Troubleshooting: Spark-Ignited Pilot Boilers - Weil-McLain CGA Series 2 Manual

CGa Series 2 Gas-Fired Water Boiler — Boiler Manual
11b
Troubleshooting — spark-pilot boilers
The information on this page and
pages 50 through 56 apply only to
spark-ignited pilot CGa boilers.
These boilers are equipped with
an ignition control module that
has indicator lights to show control
status. Charts
51-56, help you identify problems
based on indicator light condi-
tions.
Figure 29 CGa Ignition control module
Control module
Solder or water
tween plugs and circuit board
can cause improper operation of
control module. Place a shield over
the boiler internal controls and
components during installation.
Failure to comply could result in
severe personal injury, death or
substantial property damage.
Make sure
stalled per wiring diagram. Good
grounding is extremely important
for proper operation.
Part Number 550-142-900/0519
Control indicator lights —
HARD LOCKOUT Summary (Flashing LED's)
MAY remove 120 VAC power for more than 2 seconds to clear lockout OR
ignition control will automatically restart sequence of operation after 1 hour
waiting period after fault condition is cleared.
1 6
through , pages
SOFT LOCKOUT Summary (Flashing LED's)
MAY remove 120 VAC power for more than 2 seconds, cycle thermostat
for between 2 and 20 seconds, OR ignition control will automatically restart
sequence of operation after 1 hour waiting period.
NDICATOR LIGHT
I
POWER + TSTAT/CIRC
POWER + DAMPER
POWER + FLAME
splatter be-
CAUTION Summary (Flashing LED's)
INDICATOR LIGHT
DAMPER
LIMIT
FLAME
SENSOR GROUND
ground wiring is in-
Troubleshooting the control module
See Figure 30, page 50, for location of harness plug receptacles and plugs on
the control module.
INDICATOR LIGHT
POWER
Flashes once per second
Flash code 2*
Flash code 3*
Flash code 4*
Flash code 5*
Flash code 6*
Flashes once per second
* Flash code pattern:
ALL LED'S FLASHING
SOLID SENSOR GROUND LED
and "LCO" on Display
CONDITION
120 VAC connection to boiler
reversed or there is insufficient
earth ground.
Internal fault, microprocessor or
memory.
Unused.
Unused.
Internal fault, water thermistors
disagree.
Internal fault, gas valve circuit.
POWER LED flashes 2, 3, etc. times
rapidly followed by 2 seconds off,
then repeats.
Failure to establish pilot flame after
4 attempts. Propane requires Manual
Reset, see pages 34 and 35.
Indicates the sensor ground wire is not
grounded or the boiler has a poor ground
connection or stray voltage on ground.
Check both sensor ground wire on the P5
connection and the boiler ground.
CONDITION
High voltage detected on TSTAT circuit.
Damper stuck closed or unable to close end
switch within 45 seconds from TSTAT call.
Flame sensed without call for heat or out of
sequence during ignition trial.
CONDITION
Damper end switch opened after it had been
proven closed.
Fault detected in temperature sensing hardware.
Flame loss or flame not sensed during trial
for ignition.
Three (3) rapid pulses indicates the sensor
ground wire may not be connected or the
boiler has a poor ground connection or stray
voltage on ground.
49