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Weil-McLain
Series 2 manual 12b Replacement parts — section assembly, Section assembly
Models:
Series 2
1
59
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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 59
Image 59
GOLD CGi
Gas-Fired
Water Boiler — Boiler Manual
12b
Replacement parts — section assembly
Figure 39
Section assembly
Part Number
550-110-710/0107
59
Page 58
Page 60
Page 59
Image 59
Page 58
Page 60
Contents
Boiler Manual
• Installation • Maintenance
• Startup • Parts
GOLD CGi
⑤Water temperature limit switch
How it works
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
④Air pressure switch
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-Fired Induced-DraftWater Boiler
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Contents
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Please read before proceeding
Installer
When servicing boiler —
Before locating the boiler, check the following
1a Prepare boiler location — codes & checklist
Installations must follow these codes
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
1b Prepare boiler location — clearances
Recommended SERVICE clearances
Residential garage installations
Chimney or vent require- ments
1c Prepare boiler location — vent system
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
1d Prepare boiler location — air contamination
Air opening options
1e Prepare boiler location — air openings
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Air openings must be provided
Single air opening option
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Exhaust fans and air movers
Motorized air dampers
Place boiler/crate near position
2a Prepare boiler — placement & setup
Orifice replacement procedure
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Drain and remove fittings
2b Prepare boiler — pressure test
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Hydrostatic pressure test
Chimney draft venting
3a Venting — general information
Venting — chimney draft venting
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Obtain vent system components
3c Venting — Direct exhaust — components
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
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
Sidewall termination
3f Venting — direct exhaust — installation cont
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
in substantial property damage
General piping information
4a Water piping — general information
Pressure/temperature gauge
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Figure
4b Water piping — single-zonesystem
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Closed-typeexpansion tank
Converted gravity or steam systems
4c Water piping — multiple zones
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Piping multiple zones
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
4c Water piping — multiple zones continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
4d Piping — low temperature systems
Temperature gauges
Valve adjustment
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
4d Piping — low temperature systems continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
4d Piping — low temperature systems
Valve adjustment
Temperature gauges
1Boiler isolation balancing valves
4d Piping — low temperature systems continued
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
SYSTEM-bypasspiping method
4d Piping — low temperature systems
Valve adjustment
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Prevent chilled water from entering boiler
4e Water piping — refrigeration system
4d Piping — low temperature systems continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Natural Gas
5 Gas piping
Connecting gas supply piping to boiler
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
6 Field wiring
Electrical installation must comply with
Wiring connections
Check for gas leaks
7a Start-up- preparation
Freeze protection when used
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Inspect system water piping
7a Start-up— preparation continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Fill the system with water
Check system and boiler
7b Start-up— operate boiler
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Start the boiler
Pilot burner flame Figure
7b Start-up— operate boiler continued
7c Start-up— if boiler doesn’t start
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
8 Check-outprocedure — checklist
Installation and service certificate
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
9a Operation — sequence
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
9b Operation — wiring diagrams
Figure 31 Schematic wiring diagram
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Figure 32 Ladder wiring diagram
• Gas valve: Honeywell VR8204/VR8304
9c Operating instructions CGi-25to CGi-6
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
• Spark pilot • Natural or propane gas
• Gas valve: White-Rodgers36E
9c Operating instructions CGi-25to CGi-6
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
• Spark pilot • Natural or propane gas
• Gas valve: White-Rodgers36C
9c Operating instructions CGi-25to CGi-8
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
• Spark pilot • Natural or propane gas
VERIFY PROPER OPERATION AFTER SERVICING
10a Service and maintenance — schedule
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
10b Service and maintenance — annual start-up
Inspect
Reported problems
Inspect
10b Service & maintenance – annual start-up cont
Service
Start-up
Gas piping
Check/test
10b Service & maintenance – annual start-up cont
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Review with owner
Cleaning boiler heating surfaces
10b Service & maintenance – annual start-up cont
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Troubleshooting air pressure reading
11a Troubleshooting — procedure
11b Troubleshooting - components
Check pressure switch setting
Control indicator lights — LOCKOUT modes
11b Troubleshooting — components continued
Control indicator lights —
Troubleshooting the control module
Figure 38 Control module connections
11b Troubleshooting — components continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Is POWER light flashing now?
11c Troubleshooting — control module lights
Is POWER light off?
Is POWER light
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
11c Troubleshooting — control module lights cont
CHART 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 cont
CHART 3 — PRESS SWITCH & POWER lights flashing
Is PRESS SWITCH light flashing?
Are FLAME and POWER lights flashing?
11c Troubleshooting — control module lights cont
Do FLAME and POWER lights still flash?
Are FLAME & POWER lights flashing?
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
11c Troubleshooting - control module lights cont
Does the ohmmeter indicate the switch is closed?
Is PRESS SWITCH light flashing?
TURN OFF POWER to boiler
11c Troubleshooting — control module lights cont
TURN OFF POWER
TURN OFF POWER
Are limit switch contacts
11c Troubleshooting — control module lights cont
Are limit switch contacts closed?
Does voltmeter show 120 VAC across pins?
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
12a Replacement parts
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
Description
12c Replacement parts — base continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
Item
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
12d Replacement parts — jacket
Figure 41 Jacket assembly
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
12d Replacement parts — jacket continued
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
12e Replacement parts — trim
Figure 42 Trim assembly
Fittings shown are factory-installedon boiler
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
GOLD CGi Gas-FiredWater Boiler - Boiler Manual
13b Ratings
LINING OR BASE PANELS
Handling ceramic fiber and fiberglass materials
GOLD CGi Gas-FiredWater Boiler — Boiler Manual
REMOVAL OF COMBUSTION CHAMBER