GOLD CGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler Manual12aReplacement partsSection assembly. 59Base . 61Jacket . 62Trim . 63Controls . 64Replacement parts must be purchased through a local Weil-McLaindistributor. When ordering, specify boiler model and size and includedescription and part number of replacement part. Results from usingmodified or other manufactured parts will not be covered by warrantyand may damage boiler or impair operation.Weil-McLain part numbers are found in Weil-McLain Boilers andControls Repair Parts Lists.The boiler contains ceramic fiber and fiberglass materials. Use care whenhandling these materials per instructions on page 67 of this manual.Failure to comply could result in severe personal injury.58Part Number 550-110-710/1211

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler Manual12bFigure 39Replacement parts — section assemblySection assemblyItemDescriptionnumberWeil-McLainpart numberItem DescriptionnumberWeil-McLainpart number1End section, left hand, 51124311-103-8506Washer, M\zn” (1 per tie rod)562-248-6842End section, right hand 51128311-103-8217Radiation plate (1 per joint)460-003-7003Intermediate section, 14-334321-114-335Collector hood CGi-25and transition -599381-354-600notshownSection replacement kit, includesseals and sealant for 1 560-234-502560-234-503560-234-504560-234-505High limit, 30 differential,with well10Inducer fan assembly kit, includesinducer fan assembly, gasket andnuts381-356-499561-928-23511Gasket, inducer590-317-62745Tie rod, M\zn”without nut (3per boiler):CGi-25 and CGi-3CGi-4CGi-5CGi-6CGi-7CGi-8CGi-25 and CGi-3CGi-4CGi-5CGi-6CGi-7CGi-8Nut, M\zn” (2 per tie rod)Part Number B81-359

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler Manual12cReplacement parts — baseFigure 4060Base assemblyPart Number 550-110-710/1211

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler Manual12cReplacement parts — baseItem(continued)Weil-McLainpart numberDescriptionBase assembly kit(includes base panels items 1, 2, 3, 4, 5, 6and 7)CGi-25 & CGi-3CGi-4CGi-5CGi-6CGi-7CGi-81Base side panel (in Base assembly)2Base front cross-tie assembly (in Base assembly)3Base back cross-tie assembly (in Base assembly)4Burner shield (in Base assembly)5Base pan angle, left side (in Base assembly)6Base pan angle, right side (in Base assembly)7Base pan (in Base 340381-354-341381-354-3427aBase pan air baffle (in Base assembly)8aBurner mounting plateCGi-25 & ar spacing stripCGi-25 & t, hex 5mm Zp9Base insulation kit550-320-170CGi-25 & CGi-3CGi-4CGi-5CGi-6CGi-7CGi-810Boiler leg kit11Manifold12Main burner orifice — Natural gas, sea level (see Table 2, page 12for orifice size)CGi-25CGi-3 and CGi-5CGi-4 and CGi-6 - 81-354-334381-354-335550-320-219CGi-25 & 529-090560-529-126560-529-077Main burner orifice — Liquefied Petroleum (Propane) gas, sealevel (see Table 2, page 12 for orifice size)CGi-25CGi-3 and CGi-5CGi-4 and CGi-6 - 200-07614Screw, 10-32 x .0.38 STP type 23 hex, washer head slot562-135-71015Rollout thermal fuse element512-050-230Part Number 550-110-710/121161

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler Manual12dReplacement parts — jacketFigure 41Jacket assembly12345Junction box, 2 x 4Panel, left side,with insulationPanel, right side,with insulationPanel, top front,with insulationPanel, top rear,with insulationNatural GasBoilerModelPropane GasBoilerModelWeil-McLain part numberCGi-25(Available at 81-355-539CGi-25CGi-3supply el, doorCross tie,bottom frontPanel, interior,with insulationPanel, rear,with insulationNot shown — goldtouch-up -443431-223-305CGi-8Part Number 550-110-710/1211

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler Manual12eReplacement parts — trimFigure 42Itemnumber1Trim assemblyDescriptionPressure relief valve, ASME, 30 PSIG, ¾” male inletPressure relief valve, ASME, 30 PSIG, ¾” female inlet(Fittings shown are factory-installed on boiler.)ManufacturerManufacturer’spart numberWeil-McLainpart 8-05335511-546-920511-546-9242Combination pressure-temperature gauge, 3Z\,” diameter,short shank (Fittings shown are shipped loose withboiler.)Weil-McLain3Drain valve, ¾”(Fittings shown are included with 511-246-392Taco007511-405-1134Circulator(Fittings shown are shipped loose with boiler.)5Circulator gasket, universal (2 per boiler)notshown6Circulator hardware kit, includes:1 flange, 2 nuts, 2 screws, 1 gasket —¾” NPT — --1” NPT — CGi-3 through CGi-5----------------------------1¼” NPT — CGi-6 and CGi-7-------------------------------1½” NPT — Circulator wiring harness kit, with Molex (loose)Part Number -354-526381-354-531381-354-52863

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler Manual12fReplacement parts — controlsFigure 43ItemnumberGas control assemblyDescriptionNatural gas components1Gas valve, ½” x ½”Gas valve, ¾” x ¾”2Gas valve, ¾” x ¾”2Manufacturer Manufacturer’spart numberCGi-25 -- 0CGi-7 & CGi-8Pilot kit w/orifice & aluminum pilot gas tubingPropane gas components1Gas valve, ½” x ½”CGi-25 -- CGi-6CGi-7 & CGi-8Pilot kit w/orifice & aluminum pilot gas tubingNatural gas and propane gas components3Control modulenot shown Wiring harness45Air pressure switch1.79” w.c.1.40” w.c.1.12” w.c.0.80” w.c.0.75” w.c.Control transformerCGi-25 & CGi-3CGi-4CGi-5CGi-6 & CGi-8CGi-7not shown Tubing, air pressure switch, 0.12 I.D. siliconered, to collector hoodwhite, to transition64Weil-McLainpart numberBoiler 5511-842-370590-317-650590-317-651Part Number 550-110-710/1211

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler Manual13aFigure 44DimensionsDimensional drawingBoilermodelnumberSupplytapping(inches NPT)Returntapping(inches NPT)Gasconnection sizeNote 3(inches NPT)Gasmanifold sizeNote 3(inches Note 3: Gas piping from meter to boiler to be sized per local utility requirements.Part Number 550-110-710/121165

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler Manual13bRatings(Note 5)Table 10 Boiler ote 1)(Note ,00042,000CGi-351,00060,000CGi-485,000CGi-5NetI B Rratings(Btuh)BoilerDOEwaterSeasonalVent sizecontent efficiency(gallons) (% AFUE)Output(Btuh)(Note 3)(Note 5)(Note 210,000175,000169,0004.482.73”(Note 5)0 - 2,000 feetaltitude2,000 - 4,500 feetaltitude1. Add “PIN” for natural gas boiler - “PIL” for Liquefied Petroleum (propane) gas boiler.2. Based on standard test procedures prescribed by the United States Department of Energy.Notes3. Net I B R ratings are based on net installed radiation of sufficient quantity for the requirements ofthe building and nothing need be added for normal piping and pickup. Ratings are based on a pipingand pickup allowance of 1.15. An additional allowance should be made for unusual piping and pickuploads.4. CGi boilers require special venting, consistent with Category I or III boiler. Use only the vent materialsand methods specified in this manual. Vent diameter shown above is for direct exhaust venting. SeeTable 3, page 14, for vent diameter when chimney draft venting.5. As an Energy Star Partner, Weil-McLain has determined that the CGi-3 meets the Energy Star guidelines forenergy efficiency.CGi 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 returnsize 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 for50 psi working pressure.66Part Number 550-110-710/1211

GOLDCGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler ManualHandling ceramic fiber and fiberglass materialsREMOVAL OF COMBUSTION CHAMBERLINING OR BASE PANELSThe combustion chamber lining or baseinsulation panels in this product contain ceramic fiber materials. Ceramicfibers can be converted to cristobalite invery high temperature applications. TheInternational Agency for Research onCancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartzor cristobalite from occupational sourcesis carcinogenic to humans (Group 1).”:Precautionary measures Avoid breathing fiberglass dust and contact with skin oreyes. Use NIOSH certified dust respirator (N95).This type of respirator is based on theOSHA requirements for fiberglass wool at thetime this document was written. Other types ofrespirators may be needed depending on thejob site conditions. Current NIOSH recommendations can be found on the NIOSH web siteat http://www.cdc.gov/niosh/homepage.html.NIOSH approved respirators, manufacturers, andphone numbers are also listed on this web site. Wear long-sleeved, loose fitting clothing, gloves,and eye protection. Apply enough water to the combustion chamber liningor base insulation to prevent airborne dust. Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag fordisposal. Wash potentially contaminated clothes separately fromother clothing. Rinse clothes washer thoroughly.NIOSH stated First Aid. Eye: Irrigate immediately. Breathing: Fresh air.Part Number 550-110-710/1211REMOVAL OF FIBERGLASS WOOLorINSTALLATION OF FIBERGLASS WOOL,COMBUSTION CHAMBER LINING ORBASE PANELS:This product contains fiberglass jacketinsulation and ceramic fiber materials in combustion chamber lining orbase panels in gas fired products. Airborne fibers from these materials havebeen listed by the State of Californiaas a possible cause of cancer throughinhalation.Precautionary measures Avoid breathing fiberglass dust and contact with skinor eyes. Use NIOSH certified dust respirator (N95).This type of respirator is based on theOSHA requirements for fiberglass wool at thetime this document was written. Other types ofrespirators may be needed depending on thejob site conditions. Current NIOSH recommendations can be found on the NIOSH web siteat http://www.cdc.gov/niosh/homepage.html.NIOSH approved respirators, manufacturers,and phone numbers are also listed on this website. Wear long-sleeved, loose fitting clothing, gloves,and eye protection. Operations such as sawing, blowing, tear out, andspraying may generate airborne fiber concentrationrequiring additional protection. Wash potentially contaminated clothes separately fromother clothing. Rinse clothes washer thoroughly.NIOSH stated First Aid. Eye: Irrigate immediately. Breathing: Fresh air.67

GOLD68CGi GAS-FIRED WATER BOILER — SERIES 2 — Boiler 710/1211

Weil-McLain 380-000-000 3 Drain valve, ¾” (Fittings shown are included with boiler.) Conbraco Hammond Valve Matco-Norca Watts 31-606-01 710 205F04 BD-2C 511-210-423 511-246-392 511-246-392 511-246-392 4 Circulator (Fittings shown are shipped loose with boiler.) Taco 007 511-405-113 5 Circulator gasket, universal (2 per