Manuals / Weil-McLain / Household Appliance / Boiler

Weil-McLain 550-110-710/0107 manual 9c Operating instructions CGi-25to CGi-6

Models: 550-110-710/0107

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Page 40

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

9c Operating instructions CGi-25 to CGi-6

• Spark pilot • Natural or propane gas

• Gas valve: Honeywell VR8204/VR8304

40	Part Number 550-110-710/0107

Page 40

Image 40

Weil-McLain 550-110-710/0107 9c Operating instructions CGi-25to CGi-6, GOLD CGi Gas-FiredWater Boiler — Boiler Manual

Contents

• Installation • Maintenance • Startup • PartsGOLD CGi Boiler ManualHow it works GOLD CGi Gas-FiredWater Boiler - Boiler Manual④Air pressure switch ⑤Water temperature limit switchGOLD CGi Gas-Fired Induced-DraftWater Boiler GOLD CGi Gas-FiredWater Boiler — Boiler ManualContents GOLD CGi Gas-FiredWater Boiler — Boiler ManualPlease read before proceeding InstallerWhen servicing boiler — GOLD CGi Gas-FiredWater Boiler — Boiler Manual1a Prepare boiler location — codes & checklist Installations must follow these codesGOLD CGi Gas-FiredWater Boiler - Boiler Manual Before locating the boiler, check the following1b Prepare boiler location — clearances Recommended SERVICE clearancesResidential garage installations GOLD CGi Gas-FiredWater Boiler — Boiler ManualGOLD CGi Gas-FiredWater Boiler — Boiler Manual 1c Prepare boiler location — vent systemChimney or vent require- ments 1d Prepare boiler location - air contamination GOLD CGi Gas-FiredWater Boiler - Boiler Manual1e Prepare boiler location — air openings GOLD CGi Gas-FiredWater Boiler — Boiler ManualAir openings must be provided Air opening optionsGOLD CGi Gas-FiredWater Boiler — Boiler Manual Exhaust fans and air moversMotorized air dampers Single air opening option2a Prepare boiler — placement & setup Orifice replacement procedureGOLD CGi Gas-FiredWater Boiler — Boiler Manual Place boiler/crate near position2b Prepare boiler — pressure test GOLD CGi Gas-FiredWater Boiler — Boiler ManualHydrostatic pressure test Drain and remove fittings3a Venting - general information Venting — chimney draft ventingGOLD CGi Gas-FiredWater Boiler — Boiler Manual Chimney draft ventingGOLD CGi Gas-FiredWater Boiler — Boiler Manual 3c Venting — Direct exhaust — componentsObtain vent system components 3d Venting — direct exhaust — vent starter GOLD CGi Gas-FiredWater Boiler — Boiler Manual3e Venting — direct exhaust — termination GOLD CGi Gas-FiredWater Boiler — Boiler Manual3f Venting — direct exhaust — installation GOLD CGi Gas-FiredWater Boiler — Boiler Manual3f Venting — direct exhaust — installation cont GOLD CGi Gas-FiredWater Boiler — Boiler Manualin substantial property damage Sidewall termination4a Water piping — general information Pressure/temperature gaugeGOLD CGi Gas-FiredWater Boiler — Boiler Manual General piping information4b Water piping — single-zonesystem GOLD CGi Gas-FiredWater Boiler — Boiler ManualClosed-typeexpansion tank Figure4c Water piping — multiple zones GOLD CGi Gas-FiredWater Boiler — Boiler ManualPiping multiple zones Converted gravity or steam systems4c Water piping — multiple zones continued GOLD CGi Gas-FiredWater Boiler — Boiler Manual4d Piping — low temperature systems Temperature gaugesValve adjustment GOLD CGi Gas-FiredWater Boiler — Boiler Manual4d Piping - low temperature systems continued GOLD CGi Gas-FiredWater Boiler — Boiler Manual4d Piping — low temperature systems Valve adjustmentTemperature gauges GOLD CGi Gas-FiredWater Boiler — Boiler ManualGOLD CGi Gas-FiredWater Boiler — Boiler Manual 4d Piping — low temperature systems continued1Boiler isolation balancing valves 4d Piping — low temperature systems Valve adjustmentGOLD CGi Gas-FiredWater Boiler — Boiler Manual SYSTEM-bypasspiping method4e Water piping — refrigeration system 4d Piping — low temperature systems continuedGOLD CGi Gas-FiredWater Boiler — Boiler Manual Prevent chilled water from entering boiler5 Gas piping Connecting gas supply piping to boilerGOLD CGi Gas-FiredWater Boiler - Boiler Manual Natural Gas6 Field wiring Electrical installation must comply withWiring connections GOLD CGi Gas-FiredWater Boiler — Boiler Manual7a Start-up— preparation Freeze protection when usedGOLD CGi Gas-FiredWater Boiler — Boiler Manual Check for gas leaks7a Start-up— preparation continued GOLD CGi Gas-FiredWater Boiler — Boiler ManualFill the system with water Inspect system water piping7b Start-up— operate boiler GOLD CGi Gas-FiredWater Boiler — Boiler ManualStart the boiler Check system and boiler7b Start-up— operate boiler continued 7c Start-up- if boiler doesn’t startGOLD CGi Gas-FiredWater Boiler — Boiler Manual Pilot burner flame FigureInstallation and service certificate 8 Check-outprocedure — checklistGOLD CGi Gas-FiredWater Boiler — Boiler Manual 9a Operation — sequence GOLD CGi Gas-FiredWater Boiler — Boiler ManualFigure 31 Schematic wiring diagram 9b Operation — wiring diagramsGOLD CGi Gas-FiredWater Boiler — Boiler Manual Figure 32 Ladder wiring diagram GOLD CGi Gas-FiredWater Boiler — Boiler Manual9c Operating instructions CGi-25to CGi-6 GOLD CGi Gas-FiredWater Boiler — Boiler Manual• Spark pilot • Natural or propane gas • Gas valve: Honeywell VR8204/VR83049c Operating instructions CGi-25to CGi-6 GOLD CGi Gas-FiredWater Boiler — Boiler ManualSpark pilot Natural or propane gas • Gas valve: White-Rodgers36E9c Operating instructions CGi-25to CGi-8 GOLD CGi Gas-FiredWater Boiler — Boiler Manual• Spark pilot • Natural or propane gas • Gas valve: White-Rodgers36CGOLD CGi Gas-FiredWater Boiler — Boiler Manual 10a Service and maintenance — scheduleVERIFY PROPER OPERATION AFTER SERVICING 10b Service and maintenance — annual start-up InspectReported problems GOLD CGi Gas-FiredWater Boiler — Boiler Manual10b Service & maintenance – annual start-up cont ServiceStart-up InspectCheck/test 10b Service & maintenance – annual start-up contGOLD CGi Gas-FiredWater Boiler — Boiler Manual Gas pipingCleaning boiler heating surfaces 10b Service & maintenance – annual start-up contGOLD CGi Gas-FiredWater Boiler — Boiler Manual Review with owner11a Troubleshooting — procedure 11b Troubleshooting — componentsCheck pressure switch setting Troubleshooting air pressure reading11b Troubleshooting — components continued Control indicator lights —Troubleshooting the control module Control indicator lights — LOCKOUT modesGOLD CGi Gas-FiredWater Boiler — Boiler Manual 11b Troubleshooting — components continuedFigure 38 Control module connections 11c Troubleshooting — control module lights Is POWER light off?Is POWER light Is POWER light flashing now?11c Troubleshooting — control module lights cont CHART 2 — TSTAT CIRC & POWER lights flashingDo the TSTAT and POWER lights still flash? GOLD CGi Gas-FiredWater Boiler — Boiler Manual11c Troubleshooting — control module lights cont CHART 3 — PRESS SWITCH & POWER lights flashingIs PRESS SWITCH light flashing? Does the ohmmeter indicate the switch is closed?11c Troubleshooting — control module lights cont Do FLAME and POWER lights still flash?Are FLAME & POWER lights flashing? Are FLAME and POWER lights flashing?11c Troubleshooting - control module lights cont Does the ohmmeter indicate the switch is closed?Is PRESS SWITCH light flashing? GOLD CGi Gas-FiredWater Boiler — Boiler Manual11c Troubleshooting — control module lights cont TURN OFF POWERTURN OFF POWER TURN OFF POWER to boiler11c Troubleshooting — control module lights cont Are limit switch contacts closed?Does voltmeter show 120 VAC across pins? Are limit switch contacts12a Replacement parts GOLD CGi Gas-FiredWater Boiler — Boiler ManualFigure 39 Section assembly 12b Replacement parts — section assemblyGOLD CGi Gas-FiredWater Boiler — Boiler Manual Figure 40 Base assembly 12c Replacement parts — baseGOLD CGi Gas-FiredWater Boiler — Boiler Manual 12c Replacement parts — base continued GOLD CGi Gas-FiredWater Boiler — Boiler ManualItem DescriptionFigure 41 Jacket assembly 12d Replacement parts — jacketGOLD CGi Gas-FiredWater Boiler — Boiler Manual 12d Replacement parts — jacket continued GOLD CGi Gas-FiredWater Boiler — Boiler Manual12e Replacement parts — trim Figure 42 Trim assemblyFittings shown are factory-installedon boiler GOLD CGi Gas-FiredWater Boiler — Boiler ManualFigure 43 Gas control assembly 12f Replacement parts - controlsGOLD CGi Gas-FiredWater Boiler — Boiler Manual Figure 44 Dimensional drawing 13a DimensionsGOLD CGi Gas-FiredWater Boiler — Boiler Manual 13b Ratings GOLD CGi Gas-FiredWater Boiler — Boiler ManualHandling ceramic fiber and fiberglass materials GOLD CGi Gas-FiredWater Boiler — Boiler ManualREMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS