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Weil-McLain
Series 2 manual 9b Operation — wiring diagrams, Schematic wiring diagram
Models:
Series 2
1
38
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68 pages
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Troubleshooting
Install
Error codes
9b Operation — wiring diagrams
2a Prepare boiler — placement & setup
Dimension
Maintenance
Connecting gas supply piping to boiler
Reported problems
Section assembly
Page 38
Image 38
GOLD CGi
Gas-Fired
Water Boiler — Boiler Manual
9b
Operation — wiring diagrams
Figure 31
Schematic wiring diagram
38
Part Number
550-110-710/0107
Page 37
Page 39
Page 38
Image 38
Page 37
Page 39
Contents
GOLD CGi
• Installation • Maintenance
• Startup • Parts
Boiler Manual
④Air pressure switch
How it works
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
⑤Water temperature limit switch
GOLD CGi Gas-Fired Induced-DraftWater Boiler
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Contents
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
When servicing boiler —
Please read before proceeding
Installer
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
1a Prepare boiler location — codes & checklist
Installations must follow these codes
Before locating the boiler, check the following
Residential garage installations
1b Prepare boiler location — clearances
Recommended SERVICE clearances
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Chimney or vent require- ments
1c Prepare boiler location — vent system
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
1d Prepare boiler location — air contamination
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Air openings must be provided
1e Prepare boiler location — air openings
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Air opening options
Motorized air dampers
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Exhaust fans and air movers
Single air opening option
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
2a Prepare boiler — placement & setup
Orifice replacement procedure
Place boiler/crate near position
Hydrostatic pressure test
2b Prepare boiler — pressure test
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Drain and remove fittings
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
3a Venting — general information
Venting — chimney draft venting
Chimney draft venting
Obtain vent system components
3c Venting — Direct exhaust — components
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
3d Venting - direct exhaust - vent starter
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
3e Venting — direct exhaust — termination
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
3f Venting — direct exhaust — installation
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
in substantial property damage
3f Venting — direct exhaust — installation cont
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Sidewall termination
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
4a Water piping — general information
Pressure/temperature gauge
General piping information
Closed-typeexpansion tank
4b Water piping — single-zonesystem
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Figure
Piping multiple zones
4c Water piping — multiple zones
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Converted gravity or steam systems
4c Water piping — multiple zones continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Valve adjustment
4d Piping — low temperature systems
Temperature gauges
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
4d Piping — low temperature systems continued
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
Temperature gauges
4d Piping — low temperature systems
Valve adjustment
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
1Boiler isolation balancing valves
4d Piping — low temperature systems continued
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
4d Piping — low temperature systems
Valve adjustment
SYSTEM-bypasspiping method
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
4e Water piping — refrigeration system
4d Piping — low temperature systems continued
Prevent chilled water from entering boiler
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
5 Gas piping
Connecting gas supply piping to boiler
Natural Gas
Wiring connections
6 Field wiring
Electrical installation must comply with
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
7a Start-up- preparation
Freeze protection when used
Check for gas leaks
Fill the system with water
7a Start-up— preparation continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Inspect system water piping
Start the boiler
7b Start-up— operate boiler
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Check system and boiler
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
7b Start-up— operate boiler continued
7c Start-up— if boiler doesn’t start
Pilot burner flame Figure
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
8 Check-outprocedure — checklist
Installation and service certificate
9a Operation — sequence
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
9b Operation — wiring diagrams
Figure 31 Schematic wiring diagram
Figure 32 Ladder wiring diagram
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
• Spark pilot • Natural or propane gas
9c Operating instructions CGi-25to CGi-6
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
• Gas valve: Honeywell VR8204/VR8304
• Spark pilot • Natural or propane gas
9c Operating instructions CGi-25to CGi-6
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
• Gas valve: White-Rodgers36E
• Spark pilot • Natural or propane gas
9c Operating instructions CGi-25to CGi-8
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
• Gas valve: White-Rodgers36C
VERIFY PROPER OPERATION AFTER SERVICING
10a Service and maintenance — schedule
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Reported problems
10b Service and maintenance — annual start-up
Inspect
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Start-up
10b Service & maintenance – annual start-up cont
Service
Inspect
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Check/test
10b Service & maintenance – annual start-up cont
Gas piping
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Cleaning boiler heating surfaces
10b Service & maintenance – annual start-up cont
Review with owner
Check pressure switch setting
11a Troubleshooting — procedure
11b Troubleshooting - components
Troubleshooting air pressure reading
Troubleshooting the control module
11b Troubleshooting — components continued
Control indicator lights —
Control indicator lights — LOCKOUT modes
Figure 38 Control module connections
11b Troubleshooting — components continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Is POWER light
11c Troubleshooting — control module lights
Is POWER light off?
Is POWER light flashing now?
Do the TSTAT and POWER lights still flash?
11c Troubleshooting — control module lights cont
CHART 2 - TSTAT CIRC & POWER lights flashing
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Is PRESS SWITCH light flashing?
11c Troubleshooting - control module lights cont
CHART 3 — PRESS SWITCH & POWER lights flashing
Does the ohmmeter indicate the switch is closed?
Are FLAME & POWER lights flashing?
11c Troubleshooting — control module lights cont
Do FLAME and POWER lights still flash?
Are FLAME and POWER lights flashing?
Is PRESS SWITCH light flashing?
11c Troubleshooting - control module lights cont
Does the ohmmeter indicate the switch is closed?
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
TURN OFF POWER
11c Troubleshooting — control module lights cont
TURN OFF POWER
TURN OFF POWER to boiler
Does voltmeter show 120 VAC across pins?
11c Troubleshooting — control module lights cont
Are limit switch contacts closed?
Are limit switch contacts
12a Replacement parts
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
12b Replacement parts — section assembly
Figure 39 Section assembly
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
12c Replacement parts — base
Figure 40 Base assembly
Item
12c Replacement parts — base continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Description
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
12d Replacement parts — jacket
Figure 41 Jacket assembly
12d Replacement parts — jacket continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Fittings shown are factory-installedon boiler
12e Replacement parts — trim
Figure 42 Trim assembly
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
12f Replacement parts — controls
Figure 43 Gas control assembly
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
13a Dimensions
Figure 44 Dimensional drawing
13b Ratings
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
REMOVAL OF COMBUSTION CHAMBER
Handling ceramic fiber and fiberglass materials
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
LINING OR BASE PANELS