Weil-McLain CGA25SPDN manual 11c Troubleshooting spark-pilot boilers, Control module

Page 52

GOLD CGa Gas-Fired Water Boiler — Boiler Manual

11c Troubleshooting — spark-pilot boilers

The information on this page and

PAGESG THROUGHO APPLYPONLY TO SPARKIGNITEDI PILOTL #'A' BOILERS These boilers are equipped with an ignition control module that has in- dicator lights to show control status. #HARTS 2 through  PAGESG  help you identify problems based on indicator light conditions.

Control module

Solder or water splatter between 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 ground wiring is installed per wiring

DIAGRAM 'OOD GROUNDINGNIS EXTREMELYEIMPORTANTRFORO

proper operation.

Control indicator lights —

LOCKOUT modes

See Charts 1 through 7 in this section for detailed troubleshooting procedures.

4O RESETSCONTROLTAFTERTAALOCKOUT TURN OFFFPOWERWAT THEH6!# SERVICEVSWITCH OR TURN down all thermostats. Wait 45 seconds. Then restore power or call for heat.

POWER light flashing alone

5SUALLYAINDICATESIREVERSED POLARITY OF  6!# POWER WIRES

POWER and TSTAT CIRC lights flashing

Usually indicates stray voltage on external thermostat circuit wires (usually due to miswired 3-wire zone valve).

POWER and DAMPER lights flashing

Usually indicates damper circuit is closed when it should not be, or damper failed to close within 5 minutes.

POWER and FLAME lights flashing

Usually indicates false flame sense or flame sensed when it shouldn’t be there.

Control indicator lights —

NON-LOCKOUT modes

POWER light on and FLAME light flashing

Usually indicates pilot flame was not established within 15 seconds from application OF SPARK #ONTROLTWILL mASH LIGHT BUTUWILL CONTINUE TO CYCLECINDElNITELY UNTILTmAME

is established or problem is corrected.

POWER light on and DAMPER light flashing

Usually indicates the damper circuit opened during the run cycle.

Troubleshooting the control module

See Figure 30 , page 53, for location of harness plug receptacles and plugs on the control module.

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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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