MODEL CGi - Weil-McLain

1 MODEL . CGi CGi Gas-fired boiler Induced draft Installation Start-Up Service Troubleshooting Repair Parts Read all instructions before installing Installer Leave this manual in the envelope and affix near the boiler. Consider venting and piping locations when determining boiler location. Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. User Boiler Manual is only to be used and boiler installed by a qualified installer/service technician. User's Information Manual is for your reference. Regular service by your qualified service technician is recommended. 550-110-132/1298. CGi Read This Page First Hazard Definitions The following terms are used to bring attention to the presence of hazards of various risk levels or to important information concerning product life.

2 Indicates presence of hazards that will cause severe personal injury, death or substantial property damage if ignored. Indicates presence of hazards that can cause severe personal injury, death or substantial property damage if ignored. Indicates presence of hazards that will or can cause minor personal injury or property damage if ignored. Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury hazards. When Calling or Writing About the Boiler Please have boiler MODEL number from boiler rating label and CP number from boiler jacket. You may list the CP number in the space provided on page 33. Read all instructions before installing boiler. Failure to follow instructions in proper order can cause severe personal injury, death or substantial property damage.

3 2 550-110-132/1298. CGi Table of Contents Read This Page First .. 2. Table of Contents .. 3. Before Installing Boiler .. 4. Boiler 7. Water Piping .. 8. Venting and Combustion Air .. 18. Chimney Draft Venting .. 19. Direct Exhaust Vent Location .. 20. Direct Exhaust with AL29-4C .. 21. Gas Piping .. 29. Wiring .. 30. Start-Up .. 30. Check-Out Procedure .. 33. Installation and Service Certificate .. 33. Suggested Minimum Service .. 34. Control System .. 36. Wiring Diagram .. 37. Sequence of Operation .. 38. Operating Instructions .. 39. Troubleshooting .. 42. Parts List .. 48. Ratings .. 54. Dimensions .. 55. 550-110-132/1298 3. CGi Before Installing Boiler Special note on combustion air supply: Installations must comply with latest editions: All boilers experience some condensation in section assembly during start-up.

4 Flue gas con- National, state and local codes, laws, densate is slightly acidic. In most cases pH level is regulations and ordinances. not harmful to vents or drains. When combustion National Fuel Gas Code, ANSI air is contaminated by vapors from products or Standard for Controls and Safety areas listed below, condensate acidic levels in- Devices for Automatically Fired crease. Higher acidic levels attack many materi- Boilers, ANSI/ASME CSD-1, when als, including stainless steels. required. National Electrical Code. You may need to isolate the boiler if installation is Canada in an area containing contaminants listed below, National, provincial and local codes, laws, which will induce acidic contamination. regulations and ordinances. Products causing contaminated air: CAN/CGA or Installation 1. spray cans containing chloro/fluorocarbons Code.

5 2. permanent wave solutions Canadian Electrical Code 3. chlorinated waxes/cleaners Part 1. 4. chlorine-based swimming pool chemicals Gas manifold and controls met safe lighting and 5. calcium chloride used for thawing other performance criteria when boiler underwent 6. sodium chloride used for water softening tests specified in ANSI - latest edition. 7. refrigerant leaks 8. paint or varnish removers 9. hydrochloric acid/muriatic acid Before locating boiler: 10. cements and glues Check for nearby connections to: 11. antistatic fabric softeners used in clothes System water piping. dryers Venting connections. 12. chloride-type bleaches, detergents, and Gas supply piping. cleaning solvents found in household Electrical power. laundry rooms Check area around boiler. Remove any 13. adhesives used to fasten building products combustible materials, gasoline and other 14.

6 And other similar products flammable liquids. Areas causing contaminated combustion air: 1. dry cleaning/laundry areas and shops 2. metal fabrication plants Failure to keep boiler area clear 3. beauty shops and free of combustible materials, 4. refrigeration repair shops gasoline and other flammable liquids and 5. photo processing plants vapors can result in severe personal injury, 6. auto body shops death or substantial property damage. 7. plastic manufacturing plants 8. furniture refinishing areas and shops 9. new building construction Boiler must be installed so that gas control 10. remodeling areas system components are protected from 11.. and other similar areas dripping or spraying water or rain during operation or service. To prevent potential of severe personal injury or death, check for If new boiler will replace existing boiler, check products or areas listed above before installing for and correct system problems, such as: boiler.

7 If found: 1. System leaks, causing oxygen corrosion or remove products permanently. section cracks from hard water deposits. OR 2. Incorrectly sized expansion tank. isolate boiler and provide outside combustion 3. Lack of antifreeze in boiler water, causing air. See national, provincial or local codes for system and boiler to freeze and leak. further information. 4 550-110-132/1298. CGi Before Installing Boiler CONT'D. Provide clearances: Hot water pipes - at least 1/2 inch from combustible materials. Recommended service clearances - Figure 1. Minimum clearances for tight spaces - Figure 2. 35". 7". 7". 24". 18". Recommended service clearances FIGURE 1. 2" 15". Fresh air openings 6" from bottom and 6" from top 6". 1". 10". 3". Minimum clearances for tight spaces FIGURE 2. 550-110-132/1298 5. CGi Before Installing Boiler CONT'D.

8 When removing existing boiler from Lay a foundation, if needed: common venting system: CGi boiler is approved for use on combustible flooring; however, boiler must not be installed Failure to follow all instructions on carpeting. listed below can result in flue gas spillage and carbon monoxide emissions, causing Do not install boiler on carpeting even severe personal injury or death. if a foundation is used. Fire can result, causing severe personal injury, death or substan- At the time of removal of an existing boiler, the tial property damage. following steps shall be followed with each appliance remaining connected to the common venting system 1. For residential garage installation, install placed in operation, while the other appliances boiler so burners are at least 18 inches above remaining connected to the common venting system floor to avoid contact with gasoline fumes.

9 Are not in operation. 2. A level concrete or masonry foundation is 1. Seal any unused openings in the common required when: Water could flood area. venting system. 2. Visually inspect the venting system for proper Non-level conditions exist. size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. TABLE 1 - Boiler foundation size 3. Insofar as is practical, close all building doors Min. and windows and all doors between the space in Boiler Length Width Height which the appliances remaining connected to MODEL Inches Inches Inches the common venting system are located and any CGi - 25 25 12 2. other spaces of the building. Turn on clothes CGi - 3 25 12 2. dryers and any appliance not connected to the common venting system.

10 Turn on any exhaust CGi - 4 25 15 2. fans, such as range hoods and bathroom CGi - 5 25 18 2. exhausts, so they will operate at maximum CGi - 6 25 21 2. speed. Do not operate a summer exhaust fan. CGi - 7 25 24 2. Close fireplace dampers. 4. Place in operation the appliance being inspected. Follow the operating instructions. Adjust ther- mostat so appliance will operate continuously. 5. Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. 6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.