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Part Number 550-142-300/0520
29
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual
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 23, Figure 9 through Fig-
ure 16
). Route hose to an area where water can
drain and be seen.
b. Close the boiler or system isolation valve be-
tween 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 pro-
ceed 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 pressure.
h. After the system has operated for a while, elimi-
nate 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, begin-
ning 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.
Start-up — preparation (continued)
6a
Inspect system water piping
After filling the boiler and system with water, inspect
all piping
throughout the system for leaks. If found,
repair immediately. Repeat this inspection after the
boiler has been started and the system has heated up.
Leaks must be repaired at once.
Failure to do so can damage the
boiler, resulting in substantial
property damage.
Do not use petroleum-based
cleaning or sealing compounds
in boiler system. Severe damage
to boiler will occur, resulting in
substantial property damage.
Inspect base insulation
The boiler contains ceramic fiber
and fiberglass materials. Use care
when handling these materials
per instructions on page 66 of this
manual. Failure to comply could
result in severe personal injury.
Failure to replace damaged in-
sulation or reposition insulation
can result in a fire hazard, causing
severe personal injury, death or
substantial property damage.
Check to make sure
base insulation is secure against
all four sides of the base. If insulation is damaged or
displaced, do not operate boiler. Replace or reposition
insulation.
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