Weil-McLain CGa User Manual
CGa, CGi, CGs, EG,
EGH, LGB, PEG, PFG
Gas-Fired Boilers
User’s
Information
Manual
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.
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.
Part Number 550-110-592/1099
CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers
Please read this page first
How to use this
manual . . .
To . . . Read/use . . . Pages . . .
Learn
precautions
Prevent air
contamination
Identify boiler
components
Maintain
boiler
Start — or —
Shutdown
boiler
Troubleshoot
common
problems
Warnings and definitions
Read list of air contaminants you must avoid. If
found, either remove products permanently
or isolate boiler and provide outside combustion air.
The illustration on page 4 or 5, will show you the
location of the main components.
Set up a plan for maintaining the boiler using
the schedule included in this manual.
Schedule an annual start-up by a qualified service technician before every heating season.
Use the Lighting/Operating instruction sheet
for the gas valve installed on your boiler. Ask
your service technician if you are unsure which
one.
Use the common problems/solutions table to
resolve typical heating system/boiler problems.
1, 2, and 3
3
4-5
6-12
12-22
23
Hazard definitions
Boiler service and
maintenance
2 Part Number 550-1 10-592/1099
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.
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.
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
.
Users Information Manual
STOP!! — Read before proceeding
Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial
property damage.
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 out-
side to the boiler air intake.
Service and maintenance
• To avoid electric shock, disconnect electrical supply before performing
maintenance.
• To avoid severe burns,
• You must
started up and serviced at least annually by a qualified service technician
maintain the boiler as outlined in the manual and have the boiler
allow boiler to cool before performing maintenance.
to ensure boiler/system reliability.
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
• Do not use this boiler if any part has been under water. Immediately call a
•
overheating occur or gas supply fail to shut off, do not turn off or
disconnect electrical supply to pump. Instead,
location
external to the appliance.
shut off the gas supply at 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.
Products to avoid
Spray cans containing chloro/fluorocarbons
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 establishments
Swimming pools
Metal fabrication plants
Beauty shops
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
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.
makeup water will reduce boiler life. Mineral buildup in
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
3Part Number 550-1 10-592/1099
CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers
59211
Boiler components
CGa CGi
CGs
59210
1 Gas valve
2 Pilot burner
3 Main burner
4 Gas manifold/orifices
5 Control module
6 Inducer
7 Vent damper
8 Water temperature limit switch
9 Transformer
10 Spill switch
11 Air pressure switch
12 Rollout thermal fuse element
15 Draft hood
16 Circulator
17 Relief valve
18 Gauge
(CGi and CGs only)
(CGa only)
(CGa only)
(CGi and CGs only)
(CGa only)
(pressure or pressure/temperature)
4 Part Number 550-1 10-592/1099
Users Information Manual
EG/EGH PFG
1 Gas valve
2 Pilot burner
3 Main burner
4 Gas manifold/orifices
5 Control module
7 Vent damper
9 Transformer
10 Spill switch
12 Rollout thermal fuse element
13 Low water cutoff
14 Limit control(s)
15 Draft hood
16 Circulator
18 Gauge
19 Gauge glass
(pressure or pressure/temperature)
(steam boilers)
(steam only)
LGB
5Part Number 550-1 10-592/1099
CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers
Maintain boiler using schedule below
Service technician
(covered in Boiler Manual — for use only by a
qualified service technician)
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
Owner maintenance
(see following pages for instructions)
• Check boiler area
Daily
Monthly
Periodically • Test low water cutoff (if used)
Every 6 months • Operate relief valve
• Check air openings
• Check boiler pressure/
temperature gauge
• Check boiler interior piping
• Check venting system
• Check air vents
• Check boiler relief valve
• Check automatic air vents (if
used)
Check/test:
ANNNUAL START-UP
• Gas piping
• Cold fill and operating pressures
• Air vents and air elimination
• Limit controls and cutoffs
• Expansion tank
• Boiler relief valve
End of season • Shut down procedure
Review:
• Review with owner
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.
6 Part Number 550-1 10-592/1099
Users Information Manual
User maintenance procedures
Boiler must be serviced & maintained
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.
Component information
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.
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.
Figure 1
Rollout thermal fuse element
Figure 2
Spill switch
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.
59201
59202
❏ Check daily . . . . . . . . . . . . . . . . .
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.
7Part Number 550-1 10-592/1099
CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers
❏ Check daily . . . . . . . . . . . . . . . . .
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.
Air openings
1. Verify that combustion and ventilation air openings
to the boiler room and/or building are open and
unobstructed.
CGs boilers — Verify that boiler vent discharge
2.
and air intake are clean and free of obstructions.
Remove any debris on the air intake or flue exhaust
openings.
❏ Check monthly . . . . . . . . . . . . . . . .
Boiler piping
1. Visually inspect for leaks around piping, circulators,
relief valve and other fittings. Immediately call a
qualified service technician to repair any leaks.
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.
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 . . . . . . . . .
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 qualified service technician
can result in vent system failure, causing severe personal
injury or death.
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.
8 Part Number 550-1 10-592/1099
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
59203
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