Weil-McLain SERIES 7 PFG Use and maintenance manual

Part No. 550-110-643/0605
To complete boiler installation,
follow:
• General Information 2
• Boiler Wiring 3-5
• Vent Damper Installation 6
• Check-out Procedure 7
• Operating Instructions 8-10
For additional help, see:
• Troubleshooting 11-15
• Parts List 16
Controls must only be installed by and Control Supplement used by a qualified
installer/service technician. Read all instructions before installing. Failure to
follow all instructions in proper order can cause severe personal injury, death
or substantial property damage.
Control Supplement
Universal Control Systems (UCS)
PFGGas-fired
water boiler
Series 7

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PFG SerieS 7 GaS-Fired Water Boiler – UniverSal Control SyStemS
Part Number 550-110-643/0605
GENERAL INFORMATION:
PLEASE GIVE THE MODEL listed on the boiler rating label
AND THE CP NUMBER found next to the rating label.
The following dened terms are used throughout this manual.
They bring attention to the presence of hazards of various risk
levels, or to important information concerning the life of the
product.
indicates presence of hazard which can
cause severe personal injury, death or
substantial property damage if ignored.
indicates presence of hazard which will
cause severe personal injury, death or
substantial property damage if ignored.
indicates presence of hazard which will
or can cause minor personal injury or
property damage if ignored.
indicates special instructions on
installation, operation, or maintenance
which are important but not related to
personal injury hazards.
This system is used on natural gas-red boilers with or without
dampers as shipped from the factory.
This system is not offered for retrot,
or conversion from standing pilot
systems. 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.
IMPORTANT: When calling or writing about the boiler,

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PFG SerieS 7 GaS-Fired Water Boiler – UniverSal Control SyStemS
Part Number 550-110-643/0605
Section A: Installation
1. Bring supply wiring to boiler. Must be 14 ga. or heavier. See pages listed below each Figure for appropriate wiring diagram.
2. Proceed to page 6.
PFG 5 Boiler
Figure 1,
see page 4
PFG 6 thru 8 Boilers
Figure 2,
see page 5

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PFG SerieS 7 GaS-Fired Water Boiler – UniverSal Control SyStemS
Part Number 550-110-643/0605
PFG-5

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PFG SerieS 7 GaS-Fired Water Boiler – UniverSal Control SyStemS
Part Number 550-110-643/0605
PFG 6 thru 8

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PFG SerieS 7 GaS-Fired Water Boiler – UniverSal Control SyStemS
Part Number 550-110-643/0605
These boilers must have vent dampers:
• PFG 5 (U.S. only)
These boilers may have vent dampers:
• PFG 6-8 (U.S. only)
• PFG 5-7 (Canadian)
These boilers must not have vent damper:
• PFG 8 (Canadian)
If not installing damper, proceed to page 7.
1. Once damper is installed on boiler,
boiler will not operate without
damper installed.
Only dampers listed on page 16 are
approved for use on PFG Series 6 &
7 boilers. Any other damper installed
can cause severe personal injury or
death.
2. Efkal and Johnson dampers - install plug (packed in damper
carton of 4” thru 8” dampers) in hole in damper blade.
3. Minimum clearances:
PFG - 48” between jacket top and combustible ceiling.
DO NOT modify draft hood or
damper, or make another connection
between draft hood and damper
or boiler. This will void C.S.A.
certication and will not be covered
by Weil-McLain warranty. Any
changes will cause severe personal
injury, death or substantial property
damage.
4. PFG - Damper must be installed directly on top of draft
hood so that it serves only one boiler and so that damper
blade indicator is visible to homeowner. See Figure 1 or 2
and Figure 3 or 4.
Where screws or rivets are used to secure damper to draft
hood, they must not interfere with free movement of damper
blade.
5. Install damper harness between damper actuator and knock-
out in jacket top panel. Use strain relief connectors and
locknuts to secure both ends of damper harness. See Figure
1 or 2.
Keep wiring harness clear of all hot
surfaces.
6. Remove dummy receptacle from damper plug in boiler wiring
harness. Plug damper harness receptacle into damper harness
plug. See Figure 1 or 2.
Bypassing (jumpering) damper will
cause ue products such as carbon
monoxide to escape into house. This
will cause severe personal injury or
death.
After boiler has operated once, if
eitherendofharnessisdisconnected,
system shutdown will occur. Boiler
will not operate until harness is
reconnected.
7. Efkal damper - damper “Hold Open” switch must be in “Au-
tomatic Operation” position for system to operate properly.
8. Apply label shown in step 5 to damper, so that it is visible
after installation.
9. Proceed to page 7.
Johnson Damper
Figure 4
Efkal Damper
Figure 3
Section B: Damper Installation

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PFG SerieS 7 GaS-Fired Water Boiler – UniverSal Control SyStemS
Part Number 550-110-643/0605
1. See Figure 5 for operating instructions page numbers. Raise
room thermostat to call for heat. Damper actuator will slowly
open damper (if provided).
2. When damper (if provided) is fully open, ignition control
powers spark generator and opens pilot valve.
Damper must be in open position when
appliance main burners are operating.
If damper is not in open position, ue
products will escape into house, causing
severe personal injury or death.
3. a. Ifpilotdoesnotlightwithin15seconds,pilotvalveisclosed
andsparkgeneratoris turnedoff. Theignitioncontroliniti-
ates a ve minute wait period. If call for heat exists after
ve minutes, ignition sequence starts at Step 2.
b. If pilot lights and ignition control senses ame current,
main valve opens and spark generator is turned off.
4. During main burner operation:
a. Ignition control monitors pilot ame current. If signal is
lost, main valve is closed, spark generator activated, and
sequence returns to Step 3.
b. If power is interrupted, the control system shuts off pilot
and main gas valves and restarts at Step 1 when power is
restored.
5. Thermostat is satised: pilot and main gas valves are closed.
Damper (if provided) will close.
6. Boiler is now in the off cycle.
7. Repeat steps 1-6 several times to verify operation.
8. Return thermostat to normal setting.
9. Set thermostat heat anticipator setting indicated in notes on
wiring diagram.
Figure 5
Section C: Check-Out

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PFG SerieS 7 GaS-Fired Water Boiler – UniverSal Control SyStemS
Part Number 550-110-643/0605
PFG-5 WITH HONEYWELL VR8204/VR8304 GAS VALVE

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PFG SerieS 7 GaS-Fired Water Boiler – UniverSal Control SyStemS
Part Number 550-110-643/0605
PFG-5 WITH WHITE-RODGERS 36C GAS VALVE

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PFG SerieS 7 GaS-Fired Water Boiler – UniverSal Control SyStemS
Part Number 550-110-643/0605
PFG 6-8 WITH ROBERTSHAW 7000 DERHC GAS VALVE