Well-mcLain EGH 5 Series User manual

Control Supplement
EGH-105 to EGH-125
Natural gas‡
Part No. 550-110-677/1112
CSD-1 control system
‡ For propane boilers,install EGH liquefied petreoleum (propane) gas conversion kit in addition
to following the instructions in this Control Supplement.
Gas-Fired Boilers
EGH Series 5
This supplement must only be used by a qualified heating installer/service technician. Before installing, read all
instructions, including this supplement, the boiler manual and any related documents. Perform steps in the order
given. Failure to comply could result in severe personal injury, death or substantial property damage.

EGH-105 to EGH-125 Control Supplement
Part Number 550-110-677/1112
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.

  ............................................................................................ 4
  ................................................................................ 6
............................................................................. 6
 ..................................................................................... 7
 ............................................................................................ 8
 ............................................................................................ 8
  ................................................................................ 18
  ........................................................................... 20
 .................................................................... 27
............................................................................... 29
This Control Supplement must only be used by a qualified installer/service
technician. Read these instructions completely before beginning the instal-
lation. 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:
s 3TEAMBOILERSwith or without tankless heater.
This document is only intended as a supplement to the EG, PEG and
EGH (Series 5) Boiler Manual. Follow all instructions in the EG,
 in addition to the instructions in this Control
Supplement.

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 550-110-677/1112 3
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
Section assembly With tankless opening
Without tankless opening
321-711-120
321-711-125
321-711-130
321-711-135
321-711-140
321-711-145
Base assembly (a) CSD-1 381-700-507 381-700-508 381-700-509
Base panels 381-700-251 381-700-256 381-700-261
Jacket 411-800-281 411-800-291 411-800-301
Collector hood 450-014-757 450-014-758 450-014-759
Draft hood 450-206-242 450-206-243 450-206-244
Float low water cutoff (steam) Gravity return (M&M #67W-1)
Pumped return (M&M #42-A)
381-700-341
511-114-531
381-700-341
511-114-531
381-700-341
511-114-531
Vent damper (optional) (b) 381-800-446 381-800-447 381-800-447
Tankless heater (option) Steam boilers only 386-700-350 386-700-350 386-700-350
Trim & control (see below) Steam, CSD-1, Gravity return –– or ––
Steam, CSD-1, Pumped return
381-700-408
381-700-410
381-700-408
381-700-410
381-700-408
381-700-410
Note a – Base assembly includes burner tubes, gas train components, pilot assembly and control panel (with ignition control).
Note b – 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
Pressure limit control, automatic reset Pressure limit control, automatic reset
Pressure limit control, manual reset Pressure limit control, manual reset
Probe low water cutoff, manual reset Probe low water cutoff, manual reset
Transformer/relay Transformer/relay
Wire harness, steam gravity return Wire harness, steam pumped return
Crimp spade wire terminations Crimp spade wire terminations
ASME Relief valve ASME Relief valve
Pressure gauge Pressure 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-125 Control Supplement
Part Number 550-110-677/1112
4
Installation
 Refer to the Read and follow all of its guidelines.
Complete the following steps of the 
s 0LACINGTHEBOILER
s )NSTALLATIONOFOPTIONALWATERHEATERSSTEAMBOILERSONLY
s (YDROSTATICPRESSURETEST
s )NSTALLATIONOFmUECOLLECTORHOOD
s )NSTALLATIONOFBURNERDRAWERASSEMBLYANDFRONTACCESSPANELANDBACKBASECHANNEL
s *ACKETINSTALLATION
s $RAFTHOODINSTALLATION
 Connect gas train assembly to burner manifold:
s !PPLYPIPEDOPETOvNIPPLEFORINSERTIONINTOBURNERMANIFOLDCOUPLING&IGURE
item 1). Insert and tighten nipple.
s 0IPELOWERHALFOFGROUNDJOINTUNIONTOTHEvNIPPLE&IGUREITEM
s +NOCKOUTTHEJACKETGASVALVEOPENINGONTHEDESIREDSIDEOFTHEBOILERMAYBEROUTED
through either right or left side).
s 0LACE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.
s #ONNECTVENTLINESROUTEDTOOUTSIDEPERCODEREQUIREMENTSTOvTUBINGVENTCONNEC-
tions on main gas valve and pilot gas pressure regulator (Figure 3, item 3).
s #ONNECTPILOTGASTUBING1/8vALUMINUMTOADAPTERINPILOTGASVALVEOUTLET
(Figure 1, item 4).
s #RIMPCONNECTTWOvSPADETERMINALSPROVIDEDTOENDSOFPILOTGASVALVEWIRES
(Figure 1, item 5).
Figure 1
Gas train assembly

Install vent system and breeching per . If optional vent damper is
used, install vent damper (page 5) before installing breeching.
677-09
4
5
3
3
1
2

CSD-1 control system — Natural gas
Part Number 550-110-677/1112 5
If not installing a vent damper, proceed to next section
(Piping connections).
Once a vent damper has been oper-
ated on an EGH boiler, the boiler
will no longer operate without a
damper installed.
Only dampers listed in the Replace-
ment parts list in this Supplement
are certified for use with EGH
Series 5 boilers. Any other damper
installed could cause severe personal
injury or death.
-INIMUMCLEARANCES0ROVIDEAMINIMUMOF v
between the damper and any combustible material.
0ROVIDEAMINIMUMOFvBETWEEN%'(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 CSA certification and will
not be covered by Weil-McLain war-
ranty. Any changes will cause severe
personal injury, death or substantial
property damage.
Install damper directly on top of draft hood, with ar-
row 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+NOCKOUT
opening in jacket top and install strain relief bushings
Figure 2
Vent damper assemblies
Install optional vent damper (if supplied)
in jacket and actuator wiring openings. Insert wires and
secure strain relief clamps. See Figure 5 or 7 as applies.
 +EEPWIRING HARNESSES CLEAR OF ALL
hot surfaces.
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 5 or 7 as applies.
By-passing (jumpering) damper will
CAUSEmUEPRODUCTSSUCHASCARBON
monoxide to escape into the house.
This will cause severe personal in-
jury or death.
After boiler has operated once, if
either end of harness is discon-
nected, the system will shut down.
The boiler will not operate until the
harness is reconnected.

EGH-105 to EGH-125 Control Supplement
Part Number 550-110-677/1112
6
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. Sub-
stantial 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 3 and Table 2.
See also Figure 8 or Figure 10 for finished assembly.
s #3$REQUIRESTWOLOWWATERCUTOFFSONEMANUALRESETANDTWOLIMITCONTROLSONE
manual reset) as shown in the illustration.
s &ORmOATTYPEAUTOMATICRESETONLYLOWWATERCUTOFFSOTHERTHANTHOSESHOWNINTHIS
Supplement, refer to  for mounting and piping instructions.
 )NSTALLABLOWDOWNVALVEONANYmOATTYPELOWWATERCUTOFFASDESCRIBEDINTHE

Plug all unused tappings.
All piping and control connections must also comply with the 
Piping connections
Connect steam piping to the boiler per .

CSD-1 control system — Natural gas
Part Number 550-110-677/1112 7
Figure 3
Steam boiler connections
Table 2
Steam boiler connections
Optional heaters — steam boilers only
Install optional tankless heater, if used, (steam boiler only) per .
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
Pumped return –– McD-M 42-A
–––
511-114-494
511-114-531
L
Pressure gauge
Pressure limit, automatic reset
Honeywell L404C-1147 M/R limit
510-218-045
510-312-135
510-312-060
SSkim tapping (per EGH manual)–––
VGas supply connection (right or left) –––
Plug all tappings not used.
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

EGH-105 to EGH-125 Control Supplement
Part Number 550-110-677/1112
8
Gas piping
Size and connect gas supply piping per EG, PEG & EGH
.
The gas supply can enter from either the right or left side
of the jacket. Be sure the gas train is directed to the cor-
rect side.
Wiring
For your safety, turn off electrical
power supply before making any
electrical connections to avoid pos-
sible 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 two (2) wiring diagrams
and associated assembly illustrations. Refer to the fol-
lowing, as applicable:
s 3TEAMBOILERSGRAVITYRETURN&IGURESAND
s 3TEAMBOILERSPUMPEDRETURN&IGURESAND
General
Refer to  for further infor-
mation.
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 dis-
connect 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 accor-
dance 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 Install Boiler
Controls Section, page 6, of this Supplement.
Refer to the assembly illustration for the type of
boiler installed (Figure 5 or 7).
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 in-
terior panel as shown in the appropriate assembly
illustration (Figure 5 or 7), using screws and nuts
provided.
5. Crimp connect ¹⁄₄" spade terminals (provided)
to the pilot gas valve wires if not already done in
Installation Section, page 4 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 Installation Section, page 4 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 dia-
gram.
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 .

CSD-1 control system — Natural gas
Part Number 550-110-677/1112 9
General
The following sequence of operation applies to all wiring diagrams in this Supplement.
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 lock-
out.
/NFAILURETOESTABLISHPILOTmAMESIGNALWITHIN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
)NADDITIONTOLOCKOUTONmAME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 Check-out procedure — troubleshooting, page 22, of this Supplement and to
component manufacturer’s literature supplied in the boiler manual envelope for further
information on operating conditions.
Wiring — sequence of operation

Part Number 550-110-677/1012
10
Figure 4 Steam boiler wiring — ladder and schematic diagrams Wiring — steam gravity return

Part Number 550-110-677/1012 11
CSD-1 control system — Natural gasEGH-105 to EGH-125 Control Supplement

Part Number 550-110-677/1012
12
MV
MV/PV
PV
ALARM
ALARM
24V
24V (GND)
SENSE
SPARK
MV
MV/PV
PV
ALARM
ALARM
24V
24V(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 5 Control assembly — steam, gravity return Wiring — steam gravity return
When using a tankless heater,
knockout the opening in the inner panel. Locate the controls to allow room for the tankless heater piping. The tankless heater temperature control (not shown) installs in the heater tapping.

Part Number 550-110-677/1012 13
CSD-1 control system — Natural gasEGH-105 to EGH-125 Control Supplement
1 CSD-1 control panel 14 Pilot shutoff valve
2 Ignition control 15 Leak test valves with plugs
3Impulse relay and lighted push-button alarm
silencing switch 16 Gas supply connection
4 Terminal Strip 17 Burner manifold
5 Transformer/relay 18 Limit control, automatic reset
6 Junction box 19 Limit control, manual reset
7 Damper (optional) 20 Pressure gauge
8 Damper connector 21 Siphons
9 Dummy plug 22 Gauge glass & valves
10 Damper harness 23 Probe LWCO, manual reset
11 Main gas valve 24 Float LWCO, 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 550-110-677/1012
14
Figure 6 Steam boiler wiring — ladder and schematic diagrams Wiring — steam pumped return

Part Number 550-110-677/1012 15
CSD-1 control system — Natural gasEGH-105 to EGH-125 Control Supplement

Part Number 550-110-677/1012
16
MV
MV/PV
PV
ALARM
ALARM
24V
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 7 Control assembly — steam, pumped return Wiring — steam pumped return
When using a tankless heater,
knockout the opening in the inner panel. Locate the controls to allow room for the tankless heater piping. The tankless heater temperature control (not shown) installs in the heater tapping.

Part Number 550-110-677/1012 17
CSD-1 control system — Natural gasEGH-105 to EGH-125 Control Supplement
1 CSD-1 control panel 14 Pilot shutoff valve
2 Ignition control 15 Leak test valves with plugs
3Impulse relay and lighted push-button alarm
silencing switch 16 Gas supply connection
4 Terminal Strip 17 Burner manifold
5 Transformer/relay 18 Limit control, automatic reset
6 Junction box 19 Limit control, manual reset
7 Damper (optional) 20 Pressure gauge
8 Damper connector 21 Siphons
9 Dummy plug 22 Gauge glass & valves
10 Damper harness 23 Probe LWCO, manual reset
11 Main gas valve 24 Float LWCO, pump control, auto 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

EGH-105 to EGH-125 Control Supplement
Part Number 550-110-677/1112
18
Final adjustments
1. Follow  instructions for Final Adjustments,
including filling the boiler and skimming steam boilers.
Skimming the boiler as described the EG, PEG & EGH
 requires firing the boiler.
Always follow boiler Operating instructions, Figure
8, 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 the .

1. Follow Operating instructions, Figure 8, to start boiler.
2. If boiler starts correctly, proceed with Check-out procedure, page
20 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, page 22.


CSD-1 control system — Natural gas
Part Number 550-110-677/1112 19
Final adjustments — operating instructions
Figure 8 Operating instructions

EGH-105 to EGH-125 Control Supplement
Part Number 550-110-677/1112
20
Check-out procedure — operation
Always follow boiler Operating instructions, Figure 8, page 19 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)FDAMPERISNOTINOPENPOSITIONmUE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:
s 4HEIGNITIONCONTROLMONITORSPILOTmAMECURRENT)FSIGNALISLOSTMAINVALVEIS
closed, spark is activated, and the operating sequence returns to step 3.
s )F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).
s 0ILOTANDMAINGASVALVESWILLCLOSE
s $AMPER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.