EGH-85 & 95
PFG-6 & 7
Series 4
Series 6 & 7
Control Supplement
Standing Pilot Boilers
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.
Part Number 550-110-031/0605
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Control Supplement — Standing Pilot Boilers
Table of contents
Hazard definitions and Note to the installer .................................................................................... 2
Control installation — EGH-85 & 95 water boilers........................................................................ 4-5
Control installation — PFG-6 & 7 water boilers............................................................................ 6-7
Control installation — EGH-85 & 95 steam boilers with probe-type LWCO................................ 8-9
Control installation — EGH-85 & 95 steam boilers with float-type LWCO .............................. 10-11
Checkout procedure ........................................................................................................................11
Lighting instructions........................................................................................................................12
Troubleshooting ......................................................................................................................... 13-15
Parts .................................................................................................................................................16
Part Number 550-110-031/0605
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EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Control installation — EGH-85 & 95 water boilers
Part Number 550-110-031/0605
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Control Supplement — Standing Pilot Boilers
Control installation — EGH-85 & 95 water boilers
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work
on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage.
1. Mount and wire controls per wiring diagram, page
Figure 1
4, and Figure 1.
a. Attach junction box inside left jacket panel with
#8-32 x ½" machine screws and green ground
nuts provided.
b. Install transformer with plug-in relay receptacle
and relay. In Canada, use chain and hook strain
relief.
c. Operating and limit circuit wiring must be 18
gauge or heavier (as supplied with the boiler).
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
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EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Control installation — PFG-6 & 7 water boilers
Part Number 550-110-031/0605
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Control Supplement — Standing Pilot Boilers
Control installation — PFG-6 & 7 water boilers
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work
on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage.
1. Mount and wire controls per wiring diagram, page
Figure 2
6, and Figure 2.
2. Operating and limit circuit wiring must be 18 gauge
or heavier (as supplied with the boiler).
3. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
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EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Control installation — EGH-85 & 95 steam boilers
Part Number 550-110-031/0605
8
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Control Supplement — Standing Pilot Boilers
with probe-type low water cutoff
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work
on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage.
1. Mount and wire controls per wiring diagram, page
Figure 3
8, and Figure 3.
a. Attach junction box inside left jacket panel with
#8-32 x ½" machine screws and green ground
nuts provided.
b. Install transformer with plug-in relay receptacle
and relay. In Canada, use chain and hook strain
relief.
c. Operating and limit circuit wiring must be 18
gauge or heavier.
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
Part Number 550-110-031/0605
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EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Control installation — EGH-85 & 95 steam boilers
Part Number 550-110-031/0605
10
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Control Supplement — Standing Pilot Boilers
with float-type low water cutoff
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work
on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage.
1. Mount and wire controls per wiring diagram, page
Figure 4
10, and Figure 4.
a. Attach junction box inside left jacket panel with
#8-32 x ½" machine screws and green ground
nuts provided.
b. Install transformer with plug-in relay receptacle
and relay. In Canada, use chain and hook strain
relief.
c. Operating and limit circuit wiring must be 18
gauge or heavier (as supplied with the boiler).
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
Anticipator settings
Water — 0.40 amps, single zone systems only. For multiple zones using zone
valves or circulators, refer to component manufacturer’s instructions for
application, wiring and thermostat heat anticipator setting.
Steam — 0.20 amps.
Checkout procedure
1. Follow all instructions in the boiler manual, including the Checkout procedure, before proceeding.
2. See page 12 for“Lighting instructions”. Raise room thermostat to call for heat.
3. Gas valve will open and main burners will ignite.
4. Lower thermostat setting. Main burner flames will go out.
5. Repeat steps 1 through 3 several times to verify operation.
6. Return thermostat to normal setting.
Part Number 550-110-031/0605
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EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Lighting instructions — Robertshaw 7000ERHC
FOR YOUR SAFETY READ BEFORE LIGHTING
If you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
A. This appliance has a pilot, which must be lighted C. Use only your hand to depress or turn the gas control knob. Never use
by hand. When lighting the pilot, follow these
instructions exactly.
tools. If the selector arm will not depress or move by hand, don't try to
repair it, call a qualified service technician. Force or attempted repair
may result in a fire or explosion.
B. Before LIGHTING, smell all around the appliance
area for gas. Be sure to smell next to the floor because D. Do not use this appliance if any part has been under water.Immediately
some gas is heavier than air and will settle on the
floor. See below.
call a qualified service technician to inspect the appliance and to replace
any part of the control system and any gas control, which has been
under water.
WHAT TO DO IF YOU SMELL GAS
•
•
Do not try to light any appliance.
•
Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
Do not touch any electric switch; do not use any phone in
your building.
•
If you cannot reach your gas supplier,call the fire department.
LIGHTING INSTRUCTIONS
1. Stop! Read the safety information above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electrical power to the appliance.
8. Turn gas control knob counterclockwise
to PILOT.
9. Depress gas control knob and hold. Immediately light the
pilot with a match. Continue to hold gas control knob in for
about one (1) minute after the pilot is lit.
4. Depress gas control knob slightly and turn clockwise
•
If pilot can be lit without depressing gas control knob,
to OFF.
turn gas knob clockwise
technician or gas supplier.
to OFFand call your service
10. Release gas control knob. Pilot should remain lit. If pilot goes
out, repeat steps 4 through 10.
•
If gas control knob stays depressed after release, stop and
immediately call your service technician or gas supplier.
•
If the pilot will not stay lit after several tries, turn the gas
control knob clockwise
to OFF and call your service
Note: Gas control knob cannot be turned to OFF unless
knob is depressed slightly. Do not force.
technician or gas supplier.
11. Replace access panel.
5. Wait five (5) minutes to clear out any gas. Then smell for
gas, including near the floor.If you smell gas, STOP!Follow
"B" in the safety information above. If you don't smell gas,
go to the next step.
12. Turn gas control knob counterclockwise
13. Turn on all electric power to the appliance.
14. Set thermostat to desired setting.
15. Replace front panel.
to ON.
6. Remove access panel located above burners.
7. Find pilot — follow metal tube from gas
control. The pilot is between two burners
behind the access panel.
TO TURN OFF GAS TO THE APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be
performed.
4. Depress gas control knob slightly and turn clockwise
to OFF.
5. Replace front panel.
3. Remove front panel.
Part Number 550-110-031/0605
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Control Supplement — Standing Pilot Boilers
Troubleshooting
have checked the thermopile per step 1 above,
replace the thermopile lead wire assembly.
f. If reading on TOP thermopile lead wire is around
400 millivolts, move the multimeter alligator clip
to the BOTTOM thermopile lead wire terminal
and check multimeter reading.
Verify proper operation after servicing
Never jumper (bypass) any device except for momentary
testing as outlined in troubleshooting chart below.
Substantial property damage and/or severe personal
injury could occur.
g. If multimeter does not read around 400 millivolts,
check wiring connections and wire integrity to
the limit controls.
h. Check voltage at each limit terminal to make sure
limit is closed. Correct pressure or temperature
condition causing any limit to be open. Replace
limit if necessary.
Burner access panel must be in position during boiler
operation to prevent momentary flame rollout on
ignition of main flame. Severe personal injury or
substantial property damage will result.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation leading to severe personal injury,
death or substantial property damage.
Figure 5
Before troubleshooting:
1. Have a voltmeter that can check 120VAC, 24VAC, and a continuity tester.
2. Check for 120VAC (minimum 102 to maximum 132) to boiler.
3. Be sure pilot is lit. See“Lighting instructions”on page 12 for details.
4. Make sure thermostat is calling for heat and contacts (including
appropriate zone controls) are closed. Check for 24VAC between
thermostat wire nuts and ground.
Pilot does not stay lit —
Troubleshooting thermopile and high
limit control circuit
1. Checking thermopile open system (Figure 5):
a. Use an electronic multimeter, with leads fitted with alligator clips. Set
meter scale to DC Millivolts.
b. Unscrew thermopile fitting from gas valve.
c. Attach one meter lead to the end of the thermopile gas valve fitting.
d. Attach other meter lead to thermopile lead (copper surface).
Figure 6
e. Follow Lighting Instruction label on boiler (also found in Control
Supplement or User’s Information manual) to light the pilot burner
only and hold the pilot flame manually.(DO NOT light main burner.)
f. Check the reading on the multimeter. The reading should be around
700 millivolts.
g. If multimeter reading is significantly less than above, replace the
thermopile.
2. Checking thermopile circuit closed system (Figure 6):
a. Use an electronic multimeter, with leads fitted with alligator clips. Set
meter scale to DC Millivolts.
b. Loosen the insulated terminal on the TOP thermopile lead wire
enough to allow clipping a multimeter alligator clip to the spade
terminal.
c. Attach the other multimeter lead to the thermopile lead.
d. Check the reading on the multimeter. The reading should be around
400 millivolts.
e. If reading is significantly less than 400 millivolts, check tightness of
lead wire assembly in gas valve. If the connections are secure and you
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EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Troubleshooting continued
Chart 1:
Boiler will not fire — water boilers without tankless
Is damper harness securely plugged in at both ends?
No Yes
Secure connections.
Check for loose wire connections or bad relay on
transformer.
Is 24VAC present across transformer terminals C & Y?
No Yes
Check for open thermostat, LWCO, high limit, spill switch or
rollout thermal fuse element contacts or check for loose
wire connections.
Is 24VAC present across transformer terminal C and yellow
wire on vent damper connector?
No
Yes
If LWCO, spill switch or rollout thermal fuse
element contacts are open, determine cause
and correct condition. Failure to do so will
cause severe personal injury, death or
substantial property damage.
Is vent damper rotated open?
No
Yes
Check/repair out of round stack section. Does vent damper
rotate open?
Is 24VAC present across gas valve terminals?
No
Yes
No
Yes
Replace actuator.
Retest.
Is main flame on now?
No
Yes
Open thermostat contacts for 30 seconds. Vent damper will
rotate to closed position. Close thermostat contacts. Vent
damper will rotate to open position. Is 24VAC present
across gas valve terminals?
Retest
Is gas valve cock turned to ON position?
No
Yes
No
Yes
Check continuity of each wire in damper harness. Does
continuity exist for each wire? See Table below.
Turn gas valve cock to
ON position. Retest.
Replace gas valve.
Retest
No
Yes
Remove damper harness from
damper harness plug.
TEMPORARILY install jumper
Replace damper
wiring harness.
Retest.
between terminal 2 and
terminal 5 on damper plug in
boiler wiring harness. See
figure, right. Does boiler fire?
No
Yes
Replace gas valve.
Retest.
Replace damper
actuator. Retest.
Part Number 550-110-031/0605
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Control Supplement — Standing Pilot Boilers
Troubleshooting continued
Chart 2:
Boiler will not fire — water boilers with tankless
Is damper harness securely plugged in at both ends?
No Yes
Secure connections.
Is 24VAC present across combination control terminals V2
& Z?
Check for loose wire connections or bad combination
control.
No
Yes
Check for open thermostat, LWCO, high limit, spill switch or
rollout thermal fuse element contacts or check for loose
wire connections.
Is 24VAC present across transformer terminal V2 and
yellow wire on vent damper connector?
No
Yes
If LWCO, spill switch or rollout thermal fuse
element contacts are open, determine cause
and correct condition. Failure to do so will
cause severe personal injury, death or
substantial property damage.
Is vent damper rotated open?
No
Yes
Check/repair out of round stack section. Does vent damper
rotate open?
Is 24VAC present across gas valve terminals?
No
Yes
No
Yes
Replace actuator.
Retest.
Is main flame on now?
No
Yes
Open thermostat contacts for 30 seconds. Vent damper will
rotate to closed position. Close thermostat contacts. Vent
damper will rotate to open position. Is 24VAC present
across gas valve terminals?
Retest
Is gas valve cock turned to ON position?
No
Yes
No
Yes
Check continuity of each wire in damper harness. Does
continuity exist for each wire? See Table below.
Turn gas valve cock to
ON position. Retest.
Replace gas valve.
Retest
No
Yes
Remove damper harness from
damper harness plug.
TEMPORARILY install jumper
Replace damper
wiring harness.
Retest.
between terminal 2 and
terminal 5 on damper plug in
boiler wiring harness. See
figure, right. Does boiler fire?
No
Yes
Replace gas valve.
Retest.
Replace damper
actuator. Retest.
Part Number 550-110-031/0605
15
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EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Parts
Part Number 550-110-031/0605
16
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