Weil-McLain CGA25SPDN manual 11a Troubleshooting procedure, Before troubleshooting

Page 49

GOLD CGa Gas-Fired Water Boiler — Boiler Manual

10b Service & maintenance – annual start-up (cont.)

OCleaning boiler heating surfaces

The boiler contains ceramic fiber and fiberglass materi- als. Use care when handling these materials per instruc- tions on PAGE  of this manual. Failure to comply could result in severe personal injury.

1.Shut down boiler:

s &OLLOW h4O 4URNR /FFF 'ASA TO !PPLIANCEvvIN- structions on boiler and ,IGHTING OR /PERATINGA INSTRUCTIONS.

ss$O NOTODRAINABOILER UNLESS IT WILL BE EXPOSEDO to freezing temperatures. If using antifreeze in system, do not drain.

2.Follow shutdown procedure.

3.Remove venting system connection to boiler.

4.Remove top jacket panel. Turn back insulation.

 2EMOVE mUEUCOLLECTOR #LEANESEALANTLFROM ASSEMBLY and sections.

6. Remove radiation plates hanging between sections.

 2EMOVE BURNERSN FROM BASES "RUSHU ANDN VACUUM BURNERSNTO REMOVE ALLLDUST ANDNLINTN6ERIFY THAT ALLL burner ports are free of debris.

8.Place newspapers in base of boiler to collect soot.

 #LEANEBETWEENBSECTIONS WITH WIRE mUE BRUSH

2EMOVE NEWSPAPERPANDNSOOTO6ACUUM OR BRUSHUBASE and surrounding area.

11.Reinstall radiation plates.

12.Replace collector box/transition assembly. Seal with sealant. Obtain gas-tight seal to prevent flue gas spillage and carbon monoxide emissions, resulting in severe personal injury or death.

13.Replace insulation and jacket top panel.

14.Start up boiler following Section  of this manual and the boiler ,IGHTING OR /PERATINGAINSTRUCTIONS

(Section B or B). Excessive sooting indicates improper gas combustion. If found, check for proper combustion and make any necessary adjustments.

11a Troubleshooting — procedure

Label all wires prior to disconnection when servic- ing controls. Wiring errors can cause improper and dangerous operation.

.EVERVJUMPER BYPASS ROLLOUTLTHERMALRFUSE ELE- ment or any other device except for momentary testing as outlined in 4ROUBLESHOOTING #HARTS. Severe personal injury, death or substantial prop- erty damage can result.

"URNER ACCESS PANELNMUST BE IN POSITION DURING boiler operation to prevent momentary flame rollout on ignition of main flame. Severe per- sonal injury or substantial property damage will result.

3EEEPAGESG  THROUGHO  FOROADDITIONAL TROUBLE-

shooting information.

Before troubleshooting:

 (AVE THE FOLLOWING ITEMS

A 6OLTMETERMTHAT CAN CHECK  6!# AND  6!#

b.Microammeter with a minimum scale range of 0-25.

C #ONTINUITY CHECKER

d. U-tube manometer.

 #HECKEFORO6!#!MINIMUM 6!#!TO MAXIMUMIU6!# TOBOILER

3.Make sure thermostat is calling for heat and contacts (including appropriate zone controls)

ARERCLOSEDS#HECKEFORO 6!#!BETWEENWTHERMO- stat wire nuts and ground.

Part Number 550-101-009/0107



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Contents Gold CGa Other boiler components How it worksGold CGa Gas-Fired Water Boiler Contents Please read before proceeding InstallerUser Installations must follow these codes 1a Prepare boiler location codes & checklistBefore locating the boiler, check the following Ss .ATIONAL %LECTRICAL%#ODEMinimum dimensions are v Length by Residential garage installations1b Prepare boiler location clearances Foundation1c Prepare boiler location vent system When removing boiler from an existing common vent systemChimney or vent require- ments Line chimney with corrosion-resistant metalProducts to avoid 1d Prepare boiler location air contamination1e Prepare boiler location air openings THEHBOILER #HECKETHEHBOILER PlacementecomparedAir openings must be provided To a,Motorized air dampers Exhaust fans and air moversSingle air opening option Exception for large spacesOrifice replacement procedure 2a Prepare boiler placement and setupPlace boiler/crate near position Inspect orifices and burnersHydrostatic pressure test 2b Prepare boiler pressure testDrain and remove fittings Prepare boiler for testPrepare boiler install vent piping Prepare boiler draft hood & spill switchDraft hood installation Spill switch installationInstallation 2e Prepare boiler vent damper 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 Piping multiple zones 3c Water piping multiple zones3c Water piping multiple zones Temperature gauges 3d Piping low temperature systemsValve adjustment Figures 13 and 14 only Primary/secondary preferred Bypass piping methodOiler Isolation BALANCING Valves LendetemperaturemgaugeONE Valve $RAINAVALVE BOILER-bypass piping method Valve adjustment13 !IRISEPARATORRANDNAUTOMATICMVENT NIF Used .OTEOTHAT Theh SYSTEM-bypass piping method Gold CGa Gas-Fired Water Boiler Boiler Manual Connect gas supply piping to boiler Gas pipingNatural Gas Propane GasInstallation must comply with Field wiringWiring connections Ational %LECTRICAL #ODE !.3.&0! LATESTA EDI- tion6a Start-up preparation Freeze protection when usedCheck for gas leaks Determine if water treatment is needed Verify water chemistryInspect system water piping Fill the system with waterInspect base insulation  #LOSEOZONE Isolation VALVESEfore STARTINGSTHEABOILER NDO the FOLLOWING 6b Start-up operate boilerSs 6ERIFY the Boilerhand System are Full Oflwater Start the boiler 6c Start-up if boiler doesn’t startCheck system and boiler Check forCheck burner flames 6d Start-up verify operationCheck vent damper operation Check vent system operationOO Utton Onospilloswitch PUSHEDLIN Check-out procedure checklistOO !IRIPURGED FROMGSYSTEM  #ALCULATEUGASAINPUTMain ignited until thermostat circuit or limit circuit 8a Operation standing pilot boilers8b Lighting instructions CGa-25 to CGa-8 8b Lighting instructions CGa-25 to CGa-8 GAS mOWSSTO Pilot or Main GAS VALVE 9a Operation spark-ignited pilot boilers#ALL for HEATHthermostat circuit closes Damper is de-energized, and cycles to closed posi9a Operation spark-ignited pilot system Schematic wiring diagram 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 Cold fill and operating pressures Gas pipingAir vents and air elimination Limit controls and cutoffsFollowing installation, the valve Safety relief valves should beReview with owner Boiler relief valveBefore troubleshooting 11a Troubleshooting procedure #ONTINUITY CHECKER Event of vent damper failure Check the followingEffikal or Field Controls damper  ASAPRESSURESChart 1 Standing pilot Boiler will not fire 11b Troubleshooting standing pilot boilersControl indicator lights Lockout modes 11c Troubleshooting spark-pilot boilersControl 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 Section assembly Base Jacket Trim Controls 12a Replacement partsPart number 12b Replacement parts section assemblyIgure R Base assembly, manifold, orifices and burners 12c Replacement parts baseIgure R Jacket assembly 12d Replacement parts jacketIgure R Trim assembly 12e Replacement parts trimIgure R Gas control assembly 12f Replacement parts controls13a Dimensions DOE 13b RatingsJobosite CONDITIONS #URRENT ./3 Recommen Handling ceramic fiber and fiberglass materialsREATHING 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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