Weil-McLain LGB Series 3 Commercial Gas Fired Steam and Water Boilers User Manual

June 13, 2024
Weil-McLain

Weil-McLain LGB Series 3 Commercial Gas Fired Steam and Water Boilers

Product Information

  • Product Name: LGB Series 3 Commercial Gas-Fired Steam and Water Boilers
  • Manufacturer: Not mentioned in the provided text
  • Model Number: Not mentioned in the provided text
  • Manual Part Number: 550-100-206/0123

Product Usage Instructions

Safety:
The installation and service of the boiler should be carried out by a qualified installer or service technician.
Before installation or operation, read all instructions, including the manual and other information shipped with the boiler.
Follow the steps in the given order to prevent personal injury, death, or property damage.

Installation:

  • Prepare the location for the boiler installation.
  • Ensure compliance with installation requirements.
  • Perform checks before boiler installation.
  • Consider flooring and foundation requirements.
  • Determine appropriate openings and clearances for installation.
  • Assemble the boiler by following the instructions provided.
  • Conduct a hydrostatic pressure test.
  • Install the flue collector hood and inducer assembly.
  • Follow jacket installation guidelines based on the model.
  • Install the pilot and main flame sensor.
  • Install the gas train according to the number of bases.
  • Install the control system.
  • Perform boiler conversion if necessary.
  • Install water or steam boiler piping based on the requirements.
  • Ensure proper relief valve installation.
  • Consider primary/secondary piping and refrigeration system piping if applicable.
  • Follow specific guidelines for venting and combustion air based on code compliance and category requirements.
  • Test existing vent systems if applicable.

Controls:
Install general boiler controls specific to water or steam boilers. Please note that this is a partial extract from the user manual. For complete and detailed instructions, refer to the original manual provided with the product.

Boiler Manual

LGB
Series 3 Commercial Gas-Fired Steam and Water Boilers

! WARNING

Installation and service of the boiler must be performed by a qualified installer or service technician.

Read all instructions, including this manual and all other information shipped with the boiler, before

installation or operation. Perform steps in the order given. Failure to comply could result in severe

personal injury, death or substantial property damage.

Manual Part Number 550-100-206/0123

Table of ConTenTs

lGb series 3 boiler manual

Contents
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 1 – SAFETY

5

Safety Signals . . . . . . . . . . . . . . . . . . . . . . 5

Please Read Before Proceeding . . . . . . . . . . . . 5

Servicing a Boiler

5

Boiler Operation

6

Boiler Water

6

Commonwealth of Massachusetts

6

Freeze Protection Fluids

6

Damage from Water Contact

6

Frozen Water Damage

6

SECTION 2 – INSTALLATION

7

Prepare Boiler Location . . . . . . . . . . . . . . . . . 7

Installation Compliance Requirements

7

Checks Before Boiler Installation

7

Flooring and Foundation

8

Openings

8

Clearances

9

Boiler Assembly . . . . . . . . . . . . . . . . . . . . 10

Base Assembly

10

Single Base Boilers

10

Dual Base Assembly

10

Base Seal Installation

12

Section Assembly

13

Hydrostatic Pressure Test

16

Flue Collector Hood Installation

17

Inducer Assembly

19

Jacket Installation Guidelines

20

Single Base Jacket Installation (Models 4R-12)

20

Dual Base Jacket Installation (Models 14-20)

22

Pilot and Main Flame Sensor Installation

24

Gas Train Installation for Single Bases

26

Gas Train Installation for Dual Bases

26

Control Installation

27

Boiler Conversion . . . . . . . . . . . . . . . . . . . 30

Gas Orifice and Pressure Switch Conversion

30

Water Boiler Piping . . . . . . . . . . . . . . . . . . 31

Water Piping Installation

31

General Piping Information

32

Relief Valve Installation

33

Primary/Secondary Piping

34

Refrigeration System Piping

34

Steam Boiler Piping . . . . . . . . . . . . . . . . . . 35

Steam Piping Installation

35

Condensate Return

36

Piping Multiple Steam Boilers

37

Commonwealth of Massachusetts Installations . . . . . 38

Venting and Combustion Air – General . . . . . . . . 39

Code Compliance

39

Venting System Category

39

Combustion Air Provision

39

Combustion Air Contamination

39

Sizing Combustion Air Openings

40

Special Considerations

40

2

Existing Vent System

42

Existing Vent System Test Procedure

42

Steam Boiler Venting – Category I . . . . . . . . . . 43

Chimney Draft Venting

43

Condensate Drain Plug Installation

44

Water Boiler Venting – Category II . . . . . . . . . . 46

Category II Requirements

46

Using a Chimney

46

Condensate Drain Trap Construction

49

Install Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . 50

General Boiler Controls

50

Water Boiler Controls

50

Steam Boiler Controls

50

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . 52

Gas Supply Piping Connection

52

Check Natural Gas Supply Pressure

52

Gas Train Diagram

53

Pipe Sizing for Natural Gas

54

Multiple Boiler Applications – Manifolded Gas Supply Lines

54

Gas Pressure Switches (CSD-1 only)

54

SECTION 3 – ELECTRICAL

55

Electrical – General . . . . . . . . . . . . . . . . . . 55

Power Requirements

56

Power Supply Connections

56

Field Wiring . . . . . . . . . . . . . . . . . . . . . . 57

LGB 4R, 4-12 – Single Base Schematic and Ladder Diagrams 58

LGB 14-20 – Dual Base Schematic and Ladder Diagrams 60

A Power Supply — REQUIRED

62

B Circulator / Powered Outlet

62

C MODBUS and Shield

62

D Forced High Fire

62

E Enable/Disable (CH TT Input)

63

F Alarm Contacts

63

G Spare Analog Input

63

H Manual and Auto Limits

63

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lGb series 3 boiler manual

Table of ConTenTs

SECTION 4 – OPERATION

65

Control Operation . . . . . . . . . . . . . . . . . . . 65

User Interface

65

Display and Keypad

65

Menu Structure

66

User Menu

67

Advanced Menu

67

Display Screens

68

Control Settings

69

Sequence of Operations

70

Ignition Process for Single Bases

70

Ignition Process for Dual Bases (LGB 14-20)

71

Startup – Fill the System . . . . . . . . . . . . . . . 73

Freeze Protection

73

Clean the System

73

Antifreeze — Water Boilers

74

Water Chemistry

74

Fill and Test Water Boilers

74

Check Concentrations Annually

74

Recommended Inhibitor

75

Purge Air from Water Boilers

75

Fill and Test Steam Boilers

75

Skimming Procedure for Steam Boilers

75

Startup – Final Checks . . . . . . . . . . . . . . . . . 76

Check for Gas Leaks

76

Check Thermostat Circuits

76

Inspect the Condensate System — Category II Vent Systems 76

Inspect the Pressure Switch Hoses

78

Final Checks Before Starting the Boiler

78

Startup Procedure . . . . . . . . . . . . . . . . . . . 79

Starting the Boiler

79

Troubleshooting Startup Issues

79

Check Flame and Combustion

79

Gas Valve Adjustment

80

Maximum and Minimum Final Check

81

Check Ignition System Safety Shutoff Device

81

Check the System for Leaks

81

Gas Valve Leakage Testing

82

Verification Check List

82

SECTION 5 – MAINTENANCE

83

Maintenance – General . . . . . . . . . . . . . . . . 83

Handling Ceramic Fiber Materials

83

Perform Startup and Checkout

83

Annual Inspection . . . . . . . . . . . . . . . . . . . 84

First-Year Special Inspection

84

General Information

84

Inspect the Base Insulation

85

Service and Maintenance Schedules

85

Annual Startup . . . . . . . . . . . . . . . . . . . . . 86

Check Air Openings

86

Flue Vent System

86

Check the Water System

86

Check the Boiler Relief Valve

86

Check the Expansion Tank

87

Inspect the Pilot and Main Flame Sensor Assemblies

87

Inspect and Clean the Burner and Combustion Chamber 88

Cleaning the Heat Exchanger Block

89

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Reinstall All Components

89

Inspect the Flue Pressure Switch

89

Check Boiler Wiring

89

Check Control Settings

89

Perform Startup and Checks

90

Check Main Burner and Pilot Burner Flame

90

Check the Flame Signal

91

High Altitude

91

Reinstall the Jacket Door After Servicing

91

Review with the Owner

91

SECTION 6 – TROUBLESHOOTING

93

Troubleshooting – General . . . . . . . . . . . . . . 93

Errors and Lockouts . . . . . . . . . . . . . . . . . 93

Control Display

93

Loss of Power

93

Fault and Action Items

94

SECTION 7 – PARTS

99

Miscellaneous Parts . . . . . . . . . . . . . . . . . . 99

Ordering . . . . . . . . . . . . . . . . . . . . . . . . 99

The LGB Commercial Boiler . . . . . . . . . . . . . . . 100

Replacement Parts . . . . . . . . . . . . . . . . . . 102

Dimensions . . . . . . . . . . . . . . . . . . . . . . 106

SECTION 8 – SERVICE INFORMATION 107

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . 107

Derate Information

107

Boiler Ratings

108

Maintenance Log . . . . . . . . . . . . . . . . . . . 109

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Installation and Service Certificate . . . . . . . . . . 111

3

Table of ConTenTs
Tools
Table 1 Common tools needed

Tools Needed
1/16″ flat blade screwdriver
Allen wrench small

Purpose
Wiring on terminal blocks
LGB 4R, 4, & 5 gas valve adjustment

T40 bit

LGB 6-20 gas valve adjustment

7/16″ wrench
1/2″ wrench and socket

Gas orifice installation. Collector hood j-hook installation
Collector hood j-hook installation

5/16″ socket

Burner access shield screws

Phillips head screwdriver

Jacket screws

Pipe wrenches

Gas train installation

9/16″ wrench and socket

Base panels

15/16″ wrench and socket

Casting draw rod nuts

Manometer

Measuring the gas pressure

(inclined or digital) coming to the boiler

Torque wrench

Casting draw rods Collector hood bolts

Level

Casting block assembly Collector hood assembly

Scissors

Cutting fiberglass rope and tape seals

lGb series 3 boiler manual

Abbreviations
Table 2 Common abbreviations

Abbreviation AMP ANSI ASME BTUH CH CO CO2 CP CPVC CSA CSD-1 DHW LP LWCO MBH NFPA NG
NIOSH
NTC O2 P/T SCFM ULC VAC VDC W C

Description Ampere or Amperage American National Standards Institute American Society of Mechanical Engineers British Thermal Unit per Hour Central Heat Carbon Monoxide Carbon Dioxide Consumer Protection Chlorinated Polyvinyl Chloride Canadian Standards Association Controls and Safety Devices Domestic Hot Water Liquefied Petroleum (Propane) Low Water Cut-Off Thousands of Btuh National Fire and Protection Agency Natural Gas National Institute for Occupational Safety and Health Negative Temperature Coefficient Oxygen Pressure and Temperature Standard Cubic Feet per Minute Underwriters Laboratories of Canada Volts Alternating Current Volts Direct Current Water Column

4

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lGb series 3 boiler manual
SeCTion 1 Safety

safeTy
1

This section is intended to provide safety information Please Read Before Proceeding

2

Section Contents

! WARNING

Safety Signals

5 Adhere to all following guidelines and

Please Read Before Proceeding

5 instructions in this section. Failure to adhere to

these guidelines can result in severe personal

Safety Signals

injury, death, or substantial property damage.

3
The following defined terms are used throughout this Installer: Read all instructions, including this manual

manual to bring attention to the presence of hazards and all other information shipped with the boiler,

or other important information

before installation Perform steps in the order given

Consider piping and installation when determining

boiler location

! DANGER

Danger indicates the presence of hazards that

User: This manual is for use only by a qualified

4

will result in severe personal injury, death, or

heating installer or service technician Refer to the

substantial property damage.

User Manual for your reference. A qualified service

! WARNING

technician should inspect and service this boiler at least once per year

Warning indicates the presence of hazards that can result in severe personal injury, death, or substantial property damage.

Write the Consumer Protection (CP) number and

5

serial number in the space provided on the Installation

! CAUTION

and Service Certificate on page 111 The CP number can be found on the boiler jacket

Caution indicates the presence of hazards that

Please include the boiler model number, CP

will or can result in minor personal injury or

number, and serial number when inquiring about the

property damage.
NOTICE

boiler The model number can be found on the boiler rating label

6

Notice indicates additional information that may be

IMPORTANT

related to property damage, but is not related to personal injury.

Any claims for damage or shortage in shipment must be filed immediately against the transportation

IMPORTANT

company by the consignee.

7

Important indicates additional information that is

Servicing a Boiler

important, but is not related to personal injury or

property damage.

· To avoid electric shock, disconnect all electrical

supplies to the boiler before performing maintenance

· To avoid severe burns, allow boiler to cool before

performing maintenance

8

· This boiler contains ceramic fiber and fiberglass

materials Refer to the warning and instructions on

page 83

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5

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lGb series 3 boiler manual

Please Read Before Proceeding, continued

1 Boiler Operation

Freeze Protection Fluids

· Do not block flow of combustion or ventilation air

to boiler

· Should overheating occur, or gas supply fail to

2

shut off, do not turn off or disconnect electrical supply to pump. Shut off the gas supply at a

location external to the appliance

NEVER use automotive or standard glycol antifreeze Use only freeze-protection fluids recommended in this manual See page 74 for more information Thoroughly clean and flush any replacement boiler system that has used glycol before installing the new LGB boiler

Boiler Water

· The water chemistry for the boiler must be

3

checked Chemical treatment may be required See

pages 73-75 for details

· Before connecting the boiler, thoroughly flush the

system to remove sediment Install a strainer or other

sediment removal equipment if necessary

· Do not use petroleum-based cleaning or sealing

4

compounds in the boiler system Gaskets and seals in the system may be damaged, which can result in

substantial property damage

· Continual fresh make-up water will reduce boiler

life Mineral buildup in the heat exchanger reduces

heat transfer, overheats the heat exchanger, and

causes failure Addition of oxygen carried in by

5

make-up water can cause internal corrosion Leaks

in the boiler or piping must be repaired at once to

prevent make-up water Use this boiler ONLY in a

closed-loop system

· Do not add cold water to a hot boiler Thermal

shock can cause the heat exchanger to crack

6 Commonwealth of Massachusetts

Damage from Water Contact
! DANGER
DO NOT attempt to operate any boiler if any part of the boiler, burner, or controls has been partially or fully sprayed with or submerged under water. The boiler must either be replaced or completely repaired and inspected. The boiler and all components must be in good condition and fully reliable before operation.
If these requirements are not met, operating the boiler will cause fire, explosion, and electrical shock hazards, leading to serious injury, death, or substantial property damage.
Saltwater damage: The immediate effects of saltwater damage are like those of freshwater, with electrical components shorting out and the removal of critical lubricants However, salt and other contaminants left behind can lead to long term issues due to the conductive and corrosive nature of salt residue WM Technologies equipment contaminated with saltwater or polluted water will no longer be covered under warranty and should be replaced

When the boiler is installed within the Commonwealth of Massachusetts: · This product must be installed by a licensed
7 plumber or gas fitter. · If antifreeze is used, a reduced pressure back-flow preventer device shall be used
8
6

Electrical damage: If any electrical component or wiring has, or is suspected to have come into contact with water, replace the boiler
Frozen Water Damage
Power outages, unattended residences or buildings, boiler component failures, or other electrical system failures in cold weather could result in frozen plumbing and water damage in a matter of hours Consult with a boiler contractor or a home security agent to take preventative actions, such as installing a security system that operates during power outages, senses low temperature, and initiates an effective action.
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lGb series 3 boiler manual
SeCTion 2 Installation

insTallaTion
1

This section is intended to provide installation instructions for qualified heating installers.

IMPORTANT

2

The LGB boiler manifold and controls met safe

Section Contents
Prepare Boiler Location

lighting and other performance criteria when the 7 boiler underwent tests specified in ANSI Z21.13 latest

Boiler Assembly

10 edition.

Boiler Conversion Water Boiler Piping Steam Boiler Piping

30

31 Checks Before Boiler Installation

3

35

Commonwealth of Massachusetts Installations

38 1 Check for nearby connections to:

Venting and Combustion Air – General

39

· System water piping

Steam Boiler Venting – Category I

43

· Venting connections

Water Boiler Venting – Category II

46

· Gas supply piping

Install Boiler Controls Gas Piping

50

· Electrical Power

52

· Location of drain for condensate

4

Prepare Boiler Location
Installation Compliance Requirements

2 Check area around boiler Remove any combustible materials, gasoline, and other flammable liquids.
! WARNING

· Local, state, provincial, and national codes, laws, Failure to keep boiler area clear and free of

5

regulations, and ordinances

combustible materials, gasoline, and other

· National Fuel Gas Code, ANSI Z223 1/NFPA 54 latest edition

flammable liquids and vapors can create an explosion hazard, which can result in severe personal injury, death, or substantial property

· National Electrical Code ANSI/NFPA 70 latest edition For Canada, electrical installation and

damage.
6 3 Check the boiler location to ensure it protects the

grounding must be in accordance with CSA C22 1,

gas control system components from dripping

Part 1, Canadian Electrical Code and local codes

or spraying water and rain during operation or

service

· For Canada only: CAN/CSA B149 1, Natural Gas and 4 If a new boiler is replacing the existing boiler,

Propane Installation Code and local codes

7 check for and correct system problems:
· System leaks causing oxygen corrosion or heat

· Where required by the authority having

exchanger cracks from hard water deposits

jurisdiction, the installation must conform to the

· Incorrect expansion tank sizing

Standard for Controls and Safety Devices for

· Lack of freeze protection in boiler water

Automatically Fired Boilers, ANSI/ASME CSD-1

8

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7

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lGb series 3 boiler manual

Prepare Boiler Location, continued

1 Flooring and Foundation

Figure 1 Minimum foundation and boiler placement

! WARNING

dimensions

Do not install the boiler on combustible flooring or carpeting even if a foundation is used. Failure
2 to comply can cause a fire, which can result in severe personal injury, death, or substantial property damage.
! WARNING
Do not route wiring, telephone cables, or piping in the floor below the boiler. Overheating could
3 occur, which can result in severe personal injury, death, or substantial property damage.

1 The boiler mounting surface must be level and

suitable for the load

2 Provide a solid foundation pad at least 2″ (51 mm)

4

above the floor if any of the following is true: · Floor can become flooded.

· Floor is dirt, sand, gravel, or other loose material

· Boiler mounting area is severely uneven or sloped

3 Foundation must be brick or concrete

construction The minimum foundation

dimensions are shown in Figure 1 The width (W)

5

from Figure 1 is listed in Table 3 for each model

4 If flooding is possible, elevate the boiler sufficiently

to prevent water from reaching the boiler

1/4″ 2″

Foundation, minimum 2″ thick 46½”

Base end panel

W
220179

Table 3 Minimum foundation width dimensions

Boiler Model
LGB-4 LGB-5 LGB-6 LGB-7 LGB-8 LGB-9 LGB-10

Minimum Width (W) (inches)
21 26 31 36 41 46 51

Boiler Model
LGB-11 LGB-12 LGB-14 LGB-16 LGB-18 LGB-20

Minimum Width (W) (inches)
56 61 71 81 91 101

Openings
6 Openings in floors, walls, ceilings, or roofs must be designed for fire stopping as required by local codes. Vent pipe openings through combustible materials must be 3/8″ (9 5 mm) larger in diameter than the pipe
! WARNING
7 Pipe openings that do not have the required diameter can cause a fire, which can result in severe personal injury, death, or substantial property damage.
Air Openings: Follow all applicable codes to size and verify size of the combustion and ventilation air openings
8 into the space Follow the National Fuel Gas Code ANSI Z223 1/NFPA 54, latest edition for the U S Follow the Natural Gas and Propane Installation Code CAN/CSA B149 1 for Canada
8

The LGB boiler requires a special vent system See the Venting and Combustion Air sections starting on page 39 for required air openings and sizing for direct exhaust installations
Air openings into the room must be sized to handle the LGB boiler and any other appliances See pages 40-41 for required combustion air openings
! WARNING
Provide combustion air openings correctly sized for all appliances in the room, INCLUDING the LGB boiler. Failure to comply can result in severe personal injury, death, or substantial property damage.
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lGb series 3 boiler manual
Clearances See Figure 2 for required and recommended clearances Install the boiler in a large space in comparison with the boiler
Figure 2 Clearances for LGB Boilers

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IMPORTANT

1

Without the recommended minimum clearances for service access, it may not be possible to service the boiler without removing it from the space.

2

Edge of opening within 12 inches of ceiling.

Top Vpeipnet

3

A(wirheonpreeqnuiinregds)

Controls end Front

Right Side

Left Side Piping end

4 5

Edge of opening within 12 inches of floor.

220188

6

Ensure that the installation complies with all state, local, and applicable codes .

Clearance from:

Minimum clearances to combustible surfaces
(inches)

Minimum allowable service clearances
(inches)

Recommended minimum service access clearances (inches)

Controls end (Front)

24

24

Left side

24

24

Right side

24

24

35

24

7

24

Piping end

24

24

35 (Measured from jacket, not pipes)

Top

24

24

24

Floor

N/A*

Vent pipe

6

Hot water pipes

6

8

  • Non-combustible flooring only.

550-100-206/0123

9

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lGb series 3 boiler manual

Boiler Assembly
1 Base Assembly
! WARNING
The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials
2 per instructions on page 83. Failure to comply can result in severe personal injury or death.
IMPORTANT
Ensure the assembly and base assembly boxes are on hand before beginning this section See the Parts section starting on page 99 for more information
3 Before assembling the base, relocate the access shield from the lower shipping holes to the upper mounting holes using a 5/16″ nut driver See Figure 3 Remove the burner shipping bracket from the rear burner rest as shown in Figure 4
4 Single Base Boilers

Figure 3 Access shield relocation

Base front panel

Shipping hole

Mounting

hole
Base

access

shield

WasShecrrew

220182

Figure 4 Shipping bracket removal

Single base boiler bases are shipped complete and need no further modification. Proceed to Base Seal Installation on page 12
5 Dual Base Assembly
IMPORTANT
Base assembly must be installed in the order shown in Figure 5 to ensure correct positioning of the components.
6 Dual base boiler bases are shipped individually and
must be modified before section assembly.

1 Remove the right end panel from the left base

(Base 1) after removing the four bolts with a 9/16″

7 wrench and ratchet Discard the bolts and nuts 2 Temporarily remove the two rightmost burners on

Base 1

3 Remove the two bolts and nuts securing the

combustion air baffle to the cross tie on the right

side of Base 1 with a 1/2″ wrench and ratchet

Discard the bolts and nuts Ensure spacers

8

remain installed in cross ties

4 Remove the left end panel from the right base

(Base 2) after removing the four bolts with a 9/16″

wrench and ratchet Set aside the bots and nuts

10

220241
to reuse later 5 Temporarily remove the two leftmost burners on
Base 2 6 Remove the two bolts and nuts securing the
combustion air baffle to the cross tie on the left side of Base 2 with a 1/2″ wrench and ratchet Discard the bolts and nuts Ensure spacers remain installed in cross ties Trim refractory insulation flush with the flanges on the right side of Base 1 and the left side of Base 2
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lGb series 3 boiler manual

Figure 5 Dual base assembly (LGB-14 shown)

Boiler Model Number LGB-4 LGB-5 LGB-6 LGB-7 LGB-8 LGB-9 LGB-10

Base Size 4/4R
5 A B C D E

Boiler Model Number LGB-11 LGB-12 LGB-14 LGB-16 LGB-18 LGB-20

Base Size F– G– BC DC DE FE

For dual base only
Trim insulation flush with flanges where the two bases connect

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1

2

3
220243
4

5

220183

6

7

8
(continued on the next page)
11

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lGb series 3 boiler manual

Boiler Assembly, continued
1 Dual Base Assembly, continued

7 Align jacket brackets in the top holes of the base

flanges as shown in Figure 5, page 11

8 Align Base 1 and Base 2 together; secure with

2

the four bolts set aside in step 4 using a 9/16″ wrench and ratchet

9 Align the combustion air baffles and cross ties of

Base 1 and Base 2 and secure with the provided

bolts and nuts using a 1/2″ wrench and ratchet

See Figure 5, page 11

10 Reinstall all removed burners
3 Check the gas orifice to ensure proper sizing. See

Table 4 for correct orifice sizes per model and altitude.

! WARNING

The orifice size marking must match the required
4 boiler orifice size. Incorrect sizing can cause leaking gas fumes, which can result in severe personal
injury, death, or substantial property damage.

! WARNING

Failure to properly seat and level the burners can result in severe personal injury, death, or
5 substantial property damage.

Table 4 Orifice sizes

Orifice sizes per model and altitude

Boiler Models

Standard

High Altitude High Altitude

(below 2,000 ft.) (2,000-6,999 ft.) (7,000-10,000 ft.)

LGB 4* (see note)

3 95 mm

27

30

LGB 4R

25

27

30

LGB 5-20

3 95 mm

27

30

*Note: LGB-4 bases are shipped as LGB-4R bases with #25 orifices installed Follow steps 6-8 on page 30 to install 3.95 mm orifices.

Figure 6 Single base seal

Burners must be properly seated in the locating 220245
slots with the openings facing up Level and straighten the burners to avoid misfiring. The front of the burners Figure 7 Dual base seal must rest fully over the main burner orifices. Gas
6 orifices must inject down the center of the burners. If installing a boiler in an altitude 2,000 feet or
higher, follow instructions in the Gas Orifice and Pressure Switch Conversion procedure on page 30

Base Seal Installation
7 ! WARNING
Fiber glass tape seal must be installed before section installation. Failure to install seal can result in severe personal injury, death, or substantial property damage.
8 Retrieve base seal from the assembly box Seal should be cut after installation Install seal as shown in Figure 6 or Figure 7, ensuring seal edges connect with no overlap or gap
12

220246
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lGb series 3 boiler manual

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Section Assembly
IMPORTANT
The LGB Series 3 castings are not compatible with the Series 2 castings.
Ensure all boiler sections and Assembly Boxes are on hand before beginning this section Boiler Base must be constructed and in place See the Parts section starting on page 99 for details of components required for each boiler model
Prepare sections:
1 With a caulking gun, apply 1/8″ continuous bead of sealing rope adhesive in the sealing grooves of a section See Figure 8
2 Place 1/2″ rope in the groove When working around curves, grasp the rope at 1″ intervals and push together Do not stretch Rope MUST be continuous Cut the rope as each section is completed Do not precut rope used for sections DO NOT use multiple pieces of rope in a single rope groove
! WARNING
Do not precut the rope for the casting sections. A gas-tight seal must be maintained to prevent flue gas spillage and carbon monoxide emissions, which can result in personal injury or death.

IMPORTANT
Before cutting the rope for section assembly,

1

reference Table 5, page 17 for the required rope

length for collector hoods. Set aside the required

rope length for the collector hood before proceeding to ensure sufficient remaining rope for the hood.

! WARNING

2

Port opening sealing surfaces must be clear of

all grit and rust. Do not use petroleum-based

cleaning or sealing compounds in the boiler

system. Failure to comply can cause seal failure,

which can result in severe personal injury, death,

or substantial property damage.

3

3 Remove any grit or rust from port opening sealing

surfaces with a clean rag

4 Place sealing rings into port openings (Figure 8)

5 Repeat steps 1-4 for all sections Additionally,

discard any 3/8″ diameter shipping tie rods; do not use these to draw sections together

4

(continued on the next page)
5

Figure 8 Sealing rope, seals, and draw rod tightening sequence

6

9″ Elastomer sealing ring
Sealing rope
550-100-206/0123

7
6″ Elastomer sealing ring
8
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lGb series 3 boiler manual

Boiler Assembly, continued
1 Section Assembly, continued
Install the Sections:
Assembly may start with either end section For
2 easier assembly, these instructions start with the right end section

Figure 9 Retaining brackets

Top View

5 13/16″

2″

2″

1/2″

6 Install two retaining brackets over the base seal on

the right side of the assembled base Use screws

and a Phillips head screwdriver See Figure 9

7 Position the right end section up against the

3

retaining bracket Ensure the casting parting lines

are aligned with the base brackets as shown

in Figure 10 Make sure to keep the section

supported

! WARNING

4 Sections are top-heavy and will not stand individually without support. Failure to support the sections can result in severe personal injury,
death, or substantial property damage.

NOTICE
End section must be plumb. After erecting the first
5 intermediate section, check both sections for plumb. Failure to plumb sections may cause misaligned piping and breech, resulting in property damage.

220247
Figure 10 Section assembly

8 Position intermediate sections so the alignment

lugs fit into the sockets of the placed section.

6 Refer to Figure 12, page 15 9 Install a section onto the base assembly Ensure

that the section is straight and properly aligned

using the alignment lugs

10 Oil threads on all draw rods Install a washer and

nut on the end being tightened Use only a nut on

7

the opposite end

BACK

8
14

FRONT
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Section Assembly, continued

Figure 11 Draw rods

11 Insert the draw rods Tighten the rear and lower

1

front draw rods uniformly Do not torque until all

sections are installed Do not tighten the front

upper draw rods See Figure 11

! CAUTION

The front upper draw rods must remain loose

2

until the lower front and rear draw rods are

tightened to the proper torque or misalignment

may occur.

12 Repeat steps 8 to 11 for all sections 13 Uniformly draw sections together, starting at the
washer with nut end Torque the rear then lower

FRONT

BACK

220248

3

front draw rods to a range of 100-120 ft-lbs

Progress through every section to the end Do not

back off the draw rods once tightened.

14 Ensure that metal-to-metal contact is achieved

around the port opening See Figure 12 a If a gap exists around the port opening, use

4

a feeler gauge to make sure it does not

exceed 032″ If the gap is greater than 032″,

check for rope extending from rope grooves, dirt

on port openings or sockets, or misaligned lugs

b If a gap exceeding 032″ still exists after corrections are made, or nothing needs to

220249
5

be corrected, contact your WM Technologies

Figure 12 Sealing ring installation and port alignment

distributor before continuing installation

Section

Section

! WARNING

Failure to correct a gap around the port opening

that exceeds .032″ could cause seal failure, which can result in severe personal injury, death, or
substantial property damage.

Socket

Alignment lug

6

15 Tighten the upper front draw rods just enough to produce good, equal compression along the length of the rope DO NOT torque the upper front draw rods
! WARNING
Check the sealing rope of each section before proceeding to the next section. The boiler must be sealed gas-tight to prevent possible flue gas spillage and carbon monoxide emissions, which can result in severe personal injury or death.

Elastomer sealing ring

Metal-to-metal contact

7

220186

8

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lGb series 3 boiler manual

Boiler Assembly, continued
1 Hydrostatic Pressure Test

Perform a pressure test on the boiler before connecting gas piping and electrical supply or installing the jacket

2 1 Install the following items. Refer to the figures
and tables in this section for tapping locations
· Boiler drain (supplied by installer)
· Water pressure gauge (for test only) Be sure
the gauge can handle the test pressures stated
in Step 3
3 2 Plug all remaining tappings
! WARNING

Do not leave the boiler unattended during the test. Cold water fill could expand and cause excess pressure, which can result in severe personal
4 injury, death, or substantial property damage.

Figure 13 Section end tappings

220187 F1

G1 E1

M1

D1

5

J1

6″ Supply

K1

H1

H2

D2

M2

6

Left end

E2 5″ Return

C1

F2

7

M3 J2

E3 G2 D3

H3

K2

6″ Supply

H4

D4

8

M4

E4 Right end

5″ Return C2

NOTICE
Do not pressure test with any controls installed or damage could occur.
3 Fill the boiler and vent all air Pressure-test the boiler for more than 10 minutes
· Steam boilers: between 45-55 psig · Water boilers: 1 5 times the maximum working
pressure stated on the castings and boiler nameplate 4 Check for maintained gauge pressure and repair any leaks 5 Drain the boiler 6 Remove plugs from the tappings used for controls and accessories Leave all other plugs installed

Legend – Figure 13 Tapping Size (in .) Steam Boilers

Water Boilers[3]

C1, C2

1 1/4

Boiler drain

Boiler drain

D1, D2, D3, D4

1/2

Gauge glass [2]

E1, E2, E3, E4
E1, E3

1

Low water cutoff [2]

Optional low water cutoff

Pressure operating

1

and limit controls and

pressure gauge

F1, F2

1

To expansion tank or automatic air vent [4]

G1, G2

1/2

Operating and high limit control [4]

H1, H2, H3, H4 [1]

3/8

Tri-cock

J1, J2

2

Steam relief valve and skim tapping

Water relief valve and skim tapping

K1, K2

1/2

Pressure and temperature gauge [4]

M1, M2, M3, M4

1

Optional low water cutoff [2]

Optional low water cutoff

M1, M3

1

Firing rate control (when used)

Probe low water cutoff

1 Available on special request only 2 Must be on the same side as steam equalizer piping 3 Additional controls for water boilers may be placed in supply piping 4 Must be on the same side as supply to the system

16

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Flue Collector Hood Installation

Figure 14 Alignment brackets

Install the collector hood only after the pressure test

has been completed

1

Ensure the collector hood, jacket, and assembly

boxes are on hand before beginning this section See

the Parts section starting on page 99 for details of

components required for each boiler model

1 Install the two alignment brackets to the upper front draw rods a Install each bracket on the second casting from each end (Item 1) b Do not remove nuts from the draw rods; use the provided, additional nuts (Item 2)
2 Thread two screws (Item 3) into the alignment brackets Leave 1/2″ gap between the screw heads and the brackets
3 Apply silicone bead around the top of the section assembly block as shown in Figure 15
4 Retrieve rope previously set aside Lay rope on the sealant shown in Figure 15 Refer to Table 5 for rope lengths
5 Mount the flue collector hood on the section assembly and over rope, aligning the front with the alignment brackets. The flue collector hood should be centered from left to right on the section assembly
Figure 16 Flue collector hood assembly

3

2

Figure 15 Silicone and fiberglass pattern

220251

1

2

220250

3

4

5

Table 5 Rope seal lengths

Boiler

Rope Boiler

Rope Length (in)

Model Size Length Model Size

(in)

Base 1 Base 2

6

LGB 4R / 4

90

LGB 11

195

LGB 5

105

LGB 12

210

LGB 6

120

LGB 14

135

150

LGB 7 LGB 8

135

LGB 16

150

LGB 18

165

150

7

165

180

LGB 9

165

LGB 20

195

180

LGB 10

180

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8
(continued on the next page)
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lGb series 3 boiler manual

Boiler Assembly, continued
1 Flue Collector Hood Installation, continued

6 Use J hooks to attach the flue hood to the draw

rods at the top of the block Refer to Figure 17

and Figure 18

2

a Secure the front brackets of the collector hood to the front top draw rods as shown in Figure

18 using items 1-3

b Secure the rear brackets of the collector hood

to the rear top draws rods as shown in Figure

19 using items 4-9

c Different boiler models have collector hoods

3

with a varying number of brackets; each

bracket should be secured Tight nuts and

bolts with a 1/2″ wrench or ratchet

7 Ensure the flue collector hood is level after

installation is complete

! WARNING
4 The hood and boiler assembly must be sealed
gas-tight to prevent the possibility of flue gas spillage and carbon monoxide emissions, which can result in severe personal injury or death.

Figure 17 J hooks front installation Figure 18 J hooks back installation

3 2 1
220253

5 9

6

Legend – Figure 17 & Figure 18

Item No .

Description

1

J-bolts

7

2

Lock washers

3

Nuts

4

J-bolts

5

Nuts

6

Coupling nuts

7

Lock washers

8

8

Leveling washers

9

Bolts

18

220254

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Inducer Assembly

Figure 19 Inducer installation ­ water and 4R steam

Inducer orifice plates and bolts are shipped with the

1

flue collector hood and must be removed before

proceeding with installation. Orifice plates are marked

to indicate correct boiler application Ensure the

correct orifice plate is installed for each boiler.

For LGB water boilers and LGB 4R steam boilers only, refer to the following instructions and Figure 19 for typical installation

5 (x4)

2

4

1 Install a gasket (item 1) on the flue collector hood. 2 Install the orifice plate (item 2) on the installed
gasket 3 Install a gasket (item 3) over the orifice plate. 4 Install the inducer (item 4) onto the gasket 5 Secure the inducer with provided 1/4-20 stainless
steel bolts (item 5) using a 1/2″ ratchet Ensure all bolts are installed

3
23
1

For LGB Steam boilers only (except model 4R), refer to the following instructions and Figure 20 for typical installation

220255

4
Note: The small inducer shown may appear different than the inducer shipped with boiler.

1 Install the gasket (item 6) on the flue collector

Figure 20 Inducer installation ­ steam boilers (except 4R)

hood

2 Install the inducer (item 7) onto the gasket

5

3 Secure the inducer with provided 1/4-20 stainless

steel bolts (item 8) using a 1/2″ ratchet Ensure all

bolts are installed

Figure 21 Example orifice plate

8 (x4)
6
7
6

7

550-100-206/0123

220256
220278

Note: The LGB-X orifice plate shown may

appear slightly different in shape than the orifice plate shipped with boiler.

8

19

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lGb series 3 boiler manual

Boiler Assembly, continued
1 Jacket Installation Guidelines

Ensure the jacket and assembly boxes are on hand

before beginning this section See the Parts section

starting on page 99 for details of components

2 required for each boiler model

1 The following must be done before jacket

installation:

· Boiler must be pressure tested

· Plugs must be installed in unused tappings

· Flue collector hood

3

· Water boilers only: temperature sensor installed

2 The following must be done after installing the

side panels, but before installing the top panel:

· Control panel

· Routing inducer power wires, flue temperature

switch wires, and flue pressure switch tubing

4 through the wire chase 3 The following may be on the boiler before jacket

installation:

· Supply and return piping

· Gas control assembly

· Compression tank piping

· Pilot line tubing
5 4 The following must be off the boiler before jacket

installation:

· Relief valves

· P/T gauge

· Steam or water gauges

· Limit control

6

· LWCO · Gauge glass cocks and gauge glass

· Siphon

· Tri-cocks (if used)

· Drain cock

· Gas supply piping

7 · Control tray 5 Leave jacket parts in the cartons until needed to

avoid damage

6 Remove the required jacket knockout discs

Single Base Jacket Installation (Models 4R-12)
8 The recommended order of jacket installation for single bases is shown in Figure 22, page 21 Jacket screws are #10 x 1/2″ Type AB Phillips head screws unless otherwise noted All installation screws are provided 20

1 Attach four support brackets (item 1) to the side panels using provided 10-32 x 1/2″ screws and a Phillips head screwdriver
2 Hang the front top interior panel (Item 2) on alignment bracket screws through the slots See Figure 23, page 21
3 Set the side panels (Items 3-6) into the support brackets a Secure the left front panel (Item 3) to the left back panel (Item 4) (5 locations) b Secure the left front panel (Item 3) to the front top interior panel (Item 2) (3 locations) c Repeat steps a-b for the right side panels (Items 5-6)
4 To install the wire chase (Item 7), ensure insulating fiberglass tape is adhered to the bottom of the chase See Figure 24, page 21 Secure the chase to the front top interior panel (item 2) (2 locations)
5 To install the back panel (item 8), set the panel on top of the rear bracket as shown in Figure 25, page 21 Secure the back panel to the left back panel and the right back panel (12 locations)
! WARNING
The back panel must be installed on top of the rear bracket or air openings may be blocked. Blocked air openings can cause incomplete combustion, which can result in severe personal injury or death.
6 Install the front bottom interior panel (Item 9): a Secure to the front top interior panel (3 locations) b Secure to the front left and right panels (4 locations)
7 Secure the front cross tie (Item 10) to the front left and right panels (2 locations)
8 Install the top panel: a Secure to the front top interior panel (3 locations) b Secure to the side panels (10 locations) c Secure to the back panel (4 locations) d Secure to the wire chase (2 locations)
9 Secure the inducer cover (Item 12) to the top panel
10 Mark the correct model size and orifice size on the rating label
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lGb series 3 boiler manual
Figure 22 Recommended single base jacket installation

4 3

11
7 2

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1
12 8
2
3

13
4

1

9 10

6

5

220257

5

Figure 23 Front top interior panel installation

Figure 24 Wire chase installation

6

Fiberglass Tape

220259

Figure 25 Back panel installation
7

550-100-206/0123

220258

8

Note: Opening must NOT be blocked

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lGb series 3 boiler manual

Boiler Assembly, continued
1 Dual Base Jacket Installation (Models 14-20)

The recommended order of installation for the LGB Dual Base jackets is shown in Figure 26, page 23 All jacket screws are #10 x 1/2″ Type AB Phillips
2 head screws unless otherwise noted All screws for installation are provided

1 Attach four support brackets (item 1) to the side

panels using provided 10-32 x 1/2″ screws and a

Phillips head screwdriver

2 Hang the front top interior panels (Items 2-3) on

3

alignment bracket screws through the slots See

Figure 23, page 21

3 Secure the front top interior panel splice (item 4) to

the front top interior panels (6 locations)

4 Set the side panels into the support brackets

(item 1)

4

a Secure the left front panel (Item 5) to the left back panel (Item 6) (5 locations)

b Secure the left front panel (Item 5) to the front

top interior panel (Item 2) (3 locations)

c Repeat steps a-b for the right side panels

(Items 7-8)

5 To install the wire chases (Items 9-10), ensure

5

insulating fiberglass tape is adhered to the bottom

of each chase See Figure 24, page 21 Secure

each chase to the front top interior panels (items

2-3) (4 locations)

6 Install the back panels (items 11-12):

a Set the panels on top of the rear bracket as

6

shown in Figure 25, page 21 b Secure the back panels to the left back panel

and the right back panel (12 locations)

c Secure the back splice (item 13) to the back

panels (12 locations)

d Secure the back splice to the back splice

7

brackets installed during base assembly (see Figure 5, page 11) (2 locations)

! WARNING

The back panel must be installed on top of the
rear bracket or air openings may be blocked. Blocked air openings can cause incomplete
8 combustion, which can result in severe personal injury or death.

7 Install the front bottom interior panels (Items 1415): a Secure to the front top interior panels (6 locations) b Secure to the front left and right panels (4 locations) c Secure the front bottom interior splice (item 16) to the front top interior panels (2 locations) d Secure the front bottom interior splice and front bottom interior panels to the front interior splice brackets installed during base assembly (see Figure 5, page 11) (2 locations)
8 Secure the top splice panel (item 17) to the back panel splice (item 13) (2 locations)
9 To install the front splice bracket, follow the instructions below and refer to Figure 27, page 23 a Remove the two 10-32 screws securing the burner shields to the manifold bracket with a 5/16″ ratchet or wrench b Align the front splice bracket and burner shields Secure to the manifold bracket with the 10-32 screws from the previous step and a 5/16″ ratchet or wrench
10 Install the Front Splice Panel (Item 18): a Secure to the top splice panel (Item 17) (2 locations) b Secure to the front splice bracket (1 location)
11 Install the front cross ties (Item 11): a Secure to the front left and right panels (2 locations) b Secure to the front splice panel (item 18) (2 locations)
12 Install the top panels (items 21-22) a Secure to the front top interior panels (6 locations) b Secure to the side panels (10 locations) c Secure to the top splice panel (item 17) (10 locations) d Secure to the back panels (8 locations) e Secure to the wire chases (4 locations)
13 Secure the inducer covers (Items 23-24) to the top panels
14 Mark the correct model size and orifice size on the rating label

22

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lGb series 3 boiler manual
Figure 26 Recommended dual base jacket installation
23

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1

24

11

12

6 5

21

17

9

2 3

22 10

4 18

16 14

19

20

Figure 27 Front splice bracket installation

15 25

2

13

3

4
1
8 7
5
26
220261
6

7

220263
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lGb series 3 boiler manual

Boiler Assembly, continued
1 Pilot and Main Flame Sensor Installation

Pilot assemblies are installed on all LGB Boilers Main flame sensor assemblies are installed on LGB 6 through LGB 20 boilers
2

Table 6 Single base pilot and main flame sensor

Single Base Boilers

Boiler Model

Main Flame

Pilot

3

4R / 4

4

5

5

6

2

9

7

2

11

8

2

13

4

9

2

15

10

2

17

11

2

16

12

2

16

See Figure 28 and the tables below for pilot and
main flame sense locations. See Figure 29 for proper pilot burner assembly, and Figure 30 for main flame sensor assembly

Table 7 Dual base pilot and main flame sensor

Dual Base Boilers

Boiler Model
14

Base 1

Main Flame

Pilot

2

11

Base 2

Main Flame

Pilot

14

25

16

2

15

18

29

18

2

15

18

33

20

2

16

22

37

5 Figure 28 Pilot and main flame sensor layout

6

7

8
24

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lGb series 3 boiler manual

Figure 29 Pilot burner assembly, typical
Locating Slot

Igniter Sensor

Pilot Burner

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10-32 x 5/16″

1

Machine Screws(2)

Burner Support Bar

2
Pilot Mounting Bracket

Pilot Line Tubing

10-32 x 1/4″ Machine Screws (2)

220280

Sensor Lead

Main Burner

3

(with Pilot

Igniter Lead

Compression Union

Mounting Bracket)

Figure 30 Main flame sense assembly

Locating Slot

Flame Sensor

6-32 x 5/16″ Type “F”

Self Tapping Screws(2)

4

10-32 x 5/16″ Machine Screws(2)

Burner Support Bar

Ground Leadwire:

Connect to Chassis Ground (See Figure 31)

5

Flame Sensor Mounting Bracket

220281
Figure 31 Main flame chassis ground

Sensor Lead

Main Burner (with Pilot Mounting

6

Bracket)

7

550-100-2062/200122832

8
25

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Boiler Assembly, continued
1 Gas Train Installation for Single Bases

LGB models 4-12:

1 Remove any covering over the burner manifold

2

inlet pipe and apply pipe dope to the inlet pipe threads

2 Remove the free half of the union on the gas

train and thread onto the inlet pipe Use two pipe wrenches to secure the union to the inlet pipe

3 Secure the gas train to the boiler with the

remaining union half Use two pipe wrenches to

3

tighten the connection

4 Thread the gas supply piping into the manual

shut-off valve. See page 54 for appropriate

pipe sizing

5 All connections must be gas tight Verify that all

unions are tight

4

Figure 32 Gas train installation (dual base shown)

lGb series 3 boiler manual
Gas Train Installation for Dual Bases
LGB models 14-20:
1 Apply pipe dope to the gas train extension (item 2) 2 Securely thread the gas train extension into the
main gas train (item 1) 3 Remove any covering over the burner manifold
inlet pipes and apply pipe dope to the inlet pipe threads 4 Remove the free halves of the unions on the gas train and thread onto each inlet pipe Use two pipe wrenches to secure the union to each inlet pipe 5 Secure the gas train to the boiler with remaining union halves Use two pipe wrenches to tighten the connections 6 Thread the gas supply piping into the manual shut-off valve. See page 54 for appropriate pipe sizing 7 All connections must be gas tight Verify that all unions are tight

5

6

1

2

7

8
26

3 220264

4
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Control Installation
Ensure the gas control, control panel, and trim boxes are on hand before beginning this section See the Parts section starting on page 99 for details of components required for each boiler model
1 Retrieve the common control panel from the kit · For dual base boilers, also retrieve the Base 2 control panel from kit
2 Secure the common panel to the boiler jacket with a Philips head screw driver
Table 8 Pressure switches

· For dual base boilers only, secure the Base 2

1

panel to the boiler jacket with a Philips head

screw driver

3 Retrieve the pressure switch from the kit and

secure to the interior panel with a Philips head

screw driver a Single base boilers have one pressure switch

2

b Dual base boilers have two pressure switches

c Pressure switch setpoints are shown in Table 8

(continued on the next page)
3

0 to 1,999 ft

Altitude 2,000 to 6,999 ft 7,000 to 10,000 ft

Boiler Model

Setpoint

Setpoint

Setpoint

4

LGB 4R/4

2 45

2 20

2 10

LGB 5

1 36

1 12

1 12

LGB 6

1 65

1 45

1 36

LGB 7

LGB 8

5

LGB 9

2 10

1 95

1 22

LGB 10

LGB 11

2 45

2 20

1 12

LGB 12

LGB 14 Left Side

1 65

1 45

1 36

6

LGB 14 Right Side

LGB 16 Right Side

LGB 16 Left Side

2 10

1 95

1 22

LGB 18 Left Side

LGB 18 Right Side

7

LGB 20 Right Side

LGB 20 Left Side

2 45

2 20

1 12

8

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lGb series 3 boiler manual

Boiler Assembly, continued
1 Control Installation, continued

Figure 33 Common/single base control panel

4 Ensure pressure switch tubes, inducer wires, and

flue temperature switch wires are installed and

routed as shown

2

a See Figure 33 for single base boilers b See Figure 35, page 29 for dual base boilers

c Pressure switch wires have push-in wire clips

that can be inserted into the front panel

5 Connect gas valve and pressure switch wires

a Refer to the wiring diagrams on pages 58-59

for single base boilers

3

b Refer to the wiring diagrams on pages 60-61

for dual base boilers

6 Retrieve the correct configuration plug from the

trim kit Verify that the wire color and label match

the details in the schematic and wiring diagrams,

starting on page 58

220283

4 7 For LGB water boilers only: a Retrieve the water temperature sensor and

thermal paste from the water trim kit

b Insert about 1/2 a tube of thermal paste into

the sensor well

c Insert the temperature sensor into the well,

threading securely in place

5

d Retrieve the water temperature sensor wire

harness from the water trim kit 220285
e Route the harness as shown in Figure 34; connect

to the control board and sensor at both ends

Figure 34 Water temperature harness routing

IMPORTANT

6 Many boiler sizes will have excess length on the harness. Before connecting to the control board, loop the excess wire and secure to the front panel with provided wire clips.

8 For dual base boilers only, follow the instructions

7

below Refer to the dual base wiring diagrams on pages 60-61

a Disconnect the power harness from the Px

connection on the board and connect the power

Y-harness as shown in Figure 35, page 29

b Disconnect the inducer relay harness from the

Px connection on the board and connect the

8

inducer relay Y-harness as shown in Figure 34

c Connect the second power Y- harness to the

inducer output and each inducer harness as

shown in Figure 35, page 29

28

220287
9 See “Install Boiler Controls” on page 50 for proper use of external limit controls
550-100-206/0123

lGb series 3 boiler manual
Figure 35 Dual base panels 220284
220286
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1 2 3 4 5 6 7 8
29

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lGb series 3 boiler manual

Boiler Conversion
1 Gas Orifice and Pressure Switch Conversion
! DANGER
For high altitude installations, only use the high altitude kit specified for the LGB boiler being
2 converted. Verify the kit contents are the correct size, fuel type, and elevation for the boiler. Replace all burner orifices and pressure switches with the correct kit components. Failure to follow these limitations will result in severe personal injury, death, or substantial property damage.
3 All LGB boilers are shipped ready for operation at altitudes below 2,000 feet. The boilers must be fitted with high altitude burner orifices to be used at altitudes 2,000 feet and above A conversion kit to convert the boiler for high altitude is purchased separately See Miscellaneous Parts on page 99
4 ! WARNING
Turn off electrical supply to installed boilers before service. Close the external manual gas shut-off valve to isolate the boiler during conversion. Ensure the boiler is not hot. Failure to follow these instructions can result in severe
5 personal injury, death, or substantial property damage.
1 For installed boilers, turn off the electrical supply and close the external manual gas shut-off valve. Allow the boiler to cool if it has been operating
6 2 Remove the access panel 3 On the gas manifold, mark the location of the pilot burner and, on models LGB 6-20 only, the main flame sense burner. 4 Remove the pilot burner with attached pilot assembly and the main flame sense burner with
7 attached flame sense assembly from the manifold. 5 Remove all remaining burners 6 Remove and discard all burner orifices in the gas manifold 7 Ensure the size of the new orifice matches the correct model and altitude as specified in Table 4, page 12
8 8 Apply a small amount of pipe dope to each of the new orifices and install in the manifold. Make sure the orifices are aligned correctly and not crossthreaded in the manifold tappings
30

9 Reinstall the main burner with attached pilot assembly at the location marked on the gas manifold
10 Reinstall all remaining burners 11 Check that all burners are seated firmly in the
slots in the rear support The opening in each burner must be facing up. The main burner orifice must inject down the center of the burner
! WARNING
Failure to properly seat and level the burners can result in severe personal injury, death, or substantial property damage.
12 Remove the flue pressure switch tubes from the flue pressure switch, noting ports each tube are installed in
13 Remove the flue pressure switch wires 14 Remove the flue pressure switch. 15 Install the new flue pressure switch, ensuring
the pressure switch label matches the setpoint specified in Table 8, page 27 16 Reattach the flue pressure switch tubes to the new flue pressure switch, ensuring tubes are installed in the same locations as noted Reinstall the flue pressure switch wires.
! WARNING
Failure to install flue pressure switch properly can result in severe personal injury, death, or property damage.
17 If converting to a high altitude orifice and switch, apply the high altitude conversion label above the rating label
18 Reconnect the power to the boiler
Test the boiler completely after conversion Fill out the Fire Test label with the test results Follow all instructions in this manual to start up the boiler Check combustion levels and verify operation of the boiler and all system components after conversion
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Water Boiler Piping
Water Piping Installation
NOTICE
Use two wrenches when tightening water piping at the boiler with one at the boiler interior piping to prevent it from turning. Failure to prevent boiler piping connections from turning could cause damage to boiler components.
NOTICE
Improper piping systems or undersized piping can cause erratic boiler operation and possible boiler damage. Follow all piping instructions in this manual.
IMPORTANT
For the LGB models 4-12, the supply and return piping can be on the same end. For all other LGB models, the supply and return must be on opposite ends of the boiler.
1 The system supply and return piping can be installed before installing jacket
2 Do not pipe in through supply and out through return, as this will create a reverse water flow.
3 Install an expansion tank a Closed-type expansion tank: Connect the tank to the 1″ tapping F Refer to Figure 13, page 16 Use 1″ NPT piping Horizontal piping must pitch upward toward the tank at least 1″ for each 5 feet of piping See Figure 36 b Diaphragm-type expansion tank: Install the tank between the supply and inlet to circulator Install an automatic air vent in tapping F
4 Connect the supply and return piping a Size piping according to Table 9 b Install a circulator in the supply piping, with the expansion tank on the suction side c Install a system drain valve that is sized per ASME Code · Models LGB-4 to LGB-12: Use a 1″ drain valve · Models LGB-14 to LGB-20: Use a 1 25″ drain valve
5 When 3-way valves are used for temperature modulation, install slow-opening valves and a boiler mixing pump to minimize the potential of boiler thermal shock See the Weil-McLain Bulletin SB-0203
6 Piping should be sized for a 20°F rise through the boiler. For higher flow rates, use pipe sizes no smaller than those shown in Table 9
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Figure 36 Water boiler piping

3

1

1

SUPPLY
2

2

3

RETURN

220195

Legend – Figure 36

4

1 Models LGB-4 through LGB-12 only — alternate supply tapping for supply and return on the same end

2 Models LGB-4 through LGB-12 only — alternate return tapping for supply and return on the same end

3 Location for closed-type expansion tanks only Locate

diaphragm-type expansion tanks between the boiler supply

connection and the circulator suction connection

5

Table 9 Minimum supply and return pipe sizes

By Boiler Model

Boiler Model Number

Supply & Return Pipe Size

LGB-4R & LGB-4

2 .0″

LGB-5

2 .5″

6

LGB-6 to LGB-8

3 .0″

LGB-9 to LGB-16

4 .0″

LGB-18 to LGB-20

5 .0″

Water Flow Rate Supply & Return

(GPM)

Pipe Size

Up to 35

2 .0″

7

36 to 50

2 .5″

51 to 77

3 .0″

78 to 142

4 .0″

143 to 237

5 .0″

For Specified Flow Rates

NOTICE
Intermittent flow at higher velocities than shown

8

for the pipe size in Table 9 can damage the boiler,

causing substantial property damage.

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lGb series 3 boiler manual

Water Boiler Piping, continued
1 General Piping Information
The control module uses temperature sensors to provide both high limit protection and operating limit control, and is UL60730 Limit Controls certified to
2 meet ASME CSD-1 and Section IV requirements Some codes and jurisdictions may require additional external controls
For all boiler tappings and descriptions, see Figure 13, page 16
3 Additional limit controls: Consult local requirements for other codes/standards to determine if additional limit devices are needed
NOTICE
If the heating system includes circuits that require
4 lower temperature water along with circuits that require higher temperature water, it is recommended to protect low-temperature circuits with limit controls that are wired to a manual or automatic reset circuit on the control.
See instructions beginning on page 55 for wiring
5 information · The control provides two sets of limit control contacts One set will cause automatic reset, and the other set will cause manual reset of the control · The control can be reset using the manual RESET function on the control module
6

Low water cutoff: · A low-water cutoff can be installed in tappings as
indicated in Figure 13, page 16 · The low-water cutoff can be wired into the limit
control contacts on the control terminal block See page 57 for terminal descriptions
Backflow preventer: Use a backflow check valve in the water fill as required by local codes
Pressure and temperature gauge: The water trim carton includes a 1/2″ NPT pressure and temperature (P/T) gauge which has a pressure range up to 55 psig This gauge meets ASME requirements up to a relief valve setting of 30 psig
Mount the P/T gauge in the 1/2-inch tapping on the side of the boiler as indicated in Figure 13, page 16
NOTICE
For higher pressure rated relief valves, a different P/T gauge with a higher pressure range is required. When installing a gauge that requires a larger tapping than the 1/2″ NPT tapping in the side of the boiler, provide an additional tapping in the near boiler piping BEFORE any isolation valve. DO NOT add tappings to boilers castings.

7

8
32

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Relief Valve Installation
! WARNING
Do NOT install a relief valve with a pressure higher than 80 psig. This is the maximum allowable relief valve setting for the LGB boiler. The boiler is shipped with a 30 psig relief valve. Failure to comply can result in severe personal injury, death, or substantial property damage.
! WARNING
Improper installation of the relief valve and discharge line can cause valve operation failure, water damage, and scalding. Follow all following instructions and guidelines. Failure to comply can result in severe personal injury, death, or substantial property damage.
1 The water trim carton includes a relief valve Install the relief valve in the tappings indicated in Figure 13, page 16
2 Connect discharge piping to a safe disposal location according to the guidelines below
· Discharge line must be connected to the relief valve outlet and run to a safe place of disposal Terminate the discharge line in a manner that will prevent the possibility of severe burns or property damage should the valve discharge

· Discharge line must be as short as possible and

be the same diameter as the valve discharge connection throughout its entire length

1

· Discharge line must pitch downward from the valve and terminate at least 6″ above the floor drain where any discharge will be clearly visible
2 · Discharge line shall terminate plain, not threaded,
with a material serviceable for temperatures of 375°F (191°C) or greater

· Do not pipe the discharge to any place where
freezing could occur
3
· Do not install any shutoff valve between the relief valve and boiler, or in the discharge line Do not
plug or place any obstruction in the discharge line

· After filling and pressurizing the system, test the
4 operation of the valve by lifting the lever Make
sure the valve discharges freely If the valve fails to operate correctly, replace it with a new relief valve

See the Parts section starting on page 99 for alternative pressure setting relief valves
5

6

7

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Water Boiler Piping, continued
1 Primary/Secondary Piping
The recommended primary/secondary piping is shown in Figure 37 For single boilers, pipe as shown for one unit
2 1 Size secondary boiler pump GPM for 20°F to
40°F temperature rise through the boiler The secondary boiler pump head will be very low 2 Calculate only the secondary piping circuit resistance Boiler resistance will not exceed 6″ W C
3 3 Primary pump GPM and head calculation should not include secondary boiler circuits The primary pump can operate continuously during the heating season 4 Distance 12″ or less 5 Flow/check valve
4 6 Hand valve 7 Expansion tanks, relief valves, and other accessories are required but not shown

Figure 37 Primary/secondary piping
3
12 ” maximum
2
Diaphragm expansion tank (if used)

1 45
Flow/check valve

54 1
Flow/check valve

55

Refrigeration System Piping
Install the boiler so that chilled medium is piped
5 in parallel with the heating boiler, with appropriate valves to prevent the chilled medium from entering the boiler Consult AHRI Installation and Piping Guides See Figure 38 If the boiler system has heating coils in air handling units where exposure to refrigerated air is possible,
6 use flow control valves to prevent gravity circulation during cooling cycles

220196

Figure 38 Refrigeration system piping

System supply

Expansion tank

Circulator

Shut-off valve

Water chiller

7

Strainer Check valve

Boiler

System return

8

Balancing

220197

valve

34

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Steam Boiler Piping
Steam Piping Installation

Figure 39 Steam boiler piping for LGB 4-12 – single riser
1

NOTICE
Improper piping systems or undersized piping can

Steam supply

A H

cause erratic boiler operation and possible boiler

damage. Follow all piping instructions in this manual.

1

2

A boiler feed system with a level controller on the

J

boiler that operates the pump is recommended It is

2

not recommended to use a condensate return system

where the pump is operated by a receiver-mounted

J

float switch. Level controls must be mounted on the same side as the return piping and equalizer See pages 50-51 for more information on controls
For multiple steam boiler piping, see Figure 43,

Condensate return

220198

3

page 37

Figure 40 Steam boiler piping for LGB 14-20 – riser on

each end

1 Pipe the header at least 24″ above the boiler

water line 2 Install a blowdown valve in tapping C1 or C2,
sized per ASME Code

Steam supply

4

B

H

A

· Models LGB-4 to LGB-12: Use a 1″ blowdown

valve

· Models LGB-14 to LGB-20: Use a 1 25″ blowdown

1

valve

J

5

2

J

Table 10 Minimum steam boiler pipe sizes

Boiler Model Number

Risers

A

B

Header Equalizer

H

J

LGB-4 to LGB-8

4″

4″

2 0″

LGB-9 to LGB-11

5″

5″

2 5″

LGB-12

6″

6″

2 5″

LGB-14

4″

4″

6″

4 0″

LGB-16 to LGB-18 5″

5″

6″

4 0″

LGB-20

6″

6″

8″

4 0″

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Condensate return

220199

6

Figure 41 Steam boiler piping additional information

Steam supply

Header

OR

24″

Boiler

7

min

Water line

4″

Hartford loop tee 2

1 Reducing from header
to equalizer – alternate piping methods. DO NOT reduce the header in the horizontal piping.

33 7/16″

Use only close nipple or street ell here.

8

220200

Floor line

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lGb series 3 boiler manual

Steam Boiler Piping, continued
1 Condensate Return

There must be adequate return of condensate to

If condensate return is not adequate, an LWCO and

maintain steady water level for satisfactory operation pump control, condensate receiver, and condensate

of the steam heating system Avoid adding excessive boiler feed pump should be installed Refer to Figure

2 makeup water

42 and Table 11

Figure 42 Boiler feed pump and condensate receiver piping

Vent to atmosphere
3
Return
Hartford loop

4

Isolation valve

2″

5

Receiver

Strainer Feed pump Check valve

Boiler

220201

Table 11 Minimum condensate receiver capacity

Boiler Model
6

LGB-4R

LGB-4

LGB-5

LGB-6

7

LGB-7

LGB-8

LGB-9

LGB-10

LGB-11

LGB-12

8

LGB-14 LGB-16

LGB-18

LGB-20

Gross Steam Output lbs /hour
291 8 334 0 434 0 542 3 650 5 759 8 868 0 976 3 1,085 6 1,193 8 1,410 3 1,627 8 1,845 4 2,061 9

Condensate
gallons/hour 35 42 54 68 81 95 109 122 136 149 176 203 231 258

Minimum Condensate Receiver Capacity (gallons) (Select minimum receiver capacity base on time [minutes] required for condensate to return to the receiver)

15 minutes

30 minutes

45 minutes

60 minutes

11

22

33

44

13

26

39

52

17

34

51

68

21

42

64

85

25

51

76

102

30

59

89

119

34

68

102

136

38

76

114

153

42

85

127

170

47

93

140

187

55

110

165

220

64

127

191

254

72

144

216

288

81

161

242

322

Recommended Feed Pump Capacity GPM@15 PSI
1 2 1 4 1 8 2 3 2 7 3 2 3 6 4 1 4 5 5 0 5 9 6 8 7 7 8 6

36

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Piping Multiple Steam Boilers
Each boiler has a boiler feed pump controller Mount each boiler feed pump controller with the body mark at the level indicated in Figure 50, page 50

Level controls must be mounted on the same side as
1 the return piping
Boiler controls and trim (such as valves, LWCO, pump controllers, and burners) are omitted in Figure 43 for piping clarity

Figure 43 Piping multiple steam boilers
2
6

1

7

3

2

8

4

3
6
7
4

Steam supply

5 To feed pump Header Hartford loop detail

24″
min To trap
4″

Boiler 2 to 4″
Water line
Hartford loop tee

33 7/16″

Use only close nipple or street ell here.

8

4

5 To feed pump

5 6

Floor line

220240

1 Locate the steam supply takeoff outboard from the connecting piping to ensure liquid in the line will flow to the trap. 2 Locate combined header drain as shown. Install a strainer and float and a thermostatic trap in the drain line as shown. Pipe the

7

trap outlet to the condensate receiver

3 Size the common header piping per ASHRAE recommendations, but not smaller than the individual boiler headers

4 Pipe the Hartford Loop tee 4″ below the boiler waterline

5 Provide a separate feed pump for each boiler Alternatively, provide a separate automatic valve with end switch and a single feed

pump If using a valve, activate it with the boiler pump controller Activate the feed pump with the valve end switch

6 Manual steam valve or slow opening automatic steam valve, sized to the boiler output capacity

8

7 Boiler steam header for single boiler See page 35

8 Install a float and thermostatic trap and strainer off the equalizer of each boiler from 2″ to 4″ above the waterline. Connect the trap

outlet to the condensate receiver. The trap will prevent an idle boiler from flooding due to condensed steam from the system.

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lGb series 3 boiler manual

Commonwealth of Massachusetts Installations
1
Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts, the boiler must be installed by a licensed plumber or gas fitter. Read and comply with the instructions below.

1 REQUIREMENTS: For all sidewall horizontally-vented

gas-fueled equipment installed in every dwelling, building or

2

structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth

and where the side wall exhaust vent termination is less

than 7 feet above finished grade in the area of the venting,

including but not limited to decks and porches, the following

requirements shall be satisfied:

a INSTALLATION OF CARBON MONOXIDE DETECTORS

3

At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber

or gas fitter shall observe that a hard wired carbon

monoxide detector with an alarm and battery back-up is

installed on the floor level where the gas equipment is

to be installed In addition, the installing plumber or gas

fitter shall observe that a battery operated or hard wired

carbon monoxide detector with an alarm is installed on

each additional level of the dwelling, building or structure

4

served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property

owner to secure the services of qualified licensed

professionals for the installation of hard wired carbon

monoxide detectors · In the event that the side wall horizontally vented gas

fueled equipment is installed in a crawl space or an

attic, the hard wired carbon monoxide detector with

5

alarm and battery back-up may be installed on the next adjacent floor level.

· In the event that the requirements of this subdivision

can not be met at the time of completion of

installation, the owner shall have a period of thirty

(30) days to comply with the above requirements;

provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector

with an alarm shall be installed

6

b APPROVED CARBON MONOXIDE DETECTORS Each

carbon monoxide detector as required in accordance with

the above provisions shall comply with NFPA 720 and be

ANSI/UL 2034 listed and IAS certified.

c SIGNAGE A metal or plastic identification plate shall be

permanently mounted to the exterior of the building at a

minimum height of 8 feet above grade directly in line with

7

the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall

read, in print size no less than one-half (1/2) inch in size,

“GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL

OBSTRUCTIONS ”

d INSPECTION The state or local gas inspector of the

side wall horizontally vented gas fueled equipment shall

8

not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and

signage installed in accordance with the provisions of

248 CMR 5 08(2)(a) 1 through 4

2 EXEMPTIONS: The following equipment is exempt from
248 CMR 5 08(2)(a)1 through 4: a The equipment listed in Chapter 10 entitled “Equipment
Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and b Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes
3 MANUFACTURER REQUIREMENTS — GAS EQUIPMENT
VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include: a Detailed instructions for the installation of the venting
system design or the venting system components; and b A complete parts list for the venting system design or
venting system
4 MANUFACTURER REQUIREMENTS — GAS EQUIPMENT
VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer: a The referenced “special venting system” instructions shall
be included with the appliance or equipment installation instructions; and b The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions
5 PLASTIC VENTING SYSTEMS .
The only plastic piping which may be used for venting appliances shall be: a Allowed by the appliance manufacturer b Listed to a national/international standard for plastic
venting systems c Product-accepted for that purpose by the board
6 INSTALLATION INSTRUCTIONS . A copy of all installation
instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation

38

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Venting and Combustion Air – General

Code Compliance

Table 12 Corrosive contaminants and sources

1

Products to avoid

Venting and combustion air piping installations must provide provisions in accordance with the section,

Spray cans containing chloro/fluorocarbons Permanent wave solutions

“Air for Combustion and Ventilation,” of the National

Chlorinated waxes and cleaners

Fuel Gas Code – ANSI Z223 1/NFPA 54, latest edition, or Sections 8 2, 8 3, or 8 4 of the Natural Gas

Chlorine-based swimming pool chemicals Calcium chloride used for thawing

2

and Propane Installation Code – CAN/CSA B149 1,

Sodium chloride used for water softening

and applicable provisions of the local building codes

Refrigerant leaks

! DANGER

Paint or varnish removers

Hydrochloric acid and muriatic acid

Inspect finished vent system thoroughly to ensure

Cements and glues

it is airtight and complies with instructions in

Anti-static fabric softeners used in clothes dryers

3

this manual and applicable codes. Verify all air

Chlorine-type bleaches, detergents, and cleaning solvents

openings are correctly sized, unobstructed, and

Adhesives used to fasten building products and other similar products

free of airborne contaminants. Failure to provide a

Excessive dust and dirt

properly installed vent system will result in severe personal injury or death.

Areas likely to have contaminants Laundry and dry cleaning areas and establishments

! WARNING

Swimming pools

4

Metal fabrication plants

Provide a vent manufacturer’s bird screen at each Beauty shops

termination. Bird screens must be purchased

Refrigeration repair shops

from the vent piping supplier. Failure to comply

Photo processing plants

can result in severe personal injury, death, or

Auto body shops

substantial property damage.

Plastic manufacturing plants Furniture refinishing areas and establishments

5

Venting System Category

New building construction

The LGB water and steam boilers have two different venting categories with very different venting requirements However, both have the

Remodeling areas Garages with workshops
Combustion Air Provision

same combustion air provision and contamination requirements found in the following sections on this

The LGB commercial boiler can use inside air if

6

page The venting system categories used are below no contaminants are present in the boiler space

If contaminants are likely to be present, install the

LGB Steam Boilers:

boiler as a direct vent appliance Use the appropriate

vent instructions in this manual

Category I: Negative pressure, unlikely to condense within the venting system. For specific vent system requirements, see the Steam Boiler Venting –

The boiler room must be fitted with combustion air openings large enough to provide air for all

7

appliances in the room Use the following information

Category I section on page 44

to size the openings Ensure the installation complies

with all applicable codes and standards

LGB Water Boilers:

Category II: Negative pressure, likely to condense within the venting system (corrosion resistant & water

Combustion Air Contamination
8
Provide combustion air openings as described in this

tight). For specific vent system requirements, see the Water Boiler Venting – Cateory II section on page 46

manual See Table 12 for products and areas that may cause contaminated combustion air

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lGb series 3 boiler manual

Venting and Combustion Air – General, continued

1 Sizing Combustion Air Openings

Special Considerations

Air openings provide the air required by the LGB boiler to complete the combustion process Air is also needed for other appliances located in the same
2 space Use the information in Figure 44, page 41 for air openings
! WARNING
Air openings must be sized to handle all appliances and air movers, such as exhaust fans, using the air supply. Failure to comply can result
3 in severe personal injury, death, or substantial property damage.
The sizing given in Figure 44, page 41 is based on the National Fuel Gas Code – ANSI Z223 1/ NFPA 54, latest edition The sizing allows adequate
4 air openings for gravity-vented gas appliances (Category I), in addition to the needs for the LGB boiler. The air openings specified by NFPA 54 and Figure 44, page 41 will allow adequate ventilation and combustion air, provided the boiler room is not subjected to negative pressure due to exhaust fans or other mechanical ventilation devices Refer to the
5 National Fuel Gas Code when working with other conditions
Free area and louvers The free area of openings means the area after reduction for any installed louvers or grilles Be
6 sure to consider this reduction when sizing the air opening

Tight construction
The National Fuel Gas Code – ANSI Z223 1/NFPA 54, latest edition defines unusually tight construction where all of the following is true:
1 Walls and ceilings exposed to the outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings fitted with gaskets.
2 Weather-stripping has been added on windows and doors that are capable of being opened
3 Caulking or sealants are applied to areas such as joints around windows and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and in other openings
For buildings with such construction, provide air openings into the building from outside Size the openings per the appropriate condition in Figure 44, page 41 if appliances are to use inside air for combustion and ventilation
Exhaust fans and movers
The appliance space must never be under a negative pressure Always provide air openings sized to the dimensions required for the firing rate of all appliances, with the ability to handle the air movement rate of the exhaust fans or air movers using air from the building or space

7

8
40

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Figure 44 Minimum combustion air openings

1

Air openings
The required air opening sizes below are FREE AREA, after reduction for louver obstruction See the important below for large spaces

LGB boiler WITH other appliances in the same room

LGB boiler WITHOUT other appliances in the same room

a

Vent

0 to 12″
(2) Air openings

Other appliances

220265a
b Vent

0 to 12″ 0 to 12″
(2) Air openings

Other appliances

220265b

Outside or ventilated attic

c

Vent

0 to 12″

(2) Air openings

Other appliances

220265c

0 to 12″

or

Ventilated crawl space

Outside

Outside

Outside

Two openings, each at least: 1 square inch per 1,000 Btuh of all

Two openings, each at least: 1 square inch per 1,000 Btuh of all

2

appliances in the room, but not less than appliances in the room, but not less than

100 in2

100 in2

Two openings, each at least: 1 square inch per 2,000 Btuh of all
appliances in the room -OR-
One opening at least: 1 square inch per 3,000 Btuh of all
appliances in the room
Two openings, each at least: 1 square inch per 4,000 Btuh of all
appliances in the room -OR-
One opening
at least: 1 square inch per 3,000 Btuh of all
appliances in the room

Two openings, each at least:

1 square inch per 2,000 Btuh of all appliances in the room

3

-OR-

One opening* at least:

1 square inch per 3,000 Btuh of all

appliances in the room

Two openings, each at least:

1 square inch per 4,000 Btuh of all appliances in the room

4

-OR-

One opening* at least:

1 square inch per 3,000 Btuh of all

appliances in the room

d

Vent

Other appliances

220265d

0 to 12″
(2) Air openings
0 to 12″

Outside

Two openings, each at least: 1 square inch per 2,000 Btuh of all
appliances in the room -OR-
One opening* at least: 1 square inch per 3,000 Btuh of all
appliances in the room

Two openings, each at least:

1 square inch per 2,000 Btuh of all appliances in the room

5

-OR-

One opening* at least:

1 square inch per 3,000 Btuh of all

appliances in the room

  • Requirements for using the single air opening option

A single combustion air opening can be used for cases b, c, or d above, sized as listed,

provided that the following are met: · The single opening must communicate directly to open air outside of the building or

6

to a space that communicates directly to the outside of the building

· The top of the opening must be within 12″ of the ceiling

· The free area of the opening must be at least equal to the sum of the areas of all

equipment vent connectors in the space

IMPORTANT

No combustion air openings are needed when the boiler and other appliances are

installed in a space with a volume no less than 50 cubic feet per 1,000 Btuh of all appliances in the space The building must NOT be of tight construction

7

A special exception exists for large spaces. See the information
to the right.

Calculation: Take the total inputs of all appliances in MBH (1,000s Btuh) and multiply by 50 The space volume must be equal to or greater than the total of this calculation
[Total appliances input in MBH x 50] space volume

Example: For a total input of 1500 MBH (1,500,000 Btuh), the minimum space volume

necessary would be 1500 x 50 = 75,000 cubic feet

8

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Venting and Combustion Air – General, continued

1 Existing Vent System

3 Turn on the clothes dryer and any other appliance

! WARNING

not connected to the common venting system Turn on all exhaust fans, except for a summer

Follow all venting and piping instructions. Failure

exhaust fan, and operate at maximum speed

to follow all instructions can cause flue gas

Exhaust fans include range hoods and bathroom

2 spillage and carbon monoxide emissions, which can result in severe personal injury or death.

fans. Close fireplace dampers. 4 Place the appliance being inspected into

operation Follow the lighting instructions Adjust

Removal of the previous boiler may cause an issue

the thermostat so the appliance will operate

for the appliances that remain on the old common

continuously

vent as the vent may be too large The following

5 Test for spillage at the draft hood relief opening

test is intended to check for proper operation of the
3 appliances remaining on the old common vent system

after five minutes of main burner operation. Use the flame of a match or candle, or smoke from a smoke stick

Existing Vent System Test Procedure

6 After it has been determined that each appliance

remaining connected to the common venting

Perform this test when removing a boiler from the

system properly vents when tested as outlined

common venting system The following steps shall be

here, return doors, windows, exhaust fans,

4 followed with each appliance remaining connected to the common venting system Test each appliance

fireplace dampers, and any other gas-burning appliance to their previous conditions of use

separately while in operation Ensure all other

appliances connected to the common vent are not in Correct any improper operation of the common venting

operation Seal any unused openings in the common system so the installation conforms with the National

venting system before proceeding with the test

Fuel Gas Code – ANSI Z223 1/NFPA 54, latest edition

5 1 Visually inspect the venting system for proper size and horizontal pitch Ensure there is no

Adhere to the National Gas and Propane Installation Code – CAN/CSA B149 1 for Canada When resizing any portion of the common venting system, approach

blockage, restriction, leakage, corrosion, or other the minimum size as determined using the appropriate

deficiency that could cause an unsafe condition. tables in part 11 of the National Fuel Gas Code, ANSI

2 Close all building doors and windows as practical Z223 1/NFPA 54, and CAN/CSA B149 1 Natural Gas

Close all doors between the location of the

and Propane Installation Code

6

appliances connected to the common venting system and other spaces of the building

7

8
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Steam Boiler Venting – Category I

Chimney Draft Venting

1
Figure 45 Vent piping to boiler

! DANGER

Inspect existing chimney before installing boiler.

Failure to clean or replace perforated pipe or

lining will result in severe personal injury or death.

2

! WARNING
The vent connector and chimney must be

Starting section of vent piping must be crimped on both ends

designed, sized and constructed in compliance

with all applicable codes. Technical data to

support the proper sizing of the vent and chimney

3

can be found in Table 13, page 44. Failure to

comply can result in severe personal injury, death,

or substantial property damage.

1 Use single wall metal pipe, double wall Type B

gas vent, or chimney as required by the National

220177

Fuel Gas Code, ANSI Z223 1/NFPA 54 ­latest

4

edition, or in Canada, B149 1 or B149 2 Natural

6 Do not use a chimney with an open fireplace.

Gas and Propane Installation Code

7 Make horizontal runs as short as possible; long

2 To prevent downdrafts, chimney should extend

runs can cause condensation

at least 3 feet above the highest point where it

8 When longer runs are used, support pipe with

passes through a roof or snow line, and at least 2

appropriate hangers sloping the vent upward

feet higher than any portion of a building within a

towards the chimney at 1/4″ per foot

5

horizontal distance of 10 feet, and in accordance 9 To prevent blockage, do not vent into the bottom

with local codes that have jurisdiction

of the chimney

3 To vent with another appliance, see National Fuel 10 Vent pipe must not go beyond the inside wall of

Gas Code, ANSI Z223 1/NFPA 54 ­latest edition

the chimney

or in Canada B149 2 or B149 2 Natural Gas and 11 Vent passing through floors or ceilings must be

Propane Installation Code 4 Do not connect breeching to any portion of a

firestopped. 12 See Figure 45 and Table 13, page 44 to

6

mechanical draft system that can operate under

connect the boiler to the venting system

positive pressure

5 Maintain a minimum 2″ clearance from

combustible materials to vent pipe

7

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Steam Boiler Venting – Category I, continued

1 Condensate Drain Plug Installation

Figure 46 Plug condensate drain fitting

A condensate trap is not needed with Category I venting Install the provided 1/2″ NPT drain plug into the condensate drain fitting on the vent connector.
2 Use Teflon tape on the threads of the plug to provide a tight seal See Figure 46

3

Install plug into condensate drain fitting

4

220272

Table 13 Category I vent system technical data

5 Boiler Size

Maximum Input

LGB Series 3 Steam – Category I Venting Information

Max . Stack/ Vent Flow
Rate*

Minimum Input

Min . Stack/ Vent Flow
Rate*

Typical Flue Temperature

Negative Pressure to be maintained @ Vent
Connection

Vent Connection and Minimum Vent Diameter

BTU/hr

CFM

BTU/hr

CFM

°F

Inches W .C .

Inches (Qty)

LGB-4R

350,000

125

175,000

63

280 – 300

-0 .001 to -0 .1

10 (1)

LGB-4

400,000

143

200,000

72

6

LGB-5

520,000

186

260,000

93

LGB-6

650,000

233

325,000

116

280 – 300 280 – 300 280 – 300

-0 .001 to -0 .1 -0 .001 to -0 .1 -0 .001 to -0 .1

10 (1) 12 (1) 12 (1)

LGB-7

780,000

279

390,000

140

280 – 300

-0 .001 to -0 .1

12 (1)

LGB-8

910,000

326

455,000

163

280 – 300

-0 .001 to -0 .1

14 (1)

LGB-9

1,040,000

373

520,000

186

280 – 300

-0 .001 to -0 .1

14 (1)

LGB-10

1,170,000

419

585,000

210

7

LGB-11

1,300,000

466

650,000

233

LGB-12

1,430,000

512

715,000

256

280 – 300 280 – 300 280 – 300

-0 .001 to -0 .1 -0 .001 to -0 .1 -0 .001 to -0 .1

16 (1) 16 (1) 16 (1)

LGB-14

1,690,000

605

845,000

303

280 – 300

-0 .001 to -0 .1

12 (1) 14 (1)

LGB-16

1,950,000

699

975,000

349

280 – 300

-0 .001 to -0 .1

14 (2)

LGB-18

2,210,000

792

1,105,000

396

8

LGB-20

2,470,000

885

1,235,000

442

280 – 300 280 – 300

-0 .001 to -0 .1 -0 .001 to -0 .1

14 (1) 16 (1)
16 (2)

*Stack / flow rate is based on the unit operating at 7.6% CO2 . This value can vary based on the location of the installation and operating conditions .

44

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Figure 47 LGB series 3 steam — typical Category I venting
1

Vent caps

3 ft
minimum

Combined vent length (Note 3)

5 ft
minimum (Note 1)

Roof line

2 ft
minimum (Note 2)

15 ft Minimum effective

2

chimney height

Outside wall

Combined vent diameter (Note 3)

3

Individual Stub Vents

Connector rise (Note 3)

4

Connector lateral (Note 4)
15 ft Minimum effective
chimney height Connector rise (Note 4)

220180

Offset Vents

3 ft
minimum

(Also see note 2)

Combined Vents
5

Notes

1 Minimum vent height using full size connector

2 Minimum 2 feet above any structure within 10 feet

3 Vent and combined vent materials, length and diameter must be determined using the combined

6

venting tables of the National Fuel Gas Code, ANSI

Z223 1­latest edition, or other accepted engineering

design method Use a connector rise as high as

possible to improve vent connector capacity

4 Vent and vent connector material and design must

be determined using the individual venting tables

of the National Fuel Gas Code, ANSI Z223 1­latest

edition, or other accepted engineering design

7

method Use a connector rise as high as possible to

improve vent connector capacity

8

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Water Boiler Venting – Category II
1 Category II Requirements
! WARNING
Install a Category II vent system per all instructions in this manual. Improper Installation
2 of a Category II vent system that results in positive pressure in the vent system can cause flue gas spillage and carbon monoxide, which can result in severe personal injury or death.
! WARNING
Follow all applicable national and local codes for
3 installations. Failure to comply with the codes can result in severe personal injury, death, or substantial property damage.
The vent system for a Category II LGB water boiler is considered a designed and engineered vent system
4 This system should be designed by a professional using accepted engineering practices in accordance to all local codes and the authority having jurisdiction Use only the materials listed in Table 14, page 47 for vent pipe and fittings. Vent connections are sized for DuraVent Fas-N-Seal and crimped, galvanized venting A list of approved vent suppliers
5 and systems is provided in Table 15, page 47
Using a Chimney
! WARNING
DO NOT install Category II boilers into existing
6 Category I venting systems as this can cause vent pipe corrosion, condensate leakage, and flue gas leakage. Failure to comply can result in severe personal injury, death, or substantial property damage.
! WARNING
7 A chimney must be completely lined with a
suitable Category II rated, corrosion-resistant and water-tight lining, with a way to drain away condensate that is formed in the vent or chimney. Failure to comply can result in severe personal injury, death, or substantial property damage.
8 A chimney must be completely lined with a Category II rated lining in accordance with UL 1738 Venting Systems for Gas-Burning Appliances
46

The lining must be corrosion-resistant and watertight, with means to drain away condensate Only other Category II rated appliances can be common vented with the boiler in an engineered vent system designed for such an application · The Category II rated vent material must be installed
per the vent manufacturer’s instructions · The chimney must be fitted with a sealed access
opening for inspection of the chimney interior · The chimney and liner must be inspected annually
Additional Category II venting requirements: · Contact your preferred vent supplier for vent
sizing support Follow the vent supplier’s installation instructions to ensure safe and proper operation of the venting system · Category II venting is natural draft; terminations must be vertical with required bird screen and rain caps · The required information to calculate and design the engineered vent system is provided in Table 16, page 47 · The Category II vent system should be designed to ensure that the pressure at the vent connector is between the ranges provided in Table 16, page 47 · In applications where the vent system will not produce enough draft, a vent inducer may be required to ensure the vent is kept within the pressure range provided in Table 16, page 47 · In applications where the vent system provides excessive draft, a draft control device may need to be added to ensure the vent is kept within the pressure range provided in Table 16, page 47 · The vent connector supplied with the boiler provides for a 1/2″ female NPT connection to drain away condensate A condensate trap can be constructed out of CPVC or purchased from the preferred vent supplier Failure to drain away condensate can cause condensate to build up, resulting in potential shut down and lockout · Any lateral or horizontal vent runs should be sloped per the venting manufacturer’s instructions to ensure proper draining of condensate · It is recommended that carbon monoxide detectors be installed in the boiler room The carbon monoxide detector must be wired on the same electrical circuit as the boiler · Check your local codes for any additional requirements for carbon monoxide detectors
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Table 14 Vent piping materials

Vent pipe fittings

Items Material
AL29-4C or 316 stainless steel

Supplier / Manufacturer
M&G Simpson-DuraVent – Fas-N-Seal or Fas-N-Seal Flex -No adapter needed-
Heat Fab, Inc – Saf-T-VentTM -Requires adapter by others-
Metal-Fab, Inc – CORR/GUARD -Requires adapter by others-
Z-Flex, Inc – Z-Vent II -Requires adapter by others-

United States

1
Canada

Certified for Category II appliance

venting

Certified for Category II

UL1738 – Venting Systems for Gas Burning Appliances

appliance venting

2

Table 15 Vent adapters – approved vent suppliers

Supplier

Supplier vent adapter required to connect to boiler

3

Vent Model

LGB 4R-4

LGB 5-7*

LGB 8-9*

LGB 10-12*

10″

12″

14″

16″

M&G Simpson-Duravent Fas-N-Seal**

Not required

Not required

Not required

Not required

MetalFab, Inc

CORR/Guard

10FCSLCA

12FCSLCA

14FCSLCA

16FCSLCA

HeatFab, Inc Z-Flex, Inc

Saf-T-Vent Z-Vent II

91001MAD 2SVSAFNS10

91201MAD 2SVSAFNS12

91401MAD 2SVSAFNS14

91601MAD

4

2SVSAFNS16

*LGB 14-20 are dual-base vent units, requiring two adapters. Verify vent connectors on dual base units for specific sizes needed.

Table 16 Category II vent system technical data

Boiler Size

LGB Series 3 Water ­ Technical Data for Designing a Category II Vent System

5

Input

Stack / Vent Flow Rate*

Minimum Input

Min . Stack/ Vent Flow Rate*

Typical Flue Temperature

Negative Pressure to be maintained @
Vent Connection

Vent Connection and Minimum Vent Diameter

BTU/hr .

CFM

BTU/hr .

CFM

°F

Inches W .C .

Inches (Qty .)

LGB-4R

350,000

114

175,000

57

255 – 275

-0 .001 to -0 .1

10 (1)

LGB-4

400,000

131

200,000

65

255 – 275

-0 .001 to -0 .1

LGB-5

520,000

170

260,000

85

255 – 275

-0 .001 to -0 .1

10 (1)

12 (1)

6

LGB-6

650,000

212

325,000

106

255 – 275

-0 .001 to -0 .1

12 (1)

LGB-7

780,000

255

390,000

127

255 – 275

-0 .001 to -0 .1

12 (1)

LGB-8

910,000

297

455,000

149

255 – 275

-0 .001 to -0 .1

14 (1)

LGB-9

1,040,000

340

520,000

170

255 – 275

-0 .001 to -0 .1

14 (1)

LGB-10

1,170,000

382

LGB-11

1,300,000

425

585,000

191

255 – 275

650,000

212

255 – 275

-0 .001 to -0 .1 -0 .001 to -0 .1

16 (1) 16 (1)

7

LGB-12

1,430,000

467

715,000

234

255 – 275

-0 .001 to -0 .1

16 (1)

LGB-14

1,690,000

552

845,000

276

255 – 275

-0 .001 to -0 .1

12 (1) 14 (1)

LGB-16

1,950,000

637

975,000

318

255 – 275

-0 .001 to -0 .1

14 (2)

LGB-18

2,210,000

722

1,105,000

361

255 – 275

-0 .001 to -0 .1

LGB-20

2,470,000

807

1,235,000

403

255 – 275

-0 .001 to -0 .1

14 (1)

16 (1) 16 (2)

8

*Stack / vent flow rate is based on the unit operating at 8.4% CO2 . This value can vary based on the location of the installation and operating conditions .

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Water Boiler Venting – Category II, continued
1 Figure 48 LGB series 3 water — typical Category II venting

2

Roof line

Vent caps

3 ft
minimum

2 ft
minimum (Note 1)

Combined vent length (Note 2)

Outside wall

3

Combined vent diameter (Note 2)

4

Individual Stub Vents

Connector rise (Note 2)

Connector

5

lateral (Note 3)

6
Connector rise (Note 3)
7

8

220273

Offset Vents

48

3 ft
minimum
(Also see note 1)

Combined Vents
Notes 1 Minimum 2 feet above any structure within 10 feet 2 Vent and combined vent materials, length and
diameter must be determined using the combined venting tables of the National Fuel Gas Code, ANSI Z223 1­latest edition, or other accepted engineering design method Use a connector rise as high as possible to improve vent connector capacity 3 Vent and vent connector material and design must be determined using the individual venting tables of the National Fuel Gas Code, ANSI Z223 1­latest edition, or other accepted engineering design method Use a connector rise as high as possible to improve vent connector capacity

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Condensate Drain Trap Construction

Figure 49 Condensate trap, installed

! WARNING

1

A condensate drain trap MUST be in place to

prevent possible flue gas leakage through the

condensate drain system. Failure to comply

can result in severe personal injury, death, or

substantial property damage.

2

Install a condensate trap onto the boiler Trap

components are not included with the boiler The

damper connector includes a 1/2″ female threaded

boss for condensate drainage of the vent system

1 Verify that the threaded boss on the damper

3

connector is pointed directly downwards toward

the floor.

3″

2 Install a 1/2″ NPT male threaded CPVC connector

min.

into the female threaded boss on the damper

connector

3 A standard drain trap design for boilers is shown

220274

in Figure 24 Typical trap component sizes are

4

approximately one 1/2″ threaded connector, two · Cement and primer must comply with ASTM

1/2″ elbows fitting connectors, one 1/2″ “T”-fitting

D2564 or F493

connector, and 1/2″ pipe ­ cut to provide at least · For Canada, use CSA or ULC certified CPVC

the minimum trap height, and fit installation

pipe, fittings and cement.

needs 4 Create a minimum trap height of 3 0″

· The condensate line must remain unobstructed,

allowing free flow of condensate. If condensate

5

5 Use appropriate connection methods (cement

is allowed to freeze in the line or if the line is

and primer) between CPVC joints to create water- obstructed in any other manor, condensate can

tight connections

back up into the boiler, eventually leading to boiler

6 Condensate trap must be filled with condensate

lockout

(or water) before starting the boiler to prevent

· Condensate from the boiler will be slightly

possible flue gas leakage through the condensate drain system

acidic (typically with a pH from 3 2 to 4 5) Use a condensate neutralizer if required by local codes

6

! WARNING

· If installing a condensate pump, select one approved for use with condensing boilers and

Ensure the condensate trap has condensate or

furnaces. The pump should have an overflow

water before starting the boiler. Failure to comply

switch to prevent property damage from

could cause flue gas leakage, which can result in personal injury, death, or substantial property

condensate spillage Provide an external power source for the condensate pump

7

damage.

Condensate drain trap notes: · Route condensate from the trap to a drain or
condensate pump · Use materials approved by the authority having
jurisdiction · In the absence of other authority, CPVC pipe must
comply with ASTM D1785, F441 or D2665
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Install Boiler Controls
1 General Boiler Controls
See pages 26-28 for details on gas train and control board installation

Figure 50 Steam boiler level control locations

2 Water Boiler Controls

1 Install controls in the tappings given in Figure 13, page 16
2 A LWCO must be installed on any water boiler that is located above radiation level Other boilers

MMcc

DDOONNNNEELL && MMIILLLL CHICAGO, USA

EERR

A

B
CUT-OFF LEVEL

may need a LWCO according to state, local, or

3

territorial codes, or by insurance requirements

3 If a LWCO is used on a water boiler, use a control

Gauge Glass & Valves

designed for water installation See control tappings in Figure 13, page 16, or install the

Location 1
(primary)

Location 2
(back-up)

220266

LWCO in piping above the boiler

4

Install optional controls per control manufacturer’s

Table 17 Recommended steam boiler water level controls and locations

4

instructions

Location 1

A

Location 2

B

Steam Boiler Controls
1 Install pressure operating and limit controls, gauge glass, and pressure gauge as shown in Figure 50
5 2 Install water level controls as shown in Figure

Primary water level control [1] 61 and 63
150S-MD, 93
[2] [3]

Casting line height above
bottom of gauge glass
1″
2 3/8″

Primary water level control [1] —

Casting line height above
bottom of gauge glass

50 and Table 17 If the water level control is not shown in Table 17, install it according to the

51-2 and 51S-2 [2]

3 5/8″

manufacturer’s instructions

61 and 63

1 1/2″

61 and 63

1/2″

3 Install a 1″ blowdown valve at the bottom of each cross

150S-MD, 93
[2] [3]

2 3/8″

61 and 63

1/2″

6 4 Install relief valves and other items in tappings as 51-2 and 51-

specified in Figure 51, page 51

S-2 [2]

3 5/8″

61 and 63

1/2″

5 The primary level control piping components are furnished with the boiler

1 Other manufacturers’ controls providing similar function may be used, if properly located and selected to handle boiler evaporative capacity WeilMcLain does not recommend using McDonnell & Miller Model 157 or 193

6 The piping for backup control is provided by the

2 These controls cannot be used as backup water level controls

installer

3 When a pump control is used with a feed water tank, install a pump

7

7 Level controls must be mounted on the same side of the boiler as the equalizer and return piping

control on the boiler and a makeup water feeder on tank Use a separate
low water cutoff on the boiler when backup is needed. Do not install a combination low water cutoff and feeder as backup control on boiler.

Feeder will operate before pump control operates

8
50

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Figure 51 Steam boiler control installation

insTallaTion
1

Pressure operating

and limit controls

and pressure gauge 16

2

15 1812 13

11 14

16

Additional operating limit controls can be installed to allow for low-high-low operation

10

15 17

3

7

6 Primary

level control

Gauge glass

4

9

5 7
4

1 2 3
8

Back-up water level control (when used)

Return

Legend – Figure 51

Qty Item

Qty Item

2 1 . Nipple, 1″ x 4″ 2 2 . Union, 1″ 2 3 . Nipple, 1″ x 2 .5″ 2 4 . Cross, 1″ 1 5 . Nipple, 1″ x 2″ 1* 6 . Nipple, 1″ x 7″

2 7 . Plug, 1″ 8 . Nipple, 1″ x 3 .5″ 9. Nipple, 1″ x cut to fit 1 10 . Bushing, 1″ x .75″ 1 11 . Nipple, .75″ x 4 .5″ 1 12 . Cross, .75″

  • Used only with Model 61 LWCO; cut to fit for other controls. ** Not included

550-100-206/0123

220267
Qty Item 4 13 . Nipple, .75″ x 2″ 2 14 . Tee, .75″ 3 15 . Tee, .75″ x .25″ 3 16 . Nipple, .25″ x 1 .5″ 5 17 . Plug, .75″ 1 18 . Nipple, .75″ x 3 .5″

5 6 7 8
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lGb series 3 boiler manual

Gas Piping
1 Gas Supply Piping Connection
! WARNING
Use two wrenches when tightening gas piping at the boiler. Use one wrench to prevent the
2 boiler gas line connection from turning. Failure to prevent the boiler gas connection pipe from turning could damage gas line components, which can result in severe personal injury, death, or substantial property damage.

Figure 52 Gas supply piping connection (fittings and gas valve supplied by installer)

1 Connect the gas supply piping to the boiler See

3

Figure 52

a Install a union for servicing when required

b Install a manual shutoff valve in the gas supply

piping within 6′ of the boiler

c In Canada, the manual gas valve must be

identified by the installer.

4 2 Support gas piping with hangers or other devices Do not support the piping by the boiler or boiler

accessories

3 Use pipe dope compatible with propane gases

as natural gas may contain some propane Apply

pipe dope sparingly only to male threads of pipe

5

joints so that it does not block gas flow.
! WARNING

Apply pipe dope as detailed in this section. Failure to apply pipe dope properly can result in severe personal injury, death, or substantial
property damage.
6 ! WARNING

LGB boilers are shipped ready to fire natural gas ONLY and cannot be converted to propane. Failure to comply can result in severe personal injury, death, or substantial property damage.

7 4 If inlet pressure can exceed 14″ W C at any time:

a Install a 100% lock up gas pressure regulator

as defined by ANSI Z21.80 in the gas supply

line Lock up regulators can have pressure

spikes of 5″ W C or 150% of setting,

whichever is greater

8

b Adjust the lock up regulator for inlet pressure

below 10″ W C with boiler at minimum input rate

c Gas pressure can be adjusted higher or lower

as needed

52

220275
! WARNING
A lock up regulator must be installed as detailed if inlet pressure can exceed 14″ W.C. Failure to comply can result in severe personal injury, death, or substantial property damage.
Check Natural Gas Supply Pressure
1 Purge all air from the gas supply piping 2 Check the boiler and its gas connection for leaks
before placing the boiler in operation a Close manual main shutoff valve during any
pressure testing at less than 14″ W C b Disconnect the boiler gas connection from the
gas supply piping during any pressure testing greater than 14″ W C
! WARNING
DO NOT check for gas leaks with an open flame; Gas leaks can result in an explosive atmosphere Use a soapy water bubble test to check for gas leaks. Failure to eliminate gas leaks can result in severe personal injury, death, or substantial property damage.
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Check Natural Gas Supply Pressure, continued

3 Connect a manometer or pressure gauge to the

b DO NOT operate the boiler below 4″ gas inlet

1

tapping on the gas line elbow by the gas valve

pressure Verify during boiler startup while

4 Verify minimum gas pressure when all gas

boiler is at high fire.

appliances are in operation The pressure at the

c Maximum gas pressure is certified to 14″ W.C.

gas valve test port is as follows:

See page 52 for installation of a 100% lock

a Minimum gas pressure required with gas flowing = 4″ W.C.

up regulator as necessary 5 The boiler will derate below 5 75″ inlet pressure

2

See page 107 for the derate table

Gas Train Diagram

Figure 53 LGB models 4R-5 ­ gas train diagram

M

(if used)
ML

LGB 4R-5

Single Valve Body

SP

S

RP

M

Typical Gas Field Piping

C To Pilot Burner

LGB-5 CSD-1 Only

S

R

M

H
(if used)

C To Pilot Burner

P C
To Atmosphere Burner Tubes
220276

Legend
M = Manual valve L = Low gas pressure switch S = Safety shutoff valve P = Pressure test port R = Pressure regulator C = Orifice H = High gas pressure switch

3 4 5

Figure 54 LGB models 6-20 ­ gas train diagram

LGB 6-20

LGB 14-20 Only

To Atmosphere Burner Tubes

M

P

C

6

M

ML

Gas Valve Body 1
SP

Gas Valve Body 2

S

RP

M

P

Typical Gas Field Piping
550-100-206/0123

S R
S

M

H

C To Pilot Burner
M

LGB 14-20 Only

C To Pilot Burner

C
To Atmosphere Burner Tubes

7

220277

8

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lGb series 3 boiler manual

Gas Piping, continued
1 Pipe Sizing for Natural Gas

Table 18 Pipe capacity for natural gas

1 Size gas supply piping from meter outlet to the entrance of the boiler in accordances with Table 18 and Table 19

Pipe Size

Pipe Length,* in feet (natural gas capacities listed in MBH) Specific gravity 0.60 @ pressure loss of 0.30″ W.C.

2 2 Divide the total input in Btuh of all connected appliances by 1,000 to obtain approximate cubic feet per hour of natural gas

10

20

30

40

50

75 100 150

1 .25″ 1,050 730

590

500

440

360 305 250

a Pipe lengths in Table 18 are equivalent lengths of straight pipe Use Table 19 to determine

1 .50″ 1,600 1,100 890 760

670 545 460 380

equivalent length of fittings. Add the total

2 .00″ 3,050 2,100 1,650 1,450 1,270 1,020 870 710

straight pipe with the equivalent lengths of the

2 .50″ 4,800 3,300 2,700 2,300 2,000 1,650 1,400 1,130

3

fittings to determine the gas pipe total length.

b Table 18 is only for natural gas with specific

3 .00″ 8,500 5,900 4,700 4,100 3,600 2,900 2,500 2,000

gravity 0 60, with a pressure drop through the gas piping of 0 30″ W C

4 .00″ 17,500 12,000 9,700 8,300 7,400 6,000 5,100 4,100

c For additional gas pipe sizing information, refer to ANSI Z223 1/NFPA 54, latest edition

*Include measured length of gas supply piping and allowance in feet for number and size of fittings.

4

In Canada, refer to the National Gas and Propane Installation Code – CAN/CSA B149 1 Table 19 Equivalent lengths for gas line fittings

Multiple Boiler Applications – Manifolded Gas Supply Lines
1 Size the gas supply piping as instructed above
5 2 Provide a manual shutoff gas valve, union, and sediment trap (minimum 3″ below tee) at each boiler as shown in Figure 52, page 52 3 Ensure the piping is large enough to meet the minimum pressure requirement at each boiler as specified on page 53
6 Gas Pressure Switches (CSD-1 only)

Pipe Size
1 .25″ 1 .50″ 2 .00″ 2 .50″ 3 .00″ 4 .00″

Equivalent Length (feet)

90° Elbow

Tee

3 45

6 90

4 02

8 04

5 17

10 30

6 16

12 30

7 67

15 30

10 10

20 20

There is an optional kit for LGB boilers that includes manual reset high and low gas pressure switches These switches are factory set and should remain at
7 the following settings High gas pressure switch: 5″ W C Low gas pressure switch: 2″ W C

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SeCTion 3 Electrical

eleCTriCal
1

This section is intended to provide wiring and zoning instructions for qualified installers and service

The installation must comply with the National Electrical Code and any other national, state,

2

contractors

provincial, or local codes and regulations In Canada,

comply with Canadian Electrical Code Part 1 – CSA

Section Contents

C22 1, and any other local codes

Electrical – General

55

Wiring must be N E C Class 1 If original wiring

Field Wiring
Electrical – General

57 supplied with the boiler must be replaced, only
3 equivalently rated wire shall be used The boiler must
be electrically grounded as required by the National

! WARNING

Electrical Code – ANSI/NFPA 70, latest edition, or the Canadian Electrical Code Part 1 – CSA C22 1

Turn off electrical power supply at the service

The boiler must be electrically bonded to ground

entrance panel before making any electrical

when installed in accordance with the requirements

connections. Failure to turn off the electrical power can cause electric shock, which can result

of the authority having jurisdiction In the absence of such requirements, comply with the requirements in

4

in severe personal injury or death.

the National Electrical Code – ANSI/NFPA 70, latest

NOTICE
Do not use 24V from a transformer to power any

edition, or the Canadian Electrical Code Part 1 – CSA C22 1

external devices that are not listed in this manual.

! WARNING

5

Wiring errors can cause improper and dangerous

operation. Label all wires to ensure proper

connection. Never jumper (bypass) any device

except for momentary testing. Failure to comply

can result in severe personal injury, death, or substantial property damage.

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Electrical – General, continued
1 Power Requirements

· The LGB boilers are manufactured for 120 VAC,

60 Hz electrical service

· The total operating amperage indicated on the

2

nameplate requires: · LGB 4R, 4-12: Less than 12 amps at full load

· LGB 14-20: 23 amps at full load

· Before starting the boiler, ensure the proper

electrical service is connected to the boiler

· An external electrical disconnect and overload

protection (not supplied with the boiler) are
3 required

The electrical service to the boiler must be installed and grounded in accordance with local codes In the absence of such requirements, comply with National Electrical Codes, ANSI/NFPA No 70, latest edition
4 in the U S In Canada, comply with the Canadian Electrical Code, Part 1, CSA C22 1, latest edition The installed conduit must not block any of the boiler’s openings and must allow space to open the front door

Power Supply Connections
5 The LGB boilers feature three dedicated power terminals on the High Voltage terminal block for the 120 VAC, 60 Hz electrical supply See Figure 55 for the location of the Low Voltage and High Voltage terminal blocks
6

lGb series 3 boiler manual
Figure 55 Terminal block locations
220283

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Field Wiring

The figure below shows the terminal block wiring used in this section. Also refer to the schematic and ladder

1

diagrams in Figure 57, page 58 and Figure 58, page 60

Figure 56 Terminal block wiring section

P1

CIRCULATOR/ POWERED O/P

Max. Current: 2A

P7

P3

Max. Current: 100mA

FORCED HIGH FIRE

TT

P9
24 Vac Max. Current: 1A

P4
Max. Current: 24mA 24 Vac LIMIT CHAIN

2

POWER (GROUND) POWER (NEUTRAL) POWER (120Vac HOT) NEUTRAL 120 Vac (HOT)
GND RS-485 BRS-485 A+ UNUSED W R C W R Alarm Out (NO) Alarm Out UNUSED UNUSED Manual Limit Out Manual Limit In Auto Limit Out Auto Limit In

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

3

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Field Wiring, continued
1 LGB 4R, 4-12 – Single Base Schematic and Ladder Diagrams
Figure 57 Schematic and ladder wiring diagrams for LGB single base boilers (continued on next page)

2

3

4

5

6

7

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LGB 4R, 4-12 – Single Base Schematic and Ladder Diagrams, continued

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2

3

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lGb series 3 boiler manual

Field Wiring, continued
1 LGB 14-20 – Dual Base Schematic and Ladder Diagrams
Figure 58 Schematic and ladder wiring diagrams for LGB dual base boilers (continued on next page)

2

3

4

5

6

7

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LGB 14-20 – Dual Base Schematic and Ladder Diagrams, continued

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120 VAC Power for boiler

G

Field Wiring, continued
1 A . Power Supply — REQUIRED

· POWER (GROUND) ­ Connect the ground lead of the 120 Vac, 60HZ electrical service to the POWER (GROUND) terminal
2 · POWER (NEUTRAL) ­ Connect the neutral
lead of the 120 Vac, 60HZ electrical service to the POWER (NEUTRAL) terminal

· POWER (120 Vac HOT) ­ Connect the 120

Vac Hot lead of the 120 Vac 60HZ electrical

3

service to the POWER (120 Vac HOT) terminal

POWER (GROUND) POWER (NEUTRAL) POWER (120Vac HOT)
220189

B . Circulator / Powered Outlet­ As needed for systems

N

P1

H

Service switch

CIRCULATOR/ POWERED O/P

Max. Current: 2A

· Circulator / Powered Outlet can be used to

provide 120 Vac to a circulator or an auxiliary item

4

that may be energized during a call for heat

NOTICE

Powered output is limited to 2 Amps.

C . MODBUS and Shield ­ As needed for systems
5 · P7 can be used to integrate the boiler with a Building Management System, Protocol Converter, or other device capable of RS-485 2 wire MODBUS® communication

· The GND, RS-485 B-, and RS-485 A+

6

terminals are reserved for MODBUS, GND providing the connection for shield or ground

3

2

1

NEUTRAL 120 Vac (HOT)
220190
GND RS-485 BRS-485 A+
220191

P7

D . Forced High Fire ­ As needed for systems

CH Thermostat 2
N.O

P3
Max. Current: 100mA FORCED HIGH FIRE

· P3 Forced High Fire is used to connect the

7

leads to control forced high fire operation. · Water Boilers: Boiler control has an integrated

firing rate control.

· Steam Boilers: Use an additional Steam

Pressure Limit (not provided) as a firing rate control When contact is closed, the boiler will

fire at maximum rate. When contact opens, the

8

boiler will fire at reduced rate.
NOTICE

24 Vac, maximum current of 100 mA.

6

5

4

UNUSED W R
220192a

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E . Enable/Disable (CH TT Input) ­ As needed for systems

P3
Max. Current: 100mA TT

· P3 TT is used to control the central heat

operation Contact closure between W and R

7

C

enables central heat operation An open circuit

disables central heat operation

8

W

9

R
220192b

F . Alarm Contacts ­ As needed for systems

P9
24 Vac Max. Current: 1A

· P9 Alarm Contacts is used to connect an alarm to the boiler 24 Vac power with a maximum current load of 1 Amp

2

1

Alarm Out (NO) Alarm Out
220193a

G . Spare Analog Input

· Not used Reserved for future use H . Manual and Auto Limits ­ As needed for systems

4

3

UNUSED
UNUSED
220193b

P4
Max. Current: 24mA 24 Vac LIMIT CHAIN

· P4 is used to connect external limit devices · Manual Limit In/Out: These connections are
for safety devices that are required to have a manual reset before the unit will be allowed to operate following a lockout condition · Auto Limit In/Out: These connections are for operational devices that would cause the unit to shut down and automatically restart once the condition passed Examples of operational devices include a Water Temperature Operating Control or a Steam Pressure Limit
! WARNING
When wiring devices, remove the jumper from the terminals that the device is being wired into. Failure to comply can result in severe personal injury, death, or substantial property damage.
NOTICE
All devices should be 24 Vac rated with a combined current load not to exceed 24 mA.

8

7

6

5

Manual Limit Out Manual Limit In Auto Limit Out Auto Limit In
220194

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N.O

N.O

P9

N.O

N.O

CH Thermostat 1
N.O

Auto limit

Manual Limit

Alarm Contacts

1 2 3 4 5 6 7 8
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SeCTion 4 Operation

operaTion
1

This section is intended to provide instructions for control operation and boiler startup procedures

Display and Keypad
2
The display shown in Figure 59 is the default display

Section Contents

It is shown unless a user has pressed a button, or

Control Operation

65 a fault occurs After 20 minutes of no button activity,

Startup – Fill the System

73 the display will revert back to this default screen

Startup – Final Checks

76 regardless of the last menu item displayed

Startup Procedure
Control Operation

79

The control display indicates Initialization/Fault/

Operational status through its use of backlight

3

colors

User Interface
The user interface is comprised of a two-line by sixteen-character display and four pushbuttons See Figure 59 The buttons are immediately below the display These buttons allow the user to navigate a list of menu items and edit the associated parameter

1 A persistent blue backlight indicates that

initialization is taking place and some user

input may be necessary to allow initialization to

complete

4

2 A green backlight, like what’s shown in Figure 59,

means the control is running without any faults

3 A red backlight indicates a fault has occurred

Although a fault must be cleared before normal

operation can proceed, the Advanced Menu can

be used while in fault to identify the current state of parameters which may be involved in this fault

5

condition

Figure 59 User interface
Top or 1st line Bottom or 2nd line
The * here indicates that the 2nd line edit is active

Back Enter Up Down

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220270

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lGb series 3 boiler manual

Control Operation, continued
1 Menu Structure
Figure 60 depicts the functional flow and operation of the 1135-400 menu structure The default User Menu is shown on the left, and the Advanced Menu is on
2 the right The default menu is the always accessible user menu which allows display and modification of the CH and Backlight Intensity settings Figure 60 shows the sequence of operation while transitioning the menu structure Installers use the Advanced Menu to set
3 parameters that are necessary for installing a new boiler The Advanced Menu also contains the DIAGNOSTICS menu, allowing near real-time display of important system parameters; this feature is useful when attempting to quickly diagnose system problems
4 The default display will be active after control initialization See Figure 59, page 65 As shown by default, the top, left line of the display shows the Central Heat target setting The current outlet temperature of the boiler is displayed in the top, right line The second line of the control displays the current state of operation, which is Standby in the
5 image

Figure 61 User interface buttons
Back Enter Up Down
220270

Figure 60 Boiler control menu structure

6

Press and hold the Up

and Down arrows

simultaneously for 5

seconds to unlock the

7

Advanced Menu.

220271
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operaTion

User Menu

Advanced Menu

By default, the control will start in the User Menu

1 The Advanced Menu can be accessed when the User

displaying the default temperature/status display

Menu is not in edit mode

To access the Advanced Menu, press and hold the

1 Pressing any button will turn on the backlight,

Up and Down buttons simultaneously for 5 seconds

which will turn off again after 20 minutes of no

The display will change to read “Advanced Menu ”

button activity 2 The next press will advance you to a parameter

After a few seconds, the display will proceed to the first menu item, “Advanced Temperature Settings.”

2

item For example, pressing the Down button

The Advanced Menu provides access to

twice will take you to the Central Heat setting

submenus, which allow for setup, control, and

item The top line will say CH TEMP SETTING

diagnosis of advanced boiler functions: Advanced

while the second row will display a temperature

Temperature, Diagnostics and Modbus settings as

3 Pressing the Enter button will edit the parameter well as Factory Reset

The control will indicate edit mode by placing an

3

asterisk (*) on the left of the second line as shown 1 Advanced Temperature ­ This menu allows

in Figure 59, page 65

an operator to change the value of specific

4 The Up and Down buttons will now affect the

parameters, such as limits and differentials.

parameter value displayed to the right on the

2 Diagnostic ­ This submenu provides access

second line Pressing and releasing these buttons

to further submenus, which show the states

will increment or decrement the value shown 5 Press the Enter button to save the new value you

and values of sensors and various operating parameters

4

have chosen The asterisk will disappear from the

a Inputs and Outputs

bottom line, and the new value will be saved

b Temperature

6 If the Left button is pressed before the Enter

c LWCO

button, the edit function ends, the asterisk will

d Status & Faults

disappear, and the display will return to showing 3 The Modbus submenu allows you to set

the original parameter value and return you to the

communications parameters for Modbus

5

parameter selection mode

communications such as:

a Baud Rate ­ Default “38400”

When in a parameter display, pressing the Down

b Parity ­ Defaults “NONE”

button will move the display to the next parameter

c Stop Bits ­ Defaults “2”

in the menu Pressing the UP button will move the

d Communications status (Active/Inactive)

display back to the previous parameter item Editing and saving parameter values will operate the same

All of these Advanced Menus are navigated in

6

as before

exactly the same manner as is done in the default

When displaying the last item in a menu, the Down User menu To go back to the Default User Menus,

button will wrap around to the top of the menu and

repeatedly press the Back arrow until you see the

display the Default Temperature/Status screen item

Default Temperature/Status screen item

User Menu operation will continue as before

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operaTion
Control Operation, continued
1 Display Screens 2
3
4
5
6
7

lGb series 3 boiler manual
This is the main screen on the control which display This shows the setpoint temperature, the current temperature, and the current status of the boiler
This setting is on `basic’ menu of the control This setting allows the setpoint temperature to be changed
This is a screen which is displayed momentarily after the control enters the advanced menu
This is a sub menu of the advanced menu section the following items are available under this sub-menu: · Start-Up On Diff · HF On Diff · HF Off Diff · High Temp Limit This is a sub menu of the advanced menu section the following items are available under this sub-menu: · Inputs & Outputs · Temperature This is a sub menu of the diagnostics section the following items are available under this sub-menu: · Alarm Status · Circulator Status · Flame Sense Values · Inducer Status · Pilot Valve status · Main Valve status · High-Fire Status · Air Pressure Switch Status · Auto Limit Status · Manual Limit Status This is a sub menu of the diagnostics section the following items are available under this sub-menu: · Boiler Out 1 · Boiler Out 2 This is a sub menu of the advanced menu section the following items are available under this sub-menu: · Boiler status · CH input Status · Lockout/ Fault · Model information This is a sub menu of the advanced menu section the following items are available under this sub-menu: · Modbus Status · Modbus Address · Modbus Baud Rate · Modbus Parity · Modbus Stop Bits · Modbus Activity
This is a setting under the advanced menu, which allows the control to be reset to factory settings

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operaTion

Control Settings
1
Table 20 Control menus and settings information

Basic menu

Menu / Item

Description

Default Setting Range

Setpoint & Boiler Out Temp This shows the current CH Setpoint (SP), current Boiler Out Temperature

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