Weil-McLain Troubleshooting: Understanding Weil McLain Flame Light Flashing Issues

Page 45

GOLD CGs Gas-Fired Water Boiler — Boiler Manual

11c Troubleshooting — control module

Control module

Solder or water splatter between plugs and circuit board can cause improper operation of control module. Place a shield over the boiler internal controls and components during installation. Failure to comply could result in severe personal injury, death or substantial property damage.

Make sure ground wiring is installed per wiring diagram. Good grounding is extremely important for proper operation.

Control indicator lights —

LOCKOUT modes

See Charts 1 through 7 in this Section for detailed trouble- shooting procedures.

To reset control after a lockout, turn off power at the 120 VAC service switch or turn down all thermostats. Wait 45 seconds. Then restore power or call for heat.

POWER light flashing alone

Usually indicates reversed polarity of 120 VAC power wires.

POWER and TSTAT CIRC lights flashing

Usually indicates stray voltage on external thermostat circuit wires (usually due to miswired 3-wire zone valve).

POWER and PRESS SWITCH lights flashing

Usually indicates pressure switch is closed when it should not be, or pressure switch failed to close within 5 minutes of inducer starting.

POWER and FLAME lights flashing

Usually indicates false flame sense or flame sensed when it shouldn’t be there.

Control indicator lights —

NON-LOCKOUT modes

POWER light on and FLAME light flashing

Usually indicates pilot flame was not established within 15 seconds from application of spark. Control will flash light, but will continue to cycle indefinitely until flame is established or problem is corrected.

POWER light on and PRESS SWITCH light flashing

Usually indicates pressure switch opened during the run cycle.

Troubleshooting the control module

See Figure 25, page 46, for location of harness plug receptacles and plugs on the control module.

Part number 550-110-260/0107

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Contents Gold CGs How it works Gold CGs Gas-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 1c Prepare boiler location vent system When removing boiler from an existing common vent systemCGs special vent system Vent systemProducts to avoid 1d Prepare boiler location contaminationCombustion air options 1e Prepare boiler location air openingsSpecial considerations Sizing air openingsSizing air openings for CGs installations Orifice replacement procedure 2a Prepare boiler placement & setupPlace boiler/crate near position Inspect orifices and burnersHydrostatic pressure test 2b Prepare boiler pressure testDrain and remove fittings Prepare boiler for test3a Water piping general information 3b Water piping single-zone system Piping multiple zones Piping for radiant heating 3c Water piping multiple zonesSystems or converted gravity SystemsReturn water 130F or higher Valve adjustment Figures 8 and 9 only Temperature gauges3d Piping low temp systems Primary/secondary preferred bypass piping methodPrimary/secondary piping BOILER-bypass piping method Valve adjustmentFigures 8 SYSTEM-bypass piping method Prevent chilled water from entering 3e Water piping refrigeration systemsVenting and combustion air Gas piping Connecting gas supply piping to boilerNatural Gas Propane GasElectrical installation must comply with Field wiringWiring connections Thermostat7a Start-up preparation Freeze protection when usedCheck for gas leaks Verify water chemistryInspect system water piping Inspect base insulation 7b Start-up operate boilerFinal check before starting boiler Start the boilerCheck burner flames 7c Start-up if boiler doesn’t startCheck for Pilot burner flame FigureInstallation and service certificate Check-out procedure checklist9a Operation sequence Schematic wiring diagram 9b Operation wiring diagramsLadder wiring diagram 9c Operating instructions CGs-3 to CGs-6 9c Operating instructions CGs-3 to CGs-6 9c Operating instructions CGs-3 to CGi-6 Verify Proper Operation After Servicing 10a Service and maintenance schedule10b Service & maintenance annual start-up Condensate drain system Burners, base and inlet air boxInducer motor Oiled-bearing circulators10b Service & maint. annual start-up Relief valve, typical Boiler relief valveReview with owner Cleaning boiler heating surfaces11a Troubleshooting procedure Before troubleshootingCheck the following Air pressure switch 11b Troubleshooting air pressure switchCheck pressure switch setting Troubleshooting air pressure readingControl indicator lights Lockout modes 11c Troubleshooting control moduleControl indicator lights NON-LOCKOUT modes Troubleshooting the control moduleControl 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 Item 8 , Does blower motor operate? Verify Sequence of operation, , Section assembly Base Jacket Trim Controls 12a Replacement partsSection assembly 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketBoiler Model Weil-McLain part number Part number 12e Replacement parts trimPropane gas components 12f Replacement parts controlsDimensional drawing 13a DimensionsDOE 13b RatingsRemoval of Combustion Chamber Lining or Base Panels Handling ceramic fiber and fiberglass materials