Install Instructions
CG i
GAS-FIRED
wATER
BOILER-
sERIEs
a-
Boiler
Manual
7a
Start-up
- preparation (continued)
Fill
the
system
with
water
I. Close manual and automatic air vents and boiler drain cock.
2.
Fill
to co
rr
ect system pressure.
Co
rr
ec
t pressure
will
vary
with
eac
h
application.
Typical
cold water
fill
pr
essure
for
a residential system is
12 psi.
3.
Purge air
from
system:
a. Co
nn
ect a h
ose
to the purge
valve
(
see
drai11
valves,
item
6, in
su
gges
ted pipi
ng
diagrams on
pages
23 through 27, Figure 18
through Figure 23). Route hose to
an
area
whe
re water can drain
and be
see
n.
b.
Cl
ose
the boiler
or
system
i
so
lati
on
valve
between
the purge
valve
and
fill
cOJ
mection to the system.
c.
Cl
ose
zone isolation
valves.
d. Open quick-fill
va
l
ve
on cold water m
ake
up
lin
e.
e.
Open purge
valve.
f.
One zone at a tim
e,
open the
iso
la
tion
valves.
Allow
water to run
through the zone,
pus
hing out the air.
Run
until no noti
ceab
le
ai
r
fl
ow
is
present. Clo
se
t
he
zone isolation
valves
and proceed
wi
th
the next zone.
Follow
this procedure until
all
zo
n
es
are pu
rgecl
g.
Clo
se
the quick-fill
water
valve
and
purge
va
l
ve
and rem
ove
the
h
ose.
Open
all
isolation
valves.
Watch
that system pressure rises to
co
rr
ec
t cold-fill
pr
essur
e.
h. After the
sys
tem has operated
fo
r a while,
eli
minate any residual
air by
us
i
ng
the
ma
n
ua
l
ai
r
ve
nts located throughout the
sys
te
m.
i.
If purge
valves
are not installed in
sys
te
m,
open man
ual
air
ve
n
ts
in system one at a time, beginning
wi
th lowest
flo
or. Cl
ose
vent
when water squirts o
ut
Repeat wi
th
re
maining vents.
4.
Open automatic air vent (diaphragm-type or bladder-type exp
an
sio
n
tank
sys
tems o
nl
y)
one tum.
5. Open other
vents:
a. Starting on the l
owes
t
floor,
open air vents o
ne
at a time until
water
sq
u
irts
o
ut
.
b.
Repeat
with re
ma
ining
vents.
6.
Refill
to correct
pr
essur
e.
Part Number
550-
1
42-780
/0712
Inspect
system
water
piping
After
filling
the boiler and
system
with
water,
Inspect a
ll
piping throughout the system
for
l
eaks.
If found, repair
i
mm
ediately.
Repeat this inspection after the bo
il
er h
as
been started and the
sys
tem has heated u
p.
I&
WARNING
!
ft
jHddijj;l
Leaks must
be
repaired
at
once.
Fail
ur
e to do so can damage the
boiler, resulting in substantial prop-
erty
dan1age.
Do
n
ot
use
petroleum
-
based
cleaning
or
sealing compounds
in boiler
system
.
Severe
dan1ag
e to
bo
il
er
will
occur, r
es
ulting in sub-
stantial property damage.
Inspect
base
insulation
I&
WARNING
!
I&
WARNING
I
Th
e boiler contains
ce
ramic fiber
and
fiberglass
mate
rials
.
Use
care
when handling th
ese
mate
ri
als per
ins
tru
ctions on Page
70
of
this
manual. Failure to comply could
result
in
severe personal inj
ury.
Failure to replace damaged insu-
lat
i
on
or
reposition
in
s
ulat
io
n
ca
n
result in a
fire
hazard,
ca
using
severe
personal injury, death or substant
ial
prope
rt
y damag
e.
Check to
ma
ke
sure
base
Insulation Is
secure
against
a
ll
four
sides of the
base.
If insulation is dam
aged
or
d
isplaced,
do not operate boiler. R
eplace
or
reposition
insulation.
33