across the boiler T-T
3. If thermostat has a heat anticipator, set heat anticipator terminals. Failure to comply can result in
in thermostat to match power requirements of equip- damage to boiler components or cause
ment connected to it. If connected directly to boiler, set unreliable operation, resulting in severe
for 0.1 amps plus gas valve current. See information on property damage.
Figure 20
Field wiring connec-

tions —
service switch, DHW
(if used) and
thermostat
(or end switch) pro-
vided by installer
Part Number 550-142-300/0520 27

6a Start-up — preparation
Check for gas leaks Determine if water treatment

is needed
Before starting the boiler, and during Do not use petroleum-based clean-
initial operation, smell near the floor ing or sealing compounds in boiler
and around the boiler for gas odorant system. Severe damage to boiler will
or any unusual odor. Do not proceed occur, resulting in substantial property
with start-up if there is any indication damage.
of a gas leak. Repair any leak at once.
Eliminate all system leaks. Continual
fresh makeup water will reduce boiler
Propane boilers only — Your propane life. Minerals can build up in sections,
supplier mixes an odorant with the reducing heat transfer, overheating cast
propane to make its presence detect- iron, and causing section failure.
able. In some instances, the odorant
can fade and the gas may no longer Verify water chemistry
have an odor.
Consult local water treatment companies for unusually
hard water areas (above 7 grains hardness) or low pH wa-
• Propane gas can accumulate at ter conditions (below 7.0). Boiler water pH of 7.0 to 8.5 is
floor level. Smell near the floor recommended.
for the gas odorant or any unusual
odor. If you suspect a leak, do not
attempt to light the pilot. Freeze protection (when used)
Use antifreeze made especially for hydronic systems. Inhib-
• Periodically check the odorant level
of your gas. ited propylene glycol is recommended.
Do not use ethylene glycol, automo-
tive or undiluted antifreeze. Severe
• Inspect boiler and system at least personal injury or death can result.
yearly to make sure all gas piping
is leak-tight. 1. Determine antifreeze quantity according to system
water content. Boiler water content is listed on page 65.
Remember to include expansion tank water content.
• Consult your propane supplier
regarding installation of a gas leak 2. Follow antifreeze manufacturer’s instructions.
detector. There are some products
on the market intended for this 3. A 50% solution of propylene glycol/water provides
purpose. Your supplier may be able maximum protection to about -30°F.
to suggest an appropriate device. 4. Local codes may require back flow preventer or actual
disconnect from city water supply.
5. When using antifreeze in a system with automatic fill,
install a water meter to monitor water makeup. Glycol
will leak before the water begins to leak, causing glycol
level to drop. Added water will dilute the antifreeze,
reducing the freeze protection level.
28 Part Number 550-142-300/0520

6a Start-up — preparation (continued)
Fill the system with water Inspect system water piping

1. Close manual and automatic air vents and boiler After filling the boiler and system with water, inspect
drain cock. all piping throughout the system for leaks. If found,
2. Fill to correct system pressure. Correct pressure repair immediately. Repeat this inspection after the
will vary with each application. Typical cold water boiler has been started and the system has heated up.
fill pressure for a residential system is 12 psi.
Leaks must be repaired at once.
3. Purge air from system: Failure to do so can damage the
a. Connect a hose to the purge valve (see drain boiler, resulting in substantial
valves, item 6, in suggested piping diagrams property damage.
on pages 17 through 23, Figure 9 through Fig-
ure 16). Route hose to an area where water can Do not use petroleum-based
drain and be seen. cleaning or sealing compounds
b. Close the boiler or system isolation valve be- in boiler system. Severe damage
to boiler will occur, resulting in
tween the purge valve and fill connection to the
system.
c. Close zone isolation valves.
d. Open quick-fill valve on cold water makeup line.
e. Open purge valve.
f. One zone at a time, open the isolation valves. Inspect base insulation
Allow water to run through the zone, pushing
out the air. Run until no noticeable air flow is The boiler contains ceramic fiber
present. Close the zone isolation valves and pro- and fiberglass materials. Use care
ceed with the next zone. Follow this procedure when handling these materials
until all zones are purged.
per instructions on page 66 of this
g. Close the quick-fill water valve and purge valve
manual. Failure to comply could
and remove the hose. Open all isolation valves.
result in severe personal injury.
Watch that system pressure rises to correct cold-
fill pressure.
Failure to replace damaged in-
h. After the system has operated for a while, elimi-
sulation or reposition insulation
nate any residual air by using the manual air
can result in a fire hazard, causing
vents located throughout the system.
severe personal injury, death or
i. If purge valves are not installed in system, open
manual air vents in system one at a time, begin- substantial property damage.
ning with lowest floor. Close vent when water Check to make sure base insulation is secure against
squirts out. Repeat with remaining vents. all four sides of the base. If insulation is damaged or
displaced, do not operate boiler. Replace or reposition
4. Open automatic air vent (diaphragm-type or insulation.
bladder-type expansion tank systems only) one
turn.
5. Open other vents:
a. Starting on the lowest floor, open air vents one
at a time until water squirts out.
b. Repeat with remaining vents.
6. Refill to correct pressure.
Part Number 550-142-300/0520 29

6b Start-up — operate boiler

DO NOT proceed with boiler operation unless boiler and system have been filled with water and
all instructions and procedures of previous manual sections have been completed. Failure to do
so could result in severe personal injury, death or substantial property damage. Before starting the
boiler, do the following:
• Read manual Section 9 and the Operating instruction procedure (see Table 5, below).
• Verify the boiler and system are full of water.
• Verify the Start-up preparation procedures of Section 6 have been completed.
Table 5 Operating instruction location guide

Models Spark-ignited pilot Gas Page
CGa-25 Honeywell VR8204/VR8304 Natural/Propane 38
to
Robertshaw 7200 Natural 39
CGa-6
White-Rodgers 36E Natural 40
CGa-7 Honeywell VR8204/VR8304 Natural/Propane 38
&
CGa-8 White-Rodgers 36C Natural 41
Adjust boiler control settings

BOILER OPERATING TEMPERATURE
With power turned on, control module receives a signal from
the temperature/LWCO sensor and displays boiler temperature.
The control knob labeled BOILER TEMP is used to adjust the
operating temperature setpoint, turning clockwise to increase
temperature setting and counterclockwise to decrease. When the
knob is turned to adjust temperature the display will brighten to
indicate adjustment mode. After temperature is set to desired
value, display will dim after approximately 5 seconds to indicate
measurement mode.
• ADJUST BOILER OPERATING TEMPERATURE TO

DESIRED SETPOINT.
BOILER ECONOMY SETTING

IMPORTANT
To comply with Department of Energy regulations, the control
module circulates available hot water before turning on the boiler In accordance with Section 325 (f) (3) of the Energy Policy and
to attempt to satisfy a call for heat. While attempting to satisfy Conservation Act, this boiler is equipped with a feature that saves
the heat demand, the control module also monitors the boiler energy by reducing the boiler water temperature as the heating
temperature changes via the temperature/LWCO sensor and load decreases. This feature is equipped with an override which
determines whether or not the available hot water will satisfy the is provided primarily to permit the use of an external energy
demand, adjusting the time delay to turn on the boiler until it management system that serves the same function.
determines that additional heat will be needed. The knob labeled THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST
ECONOMY ADJUST provides an adjustment between maximize ONE OF THE FOLLOWING CONDITIONS IS TRUE:
(MAX) and minimize (MIN) time delay. The maximum (MAX)
• An external energy management system is installed that
adjustment position should be used to maximize energy savings. reduces the boiler water temperature as the heating load
Turning the knob counterclockwise decreases the delay time and decreases.
should only be used in the event that the heated space becomes
uncomfortable. • This boiler is part of a modular or multiple boiler system
having a total input of 300,000 BTU/hr or greater.
• ADJUST ECONOMY TO DESIRED POSITION (MAX IS • This boiler is equipped with a tankless coil.
THE PREFERRED SETTING).
30 Part Number 550-142-300/0520

6b Start-up — operate boiler (continued)
Start the boiler

• Follow the Operating Instructions from Section
9 to start the boiler. Remove boiler jacket door and Eliminate all system leaks.
note the gas valve manufacturer and model number. Continual fresh makeup water
Use only the operating instruction which applies to will reduce boiler life. Minerals
this gas valve (see Table 5, page 30). (The operating can build up in sections, reduc-
instruction label on the boiler provides the same ing heat transfer, overheating cast
information.) iron, and causing section failure.
• See Section 6c if boiler fails to start.
Check system and boiler If you discover evidence of any

gas leak, shut down the boiler at
1. Check system piping for leaks. If found, shut
once. Find the leak source with
down boiler and repair immediately.
bubble test and repair immedi-
2. Vent air from system using manual vents. Air in ately. Do not start boiler again
the system will interfere with circulation and cause until corrected. Failure to comply
heat distribution problems and noise. could result in severe personal
injury, death or substantial prop-
3. Inspect vent system thoroughly for signs of erty damage.
deterioration from corrosion, physical damage or
sagging. Verify that masonry chimney liners are in
good condition, with no obstructions, and there are
Do not use petroleum-based
no openings into the chimney.
cleaning or sealing compounds
4. Check around the boiler for gas odor following the in boiler system. Severe damage
to boiler will occur, resulting in
procedure of Section 6a of this manual. substantial property damage.
5. Verify operation per Section 6d. Perform check-out
procedure in Section 7 and fill in the Installation
and service certificate on the same page.
6c Start-up — if boiler doesn’t start . . .

Check for:
1. Loose connections, blown fuse or service switch off? 4. Gas not turned on at meter or boiler?
2. Boiler temperature adjustment set below boiler 5. Incoming gas pressure less than:
water temperature? 5” w.c. for natural gas? 11” w.c. for propane gas?
3. Thermostat set below room temperature? 6. If none of the above corrects the problem, refer to
Troubleshooting, Section 11 of this manual.
Part Number 550-142-300/0520 31

6d Start-up — verify operation
See Section 9 for operation and operating information.
Check burner flames Figure 21 Typical pilot burner flame
Pilot burner flame (Figure 21)

PROPER pilot flame
1. Blue flame.
2. Inner cone engulfing pilot flame sensor (spark-
ignited pilot).
3. Pilot flame sensor glowing cherry red.
IMPROPER pilot flame
1. Overfired — Large flame lifting or blowing past pilot
flame sensor.
2. Underfired — Small flame. Inner cone not engulfing
pilot flame sensor.
3. Lack of primary air — Yellow flame tip.
Main burner flame (Figure 22)

PROPER main burner flame
Figure 22 Typical main burner flame
1. Yellow-orange streaks may appear (caused by dust).
IMPROPER main burner flame:
1. Overfired — Large flames.
2. Underfired — Small flames.
3. Lack of primary air — Yellow tipping on flames
(sooting will occur).
Check vent damper operation

1. Raise room thermostat to call for heat — Vent
damper actuator will slowly open vent damper.
5. Return thermostat to normal setting.
2. When vent damper is fully open — Pilot will light, 6. Set thermostat heat anticipator setting indicated on
then allow main burners to ignite. wiring diagram.
Vent damper must be fully open
before main burners light. If vent
damper does not fully open, flue
Check vent system operation
products such as carbon monoxide 1. Check vent system at least once a month during
will escape into house, causing se- heating season. With boiler firing, hold candle or
vere personal injury or death. match below lower edge of draft hood “skirt”. If
flame does not blow out, but burns undisturbed,
3. Lower thermostat setting — Main burner flames vent system is functioning properly. If flame blows
will go out, then vent damper will close. out or flickers drastically, inspect vent system for
4. Repeat Steps 2 through 4 several times to verify obstructions or other causes of improper venting
operation. (such as exhaust fans in boiler room).
32 Part Number 550-142-300/0520

❏
7 Check-out procedure — checklist
Boiler and heat distribution units filled with water? ❏ Set Boiler Temp adjustment knob to system temperature re-
quirements. Adjust balancing valves and controls to provide
❏ Automatic air vent, if used, open one full turn? design temperature to system.
❏ Air purged from system? ❏ Set Economy mode, fully clockwise.
❏ Air purged from gas piping? Piping checked for leaks?
❏ For multiple zones, adjust flow so it is about the same in
❏ Correctly sized manifold orifices installed? Refer to Table 2, each zone.
page 12 to check size and fuel type.
❏ Verify thermostat heat anticipator (if available) set
Correctly sized manifold orifices must be used. properly? Refer to Field wiring, manual Section 5, page 27,
Failure to do so will cause severe personal Thermostat(s).
injury, death or substantial property damage.
❏ Cycle boiler with thermostat — Raise to highest setting and
❏ Followed operating instructions on boiler or in manual verify boiler goes through normal start-up cycle. Lower to
Section 9 for proper start-up? lowest setting and verify boiler goes off.
❏ Proper burner flame observed? Refer to Check burner flame,
manual Section 6d. ❏ Cycle DHW Aquastat if used.
❏ Test temperature limit — While burners are operating, turn ❏ Measure natural gas input:
Boiler Temp adjustment knob counterclockwise until display a. Operate boiler 10 minutes.
reading is below actual boiler water temperature. Burners
should go off while circulator continues to operate. Turn b. Turn off other appliances.
Boiler Temp adjustment knob clockwise until display read- c. At natural gas meter, measure time (in seconds) re-
ing is above boiler water temperature and ignition sequence quired to use one cubic foot of gas.
should resume.
d. Calculate gas input:
❏ Test low water cut off – While burners are operating, press
and hold “LWCO TEST” button on control. Burners should
go off while circulator continues to operate and LWCO light 3600 x 1000
= Btuh
should turn ON. Release “LWCO TEST” button and ignition number of seconds from step c
sequence should resume.
❏ Test field-installed controls — If the boiler has an additional e. Btuh calculated should approximate input rating on
low water cutoff, additional high limit or other controls, test boiler rating label.
for operation as outlined by manufacturer. Burners should ❏ Check manifold gas pressure by connecting manometer to
be operating and should go off when controls are tested. downstream test tapping on main gas valve. Manifold pres-
When controls are restored, burners should reignite.
sure for natural gas should be 3.5" w.c. and for propane gas
❏ Button on spill switch pushed in? should be 10" w.c.
❏ Test ignition system safety device
❏ Observe several operating cycles for proper operation.
Connect manometer to outlet side of gas valve. Start boiler,
allowing for normal start-up cycle to occur and main burn- ❏ Set room thermostat to desired room temperature.
ers to ignite. With main burners on, manually shut off gas
supply at manual main shutoff gas valve. Burners should go ❏ Fill in Installation and service certificate below?
off. Open manual main shutoff gas valve. Manometer should ❏ Review all instructions shipped with this boiler with owner
confirm there is no gas flow. Pilot will relight, flame sensing or maintenance person. Return instructions to envelope and
element will sense pilot flame and main burners reignite. give to owner or place in pocket inside front panel in boiler.
Installation and service certificate

Boiler model ______________ Series _______ Consumer Protection number _____________ Date installed ___________
Measured Btuh input ____________________ ❏ Installation instructions have been followed.

❏ Check out sequence has been performed.
❏ Above information is certified to be correct.
❏ Information received and left with owner/maintenance person
Installer ________________________ ________________________________ ________________________
(company) (address) (phone)
Installer’s signature: _____________________________________
Part Number 550-142-300/0520 33

8 Department of Energy – Compliance

This boiler is equipped with a control system that automatically adjusts a time delay period to turn on the boiler during a call
for heat. This is accomplished by circulating available hot water in the system while measuring water boiler water tempera-
ture changes. The control calculates a suitable delay based on temperature measurements and turns the boiler on only after it
determines that the demand for heat cannot be satisfied with the available hot water,
Due to the wide variety of controls used in boiler installations, this control is also equipped with an adjustment for the cal-
culated time delay period (ECONOMY ADJUST). In the MIN position, the time delay is zero and the IMPORTANT notice
below must be observed:
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that
saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override
which is provided primarily to permit the use of an external energy management system that serves the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:
• An external energy management system is installed that reduces the boiler water temperature as the heating load
decreases.
• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.
• This boiler is equipped with a tankless coil.
9a Operation — spark-ignited pilot boilers

Follow all procedures given in this manual b. Natural Gas - If pilot does not light within 15 seconds,
and operating instructions when operating the pilot valve is closed and spark generator is turned off. Control
boiler. Failure to do so could result in severe module waits 5 minutes, then attempts to ignite pilot again.
personal injury, death or substantial property This cycle will continue indefinitely if pilot ignition control
damage. does not sense pilot flame.
1. Standby: With no call for heat, the vent damper and circulator c. Propane Gas - If pilot does not light within 15 seconds,
are de-energized. No gas flows to pilot or main gas valve. pilot valve is closed and spark generator is turned off. Control
2. Call for heat (thermostat circuit closes): module waits 1 minute then attempts to ignite pilot again.
After first failed ignition retry attempt, control module will
a. While attempting to satisfy the heat demand, the control attempt to ignite pilot 2 more times with a 5 minute wait
module monitors the boiler temperature changes via the period after the second try and a 60 minute wait period after
temperature sensor and determines whether or not the the third try. If the ignition control does not sense pilot flame
available hot water will satisfy the demand, only running during these trials, it will lock out the boiler and require a
the circulator. If additional heat is needed, the sequence manual reset procedure to allow further attempts.
continues. When DHW (if used) calls for heat, sequence
above is bypassed. Manual Reset Procedure for Propane Gas Lockout ––
b. Vent damper and circulator energized if pilot status ac- Unburned propane gas may have accumulated
ceptable. Vent damper drives open. When vent damper end in combustion chamber. Provide adequate
switch makes circuit, ignition control begins pilot ignition ventilation to completely remove any
attempt. accumulated LP gas from boiler and adjacent
area before attempting to reset and light boiler.
c. Ignition control checks for false flame signal: If ignition Failure to do so will cause severe personal
control senses pilot signal when no pilot gas should be injury, death or substantial property damage.
present, control will lockout, requiring reset procedure as Propane Gas Lockout manual reset – ONLY
given in Figure 24. after boiler area has been cleared of any
3. Pilot ignition: Control module sparks the pilot and opens pilot accumulated LP gas:
valve in main gas valve.
• Push and hold TEST button, see page 50, Item 11.
a. If pilot does light and control module senses flame
• While holding TEST button, rotate Economy Adjust knob
current, spark generator is turned off and main valve
opens. fully clockwise then fully counter clockwise.
• Release TEST button.
• Control module is reset.
34 Part Number 550-142-300/0520
9a Operation — spark-ignited pilot boilers

4. Main burner operation: 5. Thermostat satisfied (thermostat circuit opens) — Pilot and
a. Control module monitors pilot flame current. If signal main gas valves are closed — Vent damper is de-energized, and cycles
is lost, main valve closes, spark generator activates and to closed position. Circulator is shut off.
sequence returns to step 4. 6. Boiler is now in the standby mode.
b. If power is interrupted, control system shuts off pilot 7. Thermostat anticipator setting: Set thermostat heat anticipator as
and main gas valves and restarts at step 1 when power is instructed in Figure 25b, page 37.
restored.
c. In the event the limit control shuts down the boiler — The
control module closes the main gas valve, but keeps the
circulator operating and the vent damper open.
Figure 24 Ignition control module sequence of operation — status light indications
Call for POWER TSTAT LIMIT DAMPER FLAME LWCO Timing

Heat? CIRC
STEPS
(following step 7, cycle goes back to step 1.)
1. Standby
• Waiting for call for heat NO —
2. Call for heat
• Circulator on YES —
3. Limit circuit
• Limit controls closed YES —
4. Damper circuit
• Damper proven open YES —
5. Flame proven *
• Gas valve open YES 15 sec
• Ignitor remains on
• Boiler producing heat
6. Limit cycle
• Limit circuit open YES —
• Gas valve closed
7. Flame outage *
• Flame out YES —
• Boiler recycles
8. Thermostat satisfied
NO —
• Circulator off
9. Circulator exercise routine
• Circulator turns on for 30 seconds if NO 30 sec
boiler not operated for 30 days
10. LWCO circuit
• LWCO circuit open YES/NO —
= ON = OFF
* See Section 9, Items 3b and 3c for controls response to failure to prove pilot flame.
Control will lockout under the following conditions: Control will reset after these lockouts :
• Line voltage polarity is reversed • 1 hour waiting period
• Stray voltage is sensed on thermostat line • Opening and closing of thermostat circuit for 2 to 20 seconds
• Damper end switch not proven within 5 minutes from thermostat • Removal of 120 VAC power for 2 to 20 seconds
call for heat
• Flame is sensed when it shouldn’t be there
Part Number 550-142-300/0520 35

9a Operation — spark-ignited pilot system (continued)
Figure 25a Schematic wiring diagram — Spark-ignited pilot system
CAUTION DO NOT connect directly from 3-wire zone valves to the T-T terminals on the
boiler. When using 3-wire zone valves, install an isolation relay. Connect the zone valve
end switch wires to the isolation relay coil. Connect the isolation relay contact across the
boiler T-T terminals. Failure to comply can result in damage to boiler components or
cause unreliable operation, resulting in possible severe property damage.
NOTICE • The control module is polarity-sensitive to the incoming 120 VAC power. If polarity is
reversed, control will flash the POWER light when powered and will not cycle boiler.
• All contacts shown without power applied.
• Connector and status light locations/orientations may vary.
FIELD
120 VAC — Hot Neutral Gnd WIRING
CIRCULATOR SERVICE Items not

SWITCH provided
Ground
screw
VENT DAMPER Wire nuts
White Green
Black
3 1
Junction box,
4 2
boiler left side
Y
R BK
BK W TRANSFORMER
W
Y PK/BL
G G
POWER
TSTAT/
CIRC POWER W
LIMIT
DAMPER PILOT MAIN
FLAME
LWCO
CIRC BR/Y
TRANSFORMER
BK
W
BK O PILOT
SPILL SWITCH R BURNER
Additional G Y
BK C R
limits,if used BK R BL
(note 7) BK To DHW Aquastat
OUTDOOR LWCO SENSOR Y TSTAT BL (if used)
COMM
Y
TEST
Y THERMOSTAT
ROLLOUT
TFE
70 80
60
BL W
60
R
80
70
O R G BK BK
FIELD
OUTDOOR "C" To Black WIRING Black
TEMPERATURE R
Ground
"A" Screw
SENSOR
(if used) TEMPERATURE/ "B"
LWCO SENSOR W
OFF
Terminal block
ON
GAS VALVE Jacket opening,

59374b +LWCO (Honeywell VR8204 shown) boiler left side
36 Part Number 550-142-300/0520

9a Operation — spark-ignited pilot system (continued)
Figure 25b Ladder wiring diagram — Spark-ignited pilot system
WARNING Electrical shock hazard — can Hot Neutral Gnd

cause severe injury or death. 120 VAC
Disconnect power before installing SERVICE
or servicing.
SWITCH
CONTROL
Legend for ladder wiring diagram MODULE
120 VAC field wiring HIGH 120 VAC
Low voltage field wiring VOLTAGE SECTION CIRCULATOR
120 VAC factory wiring
Low voltage factory wiring
PILOT
High voltage spark ignition wiring
IGNITION
Ground connectors
ELECTRODE
120 VAC
Table G: Gas valve terminals and anticipator settings
Anticipator
Gas valve "A" "B" "C" amps
Honeywell VR8204 MV/PV MV PV 0.6 24 VAC
Honeywell VR8304 MV/PV MV PV 0.8
White-Rodgers 36E 2 1 3 0.64
24 VAC
R Power CONSTANT
White-Rodgers 36C 2–4 * 1 3 0.7
THERMOSTAT
* Terminals 2–4 are factory-jumpered on the
White-Rodgers 36C gas valve. R Tstat–Circ
VENT
1. All wiring must be installed in accordance with: 24 VAC DAMPER
A. U.S.A. — N.E.C. And any other national, state, CALL
or local code requirements. DHW (if used) FOR HEAT
B. Canada — C.S.A. C22.1 C.E.C. Part 1 and
any other national, provincial, or local code TEMPERATURE
requirements. LWCO SENSOR
2. Pilot lead wires are not field replaceable.
Replace pilot assembly if necessary. ROLLOUT SPILL
3. If any of the original wire as supplied with the TFE SWITCH
appliance must be replaced, use minimum 105 R Limit
°C wire or equivalent. Exception — wires to a Additional PILOT GAS
rollout TFE must be 200 °C or equivalent. limits (note 7) VALVE
4. Thermostat anticipator setting (single zone) — Outdoor Temperature
Sensor (if used) "C"
see Table G for anticipator setting, depending "A"
on which gas valve is installed in boiler.
"B"
5. For multiple zoning, use either zone valves or R Damper
circulators. Refer to the component manufac- MAIN GAS
DAMPER END SWITCH
turer's instructions and this manual for applica- (INTERNAL TO DAMPER) VALVE
tion and wiring suggestions. See Table G
6. Refer to control component instructions PILOT FLAME R Flame
packed with the boiler for application informa- SENSOR
tion. HIGH
7. Wire any additional limit controls (low water VOLTAGE R LWCO
cut-off, additional high limit, etc.) in series with
boiler rollout TFE and spill switch as shown. Control Module
Low Voltage Section
59374a+LWCO
Part Number 550-142-300/0520 37

9b Operating instructions
• Spark pilot • Natural gas • Propane gas
CGa-25 to CGa-8 • Gas valve: Honeywell VR8204/VR8304
38 Part Number 550-142-300/0520

CGa-25 to CGa-6 • Spark pilot • Natural gas
• Gas valve: Robertshaw 7200
Part Number 550-142-300/0520 39

• Gas valve: White-Rodgers 36E
40 Part Number 550-142-300/0520

• Gas valve: White-Rodgers 36C
Part Number 550-142-300/0520 41

10a Service and maintenance — schedule
VERIFY PROPER OPERATION AFTER SERVICING
Table 6 Service and maintenance schedules (service technician and user)
Service technician Owner maintenance

(see following pages for instructions) (see CGa User’s Information Manual for instructions)
• Check boiler area

Inspect:
• Check air openings
Daily
• Reported problems • Check boiler pressure/
• Boiler area temperature gauge
• Air openings
• Flue gas vent system • Check boiler interior piping
• Pilot and main burner flames • Check venting system
• Water piping • Check air vents
• Boiler heating surfaces Monthly • Check boiler relief valve
• Burners and base • Check condensate drain system

start-up
• Condensate drain system • Check automatic air vents (if

used)
Service:
• Oiled-bearing circulators
• Temperature/LWCO sensor Periodically • Test low water cutoff
Annual
Start-up:
• Perform start-up per manual
Every 6 months • Operate relief valve
Check/test:
• Gas piping
• Cold fill and operating pressures
• Air vents and air elimination
• Limit controls and cutoffs
• Expansion tank
End of season • Shut down procedure
• Boiler relief valve
Review:
• Review with owner
Follow the Service and maintenance procedures given throughout this manual and in component
literature shipped with the boiler. Failure to perform the service and maintenance could result in
damage to the boiler or system. Failure to follow the directions in this manual and component
literature could result in severe personal injury, death or substantial property damage.
42 Part Number 550-142-300/0520

10b Service & maintenance — annual start-up
of the contaminants listed in Table 1 on page 9 of

this manual. If any of these are present in the boiler
The boiler should be inspected and started annu- intake air vicinity, they must be removed. If they
ally, at the beginning of the heating season, only cannot be removed, install combustion air piping
by a qualified service technician. In addition, to the boiler in accordance with national, provincial
the maintenance and care of the boiler designated or local codes.
in Table 6, page 42, and explained on the follow-
ing pages must be performed to assure maximum Air openings
boiler efficiency and reliability. Failure to service
and maintain the boiler and system could result in 1. Verify that combustion and ventilation air open-
equipment failure. ings to the boiler room and/or building are open
and unobstructed. Check operation and wiring of
automatic combustion air dampers, if used.
Eliminate all system or boiler leaks. Continual
fresh makeup water will reduce boiler life. Minerals
can build up in sections, reducing heat transfer, 2. Verify that boiler vent discharge and air intake are
overheating cast iron, and causing section failure. clean and free of obstructions.
Leaking water may also cause severe property
damage. Flue gas vent system
Do not use petroleum-based cleaning or sealing 1. Visually inspect entire flue gas venting system
compounds in boiler system. Severe damage to for blockage, deterioration or leakage. Repair any
boiler will occur, resulting in substantial property joints that show signs of leakage in accordance with
damage. vent manufacturer’s instructions.
2. Verify that masonry chimneys are lined, lining is in

Electrical shock hazard — Turn off power to good condition, and there are not openings into the
the boiler before any service operation on the
chimney.
boiler except as noted otherwise in this instruction
manual. Failure to turn off electrical power could
result in electrical shock, causing severe personal Failure to inspect for the above
injury or death. conditions and have them repaired
can result in severe personal injury
or death.
Pilot and main burner flames

❏ Inspect . . . 1. Visually inspect pilot burner and main burner
Reported problems flames as directed under Section 6d, page 32 of this
Inspect any problems reported by owner and correct manual.
before proceeding.
Water piping
Boiler area
1. Verify that boiler area is free of any combustible 1. Check the boiler interior piping and all system pip-
materials, gasoline and other flammable vapors ing for signs of leaks.
and liquids.
2. Verify that boiler area (and air intake) is free of any 2. Repair any leaks before proceeding.
Part Number 550-142-300/0520 43

10b Service & maintenance – annual start-up (cont.)
❏ Inspect . . . 3. If burners must be cleaned, raise rear of each

burner to release from support slot, slide forward
Boiler heating surfaces and remove. Then brush and vacuum the burners
1. Disconnect the vent pipe at the boiler draft hood thoroughly, making sure all ports are free of debris.
and remove draft hood after turning off power to Carefully replace all burners, making sure burner
the boiler. with pilot bracket is replaced in its original position
2. Use a bright light to inspect the boiler flue collector and all burners are upright (ports up).
and heating surfaces. 4. Inspect the base insulation.
3. If the vent pipe or boiler interior surfaces show a. Pay attention to the WARNINGS on page 66
evidence of soot, follow Cleaning boiler heating regarding working with insulation materials.
surfaces in this manual section. Remove the flue b. Verify that the insulation is intact and secure
collector and clean the boiler if necessary after closer against all four sides of the base.
inspection of boiler heating surfaces.
4. If there is evidence of rusty scale deposits on boiler ❏ Service . . .
surfaces, check the water piping and control system
Oiled-bearing circulators
to make sure the boiler return water temperature is
1. The circulator shipped with the CGa boiler is water-
properly maintained (per this manual).
lubricated. No oiling is required.
5. Reconnect vent and draft hood. Replace all boiler
2. Check other circulators in the system. Oil any
components before returning to service. circulators requiring oil, following circulator
6. Check inside and around boiler for evidence of any manufacturer’s instructions. Over-oiling will
leaks from the boiler. If found, locate source of leaks damage the circulator.
and repair. Burners and base Temperature/LWCO sensor
1. The temperature/LWCO sensor may accumulate
deposits on the probe surface. Annual inspection
The boiler contains ceramic and cleaning of the probe will improve boiler
fiber and fiberglass materials. performance.
Use care when handling these Disconnect power, unplug harness from sensor.
materials per instructions on a. Drain boiler water to a level below the sensor.
page 66 of this manual. Failure b. Remove sensor from boiler.
to comply could result in severe c. Wipe any built up contaminates from probe
personal injury. and insulator surfaces.
d. Reinstall sensor into boiler using appropriate
thread sealant. Do not overtighten.
If insulation is damaged or
displaced, do not operate the e. Refill boiler.
boiler. Replace or reposition
insulation as necessary. Failure
to replace damaged insulation
❏ Start-up . . .
can result in a fire hazard, 1. Perform all start-up procedures given in Section 6
causing severe personal injury, of this manual.
death or substantial property 2. Verify cold fill pressure is correct and that fill
damage. system is working properly.
3. Verify antifreeze level (if used) is at the right con-
centration and that inhibitor level is correct.
4. Check gas piping, per manual Sections 4 and 6,
1. After turning off power to the boiler, remove the verifying no indications of leakage and all piping
jacket door and base access panel (Figure 32, item 4, and connections are in good condition.
page 60). 5. Read the Operating instructions (manual
2. Inspect burners and all other components in the Section 9 ) applying to the boiler.
boiler base. 6. Start the boiler following appropriate Operating
instructions (manual Section 9).
44 Part Number 550-142-300/0520

❏ Check/test Expansion tank

1. Expansion tanks provide space for water to move in
an out as the heating system water expands due to
Gas piping temperature increase or contracts as the water cools.
1. Sniff near floor and around boiler area for any in- Tanks may be open, closed or diaphragm or bladder
dication of a gas leak. type. See Section 3 of this manual for suggested best
location of expansion tanks and air eliminators.
2. Test gas piping using bubble test, per Section 4
of this manual, if there is any indication of a leak. Open-type — located above highest radiator or
baseboard unit, usually in the attic or closet. Has a
Cold fill and operating pressures gauge glass and overflow pipe to a drain.
1. While the system is cold, note the pressure reading Closed-type — welded gas tight and located above
on the boiler pressure/temperature gauge. Verify that boiler. Tank is partially filled with water, leaving an
cold fill pressure is correct. air cushion for expansion.
2. Watch the pressure as the boiler and system heat • Make sure this type of tank is fitted with a tank
up to ensure pressure rise is normal. Too high a rise fitting, such as the B & G Tank-Trol or Taco
would indicate a waterlogged or undersized expan- Taco-Trol. This fitting reduces gravity circula-
sion tank. tion of air-saturated tank water back to the
system and prevents the air from bubbling up
Air vents and air elimination through the water as it returns from the system.
1. Inspect automatic air vents (if used). Also inspect • Do not use automatic air vents in systems
air separators to ensure they are operational. with closed-type tanks. The air will escape
2. The cap must be unscrewed one turn to allow air to from the system instead of returning to the tank.
escape. Eventually, the tank will waterlog and no longer
3. See Figure 26. If the air vent is leaking, remove cap control pressurization. The boiler relief valve
A and briefly push valve B and then release to clean will weep frequently.
the valve seat. Diaphragm- or bladder-type — welded gas tight
4. Replace cap A by twisting all the way onto valve B with a rubber membrane to separate the tank pres-
and then unscrewing one turn. surizing air and the water. May be located at any
point in the system, but most often found near the
boiler.
Figure 26 Automatic air vent, typical
• Systems with this type of expansion tank require
at least one automatic air vent, preferably lo-
cated on top of an air eliminator, as shown in
examples in manual Section 3.
2. If relief valve has tended to weep frequently, the
expansion tank may be waterlogged or undersized.
Closed-type tank — tank is most likely water-
logged. Install a tank fitting if not already installed.
Then check fill level per fitting manufacturer’s
instructions. If fill level is correct, check tank size
against manufacturer’s instructions. Replace with
a larger tank if necessary.
Diaphragm- or bladder-type — first, check tank
size to be sure it is large enough for the system. If
Limit controls and cutoffs size is too small, add additional tank(s) as neces-
1. Inspect and test the boiler limit control. Verify op- sary to provide sufficient expansion. If tank size is
eration by turning control set point below boiler large enough, remove tank from system and check
temperature. Boiler should cycle off. Return dial to charge pressure (usually 12 psig for residential ap-
original setting. plications). If tank won’t hold pressure, membrane
2. Inspect and test additional limit controls or low has been damaged. Replace tank.
water cutoffs installed on system.
Part Number 550-142-300/0520 45

2. After following the above warning directions, if the relief valve

Safety relief valves should be rein- weeps or will not seat properly, replace the relief valve. Ensure
spected AT LEAST ONCE EVERY that the reason for relief valve weeping is the valve and not over-
THREE YEARS, by a licensed plumb- pressurization of the system due to expansion tank waterlogging
ing contractor or authorized inspection or undersizing.
agency, to ensure that the product has
not been affected by corrosive water
conditions and to ensure that the valve Figure 27 Relief valve, typical
and discharge line have not been altered
or tampered with illegally. Certain
naturally occurring conditions may
corrode the valve or its components
over time, rendering the valve inopera-
tive. Such conditions are not detectable
unless the valve and its components are
physically removed and inspected. This
inspection must only be conducted by
a plumbing contractor or authorized
inspection agency — not by the owner.
Failure to reinspect the boiler relief
valve as directed could result in unsafe
pressure buildup, which can result in
severe personal injury, death or sub-
stantial property damage.
❏ Review with owner
Following installation, the valve lever
must be operated AT LEAST ONCE 1. Review the User’s Information Manual with the owner.
A YEAR to ensure that waterways are 2. Emphasize the need to perform the maintenance schedule speci-
clear. Certain naturally occurring min- fied in the User’s Information Manual (and in this manual as
eral deposits may adhere to the valve,
rendering it inoperative. When manu- well).
ally operating the lever, water will dis- 3. Remind the owner of the need to call in a licensed contractor
charge and precautions must be taken should the boiler or system exhibit any unusual behavior.
to avoid contact with hot water and to 4. Remind the owner to follow the proper shutdown procedure
avoid water damage. Before operating and to schedule an annual start-up at the beginning of the next
lever, check to see that a discharge line
is connected to this valve directing the heating season.
flow of hot water from the valve to
a proper place of disposal otherwise
severe personal injury may result. If
❏ Cleaning boiler heating
no water flows, valve is inoperative. surfaces
Shut down boiler until a new relief
valve has been installed.
The boiler contains ceramic fiber and fiberglass
materials. Use care when handling these materials
per instructions on page 66 of this manual. Failure
to comply could result in severe personal injury.
❏ Check/test (continued) 1. Shut down boiler:
• Follow “To Turn Off Gas to Appliance” instructions on boiler
Boiler relief valve and Operating instructions.
1. Inspect the relief valve and lift the lever to verify flow as • Do not drain boiler unless it will be exposed to freezing tem-
in the following warnings, excerpted from a relief valve peratures. If using antifreeze in system, do not drain.
manufacturer’s warning label. Before operating any 2. Follow shutdown procedure.
relief valve, ensure that it is piped with its discharge in 3. Remove venting system connection to boiler.
a safe area to avoid severe scald potential. Read manual 4. Remove top jacket panel. Turn back insulation.
Section 3 before proceeding further.
5. Remove flue collector. Clean sealant from assembly and sections.
46 Part Number 550-142-300/0520

❏ Cleaning boiler heating surfaces (continued)
6. Remove radiation plates hanging between sections. 11. Reinstall radiation plates.
7. Remove burners from base. Brush and vacuum burners to 12. Replace collector box/transition assembly. Seal with sealant.
remove all dust and lint. Verify that all burner ports are free Obtain gas-tight seal to prevent flue gas spillage and carbon
of debris. monoxide emissions, resulting in severe personal injury or
death.
8. Place newspapers in base of boiler to collect soot.
13. Replace insulation and jacket top panel.
9. Clean between sections with wire flue brush.
14. Start up boiler following Section 6 of this manual and the
10. Remove newspaper and soot. Vacuum or brush base and
boiler Operating instructions (Section 9b). Excessive sooting
surrounding area.
indicates improper gas combustion. If found, check for proper
combustion and make any necessary adjustments.
11a Troubleshooting — components

Temperature/LWCO sensor
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause 1. The boiler temperature/LWCO sensor is a resistance-type
improper and dangerous operation. device.
Never jumper (bypass) rollout thermal 2. The Table 7, below shows the correct value for the sensor at
fuse element or any other device except for various temperatures.
momentary testing as outlined in Trouble- 3. Use the resistance values at 32°F, 60°F, 70°F and 212°F to
shooting Charts. Severe personal injury, measure the sensor resistance at known temperatures (ice
death or substantial property damage can point, room temperature and sea level boiling point). For ice
result. point and boiling point, insert the sensor in water at that tem-
Burner access panel must be in position perature. Use an ohmmeter to read resistance value between
during boiler operation to prevent mo- thermister # and thermistor common. See Figure 30, page 50,
mentary flame rollout on ignition of main for sensor plug details.
flame. Severe personal injury or substantial
property damage will result.
Table 7 Temperature/LWCO sensor resistance values
See pages 48 through 56 for additional
troubleshooting information.
Sensor resistance values
Temp Sensor ohms Temp Sensor ohms

(°F) (°F)
Before troubleshooting: Min Max Min Max
32 34265 37871 120 4517 4992

1. Have the following items:
a. Voltmeter that can check 120 VAC and 24 VAC. 40 27834 30764 130 3698 4088
b. Microammeter with a minimum scale range of
0-25. 50 21630 23907 140 3043 3364
c. Continuity checker. 60 16944 18727 150 2517 2782
d. U-tube manometer.
2. Check for 120 VAC (minimum 102 VAC to maximum 70 13372 14780 160 2091 2311
132 VAC) to boiler.
80 10629 11747 170 1744 1928
3. Make sure thermostat is calling for heat and contacts
(including appropriate zone controls) are closed. Check 90 8504 9399 180 1461 1615
for 24 VAC between thermostat wire nuts and ground.
100 6847 7568 190 1229 1359
110 5545 6129 200 1038 1147
Part Number 550-142-300/0520 47

11a Troubleshooting — procedure (continued)
Check the following: pliers on flat shaft between damper and actuator.
Boiler will fire. Verify that damper service switch is
1. Wire connectors to control module are securely in Hold Damper Open position. (Figure 28)
plugged in at module and originating control.
3. Do not leave vent damper permanently in this
2. Gas pressures: position. Replace actuator immediately. If vent
damper is left in open position, boiler will not oper-
a. With boiler off — 13” w.c. maximum natural
ate at published efficiencies.
or propane gas pressure upstream of gas valve.
b. With boiler on: If troubleshooting chart recommends replacing actua-
• 5” w.c. minimum natural gas pressure or tor and actuator is not immediately available, damper
11” w.c. propane gas pressure upstream of blade can be fixed in an open position to allow boiler
gas valve. operation. Follow these instructions only in case of no
• 3.5” w.c. minimum natural gas pressure or heat or damper actuator malfunction. See Figure 28.
10” w.c. propane gas pressure downstream
tapping on gas valve — Can be adjusted by 1. Turn off power to boiler.
regulator on gas valve.
Failure to turn off power to boiler can
result in severe personal injury, death
In event of vent damper or substantial property damage.
failure:
2. Refer to vent damper manufacturer’s instructions
Effikal or Field Controls damper for procedure to fix vent damper in open position.
If troubleshooting chart recommends replacing actua-
tor and actuator is not immediately available, damper 3. Turn on power to boiler.
blade can be fixed in an open position to allow boiler
operation. Manually turning blade can cause actuator 4. Using wrench or pliers on flat shaft section, manu-
damage. Follow these instructions only in case of no ally rotate damper blade until green light turns on.
heat or damper actuator malfunction. Boiler will fire. (Figure 28)
1. Move damper service switch to Hold Damper Open 5. Do not leave vent damper permanently in this posi-
position. Apply call for heat to boiler. Damper blade
tion. Replace actuator immediately. If vent damper
should then rotate to open position and boiler will
fire. is left in open position, boiler will not operate at
published efficiencies.
2. If step 1 does not open damper, manually rotate
damper blade to open position using wrench or
Figure 28 Manually
opening the
vent damper
• Verify proper operation after servicing. • See vent damper manufacturer’s instructions packed with vent damper
for additional information. Failure to comply could result in severe personal injury, death or substantial property
damage.
48 Part Number 550-142-300/0520

11b Troubleshooting — spark-pilot boilers

The information on this page and Control indicator lights —
pages 50 through 57 apply only to
spark-ignited pilot CGa boilers. HARD LOCKOUT Summary (Flashing LED’s)
These boilers are equipped with MAY remove 120 VAC power for more than 2 seconds to clear lockout OR
an ignition control module that ignition control will automatically restart sequence of operation after 1 hour
has indicator lights to show control waiting period after fault condition is cleared.
status. Charts 1 through 7, pages
51- 57, help you identify problems INDICATOR LIGHT CONDITION
based on indicator light condi- POWER 120 VAC connection to boiler
tions.
Flashes once per second reversed or there is insufficient
earth ground.
Flash code 2* Internal fault, microprocessor or
Figure 29 CGa/EG Ignition control module memory.
Flash code 3* Internal fault, LWCO circuit.
Flash code 4* Unused.
Flash code 5* Internal fault, water thermistors

disagree.
Flash code 6* Internal fault, gas valve circuit.
Flashes once per second
* Flash code pattern: POWER LED flashes 2, 3, etc. times

rapidly followed by 2 seconds off, then repeats.

ALL LED’S FLASHING Failure to establish pilot
flame after 4 attempts.
SOLID LWCO LED Low water condition occurred.
SOFT LOCKOUT Summary (Flashing LED’s)

MAY remove 120VAC power for more than 2 seconds, cycle thermostat for
between 2 and 20 seconds, OR ignition control will automatically restart
sequence of operation after 1 hour waiting period.
INDICATOR LIGHT CONDITION
POWER + TSTAT/CIRC High voltage detected on TSTAT circuit.
POWER + DAMPER Damper stuck closed or unable to close end
switch within 45 seconds from TSTAT call.
POWER + FLAME Flame sensed without call for heat or out
Control module of sequence during ignition trial.
Solder or water splatter be- CAUTION Summary (Flashing LED’s)
tween plugs and circuit board
can cause improper operation of INDICATOR LIGHT CONDITION
control module. Place a shield over DAMPER Damper end switch opened after it had
the boiler internal controls and been proven closed.
components during installation. LIMIT Fault detected in temperature sensing
Failure to comply could result in hardware.
severe personal injury, death or FLAME Flame loss or flame not sensed during
substantial property damage. trial for ignition.
LWCO LWCO circuit approaching lockout state.
Make sure ground wiring is in- Sensor requires maintenance. LWCO
stalled per wiring diagram. Good LED will flash 3 times when maintenance
grounding is extremely important is required.
for proper operation.
Troubleshooting the control module
See Figure 30, page 50, for location of harness plug receptacles and plugs on the
control module.
Part Number 550-142-300/0520 49

11b Troubleshooting — spark-pilot boilers (continued)
Figure 30 Control module connections
50 Part Number 550-142-300/0520

CHART 1 –– Spark-ignited pilot –– Troubleshooting POWER light status
–– Usually indicates reversed 120 VAC polarity if POWER light flashes by itself ––
Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲, follow the instructions. Failure to follow
instructions could result in severe personal injury, death or substantial property damage.
Is POWER light off? • Make sure service switch or circuit breaker is on or

fuses are good.
No Yes
• Remove 120 VAC IN plug (Figure 30, Item 3,
page 50) on control module.
• Using voltmeter, check across black and white wire
Is POWER light . . . pins of 120 VAC IN plug.
Flashing Flashing with On steady Does voltmeter indicate 120 VAC ?
alone another light (NOT flashing) No Yes
TSTAT/CIRC Chart Problem is with incoming

light flashing 2 electricity. Have licensed
electrician repair circuit.
DAMPER Chart
light flashing 3
FLAME Chart Chart • Reconnect 120 VAC IN plug.

light flashing 4 6 • Remove transformer plug (Figure 30, Item 2,
page 50) on control module.
LWCO Chart
• Using voltmeter, check across left side top and
light solid 7 bottom pins of transformer receptacle.
For insufficient heat or no heat problem, go to Does voltmeter indicate 120 VAC ?
Chart 5, page 56, if POWER light is on steady,
with no other light flashing. No Yes
Replace control module.

• Usually indicates polarity on incoming 120 VAC power
Retest.
line is wrong or has insufficient earth ground.
• Check grounds to make sure unit has sufficient grounding.
• ▲ TURN OFF POWER ▲ at service switch or breaker, • Reinstall transformer plug.
then reverse the HOT and NEUTRAL wires entering • Remove TSTAT transformer plug (Figure 30, Item 5,
the boiler in the J-box. page 50) on control module.
• Restore POWER at service switch or breaker. • Using voltmeter, check across left and right pins of
Is POWER light flashing now? receptacle.
No Yes Does voltmeter indicate 120 VAC ?

No Yes
Have system checked by a

licensed electrician.
If problem persists, contact Replace transformer. Replace control module.
Boiler should now your Weil-McLain Technical
operate normally. support. Retest. Retest.
Part Number 550-142-300/0520 51

CHART 2 –– Spark-ignited pilot –– TSTAT CIRC & POWER lights flashing
–– Usually indicates 48 VAC on thermostat circuit (stray voltage) ––
• Disconnect the two external wires connected to the boiler • If a voltage does occur under any condition, check and
thermostat leads (two black low voltage leads in J-box). correct the external wiring. (This is a common problem
when using 3-wire zone valves).
• Connect a voltmeter across these two incoming wires.
Close each thermostat, zone valve and relay in the external • Once the external thermostat circuit wiring is checked and
circuit one at a time and check the voltmeter reading corrected if necessary, reconnect the external thermostat
across the wires. circuit wires to the boiler thermostat wires and allow the
boiler to cycle.
• There should NEVER be a voltage reading.
Did you find a voltage across the two external thermostat circuit wires ?
Yes No
• Leave external boiler thermostat connection wires • If no voltage is found under any condition on the external
disconnect from boiler. thermostat circuit, connect the two boiler thermostat
connection leads together (or jumper the boiler aquastat
• Troubleshoot the external thermostat circuit until you find T-T terminals).
the source of the stray voltage. (Pay close attention to
the wiring connections to 3-wire zone valves).
• Turn off power to the boiler for 1 minute.
• Correct the problem and repeat the voltmeter test above, • Turn on power and allow boiler to cycle.
verifying there is no longer a voltage reading under any
condition in the external thermostat circuit.
Do the TSTAT and POWER lights still flash ?
No Yes
• Boiler should now operate per normal sequence of • Replace control module.
operation shown in Figure 24, page 35. • Retest.
52 Part Number 550-142-300/0520

CHART 3 –– Spark-ignited pilot –– DAMPER light flashing
–– If POWER light is flashing: Usually indicates vent damper failed to prove open within 45 seconds ––
–– If POWER light is steady: Usually indicates vent damper closed during run cycle ––
• Reset boiler control by turning off power at service switch or turning down thermostat for 2 to 40 seconds.
• Thermostat should call for heat and appropriate zone valves open. The TSTAT CIRC and LIMIT lights should come on.
Does vent damper operate ?

No Yes
• Wait 45 seconds.
Does vent damper operate ?
No Yes
• Remove Damper plug (Figure 30, Item 6, page 50) • Wait 5 minutes.
from plug receptacle of control module. Is Damper light flashing?
• Place voltmeter leads across the top two pins (1 and 4)
of the Damper receptacle. No Yes
Does voltmeter indicate 24 VAC ?
No Yes
• Try reseating plug in • Boiler should be in

module receptacle and normal operating
restart. sequence.
Does vent damper actuator
• If vent damper still does • Observe operation until indicator show damper is
not work, replace vent thermostat is satisfied. open ?
damper assembly or
actuator.
• Retest. No Yes
Are the TSTAT CIRC and LIMIT lights on steady ?
Yes No • Remove damper wiring

plug at damper and firmly
• Replace vent damper reconnect.
• Make sure thermostat is assembly or actuator. • Recheck boiler operation.
• Replace control
module. calling for heat. If lights • Retest. • If problem persists,
still don’t come on, see replace vent damper
• Retest. Chart 6, page 56. assembly or actuator.
Part Number 550-142-300/0520 53

CHART 4 –– Spark-ignited pilot –– FLAME & POWER lights flashing
–– Usually indicates flame sensed when it shouldn’t be there ––
Are manual main shutoff valve and gas valve open ?

No Yes
• Leave main manual gas valve closed. • Turn off power to boiler at service switch or breaker.
• Turn off power to boiler at service switch or breaker. • Wait at least 45 seconds.
• Wait at least 45 seconds. • Turn on power to boiler.
• Turn on power to boiler. • Restart boiler, following Operating instructions in this
• Restart boiler, following Operating instructions in this manual (Section 9b) or on boiler label.
manual (Section 9b) or on boiler label. • Look through the pilot inspection port to see if the pilot is
burning.
Do FLAME and POWER lights still flash ?
Is pilot burning?
No Yes No Yes
• Replace control module.

• Retest.
• Allow boiler to continue cycling. • Replace gas valve.

• Retest.
Are FLAME and POWER lights flashing?
Are FLAME and POWER lights flashing?
No Yes
No Yes
• ▲ TURN OFF POWER ▲ • Boiler may now be • Replace control • Boiler should now • Replace control
to boiler at service switch or operating module. operate normally. module.
breaker. normally. • Retest. • Original flashing • Retest.
• Open main manual gas • Perform start-up FLAME light
valve. procedures in caused by gas
• Turn on power to boiler at boiler manual to valve not
service switch or verify proper operating properly.
breaker. operation.
• See normal
• Restart boiler per sequence of
operating instructions. operation,
• Perform start-up Figure 24,
procedures in boiler page 35.
manual to verify proper
operation.
54 Part Number 550-142-300/0520

CHART 5 –– Spark-ignited pilot –– FLAME light flashing and POWER light on steady
ALSO –– Troubleshooting failure to establish main flame
Are main manual shutoff valve and gas valve open? • Is pilot flame visible through inspection port ?
No Yes No Yes
• ▲ TURN OFF POWER ▲ to boiler at service switch or breaker.

• Check the voltage across • Make sure ground wire
• Open main manual shutoff valve and boiler gas valve (per main gas valve terminals terminal is securely fastened
Operating instructions in this manual). Wait at least 45 of the gas valve. to control module mounting
seconds. screw.
Is 24 VAC present there?
• Turn on power at service switch or breaker. Allow boiler to cycle.
Yes No
Does FLAME light flash now?
No Yes
• If the wiring from the • Check the voltage across
control module to gas valve main gas valve terminals
• Boiler should be in • Verify inlet gas pressure at gas is intact, replace the control of the gas valve.
normal operating valve:
module. Is 24 VAC present there?
sequence. Natural gas – 5.0” w.c. min/14.0”
w.c. max • Retest. No Yes
• Observe operation
until thermostat is Propane – 11.0” w.c. min/14.0”
satisfied and vent w.c. max
damper has closed. Is gas present at gas valve inlet and • Verify inlet gas pressure at gas valve:
within above range? Natural gas – 5.0” w.c. min/14.0” w.c. max
Propane – 11.0” w.c. min/14.0” w.c. max
Yes No
Is gas present at gas valve inlet and within above range?
• ▲ TURN OFF POWER ▲ No Yes

• Contact gas supplier to correct
to boiler at service switch or
pressure or gas supply.
breaker.
• Remove base access panel • ▲ TURN OFF POWER ▲ to boiler at service switch or breaker.
(see Figure 32, item 4, • Check flame signal – Detach sense lead from ignition control
page 60 for location. • ▲ TURN OFF POWER ▲ (Figure 30, Item 8, page 50).
to boiler at service switch or
breaker. • Connect negative lead of MICROAMMETER to control sense
• Verify pilot gas line is not terminal (Figure 30, Item 8, page 50). Connect positive
kinked, obstructed or dam- • Remove base access panel
(see Figure 32, item 4, lead of MICROAMMETER to sense wire.
aged and is correctly attached
to pilot and gas valve. page 60 for location. • DISCONNECT red wire connected to main gas valve terminal
• Verify pilot ignition electrode, of the gas valve.
electrode ceramic and spark • Turn on power to boiler and allow to cycle. As soon as pilot
lead wire from control are in • Verify pilot burner is securely at- is burning, the MICROAMMETER should read at least 1.0
good condition. Spark gap tached to pilot bracket, bracket
microamp.
should be approximately 1/8”. is securely attached to cross-tie,
• Correct any above problems, and there is no corrosion on the Is flame signal at least 1.0 microamp ?
replacing pilot if burner or wir- ground path for flame sense.
ing is damaged. • Verify that pilot flame rod, flame No Yes
• Reinstall base access panel to rod ceramic and lead wire from
operate boiler for retest after control module to flame rod are
any changes or corrections. in good condition. • If none of the previous steps
• If the wiring from the
• If none of the above corrects • Correct any above problems, (including replacing pilot)
replacing pilot if burner or wir- control module to gas
problems, then replace the corrects problem, then replace
ing is damaged. valve is intact, replace the
control module, reinstall base the control module, reinstall
access panel, and retest. control module and retest.
base access panel and retest.
Part Number 550-142-300/0520 55

CHART 6 –– Spark-ignited pilot –– Insufficient heat or no heat (POWER light on steady)
• Has it been at least 5 minutes since setting thermostat to Is boiler System circulator operating?
call for heat? If not, wait 5 minutes. Is system heating?
• Is thermostat set to call for heat? Remove thermostat No Yes
wires at boiler and check continuity across the two wires.
If circuit isn't closed, check external thermostat (zone
valve, relay, etc.) wiring. Correct problems and retry. • Remove CIRCULATOR harness plug from
• Reconnect external thermostat wiring at boiler. CIRCULATOR plug receptacle (Figure 30,
Is thermostat circuit closed (continuity across wires)? Item 7, page 50). Check with voltmeter across
pins of control module receptacle.
No Yes
Does voltmeter show 120 VAC across pins?
Are all red lights off? • Boiler is in standby. No Yes

• Set thermostat to call for
No Yes
heat and recheck operation.
• Replace control • Repair/replace
• Verify Sequence of module. circulator. Retest.
• Wait 30 seconds. operation, Figure 24,
• Retest. • Repair/replace
Are all red lights off? page 35.
wiring. Retest.
No Yes
• Wait 5 minutes.
• Replace control Is FLAME light on?
module.
Yes No
• Retest.
• If you have sufficient heat – boiler should be in normal

operating sequence. (See normal sequence of operation, Is LIMIT light on?
Figure 24, page 35.
No Yes
• If you have less than sufficient heat –
Is vent or combustion air piping free of blockage?
• Check temperature • Replace control module.
No Yes sensor for correct
• Retest.
resistance.
Are resistance values
• Correct conditions and Contact your Weil-McLain correct?
recheck operation. Technical support.
No Yes Check spill switch and
• See Figure 24, page 35 rollout switch continuity –
for normal sequence of
operation. • Replace temperature Are switches closed?
sensor. No Yes
• Retest.
• Reset spill switch, or replace rollout switch. • Check any other

limit controls wired
into the limit
If rollout thermal fuse element or spill switch has circuit. If all are
OK, then replace
opened, determine cause and correct condition.
control module.
Failure to do so will cause severe personal injury,
death or substantial property damage. • Retest.
56 Part Number 550-142-300/0520

CHART 7 –– Troubleshooting LWCO and POWER light Solid

and/or “LCO” shown on display
Is boiler pressurized?
Yes No
• Pressurize boiler to system design pressure.

Are lights still solid? • Check system for leaks.
No Yes Is system leaking or not
maintaining pressure?
No Yes
• System was low on water.
• Check system fill piping for
leaks or damage.
• System is losing water.
• Repair leak and retest.
• LWCO sensor is bad or fouled.
• Clean LWCO sensor
• Retest.
Are lights still solid?
No Yes
• Sensor was fouled.

• Sensor is bad. Replace sensor.
• Check water quality and
• Retest.
maintenance schedule.
Part Number 550-142-300/0520 57

12a Replacement parts
Section assembly............................................... 59
Base................................................................... 60
Jacket................................................................ 61
Trim.................................................................... 62
Controls............................................................. 63
Replacement parts must be purchased through a local Weil-McLain distributor.

When ordering, specify boiler model and size and include description and part
number of replacement part. Results from using modified or other manufac-
tured parts will not be covered by warranty and may damage boiler or impair
operation.
Weil-McLain part numbers are found in Weil-McLain Boilers and Controls

Repair Parts Lists.
The boiler contains ceramic fiber and fiberglass materials. Use care when
handling these materials per instructions on Page 66 of this manual.
Failure to comply could result in severe personal injury.
58 Part Number 550-142-300/0520

12b Replacement parts — section assembly

Figure 31 Section assembly, flue collector, draft hood and vent damper
Item Item
Description Part number number Description Part number
number
1 End section, left hand, 51124 311-103-851
9 Temperature/LWCO sensor 511-724-305
2 End section, right hand 51128 311-103-821
3 Intermediate section, 51127 311-103-845 CGa-25 450-021-240
10 Draft hood
not shown Replacement CGa-25 and CGa-3 321-114-360 CGa-3 450-021-241
section CGa-4 321-114-361 CGa-4 450-021-242
assembly CGa-5 321-114-362 CGa-5 450-021-243
CGa-6 321-114-363 CGa-6 450-021-244
CGa-7 321-114-364 CGa-7 450-021-245
CGa-8 321-114-365 CGa-8 450-021-246
not shown Section replacement kit, includes seals and 381-354-527 11 Spill switch (210°F) CGa-25 - 8 510-300-013
sealant for 1 joint
12 Vent Damper CGa-25 & 3 4” 381-800-474
4 Tie rod, 7/16” CGa-25 & CGa-3 560-234-500 CGa-4 5” 381-800-475
without nut CGa-4 560-234-501 CGa-5 & 6 6” 381-800-476
(3 per boiler): CGa-5 560-234-502 CGa-7 & 8 7” 381-800-477
CGa-6 560-234-503
CGa-7 560-234-504 13 Vent Damper Actuator 510-512-337
CGa-8 560-234-505
5 Nut, 7/16” (2 per tie rod) 561-928-235 14 Vent Damper Harness 591-391-795
6 Washer, 7/16” (1 per tie rod) 562-248-684
Radiation plate CGa 25 & 3 460-003-018
7
(1 per joint) CGa 4-8 460-003-017
8 Collector hood CGa-25 381-354-625
CGa-3 381-354-626
CGa-4 381-354-627
CGa-5 381-354-628
CGa-6 381-354-926
CGa-7 381-354-630
CGa-8 381-354-631
Part Number 550-142-300/0520 59

12c Replacement parts — base

Figure 32 Base assembly, manifold, orifices and burners
Item Description Part number

number
Base assembly kit CGa-25 381-354-362

(includes base panels CGa-3 381-354-356
items 1, 2, 3, 4, 5, 6 and 7, CGa-4 381-354-357
plus insulation, air box gaskets, CGa-5 381-354-358
and hardware)) CGa-6 381-354-359
CGa-7 381-354-360
CGa-8 381-354-361
1 Base side panel (in Base assembly)
2 Base front cross-tie assembly (in Base assembly)
3 Base back cross-tie assembly (in Base assembly)
4 Access panel (in Base assembly)
5 Base pan angle, left side (in Base assembly)
6 Base pan angle, right side (in Base assembly)
7 Base pan (in Base assembly)
8 Burner rest CGa-25 450-003-742

CGa-3 450-003-736
CGa-4 450-003-737
CGa-5 450-003-738
CGa-6 450-003-739
CGa-7 450-003-740
CGa-8 450-003-741
9 Base insulation kit CGa-25 381-354-518
(included insulation for all base CGa-3 381-354-518
parts above plus gasket material CGa-4 381-354-518
needed between block assembly CGa-5 381-354-518
and base) CGa-6 381-354-519
CGa-7 381-354-519
CGa-8 381-354-519
10 Boiler leg kit 590-424-253
11 Manifold CGa-25 591-126-615

CGa-3 591-126-616
CGa-4 591-126-617
CGa-5 591-126-618
CGa-6 591-126-619
CGa-7 591-126-556
CGa-8 591-126-557
12 Main burner orifice – Natural gas, sea level 560-528-997
Main burner orifice – Natural gas, sea level 560-528-998
13 Burner, stainless steel 512-200-077
14 Burner with pilot 512-200-078
15 Screw, 10-32 x 0.38 STP type D hex, washer

.
available at
head slot local supply
house
16 Rollout thermal fuse element 512-050-230
60 Part Number 550-142-300/0520

12d Replacement parts — jacket

Figure 33 Jacket assembly
1 2 3 4 5
Junction box, 2 x 4 Jacket panel, left side, with insulation Jacket panel, Jacket panel, Jacket panel,
right side, top front top rear
with insulation
Natural Gas Propane Gas
Spark Pilot Spark Pilot
Boiler Boiler
Model Part numbers Model
CGa-25 381-359-201 381-359-208 381-359-229 381-359-230 381-359-236 CGa-25
CGa-3 381-359-202 381-359-209 381-359-229 381-359-230 381-359-236 CGa-3
CGa-4 381-359-203 381-359-210 381-359-229 381-359-231 381-359-237 CGa-4
(Available at local
CGa-5 381-359-204 381-359-211 381-359-229 381-359-232 381-359-238 CGa-5
supply house)
CGa-6 381-359-205 381-359-212 381-359-229 381-359-233 381-359-239 CGa-6
CGa-7 381-359-206 381-359-213 381-359-229 381-359-234 381-359-240 CGa-7
CGa-8 381-359-207 381-359-214 381-359-229 381-359-235 381-359-241 CGa-8
6 7 8 9 10
Jacket panel, Jacket cross tie, Jacket panel, Jacket panel, Not shown —
door bottom front interior, rear, touch-up paint
with insulation with insulation
Boiler Boiler
Model Part numbers Model
CGa-25 381-359-248 381-359-260 381-359-266 381-359-272 CGa-25
CGa-3 381-359-248 381-359-260 381-359-266 381-359-272 CGa-3
CGa-4 381-359-249 381-359-261 381-359-267 381-359-273 381-359-278 Cloud CGa-4
CGa-5 381-359-250 381-359-262 381-359-268 381-359-274 384-000-141 Slate CGa-5
CGa-6 381-359-251 381-359-263 381-359-269 381-359-275 CGa-6
CGa-7 381-35-9252 381-359-264 381-359-270 381-359-276 CGa-7
CGa-8 381-359-253 381-359-265 381-359-271 381-359-277 CGa-8
Part Number 550-142-300/0520 61

12e Replacement parts — trim

Figure 34 Trim assembly
Item Description Part number

number
1 Pressure relief valve, ASME, 30 PSIG, ¾” male inlet 511-546-920
Pressure relief valve, ASME, 30 PSIG, ¾” female inlet 511-546-924

(Fittings shown are factory-installed on boiler.)
2 Combination pressure-temperature gauge, 3⅛,” diameter, short shank 380-000-000
(Fittings shown are shipped loose with boiler.)
3 Drain valve, ¾” 511-210-423
(Fittings shown are included with boiler.)
4 Circulator CGa 25 - 5 511-405-153

(Fittings shown are shipped loose with boiler.) CGa 6 - 8 511-405-113
5 Circulator gasket, universal (2 per boiler) 590-317-535
Circulator hardware kit, includes:
1 flange, 2 nuts, 2 screws, 1 gasket —
¾” NPT — CGa-25 --------------------------------------------- 381-354-530
not shown
1” NPT — CGa-3 through CGa-5 -------------------------- 381-354-525
1¼” NPT — CGa-6 and CGa-7 ----------------------------- 381-354-526
1½” NPT — CGa-8 -------------------------------------------- 381-354-531
6 Circulator wiring harness kit, spark-ignited with Molex (loose) 381-356-528
62 Part Number 550-142-300/0520

12f Replacement parts — controls

Figure 35 Gas control components
Item Description Boiler model Part number

number
Natural gas components
1 Gas Valve, ½” x ½” CGa-25 through CGa-6 511-044-381
Gas valve, ¾” x ¾” CGa-7 & CGa-8 511-044-382
2 Pilot kit w/orifice & aluminum pilot gas tubing 511-330-218

Liquefied Petroleum (Propane) gas components
1 Gas Valve, ¾” x ¾” CGa-25 through CGa-7 511-044-356
Gas Valve, ¾” x ¾” CGa-8 511-044-366
2 Pilot kit w/orifice & aluminum pilot gas tubing 511-330-273

Natural gas and Liquefied Petroleum (Propane) gas components
3 Control Module - Natural gas 381-330-039
- Liquefied Petroleum (Propane) gas 381-330-038

not shown Wiring Harness, Junction box to Control Module 591-391-975
not shown Wiring Harness, Controls to Control Module 591-391-977
not shown Wiring Harness, Thermostat 591-392-006
not shown Wiring Harness, Water Temperature/LWCO Sensor 591-391-995
4 Control Transformer 381-356-578
Part Number 550-142-300/0520 63

13a Dimensions
Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES
Boiler Supply Return Gas connection “A” “D” “W” “H”

model tapping tapping & manifold size Vent Vent Jacket Damper
number (inches NPT) (inches NPT) Note 3 location diameter width height
(inches NPT) (inches) (inches) (inches) (inches)
CGa-25 1¼ 1¼ ½ 5 4 10 45-3/8
CGa-3 1¼ 1¼ ½ 5 4 10 52-3/8
CGa-4 1¼ 1¼ ½ 6-½ 5 13 54-3/8
CGa-5 1¼ 1¼ ½ 8 6 16 57-7/8
CGa-6 1¼ 1¼ ½ 9-½ 6 19 60-7/8
CGa-7 1¼ 1¼ ¾ 11 7 22 62-1/8
CGa-8 1¼ 1¼ ¾ 12-½ 7 25 64-7/8
Note 3: Gas piping from meter to boiler to be sized per local utility requirements.
64 Part Number 550-142-300/0520

13b Ratings
AHRI Certified Ratings
Chimney
Boiler Seasonal Boiler and
model 0 - 2,000 feet 2,000 - 4,500 feet Heating Efficiency Net water breeching
number Altitude Altitude Capacity PIDN-PIDL Ratings content size
Input Output Input Output Btuh Btuh
(Note 1) AFUE % (gallons) Inches
(Btuh) (Btuh) (Btuh) (Btuh) (Note 2) (Note 3)
CGa-25 38,000 32,000 34,000 29,000 32,000 84.0 27,000 1.5 4"I.D. x 20’
CGa-3 67,000 56,000 60,000 50,000 56,000 84.0 48,000 1.5 4”I.D. x 20’
CGa-4 100,000 84,000 90,000 76,000 85,000 84.0 73,000 2.1 5”I.D. x 20’
CGa-5 133,000 112,000 120,000 101,000 113,000 84.0 98,000 2.7 6”I.D. x 20’
CGa-6 166,000 139,000 149,000 125,000 141,000 84.0 122,000 3.3 6”I.D. x 20’
CGa-7 200,000 168,000 180,000 151,000 170,000 84.0 147,000 3.8 7”I.D. x 20’
CGa-8 233,000 196,000 210,000 176,000 198,000 84.0 172,000 4.4 7”I.D. x 20’
1. Add “PIN” for natural gas boiler - “PIL” for Liquefied Petroleum (propane) gas boiler.
2. Based on standard test procedures prescribed by the United States Department of Energy.
Notes
3. Net AHRI 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.
Table 8 Ignition system model suffixes Pilot ignition system Natural gas Propane gas
Spark-ignite pilot PIDN PIDL
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.
Part Number 550-142-300/0520 65

Handling ceramic fiber and fiberglass materials
REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL

LINING OR BASE PANELS
or
The combustion chamber lining or base INSTALLATION OF FIBERGLASS WOOL,
insulation panels in this product con-
COMBUSTION CHAMBER LINING OR
tain ceramic fiber materials. Ceramic
fibers can be converted to cristobalite in BASE PANELS:
very high temperature applications. The
This product contains fiberglass jacket
International Agency for Research on
insulation and ceramic fiber materi-
Cancer (IARC) has concluded, “Crystal-
als in combustion chamber lining or
line silica inhaled in the form of quartz base panels in gas fired products. Air-
or cristobalite from occupational sources borne fibers from these materials have
is carcinogenic to humans (Group 1).”: been listed by the State of California
as a possible cause of cancer through
Precautionary measures
inhalation.
❏ Avoid breathing fiberglass dust and contact with skin or
Precautionary measures
eyes.
• Use NIOSH certified dust respirator (N95). ❏ Avoid breathing fiberglass dust and contact with skin
This type of respirator is based on the or eyes.
OSHA requirements for fiberglass wool at the • Use NIOSH certified dust respirator (N95).
time this document was written. Other types of This type of respirator is based on the
respirators may be needed depending on the OSHA requirements for fiberglass wool at the
time this document was written. Other types of
job site conditions. Current NIOSH recommen-
respirators may be needed depending on the
dations can be found on the NIOSH web site job site conditions. Current NIOSH recommen-
at http://www.cdc.gov/niosh/homepage.html. dations can be found on the NIOSH web site
NIOSH approved respirators, manufacturers, and at http://www.cdc.gov/niosh/homepage.html.
phone numbers are also listed on this web site. NIOSH approved respirators, manufacturers,
• Wear long-sleeved, loose fitting clothing, gloves, and phone numbers are also listed on this web
and eye protection. site.
❏ Apply enough water to the combustion chamber lining • Wear long-sleeved, loose fitting clothing, gloves,
or base insulation to prevent airborne dust. and eye protection.
❏ Operations such as sawing, blowing, tear out, and
❏ Remove combustion chamber lining or base insulation
spraying may generate airborne fiber concentration
from the boiler and place it in a plastic bag for disposal. requiring additional protection.
❏ Wash potentially contaminated clothes separately from ❏ Wash potentially contaminated clothes separately
other clothing. Rinse clothes washer thoroughly. from other clothing. Rinse clothes washer thoroughly.
NIOSH stated First Aid. NIOSH stated First Aid.
❏ Eye: Irrigate immediately. ❏ Eye: Irrigate immediately.
❏ Breathing: Fresh air. ❏ Breathing: Fresh air.
66 Part Number 550-142-300/0520

Notes
Part Number 550-142-300/0520 67

68 Part Number 550-142-300/0520

CGa Series 3 Boiler Manual 0520

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Series 3

Gas-Fired Water Boilers

Boiler Manual • Installation • Maintenance

Now With Built In

Part Number 550-142-300/0520

⑤ Water temperature/ LWCO sensor

Other boiler components:

2 Part Number 550-142-300/0520

CGa Series 3 Gas-Fired Water Boiler

Part Number 550-142-300/0520 3

Glycol — potential fire hazard —

4 Part Number 550-142-300/0520

Please read before proceeding

When servicing boiler — Boiler water — Freeze protection fluids —

Part Number 550-142-300/0520 5

1a Prepare boiler location — codes & checklist

Installations must follow these codes:

Before locating the boiler,

Failure to keep boiler area clear and free of combustible materials,

6 Part Number 550-142-300/0520

1b Prepare boiler location — clearances

Part Number 550-142-300/0520 7

1c Prepare boiler location — vent system

When removing boiler from an Chimney or vent require-

8 Part Number 550-142-300/0520

1d Prepare boiler location — air contamination

Table 1 Corrosive contaminants and likely locations

Products to avoid Areas likely to have contaminants

Spray cans containing chloro/fluorocarbons Dry cleaning/laundry areas and establishments

Permanent wave solutions Swimming pools

Chlorinated waxes/cleaners Metal fabrication plants

Chlorine-based swimming pool chemicals Beauty shops

Calcium chloride used for thawing Refrigeration repair shops

Sodium chloride used for water softening Photo processing plants

Refrigerant leaks Auto body shops

Paint or varnish removers Plastic manufacturing plants

Hydrochloric acid/muriatic acid Furniture refinishing areas and establishments

Cements and glues New building construction

Antistatic fabric softeners used in clothes dryers Remodeling areas

Chlorine-type bleaches, detergents, and cleaning

Airborne particulates (drywall dust, fiberglass particles,

Part Number 550-142-300/0520 9

1e Prepare boiler location — air openings

Figure 3 Air directly through outside wall

Air openings must be provided

Provide adequate combustion and ventilation air to

Two openings — Air supply directly from outside ✷

10 Part Number 550-142-300/0520

1e Prepare boiler location — air openings

Unusually tight construction

Part Number 550-142-300/0520 11

2a Prepare boiler — placement and setup

Place boiler/crate near Correctly-sized manifold orifices

12 Part Number 550-142-300/0520

2b Prepare boiler — pressure test

Hydrostatic pressure test 4. Close shutoff valves.

Part Number 550-142-300/0520 13

2c Prepare boiler — draft hood & spill switch

Draft hood installation Spill switch installation

2d Prepare boiler — install vent piping