Weil-McLain Gold Fuel Oil Boiler P-WGO-3

(This is a work in progress and I'll be adding more sections as I have the time)

Our Saga
Choosing a Repair Technician
The Boiler
Routine Maintenance
Troubleshooting:

The Ignition Transformer

Manuals:

Electronic Ignition Transformer

Our Fuel Oil Boiler
The first winter in our first home, a early 1900's farm house, the old fuel oil furnace gave out. It was unfortunate because we had just used most of our savings for the downpayment just a few months earlier. Of course this occured in the middle of winter as these things always must happen as required by some unwritten law of the universe. It was quickly diagnosed by a technician to require expensive repair including replacement of the motor driving the blower and pump. Because of the age of the boiler and the deteriorated condition of the firebox we decided it would have to be replaced.

So after calling every plumbing and heating company in town, we chose Alltek Plumbing Heating & Air Conditioning Co to replace the boiler. Our choice was based on the fact that they had the only boiler in town, their price was comparable to the other companies, and they had done work at the property before for previous owners. Big Mistake!

Of course we didn't know it when it was installed as the installation appeared to go smoothly plus we were just happy to have heat at the time. It was only several years later when the boil developed problems that we discovered how bad the installation and subsequent attemps at repair that Alltek Plumbing Heating & Air Conditioning Co made were.

To make a very long story short, the real problem with the new Weil-McLain boiler was that routine maintenance wasn't done and the heat exchanger had plugged up with soot. Alltek wasn't aware of this necessary maintenance and after nearly $1000 in other repairs and blaming the problem on everything from the fuel oil to the fuel oil line and gave quotes to fix these things as well. In the end they were forced to call in a competing company to fix the boiler. The competitor proved to be very competent repairing the boiler in two hours for a little over $200. More interestingly they brought with them test equipment such as a draft meter and smoke tester to test and ajust the boiler, pieces of equipment AllTek never had used. The competing technician also give AllTek's technician a crash course on the troubleshooting, maintenance and repair of the boiler while I was present which has proved very usefull for me.

Needless to say, after the boiler was finally repaired we began to look at how best to go about covering our needless losses including now over $1000 of repairs, several days lost work, and the time and expense of installing a new fuel oil line in the middle of a rainy night with the help of my then pregnate wife because we simply could not afford any more expense. In this process I got ahold of an installation manual that brought other problems to light. Among other things that were wrong with the installation, the plumming was done incorrectly and installation was done without the test equipment mentioned above. This equipment, according to the manual, is required to avoid the risk of death by carbon monoxide poisoning.

So after writing a lengthy letter detailing all the problems and what compensation I felt was fair I sent it to AllTek. I had only included the actual expenses incurred and time plus those I would have to pay to fix the remaining problems with the installation, so I felt is was a very fair request, and any lawsuit would be much, much higher. AllTek did call and try to negociate my request, offering a refund of what I actually had paid them for repairs to that point and even offering a free service contract on the boiler. But who wants a serice contract from a company who has already proved beyond any doubt that they are completely incompetent. So in end they delivered a check for every penny I had asked for.

(I should also note that at one point AllTek called in a technician from Wiel-McClain who also didn't have any equipment to test or ajust the boiler. Since the boiler was running at this point his diagnosis explaining the improper draft according to those with proper test equipment simply was "It's running so there is nothing wrong with it." It didn't give me much faith in Wiel-McClain's technicians either.)

Fortunately the boiler hasn't given many problems since, at least nothing I can't fix myself with the 'free' training and experience I have received.

Choosing a Repair Technician

Most people don't have the knowlege, experience and tools to repair fuel oil boilers. So it's important to know what to look for when searching for a plumbing and heating company to install or make repairs to your boiler. This can be especially important in areas where fuel oil boilers (or furnaces) are not as common such as where I live.

I have found that companies listed as 'heating & air conditioning' won't service boilers (at least in my area), so check with the 'plumbing & heating' companies. Even then several of the companies locally won't service fuel oil boilers, or are not qualified to do so, likely because they aren't common where I live.
Ask if they install and maintain fuel oil boilers on a regular basis and if their technition is trained on fuel oil boilers. Ask for references. It may be hard to get an honest answer from some companies.
Make sure they have the necessary test equipment with them when they arrive. A draft meter and smoke tester are essential for adjusting a fuel oil boiler. If they also have a high pressure guage for testing the oil pressure after the fuel pump and a high voltage milliameter or similar ignition transformer test equipment it is a definate plus.
Ask what the routine maintenance of the fuel oil boiler should be. If they don't know this then I'd show them the door. This one question would have saved me thousands of dollars if I had known at the time.
Check the normal resources you should always refer to when choosing a company to do any work. Ask friends and family about their experiences and recommendations and check with the Better Business Bureau.
Before authorizing any work make sure you get an estimate and a copy of any conditions, warrentees, and any other term. For big jobs it is worth getting more than one estimate. I've found most legitimate companies estimates are often fairly close so it may be worth picking the company that is more qualified if it's only a few dollars more.

Weil-McLain Gold Fuel Oil Boiler P-WGO-3

Boiler Model No.: P-WGO-3
Series No.: 3
I=B=R Input LT Oil, gph: 0.95
D.O.E Htg Cap. (Water), Btu/h: 115,000
NET I=B=R Rating Water, Btu/h: 100,000
MAWP Water: 50 PSI
Maximum Water Temp: 250°
Min. Relief Valve Cap: 15 lb/hr or MBH

Routine Maintenance

Unlike gas or propane furnaces that may run for many years with no more than changing an air filter. Fuel oil boilers require several important steps be done every year to keep them running well.

Coming soon....

Troubleshooting

(Disclaimer: I am not an expert, nor am I trained in fuel oil boiler repair. Use the information here at your own risk).
The Ignition Transformer
Comming Soon...

Manuals

Allanson Electronic Ignitor #2275 (Weil McClain QB 180)

(Replacement for Franceformer Ignition Transformer 5LAY-32)

1. Introduction

This instruction manual provides you with application information on the OMNI™ Ignitor type 2275U or the 2275 Ignitor. The device is designed for intermittent duty (constant) and/or interrupted duty and provides the most reliable ignition source for gas and oil.

2. Absolute Maximum Ratings:

Input Supply Voltage(V):	108 to 132
Input Supply Frequency (Hz):	50/50
Primary Volt - Amperes (VA)	86.5
Secondary Voltage (kV peak):	17.5
Secondary Frequency (kHz):	>20
Secondary Short Circuit Current (mA):	45
Storage Temperature (°C):	-40 to +80
Operating Temperature (°C):	-30 to +40
Operating Relative Humidity (%):	90
Loading Air Gap (Inches):	1/16 to 3/16

3. Mechanical Specifications

Ignition transformer mechanical specifications

4. Installation

a) Before installation, inspect the case and the porcelain brushings for possible damage during transportation and handling. Do not use the product if the secondary brushings are chipped or cracked.
b) Choose the correct base plate from the kit (if provided) to fit the burner. Route the primary lead wires to the appropriate lead exit on the base plate and fasten the Electronic Ignition Transformer to this plate with three self-tapping screws provided.
c) Install the electronic transformer assembly on the burner and route the primary leads to the junction box for connection. Connect the white lead to the white neutral leads and the blue lead to the orange lead from the control. Use only UL listed and CSA approved wire nuts.

5. Maintenance

The Electronic Ignition Transformer has no moving parts. The only maintenance required is the cleaning of the procelain brushings with a soft cloth during the anual fornace inspection.

6. Testing

WARNING!
This procedure is to be carried out by qualifed personnel ONLY.
The voltages and currents available can cause serios injury and/or death. Extreme caution is to be used to avoid contact with the primary live leads. Do not allow any parts of your body to come closer than 5 inches to the energized secondary terminals or parts of the secondary circuit.
Ensure the mid-point of the transformer is grounded before energizing the primary.

The OMNI™ Ignitor (2275U) or the 2275 can be tested as follows to ensure that is operating properly:
Allanson's Ignitor/Transformer tester Chek-Mate™
Use it to test any brand of Ignitor/Transformer. Simply touch the high voltage spheres to the high voltage contacts and if the greed LED lights up - the unit is good.
Short Circuit Current Test
Connect a true RMS high frequency milliameter to the output terminals. Energize the primary with 120 Volts at 60Hz. The reading on the milliameter should be within 10% of the rated.
Open Circuit Test
For this test you need an oscilloscope and a high voltage oscilloscope prob. Connect the high voltage prob from one secondary to the ground terminal which is the screw in front and between the high voltage brushings. Measure the peak of the wave form on the oscilloscope. Repeat the procedure for the opposite high voltage terminal. The sum of the two readings should be withing 10% of the name plate rating.
Field Testing
If none of the above options are available, connect the transformer grounding terminal to a good ground. Connect the primary leads of the transformer to 120 Volts 60Hz. Energize the primary. Holding the handle of a well insulated screw driver, touch one part of the shaft of the screw driver to one high voltage terminal. Pivot on this terminal until you draw an arc from the opposite terminal. Gradually increase the air grap and notice the distance at which the arc is extinguished. The minimum distance should be 1/2".