Weil-McLain CGS-4E manual 11d Troubleshooting control module lights

Page 47

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

11d Troubleshooting — control module lights

CHART 1 — Troubleshooting POWER light status

— Usually indicates reversed 120 VAC polarity if POWER light flashes by itself —

Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.

Is POWER light off?

 

No

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is POWER light ...

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Flashing

Flashing with

 

On steady

 

 

alone

another light

 

(not flashing)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TSTAT CIRC

 

Chart

 

 

 

 

 

light flashing

2

 

 

 

 

 

 

 

 

 

 

PRESS SWITCH

 

Chart

 

Chart

 

 

light flashing

3

 

5

 

 

FLAME

 

Chart

 

Chart

 

 

light flashing

4

 

6

 

 

 

 

 

 

 

 

 

 

 

For insufficient heat or no heat problem, go to Chart 7 if POWER light is on steady, with no other light flashing.

•Make sure service switch or circuit breaker is on or fuses are good.

•Remove 120 VAC IN plug (Figure 25, Item 3, page 46) on control module.

•Using voltmeter, check across top and bottom pins of

120 VAC IN plug.

Does voltmeter indicate 120 VAC?

No

Yes

 

 

 

Problem is with incoming electricity. Have licensed electrician repair circuit.

•Reconnect 120 VAC IN plug.

•Remove 120 VAC IN transformer PRIMARY plug (Figure 25, Item 3, page 46) on control module.

•Using voltmeter, check across top and bottom pins of

PRIMARY receptacle.

Does voltmeter indicate 120 VAC?

No

Yes

 

 

 

•Usually indicates polarity on incoming 120 VAC power line is wrong.

•TURN OFF POWER at service switch or breaker, then reverse the HOT and NEUTRAL wires entering the boiler in the J-box.

•Restore POWER at service switch or breaker.

Is POWER light flashing now?

No

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

Have system checked by a

 

 

 

licensed electrician. If

 

 

 

problem persists, call your

Boiler should now

 

local Weil-McLain sales

operate normally.

 

representative.

 

 

 

 

 

Replace control module.

Retest.

•Reinstall 120 VAC transformer PRIMARY plug.

•Remove 24 VAC transformer plug (Figure 25, Item 3, page 46) on control module.

•Using voltmeter, check pins of plug.

Does voltmeter indicate 24 VAC?

No

 

Yes

 

 

 

 

 

 

 

 

 

 

Replace transformer.

 

 

 

Retest and check for back

 

 

 

feed of voltage from

 

Replace control module.

system wiring.

 

Retest.

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 Vent system When removing boiler from an existing common vent system1c Prepare boiler location vent system CGs-4E special vent systemAreas likely to have contaminants 1d Prepare boiler location contaminationProducts to avoid Sizing air openings 1e Prepare boiler location air openingsCombustion air requirements Special considerationsSizing air openings for CGs-4E installations Inspect orifices and burners 2a Prepare boiler placement & setupOrifice replacement procedure Place boiler/crate near positionPrepare boiler for test 2b Prepare boiler pressure testHydrostatic pressure test Drain and remove fittings3a 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 zonesFill valve Boiler isolation balancing valves Flow/check valveSystem or zone circulator Zone valve Drain valve Relief valvePrimary/secondary preferred bypass piping method Temperature gaugesValve adjustment Figures 8 and 9 only 3d Piping low temp systemsBoiler isolation balancing valves Blend temperature gaugeBOILER-bypass piping method Valve adjustmentFigures 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 Propane Gas Connecting gas supply piping to boilerGas piping Natural GasThermostat Field wiringElectrical installation must comply with Wiring connectionsCheck for gas leaks Freeze protection when used7a Start-up preparation Determine if water treatment is neededStart the boiler 7b Start-up operate boilerInspect system water piping Inspect base insulation Final check before starting boilerMain burner flame Figure Check burner flamesPilot burner flame Figure Gas not turned on at meter or boiler? If none of the above corrects the problem, refer to7c Start-up if boiler doesn’t start Check forInstallation and service certificate Check-out procedure checklistBoiler is now in the off cycle 9a Operation sequenceSequence returns to step Operation sequence Wiring diagram 9b Operation wiring diagrams9c Operating instructions CGs-4E CMR 5.082a1 through Addendum Instruction for Commonwealth of MassachusettsCMR 5.082a 1 through Exemptions The following equipment is exempt from10a Service and maintenance schedule 10b Service & maintenance annual start-up Inducer motor With boiler power off, place a few drops of S.A.EBurners, base and inlet air box Condensate drain system10b Service & maint. annual start-up Relief valve, typical Boiler relief valvePlace newspapers in base of boiler to collect soot Clean between sections with wire flue brushReview with owner Shut down boilerCan result 11a Troubleshooting procedureBefore troubleshooting Check the followingTroubleshooting air pressure reading 11b Troubleshooting air pressure switchAir pressure switch Check pressure switch settingTroubleshooting the control module 11c Troubleshooting control moduleControl indicator lights Lockout modes Control indicator lights NON-LOCKOUT modesControl 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, , Weil-McLain part numbers are found in Weil-McLain Boilers 12a Replacement partsSection assembly Base Jacket Trim Controls 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 RatingsEye Irrigate immediately Breathing Fresh air Handling ceramic fiber and fiberglass materialsThis type of respirator is based on
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