Beginning Serial Number: CP7540456 Series 2 Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts 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.
CGa Series 2 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).
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual CGa Series 2 Gas-Fired Water Boiler Part Number 550-142-900/1016 3
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 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 ........................
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Please read before proceeding )NSTALLER 2EAD ALL INSTRUCTIONS INCLUDING THIS manual and all other information shipped with the boiler, before installing. Perform steps in the order give no prevent personal injury or death.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 1a Prepare boiler location — codes & checklist Installations must follow these codes: s s s s s ,OCAL STATE PROVINCIAL AND NATIONAL CODES LAws, regulations and ordinances. .ATIONAL &UEL 'AS #ODE !.3) : .&0! – latest edition. 3TANDARD FOR #ONTROLS AND 3AFETY $EVICES FOR !UTOMATICALLY &IRED "OILERS !.3) !3-% #3$ WHEN REQUIRED .ATIONAL %LECTRICAL #ODE &OR #ANADA ONLY .ATURAL 'AS AND 0ROPANE )NSTALLATION #ODE #!.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 1b Prepare boiler location — clearances Recommended SERVICE clearances &IGURE B Required MINIMUM clearances &IG A 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1a for recommendations. 2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 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.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 1d Prepare boiler location — air contamination Please review the following information on potential combustion air contamination problems. 2EFER TO 4ABLE for products and areas which may cause contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 1e ✷ Prepare boiler location — air openings #OMBUSTION AIR OPENING LOCATION AND SIZING REQUIREMENTS DEPEND ON THE CLEARANCES AROUND THE BOILER Check the boiler placement compared to Figure 1a, page 7. &IGURE Air openings to interior spaces ✷ )F ALL CLEARANCES ARE AT LEAST EQUAL TO &IGURE A PAGE , apply the sizing and placement of openings given on pages 10 and 11. )F !.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 1e Prepare boiler location — air openings FREE AREA of openings — the minimum areas given in this manual are free area (equals the area, length times width of opening, after deduction for louver obstruction).
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 2a Prepare boiler — placement and setup Correctly-sized manifold orifices must be used. Failure to do so will result in severe personal injury, death or substantial property damage. Place boiler/crate near position 1. ,EAVE BOILER IN CRATE AND ON PALLET until installation site is ready. -OVE ENTIRE CRATE AND PALLET NEXT TO SELECTED LOCATION 3. Level and straighten burners.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 2b Prepare boiler — pressure test Hydrostatic pressure test Pressure test boiler BEFORE attaching water or gas piping or electrical supply (except as noted below). Prepare boiler for test 2EMOVE THE SHIPPING NIPPLE FROM #'A SUPPLY tapping) and remove the boiler relief valve. 4EMPORARILY PLUG THE RELIEF VALVE TAPPING WITH A Ðv .04 PIPE PLUG 2EMOVE v NIPPLE REDUCING TEE AND DRAIN valve from accessory bag.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 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 as shown in Figure 7. 2. Secure draft hood to outlet at top of boiler with sheet metal screws. "OTTOM OF DRAFT HOOD OR hSKIRTv MUST HAVE CLEARANCE DIMENSION ABOVE jacket top panel as indicated on draft hood.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 2e Prepare boiler — vent damper installation These systems are used on gas-fired boilers with vent DAMPERS AS SHIPPED FROM FACTORY "OILER WILL NOT OPERATE without vent damper installed. /NLY VENT DAMPERS LISTED IN THE 2EPLACEMENT PARTS LIST ON PAGE ARE CERTIlED FOR USE WITH #'A BOILERS !NY other vent damper installed could cause severe personal injury or death.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3a Water piping — general information General piping information Circulator )F INSTALLATION IS TO COMPLY WITH !3-% OR #ANADIAN REQUIREMENTS AN ADditional HIGH TEMPERATURE LIMIT is needed. Install control in supply piping between boiler and isolation valve. Set second control to minimum 20°F ABOVE SETPOINT OF lRST CONTROL -AXIMUM ALLOWABLE SETPOINT IS & 3EE page 36, for wiring.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3b Water piping — single-zone system 5NDERSIZED EXPANSION TANKS CAUSE SYSTEM WATER TO BE LOST FROM RELIEF VALVE AND MAKEUP WATER TO BE ADDED THROUGH lLL VALVE %VENTUAL SECTION FAILURE CAN RESULT Diaphragm-type or bladdertype expansion tank (Figure 9) Closed-type expansion tank %NSURE EXPANSION TANK SIZE WILL HANDLE BOILER AND system water volume and temperature.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3c Water piping — multiple zones Piping multiple zones Follow instructions on pages 16 and 17 to install nearboiler or single-zone piping. (Also refer to 0IPING FOR RADIANT HEATING SYSTEMS OR CONVERTED GRAVITY SYSTEMS below, if applicable.) See &IGURE or &IGURE , page 19, to complete in- stallation. Zoning with circulators (Figure 11) (return temp over 130°F) 1. Size each circulator to individual circuit requirements. 2.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3c Water piping — multiple zones &IGURE Zoning with circulators — return water 130°F or higher. 1 "OILER ISOLATION BALANCING valves &IGURE (continued) Zoning with zone valves — return water 130°F or higher. 10 Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion tank). $/ ./4 use an automatic air vent when using closed-type expansion tank.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems Primary/secondary (preferred) Bypass piping method 0RIMARY SECONDARY bypass piping is preferred because the flow rate and temperature drop in the heating circuit(s) is determined only by the heating circuit circulator(s). So adjustment of the bypass valves in the boiler circuit will not cause a change in the heating circuit rate and temperature distribution.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) &IGURE Primary/secondary piping Zoning with circulators &IGURE Primary/secondary piping Zoning with zone valves 10 Automatic air vent (with diaphragm-type expansion 1 "OILER ISOLATION BALANCING VALVES 2 Flow/check valve 3 System or zone circulator (circulator should cycle with zone valve and switches, using circulator valve or zone control panel) 4 System temperature gauges 11 Fill
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) BOILER-bypass piping method This piping method (&IGURE or , page 23) is called a BOILER BYPASS because part of the circulator flow is bypassed around the boiler (through valve A).
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) &IGURE Boiler-bypass piping Zoning with circulators (Alternative to primary/secondary piping Figures 13 and 14) 1 "OILER ISOLATION BALANCING VALVES 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges 5 :ONE VALVE 6 Drain valve 7 System temperature valves (see instructions to the left for adjusting valves) 8 "LEND TEMPERATURE GAUGE 9 2ELIEF VALVE Part Numb
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) SYSTEM-bypass piping method This piping method (&IGURE , page 25) is called a SYSTEM BYPASS because part of the circulator flow bypasses the system (through valve A).
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) &IGURE System-bypass piping — Zoning with zone valve or circulators, return water 130°F or higher — (Alternative to boilerbypass 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 "LEND TEMPERATURE GAUGE 9 2ELIEF VALVE 10 Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 4 Gas piping Connect gas supply piping to boiler Natural Gas: 2EMOVE JACKET FRONT PANEL AND REFER TO &IGURE to pipe gas to boiler. 2EFER TO 4ABLE FOR PIPE LENGTH AND DIAMETER "ASE on rated boiler input (divide by 1,000 to obtain cubic feet per hour). 4ABLE is only for gas with SPECIlC a. )NSTALL DRIP LEG at inlet of gas connection to boiler.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 5 Field wiring For your safety, TURN OFF ELECTRICAL POWER SUPPLY AT SERVICE ENTRANCE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. 7IRING MUST BE . % # #LASS If rollout thermal fuse element wire as supplied with boiler must be replaced, type # wire or equivalent must be used.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 6a Start-up — preparation Check for gas leaks "EFORE STARTING THE BOILER AND DURING initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if there is any indication OF A GAS LEAK 2EPAIR ANY LEAK AT ONCE Determine if water treatment is needed Do not use PETROLEUM BASED CLEANING OR SEALING COMPOUNDS in boiler system.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 6a Start-up — preparation (continued) Fill the system with water Inspect system water piping 1. Close manual and automatic AIR VENTS and boiler drain cock. After filling the boiler and system with water, INSPECT ALL PIPING throughout the system for leaks. If found, repair 2. &ILL TO CORRECT SYSTEM PRESSURE Correct pressure will vary with each application. Typical cold water fill pressure for a residential system is 12 psi. 3.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 6b Start-up — operate boiler $/ ./4 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 "EFORE starting the boiler, do the following: s 2EAD MANUAL 3ECTION and the /PERATING INSTRUCTION procedure (see 4ABLE , below).
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 6b Start-up — operate boiler (continued) Start the boiler s s &OLLOW THE /PERATING )NSTRUCTIONS from 3ECTION TO START THE BOILER 2EMOVE BOILER JACKET DOOR AND note the gas valve manufacturer and model number. 5SE ONLY THE OPERATING INSTRUCTION WHICH APPLIES TO this gas valve (see 4ABLE , page 30). (The operating instruction label on the boiler provides the same information.) 3EE 3ECTION C if boiler fails to start. Check system and boiler 1.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 6d Start-up — verify operation See 3ECTION for operation and operating information. Check burner flames &IGURE Typical pilot burner flame Pilot burner flame (&IGURE ) PROPER pilot flame "LUE mAME 2. Inner cone engulfing pilot flame sensor (sparkignited pilot). 3. Pilot flame sensor glowing cherry red. IMPROPER pilot flame 1. Overfired — Large flame lifting or blowing past pilot flame sensor.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 7 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ Check-out procedure — checklist "OILER AND HEAT DISTRIBUTION UNITS lLLED WITH WATER !UTOMATIC AIR VENT IF USED OPEN ONE FULL TURN !IR PURGED FROM SYSTEM !IR PURGED FROM GAS PIPING 0IPING CHECKED FOR LEAKS #ORRECTLY SIZED MANIFOLD ORIlCES INSTALLED 2EFER TO 4ABLE , page 12 to check size and fuel type. Correctly sized manifold orifices must be used.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 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 temperature changes.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 9a Operation — spark-ignited pilot boilers 4. -AIN BURNER OPERATION a. Control module monitors pilot flame current. If signal is lost, main valve closes, spark generator activates and sequence returns to step 4. b. If power is interrupted, control system shuts off pilot and main gas valves and restarts at step 1 when power is restored. c.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 9a Figure 25a 36 Operation — spark-ignited pilot system (continued) Schematic wiring diagram — Spark-ignited pilot system Part Number 550-142-900/1016
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 9a Operation — spark-ignited pilot system (continued) Figure 25b Ladder wiring diagram — Spark-ignited pilot system Part Number 550-142-900/1016 37
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 9b Operating instructions CGa-25 to CGa-8 38 s 3PARK PILOT s .
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 9b Operating instructions CGa-25 to CGa-6 Part Number 550-142-900/1016 s 3PARK PILOT s .
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 9b Operating instructions CGa-25 to CGa-6 40 s 3PARK PILOT s .
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 9b Operating instructions CGa-7 to CGa-8 Part Number 550-142-900/1016 s 3PARK PILOT s .
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 10a Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING 4ABLE 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) s Check boiler area Inspect: s Reported problems Daily s Boiler area s Check air openings s Check boiler pressure/ temperature gauge s Air openings s Flue gas vent syst
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance — annual start-up The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 6, page 42, and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance – annual start-up ❏ Inspect . . . Boiler heating surfaces 1. Disconnect the vent pipe at the boiler draft hood and remove draft hood after turning off power to the boiler. 5SE A BRIGHT LIGHT TO INSPECT THE BOILER mUE COLLECTOR and heating surfaces. 3.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance – annual start-up ❏ Check/test Gas piping 1. Sniff near floor and around boiler area for any indication of a GAS LEAK. 2. 4EST GAS PIPING USING BUBBLE TEST per Section of this manual, if there is any indication of a leak. Cold fill and operating pressures 1. While the system is cold, note the PRESSURE READING ON THE BOILER PRESSURE TEMPERATURE GAUGE 6ERIFY THAT cold fill pressure is correct. 2.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance – annual start-up Safety relief valves should be reinSPECTED !4 ,%!34 /.#% %6%29 4(2%% 9%!23, by a licensed plumb- ing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance – annual start-up ❏ Cleaning boiler heating surfaces 2EMOVE RADIATION PLATES HANGING BETWEEN SECTIONS 2EMOVE BURNERS FROM BASE "RUSH AND VACUUM BURNERS TO REMOVE ALL DUST AND LINT 6ERIFY THAT ALL BURNER PORTS ARE FREE of debris. 8. Place newspapers in base of boiler to collect soot. 9. Clean between sections with wire flue brush. 2EMOVE NEWSPAPER AND SOOT 6ACUUM OR BRUSH BASE AND surrounding area. 11a (cont.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11a Troubleshooting — procedure Check the following: 1. Wire connectors to control module are securely plugged in at module and originating control. 'AS PRESSURES A 7ITH BOILER OFF v W C MAXIMUM NATURAL or propane gas pressure upstream of gas valve. b. With boiler on: s v W C MINIMUM NATURAL GAS PRESSURE OR v W C PROPANE GAS PRESSURE UPSTREAM OF gas valve.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers The information on this page and pages 50 through 56 apply only to SPARK IGNITED PILOT #'A BOILERS These boilers are equipped with an ignition control module that has indicator lights to show control status. Charts through , pages 51-56, help you identify problems based on indicator light conditions.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers &IGURE 50 (continued) Control module connections Part Number 550-142-900/1016
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 1 –– Spark-ignited pilot –– Troubleshooting POWER LIGHT STATUS –– ! " –– 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.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 2 –– Spark-ignited pilot –– TSTAT CIRC & POWER LIGHTS mASHING –– Usually indicates 48 VAC on thermostat circuit (stray voltage) –– 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.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 3 –– Spark-ignited pilot –– DAMPER LIGHT mASHING $$ % ! & $$ % & ' * +, ' $$ $$ Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 4 –– Spark-ignited pilot –– FLAME & POWER lights flashing $$ ! ' * - " $$ 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.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 5 –– Spark-ignited pilot –– FLAME LIGHT mASHING AND POWER LIGHT ON STEADY !,3/ –– 4ROUBLESHOOTING FAILURE TO ESTABLISH MAIN mAME 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.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 6 –– Spark-ignited pilot –– )NSUFlCIENT HEAT OR NO HEAT POWER LIGHT ON STEADY 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. s Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 7 –– Troubleshooting Sensor Ground and POWER light Solid and/or “LCO” shown on display 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 harness securely connected to control? Yes No s Secure connector.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 12a Replacement parts Section assembly .............................................. 59 Base .................................................................. 60 Jacket ............................................................... 61 Trim ................................................................... 62 Controls ............................................................
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 12b &IGURE Item number 1 2 3 Replacement parts — section assembly Section assembly, flue collector, draft hood and vent damper Description Weil-McLain part number End section, left hand, 51124 End section, right hand 51128 Intermediate section, 51125 CGa-25 and CGa-3 CGa-4 CGa-5 CGa-6 CGa-7 CGa-8 311-103-851 311-103-821 311-103-818 Replacement section assembly not shown Section replacement kit, includes seals and sealant for 1 joint 381-354-5
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 12c &IGURE Replacement parts — base Base assembly, manifold, orifices and burners Item Description number Weil-McLain part number Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6 and 7, plus insulation, air box gaskets, and hardware)) 60 CGa-25 CGa-3 CGa-4 CGa-5 CGa-6 CGa-7 CGa-8 381-354-355 381-354-356 381-354-357 381-354-358 381-354-359 381-354-360 381-354-361 1 Base side panel (in Base assembly) 2 Base front cross-tie assemb
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 12d Replacement parts — jacket &IGURE Jacket assembly 1 2 3 4 5 Junction box, 2 x 4 Jacket panel, left side, with insulation Jacket panel, right side, with insulation Jacket panel, top front Jacket panel, top rear Natural Gas Spark Pilot Boiler -ODEL CGa-25 CGa-3 CGa-4 CGa-5 CGa-6 CGa-7 CGa-8 Propane Gas Spark Pilot Boiler -ODEL Weil-McLain part number (Available at local supply house) 381-355-800 381-355-805 381-355-809 381-355-814
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 12e Replacement parts — trim &IGURE Item number 1 Trim assembly Description Pressure relief valve, ASME, 30 PSIG, ¾” male inlet Pressure relief valve, ASME, 30 PSIG, ¾” female inlet "# $ ! %& Manufacturer’s part number Weil-McLain part number Conbraco Watts Conbraco Watts 10-407-05 M330 10-408-05 335 511-546-920 2 ? short shank "#
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 12f &IGURE Replacement parts — controls Gas control assembly Boiler model Manufacturer Manufacturer’s part number Part number Gas Valve, ½” x ½” CGa-25 through CGa-6 CGa-7 & CGa-8 VR8204A2001 36E-266 7200IPER VR8304M4348 36C74-474 511-044-381 Gas valve, ¾” x ¾” Honeywell White-Rodgers Robertshaw Honeywell White-Rodgers Item Description number Natural gas components 1 2 % ` Weil-McLain 511-044-382
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 13a Dimensions Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler model number Supply tapping Return tapping Gas connection & manifold size “A” Vent location “D” Vent diameter “W” Jacket width “H” Damper height (inches NPT) (inches NPT) Note 3 (inches NPT) CGa-25 1¼ 1¼ ½ (inches) (inches) (inches) (inches) 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 CGa-6 1¼ 1¼ ½
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 13b Ratings DOE Boiler model number Input (Btuh) (Note 1) DOE Heating capacity (Btuh) 0 - 2,000 feet altitude 2,000 - 4,500 feet altitude Net AHRI ratings (Btuh) Boiler DOE water Seasonal content (gallons) (% AFUE) PIDN-PIDL (Note 2) Input (Btuh) Output (Btuh) Input (Btuh) Output (Btuh) (Note 3) Chimney and breeching size CGa-25 52,000 44,000 52,000 44,000 46,800 39,000 38,000 1.5 84.0 4"I.D.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications.
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual Notes Part Number 550-142-900/1016 67
CGa Series 2 Gas-Fired Water Boiler — Boiler Manual 68 Part Number 550-142-900/1016
