E /PE Series 6 E H Series 5 Gas-Fired Boilers Boiler Manual • Installation • Maintenance • Startup • Parts Now With Built In Low Water Cut Off Functionality EG EG Water Only PEG For additional information, refer to . . . Control Supplement and Gas Control Parts for EG/PEG – Natural gas only for EGH – Natural or Liquefied Petroleum (Propane) gas (tankless heater application optional) EGH This manual must only be used by a qualified heating installer/service technician.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Contents Hazard definitions ����������������������������������������������������������������������������������� 2 Read this page first ������������������������������������������������������������������������������� 3 Codes & Checklist ��������������������������������������������������������������������������������� 4 Prepare boiler location ��������������������������������������������������������������������������� 5 Prepare the bo
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Read this page first 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Codes & Checklist 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Prepare boiler location Recommended Service clearances Table 1 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers 1 Prepare boiler location Flooring and foundation 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers Prepare boiler location — boiler manual (continued) Vent System (continued) Air contamination 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.
EG / PEG series 6 • EGH series 5 Prepare the location gas-fired boilers — boiler manual (continued) Air openings Provide adequate combustion and ventilation air to assure proper combustion and reduce the risk of severe personal injury, death or substantial property 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 edition, or applicable local building codes.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Prepare the boiler Placing the boiler Block assembly is extremely heavy. Handle with caution to avoid personal injury. Figure 4a Corner after exposed silicone has been removed. 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.
EG / PEG series 6 • EGH series Prepare the boiler 5 gas-fired boilers boiler manual (continued) 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.
EG / PEG series 6 • EGH series Prepare the boiler 5 gas-fired boilers — boiler manual (continued) 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. Figure 6b Flue collector hood Installation of side refractory -EGH only 1.
EG / PEG series 6 • EGH series Prepare the boiler 5 gas-fired boilers — boiler manual (continued) Figure 7d EGH - Refractory placement & front base panel Figure 7c EG/EGH - Front base panel (Factory installed on PEG boilers) Four (4) refractory clips will hold refractory. Note! Silicone to be applied to inside of leg of cast surface. 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.
EG / PEG 6 • EGH series series Prepare the boiler 5 gas-fired boilers — boiler manual (continued) Installation of base shield - EGH only Draft hood installation 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Connect piping – water boilers – EG only 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 additional high temperature limit may be needed. Install control in supply piping between boiler and isolation valve.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Connect piping – water boilers – EG only 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Connect piping – water boilers – EG only Figure 16 System bypass piping in boiler loop with separate system circulator, using primary/secondary piping. (continued) Figure 17 Boiler bypass piping — use only for high water content systems —DO NOT use for radiant panel systems. System bypass method 1.
EG / PEG series 6 • EGH 5 series gas-fired boilers Connect piping – steam boilers — boiler manual (continued) General Failure to properly pipe the boiler may result in improper operation and damage to the boiler or building. Figure 18 Recommended piping for parallel-flow systems Steam to system Steam supply must be on same end as controls. Return may be from either end. 1. Install the boiler jacket before connecting return piping.
EG / PEG series 6 • EGH series 5 gas-fired boilers Connect piping – steam boilers Figure 19 Connection to counter flow steam piping — boiler manual (continued) 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 personal injury, death or substantial property damage.
EG / PEG series 6 • EGH series 5 gas-fired boilers — Connect piping – steam boilers Condensate return 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 residential installation: 1. Disconnect condensate return line at existing boiler. 2.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Install boiler controls Failure to properly install, pipe and wire boiler controls may result in severe damage to the boiler, building and personnel. Figure 21 Probe-type low water cut-off - (Left side view) 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Connect piping – tankless heater (optional) EG and EGH boilers for tankless heater application are available only on special order as factoryinstalled 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Connect gas supply piping 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Connect field wiring to boiler For your safety, turn off electrical power supply at serprotect wiring insulation. vice entrance panel before making any electrical con- 5. Multiple zones — Refer to zone valve manufacturer’s literature nections to avoid possible electric shock hazard. Failfor wiring and application. A separate transformer is required ure to do so can cause severe personal injury or death. to power zone valves.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Start-up Wiring multiple zones Freeze protection (when used) 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 circulator. Use antifreeze especially made for hydronic systems. Inhibited propylene glycol is recommended. DO NOT connect directly from 3-wire zone valves to the T-T terminals on the boiler.
EG / PEG series Start-up 6 • EGH series 5 gas-fired boilers — boiler manual (continued) Steam Boiler Water Treatment 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.
EG / PEG series Start-up 6 • EGH series 5 gas-fired boilers 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. 3. 4. 5. 6. 7. 8. 9. 10. boiler manual (continued) Skim the steam boiler 1. 2. — Do not use petroleum-based cleaning or sealing compounds in boiler system.
EG / PEG series Start-up 6 • EGH series 5 gas-fired boilers — boiler manual (continued) 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.
EG / PEG series Start-up 6 • EGH series 5 gas-fired boilers 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual 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 boiler during a call for heat. This is accomplished by circulating available hot water in the system while measuring water boiler water temperature changes.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Service and maintenance Table 12 Service and maintenance schedules (service technician and owner) Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) Daily • Check boiler area Inspect: • Check air openings • Reported problems • Check boiler pressure/ • Boiler area temperature gauge • Air openings • Flue gas vent system Monthly • Check boiler interi
EG / PEG series 6 • EGH series 5 gas-fired boilers Service and maintenance The boiler should be inspected and started annually, 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.
EG / PEG series 6 • EGH series 5 gas-fired boilers Service and maintenance o Service . . . . . . . . . . 1. 2. 3. 4. 5. Boiler pressure must be low to eliminate potential of severe burns. boiler manual (continued) Probe-type low water cutoff (when used) Gauge glass (steam boilers) Normal waterline is halfway up gauge glass. Clean when needed. Close lower gauge cock. Open pet cock. Open lower gauge cock and allow a small amount of water to flush out through open pet cock. Close pet cock.
EG / PEG series 6 • EGH series 5 gas-fired boilers Service and maintenance o 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 properly connected to valve outlet and arranged to contain and safely dispose of boiler discharge. Wear gloves to protect your hands from hot surfaces.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Replacement parts — EG/PEG Table 13 Item EG/PEG replacement parts Description Boiler Models –– B Left hand end section with heater opening (Pattern No. 1814) Left hand end section without heater opening (Pattern No. 1813) Right hand end section without heater opening (Pattern No. 18128) C Intermediate section (Pattern No.
EG / PEG series 6 • EGH series 5 gas-fired boilers Replacement parts — EG/PEG — boiler manual (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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Replacement parts — EGH Table 14 Item A B C EGH replacement parts Description Boiler Models Left hand end section with heater opening (Pattern No. 1814) –– Left hand end section without heater opening (Pattern No. 1813) –– Right hand end section with heater opening (Pattern No. 1819) –– Right hand end section without heater opening with control tappings (Pattern No. 18118) –– Intermediate section (Pattern No.
EG / PEG series 6 • EGH series 5 gas-fired boilers Replacement parts — EGH — boiler manual (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.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Dimensional data Table 15 Dimensional data Supply EG/ EGH Model number Return EG/ EGH O P W A B B1 V (note 2) EG & PEG-30 & -35 1 - 3” 1 - 2 ½” 17” 5” 11 ¾” 6 ¾” 6” EG & PEG-40 & -45 1 - 3” 1 - 2 ½” 21 ¼” 6” 11 ¾” 6 ¾” 6 ½” EG & PEG-50 & -55 1 - 3” 1 - 2 ½” 25 ½” 7” 11 ¾” 6 ¾” 9” EG & PEG-65 1 - 3” 1 - 2 ½” 29 ¾” 8” 11 ¾” 6 ¾” 9 ½” EG-75 1 - 3” 1 - 2 ½” 34” 8” 15 ¾” 8 ¾” –– EGH-85 2
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Ratings Table 16 Ratings 2,000–4,500 feet altitude (Canada) 0–2,000 feet altitude Boiler Model Number Input Rating, (MBH) (Note 1) Water Heating Capacity, (MBH) Steam Heating Capacity, (MBH) (Note 2) Input (Btuh) (Output) (Btuh) Net AHRI Ratings Sq. Ft.
EG / PEG series 6 • EGH series 5 gas-fired boilers — boiler manual Standard and optional equipment Standard equipment 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 S
