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 Steam Boilers
• Installation
• Maintenance
• Startup
• Parts
Part number 550-142-330/0421
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Table of Contents
Related Manuals for Weil-McLain SGO 4 Series
Summary of Contents for Weil-McLain SGO 4 Series
- Page 1 Series 4 Oil-Fired Steam 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: When Calling Or Writing About The Boiler
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM 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 STEAM BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Contents Using this manual .....2 To connect SGO boilers to indirect-fired When calling or writing about the boiler water heaters... -
Page 4: Read This First
• To avoid severe burns, allow boiler to cool before Therefore, Weil-McLain equipment contaminated with saltwater performing service. or polluted water will no longer be covered under warranty and should be replaced. -
Page 5: Routine Maintenance Schedule
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — 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: Please Read This Before Proceeding
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Please read this before proceeding Start-up Pressure gauge 1 If burner does not fire, check for: • Pressure gauge must not show more than 15 psig •... -
Page 7: Troubleshooting
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM 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 Common problems Common causes... -
Page 8: Before Installing Boiler
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — 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
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Before installing boiler (continued) Provide air for combustion and ventilation Lay a foundation, if needed Boiler may be installed on non-carpeted combustible Do not install exhaust fan in boiler room. -
Page 10: Air Contamination
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Before installing boiler continued Air contamination Please review the following information on potential combustion air contamination problems See Table 2 for products and areas which may cause contaminated combustion air To prevent potential of severe personal injury or death, check for products or areas listed... -
Page 11: Operation
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Operation SGO with float-type low water cutoff 2. Correct problems found in Step #1. If burner does not fire, press reset button on burner primary control only once. 1. -
Page 12: Sgo With Probe-Type Low Water Cutoff
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Operation (continued) SGO with probe-type low water cutoff 2. Correct problems found in Step #1. If burner does not fire, press reset button on burner primary control only once. -
Page 13: Install Boiler - Packaged Boilers Only
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — packaged boilers only Place boiler Perform hydrostatic pressure test 1. Remove boiler from pallet. 1. Remove steam pressure gauge furnished with boiler. Install water pres- sure gauge for test only. -
Page 14: Place Boiler
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler – Semi-packaged and Knocked-down boilers only Fiberglass wool and ceramic fiber materials are g. Oil threads on draw rods. Install washer and nut on end possible cancer hazards. - Page 15 Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler – Semi-packaged and Knocked-down boilers only continued) Figure 6 Change from back flue outlet to top flue outlet (optional) Washer Flue collector...
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Page 16: Perform Hydrostatic Pressure Test
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler – Semi-packaged and Knocked-down boilers only continued) Perform hydrostatic pressure test Table 3 Control tappings (see Figure 7, page 17 for locations) 1. - Page 17 Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler – Semi-packaged and Knocked-down boilers only continued) Figure 7 Figure 8 Steam boiler controls with float-type LWCO (optional tankless heater Control tapping control) locations...
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Page 18: Install Burner And Chimney - All Boilers
Boiler models SGO-3 through SGO-7 require the installation of SGO-8 8" x 12" 7" 7" the Field Controls OVD-7 damper, Weil-McLain part number (Note 2) SGO-9 381-800-515, which is provided with Packaged boilers, sold NOTES: 6¾” x 6¾” inside liner. - Page 19 Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect breeching (continued) Figure 10 Figure 11 Back outlet breeching connection for Back outlet breeching connection for SGO-8 and SGO-9 SGO-3 through 7 with OVD damper OVD Damper (Required) Typical location for...
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Page 20: Connect Breeching Connect Steam Piping
Piping system must be installed as One-pipe counter flow systems shown, using minimum pipe sizes shown. Consult your Weil-McLain distributor or sales office before installing alternate piping. SGO-3 2½"... - Page 21 Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect steam piping (continued) Figure 14 Steam piping for sizes 3 through 5 (see Figure 15, page 22, for sizes 6 through 9) Part number 550-142-330/0421...
- Page 22 Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect steam piping (continued) Figure 15 Steam piping for sizes 6 through 9 (see Figure 14, page 21 for sizes 3 through 5) Part number 550-142-330/0421...
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Page 23: Optional Reservoir Piping
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect steam piping (continued) Figure 16 Typical piping (one riser shown on boiler) Optional reservoir piping Modern steam boilers are designed to steam for less time than older, larger boilers. -
Page 24: Connect Tankless Heater Piping
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect tankless heater piping To pipe tankless heater Hot Water Can Scald! 1. Size piping no smaller than tankless heater inlet and outlet. - Page 25 Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect tankless heater piping (continued) Figure 17 Tankless heater piping SGO 3-5 tankless heater control location SGO 6-9 tankless heater Flow control location regulating valve Cold water...
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Page 26: Connect Wiring - General Information
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring — general information General wiring requirements • Service switch (15 amp) is provided with boiler. For Semi-packaged and Knocked-down boilers — ELECTRIC SHOCK HAZARD –... -
Page 27: Blocked Vent Shutoff Switch
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring — general information (continued) Blocked vent shutoff switch Figure 18 Blocked vent shutoff switch installation Electric shock hazard – Turn off electri- cal power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. -
Page 28: Connect Wiring (Float-Type Lwco)
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (Float-type LWCO) Figure 19 Boiler wiring for float-type LWCO — see Figure 20, page 29 for component locations Part number 550-142-330/0421... -
Page 29: Connect Wiring (Float-Type Lwco)
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (Float-type LWCO) (continued) Blocked vent shutoff switch (BVSS), Figure 20 Boiler wiring for float-type LWCO — when required component locations for wiring diagram, Figure 19, page 28 In Canada, a blocked vent shutoff switch kit must be installed (see parts list page 42). -
Page 30: Connect Wiring (Probe-Type Lwco)
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (Probe-type LWCO) Figure 22 Boiler wiring for probe-type LWCO — see Figure 23, page 31 for component locations Part number 550-142-330/0421... -
Page 31: Connect Wiring (Probe-Type Lwco)
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (Probe-type LWCO) (continued) Blocked vent shutoff switch (BVSS), when Figure 23 Boiler wiring for probe-type LWCO — required component locations for wiring diagram, Figure 22, page 30 In Canada, a blocked vent shutoff switch kit must be installed (see parts list page 42). -
Page 32: Ovd Vent Damper Wiring
Location and installation of oil tanks, oil piping and burners must follow: installation of the Field Controls OVD-7 damper, • NFPA 31 - latest edition, Standard for the Installation of Oil- Weil-McLain part number 381-800-515. The Burning Equipment. damper is included with Packaged SGO-3 to SGO-6 •... -
Page 33: Start Up
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Start up – Steam Boiler Water Treatment Systems where treatment should be Steam Heating Installation Considerations considered are: Closed steam heating systems should not have high amounts of make-up water. -
Page 34: Fill The System
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Start up (continued) Fill the system 5. Remove skim piping. Close drain valve. Fill with fresh water to normal waterline. Start burner and 1. -
Page 35: Check Out Procedure
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Check out procedure Check off Steps as completed Boiler properly filled with water? ❏ ❏ ❏ ❏ Boiler piping checked for leaks (including tankless heater, if used)? ❏... -
Page 36: Annual Service Check List
See page 34. Verify operation of all controls on boiler. See page 34. Any parts of the boiler furnished by Weil-McLain must be replaced by parts listed in Weil-McLain Boiler and Repair Parts Book. Part number 550-142-330/0421... -
Page 37: Service And Maintenance
1. Close lower gauge glass cock and carefully open petcock be- low glass to blow water and sediment out of glass by steam Weil-McLain tankless heater ratings are based on 200°F boiler pressure. water temperature. To get rated output, set tankless heater con- 2. -
Page 38: Cleaning Boiler Flue Ways
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Service and maintenance (continued) Cleaning boiler flue ways 10. Check breeching for sooting and clean if necessary. Install jacket top panel and breeching. The boiler contains ceramic fiber and fiberglass materials. -
Page 39: Service
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Service and maintenance (continued) ❏ Service..Wait 5 minutes. Boiler should not fire. 6. -
Page 40: Boiler And System Piping
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Service and maintenance (continued) Annual service Boiler and system piping Visually inspect for leaks around piping, circulators, Boiler relief valve relief valve and other fittings. Check oil lines and After following the warning directions below, if the relief valve weeps or boiler air for signs of oil leakage. -
Page 41: Replacement Parts
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts Figure 27 SGO Series 4 boiler jacket Complete Jacket cartons 3 section 416-700-453 4 section 416-700-454 5 section 416-700-455 6 section 416-700-456 7 section... - Page 42 Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts Figure 28 SGO Series 4 section and flue collector parts Part Part Item Description Item Description Number Number Wide front section (7021) 316-700-245 Tie rod 1/2 x 5 (SGO-7, 8, 9)
- Page 43 SGO Series 4 section and flue collector parts Repair parts must be purchased through Weil-McLain for the specific boiler as indicated in the list - page 42. Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation.
- Page 44 Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 30 SGO Series 4 Trim Parts Item Description Part number Syphon, 180° Bend, 1/4" brass pipe 560-640-698 Steam relief valve, set to relieve at 15 PSIG., 3/4"...
- Page 45 SGO Series 4 Trim Parts Repair parts must be purchased through Weil-McLain for the specific boiler as indicated in the list - page 42. Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation.
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Page 46: Dimensions
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Figure 32 SGO boiler dimensions — inches (mm) 20¼ [182 6] [514 4] 3¾ 7¾ [95 3] [196 9] [103 2] Steam supply Steam piping 6-9... -
Page 47: Ratings
Net ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pick-up. Steam ratings are based on a piping and pick-up allowance of 1.33. An additional allowance should be made for unusual piping and pick-up loads. Consult local Weil-McLain Sales Office. Gross output See page 18 for minimum breeching diameter. -
Page 48: Handling Ceramic Fiber And Fiberglass Materials
Boiler Manual OIL-FIRED NATURAL DRAFT STEAM 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-...