Weil-McLain CGi-25, CGi-3, CGi-4, CGi-5, CGi-6 User Manual

...

Download

Page 1

Page 2

GOLD CGi Series 2 Gas-Fired Water Boiler

How it works . . .

①

②

③

Control module

The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and inducer. When room thermostat calls for heat, the control module starts the system circulator and inducer.

The control module runs the inducer long enough to purge the boiler flue passages, then opens the pilot valve and activates pilot ignition spark.

The control module allows up to 15 seconds to establish pilot flame. If flame is not sensed within 15 seconds, the control module will turn off the gas valve, flash the Flame light, and then enter a 15-second postpurge. The control module will then start a new cycle. This will continue indefinitely until pilot flame is established or power is interrupted. Once pilot flame is proven, the control module opens the gas valve to allow main burner flame.

When the room thermostat is satisfied, the control module turns off the gas valve, operates the inducer for a 15-second postpurge and waits for the next heat call.

The control module indicator lights show normal sequence when the lights are on steady. When a problem occurs, the control module flashes combinations of lights to indicate the most likely reason for the problem (see page 47).

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.

④

⑤

Air pressure switch

The air pressure switch signals the control module, telling the control module whether the inducer is working correctly or the vent is blocked.

Water temperature limit switch

The water temperature limit switch turns off the gas valve if the temperature in the boiler goes above its setting. (The circulator will continue to run as long as there is a call for heat.)

Boiler circulator

The boiler circulator circulates water through the external (system) piping. The circulator is shipped loose, and can be mounted on either the boiler supply or return piping. The factoryinstalled circulator wiring harness provides ample length for either location. NOTE — The control module provides a pump exercising routine. If the boiler is not operated for 30 days, the control module will power the circulator for 30 seconds, then turn off.

Other boiler components:

a supply to system

b return from system

c stainless steel burners

d flue outlet

e gas valve

f pressure/temperature gauge

g relief valve

h air vent connection

i flame rollout thermal fuse

element (TFE)

j burner shield

k pilot burner and bracket

l gas manifold

m cast iron boiler sections

n flue collector

o junction box

Part Number 550-110-710/0200

Page 3

Page 4

GOLD CGi Series 2 Gas-Fired Water Boiler

Contents

How it works .................................................................. 2–3

Hazard definitions.............................................................. 4

Please read before proceeding ......................................... 5

Prepare boiler location ................................................ 6–11

Prepare boiler............................................................. 12–13

Venting ........................................................................14-19

Water piping ............................................................... 20-29

Gas piping ........................................................................ 30

Field wiring ...................................................................... 31

Start-up .......................................................................32-35

Check-out procedure....................................................... 36

Operation ....................................................................37-40

Service and maintenance........................................... 41-45

Troubleshooting ......................................................... 46-55

Replacement parts ..................................................... 56-61

Dimensions and ratings .............................................62-63

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 substantial property damage.

Indicates presence of hazards that will or can cause minor personal injury or property damage.

Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.

Part Number 550-110-710/0200

Page 5

Boiler Manual

Please read before proceeding

Installer

Read all instructions before installing.

proper order to prevent personal injury or death.

• Consider piping and installation when determining boiler location.

• Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

When calling or writing about the boiler— Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket. You may list the CP number in the space provided on the Installation and service certificate found on page 36.

Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage.

When servicing boiler —

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation —

• Do not block flow of combustion or ventilation air 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.

• 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 been under water.

Boiler water —

• Do not use petroleum-based cleaning or sealing compounds in boiler system. Water seal deterioration will occur, causing leakage between sections. This can result in substantial property damage.

• Do not use "homemade cures" or "boiler patent medicines". Serious damage to boiler, personnel and/or property may result.

Follow all instructions in

User

• This manual is for use only by your qualified

heating installer/service technician.

• Please refer to the User’s Information Manual for your reference.

• We recommend regular service by a qualified

service technician, at least annually.

• Continual fresh makeup water will reduce boiler

life. Mineral buildup in sections reduces heat transfer, overheats cast iron, and causes section failure. Addition of oxygen and other gases can cause internal corrosion. Leaks in boiler or piping must be repaired at once to prevent makeup water.

• Do not add cold water to hot boiler. Thermal

shock can cause sections to crack.

Glycol — potential fire hazard —

All glycol is flammable when exposed to high temperatures. If glycol is allowed to accumulate in or around the boiler or any other potential ignition source, a fire can develop. In order to prevent potential severe personal injury, death or substantial property damage from fire and/or structural damage:

• Never store glycol of any kind near the boiler or

any potential ignition source.

• Monitor and inspect the system and boiler

regularly for leakage. Repair any leaks immediately to prevent possible accumulation of glycol.

• Never use automotive antifreeze or ethylene

glycol in the system. Using these glycols can lead to hazardous leakage of glycol in the boiler system.

Part Number 550-110-710/0200

Page 6

GOLD CGi Series 2 Gas-Fired Water Boiler

Prepare boiler location —

Installations must

follow these codes:

• Local, state, provincial, and national codes, laws, regulations and ordinances.

• National Fuel Gas Code, ANSI Z223.1–latest edition.

• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

• National Electrical Code.

• For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

The CGi boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13–latest edition.

codes & checklist

Before 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.

Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

• Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

• If new boiler will replace existing boiler, check for and correct system problems, such as:

1. System leaks causing oxygen corrosion or section cracks from hard water deposits.

2. Incorrectly-sized expansion tank.

3. Lack of antifreeze in boiler water causing system and boiler to freeze and leak.

Part Number 550-110-710/0200

Page 7

Boiler Manual

Boiler model

Minimum foundation length

Minimum foundation width

CGi-25 25" 12"

CGi-3 25" 12"

CGi-4 25" 15"

CGi-5 25" 18"

CGi-6 25" 21"

CGi-7 25" 24"

CGi-8 25" 27"

Prepare boiler location — clearances1b

Provide the following clearances:

1. Hot water pipes — at least ½" from combustible materials.

2. Recommended service clearances — See

3. Minimum clearances for tight spaces — See

Figure 2.

Figure 1 Recommended clearances for service

35"

24"

18"

71002

Figure 1.

Flooring and foundation

Flooring

The CGi boiler is approved for installation on combustible flooring, but must never be installed on carpeting.

Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage.

Foundation

Provide a solid brick or concrete foundation pad if any of the following is true:

• floor can become flooded.

• the boiler mounting area is not level.

The minimum foundation size is:

minimum 2-inch thick

Figure 2 Minimum clearances for tight spaces

Part Number 550-110-710/0200

71003

Provide

openings

and 6" from bottom located on wall next to boiler front..

(2) fresh air

— 6" from top

Each opening must have

free area of square

inch per of

1,000 Btuh

CGi boiler input.

Residential garage installation

Precautions

Take the following special precautions when installing the boiler in a residential garage. If the boiler is located in a residential garage, per ANSI Z223.1, paragraph

5.1.9:

• Mount the boiler a minimum of

above the floor

of the garage to assure the burner and ignition devices will be no less than 18 inches above the floor.

• Locate or protect the boiler so it cannot be damaged by a moving vehicle.

18 inches

Page 8

GOLD CGi Series 2 Gas-Fired Water Boiler

Prepare boiler location — vent system

CGi venting

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death.

Do not install the CGi into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.

When removing boiler from existing common vent system:

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting

system.

b. Visually inspect the venting system for proper

size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

Test vent system — Insofar as is practical, close

all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected.

Follow the operating instructions. Adjust thermostat so appliance will operate continuously.

Test for spillage at draft hood relief opening after

5 minutes of main burner operation. Use the flame of a match or candle.

f. After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1–latest edition. Correct by resizing 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 Installation Code.

Chimney or vent requirements

1. Venting must be installed according to Part 7, Venting of Equipment, of National Fuel Gas Code, ANSI Z223.1–latest edition and applicable building codes. Canadian installations must comply with B149.1 or B149.2 Installation Codes.

2. See Ratings table on page 67 for minimum chimney or vent sizes. A chimney or vent

cap

should extend at least 3 feet above the highest

where it passes through a roof of a building

point

and

at least 2 feet higher than any portion of a

building within a horizontal distance of 10 feet

chimney or vent must not extend less than the distances stated above.

3. A lined chimney is preferred and must be used when required by local, state, provincial and national codes, laws, regulations and ordinances. Vitreous tile linings with joints that prevent retention of moisture and linings made of noncorrosive materials are best. Advice for flue connections and chimney linings can be obtained from local gas utility. pipe or single-wall vent pipe may be used as a liner.

4. Cold masonry chimneys, also known as outside chimneys, typically have one or more walls exposed to outside air.When any atmospheric gas-fired boiler with automatic vent damper is vented through this type of chimney, the potential exists for condensation to occur. Condensation can damage a masonry chimney. Weil-McLain recommends the following to prevent possible damage.

a. Line chimney with corrosion-resistant metal

liner such as AL29-4C® single-wall stainless steel or B-vent. Size liner per National Fuel Gas Code ANSI Z223.1–latest edition.

b. Provide drain trap to remove any condensate.

Type B double-wall metal vent

without a listed

. A

Part Number 550-110-710/0200

Page 9

Boiler Manual

Prepare boiler location — contamination

Air contamination

Please review the following information on potential combustion air contamination problems.

If the boiler is installed in any area likely to cause contamination, or if products which would contaminate the air cannot be removed, you must either remove products permanently or isolate the boiler and provide outside combustion air. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage.

Table 1 Corrosive contaminants

Products to avoid Areas likely to have contaminants

Spray cans containing chloro/fluorocarbons Dry cleaning/laundry areas and establishments

Permanent wave solutions Swimming pools

Refer to Table 1 for products and areas which may cause contaminated combustion air.

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 removers Plastic manufacturing plants

Hydrochloric acid/muriatic acid Furniture refinishing areas and establishments

Cements and glues New building construction

Antistatic fabric softeners used in clothes dryers Remodeling areas

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Garages with workshops

Adhesives used to fasten building products and other similar products

Part Number 550-110-710/0200

Page 10

GOLD CGi Series 2 Gas-Fired Water Boiler

Other

appliances

Air

opening

Air

opening

0 to 12"

Outside

Each opening free area = 1 sq. inch per 4,000 Btuh

71005

CGi boiler

MODEL

CGi

Prepare boiler location — air openings1e

Combustion air and ventilation openings must comply with Section 5.3, Air for Combustion and Ventilation , of National Fuel Gas Code ANSI Z223.1–latest edition, or applicable local building codes. Canadian installations must comply with B149.1 or B149.2 Installation Codes.

Provide adequate combustion and ventilation air to assure proper combustion and reduce the risk of severe personal injury, death or substantial property damage caused by flue gas spillage and carbon monoxide emissions.

Air from inside building

(boiler in interior room - Figure 3)

1. Tightly constructed buildings must be provided with openings to outside for combustion and ventilation air. These openings must be sized to handle all fuel burning appliances, exhaust or ventilation fans and fireplaces.

2. When openings to boiler room are taken to interior spaces, provide two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling.

Air directly from outside to boiler room

1. Tightly constructed buildings must be provided with combustion and ventilation air openings to boiler room, which are adequate to handle the boiler needs plus the needs of all other fuel burning appliances, exhaust or ventilation fans and fireplaces.

2. When combustion air is supplied to the boiler

directly through outside walls (Figure 4):

space Provide two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling.

Each opening must provide a minimum free area of 1 square inch per 4,000 Btuh of input of all appliances in room plus requirements for any exhaust fans in room. The interior space supplying combustion and ventilation air must have adequate infiltration from outside.

Figure 4 Air directly from outdoors

Each opening must provide a minimum free area of 1 square inch per 1,000 Btuh of input of all appliances in room plus requirements for any exhaust fans in room. The interior space supplying combustion and ventilation air must have adequate infiltration from outside.

Figure 3 Air openings to interior space

Each opening free area = 1 sq. inch per 1,000 Btuh

71004

Other

appliances

CGi boiler

MODEL

CGi

0 to 12"

Air

opening

Add air openings

to outside if

building is tight

construction.

Air

opening

3. When combustion air is supplied to the boiler space directly from outside or ventilated attic/

crawl space through vertical ducts (Figure 5)

Provide two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling.

Each opening must provide a minimum free area

1 square inch per 4,000 Btuh of input of all

of appliances in room plus requirements for any exhaust fans in room. The duct cross sectional area must be no less than the required area of the permanent openings.

Part Number 550-110-710/0200

Page 11

Boiler Manual

Figure 5 Air from outdoors — vertical ducts

Outside or ventilated attic

Each opening free area = 1 sq. inch per 4,000 Btuh

CGi

Other

appliances

boiler

MODEL

CGi

— or —

12"

Ventilated

71006

crawl space

4. When combustion air is supplied to the boiler space directly from outside through horizontal

ducts (Figure 6)

: Provide two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling.

Special considerations

Tight construction

ANSI Z223.1 defines unusually tight construction where:

a. Walls and ceilings exposed to the outside

atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed, and . . .

b. Weather-stripping has been added on openable

windows and doors, and . . .

c. Caulking or sealants are applied to areas such as

joints around windows and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and in other openings.

For buildings with such construction, provide air openings into the building from outside, sized per the appropriate case in inside air for combustion and ventilation.

Figure 4 if appliances are to use

Each opening must provide a minimum free area

1 square inch per 2,000 Btuh of input of all

of appliances in room plus requirements for any exhaust fans in room. The duct cross sectional area must be no less than the required area of the permanent openings.

Figure 6 Air from outdoors — horizontal

ducts

Each opening free area = 1 sq. inch per 2,000 Btuh

Other

appliances

71007

CGi boiler

MODEL

CGi

0 to 12"

Exhaust fans and air movers

The appliance space must never be under a negative pressure, even if the appliance(s) are installed as direct vent. Always provide air openings sized not only to the dimensions required for the firing rate of all appliances, but also to handle the air movement rate of the exhaust fans or air movers using air from the building or space.

Air

opening

i ut

Air

opening

Part Number 550-110-710/0200

Page 12

GOLD CGi Series 2 Gas-Fired Water Boiler

Prepare boiler — placement & setup2a

Place boiler/crate near position

1. Leave boiler in crate and on pallet until installation site is ready.

2. Move entire crate and pallet next to selected location.

3. Remove crate.

4. Remove boiler from pallet.

Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result.

a. Tilt left side of boiler up and place a board

under left legs.

b. Tilt boiler the other way and place a board

under right legs.

c. Slide boiler backward off pallet and into

position.

5. Check level. a. Shim legs, if necessary. b. Do not alter legs.

Inspect orifices and burners

1. Remove front jacket door. Remove burner shield (see

Figure 40, item 4, page 58).

2. Check for correctly-sized manifold orifices. See

Table 2 for sizing. (The orifice size is 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 substantial 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 substantial property damage.

Orifice replacement procedure

(when required)

1. Remove the screws securing the burner shield and remove burner shield.

2. Using a 7/16" open-end wrench, remove the burner orifices from the manifold.

3. Apply a small amount of pipe dope to each of the new orifices and install in the manifold using a open-end wrench. Make sure the orifices are aligned correctly, not cross-threaded in the manifold tappings.

Use only pipe dope compatible with propane gas, even if boiler is to be operated on natural gas. Failure to comply could result in severe personal injury, death or substantial property damage.

4. Carefully replace the burner shield.

5. Follow the check-out procedure, section 8 page 36, to assure the boiler is now operating properly after orifices are replaced.

/16"

Table 2 Manifold orifice sizing at sea level and altitudes to 4,500 feet

Location Boiler model

number

U. S.

Canada

Note 1:

For elevations above 2,000 feet, contact your local Weil-McLain sales office for details.

CGi-25 2.30 mm

CGi-3 — CGi-8 2.70 mm 1.65 mm

CGi-25 2.30 mm #44 #54 #55

CGi-3 — CGi-8 2.70 mm #38 1.65 mm #53

Natural gas Propane gas

0-2,000 ft over 2,000 ft 0-2,000 ft over 2,000 ft

(Note 1)

0-2,000 ft 2,000-4,500 0-2,000 ft 2,000-4,500

#54

(Note 1)

Part Number 550-110-710/0200

Page 13

Boiler Manual

Prepare boiler — pressure test

Perform hydrostatic pressure test

Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply.

Prepare boiler for test

1. Remove the shipping nipple (from CGi supply tapping) and remove the boiler relief

Temporarily plug the relief valve tapping with a ¾" NPT pipe plug.

valve.

2. Remove 1¼" nipple, reducing tee and drain valve from circulator hardware and pressure/ temperature gauge carton. Install in boiler return connection as shown on page 3 and

Figure 42, page 60. Install circulator on either the return or supply.

3. Remove 1¼" nipple, 1¼" x 1¼" x ½" tee and pressure/temperature gauge from circulator hardware and pressure/temperature gauge carton. Pipe to boiler supply connection as shown on page 3 and Figure 42, page 60. (Use pipe dope sparingly.)

4. Connect a hose to boiler drain valve, the other end connected to a fresh water supply. Make sure hose can also be used to drain boiler after test.

5. Connect a nipple and shutoff valve to system supply connection on the 1¼" tee. This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

6. Connect a nipple and shutoff valve to system return connection (at circulator flange if circulator installed on return). This valve will be used to bleed 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 fresh water supply to fill boiler with water.

3. When water flows from shutoff valves, close boiler drain valve.

4. Close shutoff valves.

5. Slowly reopen boiler drain valve until test pressure on the pressure/temperature gauge reaches no more than:

45 psig for boilers with 30 psig relief valve.

•

75 psig for boilers with 50 psig relief valve.

Test for no more than 10 minutes at:

• 45 psig for boilers with 30 psig relief valve.

• 75 psig for boilers with 50 psig relief valve.

Do not leave boiler unattended. A cold water fill could expand and cause

excessive pressure, resulting in severe personal injury, death or substantial property damage.

7. Make sure constant gauge pressure has been maintained throughout test. Check for leaks. Repair if found.

Leaks must be repaired at once. Failure to do so can damage boiler,

resulting in substantial property damage.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Drain and remove fittings

1. Disconnect fill water hose from water source.

2. Drain boiler at drain valve or out hose, whichever provides best access to drain. Remove hose after draining if used to drain boiler.

3. Remove nipples and valves unless they will remain for use in the system piping.

4. Remove plug from relief valve tapping. See section 4a, page 20 to replace relief valve.

Part Number 550-110-710/0200

Page 14

GOLD CGi Series 2 Gas-Fired Water Boiler

Table 3

Vent

connector

diameter

Figure 7

Chimney

draft venting

Venting —

general information

CGi venting methods

The CGi boiler can be vented using one of the following methods:

Chimney draft venting — Uses the natural draft

1. provided by a vertical vent or chimney. Category I appliance (non-positive vent static pressure and vent gas temperature that avoids excessive condensate production in vent). See section 3b, below. Chimney draft installations use:

a. Vent connector (single or doublewall) sized to

eliminate positive pressure in vent system. Diameter increases immediately at boiler.

b. Doublewall metal vent (B-vent) or chimney

Venting —

Boiler model

number

CGi-25 & CGi-3 4"

CGi-4 to CGi-8 5"

“D” Minimum

vent connector

Chimney

Tight

seal

Cleanout

71008

chimney draft venting

diameter

1. Use doublewall metal vent (B-vent) or chimney with liner

2. To prevent downdrafts, chimney should extend at least 3

3. To vent with another appliance, see National Fuel Gas Code,

4. Do not connect breeching to any portion of a mechanical

5. Maintain minimum 2" clearance from combustible

6. Do not use chimney with an open fireplace.

7. Make horizontal runs as short as possible. Long runs can

8. When longer runs are used, support pipe with appropriate

9. To prevent blockage, do not vent into bottom of chimney.

10. Vent pipe must not go beyond inside wall of chimney.

11. Vent passing through floors or ceilings must be firestopped.

12. See Figure 7 and Table 3 to connect boiler to venting system.

1/4" Rise/4 FT.

MODEL

CGi

Increaser

0322-057

with liner approved by the National Fuel Gas Code, ANSI Z223.1–latest edition, or in Canada B149.1 or B149.2 Installation Code.

Direct exhaust — vertical or sidewall — Uses

inside combustion air with no combustion air connector piping. All CGi flue gas vents are pressurized, requiring careful sealing of all joints. Category III appliance (positive vent static pressure and vent gas temperature that avoids excessive condensate production in vent). See pages 15-19. Direct exhaust installations use:

a. Vent pipe specified in this manual.

b. Vent termination through outside wall, roof or

unused chimney. Tight chimney areas will make vent joint construction very difficult.

Inspect existing chimney before installing boiler. Failure to clean or replace perforate pipe or lining will cause severe personal injury or death.

Vent sizing given in Table 3 is only a general guideline. The vent connector and chimney must be designed, sized and constructed in compliance with all applicable codes. Failure to correctly size and install the vent system could result in severe personal injury, death or substantial property damage.

as required by the National Fuel Gas Code, ANSI Z223.1– latest edition, or in Canada, B149.1 or B149.2 Installation Code.

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.

ANSI Z223.1–latest edition or in Canada B149.2 or B149.2 Installation Code

draft system that can operate under positive pressure.

materials to vent pipe.

cause condensation.

hangers.

Part Number 550-110-710/0200

Page 15

Boiler Manual

Venting —

direct exhaust — system components

Obtain vent system components

1. The following special gas vent systems comply with UL-1738 and ULC-S636 standards and are certified by CSA as the only systems suitable for use with CGi boilers (all 3" diameter):

• Heat-Fab, Inc. Saf-T Vent

• Flex-L International, Inc. StaR-34

• Z-Flex®, Inc. Z-Vent II

• ProTech 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 Table 4.

4. Select vent components from Table 5. All components, including the vent starter, must be of the same vent manufacturer. Do not mix components.

Table 4 Maximum vent length

Max.vent length (feet)

CGi-25 to CGi-6 55 48 41 34 27 20

CGi-7 35 28 21 14 7 --

CGi-8 28 21 14 7 -- --

Note 1: Do not include termination fitting when

Total number of elbows

1 2 3 4 5 6

counting total number of elbows.

(Note 1)

Table 5 Vent system components

Description

Weil-McLain part number

CGi Starter 699-999-015 73WMCGIS SRAWCG3 SVEWMFA03 FSA-WEIL-CGI Termination Coupling with

Screen Termination Elbow with Screen 699-999-069 1314TERM SRTE-03 SVSTEX0390 FSTE90 Termination Tee with Screen 699-999-026 7390TEE SRTT-03 SVSTTX03 FSTT3 45˚ Elbow 699-999-010 7311GC SRE4503 SVEEWC0345 FSEL4503 90˚ Elbow 699-999-011 7314GCTR SRE9003 SVEEWC0390 FSEL9003 6" Pipe 699-999-003 7301GC SR06P03 SVEPWC03.5 FSVL603 12" Pipe 699-999-004 7302GC SR12P03 SVEPWC0301 FSVL1203 18" Pipe 699-999-005 7304GC -- SVEPWC0318 FSVL1803 24" Pipe 699-999-006 7305GC SR24P03 SVEPWC03 FSVL2403 36" Pipe -- -- SR36P03 SVEPWC0303 FSVL3603 37 ½" Pipe 699-999-007 7307GC -- -- -48" Pipe -- -- -- SVEPWC0304 -49 ½" Pipe 699-999-008 7308GC -- -- -60" Pipe 699-999-012 7360GC SR60P03 SVEPWC0305 -Slip Connector (See Note) 699-999-009 7324GC9 SRSJ03 -- -Horizontal Support 699-999-016 7323GC -- -- FSSH Horizontal Drain Tee 699-999-014 7320GC SRTDH03 SVEDWC03 FSHDT3 Joiner Band -- -- SRJB-14 -- -Sealant As specified by individual vent pipe manufacturer Not required

Note: Use to adjust for non-standard pipe lengths and Saf-T Vent® only, before termination coupling to terminate run.

699-999-001 73WMTERM -- SVSTPX03 FSB3S

Saf-T Vent

part number

StaR-34 Z-Vent II FasNSeal™

Part Number 550-110-710/0200

Page 16

GOLD CGi Series 2 Gas-Fired Water Boiler

Venting —

direct exhaust — vent starter

1. Select a vent pipe manufacturer and obtain all vent components needed, based on boiler location and venting method.

2. You must use the vent starter made by the vent pipe manufacturer. See Table 5, page 15, Vent system

components

, for part number of each component,

listed by vent manufacturer.

Band clamp

Band clamp strap

screw

FasNSeal™ starter

Band clamp screw

Figure 8

FasNSeal™ vent starter

3. Follow all applicable national, state, local or provincial codes when venting the CGi boiler.

4. Connect vent starter to blower housing outlet as shown in the Figures 8 through 11, below.

a. Do not mix components from different vent

manufacturers.

b. Maintain minimum 2" clearance from

combustible materials to vent pipe.

c. Seal with sealant specified by vent pipe

manufacturer, using ³⁄₈" bead (not required for FasNSeal™).

d. Tighten strap at band clamp screw until strap

is snug around blower housing.

Tighten position

Feed

Band clamp strap

position

Z-Vent II starter

Band clamp screw

Band clamp strap

Blower housing outlet

71009

Saf-T Vent starter

Band clamp screw

³⁄₈" Bead of sealant

Blower housing outlet

Figure 10

Saf-T Vent® vent starter

Figure 9

Z-Vent II vent starter

Figure 11

StaR-34 vent starter

Band clamp strap

³⁄₈" Bead of sealant

Blower housing outlet

71010

StaR-34 starter

Band clamp screw

3/8" Bead of sealant

Blower housing outlet

71011

71012

Part Number 550-110-710/0200

Page 17

Boiler Manual

71014

Snow

4 ft

1 ft

4 feet

Venting —

direct exhaust — vent termination

Follow instructions on this page when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.

1. Locate the boiler and vent penetration through the wall so all requirements on this page and in Figure 12 will be met. Also follow vent manufacturer’s instructions.

2. Gases will form white plume in winter. Plume could obstruct window view.

3. Prevailing winds could cause freezing of condensate and water/ice buildup on vent termination, building, plants or roof. Ice buildup on vent termination can cause boiler shutdown and building freezeup.

4. Winds over 31 mph can cause nuisance boiler shutdown if boiler is sidewall vented. This could result in loss of heat to building, causing freezeup.

5. Locate or guard vent termination to prevent condensate from damaging exterior surfaces.

6. Locate the vent termination well away from trees, shrubs, and decorative items.

7. Locate or guard vent to prevent accidental contact by people or pets.

8. Do not terminate vent in window well, stairwell, alcove, courtyard, or other recessed areas.

9. Do not wrap or insulate vent pipe or fittings.

10. Do not terminate 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.

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 any gas service regulator.

13. See

Figure 12, showing that the vent must terminate:

• more than 4 feet below or to side of all doors

or windows.

• more than 1 foot above grade or anticipated

snow line.

• at least 7 feet above public walkway.

• 3 feet above any forced air intake within 10 feet.

14. Vent must also terminate:

• at least 6 feet away from adjacent walls.

• no closer than 5 feet below roof overhang.

• at least 4 feet horizontally (and in no case above

or below unless a 4 foot horizontal distance is maintained) from electric meters, gas meters, regulators, relief valves, and other equipment.

15. Site conditions may dictate greater clearances.

16. Do not extend exposed vent pipe outside of building. Condensate could freeze and block vent pipe.

A gas vent extending through an exterior wall shall not terminate adjacent to the wall or below building extensions such as eaves, parapets, balconies or decks. Failure to comply could result in severe personal injury, death or substantial property damage.

Figure 12 Vent termination minimum clearances

7 feet

Part Number 550-110-710/0200

71013

3 feet

If within 10 feet

blic Walkway

Forced

air intake

Page 18

GOLD CGi Series 2 Gas-Fired Water Boiler

MODEL

CGi

71015

Horizontal drain tee. Follow vent manufacturer's instructions to install condensate drain line.

Follow vent manufacturer's instructions for proper installation of vent runs, including slope and support.

Venting —

direct exhaust............................

1. Do not mix types or manufacturers of vent materials.

2. Clean all joints before sealing. See vent manufacturer’s instructions for cleaning and sealing joints. Use their specified sealant. Do not use screws.

3. Install vent pipe with seams on top of vent horizontal runs. Follow requirements in section

3e, page 17, for vent termination.

4. Maintain minimum 2" clearance from combustible materials to vent pipe.

Vertical venting — See Figure13. Follow vent manufacturer’s

5. instructions for venting through roof.

• Vent pipe must extend through roof flashing, jacket or thimble.

• Vent may pass through floor, inside wall or concealed space when

installed according to vent manufacturer’s instructions.

Sidewall venting — See Figures 14 and 15. Vent must terminate at

least one foot above anticipated snowline. Vent must be terminated only with:

• Tee or elbow with integral screen. (Tee may be mounted either

vertically or horizontally. DO NOT use horizontal tee with CGi-7 or CGi-8.)

• Elbow and termination coupling with screen (not available for

StaR-34).

Figure 13 Direct exhaust vertical venting

6. Do not seal vent pipe (slip connector for Saf-T Vent) 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 Figure 13.

9. Do not exceed the maximum vent system length given in page 15.

Using any other material could cause flue gas leakage, potentially resulting in severe personal injury, death or substantial property damage.

• Vent manufacturer shows this option in their instructions.

• Vent is sloped toward termination as shown in dotted lines in

• The vent is installed per Weil-McLain and vent manufacturer’s instructions.

Condensate drippage from such vents may accumulate on the ground below. Consider traffic in the area to avoid hazard due to ice accumulation.

Condensate drain line — use only silicone tubing rated for at least 400 °F for the condensate drain line.

Table 4,

On some installations, the condensate drain fitting may be omitted, provided:

Figure

Figure 14 Direct exhaust sidewall venting

Horizontal drain tee. Follow vent manufacturer's instructions to install condensate drain line.

Optional downward slope without drain fitting, where allowed by vent manufacturer as explained in CAUTION at left.

MODEL

CGi

Follow vent manufacturer's instructions for proper installation of vent runs, including slope, support and condensate drainage.

71016

Part Number 550-110-710/0200

Page 19

Boiler Manual

vertical or sidewall

Figure 15 Sidewall termination

Termination elbow or tee

Sealant

Saf-T Vent

Note 1

Termination elbow or tee

Sealant

Z-Vent II

Elbow and termination

coupling with screen

Sealant

Elbow and termination

coupling with screen

Sealant

Using any termination other than one of those shown could cause nuisance outages and loss of heat, resulting in substantial property damage.

Pipe

Band

clamp

Pipe section

section

Sealant

Metal

plate

Sealant

Exterior

Metal plate

18" Slip

connector

Note 1: DO NOT use horizontal tee with CGi-7 or CGi-8.

Sealant

Pipe

section

Metal plate

wall

Exterior

wall

Metal

plate

StaR-34

™

FasNSeal

Termination elbow or tee

Sealant

Termination elbow or tee

Note 1

Termination coupling

not available

Elbow and termination

coupling with screen

Locking band

Note 1: DO NOT use horizontal tee with CGi-7 or CGi-8.

Metal

plate

Sealant

Exterior

Metal plate

Pipe

section

Note 1: DO NOT use horizontal tee with CGi-7 or CGi-8.

Pipe

section

Metal plate

wall

Exterior

wall

Metal

plate

Pipe section

Pipe

section

71017

Part Number 550-110-710/0200

Page 20

GOLD CGi Series 2 Gas-Fired Water Boiler

Water piping —

general information

General piping information

If installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. Install control in supply piping between boiler and isolation valve. Set second control to minimum 20 °F above setpoint of first control. Maximum allowable setpoint is 240 °F. See section 9b, pages 38 and 39, for wiring.

A low water cutoff device is required when boiler is installed above radiation level or by certain state or local codes or insurance companies. Use low water cutoff designed for water installations. Electrode probetype is recommended. Purchase and install in tee in supply piping above boiler.

Use backflow check valve in cold water supply as required by local codes.

Pressure/temperature gauge

Install pressure/temperature gauge in tee on supply piping (as shown in drawing on page 3). The gauge well is a self-closing valve, allowing removal of the gauge without draining the system.

Slowly remove pressure/temperature gauge from well. The self-closing valve could leak if clogged with sediment. If water begins to spray, stop removing gauge. Close system fill valve and drain enough water to release system pressure before continuing with gauge removal. Escaping hot water could cause severe personal injury.

Circulator

The circulator is shipped loose (wiring pre-attached to boiler) to allow you to locate it either in the return or supply piping, as desired. See page 3 for a typical installation. Pipe the expansion tank to the suction side of the circulator whenever possible. Install an air separator in the supply piping. Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator. Always install the system fill connection at the same point as the expansion tank connection to the system. Figures 16 and 17 show typical near-boiler piping connections.

System water piping

See Figure 16 (diaphragm-type or bladder-type expansion tank) or Figure 17 (closed-type expansion tank) on page 21, and and single-zone systems designed for return water at least 130 °F.

See pages 22-23 to complete multiple-zone piping or pages 24-29 to complete piping for radiant heating systems or converted gravity systems.

Refer to page 29 for boilers used with refrigeration systems.

Table 6 below, for near-boiler

Relief valve

Install relief valve vertically in ¾" tapping on side of boiler. See Figure 16

and the tag attached to the relief valve for manufacturer’s instructions.

or 17

To avoid water damage or scalding due to relief valve operation:

• Discharge line must be connected to relief valve outlet and

safe place of disposal

possibility of severe burns should the valve discharge.

• Discharge line must be as short as possible and be the

the valve discharge connection

• Discharge line must pitch downward from the valve and terminate at least 6" above the floor drain where any discharge will be clearly visible.

• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375 °F or greater.

Do not pipe the discharge to any place where freezing could occur.

•

• No shutoff valve shall be installed between the relief valve and boiler,

or in the discharge line. Do not plug or place any obstruction in the discharge line.

•

Failure to comply with the above guidelines could result in failure of

the relief valve to operate, resulting in possibility of severe personal injury, death or substantial property damage.

• Test the operation of the valve after filling and pressurizing system

by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.

. Terminate the discharge line to eliminate

throughout its entire length.

run to a

same size as

Table 6 Water pipe size (based on 20 °F rise)

Boiler

model number

CGi-25 ¾" ¾"

CGi-3 1" 1" CGi-4 1" 1" CGi-5 1" 1" CGi-6 1¼" 1¼" CGi-7 1¼" 1¼" CGi-8 1½" 1½"

Note: Circulator flange supplied with boiler is same size as

recommended piping above.

• 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 handling units where they can be exposed to refrigerated air, use flow control valves or other automatic means to prevent gravity circulation during cooling cycle. Circulation of cold water through the boiler could result in damage to the heat exchanger, causing possible severe personal injury, death or substantial property damage.

system

Install boiler such that —

From

system

Part Number 550-110-710/0200

Page 21

Boiler Manual

CGi

71019

To system

From

system

Isolation

valve

Drain valve

Relief valve

Circulator*

Isolation

valve

Circulator

Cold water fill

CLOSED type

expansion tank

*Alternate

location

Water piping — single-zone system4b

Expansion tank

Diaphragm-type or bladder-type expansion tank — Figure 16

1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possible, before inlet side of circulator. See tank manufacturer’s instructions for details.

2. Install an automatic air vent as shown.

Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve. Eventual section failure can result.

Use Figure 16 or Figure 17 only for single-zone systems designed for return water at least 130 °F. For systems with low return water temperature possible, such as converted gravity systems and radiant heating systems, refer to the special piping suggestions of pages 24-29. Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Figure 16 Diaphragm- or bladder-type expansion tank

Piping to single-zone system using diaphragm-type or bladder-type expansion tank. See Table 6 for piping sizes.

Cold

From

system

water

fill

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 ½" NPT tapping located behind supply outlet, using ½" NPT piping. Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping.

Figure 17 Closed-type expansion tank

Piping to single-zone system using closedtype expansion tank. See Table 6 for piping sizes.

Isolation

valve

Relief valve

Circulator

Part Number 550-110-710/0200

Drain valve

To DIAPHRAGM

expansion tank

and fittings

Isolation

valve

To system

Circulator*

Automatic

EL D O

CGi

71018

air vent

*Alternate

location

Page 22

GOLD CGi Series 2 Gas-Fired Water Boiler

Water piping — multiple zones4c

Piping multiple

zones

Zoning with

circulators, return

temp over 130 °F

Zoning with zone

valves, return temp

over 130 °F

Piping for radiant

heating systems or

converted gravity

systems

Follow instructions on pages 20 and 21 to install near-boiler or single-zone piping. (Also refer to applicable.)

See

1. Size each circulator to individual circuit requirements.

2. Do not install circulator on boiler (except for primary/secondary piping).

3. Install isolation (balancing) valves to adjust flow to distribute heat to all zones.

4. Install and wire a separate relay for each zone circulator.

1. Install isolation (balancing) valves to adjust flow to distribute heat to all zones.

2. Provide a separate 24-volt transformer to power the zone valves. Size the transformer to

Converted gravity (or steam) systems

Whenever possible, use the primary/secondary piping shown in Figures 20 or 21 on page 25. This piping design allows changing boiler flow rate without affecting primary circuit flow rate.

the reduced flow rate in the heating system will not cause heat distribution problems.

Piping for radiant heating systems or converted gravity systems, below, if

Figure 18 or Figure 19 to complete installation.

handle the total rated load of all connected zone valves.

Figures 20 or 21 cannot be used, use the boiler-bypass piping shown in Figure 22 or Figure

on page 27. You can also use the piping shown in Figure 24 on page 29 (system-bypass), if

Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections 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 or 21 on page 25. Alternatively, use the method of either Figure 22 or Figure 23 on page 27. Do not use the

piping of Figure 24

supply temperature.

If radiant system tubing has no oxygen barrier, a

Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature (such as provided by an injection pumping control). Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant.

Do not apply the methods in this manual if the system is equipped with an outdoor reset control

temperature at no less than 130 °F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.

(system-bypass), because this method does not control radiant system

heat exchanger must be used.

. Instead, provide controls and piping which can regulate the boiler return water

Part Number 550-110-710/0200

Page 23

Boiler Manual

typical piping — multiple-zone installations

Figure 18

Zoning with circulators — return water 130 °F or higher.

ZONE 2

ZONE 1

CGi

Cold

water

fill

Figure 19

Zoning with zone valves — return water 130 °F or higher.

ZONE 2

ZONE 1

Alternate circulator location

Cold

water

MODEL

fill

MODEL

CGi

1 Boiler isolation (balancing) valves

2 Flow/check valve

3 System or zone circulator

5 Zone valve

6 Drain valve

9 Relief valve

10 Automatic air vent (with diaphragm-type

expansion tank), or connect to tank fitting (closedtype expansion tank).

DO NOT use an automatic

For systems with possible low return-water temperature (such as converted gravity systems, radiant heating systems and heat pump systems), refer to the special piping suggestions of

Figures 20 - 24, as applies. Failure to prevent sustained low return water temperature to the

boiler could cause corrosion of the boiler sections, resulting in severe personal injury, death or substantial property damage.

Part Number 550-110-710/0200

71020

71021

air vent when using closed-type expansion 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.)

13 Air separator and automatic vent, if used (Note that

the fill valve must always be connected to the expansion tank, regardless of location of expansion tank circulator or air separator.

Page 24

GOLD CGi Series 2 Gas-Fired Water Boiler

Water piping — low temp systems4d

Primary/secondary

(preferred) bypass

piping method

Temperature

gauges

Valve adjustment

(Figure 20 and 21 only)

Primary/secondary bypass piping is preferred because the flow rate and temperature drop in

the heating circuit(s) is determined only by the heating circuit circulator(s). So adjustment of the bypass valves in the boiler circuit will 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

The bypass valves (items system return water — set to assure a minimum return water temperature (at least 130 °F) to the boiler. Set the valves as explained below.

Gauge 4a is suggested, but optional on any system.

4b is optional on converted gravity systems, but required on radiant heating systems

Gauge — to display the water temperature being supplied to the radiant tubing.

Gauge

8 is required on all systems to assure the return water temperature is accurately set for

a minimum of 130 °F. If this gauge is not available however, adjust the valves such that the boiler-mounted temperature/pressure gauge reads at least 150 °F when the system return water is cold (approximately 60 °F water temperature).

1. Set the valves while the system is cool, setting for the coldest expected water temperature (usually 60 °F since the system will often drop to room temperature between cycles).

2. Start with valve 7a fully closed and 7b fully open.

3. Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 130 °F when gauge 4a reads 60 °F.

4. Note that valve with return water. Valve 7b regulates the amount of system water flowing through the boiler secondary loop.

. For alternatives, see pages 26 through 29.

7a and 7b) provide mixing of hot boiler outlet water with cooler

7a regulates the amount of hot water from the boiler supply which mixes

Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Radiant heating system piping should include a means of regulating the boiler return

water temperature pumping control

Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the

DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control water temperature

your Weil-McLain representative for suggested piping and control methods.

Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.

and the system supply temperature (such as provided by an injection

system supply temperature is relatively constant.

. Instead, provide controls and piping which can regulate the boiler return

at no less than 130 °F regardless of system supply temperature. Contact

Part Number 550-110-710/0200

Page 25

Boiler Manual

primary/secondary (preferred) bypass piping —

for radiant heating or converted gravity systems

Figure 20

Zoning with circulators

ZONE 2

ZONE 1

Cold

water

4a 4b

fill

12"

MAX.

Alternate circulator location

MODEL

CGi

Figure 21

Zoning with zone valves

ZONE 2

ZONE 1

1 2

Cold

water

4a 4b

fill

12"

MAX.

Alternate circulator location

MODEL

CGi

71022

1 Boiler isolation (balancing) valves

2 Flow/check valve

3 System or zone circulator

4 System temperature gauges

5 Zone valve

6 Drain valve

7 System temperature valves (see instructions to the

left for adjusting valves)

8 Blend temperature gauge

9 Relief valve

71023

10 Automatic air vent (with diaphragm-type expansion

tank), or connect to tank fitting (closed-type expansion tank). DO NOT use an automatic air vent when using closed-type expansion 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.)

13 Air separator and automatic vent, if used (Note that

the fill valve must always be connected to the expansion tank, regardless of location of expansion tank, circulator or air separator.)

Part Number 550-110-710/0200

Page 26

GOLD CGi Series 2 Gas-Fired Water Boiler

Water piping — low temp systems4e

Boiler-bypass

piping method

Temperature

gauges

Valve adjustment

This piping method is called a boiler-bypass because part of the circulator flow is bypassed around the boiler (through valve 7a). This method reduces the flow rate throughout the boiler, in order to raise the average water temperature in the boiler enough to prevent flue gas condensation. Boiler-bypass piping is effective for some boilers — including the CGi — provided the flow rates are adjusted according to the instructions following.

Figures 22 and 23 are alternative piping suggestions for converted gravity (large water content

or steam systems) or radiant heating system — for use when primary/secondary piping can’t be applied. (Figure 24 is another alternative, using system bypass in place of boilerbypass piping. Figure 24 however, is not suitable for radiant heating applications because it does not protect the radiant system from possible high water temperature.)

Boiler-bypass piping keeps system flow rate as high as possible and temperature drop as low as possible, helping to equalize the building heat distribution.

Gauge 4a is optional if the bypass valves will be adjusted using cold (or room temperature) return water to the boiler. (When setting the valves without gauge 4a installed — using cold or room temperature water — assume the return water temperature to be 60 °F. Set the valves so gauge 8 reads at least 120 °F.

4b is optional on converted gravity systems, but required on radiant heating systems

Gauge — to display the water temperature being supplied to 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.

1. Start with valve 7a fully closed and 7b fully open.

2. Gradually open valve 60 °F higher than gauge 4a. A minimum 60 °F temperature rise through the boiler assures a low enough flow rate and high enough average temperature to prevent condensation even with low system return water temperature.

3. Valve 7a regulates the system flow rate, while valve 7b regulates the boiler flow rate.

4. The boiler-mounted temperature/pressure gauge may be used in place of a separate gauge 8.

7a while closing valve 7b until the temperature at gauge 8 reads

Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Radiant heating system piping should include a means of regulating the boiler return

water temperature pumping control

Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the

DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control water temperature

your Weil-McLain representative for suggested piping and control methods.

and the system supply temperature (such as provided by an injection

system supply temperature is relatively constant.

. Instead, provide controls and piping which can regulate the boiler return

at no less than 130 °F regardless of system supply temperature. Contact

Part Number 550-110-710/0200

Page 27

Boiler Manual

boiler-bypass (alternate) piping —

for radiant heating or converted gravity systems

Figure 22 Boiler-bypass piping

Zoning with circulators

(Alternative to primary/secondary piping

Figures 20 and 21)

ZONE 2

ZONE 1

4a 4b

Cold

water

fill

MODEL

CGi

Figure 23 Boiler-bypass piping

Zoning with zone valves

(Alternative to primary/secondary piping

Figures 20 and 21)

ZONE 2

ZONE 1

Alternate

circulator

location

Cold

water

fill

MODEL

CGi

1 Boiler isolation (balancing) valves

2 Flow/check valve

3 System or zone circulator

4 System temperature gauges

5 Zone valve

6 Drain valve

7 System temperature valves (see instructions to the left

for adjusting valves)

8 Blend temperature gauge

9 Relief valve

Part Number 550-110-710/0200

71024

71025

10 Automatic air vent (with diaphragm-type

expansion tank), or connect to tank fitting (closedtype expansion tank). DO NOT use an automatic air vent when using closed-type expansion 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 of expansion tank, circulator or air separator.)

Page 28

GOLD CGi Series 2 Gas-Fired Water Boiler

Water piping — low temp systems4f

System-bypass

piping method

Valve adjustment

This piping method is called a system-bypass because part of the circulator flow bypasses the system (through valve cooler system return water temperature in order to provide minimum 130 °F return water to the boiler. Valve 7b will most often be full open, but may need to be slightly closed on some low pressure drop systems in order to cause enough flow through valve

Figure 24 is an alternative piping method that provides return water temperature control for

boilers installed on

Do not apply the piping of Figure 24 on radiant heating systems. It provides no method

regulating the water temperature provided to the system and could result in excessive water temperature in the radiant tubing.

System-bypass piping as shown in zoning. When used with circulator zoning however, the boiler circulator (item 3), must be piped as shown. It cannot be used as one of the zoning circulators.

Do not apply system-bypass piping if the reduced flow in the system could cause poor heat distribution. That is, system-bypass piping reduces the flow in the system and increases the water temperature supplied to the system. This can cause increased heat from radiators at the beginning of the system and reduced heat from radiators near the end of the system.

1. Start with valve 7a fully closed and 7b fully open.

2. Gradually open valve least 130 °F at all times.

converted gravity systems (large water content or steam systems).

7a). This bypassed hot water from the boiler outlet mixes with

7a.

Figure 24 can be used with either zone valve or circulator

7a while closing valve 7b until the temperature at gauge 8 reads at

3. Valve 7a regulates the amount of boiler supply water mixed with return water. Valve 7b causes a pressure drop in the system needed to balance flow through valve 7a and the system.

4. The valve adjustment should be done with the system at the coldest expected temperature (60 °F for converted gravity systems or high mass radiant systems).

Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Radiant heating system piping should include a means of regulating the boiler return

water temperature pumping control

Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the

DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control water temperature

your Weil-McLain representative for suggested piping and control methods.

and the system supply temperature (such as provided by an injection

system supply temperature is relatively constant.

. Instead, provide controls and piping which can regulate the boiler return

at no less than 130 °F regardless of system supply temperature. Contact

Part Number 550-110-710/0200

Page 29

Boiler Manual

system-bypass (alternate) piping —

for converted gravity (or steam) systems

Cold

water

fill

To systemFrom system

Alternate circulator location

MODEL

CGi

71026

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)

3 System or zone circulator

7 System temperature valves (see instructions to the left for

adjusting valves)

8 Blend temperature gauge

9 Relief valve

10 Automatic air vent (with diaphragm-type expansion

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.)

Water piping — refrigeration system4g

Figure 25 Piping refrigeration systems

System supply

Circulator

System return

71027

Part Number 550-110-710/0200

Water chiller

Strainer

Check valve

Balancing valve

Expansion tank

Shut-off valve

Boiler

Prevent chilled water from entering boiler

Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See for typical installation of balancing valve and check valve.

If boiler is connected to heating

MODEL

CGi

coils located in air handling units where they can be exposed to refrigerated air, use flow control valves or other automatic means to prevent gravity circulation during cooling cycle.

Figure 25

Page 30

GOLD CGi Series 2 Gas-Fired Water Boiler

Gas piping5

Connecting gas supply piping to boiler

1. Remove jacket front panel and refer to a. Install drip leg at inlet of gas connection to boiler. Where local

utility requires drip leg to be extended to the floor, use appropriate

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 main shutoff valve, it must be

identified

by the installer.

2. Support piping with hangers, not by boiler or its accessories.

3. Purge all air from gas supply piping.

4. Before placing boiler in operation,

for leaks

Close manual main shutoff valve during any pressure testing at

less than 13" w.c.

Disconnect boiler and gas valve from gas supply piping during

any pressure testing greater than 13" w.c.

Do not check for gas leaks with an open flame —

use bubble test. Failure to use bubble test or check for gas leaks can cause severe personal injury, death or substantial property damage.

5. Use pipe dope compatible with propane gases. Apply sparingly only to male threads of pipe joints so that pipe dope does not block gas flow.

Failure to apply pipe dope as detailed above can result

in severe personal injury, death or substantial property damage.

Figure 26 to pipe gas to boiler.

check boiler and its gas connection

Figure 26 Gas supply piping

Manual main shutoff gas valve (when required)

Ground joint union (when required)

Tee

Nipple

Cap

71028

Natural Gas:

1. Refer to Table 7 for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 7 is only for gas with

specific gravity 0.60, with a pressure drop through the gas piping of 0.30" w.c.

gas pipe sizing information, refer to ANSI Z223.1 (or B149.1 or B149.2 for Canadian installations).

For additional

Table 7 Pipe capacity for 0.60 specific gravity natural gas

Gas pipe

length

(feet)

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 860

40 63 130 245 500 760

50 56 115 215 440 670

75 45 93 175 360 545

100 38 79 150 305 460

150 31 64 120 250 380

Capacity of pipe for pipe size of:

(Capacity in cubic feet gas per hour)

½" ¾" 1" 1¼" 1½"

2. Inlet pressure required at gas valve inlet:

• Maximum: 13" w.c.

• Minimum: 5" w.c.

• Manifold gas pressure: 3.5" w.c.

3. Install 100% lockup gas pressure regulator in supply line

if inlet pressure exceeds 13" w.c.

Adjust for 13" w.c. maximum.

Propane Gas:

1. Contact gas supplier to size pipes, tanks and 100% lockup gas pressure regulator.

2. Adjust propane supply regulator provided by gas supplier for 13" w.c. maximum pressure.

3. Inlet pressure required at gas valve inlet:

• Maximum: 13" w.c.

• Minimum: 11" w.c.

• Manifold gas pressure: 10" w.c.

Part Number 550-110-710/0200

Page 31

Boiler Manual

Field wiring6

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 be replaced, use only type 200 °C wire or equivalent. If other original wiring as supplied with boiler must be replaced, type 105 °C wire or equivalent must be used.

Boiler must be

electrically grounded as required by

National Electrical Code ANSI/NFPA 70–latest edition.

Electrical installation must comply with:

1. National Electrical Code and any other national,

state, provincial or local codes or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code

Part 1, and any local codes.

Wiring connections

Boiler is shipped with controls completely wired.

Thermostat

1. Connect thermostat as shown on wiring diagram on boiler.

Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunrays, or fireplaces.

3. If thermostat has a heat anticipator, set heat anticipator in thermostat to match power requirements of equipment connected to it. If connected directly to boiler, set for 0.1 amps plus gas valve current. See information on wiring diagram as shown in

Figure 32, page 39. For other

devices, refer to manufacturer’s specifications. Wiring diagram on boiler gives setting for control module and gas valve. Also see instructions with thermostat.

Junction Box (furnished)

1. Connect 120 VAC power wiring as shown in

Figure 27.

2. Fused disconnect or service switch (15 amp. recommended) may be mounted on this box. For those installations with local codes which prohibit installation of fused disconnect or service switch on boiler, install a 2 x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code.

Figure 27 Field wiring connections — service switch and thermostat (or end switch) provided by installer

The CGi control module is polarity-sensitive. The hot and neutral wires must be connected to the correct leads. A flashing POWER light usually indicates reversed polarity of 120 VAC lead wires.

Service

switch

(not provided)

Field wiring

Factory wiring

120 VAC Hot Neutral

Black White Green

Junction box,

boiler left side

Ground

Thermostat

or end switch

(not provided)

Ground screw Wire nuts

Black Black

Thermostat leads, through jacket left side

71029

or end switch

Service

switch

(not provided)

Thermostat

(not provided)

Part Number 550-110-710/0200

Page 32

GOLD CGi Series 2 Gas-Fired Water Boiler

Start-up — preparation7a

Check for gas leaks

Propane boilers only — Your propane supplier mixes an odorant with the propane to make

its presence detectable. In some instances, the odorant can fade and the gas may no longer have an odor.

• Propane gas can accumulate at floor level. Smell near the floor for the gas odorant or any unusual odor. If you suspect a leak, do not attempt to light the pilot.

• Use caution when attempting to light the propane pilot. This should be done by a qualified service technician, particularly if pilot outages are common.

• Periodically check the odorant level of your gas.

• Inspect boiler and system at least yearly to make sure all gas piping is leak-tight.

• Consult your propane supplier regarding installation of a gas leak detector. There are some products on the market intended for this purpose. Your supplier may be able to suggest an appropriate device.

Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if there is any indication of a gas leak. Repair any leak at once.

Determine if water treatment is needed

Do not use petroleum-based

cleaning or sealing compounds

boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Verify water chemistry

Consult local water treatment companies for unusually hard water areas (above 7 grains hardness) or low pH water conditions (below 7.0). Boiler water pH of 7.0 to 8.5 is recommended.

Freeze protection (when used)

Use antifreeze made especially for hydronic systems. Inhibited propylene glycol is recommended.

water content. Boiler water content is listed on page 63. Remember to include expansion tank water content.

2. Follow antifreeze manufacturer's instructions.

3. A 50% solution of propylene glycol/water provides maximum protection to about -30 °F.

4. Local codes may require back flow preventer or actual disconnect from city water supply.

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.

Do not use ethylene glycol,

automotive or undiluted antifreeze

or death can result.

1. Determine antifreeze quantity according to system

. Severe personal injury

5. When using antifreeze in a system with automatic fill, install a water meter to monitor water makeup. Glycol will leak before the water begins to leak, causing glycol level to drop. Added water will dilute the antifreeze, reducing the freeze protection level.

Part Number 550-110-710/0200

Page 33

Boiler Manual

Fill the system with water

1. Close manual and automatic air vents and boiler drain cock.

2. Fill to correct system pressure. Correct pressure will vary with each application. Typical cold water fill pressure for a residential system is 12 psi.

3. Purge air from system:

a. Connect a hose to the purge valve (see drain

valves, item on pages 21 through 27, Figure 16 through

Figure 23). Route hose to an area where water

can drain and be seen.

b. Close the boiler or system isolation valve

between the purge valve and fill connection to the system.

c. Close zone isolation valves. d. Open quick-fill valve on cold water makeup

line. e. Open purge valve. f. One zone at a time, open the isolation valves.

Allow water to run through the zone, pushing

out the air. Run until no noticeable air flow is

present. Close the zone isolation valves and

proceed with the next zone. Follow this

6, in suggested piping diagrams

procedure until all zones are purged.

g. Close the quick-fill water valve and purge valve

and remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure.

h. After the system has operated for a while,

eliminate any residual air by using the manual air vents located throughout the system.

i. If purge valves are 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

5. Open other vents:

6. Refill to correct pressure.

automatic air vent (diaphragm-type or

bladder-type expansion tank systems only) one turn.

a. Starting on the lowest floor, open air vents one

at a time until water squirts out.

b. Repeat with remaining vents.

Inspect system water piping

After filling the boiler and system with water, inspect all piping throughout the system for leaks. If found, repair immediately. Repeat this inspection after the boiler has been started and the system has heated up.

Leaks must be repaired at once. Failure to do so can damage the boiler, resulting in substantial

property damage.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Inspect base insulation

Check to make sure insulation is secure against all four sides of the base. If insulation is damaged or displaced,

do not operate boiler. Replace or reposition insulation.

Failure to replace damaged insulation or reposition insulation can result in a fire hazard,

causing severe personal injury, death or substantial property damage.

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 64 of this manual. Failure to comply could result in severe personal injury.

Part Number 550-110-710/0200

Page 34

GOLD CGi Series 2 Gas-Fired Water Boiler

Start-up — operate boiler7b

Final check before starting boiler

• Read manual section 9, page 37, including the Operating instructions procedure (Figure 33, page 40).

• Verify the boiler and system are full of water.

• Verify the completed.

Start-up preparation procedures of section 7a have been

Start the boiler

• Follow the Operating instructions from section 9c to start the boiler.

• See section

7c if boiler fails to start.

Check system and boiler

Do not use petroleum-based cleaning or sealing

compounds

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.

Glycol or antifreeze leaks around the boiler may result in fire, causing severe personal injury, death or substantial property damage.

Check system piping for leaks. If found, shut down boiler and repair

1. immediately.

Vent air from system using manual vents. Air in the system will

interfere with circulation and cause heat distribution problems and noise.

3. Inspect vent system thoroughly for signs of deterioration from corrosion, physical damage or sagging. In addition — Check for gastight seal at every connection and seam.

Venting system must be sealed gas-tight to prevent

flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death.

4. Check around the boiler for gas odor following the procedure of section

7a, page 32 of this manual.

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 result in severe personal injury, death or substantial property damage.

in boiler system. Severe damage to boiler

Part Number 550-110-710/0200

Page 35

Boiler Manual

Check burner flames

View pilot and main flames through the inspection port in the base burner shield.

Pilot burner flame

Proper pilot flame characteristics (see Figure 28):

1. Blue flame.

2. Inner cone engulfing pilot flame sensor.

3. Pilot flame sensor glowing cherry red.

Improper pilot flame characteristics:

1. Overfired — 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 sensor.

Main burner flame

Proper main burner flame characteristics

Figure 29):

(see

1. Yellow-orange streaks may appear (caused by dust).

Figure 28 Typical pilot burner flame

Spark electrode

Pilot flame sensor

Figure 29 Typical main burner flame

Inner

cone

71030

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).

Start-up — if boiler doesn’t start . . .7c

Check for:

1. Loose connections, blown fuse or service switch off?

2. High limit switch set below boiler water temperature?

3. Thermostat set below room temperature?

4. Gas not turned on at meter or boiler?

Part Number 550-110-710/0200

Transparent

blue flame

Inner flame

71031

5. Incoming gas pressure less than: 5" w.c. for natural gas?

11" w.c. for propane gas?

If none of the above corrects the problem, refer to

Troubleshooting, section 11, pages 46-55 of this

manual.

Page 36

GOLD CGi Series 2 Gas-Fired Water Boiler

Check-out procedure — checklist8

❏ Boiler and heat distribution units filled with water?

❏ Automatic air vent, if used, open one full turn?

❏ Air purged from system?

❏ Air purged from gas piping? Piping checked for leaks?

❏ Correctly sized manifold orifices installed? Refer to Table 2,

page 12, to check size and fuel type.

Correctly sized manifold orifices must be used. Failure to do so will cause severe personal injury, death or substantial property damage.

❏ Followed operating instructions on boiler or in manual

section

❏ Proper burner flame observed? Refer to Check burner

flame

❏ Test limit control — While burners are operating, move

indicator on limit control below actual boiler water temperature. Burners should go off while circulator continues to operate. Raise setting on limit control above boiler water temperature and burners should reignite.

❏ Test additional field-installed controls — If boiler has a

low water cutoff, additional high limit or other controls, test for operation as outlined by manufacturer. Burners should be operating and should go off when controls are tested. When controls are restored, burners should reignite.

❏ Test ignition system safety device:

a. Connect manometer to outlet side of gas valve. b. Start boiler, allowing for normal start-up cycle to occur

c. With main burners on, manually shut off gas supply

d. Open manual main shutoff gas valve. Manometer

9, pages 37-40 for proper start-up?

, manual section 7b, page 35.

and main burners to ignite.

at manual main shutoff gas valve. Burners should go off.

should confirm there is no gas flow.

e. Pilot will relight, 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 temperature to system.

❏ For multiple zones, adjust flow so it is about the same in

each zone.

❏ Verify thermostat heat anticipator (if available) set properly?

Refer to

Thermostat(s).

❏ Cycle boiler with thermostat — Raise to highest setting

and verify boiler goes through normal start-up cycle. Lower to lowest setting and verify boiler goes off.

❏ Measure natural gas input:

a. Operate boiler 10 minutes. b. Turn off other appliances. c. At natural gas meter, measure time (in seconds)

d. Calculate gas input:

e. Btuh calculated should approximate input rating on

❏ Check manifold gas pressure by connecting manometer to

downstream test tapping on main gas valve. Manifold pressure for natural gas should be 3.5" w.c. and for propane gas should be 10" w.c.

❏ Observe several operating cycles for proper operation.

❏ Set room thermostat to desired room temperature.

❏ Fill in Installation and service certificate below?

❏ Review all instructions shipped with this boiler with owner

or maintenance person. Return instructions to envelope and give to owner or place in pocket inside front panel in boiler.

Field wiring, manual section 6, page 31,

required to use one cubic foot of gas.

3600 x 1000

number of seconds from step c

boiler rating label.

= Btuh

Installation and service certificate

Boiler model __________________ Series __________ CP number ___________ Date installed _______________

❏ Installation instructions have been followed.

Measured Btuh input ____________

Installer ________________________ ________________________________ ______________________________ (company) (address) (phone)

❏ Check out sequence has been performed. ❏ Above information is certified to be correct. ❏ Information received and left with owner/maintenance person

_____________________________________

(installer’s signature)

Part Number 550-110-710/0200

Page 37

Boiler Manual

Operation — sequence9a

1. Read Operating instructions on page 40. This information is also located on a label on the inside of the boiler jacket door panel.

2. Raise room thermostat to call for heat.

3. Inducer and circulator energize. After pressure switch proves proper airflow, control module initiates 30-second prepurge.

4. Control module sparks the pilot and opens pilot valve in main gas valve.

a. If pilot does not light within 15 seconds, pilot

valve is closed and spark generator is turned off. Control module initiates a 15-second postpurge, then starts a new cycle.

b. If pilot

does light and control 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

6. In the event the limit control shuts down the

7. Lower room thermostat setting to stop call for heat.

8. Boiler is now in the

9. Repeat steps 1 through 6 several times to verify

10. Return the thermostat to normal setting.

11. Set thermostat heat anticipator setting as instructed

generator activates and sequence returns to step

If power is interrupted, control system shuts

off

pilot and main gas valves and restarts at step

1 when power is restored.

boiler — The control module closes the pilot and

main gas valves, but keeps the inducer operating for 15-second postpurge. — The circulator continues to operate.

Thermostat is satisfied — Pilot and main gas valves are closed — Inducer operates for 15-second postpurge — Circulator is shut off.

off cycle.

operation.

in Figure 32, page 39.

Figure 30 Control module sequence of operation — status light indications

Steps

(Following step 8, cycle goes back to step 1.)

1. Standby

Waiting for call for heat·

2. Call for heat

· Circulator on

· Blower on

3. Limit circuit

· Limit controls closed

· Rollout TFE contacts closed

4. Pressure circuit

· Pressure switch contacts closed

· Prepurge for 30 seconds

5. Pilot flame proven *

· Gas valve open

· Pilot remains on

· Boiler producing heat

6. Limit cycle

· Limit circuit open

· Gas valve closed

7. Flame outage *

· Flame out

· Boiler recycles

8. Thermostat satisfied

· Circulator off

· Blower postpurge

9. Circulator exercise routine

· Circulator turns on for 30 seconds if boiler not operated for 30 days

Call for

heat?

YES

POWER TSTAT

CIRC

* If pilot flame is not proven in 15 seconds, control module will flash the FLAME light, but will continue indefinitely with attempts to light the pilot burner.

The control module will not lockout on a failure to establish flame. It will lockout if line voltage polarity is reversed, stray voltage is sensed on thermostat line, pressure switch sticks closed or fails to make within 5 minutes or if flame is sensed when it shouldn’t be there. The boiler will reset after these lockouts if any of the following occurs:

• 1 hour waiting period • Opening and closing of thermostat circuit • Removal of 120 VAC power for at least 45 seconds.

LIMIT

= "ON"

PRESS

SWITCH

FLAME

= "OFF"

Timing

—

35 sec

15 sec

—

15 sec

30 sec

71032

Part Number 550-110-710/0200

Page 38

GOLD CGi Series 2 Gas-Fired Water Boiler

THERMOSTAT

Operation — wiring diagrams9b

Figure 31 Schematic wiring diagram

• The control module is polarity-sensitive to the incoming 120 VAC power. If polarity is reversed, control will flash the light when powered

POWER

and will not cycle boiler.

• All contacts shown without power applied.

• Connector and status light locations/orientations may vary.

White

Red

White hose

Plug-in connectors

Red hose

AIR PRESSURE

SWITCH

Items not provided

TRANSFORMER

120 VAC —

SERVICE

SWITCH

Wire nuts

Black

Junction box, boiler left side

CIRCULATOR

NeutralHot

Gnd

FIELD

WIRING

THERMOSTAT

Ground screw

White

Green

Black Black

Jacket opening,

boiler left side

WATER TEMPERATURE

LIMIT SWITCH

Additional limits, if used (note 7)

71034

ROLLOUT TFE

BLOWER MOTOR

PILOT

BURNER

(Honeywell VR8204 shown)

"C"

"A"

O FF

O N

GAS VALVE

Part Number 550-110-710/0200

"B"

Terminal block (See Table G)

Page 39

Boiler Manual

Figure 32 Ladder wiring diagram

Part Number 550-110-710/0200

Page 40

GOLD CGi Series 2 Gas-Fired Water Boiler

Operation — operating instructions9c

Figure 33 Operating instructions

FOR YOUR SAFETY READ BEFORE OPERATING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance is equipped with an ignition

device which automatically lights the pilot.

try to light the pilot by hand.

not

B. Before

OPERATING, smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.

C. Use only your hand to turn the gas control knob. Never use

tools. If the knob will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

OPERATING INSTRUCTIONS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electrical power to the appliance.

4. Remove jacket front panel.

5. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

6. Turn Gas control knob clockwise to OFF.

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above. If you don't smell gas, go to the next step.

8. Turn Gas control knob counterclockwise to ON.

9. Turn on all electric power to the appliance.

10. Set thermostat to desired setting.

11. If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" below and call your service technician or gas supplier.

12. Replace jacket front panel.

71035

White-Rodgers 36C Gas valve

Position indicator

(shown in "ON" position)

White-Rodgers 36E Gas valve

Position indicator

(shown in "ON" position)

Honeywell VR8204 or VR8304 Gas valve

Position indicator

(shown in "ON" position)

Gas control knob

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove jacket front panel.

4. Turn Gas control knob clockwise to OFF. Do not force.

5. Replace jacket front panel.

Part Number 550-110-710/0200

Page 41

Boiler Manual

Service and maintenance — schedule10a

Table 8 Service and maintenance schedules

Service technician

(see following pages for instructions)

Inspect:

• Reported problems

• Boiler area

• Air openings

• Flue gas vent system

• Pilot and main burner flames

• Water piping

• Boiler heating surfaces

• Burners and burner shield

• Condensate drain system

Service:

• Inducer motor

• Oiled-bearing circulators

Start-up:

• Perform start-up per manual

NNNUAL START

Check/test:

Owner maintenance

(see CGi User’s Information Manual for instructions)

• Check boiler area

Daily

Monthly

Periodically • Test low water cutoff (if used)

Every 6 months

• Check air openings

• Check boiler pressure/ temperature gauge

• Check boiler interior piping

• Check venting system

• Check air vents

• Check boiler relief valve

• Check condensate drain system

• Check automatic air vents (if used)

• Oil inducer motor

• Operate relief valve

• Gas piping

• Cold fill and operating pressures

• Air vents and air elimination

• Limit controls and cutoffs

• Expansion tank

• Boiler relief valve

Review:

• Review with owner

Part Number 550-110-710/0200

End of season • Shut down procedure

Follow the Service and maintenance 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. Failure to follow the directions in this manual

and component literature could result in severe personal injury, death or substantial property

damage.

Page 42

GOLD CGi Series 2 Gas-Fired Water Boiler

10b

❏ Inspect . . . . . . . . . .

Service and maintenance — annual start-up

The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified

service technician

the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

Reported problems

Inspect any problems reported by owner and correct before proceeding.

Boiler area

1. Verify that boiler area is free of any combustible

materials, gasoline and other flammable vapors and

liquids.

2. Verify that boiler area (and air intake) is free of any of the

contaminants listed in Table 1 on page 9 of

this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, isolate the boiler and provide outside combustion air. See national, provincial or local codes for further information.

Air openings

1. Verify that combustion and ventilation air openings to the boiler room and/or building are open and

unobstructed.

2. Verify that boiler vent discharge is

of obstructions

. In addition, the maintenance and care of the boiler designated in Table 8 and explained on

Flue gas vent system

1. Visually inspect entire flue gas venting system for blockage, deterioration or leakage. Repair any joints that show signs of leakage in accordance with vent manufacturer’s instructions. When air is ducted to boiler, verify that air inlet hose is connected and properly sealed.

Failure to inspect for the above

conditions and have them repaired can result in severe personal injury or death.

Pilot and main burner flames

1. Visually inspect pilot burner and main burner flames as directed under Start-up, section 7 of this manual.

Water piping

1. Check the boiler interior piping and all system piping for signs of leaks.

clean and free

Eliminate all system or boiler 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. Leaking water may also cause severe property damage.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Electrical shock hazard — Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

2. Repair any leaks before proceeding.

Boiler heating surfaces

1. Disconnect the vent pipe at the boiler inducer outlet connection after turning off power to the boiler.

2. Use a bright light to inspect the flue pipe interior and inducer interior.

3. Inspect the boiler vent outlet area and heating surfaces by looking through the opening.

4. If the vent pipe or inducer interior show evidence of soot, follow Cleaning boiler heating surfaces in this manual section to remove the flue collector and clean the boiler if necessary after close inspection

of boiler heating surfaces. If there is evidence of rusty scale deposits, check the water piping and control system to make sure the boiler return water temperature is properly maintained (per this manual).

5. Reconnect vent to inducer outlet and replace all boiler components 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.

Part Number 550-110-710/0200

Page 43

Boiler Manual

❏ Inspect . . . . . . . . . .

Burners and base

If insulation is damaged or displaced, do not operate the boiler. Replace or reposition insulation as necessary. Failure to replace damaged insulation can result in a fire hazard, causing severe personal injury, death or substantial property damage.

1. After turning off power to the boiler, remove the base burner shield (Figure 40, item 4, page 58).

2. Inspect burners and all other components in the boiler base.

3. If burners must be cleaned, access the burner assembly removing the screws securing the burner tray to the manifold. Slide the burner tray out. Then brush and vacuum the burners thoroughly, making sure all ports are free of debris.

4. Inspect the slotted jacket cooling openings in the bottom left and right of the base pan ( page 58).

5. Inspect the base insulation. Pay attention to the materials. Verify that the insulation is intact and secure against all four sides of the base.

WARNING on page 64 regarding working with insulation

Figure 40, item 7,

Condensate drain system

1. Inspect condensate drain fittings and tubing. Verify that condensate can flow freely to drain.

❏ Service annually. . . . . . . . . .

Inducer motor

1. With boiler power off, place a few drops of S.A.E. 20 motor oil in each of the two oil cups.

Use only S.A.E. 20 motor oil to lubricate the inducer motor. Do not use universal household oils. Motor could be damaged, resulting in possible severe property damage.

❏ Start-up . . . . . . . . .

1. Perform start-up procedures in section 7, pages 3235 of this manual.

Oiled-bearing circulators

1. The circulator shipped with the CGi boiler is water-lubricated. No oiling is required.

2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator.

Check gas piping, per manual section 5, page 30

and section 7a, page 32, verifying no indications of leakage and all piping and connections are in good condition.

2. Verify cold fill pressure is correct and that fill system is working properly.

3. Verify

Part Number 550-110-710/0200

antifreeze level (if used) is at the right

concentration and that inhibitor level is correct.

5. Read the Operating instructions (Figure 33, page

of this manual or on boiler label) applying to

the boiler.

6. Start the boiler following the

instructions

, page 40 of this manual.

Operating

Page 44

GOLD CGi Series 2 Gas-Fired Water Boiler

Service and maintenance — annual start-up10b

(continued)

❏ Check/test . . . . . . .

Gas piping

1. Sniff near floor and around boiler area for any indication

gas leak.

of a

Test gas piping using bubble test, per section 5 of this

manual, if there is any indication of a leak.

Cold fill and operating pressures

1. While the system is cold, note the pressure reading on the boiler pressure/temperature gauge. Verify that cold fill pressure is correct.

Watch the pressure as the boiler and system heat up to

2. ensure pressure rise is normal. Too high a rise would indicate a waterlogged or undersized expansion tank.

Air vents and air elimination

1. Inspect automatic air vents (if used). Also inspect air separators to ensure they are operational.

2. The cap must be unscrewed one turn to allow air to escape.

3. See

4. Replace cap

Figure 34. If the air vent is

leaking, remove cap push valve clean the valve seat.

onto valve one turn.

B and then release to

A by twisting all the way

B and then unscrewing

A and briefly

Figure 34

Automatic air vent, typical

71036

Limit controls and cutoffs

1. Inspect and test the boiler limit control. Verify operation by turning control set point below boiler temperature. Boiler should cycle off. Return dial to original setting.

2. Inspect and test additional limit controls or low water cutoffs installed on system.

Expansion tank

1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See section best location of expansion tanks and air eliminators.

Open-type — located above highest radiator or

baseboard 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

•

Diaphragm- or bladder-type — welded gas tight with a

rubber membrane to separate the tank pressurizing air and the water. May be located at any point in the system, but most often found near the boiler.

• Systems with this type of expansion tank require at

2. If relief valve has tended to weep frequently, the expansion tank may be waterlogged or undersized.

Closed-type tank — tank is most likely waterlogged.

Install a tank fitting if not already installed. Then check fill level per fitting manufacturer’s instructions. If fill level is correct, check tank size against manufacturer’s instructions. Replace with a larger tank if necessary.

Diaphragm- or bladder-type — first, check tank size to be

sure it is large enough for the system. If size is too small, add additional tank(s) as necessary to provide sufficient expansion. If tank size is large enough, remove tank from system and check charge pressure (usually 12 psig for residential applications). If tank won’t hold pressure, membrane has been damaged. Replace tank.

3, pages 14-19 of this manual, for suggested

such as the B & G Tank-Trol or Taco Taco-Trol. This fitting reduces gravity circulation of air-saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the system.

Do not use automatic air vents in systems with closed-type tanks.

system instead of returning to the tank. Eventually, the tank will waterlog and no longer control pressurization. The boiler relief valve will weep frequently.

least one top of an air eliminator, as shown in examples in manual section

automatic air vent, preferably located on

The air will escape from the

3, pages 14-19.

tank fitting,

Part Number 550-110-710/0200

Page 45

Boiler Manual

❏ Check/test . . . . . . .

Boiler relief valve

Safety relief valves should be reinspected AT LEAST

ONCE EVERY THREE YEARS

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 or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency — not by the owner. Failure to reinspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death or substantial property damage.

Following installation, the valve lever must be

operated AT LEAST ONCE A YEAR to ensure that

waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal otherwise severe personal injury may result. If no water

flows, valve is inoperative. Shut down boiler until a

new relief valve has been installed.

Figure 35

Relief valve, typical

71037

1. Inspect the relief valve and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufacturer’s warning label. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read manual section

3a, page 14, before proceeding further.

2. After following the above warning directions, if the relief valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing.

, by a licensed plumbing

❏ Review with owner

1. Review the User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance schedule specified in the User’s Information Manual (and in this manual as well).

3. Remind the owner of the need to call in a licensed contractor should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

❏ Cleaning boiler

heating surfaces

1. Shut down boiler:

• Follow “

• Do not drain boiler unless it will be exposed to freezing

2. Follow shutdown procedure.

3. Remove venting system connection to boiler.

4. Remove top jacket panel. Turn back insulation.

5. Remove collector box/transition assembly. Clean sealant from assembly and sections.

6. Remove radiation plates hanging between sections.

7. Remove burners from base. Brush and vacuum burners to remove all dust and lint. Verify that all burner ports are free of debris.

8. Place newspapers in base of boiler to collect soot.

9. Clean between sections with wire flue brush.

10. Remove newspaper and soot. Vacuum or brush base and surrounding area.

11. Reinstall radiation plates.

12. Replace collector box/transition assembly. Seal with sealant. Obtain gas-tight seal to prevent flue gas spillage and carbon monoxide emissions, resulting in severe personal injury or death.

13. Replace insulation and jacket top panel.

14. Start up boiler following section manual and the boiler sooting indicates improper gas combustion. If found check for proper combustion and make any necessary adjustments.

To Turn Off Gas to Appliance” instructions

on boiler and

temperatures. If using antifreeze in system, do not drain.

Operating instructions.

7, pages 32-35 of this

Operating instructions. Excessive

Part Number 550-110-710/0200

Page 46

GOLD CGi Series 2 Gas-Fired Water Boiler

Boiler model number Inches W.C.

CGi-25 and CGi-3 1.79

CGi-4 1.40

CGi-5 1.12

CGi-6 and CGi-8 0.80

CGi-7 0.75

Troubleshooting — procedure11a

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Never jumper (bypass) rollout thermal fuse element or any other device except for momentary testing as outlined in Troubleshooting Charts. Severe personal injury, death or substantial property damage can result.

Before troubleshooting:

1. Have the following items: a. Voltmeter that can check 120 VAC and 24 VAC. b. Microammeter with a minimum scale range of 0-25. c. Continuity checker. d. Inclined manometer with 0 – 2.5" w.c. range.

2. Check for 120 VAC (minimum 102 VAC to maximum 132 VAC) to boiler.

3. Make sure thermostat is calling for heat and contacts

Troubleshooting — components11b

Air pressure switch

Make sure boiler water temperature is 100 °F or cooler before starting procedure to obtain appropriate readings.

Check pressure switch setting

1. See Figure 36,page 47 and Table 9.

2. Remove both air pressure switch hoses from air pressure switch.

3. Install tees and tubing as shown in inclined manometer.

4. Turn off gas valve and set thermostat to call for heat. Inducer will run but burners will not ignite.

5. Check for 24 VAC between both air pressure switch terminals.

6. If manometer reading is above the setpoint of the switch

Troubleshooting air pressure reading

1. If manometer reading is lower than the setpoint of the

Table 9), but there is not 24 VAC between both air

(see pressure switch terminals — replace air pressure switch.

switch (see

• blockage in hoses

• obstruction in inducer housing outlet

• loose inducer wheel on motor shaft

• inducer motor not in proper rpm

• inducer back plate not sealed properly

• blockage in block assembly

• blockage in flue pipe or termination

• incorrect pressure switch

Table 9) — check for possible causes:

Figure 36, page 47 to

(including appropriate zone controls) are closed. Check for 24 VAC between thermostat wire nuts and ground.

Check the following:

1. Wire connectors to control module are securely plugged in at module and originating control.

2. Air pressure switch hoses are properly and securely plugged in and are not damaged.

3. Gas pressures: a. With boiler off — 13" w.c. maximum natural or

propane gas pressure upstream of gas valve.

b. With boiler on:

• 5" w.c. minimum natural gas pressure or 11" w.c. propane gas pressure upstream of gas valve.

• 3 ½" w.c. minimum natural gas pressure or 10" w.c. propane gas pressure downstream tapping on gas valve — Can be adjusted by regulator on gas valve.

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.

The boiler will not operate correctly unless pressure switch hoses are correctly located. The red hose connects from the right side (negative) hose barb to the flue collector. The white hose connects from the left side (positive) hose barb of the switch to the connector box (between flue collector and inducer) as shown in page 47.

Table 9

Pressure switch setpoint (for elevations above 2,000

ft, contact your local Weil-McLain sales office for details.)

Part Number 550-110-710/0200

Figure 36,

Page 47

Boiler Manual

Troubleshooting — components (continued)11b

Control module

Solder or water splatter between plugs and circuit

board can cause improper operation of control module. Place a shield over the boiler internal controls and components during installation. Failure to comply could result in severe personal injury, death or substantial property damage.

Make sure ground wiring is installed per wiring diagram. Good grounding is extremely important for proper operation.

Control indicator lights — lockout modes

See Charts 1 through 7 in this section for detailed troubleshooting procedures.

To reset control after a lockout, turn off power at the 120 VAC service switch or turn down all thermostats. Wait 45 seconds. Then restore power or call for heat.

POWER light flashing alone

Usually indicates reversed polarity of 120 VAC power wires.

Figure 36 Manometer connections

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 inducer starting.

POWER and FLAME lights flashing

Usually indicates false flame sense or flame sensed when it shouldn’t be there.

Control indicator lights — non-lockout modes

FLAME light flashing alone

Usually indicates pilot flame was not established within 15 seconds from application of spark. Control will flash light, but will continue to cycle indefinitely until flame is established or problem is corrected.

PRESS SWITCH light flashing alone

Usually indicates pressure switch opened during the run cycle.

Troubleshooting the control module

See Figure 38 for location of harness plug receptacles and plugs on the control module.

Suction

Inclined tube manometer

Red

White

Side panel

Part Number 550-110-710/0200

White

Red

Interior panel

Pressure

Red

Flue collector

Rear panel

71038

Figure 37 Control module

71039

Page 48

GOLD CGi Series 2 Gas-Fired Water Boiler

Troubleshooting — components continued11b

Figure 38 Control module connections

High voltage to pilot spark electrode

Blue wire to gas valve PV

Red wires to pressure switch

Indicator lights

Red wire to gas valve MV

24 VAC control

circuits

FLAME

PRESS SWITCH

LIMIT

TSTAT CIRC

POWER

Black

White

120 VAC H

120 VAC N

120 VAC to

transformer

Black wires to

thermostat circuit

White wire to

gas valve MV/PV

Yellow wires to limit control

and rollout switch

SJO cable

to J-box

120 VAC H

Entrance ground

Chassis ground

120 VAC N

24 VAC from transformer

Black

Green

White

120 VAC IN

Red

24 VAC

120 VAC to

inducer motor

Brown

Ground

Green

120 VAC N

White

71040

High voltage to spark electrode

120 VAC to transformer

120 VAC IN

24 VAC control circuits

24 VAC from transformer

120 VAC to inducer motor

120 VAC to circulator

Sense wire to flame sensor

Part Number 550-110-710/0200

120 VAC H

120 VAC N

Flame sense wire to pilot

Yellow

White

120 VAC to circulator

Page 49

Boiler Manual

Troubleshooting — control module lights11c

CHART 1— Troubleshooting POWER light status

— Usually indicates reversed 120 VAC polarity if POWER light flashes by itself —

Electrical shock hazard — Wherever you see ▲TURN OFF POWER▲, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.

POWER

No Yes

POWER

Flashing

alone

light off?

light ...

Flashing with

another light

On steady

(not flashing)

• Make sure service switch or circuit breaker is on or fuses are good.

• Remove 120 VAC IN plug (Figure 38, Item 3, page

48) on control module.

• Using voltmeter, check across top and bottom pins of 120 VAC IN plug.

Does voltmeter indicate

No Yes

120 VAC

TSTAT CIRC

light flashing

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.

• Usually indicates polarity on incoming 120 VAC power line is wrong.

• ▲TURN OFF POWER▲ at service switch or breaker, then reverse the HOT and NEUTRAL wires entering the boiler in the J-box.

• Restore POWER at service switch or breaker.

POWER

No Yes

Chart

light flashing now?

Chart

Problem is with incoming electricity. Have licensed electrician repair circuit.

• Reconnect 120 VAC IN plug.

• Remove 120 VAC IN transformer PRIMARY plug (Figure 38, Item 2, page 48) on control module.

• Using voltmeter, check across top and bottom pins of PRIMARY receptacle.

Does voltmeter indicate

No Yes

Replace control module. Retest.

• Reinstall 120 VAC transformer PRIMARY plug.

• Remove 24 VAC transformer plug (Figure 38, Item 5, page 48) on control module.

• Using voltmeter, check pins of plug.

Does voltmeter indicate

No Yes

120 VAC

24 VAC

Have system checked by a licensed electrician. If

problem persists, call your Boiler should now operate normally.

Part Number 550-110-710/0200

local Weil-McLain sales

representative.

Replace transformer. Retest and check for back feed of voltage from system wiring.

Replace control module. Retest.

Page 50

GOLD CGi Series 2 Gas-Fired Water Boiler

Troubleshooting — control module lights11c

CHART 2 — TSTAT CIRC & POWER lights flashing

— Usually indicates 48 VAC on thermostat circuit (stray voltage) —

• Disconnect the two external wires connected 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.

Did you find a voltage across the two external thermostat circuit wires?

• Leave external boiler thermostat connection wires disconnected from boiler.

• Troubleshoot the external thermostat circuit until you find the source of the stray voltage. (Pay close attention to the wiring connections to 3-wire zone valves.)

• Correct the problem and repeat the voltmeter test above, verifying there is no longer a voltage reading under any condition in the external thermostat circuit.

• An isolating relay may be required.

• If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

• Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the boiler thermostat wires and allow the boiler to cycle.

NoYes

• If no voltage is found under any condition of the external thermostat circuit, connect the two boiler thermostat connection leads together (or jumper the boiler aquastat T-T terminals).

• Turn off power to the boiler for 1 minute.

• Turn on power and allow boiler to cycle.

Do the

TSTAT

No Yes

and

POWER

lights still flash?

• Boiler should now operate per the normal sequence of operation shown in Figure 30, page 37.

• Replace control module.

• Retest.

Part Number 550-110-710/0200

Page 51

Boiler Manual

continued

CHART 3 — PRESS SWITCH & POWER lights flashing

— Usually indicates pressure switch stuck closed or failed to make within 5 minutes —

• Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds.

• Thermostat should call for heat and appropriate zone valves open.

Does inducer motor operate?

No Yes

• Wait 45 seconds.

Does inducer motor operate?

No Yes

• Remove INDUCER plug (Figure 38, Item 6 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 right column bottom pins).

Does the voltmeter indicate

No Yes

• Try reseating plug in

• If inducer still does not

• Retest.

• Remove one of the wires connected to the pressure switch.

• Check continuity across the switch terminals.

120 VAC

module receptacle and restart.

work, replace inducer assembly.

, page 48

Does the ohmmeter indicate the switch is closed?

No Yes

)

• Wait 5 minutes.

PRESS SWITCH

No Yes

• Boiler should be in normal operating sequence.

• Observe operation until thermostat is satisfied and inducer has completed its post-purge cycle.

light flashing?

Are vent or combustion air

passages blocked?

No Yes

• Replace control module.

• Retest.

Part Number 550-110-710/0200

• Check air pressure switch per manual Section 11.

• Replace if necessary.

• Retest.

• Clear passages and recycle boiler.

• Recheck boiler operation.

Page 52

GOLD CGi Series 2 Gas-Fired Water Boiler

Troubleshooting — control module lights11c

CHART 4 — FLAME & POWER lights flashing

— Usually indicates flame sensed when it shouldn't be there —

Are manual main shutoff valve and gas valve open?

No Yes

• Leave main manual gas valve closed.

• Turn off power to boiler at service switch or breaker.

• Wait at least 45 seconds.

• Turn on power to boiler.

• Restart boiler, following Operating instructions in this manual (Figure 33, page 40).

FLAME

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Open main manual gas valve.

• Turn on power to boiler at service switch or breaker.

• Restart boiler per lighting instructions.

• Perform start-up procedures in boiler manual to verify proper operation.

and

POWER

lights still flash?

YesNo

• Replace control module.

• Retest.

• Allow boiler to continue cycling.

Are

FLAME&POWER

• Boiler may now be operating normally.

• Perform start-up procedures in boiler manual to verify proper operation.

• Replace control

• Retest.

• Turn off power to the boiler at service switch or breaker.

• Wait at least 45 seconds.

• Turn on power to boiler.

• Restart boiler, following Operating instructions in this manual (Figure 33, page 40).

• Look through the pilot inspection port to see if the pilot is burning during the prepurge period (first 30 seconds of operation).

lights flashing?

Yes

module.

Is pilot burning during prepurge period?

• Replace gas valve.

• Retest boiler.

Are

FLAME

• 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.

and

POWER

Yes

lights flashing?

Yes

• Replace control module.

• Retest.

Part Number 550-110-710/0200

Page 53

Boiler Manual

continued

CHART 5 — PRESS SWITCH light flashing and POWER light on steady

— Usually indicates pressure switch opened during run cycle —

— May also be caused by wind gusts in excess of 31 mph for non-direct vent sidewall-vented boilers —

• Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds.

• Thermostat should call for heat and appropriate zone valves open.

Does blower motor operate?

No Yes

• Remove INDUCER plug (Figure 38, Item 6 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 right column bottom pins).

Does the voltmeter indicate

No Yes

• Remove one of the wires connected to the pressure switch.

• Check continuity across the switch terminals.

120 VAC

• Replace inducer assembly.

• Retest.

, page 48

Does the ohmmeter indicate the switch is closed?

No Yes

• 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.

)

• Wait 5 minutes.

PRESS SWITCH

No Yes

• Boiler should be in normal operating sequence.

• Observe operation until thermostat is satisfied and inducer has completed its post-purge cycle.

light flashing?

Is vent blocked?

No Yes

• Clear vent and recycle boiler.

• Recheck boiler operation.

Part Number 550-110-710/0200

Page 54

GOLD CGi Series 2 Gas-Fired Water Boiler

Troubleshooting — control module lights11c

CHART 6 — FLAME light flashing and POWER light on steady

ALSO — Troubleshooting failure to establish main flame

No Yes

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Open main manual shutoff valve and boiler gas valve (per Operating instructions in this manual). seconds.

• Turn on power at service switch or breaker. A

Does

FLAME

No Yes

light flash now?

Wait at least 45

llow boiler to cycle.

(continued)

• Is pilot flame visible through inspection port?• Are main manual shutoff valve and boiler gas valve open?

No Yes

• Check the voltage across terminals PV and PV/MV of the gas valve.

24 VAC

present there?

NoYes

• Make sure ground wire terminal is securely fastened to control module mounting screw.

• Boiler should be in

• Verify inlet gas pressure at gas

normal operating sequence.

• Observe operation until thermostat is satisfied and blower has completed its post-purge cycle.

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Remove burner shield (see Figure 40, page 58 for location).

• Verify pilot gas line is not kinked, obstructed or damaged and is correctly attached to pilot and gas valve.

• Verify pilot ignition electrode, electrode ceramic and spark lead wire from control are in good condition. Spark gap should be approximately 1/8".

• Correct any above problems, replacing pilot if burner or wiring is damaged.

• Reinstall burner shield to operate boiler for retest after any changes or corrections.

• If none of the above corrects problem, then replace the control module and retest.

valve:

Natural gas — 5.0" w.c. min/14.0" w.c. max

Propane — 11.0" w.c. min/14.0" w.c. max

Is gas present at gas valve inlet and

within above range?

Yes

• Contact gas supplier to correct pressure or gas supply.

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Remove burner shield (see Figure 40, page 58 for location).

• Verify pilot burner is securely attached to pilot bracket, bracket is securely attached to cross tie, and there is no corrosion on the parts which would affect the ground path for flame sense.

• Verify that pilot flame rod, flame rod ceramic and lead wire from control module to flame rod are in good condition.

• Correct any above problems, replacing pilot if burner or wiring is damaged.

• If the wiring from the control module to gas valve is intact, replace the control module.

• Retest.

• Verify inlet gas pressure at gas valve:

Natural gas — 5.0" w.c. min/14.0" w.c. max

Propane — 11.0" w.c. min/14.0" w.c. max

Is gas present at gas valve inlet and within above range?

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

• Check flame signal — Detach sense lead from ignition control (Figure 38, item 8,

• Connect negative lead of MICROAMMETER to control sense terminal (Figure 38, item 8 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 at least 1.0 microamp.

Is flame signal at least 1.0 microamp?

No Yes

• If none of the previous steps (including replacing pilot) corrects problem, then replace the control module, reinstall burner shield and retest.

page 48

• Check the voltage across terminals MV and PV/MV of the gas valve.

24 VAC

, page 48

• If the wiring from the

present there?

No Yes

Yes

). Connect positive lead

control module to gas valve is intact, replace the control module and retest.

Part Number 550-110-710/0200

Page 55

Boiler Manual

CHART 7 — Insufficient heat or no heat to system (POWER light on steady)

• Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes. Is system heating?

• Is thermostat set to call for heat? Remove thermostat wires at boiler and check continuity across the two wires. If circuit isn't closed, check external thermostat (zone valve, relay, etc.) wiring. Correct problems and retry.

• Reconnect external thermostat wiring at boiler.

Is thermostat circuit closed (continuity across wires)?

No Yes

• Boiler is in standby.

Are all red lights off?

No Yes

Wait 30 seconds. Are all red lights off?

No Yes

Replace control module. Retest.

• If you have sufficient heat — boiler should be in normal operating sequence. (See normal sequence of operation, Figure 30.)

• If you have less than sufficient heat —

• Set thermostat to call for heat and recheck operation.

• Verify Sequence of

operation, Figure 30,

page 37.

Is vent piping free of blockage?

No Yes

• Correct conditions and recheck operation.

• See Figure 30, page 37 for normal sequence of operation.

• Wait for boiler water to cool to temperature 20 to 30 ˚F lower than temperature set on limit switch.

• Check heat loss calculation versus boiler size.

• Clock gas input.

Are limit switch contacts closed?

No Yes

•

Boiler water temperature exceeded setting on limit switch with thermostat

• Replace limit switch.

• Retest.

calling for heat. Boiler is OK. (See normal sequence of operation,

• Also check setting on limit switch (should be above 140˚F.).

Figure 30

, p. 37.)

Is boiler System circulator operating?

No Yes

• Remove CIRCULATOR harness plug from CIRCULATOR plug receptacle (Figure 38, Item

, page 48

control module receptacle.

). Check with voltmeter across pins of

Does voltmeter show 120 VAC across pins?

No Yes

• Replace control module.

• Retest.

• Wait 5 minutes.

No Yes

• Check limit switch contacts with continuity checker.

• Repair/replace

FLAME

LIMIT

circulator. Retest.

wiring. Retest.

light on?

NoYes

light on?

• Replace control module.

• Retest.

Are limit switch contacts

closed?

No Yes

Check rollout switch

continuity — is switch

closed?

No Yes

• Replace rollout switch.

If rollout thermal fuse element has opened, determine cause and correct condition. Failure to do so will cause severe personal injury, death or substantial property damage.

• Check any other limit controls wired into the limit circuit. If all are OK, then replace control module.

• Retest.

Part Number 550-110-710/0200

Page 56

GOLD CGi Series 2 Gas-Fired Water Boiler

Replacement parts12a

Section assembly................................................ 57

Base assembly .................................................... 58

Jacket assembly ................................................. 59

Trim assembly ..................................................... 60

Gas control assembly ......................................... 61

Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size 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

Part Number 550-110-710/0200

Page 57

Page 58

Page 59

Page 60

Page 61

Page 62

GOLD CGi Series 2 Gas-Fired Water Boiler

Dimensions13a

Figure 44 Dimensional drawing

Supply piping ( )

Return piping ( )

note 1

Relief valve, ¾" NPT

½" NPT to expansion tank/air vent

3" Diameter vent

A LL DIMENSIONS IN INCHES

13¹⁄₄

4³⁄₄

NOTE 2

19 19

28³⁄₈

11¹⁄₈

NOTE 2

2¹⁄₄

T OP VIEW

2³⁄₈

MODEL

CGi

Gas supply piping

Drain valve

Gas supply entrance (right or left side)

Pressure/temperature gauge

Boiler supply and return tappings are both 1¼" NPT.

Note 1:

See , page 20 for recommended system sup-

Table 6

ply and returnpiping sizes.

Boiler circulator is shipped loose. Circulator may be

Note 2:

mounted on either boiler supply or return piping. Circulator flange provided with boiler is same size as recommended pipe sizein , page 20.Table6

4³⁄₄

13¹¹₁₆

71046

Boiler model number

23¹⁄₄

(inches NPT)

1⁵⁄₈

Supply

tapping

(inches NPT)

CGi-25 1¼ 1¼ ½ ½ 10

CGi-3 1¼ 1¼ ½ ½ 10

CGi-4 1¼ 1¼ ½ ½ 13

CGi-5 1¼ 1¼ ½ ½ 16

CGi-6 1¼ 1¼ ½ ½ 19

CGi-7 1¼ 1¼ ¾ ¾ 22

CGi-8 1¼ 1¼ ¾ ¾ 25

Note 3: Gas piping from meter to boiler to be sized per local utility requirements.

Return

tapping

F RONT

Gas

connection size

Note 3

(inches NPT)

Gas

manifold size

Note 3

(inches NPT)

R IGHT SIDEL EFT SIDE

“W”

Jacket

width

(inches)

Part Number 550-110-710/0200

Page 63

Boiler Manual

13b

Ratings

Table 10 Boiler ratings

Boiler

model

number

(Note 1) (Note 2) (Note 3)

CGi-25 42,000 50,000 42,000 45,000 38,000 37,000 1.5 84.0 3"

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"

DOE

Heating

capacity

(Btuh)

0–2,000 feet

altitude

Input

(Btuh)

Output

(Btuh)

2,000–4,500 feet

altitude

Input

(Btuh)

Output

(Btuh)

Net

I=B=R

ratings

(Btuh)

Boiler water

content

(gallons)

DOE

Seasonal

efficiency

(% A.F.U.E)

DOE

Vent

size

(Note 4)

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 natural gas boiler - “PIL” for propane gas

boiler.

2. Based on standard test procedures prescribed by the United States Department of Energy.

3. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and

pickup. Ratings are based on a piping and pickup allowance of 1.15. An additional allowance should be made for unusual piping and pickup loads.

4. CGi boilers require special venting, consistent with Category I or III boiler. Use only the vent materials and methods specified in this manual. Vent diameter shown above is for direct exhaust venting. See for vent diameter when chimney draft venting.

Table 3, page 14,

CGi boilers for residential radiant panel systems, converted gravity heating systems or other low water temperature applications should be installed with balancing valves and bypass piping equal to the supply and return size to avoid excessive flue gas condensation due to lower operating water temperatures. For alternate piping, contact your Weil-McLain sales office. CSA design certified for installation on combustible flooring. Tested for 50 psi working pressure.

Part Number 550-110-710/0200

Page 64

GOLD

CGi Series 2 Gas-Fired Water Boiler — Boiler Manual

Handling fiberglass and ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS

The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).":

■ Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this web site.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

■ Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust.

■ Remove combustion chamber lining or base insulation 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 fiber materials in combustion chamber lining or base panels in gas fired products. Airborne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation.

■ Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for fiberglass wool at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this web site.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

■ Operations such as sawing, blowing, tear out, and spraying may generate airborne fiber concentration requiring additional protection.

■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

■ Eye: Irrigate immediately

■ Breathing: Fresh air.

Part Number 550-110-710/0200