Weil-McLain Series 2 manual Fill the system with water, Inspect system water piping

Page 33

GOLD CGi Gas-Fired Water Boiler — Boiler Manual

7a Start-up — preparation (continued)

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.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.

b.Close the boiler or system isolation valve between the purge valve and fill connection to the system.

c.Close zone isolation valves.

d.Open quick-fill valve on cold water makeup line.

e.Open purge valve.

f.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.

g.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.

h.After the system has operated for a while, eliminate any residual air by using the manual air vents located throughout the system.

i.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.Open automatic air vent (diaphragm-type or bladder-type expansion tank systems only) one turn.

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.

Failure 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

5.Open other vents:

a.Starting on the lowest floor, open air vents one at a time until water squirts out.

b.Repeat with remaining vents.

6.Refill to correct pressure.

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.

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 1a Prepare boiler location codes & checklist Installations must follow these codesBefore locating the boiler, check the following 1b Prepare boiler location clearances When removing boiler from an existing common vent system 1c Prepare boiler location 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 4b Water piping single-zone system Diaphragm-type or bladder- type expansion tank FigureClosed-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 neededFill the system with water Inspect system water pipingInspect base insulation 7b Start-up operate boiler Start the 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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