Weil-McLain CGi Guide

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.
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.
Part Number 550-110-592/1000
Gas-Fired Boilers
CGa, CGi, CGs, EG,
EGH, LGB, PEG, PFG
User’s
Information
Manual

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers
2Part Number 550-110-592/1000
Please read this page first
How to use this
manual . . .
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.
Boiler service and
maintenance
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.
Hazard definitions
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 in-
jury or property damage.
Indicates special instructions on installation, operation or maintenance
that are important but not related to personal injury or property damage.
To . . . Read/use . . . Pages . . .
Learn
precautions Warnings and definitions 1, 2, and 3
Prevent air
contamination
Read list of air contaminants you must avoid. If
found, either remove products permanently
or isolate boiler and provide outside com-
bustion air.
3
Identify boiler
components The illustration on page 4 or 5, will show you the
location of the main components. 4-5
Maintain
boiler
Set up a plan for maintaining the boiler using
the schedule included in this manual.
Schedule an annual start-up by a qualified ser-
vice technician before every heating season.
6-12
Start —or —
Shutdown
boiler
Use the Lighting/Operating instruction sheet
for the gas valve installed on your boiler. Ask
your service technician if you are unsure which
one.
12-22
Troubleshoot
common
problems
Use the common problems/solutions table to
resolve typical heating system/boiler problems. 23

Users Information Manual
3Part Number 550-110-592/1000
Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial
property damage.
STOP!! —Read before proceeding
Products to avoid
Spray cans containing chloro/fluorocar-
bons
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 establish-
ments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establish-
ments
New building construction
Remodeling areas
Garages with workshops
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 makeup water will reduce boiler life. Mineral buildup in
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.
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 overheating occur or gas supply fail to shut off, do not turn off or
disconnect electrical supply to pump. Instead, shut off the gas supply at a
location external to the appliance.
•Do not use this boiler if any part has been under water. Immediately call 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.
Service and maintenance
•To avoid electric shock, disconnect electrical supply before performing
maintenance.
•To avoid severe burns, allow boiler to cool before performing maintenance.
•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.
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 outside to the
boiler air intake.

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers
4Part Number 550-110-592/1000
59210
Boiler components
59211
CGa CGi
CGs
1Gas valve
2Pilot burner
3Main burner
4Gas manifold/orifices
5Control module
6Inducer (CGi and CGs only)
7Vent damper (CGa only)
8Water temperature limit switch
9Transformer
10 Spill switch (CGa only)
11 Air pressure switch (CGi and CGs only)
12 Rollout thermal fuse element
15 Draft hood (CGa only)
16 Circulator
17 Relief valve
18 Gauge (pressure or pressure/temperature)

Users Information Manual
5Part Number 550-110-592/1000
▲
▲
59215
(PFG-5
only)
(PFG-5 only)
▲
▲
Not shown
▲
EG/EGH PFG
LGB
1Gas valve
2Pilot burner
3Main burner
4Gas manifold/orifices
5Control module
7Vent damper
9Transformer
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)
59214
Not shown
59213
Not shown
▲
▲
▲
▲

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers
6Part Number 550-110-592/1000
Maintain boiler using schedule below
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.
Service technician
(covered in Boiler Manual —for use only by a
qualified service technician)
Owner maintenance
(see following pages for instructions)
ANNNUAL START-UP
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
Check/test:
• 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
Daily
• Check boiler area
• Check air openings
• Check boiler pressure/
temperature gauge
Monthly
• Check boiler interior piping
• Check venting system
• Check air vents
• Check boiler relief valve
• Check automatic air vents (if
used)
Periodically • Test low water cutoff (if used)
Every 6 months • Operate relief valve
End of season • Shut down procedure

Users Information Manual
7Part Number 550-110-592/1000
User maintenance procedures
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.
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.
59202
Figure 1
Rollout thermal fuse element
Figure 2
Spill switch
Component information
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.
❏Check daily . . . . . . . . . . . . . . . . .
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.
Boiler must be serviced & maintained
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.

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers
8Part Number 550-110-592/1000
❏Check daily . . . . . . . . . . . . . . . . .
Air openings
1. Verify that combustion and ventilation air openings
to the boiler room and/or building are open and
unobstructed.
2. CGs boilers —Verify that boiler vent discharge
and air intake are clean and free of obstructions.
Remove any debris on the air intake or flue exhaust
openings.
Pressure/temperature gauge
or pressure gauge (steam)
1. Water boilers —Make sure the pressure reading on
the boiler pressure/temperature gauge does not ex-
ceed 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 per-
sists.
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.
Boiler piping
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.
1. Visually inspect for leaks around piping, circulators,
relief valve and other fittings. Immediately call a
qualified service technician to repair any leaks.
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 below
lower edge of draft hood “skirt.”If flame does
not blow out, but burns undisturbed, the vent
system is working properly.
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.
❏Check monthly . . . . . . . . . . . . . . . .
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 . . . . . . . . .
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.
59203
Figure 3 Relief valve

Users Information Manual
9Part Number 550-110-592/1000
Figure 4
Automatic air
vent
Automatic air vents (if used)
1. See Figure 4.
2. Remove the cap from any
automatic air vent in the system
and check operation by
depressing valve Bslightly with
the tip of a screwdriver.
3. If the air vent valve appears to
be working freely and not
leaking, replace cap A, twisting
all the way on.
4. Loosen cap A one turn to allow
vent to operate.
5. Have vent replaced if it does not
operate correctly.
Pilot burner flame
Proper pilot flame (see Figure 5):
1. Blue flame.
2. Inner cone engulfing thermocouple or thermopile
(standing pilot) or pilot flame sensor (spark-ignited
pilot).
3. Thermocouple or thermopile, or pilot flame sensor
glowing cherry red.
Improper pilot flame:
1. Overfired —Large flame lifting or blowing past pilot
flame sensor.
2. Underfired —Small flame. Inner cone not engulfing
pilot flame sensor.
3. Lack of primary air —Yellow flame tip.
4. Incorrectly heated pilot flame sensor.
Main burner flame
Proper main burner flame (see Figure 6):
1. Yellow-orange streaks may appear (caused by dust).
Improper main burner flame:
1. Overfired —Large flames.
2. Underfired —Small flames.
3. Lack of primary air —Yellow tipping on flames
(sooting will occur).
59318
Spark
electrode
Inner
cone
Pilot flame
sensor (spark-
ignited pilots)
Thermocouple or thermopile
(standing pilots)
— or —
59319
Transparent
blue flame
Inner flame
Figure 5 Pilot burner and flame, typical
Figure 6 Main burner flame, typical
❏Check monthly . . . . . . . . . . . . . . . .
59204
A
B
Clean vent termination & air
intake screens —CGs boilers only
1. Remove all lint and debris from both the boiler air
intake screen and the flue discharge screen.
The boiler control module will sense blockage of
the air intake or flue and lockout if the blockage is
excessive. It will signal the failure by flashing the
appropriate indicator lights on the control board.
2. If removing the debris does not allow the boiler to
operate correctly afterwards, contact your qualified
service technician to inspect the boiler and vent/
air systems.
Check condensate drain
system
1. Inspect condensate drain fittings and tubing.Verify
that condensate can flow freely to drain.

CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Boilers
10 Part Number 550-110-592/1000
Probe type— See Figure 8
1. Clean probe type low water cutoff for proper
operation.
a. Turn off power to boiler and wait 5 minutes.
b. Drain water to bottom of gauge glass.
c. Turn on power.
d. Set thermostat to call for heat. Red neon lamp
on lower water cutoff should light.
e. Wait 5 minutes. Boiler should not fire.
f. Refill boiler to correct water line. Red lamp
should go off.
g. Wait 5 minutes. Boiler should fire.
h. Return thermostat to normal setting.
Test low water cutoff (all steam boilers)
(water boilers, if installed)
If the system is equipped with a low water cutoff, test the low water cutoff periodically during the heating season.
Figure 7 Float type low water cutoff Figure 8 Probe type low water cutoff
❏Service periodically . . . . . . . . . . . .
2. Check float type low water cutoff for proper
operation.
a. Turn operating control to call for heat.
b. Before water gets hot, drain to bottom of gauge
glass. Boiler should shut off after water level
lowers a few inches.
c. Refill boiler to correct waterline. Boiler should
come back on.
.Boiler pressure and temperature must be low to avoid
the potential of severe burns from steam or hot water
Float type —See Figure 7
1. Clean float type low water cutoff to clear float
chamber of sediment.
a. Open blowdown valve at bottom control.
b. Drain water into a bucket.
50209
Probe type
low water cutoff
Gauge glass
assembly
Indicator lamp(s)
Test switch and
reset switch (if
manual reset)