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Weil-McLain CGS-4E manual

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Table of contents for the manual

  • Page 1

    P ar t No . 550-110-282/1108 This manual must only be used by a qualified heating installer/ser vice technician. Before installing , read all instructions, including this manual, the burner manual and any related supplements. P erform steps in the order given. Failur e to comply c ould result in sever e personal injury , death or substantial prope[...]

  • Page 2

    Part number 550-110-282/1108 2 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual How it works . . . ① Control module The control module r esponds to signals from the room thermostat, air pressur e switch and boiler limit circuit to oper ate the boiler circulator , pilot burner , gas val ve and inducer . W hen room thermostat calls for heat, t[...]

  • Page 3

    Part number 550-110-282/1108 3 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual GOLD CGs-4E Gas-Fir ed Induced-Draft W ater Boiler[...]

  • Page 4

    Part number 550-110-282/1108 4 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Contents Hazar d definitions The following defined terms ar e used throughout this manual to bring attention to the pr esence of hazards of various risk le v els or to important information concerning the life of the product. Indicates presence of hazards that wi[...]

  • Page 5

    Part number 550-110-282/1108 5 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Please r ead befor e pr oceeding Installer Read all instr uctions bef ore installing. F ol- low all instructions in pr oper orde r t o pr event personal injury or death. • Alsorefert oCGs V enting Supplements . • Consider piping and install[...]

  • Page 6

    Part number 550-110-282/1108 6 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Prepare boiler location — codes & checklist 1a Installations must follow these codes: • Local, state, provincial, andnationalcodes, la ws, regulations and or dinances. • N ationalFuelGasCode,  ANSIZ223.1–lateste[...]

  • Page 7

    Part number 550-110-282/1108 7 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — clearances 1b Figure 2 Required MINIMUM clearances Figure 1 Recommended SER VICE clearances (see W ARNING below) Recommended SERVICE clearances (Fig. 1) 1. Pr ovide clearances for cleaning and serv icing the boiler and for access to[...]

  • Page 8

    Part number 550-110-282/1108 8 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — vent system 1c Failur e to follow all inst ructions can result in flue gas spillage and carbon mono xide emissions, causing se v ere personal injury or death. When r emoving boiler from an existing common vent system: At the tim[...]

  • Page 9

    Part number 550-110-282/1108 9 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — contamination 1d T able 1 Corrosive or destructive contaminants and likely locations  All CGs- 4E boile rs must be direc t v ent ed (usin g d ucte d o utsid e air).  The vent /air te rminat ion[...]

  • Page 10

    Part number 550-110-282/1108 10 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — air openings 1e Special considerations Tight construction A NS I Z 2 23 . 1 d ef i ne s  un us ua l ly  t ig h t  con s tr u c ti o n where: 1. W all s and ceili ngs expo sed to th e out side at mo- sphere have a con[...]

  • Page 11

    Part number 550-110-282/1108 11 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Figure 3 Sizing air openings for CGs-4E installations ✷[...]

  • Page 12

    Part number 550-110-282/1108 12 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Place boiler/crate near position 1. Lea ve boiler in crate and on pallet until installation site is read y . 2.  Mo ve entire crate and pallet nextto sele cted loca - tion. 3. R emove crate. 4. R emove boiler fr om pallet.  Donot?[...]

  • Page 13

    Part number 550-110-282/1108 13 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler — pr essure test 2b Hydr ostatic pressur e test Pr essure t est boiler befor e attac hing water o r gas piping (ex cept as noted below) or electrical supply . Prepar e boiler for test 1. Re movethe shippingnipple(from CGs-4Esup[...]

  • Page 14

    Part number 550-110-282/1108 14 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual W ater piping — general information 3a T able 3 W ater pipe size (based on 20°F rise) Boiler model number To system From system CGs-4E 1” 1” Note: The boiler supply and retur n connections , the retur n/ drain tee and the supply/gauge tee supplied with the [...]

  • Page 15

    Part number 550-110-282/1108 15 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Water piping — single-zone system 3b Figure 4 Diaphragm- or bladder -type expansion tank Piping to single-zone system See T able 3 for piping sizes. Figure 5 Closed-type expansion tank Piping to single-zone system See T able 3 for piping sizes. Diaphragm-type or[...]

  • Page 16

    Part number 550-110-282/1108 16 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual W ater piping — multiple zones 3c Piping multiple zones Follo w instruc tions on pages 14 and 15 to install near- boiler or single-zone piping. (Also refer to Piping for radiant heating systems or con vert ed gra vity sys- tems , below , if [...]

  • Page 17

    Part number 550-110-282/1108 17 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Figure 6 Zoning with circulators — return water 130°F or higher . Figure 7 Zoning with zone valves — return water 130°F or higher . 1  Boiler isolation (balancing)  valv es 2 Flow/check val ve 3  Syst emorzonecirculat or 5  Zone[...]

  • Page 18

    Part number 550-110-282/1108 18 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Pip in g — low temp systems 3d Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or burners, r esulting in severe p ersonal injur y , death or substantial property damage. Radiant heating system piping s[...]

  • Page 19

    Part number 550-110-282/1108 19 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual 1  Boilerisolation(balancing)valv es 2 Flow/check val ve 3  Syst emorzonecirculat or 4 Syst emtemperaturegauges 5  Zonevalv e 6  Drainvalve 7  Syst em temperaturevalves(see instruc - tions to the left for ad[...]

  • Page 20

    Part number 550-110-282/1108 20 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or burners, r esulting in severe p ersonal injur y , death or substantial property damage. Radiant heating system piping should include a means of regulati[...]

  • Page 21

    Part number 550-110-282/1108 21 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual 1  Boilerisolation(balancing)valv es 2 Flow/check val ve 3  Syst emorzonecirculat or 4 Syst emtemperaturegauges 5  Zonevalv e 6  Drainvalve 7  Sy stem tempera ture valv es ( see i nstructions to the[...]

  • Page 22

    Part number 550-110-282/1108 22 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or burners, r esulting in severe p ersonal injur y , death or substantial property damage. Radiant heating system piping should include a means of regulati[...]

  • Page 23

    Part number 550-110-282/1108 23 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual 3  Syst emorzonecirculat or 7  Syst em temperaturevalves(see instr uctionsto the left for adjusting valv es) 8  Blendtemperaturegauge 9 Relief valve 10 A utomatic air vent (w ith diaphragm-t ype expan [...]

  • Page 24

    Part number 550-110-282/1108 24 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Venting and combustion air 4 Install vent piping and air piping per appr opriate V enting Supplement included in boiler en velope assembly . Refer to V enting Supplements  and to manual Section 1 regarding r equire - ments for:  • v ent syst[...]

  • Page 25

    Part number 550-110-282/1108 25 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Gas piping 5 T able 4 Pipe capacity for 0.60 specific gravity natural gas Gas pipe length (feet) Capacity of pipe for pipe size of: (Capacity in cubic feet gas per hour) ½” ¾” 1” 1¼” 1½” 10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 [...]

  • Page 26

    Part number 550-110-282/1108 26 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Field wiring 6 Thermostat 1.  Connect thermostat as shown on wir ing diagram on boiler . 2. Install on inside wall aw ay from influences of draf ts, hot or cold water pipes, lighting fixt ures, television, sunra ys, or fir eplaces. 3. If[...]

  • Page 27

    Part number 550-110-282/1108 27 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Start-up — pr eparation 7a Fill the system with water 1.  Close manual and automatic air vents and boiler drain cock. 2. Fill to correct system pressure . Corre ct pressur e w ill var y w ith each application. T y pi cal c old wat er fil l [...]

  • Page 28

    Part number 550-110-282/1108 28 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Start-up — operate boiler 7b Inspect system water piping After lling the boiler and system with water ,  inspect all piping thr oughout the system for leaks. If found, repair immediately . Repeat this inspection after the boiler has be[...]

  • Page 29

    Part number 550-110-282/1108 29 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Start-up — operate boiler (continued) 7b Figure 16 T ypical pilot burner flame Figure 17 T ypical main burner flame Check bur ner flames V iew pilot and main ames through the insp ection port in the Air inle t box fr [...]

  • Page 30

    Part number 550-110-282/1108 30 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Start-up — i f b o i l e r d o e s n ’ t s t a r t . . . 7c 1. Loose connections, blo w n fuse or serv ice sw itc h off? 2. High limit sw itch se t belo w boiler water tempera- ture? 3. Thermostat set below room t emperature? 4.  Gasnotturnedona[...]

  • Page 31

    Part number 550-110-282/1108 31 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Check-out pr ocedur e — checklist 8 ❏ Boilerandheatdistributionunitslledw ithwater? ❏ A utomaticairv ent,ifused,o penonefullturn? ❏ Airpurgedfromsy stem? ❏ Airpurgedfromgasp[...]

  • Page 32

    Part number 550-110-282/1108 32 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Operation — sequence 9a 1. Read appropr iat e Operating instructions  in Sec tion 9c . This information is also located on a labe l on the inside of the boiler jacket door panel. 2. Raise room thermostat t o call for heat. 3. Cir culator energizes. If l[...]

  • Page 33

    Part number 550-110-282/1108 33 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Operation — sequence Figure 18 Control module sequence of operation — status light indications[...]

  • Page 34

    Part number 550-110-282/1108 34 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Operation — wiring diagrams 9b Figure 19 Wiring diagram[...]

  • Page 35

    Part number 550-110-282/1108 35 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Operating instructions CGs-4E 9c • Spark pilot • Natural or propane gas • Gas valve: Hone ywell VR8204Q[...]

  • Page 36

    Part number 550-110-282/1108 36 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Addendum Instruction for the Commonwealth of Massachusetts T hi s a d d en d um m u s t on ly b e u s e d by a qualified heating installer/ser vice t echnician. Read th ese ins tr uct ions comp lete ly b efore beginning the installation. F ailure to comply could [...]

  • Page 37

    Part number 550-110-282/1108 37 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T able 5 Service and maintenance schedules Service technician (see following pages for instructions) Owner maintenance (see CGs-4E User’ s Information Manual for instructions) A n n n u A l s t A r t - u p Inspect: Reported problems Boiler area Air openings Flue[...]

  • Page 38

    Part number 550-110-282/1108 38 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Service & maintenance — annual start-up 10b Air openings 1.  V erify th at c ombustio n and  v entilation air openings to the boiler room and/or building are open and unobstr ucted . 2.  V erify that boiler v ent discha[...]

  • Page 39

    Part number 550-110-282/1108 39 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual ❏ Inspect . . . Burners, base and inlet air box The boiler contains ceramic fib er and fiberg lass materials. U se care when handling these mate rials per instr uctions on page 64 of this manual. Failur e to co mply could result in sev ere personal injury . If[...]

  • Page 40

    Part number 550-110-282/1108 40 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Service & maint. — annual start-up (continued) 10b ❏ Check/test . . . Gas piping 1.  Sniff near oor andaround boilerarea foranyin - dication of a gas leak . 2. T est gas piping using bubble test,  perSect ion 5 of [...]

  • Page 41

    Part number 550-110-282/1108 41 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual  Safetyrelief valv esshouldbe reinspected A T LEAST ONCE EVER Y THREE YEARS , by a license d plum bing cont ractor o r author ized inspection agency , to ensur e that the product has not been affected by corrosi ve wat er co nditions and t o ensu[...]

  • Page 42

    Part number 550-110-282/1108 42 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Service & maint. — annual start-up 10b ❏ Review with owner 1. R ev iew the User’ s Information Manual w ith the owner . 2.  Emphasize the need to per form the maintenance schedule sp ecified in the User’ s Information Manual (an[...]

  • Page 43

    Part number 550-110-282/1108 43 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — pr ocedure 11a Label all w ire s prior t o disc onnection when ser vicing c ontrols. W iring errors can cause impr oper and dangerous operation.  N ever jumper (bypass) rollout thermal fuse element or any other?[...]

  • Page 44

    Part number 550-110-282/1108 44 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — air pr essure switch 11b Air pr essure switch  Mak e s ure boiler wat er t emperature is 100 °F or cooler  b efore s tarti ng pr oc ed u re t o o b ta in a pp ro pr i at e readings. Check pressur e swit[...]

  • Page 45

    Part number 550-110-282/1108 45 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module 11c Contr ol module Solder or w ater sp lat te r betw ee n pl ugs and cir cui t boa rd can c aus e impr ope r opera tio n of co ntr ol mod ule. Pl ace a shield ove r the boiler internal control s and compone nts during install[...]

  • Page 46

    Part number 550-110-282/1108 46 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module (continued) 11c Figure 25 Control module connections[...]

  • Page 47

    Part number 550-110-282/1108 47 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module lights 11d CHART 1 — Troubleshooting POWER light status Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructi ons. Failure to follow instructions coul d result in severe personal inj ury, death o[...]

  • Page 48

    Part number 550-110-282/1108 48 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module lights 11d Electrical shock ha za rd — W herever you see TURN OFF POWER , follow the instructions. Failure to follo w instructions could result in severe personal inju ry, death or substantia l property damage. CHART 2 — T[...]

  • Page 49

    Part number 550-110-282/1108 49 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module lights (cont.) 11d CHART 3 — PRE SS SWITCH & POWER lights flashing Electrical shock ha za rd — Wherever you see TUR N OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal [...]

  • Page 50

    Part number 550-110-282/1108 50 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual 11d T r oubleshooting — contr ol module lights (cont.) • Turn off power to the boiler at service switch or brea ker. • Wait at least 45 seco nds. • Turn on powe r to boiler. • Restart boiler, fo llowing Operating instruc tions in th is manual (Section 9c[...]

  • Page 51

    Part number 550-110-282/1108 51 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module lights (cont.) 11d CHART 5 — PR ESS SWITCH light flashing and POWER light on steady Electrical shock ha za rd — Wherever you see TUR N OFF POWER , follow the instructions. Failure to follow instructions could result in sev[...]

  • Page 52

    Part number 550-110-282/1108 52 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual 11d T r oubleshooting — contr ol module lights (cont.) • TURN OFF POWER to boiler at service switch or breaker. • Remove burner shield (see Figure 27, page 56 for lo cation). • Verify inlet gas pressure at gas valve: Natural gas — 5.0" w.c. min/14.0[...]

  • Page 53

    Part number 550-110-282/1108 53 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module lights (cont.) 11d CHART 7 — Insufficient heat or no heat to system ( POWER li ght on steady) Electrical shock ha za rd — W herever you see TUR N OFF POWER , follow the instructions. Failure to follow instructions could re[...]

  • Page 54

    Part number 550-110-282/1108 54 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts 12a Section assembly .............................................. 55 Base .................................................................. 56 Jacket ............................................................... 58 T rim ....................[...]

  • Page 55

    Part number 550-110-282/1108 55 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — section assembly 12b Figure 26 Section assembly Item number Description Weil-McLain part number 1 End section, left hand, 51 124 31 1-1 03-850 2 End section, right hand 51 128 31 1-1 03-821 3 Intermediate section, 51 125 31 1-1 03-818 not sho[...]

  • Page 56

    Part number 550-110-282/1108 56 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — base 12c Figure 27 Base assembly[...]

  • Page 57

    Part number 550-110-282/1108 57 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — base (continued) 12c Item Description Weil-McLain part number Base insulation kit (includes insulation for all base parts abo ve plus gasket material needed between bloc k assembly and base) CGs-4E 381 -356-516 Base assembly kit (includes bas[...]

  • Page 58

    Part number 550-110-282/1108 58 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — jacket 12d Figure 28 Jacket assembly[...]

  • Page 59

    Part number 550-110-282/1108 59 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — jacket (continued) 12d Boiler Model 1 2 3 4 5 6 Boiler Model Junction box, 2 x 4 Panel, left side , with insulation Panel, right side , with insulation Panel, top front , with insulation Panel, top rear , with insulation Panel, door Natural G[...]

  • Page 60

    Part number 550-110-282/1108 60 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — trim 12e Figure 29 T rim assembly Item number Description Manufacturer Manufacturer ’ s part number Weil-McLain part number 1 Pressur e relief valve, ASME, 30 PSIG, ¾” male inlet Pressur e relief valve, ASME, 30 PSIG, ¾” female inlet [...]

  • Page 61

    Part number 550-110-282/1108 61 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Replacement parts — contr ols 12f Figure 30 Gas control assembly Item number Description Manufacturer Manufacturer’ s part number Weil-McLain part number Natural gas components 1 Gas valve, ½” x ½” , two-stage Natural gas Honeywell VR8204Q2426 51 1 -044-[...]

  • Page 62

    Part number 550-110-282/1108 62 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Dimensions 13a Figure 31 Dimensional drawing Boiler model number Supply tapping (inc hes NPT) Return tapping (inc hes NPT) Gas connection size Note 3 (inc hes NPT) Gas manifold siz e Note 3 (inc hes NPT) “A” Air inlet pipe center (inc hes) “W” Jac k et wid[...]

  • Page 63

    Part number 550-110-282/1108 63 GOLD CGs-4E Gas-Fired W ater Boiler — Boiler Manual Ratings T able 7 Boiler ratings DOE 13b (N ote5) CGs-4E boilers used for residential radiant panel systems,  con verted g ravity heating sy stems or other low water temperature applications should be installed w i[...]

  • Page 64

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