Weil-McLain CGS-4E manual 1b Prepare boiler location clearances

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

1b Prepare boiler location — clearances

Recommended SERVICE clearances

(Fig. 1)

Figure 2 Required MINIMUM clearances

1.Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1 for recommenda- tions.

2.Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to provide at least screwdriver clearance, install unions and shutoff valves in system so boiler can be moved for servicing.

Figure 1

Recommended

SERVICE clearances

(see WARNING

below)

If any clearance is less than in Figure 1, provide openings for combustion and ventilation air located on the wall or door opposite the boiler FRONT (see Figure 2).

These openings must be located as shown in Figure 2 to provide proper air flow around the boiler. The free area of each opening (after deducting for louvers) must be at least one square inch per 1,000 Btuh of boiler input. If the building is of unusually tight construction (see page 10 for definition), the air openings must connect directly to outside or the building must have air openings to the outside as specified on page 10.

If clearances are equal to or greater than Figure 1, see pages 10 and 11 for location and sizing of combustion air openings.

Failure to comply can result in severe personal injury, death or substantial property damage and reduced boiler life.

Flooring

The CGs-4E boiler is approved for installation on combus-

tible flooring, but must never be installed on carpeting.

Do not install boiler on carpeting even

if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage.

Foundation

1.Provide a solid brick or minimum 2-inch thick concrete foundation pad if any of the following is true:

floor can become flooded.

the boiler mounting area is not level.

2.Minimum dimensions are 25” length by:

Minimum foundation width:

CGs-4E

15”

 

 

Required MINIMUM clearances (Fig. 2)

Never install the boiler in a space with clear- ances less than the minimum clearances shown in Figure 2. Failure to comply can result in severe personal injury, death or substantial property damage and reduced boiler life.

1.Hot water pipes: at least ¹⁄₂ inch from combustible material.

2.Single-wall vent pipe: at least 6 inches from combustible mate- rial.

3.Type B double-wall metal vent pipe: refer to vent manufacturer’s recommendation for clearances to combustible material.

Residential garage installations

Take the following special precautions when installing the boiler in a residential garage. If the boiler is located in a residential garage, per ANSI Z223.1:

Mount the boiler a minimum of 18 inches above the floor of the garage to assure the burner and ignition devices will be no less than 18 inches above the floor.

Locate or protect the boiler so it cannot be damaged by a moving vehicle.

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