Weil McLain GOLD CGI 4E User Manual

®
GOLD CGi-4E  
Gas-Fired Water Boiler  
• Installation • Maintenance  
Boiler Manual  
• Startup  
• Parts  
This manual must only be used by a qualified heating installer/service technician. Before installing, read all  
instructions, including this manual, the burner manual and any related supplements. Perform steps in the order  
given. Failure to comply could result in severe personal injury, death or substantial property damage.  
DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free air to the boiler area or  
follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub-  
stantial property damage.  
Part No. 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
GOLD CGi-4E Gas-Fired Induced-Draft Water Boiler  
3
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Contents  
How it works ....................................................2–3  
Hazard definitions ............................................... 4  
Please read before proceeding............................ 5  
1 Prepare boiler location...................................6–11  
2 Prepare boiler...............................................12–13  
3 Venting.........................................................14-19  
4 Water piping.................................................20-29  
5 Gas piping ......................................................... 30  
6 Field wiring ....................................................... 31  
7 Start-up........................................................32-36  
8 Check-out procedure — checklist...................... 37  
9 Operation .....................................................38-42  
10 Service and maintenance .............................43-47  
11 Troubleshooting............................................48-57  
12 Replacement parts .......................................58-65  
13 Dimensions and ratings................................66-67  
Hazard definitions  
The following defined terms are used throughout this manual to bring attention to the presence of hazards of  
various risk levels or to important information concerning the life of the product.  
Indicates presence of hazards that will cause severe personal injury, death or substantial  
property damage.  
Indicates presence of hazards that can cause severe personal injury, death or substantial  
property damage.  
Indicates presence of hazards that will or can cause minor personal injury or property dam-  
age.  
Indicates special instructions on installation, operation or maintenance that are important but  
not related to personal injury or property damage.  
4
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Please read before proceeding  
Installer  
User  
Read all instructions before in-  
stalling. Follow all instructions in  
proper order to prevent personal  
injury or death.  
This manual is for use only by your qualified  
heating installer/service technician.  
Please refer to the User’s Information Manual for  
your reference.  
Considerpiping and installation when determining  
We recommend regular service by a qualified  
service technician, at least annually.  
boiler location.  
Any claims for damage or shortage in shipment  
must be filed immediately against the transportation  
company by the consignee.  
The boiler contains ceramic fiber and fiberglass materials. Use care when handling these  
materials per instructions on page 68 of this manual. Failure to comply could result in severe  
personal injury.  
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 37.  
Failure to adhere to the guidelines on this page can result in severe personal injury, death  
or substantial property damage.  
Continual fresh makeup water will reduce  
boiler life. Mineral buildup in sections re-  
duces 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.  
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 add cold water to hot boiler.Thermal  
shock can cause sections to crack.  
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.  
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:  
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.  
Never store glycol of any kind near the boiler  
or any potential ignition source.  
Boiler water —  
Monitor and inspect the system and boiler  
regularly for leakage. Repair any leaks im-  
mediately to prevent possible accumulation  
of glycol.  
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.  
Never use automotive antifreeze or ethylene  
glycol in the system. Using these glycols can  
lead to hazardous leakage of glycol in the  
boiler system.  
Do not use “homemade cures” or “boiler patent  
medicines. Serious damage to boiler, personnel and/  
or property may result.  
5
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Prepare boiler location — codes & checklist  
1a  
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-4E boiler gas manifold and controls met safe lighting  
and other performance criteria when boiler underwent tests  
specified in ANSI Z21.13–latest edition.  
Read and follow the special instructions for the Commonwealth  
of Massachusetts, located on page 42 of this manual.  
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, or other contaminants.  
Failure to keep boiler area clear and free of combustible mate-  
rials, gasoline and other flammable liquids and vapors can  
result in severe 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.  
6
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Prepare boiler location — clearances  
1b  
Recommended SERVICE clearances  
Figure 1b Required MINIMUM clearances  
(Fig. 1a)  
1. Provide clearances for cleaning and servicing the boiler and for  
access to controls and components. See Figure 1a for recommen-  
dations.  
2. Provide at least screwdriver clearance to jacket front panel screws  
for removal of front panel for inspection and minor service. If  
unable to provide at least screwdriver clearance, install unions and  
shutoff valves in system so boiler can be moved for servicing.  
Figure 1a  
Recommended  
SERVICE clearances  
(see WARNING  
below)  
Flooring  
The CGi-4E boiler is approved for installation on combus-  
tible 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.  
If any clearance is less than in Figure 1a, pro-  
vide openings for combustion and ventilation  
air located on the wall or door opposite the  
boiler FRONT (see Figure 1b).  
These openings must be located as shown in Figure 1b to provide  
proper air flow around the boiler. The free area of each opening  
(after deducting for louvers) must be at least one square inch per  
1,000 Btuh of boiler input. If the building is of unusually tight  
construction (see page 11 for definition), the air openings must  
connect directly to outside or the building must have air openings  
to the outside as specified on page 11.  
Foundation  
1. Provide a solid brick or minimum 2-inch thick concrete  
foundation pad if any of the following is true:  
floor can become flooded.  
the boiler mounting area is not level.  
If clearances are equal to or greater than Figure 1a, see pages 10  
and 11 for location and sizing of combustion air openings.  
2. Minimum dimensions are 25” length by:  
Failure to comply can result in severe personal injury, death or  
substantial property damage and reduced boiler life.  
Minimum foundation width:  
CGi-4E  
15”  
Required MINIMUM clearances (Fig. 1b)  
Never install the boiler in a space with clear-  
ances less than the minimum clearances shown  
in Figure 1b. Failure to comply can result in severe  
personal injury, death or substantial property dam-  
age and reduced boiler life.  
Residential garage installations  
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:  
Mount the boiler a minimum of 18 inches above the  
floor of the garage to assure the burner and ignition  
devices will be no less than 18 inches above the floor.  
1. Hot water pipes: at least ¹⁄₂ inch from combustible material.  
2. Single-wall vent pipe: at least 6 inches from combustible mate-  
rial.  
3. Type B double-wall metal vent pipe: refer to vent manufacturer’s  
recommendation for clearances to combustible material.  
Locate or protect the boiler so it cannot be damaged  
by a moving vehicle.  
7
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Prepare boiler location — vent system  
1c  
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 COMMON VENT — Do not install the CGi-4E 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 an  
existing common vent system:  
Chimney or vent require-  
ments  
1. Venting must be installed according to Part 7,  
Venting of Equipment, of National Fuel Gas  
Code, ANSI Z223.1-latest edition and appli-  
cable building codes. Canadian installations  
must comply with B149.1 or B149.2 Installation  
Codes.  
At the time of removal of an existing boiler, the following  
steps shall be followed with each appliance remaining con-  
nected 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.  
2. See Ratings table on page 67 for minimum chim-  
ney or vent sizes. A chimney or vent without a  
listed cap should extend at least 3 feet above  
the highest point where it passes through a roof  
of a building and at least 2 feet higher than  
any portion of a building within a horizontal  
distance of 10 feet.A chimney or vent must not  
extend less than the distances stated above.  
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.  
c. 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.  
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 non-  
corrosive materials are best.Advice for flue con-  
nections and chimney linings can be obtained  
from local gas utility. Type B double-wall metal  
vent pipe or single-wall vent pipe may be used  
as a liner.  
d. Place in operation the appliance being inspected.  
Follow the lighting/operating instructions. Adjust  
thermostat so appliance will operate continuously.  
4. Cold masonry chimneys, also known as outside  
chimneys, typically have one or more walls ex-  
posed 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. Con-  
densation can damage a masonry chimney.Weil-  
McLain recommends the following to prevent  
possible damage.  
e. 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 con-  
ditions of use.  
a. Line chimney with corrosion-resistant  
metal liner such as AL29-4C® single-wall  
stainless steel or B-vent. Size liner per Na-  
tional Fuel Gas Code ANSI Z223.1-latest  
edition.  
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 re-  
sizing 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 Instal-  
lation Code.  
b. Provide drain trap to remove any conden-  
sate.  
8
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Prepare boiler location — air contamination  
1d  
Please review the following information on potential Refer to Table 1 for products and areas which may cause  
combustion air contamination problems. contaminated combustion air.  
To prevent potential of severe personal injury or death, check for products or areas listed  
below before installing boiler. If any of these contaminants are found:  
remove contaminants permanently  
— OR —  
isolate boiler and provide outside combustion air. See national, provincial or local codes  
for further information.  
Table 1 Corrosive or destructive contaminants and likely locations  
Products to avoid  
Areas likely to have contaminants  
Spray cans containing chloro/fluorocarbons  
Permanent wave solutions  
Dry cleaning/laundry areas and establishments  
Swimming pools  
Chlorinated waxes/cleaners  
Metal fabrication plants  
Chlorine-based swimming pool chemicals  
Calcium chloride used for thawing  
Sodium chloride used for water softening  
Refrigerant leaks  
Beauty shops  
Refrigeration repair shops  
Photo processing plants  
Auto body shops  
Paint or varnish removers  
Plastic manufacturing plants  
Furniture refinishing areas and establishments  
New building construction  
Remodeling areas  
Hydrochloric acid/muriatic acid  
Cements and glues  
Antistatic fabric softeners used in clothes dryers  
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  
Buildings under construction (where air is  
contaminated with particulates)  
Airborne particulates (drywall dust, fiberglass  
particles, road or gravel dust, lint, etc.)  
CONSTRUCTION DUST HAZARD — Airborne particulates, such as drywall dust or  
fiberglass dust, will cause blockage of the CGi-4E burners, resulting in carbon monoxide  
production, a fire hazard, or building freeze damage. If the boiler is operated during  
construction, you must isolate the boiler to provide clean air for combustion. If you are  
unable to ensure uncontaminated air in the boiler vicinity at all times, you must  
inspect the boiler at least once weekly.When inspecting, clean the burners if necessary  
using the procedure given on page 45. Failure to follow these guidelines could result in  
severe personal injury, death or substantial property damage.  
9
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Prepare boiler location — air openings  
1e  
Figure 2  
Air openings to interior spaces  
Combustion air opening location and sizing  
requirements depend on the clearances around  
the boiler. Check the boiler placement compared to  
Figure 1a, page 7.  
If all clearances are at least equal to Figure 1a,  
page 7, apply the sizing and placement of openings  
given on pages 10 and 11.  
If ANY clearance is less than Figure 1a, page 7,  
you must provide air openings sized and located as  
shown in Figure 1b, page 7. DO NOT apply the sizing  
and location information shown on page 10 or 11.  
Figure 3  
Air directly through outside wall  
Air openings must be provided  
Combustion air and ventilation openings must comply the 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.  
Figure 4  
Air from outdoors — vertical ducts  
Air opening options  
Two openings — Air supply from inside the building  
1. If the building is of unusually tight construction (see definition, next  
page), the building must also be provided with air openings directly  
to the outside, sized and located per Figure 3, Figure 4 or Figure 5.  
2. Buildings of typical construction should provide adequate combustion  
air from natural infiltration, so additional air openings to the building  
are not required.  
3. See Figure 2. Provide two openings through the interior wall, within  
12 inches of the ceiling and the floor, sized per Figure 2.  
Two openings — Air supply directly from outside  
1. Air openings must be directly through an outside wall, or into a space  
that connects directly to the outside (such as a ventilated attic or crawl  
space, for example).  
Figure 5  
Air from outdoors — horizontal ducts  
2. See Figure 3 — Openings directly through an outside wall — provide  
two openings within 12 inches of the ceiling and the floor, sized per  
Figure 3.  
3. See Figure 4 — Air supplied through vertical ducts — provide two  
openings terminated within 12 inches of the ceiling and the floor, sized  
per Figure 4.  
4. See Figure 5 — Air supplied through horizontal ducts — provide  
two openings within 12 inches of the floor and the ceiling, sized per  
Figure 5.  
10  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Unusually tight construction  
FREE AREA of openings — the minimum areas  
Unusually tight construction means (perANSI Z223.1)  
given in this manual are free area (equals the area,  
buildings in which:  
length times width of opening, after deduction for  
louver obstruction).  
Use the free area information provided by the louver manufacturer.  
When this information is not available, assume:  
a. Walls and ceilings exposed to the outside atmo-  
sphere 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 . . .  
Wood louvers — assume free area is 20% of total; so the actual area  
of each opening with wood louvers would be 5 times the required  
free area.  
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.  
Metal louvers — assume free area is 60% of actual area; so, for wood  
louvers, the actual area of each opening must be 1.67 times the  
required free area.  
For such construction cases, if appliances use inside air  
for combustion, provide air openings into the building  
from outside. Size and locate these openings per the  
appropriate case in Figure 3, 4 or 5 on page 10.  
Single air opening option  
A single combustion air opening can be used in lieu of the two-opening  
options on page 10, provided:  
Clearances from boiler to walls  
The boiler must have clearances of at least those shown in Figure 1a,  
page 7.  
Exhaust fans and air movers  
Opening must be directly to outside  
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 appli-  
ances, but also to handle the air movement rate of the  
exhaust fans or air movers using air from the building  
or space.  
The opening must connect directly to the outdoors or to a space that  
communicates directly to the outdoors (not to an interior space).  
Theaircanbeprovidedthroughadirectopeningorthroughahorizontal  
or vertical duct.  
Opening placement  
The top of the air opening must be within 12 inches of the ceiling.  
Opening size  
The free area of the opening must be at least equal to the sum of the  
areas of all equipment vent connectors in the space, and . . .  
The free area of the opening must be at least 1 square inch per 3,000  
Btu/hr input rating of all equipment located in the space.  
Motorized air dampers  
If the air openings are fitted with motorized dampers,  
electrically interlock the damper to:  
Prevent the boiler from firing if the damper is not  
fully open.  
Shut the boiler down should the damper close dur-  
ing boiler operation.  
Exception for large spaces  
No combustion air openings are needed when the boiler (and other ap-  
pliances) are installed in a space with a volume at least 50 cubic feet per  
1,000 Btuh of all installed appliances, provided:  
To accomplish this interlock, wire an isolated contact  
(proving the damper open) in series with the thermo-  
stat input to the boiler. The boiler will not start if this  
contact is open, and will shut down should it open  
during operation.  
the building must not have unusually tight construction (see defini-  
tion, this page)  
all clearances around the boiler must must be no less than shown in  
Figure 1a, page 7.  
To determine if the space is large enough to qualify:  
Add the total input of all appliances in MBH (1,000’s of Btuh).  
Multiply this number times 50 to determine minimum room volume.  
Example: For a total input of 100 MBH (100,000 Btuh), minimum  
volume is 50 x 100 = 5,000 cubic feet. At a ceiling height of 8 feet, the  
space must have at least 5,000 ÷ 8 = 625 square feet (25 feet x 25 feet,  
for instance).  
11  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
2a  
Prepare boiler — placement & setup  
Do not operate boiler without  
Place boiler/crate near  
position  
burner shield in place. Failure  
to do so could result in severe  
personal injury, death or sub-  
stantial property damage.  
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.  
Orifice replacement  
4. Remove boiler from pallet.  
procedure  
Do not drop boiler or bump jacket on  
floor or pallet. Damage to boiler can  
result.  
(when required)  
1. Remove the screws securing the burner shield  
and remove burner shield.  
a. Tilt left side of boiler up and place a board under  
left legs.  
7
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.  
2. Using a /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 us-  
ing a 7/16open-end wrench. Make sure the ori-  
fices are aligned correctly, not cross-threaded  
in the manifold tappings.  
a. Shim legs, if necessary.  
b. Do not alter legs.  
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 dam-  
age.  
Inspect orifices and burners  
1. Remove front jacket door. Remove burner shield (see  
Figure 40, item 4, page 60).  
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 sub-  
stantial property damage.  
4. Carefully replace the burner shield.  
5. Follow the check-out procedure, Section 8,  
page 37, to assure the boiler is now operating  
properly after orifices are replaced.  
3. Reinstall burner shield.  
Table 2 Manifold orifice sizing at sea level and altitudes to 4,500 feet  
Location  
U. S.  
Natural gas  
Propane gas  
0-2,000 ft  
over 2,000 ft  
(Note 1)  
0-2,000 ft  
over 2,000 ft  
(Note 1)  
2.55 mm  
0-2,000 ft  
2.55 mm  
1.60 mm  
0-2,000 ft  
1.60 mm  
2,000-4,500  
#41  
2,000-4,500  
1.45 mm  
Canada  
Note 1: For elevations above 2,000 feet, contact your local Weil-McLain sales office for details.  
12  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
2b  
Prepare boiler — pressure test  
5. Slowly reopen boiler drain valve until test pressure  
Hydrostatic pressure test  
on the pressure/temperature gauge reaches no more  
than:  
Pressure test boiler before attaching water or gas piping  
(except as noted below) or electrical supply.  
45 psig for boilers with 30 psig relief valve.  
Prepare boiler for test  
75 psig for boilers with 50 psig relief valve.  
1. Remove the shipping nipple (from CGi-4E supply  
tapping) and remove the boiler relief valve. Tempo-  
rarily plug the relief valve tapping with a ¾” NPT  
pipe plug.  
6. 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.  
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 64. Install  
circulator on either the return or supply.  
3. Remove 1¼” nipple, 1¼” x 1¼” x ½” tee and pres-  
sure/temperature gauge from circulator hardware  
and pressure/temperature gauge carton. Pipe to  
boiler supply connection as shown on page 3 and  
Figure 42, page 64. (Use pipe dope sparingly.)  
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 main-  
tained 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.  
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 re-  
turn 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.)  
Do not use petroleum-based clean-  
ing 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.  
Fill and pressure test  
1. Open the shutoff valves you installed on supply and  
return connections.  
2. Drain boiler at drain valve or out hose, whichever  
provides best access to drain. Remove hose after  
draining if used to drain boiler.  
2. Slowly open boiler drain valve and fresh water sup-  
ply to fill boiler with water.  
3. When water flows from shutoff valves, close boiler  
drain valve.  
3. Remove nipples and valves unless they will remain  
for use in the system piping.  
4. Remove plug from relief valve tapping. See page 20  
4. Close shutoff valves.  
to replace relief valve.  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
3a  
Venting — general information  
CGi-4E venting methods — Chimney draft or Direct exhaust  
Chimney draft venting  
Direct exhaust — vertical or sidewall  
Direct exhaust venting uses inside combustion air with no com-  
bustion air connector piping. The CGi-4E flue gas vent is pressur-  
ized, 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.  
Chimney draft venting uses the natural draft provided by a ver-  
tical 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. Chimney draft  
installations use:  
1. Vent connector (single or doublewall) sized to eliminate posi-  
tive pressure in vent system. Diameter increases immediately  
at boiler.  
Direct exhaust installations use:  
1. Vent pipe specified in this manual.  
2. Doublewall metal vent (B-vent) or chimney with liner ap- 2. Vent termination through outside wall, roof or unused chim-  
proved by the National Fuel Gas Code, ANSI Z223.1–latest  
edition, or in Canada B149.1 or B149.2 Installation Code.  
ney. Tight chimney areas will make vent joint construction  
very difficult.  
3b  
Venting — chimney draft venting  
Inspect existing chimney before installing boiler. Failure to  
clean or replace perforated pipe or lining will cause severe  
personal injury or death.  
Boiler  
model  
number  
“D” Minimum  
vent connector  
diameter  
Table 3  
Vent  
connector  
diameter  
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.  
CGi-4E  
5”  
Figure 7  
1. Use doublewall metal vent (B-vent) or chimney with liner as  
required by the National Fuel Gas Code,ANSI Z223.1–latest  
edition, or in Canada, B149.1 or B149.2 Installation Code.  
Chimnney  
draft  
2. To prevent downdrafts, chimney should extend at least 3 feet  
above the highest point where it passes through a roof and  
at least 2 feet higher than any portion of a building within  
a horizontal distance of 10 feet.  
venting  
3. To vent with another appliance, see National Fuel Gas Code,  
ANSI Z223.1–latest edition or in Canada B149.2 or B149.2  
Installation Code  
4. Do not connect breeching to any portion of a mechanical  
draft system that can operate under positive pressure.  
5. Maintain minimum 2clearance from combustible materials  
to vent pipe.  
6. Do not use chimney with an open fireplace.  
7. Make horizontal runs as short as possible. Long runs can  
cause condensation.  
8. When longer runs are used, support pipe with appropriate  
hangers.  
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 fire-  
stopped.  
12. See Figure 7 and Table 3 to connect boiler to venting sys-  
tem.  
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Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
3c  
Venting — Direct exhaust — 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-4E boilers (all 3” diameter):  
Heat-Fab, Inc. Saf-TVent®  
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 separate Vent Supplement. All compo-  
nents, including the vent starter, must be of the same vent manufacturer.  
Do not mix components.  
Table 4 Maximum vent length (feet)  
Total number of elbows (Note 1)  
Max.vent  
length (feet)  
1
2
3
4
5
6
55  
48  
41  
34  
27  
20  
CGi-4E  
Note 1: Do not include termination fitting when counting total number of elbows.  
Read and follow the special instructions for the Com-  
monwealth of Massachusetts, located on page 42 of this  
manual.  
15  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
3d  
Venting — direct exhaust — vent starter  
1. Select a vent pipe manufacturer and obtain all vent 3. Follow all applicable national, state, local or provin-  
components needed, based on boiler location and  
venting method.  
cial codes when venting the CGi-4E boiler.  
4. Connect vent starter to blower housing outlet as  
2. You must use the vent starter made by the vent pipe  
manufacturer. See separate Vent Supplement, for  
part number of each component, listed by vent  
manufacturer.  
shown in the Figures 8 through 11.  
a. Do not mix components from different vent  
manufacturers.  
b. Maintain minimum 2” clearance from com-  
Use only the vent starter of the same  
manufacturer as the vent compo-  
nents. Do not mix components  
from different systems. The vent  
system could fail, causing flue gas  
spillage, resulting in severe personal  
injury or death.  
bustible 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.  
Figure 8  
Figure 10  
FasNSeal™  
ventstarter  
Saf-T Vent®  
vent starter  
Figure 9  
Figure 11  
Z-Vent II  
vent starter  
StaR-34  
vent starter  
16  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
3e  
Venting — direct exhaust — termination  
Follow instructions on this page 12. Canadian installations — See B149.1 or B149.2  
when determining vent location to  
avoid possibility of severe personal  
injury, death or substantial property  
damage.  
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 termi-  
1. Locate the boiler and vent penetration through the  
wall so all requirements on this page and in Fig-  
ure 12 will be met. Also follow vent manufacturer’s  
instructions.  
nate:  
more than 4 feet below or to side of all doors  
or windows.  
2. Gases will form white plume in winter.Plume could  
more than 1 foot above grade or anticipated  
snow line.  
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 freeze-up.  
at least 7 feet above public walkway.  
3 feet above any forced air intake within 10  
feet.  
14. Vent must also terminate:  
4. Winds over 40 mph can cause nuisance boiler shut-  
down if boiler is sidewall vented. This could result  
in loss of heat to building, causing freeze-up.  
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.  
5. Locate or guard vent termination to prevent con-  
densate 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.  
15. Site conditions may dictate greater clearances.  
16. Donotextendexposedventpipeoutsideof building.  
Condensate could freeze and block vent pipe.  
8. Do not terminate vent in window well, stairwell,  
alcove, courtyard, or other recessed areas.  
A gas vent extending through an  
exterior wall shall not terminate ad-  
jacent to the wall or below building  
extensions such as eaves, parapets,  
balconies or decks. Failure to com-  
ply could result in severe personal  
injury, death or substantial property  
damage.  
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.  
Figure 12 Vent termination minimum clearances  
17  
Part Number 550-110-711/1108  
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3f  
Venting — direct exhaust — installation  
1. Do not mix types or manufacturers of vent materi-  
Figure 13 Direct exhaust vertical venting  
als.  
2. Clean all joints before sealing. See vent manufac-  
turer’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 horizon-  
tal runs. Follow requirements in Section 3e for vent  
termination.  
4. Maintain minimum 2clearance from combustible  
materials to vent pipe.  
5. Vertical venting — See Figure 13. Follow vent  
manufacturer’s 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 snow line. Vent must be termi-  
nated only with:  
Tee or elbow with integral screen. (Tee may be  
mounted either vertically or horizontally.)  
Elbow and termination coupling with screen  
(not available for StaR-34).  
6. Do not seal vent pipe (slip connector for Saf-TVent)  
to inside or outside plate.  
7. If passing through noncombustible wall, provide  
hole diameter large enough to insert the vent pipe  
(slip connector for Saf-T Vent).  
8. Install horizontal drain tee as close as possible  
to boiler, in first horizontal run. See Figures 13  
and 14.  
Figure 14 Direct exhaust sidewall venting  
9. Do not exceed the maximum vent system length  
given in Table 4, page 15.  
Condensate drain line — use only siliconetubingrated  
for at least 400°F for the first 18” of condensate drain  
line, then other non-metallic tubing may be used. Us-  
ing any other material could cause flue gas leakage,  
potentially resulting in severe personal injury, death or  
substantial property damage.  
On some installations, the condensate drain fitting may  
be omitted, provided:  
Vent manufacturer shows this option in their instruc-  
tions.  
Vent is sloped toward termination as shown in dotted  
lines in Figure 14.  
• The vent is installed per Weil-McLain and vent  
manufacturer’s instructions.  
• Condensate drippage from such vents may accumu-  
late on the ground below. Consider traffic in the area  
to avoid hazard due to ice accumulation.  
18  
Part Number 550-110-711/1108  
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3f  
Venting — direct exhaust — installation  
(cont.)  
Using any termination other than one of those shown  
could cause nuisance outages and loss of heat, resulting  
in substantial property damage.  
Figure 15 Sidewall termination  
19  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
4a  
Water piping — general information  
General piping information  
Circulator  
If installation is to comply with ASME or Canadian requirements, an ad-  
ditional 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 for wiring.  
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 instal-  
lation. Pipe the expansion tank to the suction side of the  
circulator whenever possible. Install an air separator in  
A low water cutoff device is required when boiler is installed above ra- the supply piping.Connect the expansion tank to the air  
diation level or by certain state or local codes or insurance companies. Use  
low water cutoff designed for water installations. Electrode probe-type is  
recommended. Purchase and install in tee in supply piping above boiler.  
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.  
Use backflow check valve in cold water supply as required by local  
codes.  
System water piping  
Pressure/temperature gauge  
Install pressure/temperature gauge in tee on supply piping (as shown in  
drawing on page 3).  
See Figure 16 (diaphragm-type or bladder-type expan-  
sion tank) or Figure 17 (closed-type expansion tank)  
and Table 6, for near-boiler and single-zone systems  
designed for return water at least 130°F.  
Relief valve  
See pages 22-23 to complete multiple-zone piping or  
pages 24-29 to complete piping for radiant heating  
systems or converted gravity systems (large-volume  
systems originally designed for circulation by natural  
convection rather than a pump). See page 29 for boilers  
used with refrigeration systems.  
Install relief valve vertically in ¾” tapping on side of boiler. See Figure 16  
or 17, page 21, and the tag attached to the relief valve for manufacturer’s  
instructions.  
Table 6 Water pipe size (based on 20°F rise)  
To avoid water damage or scalding due to relief valve  
operation:  
Boiler  
model number  
To  
system  
From  
system  
Discharge line must be connected to relief valve outlet and run to a  
safe place of disposal. Terminate the discharge line to eliminate  
possibility of severe burns should the valve discharge.  
CGi-4E  
1”  
1”  
Note: The boiler supply and return connections, the return/  
drain tee and the supply/gauge tee supplied with  
the boiler are 1¼” NPT. One of the circulator flanges  
supplied with the boiler is 1¼”. The other circulator  
flange is the size of the recommended system piping  
shown above.  
Discharge line must be as short as possible and be the same size as  
the valve discharge connection throughout its entire length.  
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 mate-  
rial serviceable for temperatures of 375°F or greater.  
Chillers or air handling units:  
Install boiler such that —  
Do not pipe the discharge to any place where freezing could  
occur.  
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 au-  
tomatic 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.  
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.  
20  
Part Number 550-110-711/1108  
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4b  
Water piping — single-zone system  
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.  
Diaphragm-type or bladder-  
type expansion tank (Figure 16)  
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.  
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. 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.  
2. Install an automatic air vent as shown.  
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.  
Figure 17  
Closed-type expansion tank — Piping  
to single-zone system using closed-  
type expansion tank. See Table 6 for  
piping sizes.  
21  
Part Number 550-110-711/1108  
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4c  
Water piping — multiple zones  
Piping multiple zones  
Piping for radiant heating  
Follow instructions on pages 20 and 21 to install near- systems or converted gravity  
boiler or single-zone piping. (Also refer to Piping for  
systems  
radiant heating systems or converted gravity sys-  
tems, below, if applicable.)  
Converted gravity (or steam) systems  
Whenever possible, use the primary/secondary piping  
See Figure 18 or Figure 19 to complete installation.  
shown in Figures 20 or 21 on page 25. This piping de-  
sign allows changing boiler flow rate without affecting  
primary circuit flow rate.  
Zoning with circulators (Figure 18)  
(return temp over 130°F)  
1. Size each circulator to individual circuit require-  
If Figures 20 or 21 cannot be used,use the boiler-bypass  
piping shown in Figure 22 or Figure 23 on page 27.  
You can also use the piping shown in Figure 24 on  
page 29 (system-bypass), if the reduced flow rate in  
the heating system will not cause heat distribution  
problems.  
ments.  
2. Do not install circulator on boiler (except for pri-  
mary/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 cir-  
culator.  
Failure to prevent low return water  
temperature to the boiler could  
cause corrosion of the boiler sec-  
tions or burners, resulting in severe  
personal injury, death or substantial  
property damage.  
Zoning with zone valves (Figure 19)  
(return temp over 130°F)  
1. Install isolation (balancing) valves to adjust flow to  
distribute heat to all zones.  
Radiant heating systems  
2. Provide a separate 24-volt transformer to power the  
zone valves. Size the transformer to handle the total  
rated load of all connected zone valves.  
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 (system-bypass),  
because this method does not control radiant system  
supply temperature.  
If radiant system tubing has no oxygen barrier, a heat  
exchanger must be used.  
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. Instead, provide controls and piping which can regulate the boiler return water  
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 dam-  
age.  
22  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
4c  
Water piping — multiple zones  
(continued)  
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) valves  
2 Flow/check valve  
3 System or zone circulator  
5 Zone valve  
10 Automatic air vent (with diaphragm-type expansion tank), or con-  
nect 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 loca-  
tion of expansion tank circulator or air separator.  
6 Drain valve  
9 Relief valve  
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.  
23  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
4d  
Piping — low temperature systems  
the water temperature being supplied to the radiant  
tubing.  
Primary/secondary (preferred)  
bypass piping method  
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/pres-  
sure gauge reads at least 150°F when the system return  
water is cold (approximately 60°F water temperature).  
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. For alterna-  
tives, see pages 26 through 29.  
Valve adjustment  
(Figures 20 and 21 only)  
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 tempera-  
ture between cycles).  
The bypass valves (items 7a and 7b) provide mixing of  
hot boiler outlet water with cooler system return water  
— set to assure a minimum return water temperature  
(at least 130°F) to the boiler. Set the valves as explained  
below.  
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.  
Temperature gauges  
4. Note that valve 7a regulates the amount of hot wa-  
ter from the boiler supply which mixes with return  
water.Valve 7b regulates the amount of system water  
flowing through the boiler secondary loop.  
Gauge 4a is suggested, but optional on any system.  
Gauge 4b is optional on converted gravity systems,  
but required on radiant heating systems — to display  
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 and the system supply temperature (such as provided by an injec-  
tion 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 of this manual if the system is equipped with an outdoor  
reset control. Instead, provide controls and piping which can regulate the boiler re-  
turn water 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.  
24  
Part Number 550-110-711/1108  
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4d  
Piping — low temperature systems  
(continued)  
Figure 20  
Primary/secondary piping  
Zoning with circulators  
Figure 21  
Primary/secondary piping  
Zoning with zone valves  
1 Boiler isolation (balancing) valves  
2 Flow/check valve  
9 Relief valve  
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.  
3 System or zone circulator  
4 System temperature gauges  
5 Zone valve  
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.)  
6 Drain valve  
7 System temperature valves (see instruc-  
tions to the left for adjusting valves)  
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.)  
8 Blend temperature gauge  
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4d  
Piping — low temperature systems  
justed using cold (or room temperature) return water  
BOILER-bypass piping  
method  
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.  
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). This method Gauge 4b is optional on converted gravity systems,  
reduces the flow rate throughout the boiler, in order to but required on radiant heating systems — to display  
raise the average water temperature in the boiler enough the water temperature being supplied to the radiant  
to prevent flue gas condensation. Boiler-bypass piping tubing.  
is effective for some boilers — including the CGi-4E —  
provided the flow rates are adjusted according to the  
instructions following.  
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.  
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  
boiler-bypass piping. Figure 24 however, is not suitable  
for radiant heating applications because it does not  
protect the radiant system from possible high water  
temperature.)  
Valve adjustment  
1. Start with valve 7a fully closed and 7b fully open.  
2. Gradually open valve 7a while closing valve 7b  
until the temperature at gauge 8 reads 60 °F higher  
than gauge 4a. A 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.  
Boiler-bypass piping keeps system flow rate as high as  
possible and temperature drop as low as possible, help-  
ing to equalize the building heat distribution.  
3. Valve 7a regulates the system flow rate, while valve  
7b regulates the boiler flow rate.  
4. The boiler-mounted temperature/pressure gauge  
Temperature gauges  
Gauge 4a is optional if the bypass valves will be ad-  
may be used in place of a separate gauge 8.  
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 and the system supply temperature (such as provided by an injec-  
tion 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 of this manual if the system is equipped with an outdoor  
reset control. Instead, provide controls and piping which can regulate the boiler re-  
turn water 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.  
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4d  
Piping — low temperature systems  
(continued)  
Figure 22  
Boiler-bypass piping — Zoning with  
circulators — (Alternative to primary/  
secondary piping Figures 20 and 21)  
Figure 23  
Boiler-bypass piping — Zoning with  
zone valves — (Alternative to primary/  
secondary piping Figures 20 and 21)  
1
2
3
4
5
6
7
Boiler isolation (balancing) valves  
9 Relief valve  
Flow/check valve  
System or zone circulator  
System temperature gauges  
Zone valve  
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  
Drain 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).  
System temperature valves (see in-  
structions to the left for adjusting  
valves)  
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.)  
8
Blend temperature gauge  
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4d  
Piping — low temperature systems  
Do not apply system-bypass piping if the reduced flow  
SYSTEM-bypass piping  
method  
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.  
This piping method is called a system-bypass because  
part of the circulator flow bypasses the system (through  
valve 7a). This bypassed hot water from the boiler outlet  
mixes with 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 sys-  
tems in order to cause enough flow through valve 7a.  
Valve adjustment  
1. Start with valve 7a fully closed and 7b fully open.  
Figure 24 is an alternative piping method that provides  
return water temperature control for boilers installed  
on converted gravity systems (large water content or  
steam systems).  
2. Gradually open valve 7a while closing valve 7b until  
the temperature at gauge 8 reads at least 130°F at all  
times.  
Do not apply the piping of Figure 24 on radiant heat-  
ing systems.It provides no method regulating the water  
temperature provided to the system and could result in  
excessive water temperature in the radiant tubing.  
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.  
System-bypass piping as shown in Figure 24 can be used  
with either zone valve or circulator 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.  
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 and the system supply temperature (such as provided by an injec-  
tion 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 of this manual if the system is equipped with an outdoor  
reset control. Instead, provide controls and piping which can regulate the boiler re-  
turn water 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.  
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4d  
Piping — low temperature systems  
(continued)  
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 expan-  
sion tank), or connect to tank fitting (closed-type  
expansion tank). DO NOTuse 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.)  
Water piping — refrigeration system  
4e  
Prevent chilled water from  
entering boiler  
Figure 25 Piping refrigeration systems  
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 Figure 25 for  
typical installation of balancing valve and check valve.  
If boiler is connected to heating coils located in air han-  
dling units where they can be exposed to refrigerated  
air, use flow control valves or other automatic means to  
prevent gravity circulation during cooling cycle.  
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5
Gas piping  
Connecting gas supply piping to boiler  
Natural Gas:  
1. Remove jacket front panel and refer to Figure 26 to pipe gas to boiler.  
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  
a. Install drip leg at inlet of gas connection to boiler. Where local  
utility requires drip leg to be extended to the floor, use appropri-  
ate length of pipe between cap and tee.  
b. Install ground joint union for servicing, when required.  
gas piping of 0.30” w.c. For additional gas pipe  
sizing information,refer toANSI Z223.1 (or B149.1  
or B149.2 for Canadian installations).  
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  
2. Inlet pressure required at gas valve inlet:  
identified by the installer.  
Maximum: 13” w.c.  
Minimum: 5” w.c.  
Manifold gas pressure: 3.50” w.c. at high fire  
(0.90” w.c. while in low fire at start-up)  
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,check boiler and its gas connection  
3. Install 100% lockup gas pressure regulator in supply  
line if inlet pressure exceeds 13” w.c. Adjust for  
13” w.c. maximum.  
for leaks.  
a. Close manual main shutoff valve during any pressure testing at  
less than 13” w.c.  
b. Disconnect boiler and gas valve from gas supply piping dur-  
ing any pressure testing greater than 13” w.c.  
Propane Gas:  
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.  
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:  
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.  
Maximum: 13” w.c.  
Minimum: 11” w.c.  
Manifold gas pressure: 10” w.c. at high fire  
(3.50” w.c. while in low fire at start-up)  
Failure to apply pipe dope as detailed above can result  
in severe personal injury, death or substantial property  
damage.  
Table 7 Pipe capacity for 0.60 specific gravity natural gas  
Figure 26 Gas supply piping  
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6
Field wiring  
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.  
Thermostat  
1. Connect thermostat as shown on wiring diagram  
on boiler.  
2. Install on inside wall away from influences of  
drafts, hot or cold water pipes, lighting fixtures,  
television, sunrays, or fireplaces.  
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.  
3. If thermostat has a heat anticipator, set heat antici-  
pator 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 31, page 40. For other devices, refer to manu-  
facturer’s specifications. Wiring diagram on boiler  
gives setting for control module and gas valve. Also  
see instructions with thermostat.  
Boiler must be electrically grounded as required by  
National Electrical Code ANSI/NFPA 70–latest edi-  
tion.  
Electrical installation must  
comply with:  
Junction Box (furnished)  
1. Connect 120 VAC power wiring as shown in  
1. National Electrical Code and any other national,  
Figure 27.  
state, provincial or local codes or regulations.  
2. In Canada, CSA C22.1 Canadian Electrical Code  
2. Fused disconnect or service switch (15 amp. recom-  
mended) may be mounted on this box. For those  
installations with local codes which prohibit installa-  
tion 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.  
Part 1, and any local codes.  
Wiring connections  
Boiler is shipped with controls completely wired.  
The CGi-4E 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 120VAC lead  
wires.  
Figure 27  
Field wiring connections —  
service switch and thermostat  
(or end switch)  
provided by installer  
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7a  
Start-up — preparation  
Check for gas leaks  
Determine if water treatment is needed  
Before starting the boiler, and dur-  
Do not use petroleum-based cleaning or sealing  
compounds in boiler system. Severe damage to boiler  
will occur, resulting in substantial property damage.  
ing 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.  
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.  
Propane boilers only Your pro-  
pane supplier mixes an odorant with  
the propane to make its presence Verify water chemistry  
detectable. In some instances, the  
odorant can fade and the gas may  
no longer have an odor.  
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.  
• 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.  
Freeze protection (when used)  
Use antifreeze made especially for hydronic systems. Inhibited propylene  
glycol is recommended.  
• Use caution when attempting  
to light the propane pilot. This  
should be done by a qualified  
service technician, particularly  
if pilot outages are common.  
Do not use ethylene glycol, automotive or undiluted  
antifreeze. Severe personal injury or death can result.  
1. Determine antifreeze quantity according to system water content.  
Boiler water content is listed on page 67. Remember to include expan-  
sion tank water content.  
• Periodically check the odorant  
level of your gas.  
2. Follow antifreeze manufacturer’s instructions.  
• Inspect boiler and system at least  
yearly to make sure all gas piping  
is leak-tight.  
3. A 50% solution of propylene glycol/water provides maximum protec-  
tion to about -30°F.  
4. Local codes may require back flow preventer or actual disconnect  
• 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 appro-  
priate device.  
from city water supply.  
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.  
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7a  
Start-up — preparation  
(continued)  
Fill the system with water  
Inspect system water piping  
1. Close manual and automatic air vents and boiler drain cock.  
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.  
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:  
Leaks must be repaired at once.  
Failure to do so can damage the  
boiler, resulting in substantial prop-  
erty damage.  
a. Connect a hose to the purge valve (see drain valves, item 6, in  
suggested piping diagrams on pages 23 through 27, Figure 18  
through Figure 23). Route hose to an area where water can drain  
and be seen.  
Do not use petroleum-based  
cleaning or sealing compounds  
in boiler system. Severe damage to  
boiler will occur, resulting in sub-  
stantial property damage.  
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 procedure until all zones are purged.  
Inspect base insulation  
The boiler contains ceramic fiber  
and fiberglass materials. Use care  
when handling these materials per  
instructions on page 68 of this  
manual. Failure to comply could  
result in severe personal injury.  
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.  
Failure to replace damaged insu-  
lation or reposition insulation can  
result in a fire hazard, causing severe  
personal injury, death or substantial  
property damage.  
4. Open automatic air vent (diaphragm-type or bladder-type expansion  
tank systems only) one turn.  
5. Open other vents:  
a. Starting on the lowest floor, open air vents one at a time until  
Check to make sure base insulation is secure against  
all four sides of the base. If insulation is damaged or  
displaced, do not operate boiler. Replace or reposition  
insulation.  
water squirts out.  
b. Repeat with remaining vents.  
6. Refill to correct pressure.  
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7b  
Start-up — operate boiler  
DO NOT proceed with boiler  
operation unless boiler and  
system have been filled with  
water and all instructions  
and procedures of previous  
manual sections have been  
completed. Failure to do so  
could result in severe personal  
injury, death or substantial  
property damage.Before start-  
ing the boiler, do the follow-  
ing:  
If you discover evidence of any  
gas leak, shut down the boiler  
at once. Find the leak source  
with bubble test and repair im-  
mediately. Do not start boiler  
again until corrected. Failure  
to comply could result in se-  
vere personal injury, death or  
substantial property damage.  
Eliminate all system leaks.  
Continual fresh makeup water  
will reduce boiler life. Minerals  
can build up in sections, reduc-  
ing heat transfer, overheating  
cast iron, and causing section  
failure.  
• Read manual Section 9 and  
the Operating instruction  
procedure applicable for  
the gas valve supplied on  
the boiler (Section 9c).  
Verify the boiler and system  
Glycol or antifreeze leaks  
around the boiler may result  
in fire, causing severe personal  
injury, death or substantial  
property damage.  
are full of water.  
Verify the Start-up prepa-  
ration procedures of Sec-  
tion 7 have been complet-  
ed.  
Do not use petroleum-  
based cleaning or sealing  
compounds in boiler system.  
Severe damage to boiler will  
occur, resulting in substantial  
property damage.  
Start the boiler  
Follow the Operating instructions from Section 9c  
to start the boiler.  
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.  
See Section 7c if boiler fails to start.  
Check system and boiler  
1. Check system piping for leaks. If found,shut down  
boiler and repair immediately.  
2. Vent air from system using manual vents. Air in  
the system will interfere with circulation and cause  
heat distribution problems and noise.  
4. Check around the boiler for gas odor following the  
procedure of Section 7a of this manual.  
3. Inspect vent system thoroughly for signs of  
deterioration from corrosion, physical damage or  
sagging. In addition — Check for gas-tight seal at  
every connection and seam.  
5. Verify operation per Section 7b. Perform check-out  
procedure in Section 8, and fill in the Installation  
and service certificate on the same page.  
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7b  
Start-up — operate boiler  
(continued)  
Check burner flames  
Figure 28 Typical pilot burner flame  
View pilot and main flames through the inspection port  
in the base burner shield.  
Pilot burner flame (Figure 28)  
PROPER pilot flame characteristics  
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 (Figure 29)  
Figure 29 Typical main burner flame  
PROPER main burner flame characteristics  
1. Yellow-orange streaks may appear (caused by  
dust).  
(NOTE: The CGi-4E will operate at low fire for  
the first 60 seconds.)  
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).  
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7c  
Start-up — if boiler doesn’t start . . .  
Check for:  
1. Loose connections, blown fuse or service switch  
off?  
2. High limit switch set below boiler water tempera-  
ture?  
3. Thermostat set below room temperature?  
4. Gas not turned on at meter or boiler?  
5. Incoming gas pressure less than:  
5” w.c. for natural gas? 11” w.c. for propane gas?  
6. If none of the above corrects the problem, refer to  
Troubleshooting, section 11 of this manual.  
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8
Check-out procedure — checklist  
Boiler and heat distribution units filled with water?  
Automatic air vent, if used, open one full turn?  
Air purged from system?  
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.  
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.  
Verify thermostat heat anticipator (if available) set prop-  
erly? Refer to Field wiring, manual Section 6, page 31,  
Thermostat(s).  
Correctly sized manifold orifices must be used.  
Failure to do so will cause severe personal in-  
jury, death or substantial property damage.  
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.  
Followed operating instructions on boiler or in manual  
Section 9 for proper start-up?  
Proper burner flame observed at high fire? Refer to Check  
burner flame, manual Section 7b.  
Measure natural gas input:  
a. Operate boiler 10 minutes.  
b. Turn off other appliances.  
Verify that boiler switches to high fire after 60 seconds of  
operation.  
Test limit control — While burners are operating, move  
indicator on limit control below actual boiler water tem-  
perature. Burners should go off while circulator continues  
to operate. Raise setting on limit control above boiler water  
temperature and burners should reignite.  
c. At natural gas meter, measure time (in seconds) re-  
quired to use one cubic foot of gas.  
d. Calculate gas input:  
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.  
e. Btuh calculated should approximate input rating on  
boiler rating label.  
Check manifold gas pressure by connecting manometer to  
downstream test tapping on main gas valve. Manifold pres-  
sure for natural gas should be 3.5" w.c. and for propane gas  
should be 10" w.c.  
Test ignition system safety device:  
a. Connect manometer to outlet side of gas valve.  
Observe several operating cycles for proper operation.  
Set room thermostat to desired room temperature.  
Fill in Installation and service certificate below?  
b. Start boiler, allowing for normal start-up cycle to oc-  
cur and main burners to ignite.  
c. With main burners on, manually shut off gas supply at  
manual main shutoff gas valve. Burners should go off.  
d. Open manual main shutoff gas valve. Manometer  
should confirm there is no gas flow.  
e. Pilot will relight, flame sensing element will sense pilot  
flame and main burners will reignite.  
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.  
Installation and service certificate  
Boiler model __________________  
Series __________  
CP number ___________  
Date installed ___________  
Measured Btuh input ____________________  
Installation instructions have been followed.  
Check out sequence has been performed.  
Above information is certified to be correct.  
Information received and left with owner/maintenance person  
Installer ________________________  
________________________________  
(address)  
________________________  
(company)  
(phone)  
Installer’s signature: _____________________________________  
37  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
9a  
Operation — sequence  
1. Read Operating instructions on page 41. This information is  
also located on a label on the inside of the boiler jacket door  
panel.  
b. If power is interrupted, control system shuts off pilot  
and main gas valves and restarts at step 1 when power is  
restored.  
2. Raise room thermostat to call for heat.  
7. In the event the limit control shuts down the boiler — The  
control module closes the pilot and main gas valves, but keeps  
the inducer operating for 15-second postpurge.  
3. Circulator energizes. If limit circuit is closed, the inducer  
starts. After pressure switch proves proper airflow, control  
module initiates 30-second prepurge.  
— The circulator continues to operate.  
4. Control module sparks the pilot and opens pilot valve in  
main gas valve.  
8. Lower room thermostat setting to stop call for heat. Ther-  
mostat is satisfied — Pilot and main gas valves are closed  
— Inducer operates for 15-second postpurge — Circulator  
is shut off.  
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,  
9. Boiler is now in the off cycle.  
spark generator is turned off and main valve opens.  
5. The CGi-4E timer relay delays high fire for the first 60 seconds  
10. Repeat steps 1 through 6 several times to verify operation.  
11. Return the thermostat to normal setting.  
of main flame.  
6. During main burner operation:  
a. Control module monitors pilot flame current. If signal  
is lost, main valve closes, spark generator activates and  
sequence returns to step 4.  
12. Set thermostat heat anticipator setting as instructed in Figure  
31, page 40.  
38  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Figure 30 Control module sequence of operation — status light indications  
39  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
9b  
Operation — wiring diagrams  
Figure 31 Wiring diagram  
40  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
• Spark pilot  
• Natural or propane gas  
Operating instructions  
• Gas valve: Honeywell VR8204/VR8304  
9c  
41  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Addendum Instruction for the  
Commonwealth of Massachusetts  
This addendum must only be used by a  
qualified heating installer/service technician.  
Read these instructions completely before  
beginning the installation. Failure to comply  
could result in severe personal injury, death  
or substantial property damage.  
one-half (1/2) inch in size,GAS VENT DIRECTLY BE-  
LOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”  
4. INSPECTION. The state or local gas inspector of the  
side wall horizontally vented gas fueled equipment shall  
not approve the installation unless, upon inspection,  
the inspector observes carbon monoxide detectors and  
signage installed in accordance with the provisions of  
248 CMR 5.08(2)(a) 1 through 4.  
(a) For all side wall horizontally vented gas fueled equipment  
installed in every dwelling, building or structure used in  
whole or in part for residential purposes, including those  
owned or operated by the Commonwealth and where the  
side wall exhaust vent termination is less than seven (7) feet  
above finished grade in the area of the venting, including but  
not limited to decks and porches, the following requirements  
shall be satisfied:  
(b) EXEMPTIONS: The following equipment is exempt from  
248 CMR 5.08(2)(a)1 through 4:  
1. The equipment listed in Chapter 10 entitledEquipment  
Not Required To Be Vented” in the most current edition  
of NFPA 54 as adopted by the Board; and  
1. INSTALLATION OF CARBON MONOXIDE DETEC-  
TORS.At the time of installation of the side wall horizon-  
tal vented gas fueled equipment, the installing plumber  
or gas fitter shall observe that a hard wired carbon  
monoxide detector with an alarm and battery back-up  
is installed on the floor level where the gas equipment is  
to be installed. In addition, the installing plumber or gas  
fitter shall observe that a battery operated or hard wired  
carbon monoxide detector with an alarm is installed on  
each additional level of the dwelling, building or struc-  
ture served by the side wall horizontal vented gas fueled  
equipment. It shall be the responsibility of the property  
owner to secure the services of qualified licensed profes-  
sionals for the installation of hard wired carbon monoxide  
detectors  
2. ProductApproved side wall horizontally vented gas fueled  
equipment installed in a room or structure separate from  
the dwelling, building or structure used in whole or in  
part for residential purposes.  
(c) MANUFACTURER REQUIREMENTS — GAS EQUIPMENT  
VENTING SYSTEM PROVIDED. When the manufacturer of  
Product Approved side wall horizontally vented gas equip-  
ment provides a venting system design or venting system  
components with the equipment, the instructions provided  
by the manufacturer for installation of the equipment and  
the venting system shall include:  
1. Detailed instructions for the installation of the venting  
system design or the venting system components; and  
2. A complete parts list for the venting system design or  
venting system.  
a. In the event that the side wall horizontally vented gas  
fueled equipment is installed in a crawl space or an  
attic, the hard wired carbon monoxide detector with  
alarm and battery back-up may be installed on the  
next adjacent floor level.  
b. In the event that the requirements of this subdivision  
can not be met at the time of completion of installa-  
tion, the owner shall have a period of thirty (30) days  
to comply with the above requirements; provided,  
however, that during said thirty (30) day period, a  
battery operated carbon monoxide detector with an  
alarm shall be installed.  
(d) MANUFACTURER REQUIREMENTS — GAS EQUIPMENT  
VENTING SYSTEM NOT PROVIDED. When the manufac-  
turer of a Product Approved side wall horizontally vented gas  
fueled equipment does not provide the parts for venting the  
flue gases, but identifiesspecial venting systems, the follow-  
ing requirements shall be satisfied by the manufacturer:  
1. The referencedspecial venting systeminstructions shall  
be included with the appliance or equipment installation  
instructions; and  
2. Thespecial venting systemsshall be Product Approved  
by the Board,and the instructions for that system shall in-  
clude a parts list and detailed installation instructions.  
2. APPROVED CARBON MONOXIDE DETECTORS. Each  
carbon monoxide detector as required in accordance with  
the above provisions shall comply with NFPA 720 and be  
ANSI/UL 2034 listed and IAS certified.  
3. SIGNAGE. A metal or plastic identification plate shall  
be permanently mounted to the exterior of the build-  
ing at a minimum height of eight (8) feet above grade  
directly in line with the exhaust vent terminal for the  
horizontally vented gas fueled heating appliance or  
equipment. The sign shall read, in print size no less than  
(e) A copy of all installation instructions for all ProductApproved  
side wall horizontally vented gas fueled equipment,all venting  
instructions, all parts lists for venting instructions, and/or all  
venting design instructions shall remain with the appliance  
or equipment at the completion of the installation.  
42  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
10a  
Service and maintenance — schedule  
VERIFY PROPER OPERATION AFTER SERVICING  
Table 8 Service and maintenance schedules  
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.  
43  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
10b  
Service and maintenance — annual start-up  
Air openings  
1. Verify that combustion and ventilation air openings  
The boiler should be inspected and started annu-  
to the boiler room and/or building are open and  
ally, at the beginning of the heating season, only  
by a qualified service technician. In addition, the  
maintenance and care of the boiler designated in  
Table 8, page 43, and explained on the following  
pages must be performed to assure maximum boiler  
efficiency and reliability. Failure to service and main-  
tain the boiler and system could result in equipment  
failure.  
unobstructed.  
2. Verify that boiler vent discharge is clean and free  
of obstructions.  
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.  
Eliminate all system or boiler leaks. Continual  
fresh makeup water will reduce boiler life. Miner-  
als can build up in sections, reducing heat transfer,  
overheating cast iron, and causing section failure.  
Leaking water may also cause severe property dam-  
age.  
Failure to inspect for the above  
conditions and have them repaired  
can result in severe personal injury  
or death.  
Pilot and main burner flames  
Do not use petroleum-based cleaning or sealing  
compounds in boiler system. Severe damage to  
boiler will occur, resulting in substantial property  
damage.  
1. Visually inspect pilot burner and main burner  
flames as directed under Start-up, Section 7 of this  
manual.  
Water piping  
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.  
1. Check the boiler interior piping and all system pip-  
ing for signs of leaks.  
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.  
Inspect . . .  
3. Inspect the boiler vent outlet area and heating sur-  
faces by looking through the opening.  
Reported problems  
Inspect any problems reported by owner and correct  
before proceeding.  
4. If the vent pipe or inducer interior show evidence  
of soot, follow Cleaning boiler heating surfaces  
on page 47 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).  
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  
5. Reconnect vent to inducer outlet and replace all  
boiler components before returning to service.  
cannot be removed, isolate the boiler and provide 6. Check inside and around boiler for evidence of any  
outside combustion air. See national, provincial or  
local codes for further information.  
leaks from the boiler. If found, locate source of leaks  
and repair.  
44  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
10b  
Service & maintenance – annual start-up  
(cont.)  
burner inlet while cleaning the burner ports with a wire brush. The  
vacuum will help to draw any airborne material out of the burner.  
Inspect . . .  
4. Reinstall components, starting with the burner tray, then the pilot  
bracket assembly, burner baffle, and air inlet top and front panels.  
Burners and base  
5. Follow the start-up procedure in the boiler manual.  
The boiler contains ceramic fiber  
and fiberglass materials. Use care  
when handling these materials per  
instructions on page 68 of this  
manual. Failure to comply could  
result in severe personal injury.  
Condensate drain system  
1. Inspect condensate drain fittings and tubing.Verify that condensate  
can flow freely to drain.  
If insulation is damaged or displaced,  
do not operate the boiler. Replace  
or reposition insulation as neces-  
sary. Failure to replace damaged  
insulation can result in a fire hazard,  
causing severe personal injury,death  
or substantial property damage.  
Service . . .  
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.  
1. After turning off power to the boiler, remove the base  
Use only S.A.E. 20 motor oil to lubricate the inducer  
motor. Do not use universal household oils. Mo-  
tor could be damaged, resulting in possible severe  
property damage.  
burner shield (Figure 40, item 4, page 60).  
2. Inspect burners and all other components in the boiler  
base.  
3. If burners must be cleaned see Burner cleaning in-  
structions below.  
Oiled-bearing circulators  
4. Inspect the slotted jacket cooling openings in the bot-  
tom left and right of the base pan (Figure 40, item 7,  
page 60).  
1. The circulator shipped with the CGi-4E boiler is water-lubricated.  
No oiling is required.  
5. Inspect the base insulation. Pay attention to the WARN-  
ING on page 68 regarding working with insulation  
materials.Verify that the insulation is intact and secure  
against all four sides of the base.  
2. Check other circulators in the system. Oil any circulators requiring  
oil, following circulator manufacturer’s instructions. Over-oiling  
will damage the circulator.  
Burner cleaning instructions  
Airborne materials, such as fiberglass  
and dust, are present during construc-  
tion and remodeling. These materials  
can be drawn in with the combustion  
air and obstruct burner ports, resulting  
in carbon monoxide production, a fire  
hazard,or building freeze damage.Read  
and follow the WARNING on page 9.  
Failure to inspect and clear gas burner  
ports could result in severe personal  
injury, death or substantial property  
damage.  
Start-up . . .  
1. Perform all start-up procedures in Section 7 of this manual.  
2. Verify cold fill pressure is correct and that fill system is working  
properly.  
3. Verify antifreeze level (if used) is at the right concentration and  
that inhibitor level is correct.  
4. Check gas piping per manual Sections 5 and 7a, verifying no  
indications of leakage and all piping and connections are in good  
condition.  
1. Remove burner shield and the base pan air baffle. Next  
remove the pilot bracket assembly. Then remove the  
four screws securing the burner tray to the manifold  
and slide the burner tray out under the manifold.  
2. Inspect each burner to insure that every port is com-  
pletely open.  
5. Read the appropriate Operating instructions (Section 9c of this  
manual or on boiler label) applying to the boiler.  
6. Start the boiler following the appropriate Operating instructions  
3. If any port is not completely clear, run a vacuum at the  
(Section 9c of this manual or on boiler label).  
45  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
10b  
Service & maintenance – annual start-up  
(cont.)  
an 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 4 of this manual for suggested best  
location of expansion tanks and air eliminators.  
Check/test . . .  
Gas piping  
1. Sniff near floor and around boiler area for any in-  
dication of a gas leak.  
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.  
2. 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  
Closed-type — welded gas tight and located above  
boiler. Tank is partially filled with water, leaving an  
air cushion for expansion.  
1. While the system is cold, note the pressure reading  
ontheboilerpressure/temperaturegauge.Verifythat  
cold fill pressure is correct.  
2. Watch the pressure as the boiler and system heat  
up to ensure pressure rise is normal. Too high a rise  
would indicate a waterlogged or undersized expan-  
sion tank.  
Make sure this type of tank is fitted with a tank  
fitting, such as the B & G Tank-Trol or Taco  
Taco-Trol. This fitting reduces gravity circula-  
tion of air-saturated tank water back to the  
system and prevents the air from bubbling up  
through the water as it returns from the sys-  
tem.  
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 Figure 34. If the air vent is leaking, remove cap  
A and briefly push valve B and then release to clean  
the valve seat.  
Do not use automatic air vents in systems  
with closed-type tanks. The air will escape  
from the system instead of returning to the tank.  
Eventually, the tank will waterlog and no longer  
control pressurization. The boiler relief valve  
will weep frequently.  
Diaphragm- or bladder-type — welded gas tight  
with a rubber membrane to separate the tank pres-  
surizing air and the water. May be located at any  
point in the system, but most often found near the  
boiler.  
4. Replace cap A by twisting all the way onto valve B  
and then unscrewing one turn.  
Figure 34  
Automatic air vent, typical  
Systems with this type of expansion tank require  
at least one automatic air vent, preferably lo-  
cated on top of an air eliminator, as shown in  
examples in manual Section 4.  
2. If relief valve has tended to weep frequently, the ex-  
pansion tank may be waterlogged or undersized.  
Closed-type tank — tank is most likely water-  
logged. 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.  
Limit controls and cutoffs  
1. Inspect and test the boiler limit control. Verify op-  
eration 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.  
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 neces-  
sary to provide sufficient expansion. If tank size is  
large enough, remove tank from system and check  
charge pressure (usually 12 psig for residential ap-  
plications). If tank won’t hold pressure, membrane  
has been damaged. Replace tank.  
Expansion tank  
1. Expansion tanks provide space for water to move in  
46  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
10b  
Service & maintenance – annual start-up  
(cont.)  
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.  
Safety relief valves should be reinspected AT LEAST  
ONCE EVERYTHREEYEARS,by a licensed plumb-  
ing contractor or authorized inspection agency, to  
ensure that the product has not been affected by  
corrosive water conditions and to ensure that the  
valve and discharge line have not been altered or  
tampered with illegally.Certain naturally occurring  
conditions may corrode the valve or its compo-  
nents 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.  
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  
Following installation, the valve lever must be  
operated AT LEAST ONCE AYEAR 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.  
The boiler contains ceramic fiber  
and fiberglass materials. Use care  
when handling these materials per  
instructions on page 68 of this  
manual. Failure to comply could  
result in severe personal injury.  
1. Shut down boiler:  
Follow “ToTurn Off Gas to Appliance” instructions  
on boiler and Operating instructions.  
Do not drain boiler unless it will be exposed to  
freezing temperatures. If using antifreeze in system,  
do not drain.  
2. Follow shutdown procedure.  
Boiler relief valve  
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.  
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 4 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-pres-  
surization of the system due to expansion tank waterlogging or  
undersizing.  
Figure 35 Relief valve, typical  
11. Reinstall radiation plates.  
12. Replace collector box/transition assembly. Seal with seal-  
ant. 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 7, pages 32-35 of this  
manual and the boiler Operating instructions. Excessive  
sooting indicates improper gas combustion. If found,  
check for proper combustion and make any necessary  
adjustments.  
47  
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11a  
Troubleshooting — general  
Air pressure switch  
Label all wires prior to disconnection when  
servicing controls. Wiring errors can cause  
improper and dangerous operation.  
Make sure boiler water temperature is  
100 °F or cooler before starting proce-  
dure to obtain appropriate readings.  
Never jumper (bypass) rollout thermal fuse ele-  
ment or any other device except for momentary  
testing as outlined in Troubleshooting Charts.  
Severe personal injury, death or substantial  
property damage can result.  
The boiler will not operate correctly un-  
less pressure switch hoses are correctly  
located. The red hose connects from  
the right side (negative) hose barb to  
the flue collector. The white hose con-  
nects from the left side (positive) hose  
barb of the switch to the connector box  
(between flue collector and inducer) as  
shown in Figure 36, page 49.  
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.  
Check pressure switch setting  
d. U-tube manometer.  
2. Check for 120 VAC (minimum 102 VAC to maximum 132 VAC) to  
boiler.  
3. Make sure thermostat is calling for heat and contacts (including appro-  
priate zone controls) are closed. Check for 24 VAC between thermostat  
wire nuts and ground.  
1. See Figure 36, page 49, and Table 9.  
2. Remove both air pressure switch hoses from air pressure  
switch.  
3. Install tees and tubing as shown in Figure 36, page 49, to  
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 termi-  
nals.  
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. Verify gas supply pressure:  
Troubleshooting air pressure reading  
1. If manometer reading is lower than the setpoint of the switch  
(seeTable 9) — check for possible causes:  
blockage in hoses  
a. With boiler OFF — 13w.c. maximum natural or propane gas  
pressure upstream of gas valve.  
b. With boiler ON — Upstream: 5w.c. minimum natural gas pres-  
sure or 11w.c. propane gas pressure upstream of gas valve.  
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  
4. Verify gas manifold pressure (downstream of gas valve):  
a. Natural gas:  
blockage in flue pipe or termination  
incorrect pressure switch  
Manifold pressure, high fire: 3.50w.c.  
Manifold pressure, low fire: 0.90w.c. while in low fire at start-up  
(60 seconds)  
6. If manometer reading is above the setpoint of the switch (see  
Table 9), but there is not 24 VAC between both air pressure  
switch terminals — replace air pressure switch.  
b. Propane gas:  
Manifold pressure, high fire: 10.0w.c.  
Manifold pressure, low fire: 3.50w.c. while in low fire at start-up  
(60 seconds)  
c. If necessary, adjust gas pressure on the gas valve as shown below.  
After adjustments, refer to page 35 to check the flame.  
Return to normal operation  
When pressure reading is correct and air pressure switch is oper-  
ating properly — remove tees and reinstall hoses to air pressure  
switch.  
High-fire gas pressure adjustment  
Table 9  
Pressure switch setpoint (for elevations  
above 2,000 ft, contact your local Weil-  
McLain sales office for details.)  
Low-fire gas pressure adjustment  
Boiler model number  
CGi-4E  
Inches W.C.  
Honeywell VR8204Q two-stage gas valve  
1.36  
48  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
11b  
Troubleshooting — components  
POWER light flashing alone  
Figure 36 Manometer connections  
Usually indicates reversed polarity of 120 VAC power wires.  
POWER and TSTAT CIRC lights flashing  
Usually indicates stray voltage on external thermostat circuit  
wires (usually due to miswired 3-wire zone valve).  
POWER and PRESS SWITCH lights flashing  
Usually indicates pressure switch is closed when it should  
not be, or pressure switch failed to close within 5 minutes of  
inducer starting.  
POWER and FLAME lights flashing  
Usually indicates false flame sense or flame sensed when it  
should not be there.  
Control indicator lights —  
NON-LOCKOUT modes  
POWER light on and FLAME light flashing  
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.  
POWER light on and PRESS SWITCH light flashing  
Usually indicates pressure switch opened during the run  
cycle.  
Troubleshooting the control module  
See Figure 38, page 50, for location of harness plug receptacles  
and plugs on the control module.  
Control module  
Figure 37 Control module  
Solder or water splatter between  
plugs and circuit board can cause  
improper operation of control mod-  
ule. Place a shield over the boiler  
internal controls and components  
during installation. Failure to com-  
ply could result in severe personal  
injury, death or substantial property  
damage.  
Make sure ground wiring is in-  
stalled 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 trouble-  
shooting procedures.  
To reset control after a lockout, turn off power at the 120VAC  
service switch or turn down all thermostats. Wait 45 seconds.  
Then restore power or call for heat.  
49  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
11b  
Troubleshooting — components  
(continued)  
Figure 38 Control module connections  
50  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — control module lights  
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.  
Is POWER light off?  
• Make sure service switch or circuit breaker is on or  
fuses are good.  
• Remove 120 VAC IN plug (Figure 38, Item 3, page 50)  
on control module.  
Yes  
No  
• Using voltmeter, check across top and bottom pins of  
120 VAC IN plug.  
Is POWER light ...  
Does voltmeter indicate 120 VAC?  
Flashing  
alone  
Flashing with  
another light  
On steady  
(not flashing)  
No  
Yes  
TSTAT CIRC  
light flashing  
Chart  
2
Problem is with incoming  
electricity. Have licensed  
electrician repair circuit.  
PRESS SWITCH  
light flashing  
Chart  
3
Chart  
5
FLAME  
light flashing  
Chart  
4
Chart  
6
• Reconnect 120 VAC IN plug.  
• Remove 120 VAC IN transformer PRIMARY plug  
(Figure 38, Item 2, page 50) on control module.  
• Using voltmeter, check across top and bottom pins of  
PRIMARY receptacle.  
For insufficient heat or no heat problem, go to  
Chart 7 if POWER light is on steady, with no other  
light flashing.  
Does voltmeter indicate 120 VAC?  
Yes  
No  
• 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.  
Replace control module.  
Retest.  
• Reinstall 120 VAC transformer PRIMARY plug.  
• Remove 24 VAC transformer plug (Figure 38, Item 5,  
page 50) on control module.  
• Restore POWER at service switch or breaker.  
Is POWER light flashing now?  
• Using voltmeter, check pins of plug.  
Yes  
No  
Does voltmeter indicate 24 VAC?  
Yes  
No  
Have system checked by a  
licensed electrician. If  
problem persists, call your  
local Weil-McLain sales  
representative.  
Replace transformer.  
Retest and check for back  
feed of voltage from  
system wiring.  
Boiler should now  
operate normally.  
Replace control module.  
Retest.  
51  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — control module lights  
(cont.)  
CHART 2 TSTAT CIRC & POWER lights flashing  
— Usually indicates 48 VAC on thermostat circuit (stray voltage) —  
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.  
• Disconnect the two external wires connected to the boiler  
• If a voltage does occur under any condition, check and  
thermostat leads (two black low voltage leads in J-box).  
correct the external wiring. (This is a common problem  
when using 3-wire zone valves.)  
• 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.  
• 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.  
• There should NEVER be a voltage reading.  
Did you find a voltage across the two external thermostat circuit wires?  
Yes  
No  
• 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).  
• 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.)  
• Turn off power to the boiler for 1 minute.  
• Turn on power and allow boiler to cycle.  
Do the TSTAT and POWER lights still flash?  
• 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.  
No  
Yes  
• Boiler should now operate per the normal sequence of  
• Replace control module.  
• Retest.  
operation shown in Figure 30, page 39.  
52  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — control module lights  
(cont.)  
CHART 3 PRESS SWITCH & POWER lights flashing  
— Usually indicates pressure switch stuck closed or failed to make within 5 minutes —  
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.  
• 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, page 50)  
from plug receptacle of control module.  
• Place voltmeter leads across the 120 VAC N and  
120 VAC H pins of the INDUCER receptacle (left column  
center and right column bottom pins).  
• Wait 5 minutes.  
Is PRESS SWITCH light flashing?  
No  
Yes  
Does the voltmeter indicate 120 VAC?  
No  
Yes  
• Try reseating plug in  
module receptacle and  
restart.  
• If inducer still does not  
work, replace inducer  
assembly.  
• Boiler should be in  
normal operating  
sequence.  
• Observe operation until  
thermostat is satisfied  
and inducer has  
Are vent or combustion air  
passages blocked?  
• Retest.  
completed its post-purge  
cycle.  
• Remove one of the wires connected to the pressure  
switch.  
No  
Yes  
• Check continuity across the switch terminals.  
Does the ohmmeter indicate the switch is closed?  
No  
Yes  
• Check air pressure switch  
per manual Section 11a.  
• Replace if necessary.  
• Retest.  
• Replace control  
module.  
• Retest.  
• Clear passages and  
recycle boiler.  
• Recheck boiler operation.  
53  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — control module lights  
(cont.)  
CHART 4 FLAME & POWER lights flashing  
— Usually indicates flame sensed when it shouldn't be there —  
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.  
Are manual main shutoff valve and gas valve open?  
No  
Yes  
• 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 (Section 9c).  
• Look through the pilot inspection port to see if the pilot is  
burning during the prepurge period (first 30 seconds of  
operation).  
• 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 (Section 9c).  
Do FLAME and POWER lights still flash?  
Is pilot burning during prepurge period?  
No  
Yes  
No  
Yes  
• Replace control module.  
• Retest.  
• Replace gas valve.  
• Retest boiler.  
• Allow boiler to continue cycling.  
Are FLAME & POWER lights flashing?  
Are FLAME and POWER lights flashing?  
No  
No  
Yes  
Yes  
• Boiler may now be  
operating  
• Replace control  
module.  
• Boiler should now  
operate normally.  
• Replace control  
module.  
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.  
normally.  
• Retest.  
• Original flashing  
FLAME light  
• Retest.  
• Perform start-up  
procedures in  
boiler manual to  
verify proper  
caused by gas  
valve not  
operating properly.  
operation.  
• See normal  
sequence of  
operation,  
• Perform start-up  
procedures in boiler  
manual to verify proper  
operation.  
Figure 30,  
page 39.  
54  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — control module lights  
(cont.)  
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 —  
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.  
• 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, page 50)  
from plug receptacle of control module.  
• Place voltmeter leads across the 120 VAC N and  
120 VAC H pins of the INDUCER receptacle (left column  
center and right column bottom pins).  
• Wait 5 minutes.  
Is PRESS SWITCH light flashing?  
Does the voltmeter indicate 120 VAC?  
No  
Yes  
No  
Yes  
• Replace inducer  
assembly.  
• Retest.  
• Boiler should be in  
normal operating  
sequence.  
• Observe operation until  
thermostat is satisfied  
and inducer has  
• Remove one of the wires connected to the pressure  
switch.  
• Check continuity across the switch terminals.  
completed its post-  
purge cycle.  
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.  
Is vent blocked?  
No  
Yes  
• If harness is intact and  
properly seated, but  
problem persists, replace  
control module.  
• Check air pressure switch per manual Section 11a.  
• Replace if necessary. Retest.  
• Clear vent and recycle boiler.  
• Recheck boiler operation.  
• Retest.  
55  
Part Number 550-110-711/1108  
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CGi-4E Gas-Fired Water Boiler — Boiler Manual  
11c  
Troubleshooting — control module lights  
(cont.)  
CHART 6 FLAME light flashing and POWER light on steady  
ALSO — Troubleshooting failure to establish main flame  
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.  
Are main manual shutoff valve and boiler gas valve open?  
No Yes  
Is pilot flame visible through inspection port?  
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).  
Check the voltage across  
terminals PV and C of the  
gas valve.  
Make sure ground wire  
terminal is securely fastened  
to control module mounting  
screw.  
Turn on power at service switch or breaker. A  
Is 24 VAC present there?  
Does FLAME light flash now?  
Yes  
No  
No  
Yes  
Verify inlet gas pressure at gas  
valve:  
Check the voltage across  
terminals MV and C of the  
gas valve.  
If the wiring from the  
Boiler should be in  
normal operating  
sequence.  
control module to gas  
valve is intact, replace the  
control module.  
Natural gas — 5.0" w.c. min/14.0"  
w.c. max  
Is 24 VAC present there?  
No  
Retest.  
Observe operation  
until thermostat is  
satisfied and blower  
has completed its  
post-purge cycle.  
Yes  
Propane — 11.0" w.c. min/14.0"  
w.c. max  
Is gas present at gas valve inlet and  
within above range?  
Verify inlet gas pressure at gas valve:  
Yes  
No  
Natural gas — 5.0" w.c. min/14.0" w.c. max  
Propane — 11.0" w.c. min/14.0" w.c. max  
TURN OFF POWER  
to boiler at service switch or  
breaker.  
Remove burner shield (see  
Figure 40, item 4, page 60  
for location).  
Is gas present at gas valve inlet and within above range?  
No 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, item 4, page 60 for  
location).  
TURN OFF POWER to boiler at service switch or breaker.  
Check flame signal — Detach sense lead from ignition control  
(Figure 38, item 8, page 50).  
Verify pilot gas line is not  
kinked, obstructed or  
damaged and is correctly  
attached to pilot and gas  
valve.  
Connect negative lead of MICROAMMETER to control sense  
terminal (Figure 38, item 8, page 50). Connect positive lead of  
MICROAMMETER to sense wire.  
DISCONNECT red wire connected to terminal MV of the gas  
valve.  
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.  
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.  
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?  
Verify that pilot flame rod, flame  
rod ceramic and lead wire from  
control module to flame rod are in  
good condition.  
No  
Yes  
If none of the previous steps  
(including replacing pilot)  
corrects problem, then replace  
the control module, reinstall  
burner shield and retest.  
If the wiring from the  
Correct any above problems,  
replacing pilot if burner or wiring  
is damaged.  
control module to gas  
valve is intact, replace the  
control module and retest.  
56  
Part Number 550-110-711/1108  
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11c  
Troubleshooting — control module lights  
(cont.)  
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 result in severe personal injury, death or substantial property damage.  
• 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 boiler System circulator operating?  
No Yes  
• Remove CIRCULATOR harness plug from  
CIRCULATOR plug receptacle (Figure 38, Item  
7, page 50). Check with voltmeter across pins of  
control module receptacle.  
Is thermostat circuit closed (continuity across wires)?  
Does voltmeter show 120 VAC across pins?  
No  
Yes  
No  
Yes  
Are all red lights off?  
• Boiler is in standby.  
• Set thermostat to call for  
heat and recheck  
operation.  
No  
Yes  
• Repair/replace  
circulator. Retest.  
• Repair/replace  
wiring. Retest.  
• Replace control  
module.  
• Retest.  
Wait 30 seconds.  
Are all red lights off?  
• Verify Sequence of  
operation, Figure 30,  
page 39.  
No  
Yes  
Replace control module.  
Retest.  
• Wait 5 minutes.  
Is FLAME light on?  
• If you have sufficient heat — boiler should be in normal  
Yes  
No  
operating sequence. (See normal sequence of operation,  
Figure 30  
.)  
• If you have less than sufficient heat —  
Is LIMIT light on?  
Is vent piping free of blockage?  
No  
Yes  
No  
Yes  
Is manifold pressure:  
• Correct conditions and  
recheck operation.  
• See Figure 30, page 39  
for normal sequence of  
operation.  
3.50" w.c. on natural gas?  
10.0" w.c. on propane?  
Yes  
• Check limit switch  
contacts with continuity  
checker.  
• Replace control module.  
• Retest.  
No  
Are limit switch contacts  
closed?  
Check rollout switch  
continuity — is switch  
closed?  
• Check heat loss calculation  
versus boiler size.  
• Clock gas input.  
No  
Yes  
• Replace timer relay.  
No  
Yes  
• Wait for boiler water to cool to temperature 20 to 30 °F  
lower than temperature set on limit switch.  
Are limit switch contacts closed?  
• Replace rollout switch.  
No  
Yes  
• Check any other  
limit controls wired  
into the limit  
circuit. If all are  
OK, then replace  
control module.  
• Retest.  
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.  
• Replace  
limit switch.  
• Retest.  
• Also check setting on limit switch (should  
be above 140°F.).  
57  
Part Number 550-110-711/1108  
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12a  
Replacement parts  
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.  
The boiler contains ceramic fiber and fiberglass materials. Use care when  
handling these materials per instructions on page 68 of this manual.  
Failure to comply could result in severe personal injury.  
Section assembly .............................................. 59  
Base ................................................................. 60  
Jacket .............................................................. 62  
Trim .................................................................. 64  
Controls ........................................................... 65  
58  
Part Number 550-110-711/1108  
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12b  
Replacement parts — section assembly  
Figure 39 Section assembly  
Item  
number  
Description  
Weil-McLain  
part number  
Item  
number  
Description  
Weil-McLain  
part number  
1
2
3
End section, left hand, 51124  
End section, right hand 51128  
Intermediate section, 51125  
311-103-850  
311-103-821  
311-103-818  
321-114-346  
6
7
8
562-248-684  
460-003-700  
381-354-596  
Washer, M\zn” (1 per tie rod)  
Radiation plate (1 per joint)  
Collector hood CGi-4E  
and transition  
assembly  
not  
shown  
Replacement  
section  
CGi-4E  
assembly  
9
High limit, 30° Honeywell  
510-312-250  
differential,  
with well  
L4080D1036  
White-Rodgers  
11B81-3  
not  
shown  
Section replacement kit, includes  
seals and sealant for 1 joint  
381-354-527  
560-234-501  
4
CGi-4E  
Tie rod, M\zn”  
without nut (3  
per boiler):  
10  
11  
Inducer fan assembly kit, includes  
inducer fan assembly, gasket and  
nuts  
381-356-499  
590-317-627  
5
561-928-235  
Nut, M\zn” (2 per tie rod)  
Gasket, inducer  
59  
Part Number 550-110-711/1108  
GOLD  
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12c  
Replacement parts — base  
Figure 40 Base assembly  
60  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
12c  
Replacement parts — base  
(continued)  
Weil-McLain  
part number  
Item  
Description  
Base assembly kit  
(includes base panels items 1, 2, 3, 4, 5, 6  
and 7)  
CGi-4E  
381-354-338  
Base side panel (in Base assembly)  
Base front cross-tie assembly (in Base assembly)  
Base back cross-tie assembly (in Base assembly)  
Burner shield (in Base assembly)  
Base pan angle, left side (in Base assembly)  
Base pan angle, right side (in Base assembly)  
Base pan (in Base assembly)  
1
2
3
4
5
6
7
Base pan air baffle (in Base assembly)  
Burner mounting plate  
7a  
8a  
8b  
8c  
9
CGi-4E  
CGi-4E  
450-003-691  
550-320-161  
550-320-170  
381-354-331  
Rear spacing strip  
Nut, hex 5mm Zp  
Base insulation kit  
CGi-4E  
Boiler leg kit  
Manifold  
550-320-219  
591-126-736  
10  
11  
12  
CGi-4E  
Main burner orifice — Natural gas, sea level (seeTable 2, page 12 for  
orifice size) CGi-4E  
560-529-126  
560-529-111  
Main burner orifice — Propane gas, sea level (seeTable 2, page 12 for  
orifice size)  
CGi-4E  
Burner  
512-200-076  
562-135-710  
512-050-230  
13  
14  
15  
Screw, 10-32 x .0.38 STP type 23 hx, washer Hd slot  
Rollout thermal fuse element  
61  
Part Number 550-110-711/1108  
GOLD  
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12d  
Replacement parts — jacket  
Figure 41 Jacket assembly  
62  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
12d  
Replacement parts — jacket  
(continued)  
1
2
3
4
5
Panel, left side,  
with insulation  
Boiler  
Model  
Boiler  
Model  
Panel, right side,  
with insulation  
Panel, top front, Panel, top rear, with  
Junction box, 2 x 4  
with insulation  
insulation  
Natural Gas  
Propane Gas  
(Available at local  
supply house)  
CGi-4E  
381-355-610  
381-355-612  
381-355-613  
381-355-413  
381-355-551  
CGi-4E  
6
7
8
9
10  
Boiler  
Model  
Boiler  
Model  
Cross tie,  
bottom front  
Panel, interior,  
with insulation  
Panel, rear,  
with insulation  
Not shown — gold  
touch-up paint  
Panel, door  
CGi-4E  
381-355-611  
431-223-326  
381-355-415  
431-223-301  
592-000-000  
CGi-4E  
63  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
12e  
Replacement parts — trim  
Figure 42 Trim assembly  
Item  
number  
Description  
Manufacturer  
Manufacturer’s  
part number  
Weil-McLain  
part number  
1
Pressure relief valve, ASME, 30 PSIG, ¾” male inlet  
Conbraco  
Watts  
10-407-10  
M330  
511-546-920  
Pressure relief valve, ASME, 30 PSIG, ¾” female inlet  
(Fittings shown are factory-installed on boiler.)  
Conbraco  
Watts  
10-408-05  
335  
511-546-924  
2
3
Combination pressure-temperature gauge, 3Z\,” diameter,  
short shank (Fittings shown are shipped loose with boiler.)  
Weil-McLain  
380-000-000  
Drain valve, ¾”  
(Fittings shown are included with boiler.)  
Conbraco  
Hammond  
Valve  
31-606-01  
710  
511-210-423  
511-246-392  
Matco-Norca  
Watts  
205F04  
BD-2C  
511-246-392  
511-246-392  
4
5
Circulator  
Bell & Gossett  
Taco  
NRF-22-103253  
007  
511-405-118  
511-405-113  
(Fittings shown are shipped loose with boiler.)  
Circulator gasket, universal (2 per boiler)  
Weil-McLain  
590-317-535  
not  
Circulator hardware kit, includes:  
shown  
1 flange, 2 nuts, 2 screws, 1 gasket —  
----------------------------------------------1” NPT — CGi-4E  
Weil-McLain  
381-354-525  
381-354-528  
6
Circulator wiring harness kit, with Molex (loose)  
64  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
12f  
Replacement parts — controls  
Figure 43 Gas control assembly  
Item  
number  
Description  
Boiler model  
Manufacturer Manufacturer’s  
part number  
Weil-McLain  
part number  
Natural gas components  
1
2
Gas valve, ½” x ½, two-state  
CGi-4E  
Honeywell  
VR8204Q2434  
VR8204Q2459  
1107-1  
511-044-508  
511-330-080  
Pilot kit w/orifice & aluminum pilot gas tubing  
Weil-McLain  
Propane gas components  
1
2
Gas valve, ½” x ½, two-stage  
CGi-4E  
Honeywell  
511-044-510  
511-330-081  
Pilot kit w/orifice & aluminum pilot gas tubing  
Weil-McLain  
Natural gas and propane gas components  
3
Control module  
United  
Technologies  
511-330-090  
Wiring harness  
Weil-McLain  
Weil-McLain  
591-391-951  
591-391-954  
not shown  
not shown  
4
Timer harness #1 (spliced)  
Air pressure switch  
1.36” w.c.  
CGi-4E  
CGi-4E  
Cleveland  
NS2-1047-09  
TS12190  
511-624-657  
511-842-370  
5
6
Control transformer  
60-second timer relay *  
ABB  
510-350-468  
Tubing, air pressure switch, 0.12 I.D. silicone  
red, to collector hood  
Lydall  
not shown  
590-317-650  
590-317-651  
white, to transition  
* The ABB timer relay TS12190 is designed for 90-second delay, but operates for 60 seconds in the CGi-4E boiler.  
65  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
13a  
Dimensions  
Figure 44 Dimensional drawing  
Boiler  
model  
number  
Supply  
Return  
Gas  
Gas  
“W”  
tapping  
tapping  
connection size  
Note 3  
manifold size  
Note 3  
Jacket  
width  
(inches)  
(inches NPT)  
(inches NPT)  
(inches NPT)  
(inches NPT)  
CGi-4E  
1 ¼  
1 ¼  
½
½
13  
Note 3: Gas piping from meter to boiler to be sized per local utility requirements.  
66  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
13b  
Ratings  
DOE  
(Note 5)  
Table 10 Boiler ratings  
Boiler  
model  
number  
DOE  
0–2,000 feet  
altitude  
2,000–4,500 feet  
altitude  
Net  
Boiler  
DOE  
Vent  
size  
Heating  
capacity  
(Btuh)  
I=B=R  
ratings  
(Btuh)  
water  
content  
(gallons)  
Seasonal  
efficiency  
(% A.F.U.E)  
Input  
Output  
Input  
Output  
(Btuh)  
(Btuh)  
(Btuh)  
(Btuh)  
(Note 4)  
3”  
(Note 1)  
(Note 2)  
76,000  
(Note 3)  
66,000  
90,000  
76,000  
81,000  
68,400  
2.1  
85.0  
CGi-4E  
(Note 5)  
1. Add “PIN” for natural gas boiler - “PILfor 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.  
Notes  
4. CGi-4E 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 Table 3,  
page 14, for vent diameter when chimney draft venting.  
5. As an Energy Star Partner, Weil-McLain has determined that the CGi-4E meets the Energy Star guidelines for  
energy efficiency.  
CGi-4E 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.  
67  
Part Number 550-110-711/1108  
GOLD  
CGi-4E Gas-Fired Water Boiler — Boiler Manual  
Handling ceramic fiber and fiberglass materials  
REMOVAL OF COMBUSTION CHAMBER  
LINING OR BASE PANELS  
REMOVAL OF FIBERGLASS WOOL  
or  
Thecombustion chamber lining or base  
insulation panels in this product con-  
tain 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,“Crystal-  
line silica inhaled in the form of quartz  
or cristobalite from occupational sources  
is carcinogenic to humans (Group 1).:  
INSTALLATION OF FIBERGLASS WOOL,  
COMBUSTION CHAMBER LINING OR  
BASE PANELS:  
Thisproductcontains fiberglass jacket  
insulation and ceramic fiber materi-  
als in combustion chamber lining or  
base panels in gas fired products. Air-  
borne fibers from these materials have  
been listed by the State of California  
as a possible cause of cancer through  
inhalation.  
Precautionary measures  
Avoid breathing fiberglass dust and contact with skin or  
eyes.  
Precautionary measures  
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 recommen-  
dations can be found on the NIOSH web site  
NIOSH approved respirators, manufacturers, and  
phone numbers are also listed on this web site.  
Wear long-sleeved, loose fitting clothing, gloves,  
and eye protection.  
Avoid breathing fiberglass dust and contact with skin  
or 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 recommen-  
dations can be found on the NIOSH web site  
NIOSH approved respirators, manufacturers,  
and phone numbers are also listed on this web  
site.  
Apply enough water to the combustion chamber lining  
or base insulation to prevent airborne dust.  
Wear long-sleeved, loose fitting clothing, gloves,  
and eye protection.  
Remove combustion chamber lining or base insula-  
tion from the boiler and place it in a plastic bag for  
disposal.  
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.  
Wash potentially contaminated clothes separately from  
NIOSH stated First Aid.  
other clothing. Rinse clothes washer thoroughly.  
Eye: Irrigate immediately.  
Breathing: Fresh air.  
NIOSH stated First Aid.  
Eye: Irrigate immediately.  
Breathing: Fresh air.  
68  
Part Number 550-110-711/1108  

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