Weil-McLain 550-141-850/0599, GOLD DV WATER BOILER Chart 2 Tstat Circ & Power lights flashing

Page 75

• Installation • Start-Up • Parts • Maintenance

CHART 2 — TSTAT CIRC & POWER lights flashing

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

Is return water temperature sensor clamped securely to the return pipe in the boiler?

Yes

No

 

 

 

•Attach sensor to pipe with clamp provided.

•If problem persists, replace return water temperature sensor.

•Retest.

• Check for stray voltage on the incoming thermostat wires.

does occur under any condition, check and correct the

Disconnect the two external wires connected to the boiler

external wiring. (This is a common problem when using 3-wire

thermostat wires.

zone valves.)

• Connect a voltmeter across the two incoming wires. Close •

Once the external thermostat circuit wiring is checked and

each thermostat, zone valve and relay in the external circuit

corrected if necessary, reconnect the external thermostat

one at a time and check the voltmeter reading across the

circuit wires to the boiler thermostat wires and allow the boiler

wires. There should NEVER be a voltage reading. If a voltage

to cycle.

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

Yes

No

•Boiler should now operate per the normal sequence of operation shown in Figure 22 if wiring was corrected.

•Remove CIRCULATORS plug (Figure 34, Item 4) from plug receptacle of control module.

•Place voltmeter leads across the right-side 120 VAC N and 120 VAC H pins of the CIRCULATORS receptacle.

Does the voltmeter indicate 120 VAC?

No

Yes

 

 

 

 

Is boiler internal Bypass circulator operating?

No

Yes

 

 

 

• Check the boiler internal return pipe where it enters the boiler sections. The TSTAT CIRC and POWER lights will flash as long as the return water temperature is less than

130 ˚F.

• Wait up to 20 minutes to give the boiler and system a

chance to respond.

Does problem persist?

•Replace GCM (control module).

•Retest.

•Replace circulator harness.

•Retest.

•Test wire continuity of circulator wire harness.

Is harness ok?

 

No

Yes

 

 

 

 

 

 

 

 

 

 

No

Yes

 

 

 

• Boiler may now be operating

normally. Verify against

Figure 22, sequence of

operation.

•Reconnect circulator harness to GCM.

•Attempt to get the circulator started by giving it a sharp rap on the end of the circulator motor (to release a possibly locked impeller).

•If the circulator begins to operate, allow it to operate for a few minutes to see if the problem clears.

•If problem persists, replace the Bypass circulator.

•Retest.

• If boiler appears not to be heating, troubleshoot boiler per

CHART 8 (no heat problems). If problem cannot be

resolved, replace water temperature sensor and retest.

Then replace GCM (control module) if sensor does not

correct the problem.

• If boiler is heating, but the temperature at the return pipe

does not increase above 130 ˚F, there may be an

incorrectly-piped external circulator forcing water through

the boiler. Check external piping and correct.

Part number 550-141-850/0699

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Contents Gold GV How it works Gold GV Water boiler Series Please read before proceeding Hazard definitions Installer UserWhen servicing boiler Boiler operationBoiler water Contents Contents Overview of this section Ia Prepare boiler location overviewIb Prepare boiler location codes & altitude Installations must follow these codesSmall space Ic Prepare boiler location clearancesClearance options Large spaceFlooring Residential garage installationPrecautions Flooring and foundationId Prepare boiler location vent system Removing from existing ventGV special vent system Air contamination Ie Prepare boiler location contaminationIf Prepare boiler location air openings GV in small space less than alone Special considerationsIIb Prepare boiler vent starter tee & drain IIa Prepare boiler overviewScrew hole Base rail Insert Cpvc elbow Propane Plate installationIIc Prepare boiler orifice plate Natural gasBottom side of boiler front section IId Prepare boiler high altitude kit When requiredWhite Hose Red Altitudes above 5,500 feet onlyIIe Prepare boiler place in position Rotate Fill and pressure test IIf Prepare boiler pressure testPerform hydrostatic pressure test Prepare boiler for test FigPiping connections for hydrostatic test For heating system with See pages 27 30 IIIa Water piping overviewIIIb Water piping relief valve Install relief valveExpansion tank IIIc Water piping boiler connectionsSupply & return connections Air separatorPiping closed Zoning with circulators IIId Water piping all systemsBaseboard system piping IIIe Water piping baseboard systemRadiator system piping IIIf Water piping radiator systemIIIg Water piping single-zone radiant or heat pump system Outdoor reset control IIIh Water piping multi-zone radiant systemMulti-zone radiant heating system piping Manual bypass valves for fixed temp operation only IIIi Water piping snow melt systemWater chiller systems IIIj Water piping water chiller systemsIV Venting and combustion air Connecting gas supply piping to boiler Gas pipingPropane Gas Feet Thermostats VI Field wiringElectrical installation must comply with Wiring connectionsField wiring Factory wiring Verify water chemistry Freeze protection when usedVIIa Start-up overview VIIb Start-up preparationFill the system with water VIIb Start-up preparationVerify gas/air orifice plate Check for gas leaksStart the boiler VIIc Start-up read SectionVIId Start-up to operate boiler Perform final checks before starting boilerVIIe Start-up if boiler doesn’t start VIId Start-up operate boilerConnect and adjust manometer VIIf Start-up altitude over 5,500 feet onlyCheck Gas Control Set Point At Least Inches Check-out procedure checklist VIIIa Check-out procedure overviewVIIIb Check-out procedure checklist IXa Operation overview Shows the ladder wiring diagram for the GV series 3 boilerSteps IXb Operation sequenceLadder diagram legend IXb Operation wiring diagramsGCM IXc Operation lighting instructions For Your Safety Read Before OperatingWhite-Rodgers gas valve model 36E Xa Service and maintenance overview Service technician Xb Service and maintenance scheduleAnnual start-up only by qualified service technician Xc Service & maintenance annual start-upStart-up Annual start-up check/test Xc Service & maint. annual start-upcontExpansion tank GaugesIgniter Annual start-up owner review Boiler relief valveReview with owner Condensate drain line Check valve assembly To remove the blower assembly Igniter XIa Troubleshooting overview XIb Troubleshooting procedures Before troubleshootingCheck the following Checking the air pressure switch XIc Troubleshooting air pressure switchGas Valve XId Troubleshooting servicing tipsBlower Housing IgniterControl Module XIe Troubleshooting control modulePower Symptom Common Causes Possible Corrections XIf Troubleshooting common problemsSymptom Common Causes Possible Corrections Chart 1 Troubleshooting Power light status XIg Troubleshooting GCM lightsChart 2 Tstat Circ & Power lights flashing Chart 3 Limit & Power lights flashing Chart 4 Pres Switch & Power lights flashing Chart 5 Flame & Power lights flashing Chart 6 Tstat Circ light flashing and Power light on steady Chart 7 Limit light flashing and Power light on steady Is thermostat circuit closed continuity across wires? XIIa Replacement parts overview Water trim bag assembly #1 XIIb Replacement parts accessory bagDescription Model Weil-McLain Number Part number XIIc Replacement parts section assembly85041 422-200-228 XIId Replacement parts jacket assembly85042 382-200-340 XIIe Replacement parts Blower assemblyVent starter tee not included Description Weil-McLain Number Part number XIIf Replacement parts trim assembly85048 XIIg Replacement parts interior panel Interior panel Number Xiii Dimensions and ratingsDOE Gold GV Water boiler Series
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