Weil-McLain 550-110-710/0107 manual 1a Prepare boiler location codes & checklist

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

1a Prepare boiler location — codes & checklist

Installations must follow these codes:

•Local, state, provincial, and national codes, laws, regulations and ordinances.

•National Fuel Gas Code, ANSI Z223.1–latest edition.

•Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1, when required.

•National Electrical Code.

•For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

The CGi boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13–latest edition.

Before locating the boiler, check the following:

•Check for nearby connection to:

•System water piping

•Venting connections

•Gas supply piping

•Electrical power

•Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids, or other contaminants.

Failure to keep boiler area clear and free of combustible mate- rials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

•Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

•If new boiler will replace existing boiler, check for and correct system problems, such as:

1.System leaks causing oxygen corrosion or section cracks from hard water deposits.

2.Incorrectly-sized expansion tank.

3.Lack of antifreeze in boiler water causing system and boiler to freeze and leak.

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 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 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 clearances3f 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 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 insulation7b Start-up operate boiler Start the 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 cutoffsReview with owner Boiler relief valveReview 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, Figure12a Replacement parts Section assembly Base Jacket Trim ControlsControls Repair Parts Lists 12b Replacement parts section assembly Section assembly12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyBoiler Model Weil-McLain part numberBoiler 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