Weil-McLain GOLD CGI 550-110-710/0107 User Manual
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Weil-McLain GOLD CGI 550-110-710/0107 User Manual

Weil-McLain GOLD CGI 550-110-710/0107 User Manual

Gas-fired water boilers series 2
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Boiler Manual
This manual must only be used by a qualified heating installer/service technician.
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.
DO NOT USE BOILER DURING CONSTRUCTION
follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub-
stantial property damage.
GOLD CGi
Gas-Fired Water Boilers
Series 2
• Installation
• Startup
unless you provide dust-free air to the boiler area or
• Maintenance
• Parts
Before installing
, read all
Part No. 550-110-710/0107

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Summary of Contents for Weil-McLain GOLD CGI 550-110-710/0107

  • Page 1 Boiler Manual This manual must only be used by a qualified heating installer/service technician. 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. DO NOT USE BOILER DURING CONSTRUCTION follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub- stantial property damage. GOLD CGi Gas-Fired Water Boilers Series 2 • Installation • Startup unless you provide dust-free air to the boiler area or • Maintenance • Parts Before installing , read all Part No.

  • Page 2: How It Works

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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. When room thermostat calls for heat, the control module starts the system circulator and inducer. The control module runs the inducer long enough to purge the boiler flue passages, then opens the pilot valve and activates pilot ignition spark. The control module allows up to 15 seconds to establish pilot flame. If flame is not sensed within 15 seconds, the control module will turn off the gas valve, flash the Flame light, and then enter a 15-second postpurge. The control module will then start a new cycle. This will continue indefinitely until pilot flame is established or power is interrupted. Once pilot flame is proven, the control module opens the gas valve to allow main burner flame. When the room thermostat is satisfied, the control module turns off the gas valve, operates the inducer for a 15-second postpurge and waits for the next heat call. The control module indicator lights show normal sequence when the lights are on steady. When a problem occurs, the control module flashes combinations of lights to indicate the most likely reason for the problem (see page 49). ② Transformer The control transformer reduces line voltage to 4 volts for the gas valve and limit circuit. ③ Inducer The inducer pulls flue gases through the boiler, causing air to be pulled in through the boiler air openings. The inducer pushes the flue gases through the vent pipe as well. ④ Air pressure switch The air pressure switch signals the control module, telling the control module whether the inducer is working correctly or the vent is blocked.
  • Page 3 GOLD CGi Gas-Fired Water Boiler — Boiler Manual GOLD CGi Gas-Fired Induced-Draft Water Boiler Part Number 550-110-710/0107...

  • Page 4: Table Of Contents

    GOLD CGi 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 ... 20-29 5 Gas piping ... 30 6 Field wiring ... 31 7 Start-up ... 32-35 8 Check-out procedure — checklist ..36 9 Operation ...

  • Page 5: Please Read Before Proceeding

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer Read all instructions before in- stalling proper order to prevent personal injury or death. • Consider piping and installation boiler location. claims for damage or shortage in shipment • Any must be filed immediately against the transportation company by the consignee.
  • Page 6 GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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 Z3.1–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. Installation Code, CSA C.1 Canadian Electrical Code Part 1 and any local codes. Before locating the boiler, check the following: • Check for nearby connection to: • System water piping • Venting connections...

  • Page 7: Prepare Boiler Location

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances Recommended SERVICE clearances (Fig. 1a) 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1a for recommen- dations. . Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to provide at least screwdriver clearance, install unions and shutoff valves in system so boiler can be moved for servicing. Figure 1a Recommended SERVICE clearances (see WARNING below) If any clearance is less than in Figure 1a, pro- vide openings for combustion and ventilation air located on the wall or door opposite the boiler FRONT (see Figure 1b)

  • Page 8: Prepare Boiler

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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) Connecting more than one appliance to a direct exhaust system will cause flue gas spillage or appliance malfunc- tion, resulting in possible severe personal injury, death or substantial property damage. When removing boiler from an existing common vent system: At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining con- nected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. Seal any unused openings system.
  • Page 9 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air contamination Please review the following information on potential combustion air contamination problems. Table 1 Corrosive or destructive contaminants and likely locations Products to avoid Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks...
  • Page 10 GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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 . 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.
  • Page 11 GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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. When this information is not available, assume: • Wood louvers — assume free area is 0% of total; so the actual area of each opening with wood louvers would be 5 times the required free area. • Metal louvers — assume free area is 60% of actual area; so, for wood louvers, the actual area of each opening must be 1.6 times the required free area. ✷...
  • Page 12 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler — placement & setup Place boiler/crate near position 1. Leave boiler in crate and on pallet until installation site is ready. . 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. Tilt boiler the other way and place a board under right legs. c. Slide boiler backward off pallet and into position.
  • Page 13 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test before Pressure test boiler (except as noted below) or electrical supply. Prepare boiler for test 1. Remove the shipping nipple (from CGi supply tap- ping) and remove the boiler relief valve. plug the relief valve tapping with a ¾” NPT pipe plug. 2. Remove 1¼” nipple, reducing tee and drain valve from circulator hardware and pressure/temperature gauge carton. Install in boiler return connection as shown on page 3 and circulator on either the return or supply. 3. Remove 1¼” nipple, 1¼” x 1¼” x ½” tee and pres- sure/temperature gauge from circulator hardware and pressure/temperature gauge carton. Pipe to boiler supply connection as shown on page 3 and Figure 42 , page 64. (Use pipe dope sparingly.)

  • Page 14: Venting

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Venting — general information 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- positive vent static pressure and vent gas temperature that avoids excessive condensate production in vent). See Section . Chimney draft installations use: 1. Vent connector (single or doublewall) sized to eliminate positive pressure in vent system. Diameter increases immediately at boiler. . Doublewall metal vent (B-vent) or chimney with liner approved by the National Fuel Gas Code, ANSI Z3.1–latest edition, or in Canada B149.1 or B149. Installation Code.
  • Page 15 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Venting — Direct exhaust — components 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 with CGi boilers (all 3” diameter): • Heat-Fab, Inc. • Flex-L International, Inc. • Z-Flex®, Inc. • ProTech Systems Use only the vent starter of the same manufacturer as the vent components. Do not mix components from different systems. The vent system could fail, causing flue gas spillage, resulting in severe personal injury or death. . Select vent method based on page 14 and installation requirements. Table 4 3. Refer to for maximum vent run lengths and number of elbows.
  • Page 16 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Venting — direct exhaust — vent starter 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 manufacturer. See separate Component Supplement component, listed by vent manufacturer. Use only the vent starter of the same manufacturer as the vent compo- nents. Do not mix components from different systems. The vent system could fail, causing flue gas spillage, resulting in severe personal injury or death.
  • Page 17 GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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 Fig- ure 1 will be met. Also follow vent manufacturer’s instructions. . Gases will form white plume in winter. Plume could obstruct window view. 3. Prevailing winds could cause freezing of condensate and water/ice buildup on vent termination, building, plants or roof. Ice buildup on vent termination can...
  • Page 18 On some installations, the condensate drain fitting may be omitted, provided: • Vent manufacturer shows this option in their instruc- tions. • Vent is sloped toward termination as shown in dotted lines in Figure 14 • The vent is installed per Weil-McLain and vent manufacturer’s instructions. • Condensate drippage from such vents may accumu- late on the ground below. Consider traffic in the area to avoid hazard due to ice accumulation. Figure 13 Direct exhaust vertical venting for vent — See Figure 13 . Follow vent Figures 14 and 15 — See...
  • Page 19 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Venting — direct exhaust — installation Figure 15 Sidewall termination Part Number 550-110-710/0107 Using any termination other than one of those shown could cause nuisance outages and loss of heat, resulting in substantial property damage. (cont.)

  • Page 20: Water Piping

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Water piping — general information 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 boiler and isolation valve. Set second control to minimum 0°F above setpoint of first control. Maximum allowable setpoint is 40°F. See Section for wiring. low water cutoff device is required when boiler is installed above ra- diation level or by certain state or local codes or insurance companies. Use low water cutoff designed for water installations. Electrode probe-type is recommended. Purchase and install in tee in supply piping above boiler. backflow check valve in cold water supply as required by local codes.
  • Page 21 GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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 bladder- type expansion tank 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possible, before inlet side of circulator. See tank manufacturer’s instructions for details. . Install an automatic air vent Use For systems with low return water temperature possible, such as converted gravity systems and radiant heating systems, refer to the special piping suggestions of pages 4-9. 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. Figure 16 Diaphragm- or bladder-type expansion tank — Piping to single-zone system using diaphragm-type or bladder-type expansion tank.
  • Page 22 If radiant system tubing has no oxygen barrier, a exchanger Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature (such as provided by an injection pumping control). Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant. DO NOT apply the methods in this manual if the system is equipped with an control . Instead, provide controls and piping which can regulate the boiler return water temperature at no less than 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property dam- age. Figures 20 or 21 on page 5. This piping de- Figures 20 or 21 cannot be used, use the boiler-bypass Figure 22 or Figure 23 Figure 24 Failure to prevent low return water temperature to the boiler could...
  • Page 23 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones Figure 18 Zoning with circulators — return water 130°F or higher. Boiler isolation (balancing) valves Flow/check valve System or zone circulator Zone valve Drain valve Relief valve Part Number 550-110-710/0107 Figure 19 Automatic air vent (with diaphragm-type expansion tank), or con- nect to tank fitting (closed-type expansion tank). automatic air vent when using closed-type expansion tank. It would allow air to leave the system, causing waterlogging of the expansion tank. Fill valve Diaphragm-type or bladder-type expansion tank, if used (For closed-type expansion tank, pipe from top of air separator to tank...
  • Page 24 DO NOT apply the methods of this manual if the system is equipped with an reset control. Instead, provide controls and piping turn water temperature no less than 130°F Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. required on all systems to assure the return coldest expected water temperature (usually 60°F since the system will often drop to room tempera- ture between cycles).
  • Page 25 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems Figure 20 Primary/secondary piping Zoning with circulators Boiler isolation (balancing) valves Flow/check valve System or zone circulator System temperature gauges Zone valve Drain valve System temperature valves (see instruc- tions to the left for adjusting valves) Blend temperature gauge Part Number 550-110-710/0107 Figure 21 Primary/secondary piping Zoning with zone valves Relief valve Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion tank).

  • Page 26: Temperature Gauges

    DO NOT apply the methods of this manual if the system is equipped with an reset control. provide controls and piping Instead, turn water temperature no less than 130°F Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. installed — using cold or room temperature water reads at least 10°F. is optional on converted gravity systems, required on radiant heating systems — to display...
  • Page 27 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems Figure 22 Boiler-bypass piping — Zoning with circulators — (Alternative to primary/ secondary piping Figures 20 and 21) Boiler isolation (balancing) valves Flow/check valve System or zone circulator System temperature gauges Zone valve Drain valve System temperature valves (see in- structions to the left for adjusting valves) Blend temperature gauge...
  • Page 28 Boiler return water temperature will be adequately controlled using the methods shown system supply temperature in this manual provided the DO NOT apply the methods of this manual if the system is equipped with an reset control. Instead, provide controls and piping turn water temperature no less than 130°F Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. fully closed and fully open. while closing valve the temperature at gauge reads at least 130°F at all times.
  • Page 29 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems Water piping — refrigeration system Figure 25 Piping refrigeration systems Part Number 550-110-710/0107 (continued) Figure 24 System-bypass piping — Zoning with zone valve or circulators, return water 130°F or higher —...

  • Page 30: Gas Piping

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Gas piping Connecting gas supply piping to boiler 1. Remove jacket front panel and refer to Install drip leg at inlet of gas connection to boiler. Where local utility requires drip leg to be extended to the floor, use appropri- ate length of pipe between cap and tee. Install ground joint union for servicing, when required. Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or utility requirements. In Canada — When using manual main shutoff valve, it identified by the installer. Support piping with hangers, not by boiler or its accessories. Purge all air from gas supply piping.

  • Page 31: Field Wiring

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Field wiring turn off electrical power supply at For your safety, 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.

  • Page 32: Start-Up

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Start-up — preparation 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 there is any indication of a gas leak. Repair any leak at once. Propane boilers only pane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade and the gas may no longer have an odor.
  • Page 33 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Fill the system with water air vents 1. Close manual and automatic Fill to correct system pressure. Correct pressure will vary with each application. Typical cold water fill pressure for a residential system is 1 psi. Purge air from system: a. Connect a hose to the purge valve (see drain valves, item suggested piping diagrams on pages 3 through , Figure 23 through ). Route hose to an area where water can drain and be seen. b. Close the boiler or system isolation valve between the purge valve and fill connection to the system. c. Close zone isolation valves. d. Open quick-fill valve on cold water makeup line.
  • Page 34 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler Start the boiler • Follow the Operating instructions to start the boiler. Section 7c • See if boiler fails to start. Check system and boiler Check system piping for leaks. boiler and repair immediately. Vent air from system the system will interfere with circulation and cause heat distribution problems and noise. Inspect vent system deterioration from corrosion, physical damage or sagging. In addition — Check for gas-tight seal at every connection and seam.

  • Page 35: Start-Up

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler Check burner flames View pilot and main flames through the inspection port in the base burner shield. Pilot burner flame ( PROPER pilot flame characteristics 1. Blue flame. . 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. . Underfired — Small flame. Inner cone not engulfing pilot flame sensor. 3. Lack of primary air — Yellow flame tip. 4. Incorrectly heated pilot flame sensor. Main burner flame ( PROPER main burner flame characteristics 1. Yellow-orange streaks may appear (caused by...

  • Page 36: Check-Out Procedure - Checklist

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual 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 1, to check size and fuel type. Correctly sized manifold orifices must be used. Failure to do so will cause severe personal in- jury, death or substantial property damage. ❏ Followed operating instructions on boiler or in manual Section for proper start-up? ❏ Proper burner flame observed? Refer to manual Section ❏...

  • Page 37: Operation

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Operation — sequence Read Operating instructions information is also located on a label on the inside of the boiler jacket door panel. Raise room thermostat to call for heat. Circulator energizes. inducer starts. After pressure switch proves proper airflow, control module initiates 30-second pre- purge. Control module sparks valve in main gas valve. does not a. If pilot is closed and spark generator is turned off. Control module initiates a 15-second postpurge, then starts a new cycle. does b. If pilot light and control module senses flame current, spark generator is turned off and main valve...
  • Page 38 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Operation — wiring diagrams Figure 31 Schematic wiring diagram Part Number 550-110-710/0107...
  • Page 39 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Figure 32 Ladder wiring diagram Part Number 550-110-710/0107...

  • Page 40: C Operating Instructions

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Operating instructions CGi-25 to CGi-6 • Spark pilot • Natural or propane gas • Gas valve: Honeywell VR8204/VR8304 Part Number 550-110-710/0107...
  • Page 41 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Operating instructions CGi-25 to CGi-6 Part Number 550-110-710/0107 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36E...
  • Page 42 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Operating instructions CGi-25 to CGi-8 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36C Part Number 550-110-710/0107...

  • Page 43: Service And Maintenance

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING Table 8 Service and maintenance schedules Part Number 550-110-710/0107 Follow the Service and maintenance procedures given throughout this manual and in com- ponent literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.
  • Page 44 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Service and maintenance — annual start-up The boiler should be ally , at the beginning of the heating season, by a qualified service technician maintenance and care of the boiler designated in Table 8 , page 43, and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and main- tain the boiler and system could result in equipment...
  • Page 45 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up ❏ Inspect . . . Burners and base The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on 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 neces- sary. Failure to replace damaged...
  • Page 46 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up ❏ Check/test . . . Gas piping 1. Sniff near floor and around boiler area for any in- dication of a Test gas piping using bubble test, of this manual, if there is any indication of a leak. Cold fill and operating pressures 1. While the system is cold, note the on the boiler pressure/temperature gauge. Verify that cold fill pressure is correct. Watch the pressure up to ensure pressure rise is normal. Too high a rise would indicate a waterlogged or undersized expan- sion tank.
  • Page 47 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up Safety relief valves should be ONCE EVERY THREE YEARS 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. Certain naturally occurring conditions may corrode the valve or its compo- nents over time, rendering the valve inoperative.

  • Page 48: Troubleshooting

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and danger- ous operation. Never jumper (bypass) rollout thermal fuse element or any other device except for momentary testing as Troubleshooting Charts outlined in injury, death or substantial property damage can re- sult.
  • Page 49 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — components Figure 36 Manometer connections Control module Control indicator lights — LOCKOUT modes See Charts 1 through shooting procedures. To reset control after a lockout, turn off power at the 10 VAC service switch or turn down all thermostats. Wait 45 seconds. Then restore power or call for heat. Part Number 550-110-710/0107 POWER light flashing alone Usually indicates reversed polarity of 10 VAC power wires. POWER and TSTAT CIRC lights flashing Usually indicates stray voltage on external thermostat circuit wires (usually due to miswired 3-wire zone valve).
  • Page 50 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — components Figure 38 Control module connections (continued) Part Number 550-110-710/0107...
  • Page 51 Is POWER light flashing now? Have system checked by a licensed electrician. If problem persists, call your Boiler should now local Weil-McLain sales operate normally. representative. Part Number 550-110-710/0107 • Make sure service switch or circuit breaker is on or fuses are good.
  • Page 52 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights CHART 2 — 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.
  • Page 53 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights 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.
  • Page 54 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights CHART 4 — FLAME & POWER lights flashing — Usually indicates flame sensed when it shouldn't be there — Electrical shock hazard — Wherever you see instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 55 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights 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 31 mph for non-direct vent sidewall-vented boilers — Electrical shock hazard —...
  • Page 56 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights CHART 6 — FLAME light flashing and POWER light on steady Electrical shock hazard — Wherever you see instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 57 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights 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.

  • Page 58: Replacement Parts

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Replacement parts Section assembly ... 59 Base ... 60 Jacket ... 62 Trim ..64 Controls ... 65 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 using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation. Weil-McLain part numbers are found in Controls Repair Parts Lists The boiler contains ceramic fiber and fiberglass materials. Use care when...
  • Page 59 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Replacement parts — section assembly Figure 39 Section assembly Part Number 550-110-710/0107...
  • Page 60 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Replacement parts — base Figure 40 Base assembly Part Number 550-110-710/0107...
  • Page 61 CGi-25 & CGi-3 CGi-25 & CGi-3 CGi-25 & CGi-3 CGi-25 & CGi-3 CGi-25 CGi-3 through -8 CGi-25 CGi-3 through -8 0.38 STP type 23 hx, washer Hd slot (continued) Weil-McLain part number 381-354-337 CGi-4 381-354-338 CGi-5 381-354-339 CGi-6 381-354-340 CGi-7...
  • Page 62 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Replacement parts — jacket Figure 41 Jacket assembly Part Number 550-110-710/0107...
  • Page 63 381-355-566 431-223-328 CGi-7 381-355-573 431-223-329 CGi-8 381-355-580 431-223-330 Part Number 550-110-710/0107 Panel, left side, Panel, right side, with insulation with insulation Propane Gas Weil-McLain part number 381-355-581 381-355-699 381-355-584 381-355-699 381-355-587 381-355-699 381-355-590 431-223-311 381-355-601 431-223-311 381-355-604 431-223-311 381-355-607 431-223-311...
  • Page 64 1¼" NPT — CGi-6 and CGi-7 - - - - - - - - - - - - 1½" NPT — CGi-8 - - - - - - - - - - - - - - - - - Circulator wiring harness kit, with Molex (loose) Manufacturer Manufacturer’s Weil-McLain part number part number Conbraco 10-407-10...

  • Page 65: Replacement Parts

    Part Number 550-110-710/0107 Boiler model Manufacturer Manufacturer’s part number CGi-25 — CGi-6 Honeywell VR8204A2001 White-Rodgers 36E36-266 CGi-7 & CGi-8 Honeywell VR8304M4002 White-Rodgers 36C68-478 Weil-McLain CGi-25 — CGi-6 Honeywell VR8204M2701 White-Rodgers 36E36-291 CGi-7 & CGi-8 Honeywell VR8304M4010 White-Rodgers 36C68-479 Weil-McLain United 1107-1 Technologies...

  • Page 66: Dimensions And Ratings

    GOLD CGi Gas-Fired Water Boiler — Boiler Manual Dimensions Figure 44 Dimensional drawing Part Number 550-110-710/0107...
  • Page 67 4. CGi boilers require special venting, consistent with Category I or III boiler. Use only the vent materials and methods specified in this manual. Vent diameter shown above is for direct exhaust venting. See Table 3, page 14, for vent diameter when chimney draft venting. 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 bypass piping equal to the supply and return size to avoid excessive flue gas condensation due to lower operating water temperatures. For alternate piping, contact your Weil-McLain sales office. CSA design certified for installation on combustible flooring. Tested for 50 psi working pressure. Part Number 550-110-710/0107 2,000–4,500 feet altitude Output...

  • Page 68: Handling Ceramic Fiber And Fiberglass Materials

    GOLD CGi 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 prod- uct contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to...

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