Weil-McLain CGS-4E manual Check-out procedure checklist, Installation and service certificate

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

8 Check-out procedure — checklist

❏Boiler and heat distribution units filled with water?

❏Automatic air vent, if used, open one full turn?

❏Air purged from system?

❏Air purged from gas piping? Piping checked for leaks?

❏Correctly sized manifold orifices installed? Refer to manual Section 2a to check size and fuel type.

Correctly sized manifold orifices must be used. Failure to do so will cause severe personal in- jury, death or substantial property damage.

❏Followed operating instructions on boiler or in manual Section 9 for proper start-up?

❏Verify that the boiler switches to high fire after 60 seconds of main flame operation.

❏Proper burner flame observed at high fire? Refer to Check burner flame, manual Section 7b.

❏Test limit control — While burners are operating, move indicator on limit control below actual boiler water tem- perature. Burners should go off while circulator continues to operate. Raise setting on limit control above boiler water temperature and burners should reignite.

❏Test additional field-installed controls — If boiler has a low water cutoff, additional high limit or other controls, test for operation as outlined by manufacturer. Burners should be operating and should go off when controls are tested. When controls are restored, burners should reignite.

❏Test ignition system safety device:

a.Connect manometer to outlet side of gas valve.

b.Start boiler, allowing for normal start-up cycle to oc- cur and main burners to ignite.

c.With main burners on, manually shut off gas supply at manual main shutoff gas valve. Burners should go off.

d.Open manual main shutoff gas valve. Manometer should confirm there is no gas flow.

e.Pilot will relight, flame sensing element will sense pilot flame and main burners will reignite.

❏Set limit control(s) to system temperature requirements. Adjust balancing valves and controls to provide design temperature to system.

❏For multiple zones, adjust flow so it is about the same in each zone.

❏Verify thermostat heat anticipator (if available) set properly?

Refer to Field wiring, manual Section 6, Thermostat(s).

❏Cycle boiler with thermostat — Raise to highest setting and verify boiler goes through normal start-up cycle. Lower to lowest setting and verify boiler goes off.

❏Measure natural gas input:

a.Operate boiler 10 minutes.

b.Turn off other appliances.

c.At natural gas meter, measure time (in seconds) re- quired to use one cubic foot of gas.

d.Calculate gas input:

e.Btuh calculated should approximate input rating on boiler rating label.

❏Check manifold gas pressure by connecting manometer to downstream test tapping on main gas valve. Manifold pres- sure for natural gas should be 3.5" w.c. and for propane gas should be 10" w.c.

❏Observe several operating cycles for proper operation.

❏Set room thermostat to desired room temperature.

❏Fill in Installation and service certificate below?

❏Review all instructions shipped with this boiler with owner or maintenance person. Return instructions to envelope and give to owner or place in pocket inside front panel in boiler.

Installation and service certificate

Boiler model __________________ Series __________ CP number ___________ Date installed ___________

Measured Btuh input ____________________

❏ Installation instructions have been followed.

 

 

 

 

❏ Check out sequence has been performed.

 

 

❏ Above information is certified to be correct.

 

 

❏ Information received and left with owner/maintenance person

Installer ________________________

________________________________

________________________

(company)

 

(address)

(phone)

Installer’s signature: _____________________________________

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 Vent system When removing boiler from an existing common vent system1c Prepare boiler location vent system CGs-4E special vent systemProducts to avoid 1d Prepare boiler location contaminationAreas likely to have contaminants Sizing air openings 1e Prepare boiler location air openingsCombustion air requirements Special considerationsSizing air openings for CGs-4E installations Inspect orifices and burners 2a Prepare boiler placement & setupOrifice replacement procedure Place boiler/crate near positionPrepare boiler for test 2b Prepare boiler pressure testHydrostatic pressure test Drain and remove fittings3a 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 zonesFill valve Boiler isolation balancing valves Flow/check valveSystem or zone circulator Zone valve Drain valve Relief valvePrimary/secondary preferred bypass piping method Temperature gaugesValve adjustment Figures 8 and 9 only 3d Piping low temp systemsBoiler 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 Propane Gas Connecting gas supply piping to boilerGas piping Natural GasThermostat Field wiringElectrical installation must comply with Wiring connectionsCheck for gas leaks Freeze protection when used7a Start-up preparation Determine if water treatment is neededStart the boiler 7b Start-up operate boilerInspect system water piping Inspect base insulation Final check before starting boilerPilot burner flame Figure Check burner flamesMain burner flame Figure Gas not turned on at meter or boiler? If none of the above corrects the problem, refer to7c Start-up if boiler doesn’t start Check forInstallation 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 5.082a1 through Addendum Instruction for Commonwealth of MassachusettsCMR 5.082a 1 through Exemptions The following equipment is exempt from10a Service and maintenance schedule 10b Service & maintenance annual start-up Inducer motor With boiler power off, place a few drops of S.A.EBurners, base and inlet air box Condensate drain system10b Service & maint. annual start-up Relief valve, typical Boiler relief valvePlace newspapers in base of boiler to collect soot Clean between sections with wire flue brushReview with owner Shut down boilerCan result 11a Troubleshooting procedureBefore troubleshooting Check the followingTroubleshooting air pressure reading 11b Troubleshooting air pressure switchAir pressure switch Check pressure switch settingTroubleshooting the control module 11c Troubleshooting control moduleControl indicator lights Lockout modes Control indicator lights NON-LOCKOUT modesControl 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
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