Weil McLain Boiler EGH 105 User Manual

EGH  
Gas-Fired Boiler  
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.  
Part No. 550-110-677/0299  
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CSD-1 control system — Natural gas  
Carton guide  
Table 1 Boiler cartons  
Verify that the correct cartons are available before beginning assembly. Note that the Base assembly and Trim &  
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  
Without tankless opening  
CSD-1  
321-711-120  
321-711-125  
381-700-400  
381-700-250  
411-800-280  
450-014-752  
450-206-242  
381-700-341  
511-114-531  
381-800-446  
386-700-350  
381-700-406  
381-700-408  
381-700-410  
321-711-130  
321-711-135  
381-700-402  
381-700-255  
411-800-290  
450-014-753  
450-206-243  
381-700-341  
511-114-531  
381-800-447  
386-700-350  
381-700-406  
381-700-408  
381-700-410  
321-711-140  
321-711-145  
381-700-404  
381-700-260  
411-800-300  
450-014-754  
450-206-244  
381-700-341  
511-114-531  
381-800-447  
386-700-350  
381-700-406  
381-700-408  
381-700-410  
Section assembly (a)  
Base assembly (b)  
Base panels  
Jacket  
Collector hood  
Draft hood  
Gravity return (M&M #67W-1)  
Pumped return (M&M #42-A)  
Float low water cutoff (steam)  
Vent damper (optional) (c)  
Tankless heater (optional)  
Steam boilers only  
Water, CSD-1 — or —  
Trim & controls (see below)  
Steam, CSD-1, gravity return — or —  
Steam, CSD-1, pumped return  
Note a — CSD-1 water boilers cannot be equipped with a tankless heater.  
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  
Pressure limit control, automatic reset  
Pressure limit control, manual reset  
Probe low water cutoff, manual reset  
Transformer/relay  
Aquastat, automatic reset  
Aquastat, manual reset  
Probe low water cutoff, manual reset  
Transformer/relay  
Wire harness, steam gravity return  
Crimp spade wire terminations  
ASME Relief valve  
Wire harness, steam pumped return  
Crimp spade wire terminations  
ASME Relief valve  
Wire harness, water  
Crimp spade wire terminations  
ASME Relief valve  
Pressure gauge  
Pressure gauge  
Gauge glass and valves  
Gauge glass and valves  
Pressure/temperature gauge  
Brass cross, brass nipple, bushings (3) and Brass cross, brass nipple, bushings (3)  
siphons (3) for mounting pressure controls  
and gauge  
and siphons (3) for mounting pressure  
controls and gauge  
Part Number 550-110-677/0299  
3
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EGH-105 to EGH-125 Control Supplement  
I
Installation  
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  
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  
Install gas train  
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.  
Pipe lower 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 ¼" tubing vent  
connections on main gas valve and pilot gas pressure regulator (Figure 3, item 3).  
Connect pilot gas tubing (1/8" aluminum) to adapter in pilot gas valve outlet  
(Figure 1, item 4).  
Crimp connect two ¼" spade terminals (provided) to ends of pilot gas valve wires  
(Figure 1, item 5).  
Install vent/breeching  
Install vent system and breeching per EGH Manual Section I. If optional vent damper is used,  
install vent damper (using Section I of this Supplement) before installing breeching.  
Figure 1  
Gas train assembly  
5
2
1
4
3
677-09  
4
Part Number 550-110-677/0299  
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CSD-1 control system — Natural gas  
Install optional vent damper (if supplied)  
If not installing a vent damper, proceed to next section and actuator wiring openings. Insert wires and secure  
(Piping connections).  
strain relief clamps. See Figure 6, 8, or 10 as applies.  
Once a vent damper has been  
Keep wiring harnesses clear of all hot  
surfaces.  
operated on an EGH boiler,the boiler  
will no longer operate without a  
damper installed.  
WARNING  
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.  
LINE UP KEYWAY WHEN  
CONNECTING PLUGS.  
FORCING A MISMATCH  
CAN CAUSE A  
HAZARDOUS CONDITION.  
Minimum clearances — Provide a minimum of 6" 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.  
Keyway  
Key  
677-10  
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.  
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.  
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 the vent  
pipe and the draft hood must not interfere with rotation  
of the damper blade.  
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.  
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  
Effikal damper  
Johnson Controls damper  
Figure 2  
Vent damper assemblies  
Damper  
blade  
indicator  
Hold-open switch (Effikal only) —  
Install damper so that switch is  
visible and accessible to user.  
677-05  
Part Number 550-110-677/0299  
5
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EGH-105 to EGH-125 Control Supplement  
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.  
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  
11¾"  
275/8  
163/16"  
"
Tapping Application  
W-M Part No.  
D
E
G
H
L
Boiler drain connection  
Supply  
ASME relief valve (per EGH manual)  
Pipe to air vent or compression tank  
Honeywell L4006E-1000 M/R limit  
Pressure/temperature gauge  
E
G
L
510-312-041  
510-218-097  
510-312-209  
S
H
Not  
32¾"  
used  
V
S
V
Temperature limit control, auto reset  
Gas supply connection (right or left)  
McDonnell & Miller PS852M-24 M/R  
D
165/8  
"
13½"  
Return  
Not shown probe LWCO (Mount in supply or  
511-114-530  
return piping, above top of boiler)  
211/16"  
Plug all tappings not used.  
24"  
677-08  
6
Part Number 550-110-677/0299  
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CSD-1 control system — Natural gas  
III  
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.  
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 cutoff as described in  
the EGH Manual, Section III.  
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  
11¾"  
275/8  
163/16"  
"
Tapping Application  
W-M Part No.  
McDonnell & Miller PS852M-24 M/R  
T
511-114-530  
probe LWCO  
Supply  
risers  
C
D
E
G
Not used — plug tapping  
E
G
Drain connection (per EGH manual)  
ASME relief valve (per EGH manual)  
Not used - plug tapping  
L
S
Float LWCO, automatic reset —  
Gravity return — McD-M 67W-1  
Pumped return — McD-M 42-A  
Pressure gauge  
32¾"  
C
T
H
L
511-114-494  
511-114-531  
510-218-045  
510-312-135  
510-312-060  
510-312-209  
V
2313/16"  
H
D
(Water line)  
165/8  
"
Pressure limit, automatic reset  
Honeywell L404C-1147 M/R limit  
Skim tapping (per EGH manual)  
Gas supply connection (right or left)  
Plug all tappings not used.  
13½"  
Return  
S
V
211/16"  
24"  
677-07  
Part Number 550-110-677/0299  
7
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EGH-105 to EGH-125 Control Supplement  
V
Gas piping  
Size and connect gas supply piping per EGH Manual,  
SectionV.  
Support gas line securely. Do not  
support weight of gas line off of boiler  
gas train.  
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.  
Purge air from gas piping and perform gas line and gas  
connection leak test per Section V of the EGH Manual.  
VI  
Wiring  
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.  
Wiring procedure  
A strain relief bushing and adapter  
1. Mount all controls as directed in Section III of this  
Supplement. Refer to the assembly illustration for  
the type of boiler installed (Figure 6, 8 or 10).  
must be used at each point where  
wiring passes through the boiler  
jacket or control cases to protect  
wiring insulation.  
2. Mount the junction box supplied with the boiler on  
the inside left (or right) side of the jacket as shown  
in the assembly illustration (using screws and nuts  
provided). Mount the junction box on the same  
end of the boiler as the controls will be  
mounted.  
Assembly illustrations and wiring  
diagrams  
This Supplement contains three wiring diagrams and  
associated assembly illustrations. Refer to the  
following, as applicable:  
3. Attach the transformer/relay to the junction box.  
4. Mount the CSD-1 control panel on the jacket  
interior panel as shown in the appropriate  
assembly illustration (Figure 6, 8 or 10), using  
screws and nuts provided.  
Water boilers —Figures 5 and 6  
Steam boilers, gravity return — Figures 7 and 8  
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  
Section I of this Supplement.  
6. If optional vent damper is installed, make sure  
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  
clamps provided.  
7. The main gas valve wires are pre-attached to the  
CSD-1 control panel. The spark and sense wires  
from the pilot are factory installed to the pilot.  
Connect these wires as shown in the wiring  
diagram.  
8. Use the wiring harness provided with the boiler to  
complete wiring of the remaining components  
according to the appropriate wiring diagram and  
assembly illustration.  
General  
Refer to EGH Manual, Section VI for further  
information.  
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  
boiler jacket must be N.E.C. class 1.  
Provide a separate electrical circuit with a fused  
disconnect switch (15 amp recommended) to supply  
the boiler. Wiring to the boiler must be No. 14 gauge or  
heavier, installed in conduit.  
The boiler must be electrically grounded in accordance  
with the National Electrical Code, ANSI/NFPA No. 70,  
latest edition.  
8
Part Number 550-110-677/0299  
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CSD-1 control system — Natural gas  
VI  
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.)  
If no signal is sensed (normal condition):  
a. Pilot solenoid opens.  
b. Pilot ignition spark begins.  
c. Pilot ignites.  
d. Pilot proves.  
If a signal is sensed (abnormal condition) by the ignition control, the control will lockout.  
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 A1 and A2 of the CSD-1 control panel  
terminal strip. The contact rating is 15 amps at 250VAC.  
To reset the boiler, push the 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.  
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.  
Part Number 550-110-677/0299  
9
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LADDER WIRING DIAGRAM  
EQUIPMENT  
120 V.A.C.  
GROUND  
(NOTE 7)  
VI  
Wiring — water boilers  
SERVICE  
CIRCULATOR  
SWITCH  
1K2  
Figure 5  
R
C
TRANSFORMER  
Water boiler wiring —  
ladder and schematic diagrams  
RELAY COIL  
THERMOSTAT  
1K  
G
MANUAL  
RESET  
PROBE LWCO  
MANUAL  
RESET  
HIGH LIMIT  
HIGH  
LIMIT  
1K1  
Y
CABLE  
TO  
DAMPER  
FUSE  
3
5
4
2
6
1
3
5
4
2
6
1
2K  
ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE  
INJURY OR DEATH. DISCONNECT POWER  
BEFORE INSTALLING AND/OR SERVICING.  
SEE NOTE 10  
2K4  
A
NOTES:  
A
1
2
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.  
N/A  
R
2K3  
2K2  
B. CANADA - C.S.A. C22.1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER  
NATIONAL, PROVINCIAL OR LOCAL CODE REQUIREMENTS.  
1
2. ALL CONTACTS SHOWN WITHOUT POWER APPLIED-OFF SHELF CONDITION.  
3. IF ORIGINALWIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED,  
TYPE 105o C OR IT’S EQUIVALENT MUST BE USED.  
2K1  
PILOT  
SOLENOID  
VALVE  
4. REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION  
INFORMATION.  
LOW VOLTAGE FIELD  
HIGH VOLTAGE FIELD  
LOW VOLTAGE FACTORY  
HIGH VOLTAGE FACTORY  
IGNITION CABLE  
5. THERMOSTAT - FOR SINGLE ZONE SYSTEMS, THERMOSTAT ANTICIPATOR SETTING IS 0.40 AMPS.  
FOR MULTIPLE ZONE SYSTEMS USING ZONE VALVES OR CIRCULATORS, REFER  
TO COMPONENT MANUFACTURER’S INSTRUCTIONS FOR APPLICATION WIRING AND  
THERMOSTAT ANTICIPATOR SETTING.  
TH  
TR  
MV  
MV/PV  
PV  
EMCS - FOR EMCS CONNECTION IN PLACE OF THERMOSTAT, REFER TO EMCS  
INSTALLATION/OPERATING MANUAL.  
D+  
D
ALARM  
6. L.W.C.O., HIGH LIMITS, WIRED IN SERIES.  
ALARM  
24V  
ROBERTSHAW  
GAS VALVE  
IGNITION CONTROL MODULE TERMINAL.  
IGNITION CONTROL PANEL TERMINAL  
7.  
DENOTES FIELD INSTALLED CHASSIS GROUND.  
2
24V (G)  
8. PILOT LEADWIRES ARE NOT FIELD REPLACEABLE. REPLACE  
PILOT ASSEMBLY IF NECESSARY.  
SENSE  
SPARK  
SENSOR  
IGNITOR  
TRANSFORMER TERMINAL.  
9. CIRCULATOR NOT USED WITH GRAVITY HOT WATER.  
10. ALARM CONTACT RATINGS: 15 AMP @ 250 VAC.  
IGNITION CONTROL PANEL LAMP  
R
550-225-026/0199  
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SCHEMATIC WIRING DIAGRAM  
R
W
MOMENTARY  
SWITCH  
D+  
R
R
BK  
PILOT  
SOLENOID  
VALVE  
D
TR  
TH  
W
R
ROBERTSHAW  
GAS VALVE  
IMPULSE  
RELAY  
R
W
BK  
W
R
R
UNIVERSAL SPARK  
IGNITION CONTROL  
MV  
G
(NOTE 6)  
MV/PV  
PV  
MANUAL  
RESET  
HIGH LIMIT  
MANUAL  
RESET  
PROBE LWCO  
G
EQUIPMENT  
HIGH  
LIMIT  
R
GROUND  
(NOTE 7)  
R
BK  
BK  
BK  
ALARM  
ALARM  
24V  
Y
R
Y
THERMOSTAT  
OR EMCS  
BK  
R
Y
G
(NOTE 5)  
BK  
BK  
G
G
24V (GND)  
SENSE  
SERVICE  
SWITCH  
(BY OTHERS)  
Y
W
R
G
G
G
R
G
H
TERMINAL  
BLOCK  
C
R
SPARK  
BK  
G
BK  
BK  
A
A
2
1
2
1
TRANSFORMER  
120/24 V.A.C.  
N
PRE-WIRED PANEL  
W
O
W
PLUG-IN  
Y
Y
DPST  
Y
RELAY  
W
NOTE 10  
PILOT  
(NOTE 8)  
CIRCULATOR  
(NOTE 9)  
JUNCTION BOX  
WIRE NUTS (3)  
CABLE  
TO  
DAMPER  
EGH-105 to EGH-125 Control Supplement  
CSD-1 control system — Natural gas  
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VI  
Wiring — water boilers  
10  
7
Figure 6  
Control assembly — water boiler  
(CSD-1 is not availabe for water  
boilers with tankless heaters.)  
25  
MV  
MV/PV  
PV  
ALARM  
ALARM  
9
24  
V
2
24  
V
(GND)  
19  
SENSE  
ARK  
SP  
3
1
18  
20  
8
21  
4
21  
24  
15  
6
15  
5
12  
11  
22  
17  
13  
16  
23  
13a  
14  
Install strain relief bushings  
wherever electrical wiring  
passes through jacket.  
Vent connections — Connect  
with ¼" tubing and run vent  
line outside building per code  
requirements.  
677-02  
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1
2
CSD-1 control panel  
Ignition control  
14 Pilot shutoff valve  
15 Leak test valves with plugs  
16 Gas supply connection  
17 Burner manifold  
Impulse relay and lighted push-button alarm  
silencing switch  
3
5
6
7
8
9
Transformer/relay  
Junction box  
18 Limit control, auto reset  
19 Limit control, manual reset  
20 Pressure/temperature gauge  
21 Wire harness  
Damper (optional)  
Damper connector  
Dummy plug  
22 Pilot spark & sense wires  
23 Pilot gas tubing  
10 Damper harness  
11 Main gas valve  
24 Circulator, by others  
12 Manual gas valve  
13 Pilot gas valve  
Probe LWCO, Manual reset (Mount in sup-  
25 ply or return piping above top of boiler  
between boiler and any isolation valve(s).)  
13a Pilot gas pressure regulator  
EGH-105 to EGH-125 Control Supplement  
CSD-1 control system — Natural gas  
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LADDER WIRING DIAGRAM  
EQUIPMENT  
120 V.A.C.  
GROUND  
(NOTE 7)  
VI  
Wiring — steam  
SERVICE  
SWITCH  
gravity return  
R
C
TRANSFORMER  
G
Figure 7  
RELAY COIL  
1K  
THERMOSTAT  
Water boiler wiring —  
ladder and schematic diagrams  
OPERATING CONTROL  
MANUAL RESET  
PROBE LWCO  
MANUAL RESET  
1K1  
FLOAT LWCO  
PRESSURETROL PRESSURETROL  
Y
CABLE  
TO  
DAMPER  
FUSE  
3
5
4
2
6
1
3
5
4
2
6
1
2K  
SEE NOTE 10  
2K4  
A
ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE  
INJURY OR DEATH. DISCONNECT POWER  
BEFORE INSTALLING AND/OR SERVICING.  
A
1
2
N/A  
R
NOTES:  
2K3  
2K2  
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.  
1
B. CANADA - C.S.A. C22.1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER  
NATIONAL, PROVINCIAL OR LOCAL CODE REQUIREMENTS.  
2K1  
2. ALL CONTACTS SHOWN WITHOUT POWER APPLIED-OFF SHELF CONDITION.  
PILOT  
SOLENOID  
VALVE  
3. IF ORIGINAL WIRE AS SUPPLIED WITH THE APLIANCE MUST BE REPLACED,  
TYPE 105 oC OR IT’S EQUIVALENT MUST BE USED.  
4. REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION  
INFORMATION.  
LOW VOLTAGE FIELD  
HIGH VOLTAGE FIELD  
LOW VOLTAGE FACTORY  
HIGH VOLTAGE FACTORY  
IGNITION CABLE  
TH  
TR  
MV  
5. THERMOSTAT - FOR SINGLE ZONE SYSTEMS, THERMOSTAT ANTICIPATOR SETTING IS 0.40 AMPS.  
FOR MULTIPLE ZONE SYSTEMS USING ZONE VALVES OR CIRCULATORS, REFER  
TO COMPONENT MANUFACTURER’S INSTRUCTIONS FOR APPLICATION WIRING AND  
THERMOSTAT ANTICIPATOR SETTING.  
MV/PV  
PV  
EMCS - FOR EMCS CONNECTION IN PLACE OF THERMOSTAT, REFER TO EMCS  
INSTALLATION/OPERATING MANUAL.  
D
D
ALARM  
6. L.W.C.O., PRESSURE CONTROLS, WIRED IN SERIES.  
ALARM  
24V  
ROBERTSHAW  
GAS VALVE  
IGNITION CONTROL MODULE TERMINAL.  
7.  
DENOTES FIELD INSTALLED CHASSIS GROUND.  
2
24V (G)  
IGNITION CONTROL PANEL TERMINAL.  
8. PILOT LEADWIRES ARE NOT FIELD REPLACEABLE. REPLACE  
PILOT ASSEMBLY IF NECESSARY.  
SENSE  
SPARK  
SENSOR  
IGNITOR  
TRANSFORMER TERMINAL.  
9. OPERATING CONTROL REQUIRED WITH TANKLESS HEATER.  
10. ALARM CONTACT RATINGS: 15 AMP @ 250 VAC.  
IGNITION CONTROL PANEL LAMP  
R
550-225-027/0199  
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SCHEMATIC WIRING DIAGRAM  
R
W
MOMENTARY  
SWITCH  
R
R
D
D
BK  
PILOT  
SOLENOID  
VALVE  
R
TR  
TH  
W
(NOTE 6)  
ROBERTSHAW  
GAS VALVE  
IMPULSE  
RELAY  
MANUAL RESET  
PROBE LWCO  
BK  
MANUAL RESET  
PRESSURETROL  
W
R
W
R
R
UNIVERSAL SPARK  
IGNITION CONTROL  
PRESSURETROL  
FLOAT LWCO  
BK  
BK  
BK  
BK  
MV  
G
G
MV/PV  
PV  
OPERATING  
CONTROL  
(NOTE 9)  
EQUIPMENT  
R
GROUND  
(NOTE 7)  
R
ALARM  
ALARM  
24V  
Y
Y
Y
R
Y
THERMOSTAT  
OR EMCS  
BK  
Y
G
(NOTE 5)  
BK  
BK  
R
G
24V (GND)  
SENSE  
SERVICE  
SWITCH  
(BY OTHERS)  
Y
W
G
R
G
R
G
G
G
H
TERMINAL  
BLOCK  
C
R
SPARK  
BK  
G
BK  
A
A
2
1
2
1
TRANSFORMER  
120/24 V.A.C.  
N
PRE-WIRED PANEL  
W
PLUG-IN  
O
W
Y
DPST  
WIRE NUTS (2)  
RELAY  
NOTE 10  
PILOT  
(NOTE 8)  
JUNCTION BOX  
CABLE  
TO  
DAMPER  
EGH-105 to EGH-125 Control Supplement  
CSD-1 control system — Natural gas  
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VI  
Wiring — steam  
gravity return  
10  
7
Figure 8  
Control assembly — steam, gravity return  
19  
MV  
MV/PV  
PV  
ALARM  
ALARM  
9
24  
V
2
20  
18  
24  
V
(GND)  
SENSE  
ARK  
SP  
3
1
21  
8
22  
25  
4
25  
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.  
23  
24  
15  
6
15  
5
12  
11  
26  
17  
13  
16  
27  
13a  
14  
Vent connections — Connect  
with ¼" tubing and run vent  
line outside building per code  
requirements.  
Install strain relief bushings  
wherever electrical wiring  
passes through jacket.  
677-01  
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1
2
CSD-1 control panel  
Ignition control  
14 Pilot shutoff valve  
15 Leak test valves with plugs  
Impulse relay and lighted push-button alarm  
silencing switch  
3
16 Gas supply connection  
4
5
6
7
8
9
Terminal strip  
17 Burner manifold  
Transformer/relay  
Junction box  
18 Limit control, automatic reset  
19 Limit control, manual reset  
20 Pressure gauge  
Damper (optional)  
Damper connector  
Dummy plug  
21 Siphons  
22 Gauge glass & valves  
23 Probe LWCO, manual reset  
24 Float LWCO control, automatic reset  
25 Wire harness  
10 Damper harness  
11 Main gas valve  
12 Manual gas valve  
13 Pilot gas valve  
26 Pilot spark & sense wires  
27 Pilot gas tubing  
13a Pilot gas pressure regulator  
EGH-105 to EGH-125 Control Supplement  
CSD-1 control system — Natural gas  
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LADDER WIRING DIAGRAM  
EQUIPMENT  
120 V.A.C.  
GROUND  
(NOTE 7)  
VI  
Wiring — steam  
SERVICE  
SWITCH  
pumped return  
R
C
Figure 9  
TRANSFORMER  
G
RELAY COIL  
1K  
THERMOSTAT  
Water boiler wiring —  
ladder and schematic diagrams  
OPERATING CONTROL  
N
H
C W B  
FLOAT LWCO  
MANUAL RESET  
PROBE LWCO  
(NOTE 11)  
& PUMP  
CONTROL  
MANUAL RESET  
PRESSURETROL  
1K1  
PRESSURETROL  
Y
CABLE  
TO  
DAMPER  
FUSE  
3
5
4
2
6
1
3
5
4
2
6
1
2K  
SEE NOTE 10  
ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE  
INJURY OR DEATH. DISCONNECT POWER  
BEFORE INSTALLING AND/OR SERVICING.  
2K4  
A
A
1
2
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.  
2K3  
2K2  
B. CANADA - C.S.A. C22.1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER  
1
NATIONAL, PROVINCIAL OR LOCAL CODE REQUIREMENTS.  
2. ALL CONTACTS SHOWN WITHOUT POWER APPLIED-OFF SHELF CONDITION.  
2K1  
3. IF ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED,  
TYPE 150o C OR IT’S EQUIVALENT MUST BE USED.  
PILOT  
SOLENOID  
VALVE  
4. REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION  
INFORMATION.  
5. THERMOSTAT - FOR SINGLE ZONE SYSTEMS, THERMOSTAT ANTICIPATOR SETTING IS 0.40 AMPS.  
FOR MULTIPLE ZONE SYSTEMS USING ZONE VALVES OR CIRCULATORS, REFER  
TO COMPONENT MANUFACTURER’S INSTRUCTIONS FOR APPLICATION WIRING AND  
THERMOSTAT ANTICIPATOR SETTING.  
LOW VOLTAGE FIELD  
HIGH VOLTAGE FIELD  
LOW VOLTAGE FACTORY  
HIGH VOLTAGE FACTORY  
IGNITION CABLE  
TH  
TR  
MV  
MV/PV  
PV  
EMCS - FOR EMCS CONNECTION IN PLACE OF THERMOSTAT, REFER TO EMCS  
INSTALLATION/OPERATING MANUAL.  
D
D
6. L.W.C.O., PRESSURE CONTROLS, WIRED IN SERIES.  
ALARM  
ALARM  
24V  
7.  
DENOTES FIELD INSTALLED CHASSIS GROUND.  
ROBERTSHAW  
GAS VALVE  
IGNITION CONTROL MODULE TERMINAL.  
2
24V (G)  
8. PILOT LEADWIRES ARE NOT FIELD REPLACEABLE. REPLACE  
PILOT ASSEMBLY IF NECESSARY.  
IGNITION CONTROL PANEL TERMINAL.  
SENSE  
SPARK  
9. OPERATING CONTROL REQUIRED WITH TANKLESS HEATER.  
10. ALARM CONTACT RATINGS: 15 AMP @ 250 VAC.  
SENSOR  
IGNITOR  
TRANSFORMER TERMINAL.  
IGNITION CONTROL PANEL LAMP  
R
11. REMOVE JUMPER BAR BETWEEN TERMINAL "H" AND TERMINAL "C".  
550-225-028/0399  
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SCHEMATIC WIRING DIAGRAM  
R
MOMENTARY  
SWITCH  
W
R
R
D
D
BK  
PILOT  
SOLENOID  
VALVE  
TR  
TH  
R
W
(NOTE 6)  
BK  
W
R
IMPULSE  
RELAY  
MANUAL RESET  
PROBE LWCO  
MANUAL RESET  
PRESSURETROL  
ROBERTSHAW  
GAS VALVE  
W
R
R
UNIVERSAL SPARK  
IGNITION CONTROL  
FLOAT LWCO  
& PUMP  
CONTROL  
BK  
PRESSURETROL  
BK  
MV  
BK  
G
MV/PV  
PV  
G
EQUIPMENT  
OPERATING  
CONTROL  
(NOTE 9)  
R
BK  
GROUND  
(NOTE 7)  
R
ALARM  
ALARM  
24V  
Y
Y
Y
R
Y
THERMOSTAT  
OR EMCS  
BK  
Y
G
(NOTE 5)  
R
BK  
BK  
G
24V (GND)  
SENSE  
SERVICE  
SWITCH  
(BY OTHERS)  
Y
W
G
R
G
G
R
G
G
H
TERMINAL  
BLOCK  
C
R
SPARK  
BK  
G
BK  
A
A
2
1
2
1
TRANSFORMER  
120/24 V.A.C.  
N
PRE-WIRED PANEL  
W
PLUG-IN  
Y
O
W
DPST  
WIRE NUTS (2)  
RELAY  
NOTE 10  
PILOT  
(NOTE 8)  
JUNCTION BOX  
CABLE  
TO  
DAMPER  
EGH-105 to EGH-125 Control Supplement  
CSD-1 control system — Natural gas  
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VI  
Wiring — steam  
pumped return  
10  
7
Figure 10  
Control assembly — steam, pumped return  
19  
MV  
MV/PV  
PV  
ALARM  
ALARM  
9
24  
V
2
20  
24  
18  
24  
V
(GND)  
SENSE  
ARK  
SP  
3
1
21  
8
22  
25  
4
25  
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.  
23  
15  
6
15  
5
12  
11  
26  
17  
13  
16  
27  
13a  
14  
Vent connections — Connect  
with ¼" tubing and run vent  
line outside building per code  
requirements.  
Install strain relief bushings  
wherever electrical wiring  
passes through jacket.  
677-01-p  
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1
2
CSD-1 control panel  
Ignition control  
14 Pilot shutoff valve  
15 Leak test valves with plugs  
Impulse relay and lighted push-button alarm  
silencing switch  
3
16 Gas supply connection  
4
5
6
7
8
9
Terminal strip  
17 Burner manifold  
Transformer/relay  
Junction box  
18 Limit control, auto reset  
19 Limit control, manual reset  
20 Pressure gauge  
Damper (optional)  
Damper connector  
Dummy plug  
21 Siphons  
22 Gauge glass & valves  
23 Probe LWCO, manual reset  
24 Float LWCO/pump control, auto reset  
25 Wire harness  
10 Damper harness  
11 Main gas valve  
12 Manual gas valve  
13 Pilot gas valve  
26 Pilot spark & sense wires  
27 Pilot gas tubing  
13a Pilot gas pressure regulator  
EGH-105 to EGH-125 Control Supplement  
CSD-1 control system — Natural gas  
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EGH-105 to EGH-125 Control Supplement  
VII  
Final adjustments  
Before proceeding:  
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  
the boiler. Failure to do so could result in severe personal  
injury, death or substantial property damage.  
2. Inspect base insulation as instructed in Section VII of the EGH Manual.  
To place boiler in operation:  
1. Follow Operating instructions, Figure 11, to start boiler.  
2. If boiler starts correctly, proceed with Check-out procedure, Section  
VIII of this Supplement.  
3. If boiler fails to start, check:  
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. C.?  
4. If above fails to eliminate the trouble, refer to Check-out procedure  
— troubleshooting in this Supplement, Section VIII.  
22  
Part Number 550-110-677/0299  
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CSD-1 control system — Natural gas  
VII  
Final adjustments — operating instructions  
Figure 11 Operating instructions  
Part Number 550-110-677/0299  
23  
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EGH-105 to EGH-125 Control Supplement  
VIII  
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.  
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  
control will open pilot gas valve and start spark.  
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. If pilot 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.  
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.  
24  
Part Number 550-110-677/0299  
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CSD-1 control system — Natural gas  
VIII  
Check-out procedure — leak test  
For your safety, turn off electrical 9. Open second leak test valve (Figure 12, item 4) and  
power supply before making any  
electrical connections to avoid  
possible shock hazard.  
check for pressure. See NOTICE below.  
10. Close second leak test valve and remove  
manometer.  
1. Turn off power to the boiler and remove the (RED)  
wire from terminal TH of the main gas valve  
(Figure 12, item 1). Tape off terminal end of  
removed wire and restore power to the boiler.  
11. Remove call for heat to boiler. Turn off 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. Replace (RED) wire to terminal TH of gas valve.  
3. Check that both leak test valves (Figure 12, items 3  
and 4) are closed. Then remove plugs and insert  
1/8" NPT hose barb fittings as shown in Figure 12.  
14. Open manual gas valve (Figure 12, item 2) and  
restore power to boiler.  
4. Attach a U-tube manometer to first leak test valve  
(Figure 12, item 3).  
When checking for pressure at the  
leak test valves, it is normal to find a  
small pressure reading. If the  
pressure continues to rise after  
opening the leak test valve, the main  
valve seat is leaking and should be  
replaced.  
5. Open first leak test valve (Figure 12, item 3) and  
check for pressure. See NOTICE at right.  
6. Close first leak test valve (Figure 12, item 3) and  
remove manometer.  
7. Attach manometer to second leak test valve (Figure  
12, item 4 ).  
8. Apply call for heat to boiler and check that  
electronic pilot proves.  
panel  
l
o
r
cont  
o
T
4
3
Figure 12  
Leak test procedure  
2
1
677-11  
Part Number 550-110-677/0299  
25  
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EGH-105 to EGH-125 Control Supplement  
Check-out procedure — troubleshooting  
VIII  
Verify proper operation after servicing  
2. If Step 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.  
Never jumper (bypass) any device except for momentary  
testing as outlined in Troubleshooting Charts. Substantial  
property damage and/or severe personal injury could  
occur.  
Verify that damper service switch is in "HOLD  
DAMPER OPEN" position.  
3. Do not leave damper permanently in this position.  
Replace actuator immediately. If damper is left in  
open position, boiler will not operate at published  
efficiencies.  
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.  
See damper manufacturer's instructions packed  
with damper for additional information.  
Label all wires prior to disconnection when servicing  
controls. Wiring errors can cause improper and  
dangerous operation.  
Johnson damper:  
If troubleshooting 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.  
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.  
c. Check for 24VAC at secondary side of transformer.  
1. Turn off power to boiler.  
Failure to turn off power to boiler  
can result in severe personal injury,  
death or substantial property  
damage.  
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.  
2. Refer to damper manufacturer’s instructions for  
procedure to fix damper in open position.  
3. Turn on 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. Do not leave damper permanently in this position.  
Replace actuator immediately. If damper is left in  
open position, boiler will not operate at published  
efficiencies.  
In event of actuator failure:  
Effikal damper:  
If troubleshooting 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 instructions 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.  
See damper manufacturer's instructions packed  
with damper for additional information.  
677-14  
Open  
Figure 13  
Closed  
Temporary manual opening of vent damper —  
refer also to vent damper manufacturer’s  
instructions.  
Damper blade  
indicator  
Wrench or pliers  
Effikal damper  
Johnson Controls damper  
26  
Part Number 550-110-677/0299  
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CSD-1 control system — Natural gas  
VIII  
Check-out procedure — troubleshooting  
TS-1: No Spark — System (boiler without vent damper) does not work  
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?  
Correct by making connections.  
No  
Yes  
Is 24VAC present across terminals 24V and 24V(GND)?  
No Yes  
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  
damage.  
Open thermostat (or operating control) contacts for 15  
seconds. Close thermostat contacts. Is 24VAC across  
terminals PV & MV/PV?  
Replace ignition control. Retest.  
No  
Yes  
Turn OFF supply voltage.  
Electrical shock hazard. Failure to turn off  
power before proceeding could cause  
severe personal injury or death.  
Check spark wire. Is it securely connected to spark  
transformer?  
Securely connect spark wire. Then turn ON supply  
voltage. Retest.  
No  
Yes  
Is condition of spark wire good (not cut, brittle, burned or  
cracked)?  
Replace pilot assembly. Retest.  
No  
Yes  
Is spark gap 0.125" and isolated in pilot gas stream?  
Is spark electrode ceramic cracked?  
No Yes  
No  
Yes  
Replace pilot assembly,  
turn ON supply voltage.  
Operate system several  
complete heat cycles.  
Replace ignition  
control. Retest.  
Replace pilot assembly, turn ON supply voltage, operate  
system several complete heat cycles.  
Part Number 550-110-677/0299  
27  
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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 connections.  
Is damper harness securely plugged in at both ends?  
No Yes  
Check for loose wire connections or bad relay on  
transformer.  
Is 24VAC present across transformer terminals C & Y?  
No Yes  
Check for open thermostat, circulator relay, operating  
control, limit control or LWCO. Check the CSD-1 control  
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  
lockout on manual reset, determine cause  
and correct condition. Failure to do so could  
result in severe personal injury, death or  
substantial property damage.  
No  
Yes  
Is damper rotated open?  
No  
Yes  
Check for out of round stack section. Does motor rotate  
open?  
Is 24VAC present across terminals PV and MV/PV?  
No  
Yes  
No  
Yes  
Replace actuator.  
Retest.  
Is spark present now?  
No  
Yes  
Open thermostat contacts for 30 seconds. Damper will  
rotate to closed position. Close thermostat contacts.  
Damper will rotate to open position. Is 24VAC present  
across terminals PV and MV/PV?  
Retest.  
Turn OFF supply voltage.  
Electrical shock hazard. Failure to turn off  
power before proceeding could cause  
severe personal injury or death.  
No  
Yes  
Check spark wire. Is it securely  
connected to ignition control?  
Check continuity of each wire in wiring harness to  
damper. Does continuity exist for each wire?  
Securely connect  
and turn ON supply  
voltage. Retest.  
No Yes  
No  
Yes  
Replace damper  
wiring harness.  
Retest.  
Is condition of spark wire good  
(not brittle, burned or cracked)?  
Remove damper harness from  
boiler wiring harness.  
TEMPORARILY install jumper  
between terminal 2 and  
terminal 5 on damper plug in  
boiler wiring harness. See  
figure below. Does boiler fire?  
Replace pilot  
assembly. Retest.  
No  
Yes  
Replace ignition  
control. Retest.  
Is spark gap 0.125" and  
Is spark electrode  
ceramic cracked?  
located in pilot gas stream?  
No  
Yes  
No  
Yes  
No  
Yes  
Replace  
pilot  
assembly.  
Replace pilot  
assembly.  
Replace ignition  
control. Retest.  
1
4
2
5
3
6
Temporary  
jumper  
Replace damper  
actuator. Retest.  
Turn ON supply voltage and operate  
system several complete cycles.  
28  
Part Number 550-110-677/0299  
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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  
Turn OFF supply voltage.  
Is 24VAC between terminals MV and MV/PV on ignition  
control?  
Electrical shock hazard. Failure to turn off  
power before proceeding could cause  
severe personal injury or death.  
No  
Yes  
Replace ignition control.  
Retest.  
Make sure sense wire is not wrapped around any pipe or  
accessories.  
Is inlet gas pressure at least 5.0" W.C. and not over 14"  
W.C.?  
Is sense wire securely attached to sense terminal and pilot  
assembly?  
No  
Yes  
No  
Yes  
Correct and retest.  
Contact gas supplier to  
correct.  
Is sensing probe ceramic cracked?  
No  
Yes  
Is main valve wiring secure at terminals?  
No  
Yes  
Replace pilot assembly.  
Retest.  
Is sense wire or sensing probe shorted out to metal  
surface?  
Correct wiring. Retest.  
Replace valve. Retest.  
No  
Yes  
Check for continuity of sense wire and condition of  
insulation.  
Correct and retest.  
NOT OK  
OK  
Replace pilot assembly.  
Retest.  
Does system have proper flame signal?  
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 from terminal MV on ignition control.  
d. Energize the system. Spark should ignite the pilot. As soon as pilot is burning,  
Replace ignition control.  
Retest.  
microammeter should read at least 0.5 microamp for U.T. # 1003-615.  
e. Is flame current signal less than the minimum specified in d above?  
No  
Yes  
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  
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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.  
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)  
Check ground lead from GND (Burner) terminal on  
ignition control to ignition control mounting screw and  
from C on transformer to transformer case ground.  
Make sure connections are clean and tight. If wire is  
damaged or deteriorated, replace with No. 18 gauge  
moisture-resistant, thermoplastic insulated wire with  
105 °C minimum rating.  
Pilot assembly and ignition control must share common  
ground with main burner. Nuisance shutdowns are often  
caused by poor or erratic ground.  
Check for good metal-to-metal contact between pilot  
burner bracket and main burner and between main  
burner and burner rest.  
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  
Connect securely to terminal PV on ignition control and  
terminal TR on main gas valve.  
Is inlet gas pressure at least 5.0" W.C. and not over 14"  
W.C.?  
No  
Yes  
Is pilot shutoff valve open?  
No  
Yes  
Is gas present at pilot burner assembly?  
Remove MV wire from ignition control. Use a  
match taped to a long screwdriver or pilot  
lighter rod and manually light pilot.  
Contact gas supplier to  
correct gas pressure.  
Open pilot shutoff valve.  
No  
Yes  
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.  
Is spark gap 0.125" and located in pilot gas stream?  
No  
Yes  
Replace pilot assembly.  
Block any draft around  
boiler. Check for clean  
pilot orifice.  
30  
Part Number 550-110-677/0299  
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CSD-1 control system — Natural gas  
IX  
Service and maintenance  
Complete Installation and Service Certificate in EGH Manual, Section IX.  
Follow EGH Manual, Section IX, for service and maintenance of boiler.  
Part Number 550-110-677/0299  
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EGH-105 to EGH-125 Control Supplement  
X
Replacement parts — water boilers  
Figure 14 Water boiler assembly  
17  
19  
18  
22  
MV  
MV/PV  
PV  
11  
ALARM  
ALARM  
13  
24  
V
14  
15  
24  
V
(GND)  
21  
SENSE  
ARK  
SP  
12  
20  
23  
16  
16  
7
7
24  
6
1
5
8
2
10  
8a  
9
677-12  
32  
Part Number 550-110-677/0299  
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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.  
Weil-McLain  
part number  
Item Part description  
Boiler models Vendor  
Vendor part number  
1
2
3
Main burner  
EGH-105 – 125 Weil-McLain  
EGH-105 – 125 Weil-McLain  
EGH-105 – 125 Weil-McLain  
— See EGH Manual —  
Main burner with pilot bracket  
Pilot burner bracket (not shown)  
— See EGH Manual —  
— See EGH Manual —  
E48A-1  
Beckett Gas  
4
Pilot burner (not shown)  
EGH-105 – 125  
511-330-166  
Johnson Controls  
Q90GE-1  
5
6
7
Main gas valve  
EGH-105 – 125 Robertshaw  
EGH-105 – 125 Watts  
7000DERHC-S7C 511-044-287  
Manual gas valve, 1" NPT  
Leak test valve  
FBV3-06  
511-246-290  
511-246-339  
EGH-105 – 125 Key Gas  
Honeywell  
V8046C-1014  
H91ABG  
8
Pilot gas valve  
EGH-105 – 125  
511-044-039  
Johnson Controls  
8a Pilot gas pressure regulator  
Pilot shutoff valve  
EGH-105 – 125 Maxitrol  
RV20VL  
510-933-195  
511-246-345  
9
EGH-105 – 125 Conbraco  
53-300-01  
10 Pilot tubing, alum. 1/8" O.D. x 34" long  
11 Ignition control  
EGH-105 – 125 Available at local supply house  
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  
EGH-105 – 125  
AML21CBA2AA  
511-624-580  
221K11810  
13 Push-button switch  
14 Lens cover  
Eaton Controls  
Honeywell  
EGH-105 – 125  
AML51-C10R  
511-624-581  
220PM02A  
Eaton Controls  
15 Light bulb  
EGH-105 – 125 TI-¾ (available at local supply house)  
EGH-105 – 125 Weil-McLain  
16 Wiring harness, water boilers  
591-391-886  
381-800-446  
Effikal  
RVGP-KS-10BF  
EGH-105  
Johnson Controls  
Effikal  
Q35GP-2 (note 1)  
RVGP-KS-12BF  
Q35GR-2 (note 1)  
RVGP  
Vent damper assembly — optional  
(not for use in Canada)  
17  
EGH-115 – 125  
EGH-105 – 125  
381-800-447  
Johnson Controls  
Effikal only  
Johnson only  
510-512-337  
510-312-255  
591-391-795  
18 Vent damper actuator  
19 Vent damper harness  
20 Limit control, automatic reset  
M35BE-1C  
EGH-105 – 125 Weil-McLain  
10C321  
Honeywell  
EGH-105 – 125  
L4080B-1311  
11B83-16  
510-312-209  
White-Rodgers  
21 Limit control, manual reset  
22 Probe LWCO, manual reset  
EGH-105 – 125 Honeywell  
L4006E-1000  
PS852M-24  
19998  
510-312-041  
511-114-530  
EGH-105 – 125 McDonnell & Miller  
Ametek  
EGH-105 – 125  
23 Pressure/temperature gauge  
24 Transformer/relay  
510-218-097  
510-312-169  
ENFM-USA  
4104-2-1/2-1/4CBM  
R8285D-5001  
EGH-105 – 125 Honeywell  
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  
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EGH-105 to EGH-125 Control Supplement  
X
Replacement parts — steam boilers  
Figure 15 Steam boiler assembly  
17  
19  
18  
21  
MV  
MV/PV  
PV  
11  
ALARM  
ALARM  
13  
24  
V
20  
14  
15  
24  
24  
V
(GND)  
SENSE  
ARK  
SP  
12  
16  
22  
16  
23a  
7
7
25  
6
23b  
1
5
8
2
10  
8a  
9
677-13  
34  
Part Number 550-110-677/0299  
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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.  
Weil-McLain  
part number  
Item Part description  
Boiler models Vendor  
Vendor part number  
1
2
3
Main burner  
EGH-105 – 125 Weil-McLain  
EGH-105 – 125 Weil-McLain  
EGH-105 – 125 Weil-McLain  
— See EGH Manual —  
Main burner with pilot bracket  
Pilot burner bracket (not shown)  
— See EGH Manual —  
— See EGH Manual —  
E48A-1  
Beckett Gas  
4
Pilot burner (not shown)  
EGH-105 – 125  
511-330-166  
Johnson Controls  
Q90GE-1  
5
6
7
Main gas valve  
EGH-105 – 125 Robertshaw  
EGH-105 – 125 Watts  
7000DERHC-S7C 511-044-287  
Manual gas valve, 1" NPT  
Leak test valve  
FBV3-06  
511-246-290  
511-246-339  
EGH-105 – 125 Key Gas  
Honeywell  
V8046C-1014  
H91ABG  
8
Pilot gas valve  
EGH-105 – 125  
511-044-039  
Johnson Controls  
8a Pilot gas pressure regulator  
Pilot shutoff valve  
EGH-105 – 125 Maxitrol  
RV20VL  
510-933-195  
511-246-345  
9
EGH-105 – 125 Conbraco  
53-300-01  
10 Pilot tubing, alum. 1/8" O.D. x 34" long  
11 Ignition control  
EGH-105 – 125 Available at local supply house  
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  
EGH-105 – 125  
AML21CBA2AA  
511-624-580  
221K11810  
13 Push-button switch  
Eaton Controls  
Honeywell  
EGH-105 – 125  
AML51-C10R  
511-624-581  
220PM02A  
14 Lens cover  
15 Light bulb  
Eaton Controls  
EGH-105 – 125 TI-¾ (available at local supply house)  
EGH-105 – 125 Weil-McLain  
Wiring harness, pumped return steam  
16  
591-391-888  
591-391-887  
Wiring harness, gravity return steam  
EGH-105 – 125 Weil-McLain  
Effikal  
RVGP-KS-10BF  
EGH-105  
381-800-446  
381-800-447  
Johnson Controls  
Effikal  
Q35GP-2 (note 1)  
RVGP-KS-12BF  
Q35GR-2 (note 1)  
RVGP  
Vent damper assembly — optional  
(not for use in Canada)  
17  
EGH-115 – 125  
EGH-105 – 125  
Johnson Controls  
Effikal only  
Johnson only  
510-512-337  
510-312-255  
591-391-795  
510-312-135  
510-311-023  
510-312-060  
511-114-530  
511-114-494  
511-114-531  
18 Vent damper actuator  
19 Vent damper harness  
20 Limit control, automatic reset  
M35BE-1C  
10C321  
EGH-105 – 125 Weil-McLain  
Honeywell  
EGH-105 – 125  
PA-404-A  
White-Rodgers  
P47EA-3  
21 Limit control, manual reset  
EGH-105 – 125 Honeywell  
L404C-1147  
PS852M-24  
67W-1  
22 Probe LWCO, manual reset  
23a Float LWCO, automatic reset  
23b Float LWCO/pump control, auto reset  
EGH-105 – 125 McDonnell & Miller  
EGH-105 – 125 McDonnell & Miller  
EGH-105 – 125 McDonnell & Miller  
42-A  
Ametek  
EGH-105 – 125  
Winter  
P505K  
24 Pressure gauge  
510-218-045  
510-312-169  
E1437  
25 Transformer/relay  
EGH-105 – 125 Honeywell  
R8285D-5001  
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  
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EGH-105 to EGH-125 Control Supplement  
Weil-McLain  
500 Blaine Street  
Michigan City, IN 46360-2388  
36  
Part Number 550-110-677/0299  
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