Weil-McLain CGi-3, EG Series 5, PEG Series 5, CGa Series 2, EGH Series 5 User's Information Manual
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CGa Series 2, CGi Series 3,
EG Series 5, EGH Series 5,
LGB Series 2, PEG Series 5
Gas-Fired Boilers
User’s
Information
Manual
INSTALLER:
Please take time to review this User’s information
Manual with the boiler owner. Explain all maintenance
and service procedures and the correct Operating
Instructions.
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 550-142-801/1112
CGa, CGi, EG, EGH, LGB, PEG, Boilers
How to use this
manual . . .
Please read this page first
To . . . Read/Use . . . Pages . . .
Learn
precautions
Prevent air
contamination
Identify boiler
components
Maintain
boiler
Start –or–
Shutdown
boiler
Troubleshoot
common
problems
Warnings and denitions
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 qualied ser-
vice technician before every heating season.
Use the 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
12-19
20
Hazard definitions
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.
Boiler service and
maintenance
2
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 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).
Part Number 550-142-801/1112
STOP!! — Read before proceeding
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
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
Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial
Air contamination
Service and maintenance
User’s Information Manual
property damage.
• 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.
• To avoid electric shock, disconnect electrical supply before performing
maintenance.
• To avoid severe burns,
• 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.
allow boiler to cool before performing maintenance.
Boiler operation
• Do not block flow of combustion or ventilation air to boiler. This boiler is
• Should
• Do not use this boiler if any part has been under water. Immediately call a
•
Boiler water
• DO NOT use petroleum-based cleaning or sealing compounds in boiler system.
•
• Continual fresh
•
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.
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.
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” o r “ boiler patent medicines”. Serious damage
to boiler, personnel and/or property may result.
sections reduces heat transfer, overheats cast iron, and causes section failure.
makeup water will reduce boiler life. Mineral buildup in
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.
Part Number 550-142-801/1112
3
CGa, CGi, EG, EGH, LGB, PEG, Boilers
Boiler components
CGa CGi
1 Gas valve
2 Pilot burner
3 Main burner
4 Gas manifold/orifices
5 Control module
6 Inducer (CGi only)
7 Vent damper (CGa only)
8 Water temperature sensor
9 Transformer
10 Spill switch (CGa only)
11 Air pressure switch (CGi only)
12 Rollout thermal fuse element
15 Draft hood (CGa only)
16 Circulator
17 Relief valve
18 Gauge (pressure or pressure/temperature)
19 Timer relay (CGi-4 only)
4
Part Number 550-142-801/1112
User’s Information Manual
EG/EGH
LGB
Part Number 550-142-801/1112
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 (steam boilers)
14 Limit control(s)
15 Draft hood
16 Circulator
18 Gauge (pressure or pressure/temperature)
19 Gauge glass (steam only)
5
CGa, CGi, EG, EGH, LGB, PEG, 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
• Condensate drain system
up
-
Service:
• Oiled-bearing circulators
stArt
• Temperature sensor
Start-up:
nnuAl
• Perform start-up per manual
A
Check/test:
Owner maintenance
(see following pages for instructions)
Daily
Monthly
Periodically
Every 6 months
• Check boiler area
• 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)
• Test low water cutoff (if used)
• Operate relief valve
• 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
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
6
End of season
• Shut down procedure
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.
Part Number 550-142-801/1112
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