Weil-McLain CGS-4E manual 11b Troubleshooting air pressure switch, Air pressure switch

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GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual

11b Troubleshooting — air pressure switch

Air pressure switch

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

Check pressure switch setting

1.See Figure 24 and Table 6.

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

3.Install tees and tubing as shown in Figure 24 to inclined manometer.

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

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

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

— replace air pressure switch.

Figure 24 Manometer connections

Table 6 Pressure switch setpoint

(for elevations above 2,000 ft, contact your local Weil-McLain sales office for details.)

Boiler model number	Inches W.C.
CGs-4E	1.71”

Troubleshooting air pressure reading

1.If manometer reading is lower than the setpoint of the switch (see Table 6) — 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

•blockage in flue pipe or termination

•incorrect 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.

The boiler will not operate correctly unless pressure switch hoses are correctly located. The red hose connects 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

24.

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Part number 550-110-282/1108

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Contents GOLDCGs-4E How it works Gold CGs-4EGas-Fired Induced-Draft Water Boiler Contents User InstallerPlease read before proceeding Before locating the boiler, check the following 1a Prepare boiler location codes & checklistInstallations must follow these codes 1b Prepare boiler location clearances When removing boiler from an existing common vent system 1c Prepare boiler location vent systemCGs-4E special vent system Vent systemAreas likely to have contaminants 1d Prepare boiler location contaminationProducts to avoid 1e Prepare boiler location air openings Combustion air requirementsSpecial considerations Sizing air openingsSizing air openings for CGs-4E installations 2a 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 Water piping general information Install an automatic air vent in air vent tapping as shown 3b Water piping single-zone system3c Water piping multiple zones Piping multiple zonesBoiler isolation balancing valves Flow/check valve System or zone circulator Zone valve Drain valveRelief valve Fill valveTemperature gauges Valve adjustment Figures 8 and 9 only3d Piping low temp systems Primary/secondary preferred bypass piping methodBlend temperature gauge Boiler isolation balancing valvesValve adjustment BOILER-bypass piping methodFigures 8 SYSTEM-bypass piping method Boiler 3e Water piping refrigeration systemsPrevent chilled water from entering Combustion air openings Combustion air quality Venting and combustion airVent system Connecting gas supply piping to boiler Gas pipingNatural Gas Propane GasField wiring Electrical installation must comply withWiring connections ThermostatFreeze protection when used 7a Start-up preparationDetermine if water treatment is needed Check for gas leaks7b Start-up operate boiler Inspect system water piping Inspect base insulationFinal check before starting boiler Start the boilerMain burner flame Figure Check burner flamesPilot burner flame Figure If none of the above corrects the problem, refer to 7c Start-up if boiler doesn’t startCheck for Gas not turned on at meter or boiler?Check-out procedure checklist Installation and service certificateBoiler is now in the off cycle 9a Operation sequenceSequence returns to step Operation sequence 9b Operation wiring diagrams Wiring diagram9c Operating instructions CGs-4E Addendum Instruction for Commonwealth of Massachusetts CMR 5.082a 1 throughExemptions The following equipment is exempt from CMR 5.082a1 through10a Service and maintenance schedule 10b Service & maintenance annual start-up With boiler power off, place a few drops of S.A.E Burners, base and inlet air boxCondensate drain system Inducer motor10b Service & maint. annual start-up Boiler relief valve Relief valve, typicalClean between sections with wire flue brush Review with ownerShut down boiler Place newspapers in base of boiler to collect soot11a Troubleshooting procedure Before troubleshootingCheck the following Can result11b Troubleshooting air pressure switch Air pressure switchCheck pressure switch setting Troubleshooting air pressure reading11c Troubleshooting control module Control indicator lights Lockout modesControl indicator lights NON-LOCKOUT modes Troubleshooting the control moduleControl module connections 11d 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 of operation, , Weil-McLain part numbers are found in Weil-McLain Boilers 12a Replacement partsSection assembly Base Jacket Trim Controls 12b Replacement parts section assembly Weil-McLain part number12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyBoiler 12e Replacement parts trim Fittings shown are factory-installed on boiler12f Replacement parts controls Propane gas components13a Dimensions Dimensional drawing13b Ratings Tested for 50 psi working pressureEye Irrigate immediately Breathing Fresh air Handling ceramic fiber and fiberglass materialsThis type of respirator is based on