Series 4 Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts Now With Built In Low Water Cut Off Functionality * *Blower cover on sizes CGi 25-6 only 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 could result in severe personal injury, death or substantial property damage. This manual must only be used by a qualified heating installer/service technician.
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual How it works . . . ① ② ③ ④ ⑤ ⑥ Control module The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and inducer. When room thermostat calls for heat, the control module starts the system circulator and inducer.
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual CGi Series 4 Gas-Fired Induced-Draft Water Boiler Part Number 550-142-302/0520 3
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual Contents How it works . . . ................................................. 2 Hazard definitions ............................................... 4 Please read before proceeding ............................ 5 1 Prepare boiler location ...................................6–11 2 Prepare boiler...............................................12–13 3 Venting ......................................................... 14-19 4 Water piping ...............
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual Please read before proceeding Installer User Read all instructions before installing. Fol- • • low all instructions in proper order to prevent personal injury or death. Consider piping and installation when determining boiler location. Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. • This manual is for use only by your qualified heating installer/service technician.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 1a Boiler Manual 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/NFPA 54 – latest edition. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1 –– latest edition.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 1b Boiler Manual Prepare boiler location — clearances Recommended SERVICE clearances Figure 1b Required MINIMUM clearances (Fig. 1a) 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1a for recommendations. 2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 1c Boiler Manual Prepare boiler location — vent system Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death. Direct exhaust venting (Category III) — DO NOT COMMON vent the CGi in a direct exhaust system (Category III).
CGi SERIES 4 — GAS-FIRED WATER BOILER — 1d Boiler Manual Prepare boiler location — air contamination Please review the following information on potential combustion air contamination problems. Refer to Table 1 for products and areas which may cause contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 1e Boiler Manual 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 1a, page 7. ✷ Figure 2 Air openings to interior spaces ✷ If all clearances are at least equal to Figure 1a, page 7, apply the sizing and placement of openings given on pages 10 and 11.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 1e Boiler Manual 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.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 2a Boiler Manual Prepare boiler — placement & setup Do not operate boiler without burner shield in place. Failure to do so could result in severe personal injury, death or substantial property damage. Place boiler/crate near position 1. Leave boiler in shipping carton and on pallet until installation site is ready. 2. Move entire shipping carton and pallet next to selected location. 3. Remove shipping carton. 4. Remove boiler from pallet.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 2b Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply. Prepare boiler for test 1. Remove the shipping nipple (from CGi supply tapping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾” NPT pipe plug. 2.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 3a Boiler Manual Venting — general information CGi venting methods — Chimney draft or Direct exhaust Chimney draft venting Chimney draft venting uses the natural draft provided by a vertical vent or chimney. Category I appliance (nonpositive vent static pressure and vent gas temperature that avoids excessive condensate production in vent). See Section 3b. Chimney draft installations use: 1.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 3c Boiler Manual 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-T Vent® • Flex-L International, Inc. StaR-34 • Z-Flex®, Inc. Z-Vent II • ProTech Systems FasNSeal™ Use only the vent starter of the same manufacturer as the vent components.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 3d Boiler Manual Venting — direct exhaust — vent starter 1. Select a vent pipe manufacturer and obtain all vent components needed, based on boiler location and venting 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. Use only the vent starter of the same manufacturer as the vent components.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 3e Boiler Manual Venting — direct exhaust — termination The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance from adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. The vent termination clearances below are for U.S.A.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 3f Boiler Manual 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 pipe with seams on top of vent horizontal runs. Follow requirements in Section 3e for vent termination. 4. Maintain minimum 2” clearance from combustible materials to vent pipe. 5.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 3f Boiler Manual Venting — direct exhaust — installation (cont.) Sidewall termination Using any termination other than one of those shown could cause nuisance outages and loss of heat, resulting in substantial property damage.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4a Boiler Manual Water piping — general information General piping information Circulator If installation is to comply with ASME or Canadian requirements, an additional high temperature limit maybe needed. Install control in supply piping between boiler and isolation valve. Set second control to minimum 20°F above setpoint of first control. Maximum allowable setpoint is 240°F. See Section 9b for wiring.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4b Boiler Manual Water piping — single-zone system Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve. Eventual section failure can result. Diaphragm-type or bladdertype expansion tank (Figure 16) 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possible, before inlet side of circulator.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4c Boiler Manual 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 circulator to individual circuit requirements. 2.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4c Boiler Manual Water piping — multiple zones Figure 18 Figure 19 Zoning with circulators — return water 130°F or higher. 1 Boiler isolation (balancing) valves 2 Flow/check valve (continued) Zoning with zone valves — return water 130°F or higher. 10 Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion tank). DO NOT use an automatic air vent when using closed-type expansion tank.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4d Boiler Manual Piping — low temperature systems Primary/secondary (preferred) 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.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4d Boiler Manual Piping — low temperature systems Figure 20 Primary/secondary piping Zoning with circulators 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve Figure 21 (continued) Primary/secondary piping Zoning with zone valves 9 Relief valve 10 Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion tank).
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4d Boiler Manual 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.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4d Boiler Manual Piping — low temperature systems Figure 22 Boiler-bypass piping — Zoning with circulators — (Alternative to primary/ secondary piping Figures 20 and 21) Figure 23 (continued) Boiler-bypass piping — Zoning with zone valves — (Alternative to primary/ secondary piping Figures 20 and 21) 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve 11 Fill valve 6 Drain
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4d Boiler Manual 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 (through valve 7a). This bypassed hot water from the boiler outlet mixes with cooler system return water temperature in order to provide minimum 130°F return water to the boiler.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 4d Boiler Manual Piping — low temperature systems Figure 24 (continued) System-bypass piping — Zoning with zone valve or circulators, return water 130°F or higher — (Alternative to boilerbypass piping Figures 22 and 23) 3 System or zone circulator 7 System temperature valves (see instructions to the left for adjusting valves) 8 Blend temperature gauge 9 Relief valve 10 Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-t
CGi SERIES 4 — GAS-FIRED WATER BOILER — 5 Gas piping Connecting gas supply piping to boiler 1. 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 requires drip leg to be extended to the floor, use appropriate length of pipe between cap and tee. b. Install ground joint union for servicing, when required. c.
CGi 6 SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual Field wiring For your safety, turn 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.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 7a Start-up — preparation Check for gas leaks Before starting the boiler, and during initial operation, smell 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 pro- pane supplier mixes an odorant with the propane to make its presence detectable.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 7a Boiler Manual Start-up — preparation (continued) Fill the system with water Inspect system water piping 1. 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 2. Fill to correct system pressure. Correct pressure will vary with each application. Typical cold water fill pressure for a residential system is 12 psi. 3.
CGi Boiler Manual SERIES 4 — GAS-FIRED WATER BOILER — 7b Start-up — operate boiler DO NOT proceed with boiler operation unless boiler and system have been filled 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.
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual 7b Start-up — operate boiler (continued) 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 1. Yellow-orange streaks may appear (caused by dust). IMPROPER main burner flame characteristics 1. Check system piping for leaks. If found, shut down boiler and repair immediately.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 8 ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ Boiler Manual Check-out procedure — checklist Boiler and heat distribution units filled with water? Automatic air vent, if used, open one full turn? Air purged from system? Air purged from gas piping? Piping checked for leaks? Correctly sized manifold orifices installed? Refer to Table 2, page 12, to check size and fuel type. Correctly sized manifold orifices must be used.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 9 Boiler Manual 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.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 9a Boiler Manual Operation — sequence (continued) — The circulator continues to operate. 7. Lower room thermostat setting to stop call for heat. Thermostat is satisfied — Pilot and main gas valves are closed — Inducer operates for 15-second postpurge — Circulator is shut off. 8. Boiler is now in the off cycle. 9. Repeat steps 1 through 6 several times to verify operation. 10. Return the thermostat to normal setting. 11.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 9b Figure 31 Boiler Manual Operation — wiring diagrams Schematic wiring diagram Part Number 550-142-302/0520 39
CGi SERIES 4 — GAS-FIRED WATER BOILER — 9b Figure 32 40 Boiler Manual Operation — wiring diagrams (continued) Ladder wiring diagram Part Number 550-142-302/0520
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual instructions 9c Operating CGi-25 thru -6 Part Number 550-142-302/0520 • Spark pilot • Natural or propane gas • Gas valve: Honeywell VR8204/VR8304 41
CGi SERIES 4 — GAS-FIRED WATER BOILER — 9c 42 Boiler Manual Operating instructions CGi-25 thru -6 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36E Part Number 550-142-302/0520
CGi SERIES 4 — GAS-FIRED WATER BOILER — 9c Boiler Manual Operating instructions CGi-25 thru -8 Part Number 550-142-302/0520 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36C 43
CGi SERIES 4 — GAS-FIRED WATER BOILER — 10a Boiler Manual 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: Daily • Reported problems • Check air openings • Check boiler pressure temperature gauge • Boiler area • Air openings • Flue gas vent system (and air piping) • Check
CGi SERIES 4 — GAS-FIRED WATER BOILER — 10b Boiler Manual Service and maintenance — annual start-up 2. Verify that boiler vent discharge is clean and free of obstructions. The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 8, page 44, and explained on the following pages must be performed to assure maximum boiler efficiency and reliability.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 10b ❏ Service & maintenance – annual start-up Inspect . . . Burners and base (cont.) 4. Reinstall components, starting with the burner tray, then the pilot bracket assembly, burner baffle, and air inlet top and front panels. 5. Follow the start-up procedure in the boiler manual. The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 71 of this manual.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 10b ❏ Boiler Manual Service & maintenance – annual start-up Check/test . . . Gas piping (cont.) Open-type — located above highest radiator or baseboard unit, usually in the attic or closet. Has a gauge glass and overflow pipe to a drain. 1. Sniff near floor and around boiler area for any indication of a gas leak. 2. Test gas piping using bubble test, per Section 5 of this manual, if there is any indication of a leak.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 10b Service & maintenance – annual start-up (cont.) Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11a Boiler Manual Troubleshooting — procedure Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other device except for 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.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11a Troubleshooting — components Troubleshooting air pressure reading 1. If manometer reading is lower than the setpoint of the switch (see Table 9) — check for possible causes: • • • • • • Boiler Manual 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 2.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11b Boiler Manual Troubleshooting — components The information on this page and pages 52 through 60 apply only to spark-ignited pilot CGi boilers. These boilers are equipped with an ignition control module that has indicator lights to show control status. Charts 1 through 8, pages 53-60, help you identify problems based on indicator light conditions.
11b Troubleshooting — components (continued) Control module connections :KLWH 3LQN RU %OXH 9$& + 9$& 9$& ,1 LI XVHG %OXH WR '+: %ODFN %ODFN WR *URXQG *UHHQ :KLWH ZLUH WR JDV YDOYH 09 39 %OXH ZLUH WR JDV YDOYH 39 767$7 +RW 5HG WR 7UDQVIRUPHU LI XVHG 9$& FRQWURO FLUFXLWV 5HG ZLUH WR JDV YDOYH 09 %OXH WR '+:
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11c Boiler Manual Troubleshooting — control module lights CHART 1 –– Troubleshooting POWER light status –– ! " ! # –– 120 Electrical shock hazard ! K $ Z TURN OFF POWER Z# @ [ $# $ Is POWER light off? No • Make sure service switch or circuit breaker is on or fuses are good.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11c Boiler Manual Troubleshooting — control module lights (cont.) CHART 2 –– TSTAT CIRC & POWER light flashing –– Usually indicates 48 VAC on thermostat circuit (stray voltage) –– 120 Electrical shock hazard ! K $ Z TURN OFF POWER Z# @ [ $# $ • Disconnect the two external wires connected to the boiler thermostat leads (two black low voltage leads in J-box).
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11c Boiler Manual Troubleshooting — control module lights (cont.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11c Boiler Manual Troubleshooting — control module lights (cont.) CHART 4 –– FLAME & POWER light flashing $$ " % &! ! ' # ! $$ 120 Electrical shock hazard ! K $ Z TURN OFF POWER Z# @ [ $# $ Are manual main shutoff valve and gas valve open? No • • • • • Yes Leave main manual gas valve closed.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11c Boiler Manual Troubleshooting — control module lights (cont.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11c Boiler Manual Troubleshooting — control module lights (cont.) CHART 6 –– FLAME light flashing and Power light on steady Also –– Troubleshooting failure to establish main flame.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11c Boiler Manual Troubleshooting — control module lights (cont.) CHART 7 –– Troubleshooting LWCO and POWER light Solid and/or “LCO” shown on display Electrical shock hazard ! K $ Z TURN OFF POWER Z# @ [ $# $ Is boiler pressurized? Yes No • Pressurize boiler to system design pressure. Are lights still solid? No • Check system for leaks.
CGi SERIES 4 — GAS-FIRED WATER BOILER — 11c Boiler Manual Troubleshooting — control module lights (cont.) CHART 8 –– Insufficient heat or no heat to system (POWER light on steady) Electrical shock hazard ! K $ Z TURN OFF POWER Z# @ [ $# $ • Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes.
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual Notes Part Number 550-142-302/0520 61
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual 12a Replacement parts Section assembly ............................................................... 63 Base .................................................................................................. 64 Jacket .............................................................................................. 66 Trim ................................................................................................. 67 Controls ..................
CGi SERIES 4 — GAS-FIRED WATER BOILER — 12b Figure 39 Item Replacement parts — section assembly Section assembly Description Weil-McLain part number Item 6 1 End section, left hand, 51124 311-103-851 2 End section, right hand 51128 311-103-821 3 Intermediate section, 51127 CGi-25 and CGi-3 CGi-4 CGi-5 CGi-6 CGi-7 CGi-8 311-103-845 321-114-360 321-114-361 321-114-362 321-114-363 321-114-364 321-114-365 not shown Replacement section assembly not shown Section replacement kit, includes sea
CGi SERIES 4 — GAS-FIRED WATER BOILER — 12c Boiler Manual Replacement parts — base Figure 40 Item Base assembly Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6 and 7) 64 Weil-McLain part number Description 1 Base side panel (in Base assembly) 2 Base front cross-tie assembly (in Base assembly) 3 Base back cross-tie assembly (in Base assembly) 4 Burner shield (in Base assembly) 5 Base pan angle, left side (in Base assembly) 6 Base pan angle, right side (in Base assembly)
CGi SERIES 4 — GAS-FIRED WATER BOILER — 12c Boiler Manual Replacement parts — base Part Number 550-142-302/0520 (continued) 65
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual 12d Replacement parts — jacket Figure 41 Jacket assembly 1 2 \ ]# 2x4 S # eft side# V X Boiler Model CGi-25 CGi-3 CGi-4 CGi-5 CGi-6 CGi-7 CGi-8 66 4 5 S X Boiler Model Weil-McLain part number H $ 381-359-215 381-359-216 381-359-217 381-359-218 381-359-219 381-359-220 381-359-221 381-359-222 381-359-223 381-359-224 381-359-225 381-359-226 381-359-227 381-359-228 381
CGi SERIES 4 — GAS-FIRED WATER BOILER — 12e Boiler Manual Replacement parts — trim Figure 42 Trim assembly Item Description number Weil-McLain part number Pressure relief valve, ASME, 30 PSIG, ¾” male inlet 511-546-920 Pressure relief valve, ASME, 30 PSIG, ¾” female inlet !% ' ( " 511-546-924 2 Combination pressure-temperature gauge, 3¹⁄₈” diameter, short shank !% " 380-000-000 3 Drain valve, ¾” !%
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual 12f Replacement parts — controls Figure 43 Item number Gas control assembly Description Boiler model Weil-McLain part number Gas valve, ½” x ½” CGi-25 thru -6 511-044-381 511-044-381 Gas valve, ¾” x ¾” CGi-7 & CGi-8 511-044-353 511-044-353 Natural gas components 1 2 Pilot kit w/orifice & aluminum pilot gas tubing 511-330-080 Propane gas components 1 2 Gas valve, ½” x ½” CGi-25 thru -6 511-044-354 511-044-354 Gas valve, ¾” x ¾” CGi
CGi SERIES 4 — GAS-FIRED WATER BOILER — 13a Figure 44 Boiler Manual Dimensions Dimensional drawing Boiler model number Supply tapping (inches NPT) Return tapping (inches NPT) Gas connection size Note 3 (inches NPT) Gas manifold size Note 3 (inches NPT) “W” Jacket width (inches) CGi-25 1¼ 1¼ ½ ½ 10 CGi-3 1¼ 1¼ ½ ½ 10 CGi-4 1¼ 1¼ ½ ½ 13 CGi-5 1¼ 1¼ ½ ½ 16 CGi-6 1¼ 1¼ ½ ½ 19 CGi-7 1¼ 1¼ ¾ ¾ 22 CGi-8 1¼ 1¼ ¾ ¾ 25 Note 3: Gas piping from meter to boiler to be
CGi SERIES 4 — GAS-FIRED WATER BOILER — 13b Boiler Manual Ratings Table 11 Boiler ratings AHRI Certified Ratings Boiler model number 0 - 2,000 feet Altitude 2,000 - 4,500 feet Altitude Heating Capacity Btuh Seasonal Efficiency Net Ratings (water) Btuh (Note Boiler water content Vent size Inches Input (Btuh) Output (Btuh) Input (Btuh) Output (Btuh) (Note 2) CGi-25 48,000 40,000 43,000 36,000 41,000 84.0 35,000 1.5 3" CGi-3 58,000 49,000 52,000 43,000 49,000 84.0 42,000 1.
CGi SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials that have been identified as carcinogenic, or possibly carcinogenic, to humans. Ceramic fibers can be converted to cristobalite in very high temperature applications.
CGi 72 SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual Part Number 550-142-302/0520
