Install Instructions

ManualsBrandsWeil-McLain ManualsBoilersCGI-4 - 66,000 BTU Output Cast Iron Boiler, Spark Ignition (Nat Gas)

Part Number 550-142-902/1016

CGi

GAS-FIRED WATER BOILER — SERIES 3 — Boiler Manual

10b

Service & maintenance – annual start-up (cont.)

❏ Review with owner

1. Review the User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance sched-

ule speciﬁed in the

User’s Information Manual (and

in this manual as well).

3. Remind the owner of the need to call in a licensed con-

tractor should the boiler or system exhibit any unusual

behavior.

4. Remind the owner to follow the proper shutdown

procedure and to schedule an annual start-up at the

beginning of the next heating season.

❏ Cleaning boiler

heating surfaces

The boiler contains ceramic fiber and

ﬁberglass 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.

1. Shutdownboiler:

• Follow“To Turn Off Gas to Appliance”

instructionsonboilerandOperating instruc-

tions.

• Donotdrainboilerunlessitwillbeexposedto

freezing temperatures. If using antifreeze in sys-

tem, do not drain.

2. Follow shutdown procedure.

3. Remove venting system connection to boiler.

4. Remove top jacket panel. Turn back insulation.

5. Removecollectorbox/transitionassembly.Cleansealant

from assembly and sections.

6. Remove radiation plates hanging between sections.

7. Removeburnersfrombase.Brushandvacuumburners

toremovealldustandlint.Verifythatallburnerports

are free of debris.

8. Place newspapers in base of boiler to collect soot.

9. Cleanbetweensectionswithwireuebrush.

10.Removenewspaperandsoot.Vacuum or brushbase

and surrounding area.

11. Reinstall radiation plates.

12.Replace collectorbox/transitionassembly.Sealwith

sealant. Obtain gas-tight seal to prevent ﬂue gas spill-

age and carbon monoxide emissions, resulting in severe

personal injury or death.

13. Replace insulation and jacket top panel.

14.Start up boiler following Section 7, pages 32-35 of

this manual and the boiler Operating instructions.

Excessive sooting indicates improper gas combustion.

If found check for proper combustion and make any

necessary adjustments.

 Safetyrelief valvesshouldbereinspected AT

LEAST ONCE EVERY THREE YEARS

, by a

licensed plumbing contractor or authorized

inspection agency, to ensure that the product has

not been affected by corrosive water conditions

and to ensure that the valve and discharge line

have not been altered or tampered with illegally.

Certain naturally occurring conditions may

corrode the valve or its components over time,

renderingthevalveinoperative.Suchconditions

are not detectable unless the valve and its com-

ponents are physically removed and inspected.

This inspection must only be conducted by a

plumbing contractor or authorized inspection

agency — not by the owner. Failure to reinspect

the boiler relief valve as directed could result

in unsafe pressure buildup, which can result

in severe personal injury, death or substantial

property damage.

Following installation, the valve lever must

be operated AT LEAST ONCE A YEAR

to en-

surethatwaterwaysareclear.Certainnaturally

occurring mineral deposits may adhere to the

valve, rendering it inoperative. When manually

operating the lever, water will discharge and

precautions must be taken to avoid contact with

hotwaterand to avoid waterdamage. Before

operating lever, check to see that a discharge

line is connected to this valve directing the ﬂow

of hot water from the valve to a proper place of

disposal otherwise severe personal injury may

result. If no water ows, valve is inoperative.

Shut downboiler until anew relief valve has

been installed.

Boiler relief valve

1. Inspect the relief valve and lift the lever to verify ﬂow as in the

following warnings, excerpted from a relief valve manufacturer’s

warninglabel.Beforeoperatinganyreliefvalve,ensurethatit

is piped with its discharge in a safe area to avoid severe scald

potential.ReadmanualSection4 before proceeding further.

2. Afterfollowingtheabovewarningdirections,ifthereliefvalve

weeps or will not seat properly, replace the relief valve. Ensure

that the reason for relief valve weeping is the valve and not over-

pressurization of the system due to expansion tank waterlogging

or undersizing.

Figure 35 Relief valve, typical