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Weil-McLain LGB-10 User's Manual

1. B111ABGL Vendor Part Number Honeywell 392956 Weil McLain Kinco Balon 500 Kinco Balon 600 Honeywell V8943A1003 Honeywell V8943A1111 Honeywell V8944N1053 Honeywell V8944N1061 Honeywell Q327A1642 Honeywell K14 Johnson Controls Q90GE 1 or Beckett Gas E48A1 Johnson Controls Y90AA4712 or Beckett Gas 31400 Weil McLain Honeywell S8620C 1003 United Technologies 1003 511 Honeywell V8046C1014 Johnson Controls H91ABG Conbraco 53 103 01 Johnson Controls L62GB 3C Honeywell Q309A2010 Honeywell C645B1013 Available at Local Supply House Watts FBV3 06 Watts FBV3 07 Watts FBV3 08 Contact local Weil McLain distributor agent for current replacement part and order number Part Number 550 141 797 0798 11 WEIL McLAIN 12 LGB 6 to LGB 23 Series 2 Control Supplement Weil McLain 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com Part Number 550 141 797 0798
2. T Main Burner with Pilot Mounting LGB A84 B Igniter Lead Union Bracket 6 32 x 5 16 Type F Flame L Self Tapping Screws 2 Locating Slot 10 32 x 5 16 Machine Screws 2 Ground Leadwire Connect to Main Flame Proving Module 24 V GND terminal Burner Support Bar Flame Sensor Mounting Bracket p Main Burner with Pilot Mountin Bracket Sensor Lead LGB A85 LGB 6 to LGB 23 Series 2 Control Supplement Existi ng installation conversion fom gas to propane gas This conversion is to be installed by a Weil McLain distributor or other qualified agency in accordance with the manufacturer s instructions and all codes and requirements of the authority having jurisdiction Failure to follow instructions could result in serious injury or property damage The qualified agency performing this work assumes responsibility for this conversion WARNING For your safety turn off electrical power supply before making any electrical gt 10 1 15 16 connections to avoid possible electrical shock hazard These instructions are for use with Propane Control Cartons as listed in Gas Control Arrangement Table 2 page 2 Remove jacket door s and access panel s Disconnect wiring and tubing from existing pilot burner and main flame sensor Remove all burners Remove 3 95 mm natural gas main burner orifices
3. MAIN GAS VALVE TWO STAGE COMBINATION VALVE W REGULATOR HIGH GAS PRESSURE SWITCH PILOT PROVING MODULE NOTE 7 GND BURNER 24V GND 24V UNIVERSAL SPARK IGNITION CONTROL HIGH GAS PRESSURE SWITCH WHEN USED NOTE 5 TERMINAL BLOCK PRE WIRED PANEL WHEN USED NOTE 5 UNIVERSAL SPARK IGNITION CONTROL NOTE 8 MAIN FLAME SENSOR THERMOCOUPLE WIRE TIE CLIP BK PILOT SOLENOID VALVE NOTE 12 STANDING THERMOCOUPLE PILOT NO 2 BASE WIRING SIZES 13 THRU 23 STANDARD EQUIPMENT FOR LGB 21 THRU LGB 23 MV PV TERMINAL ON MAIN GAS VALVE IS A SINGLE TERMINAL COMMON FOR LOW AND HIGH FIRE OPERATORS REFER TO CONTROL SUPPLEMENT FOR GROUND LEADWIRE ATTACHMENT IF ORIGINAL GROUND LEADWIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED TYPE 125 C OR ITS EQUIVALENT MUST BE USED WIRES ARE FACTORY INSTALLED TO CONTROL PANEL BUT MUST BE FIELD CONNECTED TO GAS VALVES AND FIRING RATE CONTROL TERMINALS WHEN USED PILOT LEADWIRES ARE NOT FIELD REPLACEABLE REPLACE PILOT ASSEMBLY IF NECESSARY g DENOTES FIELD INSTALLED CHASSIS GROUND 11 ALL CONTACTS SHOWN WITHOUT POWER APPLIED OFF SHELF CONDITION 12 WHEN CONVERTING BOILER FROM NATURAL TO PROPANE GAS REFER TO CONVERSION INSTRUCTIONS FOR DIRECTIONS TO CHANGE PILOT TAKE OFF FROM SAFETY VALVE TO PILOT SOLENOID VALVE Part Number 550 141 797 0798 FIRING RATE CONTROL WHEN USED MAIN GAS VALVE
4. 1 No 2 LGB 6 2 9 6 LGB 15 2 16 13 27 8 22 LGB 7 2 11 7 LGB 16 2 18 15 29 9 24 LGB 8 2 13 8 LGB 17 2 18 15 31 9 25 LGB 9 2 15 9 LGB 18 2 20 16 33 9 27 LGB 10 2 16 9 LGB 19 2 20 16 34 9 27 LGB 11 2 16 9 LGB 20 2 22 16 36 9 29 LGB 12 2 16 9 LGB 21 2 22 16 36 9 29 LGB 13 2 14 11 23 T 19 LGB 22 2 24 16 38 9 31 LGB 14 2 16 13 25 8 21 LGB 23 2 24 16 38 9 31 From left burner Table 2 e Propane Inlet Pipe Size nd Propane Inlet Pipe Size Gas control arrangement Number carton Left base Rightbase Number Carton Leftbase Right base LGB 6 Aand B 1 LGB 15 J 1 1 LGB 7 A and B 1 LGB 16 J ds 1 LGB 8 C and D 1 LGB 17 J fi 1 LGB 9 C and D 1 LGB 18 K 1 yA 1 LGB 10 E F and G 1 LGB 19 L 14 1 LGB 11 E F andG 1 97 LGB 20 L VA YA LGB 12 E F andG 1 LGB 21 L 14 1 LGB 13 H q 1 LGB 22 L ye 1 YAP LGB 14 1 1 LGB 23 L 1 1 Part Number 550 141 797 0798 I Figure 1 Pilot burner assembly typical Figure 2 Main flame sensor assembly Part Number 550 141 797 0798 Universal Control System Propane gas New installation continued Igniter UCS Pilot 10 32 x 5 16 Machine Screws 2 x B Sensor he Ground Leadwire Connect to Pilot Proving Module 24 V GND terminal Pilot Mounting Bracket Burner Support Bar 10 32 x 1 4 Pilot Line Tubing Machine Screws 2 Sensor Lead
5. TWO STAGE COMBINATION VALVE W REGULATOR SECONDARY GAS VALVE LOW VOLTAGE FIELD HIGH VOLTAGE FIELD LOW VOLTAGE FACTORY HIGH VOLTAGE FACTORY IGNITION SENSING CABLE MAIN GAS VALVE TERMINAL CONTROL MODULE TERMINAL IGNITION CONTROL PANEL TERMINAL TRANSFORMER TERMINAL FACTORY WIRED TO CONTROL FIELD WIRED TO GAS VALVE OR FIRING RATE CONTROL A o O HIGH GAS PRESSURE SWITCH WHEN USED NOTE 5 LGB Propane Gas 120 V A C HIGH LOW WATER LIMIT CUT OFF CONTROL OPERATING CONTROL FIRING RATE CONTROL WHEN USED PV GND BURNER SENSE SPARK NO 1 BASE MAIN FLAME PROVING MODULE PV GND BURNER 24V GND PILOT FLAME SENSOR SENSE _ SPARK NO 1 BASE PILOT PROVING MODULE FIRING RATE CONTROL WHEN USED SENSE SPARK NO 2 BASE MAIN FLAME PROVING MODULE PV GND BURNER 24V GND PILOT FLAME SENSOR SENSE O SPARK NO 2 BASE PILOT PROVING MODULE Intermittent Pilot Universal Control System Steam or Water 6thru 23 PART NUMBER Part Number 550 141 797 0798 E i PILOT BURNER NOTE 9 MAIN GAS VALVE HIGH FIRE OPERATOR NOTE 6 Wo MV PV MAIN GAS VALVE LOW FIRE OPERATOR SECONDARY GAS VALVE MAIN FLAME SENSOR PILOT SOLENOID VALVE NOTE 12 MAIN GAS VALVE HIGH FIRE OPERATOR NOTE 6 wo MV PV MAIN GA
6. 14 W C 11 Canada only manual main shut off valve must be identifed by installer Wiring For your safety turn off electrical power supply before making any electrical connections to avoid possible electrical shock hazard All wiring must be installed in accordance with the requirements of the National Electrical Code and any additional national state or local code requirements having jurisdiction All wiring must be N E C Class 1 The boiler must be electrically grounded in accordance with the National Electrical Code ANSI NFPA No 70 latest edition Use 105 C thermoplastic wire or equivalent if any of the original wire must be replaced except for pilot spark sense and ground wires Canadian installations must conform to CSA C22 1 Canadian Electrical Code Part 1 and any local or provincial codes Supply wiring to the boiler must be No 14 gauge or heavier Install in conduit A separate electrical circuit with a fused disconnect switch 15 amp recommended should be used for the boiler LGB 6 to LGB 23 Series 2 Control Supplement WATER LIMIT CIRCUIT STEAM LIMIT CIRCUIT HIGH LOW WATER LIMIT CUT OFF CONTROL OPERATING CONTROL LOW WATER CUT OFF TEMPERATURE OPERATING LIMIT COMBINATION CONTROL THESE TERMINALS TO BE JUMPERED WHEN L W C O IS NOT USED JUNCTION BOX WIRE NUTS 4 FROM TRANSFORMER FROM TRANSFORMER TO LIMIT CIRCUIT SERVICE SWITCH BY OTHERS H TRANSFORMER F
7. 98 IV Part Number 550 141 797 0798 Universal Control System Propane gas Gas piping w 10 Contact gas supplier to size pipes tanks and regulator a Inlet gas pressure to manual main shut off gas valve minimum 11 W C maximum 13 W C b If pressure to gas valve exceeds 13 W C install 100 lock up gas pressure regulator upstream of hand valve Remove gas supply knockout disc from jacket panel Follow good piping practices Pipe joint compound pipe dope must be resistant to corrosive action of liquefied petroleum gases Apply sparingly only to male threads of pipe joints Install drip leg at inlet of gas connection to boiler Where local utility requires extend drip leg to floor Install ground joint union when required for servicing Support piping by hangers not by boiler or its accessories Purge all air from supply piping Before operating boiler check boiler and its gas connections for leaks Do not check for gas leaks with an open flame BUBBLE TEST Failure to use bubble test or test for leaks can cause severe personal injury death or substantial property damage a Close manual main shut off valve during any pressure testing at less than 13 W C b Disconnect boiler and gas valve from gas supply piping during any pressure test greater than 13 W C Set gas pressure switch as follows or to local inspector s requirements LGB 21 through LGB 23 only High
8. L G B Gas fired boiler Control Supplement LGB 6 to LGB 23 Series 2 Propane gas Universal Control System U S and Canada Contents I New installation 2 ll Existing installation 4 lll Gas piping 5 IV Wiring 5 Sequence of operation 8 Wiring procedure 8 V Operating instructions 9 VI Parts list U S 10 VII Parts list Canadian 11 These terms are used throughout this WARNING Indicates presence of hazards that can cause severe personal injury death or manual to bring attention to the substantial property damage presence of hazards of various risk levels or to important information NOTICE Indicates special instructions on installation operation or maintenance that concerning the life of the product are important but not related to personal injury or property damage WARNING This Control Supplement must only be used by a qualified installer service technician Read these instructions completely before beginning the installation Failure to follow these instructions can cause severe personal injury death or substantial property damage Part Number 550 141 797 0798 LGB 6 to LGB 23 Series 2 Control Supplement New installation 1 Remove all burners from base box assembly Remove 3 95 mm natural gas main burner orifices in manifold Install 2 40 mm propane g
9. ROM FUSED DISCONNECT N WIRE NUTS 3 EQUIPMENT GROUND NOTE 10 TRANSFORMER WIRE NUTS 2 ELECTRICAL SHOCK HAZARD CAN CAUSE SEVERE INJURY OR DEATH DISCONNECT POWER BEFORE INSTALLING AND OR SERVICING NOTES 1 ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH A U S A NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL STATE OR LOCAL CODE REQUIREMENTS B CANADA C S A C22 1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER NATIONAL PROVINCIAL OR LOCAL CODE REQUIREMENTS ALL WIRING EXTERNAL TO BOILER JACKET MUST BE A U S A N E C CLASS 1 B CANADA C S A C22 1 C E C PART 1 IF ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED TYPE 105 C OR ITS EQUIVALENT MUST BE USED EXCEPTION SEE NOTE 7 REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR APPLICATION INFORMATION SCHEMATIC WIRING DIAGRAM Universal Control System Propane LADDER WIRING DIAGRAM EQUIPMENT GROUND NOTE 10 PILOT PROVING MODULE NOTE 7 GND BURNER 24V GND 24V UNIVERSAL SPARK IGNITION CONTROL PRE WIRED PANEL HIGH GAS PRESSURE SWITCH WHEN USED NOTE 5 TERMINAL BLOCK SERVICE SWITCH BY OTHERS UNIVERSAL SPARK IGNITION CONTROL NOTE 8 MAIN FLAME SENSOR THERMOCOUPLE PILOT SOLENOID VALVE STANDING THERMOCOUPLE PILOT NO 1 BASE WIRING SIZES 6 THRU 23 FIRING RATE CONTROL SECONDARY GAS VALVE WHEN USED
10. S VALVE LOW FIRE OPERATOR MV PV SECONDARY GAS VALVE MAIN FLAME SENSOR gt OO PILOT SOLENOID VALVE NOTE 12 PILOT BURNER NOTE 9 WEIL McLAIN A United Dominion Company Weil McLain 500 Blaine St Michigan City IN 46360 2388 550 101 126 0798WM Figure 3 Wiring diagram IV Sequence of operation Wiring Procedure LGB 6 to LGB 23 Series 2 Control Supplement Wiri ng continued mm Operating control begins start up sequence a Limitcontrol contacts are closed Pilot proving module energized NOTICE On failure to sense pilot flame or main flame control will wait 5 minutes then retry for ignition a Pilotsolenoid opens b Pilotignition spark begins c Pilotignites d Pilot proves Main flame proving module energized from pilot proving module a Secondary gas valve opens b Main gas valve opens to low fire position Main burners ignite at low fire d Main flame sensor proves low fire carryover e Main gas valve opens to high fire position f Main burners increase to high fire Dual base assembly LGB 13 through LGB 23 operating control energizes the controls for both base assemblies at the same time See steps 1 through 3 above Boiler shuts down when the operating control is satisfied Determine right or left electrical supply wiring Attach electrical junction box es to inside jacket end panel Screws and nuts are provided For dual base boile
11. TOP Follow B in the safety information above If you don t smell gas go to the next step Open Pilot shut off valve Press and hold the reset lever on the Pilot switch box Manually light the pilot while holding the lever down Air in the gas supply line will have to purge through the line before sufficient gas will reach the pilot After purging all air hold the Pilot switch boxlever for about 1 minute to heat the thermocouple Release the Pilot switch box lever The pilot should remain lit Open the Manual main shut off valve and follow the sequence below Thisapplianceisalso equipped with an ignition device which automatically lights the second pilot Do not try to light this pilot by hand Turn onallelectric power to the appliance Set Operating controlto desired setting Iftheappliance will not operate turn offgas to the appliance by closing the Manual main shut off valveand Pilot shut off valve Call your service technician or gas supplier Replace Base access shield and Front panel Part Number 550 141 797 0798 Pilot Switch Box This document is intended only as a supplement to the LGB Gas Fired Boiler Manual Follow all instructions in the Manual including those regarding start up found in Section VIII Thermocouple c connection Reset lever ie Pilot gas OUT Pilot gas IN suco Ref No 10 o o 10 11 12 13 14 15 16 17 LGB 6 t
12. as main burner orifices Use pipe dope sparingly only on male ends Use pipe dope compatible with propane gases Do not overtighten orifices 2 Install pilot burners and flame sensor s See Figures 1 and 2 page 3 Follow Table 1 for electronic pilot burner UCS standing pilot burner Q327 and flame sensor locations on manifold 3 Install gas controls and ignition control panel as shown in Table 2 below and either Figure 5 page 10 or Figure 6 page 11 4 Attach pilot switch box to interior jacket panel See Figure 5 page 10 or Figure 6 page 11 Connect thermocouple from standing pilot to switch box Cut 60 pilot tubing into 2 pieces to make connections from pilot valve to pilot switch box and from pilot switch box to standing pilot 5 LGB 21through LGB 23 require High Gas Pressure Switch Control Carton furnished with boilers Attach pressure switch to interior jacket panel See Figure 5 page 10 or Figure 6 page 11 6 Attach a 550 223 710 label at boiler operating instruction label Place so that this label reads first b 550 223 796 label at rating label c Wiring diagram on door one on each base d Canada only mount rating plate on interior jacket panel Table 1 Pilot burner and flame sensor locations i _ Electronic Standin Boiler _ Electronic Standin or Feme sensor Pilot Burner Pilot ai blame Sensor Pilot Burner Pilot Number No 1 No 2 No 1 No 2 No 1 No 2 Number No 1 No 2 No 1 No 2 No
13. eil McLain distributor agent for current replacement part and order number B211ABGL 511 724 274 512 200 055 423 300 420 511 246 325 511 246 330 511 044 191 511 044 192 511 044 346 511 044 218 383 300 410 383 300 411 512 200 055 460 005 624 511 330 097 511 044 039 511 246 340 511 330 229 511 724 245 511 624 555 Weil McLain Part Number Part Number 550 141 797 0798 Ref No 9 10 11 12 13 14 15 16 17 18 Universal Control System Propane gas VII Figure 6 Canadian parts drawing Parts list Canadian boilers Size Description Main flame sensor Main burner with pilot bracket Main flame sensor bracket 1 1 Va 1 1 Va 1 1 Va Manual main shut off valve Secondary gas valve Main gas valve Pilot burner standing Pilot orifice LP standing Pilot burner electronic Pilot orifice LP electronic Main burner with pilot bracket Pilot burner bracket UCS control module 2 per control panel Pilot solenoid Pilot shut off valve Pilot switch box Thermocouple High gas pressure switch Pilot tubing alum a O D x 032 20 long Pilot tubing alum a O D x 032 60 long Pressure switch tubing alum O D x 032 100 long 1 1 Va il VER Firing valve
14. hen lighting the pilot follow these instructions exactly The gas supply to this pilot is controlled by Pilot switch box This boiler is also equipped with an ignition device which automatically lights a second pilot The gas supply to this pilot is controlled by the Gas control Do not try to light this pilot by hand B BEFORE OPERATING THE MANUAL PILOT smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Donottrytolight any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions Ifyou cannot reach your gas supplier call the fire department C Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part ofthe control system and any gas control which has been under water Placing boiler in operation STOP Read the safety information above Set the Operating controlto lowest setting Turn off all electrical power to the appliance Remove the Base access shield Close Pilot shut off valve connected to Manual main shut off valve Close Manual main shut off valve Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas S
15. in manifold Install 2 40 mm propane gas main burner orifices Use pipe dope sparingly only on male ends Use pipe dope compatible with propane gases Do not overtighten orifices Remove and discard existing electronic pilot burner from pilot burner tube Replace with electronic pilot burner in carton Attach Q327 standing pilot to burner tube in kit Connect pilot tubing and thermocouple to pilot Re install burners See Table 1 page 2 for location of pilot burners and flame sensor s Attach pilot switch box to jacket See Figure 5 page 10 or Figure 6 page 11 Connect thermocouple to pilot switch box Cut 60 pilot tubing into 2 pieces to make connections from tee in pilot line to pilot switch box and from pilot switch box to standing pilot Remove natural gas valve train Install propane gas valve train and fittings from carton See page 5 section III paragraph 4 of this Supplement Re install access panel s 12 13 14 See Figure 5 page 10 or Figure 6 page 11 for propane piping Wire per wiring diagram Figure 3 pages 6 and 7 Add splices as needed Attach a 550 223 710 label at boiler operating instruction label Place so that this label reads first b 550 223 796 label at rating label c Wiring diagram over diagram on door one on each base To place in operation follow instructions on constant burner pilot light up label and boiler operating label Replace jacket doors Part Number 550 141 797 07
16. o LGB 23 Series 2 Control Supplement VI Figure 5 U S parts drawing Description Main flame sensor Main burner with pilot bracket Main flame sensor bracket Manual main shut off valve Secondary gas valve Main gas valve Pilot burner standing repair kit propane Pilot burner electronic repair kit propane Main burner with pilot bracket Pilot burner bracket UCS control module 2 per control panel Pilot solenoid Pilot shut off valve Pilot switch box Thermocouple High gas pressure switch Pilot tubing alum Va O D x 032 20 long Pilot tubing alum 74 O D x 032 60 long Pressure switch tubing alum O D x 032 100 long Parts list U S boilers Size 15 1 1 Va 4 1 48 Vendor Part Number Honeywell 392956 Weil McLain Weil McLain Kinco Balon 500 Kinco Balon 600 Honeywell V8943A1003 Honeywell V8943A1111 Honeywell V8944L1033 Honeywell V8944L1041 Weil McLain Weil McLain Weil McLain Weil McLain Honeywell S8620C1003 United Technologies 1003 511 Honeywell V8046C1014 Johnson Controls H91ABG Kinco Balon P2R Johnson Controls L62GB 3C Honeywell Q309A Honeywell C645B1013 Available at Local Supply House Contact local W
17. rs use offset nipples provided to connect juction boxes together then hang junction boxes by screwing top box to boiler jacket See Figure 4 Pe Junction box assembly Attach control transformer s to junction box es dual base boilers Drill 1 8 hole in interior jacket panel midway between ignition control panel and left jacket panel Mount wire support clip using sheet metal i Screw Holes lt P d Junction screw furnished to Mount CN ON Junction Box o Complete wiring per wiring diagram Figure 3 to Jacket i pages 6 and 7 Terminate at secondary gas valve in valve junction box with wirenuts and strain relief provided NOTICE Hot side of line voltage to boiler must be wired directly to limit circuit then fed to transformer primary ies Dual Base R terminal of secondaries are to ce 2 supply power to bases v _ i ud independently of each other Do E3 not wire R terminals together Offset Nipples 2 Install pilot proving and main flame proving ground connections as shown in Figures 1 2 and 3 Route wires through wire support clip Nd Canada only attach chain between junction box es and transformer with S hooks Part Number 550 141 797 0798 V Starting boiler Universal Control System Propane eas o Operating instructions A This boiler is equipped with a pilot which must be lighted by hand W

Weil-McLain LGB-10 User's Manual

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