Weil-McLain LGB-23 User's Manual
Contents
1. Canadian installations must conform to CSA C22 1 Canadian Electrical CodePart 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 afused disconnect switch 15 amp recommended should beused for theboiler Operating control begins start up sequence a Limit control contacts are closed Pilot proving moduleenergized NOTICE ON failureto sensepilot flameor main flame control will wait 5 minutes then retry for ignition Pilot solenoid opens Pilotignition spark begins Pilot ignites Pilot proves ain flame proving module energized from pilot provingmodule Secondary gas valveopens M ain gas valve opensto low fire position Main burnersigniteat low fire Main flame sensor proves low fire carryover Main gas valve opensto high fire position M ain burnersincrease to high fire Dual baseassembly LGB 13 through LGB 23 operating control energizes controls for both base assemblies at the sametime See steps 1 through 3 above Boiler shuts down when operating control is satisfied eencoEoon r LGB 6 to LGB 23 Series2 Control Supplement STEAM Wi ri n g continued WATER SCHEMATIC WIRING DIAGRAM LIMIT CIRCUIT LIMIT CIRCUIT HIGH OPERATING LOWWATER LIMIT LOW WATER CONTROL CUT OFF CONTROL CUTGEE PILOT PROVING MAIN FLAME MODULE PROVING MO2. Honeywell V8943A1129 511 044 193 y Honeywell V8944N1053 511 044 214 5 Main gas valve 1 Honeywell V8944N1061 511 044 215 1 Honeywell V8944N1079 511 044 216 Main burner with pilot bracket AL 5 512 200 055 S Pilot burner bracket d 460 005 624 UCS control module Honeywell S8620C 1003 7 2 per control panel United Technologies 1003 511 211390091 3 Honeywell V8046C1014 8 Pilot solenoid DEE EE 511 044 039 9 Pilot shut off valve Kinco Balon P2R 511 246 340 S Johnson Controls O90GE 1 10 Pilot burner Beckett Gas E48A1 511 330 164 11 High gas pressure switch Honeywell C645B1013 511 624 555 12 Pilot tubing alum 14 O D x 032 20 long Available at Local Supply House 13 Pressure switch tubing alum 1 4 O D x 032 100 long Available at Local Supply House ite Watts FBV3 06 511 246 290 14 Manual test firing valve 1 Watts FBV3 07 511 246 292 a Watts FBV3 08 511 246 294 Contact local Weil McLain distributor agent for current replacement part and order number Part Number 550 141 916 1001 11 LGB 6 to LGB 23 Series2 Control Supplement Weil McLain um WEIL Mc LAIN http www weil mclain com 12 Part Number 550 141 916 1001
3. LGB 21 L 1 1 o S Ce LGB 22 L 1 1 o S 2 LGB 23 L 1 1 O 2 2 2 Universal Control System Natural gas I Installation continues Igniter UCS Pilot r 10 32 x 5 16 Figure 1 7 Sumar Machine Screws 2 Pilot burner assembly typical Senor ti Locating Slot d Ground Leadwire Connect to Pilot Proving Module 24 V GND terminal r e e Pilot Mounting Bracket Burner Support Bar 10 32 x 1 4 Pilot Line Tubing Machine Screws 2 Sensor Lead Main Burner id with Pilot Compression Mounting Igniter Lead Union Bracket LGB AB4 B a 6 32 x 5 16 Type F Figure 2 ep Elie y Self Tapping Screws 2 Main flame sensor assembly 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 Sensor Lead _ ie Main Burner with Pilot Mountin Bracket LGB AB5 Part Number 550 141 916 1001 Table 3 Natural gas supply pipe sizing LGB 6 to LGB 23 Series2 Control Supplement Gas piping o gt OoN 11 12 Size gas piping considering a Diameter and length of gas supply piping b Number of fittings c Maximum gasconsumption including any possible futureexpansion d Allowable pressure drop from gas meter outlet to boiler For pressure drops see ANSI Z223 1 latest e
4. LGB Zr Gas fired boiler Control Supplement LGB 6 to LGB 23 series 2 Natural gas Universal Control System Contents I Installation 2 IL Gas PIPING a 4 HR i BE 5 Sequence of operation 5 Wiring procedure 8 IV Operating instructions 9 V Verification testing 10 VI Parts list 11 Indicates presence of hazards that can cause severe personal injury death or These terms are used throughout this k substantial property damage manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product Indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage 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 550 141 916 1001 Table 1 Pilot burner and flame sensor locations Table 2 Gas control arrangement Part Number 550 141 916 1001 LGB 6 to LGB 23 Series 2 Control Supplem Installation 1 Assemble pilot burner and flame sensor to main burners with pilot brackets See Figures 1 and 2 page 3 Install ground wiring as shown in Figures 1 and 2 page
5. 3 Reinstall burner assemblies See Table 1 below for pilot burner and flame sensor locations Install gas controls and ignition control panel as shown in Table 2 below and Figure 5 on page 10 4 LGB 21 through LGB 23 require High Gas Pressure Switch Control Carton 7 and 5 W C Attach pressure switch to interior jacket panel See Figure 5 on page 10 5 Canada only mount rating plate on interior jacket panel won Boller Flame Sensor Pilot Burner Boiler Flame Sensor Pilot Burner Model Model Number No 1 No 2 No 1 No 2 Number No 1 No 2 No 1 No 2 LGB 6 2 9 LGB 15 2 16 13 27 LGB 7 2 11 LGB 16 2 18 15 29 LGB 8 2 13 LGB 17 2 18 15 31 LGB 9 2 15 LGB 18 2 20 16 33 LGB 10 2 16 LGB 19 2 20 16 34 LGB 11 2 16 LGB 20 2 22 16 36 LGB 12 2 16 LGB 21 2 22 16 36 LGB 13 2 14 11 23 LGB 22 2 24 16 38 LGB 14 2 16 13 25 LGB 23 2 24 16 38 From left burner weh a inlet Pipe Size inlet Pipe Size Number Carton Leftbase Rightbase Carton Leftbase Right base LGB 6 A and B qe AandB 5 LGB 7 A and B 4 AandB Aw LGB 8 CandD 1 C and D 1 LGB 9 CandD 1 C and D 1 LGB 10 E F and G 1 E 1 LGB 11 E F and G 1 F and G LGB 12 E F and G 1 Fand G Ka LGB 13 H 1 4 H 11 1 LGB 14 1 1 1 e Y LGB 15 J 47 1 J 1 1 LGB 16 J AF 4 J 1 1 LGB 17 J ar g J 1 1 LGB 18 K 1 1 K 1 1 LGB 19 L 1 1 M 1 1 LGB 20 b 1 1 N 2 1
6. DULE MV NOTE 7 MV PV C PV TEMPERATURE GND BURNER NOTE 8 OPERATING LIMIT COMBINATION 24V GND CONTROL THESE TERMINALS UN TO BE JUMPERED MAIN FLAME WIRE NUTS 4 WHEN L W C O IS NOTE 7 SENSOR Uu NOT USED U FROM TRANSFORMER FROM TRANSFORMER 5 2 TO LIMIT CIRCUIT UNIVERSA SERVICE SWITCH HIGH GAS CC SPANK TERMINAL IGNITION BY OTHERS PRESSURE BLOCK CONTROL WIRE TIE CLIP TRANSFORMER SWITCH 1 2 H o o WHEN USED NOTE 5 A PRE WIRED PANEL FROM FUSED to o FIRING RATE CONTROL g DISCONNECT WHEN USED PILOT SOLENOID N Ga VANE o d a A MAIN GAS VALVE TWO SECONDARY W GAS VALVE STAGE COMBINATION VALVE W REGULATOR 4 Le NO 1 BASE WIRING WIRE NUTSIE SIZES 6 THRU 23 EQUIPMENT GROUND NOTE 10 PILOT PROVING MAIN FLAME MODULE PROVING MODULE O MV NOTE 7 o Mv Pv C O PV GND BURNER Saa GND NOTE 8 24V MAIN FLAME SENSOR SENSE T SPARK UNIVERSAL O SPARK HIGH GAS TERMINAL IGNITION PRESSURE BLOCK CONTROL SWITCH 2 WHEN USED e PRE WIRED PANEL FIRING RATE CONTROL 9 WHEN USED Le BK PILOT SOLENOID MAIN GAS VALVE TWO STAGE COMBINATION VALVE W REGULATOR MVO SECONDARY W TRANSFORMER GAS VALVE WIRE NUTS 2 z be NO 2 BASE WIRING SIZES 13 THRU 23 LOW VOLTAGE FIELD HIGH VOLTAGE FIELD LOW VOLTAGE FACTORY HIGH VOLTAGE FACTORY IGNITION SENSING CABLE A ELECTRICAL SHOCK HAZARD CAN CAUS
7. E SEVERE INJURY OR DEATH DISCONNECT POWER BEFORE INSTALLING AND OR SERVICING NOTES 5 STANDARD EOUIPMENT FOR LGB 21 THRU LGB 23 MV PV TERMINAL ON MAIN GAS VALVE IS A SINGLE TERMINAL COMMON FOR LOW AND HIGH FIRE OPERATORS 1 ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH A U S A NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL STATE OR LOCAL 6 CODE REQUIREMENTS B CANADA C S A C22 1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER NATIONAL PROVINCIAL OR LOCAL CODE REQUIREMENTS 7 MAIN GAS VALVE TERMINAL REFER TO CONTROL SUPPLEMENT FOR GROUND LEADWIRE ATTACHMENT CONTROL MODULE TERMINAL IF ORIGINAL GROUND LEADWIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED 2 ALL WIRING EXTERNAL TO BOILER JACKET MUST BE TYPE 125 C OR ITS EQUIVALENT MUST BE USED A U S A N E C CLASS 1 B CANADA C S A C22 1 C E C PART 1 8 IGNITION CONTROL WIRES ARE FACTORY INSTALLED TO CONTROL PANEL BUT MUST BE FIELD PANEL TERMINAL CONNECTED TO GAS VALVES AND FIRING RATE CONTROL TERMINALS WHEN USED TRANSFORMER TERMINAL 3 IF ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED TYPE 105 C OR 9 ITS EOUIVALENT MUST BE USED EXCEPTION SEE NOTE 7 4 REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR PILOT LEADWIRES ARE NOT FIELD REPLACEABLE REPLACE PILOT ASSEMBLY IF NECESSARY o L DENOTES FIELD INSTALLED CHASSIS GROUND APPLICATION INFORMATION 11 ALL CONTACTS SHOWN WITHOUT P
8. OWER APPLIED OFF SHELF CONDITION Oo O FACTORY WIRED TO CONTROL FIELD WIRED TO GAS VALVE OR FIRING RATE CONTROL PartNumber 550 141 916 1001 Univer Figure 3 Wiring diagram H LADDER WIRING DIAGRAM y EQUIPMENT GROUND _ 120 V A C NOTE 10 HIGH SERVICE SWITCH OPERATING LOW WATER LIMIT BY OTHERS CONTROL CUT OFF CONTROL PRIMARY 24 V AC PRIMARY VC 7 FY Y Y 24 V AC FIRING RATE CONTROL MAIN GAS VALVE HIGH FIRE WHEN USED OPERATOR NOTE 6 MP Kee eme seg Guer MV PV MAIN GAS VALVE LOW FIRE OPERATOR PV 4 anne GND NOTE 6 BURNER o 24V PV MV PV GND SECONDARY GAS VALVE 24v MAIN FLAME SENSOR SENSE __ dn O SPARK lay NO 1 BASE MAIN FLAME PROVING MODULE MEM PILOT SOLENOID VALVE pv oo HIGH GAS GND PRESSURE BURNER SWITCH WHEN USED 24V 2 NOTE 5 GND 24V PILOT FLAME SENSOR SENSE o SPARK gt PILOT BURNER NO 1 BASE PILOT PROVING MODULE NOTE 8 FIRING RATE CONTROL MAIN GAS VALVE HIGH FIRE WHEN USED OPERATOR NOTE 6 MV FESTER mod sen A MV PV _ MAIN GAS VALVE LOW FIRE OPERATOR PV gt T a NO VOZ By raed NOTE e BURNER oA O ay PV MV PV GND SECONDARY GAS VALVE 24V MAIN FLAME SENSOR SENSE o SPARK v NO 2 BASE MAIN FLAME PROVING MODULE MEN PILOT SOLENOID VALVE PV oyo GND
9. _ BURNER 24V GND T 2 24V PILOT FLAME SENSOR HIGH GAS SENSE O O PRESSURE SWITCH SPARK WHEN USED PILOT BURNER NOTE 5 NO 2 BASE NOTE 9 PILOT PROVING MODULE e Intermittent Pilot WEIL Me LAI N LG B Universal Control System A United Dominion Company Steam or Water WeilMcLain e 500 Blaine St e Michigan City IN 46360 2388 Natural Gas PART NUMBER 550 101 131 0798WM Part Number 550 141 916 1001 7 Wiring Procedure LGB 6 to LGB 23 Series2 Control Supplement Wi ri ng continued 1 Deteminerightor left electrical supply wiring 2 Attach electrical junction box es to insidejacket end panel Screwsand nutsareprovided For dual base boilers use offset nipples provided to connect junction boxes together then hangjunction boxes by screwing top box to boiler jacket See Figure 4 below 3 Attach control transformer s to junction box es Drill 1 8 holein interior jacket panel midway between ignition control panel and left jacket panel M ount wiresupport clip using sheet metal screw furnished 5 Completewiring per wiring diagram Figure 3 pages 6 and 7 NOTICE Hot sideoflinevoltageto boiler must be wired directly to limit circuit then fed to transformer primary ies Dual Base R terminal of secondaries areto supply power to bases independently of each other Do not wire R terminalstogether 6 Install pilot proving and main flame proving ground connectionsas
10. dition Canadian installations must comply with B149 1 or B149 2 Installation Code Size natural gas piping from Table 3 below Size piping to provide proper inlet pressureto gas valve when operating at rated input a Inlet gas pressure to manual main shut off gas valve minimum 7 W C standard 5 on special order maximum 13 W C b If pressureto gas valve exceeds 13 W C install positive dead end lockup gas pressure regulator upstream of hand valve c To obtain approximate cubic feet per hour divideinput BTU H R by 1000 Removegas supply knockout disc from jacket panel Follow good piping practices Pipe joint compound pipedope must beresistant to corrosiveaction of liquefied petroleum gases Apply sparingly only to malethreads of pipejoints Install drip legatinlet of gas connection to boiler W herelocal 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 Purgeall air from supply piping Before operating boiler check boiler and its gas connections for leaks WARNING Do not check for gas leaks with an open flame BUBBLE TEST Failureto use bubble test or test for leaks can cause severe personal injury death or substantial property damage a Closemanual main shut off valve during any pressure testing at less than 13 W C b Disconnect boiler and gas controls from gas supply piping during any pressu
11. pliance Set the thermostat operating control to desired setting If boiler does not operate correctly follow instructions under TO TURN OFF GAS TO APPLIANCE below Call your service technician or gas supplier On PROPANE BOILERS ONLY Replace base access shield Replace jacket front panel rr TO TURN OFF GAS TO THE APPLIANCE HAN Set thermostat or operating control to lowest 3 Close manual test firing valve c all pilot shutoff valve s g and setting gas hand valve b Turn off all electrical power to the appliance if 4 Replace base access shield on PROPANE BOILERS ONLY and jacket service is to be performed front panel service valve gas hand valve manual test firing valve pilot switch box propane only manual pilot propane only automatic pilot pilot shutoff valve s automatic gas valves typical se o oO o E 550 223 000 1001 Part Number 550 141 916 1001 9 V Manual test firing valve Verify boiler control sequence Leak test automatic gas valve 10 LGB 6 to LGB 23 Series2 Control Supplement Verification testing Before starting boiler for the first time and at least annually during annual inspection and start up follow the procedures below to verify boiler controls are operating correctly and that automatic gas valve properly shuts off gas flow Failure to verify boiler operation could result in severe pe
12. retest greater than 13 W C Set gas pressure switch as follows or to local inspector s requirements LGB 21 through LGB 23 only a High 14 W C Canada only manual main shut off valve must be identified by installer Pipe Pipe length in feet Natural Gas capacities listed in MBH Size 10 20 30 40 50 75 100 150 1V 1050 730 590 500 440 360 305 250 Li 1 600 1 100 890 760 670 545 460 380 2 3 050 2 100 1 650 1 450 1 270 1 020 870 710 2vV 4 800 3 300 2 700 2 300 2 000 1 650 1 400 1 130 3 8 500 5 900 4 700 4 100 3 600 2 900 2 500 2 000 4 17 500 12 000 9 700 8 300 7 400 6 000 5 100 4 100 Include measured length of gas supply piping and allowance in feet for number and size of fittings Part Number 550 141 916 1001 Sequence of operation Part Number 550 141 916 1001 Universal Control System Natural gas Wiring WARNING For your safety turn off electrical power supply beforemaking any electrical L connections to avoid possible electrical shock hazard All wiring mus beinstalled in accordance with therequirements of theN ational Electrical Codeand any additional national stateor local coderequirementshavingjurisdiction All wiring must beN E C Class 1 Theboiler must beelectrically grounded in accordancewith theN ational Electrical Code ANSI NFPA No 70 latest edition Use 105 C thermoplastic wire or equivalent if any of the original wiremust be replaced except for pilot spark sense and ground wires
13. rsonal injury death or substantial property damage This boiler is equipped with a manual test firing valve the manual gas valve piped between mege manifold and the first automatic gas valve in the gas train Closing the manual test firing valve allows verification of proper boiler operation without allowing gas flow to the manifold and allows leak testing of the automatic gas valves Follow the procedures below 1 Follow the Operating Instructions in this Supplement to start the boiler but do not open the manual test firing EES all other manual gas valves as instructed Leave the manual test firing valve closed 2 The automatic pilot burner should light 3 After the pilot lights the boiler controls should activate the automatic gas valves Use a voltmeter to verify voltage to automatic valves 4 With no gas flow to the manifold the boiler ignition controls should turn off the automatic gas valves after main flame ignition trial Use a voltmeter to verify voltage to automatic valves is turned off 1 Close manual test firing valve Open the service valve and gas hand valve 3 Install a hose barb into a pressure tap downstream of the first automatic gas valve Allow any accumulated gas in the line to vent off Then connect a U tube manometer If the valve seals properly there should be no gas pressure present Remove manometer and hose barb and replace pipe plug in pressure tap 4 Connect the manometer downstream of the second au
14. shown in Figures 1 and 2 page 3 and Figure 3 pages 6 and 7 Route wiresthrough wiresupport clip 7 Canadaonly attach chain between junction box es and transformer with S hooks Figure 4 J unction box assembly Pa A dual base boilers Screw Holes A lt Junction Box to Mount f Base 1 Junction Box to Jacket Offset Nipples 2 Junction Box Base 2 911BGLr0 PartNumber 550 141 916 1001 Universal Control System Natural gas IV Operating instructions This appliance is equipped with an ignition device which automatically C Use only your hand to depress or turn gas valve lights the pilot Do not try to light the automatic pilot by hand handles Never use tools If a handle will not turn For PROPANE BOILERS ONLY Propane boilers contain both an by hand don t try to repair it Call a qualified automatic pilot and a manual standing pilot A pilot switch box service technician Force or attempted repair may controls gas flow to the manual pilot Follow instructions below to resultin a fire or explosion lly light th I pilot Do not try to light the automatic pilot b hand NEUR E EE D Do not use this appliance if any part has been under water Immediately call a qualified service Before OPERATING smell all around the appliance area for gas Be technician to inspect the appliance and to replace sure to smell next to the floor because some gas is heavier than air and any part of the control sys
15. tem and any gas will settle on the floor See below control which has been under water WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance e Immediately call your gas supplier from a neighbor s phone Follow Do not touch any electric switch do not use any the gas supplier s instructions phone in your building e Ifyou cannot reach your gas supplier call the fire department STOP Read the safety information above this label Set the thermostat operating control to the lowest setting Turn off all electrical power to the appliance SE jacket front panel On PROPANE BOILERS ONLY Remove base access shield Close gas hand valve b Close manual test firing valve c Close all pilot shutoff valve s g Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you do not smell gas go to step 7 Open pilot shutoff valve s g On PROPANE BOILERS ONLY Typical gas piping only See Press and hold reset lever of pilot switch box d Control Supplement for details e Manually light manual pilot e while holding the lever down e Allow time for air to purge from the pilot line Release lever after pilot flame has had time to heat thermocouple about 1 minute Pilot burner should remain lit Open manual test firing valve c and gas hand valve b Follow sequence below Turn on electric power to the ap
16. tomatic gas valve Temporarily remove the power leads to the first automatic gas valve Then connect 24 volt power to the first automatic gas valve terminals to open it If the second valve seals properly there should be no pressure at the manometer 5 Remove the temporary power supply to the automatic gas valve Reconnect its power leads Renove the manometer and plug any open pressure taps 6 Follow Operating Instructions to place boiler in service N Replace any defective components Do not attempt to operate boiler or leave boiler in operation if any component is found to be defective or to operate incorrectly Failure to comply could result in severe personal injury death or substantial property damage Part Number 550 141 916 1001 Universal Control System Natural gas Parts list continued Figure 5 Parts drawing 4 Ox J OO ON as OO bie s WE GEN 91601 Ref No Description Size Vendor Part Number Weil McLain Part Number 1 Main flame sensor Honeywell 392956 511 724 274 2 Main burner with pilot bracket Weil McLain 512 200 055 Main flame sensor bracket 423 300 420 LN Kinco Balon 500 511 246 325 3 Manual main shut off valve inco Salone 311 246 390 1 Conbraco 50 603 511 246 300 2 Conbraco 50 703 511 246 305 iN f Honeywell V8943A1103 511 044 191 4 Secondary gas valve 1 Honeywell V8943A1111 511 044 192 1
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