Weil-McLain CGS-4E Boiler User Manual


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Part number 550-110-282/1108
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CGs-4E Gas-Fired Water Boiler — Boiler Manual
Water piping —
general information
3a
Table 3 Water pipe size (based on 20°F rise)
Boiler
model
number
To
system
From
system
CGs-4E
1” 1”
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
supplied with the boiler is 1¼”. The other circulator
flange is the size of the recommended system piping
shown above.
General piping information
IfinstallationistocomplywithASMEorCanadianrequirements,anad-
ditional high temperature limit is needed. Install control in supply piping
betweenboilerandisolationvalve.Setsecondcontroltominimum20°F
abovesetpointofrstcontrol.Maximumallowablesetpointis240°F.See
Section9b, page 34 for wiring.
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 backflow check valve in cold water supply as required by local
codes.
Pressure/temperature gauge
Install pressure/temperature gauge in tee on supply piping (as shown in
drawing on page 3).
Relief valve
Installreliefvalveverticallyin¾”tappingonsideofboiler.SeeFigure 4 or 5,
page 15, and the tag attached to the relief valve for manufacturer’s instructions.
Circulator
The circulator is shipped loose (wiring pre-attached to
boiler) to allow you to locate it either in the return or
supplypiping,asdesired.Seepage3foratypicalinstal-
lation. Pipe the expansion tank to the suction side of the
circulator whenever possible. Install an air separator in
thesupplypiping.Connecttheexpansiontanktotheair
separator only if the separator is on the suction side of
thecirculator.Alwaysinstallthesystemllconnection
at the same point as the expansion tank connection to
the system. Figures 4 and 5, page 15, show typical near-
boiler piping connections.
System water piping
SeeFigure 4 (diaphragm-type or bladder-type expan-
sion tank) or Figure 5 (closed-type expansion tank) on
page 15, and Table 3 below, for near-boiler and single-
zonesystemsdesignedforreturnwateratleast130°F.
Seepages16-17tocompletemultiple-zonepipingor
pages 18-23 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).
Chillers or air handling units:
Install boiler such that —
• Chilledmedium,ifused,ispipedinparallelwith
heating boiler. Use appropriate valves to prevent
chilled mediumfromenteringboiler.Consult
I=B=RInstallationandPipingGuides.
• If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cycle.Circulationofcoldwaterthroughthe
boiler could result in damage to the heat exchanger,
causing possible severe personal injury, death or
substantial property damage.
To avoid water damage or scalding due to relief valve
operation:
• Discharge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.
• Dischargelinemustbeasshortaspossibleandbethesame size as
the valve discharge connection
throughout its entire length.
• Dischargelinemustpitch downward from the valve and terminate
atleast6”abovetheoordrainwhereanydischargewillbeclearly
visible.
• Thedischargelineshallterminate plain, not threaded, with a mate-
rialserviceablefortemperaturesof375°Forgreater.
• Do not pipe the discharge to any place where freezing could
occur.
• No shutoff valve shall be installed between the relief valve and boiler,
orinthedischargeline.Donotplugorplaceanyobstructioninthe
discharge line.
• Failure 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.
• Test 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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