WEIL-MCLAIN CGa S3 Gas Fired Boilers User Manual

WEIL-MCLAIN CGa S3 Gas Fired Boilers

Specifications:

• Product Name: Gas-Fired Boilers
• Series: CGa Series 3, CGi Series 4, EG Series 6, PEG Series 6, LGB Series 2 & 3
• Manual Part Number: 550-142-301/0224

Product Information

The Gas-Fired Boilers come in various series including CGa Series 3, CGi Series 4, EG Series 6, PEG Series 6, and LGB Series 2 & 3. It is essential for the installer to review the User Manual with the boiler owner to explain maintenance, service procedures, and operating instructions.
WARNING: It is crucial to follow the information in the manual precisely to prevent fire or explosion risks. Avoid storing or using gasoline or other flammable
substances near the appliance to prevent personal injury, death, or property damage.

Product Usage Instructions

Safety Signals:
Important: Indicates additional important information not related to personal injury or property damage.

Please Read Before Proceeding:
This section provides essential safety and operational information to read before using the boiler.

Boiler Maintenance:
Instructions on maintaining the boiler to ensure optimal performance and longevity.

Safe Boiler Operation:
Guidelines for safe operation of the boiler to prevent accidents and ensure user safety.

Boiler Water:
Information on the importance of boiler water and its impact on the system’s efficiency.

Operating the Boiler:
Detailed steps on how to operate the boiler efficiently and effectively.

Prevent Combustion Air Contamination:
Guidance on avoiding air contamination for proper combustion and performance.

Troubleshooting:
Common issues and solutions for resolving heating system and boiler problems.

Maintenance Overview:
An overview of maintenance tasks required to keep the boiler in good working condition.

Servicing and Maintaining the Boiler:
Detailed instructions on servicing and maintaining different components of the boiler.

Frequently Asked Questions (FAQ):

Click here to view FAQ

• Q: What should I do if I smell gas?
  A: If you smell gas, immediately evacuate the area, do not operate any electrical switches, and contact your gas supplier or emergency services.

INSTALLER:
Please take time to review this User Manual with the boiler owner. Explain all maintenance and service procedures and the correct operating instructions.

WARNING
Follow the information in this manual exactly to avoid a fire or explosion. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Failure to comply can result in severe personal injury, death, or substantial property damage.

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 fire department.
• Installation & service must be performed by a qualified installer or service technician.

Section 1 Safety

Safety Signals
The following defined 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 result in severe personal injury, death, or substantial property damage.

WARNING
Warning indicates the presence of hazards that can result in severe personal injury, death, or substantial property damage.

CAUTION
Caution indicates the presence of hazards that will or can result in 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.

• This product burns gas to produce heat. The appliance must be properly installed, operated, and maintained to avoid exposure to appreciable levels of carbon monoxide and the installer is required to confirm that at least one carbon monoxide alarm is installed in the living space before the appliance is put into operation. It is important for the carbon monoxide alarms to be installed, maintained, and replaced following the alarm manufacturer’s instructions and applicable local codes.

User: Refer to this User Manual as your information source. Installation and service must be performed by a qualified installer or service technician.
Installer: Refer to the Boiler Manual and all other information shipped with the boiler for installation and service.
Please include the boiler model number and CP number when inquiring 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 filed 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 fiber and fiberglass 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 qualified service technician to ensure boiler system reliability.

Safe Boiler Operation

• Do not block flow 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 on the control display after removing a blockage. If a blockage cannot be removed, have a qualified 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 5 for details. Should overheating occur, or gas supply fail to shut off, do not turn off or disconnect electrical supply to pump. Shut off the gas supply at a location external to the appliance.

Boiler Water

• Have the boiler water chemistry checked at least annually by a qualified 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 effective 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 fire, explosion, and electrical shock hazards, leading to serious injury, death, or substantial property damage.
Saltwater damage: The immediate effects 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.

Section 2 Operation

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 re-piped and terminated to another location. Contaminated combustion air will damage the boiler, which 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 off the boiler. See Table 2 to locate the correct Operating Instructions for the gas valve model installed on your boiler.

Table Corrosive contaminants and sources

Products to avoid

Spray cans containing chloro/ fluorocarbons| 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 refinishing areas and establishments
Beauty shops| New building construction
Refrigeration repair shops| Remodeling areas
Photo processing plants| Garages with workshops

Table 2 Operating instructions guide

6
Robertshaw 7200| CGa-25 to CGa-6 EG-30 to EG-50 PEG-30 to PEG-50| 7
––| LGB| 8

Operating the Boiler, continued
CGa, EG-30 to EG-75, PEG-30 to PEG-55

• Spark-ignited pilot
• Gas valve — Honeywell VR8204/VR8304

FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

• This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.
• BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.
• 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. Force or attempted repair may result in a fire or explosion.
• Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.
• Do not touch any electric 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.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electrical power to the appliance.
4. Remove front panel.
5. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.
6. Turn gas control knob clockwise to “OFF.”
7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to the next step.
8. Turn gas control knob counterclockwise to “ON.”
9. Turn on all electric power to the appliance.
10. Set thermostat to desired setting.
11. If the appliance will not operate, follow the instructions “To Turn Off Gas To The Appliance” and call your service technician or gas supplier.
12. Replace front panel.

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Remove front panel.
4. Turn gas control knob clockwise to “OFF.” Do not force.
5. Replace front panel.

CGa-25 to CGa-6, EG-30 to EG-50, PEG-30 to PEG-50

• Spark-ignited pilot
• Gas valve — Robert shaw 7200

FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

• This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.
• BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.
• Use only your hand to depress or move the selector arm. Never use tools. If the selector arm will not depress or move by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.
• Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.
• Do not touch any electric 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.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electrical power to the appliance.

4. Remove front panel.

5. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

6. Depress and move selector arm left  to “OFF.”
   Note: Selector arm cannot be moved to “OFF” unless selector arm is depressed slightly. Do not force.
   

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to the next step.

8. Move selector arm right  to “ON.”

9. Turn on all electric power to the appliance.

10. Set thermostat to desired setting.

11. If the appliance will not operate, follow the instructions “To Turn Off Gas To The Appliance” and call your service technician or gas supplier.

12. Replace front panel.

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Remove front panel.
4. Depress and move selector arm to “OFF.” Do not force.
5. Replace front panel.

LGB

• Spark-ignited pilot

FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

• This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the automatic pilot by hand.
• Before OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. See below.
• Use only your hand to depress or turn gas valve handles. Never use tools. If a handle will not turn by hand, don’t try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion.
• Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.
• Do not touch any electric 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.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above this label.
2. Set the thermostat/operating control to the lowest setting.
3. Turn off all electrical power to the appliance.
4. Remove jacket front panel.
5. Close gas hand valve, b. Close manual test firing valve, c. Close all pilot shutoff valve(s), e.
6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow B in the safety information above. if you do not smell gas, go to step 7.
7. Open pilot shutoff valve(s), e.
8. Open manual test firing valve, c, and gas hand valve, b. Follow sequence below.
9. Turn on electric power to the appliance.
10. Set the thermostat/operating control to desired setting.
11. If boiler does not operate correctly, follow instructions under, “TO TURN OFF GAS TO APPLIANCE,” below. Call your service technician or gas supplier.
12. Replace jacket front panel.

Typical gas piping only — See Boiler Manual for details

• a service valve
• b gas hand valve
• c manual test firing valve
• d automatic pilot
• e pilot shutoff valve(s)
• f automatic gas valves, typical

TO TURN OFF GAS TO THE APPLIANCE

1. Set thermostat or operating control to lowest
2. Turn of all electrical power to the appliance if service is to be performed.
3. Close manual test firing valve (c), all pilot shutoff valves) (e) and gas hand valve (b).
4. Replace jacket front panel.

Troubleshooting

Common Issues and Solutions

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
Insufficient water flow through boiler| Check all valves to and from boiler Return to proper setting
Confirm circulator size.
**Frequent release of water through relief valve| Expansion tank sized too small| Call qualified service technician to check expansion tank operation and size
Flooded expansion tank| Call qualified service technician to check expansion tank operation
Inoperative limit control| Call qualified service technician to replace limit control.
****Need to frequently add makeup water| ** Leaks in boiler or piping| Have qualified 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 qualified 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 qualified service technician to de-lime boiler, if necessary. In some cases, deposits will be too heavy to remove with de- liming procedures
Have qualified service technician repair leaks to eliminate need for constant makeup water
Incorrect pH of boiler water| Call qualified service technician to check pH level and correct. pH should be maintained between 7 0 to 8 5
Insufficient water flow through boiler| Check all valves to and from boiler Return to proper setting
Confirm circulator size.
**Metal flakes found in vent outlet or vent — flueway 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 qualified 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 qualified service technician repair at once
High limit set too low| Adjust high limit to higher setting

Section 3 Maintenance

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 qualified 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 efficiency and reliability.
Figure 1 Service and maintenance schedule

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 qualified 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 cutoff

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 can result in severe personal injury, death, or substantial property damage.

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. 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.

Rollout Thermal Fuse Element (CGa, CGi, EG, & PEG only)
Cuts off gas flow should flame roll-out occur. See Figure 2.
Figure 2 Rollout thermal fuse element

WARNING
Do not attempt to place boiler in operation if rollout thermal fuse element cuts off gas flow. Immediately call a service technician. Failure to comply can result in severe personal injury, death or substantial property damage.

Spill Switch (CGa, EG, & PEG only)
Cuts off gas flow should vent system become blocked. See Figure 3.
Figure 3 Spill switch

WARNING
Do not attempt to place boiler in operation if spill switch cuts off gas flow. Immediately call a service technician. Failure to comply can result in severe personal injury, death or substantial property damage.

Pressure Switch (LGB Series 3 and CGi only)
Cuts off gas flow should vent system become blocked. See Figure 4.
Figure 4 Pressure switch

LGB Series 3 Boilers – 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.

CGa

• 1 Gas valve
• 2 Pilot burner (Not shown)
• 3 Main burners
• 4 Gas manifold/orifices
• 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

CGi

• 1 Gas valve
• 2 Pilot burner (not shown)
• 3 Main burners
• 4 Gas manifold/orifices
• 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

EG/PEG

• 1 Gas valve
• 2 Pilot burner
• 3 Main burners
• 4 Gas manifold/orifices
• 5 Control module
• 7 Vent damper
• 9 Transformer
• 10 Spill switch
• 12 Rollout thermal fuse element
• 13 Low water cutoff (steam boilers)
• 14 Limit control(s)
• 15 Draft hood
• 16 Circulator (water only)
• 18 Gauge (pressure or pressure/ temperature)
• 19 Gauge glass (steam only)
• 20 Water temperature/LWCO sensor (water only)

LGB Series 3

• 1 Gas valve
• 2 Pilot burner (with flame sense)
• 3 Main burners
• 4 Gas manifold/orifices
• 5 Control module
• 6 Inducer (with vent adapter)
• 9 Transformer
• 11 Air pressure switch
• 13 Low water cutoff (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 flame sense
• 22 Flue temperature switch

LGB Series 2

• 1 Gas valve
• 2 Pilot burner
• 3 Main burner
• 4 Gas manifold/orifices
• 5 Control module
• 7 Vent damper
• 9 Transformer
• 10 Spill switch
• 12 Rollout thermal fuse element
• 13 Low water cutoff (steam boilers)
• 14 Limit control(s)
• 15 Draft hood
• 18 Gauge (pressure or pressure/ temperature)
• 19 Gauge glass (steam only)

Maintenance Procedures — DAILY
Boiler Area
WARNING
Eliminate all materials discussed below from the boiler vicinity. Failure to comply can result in severe personal injury, death, or substantial property damage.

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 5.

If the above materials are 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).

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 qualified 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 — MONTHLY
Boiler Piping
Visually inspect for leaks around piping, circulators, relief valve and other fittings. Immediately call a qualified service technician to repair any leaks.

WARNING
Have leaks fixed at once by a qualified service technician. Continual fresh makeup water reduces boiler life. Minerals can build up, reducing heat transfer, overheating cast iron, and causing section failure, which can result in severe personal injury, death, or substantial property damage.

• 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 qualified service technician can cause vent system failure, which can result in severe personal injury or death.

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:
   • 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.
   • If flame blows out or flickers severely, the vent system must be checked for obstructions or other causes of improper venting.
   • Verify the vent damper 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 (Figure 5) and the relief valve discharge pipe for signs of weeping or leakage. Figure 5 Relief valve

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.

Automatic Air Vents (if used)

1. Remove the cap (A) 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.
   Figure 6 Automatic air vent

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.

Automatic Air Vents (if used)

1. Remove the cap (A) 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.

Pilot Burner Flame
Proper pilot flame (Figure 7):
Figure 7 Pilot burner and flame, typical

1. Blue flame.
2. Inner cone engulfing pilot flame sensor.
3. 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 (Figure 8):
Figure 8 Main burner flame, typical

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).

Check Condensate Drain System (if used)
While the boiler is running, check the discharge end of the condensate drain tubing by holding your fingers in front of the opening. If you notice flue gas escaping, this indicates a dry condensate drain trap. See the following steps to fill the trap. If the condensate trap dries out on a regular basis, call your qualified service technician to inspect the boiler and condensate line and refill the condensate trap.

WARNING
The condensate trap must be filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line. Failure to fill the trap can 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 flue products can be emitted into the boiler room through the condensate drain line. Follow the procedure below to fill the trap.

1. Fill the condensate trap with fresh water by pouring water into the removed trap.
   • Verify that the condensate assembly is  unobstructed by pouring until the water runs out the end of the condensate drain line.
   • If the water does not run out, there is an obstruction. Proceed to the next step.
2. To remove an obstruction, remove and flush the trap and drain line.
   • Loosen any attachments to the supplied flexible drain hose.
   • Loosen the condensate trap inlet connection.
   • Remove and flush out the condensate trap and drain line.
   • Reinstall the trap and drain line. Tighten all attachments.
   • Pour water into the port and ensure that water runs out the end of the drain line.
   • If the water still does not run out, call your  qualified service technician to inspect the boiler and clean or replace the condensate assembly.

Maintenance Procedures — PERIODICALLY
Test the Low Water Cutoff

• The system is equipped with a low water cutoff. Test the low water cutoff periodically during the heating season.

Float Type Low Water Cutoff
DANGER
Boiler pressure and temperature must be low to avoid the potential of severe burns from steam or hot water.

1. Clean float type low water cutoff to clear float chamber of sediment. See Figure 9.
   Figure 9 Float type low water cutoff

   • Open blowdown valve at bottom control.
   • Drain water into a bucket.

2. Check float type low water cutoff for proper operation.

   • Turn operating control to call for heat.
   • Before water gets hot, drain to bottom of gauge glass. Boiler should shut off after water level lowers a few inches.
   • Refill boiler to correct waterline. Boiler should  come back on.

Probe Type Low Water Cutoff
Clean the probe type low water cutoff for proper operation. See Figure 10.
Figure 10 Probe type low water cutoff

1. Turn off power to boiler and wait 5 minutes.
2. Drain water to bottom of gauge glass.
3. Turn on power.
4. Set thermostat to call for heat. Red neon lamp on lower water cutoff should light.
5. Wait 5 minutes. Boiler should not fire.
6. Refill boiler to correct water line. Red lamp should go off.
7. Wait 5 minutes. Boiler should fire.
8. Return thermostat to normal setting.

Integrated Type Low Water Cutoff

1. Test LWCO using control LWCO TEST button.

   • During burner fire, press LWCO TEST button.
   • Burner should shut off.

2. Clean periodically (when warning occurs).

   • Turn off power to boiler and wait 5 minutes.

   • Drain boiler to empty.

   • Remove sensor, wipe clean. See Figure 11.
     Figure 11 Integrated type low water cutoff

   • Reinstall sensor to specified 18 ft/lbs torque.

   • Refill boiler to pressure, purge air.

   • Turn on boiler power.

   • Ensure proper operation resumes.

Clean Gauge Glass

Normal waterline on a steam boiler is halfway up gauge glass. See Figure 12. Clean when needed.
Figure 12 Gauge glass

DANGER
Boiler pressure must be low to eliminate potential of severe burns.

1. Close lower gauge cock.
2. Open pet cock.
3. Open lower gauge cock and allow a small amount of water to flush out through open pet cock.
4. Close lower gauge cock.
5. Close pet cock.
6. Open lower gauge cock.
7. If gauge glass breaks, close both gauge cocks and call a qualified service technician to replace gauge glass. Do not replace with thin glass tubing.

Oil Inducer Motor (CGi Boilers)
WARNING
Use only SAE 20 motor oil to lubricate the inducer motor. Do not use common universal household oils. Failure to comply can result in severe personal injury, death, or substantial property damage.

1. Use only SAE 20 motor oil. DO NOT use household universal oils.
2. Place a few drops of oil in each of the two oiler cups on the inducer motor.

Maintenance Procedures — EVERY 6 MONTHS
Operate the Boiler Relief Valve
WARNING
A metal discharge line must be connected to a relief valve outlet and run to a safe place of disposal to avoid water damage or scalding. The discharge line must be terminated so as to eliminate possibility of severe burns should the valve discharge. This discharge line must be installed by a qualified heating installer or service technician in accordance with the instructions in the Boiler Manual. Failure to comply can result in severe personal injury, death, or substantial property damage.

1. Before proceeding, verify that the relief valve outlet has been piped to a safe place of discharge, avoiding any possibility of scalding from hot water.
2. Read the boiler pressure/temperature gauge to make sure the system is pressurized.
3. Lift the relief valve top lever slightly, allowing water to relieve through the valve and discharge piping.
4. If water flows freely, release the lever and allow the valve to seat. Watch the end of the relief valve discharge pipe to ensure that the valve does not weep after the line has had time to drain.
   • If the valve weeps, lift the seat again to attempt to clean the valve seat.
   • If the valve continues to weep afterwards,  contact your qualified service technician to inspect the valve and system.
5. If water does not flow from the valve when you lift  the lever completely, the valve or discharge line may be blocked.
   • Immediately shutdown the boiler, following the instructions on the inside jacket top Operating Instructions.
   • Call your qualified service technician to inspect the boiler and system.

Maintenance Procedures — END OF SEASON
Boiler Shutdown Procedure

1. Follow “TO TURN OFF GAS TO APPLIANCE” on the Operating Instructions on the inside of the jacket panel. You will also find these instructions on pages 6-8 of this manual.
   • Use the Operating Instructions for the gas valve model installed on the boiler.
2. Do not drain system unless exposure to freezing temperatures will occur.
3. Do not drain the system if it is filled with an antifreeze solution.
4. Do not shut down boilers used for domestic water heating. They must operate year-round.

Propane Gas Odorant
WARNING
Propane boilers only — Comply with the following guidelines for gas leakage. Failure to comply can result in severe personal injury, death, or substantial property damage.

• Propane suppliers mix an odorant with the propane to make its presence detectable. This odorant can fade and the gas may no longer have an odor.
• Propane gas can accumulate at floor level. Smell near the floor for the gas odorant or any unusual odor.
• Periodically check the odorant level of your gas.
• Inspect boiler and system at least yearly to make sure all gas piping is leak-tight.
• Consult your propane supplier regarding installation of a gas leak detector. There are some products on the market intended for this purpose. Your supplier may be able to suggest an appropriate device.

WM Technologies, LLC 500 Blaine Street
Michigan City, IN 46360-2388
Telephone: 800-654-2109
weil-mclain.com

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