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Weil-McLain CGS-4E manual GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual

Models: CGS-4E

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

Figure 3 Sizing air openings for CGs-4E installations ✷

Part number 550-110-282/1108

Page 11

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Weil-McLain CGS-4E manual GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual, Part number 550-110-282/1108

Contents

Boiler Manual Installation MaintenanceStartup Parts GOLDCGs-4EWater temperature limit switch How it worksGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual Air pressure switchPart number 550-110-282/1108 GOLD CGs-4E Gas-Fired Induced-DraftWater BoilerGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual Service and maintenance ContentsField wiring Check-outprocedureWhen servicing boiler InstallerPlease read before proceeding UserGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 1a Prepare boiler location - codes & checklistInstallations must follow these codes Before locating the boiler, check the followingFlooring Recommended SERVICE clearancesResidential garage installations 1b Prepare boiler location - clearancesVent system 1c Prepare boiler location - vent systemCGs-4Especial vent system GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 1d Prepare boiler location - contaminationSizing air openings 1e Prepare boiler location - air openingsCombustion air requirements Special considerationsPart number 550-110-282/1108 GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualInspect orifices and burners 2a Prepare boiler - placement & setupOrifice replacement procedure Place boiler/crate near positionGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 2b Prepare boiler - pressure testHydrostatic pressure test Drain and remove fittingsCirculator Pressure/temperature gauge3a Water piping - general information General piping informationtype expansion tank Figure 3b Water piping - single-zonesystemDiaphragm-typeor bladder Closed-typeexpansion tankConverted gravity or steam systems 3c Water piping - multiple zonesPiping multiple zones GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 3c Water piping - multiple zones continuedValve adjustment Figures 8 and 9 only 3d Piping - low temp systemsPrimary/secondary preferred bypass piping method Temperature gaugesGOLD CGs-4E Gas-FiredWater Boiler — Boiler Manual 3d Piping - low temp systems continued3d Piping - low temp systems continued BOILER-bypasspiping methodTemperature gauges Valve adjustment9Relief valve 3d Piping - low temp systems continuedGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 2Flow/check valveGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual SYSTEM-bypasspiping methodValve adjustment 3d Piping - low temp systems continuedPrevent chilled water from entering 3e Water piping - refrigeration systems3d Piping - low temp systems continued GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manualvent system 4 Venting and combustion airGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual Natural Gas Connecting gas supply piping to boiler5 Gas piping GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualThermostat 6 Field wiringElectrical installation must comply with Wiring connectionsCheck for gas leaks Freeze protection when used7a Start-up- preparation Determine if water treatment is neededInspect base insulation 7a Start-up- preparation continued7b Start-up- operate boiler Inspect system water pipingIMPROPER pilot flame characteristics 7b Start-up- operate boiler continuedCheck burner flames PROPER pilot flame characteristicsGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 7c Start-up- if boiler doesn’t startCheck for GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 8 Check-outprocedure - checklistInstallation and service certificate GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 9a Operation - sequencePart number 550-110-282/1108 Operation - sequenceGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual Part number 550-110-282/1108 9b Operation - wiring diagramsFigure 19 Wiring diagram GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualGas valve Honeywell VR8204Q 9c Operating instructions CGs-4EGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual Spark pilot Natural or propane gasGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual Addendum Instruction for theCommonwealth of Massachusetts Owner maintenance 10a Service and maintenance - scheduleVERIFY PROPER OPERATION AFTER SERVICING Service technicianGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 10b Service & maintenance - annual start-upInspect Reported problemsGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual ServiceStart-up InspectGas piping 10b Service & maint. - annual start-up continuedCheck/test GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualBoiler relief valve GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 10b Service & maint. - annual start-upCleaning boiler heating surfaces Review with ownerGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 11a Troubleshooting - procedureBefore troubleshooting Check the followingCheck pressure switch setting 11b Troubleshooting - air pressure switchAir pressure switch Return to normal operationControl indicator lights - NON-LOCKOUTmodes 11c Troubleshooting - control moduleControl module Control indicator lights - LOCKOUT modesPart number 550-110-282/1108 11c Troubleshooting - control module continuedGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual Figure 25 Control module connectionsIs POWER light flashing now? 11d Troubleshooting - control module lightsCHART 1 - Troubleshooting POWER light status Is POWER light off?GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 11d Troubleshooting - control module lightsCHART 2 - TSTAT CIRC & POWER lights flashing Do the TSTAT and POWER lights still flash?Does the ohmmeter indicate the switch is closed? 11d Troubleshooting - control module lights contCHART 3 - PRESS SWITCH & POWER lights flashing Is PRESS SWITCH light flashing?Are FLAME and POWER lights flashing? 11d Troubleshooting - control module lights contDo FLAME and POWER lights still flash? Are FLAME & POWER lights flashing?Does blower motor operate? 11d Troubleshooting - control module lights contDoes the ohmmeter indicate the switch is closed? GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 11d Troubleshooting - control module lights contTURN OFF POWER TURN OFF POWERcontinuity - is switch 11d Troubleshooting - control module lights contDoes voltmeter show 120 VAC across pins? Are limit switch contacts closed?Jacket 12a Replacement partsSection assembly Base5Nut, M\zn” 2 per tie rod 12b Replacement parts - section assemblyGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 1 2 3 not shown not shownPart number 550-110-282/1108 12c Replacement parts - baseFigure 27 Base assembly GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualWeil-McLain 12c Replacement parts - base continuedGOLD CGs-4E Gas-FiredWater Boiler — Boiler Manual DescriptionPart number 550-110-282/1108 12d Replacement parts - jacketFigure 28 Jacket assembly GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 12d Replacement parts - jacket continuedFittings shown are included with boiler 12e Replacement parts - trimFittings shown are factory-installedon boiler GOLD CGs-4E Gas-FiredWater Boiler - Boiler ManualGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 12f Replacement parts - controlsFigure 30 Gas control assembly GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 13a DimensionsGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual 13b RatingsLINING OR BASE PANELS Handling ceramic fiber and fiberglass materialsGOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual REMOVAL OF COMBUSTION CHAMBER