Weil-McLain CGI-4E manual Please read before proceeding

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

Please read before proceeding

Installer

Read all instructions before in- stalling. Follow all instructions in proper order to prevent personal injury or death.

•Consider piping and installation when determining boiler location.

•Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

User

•This manual is for use only by your qualified heating installer/service technician.

•Please refer to the User’s Information Manual for your reference.

•We recommend regular service by a qualified service technician, at least annually.

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.

When calling or writing about the boiler— Please have the boiler model number from the

boiler rating label and the CP number from the boiler jacket. You may list the CP number in

the space provided on the Installation and service certificate found on page 37.

Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage.

When servicing boiler —

•To avoid electric shock, disconnect electrical supply before performing maintenance.

•To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation —

•Do not block flow of combustion or ventilation air to boiler.

•Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

•Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water.

Boiler water —

•Do not use petroleum-based cleaning or sealing compounds in boiler system. Water seal deterioration will occur, causing leakage between sections. This can result in substantial property damage.

•Do not use “homemade cures” or “boiler patent medicines”. Serious damage to boiler, personnel and/ or property may result.

•Continual fresh makeup water will reduce boiler life. Mineral buildup in sections re- duces heat transfer, overheats cast iron, and causes section failure. Addition of oxygen and other gases can cause internal corrosion. Leaks in boiler or piping must be repaired at once to prevent makeup water.

•Do not add cold water to hot boiler. Thermal shock can cause sections to crack.

Glycol — potential fire hazard —

All glycol is flammable when exposed to high temperatures. If glycol is allowed to accumulate in or around the boiler or any other potential ignition source, a fire can develop. In order to prevent potential severe personal injury, death or substantial property damage from fire and/or structural damage:

•Never store glycol of any kind near the boiler or any potential ignition source.

•Monitor and inspect the system and boiler regularly for leakage. Repair any leaks im- mediately to prevent possible accumulation of glycol.

•Never use automotive antifreeze or ethylene glycol in the system. Using these glycols can lead to hazardous leakage of glycol in the boiler system.

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 Chimney or vent require- ments When removing boiler from an existing common vent system1c Prepare boiler location vent system 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 Closed-type expansion tank 4b Water piping single-zone systemDiaphragm-type or bladder- type expansion tank Figure 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 cockCheck system and boiler 7b Start-up operate boilerStart the boiler Main burner flame Figure Check burner flamesPilot 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 RatingsBreathing 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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