Weil-McLain CGI-4E User Manual

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®

GOLDCGi-4E

Gas-Fired Water Boiler

Boiler Manual

• Installation • Maintenance

 

• 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 air to the boiler area or follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or substantial property damage.

Part No. 550-110-711/1108

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

How it works . . .

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 49).

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.

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 factory-installed 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.

Timer relay

The timer relays delays high fire for 60 seconds.

Other boiler components:

asupply to system

breturn from system

cstainless steel burners

dflue outlet

egas valve

fpressure/temperature gauge

grelief valve

hair vent connection

iflame rollout thermal fuse element (TFE)

jburner shield

kpilot burner and bracket

lgas manifold

mcast iron boiler sections

nflue collector

ojunction box

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Part Number 550-110-711/1108

 

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

GOLD CGi-4E Gas-Fired Induced-Draft Water Boiler

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..................................................

20-29

5

Gas piping..........................................................

30

6

Field wiring........................................................

31

7

Start-up.........................................................

32-36

8

Check-out procedure — checklist......................

37

9

Operation......................................................

38-42

10

Service and maintenance..............................

43-47

11

Troubleshooting............................................

48-57

12

Replacement parts........................................

58-65

13

Dimensions and ratings.................................

66-67

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.

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

Please read before proceeding

Installer

Read all instructions before installing. Follow all instructions in proper order to prevent personal injury or death.

Considerpiping and installationwhen determining boiler location.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

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.

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 68 of this manual. Failure to comply could result in severe personal injury.

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 37.

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.

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.

Donotaddcoldwatertohotboiler.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:

Neverstoreglycolof anykindneartheboiler 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.

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

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

1a Prepare boiler location — codes & checklist

Installations must follow these codes:

Local, state, provincial, and national codes, laws, regulations and ordinances.

National Fuel Gas Code, ANSI Z223.1–latest edition.

StandardforControlsandSafetyDevicesforAutomaticallyFiredBoilers,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-4E boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13–latest edition.

Read and follow the special instructions for the Commonwealth

of Massachusetts, located on page 42 of this manual.

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, or other contaminants.

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.

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

1b Prepare boiler location — clearances

Recommended SERVICE clearances

(Fig. 1a)

1.Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1a for recommen- 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 at least screwdriver clearance, install unions and shutoff valves in system so boiler can be moved for servicing.

Figure 1a

Recommended

SERVICE clearances

(see WARNING

below)

If any clearance is less than in Figure 1a, provide openings for combustion and ventilation air located on the wall or door opposite the boiler FRONT (see Figure 1b).

These openings must be located as shown in Figure 1b to provide proper air flow around the boiler. The free area of each opening (after deducting for louvers) must be at least one square inch per 1,000 Btuh of boiler input. If the building is of unusually tight construction (see page 11 for definition), the air openings must connect directly to outside or the building must have air openings to the outside as specified on page 11.

If clearances are equal to or greater than Figure 1a, see pages 10 and 11 for location and sizing of combustion air openings.

Failure to comply can result in severe personal injury, death or substantial property damage and reduced boiler life.

Required MINIMUM clearances (Fig. 1b)

Never install the boiler in a space with clearances less than the minimum clearances shown in Figure 1b. Failure to comply can result in severe personal injury, death or substantial property damage and reduced boiler life.

1.Hot water pipes: at least ¹⁄ inch from combustible material.

2.Single-wall vent pipe: at least 6 inches from combustible material.

3.Type B double-wall metal vent pipe: refer to vent manufacturer’s recommendation for clearances to combustible material.

Figure 1b Required MINIMUM clearances

Flooring

The CGi-4E boiler is approved for installation on combus- tible 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

1.Provide a solid brick or minimum 2-inch thick concrete foundation pad if any of the following is true:

floor can become flooded.

the boiler mounting area is not level.

2. Minimum dimensions are 25” length by:

Minimum foundation width:

CGi-4E

15”

 

 

Residential garage installations

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:

Mount the boiler a minimum of 18 inches 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.

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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 — Do not install the CGi-4E 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 an 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.

c.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 lighting/operating instructions. Adjust thermostat so appliance will operate continuously.

e.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 becorrectedsotheinstallationconformswiththeNational Fuel Gas Code, ANSI Z223.1-latest edition. Correct by re- sizing 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 Instal- lation 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 appli- cable building codes. Canadian installations mustcomplywithB149.1orB149.2Installation Codes.

2.SeeRatingstableonpage67forminimumchim- ney or vent sizes. A chimney or vent without a listed cap should extend at least 3 feet above the highest point where it passes through a roof of a building and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet. A 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. Type B double-wall metal vent 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.Con- densation can damage a masonry chimney.WeilMcLain 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 Na- tional Fuel Gas Code ANSI Z223.1-latest edition.

b.Provide drain trap to remove any condensate.

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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 combustion air contamination problems.

Refer to Table 1 for products and areas which may cause 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:

remove contaminants permanently

OR —

isolateboilerandprovideoutsidecombustionair.Seenational,provincialorlocalcodes for further information.

Table 1  Corrosive or destructive contaminants and likely locations

Products to avoid

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

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

Adhesives used to fasten building products and other similar products

Airborne particulates (drywall dust, fiberglass particles, road or gravel dust, lint, etc.)

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Buildings under construction (where air is contaminated with particulates)

CONSTRUCTION DUST HAZARD — Airborne particulates, such as drywall dust or fiberglass dust,will cause blockage of the CGi-4E burners,resulting in carbon monoxide production, a fire hazard, or building freeze damage. If the boiler is operated during construction, you must isolate the boiler to provide clean air for combustion. If you are unable to ensure uncontaminated air in the boiler vicinity at all times, you must inspect the boiler at least once weekly. When inspecting, clean the burners if necessary using the procedure given on page 45. Failure to follow these guidelines could result in severe personal injury, death or substantial property damage.

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

1e Prepare boiler location — air openings

 

Combustion air opening location and sizing

 

requirements depend on the clearances around

 

the boiler. Checktheboilerplacementcomparedto

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 Figure 1a, page 7,

 

you must provide air openings sized and located as

 

shown in Figure 1b, page 7. DO NOT apply the sizing

 

and location information shown on page 10 or 11.

Figure 2 Air openings to interior spaces

Figure 3 Air directly through outside wall

Air openings must be provided

Combustion air and ventilation openings must comply the 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 opening options

Two openings — Air supply from inside the building

1.If the building is of unusually tight construction (see definition, next page), the building must also be provided with air openings directly to the outside, sized and located per Figure 3, Figure 4 or Figure 5.

2.Buildingsof typicalconstructionshouldprovideadequatecombustion air from natural infiltration, so additional air openings to the building are not required.

3.See Figure 2. Provide two openings through the interior wall, within 12 inches of the ceiling and the floor, sized per Figure 2.

Two openings — Air supply directly from outside

1.Air openings must be directly through an outside wall, or into a space that connects directly to the outside (such as a ventilated attic or crawl space, for example).

2.SeeFigure 3—Openings directly through an outside wall — provide two openings within 12 inches of the ceiling and the floor, sized per Figure 3.

3.See Figure 4 — Air supplied through vertical ducts — provide two openings terminated within 12 inches of the ceiling and the floor, sized per Figure 4.

4.See Figure 5 — Air supplied through horizontal ducts — provide two openings within 12 inches of the floor and the ceiling, sized per Figure 5.

Figure 4 Air from outdoors — vertical ducts

Figure 5 Air from outdoors — horizontal ducts

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

FREE AREA of openings — the minimum areas given in this manual are free area (equals the area, length times width of opening, after deduction for louver obstruction).

Use the free area information provided by the louver manufacturer. When this information is not available, assume:

Wood louvers — assume free area is 20% of total; so the actual area of each opening with wood louvers would be 5 times the required free area.

Metallouvers—assumefreeareais60%of actualarea;so,forwood louvers, the actual area of each opening must be 1.67 times the required free area.

Single air opening option

A single combustion air opening can be used in lieu of the two-opening options on page 10, provided:

Clearances from boiler to walls

The boiler must have clearances of at least those shown in Figure 1a, page 7.

Opening must be directly to outside

The opening must connect directly to the outdoors or to a space that communicates directly to the outdoors (not to an interior space).

Theaircanbeprovidedthroughadirectopeningorthroughahorizontal or vertical duct.

Opening placement

The top of the air opening must be within 12 inches of the ceiling.

Opening size

The free area of the opening must be at least equal to the sum of the areas of all equipment vent connectors in the space, and . . .

The free area of the opening must be at least 1 square inch per 3,000 Btu/hr input rating of all equipment located in the space.

Exception for large spaces

No combustion air openings are needed when the boiler (and other ap- pliances) are installed in a space with a volume at least 50 cubic feet per 1,000 Btuh of all installed appliances, provided:

the building must not have unusually tight construction (see definition, this page)

all clearances around the boiler must must be no less than shown in

Figure 1a, page 7.

To determine if the space is large enough to qualify:

Add the total input of all appliances in MBH (1,000’s of Btuh).

Multiply this number times 50 to determine minimum room volume.

Example: For a total input of 100 MBH (100,000 Btuh), minimum volume is 50 x 100 = 5,000 cubic feet. At a ceiling height of 8 feet, the space must have at least 5,000 ÷ 8 = 625 square feet (25 feet x 25 feet, for instance).

Unusually tight construction

Unusuallytightconstructionmeans(perANSIZ223.1) buildings in which:

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 such construction cases, if appliances use inside air for combustion, provide air openings into the building from outside. Size and locate these openings per the appropriate case in Figure 3, 4 or 5 on page 10.

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.

Motorized air dampers

If the air openings are fitted with motorized dampers, electrically interlock the damper to:

Prevent the boiler from firing if the damper is not fully open.

Shut the boiler down should the damper close dur- ing boiler operation.

To accomplish this interlock, wire an isolated contact (proving the damper open) in series with the thermostat input to the boiler. The boiler will not start if this contact is open, and will shut down should it open during operation.

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

2a Prepare boiler — placement & setup

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.

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 7/16”open-endwrench.Makesuretheori- fices are aligned correctly, not cross-threaded in the manifold tappings.

Inspect orifices and burners

1.Remove front jacket door. Remove burner shield (see Figure 40, item 4, page 60).

2.Checkforcorrectly-sizedmanifoldorifices.SeeTable 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.

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 37, to assure the boiler is now operating properly after orifices are replaced.

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

Location

Natural gas

Propane gas

 

 

 

 

 

U. S.

0-2,000 ft

over 2,000 ft

0-2,000 ft

over 2,000 ft

2.55 mm

(Note 1)

1.60 mm

(Note 1)

 

Canada

0-2,000 ft

2,000-4,500

0-2,000 ft

2,000-4,500

2.55 mm

#41

1.60 mm

1.45 mm

 

 

 

 

 

 

Note 1: For elevations above 2,000 feet, contact your local Weil-McLain sales office for details.

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2b Prepare boiler — pressure test

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-4E supply tapping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾” NPT pipe plug.

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 64. Install circulator on either the return or supply.

3.Remove 1¼” nipple, 1¼” x 1¼” x ½” tee and pres- sure/temperature gauge from circulator hardware and pressure/temperature gauge carton. Pipe to boiler supply connection as shown on page 3 and Figure 42, page 64. (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.Connectanippleandshutoff valvetosystemsupply connection on the 1¼” tee. This valve will be used tobleedairduringthefill.(Valveandnipplearenot included with boiler.)

6.Connect a nipple and shutoff valve to system re- turn connection (at circulator flange if circulator installed on return). This valve will be used to bleed airduringthefill.(Valveandnipplearenotincluded 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 sup- ply 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.

6.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 main- tained 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.

Donotusepetroleum-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 page 20 to replace relief valve.

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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

Chimney draft venting uses the natural draft provided by a ver- tical 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. Chimney draft installations use:

1.Ventconnector(singleordoublewall)sizedtoeliminateposi- tive pressure in vent system.Diameter increases immediately at boiler.

2.Doublewall metal vent (B-vent) or chimney with liner ap- proved 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

Direct exhaust venting uses inside combustion air with no com- bustionairconnectorpiping.TheCGi-4Efluegasventispressur- ized,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:

1.Vent pipe specified in this manual.

2.Ventterminationthroughoutsidewall,roof orunusedchim- ney. Tight chimney areas will make vent joint construction very difficult.

3b

Table 3

Vent connector diameter

Figure 7

Chimnney

draft

venting

Venting — chimney draft venting

Boiler

“D” Minimum

model

vent connector

number

diameter

CGi-4E

5”

Inspect existing chimney before installing boiler. Failure to clean or replace perforated 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.

1.Usedoublewallmetalvent(B-vent)orchimneywithlineras requiredbytheNationalFuelGasCode,ANSIZ223.1–latest edition, or in Canada, B149.1 or B149.2 Installation Code.

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

3.Toventwithanotherappliance,seeNationalFuelGasCode, ANSI Z223.1–latest edition or in Canada B149.2 or B149.2 Installation Code

4.Do not connect breeching to any portion of a mechanical draft system that can operate under positive pressure.

5.Maintainminimum2”clearancefromcombustiblematerials to vent pipe.

6.Do not use chimney with an open fireplace.

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

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

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 fire- stopped.

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

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3c Venting — Direct exhaust — components

Obtain vent system components

1.ThefollowingspecialgasventsystemscomplywithUL-1738andULC- S636 standards and are certified by CSA as the only systems suitable for use with CGi-4E 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 separate Vent Supplement. All components, including the vent starter, must be of the same vent manufacturer.

Do not mix components.

Table 4  Maximum vent length (feet)

Max.vent

 

Total number of elbows (Note 1)

 

length (feet)

1

2

3

4

5

6

CGi-4E

55

48

41

34

27

20

 

 

 

 

 

 

 

Note 1: Do not include termination fitting when counting total number of elbows.

Read and follow the special instructions for the Com- monwealth of Massachusetts, located on page 42 of this manual.

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

3d 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 separate Vent Supplement, for part number of each component, listed by vent manufacturer.

Use only the vent starter of the same manufacturer as the vent compo- nents. Do not mix components from different systems. The vent system could fail, causing flue gas spillage, resulting in severe personal injury or death.

3.Follow all applicable national, state, local or provin- cial codes when venting the CGi-4E boiler.

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

a.Do not mix components from different vent manufacturers.

b.Maintain minimum 2”clearance from com- bustible materials to vent pipe.

c.Seal with sealant specified by vent pipe manufacturer, using ³⁄" bead (not required for

FasNSeal™).

d.Tighten strap at band clamp screw until strap is snug around blower housing.

Figure 8

Figure 10

FasNSeal™

Saf-T Vent®

ventstarter

vent starter

Figure 9

Figure 11

Z-Vent II

StaR-34

vent starter

vent starter

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3e Venting — direct exhaust — 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.Gaseswillformwhiteplumeinwinter.Plumecould 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 freeze-up.

4.Winds over 40 mph can cause nuisance boiler shutdown if boiler is sidewall vented. This could result in loss of heat to building, causing freeze-up.

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.Donotextendexposedventpipeoutsideofbuilding. 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

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

3f Venting — direct exhaust — installation

1.Do not mix types or manufacturers of vent materi- als.

2.Clean all joints before sealing. See vent manufac- turer’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 vent termination.

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

5.Vertical venting — See Figure 13. Follow vent manufacturer’s 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 snow line.Vent must be termi- nated only with:

Tee or elbow with integral screen. (Tee may be mounted either vertically or horizontally.)

Elbow and termination coupling with screen (not available for StaR-34).

6.Donotsealventpipe(slipconnectorforSaf-TVent) 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 Figures 13 and 14.

9.Do not exceed the maximum vent system length given in Table 4, page 15.

Condensate drain line — use only siliconetubingrated for at least 400°F for the first 18” of condensate drain line, then other non-metallic tubing may be used. Using any other material could cause flue gas leakage, potentially resulting in severe personal injury, death or substantial property damage.

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

Ventmanufacturershowsthisoptionintheirinstruc- tions.

Ventisslopedtowardterminationasshownindotted lines in Figure 14.

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

Condensate drippage from such vents may accumu- lateonthegroundbelow.Considertrafficinthearea to avoid hazard due to ice accumulation.

Figure 13  Direct exhaust vertical venting

Figure 14  Direct exhaust sidewall venting

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

3f Venting — direct exhaust — installation (cont.)

Figure 15 

Sidewall termination

Using any termination other than one of those shown

could cause nuisance outages and loss of heat, resulting

 

 

 

 

in substantial property damage.

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GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

4a Water piping — general information

General piping information

If installation is to comply with ASME or Canadian requirements, an ad- ditional 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 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 probe-type 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.

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 instal- lation. Pipe the expansion tank to the suction side of the circulator whenever possible. Install an air separator in thesupplypiping.Connecttheexpansiontanktotheair 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.

Pressure/temperature gauge

Install pressure/temperature gauge in tee on supply piping (as shown in drawing on page 3).

Relief valve

Install relief valve vertically in ¾” tapping on side of boiler. See Figure 16 or 17, page 21, and the tag attached to the relief valve for manufacturer’s instructions.

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

Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line to eliminate possibility of severe burns should the valve discharge.

Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length.

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

Thedischargelineshallterminate 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 valveshall 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.

System water piping

SeeFigure 16 (diaphragm-type or bladder-type expansion tank) or Figure 17 (closed-type expansion tank) and Table 6, for near-boiler 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 (large-volume systems originally designed for circulation by natural convection rather than a pump).Seepage 29forboilers used with refrigeration systems.

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

Boiler

To

From

model number

system

system

CGi-4E

1”

1”

Note: The boiler supply and return connections, the return/ drain tee and the supply/gauge tee supplied with the boiler are 1¼” NPT. One of the circulator flanges supplied with the boiler is 1¼”. The other circulator flange is the size of the recommended system piping shown above.

Chillers or air handling units:

Install boiler such that —

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 coolingcycle.Circulationof coldwaterthroughthe boiler could result in damage to the heat exchanger, causing possible severe personal injury, death or substantial property damage.

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4b Water piping — single-zone system

Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve. Eventual section failure can result.

Diaphragm-type or bladdertype expansion tank (Figure 16)

1.Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possible, before inlet side of circulator. See tank manufacturer’s instructions for details.

2.Install an automatic air vent as shown.

Closed-type expansion tank

(Figure 17)

1.Ensure expansion tank size will handle boiler and system water volume and temperature. See tank manufacturer’s instructions for details.

2.Connect tank to ½” NPT tapping located behind supply outlet, using ½” NPT piping. Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping.

Use Figure 16 or Figure 17 only for single-zone systems designed for return water at least 130°F. For systems with low return water temperature possible, such as converted gravity systems and radiant heating systems, refer to the special piping suggestions of pages 24-29. Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.

Figure 16 Diaphragmor bladder-type expansion

Figure 17 Closed-type expansion tank — Piping

tank — Piping to single-zone system

to single-zone system using closed-

using diaphragm-type or bladder-type

type expansion tank. See Table 6 for

expansion tank. See Table 6 for piping

piping sizes.

sizes.

 

Part Number 550-110-711/1108

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