Gold CGi | Weil-McLain 550-110-710/0107 instruction

GOLD CGi

Gas-Fired Water Boilers

Series 2

Boiler Manual	• Installation • Maintenance
	• Startup • Parts

This manual must only be used by a qualified heating installer/service technician. Before installing, read all instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.

DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free air to the boiler area or follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub- stantial property damage.

Part No. 550-110-710/0107

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Weil-McLain 550-110-710/0107 manual Gold CGi

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 Products to avoid 1d Prepare boiler location air contamination Air openings must be provided 1e Prepare boiler location air openingsAir opening options Two openings Air supply from inside the building Motorized air dampers Exhaust fans and air moversSingle air opening option Exception for large spaces Orifice replacement procedure 2a Prepare boiler placement & setupPlace boiler/crate near position Inspect orifices and burners Hydrostatic pressure test 2b Prepare boiler pressure testDrain and remove fittings Prepare boiler for test Venting chimney draft venting 3a Venting general informationCGi venting methods Chimney draft or Direct exhaust Chimney draft venting Obtain vent system components 3c Venting Direct exhaust components Vent StaR-34 Vent starter 3d Venting direct exhaust vent starter Vent termination minimum clearances 3e Venting direct exhaust termination Vertical 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 Piping multiple zones 4c Water piping multiple zones Zoning with circulators Temperature gauges 4d Piping low temperature systemsValve adjustment Primary/secondary preferred bypass piping method Primary/secondary piping BOILER-bypass piping method Valve adjustment Boiler-bypass piping Zoning with SYSTEM-bypass piping method Prevent chilled water from entering boiler 4e Water piping refrigeration system Gas piping Connecting gas supply piping to boilerNatural Gas Propane Gas Electrical installation must comply with Field wiringWiring connections Thermostat 7a Start-up preparation Freeze protection when usedCheck for gas leaks Determine if water treatment is needed Fill the system with water Do not use petroleum-based cleaning or sealing compoundsInspect system water piping Inspect base insulation Start the boiler 7b Start-up operate boilerCheck system and boiler Check burner flames 7c Start-up if boiler doesn’t startCheck for Pilot burner flame Figure Thermostats Check-out procedure checklist During main burner operation 9a Operation sequence Schematic wiring diagram 9b Operation wiring diagrams Ladder 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 schedule 10b Service and maintenance annual start-up Burners and base 10b Service & maintenance annual start-upCondensate drain system Inducer motor Cold fill and operating pressures Gas pipingAir vents and air elimination Limit controls and cutoffs Boiler relief valve Review with ownerReview the User’s Information Manual with the owner 11b Troubleshooting components 11a Troubleshooting procedureBefore troubleshooting Air pressure switch Troubleshooting the control module Control indicator lightsControl indicator lights Lockout modes Control module Control module connections Chart Light flashing 11c Troubleshooting control module lightsRemove 120 VAC in plug , Item 3, page 50 on control module VAC in plug Chart 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 flashing Does blower motor operate? Item 8 , Operation, Figure Verify Sequence Section assembly Base Jacket Trim Controls 12a Replacement partsControls Repair Parts Lists Section assembly 12b Replacement parts section assembly Base assembly 12c Replacement parts base Description Weil-McLain Part number Jacket assembly 12d Replacement parts jacket Model Weil-McLain part number BoilerBoiler Model Weil-McLain part number Fittings shown are included with boiler 12e Replacement parts trim Propane gas components 12f Replacement parts controls Dimensional drawing 13a Dimensions 13b Ratings Removal of Combustion Chamber Lining or Base Panels Handling ceramic fiber and fiberglass materials