Weil McLain EG User Manual

E G , P E G , E G H  
Gas-fired Boilers — Series 4  
BBoo iillee rr MMaa nn uu aa ll  
Bo ile r M a n u a l  
BBoo iillee rr MMaa nn uu aa ll  
• In s t a lla t io n  
Op e ra t io n  
• S e rvic e  
• Bo ile r Pa rt s  
For additional information,  
refer to . . .  
Control Supplement  
and Gas Control Parts  
for Natural or Propane gas  
with optional tankless heater  
application  
EG  
EGH  
Re a d a ll in s t ru c t io n s b e fo re in s t a llin g  
In s t a lle r 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.  
Ow n e r  
Installation and service should be performed by qualified service  
technician.  
Part No.550-110-639/0703  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
1
In s t a lla t io n  
Codes  
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.  
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 Air from inside building (boiler in interior room):  
CSD-1. Safe lighting and other performance criteria were  
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.  
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 Air directly from outside to boiler room:  
with Section 5.3,Air for Combustion andVentilation,of  
Tightly constructed buildings must be provided with  
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.  
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.  
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  
buildingand boiler room toprovideadequatecombustion  
air and ventilation. Consider construction tightness of  
building when deciding whether additional outside  
openings may be needed.  
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.  
Older buildings with single-pane windows, minimal  
weatherstripping and no vapor barrier often provide  
enough natural infiltration and ventilation without  
dedicated openings.  
Part Number 550-110-639/0703  
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EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
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In s t a lla t io n  
(continued)  
Chimney or vent requirements  
(also refer to Breaching erection, Page 8)  
When removing boiler from common venting  
system  
Venting must be installed according to Part 7,Venting of  
Equipment, of National Fuel Gas Code ANSI Z223.1-  
latest edition and applicable building codes. Canadian  
installations must comply with CAN/CSA B149.1 or .2  
Installation Codes.  
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.  
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. 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 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 remaining connected to  
the common venting system properly vents when tested as outlined above,  
return doors, windows, exhaust fans, fireplace dampers, and any other gas-  
burning appliance to their previous conditions of use.  
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. Type“Bdouble 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.  
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.  
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.  
Canadian installations must comply with CAN/CSA B149.1 or .2 Installation  
Code.  
2. Provide drain trap to remove any condensate.  
Select the boiler location  
Inspect existing chimney or vent before  
installing boiler. Failure to clean or replace  
perforated pipe or tile lining will cause  
severe injury or death.  
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 ONLY. SeeBoiler foundation, Page 5.  
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.  
To avoid personal injury,death or property 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.  
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Part Number 550-110-639/0703  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
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In s t a lla t io n  
(continued)  
Installation clearances  
Figure 1  
Boiler foundation  
Suggested minimum clearancesfor 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 combustiblematerial in  
alcoveinstallations  
Top 46"  
Rear 6"  
R. Side 4"  
L. Side 4"  
Front: Alcove  
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 above the floor.  
Boiler foundation  
Figure 2  
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  
conditionsexist:  
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.  
4. After moving half-blocks into desired location, clean  
port surfaces with clean, dry rag. Do not use oil. Place  
sealingringsin recessedports. Placecopesealin section  
grooves.  
Placing the boiler  
5. Re-assemble block in reverse order. When drawing  
sections together,use 45 ( ± 5) ft-lbs torque.  
Block assembly is extremely heavy. Handle with caution to avoid  
personal injury.  
Installation of optional indirect  
water heater  
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. Tiphalfblockson endasshown in Figure2. Saveelastomer sealingringsand  
copesealbetween sections.  
Foraboilerorderedwithinternaltypeindirectwaterheater,  
remove heater opening cover plate (water boilers - round  
plateon leftside;steam boilers-rectangularplateon 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, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
1
In s t a lla t io n  
(continued)  
Figure 3  
Installation of flue collector hood  
(Factory installed on PEG boilers)  
Hydrostatic pressure test  
Set flue collector hood on boiler as shown in Figure 4.  
Use boiler cement furnished to provide gas-tight seal.  
Pressure test before attaching gas piping or electrical supply.  
1. Plug any necessary boiler tappings or openings.  
2. Donotusegaugesuppliedwith boiler for pressuretesting. Installgaugewith  
appropriate range.  
3. Fill boiler with water.Vent all air.Test steam boilers between 45 - 55 psi and  
water boilers at 1-1/2 times working pressure.  
Failure to maintain gas-tight seal can cause  
flue gas spillage and carbon monoxide  
emissions, resulting in severe personal  
injury or death.  
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.  
Figure 4  
Flue collector hood  
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.  
Installation of front and back base  
panels  
5. Drain boiler and repair leaks if found.  
6. Retest boiler after repairing leaks.  
(Factory installed on PEG boilers)  
7. Removeplugsfromanytappingsthatwillbeusedforcontrolsandaccessories.  
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.  
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  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
1
In s t a lla t io n  
(continued)  
Figure 5  
Front and back base panels  
Figure 6  
Burner drawer assembly  
Figure 7  
Pilot burner location  
Installation of drawer assembly  
and front access panel and back  
base channel  
(Factory installed on PEG boilers - follow  
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 from chart below.  
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.  
Figure 8  
Burner drawer installation  
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 9  
Access panel  
Part Number 550-110-639/0703  
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EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
1
In s t a lla t io n  
(continued)  
Jacket installation  
(Factory installed on PEG  
Spill switch installation  
boilers)  
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.  
1. Remove the proper knockout discs from panels as  
shown in tapping table, page 6.  
Tankless and storage heater knockouts  
must be removed for EG and EGH boilers  
with optional tankless heaters prior to  
jacket installation.  
Damper installation  
If damper will be installed, see Control Supplement for  
information.  
2. Follow Jacket Instructions in jacket carton.  
Breeching erection  
Draft hood installation  
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.  
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.  
Failure to maintain gas-tight seal can cause  
flue gas spillage and carbon monoxide  
emissions, resulting in severe personal  
injury or death.  
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.  
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.  
Breeching must not be connected to any portion of a  
mechanical draft system operating under positive  
pressure.  
Figure 10 Draft hood  
Seal across back of  
block assembly with  
boiler cement between  
cast iron and sheet  
metal edge of draft hood  
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Part Number 550-110-639/0703  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
2
Pip in g c o n n e c t io n s  
Pipe before installing controls. Connect return piping  
after jacket is attached. Connect supply piping before or  
after jacket is attached.  
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.  
Failure to properly pipe the boiler may  
result in improper operation and damage  
to the boiler or building.  
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.  
Forced hot water boilers and  
gravity hot water boilers  
(EG Only)  
3. Install water relief valve vertically inEtapping.  
1. To protect:  
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.  
radiant panels,plaster,etc. from high temperature water  
supplied from boiler,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.  
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 to boiler.  
7. Plug all unused tappings.  
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 11b Recommended piping connections  
forced hot water boilers with  
Figure 11a Recommended piping connections  
forced hot water boilers with closed  
type expansion tanks  
diaphragm type expansion tanks  
Part Number 550-110-639/0703  
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EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
2
Pip in g c o n n e c t io n s  
(continued)  
8. Multiple Zoning  
a) Zone valves:  
Figure 12  
Refer to zone valve manufacturers literature for wiring  
and application. A separate transformer is required to  
power zone valves.  
Provide balancing valves to adjust the flow so it is about  
the same in each zone.  
b) Circulators:  
Zoningwithcirculatorsrequiresarelayforeachcirculator.  
Install flow control valves to prevent gravity circulation.  
Provide balancing valves to adjust the flow so it is about  
the same in each zone.  
9. If system is to be ASME inspected and approved, an  
additional high temperature limit is needed. Purchase  
and install the control in supply outlet piping from  
boiler.  
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. See Figure 12 to protect:  
Figure 13  
• radiant panels, plaster, etc. from high temperature  
water supplied from boiler, or  
• boiler from condensation caused by low temperature  
water returned from system.  
2. See Figure 13 to protect boiler from condensation  
formed by low water temperature returned from large  
water content converted gravity systems, etc.  
Use with refrigeration systems  
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. See Figure 14. Consult I=B=R Installation and  
Piping Guides.  
Ifboilerisconnectedtoheatingcoilslocatedin airhandling  
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.  
10  
Part Number 550-110-639/0703  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
2
Pip in g c o n n e c t io n s  
(continued)  
Steam boilers  
1. Refer to table and Figures 14 or 15. Pipe exactly as  
shown. Satisfactory operation of a steam heating  
system depends on adequate condensate return to  
boiler to maintain a steady water level.Avoid adding  
raw make-up water.Where condensate return is not  
adequate, install low water cut-off and pump control,  
condensatereceiver,and condensateboiler feed pump.  
Refer to Figure 16 for sizing.  
2. Install steam relief valve vertically inEtapping.  
Relief valve discharge piping must be piped  
near floor close to floor drain to eliminate  
potential or severe burns. Do not pipe to  
any area where freezing could occur. Do  
not plug, valve or place any obstruction in  
discharge line.  
Figure 16 Condensate receiver capacity  
3. EGH only - install 3/4" system blow-off (drain) valve  
in lowest part of return piping close to boiler.  
Figure 14 Recommended piping connections  
EG steam boilers  
Figure 15 Recommended piping connections  
EGH steam boilers  
NOTE : Steam supply must be on same end as controls. Return may be from  
eitherend.  
Part Number 550-110-639/0703  
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EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
3
In s t a ll b o ile r c o n t ro ls  
Failure to properly install, pipe and wire  
boiler controls may result in severe damage  
to the boiler, building and personnel.  
Figure 17 Probe-type low water cut-off  
Water boiler  
1. Install controls as shown on Control Tapping Table  
and Figure 3, page 6. Limit control and supply piping  
must be on the same end of EGH boiler.  
2. Low water cut off for water boilers:  
a) Must be installed if boiler is located above radiation  
level.  
b) Must be installed on all EGH 105-125 water boilers  
to meet ASME specifications (low water cut-off  
not supplied by Weil-McLain).  
c) May be required on water boilers by certain state,  
local or territorial codes or insurance companies.  
If a low water cut-off is used on a water boiler, use a  
control designed especially for water installations.  
An electrode probe type may be located in a tee in  
the supply line above boiler,also see Control Tapping  
Table, page 6.  
NOTE: Water line dimension measured from bottom  
of boiler section leg where it rests on the boiler  
room floor or boiler foundation.  
3. If system is to be ASME inspected and approved, an  
additional high temperature limit is needed. Purchase  
and install in supply line above boiler.  
Figure 18 Float-type low water cut-off  
Steam boiler  
1. For steam boilers furnished with probe-type low  
water cut-offs, install as shown in Figure 17.  
2. For steam boilers furnished with float type low water  
cut-off, install controls as illustrated in Figure 18.  
Install blowdown line in bottom of cutoff. See Figure  
19 and control manufacturers instructions for details.  
Pipe blowdown line near floor close to floor  
drain to eliminate potential of severe burns.  
Do not plug, valve or place any obstruction  
in blowdown line.  
a) Other float-type water-level controls for EGH steam  
boilers are shown in Figure 19. (Use 1 inch I.P.S.  
connections).  
b) Water feeders are not recommended for primary  
control. A low-water cut-off with pump controller is  
recommended with a condensate receiver and feed  
pump.  
Figure 19 Piping for optional float-type water  
level controllers for steam boilers  
3. Install remaining controls as shown in Control  
Tapping Table and Figure 3, page 6.  
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Part Number 550-110-639/0703  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
4
Op t io n a l h e a t e rs  
EG and EGH boilers for tankless heater application  
are available only on special order as factory-installed  
optional equipment. Standard boilers cannot be  
adapted for heater use.  
Tankless heater hook-up  
(forced hot water or steam boilers)  
For correct operation, installasshown in Figure20(water boilers) or  
Figure 21 (steam boilers).  
1. Automatic mixing valve must be installed per mixing valve  
manufacturers instructions.  
2. Flow regulating valve must be installed. Size according to  
intermittent draw of heater as shown in following table.  
3. Operatingcontrolwithasmalldifferentialscaleisrecommended.  
Install in temperature control tapping in heater plate.  
4. In hard water areas, it isadvisabletosoften cold domesticsupply  
water to the tankless heater to prevent lime buildup.  
Figure 20 Tankless heater piping (water boiler)  
NOTE: Piping Connections not furnished. Use brass  
plugs in tees and crosses to facilitate cleaning in  
hard water areas.  
Weil-McLain ratings based on 60 PSIG domestic  
water pressure at heater.  
Notes  
Figure 21 Tankless heater piping (steam boiler)  
1. Gallons of water per minute heated from 40°F to 140°F  
with 200°F boiler water temperature.  
2. Continuous draw – no recovery period.  
3. These single wall heat exchangers comply with National  
Standard Plumbing Code provided that:  
• boiler water (including additives is pratically non toxic,  
having a toxicity range or class of 1, as listed in Clinical  
Toxicology of Commercial Products, and  
• boiler water pressureislimited tomax. 30psigbyapproved  
water or steam relief valve.  
4. EGH-85 & 95 Standing pilot systems - no tankless option  
5. EG-75 Standing pilot systems - no tankless option  
6. EGH-85 Water - use one heater only.  
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EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
5
Ga s p ip in g  
Connecting gas supply piping  
3. Remove knock-out disc from jacket panel which gas  
supply is to be piped.  
4. Follow good piping practices.  
5. Pipe joint compound (pipe dope) must be resistant  
to corrosive action of liquified petroleum gases. Apply  
sparingly only to make threads of pipe joints.  
6. Install drip leg at inlet of gas connection to boiler.  
Where local utility requires,extend drip leg to floor.  
7. Install ground joint union when required for  
servicing. See Figure 22.  
8. Install manual shut-off valve outside boiler jacket as  
shown in Figure 22 when required by local codes.  
9. Support piping by hangers, not by boiler or its  
accessories.  
Size gas piping considering:  
a. Diameter and length of gas supplying piping.  
b. Number of fittings.  
c. Maximum gas consumption (including any possible  
future expansion).  
d. Allowable loss in gas pressure from gas meter outlet  
to boiler. For pressure drops, see ANSI Z223.1.  
Canadian installations must comply with CAN/CSA  
B149.1 or .2 Installation Codes.  
1. For natural gas:  
a) Refer to following tables.To obtain cubic feet per hour,  
divide the input by 1000.  
b) Size for rated boiler input.  
10. In Canada only, the manual main shut off valve  
(when used) must be identified by the installer.  
c) Inlet gas pressure:  
5" W.C. minimum  
13" W.C. maximum  
d) Manifold gas pressure: 3¹⁄₂" W.C.  
11. Purge all air from piping.  
e) Install 100% lock-up gas pressure regulator in supply  
line if inlet pressure exceeds 13" W.C. Adjust for 13"  
W.C. maximum.  
12. Before placing boiler in operation, check boiler and  
its gas connection for leaks.  
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.  
2. For propane gas:  
a) Inlet gas pressure:  
11" W.C. minimum  
13" W.C. maximum  
b) Manifold gas pressure: 10" WC.  
a) Close manual main shut-off valve during any pressure  
testing at less than 13 inches water column.  
b) Disconnect boiler and gas valve from gas supply piping  
during any pressure test greater than 13 inches water  
column.  
c) Gas pressure regulator provided by gas supplier must be  
adjusted for maximum pressure of 13" W.C.  
d) Contact gas supplier to size pipes, tanks and regulator.  
Figure 22 Gas supply piping  
14  
Part Number 550-110-639/0703  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
6
Wirin g  
Re fe r t o c o n t ro l s u p p le m e n t fo r  
a d d it io n a l in fo rm a t io n  
For your safety, turn off electrical power  
Refer to zone valve manufacturers literature for wiring  
supply before making any electrical  
and application. A separate transformer is required to  
connections to avoid possible electrical  
shock hazard.  
power zone valves. Zoning with circulators requires a  
relay for each circuit.  
All wiring must be installed in accordance with  
requirements of National Electrical Code and any  
additional national, state or local code requirements  
Install room thermostat  
having jurisdiction. ALL wiring must be N.E.C. Class 1. Install room thermostat on an inside wall. Never install  
Boiler must be electrically grounded in accordance with where it will be influenced by drafts, hot or cold water  
National Electrical Code, ANSI/NFPA No. 70-latest pipes, lighting fixtures, television, rays of the sun or near  
edition.  
a fireplace.  
In Canada, installation must conform to CSA C22.1 Refer to Control Supplement or correct wiring diagram  
Canadian Electrical Code Part 1 and any local codes.  
for recommended heat anticipator setting with Standard  
equipment. Wire thermostat as shown.  
If original rollout thermal fuse element wire as supplied  
with boiler mustbereplaced, type200°Cwireor equivalent  
must be used. If other original wiring as supplied with  
boiler must be replaced, type 105°C wire or equivalent  
must be used.  
Figure 23 Wiring multiple zones  
Installer must attach wiring diagram inside jacket door.  
A separate electrical circuit with a fused disconnect switch  
(15 amp. recommended) should be used for the boiler.  
A strain relief bushing and adapter must be used at each  
point wherewiringpassesthrough controlcase(seeFigure  
23) to protect wiring insulation.  
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Fin a l a d ju s t m e n t s  
Water treatment  
Filling water systems  
Do not use petroleum-based cleaning or 1. Close manual air vents, drain cock, and automatic  
sealing compounds in boiler system. Severe  
boiler damage will occur.  
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 of cold fill pressure.  
Continual fresh make-up water will reduce boiler life.  
Minerals can build up in sections,reducing heat transfer,  
overheating cast iron, and causing section failure.  
3. Open automatic air vent one turn, if used.  
4. Open manual water feed valve.  
a) Starting on lowest floor, open air vents one at a time  
until water squirts out. Close vent.  
In hard water areas or low pH conditions (less than 7.0)  
consult local water treatment company.  
Freeze protection (when used):  
b) Repeat with remaining vents.  
Use antifreeze especially made for hydronic systems.  
Inhibited propylene glycol is recommended.  
5. Close manual water feed valve when correct boiler  
pressure is reached.  
Do not use automotive, ethylene glycol or  
undiluted antifreeze.Severepersonalinjury,  
death or substantial property damage can  
result.  
6. If purge valve is used - located in the return piping  
above isolation valve:  
a) Connect hose to purge 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.  
50% solution provides protection to about -30°F.  
Local codes may require back-flow preventer or actual  
disconnect from city water supply.  
d) Close purge valve and water feed valve cock.  
e) Open isolation valve.  
f) Fill system to correct pressure.  
Determine quantity according to system water content.  
Boiler water content is listed on page 27. Remember to  
add in expansion tank water content.  
Follow antifreeze manufacturers instructions.  
Filling steam boilers  
1. Do not fill (except for leakage tests) until boiler is  
ready to be fired.  
2. Fill to normal waterline, halfway up gauge glass.  
3. Boiler water pH 7.0 to 8.5 is recommended.  
4. Follow skimming procedure.  
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7
Fin a l a d ju s t m e n t s  
(continued)  
Skimming steam boilers  
To place in operation  
Clean all newly installed steam boilers to 1. Be sure boiler has been correctly filled with water.  
remove oil and grease. Failure to properly  
2. Follow lighting/operating instructions on boiler.  
clean can result in violent fluctuations of  
For propane boilers only:  
water level, water passing into steam mains,  
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.  
or high maintenance costs on strainers,  
traps and vents.  
Do not use petroleum-based cleaning or  
sealing compounds in boiler system. Severe  
boiler damage will occur.  
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.  
1. Provide 1 1/2" piping from skim tapping to floor  
drain.  
2. Adjust water line to midpoint of skim tapping.  
3. Fire boiler to maintain temperature below steaming  
rate.  
4. Feed in water to maintain water level. Cycle burners  
to prevent rise in steam pressure.  
5. Continue skimming until discharge is clear. May take  
several hours.  
6. Drain boiler.While boiler isWARM, BUT NOT HOT,  
flush all interior surfaces under full pressure until  
drain water runs clear.  
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 propanesupplier regardinginstallation ofa  
gas leak detector.There are some products on the market  
intended for this purpose.  
able to suggest an appropriate  
device.  
Your supplier may be  
3. If boiler starts, go to Step 5.  
If boiler fails to start, go to Step 4.  
7. Remove skim piping. Plug tapping.  
8. Close drain cock. Fill with fresh water to waterline.  
Start burners and steam for 15 minutes to remove  
dissolved gases. Stop burners.  
4. If boiler fails to start, check:  
a) Loose connection or blown fuse?  
b) Limit settingbelowboiler water temperatureor pressure?  
c) Thermostat below room temperature?  
d) Gas not turned on at meter and boiler?  
e) Incoming natural gas pressure less than 5" W.C. or  
propane less than 11" W.C.?  
9. Check traps and air vents for proper operation.  
Inspect base insulation  
f) If above fails to eliminate the trouble, refer to Control  
Supplement.  
The boiler contains ceramic fiber and  
fiberglassmaterials. Usecarewhen handling  
these materials per instructions on page 19  
of this manual. Failure to comply could  
result in severe personal injury.  
5. Makesureboilergoesthroughseveralnormaloperating  
cycles.  
6. Turn thermostatoroperatingcontroltodesiredsetting.  
Make sure base insulation is secure against base panels. If  
base insulation is damaged or displaced, do not operate  
boiler.Reposition or replace insulation.  
Part Number 550-110-639/0703  
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8
Ch e c k-o u t p ro c e d u re  
Check-out procedure  
b. For standingpilot - Turn gascockknobtoPILOTposition and  
extinguish pilot flame. Pilot gas flow should stop in less than 3  
minutes. Put system back into operation (see page 17).  
Check-off steps as completed.  
System properly filled with water?  
Limitcontrolsettodesigntemperatureorpressurerequirements  
ofsystem?Maximum limit setting- 240°F(water boilers) - 15#  
(steam boilers).  
Automatic air vent,if used,open one turn (water boilers only)?  
Air purged from system (water boilers only)?  
Steam boilers properly skimmed?  
For multiple zones, flow adjusted so it is about the same in  
each zone (water boilers only)?  
Air purged from gas piping?. Piping checked for leaks?  
Thermostat heat anticipator set properly? Refer to “Room  
Thermostat,”page 15 and correct wiring diagram.  
Are proper orifices installed? Check page 7 for proper size.  
Proper orificesmustbeused. Failuretodosowillcause  
severe personal injury, death or substantial property  
damage.  
Boilercycledwiththethermostat?Raisetohighestsetting. Boiler  
should go through normal start-up cycle. Lower to lowest  
setting. Boiler should go off.  
Follow operating instruction label on boiler for proper start-  
up.Also refer toTo Place in Operation,page 17.  
Measure gas input (natural gas only):  
a. Operate boiler 10 minutes.  
b. Turn off other appliances.  
Proper burner flame? Refer to “Check Main Burner Flames”  
andCheck Pilot Burner Flame,page 21.  
c.  
At thenaturalgasmeter,measuretime(in seconds) required to  
use one cubic foot of gas.  
Testlimitcontrol:Whileburnersareoperating,movelimitcontrol  
indicator below actual boiler water temperature or pressure.  
Burners should go off. Circulator should continue to operate  
(water boilers only). Raise indicator above boiler water  
temperature or pressure and burners should reignite.  
d. Calculate gas input:  
3600 x 1000  
=
Btuh  
number of seconds from step c  
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.  
e.  
Btuh calculated should approximate input rating on rating  
label.  
Check manifold gas pressure by connecting a manometer to  
the downstream test tapping on main gas valve.  
EG only - button on spill switch pushed in?  
To test ignition system shut-off device:  
MANIFOLDGASPRESSURE  
NAT. = 3.5" W.C.  
L.P. = 10.0"WC.  
a. For boilers with electronic ignition systems: Connect  
manometer to outlet side of gas valve.Start boiler,allowing for  
normalstart-upcycletooccur andmain burnerstoignite. With  
main burners on, manually shut off gas supply at manual main  
shutoff gas valve. Burners should go off. Open manual main  
shut-off gas valve. Manometer should confirm there is no gas  
flow. Pilot will relight, flame sensing element will sense pilot  
flame and main burners reignite.  
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 ServiceCertificateon thispagecompleted?  
All instructions shipped with this boiler reviewed with owner  
or maintenance person, returned to envelope and given to  
owner or displayed near boiler?  
In s t a lla t io n a n d S e rvic e Ce rt ific a t e  
Boiler Model  
BTU Input  
Series  
CP Number  
Date Installed  
Installation instructions have been followed.  
Check-out sequence has been performed.  
Above information is certified to be correct.  
Information received and left with owner/maintenance person.  
Installer  
(Company)  
(Address)  
(Phone) (Installer's Signature)  
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EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
9
S e rvic e  
Ha n d lin g fib e rg la s s a n d c e ra m ic fib e r m a t e ria ls  
REMOVAL OF COMBUS TION CHAMBER LINING OR BAS E PANELS  
The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic  
fibers can be converted to cristobalite in very high temperature 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).":  
Avoid breathing dust and contact with skin and eyes.  
Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for  
cristobalite at the time this document was written. Other types of respirators may be needed depending on  
the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://  
are also listed on this web site.  
Wear long-sleeved,loose fitting clothing,gloves,and eye protection.  
Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust.  
Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal.  
Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.  
NIOSH stated First Aid.  
Eye: Irrigate immediately  
Breathing: Fresh air.  
REMOVAL OF FIBERGLAS S WOOL — OR —  
INS TALLATION OF FIBERGLAS S WOOL, COMBUS TION CHAMBER LINING OR BAS E  
PANELS :  
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.  
Avoid breathing dust and contact with skin and 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 respirators may be needed depending  
on the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http:/  
are also listed on this web site.  
Wear long-sleeved,loose fitting clothing,gloves,and eye protection.  
Operations such as sawing, blowing, tear out, and spraying may generate airborne fiber concentration requiring  
additional protection.  
Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.  
NIOSH stated First Aid.  
Eye: Irrigate immediately  
Breathing: Fresh air.  
Part Number 550-110-639/0703  
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9
S e rvic e  
(continued)  
Also Refer to Additional Instructions  
Shipped With TheBoiler For Specific  
Control Operation and Troubleshooting.  
Verify Proper Operation After Servicing  
Label all wires prior to disconnection  
when servicing controls. Wiring errors can  
cause improper and dangerous operation.  
To avoid personal injury, death or  
property damage, keep boiler area clear  
and free from combustible materials,  
gasoline and other flammable vapors and  
liquids.  
Your boiler should be inspected,cleaned  
and,if necessary, adjusted once a year.A  
qualified service agency should be called.  
To avoid personal injury,before servicing:  
1. Disconnect electrical supply.  
2. Shut-off gas supply.  
Do not block flow of air to boiler.  
Incomplete combustion and flue gas  
spillagecan occur.  
3. Allow boiler to cool.  
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.  
Suggested m inim um service schedule for qualified service  
technician only  
Beginning of each heating season:  
Periodically duringheatingseason:  
1. Annualservicecallbyaqualified serviceagency.  
1. Checkrelief valve.Referencemanufacturersinstructions  
2. Check burners and flueways and clean if necessary.  
on relief valve tag.  
Reference “Clean Boiler Heating Surfaces” and  
2. Test low water cut-off,if used.Blowdown if low water  
“Cleaning Main Burners,page 21.  
cut-off is float type. Reference manufacturers  
3. Visuallyinspectbaseinsulation.Reference“InspectBase  
instructions.  
Insulation,page 17.  
Monthly during heating season:  
1. Check for leaks in boiler and piping. If found, repair  
4. Followprocedure“To Placein Operation,”page 17.  
5. Visually inspect pilot and burner flames. Reference  
at once.  
“Check Main Burner Flames”andCheckPilot Burner  
Continuous use of make-up water can  
damage boiler sections due to addition of  
minerals. Do not use petroleum based  
stop- leak compounds - leakage between  
the sections will occur.  
Flame,page 21.  
6. Visually inspect venting system for blockage,  
deterioration or leakage. Reference “Inspect Venting  
System,page 21.  
7. Check operation of low-water cut-off, if used, and  
additional field-installed controls. Refer to  
manufacturers instructions  
8. Checkthatboilerareaisfreefromcombustiblematerials,  
gasoline and other flammable vapors and liquids.  
9. Check for and remove any obstruction to flow of  
combustion or ventilation air.  
2. Check any gaskets for leakage. Tighten or replace, if  
needed. Do not overtighten bolts - gasket damage can  
occur.  
3. Visually inspect pilot and burner flames. Reference  
“Check Main Burner Flames”andCheckPilot Burner  
Flame,page 21.  
4. Visually inspect venting system for blockage,  
deterioration or leakage. Reference “Inspect Venting  
System,page 21.  
10. Followinstructionson circulatortooil, ifoillubricated.  
Over-oilingwilldamagethecirculator.Waterlubricated  
circulators do not need oiling.  
5. Checkautomaticairventforleakage. Ifleaking, remove  
vent cap and push valve core in to wash off sediment  
that may have accumulated oft the valve seat. Release  
valve, replace cap and open one turn.  
Daily during heating season:  
1. Checkthatboilerareaisfreefromcombustiblematerials,  
gasoline and other flammable vapors and liquids.  
2. Check for and remove any obstruction to flow of  
combustion or ventilation air.  
End of each heating season:  
1. FollowAnnual Shutdown Procedure,”page 21.  
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Part Number 550-110-639/0703  
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9
S e rvic e  
(continued)  
Check pilot burner flames  
functioning properly.If flame blows out or flickers drastically,vent system  
must be checked for obstructions or other causes of improper venting.  
2. Inspectallpartsofventingsystemsfordeterioration from corrosion, physical  
damage, sagging, etc. Correct all conditions found.  
3. Verify damper is open when burner ignites.For additionalinformation,see  
ControlSupplement.  
1. Proper pilot flame  
a) Blue flame.  
b) Inner cone engulfing pilot flame sensor.  
c) Pilot flame sensor glows cherry red.  
Clean boiler heating surfaces  
The boiler contains ceramic fiber and fiberglass materials. Use  
carewhen handlingthesematerialsper instructionson page19of  
this manual. Failure to comply could result in severe personal  
injury.  
Figure 24 Typical pilot burner flame  
1. Follow shut-down procedure  
2. Disconnect breeching and remove damper (if used) and draft hood.  
3. Removeupperrearjacketpanel.Turnbackjacketinsulationtoexposecollector  
hood.  
4. Removecollectorhood. Clean excessboilercementfrom collectorhoodand  
cast iron sections.  
5. Remove burners from base of boiler. Follow “Cleaning main burners” to  
thoroughly clean burners. Place newspaper in base of boiler to collect soot  
that will fall.  
6. With a wire flue brush, clean between the sections.  
7. Remove paper and soot. Vacuum or brush base and surrounding area.  
8. Replacecollector hood. Sealwith boiler cement.  
9. Replace draft hood, damper (if used) and breeching.  
10. Replaceinsulation and jacket panel.  
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.  
11. Replacemain burners.  
When replacing, burner tubes must be seated in slots in back  
burner support with openings face up. Gas orifices must inject  
down center of burner.Failureto properlyseat burners willresult  
in severe personal injury,death or substantial property damage.  
Figure 25 Typical main burner flame  
12. Follow“To Place in Operation”procedure.  
NOTE: Excessivesootingindicates improper gascombustion. Callaqualified  
serviceagencyor your localgasutilitytocheckfor proper combustion andmake  
any necessary adjustments.  
Cleaning main burners  
Check main burner flames  
1. Vacuum or brush burners to remove dust and lint.  
1. Proper burner flame - Yellow-orange streaks may  
appear - caused by dust.  
2. Improper flame:  
When replacing, burner tubes must be seated in slots in the back  
with openings face 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.  
a) Overfired - Flames large.  
b) Underfired - Flames small.  
c) Lack of primary air - Yellow tipping on flames; sooting  
will occur.  
Annual shut-down procedure  
1. Follow correct lighting/operating instructions on boiler.  
Inspect venting system  
2. Do not drain system unless exposure to freezing temperatures will occur.If  
antifreeze is used with system, do not drain.  
3. If complete boiler and piping system must be drained to avoid freezing,  
provide method to drain water from both ends of boiler at or below return  
tappinglevel.  
1. Check venting system at least once a month during  
heatingseason. Withboilerfiring, holdcandleormatch  
below lower edge of draft hood “skirt. If flame does  
not blow out, but burns undisturbed, vent system is  
Part Number 550-110-639/0703  
21  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
10  
Re p la c e m e n t p a rt s – EG  
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 could result in severe personal injury.  
22  
Part Number 550-110-639/0703  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
10  
Re p la c e m e n t p a rt s – EG  
(continued)  
NOTE 1: Order sufficient quantities to replace all orifices within a  
base  
Part Number 550-110-639/0703  
23  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
10  
Re p la c e m e n t p a rt s – EGH  
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 could result in severe personal injury.  
24  
Part Number 550-110-639/0703  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
10  
Re p la c e m e n t p a rt s – EGH  
(continued)  
NOTE 1: Order sufficient quantities to replace all orifices within a  
base  
Part Number 550-110-639/0703  
25  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
11  
Da t a  
Dimensions EG  
Dimensions P-EG  
Dimensions EGH  
26  
Part Number 550-110-639/0703  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
12  
Ra t in g s  
DOE  
Notes:  
*
Add prefix “P” for package boiler completely assembled and wired with  
jacket and controls (PEG-30-S through PEG-55-S only).  
heater.  
2. EGH water boilers tested for 50 P.S.I working pressure.  
3. Based on standard test procedures prescribed by the United States  
Department of Energy.  
1. EG-30 thru 75: Add suffix “SPD” or “SP” for standing pilot; add “PID” or  
“PI” for electronic ignition (30-65 — damper required in U.S.; optional in  
Canada); add “N” for natural; add “Lfor propane; add “W” for water; add  
“S” for steam; add “T” for tankless heater; add “P” for provisional tankless  
heater.  
EG-75 thru EGH-125: CSA Gross output.  
4. EGH-105 thru 125 may be installed at altitudes of 2,000-4,500 feet  
subject to acceptance by Provincial Inspections Authority based on  
field tests of individual installations.  
EGH-85 & 95: Add suffix“SP” for standing pilot; add “PI” for electronic  
ignition (damper available on PI only); add “N” for natural; add “Lfor  
propane; add “W” for water; add “S” for steam; add “T” for tankless heater  
(tankless available on EGH-85 thru 125 PI Water and Steam; EGH-85 and  
95 SP Steam only); add “P” for provisional tankless heater.  
5. Net I=B=R ratings are based on net installed radiation of sufficient  
quantity for the requirements of the building and nothing need be  
added for normal piping and pick-up. Water ratings are based on a  
piping and pick-up allowance of 1.15; steam ratings on an allowance of  
1.333. An additional allowance should be made for unusual piping  
EGH-105 thru 125: Add suffixPI” for electronic ignition (damper available  
on PI only); add “W” for water; add “S” for steam; add “T” for tankless  
and pick-up loads. Consult local Weil-McLain representative.  
Part Number 550-110-639/0703  
27  
EG, P EG, EGH GAS -FIRED BOILERS S ERIES 4 — BOILER MANUAL  
Standard equipment  
EG additional equipment  
Factory-Assembled Section Block  
Insulated Extended Jacket  
Draft Hood  
Aluminized Steel Burners  
Non-Linting Pilot Burner  
Heater Cover Plates (for boilers with tankless heater openings)  
Control Wire  
Tankless Water Heater – EG-35-65 PI and SP EG-75 PI only  
With tankless heater: Combination High Limit, Low Limit, Circulator  
Control, and Relay with 40 VA Transformer  
Tankless Steam Heater - EG35-75  
With Tankless Heater:  
Operating Control Tankless Heater 35-S-29 for All Units  
EGH boilers add:  
Electrical Junction Box  
Combination Gas Control Valve (includes main gas valve with redundant seat, PI  
and PI with damper models; main gas valve with single seat, 24V models;  
pressure regulator, gas cock, pilot filter, pilot adjustment)  
Highest Efficiency Models, PI Intermittent Electronic  
Ignition System  
High Efficiency Models, SP Constant Burning,  
Thermally Supervised Pilot System, Thermocouple  
100% Shutoff  
EG boilers add:  
Combination Gas Valve for 24 volt  
Thermocouple (high efficiency models)  
Rollout Thermal Fuse Element  
Spill Switch  
Highest Efficiency Models, PID Intermittent Electronic  
Ignition System and Automatic Vent Damper  
40 VA Transformer with Receptacle for Circulator Relay  
High Efficiency Models, SPD Constant Burning, Thermally  
Supervised Pilot System and Automatic Vent Damper  
For EGH water boilers  
For EG water boilers  
Built-in Air Eliminator  
Built-In Air Eliminator  
30 P.S.I. Relief Valve  
30 P.S.I. Relief Valve  
Combination Pressure Temperature Gauge  
High-Limit Control  
40 VA Transformer with Receptacle for Circulator Relay  
Circulator Relay  
Combination Pressure-Temperature Gauge  
High-Limit Control for PI and PI with Damper Models  
Dual-Limit Control for Standard Efficiency Models  
Circulator Relay  
For EGH steam boilers  
For EG steam boilers  
Relief Valve  
Relief Valve  
Steam Pressure Gauge  
Steam Pressure Gauge  
High-Limit Pressure Control  
Syphon  
High-Limit Pressure Control (two limit controls on EGH-85 and 95 SP)  
Syphon  
Gauge Cocks  
Gauge Cocks  
Gauge Glass  
Gauge Glass  
Low-Water Cutoff – Probe Type  
Low-Water Cutoff  
40 VA Transformer  
EGH additional equipment  
Tankless Heaters – PI Water or Steam,  
SP Steam only  
With Tankless Heater(s):  
Operating Control  
Automatic Vent Damper  
28  
Part Number 550-110-639/0703  

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