Weil-McLain 550-141-850/0599 manual Is thermostat circuit closed continuity across wires?

Page 81
Part number 550-141-850/0699

•Installation • Start-Up • Parts • Maintenance

CHART 8 — Insufficient heat or no heat to system (POWER light on steady)

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.

• Has it been at least 5 minutes since setting thermostat to

 

 

 

 

 

 

Is boiler System circulator operating?

 

call for heat? If not, wait 5 minutes. Is system heating?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

• Is thermostat set to call for heat? Remove thermostat

 

 

 

 

 

 

 

 

 

 

wires at boiler and check continuity across the two wires.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

If circuit isn't closed, check external thermostat (zone

 

 

 

 

•

Remove CIRCULATORS harness plug from

 

 

valve, relay, etc.) wiring. Correct problems and retry.

 

 

 

 

 

CIRCULATORS plug receptacle (Figure 34, Item

 

 

• Reconnect external thermostat wiring at boiler.

 

 

 

 

 

 

 

4). Check with voltmeter across left-side 120 VAC

 

 

Is thermostat circuit closed (continuity across wires)?

 

 

 

 

 

N and 120 VAC H pins of receptacle.

 

 

 

 

 

 

 

 

Does voltmeter show 120 VAC across pins?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Are all red lights off?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Replace control

 

•

Repair/replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Boiler is in standby.

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

module.

 

 

circulator. Retest.

 

 

 

 

 

 

 

 

 

• Set thermostat to call for heat

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Retest.

 

•

Repair/replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

and recheck operation.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

wiring. Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Verify Sequence of operation,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Wait 30 seconds.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 22.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Are all red lights off?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Wait 5 minutes.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is FLAME light on?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

Replace control module.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• If you have sufficient heat — boiler should be in normal

 

• Check block switch on top of boiler with continuity

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operating sequence. (See normal sequence of operation,

 

checker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 22.)

 

 

 

 

 

 

 

 

 

 

 

 

Are block switch contacts closed?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

If you have less than sufficient heat —

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

Is vent or combustion air piping free of blockage?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Wait for cast iron block to

 

 

• Check limit switch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

contacts with continuity

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

cool to room temperature.

 

 

 

 

 

•

Correct conditions and

 

 

 

 

 

 

 

 

 

checker.

 

 

 

 

 

 

 

Contact your Weil-McLain

 

 

Are block switch

 

 

 

 

 

 

 

 

 

 

recheck operation.

 

 

 

 

 

 

 

Are limit switch

 

 

 

 

 

 

sales representative.

 

 

 

 

 

 

 

 

 

 

•

See Figure 22 for

 

 

 

contacts closed?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

contacts closed?

 

 

 

 

 

normal sequence of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operation.

 

 

 

 

 

 

 

 

 

No

 

 

 

Yes

 

 

 

 

Yes

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Wait for boiler water to cool to temperature 20 to 30 ˚F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

lower than temperature set on limit switch.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Are limit switch contacts closed?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace block

 

 

Replace control

 

 

 

Replace limit

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

switch. Retest.

 

 

module. Retest.

 

 

 

switch. Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Boiler water temperature exceeded setting on limit switch

 

• Excessive block temperature has been reduced to safe

operating level. Check for low water level or mineral

 

 

 

 

 

with thermostat calling for heat. Boiler is OK. (See normal

 

deposits in sections. Correct before proceeding.

 

 

 

 

 

 

 

sequence of operation, Figure 22.)

 

• Restart boiler and check normal sequence of operation.

 

 

 

 

•

Also check operation of setting on limit switch (should be

 

(See normal sequence of operation, Figure 22.)

 

 

 

 

 

 

 

above 140˚F.).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

81

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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 codesClearance options Ic Prepare boiler location clearancesLarge space Small spacePrecautions Residential garage installationFlooring and foundation FlooringId 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 IIc Prepare boiler orifice plate Plate installationNatural gas PropaneBottom 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 Perform hydrostatic pressure test IIf Prepare boiler pressure testPrepare boiler for test Fig Fill and pressure testPiping connections for hydrostatic test For heating system with See pages 27 30 IIIa Water piping overviewIIIb Water piping relief valve Install relief valveSupply & return connections IIIc Water piping boiler connectionsAir separator Expansion tankPiping 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 Electrical installation must comply with VI Field wiringWiring connections ThermostatsField wiring Factory wiring VIIa Start-up overview Freeze protection when usedVIIb Start-up preparation Verify water chemistryVerify gas/air orifice plate VIIb Start-up preparationCheck for gas leaks Fill the system with waterVIId Start-up to operate boiler VIIc Start-up read SectionPerform final checks before starting boiler Start the 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 switchBlower Housing XId Troubleshooting servicing tipsIgniter Gas ValveControl 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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