Weil-McLain 550-110-260/02002 manual

Contents

Main How it works . . . Other boiler components: Boiler circulator Page Contents Please read before proceeding Installer User When servicing boiler Boiler operation 1a Installations must follow these codes: Before locating the boiler, check the following: Prepare boiler location clearances1b Residential garage installation Provide the following clearances: Flooring and foundation Prepare boiler location vent system 1c Removing from existing vent CGs special vent system When removing boiler from existing common vent system: Prepare boiler location contamination 1d Air contamination Prepare boiler location air openings1e Special considerations Tight construction Exhaust fans and air movers Motorized air dampers Figure 3 Sizing air openings for CGs installations Place boiler/crate near position Prepare boiler placement & setup2a Inspect orifices and burners Orifice replacement procedure Location Natural gas Propane gas Prepare boiler pressure test 2b Perform hydrostatic pressure test Water piping general information 3a General piping information Relief valve System water piping Pressure/temperature gauge Water piping single-zone system3b Expansion tank Diaphragm-type or bladder-type expansion tank Figure 4 Closed-type expansion tank Figure 5 Water piping multiple zones3c Piping for radiant heating systems or converted gravity systems Converted gravity (or steam) systems Zoning with zone valves, return temp over 130 F Zoning with circulators, return temp over 130 F typical piping multiple-zone installations (Figure 12 and 13 only) Water piping low temp systems3d Primary/secondary (preferred) bypass piping method Temperature gauges primary/secondary (preferred) bypass piping for radiant heating or converted gravity systems Water piping low temp systems3e Boiler-bypass piping method Temperature gauges boiler-bypass (alternate) piping for radiant heating or converted gravity systems Water piping low temp systems3f System-bypass piping method 3f system-bypass (alternate) piping for converted gravity (or steam) systems 9 Water piping refrigeration system3g Gas piping5 Connecting gas supply piping to boiler Venting and combustion air4 Gas piping Natural Gas: Field wiring6 Thermostat Junction Box (furnished) Wiring connections Electrical installation must comply with: Start-up preparation7a Fill the system with water Verify water chemistry Freeze protection (when used) Check for gas leaks Start-up operate boiler7b Inspect system water piping Start-up preparation continued7a Final check before starting boiler Start the boiler Start-up operate boiler continued7b Check burner flames Pilot burner flame Main burner flame Start-up if boiler doesnt start . . .7c Check-out procedure checklist8 Installation and service certificate Operation sequence9a Page MV TstatCirc Limit Press switch Flame Legend for ladder wiring diagram Operation lighting instructions9c FOR YOUR SAFETY READ BEFORE OPERATING TO TURN OFF GAS TO THE APPLIANCE OPERATING INSTRUCTIONS Table 5 Service and maintenance schedules Service and maintenance schedule10a Service technician ANNNUAL START-UP Owner maintenance Inspect: Service & maintenance annual start-up10b Reported problems Boiler area Air openings Flue gas vent system (and air piping) Service & maint. annual start-up continued10b Gas piping Cold fill and operating pressures Air vents and air elimination Limit controls and cutoffs Boiler relief valve Service & maint. annual start-up10b Troubleshooting procedure11a Before troubleshooting: VERIFY PROPER OPERATION AFTER SERVICING. Check the following: Troubleshooting air pressure switch11b Check pressure switch setting Return to normal operation Troubleshooting air pressure reading Troubleshooting control module11c Control indicator lights non-lockout modes Troubleshooting the control module Control indicator lights lockout modes Part number 550-110-260/0200 Troubleshooting control module continued11c Figure 25 Control module connections PRESS SWITCH LIMIT TSTAT CIRC CHART 1 TroubleshootingPOWER light status Is POWERlight off? Figure 25, item 3 Does voltmeter indicate120 VAC? Figure 25, item 2, CHART 2 TSTAT CIRC & POWERlights flashing Did you find a voltage across the two external thermostat circuit wires? and Do the lights still flash? CHART 3 PRESS SWITCH & POWER lights flashing Does the ohmmeter indicate the switch is closed? Does inducer motor operate? light flashing? Is CHART 4 FLAME & POWER lights flashing Are FLAME and POWER lights flashing? and Do lights still flash? Is gas present at gas valve inlet and within above range? Figure 25, item 8, page 44 Does light flash now? Is 24 VAC present there? Is gas present at gas valve inlet and within above range? CHART 6 PRESS SWITCH light flashing and POWERlight on steady Figure 25, Item 6, page 44 light flashing? Is Does the voltmeter indicate 120 VAC? CHART 7 Insufficient heat or no heat to system (POWERlight on steady) Is thermostat circuit closed (continuity across wires)? light on? Is Are limit switch contacts closed? Replacement parts12a Page Page Page Page Page Dimensions13a Figure 31 Dimensional drawing Ratings Table 7 Boiler ratings Notes 13b GOLD CGs Gas-Fired Water Boiler Boiler Manual Weil-McLain 500 Blaine Street Michigan City, IN 46360-2388 http://www.weil-mclain.com Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS NIOSH stated First Aid.