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CGS-4E manual 9c Operating instructions CGs-4E, Spark pilot Natural or propane gas
Models:
CGS-4E
1
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Troubleshooting
PROPER pilot flame characteristics
Install
Error codes
9b Operation - wiring diagrams
2a Prepare boiler - placement & setup
Dimension
Maintenance
Connecting gas supply piping to boiler
Reported problems
Page 35
Image 35
GOLD
CGs-4E
Gas-Fired
Water Boiler — Boiler Manual
9c
Operating instructions
CGs-4E
• Spark pilot • Natural or propane gas
• Gas valve: Honeywell VR8204Q
Part number
550-110-282/1108
35
Page 34
Page 36
Page 35
Image 35
Page 34
Page 36
Contents
Boiler Manual
Installation Maintenance
Startup Parts
GOLDCGs-4E
Water temperature limit switch
How it works
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Air pressure switch
Part number 550-110-282/1108
GOLD CGs-4E Gas-Fired Induced-DraftWater Boiler
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Service and maintenance
Contents
Field wiring
Check-outprocedure
When servicing boiler
Installer
Please read before proceeding
User
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
1a Prepare boiler location - codes & checklist
Installations must follow these codes
Before locating the boiler, check the following
Flooring
Recommended SERVICE clearances
Residential garage installations
1b Prepare boiler location - clearances
Vent system
1c Prepare boiler location - vent system
CGs-4Especial vent system
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
1d Prepare boiler location - contamination
Sizing air openings
1e Prepare boiler location - air openings
Combustion air requirements
Special considerations
Part number 550-110-282/1108
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Inspect orifices and burners
2a Prepare boiler - placement & setup
Orifice replacement procedure
Place boiler/crate near position
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
2b Prepare boiler - pressure test
Hydrostatic pressure test
Drain and remove fittings
Circulator
Pressure/temperature gauge
3a Water piping - general information
General piping information
type expansion tank Figure
3b Water piping - single-zonesystem
Diaphragm-typeor bladder
Closed-typeexpansion tank
Converted gravity or steam systems
3c Water piping - multiple zones
Piping multiple zones
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
3c Water piping - multiple zones continued
Valve adjustment Figures 8 and 9 only
3d Piping - low temp systems
Primary/secondary preferred bypass piping method
Temperature gauges
GOLD CGs-4E Gas-FiredWater Boiler — Boiler Manual
3d Piping - low temp systems continued
3d Piping - low temp systems continued
BOILER-bypasspiping method
Temperature gauges
Valve adjustment
9Relief valve
3d Piping - low temp systems continued
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
2Flow/check valve
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
SYSTEM-bypasspiping method
Valve adjustment
3d Piping - low temp systems continued
Prevent chilled water from entering
3e Water piping - refrigeration systems
3d Piping - low temp systems continued
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
vent system
4 Venting and combustion air
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Natural Gas
Connecting gas supply piping to boiler
5 Gas piping
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Thermostat
6 Field wiring
Electrical installation must comply with
Wiring connections
Check for gas leaks
Freeze protection when used
7a Start-up- preparation
Determine if water treatment is needed
Inspect base insulation
7a Start-up- preparation continued
7b Start-up- operate boiler
Inspect system water piping
IMPROPER pilot flame characteristics
7b Start-up- operate boiler continued
Check burner flames
PROPER pilot flame characteristics
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
7c Start-up- if boiler doesn’t start
Check for
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
8 Check-outprocedure - checklist
Installation and service certificate
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
9a Operation - sequence
Part number 550-110-282/1108
Operation - sequence
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Part number 550-110-282/1108
9b Operation - wiring diagrams
Figure 19 Wiring diagram
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Gas valve Honeywell VR8204Q
9c Operating instructions CGs-4E
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Spark pilot Natural or propane gas
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Addendum Instruction for the
Commonwealth of Massachusetts
Owner maintenance
10a Service and maintenance - schedule
VERIFY PROPER OPERATION AFTER SERVICING
Service technician
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
10b Service & maintenance - annual start-up
Inspect
Reported problems
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Service
Start-up
Inspect
Gas piping
10b Service & maint. - annual start-up continued
Check/test
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Boiler relief valve
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
10b Service & maint. - annual start-up
Cleaning boiler heating surfaces
Review with owner
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
11a Troubleshooting - procedure
Before troubleshooting
Check the following
Check pressure switch setting
11b Troubleshooting - air pressure switch
Air pressure switch
Return to normal operation
Control indicator lights - NON-LOCKOUTmodes
11c Troubleshooting - control module
Control module
Control indicator lights - LOCKOUT modes
Part number 550-110-282/1108
11c Troubleshooting - control module continued
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Figure 25 Control module connections
Is POWER light flashing now?
11d Troubleshooting - control module lights
CHART 1 - Troubleshooting POWER light status
Is POWER light off?
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
11d Troubleshooting - control module lights
CHART 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 cont
CHART 3 - PRESS SWITCH & POWER lights flashing
Is PRESS SWITCH light flashing?
Are FLAME and POWER lights flashing?
11d Troubleshooting - control module lights cont
Do FLAME and POWER lights still flash?
Are FLAME & POWER lights flashing?
Does blower motor operate?
11d Troubleshooting - control module lights cont
Does the ohmmeter indicate the switch is closed?
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
11d Troubleshooting - control module lights cont
TURN OFF POWER
TURN OFF POWER
continuity - is switch
11d Troubleshooting - control module lights cont
Does voltmeter show 120 VAC across pins?
Are limit switch contacts closed?
Jacket
12a Replacement parts
Section assembly
Base
5Nut, M\zn” 2 per tie rod
12b Replacement parts - section assembly
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
1 2 3 not shown not shown
Part number 550-110-282/1108
12c Replacement parts - base
Figure 27 Base assembly
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
Weil-McLain
12c Replacement parts - base continued
GOLD CGs-4E Gas-FiredWater Boiler — Boiler Manual
Description
Part number 550-110-282/1108
12d Replacement parts - jacket
Figure 28 Jacket assembly
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
12d Replacement parts - jacket continued
Fittings shown are included with boiler
12e Replacement parts - trim
Fittings shown are factory-installedon boiler
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
12f Replacement parts - controls
Figure 30 Gas control assembly
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
13a Dimensions
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
13b Ratings
LINING OR BASE PANELS
Handling ceramic fiber and fiberglass materials
GOLD CGs-4E Gas-FiredWater Boiler - Boiler Manual
REMOVAL OF COMBUSTION CHAMBER
