Install Instructions

CG i GAS-FIRED wATER BOILER- sERIEs a- Boiler Manual
4a Water piping - general information
General piping information
If installation is to co mply wi th ASME or Cana di an r eq uireme nt s, an ad -
ditional high temperat ure limit is needed Install control in su pp ly pipi ng
between boil er and isolation va l ve. Set second co ntr ol to mini nuu n 20•F
above se tp o int of first co n tro l. Maxi mm n allowable se tpoi nt is 240• F. See
Section 9b for wiring.
A l ow wate r cu to ff device is required when boiler is installed above ra-
diati on level or by certain state or local codes or ins ur an ce 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 c he ck valve in cold water supply as required by local codes.
Pressure/temperature gauge
Install pressure/temperature gauge in tee on supp ly piping (as shown in
drawing on page 3).
Isolation valves
Isolati on va lves are requir ed to enable servicing of the boiler's temperature
sensor. Install as shown in appropriate piping diagram.
Relief valve
Install relief valve vertically in W' tapp in g on side of bo iler. See Figure 16
or 17, page 21, and th e tag attach ed to the relief valve for manufacturer's
instruct i ons.
I& WARNIN G! To avoid water damage or scalding due to relief valve
. . operation:
20
Discharge line must be c01 mected to relief valve outlet and run to
a safe pla ce of dispo sal. Te rmi nat e the discharge li ne to eliminate
possibility
of severe burns should the valve disch ar ge.
Discharge line mu st be as sho rt as possible and be th e s ame size as
the valve dis c ha r ge c onnection throughout its entire length.
Discharge line must pitch downward from th e valve a nd ter mina te
at least 6" a bo ve th e fl oo r dr ain where any discharge will be clearly
visibl e.
Th e discharge line shall tennlnate plain, not threaded , with a ma te-
rial serviceable for temperatures of 375°F or greater.
Do not pipe the discharge to any place whe re freezing could
occu r.
No shutoff valve sha ll be installed between the reli ef valve a nd boiler,
or in th e discharge lin e. Do not plug or pl ace any obstruction in th e
discharge li ne.
Failure to comply with the above guidelines could result in fa ilure of
th e reli ef valve to operate, resulting in possibili ty of severe personal
injury,
death or substantial property damage.
Test the operation of the valve after filling and pr essur izi ng sy stem
by lifting th e lever. Make sure the val ve discharges freel y. If the valve
fails
to operate correctly, replace it with a new re li ef valve.
Circulator
The circulator is shipped loose (wiring pre-attached to
boiler) to allow you to locate it ei ther in th e re turn or
s up ply 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 on ly if the separator is on the suction side of
th e ci rc ul ator. Always in stall th e system fill cOJ mection
at the san1e point as the expa nsion tan k co nnection to
the system. Figures 16 and 17 show typical near -boiler
pipi ng connections.
System water piping
See Figure 16 (diaphragm-type or bladder-type expan-
sio n tank) or Figure 17 (closed-type expansion tank)
and Table 6, for near-boiler and single-zone systems
desi gned for return water at least 1300F.
See pages 22- 23 to co mplete multi pl e-zone pipi ng or
pages 24 -29 to co mpl ete pipi ng for rad iant heating
systems
or converted gravi ty systems (large-volume
systems originally
designed for circulation by na tu ral
co nvection rather than a pump). See page 29 for boilers
used wi
th refrigeration systems.
Table 6 Water pi
pe size (based on 20•F ri se)
Boiler To
F rom
model number system system
CGi-25 '14" '14"
CGi-3, 4, 5 1" 1"
CGi-6, 7
1 1/4" 1 1/4"
CGi..S 1'h" 1'h"
Note: The boi Ser supply and return oon nect i ~ the re tu rn!
drain lee and the s~yl¥,a~ l ee suppl1 ed wi th
th e boil er are 1 " ' N . ne Of the ci rc ul ator fl anges
suppli
ed wi th the boiler is 1l4 .. . The other ci rcu lator
fl ange is the size of th e recommended system pip in g
shown
above.
I& WARNING!
Chillers or air handling units :
Install boiler suc h that -
Chill
ed me dimn , if used, is pip ed in parallel wi th
heating boiler. Use appropr iate valves to prevent
chill ed medium from entering boiler. Consult AHRI
Installation a nd Pip in g Guides.
If bo il er is co nn ected to heating co ils l oca t ed in
air handling units where they can be exposed to
refrigerat ed air, use fl ow co nt ro l valves or o th er au-
tomatic mea ns to preve nt gravity circulatio n during
coo li ng cycle. Circulation of cold water through the
boiler could result in damage to the heat exchanger,
causi ng possible severe personal injury, death or
substantial property damage.
Part Nu m ber 550 - 142-7 80/ 07 12