Weil-McLain CGi Series 3 Product manual

~ WEil·mrlAIN ®
Series 3
Gas-Fired Water
Boilers
Boiler Manual • Installation • Maintenance
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i4 WARIIIN GI
i4 W ARIIIN GI
• Startup • Parts
DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free air to the
boiler area or follow the requirements given on page 9. Failure to comply cou ld result in severe
personal injury, death or substantial propertydamage.
This manualmustonly be used byaqualifiedh ea ting instal l er/service technician. Be foreInsta llin g, read
all instructions, includingthis ma nual, and anyrelatedsupplements. Performstepsin the ordergi ve n.
Failure
to comply could resultin severe personal injury,death or substantial property da mage.
Part Number 550-142-780/0712

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
How it works • • •
(!) Co nt ro l modul e
The control module respon ds to signals from the room thermostat, air pressure sw itch and bo il er li mi t ci rcuit to operate
the boiler
ci rculator,! il ot burner, gas valve andindu cer. When room the rm ostatcalls fo r heat,the control module starts the
system circulatoran i nd ucer.
The control module nm s th e i ndu cer long enough to purge the boiler flu e p assages, th en opens the pilot valve andactivat es
pilot ignition spark.
For naturalgas, the controlmodule
all ows up to ISseco nd s to establish pilot flam e. If fl ame is not se n se d within IS seconds,
thecontrolmodule willturnoff
th e gas val ve, fla shthe Flame light,a nd then e nt era IS-seco nd postpur ge. The co ntrolmodule
will
th en starta newcycl e. This willcontinue indefinitelyuntil p il ot fl ame is es tablished or power is i nt errupted.On ce pilot
fl ame is pr ove n, th e co ntrol module opens the gas va l ve to a ll ow ma in burner fl am e.
For pr opane gas, the controlm od ulea ll owsup to ISseco nd stoestablishpilot fl am e. If fl ameis not se nsedwithin IS seconds,
the control module will
tum offthe gas val ve, fla sh the Flante li ght,wait I mi nut e, th en starta newcy cl e. If fl ame is sti ll not
se nsed after thesecond trial, two moreattempts are made wi th Smi nut e wai t periods in between. If fl ante is not se nsedafter
4 tries, control w
ill locko ut and fla sh a ll li ght s. Control mu st be manually rese t to place b ac k i nt o service. On ce pilot fl ame
is pr oven, th e co ntrolmodule opens th e gas val ve to a ll ow main burner fl ant e.
Whe n th e r oo m thermostat is sa ti sfi ed, the co ntrol m od ule turns off the ga s val ve, operat es the i ndu cer fo r a IS-second
postpurge
and waits for the next heatcall.
Thecontr
ol module indicatorlightsshownormalsequencewhen the li ghtsareonsteady.Whena problemoccur s, thecontr ol
module fla sh es combinationsof li ghtsto indicate th e most li ke ly reason for the pr o bl em (see page 49).
@ Tran sf onner
The contr ol transformer reduces li ne voltage to 24 volts for the gas val ve and li mit circuit.
@ Inducer
The i ndu cerpulls flu e g ases through the bo il er, cau si ng ai r to bepulledin th ro ugh the bo il erairopening s. Theindu ce r pu sh es
the flu e gases through th e ve nt pipe as we ll
@ Air pre ss ure switch
The air pressure switch signals the control module, telling the contr ol module whether the indu ce r is working correctly or
the vent is blocked.
@ Water temp e ratu re lim it s en s or
The wate rtemperature li mit sensor provides asignal to thecontrol module to turnoffthegas valve ifthe temperature in the
boiler
goes above its settin g. (The ci rculatorw ill continueto runas lo ngas there is a call for heat.)
@ Boller ci rc ulato r
Theboilercirculatorcirculateswater throu gh the exte rn al(system) pipin g. Thecirculatorisshipped loose,andcan be mounted
on either the boiler supply orreturn pipin
g. The factory-installed ci rculatorwiring harn ess provides ample length fo reither
location. NOTE -The contr
ol module provides a pu mp exercising routin e. If the boiler is not operated fo r 30 days, the
contr
ol module will power the circulator fo r 30 seconds,then tum off.
Ti mer rel ay - CG I 4 Only
The timer rel ays del ays h igh fire fo r 60 seco nd s.
Other boil er c omponen ts :
2
a supply to system
b return from system
c stainless steel bu rners
d flu e outlet
e
gas valve
f pressure/temperature gauge
g relief valve
h air vent connection
i fl ame ro ll o ut thermal fu se eleme nt
( TFE)
j burnershield
k pilot bu rn erand bracket
1 gas manifold
m
cast ironboilersections
n flue co ll ector
o
ju nction box
Part Nu m ber 550 - 142-7 8 0/07 12

CG i GAS-FIRED wATER eotLER- sERIEs 3- Boiler Manual
CGi Gas-Fired Induced-Draft Water Boiler
CGi 4 Only
'/1001
PartN umbe r 550-1 42- 780/0712
3

CGi GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
4
Contents
How it works •••••••••••••••••••••••••••••••••••••••••••••••••••• 2-3
llet~Cirlt ciEtfillitiC)Il!; ••••••••••••••••••••••••••••••••••••••••••••••• 'I
Please read before proceeding ............................ 5
1 Prepare boiler location ••••••••••••••••••••••••••••••••••• 6-11
2 Prepare boiler ••••••••••••••••••••••••••••••••••••••••••••••• 12-13
3 Venting ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 14-19
4 Water piping ••••••••••••••••••••••••••••••••••••••••••••••••• 20-29
fi Clas pil)ing ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3()
6 Field wiring ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 31
7 Start-up •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 32-35
8 Check-out procedure - checklist •••••••••••••••••••••• 36
9 Department of Energy Compliance ................... 37
9a Operation ••••••••••••••••••••••••••••••••••••••••••••••••••••• 38-43
10 Service and maintenance ............................. 44-48
11 Troubleshooting •••••••••••••••••••••••••••••••••••••••••••• 49-58
12 Replacement parts ••••••••••••••••••••••••••••••••••••••• 59-65
13 Dimensions and ratings ................................ 66-67
Hazard definitions
The fo llowi ng defined terms are used througho ut tllis manual to bringattention to the presence of hazards of
various risk levels or to importantin
fo rm a ti oncon<£ming the li fe of the product.
I& WARNING I
lA CAUTlON I
NOTICE
Indicates presence of hazards that will ca u se severe personal injury, death or substantial
propertydamage.
Indicates presen<£
of hazards that ca n cause seve re personal injury, death or substantial
propertydamage.
Indicatespresence
of hazardsthatw ill or ca n ca u se minor personal injuryor propertydamage.
Indicatesspecial in str uctions on installati on, operation or maintenance that ar e im porta nt but
n ot related to personal injury or propertydamage.
Part Number 550 -14 2-780/0712

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
Please read before proceeding
Installer User
I& WARNING !
Read all Instructions before In-
stalling. Follow
all instructions in
proper order to prevent personal
in
jury or death.
Considerpiping
and Installationwhendetem1ining
boilerlocation.
Any
claims for damage or shortage In shipment
must be filed inunediatelyag:Unstthe transportation
company bythe consignee.
This
manual Is for use only by your qualified
heating Installer/service technician.
Please refer to the User's Information Manual for
your reference.
We reconmtend regular service by a qualified
se rvt ce technician, at least annually.
I& WARNING!
The boiler contains ceramic fiber and fiberglass materials. Use care when handling these
materials
per instructions on Page 70 of thisma nu al. Failure tocomplycouldresult in severe
personal injury.
NOT ICE
When calling or writing abo ut the boiler-Please have the boiler mode l number from the
boiler ratinglabel and the CP number from the boilerjacket. You maylist the CP number in
the space providedon the Installation and service certificate fo und on page 36.
I& WARNING ! Failure toadhere to the guidelines
on this page can result in severe personal injury, death
or substantial propertydamage.
When servicing boller -
Th avoid electric shock, discOJmect electrical supply
before performing maintenance.
To avoid severe burns, allow boiler to
coo l before
performing maintenanc-e.
Boller operation -
Do not blockflow of combustion or ventilationairto
boiler.
Should overheating occur or gas supply fuil to shut
off, do n
ot tum off or disconnect electrical supplyto
circulator. 1nstead,shut
off the gassupply at alocation
external to the appliance.
Do not use tllis boiler if any part has been under
water. Im mediatelycall a qualified service teclmician
to inspect the boiler
and to replace any part of the
controlsystem
and anygascontrolthathasbeen under
water.
Boller water -
Do not use petroleum -based cleaning or sealing
compounds
in boilersystem.Waterse al deterioration
will occur,causing leakagebetween sections.This
can
result in substantial propertydamage.
Do not use "homemade c ures" or ((boiler patent
medicines'~ Seriousdamage to boiler, pers01mel and/
or propertymay result.
Part Number 550-142-780/0712
Continual fresh makeup water will reduce
boiler life. Mineral buildup in sections re-
ducesheat transfer) overh eats cast iron) and
causes section failure. Addition of oxygen
and other gases can cause internal corrosion.
Leaks in boiler or piping mu st be repaired
at once to prevent makeup water.
Do not add coldwater tohot boiler.Themtal
shock
can causesections to crack.
Glycol -potential fire hazard -
All glycol is flanmtable when exposed to lligh
temperatures. Ifglycol is allowedtoaccumulate
in or around the boiler or any other potential
ignitionsource, a fire
can develop. In order to
prevent potential severe personal inj ur y, death
or substantialpropertydamage from fire and/
or structuraldamage:
Neverstoreglycol
of anykindnear th e boiler
or any potential ignitionsource.
Monitor
and inspect the system and boiler
regularly for leakage. Repair any leaks
im -
mediatelytoprevent possibleaccumulation
of glycol.
Neveruse automotiveantifreeze
or ethylene
glycol in
the system. U si ngthese glycols can
lead to hazardous leakage
of glycol in the
boilersystem.
5

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
6
1a Prepare boiler location -codes & checklist
Installations must follow these codes:
Local, state, provincial, and nationalcodes, law s, regulations and ordinances.
National Fuel Gas Code, ANSI Z223.1 -l atest edition.
Standardfor Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ ASME CSD-1, when required.
National Electrical Code.
For Canada only: BI49.1
or BI49.2 Installation Code, CSA C22.1 Canadian
Electrical Code Part I and anylocal codes.
NOTICE
NOTICE
TI1e CGi boiler gas manifold and controls met safe operating and
otherperformancecriteriawhen boiler tmderwenttestsspecified
in ANSI Z21.13 -lat est edition.
For
the Commonwealth of Massachusetts, read and follow the
special instructions located
on page 15 of this manual.
Before locating the boiler, check the
following:
Check for nearby cOJ mection to:
System water piping
Venting co nn ectio ns
Gas supplypiping
Electrical power
Checkarea around boiler. Remove any combustible materials, gasoline and
other flammable liquids, or othe r contaminants.
!&W ARNING I Failure
to keep boilerarea dear and free of combustible mate-
rials, gasoline and othe r flammable liquids and vapors can
result
in severe personal injury, death or substantial property
damage.
Boiler must be installed so that gas control system componentsare protected
from dripp ing or spraying water or rain duringoperation or service.
If new boilerwill replaceexisting boiler, checkfor and correctsystem problems,
suc h as:
I. System leaks causing oxygen corrosi
on or section cracksfrom hard water
deposits.
2. Incorrectly-sizedexpansion tank.
3. Lack of antifreeze in boilerwatercausing system and boiler to freeze and
leak.
Part Number 550 -142-780/0712

CGi GAS-FIRED wATER eotLER- sERIEs 3- Boiler Manual
1b Prepare boiler location - clearances
Recommend ed SERVICE cl e arances
(Fig. 1a)
I. Provide clearances fo r cleaning and servicing the boiler and for
access tocontrols
and co mp onents. SeeFigure Ia for recommen-
dations.
2. Provide
at leastscrewdriver clearance tOjacket front panelscrews
for removal of front panel
fo r inspection and mi nor service. If
unable to provide at leastscrewdriverclearance,install uni ons and
shutoff valves in system so boiler can be moved fo rservicing.
Figure
1a
Recommended
SERVICE cleruances ,
~,· ·
J
(see WARNING
below)
I& WARN I NG I
....
If any clearanceIs 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).
Theseopeningsmust belocated as shown in Fi gure Ib toprovide
proper air
fl ow arOtmd the boiler. Th e free area of each opening
(after
ded ucting for louvers) mu st be at least one square Inch per
1,000 Btuh of boiler inpuL If the buil ding is of unusually tight
con
st ructi on (see page II for definition), the air openings must
connectdirectly tooutside or
the building mu st haveair open ings
to
th e outside as specified on page I I.
If clearances are equal to or greater than Figure Ia, see pages 10
and II fo r location and si zi ng of combustion airopenings.
Failure to comply can result in severe personal inj
ur y, death or
substanti al propertydamage and reduce(! bo iler life.
Re qui re d MINIMUM cl e aranc es (F ig .1 b)
I& WA RN IN GI Never Install
the boiler In a space with clear-
ances less than the minimum clearances shown
In Figure 1b. Failureto complycan result in severe
personal injury,death or substantial property
dam-
age and reduced bo il er li fe.
I. Hot water pipes: at least 'h Inch from combustible material.
2. Single-wallventpipe: at least 61nches fro mcombustible mate-
rial.
3. Type Bdouble-wallmetal vent pipe: refertoventmanufacturer's
recommendati
on fo r clea ran ces tocombustible material.
Part
Nu m ber 550-142-780/0712
Flgure 1b Required MIN I MUM cl earances
Flooring
TheCGi boilerisapproved for installation onco mbu stible
fl oor ing, but mttstnever be installed on carpeting.
I& WARN I NG!
Do not install boileron carpetingeven
if foundation is used.
Fi re can result,
causing severe personal injury, death
or substantial propertydamage.
Foundat i on
l. Pr ovideasolidbrickor minimum2-inchthickconcrete
foundation pad
if any of the following is true:
fl oor can become fl ooded
the boil er motmtingarea is n ot leve l.
2. Minimumdimensions are 251nch length by:
Minimum foundation width:
CGI-2513
1 2"
CGI~ 21 "
CG~4 1 5"
CGI-7 24 "
CG~S 1 8'
CGHI
2 7"
Residential garag e installations
Ta ke the followingspecial precautions when installing the
boiler in a res
id ential garage. If the boiler is located in a
residential garage, perANSI Z22
3. 1:
Mo
unt th e boil er a mini nuun of 181nches above the
floor of the ga rage to assure the bumer and i gn ition
devices w
ill be no less than 18 in ches ab ove th e fl oor.
Locate or protect the boiler so it cann ot bedamaged
by a movingvehicle.
7

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
lc
I& WA RNING !
tr jHJUijj;l
8
Prepare boiler location -vent system
Failure to follow all instructionscan result in flue gas spillage and carbon mon oxide emissions, causing severe
personal inj
ur y or death.
Inspectexistingchimneybeforeinstalling boiler. Failuretoclean
or rep la ceperforated pipe or tile lining willcause
severe pe rson al injury or dea th.
Direct exhaust venting(Category Ill) - DO NOTCOMMONvent the CGi in a directexhaustsystem (Ci te gory
Ill ). COJ mecting more than one ap pliance to a direct exhaust system will cause flue gas spillage or appliance
malfunction, resulting in possible severe personal injury,death
or substantial propertyda ma ge.
When removing boiler from an
existing common vent system:
At the time of removal of an existing boiler, the following
stepsshallbefollowedwith each applianceremainingcon-
nectedtothe commonventingsystem placedinoperation,
while
the other appliances remaining connected to the
comm on ve ntin g syste m are not in operatio n.
a. Seal any unused openings in the co mm on ve nting
system.
b. VIsually
Inspect the venting system for propersize
and horizontal pitch and determinethere is no blockage
or restrictio
n, leakage, co rr osion or other de fi ciencies
which cou
ld cause an unsafe condition.
c.
Test vent system - Insofar as is (> Tactical, dose all
building
doo rs and windows and all doors between
thespacein wh
ic h theappliances remainingconnected
to the co
mm on ventingsystem are located and other
spaces
of the building. Turn on clothes dryers and any
appl
ia ncen ot connectedto the common ve ntingsystem.
Turn on any exhau st funs, such as range hoods and
bathroom exhausts,so they will operate at maxi mum
speed. Do not operate a stmmt er exhaust fun. Close
firep lace dampers.
d. Place In operation the appliance being inspected.
Follow
the operating instructions. Adj u st the m1 ostat
so app lian ce will oper ate continu ous l y.
e. Test for spillage at draft hood re li ef opening after 5
minutes of main burneroperation. Us e the flame of a
match or candle.
f. After it has been determined that each appliance
re mai n in g con nected to the common ven ting syste m
properly vents when tested as outlin ed above, r et urn
doors,windows, exhaustfuns, firepla
ce dampers, and
anyothergas-burning appliance to theirpreviouscon-
ditions of use.
Anyimproperoperation
of comm on ve ntingsystem sho uld
beco
rr ected so th e installationconfomtswith the National
Fuel Gas Code, ANSI Z22
3. 1 - latest edition. Correct by
resizing
to approach the minimum size as determined
using the appropriate tables
in Part I I of that code. Ca -
nadian installations must complywith BI49.1 or BI49 .2
Installation Code.
Chimney or vent
requirements
1. Venting must be installed according to Part 7,
Venting of Equipment, of National FU el Gas
Code, ANSI Z223.1 - latest e
dition and ap -
plicab le building codes. Canadian installations
must complywith BI49.1 or BI49.2 Installation
Codes.
2.
See Ratings table on pa ge 66for minintwnchim-
ney or ventsizes. A chi mn ey or vent without a
listed cap sho u ld extend at least 3 feet above
the highest pointwhere it passesthrough a r oof
of a building and at least 2 teet higher than
any portion of a building within a ho rizontal
distance of 10 teet.Achimneyor vent mu st not
extendless than the distancesstatedabove.
3. A lined chi mney is preferred and must be used
when requir ed by local, state, pr ov incial and
national codes, laws,regulations and ordinances.
Vitreous tile linings with joints that prevent
retention of moistureand Ji ni ngs m ade of non-
corrosi ve materialsare best.Adviceforfluecon-
nections and chi mn ey linings can be obta in ed
fro m local gas utility. Type Bdouble-wall metal
ve nt pipe or si ngle-wall ve nt pipe may be used
as a lin er.
4. Cold masonry c himn eys,also known as outside
chimneys, typically have one
or more walls ex-
posedtooutsideair.When anyatmosphericgas-
fired boilerwithautomaticventdamp er isvented
t
hrough this type of chimney, the potential
exists fo rcondensationtooccur.Condensation
can damage a masonrychim ney. Weil -Mclain
recommends the following to prevent possible
damage.
a. Line c himn ey wi th co rr osi on - resistant
m eta l li ner suc h as AL29-4CS single-wall
stainless steelorB-vent.Size liner per
National Fuel Gas Code
ANS I Z223.1 -
latest edition.
b. Provide drain
trap toremove anyconden-
sate.
Part Number 550-142-780/0712

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
ld Prepare boiler location - air contamination
Please review the followi ng information on potential
combustion
air co ntamination probl ems.
Refer to Table 1 for productsand areas whichm ay cause
con ta m inated com bustion air.
I& WARNIN G!
To prevent potential of severe personal injury or death,check for products or areas listed
bel
ow beforeinstal li ng boiler. If a ny of these contaminantsare found:
remove co
ntam inantspe rm ane ntl y
-O R -
i so latebo il er a nd pr ovi deoutside co mbustion air . See na ti onal,prov in cial or localcodes
for further info
rm ation.
Table 1 Corrosive
or destructivecontaminants and likely locations
Products to avo id Areas li kely to have contaminan ts
Spray cans co n ta in in g chior o/ fluorocarbo ns
Dry cleaning /l aundryareas and establishments
Permanent wavesolutions
Sw imming poo ls
Chlorinated waxes/cleaners Metal fabrication plants
Ch lorine-based sw imming poolchemicals Beauty shops
Calcium chlorideused for thawing Refrigeration repair shops
Sodium
ch lorideused f or watersoftening Photo processing plants
Refrigerant leaks Auto bodysh
ops
Paint or varni sh removers Plastic manufacturing pl an ts
Hydrochloric ac i d/m uriat ic ac id
Fum~ur e refinishing areas and establishments
Cementsand glues New
bu ildi ng construction
Ant lstatlc fabricsofteners used In clothes dryers Remodelingareas
Ch lorine-typebleaches, detergent s, and cleaning Garages wHh workshops
solvents found Inhousehold
la un dry rooms
Adhesives used to fasten building products and Buildingsunder co nstruction (where air Is
othersimilarproducts contsmlnated with particulates)
Airborne particulates (drywall dust, fiberglass
particles, road
or gravel dust, lint, etc.)
I&W ARNIN GI C
ONSTRU C TION DUST HAZARD -A ir borne particulat es, such as drywall d us t
or fiber
gl a ss du st, will ca u se bl ocka ge of th e CGi burn e rs , r es ultin g in ca rbon mon oxi de
pr od uc ti on, a fir e h aza r d, or buildin g fr eeze dan1 ag e. If th e bo il er is operated durin g
construction, you must isolate the
bo il er to provi de de an air for combustion. If you are
unable to ensure un c ontaminated ai r In the boiler vlclnHy at all Urnes, you muslin-
s pect the boile r at least once weekly.When inspecting,clean the b urn ers if n ecess a ry
us i ng the proceduregi ve n on page 45. Fai lur e to follow these guidelin es co u ld res u lt in
severe personal i njury, death or substantial propertydam age.
Pa rt Num ber 550-142-780/0712 9

CG i GAS - FIRED wATER BOILER- sERIEs a- B oi l er Manua l
1e Prepare boiler location - air openings
I& WARNING I
*
Combustion air opening location and sizing
requir ements depend on the clearances around
the boiler. Check the bo ilerp la cementcompared to
Figure Ia, page
7.
If all clea r ances are at least equal to Figure 1a ,
page 7, apply thesizing and placement of opening$
given
on pages lO and I I.
If ANY clearance Is Jess than Figure 1 a, page 7,
yo u mustprovideair openingssized and located as
shownin Figure lb,pa!>e7.
DO N OT apply the s iz.in g
and l oca ti on informa ti On shownon page I0 or I I.
Figure2
*
Figure3
Air openings must be provided *
Combustion air and ventilation openings must comply the National Fuel
Gas Code ANS I Z22 3. I -latest edition, or applicable loc al building codes.
Canadian installatio ns must comply with Bl49.1 or Bl49 .2 Installation
Codes.
I& WARNING ! Provide adequate combustion
and ventilation air to
assure proper
combus ti on and reduce the risk of severe
personal injur
y, death or substantial propertydamage
caused by flue gas
sp illage and carbo n monoxi de
em issions.
Air opening options
TWo openings - Air supply from Inside the building *
t. If thebuildingis of unusually tightconstrucUon(seedefinition, next
page), thebuilding
must also be prcwlded with air openings dlrecUy
to
the outside , sized and located per Fi gure3,Figure 4 or Figure 5.
2. Buildings of typicalconstructionshould pr ovideadequate co mbustion
air from natural infiltratio
n, so additional airopenings to the building
are not requ ir ed.
3. See Figure 2. Pr ovide two openings through the i nt erior wa ll, within
12 inches of the ceiling and the fl oor, sized per Figure 2.
TWo openings - Air supply directly from outside *
Figure4
*
I. A ir openin gs mu st bedirectly through an outside wall, or into a space Figure 5
thatconnectsdirectly to theoutside(such asa ventilated
att ic orcrawl
space, for example).
2. SeeFigure 3-
Openings directly through an outsidewall- _provide *
two openings within 12 in ches of the ceiling and the floor, SIZed per
Figure 3.
3. See Figure 4 -Air supplied through vertical ducts -provide two
openings terminatedwithin 12 in ches of the ce iling and the fl oo r,sized
per
Fi gure 4.
4. See Figure 5 - Air supplied through horizontal ducts -provide
two
openings within 12 inches of th e fl oor and the ceiling, sized per
Figure 5.
tO
Ai ropeningsto Interior spaces
Ea ch opc ni i)Q ff'Oo u re a •
1 sq. inr. h per 1,000lltuh
Air directlythrough outside wall
EIIClh opaning lr o• an: n=
1 :r;q .1nch per4,000Btuh
Air from outdoo rs -vertical duels
Ou t $1 de orv en 1Ha 1ed a ulc
E.::lc h openingInto III'O ll a
1sq.inch pe r4.000Btuh
•-
...
....
~·
V cm !llol<ld Ull1TJ1lll
Cl' swt s pace tJUJU:/JJJ
Air fr omoutdoors -horizontal duc ts
Ee ct. opening f;ee ar ea '"'
1sq.lnehp et 2.0 00 Bt uh
''"
, ....
PartNumber 550-142-780/0712

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
1e Prepare boiler location - air openings
NOTICE
FREE AREA of openi ngs th e minimum areas
gi ven in this m anua l are free area {equals th e area ,
length times width of opening, after deduction for
louver obstruction).
Use the freearea information provided by th e lo uver ma nufacturer.
Whe nthis information is not availa ble, assu m e:
Woodlouvers-assume freearea is 20%of total; sothe ac tual area
of each openi ng 'vith wood louvers would be 5 times th e required
free area.
Metal lo uvers- assumefree areais60% of actualarea;so, for wood
louvers, the actual area of each opening must be 1.67 times there -
quiredfree area.
Single air opening option *
Asingle co mbustion a ir ope ning can be used in lieu of th e two- open i ng
optionson page I0, provided:
Clearances from bolter to walls
Th e boiler must ha ve clearances of at least th ose shown in Figure Ia,
page7.
Opening must be directly to outside
Th e opening must co nn ect dir ectly to the o utd oo rs or to a space t11 at
co m mun icates directly toth e outd oors (no t to an inter ior space).
Th eaircan be provided throu gh adirectopening or throughahorizontal
or ve rt ical duct.
Opening placement
Th e top of th e airopening must bewithin 12 in ches of th e ceilin g.
Opening size
Th e free area of th e opening must be at least equal to th e sum of th e
areas
of all equipment ve nt co nnectorsin the sp ace, and ...
Th e free area of th e opening must be at least 1square inch per 3,000
Btll/hr inp ut rating of all eq uipm en t locat ed in t11 e space.
Exception for large spaces *
No co mbustion air ope nin gs are needed when t11 e bo iler ( and ot h er ap-
plian ces} are in st all ed in a space wi th a vo lum e at least 50 cubic feet per
1,000 Btuh of all installed appliances,provided:
the building must not have unusually tight construction
(see definition, this page).
allclearan
ce s aratmd th e boil er must beno less than shown in Figure Ia,
page 7.
Todete
rm ine if the space is large enough to qua lify:
Add t11 e total input of allappliances in JV!B H (1 ,OOO's of Btuh).
Multiply this munb er tin1 es 50 to detem1ine mininmm room vo lum e.
Exan1ple: For a t
ota l input of 100 MBH (100,000 Btuh), mininmm
vol um e is 50 x 100 = 5,000 cub ic fee t At a ceiling height of 8 fe .et, th e
space must ha ve at least 5,000 + 8 = 625 square feet (25 fee t x 25 fe .et,
for instance).
Part Nu m ber 550-142-780/0712
Unusually tight construction
Unusuallytight co nstruction mea ns (per ANSI Z223.1)
buildingsin which:
a. Wal ls and ceilings exposed to th e outside atm o-
spherehavea co ntinuouswatervaporretarderwi th
a rating of I perm or less with ope nings gasketed,
and ...
b. Wea th er-s trip pi ng has been added on ope nable
w in dows anddoors, a nd ...
c. Caulking or sealants are applied to areas suc h as
joi nts around windows and door frames, between
sole pl ates and fl oors, between wal l- ceilin gjoi nts ,
between wall panels,
at penetrationsfor plumbing,
electrical,
and gas lines, and in othe r open ings.
For su ch con str uc ti on cases, if appliances use in si de air
for combustion, provideair openings Into the building
from
outside . Size and locate t11 ese ope nings per th e
appropriatecase in
Figure 3,4 or 5 on page 10.
Exhaust fans and air movers
The appliancespace must never be under a negative
pressure, even if the appliance(s) are installed as di -
rect vent.Always provide air ope ningssizednot on ly
to
th e dimensions required for th e firing rate of all
app
li ances, but also to handle th e air movementrate
of the ex haust fans or a ir movers using air from the
building or space.
Motorized air dampers
If th e air openings arefitted wi th motorized dampers,
electrically interlock
the dan1per to:
Preve nt th e boil er from firing if th e damp er is n ot
fully open.
Shut th e boilerdown should th edan 1p er close dur -
ing bo il er operation.
Toaccomplish this i nt erl oc k, wire an Isolated contact
(p roving the damp er ope n) in series with th e th e rm o-
st at input to the boiler. The boiler will not start if this
conta ct is open, and will s hut down should it open
dur ing operation.
II

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
2a
12
Prepare boiler - placement & setup
Place boiler/crate near
position
t. Leaveboiler in crate and on palletuntil installationsite
is ready.
2. Move entirecrate and pallet next to selected location.
3. Remove crate.
4. Remove bo il er from pallet
NOT ICE I Do not dr op boiler or bmnp jacketon
. fl oor or pall et Damage to bo il er can
r esult
a. Tilt leftside of boiler up and placea board under
left legs.
b.
Tilt boiler th e other way and place a board u nder
rightlegs.
c. Slide boiler backward off pallet and int o position.
5. Checklevel.
a.
Shim legs, if necessary.
b.
Do not alter le gs .
Inspect orifices and burners
t. Remove frontjacketdoor. Remove burn er shield (see
Figure 40, item 4, page 60).
2. Checkf orco rr ectly-sizedmanifold orifices.See Table 2
for sizing. (
Th e orifice size is stan1ped on th e orifice
spud barrel.) Correctly-sized
manif old orifices must
be used. Fail ure to do so will result in
severe personal injury, death
or sub -
stantial propertydamage.
3. Reinstall
burner shield.
I& WARNING !
Do not operate boil er wi th o ut
burn er shield in place. Fail ur e
to do so could resu lt in severe
personal inj ur y, death or sub -
stantial propertydamage.
Orifice replacement
procedure
(w hen required)
t. Remove thescrews securing the burner shield
and removeburn er shield.
2. Using a 'h<'' op en -e nd wren ch, remove th e
burner orifices from th e manifo ld .
3. Apply a small amount of pipe dope to each of
t11 e n ew orifices and install in t11 e manif old us-
inga'I..''op en -e nd wre nch .JV!akes ur e th e ori -
fices are aligned correctly, not cross-threaded
in the man if old tapp ings.
I& WARNING ! Use
on lypipedopecompatible
withpropanegas,even
if boiler
is to be operated on natural
gas. Failure
to comply could
result inseverepersonal injury,
death or substantial property
damage.
4. Carefully replace th e burner shield.
5. Foll ow th e chec k- o ut pr oced ur e, Section 8
page 36, to assure the boiler is now operating
properly afterorifices are re
pl aced.
Table 2
Manif o ld o rifice sizing at sea l eve l and a~ltudes to4,500 feet
Location Boiler model Natural gas Propane gas
number
0-2,000 "·
over 2,000 H.
0-2,000 "·
over 2,000 ft.
CG i -25 2.30mm #54
u.s. CGi -3 and CGi -5 2.55mm (Note 1) 1.6 0m m (N ote 1)
CG i -4, CG i-6 - CGi-8 2.70mm 1.65mm
0-2,000 "·
2,000-4,500
0-2,000 "·
2,000-4,500
Canada
CG i -25 2.30mm #44 #54 #55
CG i -3 and CGi -5 2.55mm #4 1 1.60mm 1. 45 mm
CG i -4, CG i-6 - CGi-8 2.70mm #38 1.65mm #53
Note 1: For elevations above 2,000 leet, co ntact yo ur l oca l We ii·M cla in sales office lo r details .
Part Number 550-142-780/07 12

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
2b Prepare boiler -pressure test
Hydrostatic pressure test
Pressure testboiler beforeattachingwateror gaspiping
{except as notedbelow) or electrical su pp l y.
Prepare boiler for test
1. Re mov e theshippingnipple (from CGi s up plytap-
ping) and removethe bo il er reliefvalve.Temporarily
p lu g the reli ef va l ve tapping with a W' NPT pipe
plu
g.
2. Remove I\4'' nipple, reducing tee and drain valve
fromcirculatorhardwarea
nd pressure/temperature
gauge carton. Install in boiler r
eturn co nn ection as
shown on page 3
and Figure 42 , page 63. Install
circulator on either the returnor su pp l y.
3. Remo ve 1 1/a" nip pl e, l iA" x l iA" x lh'' t ee and pres ·
su re/tempera tur e gauge from circulator hardware
and pressure/temperature gauge carton. Pipe to
boiler supply connection as shown on page 3 and
Figure 42 , page 63. (Use pipe dope spar ingly.)
4. Connecta hose to boilerdrain va lve, the other end
connected to a fresh watersupply. Make sure hose
canalso be used
to drain boilerafter test.
5. Connecta nipple and shutoffvalve to system supply
connection on
th e 1 14'' tee. Thisval ve will beused
to bleedair
durin g th e fill (Val ve and nipple are not
includedwith boiler.)
6. Connect a nipple and shutoffvalve to system re-
turn connection (a t circul ator flange if circ ulat or
installedon r eturn). This va l ve will beused to bleed
air during th e fill .(Val ve and nipplearenot included
with boiler.)
Fill and pressure test
1. Open th eshutoffvalvesyouinstalledonsupply and
return co n nectio n s.
2. Sl ow ly open boil er drain va lve and fresh wa ter sup-
ply to fill boil er with water.
3. When wa t er tlo"'S from sh ut o ff va lves, close boil er
drain valve.
4. Closes hut off valves.
Part Nu mber 550-142-780/0712
5. Slowlyr eo p en boiler drain valve tmtil test pressure
on thepressure/temperaturegaugereaches no more
than:
45 psig forboilers with 30 psig relief valv e.
75 psig forboilers with 50 psig relief valv e.
6. Te st for no more than 10 minutes at:
45 psig forboilers with 30 psig relief valv e.
75 psig forboilers with 50 psig relief valv e.
I& WARNING I
Do not leave boiler un attended.
A co ld water fill co uld expa nd and
cause excess i ve pressure, resulting
in severe perso n al inj ur y, death or
substantial propertydamage.
7. Make sure co n stant gauge pressure hasbeen main-
tained throughout test. Check for leaks. Repair if
found.
I& WARNING ! Leaks must be repaired at once.
Failure to do so can damage boiler,
resul
ting in substant ial pr operty
dan1age.
Do not use petroleum-based clean-
ing or sealing co m pounds in boiler
system. Severe
damage to b oi l er
will occur, resulting in substantial
propertydamage.
Drain and remove fittings
1. DiscOJmect fi ll water hose from water so ur ce.
2. Drain boiler at drain va l ve or o ut hose, whichever
erovides best access to drain. Remove hose after
dra ining if used to drain boiler.
3. Remove nipples and valves unless theywill remain
for use in the system piping.
4. Remove plug from relief valve tapping.See page 20
to replace relief va lve.
13

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
14
3a
3b
Table3
Vent
connecto r
diameter
Figure7
Chimney
draft
venting
Venting -general information
CGi venting methods - Chimney draft or Direct exhaust
Chimney draft venting
Chimneyd ra ft venting uses the natural dr aftprovided
bya verticalventor chi
mn ey. CategoryIapp li ance (non-
pos iti ve ven ts tati c pr ess ur e and vent gas temperature
th at avoi ds excessive condensate produc t io n tn vent).
See Section 3b .Ch im ney draft installations use:
Direct exhaust - vertical or sidewall
Dir ect exhaust ve nting usesinside co mbustion air wi th
no co mbustion air co nn e ct or piping. All CG i flue ga s
vents
are pressurized, requiring careful seal i n~ of all
jo ints. Category Ill appliance (positivevent st atic pres-
sure and vent gas teml?erature that avoids excessive
co nd e ns ate pr od uc ti on mve nt ). See pages 15-19.
1. Ve nt co nn e ct or ( sin gle or do ubl e wa ll ) sized to
eliminate positive pr essure in ve nt system. Diam eter
in creases immediately at bo iler.
Dir ect exha ust installations use:
1. Ve nt pipe specified in this manu al
2.
Do uble wall metal ve nt (B-ve nt ) or chinm ey with
liner approved by
th e National Fu el Gas Code, ANSI
Z2 23 . 1-lat esteditio n, o rin C anadaBI4 9 .1 or Bl49 .2
Installat io n Co de.
2. Ve
nt termin a ti on thr oughoutside wall, r oo f or tm -
u sed chimney.Tight ch imney areas will makevent
j
oint co nstru c ti on very difficult.
Venting -chimney draft venting
Boiler ''0'
1 Minimum
model vent connector
number diameter
CG;- 25 & CGi-3 4"
CGi-4 to CGi-8 5"
Il-l .- - - Chimn ey
I &WAR NIN Gl
Inspect existing ch imn ey before in st alli ng boiler. Failure to
clean or r el? lace pe rf orated pipe or lining will ca use severe
personal inJuryor death.
Ve nt sizing given in Table 3 is on ly a ge n er al gu id elin e. Th e
ve
nt co nnect or and ch im ney mu st be design ed, sized and
co ns tru ctedincomp li ancewithallapplicablecodes. Fai lureto
co rrectlysiu and install thevent system could res ul t insevere
personal injury, dea th or substan ti al pr operty dam age.
1. Use double wall metalvent(B-vent) or chimneywithlineras
requiredby the NationalFuelGasCode,
ANSI Z223 . 1-lat est
edition, or
in Canada, B149.1 or B149.2 Installation Code.
2. To preve nt downdra fts, chimn ey shouldextendatleast3 fee t
above
th e highest poi nt where it passes t hr ough a roof an d
at least 2 feet higher than any po rti on of a bu ilding wi thin
a
ho rizontal d is tance of I0 feet.
3. To vent with anotherappliance,see Natio nal Fuel Gas Cod e,
ANSI Z223 .1-latestedition or in CanadaB149.2 or B149.2
In stallati on Code
4. Do not connect breeching to anyportion of a mechanical
dr aft syste m th at can o per ate un der posit ive pressu re.
5. Maintain minimwn2" cl e aran ce from combustible materials
to vent pipe.
6. Do not use chimney with an openfireplace.
7. Make horizontal ru ns as sh ort as possible. Long ru ns can
cause co nd en sa ti on.
8. When longer ru ns are used, su pp ort pi pe wi th a pp rop riate
hangers.
9. To p revent blockage, do not vent i nt o bo tt om of chi mn ey.
10. Ve nt pipe must notgo beyond inside wall of chimne y.
11. Ve nt passing through floors or ceilings mu st be
firestopped.
12.
See Figu re 7 an d Table 3 to co nnect boil er to ve nt ing sys-
tem.
Part Number 550-142-780/0712

CGi GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
3c Venting - Direct exhaust - components
Obtain vent system components
1. The following special gas ve nts ystems complywith UL -1 738
and ULC-S636 standards andarecerti fi ed by CSA as the only
syste mssuit ab le for us e with CGi boilers (a ll 3" diameter):
H
ea t- Fab, In c. Saf-TVen~
Fl ex -L International,In c. StaR-34
Z-Fiex"', In c. Z-Vent ll
ProTech Syste ms FasNSeal "'
ri&:--W-A_R_N ..., IN --.,... GI Use o nly the ve ntstarter of the same ma nu-
. fucturer
as the vent co mp onents. Do not mu
components from different sys t ems. Thevent
system could
fail, ca using flu e gas sp illa ge,
resulting in severe personal injury or deat h.
2. Select vent m ethod based on page 14 and installation requirements.
3. Ref er to Table 4for maximum ve nt runlengthsand number
of elbo ws. Do not exceed data in Table 4.
Massachusetts installations
(a) Por all side wall horizo nta llyvt: nt td gas futkd fllllipmc: nt installtd in ev-
ery
dwdli n g, bu i ldi ng or structu~ USt"d in wh ok or in pa rt for midt:ntial
pu r poses, including those own«< or O}M'rattd by tht Co mm onweahh and
wheno th t sidt wall ahausl ~ nt termination is l ts.s than stVt: n (7) fen ab~
finished grade in the an:a of the venting. including but not li.m.itcd to dcdu
and porches,the following nql..lin:mentsshall be satisfied:
I. INSTALLATION OF CARBON MONOXIDE DETECTORS. At
the time o( installal ion of t ht sick wall h or i zo nt al vt:nt«< gas fueltd
equipment, the installing plumber or gas fittershall observe that a
hard wirtd carbon monox ick dct«tor with an alarm and battery
back -u p is installed on the floor levd where the gas equipment is
to be installed. In addition. the installing plumber or gas fitter shall
obst:~ tha t a battery o~rated or hard wirtd carbon monox ick
dd«tor w ith an aJarm is inst a ll td on each addit ion al lt:vcl o( the
dwe Uin g, building or st rudu~ stT"Vt"d by the side wa ll horizontal
vm t«< gas futled t:qu ipm mllt sha ll ~ tht: usponsib ility o( the
property owner to secure the services of qualified licensed profc.s-
5iorialsfor
the installat ion o( hard wirtd ca r bo n monoxide dett:ctors
a. In the ~nt that the $idewall horizo nt a ll y vmttd gas futled
~uipme n t isinstalled in a crawl spaao or an attic, the h ard
wn·t:d carbo n m onoxide ddtctor with alarm a nd battt:ry back·
up may be installed on the next adjacmt floor leo."! I.
b. ln the n-mt th at the r~q u.i remt. nt s of th is subdivisio n ca n not
~ mtt at the time of comp l ttio n of installation, the owner
shall h a~ a ~ ri od of t hirty (30)days to co mpl y wit h the above
requ.in:'mcnts;
provided, hoV~"!Yet> that during said thirty (30)
day ~riod. a battery opt-rat«< carbon mo noxide det«to r with
an ala rm shall bt: installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each
carbon monoxide detecto r as uquirtd in accordanct: with the above
provisions
shall comply with NFPA 720 and be ANSIIUL20}41isted
and lAS o:rtificd.
3. SIGNAGE. A metal or plastic idC'Jltification plateshall be perma·
nm~y mount«< to the t':Xterior of the bui ldi n~at a minimum height
of tight (8) f«t abo\'t' gradt dir«tty in li ne with tht:t:xhaust \'fllt
te rm inal fort.ht horizontally vmted gas fucltd heating
appliance or ~uip m t:nt. Tht:sign sha ll rt'ad, in print 5itt no ~ss than
onc-half(l/2) inch in,;,. , "GAS VENT DIRECTIX BELOW. KEEP
C LEAR OF All OBSTRUCTIONs.•
4. INSPECTION. The state or local gas insptcto r of t.htsidewall ho ri ·
zonta Uy ~nted gas fuded equipmmt shall no t appi'O\'t' t ht
Part Nu mber550-142-780/0712
Table 4
Maximum vent length
Max. vent
Total number of elbows (Note 1)
length (feet) 1 2 3 4 5 6
CGi-25 to CGi-6 55 48
41
34
27
20
CGi -7 35 28
21 14 7
--
CGi -8 28 21
14 7
-- --
Note 1: Do notindude termination fitting IMlen
COll1ting t otal numberof elbctN.
4. Se lect vent components from separate CGi , & GV Vent
Component Supplement.
All components, in cl uding the
vent starter, must
be of the same vent manufacturer.Do not
mixcomponents.
insta ll ation unkss, upon insptction , th t: insptetor obst:rvn carbo n
monoxidt dettdors and signagt i nstalkd in accordana with t ht
provisions of248CMR5.08(2)(a) I throogl14.
(b) EXEMPTIONS:Th<foUowing<qu;pmcntis<Xt:mptfrom248CMR5.08(2)
(a)I througl14:
I. ThecquipmC'lltlisted in Chapter 10 entitled..Equipment Not Required
To Be Vented,. in the ma>t cum:nt edition ofNFPA 54 as adopted by the
Board; and
2. Product ApprovM side wa ll horizontally ~nt«< gas fueltd toquip·
ment instalkd in a roo m or structu~ St:pa rat e from the dwdling.
bui lding or structure us«< in wh ole or in part for rnide nt ial pur·
pastS.
(c) MANUFACTURER REQUIREMENTS -GAS EQUIPMENT VENT -
INGSYSTEMPRCNIDEO.
Whe n th emanufiu:turcrofProductApp<mM
side wall horizontal ly ve nt ed gas toquipment provicks a ~nt in g system
des i gn or ~ntingsystem components with thet:quipmm t, the inst ructions
provided by the manufactu~ r for installation of the toquipme nt and t ht
~nti n g system shall include:
1. Octruled instructions for the installation of the venting system
design or the ~nting system components; and
2. A co mpletepartslist for the ~nting system dtsign or ~nting system.
(d) MANUFACTURER REQUIREMENTS -GAS EQUIPMENT VENT -
ING SYSTEM NOT PROVIDED. When the manufactu«"r of a Product
Approvtd sick wa ll horizo ntally w n ttd gas fuekd t:quipmt. nt don n ot
provide the parts for venting the flue gases, but identifies..spcx:ial venting
systems~the following requirementsshall be sa tisfied by the manufactu.rer:
1. The rden:no:d "speciaJ venting S)'Stem,. instructions shall be
included w ith the app liano: or equipment installation instruction s;
and
2. The .. spcx: ial ~nting systems'" shall be Product Appro\"!d by the
Board. and the instructions for that S)'Stcm shall includea parts list
and detailed installal ion inst ructions.
(~) Acopy of al1 i nst allation ins.truct iom forall Product Approvtd sidtwal l ho ri ·
zontally\'t'flttdgas
fotkd ~uip m ml) aU\'fllting instructions,all parts li sts
forve nt ing instructions, and/or all vt:ntingdes.ign instr uctionsshall re:mai n
with theapplianct: or ('QU . ipmmt al the co mpl etio n of t.htinstallation.
15

CGi GAS - FIRED wATER eo1LER - sERIEs a - Boiler Manual
3d
16
Venting - direct exhaust - vent starter
J. Select a ve nt pipe manufa ctur er and ob tain a ll vent
components needed, based on boiler location and
ventmg method.
2. You must use t he vent starter made by the vent
pipe manufa cturer. See separate CGi, & GV Vent
Component Supp l ement, for part number of each
component. listed by vent manufacturer.
I& WAR N ING !
Figure 8
F as N SeaiTM
ventsterter
Figure 9
z- vent 11
ventstarter
Use only the ve nt starterofthe sa me
manufacturer as the vent co m po-
nents. Do not mix components
from different systems. The ve nt
sys tem co ul d f ai l, ca u sing flu e g as
spillage, resulting insevere personal
i njury or death.
6aodclamp
strap
Band c:la mp
sc:rew
FasNSeal ""
s 'l ;r; rter
Blo~t
housing
outlet
71009
Sand dam p
sc rew
~ "Bea d
of se;,lonl
8! 0\ve r
hous.ing
ou tle t
3. Followall applicable national,state, local or provin-
cia l codes when venting tb e CGi boiler.
4. Connect ve nt starter to blower housing outlet as
shown in the Figures8 through 11 .
a. Do not mix co mp onents from different ve nt
manufacturers.
b. Maintain mini mum 2" clearance from com ..
bustiblematerials to ve nt pipe.
c. Sea l witb sealant specified by ve nt pipe
manufacturer, using o/s" bead (not required for
Fa sNSeaf"" ).
d. Tighten s trap at band damp screw until strap
is snug arou nd blower housing.
Figure 10
Sal-T Vent®
ventstarter
Figure 11
StaR- 34
ventsta rter
B;mdc l om p
strap
StoR-34
staner
Part Number 550 - 142-780/07 12

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
3e Venting - direct exhaust -termination
I& WARNING ! Follow
instructio ns on this page
when detem 1i n in g ve nt location to
avoid possib ili ty of severe personal
injury,death or substantialproperty
damage.
l. Locate the bo il er and vent penetration through the
wall so all requirements on this page
and in Fig-
ure 12 will bemet. Al so follow vent manufacturer's
inst ru ctions.
2. Gaseswillfo rm white p lum e in wi nt er.P lum ecould
obstructwindow view.
3. Prevailingwinds co uld causefreezing of co nd ensate
and water/icebuildup on venttermination,building,
plants or roof. Icebuildup on ve nt termination can
cause boilershutdownand buil di ng freeze up.
4. Wi nd sover31 mp hcan cause nuisanceboiler shut -
down if boiler is sidewall ve nted. Th is could result
in loss of heat to building,causing freeze up.
5. Locate or guard vent termination to prevent co n·
densate from damagingexterior surfaces.
6. Locate th e vent termin at ion well away from trees,
shrubs, and decorative items.
7. Locate or guard ve nt to preventaccidental contact
by people
or pets.
8. Do not te rminat e ve nt in wi nd ow we ll, stairwell,
alcove, courtyard, or other recessed areas.
9. Do not wrap or insulate ve nt pipe or fittings.
l0. Do not t er minat e ve nt above any door or wi nd ow.
Condensate ca n fre . e.ze, causi ng ice formations.
11 . Do not co nn ect
Anyo th er appliance to ve nt pipe.
Multiple boilers to a co mm on ve nt pip e.
Figure 12 Vent terminati on m ini mum cl earances
Opti ona l Snorkeling
Part Nu mber 550- 1 42-7 80/0712
12. Ca nadi an insta ll atio ns -See Bl49 .1 or Bl49 .2
Installation Code. Tem 1i nate vent no less than 6
feet from ano th er combustionair inlet,3 fe .etfrom
any other buildingopening,a nd 3feet from anygas
serviceregulator.
13. See Figure 12 , showing that the ve nt mu st temli -
nate:
more th an 4 feet bel ow or to side of all doors
or wi nd ows.
more th an I footab ove gr ade or anticipated
snow li ne.
at least 7 feet above public walkway.
3feet above anyforced airintake within I0
feet.
14. Vent must also t er minat e:
at least 6 feet away from adjacent
wa lls.
no closer
th an 5 feet bel ow roof overhang.
at least 4 feet horizontally (and in no case
above or bel ow unless a 4 foot horizontal
distance is maintained) from el ectr ic meters,
gas meters, regulators, reliefvalves, and othe r
eq uipment.
IS . Siteconditions ma y dictate greater clea ran ces.
16. Do notexte nd exposed ve nt pipeoutsideof building
more than 4 feet.
Condensate could freeze and blockvent pipe.
I& WARNING ! A gas
vent extending th r ough an
exteriorwallshall notterminate ad -
jacent toth ewall or below building
exte nsions su ch as eaves, parapets,
balconies or decks. Failure to com -
ply could result in severe personal
inj ur y, death or substantial property
dan1age.
17

CGi GAS-FIRED wATER BOILER- sERIEs a- B oi l er Manua l
3f Venting - direct exhaust- installation
I& WA RN IN G!
18
1. Do not mix types or manufacturers of ve nt materi-
als.
2. Clea n all joints before sealing. See vent manufac-
turer's instructions for cleaning andsealingjoints.
Us e theirspecified sealant. Do not us e screws.
3. In stallventpipewithseamsontop of venthorizon-
talruns. Foll owrequirements inSection 3e for vent
termination.
4. Maintain mininmm 2" cl earan ce from combustible
materials to
ve nt pipe.
5.
Ve rt ica l venting - See Figure 13. Fo ll ow ve nt
manufacturer•s instructions fo r venting through
roof.
Vent pipe must ex te nd through roof flashin g,
jacket or thimble.
Vent may p ass through floor, inside wall or
co ncealedspace when installed according to
vent manufactureesinstructions.
Sid ewa ll venUng- See Figur es 14 and 15.
Vent musttemtina te at least one foot above
anticipated snowlin
e. Vent must be terminated
onlywith:
Tee
or elbow with integral screen. (Tee may be
mountedeither vertically or horizontally. DO
N OT us e horizontal t ee wi th CGi-7 or CGi-8.)
Elbo wand termination coupling wi th screen
(notavailable forStaR-34).
6. Donotseal ve nt pipe (slipco nn ec torfor Saf-TVent)
to inside or outside plate.
7. If passing through
no ncombustible wall, provide
hole diameter lar
ge enough to insert the ve nt pipe
(slip connector for
Sa f- TV e nt ).
8. Install horizontal drain tee as dose as possible
to bo il er, in first horizontal run. See Figures 13
and 14 .
9. Do not excee d the max in1un1 ve nt system length
gi
ven in Tab le 4, page 15.
Condensate drain line- use o nl y si lic onetubingrated
for
at least 4 00• F for th e first 18" ofco nd ensate drain
li ne, then other non-metal lic tubing maybeused. U s-
ing any o th er material co uld cause flu e gas leakage,
potentially resulting insevere personal injury, death or
substantial propertydam
age.
On some installations, th econdensatedrainfirting may
be omitted, provided:
Vent manufacturer shows this optionintheirinstruc-
tions.
Vent isslopedtoward termination as shownindotted
lines in Figure
14 .
The
ve nt is installed per WeB-McLain and ve nt
manufacturer's instructions.
Co nd ensate drippage fr om such ve nts may acaunu -
late on th egromtd below. Considertraffic in th earea
to avoid hazard due to ice accu mu lation.
Agure 13 Olrect exhaust vertical venting
Hortzonlal dr ain tee ,
Follow
vent
manufocturefs
Instructions to Install
condensate dr ain line.
Follow vent
monul octurefs
fnstruclions forproper
lnstololion ol vent runs,
Including slope and
support.
71015
Figure 14 Directexhaust sidewall vent in g
Fdbw ven t
\ \
manulacture~s in stru ct ioo s 1o<
pro per l ns 1ala tio n of vent runs,
i nclu ding slope, s ~ port and
oonden sa te drailage .
L.lJJ
Horizonta l drain tee .
Rllowwn t
ma nula cwrefs
i nstr u ctio ns to i nstal
condensate drain line.
1-O
pt ional downward
1 slope without drail
1 fi tti n g, where alowed
1 by wnt man ufacturer
r as expelled In
CPJJnON at left.
71 016
Part Number 550-142-780/0712

CGi GAS - FIRED wATER eotLER- sERIEs 3- Boiler Manual
3f Venting - direct exhaust -installation (cont.)
Figure 15 Sidewall termination
•
-
r:::
~
i
C/)
-
r:::
~
N
'Of'
(")
I
a:
111
-
C/)
:t
...
"iij
Q)
C/)
z
Ill
111
u..
Termination e lb ow or teo
~
Sealant
Te r mi nation el bow or tee
Term i nation el bow or t ee
~ --
Sealant
Sea lant ;/
C'- / c;r /
Note 1
Termination el bow or tee
~ -~--
l__)Y ~ Note 1
Part Number 550- 1 42-780 /0712
J.& WARNING J
1 Elbowand termination
coupling wtth screen
Elbow and te r minatio n
coupling with screen
Termi na ti on coup li ng
no t ava il ab le
El bow and termin at io n
coupling with screen
Usi ng any termination other than one of th oseshown
couldcausenuisanceoutages and loss of heat, resulti ng
in su b st antial propertydamage.
Note 1: DO NOT us~ horizontal tee with CGJ.1 or CG/-8.
Note 1: DO NOT use horizontal tee with CGi-1 o' CGi-$ ,
Nolc 1: DO NOT us.t: horizon till tee w ith CG; ·l or CGi-8.
19

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
4a Water piping -general information
General piping information
If installation is to co mply wi th ASME or Cana di an r eq uireme nt s, an ad -
ditional high temperat urelimit is needed Install controlin su pp ly pipi ng
between boil er and isolation va l ve. Set second co ntr ol to mini nuu n 20•F
above se tp o int of first co n tro l. Maxi mm n allowable se tpoi nt is 240• F. See
Section 9b for wiring.
A l ow wate r cu to ff device is required when boiler is installedabove ra-
diati on level or by certain state or local codes or ins ur an ce companies. Use
low water cutoffdesigned for water installations. Electrode probe -type is
recommended. Purchase and install in tee
in supply pipingabove boiler.
Use backflowc he ck valve in cold watersupply as required by local codes.
Pressure/temperature gauge
Install pressure/temperaturegauge in tee on supp ly piping (as shown in
drawingon page 3).
Isolation valves
Isolati on va lvesare requir ed to enableservicing of theboiler'stemperature
sensor. Install as shown in appropriatepipingdiagram.
Relief valve
Install relief valve vertically in W' tapp in g on side of bo iler. See Figure 16
or 17, page 21, and th e tag attach ed to the reliefvalve for manufacturer's
instruct i ons.
I& WARNIN G! Toavoidwater damage or scaldingdue to reliefvalve
. . operation:
20
Discharge line must be c01 mected to relief valve outlet and run to
a safe pla ce of dispo sal. Te rmi nat e the discharge li ne to eliminate
possibility
of severe burnsshould the valve disch ar ge.
Discharge line mu st be assho rt as possible and be th e s ame size as
the valve dis c ha r ge c onnection throughout its entire length.
Discharge line must pitch downward from th evalvea nd ter mina te
at least 6" a bo ve th e fl oo r dr ain where any discharge will be clearly
visibl e.
Th edischargelineshall tennlnate plain, not threaded ,with a ma te-
rial serviceable for temperatures of 375°For greater.
Do not pipe the discharge to any place whe re freezing could
occu r.
No shutoff valvesha ll be installedbetween thereli ef valvea nd boiler,
or in th e discharge lin e. Do not plug or pl ace anyobstruction in th e
discharge li ne.
Failure to complywith theaboveguidelinescould result in fa ilure of
th e reli ef valve to operate,resulting in possibili ty of severe personal
injury,deathor substantial propertydamage.
Test the operation of the valve afterfilling and pr essur izi ng sy stem
by lifting th e lever. Makesure the val ve discharges freel y. If the valve
fails
to operatecorrectly, replace it with a new re li ef valve.
Circulator
The circulatorisshippedloose (wiringpre-attached to
boiler) to allow you to locate it ei ther in th e re turn or
s up ply piping,as desired.See page 3for a typical instal-
lation. Pipe theexpansion tank
to thesuctionside of the
circulatorwheneverpossible. Install anair separator in
thesupplypiping. Connecttheexpansion tank to theair
separator on ly if the separatoris on thesuction side of
th e ci rc ul ator.Always in stall th e system fill cOJ mection
at the san1e pointas the expa nsion tan k co nnection to
thesystem. Figures 16and 17show typical near -boiler
pipi ng connections.
System water piping
See Figure 16(diaphragm-type or bladder-type expan-
sio n tank) or Figure 17 (closed-type expansion tank)
and Table 6, for near-boiler and single-zone systems
desi gned for return wateratleast 1300F.
See pages 22- 23 to co mplete multi pl e-zone pipi ng or
pages 24 -29 to co mpl ete pipi ng for rad iant heating
systems
or converted gravi ty systems (large-volume
systems originally designed for circulation
by na tu ral
co nvection rather than a pump).See page 29 for boilers
used wi
th refrigeration systems.
Table 6 Water pi
pe size (based on 20•F ri se)
Boiler To
F rom
model number system system
CGi-25 '14" '14"
CGi-3, 4, 5 1" 1"
CGi-6,7 1
1/4" 1 1/4"
CGi..S 1'h" 1'h"
Note: The boi Ser supply and return oon nect i ~ the re tu rn!
drain lee and the s~yl¥,a~ l ee suppl1 ed wi th
th e boil er are 1" ' N . ne Of the ci rc ul ator fl anges
suppli
ed wi th the boiler is 1l4 .. . The otherci rcu lator
fl ange is the size of th e recommended system pip in g
shown above.
I& WARNING!
Chillers or air handling units :
Install boiler suc h that -
Chill
ed me dimn , if used, is pip ed in parallel wi th
heating boiler. Use appropr iate valves to prevent
chill ed medium from enteringboiler. ConsultAHRI
Installation a nd Pip in g Guides.
If bo il er is co nn ected to heating co ils l oca t ed in
air handling units where they can be exposed to
refrigerat ed air, use fl ow co nt ro lvalves or o th er au-
tomatic mea ns to preve nt gravity circulatio nduring
coo li ng cycle.Circulation of cold water through the
boiler could result indamage to the heatexchanger,
causi ng possible severe personal injury, death or
substantial propertydamage.
Part Nu m ber 550 - 142-7 80/ 07 12