Install Instructions

Part Number 550-142-902/1016
CGi
GAS-FIRED WATER BOILER — SERIES 3 — Boiler Manual
46
10b
Service & maintenance – annual start-up (cont.)
❏ Inspect . . .
Burners and base
The boiler contains ceramic fiber and fi-
berglass materials. Use care when han-
dling these materials per instructions
on page 71 of this manual. Failure to
comply could result in severe personal
injury.
If insulation is damaged or displaced,
do not operate the boiler. Replace or
reposition insulation as necessary. Fail-
ure to replace damaged 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, item 4, page 64).
2. Inspect burners and all other components in the boiler
base.
3. If burners must be cleaned see Burner cleaning in-
structions
below.
4. Inspect the slotted jacket cooling openings in the bot-
tom left and right of the base pan (Figure 40, item 7,
page 64).
5. Inspect the base insulation. Pay attention to the WARN-
ING
on page 71 regarding working with insulation
materials.Verifythattheinsulationisintactandsecure
against all four sides of the base.
Burner cleaning instructions
 Airbornematerials,suchasberglassand
dust, are present during construction
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 fol-
low 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. Removeburnershieldandthebasepanairbafe.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 com-
pletely 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.
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ttingsandtubing.Verifythatcondensate
can flow freely to drain.
❏ Service . . .
Inducer motor
1. With boiler power off,placeafewdropsofS.A.E.20motoroilin
each of the two oil cups.
Use only S.A.E. 20 motor oil to lubricate the inducer
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 sensor
1. The temperature 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 insulator
surfaces.
d. Reinstallsensorintoboiler.Donotovertighten.
❏ Start-up . . .
1. Performallstart‑upproceduresinSection7 of this manual.
2. Verifycold fill pressure is correct and that fill system is working
properly.
3. Verifyantifreeze level (if used) is at the right concentration and
that inhibitor level is correct.
4. Check gas pipingper manual Sections 5 and 7a, verifying no
indications of leakage and all piping and connections are in good
condition.
5. Read the appropriate Operating instructions(Section9c of this
manual or on boiler label) applying to the boiler.
6. StarttheboilerfollowingtheappropriateOperating instructions
(Section9c of this manual or on boiler label).