Weil-McLain CGI-4E - Manuals

Page 2 - CGi-4E Gas-Fired Water Boiler — Boiler Manual

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 2 Part Number 550-110-711/1108 How it works . . . ① Control module The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and inducer. W...

Page 4 - Contents; Hazard definitions

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4 Part Number 550-110-711/1108 Contents How it works ....................................................2–3 Hazard definitions ............................................... 4 Please read before proceeding ............................ 5 1 Prepare ...

Page 5 - Please read before proceeding

Part Number 550-110-711/1108 5 GOLD CGi-4E 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...

Page 6 - Prepare boiler location — codes & checklist; Installations must follow these codes:

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 6 Part Number 550-110-711/1108 Prepare boiler location — codes & checklist 1a Installations must follow these codes: • Local, state, provincial, and national codes, la ws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223.1–latest ...

Page 7 - Prepare boiler location — clearances; SERVICE; Recommended SERVICE clearances; Required MINIMUM clearances; Flooring; Foundation; Residential garage installations

Part Number 550-110-711/1108 7 GOLD CGi-4E 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...

Page 8 - Prepare boiler location — vent system; When removing boiler from an; DO NOT COMMON VENT

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 8 Part Number 550-110-711/1108 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 ...

Page 9 - Prepare boiler location — air contamination

Part Number 550-110-711/1108 9 GOLD CGi-4E 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 Tab...

Page 10 - Air opening options; Two openings — Air supply from inside the building; Prepare boiler location — air openings; Air openings must be provided

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 10 Part Number 550-110-711/1108 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 supp...

Page 11 - Unusually tight construction; Motorized air dampers; Exhaust fans and air movers; Single air opening option; Exception for large spaces

Part Number 550-110-711/1108 11 GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Unusually tight construction Unusually tight construction means (per ANSI Z223.1) buildings in which:a. Walls and ceilings exposed to the outside atmo- sphere have a continuous water vapor retarder with a rating of 1 ...

Page 12 - Prepare boiler — placement & setup; Location; Place boiler/crate near; Orifice replacement

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 12 Part Number 550-110-711/1108 Prepare boiler — placement & setup 2a Table 2 Manifold orifice sizing at sea level and altitudes to 4,500 feet Location Natural gas Propane gas U. S. 0-2,000 ft over 2,000 ft 0-2,000 ft over 2,000 ft 2.55 mm (Note...

Page 13 - Prepare boiler — pressure test; Hydrostatic pressure test; Prepare boiler for test; Drain and remove fittings

Part Number 550-110-711/1108 13 GOLD CGi-4E 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 (f...

Page 14 - Venting — general information; CGi-4E venting methods — Chimney draft or Direct exhaust; Chimney draft venting; Venting — chimney draft venting

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 14 Part Number 550-110-711/1108 Venting — general information 3a CGi-4E venting methods — Chimney draft or Direct exhaust Chimney draft venting Chimney draft venting uses the natural draft provided by a ver - tical vent or chimney. Category I applia...

Page 15 - Venting — Direct exhaust — components; Obtain vent system components

Part Number 550-110-711/1108 15 GOLD CGi-4E 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-1738 and ULC- S636 standards and are certified by CSA as the only systems suitable for us...

Page 16 - Venting — direct exhaust — vent starter

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 16 Part Number 550-110-711/1108 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. 2. You must use the vent starter made by the vent pipe ...

Page 17 - Venting — direct exhaust — termination

Part Number 550-110-711/1108 17 GOLD CGi-4E 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 r...

Page 18 - Venting — direct exhaust — installation

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 18 Part Number 550-110-711/1108 Venting — direct exhaust — installation 3f 1. Do not mix types or manufacturers of vent materi - als. 2. Clean all joints before sealing. See vent manufac - turer’s instructions for cleaning and sealing joints. Use th...

Page 20 - Water piping — general information; General piping information; Pressure/temperature gauge; Circulator

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 20 Part Number 550-110-711/1108 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 bet...

Page 21 - Water piping — single-zone system; type expansion tank; Closed-type expansion tank

Part Number 550-110-711/1108 21 GOLD CGi-4E 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 ...

Page 22 - Piping multiple zones; Piping for radiant heating; Radiant heating systems; Water piping — multiple zones

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 22 Part Number 550-110-711/1108 4c Piping multiple zones Follow instructions on pages 20 and 21 to install near-boiler or single-zone piping. (Also refer to Piping for radiant heating systems or converted gravity sys-tems , below, if applicable.) Se...

Page 24 - Piping — low temperature systems; bypass piping method; Temperature gauges; Valve adjustment

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 24 Part Number 550-110-711/1108 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 syst...

Page 26 - BOILER-bypass piping

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 26 Part Number 550-110-711/1108 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 th...

Page 28 - SYSTEM-bypass piping

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 28 Part Number 550-110-711/1108 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 th...

Page 29 - Prevent chilled water from; Water piping — refrigeration system

Part Number 550-110-711/1108 29 GOLD CGi-4E 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 con...

Page 30 - Gas piping; Connecting gas supply piping to boiler

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 30 Part Number 550-110-711/1108 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...

Page 31 - Field wiring; Thermostat; Electrical installation must; POWER

Part Number 550-110-711/1108 31 GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Field wiring 6 Thermostat 1. Connect thermostat as shown on wiring diagram on boiler. 2. Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunrays, or firep...

Page 32 - Start-up — preparation; Check for gas leaks; Verify water chemistry

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 32 Part Number 550-110-711/1108 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 i...

Page 33 - Inspect system water piping

Part Number 550-110-711/1108 33 GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Fill the system with water 1. Close manual and automatic air vents and boiler drain cock. 2. Fill to correct system pressure. Correct pressure will vary with each application. Typical cold water fill pressure for a re...

Page 34 - Start-up — operate boiler; Start the boiler

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 34 Part Number 550-110-711/1108 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 t...

Page 35 - Check burner flames; Pilot burner flame; Main burner flame

Part Number 550-110-711/1108 35 GOLD CGi-4E 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 fla...

Page 37 - Check-out procedure — checklist; Installation and service certificate

Part Number 550-110-711/1108 37 GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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 l...

Page 38 - Operation — sequence

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 38 Part Number 550-110-711/1108 Operation — sequence 9a 1. Read Operating instructions on page 41. This information is also located on a label on the inside of the boiler jacket door panel. 2. Raise room thermostat to call for heat. 3. Circulator en...

Page 40 - Operation — wiring diagrams

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 40 Part Number 550-110-711/1108 Operation — wiring diagrams 9b Figure 31 Wiring diagram

Page 41 - Operating instructions

Part Number 550-110-711/1108 41 GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 9c Operating instructions • Spark pilot • Natural or propane gas• Gas valve: Honeywell VR8204/VR8304

Page 43 - Service and maintenance — schedule; VERIFY PROPER OPERATION AFTER SERVICING

Part Number 550-110-711/1108 43 GOLD CGi-4E 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 component literature shipped with the boiler. Failure ...

Page 44 - Service and maintenance — annual start-up

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 44 Part Number 550-110-711/1108 Air openings 1. Verify that combustion and ventilation air openings to the boiler room and/or building are open and unobstructed . 2. Verify that boiler vent discharge is clean and free of obstructions . Flue gas vent...

Page 45 - Burners and base; Condensate drain system

Part Number 550-110-711/1108 45 GOLD CGi-4E 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 ...

Page 46 - Limit controls and cutoffs

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 46 Part Number 550-110-711/1108 10b ❏ Check/test . . . Gas piping 1. Sniff near floor and around boiler area for any in - dication of a gas leak . 2. Test gas piping using bubble test, per Section 5 of this manual, if there is any indication of a le...

Page 47 - Cleaning boiler; Boiler relief valve

Part Number 550-110-711/1108 47 GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual ❏ 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 ...

Page 48 - Troubleshooting — general; Air pressure switch; Check pressure switch setting; Troubleshooting air pressure reading; Return to normal operation; Before troubleshooting:

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 48 Part Number 550-110-711/1108 Troubleshooting — general 11a Air pressure switch Make sure boiler water temperature is 100 °F or cooler before starting proce- dure to obtain appropriate readings. The boiler will not operate correctly un- less press...

Page 49 - Troubleshooting — components; Troubleshooting the control module

Part Number 550-110-711/1108 49 GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Troubleshooting — components 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 the boiler...

Page 51 - Troubleshooting — control module lights; CHART 1; — Troubleshooting; light status

Part Number 550-110-711/1108 51 GOLD CGi-4E 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...

Page 52 - CHART 2; lights flashing

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 52 Part Number 550-110-711/1108 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 ...

Page 53 - CHART 3

Part Number 550-110-711/1108 53 GOLD CGi-4E 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 instruction...

Page 54 - CHART 4

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 54 Part Number 550-110-711/1108 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 instruction...

Page 55 - CHART 5; light flashing and; light on steady

Part Number 550-110-711/1108 55 GOLD CGi-4E 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 follo...

Page 56 - CHART 6; ALSO; — Troubleshooting failure to establish; main flame

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 56 Part Number 550-110-711/1108 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 va...

Page 57 - CHART 7; — Insufficient heat or no heat to system (

Part Number 550-110-711/1108 57 GOLD CGi-4E 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...

Page 58 - Replacement parts

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 58 Part Number 550-110-711/1108 Replacement parts 12a Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size and include description and part number of replacement part. Results from...

Page 59 - Replacement parts — section assembly

Part Number 550-110-711/1108 59 GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Replacement parts — section assembly 12b Figure 39 Section assembly Item number Description Weil-McLain part number 1 End section, left hand, 51124 311-103-850 2 End section, right hand 51128 311-103-821 3 Intermediat...

Page 60 - Replacement parts — base

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 60 Part Number 550-110-711/1108 Replacement parts — base 12c Figure 40 Base assembly

Page 62 - Replacement parts — jacket

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 62 Part Number 550-110-711/1108 Replacement parts — jacket 12d Figure 41 Jacket assembly

Page 64 - Replacement parts — trim

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 64 Part Number 550-110-711/1108 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, A...

Page 65 - Replacement parts — controls

Part Number 550-110-711/1108 65 GOLD CGi-4E 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”, two-sta...

Page 66 - Dimensions

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 66 Part Number 550-110-711/1108 Dimensions 13a Figure 44 Dimensional drawing Boiler model number Supply tapping (inches NPT) Return tapping (inches NPT) Gas connection size Note 3 (inches NPT) Gas manifold size Note 3 (inches NPT) “W” Jacket width (...

Page 67 - Ratings; DOE

Part Number 550-110-711/1108 67 GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Ratings Table 10 Boiler ratings 13b CGi-4E boilers for residential radiant panel systems, converted gravity heating systems or other low water temperature applications should be installed with balancing valves and byp...

Page 68 - Handling ceramic fiber and fiberglass materials

68 Part Number 550-110-711/1108 GOLD CGi-4E 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 con- tain ceramic fiber materials. Ceramic fi...