Weil-McLain CGS-4E manual Please read before proceeding, Installer, User

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

Please read before proceeding

Installer

Read all instructions before installing. Fol-

low all instructions in proper order to prevent personal injury or death.

•Also refer to CGs Venting Supplements.

•Consider piping and installation when determining boiler location.

User

•This manual is for use only by your qualified heating installer/service technician.

•Please refer to the User’s Information Manual for your refer- ence.

•We recommend regular service by a qualified service techni- cian, at least annually.

•Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

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.

When calling or writing about the boiler— Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket. You may list the CP number in the space provided on the Installation and service certificate found on page 31.

Read and follow the special instructions for the Commonwealth of Massachusetts, located on page 36 of this manual.

Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage.

When servicing boiler —

•To avoid electric shock, disconnect electrical supply before performing maintenance.

•To avoid severe burns, allow boiler to cool before perform- ing maintenance.

Boiler operation —

•Do not block flow of combustion or ventilation air to boiler.

•Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

•Do not use this boiler if any part has been under water.

Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water.

Boiler water —

•Do not use petroleum-based cleaning or sealing compounds in boiler system. Water seal deterioration will occur, caus- ing leakage between sections. This can result in substantial property damage.

•Do not use“homemade cures” or“boiler patent medicines”. Severe personal injury, death or substantial property dam- age may result.

•Continual fresh makeup water will reduce boiler life. Min- eral buildup in sections reduces heat transfer, overheats cast iron, and causes section failure. Addition of oxygen and other gases can cause internal corrosion. Leaks in boiler or piping must be repaired at once to prevent makeup water.

•Do not add cold water to hot boiler. Thermal shock can cause sections to crack.

Glycol — potential fire hazard —

All glycol is flammable when exposed to high temperatures. If glycol is allowed to accumulate in or around the boiler or any other potential ignition source, a fire can develop. In order to prevent potential severe personal injury, death or substantial property damage from fire and/or structural damage:

•Never store glycol of any kind near the boiler or any poten- tial ignition source.

•Monitor and inspect the system and boiler regularly for leakage. Repair any leaks immediately to prevent possible accumulation of glycol.

•Never use automotive antifreeze or ethylene glycol in the system. Using these glycols can lead to hazardous leakage of glycol in the boiler system.

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
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