Weil-McLain Series 2 manual 2b Prepare boiler pressure test, Hydrostatic pressure test

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

2b Prepare boiler — pressure test

Hydrostatic pressure test

Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply.

Prepare boiler for test

1.Remove the shipping nipple (from CGi supply tap- ping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾” NPT pipe plug.

2.Remove 1¼” 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.

3.Remove 1¼” nipple, 1¼” x 1¼” x ½” 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.)

4.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.

5.Connect a nipple and shutoff valve to system supply connection on the 1¼” tee. This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

6.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

1.Open the shutoff valves you installed on supply and return connections.

2.Slowly open boiler drain valve and fresh water sup- ply to fill boiler with water.

3.When water flows from shutoff valves, close boiler drain valve.

4.Close shutoff valves.

5.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.

6.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.

7.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

1.Disconnect fill water hose from water source.

2.Drain boiler at drain valve or out hose, whichever provides best access to drain. Remove hose after draining if used to drain boiler.

3.Remove nipples and valves unless they will remain for use in the system piping.

4.Remove plug from relief valve tapping. See page 20 to replace relief valve.

Part Number 550-110-710/0107

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Contents Gold CGi How it works Gold CGi Gas-Fired Induced-Draft Water Boiler Contents Please read before proceeding Installations must follow these codes 1a Prepare boiler location codes & checklistBefore locating the boiler, check the following 1b Prepare boiler location clearances 1c Prepare boiler location vent system When removing boiler from an existing common vent systemChimney or vent require- ments Products to avoid 1d Prepare boiler location air contaminationAir openings must be provided 1e Prepare boiler location air openingsAir opening options Two openings Air supply from inside the buildingMotorized air dampers Exhaust fans and air moversSingle air opening option Exception for large spacesOrifice replacement procedure 2a Prepare boiler placement & setupPlace boiler/crate near position Inspect orifices and burnersHydrostatic pressure test 2b Prepare boiler pressure testDrain and remove fittings Prepare boiler for testVenting chimney draft venting 3a Venting general informationCGi venting methods Chimney draft or Direct exhaust Chimney draft ventingObtain vent system components 3c Venting Direct exhaust components3d Venting direct exhaust vent starter Vent termination minimum clearances 3e Venting direct exhaust terminationDirect exhaust vertical venting 3f Venting direct exhaust installationUsing any termination other than one of those shown 4a Water piping general information Diaphragm-type or bladder- type expansion tank Figure 4b Water piping single-zone systemClosed-type expansion tank Piping multiple zones 4c Water piping multiple zonesZoning with circulators Temperature gauges 4d Piping low temperature systemsValve adjustment Primary/secondary preferred bypass piping methodPrimary/secondary piping BOILER-bypass piping method Valve adjustmentBoiler-bypass piping Zoning with SYSTEM-bypass piping method Prevent chilled water from entering boiler 4e Water piping refrigeration systemGas piping Connecting gas supply piping to boilerNatural Gas Propane GasElectrical installation must comply with Field wiringWiring connections Thermostat7a Start-up preparation Freeze protection when usedCheck for gas leaks Determine if water treatment is neededInspect system water piping Fill the system with waterInspect base insulation Start the boiler 7b Start-up operate boilerCheck system and boiler Check burner flames 7c Start-up if boiler doesn’t startCheck for Pilot burner flame FigureInstallation and service certificate Check-out procedure checklist9a Operation sequence Schematic wiring diagram 9b Operation wiring diagramsLadder wiring diagram 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-8 Verify Proper Operation After Servicing 10a Service and maintenance schedule10b Service and maintenance annual start-up Burners and base 10b Service & maintenance annual start-upCondensate drain system Inducer motorCold fill and operating pressures Gas pipingAir vents and air elimination Limit controls and cutoffsBoiler relief valve Review with owner11b Troubleshooting components 11a Troubleshooting procedureBefore troubleshooting Air pressure switchTroubleshooting the control module Control indicator lightsControl indicator lights Lockout modes Control moduleControl module connections Chart 1- Troubleshooting Power light status 11c Troubleshooting control module lightsChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Chart 4 Flame & Power lights flashing Does blower motor operate? Item 8 , Verify Sequence Section assembly Base Jacket Trim Controls 12a Replacement partsSection assembly 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketBoiler Fittings shown are included with boiler 12e Replacement parts trimPropane gas components 12f Replacement parts controlsDimensional drawing 13a DimensionsDOE 13b RatingsRemoval of Combustion Chamber Lining or Base Panels Handling ceramic fiber and fiberglass materials
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Series 2 specifications

The Weil-McLain Series 2 is a highly regarded boiler system known for its robustness, efficiency, and ease of installation. Designed primarily for residential and light commercial applications, the Series 2 boasts a variety of features that cater to diverse heating needs.

One of the standout characteristics of the Series 2 is its cast iron construction, which provides durability and longevity. Cast iron is well-suited for heat retention, allowing the boiler to operate more efficiently and deliver consistent warmth. The Series 2 is available in multi-fuel options, accommodating both natural gas and propane, making it versatile for various installations.

Efficiency is a key feature of the Weil-McLain Series 2, with annual fuel utilization efficiency (AFUE) ratings that meet or exceed industry standards. This ensures that homeowners can enjoy not only a comfortable living environment but also reduced energy bills. The Series 2 is designed to provide optimal performance, minimizing fuel consumption while maximizing heat output.

Another innovative aspect of the Series 2 is its user-friendly control system. Equipped with advanced controls, the boiler allows for precise temperature management and can easily be integrated with existing heating systems. This adaptability is crucial for ensuring that the boiler matches the specific heating demands of any space, increasing overall comfort levels.

Installation is straightforward, thanks to the boiler's thoughtful design. The Series 2 features a compact footprint, allowing for flexible placement in various settings. Additionally, Weil-McLain provides comprehensive documentation and customer support, making it easier for technicians to install and maintain the system.

The Series 2 also includes features aimed at ease of maintenance. Its clean-out ports facilitate quick access for servicing, ensuring that the boiler remains in peak operating condition throughout its lifespan. Weil-McLain’s commitment to quality means users can expect reliable performance year after year.

Overall, the Weil-McLain Series 2 stands out as an excellent choice for those seeking a dependable, efficient, and straightforward heating solution. Its combination of durable construction, high efficiency, and user-centric design makes it a leading option in the boiler market, appealing to both homeowners and professionals alike. Whether for a new installation or a replacement, the Series 2 is poised to deliver exceptional heating performance.
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