Page 1
User Manual
WARNING
CGa Series 3
CGi Series 4
EG Series 6
PEG Series 6
LGB Series 2 & 3
Gas-Fired Boilers
INSTALLER:
Please take time to review this User Manual with the boiler
owner. Explain all maintenance and service procedures and
the correct operating instructions.
!
Follow the information in this manual exactly to avoid a re or explosion. Do not store
or use gasoline or other ammable vapors and liquids in the vicinity of this or any other
appliance. Failure to comply can result in severe personal injury, death, or substantial
property damage.
— WHAT TO DO IF YOU SMELL GAS —
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any telephone in your building.
• Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the re department.
• Installation & service must be performed by a qualied installer or service technician.
Manual Part Number 550-142-301/0224
Page 2
i
How to Use This Manual
1
To do the following: Read and use: Page(s)
Learn precautions Safety warnings and information 3-4
Prevent air contamination List of air contaminants to avoid 5
2
Start or shut down the boiler Operating instructions 6-8
Troubleshoot common issues
Identify and locate boiler
components
3
Maintain the boiler Boiler maintenance schedules
Contents
SECTION 1 – SAFETY 3
4
Safety Signals . . . . . . . . . . . . . . . . . . . . . . 3
Important indicates additional information that is
important, but is not related to personal injury or
property damage.
Please Read Before Proceeding . . . . . . . . . . . . 3
Boiler Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3
5
6
7
8
Safe Boiler Operation. . . . . . . . . . . . . . . . . . . . . .4
Boiler Water . . . . . . . . . . . . . . . . . . . . . . . . . .4
Frozen Water Damage . . . . . . . . . . . . . . . . . . . . .4
Damage from Water Contact . . . . . . . . . . . . . . . . . . 4
SECTION 2 – OPERATION 5
Operating the Boiler. . . . . . . . . . . . . . . . . . . 5
Prevent Combustion Air Contamination . . . . . . . . . . . .5
Operating Instructions . . . . . . . . . . . . . . . . . . . . .5
CGa, EG-30 to EG-75, PEG-30 to PEG-55 . . . . . . . . . .6
CGa-25 to CGa-6, EG-30 to EG-50, PEG-30 to PEG-50 . . . 7
LGB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 9
Common Issues and Solutions . . . . . . . . . . . . . . . . . 9
SECTION 3 – MAINTENANCE 10
Maintenance Overview . . . . . . . . . . . . . . . . 10
Servicing and Maintaining the Boiler . . . . . . . . . . . . .10
Boiler Components . . . . . . . . . . . . . . . . . . .11
Tankless Water Heater (EG and PEG only) . . . . . . . . . 11
Rollout Thermal Fuse Element (CGa, CGi, EG, & PEG only) . . 11
Spill Switch (CGa, EG, & PEG only) . . . . . . . . . . . . . 11
Pressure Switch (LGB Series 3 and CGi only) . . . . . . . . 11
Use the troubleshooting table to resolve
typical heating system and boiler issues.
Boiler illustrations
CGa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CGi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EG/PEG . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LGB Series 2 . . . . . . . . . . . . . . . . . . . . . . . . .15
Maintenance Procedures — DAILY. . . . . . . . . . 15
Boiler Area . . . . . . . . . . . . . . . . . . . . . . . . . .15
Pressure/Temperature Gauge or Pressure Gauge (Steam) . 15
Air openings . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance Procedures — MONTHLY . . . . . . . 16
Boiler Piping . . . . . . . . . . . . . . . . . . . . . . . . . 16
Venting System. . . . . . . . . . . . . . . . . . . . . . . . 16
Boiler Relief Valve . . . . . . . . . . . . . . . . . . . . . . 16
Automatic Air Vents (if used) . . . . . . . . . . . . . . . . .16
Pilot Burner Flame . . . . . . . . . . . . . . . . . . . . . . 17
Main Burner Flame . . . . . . . . . . . . . . . . . . . . . . 17
Check Condensate Drain System (if used). . . . . . . . . . 17
Maintenance Procedures — PERIODICALLY . . . . 18
Test the Low Water Cuto . . . . . . . . . . . . . . . . . . 18
Float Type Low Water Cuto . . . . . . . . . . . . . . . . .18
Probe Type Low Water Cuto . . . . . . . . . . . . . . . . 18
Integrated Type Low Water Cuto . . . . . . . . . . . . . . 19
Clean Gauge Glass. . . . . . . . . . . . . . . . . . . . . . 19
Oil Inducer Motor (CGi Boilers). . . . . . . . . . . . . . . . 19
Maintenance Procedures — EVERY 6 MONTHS. . . 20
Operate the Boiler Relief Valve. . . . . . . . . . . . . . . . 20
Maintenance Procedures — END OF SEASON . . . 20
Boiler Shutdown Procedure . . . . . . . . . . . . . . . . . 20
Propane Gas Odorant . . . . . . . . . . . . . . . . . . . . 20
9
11-15
15-20
2 550-142-301/0224
Page 3
i
DANGER
WARNING
CAUTION
NOTICE
IMPORTANT
WARNING
WARNING
IMPORTANT
Safety
Section Contents
Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important indicates additional information that is important, but
is not related to personal injury or property damage.
Please Read Before Proceeding . . . . . . . . . . . . . . . .3
Safety Signals
The following dened terms are used throughout this
manual to bring attention to the presence of hazards
or other important information.
!
Danger indicates the presence of hazards that
will result in severe personal injury, death, or
substantial property damage.
!
!
This product burns gas to produce heat. The
appliance must be properly installed, operated, and
maintained to avoid exposure to appreciable levels
of carbon monoxide and the installer is required to
conrm that at least one carbon monoxide alarm
is installed in the living space before the appliance
is put into operation. It is important for the carbon
monoxide alarms to be installed, maintained,
and replaced following the alarm manufacturer's
instructions and applicable local codes.
User: Refer to this User Manual as your information
source. Installation and service must be performed by
a qualied installer or service technician.
1
2
3
4
Warning indicates the presence of hazards that
can result in severe personal injury, death, or
substantial property damage.
!
Caution indicates the presence of hazards that
will or can result in minor personal injury or
property damage.
Notice indicates additional information that may be
related to property damage, but is not related to
personal injury.
Important indicates additional information that is
important, but is not related to personal injury or
property damage.
Please Read Before Proceeding
!
Adhere to all following guidelines and
instructions in this section. Failure to adhere to
these guidelines can result in severe personal
injury, death, or substantial property damage.
Installer: Refer to the Boiler Manual and all other
information shipped with the boiler for installation and
service.
Please include the boiler model number and CP
number when inquiring about the boiler. The model
number can be found on the boiler rating label.
Any claims for damage or shortage in shipment
must be led immediately against the transportation
company by the consignee.
Boiler Maintenance
To avoid electric shock, disconnect all electrical
supplies to the boiler before performing
maintenance.
To avoid severe burns, allow boiler to cool before
performing maintenance.
This boiler contains ceramic ber and berglass
materials. Refer to the maintenance section of
the boiler manual for warnings and information.
The boiler must be maintained as outlined in this
manual, including annual startup and service by
a qualied service technician to ensure boiler
system reliability.
5
6
7
8
3550-142-301/0224
Page 4
i
DANGER
Please Read Before Proceeding, continued
1
Safe Boiler Operation
Frozen Water Damage
• Do not block ow of combustion or ventilation
2
• Do not allow contaminated air to enter the boiler room,
3
• Should overheating occur, or gas supply fail to
4
Boiler Water
• Have the boiler water chemistry checked at least
• Do not use petroleum-based cleaning or sealing
5
• Do not use "homemade cures" or "boiler patent
• Continual fresh make-up water will reduce boiler
6
• Do not add cold water to a hot boiler. Thermal
7
• NEVER use automotive or standard glycol
air to boiler. This boiler is equipped with a control
that automatically shuts down the boiler if the air
or vent is blocked. Remove easily accessible and
removable blockages. If the boiler indicates a
manual reset lockout, select <Reset Lockout> on
the control display after removing a blockage. If
a blockage cannot be removed, have a qualied
service technician check the boiler system.
or the air inlet pipe if direct vented. See page 5 for
details.
shut o, do not turn o or disconnect electrical
supply to pump. Shut o the gas supply at a
location external to the appliance.
annually by a qualied service technician.
compounds in the boiler system. Gaskets and seals
in the system may be damaged, which can result in
substantial property damage.
medicines." Serious injury or damage may result.
life. Mineral buildup in the heat exchanger reduces
heat transfer, overheats the metal, and causes
failure. Addition of oxygen carried in by make-up
water can cause internal corrosion. Leaks in the
boiler or piping must be repaired at once to prevent
make-up water.
shock can cause the heat exchanger to crack.
antifreeze inn this boiler system, including glycol
made for hydronic systems.
Power outages, unattended residences or buildings,
boiler component failures, or other electrical system
failures in cold weather could result in frozen plumbing
and water damage in a matter of hours. Consult with
a boiler contractor or a home security agent to take
preventative actions, such as installing a security
system that operates during power outages, senses
low temperature, and initiates an eective action.
Consult with your boiler contractor or a home security
agency.
Damage from Water Contact
!
DO NOT attempt to operate any boiler if any
part of the boiler, burner, or controls has been
partially or fully sprayed with or submerged
under water. The boiler must either be replaced
or completely repaired and inspected. The boiler
and all components must be in good condition
and fully reliable before operation.
If these requirements are not met, operating
the boiler will cause re, explosion, and electrical
shock hazards, leading to serious injury, death,
or substantial property damage.
Saltwater damage: The immediate eects of
saltwater damage are like those of freshwater,
with electrical components shorting out and the
removal of critical lubricants. However, salt and other
contaminants left behind can lead to long term issues
due to the conductive and corrosive nature of salt
residue. WM Technologies equipment contaminated
with saltwater or polluted water will no longer be
covered under warranty and should be replaced.
Electrical damage: If any electrical component or
wiring has, or is suspected to have come into contact
with water, replace the boiler.
8
4 550-142-301/0224
Page 5
i
WARNING
Operation
1
This section is intended to provide operating
instructions and information for users.
Section Contents
Operating the Boiler . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .9
Operating the Boiler
Prevent Combustion Air Contamination
!
If the boiler combustion air inlet is located in any
area likely to cause contamination, or if products
which would contaminate the air cannot be
removed, you must have the combustion air and
vent re-piped and terminated to another location.
Contaminated combustion air will damage the
boiler, which can result in severe personal injury,
death, or substantial property damage.
To prevent potential of severe personal injury or
death, check for products or areas listed in Table 1
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.
Operating Instructions
See the warnings and operating instructions on the
following pages to start and turn o the boiler. See
Table 2 to locate the correct Operating Instructions for
the gas valve model installed on your boiler.
Table 1 Corrosive contaminants and sources
Products to avoid
Spray cans containing chloro/
uorocarbons
Permanent wave solutions
Chlorinated waxes and cleaners Cements and glues
Chlorine-based swimming pool
chemicals
Calcium chloride used for thawing
Sodium chloride used for water
softening
Refrigerant leaks Excessive dust and dirt
Areas likely to have contaminants
Laundry and dry cleaning areas
and establishments
Swimming pools Plastic manufacturing plants
Metal fabrication plants
Beauty shops New building construction
Refrigeration repair shops Remodeling areas
Photo processing plants Garages with workshops
Table 2 Operating instructions guide
Spark-ignited pilot Models Page
Honeywell VR8204/VR8304
Robertshaw 7200
–– LGB
Paint or varnish removers
Hydrochloric acid and muriatic
acid
Anti-static fabric softeners used in
clothes dryers
Chlorine-type bleaches,
detergents, and cleaning solvents
Adhesives used to fasten building
products and other similar products
Auto body shops
Furniture renishing areas and
establishments
CGa-25 to CGa-8
EG-30 to EG-75
PEG-30 to PEG-55
CGa-25 to CGa-6
EG-30 to EG-50
PEG-30 to PEG-50
2
3
4
5
6
6
7
8
7
8
(continued on the next page)
5550-142-301/0224
Page 6
i
Operating the Boiler, continued
1
CGa, EG-30 to EG-75, PEG-30 to PEG-55
• Spark-ignited pilot
• Gas valve — Honeywell VR8204/VR8304
2
3
4
5
6
7
8
6 550-142-301/0224
Page 7
i
CGa-25 to CGa-6, EG-30 to EG-50, PEG-30 to PEG-50
• Spark-ignited pilot
• Gas valve — Robertshaw 7200
1
2
3
4
5
6
7
8
(continued on the next page)
7550-142-301/0224
Page 8
i
1
LGB
• Spark-ignited pilot
2
3
4
5
6
7
8
8 550-142-301/0224
Page 9
i
Troubleshooting
Common Issues and Solutions
Symptom Common Causes Possible Corrections
Rapid cycling —
boiler turns on and
o frequently
Frequent release of
water through relief
valve
Need to frequently
add makeup water
Black water
condition
Popping or
percolating noise
heard in boiler
Thermostat installed where drafts or
heat aect reading
Heat anticipator in thermostat
adjusted incorrectly
Incorrect limit setting
Insucient water ow through boiler
Expansion tank sized too small
Flooded expansion tank
Inoperative limit control Call qualied service technician to replace limit control.
Leaks in boiler or piping
Oxygen corrosion due to leaks in
boiler and piping
Mineral deposits in sections due
to constant use of makeup water
Incorrect pH of boiler water
Locate thermostat on inner wall away from heat sources or
cool drafts.
Adjust thermostat per manufacturer’s instructions.
Set limit according to system needs. Maximum setting is 220°F.
Increase limit setting to decrease cycling.
Check all valves to and from boiler. Return to proper setting.
Conrm circulator size.
Call qualied service technician to check expansion tank
operation and size.
Call qualied service technician to check expansion tank
operation.
Have qualied service technician repair leaks at once to avoid
constant use of makeup water. Makeup water can cause
mineral deposits which, in turn, can cause boiler section failure.
Do not use petroleum-base stop-leak compounds.
Have qualied service technician repair at once. Keep pH of
water between 7.0 to 8.5.
Call qualied service technician to de-lime boiler, if necessary.
In some cases, deposits will be too heavy to remove with deliming procedures.
Have qualied service technician repair leaks to eliminate need
for constant makeup water.
Call qualied service technician to check pH level and correct.
pH should be maintained between 7.0 to 8.5.
1
2
3
4
5
Metal akes found in
vent outlet or vent —
ueway corrosion
Some radiators or
baseboard units do
not heat or are noisy
Insucient water ow through boiler
Contaminated combustion air
supply — See page 5 in this
manual.
Condensation of combustion gases in
boiler sections
Air in system
Low system pressure
High limit set too low Adjust high limit to higher setting.
Check all valves to and from boiler. Return to proper setting.
Conrm circulator size.
Remove any contaminating products. See page 5 in this
manual.
Provide outside air for combustion.
Have qualied service technician inspect system piping and
controls to verify proper regulation of return water temperature.
Bleed air from system through air vents in radiators or
baseboard units.
Fill to correct pressure.
Check for leaks in boiler or piping. Have qualied service
technician repair at once.
6
7
8
9550-142-301/0224
Page 10
i
WARNING
1
Maintenance
This section is intended to provide service schedules
and maintenance information for users.
2
Section Contents
Maintenance Overview . . . . . . . . . . . . . . . . . . . . 10
Boiler Components . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance Procedures — DAILY . . . . . . . . . . . . . 15
3
Maintenance Procedures — MONTHLY . . . . . . . . . . . 16
Maintenance Procedures — PERIODICALLY . . . . . . . . 18
Maintenance Procedures — EVERY 6 MONTHS . . . . . . 20
Maintenance Procedures — END OF SEASON . . . . . . . 20
Figure 1 Service and maintenance schedule
4
(see the following pages for instructions)
Contact your boiler service technician to inspect, service, and start up your boiler.
Beginning of Season
You must have an annual start-up performed by a qualied service technician to
ensure reliable operation of the boiler and system.
5
Check the boiler area
Daily
Check air openings
Check the pressure and temperature gauge
Maintenance Overview
Servicing and Maintaining the Boiler
The boiler must be inspected and started at the
beginning of the heating season every year by a
qualied service technician.
The maintenance and service of the boiler listed
in Figure 1 and explained in this manual must be
performed to assure maximum boiler eciency and
reliability.
Owner Maintenance
Check boiler interior piping
Check venting system
6
Monthly
Every 3 Months
7
Every 6 Months
End of Season
!
8
Follow the service and maintenance procedures given in this manual. Failure to perform service and
maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual
and component literature can result in severe personal injury, death, or substantial property damage.
10 550-142-301/0224
Check air vents
Check boiler relief valve
Check automatic air vents (if used)
Test low water cuto
Check the boiler gas and water piping
Operate the relief valve
Shut down procedure
Page 11
i
WARNING
WARNING
220269
Boiler Components
Tankless Water Heater (EG and PEG only)
If boiler is used to supply domestic hot water, limit control
should be set to supply adequate hot water. WeilMcLain 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. Dierential can be set to 15° and adjusted
to control level. Lowering the dierential will cause a
slight variation in water temperature but will decrease
burner on-o cycling. High limit should be set at least 20°
above low limit.
Rollout Thermal Fuse Element (CGa, CGi, EG, &
PEG only)
Cuts o gas ow should ame roll-out occur. See Figure
2.
!
Do not attempt to place boiler in operation if rollout
thermal fuse element cuts o gas ow. Immediately
call a service technician. Failure to comply can
result in severe personal injury, death or substantial
property damage.
Figure 2 Rollout thermal fuse element
Figure 3 Spill switch
1
2
3
4
Spill Switch (CGa, EG, & PEG only)
Cuts o gas ow should vent system become blocked.
See Figure 3.
!
Do not attempt to place boiler in operation if spill
switch cuts o gas ow. Immediately call a service
technician. Failure to comply can result in severe
personal injury, death or substantial property
damage.
Pressure Switch (LGB Series 3 and CGi only)
Cuts o gas ow should vent system become blocked.
See Figure 4.
LGB Series 3 Boilers - After resolving the fault, reset
the control: press Enter (square symbol), and use the
arrow keys to select YES. The fault will be reset, and the
error screen should revert to default display. If fault reoccurs, contact a service technician.
Figure 4 Pressure switch
5
6
7
8
11550-142-301/0224
Page 12
i
CGa
1
2
3
4
5
6
7
1 Gas valve
2 Pilot burner (Not shown)
3 Main burners
4 Gas manifold/orices
5 Control module
7 Vent damper (CGa only)
8
8 Water temperature/LWCO sensor
9 Transformer
10 Spill switch (CGa only)
12 Rollout thermal fuse element
13 Draft hood (CGa only)
14 Circulator
15 Relief valve
16 Gauge (pressure/temperature)
17 Drain valve
12 550-142-301/0224
Page 13
i
Boiler Components, continued
CGi
1
2
3
1 Gas valve
2 Pilot burner (not shown)
3 Main burners
4 Gas manifold/orices
5 Control module
6 Inducer (not shown)
8 Water temperature/LWCO sensor
9 Transformer
11 Air pressure switch
12 Rollout thermal fuse element
14 Circulator
15 Relief valve
16 Gauge (pressure/temperature)
17 Drain valve
4
5
6
7
8
13550-142-301/0224
Page 14
i
220294
1
2
3
4
5
6
9
11
13
14
18
19
20
21
22
Not shown
1 Gas valve
EG/PEG
1
2
3
2 Pilot burner
3 Main burners
4 Gas manifold/orices
5 Control module
7 Vent damper
9 Transformer
10 Spill switch
12 Rollout thermal fuse element
13 Low water cuto (steam boilers)
14 Limit control(s)
15 Draft hood
16 Circulator (water only)
18 Gauge (pressure or pressure/
temperature)
19 Gauge glass (steam only)
20 Water temperature/LWCO sensor
(water only)
20
▲
4
LGB Series 3
5
6
7
8
1 Gas valve
2 Pilot burner (with ame sense)
3 Main burners
4 Gas manifold/orices
5 Control module
6 Inducer (with vent adapter)
9 Transformer
11 Air pressure switch
13 Low water cuto (steam shown)
14 Limit control(s)
18 Gauge (pressure or pressure/
temperature)
19 Gauge glass (steam only)
20 Water temperature/LWCO sensor
(water only)
21 Main ame sense
22 Flue temperature switch
14 550-142-301/0224
Page 15
i
WARNING
Boiler Components, continued
LGB Series 2
1 Gas valve
2 Pilot burner
3 Main burner
4 Gas manifold/orices
5 Control module
7 Vent damper
9 Transformer
10 Spill switch
12 Rollout thermal fuse element
13 Low water cuto (steam boilers)
14 Limit control(s)
15 Draft hood
18 Gauge (pressure or pressure/
temperature)
19 Gauge glass (steam only)
1
2
3
Maintenance Procedures — DAILY
Boiler Area
!
Eliminate all materials discussed below from
the boiler vicinity. Failure to comply can result
in severe personal injury, death, or substantial
property damage.
1. Combustible/ammable materials — Do not
store combustible materials, gasoline or any
other ammable vapors or liquids near the boiler.
Remove immediately if found.
2. Air contaminants — See listing of contaminants
on page 5.
If the above materials are found:
• Remove products immediately from the area. If
they have been there for an extended period, call
a qualied service technician to inspect the boiler
and vent system for possible damage from acid
corrosion.
• If products cannot be removed, immediately call
a qualied service technician to install an outside
combustion air source for the boiler (if not already
installed).
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 qualied service technician if problem
persists.
Air openings
Verify that combustion and ventilation air openings
to the boiler room and/or building are open and
unobstructed.
4
5
6
7
8
15550-142-301/0224
Page 16
i
WARNING
WARNING
WARNING
Maintenance Procedures — MONTHLY
1
Boiler Piping
Visually inspect for leaks around piping, circulators,
relief valve and other ttings. Immediately call a
qualied service technician to repair any leaks.
Figure 5 Relief valve
2
3
4
5
6
7
8
!
Have leaks xed at once by a qualied service
technician. Continual fresh makeup water reduces
boiler life. Minerals can build up, reducing heat
transfer, overheating cast iron, and causing
section failure, which can result in severe personal
injury, death, or substantial property damage.
!
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.
Venting System
!
Failure to inspect the vent system as noted above
and have them repaired by a qualied service
technician can cause vent system failure, which
can result in severe personal injury or death.
1. Visually inspect all parts or the ue gas venting
system for any signs of blockage, leakage or
joints or deterioration of the piping.
2. CGa and EG boilers:
a. With boiler ring, hold a candle or match below
lower edge of draft hood “skirt.” If ame does
not blow out, but burns undisturbed, the vent
system is working properly.
b. If ame blows out or ickers severely, the vent
system must be checked for obstructions or
other causes of improper venting.
c. Verify the vent damper opens before burners ignite.
3. Notify your qualied service technician at once if
you nd any problem.
Boiler Relief Valve
1. Inspect the boiler relief valve (Figure 5) and the relief
valve discharge pipe for signs of weeping or leakage.
Figure 6 Automatic air vent
2. If the relief valve often weeps:
a. Water boilers — the expansion tank may not
be working properly.
b. Steam boilers — limit control may be set too
high or there may be system problems.
c. Immediately contact your qualied service
technician to inspect the boiler and system.
Automatic Air Vents (if used)
1. Remove the cap (A) from any automatic air vent
in the system and check operation by depressing
valve (B) slightly with the tip of a screwdriver. See
Figure 6.
2. If the air vent valve appears to be working freely
and not leaking, replace cap (A), twisting all the
way on.
3. Loosen cap (A) one turn to allow vent to operate.
4. Have vent replaced if it does not operate
correctly.
(continued on the next page)
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i
WARNING
Maintenance Procedures — MONTHLY, continued
Pilot Burner Flame
Proper pilot ame (Figure 7):
1. Blue ame.
2. Inner cone engulng pilot ame sensor.
3. Pilot ame sensor glowing cherry red.
Improper pilot ame:
1. Overred — Large ame lifting or blowing past
pilot ame sensor.
2. Underred — Small ame. Inner cone not
engulng pilot ame sensor.
3. Lack of primary air — Yellow ame tip.
4. Incorrectly heated pilot ame sensor.
Main Burner Flame
Proper main burner ame (Figure 8):
1. Yellow-orange streaks may appear (caused by
dust).
Figure 7 Pilot burner and ame, typical
Figure 8 Main burner ame, typical
1
2
3
4
Improper main burner ame:
1. Overred — Large ames.
2. Underred — Small ames.
3. Lack of primary air — Yellow tipping on ames
(sooting will occur).
Check Condensate Drain System (if used)
While the boiler is running, check the discharge
end of the condensate drain tubing by holding your
ngers in front of the opening. If you notice ue
gas escaping, this indicates a dry condensate drain
trap. See the following steps to ll the trap. If the
condensate trap dries out on a regular basis, call
your qualied service technician to inspect the boiler
and condensate line and rell the condensate trap.
!
The condensate trap must be lled with water
during all times of boiler operation to avoid
ue gas emission from the condensate drain
line. Failure to ll the trap can result in severe
personal injury or death.
Under some circumstances, a vent system may not
produce enough condensate to keep the trap full of liquid.
If the trap is not full, small amounts of ue products can
be emitted into the boiler room through the condensate
drain line. Follow the procedure below to ll the trap.
1. Fill the condensate trap with fresh water by
pouring water into the removed trap.
a. Verify that the condensate assembly is
unobstructed by pouring until the water runs
out the end of the condensate drain line.
b. If the water does not run out, there is an
obstruction. Proceed to the next step.
2. To remove an obstruction, remove and ush the
trap and drain line.
a. Loosen any attachments to the supplied
exible drain hose.
b. Loosen the condensate trap inlet connection.
c. Remove and ush out the condensate trap and
drain line.
d. Reinstall the trap and drain line. Tighten all
attachments.
e. Pour water into the port and ensure that water
runs out the end of the drain line.
f. If the water still does not run out, call your
qualied service technician to inspect the boiler
and clean or replace the condensate assembly.
5
6
7
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i
DANGER
Maintenance Procedures — PERIODICALLY
1
Test the Low Water Cuto
The system is equipped with a low water cuto. Test
the low water cuto periodically during the heating
season.
Float Type Low Water Cuto
2
!
Boiler pressure and temperature must be low to
avoid the potential of severe burns from steam or
hot water.
3
1. Clean oat type low water cuto to clear oat
chamber of sediment. See Figure 9.
a. Open blowdown valve at bottom control.
b. Drain water into a bucket.
2. Check oat type low water cuto for proper
operation.
4
a. Turn operating control to call for heat.
b. Before water gets hot, drain to bottom of
gauge glass. Boiler should shut o after water
level lowers a few inches.
c. Rell boiler to correct waterline. Boiler should
come back on.
Figure 9 Float type low water cuto
Figure 10 Probe type low water cuto
5
Probe Type Low Water Cuto
Clean the probe type low water cuto for proper
operation. See Figure 10.
1. Turn o power to boiler and wait 5 minutes.
6
2. Drain water to bottom of gauge glass.
3. Turn on power.
4. Set thermostat to call for heat. Red neon lamp on
lower water cuto should light.
5. Wait 5 minutes. Boiler should not re.
6. Rell boiler to correct water line. Red lamp should
7
go o.
7. Wait 5 minutes. Boiler should re.
8. Return thermostat to normal setting.
8
(continued on the next page)
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i
DANGER
WARNING
Maintenance Procedures — PERIODICALLY, continued
Integrated Type Low Water Cuto
1. Test LWCO using control LWCO TEST button.
a. During burner re, press LWCO TEST button.
b. Burner should shut o.
2. Clean periodically (when warning occurs).
a. Turn o power to boiler and wait 5 minutes.
b. Drain boiler to empty.
c. Remove sensor, wipe clean. See Figure 11.
d. Reinstall sensor to specied 18 ft/lbs torque.
e. Rell boiler to pressure, purge air.
f. Turn on boiler power.
g. Ensure proper operation resumes.
Clean Gauge Glass
Normal waterline on a steam boiler is halfway up
gauge glass. See Figure 12. Clean when needed.
!
Boiler pressure must be low to eliminate potential
of severe burns.
1
Figure 11 Integrated type low water cuto
2
3
Figure 12 Gauge glass
4
1. Close lower gauge cock.
2. Open pet cock.
3. Open lower gauge cock and allow a small amount
of water to ush out through open pet cock.
4. Close lower gauge cock.
5. Close pet cock.
6. Open lower gauge cock.
7. If gauge glass breaks, close both gauge cocks
and call a qualied service technician to replace
gauge glass. Do not replace with thin glass
tubing.
Oil Inducer Motor (CGi Boilers)
!
Use only SAE 20 motor oil to lubricate the
inducer motor. Do not use common universal
household oils. Failure to comply can result in
severe personal injury, death, or substantial
property damage.
5
6
7
1. Use only SAE 20 motor oil. DO NOT use
household universal oils.
2. Place a few drops of oil in each of the two oiler
cups on the inducer motor.
8
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i
WARNING
WARNING
Maintenance Procedures — EVERY 6 MONTHS
1
Operate the Boiler Relief Valve
!
A metal discharge line must be connected to a relief
valve outlet and run to a safe place of disposal to
avoid water damage or scalding. The discharge line
must be terminated so as to eliminate possibility
2
of severe burns should the valve discharge. This
discharge line must be installed by a qualied
heating installer or service technician in accordance
with the instructions in the Boiler Manual. Failure to
comply can result in severe personal injury, death, or
substantial property damage.
3
1. Before proceeding, verify that the relief valve
outlet has been piped to a safe place of
discharge, avoiding any possibility of scalding
from hot water.
2. Read the boiler pressure/temperature gauge to
4
make sure the system is pressurized.
3. Lift the relief valve top lever slightly, allowing
water to relieve through the valve and discharge
piping.
4. If water ows freely, release the lever and allow
the valve to seat. Watch the end of the relief valve
discharge pipe to ensure that the valve does not
weep after the line has had time to drain.
a. If the valve weeps, lift the seat again to attempt
to clean the valve seat.
b. If the valve continues to weep afterwards,
contact your qualied service technician to
inspect the valve and system.
5. If water does not ow from the valve when you lift
the lever completely, the valve or discharge line
may be blocked.
a. Immediately shutdown the boiler, following the
instructions on the inside jacket top Operating
Instructions.
b. Call your qualied service technician to inspect
the boiler and system.
Maintenance Procedures — END OF SEASON
Boiler Shutdown Procedure
1. Follow “TO TURN OFF GAS TO APPLIANCE”
5
on the Operating Instructions on the inside of the
jacket panel. You will also nd these instructions
on pages 6-8 of this manual.
a. Use the Operating Instructions for the gas
valve model installed on the boiler.
2. Do not drain system unless exposure to freezing
6
temperatures will occur.
3. Do not drain the system if it is lled with an
antifreeze solution.
4. Do not shut down boilers used for domestic water
heating. They must operate year-round.
7
Propane Gas Odorant
!
Propane boilers only — Comply with the
following guidelines for gas leakage. Failure
to comply can result in severe personal injury,
death, or substantial property damage.
• Propane suppliers mix an odorant with the propane
to make its presence detectable. This odorant can
fade and the gas may no longer have an odor.
• Propane gas can accumulate at oor level. Smell
near the oor for the gas odorant or any unusual odor.
• Periodically check the odorant level of your gas.
• Inspect boiler and system at least yearly to make
sure all gas piping is leak-tight.
• Consult your propane supplier regarding
installation of a gas leak detector. There are
some products on the market intended for this
purpose. Your supplier may be able to suggest an
appropriate device.
8
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WM Technologies, LLC
500 Blaine Street
Michigan City, IN 46360-2388
elephone: (800) 654-2109
weil-mclain.com
Manual Part Number 550-142-301/0124
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