Instruction/ maintenance manual of the product CGA25SPDN Weil-McLain
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P ar t No . 550-101-009/0107 This manual must only be used by a qualified heating installer/service technician. Before installing , read all instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 2 P ar t Number 550-101-009/0107 How it works . . . x Control module The control module (used on SPARKIGNITED PILOTBOILER S ) responds to signals from the room thermostat and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and vent damper.
P ar t Number 550-101-009/0107 3 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual GOLD CGa Gas-Fir ed W ater Boiler.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 4 P ar t Number 550-101-009/0107 Contents Hazar d definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.
P ar t Number 550-101-009/0107 5 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage. Please r ead befor e pr oceeding s #ONTINUAL FRESH MAKEUP WATER WILL REDUCE boiler life.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 6 P ar t Number 550-101-009/0107 Pr epar e boiler location — codes & checklist 1a Installations must follow these codes: s ,OCALSTATEPROVINCIALANDNATIONALCODESLA ws, regulations and ordinances.
P ar t Number 550-101-009/0107 7 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — clearances 1b &IGUREB Required MINIMUM clearances .EVER INSTALL THE BOILER IN A SPACE WITH CLEAR ANCES LESS THAN THE MINIMUM CLEARANCES SHOWN IN &IGUREB .
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 8 P ar t Number 550-101-009/0107 Pr epar e boiler location — vent system 1c Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
P ar t Number 550-101-009/0107 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — air contamination 4 ABLE Corrosive contaminants and likely locations 1d Please review the following information on potential combustion air contamination problems.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 10 P ar t Number 550-101-009/0107 Pr epar e boiler location — air openings 1e Air openings must be pr ovided #OMBUSTIONAIRAND VENTILATIONOPENINGSMUSTCOMPLY THE.ATIONAL&UEL 'AS #ODE !.
P ar t Number 550-101-009/0107 11 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Unusually tight construction 5NUSUALLY TIGHT CONSTRUCTION MEANS PER !.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 12 P ar t Number 550-101-009/0107 Pr epar e boiler — placement and setup 2a Inspect orifices and bur ners 1. Remove front jacket door. Remove base access panel (See &IGURE , item , page 62).
P ar t Number 550-101-009/0107 13 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler — pr essure test Hydr ostatic pressur e test Pressure test boiler BEFORE attaching water or gas piping or electrical supply (except as noted below).
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 14 P ar t Number 550-101-009/0107 Pr epar e boiler — draft hood & spill switch Draft hood installation 1. Orient draft hood with spill switch mounting holes to front of boiler as shown in Figure 7.
P ar t Number 550-101-009/0107 15 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler — vent damper installation 4. Read and apply the harness plug warning label (shown above) so that it is visible after installa- tion. 5. Plug damper harness receptacle into damper harness plug.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 16 P ar t Number 550-101-009/0107 W ater piping — general information 3a Boiler model To system From system CGa-25 ¾" ¾" CGa-3, 4, 5 1&.
P ar t Number 550-101-009/0107 17 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Diaphragm-type or bladder - type expansion tank (Figure 9) 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possible, before inlet side of circulator.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 18 P ar t Number 550-101-009/0107 W ater piping — multiple zones Piping multiple zones Follow instructions on pages 16 and 17 to install near- boiler or single-zone piping.
P ar t Number 550-101-009/0107 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual For systems with possible low return-water temperature (such as converted gravity systems, radiant heating systems and heat pump systems), refer to the special piping suggestions of &IGURES n , as applies.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 20 P ar t Number 550-101-009/0107 Failure to PREVENTLO WRETURNWATER TEMPERATURE to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.
P ar t Number 550-101-009/0107 21 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 1 "OILERISOLATIONBALANCINGVALVES 2 Flow/check valve 3 System or zone circulator (circulator.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 22 P ar t Number 550-101-009/0107 Failure to PREVENTLO WRETURNWATER TEMPERATURE to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.
P ar t Number 550-101-009/0107 23 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 1 "OILERISOLATIONBALANCINGVALVES 2 Flow/check valve 3 System or zone circulator 4 System te.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 24 P ar t Number 550-101-009/0107 Failure to PREVENTLO WRETURNWATER TEMPERATURE to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage.
P ar t Number 550-101-009/0107 25 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual W ater piping — refrigeration systems 3e Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 26 P ar t Number 550-101-009/0107 Gas piping Natural Gas: 1. Refer to 4 ABLE FORPIPE LENGTHAND DIAMETER"ASE on rated boiler input (divide by 1,000 to obtain cubic feet per hour).
P ar t Number 550-101-009/0107 27 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Field wiring For your safety, TURN OFF ELECTRICAL POWER SUPPLY AT SERVICE ENTRANCE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS to avoid possible electric shock hazard.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 28 P ar t Number 550-101-009/0107 Start-up — pr eparation 6a Check for gas leaks "EFORESTARTINGTHEBOILERANDDUR - ing ini.
P ar t Number 550-101-009/0107 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Fill the system with water #LOSEMANUALANDAUTOMATIC AIRVENTS and boiler drain cock. 2. &ILLTO CORRECTSYSTEMPRESSURE #ORRECT PRESSUREWILLVARY WITHEACH application.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 30 P ar t Number 550-101-009/0107 Start-up — operate boiler 6b $/ ./ 4 proceed with boiler operation unless boiler and system have been filled with water and all instruc- tions and procedures of previous manual sections have been completed.
P ar t Number 550-101-009/0107 31 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Start-up — if boiler doesn’ t start . . . 6c Check for: %LIMINATE ALL SYSTEM LEAKS #ONTINUAL FRESH MAKEUP WATER will reduce boiler life.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 32 P ar t Number 550-101-009/0107 Start-up — verify operation 6d 4HEBOILER MODELSUFlX WILLBEh 30$ v &ORSPARKIGNITED PILOTBOILERS SUFlXh 0)$ vSEE 3ECTION or for operation and lighting/operating information.
P ar t Number 550-101-009/0107 33 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Installation and service certificate "OILERMODEL?????????????????? 3ERIES??.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 34 P ar t Number 550-101-009/0107 Operation — standing pilot boilers 8a Figure 23 Wiring diagram — Standing pilot system Follow all procedures given in this manual and light- ing instructions when operating the boiler.
P ar t Number 550-101-009/0107 35 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Lighting instructions CGa-25 to CGa-8 8b s3TANDINGPILOTs.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 36 P ar t Number 550-101-009/0107 Lighting instructions CGa-25 to CGa-8 8b s3TANDINGPILOTs.
P ar t Number 550-101-009/0107 37 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Figure 24 Ignition contr ol module sequence of operation — status light indications Operation — spark-ignited pilot boilers 9a Follow all procedures given in this manual and operating instructions when operating the boiler.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 38 P ar t Number 550-101-009/0107 Figure 25a Schematic wiring diagram — Spark-ignited pilot system Operation — spark-ignited pilot system (co.
P ar t Number 550-101-009/0107 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Figure 25b Ladder wiring diagram — Spark-ignited pilot system Operation — spark-ignited pilot system (c.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 40 P ar t Number 550-101-009/0107 9b Operating instructions CGa-25 to CGa-8 s3PARKPILOTs.
P ar t Number 550-101-009/0107 41 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 9b Operating instructions CGa-25 to CGa-6 s3PARKPILOTs.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 42 P ar t Number 550-101-009/0107 9b Operating instructions CGa-25 to CGa-6 s3PARKPILOTs.
P ar t Number 550-101-009/0107 43 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 9b Operating instructions CGa-7 to CGa-8 s3PARKPILOTs.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 44 P ar t Number 550-101-009/0107 Service and maintenance — schedule 10a Follow the 3ERVICE ANDMAINTENANCE procedures given throughout this manual and in com- ponent literature shipped with the boiler.
P ar t Number 550-101-009/0107 45 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Service & maintenance — annual start-up 10b O Inspect . . . Reported problems Inspect any problems reported by owner and correct before proceeding.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 46 P ar t Number 550-101-009/0107 Service & maintenance – annual start-up (cont.) 10b O Inspect . . . Boiler heating surfaces $ISCONNECT THE VENT PIPE AT THE BOILER DRAFT HOOD and remove draft hood after turning off power to the boiler.
P ar t Number 550-101-009/0107 47 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual O Check/test Gas piping 1. Sniff near floor and around boiler area for any in- dication of a GASLEAK . 2. 4 EST GASPIPING USING B UBBLETEST per Section of this manual, if there is any indication of a leak.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 48 P ar t Number 550-101-009/0107 Service & maintenance – annual start-up (cont.) 10b O Check/test (continued) Boiler relief valve 1.
P ar t Number 550-101-009/0107 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual O Cleaning boiler heating surfaces 1. Shut down boiler: s &OLLOW h 4 O 4 URN /FF 'AS TO !PPLIANCE v IN - structions on boiler and ,IGHTING OR /PERATING INSTRUCTIONS .
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 50 P ar t Number 550-101-009/0107 T r oubleshooting — pr ocedur e (continued) 11a Check the following: 1. Wire connectors to control module are securely plugged in at module and originating control.
P ar t Number 550-101-009/0107 51 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Is 24VAC present across transformer terminals C & Y ? Is damper harness securely plugged in at both ends? Secure connections. Check for open thermostat, LWCO, high limit, spill switch or rollout thermal fuse element contacts or check for loose wire connections.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 52 P ar t Number 550-101-009/0107 T r oubleshooting — spark-pilot boilers 11c The information on this page and PAGES THROUGH .
P ar t Number 550-101-009/0107 53 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — spark-pilot boilers (continued) 11c.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 54 P ar t Number 550-101-009/0107 11c Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal injury, dea th or substantial property damage.
P ar t Number 550-101-009/0107 55 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 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.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 56 P ar t Number 550-101-009/0107 • Reset boiler control by turning off power at service switch or turning down the rmostat for at least 45 seconds. • Thermostat should call for heat and appropriate zone valves open.
P ar t Number 550-101-009/0107 57 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual • Turn off power to the boiler at service switch or breaker. • Wait at least 45 seconds. • Turn on power to boile r. • Restart boiler, fo llowing Operating instructions in this manual (Section 9b) or on boiler label.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 58 P ar t Number 550-101-009/0107 • TURN OFF POWER to boiler at service switch or breaker. • Remove base access panel (see Figure 32, item 4 , page 62 for location). • Verify inlet gas pressure at gas valve: Natural gas — 5.
P ar t Number 550-101-009/0107 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 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.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 60 P ar t Number 550-101-009/0107 Replacement parts 12a Section as sembly .............................................. 61 Base .................................................................. 62 Jacket .
P ar t Number 550-101-009/0107 61 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Replacement parts — section assembly 12b Item numbe r Description Weil-McLain part number 1 End section, left han.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 62 P ar t Number 550-101-009/0107 Replacement parts — base 12c &IGURE Base assembly , manifold, orifices and burners Item number D.
P ar t Number 550-101-009/0107 63 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Replacement parts — jacket 12d &IGURE Jacket assembly Boiler Model 1 2 3 4 Boiler Model Junction .
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 64 P ar t Number 550-101-009/0107 Replacement parts — trim 12e &IGURE T rim assembly Item numbe r Description Manufa cturer Manufac.
P ar t Number 550-101-009/0107 65 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Replacement parts — contr ols 12f &IGURE Gas control assembly Item number Description Manufacture.
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 66 P ar t Number 550-101-009/0107 Dimensions 13a Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler model number Supply tapping (i.
P ar t Number 550-101-009/0107 67 GOLD CGa Gas-Fired W ater Boiler — Boiler Manual Ratings )NSTALL #'A BOILERS FOR RESIDENTIAL RADIANT PANEL SYSTEMS CONVERTED .
GOLD CGa Gas-Fired W ater Boiler — Boiler Manual 68 P ar t Number 550-101-009/0107 Handling ceramic fiber and fiber glass materials REMOV AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The combustion chamber lining or base insulation panels in this prod- uct contain ceramic fiber materials.
An important point after buying a device Weil-McLain CGA25SPDN (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Weil-McLain CGA25SPDN yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Weil-McLain CGA25SPDN - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Weil-McLain CGA25SPDN you will learn all the available features of the product, as well as information on its operation. The information that you get Weil-McLain CGA25SPDN will certainly help you make a decision on the purchase.
If you already are a holder of Weil-McLain CGA25SPDN, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Weil-McLain CGA25SPDN.
However, one of the most important roles played by the user manual is to help in solving problems with Weil-McLain CGA25SPDN. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Weil-McLain CGA25SPDN along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
