Weil-McLain CGa-8 Owner's manual

Brand: Weil-McLain

Model: CGa-8

Category: Water heaters & boilers

Type: Owner's manual

This manual is also suitable for

550-110-132/1298

•

Installation

•

Start-Up

•

Service

•

Troubleshooting •

Repair Parts

CGiCGi

CGi

Gas-fired boiler

Induced draft

Read all instructions before installing

InstallerInstaller

Installer Leave this manual in the envelope and affix near the boiler.

Consider venting and piping locations when determining boiler location.

Any claims for damage or shortage in shipment must be filed immediately against

the transportation company by the consignee.

UserUser

User Boiler Manual is only to be used and boiler installed by a qualified

installer/service technician.

User’s Information Manual is for your reference.

Regular service by your qualified service technician is recommended.

2 550-110-132/1298

CGi

When Calling or Writing About the Boiler

Please have boiler model number from boiler rating label and CP number from boiler jacket.

You may list the CP number in the space provided on page 33.

Read all instructions before installing boiler. Failure to follow instructions in proper

order can cause severe personal injury, death or substantial property damage.

Hazard Definitions

The following terms are used to bring attention to the presence of hazards of various risk levels or

to important information concerning product life.

Indicates presence of hazards that will cause severe personal injury, death or

substantial property damage if ignored.

Indicates presence of hazards that can cause severe personal injury, death or

substantial property damage if ignored.

Indicates presence of hazards that will or can cause minor personal injury or

property damage if ignored.

Indicates special instructions on installation, operation or maintenance that are

important but not related to personal injury hazards.

Read This Page First

3550-110-132/1298

CGi

Table of Contents

Read This Page First ................................................................................2

Table of Contents .................................................................................... 3

Before Installing Boiler.............................................................................4

Boiler Preparation....................................................................................7

Water Piping ............................................................................................8

Venting and Combustion Air ...............................................................18

Chimney Draft Venting..........................................................................19

Direct Exhaust Vent Location................................................................20

Direct Exhaust with AL29-4C ................................................................21

Gas Piping .............................................................................................29

Wiring .....................................................................................................30

Start-Up ..................................................................................................30

Check-Out Procedure ..........................................................................33

Installation and Service Certificate.....................................................33

Suggested Minimum Service ...............................................................34

Control System.......................................................................................36

Wiring Diagram .....................................................................................37

Sequence of Operation ........................................................................38

Operating Instructions ..........................................................................39

Troubleshooting ....................................................................................42

Parts List ..................................................................................................48

Ratings ...................................................................................................54

Dimensions ............................................................................................55

4 550-110-132/1298

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Installations must comply with latest editions:

U.S.

— National, state and local codes, laws,

regulations and ordinances.

— National Fuel Gas Code, ANSI Z223.1.

— Standard for Controls and Safety

Devices for Automatically Fired

Boilers, ANSI/ASME CSD-1, when

required.

— National Electrical Code.

Canada

— National, provincial and local codes, laws,

regulations and ordinances.

— CAN/CGA B149.1 or B149.2 Installation

Code.

— C.S.A. C22.1 Canadian Electrical Code

Part 1.

Gas manifold and controls met safe lighting and

other performance criteria when boiler underwent

tests specified in ANSI Z21.13 - latest edition.

Before locating boiler:

Check for nearby connections 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.

●

All boilers experience some condensation in

section assembly during start-up. Flue gas con-

densate is slightly acidic. In most cases pH level is

not harmful to vents or drains. When combustion

air is contaminated by vapors from products or

areas listed below, condensate acidic levels in-

crease. Higher acidic levels attack many materi-

als, including stainless steels.

You may need to isolate the boiler if installation is

in an area containing contaminants listed below,

which will induce acidic contamination.

Products causing contaminated air:

1. spray cans containing chloro/fluorocarbons

2. permanent wave solutions

3. chlorinated waxes/cleaners

4. chlorine-based swimming pool chemicals

5. calcium chloride used for thawing

6. sodium chloride used for water softening

7. refrigerant leaks

8. paint or varnish removers

9. hydrochloric acid/muriatic acid

10. cements and glues

11. antistatic fabric softeners used in clothes

dryers

12. chloride-type bleaches, detergents, and

cleaning solvents found in household

laundry rooms

13. adhesives used to fasten building products

14. . . . and other similar products

Areas causing contaminated combustion air:

1. dry cleaning/laundry areas and shops

2. metal fabrication plants

3. beauty shops

4. refrigeration repair shops

5. photo processing plants

6. auto body shops

7. plastic manufacturing plants

8. furniture refinishing areas and shops

9. new building construction

10. remodeling areas

11. . . . and other similar areas

To prevent potential of severe

personal injury or death, check for

products or areas listed above before installing

boiler. If found:

● remove products permanently.

● isolate boiler and provide outside combustion

air. See national, provincial or local codes for

further information.

Special note on combustion air supply:

Before Installing Boiler

●

5550-110-132/1298

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Before Installing Boiler

●

Recommended service clearances

FIGURE 1

Minimum clearances for tight spaces

FIGURE 2

Hot water pipes - at least 1/2 inch from

combustible materials.

Recommended service clearances - Figure 1.

Minimum clearances for tight spaces - Figure 2.

Provide clearances:

24"

18"

35"

10"

15"

Fresh air openings

6" from bottom

and 6" from top

CONT’D

6 550-110-132/1298

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When removing existing boiler from

common venting system:

Failure to follow all instructions

listed below can result in flue gas

spillage and carbon monoxide emissions, causing

severe personal injury or death.

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.

1. Seal any unused openings in the common

venting system.

2. Visually inspect the venting system for proper

size and horizontal pitch and determine there is

no blockage or restriction, leakage, corrosion

and other deficiencies which could cause an

unsafe condition.

3. 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 any

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.

4. Place in operation the appliance being inspected.

Follow the operating instructions. Adjust ther-

mostat so appliance will operate continuously.

5. Test for spillage at draft hood relief opening

after 5 minutes of main burner operation. Use

the flame of a match or candle, or smoke from a

cigarette, cigar or pipe.

6. 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 the 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 CAN/CGA B149.1 or

B149.2 Installation Code.

Before Installing Boiler

CONT’D

Lay a foundation, if needed:

CGi boiler is approved for use on combustible

flooring; however, boiler must not be installed

on carpeting.

Do not install boiler on carpeting even

if a foundation is used. Fire can result,

causing severe personal injury, death or substan-

tial property damage.

1. For residential garage installation, install

boiler so burners are at least 18 inches above

floor to avoid contact with gasoline fumes.

2. A level concrete or masonry foundation is

required when:

Water could flood area.

Non-level conditions exist.

●

TABLE 1 - Boiler foundation size

Boiler

Model

CGi - 25

CGi - 3

CGi - 4

CGi - 5

CGi - 6

CGi - 7

Length

Inches

Width

Inches

Min.

Height

Inches

7550-110-132/1298

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Boiler Preparation

Place the boiler:

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:

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.

Do not drop boiler or bump jacket

on floor or pallet. Damage to boiler

can result.

5. Check level. Shim legs, if needed. Do not

alter legs.

6. Remove front jacket door. Remove base

access panel.

7. Check for correctly-sized manifold orifices

from Table 2. 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.

8. Level and straighten burners.

Burners must be properly seated

in burner rest slots with their

openings face up. Main burner orifices must

inject down center of burner. Failure to prop-

erly seat burners will result in severe personal

injury, death or substantial property damage.

9. Reinstall burner access panel.

Burner access panel must be in

position during boiler operation to

prevent momentary flame rollout on main

flame ignition. Failure to do so will result in

severe personal injury, death or substantial

property damage.

Perform hydrostatic pressure test:

1. Pressure test boiler before attaching piping or

electrical supply.

2. Remove shipping nipple from supply outlet.

Remove relief valve.

3. Install air vent in tapping on top of boiler.

4. Plug remaining tappings, including relief valve

opening.

5. Connect water supply. Fill boiler and purge all

air. Test at 1-1/2 times working pressure.

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.

6. Check for maintained gauge pressure for more

than 10 minutes. Visually check for leaks if

gauge pressure drops.

7. Drain boiler and repair leaks if found.

Do not use petroleum-based

compounds to repair leaks.

Severe damage to boiler will occur, resulting in

severe personal injury, death or substantial

property damage.

8. Retest boiler after repairing leaks.

9. Remove testing plugs and air vent.

TABLE 2 - Manifold orifice size

Natural Gas Propane

U.S.

2.0 MM *

1.3 MM *

Canada

0 TO

2000 FT.

2000-

4500 FT.

2.0 MM

#49

1.3 MM #56

0 TO

2000 FT.

2000-

4500 FT.

* For elevations above 2000 feet, contact your local Weil-

McLain sales office for details.

8 550-110-132/1298

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Water Piping

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 set point of first control. Maximum

allowable set point is 240°F. See page 37

for wiring.

Use a low water cutoff device when:

— Boiler is installed above radiation level.

— Required by certain state or local codes

or insurance companies.

Use low water cutoff designed for water

installations. Probe type is recommended.

Purchase and install in tee in supply line

above boiler.

Use backflow check valve in cold water

supply as required by local codes.

Install boiler so that chilled medium is piped

in parallel with heating boiler. Use appropriate

valves to prevent chilled medium from enter-

ing 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.

●

Install piping:

1. See Figure 3A or 3B and Table 3 for near-boiler

piping and single-zone piping. See page 10 for

boilers used with refrigeration systems. See

page 11 to complete multiple-zone piping or

pages 12 – 17 to complete piping for radiant

panel systems or converted gravity systems.

2. Install relief valve vertically in tapping on side

of boiler. See Figure 3A or 3B and the tag

attached to the relief valve for manufacturer’s

instructions.

Pipe relief valve discharge line

near floor close to floor drain to

eliminate potential of severe burns. Do not pipe

to any area where freezing could occur. Do not

plug, valve, or place any obstruction in dis-

charge line.

DIAPHRAGM expansion tank (Figure 3A):

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 instruc-

tions for details.

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.

2. Install automatic air vent as shown.

CLOSED expansion tank (Figure 3B):

1. Ensure expansion tank size will handle boiler

and system water volume and temperature.

See tank manufacturer’s instructions for

details.

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.

2. Connect tank to 1/2” N.P.T. tapping located

behind supply outlet, using 1/2” N.P.T. piping.

Pitch any horizontal piping up towards tank

1 inch per 5 feet of piping.

●

SYSTEM

¾"

1¼"

TABLE 3 - WATER PIPING SIZE*

BOILER

MODEL

CGi - 25

CGi - 3

CGi - 4

CGi - 5

CGi - 6

CGi - 7

FROM

SYSTEM

¾"

1¼"

* All piping sizes based on 20

F temperature rise through

boiler.

9550-110-132/1298

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Water Piping

For systems with low return water

temperature possible (such as con-

verted gravity systems and radiant heating sys-

tems), refer to the special piping suggestions of

pages 12 – 17. 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.

Piping with DIAPHRAGM expansion tank Piping with CLOSED expansion tank

Near boiler piping

For low return temperature systems, see additional requirements shown on pages 10 through 17

From

system

Cold

water

fill

To DIAPHRAGM

expansion tank

and fittings

Isolation

valve

Isolation

valve

To system

Circulator*

Circulator

Drain

valve

Relief

valve

Automatic

air vent

Alternate

location

To system

From

system

Isolation

valve

Drain

valve

Relief

valve

Circulator*

Isolation

valve

Circulator

Cold water fill

CLOSED type

expansion tank

Alternate

location

CONT’D

FIGURE 3A FIGURE 3B

10 550-110-132/1298

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Water Piping

Piping MULTIPLE ZONES:

Piping for use with REFRIGERATION SYSTEMS:

Water

chiller

Expansion tank

Circulator

Check

valve

Strainer

Boiler

Shut-off

valve

System

supply

System

return

Balancing

valve

301-067b

CONT’D

FIGURE 4

Installing boiler on

REFRIGERATION SYSTEM

The boiler must be installed so the chilled medium

is piped in parallel with the heating boiler, using

appropriate valves to prevent the chilled medium

from entering boiler. Use piping as shown in

Figure 4.

If the boiler is connected to heating coils located in

air handling units where they can be exposed to

refrigerated air, gravity circulation during the

cooling cycle must be prevented with flow control

valves or other automatic means.

Piping for RADIANT HEATING SYSTEMS or CONVERTED GRAVITY SYSTEMS

c. Install balancing valves to adjust flow to dis-

tribute heat to all zones.

d. Separate relay is required for each circula-

tor.

4. Zoning with zone valves:

a. Install balancing valves to adjust flow to dis-

tribute heat to all zones.

b. Separate transformer is required to power

zone valves.

1. Follow instructions on pages 8 and 9 to install

near-boiler piping. (Also refer to Piping for radiant

heating systems or converted gravity systems if

applicable.)

2. See Figure 5A or 5B to complete installation.

3. Zoning with circulators:

a. Size each circulator to individual circuit re-

quirements.

b. Remove circulator on boiler.

Converted gravity (or steam) systems

Whenever possible, use the primary/secondary

piping shown in Figure 6A or 6B. This piping

design allows changing boiler flow rate without

affecting primary circuit flow rate.

If Figure 6A or 6B cannot be used, use the boiler

by-pass piping shown in Figure 7A or 7B.

You can also use the piping shown in Figure 8

(system by-pass) if the reduced flow rate in the

heating system will not cause heat distribution

problems.

Radiant heating systems

Preferably, use primary/secondary piping, as

shown in either Figure 6A or 6B. Alternatively, use

the method of either Figure 7A or 7B. Do not use

the piping of Figure 8, because this method does

not control radiant system supply temperature.

Failure to prevent low return water

temperature to the boiler could cause

corrosion of the boiler sections or burners, result-

ing in severe personal injury, death or substantial

property damage.

If radiant system tubing has no oxygen barrier, a

heat exchanger must be used.

Radiant heating system piping

should include a means of regulating

the boiler return water temperature AND the

system supply temperature (such as provided by

an injection pumping control). Boiler return water

temperature will be adequately controlled using

the methods shown in this manual provided the

system supply temperature is relatively constant.

• DO NOT apply the methods in this manual if

the system is equipped with an outdoor reset

control. Instead, provide controls and piping

which can regulate the boiler return water

temperature at no less than 130 °F regardless

of system supply temperature. Contact your

Weil-McLain representative for suggested

piping and control methods. Failure to prevent

cold return water temperature to the boiler

could cause corrosion damage to the sections

or burners, resulting in possible severe

personal injury, death or substantial property

damage.

11550-110-132/1298

CGi

Cold

water

fill

ZONE 2

ZONE 1

Cold

water

fill

ZONE 2

ZONE 1

Alternate

pump

location

Water Piping

Zoning with circulators Zoning with zone valves

Typical piping for MULTIPLE ZONE installations

FIGURE 5B

FIGURE 5A

Applicable for systems with boiler return water temperature at least 130 °F

(Refer to pages 12 through 17 for low temperature systems)

1 Isolation valve

2 Flow/check valve

3 Circulator

5 Zone valve

6 Drain valve

9 Relief valve

10 Automatic air vent

11 Fill valve

12 Diaphragm expansion tank

(see Figure 3B if using closed type expansion tank. DO NOT use

automatic air vent with closed type expansion tank.)

13 In-line air separator and automatic vent, if used

(Note that the fill valve must always be connected to the

expansion tank, regardless of location of expansion tank,

circulator or air separator.)

Legend (For Figures 5A and 5B) .......................................................................................................................................

CONT’D

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 12 – 17. 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.

12 550-110-132/1298

CGi

Temperature gauges

1. Set the valves while the system is cool, setting

for the coldest expected water temperature

(usually 60 °F since the system will often drop

to room temperature between cycles).

2. Start with valve 7a fully closed and 7b fully

open.

3. Gradually open valve 7a while closing valve 7b

until the temperature at gauge 8 reads 130 °F

when gauge 4a reads 60 °F.

4. Note that valve 7a regulates the amount of hot

water from the boiler supply which mixes with

return water. Valve 7b regulates the amount of

system water flowing through the boiler sec-

ondary loop.

Water Piping - Low Temp Systems

Figures 6A and 6B show suggested piping

arrangements for low temperature systems using

primary/secondary piping. (For alternatives, see

pages 14 through 17.)

Primary/secondary piping is preferred because the

flow rate and temperature drop in the heating

circuit(s) is determined only by the heating circuit

pumps(s). So adjustment of the by-pass valves in

the boiler circuit will not cause a change in the

heating circuit flow rate and temperature

distribution.

The by-pass valves (items 7a and 7b) provide

mixing of hot boiler outlet water with cooler system

return water — set to assure a minimum return

water temperature (at least 130 °F) to the boiler.

Set the valves as explained in the following

section.

Piping for RADIANT HEATING SYSTEMS or CONVERTED GRAVITY SYSTEMS —

By-pass arrangements using PRIMARY/SECONDARY piping (preferred)

Failure to prevent low return water

temperature to the boiler could cause

corrosion of the boiler sections or burners, result-

ing in severe personal injury, death or substantial

property damage.

Radiant heating system piping

should include a means of regulating

the boiler return water temperature AND the

system supply temperature (such as provided by

an injection pumping control).

• Boiler return water temperature will be

adequately controlled using the methods

shown in this manual provided the system

supply temperature is relatively constant.

• DO NOT apply the methods in this manual if

the system is equipped with an outdoor reset

control. Instead, provide controls and piping

which can regulate the boiler return water

temperature at no less than 130 °F regardless

of system supply temperature. Contact your

Weil-McLain representative for suggested

piping and control methods.

• Failure to prevent cold return water

temperature to the boiler could cause

corrosion damage to the sections or burners,

resulting in possible severe personal injury,

death or substantial property damage.

Adjust valves as follows (Fig. 6A & 6B only):

Gauge 4a is suggested, but optional on any

system.

Gauge 4b is optional on converted gravity systems,

but required on radiant heating systems — to

display the water temperature being supplied to

the radiant tubing.

Gauge 8 is required on all systems to assure the

return water temperature is accurately set for a

minimum of 130 °F. If this gauge is not available,

however, adjust the valves such that the boiler-

mounted pressure/temperature gauge reads at

least 150 °F when the system return water is cold

(approximately 60 °F water temperature).

13550-110-132/1298

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Water Piping - Low Temp Systems

Zoning with circulators

Zoning with zone valves

By-pass arrangements using PRIMARY/SECONDARY piping (PREFERRED)

for RADIANT HEATING SYSTEMS or CONVERTED GRAVITY SYSTEMS

Legend (For Figures 6A and 6B) .....................................................................................................................................

(Do not apply to systems using outdoor reset controls)

CONT’D

ZONE 2

ZONE 1

4a 4b

12"

MAX.

Cold

water

fill

Alternate

pump

location

Cold

water

fill

ZONE 2

ZONE 1

12"

MAX.

4a 4b

Alternate

pump

location

FIGURE 6B

FIGURE 6A

11 Fill valve

12 Diaphragm expansion tank

(see Figure 3B if using closed type expansion

tank. DO NOT use automatic air vent with

closed type expansion tank.)

13 In-line air separator and automatic vent, if used

(Note that the fill valve must always be

connected to the expansion tank, regardless of

location of expansion tank, circulator or air

separator.)

1 Isolation valve

2 Flow/check valve

3 Circulator

4 System temperature gauges

5 Zone valve

6 Drain valve

7 System temperature valves

(see instructions at left for adjusting

valves)

8 Blend temperature gauge

9 Relief valve

10 Automatic air vent

14 550-110-132/1298

CGi

Adjust valves as follows (Fig. 7A & 7B only):

1. Start with valve 7a fully closed and 7b fully

open.

2. Gradually open valve 7a while closing valve 7b

until the temperature at gauge 8 reads 60 °F

higher than gauge 4a.

A minimum 60 °F temperature rise through the

boiler assures a low enough flow rate and high

enough average temperature to prevent

condensation even with low system return

water temperature.

3. Valve 7a regulates the system flow rate, while

valve 7b regulates the boiler flow rate.

4. The boiler-mounted temperature/pressure

gauge may be used in place of a separate

gauge 8.

Water Piping - Low Temp Systems

CONT’D

Piping for RADIANT HEATING SYSTEMS or CONVERTED GRAVITY SYSTEMS —

Alternate by-pass piping arrangements

Failure to prevent low return water

temperature to the boiler could cause

corrosion of the boiler sections or burners, result-

ing in severe personal injury, death or substantial

property damage.

Radiant heating system piping

should include a means of regulating

the boiler return water temperature AND the

system supply temperature (such as provided by

an injection pumping control).

• Boiler return water temperature will be

adequately controlled using the methods

shown in this manual provided the system

supply temperature is relatively constant.

• DO NOT apply the methods in this manual if

the system is equipped with an outdoor reset

control. Instead, provide controls and piping

which can regulate the boiler return water

temperature at no less than 130 °F regardless

of system supply temperature. Contact your

Weil-McLain representative for suggested

piping and control methods.

• Failure to prevent cold return water

temperature to the boiler could cause

corrosion damage to the sections or burners,

resulting in possible severe personal injury,

death or substantial property damage.

Figures 7A and 7B are alternative piping sugges-

tions for large water content (converted gravity or

steam systems) or radiant heating sytems — for

use when primary/secondary piping can't be

applied. (Figure 8 is another alternative, using

system by-pass in place of boiler by-pass piping.

Figure 8, however, is not suitable for radiant

heating applications because it does not protect

the radiant system from possible high water

temperature.)

This piping method is called a "boiler by-pass"

because part of the pump flow is by-passed around

the boiler (through valve 7a). This method reduces

the flow rate through the boiler, in order to raise

the average water temperature in the boiler

enough to prevent flue gas condensation. Boiler

by-pass piping is effective for some boilers —

including the CGi — provided the flow rates are

adjusted according to the instructions following.

Boiler by-pass piping keeps system flow rate as

high as possible and temperature drop as low as

possible, helping to equalize the building heat

distribution.

Temperature gauges

Gauge 4a is optional if the by-pass valves will be

adjusted using cold (or room temperature) return

water to the boiler. (When setting the valves

without gauge 4a installed — using cold or room

temperature water — assume the return water

temperature to be 60 °F. Set the valves so gauge 8

reads at least 120 °F.)

Gauge 4b is optional on converted gravity systems,

but required on radiant heating systems — to

display the water temperature being supplied to

the radiant tubing.

Gauge 8 is required on all systems to assure

reliable adjustment of the by-pass valves. The

boiler-mounted pressure/temperature gauge can

be used if a separate temperature gauge is not

installed.

15550-110-132/1298

CGi

Cold

water

fill

ZONE 2

ZONE 1

4a 4b

Cold

water

fill

0302-067a

Alternate

pump

location

Water Piping - Low Temp Systems

CONT’D

Alternate by-pass piping arrangements

for RADIANT HEATING SYSTEMS or CONVERTED GRAVITY SYSTEMS

Boiler by-pass — Zoning with circulators

FIGURE 7B

FIGURE 7A

Boiler by-pass

— Zoning with zone valves

Alternatives to Figures 6A and 6B

(Do not apply to systems using outdoor reset controls)

Legend (For Figures 7A and 7B) .......................................................................................................................................

11 Fill valve

12 Diaphragm expansion tank

(see Figure 3B if using closed type expansion

tank. DO NOT use automatic air vent with

closed type expansion tank.)

13 In-line air separator and automatic vent, if used

(Note that the fill valve must always be

connected to the expansion tank, regardless of

location of expansion tank, circulator or air

separator.)

1 Isolation valve

2 Flow/check valve

3 Circulator

4 System temperature gauges

5 Zone valve

6 Drain valve

7 System temperature valves

(see instructions at left for adjusting

valves)

8 Blend temperature gauge

9 Relief valve

10 Automatic air vent

16 550-110-132/1298

CGi

1. Start with valve 7a fully closed and 7b fully

open.

2. Gradually open valve 7a while closing valve 7b

until the temperature at gauge 8 reads

at least 130 °F at all times.

3. Valve 7a regulates the amount of boiler supply

water mixed with return water. Valve 7b

causes a pressure drop in the system needed

to balance flow through valve 7a and the

system.

4. The valve adjustment should be done with the

system at the coldest expected temperature

(60 °F for converted gravity systems or high

mass radiant systems).

Adjust valves as follows (Figure 8 only):

Water Piping - Low Temp Systems

CONT’D

Piping for CONVERTED GRAVITY SYSTEMS —

Alternate by-pass piping arrangement for large water content systems

Failure to prevent low return water

temperature to the boiler could cause

corrosion of the boiler sections or burners, result-

ing in severe personal injury, death or substantial

property damage.

Radiant heating system piping

should include a means of regulating

the boiler return water temperature AND the

system supply temperature (such as provided by

an injection pumping control).

• Boiler return water temperature will be

adequately controlled using the methods

shown in this manual provided the system

supply temperature is relatively constant.

• DO NOT apply the methods in this manual if

the system is equipped with an outdoor reset

control. Instead, provide controls and piping

which can regulate the boiler return water

temperature at no less than 130 °F regardless

of system supply temperature. Contact your

Weil-McLain representative for suggested

piping and control methods.

• Failure to prevent cold return water

temperature to the boiler could cause

corrosion damage to the sections or burners,

resulting in possible severe personal injury,

death or substantial property damage.

Figure 8 is an alternate piping method that pro-

vides return water temperature control for boilers

installed on large water content systems (con-

verted gravity or steam systems).

Do not apply the piping of Figure 8 on radiant

heating systems. It provides no method of regulat-

ing the water temperature provided to the system,

and could result in excessive water temperature in

the radiant tubing.

This piping method is called a "system by-pass"

because part of the pump flow by-passes the

system (through valve 7a). This by-passed hot

water from the boiler outlet mixes with cooler

system return water temperature in order to

provide minimum 130 °F return water to the boiler.

Valve 7b will most often be full open, but may need

to be slightly closed on some low pressure drop

systems in order to cause enough flow through

valve 7a.

System by-pass piping as shown in Figure 8 can

be used with either zone-valve zoning or circulator

zoning. When used with circulator zoning, how-

ever, the boiler circulator, item 3, must be piped as

shown. It cannot be used as one of the zoning

circulators.

Do not apply system by-pass piping if the reduced

flow in the system could cause poor heat distribu-

tion. That is, system by-pass piping reduces the

flow in the system and increases the water tem-

perature supplied to the system. This can cause

increased heat from radiators at the beginning of

the system and reduced heat from radiators near

the end of the system.

17550-110-132/1298

CGi

Water Piping - Low Temp Systems

CONT’D

System by-pass —

Applies to

ANY

zoning method

Alternate by-pass piping arrangement

for CONVERTED GRAVITY (OR STEAM) SYSTEMS

Alternate to Figure 7A/7B — for converted gravity (or steam) systems only

(Do not apply to radiant heating systems)

Legend ...............................................................................................................................................

11 Fill valve

12 Diaphragm expansion tank

(see Figure 3B if using closed type expansion

tank. DO NOT use automatic air vent with

closed type expansion tank.)

13 In-line air separator and automatic vent, if used

(Note that the fill valve must always be

connected to the expansion tank, regardless of

location of expansion tank, circulator or air

separator.)

1 Isolation valve

2 Flow/check valve

3 Circulator

4 System temperature gauges

5 Zone valve

6 Drain valve

7 System temperature valves

(see instructions at left for adjusting

valves)

8 Blend temperature gauge

9 Relief valve

10 Automatic air vent

Cold

water

fill

0302-067c

Alternate

pump

location

To systemFrom system

FIGURE 8

18 550-110-132/1298

CGi

Venting and Combustion Air

Venting method definitions:

1. Chimney draft venting - Category I appliance.

(non-positive vent static pressure and vent gas

temperature that avoids excessive condensate

production in vent). See page 19. Chimney

draft installation using:

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

with liner approved by National Fuel Gas

Code, ANSI Z223.1-latest edition, or in

Canada, CAN/CGA B149.1 or B149.2

Installation Code.

2. Direct exhaust - Category III appliance

(positive vent static pressure and vent gas

temperature that avoids excessive condensate

production in vent). See pages 20-28. Direct

exhaust installation using:

a. Vent pipe specified in these instructions.

b. Vent termination through outside wall,

roof or unused chimney. Tight chimney

areas will make vent joint construction

very difficult.

Combustion and ventilation air source:

Combustion and ventilation air openings must

comply with Section 5.3 of National Fuel Gas Code

ANSI Z223.1-latest edition, or applicable building

codes. Canadian installations must comply with

CAN/CGA B149.1 or B149.2 Installation Code.

Provide adequate combustion and

ventilation openings to assure

proper combustion, and prevent possibility of

flue gas spillage and carbon monoxide

emissions, which can result in severe personal

injury or death. Do not install exhaust fan in

boiler room.

For boilers located in confined rooms or in build-

ings of tight construction:

1. A confined room, as defined by National Fuel

Gas Code, is less than 50 cubic feet per 1000

Btuh input of all appliances in the room.

2. When air is taken from inside the building —

Provide 2 permanent openings, one within 12

inches of ceiling, one within 12 inches of floor.

Minimum dimension of each rectangular

opening should be at least 3 inches. Each

opening must be at least 1 square inch per

1000 Btuh input of all fuel burning appli-

ances (plus requirements for any equipment

that can pull air from room, including clothes

dryer and fireplace), but not less than 100

square inches. Openings must freely connect

with areas having adequate air flow from

outside.

3. When air is taken from outdoors — follow

either method described below:

a. Provide 2 permanent openings, one within

12 inches of ceiling, one within 12 inches

of floor. Minimum dimension of each

rectangular opening should be at least 3

inches. Openings must connect directly or

by ducts with outdoors or spaces (crawl or

attic) that freely connect to outside air. Size

as listed below:

1) Through outside wall or vertical duct -

at least 1 square inch per 4000 Btuh

input of all fuel burning appliances

(plus requirements for any equipment

that can pull air from room, including

clothes dryer and fireplace).

2) Through horizontal ducts - 1 square

inch per 2000 Btuh input of all fuel

burning appliances (plus requirements

for any equipment that can pull air

from room, including clothes dryer

and fireplace).

3) Other size ducts must comply with

local codes.

b. When boiler clearances from sides and

back are at least 1 inch and from the

front at least 6 inches, 1 permanent

opening may be provided within 12 inches

from ceiling. Opening must connect

directly or by ducts with outdoors or

spaces (crawl or attic) that freely connect

to outside air. Size as listed below:

1) 1 square inch per 3000 Btuh of total

input rating all fuel burning appli-

ances (plus requirements for any

equipment that can pull air from

room, including clothes dryer and

fireplace) . . . and . . .

2) Not less than the sum of all the areas

of all vent connectors in the room.

Boiler must be vented and

supplied with combustion and

ventilation air as described in these

instructions. Failure to do so will cause severe

personal injury or death.

19550-110-132/1298

CGi

Chimney Draft Venting

General venting information:

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

with liner as required by National Fuel Gas

Code, ANSI Z223.1-latest edition, or in

Canada, CAN/CGA B149.1 or B149.2

Installation Code.

2. To prevent downdrafts, chimney should

extend at least 3 feet above 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. To vent with another appliance, see National

Fuel Gas Code, ANSI Z223.1-latest edition, or

in Canada, CAN/CGA B149.1 or B149.2

Installation Code.

4. Inspect existing chimney before

installing boiler. Failure to clean

or replace perforated pipe or lining will cause

severe personal injury or death.

"D" Minimum

Vent connector diameter

TABLE 4 - Chimney draft venting

Boiler

Model

CGi - 25

CGi - 3

CGi - 4

CGi - 5

CGi - 6

CGi - 7

* See WARNING below regarding sizing and applicable

codes.

Chimney

Cleanout

Tight

seal

1/4" Rise/4 FT.

Increaser

Chimney draft venting

FIGURE 9

5. Do not connect breeching to any portion of a

mechanical draft system that can operate

under positive pressure.

6. Maintain minimum 2"clearance from combus-

tible materials to vent pipe.

7. Do not use chimney with an open fireplace.

8. Make horizontal runs as short as possible.

Long runs can cause condensation.

9. When longer runs are used, support pipe with

appropriate hangers.

10. To prevent blockage, do not vent into bottom

of chimney.

11. Vent pipe must not go beyond inside wall of

chimney.

12. Vent passing through floors or ceilings must

be firestopped.

13. See Figure 9 and Table 4 to connect boiler to

venting system.

Vent sizing given in Table 4 is only a

general guideline. The vent connector

and chimney must be designed, sized and con-

structed in compliance with all applicable codes,

including:

U. S. — National Fuel Gas Code, ANSI

Z223.1–latest edition.

Canada — CAN/CGA B149.1 or B149.2 Instal-

lation Code.

Failure to correctly size and install the vent sys-

tem could result in severe personal injury, death,

or substantial property damage.

20 550-110-132/1298

CGi

Direct Exhaust Vent Location

Follow instructions on this page when

determining vent location to avoid

possibility of severe personal injury, death or

substantial property damage.

1. Gases will form white plume in winter. Plume

could obstruct window view.

2. Prevailing winds could cause freezing of

condensate and water/ice buildup on

building, plants or roof.

3. Locate or guard vent to prevent accidental

contact by people or pets.

4. Do not terminate vent in window well, stair

well, alcove, courtyard, or other recessed

areas.

5. Vent termination must be located more than

4 feet below or 4 feet horizontally from any

door, window or gravity air inlet into any

building, and more than 1 foot above grade or

anticipated snowline. In addition, vent termi-

nation must be at least 7 feet above public

walkway and 3 feet above any forced air inlet

within 10 feet. Stay well away from trees,

shrubs, and decorative items. Site conditions

may dictate greater clearances. See Figure 10.

6. Vent must terminate at least 4 feet horizon-

tally, 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.

7. Locate or guard vent to prevent condensate

from damaging exterior finishes.

8. Do not extend exposed vent pipe outside of

building. Condensate could freeze and block

vent pipe.

9. Terminate vent at least 6 feet away from

adjacent walls.

10. Do not terminate vent closer than 5 feet below

roof overhang or parapet.

11. Do not terminate vent above any door,

window or gravity air inlet into any building.

Condensate can freeze, causing ice formations.

12. Do not connect:

• Any other appliance to vent pipe.

• Multiple boilers to a common vent pipe.

13. Do not wrap or insulate vent pipe and fittings.

14. Winds over 40 mph can cause nuisance boiler

shutdown if boiler is sidewall vented.

15. Canadian installations - Do not terminate vent

less than 6 feet from another combustion air

inlet or less than 3 feet from any other build-

ing opening or any gas service regulator.

16. For location of vertical termination, see vent

pipe manufacturer's instructions.

Vent termination locations

FIGURE 10

932EH

4 feet

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Weil-McLain CGa-8 Owner's manual

Brand: Weil-McLain

Model: CGa-8

Category: Water heaters & boilers

Type: Owner's manual

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