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Weil-McLain CGs - page 1
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHA T 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 sup ...
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Weil-McLain CGs - page 2
2 Part Number 550-110-592/1000 Please read this page first How to use this manual . . . The User ’ s Infor mation Manual pro vides information to the boiler o w ner/user for r outine operation and maintenance and emergency shutdown. Detailed information on boiler installation, operation, start-up, service and parts is included in the Boiler Manua ...
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Weil-McLain CGs - page 3
3 Part Number 550-110-592/1000 F ailure t o adher e to the guidelines on this pag e can result in sev ere 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 ...
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Weil-McLain CGs - page 4
4 Part Number 550-110-592/1000 5921 0 Boiler components 5921 1 1 Gas valve 2 Pilot burner 3 Main burner 4 Gas manifold/orifices 5 Control module 6 Inducer (CGi and CGs only) 7 V ent damper (CGa only) 8 W ater temperature limit switch 9 T ransformer 10 Spill switc h (CGa only) 11 Air pressure switc h (CGi and CGs only) 12 Rollout thermal fuse elemen ...
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Weil-McLain CGs - page 5
5 Part Number 550-110-592/1000 ▲ ▲ 59215 (PFG-5 only) (PFG-5 only) ▲ ▲ Not shown ▲ 1 Gas valve 2 Pilot burner 3 Main burner 4 Gas manifold/orifices 5 Control module 7 V ent damper 9 T ransformer 10 Spill switc h 12 Rollout thermal fuse element 13 Low water cutoff (steam boilers) 14 Limit control(s) 15 Draft hood 16 Circulator 18 Gauge (pr ...
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Weil-McLain CGs - page 6
6 Part Number 550-110-592/1000 Maintain boiler using schedule below T ankless water heater (EG and EGH only) If boiler is used to supply d omestic hot water , limit co ntrol should be set to suppl y adequate hot water . W eil-M cLain tankless heaters are rated at 200 ° F boile r water t emperature. T o ge t rated output, set low limit at 200 ° F ...
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Weil-McLain CGs - page 7
7 Part Number 550-110-592/1000 User maintenance procedures Do not attempt to place boiler in operation if spill switch cuts of f gas flow . Immediately call a serv ice technician. Failure to do so can cause severe personal injury , death or substantial pr oper t y damage. Rollout thermal fuse element CGa, CGi, CGs, EG, EGH, PEG & PFG-5 only Cu ...
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Weil-McLain CGs - page 8
8 Part Number 550-110-592/1000 ❏ Check daily . . . . . . . . . . . . . . . . . Air openings 1 . V er ify that combustion and v entilation air openings to the boiler room and/or building are open and unobstructed. 2. CGs boilers — V erify that b oiler vent disc harge and air intake are clean and free of obstructions. Remove any debris on the air ...
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Weil-McLain CGs - page 9
9 Part 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 B slightly with the tip of a screwdriv er . 3. If the air vent valve appears to be working freely and not leaking , replace cap A , twisting ...
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Weil-McLain CGs - page 10
10 Part Number 550-110-592/1000 Probe type— See Figure 8 1 . Clean probe type low water cutoff for proper operation. a. T urn off power to boile r and wait 5 minutes. b . Drain water to bottom of gauge glass. c. T urn o n pow er . d. Set thermostat to call for heat. Red neon lamp on lower water cutoff should light. e. W ait 5 minutes. Boile r sho ...
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Weil-McLain CGs - page 11
11 Part Number 550-110-592/1000 Operate boiler relief valve ❏ Service every 6 months . . . . . . . . . To av oid water damage or scalding due to valve operation, a metal discharge line must be connected to relief valve outlet and run to a safe place of disposal. This discharge line must be installed by a qualified heating installer or service tec ...
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Weil-McLain CGs - page 12
12 Part Number 550-110-592/1000 Follow boiler shutdown procedure ❏ End-of-season shutdown . . . . . . . . 1. Follo w “ TO TURN OFF GA S T O APPLIANCE ” on the Lighting/Operating instr uctions on the inside of the jacket panel. Y ou will also find these instructions on pages 13 through 22 of this manual. U se the Lighting/Operating instr uctio ...
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Weil-McLain CGs - page 13
13 Part Number 550-110-592/1000 Lighting instructions FOR Y OUR S AFETY READ BEFORE LIGHTING LIGHTING INSTRUCTIONS T O TURN OFF GA S T O THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediate ly call your gas supplier fr om a neighbor ’ s phone. Follo w the g ...
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Weil-McLain CGs - page 14
14 Part Number 550-110-592/1000 • Gas valve — Robertshaw 7200 FOR Y OUR SAFETY READ BEFORE LIGHTING LIGHTING INSTRUCTIONS T O TURN OFF GA S T O THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediate ly call your gas supplier fr om a neighb or ’ s phone. F ...
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Weil-McLain CGs - page 15
15 Part Number 550-110-592/1000 FOR Y OUR S AFETY READ BEFORE LIGHTING OPERA TING INS TRUCTIONS T O TURN OFF GA S T O THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediate ly call your gas supplier fr om a neighbor ’ s phone. Follo w the gas supplier ’ s i ...
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Weil-McLain CGs - page 16
16 Part Number 550-110-592/1000 FOR Y OUR SAFETY READ BEFORE OPERA TING OPERA TING INS TRUCTIONS T O TURN OFF GA S T O THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediate ly call your gas supplier fr om a neighb or ’ s phone. Follo w the gas supplier ’ s ...
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Weil-McLain CGs - page 17
17 Part Number 550-110-592/1000 FOR Y OUR SAFETY READ BEFORE OPERA TING OPERA TING INS TRUCTIONS T O TURN OFF GA S T O THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediate ly call your gas supplier fr om a neighbor ’ s phone. Follo w the gas supplier ’ s ...
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Weil-McLain CGs - page 18
18 Part Number 550-110-592/1000 FOR Y OUR SAFETY READ BEFORE OPERA TING OPERA TING INS TRUCTIONS T O TURN OFF GA S T O THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediate ly call your gas supplier fr om a neighb or ’ s phone. Follo w the gas supplier ’ s ...
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Weil-McLain CGs - page 19
19 Part Number 550-110-592/1000 FOR Y OUR SAFETY READ BEFORE OPERA TING OPERA TING INS TRUCTIONS T O TURN OFF GA S T O THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediate ly call your gas supplier fr om a neighbor ’ s phone. Follo w the gas supplier ’ s ...
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Weil-McLain CGs - page 20
20 Part Number 550-110-592/1000 FOR Y OUR SAFETY READ BEFORE LIGHTING OPERA TING INS TRUCTIONS T O TURN OFF GA S T O THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediate ly call your gas supplier fr om a neighb or ’ s phone. Follo w the gas supplier ’ s i ...
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Weil-McLain CGs - page 21
21 Part Number 550-110-592/1000 FOR YOUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE • 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 instru ...
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Weil-McLain CGs - page 22
22 Part Number 550-110-592/1000 ANNUAL SHUTDOWN PROCEDURE • 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 y our gas supplier , call the fire dep ...
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Weil-McLain CGs - page 23
23 Part Number 550-110-592/1000 Common problems and solutions Symptom Common Causes Possible Corrections Rapid cycling — boiler turns on and off frequently Thermostat installed where drafts or heat affect reading Locate thermostat on inner wall away from heat sources or cool drafts. Heat anticipator in thermostat adjusted incorrectly Adjust therm ...
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Weil-McLain CGs - page 24
24 Part No. 550-110-592/1000 W eil-McLain Limited W arranty for Residential & Commercial Cast Iron Boilers W eil-McLain 500 Blaine Street Michigan City , IN 46360-2388 http://www .weil-mclain.com RESIDENTIAL W A TER W ARRANTY—Limited Lifetime RESIDENTIAL STEAM W ARRANTY—Limited 10 Y ear COMMERCIAL W ARRANTY—Limited 10-Y ear NOTE: The resi ...
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