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Part Number 550-110-711/1108
45
GOLD
CGi-4E Gas-Fired Water Boiler — Boiler Manual
❏ Inspect . . .
Burners and base
The boiler contains ceramic fiber
and fiberglass materials. Use care
when handling these materials per
instructions on page 68 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 neces-
sary. Failure 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 60).
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 60).
5. Inspect the base insulation. Pay attention to the
WARN-
ING
on page 68 regarding working with insulation
materials.Verifythattheinsulationisintactandsecure
against all four sides of the base.
Burner cleaning instructions
Airborne materials, such as fiberglass
and dust, are present during construc-
tion 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 follow 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. Removeburnershieldandthebasepanairbafe.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. Inspectcondensatedrainttingsandtubing.Verifythatcondensate
can flow freely to drain.
❏ Service . . .
Inducer motor
1. With boiler power off,placeafewdropsofS.A.E.20motoroilin
each of the two oil cups.
Use only S.A.E. 20 motor oil to lubricate the inducer
motor.Donotuseuniversalhouseholdoils.Mo-
tor could be damaged, resulting in possible severe
property damage.
Oiled-bearing circulators
1. ThecirculatorshippedwiththeCGi-4Eboileriswater-lubricated.
Nooilingisrequired.
2. Checkothercirculatorsinthesystem.Oilanycirculatorsrequiring
oil, following circulator manufacturer’s instructions. Over-oiling
will damage the circulator.
❏ Start-up . . .
1. Performallstart-upproceduresinSection7 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 pipingpermanualSections5 and 7a, verifying no
indications of leakage and all piping and connections are in good
condition.
5. Read the appropriate
Operating instructions(Section9c of this
manual or on boiler label) applying to the boiler.
6. Starttheboilerfollowingtheappropriate
Operating instructions
(Section9c of this manual or on boiler label).
10b Service & maintenance – annual start-up (cont.)