Weil-McLain CGI-4E manual 2b Prepare boiler pressure test, Hydrostatic pressure test

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GOLD CGi-4E 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-4E supply tapping) and remove the boiler relief valve. Tempo- rarily 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 550-110-711/1108

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Contents GOLDCGi-4E How it works Gold CGi-4EGas-Fired Induced-Draft Water Boiler Contents Please read before proceeding Installations must follow these codes 1a Prepare boiler location codes & checklistBefore locating the boiler, check the following Check for nearby connection to1b Prepare boiler location clearances 1c Prepare boiler location vent system When removing boiler from an existing common vent systemChimney or vent require- ments Remove contaminants permanently 1d Prepare boiler location air contaminationProducts to avoid Areas likely to have contaminantsAir 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-4E venting methods Chimney draft or Direct exhaust Chimney draft ventingObtain vent system components 3c Venting Direct exhaust componentsDo not exceed data in Table Do not mix components3d Venting direct exhaust vent starter Do not wrap or insulate vent pipe or fittings 3e Venting direct exhaust terminationSlip connector for Saf-T Vent 3f Venting direct exhaust installationDo 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 Diaphragm-type or bladder- type expansion tank Figure 4b Water piping single-zone systemClosed-type expansion tank Piping multiple zones 4c Water piping multiple zonesSystem or zone circulator Zone valve Drain valve Boiler isolation balancing valvesTemperature gauges 4d Piping low temperature systemsValve adjustment Primary/secondary preferred bypass piping methodBlend temperature gauge BOILER-bypass piping method Valve adjustmentBoiler-bypass piping Zoning with SYSTEM-bypass piping method Prevent chilled water from entering boiler 4e Water piping refrigeration systemSystem or zone circulator Chilled medium from entering boiler. See forGas 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 Close manual and automatic air vents and boiler drain cockStart the boiler 7b Start-up operate boilerCheck system and boiler Pilot burner flame Figure Check burner flamesMain burner flame Figure 7c Start-up if boiler doesn’t start High limit switch set below boiler water tempera- ture?Check for Gas not turned on at meter or boiler?Check-out procedure checklist Boiler is now in the off cycle 9a Operation sequenceGold CGi-4E Gas-Fired Water Boiler Boiler Manual Wiring diagram 9b Operation wiring diagramsOperating instructions One-half 1/2 inch in size, GAS Vent Directly be Addendum Instruction for Commonwealth of MassachusettsCMR 5.082a 1 through CMR 5.082a1 throughVerify 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 cutoffsReview with owner Safety relief valves should be reinspected AT LeastBoiler relief valve Shut down boilerBefore troubleshooting 11a Troubleshooting generalAir pressure switch Check the followingControl module 11b Troubleshooting componentsControl 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 of operation, , Section assembly Base Jacket Trim Controls 12a Replacement partsDescription Weil-McLain Number Part number 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketBoiler Part number 12e Replacement parts trimPropane gas components 12f Replacement parts controlsWidth 13a DimensionsDOE 13b RatingsUse Niosh certified dust respirator N95 Handling ceramic fiber and fiberglass materialsBreathing 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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