Weil-McLain EG SERIES 6 GAS BOILER EG-50 Residential User Manual

For additional information, refer to . . .

Control Supplement and Gas

Control Parts

for EG/PEG – Natural gas only

for EGH – Natural or Liqueed Petroleum

(Propane) gas

(tankless heater application optional)

PEG

EGH

• Installation

• Startup

• Maintenance

• Parts

Boiler Manual

This manual must only be used by a qualified heating installer/service technician. Before installing, read

all instructions, including this manual, and any related supplements. Perform steps in the order given.

Failure to comply could result in severe personal injury, death or substantial property damage.

Part No. 550-142-303/1120

Now With Built In

Low Water Cut Off Functionality

EG Water Only

Series 6

Series 5

Gas-Fired Boilers

/PE

Part Number 550-142-303/1120

PEG sEriEs 6

•

EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Contents

The following deﬁned terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or

to important information concerning the life of 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 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 property damage.

Hazard denitions

Hazard denitions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2

Read this page rst � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3

Codes & Checklist � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4

Prepare boiler location � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5

Prepare the boiler � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9

Connect piping – water boilers – EG only

� � � � � � � � � � � � � � � � � � � � � �

Connect piping – steam boilers � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17

Install boiler controls � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20

Connect piping – tankless heater (optional)

� � � � � � � � � � � � � � � � � � �

Connect gas supply piping � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22

Connect eld wiring to boiler � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23

Start-up � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24

Steam Boiler Water Treatment � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 25

Installation and service certicate

�

� � � � � � � � � � � � � � � � � � � � � �

�

� � � 28

Department of Energy – Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Handling berglass and ceramic ber materials . . . . . . . . . . . . . . . . . 29

Service and maintenance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 30

Replacement parts — EG/PEG � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 34

Replacement parts — EGH � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36

Dimensional data � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 38

Ratings � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 39

Standard and optional equipment �

�

� � � � � � � � � � � � � � � � � � � � � �

�

� � � 40

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Read this page rst

Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

When servicing boiler —

To avoid electric shock, disconnect all

electrical supplies to the boiler before

performing maintenance.

To avoid severe burns, allow boiler to cool

before performing maintenance.

This boiler contains ceramic ﬁber and

ﬁberglass materials. Refer to the WARN-

ING and instructions on page 29.

Boiler operation —

Do not block ﬂow of combustion or ven-

tilation air to boiler.

Should overheating occur or gas supply

fail to shut off, do not turn off or discon-

nect electrical supply to pump. Instead,

shut off the gas supply at a location ex-

ternal to the appliance.

Combustion air —

DO NOT install combustion air intake

where there is a risk of combustion air

contamination.

Boiler water —

Do not use petroleum-based cleaning

or sealing compounds in boiler system.

Gaskets and seals in the system may be

damaged. This can result in substantial

property damage.

DO NOT use “ homemade cures ” or “

boiler patent medicines”. Serious dam-

age to boiler, personnel and/or property

may result.

Continual fresh make-up water will re-

duce boiler life. Mineral buildup in eat

exchanger reduces heat transfer, overheats

the cast iron, and causes section failure.

Addition of oxygen carried in by make-up

water can cause internal corrosion. Leaks

in boiler or piping must be repaired at

once to prevent make-up water. Use this

boiler ONLY in a closed-loop system.

Do not add cold water to a hot boiler.

Thermal shock can cause sections to crack.

Freeze protection ﬂuids —

• NEVER use automotive or standard

glycol antifreeze. Use only freeze-

protection ﬂuids made for hydronic

systems. Follow all guidelines given

by the antifreeze manufacturer.

Thoroughly clean and flush any

replacement boiler system that has

used glycol before installing the new

boiler.

Frozen Water Damage

Hazard

Residences or buildings that are unat-

tended in severely cold weather, boiler

system components failures, power out-

ages, or other electrical system failures

could result in frozen plumbing and water

damage in a matter of hours. For your

protection, take preventative actions such

as having a security system installed that

operates during power outages, senses low

temperature, and initiates an effective ac-

tion. Consult with your boiler contractor

or a home security agency.

If any part of a boiler, burner or its controls has

been sprayed with or submerged under water,

either partially or fully, DO NOT attempt to op-

erate the boiler until the boiler has been either

replaced or completely repaired, inspected, and

you are sure that the boiler and all components

are in good condition and fully reliable.

Otherwise, by operating this boiler, you will

cause a ﬁre or explosion hazard, and an electrical

shock hazard, leading to serious injury, death, or

substantial property damage. See the instructions

at right.

Saltwater Damage — The exposure of boiler components to

saltwater can have both immediate and long-term effects. While the

immediate effects of saltwater damage are similar to those of fresh-

water (shorting out of electrical components, washing out of critical

lubricants, etc.), the salt and other contaminants left behind can lead

to longer term issues after the water is gone due to the conductive

and corrosive nature of the salt residue. Therefore, Weil-McLain

equipment contaminated with saltwater or polluted water will no

longer be covered under warranty and should be replaced.

Electrical Damage — If any electrical component or wiring

came into contact with water, or was suspected to have come into

contact with water, replace the boiler with a new Weil-McLain boiler.

Installer— Read all instructions, including this

manual and all other information shipped with the

boiler, before installing. Perform steps in the order

given.

User — This manual is for use only by a qualiﬁed

heating installer/service technician. Refer to User’s

Information Manual for your reference.

User — Have this boiler serviced/inspected by a

qualiﬁed service technician, at least annually.

Failure to comply with the above could result in severe

personal injury, death or substantial property damage.

Improper installation, adjustment, alteration, ser-

vice or maintenance can cause property damage,

personal injury, exposure to hazardous materials,

or loss of life. Installation and service must be

performed by a qualiﬁed installer, service agency

or the gas supplier who must read and follow the

supplied instructions before installing, servicing or

removing this boiler. This boiler contains possibly

carcinogenic, to humans.

Write in the Consumer Protection (CP) number in

the space provided on the Installation and Service

Certicate

on page 28, if not already shown.

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.

Consider piping and installation when determining

boiler location.

Any claims for damage or shortage in shipment

must be ﬁled immediately against the transportation

company by the consignee.

EG and EGH boilers for tankless or storage heater

application are available only on special order as

factory-installed optional equipment. Tankless

heater cannot be added to standard block assem-

bly. Block assembly must be ordered with heater

openings. Standard boilers cannot be adapted for

heater use.

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Installation must follow these codes:

• Local, state, provincial, and national codes, laws, regulations and ordinances.

• National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edition.

• National Electrical Code, ANSI/NFPA 70 – latest edition and/or the Canadian Electrical Code

Part I, CSA C22.1, Electrical Code.

• Canadian installations must comply with the Natural Gas and Propane Installation Code, CAN/

CSA B149.1 or B149.2 Installation Codes.

• Where required by the authority having jurisdiction, the installation must conform to the Standard

for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD1.

The equipment shall be installed in accordance with those installation regulations in force in the local

area where the installation is to be made. These shall be carefully followed in all cases. Authorities having

jurisdiction shall be consulted before installations are made.

Commonwealth of Massachusetts

When the boiler is installed within the Commonwealth of Massachusetts:

• Thisproductmustbeinstalledbyalicensedplumber.

• Ifantifreezeisused,areducedpressureback-owpreventerdeviceshallbeused.

Certiﬁcation

Safe operating and other performance criteria were met with the gas manifold and con-

trol assembly provided on boiler when boiler underwent tests speciﬁed in ANSI Z21.13

- latest edition.

Before locating the boiler:

❏ Check for nearby connection to:

•Ventingconnections

•Gassupplypiping

•Electricalpower

❏ Check area around boiler. Remove any combustible materials, gasoline and other ﬂammable liquids.

Failure to keep boiler area clear and free of combustible materials, gasoline and other

ﬂammable liquids and vapors can result in severe personal injury, death or substantial

property damage.

❏ Boiler must be installed so that gas control system components are protected from dripping or spray-

ing water or rain during operation or service.

❏ If new boiler will replace existing boiler, check for and correct system problems, such as:

 •Systemleakscausingoxygencorrosionorsectioncracksfromhardwaterdeposits.

Glycol — potential ﬁre hazard —

All glycol is ﬂammable when exposed to high temperatures. If glycol is allowed to accumulate in or

around the boiler or any other potential ignition source, a ﬁre can develop. In order to prevent poten-

tial severe personal injury, death or substantial property damage from ﬁre and/or structural damage:

• Neverstoreglycolofanykindneartheboileroranypotentialignitionsource.

• Monitorandinspectthesystemandboilerregularlyforleakage.Repairanyleaksimmediatelyto

prevent possible accumulation of glycol.

Codes & Checklist

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Table 1 EG, PEG & EGH - Service and combustible

materials clearances

Prepare boiler location

Recommended Service clearances

1. Provide minimum clearances for cleaning and servicing

the boiler and for access to controls and components as

listed in the table at right.

2. Provide at least screwdriver clearance to jacket front panel

screws for removal of front panel for inspection and minor

service. If unable to provide at least screwdriver clearance,

install unions and shutoff valves in system so boiler can be

moved for servicing.

Combustible material clearances

General

1. See Table 1 for clearances to boiler and system components.

2. Clearances to Type B vent materials are as speciﬁed by the

vent manufacturer.

Alcove (not closet) installations only

EG and PEG boilers are not approved for

closet installation.

EG and PEG boilers are approved for alcove

installation, with minimum clearances to

combustible surfaces as shown in Table 1. See

Figure 1. The front side must be completely open

— that is, a three-walled room.

EGH boilers are not approved for alcove or

closet installation.

EG, PEG & EGH - Clearance for service Minimum

Clearance to boiler jacket

Top (for cleaning ue ways) 46”

Front

(for access to controls and components) 18”

Back 6”

Left side (for cleaning and servicing) 24”

Right side 6”

Clearance to combustible materials

Minimum

EG & PEG

Minimum

EGH

Clearance to boiler jacket

Top

46” 46”

Front (provides means of access)

3” 18”

Back

6” 24”

Left side (provides means of access)

4” 24”

Right side

4” 24”

Clearance to piping and vent components

Water and steam pipes

1/2” 1/2”

Vent pipe (other than Type B vent)

6” 6”

Type B vent piping

Per B vent

manufacturer

Per B vent

manufacturer

Vent damper

6” 6”

EGH installations

1. See Table 1 for clearances to boiler and system components.

2. Provide the clearances for service and clearance to combus-

tible materials as listed on this page.

3. Install in a space that is large in comparison to the size of

the boiler (see National Fuel Gas Code for details).

Residential garage installations

Take the following special precautions when installing the boiler in

a residential garage. If the boiler is located in a residential garage,

per ANSI Z223.1/NFPA 54 – latest edition:

• Mount the boiler a minimum of 18 inches above the ﬂoor of

the garage to assure the burner and ignition devices will be

no less than 18 inches above the ﬂoor.

• Locate or protecttheboilersoitcannot be damaged by a

moving vehicle.

Figure 1 Alcove installation (EG & PEG only)

Table 2 Minimum foundation size

Figure 2 Boiler foundation

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Vent System

Failure to follow all instructions can result in ﬂue gas

spillage and carbon monoxide emissions, causing severe

personal injury or death.

Inspect existing chimney before installing boiler. Failure

to clean or replace perforated pipe or tile lining will cause

severe personal injury or death.

Do not alter boiler draft diverter or place any obstruction

or non-certiﬁed vent damper in breeching or vent system.

CSA certiﬁcation will become void. Flue gas spillage and

carbon monoxide emissions will occur causing severe

personal injury or death.

The following requirements apply when you remove

an existing boiler from a vent system shared with other

appliances. If the new boiler will not use the common

vent, you must test (as described below) each remaining

appliance — operating by itself — to verify that the vent

system operates adequately.

When removing boiler from existing common vent system:

At the time of removal of an existing boiler, the following steps shall

be followed with each appliance remaining connected to the common

venting system placed in operation, while the other appliances remaining

connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting system.

b. Visually inspect the venting system for proper size and horizontal

pitch and determine there is no blockage or restriction, leakage, cor-

rosion or other deﬁciencies which could cause an unsafe condition.

c. Test vent system — Insofar as is practical, close all building doors and

windows and all doors between the space in which the appliances

remaining connected to the common venting system are located and

other spaces of the building. Turn on clothes dryers and any appli-

ance not connected to the common venting system. Turn on any

exhaust fans, such as range hoods and bathroom exhausts, so they

will operate at maximum speed. Do not operate a summer exhaust

fan. Close ﬁreplace dampers.

d. Place in operation the appliance being inspected. Follow the op-

erating instructions. Adjust thermostat so appliance will operate

continuously.

e. Test for spillage at draft diverter relief opening after 5 minutes of

main burner operation. Use the ﬂame of a match or candle.

f. After it has been determined that each appliance remaining con-

nected to the common venting system properly vents when tested

as outlined above, return doors, windows, exhaust fans, ﬁreplace

dampers, and any other gas-burning appliance to their previous

conditions of use.

Any improper operation of the common venting system should be cor-

rected so the installation conforms with the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 – latest edition and/or Natural Gas and Propane

Installation Code, CAN/CGA B149 or B149.2, Installation Codes. 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 the National Fuel Gas Code, ANSI Z223.1/

NFPA 54 – latest edition and/or Natural Gas and Propane Installation

Code, CAN/CSA B149.1 or B149.2, Installation Codes.

Flooring and foundation

Do not install boiler on combustible

ﬂooring or carpeting even if a concrete or

aerated foundation is used. Fire can result,

causing severe personal injury, death or

substantial property damage.

1. See Figure 2. A level concrete or solid brick pad is

required if:

a. There is a possibility of the ﬂoor becoming

ﬂooded.

b. Non-level conditions exist.

2. An aerated boiler foundation is recommended if

any of the following conditions exist:

a. Electrical wiring or telephone cables buried in

the concrete ﬂoor of the boiler room.

b. Concrete ﬂoor is “green.”

c. There is a history of the ﬂoor becoming ﬂooded.

d. Water is channeled under the concrete.

1 Prepare boiler location (continued)

Boiler Foundation Size - Inches

Boiler No. “L” Boiler No. “L”

EG 30-35 19” EGH 85 40 1/4”

EG 40-45 23 1/4” EGH 95 44 1/2”

EG 50-55 27 1/2” EGH 105 48 3/4”

EG 65 31 3/4” EGH 115 53”

EG 75 36” EGH 125 57 1/4”

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Products to avoid

Spray cans containing chloro/uorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents

found in household laundry rooms

Adhesives used to fasten building products and other similar

products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture renishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Buildings under construction (where air is contaminated with

particulates)

Figure 3 Terminations with Type B vent ﬁtted with listed cap,

provided vent is at least 8 feet from any vertical wall or

similar obstruction

Vent System (continued)

Chimney or vent requirements

1. Venting must be installed according to the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 – latest edition and applicable building codes.

Canadian installations must comply with Natural Gas and Propane

Installation Code, B149.1 or B149.2 Installation Codes.

2. See “Ratings” on page 39 for minimum chimney or vent sizes.

Chimney or vent termination:

• A chimney, or any vent other than a Type B vent with listed vent

cap, must extend at least 3 feet above the highest point where it

passes through a roof of a building, and at least 2 feet higher than

any portion of a building within a horizontal distance of 10 feet.

• TypeBventswithlistedcapsmayterminateasinFigure3ifno

closer than 8 feet from a vertical wall or similar obstruction.

• Otherwise,TypeBventsmustterminateatleast2feetabovethe

roof penetration and at least 2 feet higher than any portion of a

building within 10 feet.

• Ensure proper clearance above grade or snow line. Keep vents/air

intake area clear of accumulating snow.

3. A lined chimney is preferred and must be used when required by

local, state, provincial and national codes, laws, regulations and

ordinances. Vitreous tile linings with joints that prevent retention

of moisture and linings made of noncorrosive materials are best.

Advice for ﬂue connections and chimney linings can be obtained

from local gas utility. Type B double-wall metal vent pipe or single-

wall vent pipe may be used as a liner.

4. Cold masonry chimneys, also known as outside chimneys, typically

have one or more walls exposed to outside air. When any atmospheric

gas-ﬁred boiler with automatic vent damper is vented through this

type of chimney, the potential exists for condensation to occur.

Condensation can damage a masonry chimney. The following are

recommended to prevent possible damage.

a. Line chimney with corrosion-resistant metal liner such as AL29-4C®

single-wall stainless steel or B-vent. Size liner per National Fuel Gas

Code ANSI Z223.1/NFPA 54 – latest edition.

b. Provide drain trap to remove any condensate.

5. Where two or more gas appliances vent into a common chimney or

vent, equivalent area should be at least equal to area of vent outlet

on largest appliance plus 50 percent of vent outlet area of additional

appliances.

Air contamination

1. Please review the following information on potential

combustion air contamination problems.

2. See Table 3 for products and areas which may cause

contaminated combustion air.

To prevent potential of severe personal injury

or death, check for products or areas listed

below before installing boiler. If any of these

contaminants are found:

•Removecontaminantspermanently.

— OR —

 •Isolateboilerandprovideoutsidecombus-

tion air. See national, provincial or local

codes for further information.

Prepare boiler location (continued)

Table 3 Contaminants to avoid

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Air openings

Provide adequate combustion and ventilation air

to assure proper combustion and reduce the risk

of severe personal injury, death or substantial prop-

erty damage caused by ﬂue gas spillage and carbon

monoxide emissions.

Combustion air and ventilation openings must comply with

the National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edi-

tion, or applicable local building codes. Canadian installations

must comply with Natural Gas and Propane Installation Code,

B149.1 or B149.2 Installation Codes.

Air opening sizes in the following are given in free area (after

correction for louver obstruction).

Option 1 — Provide (2) openings:

Tight construction — Deﬁnition:

Tight construction means (per ANSI Z223.1/NFPA 54 – latest

edition):

• Wallsandceilingsexposedtotheoutsideatmospherehavea

continuous water vapor retarder with a rating of 1 perm or

less with openings gasketed AND

• Weather-stripping has been added on openable windows and

doors AND

• Caulkingorsealantsareappliedtoareassuchasjointsaround

windows and door frames, between sole plates and ﬂoors, be-

tween wall-ceiling joints, between wall panels, at penetrations

for plumbing, electrical, and gas lines, and in other openings.

Tight construction requirements

If building is of tight construction and air is taken from inside

the building, provide two openings in building outside wall, one

within 12 inches of ceiling, the other within 12 inches of the ﬂoor.

Each opening must have a minimum free area of 1 square inch

per 1,000 Btuh of all appliances in the building.

Exception

NO combustion air openings are needed when the boiler (and

other appliances) are installed in a space with a volume NO LESS

than 50 cubic feet per 1,000 Btuh of all installed appliances. Sum

the total input of all appliances in MBH (1,000’s of Btuh) and

multiply this number times 50. Building must not be of Tight

construction (see above).

Example: For total input of 100 MBH (100,000 Btuh), minimum

volume is 50 x 100 = 5,000 cubic feet. At a ceiling height of 8 feet,

space must have at least 5,000 ÷ 8 = 625 square feet (25 feet x 25

feet, for instance).

Exhaust fans and air movers

The appliance space must never be under a negative pressure.

Always provide air openings sized not only to the dimensions

required for the ﬁring rate of all appliances, but also to handle

the air movement rate of the exhaust fans or air movers using air

from the building or space.

Motorized air dampers

If the air openings are ﬁtted with motorized dampers, electrically

interlock the damper to:

• Preventtheboilerfromringifthedamperisnotfullyopen.

• Shuttheboilerdownshouldthedampercloseduringboiler

operation.

To accomplish this interlock, wire an isolated contact (proving the

damper open) in series with the thermostat input to the boiler.

The boiler will not start if this damper is closed, and will shut

down should damper close during operation.

Placement and setup

Place boiler/crate near position

1. Leave boiler in crate and on pallet until installation site is

ready.

2. Move entire crate and pallet next to selected location.

3. Remove crate. Leave boiler on pallet.

4. Unbolt boiler from pallet.

5. Remove boiler from pallet.

Prepare the location (continued)

Option 2 — Provide (1) opening:

A single combustion air opening can be used, provided:

• The

opening must commence within 12 inches of the ceiling.

• Theboilermusthaveclearancesofatleast1inchfromboth

sides and back, and 6 inches from the front.

• Theopeningmustconnectdirectlytotheoutdoorsortoa

space that communicates directly to the outdoors.

• Theaircanbeprovidedthroughadirectopeningorthrough

a horizontal or vertical duct.

• Thefreeareaoftheopeningmustbeatleastequaltothesum

of all vent connectors in the space.

• Thefreeareaoftheopeningmustbeatleast1squareinch

per 3000 Btu/hr input rating of all equipment located in the

space.

Figure 4 Handling split blocks

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Placing the boiler

Block assembly is extremely heavy. Handle with

caution to avoid personal injury.

EGH boilers only —

When an EGH block assembly is taken apart for handling:

1. Put a support under center of block. Support must be

within ½ inch of block bottom.

2. Detach seal replacement kit from the draw rod. Remove

short center draw rods.

3. Tip half blocks on end as shown in Figure 4. Save elas-

tomer sealing ring between sections.

4. Remove the exposed silicone from the socket areas

located in the bottom-front and top-rear corners of the

casting. See Figure 4a. Do not remove the rope seal.

5. After moving half-blocks into desired location,

clean port surfaces with clean, dry rag. Do not use

petroleum-based solvents. Place sealing rings in

recessed ports. Place new silicone in the socket area as

seen in Figure 4b. It is critical to place enough silicone

in this area to reseal the castings.

Do not use petroleum-based cleaning or

sealing compounds in boiler system. Severe

damage to system components can result,

causing substantial property damage.

6. Re-assemble block in reverse order. When drawing sec-

tions together, use 45 ( ± 5 ) ft-lbs torque.

Place enough silicone in the socket to

make a seal with the mating surface on the

adjacent casting when assembled.

Prepare the boiler

Figure 4a Corner after exposed silicone has been

removed.

Figure 4b Placing of new silicone in the sockets.

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Hydrostatic pressure test

Pressure test before attaching gas piping or electrical supply.

1. Plug any necessary boiler tappings or openings.

2. Do not use gauge supplied with boiler for pressure testing.

Install gauge with appropriate range.

3. Fill boiler with water. Vent all air. Test steam boilers between

45 - 55 psi. Test water boilers at 1-1/2 times maximum work-

ing pressure.

Do not leave boiler unattended. A cold water ﬁll

could expand and cause excessive pressure, result-

ing in severe personal injury, death or substantial

property damage.

4. Verify gauge pressure is maintained. Check for leaks. Repair

if found.

Leaks must be repaired at once. Failure to do so

can cause boiler damage, resulting in substantial

property damage.

Do not use petroleum-based sealing compounds in

boiler system. Severe damage to boiler will result,

causing substantial property damage.

5. Drain boiler and repair leaks if found.

6. Retest boiler after repairing leaks.

7. Remove plugs from any tappings that will be used for controls

and accessories. Refer to Table 4 and Figure 5.

8. On initial start-up check for leaks in the system piping.

If found, repair at once.

Installation of ﬂue bafﬂes (EG water and

EGH only)

1. Bend the two (2) tabs on the ﬂue bafﬂe approx. 90 degrees in

opposite directions.

2. Slide ﬂue bafﬂes (notch down and to the back) in between

each section.

The installer must install all ﬂue bafﬂes for proper

boiler operation.

Figure 5 Boiler tappings (see Table 4)

Table 4 Control tapping (see Figure 5)

Prepare the boiler (continued)

Tapping

Size

EG, PEG & EGH

Steam Boilers

EG Water Boilers

only

¾”

Probe-type low water cutoff

Probe-type LWCO

(when used)

¾”

Drain

¾”

Safety valve

Safety relief valve

¾”

Plugged

Piping to compression

tank or

auto air vent

½”

Gauge glass and /or optional

low water cutoff

Combination pressure

temperature gauge

⅜”

Tri cock tappings

Plugged on

(Float type LWCO)

½”

Siphon, pressure gauge, high

limit (Probe type LWCO)

Combination pressure

temperature gauge

(EGH

Only)

Float type low water cut-off, pressure

limit control and pressure gauge;

or low water cut-off and feeder

combination; or low water cut-off and

pump control

––

1 ½”

¾”

(note 1)

Skim tapping

––

Limit control

Notes:

1. Available on special request only, when tankless heater is specied.

2. Limit control and supply piping must be on the same end of the EGH

boiler.

3. When an internal type water heater is installed, use the tapping in

the heater for an additional operating control.

Figure 6a EG water & EGH - Flue bafﬂes

Installation of optional indirect water

heater

1. For a boiler ordered with internal type indirect water heater,

remove heater opening cover plate (water boilers – round

plate on left side; steam boilers – rectangular plate on front).

2. Install heater(s) as shown on page 21. Do not over tighten

studs and nuts - damage to the gasket can occur.

Bend tabs on each plate to

keep from falling through

ue way.

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Installation of ﬂue collector hood

(Factory installed on PEG boilers)

Set ﬂue collector hood on boiler as shown in Figure 6b. Use boiler

cement furnished to provide gas-tight seal.

Failure to maintain gas-tight seal can cause ﬂue gas

spillage and carbon monoxide emissions, resulting

in severe personal injury or death.

Installation of rear base panels

(Factory installed on PEG boilers)

For EG-30 through 75, see Figure 7a, for EGH-85 through

-125, see Figure 7b. Fasten rear base panel (7 5/16 inch high -

EG/PEG - 2 pieces) and rear base (11 17/32 inch high - EGH

- 1 piece) channel to section assembly. Seal with boiler cement

along top of insulation panels.

Failure to maintain gas-tight seal can cause ﬂue

gas spillage and carbon monoxide emissions,

resulting in severe personal injury or death.

Figure 7a EG/PEG - Rear base panel and base channel

Prepare the boiler (continued)

Installation of side refractory -EGH only

1. See Figure 7b & 7d. Hardware for drawer assembly must be

installed (Figure 10, page 12), before sliding refractory in place.

2. Apply silicone to the inside surface of the cast iron end

section leg.

3. Slide refractory (2 pieces left & right side) into place.

4. Install four (4) refractory clips (See Figure 7b & 7d) to hold

refractory in place.

Installation of drawer assembly, front

base panels – EG/EGH

(Factory installed on PEG boilers)

1. See Figure 7c, page 12. Fasten front base panel (6 Z\, inch high)

and rear base channel to section assembly. Seal with boiler

cement along top of insulation panels.

2. The burner drawer assembly consists of the burner drawer,

main burners, gas manifold, pilot burner, etc.

3. Check for proper oriﬁce sizing from Table 5, page 13.

Proper oriﬁces must be used. Failure to do so will

cause severe personal injury, death or substantial

property damage.

4. Place burners in the drawer assembly as shown in Figures 8

and 9, page 12.

5. Slide the drawer assembly under the front base panel and at-

tach to the section assembly as shown in Figure 10, page 12.

6. Level and straighten burners.

Burners must be properly seated in slots in back

burner support with openings facing up. Gas

oriﬁces must inject down center of burner. Failure

to properly seat burners will result in severe personal

injury, death or substantial property damage.

7. EG 30 – EG-75 only: Install rollout thermal fuse element with

wire terminals facing up on front access panel as shown in

Figure 11, page 13. Wire per the appropriate Control Supple-

ment.

Figure 6b Flue collector hood

Figure 7b EGH - Rear base panel & refractory and

refractory clip

Note! Silicone to be applied to inside of leg of cast surface.

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Prepare the boiler (continued)

Figure 10 Burner drawer installation

Figure 9 Burner and pilot burner locations

Figure 8 EGH Burner drawer assembly

Figure 7c EG/EGH - Front base panel

(Factory installed on PEG boilers)

Burner

Combination

Gas Valve

(EGH shown,

See page 35

for EG

Burner & base shield

on EGH Boilers only

Manifold

Drawer

Pilot Burner not shown

See Figure 9 for locations

Flange

to front

of boiler.

Figure 7d EGH - Refractory placement & front base panel

Four (4) refractory clips will

hold refractory.

1/4” Hardware for mounting front

and rear base panels needs to be in

place before refractory (2 pieces left

& right side) are slid into place.

Note! Silicone to be applied to

inside of leg of cast surface.

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Figure 11 EG/EGH - Access panel

(Factory installed on PEG boilers)

Spill switch installation

EG 30 – EG 75 and PEG 30 – PEG 65 boilers only, fasten spill

switch to draft hood as shown on page 34, Drawing Ref. Letter “K”.

Connect wires as shown in the appropriate Control Supplement.

Damper installation

If damper will be installed, see Control Supplement for informa-

tion.

Breeching erection

Connect from draft hood or damper outlet to chimney or vent

with same size breeching. Where possible, vertical venting to the

outside from draft hood or damper outlet will offer best perfor-

mance. Where horizontal breeching is used, slope upward at least

1/4 inch per lineal foot toward chimney or vent and support with

hangers to prevent sagging.

A vertical height of 3 feet to 5 feet of breeching before

any elbow or horizontal breeching is recommended

to reduce chances of ﬂue gas spillage at draft hood

on EGH-95 thru -125 boilers (not restricted on any

EG or EGH-85). Long horizontal breechings, exces-

sive numbers of elbows or tees, or other obstructions

which restrict the ﬂow of combustion gases should

be avoided.

Breeching must not be connected to any portion of a mechanical

draft system operating under positive pressure.

Jacket installation (Factory installed on PEG)

1. Remove the proper knockout discs from panels as shown in

Table 4, page 10.

Tankless and storage heater knockouts must be

removed for EG and EGH boilers with optional

tankless heaters prior to jacket installation.

2. Follow Jacket Instructions in jacket carton.

Figure 12 Draft hood

Prepare the boiler (continued)

Table 5 Oriﬁce drill sizes

Draft hood installation

Attach draft hood to ﬂue collector hood using #10 x 1/2” sheet

metal screws provided. Use boiler cement furnished to provide

gas tight seal.

Failure to maintain gas-tight seal can cause ﬂue gas

spillage and carbon monoxide emissions, resulting

in severe personal injury or death.

Do not alter boiler draft hood or place any obstruc-

tion or non-approved damper in the breeching or

vent system. CSA certiﬁcation will become void.

Flue gas spillage and carbon monoxide emissions

will occur causing severe personal injury or death.

Installation of base shield - EGH only

1. See Figure 8, page 12, slide base shield under burner drawer

assembly.

2. The ﬂanged end of the shield should be located at the front

of the boiler.

The installer must install base shield, ﬂanged

end of shield at front of boiler for proper boiler

operation.

Inspect burners – PEG boilers

1. PEG boiler are factory-assembled, but the burners and base

panels should be inspected to ensure they are in good condi-

tion.

2. Remove the access panel (Figure 11) and inspect the burners

per step 6 on page 11. Replace the access panel.

Orice Drill Sizes

Boiler Model Natural Gas Propane Gas

EG 30-65

2.35mm ------

EG 75

2.30mm ------

EGH 85-125

2.30mm 1.40mm

Orice Drill Sizes EG/PEG Canada Only

Elevation Natural

Propane

0-2,000 ft. 2.45mm ------

2,000-4,500 ft. 2.30mm ------

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

General

Install the boiler jacket before connecting return piping. (Supply piping

can be connected before or after jacket installation.) Connect controls

after all piping is connected.

If installation is to comply with ASME or Canadian requirements, an ad-

ditional high temperature limit may be needed. Install control in supply

piping between boiler and isolation valve. Set second control to minimum

20 °F above set point of ﬁrst control. Maximum allowable set point is 240

°F. See page 23 for wiring.

A low water cutoff device is required when boiler is installed above radia-

tion level or by certain state or local codes or insurance companies. The

boiler has a pre-installed water temperature sensor. EG water boilers are

equipped with a water temperature and low water sensor and the control

modules includes functionality for low water monitoring. An additional

external low water cutoff device may be used simultaneously if necessary.

Use backﬂow check valve in cold water supply if required by local codes.

Isolation valves

Isolation valves are required to enable servicing of the boiler’s temperature

sensor. Install as shown in appropriate piping diagram.

Near-boiler piping

Boiler connections

1. EG — Connect supply and return to left end.

2. Plug all unused connections.

Systems operating at or above 130°F (Return water temperature)

See Table 6 and Figure 14, page 15 (diaphragm-type or bladder-type ex-

pansion tank) or Figure 13 (closed-type expansion tank) on page 15 for

near-boiler piping for systems designed for return water at least 130 °F.

Low-temperature systems

1. See Figures 16 and 17, page 16 for near-boiler piping for low-temper-

ature or high-volume systems.

2. See Figure 15, page 15 for boilers used with refrigeration systems.

Relief valve

Install relief valve vertically in ¾” tapping on side of boiler. See the tag

attached to the relief valve for manufacturer’s instructions.

To avoid water damage or scalding due to valve operation, dis-

charge line must be connected to relief valve outlet and run to a

safe place of disposal. Terminate the discharge line to eliminate

possibility of severe burns should the valve discharge.

• Dischargelinemustbeasshortaspossibleandbethesamesize

as the valve discharge connection throughout its entire length.

• Dischargelinemustpitchdownwardfromthevalveandter-

minate at least 6” above the ﬂoor drain where any discharge

will be clearly visible.

• Thedischargelineshallterminateplain,notthreaded,with

a material serviceable for temperatures of 375 °F or greater.

• Donotpipethedischargetoanyplacewherefreezingcould

occur.

• Noshutoffvalveshallbeinstalledbetweenthereliefvalve

and boiler, or in the discharge line. Do not plug or place any

obstruction in the discharge line.

• Failuretocomplywiththeaboveguidelinescouldresultin

failure of the relief valve to operate, resulting in possibility of

severe personal injury, death or substantial property damage.

• Testtheoperationofthevalveafterllingandpressurizing

system by lifting the lever. Make sure the valve discharges

freely. If the valve fails to operate correctly, replace it with a

new relief valve.

Circulator

The circulator is not provided, but wiring is supplied

with boiler to allow you to locate it either in the return

or supply piping, as desired. See page 12 for a typical

installation. Pipe the expansion tank to the suction

side of the circulator whenever possible. Install an air

separator in the supply piping. Connect the expansion

tank to the air separator only if the separator is on the

suction side of the circulator. Always install the system

ﬁll connection at the same point as the expansion tank

connection to the system. Figures 13 and 14, page 15

show typical near-boiler piping connections.

Expansion tank

Diaphragm-type or bladder-type tank — Figure 14,

page 15

1. Ensure expansion tank size will handle boiler and

system water volume and temperature. Tank must

be located in boiler return piping as close to boiler

as possible, before inlet side of circulator. See tank

manufacturer’s instructions for details.

2. Install an automatic air vent as shown.

Closed-type tank — Figure 13, page 15

1. Ensure expansion tank size will handle boiler and

system water volume and temperature. See tank

manufacturer’s instructions for details.

2. Connect tank to ½” NPT tapping located behind

supply outlet, using ½” NPT piping. Pitch any

horizontal piping up towards tank 1 inch per 5 feet

of piping.

Undersized expansion tanks cause system

water to be lost from relief valve and

makeup water to be added through ﬁll

valve. Eventual section failure can result.

Water piping — multiple zone systems

Install system piping using either circulator zoning or

zone valve zoning. Install expansion tank on suction side

of system circulator. Always connect ﬁll line only at the

expansion tank — never at another point in the system.

Table 6 Minimum recommended pipe sizes

Connect piping – water boilers – EG only

Minimum Recommended Pipe Sizes (for 20°F rise)

Boiler

model

Forced-ow systems Gravity-ow systems

Supply

“A”

Return

“B”

Supply

“A”

Return

“B”

EG-30, 35 1” 1” 1 ½” 1 ½”

EG-40, 45, 50 1 ¼” 1 ¼” 2” 2”

EG-55, 65 1 ½” 1 ½” 2 ½” 2 ½”

EG-75 2” 2” 2 ½” 2 ½”

Note: * All supply and return pipe sizes are based upon a 2°

F temperature rise through the boiler.

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Figure 13 Recommended piping – forced hot water boilers

with closed type expansion tanks

Figure 14 Recommended piping – forced hot water boilers

with diaphragm type expansion tanks

Use Figure 13 or Figure 14 only for systems designed

for return water at least 130 °F. For systems with low

return water temperature possible, such as converted

gravity systems and radiant heating systems, install

bypass piping (see page 16) to protect boiler against

condensation. Failure to prevent low return water

temperature to the boiler could cause corrosion of the

boiler sections or burners, resulting in severe personal

injury, death or substantial property damage.

If system includes radiant heating circuits, provide

piping and controls to regulate the temperature sup-

plying the radiant circuits. Failure to comply could

result in substantial property damage.

Water piping — refrigeration systems

Prevent chilled water from entering boiler

Install boiler so that chilled medium is piped in parallel with the

heating boiler. Use appropriate valves to prevent chilled medium

from entering boiler. See Figure 15 for typical installation of

balancing valve and check valve.

Install boiler so that chilled medium is piped in

parallel with heating boiler (Figure 15). Use ap-

propriate valves to prevent chilled medium from

entering boiler. Consult AHRI Installation and

Piping Guides.

If boiler is connected to heating coils located in

air handling units where they can be exposed to

refrigerated air, use ﬂow control valves or other au-

tomatic means to prevent gravity circulation during

cooling cycle. Circulation of cold water through the

boiler could result in damage to the heat exchanger,

causing possible severe personal injury, death or

substantial property damage.

Figure 15 Recommended piping – refrigeration systems

Connect piping – water boilers – EG only (continued)

DO NOT connect directly from 3-wire zone

valves to the T-T terminals on the boiler

When using 3-wire zone valves, install an isolation

relay. Connect the zone valve end switch wires to

the isolation relay coil. Connect the isolation relay

contact across the boiler T-T terminals. Failure

to comply can result in damage to boiler com-

ponents or cause unreliable operation, resulting

in severe property damage.

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Figure 16 System bypass piping in boiler loop with separate

system circulator, using primary/secondary

piping.

Figure 17 Boiler bypass piping — use only for high water

content systems —DO NOT use for radiant panel

systems.

Connect piping – water boilers – EG only (continued)

Install all components speciﬁed above and adjust valves as described to prevent low temperature in the boiler. Failure to

prevent low water temperature in the boiler could cause corrosion of the boiler sections or burners, resulting in severe

personal injury, death or substantial property damage.

System bypass method

1. Apply bypass piping of Figure 16 to high water content

systems, radiant panel systems or any system that is likely

to operate with low return water temperature for extended

periods.

2. The bypass arrangement shown protects the boiler from dam-

age caused by condensate corrosion due to low return water

temperature and protects low temperature systems from too

high a supply temperature.

3. Adjust the bypass valves as indicated below.

Adjust bypass valves 1 and 2 as follows:

1. Start with valve 2 fully closed, valve 1 fully open.

2. Slowly open valve 2 while closing valve 1. Adjust the valves

until the boiler pressure/temperature gauge reads 160 °F or

higher. As you open the valves, pause long enough to allow

temperatures to level off. It takes a while for the boiler water

temperature to rise as the ﬂow changes.

3. Bypass valve 2 allows hot boiler outlet water to blend with

colder return water, raising the supply temperature to the

boiler. Bypass valve 1 balances the pressure drop through valve

4. The purpose of this piping is to raise the return water temperature

to the boiler enough to prevent condensation of ﬂue gases.

Boiler bypass method

1. Apply bypass piping of Figure 17 to high water content

systems, such as converted gravity systems.

2. The bypass arrangement shown protects the boiler from

damage caused by condensate corrosion due to low return

water temperature. This method does not provide protection

from high temperature water being supplied to the system.

3. DO NOT apply this piping to radiant panel systems.

4. Adjust the bypass valves as indicated below.

Adjust bypass valves 1 and 2 as follows:

1. Start with valve 1 fully closed, valve 2 fully open.

2. Slowly open valve 1 while closing valve 2. Adjust the valves

until the boiler pressure/temperature gauge reads approxi-

mately 60 °F higher than the system temperature gauge. As

you open the valves, pause long enough to allow temperatures

to level off. It takes a while for the boiler water temperature

to rise as the ﬂow changes.

3. Bypass valve 1 controls system ﬂow rate. Bypass valve 2

controls ﬂow through the boiler.

4. The purpose of this piping is to cause a high enough tem-

perature rise in the boiler that the average temperature will

be warm enough to prevent condensation of ﬂue gases.

Water line

Close nipple

Reducing elbow or

elbow with bushing

Condensate return

23 / "

Boiler

front

Steam to system

73832

EG/PEG

Water line

nipple

Reducing elbow or

elbow with bushing

Condensate

return

23 / "

Boiler

front

Steam to

system

73832a

Install offset header

to prevent bending

at section tappings

EGH

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

General

Failure to properly pipe the boiler may result in

improper operation and damage to the boiler or

building.

Steam supply must be on same end as controls.

Return may be from either end.

1. Install the boiler jacket before connecting return piping. (Sup-

ply piping can be connected before or after jacket installation.)

Connect controls after all piping is connected.

2. See Table 7 for recommended pipe sizing.

3. See Figure 5, page 10, for tapping locations.

4. EGH only - install 3/4” system blow-off (drain) valve in lowest

part of return piping close to boiler.

Condensate return —

• Satisfactory operation of a steam heating system depends

on adequate condensate return to boiler to maintain a

steady water level.

• Avoidaddingrawmakeupwater.

• Where condensatereturnisnotadequate,installlow

water cutoff/pump control, condensate receiver and

condensate boiler feed pump. Refer to Table 7, for sizing.

Connecting to parallel-ﬂow piping

See Figure 18 for parallel-ﬂow steam systems.

Connecting to counterﬂow piping

When connecting to a counterﬂow system, the boiler steam supply

must connect into the top of the counterﬂow system header, as

shown in Figure 19, page 18.

Figure 18 Recommended piping for parallel-ﬂow systems

Table 7 Recommended steam boiler pipe sizing

Steam Boiler Piping Minimum Recommended Pipe Sizes

Boiler Model

Riser Pipe Size

Header *

Equalizer

A B

EG-30, 35

PEG-30, 35

2” –– 2” 1 ½”

EG-40, 45, 50

PEG-40, 45, 50

2 ½” –– 2 ½”

1 ½”

2” 2” 2 ½”

EG-55, 65, 75

PEG-55, 65

2” 2”

3” 1 ½”

3” ––

EGH-85, 95

2” 2” 3” 1 ½”

EGH-105

2 ½” 2 ½” 3” 1 ½”

EGH-115, 125

2 ½” 2 ½” 4” 1 ½”

* 24” minimum from waterline to bottom of header.

Connect piping – steam boilers (continued)

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Installing the relief valve

Install relief valve in tapping on top of boiler. See Table 4, page

10, for control tapping locations. See the tag attached to the relief

valve for manufacturer’s instructions.

Follow the steps below to avoid potential severe per-

sonal injury, death or substantial property damage.

• Wheninstallingthereliefvalve,ensurethatallconnec-

tions, including the valve inlet, are clean and free from

any foreign matter.

• Mountthereliefvalveonlyintheverticalposition,directly

connected to the tapping designated in the manual on top

of the boiler.

• Usepipecompoundsparingly,ortape,onexternalthreads

only.

• Donot use apipewrench!Usepropertypeand size

wrench on wrench pads only.

During operation, this valve may discharge large

amounts of steam and/or hot water. Therefore, to

reduce the potential for bodily injury and property

damage, a discharge line MUST be installed that:

• Isconnectedfromtheoutlettoasafepointofdischarge

with no intervening valve.

• Allowscompletedrainageofboththevalveandthedis-

charge line.

• Isindependentlysupportedandsecurelyanchoredsoas

to avoid applied stress as possible.

• Terminatesfreelytoatmospherewhereanydischargewill

be clearly visible and is at no risk of freezing.

• Is,overitsentirelength,ofapipesizeequaltoorgreater

than that of the valve outlet.

Use only schedule 40 metal pipe for discharge. (Do not

use schedule 80, extra strong or double strong pipe or

connections.) DO NOT CAP, PLUG OR OTHERWISE

OBSTRUCTDISCHARGEPIPEOUTLET!Ifdischarge

is piped upward, a condensate drain must be provided in

the elbow below the vertical pipe to prevent condensate

from returning into the valve. Failure to comply with these

instructions will cause a dangerous spray of hot water and

steam that would cause severe personal injury or death.

Figure 19 Connection to counter ﬂow steam piping

Connect piping – steam boilers (continued)

Figure 20 Recommended piping for parallel-ﬂow systems

with optional reservoir pipe

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Connect piping – steam boilers (continued)

Table 9 Boiler feed system sizing

Condensate return

Modern steam boilers are designed to steam for less time than

older, larger boilers. When replacing an older steam boiler the

system condensate return time may be longer than the steaming

time. This could cause the following problems:

1. Boilers ﬁtted with an automatic water feed could overﬁll.

2. Units ﬁtted with only a low water cutoff would shut down

and cycle while waiting for condensate to return.

Following is a simple method for determining whether or not a

reservoir pipe is required to lengthen steaming time for a resi-

dential installation:

1. Disconnect condensate return line at existing boiler.

2. Heat

boiler and allow to steam for 10 minutes. Turn off boiler.

3. Measure length of time from when boiler started to steam to

when condensate begins to return through condensate line.

4. Measure length of time from when condensate begins to

return to when it stops returning. Divide this time by 2.

5. Add time measured in step 3 to time calculated in step 4. This

sum is the average time required for condensate to return to

the boiler.

6. If this total time is 10 minutes or less, no reservoir pipe is

needed.

If total time for condensate to return to boiler (from step 5) is

more than 10 minutes, a reservoir pipe (or boiler feed system) is

recommended. See Table 8 and Figure 20 for suggested reservoir

pipe size. Install as shown in Figure 20.

For larger systems (as noted in Table 8), use a boiler feed system

with a condensate tank and feed pump. You will have to install a

low water cutoff/pump control on the boiler to operate the pump.

Use Table 9 to size boiler feed systems. See Figure 5, page 10, for

tapping locations. (The use of a combination condensate tank and

ﬂoat-controlled condensate return pump is not recommended.)

For most residential installations a reservoir pipe may be all that

is necessary to ensure proper operation.

Boiler

model

number

Max.

boiler

gross

output

Time from initial steaming to average condensate return

(boiler steaming capacity based on 970 Btu per pound of steam)

15 minutes 20 minutes 30 minutes

MBH gallons

pipe

length

(feet)

gallons

pipe

length

(feet)

gallons

pipe

length

(feet)

EG/PEG-30

¾ ¾ 1 ½ 1 ½ 3 2 ½

EG/PEG-35

EG/PEG-40

106

1 ¼ 1 ¼ 2 ½ 2 ¼

Use boiler feed

system

EG/PEG-45

127

EG/PEG-50

148 1 ½ 1 ½ 3 2 ½

EG/PEG-55

169 1 ¾ 1 ¾

Use boiler feed

system

EG/PEG-65

201 2 ¼ 2 ¼

EG-75

237 2 ½ 2 ½

EGH-85

243 2 ½ 2 ½

EGH-95 up Not recommended –– Use boiler feed system if needed

Designed full capacity steaming time of modern boilers is 10 minutes.

Table 8 Reservoir pipe sizing

Boiler

Model

Gross

Output

Pounds

Steam

Per

Hour

Gallons

Conden-

sate

Per

Hour

Minimum Condensate

Receiver Capacity (Gal.)

Recom-

mended

Maximum

Minutes of boiler

operation:

Feed

Pump

Capacity

GPM

15 30 45 60

EG/PEG-30

62 7 ½ 2 5 7 10 0.3

EG/PEG-35

82 10 3 7 10 13 0.3

EG/PEG-40

103 12 ½ 4 8 12 17 0.4

EG/PEG-45

124 15 5 10 15 20 0.5

EG/PEG-50

145 17 ½ 6 12 17 23 0.6

EG/PEG-55

166 20 7 13 20 27 0.7

EG/PEG-65

198 25 8 17 25 33 0.8

EG-75

234 29 ½ 10 20 29 39 1.0

EGH-85

253 29 10 19 29 39 1.0

EGH-95

290 33 ½ 11 22 33 45 1.1

EGH-105

325 37 ½ 12 25 37 50 1.3

EGH-115

361 41 ½ 14 28 41 55 1.4

EGH-125

398 46 15 31 45 61 1.5

If pump capacity exceeds capacity shown, pump can

be throttled with globe or ball valve.

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Failure to properly install, pipe and wire boiler

controls may result in severe damage to the

boiler, building and personnel.

Water boiler - EG only

1. Install controls as shown on Control Tapping Table and

Figure 5, page 10.

2. Additional low water cut off for water boilers:

a. Install if boiler is located above radiation level.

b. May be required on water boilers by certain state, local or

territorial codes or insurance companies. If a low water

cut-off is used on a water boiler, use a control designed

especially for water installations.

An electrode probe type

may be located in a tee in

the supply line above boiler, also

see Table 4, page 10.

3. If system is to be ASME inspected and approved, an ad-

ditional high temperature limit is needed. Purchase and

install in supply line above boiler.

Steam boiler - EG, PEG & EGH

Water line dimension are measured from bot-

tom of boiler section leg where it rests on the

boiler room ﬂoor or boiler foundation.

1. For steam boilers furnished with probe-type low water

cut-offs, install as shown in Figure 21.

2. For steam boilers furnished with ﬂoat type low water

cut-off, install controls as illustrated in Figure 22.

Install blow down line in bottom of cutoff. See Figure 22

and control manufacturer’s instructions for details.

Pipe blow down line near ﬂoor close to ﬂoor

drain to eliminate potential of severe burns. Do

not plug, valve or place any obstruction in blow

down line.

a. Other ﬂoat-type water-level controls for EGH steam boilers

are shown in Figure 23. (Use 1 inch I.P.S. connections).

b. Water feeders are not recommended for primary control.

A low-water cut-off with pump controller is recommended

with a condensate receiver and feed pump.

3. Install remaining controls as shown in Table 4 and Fig-

ure 5, page 10.

Install boiler controls

Figure 23 EGH only - Piping for optional ﬂoat-type water level

controllers for steam boilers

LWCO model numbers are manufacturer’s part

numbers that can be found in the Weil-McLain

Trade Price Schedule.

LWCO Dim A.

No. 247-2

³/16”

No. 61 2 ⅝”

No. 63 2 ⅝”

No. 51-2 1 ½”

No. 150, 157 2 ¼”

No. 93 2 ⅝”

Primary oat LWCO or secondary manual reset

LWCO with primary probe LWCO

Figure 21 Probe-type low water cut-off - (Left side view)

Figure 22 Float-type low water cut-off - (Left side view)

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

EG and EGH boilers for tankless heater applica-

tion are available only on special order as factory-

installed optional equipment. Standard boilers

cannot be adapted for heater use. Install a tankless

heater only in a steam boiler or forced hot water.

For correct operation, install as shown in Figure 24 (water boilers)

or Figure 25 (steam boilers).

1. Automatic mixing valve must be installed per mixing valve

manufacturer’s instructions.

2. Flow regulating valve must be installed. Size according to

intermittent draw of heater as shown in following table.

3. Operating control with a small differential scale is recom-

mended. Install in temperature control tapping in heater plate.

4. In hard water areas, it is advisable to soften cold domestic supply

water to the tankless heater to prevent lime buildup.

Figure 24 Tankless heater piping EG (water boiler)

Connect piping – tankless heater (optional)

Table 10 Minimum recommended pipe sizes

Piping connections not furnished. Use brass plugs

in tees and crosses to facilitate cleaning in hard

water areas.

Figure 25 Tankless heater piping EG/EGH (steam boiler)

Boiler

Model

Heating

Number

(Note 3)

Intermittent

Draw GPM

100°F Av.

Temp. Rise

(Note 1)

Continuous

Draw GPM

100°F Av.

Temp. Rise

(Note 2)

Inlet and

Outlet

Tappings

Temp.

Control

Tapping

Water

EG-35 E-624 3.00 1.60

½” ¾”

EG-40 E-624 3.00 2.00

½” ¾”

EG-45 E-624 3.25 2.40

½” ¾”

EG-50 E-626 4.00 2.80

½” ¾”

EG-55 E-626 4.25 3.20

½” ¾”

EG-65 E-632 4.50 4.00

½” ¾”

EG-75 E-632 4.50 4.80

½” ¾”

Steam

EG/PEG-35 35-S-29 3.00 1.60

¾” ¾”

EG/PEG-40 35-S-29 3.00 2.00

¾” ¾”

EG/PEG-45 35-S-29 3.25 2.40

¾” ¾”

EG/PEG-50 35-S-29 3.25 2.80

¾” ¾”

EG/PEG-55 35-S-29 3.50 3.20

¾” ¾”

EG/PEG-65 35-S-29 3.75 4.00

¾” ¾”

EG-75 35-S-29 4.00 4.80

¾” ¾”

EGH-85 35-S-29 4.00 5.00

¾” ¾”

EGH-95 35-S-29 4.00 5.00

¾” ¾”

EGH-105 35-S-29 4.00 5.00

¾” ¾”

EGH-115 35-S-29 4.00 5.00

¾” ¾”

EGH-125 35-S-29 4.00 5.00

¾” ¾”

Notes:

Weil-McLain ratings based on 60 PSIG domestic water pressure

at heater.

1. Gallons of water per minute heated from 40°F to 140°F with

200°F boiler water temperature.

2. Continuous draw – no recovery period.

3. These single wall heat exchangers comply with National

Standard Plumbing Code provided that:

• Boiler water (including additives is practically non toxic,

having a toxicity range or class of 1, as listed in Clinical

Toxicology of Commercial Products, and

• Boiler water pressure is limited to max. 30 PSIG by

approved water or steam relief valve.

Studies have indicated that dangerous bacteria can form

in potable water distribution system if certain minimum

water temperatures are not maintained. Contact local

health department for more information.

These single wall heat exchangers comply with National

Standard Plumbing Code provided that:

• Boilerwater(includingadditives)ispracticallynon-

toxic, having a toxicity rating or class of 1, as listed in

Clinical Toxicology of Commercial Products.

• Boilerwaterpressureislimitedtomaximum30psig

by approved water relief valve.

See Automatic mixing valve and Scaud warnings, page 27.

NSF/ANSI 372

Tankless water heaters for EG / EGH

boilers have been tested and certied by

CSA Group (certicate # 2552127).

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Connecting gas supply piping

1. Size gas piping considering:

a. Diameter and length of gas supplying piping.

b. Number of ﬁttings.

c. Maximum gas consumption (including any possible future

expansion).

d. Allowable loss in gas pressure from gas meter outlet to

boiler. For pressure drops, see ANSI Z223.1/NFPA 54 –

latest edition. Canadian installations must comply with

Natural Gas and Propane Installation Code, CAN/CSA

B149.1 or B149.2 Installation Codes.

2. For natural gas:

a. Refer to Table 11 or the National Fuel Gas Code. To obtain

cubic feet per hour, divide the input by 1000.

b. Size for rated boiler input.

c. Inlet gas pressure: 5”

w.c. minimum

13”

w.c. maximum

d. Manifold gas pressure: 3¹⁄₂"

w.c.

e. Install 100% lock-up gas pressure regulator in supply line

if inlet pressure exceeds 13"

w.c., then adjust for 13" w.c.

maximum.

3. For propane gas:

a. Inlet gas pressure: 11”

w.c. minimum

13”

w.c. maximum

b. Manifold gas pressure: 10”

w.c.

c. Gas pressure regulator provided by gas supplier must be

adjusted for maximum pressure of 13”

w.c.

d. Contact gas supplier to size pipes, tanks and regulator.

4. Remove knock-out disc from jacket panel which gas supply

is to be piped.

5. Follow good piping practices.

6. Pipe joint compound (pipe dope) must be resistant to cor-

rosive action of liqueﬁed petroleum gases. Apply sparingly

only to make threads of pipe joints.

7. Install drip leg at inlet of gas connection to boiler. Where local

utility requires, extend drip leg to ﬂoor.

8. Install ground joint union when required for servicing. See

Figure 26.

9. Install manual shut-off valve outside boiler jacket as shown

in Figure 26 when required by local codes.

10. Support piping by hangers, not by boiler or its accessories.

11. In Canada only, the manual main shut off valve (when used)

must be identiﬁed by the installer.

12. Purge all air from piping.

13. Before placing boiler in operation, check boiler and its gas

connection for leaks.

Do not check for gas leaks with an open ﬂame – use

bubble test. Failure to do so can cause severe per-

sonal injury, death or substantial property damage.

a. Close manual main shut-off valve during any pressure testing

at less than 13 inches water column.

b. Disconnect boiler and gas valve from gas supply piping during

any pressure test greater than 13 inches water column.

Figure 26 Gas supply piping

Connect gas supply piping

Table 11 Gas pipe capacities

Adjusted

length

of gas

supply

piping in

feet *

Capacity of pipe for pipe sizes in

cubic feet of gas per hour **

½” ¾” 1” 1¼” 1½” 2”

10 132 278 520 1050 1600 3050

20 92 190 350 730 1100 2100

30 73 152 285 590 860 1650

40 63 130 245 500 760 1450

50 56 115 215 440 670 1270

75 45 93 175 360 545 1020

100 38 79 150 305 460 870

150 31 64 120 250 380 710

Notes:

Include measured length of gas supply piping and allowance

in feet for number and size of ttings.

Specic Gravity - 0.60; Pressure loss - 0.30” w.c.

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

For your safety, turn off electrical power supply at ser-

vice entrance panel before making any electrical con-

nections to avoid possible electric shock hazard. Fail-

ure to do so can cause severe personal injury or death.

Refer to the Control Supplement for additional

information, operating instructions and control

wiring diagram.

Wiring must be NEC Class 1 ANSI/NFPA 70 – latest

edition.

If rollout thermal fuse element wire supplied with

boiler must be replaced, type 200 °C wire or equiva-

lent must be used. If other original wiring supplied

with boiler must be replaced, use only type 105 °C

wire or equivalent.

Boiler must be electrically grounded as required

by National Electrical Code ANSI/NFPA 70 – latest

edition.

Electrical installation must comply with:

1. National Electrical Code ANSI/NFPA 70 – latest edition

and any other national, state, provincial or local codes or

regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and

any local codes

Wiring connections

1. Boiler is shipped with controls completely wired, except

spill switch and vent damper. See wiring diagram in Control

Supplement for details.

2. Installer must attach wiring diagram inside jacket door.

3. See Figure 27 for ﬁeld wiring. A separate 120VAC electrical

circuit with a fused disconnect switch (15 amp recommended)

should be used for the boiler.

4. A strain relief bushing and adapter must be used at each point

where wiring passes through control case (see Figure 28) to

protect wiring insulation.

5. Multiple zones — Refer to zone valve manufacturer’s literature

for wiring and application. A separate transformer is required

to power zone valves. Zoning with circulators requires a relay

for each circuit.

Room thermostat

1. Connect thermostat as shown on wiring diagram on boiler.

2. Install on inside wall away from inﬂuences of drafts, hot or cold

water pipes, lighting ﬁxtures, television, sunrays or ﬁreplaces.

3. If thermostat has a heat anticipator, set heat anticipator in

thermostat to match power requirements of equipment con-

nected to it. Refer to the appropriate Control Supplement for

instructions on the thermostat anticipator setting.

Figure 28 Provide strain reliefs

Connect eld wiring to boiler

Figure 27 Connect ﬁeld wiring in boiler junction box as shown below. See Control Supplement for more details.

DHW (if used)

Connect the DHW aquastat as shown in wiring below. The

Economy function of the control is not utilized with DHW

input.

R & C Connections (if used)

24VAC leads should be used for power stealing thermostats only !

Other devices requiring 24VAC should have separate

power supply.

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Freeze protection (when used)

Use antifreeze especially made for hydronic systems. Inhibited

propylene glycol is recommended.

Do not use automotive, ethylene glycol or undiluted

antifreeze. Severe personal injury, death or substan-

tial property damage can result.

Local codes may require back-ﬂow preventer or actual disconnect

from city water supply.

Determine quantity according to system water content. Boiler

water content is listed on page 39. Remember to add in expansion

tank water content.

Follow antifreeze manufacturer’s instructions.

Filling water systems

1. Close manual air vents, drain cock, and automatic air vent, if

used.

2. Fill to correct system pressure. Correct pressure will vary with

each application. Residential systems are often designed for

12 PSIG of cold ﬁll pressure.

3. Open automatic air vent one turn, if used.

4. Open manual water feed valve.

a. Starting on lowest ﬂoor, open air vents one at a time until

water squirts out. Close vent.

b. Repeat with remaining vents.

5. Close manual water feed valve when correct boiler pressure

is reached.

6. If purge valve is used - located in the return piping above

isolation valve:

a. Connect hose to purge valve.

b. Close isolation valve. Open purge valve.

c. Open hand water feed valve and allow system to purge all

air. If system has more than one circuit, purge each circuit

separately by opening each balancing valve one at a time.

d. Close purge valve and water feed valve cock.

e. Open isolation valve.

f. Fill system to correct pressure.

Filling steam boilers

1. Fill to normal waterline, halfway up gauge glass.

2. Boiler water pH 7.0 to 8.5 is recommended.

3. Follow skimming procedure.

Wiring multiple zones

Refer to zone valve manufacturer’s literature for wiring and ap-

plication. A separate transformer is required to power zone valves.

Zoning with circulators requires a relay for each circulator.

DO NOT connect directly from 3-wire

zone valves to the T-T terminals on the

boiler

. When using 3-wire zone valves, install

an isolation relay. Connect the zone valve

end switch wires to the isolation relay coil.

Connect the isolation relay contact across the

boiler T-T terminals. Failure to comply can

result in damage to boiler components or

cause unreliable operation, resulting in severe

property damage.

Check for gas leaks

Before starting the boiler, and during initial opera-

tion, smell near the ﬂoor and around the boiler for

gas odorant or any unusual odor. Do not proceed

with start-up if there is any indication of a gas leak.

Repair any leak at once.

Propane boilers only — Your propane supplier mixes

an odorant with the propane to make its presence

detectable. In some instances, the odorant can fade

and the gas may no longer have an odor.

• Propanegascanaccumulate at oor level.Smell

near the ﬂoor for the gas odorant or any unusual

odor. If you suspect a leak, do not attempt to light

the pilot.

• Usecautionwhenattemptingtolightthepropane

pilot. This should be done by a qualiﬁed service

technician, particularly if pilot outages are common.

• Periodicallychecktheodorantlevelofyourgas.

• Inspectboilerandsystem at least yearlytomake

sure all gas piping is leak-tight.

• Consultyourpropanesupplierregardinginstalla-

tion of a gas leak detector. There are some products

on the market intended for this purpose. Your sup-

plier may be able to suggest an appropriate device.

Fill the system

Do not ﬁll (except for leakage tests) until the boiler

is ready to be ﬁred.

Determine if water treatment is needed

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to

boiler will occur, resulting in substantial property

damage.

Eliminate all system leaks. Continual fresh makeup

water will reduce boiler life. Minerals can build up

in sections, reducing heat transfer, overheating cast

iron, and causing section failure.

Consult local water treatment companies for unusually hard water

areas (above 7 grains hardness) or low pH water conditions (below

7.0). Boiler water pH of 7.0 to 8.5 is recommended.

Start-up

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Start-up (continued)

Steam Heating Installation

Considerations

Closed steam heating systems should not have high amounts

of make-up water. Make-up water only occurs when the system

is leaking or when make-up water is incorrectly administered.

And, even with chemical treatment, make-up water will reduce

boiler life due to corrosion. And chemical treatment may be dif-

ﬁcult to execute if the system make-up volume is unpredictable.

Troubleshoot the system BEFORE considering water treatment.

If the system is using make-up water, then the following may be

likely:

• Leakingreturnlines, underground pipes, faulty steam traps,

faulty air vents

• Automaticwaterfeedisinstalledincorrectlyorincorrectly

adjusted

• Ifthesystemutilizesacondensatereceiver,thefeedermay

be ﬂooding due to long system time lag.

If the piping is NOT leaking, consider installing a boiler feed

system (NOT a condensate return system). The boiler feed

system provides condensate storage and allows the boiler to

directly control water level. This is not the case with gravity

return systems or condensate return systems — these only

provide water to the boiler when the condensate returns from

the system. If the system time lag is longer than boiler can

provide steam, and the boiler is equipped with an automatic

feeder, water will feed to the boiler before the condensate can

return from the system. This will cause overﬁll and ﬂooding

when the condensate does return. Also, pumping cold make-up

water directly into the boiler collapses the water level, causing

false indications of need for make-up. With a boiler feed system,

the ﬂoat control on the boiler turns the feed pump on and off as

needed. Make-up water is added at the boiler feed system tank.

And the storage volume of the tank makes it unlikely that make-

up will be needed UNLESS there is a system leak.

Chlorides

Over the last several decades, the level of chlorides in some

ground water and city water supplies have increased due to

use of salt during the removal of snow and ice from roads and

highways, and the increased use of water softeners. Elevated

levels of chlorides (over 200 ppm) in the water of steam boilers

will accelerate water side corrosion and shorten the operating

life of the boiler.

Chlorides and other dissolved solids are present in boiler make-

up water and are not removed from the boiler when the boiler

is producing steam. The level of chlorides and dissolved solids

in the boiler water increase when make-up water is added to the

boiler because of normal maintenance to low water cut-offs and

system leaks. If there are high chloride and dissolved solid levels

in boiler make-up water, boiler water treatment should be con-

sidered.

In general, cast iron steam boilers do not require water treatment

for protection. However, some boiler water treatment chemi-

cals can promote water level instability. Surging and priming in

steam boilers can result even though the boiler was thoroughly

cleaned before the treatment was added.

Systems where treatment should be

considered are:

 •Processapplications

 •Contaminatedcondensate

 •Largemake-upwaterrequirements

 •Systemcomponentsrequiringcorrosioninhibitor

 •Extremelyhardwater

 •Make-upwatersupplywithhigherthan30ppmofchloride

Beware the Foam

Water treatment chemicals should be thoroughly reviewed be-

fore they are introduced into the boiler and heating system. Of

particular concern are foaming agents that will interfere with

the disengagement of the steam at the boiler waterline. For this

reason, foaming agents cannot be tolerated in steam boilers.

Testing & Treatments

To test the boiler water treatment chemicals, prepare a small

amount of the chemical intended for the boiler with water. In a

ventilated area, put this mixture into a pan and bring to a “roll-

ing boil” on the stove. If the mixture foams, it is not suitable

for the boiler.

Recognized treatment compounds used for oxygen scaveng-

ing and corrosion protection should not affect the life of the

elastomer sealing rings. Asking the treatment supplier to test

a sealing ring in the proposed compound can eliminate any

doubt. In any case, a compound containing petroleum should

not be used.

Without Chemical Treatment

• When the chloride level is above 400 ppm, or the total dis-

solved solids (TDS) are above 1000 ppm, drain and reﬁll the

boiler with fresh water and bring the boiler to pressure for

15 minutes per the boiler manual to drive off excess oxygen.

• If chemical treatment is not used and chloride level and

TDS levels are not monitored, drain and reﬁll the boiler

when the chloride level is above 400 ppm, or the total dis-

solved solids (TDS) are above 1000 ppm. After reﬁlling the

boiler, bring the boiler to pressure for 15 minutes per the

boiler manual to drive off excess oxygen.

These steps will help prevent corrosion caused by high conductivity,

but may not prevent under-deposit corrosion.

In general, cast iron steam boilers do not require water treatment

for protection. However, some water conditions may require

the boiler be drained and reﬁlled, or in more aggressive areas,

chemically treated.

Follow the appropriate Boiler Manual, for all steam options.

Steam Boiler Water Treatment

Part Number 550-142-303/1120

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Operate boiler

Check system and boiler

DO NOT proceed with boiler operation unless

boiler and system have been ﬁlled with water and

all instructions and procedures of previous manual

sections have been completed. Failure to do so could

result in severe personal injury, death or substantial

property damage.

Before starting the boiler . . .

• SeeControlSupplementfor“LightingorOperating

Instructions”.

• Verifytheboilerandsystemwaterleveliscorrect

(Steam — no more than ½ of gauge glass or less

than ¼” above bottom of gauge glass).

• Verifythe“Preparation”proceduresontheprevious

pages have been completed.

Start the boiler

1. Steam boilers — Check boiler water level — Should be ap-

proximately ½ way up gauge glass.

2. Remove boiler jacket door and note the gas valve manufacturer

and model number.

3. Follow the Lighting or Operating Instructions in the Control

Supplement, depending on gas valve installed in boiler. Use

only the Operating Instruction which applies to this gas valve.

(The Operating Instruction label on the boiler provides the

same information.)

4. If boiler fails to start, see “If boiler doesn’t start . . . Check for:”

on the next page.

Check system and boiler

Eliminate all system leaks. Continual fresh makeup

water will reduce boiler life. Minerals can build up

in sections, reducing heat transfer, overheating cast

iron, and causing section failure.

If you discover evidence of any gas leak, shut down

the boiler at once. Find the leak source with bubble

test and repair immediately. Do not start boiler

again until corrected. Failure to comply could re-

sult in severe personal injury, death or substantial

property damage.

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to

boiler will occur, resulting in substantial property

damage.

1. Check system piping for leaks. If found, shut down boiler and

repair immediately.

2. Inspect vent system thoroughly for signs of deterioration from

corrosion, physical damage or sagging. Verify that masonry

chimney liners are in good condition, with no obstructions,

and there are no openings into the chimney.

3. Check around the boiler for gas leaks following the procedure

of step 13, page 22.

4. Verify operation using procedures below. Perform “Checkout

procedure”, page 28, and ﬁll in the “Installation and Service

Certiﬁcate”.

Skim the steam boiler

Clean all newly installed steam boilers to remove

oil and grease. Failure to properly clean can result

in violent ﬂuctuations of water level, water passing

into steam mains or high maintenance costs on

strainers, traps and vents.

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to

boiler will occur, resulting in substantial property

damage.

1. Provide 1½” piping from skim tapping to ﬂoor drain.

2. Adjust waterline to midpoint of skim tapping. See Figure 5,

page 10.

3. Follow “Lighting or Operating Instructions” in the Control

Supplement to ﬁre boiler to maintain temperature below

steaming rate.

4. Feed in water to maintain water level. Cycle burners to prevent

rise in steam pressure.

5. Continue skimming until discharge is clear. May take several

hours.

6. Drain boiler. While boiler is warm, but not hot, ﬂush all inte-

rior surfaces under full pressure until drain water runs clear.

7. Remove skim piping. Plug tapping.

8. Close drain cock. Fill with fresh water to waterline. Start burn-

ers and steam for 15 minutes to remove dissolved gases. Stop

burners.

9. Check traps and air vents for proper operation.

10. Process may need to be repeated after several weeks of opera-

tion.

Inspect base insulation

The boiler contains ceramic ﬁber and ﬁberglass

materials. Use care when handling these materials

per instructions on page 29 of this manual. Failure

to comply could result in severe personal injury.

Check to make sure insulation is secure against all four sides of

the base. If insulation is damaged or displaced, do not operate

boiler. Replace or reposition insulation.

Failure to replace damaged insulation or reposition

insulation can result in a ﬁre hazard, causing se-

vere personal injury, death or substantial property

damage.

Start-up (continued)

Part Number 550-142-303/1120

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4. Repeat Steps 2 through 4 several times to verify opera-

tion.

5. Return thermostat to normal setting.

6. Set thermostat heat anticipator setting indicated on

wiring diagram.

Check venting system operation

With boiler ﬁring, hold a candle or match below lower edge

of draft diverter “skirt.” If ﬂame does not blow out, but

burns undisturbed, the vent system is working properly. If

ﬂame blows out or ﬂickers severely, the vent system must

be checked for obstructions or other causes of improper

venting.

If boiler doesn’t start . . . Check for:

1. Loose connections, blown fuse or service switch off?

2. High limit switch set below boiler pressure?

3. Thermostat set below room temperature?

4. Gas not turned on at meter or boiler?

5. Incoming gas pressure less than:

5” w.c. for natural gas? 11” w.c. for propane gas?

6. If none of the above corrects the problem, see “Troubleshooting”

in the Control Supplement.

Verify operation

Check burner ﬂame — Pilot burner

1. Proper pilot ﬂame (see Figure 29):

a. Blue ﬂame.

b. Inner cone engulﬁng thermocouple.

c. Thermocouple glowing cherry red.

2. Proper pilot ﬂame:

a. Overﬁred — Large ﬂame lifting or blowing past thermocouple.

b. Underﬁred — Small ﬂame. Inner cone not engulﬁng thermocouple.

c. Lack of primary air — Yellow ﬂame tip.

d. Incorrectly heated thermocouple.

Check burner ﬂame — Main burner

1. Proper main burner ﬂame (see Figure 30):

a. Yellow-orange streaks may appear (caused by dust).

2. Improper main burner ﬂame:

a. Overﬁred — Large ﬂames.

b. Underﬁred — Small ﬂames.

c. Lack of primary air — Yellow tipping on ﬂames (sooting will occur).

Check vent damper operation

1. Raise room thermostat to call for heat — Vent damper actuator

will slowly open vent damper.

When vent damper is fully open — Pilot will light, then allow

main burners to ignite.

Vent damper must be fully open before main burners light.

If vent damper does not fully open, ﬂue products such as

carbon monoxide will escape into house, causing severe

personal injury or death.

3. Lower thermostat setting — Main burner ﬂames will go out, then

vent damper will close.

Start-up (continued)

Figure 29 Typical pilot burner ﬂame

Figure 30 Typical main burner ﬂame

Hot Water Can Scald!

• ConsumerProductSafetyCommissionandsomestatesrecommenddomestichotwater

temperature of 130°F or less.

• Wheninstallinganautomatic mixing valve, selection and installation must comply with

valve manufacturer’s recommendations and instructions.

• Waterheatedtoatemperaturesuitableforclotheswashing,dishwashingandother

sanitizing needs will scaled and cause injury.

• Children,elderly,inrmorphysicallyhandicappedpersonsaremorelikelytobeinjured

by hot water. Never leave them unattended in or near a bathtub, shower or sink. Never

allow small children to use a hot water faucet or draw their own bath. If anyone using hot

water in the building ﬁts this description, or if state laws or local codes require certain

water temperatures at hot water faucets, take special precautions:

• Installautomatic mixing valve set according to those standards.

• Uselowestpracticaltemperaturesetting.

• Checkwatertemperatureimmediatelyafterrstheatingcycleandafteranyadjustment.

  ProtectionMustBeTakenAgainstExcessiveTemperatureandPressure! —

Installation of a Temperature & Pressure (T&P) relief valve is required.

Part Number 550-142-303/1120

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Check-out procedure

Check-off steps as completed.

❏ System properly ﬁlled with water?

❏ Automatic air vent, if used, open one turn (water boilers only)?

❏ Air purged from system (water boilers only)?

❏ Steam boilers properly skimmed?

❏ Air purged from gas piping? Piping checked for leaks?

❏ Are proper oriﬁces installed? Check page 13 for proper size.

Proper oriﬁces must be used. Failure to do so will

cause severe personal injury, death or substantial

property damage.

❏ Follow operating instruction label on boiler for proper start-

up. Also refer to “Operate boiler,” page 26.

❏ Proper burner ﬂame? See “Check burner ﬂame — Main

burner” and “Check burner ﬂame — Pilot burner,” page 27.

❏ Test temperature limit — While burners are operating, turn

Boiler Temp adjustment knob counterclockwise until display

reading is below actual boiler water temperature. Burners

should go off while circulator continues to operate (water

boilers only). Turn Boiler Temp adjustment knob clockwise

until display reading is above boiler water temperature and

ignition sequence should resume.

❏ Test low water cut off (LWCO) – While burner are operating,

press and hold “LWCO TEST” button on control. Burners

should go off while circulator continues to operate and

LWCO light should turn ON. Release “LWCO TEST” button

and ignition sequence should resume.

❏ Test any additional ﬁeld-installed controls: If boiler has an

additional low water cut off, additional high limit or other

controls, test for operation as outlined by manufacturer.

Burners should be operating and should go off when con-

trols are tested. When controls are restored, burners should

reignite.

❏ EG only - button on spill switch pushed in?

❏ To test ignition system shut-off device:

Connect manometer to outlet side of gas valve. Start

boiler, allowing for normal start-up cycle to occur and

main burners to ignite. With main burners on, manu-

ally shut off gas supply at manual main shutoff gas valve.

Burners should go off. Open manual main shut-off gas valve.

Manometer should conﬁrm there is no gas ﬂow. Pilot will

relight, ﬂame sensing element will sense pilot ﬂame and

main burners reignite.

❏ Set Boiler Temp adjustment knob to system temperature re-

quirements. Adjust balancing valves and controls to provide

design temperature to system. (water boilers)

❏ Limit control set to design temperature or pressure require-

ments of system? Maximum limit set 220°F W and 10 PSI

steam.

❏ For multiple zones, ﬂow adjusted so it is about the same in

each zone (water boilers only)?

❏ Thermostat heat anticipator set properly? Refer to “Room

Thermostat,” page 23 and correct wiring diagram.

❏ Boiler cycled with the thermostat? Raise to highest setting.

Boiler should go through normal start-up cycle. Lower to

lowest setting. Boiler should go off.

❏ Measure gas input (natural gas only):

a. Operate boiler 10 minutes.

b. Turn off other appliances.

c. At the natural gas meter, measure time (in seconds)

required to use one cubic foot of gas.

d. Calculate gas input:

3600 x 1000

number of seconds from step c

=Btuh

e. Btuh calculated should approximate input rating on rating

label.

❏ Check manifold gas pressure by connecting a manometer

to the downstream test tapping on main gas valve.

MANIFOLD GAS PRESSURE

NAT = 3.5" w.c.

LP = 10.0" w.c.

❏ Several operating cycles observed for proper operation? If

damper is provided, see Control Supplement for check- out

procedure.

❏ Room thermostat set to desired temperature?

❏ Installation and Service Certiﬁcate on this page completed?

❏ All instructions shipped with this boiler reviewed with owner

or maintenance person, returned to envelope and given to

owner or displayed near boiler?

Start-up (continued)

Installation and service certiﬁcate

Boiler model _______________ Series ______ Consumer Protection (CP) number ___________ Date installed ___________

Measured Btuh input ____________________

Installer ________________________ ________________________________ ________________________

(company) (address) (phone)

Installer’s signature: _____________________________________

❏ Installation instructions have been followed.

❏ Check out sequence has been performed.

❏ Above information is certiﬁed to be correct.

❏ Information received and left with owner/maintenance person

Part Number 550-142-303/1120

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Department of Energy – Compliance

EG water boilers only

This boiler is equipped with a control system that automatically adjusts a time delay period to turn on the boil-

er during a call for heat. This is accomplished by circulating available hot water in the system while measuring wa-

ter boiler water temperature changes. The control calculates a suitable delay based on temperature measurements and

turns the boiler on only after it determines that the demand for heat cannot be satisfied with the available hot water,

Due to the wide variety of controls used in boiler installations, this control is also equipped with an adjustment for the calculated time

delay period (ECONOMY ADJUST). In the MIN position, the time delay is zero and the IMPORTANT notice below must be observed:

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves

energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is

provided primarily to permit the use of an external energy management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS

Handling berglass and ceramic ber materials

The combustion chamber lining or base insulation panels in this product contains ceramic ﬁber

materials that have been

identiﬁed as carcinogenic, or possibly carcinogenic, to humans

. Ceramic ﬁbers can be converted to cristobalite in very

high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline

silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”:

■ Avoid breathing dust and contact with skin and eyes.

• UseNIOSHcertieddustrespirator(N95).ThistypeofrespiratorisbasedontheOSHArequirementsforcristobalite

at the time this document was written. Other types of respirators may be needed depending on the job site conditions.

Current NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html.

NIOSH approved respirators, manufacturers, and phone numbers are also listed on this web site.

• Wearlong-sleeved,loosettingclothing,gloves,andeyeprotection.

■ Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust.

■ Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal.

■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

■ Eye: Irrigate immediately.

■ Breathing: Fresh air.

REMOVAL OF FIBERGLASS WOOL — OR — INSTALLATION OF FIBERGLASS WOOL,

COMBUSTION CHAMBER LINING OR BASE PANELS:

This product contains ﬁberglass jacket insulation and ceramic ﬁber materials in combustion chamber lining or base

panels in gas ﬁred products. Airborne ﬁbers from these materials have been listed by the State of California as a pos-

sible cause of cancer through inhalation.

■ Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certiﬁed dust respirator (N95). This type of respirator is based on the OSHA requirements for ﬁberglass wool

at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Cur-

rent NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH

approved respirators, manufacturers, and phone numbers are also listed on this web site.

• Wearlong-sleeved,loosettingclothing,gloves,andeyeprotection.

■ Operations such as sawing, blowing, tear out, and spraying may generate airborne ﬁber concentration requiring additional protection.

■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

■ Eye: Irrigate immediately.

■ Breathing: Fresh air.

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Table 12 Service and maintenance schedules (service technician and owner)

Follow the “Service and maintenance” procedures given throughout this manual, the Control Supplement and in com-

ponent literature shipped with the boiler. See “Read this page ﬁrst” on page 2. Failure to perform the service and main-

tenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component

literature could result in severe personal injury, death or substantial property damage.

Service and maintenance

Label all wires prior to disconnection when servic-

ing controls. Wiring errors can cause improper and

dangerous operation.

To avoid personal injury, death or property damage,

keep boiler area clear and free from combustible

materials, gasoline and other ﬂammable vapors

and liquids.

Do not block ﬂow of air to boiler. Incomplete

combustion and ﬂue gas spillage can occur.

Do not store sources of hydrocarbons (i.e., bleaches,

cleaners, chemicals, sprays, paint removers, fabric

softeners, etc.) in boiler area. This can contribute

to shortened boiler/vent system life.

Service technician

(see following pages for instructions)

Owner maintenance

(see User’s Information Manual for instructions)

nnuAl

stArt

Inspect:

• Reported problems

• Boiler area

• Air openings

• Flue gas vent system

• Pilot and main burner ﬂames

• Piping

• Boiler heating surfaces

• Burners and base

Service:

• Gauge glass

• Temperature / LWCO sensor

Start-up:

• Perform start-up per manual

• EGH - Check base insulation & fastener clips

Check/test:

• Gas piping

• Boiler waterline

• Limit controls and cutoffs

• Boiler relief valve

Review:

• Review with owner

Daily

• Check boiler area

• Check air openings

• Check boiler pressure/

temperature gauge

Monthly

• Check boiler interior piping

• Check venting system

• Check air vents

• Check boiler relief valve

• Check pilot and main burner ﬂames

Periodically

• Test low water cutoff

End of season

• Shut down procedure

Part Number 550-142-303/1120

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The boiler should be inspected and started annu-

ally, at the beginning of the heating season, only

by a qualiﬁed service technician. In addition, the

maintenance and care of the boiler designated in

Table 12, page 30 and explained on the following

pages must be performed to assure maximum

boiler efﬁciency and reliability. Failure to service

and maintain the boiler and system could result in

equipment failure.

Electrical shock hazard — Turn off power to the

boiler before any service operation on the boiler

except as noted otherwise in this manual. Failure

to turn off electrical power could result in electrical

shock, causing severe personal injury or death.

The boiler contains ceramic ﬁber and ﬁberglass

materials. Use care when handling these materials

per instructions on page 29 of this manual. Failure

to comply could result in severe personal injury.

Inspect . . . . . . . . . .

Reported problems

Inspect any problems reported by owner and correct before

proceeding.

Boiler area

1. Verify that boiler area is free of any combustible materials,

gasoline and other ﬂammable vapors and liquids.

2. Verify that boiler area is free of any of the contaminants listed

on page 7 of this manual. If any of these are present in the

boiler intake air vicinity, they must be removed. If they can-

not be removed, install combustion air piping to the boiler

in accordance with national, provincial or local codes.

Air openings

1. Verify that combustion and ventilation air openings to the

boiler room and/or building are open and unobstructed.

Check operation and wiring of automatic combustion air

dampers, if used.

2. Verify that boiler vent discharge and air intake are clean and

free of obstructions.

Flue gas vent system

1. Visually inspect entire ﬂue gas venting system for blockage,

deterioration or leakage. Repair any joints that show signs of

leakage in accordance with vent manufacturer’s instructions.

2. Verify that masonry chimneys are lined, lining is in good

condition, and there are not openings into the chimney.

Failure to inspect for the above conditions and have

them repaired can result in severe personal injury

or death.

Pilot and main burner ﬂames

Visually inspect pilot burner and main burner ﬂames as directed

on page 27 of this manual.

Piping

Check the boiler interior piping and all system piping for signs

of leaks. Repair any leaks before proceeding.

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Severe damage to

boiler will occur, resulting in substantial property

damage.

Eliminate all system or boiler leaks. Continual

fresh makeup water will reduce boiler life. Minerals

can build up in sections, reducing heat transfer,

overheating cast iron, and causing section failure.

Leaking water may also cause severe property

damage.

Boiler heating surfaces

The boiler contains ceramic ﬁber and ﬁberglass

materials. Use care when handling these materials

per instructions on page 29 of this manual. Failure

to comply could result in severe personal injury.

1. Disconnect the vent pipe at the boiler draft diverter and re-

move draft diverter after turning off power to the boiler.

2. Use a bright light to inspect the boiler ﬂue collector and heat-

ing surfaces.

3. If the vent pipe or boiler interior surfaces show evidence of

soot, follow “Cleaning boiler heating surfaces”, page 33. Re-

move the ﬂue collector and clean the boiler if necessary after

closer inspection of boiler heating surfaces.

4. If there is evidence of rusty scale deposits on boiler surfaces,

check the water piping and control system to make sure the

boiler return water temperature is properly maintained (per

this manual).

5. Re

connect vent and draft diverter. Replace all boiler components

before returning to service.

6. Check inside and around boiler for evidence of any leaks from

the boiler. If found, locate source of leaks and repair.

Burners and base

1. After turning off power to the boiler, remove the jacket door

and base access panel.

2. Inspect burners and all other components in the boiler base.

3. If burners must be cleaned, raise rear of each burner to release

from support slot, slide forward and remove. Then brush and

vacuum the burners thoroughly, making sure all ports are free

of debris. Carefully replace all burners, making sure burner

with pilot bracket is replaced in its original position and all

burners are upright (ports up).

4. Inspect the base insulation.

a. Verify that the insulation is intact and secure against all four

sides of the base and attachment clips are still in place.

If insulation is damaged or displaced, do not oper-

ate the boiler. Replace or reposition insulation as

necessary. Failure to replace damaged insulation

can result in a ﬁre hazard, causing severe personal

injury, death or substantial property damage.

Service and maintenance (continued)

Part Number 550-142-303/1120

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Service and maintenance (continued)

❏ Service . . . . . . . . . .

Gauge glass (steam boilers)

Normal waterline is halfway up gauge glass. Clean

when needed.

1. Close lower gauge cock.

2. Open pet cock.

3. Open lower gauge cock and allow a small amount of water to

ﬂush out through open pet cock.

4. Close pet cock.

5. Open lower gauge cock.

Boiler pressure must be low to eliminate potential

of severe burns.

If gauge glass breaks, close both gauge cocks. Replace

gauge glass. Do not replace with thin glass tubing.

Failure to comply could cause severe personal injury,

death or substantial property damage.

Temperature / LWCO sensor

The temperature/LWCO sensor may accumulate deposits on the

probe surface. Annual inspection and cleaning of the probe will

improve boiler performance.

Disconnect power, unplug harness from sensor.

a. Drain boiler water to a level below the sensor.

b. Remove sensor from boiler.

c. Wipe any built up contaminates from probe and insulator

surfaces.

d. Reinstall sensor into boiler.

e. Reﬁll boiler to correct waterline.

Probe-type low water cutoff (when used)

Clean probe-type low water cutoff (when used) for

proper operation.

1. Turn off power to boiler and wait 5 minutes.

2. Drain water to bottom of gauge glass.

3. Turn on power.

4. Set thermostat to call for heat. Red neon lamp on lower water

cutoff should light.

5. Wait 5 minutes. Boiler should not ﬁre.

6. Reﬁll boiler to correct waterline. Red lamp should go off.

7. Wait 5 minutes. Boiler should ﬁre.

8. Return thermostat to normal setting.

Float-type low water cutoff (when used)

Clean float-type low water cutoff to clear float

chamber of sediment.

1. Open blow down valve on the bottom control.

2. Drain water into a bucket.

Scald potential. Boiler pressure must be low to avoid

the potential of severe burns from steam.

3. Check ﬂoat-type low water cutoff for proper operation:

a. Turn operating control to call for heat.

b. Before water gets hot, drain to bottom of gauge glass.

Boiler should shut off after water level lowers a few inches.

c. Reﬁll boiler to correct waterline. Boiler should come back

on.

❏ Start-up . . . . . . . . . .

1. Perform “Start-up” procedures in this manual, pages 24–28, includ-

ing “Verify operation” of burners and vent damper on page 27.

2. C

heck gas piping, per pages 22 and 24, verifying no indica-

tions of leakage and all piping and connections are in good

condition.

3. Read the “Operating Instructions” in the Control Supplement.

4. Start the boiler following the “Operating Instructions.”

❏ Check/test . . . . . . . . . .

Gas piping

1. Sniff near ﬂoor and around boiler area for any indication of

a gas leak.

2. Test gas piping using bubble test, per page 22 of this manual,

if there is any indication of a leak.

Boiler waterline

Normal waterline is halfway up gauge glass.

Limit controls

Inspect and test the boiler limit control. Verify operation by turn-

ing control set point below boiler pressure. Boiler should cycle

off. Return dial to original setting.

Part Number 550-142-303/1120

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

❏ Check/test . . . . . . . . . .

Boiler relief valve

After following the warning directions below, if the relief valve

weeps or will not seat properly, replace the relief valve.

Before testing, make certain discharge pipe is proper-

ly connected to valve outlet and arranged to contain

and safely dispose of boiler discharge. Wear gloves

to protect your hands from hot surfaces. Verify that

discharge piping is installed in accordance with this

manual and the instructions on the relief valve tag.

Failure to comply will expose operator and others

to severe personal injury or death.

Safety relief valves should be reinspected AT LEAST

ONCE EVERY THREE YEARS, by a licensed plumb-

ing contractor or authorized inspection agency, to

ensure that the product has not been affected by

corrosive water conditions and to ensure that the

valve and discharge line have not been altered or

tampered with illegally. Certain naturally occurring

conditions may corrode the valve or its compo-

nents over time, rendering the valve inoperative.

Such conditions are not detectable unless the valve

and its components are physically removed and

inspected. This inspection must only be conducted

by a plumbing contractor or authorized inspection

agency — not by the owner. Failure to reinspect the

boiler relief valve as directed could result in unsafe

pressure buildup, which can result in severe personal

injury, death or substantial property damage.

Check the setting of the boiler limit control. The

control should never be set with a pressure above

10 PSIG. Operating at a higher pressure can cause

damage to the boiler relief valve.

The boiler relief valve must be tested at least monthly

during the heating season to verify the valve and

discharge piping ﬂow freely. If corrosion and/or

deposits are noticed within the valve body, testing

must be performed more often. A “try lever test”

must also be performed at the end of any non-

service period. Follow the instructions below for a

“try lever test”:

With the system at operating pressure, lift and hold

the test lever fully open for at least 5 seconds to ﬂush

the valve seat free of sediment and debris. Then

release lever and permit the valve to snap shut.

❏ Review with owner

1. Review the User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance schedule

specified in the User’s Information Manual (and in this

manual as well).

3. Remind the owner of the need to call in a licensed contractor

should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure

and to schedule an annual start-up at the beginning of the

next heating season.

❏ Cleaning boiler heating surfaces

The boiler contains ceramic ﬁber and ﬁberglass

materials. Use care when handling these materials

per instructions on page 29 of this manual. Failure

to comply could result in severe personal injury.

1. Follow shut-down procedure

2. Disconnect breeching and remove damper (if used) and draft

hood.

3. Remove upper rear jacket panel. Turn back jacket insulation

to expose collector hood.

4. Remove collector hood. Clean excess boiler cement from col-

lector hood and cast iron sections.

5. Remove burners from base of boiler. Follow “Cleaning main

burners” to thoroughly clean burners. Place newspaper in base

of boiler to collect soot that will fall.

6. With a wire ﬂue brush, clean between the sections.

7. Remove paper and soot. Vacuum or brush base and surround-

ing area.

8. Replace collector hood. Seal with boiler cement.

9. Replace draft hood, damper (if used) and breeching.

10. Replace insulation and jacket panel.

11. Replace main burners.

Cleaning main burners

Vacuum or brush burners to remove dust and lint.

When replacing, burner tubes must be seated in slots

in the back with openings face up. Gas oriﬁces must

inject down center of burner. Failure to properly seat

burners will result in severe personal injury, death

or substantial property damage.

Annual shut-down procedure

1. Follow correct operating instructions on boiler.

2. Do not drain system unless exposure to freezing temperatures

will occur. If antifreeze is used with system, do not drain.

a. Test antifreeze.

3. If complete boiler and piping system must be drained to avoid

freezing, provide method to drain water from both ends of

boiler at or below return tapping level.

Service and maintenance (continued)

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Replacement parts — EG/PEG

Table 13 EG/PEG replacement parts

Item Description

Boiler

Models

Part Number

Front base panel

EG-30, 35 451-800-000

EG-40, 45 451-800-001

EG-50, 55 451-800-002

EG-65 451-800-003

EG-75 451-800-004

Base insulation kit (includes front and rear base panel

insulation, water glass, and boiler cement)

––

510-811-660

Base front access panel with ame rollout switch

bracket

EG-30, 35 451-800-040

EG-40, 45 451-800-041

EG-50 451-800-039

EG-55 451-800-042

EG-65 451-800-043

EG-75 451-800-044

Back burner support

EG-30 451-800-085

EG-34 451-800-086

EG-40 451-800-087

EG-45 451-800-088

EG-50 451-800-089

EG-55 451-800-090

EG-65 451-800-092

EG-75 451-800-094

Back base panel

EG-30, 35 451-800-010

EG-40, 45 451-800-011

EG-50, 55 451-800-012

EG-65 451-800-013

EG-75 451-800-014

Back base channel

EG-30, 35 451-800-020

EG-40, 45 451-800-021

EG-50, 55 451-800-022

EG-65 451-800-023

EG-75 451-800-024

Base side rail (2 required)

––

451-800-070

Spill switch

––

510-300-013

Cover plate for heater opening (rectangular)

––

389-900-103

Gasket for cover plate (rectangular)

––

590-317-579

Cover plate for heater opening (round)

––

389-900-101

Gasket for cover plate (round)

––

590-317-495

Flue bafe (1 per joint)

––

460-003-790

Section replacement kit (includes 3” and 6” elasto-

mer seal, 2 pieces of rope, tube of silicone, order 1

per joint between sections) (not shown)

––

381-800-667

3” Diameter bottom elastomer seal (1 per joint) ––

592-800-010

6” Diameter top elastomer seal (1 per joint) ––

592-800-007

Sealer for sections (2 pieces of rope, tube of

silicone per joint between sections) (not shown)

––

591-641-865

½” x 14” Tie rod w/o nut (2 per boiler) (not shown)

EG-30, 35 560-234-470

½” x 18½” Tie rod w/o nut (2 per boiler)(not shown)

EG-40, 45 560-234-475

½” x 22¾” Tie rod w/o nut (2 per boiler)(not shown)

EG-50, 55 560-234-480

½” x 27” Tie rod w/o nut (2 per boiler)(not shown)

EG-65 560-234-485

½” x 31¼” Tie rod w/o nut (2 per boiler)(not shown)

EG-75 560-234-490

½” Nut (2 per tie rod) (not shown)

––

561-928-221

½” Lock washer (1 per tie rod) (not shown)

––

562-248-668

Note 1: Order sufcient quantities to replace all orices within a base.

Item Description

Boiler

Models

Part Number

Left hand end section with heater opening

(Pattern No. 1814)

––

311-800-014

Left hand end section without heater opening

(Pattern No. 1813)

––

311-800-007

Right hand end section without heater opening

(Pattern No. 18128)

––

311-800-029

Intermediate section (Pattern No. 1815)

––

311-800-010

Draft hood

EG 30-35 450-021-292

EG 40-45 450-021-258

EG 50-55 450-021-293

EG-65 450-021-261

EG-75 450-021-262

Collector hood

EG-30, 35 450-014-733

EG-40, 45 450-014-734

EG-50, 55 450-014-735

EG-65 450-014-736

EG-75 450-014-737

Burner, stainless tube, regular

––

512-200-000

Burner, stainless tube, with pilot bracket

––

512-200-001

Manifold

EG-30 591-125-533

EG-35 591-125-538

EG-40 591-125-534

EG-45 591-125-539

EG-50 591-125-535

EG-55 591-125-540

EG-65 591-125-541

EG-75 591-125-542

Main burner orice, natural gas, 2.35mm

EG 30-65 560-528-991

Main burner orice, natural gas, 2.30mm

EG-75 560-528-975

Section assembly complete with heater opening

(not shown)

EG 30-35

321-811-095

Section assembly complete without heater opening

(not shown)

EG-35

321-811-100

Section assembly complete with heater opening

(not shown)

EG 40-45

321-811-110

Section assembly complete without heater opening

(not shown)

EG 40-45

321-811-115

Section assembly complete with heater opening

(not shown)

EG 50-55 321-811-120

Section assembly complete without heater opening

(not shown)

EG-50-55 321-811-125

Section assembly complete with heater opening

(not shown)

EG-65 321-811-130

Section assembly complete without heater opening

(not shown)

EG-65 321-811-135

Section assembly complete with heater opening

(not shown)

EG-75 321-811-140

Section assembly complete without heater opening

(not shown)

EG-75 321-811-145

Retort cement (1 quart) (not shown) ––

591-602-913

Flue brush (not shown) ––

591-706-214

Part Number 550-142-303/1120

PEG sEriEs 6

•

EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Replacement parts — EG/PEG (continued)

The boiler contains ceramic ﬁber and ﬁberglass materials. Use care when handling these materials per instructions on

page 29

of this manual. Failure to comply could result in severe personal injury.

Part Number 550-142-303/1120

PEG sEriEs 6

•

EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Replacement parts — EGH

Table 14 EGH replacement parts

Item Description

Boiler

Models

Part Number

Left hand end section with heater opening

(Pattern No. 1814)

––

311-800-014

Left hand end section without heater opening

(Pattern No. 1813)

––

311-800-007

Right hand end section with heater opening

(Pattern No. 1819)

––

311-800-022

Right hand end section without heater opening

with control tappings (Pattern No. 18118)

––

311-800-032

Intermediate section (Pattern No. 1815)

––

311-800-010

Intermediate section with tie rod lugs

(Pattern No. 1817)

––

311-800-026

3” Diameter bottom elastomer seal (1 per joint)

––

592-800-010

6” Diameter top elastomer seal (1 per joint)

––

592-800-007

Flue bafe (1 per joint)

––

460-003-790

Draft hood

EGH-85 450-206-240

EGH-95 450-206-241

EGH-105 450-206-242

EGH-115 450-206-243

EGH-125 450-206-244

Collector hood

EGH-85 450-014-750

EGH-95 450-014-751

EGH-105 450-014-752

EGH-115 450-014-753

EGH-125 450-014-754

Burner, stainless tube, regular

–– 512-200-000

Burner, stainless tube, with pilot bracket

–– 512-200-001

Manifold

EGH-85 591-125-543

EGH-95 591-125-544

EGH-105 591-125-545

EGH-115 591-125-546

EGH-125 591-125-547

not

shown

Main burner orice, natural gas, 2.30mm

––

560-528-975

Main burner orice, propane gas, 1.40mm

––

560-528-972

Front base panel (in base panel carton)

––

Front base insulation (in base panel carton)

––

Base front access panel (in base panel carton)

––

I, I

Base panel carton

EGH-85 381-700-241

EGH-95 381-700-246

EGH-105 381-700-251

EGH-115 381-700-256

EGH-125 381-700-262

Back base panel (in base panel carton)

––

Back base insulation (in base panel carton)

––

Side rail for burner panel with bracket for burner pan

––

451-800-070

Back burner support

EGH-85 451-800-095

EGH-95 451-800-096

EGH-105 451-800-097

EGH-115 451-800-098

EGH-125 451-800-099

Item Description

Boiler

Models

Part Number

Cover plate for heater opening (rectangular)

––

389-900-103

Gasket for cover plate (rectangular)

––

590-317-579

Cover plate for heater opening (round)

––

389-900-101

Gasket for cover plate (round)

––

590-317-495

Section assembly complete with heater opening

(not shown)

EGH-85 321-711-100

Section assembly complete without heater opening

(not shown)

EGH-85 321-711-105

Section assembly complete with heater opening

(not shown)

EGH-95 321-711-110

Section assembly complete without heater opening

(not shown)

EGH-95 321-711-115

Section assembly complete with heater opening

(not shown)

EGH-105 321-711-120

Section assembly complete without heater opening

(not shown)

EGH-105 321-711-125

Section assembly complete with heater opening

(not shown)

EGH-115 321-711-130

Section assembly complete without heater opening

(not shown)

EGH-115 321-711-135

Section assembly complete with heater opening

(not shown)

EGH-125 321-711-140

Section assembly complete without heater opening

(not shown)

EGH-125 321-711-145

Section replacement kit (includes 3” and 6”

elastomer seal, 2 pieces of rope, tube of silicone,

order 1 per joint between sections) (not shown)

––

381-800-667

Burner shield (rollout)

EGH-85 451-800-120

EGH-95 451-800-121

EGH-105 451-800-122

EGH-115 451-800-123

EGH-125 451-800-124

Refractory Leg-Left and Right

––

591-222-183

Refractory clip

–– 421-800-208

Base shield

EGH-85 451-800-136

EGH-95 451-800-137

EGH-105 451-800-138

EGH-115 451-800-139

EGH-125 451-800-140

Sealer for sections (2 pieces of rope, tube of

silicone per joint between sections) (not shown)

––

591-641-865

½” x 7” Tie rod w/o nut (2 per boiler)

(not shown)

––

560-234-465

½” x 17” Tie rod w/o nut (4 – EGH-85)

(not shown) (2 – EGH-95)

––

560-234-472

½” x 21¼” Tie rod w/o nut (2 – EGH-95)

(not shown) (2 – EGH-115)

(4 – EGH-125)

––

560-234-477

½” x 25¼” Tie rod w/o nut (2 – EGH-115)

(not shown) (4 – EGH-125)

––

560-234-482

½” Nut (2 per tie rod) (not shown)

––

561-928-221

½” Lock washer (1 per tie rod) (not shown)

––

562-248-668

Retort cement (1 quart) (not shown)

––

591-602-913

Flue brush (not shown)

––

591-706-214

Note 1: Order sufcient quantities to replace all orices within a base.

Part Number 550-142-303/1120

PEG sEriEs 6

•

EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Replacement parts — EGH (continued)

The boiler contains ceramic ﬁber and ﬁberglass materials. Use care when handling these materials per instructions on

page 29

of this manual. Failure to comply could result in severe personal injury.

Part Number 550-142-303/1120

PEG sEriEs 6

•

EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Dimensional data

Table 15 Dimensional data

Tapping Size Steam Boilers Water Boilers - EG only Tapping Size Steam Boilers Water Boilers - EG only

C ¾” Probe type low water cut-off Probe type LWCO (when used)

(EGH Only)

1”

Float type LWCO, pressure limit control

and pressure gauge; or LWCO and feeder

combination; or LWCO and pump control

Float type LWCO; or LWCO and feeder

combination; or LWCO and pump control

D ¾” Drain Drain

1 ½” Skim tapping Limit control

E ¾” Safety valve Safety relief valve ¾” –– (note 1) Limit control

G ¾” Plugged Piping to compression tank or auto air vent T1

––

Optional tankless heater for

water boilers

H ½” Gauge glass and/or optional LWCO Combination pressure temperature gauge

–– –– –– ––

J ⅜” Tri cock tappings Plugged T3

––

Optional steam boiler tankless heater

––

L ½”

Syphon, pressure gauge, high limit

(probe type LWCO)

Combination pressure temperature gauge Z

––

Manual shut-off gas valve (supplied by installer)

Notes: 1. Available on special request only, when tankless heater is specied. Notes: 2. When a tankless water heater coil is installed, use the tapping in the heater for

an additional operating control.

Model

number

Supply

EG/

EGH

Return

EG/

EGH

Dimensions

(See note 3 for PEG-30 to PEG-55 crate dimensions)

Gas

Connection

“F”

Draft

hood

outlet

size

Approx.

ship wt.

O P W A B B1 V

(note 2) T (note 1) (lbs)

EG & PEG-30 & -35

1 - 3” 1 - 2 ½” 17” 5” 11 ¾” 6 ¾” 6”

Water boiler

tankless coil

removal

clearance:

E-624: 14”

E-626: 18”

E-632: 22”

½” 5” 430

EG & PEG-40 & -45

1 - 3” 1 - 2 ½” 21 ¼” 6” 11 ¾” 6 ¾” 6 ½” ½” 6” 505

EG & PEG-50 & -55

1 - 3” 1 - 2 ½” 25 ½” 7” 11 ¾” 6 ¾” 9” ½” 7” 585

EG & PEG-65

1 - 3” 1 - 2 ½” 29 ¾” 8” 11 ¾” 6 ¾” 9 ½” ¾” 8” 660

EG-75

1 - 3” 1 - 2 ½” 34” 8” 15 ¾” 8 ¾” –– ¾” 8” 735

EGH-85

2 - 3” 2 - 2 ½” 38 ¼” 9” 15 ¾” 8 ¾” ––

N/A

¾” 9” 825

EGH-95

2 - 3” 2 - 2 ½” 42 ½” 10” 15 ¾” 8 ¾” –– ¾” 10” 915

EGH-105

2 - 3” 2 - 2 ½” 46 ¾” 10” 15 ¾” 8 ¾” –– 1” 10” 1005

EGH-115

2 - 3” 2 - 2 ½” 51” 12” 15 ¾” 8 ¾” –– 1” 12” 1095

EGH-125

2 - 3” 2 - 2 ½” 55 ¼” 12” 15 ¾” 8 ¾” –– 1” 12” 1185

Notes:

1. Sizes shown are gas connection sizes, natural or liqueed petroleum (propane) gas. Gas piping from meter to boiler to be sized according to local utility requirements. Gas

line can enter on either the right or left end of the boiler.

2. Damper dimension for EG-30 through EG-75 ONLY. For all EGH boilers the damper is additional equipment.

3. PEG crates are 32” wide x 39” high. Crate lengths are 32” for PEG-30, -35, -40; 37” for PEG-45, -50, and -55; 39” for EG-65.

Part Number 550-142-303/1120

PEG sEriEs 6

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EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Notes: (Table 16)

Add preﬁx “P” for package boiler completely assembled and

wired with jacket and controls

(PEG-30-S through PEG-65-S only).

1. EG-30 thru 75: Add sufﬁx “PID” or “PI” for electronic ignition

(30-65 — damper required in U.S.; optional in Canada); add “N” for

natural; add “W” for water; add “S” for steam; add “T” for tankless

heater; add “P” for provisional tankless heater.

EGH-85 & 95: Add sufﬁx “PI” for electronic ignition (damper

available on PI only); add “N” for natural; add “S” for steam; add “T”

for tankless heater (tankless available on EGH-85 thru 125 PI Steam;

EGH-85 and 95 SP Steam only); add “P” for provisional tankless heater.

EGH-105 thru 125: Add sufﬁx “PI” for electronic ignition (damper

available on PI only); add “T” for tankless heater.

2. Based on standard test procedures prescribed by the United States

Department of Energy.

EGH-85 thru EGH-125: Gross output.

3. EGH-105 thru 125 may be installed at altitudes of 2,000-4,500 feet

subject to acceptance by Provincial Inspections Authority based on

ﬁeld tests of individual installations.

4. Net AHRI ratings are based on net installed radiation of sufﬁcient

quantity for the requirements of the building and nothing need be

added for normal piping and pick-up. Water ratings are based on a

piping and pick-up allowance of 1.15; steam ratings on an allowance

of 1.333. An additional allowance should be made for unusual piping

and pick-up loads. Consult local Weil-McLain representative.

Ratings

Table 16 Ratings

Boiler

Model

Number

AFUE

Water Steam

PIDN PIDN

EG-30

PEG-30

84.0 82.0

EG-35

PEG-35

84.0 82.0

EG-40

PEG-40

84.0 82.0

EG-45

PEG-45

84.0 82.0

EG-50

PEG-50

84.0 82.0

EG-55

PEG-55

84.0 82.0

EG-65

PEG-65

84.0 82.0

EG-75

84.0 82.0

Table 17 AFUE values

Boiler

Model

Number

0–2,000

feet altitude

2,000–4,500

feet altitude

(Canada)

Net AHRI Ratings

Chimney

Size

Boiler Water

Content

(Gallons)

Input

Rating,

(MBH)

Water

Heating

Capacity,

(MBH)

Steam

Heating

Capacity,

(MBH)

Input

(Btuh)

(Output)

(Btuh)

Sq. Ft.

Steam

(MBH)

Water

(MBH) Water

Steam

(to Waterline)

(Note 1) (Note 2) (Note 3) (Note 4)

*EG-30-

75 64 62 67,500 57,600 196 47 56 5" I.D. x 20' 12.3 8.4

*EG-35-

100 85 82 90,000 76,500 258 62 74 5" I.D. x 20' 12.3 8.4

*EG-40-

125 106 103 112,500 95,400 321 77 92 6" I.D. x 20' 14.8 9.8

*EG-45-

150 127 124 135,000 114,300 388 93 110 6" I.D. x 20' 14.8 9.8

*EG-50-

175 148 145 157,500 133,200 454 109 128 7" I.D. x 20' 17.3 11.2

*EG-55-

200 169 166 180,000 151,200 521 125 147 7" I.D. x 20' 17.3 11.2

*EG-65-

238 201 198 214,000 180,000 621 149 175 8" I.D. x 20' 19.8 12.6

EG-75-

282 237 234 253,000 213,300 733 176 206 8" I.D. x 20' 22.3 14.0

EGH-85-S

315 243 – 283,500 226,800 760 182 – 9" I.D. x 20' – 15.4

EGH-95-S

360 278 – 324,000 259,200 868 209 – 10" I.D. x 20' – 16.8

EGH-105-S

405 312 – 364,500 280,800 977 234 – 10" I.D. x 20' – 18.2

EGH-115-S

450 347 – 405,000 312,300 1,085 260 – 12" I.D. x 20' – 19.6

EGH-125-S

495 382 – 445,500 343,800 1,193 287 – 12" I.D. x 20' – 21.0

Part Number 550-142-303/1120

PEG sEriEs 6

•

EGH sEriEs 5 Gas-firEd boilErs — boilEr manual

Standard and optional equipment

Standard equipment

• Factory-Assembled Section Block

• Insulated Extended Jacket

• Draft Hood

• Aluminized Steel Burners

• Non-Linting Pilot Burner

• Heater Cover Plates (for boilers with tankless heater openings)

• Control Wire

• Electrical Junction Box

EG/PEG boilers add:

• Combination Gas Valve for 24 volt

• Rollout Thermal Fuse Element

• Spill Switch

• Highest Efﬁciency Models, PID Intermittent Electronic

Ignition System and Automatic Vent Damper

For EG water boilers

• Ignition Module United Technologies 1135-605

• Temperature / LWCO

sensor

• Built-In Air Eliminator

• 30 PSI Relief Valve

• Combination Pressure Temperature Gauge

• High-Limit Control

• 40 VA Transformer

For EG/PEG steam boilers

• Relief Valve, 15 PSI

• Steam Pressure Gauge

• High-Limit Pressure Control

• Syphon

• Gauge Cocks

• Gauge Glass

• Low-Water Cutoff, Probe Type

• 40 VA Transformer

EG additional equipment

• Tankless Water Heater (EG-35 – 65 PI; EG-75 PI only)

With tankless heater: Combination High Limit, Low Limit,

Circulator Control, and Relay with 40 VA Transformer

• Tankless Steam Heater (EG-35 – 75)

With Tankless Heater: Operating Control and Tankless Heater

35-S-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 single seat, 24V models; pressure regulator, gas cock, pilot

ﬁlter, pilot adjustment)

• Highest Efﬁciency Models, PI Intermittent Electronic

Ignition System

• High Efﬁciency Models, SP Constant Burning, Thermally

Supervised Pilot System, Thermocouple

• 100% Shutoff

• 40 VA Transformer with Receptacle for Circulator Relay

For EGH steam boilers

• Relief Valve, 15 PSI

• Steam Pressure Gauge

• High-Limit Pressure Control

(two limit controls on EGH-85 and 95 SP)

• Syphon

• Gauge Cocks

• Gauge Glass

• Low-Water Cutoff – Probe Type

EGH additional equipment

• Tankless Heaters – PI & SP Steam only

• With Tankless Heater(s):

• Operating Control

• Automatic Vent Damper

Weil-McLain EG SERIES 6 GAS BOILER EG-50 Residential Gas-fired Boiler

Product's Documents

User Manual

Specifications

Weil-McLain EG SERIES 6 GAS BOILER EG-50 Questions and Answers