Weil-McLain 550-110-710/0107 manual 7b Start-up operate boiler, Start the boiler

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

7b Start-up — operate boiler

DO NOT proceed with boiler operation unless boiler and system have been filled with water and all instructions and procedures of previous manual sections have been completed. Failure to do so could result in severe personal injury, death or substantial property damage. Before start- ing the boiler, do the follow- ing:

•Read manual Section 9 and the Operating instruction procedure applicable for the gas valve supplied on the boiler (Section 9c).

•Verify the boiler and system are full of water.

•Verify the Start-up prepa- ration procedures of Sec- tion 7 have been complet- ed.

Start the boiler

•Follow the Operating instructions from Section 9c to start the boiler.

•See Section 7c if boiler fails to start.

Check system and boiler

1.Check system piping for leaks. If found, shut down boiler and repair immediately.

2.Vent air from system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

3.Inspect vent system thoroughly for signs of deterioration from corrosion, physical damage or sagging. In addition — Check for gas-tight seal at every connection and seam.

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with bubble test and repair immediately. Do not start boiler again until corrected. Failure to comply could re- sult in severe personal injury, death or substantial property

damage.

Eliminate all system leaks.

Continual fresh makeup water will reduce boiler life. Miner- als can build up in sections, reducing heat transfer, over- heating cast iron, and causing section failure.

Glycol or antifreeze leaks

around the boiler may result in fire, causing severe personal injury, death or substantial property damage.

Do not use petroleum-based cleaning or sealing com-

pounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Venting system must be sealed gas-tight to prevent flue gas spill- age and carbon monoxide emissions which will result in severe personal injury or death.

4.Check around the boiler for gas odor following the procedure of Section 7a of this manual.

5.Verify operation per Section 7b. Perform check-out procedure in Section 8, and fill in the Installation and service certificate on the same page.

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Part Number 550-110-710/0107

 

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Contents Gold CGi How it works Gold CGi Gas-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 1b Prepare boiler location clearances 1c Prepare boiler location vent system When removing boiler from an existing common vent systemChimney or vent require- ments 1d Prepare boiler location air contamination Products to avoidAir 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 venting methods Chimney draft or Direct exhaust 3a Venting general informationVenting chimney draft venting Chimney draft venting3c Venting Direct exhaust components Obtain vent system components3d Venting direct exhaust vent starter Vent StaR-34 Vent starter3e Venting direct exhaust termination Vent termination minimum clearancesVertical venting See . Follow vent 3f Venting direct exhaust installationSidewall venting See Figures 14 Using any termination other than one of those shown 4a Water piping general information Diaphragm-type or bladder- type expansion tank Figure 4b Water piping single-zone systemClosed-type expansion tank 4c Water piping multiple zones Piping multiple zonesZoning with circulators Valve adjustment 4d Piping low temperature systemsTemperature gauges Primary/secondary preferred bypass piping methodPrimary/secondary piping Valve adjustment BOILER-bypass piping methodBoiler-bypass piping Zoning with SYSTEM-bypass piping method 4e Water piping refrigeration system Prevent chilled water from entering boilerNatural 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 system water piping Do not use petroleum-based cleaning or sealing compoundsFill the system with water Inspect base insulationStart the boiler 7b Start-up operate boilerCheck system and boiler Check for 7c Start-up if boiler doesn’t startCheck burner flames Pilot burner flame FigureCheck-out procedure checklist Thermostats9a Operation sequence During main burner operation9b Operation wiring diagrams Schematic wiring diagramLadder 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 10a 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 Review with ownerReview the User’s Information Manual with the owner Before troubleshooting 11a Troubleshooting procedure11b Troubleshooting components Air pressure switchControl indicator lights Lockout modes Control indicator lightsTroubleshooting the control module Control moduleControl module connections Remove 120 VAC in plug , Item 3, page 50 on control module 11c Troubleshooting control module lightsChart Light flashing VAC in plugChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Chart 4 Flame & Power lights flashing Usually indicates flame sensed when it shouldnt be thereDoes blower motor operate? Item 8 , Verify Sequence Operation, FigureSection assembly Base Jacket Trim Controls 12a Replacement partsControls Repair Parts Lists 12b Replacement parts section assembly Section assembly12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyModel Weil-McLain part number BoilerBoiler Model Weil-McLain part number 12e Replacement parts trim Fittings shown are included with boiler12f Replacement parts controls Propane gas components13a Dimensions Dimensional drawing13b Ratings Handling ceramic fiber and fiberglass materials Removal of Combustion Chamber Lining or Base Panels
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