Weil-McLain 550-110-710/0107 manual 1b Prepare boiler location clearances

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

1b Prepare boiler location — clearances

Recommended SERVICE clearances

(Fig. 1a)

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.

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.

Part Number 550-110-710/0107

Figure 1b Required MINIMUM clearances

Flooring

The CGi boiler is approved for installation on combustible 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-25/3

12"

CGi-6

21"

 

 

 

 

CGi-4

15"

CGi-7

24"

CGi-5

18"

CGi-8

27"

 

 

 

 

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.



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Contents Gold CGi How it works Gold CGi Gas-Fired Induced-Draft Water Boiler Contents Please read before proceeding Installations must follow these codes 1a Prepare boiler location codes & checklistBefore locating the boiler, check the following 1b 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 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 terminationVertical venting See . Follow vent 3f Venting direct exhaust installationSidewall venting See Figures 14 Using 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 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 pipingStart the boiler 7b Start-up operate boilerCheck system and 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 eliminationBoiler relief valve Review with ownerReview the User’s Information Manual with the owner 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 SequenceSection assembly Base Jacket Trim Controls 12a Replacement partsControls Repair Parts Lists Section assembly 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketModel Weil-McLain part number BoilerBoiler Model 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