Install Instructions

Part Number 550-142-902/1016
CGi
GAS-FIRED WATER BOILER — SERIES 3 — Boiler Manual
49
Troubleshooting — procedure
11a
Air pressure switch
Makesureboilerwatertemperatureis100°F
or cooler before starting procedure to obtain
appropriate readings.
The boiler will not operate correctly unless
pressure switch hoses are correctly located.
The red hose connects from the right side
(negative) hose barb to the flue collector. The
white hose connects from the left side (posi-
tive) hose barb of the switch to the connector
box (between flue collector and inducer) as
shown in Figure 36, page 50.
Check pressure switch setting
1. SeeFigure 36, page 50, and Table 9.
2. Remove both air pressure switch hoses from air pressure
switch.
3. Install tees and tubing as shown in Figure 36, page 50, to
inclined manometer.
4. Turn off gas valve and set thermostat to call for heat. Inducer
will run but burners will not ignite.
5. Checkfor24VAC betweenbothairpressureswitchterminals.
Troubleshooting — components
11b
 Labelallwirespriortodis-
connection when servicing
controls. Wiring errors can
cause improper and danger-
ous operation.
 Neverjumper(bypass)roll-
out thermal fuse element
or any other device except
for momentary testing as
outlined in
Troubleshoot-
ing Charts
.Severepersonal
injury, death or substantial
property damage can re-
sult.
Before troubleshooting:
1. Havethefollowingitems:
a. Voltmeterthatcancheck120VAC
and24VAC .
b. Microammeterwithaminimum
scale range of 0-25.
c. Continuitychecker.
d. U-tube manometer.
2. Checkfor120VAC (minimum102VAC
tomaximum132VAC ) toboiler.
3. Makesurethermostatiscallingforheat
and contacts (including appropriate zone
controls)areclosed.Checkfor24VAC be-
tween thermostat wire nuts and ground.
Check the following:
1. Wire connectors to control module are securely plugged in at module and
originating control.
2. Airpressureswitchhosesareproperlyandsecurelypluggedinandarenot
damaged.
3. Gaspressures:
a. Withboileroff—13”w.c.maximumnaturalorpropanegaspres-
sure upstream of gas valve.
b. With boiler on:
• 5”w.c.minimumnaturalgaspressureor11”w.c.propanegas
pressure upstream of gas valve.
• 3½”w.c.minimumnaturalgaspressureor10”w.c.propanegas
pressuredownstreamofgasvalve—Canbeadjustedbyregula-
tor on gas valve.
4. Verify gas manifold pressure (downstream of gas valve):
a. Natural gas:
Manifold pressure, high fire: 3.50” w.c.
b. Propane gas:
Manifold pressure, high fire: 10.0” w.c.
c. If necessary, adjust gas pressure on the gas valve as shown below. After
adjustments, refer to page 35 to check the flame.
Gas pressure adjustment