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Part No. 550-110-710/0107

This manual must only be used by a qualified heating installer/service technician.

Before

installing

, read all

instructions, including this manual, the burner manual and any related supplements. Perform steps in the order

given. Failure to comply could result in severe personal injury, death or substantial property damage.

• Installation

• Startup

Boiler Manual

• Maintenance

• Parts

GOLD CGi

Gas-Fired Water Boilers
Series 2

DO NOT USE BOILER DURING CONSTRUCTION

unless you provide dust-free air to the boiler area or

follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub-

stantial property damage.

Содержание GOLD CGi

Страница 1: ...the order given Failure to comply could result in severe personal injury death or substantial property damage Installation Startup Boiler Manual Maintenance Parts GOLD CGi Gas Fired Water Boilers Seri...

Страница 2: ...t likely reason for the problem 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 bo...

Страница 3: ...Part Number 550 110 710 0107 GOLD CGi Gas Fired Water Boiler Boiler Manual GOLD CGi Gas Fired Induced Draft Water Boiler...

Страница 4: ...7 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 of...

Страница 5: ...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 Do...

Страница 6: ...ocating the boiler check the following Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power Check area around boiler Remove any combustible materia...

Страница 7: ...r 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 unusually tight constructio...

Страница 8: ...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 vent require ments 1 Venting must be ins...

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

Страница 10: ...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 S...

Страница 11: ...ces 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 space...

Страница 12: ...stamped on the orifice spud barrel Correctly sized manifold orifices must be used Failure to do so will result in severe personal injury death or sub stantial property damage 3 Reinstall burner shiel...

Страница 13: ...uring 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 fresh...

Страница 14: ...as required by the National 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 poi...

Страница 15: ...h Systems FasNSeal Use only the vent starter of the same manufacturer as the vent components Do not mix components from different systems The vent system could fail causing flue gas spillage resulting...

Страница 16: ...erent systems 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 b...

Страница 17: ...ent 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 c...

Страница 18: ...Elbow and termination 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 h...

Страница 19: ...ired 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 hea...

Страница 20: ...circulation by natural convection rather than a pump See page 29 for boilers used with refrigeration systems Chillers or air handling units Install boiler such that Chilled medium if used is piped in...

Страница 21: ...s 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 ta...

Страница 22: ...re 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 corros...

Страница 23: ...logging of the expansion 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 Ai...

Страница 24: ...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 sys...

Страница 25: ...T usean automaticairventwhenusingclosed 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 ta...

Страница 26: ...he 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 not...

Страница 27: ...ank 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 to...

Страница 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...

Страница 29: ...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 a...

Страница 30: ...s 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 ate length of pipe between cap and tee b Install grou...

Страница 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...

Страница 32: ...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 fresh...

Страница 33: ...e 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 ty...

Страница 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...

Страница 35: ...ectly heated pilot flame sensor Main burner flame Figure 29 PROPER main burner flame characteristics 1 Yellow orange streaks may appear caused by dust IMPROPER main burner flame characteristics 1 Over...

Страница 36: ...lame and main burners will reignite Set limit control s to system temperature requirements Adjust balancing valves and controls to provide design temperature to system For multiple zones adjust flow s...

Страница 37: ...ntrol module senses flame current spark generator is turned off and main valve opens 5 During main burner operation a Control module monitors pilot flame current If signal is lost main valve closes sp...

Страница 38: ...GOLD CGi Gas Fired Water Boiler Boiler Manual 38 Part Number 550 110 710 0107 Operation wiring diagrams 9b Figure 31 Schematic wiring diagram...

Страница 39: ...Part Number 550 110 710 0107 39 GOLD CGi Gas Fired Water Boiler Boiler Manual Figure 32 Ladder wiring diagram...

Страница 40: ...GOLD CGi Gas Fired Water Boiler Boiler Manual 40 Part Number 550 110 710 0107 9c Operating instructions CGi 25 to CGi 6 Spark pilot Natural or propane gas Gas valve Honeywell VR8204 VR8304...

Страница 41: ...Part Number 550 110 710 0107 41 GOLD CGi Gas Fired Water Boiler Boiler Manual 9c Operating instructions CGi 25 to CGi 6 Spark pilot Natural or propane gas Gas valve White Rodgers 36E...

Страница 42: ...GOLD CGi Gas Fired Water Boiler Boiler Manual 42 Part Number 550 110 710 0107 9c Operating instructions CGi 25 to CGi 8 Spark pilot Natural or propane gas Gas valve White Rodgers 36C...

Страница 43: ...tenance procedures given throughout this manual and in com ponent literature shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failu...

Страница 44: ...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 a...

Страница 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...

Страница 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...

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

Страница 48: ...assembly 6 If manometer reading is above the setpoint of the switch see Table 9 but there is not 24 VAC between both air pressure switch terminals replace air pressure switch Return to normal operati...

Страница 49: ...odule 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 us...

Страница 50: ...GOLD CGi Gas Fired Water Boiler Boiler Manual 50 Part Number 550 110 710 0107 Troubleshooting components continued 11b Figure 38 Control module connections...

Страница 51: ...RESS 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 Usu...

Страница 52: ...ed 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 t...

Страница 53: ...11 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 Y...

Страница 54: ...n 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 ca...

Страница 55: ...oes 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 sea...

Страница 56: ...or 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...

Страница 57: ...hould be in normal operating sequence See normal sequence of operation Figure 30 page 37 If you have less than sufficient heat Is vent piping free of blockage No Yes Correct conditions and recheck ope...

Страница 58: ...and include description and part number of replacement part Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation Weil McLai...

Страница 59: ...Part Number 550 110 710 0107 59 GOLD CGi Gas Fired Water Boiler Boiler Manual Replacement parts section assembly 12b Figure 39 Section assembly...

Страница 60: ...GOLD CGi Gas Fired Water Boiler Boiler Manual 60 Part Number 550 110 710 0107 Replacement parts base 12c Figure 40 Base assembly...

Страница 61: ...2 450 003 693 450 003 795 450 003 796 8b Rear spacing strip CGi 25 CGi 3 CGi 4 CGi 5 CGi 6 CGi 7 CGi 8 550 320 160 550 320 161 550 320 162 550 320 163 550 320 164 550 320 165 8c Nut hex 5mm Zp 550 320...

Страница 62: ...GOLD CGi Gas Fired Water Boiler Boiler Manual 62 Part Number 550 110 710 0107 Replacement parts jacket 12d Figure 41 Jacket assembly...

Страница 63: ...431 223 311 381 355 403 381 355 403 381 355 413 381 355 420 381 355 427 381 355 434 381 355 441 381 355 539 381 355 539 381 355 551 381 355 558 381 355 565 381 355 572 381 355 579 CGi 25 CGi 3 CGi 4...

Страница 64: ...shank Fittings shown are shipped loose with boiler Weil McLain 380 000 000 3 Drain valve Fittings shown are included with boiler Conbraco Hammond Valve Matco Norca Watts 31 606 01 710 205F04 BD 2C 51...

Страница 65: ...Gi 6 CGi 7 CGi 8 Honeywell White Rodgers Honeywell White Rodgers VR8204M2701 36E36 291 VR8304M4010 36C68 479 511 044 354 511 044 354 511 044 355 511 044 355 2 Pilot kit w orifice aluminum pilot gas tu...

Страница 66: ...GOLD CGi Gas Fired Water Boiler Boiler Manual 66 Part Number 550 110 710 0107 Dimensions 13a Figure 44 Dimensional drawing...

Страница 67: ...CGi 3 51 000 60 300 51 000 54 300 46 200 45 000 1 5 85 1 3 CGi 4 85 000 100 000 85 000 90 000 76 000 74 000 2 1 84 0 3 CGi 5 100 000 119 700 100 000 108 000 90 000 87 000 2 7 83 3 3 CGi 6 140 000 167...

Страница 68: ...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 imm...

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