Weil-McLain EG 6 Series User manual

Series 6
Series 5
Gas-Fired Boilers
E
/PE
E
H
Part Number 550-142-304/1220
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.
Control Supplement – Universal Control Systems
For additional information, refer to . . .
EG•PEG•EGH Boiler manual
for EG/PEG – Natural gas only
for EGH – Natural or Liqueed Petroleum
(Propane) gas
(tankless heater application optional)
Now With Built In
Low Water Cut Off Functionality
EG Water Only

EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt
2Part Number 550-142-304/1220
Please read this page rst!
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 Consumer Protection (CP) number from the boiler jacket.
Hazard definitions
The following defined terms are used throughout these instructions to bring attention to the presence of hazards of vari-
ous 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.

3
Part Number 550-142-304/1220
Universal Control Systems
Table of contents
Hazard definitions and Note to the installer .............................................................................................. 2
Start-up ......................................................................................................................................................... 4
Department of Energy – Compliance ......................................................................................................... 5
Operation – Sequence ..............................................................................................................................5-6
Control installation — EG-30 through EG-75 water boilers without tankless heaters........................7-9
Control installation — EG-30 through EG-75 water boilers with tankless heaters..........................10-11
Control installation — EG and PEG steam boilers with probe-type low water cutoff.....................12-13
Control installation — EG steam boilers with float-type low water cutoff.......................................14-15
Control installation — EGH steam boilers with probe-type low water cut-off ................................16-17
Control installation — EGH steam boilers with float-type low water cut-off ..................................18-19
Damper installation .................................................................................................................................... 20
Checkout procedure .................................................................................................................................. 21
Operating instructions ..........................................................................................................................22-26
Troubleshooting.....................................................................................................................................27-40
Replacement parts ..................................................................................................................................... 41

EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt
4Part Number 550-142-304/1220
DO NOT proceed with boiler operation unless boiler and system have been filled with water and all
instructions and procedures of previous manual sections have been completed. Failure to do so could
result in severe personal injury, death or substantial property damage. Before starting the boiler, do
the following:
• ReadtheManual,ControlSupplementandtheOperating instruction procedure.
• Verifytheboilerandsystemwaterleveliscorrect(nomorethan1/2gaugeglassorlessthan1/4”
above bottom of gauge glass). (steam boilers)
• Verifytheboilerandsystemarefull of water. (Water boilers)
• VerifytheStart-up preparation in Boiler manual have been completed.
Start-up
EG & PEG water boilers
Adjust boiler control settings
BOILER OPERATING TEMPERATURE
With power turned on, control module receives a signal from
the temperature sensor / LWCO and displays boiler temperature.
The control knob labeled BOILER TEMP is used to adjust the
operating temperature set point, turning clockwise to increase
temperature setting and counterclockwise to decrease. When the
knob is turned to adjust temperature the display will brighten to
indicate adjustment mode. After temperature is set to desired
value, display will dim after approximately 5 seconds to indicate
measurement mode.
ADJUST BOILER OPERATING TEMPERATURE TO DESIRED
SET POINT
BOILER ECONOMY SETTING
To comply with Department of Energy regulations, the control
module circulates available hot water before turning on the boiler
to attempt to satisfy a call for heat. While attempting to satisfy
the heat demand, the control module also monitors the boiler
temperature changes via the temperature sensor / LWCO and
determines whether or not the available hot water will satisfy the
demand, adjusting the time delay to turn on the boiler until it
determines that additional heat will be needed. The knob labeled
ECONOMY ADJUST provides an adjustment between maximize
(MAX) and minimize (MIN) the delay. The maximum (MAX)
adjustment position should be used to maximize energy savings.
Turning the knob counterclockwise decreases the delay time and
should only be used in the event that the heated space becomes
uncomfortable.
ADJUST ECONOMY TO DESIRED POSITION
(MAX IS THE PREFERRED SETTING)
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy
and Conservation Act, this boiler is equipped with a feature
that saves energy by reducing the boiler water temperature
as the heating load decreases. This feature is equipped with
an override which is provided primarily to permit the use of
an external energy management system that serves the same
function.
THISOVERRIDEMUSTNOTBEUSEDUNLESSATLEAST
ONEOFTHEFOLLOWINGCONDITIONSISTRUE:
• An external energy management system is installed that
reduces the boiler water temperature as the heating load
decreases.
• This boiler is part of a modular or multiple boiler system
havingatotalinputof300,000BTU/hrorgreater.
• This boiler is equipped with a tankless coil.

5
Part Number 550-142-304/1220
Universal Control Systems
Department of Energy – Compliance
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. The control calculates a suitable delay based on temperature measure-
ments and turns the boiler on only after it determines that the demand for heat cannot be satisfied with the
available hot water,
Due to the wide variety of controls used in boiler installations, this control is also equipped with an adjustment
for the calculated time delay period (ECONOMY ADJUST). In the MIN position, the time delay is zero and the
IMPORTANT notice below must be observed:
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with
a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature
is equipped with an override which is provided primarily to permit the use of an external energy management
system that serves the same function.
THISOVERRIDEMUSTNOTBEUSEDUNLESSATLEASTONEOFTHEFOLLOWINGCONDITIONSISTRUE:
• An external energy management system is installed that reduces the boiler water temperature as the heating load
decreases.
• Thisboilerispartofamodularormultipleboilersystemhavingatotalinputof300,000BTU/hrorgreater.
• This boiler is equipped with a tankless coil.
Operation – Sequence
Follow all procedures given in this manual
and operating instructions when operating the
boiler. Failure to do so could result in severe
personal injury, death or substantial property
damage.
1. Standby: With no call for heat, the vent damper and circula-
tor are de-energized. No gas flows to pilot or main gas valve.
2. Call for heat (thermostat circuit closes):
For water boilers, while attempting to satisfy the heat demand,
the control module monitors the boiler temperature changes
via the temperature sensor and determines whether or not the
available hot water will satisfy the demand, only running the
circulator. If additional heat is needed, the sequence contin-
ues. When DHW (if used) calls for heat, sequence above is
bypassed.
a. Ventdamperandcirculatorenergizedifpilotstatusac-
ceptable.Ventdamperdrivesopen.Whenventdamper
end switch makes circuit, ignition control begins pilot
ignition attempt.
b. Ignition control checks for false flame signal: If ignition
control senses pilot signal when no pilot gas should be
present, control will lockout, requiring reset procedure
as given in Figure 1.
3. Pilot ignition: Control module sparks the pilot and opens
pilot valve in main gas valve.
a. If pilot does light and control module senses flame current,
spark generator is turned off and main valve opens.
b. Natural Gas - Ifpilotdoesnotlightwithin15seconds,
pilot valve is closed and spark generator is turned off.
Control module waits 5 minutes, then attempts to ignite
pilot again. This cycle will continue indefinitely if pilot
ignition control does not sense pilot flame.

EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt
6Part Number 550-142-304/1220
Operation – Sequence
Figure 1 Ignition control module sequence of operation — status light indications — EG Water Only
4. Main burner operation:
a. Control module monitors pilot flame current. If signal is lost,
main valve closes, spark generator activates and sequence
returns to step 4.
b. If power is interrupted, control system shuts off pilot and
maingasvalvesandrestartsatstep1whenpowerisrestored.
c. In the event the limit control shuts down the boiler — The
control module closes the main gas valve, but keeps the cir-
culator operating and the vent damper open.
5. Thermostat satisfied (thermostat circuit opens) — Pilot and
maingas valves areclosed—Vent damperisde-energized,and
cycles to closed position. Circulator is shut off.
6. Boiler is now in the standby mode.
7. Thermostat anticipator setting: Set thermostat heat anticipator as
instructed on page21.
STEPS
(After Step 8, the cycle goes back to Step 1)
Call for
Heat?
POWER TSTAT
CIRC
LIMIT DAMPER FLAME LWCO Timing
1. Standby
• Waiting for call for heat NO —
2. Call for heat
• Circulator on YES —
3. Limit circuit
• Limit controls closed YES —
4. Damper circuit
• Damper proven open YES —
5. Flame proven *
• Gas valve open
• Ignitor remains on
• Boiler producing heat
YES 15 sec
6. Limit cycle
• Limit circuit open
• Gas valve closed
YES —
7. Flame outage *
• Flame out
• Boiler recycles YES —
8. Thermostat satisfied
• Circulator off NO —
9. Circulator exercise routine
• Circulator turns on for 30 seconds if
boiler not operated for 30 days
NO 30 sec
10. LWCO circuit
• LWCO circuit open YES/NO —
= ON = OFF
* See Page 5, Items 3b for controls response to failure to prove pilot flame.
Control will lockout under the following conditions:
 •Linevoltagepolarityisreversed
 •Strayvoltageissensedonthermostatline
• Damper end switch not proven within 5 minutes from thermostat
call for heat
•Flame is sensed when it shouldn’t be there
Control will reset after these lockouts :
•1hourwaitingperiod
• Opening and closing of thermostat circuit for 2 to 20 seconds
•Removalof120VACpowerfor2to20seconds

7
Part Number 550-142-304/1220
Universal Control Systems
EG-30 through EG-75 water boilers without tankless heaters Schematic wiring diagram
Control installation

EG-30 through EG-75 water boilers without tankless heaters Ladder wiring diagram
EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt
8Part Number 550-142-304/1220
Control installation (Continued)

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 se-
vere personal injury, death or substantial
property damage.
EG-30 through EG-75 water boilers without tankless heaters
1. Mountandwirecontrolsperwiringdiagram,page9,andFigure2.
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 20.
Figure 2 EG-30 through EG-75 water boilers without tankless heaters
9
Part Number 550-142-304/1220
Universal Control Systems
Control installation (Continued)

10 Part Number 550-142-304/1220
EG & PEG Series 6 • EGH Series 5 — Universal control systems — Control Supplement
EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt

Figure 3 EG-30 through EG-75 water boilers with tankless heaters
11
Part Number 550-142-304/1220
Universal Control Systems
Control installation (Continued)
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 prop-
erty damage.
EG-30 through EG-75 water boilers with tankless heaters
1. Mountandwirecontrolsperwiringdiagram,page11,andFigure3.
a. Install combination limit control and relay in tapping. See Boiler Manual
controltappingtable.Operating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 20.

12 Part Number 550-142-304/1220
EG & PEG Series 6 • EGH Series 5 — Universal control systems — Control Supplement
EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt

Figure 4 EG and PEG steam boilers with probe-type low water cut-off
13
Part Number 550-142-304/1220
Universal Control Systems
Control installation (Continued)
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 prop-
erty damage.
1. Mountandwirecontrolsperwiringdiagram,page13,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 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 20.
EG and PEG steam boilers with probe-type low water cut-off

14 Part Number 550-142-304/1220
EG & PEG Series 6 • EGH Series 5 — Universal control systems — Control Supplement
EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt

Figure 5 EG steam boilers with float-type low water cut-off
15
Part Number 550-142-304/1220
Universal Control Systems
Control installation (Continued)
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 prop-
erty damage.
EG steam boilers with float-type low water cut-off
1. Mountandwirecontrolsperwiringdiagram,page15 and Figure 5.
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 20.

16 Part Number 550-142-304/1220
EG & PEG Series 6 • EGH Series 5 — Universal control systems — Control Supplement
EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt

Figure 6 EGH steam boilers with probe-type low water cut-off
17
Part Number 550-142-304/1220
Universal Control Systems
Control installation (Continued)
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 prop-
erty damage.
EGH steam boilers with probe-type low water cut-off
1. Mountandwirecontrolsperwiringdiagram,page17, 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 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 20.

18 Part Number 550-142-304/1220
EG & PEG Series 6 • EGH Series 5 — Universal control systems — Control Supplement
EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt

Figure 7 EGH steam boilers with float-type low water cut-off
19
Part Number 550-142-304/1220
Universal Control Systems
Control installation (Continued)
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 prop-
erty damage.
EGH steam boilers with float-type low water cut-off
1. Mountandwirecontrolsperwiringdiagram,page19, and Figure 7.
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 20.

EG /PEG sEriEs 6 • EGH sEriEs 5 Gas-firEd boilErs — Control suPPlEmEnt
20 Part Number 550-142-304/1220
5. Read and apply the harness plug warning label
(Figure9)sothatitisvisibleafterinstallation.
6. 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.
Damper setting — Damper hold open
switchmustbein“AutomaticOperation”
position for system to operate properly.
If not installing a vent damper, proceed to page 21.
Once damper is installed, boiler will not operate without a
damper installed.
Only dampers listed in the Replacement parts table on
page 42 are approved for use on EG-30 through EG-75
Series6andPEG-30throughPEG-65Series6,usingUni-
versal Control Systems. Any other vent damper installed
could cause severe personal injury or death.
The following boiler models must have
damper installed:
• EG-30 through EG-65, natural gas.
• PEG-30 through PEG-65, steam, natural gas.
The following boiler models may have
damper installed:
• EG-75, natural gas.
• EGH-85 through EGH-125, natural or liqueed
petroleum (propane) gas.
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forEG/PEGandEGH.)SeeEG•PEG•EGHBoilermanualfor
complete clearance requirements.
Installation
Damper must be installed directly on top of draft hood so
that it serves only that boiler. Do not modify draft hood or
damper, or make another connection between draft hood
and damper or boiler except as noted 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plug(packedindampercartonof4”through8”dampers)in
hole in damper blade.
2. 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.
3. Screws or rivets used to secure the vent damper to the draft hood
must not interfere with rotation of the damper blade.
4. 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 surfaces.
Figure 8 Vent damper assemblies
Figure 9 Vent damper harness plug warning label
Damper installation