Weil-McLain CGI-4E manual 3a Venting general information, Venting chimney draft venting

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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.Vent connector (single or doublewall) sized to eliminate posi- 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- bustion air connector piping. The CGi-4E flue gas vent is pressur- 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.Vent termination through outside wall, roof or unused chim- ney. Tight chimney areas will make vent joint construction very difficult.

3b

Venting — chimney draft venting

Table 3

Vent connector diameter

Figure 7

Chimnney

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.Use doublewall metal vent (B-vent) or chimney with liner as required by the National Fuel Gas Code, ANSI Z223.1–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.To vent with another appliance, see National Fuel Gas Code, 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.Maintain minimum 2”clearance from combustible materials 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 sys- tem.

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Part Number 550-110-711/1108

 

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Contents GOLDCGi-4E How it works Gold CGi-4EGas-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 Check for nearby connection to1b 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 contaminationRemove contaminants permanently Areas likely to have contaminantsAir opening options 1e Prepare boiler location air openingsAir openings must be provided Two openings Air supply from inside the buildingSingle air opening option Exhaust fans and air moversMotorized air dampers Exception for large spacesPlace 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 testCGi-4E venting methods Chimney draft or Direct exhaust 3a Venting general informationVenting chimney draft venting Chimney draft ventingDo not exceed data in Table 3c Venting Direct exhaust componentsObtain vent system components Do not mix components3d Venting direct exhaust vent starter 3e Venting direct exhaust termination Do not wrap or insulate vent pipe or fittingsDo not mix types or manufacturers of vent materi- als 3f Venting direct exhaust installationSlip connector for Saf-T Vent Use their specified sealant. Do not use screwsUsing 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 4c Water piping multiple zones Piping multiple zonesBoiler isolation balancing valves System or zone circulator Zone valve Drain valveValve adjustment 4d Piping low temperature systemsTemperature gauges Primary/secondary preferred bypass piping methodBlend temperature gauge Valve adjustment BOILER-bypass piping methodBoiler-bypass piping Zoning with SYSTEM-bypass piping method System or zone circulator 4e Water piping refrigeration systemPrevent chilled water from entering boiler Chilled medium from entering boiler. See forNatural Gas Connecting gas supply piping to boilerGas piping Propane GasWiring connections Field wiringElectrical installation must comply with ThermostatCheck for gas leaks Freeze protection when used7a Start-up preparation Determine if water treatment is neededInspect base insulation Fill the system with waterInspect system water piping Close manual and automatic air vents and boiler drain cockCheck system and boiler 7b Start-up operate boilerStart the boiler Main burner flame Figure Check burner flamesPilot burner flame Figure Check for High limit switch set below boiler water tempera- ture?7c Start-up if boiler doesn’t start Gas not turned on at meter or boiler?Check-out procedure checklist 9a Operation sequence Boiler is now in the off cycleGold CGi-4E Gas-Fired Water Boiler Boiler Manual 9b Operation wiring diagrams Wiring diagramOperating instructions CMR 5.082a 1 through Addendum Instruction for Commonwealth of MassachusettsOne-half 1/2 inch in size, GAS Vent Directly be CMR 5.082a1 through10a Service and maintenance schedule Verify Proper Operation After Servicing10b Service and maintenance annual start-up Condensate drain system 10b Service & maintenance annual start-upBurners and base Inducer motorAir vents and air elimination Gas pipingCold fill and operating pressures Limit controls and cutoffsBoiler relief valve Safety relief valves should be reinspected AT LeastReview with owner Shut down boilerAir pressure switch 11a Troubleshooting generalBefore troubleshooting Check the following11b Troubleshooting components Control moduleControl module connections 11c 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, , 12a Replacement parts Section assembly Base Jacket Trim Controls12b Replacement parts section assembly Description Weil-McLain Number Part number12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyBoiler 12e Replacement parts trim Part number12f Replacement parts controls Propane gas components13a Dimensions Width13b Ratings DOEBreathing 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.
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