Weil-McLain CGS-4E manual 1e Prepare boiler location air openings, Combustion air requirements

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

1e Prepare boiler location — air openings

Air opening location and sizing requirements de- pend on the clearances around the boiler. Check

the boiler placement compared to Figure 1, page 7.

If all clearances are at least equal to Figure 1, page 7, apply the sizing and placement of openings given on pages 10 and 11.

If ANY clearance is less than Figure 1, page 7, you must provide air openings sized and located as shown in Figure 2, page 7. DO NOT apply the sizing and location information shown on page 10 or 11. The Figure 2 air openings are required even if the boiler is direct vented (outside air piped to the boiler air intake as described in this manual). These openings ensure adequate air circulation around the boiler for cooling, even if the boiler does not use inside air for combustion.

Combustion air requirements

Using outside air — direct vent only

Combustion air must be ducted directly from outside to the CGs-4E boiler

air intake fitting. This method is defined as direct vent (also referred to as sealed combustion). Refer to the appropriate vent supplement and the instructions in this manual. Two options are available: sidewall or vertical direct vent. Each requires a special vent component kit.

Louver allowance

The free area of openings means the area after reduc-

tion for any installed louvers or grilles. Be sure to

consider this reduction when sizing the air openings.

Special considerations

Tight construction

ANSI Z223.1 defines unusually tight construction where:

1.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 . . .

2.Weather-stripping has been added on openable windows and doors, and . . .

3.Caulking or sealants are applied to areas such as joints around windows and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and in other openings.

For buildings with such construction, provide air open- ings into the building from outside, sized per the ap- propriate case in Figure 3 if appliances are to use inside air for combustion and ventilation.

Sizing air openings

Air openings provide for ventilation to prevent overheating of the boiler controls and boiler space. Air is also needed for other appliances located in the same space.

Use Figure 3, page 11, selecting the appropriate installation conditions. Note that the sizing given in Figure 3 applies only to CGs-4E installations with

clearances no smaller than shown in Figure 1, page 7 of this manual. For smaller clearances, regardless of how the air openings are arranged, two openings providing free area of 1 square inch per 1,000 Btuh input of all appliances in the space are required.

Air openings must be sized to handle all appliances and air movers (exhaust fans, etc.) using the air supply.

The sizing given in Figure 3 is based on the National Fuel Gas Code, ANSI Z223.1, allowing adequate air opening for gravity-vented gas appliances (Category I). The CGs-4E boiler is rated Category IV (pressurized vent), and has different requirements for combustion and ventilation air, reflected by the special sizing instructions given in Figure 3. The air openings rec- ommended in Figure 3 will allow adequate ventilation and combustion air provided the boiler room is not subjected to negative pressure due to exhaust fans or other mechanical ventilation devices. Refer to the National Fuel Gas Code for dealing with other conditions.

Exhaust fans and air movers

The appliance space must never be under a negative pressure unless all appliances are installed as direct vent. Always provide air openings sized not only to the dimen- sions 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 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.

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Part number 550-110-282/1108

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Contents GOLDCGs-4E How it works Gold CGs-4EGas-Fired Induced-Draft Water Boiler Contents Please read before proceeding InstallerUser Installations must follow these codes 1a Prepare boiler location codes & checklistBefore locating the boiler, check the following 1b Prepare boiler location clearances CGs-4E special vent system When removing boiler from an existing common vent system1c Prepare boiler location vent system Vent systemProducts to avoid 1d Prepare boiler location contaminationAreas likely to have contaminants Special considerations 1e Prepare boiler location air openingsCombustion air requirements Sizing air openingsSizing air openings for CGs-4E installations Place boiler/crate near position 2a Prepare boiler placement & setupOrifice replacement procedure Inspect orifices and burnersDrain and remove fittings 2b Prepare boiler pressure testHydrostatic pressure test Prepare boiler for test3a Water piping general information Install an automatic air vent in air vent tapping as shown 3b Water piping single-zone system3c Water piping multiple zones Piping multiple zonesRelief valve Boiler isolation balancing valves Flow/check valveSystem or zone circulator Zone valve Drain valve Fill valve3d Piping low temp systems Temperature gaugesValve adjustment Figures 8 and 9 only Primary/secondary preferred bypass piping methodBlend temperature gauge Boiler isolation balancing valvesValve adjustment BOILER-bypass piping methodFigures 8 SYSTEM-bypass piping method Prevent chilled water from entering 3e Water piping refrigeration systemsBoiler Vent system Venting and combustion airCombustion air openings Combustion air quality Natural Gas Connecting gas supply piping to boilerGas piping Propane GasWiring connections Field wiringElectrical installation must comply with ThermostatDetermine if water treatment is needed Freeze protection when used7a Start-up preparation Check for gas leaksFinal check before starting boiler 7b Start-up operate boilerInspect system water piping Inspect base insulation Start the boilerPilot burner flame Figure Check burner flamesMain burner flame Figure Check for If none of the above corrects the problem, refer to7c Start-up if boiler doesn’t start Gas not turned on at meter or boiler?Check-out procedure checklist Installation and service certificateSequence returns to step 9a Operation sequenceBoiler is now in the off cycle Operation sequence 9b Operation wiring diagrams Wiring diagram9c Operating instructions CGs-4E Exemptions The following equipment is exempt from Addendum Instruction for Commonwealth of MassachusettsCMR 5.082a 1 through CMR 5.082a1 through10a Service and maintenance schedule 10b Service & maintenance annual start-up Condensate drain system With boiler power off, place a few drops of S.A.EBurners, base and inlet air box Inducer motor10b Service & maint. annual start-up Boiler relief valve Relief valve, typicalShut down boiler Clean between sections with wire flue brushReview with owner Place newspapers in base of boiler to collect sootCheck the following 11a Troubleshooting procedureBefore troubleshooting Can resultCheck pressure switch setting 11b Troubleshooting air pressure switchAir pressure switch Troubleshooting air pressure readingControl indicator lights NON-LOCKOUT modes 11c Troubleshooting control moduleControl indicator lights Lockout modes Troubleshooting the control moduleControl module connections 11d Troubleshooting control module lights Chart 1 Troubleshooting Power light statusChart 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 of operation, , Section assembly Base Jacket Trim Controls 12a Replacement partsWeil-McLain part numbers are found in Weil-McLain Boilers 12b Replacement parts section assembly Weil-McLain part number12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyBoiler 12e Replacement parts trim Fittings shown are factory-installed on boiler12f Replacement parts controls Propane gas components13a Dimensions Dimensional drawing13b Ratings Tested for 50 psi working pressureThis type of respirator is based on Handling ceramic fiber and fiberglass materialsEye Irrigate immediately Breathing Fresh air