Weil-McLain CGS-4E 11d Troubleshooting - control module lights cont, Turn Off Power, item 8, page

GOLD CGs-4E Gas-Fired Water Boiler — Boiler Manual

11d 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 C of the

terminal is securely fastened

Operating instructions in this manual).

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 C of the

normal operating

Natural gas — 5.0" w.c. min/14.0"

valve is intact, replace 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 air inlet box top

pressure or gas supply.

No

Yes

(see Figure 27, page 56 for

location).

•

TURN OFF POWER

•

TURN OFF POWER to boiler at service switch or breaker.

to boiler at service switch or

•

Check flame signal — Detach sense lead from ignition control

• Verify pilot gas line is not

kinked, obstructed or

breaker.

(Figure 25, item 8, page 46).

damaged and is correctly

• Remove burner shield (see

• Connect negative lead of MICROAMMETER to control sense

attached to pilot and gas

Figure 27, page 56 for location).

terminal (Figure 25, item 8, page 46). Connect positive lead of

valve.

MICROAMMETER to sense wire.

• Verify pilot ignition electrode,

•

DISCONNECT red wire connected to terminal MV of the gas

• Verify pilot burner is securely

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.

No

Yes

• Reinstall burner shield to

rod ceramic and lead wire from

operate boiler for retest after

control module to flame rod are in

good condition.

•

If none of the previous steps

any changes or corrections.

• If the wiring from the

• Correct any above problems,

(including replacing pilot)

• If none of the above corrects

control module to gas

replacing pilot if burner or wiring

corrects problem, then replace

problem, then replace the

valve is intact, replace the

is damaged.

the control module, reinstall

control module, reinstall air

control module and retest.

burner shield and retest.

inlet box top, and retest.

52

Part number 550-110-282/1108