Manuals / Weil-McLain / Household Appliance / Boiler

Weil-McLain CGI-4E GOLD CGi-4E Gas-Fired Induced-DraftWater Boiler, Part Number 550-110-711/1108

Models: CGI-4E

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

GOLD CGi-4EGas-Fired Induced-Draft Water Boiler

Part Number 550-110-711/1108	3

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Weil-McLain CGI-4E GOLD CGi-4E Gas-Fired Induced-DraftWater Boiler, GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual

Contents

Boiler Manual Installation MaintenanceStartup Parts GOLDCGi-4E⑤Water temperature limit switch How it worksGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual ④Air pressure switchGOLD CGi-4E Gas-Fired Induced-DraftWater Boiler GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualPart Number 550-110-711/1108 GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual ContentsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Please read before proceedingInstaller When servicing boilerBefore locating the boiler, check the following 1a Prepare boiler location - codes & checklistInstallations must follow these codes GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 1b Prepare boiler location - clearancesRecommended SERVICE clearances Residential garage installations1c Prepare boiler location - vent system GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualChimney or vent require- ments GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 1d Prepare boiler location - air contaminationAir opening options 1e Prepare boiler location - air openingsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Air openings must be providedSingle air opening option GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualExhaust fans and air movers Motorized air dampersNatural gas 2a Prepare boiler - placement & setupGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual LocationDrain and remove fittings 2b Prepare boiler - pressure testGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Hydrostatic pressure testChimney draft venting 3a Venting — general informationVenting - chimney draft venting GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual3c Venting - Direct exhaust - components GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualObtain vent system components GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 3d Venting - direct exhaust - vent starterGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 3e Venting - direct exhaust - terminationGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 3f Venting - direct exhaust - installationPart Number 550-110-711/1108 3f Venting - direct exhaust - installation contGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual in substantial property damageGeneral piping information 4a Water piping - general informationPressure/temperature gauge GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual4b Water piping - single-zonesystem GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualClosed-typeexpansion tank Converted gravity or steam systems 4c Water piping - multiple zonesGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Piping multiple zonesGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 4c Water piping — multiple zones continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 4d Piping - low temperature systemsTemperature gauges Valve adjustmentGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 4d Piping - low temperature systems continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 4d Piping - low temperature systemsValve adjustment Temperature gauges9Relief valve 4d Piping - low temperature systems continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 2Flow/check valveSYSTEM-bypasspiping method 4d Piping - low temperature systemsValve adjustment GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualPrevent chilled water from entering boiler 4e Water piping - refrigeration system4d Piping - low temperature systems continued GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualNatural Gas 5 Gas pipingConnecting gas supply piping to boiler GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 6 Field wiringElectrical installation must comply with Wiring connectionsCheck for gas leaks 7a Start-up- preparationFreeze protection when used GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualInspect system water piping 7a Start-up- preparation continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Fill the system with waterCheck system and boiler 7b Start-up- operate boilerGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Start the boilerPilot burner flame Figure 7b Start-up- operate boiler continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Check burner flames7c Start-up- if boiler doesn’t start GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualCheck for 8 Check-outprocedure - checklist Installation and service certificateGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 9a Operation - sequencePart Number 550-110-711/1108 GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualPart Number 550-110-711/1108 9b Operation - wiring diagramsFigure 31 Wiring diagram GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGas valve Honeywell VR8204/VR8304 Operating instructionsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Spark pilot Natural or propane gasAddendum Instruction for the Commonwealth of MassachusettsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 10a Service and maintenance - schedule GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualVERIFY PROPER OPERATION AFTER SERVICING GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 10b Service and maintenance - annual start-upInspect Reported problemsInspect 10b Service & maintenance - annual start-up contService Start-upGas piping Check/test10b Service & maintenance - annual start-up cont GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualReview with owner Cleaning boiler heating surfaces10b Service & maintenance - annual start-up cont GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 11a Troubleshooting - generalCheck pressure switch setting Troubleshooting air pressure readingControl indicator lights - LOCKOUT modes 11b Troubleshooting - componentsControl indicator lights Troubleshooting the control modulePart Number 550-110-711/1108 11b Troubleshooting - components continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Figure 38 Control module connectionsIs POWER light flashing now? 11c Troubleshooting - control module lightsIs POWER light off? Is POWER lightGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 11c Troubleshooting - control module lights contCHART 2 - TSTAT CIRC & POWER lights flashing Do the TSTAT and POWER lights still flash?Does the ohmmeter indicate the switch is closed? 11c Troubleshooting - control module lights contCHART 3 - PRESS SWITCH & POWER lights flashing Is PRESS SWITCH light flashing?Are FLAME and POWER lights flashing? 11c Troubleshooting - control module lights contDo FLAME and POWER lights still flash? Are FLAME & POWER lights flashing?Does blower motor operate? 11c Troubleshooting - control module lights contDoes the ohmmeter indicate the switch is closed? GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 11c Troubleshooting - control module lights contTURN OFF POWER TURN OFF POWERGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 11c Troubleshooting - control module lights contDoes voltmeter show 120 VAC across pins? Are limit switch contacts closed?GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 12a Replacement partsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 12b Replacement parts - section assemblyPart Number 550-110-711/1108 12c Replacement parts - baseFigure 40 Base assembly GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 12c Replacement parts - base continuedPart Number 550-110-711/1108 12d Replacement parts - jacketFigure 41 Jacket assembly GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 12d Replacement parts - jacket continuedDescription 12e Replacement parts - trimFittings shown are factory-installedon boiler GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualDescription 12f Replacement parts - controlsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Item numberGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 13a DimensionsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 13b RatingsLINING OR BASE PANELS Handling ceramic fiber and fiberglass materialsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual REMOVAL OF COMBUSTION CHAMBER