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-7
Summarization of Contents
Using this manual
Homeowner
Specific instructions and responsibilities for homeowners regarding boiler operation and maintenance.
Service technician
Specific instructions and responsibilities for qualified technicians on boiler installation, startup, and service.
Read this first !
Homeowner
Homeowner's responsibilities for boiler installation, servicing, and maintenance.
Service technician
Service technician's responsibilities for boiler installation, startup, and servicing.
Routine maintenance schedule
Beginning each heating season
Key maintenance tasks to perform at the start of the heating season.
Daily during heating season
Daily checks for safe boiler operation during the heating season.
Weekly during heating season
Weekly inspection and maintenance tasks for the boiler.
Periodically during heating season
Periodic checks and maintenance during the heating season.
End of heating season
Maintenance tasks to complete at the end of the heating season.
Boiler shutdown
Procedures for safely shutting down the boiler for extended periods.
Please read this before proceeding
Start-Up
Step-by-step instructions for the initial startup of the boiler.
Check daily
Daily checks for the boiler area to ensure safety and clear operation.
Check monthly
Monthly inspection points for the boiler system, including venting and piping.
Periodically
Periodic maintenance tasks for specific components like oil motors and low water cutoffs.
Before installing boiler
Installations must comply with
List of applicable codes and standards for boiler installations.
Provide clearances around boiler
Specifies required minimum clearances for safe installation and servicing.
Before selecting boiler location
Key considerations for choosing an appropriate boiler location.
Provide air for combustion and ventilation
Requirements for ensuring adequate combustion and ventilation air supply.
Lay a foundation, if needed
Instructions for preparing a stable and level foundation for the boiler.
Air contamination
Identifies potential air contaminants affecting combustion and presents mitigation strategies.
Operation
SGO with float-type low water cutoff
Operational steps specific to boilers equipped with a float-type low water cutoff.
SGO with probe-type low water cutoff
Operational steps specific to boilers equipped with a probe-type low water cutoff.
Install boiler - packaged boilers only
Place boiler
Guidance on positioning and securing the packaged boiler.
Perform hydrostatic pressure test
Procedure for testing boiler integrity using hydrostatic pressure.
Tankless heater, if used
Steps for installing the optional tankless water heater.
Install boiler – Semi-packaged and Knocked-down boilers only
Place boiler
Guidance on positioning and assembling semi-packaged/knocked-down boilers.
Tankless heater, if used
Steps for installing the optional tankless water heater.
Perform hydrostatic pressure test
Procedure for testing boiler integrity using hydrostatic pressure.
Install jacket (Knocked-down boilers only)
Specific instructions for fitting the jacket onto knocked-down boiler sections.
Install boiler controls
Guidance on connecting various control components to the boiler.
Install burners and chimney – all boilers
Install burner
Steps for securely installing the oil burner onto the boiler.
General chimney requirements
Essential requirements for chimney installation and materials.
Connect breeching
How to properly connect the breeching between the boiler and the chimney.
Connect steam piping
General piping information
Fundamental principles and guidelines for steam piping installations.
Install piping
Specific steps and considerations for installing the steam piping according to specifications.
To connect SGO boilers to indirect-fired water heaters
Instructions for integrating SGO boilers with indirect-fired water heaters.
Optional reservoir piping
Guidance on installing an optional reservoir for managing condensate return.
Connect tankless heater piping
To pipe tankless heater
Specific steps for piping the tankless heater, including controls.
Connect wiring – general information
General wiring requirements
Outlines electrical codes and standards for safe wiring installations.
Thermostat wiring
Instructions for wiring the thermostat to control boiler operation.
Junction box (furnished)
Information regarding the boiler's electrical junction box.
Burner wiring
Specific wiring instructions for connecting the boiler's burner.
High temperature limit
Details on installing and setting the high temperature limit control.
Blocked vent shutoff switch
Installation and wiring guide for the blocked vent shutoff switch.
Connect wiring (Float-type LWCO)
Boiler Wiring
Overall wiring diagram for float-type LWCO systems.
Riello 530 SE/C Primary Control
Wiring details for the Riello 530 SE/C primary control unit.
Carlin 70200 Primary Control
Wiring details for the Carlin 70200 primary control unit.
Beckett Genisys Primary Control 7505
Wiring details for the Beckett Genisys Primary Control 7505 unit.
Blocked vent shutoff switch (BVSS), when required
Wiring instructions for the BVSS when used with float-type LWCO.
Connect wiring (Probe-type LWCO)
Boiler Wiring
Overall wiring diagram for probe-type LWCO systems.
Riello 530 SE/C Primary Control
Wiring details for the Riello 530 SE/C primary control unit.
Carlin 70200 Primary Control
Wiring details for the Carlin 70200 primary control unit.
Beckett Genisys Primary Control 7505
Wiring details for the Beckett Genisys Primary Control 7505 unit.
Blocked vent shutoff switch (BVSS), when required
Wiring instructions for the BVSS when used with probe-type LWCO.
OVD-Vent damper wiring
Vent damper wiring
Specific steps for connecting the vent damper's wiring.
Connect oil piping
General oil piping requirements
Essential requirements for oil tank, piping, and connections.
Oil piping connection at burner
Recommended method for connecting the oil piping to the burner assembly.
Start up – Steam Boiler Water Treatment
Steam Heating Installation Considerations
Factors influencing steam heating systems and water treatment needs.
Systems where treatment should be considered are:
Specific applications or conditions requiring boiler water treatment.
Beware the Foam
Warning regarding the use of foaming agents in boiler water treatment.
Testing & Treatments
Guidance on testing the suitability of water treatment chemicals.
Without Chemical Treatment
Procedures to follow when chemical treatment is not applied.
Start up
Fill the system
Steps for filling the boiler with water and checking pH levels.
Tips for steam systems
Advice for maintaining optimal performance of steam heating systems.
Skim steam boiler
Procedure for cleaning new boilers to remove impurities and ensure clean operation.
To place in operation
Final checks and procedures before putting the boiler into service.
Check out procedure
Check off Steps as completed
Checklist for verifying the completion of all installation and testing steps.
Installation and service certificate
A form to document installation details and certify the work performed.
Service and maintenance
General description of control operation
Explanation of how the boiler's primary controls function.
Controls requiring annual service
Identification of specific controls that need annual inspection and service.
Burner adjustments
Procedures for adjusting the burner for optimal performance and safety.
Gauge Glass
Instructions for cleaning and verifying the boiler's gauge glass.
Cleaning boiler flue ways
Detailed steps for cleaning the internal flue ways of the boiler.
Inspect
General inspection tasks for the boiler and its surrounding area.
Reported problems
How to address issues reported by the boiler owner.
Boiler area
Checks for combustibles and contaminants in the boiler's vicinity.
Piping
Inspection of all piping for leaks and proper condition.
Service.
General notes regarding service for gauge glass and controls.
Gauge glass
Detailed steps for cleaning and checking the gauge glass.
Check/test.
Procedures for testing boiler waterline and limit controls.
Boiler waterline
Verification of the correct boiler water level.
Limit controls
Testing the proper function of the boiler's limit controls.
Low water cutoffs
Cleaning and testing procedures for probe-type and float-type low water cutoffs.
Check/test.
Specific testing procedures for float-type low water cutoffs.
Check monthly
Monthly inspection of the boiler's venting system.
Boiler and system piping
Inspection of boiler and system piping for leaks and damage.
Review with owner
Key operational and maintenance information to review with the boiler owner.
Annual service
Procedures related to annual service, including relief valve testing.
Boiler relief valve
Instructions for testing and maintaining the boiler's safety relief valve.
Replacement parts
Complete Jacket cartons
Part numbers for complete jacket carton sets based on boiler size.
Common jacket parts for all boilers
Part numbers for common jacket components used across all boiler models.
Handling ceramic fiber and fiberglass materials
REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS
Safety measures and steps for removing combustion chamber lining or base panels.
REMOVAL OF FIBERGLASS WOOL or INSTALLATION OF FIBERGLASS WOOL OR BASE PANELS:
Safety precautions for handling fiberglass wool during removal or installation.
Precautionary measures
General safety advice to prevent exposure to airborne fibers.
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