Weil-McLain CGS-4E manual Field wiring, Thermostat, Electrical installation must comply with

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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual

6 Field wiring

For your safety, turn off electrical power supply at service entrance panel before making any electrical

connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

Wiring must be N.E.C. Class 1.

If original wiring as supplied with boiler must be re- placed, use only type 105°C wire or equivalent.

Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edi- tion.

Thermostat

1.Connect thermostat as shown on wiring diagram on boiler.

2.Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunrays, or fireplaces.

3.If thermostat has a heat anticipator, set heat antici- pator in thermostat to match power requirements of equipment connected to it. If connected directly to boiler, set for 0.4 amps. For other devices, refer to manufacturer’s specifications. Wiring diagram on boiler gives setting for control module and gas valve. Also see instructions with thermostat.

Electrical installation must comply with:

1.National Electrical Code and any other national, state, provincial or local codes or regulations.

2.In Canada, CSA C22.1 Canadian Electrical Code

Part 1, and any local codes.

Wiring connections

Boiler is shipped with controls completely wired.

Junction Box (continued)

1.Connect 120 VAC power wiring as shown in

Figure 15.

2.Fused disconnect or service switch (15 amp. recom- mended) may be mounted on this box. For those installations with local codes which prohibit installa- tion of fused disconnect or service switch on boiler, install a 2 x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code.

The CGs-4E control module is polarity-sensitive. The hot and neutral wires must be connected to the correct leads. A flashing POWER light usually indicates reversed polarity of 120 VAC lead wires.

Figure 15 Field wiring connections — service switch and thermostat (or end switch) provided by installer

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Part number 550-110-282/1108

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Contents GOLDCGs-4E How it works Gold CGs-4EGas-Fired Induced-Draft Water Boiler Contents User InstallerPlease read before proceeding Before locating the boiler, check the following 1a Prepare boiler location codes & checklistInstallations must follow these codes 1b Prepare boiler location clearances CGs-4E special vent system When removing boiler from an existing common vent system1c Prepare boiler location vent system Vent systemAreas likely to have contaminants 1d Prepare boiler location contaminationProducts to avoid Special considerations 1e Prepare boiler location air openingsCombustion air requirements Sizing air openingsSizing air openings for CGs-4E installations Place boiler/crate near position 2a Prepare boiler placement & setupOrifice replacement procedure Inspect orifices and burnersDrain and remove fittings 2b Prepare boiler pressure testHydrostatic pressure test Prepare boiler for test3a Water piping general information Install an automatic air vent in air vent tapping as shown 3b Water piping single-zone system3c Water piping multiple zones Piping multiple zonesRelief valve Boiler isolation balancing valves Flow/check valveSystem or zone circulator Zone valve Drain valve Fill valve3d Piping low temp systems Temperature gaugesValve adjustment Figures 8 and 9 only Primary/secondary preferred bypass piping methodBlend temperature gauge Boiler isolation balancing valvesValve adjustment BOILER-bypass piping methodFigures 8 SYSTEM-bypass piping method Boiler 3e Water piping refrigeration systemsPrevent chilled water from entering Combustion air openings Combustion air quality Venting and combustion airVent system Natural Gas Connecting gas supply piping to boilerGas piping Propane GasWiring connections Field wiringElectrical installation must comply with ThermostatDetermine if water treatment is needed Freeze protection when used7a Start-up preparation Check for gas leaksFinal check before starting boiler 7b Start-up operate boilerInspect system water piping Inspect base insulation Start the boilerMain burner flame Figure Check burner flamesPilot burner flame Figure Check for If none of the above corrects the problem, refer to7c Start-up if boiler doesn’t start Gas not turned on at meter or boiler?Check-out procedure checklist Installation and service certificateBoiler is now in the off cycle 9a Operation sequenceSequence returns to step Operation sequence 9b Operation wiring diagrams Wiring diagram9c Operating instructions CGs-4E Exemptions The following equipment is exempt from Addendum Instruction for Commonwealth of MassachusettsCMR 5.082a 1 through CMR 5.082a1 through10a Service and maintenance schedule 10b Service & maintenance annual start-up Condensate drain system With boiler power off, place a few drops of S.A.EBurners, base and inlet air box Inducer motor10b Service & maint. annual start-up Boiler relief valve Relief valve, typicalShut down boiler Clean between sections with wire flue brushReview with owner Place newspapers in base of boiler to collect sootCheck the following 11a Troubleshooting procedureBefore troubleshooting Can resultCheck pressure switch setting 11b Troubleshooting air pressure switchAir pressure switch Troubleshooting air pressure readingControl indicator lights NON-LOCKOUT modes 11c Troubleshooting control moduleControl indicator lights Lockout modes Troubleshooting the control moduleControl module connections 11d Troubleshooting control module lights Chart 1 Troubleshooting Power light statusChart 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, , Weil-McLain part numbers are found in Weil-McLain Boilers 12a Replacement partsSection assembly Base Jacket Trim Controls 12b Replacement parts section assembly Weil-McLain part number12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyBoiler 12e Replacement parts trim Fittings shown are factory-installed on boiler12f Replacement parts controls Propane gas components13a Dimensions Dimensional drawing13b Ratings Tested for 50 psi working pressureEye Irrigate immediately Breathing Fresh air Handling ceramic fiber and fiberglass materialsThis type of respirator is based on