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Part number 550-110-260/0107
27
GOLD CGs Gas-Fired Water Boiler — Boiler Manual
Start-up — preparation7a
Fill the system with water
1. Close manual and automatic air vents and
boiler drain cock.
2.
Fill to correct system pressure. Correct
pressure will vary with each application.
Typical cold water fill pressure for a residential
system is 12 psi.
3. Purge air from system:
a. Connect a hose to the purge valve (see
drain valves, item 6, in suggested piping
diagrams on pages 17 through 21, Fig-
ure 6 through Figure 11). Route hose
to an area where water can drain and be
seen.
b. Close the boiler or system isolation
valve between the purge valve and fill
connection to the system.
c. Close zone isolation valves.
d. Open quick-fill valve on cold water
makeup line.
e. Open purge valve.
f. One zone at a time, open the isolation
valves. Allow water to run through the
zone, pushing out the air. Run until no
noticeable air flow is present. Close the
zone isolation valves and proceed with
the next zone. Follow this procedure
until all zones are purged.
g. Close the quick-fill water valve and
purge valve and remove the hose. Open
all isolation valves. Watch that system
pressure rises to correct cold-fill pres
-
sure.
h. After the system has operated for a
while, eliminate any residual air by
using the manual air vents located
throughout the system.
i. If purge valves are not installed in
system, open manual air vents in system
one at a time, beginning with lowest
floor. Close vent when water squirts out.
Repeat with remaining vents.
4. Open
automatic air vent (diaphragm-type
or bladder-type expansion tank systems only)
one turn.
5. Open other vents:
a. Starting on the lowest floor, open air
vents one at a time until water squirts
out.
b. Repeat with remaining vents.
6. Refill to correct pressure.
Determine if water treatment is needed
Do not use petroleum-based cleaning or sealing com-
pounds in boiler system. Severe damage to boiler will occur,
resulting in substantial property damage.
Eliminate all system leaks. Continual fresh makeup water will
reduce boiler life. Minerals can build up in sections, reduc-
ing heat transfer, overheating cast iron, and causing section
failure.
Verify water chemistry
Consult local water treatment companies for unusually hard water areas (above
7 grains hardness) or low pH water conditions (below 7.0). Boiler water pH of
7.0 to 8.5 is recommended.
Freeze protection (when used)
Use antifreeze made especially for hydronic systems. Inhibited propylene glycol
is recommended.
Do not use ethylene glycol, automotive or undiluted anti-
freeze. Severe personal injury or death can result.
1. Determine
antifreeze quantity according to system water content. Boiler
water content is listed on page 63. Remember to include expansion tank water
content.
2. Follow antifreeze manufacturer’s instructions.
3. A 50% solution of propylene glycol/water provides maximum protection to
about -30°F.
4. Local codes may require
back flow preventer or actual disconnect from city
water supply.
5. When using antifreeze in a system with automatic fill, install a water meter
to monitor water makeup. Glycol will leak before the water begins to leak,
causing glycol level to drop. Added water will dilute the antifreeze, reducing
the freeze protection level.
Check for gas leaks
Before starting the boiler, and during initial operation, smell
near the floor and around the boiler for gas odorant or any
unusual odor. Do not proceed with start-up if there is any
indication of a gas leak. Repair any leak at once.
Propane boilers only — Your propane supplier mixes an
odorant with the propane to make its presence detectable.
In some instances, the odorant can fade and the gas may no
longer have an odor.
• Propane gas can accumulate at floor level. Smell near the
floor for the gas odorant or any unusual odor. If you suspect
a leak, do not attempt to light the pilot.
• Use caution when attempting to light the propane pilot.
This should be done by a qualified service technician, par
-
ticularly if pilot outages are common.
• Periodically check the odorant level of your gas.
• Inspect boiler and system at least yearly to make sure all
gas piping is leak-tight.
• Consult your propane supplier regarding installation of a
gas leak detector. There are some products on the market
intended for this purpose. Your supplier may be able to