Weil-McLain CGI-4E manual Fill the system with water, Inspect system water piping

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GOLD CGi-4E 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.

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.

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 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 550-110-711/1108

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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 When removing boiler from an existing common vent system 1c Prepare boiler location 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 4b Water piping single-zone system Diaphragm-type or bladder- type expansion tank FigureClosed-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 cock7b Start-up operate boiler Start the boilerCheck system and boiler Check burner flames Pilot burner flame FigureMain 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 RatingsHandling 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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