WGO SERIES 3 OIL-FIRED NATURAL DRAFT WATER BOILER

This Manual Includes: Installation Start-Up Boiler Parts

As an EVERGY STAR Partner, Weil-McLain has determined that this product meets the ENERGY STAR guidelines for energy efficiency

Installer: Make sure this is the correct manual for the boiler. Verify boiler model on rating label. Leave all documentation received with boiler and burner with unit for future reference. User: Boiler and burner must be installed and serviced by qualified service technician. Part No. 550-141-826/1201

Read This Page First

Hazard Definitions
The following terms are used to bring attention to the presence of hazards of various risk levels or to important information concerning product life. Indicates presence of hazards that will cause severe personal injury, death or substantial property damage if ignored. Indicates presence of hazards that can cause severe personal injury, death or substantial property damage if ignored. Indicates presence of hazards that will or can cause minor personal injury or property damage if ignored. Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury hazards.

Symbol Definitions
The following symbols are used to indicate sequence of installation for: Factory-assembled packaged boiler block, jacket and controls. Sizes 2 through 6 only. Factory-assembled block, no burner. Sizes 2 through 6 with jacket installed; water trim controls shipped separately. Sizes 7 through 9 with jacket and water trim controls shipped separately.

When Calling or Writing About the Boiler

Please have boiler model number and series from boiler rating label and CP number(s) from boiler jacket, burner and controls. On page 24 of this manual is space to list CP number(s).

Table of Contents
Read all instructions before installing. Failure to follow all instructions in proper order can cause severe personal injury, death or substantial property damage.

Read This Page First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before Installing Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Packaged Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Non-Packaged Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . Connect Breeching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check-Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation and Service Certificate . . . . . . . . . . . . . . . . . . . . Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.2 .3 .4-5 .6-7 .8-11 .12-13 .14-18 .19-21 .22 .23 .24 .24 .25-27 .28 .29 .30-31 .Back Cover

Before Installing Boiler

Installations must comply with:
U.S. State and local plumbing, heating and electrical codes. National codes where applicable. Canada Canadian Standards Association, CSA B139, Installation Code for Oil-Burning Equipment. CSA C22.1 Canadian Electrical Code Part One. Applicable local or provincial codes. Check for nearby connections to: System water piping. Chimney. See pages 12-13. Boiler can be top or back vented. Combustion and ventilation air supply. See page 5. Oil supply. See page 22 for oil line routing. Electrical power. Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids. Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

Provide clearances around boiler (see FIGURE 1):

Jacket cap must be in place on boiler to avoid requiring an 18" minimum clearance from back or top of boiler to combustible material. Minimum clearances from vent pipe to combustible material: 6 inches Type L doublewall vent* 18 inches Singlewall vent* Flue pipe clearances must take precedence over jacket clearances. Recommended service clearances: 24 inches Front and top 6 inches Left side, back and right side 12 inches Right side for burner door swing radius Special close clearances (alcove, closet, under counters, etc.) see Appendix, pages 25-27.

Before selecting boiler location:

* 6" (18")

* 6" (18") 24"

Ceiling

Walls 6" (12") * 6" (18") 6" 24"

6"

Wall Floor Top View Left Side

Recommended Service Clearances FIGURE 1

Before Installing Boiler

Provide air for combustion and ventilation:
Adequate combustion and ventilation air: Assures proper combustion. Reduces risk of severe personal injury or death from possible flue gas leakage and carbon monoxide emissions. Do not install exhaust fan in boiler room. Older buildings with single-pane windows, minimal weather-stripping and no vapor barrier often provide enough natural infiltration and ventilation without dedicated openings. New construction or remodeled buildings are most often built tighter. Windows and doors are weather-stripped, vapor barriers are used and openings in walls are caulked. As a result, such tight construction is unlikely to allow proper natural air infiltration and ventilation. Follow state, provincial or local codes when sizing adequate combustion and ventilation air openings. In absence of codes, use the following guidelines when boiler is in a confined room (defined by NFPA 31 as less than 7200 cubic feet per 1 GPH input of all appliances in area. A room 8 ft. high x 33.5 ft. x 33.5 ft. is 7200 cu. ft.): Provide two permanent openings one within 12 inches of ceiling, one within 12 inches of floor. Minimum height or length dimension of each rectangular opening should be at least 3 inches. 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 1 GPH input (1 sq. in. per 1000 Btu input) of all fuel-burning appliances plus requirements for any equipment that can pull air from room (including clothes dryer and fireplace). When outside air is used connect each opening directly or by ducts to the outdoors or to crawl or attic space that freely connects with outdoors. Size per below: Through outside wall or vertical ducts at least 35 sq. in. per 1 GPH input (1 sq. in. per 4000 Btu input) of all fuel-burning appliances plus requirements for equipment that can pull air from room (including clothes dryer and fireplace).

CONTINUED

Through horizontal ducts at least 70 sq. in. per 1 GPH boiler input (1 sq. in. per 2000 Btu input) of all fuel-burning appliances plus requirements for any equipment that can pull air from room (including clothes dryer and fireplace). Where ducts are used, they should have same cross-sectional area as free area of openings to which they connect. Compensate for louver, grille or screen blockage when calculating free air openings. Refer to their manufacturers instructions for details. If unknown, use: Wood louvers, which provide 20-25% free air. Metal louvers or grilles, which provide 60-75% free air. Lock louvers in open position or interlock with equipment to prove open before boiler operation.

Lay a foundation, if needed:

Boiler may be installed on non-carpeted combustible flooring. For residential garage installation, install boiler so burner is at least 18 inches above floor to avoid contact with gasoline fumes. A level concrete or masonry foundation is required when: Floor could possibly become flooded. Non-level conditions exist. Solid concrete blocks can be used to create a pad. BOILER FOUNDATION SIZE TABLE
BOILER MODEL WGO-2 WGO-3 WGO-4 WGO-5 WGO-6 WGO-7 WGO-8 WGO-9 LENGTH INCHES 14 17 17 20 23 26 29 32 WIDTH INCHES 22 22 22 22 22 22 22 22 MIN. HEIGHT INCHES 2 2 2 2 2 2 2 2

Go to page 6 to install boiler Go to page 8 to install boiler 5

Install Packaged Boiler

Place boiler:
1. Remove circulator strapped to pallet. Circulator will be damaged if not removed before boiler is lifted from pallet. 2. Remove boiler from pallet. Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result. Smaller sized boilers may be top heavy. Use caution when handling to avoid minor personal injury or property damage. 3. Boiler is shipped for back flue outlet. To change to top flue outlet (see FIGURE 2): a. Remove jacket cap on top of boiler. b. Loosen two screws holding flue cap strap to collector hood. Remove strap and flue cap from opening. Re-tighten screws. c. Check rope placement inside flue cap. (Read under step #6 below). Do not leave boiler unattended. Cold water fill can expand and damage cast iron, resulting in severe personal injury, death or substantial property damage. 6. Check for maintained gauge pressure for more than 10 minutes. Visually check for leaks if gauge pressure drops. 7. Drain boiler. Repair leaks if found. Do not use petroleum-based sealing compounds to repair leaks. Damage to system components can result, causing property damage. 8. Retest boiler after repairing leaks. 9. Remove air vent and plugs. Reinstall relief valve.

Perform hydrostatic pressure test:

1. 2. 3. 4. 5.

Remove relief valve installed in boiler. Install air vent in N tapping on top boiler. Plug supply and return tappings. Drain valve is already factory-installed. Fill boiler. Vent all air. Pressure test boiler at 1 times working pressure.

d. Loosen two screws on back flue outlet. Set flue cap on outlet. Install strap by engaging slots in screws. Tighten screws. Make sure cap is securely installed. e. Snap jacket cap in back outlet opening. Jacket cap must be in place on boiler to avoid requiring an 18 minimum clearance from back or top of boiler to combustible material. 4. Check level. Shim legs, if needed. 5. Check for secure placement of insulation on target wall, chamber floor and burner door. 6. Visually check: a. Flue collector hood seal. b. Burner mounting door seal. Obtain gas-tight seal to prevent possible flue gas leakage and carbon monoxide emissions, which can lead to severe personal injury or death.

Go to page 12 to connect breeching and venting

Install Packaged Boiler

CONTINUED

Change From Back Flue Outlet to Top Flue Outlet (Optional) FIGURE 2

Install Non-Packaged Boiler

Fiberglass wool and ceramic fiber materials:
POSSIBLE CANCER HAZARD BY INHALATION CAN CAUSE RESPIRATORY, SKIN AND EYE IRRITATION This product contains fiberglass wool and ceramic fiber materials. Airborne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation. Apply special care when handling ceramic fiber (chamber lining and base insulation) materials. Ceramic fibers can be converted to chrystobalites, a substance listed as a probable cause of cancer. Suppliers of fiberglass wool products recommend the following precautions be taken when handling these materials: Precautionary measures: Avoid breathing fiberglass dust and contact with skin and eyes. Use NIOSH approved dust/mist respirator. Wear long-sleeved, loose fitting clothing, gloves and eye protection. Wash work clothes separately from other clothing. Rinse washer thoroughly. Operations such as sawing, blowing, tearout and spraying may generate airborne fiber concentration requiring additional protection. First aid measures: Eye contact Flush eyes with water to remove dust. If symptoms persist, seek medical attention. Skin contact Wash affected areas gently with soap and warm water after handling. 3) Loosen two screws on back flue outlet. Set flue cap on outlet. Install strap by engaging slots in screws. Tighten screws. Make sure cap is securely installed. 2. a. b. Non-Packaged WGO-7, 8 & 9 split the assembled block for easier handling (see FIGURE 3): Open burner mounting door and, using utility knife, slit floor insulation at joint to be separated. Remove 5" draw rod and the longest draw rod from each side. Pull block apart. Save draw rods, nuts, washers and sealing rings for reassembly. Move divided block to location. Clean port openings with clean rag. Do not use petroleum-based compounds to clean openings. Damage to system components can result, causing property damage. e. Place rings in port openings. If ring slips out of groove, stretch ring gently for several seconds, then place in groove. f. Position sections so aligning lugs fit into sockets of next section. Make sure sealing rope is in good condition and in position. g. Oil threads on draw rods. Install washer and nut on end to be tightened. Use nut only on other end. h. With wrench at washer/nut end, uniformly tighten nuts starting with 5" rod at large port, 5" rod at small port, bottom long rod and finally top long rod. i. Torque on both 5" rods and bottom long rod should be 50-60 ft. lbs; long top rod should be 20-25 ft. lbs. Do not back-off nuts. j. Metal-to-metal contact should be made around port openings. If gap does exist, it should be less than .020". Check with feeler gauge. k. If gap around port openings exceeds .020", check for dirt on port openings, sockets or misaligned lugs. If corrections are made and gap still exists, contact your Weil-McLain distributor or sales office before continuing installation.

c. d.

Place boiler:

1. Non-Packaged WGO-2 through 6 position on site. Smaller sized boilers may be top heavy. Use caution when handling to avoid minor personal injury or property damage. a. Boiler is shipped for back flue outlet. To change to top flue outlet (see FIGURE 3): 1) Loosen two screws holding flue cap strap to collector hood. Remove strap and flue cap from opening. Re-tighten screws. 2) Check rope placement inside flue cap. (Read under Step #3 on page 9.)

Install Non-Packaged Boiler

3. Non-Packaged WGO-7, 8 & 9 install flue collector hood (see FIGURE 3): Obtain gas-tight seal to prevent possible flue gas leakage and carbon monoxide emissions, leading to severe personal injury or death. a. Thread tinnerman clip on screw so that clip fits snugly in notch of hold-down lug. Screw must not turn. b. Remove paper on sealing rope. Starting at back section near flue collar, position sealing rope around top of block with adhesive side to sections. Do not stretch rope. Make sure rope ends meet. Trim excess rope. c. Position flue collector hood on top of boiler sections and over screws and clips as shown in FIGURE 3.
Nut Washer

CONTINUED

d. Install washers and nuts. Tighten nuts until collector hood makes contact with tinnerman clip. e. Back flue outlet boiler Position flue cap and strap over opening in flue collector hood. Make sure rope in cap is in place and in good condition. Tighten strap to hood with screws provided. Top flue outlet boiler Position flue cap and strap over opening in back section. Make sure rope in cap is in place and in good condition. Tighten strap to boiler with screws provided in section. Install remaining screws in holes in flue collector hood. 4. Check level. Shim legs, if needed.

Tinnerman Clip Screw Hold-down Lug Sealing Rope in Groove Inside Cap

Flue Collector Hood

Sealing Rope with Adhesive Tape

Flue Cap Flue Cap Strap

Change From Back Flue Outlet to Top Flue Outlet (Optional) FIGURE 3

Install Packaged and Non-Packaged Boiler

Perform hydrostatic pressure test:
1. See FIGURE 4 and Control Tapping Table below to install: a. Boiler drain. b. Water pressure gauge (test only). Be sure gauge can handle test pressure. c. Air vent in upper N tapping. d. Plugs in remaining tappings. 2. Fill boiler. Vent all air. Pressure test boiler at 1 times working pressure. For boilers split and reassembled, test between 75 and 85 psig. Do not leave boiler unattended. Cold water fill could expand and damage cast iron, resulting in severe personal injury, death or substantial property damage. 3. Check for maintained gauge pressure for more than 10 minutes. Visually check for leaks if gauge pressure drops. 4. Drain boiler. Repair leaks if found. Do not use petroleum-based compounds to repair leaks. Damage to system components can result, causing property damage. 5. Re-test boiler after repairing leaks. 6. Remove pressure gauge, air vent and plugs from tappings used for controls. 7. Visually check: a. Sealing rope placement. b. Metal-to-metal contact around port openings. c. Flue collector hood seal. d. Burner mounting door seal. Obtain gas-tight seal to prevent possible flue gas leakage and carbon monoxide emissions, which can lead to severe personal injury or death.

Install jacket (sizes 7 through 9 only):

Before installing jacket, remove burner mounting door. See jacket instructions for details.

Install boiler controls:

See Control Tapping Table and FIGURES 4 and 5 to install controls. 1. Install limit control. If not furnished, use high limit with maximum 220F setting. 2. Affix CP number label(s) on jacket front panel. CONTROL TAPPING TABLE
LOCATION B1 B2 C E3 H L N SIZE 1" 1 " 1" " " " " " FUNCTION Return Piping Alternate Return Piping for A/B WGO Supply Piping Pressure-Temperature Gauge Drain Valve High Limit Control Air Vent or Expansion Tank Piping Relief Valve

E3

C L

R1

R1

B2 H Front Section B1

Back Section Control Tapping Location FIGURE 4

10

Install Packaged and Non-Packaged Boiler

Install burner (also refer to instructions packed with burner):
Burners designed for use with Weil-McLain 68 boilers must not be used on GOLD Oil boilers. Contact individual burner manufacturers for GOLD Oil applications. For P-WGO and A-WGO boiler: 1. Secure universal mounting flange and gasket to burner mounting door. Use three bolts provided. 2. Secure burner on flange with three bolts. 3. Position burner so end of air tube is level to 1 tilt downward. Open door to verify burner position. End of air tube should be flush to " recessed from inside wall of burner door refractory. Check for secure placement of insulation on target wall, chamber floor and burner mounting door. Securely close door with nut.

Circulator

Water Pressure-Temperature Gauge

Relief Valve Limit Control

Drain Valve

Water Boiler Controls FIGURE 5

11

Connect Breeching
General chimney requirements:
Designed for natural draft firing. Connect boiler to vertical chimney. Insufficient draft can cause flue gas leakage and carbon monoxide emissions, which will lead to severe personal injury or death. Use vent material approved by local codes for oil-fired burners. In their absence, refer to: NFPA 31, Installation of Oil-Burning Equipment. NFPA 211, Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances. In Canada, refer to CSA B139, Installation Code for Oil-Burning Equipment. NFPA 211 requires chimney to be lined before connected to boiler. Inspect existing chimney before installing new boiler. Failure to do any of the following will result in severe personal injury or death: Clean chimney, including removal of blockage. Repair or replace damaged pipe or liner. Repair mortar and joints. To prevent downdrafts, extend chimney at least 3 feet above highest point where it passes through roof and 2 feet higher than any portion of building within 10 feet. Increase chimney cross-sectional area and height at least 4% per 1,000 feet above sea level. Minimum clearances from vent pipe to combustible material: 6 inches Type L doublewall vent 18 inches Singlewall vent Minimum chimney sizes should be used. Oversized chimneys, outside masonry chimneys and/or derated inputs can result in condensation in chimney. MINIMUM CHIMNEY SIZE TABLE
BOILER MODEL NUMBER WGO-2 WGO-3 WGO-4 WGO-5 WGO-6 WGO-7 WGO-8 WGO-9 *** MINIMUM BREECHING DIAMETER 5" 6" 6" 7" 7" MINIMUM I=B=R CHIMNEY SIZE RECT. ROUND 8" x 8" * 8" x 8" * 8" x 12" ** 6" MINIMUM CHIMNEY HEIGHT 15'

7" 7"

15' 20'

* 6" x 6" inside liner * * 6" x 10" inside liner * * * Flue collar on boiler is 7" diameter

Connect breeching:
Long horizontal breechings, excessive number of tees and elbows or other obstructions restricting combustion gas flow can result in possibility of condensation, flue gas leakage and carbon monoxide emissions, which can lead to severe personal injury or death. 1. Install 2 flue pipe brackets. 2. Connect full-sized breeching when possible. See Minimum Chimney Size Table. Back outlet see FIGURE 6. Top outlet see FIGURE 7. 3. Connection must be made above bottom of chimney to avoid blockage. Breeching must not enter chimney far enough to cause obstruction. Use thimble or slip joint where breeching enters chimney to allow removal for cleaning. 4. When burner and boiler are properly installed, draft overfire will be approximately -0.01" to -0.02" W.C. Install barometric control in breeching, per control manufacturers instructions, when excess draft needs to be relieved or to comply with applicable codes and regulations. Use draft gauge to adjust proper opening. 5. An induced draft fan for the chimney may be necessary if: Excessive resistance to flow of combustion gases can be expected. Cross-sectional area of chimney is smaller than minimum recommended. Chimney height is less than recommended. Seal all vent joints. Interlock burner with fan operation.

12

Connect Breeching

CONTINUED

Typical Location for Barometric Control (Also see Control Manufacturers Instructions)

Flue Pipe Bracket (one on each side of pipe)

Back Outlet Breeching Connection FIGURE 6

Typical Location for Barometric Control (Also see Control Manufacturers Instructions)

Flue Pipe Bracket (one on each side of pipe)

Top Outlet Breeching Connection FIGURE 7

13

Connect Water Piping

General piping information:
If installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. Install control in supply piping between boiler and isolation valve. Set control to a minimum of 20F above set point of combination control. Maximum allowable set point is 220F. Wire control as shown on wiring diagram. Use a low water cutoff device when: Boiler is installed above radiation level. Required by certain state or local codes or insurance companies. Use low water cutoff designed for water installations. Probe-type is recommended. Purchase and install in tee in supply line above boiler. Use backflow check valve in cold water supply as required by local codes. See FIGURE 8 or 9 on page 15 and Water Piping Size Table at right for near-boiler piping and single-zone piping. See page 16 to complete multiple-zone piping or page 17 to complete piping for systems operating below 140F. For multiple-boiler piping, refer to Weil-McLains Primary/Secondary Piping Guide and M-WGO Multiple Boiler Manual. Install relief valve vertically in R1 tapping on front of boiler. See FIGURE 8 or 9 and also refer to tag attached to relief valve for manufacturers instructions. Pipe relief valve discharge line near floor close to floor drain to eliminate potential of severe burns. Do not pipe to any area where freezing could occur. Do not plug, valve or place any obstruction in discharge line.

DIAPHRAGM expansion tank (FIGURE 8):

Make sure expansion tank size will handle boiler and system water volume and temperature. Tank must be located near boiler before inlet to circulator. See tank manufacturers instructions for details. Undersized expansion tanks cause system water to be lost from relief valve and makeup water added through fill valve. Eventual section failure can result.

Install automatic air vent in N tapping as shown in FIGURE 8. Ensure expansion tank size will handle boiler and system water volume and temperature. Undersized expansion tanks cause system water to be lost from relief valve and makeup water added through fill valve. Eventual section failure can result.

CLOSED expansion tank (FIGURE 9):

Install piping:

Connect tank from N tapping shown in FIGURE 9 to expansion tank. Use " N.P.T. piping. Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping. WATER PIPING SIZE TABLE *
BOILER MODEL NUMBER WGO-2 WGO-3 WGO-4 WGO-5 WGO-6 WGO-7 WGO-8 WGO-9 * TO SYSTEM 1" 1" 1" 1" 1" 1" 2" 2" FROM SYSTEM 1" 1" 1" 1" 1" 1" 2" 2"

All piping sizes based on 20F temperature rise through boiler.

14

Connect Water Piping

Circulator Automatic Air Vent

CONTINUED

Isolation Valve To System

Isolation Valve Cold Water Fill To Diaphragm Expansion Tank and Fittings

From System

C Tapping N Tapping Relief Valve

*Circulator *Alternate Pump Location

B1 Tapping

Piping with DIAPHRAGM Expansion Tank FIGURE 8

Closed Type Expansion Tank

Circulator Cold Water Fill Isolation Valve To System C Tapping N Tapping From System Isolation Valve Relief Valve

*Circulator *Alternate Pump Location

B1 Tapping

Piping with CLOSED Expansion Tank FIGURE 9

15

Connect Water Piping

Piping MULTIPLE ZONES:

CONTINUED

1. Follow instructions on page 14 and 15 to install piping near boiler. 2. See FIGURE 10 or 11 to complete installation 3. Zoning with circulators: a. Size each circulator to individual circuit requirements. b. Remove circulator (when furnished as standard equipment). c. Install balancing valves to adjust flow to distribute heat to all zones. d. Separate relay is required for each circulator. 4. Zoning with zone valves: a. Install balancing valves to adjust flow to distribute heat to all zones. b. Separate transformer is required to power zone valves. Refer to Weil-McLain Zone Valve Wiring Guide for details.
Legend: 1 2 3 4 5 Isolation valve Flow control valve Circulator Zone valve Drain valve

ZONE 2 ZONE 1 1 2 1 2 1 1 5 3 5 5 1

ZONE 2 ZONE 1 1 4 5 1 1

16

Multiple Zoning With CIRCULATORS FIGURE 10

Multiple Zoning With ZONE VALVES FIGURE 11

Connect Water Piping

Piping for systems requiring temperatures below 140F:

CONTINUED

In most systems, this type of piping is not required. If system water temperature requirements are less than 140F, such as radiant panels or converted gravity systems, use piping as shown in FIGURE 12 or 13. If system piping is plastic without an oxygen barrier, a heat exchanger must be used.

Legend: 1 2 3 4 5 6 7 Isolation valve Flow control valve Circulator System temperature gauge Zone valve Drain valve System temperature valves Adjust valves so that: - the temperature at gauge 8 is at least 140F - the temperature at gauge 9 is at least 160F Blend temperature gauge Boiler temperature gauge

8 9

Piping with CIRCULATORS FIGURE 12

Piping with ZONE VALVES FIGURE 13

17

Connect Water Piping

Use with refrigeration systems:
Install boiler so that chilled medium is piped in parallel with heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. Consult I=B=R Installation and Piping Guides.

CONTINUED

If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air, use flow control valves or other automatic means to prevent gravity circulation during cooling cycle.

Supply 1 Circ. Chiller Strainer

1 Exp. Tank

Circ.

Exp. Tank

1 2 1

1 2

Isolation valve Balancing valve

18

Use with Refrigeration System FIGURE 14

Connect Wiring
General wiring requirements:
Electric shock hazard. Can cause severe personal injury or death if power source, including service switch on boiler, is not disconnected before installing or servicing. Installations must follow these codes: National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes. In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes. Wiring must be N.E.C. Class 1. If original wire as supplied with boiler must be replaced, type 105C wire or equivalent must be used. Supply wiring to boiler and additional control wiring must be 14 ga. or heavier. Provide electrical ground at boiler as required by codes. Install thermostat on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sun rays or fireplaces. Follow instructions with thermostat. If it has a heat anticipator, set heat anticipator in thermostat to match power requirements of equipment connected to it. Boiler wiring diagrams give setting for standard equipment.

Junction box (furnished):

Junction box houses electrical connections for all boiler components. P boilers have harnesses furnished. A boilers are furnished with burner and limit harnesses. All field-provided high voltage wiring must be sheathed in flexible metal conduit. Connect incoming line voltage HOT wire to service switch, and neutral wire to white wire. Field-install equipment ground wire to green wire with wire nut. Service switch (15 amp) is provided with boiler. A boilers install switch as shown. Some local codes may require an emergency shut-off switch installed at a location away from boiler. Follow local codes. Burner harness incorporates a disconnect plug, providing a convenient way to disconnect wiring when burner mounting door is opened. All P boilers have a power disconnect plug installed on burner. On A boilers, mount the plug (provided in water trim carton) on the burner housing as shown in FIGURE 15. For Carlin burners, screw burner plug into threaded conduit coupling, then mount this assembly to the burner housing using the chase nipple. Route wires through housing and make connections in burner junction box as shown in boiler wiring diagram.

Burner wiring:

Thermostat wiring:

19

Connect Wiring

CONTINUED

Limit Control Wiring Harness Circulator Wiring Harness (Not Furnished on A Boilers) Service Switch On Boiler

Burner Wiring Harness

Burner Disconnect Plug

20

Boiler Wiring for Forced Hot Water FIGURE 15

Connect Wiring

CONTINUED

21

Connect Oil Piping

General oil piping requirements:
Location and installation of oil tanks, oil piping and burners must follow: NFPA 31, Standard for the Installation of Oil-Burning Equipment. In Canada, CSA B139, Installation of Oil-Burning Equipment. Local codes and regulations. Information provided with burner and fuel pump. If any part of fuel oil tank is above level of burner, an anti-siphon device must be used to prevent flow of oil in case of oil line break. Support oil lines as required by codes. Make tank connections with swing joints or copper tubing to prevent breaking in case the tank settles. Make swing joints so they will tighten as tank settles. Non-hardening pipe joint compounds should be used on all threads. Do not use Teflon tape as an oil pipe sealant. It can cause valves to fail, creating hazards. Do not use compression fittings. Underground pipe must be run in a casing to prevent oil leaking into ground or under floor. Check local codes for information.

Oil piping connection at burner:

See FIGURE 16 for recommended connection at burner, allowing burner mounting door to swing open completely for servicing.

22

Recommended Oil Piping Connection to Burner FIGURE 16

Start-Up
Follow information below to prevent severe personal injury, death or substantial property damage: Do not use gasoline crankcase drainings or any oil containing gasoline. See burner manual for proper fuel oil. Do not attempt to start burner when excess oil has accumulated, when unit is full of vapor or when combustion chamber is very hot. Do not start burner unless collector hood, flue cap, jacket cap, breeching and burner mounting door are secured in place. Never burn garbage or paper in the boiler. Never leave combustible material around it. When using antifreeze: Do not use automotive, ethylene glycol, undiluted or petroleumbased antifreeze. Severe personal injury, death or substantial property damage can result. Use antifreeze especially made for hydronic systems. Inhibited propylene glycol is recommended. 50% solution provides protection to about -30F. Do not exceed 50% mixture. Local codes may require back-flow preventer or actual disconnect from city water supply. Determine quantity according to system water content. Boiler water content is listed on back cover of manual. Percent of solution will affect sizing of heat distribution units, circulator and expansion tank. Follow antifreeze manufacturers instructions.

Fill the system:

1. Close manual and automatic air vents and boiler drain cock. 2. Fill to correct system pressure. Correct pressure will vary with each installation. Normal cold water fill pressure for residential systems is 12 psig. Boiler water pH 7.0 to 8.5 is recommended. Failure to maintain recommended pH level can cause section failure and leaks. 3. Open automatic air vent one turn. 4. Open other vents. a. Starting on the lowest floor, open air vents one at a time until water squirts out. Close vent. b. Repeat with remaining vents. 5. Refill to correct pressure.

To place in operation:

1. Verify boiler is filled with water. 2. Open burner mounting door and verify rear target wall, floor and burner door insulations are in proper position. 3. Verify burner mounting door is closed tightly and burner wiring harness is connected to junction box. 4. Factory burner adjustment and settings may not be suitable for specific job conditions. See Appendix, page 25. Make final burner adjustments using combustion test equipment to assure proper operation. Do not fire boiler without water. Sections will overheat, damaging boiler and resulting in substantial property damage. 5. Vent air from system. Repeat steps 4 and 5 under Fill the system. Air in system can interfere with water circulation and cause improper heat distribution. 6. Check boiler and system piping for leaks. See Tips for water systems. 7. Inspect breeching and venting for proper operation.

Tips for water systems:

Check boiler and system piping for leaks. Continual makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer and causing cast iron to overheat, resulting in section failure. Failure to maintain recommended pH and repair leaks can cause section iron corrosion, leading to section failure and leaks. Do not use petroleum-based sealing or stop-leak compounds in boiler systems. Damage to system components can result.

For pH conditions outside 7.0 to 8.5 range or unusually hard water areas (above 7 grains hardness), consult local water treatment company.

For additional information, refer to instructions packed with boiler or burner: Burner Manual Maintenance and Service Guide for GOLD Oil Water Boilers

23

Check-Out Procedure
Check off steps as completed:

J J J J J

1. Boiler and heat distribution units filled with water? 2. Automatic air vent, if used, opened one full turn? 3. Air purged from system? Piping checked for leaks? 4. Air purged from oil piping? Piping checked for leaks? 5. Flue cap in place and tightened? Burner door closed, sealed and nut tight? Burner plugged in and service switch on? Obtain gas-tight seal to prevent possible flue gas leakage and carbon monoxide emissions, leading to severe personal injury or death.

8. Test additional field-installed controls: If boiler has a low water cutoff, additional high limit or other controls, test for 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. 9. Limit control set to system temperature requirements (max. 220F)? For multiple zones, flow adjusted to distribute heat in all zones? Thermostat heat anticipator setting (if available) set properly? Refer to Connect wiring, page 19. Boiler cycled with thermostat? Raise to highest setting and verify boiler goes through normal start-up cycle. Lower to lowest setting and verify boiler goes off. Observed several operating cycles for proper operation? Set room thermostat(s) to desired room temperature?

J 10. J 11. J 12.

J J

6. Proper draft and burner flame? Final adjustment made with combustion test equipment? 7. Test limit control: While burner is operating, move indicator on limit control below actual boiler water temperature. Burner should go off while circulator continues to operate. Raise setting on limit control above water temperature and burner should re-ignite.

J 13. J 14. J J

15. Completed Installation and Service Certificate below? 16. Reviewed Maintenance and Service Manual with owner or maintenance person and instructed person to keep for future reference? Returned all instructions provided with boiler to its envelope and placed with boiler for future reference?

J 17.

Installation and Service Certificate

Date Installed: ______________________________________________ Boiler Model Number: __________________Series: _________ CP Number(s):______________________________________________ Measured Btu or GPH Input: _____________________________

J J J J

Installation instructions have been followed. Check-out procedure has been performed. Above information is certified to be correct. Information received and left with owner/ maintenance person.

Installer:__________________________________________________________________________________________________________________________ (Company) (Address) (Phone) _________________________________________________________________ (Installers Signature)

24

Appendix
Burner adjustments for P and A boilers:
Final burner adjustments must be made using combustion test equipment to assure proper operation. Do not fire boiler without water or sections will overheat. 1. Refer to burner manual for start-up. 2. Allow boiler to heat to design condition. 3. Using combustion test equipment, adjust burner for: a. CO2 between 11% and 12% and 0 smoke. b. -0.01" to -0.02" W.C. draft in combustion chamber.

To connect WGO boilers to Weil-McLain PLUS indirect-fired water heaters:

Install and wire per water heater manual provided with water heater.

25

Appendix

CONTINUED

To provide close clearances as described in pages 26 and 27, Close Clearance Kit, W-M Part No. 386-500-050, must be obtained and installed 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.

Close clearance installation:

Substitute these instructions for corresponding material in manual. All other procedures and practices must remain the same. Recommended service and minimum clearances shown on page 4 should be used where possible. Where closer clearances are required: Top of boiler If less than 24" available, provide removable surface to allow for cleaning boiler flueways. Right or left side Minimum 2 inches. Front Minimum 2 inches from burner. Doublewall flue pipe to combustible surface as listed in Table on page 27 and FIGURES 19 through 21. Jacket cap must be in place on boiler to avoid requiring an 18" minimum clearance from back or top of boiler to combustible material. Flue pipe clearances must take precedence over jacket clearances.

1. Install boiler using clearances described at left. 2. Install barometric control 18-20 inches from boiler in breeching. 3. Attach manual reset temperature switch near upper surface of enclosed area. See FIGURE 17. 4. Wire switch in series with thermostat. See FIGURE 18. 5. Provide two combustion/ventilation openings when installing in confined space. Size opening 140 sq. in. (1000 Btu) per 1 GPH input. Locate openings near top and bottom of enclosed space.

Combustible Surface Manual Reset Temperature Switch

1 to 5 inches

#6 x " Phil. Sht. Mtl. Screw

44156

Thermostat #10 x " Phil. Sht. Mtl. Screw Bracket

Manual Reset Temperature Switch

Area Above Boiler

26

Manual Reset Temperature Switch Location FIGURE 17

Manual Reset Temperature Switch Wiring FIGURE 18

Appendix

CONTINUED

PROTECTION REQUIRED FOR CLEARANCES LESS THAN 6 INCHES FROM DOUBLEWALL VENT PIPE*
DIMENSION A When desired minimum clearance from type L doublewall vent pipe to combustible surface is: 3"

Combustible Surface A

Use the following protection**: " thick insulation board * * * over one-inch glass fiber or mineral wool batts+ 24 gauge sheet metal with one-inch ventilated air space " thick insulation board *** with one-inch ventilated air space

Protection

6"

6"

2" 3"

Type L Doublewall Vent Piping

Flue Pipe Clearances FIGURE 19

All clearances measured from outer surface of equipment to combustible surface, not to the protection used. * * Apply to combustible surface unless otherwise noted. Cover all surfaces as specified in Table and FIGURE 19. Thicknesses are minimum. * * * Factory-fabricated board made of non-combustible materials, normally fibers, having thermal conductivity in range of one (Btu-inch)/(hr./sq. ft./F) or less. + Mineral wool batts (blanket or board), having min. density of 8 lb/ft 3 and a min. melting point of 1500F. OTHER DIMENSIONS AVAILABLE. REFER TO NFPA-31.

A 24" For Servicing or Min. 2" for Close Clearances A

A A

Combustible Surface

24" For Servicing or Min. 2" for Close Clearances

Combustible Surface 2" Combustible Surface 2" NOTE: 2" Min. on Sides 2" Combustible Surface

NOTE: 2" Min. on Sides

Back Vent Clearances FIGURE 20

Top Vent Clearances FIGURE 21

27

Parts List
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.
Fig. No. A B B C D E Description Regular Front Section 7012 Wide Intermediate Section (WGO-3) 7010 Regular Intermediate Section 7015 Intermediate Section w/Draw Rod Lugs 7016 Back Section w/7" Flue, Supply & 2" Return 7017 Section Replacement Kit (For 1 Joint, includes Seals, Rope,Adhesive and Collector Hood Hardware) Front or Back Section Section Replacement Kit (For 2 Joints, includes Seals, Rope and Adhesive) Intermediate Section Section Assembly Complete, For WGO-2 Section Assembly Complete, For WGO-3 Section Assembly Complete, For WGO-4 Section Assembly Complete, For WGO-5 Section Assembly Complete, For WGO-6 Section Assembly Complete, For WGO-7 Section Assembly Complete, For WGO-8 Section Assembly Complete, For WGO-9 Collector Hood Kit For WGO-2* Collector Hood Kit For WGO-3* Collector Hood Kit For WGO-4* Collector Hood Kit For WGO-5* Collector Hood Kit For WGO-6* Collector Hood Kit For WGO-7* Collector Hood Kit For WGO-8* Collector Hood Kit For WGO-9* Tie Rod 1/ 2 x 51/2 (WGO-7, 8, 9) Tie Rod 1/ 2 x 103/4 (WGO-2 & 7) Tie Rod 1/ 2 x 12 (WGO-7) Tie Rod 1/ 2 x 14 (WGO-3, 4, 8, 9) Tie Rod 1/ 2 x 15 (WGO-9) Tie Rod 1/ 2 x 17 (WGO-5) Tie Rod 1/ 2 x 20 (WGO-6) Tie Rod 1/ 2 x 231/4 (WGO-7) Tie Rod 1/ 2 x 263/8 (WGO-8) Tie Rod 1/ 2 x 291/2 (WGO-9) Combustion Chamber Kit (Rear & Frt. Ref., Door Ref. Blanket, Rope, Blanket & Water Glass) Burner Mounting Door Assembly (Door, Obs. Port, Rope, Ins. & Pins) Burner Mounting Door 7070 Door Hinge 7054 Door Refractory Door Refractory Blanket Observation Port Shutter Door Seal Rope 5' 3 /8" Glass Rope For Collector Hood (7' For Largest Size Hood) Flue Cap Assembly (Cap, Strap, Rope & Screws) Flue Brush 123D W-M Sales Part Number 316-700-250 316-700-075 316-700-065 316-700-070 316-700-265 386-700-852 386-700-851 386-700-650 386-700-651 386-700-652 386-700-653 386-700-654 386-700-655 386-700-656 386-700-657 386-700-336 386-700-337 386-700-337 386-700-338 386-700-339 450-020-170 450-020-172 450-020-160 560-234-464 560-234-491 560-234-492 560-234-470 560-234-495 560-234-472 560-234-534 560-234-538 560-234-542 560-234-497 386-700-355 386-700-358 330-054-302 330-054-300 386-700-359 591-222-115 460-039-867 590-735-105 590-735-109 386-700-344 591-706-214

F F F F F F F F G G G G G G G G G G H J K L M N P Q R

* Includes flue cap assembly, rope and hardware for installation.

28

Parts Drawing

D F E Q

B A

K G H H H

J N

G C L M P

29

Dimensions
20 1/4 [514.4]
[196.9]

7 3/4

5 1/16 [128.6] 29/ 16 [65.1] Supply Air Vent or Expansion Tank

DIMENSIONS - in.
BOILER MODEL NUMBER WGO-2 WGO-3 WGO-4 WGO-5 WGO-6 WGO-7 WGO-8 WGO-9

B 101/2 131/2 13 /8
5

L 133 /4 167 /8 16 /8
7

35 5/8
[904.9]

43/8 DIA [111.1] Burner Opening

167 /8 20 231/8 261/4 293 /8

20 231/8 261/4 29 38 321 /2

Return

91/2 [241.3] 2 7/16 2 7/16 [61.9]

[61.9]

11 /8 [28.6]

WGO Front

DIMENSIONS - mm.
BOILER MODEL NUMBER WGO-2 WGO-3 WGO-4 WGO-5 WGO-6 WGO-7 WGO-8 WGO-9

73/1 6
[182.6]

25/8
[66.7]

B 266.7 342.9 345.9 428.7 508 587.2 666.7 746.2

L 349.2 428.7 428.7 508.0 587.2 666.7 746.2 825.5

[177.8]

7 DIA

B 151/2
[393.7]

14 Approx.

WGO Side with Burner

30

Dimensions

CONTINUED

Intermediate

7 DIA.
[177.8]

61 /4
[158.8]

For 7 DIA. [177.8]

Vent Pipe

Alternate Return (A Boilers Only)

29 9/16
[750.9]

Back

31

Ratings

WGO GOLD OIL WATER BOILER RATINGS (1)

I=B=R BURNER CAPACITY GPH (3) 0.70 0.95 1.20 1.45 1.75 2.00 2.30 2.55 NET I=B=R RATINGS (5) 75 100 126 152 184 210 231 257 DOE SEASONAL EFFICIENCY % AFUE 86.4 85.3 85.0 85.0 85.0 85.0 MINIMUM I=B=R CHIMNEY
RECT IN

BOILER MODEL NUMBER *-WGO-2 *-WGO-3 *-WGO-4 *-WGO-5 *-WGO-6 ** -WGO-7 ** -WGO-8 ** -WGO-9

DOE HEATING CAPACITY (4) MBH (2) 86 115 145 175 212 242 266 (6) 295 (6)

ROUND DRAFT FLUE BOILER LOSS OUTLET WATER THRU ROUND HEIGHT SIZE CONTENT BOILER IN FT IN (7) GAL IN W.C. (8) 6 6 6 7 7 8 8 8 15 15 15 15 15 15 20 20 7 7 7 7 7 7 7 7 11.0 14.9 13.4 15.9 18.4 20.8 23.3 25.8 .010 .020 .010 .015 .015 .015 .025 .030

8x8 8x8 8x8 8x8 8x8 8x8 8 x 12 8 x 12

* ** (1) (2) (3) (4) (5)

Substitute P for completely assembled packaged boiler without burner (WGO-2 through WGO-6 only). Substitute A for boiler only for use with approved burners as listed with I-B=R. Available only as an A unit. WGO boiler designed with convertible vertical and horizontal flue outlet. MBH refers to thousands of Btu per hour. Based on 140,000 Btu/gal. Based on standard test procedures prescribed by the United States Department of Energy at combustion condition of 13.5% CO 2 and -0.02" W.C. draft overfire. Net I=B=R 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. 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.

(6) (7) (8)

I=B=R gross output See page 12 for minimum breeching diameter. Listed draft losses are for factory-shipped settings.