Install Instructions

Part Number 550-142-902/1016
CGi
GAS-FIRED WATER BOILER — SERIES 3 — Boiler Manual
33
Start-up — preparation (continued)
7a
Fill the system with water
1. Closemanualandautomaticair vents and boiler drain cock.
2.
Fill to correct system pressure.Correctpressurewillvarywitheach
application. Typical cold water fill pressure for a residential system is
12 psi.
3.
Purge air from system:
a. Connectahosetothepurgevalve(seedrain valves, item
6, in
suggested piping diagrams on pages 23 through 27, Figure 18
through Figure 23). Route hose to an area where water can drain
and be seen.
b. Closetheboilerorsystemisolationvalvebetweenthepurgevalve
and fill connection to the system.
c. Closezoneisolationvalves.
d. Open quick-fill valve on cold water makeup line.
e. Open purge valve.
f. Onezoneatatime,opentheisolationvalves.Allowwatertorun
through the zone, pushing out the air. Run until no noticeable air
owispresent.Closethezoneisolationvalvesandproceedwith
the next zone. Follow this procedure until all zones are purged.
g. Closethequick‑llwatervalveandpurgevalveandremovethe
hose. Open all isolation valves. Watch that system pressure rises to
correct cold-fill pressure.
h. Afterthesystemhasoperatedforawhile,eliminateanyresidual
air by using the manual air vents located throughout the system.
i. If purge valves are not installed in system, open manual air vents
insystemoneatatime,beginningwithlowestoor.Closevent
when water squirts out. Repeat with remaining vents.
4. Open
automatic air vent (diaphragm-type or bladder-type expansion
tank systems only) one turn.
5. Open other vents:
a. Startingonthelowestoor,openairventsoneatatimeuntil
water squirts out.
b. Repeat with remaining vents.
6. Refill to correct pressure.
Inspect system water piping
Afterllingtheboilerandsystemwithwater,inspect all
piping
throughout the system for leaks. If found, repair
immediately. Repeat this inspection after the boiler has
been started and the system has heated up.
Leaks must be repaired at once.
Failure to do so can damage the
boiler, resulting in substantial prop-
erty damage.
 Do not use petroleum-based
cleaning or sealing compounds
inboilersystem.Severedamageto
boiler will occur, resulting in sub-
stantial property damage.
Inspect base insulation
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.
Failure to replace damaged insu-
lation or reposition insulation can
result in a fire hazard, causing severe
personal injury, death or substantial
property damage.
Checktomakesure
base insulation is secure against
all four sides of the base. If insulation is damaged or
displaced, do not operate boiler. Replace or reposition
insulation.