CGa Series 3, CGi Series 4, EG Series 5, PEG Series 5, LGB Series 2 Gas-Fired Boilers User’s Information Manual INSTALLER: Please take time to review this User’s information Manual with the boiler owner. Explain all maintenance and service procedures and the correct Operating Instructions. 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.
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers Please read this page first How to use this To . . . manual . . . Hazard definitions Read/Use . . . Pages . . Learn precautions Warnings and definitions Prevent air contamination Read list of air contaminants you must avoid. If found, either remove products permanently or isolate boiler and provide outside combustion air. 3 Identify boiler components The illustration on page 4 or 5, will show you the location of the main components.
User’s Information Manual STOP!! — Read before proceeding Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage. Air contamination • To prevent potential of severe personal injury or death, check for products or areas listed in table at right before installing boiler. If any of these contaminants are found: • remove contaminants permanently. — OR — • isolate boiler and provide outside combustion air.
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers Boiler components CGa Series 3 1 2 3 4 5 7 8 9 10 4 Gas valve Pilot burner (Not shown) Main burner Gas manifold/orifices Control module Vent damper (CGa only) Water temperature/LWCO sensor Transformer Spill switch (CGa only) 12 13 14 15 16 17 Rollout thermal fuse element Draft hood (CGa only) Circulator Relief valve Gauge (pressure/temperature) Drain valve Part Number 550-142-301/0420
User’s Information Manual Boiler components CGi Series 4 1 2 3 4 5 6 8 9 Gas valve Pilot burner (Not shown) Main burner Gas manifold/orifices Control module Inducer (CGi only) Water temperature/LWCO sensor Transformer Part Number 550-142-301/0420 11 12 14 15 16 17 Air pressure switch (CGi only) Rollout thermal fuse element Circulator Relief valve Gauge (pressure/temperature) Drain valve 5
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers Boiler components 1 2 3 4 5 7 9 10 12 13 14 15 16 18 19 20 Gas valve Pilot burner Main burner Gas manifold/orifices Control module Vent damper Transformer Spill switch Rollout thermal fuse element Low water cutoff (steam boilers) Limit control(s) Draft hood Circulator Gauge (pressure or pressure/temperature) Gauge glass (steam only) Water temperature/LWCO sensor (For EG/PEG water boilers - not shown) EG/PEG LGB 1 2 3 4 5 7 9 10 12 13 14 15 16 18 19 6 Gas valv
User’s Information Manual Maintain boiler using schedule below Service technician Owner maintenance (covered in Boiler Manual – for use only by a qualified service technician) (see following pages for instructions) • Check boiler area Inspect: • Reported problems Daily • Boiler area • Check air openings • Check boiler pressure/ temperature gauge • Air openings • Flue gas vent system • Check boiler interior piping • Pilot and main burner flames • Check venting system • Water piping • Boiler hea
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers 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.
User’s Information Manual User maintenance procedures (continued) ❏ Check daily . . . . . . . . . . . . . . . . . Pressure/temperature gauge or pressure gauge (steam) 1. Water boilers — Make sure the pressure reading on the boiler pressure/temperature gauge does not 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.
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers User maintenance procedures (continued) ❏ Check monthly . . . . . . . . . . . . . . . . Automatic air vents (if used) 1. See Figure 4. 2. Remove the cap from any automatic air vent in the system and check operation by depressing valve 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. 4. Loosen cap A one turn to allow vent to operate. 5.
User’s Information Manual User maintenance procedures (continued) ❏ Service periodically . . . . . . . . . . . . Test low water cutoff – The system is equipped with a low water cutoff. Test the low water cutoff periodically during the heating season. Float type — See Figure 7 Figure 8 Probe type low water cutoff 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. .
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers User maintenance procedures ❏ Service periodically continued . ...... Clean gauge glass Normal waterline on a steam boiler is halfway up gauge glass. See Figure 10. Clean when needed. 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 pet cock. 5. Open lower gauge cock. 6.
User’s Information Manual User maintenance procedures (continued) ❏ End-of-season shutdown . . . . . . . . Follow 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 13 through 19 of this manual. Use the Operating instruction for the gas valve model installed on the boiler. 2. Do not drain system unless exposure to freezing temperatures will occur. 3.
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers Operating instructions • Spark-ignited pilot CGa, EG-30 to EG-75, PEG-30 to PEG-55, • Gas valve — Honeywell VR8204/VR8304 14 Part Number 550-142-301/0420
User’s Information Manual Operating instructions • Spark-ignited pilot • Gas valve — White-Rodgers 36E Part Number 550-142-301/0420 CGa-25 to CGa-6, EG-30 to EG-50, PEG-30 to PEG-50 15
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers Operating instructions • Spark-ignited pilot • Gas valve — White-Rodgers 36C 16 CGa-7, CGa-8, EG-55 to EG-75, PEG-55, Part Number 550-142-301/0420
User’s Information Manual Operating instructions • Spark-ignited pilot • Gas valve — Robertshaw 7200 Part Number 550-142-301/0420 CGa-25 to CGa-6, EG-30 to EG-50, PEG-30 to PEG-50 17
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers Operating instructions • Spark-ignited pilot CGi • Gas valve — Honeywell VR8204/VR8304, White-Rodgers 36C and 36E 18 Part Number 550-142-301/0420
User’s Information Manual Operating instructions LGB • Spark-ignited pilot Part Number 550-142-301/0420 19
CGa, CGi, EG, PEG, & LGB Gas-Fired Boilers 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 thermostat per manufacturer’s instructions. Incorrect limit setting Set limit according to system needs. Maximum setting is 220°F.
