Weil-McLain GOLD CGI 2 SERIES Manual

Gas-fired water boilers gold cgi series 2

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Page 1 GOLD CGi Gas-Fired Water Boilers Series 2 Boiler Manual • Installation • Maintenance • Startup • Parts Before installing This manual must only be used by a qualified heating installer/service technician. , read all instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free air to the boiler area or follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub- stantial property damage.
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 User Read all instructions before in- This manual is for use only by your qualified • stalling . Follow all instructions in heating installer/service technician. proper order to prevent personal User’s Information Manual • Please refer to the for injury or death.
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. The CGi boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z1.13–latest edition.
Page 7: Prepare Boiler Location
GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances Recommended SERVICE clearances Figure 1b Required MINIMUM 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) Flooring The CGi boiler is approved for installation on combustible flooring, but must never be installed on carpeting.
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) — Do not common vent the CGi in a direct exhaust system (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 Chimney or vent require- existing common vent system: ments At the time of removal of an existing boiler, the following 1. Venting must be installed according to Part , steps shall be followed with each appliance remaining con- Venting of Equipment, of National Fuel Gas nected to the common venting system placed in operation, Code, ANSI Z3.1-latest edition and appli- while the other appliances remaining connected to the...
Page 9 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air contamination Table 1 Please review the following information on potential Refer to for products and areas which may cause combustion air contamination problems. contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler. If any of these contaminants are found: • remove contaminants permanently — OR — • isolate boiler and provide outside combustion air. See national, provincial or local codes for further information. Table 1 Corrosive or destructive contaminants and likely locations Products to avoid Areas likely to have contaminants Spray cans containing chloro/fluorocarbons...
Page 10 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings Figure 2 Air openings to interior spaces 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 Unusually tight construction FREE AREA of openings — the minimum areas Unusually tight construction means (per ANSI Z3.1) given in this manual are free area (equals the area, buildings in which: length times width of opening, after deduction for a. Walls and ceilings exposed to the outside atmo- louver obstruction). sphere have a continuous water vapor retarder with Use the free area information provided by the louver manufacturer. a rating of 1 perm or less with openings gasketed, When this information is not available, assume: and . . . • Wood louvers — assume free area is 0% of total; so the actual area b. Weather-stripping has been added on openable of each opening with wood louvers would be 5 times the required windows and doors, and . . .
Page 12 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler — placement & setup Place boiler/crate near Do not operate boiler without burner shield in place. Failure position to do so could result in severe personal injury, death or sub- 1. Leave boiler in crate and on pallet until installation site stantial property damage. is ready. . Move entire crate and pallet next to selected location. 3. Remove crate. Orifice replacement 4. Remove boiler from pallet. procedure Do not drop boiler or bump jacket on (when required) floor or pallet. Damage to boiler can result.
Page 13 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test 5. Slowly reopen boiler drain valve until test pressure on the pressure/temperature gauge reaches no more before Pressure test boiler attaching water or gas piping than: (except as noted below) or electrical supply. 45 psig 30 psig relief valve • for boilers with Prepare boiler for test • 75 psig for boilers with 50 psig relief valve 1. Remove the shipping nipple (from CGi supply tap- Test for no more than 10 minutes at: ping) and remove the boiler relief valve.
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 Direct exhaust — vertical or sidewall Chimney draft venting uses the natural draft provided Direct exhaust venting uses inside combustion air with by a vertical vent or chimney. Category I appliance (non- no combustion air connector piping. All CGi flue gas positive vent static pressure and vent gas temperature vents are pressurized, requiring careful sealing of all that avoids excessive condensate production in vent). joints. Category III appliance (positive vent static pres- See Section . Chimney draft installations use: sure and vent gas temperature that avoids excessive condensate production in vent). See pages 15-19.
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. Saf-T Vent ® StaR-34 • Flex-L International, Inc. Z-Vent II • Z-Flex®, Inc. FasNSeal™ • 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.
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 3. Follow all applicable national, state, local or provin- components needed, based on boiler location and cial codes when venting the CGi boiler. venting method. 4. Connect vent starter to blower housing outlet as . You must use the vent starter made by the vent pipe shown in the Figures 8 through manufacturer. See separate CGi, CGs &...
Page 17 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Venting — direct exhaust — termination Follow instructions on this page 1. Canadian installations — See B149.1 or B149. when determining vent location to Installation Code. Terminate vent no less than 6 avoid possibility of severe personal feet from another combustion air inlet, 3 feet from injury, death or substantial property any other building opening, and 3 feet from any gas damage.
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. Part Number 550-110-710/0107...
Page 19: Venting
GOLD CGi Gas-Fired Water Boiler — Boiler Manual Venting — direct exhaust — installation (cont.) Using any termination other than one of those shown Figure 15 Sidewall termination could cause nuisance outages and loss of heat, resulting in substantial property damage. Part Number 550-110-710/0107...
Page 20: Water Piping
GOLD CGi Gas-Fired Water Boiler — Boiler Manual Water piping — general information General piping information Circulator If installation is to comply with ASME or Canadian requirements, an ad- The circulator is shipped loose (wiring pre-attached to ditional high temperature limit is needed. Install control in supply piping boiler) to allow you to locate it either in the return or between boiler and isolation valve. Set second control to minimum 0°F supply piping, as desired. See page 3 for a typical instal- above setpoint of first control. Maximum allowable setpoint is 40°F. See lation. Pipe the expansion tank to the suction side of the Section for wiring. circulator whenever possible. Install an air separator in low water cutoff device is required when boiler is installed above ra- the supply piping. Connect the expansion tank to the air diation level or by certain state or local codes or insurance companies. Use separator only if the separator is on the suction side of low water cutoff designed for water installations. Electrode probe-type is the circulator. Always install the system fill connection recommended. Purchase and install in tee in supply piping above boiler.
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- Closed-type expansion tank type expansion tank (Figure 16) (Figure 17) 1. Ensure expansion tank size will handle boiler and 1. Ensure expansion tank size will handle boiler and system water volume and temperature. See tank system water volume and temperature. Tank must manufacturer’s instructions for details. be located in boiler return piping as close to boiler . Connect tank to ½” NPT tapping located behind as possible, before inlet side of circulator. See tank supply outlet, using ½” NPT piping. Pitch any manufacturer’s instructions for details.
Page 22 Figure 22 or Figure 23 on page . Do not use the piping of Figure 24 (system-bypass), because this method does not control radiant system supply temperature. If radiant system tubing has no oxygen barrier, a heat exchanger must be used. 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 outdoor reset 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. Part Number 550-110-710/0107...
Page 23 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones (continued) Figure 18 Figure 19 Zoning with circulators Zoning with zone valves — return water 130°F or higher. — return water 130°F or higher. Boiler isolation (balancing) valves Automatic air vent (with diaphragm-type expansion tank), or con- nect to tank fitting (closed-type expansion tank). DO NOT use an automatic air vent when using closed-type expansion tank. It would...
Page 24 DO NOT outdoor apply the methods of this manual if the system is equipped with an reset control. Instead, provide controls and piping which can regulate the boiler re- turn water temperature no less than 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. Part Number 550-110-710/0107...
Page 25 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Figure 20 Figure 21 Primary/secondary piping Primary/secondary piping Zoning with circulators Zoning with zone valves Boiler isolation (balancing) valves Relief valve Automatic air vent (with diaphragm-type expansion tank), or Flow/check valve DO NOT connect to tank fitting (closed-type expansion tank). use an automatic air vent when using closed-type expansion tank. System or zone circulator It would allow air to leave the system, causing waterlogging of the expansion tank. System temperature gauges Fill valve Zone valve...
Page 26: Temperature Gauges
DO NOT outdoor apply the methods of this manual if the system is equipped with an reset control. provide controls and piping regulate the boiler re- Instead, which can turn water temperature no less than 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. Part Number 550-110-710/0107...
Page 27 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Figure 22 Boiler-bypass piping — Zoning with Figure 23 Boiler-bypass piping — Zoning with circulators — (Alternative to primary/ zone valves — (Alternative to primary/ secondary piping Figures 20 and 21) secondary piping Figures 20 and 21) Boiler isolation (balancing) valves Relief valve...
Page 28 DO NOT outdoor apply the methods of this manual if the system is equipped with an reset control. Instead, provide controls and piping which can regulate the boiler re- turn water temperature no less than 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. Part Number 550-110-710/0107...
Page 29 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Figure 24 System-bypass piping — Zoning with zone valve or circulators, return water 130°F or higher — (Alternative to boiler- bypass piping Figures 22 and 23) 3 System or zone circulator 7 System temperature valves (see instructions to the left for adjusting valves)
Page 30: Gas Piping
GOLD CGi Gas-Fired Water Boiler — Boiler Manual Gas piping Connecting gas supply piping to boiler Natural Gas: 1. Remove jacket front panel and refer to Figure 26 to pipe gas to boiler. 1. Refer to Table 7 for pipe length and diameter. Base Install drip leg at inlet of gas connection to boiler. Where local on rated boiler input (divide by 1,000 to obtain cubic utility requires drip leg to be extended to the floor, use appropri- feet per hour). Table 7 is only for gas with specific ate length of pipe between cap and tee. gravity 0.60, with a pressure drop through the Install ground joint union for servicing, when required.
Page 31: Field Wiring
GOLD CGi Gas-Fired Water Boiler — Boiler Manual Field wiring Thermostat turn off electrical power supply at For your safety, service entrance panel before making any electrical 1. Connect thermostat as shown on wiring diagram connections to avoid possible electric shock hazard. on boiler. 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 Determine if water treatment is needed Before starting the boiler, and dur- petroleum-based cleaning or sealing Do not use ing initial operation, smell near the compounds in boiler system. Severe damage to boiler floor and around the boiler for gas will occur, resulting in substantial property damage. odorant or any unusual odor. Do not proceed with start-up if there is Eliminate all system leaks. Continual fresh makeup any indication of a gas leak. Repair water will reduce boiler life. Minerals can build up in any leak at once.
Page 33 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Start-up — preparation (continued) Fill the system with water Inspect system water piping air vents 1. Close manual and automatic and boiler drain cock. After filling the boiler and system with water, inspect all piping throughout the system for leaks. If found, repair Fill to correct system pressure. Correct pressure will vary with each immediately. Repeat this inspection after the boiler has application. Typical cold water fill pressure for a residential system is been started and the system has heated up. 1 psi. Purge air from system: Leaks must be repaired at once. a. Connect a hose to the purge valve (see drain valves, item , in Failure to do so can damage the...
Page 34 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler DO NOT proceed with boiler If you discover evidence of any operation unless boiler and gas leak, shut down the boiler at once. Find the leak source system have been filled with with bubble test and repair water and all instructions immediately. Do not start and procedures of previous boiler again until corrected.
Page 35 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) Check burner flames Figure 28 Typical pilot burner flame 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. . 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.
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? ❏ For multiple zones, adjust flow so it is about the same in each zone. ❏ Automatic air vent, if used, open one full turn? ❏ Air purged from system? ❏ Verify thermostat heat anticipator (if available) set prop- ❏ Field wiring Air purged from gas piping? Piping checked for leaks? erly? Refer to , manual Section , page 31, Thermostat(s) Table 2 ❏ Correctly sized manifold orifices installed? Refer to page 1, to check size and fuel type.
Page 37: Operation
GOLD CGi Gas-Fired Water Boiler — Boiler Manual Operation — sequence Read Operating instructions on page 40. This erator activates and sequence returns to step information is also located on a label on the inside If power is interrupted , control system shuts of the boiler jacket door panel. pilot and main gas valves and restarts at step Raise room thermostat to call for heat. when power is restored. Circulator energizes. 6. In the event the limit control shuts down the If limit circuit is closed, the boiler — The control module closes the pilot and...
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 • Spark pilot • Natural or propane gas CGi-25 to CGi-6 • Gas valve: Honeywell VR8204/VR8304 Part Number 550-110-710/0107...
Page 41 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural or propane gas CGi-25 to CGi-6 • Gas valve: White-Rodgers 36E Part Number 550-110-710/0107...
Page 42 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural or propane gas CGi-25 to CGi-8 • 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 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 Air openings 1. Verify that combustion and ventilation air openings inspected and started annu- The boiler should be to the boiler room and/or building are open and ally , at the beginning of the heating season, only unobstructed by a qualified service technician...
Page 45 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) ❏ Inspect . . . burner inlet while cleaning the burner ports with a wire brush. The vacuum will help to draw any airborne material out of the burner. 4. Reinstall components, starting with the burner tray, then the pilot Burners and base bracket assembly, burner baffle, and air inlet top and front panels. 5. Follow the start-up procedure in the boiler manual. The boiler contains ceramic fiber and fiberglass materials. Use care Condensate drain system when handling these materials per 1. Inspect condensate drain fittings and tubing. Verify that condensate page 68 instructions on...
Page 46 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) ❏ Check/test . . . an out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder Gas piping type. See Section of this manual for suggested best location of expansion tanks and air eliminators. 1. Sniff near floor and around boiler area for any in- gas leak dication of a Open-type — located above highest radiator or baseboard unit, usually in the attic or closet. Has a Test gas piping using bubble test, per Section gauge glass and overflow pipe to a drain.
Page 47 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) ❏ Review with owner reinspected AT LEAST Safety relief valves should be ONCE EVERY THREE YEARS , by a licensed plumb- User’s Information Manual 1. Review the with the ing contractor or authorized inspection agency, to owner. ensure that the product has not been affected by . Emphasize the need to perform the maintenance corrosive water conditions and to ensure that the User’s Information...
Page 48: Troubleshooting
GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure Label all wires prior to disconnection when servicing Check the following: controls. Wiring errors can cause improper and danger- 1. Wire connectors to control module are se- ous operation. curely plugged in at module and originating Never jumper (bypass) rollout thermal fuse element control. or any other device except for momentary testing as . Air pressure switch hoses are properly and Troubleshooting Charts outlined in...
Page 49 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — components (continued) POWER light flashing alone Figure 36 Manometer connections 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). POWER and PRESS SWITCH lights flashing Usually indicates pressure switch is closed when it should not be, or pressure switch failed to close within 5 minutes of inducer starting.
Page 50 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — components (continued) Figure 38 Control module connections Part Number 550-110-710/0107...
Page 51 Have system checked by a licensed electrician. If Replace transformer. problem persists, call your Retest and check for back Boiler should now Replace control module. local Weil-McLain sales feed of voltage from operate normally. representative. Retest. system wiring. Part Number 550-110-710/0107...
Page 52 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) CHART 2 — TSTAT CIRC & POWER lights flashing — Usually indicates 48 VAC on thermostat circuit (stray voltage) — Electrical shock hazard — Wherever you see ▲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 (cont.) CHART 3 — PRESS SWITCH & POWER lights flashing — Usually indicates pressure switch stuck closed or failed to make within 5 minutes — Electrical shock hazard — Wherever you see ▲TURN OFF POWER▲, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
Page 54 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) CHART 4 — FLAME & POWER lights flashing — Usually indicates flame sensed when it shouldn't be there — Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions.
Page 55 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) CHART 5 — PRESS SWITCH light flashing and POWER light on steady — Usually indicates pressure switch opened during run cycle — — May also be caused by wind gusts in excess of 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 (cont.) CHART 6 — FLAME light flashing and POWER light on steady ALSO — Troubleshooting failure to establish main flame Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions.
Page 57: Troubleshooting
GOLD CGi Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) CHART 7 — Insufficient heat or no heat to system (POWER light on steady) Electrical shock hazard — Wherever you see ▲TURN OFF POWER▲, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
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 Boilers and 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 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Replacement parts — base (continued) Weil-McLain Item Description part number Base assembly kit CGi-25 & CGi-3 381-354-337 (includes base panels items 1, 2, 3, 4, 5, 6 CGi-4 381-354-338 and 7) CGi-5...
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 Panel, right side, Panel, top front, Panel, top rear, with insulation with insulation with insulation with insulation Natural Gas Propane Gas Boiler Boiler Model Weil-McLain part number Model CGi-25 (Available at local 381-355-534 381-355-581 381-355-699 381-355-403 381-355-539 CGi-25 CGi-3 supply house)
Page 64 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Replacement parts — trim Figure 42 Trim assembly Item Description Manufacturer Manufacturer’s Weil-McLain number part number part number Pressure relief valve, ASME, 30 PSIG, ¾" male inlet Conbraco 10-407-10 511-546-920 Watts M330 Pressure relief valve, ASME, 30 PSIG, ¾"...
Page 65 GOLD CGi Gas-Fired Water Boiler — Boiler Manual Replacement parts — controls Figure 43 Gas control assembly Item Description Boiler model Manufacturer Manufacturer’s Weil-McLain number part number part number Natural gas components Gas valve, ½" x ½" CGi-25 — CGi-6 Honeywell...
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...
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 REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS The combustion chamber lining or INSTALLATION OF FIBERGLASS WOOL, base insulation panels in this prod- COMBUSTION CHAMBER LINING OR uct contain ceramic fiber materials. Ceramic fibers can be converted to BASE PANELS: cristobalite in very high temperature applications. The International Agency This product contains fiberglass for Research on Cancer (IARC) has...

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Weil-McLain GOLD CGI 2 SERIES Manual

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