Weil-McLain CGS-4E manual 10b Service & maintenance annual start-up

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

10b Service & maintenance — annual start-up

The boiler should be inspected and started annu- ally, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 5, page 37,and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and main- tain the boiler and system could result in equipment failure.

Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Miner- als can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure. Leaking water may also cause severe property dam- age.

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to

boiler will occur, resulting in substantial property damage.

Electrical shock hazard — Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

❏Inspect . . .

Reported problems

Inspect any problems reported by owner and correct before proceeding.

Boiler area

1.Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids.

2.Verify that boiler area (and air intake) is free of any of the contaminants listed in Table 1 on page 9 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, isolate the boiler and provide outside combustion air. See national, provincial or local codes for further information.

Air openings

1.Verify that combustion and ventilation air openings to the boiler room and/or building are open and unobstructed.

2.Verify that boiler vent discharge is clean and free of obstructions.

Flue gas vent system

1.Visually inspect entire flue gas venting system for blockage, deterioration or leakage. Repair any joints that show signs of leakage in accordance with vent manufacturer’s instructions. When air is ducted to boiler, verify that air inlet hose is connected and properly sealed.

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Pilot and main burner flames

1.Visually inspect pilot burner and main burner flames as directed under Start-up, Section 7 of this manual.

Water piping

1.Check the boiler interior piping and all system pip- ing for signs of leaks.

2.Repair any leaks before proceeding.

Boiler heating surfaces

1.Disconnect the vent pipe at the boiler inducer outlet connection after turning off power to the boiler.

2.Use a bright light to inspect the flue pipe interior and inducer interior.

3.Inspect the boiler vent outlet area and heating sur- faces by looking through the opening.

4.If the vent pipe or inducer interior show evidence of soot, follow Cleaning boiler heating surfaces in this manual section to remove the flue collector and clean the boiler if necessary after close inspection of boiler heating surfaces. If there is evidence of rusty scale deposits, check the water piping and control system to make sure the boiler return water tempera- ture is properly maintained (per this manual).

5.Reconnect vent to inducer outlet and replace all boiler components before returning to service.

6.Check inside and around boiler for evidence of any leaks from the boiler. If found, locate source of leaks and repair.

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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
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