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.
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).
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual CGa Series 3 Gas-Fired Water Boiler Part Number 550-142-300/0520 3
CGa Series 3 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 3 Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer— Read 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. User — This manual is for use only by a qualified heating installer/service technician. Refer to User’s Information Manual for your reference.
CGa Series 3 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/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.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 1b Prepare boiler location — clearances Recommended SERVICE clearances (Fig. 1a) Figure 1b Required MINIMUM clearances 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 3 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 3 Gas-Fired Water Boiler — Boiler Manual 1d Prepare boiler location — air 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.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 1e ✷ 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 1a, page 7. Figure 2 Air openings to interior spaces ✷ 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.
CGa Series 3 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). Use the free area information provided by the louver manufacturer.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 2a Prepare boiler — placement and setup Place boiler/crate near position Correctly-sized manifold orifices must be used. Failure to do so will result in severe personal injury, death or substantial property damage. 1. Leave boiler in crate and on pallet until installation site is ready. 2. Move entire crate and pallet next to selected location. 3. Level and straighten burners. 3. Remove crate. Leave boiler on pallet. 4.
CGa Series 3 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 1. Remove the shipping nipple (from CGa 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 accessory bag.
CGa Series 3 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. 3. Bottom of draft hood or “skirt” must have clearance dimension above jacket top panel as indicated on draft hood.
CGa Series 3 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. Boiler will not operate without vent damper installed. Only vent dampers listed in the Replacement parts list on page 58 are certified for use with CGa boilers. Any other vent damper installed could cause severe personal injury or death.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 3a Water piping — general information General piping information Circulator If installation is to comply with ASME or Canadian requirements, an 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 page 36, for wiring.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 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 bladdertype expansion tank (Figure 9) Closed-type expansion tank 1. Ensure expansion tank size will handle boiler and system water volume and temperature.
CGa Series 3 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 Piping for radiant heating systems or converted gravity systems, below, if applicable.) See Figure 11 or Figure 12, 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 3 Gas-Fired Water Boiler — Boiler Manual 3c Water piping — multiple zones Figure 11 Zoning with circulators — return water 130°F or higher. 1 Boiler isolation (balancing) valves Figure 12 (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). DO NOT use an automatic air vent when using closed-type expansion tank.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems Primary/secondary (preferred) Bypass piping method Primary/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 3 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) Figure 13 Primary/secondary piping Zoning with circulators 1 Boiler 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 5 Zone valve 6 Drain valve 7 System temperature valves (see instructions to the left for adjusting valves) 8 Blend temperat
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) BOILER-bypass piping method This piping method (Figure 15 or 16, page 23) is called a boiler-bypass because part of the circulator flow is bypassed around the boiler (through valve 7a). This method reduces the flow rate throughout the boiler, in order to raise the average water temperature in the boiler enough to prevent flue gas condensation.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) Figure 15 Boiler-bypass piping Zoning with circulators (Alternative to primary/secondary piping Figures 13 and 14) 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges Figure 16 Boiler-bypass piping Zoning with zone valves (Alternative to primary/secondary piping Figures 13 and 14) 10 Automatic air vent (with diaphragm-type expansion t
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) SYSTEM-bypass piping method This piping method (Figure 17, page 25) is called a system-bypass because part of the circulator flow bypasses the system (through valve 7a). This bypassed hot water from the boiler outlet mixes with cooler system return water temperature in order to provide minimum 130°F return water to the boiler.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 3d Water piping — low temperature systems (continued) Figure 17 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 Blend temperature gauge 9 Relief valve 10 Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 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 on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 4 is only for gas with specific a. Install drip leg at inlet of gas connection to boiler.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 5 Field wiring For your safety, turn off electrical power supply at ser- vice entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. If rollout thermal fuse element wire as supplied with boiler must be replaced, type 200°C wire or equivalent must be used.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 6a 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. Propane boilers only — Your propane supplier mixes an odorant with the propane to make its presence detectable.
CGa Series 3 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 immediately. Repeat this inspection after the boiler has been started and the system has heated up. 2. Fill to correct system pressure.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 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).
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 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 note the gas valve manufacturer and model number. Use only the operating instruction which applies to this gas valve (see Table 5, page 30). (The operating instruction label on the boiler provides the same information.) See Section 6c if boiler fails to start. Check system and boiler 1.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 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 (sparkignited 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.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 7 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ 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 Table 2, page 12 to check size and fuel type. Correctly sized manifold orifices must be used.
CGa Series 3 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 3 Gas-Fired Water Boiler — Boiler Manual 9a Operation — spark-ignited pilot boilers 4. Main 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 3 Gas-Fired Water Boiler — Boiler Manual 9a Figure 25a Operation — spark-ignited pilot system 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.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 9a Figure 25b WARNING Operation — spark-ignited pilot system (continued) Ladder wiring diagram — Spark-ignited pilot system Electrical shock hazard — can cause severe injury or death. Disconnect power before installing or servicing.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 9b Operating instructions CGa-25 to CGa-8 38 • Spark pilot • Natural gas • Propane gas • Gas valve: Honeywell VR8204/VR8304 Part Number 550-142-300/0520
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual instructions 9b Operating CGa-25 to CGa-6 Part Number 550-142-300/0520 • Spark pilot • Natural gas • Gas valve: Robertshaw 7200 39
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual instructions 9b Operating CGa-25 to CGa-6 40 • Spark pilot • Natural gas • Gas valve: White-Rodgers 36E Part Number 550-142-300/0520
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual instructions 9b Operating CGa-7 to CGa-8 Part Number 550-142-300/0520 • Spark pilot • Natural gas • Gas valve: White-Rodgers 36C 41
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 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: • Reported problems Daily • Boiler area • Check air openings • Check boiler pressure/ temperature gauge • Air openings • Flue gas vent syst
CGa Series 3 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 3 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. 2. Use a bright light to inspect the boiler flue collector and heating surfaces. 3. If the vent pipe or boiler interior surfaces show evidence of soot, follow Cleaning boiler heating surfaces in this manual section.
CGa Series 3 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. Test gas piping using bubble test, per Section 4 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. Verify that cold fill pressure is correct. 2.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance – annual start-up Safety relief valves should be rein- spected AT LEAST ONCE EVERY THREE YEARS, 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 3 Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance – annual start-up ❏ Cleaning boiler heating surfaces 6. Remove radiation plates hanging between sections. 7. Remove burners from base. Brush and vacuum burners to remove all dust and lint. Verify 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. 10. Remove newspaper and soot. Vacuum or brush base and surrounding area. 11a (cont.
CGa Series 3 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. 2. Gas pressures: a. With boiler off — 13” w.c. maximum natural or propane gas pressure upstream of gas valve. b. With boiler on: • 5” w.c. minimum natural gas pressure or 11” w.c. propane gas pressure upstream of gas valve. • 3.5” w.c. minimum natural gas pressure or 10” w.c.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers The information on this page and pages 50 through 57 apply only to spark-ignited pilot CGa boilers. These boilers are equipped with an ignition control module that has indicator lights to show control status. Charts 1 through 7, pages 51- 57, help you identify problems based on indicator light conditions.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 11b Figure 30 50 Troubleshooting — spark-pilot boilers (continued) Control module connections Part Number 550-142-300/0520
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) 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.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 2 –– Spark-ignited pilot –– TSTAT CIRC & POWER lights flashing –– 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 3 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) 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 –– Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲, follow the instructions.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 4 –– Spark-ignited pilot –– 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.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 5 –– Spark-ignited pilot –– 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.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 6 –– Spark-ignited pilot –– Insufficient 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. • Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — spark-pilot boilers (continued) CHART 7 –– Troubleshooting LWCO 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 boiler pressurized? Yes No • Pressurize boiler to system design pressure.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 12a Replacement parts Section assembly............................................... 59 Base................................................................... 60 Jacket................................................................ 61 Trim.................................................................... 62 Controls.............................................................
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 12b Replacement parts — section assembly Figure 31 Section assembly, flue collector, draft hood and vent damper Item number 1 2 3 Description Part number End section, left hand, 51124 End section, right hand 51128 Intermediate section, 51127 CGa-25 and CGa-3 CGa-4 CGa-5 CGa-6 CGa-7 CGa-8 311-103-851 311-103-821 311-103-845 321-114-360 321-114-361 321-114-362 321-114-363 321-114-364 321-114-365 Item number Description Part number 9 Temperature/LW
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 12c Figure 32 Replacement parts — base Base assembly, manifold, orifices and burners Item Description number Part number CGa-25 CGa-3 CGa-4 CGa-5 CGa-6 CGa-7 CGa-8 Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6 and 7, plus insulation, air box gaskets, and hardware)) 60 381-354-362 381-354-356 381-354-357 381-354-358 381-354-359 381-354-360 381-354-361 1 Base side panel (in Base assembly) 2 Base front cross-tie assembly (in Base
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 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, right side, with insulation Jacket panel, top front Jacket panel, top rear Natural Gas Spark Pilot Boiler Model CGa-25 CGa-3 CGa-4 CGa-5 CGa-6 CGa-7 CGa-8 Boiler Model Part numbers (Available at local supply house) 381-359-201 381-359-202 381-359-203 381-359-204 381-359-205 381-359-206 381-359-207
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 12e Figure 34 Item number Trim assembly Description Part number Pressure relief valve, ASME, 30 PSIG, ¾” male inlet 511-546-920 Pressure relief valve, ASME, 30 PSIG, ¾” female inlet (Fittings shown are factory-installed on boiler.) 511-546-924 2 Combination pressure-temperature gauge, 3⅛,” diameter, short shank (Fittings shown are shipped loose with boiler.) 380-000-000 3 Drain valve, ¾” (Fittings shown are included with boiler.
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 12f Figure 35 Replacement parts — controls Gas control components Item Description number Boiler model Part number 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 Natural gas components 1 2 Pilot kit w/orifice & aluminum pilot gas tubing 511-330-218 Liquefied Petroleum (Propane) gas components 1 2 Gas Valve, ¾” x ¾” CGa-25 through CGa-7 511-044-356 Gas Valve, ¾” x ¾” CGa-8 511-044-366
CGa Series 3 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 3 Gas-Fired Water Boiler — Boiler Manual 13b Ratings AHRI Certified Ratings Boiler model number 0 - 2,000 feet Altitude 2,000 - 4,500 feet Altitude Heating Capacity Seasonal Efficiency PIDN-PIDL Net Ratings Boiler water content Chimney and breeching size (Note 1) Input (Btuh) Output (Btuh) Input (Btuh) Output (Btuh) Btuh (Note 2) AFUE % Btuh (Note 3) (gallons) Inches CGa-25 38,000 32,000 34,000 29,000 32,000 84.0 27,000 1.5 4"I.D.
CGa Series 3 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 3 Gas-Fired Water Boiler — Boiler Manual Notes Part Number 550-142-300/0520 67
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual 68 Part Number 550-142-300/0520
