Weil-McLain CG Series User manual

Otetf&fcl b<f 55D-tio-l,38'/oi%
UlEIL-flldAIN
CG (Series 11) and CGX (Series 1) Gas-Fired Boilers
Boiler Manual
Includes:
• Installation
• Start-up
• Service
• Boiler Parts
Refer to Control Supplement
for additional information
and Gas Control Parts
For Natural or Propane Gas
BOILER MANUAL FOR USE BY A QUALIFIED CONTRACTOR
To the owner: Regular service on this boiler is recommended and should be performed by a qualified
contractor.
To the installer: Read all instructions and warranty before starting.
Any claims for damage or shortage in shipment must be filed immediately
against the transportation company by the consignee.
Part No. 550-110-630/0695DCP

Table of Contents
Section I: Pre-Installation Section IV: Gas Piping . 9
Air Supply for Combustion . 3
Chimney or Vent Requirements . 3
Minimum Service Clearances . 4
Boiler Foundation. 4
Section II: Boiler Set-Up
Placement . 5
Draft Hood . 5
Breeching . 5
Hydrostatic Pressure Test. 5
Section III: Piping
Supply and Return . 6
Expansion Tank Sizing . 6
Multiple Zoning with Circulators . 7
Bypass Piping . 8
Use with Refrigeration System . 8
Section V: Wiring .10
Section VI: Final Adjustments
Section VII: Check-Out Procedure .13
Section VIII: Maintenance . 14-15
Section IX: Replacement Parts. 1 6 - 2 1
Ratings & Dimensions . 2 2-23
IMPORTANT^ When calling or writing about boiler,
PLEASE GIVE MODEL and SERIES located on boiler
rating label AND C.P. NUMBER affixed next to rating
label.
The following defined terms are used throughout this manual. They bring attention to presence of hazards of various risk levels,
or to important information concerning life of product.
DANGER
WARNING
Indicates presence of a hazard which
will cause severe personal injury,
death or substantial property damage
if ignored.
Indicates presence of a hazard which
can cause severe personal injury,,
death or substantial property damage
if ignored.
CAUTION
Indicates presence of a hazard which
will or can cause minor personal in¬
jury or property damage if ignored.
NOTICE
Indicates special instructions on in¬
stallations, operation, or maintenance
which are important but not related
to personal injury hazards.
DANGER
Do not use petroleum based cleaning or sealing compounds in boiler system.
Severe damage to boiler will result, causing substantial property damage.
WARNING
Read all instructions before installing.
Failure to follow all instructions in proper order can cause severe personal injury, death, or substantial property damage.

Section I: Pre-Installation
CODES
Installation must comply with all local codes, laws, regula¬
tions and ordinances, also National Fuel Gas Code ANSI
Z223.1-latest edition. When required, installation must con¬
form to Standard for Controls and Safety Devices for Auto¬
matically Fired Boilers, ANSI/ASME CSD-1. Safe lighting
and other performance criteria were met with the gas mani¬
fold and control assembly provided on boiler when boiler
underwent tests specified in ANSI Z21.13-latest edition.
Canadian installations must comply with CAN/CGA B149.1
or .2 Installation Codes.
COMBUSTION AIR AND VENTILATION OPENINGS
Combustion air and ventilation openings must comply with
Section 5.3, Air for Combustion and Ventilation, of National
Fuel Gas Code ANSI Z223.1-latest edition, or applicable local
building codes. Canadian installations must comply with
CAN/CGA B149.1 or .2 Installation Codes.
Adequate combustion air and venti¬
lation openings must be provided to
assure proper combustion, prevent
possibility of flue gas spillage and
carbon monoxide emissions, causing
severe personal injury or death.
Boiler installation must assure sufficient openings in build¬
ing and boiler room to provide adequate combustion air and
ventilation. Consider construction tightness of building when
deciding whether additional outside openings may be needed.
Older buildings with single-pane windows, minimal
weather-stripping and no vapor barrier often provide enough
natural infiltration and ventilation without dedicated openings.
New construction or remodeled buildings are most often
built tighter. Windows and doors are weatherstripped, vapor
barriers are used and openings in walls are caulked. As a
result, such tight construction is unlikely to allow proper
natural air infiltration and ventilation.
Air from inside building (boiler in interior room):
• Tightly constructed buildings must be provided with open¬
ings to outside for combustion and ventilation air. These
openings must be sized to handle all fuel burning appli¬
ances, exhaust and ventilation fans and fireplaces.
• When openings to boiler room are taken to interior spaces,
provide two permanent openings: a combustion air opening
within 12 inches of floor and a ventilation opening within
12 inches of ceiling. Each opening must provide a minimum
free area of one square inch per 1,000 Btuh input of all
appliances in room plus requirements for any exhaust fans
in room. The interior space supplying combustion and ven¬
tilation air must have adequate infiltration from outside.
Air directly from outside to boiler room:
• Tightly constructed buildings must be provided with com¬
bustion air and ventilation openings to boiler room which
are adequate to handle the boiler needs plus the needs of
all other fuel-burning appliances, fireplaces and exhaust or
ventilation fans.
• Combustion and ventilation openings connecting directly
or by ducting to outside, or to attic or crawl spaces that
freely connect with outside, must be sized as follows:
1. Outside wall or vertical ducting - one square inch per
4,000 Btuh input of all appliances in room plus require¬
ments for any exhaust fans or other appliances in room.
2. Horizontal ducting - one square inch per 2,000 Btuh of
all appliances in room plus requirements for any exhaust
fans or other appliances in room.
3. All ducting must be same size as permanent openings.
Minimum area dimensions of ducting must be no less
than 9 square inches.
4. Other size ducting must comply with local codes.
CHIMNEY OR VENT REQUIREMENTS
Venting must be installed according to Part 7, Venting of
Equipment, of National Fuel Gas Code, ANSI Z223.1-latest edi¬
tion and applicable building codes. Canadian installations
must comply with CAN/CGA B 149.1 or .2 Installation Codes.
Minimum chimney or vent sizes sue on page 23 of these in¬
structions. A chimney or vent should extend at least 3 feet
above the highest point where it passes through a roof of a
building and at least 2 feet higher than any portion of a build¬
ing within a horizontal distance of 10 feet A chimney or vent
must not extend less than those distances stated above.
A lined chimney is preferred and must be used when required
by federal, provincial, territorial, state, or local building codes.
Vitreous tile linings with joints that prevent retention of mois¬
ture and linings made of noncorrosive materials are best.
Advice for flue connections and chimney linings can be
obtained from local gas utility. Type “B” vent material or single
wall vent pipe may be used.
Cold masonry chimneys, also known as outside chimneys, typ¬
ically have one or more walls exposed to outside air.
When any atmospheric gas-fired boiler with automatic vent
damper is vented through this type of chimney, the potential
exists for condensation to occur. Condensation can damage a
masonry chimney.
Weil-McLain recommends the following to prevent possible
damage:
1. Line chimney with corrosion-resistant metal liner such as
AL29^4C® single wall stainless steel or B-vent. Size liner
per National Fuel Gas Code ANSI Z223.1-latest edition.
2. Provide drain trap to remove any condensate.
Inspect existing chimney before
installing boiler. Failure to clean or
replace perforated pipe or tile lining
will cause severe ii\jury or death.
Do not alter boiler draft hood or place
any obstruction or non-approved
damper in breeching or vent system.
A.G.A./CGA certification will become
void. Flue gas spillage and carbon
monoxide emissions will occur causing
severe personal injury or death.
Where two or more gas appliances vent into a common chimney
or vent, equivalent area should be at least equal to area
of vent outlet on largest appliance plus 50 percent of vent outlet
area on additional appliance.
WHEN REMOVING BOILER
FROM COMMON VENTING SYSTEM:
WARNING
Failure to follow ail instructions listed
below can cause flue gas spillage and
carbon monoxide emissions, resulting
in severe personal injury, death or sub¬
stantial property damage.
3

At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected to
the common venting system placed in operation, while the
other appliances remaining connected to the common venting
system are not in operation.
a Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies which
could cause an unsafe condition.
c. Insofar as is practical, close all building doors and windows
and all doors between the space in which the appliances
remaining connected to the common venting system are
located and other spaces of the building. Turn on clothes
dryers and any appliance not connected to the common
venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at maxi¬
mum speed. Do not operate a summer exhaust fan. Close
fireplace dampers.
d. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
e. Test for spillage at the draft hood relief opening after 5 min¬
utes of main burner operation. Use the flame of a match or
candle, or smoke from a cigarette, cigar or pipe.
f. After it has been determined that each appliance remaining
connected to the common venting system properly vents
when tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers, and any other gas-burning
appliance to their previous conditions of use.
g. Any improper operation of the common venting system
should be corrected so the installation conforms with the
National Fuel Gas Code, ANSI Z223.1 - latest edition. When
resizing any portion of the common venting system, the
common venting system should be resized to approach the
minimum size as determined using the appropriate tables in
Appendix G in the National Fuel Gas Code, ANSI Z223.1-
latest edition.
Canadian installations must comply with CAN/CGA B 149.1 or
.2 Installation Codes.
SELECT THE BOILER LOCATION
• Consider all connections to boiler before selecting a location.
• Boiler must be installed so that gas control system compo¬
nents are protected from dripping or spraying water or rain
during operation or service.
WARNING
To avoid personal injury, death or
property damage, keep boiler area
clear and free from combustible ma¬
terials, gasoline and other flammable
vapors and liquids.
INSTALLATION CLEARANCES
Suggested for easy servicing:
24 inches for cleaning and servicing, left side.
18 inches for access to controls and components, front.
35 inches from top for cleaning flueways.
7 inches on remaining sides.
Screwdriver clearance for removal of jacket screws should be
provided. If not, unions and shut-off valves should be installed
in system so boiler can be moved for servicing.
Required clearances to combustible material for closet
installations
Top 35" R. Side 2" Front 3"
Rear 7" L. Side 6"
Hot water pipes must be at least l A inch from combustible
material.
Single wall vent pipe must be at least 6 inches from com¬
bustible material.
Double wall vent pipe refer to vent manufacturer’s recommen¬
dation for clearances to combustible material.
RESIDENTIAL GARAGE INSTALLATION
Install boiler so burners are at least 18 inches above the floor.
FIGURE 1
BOILER FOUNDATION
Boilers are approved for use on combustible flooring but must
not be installed on carpeting.
WARNING
Do not install boiler on carpeting even
if foundation is used. Fire can result
causing severe personal injury, death
or substantial property damage.
1. Level concrete or solid brick pad foundation is required if:
a) Water could flood area.
b) Non-level conditions exist.
2'M!N
4
BOILER FOUNDATION
FIGURE 2

Section II: Boiler Set-up
PLACING THE BOILER
Leave boiler in crate and on pallet until installation site is
ready.
1. Move entire crate and pallet next to selected location.
2. Remove crate.
3. Remove boiler from pallet as follows:
a. Tilt left side of boiler up and place a board under left
legs.
b. Tilt boiler the other way and place a board under right
legs.
c. Slide boiler backward off pallet and into position.
DO NOT DROP BOILER OR BUMP JACKET ON FLOOR
OR PALLET.
4. Check level. Shim legs, if needed. Do not alter legs.
5. Remove front jacket door. Remove base access panel (CG
models only).
6. Check for proper orifice sizing from chart below.
DANGER
Proper orifices must be used. Failure
to do so will cause severe iiyury, death
or substantial property damage.
CG Series 11 - ORIFICE SIZES
Heating Value,
Orifice
Type of Gas
BTU/cu. ft
Size
Natural 1000
2.0mm
Propane
2500
1.3mm
ORIFICE SIZE - CANADA ONLY
Elevation Natural
Propane
0 - 2000 ft.
2.0mm
1.3mm
2000 - 4500 ft. ' 1,9mm
1.2mm
CGX Series 1 - ORIFICE SIZES
Heating Value,
Orifice
Type of Gas
BTU/cu. fL
Size
Natural 1000
#35 Drill
j ORIFICE SIZE - CANADA ONLY
Elevation
Natural
Propane
0 - 2000 ft.
#35 Drill
N/A
2000 - 4500 ft.
#37 Drill
N/A
7. Level and straighten burners (CG models only).
Burners must be properly seated in
slots in burner rest with their open¬
ings face up. Main burner orifices
must inject down center of burner.
Failure to properly seat burners will
result in severe personal injury, death
or substantial property damage.
8. Reinstall access panel (CG models only).
Access panel must be secured in posi¬
tion during boiler operation to prevent
momentary flame rollout on ignition
of main flame.
CAUTION
DANGER
HYDROSTATIC PRESSURE TEST
Pressure test before attaching piping or electrical supply.
1. Remove shipping nipple from supply outlet. Remove relief
valve. Plug tappings, including compression tank tapping
and relief valve opening.
2. Connect water supply. Fill boiler and purge all air. Test at
l ‘ /2 times working pressure.
WARNING
Do not leave boiler unattended. A cold
water fill could expand and cause
excessive pressure, resulting in severe
personal injury, death or substantial
property damage.
3. Check for maintained gauge pressure for more than 10
minutes.
WARNING
Leaks must be repaired at once. Fail¬
ure to do so can damage boiler, result¬
ing in substantial property damage.
Do not use petroleum based cleaning
or sealing compounds in boiler system.
Severe damage to boiler will result,
causing substantial property, damage.
4. Drain boiler and repair leaks if found. Remove testing
plugs. Reinstall relief valve, with spindle in vertical position.
DRAFT HOOD INSTALLATION
Secure draft hood to outlet at top of boiler with sheet metal
screws. Bottom of draft hood or “skirt” must have clearance
dimension above jacket top panel as indicated on draft hood.
Do not alter boiler draft hood or place
any obstruction or non-approved
damper in breeching or vent system.
A.G.A./CGA certification will become
void. Flue gas spillage and carbon
monoxide emissions will occur caus¬
ing severe personal injury or death.
SPILL SWITCH INSTALLATION
Fasten spill switch to draft hood as shown on page 17. Connect
wires as shown in Control Supplement.
DAMPER INSTALLATION
See Control Supplement for information.
DANGER
BREECHING ERECTION
Connect from draft hood or damper outlet to chimney or vent
with same size breeching. Where possible, vertical venting to
the outside from the draft hood or damper outlet will offer best
performance. Where horizontal breeching is used, slope up¬
ward at least 'A inch per lineal foot toward chimney or vent
and support with hangers to prevent sagging.
Long horizontal breechings, excessive
numbers of elbows or tees, or other
obstructions which restrict the flow of
combustion gases should be avoided.
Breeching must not be connected to any portion of a mechan¬
ical draft system that can operate under positive pressure.
Failure to properly pipe boiler may
result in improper operation and dam¬
age to boiler or building.
CAUTION
WARNING
5

Section III: Piping
1. Pipe as shown'in Figures 3 or 4.
a. Diaphragm-type expansion tank: Be sure tank pressure
and size will handle system pressure and water volume.
1) Fill pressure may be adjusted at tank for design con¬
ditions. Follow manufacturer’s instructions.
2) Additional tanks may be connected to tees in system
near boiler.
3) Install automatic air vent as shown in Figure 3.
b. Closed-type expansion tank: Size tank to system require¬
ments. Refer to tank manufacturer’s instructions.
1) Connect from V4" N.P.T. tapping (located behind sup¬
ply outlet) to expansion tank. Use Vi" piping. Any hor¬
izontal piping must pitch up towards tank 1" per 5
feet of piping.
2) Built-in air elimination system is provided. No addi¬
tional device is needed if tank is piped as shown in
Figure 4.
2. Use low water cut-off when:
a. boiler is located above radiation level.
b. required by certain state, local, or territorial codes or
insurance companies.
Use low water cut-off designed for water installations.
Electrode probe type may be located in tee in supply piping.
TO
SYSTEM
WATER
SUPPLY
CLOSED TYPE
EXPANSION TANK
CLOSED TYPE EXPANSION TANK PIPING
FIGURE 4
TABLE I - MINIMUM RECOMMENDED PIPE SIZES
Based on 20°F temperature drop between supply and return.
DIAPHRAGM TYPE
EXPANSION TANK PIPING
FIGURE 3
3. If the system is to comply with ASME or Canadian require¬
ments, an additional high temperature limit is needed.
Install control in supply piping between boiler and isolation
valve. Set second control to minimum 20°F above set point
of first control. Maximum allowable set point is 240°F. See
Control Supplement for wiring.
4. Verify relief valve is installed with spindle in vertical posi¬
tion.
WARNING
Relief valve discharge piping must be
piped near floor close to floor drain
to eliminate potential of severe
bums. Do not pipe to any area where
freezing could occur.
5. C onnect supply, return, and cold water fill piping. See Table
I for minimum recommended pipe sizes.

MULTIPLE ZONING WITH CIRCULATORS
1. If multiple zoning with circulators, remove provided circulator. See Figure 5:
a) Determine if by-pass piping will be needed. See page 8.
b) Mount circulators as shown.
c) Install flow control valves.
d) Follow remaining piping instructions.
e) Size common supply and return piping for combined flow of all circulators.
ISOLATION
VALVES"
'DO NOT USE DRAIN COCK TAPPING
' 'MAY BE INSTALLED IN ALTERNATE LOCATIONS
MULTIPLE ZONING WITH CIRCULATORS
FIGURE 5

BYPASS PIPING
BYPASS PIPING IS NOT NORMALLY REQUIRED ON TYP¬
ICAL BASEBOARD SYSTEM.
Bypass piping should be used for the following installations.
Bypass, supply, and return piping should be same size.
1. Tb protect:
• radiant panels, plaster, etc. from high temperature
water supplied from boiler, or
• boiler from condensation caused by low temperature
water returned from system.
USE WITH REFRIGERATION SYSTEM
Boiler must be installed so that chilled medium is piped in
parallel with heating boiler using appropriate valves to pre¬
vent chilled medium from entering boiler. Consult I = B = R
Installation and Piping Guides.
If boiler is connected to heating coils located in air handling
units where they can be exposed to refrigerated air, gravity
circulation during cooling cycle must be prevented with flow
control valves or other automatic means.
RECOMMENDED PIPING FOR COMBINATION
HEATING & COOLING (REFRIGERATION) SYSTEMS
FIGURE 8
FIGURE 6
2. To protect boiler from condensation formed by low water
temperature returned from large water content converted
gravity systems, etc., see Figure 7.
TO SYSTEM
FROM
SYSTEM
8

Section IV: Gas Piping
Size gas piping considering:
a. Diameter and length of gas supply piping.
b. Number of fittings.
c. Maximum gas consumption (including any possible fu¬
ture expansion).
d. Allowable loss in gas pressure from gas meter outlet to
boiler. For pressure drops, see ANSI Z223.1-latest edition.
Canadian installations must comply with CAN/CGA
B149.1 or .2 Installation Codes.
1. F or natural gas:
a) Refer to following tables, lb obtain cubic feet per hour,
divide the input by 1000.
b) Size for rated boiler input.
c) Inlet gas pressure: 5" W.C. minimum
13" W.C. maximum
d) Manifold gas pressure: 314" W.C.
e) Install 100% lock-up gas pressure regulator in supply
line if inlet pressure exceeds 13” W.C. Adjust for 13"
W.C. maximum.
PIPE DELIVERY SCHEDULE
* 0.60 Specific Gravity, 0.30 inches water column pressure drop.
NOTE: For additional piping schedules, see ANSI Z223.1-latest edition.
Canadian installations must comply with CAN/CGA B 149.1 or .2 Instal¬
lation Codes.
2. For propane gas:
a) Inlet gas pressure: 11" W.C. minimum
13" W.C. maximum
b) Manifold gas pressure: 10" W.C.
c) Gas pressure regulator provided by gas supplier must
be adjusted for maximum pressure of 13" W.C.
d) Contact gas supplier to size pipes, tanks and regulator.
3. Remove jacket door and refer to Figure 9 for gas piping.
4. Follow good piping practices.
5. Pipe joint compound (pipe dope) must be resistant to cor¬
rosive action of liquified petroleum gases and applied
sparingly only to male threads of pipe joints.
GAS SUPPLY PIPING
FIGURE 9
6. Install drip leg at inlet of gas connection to boiler. Whei
local utility requires drip leg be extended to the floor, uf
appropriate length of pipe between cap and tee.
7. Install ground joint union to provide for servicing, wht
required.
8. Install manual shut-off valve in gas supply piping outsic
boiler jacket when required by local codes or utility r
quirements.
9. Support piping by hangers, not by boiler or its accessorie
10. Purge all air from supply piping.
11. Before placing boiler in operation, check boiler and i
gas connection for leaks.
Do not check for gas leaks with;
open flame - use bubble te.<
Failure to do so can cause seve
personal injury, death or substa
tial property damage.
a) Close manual main shut-off valve during any pressu
testing at less than 13 inches water column.
b) Disconnect boiler and gas valve from gas supply pipi)
during any pressure test greater than 13 inches wat
column.
12. I n Canada - when using manual main shutoff valve,
must be identified by installer.

Section V: Wiring
Refer to wiring diagram label on jacket door
and Control Supplement for specific wiring details.
WARNING
WIRING
For your safety, turn off electrical
power supply at service entrance
panel before making any electrical
connections to avoid possible electri¬
cal shock hazard.
All wiring must be installed in accordance with requirements
ofNational Electrical Code and any additional national, state,
or local code requirements having jurisdiction. All wiring
must be N E C. Class 1. Boiler must be electrically grounded
in accordance with the National Electrical Code, ANSI/NFPA
No. 70-latest edition.
In Canada, installation must conform to CSA C22.1 Canadian
Electrical Code Part 1 and any local codes.
If original rollout thermal fuse element wire as supplied with
boiler must be replaced, type 200°C wire or equiv. must be
used. If other original wiring as supplied with boiler must be
replaced, type 105°C wire or equivalent must be used.
Boiler is shipped with control components completely wired,
except spill switch and damper.
Separate electrical circuit with fused disconnect switch (15
amp. recommended) should be used for boiler. Bring electrical
supply through proper opening in jacket left end panel and
into electrical junction box. Wire electrical supply to leads in
junction box as shown on diagram.
INSTALL ROOM THERMOSTAT
Install room thermostat on an inside wall. Never install
where it will be influenced by drafts, hot or cold water pipes,
lighting fixtures, television, sun rays or near a fireplace.
Refer to wiring diagram on jacket door or in Control Supple¬
ment for recommended heat anticipator setting with standard
equipment. Wire thermostat as shown.
WIRING MULTIPLE ZONES
Refer to zone valve manufacturer’s literature for wiring and
application. A separate transformer is required to power zone
valves. Zoning with circulators requires a relay for each cir¬
culator.
120:24
TRANSFORMER -
DO NOT USE BOILER
TRANSFORMER
THERMOSTAT
TO ADDITIONAL
ZONES
TO THERMOSTAT
TERMINALS ON BOILER
TYPICAL WIRING - ZONING
WITH ZONE VALVES
FIGURE 10

Section VI: Final Adjustments
WATER TREATMENT
■ Do not use petroleum-based cleaning
or sealing compounds in boiler system.
Severe damage to the boiler will occur.
Continual make-up water will reduce boiler life. Minerals can
build up in sections, reducing heat transfer, overheating cast
iron, and causing section failure.
For unusually hard water areas or low pH conditions (less
than 7.0) consult local water treatment company.
Freeze protection (when used):
Use antifreeze especially made for hydronic systems. Inhib¬
ited propylene glycol is recommended.
Do not use automotive, ethylene glycol
or undiluted antifreeze. Severe per¬
sonal injury, death or substantial
property damage can result.
50% solution provides protection to about - 30°F.
Local codes may require back-flow preventer or actual dis¬
connect from city water supply.
Determine quantity according to system water content. Boiler
water content is listed on back cover. Remember to add in
expansion tank water content.
Follow antifreeze manufacturer’s instructions.
FILLING SYSTEM
1. C lose manual air vents, drain cock, and automatic air vent,
if used.
2. F ill to correct system pressure. Correct pressure will vary
with each application. Residential systems are often de¬
signed for 12 pounds of cold Fill pressure.
3. O pen automatic air vent one turn, if used.
4. O pen manual water feed valve.
5. a ) Starting on lowest floor, open air vents one at a time
until water squirts out. Close vent,
b) R epeat with remaining vents.
6. C lose manual water feed valve when correct boiler pres¬
sure is reached.
WARNING
DANGER
INSPECT BASE INSULATION
Check to make sure insulation is secure against all four sides
of the base.
WARNING
If insulation is damaged or displaced,
call service technician immediately.
DO NOT operate boiler.
Ceramic fiber material used in boiler
base insulation can cause temporary
skin, eye, and upper respiratory irri¬
tation.
Use NIOSH or MSHA approved pro¬
tection when installing or removing
this material.
TO PLACE IN OPERATION
1. B e sure boiler has been correctly filled with water.
2. F ollow correct lighting/operating instructions on boiler.
For CG propane gas boilers only:
WARNING
Your propane supplier mixes ai
odorant with the propane to make it
presence detectable. In som
instances, the odorant can fade, am
the gas may no longer have an odoi
Propane gas can accumulate at floo
level. Smell near the floor for the ga
odorant or any unusual odor. If yo
suspect a leak, do not attempt t<
light the pilot.
• Use caution when attempting to ligh
a propane pilot. This should be dom
by a qualified service technician
particularly if pilot outages ar
common.
• Periodically check the odorant lev<
of your gas.
• Inspect boiler and system at leas
yearly to make sure all gas piping i
leak-tight.
• Consult your propane supplie
regarding installation of a gas lea
detector. There are some product
on the market intended for this pui
pose. Your supplier may be able t
suggest an appropriate device.
3. If boiler starts, go to Step 5.
If boiler fails to start, go to Step 4.
4. If boiler fails to start, check for following conditions:
a) Loose connection or blown fuse?
b) Limit setting below boiler water temperature?
c) Thermostat set below room temperature?
d) Gas not turned on at meter and boiler?
e) Incoming natural gas pressure less than 5" W.C. c
propane less than 11" W.C.?
f) Access panel not secured in place?
g) If above fails to eliminate the trouble, refer to Contn
Supplement.
5. Make sure boiler goes through several normal operatin
cycles.
6. Turn thermostat or operating control to desired setting.

- j
Check pilot burner flame:
1. Proper pilot flame .
a) Blue flame.
b) Inner cone engulfing pilot flame sensor.
c) Pilot flame sensor glows cherry red.
2. Improper pilot flame
a) Overfired - flame is large and lifting or blowing past
pilot flame sensor.
b) Underfired - flame small; pilot flame sensor not en¬
gulfed by inner cone.
c) Lack of primary air - flame tip yellow.
d) Pilot flame sensor not heated properly.
INSPECT VENTING SYSTEM
1. Check venting system atleastoncea month during heating
season. With boiler firing, hold candle or match below
lower edge of draft hood “skirt”. If flame does not blow out,
but burns undisturbed, vent system is functioning prop¬
erly. If flame blows out or flickers drastically, vent system
must be checked for obstructions or other causes of im¬
proper venting.
2. Inspect all parts of venting systems for deterioration from
corrosion, physical damage, sagging, etc. Correct all con¬
ditions found.
3. Verify damper is open when burner ignites. For additional
information, see Control Supplement.
i
TYPICAL PILOT BURNER FLAME
FIGURE 11
CHECK BURNER FLAMES
1. Proper burner flame, see Figure 12. Yellow-orange streaks
may appear - caused by dust.
2. Improper flame:
a) Overfired - Flames large.
b) Underfired - Flames small.
c) Lack of primary air - Yellow tipping on flames; sooting
will occur.
TYPICAL MAIN BURNER FLAME
FIGURE 12
12

Section VII: Check-out Procedure
Check-off steps as completed.
□ ■ 1. Boiler and heat distribution units filled with water?
□ 2. Automatic air vent, if used, open one turn?
□ 3. Air purged from system?
□ 4. Air purged from gas piping? Piping checked for leaks?
□ 5. Are proper orifices installed? Check page 5 for proper
DANGER
Proper orifices must be used.
Failure to do so will cause se¬
vere injury, death or substan¬
tial property damage.
□ 6. Follow operating/lighting instruction label on boiler
for proper start-up. Also refer to “lb Place in Opera¬
tion,” page 11.
O 7. Proper burner flame? Refer to “Check Burner Flames,”
page 12.
□ 8. Tfest limit controls: While burners are operating, move
indicator of high limit control below actual boiler
water temperature. Burners should go off while cir¬
culator continues to operate. Raise limit control above
boiler water temperature and burners should reignite.
□ 9. Tfest any additional field-installed controls: If boiler
has low water cut-off, additional high limit or other
controls, test for operation as outlined by manufac¬
turer. Burners should be operating and should go off
when controls are tested. When controls are restored,
burners should reignite.
□ 10. Button on spill switch pushed in?
□ 11. Tfest ignition system shut-off device:
a. For standing pilot - TUm gas cock knob to PILOT
position and extinguish pilot flame. Pilot gas flow
should stop in less than 3 minutes. Put system back
into operation (see page 11).
b. For intermittent- ignition systems - Connect ma¬
nometer to outlet side of gas valve. Start boiler, al¬
lowing for normal start-up cycle to occur and main
burners to ignite. With main burners on, manually
shut off gas supply at manual main shut-off gas
valve. Burners should go off. Open manual main
shut-off gas valve. Manometer should confirm there
is no gas flow. Pilot will relight, flame sensing ele
ment will sense pilot flame and main burners re¬
ignite.
□ 12. High limit control set to design temperature require
ments of system? Maximum high limit setting is 240°F
□ 13. For multiple zones, flow adjusted so it is about th<
same in each zone?
□ 14. Thermostat heat anticipator set properly? Refer t(
“Install Room Thermostat” page 10, and wiring dia
gram on jacket door.
□ 15. Boiler cycled with thermostat? Raise to highest set
ting. Boiler should go through normal start-up cycle
Lower to lowest setting. Boiler should go off.
□ 16. Measure gas input (natural gas only):
a. Operate boiler 10 minutes.
b. T\im off other appliances.
c. At natural gas meter, measure time (in seconds
required to use one cubic foot of gas.
d. Calculate gas input:
3600x1000
— — —— = Btuh
number of seconds from step C
e. Btuh calculated should approximate input ratinj
on rating label.
□ 17. Check manifold gas pressure by connecting manome
ter to downstream test tapping on main gas valve
Manifold gas pressure for natural gas should be 3 V
inches water column and for propane gas should be 1(
inches water column.
D 18. Several operating cycles observed for proper operation-
See Control Supplement for damper check-out procedure.
□ 19. Room thermostat set to desired room temperature?
□ 20. Installation and Service Certificate on this page com
pleted?
□ 21. All instructions shipped with this boiler reviewed witl
owner or maintenance person, returned to envelop
and given to owner or displayed near boiler?
Installation and Service Certificate
BOILER MODEL.
.SERIES. .CP NUMBER.
DATE INSTALLED.
BTU INPUT.
□ Installation instructions have been followed.
□ Check-out sequence has been performed.
□ Above information is certified to be correct.
□ Information received and left with owner/maintenance person.
Installer.
(Company)
(Address)
(Phone)
(Installer’s Signature)
13

Also Refer to Additional Instructions Shipped With The
Boiler For Specific Control Operation and Troubleshooting
NOTICE
WARNING
Boiler should be inspected, cleaned
and, if necessary, adjusted once a year.
A qualified service agency should be
called.
TO AVOID PERSONAL INJURY,
BEFORE SERVICING:
1. Disconnect electrical supply.
2. Shut-off gas supply.
3. Allow boiler to cool.
WARNING
Tb avoid personal injury, death or
property damage, keep boiler area
clear and free from combustible ma¬
terials, gasoline and other flammable
vapors and liquids.
Do not block flow of air to boiler. In¬
complete combustion and carbon mon¬
oxide emissions can cause severe
personal injury, death or substantial
property damage.
Do not store sources of hydrocarbons
(i.e., bleaches, cleaners, chemicals,
sprays, paint removers, fabric soften¬
ers, etc.) in boiler area. This can con¬
tribute to shortened boiler/vent
system life.
Suggested Minimum Maintenance Schedule for
Qualified Service Technician Only
Beginning of each heating season:
1. Annual service call by a qualified service agency.
2. Check burners and flueways and clean if necessary. Ref¬
erence “Clean Boiler Heating Surfaces” and “Cleaning
Main Burners,” page 15.
3. Visually inspect base insulation. Reference “Inspect Base
Insulation,” page 11.
4. Follow procedure "1b Place in Operation,” page 11.
5. Visually inspect pilot and burner flames. Reference
“Check Burner Flames,” pages 11 and 12.
6. Visually inspect venting system for blockage, deteriora¬
tion or leakage. Reference “Inspect Venting System,”
page 12.
7. Check operation of low-water cut-off, if used, and addi¬
tional field-installed controls. Refer to manufacturer’s in¬
structions.
8. Check that boiler area is free from combustible materials,
gasoline and other flammable vapors and liquids.
9. Check for and remove any obstruction to flow of combus¬
tion or ventilation air.
10. F ollow instructions on circulator to oil, if oil lubricated.
Overoiling will damage the circulator. Water lubricated
circulators do not need oiling.
Daily during heating season:
1. Check that boiler area is free from combustible materials,
gasoline and other flammable vapors and liquids.
2. Check for and remove any obstruction to the flow of com¬
bustion or ventilation air.
Periodically during heating season:
1. Check relief valve. Reference manufacturer’s instructions
on relief valve tag.
2. Tfest low water cut-off, if used. Blowdown if low water cut¬
off is float type. Reference manufacturer’s instructions.
Monthly during heating season:
1. Check for leaks in boiler and piping. If found, repair at
WARNING
DANGER
Leaks must be repaired at once.
Failure to do so can damage
boiler, resulting in substantial
property damage.
Do not use petroleum based
cleaning or sealing compounds in
boiler system. Severe damage to
boiler will result, causing sub¬
stantial property damage.
2. Visually inspect pilot and burner flames. Reference
“Check Burner Flames,” pages 11 and 12.
3. Visually inspect venting system for blockage, deteriora¬
tion or leakage. Reference “Inspect Venting System,”
page 12.
4. Check automatic air vent for leakage. If leaking, remove
vent cap and push valve core in to wash off sediment that
may have accumulated on valve seat. Release valve,
replace cap and open one turn.
End of each heating season:
1. Follow “Annual Shutdown Procedure,” page 15.

Warning
Clean boiler heating surfaces:
This product contains fiberglass
wool and ceramic fiber materials.
Airborne fibers from these materials
have been listed by the State of
California as a possible cause of can¬
cer through inhalation. Apply special
care when handling ceramic fiber
(base insulation) materials. Ceramic
fibers can be converted to chrysto-
balites, a substance listed as a proba¬
ble cause of cancer through inhalation.
Suppliers of fiberglass wool products
recommend the following precau¬
tions to be taken when handling
these materials:
Precautionary Measures
• Avoid breathing fiberglass dust
and contact with skin or eyes.
• Use NIOSH approved dust/mist
respirator.
• Wear long-sleeved, loose fitting
clothing, gloves and eye protection.
• Wash work clothes separately
from other clothing. Rinse washer
thoroughly.
• Operations such as sawing, blow¬
ing, tear out, and spraying may gen¬
erate airborne fiber concentration
requiring additional protection.
First Aid Measures
• Eye contact - Flush eyes with
% water to remove dust. If symptoms
persist, seek medical attention.
• Skin contact - Wash affected
areas gently with soap and warm
water after handling.
1. Follow shut-down procedure.
2. Remove breeching, damper (when used) and draft hood.
Remove upper rear jacket panel. Turn back jacket insula¬
tion to expose collector hood.
3. Remove collection hood. Clean excess boiler cement from
collector hood and cast iron sections.
4. Remove radiation plates that hang between sections.
5. Remove burners from base of boiler. Follow “Cleaninf
Main Burners," page 15.
6. Place newspaper in base of boiler to collect soot that wil
fall.
7.
8 .
9.
10 .
11 .
12 .
With a wire flue brush, clean between sections.
Remove newspaper and soot. Vacuum or brush base anc
surrounding area.
Replace radiation plates.
Replace collector hood. Seal with boiler cement
Replace insulation and jacket panel.
Replace main burners.
DANGER
CG burner tubes must be seatec
in slots in burner rest with open
ings face up; CGX burners mus
be fastened securely to manifoh
assembly with openings face up
Main burner orifices must injec
down center of burner. Failure t<
properly seat burners will resul
in severe personal injury, death oi
substantial property damage.
13. Replace draft hood, damper (when used) and breeching
14. Follow “To Place in Operation” procedure.
NOTE: Excessive sooting indicates improper gas combustion
If found, call a qualified service agency or your loca
gas utility to check for proper combustion and maki
any necessary adjustments.
Cleaning main burners:
1. Vacuum or brush burners to remove dust and lint.
DANGER
When replacing, CG burner tube:
must be seated in slots in bume
rest with openings face up; CG?
burners must be fastened secureh
to manifold assembly with open
ings face up. Main burner orifice:
must ir\ject down center of bum
er. Failure to properly seat bum
ers will result in severe persona
injury, death or substantial prop
erty damage.
Annual shut-down procedure:
1. Follow “To Turn Off Gas to Appliance” instructions oi
boiler.
2. DO NOT drain system unless exposure to freezing temper
atures will occur. If antifreeze is used in system, do no
drain.
15

Parts Lists
Component-Assemblies Replacement
(Refer to Control Supplement for control replacement)
Section Assembly.17
Base Assembly (CG Series 11). 1 8
Base Assembly (CGX Series 1) .19
Jacket Assembly.20
Boiler Trim Assembly .21
COMPONENT REPLACEMENT INSTRUCTIONS
Before replacing any parts on the boiler:
1. Turn off power
2. Shut off gas supply
Refer to the appropriate diagram for parts replacement.
Replacement parts must be purchased through a local Weil-McLain distributor. When ordering,
specify boiler model and series and include description and number of replacement part.
Results from using modified or other manufactured parts will not be covered by warranty and
may damage boiler or impair operation.
Weil-McLain Sales Ref. No. are found in Weil-McLain Boilers and Controls Repair Parts Book.
Some parts are stock items ( ■ ) and can be purchased from a local supply house.
16

Screw, #8 x VS Sht. Mtl. Pan Hd. PM. _
Bushing, Thermostat Wire __
LISTED PART OR EQUIVALENT CAN BE PURCHASED AT LOCAL SUPPLY HOUSE.