Manuals / Weil-McLain / Household Appliance / Boiler

Weil-McLain Series 2 manual GOLD CGi Gas-Fired Induced-DraftWater Boiler

Models: Series 2

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

GOLD CGi Gas-Fired Induced-Draft Water Boiler

Part Number 550-110-710/0107

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Weil-McLain Series 2 manual GOLD CGi Gas-Fired Induced-DraftWater Boiler, GOLD CGi Gas-FiredWater Boiler — Boiler Manual

Contents

Boiler Manual • Installation • Maintenance• Startup • Parts GOLD CGi⑤Water temperature limit switch How it worksGOLD CGi Gas-FiredWater Boiler — Boiler Manual ④Air pressure switchGOLD CGi Gas-FiredWater Boiler — Boiler Manual GOLD CGi Gas-Fired Induced-DraftWater BoilerGOLD CGi Gas-FiredWater Boiler — Boiler Manual ContentsGOLD CGi Gas-FiredWater Boiler — Boiler Manual Please read before proceedingInstaller When servicing boiler —Before locating the boiler, check the following 1a Prepare boiler location — codes & checklistInstallations must follow these codes GOLD CGi Gas-FiredWater Boiler - Boiler ManualGOLD CGi Gas-FiredWater Boiler — Boiler Manual 1b Prepare boiler location — clearancesRecommended SERVICE clearances Residential garage installations1c Prepare boiler location — vent system GOLD CGi Gas-FiredWater Boiler — Boiler ManualChimney or vent require- ments GOLD CGi Gas-FiredWater Boiler — Boiler Manual 1d Prepare boiler location — air contaminationAir opening options 1e Prepare boiler location — air openingsGOLD CGi Gas-FiredWater Boiler — Boiler Manual Air openings must be providedSingle air opening option GOLD CGi Gas-FiredWater Boiler — Boiler ManualExhaust fans and air movers Motorized air dampersPlace boiler/crate near position 2a Prepare boiler — placement & setupOrifice replacement procedure GOLD CGi Gas-FiredWater Boiler — Boiler ManualDrain and remove fittings 2b Prepare boiler — pressure testGOLD CGi Gas-FiredWater Boiler — Boiler Manual Hydrostatic pressure testChimney draft venting 3a Venting — general informationVenting — chimney draft venting GOLD CGi Gas-FiredWater Boiler — Boiler Manual3c Venting — Direct exhaust — components GOLD CGi Gas-FiredWater Boiler — Boiler ManualObtain vent system components GOLD CGi Gas-FiredWater Boiler — Boiler Manual 3d Venting - direct exhaust - vent starterGOLD CGi Gas-FiredWater Boiler — Boiler Manual 3e Venting — direct exhaust — terminationGOLD CGi Gas-FiredWater Boiler - Boiler Manual 3f Venting — direct exhaust — installationSidewall termination 3f Venting — direct exhaust — installation contGOLD CGi Gas-FiredWater Boiler — Boiler Manual in substantial property damageGeneral piping information 4a Water piping — general informationPressure/temperature gauge GOLD CGi Gas-FiredWater Boiler — Boiler ManualFigure 4b Water piping — single-zonesystemGOLD CGi Gas-FiredWater Boiler — Boiler Manual Closed-typeexpansion tankConverted gravity or steam systems 4c Water piping — multiple zonesGOLD CGi Gas-FiredWater Boiler — Boiler Manual Piping multiple zonesGOLD CGi Gas-FiredWater Boiler — Boiler Manual 4c Water piping — multiple zones continuedGOLD CGi Gas-FiredWater Boiler — Boiler Manual 4d Piping — low temperature systemsTemperature gauges Valve adjustmentGOLD CGi Gas-FiredWater Boiler - Boiler Manual 4d Piping — low temperature systems continuedGOLD CGi Gas-FiredWater Boiler — Boiler Manual 4d Piping — low temperature systemsValve adjustment Temperature gauges4d Piping — low temperature systems continued GOLD CGi Gas-FiredWater Boiler - Boiler Manual1Boiler isolation balancing valves SYSTEM-bypasspiping method 4d Piping — low temperature systemsValve adjustment GOLD CGi Gas-FiredWater Boiler — Boiler ManualPrevent chilled water from entering boiler 4e Water piping — refrigeration system4d Piping — low temperature systems continued GOLD CGi Gas-FiredWater Boiler — Boiler ManualNatural Gas 5 Gas pipingConnecting gas supply piping to boiler GOLD CGi Gas-FiredWater Boiler — Boiler ManualGOLD CGi 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 Gas-FiredWater Boiler — Boiler ManualInspect system water piping 7a Start-up— preparation continuedGOLD CGi Gas-FiredWater Boiler — Boiler Manual Fill the system with waterCheck system and boiler 7b Start-up— operate boilerGOLD CGi Gas-FiredWater Boiler — Boiler Manual Start the boilerPilot burner flame Figure 7b Start-up— operate boiler continued7c Start-up— if boiler doesn’t start GOLD CGi Gas-FiredWater Boiler — Boiler Manual8 Check-outprocedure — checklist Installation and service certificateGOLD CGi Gas-FiredWater Boiler — Boiler Manual GOLD CGi Gas-FiredWater Boiler — Boiler Manual 9a Operation — sequence9b Operation — wiring diagrams Figure 31 Schematic wiring diagramGOLD CGi Gas-FiredWater Boiler — Boiler Manual GOLD CGi Gas-FiredWater Boiler — Boiler Manual Figure 32 Ladder wiring diagram• Gas valve: Honeywell VR8204/VR8304 9c Operating instructions CGi-25to CGi-6GOLD CGi Gas-FiredWater Boiler — Boiler Manual • Spark pilot • Natural or propane gas• Gas valve: White-Rodgers36E 9c Operating instructions CGi-25to CGi-6GOLD CGi Gas-FiredWater Boiler — Boiler Manual • Spark pilot • Natural or propane gas• Gas valve: White-Rodgers36C 9c Operating instructions CGi-25to CGi-8GOLD CGi Gas-FiredWater Boiler — Boiler Manual • Spark pilot • Natural or propane gas10a Service and maintenance — schedule GOLD CGi Gas-FiredWater Boiler — Boiler ManualVERIFY PROPER OPERATION AFTER SERVICING GOLD CGi 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 Gas-FiredWater Boiler — Boiler ManualReview with owner Cleaning boiler heating surfaces10b Service & maintenance – annual start-up cont GOLD CGi Gas-FiredWater Boiler — Boiler ManualTroubleshooting air pressure reading 11a Troubleshooting — procedure11b Troubleshooting - components Check pressure switch settingControl indicator lights — LOCKOUT modes 11b Troubleshooting — components continuedControl indicator lights — Troubleshooting the control module11b Troubleshooting — components continued GOLD CGi Gas-FiredWater Boiler — Boiler ManualFigure 38 Control module connections Is POWER light flashing now? 11c Troubleshooting — control module lightsIs POWER light off? Is POWER lightGOLD CGi 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?GOLD CGi Gas-FiredWater Boiler — Boiler Manual 11c Troubleshooting - control module lights contDoes the ohmmeter indicate the switch is closed? Is PRESS SWITCH light flashing?TURN OFF POWER to boiler 11c Troubleshooting — control module lights contTURN OFF POWER TURN OFF POWERAre limit switch contacts 11c Troubleshooting — control module lights contAre limit switch contacts closed? Does voltmeter show 120 VAC across pins?GOLD CGi Gas-FiredWater Boiler — Boiler Manual 12a Replacement parts12b Replacement parts — section assembly Figure 39 Section assemblyGOLD CGi Gas-FiredWater Boiler — Boiler Manual 12c Replacement parts — base Figure 40 Base assemblyGOLD CGi Gas-FiredWater Boiler — Boiler Manual Description 12c Replacement parts — base continuedGOLD CGi Gas-FiredWater Boiler — Boiler Manual Item12d Replacement parts — jacket Figure 41 Jacket assemblyGOLD CGi Gas-FiredWater Boiler — Boiler Manual GOLD CGi Gas-FiredWater Boiler — Boiler Manual 12d Replacement parts — jacket continuedGOLD CGi Gas-FiredWater Boiler — Boiler Manual 12e Replacement parts — trimFigure 42 Trim assembly Fittings shown are factory-installedon boiler12f Replacement parts — controls Figure 43 Gas control assemblyGOLD CGi Gas-FiredWater Boiler - Boiler Manual 13a Dimensions Figure 44 Dimensional drawingGOLD CGi Gas-FiredWater Boiler — Boiler Manual GOLD CGi Gas-FiredWater Boiler - Boiler Manual 13b RatingsLINING OR BASE PANELS Handling ceramic fiber and fiberglass materialsGOLD CGi Gas-FiredWater Boiler — Boiler Manual REMOVAL OF COMBUSTION CHAMBER