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

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

10b Service & maint. — annual start-up (continued)

❏Check/test . . .

Gas piping

1.Sniff near floor and around boiler area for any in- dication of a gas leak.

2.Test gas piping using bubble test, per Section 5 of this manual, if there is any indication of a leak.

Cold fill and operating pressures

1.While the system is cold, note the pressure reading on the boiler pressure/temperature gauge.Verify that cold fill pressure is correct.

2.Watch the pressure as the boiler and system heat up to ensure pressure rise is normal. Too high a rise would indicate a waterlogged or undersized expan- sion tank.

Air vents and air elimination

1.Inspect automatic air vents (if used). Also inspect air separators to ensure they are operational.

2.The cap must be unscrewed one turn to allow air to escape.

3.See Figure 22. If the air vent is leaking, remove cap A and briefly push valve B and then release to clean the valve seat.

4.Replace cap A by twisting all the way onto valve B and then unscrewing one turn.

Figure 22 Automatic air vent, typical

Limit controls and cutoffs

1.Inspect and test the boiler limit control. Verify op- eration by turning control set point below boiler temperature. Boiler should cycle off. Return dial to original setting.

2.Inspect and test additional limit controls or low water cutoffs installed on system.

Expansion tank

1.Expansion tanks provide space for water to move in an out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See Section 3 of this manual for suggested best location of expansion tanks and air eliminators.

Open-type— located above highest radiator or baseboard unit, usually in the attic or closet. Has a gauge glass and overflow pipe to a drain.

Closed-type— welded gas tight and located above boiler. Tank is partially filled with water, leaving an air cushion for expansion.

•Make sure this type of tank is fitted with a tank fitting, such as the B & G Tank-Trolor Taco Taco-Trol. This fitting reduces gravity circula- tion of air-saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the sys- tem.

•Do not use automatic air vents in systems with closed-type tanks. The air will escape from the system instead of returning to the tank.

Eventually, the tank will waterlog and no longer control pressurization. The boiler relief valve will weep frequently.

Diaphragm- or bladder-type — welded gas tight

with a rubber membrane to separate the tank pres- surizing air and the water. May be located at any point in the system, but most often found near the boiler.

•Systems with this type of expansion tank require at least one automatic air vent, preferably lo- cated on top of an air eliminator, as shown in examples in manual Section 3.

2.If relief valve has tended to weep frequently, the ex- pansion tank may be waterlogged or undersized.

Closed-type tank — tank is most likely water- logged. Install a tank fitting if not already installed. Then check fill level per fitting manufacturer’s instructions. If fill level is correct, check tank size against manufacturer’s instructions. Replace with a larger tank if necessary.

Diaphragm- or bladder-type — first, check tank size to be sure it is large enough for the system. If size is too small, add additional tank(s) as neces- sary to provide sufficient expansion. If tank size is large enough, remove tank from system and check charge pressure (usually 12 psig for residential ap- plications). If tank won’t hold pressure, membrane has been damaged. Replace tank.

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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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