Weil-McLain CGa Series User manual

Gas-Fired Boilers
User Manual
Manual Part Number 550-142-301/0123
!
WARNING
If the information in this manual is not followed exactly, a re or explosion may result,
causing property damage, personal injury or loss of life. Do not store or use gasoline or
other ammable 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 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 qualied installer, service technician or the gas
supplier.
CGa Series 3
CGi Series 4
EG Series 5
PEG Series 5
LGB Series 3
INSTALLER:
Please take time to review this User Manual with the boiler
owner. Explain all maintenance and service procedures and
the correct operating instructions.
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SECTION 1 –SAFETY 3
Safety Signals . . . . . . . . . . . . . . . . . . . . . . 3
Please Read Before Proceeding . . . . . . . . . . . . 3
Boiler Maintenance . . . . . . . . . . . . . . . . . . . . . . .3
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
CGa-7, CGa-8, EG-55 to EG-75, PEG-55 . . . . . . . . . . .8
CGa-25 to CGa-6, EG-30 to EG-50, PEG-30 to PEG-50 . . .9
CGi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
LGB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . 12
Common Issues and Solutions . . . . . . . . . . . . . . . . 12
SECTION 3 –MAINTENANCE 13
Maintenance Overview . . . . . . . . . . . . . . . . 13
Servicing and Maintaining the Boiler . . . . . . . . . . . . .13
Boiler Components . . . . . . . . . . . . . . . . . . 14
Tankless Water Heater (EG and PEG only) . . . . . . . . . 14
Rollout Thermal Fuse Element (CGa, CGi, EG, & PEG only) . .14
Spill Switch (CGa, EG, & PEG only). . . . . . . . . . . . . 14
Pressure Switch (LGB only) . . . . . . . . . . . . . . . . . 14
CGa Series 3 . . . . . . . . . . . . . . . . . . . . . . . . . 15
CGi Series 4 . . . . . . . . . . . . . . . . . . . . . . . . . 16
EG/PEG . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LGB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance Procedures — DAILY. . . . . . . . . . 18
Boiler Area . . . . . . . . . . . . . . . . . . . . . . . . . .18
Pressure/Temperature Gauge or Pressure Gauge (Steam) . 18
Air openings . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance Procedures — MONTHLY . . . . . . . 19
Boiler Piping . . . . . . . . . . . . . . . . . . . . . . . . . 19
Venting System . . . . . . . . . . . . . . . . . . . . . . . . 19
Boiler Relief Valve . . . . . . . . . . . . . . . . . . . . . . 19
Automatic Air Vents (if used) . . . . . . . . . . . . . . . . .19
Pilot Burner Flame . . . . . . . . . . . . . . . . . . . . . .20
Main Burner Flame . . . . . . . . . . . . . . . . . . . . . . 20
Check Condensate Drain System (if used). . . . . . . . . . 20
Maintenance Procedures — PERIODICALLY . . . . 21
Test the Low Water Cuto󰀨 . . . . . . . . . . . . . . . . . . 21
Float Type Low Water Cuto󰀨 . . . . . . . . . . . . . . . . .21
Probe Type Low Water Cuto󰀨 . . . . . . . . . . . . . . . . 21
Integrated Type Low Water Cuto󰀨 . . . . . . . . . . . . . .22
Clean Gauge Glass. . . . . . . . . . . . . . . . . . . . . . 22
Oil Inducer Motor (CGi Boilers). . . . . . . . . . . . . . . . 22
Maintenance Procedures — EVERY 6 MONTHS. . . 23
Operate the Boiler Relief Valve. . . . . . . . . . . . . . . . 23
Maintenance Procedures — END OF SEASON . . . 23
Boiler Shutdown Procedure . . . . . . . . . . . . . . . . . 23
Propane Gas Odorant . . . . . . . . . . . . . . . . . . . . 23
How to Use This Manual
Contents
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
Start or shut down the boiler Operating instructions 6-11
Troubleshoot common issues Use the troubleshooting table to resolve
typical heating system and boiler issues. 12
Identify and locate boiler
components Boiler illustrations 14-17
Maintain the boiler Boiler maintenance schedules 18-23
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This section is intended to provide safety information
for users.
Section Contents
Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . .3
Please Read Before Proceeding . . . . . . . . . . . . . . . .3
Safety Signals
The following dened terms are used throughout this
manual to bring attention to the presence of hazards
or other important information.
DANGER
!
Danger indicates the presence of hazards that
will cause severe personal injury, death, or
substantial property damage.
!
WARNING
Warning indicates the presence of hazards that
can cause severe personal injury, death, or
substantial property damage.
CAUTION
!
Caution indicates the presence of hazards
that will or can cause minor personal injury or
property damage.
NOTICE
Notice indicates additional information that may be
related to property damage, but is not related to
personal injury.
IMPORTANT
Important indicates additional information that is
important, but is not related to personal injury or
property damage.
Please Read Before Proceeding
!
WARNING
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.
User: Refer to this User Manual as your information
source. Installation and service must be performed
by a qualied installer, service technician, or gas
supplier.
Installer: Refer to the Boiler Manual and all other
information shipped with the boiler for installation and
service.
Please include the boiler model number, CP number,
and serial number when calling or writing about the
boiler. The model number can be found on the boiler
rating label.
IMPORTANT
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 qualied service technician to ensure boiler
system reliability.

Safety
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Safe Boiler Operation
• Do not block ow of combustion or ventilation
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 qualied
service technician check the boiler system.
• Do not allow contaminated air to enter the boiler room,
or the air inlet pipe if direct vented. See page 5for
details.
• Should overheating occur, or gas supply fail to
shut o󰀨, do not turn o󰀨 or disconnect electrical
supply to pump. Shut o󰀨 the gas supply at a
location external to the appliance.
Boiler Water
• Have the boiler water chemistry checked at least
annually by a qualied service technician.
• Do not use petroleum-based cleaning or sealing
compounds in the boiler system. Gaskets and seals
in the system may be damaged, which can result in
substantial property damage.
• Do not use "homemade cures" or "boiler patent
medicines." Serious injury or damage may result.
• Continual fresh make-up water will reduce boiler
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.
• Do not add cold water to a hot boiler. Thermal
shock can cause the heat exchanger to crack.
• NEVER use automotive or standard glycol
antifreeze inn this boiler system, including glycol
made for hydronic systems.
Frozen Water Damage
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 e󰀨ective action.
Consult with your boiler contractor or a home security
agency.
Damage from Water Contact
DANGER
!
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 e󰀨ects 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.
Please Read Before Proceeding, continued
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This section is intended to provide operating
instructions and information for users.
Section Contents
Operating the Boiler . . . . . . . . . . . . . . . . . . . . . .5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 12
Operating the Boiler
Prevent Combustion Air Contamination
!
WARNING
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 repiped and terminated to another location.
Contaminated combustion air will damage the
boiler, and 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.
(continued on the next page)

Operation
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Products to avoid
Spray cans containing chloro/
uorocarbons Paint or varnish removers
Permanent wave solutions Hydrochloric acid and muriatic
acid
Chlorinated waxes and cleaners Cements and glues
Chlorine-based swimming pool
chemicals
Anti-static fabric softeners used in
clothes dryers
Calcium chloride used for thawing Chlorine-type bleaches,
detergents, and cleaning solvents
Sodium chloride used for water
softening
Adhesives used to fasten building
products and other similar products
Refrigerant leaks Excessive dust and dirt
Areas likely to have contaminants
Laundry and dry cleaning areas
and establishments Auto body shops
Swimming pools Plastic manufacturing plants
Metal fabrication plants Furniture renishing areas and
establishments
Beauty shops New building construction
Refrigeration repair shops Remodeling areas
Photo processing plants Garages with workshops
Table 1 Corrosive contaminants and sources
Table 2 Operating instructions guide
Spark-ignited pilot Models Page
Honeywell VR8204/VR8304
CGa-25 thru CGa-8
EG-30 thru EG-75
PEG-30 thru PEG-55
6
CGi-3 thru CGi-6 10
White-Rodgers 36E
CGa-25 thru CGa-6
EG-30 thru EG-50
PEG-30 thru PEG-50
7
CGi-3 thru CGi-6 10
White-Rodgers 36C
CGa-7 & CGa-8
EG-55 thru EG-75
PEG-55
8
CGi-3 thru CGi-6 10
Robertshaw 7200
CGa-25 thru CGa-6
EG-30 thru EG-50
PEG-30 thru PEG-50
9
–– LGB 11

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Operating the Boiler, continued
CGa, EG-30 to EG-75, PEG-30 to PEG-55
• Spark-ignited pilot
• Gas valve — Honeywell VR8204/VR8304
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CGa-25 to CGa-6, EG-30 to EG-50, PEG-30 to PEG-50
• Spark-ignited pilot
• Gas valve — White-Rodgers 36E
(continued on the next page)
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Operating the Boiler, continued
CGa-7, CGa-8, EG-55 to EG-75, PEG-55
• Spark-ignited pilot
• Gas valve — White-Rodgers 36C
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CGa-25 to CGa-6, EG-30 to EG-50, PEG-30 to PEG-50
• Spark-ignited pilot
• Gas valve — Robertshaw 7200
(continued on the next page)
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CGi
• Spark-ignited pilot
• Gas valve — Honeywell VR8204/VR8304, White-Rodgers 36C and 36E
Operating the Boiler, continued
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LGB
• Spark-ignited pilot
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Common Issues and Solutions
Troubleshooting
Symptom Common Causes Possible Corrections
Rapid cycling —
boiler turns on and
o󰀨 frequently
Thermostat installed where drafts or
heat a󰀨ect reading
Locate thermostat on inner wall away from heat sources or
cool drafts.
Heat anticipator in thermostat
adjusted incorrectly Adjust thermostat per manufacturer’s instructions.
Incorrect limit setting Set limit according to system needs. Maximum setting is 220°F.
Increase limit setting to decrease cycling.
Insu󰀩cient water ow through boiler
Check all valves to and from boiler. Return to proper setting.
Conrm circulator size.
Frequent release of
water through relief
valve
Expansion tank sized too small Call qualied service technician to check expansion tank
operation and size.
Flooded expansion tank Call qualied service technician to check expansion tank
operation.
Inoperative limit control Call qualied service technician to replace limit control.
Need to frequently
add makeup water Leaks in boiler or piping
Have qualied 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.
Black water
condition
Oxygen corrosion due to leaks in
boiler and piping
Have qualied service technician repair at once. Keep pH of
water between 7.0 to 8.5.
Popping or
percolating noise
heard in boiler
Mineral deposits in sections due
to constant use of makeup water
Call qualied service technician to de-lime boiler, if necessary.
In some cases, deposits will be too heavy to remove with de-
liming procedures.
Have qualied service technician repair leaks to eliminate need
for constant makeup water.
Incorrect pH of boiler water Call qualied service technician to check pH level and correct.
pH should be maintained between 7.0 to 8.5.
Insu󰀩cient water ow through boiler
Check all valves to and from boiler. Return to proper setting.
Conrm circulator size.
Metal akes found in
vent outlet or vent —
ueway corrosion
Contaminated combustion air
supply — See page 5 in this
manual.
Remove any contaminating products. See page 5 in this
manual.
Provide outside air for combustion.
Condensation of combustion gases in
boiler sections
Have qualied service technician inspect system piping and
controls to verify proper regulation of return water temperature.
Some radiators or
baseboard units do
not heat or are noisy
Air in system Bleed air from system through air vents in radiators or
baseboard units.
Low system pressure
Fill to correct pressure.
Check for leaks in boiler or piping. Have qualied service
technician repair at once.
High limit set too low Adjust high limit to higher setting.
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This section is intended to provide service schedules
and maintenance information for users.
Section Contents
Maintenance Overview . . . . . . . . . . . . . . . . . . . . 13
Boiler Components . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance Procedures — DAILY . . . . . . . . . . . . . 18
Maintenance Procedures — MONTHLY . . . . . . . . . . . 19
Maintenance Procedures — PERIODICALLY . . . . . . . . 21
Maintenance Procedures — EVERY 6 MONTHS . . . . . . 23
Maintenance Procedures — END OF SEASON . . . . . . .23
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
qualied 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 e󰀩ciency and
reliability.

Maintenance
Owner Maintenance
(see the following pages for instructions)
Beginning of Season
Contact your boiler service technician to inspect, service, and start up your boiler.
You must have an annual start-up performed by a qualied service technician to
ensure reliable operation of the boiler and system.
Daily
Check the boiler area
Check air openings
Check the pressure and temperature gauge
Monthly
Check boiler interior piping
Check venting system
Check air vents
Check boiler relief valve
Check automatic air vents (if used)
Every 3 Months Test low water cuto󰀨
Every 6 Months Check the boiler gas and water piping
Operate the relief valve
End of Season Shut down procedure
!
WARNING
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 could result in severe personal injury, death, or substantial property damage.
Draft - For Engineering Review ONLY Jan. 2023 HC
Figure 1 Service and maintenance schedule

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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.
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. Di󰀨erential can be set to 15° and
adjusted to control level. Lowering the di󰀨erential 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.
!
WARNING
Do not attempt to place boiler in operation if
rollout thermal fuse element cuts o gas ow.
Immediately call a service technician. Failure to
do so can cause severe personal injury, death or
substantial property damage.
Spill Switch (CGa, EG, & PEG only)
Cuts o󰀨 gas ow should vent system become
blocked. See Figure 3.
!
WARNING
Do not attempt to place boiler in operation if
spill switch cuts o gas ow. Immediately call a
service technician. Failure to do so can cause
severe personal injury, death or substantial
property damage.
Pressure Switch (LGB only)
Cuts o󰀨 gas ow should vent system become
blocked. See Figure 4.
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 re-
occurs, contact a service technician.
Draft - For Engineering Review ONLY Jan. 2023 HC
Figure 2 Rollout thermal fuse element
Figure 3 Spill switch
Figure 4 Pressure switch
220269

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1 Gas valve
2 Pilot burner (Not shown)
3 Main burners
4 Gas manifold/orices
5 Control module
7 Vent damper (CGa only)
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
CGa Series 3
Draft - For Engineering Review ONLY Jan. 2023 HC

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Boiler Components, continued
1 Gas valve
2 Pilot burner (not shown)
3 Main burners
4 Gas manifold/orices
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
CGi Series 4
Draft - For Engineering Review ONLY Jan. 2023 HC

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1 Gas valve
2 Pilot burner
3 Main burners
4 Gas manifold/orices
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
18 Gauge (pressure or pressure/
temperature)
19 Gauge glass (steam only)
20 Water temperature/LWCO sensor
(water only)
EG/PEG
20 ▲
220294
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Not shown
1 Gas valve
2 Pilot burner (with ame sense)
3 Main burners
4 Gas manifold/orices
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
LGB
Draft - For Engineering Review ONLY Jan. 2023 HC

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Boiler Area
!
WARNING
To prevent potential of severe personal injury,
death or substantial property damage, eliminate
all materials discussed below from the boiler
vicinity.
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 qualied service technician to inspect the boiler
and vent system for possible damage from acid
corrosion.
• If products cannot be removed, immediately call
a qualied 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 qualied 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.
Maintenance Procedures — DAILY
Draft - For Engineering Review ONLY Jan. 2023 HC

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Boiler Piping
Visually inspect for leaks around piping, circulators,
relief valve and other ttings. Immediately call a
qualied service technician to repair any leaks.
!
WARNING
Have leaks xed at once by a qualied 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.
!
WARNING
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
!
WARNING
Failure to inspect the vent system as noted above
and have them repaired by a qualied service
technician can result in vent system failure,
causing 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 qualied 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.
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 qualied service
technician to inspect the boiler and system.
Automatic Air Vents (if used)
1. Remove the cap 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.
Maintenance Procedures — MONTHLY
(continued on the next page)
Draft - For Engineering Review ONLY Jan. 2023 HC
Figure 5 Relief valve
Figure 6 Automatic air vent

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Pilot Burner Flame
Proper pilot ame (Figure 7):
1. Blue ame.
2. Inner cone engulng thermocouple or thermopile
(standing pilot) or pilot ame sensor (spark-
ignited pilot).
3. Thermocouple or thermopile, or pilot ame sensor
glowing cherry red.
Improper pilot ame:
1. Overred — Large ame lifting or blowing past
pilot ame sensor.
2. Underred — Small ame. Inner cone not
engulng 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).
Improper main burner ame:
1. Overred — Large ames.
2. Underred — 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 qualied service technician to inspect the boiler
and condensate line and rell the condensate trap.
!
WARNING
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 could 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
qualied service technician to inspect the boiler
and clean or replace the condensate assembly.
Maintenance Procedures — MONTHLY, continued
Draft - For Engineering Review ONLY Jan. 2023 HC
Figure 7 Pilot burner and ame, typical
Figure 8 Main burner ame, typical