Weil McLain WGO User Manual

WGO, WTGO and SGO-W  
Series 3 Oil-Fired Water Boilers  
Maintenance  
and Service  
Guide  
Forfuture reference, leavethismanual  
withotherboilerinstructions  
in the envelope provided with the boiler.  
Part No. 550-141-828/1202  
ForYour Safety  
Tips for water systems:  
Follow instructions below to  
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.  
prevent severe personal injury, death or substan-  
tial property damage:  
Do n ot use crankcase drainings or any oil  
containing gasoline. See burner manual for  
proper fuel oil.  
Do n ot attempt to start burner when excess  
Failure to maintain recom-  
oil has accumulated in combustion chamber,  
when unit is full of vapor, or when combus-  
tion chamber is very hot.  
Do n ot start burner unless collector hood, flue  
cap, jacket cap, breeching and burner mount-  
ing door are secured in place.  
Never burn garbage or paper in the boiler.  
Never leave combustible material around  
boiler.  
mended 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,  
causing property damage.  
Boiler water pH 7.0 to 8.5 is recommended.  
For pH conditions outside 7.0 to 8.5 range or  
unusually hard water areas (above 7 grains  
hardness), consult local water treatment  
company.  
DO NOT TAMPER WITH UNIT OR CONTROLS.  
Always follow specific instructions when  
starting up boiler or performing routine  
maintenance or service.  
When using antifreeze:  
-
Use antifreeze especially made for  
hydronic systems. Inhibited propylene  
glycol is recommended.  
Follow instructions below to  
prevent severe personal injury, death or substan-  
tial property damage:  
Do not use automotive,  
ethylene glycol, undiluted or petroleum-  
based antifreeze. Severe personal injury,  
death or substantial property damage can  
result.  
To avoid electric shock, disconnect electrical  
supply to burner service switch and additional  
external switches before performing service.  
To avoid severe burns, allow boiler to cool  
before performing service.  
Do not block flow of combustion or ventilation  
air to boiler.  
Boiler must be connected to a flue with  
sufficient draft at all times to assure proper  
operation.  
Do not use this boiler if any part has been  
under water. Electrical and mechanical  
failures may cause electric shock and fire  
risks. Immediately call a qualified service  
technician to inspect chimney or vent,  
boiler and burner. Have the boiler flueways  
cleaned and have the following replaced:  
— all electrical and mechanical controls  
— electrical wiring  
-
-
50% solution provides protection to about  
-300F.  
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 Boiler Manual.  
Percent of solution will affect sizing of  
heat distribution units, circulator and  
expansion tank.  
-
-
Follow antifreeze manufacturer's instruc-  
tions.  
Do not add cold water to hot boiler. Thermal  
shock can cause sections to crack.  
— oil burner and controls  
— insulation and chamber lining  
3
Routine Maintenance Schedule  
The schedule below is specifically designed for the homeowner.  
Please read pages 2 and 3 before proceeding.  
Beginning each heating season:  
4
Call a qualified service technician to perform  
annual service.  
End of heating season:  
If tankless heater is installed, boiler will  
continue to operate. Check for the following:  
4
Daily during heating season:  
-
-
All daily and weekly instructions listed on  
this page must be followed.  
4
Check that boiler area is free from combusti-  
ble materials, gasoline and other flammable  
vapors and liquids.  
Burner motor may have to be oiled. Some  
motors are permanently lubricated and do  
notneed additional oil. Check for oiling  
instructions on burner or motor.  
Weekly during heating season:  
4
Check for and remove any obstructions to flow  
of combustion or ventilation air to boiler.  
4
Check that breeching is attached between  
boiler and chimney. If breeching is loose or  
damaged, immediately turn off switch on  
boiler and call service technician to repair.  
Boiler shutdown:  
Do not drain boiler unless exposure to  
freezing temperatures will occur.  
Always keep manual fuel supply shut off if  
burner is shut down for an extended period of  
time.  
Check for oil leaks in oil piping and around  
burner. If found, immediately call qualified  
service technician to correct situation.  
4
4
Check for water leaks in boiler and piping;  
also check for leaks around tankless heater  
plate, if installed. If found, immediately call  
service technician to repair.  
a. Turn off switch at boiler and any external  
switch to boiler.  
b. Close fuel valves.  
c. Turn off water feed valve.  
d. Cover burner to protect from dust and  
dampness.  
4
Start-up  
2. Correct problems found in step #1. If burner  
does not fire, press reset button on burner  
primary control only once. Repeated presses  
will deposit oil in combustion chamber.  
WGO/WTGO (see Figure 1):  
1. If bu rn er does n ot fire, check for:  
Service switch on boiler or additional  
switches turned off.  
Burner must never be fired  
Fuses or breaker switch tripped.  
Thermostat set below room temperature.  
Fuel valves turned off.  
when oil is in combustion chamber. Immedi-  
ately call qualified service technician.  
Not enough oil in tank to supply burner.  
3. If burner still does not fire, call qualified  
service technician.  
Temperature -  
Pressure Gauge  
Circulator  
Limit Control  
(on WGO)  
Water  
Relief Valve  
Combination  
Limit Control and  
Tankless Heater  
Control  
(on WTGO)  
Located in tankless  
heater plate  
Service  
Switch on  
Boiler  
Reset Button on  
Burner Primary  
Control  
Burner  
Disconnect  
Plug  
Burner Primary  
Control  
WGO and WTGO Boilers  
Figure 1  
5
Start-up  
2. Correct problems found in step #1. If burner  
does not fire, press reset button on burner  
primary control only once. Repeated presses  
will deposit oil in combustion chamber.  
SGO-W (see Figure 2):  
1. If bu rn er does n ot fire, check for:  
Service switch on boiler or additional  
switches turned off.  
Fuses or breaker switch tripped.  
Thermostat set below room temperature.  
Fuel valves turned off.  
Burner must never be fired  
when oil is in combustion chamber. Immedi-  
ately call qualified service technician.  
Not enough oil in tank to supply burner.  
3. If burner still does not fire, call qualified  
service technician.  
Water Relief Valve  
(on back of boiler)  
Circulator  
Temperature -  
Pressure Gauge  
Limit Control  
Tankless Heater  
Control  
Located in  
tankless heater plate  
Service  
Switch  
on Boiler  
Reset Button on  
Burner Primary  
Control  
Burner  
Disconnect  
Plug  
Burner Primary  
Control  
SGO-W Boiler  
Figure 2  
6
COMMON PROBLEMS  
COMMON CAUSES  
POSSIBLE CORRECTIONS  
Rapid cycling - burner turns on and off  
frequently.  
Thermostat installed where  
drafts or heat affect reading.  
Locate thermostat on inner wall away  
from heat sources or cool drafts.  
Heat anticipator in  
thermostat adjusted  
incorrectly.  
Adjust heat anticipator to match current  
draw. Refer to boiler wiring diagram.  
Incorrect limit setting.  
Have qualified service technician  
increase limit setting to decrease cycling.  
Maximum setting 220 deg. F.  
Need to frequently add makeup water.  
Leaks in boiler or piping.  
Have qualified service technician repair  
leaks at once to avoid constant use of  
makeup water.  
Popping or percolating noise heard in boiler.  
Mineral deposits in sections  
due to constant use of  
makeup water, or incorrect  
pH.  
Have qualified service technician de-lime  
boiler, repair leaks at once to avoid  
constant use of makeup water and check  
pH (between 7.0 and 8.5).  
Black water condition.  
Oxygen corrosion due to  
leaks in piping.  
Have qualified service technician repair  
leaks at once to avoid constant use of  
makeup water and check pH (between  
7.0 and 8.5).  
Frequent release of water through relief  
valve.  
Expansion tank sized too  
small or water-logged.  
Have qualified service technician check  
expansion tank operation.  
Metal flakes found in flueway.  
Contaminated combustion  
air supply.  
Remove sources of hydrocarbons in or  
near boiler area. (Bleaches, cleaners,  
chemicals, sprays, fabric softeners, paint  
remover, etc.)  
Condensation of  
combustion gases.  
Have qualified service technician check  
boiler operation.  
Some radiators or baseboard units do not  
heat or are noisy.  
Air in system.  
Bleed air from system through air vents  
in radiators or baseboard units.  
Low system pressure.  
High limit set too low.  
Have qualified service technician check  
for leaks in boiler or piping at once.  
Have qualified service technican adjust  
limit to higher setting.  
Domestic water from tankless heater is hot  
then suddenly turns cold.  
OR  
Mineral deposits insulate  
internal waterways of  
heater.  
Have qualified service technician delime  
or replace coil.  
Domestic water from tankless heater is  
always lukewarm.  
Boiler stop-leak compound  
has been added to boiler  
water and is insulating  
outside of coil.  
Have qualified service technician remove  
and clean coil AND drain and flush  
boiler to remove stop-leak.  
Incorrect mixing valve  
setting for tankless heater.  
Have quaified service technican adjust  
mixing valve setting.  
Domestic flow rate too high.  
Have qualified service technician install  
flow check valve set to rating of tankless  
heater.  
Incorrect setting on tankless  
heater control.  
Have qualified service technician raise  
tankless control setting. Adjust  
differential on tankless control to lower  
setting.  
The problems and corrections above represent common situations that can occur.  
There may be others not listed above. It is important always to contact a qualified service techni-  
cian if you have any questions about the operation of your boiler or system.  
7
Annual Service Check List  
The procedures and information on pages 7 through 11 are  
intended only for a qualified service technician who has the necessary  
equipment to inspect and adjust boiler and burner. A homeowner should  
never attempt these procedures. Qualified service technician must read  
pages 2 and 3 before proceeding.  
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Annual Service Call Check List  
(follow in order listed below)  
Comments  
Check that boiler area is free from  
combustible materials, gasoline and other  
flammable vapors and liquids.  
1
2
3
4
5
6
Check for and remove any obstruction to  
combustion and ventilation air flow to boiler.  
Check breeching and chimney or vent for  
obstructions, damage, etc. Repair or replace  
as necessary.  
Clean boiler flueways. See page 9.  
Perform service on relief valve and circulator.  
See page 11.  
Check boiler and piping for leaks and repair if  
found. Check for leaks at tankless heater  
plate. Tighten nuts only if leaks are found (for  
WTGO torque to 20-25 ft.lbs.).  
Inspect and adjust burner. See burner manual  
and:  
7
- change nozzle.  
- check ignition electrode settings.  
- clean blower housing and wheel.  
- make sure blower wheel turns freely.  
- oil burner motor if required.  
- clean air inlet.  
- clean or change fuel filter and strainer.  
Make sure boiler is filled with water.  
8
9
Start unit and verify combustion settings with  
combustion test equipment.  
See page 10.  
Verify operation of all controls on boiler. See  
page 11.  
10  
Any parts of the boiler furnished by Weil-McLain must be replaced by parts listed in  
Weil-McLain Boiler and Repair Parts Book.  
8
Detailed Service Procedures  
Cleaning boiler flueways:  
7. Once the flueways are cleaned, carefully  
remove the paper from the floor of the  
combustion chamber.  
8. Verify sealing rope around flue area is intact.  
Visually check condition and position of  
insulation in combustion chamber floor,  
and the refractories at the rear of boiler and  
in the burner mounting door. Replace any  
parts as necessary.  
Make sure all electrical connections  
to boiler are turned off and wait until boiler is  
warm, not hot, before cleaning. Failure to do so  
will result in severe personal injury, death or  
substantial property damage.  
1. Top flu e boilers -remove breeching and jacket  
top panel.  
Rear flu e boilers - remove jacket top panel.  
2. Remove flue collector hood, saving hardware  
for reassembly.  
3. Shut off oil valves. Arrange drip pans under  
the areas of oil piping that will be discon-  
nected. Disconnect oil line at burner so that  
you can swing open the door completely.  
4. Line combustion chamber floor with news-  
paper to catch any soot that will be loosened  
in the cleaning process.  
9. Close burner mounting door and tighten nut  
securely. Place flue collector hood on top of  
boiler. Secure with hardware from step #2.  
Maintain a gas-tight seal to  
avoid possible flue gas leakage and carbon  
monoxide emissions, which can lead to severe  
personal injury or death.  
10. Check breeching for sooting and clean if  
necessary. Install jacket top panel and  
breeching.  
11. Reconnect oil line and all electrical connec-  
tions.  
5. Starting at the top of the boiler, use a wire  
flue brush to thoroughly clean between all  
pins at all angles. Be careful not to damage  
side walls of rear refractory.  
6. Move to the bottom of the flueways and clean  
up between the sections to reach pins left  
uncleaned in step #5.  
.
Thoroughly clean flueways  
between all pins at all angles.  
Start on top of boiler,  
finish from the bottom.  
Cleaning Boiler Flueways  
Figure 3  
9
Detailed Service Procedures  
Fill the system:  
To place in operation:  
1. Close manual and automatic air vents and  
drain cock.  
Follow information below to prevent  
severe personal injury, death or substantial prop-  
erty damage:  
2. Fill to correct system pressure. Correct pres-  
sure 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 recom-  
mended.  
Do not use 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 in combustion chamber,  
when unit is full of vapor, or when combus-  
tion chamber is very hot.  
NOTICE  
Failure to maintain recom-  
mended pH level can cause section failure and  
leaks.  
Do not start burner unless collector hood, flue  
cap, jacket cap, breeching and burner mount-  
ing door are secured in place.  
Never burn garbage or paper in the boiler.  
Never leave combustible material around  
boiler.  
3. Open automatic air vent one turn.  
4. 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.  
1. Verify boiler is filled with water.  
2. Open burner door and verify rear target wall,  
floor and burner door insulations are in  
proper condition and position.  
3. Verify burner mounting door is closed and  
bolted tightly and burner plug is connected.  
4. Refer to burner manual for burner start-up,  
adjustment and check-out procedures.  
Factory burner adjustment and settings may  
n ot be suitable for specific job conditions.  
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. Check boiler and system piping for leaks.  
6. Inspect breeching and venting for proper  
operation.  
10  
Detailed Service Procedures  
Controls requiring annual service:  
WATER RELIEF VALVE:  
CIRCULATOR:  
Check operation of water relief valve. Follow  
instructions on label fastened to relief valve.  
Follow oil-lubricating instructions on circulator.  
Over-oiling will damage circulator.  
Water-lubricated circulators do not need oiling.  
Scald potential. Do not check  
operation of relief valve unless discharge piping  
has been installed according to Boiler Manual.  
If piping is not in place, a qualified service techni-  
cian must properly install piping.  
TANKLESS WATER HEATER:  
General description of control operation:  
Weil-McLain tankless heater ratings are based on  
2000F boiler water temperature. To get rated out-  
put, set tankless heater control to 2000F. Control  
can be adjusted to meet system hot water re-  
quirements.  
AUTOMATIC AIR VENT:  
Air is released when cap is unscrewed one turn.  
If air vent leaks, remove small cap on top of vent,  
push in stem of valve and then release to clean  
valve seat. Screw cap completely on, then unscrew  
one turn.  
EXPANSION TANK:  
As water heats up, it expands. Tank provides a  
place for increased water volume. May be open,  
closed, or diaphragm-type. If relief valve opens  
frequently, expansion tank may be water-logged.  
Drain tank and re-establish proper air cushion.  
WATER RELIEF VALVE:  
Provides discharge if boiler pressure exceeds 30  
psig.  
1. Open-type - Located above highest radiator or  
baseboard unit, usually in the attic or closet.  
Has a gauge glass and overflow pipe to drain.  
TEMPERATURE LIMIT CONTROL:  
If high boiler water temperature occurs, control  
shuts down burner, but allows circulator to run  
as long as there is a call for heat. Limit should be  
set higher than temperature needed for the sys-  
tem. Maximum limit setting is 2200F.  
2. Closed-type - Welded gas tight and located  
above boiler. Tank is partially filled with  
water, leaving an air cushion for expansion.  
3. Diaphragm-type - Welded gas tight with a  
rubber diaphragm to separate air from water.  
Tank must be located near boiler before inlet  
to circulator.  
CIRCULATOR:  
An air vent must be installed in air vent  
tapping on boiler when this type of tank is  
used. This eliminates air in system.  
Normal cold water fill pressure is 12 psig.  
Tank pressure may be checked with an air  
pressure gauge.  
Circulator provides forced water circulation  
through boiler and piping system.  
PRESSURE-TEMPERATURE GAUGE:  
Provides reading of boiler pressure and tempera-  
ture. Maximum boiler pressure is 50 psig, maxi-  
mum water temperature is 2200F. Temperature  
will vary according to system and daily heating de-  
mands. The range will be from room temperature  
up to limit control setting.  
11  
Part No. 550-141-828/1202  

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