Weil-McLain 2 Series Manual page 84

series
GV90+
Troubleshooting
CHART 2
Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to fol-
low instructions could result in severe personal injury, death or substantial property damage.
Is return water temperature sensor clamped
securely to the return pipe in the boiler?
Yes
• Check for stray voltage on the incoming thermostat wires.
Disconnect the two external wires connected to the boiler
thermostat wires.
• Connect a voltmeter across the two incoming wires. Close each
thermostat, zone valve and relay in the external circuit one at a
time and check the voltmeter reading across the wires. There
should NEVER be a voltage reading. If a voltage does occur
Did you find and correct a voltage across the two external thermostat circuit wires?
• Boiler should now operate per the normal sequence of op-
eration (Figure 75, page 66) if wiring was corrected.
• Remove CIRCULATORS plug
from plug receptacle of IBC.
• Place voltmeter leads across the right-side 120VAC N and
120VAC H pins of the CIRCULATORS receptacle.
Does the voltmeter indicate 120 VAC?
No
• Replace the IBC.
• Retest.
• Replace circulator harness.
• Retest.
• Reconnect circulator harness to IBC.
• Attempt to get the circulator started by giving it a sharp rap
on the end of the circulator motor (to release a possibly
locked impeller).
• If the circulator begins to operate, allow it to operate for a few
minutes to see if the problem clears.
• With harness connected and power to circulators, check for
120 VAC at circulator harness terminals. If no voltage is pres-
ent with circulators under load. Replace IBC and retest.
• If problem persists, replace the Bypass circulator.
• Retest.
84
gas-fired water boiler – boiler manual
2
(continued)
TSTAT/CIRC & POWER lights flashing
No
Yes
(Figure 93, page 80, Item 4)
Yes
• Test wire continuity of
circulator wire harness.
Is harness ok?
No Yes
• Attach sensor to pipe with clamp provided.
• Follow return temperature sensor checking procedure
on page 78. Replace sensor if necessary.
• Retest.
under any condition, check and correct the external wiring.
(This is a common problem when using 3-wire zone valves.)
• Once the external thermostat circuit wiring is checked and cor-
rected if necessary, reconnect the external thermostat circuit
wires to the boiler thermostat wires and allow the boiler to cycle.
Is boiler internal Bypass circulator operating?
No
• Check the boiler internal return pipe where it enters the
boiler sections. The TSTAT/CIRC and POWER lights
will flash after 30 minutes as long as the return water
temperature is less than 130 °F.
• Wait up to 20 minutes to give the boiler and system a
chance to respond.
Does problem persist?
No
• Boiler may now be operating normal-
ly. Verify against normal sequence of
operation (Figure 75, page
• If boiler appears not to be heating, troubleshoot boiler
per CHART 7, page 89. If problem cannot be resolved,
replace water temperature sensor and retest. Then
replace IBC if sensor does not correct the problem.
• If boiler is heating, but the temperature at the return
pipe does not increase above 130 °F, there may be an
incorrectly-piped external circulator forcing water through
the boiler. Check external piping and correct.
No
Yes
Yes
66).
Part number 550-143-010/1021