Weil-McLain CGI-4E Boiler User Manual


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Part Number 550-110-711/1108
13
GOLD
CGi-4E Gas-Fired Water Boiler — Boiler Manual
Prepare boiler — pressure test
Hydrostatic pressure test
Pressure test boiler before attaching water or gas piping
(except as noted below) or electrical supply.
Prepare boiler for test
1. Removetheshippingnipple(fromCGi-4Esupply
tapping) and remove the boiler relief valve. Tempo-
rarily
plugthereliefvalvetappingwitha¾”NPT
pipe plug.
2. Remove1¼”nipple,reducingteeanddrainvalve
from circulator hardware and pressure/temperature
gauge carton. Install in boiler return connection
as shown on page 3 and Figure 42, page 64. Install
circulator on either the return or supply.
3. Remove1¼”nipple,1¼”x1¼”x½”teeandpres-
sure/temperature gauge from circulator hardware
and pressure/temperature gauge carton. Pipe to
boiler supply connection as shown on page 3 and
Figure 42, page 64. (Use pipe dope sparingly.)
4. Connectahosetoboilerdrainvalve,theotherend
connected to a fresh water supply. Make sure hose
can also be used to drain boiler after test.
5. Connectanippleandshutoffvalvetosystemsupply
connectiononthe1¼”tee.Thisvalvewillbeused
tobleedairduringthell.(Valveandnipplearenot
included with boiler.)
6. Connectanippleandshutoffvalvetosystemre-
turn connection (at circulator flange if circulator
installed on return). This valve will be used to bleed
airduringthell.(Valveandnipplearenotincluded
with boiler.)
Fill and pressure test
1. Open the shutoff valves you installed on supply and
return connections.
2. Slowlyopenboilerdrainvalveandfreshwatersup-
ply to fill boiler with water.
3. When water flows from shutoff valves, close boiler
drain valve.
4. Closeshutoffvalves.
2b
5. Slowlyreopenboilerdrainvalveuntiltestpressure
on the pressure/temperature gauge reaches no more
than:
•
45 psig for boilers with 30 psig relief valve.
•
75 psig for boilers with 50 psig relief valve.
6.
Test for no more than 10 minutes at:
• 45 psig for boilers with 30 psig relief valve.
•
75 psig for boilers with 50 psig relief valve.
Do not leave boiler unattended.
A cold water fill could expand and
cause excessive pressure, resulting
in severe personal injury, death or
substantial property damage.
7. Make sure constant gauge pressure has been main-
tainedthroughouttest.Checkforleaks.Repairif
found.
Leaks must be repaired at once.
Failure to do so can damage boiler,
resulting in substantial property
damage.
Donotusepetroleum-based clean-
ing or sealing compounds in boiler
system. Severedamage to boiler
will occur, resulting in substantial
property damage.
Drain and remove fittings
1. Disconnectllwaterhosefromwatersource.
2. Drainboileratdrainvalveorouthose,whichever
provides best access to drain. Remove hose after
draining if used to drain boiler.
3. Remove nipples and valves unless they will remain
for use in the system piping.
4. Removeplugfromreliefvalvetapping.Seepage20
to replace relief valve.
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