Weil-McLain EGH-105 Series Use and maintenance manual

Control SupplementControl Supplement
Control SupplementControl Supplement
Control Supplement
EGHEGH
EGHEGH
EGH Gas-Fired Boiler
EGH-105 to EGH-125 Series 4
Natural gas‡
Part 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 Supplement.

EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125 Control Supplement
Part 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.
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.
Hazard definitions
Please read this page first
Contents I. ................. Installation .......................................................................... 4
II. ................ Piping connections .............................................................6
III. ............... Install boiler controls .........................................................6
IV. ............... Optional heaters ................................................................7
V. ................ Gas piping ........................................................................... 8
VI. .............. Wiring .................................................................................. 8
VII. ............. Final adjustments .............................................................22
VIII. ............ Check-out procedure .......................................................24
IX. .............. Service and maintenance ................................................31
X. ............... Replacement parts ........................................................... 32
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 on EGH-105 to EGH-125
boilers only, specifically for:
• 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.
To the installer:
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.

CSD-1 control system — Natural gas
Part Number 550-110-677/0299 3
Carton guide
Table 1 Boiler cartons
Verify that the correct cartons are available before beginning assembly.Note that the Base assembly andTrim &
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
Section assembly (a) With tankless opening 321-711-120 321-711-130 321-711-140
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
Float low water cutoff (steam) Gravity return (M&M #67W-1) 381-700-341 381-700-341 381-700-341
Pumped return (M&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
Trim & controls (see below)
Water, CSD-1 — or — 381-700-406 381-700-406 381-700-406
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.
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, automatic reset Aquastat, automatic reset
Pressure limit control, manual reset Pressure limit control, manual reset Aquastat, manual reset
Probe low water cutoff, manual reset Probe low water cutoff, manual reset Probe low water cutoff, manual reset
Transformer/relay Transformer/relay Transformer/relay
Wire harness, steam gravity return Wire harness, steam pumped return Wire harness, water
Crimp spade wire terminations Crimp spade wire terminations Crimp spade wire terminations
ASME Relief valve ASME Relief valve ASME Relief valve
Pressure gauge Pressure gauge
Pressure/temperature gauge
Gauge glass and valves Gauge glass and valves
Brass cross, brass nipple, bushings (3) and
siphons (3) for mounting pressure controls
and gauge
Brass cross, brass nipple, bushings (3)
and siphons (3) for mounting pressure
controls and gauge

EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125 Control Supplement
Part Number 550-110-677/0299
4
InstallationI
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).
Figure 1
Gas train assembly
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.
677-09
4
5
3
3
1
2

CSD-1 control system — Natural gas
Part Number 550-110-677/0299 5
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.
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 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.
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.
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
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.
Figure 2
Vent damper assemblies
Effikal damper Johnson Controls damper
677-05
Damper
blade
indicator
Hold-open switch (Effikal only) —
Install damper so that switch is
visible and accessible to user.
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.
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.
Keyway Key
677-10
WARNING
LINE UP KEYWAY WHEN
CONNECTING PLUGS.
FORCING A MISMATCH
CAN CAUSE A
HAZARDOUS CONDITION.

EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125 Control Supplement
Part Number 550-110-677/0299
6
Piping connectionsII
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).
Install boiler controls — water boilersIII
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
Water boiler connections
Table 2
Water boiler connections
32¾"
13½"
11¾" 27 / "
58
16 / "
316
2/"
11 16
16/"
58
24"
EG
D
Return
Not
used
Supply
H
S
V
L
677-08
Tapping Application W-M Part No.
DBoiler drain connection —
EASME relief valve (per EGH manual) —
GPipe to air vent or compression tank —
HHoneywell L4006E-1000 M/R limit 510-312-041
LPressure/temperature gauge 510-218-097
STemperature limit control, auto reset 510-312-209
VGas supply connection (right or left) —
Not shown
McDonnell & Miller PS852M-24 M/R
probe LWCO (Mount in supply or
return piping, above top of boiler) 511-114-530
Plug all tappings not used.

CSD-1 control system — Natural gas
Part Number 550-110-677/0299 7
Install boiler controls — steam boilersIII
Figure 4
Steam boiler connections
Table 3
Steam boiler connections
32¾"
23 / "
13 16
(Water line)
13½"
11¾" 27 / "
58
16 / "
316
2/"
11 16
16/"
58
24"
C
T
EG
D
Return
Supply
risers
H
S
V
L
677-07
Tapping Application W-M Part No.
TMcDonnell & Miller PS852M-24 M/R
probe LWCO 511-114-530
CNot used — plug tapping —
DDrain connection (per EGH manual) —
EASME relief valve (per EGH manual) —
GNot used - plug tapping —
H
Float LWCO, automatic reset — —
Gravity return — McD-M 67W-1 511-114-494
Pumped return — McD-M 42-A 511-114-531
L
Pressure gauge 510-218-045
Pressure limit, automatic reset 510-312-135
Honeywell L404C-1147 M/R limit 510-312-060
SSkim tapping (per EGH manual)510-312-209
VGas supply connection (right or left) —
Plug all tappings not used.
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.
Optional heaters — steam boilers onlyIV
Install optional tankless heater, if used, (steam boiler only) per EGH Manual Section IV.

EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125 Control Supplement
Part Number 550-110-677/0299
8
Gas pipingV
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 side.
WiringVI
For your safety, turn off electrical
power supply before making any
electrical connections to avoid
possible shock hazard.
A strain relief bushing and adapter
must be used at each point where
wiring passes through the boiler
jacket or control cases to protect
wiring insulation.
Assembly illustrations and wiring
diagrams
This Supplement contains three wiring diagrams and
associated assembly illustrations. Refer to the
following, as applicable:
• Water boilers —Figures 5 and 6
• Steam boilers, gravity return — Figures 7 and 8
• Steam boilers, pumped return — Figures 9 and 10
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.
Use 105 °C thermoplastic wire, or equivalent, if any
original wire must be replaced (except for pilot spark
and sense wires).
Wiring procedure
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).
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.
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.
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.
Support gas line securely. Do not
support weight of gas line off of boiler
gas train.
Purge air from gas piping and perform gas line and gas
connection leak test per Section V of the EGH Manual.

CSD-1 control system — Natural gas
Part 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. 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.
Wiring — sequence of operationVI

Part Number 550-110-677/0299
10
o
NOTES:
TO COMPONENT MANUFACTURER’S INSTRUCTIONS FOR APPLICATION WIRING AND
FOR MULTIPLE ZONE SYSTEMS USING ZONE VALVES OR CIRCULATORS, REFER
5. THERMOSTAT - FOR SINGLE ZONE SYSTEMS,THERMOSTAT ANTICIPATOR SETTING IS 0.40 AMPS.
4. REFER TO CONTROL COMPONENT INSTRUCTIONS PACKEDWITH BOILER FOR APPLICATION
3. IF ORIGINALWIRE AS SUPPLIED WITHTHE APPLIANCE MUST BE REPLACED,
8. PILOT LEADWIRES ARE NOT FIELD REPLACEABLE.REPLACE
7. DENOTES FIELD INSTALLED CHASSIS GROUND.
9. CIRCULATOR NOT USEDWITH GRAVITY HOTWATER.
INSTALLATION/OPERATING MANUAL.
EMCS - FOR EMCS CONNECTION IN PLACE OFTHERMOSTAT, REFER TO EMCS
THERMOSTAT ANTICIPATOR SETTING.
TYPE 105 C OR IT’S EQUIVALENT MUST BE USED.
NATIONAL, PROVINCIAL OR LOCAL CODE REQUIREMENTS.
B. CANADA - C.S.A. C22.1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER
A. U.S.A.- NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL, STATE OR LOCAL
1. ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH:
ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE
INJURY OR DEATH. DISCONNECT POWER
BEFORE INSTALLING AND/OR SERVICING.
2. ALL CONTACTS SHOWN WITHOUT POWER APPLIED-OFF SHELF CONDITION.
CODE REQUIREMENTS.
INFORMATION.
6. L.W.C.O., HIGH LIMITS, WIRED IN SERIES.
10. ALARM CONTACT RATINGS: 15 AMP @ 250VAC.
SPARK
24V (G)
SENSE
2
SENSOR
IGNITOR
R
2K
MV/PV
PV
MV
1
1
A
ALARM
24V
ALARM
2K1
GAS VALVE
ROBERTSHAW
D
D+
TR
TH
2K2
2K3 N/A
SEE NOTE 10
2K4 2
A
VALVE
PILOT
TRANSFORMER
FUSE
DAMPER
TO
22
11
66
44
5
3
5
3
THERMOSTAT
CABLE
1K1 RESET
HIGH LIMIT
MANUAL MANUAL
RESET
PROBE LWCO
RELAY COIL
HIGH
LIMIT
1K
LADDERWIRING DIAGRAM
SWITCH 1K2 CIRCULATOR
120 V.A.C.
SERVICE
SOLENOID
PILOT ASSEMBLY IF NECESSARY.
EQUIPMENT
(NOTE 7)
GROUND
Y
R
G
C
IGNITION CONTROL PANEL TERMINAL
TRANSFORMER TERMINAL.
IGNITION CONTROL MODULETERMINAL.
IGNITION CONTROL PANEL LAMP
HIGH VOLTAGE FIELD
LOW VOLTAGE FACTORY
R
HIGH VOLTAGE FACTORY
IGNITION CABLE
LOW VOLTAGE FIELD
550-225-026/0199
Figure 5
Water boiler wiring —
ladder and schematic diagrams
Wiring — water boilersVI

Part Number 550-110-677/0299 11
CSD-1 control system — Natural gas
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125 Control Supplement
NOTE 10
TERMINAL
BLOCK
12A1A2
W
JUNCTION BOX
EQUIPMENT
GROUND
(BY OTHERS)
(NOTE 7)
CIRCULATOR
N
(NOTE 9)
WY
H
SWITCH
SERVICE
C
WIRE NUTS (3)
W
BK
Y
BK
GYG
BK
BK
DAMPER
TO
BK
R
TRANSFORMER
120/24 V.A.C.
RELAY
DPST
PLUG-IN
CABLE
G
(NOTE 5)
THERMOSTAT
OR EMCS
PROBE LWCO
W
BK
G
BK
CONNECTOR
DAMPER
Y
GAS VALVE
ROBERTSHAW
D+
D
TH TR
BK
W
RESET
O
WR
(NOTE 8)
PILOT
MANUAL
HIGH LIMIT
MANUAL
RESET
HIGH
LIMIT
UNIVERSAL SPARK
IGNITION CONTROL
SENSE
SPARK
MV
MV/PV
PV
ALARM
ALARM
24V
24V (GND)
BK PILOT
SOLENOID
RW
R
MOMENTARY
SWITCH
R
Y
IMPULSE
RELAY
R
G
Y
R
Y
R
R
R
G
R
R
R
G
G
R
W
PRE-WIRED PANEL
SCHEMATIC WIRING DIAGRAM
BK
BK
(NOTE 6)
G
G
VALVE

Part 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
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.
13
13a
Figure 6
Control assembly — water boiler
(CSD-1 is not availabe for water
boilers with tankless heaters.)
Wiring — water boilersVI

Part Number 550-110-677/0299 13
CSD-1 control system — Natural gas
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125 Control Supplement
1CSD-1 control panel 14 Pilot shutoff valve
2Ignition control 15 Leak test valves with plugs
3Impulse relay and lighted push-button alarm
silencing switch
16 Gas supply connection
17 Burner manifold
5Transformer/relay 18 Limit control, auto reset
6Junction box 19 Limit control, manual reset
7Damper (optional) 20 Pressure/temperature gauge
8Damper connector 21 Wire harness
9Dummy plug 22 Pilot spark & sense wires
10 Damper harness 23 Pilot gas tubing
11 Main gas valve 24 Circulator, by others
12 Manual gas valve
25 Probe LWCO, Manual reset (Mount in sup-
ply or return piping above top of boiler
between boiler and any isolation valve(s).)
13 Pilot gas valve
13a Pilot gas pressure regulator

Part Number 550-110-677/0299
14
o
NOTES:
TO COMPONENT MANUFACTURER’S INSTRUCTIONS FOR APPLICATION WIRING AND
FOR MULTIPLE ZONE SYSTEMS USING ZONEVALVES OR CIRCULATORS, REFER
5. THERMOSTAT - FOR SINGLE ZONE SYSTEMS, THERMOSTAT ANTICIPATOR SETTING IS 0.40 AMPS.
4. REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION
3. IF ORIGINAL WIRE AS SUPPLIEDWITH THE APLIANCE MUST BE REPLACED,
8. PILOT LEADWIRES ARE NOT FIELD REPLACEABLE.REPLACE
7. DENOTES FIELD INSTALLED CHASSIS GROUND.
9. OPERATING CONTROL REQUIRED WITHTANKLESS HEATER.
INSTALLATION/OPERATING MANUAL.
EMCS - FOR EMCS CONNECTION IN PLACE OFTHERMOSTAT, REFER TO EMCS
THERMOSTAT ANTICIPATOR SETTING.
TYPE 105 C OR IT’S EQUIVALENT MUST BE USED.
NATIONAL, PROVINCIAL OR LOCAL CODE REQUIREMENTS.
B. CANADA - C.S.A.C22.1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER
A. U.S.A. - NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL, STATE OR LOCAL
1. ALL WIRING MUST BE INSTALLED IN ACCORDANCEWITH:
ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE
INJURY OR DEATH. DISCONNECT POWER
BEFORE INSTALLING AND/OR SERVICING.
2. ALL CONTACTS SHOWN WITHOUT POWER APPLIED-OFF SHELF CONDITION.
CODE REQUIREMENTS.
INFORMATION.
6. L.W.C.O., PRESSURE CONTROLS, WIRED IN SERIES.
10. ALARM CONTACT RATINGS: 15 AMP @ 250VAC.
PILOT ASSEMBLY IF NECESSARY.
IGNITION CONTROL PANEL TERMINAL.
TRANSFORMER TERMINAL.
IGNITION CONTROL MODULETERMINAL.
IGNITION CONTROL PANEL LAMP
HIGH VOLTAGE FIELD
LOW VOLTAGE FACTORY
R
HIGH VOLTAGE FACTORY
IGNITION CABLE
LOW VOLTAGE FIELD
SPARK
24V (G)
SENSE
2
SENSOR
IGNITOR
R
2K
MV/PV
PV
MV
1
1
A
ALARM
24V
ALARM
2K1
GAS VALVE
ROBERTSHAW
D
D
TR
TH
2K2
2K3 N/A
SEE NOTE 10
2K4 2
A
VALVE
PILOT
TRANSFORMER
FUSE
DAMPER
TO
22
11
66
44
5
3
5
3
THERMOSTAT
CABLE
1K1
MANUAL RESET
PROBE LWCO
RELAY COIL
1K
LADDERWIRING DIAGRAM
SWITCH
120 V.A.C.
SERVICE
SOLENOID
Y
G
R
EQUIPMENT
(NOTE 7)
GROUND
PRESSURETROL PRESSURETROL
MANUAL RESET
OPERATING CONTROL
FLOAT LWCO
C
550-225-027/0199
Figure 7
Water boiler wiring —
ladder and schematic diagrams
Wiring — steam
gravity return
VI

Part Number 550-110-677/0299 15
CSD-1 control system — Natural gas
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125 Control Supplement
NOTE 10
TERMINAL
BLOCK
12A1A2
W
JUNCTION BOX
EQUIPMENT
GROUND
(BY OTHERS)
(NOTE 7)
N
H
SWITCH
SERVICE
C
WIRE NUTS (2)
W
BK
GYG
BK
BK
DAMPER
TO
BK
R
TRANSFORMER
120/24 V.A.C.
RELAY
DPST
PLUG-IN
CABLE
G
(NOTE 5)
THERMOSTAT
OR EMCS
PROBE LWCO
W
BK
G
BK
CONNECTOR
DAMPER
Y
GAS VALVE
ROBERTSHAW
D
D
TH TR
BK
W
MANUAL RESET
O
WR
(NOTE 8)
PILOT
PRESSURETROL
MANUAL RESET
PRESSURETROL
UNIVERSAL SPARK
IGNITION CONTROL
SENSE
SPARK
MV
MV/PV
PV
ALARM
ALARM
24V
24V (GND)
BK PILOT
SOLENOID
RW
R
MOMENTARY
SWITCH
R
Y
IMPULSE
RELAY
R
G
Y
R
Y
R
R
R
G
R
R
R
G
G
R
W
PRE-WIRED PANEL
SCHEMATIC WIRING DIAGRAM
BK
BK
(NOTE 6)
G
Y Y
FLOAT LWCO
(NOTE 9)
CONTROL
OPERATING
BK
G
VALVE

Part 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
wherever electrical wiring
passes through jacket.
7
Vent connections — Connect
with ¼" tubing and run vent
line outside building per code
requirements.
13
13a
Figure 8
Control assembly — steam, gravity return
Wiring — steam
gravity return
VI
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.

Part Number 550-110-677/0299 17
CSD-1 control system — Natural gas
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125 Control Supplement
1CSD-1 control panel 14 Pilot shutoff valve
2Ignition control 15 Leak test valves with plugs
3Impulse relay and lighted push-button alarm
silencing switch 16 Gas supply connection
4Terminal strip 17 Burner manifold
5Transformer/relay 18 Limit control, automatic reset
6Junction box 19 Limit control, manual reset
7Damper (optional) 20 Pressure gauge
8Damper connector 21 Siphons
9Dummy plug 22 Gauge glass & valves
10 Damper harness 23 Probe LWCO, manual reset
11 Main gas valve 24 Float LWCO control, automatic reset
12 Manual gas valve 25 Wire harness
13 Pilot gas valve 26 Pilot spark & sense wires
13a Pilot gas pressure regulator 27 Pilot gas tubing

Part Number 550-110-677/0299
18
o
NOTES:
TO COMPONENT MANUFACTURER’S INSTRUCTIONS FOR APPLICATION WIRING AND
FOR MULTIPLE ZONE SYSTEMS USING ZONEVALVES OR CIRCULATORS, REFER
5. THERMOSTAT - FOR SINGLE ZONE SYSTEMS, THERMOSTAT ANTICIPATOR SETTING IS 0.40 AMPS.
4. REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION
3. IF ORIGINAL WIRE AS SUPPLIEDWITH THE APPLIANCE MUST BE REPLACED,
8. PILOT LEADWIRES ARE NOT FIELD REPLACEABLE.REPLACE
7. DENOTES FIELD INSTALLED CHASSIS GROUND.
9. OPERATING CONTROL REQUIRED WITHTANKLESS HEATER.
INSTALLATION/OPERATING MANUAL.
EMCS - FOR EMCS CONNECTION IN PLACE OFTHERMOSTAT, REFER TO EMCS
THERMOSTAT ANTICIPATOR SETTING.
TYPE 150 C OR IT’S EQUIVALENT MUST BE USED.
NATIONAL, PROVINCIAL OR LOCAL CODE REQUIREMENTS.
B. CANADA - C.S.A.C22.1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER
A. U.S.A. - NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL, STATE OR LOCAL
1. ALL WIRING MUST BE INSTALLED IN ACCORDANCEWITH:
ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE
INJURY OR DEATH. DISCONNECT POWER
BEFORE INSTALLING AND/OR SERVICING.
2. ALL CONTACTS SHOWN WITHOUT POWER APPLIED-OFF SHELF CONDITION.
CODE REQUIREMENTS.
INFORMATION.
6. L.W.C.O., PRESSURE CONTROLS, WIRED IN SERIES.
10. ALARM CONTACT RATINGS: 15 AMP @ 250VAC.
PILOT ASSEMBLY IF NECESSARY.
11. REMOVE JUMPER BAR BETWEENTERMINAL "H" AND TERMINAL "C".
IGNITION CONTROL PANEL TERMINAL.
TRANSFORMER TERMINAL.
IGNITION CONTROL MODULETERMINAL.
IGNITION CONTROL PANEL LAMP
HIGH VOLTAGE FIELD
LOW VOLTAGE FACTORY
R
HIGH VOLTAGE FACTORY
IGNITION CABLE
LOW VOLTAGE FIELD
SPARK
24V (G)
SENSE
2
SENSOR
IGNITOR
R
2K
MV/PV
PV
MV
1
1
A
ALARM
24V
ALARM
2K1
GAS VALVE
ROBERTSHAW
D
D
TR
TH
2K2
2K3 N/A
SEE NOTE 10
2K4 2
A
VALVE
PILOT
TRANSFORMER
FUSE
DAMPER
TO
22
11
66
44
5
3
5
3
THERMOSTAT
CABLE
1K1 MANUAL RESET
PROBE LWCO
RELAY COIL
1K
LADDERWIRING DIAGRAM
SWITCH
120 V.A.C.
SERVICE
SOLENOID
Y
G
R
EQUIPMENT
(NOTE 7)
GROUND
PRESSURETROL PRESSURETROL
MANUAL RESET
OPERATING CONTROL
& PUMP
CONTROL
NHCWB
(NOTE 11)
FLOAT LWCO
C
550-225-028/0399
Figure 9
Water boiler wiring —
ladder and schematic diagrams
Wiring — steam
pumped return
VI

Part Number 550-110-677/0299 19
CSD-1 control system — Natural gas
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125EGH-105 to EGH-125
EGH-105 to EGH-125 Control Supplement
NOTE 10
TERMINAL
BLOCK
12A1A2
W
JUNCTION BOX
EQUIPMENT
GROUND
(BY OTHERS)
(NOTE 7)
N
H
SWITCH
SERVICE
C
W
BK
GYG
BK
BK
DAMPER
TO
BK
R
TRANSFORMER
120/24 V.A.C.
RELAY
DPST
PLUG-IN
CABLE
G
(NOTE 5)
THERMOSTAT
OR EMCS
PROBE LWCO
W
BK
G
BK
CONNECTOR
DAMPER
Y
GAS VALVE
ROBERTSHAW
D
D
TH TR
BK
W
MANUAL RESET
O
WR
(NOTE 8)
PILOT
PRESSURETROL
MANUAL RESET
PRESSURETROL
UNIVERSAL SPARK
IGNITION CONTROL
SENSE
SPARK
MV
MV/PV
PV
ALARM
ALARM
24V
24V (GND)
BK PILOT
SOLENOID
R
W
R
MOMENTARY
SWITCH
R
Y
IMPULSE
RELAY
R
G
Y
R
Y
R
R
R
G
R
R
R
G
G
R
W
PRE-WIRED PANEL
SCHEMATIC WIRING DIAGRAM
BK
BK
(NOTE 6)
G
Y Y
CONTROL
& PUMP
BK
CONTROL
(NOTE 9)
OPERATING
G
FLOAT LWCO
VALVE
WIRE NUTS (2)

Part 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
wherever electrical wiring
passes through jacket.
Vent connections — Connect
with ¼" tubing and run vent
line outside building per code
requirements.
13
13a
Figure 10
Control assembly — steam, pumped return
Wiring — steam
pumped return
VI
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.