Weil-McLain EG-30 THRU -75 Use and maintenance manual

For additional information, refer to . . .
EG • PEG • EGH Boiler manual
for Natural or Propane gas
(tankless heater application optional)
PEG-30 thru -65
EG-30 thru -75
Gas-Fired Boilers – Series 4
Control supplement – Standing pilot
This supplement must only be used by a qualified heating installer/service technician. Before installing, read all
instructions, including this supplement, the boiler manual and any related documents. Perform steps in the order given.
Failure to comply could result in severe personal injury, death or substantial property damage.
Part Number 550-110-032/0607

2Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4
Please read this page first!
Hazard definitions
The following defined terms are used throughout these instructions 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.
Note to the installer
Controls must only be installed by a Weil-McLain distributor or other qualified
installer/service technician in accordance with this Supplement and all applicable
codes and requirements of the authority having jurisdiction. Read this Control
Supplement completely before beginning the installation. If the information
in this Supplement is not followed exactly, a fire, explosion, carbon monoxide
emission or other hazardous conditions can result,causing severe personal injury,
death or substantial property damage.
This system is used on gas-fired boilers without vent dampers as shipped from
the factory. This system is not offered for retrofit.Any attempt to apply the system
components to boilers shipped for use with a different control system will not
be covered under boiler warranty and can cause severe personal injury, death or
substantial property damage.
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.

3
Part Number 550-110-032/0607
Standing Pilot Boilers — Control Supplement
Table of contents
Hazard definitions and Note to the installer ....................................................................................2
Control installation — EG-30 thru -75 water boilers without tankless heaters........................ 4-5
Control installation — EG-30 thru -65 water boilers with tankless heaters.............................. 6-7
Control installation — EG-30 thru -75 and PEG-30 thru -65 steam boilers with probe... ........ 8-9
Control installation — EG-30 thru -75 steam boilers with float-type low water cutoff........ 10-11
Damper installation .................................................................................................................... 12-13
Checkout procedure ........................................................................................................................14
Lighting instructions .................................................................................................................. 15-18
Troubleshooting.......................................................................................................................... 19-23
Replacement parts ...........................................................................................................................24

4Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4

5
Part Number 550-110-032/0607
Standing Pilot Boilers — Control Supplement
Figure 2
EG-75 water boilers without tankless heaters
Figure 1
1. Mount and wire controls per wiring diagram, page
4, and Figure 1.
a. Attach junction box inside left jacket panel with #8-32
x ½” machine screws provided.
b. Install transformer with plug-in relay receptacle and
relay.
c. Operating and limit circuit wiring must be 18 gauge
or heavier.
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
3. Proceed to page 12.
1. Mount and wire controls per wiring diagram, page
4, and Figure 2.
a. Attach junction box inside left jacket panel with
#8-32 x ½” machine screws and green ground nuts
provided.
b. Install transformer with plug-in relay receptacle and
relay. In Canada, use chain and hook strain relief.
c. Operating and limit circuit wiring must be 18 gauge
or heavier.
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
3. Proceed to page 12.
EG-30 thru -65 water boilers without tankless heaters
Control installation
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work on the
boiler. Failure to comply can cause severe personal injury, death or substantial property damage.

6Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4

7
Part Number 550-110-032/0607
Standing Pilot Boilers — Control Supplement
Note: Tankless heater not available on EG-75 standing pilot boilers.
EG-30 thru -65 water boilers with tankless heaters
Control installation continued
1. Mount and wire controls per wiring diagram, page
6, and Figure 3.
a. Install combination limit control and relay in tap-
ping. See Boiler Manual control tapping table. Op-
erating and limit circuit wiring must be 14 gauge or
heavier.
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
3. Proceed to page 12.
Figure 3
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work on the
boiler. Failure to comply can cause severe personal injury, death or substantial property damage.

8Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4

9
Part Number 550-110-032/0607
Standing Pilot Boilers — Control Supplement
1. Mount and wire controls per wiring diagram, page
8, and Figure 5.
a. Attach junction box inside left jacket panel with
#8-32 x ½” machine screws and green ground nuts
provided.
b. Install transformer with plug-in relay receptacle. In
Canada, use chain and hook strain relief.
c. Operating and limit circuit wiring must be 18 gauge
or heavier.
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
3. Proceed to page 12.
Figure 5
EG-75 steam boilers with probe-type low water cutoff
EG-30 thru -65 and PEG-30 thru -65 steam boilers with probe-type low water cutoff
Control installation continued
1. Mount and wire controls per wiring diagram, page
8, and Figure 4.
a. Attach junction box inside left jacket panel with #8-32
x ½” machine screws provided.
b. Install transformer with plug-in relay receptacle.
c. Operating and limit circuit wiring must be 18 gauge
or heavier.
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
3. Proceed to page 12.
Figure 4
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work on the
boiler. Failure to comply can cause severe personal injury, death or substantial property damage.

10 Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4

11
Part Number 550-110-032/0607
Standing Pilot Boilers — Control Supplement
1. Mount and wire controls per wiring diagram, page
10, and Figure 7.
a. Attach junction box inside left jacket panel with
#8-32 x ½” machine screws and green ground nuts
provided.
b. Install transformer with plug-in relay receptacle. In
Canada, use chain and hook strain relief.
c. Operating and limit circuit wiring must be 18 gauge
or heavier.
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
3. Proceed to page 12.
Figure 7
EG-75 steam boilers with float-type low water cutoff
EG-30 thru -65 steam boilers with float-type low water cutoff
Control installation continued
1. Mount and wire controls per wiring diagram, page
10, and Figure 6.
a. Attach junction box inside left jacket panel with #8-32
x ½” machine screws provided.
b. Install transformer with plug-in relay receptacle.
c. Operating and limit circuit wiring must be 18 gauge
or heavier.
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
3. Proceed to page 12.
Figure 6
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work on the
boiler. Failure to comply can cause severe personal injury, death or substantial property damage.

12 Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4
Figure 8 Vent damper assemblies
The following boiler models must have damper
installed:
• EG-30 thru EG-65, natural or propane gas.
• PEG-30 thru PEG-65, steam, natural gas.
The following boiler models may have damper
installed:
• EG-75, natural or propane gas.
Once damper is installed, boiler will not operate without a
damper installed.
Only dampers listed in the Replacement parts table on page 24
are approved for use on EG and PEG Series 4 standing pilot
boilers. Any other vent damper installed could cause severe
personal injury or death.
Damper installation

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Part Number 550-110-032/0607
Standing Pilot Boilers — Control Supplement
Damper installation continued
4. Read and apply the harness plug warning label
(shown above) so that it is visible after installa-
tion.
5. Plug damper harness receptacle into damper harness
plug.
Bypassing (jumpering) vent damper will
cause flue products such as carbon mon-
oxide to escape into the house. This will
cause severe personal injury or death.
After boiler has operated once, if either
end of the harness is disconnected, the
system safety shutdown will occur. The
boiler will not operate until harness is
reconnected.
Effikal damper — Damper hold open
switch must be in“Automatic Operation”
position for system to operate properly.
Minimum clearances to
combustibles
Provide a minimum of 6” between the vent damper
and any combustible material. (Provide a minimum of
46” between jacket top and combustible ceiling.) See
EG • PEG • EGH Boiler manual for complete clearance
requirements.
Installation
Do not modify draft hood or damper, or
make another connection between draft
hood and damper or boiler except as not-
ed below. This will void CSA certification
and will not be covered by Weil-McLain
warranty. Any changes will cause severe
personal injury, death, or substantial
property damage.
1. Install vent damper horizontally or vertically as
shown in vent damper manufacturer’s instructions.
Vent damper must be installed so that it serves only
one boiler and so damper blade indicator is visible
to the user. See Figure 8.
2. Screws or rivets used to secure the vent damper to
the draft hood must not interfere with rotation of
the damper blade.
3. Install damper harness between damper actuator
and knockout in jacket top panel. Use strain relief
connectors and locknuts to secure both ends of the
damper harness.
Keep wiring harness clear of all hot sur-
faces.

14 Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4
Checkout procedure
Room thermostat anticipator settings
Water without tankless heater — 0.40 amps
Water with tankless heater — 0.20 amps
Steam — Select based on gas valve and damper. See table below.
1. See pages 15-18 for “Lighting Instructions”.
2. Raise room thermostat to call for heat. Damper actuator will slowly open damper.
3. When damper is fully open, main gas valve will open and main burners will ignite.
Damper must be fully open before main burners light. If damper does not fully
open, flue products will escape into house, causing severe personal injury or
death.
4. Lower thermostat setting. Main burner flames will go out, then damper will close.
5. Repeat steps 1 through 3 several times to verify operation.
6. Return thermostat to normal setting.

15
Part Number 550-110-032/0607
Standing Pilot Boilers — Control Supplement
Lighting instructions — Robertshaw 7200

16 Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4
Lighting instructions — Honeywell VR8200/VR8300
Natural gas boilers only

17
Part Number 550-110-032/0607
Standing Pilot Boilers — Control Supplement
Lighting instructions — Honeywell VR8200/VR8300
Propane boilers only

18 Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4
Lighting instructions — Robertshaw 7000ERHC

19
Part Number 550-110-032/0607
Standing Pilot Boilers — Control Supplement
Figure 9 Manually opening vent damper
In event of vent damper failure:
Effikal vent damper
If troubleshooting chart recommends replacing actuator and actuator is
not immediately available, damper blade can be fixed in an open position
to allow boiler operation. Manually turning blade can cause actuator
damage. Follow these instructions only in case of no heat or damper
actuator malfunction.
1. Move damper service switch to Hold Damper Open position. Apply call
for heat to boiler. Damper blade should then rotate to open position
and boiler will fire.
2. If step 1 does not open damper, manually rotate damper blade to open
position using wrench or pliers on flat shaft between damper and actua-
tor. Boiler will fire.Verify that damper service switch is in Hold Damper
Open position (Figure 9).
3. Do not leave vent damper permanently in this position. Replace actua-
tor immediately. If vent damper is left in open position, boiler will not
operate at published efficiencies.
Johnson Controls vent damper
If troubleshooting chart recommends replacing actuator and actuator is
not immediately available, damper blade can be fixed in an open position
to allow boiler operation. Follow these instructions only in case of no heat
or damper actuator malfunction. See Figure 9.
1. Turn off power to boiler.
Failure to turn off power to boiler can result in severe personal
injury, death or substantial property damage.
2. Refer to vent damper manufacturer’s instructions for procedure to fix
vent damper in open position.
3. Turn on power to boiler.
4. Using wrench or pliers on flat shaft section, manually rotate damper
blade until green light turns on. Boiler will fire (Figure 9).
5. Do not leave vent damper permanently in this position. Replace actua-
tor immediately. If vent damper is left in open position, boiler will not
operate at published efficiencies.
Before troubleshooting
1. Have a voltmeter that can check 120 VAC, 24 VAC,
and a continuity tester.
2. Check for 120 VAC (minimum 102 to maximum
132) to boiler.
3. Be sure pilot is lit. See “Lighting instructions” on
pages 15-18 for details.
4. Make sure thermostat is calling for heat and contacts
(including appropriate zone controls) are closed.
Check for 24VAC between thermostat wire nuts and
ground.
Burner access panel must be in posi-
tion during boiler operation to prevent
momentary flame rollout on ignition of
main flame. Severe personal injury or
substantial property damage will result.
Never jumper (bypass) any device ex-
cept for momentary testing as outlined
in Troubleshooting Charts. Substantial
property damage and/or severe personal
injury could occur.
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous opera-
tion.
Verify proper operation after servicing. See
vent damper manufacturer’s instructions
packed with vent damper for additional
information. Failure to comply could
result in severe personal injury, death or
substantial property damage.
Troubleshooting

20 Part Number 550-110-032/0607
EG-30 thru 75 Series 4 and PEG-30 thru 65 Series 4
Figure 11
1. Checking thermocouple or thermopile open system (Figure 10):
a. Use an electronic multimeter, with leads fitted with alligator clips.Set meter
scale to DC Millivolts.
b. Unscrew thermocouple or thermopile fitting from gas valve.
c. Attach one meter lead to the end of the thermocouple or thermopile gas
valve fitting.
d. Attach other meter lead to thermocouple or thermopile lead (copper sur-
face).
e. Follow Lighting Instruction label on boiler (also found in Control Supple-
ment or User’s Information Manual) to light the pilot burner only, and hold
the pilot flame manually. (DO NOT light main burner.)
f. Check the reading on the multimeter. The reading should be around 28
millivolts for a thermocouple, or 700 millivolts for a thermopile.
g. If multimeter reading is significantly less than above and pilot flame is
appropriate, replace the thermocouple or thermopile.
2. Checking thermopile and high limit control circuit closed system (Fig-
ure 11):
a. Use an electronic multimeter, with leads fitted with alligator clips.Set meter
scale to DC Millivolts.
b. Loosen the insulated terminal on the TOP thermopile lead wire enough to
allow clipping a multimeter alligator clip to the spade terminal.
c. Attach the other multimeter lead to the thermopile lead (copper surface).
Light the pilot burner per step 1 e, above.
d. Check the reading on the multimeter. The reading should be around 400
millivolts.
e. If reading is significantly less than 400 millivolts, check tightness of lead
wire assembly in gas valve. If the connections are secure and you have
checked the thermopile per step 1 above, replace the thermopile lead wire
assembly.
f. If reading on TOP thermopile lead wire is around 400 millivolts, move the
multimeter alligator clip to the BOTTOM thermopile lead wire terminal
and check multimeter reading.
g. If multimeter does not read around 400 millivolts,check wiring connections
and wire integrity to the high limit control.
h. Check voltage at each limit terminal to make sure limit is closed. Correct
pressure or temperature condition causing any limit to be open. Replace
limit if necessary.
Pilot does not stay lit —
Troubleshooting thermocouple or thermopile
and high limit control circuit
Figure 10
Troubleshooting continued