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GOLD

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

50

Part Number

550-110-711/1108

Troubleshooting — components

(continued)

11b

Figure 38

Control module connections

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Summary of Contents for GOLD CGi-4E

Page 1: ...in the order given Failure to comply could result in severe personal injury death or substantial property damage Installation Startup Boiler Manual Maintenance Parts Gas Fired Water Boiler DO NOT USE...

Page 2: ...lem see page 49 Transformer The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit Inducer The inducer pulls flue gases through the boiler causing air to be pulle...

Page 3: ...Part Number 550 110 711 1108 3 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual GOLD CGi 4E Gas Fired Induced Draft Water Boiler...

Page 4: ...6 67 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life...

Page 5: ...to boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance...

Page 6: ...h of Massachusetts located on page 42 of this manual Before locating the boiler check the following Check for nearby connection to System water piping Venting connections Gas supply piping Electrical...

Page 7: ...igure 1b to provide proper air flow around the boiler The free area of each opening after deducting for louvers must be at least one square inch per 1 000 Btuh of boiler input If the building is of un...

Page 8: ...t by re sizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code Canadian installations must comply with B149 1 or B149 2 Instal lation Code Chimney or ve...

Page 9: ...containing chloro fluorocarbons Dry cleaning laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes cleaners Metal fabrication plants Chlorine based swimming pool c...

Page 10: ...es of the ceiling and the floor sized per Figure 3 3 See Figure 4 Air supplied through vertical ducts provide two openings terminated within 12 inches of the ceiling and the floor sized per Figure 4 4...

Page 11: ...nces from boiler to walls The boiler must have clearances of at least those shown in Figure 1a page 7 Opening must be directly to outside The opening must connect directly to the outdoors or to a spac...

Page 12: ...acket door Remove burner shield see Figure 40 item 4 page 60 2 Check for correctly sized manifold orifices See Table 2 for sizing The orifice size is stamped on the orifice spud barrel Correctly sized...

Page 13: ...air during the fill Valve and nipple are not included with boiler Fill and pressure test 1 Open the shutoff valves you installed on supply and return connections 2 Slowly open boiler drain valve and f...

Page 14: ...nal Fuel Gas Code ANSI Z223 1 latest edition or in Canada B149 1 or B149 2 Installation Code 2 To prevent downdrafts chimney should extend at least 3 feet above the highest point where it passes throu...

Page 15: ...ystems The vent system could fail causing flue gas spillage resulting in severe personal injury or death 2 Select vent method based on page 14 and installation requirements 3 Refer to Table 4 for maxi...

Page 16: ...ms The vent system could fail causing flue gas spillage resulting in severe personal injury or death 3 Follow all applicable national state local or provin cial codes when venting the CGi 4E boiler 4...

Page 17: ...vent above any door or window Condensate can freeze causing ice formations 11 Do not connect Any other appliance to vent pipe Multiple boilers to a common vent pipe Figure 12 Vent termination minimum...

Page 18: ...on coupling with screen not available for StaR 34 6 Do not seal vent pipe slip connector for Saf TVent to inside or outside plate 7 If passing through noncombustible wall provide hole diameter large e...

Page 19: ...Fired Water Boiler Boiler Manual Figure 15 Sidewall termination Venting direct exhaust installation cont Using any termination other than one of those shown could cause nuisance outages and loss of h...

Page 20: ...der type expan sion tank or Figure 17 closed type expansion tank and Table 6 for near boiler and single zone systems designed for return water at least 130 F See pages 22 23 to complete multiple zone...

Page 21: ...es Closed type expansion tank Figure 17 1 Ensure expansion tank size will handle boiler and system water volume and temperature See tank manufacturer s instructions for details 2 Connect tank to NPT t...

Page 22: ...gure 24 on page 29 system bypass if the reduced flow rate in the heating system will not cause heat distribution problems Failure to prevent low return water temperature to the boiler could cause corr...

Page 23: ...tank 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to tank fitting as in Figure 17 13 Air separator and automati...

Page 24: ...l not cause a change in the heating circuit rate and temperature distribution Figures 20 and 21 show suggested bypass arrangements using primary secondary bypass piping preferred for low temperature s...

Page 25: ...OT usean automaticairvent when usingclosed typeexpansiontank It would allow air to leave the system causing waterlogging of the expansion tank 11 Fill valve 12 Diaphragm type or bladder type expansion...

Page 26: ...o the radiant tubing Gauge 8 is required on all systems to assure reliable adjustment of the bypass valves The boiler mounted temperature pressure gauge can be used if a separate temperature gauge is...

Page 27: ...tank It would allow air to leave the system causing waterlogging of the expansion tank 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from...

Page 28: ...beginning of the system and reduced heat from radiators near the end of the system Valve adjustment 1 Start with valve 7a fully closed and 7b fully open 2 Gradually open valve 7a while closing valve 7...

Page 29: ...f air separator to tank fitting as in Figure 17 page 21 Figure 24 System bypass piping Zoning with zone valve or circulators return water 130 F or higher Alternative to boiler bypass piping Figures 22...

Page 30: ...e jacket front panel and refer to Figure 26 to pipe gas to boiler a Install drip leg at inlet of gas connection to boiler Where local utility requires drip leg to be extended to the floor use appropri...

Page 31: ...oiler junction box and mount the service switch remotely as required by the code For your safety turn off electrical power supply at service entrance panel before making any electrical connections to...

Page 32: ...s needed Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Eliminate all system leaks Continual fres...

Page 33: ...re not installed in system open manual air vents in system one at a time beginning with lowest floor Close vent when water squirts out Repeat with remaining vents 4 Open automatic air vent diaphragm t...

Page 34: ...ghly for signs of deterioration from corrosion physical damage or sagging In addition Check for gas tight seal at every connection and seam If you discover evidence of any gas leak shut down the boile...

Page 35: ...d Large flame lifting or blowing past pilot flame sensor 2 Underfired Small flame Inner cone not engulfing pilot flame sensor 3 Lack of primary air Yellow flame tip 4 Incorrectly heated pilot flame se...

Page 36: ...use or service switch off 2 High limit switch set below boiler water tempera ture 3 Thermostat set below room temperature 4 Gas not turned on at meter or boiler 5 Incoming gas pressure less than 5 w c...

Page 37: ...light flame sensing element will sense pilot flame and main burners will reignite Set limit control s to system temperature requirements Adjust balancing valves and controls to provide design temperat...

Page 38: ...ve opens 5 The CGi 4E timer relay delays high fire for the first 60 seconds of main flame 6 During main burner operation a Control module monitors pilot flame current If signal is lost main valve clos...

Page 39: ...Part Number 550 110 711 1108 39 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual Figure 30 Control module sequence of operation status light indications...

Page 40: ...GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 40 Part Number 550 110 711 1108 Operation wiring diagrams 9b Figure 31 Wiring diagram...

Page 41: ...Part Number 550 110 711 1108 41 GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 9c Operating instructions Spark pilot Natural or propane gas Gas valve Honeywell VR8204 VR8304...

Page 42: ...plastic identification plate shall be permanently mounted to the exterior of the build ing at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the hori...

Page 43: ...intenance procedures given throughout this manual and in component literature shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Fail...

Page 44: ...ts before returning to service 6 Check inside and around boiler for evidence of any leaks from the boiler If found locate source of leaks and repair 10b The boiler should be inspected and started annu...

Page 45: ...e burner tray to the manifold and slide the burner tray out under the manifold 2 Inspect each burner to insure that every port is com pletely open 3 If any port is not completely clear run a vacuum at...

Page 46: ...unit usually in the attic or closet Has a gauge glass and overflow pipe to a drain Closed type welded gas tight and located above boiler Tank is partially filled with water leaving an air cushion for...

Page 47: ...ake any necessary adjustments Safetyrelief valvesshouldbereinspected AT LEAST ONCE EVERYTHREEYEARS byalicensedplumb ing contractor or authorized inspection agency to ensure that the product has not be...

Page 48: ...sure switch Table 9 Pressure switch setpoint for elevations above 2 000 ft contact your local Weil McLain sales office for details Boiler model number Inches W C CGi 4E 1 36 Label all wires prior to d...

Page 49: ...e POWER light flashing alone Usually indicates reversed polarity of 120 VAC power wires POWER and TSTAT CIRC lights flashing Usually indicates stray voltage on external thermostat circuit wires usuall...

Page 50: ...GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 50 Part Number 550 110 711 1108 Troubleshooting components continued 11b Figure 38 Control module connections...

Page 51: ...PRESS SWITCH light flashing FLAME light flashing For insufficient heat or no heat problem go to Chart 7 if POWER light is on steady with no other light flashing No Yes On steady not flashing No Yes U...

Page 52: ...cted to the boiler thermostat leads two black low voltage leads in J box Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a...

Page 53: ...11a Replace if necessary Retest Try reseating plug in module receptacle and restart If inducer still does not work replace inducer assembly Retest No Yes Wait 45 seconds Does inducer motor operate No...

Page 54: ...urn on power to boiler Restart boiler following Operating instructions in this manual Section 9c Do FLAME and POWER lights still flash Boiler should now operate normally Original flashing FLAME light...

Page 55: ...Does the ohmmeter indicate the switch is closed Inspect and check wire harness from control module to pressure switch Reseat connector in control module receptacle If harness is intact and properly se...

Page 56: ...breaker Check flame signal Detach sense lead from ignition control Figure 38 item 8 page 50 Connect negative lead of MICROAMMETER to control sense terminal Figure 38 item 8 page 50 Connect positive l...

Page 57: ...at Is vent piping free of blockage No Yes Correct conditions and recheck operation See Figure 30 page 39 for normal sequence of operation Check heat loss calculation versus boiler size Clock gas input...

Page 58: ...art Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation Weil McLain part numbers are found in Weil McLain Boilers and Cont...

Page 59: ...ot shown Section replacement kit includes seals and sealant for 1 joint 381 354 527 4 Tie rod M zn without nut 3 per boiler CGi 4E 560 234 501 5 Nut M zn 2 per tie rod 561 928 235 Item number Descript...

Page 60: ...GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 60 Part Number 550 110 711 1108 Replacement parts base 12c Figure 40 Base assembly...

Page 61: ...ase pan angle right side in Base assembly 7 Base pan in Base assembly 7a Base pan air baffle in Base assembly 8a Burner mounting plate CGi 4E 450 003 691 8b Rear spacing strip CGi 4E 550 320 161 8c Nu...

Page 62: ...GOLD CGi 4E Gas Fired Water Boiler Boiler Manual 62 Part Number 550 110 711 1108 Replacement parts jacket 12d Figure 41 Jacket assembly...

Page 63: ...lation Panel top front with insulation Panel top rear with insulation Natural Gas Propane Gas CGi 4E Available at local supply house 381 355 610 381 355 612 381 355 613 381 355 413 381 355 551 CGi 4E...

Page 64: ...tion pressure temperature gauge 3Z diameter short shank Fittings shown are shipped loose with boiler Weil McLain 380 000 000 3 Drain valve Fittings shown are included with boiler Conbraco Hammond Valv...

Page 65: ...1 044 510 2 Pilot kit w orifice aluminum pilot gas tubing Weil McLain 511 330 081 Natural gas and propane gas components 3 Control module United Technologies 1107 1 511 330 090 not shown Wiring harnes...

Page 66: ...Figure 44 Dimensional drawing Boiler model number Supply tapping inches NPT Return tapping inches NPT Gas connection size Note 3 inches NPT Gas manifold size Note 3 inches NPT W Jacket width inches C...

Page 67: ...Btuh Input Btuh Output Btuh Note 1 Note 2 Note 3 Note 4 CGi 4E Note 5 76 000 90 000 76 000 81 000 68 400 66 000 2 1 85 0 3 Notes 1 Add PIN for natural gas boiler PIL for propane gas boiler 2 Based on...

Page 68: ...tion from the boiler and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate...

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