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Weil-McLain CG Series User Manual

Weil-McLain CG Series
23 pages
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55D-tio-l,38'/oi%
UlEIL-flldAIN
CG
(Series
11)
and
CGX
(Series
1)
Gas-Fired
Boilers
Boiler
Manual
Includes:
Installation
Start-up
Service
Boiler
Parts
Refer
to
Control
Supplement
for
additional
information
and
Gas
Control
Parts
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
contractor.
To
the
installer:
Read
all
instructions
and
warranty
before
starting.
Any
claims
for
damage
or
shortage
in
shipment
must
be
filed
immediately
against
the
transportation
company
by
the
consignee.
Part
No.
550-110-630/0695DCP
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Weil-McLain CG Series Specifications

General IconGeneral
Fuel TypeNatural Gas or Propane
Heat Exchanger MaterialCast Iron
WarrantyLimited warranty (consult manufacturer's documentation)
Operating Pressure30 psi
Water ContentVaries by model (see specific model specifications)
WeightVaries by model (see specific model specifications)
DimensionsVaries by model (see specific model specifications)

Summary

Section I: Pre-Installation

Codes and Standards

Details on compliance with local, national, and Canadian codes for boiler installation.

Combustion Air and Ventilation Openings

Requirements for providing adequate air for combustion and ventilation to ensure safety.

Chimney or Vent Requirements

Guidelines for proper installation and sizing of chimneys or vents for safe exhaust.

Residential Garage Installation

Specific clearance requirements when installing the boiler in a residential garage.

Boiler Foundation

Requirements for a level foundation, especially for areas prone to flooding.

Section II: Boiler Set-Up

Placing the Boiler

Instructions for safely moving and positioning the boiler before installation.

Hydrostatic Pressure Test

Procedure for pressure testing the boiler with water to detect leaks.

Draft Hood Installation

Guidance on correctly installing the draft hood for proper venting.

Spill Switch Installation

Instructions for installing the spill switch on the draft hood.

Damper Installation

Reference to the Control Supplement for damper installation details.

Breeching Erection

Guidelines for connecting the breeching to the chimney or vent.

Section III: Piping

Expansion Tank Piping

Details for diaphragm and closed-type expansion tank piping configurations.

Multiple Zoning with Circulators

Piping configuration for systems with multiple heating zones using circulators.

Bypass Piping

Bypass Piping Applications

When bypass piping is required for baseboard systems and other installations.

Use With Refrigeration System

Piping recommendations for boilers used in combination heating and cooling systems.

Section IV: Gas Piping

Gas Piping Considerations

Factors to consider when sizing gas supply piping for natural and propane gas.

Gas Supply Piping Diagram

Illustrates the components and layout for gas supply piping connections.

Section V: Wiring

General Wiring Safety

Safety precautions and code compliance for electrical wiring installations.

Install Room Thermostat

Guidelines for selecting an optimal location for the room thermostat.

Wiring Multiple Zones

Wiring configurations for zoning systems using zone valves or circulators.

Section VI: Final Adjustments

Water Treatment

Recommendations for water treatment and avoiding mineral buildup.

Freeze Protection

Guidance on using appropriate antifreeze for hydronic systems.

Filling System

Step-by-step instructions for filling the boiler and heating system with water.

Inspect Base Insulation

Check the security and condition of the boiler's base insulation.

To Place in Operation

Instructions for starting up the boiler and ensuring proper operation.

Check Pilot Burner Flame

Guidance on identifying proper and improper pilot burner flame characteristics.

Check Burner Flames

Visual inspection of main burner flames for correct combustion.

Inspect Venting System

Regular checks of the venting system for obstructions and deterioration.

Section VII: Check-out Procedure

Initial System Checks

Verify water fill, air vents, purging, gas piping, and orifice installation.

Component and Control Checks

Inspect burner flames, test limit/safety controls, ignition, and high limit settings.

Operation and Documentation

Ensure proper zone flow, thermostat settings, cycling, gas input, and complete certificate.

Section VIII: Maintenance

Suggested Minimum Maintenance Schedule

Recommended maintenance tasks for qualified service technicians.

Beginning of Heating Season Maintenance

Tasks to perform before the start of each heating season.

Daily Maintenance

Routine checks to perform daily during the heating season.

Periodically During Heating Season Maintenance

Periodic checks for relief valve and low water cut-off.

Monthly During Heating Season Maintenance

Monthly inspection of boiler and piping for leaks.

End of Heating Season Procedure

Procedure to follow at the conclusion of the heating season.

Clean Boiler Heating Surfaces

Instructions for cleaning the boiler's internal heating surfaces.

Precautionary Measures for Materials

Safety precautions when handling fiberglass wool and ceramic fiber materials.

First Aid Measures

First aid procedures for eye and skin contact with materials.

Cleaning Main Burners

Steps for vacuuming or brushing burners to remove dust and lint.

Annual Shut-Down Procedure

Instructions for safely shutting down the appliance annually.

Section IX: Replacement Parts

Parts Lists

List of component assemblies available for replacement.

Component-Assemblies Replacement

Reference to control supplement for specific control component replacement.

Component Replacement Instructions

General instructions to follow before replacing any part on the boiler.

Dimensions

Ratings

Standard Equipment

List of standard equipment included with the boiler.

Additional Equipment

List of optional equipment available for the boiler system.

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