Page 1
Gas-fired
water boiler
PFG
• Installation
• Service
Series 7
• Operation
• Parts
For additional information,
refer to . . .
Control Supplement
Read all instructions before installing
This manual must only be used by a qualified heating installer/service technician.
Read all instructions before installing. Perform steps in the order given. Failure
to comply could result in severe personal injury, death or substantial property
damage.
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 must be performed by qualified contractor.
Part No. 550-110-641/0605
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Contents
Section I: Installation 2-14
Codes ................................................................. 2
Combustion air and ventilation openings............ 3
Select the boiler location .................................... 3
Installation clearances ........................................ 3
Chimney or vent requirements ........................... 4
When removing boiler from common vent .......... 4
Boiler foundation ................................................ 5
Placing the boiler ................................................ 5
Residential garage installation ........................... 5
Hydrostatic pressure test .................................... 5
Boiler piping connections . . ............................... 6
Recommended piping ........................................ 6
Multiple zoning ................................................... 7
Filling the system ................................................ 7
Bypass piping ..................................................... 8
External heat exchangers ................................... 9
Freeze protection ................................................ 9
Using with refrigeration system .......................... 9
Size and install gas piping ........................... 10-11
Draft hood installation ....................................... 12
Spill switch installation ...................................... 12
Damper installation ........................................... 12
Breeching erection ........................................... 12
Wiring ............................................................... 12
Install room thermostat ..................................... 12
Wiring multiple zones ....................................... 13
Canadian installations – chain and s-hook ....... 13
Checkout procedure ......................................... 14
Section II: Service 15-19
Section III: Replacement Parts 20-21
Section IV: Ratings, Dimensions 22-23
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.
Read before proceeding
The boiler contains ceramic fiber and fiberglass materials.
Use care when handling these materials per instructions on
page 15 of this manual. Failure to comply could 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 property 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 boiler jacket. You may list the
CP number in the space provided on the
Installation and service certificate
found on page 14.
Codes
Installation must comply with all local codes, laws,
regulations and ordinances. Also United States National
Fuel Gas Code ANSI Z223.1-latest edition. When required, the installation 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 the boiler when the
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.
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Section I: Installation
Combustion air and ventilation openings
Combustion air and ventilation openings must comply with Section 5.3, Air for Combustion and Ventilation, of National Fuel
Gas Code ANSI Z223.1-latest edition, or applicable local building codes. Canadian installations must comply with CAN/CSA
B149.1 or .2 Installation Codes.
Provide adequate combustion and ventilation air to:
• Ensure 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 ensure 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 weather stripped, 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.
Select the boiler location
• Consider all connections to boiler before selecting a location.
• Boiler must be installed so gas control system components are pro
tected from dripping or spraying water or rain during operation or
service.
• Non-combustible floor ONLY. See “Boiler foundation”, Page 5.
To avoid personal injury, death or property damage,
keep boiler area clear and free from combustible
materials, gasoline and other flammable vapors
and liquids.
Installation clearances
Suggested minimum clearances for servicing
• 24 inches for cleaning and servicing, left side.
• 18 inches for access to controls and components, front.
• 48 inches from top for cleaning flueways.
• 6 inches on remaining sides.
PFG-5 through PFG-7: Required minimum clearances
to combustible surface in alcove installations (see
below)
PFG 5 thru 7: Top 42” R. Side 5” Front: Alcove 18”
Rear 5” L. Side 5”
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Air from inside building (boiler in interior room):
• Tightly constructed buildings must be provided with openings to
outside for combustion and ventilation air. These openings 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 appli
ances in room plus requirements for any exhaust fans or other
appliances in room.
3. All ducting must be same size as permanent openings. Minimum
size of ducting must be no less than 9 square inches.
4. Other size ducting must comply with local codes.
PFG-8: Required minimum clearances to combustible
surfacel in alcove installations
PFG 8: Provide minimum 24” between jacket and any com
bustible wall(s). Provide minimum 48” between jacket top and
combustible ceiling or surface above the boiler.
Install in a space large in comparison to size of boiler.
Clearances from piping materials to combustible surfaces
• Single wall vent pipe must be at least 6 inches from combustible
surface.
• Type “B” double wall metal vent pipe - refer to vent manufacturer’s
recommendation for clearances to combustible surface.
• Hot water pipes must be at least ½” from combustible surface.
Note Minimum clearances from combustible
surfaces for models PFG-5 through PFG-7
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Chimney or vent requirements
(also refer to Breaching erection, Page 12)
Venting must be installed according to Part 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 22. 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 which
prevent the retention of moisture and linings made
of corrosion-resistant materials are best. Advice for
flue connections and chimney linings can usually be
obtained from the local gas utility. Type “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 through 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 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.
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(s).
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 sys-
tem.
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 appliance
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 remain
ing 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 Z223.1-latest 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 B149.2 Installation Code.
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
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.
Figure 1 Boiler foundation
Placing the boiler
1. Remove boiler from shipping pallet. Do not drop boiler or bump
jacket on floor or pallet.
2. Level boiler so that the built-in air separation will work correctly.
Shim legs if necessary. Do not alter legs.
3. Remove front jacket door and burner access panel. Unscrew access
panel screws, remove and discard shipping washers, and reinstall
screws.
4. Check for proper orifice sizing from charts below.
Proper orifices must be used. Failure to do so will
cause severe personal injury, death or substantial
property damage.
5. Level and straighten the burners.
Burners must be seated properly in locating slots
with their openings facing up. Gas orifices must
inject down the center of the burner. Failure to
properly seat burners will result in severe personal
injury, death or substantial property damage.
6. Reinstall access panel.
Residential garage installation
Install boiler so burners are at least 18 inches above the floor.
Hydrostatic pressure test
Pressure test before attaching gas piping or electrical supply.
1. Plug any necessary boiler tappings or openings.
2. Connect water supply. Fill boiler and purge all air. Test at 45 psi for
more than 10 minutes.
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.
3. 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.
4. Drain boiler and remove testing plugs.
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Boiler piping connections to the heating
system (refer to piping diagrams, Page 7)
Failure to properly pipe the boiler may result in
improper operation and damage to the boiler or
building.
These boilers are provided with built-in air elimination systems.
1. Install relief valve vertically in top ¾” tapping in right end section.
See WARNING following.
To avoid water damage or scalding due to relief
valve operation:
• Discharge line must be connected to relief valve
outlet and run to a safe place of disposal. Terminate
the discharge line to eliminate possibility of severe
burns should the valve discharge.
• Discharge line must be as short as possible and be
the same size as the valve discharge connection
throughout its entire length.
• Discharge line must pitch downward from the valve
and terminate at least 6” above the floor drain where
any discharge will be clearly visible.
• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of
375 °F or greater.
• Do not pipe the discharge to any place where freezing could occur.
• No shutoff valve shall be installed between the
relief valve and boiler, or in the discharge line. Do
not plug or place any obstruction in the discharge
line.
• Failure to comply with the above guidelines could
result in failure of the relief valve to operate, resulting in possibility of severe personal injury, death or
substantial property damage.
• Test the operation of the valve after filling and pressurizing system by lifting the lever. Make sure the
valve discharges freely. If the valve fails to operate
correctly, replace it with a new relief valve.
2. Install pressure-temperature gauge in tapping provided in left end
section.
3. This boiler is for forced hot water circulation only. The circulator and
expansion tank must be selected and sized according to the design
requirements of the system.
a) Size and install circulator. Can be installed on supply or return
piping
b) Size expansion tank to handle the volume of water in the sys
tem.
4. Expansion tank installations.
a) Closed type expansion tanks - connect from the ¾” N.P.T.
expansion tank tapping on the left end section (located just
behind the supply outlet tapping) to the expansion tank using
¾” N.P.T. piping. Any horizontal expansion tank piping must
pitch upward toward the tank at least 1 inch for each 5 feet of
piping.
b) Diaphragm type expansion tank - may be located anywhere in
the system, preferably near the boiler.
A manual or automatic type air vent must be
installed in the ¾” N.P.T. tapping when a diaphragm
type tank is used.
The most common cause of lime deposits in boilers is inadequate
expansion tank volume. If the expansion tank is too small, system
water is lost from the relief valve and make-up water is added
through the fill valve. Eventual section failure will result.
5. Connect the system supply piping to the supply outlet tapping on
the left end of the boiler. See Figure 2a for minimum pipe size.
6. Connect the system return piping to the return tapping on the right
end of the boiler. See Figure 2a for minimum pipe size.
7. Install drain valve provided with boiler on left side. The installer
must provide a drain cock to drain the right (return) side of the
boiler and its connecting piping. The drain cock on the left side of
the boiler will not fully drain the right side.
8. Low water cut off:
a) Must be installed on any PFG boiler if the boiler is located above
radiation level.
b) Must be installed on all PFG-8 boilers to meet ASME specifica
tions (low water cut-off not supplied by Weil-McLain).
c) May be required by certain state, local or territorial codes or
insurance companies.
If a low water cut-off is required, use a control designed especially
for water installations. An electrode probe type low water cut-off
may be located in a tee in the supply line above the boiler.
9. If the system is to be ASME inspected and approved, an additional
high temperature limit is needed. Purchase and install the control
in the supply outlet piping to the boiler.
Figure 2a Minimum recommended pipe sizes
(Supply and return sizes refer to minimum size of
pipe connected to the boiler for 20°F temperature
drop between supply and return.)
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Figure 2b Piping – Closed type expansion tank
Use circulators or zone valves in each circuit for multiple
circuit applications.
Figure 2c Piping – Closed diaphragm type expansion tank
Use circulators or zone valves in each circuit for multiple
circuit applications.
Multiple zoning
1. Zone valves:
a) Refer to zone valve manufacturer’s literature for wiring
and application. A separate transformer is required to
power zone valves.
b) Provide balancing valves to adjust the flow so it is
about the same in each zone.
2. Circulators:
a) Zoning with circulators requires a relay for each cir
cuit.
b) Install flow control valves to prevent gravity circula
tion.
c) Provide balancing valves to adjust the flow so it is
about the same in each zone.
d) Size common return and supply piping for total flow
of all circulators.
Filling the system
1. Close manual air vents, drain cock, and automatic air vent,
if used.
2. Fill to correct system pressure. Correct pressure will vary
with each application. Residential systems are often designed for 12 pounds cold fill pressure.
3. Open automatic air vent one turn, if used.
4. Air must be vented for the system. Air in the system can
interfere with water circulation and cause improper heat
distribution.
a) Open manual water feed valve.
b) Starting on the lowest floor, open the air vents one at
a time until water squirts out. Close vent.
c) Repeat with remaining vents.
d) Close manual water feed valve when correct boiler
pressure is reached.
5. To purge air from system, install isolation valve in return
piping.
a) Connect a garden hose to the purge valve located
above the isolation valve.
b) Close isolation valve. Open purge valve.
c) Open hand water feed valve and allow system to purge
all air. If system has more than one circuit, purge each
circuit separately by opening each balancing valve one
at a time.
d) Close purge valve.
e) Open isolation valve.
f) Fill the system to the correct pressure.
6. Keep the system filled by occasionally opening the air
vents as in Step 4 above. Add water to make up system
pressure.
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Bypass piping
Bypass piping is not normally required on
any baseboard system.
Bypass piping should be used for the following installations. (Bypass, supply, and return piping should be
same size.)
1. Use the piping shown in Figure 3 to protect:
• radiant panels, plaster, etc. from high temperature
water supplied from boiler, or
• boiler from condensation caused by low temperature
water returned from system.
2. Use the piping shown in Figure 4 to protect boiler from
condensation formed by low water temperature returned
from large water content converted gravity systems, etc.
Figure 3
Figure 4
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External heat exchangers
The PFG boiler can be used with a storage tank/heat exchanger unit for
domestic hot water. The boiler/tank combination should be installed and
wired in accordance with the tank manufacturer’s instructions, which will
also show any additional components required. A zone valve or separate
circulator must be installed to regulate the production of hot water.
Freeze protection
Use antifreeze especially made for hydronic systems. Inhibited propylene
glycol is recommended.
Do not use automotive, ethylene glycol or undiluted antifreeze.
Severe personal injury, death or substantial property damage
can result.
50% solution provides protection to about -30°F
Local codes may require a back-flow preventer or actual disconnect from
city water supply.
Determine quantity according to system water content. Boiler water content
is listed on page 23.
Follow antifreeze manufacturer’s instructions.
Using with refrigeration system
The boiler must be installed so that chilled medium is piped in parallel with
the heating boiler with appropriate valves to prevent the chilled medium
from entering the boiler. Consult I=B=R Installation and Piping Guides.
If boiler is connected to heating coils located in air handling units where they
can be exposed to refrigerated air, gravity circulation during the cooling cycle
must be prevented with flow control valves or other automatic means.
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Size and install gas piping
In sizing the gas piping, the following factors should
be considered.
a) Diameter and length of the gas supply piping.
b) Number of fittings.
c) Maximum gas consumption (including any pos
sible future expansion).
d) Allowable loss in gas pressure from gas meter out
let to boiler. For pressure drops, see ANSI Z223-1
latest edition. Canadian installations must comply
with CAN/CSA B149.1 or .2 Installation Codes.
1. Size natural gas piping from the following table. Piping
must be sized to provide proper inlet gas pressure to the
gas valve when boiler is operating at rated input. For
natural gas, inlet gas pressure to gas valve should be a
minimum of 5 inches water column and a maximum of 13
inches water column. If inlet natural gas pressure exceeds
13 inches water column, a 100 percent lock-up type gas
pressure regulator of adequate size must be installed in gas
supply piping and adjusted to prevent pressure in excess
of 13 inches water column.
To obtain cubic feet per hour, divide the input (Btu per
hour) by the heating value (Btu per cubic foot).
Pipe delivery schedule
2. PFG 6 thru 8 only (and no damper on PI boilers) - for
propane gas, inlet gas pressure to gas valve should be
11 to 13 inches water column. The gas pressure regulator (furnished by the gas supplier) must be adjusted
to provide lock-up pressures not exceeding 13 inches
water column. Select the pipe size, tanks and regulators
as required.
If boiler is to be propane fired, a conversion
kit must be used. Failure to use kit or to
properly install kit will result in severe
personal injury, death or substantial
property damage.
3. Remove jacket door and connect from gas valve to
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gas meter. Use a street elbow or an elbow and close
nipple at the inlet connection of the gas valve to run
gas piping through opening in jacket side panel.
4. Follow good piping practices.
5. Pipe joint compound (pipe dope) must be resistant
to corrosive action of liquefied petroleum gases and
applied sparingly only to male threads of pipe joints.
6. A drip leg must be installed at inlet of gas connection to
boiler. Where local utility requires drip leg be extended
to the floor, use an appropriate length of pipe between
the cap and tee.
7. A ground joint union must be installed in the piping
to provide for servicing (see Figure 5).
8. Install manual shut-off valve outside boiler jacket as
shown in Figure 5 when required by local codes.
9. Piping must be supported by hangers, not by the boiler
or its accessories.
10. In Canada only - when manual main shut off valve is
used, it must be identified by installer.
11. Purge all air from the supply piping.
Before starting the boiler, and during
initial operation, smell near the floor and
around the boiler for gas odorant or any
unusual odor. Remove boiler front door
and smell interior of boiler enclosure. Do
not proceed with startup if there is any
indication of a gas leak. Repair any leak
at once.
12. Before placing boiler in operation, check boiler and its
gas connection for leaks.
a) If test pressure is less than
then close manual main shut-off valve.
b) If test pressure is greater than
then boiler and gas valve must be disconnected from
gas supply piping.
13.0 inches water column
13.0 inches water column
Do not check for gas leaks with an open
flame - use bubble test. Failure to do so
can cause severe personal injury, death or
substantial property damage.
PFG-8, as required by ANSI Z21.13/CSA 4.9, is equipped
with a manual test valve as shown in Figure 5a. Close
this valve to test boiler gas valve without supplying gas
to the manifold.
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Figure 5 Gas supply piping
Figure 5a Leak test valve (model PFG-8 ONLY)
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Draft hood installation
Secure the draft hood to the outlet at the top of the boiler
with sheet metal screws. The bottom of the draft hood
or “skirt” must have the clearance dimension above the
jacket top panel as indicated on the draft hood.
Do not alter draft hood. CSA design
certification becomes void. If draft hood
is altered, severe personal injury or death
will occur, resulting from flue gas spillage
or carbon monoxide emissions.
Spill switch installation (PFG-5 ONLY)
Fasten spill switch to draft hood as shown on page 21.
Connect wires as shown on wiring diagram label located
inside boiler door.
Damper installation
If damper will be installed, see Control Supplement for
information.
Breeching erection
(Also refer to chimney or vent requirements, Page 4)
Connect from draft hood or damper outlet to chimney
or vent with same size as breeching. Where possible,
vertical venting to the outside from the draft hood or
damper outlet will offer best performance. Where horizontal breeching is used, slope upward at least ¼ inch
per lineal foot toward the chimney or vent and support
with hangers to prevent sagging.
A minimum vertical height of 3 feet of
breeching before any elbow or horizontal
breeching is recommended to reduce
chances of flue gas spillage at the draft
ho o d . Lo ng horizon t a l bre e c hings,
excessive numbers of elbows or tees, or
other obstructions that restrict the flow
of combustion gas should be avoided.
Breeching must not be connected to any portion of a
mechanical draft system that can operate under positive pressure.
Wiring
For your safety, turn off the electrical
power supply at the service entrance panel
before making any electrical connections
to avoid possible electrical shock hazard.
All wiring must be installed in accordance with requirements of the National Electrical Code and any
additional national, state or local code requirements
having jurisdiction. All wiring must be N.E.C. Class 1.
The boiler must be electrically grounded in accordance
with the National Electrical Code, ANSI/NFPA No. 70latest edition.
In Canada, all wiring must be done in accordance with
the CSA C22.1 Canadian Electrical Code Part 1.
If original rollout thermal fuse element wire as supplied with
PFG-5 boiler must be replaced, type 200°C wire or
equivalent must be used. If other original wire as supplied with any PFG boiler must be replaced, type 105°C
wire or equivalent must be used.
The boiler is shipped with control components completely wired except for spill switch and damper (if
provided).
A separate electrical circuit should be used for the
boiler with a fused disconnect switch (15 amp. recommended).
Refer to wiring diagram label affixed to the inside of
the jacket door. Bring electrical supply through proper
opening in the jacket left end panel and into the electrical junction box. Wire electrical supply, circulator and
thermostat as shown on the wiring diagram.
For boilers equipped with control systems other than
constant burner pilot, refer to separate instructions for
application data.
Install room thermostat
Install room thermostat on an inside wall. Never install
where it will be influenced by drafts, hot or cold water
pipes, lighting fixtures, television, rays of the sun or
near a fireplace.
Heat anticipator in thermostat must be set to match the
power requirements of the primary control to which it
is connected. Refer to wiring diagram on jacket door for
recommended heat anticipator setting with standard
equipment. Wire the thermostat as shown.
12
Part Number 550-110-641/0605
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Figure 6 Typical wiring – zoning with zone valves
Wiring multiple zones
Refer to zone valve manufacturer’s literature for wiring
and application. A separate transformer is required to
power zone valves. Zoning with circulators requires a
relay for each zone circulator.
Canadian installations – Chain &
s-hook
See illustration below.
The chain and s-hook should be installed
according to this instruction by a qualified
installer/service technician prior to boiler
installation. Please follow steps outlined
below for the installation of the chain and
s-hook.
1. Crimp one side of each s-hook to each end of the chain.
2. Remove the two screws that attach the transformer plate
to the junction box.
3. Remove the transformer relay assembly and drill a 1/8”
hole through the plate as shown below. Do not allow
drill shavings to fall into the boiler jacket or onto any
control.
4. Crimp the s-hook to the 1/8” hole in the transformer
plate. Crimp the other side of the chain to the junction
box lower flange as shown below.
5. Replace the transformer relay assembly on the junction
box and secure with the two screws removed in step 2.
Figure 6 Chain and s-hook installation – Canadian installations only
Part Number 550-110-641/0605
13
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Check-out procedure
Check off steps as completed.
Check to make sure base insulation is secure. See "To inspect base
❏
insulation," page 17.
Boiler and heat distribution units filled with water?
❏
Automatic air vent, if used, open one turn?
❏
Air purged from system?
❏
Air purged from gas piping? Piping checked for leaks per page 10?
❏
Follow operating/lighting instruction label on boiler for proper
❏
start-up. Also refer to “To place in operation,” page 17.
Are proper orifices installed? See page 5 for proper orifice size.
❏
Proper orifices must be used. Failure to do so will cause
severe personal injury, death or substantial property
damage.
Proper burner flame? Refer to "Check main burner
❏
flames" and "Check pilot burner flame," page 17.
Test limit control: While burners are operating, move the indicator
❏
of the high limit control below actual boiler water temperature.
The burners should go off while the circulator continues to operate.
Raise the limit control above the boiler water temperature and the
burners should reignite.
Test any additional field-installed controls: If boiler has low water
❏
cut-off, additional high limit or other controls, test for operation as
outlined by manufacturer. Burners should be operating and should
go off when controls are tested. When controls are restored, burners
should reignite.
To test ignition system shut-off device:
❏
a. For PI systems: Connect a manometer to outlet side of gas
valve. Start boiler, allowing for normal start-up cycle to occur
and main burners to ignite. With main burners on, manually
shut off gas supply at manual main shut-off gas valve. Burners
should go off. Open manual main shut-off gas valve. The manometer should confirm there is no gas flow. Pilot will relight,
flame sensing element will sense pilot flame and the main burners reignite.
b. For standing pilot systems: Turn gas knob to PILOT position
and extinguish pilot flame - Pilot gas flow should stop in less
than 3 minutes. Put system back into operation. See page 17.
High limit control set to design temperature requirements of the
❏
system? Maximum high limit setting - 240 °F.
For multiple zones, flow adjusted so it is about the same in each
❏
zone?
Thermostat heat anticipator is set properly? Refer to "Install room
❏
thermostat," page 12, and wiring diagram on jacket door.
Boiler cycled with the thermostat? Raise to highest setting. Boiler
❏
should go through normal start-up cycle. Lower to lowest setting.
Boiler should go off.
Measure gas input (natural gas only):
❏
a. Operate boiler 10 minutes.
b. Turn off all other appliances served by the gas meter, including
gas stove, pilot lights and gas yard lights.
c. At natural gas meter measure time (in seconds) required to use
on cubic foot of gas.
d. Calculate gas input:
e. Btuh calculated should approximate input rating on rating
label.
Check manifold gas pressure by connecting manometer to down-
❏
stream test tapping on main gas valve. Manifold gas pressure for
natural gas should be 3 1/2 inches water column and for propane
gas should be 10 inches water column.
Several operating cycles observed for proper operation? If damper
❏
is provided, see Control Supplement for check-out procedure.
Room thermostat set to desired temperature?
❏
Installation and Service Certificate on this page completed?
❏
All instructions shipped with this boiler reviewed with owner or
❏
maintenance person, returned to envelope and given to owner or
displayed near boiler?
Installation and Service Certificate
Boiler model __________________ Series __________ CP number ___________ Date installed _______________
o Installation instructions have been followed.
Measured Btuh input ____________
Installer ________________________ ________________________________ ______________________________
(company) (address) (phone)
_____________________________________
(installer’s signature)
14
o Check-out sequence has been performed.
o Above information is certified to be correct.
o Information received and left with owner/maintenance person.
Part Number 550-110-641/0605
Page 15
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Section II: Service
Also Refer to Additional Instructions Shipped With The Boiler For
Specific Control Operation and Troubleshooting.
Verify Proper Operation After Servicing.
Your boiler should be inspected, cleaned
and, if necessary, adjusted once a year.
A qualified service agency should be
called.
To av o id pe rs o na l i nju r y, be for e
servicing:
1. Disconnect electrical supply.
2. Shut-off gas supply.
3. Allow boiler to cool.
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
Handling ceramic fiber and fiberglass materials
This product contains fiberglass jacket insulation and
ceramic fiber materials in combustion chamber lining
or base panels in gas fired products. Airborne fibers
from these materials have been listed by the State
of California as a possible cause of cancer through
inhalation. 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 applications. The
International Agency for Research on Cancer (IARC)
has concluded, “Crystalline silica inhaled in the form
of quartz or cristobalite from occupational sources is
carcinogenic to humans (Group 1).”:
Suppliers of fiberglass wool products recommend the
following precautions be taken when handling these
materials:
Precautionary measures
• Avoid breathing fiberglass dust and contact with skin or
eyes.
• Use NIOSH certified dust respirator (N95). This type of
respirator is based on the OSHA requirements for fiberglass
wool at the time this document was written. Other types of
• Wear long-sleeved, loose fitting clothing, gloves, and eye
• Apply enough water to the combustion chamber lining or base
• Remove combustion chamber lining or base insulation from
• Operations such as sawing, blowing, tear out and spraying
• Wash potentially contaminated clothes separately from other
NIOSH stated First Aid.
• Eye: Irrigate immediately
• Breathing: Fresh air.
To avoid personal injury, death or property
damage, keep the boiler area clear and free
from combustible materials, gasoline and
other flammable vapors and liquids.
Do not block flow of air to boiler.
Incomplete combustion and carbon
monoxide emissions can cause severe
personal injury, death or substantial
property damage.
Do not store sources of hydrocarbons (i.e.,
bleaches, cleaners, chemicals, sprays, paint
removers, fabric softeners, etc.) in boiler
area. This can contribute to shortened
boiler/vent system life.
respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on
the NIOSH web site at http://www.cdc.gov/niosh/homepage.
html. NIOSH approved respirators, manufacturers, and phone
numbers are also listed on this web site.
protection.
insulation to prevent airborne dust.
the boiler and place it in a plastic bag for disposal.
may generate airborne fiber concentration requiring ad
ditional protection. Bag for disposal.
clothing. Rinse clothes washer thoroughly.
-
Part Number 550-110-641/0605
15
Page 16
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Suggested Minimum Service Schedule
for Qualified Service Technician Only
Beginning of each heating season:
1. Annual service call by a qualified service agency.
2. Check burners and flueways and clean if necessary. Reference “To clean boiler heating surfaces” and “To clean main
burners,” page 18.
3. Visually inspect base insulation. Reference “To inspect base insulation,” page 17.
4. Follow procedure “To place in operation,” page 17.
5. Visually inspect main burner flames. Refer to “Check main burner flames,” page 17.
6. Check pilot burner flame. Refer to page 17.
7. Visually inspect venting system for blockage, deterioration or leakage. Reference “Inspect venting system,”
page 18.
8. Check operation of low water cut-off, if used, and additional safety devices. Refer to manufacturer’s instruc
tions.
9. Check that boiler area is free from combustible materials, gasoline and other flammable vapors and liquids.
10. Check for and remove any obstruction to the flow of combustion or ventilation air to the boiler.
11. Follow instructions on circulator to oil, if oil lubricated. Over oiling will damage the circulator. Water lubricated
circulators do not need oiling.
-
Daily during heating season:
1. Check that boiler area is free from combustible materials, gasoline and other flammable vapors and liquids.
2. Check for and remove any obstruction to the flow of combustion or ventilation air to the boiler.
Periodically during heating season:
1. Check relief valve. Reference manufacturer’s instructions on relief valve tag.
2. Test low water cut-off, if used. Blowdown if low water cut-off is float type. Reference manufacturer’s instruc
tions.
Monthly during heating season:
1. Check for leaks in the boiler and piping. If found, repair at once.
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.
2. Visually inspect main burner flames. Reference “Check Main Burner Flames.”
3. Check pilot burner flame. Refer to page 17.
4. Visually inspect venting system for blockage, deterioration or leakage. Reference “Inspect venting system,”
page 18.
5. Check automatic air vent for leakage. If leaking, remove vent cap and push valve core in to wash off sediment that
may have accumulated on the valve seat. Release valve, replace cap, and open one turn.
-
16
End of each heating season:
1. Follow “Annual shut-down procedure,” page 18.
Part Number 550-110-641/0605
Page 17
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
To inspect base insulation:
The boiler contains ceramic fiber and fiberglass materials.
Use care when handling these materials. See WARNING
above. Failure to comply could result in severe personal
injury.
Make sure base insulation is secure against base front and back panels. If
base insulation is damaged or displaced, do not operate boiler. Replace
or reposition insulation.
Failure to replace damaged insulation or reposition
insulation can result in a fire hazard, causing severe
personal injury, death or substantial property damage.
To place in operation:
1. Make sure boiler is filled with water.
2. Follow lighting/operating instructions on boiler.
PROPANE BOILERS ONLY – Your propane
supplier mixes an odorant with the propane to
make its presence detectable. In some instances, the
odorant can fade, and the gas may no longer have
an odor.
Propane gas can accumulate at floor level. Smell
near the floor for the gas odorant or any unusual
odor. If you suspect a leak, do not attempt to light
the pilot.
• Use caution when attempting to light a propane
pilot. This should be done by a qualified service
technician, particularly if pilot outages are
common.
• Periodically check the odorant level of your gas.
• Inspect boiler and system at least yearly to make
sure all gas piping is leak-tight.
• Consult your propane supplier regarding installation
of a gas leak detector. There are some products on
the market intended for this purpose. Your supplier
may be able to suggest an appropriate device.
3. If boiler starts, go to Step 5. If boiler fails to start, go to Step 4.
4. If boiler fails to start, check for following conditions:
a) Loose connection or blown fuse?
b) High limit setting below boiler water temperature?
c) Thermostat setting below room temperature?
d) Gas not turned on at meter?
e) Gas not turned on at boiler?
f) If above fails to eliminate the trouble, refer to Control Supple
ment.
5. Make sure boiler goes through several normal operating cycles.
6. Turn thermostat or operating control to desired setting.
Check pilot burner flame:
1. Proper pilot flame
a) Blue flame.
b) Inner cone engulfing pilot flame sensor.
c) Pilot flame sensor glows cherry red.
2. Improper pilot flame
a) Overfired - flames large and lifting or blowing past pilot flame
sensor.
b) Underfired - flame small; pilot flame sensor not engulfed by
inner cone.
c) Lack of primary air - flame tip yellow.
d) Pilot flame sensor not heated properly.
Figure 7 Typical pilot burner flame
Check main burner flames:
1. Proper burner flame - Yellow-orange streaks may appear - caused
by dust.
2. Improper flame
a) Overfired - Flames large.
b) Underfired - Flames small.
c) Lack of primary air - Yellow tipping on flames; sooting will oc
cur.
Figure 8 Typical main burner flame
-
-
Part Number 550-110-641/0605
17
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Inspect venting system:
1. Check venting system at least once a month during heating season.
With boiler in operation (at least 5 minutes), hold a candle or match
below lower edge of draft hood “skirt.” If flame is undisturbed or
leans under skirt, vent system is functioning properly. If flame is
extinguished, flickers, or reduced while flame is pushed out side
skirt, the vent system must be checked for obstructions or other
causes of improper venting.
2. Inspect all parts of venting systems for deterioration from corrosion,
physical damage, sagging, etc. Correct all conditions found.
3. Verify damper, if used, is open when burner ignites. For additional
information, see Control Supplement.
To clean boiler heating surfaces
The boiler contains ceramic fiber and fiberglass materials.
Use care when handling these materials per instructions
on page 15 of this manual. Failure to comply could result
in severe personal injury.
1. Follow shut-down procedure.
2. Remove breeching, draft hood and damper (when used).
Remove jacket top panel. Turn back jacket insulation to expose col
lector hood.
3. Remove collector hood. Clean excess boiler cement from collector
hood and cast iron sections.
4. Remove radiation plates.
5. Remove burners from base of boiler. Follow “To clean main burners,”
page 18, to thoroughly clean burners.
6. Place newspaper in base of the boiler to collect soot that will fall.
7. With a wire flue brush, clean between the sections.
8. Remove newspaper and soot. Vacuum or brush base and surrounding
area to remove soot.
9. Reinstall radiation plates.
10. Reinstall collector hood. Seal with boiler cement.
11. Reinstall insulation and jacket panel.
12. Reinstall burners.
When reinstalling, burner tubes must be seated in their
locating slots with the openings facing up. Gas orifices
must inject down center of burner. Failure to properly
seat burner will result in severe personal injury, death or
substantial property damage.
13. Reinstall draft hood, damper (when used), and breeching.
14. Follow “To Place in Operation” procedure.
Excessive sooting indicates improper combustion of the
gas. Call a qualified service agency or your local gas utility
to check for proper combustion and make any necessary
adjustments.
Annual shut-down procedure:
1. Follow lighting/operating instructions label on boiler.
2. DO NOT drain the system unless exposure to freezing
temperatures will occur. If antifreeze is used with system,
do not drain.
3. If the complete boiler and piping system must be drained
to avoid freezing, then a means must be provided for
draining water from BOTH ends of the boiler at or below
the level of the return tapping. A boiler drain cock is provided by Weil-McLain on the left side of the boiler only.
To replace a boiler section
If replacing any section (see Figure 9):
• Approved RTV silicone sealant (Dow Corning 700 or
732 or G.E. 808 or 108) must be used to seal between
sections.
• Place ball bearings in the holes in the locator holes on
the sides of the sections to ensure section alignment and
reliable placement.
-
Figure 9 Section assembly
Failure to use PFG Series 7 intermediates
or to properly seal sections per Figure
9 can cause flue gas spillage or carbon
monoxide emissions, resulting in severe
personal injury, death or substantial
property damage.
To clean main burners:
1. Vacuum or brush burners to remove dust and lint.
When reinstalling, burner tubes must be seated in their
locating slots with the openings facing up. Gas orifices
must inject down center of burner. Failure to properly
seat burner will result in severe personal injury, death or
substantial property damage.
18
Part Number 550-110-641/0605
Page 19
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Common problems and possible solutions
Part Number 550-110-641/0605
19
Page 20
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Item Description Part Number
1 Draft hood: PFG-5 (7” x 7” dia x 24.45”)
PFG-6 (8” x 8” dia x 27.80”)
PFG-7 (9” x 9” dia x 31.05”)
PFG-8 (9” x 9” dia x 36.55”)
450-021-200
450-021-201
450-021-202
450-021-205
2 Collector hood: PFG-5
PFG-6
PFG-7
PFG-8
450-014-819
450-014-820
450-014-821
450-014-822
3 Right hand end section, 51113 312-804-405
4 Intermediate section, 51125 312-804-416
5 Left hand end section, 51113 312-804-405
NS Section replacement kit (one per joint; 4 seals, 4 ball bearings, and sealant) 386-700-856
6 Burner, main 512-200-022
NS Burner, main with pilot bracket 512-200-023
7 Right hand/left hand base rail 452-800-655
8 Base front panel: PFG-5
PFG-6
PFG-7
PFG-8
452-800-500
452-800-501
452-800-502
452-800-503
9 Front base insulation: PFG-5
PFG-6
PFG-7
PFG-8
591-222-020
591-222-021
591-222-022
591-222-025
10 Base access panel: PFG-5
PFG-6
PFG-7
PFG-8
452-800-540
452-800-541
452-800-542
452-800-543
11 Manifold: PFG-5
PFG-6
PFG-7
PFG-8
591-125-820
591-125-821
591-125-822
591-125-823
12 Base back panel: PFG-5
PFG-6
PFG-7
PFG-8
452-800-580
452-800-581
452-800-582
452-800-583
13 Back base insulation: PFG-5
PFG-6
PFG-7
PFG-8
591-222-030
591-222-031
591-222-032
591-222-033
14 Tie rod without nut (2 per boiler): PFG-5 ⁵⁄₈”-11
UNC
x 15”
PFG-6 ⁵⁄₈”-11
UNC
x 18”
PFG-7 ⁵⁄₈”-11
UNC
x 21”
PFG-8 ⁵⁄₈”-11
UNC
x 24”
560-134-506
560-134-507
560-134-508
560-134-509
15 Flue baffle: PFG-5
PFG-6
PFG-7
PFG-8
452-800-449
452-800-450
452-800-451
452-800-452
16 Flue baffle insulation: PFG-5
PFG-6
PFG-7
PFG-8
591-222-095
591-222-096
591-222-097
591-222-098
17 Spill switch, PFG-5 only 510-300-014
18 Rollout thermal fuse element, PFG-5 only 512-050-230
19 Radiation shield (2 per joint) 460-003-700
20 Section alignment ball bearings, 1/4” diameter (4 per joint)
Ball bearing kit (4 bearings)
562-930-250
386-700-856
NS Main burner orifice (natural gas) #37 drill 560-529-055
NS Main burner orifice (propane gas) 1.65 mm 560-529-056
Section III: Replacement Parts
The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials, per
instructions on page 15 of this manual. Failure to comply could result in severe personal injury.
To avoid personal injury, before replacing any parts on the boiler:
1. Turn off power.
2. Shut off gas supply.
3. Allow boiler to cool.
20
Part Number 550-110-641/0605
Page 21
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Part Number 550-110-641/0605
21
Page 22
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Section IV: Ratings and dimensions
DOE
Standard equipment
Factory Fire Tested
•
Insulated Extended Jacket
•
Built-In Air Separator
•
Draft Hood (Shipped in separate carton)
•
Combination Gas Valve
•
Non-Linting Pilot Burner
•
Aluminized Steel Burners
•
Combination Relay Receptacle and 40 VA Trans-
•
former
Relay
•
High Limit Control
•
Spill Switch (PFG-5 only)
•
Rollout Thermal Fuse Element (PFG-5 only)
•
30 P.S.I. Relief Valve (shipped in separate carton)
•
(boiler sections tested for 50 P.S.I. water working
pressure)
22
Combination Pressure-Temperature Gauge
•
(shipped in separate carton)
Drain Valve (shipped in separate carton)
•
PIDN
Intermittent Electronic Ignition System
•
Automatic Vent Damper
•
PIN
Intermittent Electronic Ignition System
•
SPN
Constant Burning Thermally Supervised Pilot System
•
Thermocouple
•
Part Number 550-110-641/0605
Page 23
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
* Locate manual main Shut-Off Gas Valve (where required) according to local utility requirements.
Part Number 550-110-641/0605
23
Page 24
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
24
Part Number 550-110-641/0605
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