Weil-McLain CGS-4E manual Item 8

Page 52

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

11d Troubleshooting — control module lights (cont.)

CHART 6 — FLAME light flashing and POWER light on steady

ALSO — Troubleshooting failure to establish main flame

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.

• Are main manual shutoff valve and boiler gas valve open?

 

 

 

 

 

 

•

Is pilot flame visible through inspection port?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

TURN OFF POWER to boiler at service switch or breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Check the voltage across

 

•

Make sure ground wire

• Open main manual shutoff valve and boiler gas valve (per

 

 

 

 

 

 

 

 

 

 

 

 

 

 

terminals PV and C of the

 

 

terminal is securely fastened

 

Operating instructions in this manual).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

gas valve.

 

 

 

 

 

 

 

 

to control module mounting

• Turn on power at service switch or breaker. A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is 24 VAC present there?

 

 

screw.

 

 

 

 

 

 

 

Does FLAME light flash now?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Boiler should be in

 

•

 

Verify inlet gas pressure at gas

 

 

 

 

 

 

•

If the wiring from the

 

 

•

Check the voltage across

 

 

 

valve:

 

 

 

 

 

 

 

 

 

 

 

 

 

control module to gas

 

 

 

terminals MV and C of the

 

normal operating

 

 

 

Natural gas — 5.0" w.c. min/14.0"

 

 

 

 

 

 

 

valve is intact, replace the

 

 

 

 

gas valve.

 

 

 

sequence.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

w.c. max

 

 

 

 

 

 

 

control module.

 

 

 

 

Is 24 VAC present there?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Observe operation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Propane — 11.0" w.c. min/14.0"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

Yes

 

until thermostat is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

w.c. max

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

satisfied and blower

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is gas present at gas valve inlet and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

has completed its

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

post-purge cycle.

 

 

 

 

 

within above range?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Verify inlet gas pressure at gas valve:

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Natural gas — 5.0" w.c. min/14.0" w.c. max

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Propane — 11.0" w.c. min/14.0" w.c. max

 

 

•

TURN OFF POWER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to boiler at service switch or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is gas present at gas valve inlet and within above range?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

breaker.

 

 

 

• Contact gas supplier to correct

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Remove air inlet box top

 

 

 

 

pressure or gas supply.

 

 

 

 

 

No

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see Figure 27, page 56 for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

location).

 

 

 

•

TURN OFF POWER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

TURN OFF POWER to boiler at service switch or breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to boiler at service switch or

 

 

 

•

Check flame signal — Detach sense lead from ignition control

• Verify pilot gas line is not

 

 

 

 

 

 

 

 

kinked, obstructed or

 

 

 

 

breaker.

 

 

 

 

(Figure 25, item 8, page 46).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

damaged and is correctly

 

 

 

• Remove burner shield (see

 

 

 

• Connect negative lead of MICROAMMETER to control sense

 

attached to pilot and gas

 

 

 

 

Figure 27, page 56 for location).

 

 

 

 

 

 

 

 

 

 

 

 

terminal (Figure 25, item 8, page 46). Connect positive lead of

 

valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MICROAMMETER to sense wire.

 

 

 

 

 

 

• Verify pilot ignition electrode,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

DISCONNECT red wire connected to terminal MV of the gas

 

 

• Verify pilot burner is securely

 

 

 

 

electrode ceramic and spark

 

 

 

 

 

 

 

 

 

attached to pilot bracket, bracket

 

 

 

 

valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

lead wire from control are in

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

is securely attached to cross tie,

 

 

 

•

Turn on power to boiler and allow to cycle. As soon as pilot is

 

good condition. Spark gap

 

 

 

 

 

 

 

 

 

 

 

 

and there is no corrosion on the

 

 

 

 

burning, the MICROAMMETER should read at least 1.0

 

should be approximately 1/8".

 

 

 

 

 

 

 

 

 

parts which would affect the

 

 

 

 

microamp.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Correct any above problems,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ground path for flame sense.

 

 

 

 

 

Is flame signal at least 1.0 microamp?

 

 

 

replacing pilot if burner or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Verify that pilot flame rod, flame

 

 

 

 

 

 

 

 

wiring is damaged.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Reinstall burner shield to

 

 

 

 

rod ceramic and lead wire from

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operate boiler for retest after

 

 

 

control module to flame rod are in

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

good condition.

 

 

 

•

If none of the previous steps

 

 

 

 

 

 

 

 

any changes or corrections.

 

 

 

 

 

 

 

 

• If the wiring from the

 

 

 

 

• Correct any above problems,

 

 

 

 

(including replacing pilot)

 

• If none of the above corrects

 

 

 

 

 

 

 

control module to gas

 

 

 

replacing pilot if burner or wiring

 

 

 

 

corrects problem, then replace

 

 

problem, then replace the

 

 

 

 

 

 

 

 

 

valve is intact, replace the

 

 

 

 

 

is damaged.

 

 

 

 

the control module, reinstall

 

 

control module, reinstall air

 

 

 

 

 

 

 

 

 

control module and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

burner shield and retest.

 

 

inlet box top, and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

52

Part number 550-110-282/1108

Page 51 Page 53
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Page 51 Page 53
Contents GOLDCGs-4E How it works Gold CGs-4EGas-Fired Induced-Draft Water Boiler Contents Please read before proceeding InstallerUser Installations must follow these codes 1a Prepare boiler location codes & checklistBefore 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 systemProducts to avoid 1d Prepare boiler location contaminationAreas 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 Prevent chilled water from entering 3e Water piping refrigeration systemsBoiler Vent system Venting and combustion airCombustion 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 boilerPilot burner flame Figure Check burner flamesMain 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 certificateSequence returns to step 9a Operation sequenceBoiler 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, , Section assembly Base Jacket Trim Controls 12a Replacement partsWeil-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 pressureThis type of respirator is based on Handling ceramic fiber and fiberglass materialsEye Irrigate immediately Breathing Fresh air
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