Weil-McLain CGS-4E manual Does blower motor operate?

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

11d Troubleshooting — control module lights (cont.)

CHART 5 — PRESS SWITCH light flashing and POWER light on steady

— Usually indicates pressure switch opened during run cycle —

— May also be caused by wind gusts in excess of 31 mph for non-direct vent sidewall-vented boilers —

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.

•Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds.

•Thermostat should call for heat and appropriate zone valves open.

Does blower motor operate?

No

Yes

•Remove INDUCER plug (Figure 25, Item 6, page 46) from plug receptacle of control module.

•Place voltmeter leads across the 120 VAC N and

120 VAC H pins of the INDUCER receptacle (left column center and right column bottom pins).

Does the voltmeter indicate 120 VAC?

No		Yes

• Replace inducer assembly.

• Retest.

•Remove one of the wires connected to the pressure switch.

•Check continuity across the switch terminals.

Does the ohmmeter indicate the switch is closed?

No			Yes

• Wait 5 minutes.

Is PRESS SWITCH light flashing?

No			Yes

•Boiler should be in normal operating sequence.

•Observe operation until thermostat is satisfied and inducer has completed its post- purge cycle.

•Inspect and check wire harness from control module to pressure switch.

•Reseat connector in control module receptacle.

•If harness is intact and properly seated, but problem persists, replace control module.

•Retest.

Are vent or combustion air passages blocked?

No			Yes

•	Check air pressure switch per manual Section 11.		•	Clear passages and recycle
				boiler.
•	Replace if necessary. Retest.
			•	Recheck boiler operation.

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 Vent system When removing boiler from an existing common vent system1c Prepare boiler location vent system CGs-4E special vent system1d Prepare boiler location contamination Products to avoidAreas likely to have contaminants 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 3e Water piping refrigeration systems Prevent chilled water from enteringBoiler Venting and combustion air Vent systemCombustion air openings Combustion air quality 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 boilerCheck burner flames Pilot burner flame FigureMain 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 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 5.082a1 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, , 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