Weil-McLain 4 Series Manual
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Weil-McLain 4 Series Manual

Gas-fired boilers, control supplement – universal control systems
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Control supplement – Universal control systems
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
PEG
•
Gas-Fired Boilers – Series 4
EGH
•
For additional information, refer to . . .
EG• PEG• EGH Boiler manual
for Natural or Propane gas
(tankless heater application optional)
Before installing
Part Number 550-110-646/0607
, read all

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Summary of Contents for Weil-McLain 4 Series

  • Page 1 • • Gas-Fired Boilers – Series 4 Control supplement – Universal control systems For additional information, refer to . . . EG• PEG• EGH Boiler manual for Natural or Propane gas (tankless heater application optional) Before installing This supplement must only be used by a qualified heating installer/service technician. , read all instructions, including this supplement, the boiler manual and any related documents. Perform steps in the order given.

  • 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

    Universal control systems — Control supplement Table of contents Hazard definitions and Note to the installer ..................2 Control installation — EG-30 through EG-75 water boilers without tankless heaters .... 4-5 Control installation — EG-30 through EG-75 water boilers with tankless heaters ....6-7 Control installation —...

  • Page 4: Control Installation - Eg-30 Through Eg-75 Water Boilers Without Tankless Heaters

    Part Number 550-110-646/0607...
  • Page 5 Universal control systems — Control supplement Control installation EG-30 through EG-75 water boilers without tankless heaters For your safety, turn off electrical power 1. Mount and wire controls per wiring diagram, page , and Figure 1. supply and turn off external gas supply a. Attach junction box inside left jacket panel with #8- x ½” machine screws valve before attempting to work on the provided. boiler. Failure to comply can cause severe b. Install transformer with plug-in relay receptacle and relay. personal injury, death or substantial prop- c. Operating and limit circuit wiring must be 18 gauge or heavier.

  • Page 6: Control Installation - Eg-30 Through Eg-75 Water Boilers With Tankless Heaters

    Part Number 550-110-646/0607...
  • Page 7 Universal control systems — Control supplement Control installation continued EG-30 through EG-75 water boilers with tankless heaters For your safety, turn off electrical power 1. Mount and wire controls per wiring diagram, page , and Figure . supply and turn off external gas supply a. Install combination limit control and relay in tapping. See Boiler Manual valve before attempting to work on the control tapping table. Operating and limit circuit wiring must be 1 gauge boiler. Failure to comply can cause severe or heavier. personal injury, death or substantial prop- . Bring supply wiring to boiler. Must be 1 gauge or heavier.

  • Page 8: Control Installation - Eg And Peg Steam Boilers With Probe-Type Low Water Cutoff

    Part Number 550-110-646/0607...
  • Page 9 Universal control systems — Control supplement Control installation continued EG and PEG steam boilers with probe-type low water cut-off For your safety, turn off electrical power 1. Mount and wire controls per wiring diagram, page 8, and Figure . supply and turn off external gas supply a. Attach junction box inside left jacket panel with #8- x ½” machine screws valve before attempting to work on the provided. boiler. Failure to comply can cause severe b. Install transformer with plug-in relay receptacle and relay.

  • Page 10: Control Installation - Eg Steam Boilers With Float-Type Low Water Cutoff

    Part Number 550-110-646/0607...
  • Page 11 Universal control systems — Control supplement Control installation continued EG steam boilers with float-type low water cut-off For your safety, turn off electrical power 1. Mount and wire controls per wiring diagram, page 10, and Figure . supply and turn off external gas supply a. Attach junction box inside left jacket panel with #8- x ½” machine screws valve before attempting to work on the provided. boiler. Failure to comply can cause severe b. Install transformer with plug-in relay receptacle and relay. personal injury, death or substantial prop- c. Operating and limit circuit wiring must be 18 gauge or heavier.

  • Page 12: Control Installation - Egh Water Boilers Without Tankless Heaters

    Part Number 550-110-646/0607...
  • Page 13 Universal control systems — Control supplement Control installation continued EGH water boilers without tankless heaters For your safety, turn off electrical power 1. Mount and wire controls per wiring diagram, page 1, and Figure . supply and turn off external gas supply a. Attach junction box inside left jacket panel with #8- x ½” machine screws valve before attempting to work on the provided. boiler. Failure to comply can cause severe b. Install transformer with plug-in relay receptacle and relay. personal injury, death or substantial prop- c. Operating and limit circuit wiring must be 18 gauge or heavier. erty damage.

  • Page 14: Control Installation - Egh Water Boilers With Tankless Heaters

    Part Number 550-110-646/0607...
  • Page 15 Universal control systems — Control supplement Control installation continued EGH water boilers with tankless heaters For your safety, turn off electrical power 1. Mount and wire controls per wiring diagram, page 1, and Figure . supply and turn off external gas supply a. Install combination limit control and relay in tapping. See Boiler Manual valve before attempting to work on the control tapping table. Operating and limit circuit wiring must be 1 gauge boiler. Failure to comply can cause severe or heavier. personal injury, death or substantial prop- . Bring supply wiring to boiler. Must be 1 gauge or heavier. erty damage.

  • Page 16: Control Installation - Egh Steam Boilers With Probe-Type Low Water Cut-Off

    Part Number 550-110-646/0607...
  • Page 17 Universal control systems — Control supplement Control installation continued EGH steam boilers with probe-type low water cut-off For your safety, turn off electrical power 1. Mount and wire controls per wiring diagram, page 1, and Figure . supply and turn off external gas supply a. Attach junction box inside left jacket panel with #8- x ½” machine screws valve before attempting to work on the provided. boiler. Failure to comply can cause severe b. Install transformer with plug-in relay receptacle and relay. personal injury, death or substantial prop- c. Operating and limit circuit wiring must be 18 gauge or heavier.

  • Page 18: Control Installation - Egh Steam Boilers With Float-Type Low Water Cut-Off

    Part Number 550-110-646/0607...
  • Page 19 Universal control systems — Control supplement Control installation continued EGH steam boilers with float-type low water cut-off For your safety, turn off electrical power 1. Mount and wire controls per wiring diagram, page 18, and Figure 8. supply and turn off external gas supply a. Attach junction box inside left jacket panel with #8- x ½” machine screws valve before attempting to work on the provided. boiler. Failure to comply can cause severe b. Install transformer with plug-in relay receptacle and relay. personal injury, death or substantial prop- c. Operating and limit circuit wiring must be 18 gauge or heavier.

  • Page 20: Damper Installation

    Installation Damper must be installed directly on top of draft hood so that it serves only that boiler. Do not modify draft hood or . Read and apply the harness plug warning label damper, or make another connection between draft hood and (Figure 10) so that it is visible after installation. damper or boiler except as noted below. This will void CSA . Plug damper harness receptacle into damper harness certification and will not be covered by Weil-McLain war- plug. ranty. Any changes will cause severe personal injury, death, or substantial property damage. Bypassing (jumpering) vent damper will 1. Install plug (packed in damper carton of ” through 8” dampers) in cause flue products such as carbon mon- hole in damper blade. oxide to escape into the house. This will cause severe personal injury or death. . Install vent damper horizontally or vertically as shown in vent damper manufacturer’s instructions. Vent damper must be installed so that it...

  • Page 21: Checkout Procedure

    Universal control systems — Control supplement Checkout procedure 1. See pages – for “Operating 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 22: Operating Instructions

    EG • PEG • EGH Series 4 EG and PEG with Operating instructions – Honeywell VR8204/VR8304 gas valve Part Number 550-110-646/0607...
  • Page 23 Universal control systems — Control supplement EG/PEG-30 through EG/PEG-50 with Operating instructions – White-Rodgers 36E gas valve Part Number 550-110-646/0607...
  • Page 24 EG • PEG • EGH Series 4 EG/PEG-30 through EG/PEG-50 with Operating instructions – Robertshaw 7200 gas valve Part Number 550-110-646/0607...
  • Page 25 Universal control systems — Control supplement EG/PEG-55, EG/PEG-65, EG-75 with Operating instructions – White-Rodgers 36C gas valve Part Number 550-110-646/0607...
  • Page 26 EG • PEG • EGH Series 4 with Operating instructions – Robertshaw 7000DERHC gas valve Part Number 550-110-646/0607...

  • Page 27: Troubleshooting

    Universal control systems — Control supplement Troubleshooting In event of vent damper failure: Burner access panel must be in posi- tion during boiler operation to prevent momentary flame rollout on ignition of Effikal or Field Controls vent damper main flame. Severe personal injury or If troubleshooting chart recommends replacing actuator and actuator is substantial property damage will result.
  • Page 28 EG • PEG • EGH Series 4 Troubleshooting continued CHART 1: NO SPARK — System does not work — Without vent damper VISUALLY CHECK - is ground wire connected from “GND (Burner)” to ignition control mounting screw; and ground wire connected from transformer Terminal “C”...
  • Page 29 Universal control systems — Control supplement Troubleshooting continued CHART 2: NO SPARK — System does not work — With vent damper Is damper harness securely plugged in at both ends? Secure connections. Is 24VAC present across terminals C and Y on transformer? Check for loose wire connections or bad relay on transformer.
  • Page 30 EG • PEG • EGH Series 4 Troubleshooting continued CHART 3: PILOT LIGHTS — Main valve will not come on — With or without vent damper Does spark stay on for more than a few seconds after pilot is established? Is 24VAC between terminals MV and Make sure sense wire is not wrapped around any pipes or PV on ignition control?
  • Page 31 Universal control systems — Control supplement Troubleshooting continued CHART 3 : Procedure to check system grounding (continued) Pilot assembly and ignition control must share common ground • Check ground lead from “GND (Burner)” terminal on ignition with main burner. Nuisance shutdowns are often caused by control to ignition control mounting screw, and from “C”...

  • Page 32: Replacement Parts

    EG • PEG • EGH Series 4 Replacement parts Only dampers listed below are approved for use on EG, PEG and EGH Series  boilers. Any other damper installed can cause severe personal injury or death. Description Manufacturer / Weil-McLain Mfr’s part number part number Damper 5” — EG-30, EG-35, PEG-30, PEG-35 Effikal RVGP-KS-5BKF 381-800-475 assembly Johnson Q35GD-2 6” — EG-40, EG-45, PEG-40, PEG-45 Effikal RVGP-KS-6BKF...

This manual is also suitable for:

Eg seriesPeg seriesEgh seriesEg-30Eg-35Peg-30 ... Show all

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