Weil-McLain CGS-4E manual 7b Start-up operate boiler, Final check before starting boiler

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

7a Start-up — preparation (continued)

Inspect system water piping

Inspect base insulation

After filling the boiler and system with water, inspect all piping throughout the system for leaks. If found, repair immediately. Repeat this inspection after the boiler has been started and the system has heated up.

Check to make sure insulation is secure against all four sides of the base. If insulation is damaged or dis- placed, do not operate boiler. Replace or reposition insulation.

Leaks must be repaired at once. Failure to do so can damage the boiler, resulting in substantial property damage.

Glycol or antifreeze leaks around the boiler may result in fire, causing severe personal injury, death or substantial property damage.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Failure to replace damaged insu- lation or reposition insulation can result in a fire hazard, causing severe personal injury, death or substantial property damage.

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 64 of this manual. Failure to comply could result in severe personal injury.

7b Start-up — operate boiler

Final check before starting boiler

•Read manual Section 9 including the Operating instructions (Section 9c).

•Verify the boiler and system are full of water.

•Verify the Start-up preparation procedures of Sec- tion 7a have been completed.

Start the boiler

•Follow the Operating instructions from Section 9c to start the boiler.

•See Section 7c if boiler fails to start.

Check system and boiler

Do not use petroleum-based cleaning or sealing compounds

in boiler system. Severe damage to

boiler will occur, resulting in sub- stantial property damage.

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.

1.Check system piping for leaks. If found, shut down boiler and repair immediately.

2.Vent air from system using manual vents.Air in the system will interfere with circulation and cause heat distribution problems and noise.

3.Inspect vent system thoroughly for signs of deterioration from cor- rosion, physical damage or sagging. In addition — Check for gas-tightseal at every connection and seam.

Venting system must be sealed gas-tight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death.

4.Check around the boiler for gas odor following the procedure of Sec- tion 7a of this manual.

5.Verify operation per Section 7b. Perform check-out procedure in Sec- tion 8, and fill in the Installation and service certificate on the same page.

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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 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 When removing boiler from an existing common vent system 1c Prepare boiler location vent systemCGs-4E special vent system Vent systemProducts to avoid 1d Prepare boiler location contaminationAreas likely to have contaminants 1e Prepare boiler location air openings Combustion air requirementsSpecial considerations Sizing air openingsSizing air openings for CGs-4E installations 2a Prepare boiler placement & setup Orifice replacement procedurePlace boiler/crate near position Inspect orifices and burners2b Prepare boiler pressure test Hydrostatic pressure testDrain and remove fittings 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 zonesBoiler isolation balancing valves Flow/check valve System or zone circulator Zone valve Drain valveRelief valve Fill valveTemperature gauges Valve adjustment Figures 8 and 9 only3d Piping low temp systems Primary/secondary preferred bypass piping methodBlend temperature gauge Boiler isolation balancing valvesValve adjustment BOILER-bypass piping methodFigures 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 Connecting gas supply piping to boiler Gas pipingNatural Gas Propane GasField wiring Electrical installation must comply withWiring connections ThermostatFreeze protection when used 7a Start-up preparationDetermine if water treatment is needed Check for gas leaks7b Start-up operate boiler Inspect system water piping Inspect base insulationFinal check before starting boiler Start the boilerPilot burner flame Figure Check burner flamesMain burner flame Figure If none of the above corrects the problem, refer to 7c Start-up if boiler doesn’t startCheck for Gas not turned on at meter or boiler?Check-out procedure checklist Installation and service certificateSequence returns to step 9a Operation sequenceBoiler is now in the off cycle Operation sequence 9b Operation wiring diagrams Wiring diagram9c Operating instructions CGs-4E Addendum Instruction for Commonwealth of Massachusetts CMR 5.082a 1 throughExemptions The following equipment is exempt from CMR 5.082a1 through10a Service and maintenance schedule 10b Service & maintenance annual start-up With boiler power off, place a few drops of S.A.E Burners, base and inlet air boxCondensate drain system Inducer motor10b Service & maint. annual start-up Boiler relief valve Relief valve, typicalClean between sections with wire flue brush Review with ownerShut down boiler Place newspapers in base of boiler to collect soot11a Troubleshooting procedure Before troubleshootingCheck the following Can result11b Troubleshooting air pressure switch Air pressure switchCheck pressure switch setting Troubleshooting air pressure reading11c Troubleshooting control module Control indicator lights Lockout modesControl indicator lights NON-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, , Section assembly Base Jacket Trim Controls 12a Replacement partsWeil-McLain part numbers are found in Weil-McLain Boilers 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 pressureThis type of respirator is based on Handling ceramic fiber and fiberglass materialsEye Irrigate immediately Breathing Fresh air
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