Weil-McLain CGS-4E manual 1c Prepare boiler location vent system, CGs-4E special vent system

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

1c Prepare boiler location — vent system

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death.

DO NOT COMMON VENT — Do not install the CGs-4E into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.

When removing boiler from an existing common vent system:

At the time of removal of an existing boiler, the fol- lowing steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remain- ing connected to the common venting system are not in operation.

a.Seal any unused openings in the common venting system.

b.Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condi- tion.

c.Test vent system — Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining con- nected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the com- mon venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a sum- mer exhaust fan. Close fireplace dampers.

d.Place in operation the appliance being inspected.

Follow the lighting/operating instructions. Adjust thermostat so appliance will operate continuously.

e.Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

f.After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previ- ous conditions of use.

Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1-latest edition. Correct by resizing to approach the minimum size as

determined using the appropriate tables in Part 11 of

that code. Canadian installations must comply with B149.1 or B149.2 Installation Code.

CGs-4E special vent system

Vent system

The CGs-4E boiler requires a special vent system, de- signed for pressurized venting. Model CGs-4E is rated ANSI Z21.13 Category IV (pressurized vent, likely to

condense in the vent).

You may use any of the vent systems covered by the CGs Venting Supplements included in the envelope as- sembly. The CGs vent starter is a special item, designed only for CGs and CGs-4E boilers, available from each vendor. Do not attempt to connect the vent to the CGs- 4E boiler with any other means.

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space.

Vent termination and combustion air supply

The CGs-4E boiler may be vented through the roof or through a side wall. Follow the appropriate vent supple- ment for the vent system chosen. The maximum vent length depends on boiler size. Refer to the vent supple- ment to determine acceptable vent length.

Combustion air for the CGs-4E boiler must be ducted directly to the boiler from outside. For outside air (direct vent installation), two options are available for the flue/ air termination. The air supply must ALWAYS terminate at the same location as the flue, using either:

1.Vertical direct vent installation. Obtain the

Weil-McLainThrough-Roof or Through-Unused Chimney termination kit and supplement. Refer to Vertical Direct Venting Venting Supplement, packed with the kit, and to the vent manufacturer’s instructions for the vent material chosen.

2.Sidewall direct vent installation. Use the Vent/Air Intake termination kit shipped with the boiler. Refer to CGs DirectVenting: Sidewall & Direct Exhaust Venting:Vertical or Sidewall Venting Supplement shipped with the boiler.

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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 When removing boiler from an existing common vent system 1c Prepare boiler location vent systemCGs-4E special vent system Vent systemAreas likely to have contaminants 1d Prepare boiler location contaminationProducts to avoid 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 Boiler 3e Water piping refrigeration systemsPrevent chilled water from entering Combustion air openings Combustion air quality Venting and combustion airVent system 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 boilerMain burner flame Figure Check burner flamesPilot 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 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 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, , 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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