Weil-McLain CGA25SPDN manual Item 8

Page 58

GOLD CGa Gas-Fired Water Boiler — Boiler Manual

11c Troubleshooting — spark-pilot boilers (continued)

CHART 6 — Spark-ignited pilot — FLAME light flashing and POWER light on steady ALSO — Troubleshooting failure to establish main flame

 

 

 

 

 

 

Electrical shock hazard — Wherever you see TURN OFF POWER

, follow the instructions. Failure to follow

 

 

 

 

 

 

instructions could result in severe personal injury, death or substantial property damage.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Are main manual shutoff valve and boiler gas valve open?

 

 

 

 

 

 

 

•

Is pilot flame visible through inspection port?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

No

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• sTURN OFF POWERs to boiler at service switch or breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Open main manual shutoff valve and boiler gas valve (per

 

 

 

 

 

 

 

•

Check the voltage across

 

•

Make sure ground wire

 

 

Operating instructions in this manual). Wait at least 45

 

 

 

 

 

 

 

 

main gas valve terminals of

 

 

terminal is securely fastened

 

 

seconds.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the gas valve.

 

 

 

 

 

 

to control module mounting

 

• Turn on power at service switch or breaker. Allow boiler to cycle.

 

 

 

 

 

 

 

 

Is 24 VAC present there?

 

 

screw.

 

 

 

 

 

 

 

 

Does FLAME light flash now?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Boiler should be in

 

•

 

 

Verify inlet gas pressure at gas

 

 

 

 

 

 

 

•

If the wiring from the

 

 

•

Check the voltage across

 

 

 

 

 

valve:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

control module to gas

 

 

 

main gas valve terminals of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

normal operating

 

 

 

 

Natural gas — 5.0" w.c. min/14.0"

 

 

 

 

 

 

valve is intact, replace the

 

 

 

the gas valve.

 

 

 

 

sequence.

 

 

 

 

w.c. max

 

 

 

 

 

 

 

 

control module.

 

 

 

 

Is 24 VAC present there?

 

•

Observe operation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Propane — 11.0" w.c. min/14.0"

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

Yes

 

 

until thermostat is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

w.c. max

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

satisfied and blower

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is gas present at gas valve inlet and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

has completed its

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

post-purge cycle.

 

 

 

 

 

 

 

 

within above range?

 

 

 

 

 

 

 

• Verify inlet gas pressure at gas valve:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Natural gas — 5.0" w.c. min/14.0" w.c. max

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Propane — 11.0" w.c. min/14.0" w.c. max

 

 

 

•

TURN OFF POWER

to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is gas present at gas valve inlet and within above range?

 

 

boiler at service switch or

 

 

 

 

 

 

• Contact gas supplier to correct

 

 

 

 

 

 

 

breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

pressure or gas supply.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Remove base access panel

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see Figure 32, item 4,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

page 62 for location).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

 

TURN OFF POWER to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

TURN OFF POWER to boiler at service switch or breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

boiler at service switch or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Check flame signal — Detach sense lead from igntion control

 

• Verify pilot gas line is not

 

 

 

 

 

 

 

breaker.

 

 

 

 

 

 

kinked, obstructed or damaged

 

 

•

Remove base access panel (see

 

 

 

 

 

(Figure 30, item 8, page 53).

 

 

 

 

 

 

 

 

 

and is correctly attached to

 

 

 

 

 

 

 

Figure 32, item 4, page 62 for

 

 

 

 

•

Connect negative lead of MICROAMMETER to control sense

 

 

pilot and gas valve.

 

 

 

 

 

 

 

location).

 

 

 

 

 

terminal (Figure 30, item 8, page 53). Connect positive lead of

 

• Verify pilot ignition electrode,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MICROAMMETER to sense wire.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

electrode ceramic and spark

 

 

 

 

 

 

• Verify pilot burner is securely

 

 

 

 

•

DISCONNECT red wire connected to man gas valve terminal of

 

 

lead wire from control are in

 

 

 

 

 

 

 

attached to pilot bracket, bracket

 

 

 

 

 

the gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

good condition. Spark gap

 

 

 

 

 

 

 

is securely attached to cross tie,

 

 

 

 

•

Turn on power to boiler and allow to cycle. As soon as pilot is

 

 

should be approximately 1/8".

 

 

 

 

 

and there is no corrosion on the

 

 

 

 

 

burning, the MICROAMMETER should read at least 1.0

 

• Correct any above problems,

 

 

 

 

 

parts which would affect the

 

 

 

 

 

microamp.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

replacing pilot if burner or

 

 

 

 

 

 

 

ground path for flame sense.

 

 

 

 

 

 

Is flame signal at least 1.0 microamp?

 

 

 

 

wiring is damaged.

 

 

 

 

 

 

• Verify that pilot flame rod, flame

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

Yes

 

 

 

• Reinstall base access panel to

 

 

 

 

rod ceramic and lead wire from

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operate boiler for retest after

 

 

 

 

 

 

 

control module to flame rod are in

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

any changes or corrections.

 

 

 

 

 

 

 

good condition.

 

 

 

 

•

If none of the previous steps

 

• If the wiring from the

 

• If none of the above corrects

 

 

 

 

• Correct any above problems,

 

 

 

 

 

(including replacing pilot)

 

 

 

 

 

 

 

 

 

 

 

 

control module to gas

 

 

problem, then replace the

 

 

 

 

 

 

 

replacing pilot if burner or wiring

 

 

 

 

 

corrects problem, then replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

valve is intact, replace the

 

 

control module, reinstall base

 

 

 

 

 

is damaged.

 

 

 

 

 

the control module, reinstall

 

 

 

 

 

 

 

 

 

 

 

 

 

 

control module and retest.

 

 

access panel, and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

base access panel and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

58

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part Number 550-101-009/0107

Page 57 Page 59
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Page 57 Page 59
Contents Gold CGa How it works Other boiler componentsGold CGa Gas-Fired Water Boiler Contents Please read before proceeding InstallerUser Before locating the boiler, check the following 1a Prepare boiler location codes & checklistInstallations must follow these codes Ss .ATIONAL %LECTRICAL%#ODE1b Prepare boiler location clearances Residential garage installationsMinimum dimensions are v Length by FoundationChimney or vent require- ments When removing boiler from an existing common vent system1c Prepare boiler location vent system Line chimney with corrosion-resistant metal1d Prepare boiler location air contamination Products to avoidAir openings must be provided THEHBOILER #HECKETHEHBOILER Placementecompared1e Prepare boiler location air openings To a,Single air opening option Exhaust fans and air moversMotorized air dampers Exception for large spacesPlace boiler/crate near position 2a Prepare boiler placement and setupOrifice replacement procedure Inspect orifices and burnersDrain and remove fittings 2b Prepare boiler pressure testHydrostatic pressure test Prepare boiler for testDraft hood installation Prepare boiler draft hood & spill switchPrepare boiler install vent piping Spill switch installationDamper blade 2e Prepare boiler vent damper installationInstallation 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 Valve adjustment Figures 13 and 14 only 3d Piping low temperature systemsTemperature gauges 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 Natural Gas Gas pipingConnect gas supply piping to boiler Propane GasWiring connections Field wiringInstallation must comply with Ational %LECTRICAL #ODE !.3.&0! LATESTA EDI- tionCheck for gas leaks Determine if water treatment is needed Freeze protection when used6a Start-up preparation Verify water chemistryInspect base insulation Fill the system with waterInspect system water piping  #LOSEOZONE Isolation VALVESEfore STARTINGSTHEABOILER NDO the FOLLOWING 6b Start-up operate boilerSs 6ERIFY the Boilerhand System are Full Oflwater Check system and boiler 6c Start-up if boiler doesn’t startStart the boiler Check forCheck vent damper operation 6d Start-up verify operationCheck burner flames Check vent system operationOO !IRIPURGED FROMGSYSTEM Check-out procedure checklistOO Utton Onospilloswitch PUSHEDLIN  #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 #ALL for HEATHthermostat circuit closes 9a Operation spark-ignited pilot boilersGAS mOWSSTO Pilot or Main GAS VALVE 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 Air vents and air elimination Gas pipingCold fill and operating pressures Limit controls and cutoffsReview with owner Safety relief valves should beFollowing installation, the valve Boiler relief valveBefore troubleshooting 11a Troubleshooting procedure #ONTINUITY CHECKER Effikal or Field Controls damper Check the followingEvent of vent damper failure  ASAPRESSURES11b Troubleshooting standing pilot boilers Chart 1 Standing pilot Boiler will not fireControl indicator lights NON-LOCKOUT modes 11c Troubleshooting spark-pilot boilersControl indicator lights 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 DOEREATHING H&RESHGAIR Handling ceramic fiber and fiberglass materialsJobosite CONDITIONS #URRENT ./3 Recommen 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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