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®
™
GOLD
CGs-4E
Gas-Fired Water Boiler
• Installation • Maintenance
Boiler Manual
• Startup • Parts
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.
DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free ai
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual How it works . . . Control module ① 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. The control module runs the inducer long enough to purge the boiler flue passages, then opens the pilot valve and activates pilot
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual GOLD CGs-4E Gas-Fired Induced-Draft Water Boiler 3 Part number 550-110-282/1108
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual Contents How it works ....................................................2–3 Hazard definitions ............................................... 4 Please read before proceeding ............................ 5 1 Prepare boiler location ...................................6–11 2 Prepare boiler ...............................................12–13 3 Water piping .................................................14–23 4 Venting & combustion
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 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 • P l e a s e r e f e r t o t h e User’s Information Manual for your refer- personal injury or death. ence. • A lso r e f e r t o CGs Venting Supplements. • W e r e c o m m e n d r e g u l a r service by a
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 1a Prepare boiler location — codes & checklist Installations must follow these codes: • L o cal, stat e, p r o v incial, and nat io nal c o d es, laws, regulations and ordinances. • N at io nal F ue l Gas C o d e, ANSI Z223.1–lat est e dit io n. • Standar d f o r C o nt r ols and S af e t y D e v ic es f o r A u t o mat ical l y Fir e d B o ile r s, ANSI/ ASME CSD-1, w he n r e q uir e d. • N at io nal Ele c t r ical C o d
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 1b 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 ac c ess t o c o nt r ols and c o mpo ne nts. See Figur e 1 f o r r ec o mme nda- tions. 2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to provide at least
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 1c Prepare boiler location — vent system Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death. DO NOT COMMON VENT — D o not instal l the CGs-4E int o a c o mmo n v e nt w ith an y othe r ap
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 1d Prepare boiler location — contamination Please review the following information on potential Refer to Table 1 for products and areas which may cause combustion air contamination problems. contaminated combustion air. A l l C G s - 4 E b o i l e r s m u s t b e d i r e c t v e n t e d ( u s i n g d u c t e d o u t s i d e a i r ) . T h e v e n t / a i r t e r m i n a t i o n m ust b e instal le d in a lo cat
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 1e Prepare boiler location — air openings Louver allowance Air opening location and sizing requirements de- The free area of openings means the area after reduc- pend on the clearances around the boiler. C he c k tion for any installed louvers or grilles . B e s ur e t o the boiler placement compared to Figure 1, page 7. consider this reduction when sizing the air openings. If all clearances are at least equal to Figure 1, ✷ page 7,
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual Figure 3 Sizing air openings for CGs-4E installations ✷ 11 Part number 550-110-282/1108
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 2a Prepare boiler — placement & setup Inlet air box top panel must be in Place boiler/crate near position during boiler operation. position Failure to do so could result in severe personal injury, death or 1. Leave boiler in crate and on pallet until installation substantial property damage. site is ready. 2. M o v e e nt ir e cr at e and pal le t ne xt t o se le c t e d lo ca- tion. 3. Remove crate. Orifice replacement procedu
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 2b Prepare boiler — pressure test 5. S lo w l y r e o p e n b o ile r dr ain v al v e unt il t est p r ess ur e Hydrostatic pressure test 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. • 45 psig for boilers with 30 psig relief valve. Prepare boiler for test • 75 psig for boilers with 50 psig relief valve. 1. R e mo v e
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 3a Water piping — general information General piping information Circulator I f instal lat io n is t o c o mpl y w ith ASME o r C ana dian r e q uir e me nts, an a d- The circulator is shipped loose (wiring pre-attached to ditional high temperature limit is needed. Install control in supply piping boiler) to allow you to locate it either in the return or b e tw e e n b o ile r and isolat io n v al v e. S e t se c o nd c
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 3b Water piping — single-zone system Diaphragm-type or bladder- Closed-type expansion tank type expansion tank (Figure 4) (Figure 5) 1. Ens ur e e xpansio n tank siz e w il l hand le b o ile r and 1. Ens ur e e xpansio n tank siz e w il l hand le b o ile r and system water volume and temperature. Tank must s y s te m w a te r v o l u m e a n d te m p e r a t u r e . S e e t a n k be located in boiler return pip
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 3c Water piping — multiple zones Piping multiple zones Piping for radiant heating Follow instructions on pages 14 and 15 to install near- systems or converted gravity b o ile r o r sing le-z o ne piping . (A lso r e f e r t o Piping for systems radiant heating systems or converted gravity sys- tems, below, if applicable.) Converted gravity (or steam) systems S e e Figure 6 or Figure 7, page 17, to complete instal- Whenever possible, u
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 3c 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. 1 B o i l e r i s o l a t i o n ( b a l a n c i n g ) 10 A u t o mat ic air v e nt (w ith diap hr ag m-t y p e e xpansio n tank), o r c o nne c t valves to tank fitting (closed-type expansion tank). DO NOT use an automatic air vent when using closed-ty
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems the water temperature being supplied to the radiant Primary/secondary (preferred) tubing. bypass piping method Gaug e 8 is required on all systems to assure the return Primary/secondary bypass piping is preferred because water temperature is accurately set for a minimum of the flow rate and temperature drop in the heating 130°F . I f this g aug e is not a v ailab le ho w e v e r , a dj ust the cir
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems (continued) Figure 8 Primary/secondary piping Figure 9 Primary/secondary piping Zoning with circulators Zoning with zone valves 9 Relief valve 1 B o ile r isolat io n (balancing) v al v es 10 A u t o matic air v e nt (w ith diap hr ag m-t y pe e xpansio n tank), o r 2 Flow/check valve connect to tank fitting (closed-type expansion tank). DO NOT use an automatic air vent when using closed-type expa
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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems (continued) justed using cold (or room temperature) return water BOILER-bypass piping to the boiler. (When setting the valves without gauge method 4a installed — using cold or room temperature water — ass ume the r e t ur n wat e r t e mp e r at ur e t o b e 60°F . S e t This piping method (Figures 10 and 11, page 21) is the valves so gauge 8 r ea ds at least 120°F . called a boiler-bypass because pa
