Weil-McLain CG-7 - Section II: Boiler Set-Up; Placing the Boiler; Hydrostatic Pressure Test; Draft Hood Installation

Section II: Boiler Set-up
PLACING THE BOILER
Leave boiler in crate and on 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 a board under right
legs.
c. Slide boiler backward off pallet and into position.
DO NOT DROP BOILER OR BUMP JACKET ON FLOOR
OR PALLET.
4. Check level. Shim legs, if needed. Do not alter legs.
5. Remove front jacket door. Remove base access panel (CG
models only).
6. Check for proper orifice sizing from chart below.
DANGER
Proper orifices must be used. Failure
to do so will cause severe iiyury, death
or substantial property damage.
CG Series 11 - ORIFICE SIZES
Heating Value,
Orifice
Type of Gas
BTU/cu. ft
Size
Natural 1000
2.0mm
Propane
2500
1.3mm
ORIFICE SIZE - CANADA ONLY
Elevation Natural
Propane
0 - 2000 ft.
2.0mm
1.3mm
2000 - 4500 ft. ' 1,9mm
1.2mm
CGX Series 1 - ORIFICE SIZES
Heating Value,
Orifice
Type of Gas
BTU/cu. fL
Size
Natural 1000
#35 Drill
j ORIFICE SIZE - CANADA ONLY
Elevation
Natural
Propane
0 - 2000 ft.
#35 Drill
N/A
2000 - 4500 ft.
#37 Drill
N/A
7. Level and straighten burners (CG models only).
Burners must be properly seated in
slots in burner rest with their open¬
ings face up. Main burner orifices
must inject down center of burner.
Failure to properly seat burners will
result in severe personal injury, death
or substantial property damage.
8. Reinstall access panel (CG models only).
Access panel must be secured in posi¬
tion during boiler operation to prevent
momentary flame rollout on ignition
of main flame.
CAUTION
DANGER
HYDROSTATIC PRESSURE TEST
Pressure test before attaching piping or electrical supply.
1. Remove shipping nipple from supply outlet. Remove relief
valve. Plug tappings, including compression tank tapping
and relief valve opening.
2. Connect water supply. Fill boiler and purge all air. Test at
l ‘ /2 times working pressure.
WARNING
Do not leave boiler unattended. A cold
water fill could expand and cause
excessive pressure, resulting in severe
personal injury, death or substantial
property damage.
3. Check for maintained gauge pressure for more than 10
minutes.
WARNING
Leaks must be repaired at once. Fail¬
ure to do so can damage boiler, result¬
ing in substantial property damage.
Do not use petroleum based cleaning
or sealing compounds in boiler system.
Severe damage to boiler will result,
causing substantial property, damage.
4. Drain boiler and repair leaks if found. Remove testing
plugs. Reinstall relief valve, with spindle in vertical position.
DRAFT HOOD INSTALLATION
Secure draft hood to outlet at top of boiler with sheet metal
screws. Bottom of draft hood or “skirt” must have clearance
dimension above jacket top panel as indicated on draft hood.
Do not alter boiler draft hood or place
any obstruction or non-approved
damper in breeching or vent system.
A.G.A./CGA certification will become
void. Flue gas spillage and carbon
monoxide emissions will occur caus¬
ing severe personal injury or death.
SPILL SWITCH INSTALLATION
Fasten spill switch to draft hood as shown on page 17. Connect
wires as shown in Control Supplement.
DAMPER INSTALLATION
See Control Supplement for information.
DANGER
BREECHING ERECTION
Connect from draft hood or damper outlet to chimney or vent
with same size breeching. Where possible, vertical venting to
the outside from the draft hood or damper outlet will offer best
performance. Where horizontal breeching is used, slope up¬
ward at least 'A inch per lineal foot toward chimney or vent
and support with hangers to prevent sagging.
Long horizontal breechings, excessive
numbers of elbows or tees, or other
obstructions which restrict the flow of
combustion gases should be avoided.
Breeching must not be connected to any portion of a mechan¬
ical draft system that can operate under positive pressure.
Failure to properly pipe boiler may
result in improper operation and dam¬
age to boiler or building.
CAUTION
WARNING
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