Weil McLain Boiler CGa User Manual

CGa, CGi, CGs, EG,  
EGH, LGB, PEG, PFG  
Gas-Fired Boilers  
User’s  
Information  
Manual  
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.  
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.  
Part Number 550-110-592/1000  
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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  
Products to avoid  
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:  
Spray cans containing chloro/fluorocar-  
bons  
Permanent wave solutions  
remove contaminants permanently.  
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.  
OR —  
Chlorinated waxes/cleaners  
Chlorine-based swimming pool chemicals  
Calcium chloride used for thawing  
Sodium chloride used for water softening  
Refrigerant leaks  
Service and maintenance  
To avoid electric shock, disconnect electrical supply before performing  
Paint or varnish removers  
maintenance.  
To avoid severe burns, allow boiler to cool before performing maintenance.  
Hydrochloric acid/muriatic acid  
Cements and glues  
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.  
Antistatic fabric softeners used in clothes  
dryers  
Boiler operation  
Chlorine-type bleaches, detergents, and  
cleaning solvents found in household  
laundry rooms  
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.  
Adhesives used to fasten building products  
and other similar products  
Areas likely to have  
contaminants  
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.  
Dry cleaning/laundry areas and establish-  
ments  
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.  
Swimming pools  
Metal fabrication plants  
Beauty shops  
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.  
Refrigeration repair shops  
Photo processing plants  
Auto body shops  
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.  
Plastic manufacturing plants  
DO NOT use "homemade cures" or "boiler patent medicines". Serious damage  
to boiler, personnel and/or property may result.  
Furniture refinishing areas and establish-  
ments  
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.  
New building construction  
Remodeling areas  
Do not add cold water to hot boiler. Thermal shock can cause sections to  
crack.  
Garages with workshops  
Part Number 550-110-592/1000  
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Boiler components  
59211  
59210  
1
Gas valve  
2
Pilot burner  
3
Main burner  
4
Gas manifold/orifices  
Control module  
5
6
Inducer (CGi and CGs only)  
Vent damper (CGa only)  
Water temperature limit switch  
Transformer  
7
8
9
10  
11  
12  
15  
16  
17  
18  
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)  
4
Part Number 550-110-592/1000  
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L
(PFG-5 only)  
L
L
L
L
L
L
L
(PFG-5  
only)  
L
Not shown  
59215  
Not shown  
59213  
1
Gas valve  
2
Pilot burner  
3
Main burner  
4
Gas manifold/orifices  
Control module  
Vent damper  
5
7
9
Transformer  
10  
12  
13  
14  
15  
16  
18  
19  
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)  
Not shown  
59214  
Part Number 550-110-592/1000  
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Maintain boiler using schedule below  
Service technician  
Owner maintenance  
(covered in Boiler Manual for use only by a  
(see following pages for instructions)  
qualified service technician)  
• Check boiler area  
• Check air openings  
Inspect:  
• Reported problems  
Daily  
• Check boiler pressure/  
temperature gauge  
• Boiler area  
• Air openings  
• Check boiler interior piping  
• Check venting system  
• Check air vents  
• Flue gas vent system  
• Pilot and main burner flames  
• Water piping  
Monthly  
• Check boiler relief valve  
• Boiler heating surfaces  
• Burners, base and inlet air box  
• Check automatic air vents (if  
used)  
Service:  
• Oiled-bearing circulators  
Start-up:  
Periodically  
• Test low water cutoff (if used)  
Every 6 months • Operate relief valve  
• 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  
End of season  
• Shut down procedure  
• Boiler relief valve  
Review:  
• Review with owner  
Tankless water heater (EG and EGH  
Iof nboliyler)is used to supply domestic hot water, limit  
requirements. Differential can be set to 15 ° and adjusted  
control should be set to supply adequate hot water. to control level. Lowering the differential will cause a  
Weil-McLain tankless heaters are rated at 200 °F boiler slight variation in water temperature but will decrease  
water temperature. To get rated output, set low limit at burner on-off cycling. High limit should be set at least  
200 °F. Limit can be adjusted to meet system hot water 20 ° above low limit.  
6
Part Number 550-110-592/1000  
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User maintenance procedures  
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.  
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.  
Component information  
Rollout thermal fuse element  
Figure 1  
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  
Figure 2  
Spill switch  
Cuts off gas flow should vent system become blocked.  
See Figure 2.  
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.  
59202  
L Check daily . . . . . . . . . . . . . . . . .  
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:  
qualified service technician to install an outside  
combustion air source for the boiler (if not already  
installed).  
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.  
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  
If products cannot be removed, immediately call a  
on page 3.  
Part Number 550-110-592/1000  
7
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L Check daily . . . . . . . . . . . . . . . . .  
Pressure/temperature gauge Air openings  
or pressure gauge (steam)  
1. Verify that combustion and ventilation air openings  
to the boiler room and/or building are open and  
unobstructed.  
1. Water boilers Make sure the pressure reading on  
the boiler pressure/temperature gauge does not ex-  
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.  
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.  
L Check monthly . . . . . . . . . . . . . . . .  
If flame blows out or flickers severely, the vent  
Boiler piping  
system must be checked for obstructions or  
other causes of improper venting.  
1. Visually inspect for leaks around piping, circulators,  
b. Verify the vent damper (CGa and EG boilers)  
relief valve and other fittings. Immediately call a  
opens before burners ignite.  
qualified service technician to repair any leaks.  
3. Notify your qualified service technician at once if  
you find any problem.  
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.  
Boiler relief valve . . . . . . . . .  
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.  
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.  
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.  
Immediately contact your qualified service  
technician to inspect the boiler and system.  
Figure 3 Relief valve  
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.  
59203  
8
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L Check monthly . . . . . . . . . . . . . . . .  
Automatic air vents (if used)  
Main burner flame  
Proper main burner flame (see Figure 6):  
1. See Figure 4.  
1. Yellow-orange streaks may appear (caused by dust).  
Figure 4  
Automatic air  
vent  
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 screwdriver.  
3. If the air vent valve appears to  
be working freely and not  
leaking, replace cap A, twisting  
all the way on.  
Improper main burner flame:  
1. Overfired Large flames.  
2. Underfired Small flames.  
3. Lack of primary air Yellow tipping on flames  
(sooting will occur).  
A
B
Figure 6 Main burner flame, typical  
4. Loosen cap A one turn to allow  
vent to operate.  
5. Have vent replaced if it does not  
operate correctly.  
59204  
Transparent  
blue flame  
Pilot burner flame  
Proper pilot flame (see Figure 5):  
1. Blue flame.  
Inner flame  
2. Inner cone engulfing thermocouple or thermopile  
(standing pilot) or pilot flame sensor (spark-ignited  
pilot).  
59319  
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.  
Clean vent termination & air  
2. Underfired Small flame. Inner cone not engulfing  
intake screens CGs boilers only  
pilot flame sensor.  
3. Lack of primary air Yellow flame tip.  
4. Incorrectly heated pilot flame sensor.  
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.  
Figure 5 Pilot burner and flame, typical  
Inner  
cone  
Spark  
electrode  
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.  
Pilot flame  
sensor (spark-  
Check condensate drain  
system  
ignited pilots)  
— or —  
Thermocouple or thermopile  
(standing pilots)  
1. Inspect condensate drain fittings and tubing.Verify  
that condensate can flow freely to drain.  
59318  
Part Number 550-110-592/1000  
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L 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 See Figure 7  
Probe type— See Figure 8  
1. Clean probe type low water cutoff for proper  
operation.  
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.  
a. Turn off power to boiler and wait 5 minutes.  
b. Drain water to bottom of gauge glass.  
c. Turn on power.  
.
Boiler pressure and temperature must be low to avoid  
the potential of severe burns from steam or hot water  
d. Set thermostat to call for heat. Red neon lamp  
on lower water cutoff should light.  
2. Check float type low water cutoff for proper  
operation.  
e. Wait 5 minutes. Boiler should not fire.  
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.  
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.  
c. Refill boiler to correct waterline. Boiler should  
come back on.  
Figure 7 Float type low water cutoff  
Figure 8 Probe type low water cutoff  
Indicator lamp(s)  
Test switch and  
reset switch (if  
manual reset)  
Probe type  
low water cutoff  
Gauge glass  
assembly  
50209  
10  
Part Number 550-110-592/1000  
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L Service periodically continued . . . . . . .  
Figure 9 Gauge glass  
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.  
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.  
Waterline  
4. Close pet cock.  
5. Open lower gauge cock.  
Gauge glass  
Boiler pressure must be low to eliminate potential of  
severe burns.  
6. 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.  
Gauge  
cock  
59206  
Pet cock  
L Service every 6 months . . . . . . . . .  
Operate boiler relief valve  
sure the system is pressurized.  
To avoid 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  
technician in accordance with the  
instructions in the Boiler Manual.  
The discharge line must be  
terminated so as to eliminate  
possibility of severe burns should  
the valve discharge.  
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  
Lighting Instructions. Call your qualified service  
technician to inspect the boiler and system.  
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  
Part Number 550-110-592/1000  
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L End-of-season shutdown . . . . . . . .  
Follow boiler shutdown procedure  
1. Follow TO TURN OFF GAS TO APPLIANCEon 2. Do not drain system unless exposure to freezing  
the Lighting/Operating instructions on the inside  
of the jacket panel. You will also find these  
instructions on pages 13 through 22 of this manual.  
temperatures will occur.  
3. Do not drain the system if it is filled with an  
antifreeze solution.  
Use the Lighting/Operating instruction for the gas  
valve model installed on the boiler.  
4. Do not shut down boilers used for domestic water  
heating. They must operate year-round.  
Propane gas odorant  
Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence detect-  
able. In some instances, the 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. If you  
suspect a leak, do not attempt to light the pilot.  
Use caution when attempting to light the propane pilot. This should be done by a qualified service techni-  
cian, particularly if pilot outages are common.  
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.  
Lighting instructions  
Use Table 2 below to locate the correct Lighting/Operating instruction for the gas valve model installed on your  
boiler.  
Standing pilot  
Models  
Page Spark-ignited pilot  
Models  
Page  
Table 2  
Lighting /  
Operating  
instruction  
guide  
CGa-25 – CGa-8  
EG-30 – EG-75  
PEG-30 – PEG-55  
PFG-5  
16  
Honeywell VR8204/VR8304  
13  
CGa-25 – CGa-8  
EG-30 – EG-65  
PEG-30 – PEG-55  
Honeywell VR8200/VR8300  
CGi, CGs  
21  
17  
CGa-25 – CGa-6  
EG-30 – EG-50  
PEG-30 – PEG-50  
White-Rodgers 36E  
14  
CGa-25 – CGa-6  
EG-30 – EG-50  
PEG-30 – PEG-50  
CGi  
CGs  
Robertshaw 7200  
21  
CGa-7, CGa-8  
EG-55 – EG-75  
PEG-55, PFG-5  
18  
21  
19  
White-Rodgers 36C  
CGi, CGs  
EG-75  
CGa-25 – CGa-6  
EG-30 – EG-50  
PEG-30 – PEG-50  
Robertshaw 7000ERHC  
EGH-85, EGH-95  
PFG-6, PFG-7  
15  
Robertshaw 7200  
EGH-85 – EGH-125  
PFG-6 – PFG-8  
Robertshaw 7000 DERHC  
--  
20  
22  
LGB  
12  
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Lighting instructions  
Standing pilot  
CGa, EG-30 to EG-65,  
PEG-30 to PEG-55  
Gas valve Honeywell VR8200/VR8300  
FORYOUR 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. This appliance has a pilot, which must be lighted C. Use only your hand to push down the reset button or turn the gas  
by hand. When lighting the pilot, follow these  
instructions exactly.  
control knob. Never use tools. If the knob or reset button will not  
operate by hand, don't try to repair it, call a qualified service  
technician. Force or attempted repair may result in a fire or explosion.  
B. Before LIGHTING, smell all around the appliance  
area for gas. Be sure to smell next to the floor D. Do not use this appliance if any part has been under water.  
because some gas is heavier than air and will settle  
on the floor. See below.  
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.  
Immediately call your gas supplier from a neighbors  
phone. Follow the gas suppliers instructions.  
Do not touch any electric switch; do not use any phone  
in your building.  
If you cannot reach your gas supplier, call the fire  
department.  
LIGHTING INSTRUCTIONS  
1. Stop! Read the safety information above on this label.  
9. Remove access panel located above burners.  
2. Set the thermostat to lowest setting.  
3. When equipped with Effikal vent damper Model RVGP,  
place service switch in Hold Damper Open position.  
10. Find pilot follow metal tube from gas  
control. The pilot is between two burners  
behind the access panel.  
11. Turn gas control knob counterclockwise  
4. Turn off all electrical power to the appliance.  
to PILOT.  
5. When equipped with Johnson Controls vent damper  
Model M35, manually rotate damper blade in direction  
of arrow to Open position indicated on damper assembly.  
6. Turn gas control knob clockwise  
7. When equipped with vent damper, verify damper blade  
is in full open position.  
12. Push in red reset button and hold. Immediately light the  
pilot with a match. Continue to hold reset button in for  
about one (1) minute after the pilot is lit.  
13. Release reset button. Pilot should remain lit. If pilot goes  
out, repeat steps 6 through 13.  
to OFF.  
If reset button stays depressed after release, stop and  
immediately call your service technician or gas supplier.  
Position  
If the pilot will not stay lit after several tries, turn the  
indicator  
Gas  
control  
knob  
gas control knob clockwise  
to OFF and call your  
(shown in  
ON position)  
service technician or gas supplier.  
Red  
14. Replace access panel.  
reset button  
59334  
15. Turn gas control knob counterclockwise  
16. Turn on all electric power to the appliance.  
to ON.  
17. When equipped with Effikal vent damper, place service  
switch in Automatic Operation position.  
18. Set thermostat to desired setting.  
19. Replace front panel.  
8. 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.  
TOTURN OFF GASTOTHE APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Remove front panel.  
2. Turn off all electric power to the appliance if service is to  
be performed.  
4. Turn gas control knob clockwise  
5. Replace front panel.  
to OFF.  
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Lighting instructions  
Standing pilot  
CGa-25 to CGa-6,  
EG-30 to EG-50,  
PEG-30 to PEG-50  
Gas valve Robertshaw 7200  
FORYOUR 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. This appliance has a pilot, which must be lighted C. Use only your hand to depress the selector arm. Never use tools. If  
by hand. When lighting the pilot, follow these  
instructions exactly.  
the selector arm will not 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.  
B. Before LIGHTING, smell all around the appliance  
area for gas. Be sure to smell next to the floor D. Do not use this appliance if any part has been under water.  
because some gas is heavier than air and will settle  
on the floor. See below.  
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.  
Immediately call your gas supplier from a neighbors  
phone. Follow the gas suppliers instructions.  
Do not touch any electric switch; do not use any phone  
in your building.  
If you cannot reach your gas supplier, call the fire  
department.  
LIGHTING INSTRUCTIONS  
1. Stop! Read the safety information above on this label.  
9. Remove access panel located above burners.  
2. Set the thermostat to lowest setting.  
3. When equipped with Effikal vent damper Model RVGP,  
place service switch in Hold Damper Open position.  
10. Find pilot follow metal tube from gas  
control. The pilot is between two burners  
behind the access panel.  
11. Move selector arm on gas control right  
4. Turn off all electrical power to the appliance.  
to SET position.  
5. When equipped with Johnson Controls vent damper  
Model M35, manually rotate damper blade in direction  
of arrow to Open position indicated on damper assembly.  
12. Hold selector arm in SET position and immediately light  
the pilot with a match. Continue to hold selector arm to  
SET for about one-half (1/2) minute after the pilot is lit.  
13. Release selector arm. If pilot does not remain lit, repeat  
steps 6 through 13.  
6. Depress and move selector arm left  
to OFF.  
7. When equipped with vent damper, verify damper blade  
is in full open position.  
If the pilot will not stay lit after several tries, move  
selector arm left to OFF and call your service  
technician or gas supplier.  
Position  
indicator  
Selector  
arm  
14. Replace access panel.  
15. Turn selector arm left  
(shown in  
to ON.  
OFF position)  
16. Turn on all electric power to the appliance.  
17. When equipped with Effikal vent damper, place service  
switch in Automatic Operation position.  
18. Set thermostat to desired setting.  
19. Replace front panel.  
59332  
8. 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.  
TOTURN OFF GASTOTHE APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Remove front panel.  
2. Turn off all electric power to the appliance if service is to  
be performed.  
4. Depress and move selector arm left  
5. Replace front panel.  
to OFF.  
14  
Part Number 550-110-592/1000  
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Lighting instructions  
Standing pilot  
EG-75, EGH-85, EGH-95,  
PFG-6, PFG-7  
Gas valve Robertshaw 7000ERHC  
FORYOUR 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. This appliance has a pilot, which must be lighted C. Use only your hand to depress or turn the gas control knob. Never  
by hand. When lighting the pilot, follow these  
instructions exactly.  
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.  
B. Before LIGHTING, smell all around the appliance  
area for gas. Be sure to smell next to the floor D. Do not use this appliance if any part has been under water.  
because some gas is heavier than air and will settle  
on the floor. See below.  
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.  
Immediately call your gas supplier from a neighbors  
phone. Follow the gas suppliers instructions.  
Do not touch any electric switch; do not use any phone  
in your building.  
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.  
8. Turn gas control knob counterclockwise  
to PILOT.  
9. Depress gas control knob and hold. Immediately light the  
pilot with a match. Continue to hold gas control knob in  
for about one (1) minute after the pilot is lit.  
4. Depress gas control knob slightly and turn clockwise  
If pilot can be lit without depressing gas control knob,  
turn gas knob clockwise to OFF and call your ser-  
vice technician or gas supplier.  
to OFF.  
Gas control knob  
(shown in ON position)  
10. Release gas control knob. Pilot should remain lit. If pilot  
goes out, repeat steps 4 through 10.  
Position  
indicator  
If gas control knob stays depressed after release, stop  
and immediately call your service technician or gas  
supplier.  
59205  
Note: Gas control knob cannot be turned to OFF unless knob is  
If the pilot will not stay lit after several tries, turn the  
depressed slightly. Do not force.  
gas control knob clockwise  
to OFF and call your  
service technician or gas supplier.  
5. 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.  
11. Replace access panel.  
12. Turn gas control knob counterclockwise  
13. Turn on all electric power to the appliance.  
14. Set thermostat to desired setting.  
15. Replace front panel.  
to ON.  
6. Remove access panel located above burners.  
7. Find pilot follow metal tube from gas  
control. The pilot is between two burners  
behind the access panel.  
TOTURN OFF GASTOTHE APPLIANCE  
1. Set the thermostat to lowest setting.  
2. Turn off all electric power to the appliance if service is to  
be performed.  
4. Depress gas control knob slightly and turn clockwise  
to OFF.  
5. Replace front panel.  
3. Remove front panel.  
Part Number 550-110-592/1000  
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Operating instructions  
Spark-ignited pilot  
CGa, EG-30 to EG-75,  
PEG-30 to PEG-55,  
PFG-5  
Gas valve Honeywell VR8204/VR8304  
FORYOUR 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 is equipped with an ignition C. Use only your hand to turn the gas control knob. Never use tools. If  
device which automatically lights the pilot. Do  
not try to light the pilot by hand.  
B. Before OPERATING, smell all around the  
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.  
appliance area for gas. Be sure to smell next to D. Do not use this appliance if any part has been under water.  
the floor because some gas is heavier than air and  
will settle on the floor. See below.  
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.  
Immediately call your gas supplier from a neighbors  
phone. Follow the gas suppliers instructions.  
Do not touch any electric switch; do not use any phone  
in your building.  
If you cannot reach your gas supplier, call the fire  
department.  
OPERATING INSTRUCTIONS  
1. Stop! Read the safety information above on this label.  
8. When equipped with vent damper, verify damper blade  
is in full open position.  
2. Set the thermostat to lowest setting.  
3. When equipped with Effikal vent damper Model RVGP,  
place service switch in Hold Damper Open position.  
9. 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.  
4. Turn off all electrical power to the appliance.  
5. When equipped with Johnson Controls vent damper  
Model M35, manually rotate damper blade in direction  
of arrow to Open position indicated on damper assembly.  
10. Turn gas control knob counterclockwise  
11. Turn on all electric power to the appliance.  
to ON.  
6. This appliance is equipped with an ignition device which  
automatically lights the pilot. Do not try to light the pilot  
by hand.  
12. When equipped with Effikal vent damper, place service  
switch in Automatic Operation position.  
7. Turn gas control knob clockwise  
to OFF.  
13. Set thermostat to desired setting.  
Position  
indicator  
Gas  
control  
knob  
14. If the appliance will not operate, follow the instructions  
ToTurn Off GasToThe Appliance and call your service  
technician or gas supplier.  
(shown in  
ON position)  
15. Replace front panel.  
59331  
TOTURN OFF GASTOTHE APPLIANCE  
1. Set the thermostat to lowest setting.  
4. Turn gas control knob clockwise  
force.  
to OFF. Do not  
2. Turn off all electric power to the appliance if service is to  
be performed.  
5. Replace front panel.  
3. Remove front panel.  
16  
Part Number 550-110-592/1000  
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Operating instructions  
Spark-ignited pilot  
CGa-25 to CGa-6,  
EG-30 to EG-50,  
PEG-30 to PEG-50  
Gas valve White-Rodgers 36E  
FORYOUR 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 is equipped with an ignition C. Use only your hand to turn the gas control knob. Never use tools. If  
device which automatically lights the pilot. Do  
not try to light the pilot by hand.  
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.  
B. Before OPERATING, smell all around the  
appliance area for gas. Be sure to smell next to D. Do not use this appliance if any part has been under water.  
the floor because some gas is heavier than air and  
will settle on the floor. See below.  
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.  
Immediately call your gas supplier from a neighbors  
phone. Follow the gas suppliers instructions.  
Do not touch any electric switch; do not use any phone  
in your building.  
If you cannot reach your gas supplier, call the fire  
department.  
OPERATING INSTRUCTIONS  
1. Stop! Read the safety information above on this label.  
8. When equipped with vent damper, verify damper blade  
is in full open position.  
2. Set the thermostat to lowest setting.  
3. When equipped with Effikal vent damper Model RVGP,  
place service switch in Hold Damper Open position.  
9. 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.  
4. Turn off all electrical power to the appliance.  
5. When equipped with Johnson Controls vent damper  
Model M35, manually rotate damper blade in direction  
of arrow to Open position indicated on damper assembly.  
10. Turn gas control knob counterclockwise  
11. Turn on all electric power to the appliance.  
to ON.  
6. This appliance is equipped with an ignition device which  
automatically lights the pilot. Do not try to light the pilot  
by hand.  
12. When equipped with Effikal vent damper, place service  
switch in Automatic Operation position.  
7. Turn gas control knob clockwise  
to OFF.  
13. Set thermostat to desired setting.  
Position  
indicator  
Gas  
control  
knob  
14. If the appliance will not operate, follow the instructions  
ToTurn Off GasToThe Appliance and call your service  
technician or gas supplier.  
(shown in  
ON position)  
59333  
15. Replace front panel.  
TOTURN OFF GASTOTHE APPLIANCE  
1. Set the thermostat to lowest setting.  
4. Turn gas control knob clockwise  
force.  
to OFF. Do not  
2. Turn off all electric power to the appliance if service is to  
be performed.  
5. Replace front panel.  
3. Remove front panel.  
Part Number 550-110-592/1000  
17  
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Operating instructions  
Spark-ignited pilot  
CGa-7, CGa-8,  
EG-55 to EG-75,  
PEG-55, PFG-5  
Gas valve White-Rodgers 36C  
FORYOUR 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 is equipped with an ignition C. Use only your hand to depress or turn the gas control knob. Never  
device which automatically lights the pilot. Do  
not try to light the pilot by hand.  
use tools. If the knob will not depress or 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.  
B. Before OPERATING, smell all around the  
appliance area for gas. Be sure to smell next to D. Do not use this appliance if any part has been under water.  
the floor because some gas is heavier than air and  
will settle on the floor. See below.  
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.  
Immediately call your gas supplier from a neighbors  
phone. Follow the gas suppliers instructions.  
Do not touch any electric switch; do not use any phone  
in your building.  
If you cannot reach your gas supplier, call the fire  
department.  
OPERATING INSTRUCTIONS  
1. Stop! Read the safety information above on this label.  
8. When equipped with vent damper, verify damper blade  
is in full open position.  
2. Set the thermostat to lowest setting.  
3. When equipped with Effikal vent damper Model RVGP,  
place service switch in Hold Damper Open position.  
9. 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.  
4. Turn off all electrical power to the appliance.  
5. When equipped with Johnson Controls vent damper  
Model M35, manually rotate damper blade in direction  
of arrow to Open position indicated on damper assembly.  
10. Turn gas control knob counterclockwise  
11. Turn on all electric power to the appliance.  
to ON.  
6. This appliance is equipped with an ignition device which  
automatically lights the pilot. Do not try to light the pilot  
by hand.  
12. When equipped with Effikal vent damper, place service  
switch in Automatic Operation position.  
7. Depress gas control knob slightly and turn clockwise  
to OFF. Note: Knob cannot be turned to OFF unless knob  
is depressed slightly. Do not force.  
13. Set thermostat to desired setting.  
Position  
indicator  
Gas  
control  
knob  
14. If the appliance will not operate, follow the instructions  
ToTurn Off GasToThe Appliance and call your service  
technician or gas supplier.  
(shown in  
ON position)  
15. Replace front panel.  
59330  
TOTURN OFF GASTOTHE APPLIANCE  
1. Set the thermostat to lowest setting.  
4. Depress gas control knob slightly and turn clockwise  
to OFF. Do not force.  
2. Turn off all electric power to the appliance if service is to  
be performed.  
5. Replace front panel.  
3. Remove front panel.  
18  
Part Number 550-110-592/1000  
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Operating instructions  
Spark-ignited pilot  
CGa-25 to CGa-6,  
EG-30 to EG-50,  
PEG-30 to PEG-50  
Gas valve Robertshaw 7200  
FORYOUR 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 is equipped with an ignition C. Use only your hand to depress or move the selector arm. Never use  
device which automatically lights the pilot. Do  
not try to light the pilot by hand.  
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.  
B. Before OPERATING, smell all around the  
appliance area for gas. Be sure to smell next to D. Do not use this appliance if any part has been under water.  
the floor because some gas is heavier than air and  
will settle on the floor. See below.  
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.  
Immediately call your gas supplier from a neighbors  
phone. Follow the gas suppliers instructions.  
Do not touch any electric switch; do not use any phone  
in your building.  
If you cannot reach your gas supplier, call the fire  
department.  
OPERATING INSTRUCTIONS  
1. Stop! Read the safety information above on this label.  
8. When equipped with vent damper, verify damper blade  
is in full open position.  
2. Set the thermostat to lowest setting.  
3. When equipped with Effikal vent damper Model RVGP,  
place service switch in Hold Damper Open position.  
9. 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.  
4. Turn off all electrical power to the appliance.  
5. When equipped with Johnson Controls vent damper  
Model M35, manually rotate damper blade in direction  
of arrow to Open position indicated on damper assembly.  
10. Move selector arm to ON.  
6. This appliance is equipped with an ignition device which  
automatically lights the pilot. Do not try to light the pilot  
by hand.  
11. Turn on all electric power to the appliance.  
12. When equipped with Effikal vent damper, place service  
switch in Automatic Operation position.  
7. Depress and move selector arm to OFF. Note: Selector  
arm cannot be moved to OFF unless selector arm is  
depressed slightly. Do not force.  
13. Set thermostat to desired setting.  
Position  
indicator  
Selector  
arm  
14. If the appliance will not operate, follow the instructions  
ToTurn Off GasToThe Appliance and call your service  
technician or gas supplier.  
(shown in  
OFF position)  
15. Replace front panel.  
59332  
TOTURN OFF GASTOTHE APPLIANCE  
1. Set the thermostat to lowest setting.  
4. Depress and move selector arm to OFF. Do not force.  
2. Turn off all electric power to the appliance if service is to  
be performed.  
5. Replace front panel.  
3. Remove front panel.  
Part Number 550-110-592/1000  
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Operating instructions  
Spark-ignited pilot  
EGH-85 to EGH-125,  
PFG-6 to PFG-8  
Gas valve Robertshaw 7000DERHC  
FORYOUR 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. This appliance is equipped with an ignition C. Use only your hand to turn the gas control knob. Never use tools. If  
device which automatically lights the pilot. Do  
not try to light the pilot by hand.  
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.  
B. Before OPERATING, smell all around the  
appliance area for gas. Be sure to smell next to D. Do not use this appliance if any part has been under water.  
the floor because some gas is heavier than air and  
will settle on the floor. See below.  
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.  
Immediately call your gas supplier from a neighbors  
phone. Follow the gas suppliers instructions.  
Do not touch any electric switch; do not use any phone  
in your building.  
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. When equipped with Effikal vent damper Model RVGP, place service switch in Hold  
Damper Open position.  
4. Turn off all electrical power to the appliance.  
Gas control knob  
(shown in ON position)  
5. When equipped with Johnson Controls vent damper Model M35, manually rotate  
damper blade in direction of arrow to Open position indicated on damper assembly.  
Position  
indicator  
6. Turn gas control knob clockwise  
to OFF.  
7. When equipped with vent damper, verify damper blade is in full open position.  
8. 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.  
59205b  
9. Turn gas control knob counterclockwise  
10. Turn on all electric power to the appliance.  
to PILOT.  
11. When equipped with Effikal vent damper, place service switch in Automatic Operation  
position.  
12. Set thermostat to desired setting.  
13. If the appliance will not operate, follow the instructions "TO TURN OFF GAS TO  
APPLIANCE" below and call your service technician or gas supplier.  
14. Replace front panel.  
TOTURN OFF GASTOTHE APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Remove front panel.  
2. Turn off all electric power to the appliance if service is to  
be performed.  
4. Turn gas control knob clockwise  
5. Replace front panel.  
to OFF.  
20  
Part Number 550-110-592/1000  
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Operating instructions  
CGi, CGs  
Spark-ignited pilot  
Gas valve Honeywell VR8204/VR8304, White-Rodgers 36C and 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. This appliance does not have a pilot. It is equipped  
with an ignition device which automatically lights  
the burner. Do not try to light the burner by hand.  
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. Force or attempted repair  
may result in a fire or explosion.  
B. 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.  
D. 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.  
Immediately call your gas supplier from a neighbor's phone.  
Follow the gas supplier's instructions.  
Do not touch any electric switch; do not use  
any phone in your building.  
If you cannot reach your gas supplier, call the fire department.  
OPERATING INSTRUCTIONS  
26070  
1. STOP! Read the safety information above on this label.  
2. Set the thermostat to lowest setting.  
White-Rodgers  
36C Gas valve  
3. Turn off all electrical power to the appliance.  
4. Remove jacket front panel.  
Position indicator  
(shown in "ON" position)  
5. This appliance is equipped with an ignition device which automatically lights the burner.  
Do not try to light the burner by hand.  
Gas control knob  
White-Rodgers  
36E Gas valve  
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.  
Position indicator  
(shown in "ON" position)  
8. Turn Gas control knob counterclockwise  
9. Turn on all electric power to the appliance.  
10. Set thermostat to desired setting.  
to ON.  
Gas control knob  
Honeywell  
VR8204 or  
VR8304  
Gas valve  
11. If the appliance will not operate, follow the instructions "TO TURN OFF GAS TO  
APPLIANCE" below and call your service technician or gas supplier.  
Position indicator  
(shown in "ON" position)  
Gas control knob  
12. Replace jacket front panel.  
TO TURN OFF GAS TO THE APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Remove jacket front panel.  
2. Turn off all electric power to the appliance if service is to  
be performed.  
4. Turn Gas control knob clockwise  
to OFF. Do not  
force.  
5. Replace jacket front panel.  
Part Number 550-110-592/1000  
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Operating instructions  
Spark-ignited pilot  
LGB  
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  
C. Use only your hand to turn the operating control. Never use  
tools. If the operating control will not turn by hand, don't try  
to repair it, call a qualified service technician. Force or at-  
tempted repair may result in a fire or explosion.  
with an ignition device which automatically lights  
the burner. Do nottry to light the burner by hand.  
B. 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.  
D. 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.  
Immediately call your gas supplier from a neighbor's phone.  
Follow the gas supplier's instructions.  
Do not touch any electric switch; do not use  
any phone in your building.  
If you cannot reach your gas supplier, call the fire department.  
TO PLACE IN OPERATION  
8. If boiler fails to start, check:  
1. Stop! Read the safety information  
above.  
a. Loose connection or blown fuse?  
Gas supply  
b. Limit setting below boiler water  
temperature or pressure?  
2. Turn operation control to OFF position  
or lowest position on dial. Be sure boiler  
has been correctly filled with water.  
Manual main  
shutoff gas  
valve  
c. Gas not turned on at meter?  
d. Gas not turned on at boiler?  
3. Turn off all electrical power to the  
appliance.  
e. Operation safety devices not  
working or tripped?  
Main shutoff gas valve  
must be closed for at least  
five (5) minutes before  
lighting.  
Reset system by turning off and on  
main electrical switch. If above fails to  
eliminate the trouble, call a service  
technician.  
Ground joint  
union  
4. Move operating control to call for heat.  
5. Open manual main shutoff gas valve.  
6. Turn on electrical power to the appliance.  
To gas valve and drip leg  
59207  
9. Make sure boiler goes through several  
normal operating cycles.  
10. Turn operating control to desired  
setting.  
7. If boiler starts, go to Step 9. If boiler fails  
to start, go to Step 8.  
ANNUAL SHUTDOWN PROCEDURE  
1. Close manual main shutoff valve.  
2. Disconnect electrical power supply.  
3. Move operating control indicator to low setting.  
4. DO NOT drain system unless exposure to freezing temperatures will occur.  
If antifreeze is used with system, do not drain.  
22  
Part Number 550-110-592/1000  
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Common problems and solutions  
Symptom  
Common Causes Possible Corrections  
Thermostat installed where drafts Locate thermostat on inner wall away from heat sources or cool  
Rapid cycling —  
boiler turns on and  
off frequently  
or heat affect reading  
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.  
Expansion tank sized too small  
Flooded expansion tank  
Call qualified service technician to check expansion tank  
operation and size.  
Frequent release of  
water through relief  
valve  
Call qualified service technician to check expansion tank  
operation.  
Inoperative limit control  
Leaks in boiler or piping  
Call qualified service technician to replace limit control.  
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.  
Need to frequently  
add makeup water  
Oxygen corrosion due to leaks in Have qualified service technician repair at once. Keep pH of  
Black water  
condition  
boiler and piping  
water between 7.0 to 8.5.  
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.  
Popping or  
percolating noise  
heard in boiler  
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.  
Contaminated combustion air  
supply — See page 3 in this  
manual.  
Remove any contaminating products. See page 3 in this  
manual.  
Metal flakes found in  
vent outlet or vent —  
flueway corrosion  
Provide outside air for combustion. Kit available through Weil-  
McLain distributor. Have qualified service technician pipe-up kit.  
Condensation of combustion  
gases in boiler sections  
Have qualified service technician inspect system piping and  
controls to verify proper regulation of return water temperature.  
Air in system  
Bleed air from system through air vents in radiators or  
baseboard units.  
Some radiators or  
baseboard units do  
not heat or are noisy  
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.  
Part Number 550-110-592/1000  
23  
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Weil-McLain Limited Warranty for  
Residential & Commercial Cast Iron Boilers  
These warranties do not cover:  
1. Components that are part of the heating systems, but  
were not furnished by Weil-McLain as a part of the  
boiler.  
RESIDENTIAL WATER WARRANTY—Limited Lifetime  
RESIDENTIAL STEAM WARRANTY—Limited 10 Year  
COMMERCIAL WARRANTY—Limited 10-Year  
NOTE: The residential steam and water warranties do not  
cover residential boilers installed in buildings other than one  
or two family dwelling units, unless they are buildings with  
individual boilers for each dwelling unit.  
2. The workmanship of any installer of Weil-McLain’s  
boilers. In addition, this warranty does not assume any  
liability of any nature for unsatisfactory performance  
caused by improper installation.  
First Year-(All Residential & Commercial Cast Iron  
Boilers)  
3. Any costs for labor for removal and reinstallation of the  
alleged defective part, transportation to Weil-McLain, if  
necessary, and any other materials necessary to  
perform the exchange.  
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.  
4. Improper burner adjustments, control settings,care or  
maintenance. Information is included in the installation  
Instructions, Owner’s Information Manual and/or Start-  
up, Service and Maintenance Instructions, and other  
printed technical material furnished by Weil-McLain with  
the boiler.  
Second Through Tenth Year-(Residential Water/Steam)  
Second Through Tenth Year-(Commercial Water/Steam)  
Limited Warranty for cast iron sections:  
Weil-McLain warrants that the cast iron sections of its water  
and steam boilers are free from defects in material and  
workmanship from the date of installation for the second  
through the tenth year. If, during such time period, any section  
is found to be defective, Weil-McLain will provide replacement  
for the original cast iron section(s).  
5. Boilers operated with combustion air contaminated  
externally by chemical vapors or with improper fuel  
additives, or with water conditions which may have  
caused unusual deposits in the cast iron sections.  
These warranties extend only to the first retail purchaser of the boiler  
and only to a boiler that has not been moved from its original  
installation site.  
Eleventh Year and Beyond - (Residential Water Only)  
Limited Warranty for Cast Iron Sections:  
Weil-McLain warrants that the cast iron sections of its  
residential water boilers are free from defects in material and  
workmanship for the eleventh year and beyond from the date  
of installation. If, during such time period, any section(s) is  
found to be defective, Weil-McLain will provide replacement  
for the original cast iron section(s) upon the payment of a  
proportionate charge based on the time the boiler has been  
in service. The proportionate charge will be equal to the  
appropriate percentage of the list price of such section(s) at  
the time the warranty claim is made, and will be determined  
as follows:  
THE WARRANTIES DESCRIBED ABOVE ARE IN LIEU OF ALL  
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT  
NOT LIMITED TO ANY IMPLIED WARRANTIES OF FITNESS FOR  
A PARTICULAR PURPOSE AND MERCHANTABILITY. WEIL-  
McLAIN EXPRESSLY DISCLAIMSAND EXCLUDESANY LIABILITY  
FOR CONSEQUENTIAL, INCIDENTAL, INDIRECT OR PUNITIVE  
DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED  
WARRANTY.  
For prompt product warranty claims, notify the installer who, in turn,  
will notify the Weil-McLain distributor from whom he purchased the  
boiler. If this action does not result in warranty resolution, contact  
Weil-McLain Consumer Relations Department, 500 Blaine Street,  
Michigan City, Indiana 46360-2388, with details in support of the  
warranty claim. Alleged defective part or parts must be returned  
through trade channels in accordance with the Weil-McLain  
procedure currently in force for handling returned goods for the  
purpose of inspection to determine cause of failure. Weil-McLain  
will furnish new part(s) to an authorized Weil-McLain distributor who,  
in turn will furnish the new part(s) to the heating contractor who  
installed the boiler. If you have any questions about the coverage of  
this warranty, contact Weil-McLain at the address above.  
11th year - 5%; 12th year - 10%; 13th year - 15%;  
14th year - 20%; 15th year - 25%; 16th year - 30%;  
17th year - 35%; 18th year - 40%; 19th year - 45%;  
20th year - 50%; 21st year - 55%; 22nd year - 60%;  
23rd year - 65%; 24th year - 70%; 25th year and  
beyond - 75%.  
All Residential & Commercial Cast Iron Boilers  
These warranties are subject to the condition that the boiler  
must have been installed by a heating contractor whose  
principal occupation is the sale and installation of plumbing,  
heating and/or air conditioning equipment.  
Weil-McLain  
500 Blaine Street  
Michigan City, IN 46360-2388  
24  
Part No. 550-110-592/1000  
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