Weil-McLain WTGO Installation And Start-Up Manual
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Weil-McLain WTGO Installation And Start-Up Manual

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 550-141-825/1211

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Summary of Contents for Weil-McLain WTGO

  • 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

    WTGO 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 —...

  • Page 3: Table Of Contents

    High temperature limit ....24 WTGO (see Figure 1) ....6 3-Wire zone valve applications .

  • Page 4: Please Read Before Proceeding

    WTGO 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

    WTGO 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 ❏...

  • 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 WTGO Boilers Burner disconnect plug Service switch on boiler Water relief valve Temperature-pressure gauge...

  • Page 7: Troubleshooting

    WTGO 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

    WTGO 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

    WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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 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.
  • Page 11 WTGO 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)

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

    Figure 4. sure cap is securely installed. d. Install washers and nuts. Tighten nuts until col- 2. Non-Packaged WTGO-7, 8 & 9 — split the assembled block for easier lector hood makes contact with tinnerman clip. handling (see Figure 4): e.
  • Page 13 WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — non-packaged boilers only (continued) Figure 4 Change from back flue outlet to top flue outlet (optional)

  • Page 14: Perform Hydrostatic Pressure Test

    Table 2 Figure 5 Control tappings Control tapping locations Location Size Function 1½" Return piping 1½" Alternate return piping for A/B WTGO ¾” Supply piping Pressure-temperature 1/4" gauge ¾" Drain valve ¾" High limit control (in tankless heater cover plate) 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-WTGO and A-WTGO 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

    WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect breeching General chimney requirements Table 3 Minimum chimney sizes • Designed for natural draft firing. Connect boiler to vertical chim- ney.
  • Page 17 WTGO 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)

  • Page 18: Connect Water Piping

    SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping General piping information Table 4 Water piping sizes • All packaged WTGO boilers are shipped with an installed combination temperature limit control/low water cut-off. Boiler model To system From system •...
  • Page 19 WTGO 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”...

  • Page 20: Piping Multiple Zones

    Zoning with zone valves: 1. Install balancing valves to adjust flow to distribute heat to all zones. 2. Separate transformer is required to power zone valves. Refer to “Weil-McLain Zone Valve Wiring Guide” for details. Figure 12 Multiple zoning with ZONE VALVES...

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

    WTGO 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-...

  • Page 22: Use With Refrigeration Systems

    WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Use with refrigeration systems Figure 15 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 GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — 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 24: Connect Wiring

    WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring General wiring requirements Junction box (furnished) • Junction box houses electrical connections for all boiler Electric shock hazard. Can cause severe personal components.
  • Page 25 WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (continued) Figure 17 Boiler wiring for forced hot water Limit control wiring harness Service switch on boiler...
  • Page 26 WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (continued) Figure 18 Wiring diagram Part number 550-141-825/1211...

  • Page 27: Blocked Vent Shutoff Switch

    WTGO 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 28: Connect Oil Piping

    WTGO 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 29: Start-Up

    WTGO 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.

  • Page 30: Check-Out Procedure

    WTGO 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 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 32. Verify operation of all controls on boiler. See page 32. 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 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...

  • Page 34: Close Clearance Installation

    To provide close clearances as described on page 34 and page 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 GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Close clearance installation (continued) Figure 25 Figure 26 Flue pipe clearances Back vent clearances Combustible surface 24" For servicing or min.

  • Page 36: Replacement Parts

    Series 3 section and flue collector parts 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 GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Table 8 Series 3 section and flue collector parts Part number 550-141-825/1211...
  • Page 38 WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Table 9 Series 3 trim parts Fig. Part no. Description Mfr. Mfr. part no. Combination pressure-temperature gauge kit, 60° – 360° F., 0 - 75...
  • Page 39 WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 29 Series 3 trim parts Part number 550-141-825/1211...
  • Page 40 OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Table 10 Weil-McLain part numbers Jacket panel with insulation — Model Left side and rear Right side and Top panel with...

  • Page 41: Dimensions

    WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Figure 31 WTGO dimensions — inches (mm) 20 1/4 [514.4] 3/16 7 3/4 [128.6] 1/16 [182.6] [196.9] 2 5/8 [65.1]...

  • Page 42: Ratings

    Water ratings are based on a piping and pick-up allowance of 1.15. An additional allowance should be made for unusual piping and pick-up loads. Consult local Weil-McLain Sales Office. I=B=R gross output See page 12 for minimum breeching diameter.

  • Page 43: Notes

    WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — SERVICE TECHNICIAN ONLY — read and follow completely. Notes Part number 550-141-825/1211...
  • Page 44 WTGO Boiler Manual GOLD OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Part number 550-141-825/1211...

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