GOLD CGi Gas-Fired Water Boiler — Boiler Manual

11c 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 PV/MV of

 

 

terminal is securely fastened

 

Operating instructions in this manual).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the 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 PV/MV of

 

normal operating

 

 

 

Natural gas — 5.0" w.c. min/14.0"

 

 

 

 

 

 

 

valve is intact, replace the

 

 

 

 

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 burner shield (see

 

 

 

 

pressure or gas supply.

 

 

 

 

No

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 40, item 4, page 60

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

for location).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TURN OFF POWER to boiler

 

 

 

TURN OFF POWER to boiler at service switch or breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

at service switch or breaker.

 

 

 

Check flame signal — Detach sense lead from ignition control

• Verify pilot gas line is not

 

 

 

 

 

 

 

 

 

 

kinked, obstructed or

 

 

 

 

 

Remove burner shield (see

 

 

 

 

(Figure 38, item 8, page 50).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

damaged and is correctly

 

 

 

 

 

 

Figure 40, item 4, page 60 for

 

 

 

Connect negative lead of MICROAMMETER to control sense

 

attached to pilot and gas

 

 

 

 

 

 

location).

 

 

 

 

terminal (Figure 38, item 8, page 50). Connect positive lead of

 

valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MICROAMMETER to sense wire.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Verify pilot ignition electrode,

 

 

 

Verify pilot burner is securely

 

 

 

DISCONNECT red wire connected to terminal MV of the gas

 

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.

 

 

 

 

 

 

rod ceramic and lead wire from

 

 

 

 

No

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Reinstall burner shield to

 

 

 

 

 

 

control module to flame rod are in

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operate boiler for retest after

 

 

 

 

good condition.

 

 

 

If none of the previous steps

 

• If the wiring from the

 

any changes or corrections.

 

 

 

Correct any above problems,

 

 

 

 

(including replacing pilot)

 

 

 

 

 

 

 

 

 

 

control module to gas

• If none of the above corrects

 

 

 

 

replacing pilot if burner or wiring

 

 

 

 

corrects problem, then replace

 

 

 

 

 

 

 

 

 

 

valve is intact, replace the

 

problem, then replace the

 

 

 

 

 

 

is damaged.

 

 

 

 

the control module, reinstall

 

 

 

 

 

 

 

 

 

 

 

 

 

control module and retest.

 

control module and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

burner shield and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

56

Part Number 550-110-710/0107

 

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Weil-McLain 550-110-710/0107 manual Item 8