Weil-McLain 550-110-710/0107 - Manuals

Part Number 550-110-710/0107 5 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage. • Continual fresh makeup water will reduce boiler life. Mineral bu...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 6 Part Number 550-110-710/0107 Prepare boiler location — codes & checklist 1a Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z3.1–latest editio...

Part Number 550-110-710/0107 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances 1b Figure 1b Required MINIMUM clearances Figure 1a Recommended SERVICE clearances (see WARNING below) Recommended SERVICE clearances (Fig. 1a) 1. Provide clearances for cleaning and serv...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 8 Part Number 550-110-710/0107 Prepare boiler location — vent system 1c Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. When removing boiler from an existing com...

Part Number 550-110-710/0107 9 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air contamination Table 1 Corrosive or destructive contaminants and likely locations 1d Please review the following information on potential combustion air contamination problems. Refer to Table ...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 10 Part Number 550-110-710/0107 Figure 5 Air from outdoors — horizontal ducts Figure 4 Air from outdoors — vertical ducts Figure 2 Air openings to interior spaces Figure 3 Air directly through outside wall Air opening options Two openings — Air supply ...

Part Number 550-110-710/0107 11 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Unusually tight construction Unusually tight construction means (per ANSI Z3.1) buildings in which:a. Walls and ceilings exposed to the outside atmo- sphere have a continuous water vapor retarder with a rating of 1 perm ...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 1 Part Number 550-110-710/0107 Prepare boiler — placement & setup 2a Table 2 Manifold orifice sizing at sea level and altitudes to 4,500 feet Place boiler/crate near position 1. Leave boiler in crate and on pallet until installation site is ready. ...

Part Number 550-110-710/0107 13 GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 14 Part Number 550-110-710/0107 Venting — general information 3a CGi venting methods — 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 (non-...

Part Number 550-110-710/0107 15 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Venting — Direct exhaust — components 3c Obtain vent system components 1. The following special gas vent systems comply with UL-138 and ULC- S636 standards and are certified by CSA as the only systems suitable for use wi...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 16 Part Number 550-110-710/0107 Venting — direct exhaust — vent starter 3d 1. Select a vent pipe manufacturer and obtain all vent components needed, based on boiler location and venting method. . You must use the vent starter made by the vent pipe manu...

Part Number 550-110-710/0107 1 GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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 requi...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 18 Part Number 550-110-710/0107 Venting — direct exhaust — installation 3f 1. Do not mix types or manufacturers of vent materi- als. . Clean all joints before sealing. See vent manufactur- er’s instructions for cleaning and sealing joints. Use their sp...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 0 Part Number 550-110-710/0107 Water piping — general information 4a General piping information If installation is to comply with ASME or Canadian requirements, an ad- ditional high temperature limit is needed. Install control in supply piping between ...

Part Number 550-110-710/0107 1 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Water piping — single-zone system 4b Diaphragm-type or bladder- type expansion tank (Figure 16) 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler retu...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual Part Number 550-110-710/0107 4c Piping multiple zones Follow instructions on pages 0 and 1 to install near-boiler or single-zone piping. (Also refer to Piping for radiant heating systems or converted gravity sys-tems , below, if applicable.) See Figure...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 4 Part Number 550-110-710/0107 4d 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 p...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 6 Part Number 550-110-710/0107 BOILER-bypass piping method This piping method ( Figure 22 or 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 throug...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 8 Part Number 550-110-710/0107 Piping — low temperature systems 4d SYSTEM-bypass piping method This piping method is called a system-bypass because part of the circulator flow bypasses the system (through valve 7a ). This bypassed hot water from the bo...

Part Number 550-110-710/0107 9 GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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 expan- sion tank), or connect...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 30 Part Number 550-110-710/0107 Gas piping 5 Table 7 Pipe capacity for 0.60 specific gravity natural gas Natural Gas: 1. Refer to Table 7 for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 7 ...

Part Number 550-110-710/0107 31 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Field wiring 6 Thermostat 1. Connect thermostat as shown on wiring diagram on boiler. . Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunrays, or fireplace...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 3 Part Number 550-110-710/0107 Start-up — preparation 7a Check for gas leaks Before starting the boiler, and dur- ing initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if the...

Part Number 550-110-710/0107 33 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Fill the system with water 1. Close manual and automatic air vents and boiler drain cock. . Fill to correct system pressure. Correct pressure will vary with each application. Typical cold water fill pressure for a reside...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 34 Part Number 550-110-710/0107 Start-up — operate boiler 7b DO NOT proceed with boiler operation unless boiler and system have been filled with water and al l inst r uc tions and procedures of previous manual sections have been completed. Failure to d...

Part Number 550-110-710/0107 35 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Figure 29 Typical main burner flame Check burner flames View pilot and main flames through the inspection port in the base burner shield. Pilot burner flame ( Figure 28 ) PROPER pilot flame characteristics 1. Blue flame....

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 36 Part Number 550-110-710/0107 Check-out procedure — checklist 8 ❏ 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 leak...

Part Number 550-110-710/0107 3 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Operation — sequence 9a Figure 30 Control module sequence of operation — status light indications 1. Read Operating instructions on page 40. This information is also located on a label on the inside of the boiler jacket d...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 38 Part Number 550-110-710/0107 Operation — wiring diagrams 9b Figure 31 Schematic wiring diagram

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 40 Part Number 550-110-710/0107 9c Operating instructions CGi-25 to CGi-6 • Spark pilot • Natural or propane gas• Gas valve: Honeywell VR8204/VR8304

Part Number 550-110-710/0107 43 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Table 8 Service and maintenance schedules Service and maintenance — schedule 10a Follow the Service and maintenance procedures given throughout this manual and in com- ponent literature shipped with the boiler. Failure t...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 44 Part Number 550-110-710/0107 Air openings 1. Verify that combustion and ventilation air openings to the boiler room and/or building are open and unobstructed . . Verify that boiler vent discharge is clean and free of obstructions . Flue gas vent sys...

Part Number 550-110-710/0107 45 GOLD CGi Gas-Fired Water Boiler — Boiler Manual ❏ 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 per...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 46 Part Number 550-110-710/0107 10b ❏ Check/test . . . Gas piping 1. Sniff near floor and around boiler area for any in- dication of a gas leak . . Test gas piping using bubble test, per Section 5 of this manual, if there is any indication of a leak. C...

Part Number 550-110-710/0107 4 GOLD CGi Gas-Fired Water Boiler — Boiler Manual ❏ Review with owner 1. Review the User’s Information Manual with the owner. . Emphasize the need to perform the maintenance schedule specified in the User’s Information Manual (and in this manual as well). 3. Remind the o...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 48 Part Number 550-110-710/0107 Troubleshooting — components 11b Troubleshooting — procedure 11a Air pressure switch Make sure boiler water temperature is 100 °F or cooler before starting procedure to obtain appropriate read- ings. The boiler will not ...

Part Number 550-110-710/0107 49 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — components (continued) 11b Figure 36 Manometer connections Control module Solder or water splatter between plugs and circuit board can cause improper operation of control mod- ule. Place a shield over t...

Part Number 550-110-710/0107 51 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights 11c CHART 1— Troubleshooting POWER light status Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructions could result...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 5 Part Number 550-110-710/0107 Troubleshooting — control module lights (cont.) 11c Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructions could result in severe personal injury, death or ...

Part Number 550-110-710/0107 53 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) 11c CHART 3 — PRESS SWITCH & POWER lights flashing Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructio...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 54 Part Number 550-110-710/0107 Troubleshooting — control module lights (cont.) 11c • Turn off power to the boiler at service switch or breaker. • Wait at least 45 seconds. • Turn on power to boiler. • Restart boiler, following Operating instructions i...

Part Number 550-110-710/0107 55 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) 11c CHART 5 — PRESS SWITCH light flashing and POWER light on steady Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to foll...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 56 Part Number 550-110-710/0107 Troubleshooting — control module lights (cont.) 11c • TURN OFF POWER to boiler at service switch or breaker. • Remove burner shield (see Figure 40, item 4 , page 60 for location). • Verify inlet gas pressure at gas valve...

Part Number 550-110-710/0107 5 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) 11c 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. Failur...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 58 Part Number 550-110-710/0107 Replacement parts 12a Section assembly .............................................. 59 Base ................................................................. 60 Jacket .....................................................

Part Number 550-110-710/0107 59 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Replacement parts — section assembly 12b Figure 39 Section assembly

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 60 Part Number 550-110-710/0107 Replacement parts — base 12c Figure 40 Base assembly

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 6 Part Number 550-110-710/0107 Replacement parts — jacket 12d Figure 41 Jacket assembly

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 64 Part Number 550-110-710/0107 Replacement parts — trim 12e Figure 42 Trim assembly Itemnumber Description Manufacturer Manufacturer’s part number Weil-McLainpart number 1 Pressure relief valve, ASME, 30 PSIG, ¾" male inlet Pressure relief valve, ...

Part Number 550-110-710/0107 65 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Replacement parts — controls 12f Figure 43 Gas control assembly Item number Description Boiler model Manufacturer Manufacturer’s part number Weil-McLain part number Natural gas components 1 Gas valve, ½" x ½" Gas...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 66 Part Number 550-110-710/0107 Dimensions 13a Figure 44 Dimensional drawing

Part Number 550-110-710/0107 6 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Ratings Table 10 Boiler ratings DOE 13b CGi boilers for residential radiant panel systems, converted gravity heating systems or other low water tempera- ture applications should be installed with balancing valves and bypa...

GOLD CGi Gas-Fired Water Boiler — Boiler Manual 68 Part Number 550-110-710/0107 Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this prod- uct contain ceramic fiber materials. Ceramic fiber...