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Weil-McLain GOLD CGI-4E User's Manual

1. Yes Y No Y es l e Replace rollout switch e Replace limit switch Retest Boiler water temperature exceeded setting on limit switch with thermostat calling for heat Boiler is OK See normal sequence of operation Figure 30 page 39 Also check setting on limit switch should be above 140 F Part Number 550 110 711 1108 If rollout thermal fuse element has opened determine cause and correct condition Failure to do so will cause severe personal injury death or substantial property damage e Check any other limit controls wired into the limit circuit If all are OK then replace control module Retest 57 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 12a 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 NOTICE Weil McLain part numbers are found in Weil McLain Boilers and Controls Repair Parts Lists A WARNING The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 68 of this manual Failure to comply could result in severe personal injury Section asse
2. No Yes Boiler should now operate normally Part Number 550 110 711 1108 e Reinstall 120 VAC transformer PRIMARY plug Remove 24 VAC transformer plug Figure 38 Item 5 page 50 on control module Using voltmeter check pins of plug Does voltmeter indicate 24 VAC No Yes Have system checked by a licensed electrician If problem persists call your local Weil McLain sales representative Replace transformer Retest and check for back feed of voltage from System wiring Replace control module Retest 51 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual lle Troubleshooting control module lights cont CHART 2 TSTAT CIRC amp POWER lights flashing Usually indicates 48 VAC on thermostat circuit Stray voltage AWARNING 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 Disconnect the two external wires connected to the boiler thermostat leads two black low voltage leads in J box Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the wires There should NEVER be a voltage reading Did you find a v
3. Boiler Manual 4a General piping information If installation is to comply with ASME or Canadian requirements an ad ditional high temperature limit is needed Install control in supply piping between boiler and isolation valve Set second control to minimum 20 F above setpoint of first control Maximum allowable setpoint is 240 F See Section 9b for wiring A 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 Use backflow check valve in cold water supply as required by local codes Pressure temperature gauge Install pressure temperature gauge in tee on supply piping as shown in drawing on page 3 Relief valve Install relief valve vertically in 34 tapping on side of boiler See Figure 16 or 17 page 21 and the tag attached to the relief valve for manufacturer s instructions To avoid water damage or scalding due to relief valve operation AWARNING Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line to eliminate possibility of severe burns should the valve discharge Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length Dis
4. Part Number 550 110 711 1108 43 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 10b 44 Service and maintenance annual start up The boiler should be inspected and started annu ally at the beginning of the heating season only by a qualified service technician In addition the 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 failure Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Miner als can build up in sections reducing heat transfer overheating cast iron and causing section failure Leaking water may also cause severe property dam age Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death inspect Reported problems Inspect any problems reported by owner and correct before proceeding Boiler area 1 Verify that boiler area is free of any combustible materials gasoline a
5. l l aa manual Section 9c e Look through the pilot inspection port to see if the pilot is burning during the prepurge period first 30 seconds of No Yes Is pilot burning during prepurge period i NO Yes Replace control module Retest Replace gas valve Retest boiler Are FLAME and POWER lights flashing Allow boiler to continue cycling Are FLAME amp POWER lights flashing No Yes No Yes TURN OFF POWER e Boiler may now be Replace control Boiler should now Replace control to boiler at service switch operating module operate normally module OP OSARE diii Retest Original flashing Retest Open main manual gas Perform start up FLAME light valve procedures in caused by gas e Turn on power to boiler boiler manual to Valve not at service switch or verify proper operating properly breaker operation Restart boiler per lighting e See normal instructions sequence of Perform start up operation procedures in boiler Figure 30 manual to verify proper page 39 operation a Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 1 le Troubleshooting control module lights con CHART 5 PRESS SWITCH light flashing and POWER light on steady Usually indicates pressure switch opened during run cycle May also be c
6. Monitor and inspect the system and boiler regularly for leakage Repair any leaks im mediately to prevent possible accumulation of glycol Never use automotive antifreeze or ethylene glycol in the system Using these glycols can lead to hazardous leakage of glycol in the boiler system GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 1 a Prepare boiler location codes amp 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 National Electrical Code For Canada only B149 1 or B149 2 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes NOTICE The CGi 4E boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21 13 latest edition NOTICE Read and follow the special instructions for the Commonwealth of Massachusetts located on page 42 of this manual Before locating the boiler check the following Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power Check area around boiler Remove any combustible materials gasoline and other flammable liquids or other contaminants A WARNING Failure to keep boiler area clear and
7. o _ LIMIT Oo _ TSTAT CIRC POWER Indicator lights Model 1107 1 Integrated Boiler Control pt ED os Power ON Stand by Call for heat cerculsiny bine en c Limit circuit closed Umm QD AUTO IGNITION SYSTEMS us ANSIZ21 20 Manutactuned by UT Electronic Contr 71040 5JO cable to J box Black wires to thermostat circuit White wire to gas valve C Yellow wires to limit control and rollout switch Black gt 120 VAC as Entrance Green m ground UT 2 Chassis Green ps D ground M p White gt 120 VAC N 3 120 VAC IN 2g F 1 my 9 24 VAC 24 VAC from transformer Ground Green 120 VAC HE Black a 120 VACN 6 120 VAC to High voltage to spark electrode 120 VAC to transformer 120 VAC IN 24 VAC control circuits 24 VAC from transformer 120 VAC to inducer motor 120 VAC to circulator Sense wire to flame sensor inducer motor 120 VAC to circulator 8 a Flame sense wire to pilot Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual lle Troubleshooting control module lights CHART 1 Troubleshooting POWER light status Usually indicates reversed 120 VAC polarity if POWER light flashes by itself AWARNING Electrical shock hazard Wherever you see TURN OFF POWER follow the instructions Failure to follow instructions could result in se
8. return water 130 F or higher E ZONE2 a ge ZONE2 oe lt ZONEI lt ZONE1 1 1X X X X1 1 2 5X 2 1 24 3 ES 13 46 13 65 6 Xd HX 6 1 X Xi 1 Emi Alternate A oe Y A 9 10 9 10 Cold 11 7 Cod 0211 R water PX i T water Lied fill x fill L 71020 T E 71021 1 Boiler isolation balancing valves 10 Automatic air vent with diaphragm type expansion tank or con nect to tank fitting closed type expansion tank DO NOT use an 5 Plow checkwalve automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlogging of the expansion tank 3 System or zone circulator 14A E waive 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to tank fitting as in Figure 17 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansion tank regardless of loca 9 Relief valve tion of expansion tank circulator or air separator 5 Zone valve 6 Drain valve A WARNING For systems with possible low return water temperature such as converted gravity systems radiant heating systems and heat pump systems refer to the special piping suggestions of Figures 20 24 as applies Failure to prevent sustained low return water temperature to the boiler could cause corrosion of the boiler sections resulting in severe personal inj
9. 9s js Prepare boiler pressure test Slowly reopen boiler drain valve until test pressure on the pressure temperature gauge reaches no more than 45 psig for boilers with 30 psig relief valve 75 psig for boilers with 50 psig relief valve Test for no more than 10 minutes at 45 psig for boilers with 30 psig relief valve 75 psig for boilers with 50 psig relief valve Do not leave boiler unattended A cold water fill could expand and cause excessive pressure resulting in severe personal injury death or substantial property damage Make sure constant gauge pressure has been main tained throughout test Check for leaks Repair if found Leaks must be repaired at once Failure to do so can damage boiler resulting in substantial property damage Do not use petroleum based clean ing or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Drain and remove fittings l Zs Disconnect fill water hose from water source Drain boiler at drain valve or out hose whichever provides best access to drain Remove hose after draining if used to drain boiler Remove nipples and valves unless they will remain for use in the system piping Remove plug from relief valve tapping See page 20 to replace relief valve 13 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual da Venting general information CGi 4E venting methods Ghimn
10. l t lt t Service technician see following pages for instructions Inspect e Reported problems Boiler area Air openings Flue gas vent system Pilot and main burner flames Water piping Boiler heating surfaces Burners and burner shield Condensate drain system Service e Inducer motor e Oiled bearing circulators Start up e Perform start up per manual Check test Gas piping Cold fill and operating pressures Air vents and air elimination Limit controls and cutoffs Expansion tank Boiler relief valve Review e Review with owner Owner maintenance see CGi User s Information Manual for instructions Monthly Periodically Every 6 months End of season Check boiler area Check air openings Check boiler pressure temperature gauge Check boiler interior piping Check venting system Check air vents Check boiler relief valve Check condensate drain system Check automatic air vents if used Test low water cutoff if used Oil inducer motor Operate relief valve Shut down procedure 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 Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage
11. 2 Inlet pressure required at gas valve inlet Maximum 13 w c Minimum 5 w c e Manifold gas pressure 3 50 w c at high fire 0 90 w c while in low fire at start up 3 Install 10096 lockup gas pressure regulator in supply line if inlet pressure exceeds 13 w c Adjust for 13 w c maximum Propane Gas 1 Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator 2 Adjust propane supply regulator provided by gas supplier for 13 w c maximum pressure 3 Inlet pressure required at gas valve inlet Maximum 13 w c Minimum 11 w c e Manifold gas pressure 10 w c at high fire 3 50 w c while in low fire at start up Figure 26 Gas supply piping D E F1 Manual main shutoff gas valve when required i Ground joint union when required tH T Tee Nipple Cc Cap 71028 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 6 Field wiring For your safety turn off electrical power supply at 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 Wiring must be N E C Class 1 If original rollout thermal fuse element wire as supplied with boiler must be replaced use only type 200 C wire or equivalent If other original wiring as supplied with boiler must be replaced type 105
12. GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 1 le Troubleshooting control module lights con CHART 3 PRESS SWITCH amp POWER lights flashing Usually indicates pressure switch stuck closed or failed to make within 5 minutes AWARNING 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 Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds Thermostat should call for heat and appropriate zone valves open Does inducer motor operate No Yes Wait 45 seconds Does inducer motor operate No Yes 4 R INDUCER plug Figure 38 Item 6 page 50 Me ere module i vis ipic SWITCH liaht flashina Place voltmeter leads across the 120 VAC N and g gt 120 VAC H pins of the INDUCER receptacle left column No center and right column bottom pins Does the voltmeter indicate 120 VAC No Yes l Yes e Try reseating plug in ee pep Boiler should be in e If inducer still does not normal operating work replace inducer Pd AEE l l Are vent or combustion air assembly Observe operation until passages blocked Retest thermostat is satisfied and inducer has completed its post purge e Re
13. or connect to tank fitting closed type expansion tank DO NOT use an automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlogging of the expansion tank 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to tank fitting as in Figure 17 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansion tank regardless of location of expansion tank circulator or air separator 25 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 4d Piping low temperature systems BOILER bypass piping method This piping method Figure 22 or 23 is called a boiler bypass because part of the circulator flow is bypassed around the boiler through valve 7a This method reduces the flow rate throughout the boiler in order to raise the average water temperature in the boiler enough to prevent flue gas condensation Boiler bypass piping is effective for some boilers including the CGi 4E provided the flow rates are adjusted according to the instructions following Figures 22 and 23 are alternative piping suggestions for converted gravity large water content or steam systems or radiant heating system for use when primary secondary piping can t be applied Figure 24 is another alternative using system bypass in place of boiler by
14. 110 711 1108 jus eAmbo 10 7 00Z Sup uogiubi eds aBeyor ui aq ISNU Ju I 1no 01 e 0 sarm uonda xq ua eAmbo Jo anm D SOT Wwnunuru Buu Hooe beyo MOT asn paoe dai aq 1snur a uerdde ay uir parddns se arm peursirio ayy jo Aue JT E Buui Kore OWA Oz L 1essa2au Jr Ajquuasse popid avejday apqea epdod poy jou are sarim peaj Olid Z uum pay abEjoA MO sjuauraambod apo Buuw pla DYA Og 20 10 er2utAcad JEUONEU apo Aue pue I Weg 7310 UZCO V S O epeue g un sjuauradmnbad apoo 20 10 ayeys Teuoreu 13410 Aue puy YTN VST V wie1Beip Bun sappey 10 puaBa JM JJUBPJOJJE UT pa ejsur aq jsnur Sura IV T sg I JAWA SVS HOLOW HIMOTE AVTIH empou jonuto 6 06 40019 euwe L E os EN AT deb HL r 1 mou INYT4 210Jaq 18M0d j22UUDISIG 10ld 4 m sum p Be Javon 1014 yeap 10 funfui asaras asnes A 5 URBS unm z T HJIH UEI pIEZey YIOYS E31 38 3 KG ZAN T i E aJo Ep Kums LINN gl HOLIMS 3 3HivH3diW3L 3 F 3unss3Hd HIY UIM l MM 2 ajou spw 3 al bho Puonppvy 3 ee EN HOLIMS LIMI 341 M Md dIMIL H31VM 11071084 rm o uem E dg 9 E D un e JEMOd 5j a Ms ssaud 2 o ue OWA VZ Sy 3 z 00000 QI JWA DEL Og HOLVTNIHIN Li gu II I 3100813313 mA AN NOLLINSI e E f 101d e J 2 AP H21IMS Es HOL TNJIUII JOWLION 2 pis Wal 191109 H3WHOJSNVHI V M
15. 29 Gas PIPIN amme GO FIeIO MINN asses uuuui E EuERKE NE WMRRRREEXRNUR cR ERRARE RW O Start Up eve GO Check out procedure checklist 37 Operation P Service and maintenance 43 47 Troubleshooting eee eonun nu uuu 48 57 Replacement parts nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 98 65 Dimensions and ratings 22020 222262 66 67 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product R G A CAUTION NOTICE P oO 5 E c rn Indicates presence of hazards that will cause severe personal injury death or substantial property damage Indicates presence of hazards that can cause severe personal injury death or substantial property damage Indicates presence of hazards that will or can cause minor personal injury or property dam age Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Please read before proceeding Installer User Read all instructions before in stalling Follow all instructions in proper order to prevent personal injury or deat
16. C wire or equivalent must be used Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edi tion Electrical installation must comply with 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Wiring connections Boiler is shipped with controls completely wired wires Thermostat 1 Connect thermostat as shown on wiring diagram on boiler 2 Install on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunrays or fireplaces 3 If thermostat has a heat anticipator set heat antici pator in thermostat to match power requirements of equipment connected to it If connected directly to boiler set for 0 1 amps plus gas valve current See information on wiring diagram as shown in Figure 31 page 40 For other devices refer to manu facturer s specifications Wiring diagram on boiler gives setting for control module and gas valve Also see instructions with thermostat Junction Box furnished 1 Connect 120 VAC power wiring as shown in Figure 27 2 Fused disconnect or service switch 15 amp recom mended may be mounted on this box For those installations with local codes which prohibit installa tion of fused disconnect or service switch on boiler install a 2 x 4 cover plate on the boiler junctio
17. CGi 4E Gas Fired Water Boiler Boiler Manual le Prepare boiler location air openings Combustion air opening location and sizing AWARNING requirements depend on the clearances around the boiler Check the boiler placement compared to X Figure la page 7 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 If ANY clearance is less than Figure 1a page 7 you must provide air openings sized and located as shown in Figure 1b page 7 DO NOT apply the sizing and location information shown on page 10 or 11 Air openings must be provided Combustion air and ventilation openings must comply the National Fuel Gas Code ANSI Z223 1 latest edition or applicable local building codes Canadian installations must comply with B149 1 or B149 2 Installation Codes A WARNING Provide adequate combustion and ventilation air to assure proper combustion and reduce the risk of severe personal injury death or substantial property damage caused by flue gas spillage and carbon monoxide emissions Air opening options Two openings Air supply from inside the building xk 1 Ifthe building is of unusually tight construction see definition next page the building must also be provided with air openings directly to the outside sized and located per Figure 3 Figure 4 or Figure 5 2 Buildings of typical construction should provide adequate combustion air f
18. Figure 17 71026 17 UC page 21 TRI TU Water piping refrigeration system Prevent chilled water from entering boiler Figure25 Piping refrigeration systems E t k Safe q Lp xpansion tan Install boiler so that chilled medium is piped in parallel supply with the heating boiler Use appropriate valves to prevent LN pk chilled medium from entering boiler See Figure 25 for url Shut off i le hy sek ae typical installation of balancing valve and check valve If boiler is connected to heating coils located in air han b id dling units where they can be exposed to refrigerated chiller t air use flow control valves or other automatic means to prevent gravity circulation during cooling cycle P Strainer Check Boiler valve System return i Balancing 71027 valve Part Number 550 110 711 1108 a GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Gas piping Connecting gas supply piping to boiler 1 Remove jacket front panel and refer to Figure 26 to pipe gas to boiler a 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 c Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or utility requirements d In Canada When using manual main shutoff
19. 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 Transformer The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit 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 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 Water temperature limit switch The water temperature limit switch turns off the gas valve if the temperature in the boiler goes above its setting The circula tor will continue to run as long as there is a call for heat Boiler circulator The boiler circulator circulates water through the external system piping The circu
20. free of combustible mate rials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service If new boiler will replace existing boiler check for and correct system problems such as System leaks causing oxygen corrosion or section cracks from hard water deposits Incorrectly sized expansion tank Lack of antifreeze in boiler water causing system and boiler to freeze and leak Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual lb 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 2 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 4E boiler is approved for installation on combus tible flooring but must never be installed on carpeting Do not install boiler on carp
21. in good condition Spark gap should be approximately 1 8 Correct any above problems replacing pilot if burner or wiring is damaged Reinstall burner shield to operate boiler for retest after any changes or corrections If none of the above corrects problem then replace the attached to pilot bracket bracket is securely attached to cross tie and there is no corrosion on the parts which would affect the ground path for flame sense Verify that pilot flame rod flame rod ceramic and lead wire from control module to flame rod are in good condition Correct any above problems replacing pilot if burner or wiring is damaged TURN OFF POWER to boiler at service switch or breaker e Check flame signal Detach sense lead from ignition control Figure 38 item 8 page 50 Connect negative lead of MICROAMMETER to control sense terminal Figure 38 item 8 page 50 Connect positive lead of MICROAMMETER to sense wire e DISCONNECT red wire connected to terminal MV of the gas valve Turn on power to boiler and allow to cycle As soon as pilot is burning the MICROAMMETER should read at least 1 0 microamp Is flame signal at least 1 0 microamp No Yes control module and retest 56 e f none of the previous steps including replacing pilot corrects problem then replace the control module reinstall burner shield and retest e If the wiring from the control mo
22. kit includes 1 flange 2 nuts 2 screws 1 gasket 1 NPT CGi 4E Weil McLain 381 354 525 NONU EE MEN E 64 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 12f Figure 43 Gas control assembly Replacement parts controls WAN a NY 1 N NN ROS SA N N AN NN NN NN Y NN X KVA f N ON M HAV MAU M AN WW NN N NS f a 71045 Description Boiler model Manufacturer s Weil McLain part number part number Natural gas components Gas valve 12 x Y two state CGi 4E Honeywell VR820402434 511 044 508 Pilot kit w orifice amp aluminum pilot gas tubing Weil McLain 511 330 080 Propane gas components Gas valve Y x 2 two stage CGi 4E Honeywell VR820402459 511 044 510 om Pilot kit w orifice amp aluminum pilot gas tubing Weil McLain 511 330 081 Natural gas and propane gas components 3 Control module United 1107 1 511 330 090 Technologies not shown not shown Timer harness 1 spliced Weil Mclain McLain 591 391 954 391 954 Air pressure switch 1 36 w c CGi 4E ay NS2 1047 09 511 624 657 60 second timer relay CGi 4E 1912190 510 350 468 not shown Tubing air pressure switch 0 12 I D silicone Lydall red to collector hood 590 317 650 white to transition 590 317 651 The ABB timer relay TS12190 is designed for 90 second delay but operates
23. of expansion tank require at least one automatic air vent preferably lo cated on top of an air eliminator as shown in examples in manual Section 4 If relief valve has tended to weep frequently the ex pansion tank may be waterlogged or undersized Closed type tank tank is most likely water logged Install a tank fitting if not already installed Then check fill level per fitting manufacturer s instructions If fill level is correct check tank size against manufacturer s instructions Replace with a larger tank if necessary Diaphragm or bladder type first check tank size to be sure it is large enough for the system If size 1s too small add additional tank s as neces sary to provide sufficient expansion If tank size is large enough remove tank from system and check charge pressure usually 12 psig for residential ap plications If tank won t hold pressure membrane has been damaged Replace tank Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 10b Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumb 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
24. pilot bracket assembly burner baffle and air inlet top and front panels 5 Follow the start up procedure in the boiler manual Condensate drain system 1 Inspect condensate drain fittings and tubing Verify that condensate can flow freely to drain _I Service Inducer motor 1 With boiler power off place a few drops of S A E 20 motor oil in each of the two oil cups Use only S A E 20 motor oil to lubricate the inducer motor Do not use universal household oils Mo tor could be damaged resulting in possible severe property damage Oiled bearing circulators I The circulator shipped with the CGi 4E boiler is water lubricated No oiling is required 2 Check other circulators in the system Oil any circulators requiring oil following circulator manufacturer s instructions Over oiling will damage the circulator Start up 1 Perform all start up procedures in Section 7 of this manual 2 Verify cold fill pressure is correct and that fill system is working properly 3 Verify antifreeze level if used is at the right concentration and that inhibitor level is correct 4 Check gas piping per manual Sections 5 and 7a verifying no indications of leakage and all piping and connections are in good condition 5 Read the appropriate Operating instructions Section 9c of this manual or on boiler label applying to the boiler 6 Start the boiler following the appropriate Operating instructions Section
25. plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid L1 Eye Irrigate immediately L1 Breathing Fresh air Wm UJEIL fficLAIN 68 REMOVAL OF FIBERGLASS WOOL or INSTALLATION OF FIBERGLASS WOOL COMBUSTION CHAMBER LINING OR BASE PANELS This product contains fiberglass jacket AWARNING insulation and ceramic fiber materi als in combustion chamber lining or base panels in gas fired products Air borne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation Precautionary measures L Avoid breathing fiberglass dust and contact with skin Or eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for fiberglass wool at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommen dations can be found on the NIOSH web site at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this web site Wear long sleeved loose fitting clothing gloves and eye protection Operations such as sawing blowing tear out and spraying may generate airborne fiber concentration requiring additional protection Wash potentially contaminated clothes separately from other
26. the wall or below building extensions such as eaves parapets balconies or decks Failure to com ply could result in severe personal injury death or substantial property damage Figure 12 Vent termination minimum clearances Part Number 550 110 711 1108 Forced air intake If within 10 feet 17 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual of A CAUTION 18 Venting direct exhaust installation 1 Do not mix types or manufacturers of vent materi als 2 Clean all joints before sealing See vent manufac turer s instructions for cleaning and sealing joints Use their specified sealant Do not use screws 3 Install vent pipe with seams on top of vent horizon tal runs Follow requirements in Section 3e for vent termination 4 Maintain minimum 2 clearance from combustible materials to vent pipe 5 Vertical venting See Figure 13 Follow vent manufacturer s instructions for venting through roof Vent pipe must extend through roof flashing jacket or thimble Vent may pass through floor inside wall or concealed space when installed according to vent manufacturer s instructions Sidewall venting See Figures 14 and 15 Vent must terminate at least one foot above anticipated snow line Vent must be termi nated only with Tee or elbow with integral screen Tee may be mounted either vertically or horizontally Elbow and termination c
27. valve it must be identified by the installer 2 Support piping with hangers not by boiler or its accessories 3 Purge all air from gas supply piping 4 Before placing boiler in operation check boiler and its gas connection for leaks a Close manual main shutoff valve during any pressure testing at less than 13 w c b Disconnect boiler and gas valve from gas supply piping dur ing any pressure testing greater than 13 w c heck f leaks with fl AWARNING Do not check for gas leaks with an open flame use bubble test Failure to use bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 5 Use pipe dope compatible with propane gases Apply sparingly only to male threads of pipe joints so that pipe dope does not block gas flow Failure to apply pipe dope as detailed above can result in severe personal injury death or substantial property damage Table 7 Pipe capacity for 0 60 specific gravity natural gas Capacity of pipe for pipe size of Capacity in cubic feet gas per hour 30 Natural Gas 1 Refer to Table 7 for pipe length and diameter Base on rated boiler input divide by 1 000 to obtain cubic feet per hour Table 7 is only for gas with specific gravity 0 60 with a pressure drop through the gas piping of 0 30 w c For additional gas pipe sizing information refer to ANSI Z223 1 or B149 1 or B149 2 for Canadian installations
28. 12 11008 Figure 4 Air from outdoors vertical ducts x a Outside or ventilated attic Each opening free area 1 sq inch per 4 000 Btuh CGi 4E boiler Other appliances i 8 E 1 uu Tor AE SS Ventilated mmm Mem MTM crawl space MO Figure 5 Air from outdoors horizontal ducts X Each opening free area 010 12 co 1 sq inch per 2 000 Btuh A 3 a a CGi 4E z boiler Other O appliances ey w 7 3 Aas 71007 Part Number 550 110 711 1108 GOLD CGi 4E 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 e Wood louvers assume free area is 20 of total so the actual area of each opening with wood louvers would be 5 times the required free area e Metal louvers assume free area is 60 of actual area so for wood louvers the actual area of each opening must be 1 67 times the required free area Single air opening option A single combustion air opening can be used in lieu of the two opening options on page 10 provided Clearances from boiler to walls The boiler must have clearances of at least those shown in Figure la page 7 Opening must be directly to outside The opening must connect directly to the
29. 5 second postpurge Circulator is shut off Boiler is now in the off cycle Repeat steps 1 through 6 several times to verify operation Return the thermostat to normal setting Set thermostat heat anticipator setting as instructed in Figure 31 page 40 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Figure 30 Control module sequence of operation status light indications Steps Call for POWER TSTAT LIMIT PRESS FLAME Timing heat CIRC SWITCH Following step 8 cycle goes back to step 1 l 1 f f f 1 Standby j Waiting for call for heat NO 1 2 Call for heat i Circulator on YES 1 f a 3 Limit circuit uu Limit controls closed YES fy v dr Rollout TFE contacts closed 4 Inducer Inducer turns on YES 1 5 Pressure circuit Pressure switch contacts closed YES A 5 dv f 3b sec Prepurge for 30 seconds 6 dre proven as valve open Pilot remains on YES fi y r y r 15 sec Boiler producing heat 7 Limit cycle lk T Limit circuit open YES A 5 Gas valve closed 8 Flame outage 1 Flame out YES 3 ed ed ed Boiler recycles 9 Thermostat satisfied Circulator off NO ev NE ed f 15 sec Blower postpurge 10 Circulator exercise routine Circulator turns on for 30 seconds if NO ev i 30 sec boiler not operated for 30 days ev or dr ON i OFF If pilot flame is not proven in 15 seconds cont
30. 9c of this manual or on boiler label 45 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 10b 46 Service amp maintenance annual start up on _I Check test Gas piping 1 Sniff near floor and around boiler area for any in dication of a gas leak 2 Test gas piping using bubble test per Section 5 of this manual if there is any indication of a leak Cold fill and operating pressures 1 While the system is cold note the pressure reading on the boiler pressure temperature gauge Verify that cold fill pressure is correct 2 Watch the pressure as the boiler and system heat up to ensure pressure rise is normal Too high a rise would indicate a waterlogged or undersized expan sion tank Air vents and air elimination 1 Inspect automatic air vents if used Also inspect air separators to ensure they are operational 2 The cap must be unscrewed one turn to allow air to escape 3 See Figure 34 If the air vent is leaking remove cap A and briefly push valve B and then release to clean the valve seat 4 Replace cap A by twisting all the way onto valve B and then unscrewing one turn Figure 34 Automatic air vent typical wc a a B 2 Limit controls and cutoffs 1 Inspect and test the boiler limit control Verify op eration by turning control set point below boiler temperature Boiler should cycle off Return dial to original setting 2 Inspect and test
31. C and 24 VAC b Microammeter with a minimum scale range of 0 25 c Continuity checker d U tube manometer Check for 120 VAC minimum 102 VAC to maximum 132 VAC to boiler Make sure thermostat is calling for heat and contacts including appro priate zone controls are closed Check for 24 VAC between thermostat wire nuts and ground Check the following 48 Wire connectors to control module are securely plugged in at module and originating control Air pressure switch hoses are properly and securely plugged in and are not damaged Verify gas supply pressure a With boiler OFF 13 w c maximum natural or propane gas pressure upstream of gas valve b With boiler ON Upstream 5 w c minimum natural gas pres sure or 11 w c propane gas pressure upstream of gas valve Verify gas manifold pressure downstream of gas valve a Natural gas Manifold pressure high fire 3 50 w c Manifold pressure low fire 0 90 w c while in low fire at start up 60 seconds Propane gas Manifold pressure high fire 10 0 w c Manifold pressure low fire 3 50 w c while in low fire at start up 60 seconds If necessary adjust gas pressure on the gas valve as shown below After adjustments refer to page 35 to check the flame Honeywell VR8204Q two stage gas valve Troubleshooting general Air pressure switch Make sure boiler water temperature is 100 F or cooler before starting proce dure to obtai
32. POWER follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage e Is pilot flame visible through inspection port Yes e Check the voltage across Make sure ground wire terminals PV and C of the terminal is securely fastened gas valve to control module mounting Is 24 VAC present there Screw If the wiring from the Check the voltage across control module to gas terminals MV and C of the valve is intact replace the gas valve control module Is 24 VAC present there Retest 4 No TES l to boiler at service switch or breaker Remove burner shield see Figure 40 item 4 page 60 Contact gas supplier to correct pressure or gas supply Verify inlet gas pressure at gas valve Natural gas 5 0 w c min 14 0 w c max Propane 11 0 w c min 14 0 w c max Is gas present at gas valve inlet and within above range q No Yes for location TURN OFF POWER Y to boiler at service switch or Verify pilot gas line is not breaker kinked obstructed or Remove burner shield see damaged and is correctly Figure 40 item 4 page 60 for l attached to pilot and gas location valve Verify pilot ignition electrode e Verify pilot burner is securely electrode ceramic and spark lead wire from control are
33. Part Number 550 110 711 1108 zi GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 16 od Venting direct exhaust vent starter 1 Selecta vent pipe manufacturer and obtain all vent components needed based on boiler location and venting method 2 Youmust use the vent starter made by the vent pipe manufacturer See separate Vent Supplement for part number of each component listed by vent manufacturer Use only the vent starter of the same A WARNING 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 Band clamp Figure 8 FasNSeal FasNSeal m ventstarter Band clamp Band clamp strap screw Blower housing outlet Com 71009 Tighten Figure 9 position Z Vent Il Feed position vent starter Z Vent Il starter Band clamp Band clamp en strap 35 Bead of sealant Blower housing outlet rp Gr 71010 Follow all applicable national state local or provin cial codes when venting the CGi 4E boiler Connect vent starter to blower housing outlet as shown in the Figures 8 through 11 a Do not mix components from different vent manufacturers b Maintain minimum 2 clearance from com bustible materials to vent pipe c Seal with sealant specified by vent pipe manufacturer using bead not required for FasNSeal
34. SUELE gox EN TS with insulation with insulation insulation Natural Natural Gas Propane Gas Gas Available at local 381 355 610 381 355 612 381 355 613 381 355 413 381 355 551 CGi 4E supply house PENE Boiler Boiler Model Ed DE Cross tie Panel interior Panel rear Not shown gold Model bottom front with insulation with insulation touch up paint CGi 4E 381 355 611 431 223 326 381 355 415 431 223 301 592 000 000 CGi 4E 63 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 12e Replacement parts trim Figure 42 Trim assembly Pressure relief valve ASME 30 PSIG 34 male inlet Conbraco 10 407 10 Watts M330 Pressure relief valve ASME 30 PSIG 34 female inlet Conbraco 10 408 05 Fittings shown are factory installed on boiler Watts 335 Combination pressure temperature gauge 3 diameter Weil McLain short shank Fittings shown are shipped loose with boiler Drain valve 34 Conbraco 31 606 01 Fittings shown are included with boiler Hammond 710 Valve Matco Norca 205F04 Watts BD 2C 511 546 920 511 546 924 380 000 000 911 210 423 511 246 392 911 246 392 511 246 392 Circulator Bell amp Gossett NRF 22 103253 511 405 118 C l MENMG shown are shipped loose with boiler Taco 007 511 405 113 5 Circulator Circulator gasket universal 2 per boile universal 2 per boiler Weil McLain 590 317 535 990 317 535 Circulator hardware
35. additional limit controls or low water cutoffs installed on system Expansion tank 1 Expansion tanks provide space for water to move in 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 type See Section 4 of this manual for suggested best location of expansion tanks and air eliminators Open type located above highest radiator or baseboard unit usually in the attic or closet Has a gauge glass and overflow pipe to a drain Closed type welded gas tight and located above boiler Tank is partially filled with water leaving an air cushion for expansion Make sure this type of tank is fitted with a tank fitting such as the B amp G Tank Trol or Taco Taco Trol This fitting reduces gravity circula tion of air saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the sys tem Do not use automatic air vents in systems with closed type tanks The air will escape from the system instead of returning to the tank Eventually the tank will waterlog and no longer control pressurization The boiler relief valve will weep frequently Diaphragm or bladder type welded gas tight with a rubber membrane to separate the tank pres surizing air and the water May be located at any point in the system but most often found near the boiler Systems with this type
36. al supply to circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water Boiler water Do not use petroleum based cleaning or sealing compounds in boiler system Water seal deterioration will occur causing leakage between sections This can result in substantial property damage Do not use homemade cures or boiler patent medicines Serious damage to boiler personnel and or property may result Part Number 550 110 711 1108 boiler life Mineral buildup in sections re duces heat transfer overheats cast iron and causes section failure Addition of oxygen and other gases can cause internal corrosion Leaks in boiler or piping must be repaired at once to prevent makeup water Do not add cold water to hot boiler Thermal shock can cause sections to crack Glycol potential fire hazard All glycol is flammable when exposed to high temperatures If glycol is allowed to accumulate in or around the boiler or any other potential ignition source a fire can develop In order to prevent potential severe personal injury death or substantial property damage from fire and or structural damage Never store glycol of any kind near the boiler or any potential ignition source
37. all a qualified service technician to inspect the appliance floor because some gas is heavier than air and will and to replace any part of the control system and any gas control settle on the floor See below which has been under water WHAT TO DO IF YOU SMELL GAS Do nottry to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building Ifyoucannot reach your gas supplier call the fire department OPERATING INSTRUCTIONS IN STOP Read the safety information above on this label Set the thermostat to lowest setting Honeywell VR8204 or Turn off all electrical power to the appliance VR8304 THES Remove jacket front panel Gas valve i This appliance is equipped with an ignition device which automatically lights the Position indicat burner Do not try to light the burner by hand seat eccl Turn Gas control knob clockwise vw to OFF Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Turn Gas control knob counterclockwise v to ON Turn on all electric power to the appliance Pen 40 Set thermostat to desired setting Gas valve 11 If the appliance will not operate follow the instructions TO TURN OFF GAS TO Position indicato
38. anSSaHd wy NOLLO3S HJIH am Buiuado jaxoer ZN IVA OZ L apis Ya sapag pay i J TION xog UONDUNP papmosd you sway 3e iiec LJ i TOULN l YOLOW HIINONI ap JEg RIS uaig ewuM oelg s sinu aai Fuen fiu SUONEJUALO SUONEIO US d Pans 3 om 1U I snes pue 10 38UU07 i gt punog Loe paudde 18mod ynoyym UMOYS SJJELUOI IY CS 2 ARR SNIHIM 1 v HOLIMS aj10q a aKo JOU pue pasamod uaym zz HOLIMS V ite OSERE 391438 1461 YIMOd Ul usej mm jozuo2 passaras ED AWA DEL JJIAHIS j Nad ez a ddp si Ajuejod Ji 28 od BYA oz Buuoau P Opug Opennan WHO WwiSOWHSAL puge jenneN 1046 vaoz 94101 BMNSUAS LRJOG si anpow ouo ay 40 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Oc Operating instructions spark pilot Natural or propane gas e Gas valve Honeywell VR8204 VR8304 NNN FOR YOUR SAFETY READ BEFORE OPERATING EE This appliance does not have a pilot It is equipped C Use only your hand to turn the gas control knob Never use tools If the with an ignition device which automatically lights knob will not turn by hand don t try to repair it call a qualified service the burner Do not try to light the burner by hand technician Force or attempted repair may result in a fire or explosion BEFORE OPERATING smell all around the D Do not use this appliance if any part has been under water appliance area for gas Be sure to smell next to the Immediately c
39. and should go off when controls are tested When 4 Check manifold gas pressure by connecting manometer to controls are restored burners should reignite downstream test tapping on main gas valve Manifold pres RE ET sure for natural gas should be 3 5 w c and for propane gas 5 y y i should be 10 w c a Connect manometer to outlet side of gas valve b Start boiler allowing for normal start up cycle to oc L Observe several operating cycles for proper operation cur and main burners to ignite 4 Set room thermostat to desired room temperature c With main burners on manually shut off gas supply at m l l manual main shutoff gas valve Burners should go off Fill in Installation and service certificate below d Open manual main shutoff gas valve Manometer 4 Review all instructions shipped with this boiler with owner or maintenance person Return instructions to envelope and give to owner or place in pocket inside front panel in boiler Installation and service certificate Boiler model Series CP number Date installed Installation instructions have been followed Check out sequence has been performed Above information is certified to be correct Information received and left with owner maintenance person Measured Btuh input Installer address phone company Installer s signature 37 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 38 9a Read Operating instructions o
40. apacity ratings content efficiency Btuh Input Output Btuh gallons A EU E Btuh Btuh Btuh Btuh CGi 4E 76 000 90 000 76 000 81 000 68 400 66 000 J Note 5 1 Add PIN for natural gas boiler PIL for propane gas boiler 2 Based on standard test procedures prescribed by the United States Department of Energy 3 Net I B H ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 An additional allowance should be made for unusual piping and pickup loads CGi 4E 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 As an Energy Star Partner Weil McLain has determined that the CGi 4E meets the Energy Star guidelines for energy efficiency NOTICE CGi 4E boilers for residential radiant panel systems converted gravity heating systems or other low water temperature applications should be installed with balancing valves and 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 comb
41. ation procedures of Sec tion 7 have been complet ed Start the boiler Follow the Operating instructions from Section 9c to start the boiler See Section 7c if boiler fails to start Check system and boiler LR Check system piping for leaks If found shut down boiler and repair immediately Vent air from system using manual vents Air in the system will interfere with circulation and cause heat distribution problems and noise Inspect vent system thoroughly for signs of deterioration from corrosion physical damage or sagging In addition Check for gas tight seal at every connection and seam If you discover evidence of any gas leak shut down the boiler at once Find the leak source with bubble test and repair im mediately Do not start boiler again until corrected Failure to comply could result in se vere personal injury death or substantial property damage Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reduc ing heat transfer overheating cast iron and causing section failure Glycol or antifreeze leaks around the boiler may result in fire causing severe personal injury death or substantial property damage Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will Occur resulting in substantial property damage Venting system must be sealed gas tight to prevent flue
42. aused by wind gusts in excess of 31 mph for non direct vent sidewall vented boilers AWARNING 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 Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds e Thermostat should call for heat and appropriate zone valves open Does blower motor operate No Yes l l Remove INDUCER plug Figure 38 Item 6 page 50 from plug receptacle of control module Place voltmeter leads across the 120 VAC N and Wait 5 minutes 120 VAC H pins of the INDUCER receptacle left column Is PRESS SWITCH light flashing center and right column bottom pins Does the voltmeter indicate 120 VAC No Yes No Yes l e Replace inducer assembly e Boiler should be in Retest normal operating sequence e Observe operation until Remove one of the wires connected to the pressure thermostat is satisfied switch and inducer has Check continuity across the switch terminals completed its post EN 24 purge cycle Does the ohmmeter indicate the switch is closed No Yes Inspect and check wire levant blocked harness from
43. charge line must pitch downward from the valve and terminate at least 6 above the floor drain where any discharge will be clearly visible The discharge line shall terminate plain not threaded with a mate rial serviceable for temperatures of 375 F or greater Do not pipe the discharge to any place where freezing could occur No shutoff valve shall be installed between the relief valve and boiler or in the discharge line Do not plug or place any obstruction in the discharge line Failure to comply with the above guidelines could result in failure of the relief valve to operate resulting in possibility of severe personal injury death or substantial property damage Test the operation of the valve after filling and pressurizing system by lifting the lever Make sure the valve discharges freely If the valve fails to operate correctly replace it with a new relief valve 20 Water piping general information Circulator The circulator is shipped loose wiring pre attached to boiler to allow you to locate it either in the return or supply piping as desired See page 3 for a typical instal lation Pipe the expansion tank to the suction side of the circulator whenever possible Install an air separator in the supply piping Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator Always install the system fill connection at the same point as the expansion tank con
44. ck insulation Remove collector box transition assembly Clean sealant from assembly and sections Remove radiation plates hanging between sections Remove burners from base Brush and vacuum burners to remove all dust and lint Verify that all burner ports are free of debris Place newspapers in base of boiler to collect soot Clean between sections with wire flue brush Remove newspaper and soot Vacuum or brush base and surrounding area Reinstall radiation plates Replace collector box transition assembly Seal with seal ant Obtain gas tight seal to prevent flue gas spillage and carbon monoxide emissions resulting in severe personal injury or death Replace insulation and jacket top panel Start up boiler following Section 7 pages 32 35 of this manual and the boiler Operating instructions Excessive sooting indicates improper gas combustion If found check for proper combustion and make any necessary adjustments 47 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual lla Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Never jumper bypass rollout thermal fuse ele ment or any other device except for momentary testing as outlined in Troubleshooting Charts Severe personal injury death or substantial property damage can result Before troubleshooting p Have the following items a Voltmeter that can check 120 VA
45. clothing Rinse clothes washer thoroughly NIOSH stated First Aid L1 Eye Irrigate immediately L1 Breathing Fresh air Weil McLain 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com Part Number 550 110 711 1108
46. condensate drain line Figure 14 Direct exhaust sidewall venting Horizontal drain tee Follow vent manufacturer s instructions to install condensate drain line j rr el TE A 17 Optional downward x a 4 Slope without drain v I fitting where allowed h byvent manufacturer e I as explained in GAUTION at left Follow vent manufacturer s instructions for proper installation of vent runs including slope support and condensate drainage _ CJ C L x zi Be Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Sf Venting direct exhaust installation on Figure 15 Sidewall termination AW ARNING Using any termination other than one of those shown could cause nuisance outages and loss of heat resulting in substantial property damage Termination elbow or tee Elbow and termination coupling with screen e mu 2 am ae o Termination elbow or tee Elbow and termination coupling with screen t I EH NI Sealant te bee Termination coupling not available cr E tc e alm o Note 1 Note 1 DO NOT use horizontal tee with CGi 7 or CGi 8 Termination elbow or tee Elbow and termination Note 1 DO NOT use horizontal tee with CGi 7 or CGi 8 coupling with screen Pipe section H j o lt z pa Q 3 et 3 Note 1 71017 19 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler
47. control module to pressure switch No Yes Reseat connector in control module receptacle e f harness is intact and properly seated but problem persists replace Check air pressure switch per manual Section 11a Clear vent and recycle boiler control module Replace if necessary Retest Recheck boiler operation Retest 55 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual lle Troubleshooting control module lights con CHART 6 FLAME light flashing and POWER light on steady ALSO Troubleshooting failure to establish main flame Are main manual shutoff valve and boiler gas valve open No Yes ATURN OFF POWER A to boiler at service switch or breaker Open main manual shutoff valve and boiler gas valve per Operating instructions in this manual Wait at least 45 seconds Turn on power at service switch or breaker Allow boiler to cycle Does FLAME ight flash now No Yes Y e Verify inlet gas pressure at gas valve Natural gas 5 0 w c min 14 0 W C max Boiler should be in normal operating sequence Observe operation until thermostat is satisfied and blower has completed its post purge cycle Propane 11 0 w c min 14 0 W C max Is gas present at gas valve inlet and within above range Yes No TURN OFF POWER Electrical shock hazard Wherever you see TURN OFF
48. culation during cooling cycle Circulation of cold water through the boiler could result in damage to the heat exchanger causing possible severe personal injury death or substantial property damage Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Ab Water piping single zone system A CAUTION 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 Figure 16 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 2 Install an automatic air vent as shown Closed type expansion tank Figure 17 1 Ensure expansion tank size will handle boiler and system water volume and temperature See tank manufacturer s instructions for details 2 Connect tank to 12 NPT tapping located behind supply outlet using NPT piping Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping A WARNING Use Figure 16 or Figure 17 only for single zone systems designed for return water at least 130 F For systems with low return water temperature possible such as converted gravity systems and radiant heating systems refer to the special piping su
49. d Tighten strap at band clamp screw until strap is snug around blower housing Saf T Vent starter Figure 10 Saf T Vent vent starter Band clamp screw 38 Bead of sealant Blower housing outlet 71011 StaR 34 Figure 11 starter StaR 34 Band clamp vent starter screw 3 8 Bead of sealant Blower housing outlet 71012 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 9e Venting direct exhaust termination 10 11 Follow instructions on this page when determining vent location to avold possibility of severe personal injury death or substantial property damage Locate the boiler and vent penetration through the wall so all requirements on this page and in Fig ure 12 will be met Also follow vent manufacturer s instructions Gases will form white plume in winter Plume could obstruct window view Prevailing winds could cause freezing of condensate and water ice buildup on vent termination building plants or roof Ice buildup on vent termination can cause boiler shutdown and building freeze up Winds over 40 mph can cause nuisance boiler shut down if boiler is sidewall vented This could result in loss of heat to building causing freeze up Locate or guard vent termination to prevent con densate from damaging exterior surfaces Locate the vent termination well away from trees shrubs and decorative items Locate or guard
50. d the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufac turer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the follow ing requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall in clude a parts list and detailed installation instructions e Acopy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 10a Service and maintenance schedule VERIFY PROPER OPERATION AFTER SERVICING Table 8 Service and maintenance schedules a 7 cc t o
51. dule to gas valve is intact replace the control module and retest gt Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual lle 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 e Has it been at least 5 minutes since setting thermostat to call for heat If not wait 5 minutes Is system heating e Is thermostat set to call for heat Remove thermostat wires at boiler and check continuity across the two wires If circuit isn t closed check external thermostat zone valve relay etc wiring Correct problems and retry e Reconnect external thermostat wiring at boiler Is thermostat circuit closed continuity across wires No Are all red lights off No Yes gt Is boiler System circulator operating No Yes Y Yes Boiler is in standby Wait 30 seconds Are all red lights off No Yes e Set thermostat to call for heat and recheck operation Verify Sequence of operation Figure 30 Retest Replace control module page 39 If you have sufficient heat boi
52. e 7b regulates the boiler flow rate 4 The boiler mounted temperature pressure gauge may be used in place of a separate gauge 8 Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injec tion 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 of this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the boiler re turn 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 damage 20 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 4d Piping low temperature systems continued Figure 22 Boiler bypass piping Zoning with Figure 23 A Boiler bypass piping Zo
53. e building Turn on clothes dryers and any when required by local state provincial and appliance not connected to the common venting system national codes laws regulations and ordinances Turn on any exhaust fans such as range hoods and Vitreous tile linings with joints that prevent bathroom exhausts SO they will operate at maximum retention of moisture and linings made of non speed Do not operate a summer exhaust fan Close corrosive materials are best Advice for flue con fireplace dampers nections and chimney linings can be obtained d Place in operation the appliance being inspected from local gas utility Type B double wall metal Follow the lighting operating instructions Adjust vent pipe or single wall vent pipe may be used thermostat so appliance will operate continuously as a liner e Test for spillage at draft hood relief opening after 5 4 Cold masonry chimneys also known as outside minutes of main burner operation Use the flame of a chimneys typically have one or more walls ex match or candle posed to outside air When any atmospheric gas fired boiler with automatic vent damper is vented through this type of chimney the potential exists for condensation to occur Con densation can damage a masonry chimney Weil McLain recommends the following to prevent possible damage f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above re
54. el Smell near the floor for the gas odorant or any unusual odor If you suspect a leak do not attempt to light the pilot Use caution when attempting to light the propane pilot This should be done by a qualified service technician particularly if pilot outages are common Periodically check the odorant level of your gas Inspect boiler and system at least yearly to make sure all gas piping is leak tight Consult your propane supplier regarding installation of a gas leak detector There are some products on the market intended for this purpose Your supplier may be able to suggest an appro priate device 32 Wa Start up preparation Determine if water treatment is needed A DANGER Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Eliminate all system leaks Continual fresh makeup AWARNING eee water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure Verify water chemistry Consult local water treatment companies for unusually hard water areas above 7 grains hardness or low pH water conditions below 7 0 Boiler water pH of 7 0 to 8 5 is recommended Freeze protection when used Use antifreeze made especially for hydronic systems Inhibited propylene glycol is recommended Do not use ethylene glycol automo
55. eting even If any clearance is less than in Figure 1a pro AWARNING E A WARNING vide openings for combustion and ventilation if foundation is used opi can un air located on the wall or door opposite the causing severe personal injury deat boiler FRONT see Figure 1b or substantial property damage These openings must be located as shown in Figure 1b to provide proper air flow around the boiler The free area of each opening Foundation after deducting for louvers must be at least one square inch per 1 000 Btuh of boiler input If the building is of unusually tight 1 Provide a solid brick or minimum 2 inch thick concrete construction see page 11 for definition the air openings must foundation pad if any of the following is true connect directly to outside or the building must have air openings to the outside as specified on page 11 floor can become flooded the boiler mounting area is not level If clearances are equal to or greater than Figure la see pages 10 and 11 for location and sizing of combustion air openings 2 Minimum dimensions are 25 length by Failure to comply can result in severe personal injury death or substantial property damage and reduced boiler life Minimum foundation width Required MINIMUM clearances Fig 1b AWARNING Never install the boiler in a space with clear Residential garage installations ances less than the minimum clearances shown in Figure 1b Failure to comply can re
56. ey draft or Direct exhaust Chimney draft venting Chimney draft venting uses the natural draft provided by a ver tical vent or chimney Category I appliance non positive vent static pressure and vent gas temperature that avoids excessive condensate production in vent See Section 3b Chimney draft installations use 1 Vent connector single or doublewall sized to eliminate posi tive pressure in vent system Diameter increases immediately at boiler 2 Doublewall metal vent B vent or chimney with liner ap proved by the National Fuel Gas Code ANSI Z223 1 latest edition or in Canada B149 1 or B149 2 Installation Code 9b Table 3 Boiler D Minimum V model vent connector Penne number diameter diameter CGi 4E Figure 7 Chimnney Chimney draft venting Cleanout 71008 14 Direct exhaust vertical or sidewall Direct exhaust venting uses inside combustion air with no com bustion air connector piping The CGi 4E flue gas vent is pressur ized requiring careful sealing of all joints Category III appliance positive vent static pressure and vent gas temperature that avoids excessive condensate production in vent See pages 15 19 Direct exhaust installations use 1 Vent pipe specified in this manual 2 Vent termination through outside wall roof or unused chim ney Tight chimney areas will make vent joint construction very difficult Venting chimney draft venting Inspect existing ch
57. for 60 seconds in the CGi 4E boiler Part Number 550 110 711 1108 a GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 1 oa Dimensions Figure 44 Dimensional drawing 1 Supply piping note 7 6 Gas supply piping 2 Return piping note 1 7 Drain valve re j 3 Relief valve 34 NPT 8 Gas supply entrance right or left side 4 1 NPT to expansion tank air vent 9 Pressure temperature gauge 5 3 Diameter vent Mote 1 Boiler supply and return tappings are both 114 NPT See Table 6 page 20 for recommended system sup ply and return piping sizes Top VIEW Note2 Boiler circulator is shipped loose Circulator may be mounted on either boiler supply or return piping Circulator flange provided with boiler is same size as recommended pipe size in Table 6 page 20 ALL DIMENSIONS IN INCHES i 23 1 71046 LEFT SIDE FRONT RIGHT SIDE Boiler Supply Return Gas 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 Gas piping from meter to boiler to be sized per local utility requirements ze Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 1 3b Ratings DOE ENERGY STAR Note 5 Table 10 Boiler ratings 0 2 000 feet 2 000 4 500 feet Net Boiler DOE model Heating altitude altitude I B R water Seasonal number c
58. gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check around the boiler for gas odor following the procedure of Section 7a of this manual Verify operation per Section 7b Perform check out procedure in Section 8 and fill in the Installation and service certificate on the same page Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 1b Start up operate boiler Continues Check burner flames View pilot and main flames through the inspection port in the base burner shield Pilot burner flame Figure 28 PROPER pilot flame characteristics 1 Blue flame 2 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 2 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 Figure 29 PROPER main burner flame characteristics 1 Yellow orange streaks may appear caused by dust NOTE The CGi 4E will operate at low fire for the first 60 seconds IMPROPER main burner flame characteristics 1 Overfired Large flames 2 Underfired Small flames 3 Lack of primary air Yellow tipping on flames sooting will occur Part Number 550 110 711 1108 F
59. ggestions of pages 24 29 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 See Table 6 for piping sizes Cold From water system fill To DIAPHRAGM expansion tank valve pr Isolation valve Relief To system valve Circulator Automatic air vent Alternate Circulator location 71018 Part Number 550 110 711 1108 Figure 17 Closed type expansion tank Piping to single zone system using closed type expansion tank See Table 6 for piping sizes CLOSED type expansion tank a From Cold water fill system Isolati y Isolation n aa valve valve X To system Relief valve Circulator EL ez a I Circulator Alternate 11 location pem E mu L 71018 21 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual c Water piping multiple zones Piping multiple zones Follow instructions on pages 20 and 21 to install near boiler or single zone piping Also refer to Piping for radiant heating systems or converted gravity sys tems below if applicable See Figure 18 or Figure 19 to complete installation Zoning with circulators Figure 18 return temp over 130 F 1 Size eac
60. h This manual is for use only by your qualified heating installer service technician Please refer to the User s Information Manual for os our reference Consider piping and installation when determining boiler location We recommend regular service by a qualified service technician at least annually Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 68 of this manual Failure to comply could result in severe personal injury When calling or writing about the boiler Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket You may list the CP number in the space provided on the Installation and service certificate found on page 37 Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial property damage When servicing boiler Continual fresh makeup water will reduce To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electric
61. h circulator to individual circuit require ments 2 Do not install circulator on boiler except for pri mary secondary piping 3 Install isolation balancing valves to adjust flow to distribute heat to all zones 4 Install and wire a separate relay for each zone cir culator Zoning with zone valves Figure 19 return temp over 130 F 1 Install isolation balancing valves to adjust flow to distribute heat to all zones 2 Providea separate 24 volt transformer to power the zone valves Size the transformer to handle the total rated load of all connected zone valves Piping for radiant heating systems or converted gravity systems Converted gravity or steam systems Whenever possible use the primary secondary piping shown in Figures 20 or 21 on page 25 This piping de sign allows changing boiler flow rate without affecting primary circuit flow rate If Figures 20 or 21 cannot be used use the boiler bypass piping shown in Figure 22 or Figure 23 on page 27 You can also use the piping shown in Figure 24 on page 29 system bypass if the reduced flow rate in the heating system will not cause heat distribution problems Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sec tions or burners resulting in severe personal injury death or substantial property damage Radiant heating systems Preferably use primary secondary piping as shown in Figures 20 or 21
62. he damper open in series with the thermo stat input to the boiler The boiler will not start if this contact is open and will shut down should it open during operation 11 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 12 2a Prepare boiler placement amp 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 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 5 Check level a Shim legs if necessary b Do not alter legs Inspect orifices and burners 1 Remove front jacket door Remove burner shield see Figure 40 item 4 page 60 2 Check for correctly sized manifold orifices See Table 2 for sizing The orifice size is stamped on the orifice spud barrel Correctly sized manifold orifices must be used Failure to do so will result in severe personal injury death or sub stantial property damage 3 Reinstall burner shield Do not operate boiler without burner shield in place Failure to do so could result in severe personal injury death or sub stantial property damage Orifice replacement procedu
63. igure 28 Typical pilot burner flame Spark electrode Pilot flame sensor 71030 Figure 29 Typical main burner flame Transparent blue flame Inner flame 35 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 36 4c Start up if boiler doesn t start Check for Loose connections blown fuse or service switch off High limit switch set below boiler water tempera ture Thermostat set below room temperature Gas not turned on at meter or boiler Incoming gas pressure less than 5 w c for natural gas 11 w c for propane gas If none of the above corrects the problem refer to Troubleshooting section 11 of this manual Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 8 should confirm there is no gas flow e Pilot will relight flame sensing element will sense pilot flame and main burners will reignite Check out procedure checklist 4 Boiler and heat distribution units filled with water L Set limit control s to system temperature requirements I Automatic air vent if used open one full turn Adjust balancing valves and controls to provide design j temperature to system L Air purged from system u Air purged from gas piping Piping checked for leaks 4 For multiple zones adjust flow so it is about the same in l l l l each zone L Correctly sized manifold orifices installed Refer to Table 2 page 12 t
64. im UJEIL fc LAIN GOLD CGi 4E Gas Fired Water Boiler Bo j le r IV a n Uu a e Installation Maintenance e Startup e Parts ENERGY STAR AWARNING This manual must only be used by a qualified heating installer service technician Before installing 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 AWARNING 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 Part No 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual How it works D 0 e OG 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
65. imney before installing boiler Failure to clean or replace perforated pipe or lining will cause severe personal injury or death Vent sizing given in Table 3 is only a general guideline The vent connector and chimney must be designed sized and constructed in compliance with all applicable codes Failure to correctly size and install the vent system could result in severe personal injury death or substantial property damage 1 Use doublewall metal vent B vent or chimney with liner as required by the National Fuel Gas Code ANSI Z223 1 latest edition or in Canada B149 1 or B149 2 Installation Code 2 To prevent downdrafts chimney should extend at least 3 feet above the highest point where it passes through a roof and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet 3 To vent with another appliance see National Fuel Gas Code ANSI Z223 1 latest edition or in Canada B149 2 or B149 2 Installation Code 4 Do not connect breeching to any portion of a mechanical draft system that can operate under positive pressure 5 Maintain minimum 2 clearance from combustible materials to vent pipe 6 Do not use chimney with an open fireplace 7 Make horizontal runs as short as possible Long runs can cause condensation 8 When longer runs are used support pipe with appropriate hangers 9 To prevent blockage do not vent into bottom of chimney 10 Vent pipe must not go beyond i
66. ing properly remove tees and reinstall hoses to air pressure switch Table 9 Pressure switch setpoint for elevations above 2 000 ft contact your local Weil McLain sales office for details Inches W C Boiler model number CGi 4E 1 36 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 1 lb Troubleshooting components POWER light flashing alone Usually indicates reversed polarity of 120 VAC power wires Suction Pressure 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 POWER and FLAME lights flashing Figure 36 Manometer connections Inclined tube manometer Usually indicates false flame sense or flame sensed when it should not be there White a Flue collector S Red Control indicator lights NON LOCKOUT modes Red POWER light on and FLAME light flashing Rear Diod Usually indicates pilot flame was not established within 15 seconds from application of spark Control will flash light but will continue to cycle indefinitely until flame is established or problem is corrected POWER light on and PRESS SWITCH light flashing Usually indicates pressure switch o
67. inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to reinspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever must be operated AT LEAST ONCE AYEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal otherwise severe personal injury may result If no water flows valve is inoperative Shut down boiler until a new relief valve has been installed Boiler relief valve 1 Inspect the relief valve and lift the lever to verify flow as in the following warnings excerpted from a relief valve manufacturer s warning label Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read manual Section 4 before proceeding further 2 After following the above wa
68. lation valves Open quick fill valve on cold water makeup line Open purge valve One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressure After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system If purge valves are not installed in system open manual air vents in system one at a time beginning with lowest floor Close vent when water squirts out Repeat with remaining vents 4 Openautomatic air vent diaphragm type or bladder type expansion tank systems only one turn 5 Open other vents a b Starting on the lowest floor open air vents one at a time until water squirts out Repeat with remaining vents 6 Refill to correct pressure Part Number 550 110 711 1108 Start up preparation continued Inspect system water piping After filling the boiler and system with water inspect all piping throughout the system for leaks If found repair immediately Repeat this inspection after the boiler has been started and the system has heated up Leaks must be repaired at once Fai
69. lator is shipped loose and can be mounted on either the boiler supply or return piping The factory installed circulator wiring harness provides ample length for either location NOTE The control module provides a pump exercising routine If the boiler is not operated for 30 days the control module will power the circulator for 30 seconds then turn off Timer relay The timer relays delays high fire for 60 seconds Other boiler components a supply to system f pressure temperature gauge k pilot burner and bracket b return from system g relief valve I gas manifold c stainless steel burners done m cast iron boiler sections i flame rollout thermal fuse element d flue outlet TFE n flue collector e gas valve j burner shield o junction box Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual GOLD CGi 4E Gas Fired Induced Draft Water Boiler Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Contents o oo I 0 RR c2 NWO md OE Oo N mM How it works Leer rrr rere run u uuu uuuuuuuuuuuuuuuuuaas 279 Hazard definitions errrrrrreee Please read before proceeding 5 Prepare boiler location 22 e e 07 1 1 Prepare boller unnnnnnnnnnnnnnnnnnnnnnnnnnnnnnuuuunn 12 13 VENN Je 19 19 Water piping unnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnuununnn 20
70. ler should be in normal operating sequence See normal sequence of operation Figure 30 page 39 If you have less than sufficient heat Is vent piping free of blockage No Yes Correct conditions and Is manifold pressure recheck operation 3 50 w c on natural gas See Figure 30 page 39 10 0 w c on propane for normal sequence of Yes No Operation e Check heat loss calculation versus boiler size Clock gas input J l Replace timer relay Wait for boiler water to cool to temperature 20 to 30 F lower than temperature set on limit switch Are limit switch contacts closed e Remove CIRCULATOR harness plug from CIRCULATOR plug receptacle 7 page 50 Check with voltmeter across pins of control module receptacle Does voltmeter show 120 VAC across pins Figure 38 Item No Yes Replace control Repair replace module circulator Retest Retest Repair replace wiring Retest e Wait 5 minutes Is FLAME light on Yes No Is LIMIT light on No Yes e Check limit switch Replace control module contacts with continuity Retest checker Are limit switch contacts closed N Y Check rollout switch 0 continuity is switch BAM closed No
71. lure to do so can damage the boiler resulting in substantial prop erty damage Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in sub stantial property damage Inspect base insulation The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 68 of this manual Failure to comply could result in severe personal injury Failure to replace damaged insu lation or reposition insulation can result in a fire hazard causing severe personal injury death or substantial property damage Check to make sure base insulation is secure against all four sides of the base If insulation is damaged or displaced do not operate boiler Replace or reposition insulation 33 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 34 b Start up operate boiler DO NOT proceed with boiler operation unless boiler and system have been filled with water and all instructions and procedures of previous manual sections have been completed Failure to do so could result in severe personal injury death or substantial property damage Before start ing the boiler do the follow ing Read manual Section 9 and the Operating instruction procedure applicable for the gas valve supplied on the boiler Section 9c Verifythe boiler and system are full of water Verify the Start up prepa r
72. mbly eo ooo uuuuuuuuuuuuuuussaas OD ASO ziusswwwaxuERMNaENEEEEEHEEENNNEKESEENMNEN RN E ME KERN EMN OO Jide KOL EEE UE a OS Controls Guam NM RNNE EN NNME SM MM OD 2D Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 2b Replacement parts section assembly Figure 39 Section assembly H i imd x kI x I I l d y e E gr rd en in A p ui i Description Weil McLain Weil McLain part number part number End section right hand 51128 311 103 821 Radiation plate 1 per joint 460 003 700 End section left hand 51124 311 103 850 Washer e 1 per tie rod 562 248 684 Intermediate section 51125 311 103 818 Collector hood CGi 4E 381 354 596 s pe differential L4080D1036 no ection replacemen it ne udes with well White Rodgers shown seals and sealant for 1 joint 11B81 3 I Tees Je 1955 AL I EDU Inducer fan assembly kit includes 381 356 499 without nut 3 inducer fan assembly gasket and per boiler juts 7 m A a n 590 317 627 and transition not Replacement CGi 4E 321 114 346 assembly shown section assembly High limit 30 Honeywell 510 312 250 Part Number 550 110 711 1108 oe GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 12c Replacement parts base Figure 40 Base assembly 20 Part N
73. move one of the wires connected to the pressure cycle switch e Check continuity across the switch terminals No Yes Does the ohmmeter indicate the switch is closed No Yes l e Check air pressure switch e Replace control per manual Section 11a e Clear passages and module i le boil s Retest Replace if necessary recycle boiler l e Retest e Recheck boiler operation Part Number 550 110 711 1108 9m GOLD CGi 4E Gas Fired Water Boiler Boiler Manual lle Troubleshooting control module lights cont CHART 4 FLAME amp POWER lights flashing Usually indicates flame sensed when it shouldn t be there AWARNING 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 Are manual main shutoff valve and gas valve open NO Yes Leave main manual gas valve closed Turn off power to the boiler at service switch or breaker Turn off power to boiler at service switch or breaker Wait at least 45 seconds Wait at least 45 seconds t Tun poner ie BOISE f E Turn on power to boiler Restart boiler following Operating instructions in this Restart boiler following Operating instructions in this manual Section 9c
74. move the boiler relief valve Tempo rarily plug the relief valve tapping with a 34 NPT pipe plug Remove 174 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 Figure 42 page 64 Install circulator on either the return or supply Remove 174 nipple 144 x 114 x 1 2 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 Connect a hose to boiler drain valve the other end connected to a fresh water supply Make sure hose can also be used to drain boiler after test Connect a nipple and shutoff valve to system supply connection on the 174 tee This valve will be used to bleed air during the fill Valve and nipple are not included with boiler Connect a nipple and shutoff valve to system re turn connection at circulator flange if circulator installed on return This valve will be used to bleed air during the fill Valve and nipple are not included with boiler Fill and pressure test l Open the shutoff valves you installed on supply and return connections Slowly open boiler drain valve and fresh water sup ply to fill boiler with water When water flows from shutoff valves close boiler drain valve Close shutoff valves Part Number 550 110 711 1108
75. must be cleaned see Burner cleaning in structions below Inspect the slotted jacket cooling openings in the bot tom left and right of the base pan Figure 40 item 7 page 60 Inspect the base insulation Pay attention to the WARN ING on page 68 regarding working with insulation materials Verify that the insulation is intact and secure against all four sides of the base Burner cleaning instructions Airborne materials such as fiberglass and dust are present during construc tion and remodeling These materials can be drawn in with the combustion air and obstruct burner ports resulting in carbon monoxide production a fire hazard or building freeze damage Read and follow the WARNING on page 9 Failure to inspect and clear gas burner ports could result in severe personal injury death or substantial property damage Remove burner shield and the base pan air baffle Next remove the pilot bracket assembly Then remove the four screws securing the burner tray to the manifold and slide the burner tray out under the manifold Inspect each burner to insure that every port is com pletely open If any port is not completely clear run a vacuum at the Part Number 550 110 711 1108 Service amp maintenance annual start up wn 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
76. n appropriate readings The boiler will not operate correctly un less pressure switch hoses are correctly located The red hose connects from the right side negative hose barb to the flue collector The white hose con nects from the left side positive hose barb of the switch to the connector box between flue collector and inducer as shown in Figure 36 page 49 Check pressure switch setting 1 See Figure 36 page 49 and Table 9 2 Remove both air pressure switch hoses from air pressure switch 3 Install tees and tubing as shown in Figure 36 page 49 to inclined manometer 4 Turn off gas valve and set thermostat to call for heat Inducer will run but burners will not ignite 5 Check for 24 VAC between both air pressure switch termi nals Troubleshooting air pressure reading 1 Ifmanometer reading is lower than the setpoint of the switch see Table 9 check for possible causes blockage in hoses obstruction in inducer housing outlet loose inducer wheel on motor shaft inducer motor not in proper rpm inducer back plate not sealed properly blockage in block assembly blockage in flue pipe or termination incorrect pressure switch 6 If manometer reading is above the setpoint of the switch see Table 9 but there is not 24 VAC between both air pressure switch terminals replace air pressure switch Return to normal operation When pressure reading is correct and air pressure switch is oper at
77. n box and mount the service switch remotely as required by the code The CGi 4E control module is polarity sensitive The hot and neutral wires must be connected to the correct leads A flashing POWER light usually indicates reversed polarity of 120 VAC lead A Service Figure 27 120 VAC og switch I Hot Neutral Ground RG not provided Field wiring connections Thermostat service switch and thermostat e or end switch Fa or end switch T not provided 2 ml Service provided by installer 5 switch D not provided ui ui i x gt Ww I 7 J J Thermostat p 7 A P a 4 or end switch S Ground screw Wire nuts not provided Oo t White Green Black Black s E Thermostat Junction box boiler left side Part Number 550 110 711 1108 leads through jacket left side 71029 31 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Check for gas leaks Before starting the boiler and dur A WARNING 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 A WARNING Propane boilers only Your pro 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 Propane gas can accumulate at floor lev
78. n page 41 This 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 If limit circuit is closed the inducer starts After pressure switch proves proper airflow control module initiates 30 second prepurge Control module sparks the pilot and opens pilot valve in main gas valve If pilot does not light within 15 seconds pilot valve is closed and spark generator is turned off Control module initiates a 15 second postpurge then starts a new cycle If pilot does light and control module senses flame current spark generator is turned off and main valve opens The CGi 4E timer relay delays high fire for the first 60 seconds of main flame During main burner operation a Control module monitors pilot flame current If signal is lost main valve closes spark generator activates and sequence returns to step 4 10 11 12 Operation sequence b If power is interrupted control system shuts off pilot and main gas valves and restarts at step 1 when power is restored In the event the limit control shuts down the boiler The control module closes the pilot and main gas valves but keeps the inducer operating for 15 second postpurge The circulator continues to operate Lower room thermostat setting to stop call for heat Ther mostat is satisfied Pilot and main gas valves are closed Inducer operates for 1
79. nd other flammable vapors and liquids 2 Verify that boiler area and air intake is free of any of the contaminants listed in Table 1 on page 9 of this manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed isolate the boiler and provide outside combustion air See national provincial or local codes for further information Air openings 1 Verify that combustion and ventilation air openings to the boiler room and or building are open and unobstructed 2 Verify that boiler vent discharge is clean and free of obstructions Flue gas vent system 1 Visually inspect entire flue gas venting system for blockage deterioration or leakage Repair any joints that show signs of leakage in accordance with vent manufacturer s instructions Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Pilot and main burner flames 1 Visually inspect pilot burner and main burner flames as directed under Start up Section 7 of this manual Water piping 1 Check the boiler interior piping and all system pip ing for signs of leaks 2 Repair any leaks before proceeding Boiler heating surfaces 1 Disconnect the vent pipe at the boiler inducer outlet connection after turning off power to the boiler 2 Use a bright light to inspect the flue pipe interior and inducer interior 3 Inspect the boiler vent ou
80. nection to the system Figures 16 and 17 show typical near boiler piping connections System water piping See Figure 16 diaphragm type or bladder type expan sion tank or Figure 17 closed type expansion tank and Table 6 for near boiler and single zone systems designed for return water at least 130 F See pages 22 23 to complete multiple zone piping or pages 24 29 to complete piping for radiant heating systems or converted gravity systems large volume systems originally designed for circulation by natural convection rather than a pump See page 29 for boilers used with refrigeration systems Table 6 Water pipe size based on 20 F rise Boiler To From model number system system CGi 4E Note The boiler supply and return connections the return drain tee and the supply gauge tee supplied with the boiler are 114 NPT One of the circulator flanges supplied with the boiler is 114 The other circulator flange is the size of the recommended system piping shown above Chillers or air handling units Install boiler such that A WARNING Chilled medium if used is piped in parallel with heating boiler Use appropriate valves to prevent chilled medium from entering boiler Consult I B R Installation and Piping Guides If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air use flow control valves or other au tomatic means to prevent gravity cir
81. ning with circulators Alternative to primary zone valves Alternative to primary secondary piping Figures 20 and 21 secondary piping Figures 20 and 21 ER a l as m ZONE1 ZONE1 XXI 1x X i T L X 1 1 20 4a 4b pm Q 3 2 O amp Y 4b 5 Gil by EL oe TE 1g PTS ME te Da e mee ige XH x location 2 Ja Li 8 7b I 7b Y 9 1010 fo aan mf 9 10 ne Vh 4a 04 y Ce water x H L UH v fll T 1 E e monn Cold L 1 1 j 1 2 LL mm water LA t f T L 12 3 T c 71024 71025 1 Boiler isolation balancing valves 9 Relief valve 2 Flow check valve 10 Automatic air vent with diaphragm type expansion tank or connect to tank fitting closed type expansion tank DO NOT use 3 System or zone circulator an automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlogging of the 4 System temperature gauges expansion tank 5 Zone valve 11 Fill valve 6 Drain valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to 7 System temperature valves see in tank fitting as in Figure 17 page 21 structions to the left for adjusting valves 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansion tank regardless of 8 Blend temperature gauge location of e
82. nside wall of chimney 11 Vent passing through floors or ceilings must be fire stopped 12 See Figure 7 and Table 3 to connect boiler to venting sys tem Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual C 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 diameter Heat Fab Inc Saf T Vent e Flex L International Inc StaR 34 Z Flex Inc Z Vent Il ProTech Systems FasNSeal a dn different systems The vent system could fail causing flue gas spillage resulting in severe personal injury or death 2 Select vent method based on page 14 and installation requirements Refer to Table 4 for maximum vent run lengths and number of elbows Do not exceed data in Table 4 4 Select vent components from separate Vent Supplement All compo nents including the vent starter must be of the same vent manufacturer Do not mix components Table 4 Maximum vent length feet Max vent Total number of elbows Note 1 length feet 4 2 3 4 5 CGi 4E 55 48 41 34 27 20 Note 1 Do not include termination fitting when counting total number of elbows NOTICE Read and follow the special instructions for the Com monwealth of Massachusetts located on page 42 of this manual
83. o check size and fuel type L Verify thermostat heat anticipator if available set prop Correctly sized manifold orifices must be used Eo Beer to Field winngs agua SCHO pare ede A DANGER Failure to do so will cause severe personal in Fheunastotsh jury death or substantial property damage 13 Cycle boiler with thermostat Raise to highest setting and L Followed operating instructions on boiler or in manual verify boiler goes through normal start up cycle Lower to Section 9 for proper start up lowest setting and verify boiler goes off 4 Proper burner flame observed at high fire Refer to Check Measure natural gas input burner flame manual Section 7b l l L Verify that boiler switches to high fire after 60 seconds of Operas poner Loss operation b Turn off other appliances I Test limit control While burners are operating move c At natural gas meter measure time in seconds re indicator on limit control below actual boiler water tem quired to use one cubic foot of gas perature Burners should go off while circulator continues to operate Raise setting on limit control above boiler water d Calculate gas input temperature and burners should reignite 3600x1000 Btuh L Test additional field installed controls If boiler has a low Bab Neil nandi as E ea water cutoff additional high limit or other controls test for ME we ihe PP P 5 operation as outlined by manufacturer Burners should be 5 operating
84. oiler re turn 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 damage 28 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 4d Piping low temperature systems continued From system w A Pen Figure 24 System bypass piping Zoning with X 7b zone valve or circulators return water 7a e 130 F or higher Alternative to boiler Li DX bypass piping Figures 22 and 23 i Alt t Y cineulstor 3 System or zone circulator fecation l l 8 O 7 System temperature valves see instructions to the 9 0410 left for adjusting valves ry 8 Blend temperature gauge Cod 0211 9 Relief valve water DX H cal E As 10 Automatic air vent with diaphragm type expan 12 rN sion tank or connect to tank fitting closed type 3 expansion tank DO NOT use an automatic air vent eet T when using closed type expansion tank It would allow air to leave the system causing waterlogging of the expansion tank 11 Fill valve r 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from JE 4 top of air separator to tank fitting as in
85. oltage across the two external thermostat circuit wires If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the boiler thermostat wires and allow the boiler to cycle Yes v Leave external boiler thermostat connection wires disconnected from boiler Troubleshoot the external thermostat circuit until you find the source of the stray voltage Pay close attention to the wiring connections to 3 wire zone valves Correct the problem and repeat the voltmeter test above verifying there is no longer a voltage reading under any condition in the external thermostat circuit An isolating relay may be required v Boiler should now operate per the normal sequence of operation shown in Figure 30 page 39 92 No v e f no voltage is found under any condition of the external thermostat circuit connect the two boiler thermostat connection leads together or jumper the boiler aquastat T T terminals Turn off power to the boiler for 1 minute e Turn on power and allow boiler to cycle Do the TSTAT and POWER ights still flash No Yes y e Replace control module e Retest Part Number 550 110 711 1108
86. on page 25 Alternatively use the method of either Figure 22 or Figure 23 on page 27 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 22 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual c Water piping multiple zones ie Figure 18 Zoning with circulators Figure 19 Zoning with zone valves return water 130 F or higher
87. oupling with screen not available for StaR 34 6 Donotseal vent pipe slip connector for Saf T Vent to inside or outside plate 7 If passing through noncombustible wall provide hole diameter large enough to insert the vent pipe slip connector for Saf T Vent 8 Install horizontal drain tee as close as possible to boiler in first horizontal run See Figures 13 and 14 9 Do not exceed the maximum vent system length given in Table 4 page 15 Condensate drain line use only silicone tubing rated for at least 400 F for the first 18 of condensate drain line then other non metallic tubing may be used Us ing any other material could cause flue gas leakage potentially resulting in severe personal injury death or substantial property damage 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 Follow vent manufacturer s instructions for proper installation of vent runs including slope and support Horizontal drain tee Follow vent manufacturer s instructions to install
88. outdoors or to a space that communicates directly to the outdoors not to an interior space Theaircan be provided through a direct opening or through a horizontal or vertical duct Opening placement The top of the air opening must be within 12 inches of the ceiling Opening size The free area of the opening must be at least equal to the sum of the areas of all equipment vent connectors in the space and The free area of the opening must be at least 1 square inch per 3 000 Btu hr input rating of all equipment located in the space Exception for large spaces X No combustion air openings are needed when the boiler and other ap pliances are installed in a space with a volume at least 50 cubic feet per 1 000 Btuh of all installed appliances provided the building must not have unusually tight construction see defini tion this page all clearances around the boiler must must be no less than shown in Figure la page 7 To determine if the space is large enough to qualify Add the total input of all appliances in MBH 1 000 s of Btuh Multiply this number times 50 to determine minimum room volume Example For a total input of 100 MBH 100 000 Btuh minimum volume is 50 x 100 5 000 cubic feet At a ceiling height of 8 feet the space must have at least 5 000 8 625 square feet 25 feet x 25 feet for instance Part Number 550 110 711 1108 Unusually tight construction Unusually tight con
89. pass piping Figure 24 however is not suitable for radiant heating applications because it does not protect the radiant system from possible high water temperature Boiler bypass piping keeps system flow rate as high as possible and temperature drop as low as possible help ing to equalize the building heat distribution Temperature gauges Gauge 4a is optional if the bypass valves will be ad justed using cold or room temperature return water to the boiler When setting the valves without gauge 4a installed using cold or room temperature water assume the return water temperature to be 60 F Set the valves so gauge 8 reads at least 120 F Gauge 4b is optional on converted gravity systems but required on radiant heating systems to display the water temperature being supplied to the radiant tubing Gauge 8 is required on all systems to assure reliable adjustment of the bypass valves The boiler mounted temperature pressure gauge can be used if a separate temperature gauge is not installed Valve adjustment 1 Start with valve 7a fully closed and 7b fully open 2 Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 60 F higher than gauge 4a A minimum 60 F temperature rise through the boiler assures a low enough flow rate and high enough average temperature to prevent condensation even with low system return water temperature 3 Valve 7a regulates the system flow rate while valv
90. pened during the run cycle Interior panel 71038 Troubleshooting the control module See Figure 38 page 50 for location of harness plug receptacles and plugs on the control module Control module Solder or water splatter between A WARNING plugs and circuit board can cause improper operation of control mod ule Place a shield over the boiler internal controls and components during installation Failure to com ply could result in severe personal injury death or substantial property damage Make sure ground wiring is in NOTICE stalled per wiring diagram Good grounding is extremely important for proper operation Figure 37 Control module Control indicator lights LOCKOUT modes See Charts 1 through 7 in this section for detailed trouble shooting procedures To reset control after a lockout turn off power at the 120 VAC service switch or turn down all thermostats Wait 45 seconds Then restore power or call for heat Part Number 550 110 711 1108 d GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 11b 50 Troubleshooting components continued Figure 38 Control module connections 120 VAC H QD High voltage to pilot spark electrode IEEE E 120 VACN TI 9 120VAC to set transformer Red wire to gas valve MV and timer relay Blue wire to gas valve PV Red wires to AN pressure switch 4 24 VAC control circuits O T r P z m O PRESS SWITCH
91. plate shall be permanently mounted to the exterior of the build ing at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BE LOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equip ment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment an
92. r APPLIANCE below and call your service technician or gas supplier shown in ON position 12 Replace jacket front panel Gas control knob EN TO TURN OFF GAS TO THE APPLIANCE 2S Setthermostatto lowest setting 4 Turn Gas control knob clockwise v to OFF Do not force Turn off all electric power to the appliance if service is to be 5 Replace jacket front panel performed Remove jacket front panel 550 223 237 1108 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Addendum Instruction for the Commonwealth of Massachusetts This addendum must only be used by a qualified heating installer service technician Read these instructions completely before beginning the installation Failure to comply could result in severe personal injury death or substantial property damage a For all side wall horizontally vented gas fueled equipment 42 installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETEC TORS At the time of installation of the side wall horizon tal vented gas fueled equipment the installing plumbe
93. r or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or struc ture served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed profes sionals for the installation of hard wired carbon monoxide detectors a In theevent that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b Intheevent that the requirements of this subdivision can not be met at the time of completion of installa tion the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification
94. re when required l Remove the screws securing the burner shield and remove burner shield Using a Ac open end wrench remove the burner orifices from the manifold Apply a small amount of pipe dope to each of the new orifices and install in the manifold us ing a 46 open end wrench Make sure the ori fices are aligned correctly not cross threaded in the manifold tappings Use only pipe dope compatible with propane gas even if boiler is to be operated on natural gas Failure to comply could result in severe personal injury death or substantial property dam age Carefully replace the burner shield Follow the check out procedure Section 8 page 37 to assure the boiler is now operating properly after orifices are replaced Table2 Manifold orifice sizing at sea level and altitudes to 4 500 feet Natural gas 0 2 000 ft 2 55 mm 0 2 000 ft Canada 2 55 mm 41 over 2 000 ft Note 1 2 000 4 500 0 2 000 ft over 2 000 ft Note 1 2 000 4 500 1 60 mm 0 2 000 ft 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 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Ab Hydrostatic pressure test Pressure test boiler before attaching water or gas piping except as noted below or electrical supply Prepare boiler for test l Remove the shipping nipple from CGi 4E supply tapping and re
95. rning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pres surization of the system due to expansion tank waterlogging or undersizing Figure 35 Relief valve typical Part Number 550 110 711 1108 Service amp maintenance annual start up con Review with owner Ll 2 Review the User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the User s Information Manual and in this manual as well Remind the owner of the need to call in a licensed contractor should the boiler or system exhibit any unusual behavior Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season _J Cleaning boiler oY a EE 13 14 heating surfaces The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 68 of this manual Failure to comply could result in severe personal injury Shut down boiler Follow To Turn Off Gas to Appliance instructions on boiler and Operating instructions Do not drain boiler unless it will be exposed to freezing temperatures If using antifreeze in system do not drain Follow shutdown procedure Remove venting system connection to boiler Remove top jacket panel Turn ba
96. rol module will flash the FLAME light but will continue indefinitely with attempts to light the pilot burner The control module will not lockout on a failure to establish flame It will lockout if line voltage polarity is reversed stray voltage is sensed on thermostat line pressure switch sticks closed or fails to make within 5 minutes or if flame is sensed when it shouldn t be there The boiler will reset after these lockouts if any of the following occurs 1 hour waiting period Opening and closing of thermostat circuit Removal of 120 VAC power for at least 45 seconds 71032 Part Number 550 110 711 1108 iagrams d ion wiring 9b Operat Figure 31 Wiring diagram GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 8060 LZ0 8cc 0S5S JequinN HEd UMOYS s 013000 pur Taloq YIM sanas 581185 i J8 E M D92JO e G S91 ut 7519 Jr y ry euornrppe jjo 1n2 13384 MOT sjo1juoo JU euo ppe Aue aly Z BBEZ O9ESP NI AD ueDijany 15 aurejg OOS UIETIN I8M se wnajonad Jjt 152 uoneuioju payenbi Jo E1NIEN seues uonerndde 10 apoq 34 YIM pex ed suornonajsur jusuoduro pouon 0 13J3Y 9 uoniuBi zold JUSPILLUISJU e Jt S523 suonsaddns Buum pute uonendde 10 pjenuew sr pue SUONINJJSUI s 121n ejnuetu juauoduiroo 34 0 IAY SIOJEPNIIID 10 SJAJEA 3U0Z AY asn Suruoz sjdnnur 104 S NIVIPUJ TIO vi sJojoauuoa PUNGE sdure g g 3u0z ajus Suyos 107edi nue 1e150uniau p Part Number 550
97. rom natural infiltration so additional air openings to the building are not required 3 See Figure 2 Provide two openings through the interior wall within 12 inches of the ceiling and the floor sized per Figure 2 Two openings Air supply directly from outside 1 Air openings must be directly through an outside wall or into a space that connects directly to the outside such as a ventilated attic or crawl space for example 2 SeeFigure 3 Openings directly through an outside wall provide two openings within 12 inches of the ceiling and the floor sized per Figure 3 3 See Figure 4 Air supplied through vertical ducts provide two openings terminated within 12 inches of the ceiling and the floor sized per Figure 4 4 See Figure 5 Air supplied through horizontal ducts provide two openings within 12 inches of the floor and the ceiling sized per Figute 5 10 Figure 2 Air openings to interior spaces P X Each opening free area ni s Py f m 1 sq inch per 1 000 Btuh A E i i Di 5 Add air openings CGi dE to outside if boiler buking 15 tight Other i construction appliances 1 E amp i a SS A opening s Oto 12 j T 71004 Figure 3 Air directly through outside wall X Each opening free area gis ded a o 1 sq inch per 4 000 Btuh An pt e m LL UV CGi 4E 5 boiler C Other 1 appliances afi E gt Li en y at A E s Ota
98. s It provides no method regulating the water temperature provided to the system and could result in excessive water temperature in the radiant tubing Valve 7a regulates the amount of boiler supply water mixed with return water Valve 7b causes a pressure drop in the system needed to balance flow through valve 7a and the system System bypass piping as shown in Figure 24 can be used with either zone valve or circulator zoning When used 4 The valve adjustment should be done with the with circulator zoning however the boiler circulator system at the coldest expected temperature 60 F item 3 must be piped as shown It cannot be used as for converted gravity systems or high mass radiant one of the zoning circulators systems Failure to prevent low return water temperature to the boiler could cause corrosion of A WARNING bu M E the boiler sections or burners resulting in severe personal injury death or substantial property damage 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 injec tion 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 of this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the b
99. struction means per ANSI Z223 1 buildings in which a Walls and ceilings exposed to the outside atmo sphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and b Weather stripping has been added on openable windows and doors and c Caulking or sealants are applied to areas such as joints around windows and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines and in other openings For such construction cases if appliances use inside air for combustion provide air openings into the building from outside Size and locate these openings per the appropriate case in Figure 3 4 or 5 on page 10 Exhaust fans and air movers The appliance space must never be under a negative pressure even if the appliance s are installed as direct vent Always provide air openings sized not only to the dimensions required for the firing rate of all appli ances but also to handle the air movement rate of the exhaust fans or air movers using air from the building Or space Motorized air dampers If the air openings are fitted with motorized dampers electrically interlock the damper to Prevent the boiler from firing if the damper is not fully open Shut the boiler down should the damper close dur ing boiler operation To accomplish this interlock wire an isolated contact proving t
100. sult in severe Take the following special precautions when installing the personal injury death or substantial property dam boiler in a residential garage If the boiler is located in a age and reduced boiler life residential garage per ANSI Z223 1 1 Hot water pipes at least inch from combustible material Mount the boiler a minimum of 18 inches above the Single wall vent pipe at least 6 inches from combustible mate floor of the garage to assure the burner and ignition rial devices will be no less than 18 inches above the floor 3 Type B double wall metal vent pipe refer to vent manufacturer s Locate or protect the boiler so it cannot be damaged recommendation for clearances to combustible material by a moving vehicle 7 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual le A DANGER 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 DO NOT COMMON VENT Do not install the CGi 4E into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible severe personal injury death or substantial property damage When removing boiler from an Chimney or
101. ted temperature pres sure gauge reads at least 150 F when the system return water is cold approximately 60 F water temperature Valve adjustment Figures 20 and 21 only 1 Set the valves while the system is cool setting for the coldest expected water temperature usually 60 F since the system will often drop to room tempera ture between cycles 2 Start with valve 7a fully closed and 7b fully open 3 Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 130 F when gauge 4a reads 60 F 4 Note that valve 7a regulates the amount of hot wa ter from the boiler supply which mixes with return water Valve 7b regulates the amount of system water flowing through the boiler secondary loop Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injec tion 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 of this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the boiler re turn
102. tive or undiluted AWARNING antifreeze Severe personal injury or death can result 1 Determine antifreeze quantity according to system water content Boiler water content is listed on page 67 Remember to include expan sion tank water content 2 Follow antifreeze manufacturer s instructions 3 A 50 solution of propylene glycol water provides maximum protec tion to about 30 F 4 Local codes may require back flow preventer or actual disconnect from city water supply 5 When using antifreeze in a system with automatic fill install a water meter to monitor water makeup Glycol will leak before the water begins to leak causing glycol level to drop Added water will dilute the antifreeze reducing the freeze protection level Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 4a Fill the system with water 1 Close manual and automatic air vents and boiler drain cock 2 Fill to correct system pressure Correct pressure will vary with each application Typical cold water fill pressure for a residential system is 12 psi 3 Purge air from system a o p T Connect a hose to the purge valve see drain valves item 6 in suggested piping diagrams on pages 23 through 27 Figure 18 through Figure 23 Route hose to an area where water can drain and be seen Close the boiler or system isolation valve between the purge valve and fill connection to the system Close zone iso
103. tlet area and heating sur faces by looking through the opening 4 If the vent pipe or inducer interior show evidence of soot follow Cleaning boiler heating surfaces on page 47 to remove the flue collector and clean the boiler if necessary after close inspection of boiler heating surfaces If there is evidence of rusty scale deposits check the water piping and control system to make sure the boiler return water temperature is properly maintained per this manual 5 Reconnect vent to inducer outlet and replace all boiler components before returning to service 6 Check inside and around boiler for evidence of any leaks from the boiler If found locate source of leaks and repair Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 10b Inspect Burners and base The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 68 of this manual Failure to comply could result in severe personal injury If insulation is damaged or displaced do not operate the boiler Replace or reposition insulation as neces sary Failure to replace damaged insulation can result in a fire hazard causing severe personal injury death or substantial property damage After turning off power to the boiler remove the base burner shield Figure 40 item 4 page 60 Inspect burners and all other components in the boiler base If burners
104. turn doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous con ditions of use a Line chimney with corrosion resistant metal liner such as AL29 4C single wall stainless steel or B vent Size liner per Na tional Fuel Gas Code ANSI Z223 1 latest Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 latest edition Correct by re sizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code Canadian edition installations must comply with B149 1 or B149 2 Instal b Provide drain trap to remove any conden lation Code sate Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual ld Prepare boiler location air contamination Please review the following information on potential Refer to Table 1 for products and areas which may cause combustion air contamination problems contaminated combustion air AWARNING 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 o 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 likel
105. umber 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 12c Replacement parts base continued Description Weil McLain P part number Base assembly kit includes base panels items 1 2 3 4 5 6 CGi 4E 381 354 338 and 7 EE VER 777CO T c ANN 2 ase tont rset assembly in Baseacsembi ED a A BRmesidinBmemsen 0000000 s msepamandeletsBinBmesme y SS 6 Seepmener htedeUnBasemenb me Burner mouningniete ae oe o noarspeingep ae so Ge Mee som 040 Boiler leg kit 550 320 219 Manifold CGi 4E 591 126 736 Main burner orifice Natural gas sea level see Table 2 page 12 for orifice size CGi 4E 560 529 126 Main burner orifice Propane gas sea level see Table 2 page 12 for orifice size CGi 4E 960 529 111 Screw 10 32 x 0 38 STP type 23 hx washer Hd slot 562 135 710 Rollout thermal fuse element 512 050 230 61 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 12d Replacement parts jacket Figure 41 Jacket assembly gt aT p 4b p 8 MM 4a Qu q Fe di b CK T s Q MD C E 3 E 6 A A w A G gt T N on p VU 2 j gt 7 71043 ae Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 12d Replacement parts jacket continued Panel left side with ae Panel right side Panel top front Panel top rear with
106. ury death or substantial property damage 2 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 4d Piping low temperature systems Primary secondary preferred bypass piping method Primary secondary bypass piping is preferred because the flow rate and temperature drop in the heating circuit s is determined only by the heating circuit circulator s So adjustment of the bypass valves in the boiler circuit will not cause a change in the heating circuit rate and temperature distribution Figures 20 and 21 show suggested bypass arrangements using primary secondary bypass piping preferred for low temperature systems such as radiant heating systems or converted gravity systems For alterna tives see pages 26 through 29 The bypass valves items 7a and 7b provide mixing of hot boiler outlet water with cooler system return water set to assure a minimum return water temperature at least 130 F to the boiler Set the valves as explained below Temperature gauges Gauge 4a is suggested but optional on any system Gauge 4b is optional on converted gravity systems but required on radiant heating systems to display the water temperature being supplied to the radiant tubing Gauge 8 is required on all systems to assure the return water temperature is accurately set for a minimum of 130 F If this gauge is not available however adjust the valves such that the boiler moun
107. ustible flooring Tested for 50 psi working pressure Part Number 550 110 711 1108 d GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Tm Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base A WARNING insulation panels in this product con tain 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 Crystal line silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Precautionary measures L Avoid breathing fiberglass dust and contact with skin or eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for fiberglass wool at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommen dations can be found on the NIOSH web site at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this web site Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust Remove combustion chamber lining or base insula tion from the boiler and place it in a
108. 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 7 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 Z223 1 latest edition and appli while the other appliances remaining connected to the cable building codes Canadian installations common venting system are not 1n operation must comply with B149 1 or B149 2 Installation a Seal any unused openings in the common venting Codes system 2 SeeRatings table on page 67 for minimum chim b Visually inspect the venting system for proper size ney or vent sizes A chimney or vent without a and horizontal pitch and determine there is no blockage listed cap should extend at least 3 feet above or restriction leakage corrosion or other deficiencies the highest point where it passes through a roof which could cause an unsafe condition of a building and at least 2 feet higher than any portion of a building within a horizontal c Test vent system Insofar as is practical close all distance of 10 feet A chimney or vent must not building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other 3 A lined chimney is preferred and must be used extend less than the distances stated above spaces of th
109. vent to prevent accidental contact by people or pets Do not terminate vent in window well stairwell alcove courtyard or other recessed areas Do not wrap or insulate vent pipe or fittings Do not terminate vent above any door or window Condensate can freeze causing ice formations Do not connect Any other appliance to vent pipe Multiple boilers to a common vent pipe I2 kid Canadian installations See B149 1 or B149 2 Installation Code Terminate vent no less than 6 feet from another combustion air inlet 3 feet from any other building opening and 3 feet from any gas service regulator See Figure 12 showing that the vent must termi nate e more than 4 feet below or to side of all doors or windows more than 1 foot above grade or anticipated snow line atleast 7 feet above public walkway 3 feet above any forced air intake within 10 feet 14 Vent must also terminate 15 16 atleast 6 feet away from adjacent walls nocloser than 5 feet below roof overhang atleast 4 feet horizontally and in no case above or below unless a 4 foot horizontal distance is maintained from electric meters gas meters regulators relief valves and other equipment Site conditions may dictate greater clearances Do not extend exposed vent pipe outside of building Condensate could freeze and block vent pipe A gas vent extending through an exterior wall shall not terminate ad jacent to
110. vere personal injury death or substantial property damage Is POWER ight off e Make sure service switch or circuit breaker is on or fuses are good Remove 120 VAC IN plug Figure 38 Item 3 page 50 on control module Using voltmeter check across top and bottom pins of 120 VAC IN plug Does voltmeter indicate 120 VAC No Yes Problem is with incoming electricity Have licensed electrician repair circuit No Yes Is POWER ight Flashing Flashing with On steady alone another light not flashing TSTAT CIRC Chart light flashing 2 PRESS SWITCH Chart Chart light flashing 3 5 FLAME Chart Chart light flashing 6 For insufficient heat or no heat problem go to Chart 7 if POWER light is on steady with no other light flashing Reconnect 120 VAC IN plug e Remove 120 VAC IN transformer PRIMARY plug Figure 38 Item 2 page 50 on control module Using voltmeter check across top and bottom pins of PRIMARY receptacle Does voltmeter indicate 120 VAC No Yes line is wrong boiler in the J box Usually indicates polarity on incoming 120 VAC power e TURN OFF POWER at service switch or breaker then reverse the HOT and NEUTRAL wires entering the e Restore POWER at service switch or breaker Is POWER ight flashing now Replace control module Retest
111. 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 damage 24 Part Number 550 110 711 1108 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 4d Piping low temperature systems continued Figure 20 Primary secondary piping Zoning with circulators 4 ZONE 2 pr ZONE1 x bo 2 iz 7 MAX ey fl Lj H 4 Lx HH HiH L HX L L 13 6 1 7b eet 7a BO 4f Ama Fr 9 110 Cod 0211 p water VAL fill i 12 Ci TUM TUI 1 Boiler isolation balancing valves 2 Flow check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve 6 Drain valve 7 System temperature valves see instruc tions to the left for adjusting valves 8 Blend temperature gauge Part Number 550 110 711 1108 Figure 21 Primary secondary piping Zoning with zone valves m Hh E ZONE2 4 h 4 ZONEI 1 1 ar 14 axo 4b 5 Y o MAX HY 3 tr Ul REC AEE EG i LIA ie L 113 1 ET lg Tb 6 pera Ja I 9 110 Cold 011 NE water DX L1 fill J 12 m r 71023 71022 9 Relief valve 10 Automatic air vent with diaphragm type expansion tank
112. xpansion tank circulator or air separator Part Number 550 110 711 1108 a GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 4d Piping low temperature systems SYSTEM bvpass pipin Do not apply system bypass piping if the reduced flow yp piping in the system could cause poor heat distribution That method is system bypass piping reduces the flow in the system and increases the water temperature supplied to the system This can cause increased heat from radiators at the beginning of the system and reduced heat from radiators near the end of the system This piping method is called a system bypass because part of the circulator flow bypasses the system through valve 7a This bypassed hot water from the boiler outlet mixes with cooler system return water temperature in order to provide minimum 130 F return water to the boiler Valve 7b will most often be full open but may need to be slightly closed on some low pressure drop sys Valve adjustment tems in order to cause enough flow through valve 7a l l o l 1 Start with valve 7a fully closed and 7b fully open Figure 24 is an alternative piping method that provides return water temperature control for boilers installed 2 Gradually open valve 7a while closing valve 7b until on converted gravity systems large water content or the temperature at gauge 8 reads at least 130 F at all steam systems times Do not apply the piping of Figure 24 on radiant heat 3 ing system
113. y to have contaminants 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 Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues New building construction Antistatic fabric softeners used in clothes dryers Hemodeling areas Chlorine type bleaches detergents and cleaning Garages with workshops solvents found in household laundry rooms Adhesives used to fasten building products and Buildings under construction where air is other similar products contaminated with particulates Airborne particulates drywall dust fiberglass particles road or gravel dust lint etc CONSTRUCTION DUST HAZARD Airborne particulates such as drywall dust or fiberglass dust will cause blockage of the CGi 4E burners resulting in carbon monoxide production a fire hazard or building freeze damage If the boiler is operated during construction you must isolate the boiler to provide clean air for combustion If you are unable to ensure uncontaminated air in the boiler vicinity at all times you must inspect the boiler at least once weekly When inspecting clean the burners if necessary using the procedure given on page 45 Failure to follow these guidelines could result in severe personal injury death or substantial property damage Part Number 550 110 711 1108 GOLD

Weil-McLain GOLD CGI-4E User's Manual

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