Weil-McLain CGS-4E manual 1d Prepare boiler location contamination, Products to avoid

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

1d Prepare boiler location — contamination

Please review the following information on potential combustion air contamination problems.

Refer to Table 1 for products and areas which may cause contaminated combustion air.

All CGs-4E boilers must be direct vented (using ducted outside air). The vent/air termination must be installed in a location that is free of the contaminants listed below. Allowing the boiler to operated with contaminated air can cause damage to the boiler and vent system, resulting in possible severe personal injury, death or substantial property damage.

Table 1  Corrosive or destructive contaminants and likely locations

Products to avoid

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Airborne particulates (drywall dust, fiberglass particles, road or gravel dust, lint, etc.)

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Buildings under construction (where air is contaminated with particulates)

CONSTRUCTION DUST HAZARD — Airborne particulates, such as drywall dust or fiberglass dust, will cause blockage of the CGs-4E burners, resulting in carbon monoxide production, a fire hazard, or building freeze damage. If the boiler is operated during construction, you must isolate the boiler air supply to provide clean air for combus- tion. Follow the instruction manual guidelines for piping intake air. If you are unable to ensure uncontaminated air in the boiler air intake at all times, you must inspect the boiler at least once weekly. When inspecting, clean the burners if necessary using the procedure given on page 39. Failure to follow these guidelines could result in severe personal injury, death or substantial property damage.

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 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 1c Prepare boiler location vent system When removing boiler from an existing common vent systemCGs-4E special vent system Vent system1d Prepare boiler location contamination Products to avoidAreas likely to have contaminants 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 3e Water piping refrigeration systems Prevent chilled water from enteringBoiler Venting and combustion air Vent systemCombustion air openings Combustion air quality 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 boilerCheck burner flames Pilot burner flame FigureMain 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 checklist9a Operation sequence Sequence returns to stepBoiler is now in the off cycle 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, , 12a Replacement parts Section assembly Base Jacket Trim ControlsWeil-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 RatingsHandling ceramic fiber and fiberglass materials This type of respirator is based onEye Irrigate immediately Breathing Fresh air
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