CGi Manual

Part Number 550-142-302/0520
CGi
SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual
36
Check-out procedure — checklist
8
❏ Boiler and heat distribution units filled with water?
❏ Automatic air vent, if used, open one full turn?
❏ Air purged from system?
❏ Air purged from gas piping? Piping checked for leaks?
❏ Correctly sized manifold orifices installed? Refer to
Table 2,
page 12, to check size and fuel type.
Correctly sized manifold orifices must be used.
Failure to do so will cause severe personal injury,
death or substantial property damage.
❏ Followed operating instructions on boiler or in manual
Section
9 for proper start-up?
❏ Proper burner flame observed? Refer to Check burner flame,
manual Section 7b.
❏
Test temperature limit — While burners are operating, turn
Boiler Temp adjustment knob counterclockwise until display
reading is below actual boiler water temperature. Burners
should go off while circulator continues to operate. Turn
Boiler Temp adjustment knob clockwise until display read-
ing is above boiler water temperature and ignition sequence
should resume.
❏ Test low water cut off – While burners are operating, press
and hold “LWCO TEST” button on control. Burners should
go off while circulator continues to operate and LWCO light
should turn ON. Release “LWCO TEST” button and ignition
sequence should resume.
❏ Test field-installed controls — If the boiler has an additional
low water cutoff, additional high limit or other controls, test
for operation as outlined by manufacturer. Burners should
be operating and should go off when controls are tested.
When controls are restored, burners should reignite.
❏ Test ignition system safety device:
a. Connect manometer to outlet side of gas valve.
b. Start boiler, allowing for normal start-up cycle to
occur and main burners to ignite.
c. With main burners on, manually shut off gas supply at
manual main shutoff gas valve. Burners should go off.
d. Open manual main shutoff gas valve. Manometer
should confirm there is no gas flow.
e. Pilot will relight, flame sensing element will sense pilot
flame and main burners will reignite.
❏ Set limit control(s) to system temperature requirements.
Adjust balancing valves and controls to provide design
temperature to system.
❏ Set Economy mode.
❏ For multiple zones, adjust flow so it is about the same in
each zone.
❏ Verify thermostat heat anticipator (if available) set
properly? Refer to
Field wiring, manual Section 6, page 31,
Thermostat(s).
❏ Cycle boiler with thermostat — Raise to highest setting and
verify boiler goes through normal start-up cycle. Lower to
lowest setting and verify boiler goes off.
❏ Cycle DHW Aquastat if used.
❏ Measure natural gas input:
a. Operate boiler 10 minutes.
b. Turn off other appliances.
c. At natural gas meter, measure time (in seconds) re-
quired to use one cubic foot of gas.
d. Calculate gas input:
3600 x 1000
number of seconds from step c
= Btuh
e. Btuh calculated should approximate input rating on
boiler rating label.
❏ Check manifold gas pressure by connecting manometer to
downstream test tapping on main gas valve. Manifold pres-
sure for natural gas should be 3.5" w.c. and for propane gas
should be 10" w.c.
❏ Observe several operating cycles for proper operation.
❏ Set room thermostat to desired room temperature.
❏ Fill in Installation and service certificate below?
❏ Review all instructions shipped with this boiler with owner
or maintenance person. Return instructions to envelope and
give to owner or place in pocket inside front panel in boiler.
Installation and service certificate
Boiler model ______________ Series ________ Consumer Protection number ___________ Date installed ___________
Measured Btuh input ____________________
Installer ________________________ ________________________________ ________________________
(company) (address) (phone)
Installer’s signature: _____________________________________
❏ Installation instructions have been followed.
❏ Check out sequence has been performed.
❏ Above information is certified to be correct.
❏ Information received and left with owner/maintenance person