Weil-McLainメーカーGOLD CGI 550-110-710/0107の使用説明書/サービス説明書
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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.
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 .
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.
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 .
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.
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.
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.
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.
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.
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 open.
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.
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 .
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 .
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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 ).
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.
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 ).
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 Bl.
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).
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.
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 .
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.
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.
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.
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 utomati.
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.
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.
Part Number 550-110-710/0107 39 GOLD CGi Gas-Fired W ater Boiler — Boiler Manual Figure 32 Ladder wiring diagram.
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.
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.
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.
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 .
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 .
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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 .
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.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 60 Part Number 550-110-710/0107 Replacement parts — base 12c Figure 40 Base assembly.
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-2.
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 62 Part Number 550-110-710/0107 Replacement parts — jacket 12d Figure 41 Jacket assembly.
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 i.
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 par.
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 .
GOLD CGi Gas-Fired W ater Boiler — Boiler Manual 66 Part Number 550-110-710/0107 Dimensions 13a Figure 44 Dimensional drawing.
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 h.
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.
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