EG • PEG • EGH Gas-Fired Boilers – Series 4 Boiler Manual EG PEG • Installation • Maintenance • Startup • Parts For additional information, refer to . . . Control Supplement and Gas Control Parts for Natural or Propane gas (tankless heater application optional) EGH This manual must only be used by a qualified heating installer/service technician. Before installing, read all instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Read this page first Hazard definitions 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. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Contents Codes and Checklist . . . . . . . . . . . . . . . . 3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . 21 Prepare boiler location . . . . . . . . . . . . . . 4 Prepare the boiler . . . . . . . . . . . . . . . . . . 7 Handling fiberglass and ceramic fiber materials . . . . . . . . . . . . . . . . . . . . . . . . .
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Prepare boiler location 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.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Prepare boiler location (continued) Flooring and foundation Vent System 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.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Prepare boiler location Vent System (continued) Air contamination Chimney or vent requirements 1. Venting must be installed according to the National Fuel Gas Code, ANSI Z223.1–latest edition and applicable building codes. Canadian installations must comply with B149.1 or B149.2 Installation Codes. 2. See “Ratings” on page 35 for minimum chimney or vent sizes. Chimney or vent termination: 1.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Prepare the boiler 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 1/2 inch of block bottom. 2. Remove short center draw rods. 3. Tip half blocks on end as shown in Figure 4. Save elastomer sealing rings and cope seal between sections. 4.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Prepare the boiler (continued) Installation of flue collector hood (Factory installed on PEG boilers) Set flue collector hood on boiler as shown in Figure 6. 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.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Prepare the boiler (continued) Figure 7b Front base panel Figure 10 Burner drawer installation Figure 8 Burner drawer assembly Figure 11 Access panel Figure 9 Burner and pilot burner locations Part Number 550-110-639/0706
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Prepare the boiler (continued) Jacket installation (Factory installed on PEG) 1. Remove the proper knockout discs from panels as shown in Table 4, page 7. 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.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Connect piping – water boilers General Table 6 Install the boiler jacket before connecting return piping. (Supply pipng 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 is needed. Install control in supply piping between boiler and isolation valve.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Connect piping – water boilers (continued) Figure 13 Recommended piping – forced hot water boilers with closed 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 13) to protect boiler against condensation.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Connect piping – water boilers (continued) Figure 16 System bypass piping in boiler loop with separate Figure 17 Boiler bypass piping — use only for high water 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.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Connect piping – steam boilers (continued) General Figure 18 Recommended piping for parallel-flow systems Failure to properly pipe the boiler may result in improper operation and damage to the boiler or building. 1. 2. 3. 4. Steam supply must be on same end as controls. Return may be from either end. Install the boiler jacket before connecting return piping. (Supply pipng can be connected before or after jacket installation.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Connect piping – steam boilers (continued) Figure 19 Connection to counterflow steam piping Installing the relief valve Install relief valve in tapping on top of boiler. See Table 4, page 7, 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 • EGH gas-fired boilers — series 4— boiler manual Connect piping – steam boilers (continued) Condensate return Figure 20 Recommended piping for parallel-flow systems with optional reservoir pipe 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.
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 21 Probe-type low water cut-off Water boiler 1. Install controls as shown on Control Tapping Table and Figure 5, page 7. Limit control and supply piping must be on the same end of EGH boiler. 2.
EG • PEG • EGH gas-fired boilers — series 4— 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 • EGH gas-fired boilers — series 4— boiler manual Connect gas supply piping Connecting gas supply piping 5. Follow good piping practices. 1. Size gas piping considering: 6. Pipe joint compound (pipe dope) must be resistant to corrosive action of liquified petroleum gases. Apply sparingly only to make threads of pipe joints. a) Diameter and length of gas supplying piping. b) Number of fittings. c) Maximum gas consumption (including any possible future expansion).
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Connect field wiring to boiler For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Refer to the Control Supplement for additional information, lighting instructions and control wiring diagram. Wiring must be N.E.C. Class 1.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Start-up Check for gas leaks Before starting the boiler, and during initial operation, 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. Freeze protection (when used) Use antifreeze especially made for hydronic systems. Inhibited propylene glycol is recommended.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Start-up (continued) 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.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Start-up (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 • EGH gas-fired boilers — series 4— boiler manual Start-up (continued) 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 8 for proper size. ❏ ❏ ❏ ❏ ❏ ❏ Proper orifices must be used.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual 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.
EG • PEG • EGH gas-fired boilers — series 4— 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) ❏ Inspect: • Reported problems ❏ Daily • Check boiler area • Check boiler pressure gauge • Boiler area • Check air openings • Air openings • Flue gas vent system • Pilot and main burner flames ❏ Monthly • Check
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Service and maintenance (continued) 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 26 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Service and maintenance (continued) o Service . . . . . . . . . . Probe-type low water cutoff (when used) 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. 1. 2. 3. 4. 5. 6. 7.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Service and maintenance (continued) o Check/test . . . . . . . . . . o Review with owner Boiler relief valve 1. After following the warning directions below, if the relief valve weeps or will not seat properly, replace the relief valve. 1. Review the User’s Information Manual with the owner. Before testing, make certain discharge pipe is properly connected to valve outlet and arranged to contain and safely dispose of boiler discharge.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Replacement parts — EG/PEG Table 13 EG/PEG replacement parts Item Description Boiler Models Part Number Item A Left hand end section with heater opening (Pattern No. 1814) — 311-800-014 H Left end section without heater opening(Pattern No. 1813) — 311-800-007 B Right hand end section without heater opening (Pattern No. 18118) — 311-800-029 C Intermediate section (Pattern No.
EG • PEG • EGH gas-fired boilers — series 4— 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 25 of this manual. Failure to comply could result in severe personal injury.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Replacement parts — EGH Table 14 EGH replacement parts Item Description A Left hand end section with heater opening (Pattern No. 1814) — 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.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Replacement parts — EGH (continued) The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 25 of this manual. Failure to comply could result in severe personal injury.
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Dimensional data Table 15 Dimensional data Boiler number Supply EG/EGH Return EG/EGH Dimensions Gas connection “F” W A B B1 V (note 2) T (note 1) EG & PEG-30 & -35 1 - 3” 1 - 2 ¹⁄₂” 17” 5” 11 ¾” 6 ¾” 6” ¹⁄₂” 5” 430 EG & PEG-40 & -45 1 - 3” 1 - 2 ¹⁄₂” 21¹⁄₄” 6” 11 ¾” 6 ¾” 6¹⁄₂” ¹⁄₂” 6” 505 EG & PEG-50 & -55 1 - 3” 1 - 2 ¹⁄₂” 25¹⁄₂” 7” 11 ¾” 6 ¾” 9 Water boiler tankless coil removal clearance: ¹⁄₂” 7
EG • PEG • EGH gas-fired boilers — series 4— boiler manual Ratings DOE Table 16 Capacities Boiler model number 0–2,000 feet altitude Input (Btuh) DOE Heating Capacity (Output) (Btuh) (Notes 1 & 2) *EG-30*EG-35*EG-40*EG-45*EG-50*EG-55*EG-65EG-75EGH-85EGH-95EGH-105EGH-115EGH-125- (Note 3) 75,000 100,000 125,000 150,000 175,000 200,000 250,000 300,000 349,900 400,000 450,000 500,000 550,000 62,000 83,000 104,000 125,000 145,000 167,000 209,000 240,000 280,000 320,000 360,000 400,000 440,000 2,00
EG • PEG • EGH gas-fired boilers — series 4— 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 Thermocouple (high efficiency models) Rollout Thermal Fuse Element Spill Switch Highest Eff
