Weil-McLain CGA Guide

Do not store or use gasoline or other flammable vapors and liquids in the

vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance.

•Do not touch any electrical switch; do not use any phone in your

building.

•Immediately call your gas supplier from a neighbor’s phone. Follow

the gas supplier’s instructions.

•If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service

technician or the gas supplier.

If the information in this manual is not followed exactly, a fire or

explosion may result, causing property damage, personal injury or

loss of life.

PartNumber550-110-592/1099

Gas-Fired Boilers

CGa, CGi, CGs, EG,

EGH, LGB, PEG, PFG

User’s

Information

Manual

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers

2PartNumber550-110-592/1099

Please read this page first

How to use this

manual . . .

The User’s Information Manual provides information to the boiler owner/user for routine

operation and maintenance and emergency shutdown. Detailed information on boiler

installation, operation, start-up, service and parts is included in the Boiler Manual. The Boiler

Manual is intended only for use by a qualified installer/service technician.

Boiler service and

maintenance

The following defined terms are used throughout this manual to bring attention to the presence

of hazards of various risk levels or to important information concerning the life of the product.

Hazard definitions

Indicates presence of hazards that will cause severe personal injury, death

or substantial property damage.

Indicates presence of hazards that can cause severe personal injury, death

or substantial property damage.

Indicates presence of hazards that will or can cause minor personal in-

jury or property damage.

Indicates special instructions on installation, operation or maintenance

that are important but not related to personal injury or property damage.

To . . . Read/use . . . Pages . . .

Learn

precautions Warnings and definitions 1, 2, and 3

Prevent air

contamination

Read list of air contaminants you must avoid. If

found, either remove products permanently

or isolate boiler and provide outside com-

bustion air.

Identify boiler

components The illustration on page 4 or 5, will show you the

location of the main components. 4-5

Maintain

boiler

Set up a plan for maintaining the boiler using

the schedule included in this manual.

Schedule an annual start-up by a qualified ser-

vice technician before every heating season.

6-12

Start —or —

Shutdown

boiler

Use the Lighting/Operating instruction sheet

for the gas valve installed on your boiler. Ask

your service technician if you are unsure which

one.

12-22

Troubleshoot

common

problems

Use the common problems/solutions table to

resolve typical heating system/boiler problems. 23

Users Information Manual

3PartNumber 550-110-592/1099

Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial

property damage.

STOP!! —Read before proceeding

Products to avoid

Spray cans containing chloro/fluorocar-

bons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes

dryers

Chlorine-type bleaches, detergents, and

cleaning solvents found in household

laundry rooms

Adhesives used to fasten building products

and other similar products

Areas likely to have

contaminants

Dry cleaning/laundry areas and establish-

ments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establish-

ments

New building construction

Remodeling areas

Garages with workshops

Air contamination

Boiler water

Boiler operation

Service and maintenance

• To prevent potential of severe personal injury or death, check for products or

areas listed in table at right before installing boiler. If any of these contaminants

are found:

• remove contaminants permanently. —OR —

• isolate boiler and provide outside combustion air. See national,

provincial or local codes for further information. —OR —

• for CGs boilers only — combustion air may be ducted from out-

side to the boiler air intake.

• To avoid electric shock, disconnect electrical supply before performing

maintenance.

• To avoid severe burns, allow boiler to cool before performing maintenance.

• You must maintain the boiler as outlined in the manual and have the boiler

started up and serviced at least annually by a qualified service technician

to ensure boiler/system reliability.

•Do not block flow of combustion or ventilation air to boiler. This boiler is

equipped with a control which will automatically shut down the boiler should

air or vent be blocked. If vent or air blockage is easily accessible and removable,

remove it. The boiler should attempt to restart within an hour. If blockage is

not obvious or cannot be removed, have the boiler and system checked by a

qualified service technician.

• Should overheating occur or gas supply fail to shut off, do not turn off or

disconnect electrical supply to pump. Instead, shut off the gas supply at a

location external to the appliance.

•Do not use this boiler if any part has been under water. Immediately call a

qualified service technician to inspect the boiler and to replace any part of the

control system and any gas control, which has been under water.

•Have the building monitored when it is vacant for an extended period. Safety

controls can shut down the boiler at any time. The loss of heat can result in

significant damage due to freezing.

•DO NOT use petroleum-based cleaning or sealing compounds in boiler system.

Water seal deterioration will occur, causing leakage between sections and damage

to heating system components. This can result in substantial property damage.

•DO NOT use "homemade cures" or "boiler patent medicines".Serious damage

to boiler, personnel and/or property may result.

• Continual fresh makeup water will reduce boiler life. Mineral buildup in

sections reduces heat transfer, overheats cast iron, and causes section failure.

Addition of oxygen and other gases can cause internal corrosion. Leaks in boiler

or piping must be repaired at once to prevent makeup water.

•Do not add cold water to hot boiler.Thermal shock can cause sections to

crack.

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers

4PartNumber 550-110-592/1099

59210

Boiler components

59211

CGa CGi

CGs

1Gas valve

2Pilot burner

3Main burner

4Gas manifold/orifices

5Control module

6Inducer

(CGi and CGs only)

7Vent damper

(CGa only)

8Water temperature limit switch

9Transformer

10 Spill switch

(CGa only)

11 Air pressure switch

(CGi and CGs only)

12 Rollout thermal fuse element

15 Draft hood

(CGa only)

16 Circulator

17 Relief valve

18 Gauge

(pressure or pressure/temperature)

Users Information Manual

5PartNumber 550-110-592/1099

EG/EGH PFG

LGB

1Gas valve

2Pilot burner

3Main burner

4Gas manifold/orifices

5Control module

7Vent damper

9Transformer

10 Spill switch

12 Rollout thermal fuse element

13 Low water cutoff

(steam boilers)

14 Limit control(s)

15 Draft hood

16 Circulator

18 Gauge

(pressure or pressure/temperature)

19 Gauge glass

(steam only)

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers

6PartNumber 550-110-592/1099

Maintain boiler using schedule below

Tankless water heater (EG and EGH only)

If boiler is used to supply domestic hot water, limit

control should be set to supply adequate hot water.

Weil-McLain tankless heaters are rated at 200 °F boiler

water temperature. To get rated output, set low limit at

200 °F. Limit can be adjusted to meet system hot water

requirements. Differential can be set to 15 °and adjusted

to control level. Lowering the differential will cause a

slight variation in water temperature but will decrease

burner on-off cycling. High limit should be set at least

20 °above low limit.

Service technician

(covered in Boiler Manual —for use only by a

qualified service technician)

Owner maintenance

(see following pages for instructions)

ANNNUAL START-UP

Inspect:

• Reported problems

• Boiler area

• Air openings

• Flue gas vent system

• Pilot and main burner flames

• Water piping

• Boiler heating surfaces

• Burners, base and inlet air box

Service:

• Oiled-bearing circulators

Start-up:

• Perform start-up per manual

Check/test:

• Gas piping

• Cold fill and operating pressures

• Air vents and air elimination

• Limit controls and cutoffs

• Expansion tank

• Boiler relief valve

Review:

• Review with owner

Daily

• Check boiler area

• Check air openings

• Check boiler pressure/

temperature gauge

Monthly

• Check boiler interior piping

• Check venting system

• Check air vents

• Check boiler relief valve

• Check automatic air vents (if

used)

Periodically • Test low water cutoff (if used)

Every 6 months • Operate relief valve

End of season • Shut down procedure

Users Information Manual

7PartNumber 550-110-592/1099

User maintenance procedures

Do not attempt to place boiler in operation if spill

switch cuts off gas flow. Immediately call a service

technician. Failure to do so can cause severe personal

injury, death or substantial property damage.

Rollout thermal fuse element

CGa, CGi, CGs, EG, EGH, PEG & PFG-5 only

Cuts off gas flow should flame rollout occur. See

Figure 1.

Do not attempt to place boiler in operation if rollout

thermal fuse element cuts off gas flow. Immediately

call a service technician. Failure to do so can cause

severe personal injury, death or substantial property

damage.

Spill switch

CGa, EG, EGH, PEG & PFG-5 only

Cuts off gas flow should vent system become blocked.

See Figure 2.

59202

59201

Figure 1

Rollout thermal fuse element

Figure 2

Spill switch

Component information

Boiler area

To prevent potential of severe personal injury, death

or substantial property damage, eliminate all materials

discussed below from the boiler vicinity. If found:

•Remove products immediately from the area. If

they have been there for an extended period, call a

qualified service technician to inspect the boiler and

vent system for possible damage from acid

corrosion.

•If products cannot be removed, immediately call a

qualified service technician to install an outside

combustion air source for the boiler (if not already

installed).

1. Combustible/flammable materials —Do not store

combustible materials, gasoline or any other

flammable vapors or liquids near the boiler.

Remove immediately if found.

2. Air contaminants —See listing of contaminants

on page 3.

❏Check daily . . . . . . . . . . . . . . . . .

The boiler should be inspected and started annually, at

the beginning of the heating season, only by a qualified

service technician. In addition, the maintenance and

care of the boiler designated on page 6 and explained

on the following pages must be performed to assure

maximum boiler efficiency and reliability. Failure to

service and maintain the boiler and system could result

in equipment failure, causing possible severe personal

injury, death or substantial property damage.

Boiler must be serviced & maintained

The following information

provides detailed instructions for

completing the maintenance items

listed in the maintenance schedule,

page 6. In addition to this

maintenance, the boiler must be

serviced and started up at the

beginning of each heating season

by a qualified service technician.

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers

8PartNumber 550-110-592/1099

❏Check daily . . . . . . . . . . . . . . . . .

Air openings

1. Verify that combustion and ventilation air openings

to the boiler room and/or building are open and

unobstructed.

2. CGs boilers —Verify that boiler vent discharge

and air intake are clean and free of obstructions.

Remove any debris on the air intake or flue exhaust

openings.

Pressure/temperature gauge

or pressure gauge (steam)

1. Water boilers —Make sure the pressure reading

on the boiler pressure/temperature gauge does not

exceed 24 psig. Higher pressure may indicate a

problem with the expansion tank or gauge.

2. Steam boilers —Make sure the pressure reading

on the boiler pressure gauge does not exceed 15

psig. Higher pressure indicates a problem with the

gauge or limit control.

3. Contact a qualified service technician if problem

persists.

Venting system

Failure to inspect the vent system as noted above and

have them repaired by a qualified service technician

can result in vent system failure, causing severe personal

injury or death.

Boiler piping

Have leaks fixed at once by a qualified service

technician. Continual fresh makeup water will reduce

boiler life. Minerals can build up in sections, reducing

heat transfer, overheating cast iron,and causing section

failure.

1. Visually inspect for leaks around piping, circulators,

relief valve and other fittings. Immediately call a

qualified service technician to repair any leaks.

1. Visually inspect all parts or the flue gas venting

system for any signs of blockage, leakage or joints

or deterioration of the piping.

2. CGa and EG boilers:

a. With boiler firing, hold a candle or match be-

low lower edge of draft hood “skirt.”If flame

does not blow out, but burns undisturbed, the

vent system is working properly.

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to boiler

and system components can occur, resulting in possible

severe personal injury, death or substantial property

damage.

❏Check monthly . . . . . . . . . . . . . . . .

If flame blows out or flickers severely, the vent

system must be checked for obstructions or

other causes of improper venting.

b. Verify the vent damper (CGa and EG boilers)

opens before burners ignite.

3. Notify your qualified service technician at once if

you find any problem.

Boiler relief valve . . . . . . . . .

1. Inspect the boiler relief valve (see Figure 3) and

the relief valve discharge pipe for signs of weeping

or leakage.

2. If the relief valve often weeps:

•water boilers —the expansion tank may not

be working properly.

•steam boilers —limit control may be set too

high or there may be system problems.

•Immediately contact your qualified service

technician to inspect the boiler and system.

59203

Figure 3 Relief valve

Users Information Manual

9PartNumber 550-110-592/1099

Figure 4

Automatic air

vent

Automatic air vents (if used)

1. See Figure 4.

2. Remove the cap from any

automatic air vent in the system

and check operation by

depressing valve Bslightly with

the tip of a screwdriver.

3. If the air vent valve appears to

be working freely and not

leaking, replace cap A, twisting

all the way on.

4. Loosen cap A one turn to allow

vent to operate.

5. Have vent replaced if it does not

operate correctly.

Pilot burner flame

Proper pilot flame (see Figure 5):

1. Blue flame.

2. Inner cone engulfing thermocouple (standing pilot)

or pilot flame sensor (spark-ignited pilot).

3. Thermocouple or pilot flame sensor glowing

cherry red.

Improper pilot flame:

1. Overfired —Large flame lifting or blowing past

pilot flame sensor.

2. Underfired —Small flame.Inner cone not engulfing

pilot flame sensor.

3. Lack of primary air —Yellow flame tip.

4. Incorrectly heated pilot flame sensor.

Main burner flame

Proper main burner flame (see Figure 6):

1. Yellow-orange streaks may appear (caused by dust).

Improper main burner flame:

1. Overfired —Large flames.

2. Underfired —Small flames.

3. Lack of primary air —Yellow tipping on flames

(sooting will occur).

59318

Spark

electrode

Inner

cone

Pilot flame

sensor (spark-

ignited pilots)

Thermocouple

(standing pilots)

— or —

59319

Transparent

blue flame

Inner flame

Figure 5 Pilot burner and flame, typical

Figure 6 Main burner flame, typical

❏Check monthly . . . . . . . . . . . . . . . .

59204

Clean vent termination & air

intake screens —CGs boilers only

1. Remove all lint and debris from both the boiler air

intake screen and the flue discharge screen.

The boiler control module will sense blockage of

the air intake or flue and lockout if the blockage is

excessive. It will signal the failure by flashing the

appropriate indicator lights on the control board.

2. If removing the debris does not allow the boiler to

operate correctly afterwards, contact your qualified

service technician to inspect the boiler and vent/

air systems.

Check condensate drain system

1. Inspect condensate drain fittings and tubing.Verify

that condensate can flow freely to drain.

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers

10 PartNumber 550-110-592/1099

Probe type— See Figure 8

1. Clean probe type low water cutoff for proper

operation.

a. Turn off power to boiler and wait 5 minutes.

b. Drain water to bottom of gauge glass.

c. Turn on power.

d. Set thermostat to call for heat. Red neon lamp

on lower water cutoff should light.

e. Wait 5 minutes. Boiler should not fire.

f. Refill boiler to correct water line. Red lamp

should go off.

g. Wait 5 minutes. Boiler should fire.

h. Return thermostat to normal setting.

Test low water cutoff (all steam boilers)

(water boilers, if installed)

If the system is equipped with a low water cutoff, test the low water cutoff periodically during the heating

season.

Figure 7 Float type low water cutoff Figure 8 Probe type low water cutoff

❏Service periodically . . . . . . . . . . . .

2. Check float type low water cutoff for proper

operation.

a. Turn operating control to call for heat.

b. Before water gets hot, drain to bottom of gauge

glass. Boiler should shut off after water level

lowers a few inches.

c. Refill boiler to correct waterline. Boiler should

come back on.

.Boiler pressure and temperature must be low to avoid

the potential of severe burns from steam or hot water

Float type —See Figure 7

1. Clean float type low water cutoff to clear float

chamber of sediment.

a. Open blowdown valve at bottom control.

b. Drain water into a bucket.

50209

Probe type

low water cutoff

Gauge glass

assembly

Indicator lamp(s)

Test switch and

reset switch (if

manual reset)

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