Weil-McLain Series 2 manual 7c Start-up if boiler doesn’t start, Check burner flames, Check for

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

7b Start-up — operate boiler (continued)

Check burner flames

Figure 28  Typical pilot burner flame

View pilot and main flames through the inspection port in the base burner shield.

Pilot burner flame (Figure 28)

PROPER pilot flame characteristics

1.Blue flame.

2.Inner cone engulfing pilot flame sensor.

3.Pilot flame sensor glowing cherry red.

IMPROPER pilot flame characteristics

1.Overfired — Large flame lifting or blowing past pilot flame sensor.

2.Underfired — Small flame. Inner cone not engulfing pilot flame sensor.

3.Lack of primary air — Yellow flame tip.

4.Incorrectly heated pilot flame sensor.

Main burner flame (Figure 29)

PROPER main burner flame characteristics

Figure 29  Typical main burner flame

1.Yellow-orange streaks may appear (caused by dust).

IMPROPER main burner flame characteristics

1.Overfired — Large flames.

2.Underfired — Small flames.

3.Lack of primary air — Yellow tipping on flames (sooting will occur).

7c Start-up — if boiler doesn’t start . . .

Check for:

1.Loose connections, blown fuse or service switch off?

2.High limit switch set below boiler water temperature?

3.Thermostat set below room tempera- ture?

4.Gas not turned on at meter or boiler?

5.Incoming gas pressure less than:

5” w.c. for natural gas? 11” w.c. for propane gas?

6.If none of the above corrects the problem, refer to Troubleshoot- ing, section 11 of this manual.

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 Before locating the boiler, check the following 1a Prepare boiler location codes & checklistInstallations must follow these codes 1b Prepare boiler location clearances Chimney or vent require- ments When removing boiler from an existing common vent system1c Prepare boiler location vent system Products to avoid 1d Prepare boiler location air contaminationTwo openings Air supply from inside the building 1e Prepare boiler location air openingsAir openings must be provided Air opening optionsException for large spaces Exhaust fans and air moversMotorized air dampers Single air opening optionInspect orifices and burners 2a Prepare boiler placement & setupOrifice replacement procedure Place boiler/crate near positionPrepare boiler for test 2b Prepare boiler pressure testHydrostatic pressure test Drain and remove fittingsChimney draft venting 3a Venting general informationVenting chimney draft venting CGi venting methods Chimney draft or Direct exhaustObtain 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 Closed-type expansion tank 4b Water piping single-zone systemDiaphragm-type or bladder- type expansion tank Figure Piping multiple zones 4c Water piping multiple zonesZoning with circulators Primary/secondary preferred bypass piping method 4d Piping low temperature systemsTemperature gauges Valve adjustmentPrimary/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 systemPropane Gas Connecting gas supply piping to boilerGas piping Natural GasThermostat Field wiringElectrical installation must comply with Wiring connectionsDetermine if water treatment is needed Freeze protection when used7a Start-up preparation Check for gas leaksInspect base insulation Fill the system with waterInspect system water piping Check system and boiler 7b Start-up operate boilerStart the boiler Pilot burner flame Figure 7c Start-up if boiler doesn’t startCheck burner flames Check forInstallation 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 Inducer motor 10b Service & maintenance annual start-upBurners and base Condensate drain systemLimit controls and cutoffs Gas pipingCold fill and operating pressures Air vents and air eliminationBoiler relief valve Review with ownerAir pressure switch 11a Troubleshooting procedure11b Troubleshooting components Before troubleshootingControl module Control indicator lightsTroubleshooting the control module Control indicator lights Lockout modesControl 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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