Weil-McLain CGS-4E Review with owner, Shut down boiler, Replace insulation and jacket top panel

Page 42

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

10b Service & maint. — annual start-up

❏Review with owner

1.Review the User’s Information Manual with the owner.

2.Emphasize the need to perform the maintenance schedule specified in the User’s Information Manual (and in this manual as well).

3.Remind the owner of the need to call in a licensed contractor should the boiler or system exhibit any unusual behavior.

4.Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

❏Cleaning boiler heating surfaces

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.

1.Shut down boiler:

•Follow “To Turn Off Gas to Appliance” instructions on boiler and Operating instruc- tions.

•Do not drain boiler unless it will be exposed to freezing temperatures. If using antifreeze in system, do not drain.

2.Follow shutdown procedure.

3.Remove venting system connection to boiler.

4.Remove top jacket panel. Turn back insulation.

5.Remove collector box/transition assembly. Clean sealant from assembly and sections.

6.Remove radiation plates hanging between sec- tions.

7.Remove burners from base. Brush and vacuum burners to remove all dust and lint. Verify that all burner ports are free of debris.

8.Place newspapers in base of boiler to collect soot.

9.Clean between sections with wire flue brush.

10.Remove newspaper and soot.Vacuum or brush base and surrounding area.

11.Reinstall radiation plates.

12.Replace collector box/transition assembly. Seal with sealant. Obtain gas-tight seal to prevent flue gas spillage and carbon monoxide emissions, resulting in severe personal injury or death.

13.Replace insulation and jacket top panel.

14.Start up boiler following Section 7 of this manual and the boiler Operating instructions (Section 9c of this manual). Excessive sooting indicates im- proper gas combustion. If found, check for proper combustion and make any necessary adjustments.

42

Part number 550-110-282/1108

Image 42

Contents GOLDCGs-4E How it works Gold CGs-4EGas-Fired Induced-Draft Water Boiler Contents Installer Please read before proceedingUser 1a Prepare boiler location codes & checklist Installations must follow these codesBefore locating the boiler, check the following 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 system1d Prepare boiler location contamination Products to avoidAreas likely to have contaminants 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 3e Water piping refrigeration systems Prevent chilled water from enteringBoiler Venting and combustion air Vent systemCombustion air openings Combustion air quality 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 boilerCheck burner flames Pilot burner flame FigureMain 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 certificate9a Operation sequence Sequence returns to stepBoiler is now in the off cycle 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, , 12a Replacement parts Section assembly Base Jacket Trim ControlsWeil-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 pressureHandling ceramic fiber and fiberglass materials This type of respirator is based onEye Irrigate immediately Breathing Fresh air