Manuals / Weil-McLain / Household Appliance / Boiler

Weil-McLain CGI-4E manual 11b Troubleshooting - components continued, Control module connections

Models: CGI-4E

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

11b Troubleshooting — components (continued)

Figure 38 Control module connections

50	Part Number 550-110-711/1108

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Weil-McLain CGI-4E manual 11b Troubleshooting - components continued, GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual

Contents

GOLDCGi-4E Installation MaintenanceStartup Parts Boiler Manual④Air pressure switch How it worksGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual ⑤Water temperature limit switchPart Number 550-110-711/1108 GOLD CGi-4E Gas-Fired Induced-DraftWater BoilerGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Contents GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualWhen servicing boiler Please read before proceedingInstaller GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 1a Prepare boiler location - codes & checklistInstallations must follow these codes Before locating the boiler, check the followingResidential garage installations 1b Prepare boiler location - clearancesRecommended SERVICE clearances GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualChimney or vent require- ments 1c Prepare boiler location - vent systemGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 1d Prepare boiler location - air contamination GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualAir openings must be provided 1e Prepare boiler location - air openingsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Air opening optionsMotorized air dampers GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualExhaust fans and air movers Single air opening optionLocation 2a Prepare boiler - placement & setupGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Natural gasHydrostatic pressure test 2b Prepare boiler - pressure testGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Drain and remove fittingsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 3a Venting — general informationVenting - chimney draft venting Chimney draft ventingObtain vent system components 3c Venting - Direct exhaust - componentsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 3d Venting - direct exhaust - vent starter GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual3e Venting - direct exhaust - termination GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual3f Venting - direct exhaust - installation GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manualin substantial property damage 3f Venting - direct exhaust - installation contGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Part Number 550-110-711/1108GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 4a Water piping - general informationPressure/temperature gauge General piping informationClosed-typeexpansion tank 4b Water piping - single-zonesystemGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Piping multiple zones 4c Water piping - multiple zonesGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Converted gravity or steam systems4c Water piping — multiple zones continued GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualValve adjustment 4d Piping - low temperature systemsTemperature gauges GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual4d Piping - low temperature systems continued GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualTemperature gauges 4d Piping - low temperature systemsValve adjustment GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual2Flow/check valve 4d Piping - low temperature systems continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 9Relief valveGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 4d Piping - low temperature systemsValve adjustment SYSTEM-bypasspiping methodGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 4e Water piping - refrigeration system4d Piping - low temperature systems continued Prevent chilled water from entering boilerGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 5 Gas pipingConnecting gas supply piping to boiler Natural GasWiring connections 6 Field wiringElectrical installation must comply with GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 7a Start-up- preparationFreeze protection when used Check for gas leaksFill the system with water 7a Start-up- preparation continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Inspect system water pipingStart the boiler 7b Start-up- operate boilerGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Check system and boilerCheck burner flames 7b Start-up- operate boiler continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Pilot burner flame FigureCheck for 7c Start-up- if boiler doesn’t startGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 8 Check-outprocedure - checklistInstallation and service certificate 9a Operation - sequence GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Part Number 550-110-711/1108GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 9b Operation - wiring diagramsFigure 31 Wiring diagram Part Number 550-110-711/1108Spark pilot Natural or propane gas Operating instructionsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Gas valve Honeywell VR8204/VR8304GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Addendum Instruction for theCommonwealth of Massachusetts VERIFY PROPER OPERATION AFTER SERVICING 10a Service and maintenance - scheduleGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Reported problems 10b Service and maintenance - annual start-upInspect GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualStart-up 10b Service & maintenance - annual start-up contService InspectGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Check/test10b Service & maintenance - annual start-up cont Gas pipingGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Cleaning boiler heating surfaces10b Service & maintenance - annual start-up cont Review with ownerTroubleshooting air pressure reading 11a Troubleshooting - generalCheck pressure switch setting GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualTroubleshooting the control module 11b Troubleshooting - componentsControl indicator lights Control indicator lights - LOCKOUT modesFigure 38 Control module connections 11b Troubleshooting - components continuedGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Part Number 550-110-711/1108Is POWER light 11c Troubleshooting - control module lightsIs POWER light off? Is POWER light flashing now?Do the TSTAT and POWER lights still flash? 11c Troubleshooting - control module lights contCHART 2 - TSTAT CIRC & POWER lights flashing GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualIs PRESS SWITCH light flashing? 11c Troubleshooting - control module lights contCHART 3 - PRESS SWITCH & POWER lights flashing Does the ohmmeter indicate the switch is closed?Are FLAME & POWER lights flashing? 11c Troubleshooting - control module lights contDo FLAME and POWER lights still flash? Are FLAME and POWER lights flashing?GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 11c Troubleshooting - control module lights contDoes the ohmmeter indicate the switch is closed? Does blower motor operate?TURN OFF POWER 11c Troubleshooting - control module lights contTURN OFF POWER GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualAre limit switch contacts closed? 11c Troubleshooting - control module lights contDoes voltmeter show 120 VAC across pins? GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual12a Replacement parts GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual12b Replacement parts - section assembly GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 12c Replacement parts - baseFigure 40 Base assembly Part Number 550-110-711/110812c Replacement parts - base continued GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 12d Replacement parts - jacketFigure 41 Jacket assembly Part Number 550-110-711/110812d Replacement parts - jacket continued GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual 12e Replacement parts - trimFittings shown are factory-installedon boiler DescriptionItem number 12f Replacement parts - controlsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual Description13a Dimensions GOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual13b Ratings GOLD CGi-4E Gas-FiredWater Boiler - Boiler ManualREMOVAL OF COMBUSTION CHAMBER Handling ceramic fiber and fiberglass materialsGOLD CGi-4E Gas-FiredWater Boiler - Boiler Manual LINING OR BASE PANELS