Weil-McLain WTGO 4 Series Manual
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Weil-McLain WTGO 4 Series Manual

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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
• Startup
Part number 550-142-332/0421
• Maintenance
• Parts

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Summary of Contents for Weil-McLain WTGO 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.

  • Page 2: Using This Manual

    WTGO 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.

  • Page 3: Table Of Contents

    WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Contents Using this manual . . . . . . . . . . . . . . . . 2 Connect breeching Homeowner .

  • 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

    WTGO 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

    WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Operation WTGO 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

    WTGO 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

    WTGO 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.

  • Page 9: Provide Air For Combustion And Ventilation

    WTGO 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 Lay a foundation, if needed Boiler may be installed on non-carpeted combustible Do not install exhaust fan in boiler room.

  • Page 10: Install Boiler - Packaged Boilers Only

    WTGO 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 WTGO 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 are continued on page 15. Part number 550-142-332/0421...

  • Page 12: Install Boiler - Semi-Packaged & Knocked-Down Boilers

    WTGO 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 Fiberglass wool and ceramic fiber materials are g. Oil threads on draw rods. Install washer and nut on end possible cancer hazards.
  • Page 13 WTGO 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) Figure 4 Change from back flue outlet to top flue outlet (optional) Washer Tinnerman clip...

  • Page 14: Perform Hydrostatic Pressure Test

    WTGO 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 7. Visually check: a. Sealing rope placement 1.

  • Page 15: Install Burner - All Boilers

    WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Install burner — all boilers Install burner (also refer to instructions packed with burner) For burners without OEM welded flanges: Use only burners specified for use on Weil- 1.

  • Page 16: Connect Breeching

    Field Controls OVD-7 automatic Connection must be made above bottom of chimney to avoid blockage. damper kit, Weil-McLain part number 381-800-515. Breeching must not enter chimney far enough to cause obstruction. Use thimble or slip joint where breeching enters chimney to allow Refer to Figures 7 and 8, page 17.
  • Page 17 WTGO 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 Vent Damper for Figure 9 Back outlet breeching connection for models models which require a vent damper which do not require a vent damper OVD Damper (Required)

  • Page 18: Connect Water Piping

    21 to complete piping for systems oper- WTGO-7 1½" 1½" ating below 140°F. • For multiple-boiler piping, contact Weil-McLain Technical Services for assistance, if required. WTGO-8 2" 2" • Install relief valve vertically in “R1” tapping on front of boiler. See...
  • Page 19 WTGO 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 valve Circulator Automatic To system air vent “C” tapping From “N”...

  • Page 20: Piping Multiple Zones

    WTGO 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

    WTGO 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

    WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Use with refrigeration systems Figure 17 Use with refrigeration system • Install boiler so that chilled medium is piped in parallel with heating boiler.

  • Page 23: Connect Tankless Heater Piping

    WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER 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. 2.

  • Page 24: Connect Wiring

    WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring General wiring requirements General wiring • Packaged boilers have harnesses furnished. Electric shock hazard – Can cause severe personal injury or death if power source, including service •...
  • Page 25 WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (continued) Figure 19 Boiler wiring for forced hot water Limit control Service switch on control Burner wiring harness Burner disconnect plug...
  • Page 26 WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (continued) Figure 20 Wiring diagram Part number 550-142-332/0421...

  • Page 27: Blocked Vent Shutoff Switch

    WTGO 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. Canada, blocked vent shutoff switch kit 2.

  • Page 28: Connect Wiring - Vent Damper

    Field Controls OVD-7 damper, • NFPA 31 - latest edition, Standard for the Installation Weil-McLain part number 381-800-515. of Oil-Burning Equipment. 2. When installing the boiler, wire all controls from vent damper •...

  • Page 29: Start-Up

    WTGO 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 1. Verify boiler is filled with water. drain cock.

  • Page 30: Check-Out Procedure

    WTGO 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 manufacturer. Burner should be operating and should go off when controls are tested. When controls are restored, burner should re-ignite.

  • Page 31: Annual Service Check List

    See page 34. Verify operation of all controls on boiler. See page 30. 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 32: Detailed Service Procedures

    2. Remove flue collector hood, saving hardware for Tankless water heater reassembly. Weil-McLain tankless heater ratings are based on 200°F boiler water tem- 3. Shut off oil valves. Arrange drip pans under the perature. To get rated output, set tankless heater control to 200°F. Control areas of oil piping that will be disconnected.

  • Page 33: Handling Ceramic Fiber And Fiberglass Materials

    WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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 insula- tion panels in this product contain ceramic fiber OR BASE PANELS:...

  • Page 34: Close Clearance Installation

    To provide close clearances as described on pages 34 and 35: 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 35 WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Close clearance installation (continued) Figure 28 Figure 29 Flue pipe clearances Back vent clearances Combustible surface 24" For servicing or min 2" For close clearances 6"...

  • Page 36: Replacement Parts

    WTGO Section and flue collector part numbers 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 37 WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 31 WTGO Section and flue collector parts for Series 4 Part number 550-142-332/0421...
  • Page 38 WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Table 8 WTGO 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 39 WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 32 WTGO Trim part for Series 4 Part number 550-142-332/0421...
  • Page 40 WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Table 9 WTGO part numbers for Series 4 Boiler Top panel with Jacket panel with Left side & rear Right side &...

  • Page 41: Dimensions

    WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Figure 34 WTGO dimensions — inches (mm) 3/16 [182 6] 2 5/8 [66 7] 7 Dia [177 8] 15 ½ [393 7] Approx Left side...

  • Page 42: Ratings

    WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Ratings Table 10 WTGO Series 4 oil-fired water boiler ratings ® AHRI Certified Ratings Draft Boiler Flue Seasonal Minimum Heating Loss Burner Input Rating...
  • Page 43 WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — SERVICE TECHNICIAN ONLY — read and follow completely. Ratings Table 11 WTGO Series 4 oil-fired water boiler rating notes NOTES: WTGO boiler designed with convertible vertical and horizontal flue outlet. MBH refers to thousands of Btu per hour.
  • Page 44 WTGO Boiler Manual OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Part number 550-142-332/0421...

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