CGi Manual

Part Number 550-142-302/0520
CGi
SERIES 4 — GAS-FIRED WATER BOILER — Boiler Manual
48
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 flue 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 flows, 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 under sizing.
Figure 35 Relief valve, typical