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Weil-McLain GOLD CGi-4E Manual

Weil-McLain GOLD CGi-4E Manual

Gas-fired water boiler
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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
Gas-Fired Water Boiler
CGi-4E
™
• Installation
• Maintenance
• Startup
• Parts
Before installing
unless you provide dust-free air to the boiler area or
Part No. 550-110-711/1108
, read all

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Summary of Contents for Weil-McLain GOLD CGi-4E

  • Page 1 ® CGi-4E GOLD ™ Gas-Fired Water Boiler Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualified heating installer/service technician. , read all Before installing instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given.

  • Page 2: How It Works

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.
  • Page 3 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD CGi-4E Gas-Fired Induced-Draft Water Boiler GOLD Part Number 550-110-711/1108...

  • Page 4: Table Of Contents

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Contents How it works ............2–3 Hazard definitions ..........4 Please read before proceeding ......5 Prepare boiler location ........6–11 Prepare boiler ..........12–13 Venting ............14-19 Water piping ..........20-29 Gas piping ............30 Field wiring ............

  • Page 5: Please Read Before Proceeding

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Please read before proceeding Installer User Read all instructions before in- This manual is for use only by your qualified • . Follow all instructions in stalling heating installer/service technician. proper order to prevent personal User’s Information Manual •...

  • Page 6: Prepare Boiler Location

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Prepare boiler location — codes & checklist Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223.1–latest edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1, when required.

  • Page 7: Prepare Boiler Location

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.

  • Page 8: Prepare Boiler

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.
  • Page 9 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.
  • Page 10 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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 ✷...
  • Page 11 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Unusually tight construction FREE AREA of openings — the minimum areas Unusually tight construction means (per ANSI Z223.1) given in this manual are free area (equals the area, buildings in which: length times width of opening, after deduction for a.
  • Page 12 U. S. 2.55 mm (Note 1) 1.60 mm (Note 1) 0-2,000 ft 2,000-4,500 0-2,000 ft 2,000-4,500 Canada 2.55 mm 1.60 mm 1.45 mm Note 1: For elevations above 2,000 feet, contact your local Weil-McLain sales office for details. Part Number 550-110-711/1108...
  • Page 13 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Prepare boiler — pressure test Hydrostatic pressure test 5. Slowly reopen boiler drain valve until test pressure on the pressure/temperature gauge reaches no more Pressure test boiler before attaching water or gas piping than: (except as noted below) or electrical supply.

  • Page 14: Venting

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Venting — general information CGi-4E venting methods — Chimney draft or Direct exhaust Chimney draft venting Direct exhaust — vertical or sidewall Chimney draft venting uses the natural draft provided by a ver- Direct exhaust venting uses inside combustion air with no com- tical vent or chimney.

  • Page 15: Obtain Vent System Components

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Venting — Direct exhaust — components 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 use with CGi-4E boilers (all 3”...
  • Page 16 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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-4E boiler.
  • Page 17 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Venting — direct exhaust — termination Follow instructions on this page 12. Canadian installations — See B149.1 or B149.2 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...
  • Page 18 • 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.

  • Page 19: Venting

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

  • Page 20: Water Piping

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.
  • Page 21 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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)

  • Page 22: Piping Multiple Zones

    . 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.
  • Page 23 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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).

  • Page 24: Temperature Gauges

    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.
  • Page 25 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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).
  • Page 26 130°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.
  • Page 27 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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 28 130°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.

  • Page 29: Water Piping

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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. Table 7 1. Refer to for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtain cubic Install drip leg at inlet of gas connection to boiler.

  • Page 31: Field Wiring

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.

  • Page 32: Start-Up

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.
  • Page 33 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.

  • Page 34: Start The Boiler

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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 im- water and all instructions mediately.
  • Page 35 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.
  • Page 36 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Start-up — if boiler doesn’t start . . . Check for: 1. Loose connections, blown fuse or service switch off? 2. High limit switch set below boiler water tempera- ture? 3. Thermostat set below room temperature? 4.

  • Page 37: Check-Out Procedure - Checklist

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Check-out procedure — checklist ❏ Boiler and heat distribution units filled with water? ❏ Set limit control(s) to system temperature requirements. Adjust balancing valves and controls to provide design ❏ Automatic air vent, if used, open one full turn? temperature to system.
  • Page 38 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Operation — sequence Read Operating instructions If power is interrupted shuts off on page 41. This information is , control system pilot and main gas valves and restarts at step when power is also located on a label on the inside of the boiler jacket door restored.
  • Page 39 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Figure 30 Control module sequence of operation — status light indications Part Number 550-110-711/1108...
  • Page 40 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Operation — wiring diagrams Figure 31 Wiring diagram Part Number 550-110-711/1108...

  • Page 41: C Operating Instructions

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

  • Page 42: Commonwealth Of Massachusetts

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Addendum Instruction for the Commonwealth of Massachusetts This addendum must only be used by a one-half (1/2) inch in size, “GAS VENT DIRECTLY BE- qualified heating installer/service technician. LOW. KEEP CLEAR OF ALL OBSTRUCTIONS.” Read these instructions completely before INSPECTION .

  • Page 43: Service And Maintenance

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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 component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system.

  • Page 44: Air Openings

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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...

  • Page 45: Condensate Drain System

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.

  • Page 46: Expansion Tank

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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.

  • Page 47: Service And Maintenance

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Service & maintenance – annual start-up (cont.) ❏ Review with owner reinspected AT LEAST Safety relief valves should be ONCE EVERYTHREEYEARS , by a licensed plumb- User’s Information Manual 1. Review the with the ing contractor or authorized inspection agency, to owner.

  • Page 48: Troubleshooting

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — general Air pressure switch Label all wires prior to disconnection when Make sure boiler water temperature is servicing controls. Wiring errors can cause improper and dangerous operation. 100 °F or cooler before starting proce- dure to obtain appropriate readings.
  • Page 49 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — components POWER light flashing alone Figure 36 Manometer connections Usually indicates reversed polarity of 120 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 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — components (continued) Figure 38 Control module connections Part Number 550-110-711/1108...
  • Page 51 Does voltmeter indicate 24 VAC? Have system checked by a licensed electrician. If Replace transformer. problem persists, call your Retest and check for back Boiler should now local Weil-McLain sales Replace control module. feed of voltage from operate normally. representative. Retest. system wiring.
  • Page 52 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 55 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 57 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts 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.
  • Page 59 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — section assembly Figure 39 Section assembly Item Description Weil-McLain Item Description Weil-McLain number part number number part number End section, left hand, 51124 311-103-850 Washer, M\zn” (1 per tie rod)
  • Page 60 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — base Figure 40 Base assembly Part Number 550-110-711/1108...
  • Page 61 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — base (continued) Weil-McLain Item Description part number Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6 CGi-4E 381-354-338 and 7) Base side panel (in Base assembly)
  • Page 62 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — jacket Figure 41 Jacket assembly Part Number 550-110-711/1108...
  • Page 63 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — jacket (continued) Panel, left side, Boiler Boiler with insulation Panel, right side, Panel, top front, Panel, top rear, with Model Model Junction box, 2 x 4 with insulation with insulation insulation Natural Gas Propane Gas...
  • Page 64 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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: Replacement Parts

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD 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” , two-state CGi-4E Honeywell...
  • Page 66 CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Dimensions Figure 44 Dimensional drawing Boiler Supply Return “W” model tapping tapping connection size manifold size Jacket number (inches NPT) (inches NPT) Note 3 Note 3 width (inches NPT) (inches NPT) (inches) CGi-4E 1 ¼...
  • Page 67 Vent diameter shown above is for direct exhaust venting. See Table 3, page 14, for vent diameter when chimney draft venting. 5. As an Energy Star Partner, Weil-McLain has determined that the CGi-4E meets the Energy Star guidelines for energy efficiency.

  • Page 68: Handling Ceramic Fiber And Fiberglass Materials

    CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS The combustion chamber lining or base INSTALLATION OF FIBERGLASS WOOL, insulation panels in this product con- COMBUSTION CHAMBER LINING OR tain ceramic fiber materials.

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