Weil-McLain CGI-4E manual 2a Prepare boiler placement & setup, Place boiler/crate near position

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

2a Prepare boiler — placement & setup

Place boiler/crate near position

1.Leave boiler in crate and on pallet until installation site is ready.

2.Move entire crate and pallet next to selected location.

3.Remove crate.

4.Remove boiler from pallet.

Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result.

a.Tilt left side of boiler up and place a board under left legs.

b.Tilt boiler the other way and place a board under right legs.

c.Slide boiler backward off pallet and into position.

5.Check level.

a.Shim legs, if necessary.

b.Do not alter legs.

Inspect orifices and burners

1.Remove front jacket door. Remove burner shield (see Figure 40, item 4, page 60).

2.Check for correctly-sized manifold orifices. See Table 2 for sizing. (The orifice size is stamped on the orifice spud barrel.)

Correctly-sized manifold orifices must be used. Failure to do so will result in severe personal injury, death or sub- stantial property damage.

3. Reinstall burner shield.

Do not operate boiler without burner shield in place. Failure to do so could result in severe personal injury, death or sub- stantial property damage.

Orifice replacement procedure

(when required)

1.Remove the screws securing the burner shield and remove burner shield.

2.Using a 7/16” open-end wrench, remove the burner orifices from the manifold.

3.Apply a small amount of pipe dope to each of the new orifices and install in the manifold us- ing a 7/16” open-end wrench. Make sure the ori- fices are aligned correctly, not cross-threaded in the manifold tappings.

Use only pipe dope compatible with propane gas, even if boiler is to be operated on natural gas. Failure to comply could result in severe personal injury, death or substantial property dam- age.

4.Carefully replace the burner shield.

5.Follow the check-out procedure, Section 8, page 37, to assure the boiler is now operating properly after orifices are replaced.

Table 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

over 2,000 ft

2.55 mm

(Note 1)

1.60 mm

(Note 1)

 

Canada

0-2,000 ft

2,000-4,500

0-2,000 ft

2,000-4,500

2.55 mm

#41

1.60 mm

1.45 mm

 

 

 

 

 

 

Note 1: For elevations above 2,000 feet, contact your local Weil-McLain sales office for details.

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Part Number 550-110-711/1108

 

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Contents GOLDCGi-4E How it works Gold CGi-4EGas-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 Check for nearby connection to1b Prepare boiler location clearances When removing boiler from an existing common vent system 1c Prepare boiler location vent systemChimney or vent require- ments 1d Prepare boiler location air contamination Remove contaminants permanentlyProducts to avoid Areas likely to have contaminants1e Prepare boiler location air openings Air openings must be providedAir opening options Two openings Air supply from inside the buildingExhaust fans and air movers Motorized air dampersSingle air opening option Exception for large spaces2a Prepare boiler placement & setup Orifice replacement procedurePlace boiler/crate near position Inspect orifices and burners2b Prepare boiler pressure test Hydrostatic pressure testDrain and remove fittings Prepare boiler for test3a Venting general information Venting chimney draft ventingCGi-4E venting methods Chimney draft or Direct exhaust Chimney draft venting3c Venting Direct exhaust components Obtain vent system componentsDo not exceed data in Table Do not mix components3d Venting direct exhaust vent starter 3e Venting direct exhaust termination Do not wrap or insulate vent pipe or fittings3f Venting direct exhaust installation Slip connector for Saf-T VentDo not mix types or manufacturers of vent materi- als Use their specified sealant. Do not use screwsUsing 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 4c Water piping multiple zones Piping multiple zonesBoiler isolation balancing valves System or zone circulator Zone valve Drain valve4d Piping low temperature systems Temperature gaugesValve adjustment Primary/secondary preferred bypass piping methodBlend temperature gauge Valve adjustment BOILER-bypass piping methodBoiler-bypass piping Zoning with SYSTEM-bypass piping method 4e Water piping refrigeration system Prevent chilled water from entering boilerSystem or zone circulator Chilled medium from entering boiler. See forConnecting gas supply piping to boiler Gas pipingNatural Gas Propane GasField wiring Electrical installation must comply withWiring connections ThermostatFreeze protection when used 7a Start-up preparationCheck for gas leaks Determine if water treatment is neededFill the system with water Inspect system water pipingInspect base insulation Close manual and automatic air vents and boiler drain cock7b Start-up operate boiler Start the boilerCheck system and boiler Check burner flames Pilot burner flame FigureMain burner flame Figure High limit switch set below boiler water tempera- ture? 7c Start-up if boiler doesn’t startCheck for Gas not turned on at meter or boiler?Check-out procedure checklist 9a Operation sequence Boiler is now in the off cycleGold CGi-4E Gas-Fired Water Boiler Boiler Manual 9b Operation wiring diagrams Wiring diagramOperating instructions Addendum Instruction for Commonwealth of Massachusetts One-half 1/2 inch in size, GAS Vent Directly beCMR 5.082a 1 through CMR 5.082a1 through10a Service and maintenance schedule Verify Proper Operation After Servicing10b Service and maintenance annual start-up 10b Service & maintenance annual start-up Burners and baseCondensate drain system Inducer motorGas piping Cold fill and operating pressuresAir vents and air elimination Limit controls and cutoffsSafety relief valves should be reinspected AT Least Review with ownerBoiler relief valve Shut down boiler11a Troubleshooting general Before troubleshootingAir pressure switch Check the following11b Troubleshooting components Control moduleControl module connections 11c Troubleshooting control module lights Chart 1 Troubleshooting Power light statusChart 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 of operation, , 12a Replacement parts Section assembly Base Jacket Trim Controls12b Replacement parts section assembly Description Weil-McLain Number Part number12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyBoiler 12e Replacement parts trim Part number12f Replacement parts controls Propane gas components13a Dimensions Width13b Ratings DOEHandling ceramic fiber and fiberglass materials Use Niosh certified dust respirator N95Breathing Fresh air

CGI-4E specifications

The Weil-McLain CGI-4E is a standout in the realm of commercial boilers, designed to meet the rigorous demands of a variety of heating applications. This gas-fired cast iron boiler exemplifies durability, efficiency, and performance, making it a popular choice in various commercial settings, including schools, hospitals, and office buildings.

One of the main features of the CGI-4E is its cast iron construction. Cast iron has long been favored for its excellent heat retention and distribution capabilities, leading to improved overall efficiency. The boiler is designed to maximize heat output while minimizing energy consumption. This characteristic is especially beneficial for businesses seeking to lower their energy costs without sacrificing comfort.

In terms of efficiency, the Weil-McLain CGI-4E boasts an impressive thermal efficiency rating. Its design incorporates advanced technology, allowing it to achieve an AFUE rating of up to 84%. This efficiency is achieved through features such as a full-modulating burner and a unique heat exchanger design that allows for optimal heat transfer and reduced flue gas temperatures.

The CGI-4E is also remarkable for its versatility. It is offered in a variety of sizes, making it suitable for different heating loads. This flexibility allows for installation in a wide range of environments, adapting easily to both existing and new heating systems. Additionally, the boiler comes with multiple venting options, including direct vent and conventional venting, further enhancing its installation flexibility.

Another standout feature is the integrated boiler control system, which simplifies operation and monitoring. This control system optimizes burner performance and enhances safety features, including automatic shut-off in case of system anomalies. The advanced controls also allow for easy integration with building management systems, enabling better energy management and reduced operational costs.

The CGI-4E also emphasizes ease of maintenance, with service-friendly designs that allow technicians to access components without difficulty. This consideration translates to reduced downtime and lower maintenance costs, ensuring that the boiler operates efficiently over its lifetime.

Overall, the Weil-McLain CGI-4E blends reliability, efficiency, and advanced technology, making it a premier choice for commercial heating needs. Its cast iron construction, impressive efficiency ratings, versatile installation options, and user-friendly controls solidify its reputation as a leading boiler solution in the industry.
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