Weil-McLain CGA25SPDN manual Verify Sequence

Page 59

GOLD CGa Gas-Fired Water Boiler — Boiler Manual

11c Troubleshooting — spark-pilot boilers (continued)

CHART 7 — Spark-ignited pilot — Insufficient heat or no heat (POWER light on steady)

 

 

 

 

 

 

 

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.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Has it been at least 5 minutes since setting thermostat to

 

 

 

 

 

 

 

Is boiler System circulator operating?

 

 

call for heat? If not, wait 5 minutes. Is system heating?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

Yes

 

• Is thermostat set to call for heat? Remove thermostat

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

wires at boiler and check continuity across the two wires.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

If circuit isn't closed, check external thermostat (zone

 

 

 

• Remove CIRCULATOR harness plug from

 

 

 

 

 

valve, relay, etc.) wiring. Correct problems and retry.

 

 

 

 

 

CIRCULATOR plug receptacle (Figure 30,

 

 

 

 

• Reconnect external thermostat wiring at boiler.

 

 

 

 

 

Item 7, page 53). Check with voltmeter across

 

 

 

 

 

Is thermostat circuit closed (continuity across wires)?

 

 

 

 

 

pins of control module receptacle.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does voltmeter show 120 VAC across pins?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Boiler is in standby.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Are all red lights off?

 

 

•

Set thermostat to call for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Replace control

 

•

Repair/replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

heat and recheck

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

module.

 

 

 

 

 

 

circulator. Retest.

 

 

 

 

 

 

 

 

 

 

 

 

operation.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Retest.

 

 

 

 

•

Repair/replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Verify Sequence of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

wiring. Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operation, Figure 24,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Wait 30 seconds.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Are all red lights off?

 

 

 

 

 

page 37.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

•

 

Wait 5 minutes.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is FLAME light on?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace control module.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• If you have sufficient heat — boiler should be in normal

 

 

 

 

 

 

 

 

 

 

 

 

 

Is LIMIT light on?

 

 

 

 

 

 

 

 

 

operating sequence. (See normal sequence of operation,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 24, page 37.)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

• If you have less than sufficient heat —

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is vent or combustion air piping free of blockage?

 

 

 

•

 

Check limit switch

 

 

 

•

Replace control module.

 

 

 

 

 

 

No

 

 

 

Yes

 

 

 

 

contacts with continuity

 

 

 

•

Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

checker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Correct conditions and

 

 

Contact your Weil-McLain

 

 

 

Are limit switch contacts

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

recheck operation.

 

 

sales representative.

 

 

 

 

 

 

closed?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• See Figure 24, page 37

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check spill switch and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

Yes

 

 

 

 

 

 

for normal sequence of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

rollout switch continuity —

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operation.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

are switches closed?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

Yes

 

• Wait for boiler water to cool to temperature 20 to 30 °F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

lower than temperature set on limit switch.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Are limit switch contacts closed?

 

 

 

• Reset spill switch, or replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

rollout switch.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Check any other

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Boiler water temperature exceeded

 

 

If rollout thermal fuse element or

 

 

 

 

limit controls wired

 

 

 

 

 

 

 

 

 

 

setting on limit switch with thermostat

 

 

spill switch has opened, determine

 

 

into the limit

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Replace

 

 

 

 

calling for heat. Boiler is OK.

 

 

cause and correct condition.

 

 

 

 

 

 

circuit. If all are

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Failure to do so will cause severe

 

 

 

 

OK, then replace

 

 

limit switch.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Also check setting on limit switch (should

 

 

personal injury, death or

 

 

 

 

 

 

 

 

control module.

 

•

Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

be above 140°F.).

 

 

substantial property damage.

 

 

 

 

•

Retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part Number 550-101-009/0107

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



Page 58 Page 60
Image 59
Page 58 Page 60
Contents Gold CGa Other boiler components How it worksGold CGa Gas-Fired Water Boiler Contents User InstallerPlease read before proceeding Ss .ATIONAL %LECTRICAL%#ODE 1a Prepare boiler location codes & checklistInstallations must follow these codes Before locating the boiler, check the followingFoundation Residential garage installationsMinimum dimensions are v Length by 1b Prepare boiler location clearancesLine chimney with corrosion-resistant metal When removing boiler from an existing common vent system1c Prepare boiler location vent system Chimney or vent require- mentsProducts to avoid 1d Prepare boiler location air contaminationTo a, THEHBOILER #HECKETHEHBOILER Placementecompared1e Prepare boiler location air openings Air openings must be providedException for large spaces Exhaust fans and air moversMotorized air dampers Single air opening optionInspect orifices and burners 2a Prepare boiler placement and setupOrifice replacement procedure Place boiler/crate near positionPrepare boiler for test 2b Prepare boiler pressure testHydrostatic pressure test Drain and remove fittingsSpill switch installation Prepare boiler draft hood & spill switchPrepare boiler install vent piping Draft hood installationMinimum clearances 2e Prepare boiler vent damper installationInstallation Damper blade3a Water piping general information Closed-type expansion tank 3b Water piping single-zone systemDiaphragm-type or bladder- type expansion tank Figure Piping multiple zones 3c Water piping multiple zones3c Water piping multiple zones Primary/secondary preferred Bypass piping method 3d Piping low temperature systemsTemperature gauges Valve adjustment Figures 13 and 14 onlyONE Valve $RAINAVALVE LendetemperaturemgaugeOiler Isolation BALANCING Valves BOILER-bypass piping method Valve adjustment13 !IRISEPARATORRANDNAUTOMATICMVENT NIF Used .OTEOTHAT Theh SYSTEM-bypass piping method Gold CGa Gas-Fired Water Boiler Boiler Manual Propane Gas Gas pipingConnect gas supply piping to boiler Natural GasAtional %LECTRICAL #ODE !.3.&0! LATESTA EDI- tion Field wiringInstallation must comply with Wiring connectionsVerify water chemistry Freeze protection when used6a Start-up preparation Check for gas leaks Determine if water treatment is needed #LOSEOZONE Isolation VALVES Fill the system with waterInspect system water piping Inspect base insulationSs 6ERIFY the Boilerhand System are Full Oflwater 6b Start-up operate boilerEfore STARTINGSTHEABOILER NDO the FOLLOWING Check for 6c Start-up if boiler doesn’t startStart the boiler Check system and boilerCheck vent system operation 6d Start-up verify operationCheck burner flames Check vent damper operation #ALCULATEUGASAINPUT Check-out procedure checklistOO Utton Onospilloswitch PUSHEDLIN OO !IRIPURGED FROMGSYSTEMMain 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 Damper is de-energized, and cycles to closed posi 9a Operation spark-ignited pilot boilersGAS mOWSSTO Pilot or Main GAS VALVE #ALL for HEATHthermostat circuit closes9a 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 Owner maintenance 10a Service and maintenance scheduleService technician 10b Service & maintenance annual start-up Repair.URNERSNANDRBASE Boiler heating surfacesOiled-bearing circulators Limit controls and cutoffs Gas pipingCold fill and operating pressures Air vents and air eliminationBoiler relief valve Safety relief valves should beFollowing installation, the valve Review with owner #ONTINUITY CHECKER 11a Troubleshooting procedureBefore troubleshooting  ASAPRESSURES Check the followingEvent of vent damper failure Effikal or Field Controls damperChart 1 Standing pilot Boiler will not fire 11b Troubleshooting standing pilot boilersTroubleshooting the control module 11c Troubleshooting spark-pilot boilersControl indicator lights Lockout modes Control indicator lights NON-LOCKOUT modes11c 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 RatingsSs 5SES E./3 .CERTIlED Dust Crespirator E.  Handling ceramic fiber and fiberglass materialsJobosite CONDITIONS #URRENT ./3 Recommen REATHING H&RESHGAIR

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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