Weil-McLain CGI-4E manual Field wiring, Thermostat, Electrical installation must comply with

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

6 Field wiring

For your safety, turn off electrical power supply at service entrance panel before making any electrical

connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

Wiring must be N.E.C. Class 1.

If original rollout thermal fuse element wire as supplied with boiler must be replaced, use only type 200°C wire or equivalent. If other original wiring as supplied with boiler must be replaced, type 105°C wire or equivalent must be used.

Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70–latest edi- tion.

Thermostat

1.Connect thermostat as shown on wiring diagram on boiler.

2.Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunrays, or fireplaces.

3.If thermostat has a heat anticipator, set heat antici- pator in thermostat to match power requirements of equipment connected to it. If connected directly to boiler, set for 0.1 amps plus gas valve current.

See information on wiring diagram as shown in

Figure 31, page 40. For other devices, refer to manu- facturer’s specifications. Wiring diagram on boiler gives setting for control module and gas valve. Also see instructions with thermostat.

Electrical installation must comply with:

1.National Electrical Code and any other national, state, provincial or local codes or regulations.

2.In Canada, CSA C22.1 Canadian Electrical Code

Part 1, and any local codes.

Wiring connections

Boiler is shipped with controls completely wired.

Junction Box (furnished)

1.Connect 120 VAC power wiring as shown in

Figure 27.

2.Fused disconnect or service switch (15 amp. recom- mended) may be mounted on this box. For those installations with local codes which prohibit installa- tion of fused disconnect or service switch on boiler, install a 2 x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code.

The CGi-4E control module is polarity-sensitive. The hot and neutral wires must be connected to the correct leads. A flashing POWER light usually indicates reversed polarity of 120 VAC lead wires.

Figure 27

Field wiring connections — service switch and thermostat (or end switch) provided by installer

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 Check for nearby connection to 1a Prepare boiler location codes & checklistInstallations must follow these codes Before locating the boiler, check the following1b Prepare boiler location clearances 1c Prepare boiler location vent system When removing boiler from an existing common vent systemChimney or vent require- ments Areas likely to have contaminants 1d Prepare boiler location air contaminationRemove contaminants permanently Products to avoidTwo 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-4E venting methods Chimney draft or Direct exhaustDo not mix components 3c Venting Direct exhaust componentsObtain vent system components Do not exceed data in Table3d Venting direct exhaust vent starter Do not wrap or insulate vent pipe or fittings 3e Venting direct exhaust terminationUse their specified sealant. Do not use screws 3f Venting direct exhaust installationSlip connector for Saf-T Vent Do not mix types or manufacturers of vent materi- alsUsing 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 valvesPrimary/secondary preferred bypass piping method 4d Piping low temperature systemsTemperature gauges Valve adjustmentBlend temperature gauge BOILER-bypass piping method Valve adjustmentBoiler-bypass piping Zoning with SYSTEM-bypass piping method Chilled medium from entering boiler. See for 4e Water piping refrigeration systemPrevent chilled water from entering boiler System or zone circulatorPropane 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 leaksClose manual and automatic air vents and boiler drain cock Fill the system with waterInspect system water piping Inspect base insulationStart the boiler 7b Start-up operate boilerCheck system and boiler Pilot burner flame Figure Check burner flamesMain burner flame Figure Gas not turned on at meter or boiler? High limit switch set below boiler water tempera- ture?7c Start-up if boiler doesn’t start Check forCheck-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 CMR 5.082a1 through Addendum Instruction for Commonwealth of MassachusettsOne-half 1/2 inch in size, GAS Vent Directly be CMR 5.082a 1 throughVerify 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 eliminationShut down boiler Safety relief valves should be reinspected AT LeastReview with owner Boiler relief valveCheck the following 11a Troubleshooting generalBefore troubleshooting Air pressure switchControl 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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