Part Number 550-142-302/0520
CGi
SERIES 4 — GAS-FIRED WATER BOILER —
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 fiberglass 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 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 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 fittings and tubing. Verify that condensate
can flow freely to drain.
❏
Service . . .
Inducer motor
1. With boiler power
off
, place a few drops of SAE 20 motor oil in each
of the two oil cups.
Use
only
SAE 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/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 insulator
surfaces.
d.
Reinstall sensor into boiler using appropriate thread sealant. Do
not overtighten
.
e. Refill
boiler.
❏
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).
