Weil-McLain 550-110-260/0508 manual 2b Prepare boiler pressure test, Hydrostatic pressure test

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GOLD CGs Gas-Fired Water Boiler — Boiler Manual

2b Prepare boiler — pressure test

Hydrostatic pressure test

Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply.

Prepare boiler for test

1.Remove the shipping nipple (from CGs supply tap- ping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾” NPT pipe plug.

2.Remove 1¼” nipple, reducing tee and drain valve from circulator hardware and pressure/temperature gauge carton. Install in boiler return connection as shown on page 3 and Figure 29, page 58. Install circulator on either the return or supply.

3.Remove 1¼” nipple, 1¼” x 1¼” x ½” tee and pres- sure/temperature gauge from circulator hardware and pressure/temperature gauge carton. Pipe to boiler supply connection as shown on page 3 and Figure 29, page 58. (Use pipe dope sparingly.)

4.Connect a hose to boiler drain valve, the other end connected to a fresh water supply. Make sure hose can also be used to drain boiler after test.

5.Connect a nipple and shutoff valve to system supply connection on the 1¼” tee. This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

6.Connect a nipple and shutoff valve to system re- turn connection (at circulator flange if circulator installed on return). This valve will be used to bleed air during the fill. (Valve and nipple are not included with boiler.)

Fill and pressure test

1.Open the shutoff valves you installed on supply and return connections.

2.Slowly open boiler drain valve and fresh water sup- ply to fill boiler with water.

3.When water flows from shutoff valves, close boiler drain valve.

4.Close shutoff valves.

5.Slowly reopen boiler drain valve until test pressure on the pressure/temperature gauge reaches no more than:

•45 psig for boilers with 30 psig relief valve.

•75 psig for boilers with 50 psig relief valve.

6.Test for no more than 10 minutes at:

•45 psig for boilers with 30 psig relief valve.

•75 psig for boilers with 50 psig relief valve.

Do not leave boiler unattended.

A cold water fill could expand and cause excessive pressure, resulting in severe personal injury, death or substantial property damage.

7.Make sure constant gauge pressure has been main- tained throughout test. Check for leaks. Repair if found.

Leaks must be repaired at once.

Failure to do so can damage boiler, resulting in substantial property damage.

Do not use petroleum-based clean- ing or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Drain and remove fittings

1.Disconnect fill water hose from water source.

2.Drain boiler at drain valve or out hose, whichever provides best access to drain. Remove hose after draining if used to drain boiler.

3.Remove nipples and valves unless they will remain for use in the system piping.

4.Remove plug from relief valve tapping. See page 14 to replace relief valve.

Part number 550-110-260/0508

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Contents Gold CGs How it works Gold CGs Gas-Fired Induced-Draft 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 1b Prepare boiler location clearances 1c Prepare boiler location vent system When removing boiler from an existing common vent systemCGs special vent system Vent systemProducts to avoid 1d Prepare boiler location contaminationCombustion air options 1e Prepare boiler location air openingsSizing air openings Special considerationsSizing air openings for CGs installations Orifice replacement procedure 2a Prepare boiler placement & setupPlace boiler/crate near position Inspect orifices and burnersHydrostatic pressure test 2b Prepare boiler pressure testDrain and remove fittings Prepare boiler for test3a Water piping general information 3b Water piping single-zone system Piping multiple zones 3c Water piping multiple zones3c Water piping multiple zones Valve adjustment Figures 8 and 9 only Temperature gauges3d Piping low temp systems Primary/secondary preferred bypass piping method3d Piping low temp systems BOILER-bypass piping method Valve adjustmentFigures 8 SYSTEM-bypass piping method Prevent chilled water from entering 3e Water piping refrigeration systemsBoiler Use direct vent sealed combustion if combustion air Venting and combustion airGas piping Connecting gas supply piping to boilerNatural Gas Propane GasElectrical installation must comply with Field wiringWiring connections Thermostat7a Start-up preparation Freeze protection when usedCheck for gas leaks Verify water chemistryInspect system water piping Inspect base insulation 7b Start-up operate boilerFinal check before starting boiler Start the boilerCheck burner flames 7c Start-up if boiler doesn’t startCheck for Pilot burner flame FigureInstallation and service certificate Check-out procedure checklist9a Operation sequence Schematic wiring diagram 9b Operation wiring diagramsLadder wiring diagram 9c Operating instructions CGs-3 to CGs-6 9c Operating instructions CGs-3 to CGs-6 9c Operating instructions CGs-3 to CGi-6 Verify Proper Operation After Servicing 10a Service and maintenance schedule10b Service & maintenance annual start-up Inducer motor Condensate drain system Burners, base and inlet air boxOiled-bearing circulators 10b Service & maint. annual start-up Relief valve, typical Boiler relief valveReview with owner Cleaning boiler heating surfacesBefore troubleshooting 11a Troubleshooting procedureCheck the following Air pressure switch 11b Troubleshooting air pressure switchCheck pressure switch setting Troubleshooting air pressure readingControl indicator lights Lockout modes 11c Troubleshooting control moduleControl indicator lights NON-LOCKOUT modes Troubleshooting the control moduleControl module connections Chart 1 Troubleshooting Power light status 11d Troubleshooting control module lightsChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Chart 4 Flame & Power lights flashing Item 8 , Does blower motor operate? Verify Sequence of operation, , Section assembly Base Jacket Trim Controls 12a Replacement partsItem number Description Weil-McLain part number 12b Replacement parts section assemblyPage Description Weil-McLain Part number 12c Replacement parts baseJacket assembly 12d Replacement parts jacketBoiler Model Weil-McLain part number Part number 12e Replacement parts trimPropane gas components 12f Replacement parts controlsDimensional drawing 13a DimensionsDOE 13b RatingsRemoval of Combustion Chamber Lining or Base Panels Handling ceramic fiber and fiberglass materials

550-110-260/0508 specifications

Weil-McLain is a well-known name in the heating industry, offering a wide range of high-quality boilers and heating systems. Among its impressive lineup, the Weil-McLain 550-110-260/0508 model stands out for its performance, efficiency, and advanced technologies, making it suitable for residential and commercial heating applications.

The 550-110-260/0508 boiler is designed for flexibility and performance, providing an output capacity of 110,000 BTU per hour. This makes it suitable for various heating needs, from single family homes to larger commercial spaces. One of the key features of this model is its high-efficiency design, which allows it to operate at an AFUE (Annual Fuel Utilization Efficiency) rating of up to 95%. This means that a significant portion of the fuel consumed is converted into usable heat, resulting in lower energy bills and reduced environmental impact.

A standout characteristic of the Weil-McLain 550-110-260/0508 is its durable construction. Built with high-quality materials, this boiler is designed to withstand the rigors of daily use and provide reliable service over the years. Additionally, the unit features a compact design, allowing for easy installation in various configurations, whether it be in a basement, utility room, or outdoor setting.

Another impressive technology incorporated in this model is the advanced control system, which allows for precise temperature management and improved energy efficiency. The intuitive control interface enables homeowners and facility managers to easily set and adjust heating schedules, ensuring optimal comfort while minimizing energy consumption.

Safety is also a top priority for Weil-McLain. The 550-110-260/0508 is equipped with multiple safety features, including a pressure relief valve, limit controls, and a low water cutoff, which help to ensure safe and reliable operation.

In conclusion, the Weil-McLain 550-110-260/0508 model boasts a combination of efficient heating, durable construction, advanced control technology, and safety features, making it an excellent choice for those seeking a reliable and effective heating solution. Its versatility and performance make it well-suited for a variety of applications in both residential and commercial settings.
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