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Weil-McLain Gold CGa Chart 4 Spark-ignited pilot DAMPERlight flashing

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GOLD CGa Gas-Fired Water Boiler

56 Part Number 550-110-593/1099

Troubleshooting — spark-ignited pilot boilers11c

• Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds.

• Thermostat should call for heat and appropriate zone valves open. The TSTAT CIRC and LIMIT lights should come on.

Does vent damper operate?

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.

• Boiler should be in

normal operating

sequence.

• Observe operation until

thermostat is satisfied.

Are the

TSTAT CIRC

and

LIMIT

lights on steady?

• Replace control

module.

• Retest.

• Make sure thermostat is

calling for heat. If lights

still don't come on, see

Chart 7.

• Try reseating plug in

module receptacle and

restart.

• If vent damper still does

not work, replace vent

damper assembly or

actuator.

• Retest.

No Yes

• Wait 45 seconds.

Does vent damper operate?

No Yes

• Remove DAMPER plug (

Figure 30, Item 6, page 53

)

from plug receptacle of control module.

• Place voltmeter leads across the top two pins (1 and 4)

of the DAMPERreceptacle.

Does the voltmeter indicate 24 VAC?

No Yes

Does vent damper actuator

indicator show damper is

open?

No Yes

• Remove damper wiring

plug at damper and firmly

reconnect.

• Recheck boiler operation.

• If problem persists,

replace vent damper

assembly or actuator.

No Yes

• Wait 5 minutes.

Is

DAMPER

light flashing?

Yes No

— If POWER light is flashing: Usually indicates vent damper failed to prove open within 5 minutes —

— If POWER light is steady: Usually indicates vent damper closed during run cycle —

Chart 4 — Spark-ignited pilot —DAMPERlight flashing

• Replace vent damper

assembly or actuator.

• Retest.

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