Weil-McLain 550-110-710/0107 manual Exhaust fans and air movers, Motorized air dampers

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GOLD CGi 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 550-110-710/0107

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Contents Gold CGi How it works Gold CGi Gas-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 1b 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 contaminationTwo 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 venting methods Chimney draft or Direct exhaustObtain vent system components 3c Venting Direct exhaust componentsVent StaR-34 Vent starter 3d Venting direct exhaust vent starterVent termination minimum clearances 3e Venting direct exhaust terminationSidewall venting See Figures 14 3f Venting direct exhaust installationVertical venting See . Follow vent Using 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 zonesZoning with circulators Primary/secondary preferred bypass piping method 4d Piping low temperature systemsTemperature gauges Valve adjustmentPrimary/secondary piping BOILER-bypass piping method Valve adjustmentBoiler-bypass piping Zoning with SYSTEM-bypass piping method Prevent chilled water from entering boiler 4e Water piping refrigeration systemPropane 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 leaksInspect base insulation Do not use petroleum-based cleaning or sealing compoundsFill the system with water Inspect system water pipingCheck system and boiler 7b Start-up operate boilerStart the boiler Pilot burner flame Figure 7c Start-up if boiler doesn’t startCheck burner flames Check forThermostats Check-out procedure checklistDuring main burner operation 9a Operation sequenceSchematic wiring diagram 9b Operation wiring diagramsLadder wiring diagram 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-8 Verify 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 eliminationReview the User’s Information Manual with the owner Review with ownerBoiler relief valve Air pressure switch 11a Troubleshooting procedure11b Troubleshooting components Before troubleshootingControl module Control indicator lightsTroubleshooting the control module Control indicator lights Lockout modesControl module connections VAC in plug 11c Troubleshooting control module lightsChart Light flashing Remove 120 VAC in plug , Item 3, page 50 on control moduleChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Usually indicates flame sensed when it shouldnt be there Chart 4 Flame & Power lights flashingDoes blower motor operate? Item 8 , Operation, Figure Verify SequenceControls Repair Parts Lists 12a Replacement partsSection assembly Base Jacket Trim Controls Section assembly 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketBoiler Model Weil-McLain part number BoilerModel Weil-McLain part number Fittings shown are included with boiler 12e Replacement parts trimPropane gas components 12f Replacement parts controlsDimensional drawing 13a Dimensions13b Ratings Removal of Combustion Chamber Lining or Base Panels Handling ceramic fiber and fiberglass materials