Weil-McLain EGH-85 Series Use and maintenance manual

EGH-85 & 95 Series 4
PFG-6 & 7 Series 6 & 7
Part Number 550-110-031/0605
Control Supplement
Standing Pilot Boilers
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.

2Part Number 550-110-031/0605
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
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.
Note to the installer
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.
Hazard definitions
Please read this page first!

3
Part Number 550-110-031/0605
Control Supplement — Standing Pilot Boilers
Hazard definitions and Note to the installer ....................................................................................2
Control installation — EGH-85 & 95 water boilers........................................................................ 4-5
Control installation — PFG-6 & 7 water boilers............................................................................ 6-7
Control installation — EGH-85 & 95 steam boilers with probe-type LWCO ................................ 8-9
Control installation — EGH-85 & 95 steam boilers with float-type LWCO .............................. 10-11
Checkout procedure ........................................................................................................................ 11
Lighting instructions ........................................................................................................................12
Troubleshooting ......................................................................................................................... 13-15
Parts .................................................................................................................................................16
Table of contents

4Part Number 550-110-031/0605
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Control installation — EGH-85 & 95 water boilers

5
Part Number 550-110-031/0605
Control Supplement — Standing Pilot Boilers
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.
Figure 1
Control installation — EGH-85 & 95 water boilers
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 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 (as supplied with the boiler).
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.

6Part Number 550-110-031/0605
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Control installation — PFG-6 & 7 water boilers

7
Part Number 550-110-031/0605
Control Supplement — Standing Pilot Boilers
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.
Figure 2
Control installation — PFG-6 & 7 water boilers
1. Mount and wire controls per wiring diagram, page
6, and Figure 2.
2. Operating and limit circuit wiring must be 18 gauge
or heavier (as supplied with the boiler).
3. Bring supply wiring to boiler. Must be 14 gauge or
heavier.

8Part Number 550-110-031/0605
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Control installation — EGH-85 & 95 steam boilers

9
Part Number 550-110-031/0605
Control Supplement — Standing Pilot Boilers
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.
Figure 3
with probe-type low water cutoff
1. Mount and wire controls per wiring diagram, page
8, and Figure 3.
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.

10 Part Number 550-110-031/0605
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Control installation — EGH-85 & 95 steam boilers

11
Part Number 550-110-031/0605
Control Supplement — Standing Pilot Boilers
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.
Figure 4
with float-type low water cutoff
1. Mount and wire controls per wiring diagram, page
10, and Figure 4.
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 (as supplied with the boiler).
2. Bring supply wiring to boiler. Must be 14 gauge or
heavier.
Checkout procedure
1. Follow all instructions in the boiler manual, including the Checkout procedure, before proceeding.
2. See page 12 for“Lighting instructions”. Raise room thermostat to call for heat.
3. Gas valve will open and main burners will ignite.
4. Lower thermostat setting. Main burner flames will go out.
5. Repeat steps 1 through 3 several times to verify operation.
6. Return thermostat to normal setting.
Anticipator settings
Water — 0.40 amps, single zone systems only. For multiple zones using zone
valves or circulators, refer to component manufacturer’s instructions for
application, wiring and thermostat heat anticipator setting.
Steam — 0.20 amps.

12 Part Number 550-110-031/0605
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Lighting instructions — Robertshaw 7000ERHC
FOR YOUR SAFETY READ BEFORE LIGHTING
LIGHTING INSTRUCTIONS
TO TURN OFF GAS TO THE APPLIANCE
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in
your building.
• Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
WHAT TO DO IF YOU SMELL GAS
If you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
1. Stop! Read the safety information above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electrical power to the appliance.
4. Depress gas control knob slightly and turn clockwise
to OFF.
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be
performed.
3. Remove front panel.
4. Depress gas control knob slightly and turn clockwise
to OFF.
5. Replace front panel.
5. Wait five (5) minutes to clear out any gas. Then smell for
gas, including near the floor.If you smell gas, STOP! Follow
"B" in the safety information above. If you don't smell gas,
go to the next step.
6. Remove access panel located above burners.
7. Find pilot — follow metal tube from gas
control. The pilot is between two burners
behind the access panel.
A. This appliance has a pilot, which must be lighted
by hand. When lighting the pilot, follow these
instructions exactly.
B. Before LIGHTING, smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the
floor. See below.
C. Use only your hand to depress or turn the gas control knob. Never use
tools. If the selector arm will not depress or move by hand, don't try to
repair it, call a qualified service technician. Force or attempted repair
may result in a fire or explosion.
D. Do not use this appliance if any part has been under water.Immediately
call a qualified service technician to inspect the appliance and to replace
any part of the control system and any gas control, which has been
under water.
Note: Gas control knob cannot be turned to OFF unless
knob is depressed slightly. Do not force.
8. Turn gas control knob counterclockwise to PILOT.
9. Depress gas control knob and hold. Immediately light the
pilot with a match. Continue to hold gas control knob in for
about one (1) minute after the pilot is lit.
• If pilot can be lit without depressing gas control knob,
turn gas knob clockwise to OFF and call your service
technician or gas supplier.
10. Release gas control knob. Pilot should remain lit. If pilot goes
out, repeat steps 4 through 10.
• If gas control knob stays depressed after release, stop and
immediately call your service technician or gas supplier.
• If the pilot will not stay lit after several tries, turn the gas
control knob clockwise to OFF and call your service
technician or gas supplier.
11. Replace access panel.
12. Turn gas control knob counterclockwise to ON.
13. Turn on all electric power to the appliance.
14. Set thermostat to desired setting.
15. Replace front panel.

13
Part Number 550-110-031/0605
Control Supplement — Standing Pilot Boilers
Troubleshooting
Verify proper operation after servicing
Never jumper (bypass) any device except for momentary
testing as outlined in troubleshooting chart below.
Substantial property damage and/or severe personal
injury could occur.
Burner access panel must be in position during boiler
operation to prevent momentary flame rollout on
ignition of main flame. Severe personal injury or
substantial property damage will result.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation leading to severe personal injury,
death or substantial property damage.
Before troubleshooting:
1. Have a voltmeter that can check 120VAC, 24VAC, and a continuity tester.
2. Check for 120VAC (minimum 102 to maximum 132) to boiler.
3. Be sure pilot is lit. See“Lighting instructions” on page 12 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.
Pilot does not stay lit —
Troubleshooting thermopile and high
limit control circuit
1. Checking thermopile open system (Figure 5):
a. Use an electronic multimeter, with leads fitted with alligator clips. Set
meter scale to DC Millivolts.
b. Unscrew thermopile fitting from gas valve.
c. Attach one meter lead to the end of the thermopile gas valve fitting.
d. Attach other meter lead to thermopile lead (copper surface).
e. Follow Lighting Instruction label on boiler (also found in Control
Supplement 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
700 millivolts.
g. If multimeter reading is significantly less than above, replace the
thermopile.
2. Checking thermopile circuit closed system (Figure 6):
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.
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
Figure 5
Figure 6
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 limit controls.
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.

14 Part Number 550-110-031/0605
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Is 24VAC present across transformer terminals C& Y?
Is damper harness securely plugged in at both ends?
Secure connections.
Check for open thermostat, LWCO, high limit, spill switch or
rollout thermal fuse element contacts or check for loose
wire connections.
If LWCO, spill switch or rollout thermal fuse
element contacts are open, determine cause
and correct condition. Failure to do so will
cause severe personal injury, death or
substantial property damage.
Check/repair out of round stack section. Does vent damper
rotate open?
Is 24VAC present across transformer terminal Cand yellow
wire on vent damper connector?
Is 24VAC present across gas valve terminals?
Open thermostat contacts for 30 seconds. Vent damper will
rotate to closed position. Close thermostat contacts. Vent
damper will rotate to open position. Is 24VAC present
across gas valve terminals?
Remove damper harness from
damper harness plug.
TEMPORARILY install jumper
between terminal 2and
terminal 5on damper plug in
boiler wiring harness. See
figure, right. Does boiler fire?
No Yes
No Yes
Chart 1: Boiler will not fire — water boilers without tankless
Check for loose wire connections or bad relay on
transformer.
No Yes
Is vent damper rotated open?
No Yes
No Yes
Replace actuator.
Retest.
Check continuity of each wire in damper harness. Does
continuity exist for each wire? See Table below.
Replace damper
wiring harness.
Retest.
Replace gas valve.
Retest.
Is main flame on now?
No Yes
Retest
No Yes
No Yes
No Yes
No Yes
Replace damper
actuator. Retest.
Turn gas valve cock to
ON position. Retest.
Replace gas valve.
Retest
Is gas valve cock turned to ON position?
No Yes
Troubleshooting continued

15
Part Number 550-110-031/0605
Control Supplement — Standing Pilot Boilers
Troubleshooting continued
Is 24VAC present across combination control terminals V
2
& Z?
Is damper harness securely plugged in at both ends?
Secure connections.
Check for open thermostat, LWCO, high limit, spill switch or
rollout thermal fuse element contacts or check for loose
wire connections.
If LWCO, spill switch or rollout thermal fuse
element contacts are open, determine cause
and correct condition. Failure to do so will
cause severe personal injury, death or
substantial property damage.
Check/repair out of round stack section. Does vent damper
rotate open?
Is 24VAC present across transformer terminal V
2
and
yellow wire on vent damper connector?
Is 24VAC present across gas valve terminals?
Open thermostat contacts for 30 seconds. Vent damper will
rotate to closed position. Close thermostat contacts. Vent
damper will rotate to open position. Is 24VAC present
across gas valve terminals?
Remove damper harness from
damper harness plug.
TEMPORARILY install jumper
between terminal 2and
terminal 5on damper plug in
boiler wiring harness. See
figure, right. Does boiler fire?
No Yes
No Yes
Chart 2: Boiler will not fire — water boilers with tankless
Check for loose wire connections or bad combination
control.
No Yes
Is vent damper rotated open?
No Yes
No Yes
Replace actuator.
Retest.
Check continuity of each wire in damper harness. Does
continuity exist for each wire? See Table below.
Replace damper
wiring harness.
Retest.
Replace gas valve.
Retest.
Is main flame on now?
No Yes
Retest
No Yes
No Yes
No Yes
No Yes
Replace damper
actuator. Retest.
Turn gas valve cock to
ON position. Retest.
Replace gas valve.
Retest
Is gas valve cock turned to ON position?
No Yes

16 Part Number 550-110-031/0605
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7
Parts