Weil-McLain Series 4 User manual

Part Number 550-110-646/0607
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 Natural or Propane gas
(tankless heater application optional)
Gas-Fired Boilers – Series 4
EG• PEG• EGH

2Part Number 550-110-646/0607
EG • PEG • EGH Series 4
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.
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!

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Part Number 550-110-646/0607
Universal control systems — Control supplement
Hazard definitions and Note to the installer ....................................................................................2
Control installation — EG-30 through EG-75 water boilers without tankless heaters ............ 4-5
Control installation — EG-30 through EG-75 water boilers with tankless heaters .................. 6-7
Control installation — EG and PEG steam boilers with probe-type low water cutoff ............. 8-9
Control installation — EG steam boilers with float-type low water cutoff............................ 10-11
Control installation — EGH water boilers without tankless heaters ..................................... 12-13
Control installation — EGH water boilers with tankless heaters........................................... 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.......................................................................................................................... 27-31
Replacement parts ...........................................................................................................................32
Table of contents

4Part Number 550-110-646/0607
EG • PEG • EGH Series 4 — Universal control systems — Control Supplement

5
Part Number 550-110-646/0607
Universal control systems — Control supplement
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.
Control installation
EG-30 through EG-75 water boilers without tankless heaters
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 20.
Figure 1 EG-30 through EG-75 water boilers without tankless heaters

6Part Number 550-110-646/0607
EG • PEG • EGH Series 4 — Universal control systems — Control Supplement

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Part Number 550-110-646/0607
Universal control systems — Control supplement
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.
Control installation continued
EG-30 through EG-75 water boilers with tankless heaters
1. Mount and wire controls per wiring diagram, page 6, and Figure 2.
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.
Figure 2 EG-30 through EG-75 water boilers with tankless heaters

8Part Number 550-110-646/0607
EG • PEG • EGH Series 4 — Universal control systems — Control Supplement

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Part Number 550-110-646/0607
Universal control systems — Control supplement
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.
Control installation continued
EG and PEG steam boilers with probe-type low water cut-off
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
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 3 EG and PEG steam boilers with probe-type low water cut-off

10 Part Number 550-110-646/0607
EG • PEG • EGH Series 4 — Universal control systems — Control Supplement

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Part Number 550-110-646/0607
Universal control systems — Control supplement
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 10, 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.
Figure 4 EG steam boilers with float-type low water cut-off

12 Part Number 550-110-646/0607
EG • PEG • EGH Series 4 — Universal control systems — Control Supplement

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Part Number 550-110-646/0607
Universal control systems — Control supplement
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 water boilers without tankless heaters
1. Mount and wire controls per wiring diagram, page 12, 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.
Figure 5 EGH water boilers without tankless heaters

14 Part Number 550-110-646/0607
EG • PEG • EGH Series 4 — Universal control systems — Control Supplement

15
Part Number 550-110-646/0607
Universal control systems — Control supplement
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.
Control installation continued
EGH water boilers with tankless heaters
1. Mount and wire controls per wiring diagram, page 14, and Figure 6.
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.
Figure 6 EGH water boilers with tankless heaters

16 Part Number 550-110-646/0607
EG • PEG • EGH Series 4 — Universal control systems — Control Supplement

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Part Number 550-110-646/0607
Universal control systems — Control supplement
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.
Control installation continued
EGH steam boilers with probe-type low water cut-off
1. Mount and wire controls per wiring diagram, page 16, 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.
Figure 7 EGH steam boilers with probe-type low water cut-off

18 Part Number 550-110-646/0607
EG • PEG • EGH Series 4 — Universal control systems — Control Supplement

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Part Number 550-110-646/0607
Universal control systems — Control supplement
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.
Control installation continued
EGH steam boilers with float-type low water cut-off
1. Mount and wire controls per wiring diagram, page 18, and Figure 8.
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 8 EGH steam boilers with float-type low water cut-off

20 Part Number 550-110-646/0607
EG • PEG • EGH Series 4
5. Read and apply the harness plug warning label
(Figure 10) 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.
Effikal or Field Controls damper— Damp-
er hold open switch must be in“Automatic
Operation”position for system to operate
properly.
Damper installation
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 32
are approved for use on EG-30 through EG-75 Series 4 and
PEG-30 through PEG-65 Series 4 using Universal 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 or propane gas.
• PEG-30 through PEG-65, steam, natural gas.
The following boiler models may have damper
installed:
• EG-75 and EGH-85 through EGH-125, natural or 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, or 24” for 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 war-
ranty. 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 9.
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 9 Vent damper assemblies
Figure 10 Vent damper harness plug warning label