EG, PEG, EGH Gas-fired Boilers — Series 4 Boiler Manual • Installation • Service • Operation • Boiler Parts For additional information, refer to . . . Control Supplement and Gas Control Parts for Natural or Propane gas with optional tankless heater application EG EGH Read all instructions before installing Installer Owner Leave all instructions with boiler for future reference.
1 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Contents Installation ............................................................................................. 3 Piping Connections................................................................................ 9 Install Boiler Controls .......................................................................... 12 Optional Heaters ................................................................................. 13 Gas Piping ..............
1 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Installation Codes Installations must comply with all local codes, laws, regulations and ordinances. Also National Fuel Gas Code ANSI Z223.1-latest edition. When required, installations must conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
1 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Installation (continued) Chimney or vent requirements (also refer to Breaching erection, Page 8) Venting must be installed according to Part 7, Venting of Equipment, of National Fuel Gas Code ANSI Z223.1latest edition and applicable building codes. Canadian installations must comply with CAN/CSA B149.1 or .2 Installation Codes. Minimum chimney or vent sizes are on page 27 of these instructions.
1 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Installation (continued) Installation clearances Figure 1 Boiler foundation Suggested minimum clearances for servicing • 24 inches for cleaning and servicing, left side. • 18 inches for access to controls and components, front. • 46 inches from top for cleaning flueways. • 6 inches on remaining sides. Required minimum clearances to combustible material in alcove installations Top 46" R. Side 4" Front: Alcove Rear 6" L.
1 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Installation (continued) Figure 3 Installation of flue collector hood 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 and water boilers at 1-1/2 times working pressure.
1 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Installation (continued) Figure 5 Front and back base panels Installation of drawer assembly and front access panel and back base channel (Factory installed on PEG boilers - follow Figure 6 Burner drawer assembly Figure 7 Pilot burner location Figure 8 Burner drawer installation Figure 9 Access panel steps 2 and 3) 1. The drawer assembly consists of the burner drawer, main burners, gas manifold, pilot burner, etc.
1 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Installation (continued) Jacket installation (Factory installed on PEG boilers) 1. Remove the proper knockout discs from panels as shown in tapping table, page 6. Tankless and storage heater knockouts must be removed for EG and EGH boilers with optional tankless heaters prior to jacket installation. Spill switch installation On EG 30-75 boilers only, fasten spill switch to draft hood as shown on page 22, Drawing Ref. Letter “K”.
2 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Piping connections Pipe before installing controls. Connect return piping after jacket is attached. Connect supply piping before or after jacket is attached. Failure to properly pipe the boiler may result in improper operation and damage to the boiler or building. Forced hot water boilers and gravity hot water boilers (EG Only) 1. To protect: • radiant panels, plaster, etc.
2 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Piping connections (continued) 8. Multiple Zoning a) Zone valves: Refer to zone valve manufacturer’s literature for wiring and application. A separate transformer is required to power zone valves. Provide balancing valves to adjust the flow so it is about the same in each zone. b) Circulators: Zoning with circulators requires a relay for each circulator. Install flow control valves to prevent gravity circulation.
2 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Piping connections (continued) Steam boilers 1. Refer to table and Figures 14 or 15. Pipe exactly as shown. Satisfactory operation of a steam heating system depends on adequate condensate return to boiler to maintain a steady water level. Avoid adding raw make-up water. Where condensate return is not adequate, install low water cut-off and pump control, condensate receiver, and condensate boiler feed pump. Refer to Figure 16 for sizing. 2.
3 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — 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 17 Probe-type low water cut-off Water boiler 1. Install controls as shown on Control Tapping Table and Figure 3, page 6. Limit control and supply piping must be on the same end of EGH boiler. 2.
4 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Optional heaters EG and EGH boilers for tankless heater application are available only on special order as factory-installed optional equipment. Standard boilers cannot be adapted for heater use. Tankless heater hook-up (forced hot water or steam boilers) For correct operation, install as shown in Figure 20 (water boilers) or Figure 21 (steam boilers). 1. Automatic mixing valve must be installed per mixing valve manufacturer’s instructions. 2.
5 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Gas piping Connecting gas supply piping Size gas piping considering: a. Diameter and length of gas supplying piping. b. Number of fittings. c. Maximum gas consumption (including any possible future expansion). d. Allowable loss in gas pressure from gas meter outlet to boiler. For pressure drops, see ANSI Z223.1. Canadian installations must comply with CAN/CSA B149.1 or .2 Installation Codes. 1. For natural gas: a) Refer to following tables.
6 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Wiring Refer to control supplement for additional information For your safety, turn off electrical power supply before making any electrical connections to avoid possible electrical shock hazard. All wiring must be installed in accordance with requirements of National Electrical Code and any additional national, state or local code requirements having jurisdiction. ALL wiring must be N.E.C. Class 1.
7 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Final adjustments Water treatment Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe boiler damage will occur. Continual fresh make-up water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure. In hard water areas or low pH conditions (less than 7.0) consult local water treatment company.
7 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Final adjustments (continued) Skimming steam 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. Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe boiler damage will occur. 1.
8 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Check-out procedure Check-out procedure b. 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 7 for proper size. Proper orifices must be used.
9 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Service Handling fiberglass and ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications.
9 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Service (continued) Also Refer to Additional Instructions Shipped With The Boiler For Specific Control Operation and Troubleshooting. Verify Proper Operation After Servicing Your boiler should be inspected, cleaned and, if necessary, adjusted once a year. A qualified service agency should be called. To avoid personal injury, before servicing: 1. Disconnect electrical supply. 2. Shut-off gas supply. 3. Allow boiler to cool.
9 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Service (continued) Check pilot burner flames 1. Proper pilot flame a) Blue flame. b) Inner cone engulfing pilot flame sensor. c) Pilot flame sensor glows cherry red. functioning properly. If flame blows out or flickers drastically, vent system must be checked for obstructions or other causes of improper venting. 2. Inspect all parts of venting systems for deterioration from corrosion, physical damage, sagging, etc.
10 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Replacement parts – EG The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 19 of this manual. Failure to comply could result in severe personal injury.
10 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Replacement parts – EG (continued) NOTE 1: Order sufficient quantities to replace all orifices within a base Part Number 550-110-639/0703 23
10 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Replacement parts – EGH The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 19 of this manual. Failure to comply could result in severe personal injury.
10 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Replacement parts – EGH (continued) NOTE 1: Order sufficient quantities to replace all orifices within a base Part Number 550-110-639/0703 25
11 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Data Dimensions EG Dimensions P-EG Dimensions EGH 26 Part Number 550-110-639/0703
12 EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Ratings DOE Notes: * 1. Add prefix “P” for package boiler completely assembled and wired with jacket and controls (PEG-30-S through PEG-55-S only). EG-30 thru 75: Add suffix “SPD” or “SP” for standing pilot; add “PID” or “PI” for electronic ignition (30-65 — damper required in U.S.
EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL Standard equipment EG additional equipment Factory-Assembled Section Block Insulated Extended Jacket Draft Hood Aluminized Steel Burners Non-Linting Pilot Burner Heater Cover Plates (for boilers with tankless heater openings) Control Wire Electrical Junction Box Tankless Water Heater – EG-35-65 PI and SP EG-75 PI only With tankless heater: Combination High Limit, Low Limit, Circulator Control, and Relay with 40 VA Transformer Tankless Steam Hea
