Weil-McLain EG-30 THRU -75 Control Supplement

Gas-fired boilers – series 4
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Control supplement – Standing pilot
This supplement must only be used by a qualified heating installer/service technician.
instructions, including this supplement, the boiler manual and any related documents. Perform steps in the order given.
Failure to comply could result in severe personal injury, death or substantial property damage.
EG-30 thru -75
PEG-30 thru -65
Gas-Fired Boilers – Series 4
For additional information, refer to . . .
EG• PEG• EGH Boiler manual
for Natural or Propane gas
(tankless heater application optional)
Before installing
Part Number 550-110-032/0607
, read all

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Summary of Contents for Weil-McLain EG-30 THRU -75

  • Page 1 Control supplement – Standing pilot This supplement must only be used by a qualified heating installer/service technician. instructions, including this supplement, the boiler manual and any related documents. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. EG-30 thru -75 PEG-30 thru -65 Gas-Fired Boilers – Series 4 For additional information, refer to . . . EG• PEG• EGH Boiler manual for Natural or Propane gas (tankless heater application optional) Part Number 550-110-032/0607 Before installing...
  • Page 2: Hazard Definitions And Note To The Installer

    Indicates presence of hazards that can cause severe personal injury, death or substantial property damage. Indicates presence of hazards that will or can cause minor personal injury or property damage. Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage. Note to the installer Controls must only be installed by a Weil-McLain distributor or other qualified installer/service technician in accordance with this Supplement and all applicable codes and requirements of the authority having jurisdiction. Read this Control Supplement completely before beginning the installation. If the information in this Supplement is not followed exactly, a fire, explosion, carbon monoxide emission or other hazardous conditions can result, causing severe personal injury, death or substantial property damage.
  • Page 3: Table Of Contents

    Control installation — EG-30 thru -65 water boilers with tankless heaters ... 6-7 Control installation — EG-30 thru -75 and PEG-30 thru -65 steam boilers with probe..8-9 Control installation — EG-30 thru -75 steam boilers with float-type low water cutoff ... 10-11 Damper installation ...
  • Page 4: Control Installation - Eg-30 Thru -75 Water Boilers Without Tankless Heaters

    Part Number 550-110-032/0607...
  • Page 5 Standing Pilot Boilers — Control Supplement Control installation For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage. EG-30 thru -65 water boilers without tankless heaters 1. Mount and wire controls per wiring diagram, page , and Figure 1. a. Attach junction box inside left jacket panel with #8- x ½” machine screws provided. b. Install transformer with plug-in relay receptacle and relay. c. Operating and limit circuit wiring must be 18 gauge or heavier. . Bring supply wiring to boiler. Must be 1 gauge or heavier. . Proceed to page 1. EG-75 water boilers without tankless heaters 1. Mount and wire controls per wiring diagram, page , and Figure . a. Attach junction box inside left jacket panel with #8- x ½” machine screws and green ground nuts provided.
  • Page 6: Control Installation - Eg-30 Thru -65 Water Boilers With Tankless Heaters

    Part Number 550-110-032/0607...
  • Page 7 Standing Pilot Boilers — Control Supplement Control installation For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage. EG-30 thru -65 water boilers with tankless heaters 1. Mount and wire controls per wiring diagram, page , and Figure . a. Install combination limit control and relay in tap- ping. See Boiler Manual control tapping table. Op- erating and limit circuit wiring must be 1 gauge or heavier. . Bring supply wiring to boiler. Must be 1 gauge or heavier. . Proceed to page 1. Note: Tankless heater not available on EG-75 standing pilot boilers. Part Number 550-110-032/0607 continued Figure 3...
  • Page 8: Control Installation - Eg-30 Thru -75 And Peg-30 Thru -65 Steam Boilers With Probe

    Part Number 550-110-032/0607...
  • Page 9 Standing Pilot Boilers — Control Supplement Control installation For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage. EG-30 thru -65 and PEG-30 thru -65 steam boilers with probe-type low water cutoff 1. Mount and wire controls per wiring diagram, page 8, and Figure . a. Attach junction box inside left jacket panel with #8- x ½” machine screws provided. b. Install transformer with plug-in relay receptacle. c. Operating and limit circuit wiring must be 18 gauge or heavier. . Bring supply wiring to boiler. Must be 1 gauge or heavier. . Proceed to page 1. EG-75 steam boilers with probe-type low water cutoff 1. Mount and wire controls per wiring diagram, page 8, and Figure .
  • Page 10: Control Installation - Eg-30 Thru -75 Steam Boilers With Float-Type Low Water Cutoff

    Part Number 550-110-032/0607...
  • Page 11 Standing Pilot Boilers — Control Supplement Control installation For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage. EG-30 thru -65 steam boilers with float-type low water cutoff 1. Mount and wire controls per wiring diagram, page 10, and Figure . a. Attach junction box inside left jacket panel with #8- x ½” machine screws provided. b. Install transformer with plug-in relay receptacle. c. Operating and limit circuit wiring must be 18 gauge or heavier. . Bring supply wiring to boiler. Must be 1 gauge or heavier. . Proceed to page 1. EG-75 steam boilers with float-type low water cutoff 1. Mount and wire controls per wiring diagram, page 10, and Figure .
  • Page 12: Damper Installation

    EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4 Damper installation The following boiler models must have damper installed: • • The following boiler models may have damper installed: • Figure 8 Once damper is installed, boiler will not operate without a damper installed. Only dampers listed in the Replacement parts table on page  are approved for use on EG and PEG Series  standing pilot boilers. Any other vent damper installed could cause severe personal injury or death. EG-30 thru EG-65, natural or propane gas. PEG-30 thru PEG-65, steam, natural gas. EG-75, natural or propane gas.
  • Page 13 Provide a minimum of ” between the vent damper and any combustible material. (Provide a minimum of ” between jacket top and combustible ceiling.) See EG • PEG • EGH Boiler manual for complete clearance requirements. Installation Do not modify draft hood or damper, or make another connection between draft hood and damper or boiler except as not- ed below. This will void CSA certification and will not be covered by Weil-McLain warranty. Any changes will cause severe personal injury, death, or substantial property damage. 1. Install vent damper horizontally or vertically as shown in vent damper manufacturer’s instructions. Vent damper must be installed so that it serves only one boiler and so damper blade indicator is visible to the user. See Figure 8. . Screws or rivets used to secure the vent damper to the draft hood must not interfere with rotation of the damper blade.
  • Page 14: Checkout Procedure

    EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4 Checkout procedure 1. See pages 1-18 for “Lighting Instructions”. . Raise room thermostat to call for heat. Damper actuator will slowly open damper. . When damper is fully open, main gas valve will open and main burners will ignite. Damper must be fully open before main burners light. If damper does not fully open, flue products will escape into house, causing severe personal injury or death. . Lower thermostat setting. Main burner flames will go out, then damper will close. . Repeat steps 1 through  several times to verify operation. . Return thermostat to normal setting. Room thermostat anticipator settings Water without tankless heater — 0.40 amps Water with tankless heater —...
  • Page 15: Lighting Instructions

    Standing Pilot Boilers — Control Supplement Lighting instructions — Robertshaw 7200 Part Number 550-110-032/0607...
  • Page 16: Lighting Instructions

    EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4 Lighting instructions — Honeywell VR8200/VR8300 Natural gas boilers only Part Number 550-110-032/0607...
  • Page 17 Standing Pilot Boilers — Control Supplement Lighting instructions — Honeywell VR8200/VR8300 Propane boilers only Part Number 550-110-032/0607...
  • Page 18 EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4 Lighting instructions — Robertshaw 7000ERHC Part Number 550-110-032/0607...
  • Page 19: Troubleshooting

    Standing Pilot Boilers — Control Supplement Troubleshooting Burner access panel must be in posi- tion during boiler operation to prevent momentary flame rollout on ignition of main flame. Severe personal injury or substantial property damage will result. Never jumper (bypass) any device ex- cept for momentary testing as outlined in Troubleshooting Charts. Substantial property damage and/or severe personal injury could occur.
  • Page 20: Troubleshooting

    EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4 Troubleshooting Pilot does not stay lit — Troubleshooting thermocouple or thermopile and high limit control circuit 1. Checking thermocouple or thermopile open system (Figure 10): a. Use an electronic multimeter, with leads fitted with alligator clips. Set meter scale to DC Millivolts. b. Unscrew thermocouple or thermopile fitting from gas valve. c. Attach one meter lead to the end of the thermocouple or thermopile gas valve fitting. d. Attach other meter lead to thermocouple or thermopile lead (copper sur- face). e. Follow Lighting Instruction label on boiler (also found in Control Supple- ment or User’s Information Manual) to light the pilot burner only, and hold the pilot flame manually. (DO NOT light main burner.) f. Check the reading on the multimeter. The reading should be around 8 millivolts for a thermocouple, or 00 millivolts for a thermopile. g. If multimeter reading is significantly less than above and pilot flame is appropriate, replace the thermocouple or thermopile.
  • Page 21 Standing Pilot Boilers — Control Supplement Troubleshooting continued Part Number 550-110-032/0607...
  • Page 22 EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4 Troubleshooting continued Part Number 550-110-032/0607...
  • Page 23 Standing Pilot Boilers — Control Supplement Troubleshooting continued Part Number 550-110-032/0607...
  • Page 24: Replacement Parts

    Gas valve, ½” x ½”, Propane gas, sizes 30 thru 50 propane ¾” x ¾”, Propane gas, sizes 55 thru 65 ¾” x 1”, Propane gas, size 75 Manufacturer / Weil-McLain Mfr’s part number part number Effikal RVGP-KS-5BKF 381-800-475 Johnson Q35GD-2...

This manual is also suitable for:

Peg-30Eg-75Peg-65

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