Weil-McLain CGI-4E Boiler manual

Summary of contents each page of manual

Page 1

P ar t No . 550-110-711/1108 This manual must only be used by a qualiﬁed heating installer/ser vice technician. Before installing , read all instructions, including this manual, the burner manual and any related supplements. P erform steps in the order given.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 2 Part Number 550-110-711/1108 How it works . . . ① Control module The control module r esponds to signals from the room thermostat, air pressur e switch and boiler limit circuit to oper ate the boiler circulator , pilot burner , gas val ve and inducer .
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Part Number 550-110-711/1108 3 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual GOLD CGi-4E Gas-Fir ed Induced-Draft W ater Boiler.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 4 Part Number 550-110-711/1108 Contents How it works .................................................... 2–3 Hazar d deﬁnitions ............................................... 4 Please r ead before pr oceeding .
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Part Number 550-110-711/1108 5 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Please r ead befor e pr oceeding Failur e to adhere to the guidelines on this page can r esult in severe personal injury , death or substantial property damage. • Continual fresh mak eup water wil l reduce boiler life.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 6 Part Number 550-110-711/1108 Pr epar e boiler location — codes & checklist 1a Installations must follow these codes: • Local, state, provincial, andnationalcodes, la ws, regulations and or dinances.
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Part Number 550-110-711/1108 7 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — clearances 1b Figure 1b Required MINIMUM clearances Figure 1a Recommended SER VICE clearances (see W ARNING below) Recommended SERVICE clearances (Fig.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 8 Part Number 550-110-711/1108 Pr epar e boiler location — vent system 1c Failur e to follow all inst ructions can result in ﬂue gas spillage and carbon mono xide emissions, causing se v ere personal injury or death.
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Part Number 550-110-711/1108 9 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — air contamination T able 1 Corrosive or destructive contaminants and likely locations 1d Please review the following information on potential combustion air c ontamination problems.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 10 Part Number 550-110-711/1108 Figure 5 Air from outdoors — horizontal ducts Figure 4 Air from outdoors — vertical ducts Figure 2 Air openings to interior spaces Figure 3 Air directly through outside wall Air opening options T wo openings — Air su pply fr om insi de the buil ding ✷ 1.
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Part Number 550-110-711/1108 11 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Unusually tight construction U nusually tight construction means (per ANSI Z2 23.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 12 Part Number 550-110-711/1108 Pr epar e boiler — placement & setup 2a T able 2 Manifold oriﬁce sizing at sea level and altitudes to 4,500 feet Location Natural gas Propane gas U . S. 0-2,000 ft over 2,000 ft 0-2,000 ft o ver 2,000 ft 2.
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Part Number 550-110-711/1108 13 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler — pr essure test Hydr ostatic pressur e test Pr essure t est boiler befor e attac hing water o r gas piping (ex cept as noted below) or electrical supply .
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 14 Part Number 550-110-711/1108 V enting — general information 3a CGi-4E venting methods — Chimney draft or Dir ect exhaust Chimney draft venting Chimneydr aftventinguses thenatural draftprovidedby aver - tical vent or chimney .
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Part Number 550-110-711/1108 15 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual V enting — Dir ect exhaust — components 3c Obtain vent system components 1.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 16 Part Number 550-110-711/1108 V enting — dir ect exhaust — vent starter 3d 1.  Selectav ent pipemanufacturer and obtainall vent components ne eded, based on boiler location and venting method.
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Part Number 550-110-711/1108 17 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Fol lo w i ns tr u ct io n s on th i s p ag e when determining vent lo cation to av oid possibility of sever e personal inju r y , de ath or substa ntial pr operty damage.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 18 Part Number 550-110-711/1108 V enting — dir ect exhaust — installation 3f 1.  Donot mix ty pes or manufacturers ofv ent materi - als. 2.  Clean all joints before sealing.
Page 19

Part Number 550-110-711/1108 19 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Figure 15 Sidewall termination V enting — dir ect exhaust — installation (cont.) U sing an y te rmination other than one of those shown could cause nuisance outag es and loss of heat, resulting in substantial property damage.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 20 Part Number 550-110-711/1108 W ater piping — general information 4a General piping information If installation isto c omply withASME orCanadian requir ements,  anad - ditional high t emperatur e limit is needed.
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Part Number 550-110-711/1108 21 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual W ater piping — single-zone system 4b Diaphragm-type or bladder - type expansion tank (Figure 16) 1. Ensure expansion tank size w ill handle boiler and system water vol ume and temperature.
Page 22

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 22 Part Number 550-110-711/1108 4c Piping multiple zones Follo w instruc tions on pages 20 and 21 to install near- boiler or single-zone piping. (Also refer to Piping for radiant heating systems or con vert ed gra vity sys- tems , below , if applicable.
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Part Number 550-110-711/1108 23 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Figure 18 Zoning with circulators — return water 130°F or higher .
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 24 Part Number 550-110-711/1108 4d Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or burners, r esulting in severe p ersonal injur y , death or substantial property damage.
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Part Number 550-110-711/1108 25 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 1  B oilerisolation(balancing)val ves 2 Flow/check valv e 3  Systemorzonecir culator 4 Sys.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 26 Part Number 550-110-711/1108 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 ) .
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Part Number 550-110-711/1108 27 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 1  Boilerisolation(balancing)valv es 2 Flow/check val ve 3  Syst emorzonecirculat or 4 Sys.
Page 28

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 28 Part Number 550-110-711/1108 Piping — low temperatur e systems 4d SYSTEM-bypass piping method This piping method is cal led a system-bypass be cause part of the circulat or ﬂo w b ypasses the system (through valve 7a ).
Page 29

Part Number 550-110-711/1108 29 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 3 Systemo rzonecirculator 7 Systemtemperaturev alv es (seeinst ructions tothe .
Page 30

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 30 Part Number 550-110-711/1108 Gas piping 5 T able 7 Pipe capacity for 0.60 speciﬁc gravity natural gas Natural Gas: 1. R efer to T able 7  forpipelengthanddiamet er . Base on ra ted bo ile r inpu t (di vide by 1 ,00 0 to obta in cub ic feet per hour).
Page 31

Part Number 550-110-711/1108 31 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Field wiring 6 Thermostat 1.  Connect thermostat as shown on wir ing diagram on boiler . 2. Install on inside wall aw ay from inﬂuences of draf ts, hot or cold water pipes, lighting ﬁxt ures, television, sunra ys, or ﬁr eplaces.
Page 32

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 32 Part Number 550-110-711/1108 Start-up — pr eparation 7a Check for gas leaks  Beforestarting the boiler ,and dur - ing initial operation, smell near the ﬂoor and around the boiler for gas odor ant or any unusu al odor .
Page 33

Part Number 550-110-711/1108 33 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Fill the system with water 1.  Closemanualandautomatic air vents and boiler drain cock. 2. Fill to correct system pressure. Correct pressure wil l var ywitheac h application.
Page 34

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 34 Part Number 550-110-711/1108 Start-up — operate boiler 7b DO NO T proceed with boiler op er at io n un le ss b oil er a nd system h av e be en ﬁll ed w ith water and all instructions an d pr oce du res of pr ev io us m an u a l s e c t i on s h av e b e e n com pl ete d.
Page 35

Part Number 550-110-711/1108 35 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Figure 29 T ypical main burner ﬂame Check bur ner ﬂames V iew pilot and ma in a mes through the i nspection port in the base burner shield.
Page 36

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 36 Part Number 550-110-711/1108 Start-up — if boiler doesn’ t start . . . 7c 1. Loose conne ctio ns, bl own fuse or s er vice sw itch off? 2.  High limit switch set below boiler water tempera - ture? 3.
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Part Number 550-110-711/1108 37 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Check-out pr ocedur e — checklist 8 ❏ Boilerandheatdistributionunitslledw ithwater?.
Page 38

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 38 Part Number 550-110-711/1108 Operation — sequence 9a 1. Read Operating instr uctions on pa ge 4 1. This inf ormation is also located on a label on the inside o f the boiler jacket d oor panel.
Page 39

Part Number 550-110-711/1108 39 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Figure 30 Control module sequence of operation — status light indications.
Page 40

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 40 Part Number 550-110-711/1108 Operation — wiring diagrams 9b Figure 31 Wiring diagram.
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Part Number 550-110-711/1108 41 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 9c Operating instructions • Spark pilot • Natural or propane gas • Gas valve: Hone ywell VR8204/VR8304.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 42 Part Number 550-110-711/1108 Addendum Instruction for the Commonwealth of Massachusetts T hi s a d de n d um m u s t o n l y be u s ed b y a qualiﬁed heating installer/ser vice t echnician. Read th ese in str uct ion s com ple tely be fore beginning the installation.
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Part Number 550-110-711/1108 43 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T able 8 Service and maintenance schedules Service and maintenance — schedule 10a Follo w the Service and maint enance procedur es given throughout this manual and in component literature shipped with the boiler .
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 44 Part Number 550-110-711/1108 Air openings 1.  V erify th at c ombustio n and  v entilation air openings to the boiler room and/or building are open and unobstr ucted . 2.
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Part Number 550-110-711/1108 45 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual ❏ Inspect . . . Burners and base Th e b oil er cont ain s c era mic ﬁb er and ﬁb erg las s m ater ial s. Use ca re when handling these materials per instructions on page 68 o f t h is ma nua l.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 46 Part Number 550-110-711/1108 10b ❏ Check/test . . . Gas piping 1.  Sniff near oor andaround boilerarea foranyin - dication of a gas leak . 2. T est gas piping using bubble test,  perSect ion 5 of this manual, if there is any indication of a leak.
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Part Number 550-110-711/1108 47 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual ❏ Review with owner 1. R ev iew the User’ s Information Manual w ith the owner . 2. Emphasize the need to perform the maintenance schedule sp ecified in the User’ s Information Manual (and in this manual as well).
Page 48

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 48 Part Number 550-110-711/1108 T r oubleshooting — general 11a Air pr essure switch Mak e sure boiler water temperature is 100 °F or cooler before starting proce- dure t o obtain appropriate readings.
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Part Number 550-110-711/1108 49 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — components 11b Figure 36 Manometer connections Contr ol module Solder or water splatter b etween plugs and circuit board can c ause improper operation of control mod - ule.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 50 Part Number 550-110-711/1108 T r oubleshooting — components (continued) 11b Figure 38 Control module connections.
Page 51

Part Number 550-110-711/1108 51 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights 11c CHART 1 — Troubleshooting POWE R light status Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions.
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GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 52 Part Number 550-110-711/1108 T r oubleshooting — control module lights (cont.) 11c Electrical shock ha za rd — Wherever you see TURN OFF PO WER , follow the instructions. Failu re to follow instructions could result in severe personal inju ry, death or substantia l property damage.
Page 53

Part Number 550-110-711/1108 53 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 3 — PRESS SWITCH & POWER lights flashing Electrical shock ha za rd — Wherever you see TUR N OFF POWER , follow the instructions.
Page 54

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 54 Part Number 550-110-711/1108 T r oubleshooting — control module lights (cont.) 11c • Turn off power to the boiler at service switch or brea ker. • Wait at least 45 seco nds. • Turn on powe r to boiler.
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Part Number 550-110-711/1108 55 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 5 — PR ESS SWITCH light flashing and POWER light on steady Electrical shock ha za rd — Wherever you see TUR N OFF POWER , follow the instructions.
Page 56

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 56 Part Number 550-110-711/1108 T r oubleshooting — control module lights (cont.) 11c • TURN OFF POWER to boiler at service switch or breaker. • Remove burner shield (see Figure 40, item 4 , page 60 for location).
Page 57

Part Number 550-110-711/1108 57 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 7 — Insufficient heat or no heat to system ( POWER light on steady) Electrical shock ha za rd — Wherever you see TURN OFF PO WER , follow the instructions.
Page 58

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 58 Part Number 550-110-711/1108 Replacement parts 12a R eplacement parts must be purchased through a local W eil-McLain distributor . W hen ordering, specify boiler model and size and include description and part number of replaceme nt part.
Page 59

Part Number 550-110-711/1108 59 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — section assembly 12b Figure 39 Section assembly Item number Description Weil-McLain part num.
Page 60

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 60 Part Number 550-110-711/1108 Replacement parts — base 12c Figure 40 Base assembly.
Page 61

Part Number 550-110-711/1108 61 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — base (continued) 12c Item Description W eil-McLain part number Base assembly kit (includes b.
Page 62

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 62 Part Number 550-110-711/1108 Replacement parts — jacket 12d Figure 41 Jacket assembly.
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Part Number 550-110-711/1108 63 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — jacket (continued) 12d Boiler Model 1 2 3 4 5 Boiler Model Junction bo x, 2 x 4 P anel, left.
Page 64

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 64 Part Number 550-110-711/1108 Replacement parts — trim 12e Figure 42 T rim assembly Item number Description Manufacturer Manufacturer’ s par.
Page 65

Part Number 550-110-711/1108 65 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — contr ols 12f Figure 43 Gas control assembly Item number Description Boiler model Manufactur.
Page 66

GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 66 Part Number 550-110-711/1108 Dimensions 13a Figure 44 Dimensional drawing Boiler model number Supply tapping (inc hes NPT) Return tapping (inc .
Page 67

Part Number 550-110-711/1108 67 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Ratings T able 10 Boiler ratings 13b  CGi-4E boilers for residential r adiant panel systems, .
Page 68

68 Part Number 550-110-711/1108 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Handling ceramic ﬁber and ﬁber glass materials REMOV AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The co mbu sti on cha mbe r lini ng or bas e insulation panels in this pr oduct c on- tainceramicbermat erials.

Read the Weil-McLain CGI-4E manual - avoid problems

An important point after buying a device Weil-McLain CGI-4E (or even before the purchase) is to read its user manual. We should do this for several simple reasons:

to know how to properly use the device
to know how to perform maintenance/ periodic checks of correct operation of the product Weil-McLain CGI-4E
to know what to do in case of failure Weil-McLain CGI-4E

If you have not bought Weil-McLain CGI-4E yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Weil-McLain CGI-4E - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Weil-McLain CGI-4E you will learn all the available features of the product, as well as information on its operation. The information that you get Weil-McLain CGI-4E will certainly help you make a decision on the purchase.

If you already are a holder of Weil-McLain CGI-4E, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Weil-McLain CGI-4E.

However, one of the most important roles played by the user manual is to help in solving problems with Weil-McLain CGI-4E. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Weil-McLain CGI-4E along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center

Weil-McLain CGI-4E manual

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