Weil-McLain PEG-30 User's Manual
Contents
1. Damper harness optional Wiring harness Jumper plug required without damper Damper harness receptacle Optional Damper harness plug Gas valve Thermopile lead wire Thermopile lead Rollout TFE 9070 CVL EC7 0SS JEquUINN Hed 88EZ 09E9H NI AD UBBIUDIN IS SUEI OOS UIETOW IOM NIVT UU 13m Ui ajdnooowey e ym paddinba are G9 93d 94 yBnouyy 0 93d 9F lldouu u e ym paddinba si 7 93 Ajuo 94 94 104 p sn aBeyno jo ld souesinu plore o Bunjas tu s s AOGE Sd Z WNWIUIW 0 uui YBIY sn py Buas Wa sAs p Jzis p o onuo2 llu 1sn pvy OL 19 e u ss yue YIM p nb jonuoo BuneJ do punouB sisseyo palje sul piay sajousq Salles Ul pasm 94 yw Yy Ieuonippe O O M 1 weJ6elp uo umoys suonguBis p YL HL HL HL 1ouBI SUOISUUOI AJBA seb g9 94d 93 uBnolu 0 O3d 93 104 Jenueui uon e1 do uone le su qO8 0 19431 Je souuau JO a0e d u uollo9uuo2 49g 104 d98 p sn Jedwep uaa snid A BA seb Jo mep auedwe YoJeW o 1ojedionue Jas e souusu uoneuuojJul UOed dde JO J jioq uM payoed SUOHONSU JUSUOCGWOD 01 U09 0 JAJOY p sn aq 1snui juajeainba S l 10 9 90 ed paoejd as q 1snuu avue jdde y ym p aijddns se asim jeulbuo Jayjo J p sn aq 1snui zuajeanb S JO JIA 200Z dA p sejd aq snw eoueljdde y UyIM palddns se JIA 3341 nolloi jeUIBuO J uonipuoo Jl2. Check for 24VAC between thermostat wire nuts and ground Part Number 550 110 032 0607 In event of vent damper failure Effikal vent damper If troubleshooting chart recommends replacing actuator and actuator is not immediately available damper blade can be fixed in an open position to allow boiler operation Manually turning blade can cause actuator damage Follow these instructions only in case of no heat or damper actuator malfunction 1 Move damper service switch to Hold Damper Open position Apply call for heat to boiler Damper blade should then rotate to open position and boiler will fire 2 Ifstep 1 does not open damper manually rotate damper blade to open position using wrench or pliers on flat shaft between damper and actua tor Boiler will fire Verify that damper service switch is in Hold Damper Open position Figure 9 3 Donot leave vent damper permanently in this position Replace actua tor immediately If vent damper is left in open position boiler will not operate at published efficiencies Johnson Controls vent damper If troubleshooting chart recommends replacing actuator and actuator is not immediately available damper blade can be fixed in an open position to allow boiler operation Follow these instructions only in case of no heat or damper actuator malfunction See Figure 9 1 Turn off power to boiler Failure to turn off power to boiler can result in severe personal injury death or substantial pr
3. minute after the pilot is lit ON position ON control Release reset button Pilot should remain lit If pilot goes out Red 7 Ta repeat steps 5through 11 reset button o If reset button stays depressed after release stop and 89334 immediately call your service technician or gas supplier If the pilot will not stay lit after several tries turn the gas Wait five 5 minutes to clear out any gas Then smell for gas control knob clockwise x to OFF and call your service including near the floor If you smell gas STOP Follow B in technician or gas supplier the safety information above If you don t smell gas go to the 12 Replace access panel next step 13 Turn gas control knob counterclockwise v to ON 14 Turn on all electric power to the appliance 15 Set thermostat to desired setting 16 Replace front panel WIII To TURN OFF GAS TO THE APPLIANCE OE S 1 Setthe thermostat to lowest setting 3 Remove front panel 2 Turn off all electric power to the appliance if service is to be 4 Turn gas control knob clockwise x to OFF performed 5 Replace front panel 550 223 040 0906 Remove access panel located above burners Part Number 550 110 032 0607 17 EG 30 thru 75 Series 4 and PEG 30 thru 65 Series 4 Lighting instructions Robertshaw 7OOOERHC FU FOR YOUR SAFETY READ BEFORE LIGHTING M This appliance has a pilot which must be ligh
4. puaba7 punou6 sisseyo paljeysul pjay sajouag Z YOLIN sales U pasim 94a Yur YBIY Ieuolippe O O M 1 Jenuew uon B1 do uoni B su dog 0 13421 JelsoLLU U oo Q 0 5 _ adr HOLIMS pasn j 3K 40 e0e d ul uooeuU0 Og 404 dod 1noTiou TildS SIIN VNOlLLIGQV Bum s 1oledionue JeJsouayy pue Bum JO suollonulsui s Jaun oe nuew Ju uoduuoo 0 13431 gJoye noslo JO S A BA 8 uoz Bulsn suu s s uoz jdynu 104 sduie 0Z 0 0 Jojedionue agra hte Jas swajs s uoz Bus 104 Je souueul uoneuuojul UOHEOI dde 10 1 lloq y m payoed suolonilsui Ju uodulo2 01 U09 0 JAJOY O mia H pasn aq snu juajeainba if j S 10 9 90 d peoejdas q snw HOLIMS aouel dde ay yim palddns se eM jeulBuo aa beter ees 39IA8H3S 1 4 0 J p sn aq 1snuu Ju gAInb s 10 JIA a 9 002 8d paoejdes aq ysnw aouel dde au OL TVD PONOV NENOS y m paijddns se aim 3341 nollo1 jeubuo J UONIPUOD J gus JJO lldd samod yno ee sS A py S a10u dog YO lou pall noy us s oB8 uoo y s ejou dog 331 LVISOWNSHL ANNONO 3 YO LWLSOWYSHL YOLOANNOD 1noTiou INAWdINOA po2 200 JO jeloulAoud jeuoneu Jayjo Aue Fret pue ped 0 39 1229 V S O epeueg g TOYLNOD YOLVINOYIO Jeuoyeu Jeyjo Aue puy O 3 N V S N V HOLIMS Kiojaey HOLIMS 9 aou 351A83s ULIM OWA 0ZL TWNOILIGGY 3 6 et eee webeiq Buum Jeppe7 webeiq BuuiAA opeway
5. Retest Y Open thermostat contacts for 30 seconds Vent damper will rotate to closed position Close thermostat contacts Vent damper will rotate to open position Is 24VAC present across gas valve terminals No Yes No Yes v Is main flame on now No Yes v Retest Is gas valve cock turned to ON position v No Yes Check continuity of each wire in damper harness Does continuity exist for each wire See Table below No Yes Replace damper wiring harness Retest Y Remove damper harness from damper harness plug TEMPORARILY install jumper between terminal 2 and terminal 5 on damper plug in boiler wiring harness See figure right Does boiler fire No Yes v Replace gas valve Retest Replace damper actuator Retest Part Number 550 110 032 0607 Y y Turn gas valve cock to ON position Retest Replace gas valve Retest Damper Harness Continuity Table 6 Pin Molex 4 Pin Molex os roar Pin ea Pin 10 20 A30 2 3 5 5 3 4 H 3 4 Not used 20 10 5 2 6 Not used 03106 EG 30 thru 75 Series 4 and PEG 30 thru 65 Series 4 Troubleshooting continued Chart 2 Boiler will not fire water boilers with tankless Secure connections Check for loose wire connections or bad combination control Check for open thermostat LWCO high l
6. See below and to replace any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Do nottry to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building Ifyou cannot reach your gas supplier call the fire department LIGHTING INSTRUCTIONS I STOP Read the safety information above on this label 8 Find pilot follow metal tube from gas control The Setthe thermostat to lowest setting pilot is between two burners behind the access uu off n reine power to the appliance panel Remove front panel iaht v to SET Depress and move selector arm left v to OFF Note ao aa s i Selector arm cannot be moved to OFF unless selector arm 59337 is depressed slightly Do not force 10 Hold selector arm in SET position and immediately light the pilot with a match Continue to hold selector arm to SET for about one half 2 minute after the pilot is lit Position ED Selector Release selector arm Pilot should remain lit If pilot goes out indicator arm repeat steps 5 through 11 toe coat Ifthe pilot will not stay lit after several tries move selector arm left lt gt to OFF and call your service technician or seaae gas supplier 12 Replace access panel Wait five 5 minutes to clear o
7. box Rollout TFE Transformer relay EG 75 water boilers without tankless heaters 1 Mount and wire controls per wiring diagram page 4 and Figure 2 a Attach junction box inside left jacket panel with 8 32 x 1 2 machine screws and green ground nuts provided Install transformer with plug in relay receptacle and relay In Canada use chain and hook strain relief Operating and limit circuit wiring must be 18 gauge or heavier 2 Bring supply wiring to boiler Must be 14 gauge or heavier 3 Proceed to page 12 Part Number 550 110 032 0607 Figure 2 Damper Optional Damper harness optional Draft hood Wiring harness Spill Jumper plug switch required without damper wires Damper harness receptacle Optional Dual limit control Damper harness lt my plug Gas valve Circulator by others Thermopile lead wire Junction box Thermopile lead Transformer relay Rollout TFE 90 0 Z08 727 0SS J qQWNN Hed 1 e y ss yue yM 88EZ 09E9P NI AID ueBIu9IN IS Suerg 00G ute TONW II A Ja yeM JOY p 2104 NIVP U lm UF ores 99 02 93 papiaoid jou swa AIdNODOWHYSHL FIdOWYAHL ATIdNODOWYSHL INWA NIXIM AYOLOVS 39VLTOA MOT svo SNI3IM AYOLOVS OWA 021 INYA 1Olld NIzIIA Q13ld 39VLTOA MOT SY9 t JINODOWYIHL BuloiAJ s 10 Buljeysul a10jaq amod jo uuoosiq Yeap 10 Anfu J9A9s Penney asnes ues puezey yooys 910593 aL Lal
8. limit to be open Replace limit if necessary Figure 10 B R w 03201 Ne Figure 11 Thermopile lead wire top To limit controls From limit controls Thermopile lead wire bottom Thermopile lead to pilot burner 03105 Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Troubleshooting continued Chart 1 Boiler will not fire water boilers without tankless Secure connections Is damper harness securely plugged in at both ends Check for loose wire connections or bad relay on transformer Check for open thermostat LWCO high limit spill switch or rollout thermal fuse element contacts or check for loose wire connections DANGER If LWCO spill switch or rollout thermal fuse element contacts are open determine cause and correct condition Failure to do so will cause severe personal injury death or substantial property damage No Yes v Is 24VAC present across transformer terminals C amp Y No Yes v Is 24VAC present across transformer terminal C and yellow wire on vent damper connector No Yes v Is vent damper rotated open No Yes Check repair out of round stack section Does vent damper rotate open No Yes Y Is 24VAC present across gas valve terminals OP Y Replace actuator
9. mW MARIN EG 30 thru 75 PEG 30 thru 65 Gas Fired Boilers Series 4 Control supplement Standing pilot For additional information refer to EG PEG EGH Boiler manual for Natural or Propane gas tankless heater application optional CERTIFIED WARNING This supplement must only be used by a qualified heating installer service technician Before installing read all instructions including this supplement the boiler manual and any related documents Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Part Number 550 110 032 0607 EG 30 thru 75 Series 4 and PEG 30 thru 65 Series 4 Please read this page first Hazard definitions The following defined terms are used throughout these instructions to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product DANGER Indicates presence of hazards that will cause severe personal injury death or CAUTION NOTICE substantial property damage Indicates presence of hazards that can cause severe personal injury death or substantial property damage Indicates presence of hazards that will or can cause minor personal injury or property damage Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or prop
10. y m peddinbe s g 93 luo G 93 104 p sn L Bel no 1olid souesinu pore o Buas uu s s aAoge Sq Z unullului 0 pwu YBIY ysnipy Bum s uu ls s p uls p 0 04 UCO Jayeoy ss yue YIM p nb jonuoo BuneJ do punoub sisseuo p lle sur pi lj sejoueg s l1 s U pasim 943 Yw uBiu Ieuolippe O M 1 weiBelp uo umoys suonguBis p YL HL YL HL 1ouBI suoll99uUu00 AJLA se g S3d 3 uBnouu 0 93d 93 104 yenuew uo g1 do uollle su qO8 0 143 Je souueu JO vejd u u0ll99uuo5 dO8g 104 d98 p sn J Jadwep juan snjd Ajea seb Jo mesp sadwe yoyew 0 1oledionue Jag elsouusu uoneuuojJul uoneojdde JO J loq YIM payoed suononuisui JUBUOCWOD oJ uo2 0 1342 p sn aq snui juajeninbe S 10 9 60 adh p o d aq 1sntu souel dde ay yim paliddns se eum jeulBuo Jaujo J pasn aq Jsnw 1u gAInb s JO JIW 9 002 ad paoejdes aq jsnw aoueljdde y UA paliddns se JIA 331 lnolloi eUIBUO J uolipuoo Jl us JJo p lldde Jamod jnouyim UMOYs 9e U09 IV sjuawauinbes po2 e90 JO jelouIAOJd jeuoneu 134 0 Aue pue ped O T 1220 VSO Bpeued g syuaw a nb u poo e2o JO 942S jeuoyeu Jayjo Aue puy O 3 N V S n V gouepsoode ul palje sul aq snw Bul S8JON I1sn pv OL seb jeunjen olid Bulpueys s 0 93 AMdOWYSHL 10 FIdNODOWYSHL 9 lou AATVA SV LL 9 OL sajou LIWN
11. 0 thru 65 water boilers with tankless heaters 6 7 Control installation EG 30 thru 75 and PEG 30 thru 65 steam boilers with probe 8 9 Control installation EG 30 thru 75 steam boilers with float type low water cutoff 10 11 Damper instalatii isi LLL III sued asana amanda aaaeeeaa aeaaea aaiae 12 13 CHECKOUT procedure ULU dente aannaaien ainiaan naandaa anaiai anaa iannis 14 Lighting IMSTHUCTIONS LULU ULU 15 18 Troubleshootiig u IILI Issa aa aaa aaa aaa a aA Aaaa aS Eada aAa aaaea BAE aada 19 23 Replacement parts U UU ULLA UI 24 Part Number 550 110 032 0607 9070 LVL 27 0SS 19 EMA Joy Aynes6 YIM pasn jou 1oje n2JiO 0 punou6 sisseyo pajle sul pjay sejoueq a6 Salas U Paula 943 Yuu uBiu jeuoHIppe O O M 19 weJ6elp uo umoys suonguBis p YL HL HL HL 1ouBi suo lo guuoo anjea seb 9 93 uBnouu 0 93 104 dnooouu1 u e y m p ddinb ale g 93 uBnouu 0 93 lldouu u e ym p ddinb si 93 juo G 93 104 p sn Jenuew uo e1 do uonelle su qO8 0 19431 1e souuSUu JO a0e d u uollo9uuo2 49g 104 d98 Bum s 1oledionue e souuu9u pue uM 10 suononilsu sJ 1n o jnueui JUBUOCWOD 0 19494 sJoye noulo JO S A BA uoz Husn suu s s uoz l dninuu 104 sdwe 0p 0 0 JoJedioUe 8s stuu s s uoz l B5uls 104 Je souusul uoljgulJoJu uoneojdde 10 1 ioq UJIA pa
12. 3WdI0O3 asl G lou 1noTiou dog uO IVLSOWYSHL 3 6 ajou TOMLNOD fio e4 0 a100 HOLIMS ajou SNI1V33dO JOYLNOD TildS p sn J SLINIT 1IWI1 TWNOILIGAY 3 wejsbeig BulliAA deWaYyOS Part Number 550 110 032 0607 10 Standing Pilot Boilers Control Supplement Control installation continued For your safety turn off electrical power supply and turn off external gas supply valve before attempting to work on the boiler Failure to comply can cause severe personal injury death or substantial property damage EG 30 thru 65 steam boilers with float type low water cutoff 1 Mount and wire controls per wiring diagram page 10 and Figure 6 a b c Attach junction box inside left jacket panel with 8 32 x 1 2 machine screws provided Install transformer with plug in relay receptacle Operating and limit circuit wiring must be 18 gauge or heavier 2 Bring supply wiring to boiler Must be 14 gauge or heavier 3 Proceed to page 12 Figure 6 Damper lt gt Damper harness Draft hood i i 2 Wiring harness Spill switch Damper harness wires L receptacle Pressure Damper harness limit plug control Beeps Gas valve low water A cutoff Junction box Rollout TFE Transformer relay EG 75 steam boilers with float type low water cutoff 1 Mount and wire controls per wiring diagram page 10 and Figure 7 a b C Attach junction b
13. A OZ puaba7 9 lou FYIM GV31 STIdOWYSHL Buloias 10 Buyjeysul asojaq amod yoauuoosiq yeep 10 Aunful auanes asneo ued puezey yooys 291399 ETTI AYY sol 0980 NFOMd SInN3WMA 0 10u xog AYOLINI NOLLONAr HOLIMS 30IA83S 6 30u 1N3NWdI0O3 OWA PZ OWA 021 YSWYOSSNVYL LINIT Geen Aioye4 HOLIMS g 30u NILYYIdO TildS pesn 4 SLINIT TWNOILIGQY 3 wejbeig BulliAA deWaYyOS Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Control installation For your safety turn off electrical power supply and turn off external gas supply valve before attempting to work on the boiler Failure to comply can cause severe personal injury death or substantial property damage EG 30 thru 65 water boilers without tankless heaters 1 Mount and wire controls per wiring diagram page 4 and Figure 1 a b Attach junction box inside left jacket panel with 8 32 x 1 2 machine screws provided Install transformer with plug in relay receptacle and relay Operating and limit circuit wiring must be 18 gauge or heavier 2 Bring supply wiring to boiler Must be 14 gauge or heavier 3 Proceed to page 12 Figure 1 Damper C Damper harness Draft hood A f lt Wiring harness Spill switch Damper harness wires r receptacle g Damper harness O lt F SS lu Circulator N plug Limit control Gas valve Junction
14. EG 30 thru 65 and PEG 30 thru 65 steam boilers with probe type low water cutoff 1 Mount and wire controls per wiring diagram page 8 and Figure 4 a b c Attach junction box inside left jacket panel with 8 32 x 1 2 machine screws provided Install transformer with plug in relay receptacle Operating and limit circuit wiring must be 18 gauge or heavier 2 Bring supply wiring to boiler Must be 14 gauge or heavier 3 Proceed to page 12 Figure 4 Damper Draft hood Pressure limit control Spill switch wires Probe type low water cutoff Junction box Transforme Damper harness Wiring harness Damper harness receptacle r relay EG 75 steam boilers with probe type low water cutoff 1 Mount and wire controls per wiring diagram page 8 and Figure 5 a Attach junction box inside left jacket panel with 8 32 x 1 2 machine screws and green ground nuts provided Install transformer with plug in relay receptacle In Canada use chain and hook strain relief Operating and limit circuit wiring must be 18 gauge or heavier 2 Bring supply wiring to boiler Must be 14 gauge or heavier 3 Proceed to page 12 Part Number 550 110 032 0607 Damper harness plug Gas valve Rollout TFE Figure 5 Damper Optional Operating limit control High limit control Probe type low water cutoff Junction box Transformer relay
15. HOIH pasn J 3K THdS SLIWITINOILIGaY 341 0 aou HOLIMS LNOTION JOULNOOD LNT G 310u dog 3 YO LVLSOWYSHL 6 30u TONLNOD NILYYIdO YOLIJNNO9 Y3dNYa 340 LN9 Y3LYM MOT Y3dNYa OL 318V9 Laou annoya INaNdINOA OWA Och HOLIMS 33IAN3S OWA 021 wejbeiq BuHiAA 12ppe7 p S 19S GO NAY O DAd PUE p S 19S GZ NAY 0 93 ONIYIM AYOLOVS SDVLIOA MOT ONIMIM AYOLOVS OWA 021 ONIMIM 07314 SDVLIOA MOT ONIMIM 07314 OWA 02 AidOWYSHL AIdNOOONs aaa Ti I ATIdOWYSHL 10 1O1ld 31d nOOONWsH3H1 puaba7 LL lou YIM GV3131IdONH3H1L BulolAu8s 10 Bullle su aJ0jeq samod yoauuodsiq yjeap 10 Aunful aianes asneo ued puezey yous e211199 3 ONINUYM L pue 0 sajou LINT H9IH 3ATVA SVD YOLOANNOO uYadWvd XO8 NOILONN qasn LON 319Y1d3934 AVIS SLAN SUIM HOLIMS AOIAYSS SS I OVA PZ DVA 021 USWYOSSNVYL 8 ajou 440 LNO Se Y3LYM MO1 T LNAWdINOA G jou dO YO LWISOWYSHL 6 3100 JONLNOOD Aioye4 01 30u HOLIMS a ajou ONILVYAdO TOYLNOD TildS pasn 4 SLINIT WN TWNOILIGOY X wejsbeig BuniMm dIVeWaYyoS Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Control installation continued For your safety turn off electrical power supply and turn off external gas supply valve before attempting to work on the boiler Failure to comply can cause severe personal injury death or substantial property damage
16. Series 4 standing pilot ignition system boilers Any other damper installed can cause severe personal injury or death Description Manufacturer Weil McLain Mfr s part number part number Damper 5 EG 30 and EG 35 PEG 30 and PEG 35 Effikal RVGP KS 5BKF 381 800 475 assembly Johnson Q35GD 2 6 EG 40 and EG 45 PEG 40 and PEG 45 Effikal RVGP KS 6BKF 381 800 476 Field Controls 02722701 Johnson Q35GF 2 7 EG 50 and EG 55 PEG 50 and PEG 55 Effikal RVGP KS 7BKF 381 800 477 Field Controls 02723101 Johnson Q35GH 2 8 EG 65 and EG 75 PEG 65 Effikal RVGP KS 8BKF 381 800 478 Johnson Q35GK 2 Damper actuator Effikal RVGP 510 512 337 Johnson M35BE 1C 510 312 255 Damper harness Weil McLain 591 391 795 Boiler EG 30 thru 75 water Weil McLain 591 391 864 wiring EG 35 thru 65 water with tankless 591 391 865 harness EG 30 thru 75 steam float LWCO 591 391 866 EG 30 thru 75 PEG 30 thru 65 steam probe LWCO 591 391 867 Pilot kit EG PEG 30 thru 65 Natural gas Weil McLain 510 811 640 Propane gas 510 811 642 Pilot burner EG 75 Honeywell Q327A1642 511 330 186 Thermopile 36 long EG 75 Robertshaw CP 2 511 724 259 Second pressuretrol wire harness Weil McLain 591 391 825 Thermopile lead wire 5 EG 75 Robertshaw 590 850 561 Gas valve x 1 2 sizes 30 thru 50 Honeywell VR8200A2116 OAA natural Robertshaw 7200ER 7A0 A1B 042 511 044 360 gas 3 2 x 3 1 2 st
17. el 2 Turn off all electric power to the appliance if service is to be 4 popis gas control knob slightly and turn clockwise to performed I 5 Replace front panel 550 223 081 0706 18 Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Troubleshooting DANGER Burner access panel must be in posi tion during boiler operation to prevent momentary flame rollout on ignition of main flame Severe personal injury or substantial property damage will result Never jumper bypass any device ex cept for momentary testing as outlined in Troubleshooting Charts Substantial property damage and or severe personal injury could occur Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous opera tion Verify proper operation after servicing See vent damper manufacturer s instructions packed with vent damper for additional information Failure to comply could result in severe personal injury death or substantial property damage Before troubleshooting 1 Have a voltmeter that can check 120 VAC 24 VAC and a continuity tester Check for 120 VAC minimum 102 to maximum 132 to boiler Be sure pilot is lit See Lighting instructions on pages 15 18 for details Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed
18. ep sizes 55 thru 65 Honeywell VR8300C4050 511 044 256 3 2 x 1 size 75 Robertshaw 7000ERHC S7C 511 044 505 Gas valve 1 2 x Propane gas sizes 30 thru 50 Honeywell VR8200C1074 511 044 258 propane gas 3 x 34 Propane gas sizes 55 thru 65 Honeywell VR8300C4100 511 044 257 x 1 Propane gas size 75 Robertshaw 7000ERHC S7C 511 044 506 Weil McLain Com WEIL MLAIN soo Baie Ste 24 Michigan City IN 46360 2388 http www weil mclain com Part Number 550 110 032 0607
19. erty damage Note to the installer NOTICE Controls must only be installed by a Weil McLain distributor or other qualified installer service technician in accordance with this Supplement and all applicable codes and requirements of the authority having jurisdiction Read this Control Supplement completely before beginning the installation If the information in this Supplement is not followed exactly a fire explosion carbon monoxide emission or other hazardous conditions can result causing severe personal injury death or substantial property damage This system is used on gas fired boilers without vent dampers as shipped from the factory This system is not offered for retrofit Any attempt to apply the system components to boilers shipped for use with a different control system will not be covered under boiler warranty and can cause severe personal injury death or substantial property damage When calling or writing about the boiler please have the boiler model number from the boiler rating label and the CP number from the boiler jacket Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Table of contents Hazard definitions and Note to the installer 2 Control installation EG 30 thru 75 water boilers without tankless heaters 4 5 Control installation EG 3
20. imit spill switch or rollout thermal fuse element connections DANGER If LWCO spill switch or rollout thermal fuse i element contacts are open determine cause and correct condition Failure to do so will cause severe personal injury death or substantial property damage contacts or check for loose wire Check repair out of round stack section Does vent damper rotate open No Yes y Replace actuator Retest lt No Yes Is damper harness securely plugged in at both ends Is 24VAC present across combination control terminals V2 amp Z No Yes Y Is 24VAC present across transformer terminal V2 and yellow wire on vent damper connector No Yes y Is vent damper rotated open No Yes gt Is 24VAC present across gas valve terminals No Yes Y Open thermostat contacts for 30 seconds Vent damper will rotate to closed position Close thermostat contacts Vent damper will rotate to open position Is 24VAC present across gas valve terminals No Yes v Check continuity of each wire in damper harness Does continuity exist for each wire See Table below No Yes Y l Replace damper wiring harness Retest Remove damper harness from damper harness plug TEMPORARILY install jumper between terminal 2 and terminal 5 on damper plug in boiler wiring harness See figure right D
21. k the reading on the multimeter The reading should be around 28 millivolts for a thermocouple or 700 millivolts for a thermopile g If multimeter reading is significantly less than above and pilot flame is appropriate replace the thermocouple or thermopile 2 Checking thermopile and high limit control circuit closed system Fig ure 11 a Usean electronic multimeter with leads fitted with alligator clips Set meter scale to DC Millivolts b Loosen the insulated terminal on the TOP thermopile lead wire enough to allow clipping a multimeter alligator clip to the spade terminal c Attach the other multimeter lead to the thermopile lead copper surface Light the pilot burner per step 1 e above d Check the reading on the multimeter The reading should be around 400 millivolts e If reading is significantly less than 400 millivolts check tightness of lead wire assembly in gas valve If the connections are secure and you have checked the thermopile per step 1 above replace the thermopile lead wire assembly f Ifreading on TOP thermopile lead wire is around 400 millivolts move the multimeter alligator clip to the BOTTOM thermopile lead wire terminal and check multimeter reading g Ifmultimeter does not read around 400 millivolts check wiring connections and wire integrity to the high limit control h Check voltage at each limit terminal to make sure limit is closed Correct 20 pressure or temperature condition causing any
22. oes boiler fire No Yes Replace gas valve Retest 22 l Y Replace damper actuator Retest gt Is main flame on now No Yes v Retest Is gas valve cock turned to ON position No Yes Turn gas valve cock to Replace gas valve ON position Retest Retest Damper Harness Continuity Table 6 Pin Molex 4 Pin Molex n a PinNumber Pin Number 10 20 30 1 1 2 3 5 5 3 4 i i 4 Not used 20 10 5 2 6 Not used 03106 Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Troubleshooting continued Chart 3 Boiler will not fire steam boilers with or without tankless Secure connections Check for loose wire connections or bad relay on transformer Check for open thermostat LWCO high limit spill switch or rollout thermal fuse element contacts or check for loose wire connections Is damper harness securely plugged in at both ends lt No Yes y Is 24VAC present across transformer terminals C amp Y No Yes Y Is 24VAC present across transformer terminal C and yellow wire on vent damper connector DANGER If LWCO spill switch or rollout thermal fuse lt No Yes element contacts are open determine cause and correct condition Failure to do so will Y cause se
23. onal injury or death 4 Lower thermostat setting Main burner flames will go out then damper will close 5 Repeat steps 1 through 3 several times to verify operation 6 Return thermostat to normal setting Room thermostat anticipator settings Water without tankless heater 0 40 amps Water with tankless heater 0 20 amps Steam Select based on gas valve and damper See table below Gas valve Without With With damper Effikal Johnson amps damper damper amps amps Honeywell VR8200 0 50 0 60 0 70 Honeywell VR8300 0 70 0 80 0 90 Robertshaw 7200ER 0 40 0 50 0 60 Robertshaw 7000ERHC 0 20 0 30 0 40 14 Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Lighting instructions Robertshaw 7200 This appliance has a pilot which must be lighted C Use only your hand to depress or move the selector arm Never use by hand When lighting the pilot follow these tools If the selector arm will not depress or move by hand don t try to instructions exactly repair it call a qualified service technician Force or attempted repair BEFORE LIGHTING smell all around the appliance may result in a fire or explosion area for gas Be sure to smell next to the floor D Do not use this appliance if any part has been under water because some gas is heavier than air and will settle Immediately call a qualified service technician to inspect the appliance onthe floor
24. operty damage 2 Refer to vent damper manufacturer s instructions for procedure to fix vent damper in open position 3 Turn on power to boiler Using wrench or pliers on flat shaft section manually rotate damper blade until green light turns on Boiler will fire Figure 9 5 Do not leave vent damper permanently in this position Replace actua tor immediately If vent damper is left in open position boiler will not operate at published efficiencies Figure 9 Manually opening vent damper Effikal or Field Controls Open Johnson Controls I 3 Closed D lt ri Damper blade indicator Wrench or pliers 59303 19 EG 30 thru 75 Series 4 and PEG 30 thru 65 Series 4 Troubleshooting continued Pilot does not stay lit Troubleshooting thermocouple or thermopile and high limit control circuit 1 Checking thermocouple or thermopile open system Figure 10 a Use an electronic multimeter with leads fitted with alligator clips Set meter scale to DC Millivolts b Unscrew thermocouple or thermopile fitting from gas valve c Attach one meter lead to the end of the thermocouple or thermopile gas valve fitting d Attach other meter lead to thermocouple or thermopile lead copper sur face e Follow Lighting Instruction label on boiler also found in Control Supple ment or User s Information Manual to light the pilot burner only and hold the pilot flame manually DO NOT light main burner f Chec
25. os p S 19S GO NAY O DAd PUE p S 19S GZ NAY 0 93 Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Control installation continued For your safety turn off electrical power supply and turn off external gas supply valve before attempting to work on the boiler Failure to comply can cause severe personal injury death or substantial property damage EG 30 thru 65 water boilers with tankless heaters 1 Mount and wire controls per wiring diagram page 6 and Figure 3 a Install combination limit control and relay in tap ping See Boiler Manual control tapping table Op erating and limit circuit wiring must be 14 gauge or heavier 2 Bring supply wiring to boiler Must be 14 gauge or heavier 3 Proceed to page 12 Figure 3 Damper Damper harness Draft hood Spill switch wires Damper harness receptacle Combination high low limit circulator control Damper harness plug Circulator Gas valve Rollout TFE Wiring harness Note Tankless heater not available on EG 75 standing pilot boilers Part Number 550 110 032 0607 90V0 EVL Ec7 0SS JOquINN Hed 8BEZ 09E9H NI ALD UEBIYDIN IS SUIELG OOS UETON IOM JJo In2 4ayeM MoO d q01d ss yue 1 1noullA JO YIM WESS papinoud you swe S9 0 Dad NIVT UU Tl3m Ui a dnosowway e yim paddinbs ae g S3d 93 yBnowy 0 93d 93 lldouu u e
26. ox inside left jacket panel with 8 32 x 1 2 machine screws and green ground nuts provided Install transformer with plug in relay receptacle In Canada use chain and hook strain relief Operating and limit circuit wiring must be 18 gauge or heavier 2 Bring supply wiring to boiler Must be 14 gauge or heavier 3 Proceed to page 12 Part Number 550 110 032 0607 Figure 7 Damper Optional Damper harness optional Drafthood AN JA L Wiring harness Spill switch Jumper plug wires required without damper Damper harness Operating receptacle Optional limit control Damper harness plug High limit control Gas valve Float type Thermopile low water lead wire cutoff f Junction box Thermopile lead Transformer relay Rollout TFE 11 EG 30 thru 75 Series 4 and PEG 30 thru 65 Series 4 Damper installation NOTICE Once damper is installed boiler will not operate without a damper installed WARNING Only dampers listed in the Replacement parts table on page 24 are approved for use on EG and PEG Series 4 standing pilot boilers Any other vent damper installed could cause severe personal injury or death The following boiler models must have damper installed e EG 30 thru EG 65 natural or propane gas e PEG 30 thru PEG 65 steam natural gas The following boiler models may have damper installed e EG 75 natural or propane gas Fig
27. serves only DANGER Bypassing jumpering vent damper will one boiler and so damper blade indicator is visible cause flue products such as carbon mon to the user See Figure 8 oxide to escape into the house This will cause severe personal injury or death 2 Screws or rivets used to secure the vent damper to P Jury the draft hood must not interfere with rotation of CAUTION After boiler has operated once if either the damper blade Install damper harness between damper actuator and knockout in jacket top panel Use strain relief connectors and locknuts to secure both ends of the damper harness CAUTION Keep wiring harness clear of all hot sur faces Part Number 550 110 032 0607 end of the harness is disconnected the system safety shutdown will occur The boiler will not operate until harness is reconnected Notice Effikal damper Damper hold open switch must be in Automatic Operation position for system to operate properly 13 EG 30 thru 75 Series 4 and PEG 30 thru 65 Series 4 Checkout procedure 1 See pages 15 18 for Lighting Instructions 2 Raise room thermostat to call for heat Damper actuator will slowly open damper 3 When damper is fully open main gas valve will open and main burners will ignite Damper must be fully open before main burners light If damper does not fully open flue products will escape into house causing severe pers
28. set button oF immediately call your service technician or gas supplier a If the pilot will not stay lit after several tries turn the gas control knob clockwise x to OFF and call your service Wait five 5 minutes to clear out any gas Then smell for gas technician or gas supplier including near the floor If you smell gas STOP Follow B in 12 Replaceaccess panel the safety information above If you don t smell gas go to the 13 Turn gas control knob counterclockwise v to ON next step 14 Turn on all electric power to the appliance Remove access panel located above burners 15 Set thermostat to desired setting 16 Replace front panel JV gt IIIAKX TO TURN OFF GAS TO THE APPLIANCE SQ 1 Setthe thermostat to lowest setting 3 Remove front panel 2 Turn off all electric power to the appliance if service is tobe 4 Turn gas control knob clockwise v to OFF performed 5 Replace front panel 550 223 038 0906 16 Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Lighting instructions Honeywell VR8200 VR8300 Propane boilers only UW FOR YOUR SAFETY READ BEFORE LIGHTING ME This appliance has a pilot which must be lighted C Use only your hand to push down the reset button or turn the gas by hand When lighting the pilot follow these control knob Never use tools If the knob or rese
29. smell next to the floor D Do not use this appliance if any part has been under water because some gas is heavier than air and will settle Immediately call a qualified service technician to inspect the appliance on the floor See below and to replace any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Do nottry to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building Ifyou cannot reach your gas supplier call the fire department SS LIGHTING INSTRUCTIONS EN STOP Read the safety information above on this label 8 Find pilot follow metal tube from gas control The Setthe thermostat to lowest setting pilot is between two burners behind the access a Turn offall electrical power to the appliance panel Remove front panel Turn gas control knob counterclockwise v to Turn gas control knob clockwise to OFF PILOT bd Push in red reset button and hold Immediately light the pilot Position with a match Continue to hold reset button in for about one dicate Honeywell 1 minute after the pilot is lit shown in Q Gas Release reset button Pilot should remain lit If pilot goes out ON position N control repeat steps 5 through 11 Red JAA knob If reset button stays depressed after release stop and re
30. t button will not instructions exactly operate by hand don t try to repair it call a qualified service BEFORE LIGHTING smell all around the appliance technician Force or attempted repair may resultin a fire or explosion area for gas Be sure to smell next to the floor D Do not use this appliance if any part has been under water because some gas is heavier than air and will settle Immediately call a qualified service technician to inspect the appliance on the floor See below and to replace any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Do nottry to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building fyoucannotreach your gas supplier call the fire department LIGHTING INSTRUCTIONS E s d STOP Read the safety information above on this label 8 Find pilot follow metal tube from gas control The Setthe thermostat to lowest setting pilot is between two burners behind the access Turnoffall electrical power to the appliance panel Remove front panel Turn gas control knob counterclockwise gt to Turn gas control knob clockwise to OFF PILOT oe Post Push in red reset button and hold Immediately light the pilot ieee 7 with a match Continue to hold reset button in for about one rere O Gas 1
31. ted C Use only your hand to push down the reset button or turn the gas by hand When lighting the pilot follow these control knob Never use tools If the knob or reset button will not instructions exactly operate by hand don t try to repair it call a qualified service BEFORE LIGHTING smell all around the appliance technician Force or attempted repair may result in a fire or explosion area for gas Be sure to smell next to the floor D Do not use this appliance if any part has been under water because some gas is heavier than air and will settle Immediately call a qualified service technician to inspect the appliance on the floor See below and to replace any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Do nottry to light any appliance Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building fyoucannot reach your gas supplier call the fire department DN LiGHTING iNsTRUCTIONs B STOP Read the safety information above on this label 9 Turn gas control knob counterclockwise v to PILOT Setthe thermostattolowestsetting 10 Depress gas control knob and hold Immediately light the Turn offall electrical power to the appliance pilot with a match Continue to hold gas control knob in for Remove front panel about one 1 minute after the pilo
32. tis lit Depress gas control knob slightly and turn clockwise v to If pilot can be lit without depressing gas control knob turn OFF Note Gas control knob cannot be turned to OFF gas knob clockwise to OFF and call your service unless knob is depressed slightly Do not force technician or gas supplier Gas control knob shown in ON position Release gas control knob Pilot should remain lit If pilot goes on repeat steps 5 through 11 Position If gas control knob stays depressed after release stop and indicator immediately call your service technician or gas supplier If pilot will not stay lit after several tries turn the gas control knob clockwise to OFF and call your service Wait five 5 minutes to clear out any gas Then smell for gas technician or gas supplier including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the 12 Replace access panel next step 13 Turn gas control knob counterclockwise gt to ON Remove access panel located above burners Ge 14 Turn onallelectric power to the appliance Find pilot follow metal tube from gas control 45 Setth tatto desired setti The pilot is between two burners behind the Setthermostat to desired setting access panel 16 Replace front panel VPIJWISSW To TURN OFF GAS TO THE APPLIANCE M 1 Setthe thermostat to lowest setting 3 Remove front pan
33. ure 8 Vent damper assemblies Effikal or Field Controls Johnson Controls damper damper Refer to vent manufacturer s instructions to install plug shipped with damper in damper hole Hold open switch Effikal or Field Controls only Install vent damper so that switch is visible and accessible to user 59325 Part Number 550 110 032 0607 Standing Pilot Boilers Control Supplement Damper installation continued Minimum clearances to combustibles Provide a minimum of 6 between the vent damper and any combustible material Provide a minimum of 46 between jacket top and combustible ceiling See EG PEG EGH Boiler manual for complete clearance requirements WARNING LINE UP KEYWAY WHEN CONNECTING PLUGS FORCING A MISMATCH CAN CAUSE A HAZARDOUS CONDITION Installation DANGER Do not modify draft hood or damper or make another connection between draft hood and damper or boiler except as not ed below This will void CSA certification and will not be covered by Weil McLain warranty Any changes will cause severe personal injury death or substantial property damage Se ss 4 Read and apply the harness plug warning label shown above so that it is visible after installa tion i 5 Plug damper harness receptacle into damper harness 1 Install vent damper horizontally or vertically as plug shown in vent damper manufacturer s instructions Vent damper must be installed so that it
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35. ut any gas Then smell for gas 43 Turn selector arm left to ON including near the floor If you smell gas STOP Follow B in 4 the safety information above If you don t smell gas go to the l Turnonallelectric powerto theappliance next step 5 Set thermostat to desired setting Remove access panel located above burners 16 Replace front panel NN TO TURN OFF GAS TO THE APPLIANCE E P E q 1 Setthe thermostat to lowest setting 3 Remove front panel 2 Turn off all electric power to the appliance if service is tobe 4 Depress and move selector arm left v to OFF Do not performed force 5 Replace front panel 550 223 039 0906 Part Number 550 110 032 0607 15 EG 30 thru 75 Series 4 and PEG 30 thru 65 Series 4 Lighting instructions Honeywell VR8200 VR8300 Natural gas boilers only NN FOR YOUR SAFETY READ BEFORE LIGHTING ME This appliance has a pilot which must be lighted C Use only your hand to push down the reset button or turn the gas by hand When lighting the pilot follow these control knob Never use tools If the knob or reset button will not instructions exactly operate by hand don t try to repair it call a qualified service BEFORE LIGHTING smell all around the appliance technician Force or attempted repair may result in a fire or explosion area for gas Be sure to
36. vere personal injury death or Is vent damper rotated open substantial property damage No Yes Check repair out of round stack section Does vent damper lt Y rotate open gt Is 24VAC present across gas valve terminals No Yes No Yes Replace actuator Y Retest P Is main flame on now No Yes Open thermostat contacts for 30 seconds Vent damper will Y rotate to closed position Close thermostat contacts Vent Retest damper will rotate to open position Is 24VAC present v across gas valve terminals z g Is gas valve cock turned to ON position Yes No Yes Check continuity of each wire in damper harness Does continuity exist for each wire See Table below Turn gas valve cock to Replace gas valve No T ON position Retest Retest l Remove damper harness from Replace damper damper harness plug wiring harness TEMPORARILY install jumper Retest between terminal 2 and terminal 5 on damper plug in boiler wiring harness See figure right Does boiler fire No Yes I I Replace gas valve Replace damper Retest actuator Retest Part Number 550 110 032 0607 Damper Harness Continuity Table 6 Pin Molex 4 Pin Molex os ronal Pin ea Pin 10 20 A30 2 3 5 5 3 4 4 3 4 Not used 20 10 5 2 6 Not used 03106 23 EG 30 thru 75 Series 4 and PEG 30 thru 65 Series 4 Replacement parts Only dampers listed below are approved for use on EG 30 thru 75 Series 4 and PEG 30 thru 55
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