Weil-McLain CGI-4E manual Check-out procedure checklist

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

8 Check-out procedure — checklist

❏Boiler and heat distribution units filled with water?

❏Automatic air vent, if used, open one full turn?

❏Air purged from system?

❏Air purged from gas piping? Piping checked for leaks?

❏Correctly sized manifold orifices installed? Refer to Table 2, page 12, to check size and fuel type.

Correctly sized manifold orifices must be used. Failure to do so will cause severe personal in- jury, death or substantial property damage.

❏Followed operating instructions on boiler or in manual Section 9 for proper start-up?

❏Proper burner flame observed at high fire? Refer to Check burner flame, manual Section 7b.

❏Verify that boiler switches to high fire after 60 seconds of operation.

❏Test limit control — While burners are operating, move indicator on limit control below actual boiler water tem- perature. Burners should go off while circulator continues to operate. Raise setting on limit control above boiler water temperature and burners should reignite.

❏Test additional field-installed controls — If boiler has a low water cutoff, additional high limit or other controls, test for operation as outlined by manufacturer. Burners should be operating and should go off when controls are tested. When controls are restored, burners should reignite.

❏Test ignition system safety device:

a.Connect manometer to outlet side of gas valve.

b.Start boiler, allowing for normal start-up cycle to oc- cur and main burners to ignite.

c.With main burners on, manually shut off gas supply at manual main shutoff gas valve. Burners should go off.

d.Open manual main shutoff gas valve. Manometer should confirm there is no gas flow.

e.Pilot will relight, flame sensing element will sense pilot flame and main burners will reignite.

❏Set limit control(s) to system temperature requirements.

Adjust balancing valves and controls to provide design temperature to system.

❏For multiple zones, adjust flow so it is about the same in each zone.

❏Verify thermostat heat anticipator (if available) set prop- erly? Refer to Field wiring, manual Section 6, page 31,

Thermostat(s).

❏Cycle boiler with thermostat — Raise to highest setting and verify boiler goes through normal start-up cycle. Lower to lowest setting and verify boiler goes off.

❏Measure natural gas input:

a.Operate boiler 10 minutes.

b.Turn off other appliances.

c.At natural gas meter, measure time (in seconds) re- quired to use one cubic foot of gas.

d.Calculate gas input:

e.Btuh calculated should approximate input rating on boiler rating label.

❏Check manifold gas pressure by connecting manometer to downstream test tapping on main gas valve. Manifold pres- sure for natural gas should be 3.5" w.c. and for propane gas should be 10" w.c.

❏Observe several operating cycles for proper operation.

❏Set room thermostat to desired room temperature.

❏Fill in Installation and service certificate below?

❏Review all instructions shipped with this boiler with owner or maintenance person. Return instructions to envelope and give to owner or place in pocket inside front panel in boiler.

Installation and service certificate

Boiler model __________________

Series __________

CP number ___________

Date installed ___________

Measured Btuh input ____________________

❏ Installation instructions have been followed.

❏Check out sequence has been performed.

❏Above information is certified to be correct.

❏Information received and left with owner/maintenance person

Installer ________________________

________________________________

________________________

(company)

(address)

(phone)

Installer’s signature: _____________________________________

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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