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®
™
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 ai
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GOLD CGi-4E 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 thermostat calls for heat, the control module starts the system circulator and inducer. The control module runs the inducer long enough to purge the boiler flue passages, then opens the pilot valve and activates pilot
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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
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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 .....
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GOLD CGi-4E 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 r e f e r t o the User’s Information Manual for injury or death. your reference. • C o n s i d e r piping and installation when determining • W e r e c o m m e n d r e g u l a r service
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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 1a Prepare boiler location — codes & checklist Installations must follow these codes: • L o cal, stat e, p r o v incial, and nat io nal c o d es, laws, regulations and ordinances. • N at io nal F ue l Gas C o d e, ANSI Z223.1–lat est e dit io n. • Standar d f o r C o nt r ols and S af e t y D e v ic es f o r A u t o mat ical l y Fir e d B o ile r s, ANSI/ ASME CSD-1, w he n r e q uir e d. • N at io nal Ele c t r ical C o d
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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 a c c ess t o c o nt r ols and c o mp o ne nts. S e e Figur e 1a f o r r e c o mme n- 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
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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 — D o not instal l the CGi-4E int o a c o mmo n v e nt w ith an y othe r ap
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GOLD CGi-4E 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 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: • r e mo v e c o ntaminants p e r mane ntl y — OR —
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GOLD CGi-4E 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. C h ec k t h e b o i l e r p l ac e m e n t c o m p a r ed t o ✷ 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 F
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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual Unusually tight construction FREE AREA of openings — the minimum areas U n u s u a l l y t i g h t c o n s t r u c t i o n m e a n s ( p e r A N S I Z 2 2 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- louver obstruction). sphere have a continuous water vapor retarder with Use the free area
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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 2a Prepare boiler — placement & setup D o not o p e r at e b o ile r w ithou t Place boiler/crate near 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. 2. Move entire crate and pallet next to selected location. 3. Remove crate. Orifice replacement 4. Remove boiler from pallet. proc
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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 2b Prepare boiler — pressure test 5. S lo w l y r e o p e n b o ile r dr ain v al v e unt il t est p r ess ur e 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) 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. R e mo v
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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 D ir e c t e xhaust v e nt ing uses insid e c o mb ust io n air w ith no c o m- C himne y dr aft v e nt ing uses the nat ur al dr aft p r o v id e d b y a v e r- t ical v e nt o r c himne y . C at e g o r y I ap plianc e (no n-p osit i v e v e nt b ustio n air c o
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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 3c Venting — Direct exhaust — components Obtain vent system components 1. T h e f o l l o w i n g s p e c i a l g a s v e n t s y s t e m s c o m p l y w i t h U L - 1 7 3 8 a n d U L C - S636 standar ds and ar e c e r t ifie d b y CSA as the o nl y sy st e ms s uitab le f o r use w ith CGi-4E b o ile r s (al l 3” diame t e r): ® • H eat-F ab , I nc. Saf-T Vent • Fle x-L I nt e r nat io nal, I nc. StaR-
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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 3d Venting — direct exhaust — vent starter 1. S e le c t a v e nt pip e man ufa c t ur e r and o b tain al l v e nt 3. Follow all applicable national, state, local or provin- components needed, based on boiler location and cial c o d es w he n v e nt ing the CGi-4E b o ile r . venting method. 4. C on n e c t v en t s t a r t er t o b l o w er h o u s i n g o ut l e t a s 2. Y ou m ust use the v e nt star t e r
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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 3e Venting — direct exhaust — termination Follow instructions on this page 12. C a n a d i a n i n s t a l l a t i o n s — S e e B 1 4 9 . 1 o r B 1 4 9 . 2 when determining vent location to I n s t a l l a t i o n C o d e . T e r m i n a t e v e n t n o l e s s t h a n 6 avoid possibility of severe personal feet from another combustion air inlet, 3 feet from injury, death or substantial property any other buildi
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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 3f Venting — direct exhaust — installation 1. D o not mix t y p es o r man ufa c t ur e r s o f v e nt mat e r i- Figure 13 Direct exhaust vertical venting als. 2. C lean al l jo ints b e f o r e sealing . S e e v e nt man ufa c- turer’s instructions for cleaning and sealing joints. U se the ir sp e cifie d sealant. D o not use scr e w s. 3. Install vent pipe with seams on top of vent horizon- tal r uns. F ol lo w r e
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GOLD CGi-4E 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 in substantial property damage. 19 Part Number 550-110-711/1108
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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual 4a Water piping — general information General piping information Circulator I f instal lat io n is t o c o mpl y w ith ASME o r C ana dian r e q uir e me nts, an a d- 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 b e tw e e n b o ile r and isolat io n v al v e. S e t se c o nd c
