Weil-McLain Evergreen EVG 110 User Manual

This manual must only be used by a qualifi ed heating installer/service technician. Read all instructions, including this manual and
all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in
severe personal injury, death or substantial property damage.
Part number 550-100-191/0917
®
• Installation
• Startup
• Maintenance
• Parts
Boiler Manual
CONDENSING GAS BOILER
70/110/155

Weil-McLain Evergreen EVG 110 Specifications

General

Model	Evergreen EVG 110
Boiler Type	Condensing
Fuel Type	Natural Gas or Propane
Input BTU/hr	110, 000
Efficiency	95% AFUE
Modulation Ratio	5:1
Heat Exchanger Material	Stainless Steel
Vent Type	Direct Vent
Water Content	1.5 gallons
Vent Diameter	2" or 3"
Water Connection Size	1-1/4" NPT
Minimum Vent Length	5 ft

Summary

Hazard Definitions

General Safety Warnings

Crucial safety warnings regarding installation, operation, and maintenance.

Important Safety Information

Please Read Before Proceeding

Essential pre-installation warnings and user information.

Boiler Operation Precautions

Guidelines for safe operation, including combustion air and carbon monoxide.

Water Chemistry Requirements

Boiler Hydrostatic Test

Install Pipe Fittings for Relief Valve and P/T Gauge

Fill and Pressure Test Procedure

Detailed steps for filling the system and performing the hydrostatic test.

Converting Boiler to Propane

Propane Operation Requirements

General requirements for converting to propane fuel.

Installing Propane Orifice (EVG 70)

Step-by-step guide for replacing the gas orifice for EVG 70 model.

Converting Boiler to Propane — EVG 110

Installing Propane Orifice (EVG 110)

Procedure for replacing the gas orifice for EVG 110 model.

Converting Boiler to Propane — EVG 155

Installing Propane Orifice (EVG 155)

Procedure for replacing the gas orifice for EVG 155 model.

Primary/Secondary System Piping - Single Boiler System (continued)

ZONE VALVE Zoning – Primary/Secondary

Install Relief Valve

Instructions for correctly installing the pressure relief valve.

Field Wiring

Connecting Terminals

Field Wiring (continued)

A. 120 VAC Power Supply – REQUIRED

Instructions for connecting the main 120VAC power supply.

C. 120 VAC to Boiler Circulator – REQUIRED

Instructions for wiring the boiler circulator.

E. System Supply and Return Temperature Sensors – REQUIRED

Installing and wiring system supply and return temperature sensors.

K. Proof of Closure (Flow Switch and/or CAD) – see ADVANCED Manual – OPTIONAL

M. 0–10 VDC Remote MODULATION Input – OPTIONAL

B. 120 VAC Outputs 1, 2 & 3 – As Needed for Systems

D. Inputs 1, 2 and 3 (tstats, end switches, etc.) – As Needed for Systems

F. Outdoor Temperature Sensor – REQUIRED unless Exempted

H. Low Water Cutoff – Standard Equipment

Installing and wiring the low water cutoff device.

L. 0–10 VDC Remote TARGET Input – OPTIONAL

Wiring Diagram — Schematic

Figure 60 Schematic Wiring Diagram

Schematic diagram illustrating all boiler wiring connections.

Wiring Diagram — Ladder

Figure 61 Ladder Wiring Diagram

Ladder diagram illustrating all boiler wiring connections.

Evergreen Control Operation

Evergreen Control Setup

Boiler Model, Altitude and Fuel Type Settings

Critical settings for correct boiler operation and safety.

Evergreen Control Operation (continued)

EVG Control Priorities & Input/Outputs

Managing system operation order using priorities and I/O assignments.

Outdoor Reset Operation

Figure 65 Evergreen Single Boiler Essential Settings

Required initial settings for single boiler configuration.

Setting Up the Boiler

Steps to configure the boiler for operation.

Remote Target Operation (0–10VDC Input)

Evergreen Control WIZARD

EXPRESS SETUP — Example A

Multi-zone SPACE HEATING (Circulators with circulator relays) | DHW (Direct-piped)

Example setup for space heating zones and direct-piped DHW.

EXPRESS SETUP — Example B

2- or 3- Zone SPACE HEATING (Circulators without circulator relays) | DHW (Direct-piped)

Example setup for heating zones using circulators and direct-piped DHW.

EXPRESS SETUP — Example C

Multi-zone SPACE HEATING (Zone valves + WMZV controller) | DHW (Direct-piped)

Example setup for zone valves and direct-piped DHW.

CONTRACTOR Menus

Figure 69 Evergreen Control Menu Access

Guide to accessing the contractor menus for boiler settings.

Boiler Settings Menu, BASIC Mode

Figure 70 Evergreen BASIC Mode Boiler Settings Options

Detailed explanation of the boiler settings menu options.

PRIORITY 1, 2, 3 Menus, BASIC Mode

Figure 71 Evergreen BASIC Mode Priority Options

Explanation of priority settings for system control.

ASSIGN INPUTS Menu, BASIC Mode

Figure 72 Evergreen BASIC Mode Assign Inputs Options

Guide to assigning inputs to priorities and system types.

DIAGNOSTIC Menu

Figure 75 Diagnostics Menu Navigation

How to navigate the diagnostics menu for system status.

DIAGNOSTICS Menu (continued)

Figure 76 Diagnostics Menu Navigation, Continued

Further navigation within the diagnostics menu for error logs.

Figure 77 Diagnostics Menu Details

Detailed explanations of diagnostic menu items and their meanings.

Figure 78 Diagnostics Menu Details (continued)

Further details on diagnostic menu items like run times and lockout histories.

Startup — Fill the System

Clean System to Remove Sediment

Procedure for flushing the system to remove debris before filling.

Antifreeze Requirements

Fill and Test Water System

Steps for filling the system and checking for leaks.

Startup — Fill the System (continued)

Freeze Protection (if used)

Use of X100 Inhibitor is REQUIRED

Mandatory use of Sentinel X100 inhibitor for boiler protection.

Startup — Final Checks

Check for Gas Leaks

Procedure for detecting and correcting gas leaks before startup.

Check Thermostat Circuits

Inspect/Fill Condensate System

Checking and filling the condensate trap and lines.

Startup — Final Checks (continued)

Final Checks Before Starting Boiler

Checklist of essential items before initiating boiler startup.

Throttle Screw Adjustment (EVG 70 ONLY)

Adjusting the throttle screw for EVG 70 combustion tuning.

Throttle Screw Adjustment (EVG 110 ONLY)

Adjusting the throttle screw for EVG 110 combustion tuning.

Throttle Screw Adjustment (EVG 155 ONLY)

Adjusting the throttle screw for EVG 155 combustion tuning.

If Boiler Does Not Start Correctly

Troubleshooting steps for common startup issues.

Check Heat Exchanger and Vent Seals

Inspecting seals for leaks using an inspection mirror.

Check System and Boiler

Check Flame & Combustion with Instruments

Performing combustion analysis for optimal performance.

Check-out/Startup Verification

Adjust and Test Boiler Controls

Verifying proper setup and operation of boiler controls.

Have the Following Been Done?

Checklist of completed installation and startup steps.

Annual Startup and General Maintenance

Service Technician Schedule

Tasks performed by a qualified service technician during annual startup.

Annual Startup

Handling Ceramic Fiber Materials

Safety precautions for handling ceramic fiber components.

First-Year Special Inspection

Recommended inspection procedures for the first year of operation.

Annual Startup (continued)

Address Reported Problems

Check Ignition Wiring

Check Flue Gas Temperature

Check Boiler Relief Valve

Inspecting and testing the boiler's pressure relief valve.

Flue Vent System and Air Piping

Check All Boiler Wiring

Reinstall Jacket Door After Servicing

Inspect Boiler Interior & Jacket Door Gaskets

Check Control Settings

Clean Condensate Trap

Procedure for cleaning the condensate trap assembly.

Check Expansion Tank(s)

Perform Startup and Checks

Executing startup procedures and tests specified in the manual.

Check All Piping for Leaks

Inspecting all water and gas piping for leaks.

Inspect Ignition Electrode

Checking and cleaning the ignition electrode.

Check Burner Flame

Inspecting the burner flame for proper appearance and adjustment.

Check Flame Signal

Check Blower Speeds

Troubleshooting

Verify Proper Operation After Servicing

Checks to perform after maintenance to ensure proper operation.

Before Troubleshooting –

Check the Following:

Troubleshooting (continued)

Check Control Fuses

Procedure for inspecting and replacing control fuses.

Control Fault Indications

Understanding fault displays and navigating diagnostic menus.

Figure 95 Troubleshooting Suggestions for EVG Boilers – EVG Control Error Condition Log

Troubleshooting error logs for EVG control.

Figure 97 Troubleshooting Suggestions for EVG Boilers – Fault Displays, Diagnostics and Corrective Actions

Troubleshooting fault displays and corrective actions.

Figure 98 Troubleshooting Suggestions for EVG Boilers – Fault Displays, Diagnostics and Corrective Actions

Troubleshooting fault displays and corrective actions.

Figure 99 Troubleshooting Suggestions for EVG Boilers – Fault Displays, Diagnostics and Corrective Actions

Troubleshooting fault displays and corrective actions.

Figure 100 Troubleshooting Suggestions for EVG Boilers – Fault Displays, Diagnostics and Corrective Actions

Troubleshooting fault displays and corrective actions.

Checking Temperature Sensors

Figure 96 Troubleshooting Suggestions for Evergreen® Boilers – Control Error Condition Log

Guidance on interpreting control error condition logs.

Maintenance

Disconnect Power

Safety procedure for disconnecting electrical power before maintenance.

Reinstall Boiler Jacket Door After Startup or Servicing

Start-up and Check/out

Cleaning the Heat Exchanger WATER SIDE, when required

Cleaning Heat Exchanger Flue Side, 70

Cleaning the EVG 70 Heat Exchanger FLUE SIDE or Accessing the Burner

Steps for cleaning the EVG 70 heat exchanger's flue side.

Cleaning Heat Exchanger Flue Side, 110

Cleaning the EVG 110 Heat Exchanger FLUE SIDE or Accessing the Burner

Steps for cleaning the EVG 110 heat exchanger's flue side.

Cleaning Heat Exchanger Flue Side, 155

Cleaning the EVG 155 Heat Exchanger FLUE SIDE or Accessing the Burner

Steps for cleaning the EVG 155 heat exchanger's flue side.

Remove and Inspect the Igniter Assembly

Remove Components to Allow Access

Inspect and Clean the Burner

Inspect Refractory and Replace Burner Gasket

Replacement Parts

Obtain Parts Only Through Weil-McLain

The Boiler Contains Ceramic Fiber Materials

Reinstall Jacket Door

Before Servicing or Making Connections

Safety precautions before performing any service or electrical connections.

Label Wires Before Removing

When Operating the Boiler on Propane Gas

Replacement Parts (continued)