System Start-Up And Checkout; Main Burner Check; Initial Start; Check Gas Input To Boiler - New Yorker CG-E SERIES Installation, Operating And Service Instructions

VII. System Start-up and Checkout
A
. Main Burner Check - Check main burners to see
that they were not dislodged during shipment. Rear
of burners should be in the vertical slots in the rear of
burner tray and the front of the burners should be seated
completely on the orifices.
B.

Initial start -

1. Fill entire heating system with water and vent
air from system. Use the following procedure on a
System equipped with zone valves.
a. Close isolation valve in boiler supply piping.
b. Isolate all circuits by closing zone valves or
balancing valves.
c. Attach a hose to hose bib located just below
isolation valve in boiler supply piping. (Note
- Terminate hose in five gallon bucket, at a
suitable floor drain, or outdoor area).
d. Starting with one circuit, open zone valve.
e. Open hose bib.
f. Open fill valve (Make-up water line should be
located directly above isolation valve in boiler
supply piping).
g. Allow water to overflow from bucket until
discharge from hose is bubble free for 30
seconds.
h. Open zone valve to the second zone to be
purged, then close the first. Repeat this step until
all zones have been purged, but always have one
zone open. At completion, open all zone valves.
i. Close hose bib, continue filling the system
until the pressure gauge reads 12 psi. Close fill
valve. (Note - If make-up water line is equipped
with pressure reducing valve, system will
automatically fill to 12 psi. Leave globe valve
open).
j. Open isolation valve in boiler supply piping.
k. Remove hose from hose bib.
2. Turn ROOM THERMOSTAT to lowest setting.
3. Be sure that gas to pilot and main burners has been
off for at least five minutes and vent damper has
been in the open position.
4. Turn "OFF" the electric switch serving boiler.
5. Open valve on main gas line at meter.
6. PURGE AIR FROM GAS PIPING. Adequate
ventilation must be provided and no smoking or
open flame permitted.
7. Turn "ON" electric switch serving boiler.
8. Open Manual Shut-off Valve upstream of
Combination Gas Valve.
Figure 13: Top View of Honeywell Gas Valves
9. Loosen or remove Inlet Pressure Tap Plug in
Combination Gas Valve and when purging is
complete, tighten or replace plug. (See Figure 13).
10. Check pipe and fittings from meter to Combination
Gas Valve using soap solution or other approved
methods.
CAUTION
11. Test gas piping and connections between
Combination Gas Valve and manifold, orifices, and
pilot piping for leaks after boiler is operating. Use
soap solution or other approved method.
C.

Check Gas Input to Boiler

1. Input Rate and Maximum Inlet Pressure shown on
Rating Label must not be exceeded. Inlet pressure
must not be lower than minimum inlet pressure
shown on Rating Label.
2. Input ratings shown on boiler rating label can be
used for elevations up to 2000 ft. For elevations
2000 ft or higher, reduce input rate 4 percent per
1000 ft above sea level. Do not install at elevations
above 12,000 ft. See Table below.
Boiler
Rating 5000 ft.
Model
Label (1525 m)
CG30E 70.0 56.0
CG40E 105.0 84.0
CG50E 140.0 112.0
CG60E 175.0 140.0
CG70E 210.0 168.0
CG80E 245.0 196.0
CG90E 280.0 224.0
3. All Rate checks and all adjustments are to be made
while boiler is firing - all other appliances connected
to the same meter as the boiler must be off.
Input [Mbh]
7,000 ft. 10,000 ft.
(2130 m) (3050 m)
49.0 42.0
73.5 63.0
98.0 84.0
122.5 105.0
147.0 126.0
171.5 147.0
196.0 168.0
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