Weil-McLain Series 2 manual Exhaust fans and air movers, Motorized air dampers

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GOLD CGi 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.

•Metal louvers — assume free area is 60% of actual area; so, for wood 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).

•The air can be provided through a direct opening or through a horizontal 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 defini- tion, 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

Unusually tight construction means (per ANSI Z223.1) buildings in which:

a.Walls and ceilings exposed to the outside atmo- sphere 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 appli- ances, 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 thermo- stat input to the boiler. The boiler will not start if this contact is open, and will shut down should it open during operation.

Part Number 550-110-710/0107

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Contents Gold CGi How it works Gold CGi Gas-Fired Induced-Draft Water Boiler Contents Please read before proceeding Before locating the boiler, check the following 1a Prepare boiler location codes & checklistInstallations must follow these codes 1b Prepare boiler location clearances Chimney or vent require- ments When removing boiler from an existing common vent system1c Prepare boiler location vent system Products to avoid 1d Prepare boiler location air contaminationTwo openings Air supply from inside the building 1e Prepare boiler location air openingsAir openings must be provided Air opening optionsException for large spaces Exhaust fans and air moversMotorized air dampers Single air opening optionInspect orifices and burners 2a Prepare boiler placement & setupOrifice replacement procedure Place boiler/crate near positionPrepare boiler for test 2b Prepare boiler pressure testHydrostatic pressure test Drain and remove fittingsChimney draft venting 3a Venting general informationVenting chimney draft venting CGi venting methods Chimney draft or Direct exhaustObtain vent system components 3c Venting Direct exhaust components3d Venting direct exhaust vent starter Vent termination minimum clearances 3e Venting direct exhaust terminationDirect exhaust vertical venting 3f Venting direct exhaust installationUsing any termination other than one of those shown 4a Water piping general information Closed-type expansion tank 4b Water piping single-zone systemDiaphragm-type or bladder- type expansion tank Figure Piping multiple zones 4c Water piping multiple zonesZoning with circulators Primary/secondary preferred bypass piping method 4d Piping low temperature systemsTemperature gauges Valve adjustmentPrimary/secondary piping BOILER-bypass piping method Valve adjustmentBoiler-bypass piping Zoning with SYSTEM-bypass piping method Prevent chilled water from entering boiler 4e Water piping refrigeration systemPropane Gas Connecting gas supply piping to boilerGas piping Natural GasThermostat Field wiringElectrical installation must comply with Wiring connectionsDetermine if water treatment is needed Freeze protection when used7a Start-up preparation Check for gas leaksInspect base insulation Fill the system with waterInspect system water piping Check system and boiler 7b Start-up operate boilerStart the boiler Pilot burner flame Figure 7c Start-up if boiler doesn’t startCheck burner flames Check forInstallation and service certificate Check-out procedure checklist9a Operation sequence Schematic wiring diagram 9b Operation wiring diagramsLadder wiring diagram 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-8 Verify Proper Operation After Servicing 10a Service and maintenance schedule10b Service and maintenance annual start-up Inducer motor 10b Service & maintenance annual start-upBurners and base Condensate drain systemLimit controls and cutoffs Gas pipingCold fill and operating pressures Air vents and air eliminationBoiler relief valve Review with ownerAir pressure switch 11a Troubleshooting procedure11b Troubleshooting components Before troubleshootingControl module Control indicator lightsTroubleshooting the control module Control indicator lights Lockout modesControl module connections Chart 1- Troubleshooting Power light status 11c Troubleshooting control module lightsChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Chart 4 Flame & Power lights flashing Does blower motor operate? Item 8 , Verify Sequence Section assembly Base Jacket Trim Controls 12a Replacement partsSection assembly 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketBoiler Fittings shown are included with boiler 12e Replacement parts trimPropane gas components 12f Replacement parts controlsDimensional drawing 13a DimensionsDOE 13b RatingsRemoval of Combustion Chamber Lining or Base Panels Handling ceramic fiber and fiberglass materials
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Series 2 specifications

The Weil-McLain Series 2 is a highly regarded boiler system known for its robustness, efficiency, and ease of installation. Designed primarily for residential and light commercial applications, the Series 2 boasts a variety of features that cater to diverse heating needs.

One of the standout characteristics of the Series 2 is its cast iron construction, which provides durability and longevity. Cast iron is well-suited for heat retention, allowing the boiler to operate more efficiently and deliver consistent warmth. The Series 2 is available in multi-fuel options, accommodating both natural gas and propane, making it versatile for various installations.

Efficiency is a key feature of the Weil-McLain Series 2, with annual fuel utilization efficiency (AFUE) ratings that meet or exceed industry standards. This ensures that homeowners can enjoy not only a comfortable living environment but also reduced energy bills. The Series 2 is designed to provide optimal performance, minimizing fuel consumption while maximizing heat output.

Another innovative aspect of the Series 2 is its user-friendly control system. Equipped with advanced controls, the boiler allows for precise temperature management and can easily be integrated with existing heating systems. This adaptability is crucial for ensuring that the boiler matches the specific heating demands of any space, increasing overall comfort levels.

Installation is straightforward, thanks to the boiler's thoughtful design. The Series 2 features a compact footprint, allowing for flexible placement in various settings. Additionally, Weil-McLain provides comprehensive documentation and customer support, making it easier for technicians to install and maintain the system.

The Series 2 also includes features aimed at ease of maintenance. Its clean-out ports facilitate quick access for servicing, ensuring that the boiler remains in peak operating condition throughout its lifespan. Weil-McLain’s commitment to quality means users can expect reliable performance year after year.

Overall, the Weil-McLain Series 2 stands out as an excellent choice for those seeking a dependable, efficient, and straightforward heating solution. Its combination of durable construction, high efficiency, and user-centric design makes it a leading option in the boiler market, appealing to both homeowners and professionals alike. Whether for a new installation or a replacement, the Series 2 is poised to deliver exceptional heating performance.
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