GOLD CGt Gas-Fired Water Boiler With Tankless Heater 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, the burner manual and any related supplements. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual How it works . . . ① ② ③ ④ on the boiler return piping as shown. NOTE — The Control module The control module responds to signals from the room thermostat, tankless heater low limit, air pressure switch and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and inducer. When room thermostat calls for heat, the control module starts the system circulator and inducer.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual CGt Gas-Fired Water Boiler with tankless heater Part Number 550-110-290/0107
GOLD CGt 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................................................12–13 3 Venting.......................................................... 14-19 4 Water piping................
GOLD CGt Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User Read all instructions before installing. Follow all instructions in • • proper order to prevent personal injury or death. Consider piping and installation when determining boiler location. Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. • This manual is for use only by your qualified heating installer/service technician.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 1a Prepare boiler location — codes & checklist Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223.1–latest edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1, when required. • National Electrical Code. • For Canada only: B149.1 or B149.2 Installation Code, CSA C22.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 1c Prepare boiler location — clearances Recommended SERVICE clearances Figure 2 Required MINIMUM clearances (Fig. 1) 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1 for recommendations. 2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 1d 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. Direct exhaust venting (Category III) — Do not common vent the CGt in a direct exhaust system (Category III).
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 1e Prepare boiler location — contamination Please review the following information on potential combustion air contamination problems. Refer to Table 1 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.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 1f ✷ Prepare boiler location — air openings Combustion air opening location and sizing requirements depend on the clearances around the boiler. Check the boiler placement compared to Figure 1, page 7. Figure 3 Air openings to interior spaces ✷ If all clearances are at least equal to Figure 1, page 7, apply the sizing and placement of openings given on pages 10 and 11.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 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). Use the free area information provided by the louver manufacturer.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 2a Prepare boiler — placement and setup Place boiler/crate near position 1. Leave boiler in crate and on pallet until installation site is ready. 2. Move entire crate and pallet next to selected location. 3. Remove crate. 4. Remove boiler from pallet. Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result. a. Tilt left side of boiler up and place a board under left legs. b.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 2b Prepare boiler — pressure test Hydrostatic pressure test Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply. Prepare boiler for test 1. Remove the shipping nipple (from CGt supply tapping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾” NPT pipe plug. 2. Remove 1¼” nipple, reducing tee and drain valve from circulator hardware bag.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 3a Venting — general information CGt venting options — Chimney draft or Direct exhaust Chimney draft venting Chimney draft venting uses the natural draft provided by a vertical vent or chimney. Category I appliance (nonpositive vent static pressure and vent gas temperature that avoids excessive condensate production in vent). See Section 3b. Chimney draft installations use: 1.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 3c Venting — direct exhaust — components Obtain vent components 1. The following special gas vent systems comply with UL-1738 and ULC-S636 standards and are certified by CSA as the only systems suitable for use with CGt boilers (all 3” diameter): • Heat-Fab, Inc. Saf-T Vent® • Flex-L International, Inc. StaR-34 • Z-Flex®, Inc. Z-Vent II • ProTech Systems FasNSeal™ 2. Select vent method based on page 14 and installation requirements. 3.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 3d Venting — direct exhaust — vent starter 1. Select a vent pipe manufacturer and obtain all vent components needed, based on boiler location and venting method. Figure 8 FasNSeal™ vent starter Figure 9 Z-Vent II vent starter Figure 10 Saf-T Vent® vent starter Figure 11 StaR-34 vent starter 2. You must use the vent starter made by the vent pipe manufacturer.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 3e Venting — direct exhaust — termination Follow instructions on this page when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. 1. Locate the boiler and vent penetration through the wall so all requirements on this page and in Figure 12 will be met. Also follow vent manufacturer’s instructions. 2. Gases will form white plume in winter. Plume could obstruct window view. 3.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 3f Venting – direct exhaust – vertical or sidewall 1. Do not mix types or manufacturers of vent materials. 2. Clean all joints before sealing. See vent manufacturer’s instructions for cleaning and sealing joints. Use their specified sealant. Do not use screws. 3. Install vent pipe with seams on top of vent horizontal runs. Follow requirements in Section 3e, page 17, for vent termination. 4.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual Using any termination other than one of those shown could cause nuisance outages and loss of heat, resulting in substantial property damage.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 4a Water piping — general information General piping information If installation is to comply with ASME or Canadian 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 first control. Maximum allowable setpoint is 240°F. See Section 9b for wiring.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 4b Water piping — system System water piping See Figure 16 and Table 5 for near-boiler piping and piping for single-zone systems designed for return water at least 130°F. See pages 22-23 to for multiple-zone piping for systems with return water tempeature of at least 130°F. See pages 24-25 for low-temperature system piping; i.e.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 4c Water piping — multiple zones Piping multiple zones Follow instructions on pages 20 and 21 to install nearboiler piping or for single-zone systems. (Also see ”Piping for radiant heating systems or converted gravity systems” if applicable.) See Figure 18 or Figure 19, page 23, to complete installation. Zoning with circulators (Figure 18) (return temp over 130°F) 1. Size each circulator to individual circuit requirements. 2.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 4c Water piping — multiple zones Figure 18 Figure 19 Zoning with circulators — return water 130°F or higher. 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 5 Zone valve 6 Drain valve 9 Relief valve (continued) Zoning with zone valves — return water 130°F or higher. 10 Automatic air vent (with diaphragm-type expansion tank), or con- nect to tank fitting (closed-type expansion tank).
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 4d Piping — low temperature systems Bypass piping Figures 20 and 21, page 25, show suggested bypass ar- rangements using bypass piping for low temperature systems such as radiant heating systems or converted gravity systems. Primary/secondary bypass piping is required because the boiler circulator must install on the return line and be used to provide domestic water priority.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 4d Piping — low temperature systems Figure 20 By-pass piping Zoning with circulators Figure 21 By-pass piping Zoning with zone valves 1 Boiler isolation (balancing) valves 8 Blend temperature gauge 2 Flow/check valve 9 Relief valve 3 System or zone circulator 4 (continued) 10 Automatic air vent System temperature gauges 5 Zone valve 6 Drain valve 7 System temperature valves (see instruc- tions on page 24 for adjusting valves) Part Number 550-11
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 4e Water piping — connect tankless heater Hot Water Can Scald! • Consumer Product Safety Commission and some states recommend domestic hot water temperature of 130°F or less. • When installing an automatic mixing valve, selection and installation must comply with valve manufacturer’s recommendations and instructions.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 4f Water 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 23 for typical installation of balancing valve and check valve.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 5 Gas piping Connecting gas supply piping to boiler 1. Remove jacket front panel and refer to Figure 24 to pipe gas to boiler. a. Install drip leg at inlet of gas connection to boiler. Where local utility requires drip leg to be extended to the floor, use appropriate length of pipe between cap and tee. b. Install ground joint union for servicing, when required. c.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 6 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. Thermostat Wiring must be N.E.C. Class 1. 2.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 7a Start-up — preparation Check for gas leaks Before 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. Repair any leak at once. Determine if water treatment is needed Do not use petroleum-based cleaning or sealing compounds in boiler system.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 7a Start-up — preparation Inspect system water piping (continued) Inspect base insulation After filling the boiler and system with water, inspect all piping throughout the system for leaks. If found, repair immediately. Repeat this inspection after the boiler has been started and the system has heated up. The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 68 of this manual.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 7b Start-up — operate boiler (continued) Check burner flames View pilot and main flames through the inspection port in the base burner shield. Figure 26 Typical pilot burner flame Pilot burner flame (Figure 26) PROPER pilot flame characteristics: 1. Blue flame. 2. Inner cone engulfing pilot flame sensor. 3. Pilot flame sensor glowing cherry red. IMPROPER pilot flame characteristics: 1. Overfired — Large flame lifting or blowing past pilot flame sensor.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 8 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ Check-out procedure — checklist Boiler and heat distribution units filled with water? Automatic air vent, if used, open one full turn? Air purged from system? Air purged from gas piping? Piping checked for leaks? Correctly sized manifold orifices installed? Refer to page 12 to check size. Correctly sized manifold orifices must be used. Failure to do so will cause severe personal injury, death or substantial property damage.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 9a Operation — sequence 1. Read Operating instructions in Section 9c. This information is also located on a label on the inside of the boiler jacket door panel. Notice that either the room thermostat or the tankless heater low limit control can cause a call for heat. 2. Raise room thermostat (or raise setting of tankless heater low limit control) to call for heat. 3. Circulator energizes. If limit circuit is closed, the inducer starts.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 9b Operation — wiring diagram Figure 29 Schematic and ladder wiring diagram Part Number 550-110-290/0107 35
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 9c 36 Operating instructions • Spark pilot • Natural or propane gas • Gas valve: Honeywell VR8204/VR8304 Part Number 550-110-290/0107
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 9c Operating instructions Part Number 550-110-290/0107 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36E 37
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 9c 38 Operating instructions • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36C Part Number 550-110-290/0107
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 10a Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING Table 8 Service and maintenance schedules 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.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 10b Service and maintenance — annual start-up Air openings 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 8, page 39, and explained on the following pages must be performed to assure maximum boiler efficiency and reliability.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 10b ❏ Service and maintenance – annual start-up (cont.) Inspect . . . Burners and base The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 68 of this manual. Failure to comply could result in severe personal injury. If insulation is damaged or displaced, do not operate the boiler. Replace or reposition insulation as necessary.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 10b Service and maintenance – annual start-up (cont.) ❏ Check/test . . . Figure 31 Automatic air vent, typical Gas piping 1. Sniff near floor and around boiler area for any indication of a gas leak. 2. Test gas piping using bubble test, per Section 5 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.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 10b Service and maintenance – annual start-up (cont.) 2. Diaphragm- or bladder-type expansion tanks These tanks are welded gas tight with a rubber membrane to separate the tank pressurizing air and the water. May be located at any point in the system, but most often found near the boiler.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 10b Service and maintenance – annual start-up (cont.) ❏ Review with owner 1. Review the User’s Information Manual with the owner. 2. Emphasize the need to perform the maintenance schedule specified in the User’s Information Manual (and in this manual as well). 3. Remind the owner of the need to call in a licensed contractor should the boiler or system exhibit any unusual behavior. 4.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11a Troubleshooting — procedure Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other device except for momentary testing as outlined in Troubleshooting Charts. Severe personal injury, death or substantial property damage can result. Before troubleshooting: 1. Have the following items: a.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — components Check pressure switch setting 1. See Figure 33. 2. Remove both air pressure switch hoses from air pressure switch. 3. Install tees and tubing as shown in Figure 33 to inclined manometer. 4. Turn off gas valve and set thermostat to call for heat. Inducer will run but burners will not ignite. 5. Check for 24 VAC between both air pressure switch terminals. 6.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — components (continued) Control module Solder or water splatter between plugs and circuit board can cause improper operation of control module. Place a shield over the boiler internal controls and components during installation. Failure to comply could result in severe personal injury, death or substantial property damage. Figure 34 Control module Make sure ground wiring is installed per wiring diagram.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — components (continued) Figure 35 Control module connections 48 Part Number 550-110-290/0107
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11c Troubleshooting — control module lights CHART 1— 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? No • Make sure service switch or circuit breaker is on or fuses are good.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11c Troubleshooting — control module lights (cont.) CHART 2 — TSTAT CIRC & POWER lights flashing — Usually indicates 48 VAC on thermostat circuit (stray voltage) — Electrical shock hazard — Wherever you see sTURN OFF POWERs, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11c Troubleshooting — control module lights (cont.) CHART 3 — PRESS SWITCH & POWER lights flashing — Usually indicates pressure switch stuck closed or failed to make within 5 minutes — 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.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11c Troubleshooting — control module lights (cont.) CHART 4 — FLAME & POWER lights flashing — Usually indicates flame sensed when it shouldn't be there — 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.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11c Troubleshooting — control module lights (cont.) CHART 5 — PRESS SWITCH light flashing and POWER light on steady — Usually indicates pressure switch opened during run cycle — — May also be caused by wind gusts in excess of 40 mph for non-direct vent sidewall-vented boilers — Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11c Troubleshooting — control module lights (cont.) CHART 6 — FLAME light flashing and POWER light on steady ALSO — Troubleshooting failure to establish main flame 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.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11c Troubleshooting — control module lights (cont.) CHART 7 — Insufficient heat or no heat to system (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. • • • Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11d 56 Troubleshooting — common problems Part Number 550-110-290/0107
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — common problems Part Number 550-110-290/0107 (continued) 57
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 12a Replacement parts Section assembly............................................... 59 Base .................................................................. 60 Jacket ............................................................... 62 Trim ................................................................... 64 Controls.............................................................
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 12b Replacement parts — section assembly Figure 36 Section assembly Part Number 550-110-290/0107 59
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 12c Replacement parts — base Figure 37 Base assembly 60 Part Number 550-110-290/0107
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 12c Replacement parts — base (continued) Item number Description Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6 and 7) Weil-McLain part number 381-354-339 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 Burner shield (in Base assembly) 5 Base pan angle, left side (in Base assembly) 6 Base pan angle, right side (in Base assembly) 7 Bas
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 12d Replacement parts — jacket Figure 38 Jacket assembly 62 Part Number 550-110-290/0107
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 12d Replacement parts — jacket Item number Description (continued) Weil-McLain part number 1 Junction box, 2 x 4 x 1.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 12e Replacement parts — trim Figure 39 Trim assembly Item Description number 1 Drain valve, ¾" NPT/Bibb 2 3 4 5 6 7 8 9 10 11 13 15 16 17 18 19 20 21 22 23 24 25 64 Tee, 1" x ¾" x 1" Nipple, 1¼" x 2¾" NPT Nipple, 1¼" x 2" NPT Circulator, pre-piped (Circulator hardware kit includes 2 flanges, 2 nuts, 2 screws) Circulator gasket, universal (2 per boiler) Circulator wiring harness kit (Molex for control end shipped loose) Adapter, copper/NPT, 1" x 1" Nip
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 12f Replacement parts — controls Figure 40 Gas control assembly Item Description number Manufacturer Manufacturer’s Weil-McLain part number part number 1 Gas valve, ½" x ½" 2 Pilot kit w/orifice & aluminum pilot gas tubing Weil-McLain 3 Control module United Technologies 4 Air pressure switch, 1.53" w.c.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 13a Dimensions Figure 41 Dimensional drawing 66 Part Number 550-110-290/0107
GOLD CGt Gas-Fired Water Boiler — Boiler Manual 13b Ratings DOE Table 9 Boiler ratings Boiler model number DOE Heating capacity (Btuh) Input (Btuh) Output (Btuh) (Note 1) CGt-PIN Notes 108,000 Net I=B=R ratings (Btuh) Boiler water content (gallons) DOE Seasonal efficiency (% A.F.U.E) Vent size Direct exhaust (Note 2) 133,000 108,000 94,000 Chimney draft (Note 3) 3.1 81.0 3" 5" 1. Based on standard test procedures prescribed by the United States Department of Energy. 2.
GOLD CGt Gas-Fired Water Boiler — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER 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.
