Weil-McLain EGH-105 User's Manual
Contents
1. 23 24 25 26 27 Pilot shutoff valve Leak test valves with plugs Gas supply connection Burner manifold Limit control automatic reset Limit control manual reset Pressure gauge Siphons Gauge glass amp valves Probe LWCO manual reset Float LWCO control automatic reset Wire harness Pilot spark amp sense wires Pilot gas tubing EGH 105 to EGH 125 control Supplement CSD 1 control system Natural gas 6620 7 9 011 044 J8QUINN Hed LADDER WIRING DIAGRAM 120 V A C EQUIPMENT VI Wiring steam r pumped return SERVICE SWITCH GROUND NOTE 7 Figure 9 TRANSFORMER THERMOSTAT REL GOL Water boiler wiring oTo ladder and schematic diagrams OPERATING CONTROL mm o o FLOAT LWCO MANUAL RESET amp PUMP p ien bd PRESSURETROL PRESSURETROL CONTROL 1 0 4 2 CABLE TO FUSE DAMPER O 3 2K ELECTRICAL SHOCK HAZARD CAN CAUSE SEVERE SEE NOTE 10 MEA e INJURY OR DEATH DISCONNECT POWER 2K4 BEFORE INSTALLING AND OR SERVICING el NOTES N A R 1 ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH A U S A NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL STATE OR LOCAL CODE REQUIREMENTS B CANADA C S A C22 1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER 2K2 NATIONAL PROVINCIAL OR LOCAL CODE REQUIREMENTS 2 ALL CON2. PRESSURETROL EQUIPMENT OPERATING GROUND CONTROL NOTE 7 NOTE 9 THERMOSTAT OR EMCS NOTE 5 SERVICE SWITCH BY OTHERS r 21 H mC L 4 TRANSFORMER 120 24 V A C PLUG IN DPST WIRE NUTS 2 JUNCTION BOX FLOAT LWCO amp PUMP CONTROL EGH 105 to EGH 125 control Supplement CABLE TO DAMPER DAMPER CONNECTOR SCHEMATIC WIRING DIAGRAM l l l MOMENTARY SWITCH l l l 1 1 IMPULSE RELAY w R R LG R Tt T tH 1 Y R G R R TERMINAL BLOCK NOTE 10 PRE WIRED PANEL UNIVERSAL SPARK IGNITION CONTROL PILOT SOLENOID VALVE R 1 ALARM R ALARM Y G CSD 1 control system Natural gas PILOT NOTE 8 VI Wiring steam ER pumped return Figure 10 Control assembly steam pumped return When using a tankless heater NOTICE knockout the opening in the inner panel Locate the controls to allow room for the tankless heater piping The tankless heater temperature control not shown installs in the heater tapping 2 CC 7 Y Z N 0 76 660 19 011 099 J8QUINN Hed Install strain relief bushings wherever electrical wiring passes through jacket 677 01 p Vent connections Connect with 1 4 tubing and run
3. gel TERMINAL 5 21 BLOCK 120 24 V A C PLUG IN DPST PRE WIRED PANEL WIRE NUTS 2 c 2 NOTE 10 EG PILOT zz NOTE 8 DAMPER EGH 105 to EGH 125 control Supplement CSD 1 control system Natural gas 660 19 011 099 J8QUINN Hed VI Wiring steam gravity return Figure 8 Control assembly steam gravity return NOTICE When using a tankless heater knockout the opening in the inner panel Locate the controls to allow room for the tankless heater piping The tankless heater temperature control not shown installs in the heater tapping Install strain relief bushings wherever electrical wiring passes through jacket 677 01 Vent connections Connect with tubing and run vent line outside building per code requirements 6670 449 04 L 088 JequunN Hed LI 10 11 12 13 13a CSD 1 control panel Ignition control Impulse relay and lighted push button alarm silencing switch Terminal strip Transformer relay Junction box Damper optional Damper connector Dummy plug Damper harness Main gas valve Manual gas valve Pilot gas valve Pilot gas pressure regulator 14 15 16 17 18 19 20 21 22
4. No Yes lt Y Open thermostat or operating control contacts for 15 seconds Close thermostat contacts Is 24VAC across terminals PV amp MV PV G No Yes E voltage Retest Securely connect spark wire Then turn ON supply Turn OFF supply voltage Electrical shock hazard Failure to turn off power before proceeding could cause severe personal injury or death Replace pilot assembly Retest Is spark gap 0 125 and isolated in pilot gas stream No Yes Replace pilot assembly turn ON supply voltage Operate system several complete heat cycles Replace ignition control Retest Part Number 550 110 677 0299 Y Check spark wire Is it securely connected to spark transformer 4 No Yes Y Is condition of spark wire good not cut brittle burned or cracked 4 No Yes E Is spark electrode ceramic cracked No Yes Y Replace pilot assembly turn ON supply voltage operate system several complete heat cycles 27 EGH 105 to EGH 125 control Supplement VIII Check out procedure troubleshooting TS 2 No Spark System boiler with vent damper does not work Secure con
5. 312 041 32 heed CERO H 7 L Pressure temperature gauge 510 218 097 6 yo 59 5 Temperature limit control auto reset 510 312 209 Q TG he iG Gas supply connection right or left 8 1372 McDonnell amp Miller PS852M 24 WR Not shown probe LWCO Mount in supply or 511 114 530 Y l return piping above top of boiler 21h gt P P 24 Plug all tappings not used 6 Part Number 550 110 677 0299 CSD 1 control system Natural gas Install boiler controls steam boilers All water level controls must mount on the left end of the boiler Failure to do so could result in nuisance shutdowns and possible lockout on the manual reset control due to water level variations from end to end Substantial property damage could result from freezing due to loss of heat All controls must mount on left end of the boiler The correct tappings are available only on the left end section NOTICE Install steam trim components as required by CSD 1 latest edition See Figure 4 and Table 3 See also Figure 8 or Figure 10 for finished assembly CSD 1 requires two low water cutoffs one manual reset and two limit controls one manual reset as shown in the illustration For float type automatic reset only low water cutoffs other than those shown in this Supplement refer to EGH Manual for mounting and piping instructions Install a blowdown valve on any float type low water
6. Carton guide Table1 Boiler cartons Verify that the correct cartons are available before beginning assembly Note that the Base assembly and Trim amp controls cartons for CSD 1 are special The CSD 1 ignition control panel in Base assembly carton consists of ignition control module impulse relay and lighted push button switch mounted and wired on a panel base Carton Comments EGH 105 EGH 115 EGH 125 With tankless opening 321 711 120 321 711 130 321 711 140 Section assembly a Without tankless opening 321 711 125 321 711 135 321 711 145 Base assembly b CSD 1 381 700 400 381 700 402 381 700 404 Base panels 381 700 250 381 700 255 381 700 260 Jacket 411 800 280 411 800 290 411 800 300 Collector hood 450 014 752 450 014 753 450 014 754 Draft hood 450 206 242 450 206 243 450 206 244 Gravity return M amp M 67W 1 381 700 341 381 700 341 381 700 341 Float low water cutoff steam Pumped return M amp M 42 A 511 114 531 511 114 531 511 114 531 Vent damper optional c 381 800 446 381 800 447 381 800 447 Tankless heater optional Steam boilers only 386 700 350 386 700 350 386 700 350 Water CSD 1 or 381 700 406 381 700 406 381 700 406 Trim amp controls see below Steam CSD 1 gravity return or 381 700 408 381 700 408 381 700 408 Steam CSD 1 pumped return 381 700 410 381 700 410 381 700 410 Note a CSD 1 water boilers cannot be equipped with a tankless heater
7. red reset button on the CSD 1 control panel 4 Once pilot is proved the ignition control activates main gas valve Main burners will ignite and boiler will continue to fire until terminated by limit action or no call for heat Lockout modes In addition to lockout on flame sense failure the boiler may also experience lockout due to shutdown of a manual reset control NOTICE CAUTION The boiler is equipped with a manual reset limit control and a manual reset low water cutoff Should the limit control lockout it can only be reset by pressing the reset button on the control The manual reset probe low water cutoff can be reset after lockout by pressing the reset button on the control or by interrupting power momentarily Steam boilers Do not substitute another manual reset low water cutoff for the one specified and supplied with the boiler Other controls may not operate as intended and could cause serious operating problems or failures Troubleshooting Refer to Section VIII Check out procedure troubleshooting of this Supplement and to component manufacturer s literature supplied in the boiler manual envelope for further information on operating conditions GROUND Wiring water boilers y SWITCH CIRCULATOR VI LADDER WIRING DIAGRAM S Figure 5 Water boiler wiring ant RELAY COIL ladder and schematic diagrams e d 1K MANUAL M
8. voltage Is 24VAC between terminals MV and MV PV on ignition control WARNING Electrical shock hazard Failure to turn off power before proceeding could cause No Yes severe personal injury or death _Y Y Replace ignition control Make sure sense wire is not wrapped around any pipe or Retest accessories Y Y Is inlet gas pressure at least 5 0 W C and not over 14 Is sense wire securely attached to sense terminal and pilot W C assembly No Yes No Yes Y Y Correct and retest Contact gas supplier to correct Y Is sensing probe ceramic cracked m w No Yes Is main valve wiring secure at terminals Y No Yes Replace pilot assembly Retest Y Correct wiring Retest Replace valve Retest Is sense wire or sensing probe shorted out to metal surface e 7 No Yes Check for continuity of sense wire and condition of la insulation NOT OK OK Correct and retest Replace pilot assembly Does system have proper flame signal Retest Set up microammeter to measure output current in flame sensor circuit as follows a Detach sense lead from ignition control Attach negative lead from microammeter to sense terminal on ignition control b Attach positive lead to sense wire from pilot assembly c Disconnect main valve lead
9. 0 677 0299 CSD 1 control system Natural gas VIII Check out procedure leak test WARNING For your safety turn off electrical 9 Opensecond leak test valve Figure 12 item 4 and power supply before making any check for pressure See NOTICE below x 2 Mot 10 Moi leak test valve and remove 1 Turn off power to the boiler and remove the RED 11 Remove call for heat to boiler Turn off power to wire from terminal TH ofthe main gas valve the boiler Figure 12 item 1 Tape off terminal end of removed wire and restore power to the boiler 12 Remove hose barbs from leak test valves and replace plugs 2 Close manual gas valve Figure 12 item 2 13 Repl RED wire to terminal TH of Ive 3 Check that both leak test valves Figure 12 items 3 pa WEITEN VANE and 4 are closed Then remove plugs and insert 14 Open manual gas valve Figure 12 item 2 and 1 8 NPT hose barb fittings as shown in Figure 12 restore power to boiler 4 Attach a U tube manometer to first leak test valve NOTICE When checking for pressure at the Figure 12 item 3 leak test valves it is normal to find a 5 Open first leak test valve Figure 12 item 3 and 22 4 oe dd check for pressure See NOTICE at right opening the leak testvalye 6 Close first leak test valve Figure 12 item 3 and valve seat is leaking and should be remove manometer replaced 7 Attach manometer to second leak test valve Fig
10. 1 510 312 169 Note 1 Johnson damper assembly consists of M35BC actuator and Y15 vent pipe Replacement parts must be purchased through a local Weil McLain distributor When ordering specify boiler model and series and include description and number of replacement part Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation Refer to boiler manual for parts not listed above Part Number 550 110 677 0299 33 EGH 105 to EGH 125 control Supplement X Replacement parts steam boilers Figure 15 Steam boiler assembly 677 13 34 Part Number 550 110 677 0299 CSD 1 control system Natural gas Table 6 Steam boiler replacement parts Before replacing any parts on the boiler Turn off power to boiler and shut off gas supply Failure to comply could result in severe personal injury death or substantial property damage Item Part description Boiler models Vendor Vendor part number Nei Meta part number 1 Main burner EGH 105 125 Weil McLain See EGH Manual 2 Main burner with pilot bracket EGH 105 125 Weil McLain See EGH Manual 3 Pilot burner bracket not shown EGH 105 125 Weil McLain See EGH Manual Beckett Gas E48A 1 i EGH 105 12 11 330 1 4 Pilot burner not shown GH 105 5 S s nD Q90GE 1 511 330 166 5 Main gas valve EGH 105 12
11. 5 125 Weil McLain 10C321 591 391 795 m Honeywell PA 404 A 510 312 135 20 Limit control automatic reset EGH 105 125 White Rodgers PATEA 3 510 311 023 21 Limit control manual reset EGH 105 125 Honeywell L404C 1147 510 312 060 22 Probe LWCO manual reset EGH 105 125 McDonnell amp Miller PS852M 24 511 114 530 23a Float LWCO automatic reset EGH 105 125 McDonnell amp Miller 67W 1 511 114 494 23b Float LWCO pump control auto reset EGH 105 125 McDonnell amp Miller 42 A 511 114 531 Ametek P505K 10 218 04 24 Pressure gauge EGH 105 125 Winter E1437 510 218 045 25 Transformer relay EGH 105 125 Honeywell R8285D 5001 510 312 169 Note 1 Johnson damper assembly consists of M35BC actuator and Y15 vent pipe Replacement parts must be purchased through a local Weil McLain distributor When ordering specify boiler model and series and include description and number of replacement part Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation Refer to boiler manual for parts not listed above Part Number 550 110 677 0299 35 36 EGH 105 to EGH 125 control Supplement Weil McLain 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com Part Number 550 110 677 0299
12. 5 Robertshaw 7000DERHC S7C 511 044 287 6 Manual gas valve 1 NPT EGH 105 125 Watts FBV3 06 511 246 290 7 Leak test valve EGH 105 125 Key Gas 511 246 339 Honeywell V8046C 1014 i EGH 105 12 11 044 8 Pilot gas valve GH 105 5 Contes H91ABG 511 044 039 8a Pilot gas pressure regulator EGH 105 125 Maxitrol RV20VL 510 933 195 9 Pilot shutoff valve EGH 105 125 Conbraco 53 300 01 511 246 345 10 Pilot tubing alum 1 8 O D x 34 long EGH 105 125 Available at local supply house 11 Ignition control EGH 105 125 United Technologies 1003 615 511 330 086 12 Impulse relay EGH 105 125 Potter Brumfield S89R 11ABD1 24 510 350 226 Honeywell AML21CBA2AA i 11 624 13 Push button switch EGH 105 125 SE 221K11810 511 624 580 Honeywell AML51 C10R 11 624 581 14 Lens cover EGH 105 125 Eaton Controls 220PM02A 511 624 58 15 Light bulb EGH 105 125 TI available at local supply house 16 Wiring harness pumped return steam EGH 105 125 Weil McLain 591 391 888 Wiring harness gravity return steam EGH 105 125 Weil McLain 591 391 887 i RVGP KS 10BF EGH 105 ed OF KS 10 381 800 446 17 Vent damper assembly optional Johnson Controls Q35GP 2 note 1 not for use in Canada Effikal RVGP KS 12BF EGH 115 125 381 800 447 G Johnson Controls Q35GR 2 note 1 Effikal only RVGP 510 512 337 18 V EGH 105 12 Bv yent camper actuator TETT M35BE 1C 510 312 255 19 Vent damper harness EGH 10
13. ANUAL RESET RESET HIGH PROBE LWCO HIGH LIMIT LIMIT 2K o yo ELECTRICAL SHOCK HAZARD CAN CAUSE SEVERE e PNE De INJURY OR DEATH DISCONNECT POWER BEFORE INSTALLING AND OR SERVICING EE NOTE 10 NOTES 2K4 1 ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH el 29 U S A NATIONAL ELECTRICAL CODE AND OTHER NATIONAL STATE OR LOCAL SN e R e CODE REQUIREMENTS 2K3 B CANADA C S A C22 1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER NATIONAL PROVINCIAL OR LOCAL CODE REQUIREMENTS 2 2 2 ALL CONTACTS SHOWN WITHOUT POWER APPLIED OFF SHELF CONDITION 3 IF ORIGINALWIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED b TYPE 105 C OR IT S EQUIVALENT MUST BE USED PILOT SOLENOID 4 REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION VALVE INFORMATION LOW VOLTAGE FIELD 5 THERMOSTAT FOR SINGLE ZONE SYSTEMS THERMOSTAT ANTICIPATOR SETTING IS 0 40 AMPS HIGH VOLTAGE FIELD FOR MULTIPLE ZONE SYSTEMS USING ZONE VALVES OR CIRCULATORS REFER TO COMPONENT MANUFACTURER S INSTRUCTIONS FOR APPLICATION WIRING AND LOW VOLTAGE FACTORY MY THERMOSTAT ANTICIPATOR SETTING HIGH VOLTAGE FACTORY Udo EMCS FOR EMCS CONNECTION IN PLACE OF THERMOSTAT REFER TO EMCS INSTALLATION OPERATING MANUAL IGNITION CABLE PV ru TH TR D ALARM ALARM 24V 6 L W C O HIGH LIMITS WIRED IN SERIES D ROBERTSHAW GAS VALVE IGN
14. B EGH Gas Fired Boiler Control Supplement EGH 105 to EGH 125 Series 4 Natural gast CSD 1 control system t For propane boilers install EGH propane conversion kit in addition to following the instructions in this Control Supplement Part No 550 110 677 0299 Hazard definitions To the installer Contents EGH 105 to EGH 125 control Supplement Please read this page first The following terms are used throughout this Control Supplement to bring attention to the presence of hazards of various risk levels or to important information concerning the life ofthe product BST VIL ed L RI l he CAUTION NOTICE NOTICE 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 This Control Supplement must only be used by a qualified installer service technician Read these instructions completely before beginning the installation Failure to follow these instructions can cause severe personal injury death or substantial property damage This Control Supplement is for CSD 1 controls
15. EGH 125 control Supplement Installation Refer to the EGH Manual Read Section I and follow all of its guidelines Complete the following steps of Section I ofthe EGH Manual Placing the boiler Installation of optional water heaters steam boilers only including pages 13 14 Hydrostatic pressure test Installation of flue collector hood Installation of burner drawer assembly and front access panel and back base channel Jacket installation Draft hood installation Connect gas train assembly to burner manifold Apply pipe dope to 1 nipple for insertion into burner manifold coupling Figure 1 item 1 Insert and tighten nipple Pipelower half of ground joint union to the 1 nipple Figure 1 item 2 Knock out the jacket gas valve opening on the desired side of the boiler may be routed through either right or left side Place gas train in position either routed to the left as shown or to the right and tighten the ground joint union loosely Position the gas train assembly and tighten the union Connect vent lines routed to outside per code requirements to 14 tubing vent connections on main gas valve and pilot gas pressure regulator Figure 3 item 3 Connect pilot gas tubing s aluminum to adapter in pilot gas valve outlet Figure 1 item 4 Crimp connect two spade terminals provided to ends of pilot gas valve wires Figure 1 item 5 Install vent system and breeching per EGH Manual Section I If optional
16. H 105 125 Conbraco 53 300 01 511 246 345 10 Pilot tubing alum 1 8 O D x 34 long EGH 105 125 Available at local supply house 11 lgnition control EGH 105 125 United Technologies 1003 615 511 330 086 12 Impulse relay EGH 105 125 Potter Brumfield S89R 11ABD1 24 510 350 226 Honeywell AML21CBA2AA 105 12 11 624 13 Push button switch EGH 105 5 O m 224K11810 511 624 580 Honeywell AML51 C10R 105 11 624 581 14 Lens cover EGH 105 125 Eaton Controls 220PMO2A 511 624 58 15 Light bulb EGH 105 125 TI available at local supply house 16 Wiring harness water boilers EGH 105 125 Weil McLain 591 391 886 Effikal RVGP KS 10BF EGH 105 T 17 Vent damper assembly optional Johnson Controls Q35GP 2 note 1 not for use in Canada Effikal RVGP KS 12BF EGH 115 125 381 800 447 Johnson Controls Q35GR 2 note 1 Effikal only RVGP 510 512 337 1 V EGH 105 12 erm M35BE 1C 510 312 255 19 Vent damper harness EGH 105 125 Weil McLain 10C321 591 391 795 Honeywell L4080B 1311 20 Limi l i EGH 105 125 510 312 209 0 Limit control automatic reset White Rodgers 11B83 16 21 Limit control manual reset EGH 105 125 Honeywell L4006E 1000 510 312 041 22 Probe LWCO manual reset EGH 105 125 McDonnell amp Miller PS852M 24 511 114 530 Ametek 19998 23 Pressure temperature gauge EGH 105 125 ENEM USA 4104 2 1 2 1 40BM 510 218 097 24 Transformer relay EGH 105 125 Honeywell R8285D 500
17. H Manual Section IX Follow EGH Manual Section IX for service and maintenance of boiler Part Number 550 110 677 0299 31 EGH 105 to EGH 125 control Supplement X Replacement parts water boilers Figure 14 Water boiler assembly CU D 677 12 Part Number 550 110 677 0299 32 CSD 1 control system Natural gas Table 5 Water boiler replacement parts Before replacing any parts on the boiler Turn off power to boiler and shut off gas supply Failure to comply could result in severe personal injury death or substantial property damage Item Part description Boiler models Vendor Vendor part number Ve eran part number 1 Main burner EGH 105 125 Weil McLain See EGH Manual 2 Main burner with pilot bracket EGH 105 125 Weil McLain See EGH Manual 3 Pilot burner bracket not shown EGH 105 125 Weil McLain See EGH Manual Beckett Gas E48A 1 4 Pil h EGH 105 125 511 330 166 pe E Johnson Controls Q90GE 1 5 Main gas valve EGH 105 125 Robertshaw 7000DERHC S7C 511 044 287 6 Manual gas valve 1 NPT EGH 105 125 Watts FBV3 06 511 246 290 7 Leak test valve EGH 105 125 Key Gas 511 246 339 Honeywell V8046C 1014 Pil EGH 105 12 511 044 039 8 gas va ve er 2 Johnson Controls H91ABG 8a Pilot gas pressure regulator EGH 105 125 Maxitrol RV20VL 510 933 195 9 Pilot shutoff valve EG
18. IL THERMOSTAT 1K Water boiler wiring ladder and schematic diagrams MANUAL RESET PROBE LWCO ETE MANUAL RESET PRESSURETROL PRESSURETROL FLOAT LWCO 1K1 2K SEE NOTE 10 ELECTRICAL SHOCK HAZARD CAN CAUSE SEVERE n L UNS e INJURY OR DEATH DISCONNECT POWER ei o BEFORE INSTALLING AND OR SERVICING N A Ne NA Re 2K3 NOTES 1 ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH U S A NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL STATE OR LOCAL CODE REQUIREMENTS B CANADA C S A C22 1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER NATIONAL PROVINCIAL OR LOCAL CODE REQUIREMENTS n 2 ALL CONTACTS SHOWN WITHOUT POWER APPLIED OFF SHELF CONDITION 3 IF ORIGINAL WIRE AS SUPPLIED WITH THE APLIANCE MUST BE REPLACED SOLENOID TYPE 105 C OR IT S EQUIVALENT MUST BE USED VALVE 5 4 REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION INFORMATION LOW VOLTAGE FIELD hU 3 5 THERMOSTAT FOR SINGLE ZONE SYSTEMS THERMOSTAT ANTICIPATOR SETTING IS 0 40 AMPS HIGH VOLTAGE FIELD _ 2 TH FOR MULTIPLE ZONE SYSTEMS USING ZONE VALVES OR CIRCULATORS REFER z TO COMPONENT MANUFACTURER S INSTRUCTIONS FOR APPLICATION WIRING AND LOW VOLTAGE FACTORY 2 TR THERMOSTAT ANTICIPATOR SETTING 3 EMCS FOR EMCS CONNECTION IN PLACE OF THERMOSTAT REFER TO EMCS PIGH VOL
19. ITION CONTROL MODULE TERMINAL 0005000 H 7 9 DENOTES FIELD INSTALLED CHASSIS GROUND IGNITION CONTROL PANEL TERMINAL 24V G SENSE SENSOR TRANSFORMER TERMINAL SPARK IGNITION CONTROL PANEL LAMP IGNITOR 8 PILOT LEADWIRES ARE NOT FIELD REPLACEABLE REPLACE PILOT ASSEMBLY IF NECESSARY 9 CIRCULATOR NOT USED WITH GRAVITY HOT WATER 10 ALARM CONTACT RATINGS 15 AMP 250 VAC 550 225 026 0199 6620 7 9 011 044 J8QUINN Hed BOO 6620 7 9 011 044 J8QUINN Hed IT IMPULSE RELAY R R NOTE 6 7 MANUAL MANUAL EQUIPMENT HIGH RESET RESET GROUND LIMIT HIGH LIMIT PROBE i NOTE 7 BK I 1 9 e R y NOTE 5 SERVICE SWITCH BY OTHERS 221 Lou dd BK TRANSFORMER 120 24 V A C N w Y PLUG IN DPST w Y Whey amp 2 2 lt 2 eo CIRCULATOR JUNCTION BOX CABLE 9 TO WIRE NUTS 3 DAMPER EGH 105 to EGH 125 control Supplement SCHEMATIC WIRING DIAGRAM MOMENTARY SWITCH l R R l TH TR W I R AA v ROBERTSHAW u GAS VALVE BK w R w LE G R R G R TERMINAL BLOCK NOTE 10 PILOT SOLENOID VALVE UNIVERSAL SPARK IGNITION CONTROL C PRE WIRED PANEL CSD 1 control system Natural gas PILOT NOTE 8 660 19 011 099 J8QUINN Hed VI Wiring wa
20. Note b Base assembly includes burner tubes gas train components pilot assembly and control panel with ignition control Note c EGH vent dampers meet ASME CSD 1 requirements paragraph CF 210 c because they comply with ANSI Z21 13 Steam trim and control carton Gravity return Steam trim and control carton Pumped return Water trim carton Pressure limit control automatic reset Pressure limit control manual reset Probe low water cutoff manual reset Transformer relay Wire harness steam gravity return Crimp spade wire terminations ASME Relief valve Pressure gauge Gauge glass and valves Brass cross brass nipple bushings 3 and siphons 3 for mounting pressure controls and gauge Pressure limit control automatic reset Pressure limit control manual reset Probe low water cutoff manual reset Transformer relay Wire harness steam pumped return Crimp spade wire terminations ASME Relief valve Pressure gauge Gauge glass and valves Brass cross brass nipple bushings 3 and siphons 3 for mounting pressure controls and gauge Aquastat automatic reset Aquastat manual reset Probe low water cutoff manual reset Transformer relay Wire harness water Crimp spade wire terminations ASME Relief valve Pressure temperature gauge Part Number 550 110 677 0299 195 Place the boiler Install gas train Install vent breeching Figure 1 Gas train assembly EGH 105 to
21. TACTS SHOWN WITHOUT POWER APPLIED OFF SHELF CONDITION IF ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST REPLACED 21 PILOT TYPE 150 C OR IT S EQUIVALENT MUST BE USED SOLENOID 4 REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION INFORMATION 0 5 THERMOSTAT FOR SINGLE ZONE SYSTEMS THERMOSTAT ANTICIPATOR SETTING IS 0 40 AMPS LOW VOLTAGE FIELD FOR MULTIPLE ZONE SYSTEMS USING ZONE VALVES OR CIRCULATORS REFER pm TH TO COMPONENT MANUFACTURER S INSTRUCTIONS FOR APPLICATION WIRING AND HIGH VOLTAGE FIELD THERMOSTAT ANTICIPATOR SETTING TR EMCS FOR EMCS CONNECTION IN PLACE OF THERMOSTAT REFER TO EMCS LOW VOLTAGE FAG TORY EE INSTALLATION OPERATING MANUAL HIGH VOLTAGE FACTORY co 6 L W C 0 PRESSURE CONTROLS WIRED IN SERIES IGNITION CABLE ALARM D ALARM 7 9 DENOTES FIELD INSTALLED CHASSIS GROUND a ROBERTSHAW IGNITION CONTROL MODULE TERMINAL GAS VALVE 8 PILOT LEADWIRES ARE NOT FIELD REPLACEABLE REPLACE 24V G 2 PILOT ASSEMBLY IF NECESSARY O IGNITION CONTROL PANEL TERMINAL SENSE r gt 9 OPERATING CONTROL REQUIRED WITH TANKLESS HEATER SENSOR Q TRANSFORMER TERMINAL SPARK 10 ALARM CONTACT RATINGS 15 250 VAC oe IGNITOR 11 REMOVE JUMPER BAR BETWEEN TERMINAL H AND TERMINAL C 550 225 028 0399 IGNITION CONTROL PANEL LAMP ia 6620 7 9 011 044 Jequunw Hed 6I NOTE 6 MANUAL RESET PRESSURETROL
22. TAGE FACTORY py D INSTALLATION OPERATING MANUAL IGNITION CABLE lt ALARM 6 LW C O PRESSURE CONTROLS WIRED IN SERIES ALARM o um ROBERTSHAW 7 DENOTES FIELD INSTALLED CHASSIS GROUND IGNITION CONTROL MODULE TERMINAL GAS VALVE o 24V G 8 PILOT LEADWIRES ARE NOT FIELD REPLACEABLE REPLACE O IGNITION CONTROLPANEL TERMINAL SENSE zl PILOT ASSEMBLY IF NECESSARY SENSOR I O TRANSFORMER TERMINAL SPARK S 9 OPERATING CONTROL REQUIRED WITH TANKLESS HEATER IGNITOR 59 10 ALARM CONTACT RATINGS 15 250 VAC 550 225 027 0199 IGNITION CONTROL PANEL LAMP EQUIPMENT GROUND NOTE 7 6620 7 9 011 044 Jequunw Hed SCHEMATIC WIRING DIAGRAM SI TRANSFORMER EEE 7 i SWITCH PILOT SOLENOID 8 VALVE NOTE 6 I AA E IMPULSE l ROBERTSHAW MANUAL RESET MANUAL RESET RELAY w GAS VALVE BK R PRESSURETROL PROBELWCO R TT UNIVERSAL SPARK PRESSURETROL FLOAT LWCO l R IGNITION CONTROL s 4 MV MV PV l OPERATING PV CONTROL GROUND 9 I R NOTE 7 1 ALARM R ALARM I THERMOSTAT X 24V OR EMCS Y 5 G SERVICE 24V GND SWITCH G R R BY OTHERS l SENSE
23. as Be sure to smell next to the floor because some cal a qualified service technician Force or attempted gas is heavier than air and will settle on the floor repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been under water Do not try to light any appliance Immediately call a qualified service technician to inspect Do not touch any electric switch do not use any phone in the appliance and to replace any part of the control system your building and any gas control which has been under water Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS STOP Read the safety information above on this label Setthe thermostat to lowest setting When equipped with Effikal vent damper Model RVGP place service switch in HOLD DAMPER OPEN position See Control Supplement for additional information Turn off all electric power to the appliance When equipped with Johnson vent damper Model M35 manually rotate damper blade in direction of arrow to OPEN position indicated on damper assembly See Control Supplement for additional information This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Turn gas control knob clockwise w to GAS CONTROL KNOB SHOWN IN ON POSITION When equipped with vent damper
24. at 2 Vent damper if provided will slowly open When damper is fully open the ignition control will open pilot gas valve and start spark DANGER Vent damper must be in open position when appliance main burners are operating If damper is not in open position flue products will spill into the building causing severe personal injury or death 3 Ifpilot lights and proves within 15 seconds the ignition control turns off the spark and opens the main gas valve dual valves in single body Main burners ignite NOTICE If pilot does not light and prove within 15 seconds the ignition control shuts off pilot gas and spark and waits 5 minutes It then will retry If the second ignition attempt fails the ignition control will lockout and close the alarm contact of the impulse relay 4 During main burner operation The ignition control monitors pilot flame current If signal is lost main valve is closed spark is activated and the operating sequence returns to step 3 If power is interrupted the control system shuts off pilot and main gas valves and restarts at Step 1 when power is restored 5 Stop the call for heat lower thermostat or operating control Pilot and main gas valves will close Damper if provided will close 6 Boiler is now in the off cycle 7 Repeat steps 1 through 6 several times to verify operation 8 Return thermostat or operating control to normal setting Part Number 550 11
25. burner and between main moisture resistant thermoplastic insulated wire with burner and burner rest 105 C minimum rating TS 4 Spark is present pilot will not light boiler with or without damper Are pilot valve wiring connections CORRECT and securely fastened No Yes Y Y Connect securely to terminal PV on ignition control and Is inlet gas pressure at least 5 0 W C and not over 14 terminal TR on main gas valve W C No Yes Y Is pilot shutoff valve open Y No Yes Is gas present at pilot burner assembly Y CAUTION Remove MV wire from ignition control Use a ilot shutoff val Contact gas supplier to match taped to a long screwdriver or pilot pilot shutott valve correct gas pressure lighter rod and manually light pilot No Yes Make sure pilot shutoff valve is open 24VAC is present to Y pilot valve and pilot line is not kinked or obstructed Check Is spark gap 0 125 and located in pilot gas stream for clean pilot orifice If OK replace pilot gas valve No Vee Replace pilot assembly lt Block any draft around boiler Check for clean pilot orifice 30 Part Number 550 110 677 0299 CSD 1 control system Natural gas IX Service and maintenance Complete Installation and Service Certificate in EG
26. cutoff as described in the EGH Manual Section III NOTICE Plug all unused tappings All piping and control connections must also comply with the EGH Manual IV Optional heaters steam boilers only Install optional tankless heater if used steam boiler only per EGH Manual Section IV Figure 4 Table 3 Steam boiler connections Steam boiler connections PE lt ene Tapping Application W M Part No lt 16 McDonnell amp Miller PS852M 24 M R T probe LWCO 511 114 530 Gr Supply Not used plug tapping i Drain connection per EGH manual o L E ASME relief valve per EGH manual S G Not used plug tapping 32 m Float LWCO automatic reset 23 47 l V H Gravity return McD M 67W 1 511 114 494 Water line A H Pumped return McD M 42 511 114 531 B Pressure gauge 510 218 045 ae 16 L Pressure limit automatic reset 510 312 135 Return Honeywell L404C 1147 M R limit 510 312 060 Y Y I s Skim tapping per EGH manual 510 312 209 2UAS lt Gas supply connection right or left lt 24 gt 22 Plug all tappings not used Part Number 550 110 677 0299 EGH 105 to EGH 125 control Supplement V Gas piping Size and connect gas supply piping per EGH Manual Section V Support gas line securely Do not support we
27. e figure below Does boiler fire Replace ignition control Retest to No Yes 2 gt Temporary 1 Replace damper jumper 40 5 60 actuator Retest 28 Turn OFF supply voltage Electrical shock hazard Failure to turn off power before proceeding could cause Severe personal injury or death Securely connect Check spark wire Is it securely and turn ON supply lt connected to ignition control voltage Retest No Yes Is condition of spark wire good Replace pilot not brittle burned or cracked assembly Retest Yes Is spark gap 0 125 and located in pilot gas stream Is spark electrode ceramic cracked 1 No Yes No Yes Y Y Replace pilot gt Replace ignition Replace assembly control Retest pilot assembly Turn ON supply voltage and operate system several complete cycles Part Number 550 110 677 0299 CSD 1 control system Natural gas VIII Check out procedure troubleshooting TS 3 Pilot lights Main valve will not come on boiler with or without damper Does spark stay on for more than a few seconds after pilot is established No Yes Y Turn OFF supply
28. e vent pipe and the draft hood must not interfere with rotation of the damper blade Install damper harness between damper actuator and knockout in right top of boiler jacket Knock out opening in jacket top and install strain relief bushings in jacket Figure 2 Vent damper assemblies Effikal damper and actuator wiring openings Insert wires and secure strain relief clamps See Figure 6 8 or 10 as applies Keep wiring harnesses clear of all hot surfaces CAUTION WARNING LINE UP KEYWAY WHEN CONNECTING PLUGS FORCING A MISMATCH CAN CAUSE A HAZARDOUS CONDITION Read and apply the harness plug warning label above so that it is visible after installation Remove dummy plug from damper connector in boiler wiring harness Plug damper harness receptacle into damper harness plug See Figure 6 8 or 10 as applies DANGER By passing jumpering damper will cause flue products such as carbon monoxide to escape into the house This will cause severe personal injury or death After boiler has operated once if either end of harness is disconnected the system will shut down The boiler will not operate until the harness is reconnected CAUTION Johnson Controls damper Damper blade indicator Hold open switch Effikal only Install damper so that switch is visible and accessible to user Part Number 550 110 677 0299 677 05 EGH 105 to EGH 125 control Supplem
29. ent II Piping connections Connect steam water piping to the boiler per EGH Manual Section II Water boilers make provision for mounting probe low water cutoff in the supply or return piping above the top of the boiler The low water cutoff must be between the boiler and any isolation valve s III Install boiler controls water boilers The controls may be mounted on either end of the boiler Mount all controls on the same end The junction box electrical entrance must also be mounted on the same end as the controls NOTICE Install the probe low water cutoff in the supply or return piping above the top of the boiler The low water cutoff must be mounted between the boiler and any isolation valve s installed in the piping Install water trim components as required by ASME CSD 1 latest edition See Figure 3 and Table 2 for controls required and tapping usage See Figure 6 for finished assembly Plug all unused tappings All piping and control connections must also comply with the EGH Manual Figure 3 Table 2 Water boiler connections Water boiler connections 4 1 13 4 gt lt 275 Tapping Application W M Part No 167 16 D Boiler drain connection 6 Supply E ASME relief valve per EGH manual GL G Pipe to air vent or compression tank lt S H Honeywell L4006E 1000 M R limit 510
30. from terminal MV on ignition control d Repl ERES Energize the system Spark should ignite the pilot As soon as pilot is burning eplace ignition control microammeter should read at least 0 5 microamp for U T 1003 615 Retest Is flame current signal less than the minimum specified in d above T j No Yes Y Check for proper gas pressure clean pilot assembly tight mechanical and electrical connections Also check for proper system grounding per following page Part Number 550 110 677 0299 29 EGH 105 to EGH 125 control Supplement VIII Check out procedure troubleshooting TS 3 Pilot lights Main valve will not come on continued from previous page Turn OFF supply voltage WARNING Electrical shock hazard Failure to turn off power before proceeding could cause severe personal injury or death To check ignition system grounding instruction for continuation of TS 3 Pilot assembly and ignition control must share common 4 Check ground lead from GND Burner terminal ground with main burner Nuisance shutdowns are often ignition control to ignition control mounting screw and caused by poor or erratic ground from C on transformer to transformer case ground Make sure connections are clean and tight If wire is 4 Check for good metal to metal contact between pilot damaged or deteriorated replace with No 18 gauge burner bracket and main
31. ight of gas line off of boiler gas train The gas supply can enter from either the right or left side ofthe jacket Be sure the gas train is directed to the Purge air from gas piping and perform gas line and gas correct side connection leak test per Section V ofthe EGH Manual For your safety turn off electrical Use 105 C thermoplastic wire or equivalent if any power supply before making any original wire must be replaced except for pilot spark electrical connections to avoid and sense wires possible shock hazard A strain relief bushing and adapter Wiring procedure must be used at each point where 1 Mount all controls as directed in Section III of this wiring passes through the boiler Supplement Refer to the assembly illustration for jacket or control cases to protect the type of boiler installed Figure 6 8 10 wiring insulation 2 Mount the junction box supplied with the boiler on the inside left or right side of the jacket as shown Assembly illustrations and wiring in the assembly illustration using screws and nuts diagrams provided Mount the junction box on the same end of the boiler as the controls will be This Supplement contains three wiring diagrams and mounted associated assembly illustrations Refer to the 3 Attach the transformer relay to the junction box following ds applicable Mount the CSD 1 control panel on the jacket Water boilers Figures 5 and 6 interior panel as shown in the appr
32. n power to boiler 4 Using wrench or pliers on flat shaft section manually rotate damper blade until green light turns on Boiler will fire 5 Donotleave damper permanently in this position Replace actuator immediately If damper is left in open position boiler will not operate at published efficiencies See damper manufacturer s instructions packed with damper for additional information Figure 13 Temporary manual opening of vent damper refer also to vent damper manufacturer s instructions Part Number 550 110 677 0299 VIII CSD 1 control system Natural gas Check out procedure troubleshooting TS 1 No Spark System boiler without vent damper does not work Correct by making connections damage Check for open thermostat circulator relay operating control limit control or LWCO Check the CSD 1 control panel impulse relay and push button switch If limit controls or water level controls lockout on manual reset determine cause and correct condition Failure to do so could result in severe personal injury death or substantial property VISUALLY CHECK Is ground wire connected from GND Burner to ignition control mounting screw and ground wire connected from transformer terminal C to case ground Replace ignition control Retest G No Yes Y Is 24VAC present across terminals 24V and 24V GND
33. nections lt Is damper harness securely plugged in at both ends No Yes Check for loose wire connections or bad relay on Y transformer Is 24VAC present across transformer terminals C amp Y No Yes Check for open thermostat circulator relay operating c control limit control or LWCO Check the CSD 1 control inal I panel impulse relay and push button switch Is 24VAC present across terminal C and yellow wire on damper connector If limit controls or water level controls 4 No Em lockout on manual reset determine cause and correct condition Failure to do so could v result in severe personal injury death or substantial property damage Is damper rotated open No Yes Check for out of round stack section Does motor rotate v gt Is 24VAC present across terminals PV and MV PV No Yes gt Replace actuator Retest gt Is spark present now No Yes Y Open thermostat contacts for 30 seconds Damper will Retest Y rotate to closed position Close thermostat contacts Damper will rotate to open position Is 24VAC present across terminals PV and MV PV No Yes Check continuity of each wire in wiring harness to damper Does continuity exist for each wire No Yes Y Y Replace damper 2 Remove damper harness from wiring harness Retest boiler wiring harness TEMPORARILY install jumper between terminal 2 and terminal 5 on damper plug in boiler wiring harness Se
34. on EGH 105 to EGH 125 boilers only specifically for e Water boilers without tankless heater CSD 1 is not available for water boilers with tankless heater Steam boilers with or without tankless heater This document is only intended as a supplement to the EG PEG and EGH Series 4 Boiler Manual referred to in this Supplement as the EGH Manual Follow all instructions in the EGH Manual in addition to the instructions in this Control Supplement The installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z 223 1 NFPA 54 latest edition Where required by the authority having jurisdiction the installation must conform to the American Society of Mechanical Engineers ASME Safety Code for Controls and Safety Devices for Automatically Fired Boilers Number CSD 1 Install tion u uu 4 Piping 2 2 2244 111221 6 Install boiler controls 2 6 Optional heaters eoe itin 7 Gas PP EN ee 8 Wiring vassere ee 8 Final 22 2 22 Check out procedure 22222 1 24 Service and maintenance 31 Replacement 1 1 32 Part Number 550 110 677 0299 CSD 1 control system Natural gas
35. opriate Steam boilers gravity return Figures 7 and 8 assembly illustration Figure 6 8 or 10 using screws and nuts provided Steam boilers pumped return Figures 9 and 10 5 Crimp connect 1 4 spade terminals provided to the pilot gas valve wires if not already done in General prot gas y Section I of this Supplement Refer to EGH Manual Section VI for further 6 Ifoptional vent damper is installed make sure information damper harness has been routed through a strain relief bushing in the jacket and damper actuator as directed in Section I of this Supplement Secure damper harness conduit to top of jacket with All wiring must be installed in accordance with the requirements of the National Electrical Code and any additional national state or local code requirements having jurisdiction All line voltage wiring external to clamps provided boiler jacket must be N E C class 1 7 The main gas valve wires are pre attached to the NEMPE CSD 1 control panel The spark and sense wires Provide a separate electrical circuit with a fused from the pilot are factory installed to the pilot disconnect switch 15 amp recommended to supply Connect these wires as shown in the wiring the boiler Wiring to the boiler must be No 14 gauge or diagram heavier installed in conduit 8 Usethe wiring harness provided with the boiler to The boiler must be electrically grounded in accordance complete wiring ofthe remaining com
36. ponents with the National Electrical Code ANSI NFPA No 70 according to the appropriate wiring diagram and latest edition assembly illustration Part Number 550 110 677 0299 VI Part Number 550 110 677 0299 CSD 1 control system Natural gas Wiring sequence of operation General The following sequence of operation applies to all wiring diagrams in this Supplement both water and steam Call for heat On a call for heat from thermostat or operating control 1 Limit control and water level control contacts are assumed closed 2 Vent damper if provided will open 3 Ignition control checks for signal at pilot No signal should be present Ifno signal is sensed normal condition Pilot solenoid opens a b Pilotignition spark begins Pilot ignites d Pilot proves Ifa signal is sensed abnormal condition by the ignition control the control will lockout NOTICE On failure to establish pilot flame signal within 15 seconds the ignition control will turn off the pilot gas valve It will wait 5 minutes then retry for ignition If the second ignition attempt fails the ignition control will lockout and illuminate the red lockout light This will activate the alarm contact of the impulse relay providing an isolated contact closure across terminals Al and A2 of the CSD 1 control panel terminal strip The contact rating is 15 amps at 250VAC To reset the boiler push the
37. r substantial property damage 2 Inspect base insulation as instructed in Section VII ofthe EGH Manual 1 Follow Operating instructions Figure 11 to start boiler 2 Ifboiler starts correctly proceed with Check out procedure Section VIII of this Supplement 3 Ifboiler fails to start check D D DU d Loose connection or blown fuse Limit setting below boiler water temperature or steam pressure Thermostat below room temperature Manual reset device needs to be reset Gas not turned on at meter and boiler Incoming natural gas pressure less than 5 W 4 Ifabove fails to eliminate the trouble refer to Check out procedure troubleshooting in this Supplement Section VIII Part Number 550 110 677 0299 VII CSD 1 control system Natural gas Final adjustments operating instructions Figure 11 Operating instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance is equipped with an ignition device which If you cannot reach your gas supplier call the fire automatically fights the pilot Do not try to light the pilot by department hand C Use only your hand to turn the gas control knob Never use BEFORE OPERATING smell al around the appliance area tools If the knob will not turn by hand don t try to repair it for g
38. ructions only in case of no heat or damper actuator malfunction See Figure 13 1 Move damper service switch to HOLD DAMPER OPEN position Apply call for heat to boiler Damper blade should then rotate to open position and boiler will fire 677 14 Closed Damper blade indicator Wrench or pliers Effikal damper Johnson Controls damper 26 Check out procedure troubleshooting 2 IfStep 1 does not open damper manually rotate damper blade to open position using wrench or pliers on flat shaft between damper and actuator Figure 13 Boiler will fire Verify that damper service switch is in HOLD DAMPER OPEN position 3 Donotleave damper permanently in this position Replace actuator immediately If damper is left in open position boiler will not operate at published efficiencies See damper manufacturer s instructions packed with damper for additional information Johnson damper Iftroubleshooting chart recommends replacing actuator and actuator is not immediately available damper blade can be fixed in an open position to allow boiler operation Follow these instructions only in case of no heat or damper actuator malfunction See Figure 13 1 Turn off power to boiler P Failure to turn off power to boiler WARNING can result in severe personal injury death or substantial property damage 2 Referto damper manufacturer s instructions for procedure to fix damper in open position 3 Turn o
39. ter boilers Figure 6 Control assembly water boiler CSD 1 is not availabe for water boilers with tankless heaters Install strain relief bushings wherever electrical wiring passes through jacket 677 02 Vent connections Connect with 1 4 tubing and run vent line outside building per code requirements 6670 449 04 L 088 JequunN Hed I 10 11 12 13 13a CSD 1 control panel Ignition control Impulse relay and lighted push button alarm silencing switch Transformer relay Junction box Damper optional Damper connector Dummy plug Damper harness Main gas valve Manual gas valve Pilot gas valve Pilot gas pressure regulator 14 15 16 17 18 19 20 21 22 23 24 25 Pilot shutoff valve Leak test valves with plugs Gas supply connection Burner manifold Limit control auto reset Limit control manual reset Pressure temperature gauge Wire harness Pilot spark amp sense wires Pilot gas tubing Circulator by others Probe LWCO Manual reset Mount in sup ply or return piping above top of boiler between boiler and any isolation valve s EGH 105 to EGH 125 control Supplement CSD 1 control system Natural gas LADDER WIRING DIAGRAM 120 V A C VI Wiring steam gravity return SERVICE SWITCH TRANSFORMER Figure 7 RELAY CO
40. ure 12 item 4 8 Apply call for heat to boiler and check that electronic pilot proves Figure 12 Leak test procedure Part Number 550 110 677 0299 25 EGH 105 to EGH 125 control Supplement VIII Verify proper operation after servicing Never jumper bypass any device except for momentary testing as outlined in Troubleshooting Charts 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 Before troubleshooting a Have a voltmeter that can check 120VAC 24VAC a microammeter with minimum scale range of 0 25 and continuity tester b Check for 120VAC minimum 102 maximum 132 to boiler Check for 24VAC at secondary side of transformer d Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Check for 24VAC between thermostat wire nuts and ground o In event of actuator failure Effikal damper Iftroubleshooting chart recommends replacing actuator and actuator is not immediately available damper blade can be fixed in an open position to allow boiler operation Manually turning blade can cause actuator damage Follow these inst
41. vent line outside building per code requirements 6670 449 04 L 088 JequunN Hed Ic 10 11 12 13 13a CSD 1 control panel Ignition control Impulse relay and lighted push button alarm silencing switch Terminal strip Transformer relay Junction box Damper optional Damper connector Dummy plug Damper harness Main gas valve Manual gas valve Pilot gas valve Pilot gas pressure regulator 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Pilot shutoff valve Leak test valves with plugs Gas supply connection Burner manifold Limit control auto reset Limit control manual reset Pressure gauge Siphons Gauge glass amp valves Probe LWCO manual reset Float LWCO pump control auto reset Wire harness Pilot spark amp sense wires Pilot gas tubing EGH 105 to EGH 125 control Supplement CSD 1 control system Natural gas 22 EGH 105 to EGH 125 control Supplement VII Before proceeding To place boiler in operation Final adjustments 1 Follow EGH Manual instructions for Final Adjustments Section VII including filling the boiler and skimming steam boilers Skimming the boiler as described in Section VII of the EGH Manual requires firing the boiler Always follow boiler Operating instructions Figure 11 when starting theboiler Failure to do so could result in severe personal injury death o
42. vent damper is used install vent damper using Section I ofthis Supplement before installing breeching 677 09 Part Number 550 110 677 0299 CSD 1 control system Natural gas Install optional vent damper if supplied If not installing a vent damper proceed to next section Piping connections Once a vent damper has been operated on an EGH boiler the boiler will no longer operate without a damper installed NOTICE Only dampers listed in the Replacement parts list in this Supplement are certified for use with EGH Series 4 boilers Any other damper installed could cause severe personal injury or death Minimum clearances Provide a minimum of6 between the damper and any combustible material Provide a minimum of 46 between EGH jacket top and a combustible ceiling 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 This will void AGA CGA certification and will not be covered by Weil McLain warranty Any changes will cause severe personal injury death or substantial property damage Install damper directly on top of draft hood with arrow pointing straight up Install so the damper blade indicator is visible to the user See Figure 2 Screws or rivets used to secure the damper to th
43. verify damper blade is in full open position See Control Supplement for additional information 2 POSITION Wait five 5 minutes to clear out any gas Then smell for gas including near HR REN NN INDICATOR the floor you smell gas STOP Follow B in the safety information above i 5 j on this label If you don t smell gas go to the next step G a 2 SV 10 Turn gas control knob counterclockwise KY to ON SUME JE A 11 Turn on all electric power to the appliance AS 12 When equipped with Effikal vent damper place service switch in AUTOMATIC OPERATION position 13 Set thermostat to desired setting 14 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier 15 Replace front panel TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 3 Turn gas control knob clockwise TN to OFF Do not force 2 Turn off all electric power to the appliance If service is to be performed 4 Replace front panel 550 223 045 1192 Part Number 550 110 677 0299 23 24 VIII EGH 105 to EGH 125 control Supplement Check out procedure operation Always follow boiler Operating instructions Figure 11 when starting the boiler Failure to do so could result in severe personal injury death or substantial property damage l Increase setting of room thermostat or operating control to call for he
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