Common Problems And Solutions - Weil-McLain GOLD CGt User's Information Manual

GOLD CGt Gas-Fired Water Boiler User's Information Manual

Common problems and solutions

Symptom
Rapid cycling — boiler
turns on and off
frequently
Frequent release of
water through relief
valve
Need to frequently add
makeup water
Black water condition
Popping or percolating
noise heard in boiler
Metal flakes found in
vent outlet or vent —
flueway corrosion
Some radiators or
baseboard units do not
heat or are noisy
Domestic water from
tankless heater is hot
then suddenly turn cold.
OR
Domestic water from
tankless heater is
always lukewarm.
Part Number 550-110-291/0703
Common Causes
Thermostat installed where drafts
or heat affect reading
Heat anticipator in thermostat
adjusted incorrectly
Incorrect limit setting
Insufficient water flow through
boiler
Expansion tank sized too small
Flooded expansion tank
Inoperative limit control
Leaks in boiler or piping
Oxygen corrosion due to leaks in
boiler and piping
Mineral deposits in sections due to
constant use of makeup water
Incorrect pH of boiler water
Insufficient water flow through
boiler
Contaminated combustion air
supply — See page 3 in this
manual.
Condensation of combustion
gases in boiler sections
Air in system
Low system pressure
High limit set too low
Mineral deposits insulate internal
waterways of heater.
Boiler stop-leak compound has
been added to boiler water and is
insulating outside of coil.
Incorrect mixing valve setting for
tankless heater.
Domestic flow rate too high.
Incorrect setting on tankless
heater control.
3-Way valve does not work.
Possible Corrections
Locate thermostat on inner wall away from heat sources or cool
drafts.
Adjust thermostat per manufacturer's instructions.
Set limit according to system needs. Maximum setting is 220˚F.
Increase limit setting to decrease cycling.
Check all valves to and from boiler. Return to proper setting.
Confirm circulator size.
Call qualified service technician to check expansion tank
operation and size.
Call qualified service technician to check expansion tank
operation.
Call qualified service technician to replace limit control.
Have qualified service technician repair leaks at once to avoid
constant use of makeup water. Makeup water can cause mineral
deposits which, in turn, can cause boiler section failure. Do not
use petroleum-base stop-leak compounds.
Have qualified service technician repair at once. Keep pH of
water between 7.0 to 8.5.
Call qualified service technician to de-lime boiler, if necessary. In
some cases, deposits will be too heavy to remove with de-liming
procedures.
Have qualified service technician repair leaks to eliminate need
for constant makeup water.
Call qualified service technician to check pH level and correct.
pH should be maintained between 7.0 to 8.5.
Check all valves to and from boiler. Return to proper setting.
Confirm circulator size.
Remove any contaminating products. See page 3 in this manual.
Provide outside air for combustion. Kit available through Weil-
McLain distributor. Have qualified service technician pipe-up kit.
Have qualified service technician inspect system piping and
controls to verify proper regulation of return water temperature.
Bleed air from system through air vents in radiators or
baseboard units.
Fill to correct pressure.
Check for leaks in boiler or piping. Have qualified service
technician repair at once.
Adjust high limit to higher setting.
Have qualified service technician delime or replace coil.
Have qualified service technician remove and clean coil AND
drain and flush boiler to remove stop-leak.
Have qualified service technician adjust mixing valve setting.
Have qualified service technician install flow check valve set to
rating of tankless heater.
Have qualified service technician raise tankless control setting.
Adjust differential on tankless control to lower setting.
Have qualified service technician inspect the 3-way valve wiring,
actuator and body. Check operation of valve. If actuator does not
move when the boiler is shut off and there is a call for domestic
water replace valve and actuator.
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