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Weil-McLain CGi User's Information Manual

Gas-fired boilers
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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.
•
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.
CGa, CGi, CGs, EG,
EGH, LGB, PEG, PFG
Gas-Fired Boilers
Information
WHAT TO DO IF YOU SMELL GAS
User's
Manual
Part Number 550-110-592/1000

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Summary of Contents for Weil-McLain CGi

  • Page 1 CGa, CGi, CGs, EG, EGH, LGB, PEG, PFG Gas-Fired Boilers 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.

  • Page 2: Hazard Definitions

    Please read this page first How to use this To . . . manual . . . Learn precautions Prevent air contamination Identify boiler components Maintain boiler Start — or — Shutdown boiler Troubleshoot common problems 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.

  • Page 3: Service And Maintenance

    STOP!! — Read before proceeding Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage. Air contamination • To prevent potential of severe personal injury or death, check for products or areas listed in table at right before installing boiler.

  • Page 4: Boiler Components

    Inducer (CGi and CGs only) Vent damper (CGa only) Water temperature limit switch Transformer Spill switch (CGa only) Air pressure switch (CGi and CGs only) Rollout thermal fuse element Draft hood (CGa only) Circulator Relief valve Gauge (pressure or pressure/temperature)
  • Page 5 EG/EGH Not shown Gas valve Pilot burner Main burner Gas manifold/orifices Control module Vent damper Transformer Spill switch Rollout thermal fuse element Low water cutoff (steam boilers) Limit control(s) Draft hood Circulator Gauge (pressure or pressure/temperature) Gauge glass (steam only) Part Number 550-110-592/1000 (PFG-5 only)

  • Page 6: Service Technician

    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...

  • Page 7: User Maintenance Procedures

    Component information Rollout thermal fuse element CGa, CGi, CGs, EG, EGH, PEG & PFG-5 only Cuts off gas flow should flame rollout occur. See Figure 1 Do not attempt to place boiler in operation if rollout thermal fuse element cuts off gas flow.

  • Page 8: Air Openings

    Check daily ....Pressure/temperature gauge or pressure gauge (steam) 1. Water boilers — Make sure the pressure reading on the boiler pressure/temperature gauge does not ex- ceed 24 psig.

  • Page 9: Check Condensate Drain System

    Check monthly ....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 the tip of a screwdriver.
  • Page 10 Service periodically ... . 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. Float type —...
  • Page 11 Service periodically Clean gauge glass Normal waterline on a steam boiler is halfway up gauge glass. See Figure 9. Clean when needed. 1. Close lower gauge cock. 2. Open pet cock. 3. Open lower gauge cock and allow a small amount 4.

  • Page 12: To Turn Off Gas To Appliance

    PFG-6, PFG-7 Robertshaw 7000 DERHC Models Page CGa-25 – CGa-8 EG-30 – EG-75 PEG-30 – PEG-55 PFG-5 CGi, CGs CGa-25 – CGa-6 EG-30 – EG-50 PEG-30 – PEG-50 CGa-7, CGa-8 EG-55 – EG-75 PEG-55, PFG-5 CGi, CGs CGa-25 – CGa-6 EG-30 –...

  • Page 13: For Your Safety Read Before Lighting

    Lighting instructions • Standing pilot • Gas valve — Honeywell VR8200/VR8300 FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.

  • Page 14: What To Do If You Smell Gas

    Lighting instructions • Standing pilot • Gas valve — Robertshaw 7200 FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.

  • Page 15: Operating Instructions

    Lighting instructions • Standing pilot • Gas valve — Robertshaw 7000ERHC FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.

  • Page 16: For Your Safety Read Before Operating

    Operating instructions • Spark-ignited pilot • Gas valve — Honeywell VR8204/VR8304 FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 17 Operating instructions • Spark-ignited pilot • Gas valve — White-Rodgers 36E FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 18 Operating instructions • Spark-ignited pilot • Gas valve — White-Rodgers 36C FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 19 Operating instructions • Spark-ignited pilot • Gas valve — Robertshaw 7200 FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 20 Operating instructions • Spark-ignited pilot • Gas valve — Robertshaw 7000DERHC FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 21 2. Turn off all electric power to the appliance if service is to be performed. Part Number 550-110-592/1000 CGi, CGs C. Use only your hand to turn the gas control knob. Never use tools. If the knob will not turn by hand, don't try to repair it, call a qualified service technician.

  • Page 22: To Place In Operation

    Operating instructions • Spark-ignited pilot FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner.

  • Page 23: Common Problems And Solutions

    Common problems and solutions Symptom Common Causes Rapid cycling — Thermostat installed where drafts boiler turns on and or heat affect reading off frequently Heat anticipator in thermostat adjusted incorrectly Incorrect limit setting Insufficient water flow through boiler Frequent release of Expansion tank sized too small water through relief valve...
  • Page 24 First Year-(All Residential & Commercial Cast Iron Boilers) Limited Warranty for Cast Iron Boilers: Weil-McLain warrants that its cast iron boilers are free from defects in material and workmanship for one year from the date of installation. If any parts are found to be defective in manufacture, Weil-McLain will provide replacement of such defective parts.

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