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HomeMy WebLinkAboutMP22-056 Qy t it.°jJ�u Ct 4t* (butft em=q VILLAGE OF RYE BROOK MAYOR 938 King Street, Rye Brook,N.Y. 10573 ADMINISTRATOR Jason A. Klein (914) 939-0668 Christopher J.Bradbury www.ryebrook.org TRUSTEES BUILDING & FIRE INSPECTOR Susan R. Epstein Michael J. Izzo Stephanie J. Fischer David M. Heiser Salvatore W. Morlino CERTIFICATE OF COMPLIANCE June 13,2022 Steven Mein 137 Brush Hollow Crescent Rye Brook,New York 10573 Re: 137 Brush Hollow Crescent, Rye Brook,New York 10573 Parcel ID#: 129.76-1-123 This document certifies that the work done under Mechanical Permit #22-056 issued on 4/8/2022 for the installation of a new oil fired boiler has been satisfactorily completed. Sincerely, Michael J. Izzo Building&Fire Inspector /to QyE Ma( O� 2m 1982 �7 BUILDING DEPARTMENT UILDINGINSPECTOR ASSISTANT BUILDING INSPECTOR VILLAGE OF RYE BROOK ❑CODE ENFORCEMENT OFFICER 938 KING STREET • RYE BROOK,NY 10573 (914) 939-0668 FAX (914) 939-5801 www ryebrook.org - - - - - - - - - -- - - - - - - - - - INSPECTION REPORT - - - - - - - - - - - - - - - - - - - - ADDRESS: I C'(< U so { \/1`\ulli - DATE: PERMIT# 054O ISSUED: CT: LOCK: LOT: LOCATION: UPANCY• C� ❑ VIOLATION NOTED THE WORK IS... Al ACCEPTED ❑ REJECTED/REINSPECTION ❑ SITE INSPECTION W n REQUIRED ,3'`_y1 ❑ FOOTING ❑ FOOTING DRAINAGE ❑ FOUNDATION ❑ UNDERGROUND PLUMBING NOTES ON INSPECTION: ❑ ROUGH PLUMBING ❑ ROUGH FRAMING ❑ INSULATION ❑ NATURAL GAS ❑ L.P. GAS ❑ FUEL TANK ❑ FIRE SPRINKLER ❑ FINAL PLUMBING CROSS CONNECTION ❑ FINAL ❑ OTHER = a a ` _ ti a � w � O O W 1 C ed u N N N cr a _ 00 a' w ^C7 m 00 E a x a a o O.' a CA 0 A O n 00 %j Q p 1-�-4 O W o o s 72 a C �) � n � a W � o � p FBI � 0 � � � W � � CJ �' O `' O •� a 1 p z � >0 a lm W 'Ono r .� A a W � o ° w0w 00 C/� © L z A U W ~ U z v b a ■ M ID00 all IT ad V1 Z � ww 1151 z o oa a.o t x � � . u� w u. o O w c °zE" atu �4 Z q a a ° �•"� Z p W A O � •� W o a z 5 0 .0 .. u �I � a VILLAGE'( F BROOK BUD DING DEP' RTMENT APR - 6 2022 938 KING SU��I YE BROOK,NY 10573 VILLAGE OF RYE BROOK (914)939 06 _ � � ebrook.or B1IILDING DEPARTMENT APPLICATION FOR PERMIT TO INSTALL, MODIFY AND/OR REMOVE MECHANICAL EQUIPMENT OFFICE USE ONLY: ��_ S& Permit#: Building Inspector: _ Fee Paid:- A /0C'' b Date of Approval: Parcel ID#: Bldg/Use Class:Res. ,Comm. ( ); REQUIREMENTS FOR RELEASE OF PERMIT: (A CERTIFICATE OF COMPLIANCE IS REQUIRED TO CLOSE OUT THIS PERMIT) 1. Properly Completed&Signed Application. 2. Payment of Application Fee: Residential =$100.00; Commercial =$250.00 (Pees are non-refundable) 3. Site/Staging Plan as required by the Building Inspector. 4. Sealed Construction/Installation Documents& Specifications as required by the Building Inspector. 5. Copy of Licensed Contractor's Liability Insurance. (Village ofRye Brook must be listed as certificate holder) & Workers Compensation insurance on a NYS Board form (Form#Cl05.2 or Form#U26.3/or NY State Workers Compensation Waiver) 6. Payment of Permit Fee: Residential =$15.00/1000.00 of Construction/Materials Cost with a minimum fee of$100.00. Commercial=$25.00/1000.00 of Construction/Materials Cost with a minimum fee of$275.00. 7. Inspection by Building Department for removal and/or installation. (48 hour notice required) 8. Any electrical work requires a separate Electrical Permit and Electrical Inspection. 9.Any gas/plumbing work requires a separate Plumbing Permit and Plumbing Inspection. Application dated, 04/04/2022 is hereby made to the Building Inspector of the Village of Rye Brook,NY,for a permit for the installation,modification,and/or removal of the specific Mechanical Equipment as listed below.The applicant and property owner,by signing this document agrees that said equipment will be installed and/or removed in conformance with the approved plans,and with all applicable Local,County,State&Federal laws,codes,rules and regulations.1.Address: 137 BRUSH HOLLOW CRESANT SBL:/ A 7/0—/— /a 3 Zone: tou6 2.Property Owner: HOPE KLEIN Address: 137 BRUSH HOLLOW CRESANT Phone#: Cell#: 914-473-8009 email: mrshopeklein@gmail.eom 3.Contractor: Salvatore Morlino Address: 1 Bonwit Road Rye Brook NY 10573 Phone#: Cell#: 914-260-1592 email: salvatoreserious@gmail.eom 4,Applicant: Salvatore W Morlino Address: 1 Bonwit Road Rye Brook NY 10573 Phone#: Cell: 914-260-1592 email: salvatoreserious@gmaii.com 5.Scope of Work:New Installation(X•Replacement( )•Removal ( )•Other( ) 6.Type of Equipment: OIL FIRED Roll ER Model WTG-3 7.Location of Equipment: SHED S.Cost of Equipment including Installation Cost:$ I 8/12/2021 STATE OF NEW YORK,COUNTY OF WESTCHESTER ) as: Salvatore wMorlino ,being duly sworn,deposes and states that he/she is the applicant above named, (print name of individual signing as the applicant) and further states that(s)he is the legal owner of the property to which this application pertains,or that(s)he is the Contractor for the legal owner and is duly authorized to make and file this application. (indicate architect,contractor,agent,attomey,etc.) That all statements contained herein are true to the best of his/her knowledge and belief,and that any work performed,or use conducted at the above captioned property will be in conformance with the details as set forth and contained in this application and in any accompanying approved plans and specifications,as well as in accordance with the New York State Uniform Fire Prevention&Building Code,the Code of the village of Rye Brook and all other applicable laws,ordinances and regulations. Sworn to before me this 4th Sworn to before me this 4TH day of April ,20 22 day of April 20 22 Signature of Property O Sign re of Applicant Hope Klein Salvatore W Morlino Print Name of Property Owner Print Name of Applicant C 1 F 3 Notary Public js '1`l Notary Pule s y NN (!' " = �5,._• [eta' €sti e `l�'� ssp11� Ci33' � This application must be properly completed in its entirety and must inAdi a the notarized signature(s) of the legal owner(s)of the subject property, and the applicant of record in the spaces provided. Any application not properly completed in its entirety and/or not properly signed shall be deemed null and void and will be returned to the applicant. z sn 2/2021 WEWMdAlNg GOLD SERIES-OIL BOILER Oil-Firedicp Series 3 C us WaterBoilers Boiler Manual Startup 9 Parts wEn•mieiN rr 1 i • 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. Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler ManualFA AWARNING 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. AWARNING Failure to follow all instructions in proper order can cause severe personal injury,death or substantial property damage. 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 30 of this manual is space to list CP number(s). Packaged and non-packaged boilers Packaged boilers,available only in sizes 2 through 6,are factory assembled,complete with block,jacket and controls.Burner is shipped separately. Non-packaged boilers, available in all sizes, 2 through 9, are shipped with block assembled, with jacket. Controls,trim and burner shipped separately for field assembly. Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Indicates presence of hazards that will cause severe personal injury, death or substantial property damage. AWARNING Indicates presence of hazards that can cause severe personal injury, death or substantial property damage. ACAUTION Indicates presence of hazards that will or can cause minor personal injury or property damage. NOTICE Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage. 2 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fum] AWARNING HOMEOWNER and SERVICE TECHNICIAN—read and follow completely. Contents Using this manual . . . . . . . . . . . . . . . . . . . . .2 Install piping: . . . . . . . . . . . . . . . . . . . . . 18 When calling or writing about the boiler . . . . . . . .2 DIAPHRAGM expansion tank(Figure 9) . . . . . . . 18 Packaged and non-packaged boilers. . . . . . . . . .2 CLOSED expansion tank(Figure 10) . . . . . . . . 18 Hazard definitions. . . . . . . . . . . . . . . . . . . . .2 To connect WTGO boilers to Please read before proceeding. . . . . . . . . . . . . .4 indirect-fired water heaters. . . . . . . . . . . . . . 18 Tips for water systems— . . . . . . . . . . . . . . .4 Piping MULTIPLE ZONES . . . . . . . . . . . . . . 20 Piping for systems requiring Routine maintenance schedule. .5 temperatures below 140°F . . . . . . . . . . . . . . 21 Beginning each heating season . . . . . . . . . . . .5 Use with refrigeration systems. . . . . . . . . . . . 22 Daily during heating season . . . . . . . . . . . . . .5 Connect tankless heater piping . . . . . . . . . . 23 Weekly during heating season . . . . . . . . . . . . .5 End of heating season . . . . . . . . . . . . . . . . .5 Connect wiring. . . . . . . . . . . . . . . . . . . . . . 24 Boiler shutdown . . . . . . . . . . . . . . . . . . . .5 General wiring requirements . . . . . . . . . . . . . 24 Operation. . . . . . . . . . . . . . . . . . . . . . . .6 General wiring . . . . . . . . . . . . . . . . . . . . 24 WTGO (see Figure 1) . . . . . . . . . . . . . . . . .6 High temperature limit . . . . . . . . . . . . . . . . 24 Troubleshooting . . . . . . . . . . . . . . . . . . . .7 3-Wire zone valve applications. . . . . . . . . . . . 24 Blocked vent shutoff switch . . . . . . . . . . . . . 27 Before installing boiler . . . . . . . . . . . . . . . . . .8 Connect oil piping. . . . . . . . . . . . . . . . . . . . 28 Installations must comply with . . . . . . . . . . . . .8 General oil piping requirements . 28 Before selecting boiler location. . . . . . . . . . . . .8 Provide clearances around boiler(see Figure 2). . . .8 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . 29 Provide air for combustion and ventilation . . . . . . .9 Fill the system . . . . . . . . . . . . . . . . . . . . 29 Lay a foundation, if needed . . . . . . . . . . . . . .9 When using antifreeze . . . . . . . . . . . . . . . . 29 Install boiler—packaged boilers only. . . . . . . . . 10 To place in operation . . . . . . . . . . . . . . . . . 29 Place boiler. . . . . . . . . . . . . . . . . . . . . . 10 Burner adjustments . . . . . . . . . . . . . . . . . 29 Perform hydrostatic pressure test . . . . . . . . . . 10 Check-out procedure . . . . . . . . . . . . . . . . . . 30 Install boiler—non-packaged boilers only . . . . . . 12 Check off steps as completed . . . . . . . . . . . . 30 Place boiler. . . . . . . . . . . . . . . . . . . . . . 12 Installation and service certificate . . . . . . . . . . 30 Tankless heater, if used . . . . . . . . . . . . . . . 12 Annual service check list . . . . . . . . . . . . . . . . 31 Perform hydrostatic pressure test . . . . . . . . . . 14 Controls requiring annual service . . . . . . . . . . 31 Install jacket(required on sizes 7 through 9 only) . . 14 Detailed service procedures . . . . . . . . . . . . . . 32 Install boiler controls . . . . . . . . . . . . . . . . . 14 Cleaning boiler flueways . . . . . . . . . . . . . . . 32 Install burner —all boilers. . . . . . . . . . . . . . . 15 General description of control operation . . . . . . . 32 Install burner(also refer to instructions Handling ceramic fiber and fiberglass materials . . . 33 packed with burner) . 15 For P-WTGO and A-WTGO boiler . . . . . . . . . . 15 Close clearance installation . . . . . . . . . . . . 34 Close clearance installation . . . . . . . . . . . . . 34 Connect breeching . . . . . . . . . . . . . . . . . . . 16 General chimney requirements. . . . . . . . . . . . 16 Replacement parts . . . . . . . . . . . . . . . . . . . 36 Connect breeching . . . . . . . . . . . . . . . . . . 16 Dimensions . . . . . . . . . . . . . . . . . . . . . . . 41 Connect water piping . . . . . . . . . . . . . . . . . . 18 Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . 42 General piping information . . . . . . . . . . . . . . 18 Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Part number 550-141-825/1218 3 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boller ManualFA AWARNING HOMEOWNER and SERVICE TECHNICIAN—read and follow completely. Please read before proceeding AWARNING Follow instructions below to prevent severe personal injury, Homeowner — death or substantial property damage: • For homeowner or person responsible for To avoid electric shock,disconnect electrical supply to burner service simple start-up and routine maintenance of switch and additional external switches before performing service. the system To avoid severe burns,allow boiler to cool before performing service. • Instructions on pages 1 through page 7 must Do not block flow of combustion or ventilation air to boiler. be followed to assure proper operation of Boiler must be connected to a flue with sufficient draft at all times to your boiler.See page 7 for a list of common assure proper operation. problems and possible corrections.In addi- Do not use this boiler if any part has been under water.Electrical and tion,it is your responsibility to: mechanical failures may cause electric shock and fire risks.Immediately • Have boiler and burner installed by a call a qualified service technician to inspect chimney or vent,boiler qualified installer. and burner.Have the boiler flueways cleaned and have the following • Have boiler and burner serviced annually replaced: by a qualified service technician. all electrical and mechanical controls • Review and understand start-up and electrical wiring routine maintenance procedures with oil burner and controls qualified service technician. insulation and chamber lining • Perform routine maintenance as de- scribed on page 5. Tips for Water systems — Service technician — Check boiler and system piping for leaks. Continual makeup water will reduce boiler life.Minerals can build up in sections,reducing heat • For a qualified service technician who has transfer and causing cast iron to overheat,resulting in section failure. the necessary equipment to check the boiler Failure to maintain recommended H and repair leaks can and system performance,and is responsible ACAUTION cause section iron corrosion,leading to section failure and for start-up and service of boiler and system. leaks.Do not use petroleum-based sealing or stop-leak com- • All instructions in this manual must be pounds in boiler systems. Damage to system components followed to assure proper operation of this can result,causing property damage. boiler. Boiler water pH 7.0 to 8.5 is recommended.For pH conditions outside • Annually service boiler and burner to assure 7.0 to 8.5 range or unusually hard water areas (above 7 grains hard- proper operation. See page 31 for service ness),consult local water treatment company. record. When using antifreeze: ❑ Use antifreeze especially made for hydronic systems. Inhibited • Review and explain start-up and routine propylene glycol is recommended. maintenance procedures with homeowner. �AWARNIN(il Do not use automotive, ethylene glycol, undiluted or petroleum-based antifreeze. Severe personal injury, death or substantial property damage can result. ❑ 50%solution provides protection to about—30'E ❑ Local codes may require back-flow preventer or actual disconnect Follow instructions below to pre- from city water supply. vent severe personal injury,death ❑ Determine quantity according to system water content.Boiler water or substantial property damage: content is listed on back cover of Boiler Manual. • Do not use crankcase drainings or any oil ❑ Percent of solution will affect sizing of heat distribution units, containing gasoline.See burner manual for circulator and expansion tank. proper fuel oil. ❑ Follow antifreeze manufacturer's instructions. ❑ Do not add cold water to hot boiler. Thermal shock can cause • Do not attempt to start burner when excess sections to crack. oil has accumulated in combustion cham- ber, when unit is full of vapor, or when Saltwater Damage — The exposure of boiler components to saltwater combustion chamber is very hot. can have both immediate and long-term effects.While the immediate effects of saltwater damage are similar to those of freshwater(shorting • Do not start burner unless collector hood, out of electrical components,washing out of critical lubricants,etc.),the flue cap, jacket cap, breeching and burner salt and other contaminants left behind can lead to longer term issues mounting door are secured in place. after the water is gone due to the conductive and corrosive nature of • Never burn garbage or paper in the boiler. the salt residue.Therefore,Weil-McLain equipment contaminated with Never leave combustible material around saltwater or polluted water will no longer be covered under warranty boiler. and should be replaced. • DO NOT TAMPERWITH UNIT OR CON- Electrical Damage — If any electrical component or wiring came TROLS.Always follow specific instructions into contact with water,or was suspected to have come into contact with when starting up boiler or performing rou- water,replace the boiler with a new Weil-McLain boiler. tine maintenance or service. continued-top of next page 4 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fum] AWARNING HOMEOWNER and SERVICE TECHNICIAN—read and follow completely. ACAUTION 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.For your protection,take preventative actions such as having a security system installed that operates during power outages,senses low temperature,and initiates an effective action.Consult with your boiler contractor or a home security agency. Routine maintenance schedule Beginning ❑ Call a qualified service technician to perform annual service. each heating season Daily ❑ Check that boiler area is free from combustible materials, gasoline during heating season and other flammable vapors and liquids. ❑ Check for and remove any obstructions to flow of combustion or ventilation air to boiler. ❑ Check that breeching is attached between boiler and chimney.If breeching is loose or damaged,immediately turn off switch on Weekly boiler and call service technician to repair. during heating season ❑ Check for oil leaks in oil piping and around burner.If found,im- mediately call qualified service technician to correct situation. ❑ Check for water leaks in boiler and piping; also check for leaks around tankless heater plate,if installed.If found,immediately call service technician to repair. ❑ If tankless heater is installed,boiler will continue to operate. Check for the following: All daily and weekly instructions listed on this page must be fol- End lowed. of heating season • Burner motor may have to be oiled.Some motors are permanently lubricated and do not need additional oil.Check for oiling instruc- tions on burner or motor. ❑ Do not drain boiler unless exposure to freezing temperatures will occur. ❑ Always keep manual fuel supply shut off if burner is shut down for an extended period of time. Boiler • Turn off switch at boiler and any external switch to boiler. shutdown • Close fuel valves. • Turn off water feed valve. • Cover burner to protect from dust and dampness. Part number 550-141-825/1218 5 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler ManuaiFA AWARNING HOMEOWNER and SERVICE TECHNICIAN—read and follow completely. Operation WTGO (see Figure 1) 2. Correct problems found instep#1.If burner does not fire, 1. If burner does not fire,check for: press reset button on burner primary control only once. • Service switch on control or additional switches turned Repeated presses will deposit oil in combustion chamber. off. , , . Burner must never be fired when oil is in combus- • Fuses or breaker switch tripped. tion chamber. Immediately call qualified service • Thermostat set below room temperature. • Fuel valves turned off. technician. • Not enough oil in tank to supply burner. 3. If burner still does not fire,call qualified service technician. Figure 1 WTGO Boilers 4 1 Burner disconnect plug 3 e 2 Water relief valve Temperature-pressure gauge 2 Circulator 5 Combination limit control, tankless heater control and [Oo low water cut-off(located in tankless heater plate) O00 5 6 Reset button on burner 0 primary control O 1H 0 0 Burner primary control 6 a 1 0264-0566 6 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fum] AWARNING HOMEOWNER and SERVICE TECHNICIAN—read and follow completely. Troubleshooting AWARNING Homeowners—The problems and corrections below represent common situations that can occur.There maybe 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 Possible Corrections Rapid cycling—burner Thermostat installed where Locate thermostat on inner wall away from heat sources or cool drafts. turns on and off frequently. drafts or heat affect reading. Heat anticipator in thermo- Adjust heat anticipator to match current draw.Refer to boiler wiring stat adjusted incorrectly. diagram. Incorrect limit setting. Have qualified service technician increase limit setting to decrease cycling.Maximum setting 220'E Need to frequently add Leaks in boiler or piping. Have qualified service technician repair leaks at once to avoid constant makeup water. use of makeup water. Popping or percolating Mineral deposits in sections Have qualified service technician de-lime boiler,repair leaks at once noise heard in boiler. due to constant use of make- to avoid constant use of makeup water and check pH (between 7.0 up water,or incorrect pH. and 8.5). Black water condition. Oxygen corrosion due to Have qualified service technician repair leaks at once to avoid constant leaks in piping. use of makeup water and check pH(between 7.0 and 8.5). Frequent release of water Expansion tank sized too Have qualified service technician check expansion tank operation. through relief valve. small or water-logged. Metal flakes found in Contaminated combustion Remove sources of hydrocarbons in or near boiler area. (Bleaches, flueway. air supply. cleaners,chemicals,sprays,fabric softeners,paint remover,etc.) Condensation of combustion Have qualified service technician check boiler operation. gases. Some radiators or Air in system. Bleed air from system through air vents in radiators or baseboard units. baseboard units do not heat or are noisy. Low system pressure. Have qualified service technician check for leaks in boiler or piping at once. High limit set too low. Have qualified service technician adjust limit to higher setting. Domestic water from Mineral deposits insulate Have qualified service technician de-lime or replace coil. tankless heater is hot then internal waterways of heater. suddenly turns cold. OR Boiler stop-leak compound Have qualified service technician remove and clean coil and drain, Domestic water from has been added to boiler wa- and flush boiler to remove stop-leak. tankless heater is always ter and is insulating outside lukewarm. of coil. Incorrect mixing valve setting Have qualified service technician adjust mixing valve setting. for tankless heater. Domestic flow rate too high. Have qualified service technician install flow check valve set to rating of tankless heater. Incorrect setting on tankless Have qualified service technician raise tankless control setting.Adjust heater control. differential on tankless control to lower setting. Part number 550-141-825/1218 7 Fum]GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual AWARNING 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 quali- fied 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. Installations must comply with Provide clearances around boiler • United States (see Figure 2) • State and local plumbing,heating and electrical codes. NOTICE Jacket cap must be in place on boiler to • National codes where applicable. avoid requiring an 9"minimum clearance • Canada from back or top of boiler to combustible • Canadian Standards Association,CSA B139,Installation Code for material. Oil-Burning Equipment-latest edition. MINIMUM clearances from vent pipe to combus- • CSA C22.1 Canadian Electrical Code Part One -latest edition. tible material: • Applicable local or provincial codes. • 6 inches — Type"L"double-wall vent* Before selecting boiler location 9 inches — Single-wall vent NOTICE Flue pipe clearances must take precedence • Check for nearby connections to: over jacket clearances. • System water piping. Recommended SERVICE clearances: • Chimney.See page 16.Boiler can be top or back vented. 24 inches — Front and top • Combustion and ventilation air supply.See page 9. 6 inches — Left side,back and right side • Oil supply.See page 28 for oil line routing. 12 inches — Right side for burner door swing • Electrical power. radius • Check area around boiler.Remove any combustible materials,gasoline Special close clearances(alcove,closet,under counters, and other flammable liquids. etc.)—see Appendix,page 34. AWARNING 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. Figure 2 Recommended service clearances Walls j �LLLL1� Ceiling � A II24" A10 24" B-*- / r---i A Top View A Provide 6"minimum clearance for service,provide 12" minimum clearance for burner door swing. Wall B Minimum clearance from vent pipe to combustible mate- rial:6"for type"L"double-wall vent,9"for single-wall Floor vent. � Left side 8 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Before installing boiler (continued) Provide air for combustion and ventilation Lay a foundation, if needed AWARNING Do not install exhaust fan in boiler 0 room. Boiler may be installed on non-carpeted combustible flooring. Adequate combustion and ventilation air: For residential garage installation, install boiler so • Assures proper combustion. burner is at least 18 inches above floor to avoid contact • Reduces risk of severe personal injury or death from possible flue gas with gasoline fumes. leakage and carbon monoxide emissions. A level concrete or masonry foundation is required when: Older buildings with single-pane windows,minimal weather-stripping and Floor could possibly become flooded. no vapor barrier often provide enough natural infiltration and ventilation Non-level conditions exist. without dedicated openings. New construction or remodeled buildings are most often built tighter. Solid concrete blocks can be used to create a pad. Windows and doors are weather-stripped, vapor barriers are used and openings in walls are caulked.As a result,such tight construction is unlikely Table 1 Boiler foundation sizes to allow proper natural air infiltration and ventilation. Follow state,provincial or local codes when sizing adequate combustion and Boiler Length Width Min. ventilation air openings.In absence of codes,use the following guidelines model inches inches height when boiler is in a confined room(defined by NFPA 31 as less than 7200 inches cubic feet per 1 GPH input of all appliances in area.A room 8 ft. high x WTGO-2 17 22 2 33.5 ft.x 33.5 ft.is 7200 cu.ft.): • Provide two permanent openings—one within 12 inches of ceiling, WTGO-3 17 22 2 one within 12 inches of floor. Minimum height or length dimension of each rectangular opening should be at least 3 inches. WTGO-4 20 22 2 • 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 WTGO-5 20 22 2 fuel-burning appliances plus requirements for any equipment that can pull air from room(including clothes dryer and fireplace). WTGO-6 23 22 2 • 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 WTGO-7 26 22 2 outdoors.Size per below: • Through outside wall or vertical ducts — at least 35 sq. in. per WTGO-8 29 22 2 1 GPH input (1 sq. in. per 4000 Btu input) of all fuel-burning appliances plus requirements for any equipment that can pull air WTGO-9 32 22 2 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. Part number 550-141-825/1218 9 Fum]GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual AWARNING 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. NOTICE Circulator will be damaged if not removed before 2. Install air vent in"N"tapping on top boiler. boiler is lifted from pallet. 3. Plug supply and return tappings. 2. Remove boiler from pallet. 4. Drain valve is already factory-installed. NOTICE Do not drop boiler or bump jacket on floor or 5. Fill boiler.Vent all air.Pressure test boiler at 11/2 times work- pallet.Damage to boiler can result. ing pressure. A CAUTION Smaller sized boilers may be top heavy.Use caution AWARNING Do not leave boiler unattended.Cold water fill can when handling to avoid minor personal injury or expand and damage cast iron,resulting in severe property damage. personal injury,death or substantial property dam- age. 3. Boiler is shipped for back flue outlet.To change to top flue 6. Check for maintained gauge pressure for more than 10 min- outlet(see Figure 3,page 11): utes.Visually check for leaks if gauge pressure drops. a. Remove jacket cap on top of boiler. b. Loosen two screws holding flue cap strap to collector 7. Drain boiler.Repair leaks if found. hood. Remove strap and flue cap from opening. Re- ACAUTION Do not use petroleum-based sealing compounds tighten screws. to repair leaks.Damage to system components can c. Check rope placement inside flue cap. result,causing property damage. (Read AWARNING under step#6). 8. Retest boiler after repairing leaks. d. Loosen two screws on back flue outlet. Set flue cap on 9. Remove air vent and plugs.Reinstall relief valve. outlet.Install strap by engaging slots in screws.Tighten screws.Make sure cap is securely installed. e. Snap jacket cap in back outlet opening. NOTICE Jacket cap must be in place on boiler to avoid re- quiring an 18"minimum clearance from back 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. AWARNING Obtain gas-tight seal to prevent possible flue gas leakage and carbon monoxide emissions, which can lead to severe personal injury or death. 10 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fum] AWARNING 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) Sealing rope inside groove Jacket cap in cap insulation , o Flue cap Flue cap strap Jacket cap 82601 Instructions for packaged boilers are continued on page 15. Part number 550-141-825/1218 11 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boller ManualFua AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Install boiler — non-packaged boilers only AWARNING Fiberglass wool and ceramic fiber materials are possible cancer 3. Non-Packaged WTGO-7,8&9— install flue col- hazards.See warning on page 33. lector hood (see Figure 4,page 13): AWARNING Obtain gas-tight seal to prevent possible Place boiler flue gas leakage and carbon monoxide emissions, leading to severe personal 1. Non-Packaged WTGO-3 through 6—position on site. injury or death. AWARNING Smaller sized boilers may be top heavy. Use caution when a. Thread Tinnerman clip on screw so that clip handling to avoid minor personal injury or property damage. fits snugly in notch of hold-down lug. Screw must not turn. a. Boiler is shipped for back flue outlet.To change to top flue outlet (see Figure 4,page 13): b. Remove paper on sealing rope.Starting at back • Loosen two(2)screws holding flue cap strap to collector hood. section near flue collar, position sealing rope Remove strap and flue cap from opening.Re-tighten screws. around top of block with adhesive side to sec- tions.Do not stretch rope.Make sure rope ends • Check rope placement inside flue cap. (Read AWARNING under meet.Trim excess rope. Step#3.) • Loosen two(2)screws on back flue outlet. Set flue cap on outlet c. Position flue collector hood on top of boiler Install strap by engaging slots in screws.Tighten screws. Make sections and over screws and clips as shown in sure cap is securely installed. Figure 4. 2. Non-Packaged WTGO-7,8&9—split the assembled block for easier d. Install washers and nuts.Tighten nuts until col- handling(see Figure 4): lector hood makes contact with Tinnerman clip. a. Open burner mounting door and, using utility knife, slit floor e. Back flue outlet boiler — Position flue cap insulation at joint to be separated. and strap over opening in flue collector hood. b. Remove 51/2"draw rod and the longest draw rod from each side. Make sure rope in cap is in place and in good Pull block apart. Save draw rods,nuts,washers and sealing rings condition. Tighten strap to hood with screws for reassembly. provided. c. Move divided block to location. Top flue outlet boiler—Position flue cap and d. Clean port openings with clean rag. strap over opening in back section. p petroleum use Do not etroleum-based compounds to clean openings. f. Make sure rope in cap is in place and in good ACAUTIUN Damage to system components can result,causing property condition.Tighten strap to boiler with screws provided in section.Install remaining screws in damage. holes in flue collector hood. e. Place rings in port openings.If ring slips out of groove,stretch ring gently for several seconds,then place in groove. Tankless heater, if used f. Position sections so aligning lugs fit into sockets of next section. Make sure sealing rope is in good condition and in position. 1. Remove tankless heater cover plate and gasket. g. Oil threads on draw rods. Install washer and nut on end to be 2. Install new gasket and tankless heater over studs tightened.Use nut only on other end. around opening.Secure with 3/8"nuts,tightening h. With wrench at washer/nut end,uniformly tighten nuts starting until metal-to-metal contact is made(20-25 ft-lbs). with 51/2"rod at large port,51/2"rod at small port,bottom long rod and finally top long rod. i. Torque on both 51/2" 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. 12 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Install boiler — non-packaged boilers only (continued) Figure 4 Change from back flue outlet to top flue outlet(optional) Nut Washer Tinnerman clip Sealing � rope in groove Flue Screw inside cap Hold-down collector hood lug Sealing rope with adhesive tape Flue cap Flue cap strap ozso-oss Separate block here for easier handling Part number 550-141-825/1218 13 FmalGOLD WTG O OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Install boiler — non-packaged boilers only ;ontinued) Perform hydrostatic pressure test 7. Visually check: a. Sealing rope placement 1. Refer to Control Tapping Table 2 and Figure 5 to install: b. Metal-to-metal contact around port openings. a. Boiler drain. c. Flue collector hood seal. b. Water pressure gauge (test only). Be sure gauge can d. Burner mounting door seal. handle test pressure. c. Air vent in upper"N"tapping. AWARNING Obtain gas-tight seal to prevent possible flue gas leakage and carbon monoxide emissions, which d. Plugs in remaining tappings. can lead to severe personal injury or death. 2. Fill boiler.Vent all air.Pressure test boiler at 11/2 times work- ing pressure.For boilers split and reassembled,test between 75 and 85 psig. Install jacket AWARNING Do not leave boiler unattended. Cold water fill (required on sizes 7 through 9 only) could expand and damage cast iron,resulting in Before installing jacket,remove burner mounting door.See jacket severe personal injury,death or substantial prop- instructions for details. erty damage. 3. Check for maintained gauge pressure for more than 10min- Install boiler controls utes.Visually check for leaks if gauge pressure drops. 4. Drain boiler.Repair leaks if found. See Control tapping(Table 2),Figure 5, and Figure 6 to install controls. A CAUTION Do not use petroleum-based compounds to repair 1. Install tankless heater control if tankless heater is used. If leaks. Damage to system components can result, not furnished, use operating control with maximum 10°F causing property damage. differential. 5. Re-test boiler after repairing leaks. 2. Install limit control. If not furnished, use high limit with 6. Remove pressure gauge, air vent and plugs from tappings maximum 220°F setting. used for controls. 3. Affix CP number label(s) on jacket front panel. Table 2 Control tappings Figure 5 Control tapping locations Location Size Function E3 N C B1 11/2" Return piping IL/ L B2 11/2" Alternate return piping for R1 A/B WTGO 0 C 11/2" Supply piping E3 1/4" Pressure-temperature 1 gauge H 3/4 Drain valve L 3/4" High limit control (in tankless heater cover plate) 0 N 1/2" Air vent or expansion tank o (� B2 piping �B1 H .,. 7_. R1 3/4" Relief valve Front section Back section 14 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Install burner — all boilers Install burner For P-WTGO and A-WTGO boiler (also refer to instructions packed with burner) 1. Secure universal mounting flange and gasket to burner mounting door. Use three bolts provided. Use only burners specified for use on 2. Secure burner on flange with three bolts. NOTICE Weil-McLain GOLD oil boilers. DO 3. Position burner so end of air tube is level to 11/2'tilt downward.Open NOT use burners specified for use on door to verify burner position.End of air tube should be flush to 1/4" Weil-McLain Model 68 boilers. Contact recessed from inside wall of burner door refractory.Check for secure individual burner manufacturers for placement of insulation on target wall, chamber floor and burner proper burner selections. mounting door.Securely close door with nut. Figure 6 Water boiler controls J Circulator ID Water pressure-temperature gauge Relief �0 1 valve J � o CO) Combination DODO Limit control and low water cut-off 0 Drain valve V,7Ga-M Part number 550-141-825/1218 15 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boller ManualFua AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect breeching General chimney requirements Table 3 Minimum chimney sizes • Designed for natural draft firing.Connect boiler to vertical chim- ney. Minimum AHRI F,JMinimum chimney size Minimum � , Insufficient draft can cause flue gas leakage and carbon Bo breeching monoxide emissions,which will lead to severe personal model diameter chimney injury or death. number Note a height Rect. Round • Use vent material approved by local codes for oil-fired burners.In their absence,refer to: • NFPA 31,Installation of Oil-Burning Equipment. WTGO-3 5" • NFPA 211,Standard for Chimneys,Fireplaces,Uents and Solid Fuel 8 x 8 (Note 1) 6" 15' Burning Appliances. • In Canada, refer to CSA B139, Installation Code for Oil- WTGO-4 6" Burning Equipment. • NFPA 211 requires chimney to be lined before connected to boiler. WTGO-5 6" Inspect existing chimney before installing new boiler. Failure to do any of the following will result in severe 8"x 8" personal injury or death: WTGO-6 (Nate 1) 7" 15' • Clean chimney,including removal of blockage. 71[ • Repair or replace damaged pipe or liner. WTGO-7 • Repair mortar and joints. To prevent downdrafts,extend chimney at least 3 feet above highest WTGO-8 point where it passes through roof and 2 feet higher than any portion 7„ 8"x 12" 7" 20' of building within 10 feet.Increase chimney cross-sectional area and (Note 2) height at least 4%per 1,000 feet above sea level. WTGO-9 • Minimum clearances from vent pipe to combustible material: Type"L"double-wall vent — 6 inches Note 1 6 3/4"x 6 3/4"inside liner Single-wall vent — 9 inches • Minimum chimney sizes should be used. Note 2 6 1/2"x 101/2"inside liner NOTICE Oversized chimneys,outside masonry chimneys and/or de-rated inputs can result in condensation in chimney. Note 3 Flue collar on boiler is 7"diameter Connect breeching AWARNING Long horizontal breechings, excessive numbers of tees 4. When burner and boiler are properly installed, draft and elbows or other obstructions restricting combustion overfire will be approximately -0.01" to -0.02" W.C. gas flow can result in possibility of condensation,flue gas Install barometric control in breeching, per control leakage and carbon monoxide emissions,which can lead manufacturer's instructions, when excess draft needs to severe personal injury or death. to be relieved or to comply with applicable codes and 1. Install 2 flue pipe brackets. regulations.Use draft gauge to adjust proper opening. 2. Connect full-sized breeching when possible.See Minimum Chim- 5. An induced draft fan for the chimney may be neces- ney Size Table. sary if: Back outlet — see Figure 7,page 17. • Excessive resistance to flow of combustion gases can be expected. Top outlet — see Figure 8,page 17. Cross-sectional area of chimney is smaller than minimum recommended. 3. Connection must be made above bottom of chimney to avoid Chimney height is less than recommended. blockage.Breeching must not enter chimney far enough to cause obstruction. Use thimble or slip joint where breeching enters AWARNING Seal all vent joints.Interlock burner with fan chimney to allow removal for cleaning. operation. 16 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manuai Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect breeching (continued) Figure 7 Back outlet breeching connection Typical location for barometric control (Also see control manufacturer's instructions) 0 Flue pipe bracket (One on each — side of pipe) 0 025�-056 Figure 8 Top outlet breeching connection Typical location for barometric control - --� _ (Also see control manufacturer's instructions) Flue pipe bracket ° (One on each side of pipe) ° 0 0 0250-056 Part number 550-141-825/1218 17 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boller ManualFA AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect water piping General piping information Table 4 Water piping sizes • 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 Boiler model To system From system limit is needed.If installation is to comply with Canadian requirements, number an additional high temperature limit maybe needed. Consult local inspector.Install control in supply piping between boiler and isolation valve.Set control to a minimum of 20°F above set point of combination control.Maximum allowable set point is 220°E Wire control as shown WTGO 3 1/a" 1/4" on wiring diagram. • Use backflow check valve in cold water supply as required bylocal codes. WTGO-4 1 1/4" 1 1/4" Install piping: WTGO-5 11/2" 11/2" • See Figure 9 or Figure 10,page 19 and Water Piping Size Table 4 for near-boiler piping and single-zone piping. See page 20 to complete WTGO-6 11/2" 11/2" multiple-zone piping or page 21 to complete piping for systems oper- ating below 140°F. WTGO-7 1�/2" 1�/2" • For multiple-boiler piping,refer to Weil-McLain's"Primary/Secondary Piping Guide." • Install relief valve vertically in "Rl" tapping on front of boiler. See WTGO-8 2" 2" Figure 9 or Figure 10 and also refer to tag attached to relief valve for manufacturer's instructions. WTGO-9 2" 2" AWARNING Pipe relief valve discharge line near floor close to floor drain *All sizes based on 20°F severe to eliminate potential of b Do not pipe to an piping p p p y temperature rise through boiler. area where freezing could occur.Do not plug,valve or place any obstruction in discharge line. DIAPHRAGM expansion tank Connect tank from"N"tapping shown in Figure 10 (Figure 9) to expansion tank.Use 1/2"NPT piping. Pitch any horizontal piping up towards tank 1 inch per 5 • Make sure expansion tank size will handle boiler and system water feet of piping. volume and temperature.Tank must be located near boiler before inlet to circulator.See tank manufacturer's instructions for details. ACAUTION Undersized expansion tanks cause system water to be lost To connect WTGO boilers to from relief valve and makeup water added through fill valve. indirect-fired water heaters Eventual section failure can result. • Install automatic air vent in"N"tapping as shown in Figure 9. Install and wire per water heater manual provided with water heater. CLOSED expansion tank If boiler has a tankless heater installed: (Figure 10) Remove tankless heater and install cover plate. • Ensure expansion tank size will handle boiler and system water volume OR and temperature. • Undersized expansion tanks cause system water to be lost from relief Leave tankless heater installed. Drain coil and re- valve and makeup water added through fill valve. Eventual section move piping.Do not plug holes in tankless heater failure can result. front plate. 18 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manuai Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect water piping Figure 9 Piping with DIAPHRAGM expansion tank Circulator Isolation <� valve Automatic air vent To system "C"tapping From Isolation system "N"tapping valve Relief Cold water valve fill i To diaphragm expansion tank 0254.056 and fittings Circulator "B1"tapping (Alternate circulator location) Figure 10 Piping with CLOSED expansion tank Closed type expansion tank Circulator Cold water fill Isolation valve To system "C"tapping From V""N"tapping system Relief valve Isolation valve i 0255-056 Circulator z (Alternate circulator location) "131"tapping Part number 550-141-825/1218 19 Fum]GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect water piping (continued) Piping MULTIPLE ZONES Figure 11 Multiple zoning with CIRCULATORS Follow instructions on page 18 and page 19 to install piping near boiler. —� ---F Zone 2 — ---i See Figure 11 or Figure 12 to complete installation. L— } Zoning with circulators: Zone 1 1I 1. Size each circulator to individual circuit require- 2 `c ments. 2. Remove circulator (when furnished as standard 1 I' equipment). ' IT 3. Install balancing valves to adjust flow to distribute 5 heat to all zones. 4. Separate relay is required for each circulator. Zoning with zone valves: 0 1. Install balancing valves to adjust flow to distribute heat to all zones. 2. Separate transformer is required to power zone valves. Refer to"Weil-McLain Zone Valve Wiring Guide"for details. -71 0253-055 Legend 3 Circulator Figure 12 Multiple zoning with ZONE VALVES 1 Isolation valve 4 Zone valve —� ---F— Zone 2 I__ -- L----- I I 2 Flow control valve 5 Drain valve j Zone 1 I 4 I 5 -71 Lr szss-ss5 20 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect water piping Piping for systems requiring Figure 13 Piping with CIRCULATORS temperatures below 140°F —� -- Zone 2— ---i In most systems,this type of piping is not required.If L———— r----- } I system water temperature requirements are less than Zone 1 I 140°F,such as radiant panels or converted gravity sys- tems,use piping as shown in Figure 13 or Figure 14.If 2 Q P P g � >� li system piping is plastic without an oxygen barrier, a 2 as Max. 4 3 heat exchanger must be used. 12'°�.- 1 7 1 6 6 7 8 i E 0 9 0 Lf 0262-056 Legend 7 System temperature Figure 14 Piping with ZONE VALVES valves 1 Isolation valve Adjust valves so that: —� -- Zone2 —� ------- -the temperature at L————� 2 Flow control valve gauge 8 is at least 140°F 3 Circulator -the temperature at j Zone t 4 System temperature gauge 9 is at least 160°F 1 gauge 8 Blend temperature 4a Max. 4 5 5 Zone valve gauge 12" 3 9 Boiler temperature 6 Drain valve gauge 7 6 t 6 8 7 ;;c 0 9 0 Part number 550-141-825/1218 21 Fum]GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manuai AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect water piping kcontinued) Use with refrigeration systems Figure 15 Use with refrigeration system • Install boiler so that chilled medium is piped in 1 parallel with heating boiler.Use appropriate valves to prevent chilled medium from entering boiler. Supply Exp.tank Consult AHRI Installation and Piping Guides. 1 • If boiler is connected to heating coils located in air handling units where they can be exposed to Circ. Circ. refrigerated air, use flow control valves or other automatic means to prevent gravity circulation Chiller during cooling cycle. Strainer Exp.tank 1 2 1 ozss-as 1 Isolation valves 2 Balancing valve 22 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect tankless heater piping To pipe tankless heater: Hot Water Can Scald! 1. Size piping no smaller than tankless heater inlet and outlet. 2. Following controls(furnished by others)must be installed: • Consumer Product Safety Commission and a. Automatic mixingvalve. -See Figure 16. some states recommend domestic hot water b. Flow regulating valve. Size according to intermittent draw of tankless temperature of 130°F or less. heater.See Table 5 Follow valve manufacturer's instructions to install. 3. Additional anti-scald devices maybe installed at each hot water faucet, • When installing an automatic mixing valve, bath and shower outlet. selection and installation must comply with 4. In hard water areas,soften cold domestic supply water to heaters to valve manufacturer's recommendations and prevent lime build-up instructions. • Water heated to a temperature suitable for AWARNING Studies have indicated that dangerous bacteria can form1 clothes washing,dish washing and other sanitiz- in potable water distribution systems if certain minimum ing needs will scald and cause injury. water temperatures are not maintained. Contact local health department for more information. • Children, elderly, infirm or physically handi- capped persons are more likely to be injured by hot water. Never leave them unattended in or near a bathtub,shower or sink.Never allow ® Tankless water heaters for WTGO and P-WTGO small children to use a hot water faucet or draw boilers have been tested and certified by their own bath.If anyone using hot water in the C US CSA Group(certificate#2552127). building fits this description,or if state laws or NSF/ANSI local codes require certain water temperatures 372 at hot water faucets,take special precautions: These single wall heat exchangers comply with National Standard • Install automatic mixing valve set according Plumbing Code provided that: to those standards. Boiler water(including additives)is practically non-toxic,having a • Use lowest practical temperature setting. toxicity rating or class of 1,as listed in Clinical Toxicology of Com- mercial Products. • Check water temperature immediately after Boiler water pressure is limited to max.30 psig by approved water first heating cycle and after any adjustment. relief valve. Table 5 Tankless heater ratings Figure 16 Tankless heater piping Limit Control with Flow Regulating Tankless Control Valve Boiler Intermittent Inlet model Heater draw and outlet Cold Water number number ratings tapping _ Supply (gpm)* sizes F WTGO-3 WT-14 3.25 1/2" @ 0 I ® I J WTGO-4 WT-14 3.75 Y2" Mixed WTGO-5 WT-14 4.00 1/2" o 12" min. WTGO-6 WT-14 4.25 1/2" WTGO-7 WT-20 5.50 1/2" WTGO-8 WT-20 5.75 1/2" Hot O WTGO-9 WT-20 6.00 1/2" Automatic Mixing Cold * Gallons of water per minute heated from 40°F Valve to 140°F with 200°F boiler water temperature. Tested in accordance with AHRI Testing and Rating Standard for Indirect Tankless Water O Heaters Tested with Boilers. os Part number 550-141-825/1218 23 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boller ManualFA AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect wiring General wiring requirements General wiring WARNING Electric shock hazard. Can cause severe personal "P"boilers have harnesses furnished. A injury or death if power source,including service A'boilers are furnished with burner and limit harnesses switch on boiler,is not disconnected before install- integrated with Hydrolevel control. ing or servicing. All field-provided high voltage wiring must be sheathed in • Installations must follow these codes: flexible metal conduit. • National Electrical Code,ANSI/NFPA 70,-latest edition Connect incoming line voltage"HOT"wire to service switch, and any additional national,state or local codes. and neutral wire to white wire. Field-install equipment • In Canada,CSA C22.1 Canadian Electrical Code Part 1, ground wire to green wire with wire nut inside Hydrolevel -latest edition and any local codes. control. • Wiring must be N.E.C. Class 1.If original wire as supplied with boiler must be replaced,type 105°C wire or equivalent Service switch is integrated into the Hydrolevel control. must be used.Supply wiring to boiler and additional control Some local codes may require an emergency shut-off switch wiring must be 14 gauge or heavier. installed at a location away from boiler.Follow local codes. • Provide electrical ground at boiler as required by codes. Burner wiring Thermostat wiring Burner harness incorporates a disconnect plug,providing a • Install thermostat on inside wall away from influences of convenient way to disconnect wiring when burner mounting drafts,hot or cold water pipes,lighting fixtures,television, door is opened. sun rays or fireplaces. All"P"boilers have a power disconnect plug installed on • Follow instructions with thermostat. If it has a heat an- burner. ticipator,set heat anticipator in thermostat to match power On"N'boilers, mount the plug (provided in water trim requirements of equipment connected to it. Boiler wiring diagrams give setting for standard equipment. carton) on the burner housing as shown in Figure 17. For Carlin burners, screw burner plug into threaded conduit coupling,then mount this assembly to the burner housing Zone Valve Wiring using the chase nipple. High temperature limit ACAUTION DO NOT connect directly from 3-wire To comply with ASME,UL 726 or Canadian requirements, zone valves to the T T terminals on the an additional high temperature limit is needed. boiler.When using 3-wire zone valves,install Install the secondary control in the supply piping between an isolation relay.Connect the zone valve end boiler and isolation valve. switch wires to the isolation relay coil.Connect Set the control to a minimum of 20°F above the set point of the isolation relay contact across the boiler the combination control. T-T terminals.Failure to comply can result in • The maximum allowable set point is 220°F. damage to boiler components or cause unre- liable operation, resulting in possible severe Wire the control as shown on page 26. property damage. 4-wire zone valves may be connected directly to the boiler control. 24 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manuai Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect wiring (continued) Figure 17 Boiler wiring for forced hot water Limit control ¢Do O CO) C 1H Service 110 switch on 110 control Burner ° wiring harness Burner disconnect plug WTGO-20 Part number 550-141-825/1218 25 Fum]GOLD WTG O OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Man uai AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect wiring Continued) Figure 18 Wiring diagram Boiler Wiring Riello 530 SE/C Primary Control AWARNING Electrical shock hazard—can cause severe injury or death. PRIMARY Disconnect power before installing or servicing. Aux. POSITION CONTROL KEY BK SUB-BASE ACAUTIDN DO NOT connect directly from 3-wire zone valves to the T-T terminals BK L / 0� t t BL on the boiler.When using 3-wire zone valves,install an isolation relay. Connect the zone valve end switch wires to the isolation relay coil.Connect G QT 10 t DAMPER O the isolation relay contact across the boiler T-T terminals.Failure to comply W MOTOR s YBURNER can result in damage to boiler components or cause unreliable operation, resulting in possible severe property damage. BURNER $ DISCONNECT 7 Low Limit Setting: ON BOILER 6 WGO- Set to "OFF" 5 WTGO-Set Low Limit Temperature Q43 POWER SWITCH BK C 2 BL 1 HOT '4 BR BURNER PRIMARY Ll PK SOLENOID VALVE CONTROL NEUTRAL Lz —BURNER WIRING------------------------------J SPILLSWITCH r T ZRO (REQUIRED FOR Carlin 70200 Primary Control CANADIAN T ZCO INSTALLATION) TRANSFORMER BK'- BK.____ BL THERMOSTAT /IGNITOR IGNITOR NOTES) B1 OI O O O BL W W L2 IGN A W O; ADDITIONAL ( ) Alarm B20 __ TEMPERATURE Circuit LIMIT CONTROL Y POSITION O < MOTOR �C G C1 BK (WHEN USED) KEY BK O Y/ W L2(MTR) C2O BURNER W R/W MOTOR RNV F2 L1 G BK LIMIT F1 CIRCULATOR W HARNESS TO W L2 CAD cell CIRCULATOR BURNER V Y DISCONNECT W VALVE ON BOILER L80VFLA ENOID L2(VLV) T2 W LVE W O< L1 Our Ti BURNER L10UT BK PK DISCONNECT a0 CAD cell flazne detector. G G ©Jumper these T-T terminals. Connect thermostat to boiler W G BURNER �high limit. BURNER POSITION GROUND BURNER `cJ Low voltage alarm circuit_ HARNESS KEY SCREW JUNCTION BOX O Cap L1 OUT which is live 120V. BURNER WIRING----------------------- — — — Beckett GeniSys Primary Control 7505 NOTICE Burners with Beckett Clean Cut Pump must be used with a primary L RANSFORMER BL/W control that has avalve-on delay(pre-purge).Controls shown have /IGNITOR IGNITOR NOTES: valve on delay(see control manufacturer's Instructions for timings.) NJ 0 W W L2(IGN) Optional Alarm O Circuit POSITION O W W <MOTOR Optional 1.All wiring must be installed In accordance with N.E.C.and any other KEY R BURNER � L2(MTR) Alarm national,state,or local code requirements.For Canadian installations,all T MOTOR BK Module wiring must comply with the Canadian Electrical Code. R I Ll 2.All wiring must be N.E.C.Class 1. LIMY TR3.Refer to control component instructions packed with the boiler for WLz application information. BURNNE V W J `�4.Ifanyofthe original wire as suppliedwith the appliance mustbe replaced, DISCONN w VALVE use minimum 105°C wire or equivalent. ONBOILOLENOID L2(VLV) primar5.Set thermostat heat anticipator as per control manufacturer's VALVE Y CAD Control recommendations. J WJF;: Y CELL (Front) BURNER PRIMARY 120 VAC FIELD WIRING Cl CONTROL(Battmeu LOW VOLTAGE FIELD WIRING G O OSumperTR-TW terminals_ 120 VAC FACTORY WIRING — Connect thermostat to boiler LOW VOLTAGE FACTORY WIRING BURNER _ high limit. GROUND BURNER L< 1/4"QUICK CONNECT TERMINAL SCREW JUNCTION BOX —BURNER WIRING -—-—-—-—-—-—-—-—-—-—-—-—-—-—- WGO WTG O WG° IN WEIL•mcLA�N • Water without tankless heater WTGO Weil-McLain•500 Blaine St.•Michigan City,IN 46360-2388 2 thru 9 3 thru 9 • Water with tankless heater PART NUMBER 550-200-018/0417 IIIIIIIIIIIIIIIIIIIIIIIIIIIIII 26 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual Fun] AtNARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect wiring — blocked vent shutoff switch option Blocked Vent shutoff switch 2. Install Spill Switch(BVSS)Wiring Harness(P/N 591-391-942)as fol- lows: NOTICE In Canada,blocked vent shutoff switch kit a. Remove cover from BVSS Box. (see parts list page 36)must be installed. b. Install straight fitting end of the harness on the BVSS Box. Install See Figure 19. The wiring diagram in elbow(90o)end fitting on the right side of the Hydrolevel control. Figure 20 shows boiler wiring only up c. Install both the fork ends to the screw terminals on the BVSS Switch to the burner disconnect.For additional as per the wiring diagram,(see Figure 20). information, refer to manufacturer's d. Replace BVSS box cover. instructions. e. Locate Combination Control, remove cover, and disconnect red AWARNING Electric shock hazard.Turn off electrical wire from`B 1"terminal. 0 power supply at service entrance panel f. If red wire from Step"e" has uninsulated female end,replace it before making any electrical connections with insulated female end as supplied in kit. to avoid possible electric shock hazard. g• Connect female end of Spill Switch BVSS Harness (blue wire) to Failure to do so can cause severe personal "B 1"terminal. injury or death. h. Connect male end of Spill Switch BVSS Harness to the red wire removed in Step"e". i. Replace Combination Control Cover. After installing BVSS switch,proceed as follows 3. Turn on power and verify safe operation of the appliance. 1. Disconnect power. 4. Restore boiler to normal operation. Figure 19 Blocked vent shutoff switch installation Figure 20 BVSS wiring diagram Spill switch Combination high limit, 120 vac relay& O * Install BVSS upstream of transformer field wiring O barometric control Hot Low voltage PK field wiring BVSS(WMo-1) Neutral L1 Low water — cutoff 120 vac L2 (when used) factory wiring Spill switch __r — wiring harness T ZRQ Spill switch Low voltage g 1 T ZCO (required for Canadian factory wiring _ Thermostat B ___K; BK,---- installation) Combination B1 Q I �p Q—Q limit control 6-$„ _ B2 Q - W Additional - ' temperature Y limit control C1 Q I BK (when used) G C201 w ° III IIIo Circulator R harness \ CFirculator Y To pump W Burner BK C PK disconnect G i \i To � 1 < burner 8 � L W G Burner Position ® BVSSWiringDiagram harness key BVSSW iringHo�kup-WTGO Part number 550-141-825/1218 27 Fum]GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Connect oil piping General oil piping requirements AWARNING Do not use Teflon tape as an oil pipe sealant.It can cause valves to fail,creating • Location and installation of oil tanks, oil piping and burners must hazards.Do not use compression fittings. follow: • NFPA 31,Standard for the Installation of Oil-Burning Equipment. Underground pipe must be run in a casing to pre- In Canada,CSA B139,Installation of Oil-Burning Equipment. vent oil leaking into ground or under floor.Check • Local codes and regulations. local codes for information. • Information provided with burner and fuel pump. Oil piping connection at burner • If any part of fuel oil tank is above level of burner,installation of an anti-siphon device is highly recommended to be used to prevent flow See Figure 21 for recommended connection at of oil in case of oil line break. burner,allowing burner mounting door to swing • Support oil lines as required by codes. open completely for servicing. • Make tank connections with swing joints or copper tubing to prevent breaking in case the tank settles.Make swing joints so they will tighten as tank settles.Non-hardening pipe joint compounds should be used on all threads. Figure 21 Recommended oil piping connection to burner 0 ,I 0208-025 See local codes for Flare fitting appropriate arrangement and piping of filter control valves, etc., back to oil tank 28 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual Fum] AWARNING 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 1. Verify boiler is filled with water. drain cock. 2. Open burner mounting door and verify rear tar- t. Fill to correct system pressure.Correct pressure will get wall,floor and burner door insulations are in vary with each installation.Normal cold water fill proper position. pressure for residential systems is 12 psig. Boiler 3. Verify burner mounting door is closed tightly and water pH 7.0 to 8.5 is recommended. burner wiring harness is connected to Hydrolevel NOTICE Failure to maintain recommended pH control. level can cause section failure and leaks. Factory burner adjustment and settings may not be 3. Open automatic air vent one turn. suitable for specific job conditions. See 4. Open other vents. "Burner adjustments". a. Starting on the lowest floor,open air vents one AWARNING Make final burner adjustments using at a time until water squirts out. Close vent. combustion test equipment to assure b. Repeat with remaining vents. proper operation. Do not fire boiler 5. Refill to correct pressure. without water. Sections will overheat, damaging boiler and resulting in sub- When using antifreeze stantial property damage. 4. Vent air from system.Repeat steps 4 and 5 under AWARNING Do not use automotive,ethylene glycol, "Fill the system."Air in system can interfere with undiluted or petroleum-based antifreeze. water circulation and cause improper heat distri- Severe personal injury,death or substan- bution. tial property damage can result. 5. Check boiler and system piping for leaks.See"Tips • Use antifreeze especially made for hydronic systems. for water systems"on page 4. Inhibited propylene glycol is recommended. 6. Inspect breeching and venting for proper operation. • 50% solution provides protection to about-30°F. Do not exceed 50%mixture. Burner adjustments • Local codes may require back-flow preventer or actual disconnect from city water supply. AWARNING Final burner adjustments must be made • Determine quantity according to system water con- using combustion test equipment to as- tent.Boiler water content is listed on back cover of sure proper operation.Do not fire boiler manual.Percent of solution will affect sizing of heat without water or sections will overheat. distribution units,circulator and expansion tank. 1. Refer to burner manual for start-up. • Follow antifreeze manufacturer's instructions. 2. Allow boiler to heat to design condition. • Do not add cold water to hot boiler.Thermal shock 3. Burner should be adjusted to 13% CO or less can cause sections to crack. Z with a smoke level of zero and over-fire of-0.01" to-0.02"Re-adjust burner combustion to account for environmental conditions. Actual CO2 value will vary and should be adjusted for clean and safe combustion operation.Seasonal variations as well as sufficient combustion air supply can affect proper combustion and boiler performance. The burner should only be adjusted by a service profes- sional with appropriate instrumentation. Part number 550-141-825/1218 29 Fum]GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Check-out procedure Check off steps as completed 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. ❑ Boiler and heat distribution units filled with water? ❑ Limit control set to system temperature requirements(max. ❑ Automatic air vent,if used,opened one full turn? 220-F)? ❑ Air purged from system?Piping checked for leaks? ❑ For multiple zones, flow adjusted to distribute heat in all zones? ❑ Air purged from oil piping?Piping checked for leaks? ❑ Thermostat heat anticipator setting(if available)set properly? ❑ Flue cap in place and tightened?Burner door closed,sealed Refer to"Connect wiring,"page 24. and nut tight?Burner plugged in and service switch on? ❑ Boiler cycled with thermostat? Raise to highest setting and AWARNING Obtain gas-tight seal to prevent possible flue gas verify boiler goes through normal start-up cycle. Lower to leakage and carbon monoxide emissions, leading lowest setting and verify boiler goes off. to severe personal injury or death. ❑ Observed several operating cycles for proper operation? ❑ Proper draft and burner flame?Final adjustment made with combustion test equipment? ❑ Set room thermostat(s) to desired room temperature? ❑ Test limit control:While burner is operating,move indica- ❑ Completed Installation and Service Certificate below? for on limit control below actual boiler water temperature. Burner should go off while circulator continues to operate. Raise setting on limit control above water temperature and ❑ Reviewed pages 1-7 with owner or maintenance person and burner should re-ignite. instructed person to keep for future reference? ❑ Test additional field-installed controls: If boiler has a low ❑ Returned all instructions provided with boiler to its envelope water cutoff,additional high limit or other controls,test for and placed with boiler for future reference? Installation and service certificate Date Installed: ❑ Installation instructions have been followed. Boiler Model Number: Series: ❑ Check-out procedure has been performed. ❑ Above information is certified to be correct. CP Number(s): ❑ Information received and left with owner/maintenance Measured Btu or GPH Input: person. Installer: (Company) (Address) (Phone) (Installer's Signature) 30 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Annual service check list Annual Service Call Checklist Dates Comments (follow in order listed below) Check that boiler area is free from combus- t tible materials,gasoline and other flam- mable vapors and liquids. Check for and remove any obstruction Q to combustion and ventilation air flow to boiler. Check breeching and chimney or vent for $ obstructions,damage,etc.Repair or replace as necessary. 4 Clean boiler flueways.See page 32. 5 Perform service on relief valve and circula- tor.See below. Check boiler and piping for leaks and repair 6 if found.Check for leaks at tankless heater plate.Tighten nuts only if leaks are found (for WTGO torque to 20-25 ft.lbs.). Inspect and adjust burner.See burner manual and: change nozzle. check ignition electrode settings. 7 clean blower housing and wheel. make sure blower wheel turns freely. oil burner motor if required. clean air inlet. clean or change fuel filter and strainer. $ Make sure boiler is filled with water. Start unit and verify combustion settings 9 with combustion test equipment. See page 32. 10 Verify operation of all controls on boiler. See page 32. Any parts of the boiler furnished by Weil-McLain must be replaced by parts listed in Weil-McLain Boiler and Repair Parts Book. Controls requiring annual service Water Relief Valve FIM= Scald potential.Do not check Circulator operation of relief valve un- Check operation of water relief valve. less discharge piping has Follow oil-lubricating instructions on cir- Follow instructions on label fastened to been installed according to culator.Over-oiling will damage circulator. relief valve. Boiler Manual. If piping is Water-lubricated circulators do not need not in place, a qualified ser- oiling vice technician must prop- erly install piping. Part number 550-141-825/1218 31 Fum]GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Detailed service procedures Figure 22 Thoroughly clean flueways between all tion chamber floor,and the refractories at the rear of boiler and in the burner pins at all angles.Start on top of boiler, mounting door.Replace any parts as necessary. finish from the bottom. 9. Close burner mounting door and tighten nut securely.Place flue col- lector hood on top of boiler.Secure with hardware from step#2. AWARNING Maintain a gas-tight seal to avoid possible flue gas leakage and carbon monoxide emissions,which can lead to severe personal injury or death. 10. Check breeching for sooting and clean if necessary.Install jacket top panel and breeching. 11. Reconnect oil line and all electrical connections. t General description of control operation i Automatic air vent Air is released when cap is unscrewed one turn. If air vent leaks,remove small cap on top of vent,push in stem of valve and then release to clean ., valve seat.Screw cap completely on,then unscrew one turn. �L ,�- Water relief valve 6L y Provides discharge if boiler pressure exceeds 30 psig. Temperature limit control If high boiler water temperature occurs,control shuts down burner,but allows circulator to run as long as there is a call for heat.Limit should be set higher Cleaning boiler flueways than temperature needed for the system.Maximum limit setting is 220'E Make sure all electrical connections to Circulator boiler are turned off and wait until boiler is warm,not hot,before cleaning.Failure Circulator provides forced water circulation through boiler and piping system. to do so will result in severe personal injury, death or substantial property Pressure-temperature gauge damage. Provides reading of boiler pressure and temperature. Maximum boiler 1. Top flue boilers —remove breeching and jacket pressure is 50 psig, maximum water temperature is 220'E Temperature top panel. Rear flue boilers—remove jacket top will vary according to system and daily heating demands.The range will panel. be from room temperature up to limit control setting. 2. Remove flue collector hood, saving hardware for reassembly. Tankless water heater 3. Shut off oil valves. Arrange drip pans under the Weil-McLain tankless heater ratings are based on 200°F boiler water tem- areas of oil piping that will be disconnected.Dis- perature.To get rated output,set tankless heater control to 200°E Control connect oil line at burner so that you can swing can be adjusted to meet system hot water requirements. open the door completely. 4. Line combustion chamber floor with newspaper to Expansion tank catch any soot that will be loosened in the cleaning As water heats up,it expands.Tank provides a place for increased water volume. process. Maybe open,closed,or diaphragm-type.If relief valve opens frequently,expan- 5. Starting at the top of the boiler,use a wire flue brush sion tank may be water-logged.Drain tank and re-establish proper air cushion. to thoroughly clean between all pins at all angles.Be 1. Open-type—Located above highest radiator or baseboard unit,usu- careful not to damage side walls of rear refractory. ally in the attic or closet.Has a gauge glass and overflow pipe to drain. 6. Move to the bottom of the flueways and clean up 2. Closed-type—Welded gas tight and located above boiler.Tank is par- betweenthe sections to reach pins left uncleaned in step#5. tially filled with water,leaving an air cushion for expansion. 7. Once the flueways are cleaned,carefully remove the 3. Diaphragm-type—Welded gas tight with a rubber diaphragm to separate paper from the floor of the combustion chamber. air from water.Tank must be located near boiler before inlet to circulator. 8. Verify sealing rope around flue area is intact.Visually An air vent must be installed in air vent tapping on boiler when this type check condition and position of insulation in combus- of tank is used.This eliminates air in system.Normal cold water fill pres- sure is 12 psig.Tank pressure maybe checked with an air pressure gauge. 32 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fol AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS or AWARNING The combustion chamber lining or base insula- INSTALLATION OF FIBERGLASS WOOL tion panels in this product contain ceramic fiber OR BASE PANELS' materials that have been identified as carcinogenic, or possibly carcinogenic, to humans. Ceramic AWARNING This product contains fiberglass jacket fibers can be converted to cristobalite in very insulation and ceramic fiber materials in high temperature applications.The International combustion chamber lining or base panels Agency for Research on Cancer(IARC)has con- in gas fired products. Airborne fibers from cluded,"Crystalline silica inhaled in the form of these materials have been listed by the State quartz or cristobalite from occupational sources of California as a possible cause of cancer is carcinogenic to humans(Group 1).": through inhalation. Precautionary measures Precautionary measures ❑ Avoid breathing fiberglass dust and contact with skin ❑ Avoid breathing fiberglass dust and contact with or eyes. skin or eyes. • • Use NIOSH certified dust respirator (N95). Use NIOSH certified dust respirator (N95). This type of respirator is based This type of respirator is based on the OSHA on the OSHA requirements for fiberglass requirements for fiberglass wool at the time this wool at the time this document was writ- document was written. Other types of respirators ten. Other types of respirators may be may be needed depending on the job site condi- needed depending on the job site condi- tions. Current NIOSH recommendations can be tions. Current NIOSH recommendations found on the NIOSH web site at http://www. can be found on the NIOSH web site at cdc.gov/niosh/homepage.html. NIOSH approved http://www.cdc.gov/niosh/homepage.html. respirators,manufacturers,and phone numbers are NIOSH approved respirators,manufactur- also listed on this web site. ers, and phone numbers are also listed on this web site. • Wear long-sleeved, loose fitting clothing, gloves, Wear long-sleeved, loose fitting clothing, and eye protection. gloves,and eye protection. ❑ Apply enough water to the combustion chamber lining ❑ Operations such as sawing,blowing,tear out,and or base insulation to prevent airborne dust. spraying may generate airborne fiber concentra- ❑ Remove combustion chamber lining or base insulation tion requiring additional protection. from the boiler and place it in a plastic bag for disposal. ❑ Wash potentially contaminated clothes separately ❑ Wash potentially contaminated clothes separately from from other clothing. Rinse clothes washer thor- other clothing. Rinse clothes washer thoroughly. oughly. NIOSH stated First Aid NIOSH stated First Aid ❑ Eye: Irrigate immediately ❑ Eye: Irrigate immediately 6 ❑ Breathing: Fresh air ❑ Breathing: Fresh air Part number 550-141-825/1218 33 Fum]GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Close clearance installation AWARNING To provide close clearances as described on page 34 and page 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. Close clearance installation NOTICE Jacket cap must be in place on boiler to avoid requir- ing an 9"minimum clearance from back or top of Substitute these instructions for corresponding material in boiler to combustible material.Flue pipe clearances manual.All other procedures and practices must remain the same. must take precedence over jacket clearances. Recommended service and minimum clearances shown on 1. Install boiler using clearances described at left. page 8 should be used where possible.Where closer clearances 2. Install barometric control 18-20 inches from boiler in are required: breeching. • Top of boiler—If less than 24"available,provide removable 3. Attach manual reset temperature switch near upper surface surface to allow for cleaning boiler flueways. of enclosed area.See Figure 23. • Right or left side—Minimum 2 inches. 4. Wire switch in series with thermostat.See Figure 24. • Front—Minimum 2 inches from burner. 5. Provide two combustion/ventilation openings when install- ing in confined space. Size opening 140 sq. in. (1000 Btu) • Type"1:'double-wall flue pipe to combustible surface—as per 1 GPH input.Locate openings near top and bottom of listed in Table 6 and Figure 25 through Figure 27,page 35. enclosed space. Figure 23 Manual reset temperature switch location Figure 24 Manual reset temperature switch wiring Combustible surface Manual reset temperature switch — — — —#6 X 1/2" Phillips 44156 1 to 5 Sheet metal inches screw Thermostat Manual reset temperature switch Bracket #10 X 1/2'' Phillips sheet metal screw Area above boiler 34 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Close clearance installation :ontinued) Figure 25 Flue pipe clearances Figure 26 Back vent clearances Combustible surface 24" For servicing or min.2" For close A clearances A 6" 6" Protection Combustible surface Type 'L" double-wall vent pipe Combustible surface Table 6 Protection required for clearances less than 6 inches from double-wall 2 vent pipe* Note:2'' min.on sides Dimension A (When desired minimum clearance from Use the following Type"1;'double-wall protection**: vent pipe to combustible surface is:) 1/2"thick insulation board Figure 27 Top vent clearances *** 3 over one-inch glass fiber or mineral wool batts+ A 24 gauge sheet metal with A 2" one-inch ventilated air space 1/2"thick insulation board 24"Combustible For icing 3 with one-inch ventilated air surface or min.2" space For close clearances * All clearances measured from outer surface of equipment to combustible surface,not to the protection used. ** Apply to combustible surface unless otherwise 2'' noted.Cover all surfaces as specified in Table and Figure 25.Thicknesses are minimum. *** Factory-fabricated board made of non- combustible materials,normally fibers,having thermal conductivity in range of one(Btu-inch)/ (hr./sq.ft./1F)or less. 2'' Combustible surface + Mineral wool batts(blanket or board),having min.density of 8 lb/ft3 and a min.melting point of 15001E Note:2'' min.on sides Other dimensions available.Refer to NFPA-31. Part number 550-141-825/1218 35 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boller ManualFA AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Replacement parts Table 7 Section and flue collector parts for Series 3 NOTICE 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. Item Description Part No. A Front section w/heater opening 316-700-260 F Collector hood kit for WTGO-9* 450-020-190 7013 G Tie rod 1/2 x 51/2 (WTGO-7, 8, 9) 560-234-464 B Wide intermediate section 316-700-075 , s (WTGO-3) 7010 G Tie rod /2 x 10/4 (WTGO-7) 560-234-491 B Narrow intermediate section 7015 316-700-065 G Tie rod 1/2 x 12 (WTGO-7) 560-234-492 Intermediate section w/draw rod G Tie rod 1/2 x 14(WTGO-3, 4, 8, 9) 560-234-470 C lugs 7016 316-700-070 1 G Tie rod /2 x 15 (WTGO-9) 560-234-495 D Back section w/7"flue, supply & 316-700-235 G Tie rod 1/2 x 17(WTGO-5) 560-234-472 2' return 7027 Section replacement kit G Tie rod 1h x 20 (WTGO-6) 560-234-534 E (for 1 joint, includes seals, rope, 386-700-852 G Tie rod 1/2 x 231/4 (WTGO-7) 560-234-538 adhesive and collector hood hardware)front or back section G Tie rod 11/42 x 26 3/8 (WTGO-8) 560-234-542 Section replacement kit G Tie rod 1/2 x 291/2(WTGO-9) 560-234-497 (for 2 joints, includes seals, rope 386-700-851 and adhesive) intermediate H Heater cover plate carton (cover 386-700-360 section plate, gasket, studs, & nuts) Section assembly complete, for F86-700-658 Combustion chamber kit (rear& WTGO-3 J frt. Ref., Door ref. Blanket, 386-700-355 rope, blanket &water glass) Section assembly complete, for 386-700-659 WTGO-4 Burner mounting door assembly 386-700-358 (door, obs. port, rope, ins.& pins) Section assembly complete, for 386-700-660 WTGO-5 K Burner mounting door 7070 330-054-302 Section assembly complete, for 386-700-661 L Door hinge 7054 330-054-300 WTGO-6 M Door refractory 386-700-359 Section assembly complete, for 386-700-662 WTGO-7 N Door refractory blanket 591-222-115 Section assembly complete, for P Observation port shutter 460-039-867 WTG O-8 386-700-663 O Door seal rope 5' 590-735-105 Section assembly complete, for 386-700-664 3/8" Glass rope for collector hood WTGO-9 R (7'for largest size hood) 590-735-109 F Collector hood kit for WTGO-3* 386-700-337 Flue cap assembly (cap, strap, S e 386-700-344 F Collector hood kit for WTGO-4* 386-700-337 rope& screws) F Collector hood kit for WTGO-5* 386-700-338 Flue brush 123D 591-706-214 F Collector hood kit for WTGO-6* 386-700-339 Blocked vent shutoff switch 511-624-650 (Canada only) F Collector hood kit for WTGO-7* 450-020-188 Includes flue cap assembly, rope and hardware for F Collector hood kit for WTGO-8* 450-020-189 installation. 36 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Replacement parts (continued) Table 8 Section and flue collector parts for Series 3 S D F E G B A ® o H J � Y M N Q K 0246-O5G C /P G I� i 0 J Part number 550-141-825/1218 37 Fum]GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Replacement parts (continued) Table 9 WTGO Trim part for Series 3 Item Description Mfr. Mf r.nopart Part no. 1 Combination pressure-temperature gauge kit, 60'—360' F., 0-75 psi, Weil-McLain 380-000-000 31/s" dia., '/4'' NPT, short shank,with x'/2" reducing bushing 2 ASME pressure relief valve, set to relieve at 30 PSIG, 3/4" male inlet,3 Conbraco M330 511-546-920 female outlet Electronic aquastat, high limit or combination high/low limit,with LWCO, high 3 limit 100°—220°, low limit 110°-200°, circulator amps:5.8 FLA, anticipator: Hydrolevel 3257 381-300-000 0.2 amps Drain cock,3/4" NPT, 1'/2"shank Conbraco 31-606-01 511-210-423 Drain cock,3/4" NPT Hammond 710 4 Drain cock,3/4" NPT Watts BD2C 511-246-392 Drain cock,3/4" NPT Matco-Norca Drain cock,3/4" NPT Nibco #74 WTGO 3&4 Taco 007e ECM 511-405-153 5 Circulator WTGO 3-6 Taco 007 511-405-113 Circulator universal hardware kit 1'/4" (Includes: (1) Flange, (1) Weil-McLain 381-354-526 6 Gasket, (2)Screws and (2) nuts)for sizes 2, 3&4 only Circulator universal hardware kit 1'/z" (Includes: (1) Flange, (1) Weil-McLain 381-354-531 Gasket, (2) Screws and (2) nuts)for sizes 5& 6 only 7 Well 3/4" NPT, 6.25" long, extended shank type Hydrolevel 592-300-027 8 Burner harness assembly Weil-McLain 591-391-850 9 Barometric damper Weil-McLain 510-512-267 10 Flue pipe brackets(set of 2) (Not shown) Weil-McLain 426-700-268 Vent damper kits-Required for ENERGY STAR°compliance, (Version 3.0 Boilers Field Controls OVD-7 specification of87%AFUE),with reduced rates only WTGO-3RD (Optional equipment) Weil-McLain 381-800-502 11 WTGO-4RD (Optional equipment) 381-800-503 WTGO-5RD (Optional equipment) 381-800-504 WTGO-6RD (Optional equipment) 381-800-505 WTGO-7RD (Optional equipment) 381-800-506 38 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Replacement parts (continued) Figure 28 Trim part for Series 3 9 3 2 5 t x 1 6 A-- 8 11 7 i AMM ITCH ME 0264-57 Part number 550-141-825/1218 39 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boller ManualFA AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Replacement parts (continued) Table 10 Weil-McLain part numbers for Series 3 Model Jacket panel with Left side and rear Right side and rear Top panel with cap insulation—front WTGO-3L 381-355-509 381-355-510 426-700-250 381-355-772 WTGO-3 381-355-512 381-355-513 426-700-252 381-355-773 WTGO-4 381-355-512 381-355-515 426-700-252 381-355-774 WTGO-5 381-355-512 381-355-517 426-700-256 381-355-775 WTGO-6 381-355-512 381-355-519 426-700-258 381-355-776 Complete Jacket cartons Common jacket parts for all boilers 7 section 416-700-170 Plastic flue cap cover w/insulation 560-907-687 8 section 416-700-172 Jacket hardware kit 386-700-853 9 section 416-700-174 Touch up paint, gold spray can 592-000-000 Figure 29 Boiler jacket for Series 3 8 0 o 0 i� 0 0 GO 0 0 40 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER - SERIES 3 - Boiler Manuai Fum] AWARNING SERVICE TECHNICIAN ONLY-read and follow completely. Dimensions Figure 30 WTGO dimensions-inches(mm) 201/a 30 10 7 3/16 [514.4] 1182.61 7 3/45 1/is [128.6] I F 2 5/8 [196.9] , �� F 2 9/16 [65.1] 7-Aa ,1 [66.7] 1 Supply [177.8] F 2¢oa a oa� Air vent or expansion m m 0 tank 0 r` �u 35 5/8 ° -- [904.9] 4 3/8 Dia [111.1] Burner B ° opening 151/ Return o [393.7] O 91/2 [241.3] �A L 14 27/6 moos Approx. 2 7/is [61.9] 1 1/8[28.6] Left side [61.9] Front 7 Dia. 6 1/a [177.8] [158.8] For 7 dia. [177.8] 'O Vent pipe 00 O � OOOOo o� p 0 0 boo 0 000 ° 0 000 00 0000 0°0 00 0 0 0 )e u°o o uoo 0000000000000P Alternate 14 1/8[358.81 return 29 s/16 ("A"boilers [750.9] only) o O0122-025 azsi os Intermediate Back Boiler model WTGO-3L WTGO-3 WTGO-4 WTGO-5 WTGO-6 WTGO-7 WTGO-8 WTGO-9 inches 13 1/2 13 1/2 13% 16 7/8 20 23 1/8 26 1/4 29 Y8 B mm 342.9 342.9 345.9 428.7 508 587.2 666.7 746.2 inches 13 3/a 16 7/8 16 7/8 20 22 1/6 26 1/4 29% 32 1/2 L mm 349.2 428.7 428.7 508 587.2 666.7 746.2 825.5 Part number 550-141-825/1218 41 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER - SERIES 3 - Boller ManuaiFA AWARNING SERVICE TECHNICIAN ONLY-read and follow completely. Ratings Table 11 GOLD WTGO Series 3 oil-fired water boiler ratings A CIP® DOELC SME C US H AHRI Certified Ratings Heating Seasonal Net Boiler Flue Minimum Draft Boiler Burner Input Rating Water Outlet Loss Model Capacity Efficiency (water) Content Diameter Chimney Thru boiler (8) GPH MBH MBH AFUE MBH Gallons Inches Rect Round Height In W.C. (3) (3) (2)(4) % (2)(5) (6) In In Ft (7) *WTGO-3LR 0.70 98 86 86.4 75 0.010 11.0 7 8 x 8 6 15 *WTGO-3L 0.95 133 114 85.0 99 0.010 *WTGO-3R 0.80 112 98 86.2 85 0.020 14.9 7 8 x 8 6 15 WTGO-3 0.95 133 115 85.3 100 0.020 *WTGO-4R 1.00 140 122 86.2 106 0.010 13.4 7 � 8 x 8 6 15 *WTGO-4 1.20 168 145 85.0 126 0.010 *WTGO-5R 1.20 168 147 86.1 128 0.015 15.9 7 8 x 8 7 15 *WTGO-5 1.45 203 175 85.0 152 0.015 F*WTG0-6R 1.40 196 171 86.1 149 0.015 18.4 7 8 x 8 7 15 1.75 245 212 85.0 184 0.015 *WTGO-7R 1.60 224 196 86.0 170 0.015 20.8 7 8 x 8 8 15 *WTGO-7 2.00 280 242 85.0 210 0.015 *WTGO-8 2.30 322 266(6) - 231 23.3 20 0.025 7 8x12 8 *WTGO-9 2.55 357 295(6) - 257 25.8 20 0.030 * Substitute"P"for completely assembled packaged boiler without burner(WTGO-3 through WTGO-6 only). Substitute"A'for boiler only for use with approved burners as listed with AHRI. ** Available only as an"A'unit. (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%COz and-0.02"W.C.draft overfire. (5) Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pick-up.Water ratings are based on a piping and pick-up allowance of 1.15.An additional allowance should be made for unusual piping and pick-up loads. (6) AHRI gross output. (7) See page 12 for minimum breeching diameter. (8) Listed draft losses are for factory-shipped settings. (9) Boiler model suffixes: "R"designates a reduced input version.NOTE:A burner nozzle change is required-refer to the burner instructions or boiler's rating label for correct selection. (10) "L"designates a boiler with special front section(1'/2"supply tapping). 42 Part number 550-141-825/1218 GOLD WTGO OIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 - Boiler Manual Fum] AWARNING SERVICE TECHNICIAN ONLY—read and follow completely. Notes Part number 550-141-825/1218 43 GOLDWTGOOIL-FIRED NATURAL DRAFT WATER BOILER — SERIES 3 — Boiler Manual Fum] Weil-McLain W�1 WEILm f�1c LAIN o 5, I Blaine Street Michigan City, N 46360-2388 http://www.weil-nic7aiti.coni Part number 550-141-825/1218