Weil-McLain CGS-4E manual Check burner flames, Pilot burner flame Figure, Main burner flame Figure

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

7b Start-up — operate boiler (continued)

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with bubble test and repair immediately. Do not start boiler again until cor- rected. Failure to comply could result in severe personal injury, death or substantial property damage.

Check burner flames

View pilot and main flames through the inspection port in the Air inlet

box front cover.

Pilot burner flame (Figure 16)

PROPER pilot flame characteristics

1.Blue flame.

2.Inner cone engulfing pilot flame sensor.

3.Pilot flame sensor glowing cherry red.

IMPROPER pilot flame characteristics:

1.Overfired — Large flame lifting or blowing past pilot flame sensor.

2.Underfired — Small flame. Inner cone not engulfing pilot flame sen- sor.

3.Lack of primary air — Yellow flame tip.

4.Incorrectly heated pilot flame sensor.

Figure 16 Typical pilot burner flame

Figure 17 Typical main burner flame

Main burner flame (Figure 17)

PROPER main burner flame characteristics

1. Yellow-orange streaks may appear (caused by dust).

(NOTE: The CGs-4E will operate at low fire for the first 60 seconds.)

IMPROPER main burner flame characteristics

1.Overfired — Large flames.

2.Underfired — Small flames.

3.Lack of primary air — Yellow tipping on flames (sooting will occur).

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 1c Prepare boiler location vent system When removing boiler from an existing common vent systemCGs-4E special vent system Vent systemAreas likely to have contaminants 1d Prepare boiler location contaminationProducts to avoid 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 Boiler 3e Water piping refrigeration systemsPrevent chilled water from entering Combustion air openings Combustion air quality Venting and combustion airVent system 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 boilerMain burner flame Figure Check burner flamesPilot 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 checklistBoiler is now in the off cycle 9a Operation sequenceSequence returns to step 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, , Weil-McLain part numbers are found in Weil-McLain Boilers 12a Replacement partsSection assembly Base Jacket Trim Controls 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 RatingsEye Irrigate immediately Breathing Fresh air Handling ceramic fiber and fiberglass materialsThis type of respirator is based on