Table of Contents
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EGH
EGH
EGH
EGH
EGH
Control Supplement
Control Supplement
Control Supplement
Control Supplement
Control Supplement
EGH-105 to EGH-125 Series 4
Natural gas
CSD-1 control system
‡ For
propane
boilers, install EGH propane conversion kit in addition to following the
instructions in this Control Supplement.
Gas-Fired Boiler
‡
Part No. 550-110-677/0299
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Table of Contents
Troubleshooting
Related Manuals for Weil-McLain EGH-105
Summary of Contents for Weil-McLain EGH-105
- Page 1 Control Supplement Control Supplement Control Supplement Control Supplement Control Supplement EGH-105 to EGH-125 Series 4 ‡ Natural gas CSD-1 control system ‡ For propane boilers, install EGH propane conversion kit in addition to following the instructions in this Control Supplement.
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Page 2: Table Of Contents
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 on EGH-105 to EGH-125 boilers only, specifically for: •... - Page 3 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 Part Number 550-110-677/0299 EGH-105 321-711-120 321-711-125 381-700-400 381-700-250 411-800-280 450-014-752 450-206-242 381-700-341...
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Page 4: Installation
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 Installation Place the boiler Refer to the following steps of Section I of the • • • • • • • Install gas train Connect gas train assembly to burner manifold: •... - Page 5 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.
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Page 6: Piping Connections
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 Piping connections Connect steam (water) piping to the boiler per Water boilers — make provision for mounting probe low water cutoff in the supply or return piping, above the top of the boiler. -
Page 7: Optional Heaters
CSD-1 control system — Natural gas Install boiler controls — 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. • • Plug all unused tappings. All piping and control connections must also comply with the Optional heaters —... -
Page 8: Gas Piping
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 Gas piping Size and connect gas supply piping per 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 side. -
Page 9: Troubleshooting
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. - Page 10 Wiring — water boilers Figure 5 Water boiler wiring — ladder and schematic diagrams ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE INJURY OR DEATH. DISCONNECT POWER BEFORE INSTALLING AND/OR SERVICING. NOTES: 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.
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Page 11: Schematic Wiring Diagram
TRANSFORMER 120/24 V.A.C. PLUG-IN DPST RELAY CIRCULATOR JUNCTION BOX CABLE (NOTE 9) WIRE NUTS (3) DAMPER 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 SCHEMATIC WIRING DIAGRAM MOMENTARY SWITCH IMPULSE RELAY TERMINAL BLOCK NOTE 10 CSD-1 control system —... - Page 12 Wiring — water boilers Figure 6 Control assembly — water boiler (CSD-1 is not availabe for water boilers with tankless heaters.) 677-02 Install strain relief bushings wherever electrical wiring passes through jacket. / P V / P V Vent connections — Connect with ¼"...
- Page 13 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 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 10 Damper harness...
- Page 14 Wiring — steam gravity return Figure 7 Water boiler wiring — ladder and schematic diagrams ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE INJURY OR DEATH. DISCONNECT POWER BEFORE INSTALLING AND/OR SERVICING. NOTES: 1. ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH: A.
- Page 15 SWITCH (BY OTHERS) TRANSFORMER 120/24 V.A.C. PLUG-IN DPST WIRE NUTS (2) RELAY JUNCTION BOX CABLE DAMPER 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 SCHEMATIC WIRING DIAGRAM MOMENTARY SWITCH IMPULSE RELAY TERMINAL BLOCK NOTE 10 CSD-1 control system —...
- Page 16 Wiring — steam gravity return Figure 8 Control assembly — steam, gravity return 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.
- Page 17 13a Pilot gas pressure regulator 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 CSD-1 control panel Ignition control Impulse relay and lighted push-button alarm silencing switch Terminal strip Transformer/relay Junction box Damper (optional)
- Page 18 Wiring — steam pumped return Figure 9 Water boiler wiring — ladder and schematic diagrams ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE INJURY OR DEATH. DISCONNECT POWER BEFORE INSTALLING AND/OR SERVICING. NOTES: 1. ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH: A.
- Page 19 SWITCH (BY OTHERS) TRANSFORMER 120/24 V.A.C. PLUG-IN DPST WIRE NUTS (2) RELAY JUNCTION BOX CABLE DAMPER 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 SCHEMATIC WIRING DIAGRAM MOMENTARY SWITCH IMPULSE RELAY TERMINAL BLOCK NOTE 10 CSD-1 control system —...
- Page 20 Wiring — steam pumped return Figure 10 Control assembly — steam, pumped return 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.
- Page 21 13a Pilot gas pressure regulator 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 CSD-1 control panel Ignition control Impulse relay and lighted push-button alarm silencing switch Terminal strip Transformer/relay Junction box Damper (optional)
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Page 22: Final Adjustments
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 Before proceeding: To place boiler in operation: Final adjustments 1. Follow EGH Manual including filling the boiler and skimming steam boilers. Skimming the boiler as described in Section VII of the... - Page 23 CSD-1 control system — Natural gas Final adjustments — operating instructions Figure 11 Operating instructions Part Number 550-110-677/0299...
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Page 24: Check-Out Procedure
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 VIII Check-out procedure — operation 1. Increase setting of room thermostat (or operating control) to call for heat. 2. Vent damper (if provided) will slowly open. When damper is fully open, the ignition 3. - Page 25 CSD-1 control system — Natural gas VIII Check-out procedure — leak test For your safety, turn off electrical power supply before making any electrical connections to avoid possible shock hazard. 1. Turn off power to the boiler and remove the (RED) wire from terminal TH of the main gas valve (Figure 12, item 1).
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Page 26: Before Troubleshooting
Open Closed Damper blade indicator Wrench or pliers Effikal damper 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 2. If Step 1 does not open damper, manually rotate 3. Do not leave damper permanently in this position. - Page 27 VIII Check-out procedure — troubleshooting TS-1: No Spark — System (boiler without vent damper) does not work Correct by making connections. 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.
- Page 28 5 on damper plug in control. Retest. boiler wiring harness. See figure below. Does boiler fire? Temporary jumper 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 Is damper harness securely plugged in at both ends? Is 24VAC present across transformer terminals C &...
- Page 29 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? Is 24VAC between terminals MV and MV/PV on ignition control? Replace ignition control.
- Page 30 Make sure pilot shutoff valve is open, 24VAC is present to pilot valve and pilot line is not kinked or obstructed. Check for clean pilot orifice. If OK, replace pilot gas valve. Replace pilot assembly. 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 Turn OFF supply voltage.
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Page 31: Service And Maintenance
CSD-1 control system — Natural gas Service and maintenance Complete Installation and Service Certificate in , Section IX. EGH Manual Follow EGH Manual , Section IX, for service and maintenance of boiler. Part Number 550-110-677/0299... -
Page 32: Replacement Parts
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 Replacement parts — water boilers Figure 14 Water boiler assembly Control Supplement / P V / P V Part Number 550-110-677/0299 677-12... - Page 33 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.
- 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 Replacement parts — steam boilers Figure 15 Steam boiler assembly Control Supplement / P V / P V Part Number 550-110-677/0299 677-13...
- Page 35 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.
- 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 Weil-McLain 500 Blaine Street Michigan City, IN 46360-2388 http://www.weil-mclain.com Part Number 550-110-677/0299...