Weil-McLain 550-141-827-1201 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

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 block, no burner. Sizes 3 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 22 of this manual is space to list CP number(s).

Table of Contents

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

Read This Page First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

Connect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

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 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.

• Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids.

Failure to keep boiler area clear

and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

Provide clearances around boiler (see FIGURE 1):

Jacket cap must be in place on

boiler to avoid requiring an 18" minimum clearance from back or top of boiler to combustible material.

• Minimum clearances from vent pipe to

combustible material:

6 inches — Type “L” doublewall vent*

18 inches — Singlewall vent*

Flue pipe clearances must take precedence over jacket clearances.

• Recommended service clearances:

24 inches — Front and top

6 inches — Left side**, back and right side ∆ 15 inches — Left side with tankless heater** 12 inches — Right side for burner door

swing radius ∆

Ceiling

6" (12") ∆

6" (15")**

Top View

Walls

24"

Recommended Service Clearances

FIGURE 1

(18")

Wall

(18")

Left Side

24"

Floor

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 any 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

BOILER MODEL

SGO-3W

SGO-4W

SGO-5W

SGO-6W

SGO-7W

SGO-8W

SGO-9W

LENGTH

INCHES

WIDTH INCHES

MIN.

HEIGHT

INCHES

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, 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. 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.

3) Loosen two screws on back flue outlet. Set flue cap on outlet. Install strap by engaging slots in screws. Tighten screws. Make sure cap is securely installed.

2. A-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.

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.

(Read under Step #3 on page 7.)

SGO-3 through 6W — remove knockout in left

Remove tankless heater cover plate and gasket.

and reassembled, test between 75 and 85 psig.

Cold water fill could expand and

Check for maintained gauge pressure for more

Metal-to-metal contact around port openings.

Install Non-Packaged Boiler

CONTINUED

3. A-SGO-7, 8 & 9W — install flue collector hood

(see FIGURE 2):

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 2.

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.

Nut

Washer

Flue Collector Sealing Rope in Groove Inside Cap

Hood

Sealing Rope with Adhesive Tape

Tankless heater, if used:

1. side jacket panel.

3. Install new gasket and tankless heater over studs around opening. Secure with 3/8" nuts.

Perform hydrostatic pressure test:

1. See FIGURE 3 and Control Tapping Table on page 8 to install: a. Boiler drain. 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 11¼2 times working pressure. For boilers split

Do not leave boiler unattended.

damage cast iron, resulting in severe personal injury, death or substantial property damage.

3. than 10 minutes. Visually check for leaks if gauge pressure drops.

4. Drain boiler. Repair leaks if found.

Do not use petroleum-based

compounds to repair leaks. Damage to system components can result, causing property damage.

5. Re-test boiler after repairing leaks.

6. Remove pressure gauge, air vent and plugs from tappings used for controls.

7. Visually check: a. Sealing rope placement. b. 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.

Flue Cap Strap

Change from Back Flue Outlet to Top Flue Outlet (Optional)

Flue Cap

FIGURE 2

Tinnerman Clip

Screw

Install Non-Packaged Boiler

CONTINUED

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 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.

3. Affix CP number label(s) on jacket front panel.

CONTROL TAPPING TABLE

TAPPING SIZE FUNCTION

A1 1½" Supply Piping

A2 2½" Air Vent or Expansion Tank Piping

A3 2½" Plugged

B1 1½" Return Piping

B2 2" Plugged

E1 ½" Pressure-Temperature Gauge

E2 ½" Plugged

H ¾" Drain Valve

L ¾" High Limit Control

P ¾" Plugged

R ¾" Relief Valve

S1 & S2 ½" Plugged

U1 1" Plugged

U2 ¾" Plugged

Operating Control for Tankless

U3 ¾" Heater

(located in heater plate)

Front Section

Control Tapping Location

FIGURE 3

Back Section

Install 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.

CONTINUED

For A-SGO-W boiler:

1. Secure universal mounting flange and gasket to burner mounting door. Use three bolts provided.

2. Secure burner on flange with three bolts.

3. Position burner so end of air tube is level to 1½° tilt downward. Open door to verify burner

Water

Pressure

Gauge

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.

Circulator

Limit

Control

Tankless

Heater

Control

Drain Valve

Water Boiler Controls

FIGURE 4

+ 19 hidden pages

Weil-McLain 550-141-827-1201 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual