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CGI-4E Operating instructions, GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Models:
CGI-4E
1
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Troubleshooting
Install
Error messages
9b Operation - wiring diagrams
2a Prepare boiler - placement & setup
Dimension
Maintenance
Connecting gas supply piping to boiler
Reported problems
Base assembly
Page 41
Image 41
GOLD
CGi-4E
Gas-Fired
Water Boiler — Boiler Manual
9c
Operating instructions
• Spark pilot • Natural or propane gas
• Gas valve: Honeywell VR8204/VR8304
Part Number
550-110-711/1108
41
Page 40
Page 42
Page 41
Image 41
Page 40
Page 42
Contents
Startup Parts
Installation Maintenance
GOLDCGi-4E
Boiler Manual
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
How it works
④Air pressure switch
⑤Water temperature limit switch
Part Number 550-110-711/1108
GOLD CGi-4E Gas-Fired Induced-DraftWater Boiler
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Contents
Installer
Please read before proceeding
When servicing boiler
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Installations must follow these codes
1a Prepare boiler location - codes & checklist
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Before locating the boiler, check the following
Recommended SERVICE clearances
1b Prepare boiler location - clearances
Residential garage installations
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Chimney or vent require- ments
1c Prepare boiler location - vent system
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
1d Prepare boiler location - air contamination
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
1e Prepare boiler location - air openings
Air openings must be provided
Air opening options
Exhaust fans and air movers
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Motorized air dampers
Single air opening option
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
2a Prepare boiler - placement & setup
Location
Natural gas
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
2b Prepare boiler - pressure test
Hydrostatic pressure test
Drain and remove fittings
Venting - chimney draft venting
3a Venting — general information
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Chimney draft venting
Obtain vent system components
3c Venting - Direct exhaust - components
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
3d Venting - direct exhaust - vent starter
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
3e Venting - direct exhaust - termination
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
3f Venting - direct exhaust - installation
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
3f Venting - direct exhaust - installation cont
in substantial property damage
Part Number 550-110-711/1108
Pressure/temperature gauge
4a Water piping - general information
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
General piping information
Closed-typeexpansion tank
4b Water piping - single-zonesystem
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
4c Water piping - multiple zones
Piping multiple zones
Converted gravity or steam systems
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
4c Water piping — multiple zones continued
Temperature gauges
4d Piping - low temperature systems
Valve adjustment
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
4d Piping - low temperature systems continued
Valve adjustment
4d Piping - low temperature systems
Temperature gauges
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
4d Piping - low temperature systems continued
2Flow/check valve
9Relief valve
Valve adjustment
4d Piping - low temperature systems
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
SYSTEM-bypasspiping method
4d Piping - low temperature systems continued
4e Water piping - refrigeration system
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Prevent chilled water from entering boiler
Connecting gas supply piping to boiler
5 Gas piping
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Natural Gas
Electrical installation must comply with
6 Field wiring
Wiring connections
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Freeze protection when used
7a Start-up- preparation
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Check for gas leaks
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
7a Start-up- preparation continued
Fill the system with water
Inspect system water piping
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
7b Start-up- operate boiler
Start the boiler
Check system and boiler
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
7b Start-up- operate boiler continued
Check burner flames
Pilot burner flame Figure
Check for
7c Start-up- if boiler doesn’t start
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
8 Check-outprocedure - checklist
Installation and service certificate
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
9a Operation - sequence
Part Number 550-110-711/1108
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Figure 31 Wiring diagram
9b Operation - wiring diagrams
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Part Number 550-110-711/1108
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Operating instructions
Spark pilot Natural or propane gas
Gas valve Honeywell VR8204/VR8304
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Addendum Instruction for the
Commonwealth of Massachusetts
VERIFY PROPER OPERATION AFTER SERVICING
10a Service and maintenance - schedule
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Inspect
10b Service and maintenance - annual start-up
Reported problems
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Service
10b Service & maintenance - annual start-up cont
Start-up
Inspect
10b Service & maintenance - annual start-up cont
Check/test
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Gas piping
10b Service & maintenance - annual start-up cont
Cleaning boiler heating surfaces
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Review with owner
Check pressure switch setting
11a Troubleshooting - general
Troubleshooting air pressure reading
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Control indicator lights
11b Troubleshooting - components
Troubleshooting the control module
Control indicator lights - LOCKOUT modes
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
11b Troubleshooting - components continued
Figure 38 Control module connections
Part Number 550-110-711/1108
Is POWER light off?
11c Troubleshooting - control module lights
Is POWER light
Is POWER light flashing now?
CHART 2 - TSTAT CIRC & POWER lights flashing
11c Troubleshooting - control module lights cont
Do the TSTAT and POWER lights still flash?
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
CHART 3 - PRESS SWITCH & POWER lights flashing
11c Troubleshooting - control module lights cont
Is PRESS SWITCH light flashing?
Does the ohmmeter indicate the switch is closed?
Do FLAME and POWER lights still flash?
11c Troubleshooting - control module lights cont
Are FLAME & POWER lights flashing?
Are FLAME and POWER lights flashing?
Does the ohmmeter indicate the switch is closed?
11c Troubleshooting - control module lights cont
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Does blower motor operate?
TURN OFF POWER
11c Troubleshooting - control module lights cont
TURN OFF POWER
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Does voltmeter show 120 VAC across pins?
11c Troubleshooting - control module lights cont
Are limit switch contacts closed?
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
12a Replacement parts
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
12b Replacement parts - section assembly
Figure 40 Base assembly
12c Replacement parts - base
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Part Number 550-110-711/1108
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
12c Replacement parts - base continued
Figure 41 Jacket assembly
12d Replacement parts - jacket
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Part Number 550-110-711/1108
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
12d Replacement parts - jacket continued
Fittings shown are factory-installedon boiler
12e Replacement parts - trim
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Description
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
12f Replacement parts - controls
Item number
Description
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
13a Dimensions
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
13b Ratings
GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual
Handling ceramic fiber and fiberglass materials
REMOVAL OF COMBUSTION CHAMBER
LINING OR BASE PANELS
