Weil-McLain CGA25SPDN manual 3a Water piping general information

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GOLD CGa Gas-Fired Water Boiler — Boiler Manual

3a Water piping — general information

General piping information

)F INSTALLATION IS TO COMPLY WITH !3-% OR #ANADIAN REQUIREMENTS AN AD- ditional HIGH TEMPERATURERLIMIT is needed. Install control in supply piping between boiler and isolation valve. Set second control to minimum 20°F above setpoint of first control. Maximum allowable setpoint is 240°F. See page 34 or 38, for wiring.

A LOWWWATERTCUTOFF DEVICE is required when boiler is installed above ra- diation level or by certain state or local codes or insurance companies. Use low water cutoff designed for water installations. Electrode probe-type is recommended. Purchase and install in tee in supply piping above boiler.

Use BACKmOW CHECKK VALVE in cold water supply as required by local codes.

Circulator

The circulator is shipped loose (wiring pre-attached to boiler) to allow you to locate it either in the return or supply piping, as desired. See page 3 for a typical instal- lation. Pipe the expansion tank to the suction side of the circulator whenever possible. Install an air separator in

THEHSUPPLY PIPINGI#ONNECTNTHEHEXPANSIONNTANK TO THEHAIR separator only if the separator is on the suction side of the circulator. Always install the system fill connection at the same point as the expansion tank connection to the system. &IGURESU and  show typical near-boiler piping connections.

Pressure/temperature gauge

Install pressure/temperature gauge in tee on supply piping (as shown in drawing on page 3).

Relief valve

)NSTALLTRELIEF VALVELVERTICALLY IN Ðv TAPPINGPON SIDE OF BOILER3EEE&IGURE  OR , page 17, and the tag attached to the relief valve for manufacturer’s

instructions.

System water piping

See &IGURE  (diaphragm-type or bladder-type expan- sion tank) or &IGURE  (closed-type expansion tank), and 4ABLE  below, for near-boiler and single-zone systems designed for return water at least 130°F.

3EEEPAGESGTO COMPLETE MULTIPLEZONELPIPING OR

pages 20-25 to complete piping for radiant heating systems or converted gravity systems (large-volume systems originally designed for circulation by natural convection rather than a pump). See page 25 for boilers used with refrigeration systems.

To avoid water damage or scalding due to relief valve operation:

ss$ISCHARGEHLINE MUST BE CONNECTEDETO RELIEF VALVELOUTLET ANDNRUNUTO AA SAFEEPLACEAOF DISPOSAL. Terminate the discharge line to eliminate possibility of severe burns should the valve discharge.

ss$ISCHARGEHLINE MUST BE AS SHORTOAS POSSIBLE ANDNBE THEHSAME SIZEEAS THEHVALVE DISCHARGEECONNECTION throughout its entire length.

ss$ISCHARGEHLINE MUST PITCHHDOWNWARD from the valve and terminate

AT LEASTAv ABOVEOTHEHmOOR DRAINAWHEREEANYNDISCHARGEHWILL BE CLEARLYR visible.

ss4HEHDISCHARGEHLINE SHALLATERMINATEIPLAIN NOTOTHREADED, with a mate- rial serviceable for temperatures of 375°F or greater.

ss$O NOTOPIPE THEHDISCHARGE TO ANYYPLACEAWHEREEFREEZING COULDU OCCUR

ss.O SHUTOFFTVALVE shall be installed between the relief valve and boiler,

OR IN THEHDISCHARGEHLINEN$O NOTOPLUG OR PLACEAANYNOBSTRUCTIONUIN THEH discharge line.

ss&AILURE TO COMPLY with the above guidelines could result in failure of the relief valve to operate, resulting in possibility of severe personal injury, death or substantial property damage.

ss4ESTSTHEHOPERATIONAOF THEHVALVE after filling and pressurizing system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.

Table 3 Water pipe size (based on 20°F rise)

Boiler model

To

From

 

system

system

CGa-25

¾"

¾"

 

 

 

CGa-3, 4, 5

1"

1"

CGa-6, 7

1 ¼"

1 ¼"

 

 

 

CGa-8

1 ½"

1 ½"

 

 

 

Note: The boiler supply and return connections, the return/ drain tee and the supply/gauge tee supplied with the boiler are 1¼” NPT. One of the circulator flanges sup- plied with the boiler is 1¼”. The other circulator flange is the size of the recommended system piping shown above.

#HILLERSSOR AIR HANDLING UNITS:

Install boiler such that —

ss#HILLEDLMEDIUM IIF USED EIS PIPEDPIN PARALLEL WITH heating boiler. Use appropriate valves to prevent

CHILLEDL MEDIUM FROM ENTERING BOILERL #ONSULT )"2")NSTALLATION AND 0IPINGT'UIDES

s)F BOILER IS CONNECTEDETO HEATINGTCOILSILOCATEDAIN air handling units where they can be exposed to refrigerated air, use flow control valves or other au- tomatic means to prevent gravity circulation during

COOLINGLCYCLE #IRCULATIONLOF COLD WATERTTHROUGHOTHEH boiler could result in damage to the heat exchanger, causing possible severe personal injury, death or substantial property damage.

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Part Number 550-101-009/0107

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Contents Gold CGa How it works Other boiler componentsGold CGa Gas-Fired Water Boiler Contents Please read before proceeding InstallerUser 1a Prepare boiler location codes & checklist Installations must follow these codesBefore locating the boiler, check the following Ss .ATIONAL %LECTRICAL%#ODEResidential garage installations Minimum dimensions are v Length by1b Prepare boiler location clearances FoundationWhen removing boiler from an existing common vent system 1c Prepare boiler location vent systemChimney or vent require- ments Line chimney with corrosion-resistant metal1d Prepare boiler location air contamination Products to avoidTHEHBOILER #HECKETHEHBOILER Placementecompared 1e Prepare boiler location air openingsAir openings must be provided To a,Exhaust fans and air movers Motorized air dampersSingle air opening option Exception for large spaces2a Prepare boiler placement and setup Orifice replacement procedurePlace boiler/crate near position Inspect orifices and burners2b Prepare boiler pressure test Hydrostatic pressure testDrain and remove fittings Prepare boiler for testPrepare boiler draft hood & spill switch Prepare boiler install vent pipingDraft hood installation Spill switch installation2e Prepare boiler vent damper installation InstallationDamper blade Minimum clearances3a Water piping general information Diaphragm-type or bladder- type expansion tank Figure 3b Water piping single-zone systemClosed-type expansion tank 3c Water piping multiple zones Piping multiple zones3c Water piping multiple zones 3d Piping low temperature systems Temperature gaugesValve adjustment Figures 13 and 14 only Primary/secondary preferred Bypass piping methodOiler Isolation BALANCING Valves LendetemperaturemgaugeONE Valve $RAINAVALVE Valve adjustment BOILER-bypass piping method13 !IRISEPARATORRANDNAUTOMATICMVENT NIF Used .OTEOTHAT Theh SYSTEM-bypass piping method Gold CGa Gas-Fired Water Boiler Boiler Manual Gas piping Connect gas supply piping to boilerNatural Gas Propane GasField wiring Installation must comply withWiring connections Ational %LECTRICAL #ODE !.3.&0! LATESTA EDI- tionFreeze protection when used 6a Start-up preparationCheck for gas leaks Determine if water treatment is needed Verify water chemistryFill the system with water Inspect system water pipingInspect base insulation  #LOSEOZONE Isolation VALVESEfore STARTINGSTHEABOILER NDO the FOLLOWING 6b Start-up operate boilerSs 6ERIFY the Boilerhand System are Full Oflwater 6c Start-up if boiler doesn’t start Start the boilerCheck system and boiler Check for6d Start-up verify operation Check burner flamesCheck vent damper operation Check vent system operationCheck-out procedure checklist OO Utton Onospilloswitch PUSHEDLINOO !IRIPURGED FROMGSYSTEM  #ALCULATEUGASAINPUT8a Operation standing pilot boilers Main ignited until thermostat circuit or limit circuit8b Lighting instructions CGa-25 to CGa-8 8b Lighting instructions CGa-25 to CGa-8 9a Operation spark-ignited pilot boilers GAS mOWSSTO Pilot or Main GAS VALVE#ALL for HEATHthermostat circuit closes Damper is de-energized, and cycles to closed posiSchematic wiring diagram Spark-ignited pilot system 9a Operation spark-ignited pilot systemLadder wiring diagram Spark-ignited pilot system 9b Operating instructions CGa-25 to CGa-8 9b Operating instructions CGa-25 to CGa-6 9b Operating instructions CGa-25 to CGa-6 9b Operating instructions CGa-7 to CGa-8 Service technician 10a Service and maintenance scheduleOwner maintenance 10b Service & maintenance annual start-up Oiled-bearing circulators Boiler heating surfacesRepair.URNERSNANDRBASE Gas piping Cold fill and operating pressuresAir vents and air elimination Limit controls and cutoffsSafety relief valves should be Following installation, the valveReview with owner Boiler relief valveBefore troubleshooting 11a Troubleshooting procedure #ONTINUITY CHECKER Check the following Event of vent damper failureEffikal or Field Controls damper  ASAPRESSURES11b Troubleshooting standing pilot boilers Chart 1 Standing pilot Boiler will not fire11c Troubleshooting spark-pilot boilers Control indicator lights Lockout modesControl indicator lights NON-LOCKOUT modes Troubleshooting the control module11c Troubleshooting spark-pilot boilers Tstat Circ Usually indicates 48 VAC on thermostat circuit stray voltage Chart 4 Spark-ignited pilot Damper light flashing Chart 5 Spark-ignited pilot Flame & Power lights flashing Item 8 , Verify Sequence 12a Replacement parts Section assembly Base Jacket Trim Controls12b Replacement parts section assembly Part number12c Replacement parts base Igure R Base assembly, manifold, orifices and burners12d Replacement parts jacket Igure R Jacket assembly12e Replacement parts trim Igure R Trim assembly12f Replacement parts controls Igure R Gas control assembly13a Dimensions 13b Ratings DOEHandling ceramic fiber and fiberglass materials Jobosite CONDITIONS #URRENT ./3 RecommenREATHING H&RESHGAIR Ss 5SES E./3 .CERTIlED Dust Crespirator E. 

CGA25SPDN specifications

The Weil-McLain CGA25SPDN is a high-efficiency gas-fired boiler designed to deliver dependable heating performance while maintaining a strong focus on energy savings and user-friendly operation. Ideal for residential applications, this boiler is engineered to provide consistent warmth and comfort in homes with various heating demands.

One of the main features of the CGA25SPDN is its durable construction. Built with high-quality materials, this boiler is designed to withstand the rigors of frequent operation while maximizing longevity. It features an advanced cast iron heat exchanger that efficiently transfers heat to the water, resulting in lower energy costs and improved overall performance.

Efficiency is a key characteristic of the Weil-McLain CGA25SPDN. Its design promotes efficient combustion, allowing for a higher Annual Fuel Utilization Efficiency (AFUE) rating. With an AFUE rating of up to 82%, this boiler ensures that more of the fuel used is converted into usable heat, which translates to reduced energy bills for homeowners.

The boiler exhibits a user-friendly control system that allows for easy operation and maintenance. It comes equipped with an integrated vent damper that maximizes efficiency by reducing heat loss during standby periods. Additionally, the CGA25SPDN features an adjustable thermostat, enabling homeowners to customize their heating preferences easily.

Another significant feature of the CGA25SPDN is its versatility. The boiler is compatible with various heating applications, including hot water heating systems and home heating configurations. This adaptability makes it a great choice for both new installations and retrofitting existing systems.

Safety is always a concern with gas-fired appliances, and the Weil-McLain CGA25SPDN addresses this through its advanced safety mechanisms. The boiler incorporates safety controls that prevent overheating and ensure proper operation, providing peace of mind to homeowners.

In summary, the Weil-McLain CGA25SPDN stands out as a reliable and efficient heating solution for residential settings. With its durable construction, high-efficiency performance, user-friendly controls, and impressive safety features, it is an exceptional choice for those seeking a dependable gas-fired boiler that meets modern heating demands while keeping energy costs in check. Homeowners can trust the Weil-McLain CGA25SPDN for warmth and comfort through the cold months.
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