® GOLD ™ CGi-4E Gas-Fired Water Boiler Boiler Manual • Installation • Maintenance • 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual How it works . . . ① ② ③ ④ ⑤ ⑥ ⑦ Control module The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and inducer. When room thermostat calls for heat, the control module starts the system circulator and inducer.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual GOLD CGi-4E Gas-Fired Induced-Draft Water Boiler Part Number 550-110-711/1108 3
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....................
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User Read all instructions before installing. Follow all instructions in • • proper order to prevent personal injury or death. Consider piping and installation when determining boiler location. Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. • This manual is for use only by your qualified heating installer/service technician.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 1a Prepare boiler location — codes & checklist 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 1b Prepare boiler location — clearances 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 recommendations. 2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 1c Prepare boiler location — vent system 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 1d Prepare boiler location — air contamination Please review the following information on potential combustion air contamination problems. Refer to Table 1 for products and areas which may cause contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 1e ✷ Prepare boiler location — air openings Combustion air opening location and sizing requirements depend on the clearances around the boiler. Check the boiler placement compared to Figure 1a, page 7. Figure 2 Air openings to interior spaces ✷ 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual FREE AREA of openings — the minimum areas given in this manual are free area (equals the area, 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: • 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 2a Prepare boiler — placement & setup Place boiler/crate near position 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. 4. Remove boiler from pallet. Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result. a. Tilt left side of boiler up and place a board under left legs. b.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 2b Prepare boiler — pressure test Hydrostatic pressure test Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply. Prepare boiler for test 1. Remove the shipping nipple (from CGi-4E supply tapping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾” NPT pipe plug. 2.
GOLD 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 Chimney draft venting uses the natural draft provided by a vertical 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.
GOLD 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 ULCS636 standards and are certified by CSA as the only systems suitable for use with CGi-4E boilers (all 3” diameter): • • • • Heat-Fab, Inc. Saf-T Vent® 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 3d Venting — direct exhaust — vent starter 1. Select a vent pipe manufacturer and obtain all vent components needed, based on boiler location and venting method. 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. Use only the vent starter of the same manufacturer as the vent components. Do not mix components from different systems.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 3e Venting — direct exhaust — termination Follow instructions on this page when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. 1. Locate the boiler and vent penetration through the wall so all requirements on this page and in Figure 12 will be met. Also follow vent manufacturer’s instructions. 2. Gases will form white plume in winter. Plume could obstruct window view. 3.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 3f Venting — direct exhaust — installation 1. Do not mix types or manufacturers of vent materials. 2. Clean all joints before sealing. See vent manufacturer’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 horizontal runs. Follow requirements in Section 3e for vent termination. 4. Maintain minimum 2” clearance from combustible materials to vent pipe. 5.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 3f Figure 15 Venting — direct exhaust — installation Sidewall termination Part Number 550-110-711/1108 (cont.) Using any termination other than one of those shown could cause nuisance outages and loss of heat, resulting in substantial property damage.
GOLD 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 additional 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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 bladdertype expansion tank (Figure 16) 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4c Water piping — multiple zones Piping multiple zones Follow instructions on pages 20 and 21 to install nearboiler or single-zone piping. (Also refer to Piping for radiant heating systems or converted gravity systems, below, if applicable.) See Figure 18 or Figure 19 to complete installation. Zoning with circulators (Figure 18) (return temp over 130°F) 1. Size each circulator to individual circuit requirements. 2.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4c Water piping — multiple zones Figure 18 Zoning with circulators — return water 130°F or higher. 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 5 Zone valve 6 Drain valve 9 Relief valve Figure 19 (continued) Zoning with zone valves — return water 130°F or higher. 10 Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion tank).
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4d Piping — low temperature systems Primary/secondary (preferred) bypass piping method 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4d Piping — low temperature systems Figure 20 Primary/secondary piping Zoning with circulators 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve 6 Drain valve 7 System temperature valves (see instruc- tions to the left for adjusting valves) 8 Blend temperature gauge Part Number 550-110-711/1108 Figure 21 (continued) Primary/secondary piping Zoning with zone valves 9 Reli
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4d Piping — low temperature systems BOILER-bypass piping method This piping method (Figure 22 or 23) is called a boilerbypass because part of the circulator flow is bypassed around the boiler (through valve 7a). This method reduces the flow rate throughout the boiler, in order to raise the average water temperature in the boiler enough to prevent flue gas condensation.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4d Piping — low temperature systems Figure 22 Boiler-bypass piping — Zoning with circulators — (Alternative to primary/ secondary piping Figures 20 and 21) 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges Figure 23 (continued) Boiler-bypass piping — Zoning with zone valves — (Alternative to primary/ secondary piping Figures 20 and 21) 9 Relief valve 10 Automatic air vent (with diaphra
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4d Piping — low temperature systems SYSTEM-bypass piping method 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4d Piping — low temperature systems Figure 24 (continued) System-bypass piping — Zoning with zone valve or circulators, return water 130°F or higher — (Alternative to boilerbypass 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 expansion tank), or connect to tank fitting (closed-type
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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. a. Install drip leg at inlet of gas connection to boiler. Where local utility requires drip leg to be extended to the floor, use appropriate length of pipe between cap and tee. b. Install ground joint union for servicing, when required. c.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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. 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 7a Start-up — preparation Check for gas leaks Before starting the boiler, and during 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. Propane boilers only — Your pro- pane supplier mixes an odorant with the propane to make its presence detectable.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 7b Start-up — operate boiler Check burner flames (continued) 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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 temperature? 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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? 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. Correctly sized manifold orifices must be used.
GOLD 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. 2. Raise room thermostat to call for heat. 3. Circulator energizes. If limit circuit is closed, the inducer starts. After pressure switch proves proper airflow, control module initiates 30-second prepurge. 4. Control module sparks the pilot and opens pilot valve in main gas valve. a.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Figure 30 Control module sequence of operation — status light indications Part Number 550-110-711/1108 39
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 9b Figure 31 40 Operation — wiring diagrams Wiring diagram Part Number 550-110-711/1108
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 9c Operating instructions Part Number 550-110-711/1108 • Spark pilot • Natural or propane gas • Gas valve: Honeywell VR8204/VR8304 41
GOLD 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.
GOLD 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 10b Service and maintenance — annual start-up Air openings The boiler should be inspected and started annually, 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 10b ❏ Service & maintenance – annual start-up Inspect . . . Burners and base 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. If insulation is damaged or displaced, do not operate the boiler. Replace or reposition insulation as necessary.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance – annual start-up ❏ Check/test . . . Gas piping 1. Sniff near floor and around boiler area for any indication of a gas leak. (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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance – annual start-up Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 11a Troubleshooting — general Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other device except for momentary testing as outlined in Troubleshooting Charts. Severe personal injury, death or substantial property damage can result.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — components Figure 36 Manometer connections POWER light flashing alone 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).
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — components Figure 38 50 (continued) Control module connections Part Number 550-110-711/1108
GOLD 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.
GOLD 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.
GOLD 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.
GOLD 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.
GOLD 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.
GOLD 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 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.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 12b Figure 39 Replacement parts — section assembly Section assembly Item Description number Weil-McLain part number Item Description number Weil-McLain part number 1 End section, left hand, 51124 311-103-850 6 Washer, M\zn” (1 per tie rod) 562-248-684 2 End section, right hand 51128 311-103-821 7 Radiation plate (1 per joint) 460-003-700 3 Intermediate section, 51125 311-103-818 8 381-354-596 Replacement section assembly 321-114-3
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 12c Replacement parts — base Figure 40 60 Base assembly Part Number 550-110-711/1108
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 12c Replacement parts — base Item (continued) Weil-McLain part number Description Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6 and 7) 1 Base side panel (in Base assembly) 2 Base front cross-tie assembly (in Base assembly) 3 Base back cross-tie assembly (in Base assembly) 4 Burner shield (in Base assembly) 5 Base pan angle, left side (in Base assembly) 6 Base pan angle, right side (in Base assembly) 7 Base pan (in Base a
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 12d Replacement parts — jacket Figure 41 62 Jacket assembly Part Number 550-110-711/1108
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 12d Boiler Model CGi-4E Replacement parts — jacket 1 2 Junction box, 2 x 4 Panel, left side, with insulation (Available at local supply house) (continued) 3 4 5 Panel, right side, with insulation Panel, top front, with insulation Panel, top rear, with insulation 381-355-551 Natural Gas Propane Gas 381-355-610 381-355-612 381-355-613 381-355-413 6 7 8 9 10 Boiler Model Panel, door Cross tie, bottom front Panel, interior, with i
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 12e Replacement parts — trim Figure 42 Item number 1 Trim assembly Description Pressure relief valve, ASME, 30 PSIG, ¾” male inlet Pressure relief valve, ASME, 30 PSIG, ¾” female inlet (Fittings shown are factory-installed on boiler.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 12f Figure 43 Replacement parts — controls Gas control assembly Item Description number Boiler model Manufacturer Manufacturer’s part number CGi-4E Honeywell Weil-McLain part number Natural gas components 1 Gas valve, ½” x ½”, two-state 2 Pilot kit w/orifice & aluminum pilot gas tubing VR8204Q2434 Weil-McLain 511-044-508 511-330-080 Propane gas components 1 Gas valve, ½” x ½”, two-stage 2 Pilot kit w/orifice & aluminum pilot gas tubing
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 13a Figure 44 Dimensions Dimensional drawing Boiler model number CGi-4E 1¼ Note 3: 66 Supply tapping (inches NPT) Return tapping (inches NPT) 1¼ Gas connection size Note 3 (inches NPT) Gas manifold size Note 3 (inches NPT) ½ ½ “W” Jacket width (inches) 13 Gas piping from meter to boiler to be sized per local utility requirements.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 13b Ratings DOE (Note 5) Table 10 Boiler model number (Note 1) CGi-4E Boiler ratings 0–2,000 feet altitude DOE Heating capacity (Btuh) Input (Btuh) Output (Btuh) 2,000–4,500 feet altitude Input (Btuh) Output (Btuh) (Note 2) 76,000 Net I=B=R ratings (Btuh) Boiler water content (gallons) DOE Seasonal efficiency (% A.F.U.E) (Note 4) (Note 3) 90,000 76,000 81,000 68,400 66,000 Vent size 2.1 85.0 3” (Note 5) 1.
GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications.