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Weil-McLain Gold CGs-4E Manual Download Page 1

Part No. 550-110-282/1108

 

This  manual  must  only  be  used  by  a  qualified  heating  installer/service  technician. 

Before

 

installing

,  read  all 

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. 

• Installation

• Startup

Boiler Manual

• Maintenance

• Parts

 

DO NOT USE BOILER DURING CONSTRUCTION

 unless you provide dust-free air to the boiler area or 

follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub-

stantial property damage.

GOLD

 

CGs-4E

Gas-Fired  Water  Boiler

®

™

Summary of Contents for Gold CGs-4E

Page 1: ...in the order given Failure to comply could result in severe personal injury death or substantial property damage Installation Startup Boiler Manual Maintenance Parts DO NOT USE BOILER DURING CONSTRUCT...

Page 2: ...nsformer The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit Inducer The inducer pulls flue gases through the boiler causing air to be pulled in through the ai...

Page 3: ...Part number 550 110 282 1108 3 GOLD CGs 4E Gas Fired Water Boiler Boiler Manual GOLD CGs 4E Gas Fired Induced Draft Water Boiler...

Page 4: ...injury death or substantial property damage Indicates presence of hazards that will or can cause minor personal injury or property dam age Indicates special instructions on installation operation or m...

Page 5: ...or ventilation air to boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location extern...

Page 6: ...ore locating the boiler check the following Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power Check area around boiler Remove any combustible ma...

Page 7: ...ure 2 to provide proper air flow around the boiler The free area of each opening after deducting for louvers must be at least one square inch per 1 000 Btuh of boiler input If the building is of unusu...

Page 8: ...approach the minimum size as determined using the appropriate tables in Part 11 of that code Canadian installations must comply with B149 1 or B149 2 Installation Code CGs 4E special vent system Vent...

Page 9: ...re 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...

Page 10: ...Each requires a special vent component kit Sizing air openings Air openings provide for ventilation to prevent overheating of the boiler controls and boiler space Air is also needed for other applian...

Page 11: ...Part number 550 110 282 1108 11 GOLD CGs 4E Gas Fired Water Boiler Boiler Manual Figure 3 Sizing air openings for CGs 4E installations...

Page 12: ...on the orifice spud barrel Correctly sized manifold orifices must be used Failure to do so will result in severe personal injury death or substantial property dam age 3 Reinstall inlet air box top pa...

Page 13: ...ed air during the fill Valve and nipple are not included with boiler Fill and pressure test 1 Open the shutoff valves you installed on supply and return connections 2 Slowly open boiler drain valve an...

Page 14: ...4 diaphragm type or bladder type expan sion tank or Figure 5 closed type expansion tank on page 15 and Table 3 below for near boiler and single zone systems designed for return water at least 130 F S...

Page 15: ...gure 5 1 Ensure expansion tank size will handle boiler and system water volume and temperature See tank manufacturer s instructions for details 2 Connect tank to NPT tapping located behind supply outl...

Page 16: ...so use the piping shown in Figure 12 on page 23 system bypass if the reduced flow rate in the heating system will not cause heat distribution problems Failure to prevent low return water temperature t...

Page 17: ...k 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to tank fitting as in Figure 5 page 15 13 Air separator and autom...

Page 18: ...hange in the heating circuit rate and temperature distribution Figures 8 and 9 page 19 show suggested bypass ar rangements using primary secondary bypass piping preferred for low temperature systems s...

Page 19: ...use an automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlog ging of the expansion tank 11 Fill valve 12 Diaphragm type or bladder type expan...

Page 20: ...to the instructions following Figures 10 and 11 are alternative piping suggestions for converted gravity large water content or steam systems or radiant heating system for use when primary secondary...

Page 21: ...pansion tank It would allow air to leave the system causing wa terlogging of the expansion tank 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pi...

Page 22: ...return water to the boiler Valve 7b will most often be full open but may need to be slightly closed on some low pressure drop systems in order to cause enough flow through valve 7a Figure 12 is an al...

Page 23: ...f air separator to tank fitting as in Figure 5 page 15 Figure 12 System bypass piping Zoning with zone valve or circulators return water 130 F or higher Alternative to boiler bypass piping Figures 10...

Page 24: ...egarding require ments for vent system combustion air openings combustion air quality CGs 4E Boiler must be vented and supplied with combustion and ventilation air as described in Weil McLain CGs Vent...

Page 25: ...mum 11 w c Manifold gas pressure 10 w c at high fire 3 50 w c at low fire while in low fire at start up Connecting gas supply piping to boiler 1 Remove jacket front panel and refer to Figure 14 to pip...

Page 26: ...x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code For your safety turn off electrical power supply at service entrance panel before making any el...

Page 27: ...build up in sections reduc ing heat transfer overheating cast iron and causing section failure Verify water chemistry Consult local water treatment companies for unusually hard water areas above 7 gr...

Page 28: ...iminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure 1 Check system...

Page 29: ...2 Underfired Small flame Inner cone not engulfing pilot flame sen sor 3 Lack of primary air Yellow flame tip 4 Incorrectly heated pilot flame sensor Main burner flame Figure 17 PROPER main burner flam...

Page 30: ...use or service switch off 2 High limit switch set below boiler water tempera ture 3 Thermostat set below room temperature 4 Gas not turned on at meter or boiler 5 Incoming gas pressure less than 5 w c...

Page 31: ...Pilot will relight flame sensing element will sense pilot flame and main burners will reignite Set limit control s to system temperature requirements Adjust balancing valves and controls to provide de...

Page 32: ...e opens 5 The CGs 4E timer relay delays high fire for the first 60 seconds of main flame 6 During main burner operation a Control module monitors pilot flame current If signal is lost main valve close...

Page 33: ...Part number 550 110 282 1108 33 GOLD CGs 4E Gas Fired Water 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 Water 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 Water Boiler Boiler Manual Operating instructions CGs 4E 9c Spark pilot Natural or propane gas Gas valve Honeywell VR8204Q...

Page 36: ...plastic identification plate shall be permanently mounted to the exterior of the build ing at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the hori...

Page 37: ...ef valve Review Review with owner Daily Check boiler area Check air openings Check boiler pressure temperature gauge Monthly Check boiler interior piping Check venting system Check air vents Check boi...

Page 38: ...tained per this manual 5 Reconnect vent to inducer outlet and replace all boiler components before returning to service 6 Check inside and around boiler for evidence of any leaks from the boiler If fo...

Page 39: ...building freeze damage Read and follow the WARNING on page 9 Failure to inspect and clear gas burner ports could result in severe personal injury death or substantial property damage 1 Inspect each bu...

Page 40: ...cated above highest radiator or baseboard unit usually in the attic or closet Has a gauge glass and overflow pipe to a drain Closed type welded gas tight and located above boiler Tank is partially fil...

Page 41: ...rways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inop erative When manually operating the lever water will discharge and precautions must be taken to a...

Page 42: ...ll be exposed to freezing temperatures If using antifreeze in system do not drain 2 Follow shutdown procedure 3 Remove venting system connection to boiler 4 Remove top jacket panel Turn back insulatio...

Page 43: ...etween thermostat wire nuts and ground Check the following 1 Wire connectors to control module are securely plugged in at module and originating control 2 Air pressure switch hoses are properly and se...

Page 44: ...6 Pressure switch setpoint for elevations above 2 000 ft contact your local Weil McLain sales office for details Boiler model number Inches W C CGs 4E 1 71 Troubleshooting air pressure reading 1 If ma...

Page 45: ...ally indicates reversed polarity of 120 VAC power wires POWER and TSTAT CIRC lights flashing Usually indicates stray voltage on external thermostat circuit wires usually due to miswired 3 wire zone va...

Page 46: ...Part number 550 110 282 1108 46 GOLD CGs 4E Gas Fired Water Boiler Boiler Manual Troubleshooting control module continued 11c Figure 25 Control module connections...

Page 47: ...PRESS SWITCH light flashing FLAME light flashing For insufficient heat or no heat problem go to Chart 7 if POWER light is on steady with no other light flashing No Yes On steady not flashing No Yes U...

Page 48: ...d to the boiler thermostat leads two black low voltage leads in J box Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a ti...

Page 49: ...11b Replace if necessary Retest Try reseating plug in module receptacle and restart If inducer still does not work replace inducer assembly Retest No Yes Wait 45 seconds Does inducer motor operate No...

Page 50: ...45 seconds Turn on power to boiler Restart boiler following Operating instructions in this manual Section 9c Do FLAME and POWER lights still flash Boiler should now operate normally Original flashing...

Page 51: ...er indicate the switch is closed Inspect and check wire harness from control module to pressure switch Reseat connector in control module receptacle If harness is intact and properly seated but proble...

Page 52: ...lame signal Detach sense lead from ignition control Figure 25 item 8 page 46 Connect negative lead of MICROAMMETER to control sense terminal Figure 25 item 8 page 46 Connect positive lead of MICROAMME...

Page 53: ...heat Are vent and combustion air piping free of blockage No Yes Correct conditions and recheck operation See Figure 18 page 33 for normal sequence of operation Check heat loss calculation versus boil...

Page 54: ...e 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 Weil McL...

Page 55: ...bly CGs 4E 321 114 346 not shown Section replacement kit includes seals and sealant for 1 joint 381 354 527 4 Tie rod M zn without nut 3 per boiler CGs 4E 560 234 501 5 Nut M zn 2 per tie rod 561 928...

Page 56: ...Part number 550 110 282 1108 56 GOLD CGs 4E Gas Fired Water Boiler Boiler Manual Replacement parts base 12c Figure 27 Base assembly...

Page 57: ...mbly 7 Base back panel in Base assembly 8 Base front cross tie assembly in Base assembly 9 Pilot bracket 450 003 689 10 Pilot burner assembly Natural gas Pilot burner assembly Propane gas 511 330 080...

Page 58: ...Part number 550 110 282 1108 58 GOLD CGs 4E Gas Fired Water Boiler Boiler Manual Replacement parts jacket 12d Figure 28 Jacket assembly...

Page 59: ...el top rear with insulation Panel door Natural Gas Propane Gas CGs 4E Available at local supply house 381 355 794 381 355 796 381 355 614 381 355 413 381 355 713 381 355 795 CGs 4E Boiler Model 7 8 9...

Page 60: ...perature gauge 3Z diameter short shank Fittings shown are shipped loose with boiler Weil McLain 380 000 000 3 Drain valve Fittings shown are included with boiler Conbraco Hammond Valve Matco Norca Wat...

Page 61: ...bly kit with orifice and aluminum pilot gas tubing Weil McLain 511 330 081 Natural gas and propane gas components 3 Control module United Technologies 1107 1 511 330 090 not shown Wiring harness contr...

Page 62: ...sional drawing Boiler model number Supply tapping inches NPT Return tapping inches NPT Gas connection size Note 3 inches NPT Gas manifold size Note 3 inches NPT A Air inlet pipe center inches W Jacket...

Page 63: ...Btuh Input Btuh Output Btuh Note 1 Note 2 Note 3 Note 5 Note 4 CGs 4E Note 5 77 000 90 000 77 000 81 000 69 300 67 000 2 1 85 0 3 Notes 1 Add PIN for natural gas boiler PIL for propane gas boiler 2 Ba...

Page 64: ...tion from the boiler and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate...

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