Weil-McLain HE (Series 2) Owner's manual

UIEII- flic IAIN
MODELS HE (Series 2) AND VHE (Series 2)
NATURAL GAS-FIRED
INDUCED DRAFT BOILERS
SUPPLEMENTAL
INSTRUCTIONS
WITH WHITE-RODGERS
CYCLE-PILOT® SYSTEM FOR
NATURAL GAS-FIRED BOILERS
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MODEL VHE (Series 2)
MODEL HE (Series 2)
NATURAL
GAS
Part No. 550-Mi-422/0982WP

HE (Series 2) and VHE (Series 2) with White-Rodgers Cycle-Pilot* for Natural Gas Firing
TABLE OF CONTENTS
Base Assembly Parts Description
With White-Rodgers Cycle-Pilot*
For Natural Gas Firing..
Ignition System Components. 3
Boiler Equipment Components ... 4
Sequence of Operation ..
Schematic Wiring Diagram ..
Ladder Wiring Diagram ..
Trouble Shooting Procedure ..
Checking The Pressure Differential Switch.6
Trouble Shooting Charts ..
HE (Series 2) and VHE (Series 2)
Base Assembly Parts Description
With White-Rodgers Cycle-Pilot*
For Natural Gas Firing
FIGURE
MODEL NO.
HE & VHE 3
HE & VHE 4
HE & VHE 5
HE & VHE 6
NO.
PART DESCRIPTION
QTY. PART NO.
QTY. PART NO.
QTY. PART NO.
QTY. PART NO.
3
7
■
Relite Control
Gas Valve Assembly
Orifice. Main Burner Natural Gas No. 47 Drill
1 511-330-111
1 511-044-288
4 560-528-992
1 511-330-111
1 511-044-288
6 560-528-992
1 511-330-111
1 511-044-288
8 560-528992
1 511-330-111
1 511-044-288
10 560-528992
Not Shown.
NOTE: PARTS LISTED ABOVE ARE FOR BOILERS FIRED WITH NATURAL GAS ONLY. FOR ADDITIONAL PARTS
COMMON TO NATURAL AND PROPANE GASES REFER TO BOILER MANUAL.
IMPORT ANT: When calling or writing about the boiler,
PLEASE GIVE THE MODEL, SERJES, AND C.P. NUM¬
BERS, located on the boiler. *
Any reuse or reproduction of the artwork and copy in
this manual is strictly prohibited without the written
consent of Weil-McLain.
UlEIL'DIclAIN
••Canada CanadatTO lift f7ff€awO> S*anwvi OnaeUT tC?
Michigan City,
Indiana 46360 ■ A
Marley Company

HE (Series 2) and VHE (Series 2)
WHITE-RODGERS CYCLE-PILOT* IGNITION SYSTEM COMPONENTS
FOR NATURAL GAS FIRING
Cfc
TRANSFORMER
FIGURE 1
r
psEssime
PRESSURE SWITCH
FIGURE 2
5059 RELITE CONTROL
RGURE 3
PRE-PURGE TIMER
RGURE 5
NOTE: When gas cock is positioned over
black line on collar around knob, pilot will cycle
on and off but main burner gas will not flow.
36C84 GAS COCK KNOB
RGURE 6
36C84 GAS VALVE
RGURE 7
CHECKING FOR ENERGIZED PILOT
SOLENOID COIL MAGNETIC PULL
MEANS COIL IS "ON”.
RGURE 9
•OCSSVOC
SWITCH
TERMINALS
FLAME SENSOR SOCKET
RGURE 10
THERMAL FUSE ELEMENT (TFE)
RGURE 4
E50 PILOT BURNER ASSY.
RGURE 8
3098 MERCURY FLAME SENSOR
RGURE 11

Operation, Wiring Diagrams, Trouble Shooting
HE (Series 2) and VHE (Series 2) With White-Rodgers Cycle-Pilot®
For Natural Gas Firing
BOILER EQUIPMENT COMPONENTS
BLOWER MOTOR
120/60/1,3450 RPM permanent split capacitor motor with ca¬
pacitor start and internal overload protection provides rota¬
tion of induced draft fan.
FAN (BLOWER WHEEL)
Develops induced draft to supply combustion air to boiler.
PRE-PURGE TIMER
Provides 30 second pre-purge prior to pilot ignition.
HIGH TEMPERATURE LIMIT CONTROL
In the event of high boiler water temperature, shuts down fan
and burners but allows circulator to run as long as there is a
call for heat from thermostat.
PRESSURE SWITCH
Detects pressure differential across fixed metering orifice to
prove air flow through boiler.
COMBINATION PRESSURE AND
TEMPERATURE GAUGE
Provides readings of boiler water pressure and temperature.
COMBINATION RELAY RECEPTACLE,
JUNCTION BOX AND TRANSFORMER
120/24 VOLT 40 VA transformer provides low voltage for con¬
trol circuit. Relay receptacle for plug-in circulator relay. Ter¬
minal strip for control circuit wiring.
PLUG-IN CIRCULATOR RELAY
Provides contact to energize circulator and fan and contact to
prove operation of pressure switch.
ASME SAFETY PRESSURE RELIEF VALVE
Provides safety discharge in the event boiler water pressure
exceeds 30 PSIG.
FILL-TROL SYSTEM (TYPES P-HE AND P-VHE ONLY)
Includes compression tank with permanent air cushion and
combination manual shut-off valve, check valve, pressure re¬
ducing valve and strainer for automatic filling and maintai n,
ing m i nim um system pressure.
«
AUTOMATIC AIR VENT (TYPES P-HE AND P-VHE ONLY)
Vents air from boiler built-in air el imi n ator tapping.
GAS VALVE
Incorporates a pilot/redundant solenoid valve, integral pres¬
sure switch to sense incoming gas pressure, pressure regula¬
tor, main valve operator and socket to accept plug-in Mercury
Flame Sensor.
MERCURY FLAME SENSOR
Consists of sensing bulb, capillary tube and diaphra gm filled
with mercury and connected to SPDT switch. Heat from pilot
vaporizes mercury causing diaphragm to snap switch.
RELITE CONTROL
Provides spark to light pilot.
PILOT BURNER ASSEMBLY
Includes spark ignition pilot with mercury flame sensing
probe.
THERMAL FUSE ELEMENT (TFE)
Provides safety shutdown of burners and pilot if flame is not
contained in firebox.
DRAIN VALVE
Used to drain boiler if necessary.
CIRCULATOR
Provides forced water circulation to hot water heating system.
SEQUENCE OF OPERATION
Referring to Ladder Diagram, Page 5.
1. Thermostat closes, activating relay CR (through pressure
switch). Contacts CR1 and CR2 close:
a) CR2 activates circulator.
b) Blower is activated through limit switch.
c) CRl provides a bypass around pressure switch to prove
its operation.
2. When adequate draft is proven by pressure switch, the 30
second pre-purge timer starts.
3. After a 30 second delay, 24 VAC is provided to terminals:
a) T2 on relite control which starts spark.
b) L on gas valve which opens pilot valve.
4. Pilot ignites:
a) Flame conduction stops spark from relite.
b) Mercury flame sensor opens main gas valve and pres¬
sure switch in gas valve holds pilot open.
5. After thermostat is satisfied, CR is deactivated:
a) CR2 opens turning off blower and pump.
b) CRl opens turning off gas flow.
6. As air flow from blower reduces pressure, switch changes to
normally closed position.
7. Boiler is now in "off” cycle.
4

trouble shooting procedure
NEVER jumper out (by-pass) the Thermal Fuse Element (TFE) or n «y other for
moment Ly Sting as outlined in Trouble Shooting Tables). A Hre causing property damage
and/or personal injury could result.
A. Before tsH-ing the trouble shooting procedure, be sure of to sioe of
the following:
1. You have a voltmeter capable of checking 120 VAC, 24
VAC and a continuity tester.
2. That 120 VAC power supply is available to the boiler
(' minimum 102 VAC, maximum 132 VAC).
3. That there is 24 VAC at the secondary side of the con¬
trol transformer.
4. You have an inclined manometer with a range of 0-2.0
W.C.
FIGURE 12
CHECKING THE PRESSURE DIFFERENTIAL SWITCH
Note:Make sure boiler water temperature is 100* F or cooler
before beginning procedure.
1. Remove the sensing tube at the front of the pressure
switch (closest to you as you face the boiler). Refer to Fig¬
ure 12.
2. Install a "T” into the sensing tube and another piece of
tubing from the ”T” to the pressure switch.
3. Attach the third leg of the "T” to the suction side of an
inclined manometer.
4. Remove the sensing tube at the rear of the pressure
switch.
5. Install a "T” into the sensing tube and another piece of
tubing from the "T” to the pressure switch.
6. Attach the third leg of the "T” to the pressure side of the
manometer.
7. Close the manual main gas valve and set thermostat to
call for heat. Blower will run but pilot and main burners
will not ignite. *
8. Check for 24 VAC between normally open terminal on
pressure switch and terminal C on transformer (Figure 1
and 2).
9. If the reading on the .nanometer is at least L8 ^ hes wa-
I .i i h«re is not 24 V across N.O. ter-
ter column pressure, but .heje t replace
mmal on pressure swltcn ana ierw» r
pressure switch.
,n - • 1 „ 1 1 ,an 1 8' W.C. look for tbe follow-
10. Ifthe reamngis lower tima a-o
ing causes:
a. Blockage in sensing tube.
b. Obstruction in the blnwer housing nutlet.
c. Loose bucwer wheel ««• motor shaft.
d. Blower =ocor not at (>ruper RPM.
e. Blower ruck plate net sealed properly.
f. Block airs in the block assembly.
g. Blockade in the flu" |»i|*** o r termination.
1. When pressure reading « proper and pressure switch is
operating properly, rnuu.ve ”T"s and re-.nstall sensing
tubes to tbs pressure switch.

r
HE (Series 2) and VHE (Series 2) with White-Rodgers Cycle-Pilot* for Natural Gas Firing * ' ■ ■ ;
TABLE I—BLOWER AND CIRCULATOR WILL NOT OPERATE
TABLE II—BLOWER WILL NOT OPERATE, BUT CIRCULATOR DOES OPERATE
7

HE (Series 2) and VHE (Series 2) with Whit e-Rodger* Cycle-Pilot* for Natural Gas Firing
TABLE III—CIRCULATOR WILL NOT OPERATE, BUT BLOWER DOES OPERATE
TABLE IV—NO SPARK AT PILOT—BLOWER & CIRCULATOR BOTH OPERATE

HE (Series 2) and VHE (Series 2) with Whit e-Rodgers Cycle-Pilot* for Natural Gas Firing
TABLE V—SPARK IS PRESENT—PILOT WILL NOT LIGHT
Make sura all gas cocks and gas shut-off
valve# are open, la the gas cock knop on
the 36C84 valve in the "on" position?
(Figure 6)
Is incoming pressure at least 5.0'?
Move gas cock knob to the “ON” position.
(Figure 6)
Is 3098 Mercury Flame Sensor plugged
into gas valve? (Figure 11)
If alt gas cocks are open, contact the gas
supplier. The 36C84 series valve requires a
minimum of 5.0" W.C. inlet. (Figure 7)
Place a steel rule or small screwdriver
blade across the top of the pilot solenoid
coil. Is a magnetic pull felt? (Figure 9)
Firmly seat 3098 Flame Sensor into gas
valve socket. (Figures 10-11)
Is gas present at the pilot burner? (Use a
match taped to a long screwdriver or a pilot
lighter to manually light pilot) (Figure 8)
Is 24 VAC across terminals C and L on
36C84 gas valve? (Figure 7)
Check wiring to gas valve.
Check for ignition sparks between the
electrode tip and the sensing bulb. Does
spark occur in the middle of the pilot gas
stream.
Check for blocked pilot orifice or tubing.
(Figure 8). If orifice and tubing are dear,
replace gas valve. (Figure 7)
Check for physical damage to the pilot
bumers/electrode or debris near electrode.
With a manually lit pilot flame, check the
position of the tip of the ignition electrode.
The tip should be in the soft blue portion of
the pilot flame so that a spark to the pilot
head will ignite pilot gas. On an ignition trial
does the gas sputter past the spark? (See
Figure 8)
Remove the flame sensor from valve socket, and
place a jumper wire between holes 3 and 4 on
the gas.valve. With jumper in place, check for
magnetic field on top of solenoid coil. If
magnetic pull is not felt, replace gas valve. If
pull is felt, check flame sensor/gas valve
socket connections. Clean pins on sensor plug
with emery cloth. (Figure 10). Replace flame
sensor if condition is not corrected.
Check for weak ignition spark, spark
occurring at locations other than ignition
electrode, high drafts across pilot
burner, and damaged pilot burner
assembly. (Figure 8)
Decrease pilot gas pressure. Remove
pilot adjust cover screw and rotate
adjust screw dockwise to decrease gas
pressure (Figure 7}
Attempt to increase pilot gas pressure
by removing pilot adjust cover-screw
and rotating pilot adjust screw
counterclockwise. If pilot flame size
does not increase, check for high drafts
across pilot burner. (Figure 10)
9

HE (Series 2) and VHE (Series 2) with White-Rodgers Cycle-Pilot® for Natural Gas Firing
TABLE VI—SPARK WILL NOT SHUT-OFF AFTER PILOT FLAME IS ESTABLISHED
r

HE (Series 2) and VHE (Series 2) with Whtte-Rodgers Cycle-Pilot* for Natural Gas Firing
TABLE VII—PILOT LIGHTS—NO MAIN BURNER IGNITION