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GOLD CGs Gas-Fired Water Boiler How it works . . . Control module ① The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and inducer. When room thermostat calls for heat, the control module starts the system circulator and inducer. The control module runs the inducer long enough to purge the boiler flue passages, then opens the pilot valve and activates pilot ignition spark. The con
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GOLD CGs Gas-Fired Water Boiler Contents How it works .................................................................. 2–3 Hazard definitions.............................................................. 4 Please read before proceeding ......................................... 5 1. Prepare boiler location ............................................ 6–11 2. Prepare boiler......................................................... 12–13 3. Water piping.............................................
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Boiler Manual Please read before proceeding Installer User Read all instructions before • This manual is for use only by your qualified installing. Follow all instructions in heating installer/service technician. proper order to prevent personal • Please refer to the User’s Information Manual for injury or death. your reference. • We recommend regular service by a qualified • Also refer to CGs Venting Supplements. service technician, at least annually. • Consider piping and installation when det
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GOLD CGs Gas-Fired Water Boiler 1a Prepare boiler location — codes & checklist Installations must • Local, state, provincial, and national codes, laws, regulations and follow these codes: ordinances. • National Fuel Gas Code, ANSI Z223.1 – latest edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required. • National Electrical Code. • For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any loc
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Boiler Manual 1b Prepare boiler location — clearances Provide the following clearances: Flooring and foundation Flooring 1. Hot water pipes — at least ½" from combustible materials. The CGs boiler is approved for installation on 2. Recommended service clearances — See Figure 1. combustible flooring, but must never be installed on carpeting. 3. Minimum clearances for tight spaces — See Figure 2. Do not install boiler on carpeting even if foundation is used. Fire can Figure 1 Recommended clearance
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GOLD CGs Gas-Fired Water Boiler 1c Prepare boiler location — vent system appliance to their previous conditions of use. Removing from existing vent Any improper operation of common venting system Do not install the CGs into a should be corrected so the installation conforms with common vent with any other the National Fuel Gas Code, ANSI Z223.1 — latest appliance. This will cause flue gas edition. Correct by resizing to approach the minimum spillage or appliance malfunction, size as determined u
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Boiler Manual 1d Prepare boiler location — contamination Air contamination Please review the following information on potential Refer to Table 1 for products and areas which may cause combustion air contamination problems. contaminated combustion air. If the boiler is installed in any area likely to cause contamination, or if products which would contaminate the air cannot be removed, you must pipe combustion air to the boiler air intake. Contaminated combustion air will damage the boiler, resul
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GOLD CGs Gas-Fired Water Boiler 1e Prepare boiler location — air openings CGs combustion air options Louver allowance Using inside air — direct exhaust vent The free area of openings means the area after reduction for any installed louvers or grilles. Be sure The CGs boiler can use inside air if no contaminants to consider this reduction when sizing the air openings. are present in the boiler space. If contaminants are likely to be present, install the CGs boiler as a direct vent appliance, usin
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Boiler Manual Figure 3 Sizing air openings for CGs installations Room Air Openings Direct exhaust vent installation Direct vent installation (CGs using room air for combustion) (combustion air piped to CGs) Required area of the air openings given in this table are free area — after the correction for louver obstruction. (See Exception below.) Combustion Combustion air piping air piping Apply this table only to installations with Other Other clearances no smaller than those shown in appliances ap
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GOLD CGs Gas-Fired Water Boiler 2a Prepare boiler — placement & setup Place boiler/crate near position death or substantial property damage. 1. Leave boiler in crate and on pallet until installation site is ready. 3. Reinstall inlet air box top panel. Inlet air box top panel must be in 2. Move entire crate and pallet next to selected position during boiler operation. location. Failure to do so could result in severe personal injury, death or 3. Remove crate. substantial property damage. 4. Remov
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Boiler Manual 2b Prepare boiler — pressure test Perform hydrostatic pressure test Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply. Prepare boiler for test 1. Remove the shipping nipple (from CGs supply tapping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾" NPT pipe plug. 2. Remove 1¼" nipple, reducing tee and drain valve from accessory bag. Install in boiler return connection as shown on page 3 and F
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GOLD CGs Gas-Fired Water Boiler 3a Water piping — general information General piping information Circulator If installation is to comply with ASME or Canadian requirements, an The circulator is shipped loose (wiring pre-attached additional high temperature limit is needed. Install control in supply to boiler) to allow you to locate it either in the return piping between boiler and isolation valve. Set second control to minimum or supply piping, as desired. See page 3 for a typical 20 °F above se
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Boiler Manual 3b Water piping — single-zone system Expansion tank Closed-type expansion tank — Diaphragm-type or bladder-type Figure 5 expansion tank — Figure 4 1. Ensure expansion tank size will handle boiler and system water volume and temperature. See tank 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must manufacturer’s instructions for details. 2. Connect tank to ½" NPT tapping located behind be located in boiler return piping as close to boi
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GOLD CGs Gas-Fired Water Boiler 3c Water piping — multiple zones Piping multiple zones Follow instructions on pages 14 and 15 to install near-boiler or single-zone piping. (Also refer to Piping for radiant heating systems or converted gravity systems, below, if applicable.) See Figure 6 or Figure 7 to complete installation. Zoning with 1. Size each circulator to individual circuit requirements. circulators, return 2. Do not install circulator on boiler (except for primary/secondary piping). temp
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Boiler Manual typical piping — multiple-zone installations Figure 6 Figure 7 Zoning with circulators Zoning with zone valves — return water 130 °F or higher. — return water 130 °F or higher. ZONE 2 ZONE 2 ZONE 1 ZONE 1 1 1 1 1 2 5 3 2 11 13 13 6 6 6 6 11 Alternate circulator location 9 10 9 10 11 Cold 11 Cold water water fill fill 12 12 26012 26013 1 Boiler isolation (balancing) valves air vent when using closed-type expansion tank. It would allow air to leave the system, causing 2 Flow/check va
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GOLD CGs Gas-Fired Water Boiler 3d Water piping — low temp systems Primary/secondary Primary/secondary 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 (preferred) bypass of the bypass valves in the boiler circuit will not cause a change in the heating circuit rate and piping method temperature distribution. Figures 8 and 9 show suggested bypass arrangements using primary/seconda
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Boiler Manual primary/secondary (preferred) bypass piping — for radiant heating or converted gravity systems Figure 8 Figure 9 Zoning with circulators Zoning with zone valves ZONE 2 ZONE 2 ZONE 1 ZONE 1 1 1 1 2 1 4a 4b 4a 4b 12" 5 12" 3 3 2 MAX. 1 MAX. 1 13 13 1 1 7b 66 66 7b 7a 7a Alternate Alternate 8 circulator circulator 8 location location 9 10 9 10 Cold 11 Cold 11 water water fill fill 12 12 26014 26015 1 Boiler isolation (balancing) valves 10 Automatic air vent (with diaphragm-type expans
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GOLD CGs Gas-Fired Water Boiler 3e Water piping — low temp systems Boiler-bypass piping This piping method is called a boiler-bypass because part of the circulator flow is bypassed around the boiler (through valve 7a). This method reduces the flow rate throughout the method boiler, in order to raise the average water temperature in the boiler enough to prevent flue gas condensation. Boiler-bypass piping is effective for some boilers — including the CGs — provided the flow rates are adjusted acco
