Weil-McLain CGS-4E manual Chart 2 Tstat Circ & Power lights flashing

Page 48

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

11d Troubleshooting — control module lights

CHART 2 — TSTAT CIRC & POWER lights flashing

— Usually indicates 48 VAC on thermostat circuit (stray voltage) —

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.

• Disconnect the two external wires connected to the boiler			• If a voltage does occur under any condition, check and
thermostat leads (two black low voltage leads in J-box).				correct the external wiring. (This is a common problem
• Connect a voltmeter across these two incoming wires.				when using 3-wire zone valves.)

Close each thermostat, zone valve and relay in the external			• Once the external thermostat circuit wiring is checked and
circuit one at a time and check the voltmeter reading				corrected if necessary, reconnect the external thermostat
across the wires.				circuit wires to the boiler thermostat wires and allow the
• There should NEVER be a voltage reading.				boiler to cycle.

Did you find a voltage across the two external thermostat circuit wires?

Yes				No

•Leave external boiler thermostat connection wires disconnected from boiler.

•Troubleshoot the external thermostat circuit until you find the source of the stray voltage. (Pay close attention to the wiring connections to 3-wire zone valves.)

•Correct the problem and repeat the voltmeter test above, verifying there is no longer a voltage reading under any condition in the external thermostat circuit.

•An isolating relay may be required.

•If no voltage is found under any condition of the external thermostat circuit, connect the two boiler thermostat connection leads together (or jumper the boiler aquastat T-T terminals).

• Turn off power to the boiler for 1 minute.

• Turn on power and allow boiler to cycle.

Do the TSTAT and POWER lights still flash?

No		Yes

•Boiler should now operate per the normal sequence of operation shown in Figure 18, page 33.

•Replace control module.

•Retest.

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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 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 When removing boiler from an existing common vent system 1c Prepare boiler location vent systemCGs-4E special vent system Vent system1d Prepare boiler location contamination Products to avoidAreas likely to have contaminants 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 3e Water piping refrigeration systems Prevent chilled water from enteringBoiler Venting and combustion air Vent systemCombustion air openings Combustion air quality 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 boilerCheck burner flames Pilot burner flame FigureMain 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 certificate9a Operation sequence Sequence returns to stepBoiler is now in the off cycle 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, , 12a Replacement parts Section assembly Base Jacket Trim ControlsWeil-McLain part numbers are found in Weil-McLain Boilers 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 pressureHandling ceramic fiber and fiberglass materials This type of respirator is based onEye Irrigate immediately Breathing Fresh air