Weil-McLain CGi Series 2, Manual

Page 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 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 deat...

Page 2: ...st 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 boiler causing air to be pulled in through the boiler air openings The inducer pushes the flue gases through the vent pipe as well Air pressure switch The air pressure switch signals the control module...

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

Page 4: ...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 of the product Indicates presence of hazards that will cause severe personal injury death or substantial property damage Indicates presence of hazards that can cause severe personal injury death or sub...

Page 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 not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has b...

Page 6: ...locating 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 materials gasoline and other flammable liquids or other contaminants Failure to keep boiler area clear and free of combustible mate rials gasoline and other flammable liquids and vapors can result in severe...

Page 7: ...er 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 construction see page 11 for definition the air openings must connect directly to outside or the building must have air openings to the outside as specified on page 11 If clearances are equal to or greater than...

Page 8: ...m 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 installed according to Part 7 Venting of Equipment of National Fuel Gas Code ANSI Z223 1 latest edition and appli cable building codes Canadian installations must comply with B149 1 or B149 2 Installati...

Page 9: ...taining chloro fluorocarbons Dry cleaning laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes cleaners Metal fabrication plants Chlorine based swimming pool chemicals Beauty shops Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish remo...

Page 10: ...s 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 See Figure 5 Air supplied through horizontal ducts provide two openings within 12 inches of the floor and the ceiling sized per Figure 5 Prepare boiler location air openings 1e Air openings must be pr...

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 space that communicates directly to the outdoors not to an interior space Theaircanbeprovidedthroughadirectopeningorthroughahorizontal or vertical duct Opening placement The top of the air opening must be...

Page 12: ...s 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 shield Do not operate boiler without burner shield in place Failure to do so could result in severe personal injury death or sub stantial property damage Orifice replacement procedure when required 1 Remo...

Page 13: ...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 fresh water sup ply to fill boiler with water 3 When water flows from shutoff valves close boiler drain valve 4 Close shutoff valves 2b 5 Slowly reopen boiler drain valve until test pressure on the pressur...

Page 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 point where it passes through a roof and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet 3 To vent with another appliance see National Fuel Gas Code ANSI Z2...

Page 15: ...ch 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 in severe personal injury or death 2 Select vent method based on page 14 and installation requirements 3 Refer to Table 4 for maximum vent run lengths and number of elbows Do not exceed data in Tabl...

Page 16: ...ferent 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 boiler 4 Connect vent starter to blower housing outlet as shown in the Figures 8 through 11 a Do not mix components from different vent manufacturers b Maintain minimum 2 clearance from com bustible m...

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 clearances 12 Canadian installations See B149 1 or B149 2 Installation Code Terminate vent no less than 6 feet from another combustion air inlet 3 feet from any other building opening and 3 feet from ...

Page 18: ...8 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 hole diameter large enough to insert the vent pipe slip connector for Saf T Vent 8 Install horizontal drain tee as close as possible to boiler in first horizontal run See Figures 13 and 14 9 Do not ex...

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 heat resulting in substantial property damage 3f ...

Page 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 parallel with heating boiler Use appropriate valves to prevent chilled medium from entering boiler Consult I B R Installation and Piping Guides If boiler is connected to heating coils located in air ...

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 tapping located behind supply outlet using NPT piping Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping Use Figure 16 or Figure 17 only for single zone systems designed for return...

Page 22: ...ure 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 corrosion of the boiler sec tions or burners resulting in severe personal injury death or substantial property damage Radiant heating systems Preferably use primary secondary piping as shown in Figures 20 ...

Page 23: ...rlogging 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 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansion tank regardless of loca For systems with possible low return water temperature such as conver...

Page 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 systems such as radiant heating systems or converted gravity systems For alterna tives see pages 26 through 29 The bypass valves items 7a and 7b provide mixing of hot boiler outlet water with cooler sys...

Page 25: ...OT 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 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 automatic vent if used Note that the fill valve must always be connected ...

Page 26: ...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 not installed Valve adjustment 1 Start with valve 7a fully closed and 7b fully open 2 Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 60 F higher than gauge 4a A mi...

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 top of air separator to tank fitting as in Figure 17 page 21 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansion tank regardless of location o...

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 7b until the temperature at gauge 8 reads at least 130 F at all times 3 Valve 7a regulates the amount of boiler supply water mixed with return water Valve 7b causes a pressure drop in the system neede...

Page 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 and 23 Figure 25 Piping refrigeration systems 4e Prevent chilled water from entering boiler Water piping refrigeration system Install boiler so that chilled medium is piped in parallel with the heatin...

Page 30: ...as 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 ground joint union for servicing when required c Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or utility requirements d In Canada When using manual...

Page 31: ...boiler 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 avoid possible electric shock hazard Failure to do so can cause severe personal injury or death Wiring must be N E C Class 1 If original rollout thermal fuse element wire as supplied with boiler must...

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 fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure Verify water chemistry Consult local water treatment c...

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 type or bladder type expansion tank systems only one turn 5 Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out b Repeat with remaining vents 6 Refill t...

Page 34: ...ughly 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 boiler at once Find the leak source with bubble test and repair immediately Do not start boiler again until corrected Failure to comply could re sult in severe personal injury death or substantial propert...

Page 35: ...rectly 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 Overfired Large flames 2 Underfired Small flames 3 Lack of primary air Yellow tipping on flames sooting will occur Figure 28 Typical pilot burner flame Start up operate boiler continued 7b Start up if bo...

Page 36: ...flame 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 so it is about the same in each zone Verify thermostat heat anticipator if available set prop erly Refer to Field wiring manual Section 6 page 31 Thermostat s Cycle boiler with thermostat Raise to hig...

Page 37: ...ontrol 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 spark gen erator activates and sequence returns to step 4 b If power is interrupted control system shuts off pilot and main gas valves and restarts at step 1 when power is restored 6 In the event the l...

Page 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 ...

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

Page 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 ...

Page 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 ...

Page 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 ...

Page 43: ...ntenance 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 Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage VERIFY PROPER OPERATION AFTER SERVICING ...

Page 44: ...s 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 ally at the beginning of the heating season only by a qualified service technician In addition the maintenance and care of the boiler designated in Table 8 page 43 and explained on the following pages...

Page 45: ...he 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 the burner inlet while cleaning the burner ports with a wire brush The vacuum will help to draw any airborne material out of the burner 4 Reinstall components starting with the burner tray then the ...

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 expansion Make sure this type of tank is fitted with a tank fitting such as the B G Tank Trol or Taco Taco Trol This fitting reduces gravity circula tion of air saturated tank water back to the syste...

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 been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve ...

Page 48: ...k 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 operation When pressure reading is correct and air pressure switch is operating properly remove tees and reinstall hoses to air pressure switch Check the following 1 Wire connectors to control module are se...

Page 49: ...module 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 usually due to miswired 3 wire zone valve POWER and PRESS SWITCH lights flashing Usually indicates pressure switch is closed when it should not be or pressure switch failed to close within 5 minutes of...

Page 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 ...

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 Usually indicates reversed 120 VAC polarity if POWER light flashes by itself Is POWER light off Is POWER light Flashing alone Flashing with another light Reconnect 120 VAC IN plug Remove 120 VAC IN tran...

Page 52: ...ted 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 time and check the voltmeter reading across the wires There should NEVER be a voltage reading If a voltage does occur under any condition check and correct the external wiring This is a common problem...

Page 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 Yes Remove INDUCER plug Figure 38 Item 6 page 50 from plug receptacle of control module Place voltmeter leads across the 120 VAC N and 120 VAC H pins of the INDUCER receptacle left column center and r...

Page 54: ...rn 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 caused by gas valve not operating properly See normal sequence of operation Figure 30 page 37 Replace gas valve Retest boiler Are FLAME and POWER lights flashing No Yes No Yes Are manual main shutoff v...

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 seated but problem persists replace control module Retest Check air pressure switch per manual Section 11b Replace if necessary Retest Replace inducer assembly Retest No Yes Remove INDUCER plug Figure 3...

Page 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 lead of MICROAMMETER to sense wire DISCONNECT red wire connected to terminal MV of the gas valve Turn on power to boiler and allow to cycle As soon as pilot is burning the MICROAMMETER should read a...

Page 57: ...should 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 operation See Figure 30 page 37 for normal sequence of operation Check heat loss calculation versus boiler size Clock gas input Replace control module Retest Repair replace circulator Retest Repair repl...

Page 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 McLain part numbers are found in Weil McLain Boilers and Controls Repair Parts Lists The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on p...

Page 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 ...

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

Page 61: ...92 450 003 693 450 003 795 450 003 796 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 550 320 170 9 Base insulation kit CGi 25 CGi 3 CGi 4 CGi 5 CGi 6 CGi 7 CGi 8 381 354 330 381 354 331 381 354 332 381 354 333 381 354 334 381 354 335 10 Boiler leg kit 550 320 219 11 Manifold CGi 25 CGi 3 CG...

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

Page 63: ...1 431 223 311 381 355 403 381 355 403 381 355 413 381 355 420 381 355 427 381 355 434 381 355 441 381 355 539 381 355 539 381 355 551 381 355 558 381 355 565 381 355 572 381 355 579 CGi 25 CGi 3 CGi 4 CGi 5 CGi 6 CGi 7 CGi 8 Boiler Model 6 7 8 9 10 Boiler Model Panel door Cross tie bottom front Panel interior with insulation Panel rear with insulation Not shown gold touch up paint Weil McLain part...

Page 64: ...t 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 511 210 423 511 246 392 511 246 392 511 246 392 4 Circulator Fittings shown are shipped loose with boiler Bell Gossett Taco NRF 22 103253 007 511 405 118 511 405 113 5 Circulator gasket universal 2 per...

Page 65: ...CGi 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 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 harness Weil McLain 591 391 894 4 Air pressure switch 1 79...

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

Page 67: ... CGi 3 57 000 67 000 57 000 60 000 51 000 50 000 1 5 84 3 3 CGi 4 85 000 100 000 85 000 90 000 76 000 74 000 2 1 84 0 3 CGi 5 112 000 133 000 112 000 120 000 101 000 97 000 2 7 83 7 3 CGi 6 140 000 167 000 140 000 150 000 126 000 122 000 3 3 83 3 3 CGi 7 167 000 200 000 167 000 180 000 150 000 145 000 3 8 83 0 3 CGi 8 194 000 233 000 194 000 210 000 175 000 169 000 4 4 82 7 3 Notes 1 Add PIN for n...

Page 68: ...n 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 immediately Breathing Fresh air REMOVAL OF FIBERGLASS WOOL or INSTALLATION OF FIBERGLASS WOOL COMBUSTION CHAMBER LINING OR BASE PANELS This product contains fiberglass jacket insulation and ceramic fibe...