Boiler Manual - Weil
Contents
1. TORE PE pa LE ened be ot Price Dike gy P ni wawww EEG Oj pas EY n SIME TASE FTE EE 3 EEL BAA ADET NEM PUL PL S u iz sie I ELS RH AR pF Le eg Pe RQ Ue E Por LE pF Te LFA TF Freres ROS Fa tj E tiw pan da ph E hk Fa pq HA batang BH Ba ELE LOH EK at tk ib Fi BF Kish i tip v pereg Feet FF AMH e A PPR YT pal 7 Haden Habits uPA EEE Ter RTA TEST Hasir ot Ce Connect Oil Piping General oil piping requirements arrangement and piping of titer control valves etc back te oll tank Location and installation of oil tanks oil piping and burners must follow NFPA 31 Standard for the Installation of Oil Burning Equipment In Canada CSA B139 Installation of Oil Burning Equipment Local codes and regulations Information provided with burner and fuel pump If any part of fuel oil tank is above level of burner an anti siphon device must be used to prevent flow of oil in case of oil line break Support oil lines as required2. WIGO SERIES 3 OIL FIRED NATURAL DRAFT WATER BOILER This Manual Includes Installation Start Up Boiler Parts SAVING THE EARTH SAVING YOUR MONEY As an EVERGY STAR Partner Weil McLain has determined that this product meets the ENERGY STAR guidelines for energy efficiency _ Installer Make sure this is correct manual for the boiler Verify boiler model on rating label Leave all documentation received with boiler and burner with unit for future reference User Boiler and burner must be installed and serviced by qualified service technician 550 141 825 1201 Read This Page First Hazard Definitions The following terms are used to bring attention to the presence of hazards of various risk levels or to important information concerning product life DANGER Indicates presence of hazards that will cause severe personal injury death or substantial property damage if ignored l Indicates presence of hazards that can cause severe personal injury death or substantial property damage if ignored Indicates presence of hazards that will or can cause minor personal injury or property damage if ignored NOTICE Indicates special instructions on installation operation or maintenance that are important but not related to personal injury hazards Symbol Definitions The following symbols are used to indicate sequence of installation for
3. Factory assembled packaged boiler block jacket and controls Sizes 3 through 6 only Factory assembled block no burner Sizes 3 through 6 with jacket installed water trim controls shipped separately Sizes 7 through 9 with jacket and water trim controls shipped separately When Calling or Writing About the Boiler Please have boiler model number and series from boiler rating label and CP number s from boiler jacket burner and controls On page 24 of this manual is space to list CP number s Table of Contents Read all instructions before installing Failure to follow all instructions in proper order can cause severe personal injury death or substantial property damage Read This Page First 2 Table of Contents SiO LORS oa 3 Before Installing Boiler 4 5 Install Packaged Boiler 6 7 Install Non Packaged Boiler 8 11 Connect Breeching 12 13 Connect Water Piping 14 18 Connect Tankless Heater Piping 18 19 Connect Wiring iis 20 21 Connect OIL PIPING isani ods 22 Start UP 23 Check Out Procedure 24 Installation and Service Certificate 24 Appendix wei eee 25 27 Parts 2252355 28 Parts DO
4. Remove tankless heater cover plate and gasket Install new gasket and tankless heater over studs around opening Secure with nuts tightening until metal to metal contact is made 20 25 ft Ib Flue Collector Hood Tape N Sealing Rope with Adhesive Change From Back Flue Outlet to Top Flue Outlet Optional FIGURE 3 Perform hydrostatic pressure test 1 Refer to FIGURE 4 and Control Tapping Table to install a Boiler drain b Water pressure gauge test only Be sure gauge can handle test pressure c Air vent in upper N tapping d Plugs in remaining tappings Fill boiler Vent all air Pressure test boiler at 1 times working pressure For boilers split and reassembled test between 75 and 85 psig Do not leave boiler unattended Cold water fill could expand and damage cast iron resulting in severe personal injury death or substantial property damage Check for maintained gauge pressure for more than 10 minutes Visually check for leaks if gauge pressure drops Drain boiler Repair leaks if found Do not use petroleum based compounds to repair leaks Damage to system components can result causing property damage Re test boiler after repairing leaks Remove pressure gauge air vent and plugs from tappings used for controls Visually check Sealing rope placement Metal to metal contact around port openings Flue collector hood seal Bu
5. BOILER NUMBER GPH 3 MBH 2 AFUE GA 1 6 m 7 EE 5 75 r ie ar se s WTGO6 175 22 14 o x 7 5 7 184 os O m axe ei WTGO 8_ 230 269 233 05 _ eee Substitute for completely assembled packaged boiler without burner WTGO 3 through WTGO 6 only Substitute for boiler only for use with approved burners as listed with I B R Available only as an unit 1 WTGO boiler designed with convertible vertical and horizontal flue outlet 2 MBH refers to thousands of Btu per hour 3 Based 140 000 Btu gal 4 Based on standard test procedures prescribed by the United States Department of Energy at combustion condition of 13 5 and 0 02 W C draft overfire 5 Net I B R ratings are based 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 Consult local Weil McLain Sales Office 6 I B R gross output 7 See page 12 for minimum breeching diameter Mhige 1 ik EG OTE It a wow we acl WEIL Mc LAIN
6. l_J 14 Set room thermostat s to desired J 7 Test limit control While burner is room temperature operating move indicator on limit control below actual boiler water temperature 1 15 Completed Installation and Service Burner should go off while circulator Certificate below continues to operate Raise setting on limit control above water temperature and l_J 16 Reviewed Maintenance and Service Manual burner should re ignite 1 17 with owner maintenance person and instructed person to keep for future reference Returned all instructions provided with boiler to its envelope and placed with boiler for future reference Installation and Service Certificate Date Installed Installation instructions have been followed Boiler Model Series 1 Check out procedure has been performed CP Number s l_J Above information is certified to be correct Measured Btu or GPH Input I_J Information received and left with owner maintenance person Installer Company Address Phone Installer s Sionature Burner adjustments for and boilers 0 Final burner adjustments must be J made using combustion test equipment to assure proper operation Do not fire boiler without water or sections will overheat 1 Refer to burner manual for start up 2 Allow boiler to heat to design condition 3 Using combustion test equipment adjust burner for a between 11 and 1
7. air space Flue Pipe Clearances All clearances measured from outer surface of equipment to combustible surface FIGURE 20 not to the protection used Apply to combustible surface unless otherwise noted Cover all surfaces as specified in Table and FIGURE 20 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 F or less Mineral wool batts blanket or board having min density of 8 and a min melting point of 1500 F OTHER DIMENSIONS AVAILABLE REFER TO NFPA 31 a kK 24 For Servicing or Min 2 for Close Clearances m I Combustible 24 For Servicing A Surface or Min 2 for Close Clearances Combustible Surface 2 Combustible Surface Combustible 2 2 Surface NOTE 2 Min on Sides NOTE 2 Min on Sides Back Vent Clearances Top Vent Clearances FIGURE 2 FIGURE 22 NOTICE Repair parts must 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 Fig Weil McLain No Description Part Number A 316 700 260 B Wide Intermediate Section WTGO 3 7010 Regular Intermediate Section 7015 C Intermediate Section w Draw Rod Lugs 7016 D Back Section w 7 Flue Supply amp 2 Return
8. by codes 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 Do not use Teflon tape as an oil pipe sealant It can cause valves to fail creating hazards Do not use compression fittings u u saa i NIN e Underground pipe must be run in a casing to prevent oil leaking into ground or under floor Check local codes for information Oil piping connection at burner See FIGURE 17 for recommended connection at burner allowing burner mounting door to swing open completely for servicing fitting Recommended Oil Piping Connection to Burner FIGURE 17 2 Follow information below to prevent severe personal injury death or substantial property damage Do not use gasoline crankcase drainings or any oil containing gasoline See burner manual for proper fuel oil Do not attempt to start burner when excess oil has accumulated when unit is full of vapor or when combustion chamber is very hot Do not start burner unless collector hood flue cap jacket cap breeching and burner mounting door are secured in place Never burn garbage or paper in the boiler Never leave combustible material around it Fill the system L 2 5 Close manual automatic air vents boiler drain cock Fill
9. 2 and O smoke b 0 01 0 02 W C draft in combus tion chamber To connect WTGO boilers to Weil McLain PLUS indirect fired water heaters Install and wire per water heater manual provided with water heater If boiler has a tankless heater installed e Remove tankless heater and install cover plate OR e Leave tankless heater installed Drain coil and remove piping Do not plug holes in tankless heater front plate F provide close clearances as described pages 26 27 Close Clearance Kit 1 W M Part No 386 500 050 must be obtained and installed 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 Substitute these instructions for corresponding material in manual All other procedures and practices must remain the same Install boiler using clearances described at left Install barometric control 18 20 inches from boiler in breeching 3 Attach manual reset temperature switch near upper surface of enclosed area See FIGURE 18 Wire switch in series with thermostat See FIGURE 19 5 Provide two combustion ventilation openings provide removable surface to allow for cleaning when installing in confined space Size opening boiler flueways 140 sq in 1000 Btu per 1 GPH input Locate Right or left side Minimum 2 inches openings near top and bot
10. 7017 E Section Replacement Kit For 1 Joint includes Seals Rope Adhesive and Collector Hood 386 700 852 Hardware Front or Back Section Section Replacement Kit For 2 Joints includes Seals Rope and Adhesive Intermediate Section Section Assembly Complete For WTGO 3 Section Assembly Complete For WTGO 4 Section Assembly Complete For 5 Section Assembly Complete For WTGO 6 Section Assembly Complete For 7 386 700 662 Section Assembly Complete For 8 Section Assembly Complete For 9 Collector Hood Kit For WTGO 3 Collector Hood Kit For WTGO 4 Collector Hood Kit For WTGO 5 Collector Hood Kit For WTGO 6 Collector Hood Kit For WTGO 7 Collector Hood Kit For WTGO 8 Collector Hood Kit For 9 Tie Rod 2 x 5 2 GO 7 8 9 560 234 464 Tie Rod 2 10 4 WTGO 7 Tie Rod 2 x 12 WTGO 7 560 234 492 Tie Rod 2 x 14 WTGO 3 4 8 9 560 234 470 Tie Rod 15 WTGO 9 Tie Rod 17 WTGO 5 Tie Rod 2 20 WTGO 6 Tie Rod hx 237 7 Tie Rod gt 26 s WTGO 8 Tie Rod 2 x 29 2 WTGO 9 Heater Cover Plate Carton Cover Plate Gasket Studs amp Nuts Combustion Chamber Kit Rear amp Frt Ref Door Ref Blanket Rope Blanket amp Water Glass 386 700 355 Burner Mounting Door Assembly Door Obs Port Rope Ins amp Pins 386 700 358 Burner Mounting Door 7070 Door Hinge 7054 Door Refractory 386 700 359 Door Refractory Blanket 591 222 115 O
11. A WING Gaga 29 DIMENSIONS 45 54 30 31 Ratings Bh Back Cover Before Installing Boiler Installations must comply with U S State and local plumbing heating and electrical codes National codes where applicable Canada Canadian Standards Association CSA B139 Installation Code for Oil Burning Equipment CSA C22 1 Canadian Electrical Code Part One Applicable local or provincial codes Before selecting boiler location Check for nearby connections to System water piping Chimney See pages 12 13 Boiler can be top or back vented Combustion and ventilation air supply See page 5 Oil supply See page 22 for oil line routing Electrical power Check area around boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep boiler area clear and free of combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage Z Walls Z 6 12 A Z a w Ta 24 gt 6 15 2 Top View Provide clearances around boiler see FIGURE 1 Jacket cap must be in place on boiler to avoid requiring an 18 minimum clearance from back or top of boiler to combustible material NOTICE Minimum clearances from vent p
12. See tank manufacturer s instructions for details Undersized expansion tanks cause system water to be lost from relief valve and makeup water added through fill valve Eventual section failure can result Install automatic air vent in N tapping as shown in FIGURE 8 CLOSED expansion tank FIGURE 9 Ensure expansion tank size will handle boiler and system water volume and temperature Undersized expansion tanks cause system water to be lost from relief valve and makeup water added through fill valve Eventual section failure can result Connect tank from N tapping shown in FIGURE 9 to expansion tank Use 12 N P T piping Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping WATER PIPING SIZE TABLE BOILER TO FROM SYSTEM SYSTEM MODEL NUMBER e 9 4 4 2 2 2 All piping sizes based 20 F temperature rise through boiler Connect Water Piping CONTINUED Circulator is lsusa Automatic Valve Air Vent To System C Tapping Isolation N Tapping Valve From Relief Valve Cold f Water Fill 4 lt r i A R To Diaphragm i Expansion Tank and Fittings Circulator B1 Tapping Alternate Pump Location Piping with DIAPHRAGM Expansion Tank FIGURE 8 Closed Type Expansion Tank Circulator ee Cold Water Fill
13. alifornia as a a Open burner mounting door and possible cause of cancer through inhalation Apply using utility knife slit floor insulation at special care when handling ceramic fiber chamber joint to be separated lining and base insulation materials Ceramic fibers b Remove 5 draw rod and the longest can be converted to chrystobalites a substance listed draw rod from each side Pull block apart as a probable cause of cancer Save draw rods nuts washers and sealing rings for reassembly Move divided block to location Clean port openings with clean rag Suppliers of fiberglass wool products recommend the following precautions be taken when handling these materials Precautionary measures Do not use petroleum based compounds to clean Avoid breathing fiberglass dust and contact with skin and eyes openings Damage to system components e Use NIOSH approved dust mist respirator can result causing property damage e Wear long sleeved loose fitting clothing gloves and eye protection e Place rings in port openings If ring slips e Wash work clothes separately from other out of groove stretch ring gently for several clothing Rinse washer thoroughly seconds then place in groove Operations such as sawing blowing tearout f Position sections so aligning lugs fit into and spraying may generate airborne fiber sockets of next section Make sure sealing concentration requiring additional protection rope is in g
14. allations must follow these codes National Electrical Code ANSI NFPA 70 latest edition and any additional national state or local codes In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Wiring must be N E C Class 1 If original wire as supplied with boiler must be replaced type 105 C wire or equivalent must be used Supply wiring to boiler and additional control wiring must be 14 gauge or heavier Provide electrical ground at boiler as required by codes Thermostat wiring Install thermostat on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sun rays or fireplaces Follow instructions with thermostat If it has a heat anticipator set heat anticipator in thermostat to match power requirements of equipment connected to it Boiler wiring diagrams give setting for standard equipment Limit Control Wiring Harness Service Switch on Boiler Burner Wiring Harness Burner Disconnect Plug I Junction box furnished Junction box houses electrical connections for all boiler components P boilers have harnesses furnished A boilers are furnished with burner and limit harnesses All field provided high voltage wiring must be sheathed in flexible metal conduit Connect incoming line voltage HOT wire to service switch and neutral wire to white wire Field install equipment ground wire to green wire with wi
15. alve is already factory installed Fill boiler Vent all air Pressure test boiler at 1 times working pressure as Do not leave boiler unattended 25 Cold water fill can expand cast iron resulting in severe personal injury death or substantial property damage 6 Check for maintained gauge pressure for more than 10 minutes Visually check for leaks if gauge pressure drops 7 Drain boiler Repair leaks if found Do not use petroleum based sealing compounds to repair leaks Damage to system components can result causing property damage 8 Retest boiler after repairing leaks 9 Remove air vent and plugs Reinstall relief valve Go to page 12 to connect breeching and venting FORE groove Change From Back Flue Outlet to Top Flue Outlet Optional FIGURE 2 Install Non Packaged Boiler Fiberglass wool and ceramic fiber materials 3 Loosen two screws on back flue outlet Set flue cap on outlet Install strap by e POSSIBLE CANCER HAZARD engaging slots in screws Tighten screws BY INHALATION Make sure cap is securely installed e CAN CAUSE RESPIRATORY SKIN AND EYE IRRITATION 2 Non Packaged WTGO 7 8 amp 9 split the This product contains fiberglass wool and ceramic assembled block for easier handling see fiber materials Airborne fibers from these materials FIGURE 3 have been listed by the State of C
16. bservation Port Shutter Door Seal Rope 5 Glass Rope For Collector Hood 7 For Largest Size Hood Flue Cap Assembly Cap Strap Rope amp Screws 386 700 344 Flue Brush 123D 591 706 214 Includes flue cap assembly rope and hardware for installation AI PO AY SP O g 7 J P m y i pe uU uuu a BOILER MODEL NUMBER L WTGO 3 1 2 16 7 8 4 13 5 8 16 7 8 WTGO 6 20 22 118 7 23 1 8 26 1 4 26 1 4 29 3 8 BOILER MODEL NUMBER WTGO 5 428 7 508 0 WTGO 6 OPI 587 2 WTGO 7 587 2 666 7 WTGO 8 666 7 746 2 20 1 4 514 4 1 H B 7A 1185 9 Supply Went or expansion li tank 3558 04 9 VEHI 4 ae dia AL 111 1 I l Bumer x 41113 241 3 Beturn 1 2 718 BTA i TT TT T T TT T T T T 1 1H 2 Front 14 apprxims te II ib WTGO Side with Burner Intermediate For z dla RFEA vant aipe 2B B18 ratum WA arly Ratings WTGO GOLD OIL WATER BOILER RATINGS 1 I B R DOE MINIMUM BOILER BOILER BURNER DOEHEATING B SEASONAL I B R CHIMNEY OUTLET WATER MODEL CAPACITY CAPACITY 4 RATINGS 5 EFFICIENCY HEIGHT
17. der Step 3 on page 9 Install Non Packaged Boiler continuep 3 Non Packaged WTGO 7 8 amp 9 install flue collector hood see FIGURE 3 Obtain gas tight seal to prevent Si possible flue gas leakage and hon monoxide emissions leading to severe personal injury or death a Thread tinnerman clip on screw so that clip fits snugly in notch of hold down lug Screw must not turn b Remove paper on sealing rope Starting at back section near flue collar position sealing rope around top of block with adhesive side to sections Do not stretch rope Make sure rope ends meet Trim excess rope c Position flue collector hood on top of boiler 1 sections and over screws clips as 2 shown in FIGURE 3 Washer at at Tinnerman Clip Screw Sealing Rope in Hold down Groove Inside Cap Lug Flue Cap Flue Cap Strap d Install washers and nuts Tighten nuts until collector hood makes contact with tinnerman clip e Back flue outlet boiler Position flue cap and strap over opening in flue collector hood Make sure rope in cap is in place and in good condition Tighten strap to hood with screws provided Top flue outlet boiler Position flue cap and strap over opening in back section Make sure rope in cap is in place and in good condition Tighten strap to boiler with screws provided in section Install remaining screws in holes in flue collector hood Tankless heater if used
18. e cross sectional area as free area of openings to which they connect Compensate for louver grille or screen blockage when calculating free air openings Refer to their manufacturer s instructions for details If unknown use Wood louvers which provide 20 25 free air Metal louvers or grilles which provide 60 75 free air Lock louvers in open position or interlock with equipment to prove open before boiler operation Lay a foundation if needed Boiler may be installed on non carpeted combustible flooring For residential garage installation install boiler so burner is at least 18 inches above floor to avoid contact with gasoline fumes A level concrete or masonry foundation is required when e Floor could possibly become flooded Non level conditions exist Solid concrete blocks can be used to create a pad BOILER FOUNDATION SIZE TABLE LENGTH INCHES 17 17 23 HEIGHT INCHES BOILER MODEL WIDTH INCHES WTGO 3 4 5 6 7 8 9 x 7 Le ___20_ 2 2 8 Com a 2 _ Go to page P to install boiler a Go to page 8 to install boiler Install Packaged Boiler Place boiler 1 Remove circulator strapped to pallet Circulator will be damaged if not removed before boiler is lifted from pallet NOTICE 2 Remove b
19. e Isolation Valve To System oe C Tapping N Tapping From gt Isolation System Valve Relief Valve Circulator B1 Tapping Alternate Pump Location Piping with CLOSED Expansion Tank FIGURE 9 Connect Water Piping CONTINUED Piping MULTIPLE ZONES Follow instructions on page 14 and 15 to install piping near boiler See FIGURE 10 11 to complete installation 3 Zoning with circulators a Size each circulator to individual circuit requirements b Remove circulator when furnished as standard equipment c Install balancing valves to adjust flow to distribute heat to all zones d Separate relay is required for each circulator 4 Zoning with zone valves a Install balancing valves to adjust flow to distribute heat to all zones b Separate transformer is required to power zone valves Refer to Weil McLain Zone Valve Wiring Guide for details Legend 1 Isolation valve 2 Flow control valve 3 Circulator 4 Zone valve 5 Drain valve SE s w jih ZONE 2 F ZONE 2 2 L f i 5 Multiple Zoning With CIRCULATORS Multiple Zoning With ZONE VALVES FIGURE 10 FIGURE 11 Connect Water Piping continued Piping for systems requiring temperatures below 40 F In most systems this type of piping is not required If system water temperature requirements are less than 140 F such as radia
20. e for GOLD Oil Water Boilers Check Out Procedure Check off steps as completed 1 1 Boiler and heat distribution units filled with water door closed sealed and nut tight Burner plugged in and service switch on Test additional field installed controls If boiler has a low water cutoff additional high limit or other controls test for operation as outlined by manufacturer Burner should be operating and should go i_J 2 Automatic air vent if used opened one off when controls are tested When controls full turn are restored burner should re ignite J 3 Air purged from system Piping checked I_J 9 Limit control set to system temperature for leaks requirements max 220 F 4 Air purged from oil piping Piping checked I_J 10 For multiple zones flow adjusted to for leaks distribute heat in all zones lJ 5 Flue cap in place and tightened Burner J 11 Thermostat heat anticipator setting if available set properly Refer to Connect wiring page 20 Obtain gas tight seal to 1 12 Boiler cycled with thermostat Raise to prevent possible flue gas highest setting and verify boiler goes ee and carbon monoxide emissions through normal start up cycle Lower to leading to severe personal injury or death lowest setting and verify boiler goes off lJ 6 Proper draft and burner flame Final 1 13 Observed several operating cycles for adjustment made with combustion proper operation test equipment
21. ection and installation must comply with valve manufacturers recommendations and instructions Water heated to a temperature suitable for clothes washing dish washing and other sanitizing needs will scald and cause injury CONTINUED 1 Isolation valve 2 Balancing valve Use with Refrigeration System FIGURE 14 Connect Tankless Heater Piping Children elderly infirm or physically handicapped persons are more likely to be injured by hot water Never leave them unattended in or near a bathtub shower or sink Never allow small children to use a hot water faucet or draw their own bath If anyone using hot water in the building fits this description or if state laws or local codes require certain water temperatures at hot water faucets take special precautions Install automatic mixing valve set according to those standards Use lowest practical temperature setting Check water temperature immediately after first heating cycle and after any adjustment Connect Tankless Heater Piping CONTINUED TANKLESS HEATER RATINGS TABLE 4 dangerous bacteria can form in potable water distribution systems if certain BOILER INTERMITTENT INLET minimum water temperatures are not maintained MODEL HEATER DRAWRATINGS AND OUTLET Contact local health department for more information NUMBER NUMBER TAPPING SIZES To pipe tankless heater 1 Size piping no smaller than tankless heater inlet and out
22. ence of codes use the following guidelines when boiler is in a confined room defined by NFPA 31 as less than 7200 cubic feet per 1 GPH input of all appliances in area A room 8 ft high x 33 5 ft x 33 5 ft is 7200 cu ft Provide two permanent openings one within 12 inches of ceiling one within 12 inches of floor Minimum height or length dimension of each rectangular opening should be at least 3 inches When inside air is used each opening must freely connect with areas having adequate infiltration from outside Each opening should be at least 140 sq in per 1 GPH input 1 sq in per 1000 Btu input of all fuel burning appliances plus requirements for any equipment that can pull air from room including clothes dryer and fireplace When outside air is used connect each opening directly or by ducts to the outdoors or to crawl or attic space that freely connects with outdoors Size per below e Through outside wall or vertical ducts at least 35 sq in per 1 GPH input 1 sq in per 4000 Btu input of all fuel burning appliances plus requirements for any equipment that can pull air from room including clothes dryer and fireplace e 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 e Where ducts are used they should have sam
23. et control to a minimum of 20 F above set point of combination control Maximum allowable set point is 220 F Wire control as shown on wiring diagram Use a low water cutoff device when Boiler is installed above radiation level Required by certain state or local codes or insurance companies Use low water cutoff designed for water installations Probe type is recommended Purchase and install in tee in supply line above boiler Use backflow check valve in cold water supply as required by local codes tall piping See FIGURE 8 or 9 on page 15 and Water Piping Size Table at right for near boiler piping and single zone piping See page 16 to complete multiple zone piping or page 17 to complete piping for systems operating below 140 F For multiple boiler piping refer to Weil McLain s Primary Secondary Piping Guide Install relief valve vertically in R1 tapping on front of boiler See FIGURE 8 or 9 and also refer to tag attached to relief valve for manufacturer s instructions Pipe relief valve discharge line 2 near floor close to floor drain to eliminate potential of severe burns Do not pipe to any area where freezing could occur Do not plug valve or place any obstruction in discharge line DIAPHRAGM expansion tank FIGURE 8 Make sure expansion tank size will handle boiler and system water volume and temperature Tank must be located near boiler before inlet to circulator
24. ipe to combustible material 6 inches Type L doublewall vent 18 inches Singlewall vent Flue pipe clearances must take precedence over jacket clearances NOTICE e Recommended service clearances 24 inches Front and top 6 inches Left side back and right side A 12 inches Right side for burner door swing radius A e Special close clearances alcove closet under counters etc see Appendix pages 26 27 Ceiling 6 18 18 24 gt Floor Left Side Recommended Service Clearances FIGURE 1 Before Installing Boiler Provide air for combustion and ventilation Adequate combustion and ventilation air Assures proper combustion e Reduces risk of severe personal injury or death from possible flue gas leakage and carbon monoxide emissions Do not install exhaust fan in boiler room Older buildings with single pane windows minimal weather stripping and no vapor barrier often provide enough natural infiltration and ventilation without dedicated openings New construction or remodeled buildings are most often built tighter Windows and doors are weather stripped vapor barriers are used and openings in walls are caulked As a result such tight construction is unlikely to allow proper natural air infiltration and ventilation Follow state provincial or local codes when sizing adequate combustion and ventilation air openings In abs
25. let 2 Following controls furnished by others must be installed a Automatic mixing valve See FIGURE 15 Read DANGER at bottom of page 18 b Flow regulating valve Size according to intermittent draw of tankless heater See Table at right Follow valve manufacturer s instructions to install 3 Additional anti scald devices may be installed at each hot water faucet bath and shower outlet 4 In hard water areas soften cold domestic supply Gallons of water per minute heated from 40 F 1409 with 200 F boiler water temperature Tested in accordance with I W H Testing and water to heaters to prevent lime build up Rating Standard for Indirect Tankless Water Heaters Tested with Boilers Limit Control with Tankless Control Flow Regulating Valve These single wall heat exchangers comply with National Standard Plumbing Code provided that Boiler water including additives is practically non toxic having a toxicity rating or class of 1 as listed in Clinical Toxicology of Commercial Products Boiler water pressure is limited to max 30 psig b d wat lief valve psig by approved water relief valve 12 min Automatic Mixing Valve Tankless Heater Piping FIGURE 15 General wiring requirements Electric shock hazard Can cause severe personal injury or death if power source including service switch on boiler is not disconnected before installing or servicing Inst
26. nt panels or converted gravity systems use piping as shown in FIGURE 12 or 13 If system piping is plastic without an oxygen barrier a heat exchanger must be used Legend 1 Isolation valve 2 Flow control valve 3 Circulator 4 System temperature gauge 5 Zone valve 6 Drain valve 7 System temperature valves Adjust valves so that the temperature at gauge 8 is at least 140 the temperature at gauge 9 is at least 60 F 8 Blend temperature gauge 9 Boiler temperature gauge fae eee one l l 1 x Fone 1 I a eee K 1 20 Ja 4 r 2 3 4 1 bet rel ey F py 12 1 q Piping with CIRCULATORS Piping with ZONE VALVES FIGURE 12 FIGURE Connect Water Piping Use with refrigeration systems DANGER Hot Water Can Scald Install boiler so that chilled medium is piped in parallel with heating boiler Use appropriate valves to prevent chilled medium from entering boiler Consult I B R Installation and Piping Guides If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air use flow control valves or other automatic means to prevent gravity circulation during cooling cycle Consumer Product Safety Commission and some states recommend domestic hot water temperature of 130 F or less When installing an automatic mixing valve sel
27. nter chimney far enough to cause obstruction Use thimble or slip joint where breeching enters chimney to allow removal for cleaning 4 When burner and boiler are properly installed draft overfire will be approximately 0 01 to 0 02 W C Install barometric control in breeching per control manufacturer s instructions when excess draft needs to be relieved or to comply with applicable codes and regulations Use draft gauge to adjust proper opening 5 An induced draft fan for the chimney may be necessary if Excessive resistance to flow of combustion gases can be expected Cross sectional area of chimney is smaller than minimum recommended Chimney height is less than recommended Seal all vent joints Interlock burner with fan operation Connect Breeching CONTINUED Typical Location for Barometric Control Also see Control Manufacturer s Instructions x Flue Pipe Bracket One on Each Side of Pipe ee Back Outlet Breeching Connection FIGURE 6 Typical Location for Barometric Control Also see Control Manufacturer s Instructions Flue Pipe Bracket One on Each Side of Pipe Top Outlet Breeching Connection FIGURE 7 Connect Water Piping General piping information Ins If installation is to comply with ASME or Canadian requirements an additional high temperature limit is needed Install control in supply piping between boiler and isolation valve S
28. oiler from pallet Do not drop boiler or bump jacket on floor or pallet Damage to boiler can result NOTICE Smaller sized boilers may be top heavy Use caution when handling to avoid minor personal injury or property damage 3 Boiler is shipped for back flue outlet To change to top flue outlet see FIGURE 2 a Remove jacket cap on top of boiler b Loosen two screws holding flue cap strap to collector hood Remove strap and flue cap from opening Re tighten screws c Check rope placement inside flue cap Read under step 6 below d Loosen two screws on back flue outlet Set flue cap on outlet Install strap by engaging slots in screws Tighten screws Make sure cap is securely installed e Snap jacket cap in back outlet opening Jacket cap must be in place on boiler to avoid requiring an 18 minimum clearance from back of boiler to combustible material NOTICE 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 Obtain gas tight seal to prevent possible flue gas leakage and carbon monoxide emissions which can lead to severe personal injury or death P Perform hydrostatic pressure test Remove relief valve installed in boiler Install air vent in N tapping on top boiler Plug supply and return tappings Drain v
29. onic systems Inhibited propylene glycol is recommended 50 solution provides protection to about 30 F Do not exceed 50 mixture Local codes may require back flow preventer or actual disconnect from city water supply Determine quantity according to system water content Boiler water content is listed on back cover of manual Percent of solution will affect sizing of heat distribution units circulator and expansion tank Follow antifreeze manufacturer s instructions To place in operation 1 2 6 7 Verify boiler is filled with water Open burner mounting door and verify rear target wall floor and burner door insulations are in proper position Verify burner mounting door is closed tightly and burner wiring harness is connected to junction box Factory burner adjustment and settings may not be suitable for specific job conditions See Appendix page 25 Make final burner adjustments using combustion test equipment to assure proper operation Do not fire boiler without water Sections will overheat damaging boiler and resulting in substantial property damage Vent air from system Repeat steps 4 and 5 under Fill the system Air in system can interfere with water circulation and cause improper heat distribution Check boiler and system piping for leaks See Tips for water systems Inspect breeching and venting for proper operation 33 Maintenance and Service Guid
30. ood condition and in position First aid measures g Oil threads on draw rods Install e Eye contact Flush eyes with water to remove washer and nut on end to be tightened dust If symptoms persist seek medical attention Use nut only on other end Skin contact Wash affected areas gently h With wrench at washer nut end with soap and warm water after handling uniformly tighten nuts starting with Dy rod at large port 512 rod at Place boiler small port bottom long rod and finally 1 Non Packaged WTGO 3 through 6 position on site top long rod i Torque on both 5 rods and bottom Smaller sized boilers may be long rod should be 50 60 ft Ibs long top heavy Use caution when top rod should be 20 25 ft Ibs Do not handling to avoid minor personal injury or back off nuts property damage j Metal to metal contact should be made around port openings If gap a Boiler is shipped for back flue outlet To does exist it should be less than 020 change to top flue outlet see FIGURE 3 Check with feeler gauge 1 Loosen two screws holding flue cap k If gap around port openings exceeds strap to collector hood Remove strap 020 check for dirt on port openings and flue cap from opening sockets or misaligned lugs If corrections Re tighten screws are made and gap still exists contact your 2 Check rope placement inside flue cap Weil McLain distributor or sales office before continuing installation Read j rl l un
31. re nut Service switch 15 amp is provided with boiler A boilers install switch as shown Some local codes may require an emergency shut off switch installed at a location away from boiler Follow local codes Burner wiring J Burner harness incorporates disconnect plug providing a convenient way to disconnect wiring when burner mounting door is opened All P boilers have a power disconnect plug installed on burner On A boilers mount the plug provided in water trim carton on the burner housing as shown in FIGURE 16 For Carlin burners screw burner plug into threaded conduit coupling then mount this assembly to the burner housing using the chase nipple Route wires through housing and make connections in burner junction box as shown in boiler wiring diagram Circulator Wiring Harness Not Furnished on A Boilers Boiler Wiring for Forced Hot Water FIGURE 16 JBU SSAPUR YM STEN waar 5 Spur sabe tH FF Mp assaka e S BP SE Dead PUP oe EYA Be Eq mA Ct qo REE HUB CIP FH E SEER GUTH EDGE AD adil aman TUR LEE KELLA BAL ee LHe Ta en
32. rner mounting door seal R1 H Front Section Obtain gas tight seal to prevent possible flue gas leakage and carbon monoxide emissions which can lead to severe personal injury or death Install jacket sizes 7 through 9 only Before installing jacket remove burner mounting door See jacket instructions for details Install boiler controls See Control Tapping Table and FIGURES 4 and 5 to install controls 1 Install tankless heater control if tankless heater is used If not furnished use operating control with maximum 10 F differential 2 Install limit control If not furnished use high limit with maximum 220 F setting 3 Affix CP number label s on jacket front panel CONTROL TAPPING TABLE FUNCTION Alternate Return Piping for A WTGO Supply Piping Pressure Temperature Gauge Drain Valve Back Section Control Tapping Location FIGURE 4 Install Packaged Non Packaged Boiler P 8 Install burner also refer to instructions packed with burner NOTICE Burners designed for use with Weil McLain 68 boilers must not be used on GOLD Oil boilers Contact individual burner manufacturers for GOLD Oil applications For P WTGO A WTGO boiler from inside wall of burner door refractory Check 1 Secure universal mounting flange and gasket to for secure placement of insulation on target wall burner mounting door Use three bolts pro
33. st 3 feet above highest point where it passes through roof and 2 feet higher than any portion of building within 10 feet Increase chimney cross sectional area and height at least 4 per 1 000 feet above sea level Minimum clearances from vent pipe to combustible material 6 inches L doublewall vent 18 inches Singlewall vent Minimum chimney sizes should be used Oversized chimneys outside masonry chimneys and or derated inputs can result in condensation in chimney NOTICE MINIMUM CHIMNEY SIZE TABLE MINIMUM MODEL BREECHING CHIMNEY SIZE CHIMNEY NUMBER DIAMETER RECT ROUND HEIGHT 3 50 _WTGO 4 6 8 x8 6 weer WTGO 7 WTGO 9 634 6 inside liner 6 x 10 inside liner Flue collar on boiler is 7 diameter BOILER Connect breeching m Long horizontal breechings excessive number of tees and elbows or other obstructions restricting combustion gas flow can result in possibility of condensation flue gas leakage and carbon monoxide emissions which can lead to severe personal injury or death 1 Install 2 flue pipe brackets 2 Connect full sized breeching when possible See Minimum Chimney Size Table Back outlet see FIGURE 6 Top outlet see FIGURE 7 3 Connection must be made above bottom of chimney to avoid blockage Breeching must not e
34. to correct system pressure Correct pressure will vary with each installation Normal cold water fill pressure for residential systems is 12 psig Boiler water pH 7 0 to 8 5 is recommended Failure to maintain recom mended pH level can cause section failure and leaks NOTICE Open automatic air vent one turn Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out Close vent b Repeat with remaining vents Refill to correct pressure Tips for water systems For additional information refer to instructions packed with boiler or burner Check boiler and system piping for leaks Continual makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer and causing cast iron to overheat resulting in section failure Failure to maintain recommended pH and repair leaks can cause section iron corrosion leading to section failure and leaks Do not use petroleum based sealing or stop leak compounds in boiler systems Damage to system components can result For pH conditions outside 7 0 to 8 5 range or unusually hard water areas above 7 grains hardness consult local water treatment company Burner Manual When using antifreeze Do not use automotive ethylene 21 glycol undiluted or petroleum based antifreeze Severe personal injury death or substantial property damage can result Use antifreeze especially made for hydr
35. tom of enclosed space e Front Minimum 2 inches from burner L doublewall flue pipe to combustible surface as listed in Table on page 27 FIGURES 20 through 22 N Recommended service and minimum clearances shown on page 4 should be used where possible Where closer clearances are required of boiler If less than 24 available NOTICE Jacket cap must be place on boiler to avoid requiring an 18 minimum clearance from back or top of boiler to combustible material Flue pipe clearances must take precedence over jacket clearances Combustible Surface Manual Reset Temperature Switch TO LEI 6 x Phil Sht Mtl Screw 44156 Thermostat 10 2 Phil Bracket Sht Mtl Screw Manual Reset Temperature Switch Area Above Boiler Manual Reset Temperature Switch Location Manual Reset Temperature Switch Wiring FIGURE 18 FIGURE 19 CONTINUED PROTECTION REQUIRED FOR CLEARANCES LESS THAN 6 INCHES FROM DOUBLEWALL VENT PIPE Dimension A When desired minimum clearance from Type L Combustible Surface doublewall vent pipe to Use the following combustible surface is protection A 2 thick insulation board over one inch glass fiber or x F mineral wool batts Protection 24 gauge sheet metal with one inch ventilated air space Type L Doublewall Vent Piping thick insulation board with one inch ventilated
36. vided chamber floor and burner mounting door 2 Secure burner on flange with three bolts Securely close door with nut 3 Position burner so end of air tube is level to 1199 tilt downward Open door to verify burner position End of air tube should be flush to 1 4 recessed Water Pressure Temperature Gauge Relief as 1 Valve Limit Control gt ac os 2 Drain Valve Water Boiler Controls FIGURE 5 1 Connect Breeching General chimney requirements Designed for natural draft firing Connect boiler to vertical chimney DANGER Insufficient draft can cause flue gas leakage and carbon monoxide emissions which will lead to severe personal injury or death Use vent material approved by local codes for oil fired burners In their absence refer to NFPA 31 Installation of Oil Burning Equipment NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances In Canada refer to CSA 139 Installation Code for Oil Burning Equipment NFPA 211 requires chimney to be lined before connected to boiler DANGER Inspect existing chimney before installing new boiler Failure to do any of the following will result in severe personal injury or death Clean chimney including removal of blockage Repair or replace damaged pipe or liner Repair mortar and joints To prevent downdrafts extend chimney at lea
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