10042 - MBH International Corp.

INSTALLATION and OPERATION
MANUAL
GAS BOILERS
MODELS: CG-214 (E)
CG-314 (E)
CG-414 (E)
CG-220 (E)
CG-320 (E)
CG-325 (E)
CG-330 (E)
CROWN FOOD SERVICE EQUIPMENT LTD.
70 OAKDALE ROAD, DOWNSVIEW (TORONTO), ONTARIO, CANADA, M3N 1V9
TELEPHONE: (416) 746-2358, FAX: (416) 746-8324
PRINTED IN CANADA
PART NUMBER 10042R3
1
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
IMPORTANT NOTES FOR INSTALLATION AND OPERATION
It is recommended that this manual be read thoroughly and that all instructions be followed
carefully. This manual should be retained for future reference.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other
flammable vapours or liquids in the vicinity of this or any other
appliance.
PURCHASER: Instructions to be followed in the event that the operator of this
appliance smells gas must be posted in a prominent location. This information
shall be obtained by consulting the local gas supplier.
Do not attempt to operate this unit in the event of a power failure.
Keep the appliance area free and clear from combustibles.
Do not obstruct the flow of combustion and ventilation air.
Adequate clearances must be maintained for servicing and proper operation.
WARNING: Improper installation, operation, adjustment, alteration,
service or maintenance can cause property damage, injury or death.
Read the installation, operating and maintenance instructions
thoroughly before installing, operating or servicing this equipment.
NOTICE: Contact the factory, the factory representative or local
service company to perform maintenance and repairs.
PART NUMBER 10042R3
2
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
TABLE OF CONTENTS
DESCRIPTION
PAGE
1.0 Service Connections
....................................................4
2.0 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.0 Service Connections
4.0 Operation Instructions
....................................................8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.0 Operation Instructions for CSD-1 Equipped Units
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.0 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.0 Adjustments
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.0 Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PART NUMBER 10042R3
3
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
1.0 SERVICE CONNECTIONS
PART NUMBER 10042R3
4
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
GENERAL
The gas boiler is designed to ASME Code and approved as a steam heating boiler restricted to
operation at pressure not to exceed 15 psi. The gas boiler may be in a 24" cabinet base rated
at 140,000 or 200,000 BTU, 36" cabinet base rated at 140,000, 200,000, 250,000 or 300,000
BTU, operational on Natural or Propane gas. Boilers may have optional electronic ignition and
CSD-1 controls.
2.0 INSTALLATION INSTRUCTIONS
UNPACKING
Immediately after unpacking, check for possible shipping damage. If the appliance is found to
be damaged, save the packaging material and contact the carrier within 15 days of delivery.
Before installing, verify that the gas (natural or propane), the elevation from sea level and the
electrical supply agree with the specification on the data plate. NOTE: If this appliance is being
installed above 2,000 feet altitude, contact your authorized service office to assure that the
proper orifice size for your elevation has been installed.
LOCATION
The installation location must be kept free and clear of combustibles. Do not obstruct the flow
of combustion and ventilation air. Clearance from combustible construction must be a minimum
of 3 inches from the sides and 6 inches from the back. The appliance should be installed on a
noncombustible floor. Provide adequate clearances for cleaning, maintenance, service and
proper operation.
Sufficient air should be allowed to enter the room to compensate for the amount of air removed
by any ventilating system and for combustion of the gas burners. Do not obstruct the air flow
into and around the appliance. Do not obstruct the flow of flue gases from the flue duct located
at the rear and above the cabinet. Position the appliance in its final location. Check that there
are sufficient clearances to service the controls, for door swings, etc., so there will be no
problem in making the required supply and drain connections.
Allow enough space between any other piece of equipment or a wall for service access.
Service on the cabinet base may require access to the left and/or right side panels.
PART NUMBER 10042R3
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INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
LEVELING AND ANCHORING THE CABINET
1. Place appliance in the installation position.
2. Place a carpenter’s level on top of the appliance and turn the adjustable feet to level sideto-side and front-to-back.
3. Mark hole locations on the floor through the anchoring holes provided in the rear flanged
adjustable feet.
4. Remove appliance from installation position and drill holes in locations marked on the floor.
Insert proper anchoring devices (not supplied).
5. Place appliance back in the installation position.
6. Place carpenter’s level on top appliance and re-level side-to-side and front-to-back.
7. Bolt and anchor appliance securely to the floor.
8. Seal bolts and flanged feet with Silastic or equivalent compound.
INSTALLATION CODES AND STANDARDS
The boiler must be installed in accordance with:
Gas installation to conform to local codes, or in absence of local codes, with the National Fuel
Gas Code - ANSI Z223.1/NFPA 54. In Canada installation to be in accordance with CSA
B149.1 Natural Gas and Propane Installation Code.
1. The appliance and its individual shut off valve must be disconnected from the gas supply
piping system during any pressure testing of that system at pressures in excess of ½ psig
(3.5 kPa).
2. The appliance must be isolated from the gas supply piping system by closing its individual
manual shut off valve during any pressure testing of the gas supply piping system at test
pressures equal to or less than ½ psig (3.5 kPa).
Electrical grounding must be provided in accordance with local codes, or in the absence of local
codes, with the National Electrical Code ANSI/NFPA 70. In Canada, installation must be in
accordance with the Canadian Electrical Code CSA C22.2.
PART NUMBER 10042R3
6
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
INSTALLATION CODES AND STANDARDS (Continued)
WIRING DIAGRAM FOR APPLIANCE IS LOCATED INSIDE CABINET DOOR.
EXHAUST FANS AND CANOPIES:
Canopies are set over ranges, ovens, kettles, etc., for ventilation purposes. It is recommended
that a canopy extend 6 inches past the appliance and be located 6 feet 6 inches from the floor.
Filters should be installed at an angle of 45 degrees or more with the horizontal. This position
prevents dripping of grease and facilitates collecting the run-off grease in a drip pan, usually
installed with the filter. A strong exhaust fan tends to create a vacuum in the room and may
interfere with burner performance or may extinguish pilot flames. Makeup air openings
approximately equal to the fan area will relieve such vacuum. In case of unsatisfactory
performance on an appliance, check with the exhaust fan in the “OFF” position.
PART NUMBER 10042R3
7
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
3.0 SERVICE CONNECTIONS
PLUMBING CONNECTIONS
WARNING: Plumbing connections must comply with applicable
sanitary, safety, and plumbing codes.
WATER SUPPLY CONNECTION
The incoming cold water supply connection, at the rear of the steamer cabinet, requires 3/8"
tubing and water pressure of 25-50 psi. A manual shut-off valve must be provided convenient
to the appliance; this valve should be open when the boiler is in operation.
FAILURE OR MALFUNCTION OF THIS APPLIANCE DUE TO POOR WATER QUALITY IS
NOT COVERED UNDER WARRANTY. SEE WATER QUALITY STATEMENT, PAGE 4.
DRAIN CONNECTION
The drain (2" IPS) should be piped to a floor drain near the unit. There should be no solid drain
connection; an “open gap” between the boiler and the floor drain is required.
GAS CONNECTION
1. The data plate on the cabinet door of the boiler indicates the type of gas your unit is
equipped to burn. DO NOT connect to any other gas type.
Keep the appliance area free and clear from combustible substances. Do not obstruct the
flow of combustion and ventilation air.
2. A 3/4" NPT line is provided at the rear for the connection. Each boiler is equipped with an
internal pressure regulator which is set at 3.5" W.C. manifold pressure for natural gas or
10.5" W.C. for LP gas. Use the 1/8" pipe tap on the burner manifold for checking pressure.
An adequate gas supply is necessary. Undersized or low pressure lines will restrict the volume
of gas required for satisfactory performance. A steady supply pressure, between 7" W.C. and
14" W.C. for natural gas and 11" W.C. and 14" W.C. for propane gas is recommended. With all
units operating simultaneously, the manifold pressure on all units should not show any
appreciable drop. Fluctuations of more than 25% on natural gas, and 10% on propane gas, will
create pilot problems and affect burner operating characteristics.
PART NUMBER 10042R3
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2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
GAS CONNECTION (Continued)
Contact your gas company for correct supply line sizes.
Purge the supply line to clean out any dust, dirt, or foreign matter before connecting the line to
the unit.
CAUTION: The pipe thread compound used when installing pipes
must be a type that is resistant to the action of liquified petroleum or
propane gases.
Codes require that a gas shut-off valve be installed in the gas line prior to the unit. Make sure
the pipes are clean and free of obstructions, dirt, and piping compound.
WARNING: Prior to start-up, check all joints in the gas supply line
for leaks. Use soap and water solution. Do not use an open flame.
Do not connect the appliance to the electrical supply until after the gas connection has been
made.
ELECTRICAL CONNECTIONS
120 VAC-60 Hz - Single Phase
Refer to the electrical diagram located inside cabinet on door.
PART NUMBER 10042R3
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2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
4.0 OPERATION INSTRUCTIONS
WARNING: Do not force the gas control knob. Use only your hand
to turn the gas control knob. Never use any tool. If the gas control
knob will not operate by hand the gas control should be replaced by
a qualified service technician.
WARNING: Do not disassemble the gas control; it contains no
replaceable components. Attempted disassembly or repair may
damage the gas control.
WARNING: In the event of main burner ignition failure, a 5 minute
purge period must be observed prior to re-establishing ignition
source.
For CSD-1 equipped boilers, see section 5.0 Operation Instructions for CSD-1 Equipped Boiler.
BOILER CONTROLS (Inside Cabinet)
Main Power Switch
-
ON fills the boiler tank and turns the boiler controls on. You
should allow 20 minutes to fill the tank and generate steam.
-
OFF shuts off the boiler controls and opens the automatic
blowdown valve, emptying the boiler tank and releasing water
and steam to the drain. This should be done at least once
daily to remove sediment, lime or scale.
Pilot Light
-
Indicates main power is ON.
Boiler Pressure Gauge
-
Should read 9 - 11 psi during operation, 0 psi during
shutdown.
Water Level Sight Glass
-
Observe level of water in the boiler and water quality.
Murkiness in the water indicates inadequate water quality; the
owner must supply proper water to the boiler. See page 4
Water Quality Statement.
PART NUMBER 10042R3
10
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
BOILER CONTROLS (Inside Cabinet) (Continued)
Water Level Control - While ON, briefly open the water level control once each week to
remove any sediment that might accumulate.
Safety Valve -
This valve will release (pop off) if the boiler has too much pressure.
Once a week, this valve should be tripped during operation to make sure
it functions properly.
1. START UP - BOILER OPERATION WITH STANDING PILOT IGNITION
Open manual gas shut off supply valve and if the appliance has a manual blowdown valve,
close it. Open cabinet door and turn ON power switch located on left side. Green pilot light will
come on, water will begin to enter boiler and required water level will be reached in about three
minutes. Observe water gauge glass to verify.
The dial on the combination gas control valve has three positions (ON-PILOT-OFF) for manual
gas control of main burners and pilot. Turn DIAL to PILOT. Depress dial and light pilot burner
located on centre main burner of boiler. Maintain dial in depressed position for about 30
seconds and release. Observe that the pilot burner flame stays on. If at any time the flame
should become extinguished, a 5 minute period of complete shut off of gas supply is required
before relighting.
Turn dial to ON and burners should ignite. Steam generation will now commence and be
completed in approximately 15 minutes. Steam generation should reach approximately 11 psi
as indicated on the pressure gauge on the boiler.
2. START UP - BOILER OPERATION WITH ELECTRONIC IGNITION
Open manual gas supply valve.
Open cabinet door and turn main power switch ON. Green pilot light will come on, water will
begin to enter boiler and required water level will be reached in about 3 minutes. Observe
water gauge sight glass to verify.
The dial on the gas combination control valve has 2 positions (ON and OFF).
ON - [Rotated counterclockwise] permits gas to flow to the pilot and main burner.
OFF - [Rotated clockwise] prevents gas flow to pilot and main burner.
NOTE: Units are shipped with the control in the ON position.
PART NUMBER 10042R3
11
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
2. START UP - BOILER OPERATION WITH ELECTRONIC IGNITION (Continued)
With the gas control valve, power switch and water supply all ON, water begins entering the
boiler and gas flows to the pilot: Spark will begin in 2 to 3 seconds. If the pilot fails to light in 90
seconds, the control will provide 100% lockout. If this occurs: Wait 5 minutes, then turn power
switch off for one minute before turning power switch back on.
Once the pilot is lit and the required water level has been reached, the main burners will ignite.
Burners will cycle to meet the steam pressure required. Steam pressure should reach
approximately 11 psi as indicated on the pressure gauge on the boiler.
DAILY SHUT DOWN
Turn power switch off.
Open blowdown valve if so equipped.
COMPLETE BOILER SHUT DOWN
If boiler is not intended to be operated for a lengthy period of time, shut off all power, gas and
water supplies to the appliance. Open blowdown valve if so equipped.
PART NUMBER 10042R3
12
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
5.0 OPERATION INSTRUCTIONS FOR CSD-1 EQUIPPED UNITS
Initial Start-Up Procedure
1. Open the manual gas shut-off supply valve.
2. Close the manual blowdown valve, if so equipped.
3. Light the pilot burner.
The dial on the combination gas valve has three positions (ON-OFF-PILOT) for manual gas
control of main burners and pilot burner. Turn the dial to PILOT. Depress the dial and light
the pilot burner on the centre burner of boiler. Maintain the dial in depressed position for
about 30 seconds and release. Observe that the pilot flame stays ON. Turn dial to “ON”.
4. Open cabinet door and turn “ON” the power switch. The green pilot light will come “ON”.
Water will begin to enter the boiler. When enough water has entered the boiler the (amber)
“STAND BY” pilot light will come on.
5. Press the “RESET” switch to begin boiler operation. The “STAND BY” pilot light will go off
and the boiler will begin operation.
If at anytime the flame should become extinguished, a five (5) minute purging is required before
relighting is attempted.
Daily Startup Procedure
1. Close the manual blowdown valve, if so equipped.
2. Examine that the pilot burner flame is burning. If the pilot burner is out, a five (5) minute
period of complete gas supply shut off is required before relighting. Follow initial start up
instructions above.
3. Open cabinet door and turn “ON” the power switch. The green pilot light will come “ON”.
Water will begin to enter the boiler. When enough water has entered the boiler the (amber)
“STAND BY” pilot light will come on.
4. Press the “RESET” switch to begin boiler operation. The “STAND BY” pilot light will go off
and the boiler will begin operation.
PART NUMBER 10042R3
13
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
5.0 OPERATION INSTRUCTIONS FOR CSD-1 EQUIPPED UNITS (Continued)
Daily Shutdown Procedure
1. Turn “OFF” the power switch. Observe that the burners go off.
2. Open the manual blowdown valve, if so equipped. If the appliance is equipped with an
automatic blowdown solenoid valve, the boiler’s contents, water and steam, will be blown
out and exhausted through the appliance drain. The cold water solenoid valve will be
activated.
Complete Shutdown Procedure
If the appliance is not intended to be operational for a lengthy period, then shut it down
completely.
1. Open the manual blowdown valve, is so equipped.
2. Shut off all supplies of power, gas and water to the appliance.
Normal Boiler Operating Cycle
Water Fill Cycle
On the initial filling of the boiler, the reset switch must be activated to initialize the safety lockout
circuit. Once the water in the boiler has reached the proper level, the level control will stop the
flow of water to the boiler. As water is consumed in the production of steam, the level control
will replenish water to the boiler.
Firing Cycle
The gas valve is controlled by pressure sensing devices. On initial operation of the boiler,
steam generation should reach 11 psi in approximately 15 minutes. At this point the “Operating
Pressure” switch will close the gas valve. When pressure drops to 9 psi, the pressure switch
opens the gas valve and ignition should occur.
Should the pressure rise to more than 14.5 psi the “Overrride pressure switch” will open the
override solenoid valve, releasing the excess steam.
Condensing Drain
A thermostat is located in the drain assembly and is activated by the temperature of steam.
The thermostat opens the cooling solenoid valve, supplying water to the drain to condense the
steam.
PART NUMBER 10042R3
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2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
OPERATION INSTRUCTIONS (Continued)
Automatic Blowdown Valve
If the unit has an automatic blowdown valve, it is activated by the main power switch. The
boiler will drain should the main power switch be turned “OFF.”
Safety Lockout Conditions
High Temperature Condition
A high temperature safety device is installed on the boiler. Should the temperature exceed the
limit of this device, the boiler will be shut down and be put in a state of lockout. The
“Temperature” pilot light (Red), and the “Standby” pilot (amber), will come on.
High Pressure Condition
A high pressure safety switch is installed on the boiler. Should the pressure exceed the limit of
this device, the boiler will be shut down and be put into a state of lockout. The “Pressure” pilot
light (Red), and the Stand By pilot (amber), will come on. Should this device fail to operate, the
safety relief valve will open.
Low Water Condition
A second low water safety cut off is supplied with the boiler. Should the water level fall below
normal operating levels, this device will activate and put the boiler in a state of lockout. The
“Low Water” pilot light (Red), and the “Stand By” pilot (amber) will come on.
PART NUMBER 10042R3
15
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
6.0 PERIODIC MAINTENANCE
Be sure to flush your boiler water level control daily. Failure to follow this procedure can cause
the control to malfunction resulting in serious boiler damage.
The Boiler Water Level Control installed on your boiler requires periodic maintenance. As boiler
water circulates into the float chamber, sand, scale and other sediment may be deposited in the
float chamber. While the chamber has been designed with a large accumulation bowl, it is
necessary to flush the sediment from the chamber by blowing down the control so that the
accumulation of sediment does not interfere with the movement of the float in the control.
Control must be flushed at least once a day.
CAUTION: Protect yourself. When flushing control, hot water and
steam will flow out of the drain.
When flushing control, note water level in gauge glass, allow the boiler to fill if necessary and
also to come up to temperature.
Before flushing control, note that water level in gauge glass is within operating range and the
boiler pressure is at least 6 psi. While the boiler is being fired, open blowdown valve at bottom
of control by rotating the handle counterclockwise about 1/4 turn to fully open the valve.
Opening the blowdown valve also checks the cut-off operation. Float should drop shutting
burner off, hot water and steam will flow out the drain flushing away sediment.
PART NUMBER 10042R3
16
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
6.0 PERIODIC MAINTENANCE (Continued)
CAUTION: If burner does not shut off during blowdown,
immediately discontinue use of appliance and call for service.
Continue draining water for about fifteen (15) seconds, from control until water is clean.
Manually close valve. Recheck gauge glass. If water level has dropped significantly, wait for
the boiler to restore water level and pressure and repeat if necessary.
PERIODIC MAINTENANCE
WARNING: Disconnect the power supply to the appliance before
cleaning or servicing.
1. If water in sight glass is not clear and appears murky, this indicates poor water quality and
may cause control failure. SEE WATER QUALITY STATEMENT, page 4.
2. Safety valve should be tripped during operation once a week to ensure that it is functioning
properly.
3. Clean around burners and orifices if lint has accumulated.
4. Visually ensure carry over ports are unobstructed.
5. Visually check that the flue is not obstructed.
CLEANING
DO NOT allow water near the electrical components.
At the end of the day, turn the Main Power Switch OFF (automatic blowdown drains the boiler
tank) or if equipped with manual blowdown valve, open. Wash exterior with mild detergent and
warm water, rinse, and wipe dry. Do not use steel wool on stainless steel surfaces.
PART NUMBER 10042R3
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2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
MAINTENANCE
REMOVAL OF LIME SCALE DEPOSITS
The interior of the steam boiler should be inspected at least twice a year by your authorized
servicer to determine whether the boiler needs to be delimed. The servicer should perform any
necessary deliming procedure. See descaling instructions.
VENT HOOD
Twice a year check the venting system (hood); remove any obstructions; and clean as
necessary.
BOILER DESCALING INSTRUCTIONS
It is recommended that the boiler be checked every 90 to 120 days for scale build up. Regular
maintenance should be carried out at this time.
If the boiler is descaled, a new Anode should be installed in the boiler to help extend its life.
1.
With boiler empty, close manual blowdown valve. If appliance is equipped with automatic
blowdown, turn water supply OFF to appliance. Turn power switch ON. This will energize
and close blowdown valve.
2.
Remove 3/4" pipe plug from fitting on left front of boiler.
3.
Insert appropriate hose or tube through fitting and pour in (½) half gallon (U.S.) of CLR
Descaling solution.
Or use the Optional Deliming assembly DPA-1 available from your dealer. For appliances
equipped with CSD-1, descaling solution must be introduced through hand hole.
4.
Replace 3/4" pipe plug securely.
5.
Open water supply to appliance allowing water to fill boiler to required level.
PART NUMBER 10042R3
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2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
BOILER DESCALING INSTRUCTIONS (Continued)
6.
Let appliance cycle, allowing two hours for descaling and cleaning. DO NOT TURN
STEAM ON TO CONNECTED APPLIANCES OR TO UPPER COMPARTMENTS.
7.
Open both the blowdown and low water level control valves for complete drainage. Then
close both valves.
For appliances equipped with automatic blowdown, turn OFF power switch and open low
water control valve. This will allow complete drainage. Once drained close water level
control valve.
8.
Turn appliance switch ON. When boiler is completely filled, turn power switch OFF. This
will rinse and drain boiler. Appliance with manual blowdown valve must be opened to
drain.
9.
Complete Step 8 twice to assure boiler is completely rinsed.
10. Appliance is now ready for use.
7.0 ADJUSTMENTS
WARNING: At least twice a year have an authorized service person clean and
adjust the unit for maximum performance.
TO CALIBRATE PRESSURE SWITCHES
NOTE: Pressure switches are factory set. Calibration is only required if
pressure switches are replaced or if adjustment is required.
PART NUMBER 10042R3
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INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
TO CALIBRATE PRESSURE SWITCHES (Continued)
Pressure switch range is from 1 to 15 psi.
Adjust all settings to maximum on high signal adjustment screw on pressure switches.
Adjust in the following sequence:
- High limit pressure switch.
- Override pressure switch.
- Operating pressure switch.
- Turning screw clockwise to increase, counterclockwise to decrease pressure.
- Use relief valve to release pressure from boiler for setting adjustments.
1. HIGH LIMIT PRESSURE SWITCHES
Allow pressure to build until unit shuts off. This should occur at 15 psi. Set the high signal
to switch at 14.5 psi on the gauge and the low signal to 13.0 psi.
2. OVERRIDE PRESSURE SWITCHES
Allow pressure to increase to 13 psi. Set the high signal to switch at 13 psi on the gauge
and the low signal to 11 psi.
3. OPERATING PRESSURE SWITCHES
Set the high signal to switch at 11 psi on the gauge and the low signal to 9 psi.
4
Release pressure in boiler to below 9 psi. Burner will come on. Once pressure has
reached 11 psi, burners will shut off. Repeat this process several times to make sure
burners come on at 9 psi and shut off at 11 psi.
Once completed, pressure switches have been calibrated.
Should your unit not have the High Limit pressure switch, start procedure at Override pressure
switch.
SERVICE
Contact your local authorized service office for any repairs or adjustments needed on this
equipment.
PART NUMBER 10042R3
20
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
8.0 TROUBLESHOOTING
WARNING: The boiler and its parts are hot. Use care when operating,
cleaning, or servicing the boiler.
BURNERS PRODUCE CARBON DEPOSITS
1. Wrong size orifices.
2. Burner air not adjusted properly.
3. Wrong gas supply.
4. Incorrect pressure at supply.
PILOT DOES NOT LIGHT
1. Gas supply to unit is OFF.
2. Power supply is OFF.
3. Gas control knob is OFF.
4. Dirty or loose wire connection to module - clean and/or tighten.
5. Ignitor cable, shorting out - check that not in contact with metal or damaged; may require
replacement.
6. Defective control or module.
7. Unit goes into 100% lockout - turn off and try again in five minutes.
8. Dirty flame sensor - clean with emery cloth.
9. Cracked ceramic insulator - replace pilot burner/ignitor sensor.
10.
Too much draft.
PART NUMBER 10042R3
21
2005-12-19
INSTALLATION AND OPERATION MANUAL, GAS BOILERS,
MODELS CG-214(E), CG-314(E), CG-414(E), CG-220(E), CG-320(E), CG-325(E), CG-330(E)
BURNER DOES NOT COME ON
1.
Gas supply to unit is “OFF”.
2.
Manual shut off valve is “OFF”.
3.
Power supply is “OFF”.
4.
Faulty valve or ignition module.
5.
Pilot out.
6.
Pilot may require flame adjustment.
7.
Water level has not been reached in boiler. Check water supply is on, check water level
control.
8.
If water at proper level, check relay which energizes pressure switch and gas control.
9.
Pressure switch may need to be replaced if relay is operating.
10. Gas control may also require replacement if energized but not operating.
SAFETY RELIEF VALVE BLOWS
1.
Defective valve.
2.
Pressure too high, pressure switch requires adjustment (lower) or may be defective.
WATER NOT BEING SUPPLIED TO BOILER
1.
Water supply is “OFF”.
2.
Defective water fill Solenoid Valve.
3.
Water level control clogged or defective, unable to operate fill valve.
4.
Check that drain valve is closed.
5.
Supply water pressure too low.
BOILER SLOW TO HEAT UP
1.
Lime build up - contact service.
PART NUMBER 10042R3
22
2005-12-19