Series 3 Oil-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualified heating installer/service technician. BEFORE installing, read all instructions in this manual and all other information shipped with the boiler. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Using this manual Homeowner — Read and follow all information on pages 1 through 7 ONLY. Service technician — Read and follow ALL information in the entire manual. Failure to follow all instructions in proper order can cause severe personal injury, death or substantial property damage.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Contents Using this manual . . . . . . . . . . . . . . . . . . . . 2 CLOSED expansion tank (Figure 10, page 19) . . . 18 When calling or writing about the boiler . . . . . . . . 2 To connect WGO boilers to indirect-fired Packaged and non-packaged boilers . . . . . . . . . 2 water heaters . . . . . . . . . . . . .
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Please read before proceeding Homeowner — • • For homeowner or person responsible for simple start-up and routine maintenance of the system Instructions on pages 1 through page 7 must be followed to assure proper operation of your boiler. See page 7 for a list of common problems and possible corrections.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Frozen Water Damage Hazard Residences or buildings that are unattended in severely cold weather, boiler system components failures, power outages, or other electrical system failures could result in frozen plumbing and water damage in a matter of hours.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Operation WGO (see Figure 1) 1. If burner does not fire, check for: • Service switch on control or additional switches turned off. • Fuses or breaker switch tripped. • Thermostat set below room temperature. • Fuel valves turned off. • Not enough oil in tank to supply burner. Figure 1 2. Correct problems found in step #1.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Troubleshooting Homeowners — The problems and corrections below represent common situations that can occur. There may be others not listed below. It is important always to contact a qualified service technician if you have any questions about the operation of your boiler or system.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Before installing boiler Homeowner — STOP! The procedures and information on this and following pages 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. The service technician must also read pages 1 through 7 before proceeding.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Before installing boiler (continued) Provide air for combustion and ventilation Do not install exhaust fan in boiler room. 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.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — packaged boilers only Place boiler Perform hydrostatic pressure test 1. Remove circulator strapped to pallet. 1. Remove relief valve installed in boiler. 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.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — packaged boilers only Figure 3 (continued) Change from back flue outlet to top flue outlet (optional) Instructions for packaged boilers continued on page 15.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — non-packaged boilers only Fiberglass wool and ceramic fiber materials are possible cancer hazards. See warning on page 31. 1. Open burner mounting door and, using utility knife, slit floor insulation at joint to be separated. Place boiler Non-Packaged WGO-2 through 6 — position on site Smaller sized boilers may be top heavy.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — non-packaged boilers only Non-Packaged WGO-7, 8 & 9 — install flue collector hood (see Figure 4) Obtain gas-tight seal to prevent possible flue gas leakage and carbon monoxide emissions, leading to severe personal injury or death. 1. Thread Tinnerman clip on screw so that clip fits snugly in notch of hold-down lug. Screw must not turn. 2.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — non-packaged boilers only Perform hydrostatic pressure test 1. See Figure 5 and Control Tapping table 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 1½ times working pressure.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install burner — all boilers Install burner (also refer to instructions packed with burner) For P-WGO and A-WGO boiler: 1. Secure universal mounting flange and gasket to burner mounting door. Use three bolts provided. 2. Secure burner on flange with three bolts. Use only burners specified for use on Weil-McLain GOLD oil boilers.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect breeching General chimney requirements • Designed for natural draft firing. Connect boiler to vertical chimney. • Insufficient draft can cause flue gas leakage and carbon monoxide emissions, which will lead to severe personal injury or death. • Use vent material approved by local codes for oil-fired burners.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping General piping information CLOSED expansion tank • All packaged WGO boilers are shipped with an installed combination temperature limit control/low water cut-off. (Figure 10, page 19) • If installation is to comply with ASME, an additional high temperature limit is needed.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Piping MULTIPLE ZONES Figure 11 Multiple zoning with CIRCULATORS 1. Follow instructions on page 18 and page 19 to install piping near boiler. Zone 2 2. See Figure 11 or Figure 12 to complete installation 3. Zoning with circulators: a. Size each circulator to individual circuit requirements. b.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping Piping for systems requiring temperatures below 140°F (continued) Figure 13 Piping with CIRCULATORS 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 13 or Figure 14.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Use with refrigeration systems • Install boiler so that chilled medium is piped in parallel with heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. Consult AHRI Installation and Piping Guides.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (continued) General wiring High temperature limit • • • • • • • “P” boilers have harnesses furnished. “A” boilers are furnished with burner and limit harnesses integrated with Hydrolevel control. All field-provided high voltage wiring must be sheathed in flexible metal conduit.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring — blocked vent shutoff switch option Blocked vent shutoff switch In Canada, blocked vent shutoff switch kit (see parts list page 34) must be installed. See Figure 18. The wiring diagram in Figure 19 shows boiler wiring only up to the burner disconnect. For additional information, refer to manufacturer’s instructions. Electric shock hazard.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect oil piping General oil piping requirements • • • • Location and installation of oil tanks, oil piping and burners must follow: • NFPA 31, Standard for the Installation of OilBurning Equipment. • In Canada, CSA B139, Installation of OilBurning Equipment. • Local codes and regulations. • Information provided with burner and fuel pump.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Start-up Fill the system To place in operation 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. 1. Verify boiler is filled with water. 2.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Check-out procedure Check off steps as completed operation as outlined by the manufacturer. Burner should be operating and should go off when controls are tested. When controls are restored, burner should re-ignite. ❏❏ Boiler and heat distribution units filled with water? ❏❏ Limit control set to system temperature requirements (max.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Annual service check list Annual Service Call Checklist (follow in order listed below) 1 Check that boiler area is free from combustible materials, gasoline and other flammable vapors and liquids. 2 Check for and remove any obstruction to combustion and ventilation air flow to boiler. 3 Check breeching and chimney or vent for obstructions, damage, etc.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Detailed service procedures Cleaning boiler flueways 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. Figure 21 Thoroughly clean flueways between all pins at all angles. Start on top of boiler, finish from the bottom.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials that have been identified as carcinogenic, or possibly carcinogenic, to humans. Ceramic fibers can be converted to cristobalite in very high temperature applications.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Close clearance installation To provide close clearances as described on pages 26 and 27: Obtain the Close Clearance Kit, Weil-McLain Part No. 386‑500‑050. Install the kit as described below. Failure to use kit or install as described can result in a fire hazard, causing severe personal injury, death or substantial property damage.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Close clearance installation Figure 24 Flue pipe clearances (continued) Figure 25 Back vent clearances Combustible surface 24" For servicing or min.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts Table 6 Item 34 Series 3 section and flue collector parts Description Part no. Item Description Part no.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 27 Parts drawing R D F E Q G B A K H G H H H J N G C L M P 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.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts Table 7 (continued) Series 3 trim parts Item Description Mfr. Part no. 1 Combination pressure-temperature gauge kit, 60° – 360° F., 0 - 75 psi, 31/8" dia.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Figure 30 WGO dimensions — inches (mm) — see Table 9, page 41 7 3/16 [182.6] 7 Dia [177.8] 7 3/4 [196.9] 2 5/8 [66.7] 20 1/4 [514.4] 5 1/16 [128.6] 2 9/16 [65.1] Supply 7 Dia [177.8] Air vent or expansion tank 35 5/8 [904.9] 4 3/8 Dia [111.1] Burner opening B Return 15 1/2 [393.7] 9 1/2 [241.3] L Left side 14 Approx. 2 7/16 [61.9] 2 7/16 [61.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Table 9 (continued) Dimensions B L BOILER MODEL NUMBER Inches mm. Inches mm. WGO-2 10 1/2 266.7 13 3/4 349.2 WGO-3 13 1/2 342.9 16 7/8 428.7 WGO-4 13 5/8 345.9 16 7/8 428.7 WGO-5 16 7/8 428.7 20 508.0 WGO-6 20 508 23 1/8 587.2 WGO-7 23 1/8 587.2 26 1/4 666.7 WGO-8 26 1/4 666.7 29 3/8 746.2 box 29 3/8 746.2 32 1/2 825.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Ratings Table 10 GOLD WGO oil-fired water boiler ratings DOE ® AHRI Certified Ratings Boiler Model (9) Burner Input GPH (3) Net Rating (water) Boiler Water Content Flue Outlet Diameter 0.010 (2) (5) MBH Gallons Inches 11.0 7 8x8 6 15 14.9 7 8x8 6 15 13.4 7 8x8 6 15 15.9 7 8x8 7 15 18.4 7 8x8 7 15 20.8 7 8x8 8 15 7 8 x 12 8 20 86.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD WGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual Part number 550-141-826/1218
