Weil-McLain 550-110-710/0107 1d Prepare boiler location air contamination, Products to avoid

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

1d Prepare boiler location — air contamination

Please review the following information on potential combustion air contamination problems.

Refer to Table 1 for products and areas which may cause contaminated combustion air.

To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler. If any of these contaminants are found:

•remove contaminants permanently

—OR —

•isolate boiler and provide outside combustion air. See national, provincial or local codes for further information.

Table 1  Corrosive or destructive contaminants and likely locations

Products to avoid

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Airborne particulates (drywall dust, fiberglass particles, road or gravel dust, lint, etc.)

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Buildings under construction (where air is contaminated with particulates)

CONSTRUCTION DUST HAZARD — Airborne particulates, such as drywall dust or fiberglass dust, will cause blockage of the CGi burners, resulting in carbon monoxide production, a fire hazard, or building freeze damage. If the boiler is operated during construction, you must isolate the boiler to provide clean air for combustion. If you are unable to ensure uncontaminated air in the boiler vicinity at all times, you must inspect the boiler at least once weekly. When inspecting, clean the burners if necessary using the procedure given on page 45. Failure to follow these guidelines could result in severe personal injury, death or substantial property damage.

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 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 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 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 insulation7b Start-up operate boiler Start the boilerCheck system and 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 with owner Boiler relief valveReview the User’s Information Manual with the owner 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 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
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