Table of Contents
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Boiler Manual
This manual must only be used by a qualified heating installer/service technician. BEFORE installing, read
all instructions in this manual and all other information shipped with the boiler. Perform steps in the order
given. Failure to comply could result in severe personal injury, death or substantial property damage.
Series 4
Oil-Fired Water Boilers
• Installation
• Maintenance
• Startup
• Parts
Part number 550-142-331/0421
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Table of Contents
Related Manuals for Weil-McLain WGO 4 Series
Summary of Contents for Weil-McLain WGO 4 Series
- Page 1 Series 4 Oil-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualified heating installer/service technician. BEFORE installing, read all instructions in this manual and all other information shipped with the boiler. Perform steps in the order given.
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Page 2: Using This Manual
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Using this manual Homeowner — Read and follow all information on pages 1 through 7 ONLY. Service technician — Read and follow ALL information in the entire manual. Failure to follow all instructions in proper order can cause severe personal injury, death or substantial property damage. -
Page 3: Table Of Contents
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Contents Using this manual . . . . . . . . . . . . . . . . 2 Connect water piping . -
Page 4: Please Read Before Proceeding
TROLS. Always follow specific instructions into contact with water, or was suspected to have come into contact with when starting up boiler or performing rou- water, replace the boiler with a new Weil-McLain boiler. tine maintenance or service. continued - top of next page... -
Page 5: Frozen Water Damage Hazard
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Frozen Water Damage Hazard Residences or buildings that are unattended in severely cold weather, boiler system components failures, power outages, or other electrical system failures could result in frozen plumbing and water damage in a matter of hours. -
Page 6: Operation
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Operation 2. Correct problems found in step #1. If burner does not fire, (see Figure 1) press reset button on burner primary control only once. 1. -
Page 7: Troubleshooting
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Troubleshooting Homeowners — The problems and corrections below represent common situations that can occur. There may be others not listed below. It is important always to contact a qualified service technician if you have any questions about the operation of your boiler or system. -
Page 8: Before Installing Boiler
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Before installing boiler Homeowner — STOP! The procedures and information on this and following pages 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. -
Page 9: Provide Air For Combustion And Ventilation
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Before installing boiler (continued) Provide air for combustion and ventilation Where ducts are used, they should have same cross-sec- tional area as free area of openings to which they connect. Compensate for louver, grille or screen blockage when Do not install exhaust fan in boiler room. -
Page 10: Install Boiler - Packaged Boilers Only
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — Packaged boilers only Place boiler Perform hydrostatic pressure test 1. Remove circulator strapped to pallet. 1. Remove relief valve installed in boiler. 2. - Page 11 Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — Packaged boilers only (continued) Figure 3 Change from back flue outlet to top flue outlet (optional) Instructions for Packaged boilers continued on page 15. Part number 550-142-331/0421...
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Page 12: Place Boiler
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler – Semi-packaged and Knocked-down boilers only Knocked-down WGO-7, 8 & 9 — split the Fiberglass wool and ceramic fiber materials are possible cancer hazards. - Page 13 Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler – Semi-packaged and Knocked-down boilers only continued) Knocked-down WGO-2 through 9 — install 4. Install washers and nuts. Tighten nuts until collector hood makes contact with Tinnerman clip.
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Page 14: Perform Hydrostatic Pressure Test
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler – Semi-packaged and Knocked-down boilers only continued) Perform hydrostatic pressure test 6. Remove pressure gauge, air vent and plugs from tappings used for controls. -
Page 15: Install Burner - All Boilers
3. Securely close door and tighten nut. (also refer to instructions packed with burner) For burners without OEM welded flanges: Use only burners specified for use on Weil-McLain 1. Secure universal mounting flange and gasket to burner mount- oil boilers. Contact individual burner manufactur- ing door. -
Page 16: (Also Refer To Instructions Packed With Burner) Connect Breeching
Field Controls OVD-7 automatic blockage. Breeching must not enter chimney far enough to cause obstruction. Use thimble or slip joint where breeching enters damper kit, Weil-McLain part number 381-800-515. chimney to allow removal for cleaning. Refer to Figures 7 and 8, page 17. - Page 17 Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect breeching (continued) Figure 7 Back Outlet Breeching for models which Figure 9 Back outlet breeching connection for models require a vent damper which do not require a vent damper OVD Damper (Required)
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Page 18: Connect Water Piping
See page 20 to com- plete multiple-zone piping or page 21 to complete piping for Table 4 Water piping sizes systems operating below 140°F. • For multiple-boiler piping, contact Weil-McLain Technical Services for assistance, if required. Boiler To system From system •... -
Page 19: Diaphragm Expansion Tank (Figure 11)
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Figure 11 Piping with DIAPHRAGM expansion tank Isolation Circulator valve Automatic air vent system “C” tapping From “N”... -
Page 20: Piping Multiple Zones
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Piping MULTIPLE ZONES Figure 13 Multiple zoning with CIRCULATORS Follow instructions on page 18 and page 19 to install piping near boiler. -
Page 21: Piping For Systems Requiring Temperatures Below 140°F
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Piping for systems requiring Figure 15 Piping with CIRCULATORS temperatures below 140°F In most systems, this type of piping is not required. If system water temperature requirements are less than 140°F, such as radiant panels or converted gravity sys- tems, use piping as shown in Figure 15 or Figure 16. -
Page 22: Use With Refrigeration Systems
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping Connect wiring (continued) Use with refrigeration systems General wiring requirements • Install boiler so that chilled medium is piped in Electric shock hazard –... -
Page 23: General Wiring
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (continued) General wiring Figure 18 Boiler wiring for forced hot water • Packaged boilers have harnesses furnished. • For Semi-packaged and Knocked-down boilers, trim kits are furnished with burner and limit harnesses integrated Limit control with Hydrolevel control. - Page 24 Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (continued) Figure 19 Wiring diagram Part number 550-142-331/0421...
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Page 25: Connect Wiring - Blocked Vent
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring — blocked vent shutoff switch option Blocked vent shutoff switch After installing BVSS switch, proceed as follows: 1. Disconnect power. In Canada, blocked vent shutoff switch kit 2. -
Page 26: Connect Wiring - Vent Damper
Field Controls OVD-7 damper, • NFPA 31- latest edition, Standard for the Installation Weil-McLain part number 381-800-515, sold separately. of Oil-Burning Equipment. 2. To configure the WGO boiler as a model ending in “RD” and •... -
Page 27: Start-Up
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Start-up Fill the system To place in operation 1. Close manual and automatic air vents and boiler drain cock. 1. Verify boiler is filled with water. 2. -
Page 28: Check-Out Procedure
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Check-out procedure Check off steps as completed operation as outlined by the manufacturer. Burner should be operating and should go off when controls are tested. When controls are restored, burner should re-ignite. -
Page 29: Annual Service Check List
See page 31. Verify operation of all controls on boiler. See page 28. Any parts of the boiler furnished by Weil-McLain must be replaced by parts listed in Weil-McLain Boiler and Repair Parts Book. Controls requiring annual service Water Relief Valve Scald potential. -
Page 30: Detailed Service Procedures
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Detailed service procedures Cleaning boiler flue ways Figure 24 Thoroughly clean flue ways between all pins at all angles Start on top of boiler, Make sure all electrical connections to boiler are turned finish from the bottom off and wait until boiler is warm, not hot, before clean-... -
Page 31: Close Clearance Installation
To provide close clearances as described on pages 31 and 32: Obtain the Close Clearance Kit, Weil-McLain Part No. 386-500-050. Install the kit as described below. Failure to use kit or install as described can result in a fire hazard, causing severe personal injury, death or substantial property damage. - Page 32 Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Close clearance installation (continued) Figure 27 Figure 28 Flue pipe clearances Back vent clearances Combustible surface 24" For servicing or min 2" For close clearances 6"...
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Page 33: Replacement Parts
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts Figure 30 WGO Boiler jacket for Series 4 Boiler Jacket panel with Left side and Right side and Top panel with Size insulation —... - Page 34 Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Table 6 WGO Section and flue collector part numbers for Series 4 Description Part no. Item Description Part no. Item Regular front section 7022 316-700-215...
- Page 35 WGO Section and flue collector parts for Series 4 Repair parts must be purchased through Weil-McLain for the specific boiler as indicated in the list below. Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation.
- Page 36 Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Table 7 WGO Trim part numbers for Series 4 Item Description Part no. Combination pressure-temperature gauge kit, 60° – 360° F., 0 - 75 psi, 380-000-000 31/8"...
- Page 37 Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 32 WGO Trim part for Series 4 Part number 550-142-331/0421...
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Page 38: Dimensions
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4— SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Figure 33 WGO dimensions — inches (mm) 7 3/16 [182 6] 2 5/8 [66 7] 7 Dia [177 8] 15 1/2 [393 7] Approx Front... -
Page 39: Ratings
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Ratings Table 8 WGO Series 4 oil-fired water boiler ratings ® AHRI Certified Ratings Draft Boiler Flue Heating Seasonal Minimum Loss Burner Input Rating Water... -
Page 40: Handling Ceramic Fiber And Fiberglass Materials
Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS The combustion chamber lining or base insu- INSTALLATION OF FIBERGLASS WOOL lation panels in this product contain ceramic OR BASE PANELS: fiber materials that have been identified as car-...