Oil-Fired Steam 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 SGO OIL-FIRED NATURAL DRAFT STEAM 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 8 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 SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Contents Using this manual . . . . . . . . . . . . . . . . . . . . 2 When calling or writing about the boiler . . . . . . . . 2 Packaged and non-packaged boilers . . . . . . . . . 2 Hazard definitions . . . . . . . . . . . . . . . . . . . . 2 Contents . . . . . . . . . . . . . . . . . . . . . .
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Please read before proceeding Homeowner — Tips for water systems — • For homeowner or person responsible for simple start-up and routine maintenance of the system • • Instructions on 1 through page 8 must be followed to assure proper operation of your boiler. See page 8 for lists common problems and possible corrections.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Routine maintenance schedule Beginning each heating season Daily during heating season Weekly during heating season ❏❏ Call a qualified service technician to perform annual service. ❏❏ Check that boiler area is free from combustible materials, gasoline and other flammable vapors and liquids.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Operation SGO with float-type low water cutoff 1. If burner does not fire, check for: • Switch on boiler or additional shut-off 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. • No water in gauge glass. Figure 1 2. Correct problems found in step #1.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual HOMEOWNER and SERVICE TECHNICIAN — read and follow completely. Operation (continued) SGO with probe-type low water cutoff 1. If burner does not 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. Not enough oil in tank to supply burner. • No water in gauge glass. Figure 2 2.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM 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 SGO OIL-FIRED NATURAL DRAFT STEAM 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 8 before proceeding.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM 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 SGO OIL-FIRED NATURAL DRAFT STEAM 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 boiler from pallet. 1. Remove steam pressure gauge furnished with boiler. Install water pressure gauge for test only. Be sure gauge can handle test pressure. 2. Install air vent in tapping on top of boiler. 3. Remove pressure control and low water cutoff. Plug tappings. 4.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM 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 37. Place boiler 1. Non-Packaged SGO-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.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Install boiler — non-packaged boilers only Perform hydrostatic pressure test 1. Refer to Figure 6 and Control Tapping Table 2, to install: a. Boiler drain. b. Water pressure gauge (test only). Be sure gauge can handle test pressure. c. Air vent in tapping on top of boiler. d. Plugs in remaining tappings. 2. Fill boiler. Vent all air. Pressure test boiler at 45-55 psig.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM 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) Table 3 Minimum chimney sizes Boiler model number Minimum breeching diameter (Note 3) SGO-3 5" SGO-4 6" For P-SGO and A-SGO boiler: SGO-5 6" 1. Secure universal mounting flange and gasket to burner mounting door. Use three bolts provided. 2.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect breeching Connect breeching 1. 2. 3. 4. 5. Long horizontal breechings, excessive number of tees and elbows, or other obstructions restricting combustion gas flow can result in possibility of condensation, flue gas leakage and carbon monoxide emissions, which can lead to severe personal injury or death. Install two (2) flue pipe brackets.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect steam piping General piping information • Hartford Loop piping arrangement and wet return are required for steam boilers. • Maintain 24-inch minimum from waterline to bottom of header (minimum 50 7/8" from floor or top of foundation). • When using condensate receiver, feed pump must be energized by boiler-mounted pump control. • Use swing joints in steam piping.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect steam piping (continued) Figure 13 Typical piping (one riser shown on boiler) Optional reservoir piping Modern steam boilers are designed to steam for less time than older, larger boilers. When replacing an older steam boiler, the system condensate return time may be longer than the steaming time.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — 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.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect tankless heater piping Figure 14 Tankless heater piping SGO 3-5 tankless heater control location SGO 6-9 tankless heater control location Flow regulating valve Cold water supply Mixed 12" Min.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring — general information 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.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring — general information Blocked vent shutoff switch (continued) Figure 15 Blocked vent shutoff switch installation In Canada, a blocked vent shutoff switch kit must be installed (see parts list page 38). See Figure 15. Electric shock hazard.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (Float-type LWCO) Figure 18 Boiler wiring for float-type LWCO — component locations for wiring diagram, Figure 16, page 26 5 1 (continued) Blocked vent safety switch (BVSS), when required In Canada, a blocked vent shutoff switch kit must be installed (see parts list page 38). See Figure 15, page 25.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect wiring (Probe-type LWCO) Figure 20 Boiler wiring for probe-type LWCO — component locations for wiring diagram, Figure 19, page 28 Blocked vent safety switch (BVSS), when required In Canada, a blocked vent shutoff switch kit must be installed (see parts list page 38). See Figure 15, page 25. 1 5 1. 2. 3. 4. 2 (continued) 5. 6. 7. 8.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Connect oil piping General oil piping requirements • • • • Figure 22 Recommended oil piping connection to burner 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.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Start up Fill the system 1. Do not fill (except for leakage tests) until boiler is ready to be fired. 2. Fill to normal water line as indicated on jacket front panel. 3. Boiler water pH 7.0 to 8.5 is recommended. Failure to maintain recommended pH level can cause section failure and leaks. 4. Follow “Skim steam boiler” to assure proper operation.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Installation and service certificate Installation and service certificate Date Installed:_____________________________ Boiler Model Number:________ Series:_____________ ❏❏ Installation instructions have been followed. ❏❏ Check-out procedure has been performed. ❏❏ Above information is certified to be correct.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM 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 SGO OIL-FIRED NATURAL DRAFT STEAM 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 23 Thoroughly clean flueways between all pins at all angles. Start on top of boiler, finish from the bottom.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Detailed service procedures (continued) General description of control operation Controls requiring annual service Low water cutoff Float-type low water cutoff Shuts down boiler if there is a low water condition. Steam relief valve Follow instructions to blowdown cutoff on page 4.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM 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 SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Parts list Table 7 Item 38 Series 3 section and flue collector parts Description Part No. Item Description Part No.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Parts drawing Table 8 Series 3 section and flue collector parts S D E F R G B A J L J J M G G J K P C N Q H 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 SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts Table 9 Series 3 trim parts Fig. No. Part no. 1 560-640-698 2a 511-548-023 2b Description Mfr. Mfr. part no. Steam relief valve, set to relieve at 15 PSIG., 3/4" NPT inlet 3/4" NPT side outlet, 300 lbs./hr steam capacity Watts 315 Steam relief valve, set to relieve at 15 PSIG., 3/4" NPT male inlet 3/4" NPT female side outlet, 407 lbs.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 24 Series 3 trim parts 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 SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Replacement parts (continued) Figure 25 Boiler jacket 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 SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Figure 26 SGO dimensions — inches (mm) — see Table 11, page 45 73/16 [182.6] 201/4 [514.4] 7 /4 [196.9] 33/4 [95.3] 3 A Steam supply piping 6-9 41/16 [103.2] 7 DIA [177.8] Skim tapping 101/4 [260.4] [177.8] 7 DIA Steam supply Steam supply piping 3-9 355/8 [904.88] B 151¼2 [393.7] 43/8 DIA [111.1] burner opening 267/8 [682.6] Water Line 301/16 [763.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Dimensions Table 11 (continued) Dimensions A B L Boiler model number Inches mm. Inches mm. Inches mm. SGO-3 — — 13½ 342.9 167/8 428.7 SGO-4 — — 165/8 422.1 20 508.0 SGO-5 — — 197/8 504.9 221/8 587.2 SGO-6 19 482.6 231/2 584.2 261/4 666.7 SGO-7 221/8 561.8 261/8 663.4 293/8 746.2 SGO-8 251/4 641.4 29¼ 742.9 321/2 825.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely. Ratings Table 12 SGO GOLD Oil steam boiler ratings DOE ® AHRI Certified Rating Net Ratings (5) Minimum Chimney Dimensions Round Flue Outlet Size In Steam Boiler Water Content Gal (8) Draft Loss Thru Boiler In W.C.(9) Steam MBH Seasonal Efficiency % AFUE Rect In 354 85 84.0 8x8 6 15 7 10.7 .020 144 450 108 84.0 8x8 6 15 7 12.5 .010 1.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual SERVICE TECHNICIAN ONLY — read and follow completely.
GOLD SGO OIL-FIRED NATURAL DRAFT STEAM BOILER — SERIES 3 — Boiler Manual Part number 550-141-829/0316