Weil-McLain 550-110-710/0107 manual Boiler-bypass piping Zoning with

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

4d Piping — low temperature systems (continued)

Figure 22 Boiler-bypass piping — Zoning with	Figure 23 Boiler-bypass piping — Zoning with
circulators — (Alternative to primary/	zone valves — (Alternative to primary/
secondary piping Figures 20 and 21)	secondary piping Figures 20 and 21)

1Boiler isolation (balancing) valves

2Flow/check valve

3System or zone circulator

4System temperature gauges

5Zone valve

6Drain valve

7System temperature valves (see in- structions to the left for adjusting valves)

8Blend temperature gauge

9Relief valve

10Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion tank). DO NOT use an automatic air vent when using closed-type expansion tank. It would allow air to leave the system, causing waterlogging of the expansion tank.

11Fill valve

12Diaphragm-type or bladder-type expansion tank, if used (For closed-type expansion tank, pipe from top of air separator to tank fitting as in Figure 17, page 21).

13Air separator and automatic vent, if used (Note that the fill valve must always be connected to the expansion tank, regardless of location of expansion tank, circulator or air separator.)

Part Number 550-110-710/0107	27

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Contents Gold CGi How it works Gold CGi Gas-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 1b 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 contaminationTwo openings Air supply from inside the building 1e Prepare boiler location air openingsAir openings must be provided Air opening optionsException for large spaces Exhaust fans and air moversMotorized air dampers Single air opening optionInspect orifices and burners 2a Prepare boiler placement & setupOrifice replacement procedure Place boiler/crate near positionPrepare boiler for test 2b Prepare boiler pressure testHydrostatic pressure test Drain and remove fittingsChimney draft venting 3a Venting general informationVenting chimney draft venting CGi venting methods Chimney draft or Direct exhaustObtain vent system components 3c Venting Direct exhaust componentsVent StaR-34 Vent starter 3d Venting direct exhaust vent starterVent termination minimum clearances 3e Venting direct exhaust termination3f Venting direct exhaust installation Vertical venting See . Follow ventSidewall venting See Figures 14 Using 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 zonesZoning with circulators Primary/secondary preferred bypass piping method 4d Piping low temperature systemsTemperature gauges Valve adjustmentPrimary/secondary piping BOILER-bypass piping method Valve adjustmentBoiler-bypass piping Zoning with SYSTEM-bypass piping method Prevent chilled water from entering boiler 4e Water piping refrigeration systemPropane Gas Connecting gas supply piping to boilerGas piping Natural GasThermostat Field wiringElectrical installation must comply with Wiring connectionsDetermine if water treatment is needed Freeze protection when used7a Start-up preparation Check for gas leaksInspect base insulation Do not use petroleum-based cleaning or sealing compoundsFill the system with water Inspect system water piping7b Start-up operate boiler Start the boilerCheck system and boiler Pilot burner flame Figure 7c Start-up if boiler doesn’t startCheck burner flames Check forThermostats Check-out procedure checklistDuring main burner operation 9a Operation sequenceSchematic wiring diagram 9b Operation wiring diagramsLadder wiring diagram 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-8 Verify Proper Operation After Servicing 10a Service and maintenance schedule10b Service and maintenance annual start-up Inducer motor 10b Service & maintenance annual start-upBurners and base Condensate drain systemLimit controls and cutoffs Gas pipingCold fill and operating pressures Air vents and air eliminationReview with owner Boiler relief valveReview the User’s Information Manual with the owner Air pressure switch 11a Troubleshooting procedure11b Troubleshooting components Before troubleshootingControl module Control indicator lightsTroubleshooting the control module Control indicator lights Lockout modesControl module connections VAC in plug 11c Troubleshooting control module lightsChart Light flashing Remove 120 VAC in plug , Item 3, page 50 on control moduleChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Usually indicates flame sensed when it shouldnt be there Chart 4 Flame & Power lights flashingDoes blower motor operate? Item 8 , Operation, Figure Verify Sequence12a Replacement parts Section assembly Base Jacket Trim ControlsControls Repair Parts Lists Section assembly 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketBoiler Model Weil-McLain part numberBoiler Model Weil-McLain part number Fittings shown are included with boiler 12e Replacement parts trimPropane gas components 12f Replacement parts controlsDimensional drawing 13a Dimensions13b Ratings Removal of Combustion Chamber Lining or Base Panels Handling ceramic fiber and fiberglass materials