Table of Contents
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Boiler Manual
EG
PEG
EGH
EG & PEG
EGH
G a s - F i r e d
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.
, 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.
Series 5
Series 5
B o i l e r s
Part No. 550-142-782/1112
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Table of Contents
Related Manuals for Weil-McLain EG 5 Series
Summary of Contents for Weil-McLain EG 5 Series
- Page 1 EG & PEG Series 5 Series 5 G a s - F i r e d B o i l e r s Boiler Manual 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 — & SERIES SERIES FIRED BOILERS BOILER MANUAL 5HDG WKLV SDJH ÀUVW Hazard definitions Failure to adhere to the guidelines below can result in severe personal injury, death or sub- The following defined terms are used throughout this manual to stantial property damage.
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Page 3: Table Of Contents
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Contents Codes and Checklist ......... 4 Prepare boiler location . -
Page 4: Codes And Checklist
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Codes & Checklist Installation must follow these codes: Local codes, laws, provincial and national codes, laws, regulations and ordinances CSD-1, when required The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. -
Page 5: Prepare Boiler Location
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Prepare boiler location Recommended Service clearances EG, PEG & EGH -Service and combustible materials clearances 1. Provide minimum clearances for cleaning and servicing the boiler and for access to controls and components as EG, PEG &... -
Page 6: Flooring And Foundation
— & SERIES SERIES FIRED BOILERS BOILER MANUAL 1 Prepare boiler location (continued) Flooring and foundation Vent System Do not install boiler on combustible Failure to follow all instructions can result in flue gas spill- flooring or carpeting even if a concrete or age and carbon monoxide emissions, causing severe personal aerated foundation is used. - Page 7 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Prepare boiler location Vent System Air contamination (continued) 1. Please review the following information on potential Chimney or vent requirements combustion air contamination problems. 2. See Table 3 for products and areas which may cause installations must comply with B149.1 or B149.2 Installation Codes.
- Page 8 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Prepare the location Tight construction — Definition: Provide adequate combustion and ventilation air 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- less with openings gasketed.
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Page 9: Prepare The Boiler
— & SERIES SERIES FIRED BOILERS 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
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Prepare the boiler (continued) Hydrostatic pressure test Installation of optional indirect water Pressure test before attaching gas piping or electrical supply. heater 1. Plug any necessary boiler tappings or openings. 1. For a boiler ordered with internal type indirect water heater, 2. - Page 11 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Prepare the boiler (continued) Installation of side refractory -EGH only Installation of flue collector hood (Factory installed on PEG boilers) 1. See Figure 7b & 7d. Hardware for drawer assembly must Set flue collector hood on boiler as shown in Figure 6b. Use boiler be installed (See Figure 10), before sliding refractory in to cement furnished to provide gas-tight seal.
- Page 12 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Prepare the boiler (continued) EGH - Refractory placement & front base panel Front base panel (Factory installed on PEG boilers) )RXU UHIUDFWRU\ FOLSV ZLOO KROG UHIUDFWRU\ ´ +DUGZDUH IRU PRXQWLQJ IURQW Note! Silicone to be applied to and rear base panels needs to be in SODFH EHIRUH UHIUDFWRU\ SLHFHV OHIW...
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Page 13: Breeching Erection
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Prepare the boiler (continued) Installation of base shield - EGH only Draft hood installation Attach draft hood to flue collector hood using #10 x 1/2” sheet 1. See Figure 8, slide base shield under burner drawer assem- metal screws provided. -
Page 14: Connect Piping - Water Boilers
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Connect piping – water boilers – EG only General Minimum recommended pipe sizes Install the boiler jacket before connecting return piping. (Supply piping can be connected before or after jacket installation.) Connect controls after all piping is connected. - Page 15 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Connect piping – water boilers – EG only (continued) Use Figure 13 or Figure 14 only for systems designed for return water at least 130 °F. For systems with low return water temperature possible, such as con- When using 3-wire zone valves, install an isolation verted gravity systems and radiant heating systems, relay.
- Page 16 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Connect piping – water boilers – EG only (continued) 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.
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Page 17: Connect Piping - Steam Boilers
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Connect piping – steam boilers (continued) General Recommended piping for parallel-flow systems Failure to properly pipe the boiler may result in improper operation and damage to the boiler or building. Steam supply must be on same end as controls. Return may be from either end. - Page 18 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Connect piping – steam boilers (continued) Installing the relief valve Connection to counterflow steam piping Install relief valve in tapping on top of boiler. See Table 4, page 10, for control tapping locations. See the tag attached to the relief valve for manufacturer’s instructions.
- Page 19 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Connect piping – steam boilers (continued) Condensate return Recommended piping for parallel-flow systems with optional reservoir pipe Modern steam boilers are designed to steam for less time than older, larger boilers. When replacing an older steam boiler the system condensate return time may be longer than the steaming time.
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Page 20: Install Boiler Controls
No. 93 ´ pump. 3. Install remaining controls as shown in Table 4 and LWCO model numbers are manufacturer’s part Figure 5, page 10. numbers that can be found in the Weil-McLain Trade Price Schedule. Part Number 550-142-782/1112... -
Page 21: Connect Piping - Tankless Heater
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Connect piping – tankless heater (optional) EG and EGH boilers for tankless heater applica- Minimum recommended pipe sizes tion are available only on special order as factory- installed optional equipment. Standard boilers cannot be adapted for heater use. -
Page 22: Connect Gas Supply Piping
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Connect gas supply piping Connecting gas supply piping 6. Pipe joint compound (pipe dope) must be resistant to cor- rosive action of liquefied petroleum gases. Apply sparingly 1. Size gas piping considering only to make threads of pipe joints. -
Page 23: Rqqhfw Àhog Zlulqj Wr Erlohu
— & SERIES SERIES FIRED BOILERS BOILER MANUAL &RQQHFW ÀHOG ZLULQJ WR ERLOHU For your safety, turn off electrical power supply at ser- 5. Multiple zones — Refer to zone valve manufacturer’s literature vice entrance panel before making any electrical con- for wiring and application. -
Page 24: Start-Up
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Start-up Wiring multiple zones Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting Refer to zone valve manufacturer’s literature for wiring in substantial property damage. and application. - Page 25 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Start-up (continued) Skim the steam boiler Operate boiler Clean all newly installed steam boilers to Check system and boiler remove oil and grease. Failure to properly clean can result in violent fluctuations DO NOT proceed with boiler operation unless boiler and of water level, water passing into steam system have been filled with water and all instructions and...
- Page 26 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Start-up (continued) If boiler doesn’t start . . . Check for: Typical pilot burner flame 1. Loose connections, blown fuse or service switch off? 2. High limit switch set below boiler pressure? 3.
- Page 27 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Start-up (continued) ❏ Check-out procedure Set Boiler Temp adjustment knob to system temperature requirements. Adjust balancing valves and controls to pro- Check-off steps as completed. vide design temperature to system. (water boilers) ❏...
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Page 28: Department Of Energy - Compliance
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Department of Energy – Compliance EG water boilers only This boiler is equipped with a control system that automatically adjusts a time delay period to turn on the boiler during a call for heat. This is accomplished by circulating available hot water in the system while measuring water boiler water temperature changes. -
Page 29: Service And Maintenance
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Service and maintenance Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) Daily Check boiler area Inspect: Check air openings Reported problems Check boiler pressure/ Boiler area temperature gauge Air openings Monthly... - Page 30 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Service and maintenance (continued) The boiler should be inspected and started annu- Piping ally, at the beginning of the heating season, only 1. Check the boiler interior piping and all system piping for signs by a qualified service technician.
- Page 31 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Service and maintenance (continued) ❏ Probe-type low water cutoff (when used) Clean probe-type low water cutoff (when used) for proper Gauge glass (steam boilers) operation. Normal waterline is halfway up gauge 1. Turn off power to boiler and wait 5 minutes. glass.
- Page 32 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Service and maintenance (continued) ❏ ❏ 1. Review the User’s Information Manual with the owner. Boiler relief valve 2. Emphasize the need to perform the maintenance schedule speci- 1. After following the warning directions below, if the fied in the User’s Information Manual (and in this manual as well).
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Page 33: Dqgolqj Àehujodvv Dqg Fhudplf Àehu Pdwhuldov
— & SERIES SERIES FIRED BOILERS BOILER MANUAL +DQGOLQJ ÀEHUJODVV DQG FHUDPLF ÀEHU PDWHULDOV 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 34: Replacement Parts - Eg/Peg
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Replacement parts — EG/PEG EG/PEG replacement parts Item Description Boiler Part Number Item Description Boiler Part Number Models Models /HIW KDQG HQG VHFWLRQ ZLWK KHDWHU RSHQLQJ EG-30, 35 451-800-000 –– 311-800-014 Front base panel 3DWWHUQ 1R EG-40, 45 451-800-001... - Page 35 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Replacement parts — EG/PEG (continued) The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on of this manual. Failure to comply could result in severe personal injury. page 33 Part Number 550-142-782/1112...
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Page 36: Replacement Parts - Egh
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Replacement parts — EGH EGH replacement parts Item Description Boiler Part Number Item Description Boiler Part Number Models Models /HIW KDQG HQG VHFWLRQ ZLWK KHDWHU RSHQLQJ –– 311-800-014 &RYHU SODWH IRU KHDWHU RSHQLQJ UHFWDQJXODU 389-900-103 ––... - Page 37 — & SERIES SERIES FIRED BOILERS BOILER MANUAL Replacement parts — EGH (continued) The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on of this manual. Failure to comply could result in severe personal injury. page 33 Part Number 550-142-782/1112...
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Page 38: Dimensional Data
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Dimensional data Dimensional data Gas Connection Draft hood Approx. Dimensions Model Supply Supply “F” outlet size ship. wt. 6HH QRWH IRU 3(* WR 3(* FUDWH GLPHQVLRQV number EG/EGH EG/EGH QRWH OEV QRWH EG &... -
Page 39: Ratings
1.15; steam ratings on an allowance of 1.333. An additional allow- EG-75 82.7 82.4 ance should be made for unusual piping and pick-up loads. Consult local Weil-McLain representative. Part Number 550-142-782/1112... -
Page 40: Standard And Optional Equipment
— & SERIES SERIES FIRED BOILERS BOILER MANUAL Standard and optional equipment Standard equipment EG additional equipment Factory-Assembled Section Block Tankless Water Heater Insulated Extended Jacket With tankless heater: Combination High Limit, Low Limit, Circu- Draft Hood Aluminized Steel Burners Tankless Steam Heater Non-Linting Pilot Burner With Tankless Heater: Operating Control and Tankless Heater...