Weil-McLain CGA Leitfaden

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.

CGa, CGi, CGs, EG,

EGH, LGB, PEG, PFG

Gas-Fired Boilers

User’s

Information

Manual

Part Number 550-110-592/0709

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

2Part Number 550-110-592/0709

Please read this page ﬁrst

How to use this

manual . . .

The Boiler manual is for use only by a qualiﬁed heating installer/service

technician. Refer only to this User’s Information Manual for your reference.

Improper installation, adjustment, alteration, service or maintenance can

cause property damage, personal injury (exposure to hazardous materials)

or loss of life. Installation and service must be performed by a qualiﬁed

installer, service agency or the gas supplier (who must read and follow the

supplied instructions before installing, servicing, or removing this boiler.

This boiler contains materials that have been identiﬁed as carcinogenic, or

possibly carcinogenic, to humans).

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 injury

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.

User’s Information Manual

Part Number 550-110-592/0709

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

Boiler water

• 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.

Boiler operation

• 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.

Service and maintenance

• 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.

Air contamination

• 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outsidetotheboiler

air intake.

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

4Part Number 550-110-592/0709

Boiler components

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)

CGs

CGa CGi

User’s Information Manual

Part Number 550-110-592/0709

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

6Part Number 550-110-592/0709

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

Part Number 550-110-592/0709

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owshouldventsystembecomeblocked.

See Figure 2.

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

8Part Number 550-110-592/0709

❏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 qualied 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

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 below

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

not blow out, but burns undisturbed, the vent

system is working properly.

failure.

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

❏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.

Figure 3 Relief valve

User’s Information Manual

Part Number 550-110-592/0709

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 or thermopile

(standing pilot) or pilot ﬂame sensor (spark-ignited

pilot).

3. Thermocouple or thermopile, or pilot ﬂame sensor

glowing cherry red.

Improper pilot ﬂame:

1. Overred—Largeameliftingorblowingpastpilot

ﬂame sensor.

2. Underred—Smallame.Innerconenotengulng

pilot ﬂame sensor.

3. Lackofprimaryair—Yellowame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. Overred—Largeames.

2. Underred—Smallames.

3. Lackof primary air — Yellowtippingon ames

(sooting will occur).

Figure 5 Pilot burner and ﬂame, typical

Figure 6 Main burner ﬂame, typical

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

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 Part Number 550-110-592/0709

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.

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