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Weil-McLain EGH-105 manual

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Table of contents for the manual

  • Page 1

    Control Supplement Control Supplement Control Supplement Control Supplement Control Supplement EGH EGH EGH EGH EGH Gas-Fired Boiler EGH-105 t o EGH-125 Series 4 Natural gas ‡ P art No. 550-110-677/0299 CSD -1 control system ‡ For propane boilers, install EGH propane conversion kit in addition to following the instructions in this Control Supple[...]

  • Page 2

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 2 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 of the product. Indicat[...]

  • Page 3

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 3 Carton guide T able 1 Boiler car tons V erify that the correct car tons are av ailable bef ore beginning assemb ly . Note that the Base assembly and T rim & controls car tons for CSD-1 are special. The CSD-1 ignition control panel (in Base assemb ly car ton) consists of igniti[...]

  • Page 4

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 4 Installation I Place the boiler Refer to the EGH Manual. Read Section I and follow all of its guidelines. Complete the following steps of Section I of the EGH Manual: • Placing the boiler • Installati[...]

  • Page 5

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 5 Install optional vent damper (if supplied) If not instal ling a vent damper , proc eed 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. Only dampers listed in the Replaceme[...]

  • Page 6

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 6 P iping connections II Connect steam (water) piping to the boiler per EGH Manual Section II. W ater boilers — make pr ovision for mounting probe low water cut off in the supply or retur n piping, above [...]

  • Page 7

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 7 Install boiler controls — steam boilers III Figure 4 Steam boiler connections T able 3 Steam boiler connections 32¾" 23 / " 13 16 (W ater line) 13½" 11¾" 27 / " 5 8 16 / " 3 16 2/" 11 16 1 6/" 5 8 24" C T EG D Return Supply risers [...]

  • Page 8

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 8 Gas piping V Size and connect gas supply piping per EGH Manual , Section V . The gas supply can enter from either the right or left side of the jacket. Be sure the gas train is directed to the correct sid[...]

  • Page 9

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 9 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 . V ent damper [...]

  • Page 10

    P art Number 550-110-677/0299 10 o NOTES: TO COMPONENT MANUF ACTURER’S INSTR UCTIONS FOR APPLICA TION WIRING AND FOR MUL TIPLE ZONE SYSTEMS USING ZONE V AL VES OR CIRCULA TORS , REFER 5. THERMOST A T - FOR SINGLE ZONE SYSTEMS, THERMOST A T ANTICIP A TOR SETTING IS 0.40 AMPS . 4. REFER T O CONTROL COMPONENT INSTR UCTIONS P ACKED WITH BOILER FOR AP[...]

  • Page 11

    P art Number 550-110-677/0299 11 CSD-1 control system — Natural gas EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement NOTE 10 TERMINAL BLOCK 1 2 A 1 A 2 W JUNCTION BO X EQUIPMENT GROUND (BY OTHERS) (NOTE 7) CIRCULA T OR N (NOTE 9) W Y H SWITCH SER VICE C WIRE NUTS (3) W BK Y BK G Y G[...]

  • Page 12

    P art Number 550-110-677/0299 12 MV MV/PV PV ALARM ALARM 24 V 24 V (GND) SENSE SPARK MV MV/PV PV ALARM ALARM 24 V 24 V (GND) SENSE SPARK 677-02 1 2 3 4 5 6 10 8 9 11 12 14 15 15 16 17 18 19 20 24 21 25 21 22 23 7 V ent connections — Connect with ¼" tubing and run vent line outside building per code requirements. Install strain relief bushin[...]

  • Page 13

    P art Number 550-110-677/0299 13 CSD-1 control system — Natural gas EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement 1 CSD-1 control panel 14 Pilot shutoff valv e 2 Ignition control 15 Leak test v alv es with plugs 3 Impulse rela y and lighted push-b utton alarm silencing s witch 16[...]

  • Page 14

    P art Number 550-110-677/0299 14 o NOTES: TO COMPONENT MANUF ACTURER’S INSTR UCTIONS FOR APPLICA TION WIRING AND FOR MUL TIPLE ZONE SYSTEMS USING ZONE V AL VES OR CIRCULA TORS, REFER 5. THERMOST A T - FOR SINGLE ZONE SYSTEMS, THERMOST A T ANTICIP A T OR SETTING IS 0.40 AMPS. 4. REFER T O CONTROL COMPONENT INSTR UCTIONS P ACKED WITH BOILER FOR APP[...]

  • Page 15

    P art Number 550-110-677/0299 15 CSD-1 control system — Natural gas EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement NO TE 10 TERMINAL BLOCK 1 2 A 1 A 2 W JUNCTION BO X EQUIPMENT GROUND (BY O THERS) (NO TE 7) N H SWITCH SER VICE C WIRE NUTS (2) W BK G Y G BK BK D AMPER TO BK R TRANS[...]

  • Page 16

    P art Number 550-110-677/0299 16 MV MV/PV PV ALARM ALARM 24 V 24 V (GND) SENSE SPARK MV MV/PV PV ALARM ALARM 24 V 24 V (GND) SENSE SPARK 677-01 1 2 3 4 5 6 10 8 9 11 12 14 15 15 16 17 18 19 20 21 22 23 24 25 25 26 27 Install strain relief bushings wherev er electr ical wiring passes through jack et. 7 V ent connections — Connect with ¼" tub[...]

  • Page 17

    P art Number 550-110-677/0299 17 CSD-1 control system — Natural gas EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement 1 CSD-1 control panel 14 Pilot shutoff valv e 2 Ignition control 15 Leak test valves with plugs 3 Impulse rela y and lighted push-b utton alarm silencing s witch 16 G[...]

  • Page 18

    P art Number 550-110-677/0299 18 o NOTES: TO COMPONENT MANUF ACTURER’S INSTR UCTIONS FOR APPLICA TION WIRING AND FOR MUL TIPLE ZONE SYSTEMS USING ZONE V AL VES OR CIRCULA TORS, REFER 5. THERMOST A T - FOR SINGLE ZONE SYSTEMS, THERMOST A T ANTICIP A T OR SETTING IS 0.40 AMPS. 4. REFER T O CONTROL COMPONENT INSTR UCTIONS P ACKED WITH BOILER FOR APP[...]

  • Page 19

    P art Number 550-110-677/0299 19 CSD-1 control system — Natural gas EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement NO TE 10 TERMINAL BLOCK 1 2 A 1 A 2 W JUNCTION BO X EQUIPMENT GROUND (BY O THERS) (NO TE 7) N H SWITCH SER VICE C W BK G Y G BK BK D AMPER TO BK R TRANSFORMER 120/24 [...]

  • Page 20

    P art Number 550-110-677/0299 20 MV MV/PV PV ALARM ALARM 24 V 24 V (GND) SENSE SPARK 677-01-p 1 2 3 4 5 6 7 10 8 9 11 12 14 15 15 16 17 18 19 20 21 22 25 25 26 27 23 24 Install strain relief bushings wherev er electr ical wiring passes through jack et. V ent connections — Connect with ¼" tubing and run vent line outside building per code re[...]

  • Page 21

    P art Number 550-110-677/0299 21 CSD-1 control system — Natural gas EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement 1 CSD-1 control panel 14 P ilot shutoff v alv e 2 Ignition control 15 Leak test valv es with plugs 3 Impulse rela y and lighted push-b utton alarm silencing s witch 1[...]

  • Page 22

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 22 Final adjustments VII 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 t[...]

  • Page 23

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 23 Final adjustments — operating instructions VII Figure 11 Operating instructions[...]

  • Page 24

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 24 Check - out procedure — operation VIII Always follow boiler Operating instructions , Figure 11, when starting the boiler . F ailure to do so could r esult in sev ere personal injury , death or substant[...]

  • Page 25

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 25 Check - out procedure — leak test VIII 677-11 1 2 4 3 T o control panel Fo r your safety , turn off electrical power supply before making any electrical connections to avoid possible shock hazard. 1 . T urn off p owe r to the boiler and rem ove the (RED) wire from terminal TH o[...]

  • Page 26

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 26 Check - out procedure — troubleshooting VIII V erify proper operation after servicing Never jumper (bypass) any device except for momentary testing as outlined in T roubleshooting Char ts. Substantial [...]

  • Page 27

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 27 Check - out procedure — troubleshooting VIII VISU ALL Y CHECK — Is ground wire connected from GND (Burner) to ignition control mounting screw , and ground wire connected from transf or mer ter minal C to case ground? Correct by making connections . Is 24V A C present across t[...]

  • Page 28

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 28 Check - out procedure — troubleshooting VIII Is damper harness securely plugged in at both ends? Secure connections . Is 24V A C present across transf ormer ter minals C & Y ? Check f or open ther [...]

  • Page 29

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 29 Check - out procedure — troubleshooting VIII Set up microammeter to measure output current in flame sensor circuit as f ollows . a . Detach sense lead from ignition control. Attach negative lead from microammeter to sense terminal on ignition control. b . Attach positive lead t[...]

  • Page 30

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 30 Check - out procedure — troubleshooting VIII Are pilot valv e wir ing connections CORRECT and securely fastened? Connect securely to terminal PV on ignition control and terminal TR on main gas valve . [...]

  • Page 31

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 31 Service and maintenance IX Complete Installation and Service Certificate in EGH Manual , Section IX. Fol l ow EGH Manual , Section IX, fo r serv ice and maintenanc e of boiler .[...]

  • Page 32

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 32 Replacement parts — water boilers X Figure 14 W ater boiler assembl y MV MV/PV PV ALARM ALARM 24 V 24 V (GND) SENSE SPARK MV MV/PV PV ALARM ALARM 24 V 24 V (GND) SENSE SPARK 677-12 1 2 5 6 10 9 11 12 1[...]

  • Page 33

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 33 T able 5 W ater boiler replacement par ts Before r eplacing any parts on the boiler — T urn off power to boiler and shut off g as supply . Failure t o comply c ould result in sev ere personal injury , death or substantial propert y damage. Item Part description Boiler models Ve[...]

  • Page 34

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 34 Replacement parts — steam boilers X Figure 15 Steam boiler assembly MV MV/PV PV ALARM ALARM 24 V 24 V (GND) SENSE SPARK MV MV/PV PV ALARM ALARM 24 V 24 V (GND) SENSE SPARK 677-13 1 2 5 6 10 9 11 12 13 [...]

  • Page 35

    CSD-1 control system — Natural gas P art Number 550-110-677/0299 35 T able 6 Steam boiler replacement par ts Before r eplacing an y parts on the b oiler — T ur n off power t o boiler and shut off gas supply . Failure to c omply could result in sev ere personal injury , death or substantial propert y damage. Item Part description Boiler models V[...]

  • Page 36

    EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 EGH-105 to EGH-125 Control Supplement P art Number 550-110-677/0299 36 W eil-McLain 500 Blaine Street Michigan City , IN 46360-2388 http://www .weil-mclain.com[...]