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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 servi
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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 inju
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Before Installing Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 Install Packaged Boiler . . .
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Before Installing Boiler Installations must comply with: Provide clearances around boiler • U.S. (see FIGURE 1): — State and local plumbing, heating and electrical codes. Jacket cap must be in place on — National codes where applicable. boiler to avoid requiring an 18" • Canada minimum clearance from back or top of boiler to — Canadian Standards Association, combustible material. CSA B139, Installation Code for Oil-Burning Equipment. • Minimum clearances from vent pipe to — CSA C22.1 Canadian
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Before Installing Boiler CONTINUED • Through horizontal ducts — at least 70 sq. in. per Provide air for combustion and ventilation: 1 GPH boiler input (1 sq. in. per 2000 Btu input) of all fuel-burning appliances plus requirements for Adequate combustion and any equipment that can pull air from room ventilation air: (including clothes dryer and fireplace). • Assures proper combustion. • Where ducts are used, they should have same • Reduces risk of severe personal injury or death cross-sectional
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Install Packaged Boiler Place boiler: Perform hydrostatic pressure test: 1. Remove circulator strapped to pallet. 1. Remove relief valve installed in boiler. 2. Install air vent in “N” tapping on top boiler. Circulator will be damaged if 3. Plug supply and return tappings. not removed before boiler is 4. Drain valve is already factory-installed. lifted from pallet. 5. Fill boiler. Vent all air. Pressure test boiler at 1½ times working pressure. 2. Remove boiler from pallet. Do not leave boiler u
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Install Packaged Boiler CONTINUED Change From Back Flue Outlet to Top Flue Outlet (Optional) FIGURE 2 7
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Install Non-Packaged Boiler 3) Loosen two screws on back flue outlet. Fiberglass wool and ceramic fiber materials: Set flue cap on outlet. Install strap by engaging slots in screws. Tighten screws. • POSSIBLE CANCER HAZARD Make sure cap is securely installed. BY INHALATION • CAN CAUSE RESPIRATORY, 2. Non-Packaged WGO-7, 8 & 9 — split the SKIN AND EYE IRRITATION assembled block for easier handling (see This product contains fiberglass wool and ceramic FIGURE 3): fiber materials. Airborne fib
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Install Non-Packaged Boiler CONTINUED 3. Non-Packaged WGO-7, 8 & 9 — install flue d. Install washers and nuts. Tighten nuts collector hood (see FIGURE 3): until collector hood makes contact with tinnerman clip. Obtain gas-tight seal to prevent e. Back flue outlet boiler — Position flue possible flue gas leakage and cap and strap over opening in flue collector carbon monoxide emissions, leading to severe hood. Make sure rope in cap is in place personal injury or death. and in good condition
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Install Packaged and Non-Packaged Boiler 7. Visually check: Perform hydrostatic pressure test: a. Sealing rope placement. 1. See FIGURE 4 and Control Tapping Table b. Metal-to-metal contact around port openings. below to install: c. Flue collector hood seal. a. Boiler drain. d. Burner mounting door seal. b. Water pressure gauge (test only). Be sure gauge can handle test pressure. Obtain gas-tight seal to prevent c. Air vent in upper “N” tapping. possible flue gas leakage and d. Plugs in remaini
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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: from inside wall of burner door refractory. Check 1. Secure universal mounting flange and gasket to for secure placement of insulation on target wall, burner mounting door. Use three bolts provided. chamber fl
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Connect Breeching General chimney requirements: MINIMUM CHIMNEY SIZE TABLE • Designed for natural draft firing. Connect MINIMUM *** boiler to vertical chimney. BOILER MINIMUM I=B=R MINIMUM MODEL BREECHING CHIMNEY SIZE CHIMNEY Insufficient draft can cause flue NUMBER DIAMETER RECT. ROUND HEIGHT gas leakage and carbon WGO-2 5" monoxide emissions, which will lead to severe WGO-3 8" x 8" 6" 15' personal injury or death. WGO-4 6" * WGO-5 6" • Use vent material approved by local codes for WGO-6 8" x
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Connect Breeching CONTINUED Typical Location for Barometric Control (Also see Control Manufacturer’s Instructions) Flue Pipe Bracket (one on each side of pipe) Back Outlet Breeching Connection FIGURE 6 Typical Location for Barometric Control (Also see Control Manufacturer’s Instructions) Flue Pipe Bracket (one on each side of pipe) Top Outlet Breeching Connection FIGURE 7 13
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Connect Water Piping General piping information: DIAPHRAGM expansion tank (FIGURE 8): • If installation is to comply with ASME or • Make sure expansion tank size will handle Canadian requirements, an additional high boiler and system water volume and temperature limit is needed. Install control in temperature. Tank must be located near boiler supply piping between boiler and isolation before inlet to circulator. See tank valve. Set control to a minimum of 20°F above manufacturer’s instructions f
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Connect Water Piping CONTINUED Isolation Circulator Valve Automatic To Air Vent System “C” Tapping From “N” Tapping System Isolation Valve Relief Valve Cold Water Fill To Diaphragm Expansion Tank and Fittings *Circulator “B1” Tapping *Alternate Pump Location Piping with DIAPHRAGM Expansion Tank FIGURE 8 Closed Type Expansion Tank Circulator Cold Water Fill Isolation Valve To System “C” Tapping “N” Tapping From Relief System Valve Isolation Valve *Circulator “B1” Tapping *Alternate Pump Location
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Connect Water Piping CONTINUED Piping MULTIPLE ZONES: 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 v
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Connect Water Piping CONTINUED Piping for systems requiring 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 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 Isolation valve 2 Flow control valve 3 Circulator 4 System temperature gauge 5 Zone valve 6 Drain valve 7 Sys
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Connect Water Piping CONTINUED Use with refrigeration systems: • If boiler is connected to heating coils located in • Install boiler so that chilled medium is piped in air handling units where they can be exposed parallel with heating boiler. Use appropriate valves to refrigerated air, use flow control valves or to prevent chilled medium from entering boiler. other automatic means to prevent gravity Consult I=B=R Installation and Piping Guides. circulation during cooling cycle. 1 Supply Exp. Tan
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Connect Wiring General wiring requirements: Junction box (furnished): • Junction box houses electrical connections for all boiler components. Electric shock hazard. Can cause • “P” boilers have harnesses furnished. severe personal injury or death if • “A” boilers are furnished with burner and limit power source, including service switch on boiler, is harnesses. not disconnected before installing or servicing. • All field-provided high voltage wiring must be sheathed in flexible metal conduit. •
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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 Boiler Wiring for Forced Hot Water FIGURE 15 20
