Weil-McLain Series 2 manual 11a Troubleshooting procedure, 11b Troubleshooting components

Page 48

GOLD CGi Gas-Fired Water Boiler — Boiler Manual

11a Troubleshooting — procedure

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and danger- ous operation.

Never jumper (bypass) rollout thermal fuse element or any other device except for momentary testing as outlined in Troubleshooting Charts. Severe personal injury, death or substantial property damage can re- sult.

Before troubleshooting:

1.Have the following items:

a.Voltmeter that can check 120 VAC and 24 VAC.

b.Microammeter with a minimum scale range of 0-25.

c.Continuity checker.

d.U-tube manometer.

2.Check for 120 VAC (minimum 102 VAC to maximum 132 VAC) to boiler.

3.Make sure thermostat is calling for heat and contacts (including appro- priate zone controls) are closed. Check for 24 VAC between thermostat wire nuts and ground.

Check the following:

1.Wire connectors to control module are se- curely plugged in at module and originating control.

2.Air pressure switch hoses are properly and securely plugged in and are not damaged.

3.Gas pressures:

a.With boiler off — 13” w.c. maximum natural or propane gas pressure up- stream of gas valve.

b.With boiler on:

•5” w.c. minimum natural gas pressure or 11” w.c. propane gas pressure upstream of gas valve.

•3 ½” w.c. minimum natural gas pressure or 10” w.c. propane gas pressure downstream of gas valve

— Can be adjusted by regulator on gas valve.

11b Troubleshooting — components

Air pressure switch

Make sure boiler water temperature is 100 °F or cooler before starting procedure to obtain appropriate read- ings.

The boiler will not operate correctly unless pressure switch hoses are correctly located. The red hose con- nects from the right side (negative) hose barb to the flue collector. The white hose connects from the left side (positive) hose barb of the switch to the connector box (between flue collector and inducer) as shown in Figure 36, page 49.

Check pressure switch setting

1.See Figure 36, page 49, and Table 9.

2.Remove both air pressure switch hoses from air pressure switch.

3.Install tees and tubing as shown in Figure 36, page 49, to inclined manom- eter.

4.Turn off gas valve and set thermostat to call for heat. Inducer will run but burn- ers will not ignite.

5.Check for 24 VAC between both air pressure switch terminals.

Troubleshooting air pressure reading

1.If manometer reading is lower than the setpoint of the switch (see Table 9)

— check for possible causes:

•blockage in hoses

•obstruction in inducer housing outlet

•loose inducer wheel on motor shaft

•inducer motor not in proper rpm

•inducer back plate not sealed properly

•blockage in block assembly

6.If manometer reading is above the setpoint of the switch (see Table 9), but there is not 24 VAC between both air pressure switch terminals — replace air pressure switch.

Return to normal operation

When pressure reading is correct and air pressure switch is operating properly — remove tees and reinstall hoses to air pressure switch.

Table 9 Pressure switch setpoint (for elevations above 2,000 ft, contact your local Weil- McLain sales office for details.)

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Part Number 550-110-710/0107

 

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Contents Gold CGi How it works Gold CGi Gas-Fired Induced-Draft Water Boiler Contents Please read before proceeding 1a Prepare boiler location codes & checklist Installations must follow these codesBefore locating the boiler, check the following 1b Prepare boiler location clearances When removing boiler from an existing common vent system 1c Prepare boiler location vent systemChimney or vent require- ments 1d Prepare boiler location air contamination Products to avoid1e Prepare boiler location air openings Air openings must be providedAir opening options Two openings Air supply from inside the buildingExhaust fans and air movers Motorized air dampersSingle air opening option Exception for large spaces2a Prepare boiler placement & setup Orifice replacement procedurePlace boiler/crate near position Inspect orifices and burners2b Prepare boiler pressure test Hydrostatic pressure testDrain and remove fittings Prepare boiler for test3a Venting general information Venting chimney draft ventingCGi venting methods Chimney draft or Direct exhaust Chimney draft venting3c Venting Direct exhaust components Obtain vent system components3d Venting direct exhaust vent starter 3e Venting direct exhaust termination Vent termination minimum clearances3f Venting direct exhaust installation Direct exhaust vertical ventingUsing any termination other than one of those shown 4a Water piping general information 4b Water piping single-zone system Diaphragm-type or bladder- type expansion tank FigureClosed-type expansion tank 4c Water piping multiple zones Piping multiple zonesZoning with circulators 4d Piping low temperature systems Temperature gaugesValve adjustment Primary/secondary preferred bypass piping methodPrimary/secondary piping Valve adjustment BOILER-bypass piping methodBoiler-bypass piping Zoning with SYSTEM-bypass piping method 4e Water piping refrigeration system Prevent chilled water from entering boilerConnecting gas supply piping to boiler Gas pipingNatural Gas Propane GasField wiring Electrical installation must comply withWiring connections ThermostatFreeze protection when used 7a Start-up preparationCheck for gas leaks Determine if water treatment is neededFill the system with water Inspect system water pipingInspect base insulation 7b Start-up operate boiler Start the boilerCheck system and boiler 7c Start-up if boiler doesn’t start Check burner flamesCheck for Pilot burner flame FigureCheck-out procedure checklist Installation and service certificate9a Operation sequence 9b Operation wiring diagrams Schematic wiring diagramLadder wiring diagram 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-8 10a Service and maintenance schedule Verify Proper Operation After Servicing10b Service and maintenance annual start-up 10b Service & maintenance annual start-up Burners and baseCondensate drain system Inducer motorGas piping Cold fill and operating pressuresAir vents and air elimination Limit controls and cutoffsReview with owner Boiler relief valve11a Troubleshooting procedure 11b Troubleshooting componentsBefore troubleshooting Air pressure switchControl indicator lights Troubleshooting the control moduleControl indicator lights Lockout modes Control moduleControl module connections 11c Troubleshooting control module lights Chart 1- Troubleshooting Power light statusChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Chart 4 Flame & Power lights flashing Does blower motor operate? Item 8 , Verify Sequence 12a Replacement parts Section assembly Base Jacket Trim Controls12b Replacement parts section assembly Section assembly12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyBoiler 12e Replacement parts trim Fittings shown are included with boiler12f Replacement parts controls Propane gas components13a Dimensions Dimensional drawing13b Ratings DOEHandling ceramic fiber and fiberglass materials Removal of Combustion Chamber Lining or Base Panels
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Series 2 specifications

The Weil-McLain Series 2 is a highly regarded boiler system known for its robustness, efficiency, and ease of installation. Designed primarily for residential and light commercial applications, the Series 2 boasts a variety of features that cater to diverse heating needs.

One of the standout characteristics of the Series 2 is its cast iron construction, which provides durability and longevity. Cast iron is well-suited for heat retention, allowing the boiler to operate more efficiently and deliver consistent warmth. The Series 2 is available in multi-fuel options, accommodating both natural gas and propane, making it versatile for various installations.

Efficiency is a key feature of the Weil-McLain Series 2, with annual fuel utilization efficiency (AFUE) ratings that meet or exceed industry standards. This ensures that homeowners can enjoy not only a comfortable living environment but also reduced energy bills. The Series 2 is designed to provide optimal performance, minimizing fuel consumption while maximizing heat output.

Another innovative aspect of the Series 2 is its user-friendly control system. Equipped with advanced controls, the boiler allows for precise temperature management and can easily be integrated with existing heating systems. This adaptability is crucial for ensuring that the boiler matches the specific heating demands of any space, increasing overall comfort levels.

Installation is straightforward, thanks to the boiler's thoughtful design. The Series 2 features a compact footprint, allowing for flexible placement in various settings. Additionally, Weil-McLain provides comprehensive documentation and customer support, making it easier for technicians to install and maintain the system.

The Series 2 also includes features aimed at ease of maintenance. Its clean-out ports facilitate quick access for servicing, ensuring that the boiler remains in peak operating condition throughout its lifespan. Weil-McLain’s commitment to quality means users can expect reliable performance year after year.

Overall, the Weil-McLain Series 2 stands out as an excellent choice for those seeking a dependable, efficient, and straightforward heating solution. Its combination of durable construction, high efficiency, and user-centric design makes it a leading option in the boiler market, appealing to both homeowners and professionals alike. Whether for a new installation or a replacement, the Series 2 is poised to deliver exceptional heating performance.
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