Weil-McLain GOLD CGi-4E User Manual

Part No. 550-110-711/1108 This manual must only be used by a qualified heating installer/service technician. Before installing, read all instructi

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual10Part Number 550-110-711/1108Figure 5 Air from outdoors — horizontal ductsFigure 4 Air from outdo

Part Number 550-110-711/110811GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualUnusually tight constructionUnusuallytightconstructionmeans(perAN

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual12Part Number 550-110-711/1108Prepare boiler — placement & setup2aTable 2 Manifold orifice sizin

Part Number 550-110-711/110813GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualPrepare boiler — pressure testHydrostatic pressure testPressure test b

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual14Part Number 550-110-711/1108Venting — general information3aCGi-4E venting methods — Chimney draft

Part Number 550-110-711/110815GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualVenting — Direct exhaust — components3cObtain vent system components1.

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual16Part Number 550-110-711/1108Venting — direct exhaust — vent starter3d1. Selectaventpipemanufa

Part Number 550-110-711/110817GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Follow instructions on this page when determining vent location

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual18Part Number 550-110-711/1108Venting — direct exhaust — installation3f1. Donotmixtypesormanuf

Part Number 550-110-711/110819GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualFigure 15 Sidewall terminationVenting — direct exhaust — installation

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual2Part Number 550-110-711/1108How it works . . .① Control moduleThe control module responds to signa

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual20Part Number 550-110-711/1108Water piping — general information4aGeneral piping informationIfinsta

Part Number 550-110-711/110821GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualWater piping — single-zone system4bDiaphragm-type or bladder-type expa

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual22Part Number 550-110-711/11084cPiping multiple zonesFollow instructions on pages 20 and 21 to insta

Part Number 550-110-711/110823GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualFigure 18 Zoning with circulators — return water 130°F or higher.Figu

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual24Part Number 550-110-711/11084d Failure to prevent low return water temperature to the boiler coul

Part Number 550-110-711/110825GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 1Boilerisolation(balancing)valves 2 Flow/check valve 3System

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual26Part Number 550-110-711/1108BOILER-bypass piping methodThis piping method (Figure 22 or 23) is cal

Part Number 550-110-711/110827GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual1 Boilerisolation(balancing)valves2 Flow/check valve3 Systemor

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual28Part Number 550-110-711/1108Piping — low temperature systems4dSYSTEM-bypass piping methodThis pipi

Part Number 550-110-711/110829GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 3Systemorzonecirculator 7Systemtemperaturevalves(seeinstru

Part Number 550-110-711/11083GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualGOLD CGi-4E Gas-Fired Induced-Draft Water Boiler

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual30Part Number 550-110-711/1108Gas piping5Table 7 Pipe capacity for 0.60 specific gravity natural gas

Part Number 550-110-711/110831GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualField wiring6Thermostat1. Connectthermostatasshownonwiringdiagr

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual32Part Number 550-110-711/1108Start-up — preparation7aCheck for gas leaks  Beforestartingtheboil

Part Number 550-110-711/110833GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualFill the system with water1. Closemanualandautomaticair vents and

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual34Part Number 550-110-711/1108Start-up — operate boiler7b DO NOT proceed with boiler operation unl

Part Number 550-110-711/110835GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualFigure 29 Typical main burner flameCheck burner flamesViewpilotandma

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual36Part Number 550-110-711/1108Start-up — if boiler doesn’t start . . .7c1. Loose connections, blown

Part Number 550-110-711/110837GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualCheck-out procedure — checklist8❏ Boilerandheatdistributionunits

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual38Part Number 550-110-711/1108Operation — sequence9a1. Read Operating instructions on page 41. This

Part Number 550-110-711/110839GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Figure 30 Control module sequence of operation — status light indica

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual4Part Number 550-110-711/1108Contents How it works ...

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual40Part Number 550-110-711/1108Operation — wiring diagrams9bFigure 31 Wiring diagram

Part Number 550-110-711/110841GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual9c Operating instructions• Spark pilot • Natural or propane gas

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual42Part Number 550-110-711/1108Addendum Instruction for the Commonwealth of Massachusetts This adde

Part Number 550-110-711/110843GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualTable 8 Service and maintenance schedulesService and maintenance — sc

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual44Part Number 550-110-711/1108Air openings1. Verifythatcombustionandventilationairopeningsto

Part Number 550-110-711/110845GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual❏ Inspect . . .Burners and base The boiler contains ceramic fiber

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual46Part Number 550-110-711/110810b❏ Check/test . . .Gas piping1. Sniffnearoorandaroundboiler

Part Number 550-110-711/110847GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual❏ Review with owner1. Review the User’s Information Manual with t

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual48Part Number 550-110-711/1108Troubleshooting — general11aAir pressure switch Make sure boiler wate

Part Number 550-110-711/110849GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualTroubleshooting — components11bFigure 36 Manometer connectionsControl

Part Number 550-110-711/11085GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualPlease read before proceeding Failure to adhere to the guidelines on t

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual50Part Number 550-110-711/1108Troubleshooting — components (continued)11bFigure 38 Control module c

Part Number 550-110-711/110851GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualTroubleshooting — control module lights11cCHART 1 — Troubleshooting PO

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual52Part Number 550-110-711/1108Troubleshooting — control module lights (cont.)11cElectrical shock haz

Part Number 550-110-711/110853GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualTroubleshooting — control module lights (cont.)11cCHART 3 — PRESS SWIT

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual54Part Number 550-110-711/1108Troubleshooting — control module lights (cont.)11c• Turn off power to

Part Number 550-110-711/110855GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualTroubleshooting — control module lights (cont.)11cCHART 5 — PRESS SWIT

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual56Part Number 550-110-711/1108Troubleshooting — control module lights (cont.)11c• TURN OFF POWERto b

Part Number 550-110-711/110857GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualTroubleshooting — control module lights (cont.)11cCHART 7 — Insufficie

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual58Part Number 550-110-711/1108Replacement parts12a Replacement parts must be purchased through a l

Part Number 550-110-711/110859GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualReplacement parts — section assembly12bFigure 39 Section assemblyItem

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual6Part Number 550-110-711/1108Prepare boiler location — codes & checklist1aInstallations must fol

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual60Part Number 550-110-711/1108Replacement parts — base12cFigure 40 Base assembly

Part Number 550-110-711/110861GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualReplacement parts — base (continued)12cItem DescriptionWeil-McLainpart

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual62Part Number 550-110-711/1108Replacement parts — jacket12dFigure 41 Jacket assembly

Part Number 550-110-711/110863GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualReplacement parts — jacket (continued)12dBoiler Model1 2 3 4 5Boiler M

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual64Part Number 550-110-711/1108Replacement parts — trim12eFigure 42 Trim assemblyItemnumberDescripti

Part Number 550-110-711/110865GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualReplacement parts — controls12fFigure 43 Gas control assemblyItemnumb

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual66Part Number 550-110-711/1108Dimensions13aFigure 44 Dimensional drawingBoilermodelnumberSupplytapp

Part Number 550-110-711/110867GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualRatingsTable 10 Boiler ratings13b CGi-4Eboilersforresidentialrad

68Part Number 550-110-711/1108GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualHandling ceramic fiber and fiberglass materialsREMOVAL OF COMBUSTION CHA

Part Number 550-110-711/11087GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualPrepare boiler location — clearances1bFigure 1b Required MINIMUM clear

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual8Part Number 550-110-711/1108Prepare boiler location — vent system1c Failure to follow all instruct

Part Number 550-110-711/11089GOLD CGi-4E Gas-Fired Water Boiler — Boiler ManualPrepare boiler location — air contaminationTable 1 Corrosive or destru