Series 4 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Contents Using this manual . . . . . . . . . . . . . . . . 2 Connect breeching . . . . . . . . . . . . . . . . . . 16 Homeowner . . . . . . . . . . . . . . . . . .2 Service technicians . . . . . . . . . . . . . . . . . . 2 When calling or writing about the boiler . . . . . . .
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Operation WTGO (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. 2. Correct problems found in Step #1.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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. Common Problems Common Causes Rapid cycling — burner turns on and off frequently.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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. 2. 3. 4. 5. 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — Packaged boilers only (continued) Figure 3 Change from back flue outlet to top flue outlet (optional) Instructions for Packaged boilers are continued on page 15.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler – Semi-packaged and Knocked-down boilers only Fiberglass wool and ceramic fiber materials are possible cancer hazards. See warning on page 33. Place boiler 1. Semi-packaged WTGO-3 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler – Semi-packaged and Knocked-down boilers only (continued) Perform hydrostatic pressure test 1. Refer to Control Tapping Table 2 and Figure 5 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install burner — all boilers Install burner (also refer to instructions packed with burner) Use only burners specified for use on WeilMcLain oil boilers. Contact individual burner manufacturers for proper burner selections. For burners with OEM welded flanges: 1. Secure mounting flange and gasket to burner mounting door. Use three (3) bolts provided. 2.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect breeching (continued) Figure 7 Back Outlet Breeching Vent Damper for models which require a vent damper. OVD Damper (Required) BVSS (WMO-1) (Integrated with damper) BVSS must be installed upstream of the barometric damper.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping General piping information • All Packaged WTGO boilers are shipped with an installed combination temperature limit control/low water cut-off. • If installation is to comply with ASME, an additional high temperature limit is needed. If installation is to comply with Canadian requirements, an additional high temperature limit maybe needed. Consult local inspector.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping Piping MULTIPLE ZONES Follow instructions on page 18 and page 19 to install piping near boiler. See Figure 13 or Figure 14 to complete installation. Zoning with circulators: (continued) Figure 13 Multiple zoning with CIRCULATORS Zone 2 Zone 1 1. Size each circulator to individual circuit requirements. 2.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping (continued) Piping for systems requiring temperatures below 140°F Figure 15 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 15 or Figure 16.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect water piping 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect tankless heater piping To pipe tankless heater: Hot Water Can Scald! • 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring General wiring requirements • • • 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. • Packaged boilers have harnesses furnished.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring — blocked vent shutoff switch option Blocked vent shutoff switch Canada, blocked vent shutoff switch kit (see parts list page 36) must be installed. See Figure 21. When using the OVD damper kit, the BVSS is required, and is integrated into the damper harness wiring.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring - vent damper 1. WTGO Boiler models ending in “D”, such as WTGO-3D, require the installation of the Field Controls OVD-7 damper, Weil-McLain part number 381-800-515. 2. When installing the boiler, wire all controls from vent damper and thermal switch in accordance with the OVD damper manual and the following wire diagrams. 3.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Check-out procedure Check off Steps as completed ❏❏ Boiler and heat distribution units filled with water? ❏❏ Automatic air vent, if used, opened one full turn? ❏❏ Air purged from system? Piping checked for leaks? 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Detailed service procedures Figure 25 Thoroughly clean flue ways between all pins at all angles. Start on top of boiler, finish from the bottom. tion chamber floor, and the refractories at the rear of boiler and in the burner mounting door. Replace any parts as necessary. 9. Close burner mounting door and tighten nut securely. Place flue collector hood on top of boiler.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Close clearance installation To provide close clearances as described on pages 34 and 35: 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Close clearance installation (continued) Figure 28 Flue pipe clearances Figure 29 Back vent clearances Combustible surface 24" For servicing or min. 2" For close clearances A A A Protection 6" 6" Combustible surface Type "L" double-wall vent pipe Table 6 Combustible surface Protection required for clearances less than 6 inches from double-wall vent pipe* Note: 2" min.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts Table 7 WTGO Section and flue collector part numbers for Series 4 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. Item Description Part No.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts Table 8 (continued) WTGO Trim part numbers for Series 4 Item Description Part no. 1 Combination pressure-temperature gauge kit, 60° – 360° F., 0 - 75 psi, 31/8" dia.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Figure 34 WTGO dimensions — inches (mm) 7 3/16 [182.6] 2 5/8 [66.7] 7 Dia [177.8] 7 Dia [177.8] B 15 ½ [393.7] 14 Approx. L Left side Front 7 Dia. [177.8] 6 1/4 [158.8] For 7 dia. [177.8] Vent pipe Alternate return (“A” boilers only) 14 ⅛ [358.8] 29 9/16 [750.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Ratings Table 10 WTGO Series 4 oil-fired water boiler ratings DOE ® AHRI Certified Ratings Burner Input Heating Seasonal Capacity Efficiency Net Rating (water) Draft Loss Thru boiler Boiler Flue Water Outlet Content Diameter OVD Damper Required Minimum Chimney Boiler Model GPH MBH MBH (2) AFUE % (2) (5) MBH In W.C. (8) WTGO-3LR 0.70 98 86 (4) 86.4 75 0.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Ratings Table 11 WTGO Series 4 oil-fired water boiler rating notes NOTES: (1) WTGO 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.
WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 4 — Boiler Manual 44 Part number 550-142-332/0421
