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
1
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“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.
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. See“Boiler 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.
4
Part Number 550-110-639/0703
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1
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
8
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 in“E”tapping.
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 manufacturer’s 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 in“E”tapping.
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 manufacturer’s 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.
12
Part Number 550-110-639/0703
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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
manufacturer’s 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.
Part Number 550-110-639/0703
13
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
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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 manufacturer’s 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.
Part Number 550-110-639/0703
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EG, P EG, EGH GAS -FIRED BOILERS — S ERIES 4 — BOILER MANUAL
7
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 manufacturer’s 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
17
EG, P EG, EGH GAS -FIRED BOILERS — S ERIES 4 — BOILER MANUAL
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 to“To 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”
and“Check 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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Part Number 550-110-639/0703
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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
19
EG, P EG, EGH GAS -FIRED BOILERS — S ERIES 4 — BOILER MANUAL
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.Referencemanufacturer’sinstructions
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 manufacturer’s
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”and“CheckPilot 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
manufacturer’s 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”and“CheckPilot 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. Follow“Annual Shutdown Procedure,”page 21.
20
Part Number 550-110-639/0703
EG, P EG, EGH GAS -FIRED BOILERS — S ERIES 4 — BOILER MANUAL
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 “L” for 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 “L” for
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 suffix“PI” 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
|