Weil-McLain CGI-4E 10b Service & maintenance annual start-up, Burners and base, Inducer motor

Page 45

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

10b Service & maintenance – annual start-up (cont.)

❏Inspect . . .

Burners and base

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per

burner inlet while cleaning the burner ports with a wire brush. The vacuum will help to draw any airborne material out of the burner.

4.Reinstall components, starting with the burner tray, then the pilot bracket assembly, burner baffle, and air inlet top and front panels.

5.Follow the start-up procedure in the boiler manual.

Condensate drain system

instructions on page 68 of this manual. Failure to comply could result in severe personal injury.

If insulation is damaged or displaced, do not operate the boiler. Replace or reposition insulation as neces- sary. Failure to replace damaged insulation can result in a fire hazard, causing severe personal injury, death or substantial property damage.

1.After turning off power to the boiler, remove the base burner shield (Figure 40, item 4, page 60).

2.Inspect burners and all other components in the boiler base.

3.If burners must be cleaned see Burner cleaning in- structions below.

4.Inspect the slotted jacket cooling openings in the bot- tom left and right of the base pan (Figure 40, item 7, page 60).

5.Inspect the base insulation. Pay attention to the WARN- ING on page 68 regarding working with insulation materials. Verify that the insulation is intact and secure against all four sides of the base.

Burner cleaning instructions

1.Inspect condensate drain fittings and tubing. Verify that condensate can flow freely to drain.

❏Service . . .

Inducer motor

1.With boiler power off, place a few drops of S.A.E. 20 motor oil in each of the two oil cups.

Use only S.A.E. 20 motor oil to lubricate the inducer motor. Do not use universal household oils. Mo- tor could be damaged, resulting in possible severe property damage.

Oiled-bearing circulators

1.The circulator shipped with the CGi-4E boiler is water-lubricated. No oiling is required.

2.Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator.

Airborne materials, such as fiberglass and dust, are present during construc- tion and remodeling. These materials can be drawn in with the combustion air and obstruct burner ports, resulting in carbon monoxide production, a fire hazard, or building freeze damage. Read and follow the WARNING on page 9. Failure to inspect and clear gas burner ports could result in severe personal injury, death or substantial property damage.

1.Remove burner shield and the base pan air baffle. Next remove the pilot bracket assembly. Then remove the four screws securing the burner tray to the manifold and slide the burner tray out under the manifold.

2.Inspect each burner to insure that every port is com- pletely open.

3.If any port is not completely clear, run a vacuum at the

❏Start-up . . .

1.Perform all start-up procedures in Section 7 of this manual.

2.Verify cold fill pressure is correct and that fill system is working properly.

3.Verify antifreeze level (if used) is at the right concentration and that inhibitor level is correct.

4.Check gas piping per manual Sections 5 and 7a, verifying no indications of leakage and all piping and connections are in good condition.

5.Read the appropriate Operating instructions (Section 9c of this manual or on boiler label) applying to the boiler.

6.Start the boiler following the appropriate Operating instructions

(Section 9c of this manual or on boiler label).

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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