Weil-McLain CGi Series 2 User's Manual
Contents
1. Series 2 GAS BOILER for Direct Exhaust Induced Draft Water Net Ratings 37 000 to 169 000 Btu Hr Applications Residential Multiple Boilers echools and O Easy to Install and Service Other Institutions Indirect fired Unique Control Technology Water Heating Radiant Heating Made with Weil McLain Quality And Much More Series 2 GAS BOILER for Sidewall or Natural Draft Venting Induced Draft Water Net Ratings 37 000 to 169 000 Btu Hr Design Advantages Cast Iron Sections with Elastomer Sealing Rings Boiler sections are made of durable cast iron for strength efficiency and long life It s not uncommon for a Weil McLain cast iron boiler to last 35 years or more The heat pins in the vertical flue passages cause the hot gases to swirl about covering the entire surface of each section for maximum heat transfer Radiation plates further increase heat transfer for maximum efficiency Modern elastomer sealing rings in the port openings assure a permanent water tight seal The flexibility and elastic memory of these seals unlike metal push nipples prevent leaks caused by thermal expansion and contraction A special high temperature sealant between boiler sections assures tightness from gas leakage in the black High Grade Stainless Steel Burners European designed high grade stainless steel burners have internal venturi air flow technology2. 5 Limit switch i Relef valve a Junction box 6 Boller circulator h X Airvant connection How the boiler works When a 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 pilol valve and activates the pilot ignition spark The control module allows up to 15 seconds to establish pilot flame If flame is not sensed within 15 seconds the control module will turn off the gas valve flash the Flame light and then enter a 15 second postpurge The control module will then start a new cycle This will continue indefinitely until pilot flame is established or power is interrupted Once pilot flame is proven the control module opens the gas valve to allow main burner flame When the room thermostat is satisfied the control module turns off the gas valve and pilot valve operates the inducer for a 15 second postpurge and waits for the next call for heat The control module indicator lights show normal sequence when the lights are on steady When a problem occurs the control module flashes a combination of lights to indicate the most likely reason for the problem Features Ad vantages Benef ts Weil MicLain Control Module and Ignition Control Designed for Weil McLain mistake proof wiring diagnostic indicator lights Compact design Saves valuable living space Boiler is only 26 inches high
3. on wl free area of 1 square mech nest in boller borni per 1 000 Buh of Ci Standard and Additional Equipment baile Standard Equipment Ar Pressure Swatch Additional Equipment Factory Tested i Mon Linling Prot Bumar CE ALZS 4C Starter same as Gs Starter Two Pieca Top Jacket Paral High Grade Stainlass Steal Burmers Taco 007 Circulator Insulated Extended Sieci Jackal Transformer Expanalan Tank Package axpansion tank fil Cast bon Sectians will Built in Ar Separator etnies Junction Box amp check valve auta air vent and fittings Fackation Pigs Pula Thermal Fuse Semen 100 sizes 3 thru 5 110 sizes B thru B Staal Basa High Limi Temperatura Control Shipped in caran Integrated Bother Contro Madule with Circutator when ordernd High Altitude Ks Electronic Igrsti n Sysglem amp 30 PS5 ASME Reiet Valve W M 5 amp 10 Year Homacwnar Protection Plan Indicador 7 Diagnealic Lighis boiler sections for 50 PSI working V M indirect fined Waler Heaters lidiucer Ageambly W M Pool Healers Flue Gas Collector Transition Assembly Combination Pressure Temparaiure Gauge W M Basaboard Urits Combination Gas Yabe for 24 Voll Crain valve Wiring Harness In the interest of continual improvements in peoduct and performance Weil McLain reserves the right to change specifications without notice Weil MeLain m FII Locate our Sales Offices by visiting cur website Perge tac
4. 23 inches deep Power venting eliminates the need for a draft hood High grade stainless steel burners European designed high grade stainless steel burners for quiet ignition longer life and improved combustion Wiring harness Plug in connectors that attach only one way to assure mistake proof wiring for installation and component replacement Easy power hook up J box located on outside of boiler with pre stripped wires Convenient servicing Accessible controls control module with diagnostic indicator lights simplified wiring vertical fluaways top cleaning Factory tested Every bailer is tested at the factory to assure reliable operation Improved parts kits Parts furnished in convenient kits Limited lifetime warranty Covers cast iron sections Multiple boiler systems Use two or more high efficiency CGi boilers in place of one large capacity boiler to meet the space heating requirements of larger buildings Homeowner Protection Plan Covers labor and all Weil McLain supplied parts for 5 or 10 full years Available through participating Installers Weil McLain Control Module and Ignition Control Tha control module has The control module responds to signals from the room thermostat air pressure switch and boiler limit control ta aperate the boiler circulator pilot burner gas valve and inducer The module controls all ignition operating and safety related functions In addition its microprocess
5. 70 38 8 LD 233 14 16 827 45 44 51 Mob 11 FN for natural gas PL tor propane 2 an Gland ex gecedares preecnbed Dy the Urari Sates of Energy 3j 1 rains ore manet ao net rection pi suffice quently lor the mquirersents of the 32d need Da added ior oon peng ered Hors ine bakad pp and pick up slkowanee 1 13 An aciei alice b made for granoa pets aad picx up H Fuer Halena Clas Coda AME 2223 1 cin Ky chimie disg ast vea coagseckr lanes L3 bollerz gt CAA desgn ceed kr ie on Coe eee Teed for 3 pei acriumg pressus Dimensions Dimension Supply Return NatorLP Gas Crate Dimensions Boiler inches Piping Piping Connection Outside Measurements bn Modal W 1 1 Sizeinches Length Width Height CGi 25 1b us 2T 27 3145 CGk3 10 1 27 7 31 13 1 1 p er 27 31 15 CGi 5 16 1 1 s 30 27 314 CGH 18 1 T4 5 odd ot VS 3114 CGk 22 1 1 5 15 2 1 31 15 jr 25 1 m u 4 s 12 ry Holes Fange wi bober is sane sire 23 recommenced pipa sce Far supply and reium boter tapping sine es nim E 23 E qi ren t LEFT See CULL Le seippea las Cada iip ie pub akira ci reve pig Sui ara bare fer pipe sine i Cem Longe Each opening musi have located
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7. for accurate mixture of fuel and air This pravides for maximum efficiancy in fuel usage These bumers are made entirely of stainlass steel and designed so the burner parts provide exceptional stability with natural or propane gas for quieter operation longer life and improved combustion Venting Flexibility The CGi boiler has the flexibility to be vented one of two ways Direct Exhaust Venting Direct exhaust venting also known as induced draft uses inside combustion air with no combustion air connector piping The boiler can be non direct vented either through a side wall or through the roof This is considered a Category 111 appliance positive vent static pressure and vent gas temp erature that avoids excessive condensate in vent Natural Draft Venting Natural draft venting also Known as chimney draft venting uses the natural draft provided by a vertical vent or chimney This is considered a Category appliance non positive vent static pressure and vent gas temperature that avoids excessive condensate in vent Sequence of Operation 4 Supply to system i Flame rollout thermal fuse alement 1 Control Module 2 3 i Relum from system Burner shield Transrormner E Slainiess steel burners k Pilot burner and bracket 3 Inducer d Flue outlet Gas manifold 4 Air pressure switch B Gas vaha m ast iron boler sections F Pressure temperature gauge n Flue collectar
8. or continually checks itself 60 times each second If a situation such as electrical noise ar low voltage is encountered the control module restarts and retries eliminating nuisance lackouts And regardless of future control improvements the Weil McLain control module assures newer controls will always fit five indicator lights power thermostat amp circulator limit pressure switch flame that show proper operation and make troubleshooting easy plug in connectors that attach only one way t assure mistaka proof wiring if components ever need to be replaced Temperature amp Pressure Gauge All CGi boilers come with a large faced temperature and pressure gauge which installs in a tee in the boiler supply an the top of the boiler By installing the gauge in the system supply flow a more accurate reading is provided Also the location of the gauge and the larger face provide for easy monitoring of boiler temperature and pressure DOE Neti B R Approx Boiler Minimum Bailer Heating Water Shipping Water Vent Model Input Capacity Ratings DOE Seasonal Efficlency Weight Content Connector 1 MBHi2 MBH 2 MEH 3 Percent AFUE Lbs Gai Diameter 4 CGi25 42 37 B4 0 200 15 4 LD CGI 3 60 51 45 85 1 200 15 4 LD CGi 4 100 85 fd 240 2 1 51 0 CGi 5 120 100 87 83 3 280 2 7 8 1 0 CGI 6 167 40 122 81 3 325 33 s ID Oe CGi 7 200 187 145 830 3
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