Weil-McLain 550-141-830/1202 Boiler User Manual
Contents
1. WEIL Mc LAIN SGO Series 3 Oil Fired Steam Boiler Maintenance and Service Guide For future reference leave this manual with other boiler instructions in the envelope provided with the boiler Part No 550 141 830 1202 En ma Read This Page First Hazard Definitions Following terms are used to bring attention to the presence of hazards of various risk levels or to important information concerning product life A DANGER Indicates presence of hazards that will cause severe personal injury death or substantial property damage if ignored AWARNING Indicates presence of hazards that can cause severe personal injury death or substantial property damage if ignored ACAUTION 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 These symbols indicate information for and procedures to be followed by Homeowner or person responsible for simple start up and routine maintenance of boiler and system Pages 2 through 6 must be followed to assure proper operation of your boiler Page 7 lists common problems and possible corrections In addition it is your responsibility to e Have boiler and burner installed by a qualified installer e Have boiler and burner serviced annually by a2. Any parts of the boiler furnished by Weil McLain must be replaced by parts listed in Weil McLain Boiler and Repair Parts Book Part No 550 141 830 1202 Detailed Service Procedures Cleaning boiler flueways Make sure all electrical connec 7 Once the flueways are cleaned carefully tions to boiler are turned off and wait until boiler remove the paper from the floor of the is warm not hot before cleaning Failure to do so combustion chamber will result in severe personal injury death or 8 Verify sealing rope around flue area is intact substantial property damage Visually check condition and position of insulation in combustion chamber floor 1 Top flue boilers remove breeching and jacket and the refractories at the rear of boiler and top panel in the burner mounting door Replace any Rear flue boilers remove jacket top panel parts as necessary 2 Remove flue collector hood saving hardware 9 Close burner mounting door and tighten nut for reassembly 3 Shut off oil valves Arrange drip pans under the areas of oil piping that will be discon securely Place flue collector hood on top of boiler Secure with hardware from step 2 nected Disconnect oil line at burner so AWARNING Maintain a gas tight seal to that you can swing open the door complete avoid possible flue gas leakage and carbon ly monoxide emissions which can lead to severe 4 Line combustion chamber floor with news paper to catch
3. causing property damage 1 Provide 1 1 2 skim piping from skim tapping located on front of boiler to floor drain Add a tee in piping to observe skim water level Raise waterline to midpoint of skim tapping 2 Fire burner to maintain water temperature below steaming temperature during skimming process 3 Feed in water to maintain water level Cycle burner to prevent rise in steam pressure Continue skimming until discharge is clear 4 While boiler is warm but not hot drain boiler through drain valve 5 Remove skim piping Close drain valve Fill with fresh water to normal waterline Start burner and steam for 15 minutes to remove dissolved gases Stop burner 6 Check traps and air vents for proper opera tion 7 Process may need to be repeated after several weeks of operation To place in operation Follow information below to prevent severe personal injury death or substantial prop erty damage e Do not use crankcase drainings or any oil containing gasoline See burner manual for proper fuel oil e Donotattemptto start burner when excess oil has accumulated in combustion chamber when unit is full of vapor or when combustion chamber is very hot e__Do not start burner unless collector hood flue cap jacket cap breeching and burner mount ing door are secured in place e Never burn garbage or paper in the boiler e Never leave combustible material around boiler 1 Verify boiler is filled with water
4. heard in boiler Mineral deposits in sections due to constant use of makeup water or incorrect pH Metal flakes found in flueway Contaminated combustion air supply Condensation of combustion gases Have qualified service technician increase limit setting to decrease cycling Normal operation is usually less than 5 psig Have qualified service technician repair leaks at once to avoid constant use of makeup water Have qualified service technician de lime boiler and repair leaks at once to avoid constant use of makeup water and check pH 7 0 8 5 Remove sources of hydrocarbons in or near boiler area Bleaches cleaners chemicals sprays fabric softeners paint remover etc Have qualified service technician check boiler operation Isolated radiation does not Air vents or traps inoperative Have qualified service technician repair heat clean or replace air vents or traps Water disappearing from gauge glass and back into system through return piping Incorrect Hartford Loop piping Vacuum breaker inoperative Violent waterline fluctuations surging OR Water passing into steam mains priming Waterline too high Sudden release of boiler steam pressure by action of zone valves Domestic water from tankless heater is hot then suddenly turns cold OR Domestic water from tankless heater is always lukewarm Mineral deposits insulate internal waterways of heater Boiler stop leak compound
5. any soot that will be loosened in the cleaning process 10 Check breeching for sooting and clean if personal injury or death 5 Starting at the top of the boiler use a wire flue brush to thoroughly clean between all pins at all angles Be careful not to damage side wall of rear refractory necessary Install jacket top panel and breeching Reconnect oil line and all electrical connec tions 6 Move to the bottom of the flueways and clean up between the sections to reach pins left uncleaned in step 5 Thoroughly clean flueways between all pins at all angles Start on top of boiler finish from the bottom Cleaning Boiler Flueways 9 Figure 3 Part No 550 141 830 1202 Detailed Service Procedures Fill the system 1 Donot fill except for leakage tests until boiler is ready to be fired 2 Fill to normal water line as indicated on jacket front panel 3 Boiler water pH 7 0 to 8 5 is recommended NOTICE Failure to maintain recom mended pH can cause section failure and leaks Skim steam boiler NOTICE Clean new steam boilers to remove any impurities Failure to properly clean can result in violent water level fluctuations water passing into steam mains or high maintenence costs on strainers traps or vents Skim boiler only Do not clean old piping or leaks can occur ACAUTION Do not use petroleum based compounds in boiler system Damage to system components can result
6. has been added to boiler water and is insulating outside of coil Incorrect mixing valve setting for tankless heater Domestic flow rate too high Incorrect setting on tankless heater control Incorrect piping Have qualified service technician pipe boiler exactly as shown in Boiler Manual Check valve inoperative Have qualified service technician clean or replace check valve Have qualified service technician clean or replace vacuum breaker Dirt oil or other impurities in water Have qualified service technician skim boiler Have qualified service technician adjust waterline to normal height Have qualified service technician pipe boiler exactly as shown in Boiler Manual Have qualified service technician adjust valve operating time or install slow opening valves Have qualified service technician delime or replace coil Have qualified service technician remove and clean coil AND drain and flush boiler to remove stop leak Have qualified service technican adjust mixing valve setting Have qualified service technician install flow check valve set to rating of tankless heater Have qualified service technician raise tankless control setting Adjust differential on tankless control to lower setting NOTICE The problems and corrections above represent common situations that can occur There may be others not listed above It is important always to contact a qualified service techni cian if y
7. qualified service technician e Review and understand start up and routine maintenance procedures with qualified service technician e Perform routine maintenance as described on page 4 Y Oualified service technician who has the necessary eguipment to check the boiler and system performance and is responsible for start up and service of boiler and system Pages 2 and 3 and 8 through 11 must be followed to assure proper operation of this boiler In addition it is the responsibility of this person to e Annually service boiler and burner to assure proper operation See page 8 for service record e_ Review and explain start up and routine maintenance procedures with homeowner Part No 550 141 830 1202 For Your Safety Follow instructions below to prevent severe personal injury death or substan tial property damage Do not use 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 in combustion chamber when unit is full of vapor or when combus tion chamber is very hot Donot start burner unless collector hood flue cap jacket cap breeching and burner mount ing door are secured in place Never burn garbage or paper in the boiler Never leave combustible material around boiler DO NOT TAMPER WITH UNIT OR CONTROLS Always follow specific instructions when starting up boiler or performing routine maintenan
8. al switches turned off Burner must never be fired e Fuses or breaker switch tripped when oil is in combustion chamber Immedi e Thermostat set below room temperature ately call qualified service technician e Fuel valves turned off e Not enough oil in tank to supply burner 3 Ifburner still does not fire call qualified e No water in gauge glass service technician Steam Relief Valve on back of a ee Pressure Control mul Pressure Gauge Tankless Heater Control Located in tankless heater plate sizes 3 5 or in tapping in back section sizes 6 9 TT Probe Type Low Water N Cutoff Service Switch f i on Boiler Reset Button on J m Burner Primary N Control i Gauge Glass Burner Primary Control Burner Disconnect Plug SGO Boiler with Probe Type Low Water Cutoff See Page 5 for Float Type Low Water Cutoff Figure 2 Part No 550 141 830 1202 COMMON PROBLEMS COMMON CAUSES POSSIBLE CORRECTIONS Rapid cycling burner turns on and off frequently Thermostat installed where drafts or Locate thermostat on inner wall away from heat affect reading heat sources or cool drafts Heat anticipator in thermostat Adjust heat anticipator to match current adjusted incorrectly draw Refer to boiler wiring diagram Incorrect limit setting Need to frequently add makeup water Leaks in boiler or piping Popping or percolating noise
9. can result Boiler water pH 7 0 to 8 5 is recommended For pH conditions outside 7 0 to 8 5 range or unusually hard water areas above 7 grains hardness consult local water treatment company Do not add cold water to hot boiler Thermal shock can cause sections to crack Clean newly installed steam boiler to remove oil grease and other foreign material Failure to properly clean can result in violent water level fluctuations water passing into steam mains or high maintenance costs on strainers traps and and vents A qualified service techni cian should skim the boiler by following instructions on page 10 of this manual Routine Maintenance Schedule The schedule below is specifically designed for the homeowner Please read pages 2 and 3 before proceeding Beginning each heating season Y Call a qualified service technician to perform annual service Daily during heating season v Check that boiler area is free from combusti ble materials gasoline and other flammable vapors and liguids Weekly during heating season Y Y 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 front of boiler and call qualified service technician to repair Check for oil leaks in oil piping and around burner If found immediately call qualified service
10. ce or service AWARNING Follow instructions below to prevent severe personal injury death or substan tial property damage To avoid electric shock turn off electrical supply at switch on boiler and additional external switches before performing service To avoid severe burns allow boiler to cool before performing service Do not block flow of combustion or ventilation air to boiler Boiler must be connected to a flue with sufficient draft at all times to assure proper operation Do not use this boiler if any part has been under water Electrical and mechanical failures may cause electric shock and fire risks Immediately call a qualified service technician to inspect chimney or vent boiler and burner Have the boiler flueways cleaned and have the following replaced all electrical and mechanical controls electrical wiring oil burner and controls insulation and chamber lining Part No 550 141 830 1202 Tips for steam systems 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 ACAUTION Failure to maintain recom mended pH and to 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
11. ner SGO with float type low water cutoff does not fire press reset button on burner primary control only once Repeated presses 1 If burner does not fire check for will deposit oil in combustion chamber Switch on boiler or additional shut off switches turned off Burner must never be fired e Fuses or breaker switch tripped when oil is in combustion chamber Immedi e Thermostat set below room temperature ately call qualified service technician e Fuel valves turned off e Not enough oil in tank to supply burner 3 Ifburner still does not fire call qualified e No water in gauge glass service technician Steam Relief Valve aa on back of boiler s Gauge Glass Tankless Heater Control Located in tankless heater plate sizes 3 5 or in tapping in back section sizes 6 9 Pressure Control Pressure Gauge Service Switch on Boiler Reset Button on Burner Primary Float Type Control Low Water Cutoff Burner Primary Control Burner Disconnect Plug SGO Boiler with Float Type Low Water Cutoff See Page 6 for Probe Type Low Water Cutoff Figure 5 Part No 550 141 830 1202 Start up 2 Correct problems found in step 1 If burner SGO with probe type low water cutoff does not fire press reset button on burner primary control only once Repeated presses 1 If burner does not fire check for will deposit oil in combustion chamber e Service switch on boiler or addition
12. ording to Boiler Manual If piping is not in place a qualified service technician must properly install piping General description of control operation LOW WATER CUTOFF Shuts down boiler if there is a low water condi tion STEAM RELIEF VALVE Provides discharge if boiler pressure exceeds 15 psig PRESSURE LIMIT CONTROL If high steam pressure occurs control shuts down burners until pressure drops Limit should be set higher than design pressure of system Op erating control can be set at 5 psig and adjusted to comfort level Normal operation is usually less than 5 psig At certain times the system may operate under vacuum conditions Part No 550 141 830 1202 GAUGE GLASS To clean glass 1 Close lower gauge glass cock and carefully open petcock below glass to blow water and sediment out of glass by steam pressure 2 Slowly open lower gauge glass cock and allow a small amount of water to flush out through the open petcock 3 Close petcock and fully open lower gauge cock The water level should immediately rise to its proper level 4 If gauge glass breaks close off both gauge cocks and loosen glass retaining nuts to remove gauge glass Do not use thin glass tubing as a replacement GAUGE GLASS Indicates boiler water level Cold fill water level should correspond to line stamped on boiler jacket When boiler operates water level will fluc tuate PRESSURE GAUGE Provides reading of boiler pressu
13. ou have any questions about the operation of your boiler or system Annual Service Check List The procedures and information on pages 8 through II are intended only for a qualified service technician who has the necessary equipment to inspect and adjust boiler and burner A homeowner should never attempt these procedures Qualified service technician must read pages 2 and 3 before proceeding Annual Service Call Check List follow in order listed below Comments Check that boiler area is free from combustible materials gasoline and other flammable vapors and liquids Check for and remove any obstruction to combustion and ventilation air flow to boiler Check breeching and chimney or vent for obstructions damage etc Repair or replace as necessary Clean boiler flueways See page 9 Perform service on low water cutoff relief valve and gauge glass See page Check boiler and piping for leaks and repair if found Inspect and adjust burner See burner manual and change nozzle check ignition electrode settings 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 to correct water level See page 10 Start unit and verify combustion settings with combustion test eguipment See page 10 Verify operation of all controls on boiler See page IL
14. re Maximum boiler pressure is 15 psig TANKLESS WATER HEATER Weil McLain tankless heater ratings are based on 200 F boiler water temperature To get rated out put set tankless heater control to 200 F Control can be adjusted to meet system hot water require ments m WEIL M LAIN Weil McLain 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com Part No 550 1 41 830 1202
15. technician to correct situation Check for water leaks in boiler and piping also check for leaks around tankless heater plate If found immediately call qualified service technician to repair Float type low water cutoff when used Refer to control manufacturer s instructions Scald potential Do not blow down low water cutoff unless blowdown piping has been installed according to Boiler Manual If piping is not in place call qualified service technician to install Periodically during heating season y Probe type low water cutoff when used Refer to control manufacturer s instructions for testing End of heating season w If tankless heater is installed boiler will continue to operate Check for the following All daily weekly and monthly instructions listed on this page must be followed Burner motor may have to be oiled Some motors are permanently lubricated and do not need additional oil Check for oiling instructions on burner or motor Boiler shutdown Do not drain boiler unless exposure to freezing temperatures will occur Do not use antifreeze in steam systems Always keep manual fuel supply shut off if burner is shut down for an extended period of time a Turn off switch at boiler and any external switch to boiler b Close fuel valves Turn off water feed valve d Cover burner to protect from dust and dampness z Part No 550 141 830 1202 2 Correct problems found in step 1 If bur
16. to normal waterline as indicated on jacket front panel 2 Open burner door and verify rear target wall floor and burner door insulations are in proper condition and position 3 Verify burner mounting door is closed and bolted tightly and burner plug is connected 4 Refer to burner manual for burner start up adjustment and check out procedures Factory burner adjustment and settings may not be suitable for specific job conditions AWARNING 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 5 Check boiler and system piping for leaks 6 Inspect breeching and venting for proper operation Part No 550 1 41 830 1202 Detailed Service Procedures Controls requiring annual service FLOAT TYPE LOW WATER CUTOFF Follow instructions to blowdown cutoff on page 4 Also refer to instructions from cutoff manufac turer in envelope assembly provided with boiler PROBE TYPE LOW WATER CUTOFF Cutoff must be removed and inspected and cleaned annually Refer to cutoff manufacturer s instructions in envelope assembly provided with boiler STEAM RELIEF VALVE Check operation of steam relief valve Follow instructions on label fastened to relief valve ANI scala potential Do not check operation of relief valve unless discharge piping has been installed acc
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