Weil-McLain 550-110-710/0107 manual Control module, Control indicator lights, NON-LOCKOUT modes

Page 49

GOLD CGi Gas-Fired Water Boiler — Boiler Manual

11b Troubleshooting — components (continued)

 

 

POWER light flashing alone

Figure 36 

Manometer connections

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 38, page 50, for location of harness plug receptacles

 

and plugs on the control module.

Control module

 

Figure 37  Control module

Solder or water splatter between

 

plugs and circuit board can cause

 

improper operation of control mod-

 

ule. Place a shield over the boiler

 

internal controls and components

 

during installation. Failure to com-

 

ply could result in severe personal

 

injury, death or substantial property

 

damage.

 

Make sure ground wiring is in-

 

stalled 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.

Part Number 550-110-710/0107

49

 

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Contents Gold CGi How it works Gold CGi Gas-Fired Induced-Draft Water Boiler Contents Please read before proceeding Installations must follow these codes 1a Prepare boiler location codes & checklistBefore 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 systemChimney or vent require- ments Products to avoid 1d Prepare boiler location air contaminationAir openings must be provided 1e Prepare boiler location air openingsAir opening options Two openings Air supply from inside the buildingMotorized air dampers Exhaust fans and air moversSingle air opening option Exception for large spacesOrifice 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 testVenting chimney draft venting 3a Venting general informationCGi venting methods Chimney draft or Direct exhaust Chimney draft ventingObtain vent system components 3c Venting Direct exhaust componentsVent StaR-34 Vent starter 3d Venting direct exhaust vent starterVent termination minimum clearances 3e Venting direct exhaust terminationVertical venting See . Follow vent 3f Venting direct exhaust installationSidewall venting See Figures 14 Using any termination other than one of those shown 4a Water piping general information Diaphragm-type or bladder- type expansion tank Figure 4b Water piping single-zone systemClosed-type expansion tank Piping multiple zones 4c Water piping multiple zonesZoning with circulators Temperature gauges 4d Piping low temperature systemsValve adjustment Primary/secondary preferred bypass piping methodPrimary/secondary piping BOILER-bypass piping method Valve adjustmentBoiler-bypass piping Zoning with SYSTEM-bypass piping method Prevent chilled water from entering boiler 4e Water piping refrigeration systemGas 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 Determine if water treatment is neededFill the system with water Do not use petroleum-based cleaning or sealing compoundsInspect system water piping Inspect base insulationStart the boiler 7b Start-up operate boilerCheck system and boiler Check burner flames 7c Start-up if boiler doesn’t startCheck for Pilot burner flame FigureThermostats Check-out procedure checklistDuring main burner operation 9a Operation sequenceSchematic wiring diagram 9b Operation wiring diagramsLadder wiring diagram 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-6 9c Operating instructions CGi-25 to CGi-8 Verify Proper Operation After Servicing 10a Service and maintenance schedule10b Service and maintenance annual start-up Burners and base 10b Service & maintenance annual start-upCondensate drain system Inducer motorCold fill and operating pressures Gas pipingAir vents and air elimination Limit controls and cutoffsBoiler relief valve Review with ownerReview the User’s Information Manual with the owner 11b Troubleshooting components 11a Troubleshooting procedureBefore troubleshooting Air pressure switchTroubleshooting the control module Control indicator lightsControl indicator lights Lockout modes Control moduleControl module connections Chart Light flashing 11c Troubleshooting control module lightsRemove 120 VAC in plug , Item 3, page 50 on control module VAC in plugChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Usually indicates flame sensed when it shouldnt be there Chart 4 Flame & Power lights flashingDoes blower motor operate? Item 8 , Operation, Figure Verify SequenceSection assembly Base Jacket Trim Controls 12a Replacement partsControls Repair Parts Lists Section assembly 12b Replacement parts section assemblyBase assembly 12c Replacement parts baseDescription Weil-McLain Part number Jacket assembly 12d Replacement parts jacketModel Weil-McLain part number BoilerBoiler Model Weil-McLain part number Fittings shown are included with boiler 12e Replacement parts trimPropane gas components 12f Replacement parts controlsDimensional drawing 13a Dimensions13b Ratings Removal of Combustion Chamber Lining or Base Panels Handling ceramic fiber and fiberglass materials
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