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Weil-McLain EG Manual

Gas-fired boilers – series 4
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See also: User's Information Manual
Boiler Manual
EG
PEG
EGH
EG
•
Gas-Fired Boilers – Series 4
This manual must only be used by a qualified heating installer/service technician.
Before installing
, read all instructions, including this manual, the burner manual
and any related supplements. Perform steps in the order given. Failure to comply
could result in severe personal injury, death or substantial property damage.
PEG
•
• Installation
• Startup
For additional information, refer to . . .
Control Supplement and Gas
Control Parts
for Natural or Propane gas
(tankless heater application optional)
Part No. 550-110-639/0512
EGH
• Maintenance
• Parts

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Summary of Contents for Weil-McLain EG

  • Page 1 • • Gas-Fired Boilers – Series 4 Boiler Manual • Installation • Maintenance • Startup • Parts For additional information, refer to . . . Control Supplement and Gas Control Parts for Natural or Propane gas (tankless heater application optional) This manual must only be used by a qualified heating installer/service technician.

  • Page 2: Read This Page First

    • Never store glycol of any kind near the boiler or any EG and EGH boilers for tankless or storage heater potential ignition source. application are available only on special order as factory-installed optional equipment. Tankless •...

  • Page 3: Table Of Contents

    . . . . . . . . . . . . . . . . . 28 Service and maintenance . . . . . 29 Replacement parts — EG/PEG . . 33 Replacement parts — EGH . . . . 35 Dimensional data .

  • Page 4: Codes And Checklist

    — 4 — • • firEd boilErs sEriEs boilEr manual Codes & Checklist Installation must follow these codes: • Local codes, laws, provincial and national codes, laws, regulations and ordinances • National Fuel Gas Code ANSI Z223.1- latest edition • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required •...

  • Page 5: Prepare Boiler Location

    1. Provide minimum clearances for cleaning and servicing the boiler and for access to controls and components as EG, PEG & EGH - Clearance for service listed in the table at right. Minimum 2. Provide at least screwdriver clearance to jacket front panel...

  • Page 6: Vent System

    Boiler No. “L” to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any EG 30-35 EGH 85 40 1/4 other gas-burning appliance to their previous conditions of use. EG 40-45...
  • Page 7 — 4 — • • firEd boilErs sEriEs boilEr manual Prepare boiler location Vent System Air contamination (continued) Chimney or vent requirements 1. Please review the following information on potential combustion air contamination problems. 1. Venting must be installed according to the National Fuel Gas Code, ANSI Z223.1–latest edition and applicable building codes.

  • Page 8: Air Openings

    — 4 — • • firEd boilErs sEriEs boilEr manual Prepare the location Tight construction — Definition: Air openings Tight construction means (per ANSI Z223.1): Provide adequate combustion and ventilation air • Walls and ceilings exposed to the outside atmosphere have a to assure proper combustion and reduce the risk continuous water vapor retarder with a rating of 1 perm or of severe personal injury, death or substantial prop-...

  • Page 9: Prepare The Boiler

    — 4 — • • firEd boilErs sEriEs boilEr manual Prepare the boiler Placing the boiler Figure 4a Corner after exposed silicone has been removed. Block assembly is extremely heavy. Handle with caution to avoid personal injury. EGH boilers only — When an EGH block assembly is taken apart for handling: 1.

  • Page 10: Hydrostatic Pressure Test

    — 4 — • • firEd boilErs sEriEs boilEr manual Prepare the boiler (continued) Installation of optional indirect Figure 5 Boiler tappings (see Table 4) water heater 1. For a boiler ordered with internal type indirect water heater, remove heater opening cover plate (water boil- ers –...
  • Page 11 Standard Orifice BTU/cu. ft. drill size Natural 1,000 2.45 mm Propane 2,500 1.55 mm Orifice Drill Sizes - EG - Canada Only Elevation Natural Propane 0 - 2,000 ft. 2.45 mm 1.55 mm 2,000 -4,500 ft. 2.30 mm 1.45 mm Inspect burners –...
  • Page 12 — 4 — • • firEd boilErs sEriEs boilEr manual Prepare the boiler (continued) Figure 7b Figure 10 Front base panel Burner drawer installation Figure 8 Figure 11 Burner drawer assembly Access panel Figure 9 Burner and pilot burner locations Part Number 550-110-639/0512...

  • Page 13: Jacket Installation

    34, Drawing Ref. Letter “K”. Connect wires as shown in the Tankless and storage heater knockouts appropriate Control Supplement. must be removed for EG and EGH boil- ers with optional tankless heaters prior to jacket installation. Damper installation 2.

  • Page 14: Connect Piping - Water Boilers

    The circulator is shipped loose (wiring pre-attached to boiler) to allow you to locate it either in the return or 1. EG — Connect supply and return to left end. supply piping, as desired. See page 12 for a typical instal- 2.
  • Page 15 — 4 — • • firEd boilErs sEriEs boilEr manual Connect piping – water boilers (continued) Use Figure 13 or Figure 14 only for systems designed for Figure 13 Recommended piping – forced hot water return water at least 130 °F. For systems with low return boilers with closed type expansion tanks water temperature possible, such as converted gravity systems and radiant heating systems, install bypass pip-...
  • Page 16 — 4 — • • firEd boilErs sEriEs boilEr manual Connect piping – water boilers (continued) Figure 16 Figure 17 System bypass piping in boiler loop with separate Boiler bypass piping — use only for high water system circulator, using primary/secondary content systems —DO NOT use for radiant panel piping.

  • Page 17: Connect Piping - Steam Boilers

    Header Equalizer EG-30, 35 2” – 2” 1 ¹⁄₂” PEG-30,35 2 ¹⁄₂” – 2 ¹⁄₂” 1 ¹⁄₂” EG-40, 45, 50 PEG-40, 45, 50 2” – 2” 1 ¹⁄₂” EG-55, 65, 75 3” – 3” 1 ¹⁄₂” PEG-55, 65 EGH-85, 95 2”...
  • Page 18 — 4 — • • firEd boilErs sEriEs boilEr manual Connect piping – steam boilers (continued) Installing the relief valve Figure 19 Connection to counterflow steam piping Install relief valve in tapping on top of boiler. See Table 4, page 10, for control tapping locations.

  • Page 19: Steam

    GPM * Use Table 9 to size boiler feed systems. See Figure 5, page 10, for EG/PEG-30 tapping locations. (The use of a combination condensate tank and float-controlled condensate return pump is not recommended.)

  • Page 20: Install Boiler Controls

    LWCO model numbers are manufacturer’s part 3. Install remaining controls as shown in Table 4 and numbers that can be found in the Weil-McLain Figure 5, page 10. Trade Price Schedule. Part Number 550-110-639/0512...

  • Page 21: Connect Piping - Tankless Heater

    • boiler water pressure is limited to max. 30 psig by approved water or steam relief valve. 4. EGH-85 & 95 Standing pilot systems - no tankless option 5. EG-75 Standing pilot systems - no tankless option 6. EGH-85 Water - use one heater only. Part Number 550-110-639/0512...

  • Page 22: Connect Gas Supply Piping

    — 4 — • • firEd boilErs sEriEs boilEr manual Connect gas supply piping Connecting gas supply piping 5. Follow good piping practices. 6. Pipe joint compound (pipe dope) must be resistant 1. Size gas piping considering to corrosive action of liquified petroleum gases. Ap- a) Diameter and length of gas supplying piping.

  • Page 23: Connect Field Wiring To Boiler

    — 4 — • • firEd boilErs sEriEs boilEr manual Connect field wiring to boiler For your safety, turn off electrical power supply at service 4. A strain relief bushing and adapter must be used entrance panel before making any electrical connections to at each point where wiring passes through control avoid possible electric shock hazard.

  • Page 24: Start-Up

    — 4 — • • firEd boilErs sEriEs boilEr manual Start-up Check for gas leaks Freeze protection (when used) Use antifreeze especially made for hydronic systems. fore starting the boiler, and during initial Inhibited propylene glycol is recommended. ation, smell near the floor and around oper the boiler for gas odorant or any unusual Do not use automotive, ethylene glycol...
  • Page 25 — 4 — • • firEd boilErs sEriEs boilEr manual Start-up (continued) Skim the steam boiler Operate boiler Check system and boiler Clean all newly installed steam boilers to remove oil and grease. Failure to properly DO NOT proceed with boiler operation unless boiler and clean can result in violent fluctuations system have been filled with water and all instructions and of water level, water passing into steam...
  • Page 26 — 4 — • • firEd boilErs sEriEs boilEr manual Start-up (continued) If boiler doesn’t start . . . Check for: Figure 28 Typical pilot burner flame 1. Loose connections, blown fuse or service switch off? 2. High limit switch set below boiler pressure? 3.

  • Page 27: Installation And Service Certificate

    When MANIFOLD GAS PRESSURE controls are restored, burners should reignite. NAT. = 3.5" ❏ EG only - button on spill switch pushed in? L.P. = 10.0" WC. ❏ To test ignition system shut-off device: ❏...

  • Page 28: Handling Fiberglass And Ceramic Fiber

    — 4 — • • firEd boilErs sEriEs boilEr manual Handling fiberglass and ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applica- tions.

  • Page 29: Service And Maintenance

    — 4 — • • firEd boilErs sEriEs boilEr manual Service and maintenance Table 12 Service and maintenance schedules (service technician and owner) Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) Inspect: ❏ ❏...
  • Page 30 — 4 — • • firEd boilErs sEriEs boilEr manual Service and maintenance (continued) Piping The boiler should be inspected and started annu- ally, at the beginning of the heating season, only 1. Check the boiler interior piping and all system piping for by a qualified service technician.
  • Page 31 — 4 — • • firEd boilErs sEriEs boilEr manual Service and maintenance (continued) Probe-type low water cutoff (when used) ❏ Service ..Clean probe-type low water cutoff (when used) for proper operation.

  • Page 32: Review With Owner

    — 4 — • • firEd boilErs sEriEs boilEr manual Service and maintenance (continued) ❏ Check/test ..❏ Review with owner 1. Review the User’s Information Manual with the owner. Boiler relief valve 2.

  • Page 33: Replacement Parts - Eg/Peg

    — 4 — • • firEd boilErs sEriEs boilEr manual Replacement parts — EG/PEG Table 13 EG/PEG replacement parts Item Description Boiler Part Number Item Description Boiler Part Number Models Models Left hand end section with heater opening (Pattern No.
  • Page 34 • firEd boilErs sEriEs boilEr manual Replacement parts — EG/PEG (continued) The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 28 of this manual. Failure to comply could result in severe personal injury.

  • Page 35: Replacement Parts - Egh

    — 4 — • • firEd boilErs sEriEs boilEr manual Replacement parts — EGH Table 14 EGH replacement parts Item Description Boiler Part Number Item Description Boiler Part Number Models Models Left hand end section with heater opening (Pattern No. —...
  • Page 36 — 4 — • • firEd boilErs sEriEs boilEr manual Replacement parts — EGH (continued) The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 28 of this manual. Failure to comply could result in severe personal injury. Part Number 550-110-639/0512...

  • Page 37: Dimensional Data

    2. Damper dimension for EG-30 through EG-65 ONLY. For EG-75 and all EGH the damper is additional equipment. 3. PEG crates are 32” wide by 39” high. Crate lengths are: 32” for PEG-30, -35, -40; 37” for PEG -45, -50, -and -55; 39” for PEG-65.

  • Page 38: Ratings

    Add prefix “P” for package boiler completely assembled and wired with jacket and controls (PEG-30-S through PEG-65-S DOE season efficiency (AFUE) only). Boiler EG-30 thru 75 : Add suffix “SPD” or “SP” for standing pilot; Model Water Steam add “PID” or “PI” for electronic ignition (30-65 — damper Number required in U.S.;...

  • Page 39: Standard And Optional Equipment

    Standard equipment EG additional equipment • Factory-Assembled Section Block • Tankless Water Heater (EG-35 – 65 PI and SP; EG-75 PI only) • Insulated Extended Jacket With tankless heater: Combination High Limit, Low Limit, • Draft Hood Circulator Control, and Relay with 40 VA Transformer •...
  • Page 40 — 4 — • • firEd boilErs sEriEs boilEr manual Part Number 550-110-639/0512...

This manual is also suitable for:

PegEghEg-30Eg-35Peg-30Peg-35 ... Show all

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