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Weil-McLain LGB, Manual

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Weil-McLain LGB Manual Download Page 27

Part Number 550-141-186/0703

27

• Installation • Start-Up • Maintenance • Parts

1. System properly filled with water?
2. Automatic air vent, if used, open one turn (water boilers only)?
3. Air purged from system (water boilers only)?
4. Steam boilers properly skimmed?
5. Air purged from gas piping? Piping checked for leaks?
6. Are proper orifices installed? See

 Control Supplements

 for orifice sizes.

7. Follow 

Control Supplement

 and operating instruction label on boiler for proper start-up. Also refer to

Section 8, Placing boiler in operation

, page 26.

8. Proper burner flame? Refer to 

Check Pilot Burner Flames

 and 

Check Main Burner Flame

, 

Section 10

, page 30.

9. Test limit control — While burners are operating, move the indicator of the limit control below actual boiler

water temperature or pressure. Burners should go off. The circulator should continue to operate (water
boilers only). Raise the limit control above boiler water temperature or pressure and burners should reignite.

10. Test any additional field-installed controls — If boiler has low water cutoff or additional high limit or other

controls, test for operation as outlined by the manufacturer. Burners should be operating and should go off
when controls are tested. When controls are reset, burners should reignite.

11. Test ignition shutoff device — Turn off gas at manual main gas valve. Connect 24 VAC leads across PV and

MV/PV terminals on pilot proving control module. Establish call for heat. Pilot solenoid valve will close
within 15 seconds and remain off for minimum 5 minutes, then retry for ignition. Reset system by turning
off and on the main electrical switch.

12. Limit control set to design temperature or pressure requirements of system?
13. For multiple zones, flow adjusted so it is about the same in each zone (water boilers only)?
14. Boiler cycled with operating control? Raise to highest setting. Boiler should go through normal start-up

cycle. Lower to lowest setting. Boiler should turn off.

15. Measure gas input (natural gas only):

a. Operate boiler 10 minutes.
b. Turn off all other appliances.
c. At the natural gas meter, measure cubic feet of gas in ten seconds.
d. Calculate gas input:

•

Btuh = 1000 x (3600 x CFH)/10

e. Btuh calculated should approximate input rating on rating plate.

16. Check manifold gas pressure by connecting a manometer to the downstream test tapping on main gas valve.

•

Manifold gas pressure = 3.5" w.c. for 

natural gas

.

•

Manifold gas pressure = 10" w.c. for 

propane gas

.

17. Several operating cycles observed for proper operation?
18. Operating control set to the design requirement?
19.

Installation and service certificate

 on this page completed?

20. All instructions shipped with this boiler reviewed with owner or maintenance personnel, returned to envelope

and given to the owner or displayed near boiler?

†

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Boiler model

Btuh input

Series

CP number

Date installed

____________

____________

____________

____________

____________

†

Installation instructions have been
followed.

†

Check-out sequence has been
performed.

†

Information on this form is certified to
be correct.

†

Information received and left with
owner/maintenance personnel.

Installer

Address

Phone

Signature

___________________________

___________________________

___________________________

___________________________

___________________________

Orifices

9

Check-out procedure

 — 

check off steps as completed

Proper orifices must be used. Failure to do so will cause severe personal injury, death or substantial
property damage.

Installation and service certificate

Summary of Contents for LGB

Page 1: ...s for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Owner Installation and service should be performed by qualified contractor Refer to Control Supplement for additional information Gas Fired Boiler Boiler Manual Installation Start up Maintenance Parts Part No 550 141 186 0703 ...

Page 2: ...onal injury death or substantial property damage Indicates presence of hazards that can cause severe personal injury death or substantial property damage Indicates presence of hazards that will or can cause minor personal injury or property damage Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Read th...

Page 3: ...oilers 20 Jacket 21 Draft hood 21 Install boiler controls 22 Final adjustment Water boilers 24 Steam boilers 25 Placing boiler in operation 26 Check out procedure 27 Maintenance 28 Replacement parts 32 Dimensions 34 Equipment standard and optional 35 Ratings 36 Gas piping See Control Supplement Wiring See Control Supplement 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 7 7 7 7 7 8 8 ...

Page 4: ... Ventilation of National Fuel Gas Code ANSI Z233 1 latest edition or applicable local building codes Canadian installations must comply with CAN CSA B149 1 or B149 2 Installation Code Boilerinstallationmustassuresufficientopeningsinbuildingandboilerroomtoprovideadequate combustionairandventilation Considerconstructiontightnessofbuildingwhendecidingwhether additional outside openings may be needed ...

Page 5: ...ombustion air and ventilation openings to boiler room which are adequate to handle the boiler needs plus the needs of all other fuel burning appliances fireplaces and exhaust or ventilation fans Combustion and ventilation openings connecting directly or by ducting to outside or to attic or crawl spaces that freely connect with outside must be sized as follows 1 Outside wall or vertical ducting one...

Page 6: ...r spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Any impro...

Page 7: ...er must be determined using the combinedventingtablesoftheNationalFuel Gas Code ANSI Z223 1 latest edition or otheracceptedengineeringdesignmethod Use aconnectorriseashighaspossibletoimprove ventconnectorcapacity Vent and vent connector material and design must be determined using the individual ventingtablesoftheNationalFuelGasCode ANSIZ223 1 latestedition orotheraccepted engineering design metho...

Page 8: ...Use foundation with airways when concrete floor is green Fire hazard Never install boiler on combustible flooring or carpeting even if a concrete or aerated foundation is used Severe personal injury death or substantial property damage can result Do not route wiring telephone cables or piping in the floor below the boiler Overheating could occur resulting in severe personal injury death or substan...

Page 9: ...dinordershowninBaseArrangementTable below sofluecollector drafthoods jackets andgascontrolsareinstalledincorrectposition Burners must be properly seated in their locating slots with openings facing up Front of burners mustrestfullyovermainburnerorifices Gasorificesmustinjectdowncenterofburners Failureto properly level and seat burners will result in severe personal injury death or substantial prop...

Page 10: ...grit or rust from port opening sealing surfaces Failure to do so may cause a seal failure resulting in severe personal injury death or substantial property damage No petroleum based chemicals Do not use any cleaner containing petroleum based distillate oil Elastomer seal failure will occur causing substantial property damage Do not precut rope Do not precut rope Gas tight seal must be maintained t...

Page 11: ...ough 8 for remaining intermediates and left end section Check sealing rope Check sealing rope of each section before proceeding to next section Boiler must be sealed gas tight to prevent possibility of flue gas spillage and carbon monoxide emissions causing severe personal injury or death End section must be plumb End section must be plumb After erecting 1st intermediate section check both section...

Page 12: ... unattended Do not leave boiler unattended Cold water fill could expand and cause excess pressure resulting in severe personal injury death or substantial property damage Tapping Size Inches Steam Boilers Water Boilers note 4 C1 11 4 Boiler drain Boiler drain D1 D2 1 2 Gauge glass note 3 E1 E2 1 Low water cutoff note 3 Optional low water cutoff E1 1 Pressure operating limit controls and pressure g...

Page 13: ...oilers Water Boilers note 4 C2 11 4 Boiler drain Boiler drain D3 D4 1 2 Gauge glass note 3 E3 E4 1 Low water cutoff note 3 Optional low water cutoff E3 1 Pressure operating limit controls and pressure gauge Limit control note 2 F2 1 To expansion tank or automatic air vent note 2 G2 3 4 Operating control note 2 H3 H4 note 1 3 8 Tri cock J2 2 Steam relief valve skim tapping Water relief valve skim t...

Page 14: ...assembly cleanout plates cleanout plates cleanout plates cleanout plates cleanout plates Cleanout plates must be sealed gas tight to prevent possibility of flue gas spillage and carbon monoxide emissions causing severe personal injury or death Theboilercontainsceramicfiberandfiberglassmaterials Usecarewhenhandling these materials per instructions on page 28 of this manual Failure to comply couldre...

Page 15: ...o prevent possibility of flue gas spillage and carbon monoxide emissions causing severe personal injury or death 3 Mount hood on section assembly Fasten with washers and nuts Apply retort cement between bottom of sections and top of base assembly See Figure 13 Sealing the boiler Boiler must be sealed gas tight to prevent possibility of flue gas spillage and carbon monoxide emissions causing severe...

Page 16: ...ing valves and boiler mixing pump to minimize potential of boiler thermal shock See Weil McLain Bulletin AE 8402 6 Multiple boilers see Figure 15 page 17 7 Piping should be sized for a 20 F rise through the boiler See Table 1 below For higher flow rates when specified use pipe sizes no smaller than those given in Table 2 below Table 1 20 F rise through boiler Recommended minimum pipe sizes Figure ...

Page 17: ...its Primary pump can operate continuously during heating season Distance 12 or less Flow check valve Hand valve Expansion tank s relief valves and other accessories are required but not shown Refrigeration system piping The boiler must be installed so that chilled medium is piped in parallel with the heating boiler with appropriate valves to prevent the chilled medium from entering the boiler See ...

Page 18: ...se 1 blowdown valve Models LGB 13 through LGB 23 use 1 blowdown valve See Figure 20 Page 20 for multiple steam boiler piping Figure 17 Steam boiler piping for LGB 4 through LGB 12 single riser Figure 18 Steam boiler piping for LGB 13 through LGB 23 riser each end 3b Piping steam boilers steam boilers steam boilers steam boilers steam boilers Improper piping systems and or undersized piping can con...

Page 19: ...ns Select minimum receiver capacity based on time minutes required for condensate to return to the receiver Recommended Feed Pump Capacity lbs hour gallons hour 15 min 30 min 45 min 60 min GPM 15 PSI LGB 4 324 0 39 12 23 35 47 1 3 LGB 5 421 2 51 15 30 46 61 1 7 LGB 6 526 5 63 19 38 58 77 2 1 LGB 7 631 8 76 23 46 68 91 2 5 LGB 8 737 1 88 26 52 78 104 2 9 LGB 9 842 4 101 30 60 90 120 3 3 LGB 10 947 ...

Page 20: ...ooptee4 belowboilerwaterline Boilercontrolsandtrim valves lowwatercutoffs pumpcontrollers burners etc areomittedinordertoemphasizesteamandreturnpiping Provideaseparatefeedpumpforeachboiler Alternatively provideaseparateautomaticvalvewithendswitchandasinglefeedpump When valves are used activate the valve with the boiler pump controller Activate the feed pump with the valve end switch Manual steam v...

Page 21: ... left side front view LGB 4 4 LGB 13 B B LGB 5 5 LGB 14 C B LGB 6 A LGB 15 C C LGB 7 B LGB 16 D C LGB 8 C LGB 17 D D LGB 9 D LGB 18 E D LGB 10 E LGB 19 E E LGB 11 F LGB 20 F E LGB 12 G LGB 21 F F LGB 22 G F LGB 23 G G Refer to separate instructions Refer to separate LGB Jacket erecting instructions packed in Jacket Carton Boiler must be hydrostatically pressure tested plugs for unused tappings ins...

Page 22: ...igures 22 and 23 Install relief valve s blowdown valve and other items as given in Figures 11a or 11b pages 12 and 13 2 Install water level control s as shown in Figures 22 and 23 and Table 4 below If water level control to be used is not shown in the table install according to manufacturer s instructions Steam boiler controls 1 Install controls in the tappings given in Figures 11a or 11b pages 12...

Page 23: ...ls must be mounted on same side of boiler as the equalizer and return piping Install 1 blowdown valve in bottom of each cross 1 Nipple 1 x 4 2 2 Union 1 2 3 Nipple 1 x 2 2 4 Cross 1 2 5 Nipple 1 x 2 1 6 Nipple 1 x 7 1 used only with Model 61 lwco cut to fit for other controls 7 Plug 1 2 8 Nipple 1 x 3 not included 9 Nipple 1 x cut to fit not included 10 Bushing 1 x 1 11 Nipple x 4 1 12 Cross 1 13 ...

Page 24: ...if used 2 Fill to correct system pressure Correct pressure will vary with each application 3 Open automatic air vent one turn if used 4 Starting on the lowest floor open air vents one at a time until water squirts out Close vent 5 Repeat with remaining vents 6 Refill to correct pressure Water treatment Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing ...

Page 25: ...traps and air vents for proper operation Cleaning compounds Clean all newly installed steam boilers to remove oil and grease Failure to properly clean can result in violent fluctuations of water level water passing into steam mains or high maintenance costs on strainers traps and vents Do not use petroleum based cleaning or sealing compounds in boiler system Severe boiler damage will occur Filling...

Page 26: ...uld be done by a qualified service technician particularly if pilot outages are common Ask your propane dealer or service technician to periodically check the odorant level of your gas Have a qualified service technician inspect your boiler and system at least yearly to make sure all gas piping is leak tight Consult your propane supplier regarding installation of a gas leak detector There are some...

Page 27: ...ntrol set to design temperature or pressure requirements of system 13 For multiple zones flow adjusted so it is about the same in each zone water boilers only 14 Boiler cycled with operating control Raise to highest setting Boiler should go through normal start up cycle Lower to lowest setting Boiler should turn off 15 Measure gas input natural gas only a Operate boiler 10 minutes b Turn off all o...

Page 28: ...d on this web site Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust Removecombustionchamberliningorbaseinsulationfromtheboilerandplaceitinaplastic bag for disposal Operations such as sawing blowing tear out and spraying may generate airborne fiber concentration requiring additional pro...

Page 29: ... 1 Check relief valve Refer to relief valve manufacturer s instructions on relief valve tag 2 Test low water cutoff if used Blowdown if low water cutoff is float type Refer to low water cutoff manufacturer s instructions Beginning of each heating season 1 Annual service call by a qualified service agency 2 Check burners and flueways and clean if necessary Refer to Clean boiler heating surfaces and...

Page 30: ...d Flames large b Underfired Flames small c Lack of primary air Yellow tipping on flames sooting will occur Figure 24 Typical pilot burner flame Figure 25 Typical main burner flame 10c Maintenance procedures The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 28 of this manual Failure to comply could result in severe personal in...

Page 31: ... burners Place newspaper in base of boiler to collect soot 4 With a wire flue brush clean between sections 5 Remove paper and soot Vacuum or brush base and surrounding area 6 Replace cleanout plates and back jacket panel 7 Replace main burners Clean main burners Seating burners 1 Vacuum or brush burners to remove dust and lint When replacing burners must be seated in slots in back with openings fa...

Page 32: ...86 0703 32 11 Replacement parts Base Insulation Table Base Size Note 1 Base Insulation Size Note 2 4 4 5 5 A A B B C C D A and K E B and K F A and J G B and J Notes 1 See page 9 Base Arrangement Table to determine base size for your boiler 2 Contains 1 each front and back ...

Page 33: ...Part Number 550 141 186 0703 33 Installation Start Up Maintenance Parts ...

Page 34: ... 2 5 53 26 1 2 56 1 1 1 1 2 1 1 1 4 1 16 LGB 12 2 6 2 5 58 29 61 1 1 1 1 2 1 1 1 4 1 16 LGB 13 2 6 2 5 63 16 1 2 30 66 2 2 1 1 4 2 1 2 12 LGB 14 2 6 2 5 68 19 32 1 2 71 2 2 1 1 4 2 1 1 12 2 6 2 5 1 14 LGB 15 2 6 2 5 73 19 35 76 2 2 1 1 4 2 1 2 14 LGB 16 2 6 2 5 78 21 1 2 37 1 2 81 2 2 1 1 4 2 1 2 14 LGB 17 2 6 2 5 83 21 1 2 40 86 2 2 1 1 4 2 1 2 14 LGB 18 2 6 2 5 88 24 42 1 2 91 2 1 1 1 4 1 1 1 14...

Page 35: ...ittent Electronic Ignition Pilot System Electronically Supervised Pilot Burner Main Flame Sensor 8 Intermittent Ignition Control System LGB 4 and LGB 5 only Intermittent Ignition Control Module Electronically Supervised Pilot Burner Wire Harness Water boilers 1 Combination Operating and High Limit Temperature Control LGB 4 through LGB 20 only 2 Operating Temperature Control LGB 21 through LGB 23 o...

Page 36: ...ng Size I D Note 1 Note 2 Note 2 Square Feet Steam MBH Steam Note 2 MBH Water Note 2 Steam to Waterline Water lbs Models PLGB Note 4 Inches Note 5 LGB 4 400 324 0 1013 243 282 9 7 23 2 36 5 1185 975 1600 10 LGB 5 520 421 2 1317 316 366 12 6 28 9 45 6 1455 1200 1800 12 LGB 6 650 526 5 1646 395 458 15 7 34 6 54 7 1725 1425 2000 12 LGB 7 780 631 8 1975 474 549 18 9 40 3 63 9 2005 1650 2300 12 LGB 8 9...

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