Weil-McLain CGi Series 2 User manual

GOLD CGi
Series 2 Gas-Fired Water Boiler
High Altitude Conversion Kit
Instructions
Part Number 550-141-890/0300
Note to the installer
Failure to follow the limitations listed below will cause severe personal injury,
death or substantial property damage.
• Do not use this kit to convert a CGi boiler from natural gas to propane
gas or from propane gas to natural gas.
• Use only the kit specified for the CGi boiler being converted.
This conversion kit must only be installed by a Weil-McLain distributor or
other qualified technician in accordance with these Instructions and all
applicable codes and requirements of the authority having jurisdiction. Read
these instructions completely before beginning the installation. If the
information in these Instructions is not followed exactly, a fire, explosion,
carbon monoxide emission or other hazardous conditions can result,
causing severe personal injury, death or substantial property damage. The
qualified technician performing this work assumes responsibility for this
conversion.
Hazard definitions
The following terms are used throughout these Instructions to bring attention to the presence
of hazards of various risk levels or to important information concerning the life of the product.
Indicates presence of hazards that will cause severe personal injury, death
or substantial property damage.
Indicates presence of hazards that can cause severe personal injury, death
or substantial property damage.
Indicates presence of hazards that will or can cause minor personal injury
or property damage.
Indicates special instructions on installation, operation or maintenance that
are important but not related to personal injury or property damage.
2,000 to 10,000 feet

Part Number 550-141-890/0300
2
GOLD CGi Series 2 Gas-Fired Water Boiler
Conversion instructions
For the boiler to operate correctly
at high altitude, you must replace
the main burner orifices and the air
pressure switch with the parts
supplied in the appropriate
conversion kit (selected by altitude
and boiler model). Failure to do so
could result in severe personal
injury, death or substantial property
damage.
For your safety, turn off electrical
power supply and turn off external
gas supply valve before attempting
to work on the boiler. Failure to
comply could result in severe
personal injury, death or substantial
property damage.
1. Using a 7 /16" open-end wrench, remove the burner
orifices from the manifold.
2. Apply a small amount of pipe dope to each of the
new (conversion kit) orifices and install in the
manifold using the 7 /
16" open-end wrench. Make sure
the orifices are aligned correctly, not cross-threaded
in the manifold tappings. Do not over-tighten
orifices.
Use only pipe dope compatible with
propane gas, even if boiler is to be
operated on natural gas. Failure to
comply could result in severe
personal injury, death or substantial
property damage.
Refer to Table 1 and Table 2 on page
3 for the conversion kit components.
Verify that you have the correct
orifice size and quantity for the
altitude and boiler model.You must
replace all burner orifices with the
correctly-sized conversion kit
orifices. Failure to do so will result
in severe personal injury, death or
substantial property damage.
3. Affix“High Altitude Conversion Label”above boiler
rating label. Affix “Consumer Protection Label”
above the boiler CP label.
4. Remove tubing and wires from existing pressure
switch. Remove pressure switch and replace with
pressure switch in kit (Refer to Figure 1):
a. Reconnect white hose to left side barb on
pressure switch.
b. Reconnect red hose to right side barb on
pressure switch.
c. Reconnect the two red wires to the pressure
switch.
5. Follow CGi Series 2 Boiler Manual “Start-up” and
“Operation” procedures to assure the boiler is now
operating properly after conversion parts are
installed.
Figure 1 Pressure switch connections
White
White
White
Flue collector
Interior
panel
Rear
panel
Side
panel
Red
Red
Red
73001

Part Number 550-141-890/0300 3
High Altitude Conversion Kit Instructions
Parts
Table 1 Natural gas conversion kit Table 2 Propane gas conversion kit
Boiler
model
number
Altitude
(feet) Kit part number Main burner
orifices
Air
pressure
switch
setting
Qty Size
CGi-25
2,000 to 4,999 510-811-840 2#45
1.22" w.c.
5,000 to 6,999 510-811-841 2#46
7,000 to 8,999 510-811-842 2#47
9,000 to 10,000 510-811-843 2#48
CGi-3
2,000 to 4,999 510-811-845 2#38
1.22" w.c.
5,000 to 6,999 510-811-846 2#40
7,000 to 8,999 510-811-847 2#41
9,000 to 10,000 510-811-848 2#43
CGi-4
2,000 to 4,999 510-811-850 3#38
0.95" w.c.
5,000 to 6,999 510-811-851 3#40
7,000 to 8,999 510-811-852 3#41
9,000 to 10,000 510-811-853 3#43
CGi-5
2,000 to 4,999 510-811-855 4#38
0.80" w.c.
5,000 to 6,999 510-811-856 4#40
7,000 to 8,999 510-811-857 4#41
9,000 to 10,000 510-811-858 4#43
CGi-6
CGi-7
CGi-8
2,000 to 4,999 510-811-860 7#38
0.60" w.c.
5,000 to 6,999 510-811-861 7#40
7,000 to 8,999 510-811-862 7#41
9,000 to 10,000 510-811-863 7#43
Note: Each kit also includes (1) High Altitude Label, (1) Consumer
Protection Label and (1) Instruction Sheet
Boiler
model
number
Altitude
(feet) Kit part number Main burner
orifices
Air
pressure
switch
setting
Qty Size
CGi-25
2,000 to 6,999 510-811-875 2#55 1.22" w.c.
7,000 to 10,000 510-811-876 2#56
CGi-3
2,000 to 6,999 510-811-878 2#53 1.22" w.c.
7,000 to 10,000 510-811-879 2#54
CGi-4
2,000 to 6,999 510-811-881 3#53 0.95" w.c.
7,000 to 10,000 510-811-882 3#54
CGi-5
2,000 to 6,999 510-811-884 4#53 0.80" w.c.
7,000 to 10,000 510-811-885 4#54
CGi-6
CGi-7
CGi-8
2,000 to 6,999 510-811-887 7#53 0.60" w.c.
7,000 to 10,000 510-811-888 7#54
Note: Each kit also includes (1) High Altitude Label, (1) Consumer
Protection Label and (1) Instruction Sheet

4Part Number 550-141-890/0300
GOLD CGi Series 2 High Altitude Conversion Kit Instructions