Weil-McLain CGI-4E manual 10b Service and maintenance annual start-up

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

10b Service and maintenance — annual start-up

The boiler should be inspected and started annu- ally, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 8, page 43, and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and main- tain the boiler and system could result in equipment failure.

Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Miner- als can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure. Leaking water may also cause severe property dam- age.

Air openings

1.Verify that combustion and ventilation air openings to the boiler room and/or building are open and unobstructed.

2.Verify that boiler vent discharge is clean and free of obstructions.

Flue gas vent system

1.Visually inspect entire flue gas venting system for blockage, deterioration or leakage. Repair any joints that show signs of leakage in accordance with vent manufacturer’s instructions.

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to

boiler will occur, resulting in substantial property damage.

Pilot and main burner flames

1.Visually inspect pilot burner and main burner flames as directed under Start-up, Section 7 of this manual.

Electrical shock hazard — Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

❏Inspect . . .

Reported problems

Inspect any problems reported by owner and correct before proceeding.

Boiler area

1.Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids.

2.Verify that boiler area (and air intake) is free of any of the contaminants listed in Table 1 on page 9 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, isolate the boiler and provide outside combustion air. See national, provincial or local codes for further information.

Water piping

1.Check the boiler interior piping and all system pip- ing for signs of leaks.

2.Repair any leaks before proceeding.

Boiler heating surfaces

1.Disconnect the vent pipe at the boiler inducer outlet connection after turning off power to the boiler.

2.Use a bright light to inspect the flue pipe interior and inducer interior.

3.Inspect the boiler vent outlet area and heating sur- faces by looking through the opening.

4.If the vent pipe or inducer interior show evidence of soot, follow Cleaning boiler heating surfaces on page 47 to remove the flue collector and clean the boiler if necessary after close inspection of boiler heating surfaces. If there is evidence of rusty scale deposits, check the water piping and control system to make sure the boiler return water temperature is properly maintained (per this manual).

5.Reconnect vent to inducer outlet and replace all boiler components before returning to service.

6.Check inside and around boiler for evidence of any leaks from the boiler. If found, locate source of leaks and repair.

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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 Chimney or vent require- ments When removing boiler from an existing common vent system1c Prepare boiler location vent system 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 Closed-type expansion tank 4b Water piping single-zone systemDiaphragm-type or bladder- type expansion tank Figure 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 cockCheck system and boiler 7b Start-up operate boilerStart the boiler Main burner flame Figure Check burner flamesPilot 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 DOEBreathing Fresh air Handling ceramic fiber and fiberglass materialsUse Niosh certified dust respirator N95

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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