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GOLD CGi
Gas-Fired Water Boilers
Series 2
• 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.F ailuret o complyc ouldr esultin severep ersonalinj ury, d eatho r substantialp ropertydamag e.
DO NOT USE B
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual How it works . . . Control module ① 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 thermostatcal ls forheat, thec ontrol modulestar ts the system circulator and inducer. The control module runs the inducer long enough to purge the boiler flue passages, t
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual GOLD CGi Gas-Fired Induced-Draft Water Boiler 3 Part Number 550-110-710/0107
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual Contents Howit works ....................................................2–3 Hazard definitions ............................................... 4 Pleaser eadbefor e proceeding ............................ 5 1 Prepare boilerlocation ...................................6–11 2 Prepare boiler ...............................................12–13 3 Venting .........................................................14-19 4
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User Read all instructions before in- • This manual is for use only by your qualified stalling. Follow all instructions in heating installer/service technician. proper order to prevent personal • Please refer to the User’s Information Manual for injury ord eath. yourr eference. • Consider piping and installation when determining • We recommend regular service by a qualified
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 1a Prepare boiler location — codes & checklist Installations must followthese codes: • Local, stat e, provincial, and national codes, la ws, regulations ando rdinances. • NationalF uel Gas Code, ANSI Z3.1–lat est edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1, w henr equired. • NationalEle ctrical Code. • For Canada only: B149.1 or B149. Installati
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 1b Prepare boiler location — clearances RecommendedSER VICEclearances Figure 1b Required MINIMUM clearances (Fig. 1a) 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure1a for recommen- dations. . Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to
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GOLD CGi 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 personalinj ury or death. Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe personalinj ury or death. Direct exhaust venting (Category III) — Do not common vent the CGi
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 1d Prepare boiler location — air contamination Please review the following information on potential Refer to Table 1 for products and areas which may cause combustion airc ontamination problems. contaminatedc ombustionair . To prevent potential of severe personal injury or death, check for products or areas listed below beforeinstal lingb oiler. If any of these contaminants are found: • remove contami
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 1e Prepare boiler location — air openings 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. ✷ If all clearances are at least equal to Figure 1a, page 7, apply the sizing and placement of openings given onpag es 10 and 11. If ANY clearance is less than Figure 1a, page 7, y
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual Unusually tight construction FREE AREA of openings — the minimum areas Unusually tight construction means (per ANSI Z 3.1) given in this manual are free area (equals the area, buildings in which: length times width of opening, after deduction for a. Walls and ceilings exposed to the outside atmo- louvero bstruction). sphere have a continuous water vapor retarder with Use thefr eear eainf
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 2a Prepare boiler — placement & setup Do not operate boiler without Place boiler/cratenear burner shield in place. Failure position to do so could result in severe personal injury, death or sub- 1. Leave boiler in crate and on pallet until installation site stantial property damage. is ready. . Movee ntire crate and pallet next tose lected location. 3. Removecr ate. Orifice replacement 4. Remove boi
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GOLD CGi 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 Pressure test boiler before attaching water or gas piping than: (except as noted below)o r electrical supply. • 45 psigf orb oilers with 30 psig relief valve. Prepareboiler for test • 75 psig forb oilersw ith 50 psig relief valve. 1. Remove
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 3a Venting — general information CGiventing methods — Chimney draft or Directexhaust Chimney draftventing Direct exhaust— verticalor sidewall Chimney draftv entinguses the natural draftp rovided Direct exhaust venting uses inside combustion air with by a vertical vent or chimney. Category I appliance (non- no combustion air connector piping. All CGi flue gas positive vent static pressure
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 3c Venting — Direct exhaust — components Obtain ventsystem components 1. The following special gas vent systems comply with UL-1 38 and ULC- S636 standards and are certified by CSA as the only systems suitable for use with CGib oilers (all3” diameter): ® • Heat-Fab, I nc. Saf-T Vent • Flex-L International, I nc. StaR-34 • Z-Flex®, I nc. Z-Vent II • ProTechS ystems FasNSeal™ Use only the vent
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GOLD CGi 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 cial codesw hen venting the CGib oiler. venting method. 4. Connect vent starter to blower housing outlet as . You must use the vent starter made by the vent pipe shown inthe Figures 8thr o
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 3e Venting — direct exhaust — termination Follow instructions on this page 1. Canadian installations — See B149.1 or B149. when determining vent location to Installation Code. Terminate vent no less than 6 avoid possibility of severe personal feet from another combustion air inlet, 3 feet from injury, death or substantial property any other building opening, and 3 feet from any gas damage.
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 3f Venting — direct exhaust — installation 1. Do not mix types or manufacturers of vent materi- Figure 13 Direct exhaust vertical venting als. . Clean all joints before sealing. See vent manufactur- er’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 v
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 3f Venting — direct exhaust — installation (cont.) Using any termination other than one of those shown Figure 15 Sidewall termination could cause nuisance outages and loss of heat, resulting ins ubstantial propertydamag e. 19 Part Number 550-110-710/0107
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GOLD CGi Gas-Fired Water Boiler — Boiler Manual 4a Water piping — general information Generalpiping information Circulator If installation is to comply with ASME or Canadian requirements, an ad- The circulator is shipped loose (wiring pre-attached to ditional high temperature limit is needed. Install control in supply piping boiler) to allow you to locate it either in the return or between boiler and isolation valve. Set second control to mini
