Weil-McLain 550-141-826-1201 User Manual
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).
2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Install Non-Packaged Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
Connect Breeching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
Connect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-18
Connect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-21
Connect Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Check-Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Installation and Service Certificate . . . . . . . . . . . . . . . . . . . . . . . .24
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-27
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
3
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.
Before selecting boiler location:
• 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.
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.
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.
Walls
6" (12") ∆
6"
6"
Top View
24"
*
6"
(18")
Wall
*
6"
(18")
*
6"
(18")
Left Side
Ceiling
24"
Floor
Recommended Service Clearances
FIGURE 1
4
Before Installing Boiler
CONTINUED
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).
• 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.
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
MIN.
BOILER LENGTH WIDTH HEIGHT
MODEL INCHES INCHES INCHES
WGO-2 14 22 2
WGO-3 17 22 2
WGO-4 17 22 2
WGO-5 20 22 2
WGO-6 23 22 2
WGO-7 26 22 2
WGO-8 29 22 2
WGO-9 32 22 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).
Perform hydrostatic pressure test:
1. Remove relief valve installed in boiler.
2. Install air vent in “N” tapping on top boiler.
3. Plug supply and return tappings.
4. Drain valve is already factory-installed.
5. Fill boiler. Vent all air. Pressure test boiler at
1½ times working pressure.
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.
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
6
Install Packaged Boiler
CONTINUED
Change From Back Flue Outlet to Top Flue Outlet (Optional)
FIGURE 2
7
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.
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.)
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. Non-Packaged WGO-7, 8 & 9 — split the
assembled block for easier handling (see
FIGURE 3):
a. Open burner mounting door and,
using utility knife, slit floor insulation at
joint to be separated.
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.
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
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.
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.
8
Install Non-Packaged Boiler
CONTINUED
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
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
Flue Cap
Strap
Flue Collector
Hood
Sealing Rope in
Groove Inside Cap
Sealing Rope
with Adhesive
Tape
Flue
Cap
Change From Back Flue Outlet to Top Flue Outlet (Optional)
FIGURE 3
9
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.
N
E3
C
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 220°F setting.
2. Affix CP number label(s) on jacket front panel.
CONTROL TAPPING TABLE
LOCATION SIZE FUNCTION
B1 1½" Return Piping
B2 1½"
C 1½" Supply Piping
E3 ¾" Pressure-Temperature Gauge
H ¾" Drain Valve
L ¾" High Limit Control
N
R1 ¾" Relief Valve
½"
Alternate Return Piping
for A/B WGO
Air Vent or
Expansion Tank Piping
10
R1
B1
L
B2
H
Back SectionFront Section
Control Tapping Location
FIGURE 4
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