Weil-McLain CGI-4E manual 4c Water piping multiple zones, Piping multiple zones

Page 22

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

4c Water piping — multiple zones

Piping multiple zones

Follow instructions on pages 20 and 21 to install near-

boiler or single-zone piping. (Also refer to Piping for radiant heating systems or converted gravity sys-

tems, below, if applicable.)

See Figure 18 or Figure 19 to complete installation.

Zoning with circulators (Figure 18) (return temp over 130°F)

1.Size each circulator to individual circuit require- ments.

2.Do not install circulator on boiler (except for pri- mary/secondary piping).

3.Install isolation (balancing) valves to adjust flow to distribute heat to all zones.

4.Install and wire a separate relay for each zone cir- culator.

Zoning with zone valves (Figure 19) (return temp over 130°F)

1.Install isolation (balancing) valves to adjust flow to distribute heat to all zones.

2.Provide a separate 24-volt transformer to power the zone valves. Size the transformer to handle the total rated load of all connected zone valves.

Piping for radiant heating systems or converted gravity systems

Converted gravity (or steam) systems

Whenever possible, use the primary/secondary piping shown in Figures 20 or 21 on page 25. This piping de- sign allows changing boiler flow rate without affecting primary circuit flow rate.

If Figures 20 or 21 cannot be used, use the boiler-bypass piping shown in Figure 22 or Figure 23 on page 27. You can also use the piping shown in Figure 24 on page 29 (system-bypass), if the reduced flow rate in the heating system will not cause heat distribution problems.

Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sec- tions or burners, resulting in severe personal injury, death or substantial property damage.

Radiant heating systems

Preferably, use primary/secondary piping, as shown in Figures 20 or 21 on page 25. Alternatively, use the method of either Figure 22 or Figure 23 on page 27. Do not use the piping of Figure 24 (system-bypass), because this method does not control radiant system supply temperature.

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 dam- age.

22

Part Number 550-110-711/1108

 

Page 21 Page 23
Image 22
Page 21 Page 23
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 1c Prepare boiler location vent system When removing boiler from an existing common vent systemChimney or vent require- ments 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 Diaphragm-type or bladder- type expansion tank Figure 4b Water piping single-zone systemClosed-type expansion tank 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 cockStart the boiler 7b Start-up operate boilerCheck system and boiler Pilot burner flame Figure Check burner flamesMain 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 DOEUse Niosh certified dust respirator N95 Handling ceramic fiber and fiberglass materialsBreathing Fresh air

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