Weil McLain Boiler SGO W SERIES 3 OIL FIRED NATURAL DRAFT WATER BOILER User Manual

SGO-W  
SERIES 3 OIL-FIRED NATURAL DRAFT WATER BOILER  
This Manual  
Includes:  
Installation  
Start-Up  
Boiler Parts  
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. 550-141-827/1201  
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 Non-Packaged Boiler . . . . . . . . . . . . . . . . . . . . . . . .6-9  
Connect Breeching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11  
Connect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-16  
Connect Tankless Heater Piping . . . . . . . . . . . . . . . . . . . .16-17  
ConnectWiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19  
Connect Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20  
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21  
Check-Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .22  
Installation and Service Certificate . . . . . . . . . . . . . . . . . .22  
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23  
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24  
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25  
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-27  
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover  
3
Before Installing Boiler  
Installations must comply with:  
Provide clearances around boiler  
(see FIGURE 1):  
U.S.  
— State and local plumbing, heating and  
electrical codes.  
Jacket cap must be in place on  
— National codes where applicable.  
Canada  
boiler to avoid requiring an 18"  
minimum clearance from back or top of boiler to  
combustible material.  
— Canadian Standards Association, CSA B139,  
Installation Code for Oil-Burning Equipment.  
— CSA C22.1 Canadian Electrical Code Part One.  
— Applicable local or provincial codes.  
Minimum clearances from vent pipe to  
combustible material:  
6 inches — Type “L” doublewall vent*  
18 inches — Singlewall vent*  
Before selecting boiler location:  
Check for nearby connections to:  
— System water piping.  
Flue pipe clearances must take  
precedence over jacket clearances.  
— Chimney. See pages 10-11. Boiler can be top or  
back vented.  
— Combustion and ventilation air supply.  
See page 5.  
— Oil supply. See page 20 for oil line routing.  
— Electrical power.  
Recommended service clearances:  
24 inches — Front and top  
6 inches — Left side**, back and right side  
15 inches — Left side with tankless heater**  
12 inches — Right side for burner door  
swing radius ∆  
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.  
Ceiling  
*
*
6"  
6"  
(18")  
(18")  
24"  
Walls  
6" (12") ∆  
*
6"  
(18")  
6"  
24"  
Wall  
6" (15")**  
TopView  
Floor  
Left Side  
Recommended Service Clearances  
FIGURE 1  
4
Before Installing Boiler  
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 manufacturer’s  
instructions for details. If unknown, use:  
— Wood louvers, which provide 20-25% free air.  
— Metal louvers or grilles, which provide  
60-75% free air.  
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.  
Lock louvers in open position or interlock with  
equipment to prove open before boiler operation.  
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.  
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.  
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.):  
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.  
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.  
BOILER FOUNDATION SIZE TABLE  
MIN.  
BOILER  
MODEL  
LENGTH  
INCHES  
WIDTH  
INCHES  
HEIGHT  
INCHES  
When inside air is used — each opening must  
freely connect with areas having adequate  
SGO-3W  
SGO-4W  
SGO-5W  
SGO-6W  
SGO-7W  
SGO-8W  
SGO-9W  
17  
20  
23  
26  
29  
32  
35  
22  
22  
22  
22  
22  
22  
22  
2
2
2
2
2
2
2
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 any equipment that can pull  
air from room (including clothes dryer  
and fireplace).  
5
Install Non-Packaged Boiler  
3) Loosen two screws on back flue outlet. Set  
Fiberglass wool and ceramic fiber materials:  
flue cap on outlet. Install strap by  
engaging slots in screws. Tighten screws.  
Make sure cap is securely installed.  
• POSSIBLE CANCER HAZARD  
BY INHALATION  
• CAN CAUSE RESPIRATORY,  
2. A-SGO-7, 8 & 9W— split the assembled block  
for easier handling (see FIGURE 2):  
a. Open burner mounting door and,  
using utility knife, slit floor insulation at  
joint to be separated.  
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, base insulation) materials. Ceramic fibers can  
be converted to chrystobalites, a substance listed as a  
probable cause of cancer.  
b. Remove 5½" draw rod and the longest draw  
rod from each side. Pull block apart. Save  
draw rods, nuts, washers and sealing rings  
for reassembly.  
c. Move divided block to location.  
d. Clean port openings with clean rag.  
Suppliers of fiberglass wool products recommend  
the following precautions be taken when handling  
these materials:  
Do not use petroleum-based  
compounds to clean  
openings. Damage to system components  
can result, causing property damage.  
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.  
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 5½"  
rod at large port, 5½" rod at small port,  
bottom long rod and finally top long rod.  
i. Torque on both 5½" 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.  
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.  
Place boiler:  
1. A-SGO-3 through 6W — 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 2):  
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.  
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.  
(Read  
under Step #3 on  
page 7.)  
6
Install Non-Packaged Boiler  
CONTINUED  
3. A-SGO-7, 8 & 9W — install flue collector hood  
Tankless heater, if used:  
1. SGO-3 through 6W — remove knockout in left  
side jacket panel.  
(see FIGURE 2):  
Obtain gas-tight seal to prevent  
possible flue gas leakage and  
carbon monoxide emissions, leading to severe  
personal injury or death.  
2. Remove tankless heater cover plate and gasket.  
3. Install new gasket and tankless heater over  
3
studs around opening. Secure with /8" nuts.  
Perform hydrostatic pressure test:  
1. See FIGURE 3 and Control Tapping Table on  
page 8 to install:  
a. Thread tinnerman clip on screw so that clip  
fits snugly in notch of hold-down lug. Screw  
must not turn.  
a. Boiler drain.  
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 2.  
b. Water pressure gauge (test only). Be sure  
gauge can handle test pressure.  
c. Air vent in upper tapping.  
d. Plugs in remaining tappings.  
2. Fill boiler. Vent all air. Pressure test boiler at  
1
1 ¼  
2
times working pressure. For boilers split  
and reassembled, test between 75 and 85 psig.  
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.  
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.  
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. Drain boiler. Repair leaks if found.  
Do not use petroleum-based  
compounds to repair leaks.  
Damage to system components can result,  
causing property damage.  
4. Check level. Shim legs, if needed.  
5. Re-test boiler after repairing leaks.  
6. Remove pressure gauge, air vent and plugs  
from tappings used for controls.  
7. Visually check:  
Nut  
Washer  
a. Sealing rope placement.  
b. Metal-to-metal contact around port openings.  
c. Flue collector hood seal.  
d. Burner mounting door seal.  
Flue Collector  
Hood  
Sealing Rope in  
Groove Inside Cap  
Sealing Rope with  
Adhesive Tape  
Obtain gas-tight seal to prevent  
possible flue gas leakage and  
carbon monoxide emissions, which can lead to  
severe personal injury or death.  
Flue  
Cap  
Strap  
Flue  
Cap  
Tinnerman Clip  
Screw  
Change from Back Flue Outlet to Top Flue Outlet (Optional)  
FIGURE 2  
7
Install Non-Packaged Boiler  
CONTINUED  
Install jacket (sizes 7 through 9 only):  
CONTROLTAPPINGTABLE  
Before installing jacket, remove burner mounting  
door. See jacket instructions for details.  
TAPPING  
SIZE  
FUNCTION  
Supply Piping  
A1  
A2  
A3  
B1  
B2  
E1  
E2  
H
1½"  
2½"  
2½"  
1½"  
2"  
Install boiler controls:  
See Control Tapping Table and FIGURES 3 and 4  
to install controls.  
1. Install tankless heater control if tankless  
heater is used. If not furnished, use operating  
control with maximum 10°F differential.  
2. Install limit control. If not furnished, use high  
limit with maximum 220°F setting.  
Air Vent or Expansion Tank Piping  
Plugged  
Return Piping  
Plugged  
½"  
½"  
¾"  
¾"  
¾"  
¾"  
½"  
1"  
Pressure-Temperature Gauge  
Plugged  
3. Affix CP number label(s) on jacket front panel.  
DrainValve  
L
High Limit Control  
Plugged  
P
R
ReliefValve  
S1 & S2  
U1  
U2  
Plugged  
Plugged  
¾"  
Plugged  
Operating Control for Tankless  
U3  
¾"  
Heater  
(located in heater plate)  
A1  
A2  
A3  
R
S1  
L
E1  
E2  
U1  
P
U3  
S2  
U2  
B2  
B1  
H
Front Section  
Back Section  
Control Tapping Location  
FIGURE 3  
8
Install Non-Packaged Boiler  
CONTINUED  
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 A-SGO-W boiler:  
position. End of air tube should be flush to ¼"  
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.  
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  
1½° tilt downward. Open door to verify burner  
Circulator  
Water  
Pressure  
Gauge  
Limit  
Control  
Tankless  
Heater  
Control  
Drain  
Valve  
Water Boiler Controls  
FIGURE 4  
9
Connect Breeching  
General chimney requirements:  
MINIMUM CHIMNEY SIZE TABLE  
Designed for natural draft firing. Connect  
boiler to vertical chimney.  
***  
MINIMUM  
I=B=R  
CHIMNEY SIZE  
BOILER  
MODEL  
NUMBER  
MINIMUM  
BREECHING  
DIAMETER  
MINIMUM  
CHIMNEY  
HEIGHT  
Insufficient draft can cause flue  
gas leakage and carbon  
monoxide emissions, which will lead to severe  
personal injury or death.  
RECT. ROUND  
SGO-3W  
SGO-4W  
5"  
6"  
8" x 8"  
*
6"  
15'  
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.  
SGO-5W  
SGO-6W  
SGO-7W  
6"  
7"  
8" x 8"  
*
7"  
7"  
15'  
20'  
SGO-8W  
SGO-9W  
7"  
8" x 12"  
**  
NFPA 211 requires chimney to be lined before  
connected to boiler.  
*
6¾" x 6¾" inside liner  
** 6½" x 10½" inside liner  
*** Flue collar on boiler is 7" diameter  
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.  
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 5.  
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.  
— Top outlet — see FIGURE 6.  
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 manufacturer’s  
instructions, when excess draft needs to be  
relieved or to comply with applicable codes  
and regulations. Use draft gauge to adjust  
proper opening.  
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.  
5. An induced draft fan for the chimney may be  
necessary if:  
Connect breeching:  
— 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.  
Long horizontal breechings,  
excessive number of tees and  
elbows or other obstructions restricting  
combustion gas flow can result in possibility of  
10  
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 5  
Typical Location for  
Barometric Control  
(Also see Control  
cturer’s  
ctions)  
Flue Pipe Bracket  
(One on Each Side of Pipe)  
Top Outlet Breeching Connection  
FIGURE 6  
11  
Connect Water Piping  
General piping information:  
DIAPHRAGM expansion tank (FIGURE 7):  
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 20°F above set  
point of combination control. Maximum  
allowable set point is 220°F. Wire control as  
shown on wiring diagram.  
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 manufacturer’s 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.  
Use a low water cutoff device when:  
— Boiler is installed above radiation level.  
— Required by certain state or local codes or  
insurance companies.  
Install automatic air vent in “A2” tapping as  
shown in FIGURE 7.  
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.  
“A2” or “A3” tapping not recommended for  
system supply piping. If “A2” or “A3” tapping  
must be used, adequate air elimination method  
must be provided.  
CLOSED expansion tank (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.  
Install piping:  
Connect tank from “A2” tapping shown in  
FIGURE 8 to expansion tank. Use ¼2" N.P.T.  
piping. Pitch any horizontal piping up towards  
tank 1 inch per 5 feet of piping.  
1
See FIGURE 7 or 8 on page 13 and Water  
Piping Size Table at right for near-boiler piping  
and single-zone piping. See page 14 to complete  
multiple-zone piping or page 15 to complete  
piping for systems operating below 140°F.  
WATER PIPING SIZE TABLE*  
BOILER  
For multiple-boiler piping, refer to Weil-McLain’s  
“Primary/Secondary Piping Guide."  
MODEL  
TO  
FROM  
NUMBER  
SYSTEM  
SYSTEM  
Install relief valve vertically in “R” tapping  
on back of boiler. See FIGURE 7 or 8 and also  
refer to tag attached to relief valve for  
manufacturer’s instructions.  
SGO-3W  
SGO-4W  
SGO-5W  
SGO-6W  
SGO-7W  
SGO-8W  
SGO-9W  
1¼"  
1¼"  
1½"  
1½"  
1½"  
2"  
1¼"  
1¼"  
1½"  
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.  
11¼  
2
"
1½"  
2"  
2"  
2"  
*
All piping sizes based on 20°F temperature rise through boiler.  
12  
Connect Water Piping  
CONTINUED  
IsolationValve  
Automatic  
Air Vent  
Cold Water Fill  
ReliefValve  
Alternate Location  
To Diaphragm  
Expansion Tank and  
Fittings  
IsolationValve  
Pump  
From  
System  
IsolationValve  
To Diaphragm  
Expansion Tank  
and Fittings  
Piping with DIAPHRAGM Expansion Tank  
FIGURE 7  
ClosedType  
ExpansionTank  
Cold Water Fill  
To  
System  
Relief Valve  
IsolationValve  
Pump  
From  
System  
IsolationValve  
Piping with CLOSED Expansion Tank  
FIGURE 8  
13  
Connect Water Piping  
CONTINUED  
Piping MULTIPLE ZONES:  
1. Follow instructions on page 12 and 13 to install piping near boiler.  
2. See FIGURE 9 or 10 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 2  
ZONE 1  
ZONE 1  
1
1
1
1
4
2
3
2
1
5
1
5
1
1
5
5
Multiple Zoning With CIRCULATORS  
FIGURE 9  
Multiple Zoning With ZONE VALVES  
FIGURE 10  
14  
Connect Water Piping  
CONTINUED  
Recommended 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 11 or 12. 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 these valves so that:  
- the temperature at gauge 8 is at least 140°F  
- the temperature at gauge 9 is at least 160°F  
8
9
Blend temperature gauge  
Boiler temperature gauge  
Piping with CIRCULATORS  
Piping with ZONE VALVES  
FIGURE 12  
FIGURE 11  
15  
Connect Water Piping  
CONTINUED  
Use with refrigeration systems:  
Install boiler so that chilled medium is piped in  
Supply  
parallel with heating boiler. Use appropriate valves  
to prevent chilled medium from entering boiler.  
Consult I=B=R Installation and Piping Guides.  
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.  
Exp.Tank  
1
1
Circ.  
Chiller  
Circ.  
Strainer  
Exp.Tank  
1
1
2
1
Isolation Valve  
BalancingValve  
2
Use with Refrigeration System  
FIGURE 13  
ConnectTankless Heater Piping  
Hot Water Can Scald!  
Children, elderly, infirm or physically  
handicapped persons are more likely to be  
injured by hot water. Never leave them  
unattended in or near a bathtub, shower or  
sink. Never allow small children to use a hot  
water faucet or draw their own bath. If anyone  
using hot water in the building fits this  
description, or if state laws or local codes  
require certain water temperatures at hot  
water faucets, take special precautions:  
— Install automatic mixing valve set according  
to those standards.  
Consumer Product Safety Commission and  
some states recommend domestic hot water  
temperature of 130°F or less.  
When installing an automatic mixing valve,  
selection and installation must comply with valve  
manufacturer’s recommendations and instructions.  
Water heated to a temperature suitable for  
clothes washing, dish washing and other  
sanitizing needs will scald and cause injury.  
— Use lowest practical temperature setting.  
— Check water temperature immediately after  
first heating cycle and after any adjustment.  
16  
ConnectTankless Heater Piping  
CONTINUED  
Studies have indicated that  
dangerous bacteria can form in  
TANKLESS HEATER RATINGS TABLE  
potable water distribution system if certain minimum  
water temperatures are not maintained. Contact local  
health department for more information.  
BOILER  
MODEL  
NUMBER NUMBER  
INTERMITTENT  
DRAW RATINGS  
(GPM)*  
INLET  
AND OUTLET  
TAPPING SIZES  
HEATER  
To pipe tankless heater:  
SGO-3W  
SGO-4W  
SGO-5W  
SGO-6W  
SGO-7W  
SGO-8W  
SGO-9W  
35-S-29  
35-S-29  
35-S-29  
35-S-29  
35-S-29  
35-S-29  
35-S-29  
3.50  
3.75  
4.00  
4.00  
4.00  
4.00  
4.00  
¾"  
¾"  
¾"  
¾"  
¾"  
¾"  
¾ "  
1. Size piping no smaller than tankless heater  
inlet and outlet.  
2. Following controls (furnished by others) must  
be installed:  
a. Automatic mixing valve. See FIGURE 14.  
(Read  
at bottom of p. 16)  
b. Flow regulating valve. Size according to  
intermittent draw of tankless heater. See  
Table at right. Follow valve manufacturer’s  
instructions to install.  
*
Gallons of water per minute heated from 40°F to 140°F with  
200°F boiler water temperature. Tested in accordance with  
I=W=H Testing and Rating Standard for Indirect Tankless Water  
Heaters Tested with Boilers.  
3. Additional anti-scald devices may be installed at  
each hot water faucet, bath and shower outlet.  
4. In hard water areas, soften cold domestic supply  
water to heaters to prevent lime build-up.  
Tankless Heater  
Control  
These single wall heat exchangers  
comply with National Standard  
Plumbing Code provided that:  
Flow  
Regulating  
Valve  
Boiler water (including  
additives) is practically non-  
toxic, having a toxicity rating  
or class of 1, as listed in  
Clinical Toxicology of  
Cold  
Water  
Supply  
Commercial Products.  
Boiler water pressure is  
limited to max. 30 psig by  
approved water relief valve.  
12" Min.  
Automatic  
Mixing  
Valve  
Tankless Heater Piping  
FIGURE 14  
17  
Connect Wiring  
General wiring requirements:  
Junction box (furnished):  
Junction box houses electrical connections for  
all boiler components.  
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.  
“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.  
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.  
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.  
Wiring must be N.E.C. Class 1. If original wire  
as supplied with boiler must be replaced, type  
105°C wire or equivalent must be used. Supply  
wiring to boiler and additional control wiring  
must be 14 ga. or heavier.  
Burner wiring:  
Burner harness incorporates a disconnect  
plug, providing a convenient way to disconnect  
wiring when burner mounting door is opened.  
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.  
Provide electrical ground at boiler as required  
by codes.  
Thermostat wiring:  
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.  
Circulator Wiring Harness  
(Not Furnished on A Boilers)  
Tankless Heater Control  
Wiring Harness  
(Furnished as part of tankless  
heater kit as additional  
equipment from W-M)  
Limit Wiring Harness  
Burner Wiring Harness  
Burner Disconnect Plug  
Boiler Wiring for Forced Hot Water  
FIGURE 15  
18  
Connect Wiring  
CONTINUED  
19  
Connect Oil Piping  
Do not use Teflon tape as an  
General oil piping requirements:  
oil pipe sealant. It can cause  
valves to fail, creating hazards. Do not use  
compression fittings.  
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.  
Underground pipe must be run in a casing to  
prevent oil leaking into ground or under floor.  
Check local codes for information.  
— Local codes and regulations.  
— Information provided with burner and  
fuel pump.  
Oil piping connection at burner:  
See FIGURE 16 for recommended connection at  
burner, allowing burner mounting door to swing  
open completely for servicing.  
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.  
Recommended Oil Piping Connection to Burner  
FIGURE 16  
20  
Start-Up  
Follow information below to prevent  
severe personal injury, death or  
substantial property damage:  
When using antifreeze:  
Do not use automotive, ethylene  
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.  
glycol, undiluted or petroleum-  
based 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 -30°F. 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.  
Never burn garbage or paper in the boiler.  
Never leave combustible material around it.  
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.  
— Follow antifreeze manufacturer’s instructions.  
To place in operation:  
1. Verify boiler is filled with water.  
Failure to maintain  
recommended pH level can  
cause section failure and leaks.  
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. For “A”  
boilers, see Appendix, page 23.  
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.  
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.  
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.  
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.  
Failure to maintain recommended  
pH and repair leaks can cause  
6. Check boiler and system piping for leaks. See  
“Tips for water systems.”  
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.  
7. Inspect breeching and venting for  
proper operation.  
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  
21  
Check-Out Procedure  
Check off steps as completed:  
J 1. Boiler and heat distribution units filled with water?  
J 9. Limit control set to system temperature  
requirements (max. 220°F)?  
J 2. Automatic air vent, if used, opened one full turn?  
J 10. For multiple zones, flow adjusted to  
J 3. Air purged from system? Piping checked for leaks  
distribute heat in all zones?  
(including tankless heater, if used)?  
J 11. Thermostat heat anticipator setting  
(if available) set properly? Refer to “Connect  
wiring,” page 18.  
J 4. Air purged from oil piping? Piping checked  
for leaks?  
J 5. Flue cap in place and tightened? Burner  
door closed, sealed and nut tight? Burner  
plugged in and service switch on?  
J 12. 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.  
Obtain gas-tight seal to  
prevent possible flue gas  
leakage and carbon monoxide emissions,  
leading to severe personal injury or death.  
J 13. Observed several operating cycles for  
proper operation?  
J 14. Set room thermostat(s) to desired  
room temperature?  
J 6. Proper draft and burner flame? Final adjustment  
made with combustion test equipment?  
J 15. Completed Installation and Service  
Certificate below?  
J 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 16. Reviewed Maintenance and Service  
Manual with owner or maintenance  
person and instructed person to keep for  
future reference?  
J 17. Returned all instructions provided with  
boiler to its envelope and placed with boiler  
for future reference?  
J 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.  
Installation and Service Certificate  
Date Installed: ______________________________________________  
Boiler Model Number: __________________ Series: _________  
CP Number(s):______________________________________________  
Measured Btu or GPH Input: _____________________________  
J Installation instructions have been followed.  
J Check-out procedure has been performed.  
J Above information is certified to be correct.  
J Information received and left with owner/  
maintenance person.  
Installer:__________________________________________________________________________________________________________________________  
(Company) (Address) (Phone)  
_________________________________________________________________  
22  
(Installer’s Signature)  
Appendix  
Burner adjustments for “A” boilers:  
To connect SGO-W boilers to Weil-McLain  
PLUS indirect-fired water heaters:  
Install and wire per water heater manual provided  
with water heater.  
Final burner adjustments must be  
made using combustion test  
equipment to assure proper operation. Do not fire  
boiler without water or sections will overheat.  
If boiler already has a tankless heater installed:  
Remove tankless heater and install cover plate  
OR  
Leave tankless heater installed. Drain coil and  
remove piping. Do not plug holes in tankless  
heater front plate.  
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.  
23  
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
C
W-M Sales  
Description  
Wide Front Section (7011)  
Regular Intermediate Section (7015)  
Part Number  
316-700-245  
316-700-065  
316-700-070  
316-700-265  
386-700-852  
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 SGO-3W  
Section Assembly Complete, For SGO-4W  
Section Assembly Complete, For SGO-5W  
Section Assembly Complete, For SGO-6W  
Section Assembly Complete, For SGO-7W  
Section Assembly Complete, For SGO-8W  
Section Assembly Complete, For SGO-9W  
Collector Hood Kit For SGO-3W*  
D
E
386-700-851  
386-700-665  
386-700-666  
386-700-667  
386-700-668  
386-700-669  
386-700-670  
386-700-671  
386-700-340  
386-700-341  
386-700-342  
386-700-343  
450-020-182  
450-020-184  
450-020-186  
560-234-464  
560-234-491  
560-234-493  
560-234-494  
560-234-470  
560-234-495  
560-234-532  
560-234-496  
560-234-475  
560-234-536  
560-234-540  
560-234-544  
560-234-546  
389-900-103  
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  
F
F
F
F
F
F
F
G
G
G
G
G
G
G
G
G
G
G
G
G
H
J
Collector Hood Kit For SGO-4W*  
Collector Hood Kit For SGO-5W*  
Collector Hood Kit For SGO-6W*  
Collector Hood Kit For SGO-7W*  
Collector Hood Kit For SGO-8W*  
Collector Hood Kit For SGO-9W*  
1
1
Tie Rod /2 x 5 /2 (SGO-7, 8, 9W)  
1
3
Tie Rod /2 x 10/4 (SGO-2 & 7W)  
1
1
Tie Rod /2 x 12/4 (SGO-3W)  
1
3
Tie Rod /2 x 13/8 (SGO-7 & 8W)  
1
Tie Rod /2 x 14 (SGO-8 &9W)  
1
Tie Rod /2 x 15 (SGO-9W)  
1
3
Tie Rod /2 x 15/8 (SGO-4W)  
1
1
Tie Rod /2 x 16/2 (SGO-9W)  
1
1
Tie Rod /2 x 18/2 (SGO-5W)  
1
5
Tie Rod /2 x 21/8 (SGO-6W)  
1
3
Tie Rod /2 x 24/4 (SGO-7W)  
1
Tie Rod /2 x 28 (SGO-8W)  
1
Tie Rod /2 x 31 (SGO-9W)  
Heater Cover Plate Carton (Cover Plate, Gasket, Studs & Nuts)  
Combustion Chamber Kit (Rear & Frt. Ref., Door Refractory Blanket, Rope, Blanket & Water Glass)  
Burner Mounting Door Assembly (Door, Obs. Port, Rope, Ins. & Pins)  
Burner Mounting Door (7070)  
Door Hinge (7054)  
Door Refractory  
K
L
M
N
P
Door Refractory Blanket  
Observation Port Shutter  
Door Seal Rope 5'  
Q
3
R
S
/
8" Glass Rope For Collector Hood (7' For Largest Size Hood)  
Flue Cap Assembly (Cap, Strap, Rope & Screws)  
Flue Brush (123D)  
386-700-344  
591-706-214  
*
Includes flue cap assembly, rope and hardware for installation.  
24  
Parts Drawing  
S
D
F
E
R
G
B
A
J
L
J
J
M
J
G
K
G
C
P
N
Q
H
25  
Dimensions  
201/4 [514.4]  
73/4 [196.9]  
DIMENSIONS - in.  
BOILER  
MODEL  
Water Supply  
Piping  
NUMBER  
B
L
101/4  
131/2  
167/8  
[260.4]  
SGO-3W  
SGO-4W  
SGO-5W  
SGO-6W  
SGO-7W  
SGO-8W  
SGO-9W  
165/8  
197/8  
23  
20  
355/8  
[904.88]  
231/8  
261/4  
43/8 DIA [111.1]  
Burner Opening  
301/16  
[763.6]  
Return  
261/8  
291/4  
323/8  
29 /8  
3
91/2 [241.3]  
321/2  
355/8  
27/16  
[61.9]  
27/16  
11/8  
[28.6]  
[61.9]  
SGO-W Front  
73/16  
[182.6]  
DIMENSIONS - mm.  
BOILER  
MODEL  
7 DIA  
[177.8]  
NUMBER  
B
L
SGO-3W  
SGO-4W  
SGO-5W  
SGO-6W  
SGO-7W  
SGO-8W  
SGO-9W  
342.9  
428.7  
422.1  
504.9  
584.2  
663.4  
742.9  
822.4  
508.0  
587.2  
666.7  
746.2  
825.5  
904.7  
Heater  
Location  
B
151/2  
[393.7]  
L
14 Approx.  
SGO-W Side with Burner  
26  
Dimensions  
CONTINUED  
Intermediate  
7 DIA  
[177.8]  
61/4  
[158.8]  
7 DIA  
[177.8]  
R
299/16  
[750.9]  
Back  
27  
Ratings  
SGO-W GOLD OIL WATER BOILER RATINGS (1)  
ROUND  
FLUE  
OUTLET  
SIZE CONTENT BOILER  
IN (7)  
DRAFT  
LOSS  
THRU  
I=B=R  
BURNER  
CAPACITY  
GPH (3)  
NET  
I=B=R  
RATINGS  
(5)  
DOE  
SEASONAL  
EFFICIENCY %  
AFUE  
MINIMUM  
I=B=R CHIMNEY  
BOILER  
WATER  
BOILER  
MODEL  
NUMBER  
DOE HEATING  
CAPACITY (4)  
MBH (2)  
RECT  
ROUND HEIGHT  
IN  
IN  
FT  
GAL  
IN W.C. (8)  
* * -SGO-3W  
**-SGO-4W  
**-SGO-5W  
**-SGO-6W  
**-SGO-7W  
**-SGO-8W  
**-SGO-9W  
0.95  
1.20  
1.45  
1.75  
2.00  
2.30  
2.55  
115  
100  
126  
152  
184  
210  
231  
257  
85.3  
85.0  
85.0  
85.0  
85.0  
8 x 8  
8 x 8  
8 x 8  
8 x 8  
8 x 8  
8 x 12  
8 x 12  
6
6
7
7
8
8
8
15  
15  
15  
15  
15  
20  
20  
7
7
7
7
7
7
7
14.6  
16.3  
18.8  
21.2  
23.7  
26.2  
28.6  
.020  
.010  
.015  
.015  
.015  
.025  
.030  
145  
175  
212  
242  
266 (6)  
295 (6)  
** Available only as an “A” unit. “A” boiler only for use with approved burners as listed with I=B=R.  
(1) SGO-W boiler designed with convertible vertical and horizontal flue outlet.  
(2) MBH refers to thousands of Btu per hour.  
(3) Based on 140,000 Btu/gal.  
(4) Based on standard test procedures prescribed by the United States Department of Energy at combustion condition of 13.5% CO2 and -0.02" W.C. draft  
overfire.  
(5) 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) I=B=R gross output.  
(7) See page 10 for minimum breeching diameter.  
(8) Listed draft losses are for factory-shipped settings.  

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