Weil-McLain LGB Series 3 Commercial Gas Fired Steam and Water Boilers User Manual
- June 13, 2024
- Weil-McLain
Table of Contents
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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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
550-100-206/0123
5
safeTy
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
550-100-206/0123
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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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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
220185 13
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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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15
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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
550-100-206/0123
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8
(continued on the next page)
17
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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
8 7 6 5 4
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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
220260
21
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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
550-100-206/0123
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
550-100-206/0123
8
23
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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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lGb series 3 boiler manual
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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
550-100-206/0123
27
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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
550-100-206/0123
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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
550-100-206/0123
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.
31
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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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8
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lGb series 3 boiler manual
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″
550-100-206/0123
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
35
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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
550-100-206/0123
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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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lGb series 3 boiler manual
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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
42
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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
550-100-206/0123
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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
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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
51
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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
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S R
S
M
H
C To Pilot Burner
M
LGB 14-20 Only
C To Pilot Burner
C
To Atmosphere Burner Tubes
7
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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
8
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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.
6
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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
7
8
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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
220239
4
5
6
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lGb series 3 boiler manual
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
8
58
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LGB 4R, 4-12 – Single Base Schematic and Ladder Diagrams, continued
1
2
3
4
5
6
7
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59
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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
8
60
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LGB 14-20 – Dual Base Schematic and Ladder Diagrams, continued
eleCTriCal
1
2
3
4
5
6
7
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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
6
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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.
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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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67
operaTion
Control Operation, continued
1 Display Screens 2
3
4
5
6
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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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