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CGi
SERIES 4 — GAS-FIRED WATER BOILER —
10b
Service & maintenance – annual start-up
Inspect . . .
Burners and base
The boiler contains ceramic fiber
and fiberglass materials. Use care
when handling these materials
per instructions on page 71 of this
manual. Failure to comply could
result in severe personal injury.
If insulation is damaged or dis-
placed, do not operate the boiler.
Replace or reposition insulation as
necessary. Failure to replace dam-
aged insulation can result in a fire
hazard, causing severe personal
injury, death or substantial property
damage.
1. After turning off power to the boiler, remove the base
burner shield (
Figure 40
2. Inspect burners and all other components in the
boiler base.
3. If burners must be cleaned see
below.
instructions
4. Inspect the slotted jacket cooling openings in the
bottom left and right of the base pan (
item
, page 64).
7
5. Inspect the base insulation. Pay attention to the
on page 71 regarding working with insu-
WARNING
lation materials. Verify that the insulation is intact
and secure against all four sides of the base.
Burner cleaning instructions
Airborne materials, such as fiberglass
and dust, are present during construc-
tion and remodeling. These materials
can be drawn in with the combustion
air and obstruct burner ports, resulting
in carbon monoxide production, a fire
hazard, or building freeze damage.
Read and follow the
page 9. Failure to inspect and clear
gas burner ports could result in severe
personal injury, death or substantial
property damage.
1. Remove burner shield and the base pan air baffle.
Next remove the pilot bracket assembly. Then
remove the four screws securing the burner tray
to the manifold and slide the burner tray out under
the manifold.
2. Inspect each burner to insure that every port is
completely open.
3. If any port is not completely clear, run a vacuum
at the burner inlet while cleaning the burner ports
with a wire brush. The vacuum will help to draw
any airborne material out of the burner.
46
, item
, page 64).
4
Burner cleaning
,
Figure 40
WARNING
on
Boiler Manual
4. Reinstall components, starting with the burner tray, then the
pilot bracket assembly, burner baffle, and air inlet top and
front panels.
5. Follow the start-up procedure in the boiler manual.
Condensate drain system
1. Inspect condensate drain fittings and tubing. Verify that con-
densate can flow freely to drain.
Service . . .
Inducer motor
1. With boiler power
off
in each of the two oil cups.
Use only
motor. Do not use universal household oils. Motor
could be damaged, resulting in possible severe
property damage.
Oiled-bearing circulators
1. The circulator shipped with the CGi boiler is water-lubricated.
No oiling is required.
2. Check other circulators in the system. Oil any circulators
requiring oil, following circulator manufacturer's instructions.
Over-oiling will damage the circulator.
Temperature/LWCO sensor
1. The temperature/LWCO sensor may accumulate deposits
on the probe surface. Annual inspection and cleaning of the
probe will improve boiler performance.
Disconnect power, unplug harness from sensor.
a. Drain boiler water to a level below the sensor.
b. Remove sensor from boiler.
c. Wipe any built up contaminates from probe and insula-
tor surfaces.
d.
Reinstall sensor into boiler using appropriate thread seal-
ant. Do not
overtighten.
e. Refill boiler.
Start-up . . .
1. Perform all start-up procedures in Section
2. Verify
cold fill pressure
properly.
3. Verify
antifreeze level
that inhibitor level is correct.
4.
per manual Sections
Check gas piping
indications of leakage and all piping and connections are in
good condition.
5. Read the appropriate
this manual or on boiler label) applying to the boiler.
6. Start the boiler following the appropriate
(Section
of this manual or on boiler label).
9c
, place a few drops of SAE 20 motor oil
to lubricate the inducer
SAE 20 motor oil
of this manual.
7
is correct and that fill system is working
(if used) is at the right concentration and
and
5
7a
(Section
Operating instructions
Operating instructions
Part Number 550-142-302/0124
(cont.)
, verifying no
of
9c
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