Instruction/ maintenance manual of the product GOLD CGI 550-110-710/0107 Weil-McLain
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P ar t No . 550-110-710/0107 This manual must only be used b y a qualified heating installer/serv ice t echnician. Before installing , read all instructions, including this manual, the burner manual and any related supplements. P erform steps in the order given.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 2 Part Number 550-110-710/0107 How it works . . . ① Control module The control module responds to sig nals from the r oom thermostat, air pressure switch and boiler limit circuit to operate the boiler circulat or , pilot burner , g as valve and inducer .
Part Number 550-110-710/0107 3 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual GOLD CGi Gas-Fir ed Induced-Draft W ater Boiler.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 4 Part Number 550-110-710/0107 Contents How it works .................................................... 2–3 Hazar d definitions ............................................... 4 Please r ead before pr oceeding .
Part Number 550-110-710/0107 5 GOLD CGi 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. • C ontinual fresh makeup water will reduce boiler life.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 6 Part Number 550-110-710/0107 Pr epar e boiler location — codes & checklist 1a Installations must follow these codes: • L ocal, state, pr ovincial, and national c odes, la ws, regulations and ordinanc es.
Part Number 550-110-710/0107 7 GOLD CGi 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.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 8 Part Number 550-110-710/0107 Pr epar e boiler location — vent system 1c Failur e to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
Part Number 550-110-710/0107 9 GOLD CGi 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 rev iew the following information on potential combustion air c ontamination problems.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 10 Part Number 550-110-710/0107 Figure 5 Air fr om o utdoo rs — hori zont al du cts Figure 4 Air from outdoors — vertical ducts Figure 2 Air open.
Part Number 550-110-710/0107 11 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Unusually tight construction U nusually tight construction means (per ANSI Z2 23.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 12 Part Number 550-110-710/0107 Pr epar e boiler — placement & setup 2a T able 2 Manifold orifice sizing at sea level and altitudes to 4,500 feet Place boiler/crate near position 1. Lea ve boiler in crate and on palle t unt il instal lation sit e is ready .
Part Number 550-110-710/0107 13 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler — pr essure test Hydr ostatic pressur e test Pr essure tes t boil er bef or e attaching water or gas piping (ex cept as noted below) or electrical supply .
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 14 Part Number 550-110-710/0107 V enting — general information 3a CGi venting methods — Chimney draft or Dir ect exhaust Chimney draft venting Chimney draft venting uses the natural draft provided by a v erti cal ve nt or ch imney .
Part Number 550-110-710/0107 15 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual V enting — Dir ect exhaust — components 3c Obtain vent system components 1.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 16 Part Number 550-110-710/0107 V enting — dir ect exhaust — vent starter 3d 1. Select a vent pipe man ufacturer and obtain all vent components ne eded, based on boiler location and venting method.
Part Number 550-110-710/0107 17 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Fol lo w i ns tr u ct i on s o n t hi s p ag e when determining vent locat ion to av oid possibility of sever e personal inj ur y , de ath or substa ntial pr operty damage.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 18 Part Number 550-110-710/0107 V enting — dir ect exhaust — installation 3f 1. Do not mix t ypes or manufactur ers of vent materi- als. 2. Clean all j oints before sealing. See vent manufactur - er’ s instructions for c leaning and sealing joints.
Part Number 550-110-710/0107 19 GOLD CGi 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.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 20 Part Number 550-110-710/0107 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.
Part Number 550-110-710/0107 21 GOLD CGi 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.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 22 Part Number 550-110-710/0107 4c Piping multiple zones Follo w instruc tions on pages 20 and 21 to install near- boiler or single-zone piping. (Also re fer to Piping for radiant heating systems or conv ert ed gravity sys- tems , below , if applicable.
Part Number 550-110-710/0107 23 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Figure 18 Zoning with circulators — return water 130°F or higher .
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 24 Part Number 550-110-710/0107 4d Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or burners, resulting in sever e personal injur y , death or substantial property damage.
Part Number 550-110-710/0107 25 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 1 Boiler isolation (balancing) valv es 2 Flow/chec k valve 3 Syst em or zone circulat or 4 System t emperature gauges.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 26 Part Number 550-110-710/0107 BOILER-bypass piping method This piping method ( Figure 22 or 23 ) is called a boiler - bypass because part of the circulator flow is b y passed arou nd th e b oile r ( thro ugh va lve 7 a ).
Part Number 550-110-710/0107 27 GOLD CGi 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 Syst em temperature gauges.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 28 Part Number 550-110-710/0107 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 val ve 7a ).
Part Number 550-110-710/0107 29 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 3 System o r zone circulator 7 System temperature v alv es (see inst ructions to the left for adjusting valv es) 8 Bl.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 30 Part Number 550-110-710/0107 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 b oile r inpu t (di vide b y 1,00 0 to obtai n cubi c feet per hour).
Part Number 550-110-710/0107 31 GOLD CGi 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.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 32 Part Number 550-110-710/0107 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 .
Part Number 550-110-710/0107 33 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Fill the system with water 1. Close manual and aut omatic air vents and boiler drain cock. 2. Fill to correct system pressure. Correct pressure wil l var y with eac h application.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 34 Part Number 550-110-710/0107 Start-up — operate boiler 7b DO NOT proceed with boiler op er at io n u nl es s b oil er a nd system h a ve be en fille d wit h w a t e r a n d a l l i n s t r u c t i o n s an d p roce du res o f p re vi ou s m an u a l s e ct i o n s h ave b e e n com pl ete d.
Part Number 550-110-710/0107 35 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Figure 29 T ypical main burner flame Check bur ner flames V iew pilot and ma in fla mes through the i nspection port in the base burner shield. Pilot burner flame ( Figure 28 ) PROPER pilot flame characteristics 1.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 36 Part Number 550-110-710/0107 Check-out pr ocedur e — checklist 8 ❏ Boiler and heat distribution units filled w ith water? ❏ A utomati.
Part Number 550-110-710/0107 37 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Operation — sequence 9a Figure 30 Control module sequence of operation — status light indications 1. Read Operating instr uctions o n p age 40 . Th is information is also located on a label on the inside of the boiler jack et door panel.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 38 Part Number 550-110-710/0107 Operation — wiring diagrams 9b Figure 31 Schematic wiring diagram.
Part Number 550-110-710/0107 39 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Figure 32 Ladder wiring diagram.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 40 Part Number 550-110-710/0107 9c Operating instructions CGi-25 to CGi-6 • Spark pilot • Natural or propane gas • Gas valve: Hone ywell VR8204.
Part Number 550-110-710/0107 41 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 9c Operating instructions CGi-25 to CGi-6 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36E.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 42 Part Number 550-110-710/0107 9c Operating instructions CGi-25 to CGi-8 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36C.
Part Number 550-110-710/0107 43 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T able 8 Service and maintenance schedules Service and maintenance — schedule 10a Follo w the Service and maintenance procedur es given throughout this manual and in com- ponent literature shipped w ith the b oiler .
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 44 Part Number 550-110-710/0107 Air openings 1. V erify that comb ustion and v entilati on air open ings to the boiler room and/or building are open and unobstr ucted . 2. V erify that boiler vent discharge is clean and free of obstr uctions .
Part Number 550-110-710/0107 45 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual ❏ Inspect . . . Burners and base Th e b oil er con tain s cer ami c fi ber and fib erg las s m ater ial s. U s e ca re when handling these materials p er i ns t r uc t io n s o n p a g e 6 8 o f t h is ma nua l.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 46 Part Number 550-110-710/0107 10b ❏ Check/test . . . Gas piping 1. Sniff near floor and around boiler area for an y 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.
Part Number 550-110-710/0107 47 GOLD CGi 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 s c h e du l e s p e c i f i e d i n t h e User’ s Information Manual (and in this manual as well).
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 48 Part Number 550-110-710/0107 T r oubleshooting — components 11b T r oubleshooting — procedur e 11a Air pr essure switch Mak e sure boiler water t emperature is 100 °F or cooler before start ing procedur e to obtain appr opriate r ead- ings.
Part Number 550-110-710/0107 49 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — components (continued) 11b Figure 36 Manometer connections Contr ol module Solder or wat er splat ter be tween plugs and circuit board ca n cause imp r ope r ope rati on of con tr ol mod- ule.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 50 Part Number 550-110-710/0107 T r oubleshooting — components (continued) 11b Figure 38 Control module connections.
Part Number 550-110-710/0107 51 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights 11c CHART 1— Troubleshooting POWER light status Electrical shock hazard — Wherever you see ▲ TURN OFF PO WER ▲ , follow the instructions.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 52 Part Number 550-110-710/0107 T r oubleshooting — control module lights (cont.) 11c 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.
Part Number 550-110-710/0107 53 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 3 — PR ESS SWITCH & POWER lights flashing Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 54 Part Number 550-110-710/0107 T r oubleshooting — control module lights (cont.) 11c • Turn off power to the boiler at service switch or breaker. • Wait at least 45 seconds. • Turn on power to boiler.
Part Number 550-110-710/0107 55 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 5 — P RESS SWITCH light flash ing and POWER light on steady Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 56 Part Number 550-110-710/0107 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).
Part Number 550-110-710/0107 57 GOLD CGi 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 hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 58 Part Number 550-110-710/0107 Replacement parts 12a Section assembly .............................................. 59 Base ................................................................. 60 Jacket .
Part Number 550-110-710/0107 59 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Replacement parts — section assembly 12b Figure 39 Section assembly.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 60 Part Number 550-110-710/0107 Replacement parts — base 12c Figure 40 Base assembly.
Part Number 550-110-710/0107 61 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Item Description W eil-McLain part number Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6 and 7) CGi-2.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 62 Part Number 550-110-710/0107 Replacement parts — jacket 12d Figure 41 Jacket assembly.
Part Number 550-110-710/0107 63 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Boiler Model 1 2 3 4 5 Boiler Model Junction box, 2 x 4 Panel, left side , with insulation Panel, right side , with i.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 64 Part Number 550-110-710/0107 Replacement parts — trim 12e Figure 42 T rim assembly Item number Description Manu facturer Ma nufact urer’ s par.
Part Number 550-110-710/0107 65 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Replacement parts — contr ols 12f Figure 43 Gas control assembly Item number Description Boiler model Manufacturer .
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 66 Part Number 550-110-710/0107 Dimensions 13a Figure 44 Dimensional drawing.
Part Number 550-110-710/0107 67 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Ratings T able 10 Boiler ratings DOE 13b CGi boilers fo r r esidential radiant panel systems, con verted gr a vit y h.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 68 Part Number 550-110-710/0107 Handling ceramic fiber and fiber glass materials REMOV AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The combustion chamber l ining or base insulation pane ls in this prod- uct contain ceramic fib er materials.
An important point after buying a device Weil-McLain GOLD CGI 550-110-710/0107 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Weil-McLain GOLD CGI 550-110-710/0107 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 GOLD CGI 550-110-710/0107 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Weil-McLain GOLD CGI 550-110-710/0107 you will learn all the available features of the product, as well as information on its operation. The information that you get Weil-McLain GOLD CGI 550-110-710/0107 will certainly help you make a decision on the purchase.
If you already are a holder of Weil-McLain GOLD CGI 550-110-710/0107, 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 GOLD CGI 550-110-710/0107.
However, one of the most important roles played by the user manual is to help in solving problems with Weil-McLain GOLD CGI 550-110-710/0107. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Weil-McLain GOLD CGI 550-110-710/0107 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
