Weil-McLain Gold CGa MV

Boiler Manual

Part Number 550-110-593/1099 39

Figure 25b Ladder wiring diagram — Spark-ignited pilot system

59347a

HoneywellVR8204

HoneywellVR8304

Robertshaw 7200

White-Rodgers 36C

* Terminals 2–4 are factory-jumpered on the

White-Rodgers 36C gas valve.

MV/PV

MV/PV

C

2–4 *

MV

MV

M

1

PV

PV

P

3

Table G: Gas valve terminals and anticipator settings

Gas valve "A" "B" "C"

Anticipator

amps

0.6

0.8

0.55

0.7

1. All w iring must be installed in accordance with:

A. U.S.A.— N.E.C. And any other national, state,

or local code requirements.

B. Canada — C.S.A. C22.1 C.E.C. Part 1 and any

other national,provincial, or local code require-

ments.

2. Pilot lead w ires are not field replaceable.Replace pi-

lot assembly if necessary.

3. Ifany of the original wire as supplied with the ap-

pliance must be replaced,use minimum 105 °C

wire or equivalent.Exception — wires to a rollout

TFE must be 200 °C or equivalent.

4. Ther mostat anticipator setting (single zone) — see

Table G for anticipator setting,depending on

which gas valve is installed in boiler.

5. For multiple zoning, use either zone valves or

circulators.Refer to the component manufac-

turer's instructions and this manual for applica-

tion and wiring suggestions.

6. Refer to control component instructions packed

with the boiler for application information.

7. Wire any additional limit controls (low water cut-

off,additional high limit, etc.) in series with boiler

limit control as shown.

Electrical shock hazard — can cause

severe injury or death. Disconnect

power before installing or servicing.

TSTAT/CIRC

LIMIT

DAMPER

SERVICE

SWITCH

THERMOSTAT

120 VAC

24 VAC

CONTROL MODULE

LOW VOLTAGE

SECTION

CONTROL

MODULE

120VAC

SECTION

POWER

G

R

R

R

ROLLOUT

TFE

SPILL

SWITCH

Additional

limits

(note 7)

CIRCULATOR

WATER

TEMPERATURE

LIMIT SWITCH

PILOT GAS

VALVE

VENT

DAMPER

24VAC

CALL FOR

HEAT

24VAC

CONSTANT

MAIN GAS

VALVE

DAMPER END SWITCH

(INTERNAL TO DAMPER)

PILOT

IGNITION

ELECTRODE

HIGH

VOLTAGE

120 VAC

GndNeutralHot

SeeTable G

"A"

"C"

"B"

FLAME

PILOT

FLAME

SENSOR

HIGH

VOLTAGE

R

Legend for ladder wiring diagram

120VAC factory wiring

High voltage spark ignition wiring

Low voltage factory wiring

Ground connectors

120VAC field wiring

Low voltage field wiring

Contents

Main Please read before proceeding When servicing boiler Boiler operation Boiler water Installer Page How it works . . . Other boiler components: Boiler circulator Contents Hazard definitions Prepare boiler location codes & checklist 1a Installations must follow these codes: Before locating the boiler, check the following: Prepare boiler location clearances1b Service clearances Flooring and foundation Residential garage installation Small space installations Prepare boiler location vent system1c When removing boiler from existing common vent system: Chimney or vent requirements Prepare boiler location air contamination 1d Air from inside building Prepare boiler location air openings1c Special considerations Tight construction Prepare boiler placement and setup 2a Inspect orifices and burners Place boiler/crate near position Orifice replacement procedure 2b Prepare boiler pressure test Perform hydrostatic pressure test Page Prepare boiler vent damper installation Water piping general information3a General piping information Relief valve System water piping Pressure/temperature gauge 3b Water piping multiple zones Typical piping multiple-zone installations 3d Primary/secondary (preferred) bypass piping method Temperature gauges Primary/secondary (preferred) piping for radiant heating or converted gravity systems 3e Temperature gauges Boiler-bypass piping method Boiler-bypass (alternate) piping for radiant heating or converted gravity systems 3f System-bypass piping method System-bypass piping for converted gravity (or steam) systems 9 3g Gas piping Field wiring Electrical installation must comply with: Wiring connections Start-up preparation6a Determine if water treatment is needed Check for gas leaks Fill the system with water Inspect system water piping Start-up operate boiler6b Start-up preparation continued6a Inspect base insulation Start the boiler Start-up if boiler doesnt start . . .6c Check for: Start-up operate boiler continued6b Check system and boiler Start-up Check-out procedure checklist7 Installation and service certificate 34 Operation Standing Pilot CGa Lighting instructions CGa-25 to CGa-88b FOR YOUR SAFETY READ BEFORE LIGHTING LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING LIGHTING INSTRUCTIONS Lighting instructions CGa-25 to CGa-88b Natural gas Standing pilot Gas valve manufacturer Robertshaw Gas valve model(s) 7200 Figure 24 Ignition control module sequence of operation status light indications Operation Figure 25b Ladder wiring diagram Spark-ignited pilot system MV FLAME LIMIT DAMPER Legend for ladder wiring diagram Page Operating instructions CGa-25 to CGa-69b Natural gas Spark pilot Gas valve manufacturer Robertshaw Gas valve model(s) 7200 Page Page 44 Service and maintenance Table 6 Service and maintenance schedules (service technician and user) ANNNUAL START-UP Service technician Owner maintenance Service & maintenance annual start-up10b Reported problems Boiler area Air openings Flue gas vent system Service & maint. annual start-up continued10b Oiled-bearing circulators Boiler heating surfaces Burners and base Gas piping Service & maint. annual start-up continued10b Before troubleshooting: Troubleshooting procedure11a Page Chart 1 Standing pilot Boiler will not fire Troubleshooting standing pilot boilers11b Control indicator lights non-lockout modes Troubleshooting the control module Control indicator lights lockout modes Part Number 550-110-593/1099 53 Figure 30 Control module connections DAMPER LIMIT TSTAT CIRC Indicator lights Chart 2 Spark-ignited pilot Troubleshooting POWER light status Is POWER light... Chart 3 Spark-ignited pilot TSTAT CIRC & POWER lights flashing Did you find a voltage across the two external thermostat circuit wires? and Do the lights still flash? Chart 4 Spark-ignited pilot DAMPERlight flashing Chart 5 Spark-ignited pilot FLAME & POWER lights flashing Is pilot burning? Do Are lights flashing? Is gas present at gas valve inlet and within above range? Figure 30, item 8, page 53 Does light flash now? Is 24 VAC present there? Is gas present at gas valve inlet and within above range? Chart 7 Spark-ignited pilot Insufficient heat or no heat (POWERlight on steady) Is thermostat circuit closed (continuity across wires)? Is vent or combustion air piping free of blockage? Are limit switch contacts closed? Figure 30, Item 7, page 53 Replacement parts12a Page Page Page Page Page 66 Dimensions13a Figure 36 Dimensional drawing ALL DIMENSIONS IN INCHES Ratings13b 1 Table 7 Ignition system model suffixes Notes DOE