Install Instructions

CG i GAS - FIRED wATER BOILER- sERIEs 3- Boiler Manual
11 a Troubleshooting - procedure
!& WARNIN G!
Labe l al l wires prior to dis-
connection wh en se rvi ci ng
cont
rols. W irin g e rr ors ca n
cause im proper and dan ger-
ous opera t ion.
Check the following:
I. Wire connectors to control mod ul e are secur ely plu gg ed in at module and
or
ig inating control.
2. Air p ress ure S\vitch hoses are proper ly and securely plugged in a nd are not
damaged.
!& WARNING !
N eve r jmnper (byp as s) ro ll -
out therm al fuse eleme nt
or any other device excep t
fo r mo mentary t es ting as
outlined in
Tr oub leshoot-
Ing
Charts. S eve re personal
injury, death
or substantial
property damage can result.
3.
Gas pressures:
a. With bo il er off- 13 " w. c. maximum natural or propane g as pres-
sure u ps tream of gas va lve.
b. With bo il er on:
s• w.c. minimum natural gas pr essure or 11 " w.c. propane gas
pressure u ps tream of gas valve.
3 in" w.c. minimum natural gas pr essure or 10" w.c. propane gas
pressure d ow n st ream of gas val ve- Ca n be adjusted by regula-
tor on gas valve.
4. Ve r ify gas man i fol d pressure (d owns tr eam of gas va l ve):
Before troubleshooting:
a. Na t ural gas:
Manifo ld pressure,high tire : 3. 50"w .c.
1. Ha ve the fo ll owing ite ms :
a.
Voltmeter that can check 12 0 VAC
and 24 VA C.
CGi-4 only- Manif o ld pressure, l ow tire : 0 90 " w.c. while in low fire at
start·up (60seconds)
b. P ropane gas :
Manifo ld pressure,high tire : IO .O "w .c.
b. Mi cro amm eter wi th a m in i mum
scale range of 0-25.
CGi-4 only- Manif o ld pressure, l ow tire : 3S O" w.c. while in low fire at
start·up (60 seconds)
c. Continuity checker.
d U- tu be manometer.
c. If n ecessa r y, adjust gas pr essure on the gas va l ve as sh ow n be l ow. After
adjustments , refer to page 35 to check the flame.
2. Ch ec k for 120 VAC (minimum 102 VAC
to maximmn 13 2 VA C) to boiler.
3. Ma ke su re the m1 ostat is calling for heat
a
nd contacts (including appropriate zone
contro
ls ) are closed. Check for 24 VAC
between th e m1 ostat wi re nuts and ground.
pressure a4ustment
ll oueywel two-otage gas vtlve
11b
Troubleshooting - components
Air pressure switch
NOTICE
NOTICE
50
Make sure boiler wa ter temperature is I 00 °F
or cooler before starting procedure to obtain
appropriate readings.
The boi
le r will not operate correctly unl ess
pressure S\vi tch hoses are correctly located.
The red hose connects from the right
si de
(negati
ve) hose barb to th e flu e co ll ector. Th e
w
hi te hose connects from the left side (posi-
tive) hose barb of the switch to the co nnector
box (bet
wee n flu e co ll ector a nd indu ce r) as
shown in Figu re 36, page 49.
Che ck pre ss ure s witch setting
1. See Figure 36, page 49, and Table 9.
2. Remove both air pr essure switch hoses from air pressure switch.
3.
Install tees and t ub i ng as shown in F igure 38. page 49, to indined
manometer.
4. Turn off gas valve and set thermostat to call for heaL Inducer will
r un but burners will not i gn i te .
5. C he ck for 24 VAC between both air pre ss u re switch terminal s.
Pa rt N um ber 550 - 142-7 8 0/07 12