Weil-McLain CGI-4E Exhaust fans and air movers, Motorized air dampers, Single air opening option

Page 11

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.

•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 550-110-711/1108

11

 

Page 10 Page 12
Image 11
Page 10 Page 12
Contents GOLDCGi-4E How it works Gold CGi-4EGas-Fired Induced-Draft Water Boiler Contents Please read before proceeding Check for nearby connection to 1a Prepare boiler location codes & checklistInstallations must follow these codes Before locating the boiler, check the following1b Prepare boiler location clearances Chimney or vent require- ments When removing boiler from an existing common vent system1c Prepare boiler location vent system Areas likely to have contaminants 1d Prepare boiler location air contaminationRemove contaminants permanently Products to avoidTwo 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-4E venting methods Chimney draft or Direct exhaustDo not mix components 3c Venting Direct exhaust componentsObtain vent system components Do not exceed data in Table3d Venting direct exhaust vent starter Do not wrap or insulate vent pipe or fittings 3e Venting direct exhaust terminationUse their specified sealant. Do not use screws 3f Venting direct exhaust installationSlip connector for Saf-T Vent Do not mix types or manufacturers of vent materi- alsUsing 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 zonesSystem or zone circulator Zone valve Drain valve Boiler isolation balancing valvesPrimary/secondary preferred bypass piping method 4d Piping low temperature systemsTemperature gauges Valve adjustmentBlend temperature gauge BOILER-bypass piping method Valve adjustmentBoiler-bypass piping Zoning with SYSTEM-bypass piping method Chilled medium from entering boiler. See for 4e Water piping refrigeration systemPrevent chilled water from entering boiler System or zone circulatorPropane 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 leaksClose manual and automatic air vents and boiler drain cock Fill the system with waterInspect system water piping Inspect base insulationCheck system and boiler 7b Start-up operate boilerStart the boiler Main burner flame Figure Check burner flamesPilot burner flame Figure Gas not turned on at meter or boiler? High limit switch set below boiler water tempera- ture?7c Start-up if boiler doesn’t start Check forCheck-out procedure checklist Boiler is now in the off cycle 9a Operation sequenceGold CGi-4E Gas-Fired Water Boiler Boiler Manual Wiring diagram 9b Operation wiring diagramsOperating instructions CMR 5.082a1 through Addendum Instruction for Commonwealth of MassachusettsOne-half 1/2 inch in size, GAS Vent Directly be CMR 5.082a 1 throughVerify 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 eliminationShut down boiler Safety relief valves should be reinspected AT LeastReview with owner Boiler relief valveCheck the following 11a Troubleshooting generalBefore troubleshooting Air pressure switchControl module 11b Troubleshooting componentsControl 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 of operation, , Section assembly Base Jacket Trim Controls 12a Replacement partsDescription Weil-McLain Number Part number 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketBoiler Part number 12e Replacement parts trimPropane gas components 12f Replacement parts controlsWidth 13a DimensionsDOE 13b RatingsBreathing Fresh air Handling ceramic fiber and fiberglass materialsUse Niosh certified dust respirator N95

CGI-4E specifications

The Weil-McLain CGI-4E is a standout in the realm of commercial boilers, designed to meet the rigorous demands of a variety of heating applications. This gas-fired cast iron boiler exemplifies durability, efficiency, and performance, making it a popular choice in various commercial settings, including schools, hospitals, and office buildings.

One of the main features of the CGI-4E is its cast iron construction. Cast iron has long been favored for its excellent heat retention and distribution capabilities, leading to improved overall efficiency. The boiler is designed to maximize heat output while minimizing energy consumption. This characteristic is especially beneficial for businesses seeking to lower their energy costs without sacrificing comfort.

In terms of efficiency, the Weil-McLain CGI-4E boasts an impressive thermal efficiency rating. Its design incorporates advanced technology, allowing it to achieve an AFUE rating of up to 84%. This efficiency is achieved through features such as a full-modulating burner and a unique heat exchanger design that allows for optimal heat transfer and reduced flue gas temperatures.

The CGI-4E is also remarkable for its versatility. It is offered in a variety of sizes, making it suitable for different heating loads. This flexibility allows for installation in a wide range of environments, adapting easily to both existing and new heating systems. Additionally, the boiler comes with multiple venting options, including direct vent and conventional venting, further enhancing its installation flexibility.

Another standout feature is the integrated boiler control system, which simplifies operation and monitoring. This control system optimizes burner performance and enhances safety features, including automatic shut-off in case of system anomalies. The advanced controls also allow for easy integration with building management systems, enabling better energy management and reduced operational costs.

The CGI-4E also emphasizes ease of maintenance, with service-friendly designs that allow technicians to access components without difficulty. This consideration translates to reduced downtime and lower maintenance costs, ensuring that the boiler operates efficiently over its lifetime.

Overall, the Weil-McLain CGI-4E blends reliability, efficiency, and advanced technology, making it a premier choice for commercial heating needs. Its cast iron construction, impressive efficiency ratings, versatile installation options, and user-friendly controls solidify its reputation as a leading boiler solution in the industry.
Top Page Image Contents