Weil-McLain CGS-4E manual 11c Troubleshooting control module, Control module

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

11c Troubleshooting — control module

Control module

Solder or water splatter between plugs and circuit board can cause improper operation of control module. Place a shield over the boiler internal controls and components during installation. Failure to comply could result in severe personal injury, death or substantial property damage.

Make sure ground wiring is installed per wiring diagram. Good grounding is extremely important for proper operation.

Control indicator lights —

LOCKOUT modes

See Charts 1 through 7 in this Section for detailed trouble-

shooting procedures.

To reset control after a lockout, turn off power at the 120 VAC service switch or turn down all thermostats. Wait 45 seconds. Then restore power or call for heat.

POWER light flashing alone

Usually indicates reversed polarity of 120 VAC power wires.

POWER and TSTAT CIRC lights flashing

Usually indicates stray voltage on external thermostat circuit wires (usually due to miswired 3-wire zone valve).

POWER and PRESS SWITCH lights flashing

Usually indicates pressure switch is closed when it should not be, or pressure switch failed to close within 5 minutes of inducer starting.

POWER and FLAME lights flashing

Usually indicates false flame sense or flame sensed when it shouldn’t be there.

Control indicator lights —

NON-LOCKOUT modes

POWER light on and FLAME light flashing

Usually indicates pilot flame was not established within 15 seconds from application of spark. Control will flash light, but will continue to cycle indefinitely until flame is established or problem is corrected.

POWER light on and PRESS SWITCH light flashing

Usually indicates pressure switch opened during the run cycle.

Troubleshooting the control module

See Figure 25, page 46, for location of harness plug receptacles and plugs on the control module.

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 Installer Please read before proceedingUser 1a Prepare boiler location codes & checklist Installations must follow these codesBefore locating the boiler, check the following 1b Prepare boiler location clearances 1c Prepare boiler location vent system When removing boiler from an existing common vent systemCGs-4E special vent system Vent system1d Prepare boiler location contamination Products to avoidAreas likely to have contaminants Combustion air requirements 1e Prepare boiler location air openingsSpecial considerations Sizing air openingsSizing air openings for CGs-4E installations Orifice replacement procedure 2a Prepare boiler placement & setupPlace boiler/crate near position Inspect orifices and burnersHydrostatic pressure test 2b Prepare boiler pressure testDrain and remove fittings Prepare boiler for test3a Water piping general information 3b Water piping single-zone system Install an automatic air vent in air vent tapping as shownPiping multiple zones 3c Water piping multiple zonesSystem or zone circulator Zone valve Drain valve Boiler isolation balancing valves Flow/check valveRelief valve Fill valveValve adjustment Figures 8 and 9 only Temperature gauges3d Piping low temp systems Primary/secondary preferred bypass piping methodBoiler isolation balancing valves Blend temperature gaugeBOILER-bypass piping method Valve adjustmentFigures 8 SYSTEM-bypass piping method 3e Water piping refrigeration systems Prevent chilled water from enteringBoiler Venting and combustion air Vent systemCombustion air openings Combustion air quality Gas piping Connecting gas supply piping to boilerNatural Gas Propane GasElectrical installation must comply with Field wiringWiring connections Thermostat7a Start-up preparation Freeze protection when usedDetermine if water treatment is needed Check for gas leaksInspect system water piping Inspect base insulation 7b Start-up operate boilerFinal check before starting boiler Start the boilerCheck burner flames Pilot burner flame FigureMain burner flame Figure 7c Start-up if boiler doesn’t start If none of the above corrects the problem, refer toCheck for Gas not turned on at meter or boiler?Installation and service certificate Check-out procedure checklist9a Operation sequence Sequence returns to stepBoiler is now in the off cycle Operation sequence Wiring diagram 9b Operation wiring diagrams9c Operating instructions CGs-4E CMR 5.082a 1 through Addendum Instruction for Commonwealth of MassachusettsExemptions The following equipment is exempt from CMR 5.082a1 through10a Service and maintenance schedule 10b Service & maintenance annual start-up Burners, base and inlet air box With boiler power off, place a few drops of S.A.ECondensate drain system Inducer motor10b Service & maint. annual start-up Relief valve, typical Boiler relief valveReview with owner Clean between sections with wire flue brushShut down boiler Place newspapers in base of boiler to collect sootBefore troubleshooting 11a Troubleshooting procedureCheck the following Can resultAir pressure switch 11b Troubleshooting air pressure switchCheck pressure switch setting Troubleshooting air pressure readingControl indicator lights Lockout modes 11c Troubleshooting control moduleControl indicator lights NON-LOCKOUT modes Troubleshooting the control moduleControl module connections Chart 1 Troubleshooting Power light status 11d Troubleshooting control module lightsChart 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, , 12a Replacement parts Section assembly Base Jacket Trim ControlsWeil-McLain part numbers are found in Weil-McLain Boilers Weil-McLain part number 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketBoiler Fittings shown are factory-installed on boiler 12e Replacement parts trimPropane gas components 12f Replacement parts controlsDimensional drawing 13a DimensionsTested for 50 psi working pressure 13b RatingsHandling ceramic fiber and fiberglass materials This type of respirator is based onEye Irrigate immediately Breathing Fresh air