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

11c Troubleshooting — control module lights (cont.)

CHART 7 — Insufficient heat or no heat to system (POWER light on steady)

Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.

• Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes. Is system heating?

• Is thermostat set to call for heat? Remove thermostat wires at boiler and check continuity across the two wires. If circuit isn't closed, check external thermostat (zone valve, relay, etc.) wiring. Correct problems and retry.

• Reconnect external thermostat wiring at boiler.

Is thermostat circuit closed (continuity across wires)?

No

 

Yes

 

 

 

 

Is boiler System circulator operating?

No

Yes

Remove CIRCULATOR harness plug from CIRCULATOR plug receptacle (Figure 38, Item 7, page 50). Check with voltmeter across pins of control module receptacle.

Does voltmeter show 120 VAC across pins?

No

Yes

Are all red lights off?

No Yes

Wait 30 seconds. Are all red lights off?

No Yes

Replace control module. Retest.

Boiler is in standby.

Set thermostat to call for heat and recheck

operation.

Verify Sequence of operation, Figure 30, page 39.

Replace control

 

Repair/replace

 

module.

 

 

circulator. Retest.

Retest.

 

Repair/replace

 

 

 

 

wiring. Retest.

 

 

 

 

 

 

 

 

 

• Wait 5 minutes.

• If you have sufficient heat — boiler should be in normal operating sequence. (See normal sequence of operation,

Figure 30

.)

 

 

 

• If you have less than sufficient heat —

 

Is vent piping free of blockage?

No

 

 

Yes

 

 

 

 

 

 

 

Is FLAME light on?

Yes

No

 

Is LIMIT light on?

No

Yes

Correct conditions and

 

Is manifold pressure:

 

 

 

recheck operation.

 

 

3.50" w.c. on natural gas?

• See Figure 30, page 39

 

 

10.0" w.c. on propane?

 

for normal sequence of

 

 

Yes

 

 

 

No

 

operation.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Check heat loss calculation

 

 

 

 

 

 

 

 

 

versus boiler size.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Clock gas input.

 

 

• Replace timer relay.

Wait for boiler water to cool to temperature 20 to 30 °F lower than temperature set on limit switch.

Are limit switch contacts closed?

Check limit switch

 

 

Replace control module.

 

contacts with continuity

 

 

Retest.

 

 

 

 

checker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Are limit switch contacts

 

 

 

 

 

 

 

 

 

 

closed?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check rollout switch

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

continuity — is switch

 

 

 

 

 

 

 

 

 

 

 

 

closed?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace rollout switch.

 

 

 

 

 

 

No

Replace limit switch.

Retest.

Yes

Also check setting on limit switch (should be above 140°F.).

 

 

 

 

If rollout thermal fuse element has

 

Check any other

 

 

limit controls wired

opened, determine cause and

 

 

into the limit

correct condition. Failure to do so

 

 

circuit. If all are

will cause severe personal injury,

 

 

OK, then replace

death or substantial property

 

 

control module.

damage.

 

Retest.

Part Number 550-110-711/1108

57

 

Page 57
Image 57
Weil-McLain CGI-4E manual Verify Sequence of operation

CGI-4E specifications

The Weil-McLain CGI-4E is a standout in the realm of commercial boilers, designed to meet the rigorous demands of a variety of heating applications. This gas-fired cast iron boiler exemplifies durability, efficiency, and performance, making it a popular choice in various commercial settings, including schools, hospitals, and office buildings.

One of the main features of the CGI-4E is its cast iron construction. Cast iron has long been favored for its excellent heat retention and distribution capabilities, leading to improved overall efficiency. The boiler is designed to maximize heat output while minimizing energy consumption. This characteristic is especially beneficial for businesses seeking to lower their energy costs without sacrificing comfort.

In terms of efficiency, the Weil-McLain CGI-4E boasts an impressive thermal efficiency rating. Its design incorporates advanced technology, allowing it to achieve an AFUE rating of up to 84%. This efficiency is achieved through features such as a full-modulating burner and a unique heat exchanger design that allows for optimal heat transfer and reduced flue gas temperatures.

The CGI-4E is also remarkable for its versatility. It is offered in a variety of sizes, making it suitable for different heating loads. This flexibility allows for installation in a wide range of environments, adapting easily to both existing and new heating systems. Additionally, the boiler comes with multiple venting options, including direct vent and conventional venting, further enhancing its installation flexibility.

Another standout feature is the integrated boiler control system, which simplifies operation and monitoring. This control system optimizes burner performance and enhances safety features, including automatic shut-off in case of system anomalies. The advanced controls also allow for easy integration with building management systems, enabling better energy management and reduced operational costs.

The CGI-4E also emphasizes ease of maintenance, with service-friendly designs that allow technicians to access components without difficulty. This consideration translates to reduced downtime and lower maintenance costs, ensuring that the boiler operates efficiently over its lifetime.

Overall, the Weil-McLain CGI-4E blends reliability, efficiency, and advanced technology, making it a premier choice for commercial heating needs. Its cast iron construction, impressive efficiency ratings, versatile installation options, and user-friendly controls solidify its reputation as a leading boiler solution in the industry.