~ WEil·mrlAIN® Series 3 Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts i4WARIIINGI DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free air to the =e~~i'S'~ L.:J ~ .~ .,t:., ,.§] ~t, ~ Mobile P roduet Library boiler area or follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or substantial property damage.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual How it works (!) • • • Control module The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler circulator,!ilot burner, gas valve and inducer. When room thermostat calls for heat, the control module starts the system circulator an inducer.
CG i GAS-FIRED wATER eotLER- sERIEs 3 - Boiler Manual CGi Gas-Fired Induced-Draft Water Boiler CGi 4 Only '/1001 Part Number 550-142-780/0712 3
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual Contents How it works •••••••••••••••••••••••••••••••••••••••••••••••••••• 2-3 llet~Cirlt ciEtfillitiC)Il!; ••••••••••••••••••••••••••••••••••••••••••••••• 'I Please read before proceeding ............................
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual Please read before proceeding Installer I&WARNING! User Read all Instructions before Installing. Follow all instructions in proper order to prevent personal injury or death. Consider piping and Installation when detem1ining boiler location. Any claims for damage or shortage In shipment must be filed inunediatelyag:Unst the transportation company by the consignee. This manual Is for use only by your qualified heating Installer/service technician.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 1a Prepare boiler location - codes & checklist Installations must follow these codes: Local, state, provincial, and national codes, laws, regulations and ordinances. National Fuel Gas Code, ANSI Z223.1 - latest edition. Standard for 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.
CG i GAS-FIRED wATER eotLER- sERIEs 3 - Boiler Manual 1b Prepare boiler location - clearances Recommended SERVICE clearances Flgure 1b Required MINIMUM clearances (Fig. 1a) I. Provide clearances fo r cleaning and servicing the boiler and for access to controls and components. See Figure Ia for recommendations. 2. Provide at least screwdriver clearance tOjacket fron t panel screws for removal of front panel for inspectio n and m inor service.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual lc Prepare boiler location - vent system I&WARNING! Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. trjHJUijj;l Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual ld Prepare boiler location - air contamination Please review the followi ng i nformation on potential combustion air contamination problems. I&WARNING! Refer to Table 1 for products an d areas which may cause contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before i nstalling boiler.
CG i GAS- FIRED wATER BOILER- sERIEs a - B oiler Manual 1e I&WARNINGI * Prepare boiler location - air openings Combustion air opening location and sizing requirements depend on the clearances around the boiler. Check the boiler placement compared to Figure I a, page 7. If all clearances are at least equal to Figure 1a, page 7, apply the sizing and placement of opening$ given on pages lO and I I.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 1e NOTICE Prepare boiler location - air openings 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.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 2a Prepare boiler - placement & setup I&WARNING! Place boiler/crate near position Do no t operate boiler without burner shield in place. Failure to do so could result in severe personal injury, death or substantial property damage. t. Leave boiler in crate and on pallet until installatio n site is ready. 2. Move entire crate and pallet next to selected location. 3. Remove crate. 4.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 2b Prepare boiler - pressure test Hydrostatic pressure test Pressure test boiler before attaching water o r gas piping {except as noted below) o r electrical supply. Prepare boiler for test 1. Remove the shipping nipple (from CGi supply tap ping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a W' NPT pipe plug. 2. Remove I \4'' nipple, reducing tee and drain valve from circulator hardware and pressure/temperature g
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 3a Venting - general information CGi venting methods - Chimney draft or Direct exhaust Chimney draft venting Direct exhaust - vertical or sidewall Chimney d raft venting uses the natural draft p rovided by a vertical vent o r chimney. Category I appliance (no npositive vent static pressure and vent gas temperature that avoids excessive condensate production tn ven t). See Section 3b. Chimney draft installations use: 1.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 3c Venting - Direct exhaust - components Obtain vent system components 1. The following special gas vent systems comply with UL- 1738 and ULC-S636 standards and are certified by CSA as the only systems suitable for use with CGi boilers (all 3" diameter): Heat-Fab, Inc. Saf-TVen~ Flex-L International, Inc. StaR-34 Z-Fiex"', Inc. Z-Vent ll ProTech Systems FasNSeal"' ri&:-W-A_R_N...,IN --.,... GI Use only the vent starter of the same manu.
CG i GAS- FIRED wATER eo1LER - 3d Venting - sERIEs a - Boiler Manual direct exhaust - vent starter J. Select a vent pipe manufacturer and obtain all vent components needed, based o n boiler location and ventmg method. 2. You must use the vent starter made by the vent pipe manufacturer. See separate CGi, & GV Vent Component Supplement, for part number of each component. listed by vent manufacturer. I&WARNING! 3.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 3e Venting - direct exhaust - termination I&WARNING! l. 2. 3. 4. Follow instructions on this page when detem1ining vent location to avoid possibility of severe personal injury, death or substantial property damage. Locate the boiler and vent penetration through the wall so all requirements o n this page and in Figure 12 will be met. Also follow vent manufacturer's instructions. Gases will form white plume in winter. Plume could obstruct window view.
CG i GAS-FIRED wATER BOILER- sERIEs a - B oiler Manual 3f Venting - direct exhaust- installation 1. Do not mix types or manufacturers of vent materials. 2. Clean all joints before sealing. See vent manufacturer's instructions for cleaning and sealing joints. Use their specified sealant. Do not use screws. 3. Install vent pipewithseams on top of vent horizontal runs.
CG i GAS- FIRED wATER eotLER- sERIEs 3 - Boiler Manual 3f Venting - direct exhaust - installation J.&WARNINGJ Figure 15 Sidewall termination Termination elbow or teo • - 1 (cont.) Using any termination other than one of those shown could cause nuisance o utages and loss of heat, resulting in substantial property damage. Elbow and termination coupling wtth screen ~ r::: ~ Sealant i C/) Note 1: DO NOT us~ horizontal tee with CGJ.1 or CG/-8.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4a Water piping - general information General piping information If installation is to com ply with ASME o r Canadian requirements, an additional high temperature limit is needed Install control in su pply piping between boiler and isolation valve. Set second control to mininuun 20•F above setpoint of first control. Maximmn allowable setpoint is 240•F. See Section 9b for wiring.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4b Water piping - single-zone system IAcAunoNI Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through till valve. Eventual section failure can result Diaphragm-type or bladdertype expansion tank (Figure 16) t. Ensure expansion tank size will handle ooiler and system water volume and temperature.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4c Water piping - multiple zones Piping multiple zones Follow instructions on pages 20 and 21 to install nearboiler or single-zone piping. (Also refer to Piping for radiant heating systems or converted gravity systems, below, if applicable.) See Figure 18 or Figure 19 to complete installation. Zoning with circulators (Figure 18) (return temp over 130•F) 1. Size each circulato r to individual circuit requirements. 2.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4c Water piping - multiple zones Figure 18 Zoning with circulators - return water 130•F or higher. Figure 19 (continued) Zoning with zone valves - return water 130•F or higher. r----------, .r--------------1 ZONE 2 ~--------+:,. i ----;~~~--1 i .
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4d Piping - low temperature systems Primary/secondary (prefe rred) bypass piping method Primary/secondary bypass piping is preferred because the flow rate and temperature drop in the heating circuit(s) is determined only by the heating circuit circulator(s). So adjustment of the bypass valves in the boiler circuit will not cause a change in the heating circuit rate and temperature distribution.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4d Piping - low temperature systems Figure 20 Figure 21 Primary/secondary piping Zoning wtth circulators
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4d Piping - low temperature systems BOILER-bypass piping method This piping method (Figure 22 or 23) is called a boilerbypass because part of the circulator flow is bypassed around the boiler (through valve 7a). This method reduces the flow rate throughout the boiler, in order to raise the average water temperature in the boiler enough to prevent flue gas condensation.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4d Piping - low temperature systems Figure 22 Boiler-bypass piping - Zoning with circulators - (Aitematlve to primary/ secondary piping Figures 20 and 21) Figure 23
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4d Piping - low temperature systems SYSTEM-bypass piping method This piping method is called a system-bypass because part of the circulator flow bypasses the system (thro ugh valve 7a). This bypassed hot water fro m the boiler outlet mixes with cooler system return water temperature in order to provide minimum 130°F return water to the boiler.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 4d Piping - low temperature systems From system To system Aft~~~~ t:lrcu/4tor locstlon 8 Figure 24
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 5 Gas piping Connecting gas supply piping to boiler I. Remove jacket front panel and refer to Figure 26 to pipe gas to boiler. a. Install drip leg at inlet of gas connection to boiler. Where local utility re
CG i GAS- FIRED wATER BOILER- sERIEs a - Boiler Manual 6 Field wiring I& WARNING! NOTICE For your safety, tum off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N. E.C. Class 1. If original rollout thermal fuse element wire as supplied with boiler must be replaced, use only type 200'C wire or equivalent.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 7a Start-up - preparation Check for gas leaks I&WARNING! I&WARNING! Before starting the boiler, and during initial operation, smel1 near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if there is any indication of a gas leak. Repair any leak at once. Propane boilers only - Your propane supplier mixes an odorant with the propane to make its presence detectable.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 7a Start-up - preparation (continued) Fill the system with water Inspect system water piping I. Close manual and automatic air vents and boiler drain cock. After filling the boiler and system with water, Inspect all piping throughout the system for leaks. If found, repair immediately. Repeat this inspection after the boiler has been started and the system has heated up. 2. Fill to correct system pressure.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 7b Start-up - operate boiler r-1&:-:-:W:-:A-::R.,-N"'INc-G :'\1 . DO NOT proa!ed with boiler operation mliess boiler and system have been tilled with water and all instructions . and procedures of previous manual sections have been completed. Failure to do so could result in severe personal injury, death or substantial property damage.
CG i GAS-FIRED wATER BOILER- sERIEs 3 - Boiler Manual 7b Start-up - operate boiler (continued) 4. Incorrectly heated pilot flame sensor. Start the boiler Follow the Operating instructions from Section 9c to start the boiler. See Section 7c if boiler fails to start. Check system and boiler Main burner flame (Figure 29) PROPER main burner flame characteristics I. Yellow-orange streaks may appear (caused by dust). IMPROPER main burner flame characteristics t. Check system piping for leaks.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 8 Check-out procedure - checklist 0 Boiler and heat distribution units filled with water? 0 Set Economy mode, fully clockwise. 0 Automatic air vent, if used, o pen one full turn? 0 0 0 0 Air purged from system ? Air purged from gllS piping? Piping checked for leaks? Correctly sized manifold o rifices installed? Refer to Table 2, page 12, to check size and fuel type. For multiple zones, adjust flow so it is about the same in each rone.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 9 Department of Energy - Compliance This boiler is equipped with a control system that automatically adjusts a time delay period to turn on the boiler during a call for heat. This is accomplished by circulating available hot water in the system while measuring water boiler water temperature changes.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 9a Operation - sequence (continued) - The circu1ator continues to operate. 8. Lower room thermostat setting to stop call for heat Themtostat is satisfied - Pilot and main gas valves are d osed - Inducer operates for IS-second postpurge - Circulator is shut off. 9. Boiler is now in the off cycle. 10. Repeat steps 1 through 6 several times to verify operation. I I. Return the thermostat to normal setting. 12.
CG i GAS-FIRED wATER eotLER- sERIEs 3 - Boiler Manual 9b Figure 31 Schematic wtrlng diagram lACAUTlON ! NOTICE Operation - wiring diagrams DO NOT connect directly from 3-wlre zone valves to the T- T terminals on the boiler. When using 3--..ire zone valves. instal an isola~on relay. Connect the zone valve end switch wires to the Isolation relay coil. Connect the Isolation relay coo tact across the boiler T-T terminals.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 9b Operation - wiring diagrams (continued> Figure 32 Ladder wiring diagram Electricol shock huard- can lAWARNlNG! cause severe injury or death. Disconnect power before instaling or servicing. Neutral Gnd Q Hot 1<-- - - - - -120VAC--------<.. 11 '\ SERV!Cf SWITCH * i Legend for ladder wiring diagram 120 VAC field wiring Low voltage lieid wiring 120 VAC fadory wiring Low voltage &actory wiring H9l voltage spark ignition wiring Ground coooectors T1
CG i GAS- FIRED wATER eotLER- sERIEs 3 - Boiler Man ual 9c Operating instructions CGi-25, 3, 5, & 6 • Spark pilot • Natural or propane gas • Gas valve: HoneyweiiVR8204NR8304 FOR YOUR SAFETY READ BEFORE OPERATING !AWARNING! If you do not fo.llow these instructions exactl~, ~ fire or explo~ion may result causmg property damage, personalmJury or loss ofhfe. A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light tile pilot by hand. B.
CG i GAS- FIRED wATER eo1LER- sERIEs a- Boiler Manual 9c Operating instructions . Spark pilot • Natural or propane gas CGi-25, 3, 5, & 6 • Gas valve: White-Rodgers 36E - FOR YOUR SAFETY READ BEFORE OPERATING !AWARNING! - If you do not fo!low these instructions exactl~, a fire or explo~lon may result caus10g property damage, personal~njury or loss of hfe. A. This appliance Is equipped with an Ignition device which automatically lights the pilot. Do not try lo light the pilot by hand. B.
CG i GAS- FIRED wATER eotLER- sERIEs 3 - Boiler Man ual 9c Operating instructions . Spark pilot • Natural or propane gas CGi-25, 3, 5, thru 8 • Gas valve: White-Rodgers 36C - FOR YOUR SAFETY READ BEFORE OPERATING IA WARNINGI - If you do not follow these Instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition device which aulomatical ly lighls the pilot. Do M.t try to llghtthe pilot by hand. B.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 9c - Operating instructions CGi-4 • Spark pilot • Natural or propane gas • Gas valve: HoneyweiiVR8204NR8304 FOR YOUR SAFETY READ BEFORE OPERATING - IAWARNINGI Ifyou do ~~!follow these.lnstructions exactly, a fire or explosion may result causing property damage, personal InJUry or loss of lrfe. A. This appliance does not have a pilol.lt is equipped with an ignition device which automatically lights the burner.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual lOa Service and maintenance - schedule ( VERIFY PROPER OPERATION AFTER SERVICING Table 8 Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see CGi User's Information Manual for instructions) • Check boiler area Inspect: Reported problems Boiler area • Check air openings • Check boiler pressure temperature gauge • Air openings • Flue gas vent system (and air piping) • Pilot and main
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual lOb Service and maintenance - annual start-up 2. Verify that boiler vent discharge is clean and free of obstructions. I&WARNINGI I&WARNINGI The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual lOb Service & maintenance - annual start-up 0 Inspect ••• Burners and base boiler contains ceramic fiber and I&WARNINGI The fiberglass materials. Use care when handling these materials per instructions o n Page 70 of thi s man ual. Failure to comply could result in severe personal injury. If insulation is damaged or displaced, I&WARNINGI do not operate the boiler. Replace or reposition insulation as necessary.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual lOb Service & maintenance - annual start-up 0 Check/test ••• Gas piping 1. Sniff near floor and around boiler area for any indication of a gas leak.
CG i GAS- FIRED wATER BOILER - seRIES 3 - Boiler Manual lOb Service & maintenance - annual start-up 0 Review with owner retief nlves should be reinspected AT I&WARNINGI Safely LEAST ONCE EVERY THREE YEARS, by a licen~ I&WARNING! plumbing con1ractor or aulhorized inspection agency,lo ensure lhallhe product has nol b«n affected by corrosive waler conditions and 10 ensut'1' lhal 1he valve and discharge line ha'"' nol b«n ahered or lampered wilh illegally.
CG i GAS- FIRED wATER BOILER- sERIEs 3 - Boiler Manual 11 a Troubleshooting !&WARNING! !&WARNING! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Never jmnper (bypass) rollout thermal fuse element or any other device except fo r momentary testing as outlined in TroubleshootIng Charts. Severe personal injury, death or substantial property damage can result. Before troubleshooting: 1. Have the following items: a.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual lla Troubleshooting - components Troubleshooting air pressure reading Temperature sensor I. If manometer reading is lower than the setpoint of the switch (see Table 9) - check for possible causes: I. The boiler temperature sensor is a resistance· type device. blockage in hoses obstruction in inducer housing outlet loose inducer wheel on motor shaft inducer motor not in proper rpm inducer back plate not sealed properly blockage in block assembly 6.
CG i GAS-FI RED wATER eo1LER- sERIEs a- Boiler Manual llb NOTICE Troubleshooting - components The information on th is page and pages 50 th ro ugh 56 app ly o nly to spark-ignited pilot CGi boilers. These boilers are equipped with an ignition con trol module that has indicator lights to s how co ntrol status. Chart$ 1 tluough 6, pages 51 56, help you identify problems based on indicator light conditions.
CG i GAS- FIRED wATER eotLER- sERIEs 3 - Boiler Manual llb Troubleshooting - components (continued) Agure 38 Control module connections High vohgo co @ pl•n spark electrOde Transformer !" J ~ "' 2 ~ ;; @ ® UVAC~ntrol .. •• ~~ sl: 00 <:ircufU s;:: n ~ H -"' -""' "' I I~ 2 " .!! 2 ~. I! s .~ l B~ ·~-i H . t: T$TAT l 11.
CG i GAS- FI RED wATER eo1LER- sERIEs a- Boiler Manual llc Troubleshooting - control module lights CHART 1 - Troubleshooting POWER light statu s - Usually indicates reversed 120 VAC polarity if POWER light flashes by itself - IAWARNINGI Electrical shock hazard - Wherever you see .t. TURN OFF POWER & , follow the instructions. Failure to follow · instructions could result in severe personal injury, death or substantial property damage.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual llc Troubleshooting - control module lights (cont.J CHART 2 - TSTAT CIRC & POWER lights flashmg - I&WARNINGI . . . Usually indicates 48 VAC on thermostat circuit (stray voltage) - Electrical shock hazard - Wherever you see .t.TURN OFF POWER&, follow the instructions. Failure to follow instructions could result in severe personal injury, death, or substantial property damage. .
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual llc Troubleshooting - control module lights (cont.) CHART 3 - Usually i ndicates p ressure switch stuck closed or failed to make within 5 minutes - Electrical shock hazard - Wherever you see & TURN OFF POWER&, follow the instructions. Failure to follow instructions could result in severe personal injury, death, ()(substantial property damage. I& WARNINGI ..
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual llc Troubleshooting - control module lights (cont.) CHART 4 - FLAME & POWER lights flashmg - I&WARNINGI Usually indicates flame sensed when it shouldn't be there - Electrical shock hazard- Wherever you see & TURN OFF POWER&, follow the instructions. Failure to follow instructions could resuk in severe personal injury, death, or substantial property damage. Are manual main shutoff valve and gas valve open? No .. .. . I + .. .. .
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual llc Troubleshooting - control module lights (cont.) CHART 5 - PURGE light flashmg and POWER light on steady - Usually indicates pressure switch opened during run cycle May also be caused by wind gusts in excess of 31 mph for non -direct vent sidewall-vented boilers Electrical shock hazard - Wherever you see & TURN OFF POWER& , follow the instructions.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual llc Troubleshooting - control module lights (cont.) CHART 6 - FLAME light flashing and POWER light on steady ALSO- Troubleshootmg fa1lure to establish main f lame I&WARNINGI . Electrical shock hazard- Wherever you see & TURN OFF POWER&, follow the instructions. Failure to follow instructions could resuk in severe personal injury, death, or substantial property damage. Ale main manual shutoff valve and boiler gas valve open? No .. .
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual llc Troubleshooting - control module lights (cont.) CHART 7 - lnsuff1c1ent heat or no heat to system (POWER light on steady) I& WARNINGI . . . Electrical shock hazard - Wherever you see & TURN OFF POWER&, follow the instructions. Failure to follow instructions could resuk in severe personal injury, death, or substantial property damage. - Has ~ been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 12a Replacement parts !;E!c:tie»ll Cl!t~E!IIIIJI]f •••••••••••••••••••••••••••••••••••••••••••••• Ei:! EICI!tE! ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Ei~ .Je~c:ltt!t •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Ei!S 1nrilll •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• EiEi C:e»lltr1»l!t ........•••••••••••••••••••••••••••••••••••••••••••••......
CG i GAS- FIRED wATER eo1LER- sERIEs a- Boiler Manual 12b Figure 39 Replacement parts - section assembly Section assembly 1104) Item Description number Item Description number Weii·Mclain part number v..· (1 per tie rod) 1 End section, left hand, 51124 311-103-851 6 Washer, 2 End section, right hand 51128 311 ·103-821 7 Radiation plate (1 per joint) 460.003·700 3 Intermediate section, 51125 311 ·103-818 8 Replacement 321·114..:330 321·114..:331 321·114..:332 321·114..:333 321·114..
CG i GAS-FIRED wATER BOILER- sERIEs 3 - Boiler Manual 12C Replacement parts - base Figure 40 Base assembly .
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual 12C Replacement parts- base Item Well-McLain part number Description Base assembly kit Yrc::ludes base panels items 64
CG i GAS- FIRED wATER eotLER- sERIEs 3 - Boiler Manual 12d Replacement parts Figure 41 jacket Jacket assembly @ ® •• 0 @ ,... 1 2 J unction box. 2x 4 Panel. left side. with insulation Natural Gas Boiler Model CGi-25 CGi-3 CGi-4 CGi-5 CGi-6 CGi-7 CGi-8 3 4 Panel. right side. Panel, top front. with insulation with insula tion 5 Panel. top rear.
CG i GAS- FIRED wATER eo1LER- sERIEs a- Boiler Manual 12e Replacement parts - trim Figure 42 Trim assem bly ® "'" I tom o- rtptlon Manufacturer Manufaeturtr's partnumbor Woii-Mcl.aln partnumbor Conbtaco Watts Conbtaco Watts 1().407..()5 M330 1().408..()5 335 511·546·920 number I Pressure reDef valve, ASME, 30 PSIG, '14" male Inlet Pressure reDef valve, ASME, 30 PSIG, '14" female Inlet (FIItinos shown 81'8 fact(){y.J/Isfalled on boiler.
CG i GAS- FIRED wATER eotLER- sERIEs 3 - Boiler Manual 12f Replacement parts - controls Figure 43 Gas control assembly ® CGI 4 Only ® CGi 4 Only 1 2 Boiler model Manufactur-er Manufacturer's part number WeiJ-McLain part number ues valve, 'h• x 'h..
CG i GAS- FIRED wATER eo1LER - 13a sERIEs a - Boiler Manual Dimensions Figure 44 Dimensional drawing (!) Supply piping (note I) ® Return piping (note 1) ® Relief valve, :Y.." NPT @ Gas supply piping t ! 11\ii ® @J Gas supply entrance (right or left side) ® @ y,• NPT to expansion tank/air vent ® Drain valve 3" Diam et er vent TOP VIEYI Pressure/temperature gauge Hotel: 8041c.r supply and return tappings are both 1!.4" NPT.
CG i GAS-FIRED wATER BOILER- sERIEs 3 - Boiler Manual 13b Ratings ~I.IDI .,.. •••II CERTIFIED,.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS I&WARNING! The combustion chamber lining or base insulation panels in this product contain a!ramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications.
CG i GAS-FIRED wATER BOILER- sERIEs a - Boiler Manual Notes Part Number 550-142-780/0712 71
CG i GAS-RREo wATER BOILER - ~ WEIL·m~:LAIN" 72 SERIEs a - Boiler Manual Wei~Mcl.ail 500 Blaine Street Michigan City. IN 4636(}.2388 lmp://ww'M', ""'t'il-mclain.
