Weil-McLain CGI-4E manual 1b Prepare boiler location clearances

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

1b Prepare boiler location — clearances

Recommended SERVICE clearances

(Fig. 1a)

Figure 1b Required MINIMUM clearances

1.Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1a for recommen- dations.

2.Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to provide at least screwdriver clearance, install unions and shutoff valves in system so boiler can be moved for servicing.

Figure 1a

Recommended

SERVICE clearances

(see WARNING

below)

If any clearance is less than in Figure 1a, pro- vide openings for combustion and ventilation air located on the wall or door opposite the boiler FRONT (see Figure 1b).

These openings must be located as shown in Figure 1b to provide proper air flow around the boiler. The free area of each opening (after deducting for louvers) must be at least one square inch per 1,000 Btuh of boiler input. If the building is of unusually tight construction (see page 11 for definition), the air openings must connect directly to outside or the building must have air openings to the outside as specified on page 11.

If clearances are equal to or greater than Figure 1a, see pages 10 and 11 for location and sizing of combustion air openings.

Failure to comply can result in severe personal injury, death or substantial property damage and reduced boiler life.

Flooring

The CGi-4E boiler is approved for installation on combus-

tible flooring, but must never be installed on carpeting.

Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage.

Foundation

1.Provide a solid brick or minimum 2-inch thick concrete foundation pad if any of the following is true:

•floor can become flooded.

•the boiler mounting area is not level.

2. Minimum dimensions are 25” length by:

Minimum foundation width:

CGi-4E

15”

 

 

Required MINIMUM clearances (Fig. 1b)

Never install the boiler in a space with clear- ances less than the minimum clearances shown in Figure 1b. Failure to comply can result in severe personal injury, death or substantial property dam- age and reduced boiler life.

1.Hot water pipes: at least ¹⁄₂ inch from combustible material.

2.Single-wall vent pipe: at least 6 inches from combustible mate- rial.

3.Type B double-wall metal vent pipe: refer to vent manufacturer’s recommendation for clearances to combustible material.

Residential garage installations

Take the following special precautions when installing the boiler in a residential garage. If the boiler is located in a residential garage, per ANSI Z223.1:

•Mount the boiler a minimum of 18 inches above the floor of the garage to assure the burner and ignition devices will be no less than 18 inches above the floor.

•Locate or protect the boiler so it cannot be damaged by a moving vehicle.

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 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 1c Prepare boiler location vent system When removing boiler from an existing common vent systemChimney or vent require- ments 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 Diaphragm-type or bladder- type expansion tank Figure 4b Water piping single-zone systemClosed-type expansion tank 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 insulationStart the boiler 7b Start-up operate boilerCheck system and boiler Pilot burner flame Figure Check burner flamesMain 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 RatingsUse 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.
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