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Weil-McLain 550-110-710/0107 manuel d'utilisation

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  • Page 1

    P ar t No . 550-110-710/0107 This manual must only be used b y a qualified heating installer/serv ice t echnician. 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 pro[...]

  • Page 2

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 2 Part Number 550-110-710/0107 How it works . . . ① Control module The control module responds to sig nals from the r oom thermostat, air pressure switch and boiler limit circuit to operate the boiler circulat or , pilot burner , g as valve and inducer . Whe n room thermostat calls for heat, the [...]

  • Page 3

    Part Number 550-110-710/0107 3 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual GOLD CGi Gas-Fir ed Induced-Draft W ater Boiler[...]

  • Page 4

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 4 Part Number 550-110-710/0107 Contents How it works .................................................... 2–3 Hazar d definitions ............................................... 4 Please r ead before pr oceeding ............................ 5 1 Pr epare boiler location ..........................[...]

  • Page 5

    Part Number 550-110-710/0107 5 GOLD CGi 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. • C ontinual fresh makeup water will reduce boiler life. Mine ral buildup in sections re- duces heat tran[...]

  • Page 6

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 6 Part Number 550-110-710/0107 Pr epar e boiler location — codes & checklist 1a Installations must follow these codes: • L ocal, state, pr ovincial, and national c odes, la ws, regulations and ordinanc es. • N ational F uel Gas Code, ANSI Z223.1–latest edition. • Standar d for Control[...]

  • Page 7

    Part Number 550-110-710/0107 7 GOLD CGi 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 ser vicing the boiler and for access to c [...]

  • Page 8

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 8 Part Number 550-110-710/0107 Pr epar e boiler location — vent system 1c Failur e to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. W he n r em o vi n g b oi l e r f r o m a n e xi s ti n g c o mm o n v en t sy s t[...]

  • Page 9

    Part Number 550-110-710/0107 9 GOLD CGi 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 rev iew the following information on potential combustion air c ontamination problems. R efer to T able 1 fo r pr oduct s a nd a reas whic h m[...]

  • Page 10

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 10 Part Number 550-110-710/0107 Figure 5 Air fr om o utdoo rs — hori zont al du cts 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 — Ai r su pply fr om ins ide the buil din g ✷[...]

  • Page 11

    Part Number 550-110-710/0107 11 GOLD CGi 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 an d ceili ngs expo sed to th e out side at mo- sphere have a continuous water vapor retarder w ith a rating of 1 perm or less w ith openings gasketed, [...]

  • Page 12

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 12 Part Number 550-110-710/0107 Pr epar e boiler — placement & setup 2a T able 2 Manifold orifice sizing at sea level and altitudes to 4,500 feet Place boiler/crate near position 1. Lea ve boiler in crate and on palle t unt il instal lation sit e is ready . 2. M ove entir e crate and pallet [...]

  • Page 13

    Part Number 550-110-710/0107 13 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler — pr essure test Hydr ostatic pressur e test Pr essure tes t boil er bef or e attaching water or gas piping (ex cept as noted below) or electrical supply . Prepar e boiler for test 1. R emove the shipping nipple (from CGi suppl y tap - pin g) and r[...]

  • Page 14

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 14 Part Number 550-110-710/0107 V enting — general information 3a CGi venting methods — Chimney draft or Dir ect exhaust Chimney draft venting Chimney draft venting uses the natural draft provided by a v erti cal ve nt or ch imney . Cat ego ry I ap pli anc e (non- positive ve nt stat ic pressur[...]

  • Page 15

    Part Number 550-110-710/0107 15 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual V enting — Dir ect exhaust — components 3c Obtain vent system components 1. The following special g as vent systems c omply w ith UL-1738 and UL C- S636 standards and are c ertified by CSA as the only syst ems suitable fo r use with CGi boilers (all 3” diamete[...]

  • Page 16

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 16 Part Number 550-110-710/0107 V enting — dir ect exhaust — vent starter 3d 1. Select a vent pipe man ufacturer and obtain all vent components ne eded, based on boiler location and venting method. 2. Y ou must use the vent starter made b y the v ent pipe manufacturer . See separate CGi, CGs &a[...]

  • Page 17

    Part Number 550-110-710/0107 17 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Fol lo w i ns tr u ct i on s o n t hi s p ag e when determining vent locat ion to av oid possibility of sever e personal inj ur 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 page [...]

  • Page 18

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 18 Part Number 550-110-710/0107 V enting — dir ect exhaust — installation 3f 1. Do not mix t ypes or manufactur ers of vent materi- als. 2. Clean all j oints before sealing. See vent manufactur - er’ s instructions for c leaning and sealing joints. U se their specified sealant. Do not use sc[...]

  • Page 19

    Part Number 550-110-710/0107 19 GOLD CGi 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[...]

  • Page 20

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 20 Part Number 550-110-710/0107 W ater piping — general information 4a General piping information If installation is to c omply with ASME or Canadian requir ements, an ad- ditional high t emperatur e limit is needed. Install c ontrol in suppl y piping between boiler and isolation valve. Set secon[...]

  • Page 21

    Part Number 550-110-710/0107 21 GOLD CGi 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 possibl[...]

  • Page 22

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 22 Part Number 550-110-710/0107 4c Piping multiple zones Follo w instruc tions on pages 20 and 21 to install near- boiler or single-zone piping. (Also re fer to Piping for radiant heating systems or conv ert ed gravity sys- tems , below , if applicable.) See Figure 1 8 or Figur e 19 to c omplete in[...]

  • Page 23

    Part Number 550-110-710/0107 23 GOLD CGi 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 Boiler isolation (balancing) valv es 2 Flow/chec k valve 3 Syst em or zone circulat or 5 Zone valv e 6 Drain valve 9 Relief v[...]

  • Page 24

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 24 Part Number 550-110-710/0107 4d Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or burners, resulting in sever e personal injur y , death or substantial property damage. Radiant heating system piping should include a means of regulatin[...]

  • Page 25

    Part Number 550-110-710/0107 25 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 1 Boiler isolation (balancing) valv es 2 Flow/chec k valve 3 Syst em or zone circulat or 4 System t emperature gauges 5 Zone valv e 6 Drain valve 7 Sy stem temperatur e val ves (see instruc- tions to the left for adjusting val ves) 8 Blend temperature gauge 9 Relief [...]

  • Page 26

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 26 Part Number 550-110-710/0107 BOILER-bypass piping method This piping method ( Figure 22 or 23 ) is called a boiler - bypass because part of the circulator flow is b y passed arou nd th e b oile r ( thro ugh va lve 7 a ). Th is me tho d reduces the flow rate throughout the boiler , in order to [...]

  • Page 27

    Part Number 550-110-710/0107 27 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 1 Boiler isolation (balancing) valv es 2 Flow/check val ve 3 Syst em or zone circulat or 4 Syst em temperature gauges 5 Zone valv e 6 Drain valve 7 Syste m te mpe rat ure va lves (s ee in - st r uc ti on s to t he l ef t fo r a dj us ti ng valves) 8 Blend temperature[...]

  • Page 28

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 28 Part Number 550-110-710/0107 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 val ve 7a ). This bypassed ho t wa ter fr om the b oiler outl et mix es with cooler [...]

  • Page 29

    Part Number 550-110-710/0107 29 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 3 System o r zone circulator 7 System temperature v alv es (see inst ructions to the left for adjusting valv es) 8 Blend temperature gauge 9 Relief valve 10 A utomatic air vent (w ith diaphr agm-ty pe expan- sion tank), or connect to tank fitting (closed-typ e ex pa[...]

  • Page 30

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 30 Part Number 550-110-710/0107 Gas piping 5 T able 7 Pipe capacity for 0.60 specific gravity natural gas Natural Gas: 1. R efer to T able 7 for pipe length and diamet er . Base on ra ted b oile r inpu t (di vide b y 1,00 0 to obtai n cubi c feet per hour). T able 7 is o nly for gas with specific[...]

  • Page 31

    Part Number 550-110-710/0107 31 GOLD CGi 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 thermostat has a heat antic[...]

  • Page 32

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 32 Part Number 550-110-710/0107 Start-up — pr eparation 7a Check for gas leaks Before starting 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 ther e is any indication of a gas leak[...]

  • Page 33

    Part Number 550-110-710/0107 33 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Fill the system with water 1. Close manual and aut omatic air vents and boiler drain cock. 2. Fill to correct system pressure. Correct pressure wil l var y with eac h application. T y pical cold water fill pressure for a residential system is 12 psi. 3. Purge air fr[...]

  • Page 34

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 34 Part Number 550-110-710/0107 Start-up — operate boiler 7b DO NOT proceed with boiler op er at io n u nl es s b oil er a nd system h a ve be en fille d wit h w a t e r a n d a l l i n s t r u c t i o n s an d p roce du res o f p re vi ou s m an u a l s e ct i o n s h ave b e e n com pl ete d. [...]

  • Page 35

    Part Number 550-110-710/0107 35 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Figure 29 T ypical main burner flame Check bur ner flames V iew pilot and ma in fla mes through the i nspection port in the base burner shield. Pilot burner flame ( Figure 28 ) PROPER pilot flame characteristics 1. Blue flame. 2. Inner c one engulfing pilot ?[...]

  • Page 36

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 36 Part Number 550-110-710/0107 Check-out pr ocedur e — checklist 8 ❏ Boiler and heat distribution units filled w ith water? ❏ 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 leaks? ❏ Correc[...]

  • Page 37

    Part Number 550-110-710/0107 37 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Operation — sequence 9a Figure 30 Control module sequence of operation — status light indications 1. Read Operating instr uctions o n p age 40 . Th is information is also located on a label on the inside of the boiler jack et door panel. 2. Raise room the rmostat[...]

  • Page 38

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 38 Part Number 550-110-710/0107 Operation — wiring diagrams 9b Figure 31 Schematic wiring diagram[...]

  • Page 39

    Part Number 550-110-710/0107 39 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Figure 32 Ladder wiring diagram[...]

  • Page 40

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 40 Part Number 550-110-710/0107 9c Operating instructions CGi-25 to CGi-6 • Spark pilot • Natural or propane gas • Gas valve: Hone ywell VR8204/VR8304[...]

  • Page 41

    Part Number 550-110-710/0107 41 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 9c Operating instructions CGi-25 to CGi-6 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36E[...]

  • Page 42

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 42 Part Number 550-110-710/0107 9c Operating instructions CGi-25 to CGi-8 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36C[...]

  • Page 43

    Part Number 550-110-710/0107 43 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T able 8 Service and maintenance schedules Service and maintenance — schedule 10a Follo w the Service and maintenance procedur es given throughout this manual and in com- ponent literature shipped w ith the b oiler . Failure to perform the ser vice and maintenanc e[...]

  • Page 44

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 44 Part Number 550-110-710/0107 Air openings 1. V erify that comb ustion and v entilati on air open ings to the boiler room and/or building are open and unobstr ucted . 2. V erify that boiler vent discharge is clean and free of obstr uctions . Flue gas vent system 1. Visually inspect entire flue g[...]

  • Page 45

    Part Number 550-110-710/0107 45 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual ❏ Inspect . . . Burners and base Th e b oil er con tain s cer ami c fi ber and fib erg las s m ater ial s. U s e ca re when handling these materials p er i ns t r uc t io n s o n p a g e 6 8 o f t h is ma nua l. Fa ilu re t o c omp ly co ul d result in seve re pe[...]

  • Page 46

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 46 Part Number 550-110-710/0107 10b ❏ Check/test . . . Gas piping 1. Sniff near floor and around boiler area for an y in- dication of a gas leak . 2. T est gas piping using bubble test, per Sect ion 5 of this manual, if there is any indication of a leak. Cold fill and operating pressur es 1. W [...]

  • Page 47

    Part Number 550-110-710/0107 47 GOLD CGi 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 s c h e du l e s p e c i f i e d i n t h e User’ s Information Manual (and in this manual as well). 3. R emind the owner of the nee[...]

  • Page 48

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 48 Part Number 550-110-710/0107 T r oubleshooting — components 11b T r oubleshooting — procedur e 11a Air pr essure switch Mak e sure boiler water t emperature is 100 °F or cooler before start ing procedur e to obtain appr opriate r ead- ings. The boi ler wil l not oper ate correctly unl ess p[...]

  • Page 49

    Part Number 550-110-710/0107 49 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — components (continued) 11b Figure 36 Manometer connections Contr ol module Solder or wat er splat ter be tween plugs and circuit board ca n cause imp r ope r ope rati on of con tr ol mod- ule. Pl ace a shi eld over th e boi ler internal controls[...]

  • Page 50

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 50 Part Number 550-110-710/0107 T r oubleshooting — components (continued) 11b Figure 38 Control module connections[...]

  • Page 51

    Part Number 550-110-710/0107 51 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights 11c CHART 1— Troubleshooting POWER light status Electrical shock hazard — Wherever you see ▲ TURN OFF PO WER ▲ , follow the instructions. Failure to follow instructions could result in severe personal injury, death [...]

  • Page 52

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 52 Part Number 550-110-710/0107 T r oubleshooting — control module lights (cont.) 11c 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. CHART 2[...]

  • Page 53

    Part Number 550-110-710/0107 53 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 3 — PR ESS SWITCH & POWER lights flashing Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructions could result in severe personal[...]

  • Page 54

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 54 Part Number 550-110-710/0107 T r oubleshooting — control module lights (cont.) 11c • 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 instr uctions in this manual (Section 9c ). • L[...]

  • Page 55

    Part Number 550-110-710/0107 55 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — control module lights (cont.) 11c CHART 5 — P RESS SWITCH light flash ing and POWER light on steady Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructions could result in s[...]

  • Page 56

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 56 Part Number 550-110-710/0107 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. min [...]

  • Page 57

    Part Number 550-110-710/0107 57 GOLD CGi 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 hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructions could res[...]

  • Page 58

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 58 Part Number 550-110-710/0107 Replacement parts 12a Section assembly .............................................. 59 Base ................................................................. 60 Jacket .............................................................. 62 T rim .........................[...]

  • Page 59

    Part Number 550-110-710/0107 59 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Replacement parts — section assembly 12b Figure 39 Section assembly[...]

  • Page 60

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 60 Part Number 550-110-710/0107 Replacement parts — base 12c Figure 40 Base assembly[...]

  • Page 61

    Part Number 550-110-710/0107 61 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Item Description W eil-McLain part number Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6 and 7) CGi-25 & CGi-3 CGi-4 CGi-5 CGi-6 CGi-7 CGi-8 381-354-337 381-354-338 381-354-339 381-354-340 381-354-341 381-354-342 1 Base side panel (in Base assem b[...]

  • Page 62

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 62 Part Number 550-110-710/0107 Replacement parts — jacket 12d Figure 41 Jacket assembly[...]

  • Page 63

    Part Number 550-110-710/0107 63 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Boiler Model 1 2 3 4 5 Boiler Model Junction box, 2 x 4 Panel, left side , with insulation Panel, right side , with insulatio n Panel, top front , with insulation Panel, top rea r , with insulation Natural Gas Pr opane Gas W eil-McLain part number CGi-25 CGi-3 CGi-4 [...]

  • Page 64

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 64 Part Number 550-110-710/0107 Replacement parts — trim 12e Figure 42 T rim assembly Item number Description Manu facturer Ma nufact urer’ 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" female [...]

  • Page 65

    Part Number 550-110-710/0107 65 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Replacement parts — contr ols 12f Figure 43 Gas control assembly Item number Description Boiler model Manufacturer Manufactu rer’ s part number Weil-McLain part number Natural gas components 1 Gas valve, ½" x ½" Gas valve, ¾" x ¾" CGi-25 ?[...]

  • Page 66

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 66 Part Number 550-110-710/0107 Dimensions 13a Figure 44 Dimensional drawing[...]

  • Page 67

    Part Number 550-110-710/0107 67 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Ratings T able 10 Boiler ratings DOE 13b CGi boilers fo r r esidential radiant panel systems, con verted gr a vit y heating sy stems or other low water tempera- ture applications should be installed w ith balancing valves and by pass piping equal to the supply and re[...]

  • Page 68

    GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 68 Part Number 550-110-710/0107 Handling ceramic fiber and fiber glass materials REMOV AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The combustion chamber l ining or base insulation pane ls in this prod- uct contain ceramic fib er materials. C er a m i c f i b e rs c a n b e c onv e r te d t [...]