Weil-McLain WGO Manual
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Weil-McLain WGO Manual

Gold series oil-fired water boilers
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See also: Maintenance and Service Manual , Service Manual
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.
Oil-Fired Water Boilers
• Installation
• Maintenance
• Startup
• Parts
Part number 550-141-826/1014

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Summary of Contents for Weil-McLain WGO

  • Page 1 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.

  • Page 2: Using This Manual

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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.

  • Page 3: Table Of Contents

    Connect wiring — blocked vent WGO (see Figure 1) ....6 shutoff switch option ....25 Troubleshooting .

  • Page 4: Please Read Before Proceeding

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Please read before proceeding Homeowner — Follow instructions below to prevent severe personal injury, death or substantial property damage: •...

  • Page 5: Routine Maintenance Schedule

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Routine maintenance schedule Beginning ❏ Call a qualified service technician to perform annual service. each heating season Daily ❏ Check that boiler area is free from combustible materials, gasoline and other flammable vapors and liquids.

  • Page 6: Operation

    Fuel valves turned off. • Not enough oil in tank to supply burner. 3. If burner still does not fire, call qualified service technician. Figure 1 WGO Boilers Burner disconnect plug Service switch on boiler Water relief valve Temperature-pressure gauge...

  • Page 7: Troubleshooting

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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 GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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 quali- fied service technician who has the necessary equipment to inspect and adjust boiler and burner.

  • Page 9: Provide Air For Combustion And Ventilation

    3 inches. WGO-2 Inside air WGO-3 When inside air is used, each opening must freely connect with areas having adequate infiltration from outside. Each opening should be at least 140 sq. in. per WGO-4 1 GPH input (1 sq.

  • Page 10: Install Boiler - Packaged Boilers Only

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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. Circulator will be damaged if not removed before boiler is 2.
  • Page 11 Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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 Part number 550-141-826/1014...

  • Page 12: Install Boiler - Non-Packaged Boilers Only

    OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — non-packaged boilers only Non-Packaged WGO-7, 8 & 9 — split the assembled Fiberglass wool and ceramic fiber ma- terials are possible cancer hazards. See...
  • Page 13 SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — non-packaged boilers only (continued) Non-Packaged WGO-7, 8 & 9 — install flue 4. Install washers and nuts. Tighten nuts until collector hood makes contact with Tinnerman clip. collector hood (see Figure 4) 5.

  • Page 14: Perform Hydrostatic Pressure Test

    Table 2 Figure 5 Control tappings Control tapping locations Location Size Function 1½" Return piping Alternate return piping for 1½" A/B WGO 1½" Supply piping Pressure-temperature 1/4" gauge ¾" Drain valve ¾" High limit control Air vent or expansion ½"...

  • Page 15: Install Burner - All Boilers

    OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Install burner — all boilers Install burner For P-WGO and A-WGO boiler: (also refer to instructions packed with 1. Secure universal mounting flange and gasket to burner mounting door. burner) Use three bolts provided.

  • Page 16: Connect Breeching

    Rect. Round • NFPA 31, Installation of Oil-Burning Equipment. • NFPA 211, Standard for Chimneys, Fireplaces, Vents and Solid Fuel WGO-2 Burning Appliances. 5" 8" x 8" • In Canada, refer to CSA B139, Installation Code for Oil-Burning WGO-3 (note 1) 6"...
  • Page 17 Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect breeching (continued) Figure 7 Back outlet breeching connection Typical location for barometric control (Also see control manufacturer’s instructions) Flue pipe bracket (One on each side of pipe)

  • Page 18: Connect Water Piping

    General piping information CLOSED expansion tank (Figure 10, page 19) • All packaged WGO boilers are shipped with an installed combination temperature limit control/low water cut-off. • Ensure expansion tank size will handle boiler and system water volume and temperature.
  • Page 19 Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Figure 9 Piping with DIAPHRAGM expansion tank Isolation Circulator valve Automatic To system air vent “C” tapping From “N”...

  • Page 20: Piping Multiple Zones

    Install balancing valves to adjust flow to distrib- ute heat to all zones. b. Separate transformer is required to power zone valves. Refer to “Weil-McLain Zone Valve Wir- ing Guide” for details. Figure 12 Multiple zoning with ZONE VALVES...

  • Page 21: Piping For Systems Requiring Temperatures Below 140°F

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Piping for systems requiring Figure 13 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 13 or Figure 14.

  • Page 22: Use With Refrigeration Systems

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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 parallel with heating boiler.

  • Page 23: Junction Box (Furnished)

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (continued) Junction box (furnished) High temperature limit • Junction box houses electrical connections for all • To comply with ASME, UL 726 or Canadian requirements, an additional boiler components.
  • Page 24 Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (continued) Figure 17 Wiring diagram Part number 550-141-826/1014...

  • Page 25: Connect Wiring - Blocked Vent Shutoff Switch Option

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring — blocked vent shutoff switch option Blocked vent shutoff switch 2. Install Spill Switch (BVSS) Wiring Harness (P/N 591-391-942) as fol- lows: a.

  • Page 26: Connect Oil Piping

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect oil piping General oil piping requirements Do not use Teflon tape as an oil pipe sealant. It can cause valves to fail, creating •...

  • Page 27: Start-Up

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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 1. Verify boiler is filled with water. drain cock.

  • Page 28: Check-Out Procedure

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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 28. 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 GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Detailed service procedures Cleaning boiler flueways Figure 21 Thoroughly clean flueways between all pins at all angles. Start on top of boiler, finish from Make sure all electrical connections to boiler are turned the bottom.

  • Page 31: Handling Ceramic Fiber And Fiberglass Materials

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS INSTALLATION OF FIBERGLASS WOOL The combustion chamber lining or base insulation panels in this product contain OR BASE PANELS:...

  • Page 32: Close Clearance Installation

    To provide close clearances as described on pages 26 and 27: 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 33 Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Close clearance installation (continued) Figure 24 Figure 25 Flue pipe clearances Back vent clearances Combustible surface 24" For servicing or min. 2" For close clearances 6"...

  • Page 34: Replacement Parts

    7016 Tie rod x 12 (WGO-7) 560-234-492 Back section w/7" flue, supply & 316-700-235 Tie rod x 14 (WGO-3, 4, 8, 9) 560-234-470 2" return 7027 Tie rod x 15 (WGO-9) 560-234-495 Section replacement kit (for 1 joint, includes seals, rope,...
  • Page 35 Figure 27 Parts drawing 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 36 426-700-268 ® Field Controls OVD-7 Vent damper kits - Required for ENERGY STAR compliance, (Version 3.0 Boilers specification of 87% AFUE), with reduced rates only Weil-McLain 381-800-501 WGO-2RD (Optional equipment) 381-800-502 WGO-3RD (Optional equipment) 381-800-503 WGO-4RD (Optional equipment) 381-800-504 WGO-5RD...
  • Page 37 Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 28 Series 3 trim Part number 550-141-826/1014...
  • Page 38 OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Table 8 Weil-McLain part numbers Jacket panel with insulation — Model Left side and rear Right side and Top panel with...
  • Page 39 Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 29 Boiler jacket Part number 550-141-826/1014...

  • Page 40: Dimensions

    GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Figure 30 WGO dimensions — inches (mm) — see Table 9, page 41 7 3/16 [514.4] 7 3/4 5 1/16 [128.6] [182.6]...
  • Page 41 GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions (continued) Table 9 Dimensions BOILER MODEL NUMBER Inches Inches WGO-2 266.7 349.2 WGO-3 342.9 428.7 WGO-4 345.9 428.7 WGO-5 428.7 508.0 WGO-6 587.2...

  • Page 42: Ratings

    295 (6) 25.8 0.030 Substitute “P” for completely assembled packaged boiler without burner (WGO-3 through WGO-6 only). Substitute “A” for boiler only for use with approved burners as listed with AHRI. Available only as an “A” unit. WGO boiler designed with convertible vertical and horizontal flue outlet.

  • Page 43: Notes

    Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Notes Part number 550-141-826/1014...
  • Page 44 Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Part number 550-141-826/1014...

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