Weil-McLain EG User Manual
EGEG
EG
EGEG
Gas-fired Boilers — Series 4
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EGHEGH
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• Installation
• Operation
EG
• Service
• Boiler Parts
For additional information,
refer to . . .
Control Supplement
and Gas Control Parts
for Natural or Propane gas
with optional tankless heater
application
EGH
Read all instructions before installing
Installer Leave all instructions with boiler for future reference.
Any claims for damage or shortage in shipment must be filed
immediately against the transportation company by the consignee.
Owner Installation and service should be performed by qualified service
technician.
Part No. 550-110-639/0703
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL
Contents
Installation .............................................................................................3
Piping Connections................................................................................9
Install Boiler Controls..........................................................................12
Optional Heaters .................................................................................13
Gas Piping............................................................................................14
Wiring ...................................................................................................15
Final Adjustments................................................................................16
Check Out Procedure ..........................................................................18
Service..................................................................................................19
Replacement Parts...............................................................................22
Data ......................................................................................................26
Ratings .................................................................................................27
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various
risk levels, or to important information concerning the life of the product.
Indicates presence of hazards that will cause severe personal injury, death or substantial property
damage.
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.
The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per
instructions on page 19 of this manual. Failure to comply c ould result in severe personal injury .
Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to system
components can result, causing substantial property damage.
Read all instructions before installing. Failure to follow all instructions in proper order can cause severe
personal injury, death or substantial pro perty damage.
When calling or writing about the boiler— Please have the boiler model number from the boiler rating
label and the CP number from the boile r jacket. You may list the CP number in the space pr ovided on
the Installation and service certificate found on page 18.
Important
EG and EGH boilers for tankless or storage heater application are available only on special order as factory-installed
optional equipment. T ankless heat er cannot be added to standard block assembl y . Block assemb ly must be ordered
with heater openings. Standard boilers cannot be adapted for heater use.
2
Part Number 550-110-639/0703
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL
Installation
Codes
Installations must comply with all local codes, laws,
regulations and ordinances. Also National Fuel Gas Code
ANSI Z223.1-latest edition. When required, installations
must conform to Standard for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME
CSD-1. Safe lighting and other performance criteria were
met with the gas manifold and control assembly provided
on boiler when boiler underwent tests specified in ANSI
Z21.13-latest edition.
Canadian installations must comply with CAN/CSA
B149.1 or .2 Installation Codes. The equipment shall be
installed in accordance with those installation regulations
in force in the local area where the installation is to be
made. These shall be carefully followed in all cases.
Authorities having jurisdiction shall be consulted before
installations are made.
Combustion air and ventilation
openings
Combustion air and ventilation openings must comply
with Section 5.3, Air fo r Combustion and Ventilation, of
National Fuel Gas Code ANSI-Z223.1-latest edition, or
applicable building codes. Canadian installations must
comply with CAN/CSA B149.1 or .2 Installation Codes.
Provide adequate combustion and
ventilation air to:
• Assure proper combustion
• Reduce risk or severe personal injury
or death from flue gas spillage and
carbon monoxide emissions.
Do not install an exhaust fan in the boiler
room.
Boiler installation must assure sufficient openings in
building and boiler room to provide adequate combustion
air and ventilation. Consider construction tightness of
building when deciding whether additional outside
openings may be needed.
Older buildings with single-pane windows, minimal
weatherstripping and no vapor barrier often provide
enough natural infiltration and ventilation without
dedicated openings.
New construction or remodeled buildings are most often
built tighter. Windows and doors are weatherstripped,
vapor barriers are used and openings in walls are caulked.
As a result, such tight construction is unlikely to allow
proper natural air infiltration and ventilation.
Air from inside building (boiler in interior room):
• Tightly constructed buildings must be provided with
openings to outside for combustion and ventilation
air. These o penings must be sized to handle all fuel
burning appliances, exhaust and ventilation fans and
fireplaces.
• When openings to boiler room are taken to interior
spaces, provide two permanent openings: a
combustion air opening within 12 inches of floor
and a ventilation opening within 12 inches of ceiling.
Each opening must provide a minimum free area of
one square inch per 1,000 Btuh input of all appliances
in room plus requirements for any exhaust fans in
room. The interior space supplying combustion and
ventilation air must have adequate infiltration from
outside.
Air directly from outside to boiler room:
• Tightly constructed buildings must be provided with
combustion air and ventilation openings to boiler
room which are adequate to handle the boiler needs
plus the needs of all other fuel-burning appliances,
fireplaces and exhaust or ventilation fans.
• Combustion and ventilation openings connecting
directly or by ducting to outside, or to attic or crawl
spaces that freely connect with outside, must be sized
as follows:
1. Outside wall or vertical ducting - one square
inch per 4,000 Btuh input of all appliances in
room plus requirements for any exhaust fans
or other appliances in room.
2. Horizontal ducting - one square inch per 2,000
Btuh of all appliances in room plus
requirements for any exhaust fans or other
appliances in room.
3. All ducting must be same size as permanent
openings. Minimum area dimensions of
ducting must be no less than 9 square inches.
4. Other size ducting must comply with local
codes.
Part Number 550-110-639/0703
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL
Installation
(continued)
Chimney or vent requirements
(also refer to Breaching erection, Page 8)
V enting must be installed acc ording to Pa rt 7, Venting of
Equipment, of National Fuel Gas Code ANSI Z223.1latest edition and applicable building codes. Canadian
installations must comply with CAN/CSA B149.1 or .2
Installation Codes.
Minimum chimney or vent sizes are on page 27 of these
instructions. A chimney or vent without a listed cap
should extend at least 3 feet above the highest point where
it passes through a roof of a building and at least 2 feet
higher than any portion of a building within a horizontal
distance of 10 feet. A chimney or vent must not extend
less than those distances stated above.
A lined chimney is preferred and must be used when
required by federal, provincial, territorial, state, or local
building codes. Vitreous tile linings with joints that
prevent retention of moisture and linings made of
noncorrosive materials are best. Advice for flue
connections and chimney linings can be obtained from
local gas utility. T ype “B” double wall metal vent pipe or
single wall vent pipe may be used as a liner.
Cold masonry chimneys, also known as outside
chimneys, typically have one or more walls exposed to
outside air .
When any atmospheric gas-fired boiler with automatic
vent damper is vented thr ough this type of chimney, the
potential exists for condensation to occur . Condensation
can damage a masonry chimney.
Weil-McLain recommends the following to prevent
possible damage:
1. Line chimney with corrosion-resistant metal liner
such as AL29-4C® single wall stainless steel or B-vent.
Size liner per National Fuel Gas Code ANSI Z223.1-latest
edition.
2. Provide drain trap to remove any condensate.
Inspect existing chimney or vent before
installing boiler. Failure to clean or replace
perforated pipe or tile lining will cause
severe injury or death.
Do not alter boiler draft hood or place any
obstruction or non-approved damper in
the breeching of vent system. CSA
certification becomes void. Flue gas spillage
and carbon monoxide emissions will occur
causing severe personal injury or death.
When removing boiler from common venting
system
Failure to follow all instructions listed below can cause flue gas
spillage and carbon monoxide emissions, resulting in severe
personal injury, death or substantial property damage.
At the time of removal of an existing boiler, the following steps shall be
followed with each appliance remaining connected to the common venting
system placed in operation, while the other appliances remaining connected
to the common venting system are not in operation.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and horizontal pitch and
determine there is no blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
c. Insofar as is practical, close all building doors and windows and all doors
between the space in which the appliances remaining connected to the
common venting system are located and other spaces of the building. Turn
on clothes dryers and any appliance not connected to the common venting
system. Turn on any exhaust fans, such as range hoods and bathroom exhausts,
so they will operate at maximum speed. Do not operate a summer exhaust
fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow the lighting
instructions. Adjust thermostat so applianc e will operate continuously.
e. Test for spillage at the draft hood relief opening after 5 minutes of main
burner operation. Use the flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
f. After it has been determined that each appliance remaining connected to
the common venting system properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace dampers, and any other gasburning appliance to their previous conditions of use.
g. Any improper operation of the common venting system should be corrected
so the installation conforms with the National Fuel Gas Code, ANSI Z223.1latest edition. When resizing any portion of the common venting system,
the common venting system should be resized to approach the minimum
size as determined using the appropriate tables in Part 11 in the National
Fuel Gas Code, ANSI Z223.1-latest edition.
Canadian installations must comply with CAN/CSA B149.1 or .2 Installation
Code.
Select the boiler location
• Consider all connections to boiler before selecting a location.
• Boiler must be installed so gas control system components are protected
from dipping or spraying water or rain during operation or service.
• Non-combustible floor ONL Y. See “Boiler foundation ”, P age 5.
T o a void personal injury , death or prope rty damage, keep boiler
area clear and free from combustible materials, gasoline and
other flammable vapors and liquids.
Where two or more gas appliances vent into a common
chimney or vent, equivalent area should be at least equal
to the area of the vent outlet on the largest appliance plus
50 percent of the area of the vent outlet on the additional
appliance.
4
Part Number 550-110-639/0703
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL
Installation
(continued)
Installation clearances
Suggested minimum clearances for servicing
• 24 inches for cleaning and servicing, left side.
• 18 inches for access to controls and components, front.
• 46 inches from top for cleaning flueways.
• 6 inches on remaining sides.
Required minimum clearances to combustible material in
alcove installations
T op 46" R. Side 4" Front: Alcove
Rear 6" L. Side 4"
EGH 105-125: Provide service clearances listed above and minimum 24"
between jacket and any combustible wall(s) and ceiling.
Install in space large in comparison to size of boiler.
• Single wall vent pipe must be at least 6 inches from combustible material.
• Type "B" double wall metal vent pipe - refer to vent manufacturer's
recommendation for clearances to combustible material.
• Hot water pipes must be at least ½" from combustible material.
Residential garage installation
Install boiler so burners are at least 18 inches abov e the floor .
Figure 1 Boiler foundation
Boiler foundation
Never install boiler on combustible flooring or carpeting, even if
a concrete or aerated foundation is used. Severe personal injury,
death or substantial property damage can result.
1. See Figure 1. A level concrete or solid brick pad is required if:
a) There is a possibility of the floor becoming flooded.
b) Non-level conditions exist.
2. An aerated boiler foundation is recommended if any of the following
conditions exist:
a) Electrical wiring or telephone cables buried in the concrete floor of the boiler
room.
b) Concrete floor is "green."
c) There is a history of the floor becoming flooded.
d) Water is channeled under the concrete.
Placing the boiler
Block assembly is extremely heavy. Handle with caution to avoid
personal injury.
Where the EGH block assembly is taken apart for handling:
1. Put a support under center of block. Support must be within 1/2 inch of
block bottom.
2. Remove short center draw rods.
3. Tip half blocks on end as shown in Figure 2. Save elastomer sealing rings and
cope seal between sections.
Figure 2
4. After moving half-blocks into desired location, clean
port surfaces with clean, dry rag. Do not use oil. Place
sealing rings in recessed ports. Place cope seal in section
grooves.
5. Re-assemble block in reverse order. When drawing
sections together , use 45 ( ± 5) ft-lbs tor que.
Installation of optional indirect
water heater
For a boiler ordered with internal type indirect water heater ,
remove heater opening cover plate (water boilers - round
plate on left side; steam boilers - rectangular plate on front).
Install heater(s) as shown on pages 13. Do not over tighten
studs and nuts - damage to the gasket can occur ..
Part Number 550-110-639/0703
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL
Installation
Figure 3
(continued)
Hydrostatic pressure test
Pressure test before attaching gas piping or electrical supply .
1. Plug any necessary boiler tappings or openings.
2. Do not use gauge supplied with boiler for pressure testing. Install gauge with
appropriate range.
3. Fill boiler with water . V ent all air . Test steam boilers between 45 - 55 psi and
water boilers at 1-1/2 times working pressure.
Do not leave boiler unattended. A cold water fill could expand
and cause excessive pressure, resulting in severe personal injury,
death or substantial property damage.
4. Check for maintained gauge pressure and leaks. Repair if found.
Leaks must be repaired at once. Failure to do so can cause boiler
damage, resulting in substantial property damage.
Do not use petroleum-based sealing compounds in boiler system.
Severe damage to boiler will result, causing substantial property
damage.
5. Drain boiler and repair leaks if found.
6. Retest boiler after repairing leaks.
7. Remove plugs from any tappings that will be used for controls and accessories.
Refer to control tapping table and Figure 3.
8. On initial start-up check for leaks in the system piping. If found, repair at
once.
Installation of flue collector hood
(Factory installed on PEG boilers)
Set flue collector hood on boiler as shown in Figure 4.
Use boiler cement furnished to provide gas-tight seal.
Failure to maintain gas-tight seal can cause
flue gas spillage and carbon monoxide
emissions, resulting in severe personal
injury or death.
Figure 4 Flue collector hood
Installation of front and back base
panels (Factory installed on PEG boilers)
See Figure 5 for installation. Fasten front (6 1/8 inch) and
back 7 5/16 inch) base panels to sections. Seal with boiler
cement along top of insulation panels.
Failure to maintain gas-tight seal can cause
flue gas spillage and carbon monoxide
emissions, resulting in severe personal
injury or death.
6
Part Number 550-110-639/0703
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL
Installation
Figure 5 Front and back base panels
Installation of drawer assembly
and front access panel and back
base channel
steps 2 and 3)
1. The drawer assembly consists of the burner drawer ,
main burners, gas manifold, pilot burner, etc. See
Figures 6, 7 and 8 for installation.
2. Check for proper orifice sizing fro m chart below.
(continued)
Figure 6 Burner drawer assembly
Figure 7 Pilot burner location
(Factory installed on PEG boilers - follow
Proper orifices must be used. Failure to do
so will cause severe personal injury, death
or substantial property damage.
3. Level and straighten burners.
Burners must be properly seated in slots in
back burner support with openings facing
up. Gas orifices must inject down center of
burner. Failure to properly seat burners
will result in severe personal injury, death
or substantial property damage.
4. Install front access panel and back base channel. See
Figure 9.
5. Install rollout thermal fuse element with wire
terminals facing up on front access panel of EG 30-75
boilers only as shown in Figure 9. Wire per Control
Supplement.
Figure 8 Burner drawer installation
Figure 9 Access panel
Part Number 550-110-639/0703
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL
Installation
Jacket installation (Factory installed on PEG
boilers)
1. Remove the proper knockout discs from panels as
shown in tapping table, page 6.
2. Follow Jacket Instructions in jacket carton.
Draft hood installation
Attach draft hood to flue collector hood using #10 x 1/2"
sheet metal screws provided. Use boiler cement furnished
to provide gas tight seal.
(continued)
Tankless and storage heater knockouts
must be removed for EG and EGH boilers
with optional tankless heaters prior to
jacket installation.
Failure to maintain gas-tight seal can cause
flue gas spillage and carbon monoxide
emissions, resulting in severe personal
injury or death.
Do not alter boiler draft hood or place any
obstruction or non-approved damper in
the breeching or vent system. A.G.A. and
C.S.A. certifications will become void. Flue
gas spillage and carbon monoxide
emissions will occur causing severe
personal injury or death.
Spill switch installation
On EG 30-75 boilers only, fasten spill switch to draft
hood as shown on page 22, Drawing Ref. Letter “K”.
Connect wires as shown in Control Supplement.
Damper installation
If damper will be installed, see Control Supplement for
information.
Breeching erection
Connect from draft hood or damper outlet to chimney
or vent with same size breeching. Where possible, vertical
venting to the outside from draft hood or damper outlet
will offer best performance. Where horizontal breeching
is used, slope upward at least 1/4 inch per lineal foot
toward chimney or vent and support with hangers to
prevent sagging.
A vertical height of 3 feet to 5 feet of
breeching before any elbow or horizontal
breeching is recommended to reduce
chances of flue gas spillage at draft hood
on EGH-95 thru -125 boilers (not
restricted on any EG or EGH-85). Long
horizontal breechings, excessive numbers
of elbows or tees, or other obstructions
which restrict the flow of combustion gases
should be avoided.
Figure 10 Draft hood
Breeching must not be connected to any portion of a
mechanical draft system operating under positive
pressure.
Seal across back of
block assembly with
boiler cement between
cast iron and sheet
metal edge of draft hood
8
Part Number 550-110-639/0703
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL
Piping connections
Pipe before installing controls. Connect return piping
after jacket is attached. Connect supply piping before or
after jacket is attached.
Failure to properly pipe the boiler may
result in improper operation and damage
to the boiler or building.
Forced hot water boilers and
gravity hot water boilers (EG Only)
1. T o protect:
• radiant panels, plaster, etc. from high temperature water
supplied from boile r, or
• boiler from condensation caused by low temperature
water returned from system.
2. To protect boiler from condensation formed by low
water temperature returned from large water content
converted gravity systems, etc., see Figure 4, page 6.
Refer to tables and Figures 11a and 11b.
1. Circulator must be selected and sized according to
the design requirements of the system. Size expansion
tank to handle the volume of water in the system.
2. Small expansion tanks cause system water to be lost
from relief valve. Make-up water is then added
Figure 11a Recommended piping connections
forced hot water boilers with closed
type expansion tanks
through fill valve. Eventual section failure can result.
Expansion tank installation:
a) Closed type expansion tank - connect from the 3/4"
N.P.T. tapping on left end section to expansion tank
using 3/4" N.P.T. piping. Any horizontal piping must
pitch upward toward tank at least 1 inch per 5 feet of
piping.
b) Diaphragm type expansion tank - may be located
anywhere in the system, preferably near the boiler . Install
automatic air vent as shown in Figure 11b.
3. Install water relief valve vertically in “E” tapping.
Relief valve discharge piping must be piped
near floor close to floor drain to eliminate
potential of severe burns. Do not pipe to
any area where freezing could occur. Do
not plug, valve or place any obstruction in
discharge line.
4. Connect system return piping to left end for EG -
right or left for EGH. Supply and return must be on
same end of EGH boiler, for proper flow and
disposition of water throughout the sections.
5. Installer must provide drain cock(s).
6. Connect cold water fill supply piping close t o boiler.
7. Plug all unused tappings.
Figure 11b Recommended piping connections
forced hot water boilers with
diaphragm type expansion tanks
Part Number 550-110-639/0703
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