Weil-McLain CGI-4E Bedienungsanleitung
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Inhaltsverzeichnis der Gebrauchsanleitungen
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Seite 1
P ar t No . 550-110-711/1108 This manual must only be used by a qualified heating installer/ser vice technician. Before installing , read all instructions, including this manual, the burner manual and any related supplements. P erform steps in the order given. Failur e to comply c ould result in sever e personal injury , death or substantial prope[...]
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Seite 2
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 2 Part Number 550-110-711/1108 How it works . . . ① Control module The control module r esponds to signals from the room thermostat, air pressur e switch and boiler limit circuit to oper ate the boiler circulator , pilot burner , gas val ve and inducer . W hen room thermostat calls for heat, t[...]
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Seite 3
Part Number 550-110-711/1108 3 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual GOLD CGi-4E Gas-Fir ed Induced-Draft W ater Boiler[...]
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Seite 4
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 4 Part Number 550-110-711/1108 Contents How it works .................................................... 2–3 Hazar d definitions ............................................... 4 Please r ead before pr oceeding ............................ 5 1 Pr epare boiler location .......................[...]
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Seite 5
Part Number 550-110-711/1108 5 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Please r ead befor e pr oceeding Failur e to adhere to the guidelines on this page can r esult in severe personal injury , death or substantial property damage. • Continual fresh mak eup water wil l reduce boiler life. Mineral buildup in sect[...]
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Seite 6
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 6 Part Number 550-110-711/1108 Pr epar e boiler location — codes & checklist 1a Installations must follow these codes: • Local, state, provincial, andnationalcodes, la ws, regulations and or dinances. • N ationalFuelGasCode, ANSIZ223.1–latest?[...]
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Seite 7
Part Number 550-110-711/1108 7 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — clearances 1b Figure 1b Required MINIMUM clearances Figure 1a Recommended SER VICE clearances (see W ARNING below) Recommended SERVICE clearances (Fig. 1a) 1. Pr ovide clearances for cleaning and serv icing the boiler and for access[...]
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Seite 8
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 8 Part Number 550-110-711/1108 Pr epar e boiler location — vent system 1c Failur e to follow all inst ructions can result in flue gas spillage and carbon mono xide emissions, causing se v ere personal injury or death. When r emoving boiler from an existing common vent system: At the time of r[...]
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Seite 9
Part Number 550-110-711/1108 9 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — air contamination T able 1 Corrosive or destructive contaminants and likely locations 1d Please review the following information on potential combustion air c ontamination problems. Refer to T able 1 for prod ucts and areas which ma y [...]
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Seite 10
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 10 Part Number 550-110-711/1108 Figure 5 Air from outdoors — horizontal ducts Figure 4 Air from outdoors — vertical ducts Figure 2 Air openings to interior spaces Figure 3 Air directly through outside wall Air opening options T wo openings — Air su pply fr om insi de the buil ding ✷ 1. I[...]
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Seite 11
Part Number 550-110-711/1108 11 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Unusually tight construction U nusually tight construction means (per ANSI Z2 23.1) buildings in which: a. W all s and ceili ngs expos ed to the o utside atm o- sphere have a continuous water vapor retarder w ith a rating of 1 perm or less wit[...]
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Seite 12
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 12 Part Number 550-110-711/1108 Pr epar e boiler — placement & setup 2a T able 2 Manifold orifice sizing at sea level and altitudes to 4,500 feet Location Natural gas Propane gas U . S. 0-2,000 ft over 2,000 ft 0-2,000 ft o ver 2,000 ft 2.55 mm (Note 1) 1.60 mm (Note 1) Canada 0-2,000 ft [...]
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Seite 13
Part Number 550-110-711/1108 13 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler — pr essure test Hydr ostatic pressur e test Pr essure t est boiler befor e attac hing water o r gas piping (ex cept as noted below) or electrical supply . Prepar e boiler for test 1. Remo ve the shippingnipple (from CGi-4E[...]
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Seite 14
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 14 Part Number 550-110-711/1108 V enting — general information 3a CGi-4E venting methods — Chimney draft or Dir ect exhaust Chimney draft venting Chimneydr aftventinguses thenatural draftprovidedby aver - tical vent or chimney . Categor y I ap[...]
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Seite 15
Part Number 550-110-711/1108 15 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual V enting — Dir ect exhaust — components 3c Obtain vent system components 1. The follo w ing special gas vent sy stems c omply w ith UL-1738 and UL C- S636 standards and are c ertied by CSA as the [...]
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Seite 16
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 16 Part Number 550-110-711/1108 V enting — dir ect exhaust — vent starter 3d 1. Selectav ent pipemanufacturer and obtainall vent components ne eded, based on boiler location and venting method. 2. Y ou must use the vent starter made by?[...]
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Seite 17
Part Number 550-110-711/1108 17 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Fol lo w i ns tr u ct io n s on th i s p ag e when determining vent lo cation to av oid possibility of sever e personal inju r y , de ath or substa ntial pr operty damage. 1. Locate the boiler and v ent penetration through the wall so all requireme nts on this pag[...]
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Seite 18
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 18 Part Number 550-110-711/1108 V enting — dir ect exhaust — installation 3f 1. Donot mix ty pes or manufacturers ofv ent materi - als. 2. Clean all joints before sealing. See v ent manufac - turer’ s instruc tions for cleaning and seali[...]
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Seite 19
Part Number 550-110-711/1108 19 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Figure 15 Sidewall termination V enting — dir ect exhaust — installation (cont.) U sing an y te rmination other than one of those shown could cause nuisance outag es and loss of heat, resulting in substantial property damage. 3f[...]
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Seite 20
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 20 Part Number 550-110-711/1108 W ater piping — general information 4a General piping information If installation isto c omply withASME orCanadian requir ements, anad - ditional high t emperatur e limit is needed. Install c ontrol in suppl y piping between [...]
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Seite 21
Part Number 550-110-711/1108 21 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual W ater piping — single-zone system 4b Diaphragm-type or bladder - type expansion tank (Figure 16) 1. Ensure expansion tank size w ill handle boiler and system water vol ume and temperature. T ank must be located in boiler return piping as close to boiler as p[...]
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Seite 22
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 22 Part Number 550-110-711/1108 4c Piping multiple zones Follo w instruc tions on pages 20 and 21 to install near- boiler or single-zone piping. (Also refer to Piping for radiant heating systems or con vert ed gra vity sys- tems , below , if applicable.) See Figure 1 8 or Figur e 19 to c ompl[...]
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Seite 23
Part Number 550-110-711/1108 23 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Figure 18 Zoning with circulators — return water 130°F or higher . Figure 19 Zoning with zone valves — return water 130°F or higher . 1 B oilerisolation(balancing)val ves 2 Flow/check valv e 3 Systemorzonecir culator 5 Zoneva[...]
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Seite 24
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 24 Part Number 550-110-711/1108 4d Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or burners, r esulting in severe p ersonal injur y , death or substantial property damage. Radiant heating system piping should include a means of regul[...]
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Seite 25
Part Number 550-110-711/1108 25 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 1 B oilerisolation(balancing)val ves 2 Flow/check valv e 3 Systemorzonecir culator 4 Systemt emperaturegauges 5 Zonevalve 6 Dr ainvalv e 7 Syst em temperatur e valv es (see inst ruc - tions to the left [...]
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Seite 26
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 26 Part Number 550-110-711/1108 BOILER-bypass piping method This piping method ( Figure 22 or 23 ) is called a boiler - bypass because part of the circulator flow is bypassed around the boiler (through valve 7a ) . T his me tho d reduces the flow rate throughout the boiler , in or der t o rais[...]
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Seite 27
Part Number 550-110-711/1108 27 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 1 Boilerisolation(balancing)valv es 2 Flow/check val ve 3 Syst emorzonecirculat or 4 Syst emtemperaturegauges 5 Zonevalv e 6 Drainvalve 7 Syst em temperature valves (see in - st r uc ti on s to t he l e[...]
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Seite 28
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 28 Part Number 550-110-711/1108 Piping — low temperatur e systems 4d SYSTEM-bypass piping method This piping method is cal led a system-bypass be cause part of the circulat or flo w b ypasses the system (through valve 7a ). T his bypassed hot wa ter fro m the b oiler ou tlet mix es with coole[...]
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Seite 29
Part Number 550-110-711/1108 29 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 3 Systemo rzonecirculator 7 Systemtemperaturev alv es (seeinst ructions tothe left for adjusting valv es) 8 Blendtemperaturegauge 9 Relief valve 10 A utomatic air vent (w ith diaphragm-t ype expan- sion tank), or connec[...]
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Seite 30
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 30 Part Number 550-110-711/1108 Gas piping 5 T able 7 Pipe capacity for 0.60 specific gravity natural gas Natural Gas: 1. R efer to T able 7 forpipelengthanddiamet er . Base on ra ted bo ile r inpu t (di vide by 1 ,00 0 to obta in cub ic feet per hour). T able 7 is only fo[...]
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Seite 31
Part Number 550-110-711/1108 31 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Field wiring 6 Thermostat 1. Connect thermostat as shown on wir ing diagram on boiler . 2. Install on inside wall aw ay from influences of draf ts, hot or cold water pipes, lighting fixt ures, television, sunra ys, or fir eplaces. 3. If[...]
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Seite 32
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 32 Part Number 550-110-711/1108 Start-up — pr eparation 7a Check for gas leaks Beforestarting the boiler ,and dur - ing initial operation, smell near the floor and around the boiler for gas odor ant or any unusu al odor . Do not proc eed w ith start-up if [...]
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Seite 33
Part Number 550-110-711/1108 33 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Fill the system with water 1. Closemanualandautomatic air vents and boiler drain cock. 2. Fill to correct system pressure. Correct pressure wil l var ywitheac h application. T y pical cold water fill pressure for a residential[...]
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Seite 34
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 34 Part Number 550-110-711/1108 Start-up — operate boiler 7b DO NO T proceed with boiler op er at io n un le ss b oil er a nd system h av e be en fill ed w ith water and all instructions an d pr oce du res of pr ev io us m an u a l s e c t i on s h av e b e e n com pl ete d. F ail ure to d o [...]
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Seite 35
Part Number 550-110-711/1108 35 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Figure 29 T ypical main burner flame Check bur ner flames V iew pilot and ma in a mes through the i nspection port in the base burner shield. Pilot burner flame ( Figure 28 ) PROPER pilot flame characteristics 1. Blueame[...]
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Seite 36
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 36 Part Number 550-110-711/1108 Start-up — if boiler doesn’ t start . . . 7c 1. Loose conne ctio ns, bl own fuse or s er vice sw itch off? 2. High limit switch set below boiler water tempera - ture? 3. Thermostat set below room t emperature? 4. Gasnotturned[...]
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Seite 37
Part Number 550-110-711/1108 37 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Check-out pr ocedur e — checklist 8 ❏ Boilerandheatdistributionunitslledw ithwater? ❏ A utomatic air v ent, if used, o pen one full turn? ❏ Air purged from sy stem? ❏ Air purged from gas piping? Piping c hecked for lea[...]
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Seite 38
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 38 Part Number 550-110-711/1108 Operation — sequence 9a 1. Read Operating instr uctions on pa ge 4 1. This inf ormation is also located on a label on the inside o f the boiler jacket d oor panel. 2. Raise room thermostat t o call for heat. 3. Cir culator energizes. If limit circuit is closed, [...]
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Seite 39
Part Number 550-110-711/1108 39 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Figure 30 Control module sequence of operation — status light indications[...]
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Seite 40
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 40 Part Number 550-110-711/1108 Operation — wiring diagrams 9b Figure 31 Wiring diagram[...]
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Seite 41
Part Number 550-110-711/1108 41 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 9c Operating instructions • Spark pilot • Natural or propane gas • Gas valve: Hone ywell VR8204/VR8304[...]
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Seite 42
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 42 Part Number 550-110-711/1108 Addendum Instruction for the Commonwealth of Massachusetts T hi s a d de n d um m u s t o n l y be u s ed b y a qualified heating installer/ser vice t echnician. Read th ese in str uct ion s com ple tely be fore beginning the installation. F ailure to comply coul[...]
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Seite 43
Part Number 550-110-711/1108 43 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T able 8 Service and maintenance schedules Service and maintenance — schedule 10a Follo w the Service and maint enance procedur es given throughout this manual and in component literature shipped with the boiler . Failur e to perform the service and maintenance [...]
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Seite 44
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 44 Part Number 550-110-711/1108 Air openings 1. V erify th at c ombustio n and v entilation air openings to the boiler room and/or building are open and unobstr ucted . 2. V erify that boiler v ent discharge is clean and fr ee of obstr uctions . Fl[...]
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Seite 45
Part Number 550-110-711/1108 45 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual ❏ Inspect . . . Burners and base Th e b oil er cont ain s c era mic fib er and fib erg las s m ater ial s. Use ca re when handling these materials per instructions on page 68 o f t h is ma nua l. Fa ilu re to c omp ly co ul d result in seve re personal injury [...]
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Seite 46
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 46 Part Number 550-110-711/1108 10b ❏ Check/test . . . Gas piping 1. Sniff near oor andaround boilerarea foranyin - dication of a gas leak . 2. T est gas piping using bubble test, perSect ion 5 of this manual, if there is any indication of a leak. Co[...]
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Seite 47
Part Number 550-110-711/1108 47 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual ❏ Review with owner 1. R ev iew the User’ s Information Manual w ith the owner . 2. Emphasize the need to perform the maintenance schedule sp ecified in the User’ s Information Manual (and in this manual as well). 3. R emind the owner of the need to call in [...]
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Seite 48
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 48 Part Number 550-110-711/1108 T r oubleshooting — general 11a Air pr essure switch Mak e sure boiler water temperature is 100 °F or cooler before starting proce- dure t o obtain appropriate readings. The boiler w ill not operate correctly un - less pressur e sw itc h hoses are correctly loc[...]
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Seite 49
Part Number 550-110-711/1108 49 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — components 11b Figure 36 Manometer connections Contr ol module Solder or water splatter b etween plugs and circuit board can c ause improper operation of control mod - ule. Pl ace a shi eld over th e boi ler internal controls and components d[...]
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Seite 50
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 50 Part Number 550-110-711/1108 T r oubleshooting — components (continued) 11b Figure 38 Control module connections[...]
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Seite 51
Part Number 550-110-711/1108 51 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights 11c CHART 1 — Troubleshooting POWE R light status Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Fa ilure to follow instructions coul d result in severe personal i njury, death o[...]
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Seite 52
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 52 Part Number 550-110-711/1108 T r oubleshooting — control module lights (cont.) 11c Electrical shock ha za rd — Wherever you see TURN OFF PO WER , follow the instructions. Failu re to follow instructions could result in severe personal inju ry, death or substantia l property damage. CHART [...]
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Seite 53
Part Number 550-110-711/1108 53 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 3 — PRESS SWITCH & POWER lights flashing Electrical shock ha za rd — Wherever you see TUR N OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal in[...]
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Seite 54
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 54 Part Number 550-110-711/1108 T r oubleshooting — control module lights (cont.) 11c • Turn off power to the boiler at service switch or brea ker. • Wait at least 45 seco nds. • Turn on powe r to boiler. • Restart boiler, follo wing Operating instruc tions i n this manual (Section 9c [...]
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Seite 55
Part Number 550-110-711/1108 55 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 5 — PR ESS SWITCH light flashing and POWER light on steady Electrical shock ha za rd — Wherever you see TUR N OFF POWER , follow the instructions. Failure to follow instructions could result in seve[...]
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Seite 56
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 56 Part Number 550-110-711/1108 T r oubleshooting — control module lights (cont.) 11c • TURN OFF POWER to boiler at service switch or breaker. • Remove burner shield (see Figure 40, item 4 , page 60 for location). • Verify inlet gas pressure at gas valve: Natural gas — 5.0" w.c. m[...]
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Seite 57
Part Number 550-110-711/1108 57 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 7 — Insufficient heat or no heat to system ( POWER light on steady) Electrical shock ha za rd — Wherever you see TURN OFF PO WER , follow the instructions. Failu re to follow instructions could resu[...]
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Seite 58
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 58 Part Number 550-110-711/1108 Replacement parts 12a R eplacement parts must be purchased through a local W eil-McLain distributor . W hen ordering, specify boiler model and size and include description and part number of replaceme nt part. Results fr om using modified or other man ufactured p[...]
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Seite 59
Part Number 550-110-711/1108 59 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — section assembly 12b Figure 39 Section assembly Item number Description Weil-McLain part number 1 End section, left hand, 51 124 31 1-1 03-850 2 End section, right hand 51 128 31 1-1 03-821 3 Intermediate section, 51 125 31 1-1 03-81 8 not sh[...]
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Seite 60
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 60 Part Number 550-110-711/1108 Replacement parts — base 12c Figure 40 Base assembly[...]
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Seite 61
Part Number 550-110-711/1108 61 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — base (continued) 12c Item Description W eil-McLain part number Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6 and 7) CGi-4E 381 -354-338 1 Base side panel (in Base assembly) 2 Base front cross-tie assembly (in Base assembly) 3[...]
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Seite 62
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 62 Part Number 550-110-711/1108 Replacement parts — jacket 12d Figure 41 Jacket assembly[...]
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Seite 63
Part Number 550-110-711/1108 63 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — jacket (continued) 12d Boiler Model 1 2 3 4 5 Boiler Model Junction bo x, 2 x 4 P anel, left side, with insulation Panel, right side, with insulation P anel, top front, with insulation Panel, top rear , with insulation Natural Gas Propane Gas[...]
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Seite 64
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 64 Part Number 550-110-711/1108 Replacement parts — trim 12e Figure 42 T rim assembly Item number Description Manufacturer Manufacturer’ s part number W eil-McLain part number 1 Pressure relief valv e, ASME, 30 PSIG, ¾” male inlet Pressure relief valv e, ASME, 30 PSIG, ¾” f emale inlet[...]
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Seite 65
Part Number 550-110-711/1108 65 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — contr ols 12f Figure 43 Gas control assembly Item number Description Boiler model Manufacturer Manufacturer’ s part number Weil-McLain part number Natural gas components 1 Gas valve, ½” x ½” , two-state CGi-4E Honeywell VR8204Q2434 51[...]
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Seite 66
GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual 66 Part Number 550-110-711/1108 Dimensions 13a Figure 44 Dimensional drawing Boiler model number Supply tapping (inc hes NPT) Return tapping (inc hes NPT) Gas connection size Note 3 (inc hes NPT) Gas manifold siz e Note 3 (inc hes NPT) “W” Jac ket width (inc hes) CGi-4E 1 ¼ 1 ¼ ½ ½ 13 No[...]
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Seite 67
Part Number 550-110-711/1108 67 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Ratings T able 10 Boiler ratings 13b CGi-4E boilers for residential r adiant panel systems, conv erted gravit y heating systems or other low water temperature applications should be installed w ith balancing valves[...]
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Seite 68
68 Part Number 550-110-711/1108 GOLD CGi-4E Gas-Fired W ater Boiler — Boiler Manual Handling ceramic fiber and fiber glass materials REMOV AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The co mbu sti on cha mbe r lini ng or bas e insulation panels in this pr oduct c on- tainceramicbermat erials.C eramic fibers c[...]