Weil-McLain CGS-4E manual GOLDCGs-4E

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®

GOLD™CGs-4E

Gas-Fired Water Boiler

Boiler Manual	• Installation • Maintenance
	• Startup • Parts

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.

DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free air to the boiler area or follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub- stantial property damage.

Part No. 550-110-282/1108

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Contents GOLDCGs-4E How it works Gold CGs-4EGas-Fired Induced-Draft Water Boiler Contents Please read before proceeding InstallerUser Installations must follow these codes 1a Prepare boiler location codes & checklistBefore locating the boiler, check the following 1b Prepare boiler location clearances 1c Prepare boiler location vent system When removing boiler from an existing common vent systemCGs-4E special vent system Vent systemProducts to avoid 1d Prepare boiler location contaminationAreas likely to have contaminants Combustion air requirements 1e Prepare boiler location air openingsSpecial considerations Sizing air openingsSizing air openings for CGs-4E installations Orifice replacement procedure 2a Prepare boiler placement & setupPlace boiler/crate near position Inspect orifices and burnersHydrostatic pressure test 2b Prepare boiler pressure testDrain and remove fittings Prepare boiler for test3a Water piping general information 3b Water piping single-zone system Install an automatic air vent in air vent tapping as shownPiping multiple zones 3c Water piping multiple zonesSystem or zone circulator Zone valve Drain valve Boiler isolation balancing valves Flow/check valveRelief valve Fill valveValve adjustment Figures 8 and 9 only Temperature gauges3d Piping low temp systems Primary/secondary preferred bypass piping methodBoiler isolation balancing valves Blend temperature gaugeBOILER-bypass piping method Valve adjustmentFigures 8 SYSTEM-bypass piping method Prevent chilled water from entering 3e Water piping refrigeration systemsBoiler Vent system Venting and combustion airCombustion air openings Combustion air quality Gas piping Connecting gas supply piping to boilerNatural Gas Propane GasElectrical installation must comply with Field wiringWiring connections Thermostat7a Start-up preparation Freeze protection when usedDetermine if water treatment is needed Check for gas leaksInspect system water piping Inspect base insulation 7b Start-up operate boilerFinal check before starting boiler Start the boilerPilot burner flame Figure Check burner flamesMain burner flame Figure 7c Start-up if boiler doesn’t start If none of the above corrects the problem, refer toCheck for Gas not turned on at meter or boiler?Installation and service certificate Check-out procedure checklistSequence returns to step 9a Operation sequenceBoiler is now in the off cycle Operation sequence Wiring diagram 9b Operation wiring diagrams9c Operating instructions CGs-4E CMR 5.082a 1 through Addendum Instruction for Commonwealth of MassachusettsExemptions The following equipment is exempt from CMR 5.082a1 through10a Service and maintenance schedule 10b Service & maintenance annual start-up Burners, base and inlet air box With boiler power off, place a few drops of S.A.ECondensate drain system Inducer motor10b Service & maint. annual start-up Relief valve, typical Boiler relief valveReview with owner Clean between sections with wire flue brushShut down boiler Place newspapers in base of boiler to collect sootBefore troubleshooting 11a Troubleshooting procedureCheck the following Can resultAir pressure switch 11b Troubleshooting air pressure switchCheck pressure switch setting Troubleshooting air pressure readingControl indicator lights Lockout modes 11c Troubleshooting control moduleControl indicator lights NON-LOCKOUT modes Troubleshooting the control moduleControl module connections Chart 1 Troubleshooting Power light status 11d Troubleshooting control module lightsChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Chart 4 Flame & Power lights flashing Does blower motor operate? Item 8 , Verify Sequence of operation, , Section assembly Base Jacket Trim Controls 12a Replacement partsWeil-McLain part numbers are found in Weil-McLain Boilers Weil-McLain part number 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketBoiler Fittings shown are factory-installed on boiler 12e Replacement parts trimPropane gas components 12f Replacement parts controlsDimensional drawing 13a DimensionsTested for 50 psi working pressure 13b RatingsThis type of respirator is based on Handling ceramic fiber and fiberglass materialsEye Irrigate immediately Breathing Fresh air