Weil-McLain CGI-4E 10b Service & maintenance annual start-up, Burners and base, Inducer motor

GOLD CGi-4E Gas-Fired Water Boiler — Boiler Manual

10b Service & maintenance – annual start-up (cont.)

❏Inspect . . .

Burners and base

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per

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

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. Verify that the insulation is intact and secure against all four sides of the base.

Burner cleaning instructions

1.Inspect condensate drain fittings and tubing. Verify that condensate can flow freely to drain.

❏Service . . .

Inducer motor

1.With boiler power off, place a few drops of S.A.E. 20 motor oil in each of the two oil cups.

Use only S.A.E. 20 motor oil to lubricate the inducer motor. Do not use universal household oils. Mo- tor could be damaged, resulting in possible severe property damage.

Oiled-bearing circulators

1.The circulator shipped with the CGi-4E boiler is water-lubricated. No oiling is required.

2.Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator.

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.Remove burner shield and the base pan air baffle. 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

❏Start-up . . .

1.Perform all start-up procedures in Section 7 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 piping per manual Sections 5 and 7a, verifying no indications of leakage and all piping and connections are in good condition.

5.Read the appropriate Operating instructions (Section 9c of this manual or on boiler label) applying to the boiler.

6.Start the boiler following the appropriate Operating instructions

(Section 9c of this manual or on boiler label).

Part Number 550-110-711/1108 45