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Weil-McLain Gold CGs-4E Manual

Gas-fired water boiler
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Boiler Manual
This manual must only be used by a qualified heating installer/service technician.
instructions, including this manual, the burner manual and any related supplements. Perform steps in the order
given. Failure to comply could result in severe personal injury, death or substantial property damage.
DO NOT USE BOILER DURING CONSTRUCTION
follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub-
stantial property damage.
®
GOLD
Gas-Fired Water Boiler
CGs-4E
™
• Installation
• Maintenance
• Startup
• Parts
Before installing
unless you provide dust-free air to the boiler area or
Part No. 550-110-282/1108
, read all

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Summary of Contents for Weil-McLain Gold CGs-4E

  • Page 1 ® CGs-4E GOLD ™ Gas-Fired Water Boiler Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualified heating installer/service technician. , read all Before installing instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given.

  • Page 2: How It Works

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD How it works . . . ① Control module The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and inducer. When room thermostat calls for heat, the control module starts the system circulator and inducer.
  • Page 3 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD CGs-4E Gas-Fired Induced-Draft Water Boiler GOLD Part number 550-110-282/1108...

  • Page 4: Table Of Contents

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Contents How it works ............2–3 Hazard definitions ..........4 Please read before proceeding ......5 Prepare boiler location ........6–11 Prepare boiler ..........12–13 Water piping ..........14–23 Venting & combustion air ........24 Gas piping ............25 Field wiring ............

  • Page 5: Please Read Before Proceeding

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Please read before proceeding Installer User This manual is for use only by your qualified heating • Read all instructions before installing. Fol- installer/service technician. low all instructions in proper order to prevent User’s Information Manual •...
  • Page 6 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Prepare boiler location — codes & checklist Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223.1–latest edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1, when required.

  • Page 7: Prepare Boiler Location

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Prepare boiler location — clearances Recommended SERVICE clearances Figure 2 Required MINIMUM clearances (Fig. 1) 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1 for recommenda- tions.

  • Page 8: Prepare Boiler

    Vertical direct vent installation. Obtain the properly vents when tested as outlined above, return Through-Roof or Through-Unused Weil-McLain doors, windows, exhaust fans, fireplace dampers, Chimney termination kit and supplement. Refer and any other gas-burning appliance to their previ-...
  • Page 9 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Prepare boiler location — contamination Table 1 Please review the following information on potential Refer to for products and areas which may cause combustion air contamination problems. 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.

  • Page 10: Combustion Air Requirements

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Prepare boiler location — air openings Louver allowance Air opening location and sizing requirements de- after reduc- The free area of openings means the area pend on the clearances around the boiler. Check tion for any installed louvers or grilles .
  • Page 11 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD ✷ Figure 3 Sizing air openings for CGs-4E installations Part number 550-110-282/1108...

  • Page 12: Prepare Boiler

    U. S. 2.55 mm (Note 1) 1.60 mm (Note 1) 0-2,000 ft 2,000-4,500 0-2,000 ft 2,000-4,500 Canada 2.55 mm 1.60 mm 1.45 mm Note 1: For elevations above 2,000 feet, contact your local Weil-McLain sales office for details. Part number 550-110-282/1108...

  • Page 13: Prepare Boiler

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Prepare boiler — pressure test Hydrostatic pressure test 5. Slowly reopen boiler drain valve until test pressure on the pressure/temperature gauge reaches no more Pressure test boiler before attaching water or gas piping than: (except as noted below) or electrical supply.

  • Page 14: Water Piping

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Water piping — general information General piping information Circulator If installation is to comply with ASME or Canadian requirements, an ad- The circulator is shipped loose (wiring pre-attached to ditional high temperature limit is needed.
  • Page 15 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Water piping — single-zone system Diaphragm-type or bladder- Closed-type expansion tank type expansion tank (Figure 4) (Figure 5) 1. Ensure expansion tank size will handle boiler and 1. Ensure expansion tank size will handle boiler and system water volume and temperature.

  • Page 16: Piping Multiple Zones

    . Instead, provide controls and piping which can regulate the boiler return water temperature at no less than 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property dam- age.
  • Page 17 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Water piping — multiple zones (continued) Figure 6 Zoning with circulators Figure 7 Zoning with zone valves — return water 130°F or higher. — return water 130°F or higher. Boiler isolation (balancing) Automatic air vent (with diaphragm-type expansion tank), or connect valves to tank fitting (closed-type expansion tank).

  • Page 18: Temperature Gauges

    130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 19 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Piping — low temp systems (continued) Figure 8 Primary/secondary piping Figure 9 Primary/secondary piping Zoning with circulators Zoning with zone valves Relief valve Boiler isolation (balancing) valves Automatic air vent (with diaphragm-type expansion tank), or Flow/check valve DO NOT connect to tank fitting (closed-type expansion tank).
  • Page 20 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 21 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Piping — low temp systems (continued) Figure 10 Boiler-bypass piping Figure 11 Boiler-bypass piping Zoning with circulators Zoning with zone valves Alternative to primary/secondary piping (Alternative to primary/secondary piping Figures 8 and 9) Figures 8 and 9) Boiler isolation (balancing) valves Automatic air vent (with diaphragm-type expan-...
  • Page 22 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.

  • Page 23: Water Piping

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Piping — low temp systems (continued) Figure 12 System-bypass piping Zoning with zone valve or circulators, return water 130°F or higher. (Alternative to boiler-bypass piping Figures 10 and 11, page 21) 3 System or zone circulator 7 System temperature valves (see instructions to the left for adjusting valves) 8 Blend temperature gauge...

  • Page 24: Venting & Combustion Air

    CGs-4E Boiler must be combustion and ventilation air as described in Venting Supplements Weil-McLain CGs packed in envelope assembly with boiler. Also see Boiler Manual pages 9 through 11. Failure to do so will cause severe personal injury or death.

  • Page 25: Gas Piping

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Gas piping Connecting gas supply piping to boiler Natural Gas: 1. Refer to Table 4 for pipe length and diameter. Base Figure 14 1. Remove jacket front panel and refer to to pipe gas to boiler. on rated boiler input (divide by 1,000 to obtain cubic Install drip leg at inlet of gas connection to boiler.

  • Page 26: Field Wiring

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Field wiring Thermostat turn off electrical power supply at For your safety, service entrance panel before making any electrical 1. Connect thermostat as shown on wiring diagram connections to avoid possible electric shock hazard. on boiler.
  • Page 27 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Start-up — preparation Determine if water treatment is needed Fill the system with water petroleum-based cleaning or sealing com- Do not use air vents 1. Close manual and automatic pounds in boiler system. Severe damage to boiler will occur, boiler drain cock.

  • Page 28: Start The Boiler

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Start-up — preparation (continued) Inspect system water piping Inspect base insulation Check to make sure insulation is secure against all After filling the boiler and system with water, inspect all piping throughout four sides of the base.
  • Page 29 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Start-up — operate boiler (continued) If you discover evidence of any gas leak, shut down the Figure 16 Typical pilot burner flame boiler at once. Find the leak source with bubble test and repair immediately.
  • Page 30 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Start-up — if boiler doesn’t start . . . Check for: 1. Loose connections, blown fuse or service switch off? 2. High limit switch set below boiler water tempera- ture? 3. Thermostat set below room temperature? 4.
  • Page 31 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Check-out procedure — checklist ❏ Boiler and heat distribution units filled with water? ❏ Set limit control(s) to system temperature requirements. Adjust balancing valves and controls to provide design ❏ Automatic air vent, if used, open one full turn? temperature to system.
  • Page 32 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Operation — sequence Read appropriate Operating instructions in Section sequence returns to step This information is also located on a label on the inside of If power is interrupted shuts off , control system pilot the boiler jacket door panel.
  • Page 33 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Operation — sequence Figure 18 Control module sequence of operation — status light indications Part number 550-110-282/1108...
  • Page 34 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Operation — wiring diagrams Figure 19 Wiring diagram Part number 550-110-282/1108...

  • Page 35: C Operating Instructions

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Operating instructions • Spark pilot • Natural or propane gas CGs-4E • Gas valve: Honeywell VR8204Q Part number 550-110-282/1108...
  • Page 36 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Addendum Instruction for the Commonwealth of Massachusetts This addendum must only be used by a one-half (1/2) inch in size, “GAS VENT DIRECTLY BE- LOW. KEEP CLEAR OF ALL OBSTRUCTIONS.” qualified heating installer/service technician. Read these instructions completely before INSPECTION .

  • Page 37: Service And Maintenance

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING Table 5 Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see CGs-4E User’s Information Manual for instructions) Inspect: Check boiler area Reported problems...

  • Page 38: Air Openings

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Service & maintenance — annual start-up Air openings 1. Verify that combustion and ventilation air openings inspected and started annu- The boiler should be to the boiler room and/or building are open and ally only , at the beginning of the heating season,...

  • Page 39: Start-Up

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD ❏ Inspect . . . Condensate drain system 1. Inspect condensate drain fittings and tubing. Verify that condensate can flow freely to drain. Burners, base and inlet air box ❏ Service . . . The boiler contains ceramic fiber and fiberglass materials.

  • Page 40: Expansion Tank

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Service & maint. — annual start-up (continued) ❏ Check/test . . . Expansion tank 1. Expansion tanks provide space for water to move in an out as the heating system water expands due to Gas piping temperature increase or contracts as the water cools.
  • Page 41 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD reinspected AT LEAST ONCE EVERY Safety relief valves should be THREE YEARS , by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally.

  • Page 42: Review With Owner

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Service & maint. — annual start-up ❏ Review with owner 2. Follow shutdown procedure. 3. Remove venting system connection to boiler. User’s Information Manual 1. Review the with the owner. 4. Remove top jacket panel. Turn back insulation. 2.
  • Page 43 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — procedure Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other Troubleshooting device except for momentary testing as outlined in Charts .

  • Page 44: Air Pressure Switch

    Air pressure switch Table 6 Pressure switch setpoint (for elevations above 2,000 ft, contact your Make sure boiler water temperature local Weil-McLain sales office for details.) is 100 °F or cooler before starting procedure to obtain appropriate readings. Boiler model number Inches W.C.
  • Page 45 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — control module Control module Control indicator lights — LOCKOUT modes Charts 1 through in this Section for detailed trouble- Solder or water splatter between plugs and circuit board shooting procedures. can cause improper operation of control module.
  • Page 46 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — control module (continued) Figure 25 Control module connections Part number 550-110-282/1108...
  • Page 47 Have system checked by a licensed electrician. If Replace transformer. problem persists, call your Retest and check for back Boiler should now Replace control module. local Weil-McLain sales feed of voltage from operate normally. representative. Retest. system wiring. Part number 550-110-282/1108...
  • Page 48 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — control module lights CHART 2 — TSTAT CIRC & POWER lights flashing — Usually indicates 48 VAC on thermostat circuit (stray voltage) — Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 49 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — control module lights (cont.) CHART 3 — PRESS SWITCH & POWER lights flashing — Usually indicates pressure switch stuck closed or failed to make within 5 minutes — Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.

  • Page 50: Operation

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — control module lights (cont.) CHART 4 — FLAME & POWER lights flashing — Usually indicates flame sensed when it shouldn't be there — Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 51 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — control module lights (cont.) CHART 5 — PRESS SWITCH light flashing and POWER light on steady — Usually indicates pressure switch opened during run cycle — — May also be caused by wind gusts in excess of 31 mph for non-direct vent sidewall-vented boilers — Electrical shock hazard —...
  • Page 52 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — control module lights (cont.) CHART 6 — FLAME light flashing and POWER light on steady ALSO — Troubleshooting failure to establish main flame Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 53 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Troubleshooting — control module lights (cont.) CHART 7 — Insufficient heat or no heat to system (POWER light on steady) Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.

  • Page 54: Replacement Parts

    Jacket ............... 58 Trim ..............60 Controls ............61 Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size and include description and part number of replacement part. Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation.
  • Page 55 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — section assembly Figure 26 Section assembly Item number Description Weil-McLain part number End section, left hand, 51124 311-103-850 End section, right hand 51128 311-103-821 Intermediate section, 51125 311-103-818 not shown...
  • Page 56 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — base Figure 27 Base assembly Part number 550-110-282/1108...
  • Page 57 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — base (continued) Item Description Weil-McLain part number Base insulation kit CGs-4E 381-356-516 (includes insulation for all base parts above plus gasket material needed between block assembly and base) Base assembly kit...
  • Page 58 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — jacket Figure 28 Jacket assembly Part number 550-110-282/1108...
  • Page 59 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — jacket (continued) Boiler Panel, left side, Boiler Model Panel, right Model with insulation Junction box, Panel, top front, Panel, top rear, side, with Panel, door 2 x 4 with insulation with insulation insulation Natural Gas...
  • Page 60 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — trim Figure 29 Trim assembly Item Description Weil-McLain Manufacturer Manufacturer’s part number number part number Pressure relief valve, ASME, 30 PSIG, ¾” male inlet Conbraco 10-407-10 511-546-920 Watts M330 Pressure relief valve, ASME, 30 PSIG, ¾”...

  • Page 61: Replacement Parts

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Replacement parts — controls Figure 30 Gas control assembly Item Manufacturer’s Weil-McLain Description Manufacturer number part number part number Natural gas components Gas valve, ½” x ½” , two-stage Natural gas Honeywell...
  • Page 62 CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Dimensions Figure 31 Dimensional drawing Boiler Supply Return “A” “W” model tapping tapping connection size manifold size Air inlet Jacket number pipe center width (inches NPT) (inches NPT) Note 3 Note 3 (inches NPT) (inches NPT) (inches)
  • Page 63 CGs vent supplements. The CGs-4E boiler MUST be direct-vented (using 3” diameter air piping) as specified in the direct vent supplements. 5. As an Energy Star Partner, Weil-McLain has determined that the CGs-4E meets the Energy Star guidelines for energy efficiency.

  • Page 64: Handling Ceramic Fiber And Fiberglass Materials

    CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS The combustion chamber lining or base INSTALLATION OF FIBERGLASS WOOL, insulation panels in this product con- COMBUSTION CHAMBER LINING OR tain ceramic fiber materials.

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