9a Operation spark-ignited pilot boilers | Weil-McLain CGA25SPDN

GOLD CGa Gas-Fired Water Boiler — Boiler Manual

9a Operation — spark-ignited pilot boilers

Follow all procedures given in this manual and operating instructions when operating the boiler. Failure to do so could result in severe personal injury, death or substantial property damage.

1.3TANDBY With no call for heat, the vent damper and circulator are de-energized.

.O GAS mOWSSTO PILOT OR MAIN GAS VALVE

2.#ALL FOR HEATH(thermostat circuit closes):

A 6ENT DAMPERDANDMCIRCULATOR ENERGIZED IFCPILOTASTATUS ACCEPTABLE 6ENT damper drives open. When vent damper end switch makes circuit, igni- tion control begins pilot ignition attempt.

b.Ignition control checks for false ﬂame signal: If ignition control senses pilot signal when no pilot gas should be present, control will lockout, requiring reset procedure as given in &IGURE

3.0ILOTLIGNITION #ONTROLTMODULE SPARKS THEHPILOTLANDNOPENSEPILOTLVALVELIN MAIN gas valve.

a.If pilot does light and control module senses ﬂame current, spark generator is turned off and main valve opens.

b.If pilot does not light within 15 seconds, pilot valve is closed and

SPARKAGENERATOREIS TURNEDTOFF #ONTROL MODULENWAITS OMINUTES THEN attempts to ignite pilot again. This cycle will continue indeﬁnitely if pilot ignition control does not sense pilot ﬂame.

4.-AIN BURNERNOPERATION

A #ONTROLTMODULE MONITORSUPILOT mAME current. If signal is lost, main valve closes, spark generator activates and sequence returns to step 4.

b.If power is interrupted, control system shuts off pilot and main gas valves and restarts at step 1 when power is restored.

c.In the event the limit control shuts down the boiler — The control module closes the main gas valve, but keeps the circula- tor operating and the vent damper open.

5. 4HERMOSTAT SATISlED (thermostat circuit opens)

0ILOTLANDNMAIN GASAVALVES ARERCLOSED 6ENT

damper is de-energized, and cycles to closed posi-

TIONO#IRCULATOR ISCSHUT OFF

"OILER ISENOW IN THE STANDBY MODE

7.Thermostat anticipator setting: Set thermostat heat anticipator as instructed in &IGURE B, page

Figure 24 Ignition control module sequence of operation — status light indications
Part Number 550-101-009/0107	37

Image 37

Weil-McLain CGA25SPDN manual 9a Operation spark-ignited pilot boilers, GAS mOWSSTO Pilot or Main GAS VALVE,

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.

Contents

Gold CGa Other boiler components How it works Gold 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%#ODE Minimum dimensions are v Length by Residential garage installations1b Prepare boiler location clearances Foundation 1c Prepare boiler location vent system When removing boiler from an existing common vent systemChimney or vent require- ments Line chimney with corrosion-resistant metal Products to avoid 1d Prepare boiler location air contamination 1e 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 spaces Oriﬁce replacement procedure 2a Prepare boiler placement and setupPlace boiler/crate near position Inspect oriﬁces and burners Hydrostatic pressure test 2b Prepare boiler pressure testDrain and remove ﬁttings Prepare boiler for test Prepare boiler install vent piping Prepare boiler draft hood & spill switchDraft hood installation Spill switch installation Installation 2e Prepare boiler vent damper installationDamper blade Minimum clearances 3a 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 zones 3c Water piping multiple zones Temperature gauges 3d Piping low temperature systemsValve adjustment Figures 13 and 14 only Primary/secondary preferred Bypass piping method Oiler Isolation BALANCING Valves LendetemperaturemgaugeONE Valve $RAINAVALVE BOILER-bypass piping method Valve adjustment 13 !IRISEPARATORRANDNAUTOMATICMVENTNIF 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 Gas Installation must comply with Field wiringWiring connections Ational %LECTRICAL #ODE !.3.&0! LATESTA EDI- tion 6a Start-up preparation Freeze protection when usedCheck for gas leaks Determine if water treatment is needed Verify water chemistry Inspect system water piping Fill the system with waterInspect base insulation #LOSEOZONE Isolation VALVES Efore STARTINGSTHEABOILERNDO 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 for Check burner ﬂames 6d Start-up verify operationCheck vent damper operation Check vent system operation OO Utton Onospilloswitch PUSHEDLIN Check-out procedure checklistOO !IRIPURGED FROMGSYSTEM #ALCULATEUGASAINPUT Main ignited until thermostat circuit or limit circuit 8a Operation standing pilot boilers 8b 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 posi 9a Operation spark-ignited pilot system Schematic wiring diagram Spark-ignited pilot system Ladder 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 cutoffs Following installation, the valve Safety relief valves should beReview with owner Boiler relief valve Before troubleshooting 11a Troubleshooting procedure #ONTINUITY CHECKER Event of vent damper failure Check the followingEfﬁkal or Field Controls damper ASAPRESSURES Chart 1 Standing pilot Boiler will not fire 11b Troubleshooting standing pilot boilers Control indicator lights Lockout modes 11c Troubleshooting spark-pilot boilersControl indicator lights NON-LOCKOUT modes Troubleshooting the control module 11c 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 parts Part number 12b Replacement parts section assembly Igure R Base assembly, manifold, oriﬁces and burners 12c Replacement parts base Igure R Jacket assembly 12d Replacement parts jacket Igure R Trim assembly 12e Replacement parts trim Igure R Gas control assembly 12f Replacement parts controls 13a Dimensions DOE 13b Ratings Jobosite CONDITIONS #URRENT ./3 Recommen Handling ceramic ﬁber and ﬁberglass materialsREATHING H&RESHGAIR Ss 5SES E./3 .CERTIlED Dust Crespirator E.