Manuals / Weil-McLain / Household Appliance / Boiler

Weil-McLain Series 2 manual 11b Troubleshooting — components continued, Control module connections

Models: Series 2

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GOLD CGi Gas-Fired Water Boiler — Boiler Manual

11b Troubleshooting — components (continued)

Figure 38 Control module connections

50	Part Number 550-110-710/0107

Page 50

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Weil-McLain Series 2 manual 11b Troubleshooting — components continued, GOLD CGi Gas-FiredWater Boiler — Boiler Manual

Contents

GOLD CGi • Installation • Maintenance• Startup • Parts Boiler Manual④Air pressure switch How it worksGOLD CGi Gas-FiredWater Boiler — Boiler Manual ⑤Water temperature limit switchGOLD CGi Gas-Fired Induced-DraftWater Boiler GOLD CGi Gas-FiredWater Boiler — Boiler ManualContents GOLD CGi Gas-FiredWater Boiler — Boiler ManualWhen servicing boiler — Please read before proceedingInstaller GOLD CGi Gas-FiredWater Boiler — Boiler ManualGOLD CGi Gas-FiredWater Boiler - Boiler Manual 1a Prepare boiler location - codes & checklistInstallations must follow these codes Before locating the boiler, check the followingResidential garage installations 1b Prepare boiler location — clearancesRecommended SERVICE clearances GOLD CGi Gas-FiredWater Boiler — Boiler ManualChimney or vent require- ments 1c Prepare boiler location — vent systemGOLD CGi Gas-FiredWater Boiler — Boiler Manual 1d Prepare boiler location — air contamination GOLD CGi Gas-FiredWater Boiler — Boiler ManualAir openings must be provided 1e Prepare boiler location — air openingsGOLD CGi Gas-FiredWater Boiler — Boiler Manual Air opening optionsMotorized air dampers GOLD CGi Gas-FiredWater Boiler - Boiler ManualExhaust fans and air movers Single air opening optionGOLD CGi Gas-FiredWater Boiler — Boiler Manual 2a Prepare boiler — placement & setupOrifice replacement procedure Place boiler/crate near positionHydrostatic pressure test 2b Prepare boiler — pressure testGOLD CGi Gas-FiredWater Boiler — Boiler Manual Drain and remove fittingsGOLD CGi Gas-FiredWater Boiler — Boiler Manual 3a Venting — general informationVenting — chimney draft venting Chimney draft ventingObtain vent system components 3c Venting — Direct exhaust — componentsGOLD CGi Gas-FiredWater Boiler — Boiler Manual 3d Venting - direct exhaust - vent starter GOLD CGi Gas-FiredWater Boiler — Boiler Manual3e Venting — direct exhaust — termination GOLD CGi Gas-FiredWater Boiler — Boiler Manual3f Venting — direct exhaust — installation GOLD CGi Gas-FiredWater Boiler - Boiler Manualin substantial property damage 3f Venting — direct exhaust — installation contGOLD CGi Gas-FiredWater Boiler — Boiler Manual Sidewall terminationGeneral piping information 4a Water piping — general informationGOLD CGi Gas-FiredWater Boiler — Boiler Manual CirculatorClosed-typeexpansion tank 4b Water piping — single-zonesystemGOLD CGi Gas-FiredWater Boiler — Boiler Manual FigurePiping multiple zones 4c Water piping — multiple zonesGOLD CGi Gas-FiredWater Boiler — Boiler Manual Converted gravity or steam systems4c Water piping — multiple zones continued GOLD CGi Gas-FiredWater Boiler — Boiler ManualGOLD CGi Gas-FiredWater Boiler - Boiler Manual 4d Piping — low temperature systemsValve adjustment Temperature gauges4d Piping — low temperature systems continued GOLD CGi Gas-FiredWater Boiler - Boiler ManualGOLD CGi Gas-FiredWater Boiler — Boiler Manual Valve adjustment4d Piping — low temperature systems BOILER-bypasspiping method1Boiler isolation balancing valves 4d Piping — low temperature systems continuedGOLD CGi Gas-FiredWater Boiler - Boiler Manual GOLD CGi Gas-FiredWater Boiler — Boiler Manual Valve adjustment4d Piping — low temperature systems SYSTEM-bypasspiping methodGOLD CGi Gas-FiredWater Boiler — Boiler Manual 4e Water piping — refrigeration system4d Piping — low temperature systems continued Prevent chilled water from entering boilerGOLD CGi Gas-FiredWater Boiler — Boiler Manual 5 Gas pipingConnecting gas supply piping to boiler Natural GasWiring connections 6 Field wiringElectrical installation must comply with GOLD CGi Gas-FiredWater Boiler — Boiler ManualGOLD CGi Gas-FiredWater Boiler — Boiler Manual 7a Start-up- preparationFreeze protection when used Check for gas leaksFill the system with water 7a Start-up— preparation continuedGOLD CGi Gas-FiredWater Boiler - Boiler Manual Inspect system water pipingStart the boiler 7b Start-up— operate boilerGOLD CGi Gas-FiredWater Boiler — Boiler Manual Check system and boilerGOLD CGi Gas-FiredWater Boiler — Boiler Manual 7b Start-up— operate boiler continued7c Start-up— if boiler doesn’t start Pilot burner flame FigureGOLD CGi Gas-FiredWater Boiler — Boiler Manual 8 Check-outprocedure — checklistInstallation and service certificate 9a Operation — sequence GOLD CGi Gas-FiredWater Boiler — Boiler ManualGOLD CGi Gas-FiredWater Boiler — Boiler Manual 9b Operation — wiring diagramsFigure 31 Schematic wiring diagram Figure 32 Ladder wiring diagram GOLD CGi Gas-FiredWater Boiler - Boiler Manual• Spark pilot • Natural or propane gas 9c Operating instructions CGi-25to CGi-6GOLD CGi Gas-FiredWater Boiler — Boiler Manual • Gas valve: Honeywell VR8204/VR8304• Spark pilot • Natural or propane gas 9c Operating instructions CGi-25to CGi-6GOLD CGi Gas-FiredWater Boiler — Boiler Manual • Gas valve: White-Rodgers36E• Spark pilot • Natural or propane gas 9c Operating instructions CGi-25to CGi-8GOLD CGi Gas-FiredWater Boiler — Boiler Manual • Gas valve: White-Rodgers36CVERIFY PROPER OPERATION AFTER SERVICING 10a Service and maintenance — scheduleGOLD CGi Gas-FiredWater Boiler — Boiler Manual Reported problems 10b Service and maintenance — annual start-upInspect GOLD CGi Gas-FiredWater Boiler — Boiler ManualStart-up 10b Service & maintenance – annual start-up contService InspectGOLD CGi Gas-FiredWater Boiler — Boiler Manual Check/test10b Service & maintenance - annual start-up cont Gas pipingGOLD CGi Gas-FiredWater Boiler — Boiler Manual Cleaning boiler heating surfaces10b Service & maintenance – annual start-up cont Review with ownerCheck pressure switch setting 11a Troubleshooting — procedure11b Troubleshooting - components Troubleshooting air pressure readingTroubleshooting the control module 11b Troubleshooting — components continuedControl indicator lights — Control indicator lights — LOCKOUT modesFigure 38 Control module connections 11b Troubleshooting — components continuedGOLD CGi Gas-FiredWater Boiler — Boiler Manual Is POWER light 11c Troubleshooting — control module lightsIs POWER light off? Is POWER light flashing now?Do the TSTAT and POWER lights still flash? 11c Troubleshooting — control module lights contCHART 2 - TSTAT CIRC & POWER lights flashing GOLD CGi Gas-FiredWater Boiler — Boiler ManualIs PRESS SWITCH light flashing? 11c Troubleshooting - control module lights contCHART 3 — PRESS SWITCH & POWER lights flashing Does the ohmmeter indicate the switch is closed?Are FLAME & POWER lights flashing? 11c Troubleshooting - control module lights contDo FLAME and POWER lights still flash? Are FLAME and POWER lights flashing?Is PRESS SWITCH light flashing? 11c Troubleshooting - control module lights contDoes the ohmmeter indicate the switch is closed? GOLD CGi Gas-FiredWater Boiler — Boiler ManualTURN OFF POWER 11c Troubleshooting — control module lights contTURN OFF POWER TURN OFF POWER to boilerDoes voltmeter show 120 VAC across pins? 11c Troubleshooting — control module lights contAre limit switch contacts closed? Are limit switch contacts12a Replacement parts GOLD CGi Gas-FiredWater Boiler — Boiler ManualGOLD CGi Gas-FiredWater Boiler — Boiler Manual 12b Replacement parts — section assemblyFigure 39 Section assembly GOLD CGi Gas-FiredWater Boiler — Boiler Manual 12c Replacement parts — baseFigure 40 Base assembly Item 12c Replacement parts — base continuedGOLD CGi Gas-FiredWater Boiler — Boiler Manual DescriptionGOLD CGi Gas-FiredWater Boiler — Boiler Manual 12d Replacement parts - jacketFigure 41 Jacket assembly 12d Replacement parts — jacket continued GOLD CGi Gas-FiredWater Boiler — Boiler ManualFittings shown are factory-installedon boiler 12e Replacement parts — trimFigure 42 Trim assembly GOLD CGi Gas-FiredWater Boiler — Boiler ManualGOLD CGi Gas-FiredWater Boiler - Boiler Manual 12f Replacement parts — controlsFigure 43 Gas control assembly GOLD CGi Gas-FiredWater Boiler — Boiler Manual 13a DimensionsFigure 44 Dimensional drawing 13b Ratings GOLD CGi Gas-FiredWater Boiler - Boiler ManualREMOVAL OF COMBUSTION CHAMBER Handling ceramic fiber and fiberglass materialsGOLD CGi Gas-FiredWater Boiler — Boiler Manual LINING OR BASE PANELS