Weil McLain Boiler CGA25SPDN User Manual

™

GOLD CGa

Gas-Fired Water Boilers

s )NSTALLATION s -AINTENANCE

Boiler Manual

s 3TARTUP

s 0ARTS

This manual must only be used by a qualiﬁed heating installer/service technician. Before installing, read all

instructions, including this manual, the burner manual and any related supplements. Perform steps in the order

given. Failure to comply could result in severe personal injury, death or substantial property damage.

Part No. 550-101-009/0107

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GOLD CGa Gas-Fired Water Boiler — Boiler Manual

GOLD CGa Gas-Fired Water Boiler

Part Number 550-101-009/0107

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GOLD CGa Gas-Fired Water Boiler — Boiler Manual

Contents

How is works....................................................2-3

Hazard deﬁnitions ............................................... 4

Please read before proceeding............................ 5

1 Prepare boiler location...................................6–11

2 Prepare boiler...............................................12-15

3 Waterpiping.................................................16-25

4 Gas piping ......................................................... 26

5 Field wiring ....................................................... 27

6 Start-up........................................................28-32

7 Check-outpr ocedure......................................... 33

8 Operation – standing pilot boilers.................34-36

9 Operation – spark-ignited pilot boilers..........37-43

10 Service and maintenance .............................44-49

11 Troubleshooting:

Standing pilot boilers .............................49-50, 51

Spark-ignited pilot boilers .................49-50, 51-59

12 Replacement parts .......................................60-65

13 Dimensions and ratings................................66-67

Hazard deﬁnitions

The following deﬁned terms are used throughout this manual to bring attention to the presence of hazards of

various risk levels or to important information concerning the life of the product.

Indicates presence of hazards that WILL CAUSE SEVERE personal injury, death or substantial

property damage.

Indicates presence of hazards that CAN CAUSE SEVERE personal injury, death or substantial

property damage.

Indicates presence of hazards that WILL OR CAN CAUSE MINOR personal injury or property dam-

age.

Indicates special instructions on installation, operation or maintenance that are important but

not related to personal injury or property damage.

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GOLD CGa Gas-Fired Water Boiler — Boiler Manual

Please read before proceeding

Installer

User

2EAD ALL INSTRUCTIONS BEFORE INꢀ

stalling. Follow all instructions in

proper order to prevent personal

injury or death.

4HIS MANUAL IS FOR USE ONLY BY YOUR QUALIlED

HEATING INSTALLERꢁSERVICE TECHNICIANꢂ

0LEASE REFER TO THE 5SERꢃS )NFORMATION -ANUAL for

your reference.

#ONSIDER PIPING AND INSTALLATION when determining

boiler location.

7E RECOMMEND REGULAR SERVICE BY A QUALIlED

SERVICE TECHNICIANꢄ AT LEAST ANNUALLY.

!NY CLAIMS FOR DAMAGE OR SHORTAGE IN SHIPMENT

must be ﬁled immediately against the transportation

company by the consignee.

The boiler contains ceramic ﬁber and ﬁberglass materials. Use care when handling these

materials per instructions on page 68 of this manual. Failure to comply could result in severe

personal injury.

When calling or writing about the boiler— Please have the boiler model number from the

BOILER RATING LABEL AND THE #0 NUMBER FROM THE BOILER JACKETꢀ 9OU MAY LIST THE #0 NUMBER IN

the space provided on the )NSTALLATION AND SERVICE CERTIlCATE found on page 33.

Failure to adhere to the guidelines on this page can result in severe personal injury, death

or substantial property damage.

#ONTINUAL FRESH MAKEUP WATER WILL REDUCE

boiler life. Mineral buildup in sections re-

duces heat transfer, overheats cast iron, and

causes section failure. Addition of oxygen

and other gases can cause internal corrosion.

Leaks in boiler or piping must be repaired

at once to prevent makeup water.

When servicing boiler —

4O AVOID ELECTRIC SHOCKꢁ DISCONNECT ELECTRICAL SUPPLY

before performing maintenance.

4O AVOID SEVERE BURNSꢁ ALLOW BOILER TO COOL BEFORE

performing maintenance.

Boiler operation —

$O NOT ADD COLD WATER TO HOT BOILERꢀ 4HERMAL

shock can cause sections to crack.

$O NOT BLOCK mOW OF COMBUSTION OR VENTILATION AIR

to boiler.

Glycol — potential ﬁre hazard —

3HOULD OVERHEATING OCCUR OR GAS SUPPLY FAIL TO SHUT

off, do not turn off or disconnect electrical supply to

circulator. Instead, shut off the gas supply at a location

external to the appliance.

All glycol is ﬂammable when exposed to high

temperatures. If glycol is allowed to accumulate

in or around the boiler or any other potential

ignition source, a ﬁre can develop. In order to

prevent potential severe personal injury, death

or substantial property damage from ﬁre and/or

structural damage:

$O NOT USE THIS BOILER IF ANY PART HAS BEEN UNDER

water. Immediately call a qualiﬁed service techni-

cian to inspect the boiler and to replace any part of

the control system and any gas control that has been

under water.

.EVER STORE GLYCOL OF ANY KIND NEAR THE BOILER

or any potential ignition source.

Boiler water —

-ONITOR AND INSPECT THE SYSTEM AND BOILER

regularly for leakage. Repair any leaks im-

mediately to prevent possible accumulation

of glycol.

$O NOT USE PETROLEUMꢂBASED CLEANING OR SEALING

compounds in boiler system. Water seal deterioration

will occur, causing leakage between sections. This can

result in substantial property damage.

.EVER USE AUTOMOTIVE ANTIFREEZE OR ETHYLENE

glycol in the system. Using these glycols can

lead to hazardous leakage of glycol in the

boiler system.

$O NOT USE hHOMEMADE CURESv OR hBOILER PATENT MEDI-

CINESvꢀ 3ERIOUS DAMAGE TO BOILERꢁ PERSONNEL ANDꢃOR

property may result.

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Prepare boiler location — codes & checklist

Installations must follow these codes:

,OCALꢁ STATEꢁ PROVINCIALꢁ AND NATIONAL CODESꢁ LAws, regulations and ordinances.

.ATIONAL &UEL 'AS #ODEꢁ !.3) :ꢄꢄꢅꢀꢆnLATEST EDITIONꢀ

3TANDARD FOR #ONTROLS AND 3AFETY $EVICES FOR !UTOMATICALLY &IRED "OILERSꢁ !.3)ꢃ

!3-% #3$ꢂꢆꢁ WHEN REQUIREDꢀ

.ATIONAL %LECTRICAL #ODEꢀ

&OR #ANADA ONLYꢇ "ꢆꢈꢉꢀꢆ OR "ꢆꢈꢉꢀꢄ )NSTALLATION #ODEꢁ #3! #ꢄꢄꢀꢆ #ANADIAN

%LECTRICAL #ODE 0ART ꢆ AND ANY LOCAL COdes.

4HE #'A BOILER GAS MANIFOLD AND CONTROLS MET SAFE LIGHTING AND

other performance criteria when boiler underwent tests speciﬁed

IN !.3) :ꢄꢆꢀꢆꢅnLATEST EDITIONꢀ

Before locating the boiler,

check the following:

#HECK FOR NEARBY CONNECTION TOꢇ

3YStem water piping

6ENTING CONNECTIONS

'AS SUPPLY PIPING

%LECtrical power

#HECK AREA AROUND BOILERꢀ 2EMOVE ANY COMBUSTIBLE MATERIALSꢄ GASOLINE AND

OTHER mAMMABLE LIQUIDSꢄ OR OTHER CONTAMINANTS.

Failure to keep boiler area clear and free of COMBUSTIBLE MATEꢀ

RIALSꢄ GASOLINE AND OTHER mAMMABLE LIQUIDS AND VAPORS can

result in severe personal injury, death or substantial property

damage.

"Oiler must be installed so that gas control system components are protected

from dripping or spraying water or rain during operation or service.

)F New boiler will replace existing boiler, check for and correct system problems,

such as:

1. System leaks causing oxygen corrosion or section cracks from hard water

deposits.

2. Incorrectly-sized expansion tank.

3. Lack of antifreeze in boiler water causing system and boiler to freeze and

leak.

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GOLD CGa Gas-Fired Water Boiler — Boiler Manual

Prepare boiler location — clearances

&IGURE ꢅB Required MINIMUM clearances

$O NOT INSTALL BOILER ON CARPETING EVEN

if foundation is used. Fire can result,

causing severe personal injury, death

or substantial property damage.

)F ANY CLEARANCE IS LESS THAN IN &IGURE 1aꢄ

PROVIDE OPENINGS FOR COMBUSTION AND

VENTILATION AIR located on the wall or door

opposite the boiler FRONT (see Figure 1b).

These openings must be located as shown in Figure 1b to provide

proper air ﬂow around the boiler. The free area of each opening

Foundation

(after deducting for louvers) must be at least ONE SQUARE INCH

PER ꢅꢄꢈꢈꢈ "TUH of boiler input. If the building is of unusually

tight construction (see page 11 for deﬁnition), the air openings

must connect directly to outside or the building must have air

openings to the outside as speciﬁed on page 11.

1. Provide a solid brick or minimum 2-inch thick concrete

foundation pad if any of the following is true:

mOOR CAN BECOME mOODEDꢀ

THE BOILER MOUNTING AREA IS NOT LEVELꢀ

If clearances are equal to or greater than Figure 1a, see pages 10

and 11 for location and sizing of combustion air openings.

2. Minimum dimensions are ꢉꢊv LENGTH by:

Minimum foundation width:

Failure to comply can result in severe personal injury, death or

substantial property damage and reduced boiler life.

CGa-25/3

CGa-4

CGa-5

12"

15"

18"

CGa-6

CGa-7

CGa-8

21"

24"

27"

.EVER INSTALL THE BOILER IN A SPACE WITH CLEARꢀ

ANCES LESS THAN THE MINIMUM CLEARANCES SHOWN

IN &IGURE ꢅB. Failure to comply can result in severe

personal injury, death or substantial property

damage and reduced boiler life.

Residential garage installations

Take the following special precautions when installing the

boiler in a residential garage. If the boiler is located in a

RESIDENTIAL GARAGEꢁ PER !.3) :ꢄꢄꢅꢀꢆꢇ

-OUNT THE BOILER A MINIMUM OF ꢅꢋ INCHES ABOVE THE

mOOR of the garage to assure the burner and ignition

devices will be no less than 18 inches above the ﬂoor.

1. (OT WATER PIPESꢆ AT LEAST 56O INCH from combustible material.

2. 3INGLEꢀWALL VENT PIPEꢆ AT LEAST ꢇ INCHES from combustible mate-

rial.

3. 4YPE " DOUBLEꢀWALL METAL VENT PIPE: refer to vent manufacturer’s

recommendation for clearances to combustible material.

,OCATE OR PROTECT THE BOILER so it cannot be damaged

by a moving vehicle.

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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.

$O NOT ALTER BOILER DRAFT HOOD OR PLACE ANY OBSTRUCTION OR NONꢂAPPROVED VENT DAMPER IN BREECHING OR VENT SYSTEMꢀ

#3! CERTIlCATION WILL BECOME VOIDꢀ &LUE GAS SPILLAGE AND CARBON MONOXIDE EMISSIONS WILL OCCUR CAUSING SEVERE

personal injury or death.

When removing boiler from an Chimney or vent require-

existing common vent system: ments

At the time of removal of an existing boiler, the following

steps shall be followed with each appliance remaining

connected to the common venting system placed in op-

eration, while the other appliances remaining connected

to the common venting system are not in operation.

ꢆꢀ 6ENTING MUST BE INSTALLED ACCORDING TO 0ART ꢊꢁ 6ENT-

ING OF %QUIPMENTꢁ OF .ATIONAL &UEL 'AS #ODEꢁ !.3)

:ꢄꢄꢅꢀꢆꢂLATEST EDITION AND APPLICABLE BUILDING CODESꢀ

#ANADIAN INSTALLATIONS MUST COMPLY WITH "ꢆꢈꢉꢀꢆ OR

"ꢆꢈꢉꢀꢄ )NSTALLATION #ODESꢀ

a. 3EAL ANY UNUSED OPENINGS in the common venting

2. See Ratings table on page 67 for minimum chimney

or vent sizes. A chimney or vent WITHOUT A LISTED

CAP should extend AT LEAST ꢌ FEET ABOVE THE HIGHEST

POINT where it passes through a roof of a building

and AT LEAST ꢉ FEET HIGHER than ANY PORTION OF A

BUILDING WITHIN A HORIZONTAL DISTANCE OF ꢅꢈ FEET.

A chimney or vent must not extend less than the

distances stated above.

system.

b. 6ISUALLY INSPECT THE VENTING SYSTEM for proper

size and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion or other

deﬁciencies which could cause an unsafe condi-

tion.

c. 4EST VENT SYSTEM — Insofar as is practical, close all

building doors and windows and all doors between

the space in which the appliances remaining con-

nected to the common venting system are located

and other spaces of the building. Turn on clothes

dryers and any appliance not connected to the com-

mon venting system. Turn on any exhaust fans, such

as range hoods and bathroom exhausts, so they will

OPERATE AT MAXIMUM SPEEDꢀ $O NOT OPERATE A SUM-

MER EXHAUST FANꢀ #LOSE lREPLACE DAMPERSꢀ

3. A lined chimney is preferred and must be used when

required by local, state, provincial and national

CODESꢁ LAWSꢁ REGULATIONS AND ORDINANCESꢀ 6ITREOUS TILE

linings with joints that prevent retention of moisture

and linings made of noncorrosive materials are best.

Advice for ﬂue connections and chimney linings can

be obtained from local gas utility. 4YPE " double-

wall metal vent pipe or single-wall vent pipe may

be used as a liner.

d. 0LACE IN OPERATION the appliance being inspected.

Follow the lighting/operating instructions. Adjust

thermostat so appliance will operate continuously.

ꢈꢀ #OLD MASONRY CHIMNEYSꢁ ALSO KNOWN AS OUTSIDE

chimneys, typically have one or more walls ex-

posed to outside air. When any atmospheric gas-

ﬁred boiler with automatic vent damper is vented

through this type of chimney, the potential exists for

CONDENSATION TO OCCURꢀ #ONDENSATION CAN DAMAGE

a masonry chimney. Weil-McLain recommends the

following to prevent possible damage.

e. 4EST FOR SPILLAGE at draft hood relief opening after

5 minutes of main burner operation. Use the ﬂame

of a match or candle.

f. After it has been determined that EACH APPLIANCE

remaining connected to the common venting system

properly vents when tested as outlined above, return

doors, windows, exhaust fans, ﬁreplace dampers,

and any other gas-burning appliance to their previ-

ous conditions of use.

a. Line chimney with corrosion-resistant metal

LINER SUCH AS !,ꢄꢉꢂꢈ#® SINGLEꢂWALL STAINLESS

STEEL OR "ꢂVENTꢀ 3IZE LINER PER .ATIONAL &UEL

'AS #ODE !.3) :ꢄꢄꢅꢀꢆꢂLATEST EDITIONꢀ

Any improper operation of common venting system

should be corrected so the installation conforms with

THE .ATIONAL &UEL 'AS #ODEꢁ !.3) :ꢄꢄꢅꢀꢆꢂLATEST EDITIONꢀ

#ORRECT BY RESIZING TO APPROACH THE MINIMUM SIZE AS

determined using the appropriate tables in Part 11 of

THAT CODEꢀ #ANADIAN INSTALLATIONS MUST COMPLY WITH

"ꢆꢈꢉꢀꢆ OR "ꢆꢈꢉꢀꢄ )NSTALLATION #ODEꢀ

b. Provide drain trap to remove any condensate.

5. Where two or more gas appliances vent into a

common chimney or vent, equivalent area should

be AT LEAST EQUAL to area of vent outlet on largest

appliance PLUS ꢊꢈ PERCENT of vent outlet area on

additional appliance.

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GOLD CGa Gas-Fired Water Boiler — Boiler Manual

Prepare boiler location — air contamination

Please review the following information on potential Refer to 4ABLE ꢅ for products and areas which may cause

combustion air contamination problems.

contaminated combustion air.

To prevent potential of severe personal injury or death, check for products or areas listed

below before installing boiler. If any of these contaminants are found:

s REMOVE CONTAMINANTS PERMANENTLY

— OR —

s ISOLATE BOILER AND PROVIDE OUTSIDE COMBUSTION AIRꢀ 3EE NATIONALꢁ PROVINCIAL OR LOCAL CODES

for further information.

4ABLE ꢅ Corrosive contaminants and likely locations

Products to avoid

Areas likely to have contaminants

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Dry cleaning/laundry areas and establishments

Swimming pools

Chlorinated waxes/cleaners

Metal fabrication plants

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Paint or varnish removers

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning

solvents found in household laundry rooms

Garages with workshops

Adhesives used to fasten building products and

other similar products

Buildings under construction (where air is

contaminated with particulates)

Airborne particulates (drywall dust, fiberglass

particles, road or gravel dust, lint, etc.)

ꢉ

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Prepare boiler location — air openings

#OMBUSTION AIR OPENING LOCATION AND SIZING

REQUIREMENTS DEPEND ON THE CLEARANCES AROUND

THE BOILERꢂ #HECK THE BOILER PLACEMENT COMPARED

to Figure 1a, page 7.

)F ALL CLEARANCES ARE AT LEAST EQUAL TO &IGURE ꢅAꢄ

PAGE ꢍ, apply the sizing and placement of openings

given on pages 10 and 11.

)F !.9 CLEARANCE IS LESS THAN &IGURE ꢅAꢄ PAGE ꢍ,

you must provide air openings sized and located as

shown in Figure 1b, page 7. $/ ./4 apply the sizing

and location information shown on page 10 or 11.

Air openings must be provided

#OMBUSTION AIR AND VENTILATION OPENINGS MUST COMPLY THE .ATIONAL &UEL

'AS #ODE !.3) :ꢄꢄꢅꢀꢆꢂLATEST EDITIONꢁ OR APPLICABLE LOCAL BUILDING CODESꢀ

#ANADIAN INSTALLATIONS MUST COMPLY WITH "ꢆꢈꢉꢀꢆ OR "ꢆꢈꢉꢀꢄ )NSTALLATION

#ODESꢀ

Provide adequate combustion and ventilation air to

assure proper combustion and reduce the risk of severe

personal injury, death or substantial property damage

caused by flue gas spillage and carbon monoxide

emissions.

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Unusually tight construction

FREE AREA of openings — the minimum areas

5NUSUALLY TIGHT CONSTRUCTION MEANS ꢋPER !.3) :ꢄꢄꢅꢀꢆ

given in this manual are free area (equals the area,

buildings in which:

length times width of opening, after deduction for

louver obstruction).

a. Walls and ceilings exposed to the outside atmo-

sphere have a continuous water vapor retarder with

a rating of 1 perm or less with openings gasketed,

and . . .

b. Weather-stripping has been added on openable

windows and doors, and . . .

Cꢀ #AULKING OR SEALANTS ARE APPLIED TO AREAS SUCH AS

joints around windows and door frames, between

sole plates and ﬂoors, between wall-ceiling joints,

between wall panels, at penetrations for plumbing,

electrical, and gas lines, and in other openings.

Use the free area information provided by the louver manufacturer.

When this information is not available, assume:

7OOD LOUVERS ˆ ASSUME FREE AREA IS ꢄꢌꢍ OF TOTALꢎ SO THE ACTUAL AREA

of each opening with wood louvers would be 5 times the required

free area.

-ETAL LOUVERS ˆ ASSUME FREE AREA IS ꢏꢌꢍ OF ACTUAL AREAꢎ SOꢁ FOR WOOD

louvers, the actual area of each opening must be 1.67 times the

required free area.

For such construction cases, if appliances use inside air

for combustion, PROVIDE AIR OPENINGS INTO THE BUILDING

FROM OUTSIDE. Size and locate these openings per the

appropriate case in &IGURE ꢌꢄ ꢎ OR ꢊ on page 10.

Single air opening option

A single combustion air opening can be used in lieu of the two-opening

options on page 10, provided:

Clearances from boiler to walls

4HE BOILER MUST HAVE CLEARANCES OF AT LEAST THOSE SHOWN IN &IGURE ꢆAꢁ

page 7.

Exhaust fans and air movers

Opening must be directly to outside

The appliance space must never be under a negative

pressure, even if the appliance(s) are installed as direct

vent. Always provide air openings sized not only to the

dimensions required for the ﬁring rate of all appli-

ances, but also to handle the air movement rate of the

exhaust fans or air movers using air from the building

or space.

4HE OPENING MUST CONNECT DIRECTLY TO THE OUTDOORS OR TO A SPACE THAT

communicates directly to the outdoors (not to an interior space).

4HE AIR CAN BE PROVIDED THROUGH A DIRECT OPENING OR THROUGH A HORIZONTAL

or vertical duct.

Opening placement

4HE TOP OF THE AIR OPENING MUST BE WITHIN ꢆꢄ INCHES OF THE CEILINGꢀ

Opening size

Motorized air dampers

4HE FREE AREA OF THE OPENING MUST BE AT LEAST EQUAL TO THE SUM OF THE

area of all equipment vent connectors in the space, and . . .

If the air openings are ﬁtted with motorized dampers,

electrically interlock the damper to:

4HE FREE AREA OF THE OPENING MUST BE AT LEAST ꢆ SQUARE INCH PER ꢅꢁꢌꢌꢌ

"TUꢃHR INPUT RATING OF ALL EQUIPMENT LOCATED IN THE SPACEꢀ

0REVENT THE BOILER FROM lRING IF THE DAMPER IS NOT

fully open.

Exception for large spaces

3HUT THE BOILER DOWN SHOULD THE DAMPER CLOSE DUR-

ing boiler operation.

.O COMBUSTION AIR OPENINGS ARE NEEDED WHEN THE BOILER ꢋAND OTHER AP-

pliances) are installed in a space with a volume AT LEAST ꢊꢈ CUBIC FEET PER

ꢅꢄꢈꢈꢈ "TUH of all installed appliances, provided:

To accomplish this interlock, wire an ISOLATED CONTACT

(proving the damper open) in series with the thermo-

stat input to the boiler. The boiler will not start if this

contact is open, and will shut down should it open

during operation.

THE BUILDING MUST NOT HAVE UNUSUALLY TIGHT CONSTRUCTION (see deﬁni-

tion, this page)

ALL CLEARANCES AROUND THE BOILER MUST MUST BE NO LESS THAN SHOWN IN

Figure 1a, page 7.

To determine if the space is large enough to qualify:

!DD THE TOTAL INPUT OF ALL APPLIANCES IN -"( ꢋꢆꢁꢌꢌꢌꢐS OF "TUH ꢀ

-ULTIPLY THIS NUMBER TIMES ꢑꢌ TO DETERMINE MINIMUM ROOM VOLUMEꢀ

%XAMPLEꢇ &OR A TOTAL INPUT OF ꢆꢌꢌ -"( ꢋꢆꢌꢌꢁꢌꢌꢌ "TUH ꢁ MINIMUM

volume is 50 x 100 = 5,000 cubic feet. At a ceiling height of 8 feet, the

space must have at least 5,000 ÷ 8 = 625 square feet (25 feet x 25 feet,

for instance).

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GOLD CGa Gas-Fired Water Boiler — Boiler Manual

Prepare boiler — placement and setup

#ORRECTLYꢂSIZED MANIFOLD ORIFICES

Place boiler/crate near

position

must be used. Failure to do so will

result in severe personal injury,

death or substantial property dam-

age.

1. ,EAVE BOILER IN CRATE AND ON PALLET until installa-

tion site is ready.

2. Move entire crate and pallet next to selected loca-

tion.

3. Level and straighten burners.

"URNERS 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 dam-

age.

3. Remove crate. ,EAVE BOILER ON PALLETꢂ

4. 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 backwards off pallet and into posi-

tion.

$O NOT DROP BOILER OR BUMP JACKET

ON mOOR OR PALLETꢀ $AMAGE TO BOILER

can result.

4. Reinstall access panel.

$O NOT OPERATE BOILER WITHOUT AC-

cess panel secured in place. Failure

to comply could cause momentary

ﬂame rollout on ignition of main

ﬂame, resulting in possible ﬁre or

personal injury hazard.

ꢑꢀ #HECK LEVELꢀ

a. Shim legs, if necessary.

Bꢀ $O NOT ALTER LEGSꢀ

Inspect oriﬁces and burners

1. Remove front jacket door. Remove base access panel

(See &IGURE ꢌꢉ, item ꢎ, page 62).

Oriﬁce replacement procedure

ꢄꢀ #HECK FOR CORRECTLYꢂSIZED MANIFOLD ORIlCESꢀ 3EE

4ABLE ꢉ below for sizing. (The oriﬁce size is stamped

on the oriﬁce spud barrel.)

(when required)

1. Remove access panel.

2. On gas manifold, mark location of main burner with

attached pilot assembly.

4ABLE ꢉ Manifold oriﬁce sizing

Location

U. S.

Natural gas

3. Remove main burner with attached pilot assembly

from manifold. Remove all remaining burners.

0-2,000 ft

over 2,000 ft

(Note 1)

4. Remove and discard all main burner oriﬁces in gas

manifold.

2.00 mm

0-2,000 ft

2.00 mm

Canada

2,000-4,500

1.90 mm

5. Apply a small amount of pipe dope to each of the

new oriﬁces and install in the manifold. Make sure

the oriﬁces are aligned correctly, not cross-threaded

in the manifold tappings.

Location

U. S.

Propane gas

Use only pipe dope compatible with

propane gas, even if boiler is to be

operated on natural gas. Failure to

comply could result in severe per-

sonal injury, death or substantial

property damage.

0-2,000 ft

1.30 mm

0-2,000 ft

1.30 mm

over 2,000 ft

(Note 1)

Canada

2,000-4,500

1.20 mm

6. Reinstall main burner with attached pilot assembly

at location marked on gas manifold. Reinstall all

remaining burners.

Note 1: For elevations above 2,000 feet, contact your

local Weil-McLain sales office for details.

7. Follow check-out procedure, Section ꢍ, page 33.

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Prepare boiler — pressure test

ꢈꢀ #LOSE SHUTOFF VALVESꢀ

5. Slowly reopen boiler drain valve until test pressure

Hydrostatic pressure test

Pressure test boiler BEFORE attaching water or gas piping

of not more than 45 psi is reached on the pressure/

or electrical supply (except as noted below).

temperature gauge.

6. Test at no more than ꢎꢊ PSI FOR NO MORE THAN ꢅꢈ

Prepare boiler for test

MINUTESꢂ

ꢆꢀ 2EMOVE THE SHIPPING NIPPLE ꢋFROM #'A SUPPLY

tapping) and remove the boiler relief valve. 4EMPOꢀ

RARILY PLUG THE RELIEF VALVE TAPPING WITH A Ðv .04

pipe plug.

$O NOT LEAVE BOILER UNATTENDED.

A cold water ﬁll could expand and

cause excessive pressure, resulting

in severe personal injury, death or

substantial property damage.

ꢄꢀ 2EMOVE ꢆv NIPPLEꢁ REDUCING TEE AND DRAIN VALVE

from accessory bag. Install in boiler return con-

nection as shown on page 3 or in &IGURE ꢌꢎ, item

3, page 64. Install circulator on either the return or

supply.

7. Make sure constant gauge pressure has been main-

TAINED THROUGHOUT TESTꢀ #HECK FOR LEAKSꢀ 2EPAIR IF

found.

ꢅꢀ 2EMOVE ꢆv NIPPLEꢁ ꢆv TEEꢁ BUSHING AND PRES-

sure/temperature gauge from accessory bag. Pipe

to boiler supply connection as shown in &IGURE ꢌꢎ,

page 64. (Use pipe dope sparingly.)

,EAKS MUST BE REPAIRED AT ONCE.

Failure to do so can damage boiler,

resulting in substantial property

damage.

ꢈꢀ #ONNECT A HOSE TO BOILER DRAIN VALVEꢁ THE OTHER END

connected to a fresh water supply. Make sure hose

can also be used to drain boiler after test.

$O NOT USE PETROLEUMꢀBASED clean-

ing or sealing compounds in boiler

system. Severe damage to boiler

will occur, resulting in substantial

property damage.

ꢑꢀ #ONNECT A NIPPLE AND SHUTOFF VALVE TO SYSTEM SUPPLY

CONNECTION ON THE ꢆv TEEꢀ 4HIS VALVE WILL BE USED

TO BLEED AIR DURING THE lLLꢀ ꢋ6ALVE AND NIPPLE ARE

not included with boiler.)

ꢏꢀ #ONNECT A NIPPLE AND SHUTOFF VALVE TO SYSTEM

return connection (at circulator ﬂange if circula-

tor installed on return). This valve will be used to

BLEED AIR DURING THE lLLꢀ ꢋ6ALVE AND NIPPLE ARE NOT

included with boiler.)

Drain and remove ﬁttings

ꢆꢀ $ISCONNECT lLL WATER HOSE FROM WATER SOURCEꢀ

ꢄꢀ $RAIN BOILER AT DRAIN VALVE OR OUT HOSEꢁ WHICHEVER

provides best access to drain. Remove hose after

draining if used to drain boiler.

Fill and pressure test

1. Open the shutoff valves you installed on supply and

return connections.

3. Remove nipples and valves unless they will remain

for use in the system piping.

2. Slowly open boiler drain valve and fresh water sup-

ply to ﬁll boiler with water.

4. Remove plug from relief valve tapping. See Section ꢌ

3. When water ﬂows from shutoff valves, close boiler

drain valve.

to replace relief valve.

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Prepare boiler — draft hood & spill switch

Draft hood installation

1. Orient draft hood with spill switch mounting holes to front of boiler

as shown in Figure 7.

Spill switch installation

1. Fasten spill switch to draft hood as shown in &IGURE ꢇ

and &IGURE ꢍ.

2. See Wiring diagram to connect wires:

2. Secure draft hood to outlet at top of boiler with sheet metal screws.

a. Standing pilot boiler — see PAGE ꢌꢎ.

ꢅꢀ "OTTOM OF DRAFT HOOD OR hSKIRTv MUST HAVE CLEARANCE DIMENSION ABOVE

b. Spark-ignited pilot boiler —

jacket top panel as indicated on draft hood.

see PAGES ꢌꢋ and ꢌꢏ.

$O NOT ALTER BOILER DRAFT HOOD OR PLACE ANY OBSTRUCTION OR

non-approved vent damper in breeching or vent system.

#3! CERTIlCATION WILL BECOME VOIDꢀ &LUE GAS SPILLAGE AND

carbon monoxide emissions will occur causing severe

personal injury or death.

Improper orientation of spill switch

may cause boiler to shut down. The

loss of heat can result in signiﬁcant

damage due to freezing.

Prepare boiler — install vent piping

ꢆꢀ #ONNECT FROM DRAFT HOOD OR VENT DAMPER OUTLET TO CHIMNEY OR VENT

with same size vent connector.

Long horizontal vent connector,

excessive number of elbow or

tees, or other obstructions that

restrict the ﬂow of combustion

gases should be avoided. Severe

personal injury, death or sub-

stantial property damage could

result.

2. Where possible, vertical venting to the outside from the draft hood or

vent damper outlet will offer best performance.

ꢅꢀ 7HERE HORIZONTAL VENT CONNECTOR IS USEDꢁ SLOPE UPWARD AT LEAST v PER

lineal foot toward chimney or vent and support with hangers to prevent

sagging.

ꢈꢀ "REECHING MUST NOT be connected to any portion of a mechanical draft

system that can operate under positive pressure.

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Prepare boiler — vent damper installation

These systems are used on gas-ﬁred boilers with vent

Installation

DAMPERS AS SHIPPED FROM FACTORYꢀ "OILER WILL NOT OPERATE

without vent damper installed.

1. Install vent damper horizontally or vertically as

shown in vent damper manufacturer’s instructions.

Only vent dampers listed in the Replacement parts list

ON PAGE ꢏꢆ ARE CERTIlED FOR USE WITH #'A BOILERSꢀ !NY

other vent damper installed could cause severe personal

injury or death.

6ENT DAMPER MUST BE INSTALLED SO THAT IT SERVES ONLY

one boiler and so damper blade indicator is visible

to the user. See &IGURE ꢋ.

2. Screws or rivets used to secure the vent damper to

the draft hood must not interfere with rotation of

Damper blade

the damper blade.

3TANDING PILOT IGNITION SYSTEMSˆ Refer to vent

3. Install damper harness between damper actuator

manufacturer’s instructions to install plug (shipped

and knockout in jacket top panel. Use strain relief

with damper) in damper hole. For standing pilot boil-

connectors and locknuts to secure both ends of

damper harness.

ꢌ

ers only, install PLUG WITH /_ꢋv DIAMETER HOLE in vent

damper hole.

3PARKꢀIGNITED PILOT SYSTEMSˆ Refer to vent man-

ufacturer’s instructions to install plug (shipped with

damper) in damper hole. For spark-ignited pilot boilers

only, install PLUG WITH NO HOLE in vent damper hole.

Keep wiring harness clear of all hot

surfaces.

Minimum clearances

0ROVIDE A MINIMUM OF ꢏv BETWEEN THE VENT DAMPER AND

any combustible material. (Provide a minimum of 36 "

between jacket top and combustible ceiling.)

$O NOT modify draft hood or vent damper, or make an-

other connection between draft hood and vent damper

OR BOILER EXCEPT AS NOTED BELOWꢀ 4HIS WILL VOID #3!

certiﬁcation and will not be covered by Weil-McLain

warranty. Any changes will cause severe personal injury,

death or substantial property damage.

4. Read and apply the harness plug warning label

(shown above) so that it is visible after installa-

tion.

Figure 8 Vent damper assemblies

5. Plug damper harness receptacle into damper harness

plug.

"YPASSING ꢋJUMPERING VENT DAMPER

will cause flue products such as

carbon monoxide to escape into

the house. This will cause severe

personal injury or death.

After boiler has operated once, if ei-

ther end of harness is disconnected,

the system safety shutdown will oc-

cur. The boiler will not operate until

harness is reconnected.

%FlKAL OR &IELD #ONTROLS DAMPER—

$AMPER HOLD OPEN SWITCH MUST BE

in !UTOMATIC /PERATION position

for system to operate properly.

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Water piping — general information

General piping information

Circulator

)F INSTALLATION IS TO COMPLY WITH !3-% OR #ANADIAN REQUIREMENTSꢁ AN AD- The circulator is shipped loose (wiring pre-attached to

ditional HIGH TEMPERATURE LIMIT is needed. Install control in supply piping boiler) to allow you to locate it either in the return or

between boiler and isolation valve. Set second control to minimum 20°F supply piping, as desired. See page 3 for a typical instal-

above setpoint of ﬁrst control. Maximum allowable setpoint is 240°F. See lation. Pipe the expansion tank to the suction side of the

page 34 or 38, for wiring.

circulator whenever possible. Install an air separator in

THE SUPPLY PIPINGꢀ #ONNECT THE EXPANSION TANK TO THE AIR

separator only if the separator is on the suction side of

the circulator. Always install the system ﬁll connection

at the same point as the expansion tank connection to

the system. &IGURES ꢏ and ꢅꢈ show typical near-boiler

piping connections.

A LOW WATER CUTOFF DEVICE is required when boiler is installed above ra-

diation level or by certain state or local codes or insurance companies. Use

low water cutoff designed for water installations. Electrode probe-type is

recommended. Purchase and install in tee in supply piping above boiler.

Use BACKmOW CHECK VALVE in cold water supply as required by local

codes.

System water piping

Pressure/temperature gauge

Install pressure/temperature gauge in tee on supply piping (as shown in

drawing on page 3).

See &IGURE ꢏ (diaphragm-type or bladder-type expan-

sion tank) or &IGURE ꢅꢈ (closed-type expansion tank),

and 4ABLE ꢌ below, for near-boiler and single-zone

systems designed for return water at least 130°F.

3EE PAGES ꢆꢒꢂꢆꢉ TO COMPLETE MULTIPLEꢂZONE PIPING OR

pages 20-25 to complete piping for radiant heating

systems or converted gravity systems (large-volume

systems originally designed for circulation by natural

convection rather than a pump). See page 25 for boilers

used with refrigeration systems.

Relief valve

)NSTALL RELIEF VALVE VERTICALLY IN Ðv TAPPING ON SIDE OF BOILERꢀ 3EE &IGURE ꢏ

OR ꢅꢈ, page 17, and the tag attached to the relief valve for manufacturer’s

instructions.

Table 3 Water pipe size (based on 20°F rise)

To avoid water damage or scalding due to relief valve

operation:

Boiler model

From

system

$ISCHARGE LINE MUST BE CONNECTED TO RELIEF VALVE OUTLET AND RUN TO A

SAFE PLACE OF DISPOSAL. Terminate the discharge line to eliminate

possibility of severe burns should the valve discharge.

CGa-25

CGa-3, 4, 5

CGa-6, 7

CGa-8

¾"

$ISCHARGE LINE MUST BE AS SHORT AS POSSIBLE AND BE THE SAME SIZE AS

THE VALVE DISCHARGE CONNECTION throughout its entire length.

1 ¼"

1 ½"

1 ¼"

1 ½"

$ISCHARGE LINE MUST PITCH DOWNWARD from the valve and terminate

AT LEAST ꢏv ABOVE THE mOOR DRAIN WHERE ANY DISCHARGE WILL BE CLEARLY

visible.

Note: The boiler supply and return connections, the return/

drain tee and the supply/gauge tee supplied with the

boiler are 1¼” NPT. One of the circulator flanges sup-

plied with the boiler is 1¼”. The other circulator flange

is the size of the recommended system piping shown

above.

4HE DISCHARGE LINE SHALL TERMINATE PLAINꢄ NOT THREADED, with a mate-

rial serviceable for temperatures of 375°F or greater.

$O NOT PIPE THE DISCHARGE TO ANY PLACE WHERE FREEZING COULD

OCCURꢂ

#HILLERS OR AIR HANDLING UNITS:

Install boiler such that —

.O SHUTOFF VALVE shall be installed between the relief valve and boiler,

OR IN THE DISCHARGE LINEꢀ $O NOT PLUG OR PLACE ANY OBSTRUCTION IN THE

discharge line.

#HILLED MEDIUMꢁ IF USEDꢁ IS PIPED IN PARALLEL WITH

heating boiler. Use appropriate valves to prevent

CHILLED MEDIUM FROM ENTERING BOILERꢀ #ONSULT

)ꢓ"ꢓ2 )NSTALLATION AND 0IPING 'UIDESꢀ

)F BOILER IS CONNECTED TO HEATING COILS LOCATED IN

air handling units where they can be exposed to

refrigerated air, use ﬂow control valves or other au-

tomatic means to prevent gravity circulation during

COOLING CYCLEꢀ #IRCULATION OF COLD WATER THROUGH THE

boiler could result in damage to the heat exchanger,

causing possible severe personal injury, death or

substantial property damage.

&AILURE TO COMPLY with the above guidelines could result in failure of

the relief valve to operate, resulting in possibility of severe personal

injury, death or substantial property damage.

4EST THE OPERATION OF THE VALVE after ﬁlling and pressurizing system

by lifting the lever. Make sure the valve discharges freely. If the valve

fails to operate correctly, replace it with a new relief valve.

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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 bladder-

type expansion tank (Figure 9)

Closed-type expansion tank

(Figure 10)

1. Ensure expansion tank size will handle boiler and

system water volume and temperature. See tank

manufacturer’s instructions for details.

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. See tank ꢄꢀ #ONNECT TANK TO v .04 TAPPING LOCATED BEHIND

manufacturer’s instructions for details.

SUPPLY OUTLETꢁ USING v .04 PIPINGꢀ 0ITCH ANY

horizontal piping up towards tank 1 inch per 5 feet

of piping.

2. Install an AUTOMATIC AIR VENT as shown.

Use &IGURE ꢏ or &IGURE ꢅꢈ only for single-zone systems designed for RETURN WATER AT LEAST

ꢅꢌꢈ—&ꢂ For systems with low return water temperature possible, such as converted gravity

systems and radiant heating systems, refer to the special piping suggestions of pages 20-25.

Failure to prevent low return water temperature to the boiler could cause corrosion of the

boiler sections or burners, resulting in severe personal injury, death or substantial property

damage.

&IGURE ꢏ

Diaphragm- or bladder-type expansion

tank — Single-zone system using dia-

phragm-type or bladder-type expansion

tank. See Table 3 for piping sizes.

&IGURE ꢅꢈ

Closed-type expansion tank — Single-

zone system using closed-type expan-

sion tank. See Table 3 for piping sizes.

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Water piping — multiple zones

Piping multiple zones

Piping for radiant heating

Follow instructions on pages 16 and 17 to install near-

boiler or single-zone piping. (Also refer to 0IPING FOR

RADIANT HEATING SYSTEMS OR CONVERTED GRAVITY SYSꢀ

TEMSꢄ below, if applicable.)

systems or converted gravity

systems

Converted gravity (or steam) systems

See &IGURE ꢅꢅ or &IGURE ꢅꢉꢁ PAGE ꢆꢉꢁ TO COMPLETE IN-

stallation.

Whenever possible, use the primary/secondary piping

shown in &IGURES ꢅꢌ or ꢅꢎ on page 21. This piping de-

sign allows changing boiler ﬂow rate without affecting

primary circuit ﬂow rate.

Zoning with circulators (Figure 11)

(return temp over 130°F)

1. Size each circulator to individual circuit require-

ments.

If &IGURES ꢅꢌ or ꢅꢎ cannot be used, use the boiler-bypass

piping shown in &IGURE ꢅꢊ or &IGURE ꢅꢇ ON PAGE ꢄꢅꢀ 9OU

can also use the piping shown in &IGURE ꢅꢍ on page 25

(system-bypass), if the reduced ﬂow rate in the heating

system will not cause heat distribution problems.

ꢄꢀ $O NOT INSTALL CIRCULATOR ON BOILER ꢋEXCEPT FOR PRI-

mary/secondary piping).

Failure to prevent low return water

temperature to the boiler could

cause corrosion of the boiler sec-

tions or burners, resulting in severe

personal injury, death or substantial

property damage.

3. Install isolation (balancing) valves to adjust ﬂow to

distribute heat to all zones.

4. Install and wire a separate relay for each zone cir-

culator.

Zoning with zone valves (Figure 12)

(return temp over 130°F)

1. Install isolation (balancing) valves to adjust ﬂow to

distribute heat to all zones.

Radiant heating systems

Preferably, use primary/secondary piping, as shown

in &IGURES ꢅꢌ or ꢅꢎ on page 21. Alternatively, use the

method of either &IGURE ꢅꢊ or &IGURE ꢅꢇ on page 23.

$O NOT USE THE PIPING OF &IGURE ꢅꢍ (system-bypass),

because this method does not control radiant system

supply temperature.

2. Provide a separate 24-volt transformer to power the

zone valves. Size the transformer to handle the total

rated load of all connected zone valves.

If radiant system tubing has no oxygen barrier, a HEAT

EXCHANGER must be used.

Radiant heating system piping should include a means of regulating the boiler return water

temperature and the system supply temperature (such as provided by an injection pumping

CONTROL ꢀ "OILER RETURN WATER TEMPERATURE WILL BE ADEQUATELY CONTROLLED USING THE METHODS

shown in this manual provided the system supply temperature is relatively constant.

$/ ./4 apply the methods in this manual if the system is equipped with an OUTDOOR RESET

CONTROL. Instead, provide controls and piping which can regulate the boiler return water

TEMPERATURE AT NO LESS THAN ꢆꢅꢌ—& REGARDLESS OF SYSTEM SUPPLY TEMPERATUREꢀ #ONTACT YOUR

Weil-McLain representative for suggested piping and control methods. Failure to prevent

cold return water temperature to the boiler could cause corrosion damage to the sections

or burners, resulting in possible severe personal injury, death or substantial property dam-

age.

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Water piping — multiple zones

(continued)

For systems with possible low return-water temperature (such as converted gravity systems,

radiant heating systems and heat pump systems), refer to the special piping suggestions of

&IGURES ꢅꢌ n ꢅꢍ, as applies. Failure to prevent sustained low return water temperature to

the boiler could cause corrosion of the boiler sections, resulting in severe personal injury,

death or substantial property damage.

ꢆꢉ

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Piping — low temperature systems

the water temperature being supplied to the radiant

tubing.

Primary/secondary (preferred)

Bypass piping method

'AUGE ꢋ is REQUIRED on all systems to assure the return

water temperature is accurately set for a minimum of

130°F. If this gauge is not available however, adjust the

valves such that the boiler-mounted temperature/pres-

sure gauge reads at least 150°F when the system return

water is cold (approximately 60°F water temperature).

0RIMARYꢁSECONDARY 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.

Figures 13 and 14, page 21, show suggested bypass

arrangements using PRIMARYꢁSECONDARY bypass piping

(preferred) for low temperature systems such as RADIANT

HEATING SYSTEMS or CONVERTED GRAVITY SYSTEMS. For

alternatives, see pages 22 through 25.

Valve adjustment

(Figures 13 and 14 only)

1. Set the valves while the system is cool, setting for the

coldest expected water temperature (usually 60°F

since the system will often drop to room tempera-

ture between cycles).

The bypass valves (items ꢍA and ꢍB) provide mixing of

hot boiler outlet water with cooler system return water

— set to assure a minimum return water temperature

(at least 130°F) to the boiler. Set the valves as explained

below.

2. Start with valve ꢍA fully closed and ꢍB fully open.

ꢅꢀ 'RADUALLY OPEN VALVE ꢍA while closing valve ꢍB until

the temperature at gauge ꢋ reads 130°F when gauge

ꢎA reads 60°F.

Temperature gauges

ꢈꢀ .OTE THAT VALVE ꢍA regulates the amount of hot wa-

ter from the boiler supply which mixes with return

WATERꢀ 6ALVE ꢍB regulates the amount of system water

ﬂowing through the boiler secondary loop.

'AUGE ꢎA is suggested, but optional on any system.

'AUGE ꢎB is optional on converted gravity systems,

but REQUIRED on radiant heating systems — to display

Failure to PREVENT LOW RETURN WATER TEMPERATURE to the boiler could cause corrosion of

the boiler sections or burners, resulting in severe personal injury, death or substantial

property damage.

Radiant heating system piping should include a means of REGULATING THE BOILER RETURN

WATER TEMPERATURE and the SYSTEM SUPPLY TEMPERATURE (such as provided by an INJECꢀ

TION PUMPING CONTROL).

"OILER RETURN WATER TEMPERATURE WILL BE ADEQUATELY CONTROLLED USING THE METHODS SHOWN

in this manual provided the SYSTEM SUPPLY TEMPERATURE is RELATIVELY CONSTANTꢂ

DO NOT apply the methods of this manual if the system is equipped with an OUTDOOR

RESET CONTROLꢂ Instead, PROVIDE CONTROLS AND PIPING which can REGULATE THE BOILER REꢀ

TURN WATER TEMPERATURE at NO LESS THAN ꢅꢌꢈ—& regardless of system supply temperature.

#ONTACT YOUR 7EILꢂ-C,AIN REPRESENTATIVE FOR SUGGESTED PIPING AND CONTROL METHODSꢀ

Failure to PREVENT COLD RETURN WATER TEMPERATURE to the boiler could cause corrosion

damage to the sections or burners, resulting in possible severe personal injury, death or

substantial property damage.

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Piping — low temperature systems

(continued)

10 Automatic air vent (with diaphragm-type expansion

tank), or connect to tank ﬁtting (closed-type expan-

sion tank). DO NOT use an automatic air vent when

using closed-type expansion tank. It would allow

air to leave the system, causing waterlogging of the

expansion tank.

"OILER ISOLATION ꢋBALANCING VALVES

Flow/check valve

System or zone circulator (circulator should cycle

with zone valve and switches, using circulator valve

or zone control panel)

11 Fill valve

System temperature gauges

:ONE VALVE

12 $IAPHRAGMꢂTYPE OR BLADDERꢂTYPE EXPANSION TANKꢁ

if used (For closed-type expansion tank, pipe from

top of air separator to tank ﬁtting as in &IGURE ꢅꢈ,

page 17.)

$RAIN VALVE

System temperature valves (see instructions to the

left for adjusting valves)

13 !IR SEPARATOR AND AUTOMATIC VENTꢁ IF USED ꢋ.OTE THAT

the ﬁll valve must always be connected to the expan-

sion tank, regardless of location of expansion tank,

circulator or air separator.)

"LEND TEMPERATURE GAUGE

Relief valve

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Piping — low temperature systems

(continued)

to the boiler. (When setting the valves without gauge

ꢎA installed — using cold or room temperature water

— assume the return water temperature to be 60°F. Set

the valves so gauge ꢋ reads at least 120°F.

BOILER-bypass piping

method

This piping method (&IGURE ꢅꢊ or ꢅꢇ, page 23) is called

a BOILERꢀBYPASS because part of the circulator ﬂow is

bypassed around the boiler (through valve ꢍA). This

method reduces the ﬂow rate throughout the boiler, in

order to raise the average water temperature in the boiler

ENOUGH TO PREVENT mUE GAS CONDENSATIONꢀ "OILERꢂBYPASS

PIPING IS EFFECTIVE FOR SOME BOILERS ˆ INCLUDING THE #'A

— provided the ﬂow rates are adjusted according to the

instructions following.

'AUGE ꢎB is optional on converted gravity systems,

but REQUIRED on radiant heating systems — to display

the water temperature being supplied to the radiant

tubing.

'AUGE ꢋ is REQUIRED on all systems to assure reliable

adjustment of the bypass valves. The boiler-mounted

temperature/pressure gauge can be used if a separate

temperature gauge is not installed.

&IGURES ꢅꢊ and ꢅꢇ are alternative piping suggestions

for CONVERTED GRAVITY (large water content or steam

systems) or RADIANT HEATING SYSTEM — for use when

primary/secondary piping can’t be applied. (&IGURE ꢅꢍ,

page 25, is another alternative, using system bypass in

place of boiler-bypass piping. &IGURE ꢅꢍ however, is

not suitable for radiant heating applications because it

does not protect the radiant system from possible high

water temperature.)

Valve adjustment

1. Start with valve ꢍA fully closed and ꢍB fully open.

ꢄꢀ 'RADUALLY OPEN VALVE ꢍA while closing valve ꢍB

until the temperature at gauge ꢋ reads 60 °F higher

than gauge ꢎA. A minimum 60°F temperature rise

through the boiler assures a low enough ﬂow rate

and high enough average temperature to prevent

condensation even with low system return water

temperature.

"OILERꢂBYPASS PIPING KEEPS SYSTEM mOW RATE AS HIGH AS

possible and temperature drop as low as possible, help-

ing to equalize the building heat distribution.

ꢅꢀ 6ALVE ꢍA regulates the system ﬂow rate, while valve

ꢍB regulates the boiler ﬂow rate.

Temperature gauges

'AUGE ꢎA is optional if the bypass valves will be ad- 4. The boiler-mounted temperature/pressure gauge

justed using cold (or room temperature) return water may be used in place of a separate gauge ꢋ.