Weil-McLain CGi-25, CGi-3, CGi-4, CGi-5, CGi-6 User Manual

...

GOLD CGi Series 2 Gas-Fired Water Boiler

How it works . . .

①

②

③

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.

The control module runs the inducer long enough to purge the boiler flue passages, then opens the pilot valve and activates pilot ignition spark.

The control module allows up to 15 seconds to establish pilot flame. If flame is not sensed within 15 seconds, the control module will turn off the gas valve, flash the Flame light, and then enter a 15-second postpurge. The control module will then start a new cycle. This will continue indefinitely until pilot flame is established or power is interrupted. Once pilot flame is proven, the control module opens the gas valve to allow main burner flame.

When the room thermostat is satisfied, the control module turns off the gas valve, operates the inducer for a 15-second postpurge and waits for the next heat call.

The control module indicator lights show normal sequence when the lights are on steady. When a problem occurs, the control module flashes combinations of lights to indicate the most likely reason for the problem (see page 47).

Transformer

The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit.

Inducer

The inducer pulls flue gases through the boiler, causing air to be pulled in through the boiler air openings. The inducer pushes the flue gases through the vent pipe as well.

④

⑤

Air pressure switch

The air pressure switch signals the control module, telling the control module whether the inducer is working correctly or the vent is blocked.

Water temperature limit switch

The water temperature limit switch turns off the gas valve if the temperature in the boiler goes above its setting. (The circulator will continue to run as long as there is a call for heat.)

Boiler circulator

The boiler circulator circulates water through the external (system) piping. The circulator is shipped loose, and can be mounted on either the boiler supply or return piping. The factoryinstalled circulator wiring harness provides ample length for either location. NOTE — The control module provides a pump exercising routine. If the boiler is not operated for 30 days, the control module will power the circulator for 30 seconds, then turn off.

Other boiler components:

a supply to system

b return from system

c stainless steel burners

d flue outlet

e gas valve

f pressure/temperature gauge

g relief valve

h air vent connection

i flame rollout thermal fuse

element (TFE)

j burner shield

k pilot burner and bracket

l gas manifold

m cast iron boiler sections

n flue collector

o junction box

Part Number 550-110-710/0200

GOLD CGi Series 2 Gas-Fired Water Boiler

Contents

How it works .................................................................. 2–3

Hazard definitions.............................................................. 4

Please read before proceeding ......................................... 5

Prepare boiler location ................................................ 6–11

Prepare boiler............................................................. 12–13

Venting ........................................................................14-19

Water piping ............................................................... 20-29

Gas piping ........................................................................ 30

Field wiring ...................................................................... 31

Start-up .......................................................................32-35

Check-out procedure....................................................... 36

Operation ....................................................................37-40

Service and maintenance........................................... 41-45

Troubleshooting ......................................................... 46-55

Replacement parts ..................................................... 56-61

Dimensions and ratings .............................................62-63

Hazard definitions

The following defined terms are used throughout this manual 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.

Part Number 550-110-710/0200

Boiler Manual

Please read before proceeding

Installer

Read all instructions before installing.

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.

When calling or writing about the boiler— Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket. You may list the CP number in the space provided on the Installation and service certificate found on page 36.

Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage.

When servicing boiler —

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation —

• Do not block flow of combustion or ventilation air to boiler.

• Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

• Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water.

Boiler water —

• Do not use petroleum-based cleaning or sealing compounds in boiler system. Water seal deterioration will occur, causing leakage between sections. This can result in substantial property damage.

• Do not use "homemade cures" or "boiler patent medicines". Serious damage to boiler, personnel and/or property may result.

Follow all instructions in

User

• This manual is for use only by your qualified

heating installer/service technician.

• Please refer to the User’s Information Manual for your reference.

• We recommend regular service by a qualified

service technician, at least annually.

• Continual fresh makeup water will reduce boiler

life. Mineral buildup in sections reduces heat transfer, overheats cast iron, and causes section failure. Addition of oxygen and other gases can cause internal corrosion. Leaks in boiler or piping must be repaired at once to prevent makeup water.

• Do not add cold water to hot boiler. Thermal

shock can cause sections to crack.

Glycol — potential fire hazard —

All glycol is flammable when exposed to high temperatures. If glycol is allowed to accumulate in or around the boiler or any other potential ignition source, a fire can develop. In order to prevent potential severe personal injury, death or substantial property damage from fire and/or structural damage:

• Never store glycol of any kind near the boiler or

any potential ignition source.

• Monitor and inspect the system and boiler

regularly for leakage. Repair any leaks immediately to prevent possible accumulation of glycol.

• Never use automotive antifreeze or ethylene

glycol in the system. Using these glycols can lead to hazardous leakage of glycol in the boiler system.

Part Number 550-110-710/0200

GOLD CGi Series 2 Gas-Fired Water Boiler

Prepare boiler location —

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 C22.1 Canadian Electrical Code Part 1 and any local codes.

The CGi boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13–latest edition.

codes & checklist

Before locating the boiler,

check the following:

• Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids.

Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

• Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

• If new boiler will replace existing boiler, check for and correct system problems, such as:

1. System leaks causing oxygen corrosion or section cracks from hard water deposits.

2. Incorrectly-sized expansion tank.

3. Lack of antifreeze in boiler water causing system and boiler to freeze and leak.

Part Number 550-110-710/0200

Boiler Manual

Boiler model

Minimum foundation length

Minimum foundation width

CGi-25 25" 12"

CGi-3 25" 12"

CGi-4 25" 15"

CGi-5 25" 18"

CGi-6 25" 21"

CGi-7 25" 24"

CGi-8 25" 27"

Prepare boiler location — clearances1b

Provide the following clearances:

1. Hot water pipes — at least ½" from combustible materials.

2. Recommended service clearances — See

3. Minimum clearances for tight spaces — See

Figure 2.

Figure 1 Recommended clearances for service

35"

24"

18"

71002

Figure 1.

Flooring and foundation

Flooring

The CGi boiler is approved for installation on combustible flooring, but must never be installed on carpeting.

Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage.

Foundation

Provide a solid brick or concrete foundation pad if any of the following is true:

• floor can become flooded.

• the boiler mounting area is not level.

The minimum foundation size is:

minimum 2-inch thick

Figure 2 Minimum clearances for tight spaces

Part Number 550-110-710/0200

71003

Provide

openings

and 6" from bottom located on wall next to boiler front..

(2) fresh air

— 6" from top

Each opening must have

free area of square

inch per of

1,000 Btuh

CGi boiler input.

Residential garage installation

Precautions

Take the following special precautions when installing the boiler in a residential garage. If the boiler is located in a residential garage, per ANSI Z223.1, paragraph

5.1.9:

• Mount the boiler a minimum of

above the floor

of the garage to assure the burner and ignition devices will be no less than 18 inches above the floor.

• Locate or protect the boiler so it cannot be damaged by a moving vehicle.

18 inches

GOLD CGi Series 2 Gas-Fired Water Boiler

Prepare boiler location — vent system

CGi venting

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 install the CGi into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.

When removing boiler from existing common vent system:

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting

system.

b. Visually inspect the venting system for proper

size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

Test vent system — Insofar as is practical, close

all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected.

Follow the operating instructions. Adjust thermostat so appliance will operate continuously.

Test for spillage at draft hood relief opening after

5 minutes of main burner operation. Use the flame of a match or candle.

f. After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1–latest edition. Correct by resizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code. Canadian installations must comply with B149.1 or B149.2 Installation Code.

Chimney or vent requirements

1. Venting must be installed according to Part 7, Venting of Equipment, of National Fuel Gas Code, ANSI Z223.1–latest edition and applicable building codes. Canadian installations must comply with B149.1 or B149.2 Installation Codes.

2. See Ratings table on page 67 for minimum chimney or vent sizes. A chimney or vent

cap

should extend at least 3 feet above the highest

where it passes through a roof of a building

point

and

at least 2 feet higher than any portion of a

building within a horizontal distance of 10 feet

chimney or vent must not extend less than the distances stated above.

3. A lined chimney is preferred and must be used when required by local, state, provincial and national codes, laws, regulations and ordinances. Vitreous tile linings with joints that prevent retention of moisture and linings made of noncorrosive materials are best. Advice for flue connections and chimney linings can be obtained from local gas utility. pipe or single-wall vent pipe may be used as a liner.

4. Cold masonry chimneys, also known as outside chimneys, typically have one or more walls exposed to outside air.When any atmospheric gas-fired boiler with automatic vent damper is vented through this type of chimney, the potential exists for condensation to occur. Condensation can damage a masonry chimney. Weil-McLain recommends the following to prevent possible damage.

a. Line chimney with corrosion-resistant metal

liner such as AL29-4C® single-wall stainless steel or B-vent. Size liner per National Fuel Gas Code ANSI Z223.1–latest edition.

b. Provide drain trap to remove any condensate.

Type B double-wall metal vent

without a listed

. A

Part Number 550-110-710/0200

Boiler Manual

Prepare boiler location — contamination

Air contamination

Please review the following information on potential combustion air contamination problems.

If the boiler is installed in any area likely to cause contamination, or if products which would contaminate the air cannot be removed, you must either remove products permanently or isolate the boiler and provide outside combustion air. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage.

Table 1 Corrosive contaminants

Products to avoid Areas likely to have contaminants

Spray cans containing chloro/fluorocarbons Dry cleaning/laundry areas and establishments

Permanent wave solutions Swimming pools

Refer to Table 1 for products and areas which may cause contaminated combustion air.

Chlorinated waxes/cleaners Metal fabrication plants

Chlorine-based swimming pool chemicals Beauty shops

Calcium chloride used for thawing Refrigeration repair shops

Sodium chloride used for water softening Photo processing plants

Refrigerant leaks Auto body shops

Paint or varnish removers Plastic manufacturing plants

Hydrochloric acid/muriatic acid Furniture refinishing areas and establishments

Cements and glues New building construction

Antistatic fabric softeners used in clothes dryers Remodeling areas

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Garages with workshops

Adhesives used to fasten building products and other similar products

Part Number 550-110-710/0200

GOLD CGi Series 2 Gas-Fired Water Boiler

Other

appliances

Air

opening

Air

opening

0 to 12"

Outside

Each opening free area = 1 sq. inch per 4,000 Btuh

71005

CGi boiler

MODEL

CGi

Prepare boiler location — air openings1e

Combustion air and ventilation openings must comply with Section 5.3, Air for Combustion and Ventilation , of National Fuel Gas Code ANSI Z223.1–latest edition, or applicable local building codes. Canadian installations must comply with B149.1 or B149.2 Installation Codes.

Provide adequate combustion and ventilation air to assure proper combustion and reduce the risk of severe personal injury, death or substantial property damage caused by flue gas spillage and carbon monoxide emissions.

Air from inside building

(boiler in interior room - Figure 3)

1. Tightly constructed buildings must be provided with openings to outside for combustion and ventilation air. These openings must be sized to handle all fuel burning appliances, exhaust or ventilation fans and fireplaces.

2. When openings to boiler room are taken to interior spaces, provide two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling.

Air directly from outside to boiler room

1. Tightly constructed buildings must be provided with combustion and ventilation air openings to boiler room, which are adequate to handle the boiler needs plus the needs of all other fuel burning appliances, exhaust or ventilation fans and fireplaces.

2. When combustion air is supplied to the boiler

directly through outside walls (Figure 4):

space Provide two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling.

Each opening must provide a minimum free area of 1 square inch per 4,000 Btuh of input of all appliances in room plus requirements for any exhaust fans in room. The interior space supplying combustion and ventilation air must have adequate infiltration from outside.

Figure 4 Air directly from outdoors

Each opening must provide a minimum free area of 1 square inch per 1,000 Btuh of input of all appliances in room plus requirements for any exhaust fans in room. The interior space supplying combustion and ventilation air must have adequate infiltration from outside.

Figure 3 Air openings to interior space

Each opening free area = 1 sq. inch per 1,000 Btuh

71004

Other

appliances

CGi boiler

MODEL

CGi

0 to 12"

Air

opening

Add air openings

to outside if

building is tight

construction.

Air

opening

3. When combustion air is supplied to the boiler space directly from outside or ventilated attic/

crawl space through vertical ducts (Figure 5)

Provide two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling.

Each opening must provide a minimum free area

1 square inch per 4,000 Btuh of input of all

of appliances in room plus requirements for any exhaust fans in room. The duct cross sectional area must be no less than the required area of the permanent openings.

Part Number 550-110-710/0200

Boiler Manual

Figure 5 Air from outdoors — vertical ducts

Outside or ventilated attic

Each opening free area = 1 sq. inch per 4,000 Btuh

CGi

Other

appliances

boiler

MODEL

CGi

— or —

12"

Ventilated

71006

crawl space

4. When combustion air is supplied to the boiler space directly from outside through horizontal

ducts (Figure 6)

: Provide two permanent openings:

• One air opening within 12 inches of floor.

• A second opening within 12 inches of ceiling.

Special considerations

Tight construction

ANSI Z223.1 defines unusually tight construction where:

a. Walls and ceilings exposed to the outside

atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed, and . . .

b. Weather-stripping has been added on openable

windows and doors, and . . .

c. Caulking or sealants are applied to areas such as

joints around windows and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and in other openings.

For buildings with such construction, provide air openings into the building from outside, sized per the appropriate case in inside air for combustion and ventilation.

Figure 4 if appliances are to use

Each opening must provide a minimum free area

1 square inch per 2,000 Btuh of input of all

of appliances in room plus requirements for any exhaust fans in room. The duct cross sectional area must be no less than the required area of the permanent openings.

Figure 6 Air from outdoors — horizontal

ducts

Each opening free area = 1 sq. inch per 2,000 Btuh

Other

appliances

71007

CGi boiler

MODEL

CGi

0 to 12"

Exhaust fans and air movers

The appliance space must never be under a negative pressure, even if the appliance(s) are installed as direct vent. Always provide air openings sized not only to the dimensions required for the firing rate of all appliances, but also to handle the air movement rate of the exhaust fans or air movers using air from the building or space.

Air

opening

i ut

Air

opening

Part Number 550-110-710/0200

GOLD CGi Series 2 Gas-Fired Water Boiler

Prepare boiler — placement & setup2a

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. Tilt boiler the other way and place a board

under right legs.

c. Slide boiler backward off pallet and into

position.

5. Check level. a. Shim legs, if necessary. b. Do not alter legs.

Inspect orifices and burners

1. Remove front jacket door. Remove burner shield (see

Figure 40, item 4, page 58).

2. Check for correctly-sized manifold orifices. See

Table 2 for sizing. (The orifice size is stamped on

the orifice spud barrel.)

Correctly-sized manifold orifices must be used. Failure to do so will result in severe personal injury,

death or substantial property damage.

3. Reinstall burner shield.

Do not operate boiler without burner shield in place. Failure to do so could result in severe personal injury, death or substantial property damage.

Orifice replacement procedure

(when required)

1. Remove the screws securing the burner shield and remove burner shield.

2. Using a 7/16" open-end wrench, remove the burner orifices from the manifold.

3. Apply a small amount of pipe dope to each of the new orifices and install in the manifold using a open-end wrench. Make sure the orifices are aligned correctly, not cross-threaded in the manifold tappings.

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.

4. Carefully replace the burner shield.

5. Follow the check-out procedure, section 8 page 36, to assure the boiler is now operating properly after orifices are replaced.

/16"

Table 2 Manifold orifice sizing at sea level and altitudes to 4,500 feet

Location Boiler model

number

U. S.

Canada

Note 1:

For elevations above 2,000 feet, contact your local Weil-McLain sales office for details.

CGi-25 2.30 mm

CGi-3 — CGi-8 2.70 mm 1.65 mm

CGi-25 2.30 mm #44 #54 #55

CGi-3 — CGi-8 2.70 mm #38 1.65 mm #53

Natural gas Propane gas

0-2,000 ft over 2,000 ft 0-2,000 ft over 2,000 ft

(Note 1)

0-2,000 ft 2,000-4,500 0-2,000 ft 2,000-4,500

#54

(Note 1)

Part Number 550-110-710/0200

Boiler Manual

Prepare boiler — pressure test

Perform 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 supply tapping) and remove the boiler relief

Temporarily plug the relief valve tapping with a ¾" NPT pipe plug.

valve.

2. Remove 1¼" nipple, reducing tee and drain valve from circulator hardware and pressure/ temperature gauge carton. Install in boiler return connection as shown on page 3 and

Figure 42, page 60. Install circulator on either the return or supply.

3. Remove 1¼" nipple, 1¼" x 1¼" x ½" tee and pressure/temperature gauge from circulator hardware and pressure/temperature gauge carton. Pipe to boiler supply connection as shown on page 3 and Figure 42, page 60. (Use pipe dope sparingly.)

4. Connect a hose to boiler drain valve, the other end connected to a fresh water supply. Make sure hose can also be used to drain boiler after test.

5. Connect a nipple and shutoff valve to system supply connection on the 1¼" tee. This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

6. Connect a nipple and shutoff valve to system return connection (at circulator flange if circulator installed on return). This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

Fill and pressure test

1. Open the shutoff valves you installed on supply and return connections.

2. Slowly open boiler drain valve and fresh water supply to fill boiler with water.

3. When water flows from shutoff valves, close boiler drain valve.

4. Close shutoff valves.

5. Slowly reopen boiler drain valve until test pressure on the pressure/temperature gauge reaches no more than:

45 psig for boilers with 30 psig relief valve.

•

75 psig for boilers with 50 psig relief valve.

Test for no more than 10 minutes at:

• 45 psig for boilers with 30 psig relief valve.

• 75 psig for boilers with 50 psig relief valve.

Do not leave boiler unattended. A cold water fill could expand and cause

excessive pressure, resulting in severe personal injury, death or substantial property damage.

7. Make sure constant gauge pressure has been maintained throughout test. Check for leaks. Repair if found.

Leaks must be repaired at once. Failure to do so can damage boiler,

resulting in substantial property damage.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Drain and remove fittings

1. Disconnect fill water hose from water source.

2. Drain boiler at drain valve or out hose, whichever provides best access to drain. Remove hose after draining if used to drain boiler.

3. Remove nipples and valves unless they will remain for use in the system piping.

4. Remove plug from relief valve tapping. See section 4a, page 20 to replace relief valve.

Part Number 550-110-710/0200

GOLD CGi Series 2 Gas-Fired Water Boiler

Table 3

Vent

connector

diameter

Figure 7

Chimney

draft venting

Venting —

general information

CGi venting methods

The CGi boiler can be vented using one of the following methods:

Chimney draft venting — Uses the natural draft

1. 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, below. Chimney draft installations use:

a. Vent connector (single or doublewall) sized to

eliminate positive pressure in vent system. Diameter increases immediately at boiler.

b. Doublewall metal vent (B-vent) or chimney

Venting —

Boiler model

number

CGi-25 & CGi-3 4"

CGi-4 to CGi-8 5"

“D” Minimum

vent connector

Chimney

Tight

seal

Cleanout

71008

chimney draft venting

diameter

1. Use doublewall metal vent (B-vent) or chimney with liner

2. To prevent downdrafts, chimney should extend at least 3

3. To vent with another appliance, see National Fuel Gas Code,

4. Do not connect breeching to any portion of a mechanical

5. Maintain minimum 2" clearance from combustible

6. Do not use chimney with an open fireplace.

7. Make horizontal runs as short as possible. Long runs can

8. When longer runs are used, support pipe with appropriate

9. To prevent blockage, do not vent into bottom of chimney.

10. Vent pipe must not go beyond inside wall of chimney.

11. Vent passing through floors or ceilings must be firestopped.

12. See Figure 7 and Table 3 to connect boiler to venting system.

1/4" Rise/4 FT.

MODEL

CGi

Increaser

0322-057

with liner approved by the National Fuel Gas Code, ANSI Z223.1–latest edition, or in Canada B149.1 or B149.2 Installation Code.

Direct exhaust — vertical or sidewall — Uses

inside combustion air with no combustion air connector piping. All CGi flue gas vents are pressurized, requiring careful sealing of all joints. Category III appliance (positive vent static pressure and vent gas temperature that avoids excessive condensate production in vent). See pages 15-19. Direct exhaust installations use:

a. Vent pipe specified in this manual.

b. Vent termination through outside wall, roof or

unused chimney. Tight chimney areas will make vent joint construction very difficult.

Inspect existing chimney before installing boiler. Failure to clean or replace perforate pipe or lining will cause severe personal injury or death.

Vent sizing given in Table 3 is only a general guideline. The vent connector and chimney must be designed, sized and constructed in compliance with all applicable codes. Failure to correctly size and install the vent system could result in severe personal injury, death or substantial property damage.

as required by the National Fuel Gas Code, ANSI Z223.1– latest edition, or in Canada, B149.1 or B149.2 Installation Code.

feet above the highest point where it passes through a roof and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet.

ANSI Z223.1–latest edition or in Canada B149.2 or B149.2 Installation Code

draft system that can operate under positive pressure.

materials to vent pipe.

cause condensation.

hangers.

Part Number 550-110-710/0200

Boiler Manual

Venting —

direct exhaust — system components

Obtain vent system components

1. The following special gas vent systems comply with UL-1738 and ULC-S636 standards and are certified by CSA as the only systems suitable for use with CGi 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. Do not mix components from different systems. The vent system could fail, causing flue gas spillage, resulting in severe personal injury or death.

2. Select vent method based on page 14 and installation requirements.

3. Refer to Table 4 for maximum vent run lengths and number of elbows. Do not exceed data in Table 4.

4. Select vent components from Table 5. All components, including the vent starter, must be of the same vent manufacturer. Do not mix components.

Table 4 Maximum vent length

Max.vent length (feet)

CGi-25 to CGi-6 55 48 41 34 27 20

CGi-7 35 28 21 14 7 --

CGi-8 28 21 14 7 -- --

Note 1: Do not include termination fitting when

Total number of elbows

1 2 3 4 5 6

counting total number of elbows.

(Note 1)

Table 5 Vent system components

Description

Weil-McLain part number

CGi Starter 699-999-015 73WMCGIS SRAWCG3 SVEWMFA03 FSA-WEIL-CGI Termination Coupling with

Screen Termination Elbow with Screen 699-999-069 1314TERM SRTE-03 SVSTEX0390 FSTE90 Termination Tee with Screen 699-999-026 7390TEE SRTT-03 SVSTTX03 FSTT3 45˚ Elbow 699-999-010 7311GC SRE4503 SVEEWC0345 FSEL4503 90˚ Elbow 699-999-011 7314GCTR SRE9003 SVEEWC0390 FSEL9003 6" Pipe 699-999-003 7301GC SR06P03 SVEPWC03.5 FSVL603 12" Pipe 699-999-004 7302GC SR12P03 SVEPWC0301 FSVL1203 18" Pipe 699-999-005 7304GC -- SVEPWC0318 FSVL1803 24" Pipe 699-999-006 7305GC SR24P03 SVEPWC03 FSVL2403 36" Pipe -- -- SR36P03 SVEPWC0303 FSVL3603 37 ½" Pipe 699-999-007 7307GC -- -- -48" Pipe -- -- -- SVEPWC0304 -49 ½" Pipe 699-999-008 7308GC -- -- -60" Pipe 699-999-012 7360GC SR60P03 SVEPWC0305 -Slip Connector (See Note) 699-999-009 7324GC9 SRSJ03 -- -Horizontal Support 699-999-016 7323GC -- -- FSSH Horizontal Drain Tee 699-999-014 7320GC SRTDH03 SVEDWC03 FSHDT3 Joiner Band -- -- SRJB-14 -- -Sealant As specified by individual vent pipe manufacturer Not required

Note: Use to adjust for non-standard pipe lengths and Saf-T Vent® only, before termination coupling to terminate run.

699-999-001 73WMTERM -- SVSTPX03 FSB3S

Saf-T Vent

part number

StaR-34 Z-Vent II FasNSeal™

Part Number 550-110-710/0200

GOLD CGi Series 2 Gas-Fired Water Boiler

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 Table 5, page 15, Vent system

components

, for part number of each component,

listed by vent manufacturer.

Band clamp

Band clamp strap

screw

FasNSeal™ starter

Band clamp screw

Figure 8

FasNSeal™ vent starter

3. Follow all applicable national, state, local or provincial codes when venting the CGi boiler.

4. Connect vent starter to blower housing outlet as shown in the Figures 8 through 11, below.

a. Do not mix components from different vent

manufacturers.

b. Maintain minimum 2" clearance from

combustible materials to vent pipe.

c. Seal with sealant specified by vent pipe

manufacturer, using ³⁄₈" bead (not required for FasNSeal™).

d. Tighten strap at band clamp screw until strap

is snug around blower housing.

Tighten position

Feed

Band clamp strap

position

Z-Vent II starter

Band clamp screw

Band clamp strap

Blower housing outlet

71009

Saf-T Vent starter

Band clamp screw

³⁄₈" Bead of sealant

Blower housing outlet

Figure 10

Saf-T Vent® vent starter

Figure 9

Z-Vent II vent starter

Figure 11

StaR-34 vent starter

Band clamp strap

³⁄₈" Bead of sealant

Blower housing outlet

71010

StaR-34 starter

Band clamp screw

3/8" Bead of sealant

Blower housing outlet

71011

71012

Part Number 550-110-710/0200

Boiler Manual

71014

Snow

4 ft

1 ft

4 feet

Venting —

direct exhaust — vent 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. Prevailing winds could cause freezing of condensate and water/ice buildup on vent termination, building, plants or roof. Ice buildup on vent termination can cause boiler shutdown and building freezeup.

4. Winds over 31 mph can cause nuisance boiler shutdown if boiler is sidewall vented. This could result in loss of heat to building, causing freezeup.

5. Locate or guard vent termination to prevent condensate from damaging exterior surfaces.

6. Locate the vent termination well away from trees, shrubs, and decorative items.

7. Locate or guard vent to prevent accidental contact by people or pets.

8. Do not terminate vent in window well, stairwell, alcove, courtyard, or other recessed areas.

9. Do not wrap or insulate vent pipe or fittings.

10. Do not terminate vent above any door or window. Condensate can freeze, causing ice formations.

11. Do not connect:

• Any other appliance to vent pipe.

• Multiple boilers to a common vent pipe.

12. Canadian installations — See B149.1 or B149.2 Installation Code. Terminate vent no less than 6 feet from another combustion air inlet, 3 feet from any other building opening, and 3 feet from any gas service regulator.

13. See

Figure 12, showing that the vent must terminate:

• more than 4 feet below or to side of all doors

or windows.

• more than 1 foot above grade or anticipated

snow line.

• at least 7 feet above public walkway.

• 3 feet above any forced air intake within 10 feet.

14. Vent must also terminate:

• at least 6 feet away from adjacent walls.

• no closer than 5 feet below roof overhang.

• at least 4 feet horizontally (and in no case above

or below unless a 4 foot horizontal distance is maintained) from electric meters, gas meters, regulators, relief valves, and other equipment.

15. Site conditions may dictate greater clearances.

16. Do not extend exposed vent pipe outside of building. Condensate could freeze and block vent pipe.

A gas vent extending through an exterior wall shall not terminate adjacent to the wall or below building extensions such as eaves, parapets, balconies or decks. Failure to comply could result in severe personal injury, death or substantial property damage.

Figure 12 Vent termination minimum clearances

7 feet

Part Number 550-110-710/0200

71013

3 feet

If within 10 feet

blic Walkway

Forced

air intake

GOLD CGi Series 2 Gas-Fired Water Boiler

MODEL

CGi

71015

Horizontal drain tee. Follow vent manufacturer's instructions to install condensate drain line.

Follow vent manufacturer's instructions for proper installation of vent runs, including slope and support.

Venting —

direct exhaust............................

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, page 17, for vent termination.

4. Maintain minimum 2" clearance from combustible materials to vent pipe.

Vertical venting — See Figure13. Follow vent manufacturer’s

5. instructions for venting through roof.

• Vent pipe must extend through roof flashing, jacket or thimble.

• Vent may pass through floor, inside wall or concealed space when

installed according to vent manufacturer’s instructions.

Sidewall venting — See Figures 14 and 15. Vent must terminate at

least one foot above anticipated snowline. Vent must be terminated only with:

• Tee or elbow with integral screen. (Tee may be mounted either

vertically or horizontally. DO NOT use horizontal tee with CGi-7 or CGi-8.)

• Elbow and termination coupling with screen (not available for

StaR-34).

Figure 13 Direct exhaust vertical venting

6. Do not seal vent pipe (slip connector for Saf-T Vent) to inside or outside plate.

7. If passing through noncombustible wall, provide hole diameter large enough to insert the vent pipe (slip connector for Saf-T Vent).

8. Install horizontal drain tee as close as possible to boiler, in first horizontal run. See Figure 13.

9. Do not exceed the maximum vent system length given in page 15.

Using any other material could cause flue gas leakage, potentially resulting in severe personal injury, death or substantial property damage.

• Vent manufacturer shows this option in their instructions.

• Vent is sloped toward termination as shown in dotted lines in

• The vent is installed per Weil-McLain and vent manufacturer’s instructions.

Condensate drippage from such vents may accumulate on the ground below. Consider traffic in the area to avoid hazard due to ice accumulation.

Condensate drain line — use only silicone tubing rated for at least 400 °F for the condensate drain line.

Table 4,

On some installations, the condensate drain fitting may be omitted, provided:

Figure

Figure 14 Direct exhaust sidewall venting

Horizontal drain tee. Follow vent manufacturer's instructions to install condensate drain line.

Optional downward slope without drain fitting, where allowed by vent manufacturer as explained in CAUTION at left.

MODEL

CGi

Follow vent manufacturer's instructions for proper installation of vent runs, including slope, support and condensate drainage.

71016

Part Number 550-110-710/0200

Boiler Manual

vertical or sidewall

Figure 15 Sidewall termination

Termination elbow or tee

Sealant

Saf-T Vent

Note 1

Termination elbow or tee

Sealant

Z-Vent II

Elbow and termination

coupling with screen

Sealant

Elbow and termination

coupling with screen

Sealant

Using any termination other than one of those shown could cause nuisance outages and loss of heat, resulting in substantial property damage.

Pipe

Band

clamp

Pipe section

section

Sealant

Metal

plate

Sealant

Exterior

Metal plate

18" Slip

connector

Note 1: DO NOT use horizontal tee with CGi-7 or CGi-8.

Sealant

Pipe

section

Metal plate

wall

Exterior

wall

Metal

plate

StaR-34

™

FasNSeal

Termination elbow or tee

Sealant

Termination elbow or tee

Note 1

Termination coupling

not available

Elbow and termination

coupling with screen

Locking band

Note 1: DO NOT use horizontal tee with CGi-7 or CGi-8.

Metal

plate

Sealant

Exterior

Metal plate

Pipe

section

Note 1: DO NOT use horizontal tee with CGi-7 or CGi-8.

Pipe

section

Metal plate

wall

Exterior

wall

Metal

plate

Pipe section

Pipe

section

71017

Part Number 550-110-710/0200

GOLD CGi Series 2 Gas-Fired Water Boiler

Water piping —

general information

General piping information

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, pages 38 and 39, for wiring.

A low water cutoff device is required when boiler is installed above radiation level or by certain state or local codes or insurance companies. Use low water cutoff designed for water installations. Electrode probetype is recommended. Purchase and install in tee in supply piping above boiler.

Use backflow check valve in cold water supply as required by local codes.

Pressure/temperature gauge

Install pressure/temperature gauge in tee on supply piping (as shown in drawing on page 3). The gauge well is a self-closing valve, allowing removal of the gauge without draining the system.

Slowly remove pressure/temperature gauge from well. The self-closing valve could leak if clogged with sediment. If water begins to spray, stop removing gauge. Close system fill valve and drain enough water to release system pressure before continuing with gauge removal. Escaping hot water could cause severe personal injury.

Circulator

The circulator is shipped loose (wiring pre-attached to boiler) to allow you to locate it either in the return or supply piping, as desired. See page 3 for a typical installation. Pipe the expansion tank to the suction side of the circulator whenever possible. Install an air separator in the supply piping. Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator. Always install the system fill connection at the same point as the expansion tank connection to the system. Figures 16 and 17 show typical near-boiler piping connections.

System water piping

See Figure 16 (diaphragm-type or bladder-type expansion tank) or Figure 17 (closed-type expansion tank) on page 21, and and single-zone systems designed for return water at least 130 °F.

See pages 22-23 to complete multiple-zone piping or pages 24-29 to complete piping for radiant heating systems or converted gravity systems.

Refer to page 29 for boilers used with refrigeration systems.

Table 6 below, for near-boiler

Relief valve

Install relief valve vertically in ¾" tapping on side of boiler. See Figure 16

and the tag attached to the relief valve for manufacturer’s instructions.

or 17

To avoid water damage or scalding due to relief valve operation:

• Discharge line must be connected to relief valve outlet and

safe place of disposal

possibility of severe burns should the valve discharge.

• Discharge line must be as short as possible and be the

the valve discharge connection

• Discharge line must pitch downward from the valve and terminate at least 6" above the floor drain where any discharge will be clearly visible.

• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375 °F or greater.

Do not pipe the discharge to any place where freezing could occur.

•

• No shutoff valve shall be installed between the relief valve and boiler,

or in the discharge line. Do not plug or place any obstruction in the discharge line.

•

Failure to comply with the above guidelines could result in failure of

the relief valve to operate, resulting in possibility of severe personal injury, death or substantial property damage.

• Test the operation of the valve after filling and pressurizing system

by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.

. Terminate the discharge line to eliminate

throughout its entire length.

run to a

same size as

Table 6 Water pipe size (based on 20 °F rise)

Boiler

model number

CGi-25 ¾" ¾"

CGi-3 1" 1" CGi-4 1" 1" CGi-5 1" 1" CGi-6 1¼" 1¼" CGi-7 1¼" 1¼" CGi-8 1½" 1½"

Note: Circulator flange supplied with boiler is same size as

recommended piping above.

• Chilled medium, if used, is piped in parallel with heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. Consult I=B=R Installation and Piping Guides.

• If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air, use flow control valves or other automatic means to prevent gravity circulation during cooling cycle. Circulation of cold water through the boiler could result in damage to the heat exchanger, causing possible severe personal injury, death or substantial property damage.

system

Install boiler such that —

From

system

Part Number 550-110-710/0200

+ 44 hidden pages

Weil-McLain CGi-25, CGi-3, CGi-4, CGi-5, CGi-6 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual