Weil-McLain EG User's Manual
Contents
1. E ieee hood isses ER E REID mm BETS aso Rumer see abe regir sins suce AW po a ee miei 55 451 800 012 TE bored xs nns m cus xs prem wr parar ma fass mais ori af isi saa ma BCLS mos facies Eure ue i ERE Section assembly complete without heater opening BG8S 321 811 100 Jy zn Ec aa E in Ta ari or cos pue Gun T sens naar mm apa M o Hong 4 dimer lop elastomer seal 1 joint 29400 Sn NA NH pei o ope SELE steer eer esr pam imei prions reas iss FF a wT Toca mu Sa ZN SES Tab ENE E ee r SES RESI s I E us 35m are owe NOTE 1 Order sufficient quantitiesto replaceall orifices within a base Part Number 55010 639 0703 3 10 EG PEG Gas firep BOILERS series 4 BOILER MANUAL Replacement parts EGH Thebolercontainsceramicfiber and fiberglass materials Usecare when handling these matralsperinstructionson page 38 of thismanual Falureto comply could2. BOILERS SERIES 4 BOILER MANUAL Installation Figure5 Frontand back base panels 53 Installation of drawer assembly and front access panel and back base channel nstaled on PEG balers stops 2 and 3 1 Thedrawer assembly consistsoftheburner drawer main burners gas manifold pilot burner et See Figures6 7and for installation 2 Check for proper orificesizing from chart below Prope orifices must beused Failureto do so will cause severe personal injury desth or substantial property damage 3 Leveland straighten burners 41725 ust be properly setedin sotsin back burner support with openingsfacin up Gasorificesmust inject down center of burner Failure to properly seat burners will result in severe personal injury death or substantial property damage 4 Install front access panel and back base channel See Figures 5 Install rollout thermal fuse element with wire terminalsfacingup on frontaccesspanel of EG 30 75 boilersonly asshown in Figure9 Wire per Control Supplement Gries Drin Sizes standard orice ct ons tise Natural 288 nm Propane T m rice Sizes EG Canada Only Figure Bumer drawer assembly PILOT BURNERS ic gu DRAWER S AN ES d COMBINATION Sat ASAE NEF EGH shonn See page Z2 br EG BURNER SHIELD an R BOILERS OnLy MANIFOLD Figur
3. oe Men burner orfice propane gas 1 35mm nate 2 serso ak boo Sian Sealer for sectons cope seal 4 ft per joint 591 600 865 LT Aer Nee SRI SEIT SEXT wie not 2 per aie ten sena Y manm FEE EGH 105 281 700 250 WF Te rod went B eu iren Rie WN 0917 Tie rod wie nut 2 EGH 115 zs EIE 5 1 sc a Pees pete seats 1 Side rali for burner pane with bracket for burner pan _ 451 800 070 LIII EEE a Soe 4946487 NOTE 1 Order sufficient quantities to replaceall orifices within a EGH 115 451 800 098 base as sri 11 EG PEG Gas firep BOILERS series 4 BOILER MANUAL Data E cem CESSES Es ES sd sacs cs pe E even AME Dimensions EG imensions P EG Lr a 26 Part Number 550 110 639 0703 12 EG PEG Gas FIRED BOILERS SERIES 4 BOILER MANUAL Ratings DOE 2 000 4 500 Chimney Boiler water feet altitude size content Canada catons input DOE Heating input Output Sq Ft Steam Water Water Steam tuh Capac
4. Boer DOE seasonal ficiency AFUE model Water Steam SPON PION SPON PION 0 ES ES Ges wo mz 4 Mo Hs s29 MT EG ss HS Mt sze Part Number 55010 639 0703 x EG PEG Gas firep BOILERS series 4 BOILER MANUAL Standard equipment Fectory Assembled Section Block Insulated Extended Jacket Draft Hood Aluminized See Burners Non Lintng Pilot Burner Hester Cover Plates boilers with tanki Control Wire Electrical Junction Box EG boilers add Combination Gas Valve for 24 volt Thermocouple high efficiency models Rollout Thermal FuseElement Spl Sitch Highest Efficiency Models PID Intermittent Electronic Ignition System and Automatic Vent Damper High Efficiency Models SPD Constant Burning Thermally Supervised Pilot System and Automatic Vent Damper For EG water boilers Built in Air Eliminator 30PSI Adie Valve Combination Pressure Temperature Gauge High Limit Control 40 VA Transformer with Receptacle for Circulator Relay Circulator day For EG steam boilers Rel Valve Steam PressureGauge High LimitPressureControl Syphon GaugeCocks GaugeGlass Low Water Cutoff 40A Transformer
5. mo 9 a e of x os Easo o 12 as uen 15 s s s os Easo wen 0 s w 2 eass iso 20 2 f 2 Eass 2030 24 7 u 2 a 200 29 wl om os 1o EGHas 200 34 w o a a 2200 38 a n a a 4000 is 4400 w a e u NOTE Steam supply mustbeon sameendascantrols Return maybefrom itheren n 3 EG PEG Gas firep BOILERS series 4 BOILER MANUAL Install boiler controls faiureto propery install pipe and wire boile cont ols may result severedarage totheboiler buildingand personnel Water boiler 1 Insalicontrolsasshown on Control Tapping Table and Figure3 page6 Limit control and supply piping must eon thesameend of EGH boiler 2 Low water cutoff for water boilers Mustbeinstalled if boller islocated aboveradiation leve b Must beinstalled on all EGH 105 125 water boilers to mes ASME specifications low water cut off not supplied byWell McLain May berequirel on water boilers by certain state local ar territorial codesor insurance companies Ifalow water cut off isused on awate boiler usea control designed especially for water installations An dectrode probe type may be located in ateein thesupplylineaboveboile aso see C ontral Tapping Tabie pane6 3 Ifsystem isto beASME inspected and approved an additional hig
6. 5 BOILERS SERIES 4 BOILER MANUAL Installation Installation clearances Suggested minimum clearances forservicing 2inchesfor deaningand servicing left side 1Binchesfor accessto controlsand components front 46inchesfrom top for deaningflueways Gincheson remainingsides Required minimum clearances to combustible materialin alcove installations R Sidea L Side 4 Provideserviceclesranceslisted aboveand minimum 24 between jacket and any combustiblewalls nd ceiling Install in spacelargein comparison to sizeof boiler Singewallventpipemustbeatleast 6 inchesfrom combustible material B double wall metal vent pipe refer to vent manufacturer s recommendation for clearances to combustible material Hot water pipes must beat least from combustible material Residential garage installation Install boiler so burners at least 18 inches abovethefloor Boiler foundation Never inal boiler on combustible faring or carpeing even if EEIN onae or arated foundation Severe ond injury death or substantial property damage ret 1 SeeFigurel A level concreteor solid brick padisrequired if Theeisaposibiliofthefloorbecomingflooded 9 Non leva conditions ext 2 aerated boiler foundation is recommended if any of the following conditionsexis wiring or telephone cables buried concrete floor of the boiler b Concretetioor is green
7. ANSI 2223 1 atest edition When require installations must conform to Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASM CSD 1 Safelightingand other performancecriteriawere Inet thees manifoldand 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 Theequipment shall be installed in accordancewith thoseinstallation regulations in forcein the local area where the installation isto be made These shall be carefully followed in all cases Authoritieshavingjurisdiction shall beconsultad before instaltionsaremade Combustion air and ventilation openings Combustion air and ventilation openings must comply with Section 5 3 Air for Combustion and Ventilation of National Fuel GasCodeANSI 2223 1 lates edition or applicable building codes Canadian installations must comply with CAN CSA B149 10r 2 Installation Codes Provdeadequatecombusion and ventilation arto Assureproper combustion lt Reducerisk or severepersonal injury or death from fluegasspillageand carbon monoxideemissions Do notinstall an exhaust fan in theboiler Do Boiler installation must assure sufficient openings in buildingand boiler room to provideadequatecombustion air and ventilation Consider construction tightness of building when deciding whether additional outside openings may beneeded
8. Older buildings with singe pane windows minimal weatherstripping and no vapor barrier often provide enough natural infltration and ventilation without dedicated openings Part Number 55010 639 0703 New construction or remodeled buildingsaremost often built tighter Windows and doors are weatheriripped vapor barriersareused and openingsin wallsarecaulked Asaresult such tight construction is unlikely to allow proper natural air infiltration and ventilation Airfrom insidebuilding boilerin interior room Tightly constructed buildingsmust beprovided with openingsto outsidefor combustion and ventilation air These openings must besized to handle all fud burningappliances exhaust and ventilation fansand fireplaces Whenopeningsto boiler room aretaken to interior Spaces provide two permanent openings combustion air opening within 12 inches of floor and aventilation opening within 12inchesof ceiling Each opening must provideaminimum freeareaot onesquareinch per 1 000Btuh input of appliances in room plus requirements for any exhaust fans in room Theintesior spacesupplying combustion and ventilation air must haveadequateinfitration from outside Air directly from outsideto boiler room Tightly constructed buildings must be provide with combustion air and ventilation openings to boiler room which areadequateto handlethe boiler needs plustheneeds of all other fuel burning appliances fireplacesand exhaust or ventilat
9. Thereisa history of thefloor becoming flooded 6 Water is channeled under the concrete Front Alcove EGH 105 125 Placing the boiler Beck assembly etremey heavy Handle with cation to avid persona injury WharetheEGH block asemblyistaken apart for handling 1 Puta support under center of block Support must be within 1 2 inch of block bottom 2 Removeshort center draw rods 3 Tiphalfbloccson end asshown in Figure2 Savedastomer sedingringsand copesea between sections Part Number 55010 639 0703 Boller foundation 22 Figure 1 Boiler Foundation Size inches Beller Boller No E am arm GH 126 Figure2 4 After movinghalf blocksinto desired location clean portsurfaceswith dean dry rag Donotuseoil Place Sesingringsinrecessed ports Placecopesea in section grooves 5 Reassemble block in reverse order When drawing sectionstogether use45 5 ft lbs torque Installation of optional indirect water heater For aboiler ordered with intemal typeindirect water hester removeheater opening cover plate water boilers round lateon leftside team boilers rectangular plateon front Install ester s asshown on pages13 Do not ove tighten studsand nuts damageto the gasket can occur 1 EG PEG Gas FIRED BOILERS s
10. not plug valveor placeany obstruction in dischargeline 4 Connect system return piping to left end for EG Tightor leftfor EGH Supply and return must beon same end of EGH boiler for proper flow and disposition of water throughout thesections 5 Installer must providedrain 6 Connect cold water fill supply piping closeto boiler 7 Plugall unused tzppings Figure 11b Recommended piping connections forced hot water boilers with diaphragm type expansion tanks To syslem Closed diaphragm pre pressured expansion tank From system TR a TTT TS max or e linis i Part Number 55010 639 0703 2 EG PEG Gas firep BOILERS series 4 BOILER MANUAL Piping connections continued 10 8 MultipleZoning Zonevavs Rer to zone valvemanufacturer sliteraturefor wiring and appl On separate Is required t zonevalves Providebalancing valvesto adjust theflow so itisabout thesamein exch zone b Circulators Zoninguith circulatorsrapuiresarelay foreach circulator Install ow control valvesto prevent gravity circulation Providebalancing valvesto adus theflow s0 itis about thesamein each zone 9 Ifsystemisto beASME inspected and approved an additional high temperaturelimitisneeded Purchase ang instal the control in supply outlet piping from oiler Bypass piping BYPASSP
11. 1 Close manual air vents drain cock and automatic r vent fused 2 Filta correct system pressure Correct pressure will vary with each application Residential systems are often designed for 12 poundsof cold fill pressure 3 Open automaticair vent onetum ifused 4 Open manual water feed valve Starting on lowest floor open vents one at atime until water squirts out Close vet b Repeat with remaining vents 5 Closemanual water feed valve when correct boiler pressureisreached 6 If purgevalveis used located in the return piping aboveisolation valve Connect hoseto purgevalve b Closeisltion valve Open Open hand water fed valveand allow system to purge air If system has morethan one circuit purgeeach dreultseparately by opening each balancing valveone 4 Closepurgevalveand water feed valve cock 8 Open isolation valve f Fill yste to correct presure ing steam boilers 1 Do not fill except for leakage tests until boller is ready to befired 2 Fillto normal waterline halfway up gauge glass 3 Boiler water pH 7 0to 8 Sisrecommended 4 Follow skimmingprocedure Part Number 550104390703 EG PEG Gas FIRED BOILERS SERIES 4 BOILER MANUAL Final adjustments continued Skimming steam boilers Clean all newly installed steam boilers to and grease Fallureto properly clean can result in violent fluctuations of water level wa
12. Connect wiresasshown in Control Supplement Damper installation If damper will beinstalled see Control Supplement for information Breeching erection Connect from draft hood or damper outlet to chimney or vent with samesizebreeching Where possible vertical ventingto theoutside from draft hood or damper outlet will offer best performance Wherehorizontal breeching is used dope upward at least 1 4 inch per lineal foot toward chimney or vent and support with hangers to prevent sagging EAI vertical height of 3 feet to 5 fest of breechingbeforeany 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 excessivenumbers of elbows or tees or other obstructions which restricttheflow of combustion gases should beavoided Breeching must not be connected to any portion of a mechanical draft system operating under positive pressure Part Number 550104390703 2 Piping connections Pipe before installing controls Connect return piping after jacketisattached Connect supply piping beforeor after jacketisattached Failure to properly pipe the boiler resultin improper operation and damage totheboileror building Forced hot water boilers and gravity hot water boilers on 1 Toprotet Tadiantpands plaster etc from high temperturewater supplied from boiler or boiler fr
13. for and remove any obstruction to flow of combustion or ventilation air Pasiodically during hestingseason 1 valve Refernncemanufacturersinstrucions on relief valvetag 2 Teslowwater cutoff if used Blowdown if low water cut off is float type Reference manufacturer s instructions Monthly during heating season 1 Check for leaksin boiler and piping found repair Continuous use of make up water can damage oiler sections dueto addition of minerals Do not use petroleum based lesk compounds leakage thesectionswill occur 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 Check Pilot Burner Flame page21 4 Visually inspect venting system for blockage deterioration or leakage Reference Inspect Venting System 21 5 Cherkautomaticar ventfor leakage If leaking remove vent cap and push valvecorein to wash off sediment that may haveaccumulated oft thevalve sest Release valve replacecap and open oneturn End of each heating season 1 Follow Annual Shutdown Procedure page21 Part Number 550104390703 9 EG PEG 5 BOILERS SERIES 4 BOILER MANUAL Service continued Check pilot burner flames functioning properly f flame blows out or flickers drastically vent system 1 Properp
14. odorant with the propane to make its presence detectable In some instances the odorantcan fade and thegasmay no longer havean odor Propane gas can accumulate at for level Small near the floor for the gas odorant any unusual odor If you suspect a leak do notattemptto lightthepilot Usecaution when attempting to light a propane pilot This should be done by a qualified service technician particulariy i plot outagesarecommon Periodically check theodorant level of your gas Inspect boiler and system at lest yearly to makesureall Consityour ropanesupple regerdinginstalaion ofa detector Therearesomeproducison themarket lntendedforthspurpose Yoursupplie maybe abieto suggest an appropriate 3 If boiler starts goto Step 5 If boiler failsto start go to Step 4 4 If boiler failsto start check Looseconnetton or blown fuse b Limitsatingbdon boiler water temperatureor pressure 9 Thermostat below room temperature 4 Gasnot turned on at meter and boiler 8 Incoming natural ges pressure less than S W C or propane less than 11 WiC 1 If above listo diminate the trouble refer to Control Supplement 5 Makesureboiler goesthrough several normal operating odes 6 Tumthermositoroperatingcontrol to desired setting 8 EG PEG Gas firep BOILERS series 4 BOILER MANUAL Check out procedure Check out procedure Check offst
15. result in severe personal injury 24 Part Number 550 110 639 0703 10 EG PEG Gas FIRED BOILERS SERIES 4 BOILER MANUAL Replacement parts continued Part Number 55010 639 0703 VERRE UT e aad a A hand end section without hester opening Patter eani Sao it ERES IU Tg reee TEE Hir aes dl esas snum UST assembly complete with iter opening net 45 321 711 105 hos TE Th 3 Diarieler bottom elastomer seal 1 joint 592 800 010 us re MGR GE Diameter top elastomer seal T per joint EX iic e TE FFE EGIFTIS 45 20 03 Section assembly complete with beater opening ret EGH 115 321 711 130 maa pe TE LEAL IIS Section assembly complete with heater opening inet EGH 125 321 711 140 commen Se GT TE TT ERI ar Th CAC eid ERES E Fl GROS 451002102 mens cues EXE EN CEE
16. EG PEG EGH Gas fired Boilers Series 4 Boiler Manual Installation Service Operation Boiler Parts For additional information referto Control Supplement and Gas Control Parts for Natural or Propane gas with optional tankless heater application Read all instructions before installing Installer Leaveaall instructions with boiler for future reference Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Owner Installation and service should be performed by qualified service technician Part No 550 110 639 0703 1 EG Gas firep BOILERS series 4 BOILER MANUAL Contents Installation Piping Connections Install Boiler Controls Optional Heaters Gas Piping Wiring Final Adjustments Check Out Procedure Ser Replacement Parts Data Ratings Hazard definitions Thefollouingdefined termsareused throughoutthismanual to bring attention to thepresenceof hazardsof various risk levels or to importantinformation concerningthelifeof the product Indicates presence of hazards that will cause severe personal injury death or substantial property damage Indicates presence of hazards that can cause severe personal injury death or substantial property TET Indicates presenceof hazardsthat will or can causeminor personal injury property da
17. IPING ISNOT NORMALLY REQUIRED ON ANY BASEBOARD SYSTEM Bypass piping should be used for the following ingallations Bypass supply and return piping should besamesze 1 SeeFipure12toprotect radiant panels plaster etc from high temperature water supplied from boiler or boiler from condensation caused by ow temperature water returned from system 2 See Figure 13 to protect boiler from condensation formed ow water temperatureretured from aroe water content converted gravity systems etc Use with refrigeration systems The boiler must be installed so that chilled medium is pipedin paralla with theheating boiler with appropriate valvesto prevent the chilled medium from enteringthe boiler See Figure 14 Consult 1 8 R Installation and Piping Guides fooler isconnected to hestingcoilslocatedin handling nits wherethey can beexposed to refrigerated air gravity circulation during the cooling cycle must be prevented with flow control valvesor other automatic means Figure 12 Circulator oy others From 54 system 0e sy pee Agusta to maintain 180 F or greater in boilor circulator aa Figure 13 7 Adjust valves to To maintain 160 F or system vivet From d system L Part Number 550104390703 2 EG PEG 5 BOILERS SERIES 4 BOILER MANUAL Piping connections ue Steam boilers 1 Refer to table and Figures 14
18. MANUAL Optional heaters EG and EGH boilers for tankless heater application areavalableonlyon special order asfactory installed optional equipment Standard boilers cannot be adapted for hester use Tankless heater hook up Forcorrectoperation install asshown in Figure20 water boilers or Figure21 steam boilers 1 Automatic mixing valve must be installed per mixing valve manufacturersinstuctions 2 Flow regulating valve must be installed Size according to intermittent draw of hester asshown in following table 3 Operatingcontrol witha smal differentia scaleisrecommended Insallintemperaturecontroi tappingin heater plate 4 Inhardwcter areas itisadvisableto soften cold domestic supply Watertothetankless heater to prevent limebuildup Figure 20 Tankless heater piping water baller Flow Col Contre tapping Brass tee 7 NOTE Piping Connectionsnot furnished Usebrass lugsin teesand crossesto falitteclesningin Water areas Figure 21 Tankless heater piping steam boiler Me Temperature eL gr lou control valve Heater gt oF ae Part Number 55010 639 0703 Steam and Forced Hot Water Boiler Tankless Heater Ratings Intermittent Continuous Boner Hosting raw GPa Inlet and Tomp Men Numer Bim Control hae Tappings Tapping
19. Water gas eee w w leao CO w w sas Eam 325 w pao 4m w w ass am w Eas noma 450 am w w 892 w ow sm Eanes nenn 550 pens em sm w esa w vw Steam lecas w w xg 355 soo 2 w lecas 3548 240 w w za 3esas 9 ze w ass 350 222 sss 35548 57 406 w onas 89 kanos 2029 w w ains 58 400 sm w pens 52 so w amus assa sm w Noles ratings based on 60 PSIG domestic water pressureat heater 1 Gallons of water per minute heated from 40 F to 140 F with 200 boiler water temperature 2 Continuousdran no recovery perio 3 Thesesingle wall hest exchangers comply with National Standard Plumbing Codeprovided 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 presureslimited to max 30psigby approved water or seam rae valve 4 EGH 85 6 95 Sanding pilot systems no tankless option 5 EG 75 Standing pilot systems no tankless option 6 EGH 85 Water use onehester only 5 EG Gas firep BOILERS series 4 BOILER MANUAL Gas piping Connecting
20. art Number 550 110 639 0703
21. at least equal ta thearesafthe vent outieton applianceplus 50 percent of thearea ofthevent outlet on theadditional appliance When removing boiler from common venting system Failure to follow all instructions listed below can cause and arbon monoxide emissions resting 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 sach applianceremaining connected to the common venting system placed in operation whiletheother appliancesremaining connected tothecommon ventingsystem arenatin operation Seal any unused openings in the common venting system b Visualy inspect the ventingsystem for proper sizeand horizontal pitch and determine thereis no blockage or restriction leakage corrosion and other daficencieswhich could causean unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space which the appliances remaining connected to the venting system are located and other spaces of the building Turn clothes dryersand any appliance not connected to the common venting sytem Turn on any exhaust fans such asrangehoodsand bathroom they will operate at maximum Do not operate a summer exhaust fen Closefireplace dampers d Place operation the appliance being inspected Follow the lighting instructions Adjust therm
22. d for proper operation If damper is provided see Control Supplement for check out procedure Room thermostat set to desired temperature Installation and ServiceCertificateon thispagecompletedi Allinstructionsshipped with this boiler reviewed with owner or maintenance person returned to envelope and given to owner or displayed near boiler Buh 5 ooo Installation and Service Certificate Boiler Model CP Number Datelnsalled BTU Input Insallationinstructionshavebeen followed 2 Chedcoutsequencehasbeen performed a Aboveinformation iscerified to becorrect a dnformation received and left with ownes maintenanceperson Installer Company Address Phone Installers Signature 18 Part Number 550 110 639 0703 9 EG PEG 5 BOILERS SERIES 4 BOILER MANUAL Service Handling fiberglass and ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS Thecombustion chamber lining or baseinsulation paneisin this product contain ceramic fiber materials Ceramic fiberscan beconverted to cristobalitein very high temperatureapplications TheInternational Agency for Research on Cancer IARC hasconcluded Crystalinesilicainhaled in theform of quartz orcristobalitefrom occupational sourcesiscarcinogenicto humans Group 1 m Avoid breathing dust and contact with skin and eyes UseNIOSH certified dust respirator N95 Thistypeof respirator isbased o
23. e7 Pilot burner location E 00 EE Figure Bumer drawer installation screw E AN Sow Figure8 Access panel Elevation Natural Propane EI Vas Part Number 55010 639 0703 1 EG Gas FIRED BOILERS series 4 BOILER MANUAL Installation continued Jacket installation nale on Pec 1 Removetheproper knockout discs from panels as shown in tappingtable page6 Tankless and storage heater knockouts beramoved or and EGH Polls with optional tankless heaters prior to jacketinstallation 2 Follow jacket Instructionsin jacket carton Draft hood installation Attach draft hood to flue collector hood using 0x 1 2 sheet metal screws provided Useboiler cement furnished to providegas tight se EA Faureto maintain gas tight cause flue gas spillage and carbon monoxide emissions resulting in severe personal injury or death 8 Donotaterboller draft hood or placeany obstruction or non approved damper in thebreechingor vent system A G A and CSA cestifcationswill becomevoid Flue gas spillage and carbon monoxide emissions will occur causing severe personal injury or death Figure 10 of dat nood Spill switch installation On EG 30 75 boilers only fasten spill switch to draft hood as shown on page 22 Drawing Ref Letter
24. ed 4 Follow good piping practices 5 Pipejointcompound pipedope must beresistant tocorrosiveaction f liquified petroleum gases Apply sparingly only to makethreads of pipejoints 6 Install drip leg at inlet of gas connection to boiler Wherelocal utility requires extend drip legto floor Install ground joint union when required for servicing SeeFigure22 Install manual shut off valveoutsideboiler jacket as shown in Figure22 when required by local codes Support piping by hangers not by boiler or its accessories In Canada only the manual main shut off valve when used must beidentified by theinstaller Purgeall air from piping Beforeplacing boiler in operation check boiler and itsgasconnection for leaks Do not check for gas leaks with an open flame use bubble test Failure to do o can causeseverepersonal injury death substantial property damage 8 Closemanual main shut off valveduringany presure testing at less than 13 inches water column b Disconnect boiler and gas valvefrom gassupply piping during any pressure test greater than 13 inches water column Be Figure22 Gas supply piping Manual main shut off gas valve when red Ground joint union innen required Jacket Elbow Nipple pole cw 8 Gas vale Part Number 501106390703 Wiring EG PEG 5 BOILERS SERIES 4 BOILER MANUAL Refer to control supplement for additional info
25. epsascompleted 2 System properiy filled with water Automaticair vent if used open oneturn water bollersonly 2 Air purged from system water boilersonly Steam boilersproperty skimmed 2 Airpurgad from gaspiping Pipingchecked for leaks _Areproper orficesinstalled Check page for proper size Proper orficesmust beused Falureto do so wil cause severe personal injury death or substantial property damage Follow operating instruction labe on boiler for proper sart Up Alo refer to To Placein Operation page17 Proper burner flame Refer to Check Main Burner Flames and Check Pilot Bumer Flame page21 2 Tetlimitcontrol Whilebumersareoperating movelimitcontrol indicator below actual boiler water temperature pressure Burners should go off Circulator should continueto operate water boilers only Raise indicator above boiler water temperatureor pressureand burners should reignite Test any additional fidd installed controls If boiler has low water cut off additional high limit or other controls test for operation as outlined by manufactures Burners should be operating and should go off when controls are tested When controlsarerestored bumersshould reignite EG only button on spill switch pushedin Totestignition system shut off device a For boilers with electronic ignition systems Connect manometer to outlet sideof gasvalve Strt boiler allowing for normal start up ycleto occur and bumersto
26. eries 4 BOILER MANUAL Installation continued Figure3 Steam Boilers Water Boilers robo EGO when uses 2 2 sete let valve Piping lo compression tank or temperate Plugge on Float ype Ceriraten pressure ve gauge tigh imi Probe ype ucc P 7 ype ow waar eu pressure tint Float ype ow watar et rl presse guage er ow aer ow ct and foe ard orm eter cut ot Wear eat ana pomp conl fin pump contra EP Lmt contro CIN q Beckie preve Backup DNCO probe Notes Avete on ses on ton Fer st maton on e ra e EGH ilr S lo ner ste o ener a ao Hydrostatic pressure test Pressuretest beforeattaching gaspipingor electrical supply 1 Plugany necessary boiler tappingsor openings 2 Donotusegaugesupplied with boiler for pressretesting Install gauge with appropriaterange 3 Fill boiler with water Ventall air Test steem boilersbehween 45 55 and water boilersat 1 1 2timesworking pressure EEEE Donotleweboler unattended cold water fill could expand and cause excessive pressure resulting i severe personal injury desth or substantial property damage 4 Check for maintained gaugepressureand les Repair if found Leksmusberepdred at once Falureto do so ca
27. gas supply piping Size gas piping considering Diameter and length of gessupplyingpiping b Number of fittings c Maximum gesconsumption includingany possible futureexpansion d Allowable lossin gaspressurefrom gasmeter outlet to boiler For pressure drops see ANSI 222311 Canadian installations must comply with CAN CSA 9 1 2 Installation Codes 1 For natural gas Refer to following tables To obtain cubic feet per hour divide theinput by 1000 b Sizefor rated boiler input 9 Inltgaspresure 5 minimum 13 WC maximum 9 Manifold gas pressure 3 W C 8 Install 100 lock up gas pressureregulator in supply line if inlet pressure exceeds 13 W C Adjust for 13 maximum 2 For propane gas Inlet gespresure C minimum C maximum b Manifold gas pressure 10 WC Gaspressureregutor provided by gas supplier must be adjusted for maximum pressure of 13 W C 8 Contact gas supplier to size pipes tanksand regulator Pipe Delivery Scedule Table Capac isse in Sable tet o da pe hour sede lan ae een em mw sm um 3596 a spam sm wm E s uus ms em iz 108 opos puso e em n a m T ee mannan brn oa ra ra eir Inlet nar os Gey 088 Presse Lone 030 3 Removeknock out disc from jacket panel which gas supplyisto bepip
28. h temperaturelimitisneeded Purchase and instal in supply lineaboveboiler Steam boiler 1 For steam boilers furnished with probe type low water cut offs install as shown in Figure 17 2 For steam boilersfurnished with floattypelow water cut off install controlsasillustratedin Figure 18 Install lowdown linein bottom of cutoff SeeFigure 19and control manufacturersinstructionsfor details E Pipeblowdownlinenear floor doseto floor drainto eiminatepotential of severeburns Do not plug valveor placeany obstruction inblovidown line Other float type water level controls for steam boilers are shown in Figure 19 Use 1 inch LPS connections t Water feeders are not recommended for primary control A low water cut off with pump controller is recommended with a condensate recaver and feed pump 3 Install remaining controls as shown in Control Tapping Tableand Figure 3 page6 Figure 17 low water cutoff INDICATOR NOTE Waterlinedimension measured from bottom of boiler section legwhereitrestson theboiler room floor or boiler foundation Figure 18 Float type low water cutoff ow Waren Figure 19 Piping for optional float type water level controllers for steam boilers oma zw wt esae Ve rox zw Part Number 550104390703 4 EG PEG 5 BOILERS SERIES 4 BOILER
29. heater openings wm WEIL Mc LAIN EG additional equipment Tankless Water Hester EG 35 65 PI and SP EG 75 PI only With tankless hester Combination High Limit Low Limit Circulator Control nd Relay with 40 VA Transformer Tankless Steam Hester EG35 75 With Tankless Heater Operating Control Tankless Hester 35 5 29 for All Units EGH boilers add Combination Gas Control Valve includes main gas valve with redundant seat PI and PI with damper models main gas valve with singe seat 24V models pressure regulator gas cock lot filter pilot adjustment Highest Efficiency PI Intermittent Electronic Ignition System High Efficiency Models SP Constant Burning Thermally Supervised Pilot Sytem Thermocouple 100 Shutoff 40VA Transformer with Receptadefor Circulator Relay For EGH water boilers Built in Air Eliminator 30951 Reid Valve Combination Pressure TemperatureGauge High Limit Control for PI and PI with Damper M odds Dua Limit Control for Standard Efficiency Circulator Rday For EGH steam boilers Relief Valve Steam PressureGauge High Limit Pressure Control two limit controlson EGH 85 and 95 SP Syphon GaugeCocks GaugeGlas Low Water Cutoff ProbeType EGH additional equipment ankles Heaters Water or Seam SP Steam only With TanklessHeater s Operating Control Automatic Vent Damper 500 Blaine Street Michigan Cy IN 46360 2388 com 28 P
30. ignite With main bumerson manually shutoff ges supply at manual main shutoff gas valve Burners should oo off Open manual main shut off qas valve Manometer should confirm thereisno gas flow Pilot will relight flame sensing element will sense pilot flameand main burnersregnite oo b Forsandingpilot Turn gascock knob to PILOT position and extinguish pilot flame Pilot gasflow should stop in lessthan 3 minutes Put system back into operation seepage 17 Limitcontrolsettodesigntemperatureor presurerequirements ofsystem Maximum limit seting 240 F water boilers 15 steam boilers Formultiplezones fowaijutei sotis about the same in each zone water boilersonly Thermostat heat anticipator set properly Refer to Room Thermostat page 15 and correct wiringdiagram Boiler cycled with thethermostat Raiseto highest seting Boiler Should go through normal start up Lower to lowest setting Boiler should go off Measuregasinput natural gas only Operateboiler 10minutes other appliances Atthenatural gasmeter messuretime in seconds required to useonecubiclootof gas d Caculategsinput 3600 x 1000 number of seconds from step Buh calculate should approximate input rating on rating k Check manifold gas pressure by connecting a manometer to thedownstream test tapping on main gas valve MANIFOLD GASPRESSURE NAT 235 WC LP 2109 WC Several operating cycles observe
31. ilotflame must bechecked for obstructionsor other causes of improper venting Blueflame 2 Inspetall partsof ventingsystemsfor deterioration from corrosion physical b Inner cone engulfing pilot flame sensor damage sagging etc Correct all conditionsfound Pilot flamesensor glows cherry red 3 Verify damper isopen when burner ignites For additional information see Control Supplement Clean boiler heating surfaces Figure 24 Typical pilot burner flame EER Theboiler contains ceramic fiber and fiberglass materials Use carewhen handlngthesematerialsper instructionson page 190f thismanual Fallureto comply could result in severe personal Spark electrode Inner cone injury used on spark Igniton systems ony 1 Follow shut down procedure 2 Disconnectbreschingand removedampe if used and draft hood Pilot lame 3 Removeupper rar jacet panai Tum ba kjadetina lion toeposecoleior sensor 4 Removecollecor hood Clean excess boiler cement from collector hood and cast iron sections 5 Removeburnersfrom base of boiler Follow Cleaning main burners to thoroughly clean burners Placenewspaper in aseo boiler to collect soot 2 Improper pilotflame thet wil fall fameirgendifingorbowngpesit 6 withavirefluebru den between thesertions 1 Underired flmesmalpiotamesssornotengiled 7 Remove paper and soot Vacuum or brush baseand surrounding area by nner cone 8 Replacecollector hood Seal with boiler cement 9 Lackaf
32. ion fans Combustion and ventilation openings connecting directly or by ductingto outside or to attic or crawl spacesthatfredy connect with outside mustbesized as follows L Qutsidewall or vertical ducting onesquare inch per 4 000 Btu input of all appliancesin room plus requirements for any exhaust fans or other appliancesin room 2 Horizontal ducting onesquareinch per 2 000 Btuh of al appliancesin room plus requirements for any exhaust fansor other appliancesin room 3 Aliducingmustbesamesizeaspermanent openings Minimum area dimensionsof d ctingmust beno lessthan 9 squareinches 4 Othersizeductingmust comply with local codes 1 EG PEG Gas FIRED BOILERS series 4 BOILER MANUAL Installation continued Chimney or vent requirements also rele to Braaching erection Page 8 Ventingmust beinstalled accordingto Part 7 Ventingof Equipment of National Fuel Gas Code ANSI 72231 latest edition and applicable building codes Canadian installations must comply with CAN CSA B149 1 or 2 Installation Codes Minimum chimney or ventsizesareon page27 ofthese instructions A chimney or vent without a listed cap should extend at least 3 feet abovethehighest point where it passesthrough a roof of a building and at least 2 feet higher than any portion of abuildingwithin ahorizontal distance of 10 feet A chimney or vent must not extend lessthan thosedistancesstated above lined chimney is preferred and must be u
33. ity Steam Btuh Btuh do Output Btun waterline Notes 18 2 Noe 3 Wate 4 Note 5 EG 3 751000 S000 67500 550001 1 47000 55000 SiDx20 123 63 100 000 83000 9000 75000 258 62000 7800 SID x20 123 EGA 125000 104000 112 500 93000 325 78000 91 000 1D x20 14 8 750 000 125000 135000 112 000 382 S4000 110 000 61 0 x20 148 Easo 175000 145000 157500 131000 454 109 000 128 000 TID x20 173 112 EGS 200 000 167000 180000 150 000 821 125000 146 000 TiD x20 173 112 55 250000 208 000 225000 188 000 654 157000 13000 81 20 198 126 EGS 300 000 240 000 270 000 216 000 750 180 000 x20 228 140 348 900 280 000 315 000 252 000 875 210 000 SID x20 248 154 EGH 5 406 000 320000 360 000 288 00 1 000 240 000 2087273 168 EGH 105 450 000 260 000 E 1125 270 000 373 000 1010 20 298 182 115 500260 400 00 E 1280 308 000 348000 1210 x20 323 186 EGH 125 550000 440000 1 875 30 000 383000 348 210 Notes Add prix P for package boller completely assembled and wired with Jacket and controls PEG 30 S through 6 55 9 ony 930 thru 75 Add si PO or Sfr anding pilot add PID or PI for electronic ignition 30 65 damper req
34. ld water pipes lighting fixtures television raysofthesun or near afireplace Refer to Control Supplement or correct wiring diagram for recommended heat anticipator setting with Standard equipment Wirethermostat asshown Figure23 Wiring multiple zones Strain roliet adapter Stee tab Contro case Low energy Stain roliet control wire bushing 7 EG PEG Gas firep BOILERS series 4 BOILER MANUAL Final adjustments Water treatment Do not use petroleum based cleaning or sing compoundsin bolle sem Serre boiler damagewill occur Continual fresh make up water will reduce boiler life Minerals can build up in sections reducingheat transfer overheating castiron and causing section failure In hard water areasor low pH conditions lessthan 7 0 Consultlocal water treatment company Freeze protection when used Use antifreeze especially made for hydronic systems Inhibited propylenegiyco isrecommended Donotuseautomotive ethyleneglycol ssereperand uy death or substantial property damage can result 50 solution providesprotection to about 30 F Local codes may require back flow preventer or actual disconnect from city water supply Determinequantity according to system water content Boiler water content is listed on page 27 Remember to addin expansion tank water content Follow antifreeze manufacture sinstructions 15 Filling water systems
35. mage Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Theboiler contains ceramic fiber and fiberglass materials Usecarewhen handlingthese materials per insructionson page 19 of this manual Failureto comply could result in severe personal injury Do notuse petroleum based cleaning or sealing compoundsin boiler system Severedamageto system componentscan result causing substantial property damage Rexdallinstructonsbeforeinstalling Falluretofollowallinstructionsin proper order can causesevere personal injury death or substantial property damage When calling or writing about theboiler Pleasehavethe boiler moda number from theboiler rating label and theCP number from the boiler jacket You may lst the CP number in thespaceprovided on thelnstallation and service certificate found on 18 Important EG and EGH boilersfor tanklessor storagehester application areavallableonly on special order as factory installed optional equipment Tanklessheater cannot beadded to standard block assembly Block assembly must beordered with heater openings Standard boilers cannot beadapted for heater use 2 Part Number 550110 639 0703 1 EG 5 BOILERS SERIES 4 BOILER MANUAL Installation Codes Installations must comply with all local codes laws regulationsand ordinances Also National Fuel GasCode
36. n cause boiler damage resulting in substantial property damage 22 not usepetroleum base sealing compoundsin boiler system Severe damage to boiler will result causing substantial property damage Drain boiler and repair leaksif found Reet boiler afterrepairinglesks Removeplugsfrom any tappingsthat wll beusad for controlsand accesories Refer to control tapping tableand Figure3 8 On initial start up check for lesksin thesystem piping If found repair at once sow Right siae O healer or waler baler Optional hanter tor waler beller available on EGH boters valle oniy on EGH bo Installation of flue collector hood Facer instale on PEG balers Set flue collector hood on boiler as shown in Figure4 Useboiler cement furnished to provide gas tight seal CEI faluretom ntsin gas tight seal can cause flue gas spillage and carbon monoxide emissions resulting in severe personal injuryor death Figure4 Flue collector hood Installation of front and back base panels racer rst Pea olen Se Figure5 for installation Fasten front 6 L 8inch and back 75 16inch base pandsto sections Seal with boiler cement along top of insulation panels EA Falureto maintain gas tight seal can cause flue gas spillage and carbon monoxide emissions resulting in severe personal injuryor death Part Number 550104390703 EG PEG 5
37. n theOSHA requirements for cristobaliteat thetimethisdocument was written Other typesof respirators may beneerled depending on thejobsiteconditions Current NIOSH recommendationscan befound on the NIOSH web siteat http www cde gov niosh homepagehtm NIOSH approved respirators manufacturers and phonenumbers arealso listed on thisweb site Wear long sleeved loosefitting clothing gloves and eyeprotection m Apply enough water to thecombustion chamber lining or baseinsulation to preventairbornedust Removecombustion chamber liningor baseinsulation from the boiler and placeit in a plastic bag for disposal Im Wash potentially contaminated clothes separately from other clothing Rinseclothes washer thoroughly NIOSH stated First Aid m Eye Irrigateimmediatay Breathing Fresh ar REMOVAL OF FIBERGLASS WOOL OR INSTALLATION OF FIBERGLASS WOOL COMBUSTION CHAMBER LINING OR BASE PANELS Thisproduct contains iberglassjacket insulation and ceramic fiber materialsin combustion chamber lningor base panes in gas fired products Airborne fibers from these materials have been listed by the State of California as a possiblecauseof cancer through inhalation Avoid breathing dust and contact with skin and eyes UseNIOSH certified dust respirator N95 Thistypeof respirator is based on theOSHA requirements for fiberglass wool atthetimethisdocument was written Other typesof respirators may beneeded depending onthejob siteconditions Cur
38. occur Do not storesourcesof hydrocarbons ie bleaches cleaners chemicals sprays aint removers fabric softeners ec in oiler area Thiscan contributeto shortened boiler ventsystem life Suggested minimum service schedule for qualified service technician only Beginning ofeach heating season 1 Annual sevicecall by aqualfied serviceagency 2 Check burners and 5 and dean if necessary Reference Clean Boiler Heating Surfaces and CleaningM ain Burners 21 3 Viguallyingpectbaseinsulation Reference Inspect Base Insulation page 17 4 Followprocedure To Placein Operation page17 5 Visually inspect pilot and burner flames Reference Check Main Burner Flames and Check Pilot Burner Flame page2 6 Visually inspect venting system for block 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 sinstructions 8 Cherkthatboileraresisfreefrom combustiblematerials gasolineand other fiammablevaporsand liquids 9 Check for and remove any obstruction to flow of combustion or ventilation air 10 Followinstructionson circultorto il ifoil lubricated Overolingwilldamagethecircultor Water lubricated Circulatorsdo not need oiling Daily during heating season 1 Checkthatboilerarensfreetrom combusiblemateials gasolineand other fiammablevaporsand liquids 2 Check
39. om condensation caused by low temperature wate returned from sstem 2 To protect boiler from condensation formed by low water temperatureretumed from largewater content converted gravity systems etc seeFigure 4 Refer to tablesand Figures 11a and 11b 1 Circulator must be selected and sized according to thedesign renuirementsof thesystem Sizeepanson tank to handlethevolumeof water in thesystem 2 Small expansion tankscausesystem water to belost from relief valve Make up water is then added Figure 11a Recommended piping connections forced hot water boilers with closed type expansion tanks Closed type expansion tank Boer Number Sup Rem xg e ve 50 E G5 65 75 aw 27 EG Gas FIRED BOILERS SERIES 4 BOILER MANUAL through fil valve Eventual section failurecan result Expansion tank installation Closed type expansion tank connect from the 3 4 on et end selon t erpansion ini using 314 N PT piping Any horizontal piping must pitch upward toward tank at lest Linch per Ses of piping Diaphragm type expansion tank may be located anys estem preferably nesr theo nsa automatic air vent as shown in Figure 3 Install water relie valveverticallyin E tapping Reli vavedischargepipingmustbepiped er toordosetofoordrantosiminate potential of severe burns Do not pipeto any area where freezing could occur Do
40. or 15 Pipe exactly as Shown Satisfactory operation of a steam heating system denends on adequate condensate return to boiler to maintain a steady water level Avoid adding raw make up water Wherecondensatereturn isnot adequate install low water cut off and pump control Condensate receiver and condenssteboie feed pump Refer to Figure 6 or sizing 2 Install steam relief valveverticallyin E tapping Relief valvedischarge piping must bepiped nex floor close to fior 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 3 EGH only install 3 4 sytem blow off drain valve in lowest part of retur pipingcloseto boiler Figure 14 Recommended piping connections EG steam boilers Figure 15 Recommended piping connections EGH steam boilers Part Number 55010 639 0703 I Steam Boiler Piping Minimum Recommended Pipe Sizes Riser Pipe Ste g E z E Tw E z 1w E ILS E T 2 New 34 minimum tom watering header Figure 16 Condensate receiver capacity Talley Si Condensate Minimum Condensate Receiver correre st eed Pump Number Steam Capacity sues 15 min 30min 48 mn som eas eso El E EEE oa
41. ostat so appliance will operate continuously Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of match or candle or smoke from a cigarette cigar or pipe 1 After it has been determined that each appliance remaining connected to hecommon venting system properly vents when tested as outlined above retum doors windows exhaust fans fireplace dampers and any ather gas burningapplianceto their previous conditions ofuse 9 Any improper operation of the common venting system should becorreced otheinstalation conforms with theN ational Fuel Gas Code AN SI 223 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 Fue Gas Code ANSI Z223 1 atest edition Canadian installations mustcomply with CAN CSA 481r 2 Installation Code Select the boiler location Consider all connectionsto boiler beforeselectingalocation Boiler mustbeinstalled so gas control system components areprotected from dipping or spraying water or rain duringoperation or service Non combustiblefloor ON LY See Boiler foundation Pages To avoid personal injury desth or property damage keep boiler ea cle and free combusiti maris heand other flammablevapors and liquids Part Number 550104390703 1 EG
42. primary ar fametip yellow 8 Replacedraft hood damper if used and breeching 8 Pilot fame sensor not hes properly 10 Replceinsultion and xke 11 Replacemain burners Figure 25 burner flame When replacing burner tubes must be seated in dots in back ds EIE Gasorifices must inject down center of burner Failureto property set burnerswill result inseverepersonal injury death or substantia property damage 12 Follow To Placein Operation procedure NOTE Excesivesootingindicatesimproper gascombustion Call aqualified serviceagency or your local ges utilityto check for proper combustion and make any necessary adjustments Transparent blue flame Cleaning main burners Check main burner flames 1 Vacuum or brush burnersto removedust and lint 1 Proper burner flame Yellow orange streaks may When replacing burertubesmustbessstedin slotsin thebadk appear caused by dust with openings face up Gas orifices must inject down center of 2 Improperfiame burner Failure to properly ss burners will result in severe Overfred Flameslarge personal injury death or substantial property damage B Underfired Flamessmal 9 Lack of primary air Yalow tippingon fames sooting Annual shut down procedure Woar 1 Follow correctlighting operatinginstructionson boiler Inspect venting system 2 Donotdrain system unlesserposureto freezingtemperatureswill occur If an
43. rent NIOSH recommendationscan befound on theNIOSH web steathttp Jwww cdc goviniosh homepage html NIOSH approved respirators manufacturers and phonenumbers arealso listed on thisweb ite Wear long sleeved loosefitting clothing loves and eyeprotection m Operationssuch assowing blowing tear out and spraying may generateairbornefiber concentration requiring additional protection I Wash potentially contaminated clothes separately from other clothing Rinseclothes washer thoroughly NIOSH stated First Aid m Eye Irrigateimmediatey m Breathing Fresh air Part Number 55010 639 0703 19 9 EG PEG Gas firep BOILERS series 4 BOILER MANUAL Service continued 20 Also Referto Additional Instructions Sh hebole For Specife Control Operation and Troubleshooting Verify Proper Operation After Servicing Your boiler should beinsperted desned and if ecesary austen oncea aA qualified serviceagency should becallad personal injury beforesevidng LDistonnet electrica supply 2 Shut off gas supply 3 Allow boiler to cool EE Late all wires prior to disconnection When servicing controls Wiringerrorscan causeimproper and dangerousoperation EA To aoid personal injury death or property damage keep boiler area clear and freefrom combustiblematerials esolineand other fiammableveporsand liquids Donotbiock flow of ar to boiler Incompletecombustion and fluegas spillagecan
44. rmation For your safety turn off electrical power supply before making any electrical Connections to avoid possible electrical shock hazard All wiring must be installed in accordance with requirements of National Electrical Code and any additional national state or local code requirements havingjurisdiction ALL wiring must beN E C Class1 Boiler must beeletrically grounded in accordancewith National Electrical Code ANSI NFPA No 70 latest edition In Canada installation must conform to CSA C22 1 Canadian Electrical Code Part 1and any local codes Iforiginal rolloutthermal fuseelement wireassupplied with boiler must bereplaced type200 C wireor equivalent must be used If other original wiring as supplied with boiler must be replaced type 105 C wire or equivalent must beused Installer mustattach wiring diagram inside jacket door A separatedectrical circuit with a fused disconnect switch 15 amp recommended should beused for the boiler A strain relief bushingand adapter must beused at each point wherewiring passes through control case seeFigure 23 to protect wiringinsulation Part Number 55010 639 0703 Refer to zonevalvemanufacturer sliteraturefor wiring and application A separate transformer is required to power zone valves Zoning with circulators requires a Teayfor esch circuit Install room thermostat Install room thermostat on an inside wall Never install where it will influenced by drafts hot or co
45. sed 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 materials are best Advice for flue onnectionsand chimney linings can be obtained from local gas utility Type B double wall metal vent pipeor singlewall vent pipemay beused asaliner Cold masonry chimneys also known as outside chimneys typically have one or more walls exposed to outsideair When any atmospheric gas fired boiler with automatic vent damper is vented through thistypeof chimney the potential exists for condensation to occur Condensation can damagea masonry chimney Well McLain recommends the following to prevent possibledamage 1 Line chimney with corrosion resistant metal liner Such as AL29 4C single wall stainless steel or B vent Sizeliner per National Fue Gas CodeANSI Z223 1 latest edition 2 Providedrain trap to removeany condensate BEI pect existing chimney or vent before installing boile Failureto dean or replace perforated pipe or tile lining will cause severe injury or death Donotalter boiler draft hood or placeany obstruction or non approved damper in the breeching of vent system CSA certification becomesvoid Flue gas spillage and carbon monoxideemissonswilloccur causing severepersonal injury or death Wheretwo or moregasappliancesventinto a common chimney or vent equivalent area should be
46. ter passinginto steam mains high maintenance costs on strainers trapsand vents Do not use petroleum based cleaning or sealing compoundsin boiler system Severe boiler damage will occur 1 Provide 1 12 piping from skim tapping to floor drain 2 Adjust water lineto midpointof skim tapping 3 Fireboilerto maintain temperaturebaow steaming rate 4 Feed in water to maintain water level Cycleburners to prevent risein steam pressure 5 Continueskimminguntil dischargeisdear M ay take several hours 6 Drain boiler Whileboiler isWARM BUT NOT HOT flush all interior surfaces under full pressure until drain water runs dear 7 Removeskim piping Plugtapping 8 Close drain cock Fill with fresh water to waterline Start burners and steam for 15 minutes to remove dissolved gases Stop burners 9 Check trapsand air vents for proper operation Inspect base insulation Ihe boiler contains ceramic fiber and fibergassmaterias Usecarewhen handling thesematerialsperinstructionson 19 of this manual Failureto comply could resultin severepersonal injury Makesurebaseinsulation is secureagainst basepanels If baseinsulation s damaged or displaced do not operate boiler Reposition or replaceinsulation Part Number 55010 639 0703 To place in operation 1 Besureboilerhasbeen correct filed with water 2 Followlighting operatinginstructionson boiler Forpropane boilers only Your propanesupplier mixesan
47. tifreezeisused with system do notdrain 1 erem pls 3 Ifcompleteboiler and piping sytem must be drained to avoid freezing bow lower adge of draft hood skirt If fame does providemethodto drain water from both endsof boiler ator below return not blow out but burns undisturbed vent system is tappinglevd Part Number 55010 639 0703 n 10 EG PEG Gas firep BOILERS series 4 BOILER MANUAL Replacement parts EG EAI Thebolercontainsceramicfiber and fibergassmaterials Usecare when handling these materalsperinstructionson page this manual Falureto comply could result in severe personal injury Used only on 30 40 and 50 Used on remaining EG boller sizes 2 Part Number 550104390703 10 EG PEG Gas FIRED BOILERS SERIES 4 BOILER MANUAL Replacement parts EG continues nem Description Boller Part Number tem Description Boiler Pari Number Es E3 Sra DG mere amos a s TG 45 Visus ORT pras seam Weisen uaa EET TT LD D Peat hood Boa 450 021 255 TANIEN rey ee ee ea nee aie ee SLE BOSS
48. uired iU S optional in Canada add N or natural add 1 for propane add W for water add S for steam add T foc tankless heater add P for provisional tankless heter EGHAS amp 95 Add suffix SP for sanding pilot add PI for Ignition damper available on Pl anl N Tor natural add L for propane add W or water add 5 for sum add T or tankless henter tankless available on 5 thru 125 P1 Water and seam EGH and SS SP Steam only add for providonal tankless henter EGH 105 thru 128 Add suffix PI for electronic ignition damper available PI only add for water add 5 for steam add T for tankless EGH boilers teged for 50 PS working pressure Based on standard test procedures prescribed by the United States Department of Energy EG 75 thru 125 CSA Gross output EGH 105 thru 125 may be installed at atitudes of 2 000 4 500 feet Subject to acceptance by Provincial Inspections Authority Based on teats of Individual zations Net 1 ratings are based on net inzalld radiation of sufficient sett for the requirements of the building and nothing need be added for normal piping and pick up Water ratings are based on Piping nd pick up allowance of LIS stam ratings on an alowance of 1333 An additional allowance should be made far unusual piping and pick up loads Consult loca Weil McLain representative
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