Weil-McLain CGI-4E manual Chart 4 Flame & Power lights flashing

Page 54

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

11c Troubleshooting — control module lights (cont.)

CHART 4 — FLAME & POWER lights flashing

— Usually indicates flame sensed when it shouldn't be there —

Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.

Are manual main shutoff valve and gas valve open?

No

Yes

• Leave main manual gas valve closed.

 

 

 

• Turn off power to the boiler at service switch or breaker.

 

 

 

• Wait at least 45 seconds.

 

 

• Turn off power to boiler at service switch or breaker.

 

 

 

 

• Turn on power to boiler.

 

 

• Wait at least 45 seconds.

 

 

 

 

 

 

 

 

• Restart boiler, following Operating instructions in this

• Turn on power to boiler.

 

 

 

 

 

 

manual (Section 9c).

 

 

• Restart boiler, following Operating instructions in this

 

 

 

 

• Look through the pilot inspection port to see if the pilot is

manual (Section 9c).

 

 

 

 

 

 

burning during the prepurge period (first 30 seconds of

Do FLAME and POWER lights still flash?

 

 

operation).

 

 

 

 

 

 

 

 

Is pilot burning during prepurge period?

No

 

 

Yes

 

 

 

 

 

 

 

No

 

Yes

 

 

 

 

 

 

 

 

 

•Replace control module.

•Retest.

 

 

 

• Allow boiler to continue cycling.

 

•

Replace gas valve.

 

 

 

 

 

 

 

 

•

Retest boiler.

 

 

 

 

 

 

 

 

Are FLAME & POWER lights flashing?

 

 

 

 

 

 

 

 

 

 

 

Are FLAME and POWER lights flashing?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

TURN OFF POWER

 

•

Boiler may now be

 

•

Replace control

 

•

Boiler should now

 

•

Replace control

 

 

operating

 

 

module.

 

 

operate normally.

 

 

module.

 

to boiler at service switch

 

 

 

 

 

 

 

 

 

 

 

normally.

 

 

 

 

 

 

 

 

 

 

 

 

 

or breaker.

 

 

 

•

Retest.

 

•

Original flashing

 

•

Retest.

 

 

 

 

 

 

 

 

•

Open main manual gas

 

•

Perform start-up

 

 

 

 

 

 

FLAME light

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

valve.

 

 

procedures in

 

 

 

 

 

 

caused by gas

 

 

 

 

• Turn on power to boiler

 

 

boiler manual to

 

 

 

 

 

 

valve not

 

 

 

 

 

at service switch or

 

 

verify proper

 

 

 

 

 

 

operating properly.

 

 

 

 

 

breaker.

 

 

operation.

 

 

 

 

 

•

See normal

 

 

 

 

• Restart boiler per lighting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

instructions.

 

 

 

 

 

 

 

 

 

 

sequence of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Perform start-up

 

 

 

 

 

 

 

 

 

 

operation,

 

 

 

 

 

procedures in boiler

 

 

 

 

 

 

 

 

 

 

Figure 30,

 

 

 

 

 

manual to verify proper

 

 

 

 

 

 

 

 

 

 

page 39.

 

 

 

 

 

operation.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

54

Part Number 550-110-711/1108

 

Page 53 Page 55
Image 54
Page 53 Page 55
Contents GOLDCGi-4E How it works Gold CGi-4EGas-Fired Induced-Draft Water Boiler Contents Please read before proceeding Before locating the boiler, check the following 1a Prepare boiler location codes & checklistInstallations must follow these codes 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 Products to avoid 1d Prepare boiler location air contaminationRemove contaminants permanently Areas likely to have contaminantsAir opening options 1e Prepare boiler location air openingsAir openings must be provided Two openings Air supply from inside the buildingSingle air opening option Exhaust fans and air moversMotorized air dampers Exception for large spacesPlace boiler/crate near position 2a Prepare boiler placement & setupOrifice replacement procedure Inspect orifices and burnersDrain and remove fittings 2b Prepare boiler pressure testHydrostatic pressure test Prepare boiler for testCGi-4E venting methods Chimney draft or Direct exhaust 3a Venting general informationVenting chimney draft venting Chimney draft ventingDo not exceed data in Table 3c Venting Direct exhaust componentsObtain vent system components Do not mix components3d Venting direct exhaust vent starter 3e Venting direct exhaust termination Do not wrap or insulate vent pipe or fittingsDo not mix types or manufacturers of vent materi- als 3f Venting direct exhaust installationSlip connector for Saf-T Vent 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 4c Water piping multiple zones Piping multiple zonesBoiler isolation balancing valves System or zone circulator Zone valve Drain valveValve adjustment 4d Piping low temperature systemsTemperature gauges Primary/secondary preferred bypass piping methodBlend temperature gauge Valve adjustment BOILER-bypass piping methodBoiler-bypass piping Zoning with SYSTEM-bypass piping method System or zone circulator 4e Water piping refrigeration systemPrevent chilled water from entering boiler Chilled medium from entering boiler. See forNatural Gas Connecting gas supply piping to boilerGas piping Propane GasWiring connections Field wiringElectrical installation must comply with ThermostatCheck for gas leaks Freeze protection when used7a Start-up preparation Determine if water treatment is neededInspect base insulation Fill the system with waterInspect system water piping 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 Check for High limit switch set below boiler water tempera- ture?7c Start-up if boiler doesn’t start 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 CMR 5.082a 1 through Addendum Instruction for Commonwealth of MassachusettsOne-half 1/2 inch in size, GAS Vent Directly be CMR 5.082a1 through10a Service and maintenance schedule Verify Proper Operation After Servicing10b Service and maintenance annual start-up Condensate drain system 10b Service & maintenance annual start-upBurners and base Inducer motorAir vents and air elimination Gas pipingCold fill and operating pressures Limit controls and cutoffsBoiler relief valve Safety relief valves should be reinspected AT LeastReview with owner Shut down boilerAir pressure switch 11a Troubleshooting generalBefore troubleshooting 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 DOEHandling 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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