Weil-McLain 550-110-260/0508 manual Item 8

Page 51

GOLD CGs Gas-Fired Water Boiler — Boiler Manual

11d Troubleshooting — control module lights (cont.)

CHART 5 — 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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• ▲ TURN OFF POWER ▲ to boiler at service switch or breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

• Check the voltage across

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

terminals "C" and "A" of the

 

 

•

Make sure ground wire

 

 

Lighting instructions in this manual). Wait at least 45

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

gas valve (see Table G,

 

 

 

terminal is securely fastened

 

 

seconds.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

page 33).

 

 

 

 

 

 

 

 

 

to control module mounting

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

screw.

 

 

 

 

cycle.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is 24 VAC present there?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does FLAME light flash now?

 

 

 

 

 

 

 

 

Yes

 

 

No

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Check the voltage across

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Boiler should be in

 

• Verify inlet gas pressure at gas

 

 

 

 

 

 

 

•

If the wiring from the

 

 

 

 

 

terminals "B" and "A" (see

 

 

 

 

valve:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

control module to gas

 

 

 

 

 

Table G, page 33) of the

 

 

normal operating

 

 

Natural gas — 5.0" w.c. min/14.0"

 

 

 

 

 

 

 

valve is intact, replace 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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

has completed its

 

 

Is gas present at gas valve inlet and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

• Remove air inlet box top

 

 

 

 

 

 

 

pressure or gas supply.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see Figure 27, page 56 for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

location).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

 

▲TURN OFF POWER▲ to boiler

 

 

 

 

• ▲TURN OFF POWER▲ to boiler at service switch or breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

•

Check flame signal — Detach sense lead from igntion control

 

 

• Verify pilot gas line is not

 

 

 

 

 

 

 

at service switch or breaker.

 

 

 

 

 

 

kinked, obstructed or damaged

 

 

• Remove air inlet box cover (see

 

 

 

 

 

(Figure 25, item 8, page 46).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

and is correctly attached to

 

 

 

 

 

 

 

 

•

Connect negative lead of MICROAMMETER to control sense

 

 

 

 

 

 

 

 

 

Figure 27, page 56 for location).

 

 

 

 

 

 

pilot and gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

terminal (Figure 25, item 8, page 46). 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 terminal "B" (see Table

 

 

lead wire from control are in

 

 

 

 

 

 

 

attached to pilot bracket, bracket is

 

 

 

 

 

G, page 33) of the gas valve.

 

 

 

 

 

 

 

 

good condition. Spark gap

 

 

 

 

 

 

 

securely attached to cross tie, and

 

 

 

 

•

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

 

 

should be approximately 1/8".

 

 

 

 

 

there is no corrosion on the parts

 

 

 

 

 

burning, the MICROAMMETER should read at least 1.0

 

 

• Correct any above problems,

 

 

 

 

 

 

 

which would affect the ground path

 

 

 

 

 

microamp.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

replacing pilot if burner or

 

 

 

 

 

 

 

for flame sense.

 

 

 

 

 

 

 

Is flame signal at least 1.0 microamp?

 

 

 

 

wiring is damaged.

 

 

 

 

•

 

Verify that pilot flame rod, flame rod

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

Yes

 

 

 

 

• Reinstall air box top to operate

 

 

 

 

 

 

ceramic and lead wire from control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

boiler for retest after any

 

 

 

 

 

 

 

module to flame rod are in good

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

changes or corrections.

 

 

 

 

 

 

 

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 is

 

 

 

 

 

corrects problem, then replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

valve is intact, replace the

 

 

control module, reinstall air box

 

 

 

 

 

 

damaged.

 

 

 

 

 

the control module, reinstall air

 

 

 

 

 

 

 

 

 

 

 

 

 

 

control module and retest.

 

 

top, and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

box cover and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part number 550-110-260/0508

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

51

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Contents Gold CGs How it works Gold CGs Gas-Fired Induced-Draft Water Boiler Contents Installer Please read before proceedingUser 1a Prepare boiler location codes & checklist Installations must follow these codesBefore locating the boiler, check the following 1b Prepare boiler location clearances Vent system When removing boiler from an existing common vent system1c Prepare boiler location vent system CGs special vent systemProducts to avoid 1d Prepare boiler location contaminationSpecial considerations 1e Prepare boiler location air openingsCombustion air options Sizing air openingsSizing air openings for CGs installations Inspect orifices and burners 2a Prepare boiler placement & setupOrifice replacement procedure Place boiler/crate near positionPrepare boiler for test 2b Prepare boiler pressure testHydrostatic pressure test Drain and remove fittings3a Water piping general information 3b Water piping single-zone system Piping multiple zones 3c Water piping multiple zones3c Water piping multiple zones Primary/secondary preferred bypass piping method Temperature gaugesValve adjustment Figures 8 and 9 only 3d Piping low temp systems3d Piping low temp systems BOILER-bypass piping method Valve adjustmentFigures 8 SYSTEM-bypass piping method 3e Water piping refrigeration systems Prevent chilled water from enteringBoiler Use direct vent sealed combustion if combustion air Venting and combustion airPropane Gas Connecting gas supply piping to boilerGas piping Natural GasThermostat Field wiringElectrical installation must comply with Wiring connectionsVerify water chemistry Freeze protection when used7a Start-up preparation Check for gas leaksStart the boiler 7b Start-up operate boilerInspect system water piping Inspect base insulation Final check before starting boilerPilot burner flame Figure 7c Start-up if boiler doesn’t startCheck burner flames Check forInstallation 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 Condensate drain system Burners, base and inlet air box Inducer motorOiled-bearing circulators 10b Service & maint. annual start-up Relief valve, typical Boiler relief valveReview with owner Cleaning boiler heating surfaces11a Troubleshooting procedure Before troubleshootingCheck the following Troubleshooting air pressure reading 11b Troubleshooting air pressure switchAir pressure switch Check pressure switch settingTroubleshooting the control module 11c Troubleshooting control moduleControl indicator lights Lockout modes Control indicator lights NON-LOCKOUT modesControl 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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