Weil-McLain WGO User manual

WGO, WTGO and SGO-WWGO, WTGO and SGO-W
WGO, WTGO and SGO-WWGO, WTGO and SGO-W
WGO, WTGO and SGO-W
Series 3Series 3
Series 3Series 3
Series 3 Oil-FirOil-Fir
Oil-FirOil-Fir
Oil-Fired Wed W
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Part No. 550-141-828/1202Part No. 550-141-828/1202
Part No. 550-141-828/1202Part No. 550-141-828/1202
Part No. 550-141-828/1202
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MaintenanceMaintenance
MaintenanceMaintenance
Maintenance
and Serviceand Service
and Serviceand Service
and Service
GuideGuide
GuideGuide
Guide

2
Hazard Definitions
Following terms are used to bring attention to the presence of hazards of various risk levels, or
to important information concerning product life.
Indicates presence of hazards that will cause severe personal injury, death or
substantial property damage if ignored.
Indicates presence of hazards that can cause severe personal injury, death or
substantial property damage if ignored.
Indicates presence of hazards that will or can cause minor personal injury or
property damage if ignored.
Indicates special instructions on installation, operation, or maintenance that
are important but not related to personal injury hazards.
Read This Page First
Symbol Definitions
These symbols indicate information for and procedures to be followed by:
Homeowner or person responsible for simple start-up and routine
maintenance of boiler and system. Pages 2 through 6 must be followed
to assure proper operation of your boiler. Page 7 lists common problems
and possible corrections. In addition, it is your responsibility to:
Have boiler and burner installed by a qualified installer.
Have boiler and burner serviced annually by a qualified service
technician.
Review and understand start-up and routine maintenance
procedures with qualified service technician.
Perform routine maintenance as described on page 4.
Qualified service technician who has the necessary equipment to
check the boiler and system performance, and is responsible for
start-up and service of boiler and system. Pages 2 and 3 and 8
through 11 must be followed to assure proper operation of this boiler.
In addition, it is the responsibility of this person to:
Annually service boiler and burner to assure proper operation. See page 8
for service record.
Review and explain start-up and routine maintenance procedures with
homeowner.
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3
ForYour Safety
Follow instructions below to
prevent severe personal injury, death or substan-
tial property damage:
Do not use crankcase drainings or any oil
containing gasoline. See burner manual for
proper fuel oil.
Do not attempt to start burner when excess
oil has accumulated in combustion chamber,
when unit is full of vapor, or when combus-
tion chamber is very hot.
Do not start burner unless collector hood, flue
cap, jacket cap, breeching and burner mount-
ing door are secured in place.
Never burn garbage or paper in the boiler.
Never leave combustible material around
boiler.
DO NOT TAMPER WITH UNIT OR CONTROLS.
Always follow specific instructions when
starting up boiler or performing routine
maintenance or service.
DANGER
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Tips for water systems:
Check boiler and system piping for leaks.
Continual makeup water will reduce boiler
life. Minerals can build up in sections,
reducing heat transfer and causing cast iron
to overheat, resulting in section failure.
Failure to maintain recom-
mended pH and repair leaks can cause section
iron corrosion, leading to section failure and
leaks. Do not use petroleum-based sealing
or stop-leak compounds in boiler systems.
Damage to system components can result,
causing property damage.
Boiler water pH 7.0 to 8.5 is recommended.
For pH conditions outside 7.0 to 8.5 range or
unusually hard water areas (above 7 grains
hardness), consult local water treatment
company.
When using antifreeze:
- Use antifreeze especially made for
hydronic systems. Inhibited propylene
glycol is recommended.
Do not use automotive,
ethylene glycol, undiluted or petroleum-
based antifreeze. Severe personal injury,
death or substantial property damage can
result.
- 50% solution provides protection to about
-300F.
- Local codes may require back-flow
preventer or actual disconnect from city
water supply.
- Determine quantity according to system
water content. Boiler water content is
listed on back cover of Boiler Manual.
Percent of solution will affect sizing of
heat distribution units, circulator and
expansion tank.
- Follow antifreeze manufacturer's instruc-
tions.
Do not add cold water to hot boiler. Thermal
shock can cause sections to crack.
CAUTION
Follow instructions below to
prevent severe personal injury, death or substan-
tial property damage:
To avoid electric shock, disconnect electrical
supply to burner service switch and additional
external switches before performing service.
To avoid severe burns, allow boiler to cool
before performing service.
Do not block flow of combustion or ventilation
air to boiler.
Boiler must be connected to a flue with
sufficient draft at all times to assure proper
operation.
Do not use this boiler if any part has been
under water. Electrical and mechanical
failures may cause electric shock and fire
risks. Immediately call a qualified service
technician to inspect chimney or vent,
boiler and burner. Have the boiler flueways
cleaned and have the following replaced:
— all electrical and mechanical controls
— electrical wiring
— oil burner and controls
— insulation and chamber lining
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4
Routine Maintenance Schedule
The schedule below is specifically designed for the homeowner.
Please read pages 2 and 3 before proceeding.
Beginning each heating season:
Call a qualified service technician to perform
annual service.
Daily during heating season:
Check that boiler area is free from combusti-
ble materials, gasoline and other flammable
vapors and liquids.
Weekly during heating season:
Check for and remove any obstructions to flow
of combustion or ventilation air to boiler.
Check that breeching is attached between
boiler and chimney. If breeching is loose or
damaged, immediately turn off switch on
boiler and call service technician to repair.
Check for oil leaks in oil piping and around
burner. If found, immediately call qualified
service technician to correct situation.
Check for water leaks in boiler and piping;
also check for leaks around tankless heater
plate, if installed. If found, immediately call
service technician to repair.
End of heating season:
If tankless heater is installed, boiler will
continue to operate. Check for the following:
- All daily and weekly instructions listed on
this page must be followed.
- Burner motor may have to be oiled. Some
motors are permanently lubricated and do
not need additional oil. Check for oiling
instructions on burner or motor.
Boiler shutdown:
Do not drain boiler unless exposure to
freezing temperatures will occur.
Always keep manual fuel supply shut off if
burner is shut down for an extended period of
time.
a. Turn off switch at boiler and any external
switch to boiler.
b. Close fuel valves.
c. Turn off water feed valve.
d. Cover burner to protect from dust and
dampness.
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5
Start-up
WGO/WTGO (see Figure 1):
1. If burner does not fire, check for:
Service switch on boiler or additional
switches turned off.
Fuses or breaker switch tripped.
Thermostat set below room temperature.
Fuel valves turned off.
Not enough oil in tank to supply burner.
DANGER
WGO and WTGO Boilers
Figure 1
2. Correct problems found in step #1. If burner
does not fire, press reset button on burner
primary control only once. Repeated presses
will deposit oil in combustion chamber.
Burner must never be fired
when oil is in combustion chamber. Immedi-
atelycall qualified service technician.
3. If burner still does not fire, call qualified
service technician.
Service
Switch on
Boiler
Burner Primary
Control
Reset Button on
Burner Primary
Control
Limit Control
(on WGO)
Combination
Limit Control and
Tankless Heater
Control
(on WTGO)
Located in tankless
heater plate
Circulator
Temperature -
Pressure Gauge
Burner
Disconnect
Plug
Water
Relief Valve

6
Start-up
SGO-W Boiler
Figure 2
2. Correct problems found in step #1. If burner
does not fire, press reset button on burner
primary control only once. Repeated presses
will deposit oil in combustion chamber.
Burner must never be fired
when oil is in combustion chamber. Immedi-
ately call qualified service technician.
3. If burner still does not fire, call qualified
service technician.
SGO-W (see Figure 2):
1. If burner does not fire, check for:
Service switch on boiler or additional
switches turned off.
Fuses or breaker switch tripped.
Thermostat set below room temperature.
Fuel valves turned off.
Not enough oil in tank to supply burner.
DANGER
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Circulator
Limit Control
Reset Button on
Burner Primary
Control
Burner Primary
Control
Temperature -
Pressure Gauge
Tankless Heater
Control
Located in
tankless heater plate
Burner
Disconnect
Plug
Service
Switch
on Boiler
Water Relief Valve
(on back of boiler)
n

7
The problems and corrections above represent common situations that can occur.
There may be others not listed above. It is important always to contact a qualified service techni-
cian if you have any questions about the operation of your boiler or system.
COMMON PROBLEMS COMMON CAUSES POSSIBLE CORRECTIONS
Rapid cycling - burner turns on and off
frequently. Thermostat installed where drafts or heat affect reading. Locate thermostat on inner wall away from heat sources or cool drafts.
Heat anticipator in
thermostat adjusted
incorrectly.
Adjust heat anticipator to match current
draw. Refer to boiler wiring diagram.
Incorrect limit setting. Have qualified service technician
increase limit setting to decrease cycling.
Maximum setting 220 deg. F.
Need to frequently add makeup water. Leaks in boiler or piping. Have qualified service technician repair
leaks at once to avoid constant use of
makeup water.
Popping or percolating noise heard in boiler. Mineral deposits in sections
due to constant use of
makeup water, or incorrect
pH.
Have qualified service technician de-lime
boiler, repair leaks at once to avoid
constant use of makeup water and check
pH (between 7.0 and 8.5).
Black water condition. Oxygen corrosion due to
leaks in piping. Have qualified service technician repair leaks at once to avoid constant use of
makeup water and check pH (between
7.0 and 8.5).
Frequent release of water through relief
valve. Expansion tank sized too small or water-logged. Have qualified service technician check expansion tank operation.
Metal flakes found in flueway. Contaminated combustion
air supply. Remove sources of hydrocarbons in or near boiler area. (Bleaches, cleaners,
chemicals, sprays, fabric softeners, paint
remover, etc.)
Condensation of
combustion gases. Have qualified service technician check boiler operation.
Some radiators or baseboard units do not
heat or are noisy. Air in system. Bleed air from system through air vents in radiators or baseboard units.
Low system pressure. Have qualified service technician check
for leaks in boiler or piping at once.
High limit set too low. Have qualified service technican adjust
limit to higher setting.
Domestic water from tankless heater is hot
then suddenly turns cold.
OR
Domestic water from tankless heater is
always lukewarm.
Mineral deposits insulate
internal waterways of
heater.
Have qualified service technician delime
or replace coil.
Boiler stop-leak compound
has been added to boiler
water and is insulating
outside of coil.
Have qualified service technician remove
and clean coil AND drain and flush
boiler to remove stop-leak.
Incorrect mixing valve
setting for tankless heater. Have quaified service technican adjust mixing valve setting.
Domestic flow rate too high. Have qualified service technician install
flow check valve set to rating of tankless
heater.
Incorrect setting on tankless
heater control. Have qualified service technician raise tankless control setting. Adjust
differential on tankless control to lower
setting.

8
The procedures and information on pages 7 through 11 are
intended only for a qualified service technician who has the necessary
equipment to inspect and adjust boiler and burner. A homeowner should
never attempt these procedures. Qualified service technician must read
pages 2 and 3 before proceeding.
Annual Service Check List
Any parts of the boiler furnished by Weil-McLain must be replaced by parts listed in
Weil-McLain Boiler and Repair Parts Book.
Annual Service Call Check List
(follow in order listed below)
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1Check that boiler area is free from
combustible materials, gasoline and other
flammable vapors and liquids.
2Check for and remove any obstruction to
combustion and ventilation air flow to boiler.
3Check breeching and chimney or vent for
obstructions, damage, etc. Repair or replace
as necessary.
4Clean boiler flueways. See page 9.
5Perform service on relief valve and circulator.
See page 11.
6Check boiler and piping for leaks and repair if
found. Check for leaks at tankless heater
plate. Tighten nuts only if leaks are found (for
WTGO torque to 20-25 ft.lbs.).
7Inspect and adjust burner. See burner manual
and:
- change nozzle.
- check ignition electrode settings.
- clean blower housing and wheel.
- make sure blower wheel turns freely.
- oil burner motor if required.
- clean air inlet.
- clean or change fuel filter and strainer.
8Make sure boiler is filled with water.
9Start unit and verify combustion settings with
combustion test equipment.
See page 10.
10 Verify operation of all controls on boiler. See
page 11.

9
Cleaning Boiler Flueways
Figure 3
Thoroughly clean flueways
between all pins at all angles.
Start on top of boiler,
finish from the bottom.
Detailed Service Procedures
Cleaning boiler flueways:
Make sure all electrical connections
to boiler are turned off and wait until boiler is
warm, not hot, before cleaning. Failure to do so
will result in severe personal injury, death or
substantial property damage.
1. Top flue boilers -remove breeching and jacket
top panel.
Rear flue boilers - remove jacket top panel.
2. Remove flue collector hood, saving hardware
for reassembly.
3. Shut off oil valves. Arrange drip pans under
the areas of oil piping that will be discon-
nected. Disconnect oil line at burner so that
you can swing open the door completely.
4. Line combustion chamber floor with news-
paper to catch any soot that will be loosened
in the cleaning process.
5. Starting at the top of the boiler, use a wire
flue brush to thoroughly clean between all
pins at all angles. Be careful not to damage
side walls of rear refractory.
6. Move to the bottom of the flueways and clean
up between the sections to reach pins left
uncleaned in step #5.
DANGER 7. Once the flueways are cleaned, carefully
remove the paper from the floor of the
combustion chamber.
8. Verify sealing rope around flue area is intact.
Visually check condition and position of
insulation in combustion chamber floor,
and the refractories at the rear of boiler and
in the burner mounting door. Replace any
parts as necessary.
9. Close burner mounting door and tighten nut
securely. Place flue collector hood on top of
boiler. Secure with hardware from step #2.
Maintain a gas-tight seal to
avoid possible flue gas leakage and carbon
monoxide emissions, which can lead to severe
personal injury or death.
10. Check breeching for sooting and clean if
necessary. Install jacket top panel and
breeching.
11. Reconnect oil line and all electrical connec-
tions.
.

10
Fill the system:
1. Close manual and automatic air vents and
drain cock.
2. Fill to correct system pressure. Correct pres-
sure will vary with each installation. Normal
cold water fill pressure for residential systems
is 12 psig. Boiler water pH 7.0 to 8.5 is recom-
mended.
Failure to maintain recom-
mended pH level can cause section failure and
leaks.
3. Open automatic air vent one turn.
4. a. Starting on the lowest floor, open air vents
one at a time until water squirts out. Close
vent.
b. Repeat with remaining vents.
5. Refill to correct pressure.
NOTICE
Detailed Service Procedures
DANGER
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To place in operation:
Follow information below to prevent
severe personal injury, death or substantial prop-
erty damage:
Do not use crankcase drainings or any oil
containing gasoline. See burner manual for
proper fuel oil.
Do not attempt to start burner when excess oil
has accumulated in combustion chamber,
when unit is full of vapor, or when combus-
tion chamber is very hot.
Do not start burner unless collector hood, flue
cap, jacket cap, breeching and burner mount-
ing door are secured in place.
Never burn garbage or paper in the boiler.
Never leave combustible material around
boiler.
1. Verify boiler is filled with water.
2. Open burner door and verify rear target wall,
floor and burner door insulations are in
proper condition and position.
3. Verify burner mounting door is closed and
bolted tightly and burner plug is connected.
4. Refer to burner manual for burner start-up,
adjustment and check-out procedures.
Factory burner adjustment and settings may
not be suitable for specific job conditions.
Make final burner adjustments
using combustion test equipment to assure
proper operation. Do not fire boiler without
water. Sections will overheat, damaging boiler
and resulting in substantial property damage.
5. Check boiler and system piping for leaks.
6. Inspect breeching and venting for proper
operation.

11
Detailed Service Procedures
Controls requiring annual service:
WATER RELIEF VALVE:
Check operation of water relief valve. Follow
instructions on label fastened to relief valve.
Scald potential. Do not check
operation of relief valve unless discharge piping
has been installed according to Boiler Manual.
If piping is not in place, a qualified service techni-
cian must properly install piping.
CIRCULATOR:
Follow oil-lubricating instructions on circulator.
Over-oiling will damage circulator.
Water-lubricated circulators do not need oiling.
General description of control operation:
AUTOMATIC AIR VENT:
Air is released when cap is unscrewed one turn.
If air vent leaks, remove small cap on top of vent,
push in stem of valve and then release to clean
valve seat. Screw cap completely on, then unscrew
one turn.
WATER RELIEF VALVE:
Provides discharge if boiler pressure exceeds 30
psig.
TEMPERATURE LIMIT CONTROL:
If high boiler water temperature occurs, control
shuts down burner, but allows circulator to run
as long as there is a call for heat. Limit should be
set higher than temperature needed for the sys-
tem. Maximum limit setting is 2200F.
CIRCULATOR:
Circulator provides forced water circulation
through boiler and piping system.
PRESSURE-TEMPERATURE GAUGE:
Provides reading of boiler pressure and tempera-
ture. Maximum boiler pressure is 50 psig, maxi-
mum water temperature is 2200F. Temperature
will vary according to system and daily heating de-
mands. The range will be from room temperature
up to limit control setting.
TANKLESS WATER HEATER:
Weil-McLain tankless heater ratings are based on
2000F boiler water temperature. To get rated out-
put, set tankless heater control to 2000F. Control
can be adjusted to meet system hot water re-
quirements.
EXPANSION TANK:
As water heats up, it expands. Tank provides a
place for increased water volume. May be open,
closed, or diaphragm-type. If relief valve opens
frequently, expansion tank may be water-logged.
Drain tank and re-establish proper air cushion.
1. Open-type - Located above highest radiator or
baseboard unit, usually in the attic or closet.
Has a gauge glass and overflow pipe to drain.
2. Closed-type - Welded gas tight and located
above boiler. Tank is partially filled with
water, leaving an air cushion for expansion.
3. Diaphragm-type - Welded gas tight with a
rubber diaphragm to separate air from water.
Tank must be located near boiler before inlet
to circulator.
An air vent must be installed in air vent
tapping on boiler when this type of tank is
used. This eliminates air in system.
Normal cold water fill pressure is 12 psig.
Tank pressure may be checked with an air
pressure gauge.
DANGER

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Part No. 550-141-828/1202