550 11p. ;wa WILE-McLAIN flm A CGM (Series 10) Gas-Fired Boiler Manual ) Includes: e « Installation ¢ Start-up * Service * Parts Refer to Control Supplement for additional information For Natural or Propane Gas BOILER MANUAL FOR USE BY A QUALIFIED CONTRACTOR To the owner: Regular service on this boiler is recommended and should be performed by a qualified confer TS RS UL Read al! instructions and warranty before starting.
Table of Contents | — Air Supply for Combustion . .. .. Chimney or Vent Requirements Minimum Service Clearances Roller Foundation Section Boiler Set-Up Placement .. 5 Draft Hood . 5 Breaching Hydro static Pressure Test .. 5 Section I1: Piping Supply and Return . Expansion Tank Sizing Multiple Zoning with Circulatory Bypass Piping . Use with Refrigeration System . Section Vi Final Adjustments Water Treatment Filling the System . . Inspect Base Insulation . To Place in Operation Check Burner Flames . .
s m— LG FAILURE TO FOLLOW ALL INSTRUCTIONS IN PROPER ORDER CAN CAUSE PERSONAL INJURY OR DEATH. READ ALL INSTRUCTIONS BEFORE INSTALLING. Section I: Pr-installation CODES Installations must comply with all local codes, laws, regulations and ordinances, also United States National Fuel Gas Code ANSI edition. When required, installations must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, No. CAD-1.
v so— d. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. e. 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. .
—Hfl‘m_ Section II: Boiler Set-up PLACING THE BOILER Leave boiler in crate and ¢n pallet until installation site is ready. 1. Move entire crate and pallet next to selected location. 2. Remove crate. 3. Remove boiler from pallet as follows: a. Tilt left side of boiler up and place a board under left legs. b. Tilt boiler the other way and place & board under right legs. ¢. Slide boiler backward off pallet and inch position. DONOR DROP BOILER OR BUMP JACKET ON FLOOR OR PALLET.
Section IlI: Piping CAUTION Failure to properly pipe boiler may result in improper operation and damage to boiler or building. CLOSED TYPE EXPANSION TANK 1. Pipe as shown in Figures Diaphragm-type expansion tank: Be sure tank pres. sure and size will handle system pressure and water volume, 1) Fill pressure may be adjusted at tank for design conditions. Follow manufacturer's instructions. 2) Additional tanks may be connected to tees in system near boiler. See Table L.
MULTIPLE ZONING WITH CIRCULATORY 1. Multiple zoning with circulatory, boiler must be repined. See Figure 8. a} Remove provided circulatory. b} Determine if by-pass piping will be needed. See page 8. <} Mount circulatory as shown. d} Install flow control valves. €) Follow remaining piping instructions ISOLATION VALVES' FLOW CONTROL VALVES® " YO RADIATION RELIEF VALVE DISCHARGE Fining COMPRESSION TANK +0C NOT USE DRAIN COCK TAPPING *MAY BE INSTALLED IN'ALTERNATE LOCATIONS.
—flm_ BYPASS PIPING BYPASS PIPING I8 NOT NORMALLY REQUIRED ON TYPICAL BASEBOARD SYSTEM. Bypass piping should be used for the following installations. Bypass, supply, and return piping should be same size. 1. When return water temperature is 130°F or greater: to protect system radiant panels, plaster, etc. from high tempera. true water supplied from boiler, see Figure 7. ol salivate system Temperature GAUGE % . ADJUST VALVES MAINTAIN SYSTEM TEMPERATURE REQUIREMENTS VALVE* FROM SYSTEM CIRCULATORY FIGURE 7 2.
] e—— Section IV: Gas Piping Size gas piping considering: a. Diameter and length of gas supply piping. b. Number of fittings. ¢. Maximum gas consumption (including any possible future expansion). o . Allowable loss in gas pressure from gas meter outlet to boiler, For pressure drops, see ANSI 2223.1. 1. For natural gas: a) Refer to following tables, To obtain cubic feet per hour, divide the input by 1000. b} Size for rated boiler input. ¢} Inlet gas pressure: 5” W.C. minimum 13" W.C.
Section V: Wiring Refer to wiring diagram label on jacket door and Control Supplement for specific wiring details. WIRING For your safety, turn off electrical NEGLECT power supply at service entrance panel before making any electrical connections to avid possible elev trial shock hazard. All wiring must be installed in accordance with requirements of the National Electrical Code and any additional national, state, or local code requirements having jurisdiction. All safety circuit wiring must be N.E.C.
—flflm— Section VI: Final Adjustments WATER TREATMENT Never use petroleum based stop leak compounds. Water seal deterioration will occur, resulting in leakage between sections. Continual make up water will reduce boiler life. Minerals can build up in the sections, reducing heat transfer, overheating the east iron, and causing section failure. For unusually hard water areas or low pH conditions (less than 7.0) consult local water treatment company.
”m— Check pilot burner flame: 1. Proper pilot flame a} Blue flame. by Inner cone engulfing pilot flame sensor <} Pilot flame sensor glows cherry red. 2. Improper pilot flame a) Overinflated is large and lifting or blowing past pilot flame sensor. b} Underinflated small; pilot flame sensor not engulfed by inner cone. ¢} Lack of primary air—flame tip yellow. d) Filet flame sensor not heated properly. 3.
s — FOR YOUR SAFETY READ BEFORE LIGHTING NN WANING: if you do not follow these instructions exactly, & fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted by hand. « If you cannot reach your gas supplier, call the fire Wuhan lighting the pilot, follow theses instructions exactly. department. B. BEFORE LIGHTING, smell all around the appliance area for C. Use only your hand to push in or turn the gas control nab. gas.
—m— — FOR YOUR SAFETY READ BEFORE OPERATING [N WARNING: It 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 automatically tights the pilot. Do not try to light the pilot by hand. B. BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
v s— Section VII: Check-out Procedure Check-off steps as completed. 1. anon Boiler and heat distribution units filled with water? . Automatic air vent, if used, open one turn? . Air purged from system? . Air purged from gas piping? Piping checked for leaks? . Follow operating instruction label on boiler for proper start-up. Also refer to “To Place in Operation”, page 1.
-mflm— Section VIII: Maintenance Also Refer to Additional Instructions Shipped With The Boiler For Specific Control Operation and Troubleshooting Your boiler should be inspected, NOTICE cleaned and, if necessary, adjusted once a year, A qualified service agency should be called. TO AVOID PERSONAL INJURY, 1. Disconnect electrical supply. 2. Shut-off gas supply. 3. Allow boiler to cool.
Clean boiler heating surfaces: 1. Follow shut-down procedure. 2. Remove upper rear jacket panel. Turn back jacket insulation to expose escalator hood. 3. Remove collection hood. Clean excess boiler cement from collector hood and cast iron sections. 4. Remove radiation plates (not used on CHM-25) that hang between sections. 5. Remove burners from base of boiler. Follow “Cleaning Main Burners,” page 17. 6. ?lice newspaper in beige of boiler to collect soot that will all, 7.
Section IX: Replacement Parts Parts Lists Component-Assemblies Replacement (Refer to Control Supplement for control replacement) Section Assembly ...l 19 Base Assembly Jacket Assembly Boiler Trim Assembly 22 COMPONENT REPLACEMENT INSTRUCTIONS Before replacing any parts on the boiler: 1. Turn off power 2. Shut off gas supply Refer to the appropriate diagram for parts replacement. Replacement parts can be ordered or purchased through a local Wei-McLain distributor.
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airlifts sere mi— e B} ooy FRONT S et S EXPANSION TANK rage I ‘%—i RIGHT SIDE LEFT SIDE * Supply Cutie Return Inlet Gas Connection Pipe Size | Gas Manifold Dimensions Holier Pipe Stan Number Ne. Pipe Size No. Pipe Size Natural Gas Propane Gas | All Gases CHM-285 360%™ CHM-3 1 114" 182" 467" 184" 4" 142" 10" Cam-4 46%" 211" 5" 1" 13" CONS 51%" 244" 8" 1" 167 CHM-8 1 1ia" 307" 8" 4" 19" COM-7. 249" CHM-8 557" 367" Add 412" when automatic vent damper is used. * Supply lapping size 11e” if loh and section.
< RATINGS . DOE Maximum Allowable D.0.E. Seasonal System Water Efficiency (A FURN D.OE. NET 18R Content In Gallons Boiler Input Nesting Ratings Boiler Water with Standard Plw/ Chimney and Number Byword. | Capacity | 8TUHr® | Content Gallons Fill-Trot» Tending Pilot | 1 damper | Breaching Size** 1CGM-26 52,000 43,000 37,000 154 18 87.4 72n 81.1 1CGM-3 70,000 58,005 50,000 1.54 18 703 733 81.8 471D, x 20 DOGMA-4 105,000 86,000 75,000 2.