Weil-McLain Replacement Parts for 511-044-381 Gas Control Assembly

Page 65

GOLD CGi Gas-Fired Water Boiler — Boiler Manual

12f Replacement parts — controls

Figure 43 Gas control assembly

Item	Description	Boiler model	Manufacturer	Manufacturer’s	Weil-McLain
number				part number	part number
Natural gas components

1	Gas valve, ½" x ½"	CGi-25 — CGi-6	Honeywell	VR8204A2001	511-044-381
			White-Rodgers	36E36-266	511-044-381
	Gas valve, ¾" x ¾"	CGi-7 & CGi-8	Honeywell	VR8304M4002	511-044-353
			White-Rodgers	36C68-478	511-044-353
2	Pilot kit w/orifice & aluminum pilot gas tubing		Weil-McLain		511-330-080

Propane gas components

1	Gas valve, ½" x ½"	CGi-25 — CGi-6	Honeywell	VR8204M2701	511-044-354
			White-Rodgers	36E36-291	511-044-354
	Gas valve, ¾" x ¾"	CGi-7 & CGi-8	Honeywell	VR8304M4010	511-044-355
			White-Rodgers	36C68-479	511-044-355
2	Pilot kit w/orifice & aluminum pilot gas tubing		Weil-McLain		511-330-081

Natural gas and propane gas components
3	Control module		United	1107-1	511-330-090
			Technologies
not shown	Wiring harness		Weil-McLain		591-391-894

4	Air pressure switch		Tri-Delta
	1.79" w.c.	CGi-25 & CGi-3		PPS10171-3013	511-624-401
	1.40" w.c.	CGi-4		PPS10171-3094	511-624-302
	1.12" w.c.	CGi-5		PPS10171-3095	511-624-303
	0.80" w.c.	CGi-6 & CGi-8		PPS10171-3096	511-624-304
	0.75" w.c.	CGi-7		PPS10171-3031	511-624-405
5	Control transformer				511-842-370

not shown	Tubing, air pressure switch, 0.12 I.D. silicone		Lydall
	red, to collector hood				590-317-650
	white, to transition				590-317-651

Part Number 550-110-710/0107	65

Image 65

Contents Gold CGi How it works Gold CGi Gas-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 1b Prepare boiler location clearances Chimney or vent require- ments When removing boiler from an existing common vent system1c Prepare boiler location vent system Products to avoid 1d Prepare boiler location air contaminationAir 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 venting methods Chimney draft or Direct exhaust Chimney draft ventingObtain 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 terminationSidewall venting See Figures 14 3f Venting direct exhaust installationVertical venting See . Follow vent Using 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 zonesZoning with circulators Temperature gauges 4d Piping low temperature systemsValve adjustment Primary/secondary preferred bypass piping methodPrimary/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 systemGas 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 neededFill the system with water Do not use petroleum-based cleaning or sealing compoundsInspect system water piping Inspect base insulationCheck system and boiler 7b Start-up operate boilerStart the boiler Check burner flames 7c Start-up if boiler doesn’t startCheck for Pilot burner flame FigureThermostats 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 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 the User’s Information Manual with the owner Review with ownerBoiler relief valve 11b Troubleshooting components 11a Troubleshooting procedureBefore troubleshooting Air pressure switchTroubleshooting the control module Control indicator lightsControl indicator lights Lockout modes Control moduleControl module connections Chart Light flashing 11c Troubleshooting control module lightsRemove 120 VAC in plug , Item 3, page 50 on control module VAC in plugChart 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 SequenceControls Repair Parts Lists 12a Replacement partsSection assembly Base Jacket Trim Controls 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 number BoilerModel 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