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EG EG EG, , , PEG PEG PEG, , , EGH EGH EGH
EG EG, , PEG PEG, , EGH EGH
Gas-fired Boilers — Series 4
Boiler Manual Boiler Manual Boiler Manual
Boiler Manual 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 Leave all instructions with boiler for future reference.
Any claims
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 1 Contents Installation ............................................................................................. 3 Piping Connections................................................................................ 9 Install Boiler Controls.......................................................................... 12 Optional Heaters .................................................................................13 Gas Piping ........
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 1 Installation Codes New construction or remodeled buildings are most often built tighter. Windows and doors are weatherstripped, Installations must comply with all local codes, laws, vapor barriers are used and openings in walls are caulked. regulations and ordinances. Also National Fuel Gas Code As a result, such tight construction is unlikely to allow ANSI Z223.1-latest edition. When required, installations proper natural air infiltrat
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 1 Installation (continued) Chimney or vent requirements When removing boiler from common venting (also refer to Breaching erection, Page 8) system Venting must be installed according to Part 7, Venting of Failure to follow all instructions listed below can cause flue gas Equipment, of National Fuel Gas Code ANSI Z223.1- spillage and carbon monoxide emissions, resulting in severe latest edition and applicable building codes. Canadian perso
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 1 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. Side 4" EGH 105-
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 1 Installation (continued) Figure 3 Installation of flue collector hood (Factory installed on PEG boilers) Hydrostatic pressure test Set flue collector hood on boiler as shown in Figure 4. Pressure test before attaching gas piping or electrical supply. Use boiler cement furnished to provide gas-tight seal. 1. Plug any necessary boiler tappings or openings. Failure to maintain gas-tight seal can cause 2. Do not use gauge supplied with boil
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 1 Installation (continued) Figure 5 Front and back base panels Figure 6 Burner drawer assembly Figure 7 Pilot burner location Installation of drawer assembly and front access panel and back base channel (Factory installed on PEG boilers - follow steps 2 and 3) 1. The drawer assembly consists of the burner drawer, main burners, gas manifold, pilot burner, etc. See Figures 6, 7 and 8 for installation. 2. Check for proper orifice sizing fro
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 1 Installation (continued) Jacket installation (Factory installed on PEG Spill switch installation boilers) On EG 30-75 boilers only, fasten spill switch to draft 1. Remove the proper knockout discs from panels as hood as shown on page 22, Drawing Ref. Letter “K”. shown in tapping table, page 6. Connect wires as shown in Control Supplement. Tankless and storage heater knockouts must be removed for EG and EGH boilers Damper installation wi
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 2 Piping connections Pipe before installing controls. Connect return piping through fill valve. Eventual section failure can result. after jacket is attached. Connect supply piping before or Expansion tank installation: after jacket is attached. a) Closed type expansion tank - connect from the 3/4" N.P.T. tapping on left end section to expansion tank Failure to properly pipe the boiler may using 3/4" N.P.T. piping. Any horizontal piping m
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 2 Piping connections (continued) 8. Multiple Zoning Figure 12 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. Provide balan
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 2 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.
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 3 Install boiler controls Failure to properly install, pipe and wire Figure 17 Probe-type low water cut-off boiler controls may result in severe damage to the boiler, building and personnel. 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. Low water cut off for water boilers: a) Must be installed if boiler is located above rad
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 4 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 instructi
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 5 Gas piping Connecting gas supply piping 3. Remove knock-out disc from jacket panel which gas supply is to be piped. Size gas piping considering: 4. Follow good piping practices. a. Diameter and length of gas supplying piping. 5. Pipe joint compound (pipe dope) must be resistant b. Number of fittings. to corrosive action of liquified petroleum gases. Apply c. Maximum gas consumption (including any possible sparingly only to make threads
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 6 Wiring Refer to control supplement for additional information For your safety, turn off electrical power Refer to zone valve manufacturer’s literature for wiring supply before making any electrical and application. A separate transformer is required to connections to avoid possible electrical power zone valves. Zoning with circulators requires a shock hazard. relay for each circuit. All wiring must be installed in accordance with requir
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 7 Final adjustments Water treatment Filling water systems Do not use petroleum-based cleaning or 1. Close manual air vents, drain cock, and automatic sealing compounds in boiler system. Severe air vent, if used. boiler damage will occur. 2. Fill to correct system pressure. Correct pressure will vary with each application. Residential systems are Continual fresh make-up water will reduce boiler life. often designed for 12 pounds of cold fi
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 7 Final adjustments (continued) Skimming steam boilers To place in operation Clean all newly installed steam boilers to 1. Be sure boiler has been correctly filled with water. remove oil and grease. Failure to properly 2. Follow lighting/operating instructions on boiler. clean can result in violent fluctuations of For propane boilers only: water level, water passing into steam mains, Your propane supplier mixes an odorant with the propane
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 8 Check-out procedure Check-out procedure b. For standing pilot - Turn gas cock knob to PILOT position and extinguish pilot flame. Pilot gas flow should stop in less than 3 Check-off steps as completed. minutes. Put system back into operation (see page 17). ❏ System properly filled with water? ❏ Limit control set to design temperature or pressure requirements ❏ Automatic air vent, if used, open one turn (water boilers only)? of system? Ma
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 9 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. The International Agency for Research on Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite fr
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EG, PEG, EGH GAS-FIRED BOILERS — SERIES 4 — BOILER MANUAL 9 Service (continued) Also Refer to Additional Instructions Label all wires prior to disconnection Shipped With The Boiler For Specific when servicing controls. Wiring errors can Control Operation and Troubleshooting. cause improper and dangerous operation. Verify Proper Operation After Servicing To avoid personal injury, death or Your boiler should be inspected, cleaned property damage, keep boiler area clear and, if necessary, adjusted
