Gas-fired
water boiler
Series 7
PFG
• Installation • Operation
• Service
• Parts
For additional information,
refer to . . .
Control Supplement
Read all instructions before installing
This manual must only be used by a qualified heating installer/service technician.
Read all instructions before installing. Perform steps in the order given. Failure
to comply could result in severe personal injury, death or substantial property
damage.
Installer Leave all instructions with boiler for future reference.
Any claims for damage or shortage in shipment must be filed immediately against
the transportation company by the consignee.
Owner
Installation and service must be performed by qualified contractor.
Part No. 550-110-641/0605
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Section I: Installation
Combustion air and ventilation openings
Select the boiler location
Combustion air and ventilation openings must comply with Sec-
tion 5.3, Air for Combustion and Ventilation, of National Fuel
Gas Code ANSI Zꢀꢀ3.1-latest edition, or applicable local build-
ing codes. Canadian installations must comply with CAN/CSA
B149.1 or .ꢀ Installation Codes.
•
Consider all connections to boiler before selecting a location.
•
Boiler must be installed so gas control system components are pro-
tected from dripping or spraying water or rain during operation or
service.
•
Non-combustible floor ONLY. See “Boiler foundation”, Page 5.
Provide adequate combustion and ventilation air to:
To avoid personal injury,death or property damage,
keep boiler area clear and free from combustible
materials, gasoline and other flammable vapors
and liquids.
•
•
Ensure proper combustion
Reduce risk or severe personal injury or
death from flue gas spillage and carbon
monoxide emissions.
Do not install an exhaust fan in the boiler room.
Installation clearances
Boiler installation must ensure sufficient openings in building
and boiler room to provide adequate combustion air and ventila-
tion. Consider construction tightness of building when deciding
whether additional outside openings may be needed.
Older buildings with single-pane windows, minimal weather-
stripping and no vapor barrier often provide enough natural
infiltration and ventilation without dedicated openings.
Suggested minimum clearances for servicing
•
•
•
•
ꢀ4 inches for cleaning and servicing, left side.
18 inches for access to controls and components, front.
48 inches from top for cleaning flueways.
6 inches on remaining sides.
New construction or remodeled buildings are most often built
tighter. Windows and doors are weather stripped, vapor barriers
are used and openings in walls are caulked. As a result, such tight
construction is unlikely to allow proper natural air infiltration
and ventilation.
PFG-5 through PFG-7: Required minimum clearances
to combustible surface in alcove installations (see
below)
PFG 5 thru 7: Top 4ꢀ”
Rear 5”
R. Side 5”
L. Side 5”
Front: Alcove 18”
Air from inside building (boiler in interior room):
PFG-8: Required minimum clearances to combustible
surfacel in alcove installations
•
Tightly constructed buildings must be provided with openings to
outside for combustion and ventilation air. These openings must be
sized to handle all fuel burning appliances, exhaust and ventilation
fans and fireplaces.
PFG 8: Provide minimum ꢀ4” between jacket and any com-
bustible wall(s). Provide minimum 48” between jacket top and
combustible ceiling or surface above the boiler.
•
When openings to boiler room are taken to interior spaces, provide
two permanent openings: a combustion air opening within 1ꢀ inches
of floor and a ventilation opening within 1ꢀ inches of ceiling. Each
opening must provide a minimum free area of one square inch per
1,000 Btuh input of all appliances in room plus requirements for
any exhaust fans in room. The interior space supplying combustion
and ventilation air must have adequate infiltration from outside.
Install in a space large in comparison to size of boiler.
Clearances from piping materials to combustible sur-
faces
•
•
•
Single wall vent pipe must be at least 6 inches from combustible
surface.
Type “B” double wall metal vent pipe - refer to vent manufacturer’s
recommendation for clearances to combustible surface.
Air directly from outside to boiler room:
•
Tightly constructed buildings must be provided with combustion
air and ventilation openings to boiler room which are adequate to
handle the boiler needs plus the needs of all other fuel-burning ap-
pliances, fireplaces and exhaust or ventilation fans.
Hot water pipes must be at least ½” from combustible surface.
Note
Minimum clearances from combustible
surfaces for models PFG-5 through PFG-7
•
Combustion and ventilation openings connecting directly or by
ducting to outside, or to attic or crawl spaces that freely connect
with outside, must be sized as follows:
1. Outside wall or vertical ducting - one square inch per 4,000
Btuh input of all appliances in room plus requirements for any
exhaust fans or other appliances in room.
ꢀ. Horizontal ducting - one square inch per ꢀ,000 Btuh of all appli-
ances in room plus requirements for any exhaust fans or other
appliances in room.
3. All ducting must be same size as permanent openings.Minimum
size of ducting must be no less than 9 square inches.
4. Other size ducting must comply with local codes.
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Chimney or vent requirements
(also refer to Breaching erection, Page 12)
When removing boiler from
common venting system
Venting must be installed according to Part 7,Venting of
Equipment, of National Fuel Gas Code, ANSI Zꢀꢀ3.1-
latest edition and applicable building codes. Canadian
installations must comply with CAN/CSA B149.1 or .ꢀ
Installation Codes.
Failure to follow all instructions listed
below can cause flue gas spillage and
carbon monoxide emissions, resulting in
severe personal injury,death or substantial
property damage.
Minimum chimney or vent sizes are on page ꢀꢀ.A chim-
ney or vent without a listed cap should extend at least
3 feet above the highest point where it passes through
a roof of a building and at least ꢀ feet higher than any
portion of a building within a horizontal distance of 10
feet. A chimney or vent must not extend less than those
distances stated above.
At the time of removal of an existing boiler,the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in op-
eration,while the other appliances remaining connected
to the common venting system are not in operation.
a. Seal any unused openings in the common venting sys-
tem.
A lined chimney is preferred and must be used when
required by federal, provincial, territorial, state or local
building codes. Vitreous tile linings with joints which
prevent the retention of moisture and linings made
of corrosion-resistant materials are best. Advice for
flue connections and chimney linings can usually be
obtained from the local gas utility. Type “B” double
wall metal vent pipe or single wall vent pipe may be
used as a liner.
Cold masonry chimneys, also known as outside chim-
neys, typically have one or more walls exposed to
outside air.
When any atmospheric gas-fired boiler with automatic
vent damper is vented through this type of chimney, the
potential exists for condensation to occur.Condensation
can damage a masonry chimney.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction,leakage,corrosion and other deficiencies which
could cause an unsafe condition.
c. Insofar as is practical,close all building doors and windows
and all doors between the space in which the appliances
remaining connected to the common venting system are
located and other spaces of the building. Turn on clothes
dryers and any appliance not connected to the common
venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at
maximum speed. Do not operate a summer exhaust fan.
Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
Weil-McLain recommends the following to prevent
possible damage:
1. Line chimney with corrosion-resistant metal liner such as
ALꢀ9-4C® single wall stainless steel or B-vent. Size liner
per National Fuel Code ANSI Zꢀꢀ3.1-latest edition.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of
a match or candle, or smoke from a cigarette, cigar or
pipe.
f. After it has been determined that each appliance remain-
ing connected to the common venting system properly
vents when tested as outlined above, return doors, win-
dows, exhaust fans, fireplace dampers, and any other gas-
burning appliance to their previous conditions of use.
ꢀ. Provide drain trap to remove any condensate.
Inspect existing chimney or vent before
installing boiler.Failure to clean or replace
perforated pipe or tile lining will cause
severe injury or death.
g. Any improper operation of the common venting system
should be corrected so the installation conforms with the
National Fuel Gas Code,ANSI Zꢀꢀ3.1-latest edition.When
resizing any portion of the common venting system, the
common venting system should be resized to approach
the minimum size as determined using the appropriate
tables in Part 11 in the National Fuel Gas Code, ANSI
Zꢀꢀ3.1-latest edition.
Do not alter boiler draft hood or place
any obstruction or non-approved damper
in the breeching of vent system. CSA
certification becomes void. Flue gas
spillage and carbon monoxide emissions
will occur causing severe personal injury
or death.
Canadian installations must comply with CAN/CSA
B149.1 or B149.ꢀ Installation Code.
Where two or more gas appliances vent into a common
chimney or vent, equivalent area should be at least equal
to the area of the vent outlet on the largest appliance
plus 50 percent of the area of the vent outlet on the ad-
ditional appliance(s).
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Boiler foundation
Placing the boiler
1. Remove boiler from shipping pallet. Do not drop boiler or bump
jacket on floor or pallet.
Never install boiler on combustible flooring or
carpeting, even if a concrete or aerated foundation
is used. Severe personal injury, death or substantial
property damage can result.
ꢀ. Level boiler so that the built-in air separation will work correctly.
Shim legs if necessary. Do not alter legs.
1. See Figure 1. A level concrete or solid brick pad is required if:
a) There is a possibility of the floor becoming flooded.
b) Non-level conditions exist.
3. Remove front jacket door and burner access panel. Unscrew access
panel screws, remove and discard shipping washers, and reinstall
screws.
4. Check for proper orifice sizing from charts below.
Proper orifices must be used. Failure to do so will
cause severe personal injury, death or substantial
property damage.
ꢀ. An aerated boiler foundation is recommended if any of the following
conditions exist:
a) Electrical wiring or telephone cables buried in the concrete floor
of the boiler room.
b) Concrete floor is “green.”
c) There is a history of the floor becoming flooded.
d) Water is channeled under the concrete.
5. Level and straighten the burners.
Burners must be seated properly in locating slots
with their openings facing up. Gas orifices must
inject down the center of the burner. Failure to
properly seat burners will result in severe personal
injury, death or substantial property damage.
Figure 1
Boiler foundation
6. Reinstall access panel.
Residential garage installation
Install boiler so burners are at least 18 inches above the floor.
Hydrostatic pressure test
Pressure test before attaching gas piping or electrical supply.
1. Plug any necessary boiler tappings or openings.
ꢀ. Connect water supply. Fill boiler and purge all air. Test at 45 psi for
more than 10 minutes.
Do not leave boiler unattended. A cold water
fill could expand and cause excessive pressure,
resulting in severe personal injury, death or
substantial property damage.
3. Check for maintained gauge pressure and leaks. Repair if found.
Leaks must be repaired at once. Failure to do so
can cause boiler damage, resulting in substantial
property damage.
Do not use petroleum-based sealing compounds in
boiler system. Severe damage to boiler will result,
causing substantial property damage.
4. Drain boiler and remove testing plugs.
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
4. Expansion tank installations.
Boiler piping connections to the heating
a) Closed type expansion tanks - connect from the ¾” N.P.T.
system (refer to piping diagrams, Page 7)
expansion tank tapping on the left end section (located just
behind the supply outlet tapping) to the expansion tank using
¾” N.P.T. piping. Any horizontal expansion tank piping must
pitch upward toward the tank at least 1 inch for each 5 feet of
piping.
Failure to properly pipe the boiler may result in
improper operation and damage to the boiler or
building.
These boilers are provided with built-in air elimination sys-
tems.
b) Diaphragm type expansion tank - may be located anywhere in
the system, preferably near the boiler.
1. Install relief valve vertically in top ¾” tapping in right end section.
See WARNING following.
A manual or automatic type air vent must be
installed in the ¾”N.P.T.tapping when a diaphragm
type tank is used.
To avoid water damage or scalding due to relief
valve operation:
The most common cause of lime deposits in boilers is inadequate
expansion tank volume. If the expansion tank is too small, system
water is lost from the relief valve and make-up water is added
through the fill valve. Eventual section failure will result.
5. Connect the system supply piping to the supply outlet tapping on
the left end of the boiler. See Figure ꢀa for minimum pipe size.
•
Discharge line must be connected to relief valve
outlet and run to a safe place of disposal. Terminate
the discharge line to eliminate possibility of severe
burns should the valve discharge.
•
•
•
Discharge line must be as short as possible and be
the same size as the valve discharge connection
throughout its entire length.
6. Connect the system return piping to the return tapping on the right
end of the boiler. See Figure ꢀa for minimum pipe size.
Discharge line must pitch downward from the valve
and terminate at least 6”above the floor drain where
any discharge will be clearly visible.
7. Install drain valve provided with boiler on left side. The installer
must provide a drain cock to drain the right (return) side of the
boiler and its connecting piping. The drain cock on the left side of
the boiler will not fully drain the right side.
The discharge line shall terminate plain,not thread-
ed, with a material serviceable for temperatures of
375 °F or greater.
8. Low water cut off:
a) Must be installed on any PFG boiler if the boiler is located above
radiation level.
•
•
Do not pipe the discharge to any place where freez-
ing could occur.
b) Must be installed on all PFG-8 boilers to meet ASME specifica-
tions (low water cut-off not supplied by Weil-McLain).
No shutoff valve shall be installed between the
relief valve and boiler, or in the discharge line. Do
not plug or place any obstruction in the discharge
line.
c) May be required by certain state, local or territorial codes or
insurance companies.
If a low water cut-off is required, use a control designed especially
for water installations. An electrode probe type low water cut-off
may be located in a tee in the supply line above the boiler.
•
•
Failure to comply with the above guidelines could
result in failure of the relief valve to operate, result-
ing in possibility of severe personal injury, death or
substantial property damage.
9. If the system is to be ASME inspected and approved, an additional
high temperature limit is needed. Purchase and install the control
in the supply outlet piping to the boiler.
Test the operation of the valve after filling and pres-
surizing system by lifting the lever. Make sure the
valve discharges freely. If the valve fails to operate
correctly, replace it with a new relief valve.
Figure 2a Minimum recommended pipe sizes
(Supply and return sizes refer to minimum size of
pipe connected to the boiler for 20°F temperature
drop between supply and return.)
ꢀ. Install pressure-temperature gauge in tapping provided in left end
section.
3. This boiler is for forced hot water circulation only.The circulator and
expansion tank must be selected and sized according to the design
requirements of the system.
a) Size and install circulator. Can be installed on supply or return
piping
b) Size expansion tank to handle the volume of water in the sys-
tem.
Part Number 550-110-641/0605
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Multiple zoning
Figure 2b Piping – Closed type expansion tank
1. Zone valves:
a) Refer to zone valve manufacturer’s literature for wiring
and application.A separate transformer is required to
power zone valves.
b) Provide balancing valves to adjust the flow so it is
about the same in each zone.
ꢀ. Circulators:
a) Zoning with circulators requires a relay for each cir-
cuit.
b) Install flow control valves to prevent gravity circula-
tion.
c) Provide balancing valves to adjust the flow so it is
about the same in each zone.
d) Size common return and supply piping for total flow
of all circulators.
Filling the system
1. Close manual air vents, drain cock, and automatic air vent,
if used.
Use circulators or zone valves in each circuit for multiple
circuit applications.
ꢀ. Fill to correct system pressure. Correct pressure will vary
with each application. Residential systems are often de-
signed for 1ꢀ pounds cold fill pressure.
3. Open automatic air vent one turn, if used.
Figure 2c Piping – Closed diaphragm type expansion tank
4. Air must be vented for the system. Air in the system can
interfere with water circulation and cause improper heat
distribution.
a) Open manual water feed valve.
b) Starting on the lowest floor, open the air vents one at
a time until water squirts out. Close vent.
c) Repeat with remaining vents.
d) Close manual water feed valve when correct boiler
pressure is reached.
5. To purge air from system, install isolation valve in return
piping.
a) Connect a garden hose to the purge valve located
above the isolation valve.
b) Close isolation valve. Open purge valve.
c) Open hand water feed valve and allow system to purge
all air. If system has more than one circuit, purge each
circuit separately by opening each balancing valve one
at a time.
Use circulators or zone valves in each circuit for multiple
circuit applications.
d) Close purge valve.
e) Open isolation valve.
f) Fill the system to the correct pressure.
6. Keep the system filled by occasionally opening the air
vents as in Step 4 above. Add water to make up system
pressure.
Part Number 550-110-641/0605
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Bypass piping
Figure 3
Bypass piping is not normally required on
any baseboard system.
Bypass piping should be used for the following instal-
lations. (Bypass, supply, and return piping should be
same size.)
1. Use the piping shown in Figure 3 to protect:
•
radiant panels, plaster, etc. from high temperature
water supplied from boiler, or
•
boiler from condensation caused by low temperature
water returned from system.
ꢀ. Use the piping shown in Figure 4 to protect boiler from
condensation formed by low water temperature returned
from large water content converted gravity systems, etc.
Figure 4
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
External heat exchangers
The PFG boiler can be used with a storage tank/heat exchanger unit for
domestic hot water. The boiler/tank combination should be installed and
wired in accordance with the tank manufacturer’s instructions, which will
also show any additional components required. A zone valve or separate
circulator must be installed to regulate the production of hot water.
Freeze protection
Use antifreeze especially made for hydronic systems. Inhibited propylene
glycol is recommended.
Do not use automotive,ethylene glycol or undiluted antifreeze.
Severe personal injury, death or substantial property damage
can result.
50% solution provides protection to about -30°F
Local codes may require a back-flow preventer or actual disconnect from
city water supply.
Determine quantity according to system water content. Boiler water content
is listed on page ꢀ3.
Follow antifreeze manufacturer’s instructions.
Using with refrigeration system
The boiler must be installed so that chilled medium is piped in parallel with
the heating boiler with appropriate valves to prevent the chilled medium
from entering the boiler. Consult I=B=R Installation and Piping Guides.
If boiler is connected to heating coils located in air handling units where they
can be exposed to refrigerated air,gravity circulation during the cooling cycle
must be prevented with flow control valves or other automatic means.
Part Number 550-110-641/0605
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
If boileristobepropanefired,aconversion
Size and install gas piping
In sizing the gas piping, the following factors should
be considered.
kit must be used. Failure to use kit or to
properly install kit will result in severe
personal injury, death or substantial
property damage.
a) Diameter and length of the gas supply piping.
b) Number of fittings.
3. Remove jacket door and connect from gas valve to
gas meter. Use a street elbow or an elbow and close
nipple at the inlet connection of the gas valve to run
gas piping through opening in jacket side panel.
c) Maximum gas consumption (including any pos-
sible future expansion).
d) Allowable loss in gas pressure from gas meter out-
let to boiler. For pressure drops, see ANSI Zꢀꢀ3-1
latest edition.Canadian installations must comply
with CAN/CSA B149.1 or .ꢀ Installation Codes.
4. Follow good piping practices.
5. Pipe joint compound (pipe dope) must be resistant
to corrosive action of liquefied petroleum gases and
applied sparingly only to male threads of pipe joints.
1. Size natural gas piping from the following table. Piping
must be sized to provide proper inlet gas pressure to the
gas valve when boiler is operating at rated input. For
natural gas, inlet gas pressure to gas valve should be a
minimum of 5 inches water column and a maximum of 13
inches water column. If inlet natural gas pressure exceeds
13 inches water column, a 100 percent lock-up type gas
pressure regulator of adequate size must be installed in gas
supply piping and adjusted to prevent pressure in excess
of 13 inches water column.
6. A drip leg must be installed at inlet of gas connection to
boiler.Where local utility requires drip leg be extended
to the floor, use an appropriate length of pipe between
the cap and tee.
7. A ground joint union must be installed in the piping
to provide for servicing (see Figure 5).
8. Install manual shut-off valve outside boiler jacket as
shown in Figure 5 when required by local codes.
9. Piping must be supported by hangers, not by the boiler
or its accessories.
To obtain cubic feet per hour, divide the input (Btu per
hour) by the heating value (Btu per cubic foot).
10. In Canada only - when manual main shut off valve is
used, it must be identified by installer.
11. Purge all air from the supply piping.
Pipe delivery schedule
Before starting the boiler, and during
initial operation, smell near the floor and
around the boiler for gas odorant or any
unusual odor. Remove boiler front door
and smell interior of boiler enclosure. Do
not proceed with startup if there is any
indication of a gas leak. Repair any leak
at once.
1ꢀ. Before placing boiler in operation, check boiler and its
gas connection for leaks.
a) If test pressure is less than 13.0 inches water column
then close manual main shut-off valve.
b) If test pressure is greaterthan 13.0 inches water column
then boiler and gas valve must be disconnected from
gas supply piping.
Do not check for gas leaks with an open
flame - use bubble test. Failure to do so
can cause severe personal injury, death or
substantial property damage.
ꢀ. PFG 6 thru 8 only (and no damper on PI boilers) - for
propane gas, inlet gas pressure to gas valve should be
11 to 13 inches water column. The gas pressure regula-
tor (furnished by the gas supplier) must be adjusted
to provide lock-up pressures not exceeding 13 inches
water column. Select the pipe size, tanks and regulators
as required.
PFG-8,as required byANSI Zꢀ1.13/CSA 4.9,is equipped
with a manual test valve as shown in Figure 5a. Close
this valve to test boiler gas valve without supplying gas
to the manifold.
Part Number 550-110-641/0605
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Figure 5
Gas supply piping
Figure 5a Leak test valve (model PFG-8 ONLY)
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Draft hood installation
Wiring
Secure the draft hood to the outlet at the top of the boiler
with sheet metal screws. The bottom of the draft hood
or“skirt”must have the clearance dimension above the
jacket top panel as indicated on the draft hood.
For your safety, turn off the electrical
power supply at the service entrance panel
before making any electrical connections
to avoid possible electrical shock hazard.
Do not alter draft hood. CSA design
certification becomes void. If draft hood
is altered, severe personal injury or death
will occur, resulting from flue gas spillage
or carbon monoxide emissions.
All wiring must be installed in accordance with re-
quirements of the National Electrical Code and any
additional national, state or local code requirements
having jurisdiction. All wiring must be N.E.C. Class 1.
The boiler must be electrically grounded in accordance
with the National Electrical Code, ANSI/NFPA No. 70-
latest edition.
In Canada, all wiring must be done in accordance with
the CSA Cꢀꢀ.1 Canadian Electrical Code Part 1.
Iforiginalrolloutthermalfuseelementwireassuppliedwith
PFG-5 boiler must be replaced, type ꢀ00°C wire or
equivalent must be used. If other original wire as sup-
plied with any PFG boiler must be replaced, type 105°C
wire or equivalent must be used.
The boiler is shipped with control components com-
pletely wired except for spill switch and damper (if
provided).
A separate electrical circuit should be used for the
boiler with a fused disconnect switch (15 amp. recom-
mended).
Refer to wiring diagram label affixed to the inside of
the jacket door. Bring electrical supply through proper
opening in the jacket left end panel and into the electri-
cal junction box. Wire electrical supply, circulator and
thermostat as shown on the wiring diagram.
For boilers equipped with control systems other than
constant burner pilot, refer to separate instructions for
application data.
Spill switch installation (PFG-5 ONLY)
Fasten spill switch to draft hood as shown on page ꢀ1.
Connect wires as shown on wiring diagram label located
inside boiler door.
Damper installation
If damper will be installed, see Control Supplement for
information.
Breeching erection
(Also refer to chimney or vent requirements, Page 4)
Connect from draft hood or damper outlet to chimney
or vent with same size as breeching. Where possible,
vertical venting to the outside from the draft hood or
damper outlet will offer best performance.Where hori-
zontal breeching is used, slope upward at least ¼ inch
per lineal foot toward the chimney or vent and support
with hangers to prevent sagging.
A minimum vertical height of 3 feet of
breeching before any elbow or horizontal
breeching is recommended to reduce
chances of flue gas spillage at the draft
hood. Long horizontal breechings,
excessive numbers of elbows or tees, or
other obstructions that restrict the flow
of combustion gas should be avoided.
Install room thermostat
Install room thermostat on an inside wall. Never install
where it will be influenced by drafts, hot or cold water
pipes, lighting fixtures, television, rays of the sun or
near a fireplace.
Breeching must not be connected to any portion of a
mechanical draft system that can operate under posi-
tive pressure.
Heat anticipator in thermostat must be set to match the
power requirements of the primary control to which it
is connected. Refer to wiring diagram on jacket door for
recommended heat anticipator setting with standard
equipment. Wire the thermostat as shown.
Part Number 550-110-641/0605
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Wiring multiple zones
Figure 6
Typical wiring – zoning with zone valves
Refer to zone valve manufacturer’s literature for wiring
and application. A separate transformer is required to
power zone valves. Zoning with circulators requires a
relay for each zone circulator.
Canadian installations – Chain &
s-hook
See illustration below.
The chain and s-hook should be installed
according to this instruction by a qualified
installer/service technician prior to boiler
installation. Please follow steps outlined
below for the installation of the chain and
s-hook.
1. Crimp one side of each s-hook to each end of the chain.
ꢀ. Remove the two screws that attach the transformer plate
to the junction box.
3. Remove the transformer relay assembly and drill a 1/8”
hole through the plate as shown below. Do not allow
drill shavings to fall into the boiler jacket or onto any
control.
4. Crimp the s-hook to the 1/8” hole in the transformer
plate. Crimp the other side of the chain to the junction
box lower flange as shown below.
5. Replace the transformer relay assembly on the junction
box and secure with the two screws removed in step ꢀ.
Figure 6
Chain and s-hook installation – Canadian installations only
Part Number 550-110-641/0605
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PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
b. For standing pilot systems: Turn gas knob to PILOT position
Check-out procedure
and extinguish pilot flame - Pilot gas flow should stop in less
than 3 minutes. Put system back into operation. See page 17.
Check off steps as completed.
High limit control set to design temperature requirements of the
system? Maximum high limit setting - ꢀ40 °F.
Check to make sure base insulation is secure. See "To inspect base
insulation," page 17.
❏
❏
❏
❏
❏
For multiple zones, flow adjusted so it is about the same in each
zone?
Boiler and heat distribution units filled with water?
❏
❏
❏
❏
Automatic air vent, if used, open one turn?
Thermostat heat anticipator is set properly? Refer to "Install room
thermostat," page 1ꢀ, and wiring diagram on jacket door.
Air purged from system?
Air purged from gas piping? Piping checked for leaks per page 10?
Boiler cycled with the thermostat? Raise to highest setting. Boiler
should go through normal start-up cycle. Lower to lowest setting.
Boiler should go off.
Follow operating/lighting instruction label on boiler for proper
start-up. Also refer to “To place in operation,” page 17.
❏
Measure gas input (natural gas only):
a. Operate boiler 10 minutes.
Are proper orifices installed? See page 5 for proper orifice size.
❏
❏
Proper orifices must be used.Failure to do so will cause
severe personal injury, death or substantial property
damage.
b. Turn off all other appliances served by the gas meter, including
gas stove, pilot lights and gas yard lights.
c. At natural gas meter measure time (in seconds) required to use
on cubic foot of gas.
Proper burner flame? Refer to "Check main burner
flames" and "Check pilot burner flame," page 17.
❏
d. Calculate gas input:
Test limit control: While burners are operating, move the indicator
❏
of the high limit control below actual boiler water temperature.
The burners should go off while the circulator continues to operate.
Raise the limit control above the boiler water temperature and the
burners should reignite.
e. Btuh calculated should approximate input rating on rating
label.
Check manifold gas pressure by connecting manometer to down-
stream test tapping on main gas valve. Manifold gas pressure for
natural gas should be 3 1/ꢀ inches water column and for propane
gas should be 10 inches water column.
Test any additional field-installed controls: If boiler has low water
❏
❏
❏
cut-off, additional high limit or other controls, test for operation as
outlined by manufacturer. Burners should be operating and should
go off when controls are tested.When controls are restored, burners
should reignite.
Several operating cycles observed for proper operation? If damper
is provided, see Control Supplement for check-out procedure.
To test ignition system shut-off device:
❏
a. For PI systems: Connect a manometer to outlet side of gas
valve. Start boiler, allowing for normal start-up cycle to occur
and main burners to ignite. With main burners on, manually
shut off gas supply at manual main shut-off gas valve. Burners
should go off. Open manual main shut-off gas valve. The ma-
nometer should confirm there is no gas flow. Pilot will relight,
flame sensing element will sense pilot flame and the main burn-
ers reignite.
Room thermostat set to desired temperature?
❏
❏
❏
Installation and Service Certificate on this page completed?
All instructions shipped with this boiler reviewed with owner or
maintenance person, returned to envelope and given to owner or
displayed near boiler?
Installation and Service Certificate
Boiler model __________________
Series __________
CP number ___________
Date installed _______________
o Installation instructions have been followed.
o Check-out sequence has been performed.
Measured Btuh input ____________
o Above information is certified to be correct.
o Information received and left with owner/maintenance person.
Installer ________________________
(company)
________________________________
(address)
______________________________
(phone)
_____________________________________
(installer’s signature)
Part Number 550-110-641/0605
14
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Section II: Service
Also Refer to Additional Instructions Shipped With The Boiler For
Specific Control Operation and Troubleshooting.
Verify Proper Operation After Servicing.
Your boiler should be inspected, cleaned
and, if necessary, adjusted once a year.
A qualified service agency should be
called.
Toavoidpersonalinjury,deathorproperty
damage, keep the boiler area clear and free
from combustible materials, gasoline and
other flammable vapors and liquids.
Do not block flow of air to boiler.
Incomplete combustion and carbon
monoxide emissions can cause severe
personal injury, death or substantial
property damage.
To avoid personal injury, before
servicing:
1. Disconnect electrical supply.
ꢀ. Shut-off gas supply.
Do not store sources of hydrocarbons (i.e.,
bleaches,cleaners,chemicals,sprays,paint
removers, fabric softeners, etc.) in boiler
area. This can contribute to shortened
boiler/vent system life.
3. Allow boiler to cool.
Labelallwirespriortodisconnectionwhen
servicing controls.Wiring errors can cause
improper and dangerous operation.
Handling ceramic fiber and fiberglass materials
respirators may be needed depending on the job site condi-
tions. Current NIOSH recommendations can be found on
html.NIOSH approved respirators,manufacturers,and phone
numbers are also listed on this web site.
This product contains fiberglass jacket insulation and
ceramic fiber materials in combustion chamber lining
or base panels in gas fired products. Airborne fibers
from these materials have been listed by the State
of California as a possible cause of cancer through
inhalation. The combustion chamber lining or base
insulation panels in this product contain ceramic
fiber materials. Ceramic fibers can be converted to
cristobalite in very high temperature applications. The
International Agency for Research on Cancer (IARC)
has concluded, “Crystalline silica inhaled in the form
of quartz or cristobalite from occupational sources is
carcinogenic to humans (Group 1).”:
•
Wear long-sleeved, loose fitting clothing, gloves, and eye
protection.
•
Apply enough water to the combustion chamber lining or base
insulation to prevent airborne dust.
•
•
Remove combustion chamber lining or base insulation from
the boiler and place it in a plastic bag for disposal.
Operations such as sawing, blowing, tear out and spraying
may generate airborne fiber
ditional protection. Bag for disposal.
concentration requiring ad-
Suppliers of fiberglass wool products recommend the
following precautions be taken when handling these
materials:
•
Wash potentially contaminated clothes separately from other
clothing. Rinse clothes washer thoroughly.
Precautionary measures
•
Avoid breathing fiberglass dust and contact with skin or
eyes.
NIOSH stated First Aid.
•
•
Eye: Irrigate immediately
Breathing: Fresh air.
•
Use NIOSH certified dust respirator (N95). This type of
respirator is based on the OSHA requirements for fiberglass
wool at the time this document was written. Other types of
Part Number 550-110-641/0605
15
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Suggested Minimum Service Schedule
for Qualified Service Technician Only
Beginning of each heating season:
1. Annual service call by a qualified service agency.
ꢀ. Check burners and flueways and clean if necessary. Reference“To clean boiler heating surfaces”and“To clean main
burners,” page 18.
3. Visually inspect base insulation. Reference “To inspect base insulation,” page 17.
4. Follow procedure “To place in operation,” page 17.
5. Visually inspect main burner flames. Refer to “Check main burner flames,” page 17.
6. Check pilot burner flame. Refer to page 17.
7. Visually inspect venting system for blockage, deterioration or leakage. Reference “Inspect venting system,”
page 18.
8. Check operation of low water cut-off, if used, and additional safety devices. Refer to manufacturer’s instruc-
tions.
9. Check that boiler area is free from combustible materials, gasoline and other flammable vapors and liquids.
10. Check for and remove any obstruction to the flow of combustion or ventilation air to the boiler.
11. Follow instructions on circulator to oil, if oil lubricated. Over oiling will damage the circulator. Water lubricated
circulators do not need oiling.
Daily during heating season:
1. Check that boiler area is free from combustible materials, gasoline and other flammable vapors and liquids.
ꢀ. Check for and remove any obstruction to the flow of combustion or ventilation air to the boiler.
Periodically during heating season:
1. Check relief valve. Reference manufacturer’s instructions on relief valve tag.
ꢀ. Test low water cut-off, if used. Blowdown if low water cut-off is float type. Reference manufacturer’s instruc-
tions.
Monthly during heating season:
1. Check for leaks in the boiler and piping. If found, repair at once.
Leaks must be repaired at once. Failure to do so can cause boiler damage, resulting in substantial
property damage.
Do not use petroleum-based sealing compounds in boiler system. Severe damage to boiler will result,
causing substantial property damage.
ꢀ. Visually inspect main burner flames. Reference “Check Main Burner Flames.”
3. Check pilot burner flame. Refer to page 17.
4. Visually inspect venting system for blockage, deterioration or leakage. Reference “Inspect venting system,”
page 18.
5. Check automatic air vent for leakage. If leaking, remove vent cap and push valve core in to wash off sediment that
may have accumulated on the valve seat. Release valve, replace cap, and open one turn.
End of each heating season:
1. Follow “Annual shut-down procedure,” page 18.
Part Number 550-110-641/0605
16
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
To inspect base insulation:
Check pilot burner flame:
1. Proper pilot flame
The boiler contains ceramic fiber and fiberglass materials.
Use care when handling these materials. See WARNING
above. Failure to comply could result in severe personal
injury.
a) Blue flame.
b) Inner cone engulfing pilot flame sensor.
c) Pilot flame sensor glows cherry red.
ꢀ. Improper pilot flame
Make sure base insulation is secure against base front and back panels. If
base insulation is damaged or displaced, do not operate boiler. Replace
or reposition insulation.
a) Overfired - flames large and lifting or blowing past pilot flame
sensor.
Failure to replace damaged insulation or reposition
insulation can result in a fire hazard, causing severe
personal injury, death or substantial property damage.
b) Underfired - flame small; pilot flame sensor not engulfed by
inner cone.
c) Lack of primary air - flame tip yellow.
d) Pilot flame sensor not heated properly.
To place in operation:
Figure 7
Typical pilot burner flame
1. Make sure boiler is filled with water.
ꢀ. Follow lighting/operating instructions on boiler.
PROPANE BOILERS ONLY – Your propane
supplier mixes an odorant with the propane to
make its presence detectable. In some instances, the
odorant can fade, and the gas may no longer have
an odor.
Propane gas can accumulate at floor level. Smell
near the floor for the gas odorant or any unusual
odor. If you suspect a leak, do not attempt to light
the pilot.
•
Use caution when attempting to light a propane
pilot. This should be done by a qualified service
technician, particularly if pilot outages are
common.
•
•
Periodically check the odorant level of your gas.
Inspect boiler and system at least yearly to make
sure all gas piping is leak-tight.
Check main burner flames:
1. Proper burner flame - Yellow-orange streaks may appear - caused
by dust.
•
Consultyourpropanesupplierregardinginstallation
of a gas leak detector. There are some products on
the market intended for this purpose. Your supplier
may be able to suggest an appropriate device.
ꢀ. Improper flame
a) Overfired - Flames large.
3. If boiler starts, go to Step 5. If boiler fails to start, go to Step 4.
4. If boiler fails to start, check for following conditions:
a) Loose connection or blown fuse?
b) Underfired - Flames small.
c) Lack of primary air - Yellow tipping on flames; sooting will oc-
cur.
b) High limit setting below boiler water temperature?
c) Thermostat setting below room temperature?
d) Gas not turned on at meter?
Figure 8
Typical main burner flame
e) Gas not turned on at boiler?
f) If above fails to eliminate the trouble, refer to Control Supple-
ment.
5. Make sure boiler goes through several normal operating cycles.
6. Turn thermostat or operating control to desired setting.
Part Number 550-110-641/0605
17
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Inspect venting system:
Annual shut-down procedure:
1. Check venting system at least once a month during heating season.
With boiler in operation (at least 5 minutes), hold a candle or match
below lower edge of draft hood “skirt.” If flame is undisturbed or
leans under skirt, vent system is functioning properly. If flame is
extinguished, flickers, or reduced while flame is pushed out side
skirt, the vent system must be checked for obstructions or other
causes of improper venting.
1. Follow lighting/operating instructions label on boiler.
ꢀ. DO NOT drain the system unless exposure to freezing
temperatures will occur. If antifreeze is used with system,
do not drain.
3. If the complete boiler and piping system must be drained
to avoid freezing, then a means must be provided for
draining water from BOTH ends of the boiler at or below
the level of the return tapping. A boiler drain cock is pro-
vided by Weil-McLain on the left side of the boiler only.
ꢀ. Inspect all parts of venting systems for deterioration from corrosion,
physical damage, sagging, etc. Correct all conditions found.
3. Verify damper, if used, is open when burner ignites. For additional
information, see Control Supplement.
To replace a boiler section
If replacing any section (see Figure 9):
To clean boiler heating surfaces
•
Approved RTV silicone sealant (Dow Corning 700 or
73ꢀ or G.E. 808 or 108) must be used to seal between
sections.
The boiler contains ceramic fiber and fiberglass materials.
Use care when handling these materials per instructions
on page 15 of this manual. Failure to comply could result
in severe personal injury.
•
Place ball bearings in the holes in the locator holes on
the sides of the sections to ensure section alignment and
reliable placement.
1. Follow shut-down procedure.
ꢀ. Remove breeching, draft hood and damper (when used).
Failure to use PFG Series 7 intermediates
or to properly seal sections per Figure
9 can cause flue gas spillage or carbon
monoxide emissions, resulting in severe
personal injury, death or substantial
property damage.
Remove jacket top panel. Turn back jacket insulation to expose col-
lector hood.
3. Remove collector hood. Clean excess boiler cement from collector
hood and cast iron sections.
4. Remove radiation plates.
5. Remove burners from base of boiler.Follow“To clean main burners,”
page 18, to thoroughly clean burners.
Figure 9
Section assembly
6. Place newspaper in base of the boiler to collect soot that will fall.
7. With a wire flue brush, clean between the sections.
8. Remove newspaper and soot.Vacuum or brush base and surrounding
area to remove soot.
9. Reinstall radiation plates.
10. Reinstall collector hood. Seal with boiler cement.
11. Reinstall insulation and jacket panel.
1ꢀ. Reinstall burners.
When reinstalling, burner tubes must be seated in their
locating slots with the openings facing up. Gas orifices
must inject down center of burner. Failure to properly
seat burner will result in severe personal injury, death or
substantial property damage.
13. Reinstall draft hood, damper (when used), and breeching.
14. Follow “To Place in Operation” procedure.
Excessive sooting indicates improper combustion of the
gas. Call a qualified service agency or your local gas utility
to check for proper combustion and make any necessary
adjustments.
To clean main burners:
1. Vacuum or brush burners to remove dust and lint.
When reinstalling, burner tubes must be seated in their
locating slots with the openings facing up. Gas orifices
must inject down center of burner. Failure to properly
seat burner will result in severe personal injury, death or
substantial property damage.
Part Number 550-110-641/0605
18
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Common problems and possible solutions
Part Number 550-110-641/0605
19
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Section III: Replacement Parts
The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials, per
instructions on page 15 of this manual. Failure to comply could result in severe personal injury.
To avoid personal injury, before replacing any parts on the boiler:
1. Turn off power.
ꢀ. Shut off gas supply.
3. Allow boiler to cool.
Item
1
Description
Part Number
Draft hood:
PFG-5 (7” x 7” dia x 24.45”)
PFG-6 (8” x 8” dia x 27.80”)
PFG-7 (9” x 9” dia x 31.05”)
PFG-8 (9” x 9” dia x 36.55”)
PFG-5
PFG-6
PFG-7
PFG-8
450-021-200
450-021-201
450-021-202
450-021-205
450-014-819
450-014-820
450-014-821
450-014-822
312-804-405
312-804-416
312-804-405
386-700-856
512-200-022
512-200-023
452-800-655
452-800-500
452-800-501
452-800-502
452-800-503
591-222-020
591-222-021
591-222-022
591-222-025
452-800-540
452-800-541
452-800-542
452-800-543
591-125-820
591-125-821
591-125-822
591-125-823
452-800-580
452-800-581
452-800-582
452-800-583
591-222-030
591-222-031
591-222-032
591-222-033
560-134-506
560-134-507
560-134-508
560-134-509
452-800-449
452-800-450
452-800-451
452-800-452
591-222-095
591-222-096
591-222-097
591-222-098
510-300-014
512-050-230
460-003-700
562-930-250
386-700-856
560-529-055
560-529-056
2
Collector hood:
3
4
5
NS
6
NS
7
Right hand end section, 51113
Intermediate section, 51125
Left hand end section, 51113
Section replacement kit (one per joint; 4 seals, 4 ball bearings, and sealant)
Burner, main
Burner, main with pilot bracket
Right hand/left hand base rail
Base front panel:
8
PFG-5
PFG-6
PFG-7
PFG-8
PFG-5
PFG-6
PFG-7
PFG-8
PFG-5
PFG-6
PFG-7
PFG-8
PFG-5
PFG-6
PFG-7
PFG-8
PFG-5
PFG-6
PFG-7
PFG-8
PFG-5
PFG-6
PFG-7
PFG-8
PFG-5 ⁵⁄₈”-11 UNC x 15”
PFG-6 ⁵⁄₈”-11 UNC x 18”
PFG-7 ⁵⁄₈”-11 UNC x 21”
PFG-8 ⁵⁄₈”-11 UNC x 24”
PFG-5
PFG-6
PFG-7
PFG-8
PFG-5
PFG-6
PFG-7
PFG-8
9
Front base insulation:
Base access panel:
Manifold:
10
11
12
13
14
15
16
Base back panel:
Back base insulation:
Tie rod without nut (2 per boiler):
Flue baffle:
Flue baffle insulation:
17
18
19
20
Spill switch, PFG-5 only
Rollout thermal fuse element, PFG-5 only
Radiation shield (2 per joint)
Section alignment ball bearings, 1/4” diameter (4 per joint)
Ball bearing kit (4 bearings)
Main burner orifice (natural gas) #37 drill
Main burner orifice (propane gas) 1.65 mm
NS
NS
Part Number 550-110-641/0605
ꢀ0
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Part Number 550-110-641/0605
ꢀ1
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Section IV: Ratings and dimensions
DOE
Standard equipment
•
•
•
•
•
•
•
•
Factory Fire Tested
•
•
Combination Pressure-Temperature Gauge
(shipped in separate carton)
Insulated Extended Jacket
Built-In Air Separator
Drain Valve (shipped in separate carton)
Draft Hood (Shipped in separate carton)
Combination Gas Valve
PIDN
•
•
Non-Linting Pilot Burner
Aluminized Steel Burners
Intermittent Electronic Ignition System
Automatic Vent Damper
Combination Relay Receptacle and 40 VA Trans-
former
PIN
•
•
•
•
•
•
Relay
Intermittent Electronic Ignition System
High Limit Control
SPN
•
•
Spill Switch (PFG-5 only)
Rollout Thermal Fuse Element (PFG-5 only)
Constant Burning Thermally Supervised Pilot System
Thermocouple
30 P.S.I. Relief Valve (shipped in separate carton)
(boiler sections tested for 50 P.S.I. water working
pressure)
Part Number 550-110-641/0605
ꢀꢀ
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
* Locate manual main Shut-Off Gas Valve (where required) according to local utility requirements.
Part Number 550-110-641/0605
ꢀ3
PFG SerieS 7 GaS-Fired Water Boiler — Boiler Manual
Part Number 550-110-641/0605
ꢀ4
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