Contents | Weil-McLain 550-110-710/0107 guide

GOLD CGi Gas-Fired Water Boiler — Boiler Manual

Contents
	How it works	2–3
	Hazard definitions	4
	Please read before proceeding	5
1	Prepare boiler location	6–11
2	Prepare boiler	12–13
3	Venting	14-19
4	Water piping	20-29
5	Gas piping	30
6	Field wiring	31
7	Start-up	32-35
8	Check-out procedure — checklist	36
9	Operation	37-42
10	Service and maintenance	43-47
11	Troubleshooting	48-57
12	Replacement parts	58-65
13	Dimensions and ratings	66-67

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

Indicates presence of hazards that will cause severe personal injury, death or substantial property damage.

Indicates presence of hazards that can cause severe personal injury, death or substantial property damage.

Indicates presence of hazards that will or can cause minor personal injury or property dam- age.

Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.

Part Number 550-110-710/0107

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Weil-McLain 550-110-710/0107 manual Contents

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 avoid 1e Prepare boiler location air openings Air openings must be providedAir opening options Two openings Air supply from inside the building Exhaust fans and air movers Motorized air dampersSingle air opening option Exception for large spaces 2a Prepare boiler placement & setup Orifice replacement procedurePlace boiler/crate near position Inspect orifices and burners 2b Prepare boiler pressure test Hydrostatic pressure testDrain and remove fittings Prepare boiler for test 3a Venting general information Venting chimney draft ventingCGi venting methods Chimney draft or Direct exhaust Chimney draft venting 3c Venting Direct exhaust components Obtain vent system components 3d Venting direct exhaust vent starter Vent StaR-34 Vent starter 3e Venting direct exhaust termination Vent termination minimum clearances 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 4c Water piping multiple zones Piping multiple zones Zoning with circulators 4d Piping low temperature systems Temperature gaugesValve adjustment Primary/secondary preferred bypass piping method Primary/secondary piping Valve adjustment BOILER-bypass piping method Boiler-bypass piping Zoning with SYSTEM-bypass piping method 4e Water piping refrigeration system Prevent chilled water from entering boiler Connecting gas supply piping to boiler Gas pipingNatural Gas Propane Gas Field wiring Electrical installation must comply withWiring connections Thermostat Freeze protection when used 7a Start-up preparationCheck for gas leaks Determine if water treatment is needed Do not use petroleum-based cleaning or sealing compounds Fill the system with waterInspect system water piping Inspect base insulation Start the boiler 7b Start-up operate boilerCheck system and boiler 7c Start-up if boiler doesn’t start Check burner flamesCheck for Pilot burner flame Figure Check-out procedure checklist Thermostats 9a Operation sequence During main burner operation 9b Operation wiring diagrams Schematic wiring diagram 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 10a Service and maintenance schedule Verify Proper Operation After Servicing 10b Service and maintenance annual start-up 10b Service & maintenance annual start-up Burners and baseCondensate drain system Inducer motor Gas piping Cold fill and operating pressuresAir vents and air elimination Limit controls and cutoffs Boiler relief valve Review with ownerReview the User’s Information Manual with the owner 11a Troubleshooting procedure 11b Troubleshooting componentsBefore troubleshooting Air pressure switch Control indicator lights Troubleshooting the control moduleControl indicator lights Lockout modes Control module Control module connections 11c Troubleshooting control module lights Chart Light flashingRemove 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 Chart 4 Flame & Power lights flashing Usually indicates flame sensed when it shouldnt be there Does blower motor operate? Item 8 , Verify Sequence Operation, Figure Section assembly Base Jacket Trim Controls 12a Replacement partsControls Repair Parts Lists 12b Replacement parts section assembly Section assembly 12c Replacement parts base Base assembly Description Weil-McLain Part number 12d Replacement parts jacket Jacket assembly Model Weil-McLain part number BoilerBoiler Model Weil-McLain part number 12e Replacement parts trim Fittings shown are included with boiler 12f Replacement parts controls Propane gas components 13a Dimensions Dimensional drawing 13b Ratings Handling ceramic fiber and fiberglass materials Removal of Combustion Chamber Lining or Base Panels