PB Heat Gas/Oil Boilers Boiler User Manual
Contents
1. AST juaA Juan 81 our 11427 Jauing GO Surddej ejerpeuueju AOT Dy spuq Jaquinyy Jaquinyy 19166 28 Dus IPON 191109 SUONEJ0 SNOISNANIG 171109 dOTO T SdlHdS uinjoy Ajddns jexper suoisueuig 191109 321 21 seues Z LL eiqer 44 REPAIR PARTS 12 REPAIR PARTS Repair parts are available from vour installer or by contacting PB Heat LLC New Berlinville PA Use the Figures and Tables on pages 45 50 to assist in ordering parts Note Remember to include boiler model number and serial number when ordering parts Figure 12 1 Series LC Boiler Assembly 45 REPAIR PARTS Table 12 1A Series LC Repair Parts Front Section See Table 3 for Stock Code Intermediate Section w 1 Tapping See Table 3 for Stock Code Intermediate Section See Table 3 for Stock Code Back Section See Table 3 for Stock Code Tapped Intermediate Section See Table 3 for Stock Code Upper Flow Port Gasket 2 Reguired per Flueway Lower Flow Port Gasket 1 Reguired per Flueway Tie Rod 4 Reguired per Flueway 5 8 Diameter High Temp Rope 13 Feet Required per Flueway2. PDN K DID K DID K tS ES K tS KIK N E NID DDD IS ES tS P2 DO PO DN Above heater ratings are based on intermittent demand for water from 40 to 140 F with 200 boiler water DANGER Install mixing valve in hot water supply piping Water temperature over 125 F can cause severe burns instantly or death from scalds 17 PLACE THE BOILER F APPLY CLEANOUT COVER PLATES 1 Apply the Cleanout Cover Plates on the tops of the section joints as shown in Figure 2 11 2 Pre assemble a steel flat washer and steel nut on the carriage bolts Place a carriage bolt into each side of the cleanout opening as shown in the figure 3 Tighten the lower nut securely 4 Press Cleanout Plate with insulation over the protruding carriage bolts until the insulation lays flush against the cast iron 5 Apply a flat washer and brass nut to the carriage bolt Draw the brass nuts down until the insulation presses firmly against the iron G INSTALL FLUE COLLAR 1 LC Remove the Flue Collar and Rear Observation Door Assembly from the LC Rear Flue Box Carton LCE Remove the Top Flue Outlet Plate the Rear Flue Cover Plate and the Rear Observation Door Assembly from the LCE Top Flue Outlet Carton 2 LC Attach the Flue Collar to the Back Section with 5 16 x 1 1 2 studs flat washers and hex nuts supplied See Figure 2 12 LCE Attach t
3. 225 sjoueq siuajuon adoy eas SN pog ALL apgeg dey jg OOMT PPON juejeag uoolIS 514529 1104 W doy auueyy 1epog suondo 10 amp T 2991 225 suo 1eO 32s2ep Su0j31e quiessy suondo 103 T lqeL 225 SUOT IAG 6 Buiddius 321 gz L PREINSTALLATION Table 1 3 Standard and Optional Sections for Knockdown Boilers 50 psig MAWP 80 psig MAWP Sections Front Part UPC Standard No Inspection Tappings LC 1001 LC 1013 w Inspection Tappings No Inspection Tappings LC 1001 2 LC 1013 2 w Inspection Tappings Plain Interm Part UPC LC 1000 LC 1014 LC 1000 2 LC 1014 1 Top Flue Interm Part UPC LCE 1056 LCE 1064 LCE 1056 1 LCE 1064 1 LWCO Interm Part UPC LC 1000 1 LC 1014 2 LC 1000 3 LC 1014 3 3 Tap Interm Part 2 LC 1003 LC 1015 LC 1003 2 LC 1015 1 Closed Back Part UPC LC 1007 LC 1016 LC 1007 2 LC 1016 2 Coil Back Part UPC LC 1002 LC 1017 Table 1 4 Standard and Optional Jacket Cartons Front Back Panels Standard 50 psig MAWP 30 psig MAWP 80 psig MAWP Note 80 psig MAWP not available in Canada Table 1 6A Bu
4. 120371 ar M imal E Figure 2 5 Series LC Boiler Assembly Right Side View 13 PLACE THE BOILER tc u lt C Rear Flue Cover Flue u O Z Figure 2 6 Series LCE Boiler Assembly Right Side View 14 PLACE THE BOILER 16 To properly assemble LC LCE sections in the field the following steps must be followed to ensure that no damage occurs to the tie rod lugs 0 100 ft Ibs torque wrench is required a Use a spirit level as shown in Figure 2 4 to check the alignment of the sections as the nuts are drawn up Keep the sections plumb b Draw the sections together evenly in three rotations Torque each port to 20 ft lbs for the first rotation then to 40 ft lbs for the second rotation then to 60 ft lbs for the third rotation Use the following sequence until all three ports touch metal to metal at 60 ft lbs See Figure 2 7 for port reference i First Lower Top Port ii Second Bottom Port iii Third Upper Top Port c Tighten these 3 three locations only to a torque value of 60 ft lbs DO NOT EXCEED d After the three ports have been tightened to 60 ft lbs tighten the draw rod at the bumping pads until metal to metal contact is reached This will assure a proper gas tight seal and prevent the products of combustion from migrating into the boiler room A WARNING Do not exceed the manufacturer s torgue recommendations UPPER TOP PORT L
5. Ceramic Fiber Base Liner Models LC 04 through LC 12 Ceramic Fiber Target Wall Front Cleanout Plate C 1 5 16 18 x 1 1 4 Studs w Brass Nuts 4 Reguired Steel Cover Plate Steel Cover Plate Tankless Heater Location 1 Specify Heater Model Number Tankless Heater Location 2 Specify Heater Model Number Rubber Gasket Specify Quantity 3 8 16 x 3 4 SS Hex Head Cap Screw Specify Quantity Rear Observation Assembly 5 16 18 x 3 4 Hex Head Cap Screw Specify Quantity Burner Mounting Plate Specify Burner Model 3 8 16 x 2 1 4 Studs with Nuts 7 Required Flame Observation Assembly 3 8 16 x 1 Studs for Burner Mounting 4 Required 1 4 20 1 2 Hex Head Machine Screw 4 Required Cleanout Cover Plate Steel 1 Required per Flueway Rear Flue Box w 9 Flue Outlet Models LC 04 and LC 05 Rear Flue Box w 10 Flue Outlet Models LC 06 LC 07 and LC 08 Rear Flue Box w 12 Flue Outlet Models LC 09 LC 10 LC 11 and LC 12 Rear Flue Box Stud 5 16 18 x 1 1 2 7 Required Rear Flue Box Hi Temp Rope 1 4 Diameter x 65 Long Side Jacket Panel LC 6000 For Models LC 04 and LC 08 Side Jacket Panel LC 6001 For Models LC 05 LC 08 LC 09 and LC 10 Side Jacket Panel LC 6002 For Models LC 06 LC 10 LC 11 and LC 12 Side Jacket Panel LC 6003 For Models LC 07 and LC 12 Left Front Jacke
6. Plug Top of First Intermediate for Float LWCO 4 4198 Tankless Coil Temp Control Tapping 3 4 NPT 7gM Tapping 2 1 27 15 with Optional Tkls Coil Back Section 16 Control Tapping 3 4 NPT Both limits in special tapped plate if no tankless in opening Operating Limit Control here if Coil Installed Figure 8 2 Control and Pipe Tapping Locations 35 INSTALL CONTROLS AND TRIM 3 4 Control High Temperature A DANGER Tapping Hot Water Provide anti scald devices in the system Mixed Water Where needed Tankless 1 Heater N Failure to control water Dr temperature to showers or other usage areas Flow p 5 where a scald risk exists Control can result in severe T personal injury Cold aN Water Water Inlet Mixer Figure 8 3 Suggested Piping Single Tankless Coil Installation High Temperature Hot Water Tankless Heaters Mixed Water Tapping i Flow Control Figure 8 4 Suggested Piping Dual Tankless Coil Installation 36 9 STARTING THE BOILER A CHECK THE PIPING 1 Water Piping a The Boiler must have been hydrostatically tested b Check the attached for joint tightness c Continue monitoring as you proceed through start up 2 Gas Piping a Make sure the gas system piping and the connections to the boiler Gas Control Train s have been leak tested b After the boiler is in operation
7. 5 After all controls have been proven set the 1 Limit and Operating Temperature Controls Operating and High Limit Temperature Controls to a Lower the setting of each control until the burner the temperatures desired shuts down Table 9 1 Typical Combustion Chamber Pressure and Boiler Draft Loss Combustion Chamber Pressure with 0 1 w c at Rear Flue Box Test Port Inches w c Boiler Draft Loss Inches w c NOTE Actual chamber pressure and draft loss readings may vary with each boiler and installation due to variation in the heat exchanger deposits in the flueways actual burner firing rate and excess air conditions Use the above numbers as a general guide only If the measured draft loss is considerably higher than the above check the flueways for deposits and confirm the burner firing rate 38 10 MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers RCF Airborne RCF when inhaled have been classified by the International Agency for Research on Cancer IARC as a possible carcinogen to humans After the RCF materials have been exposed to temperatures above 1800 F 982 C they can change into crystalline silica which has been classified by the IARC as carcinogenic to humans If particles become airborne during service or repair inhalation of these particles may be hazardous to
8. LC LCE 07 MCE Gas Oil Boilers Water Installation Operation amp Maintenance Manual USING THIS MANUAL 1 INSTRUCTION MANUALS 1 SPECIAL ATTENTION BOXES 1 1 PREINSTALLATION 2 A ACCESSIBILITY CLEARANCES 2 B CLEARANCE FROM COMBUSTIBLE CONSTRUCTION 3 C COMBUSTION AND VENTILATION AIR 3 D CHIMNEY OR 3 E BOILER SETTING 4 INSTALLATION SURVEY 5 G PLANNING THE LAYOUT 5 H VERIFY COMPONENTS 5 2 PLACE THE BOILER 10 A PACKAGED BOILER 10 ASSEMBLED BLOCK BOILER 10 KNOCKDOWN BOILER PLACING THE SECTIONS 10 D INSTALL COILS OR PLATES 17 E HYDROSTATIC TEST THE BOILER 17 APPLY CLEANOUT COVER PLATES 18 INSTALL FLUE COLLAR 18 H INSTALL FLUE BAFFLES 19 I INSTALL CHAMBER LINER 19 3 PIPE THE BOILER 20 A PREPARATION 20 B SUPPLY AND RETURN PIPING 20 C LOW SYSTEM TEMPERATURE 20 D CHILLED WATER SYSTEMS 23 E HIGH FLOW RATE PIPING 23 MULTIPLE BOILER INSTALLATIONS 23 4 ASSEMBLE THE JACKET 27 A PREPARE THE PARTS 27 B APPLY JACKET SIDES AND CORNERS 27 APPLY JACKET FRONT PANEL
9. A A 10 4 081 46051 MOT3S dINAIL IN3LSAS J318VIHVA 25 Figure 3 7 Multiple Boiler Piping System Return Temperature Above 130 F on Gas 150 F on Oil PIPE THE BOILER GOHLIW AHVANOIIS AHVNIUA TWOIdAL DNidid 4371084 yue uoisuedx3 8 Joyesedas 9 2942 NNVL NOISNWdX3 Y 4 T 20119 gt Ses 191109 D u n Mg L ye i O 40 4 081 356061 J3AO8V NYNLIY INALSAS 404 Figure 3 8 Piping for Variable Low Temperature Systems Multiple Boilers 26 4 ASSEMBLE THE JACKET A PREPARE THE PARTS 2 Attach the Middle Front Panel and Lower Front Rail in the same manner 1 Collect all the jacket cartons Jacket Front amp Back 3 Carton plus Jacket Side amp Top Cartons See pushed up against the front section You will need the Shipping List n the front of this manual for the the jacket in this position to install the Burner Front jacket cartons required The cartons contain the Plate jacket parts and screws The jacket panels are pre i insulated D APPLY JACKET REAR PANEL 2 Remove all needed knockouts from the jacket parts before beginning assembly 1 Attach the Rear Jacket Panel to the Jacket Side Panels with 410 x 1 2 sheet metal screws B APPLY JACKET SIDES AND CORNERS E APPLY JACKET TOP PANELS 1 See Figur
10. PowerFlame C 36 J 29 Gordon Piatt 37 Webster J 31 REAR 43 2 2 n D J n 9 lt a a 9108 491 Sov PASII eyeuurxoudde suorsueuip s u L 24217531 9108 491 07 Veo TT 661 491 81 07 WALD LOT PLIT 491 81 PSE AIP 01 484611 19407 491 81 WALD ELO SLOT 9102 AST WALD 18666 1601 9108 491 181 WALD 55 8 PL6 9108 491 ST WALD 168 916 491 81 AVIS YLL 2198 400 81 eov PGL SIS 19407 81 WALD WALI PVerOL AA PRIE 491449 WALL SG 196 ALS 57699 SG 496 ATI AVS WAST ASI PYZ SOV 99 WAST AST 9106 lv ATS SG AST 81 PVerGT PTE PIV SG WAST AST IS WALD 181 18 69 9E SG Velo 415 AVS AST 81 Velo Lal N N NINNIN NINNIN NNN O N CN N N NIN N N N QI N NI GN 16 1uBreH 19190610
11. check the tightness of all joints in the boiler gas piping with a soap suds solution c Purge the gas piping of all air up to the boiler Gas Control Train 3 Oil Piping a Check the oil piping visually Make sure all joints are tight b When the burner is firing check the suction line and return line pressures c If the pressure exceeds the allowable pressure in the Burner Manual or if the suction line vacuum is higher than allowable correct the piping as needed to bring the suction line and return line pressures within acceptable range d Excess pressure can cause pump seal failures Excess vacuum will cause fuel flow problems with the burner oil pump B FILL THE BOILER 1 Fill the boiler and system a Fill the system with fresh water only If the water hardness is high use water treatment to reduce the deposition of minerals in the boiler CAUTION Check the system for leaks and make sure the automatic fill valve if used and the expansion tank are operating correctly Leakage or weeping of the relief valve will cause make up water to be added to the system Excessive make up water will damage the boiler and system components due to liming and oxygen corrosion b If the system reguires antifreeze use only antifreeze designed for hydronic systems These contain inhibitors to prevent corrosion of the boiler and system components Do not use ethylene alycol or automotive antifreezes Make sure th
12. Figure 7 1 Gas Supply Connection to Boiler 4 Install a Service Valve Sediment Trap and Ground Joint Union at the supply connection to the Gas Control Train as shown in Figure 7 1 These are not supplied with the boiler Install them in accordance with local codes 5 Use only pipe joint compounds rated for use with Liquefied Petroleum Gases D TEST GAS SUPPLY PIPING 1 ISOLATE THE BOILER GAS CONTROL TRAIN FROM THE SYSTEM DURING TEST a Test pressure 1 2 psig or less Close the Manual Shut Off Valve on the Boiler Gas Control Train b Test pressure over 1 2 psig Disconnect the gas supply piping upstream of the Boiler Manual Shut Off Valve A WARNING Do not expose the Gas Control Train to excessive pressure The gas valves can be damaged This could result in explosion hazard and severe personal injury or death Do not test gas supply piping with open flame Use a soap suds mixture brushed onto the pipe joints to test for leaks 31 CONNECT FUEL PIPING Table 7 1 Capacity of Gas Supply Pipe in Cubic Feet Per Hour of Natural Gas for Pressure Drop of 0 3 inch Water Column Pipe Length Feet Above ratings based on natural gas with specific gravity of 0 60 allowing pressure drop of 0 3 inches water column No allowance is needed for pipe fittings Use the following multipliers on above capacities for specific gravity other than 0 60 Specific Gravity
13. Steel Baffles Must be in Bottom Row Have 1 4 Hole As Shown Remove the Front Cleanout Plate from Front Section Open Baffles carton Remove Baffles For LC Only Save Ceramic Fiber Liner for Section 1 Save Rating Label for Chapter 4 Models LCE 13 through LCE 20 do not require baffles Place baffles as shown in Figure 2 14 Three of these are special stainless steel baffles identified with a 1 4 hole punched in each end These baffles must be placed in the lowest row of tubes Install the Front Cleanout Plate Front Cleanout Plate 1 LCE Remove Ceramic Fiber Liner from Jacket Carton E Place the liner on the floor of the combustion chamber Place the front end of the liner flush with the inside of the Front Section The liner is 24 inches wide It will not extend all the way to the rear of the boiler on all boiler sizes No adhesive is required just press the liner down firmly Figure 2 14 Flue Baffle Locations 19 PIPE THE BOILER 3 PIPE THE BOILER A PREPARATION 1 Make sure the boiler has been pressure tested as outlined in Place the Boiler Sections in this manual 2 The Supply and Return piping can be installed before installing the jacket Use nipples long enough to extend through the jacket 3 Install a pipe plug or nipple and cap in the 3 tapping in the top of the tapped intermediate section when necessary Use only the lower side connection reguired
14. reliability of the oil delivery to the burner 4 Use flare fittings when using copper tubing e Provide an oil line filter in the suction line Size the filter for the suction gear capacity of the burner oil pump if running a two pipe system f If burner is above the top of the fuel oil tank install a check valve on the oil suction line at the burner to prevent oil from evacuating the line If burner is below the top of the tank install an anti siphon device to prevent oil flow should the oil line break C INSTALL GAS SUPPLY PIPING 1 Size the piping as required by the National Fuel Gas Code ANSI Z223 1 or as reguired by local codes a Use Table 7 1 for sizing of natural gas for a system pressure drop of 0 3 inch water column The standard gas train is designed for a maximum pressure of 1 2 psig 14 inches water column Make sure the system regulator will not allow a higher pressure to the Gas Control Train under any conditions The minimum gas supply pressure is listed on the Burner Rating Plate Make sure the system regulator and the piping are sized and adjusted properly to provide this pressure under all conditions CONNECT FUEL PIPING 7 CONNECT FUEL PIPING 1 Read the Burner Instruction Manual supplied with To Gas Supply gt Service Valve gt ipi c io cM To Boiler Gas Control Train Sediment Trap 27
15. the owner and must be affixed near the boiler for future reference TO THE OWNER This boiler should be inspected annually by a Oualified Service Agency OWA Gp H member gama HI Division ASME of gama PeerlessBoilers com PB HEAT LLC PO BOX 447 NEW BERLINVILLE PA 19545 0447 O2007 LC8043 R8 3 07 2M Printed in U S A
16. these instructions before beginning work Understand all aspects of the installation Contact vour PB Heat s sales representative or customer service for help in answering auestions This boiler must be installed by a gualified contractor The boiler warranty can be voided if the boiler is not installed maintained and serviced correctly E 18 nin gt to Combustible Piping Typical N 4 CE Only 48 min for Servicing Burner 24 nin to Combustible 45 min for Tankless Heater Combustible Right Side View Figure 1 1 Clearance Reguirements A ACCESSIBILITY CLEARANCES 1 Clearances for service and from combustible surfaces are the same for the LCE as for the LC The following recommendations allow for reasonable access to the boiler Follow local codes and reguirements when setting actual layout See Figure 1 1 a For installing removing and servicing the burner provide 48 between the front of the boiler and any adjacent wall or other appliance b For access to the top of the boiler for cleaning flueways provide 24 above top of jacket c lt Vent typical 24 min for Cleaning from Top 57 lt 12 for Assembly Rear View For accessing and servicing of level controls and inspection tappings if used provide 24 minimum from the right side of the boiler to any wall or obstruction For installation of jacket provide at le
17. to the Right F APPLY PLATES AND LABELS Side Panel with 410 x 1 2 sheet metal screws 1 Mount Boiler Rating Plates and Agency Plates on the C APPLY JACKET FRONT PANELS Upper Jacket Front Panel as shown in Figure 4 1 2 Secure metal plates with 6 x 1 4 sheet metal 1 Attach the Upper Front Panel to the Right and Left screws Apply all adhesive backed labels Front Corner Panels with 10 x 1 2 sheet metal screws Table 4 1 Jacket Top amp Side Panel Placement ASME Plate Locate Jacket Top and Side Panels in the Position Below Rating Numbers are from Rear to Front 5 3 2 1 Front Rear NYC MEA Plate When Required O Figure 4 1 Location of Rating Agency and Instruction Plates on Jacket Front Top Panel UJ W WW gt OIW gt mm m m UJ UJ 00100 UJ 00100 UJ 0100 w w O O 00 vo nu O gt gt mim m 27 ASSEMBLE THE JACKET Jacket Top Panel Jacket Top Panel Jacket Top Rear Panel Jacket Rear Panel Jacket Top Rear Panel Jacket Top Front Panel Jacket Front Top Panel Jacket Side Panel Jacket Front Middle Panel Jacket Catt Side Panel Front Support Corner Panel Angle Jacket Front Jacket Right Front Lower Rail Corner Panel Figure 4 2 Jacket Assembly 28 5 VENTING Refer to Chapter 1 Preinstallation Section D Chimney or Vent for installatio
18. your health Avoid Breathing Fiber Particulates and Dust Suppliers of RCF recommend the following precautions be taken when handling these materials Precautionary Measures Provide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to prevent skin contact Wear eye goggles Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials Wash work clothes separately from others Rinse washer thoroughly after use Discard RCF materials by sealing in an airtight plastic bag First Aid Procedures Inhalation If breathing difficulty or irritation occurs move to a location with fresh clean air Seek immediate medical attention if symptoms persist Skin Contact Wash affected area gently with a mild soap and warm water Seek immediate medical attention if irritation persists Eye Contact Flush eyes with water for 15 minutes while holding eyelids apart Do not rub eyes Seek immediate medical attention if irritation persists Ingestion Drink 1 to 2 glasses of water Do not induce vomiting Seek immediate medical attention 39 WARNING Do not store or allow combustible flammable materials near the boiler Substantial fire or explosion hazard could result causing risk of personal injury death or property damage Do not use this boiler if any part of it has been under water
19. 0 F on oil boilers for extended periods heat pump systems outdoor reset snow melt etc provide piping and controls to protect the boiler from condensation Condensation will damage the boiler and will lead to shortened boiler life and maintenance problems Supply Return Figure 3 1 Piping Detail Supply and Return Connections 20 PIPE THE BOILER BOILER HEADER Pipe with offset to allow for header expansion Use threaded fittings for swing joints Return Return Return Figure 3 2 LC LCE Boiler Piping Table 3 1 Boiler Supply and Return Connections amp Recommended Header Sizing Suggested Supply Return Connections Connections Top Rear and Side Size Header Inches Inches Size Header Inches Inches Number Number DRD D DRD D NINN NPD NINN ND NIN H HIH KH BB BLA P P IPS P P USUS El P P OUO W W A UT UT E GA DAGS gt wlw ww WWWIWNNINN NINN D NIN e WW ww O ww w ww w ww O O ww WO O ala UT UT EE Aa ALa p gt wlw ww 21 PIPE THE BOILER b Temporary low temperature operation is acceptable within limits For occasional cold start ups condensation will occur but will have limited effects If the system is freguently allowed to cool to room temperature such as on night set back systems or energy management systems cold start ups will occur often Th
20. 0008 21 20601 01 1 6201 21 8001 27 10001071 0001 07 1001 31 1001 07 ON Hed 22098 2 26098 05098 27098 29098 2 19098 01058 1 80098 1 90098 L 70098 22098 00098 poO 4901S 9 g 9 9 2 1109 21 T 410901 9109 97 1005 01 000101 1220101 9 201 21 00T 07 000 21 0001 07 1001 31 1001 07 ON Hed T T 22098 05098 27098 T 15098 I 60098 80098 20098 9 70098 22098 00098 POD 42015 9 9 9 60 21 1 1109 21 9109 27 0005 01 1220101 9870101 00T OT 000 21 0001 07 L00T OT 1001071 Hed 22098 2 12098 05098 17098 19098 2 05098 80098 80098 1 20098 S 70098 6098 I 00098 4901S 9 80 01 T L109 01 1109 21 9109 27 T p00S 21 1220101 000101 v 60r oT 2001707 10001071 0001 07 1001 31 Hed T T 75098 T 05098 T 17098 T 29098 T 10088 T 20098 v 70098 T 22098 T 00098 Auen 4901S 10 21 2 2109 01 9109 01 008 21 6201 01 Z0T 01 100010
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22. 71 0001 07 1001 31 1001 07 Hed T 22098 T 05098 17098 24098 1 90088 T 50098 v 70098 22098 00098 4015 9 9 90 21 21109 21 9109 27 T p00S 91 0000101 2220 071 000 21 0001 07 1001 31 TOOT O1 ON Hed 22098 1 05098 07098 19098 50058 50098 70098 22098 00098 2015 g 0 91 T 410901 9109 97 T0081 1220101 T 870101 10001071 0001 07 1001 31 1001 07 ON Hed 1 22098 05098 07098 19098 40148 90098 2 70098 22098 00098 4201S g 90 91 T 4109 01 9109 97 7005 97 1220101 Z0T 071 10001071 0001 07 1001 27 1001 07 ON Hed 12098 05098 07098 05098 70098 20098 2 70098 22098 00098 2035 Y Y Y 10 01 927 1109 01 9109 27 7005 97 00101 ZOT OT 000 21 0001 07 L00T OT 1001071 Hed 1 ur s aueg apIs dop sjaued 1 juo 2 way sjUajUoJ T 225 sjUajUoJ s
23. ILER Recess Machined Flat Machined Flow Port Gasket Figure 2 2 Flow Port Machining amp Gasket A CAUTION Gaskets will be damaged by petroleum or its derivatives Completely remove all solvent residue before placing gaskets Do not use petroleum based compounds in the boiler 5 Clean the area around the flow ports and in the seal recess Use solvent and a clean cloth to thoroughly clean all of the sealing surfaces Remove all foreign matter to assure a water tight seal when the sections are drawn together 6 Place a Flow Port Gasket in each of the three flow port recesses as shown in Figures 2 1 and 2 2 7 Apply spray adhesive in the rope groove around the perimeter of the section 8 Place the sealing rope completely around the rope groove being careful not to stretch the rope Extend the rope from 1 4 to 1 2 past the end of the aroove on both sides of the cleanout opening on top of the section This will assure a gas tight seal when the cleanout cover plate is applied 9 Apply a bead of silicone sealant around each flow port as shown in Figure 2 3 Do not get sealant on the flow port gaskets A WARNING The sections are heavy and must be supported securely 10 Lift up the Rear Section and move into position on the steel channels on the boiler foundation 11 Screw a 3 pipe at least 30 inches long into the lower 3 tapping on the back of the Rear Section as shown in Figur
24. Immediately call a gualified service technician to inspect the boiler Any part of the control system any gas control or any burner or gas component which has been under water must be replaced Should overheating occur or the fuel supply fail to shut off Shut off the fuel supply at a location external to the boiler Do not turn off or disconnect the electrical supply to the pump Immediately call a gualified service technician to inspect the boiler for damage and defective components A PLACING BOILER IN OPERATION 1 Start up the Burner Boiler per the Burner Manual and the instructions in this manual on starting the boiler 2 Prove the correct operation of all controls on the boiler and burner as outlined below 3 Check the operation of the ignition and flame proving controls as described in the Burner Manual 4 Test the limit and operating controls to assure they are operating correctly 5 Inspect and test all low water cutoffs 6 Test the safety relief valve s using the procedure given by the valve manufacturer on the valve tag 7 Visually inspect the burner and pilot flames if applicable B TO SHUT DOWN THE BOILER 1 Turn off Burner 2 Open main line power disconnect switch to boiler burner 3 Close fuel shut off valves 4 To take boiler out of service if the boiler and system are not to be used when temperatures are below freezing a Drain the boiler and system completely and shut off make u
25. LCE 13 to LCE 15 LCE 17 to LCE 24 Side Jacket Panel LC 6002 For All LCE Boilers 30 Left Front Jacket Corner Panel LC 6011 31 Right Front Jacket Corner Panel LC 6010 32 Upper Front Jacket Panel LC 6007 33 Middle Front Jacket Panel LC 6008 34 Lower Front Jacket Rail LC 6009 35 Back Jacket Panel LC 6012 36 Side Jacket Panel Support Angle LC 6014 37 Front Top Jacket Panel LC 6005 38 Top Jacket Panel LC 6004 For Models LCE 13 17 20 amp 21 Top Jacket Panel LC 6004 1 For Models LCE 13 to LCE 15 LCE 17 to LCE 24 49 REPAIR PARTS Table 12 2B Series LCE Repair Parts continued Top Jacket Panel LC 6004 2 For Models LCE 15 16 19 23 amp 24 40 Top Jacket Panel with Flue Opening LC 6022 For All LCE Boilers 39 Rear Top Jacket Panel LC 6006 41 Top Flue Outlet Plate 14 Flue For Models LCE 13 through LCE 17 51132 Top Flue Outlet Plate 16 Flue For Models LCE 18 and Larger 51133 42 5 8 Diameter High Temperature Rope For Top Flue Outlet Plate 6 Feet 55723 43 3 8 Diameter Tie Down Assembly For Top Flue Outlet Plate 4 Reguired 51604 44 Draft Damper 14 For Models LCE 13 through LCE 17 90523 Draft Damper 16 For Models LCE 18 and Larger 90524 Baffles Models LCE 21 through LCE 24 Only 50 NOTES 51 NOTES 52 Series LC LCE Oil Gas 8 Gas Oil Boilers Water Installation Operation amp Maintenance Manual TO THE INSTALLER This manual is the property of
26. LER INSTALLATIONS the system as a secondary loop See Figure 3 6 for a single boiler and Figure 3 7 for multiple 1 For multiple boiler installations piping the boilers in boilers a secondary loop is recommended Each boiler should be provided with its own pump and piped off D CHILLED WATER SYSTEMS of the secondary loop header See Figure 3 7 for systems with return temperature above 130 F on gas 1 If the boiler will be used in conjunction with a boilers or 150 F on oil boilers For low temperature refrigeration system the chilled medium must be systems see Figure 3 4 constant low temperature placed in parallel with the boiler and proper valves systems or Figure 3 8 variable low temperature applied to prevent the chilled medium from entering systems the boiler See Figure 3 5 2 You can use alternative piping if desired such as parallel piping or series piping in the primary system E HIGH FLOW RATE PIPING loop But these systems are less versatile a With parallel piping for instance the system flow 1 Forflow rates higher than given in Table 3 1 provide 3 conditions change if one or more of the boiler bypass piping around the boiler to limit the boiler OTE flow to that given in the table or pipe the boiler in a shut off valves are closed It is difficult to pipe secondary loop with its own pump as shown in parallel boilers to protect the boiler from low Figure 3 3 return temperatures E With series pipin
27. Multiply Capacity by 32 8 INSTALL CONTROLS AND TRIM A INSTALL SAFETY RELIEF VALVE at the upper left side of the Rear Section Make sure the relief valve sizing meets local code requirements See Figure 8 1 A CAUTION Pipe the discharge of the Safety Relief Valve s away from any traffic area preferably to a floor drain This 1 is necessary to prevent injury should the valve discharge Pipe the discharge full size of valve outlet B INSTALL DRAIN VALVE 1 Install a 3 4 drain valve in the lower center tapping in the Rear Section See Figure 8 1 and Figure 8 2 2 Pipe the valve discharge to a floor drain if available or apply a nipple and cap to close off when not in use Install a 34 Drain Valve Pipe to floor drain or cap off Figure 8 1 Safety Relief Valve Piping C INSTALL LOW WATER CUTOFFS 1 Pipe the Safety Relief Valve off of the 2 1 2 tapping 1 See Figure 8 2 for the locations of tappings for probe type and float type low water cutoffs The Front Section has a 3 4 tapping for a probe type control The Rear Section has two 1 tappings for mounting a float type control D INSTALL CONTROLS amp TRIM Install the Temperature Pressure Gage in the 1 2 tapping at the upper center of the Front Section See Figure 8 2 Mount the Operating Temperature Limit Control bulb well in the Coil Cover Plate at the upper right of the Front Section Place the well in the right side 3 4 contro
28. N MANUALS The Series LC LCE Installation Operation amp Maintenance Manual is divided into four basic sections Indicates a condition or hazard which will cause severe personal injury death or major property 1 Preinstallation Section 1 damage 2 Installation Sections 2 through 8 3 Start Up Section 9 4 Maintenance Section 10 VN WARNING SPECIAL ATTENTION BOXES Indicates a condition or hazard which may cause Throughout this manual you will see special attention severe personal injury death or major property boxes intended to supplement the instructions and make damage special notice of potential hazards These categories mean in the judgment of PB Heat LLC CAUTION Indicates condition hazard which will or can cause minor personal injury or property damage N NOTICE Indicates special attention is needed but not directly related to potential personal injury or property damage PREINSTALLATION 1 PREINSTALLATION A NOTICE The eguipment must be installed in accordance with installation reguirements of the authority having jurisdiction or in the absence of such reguirements to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 Where reguired by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 Carefully read
29. OILER A PACKAGED BOILER 2 Remove lifting frame and hardware 1 Remove crate top and sides Remove any loose 3 Proceed to Section D Install Coils or Plates cartons Remove burner support pedestal and nipple if supplied 1 Place channel rails as shown in Figure 1 4 2 Lift boiler off crate pallet Move to location determined in Chapter 1 Preinstallation 2 Open the Section Assembly Kit cartons These cartons contain the parts needed for assembly of the 3 Remove lifting frame and hardware sections 4 Re install burner support pedestal and nipple if 3 Place the Back Section on the floor as shown in necessary Figure 2 1 5 Proceed to Chapter 3 Piping the Boiler 4 The Back Section combustion chamber area is lined with a ceramic fiber blanket liner Make sure the liner B ASSEMBLED BLOCK BOILER is in good condition Minor tears are not problem but there should be no holes in the insulation 1 Move block to location determined in Chapter 1 Preinstallation Apply rope adhesive in the rope groove around the complete perimeter of the section Lay the rope into the rope groove being careful not to stretch Extend the rope 1 4 to 1 2 past the end of the groove at the top Install a gasket in each of the three port machined grooves Lay sections on floor as shown with machined groove side up Figure 2 1 Lay Sections on Floor and Apply Rope Seal and Gaskets 10 PLACE THE BO
30. OWER TOP PORT BUMPING PAD Figure 2 7 Torgue Specification Procedure 17 Repeat with the remaining sections a Save the LWCO Intermediate with two 1 tappings for level control for use as the section closest to the front section b Place the Intermediate Section with 3 top tapping Tapped Intermediate in the position given in Figure 2 9 LCE ONLY Save the 3 Top Flue Outlet Intermediates with wide opening in top of the flue collector for use as the sections closest to the LWCO Intermediate Section See Figure 2 9 i The sequence from Front to Rear is Front Section 1 Low Water Cut off Intermediate Three 3 Top Flue Outlet Intermediates ii The remaining intermediate sections are 3 Tapped Intermediates or Plain Intermediates as shown in Figure 2 8 and Figure 2 9 Front 13 12 1110 9 8 7 6 5 4 3 2 1 Rear Figure 2 8 Section Positioning Numbering Table 2 1 Section Numbering Sequence Place a Tapped Intermediate Section at Position Numbered Rear to Front 15 PLACE THE BOILER SERIES LC SERIES LCE 15 14 13 12 1 10 9 8 7 6 5 4 16 15 4 13 12 1 10 9 8 7 6 5 4 3 2 1 Rear 17 16 15 14 1 2 11109 8 7 6 5 4 3 2 1 Rear 18 17 16 15 14 13 12 11 10 9 8 7 6 54 3 2 1 Rear 3 2 Rear 1110 9 4 3 2 1 Rear i i 12 11 10 9 5 4321 Rear 1 LWCO Front Tapped Section Interm Section Top Flue Tapped Interm Interm Interm Section Section Sec
31. S 27 D APPLY JACKET REAR PANEL 27 E APPLY JACKET TOP PANELS 27 APPLY PLATES AND LABELS 27 TABLE OF CONTENTS 5 VENTING 29 6 INSTALL THE BURNER 29 A BURNER APPLICATION 29 B INSTALL BURNER MOUNTING PLATE 29 C MOUNT THE BURNER 29 7 CONNECT FUEL PIPING 31 A GENERAL dn 31 INSTALL FUEL OIL PIPING 31 C INSTALL GAS SUPPLY PIPING 31 D TEST GAS SUPPLY PIPING 31 8 INSTALL CONTROLS AND TRIM 33 A INSTALL SAFETY RELIEF VALVE 33 B INSTALL DRAIN VALVE 33 C INSTALL LOW WATER COUTOUTIS 33 D INSTALL CONTROLS amp TRIM 33 PIPE TANKLESS HEATERS IF USED 34 F CONNECT SUPPLY WIRING 34 G INSTALL CONTROL WIRING 34 9 STARTING THE BOILER 37 A CHECK THE PIPING 37 FILL THE BOILER 37 C RUN BURNER CHECK OUT 37 D CHECK BOILER CONTROLS 38 10 MAINTENANCE 39 A PLACING BOILER IN OPERATION 40 TO SHUT DOWN THE BOILER 40 C MAINTENANCE ANNUAL 40 D MONTHLY MAINTENANCE 41 E DAILY MAINTENANCE 41 11 BOILER RATINGS DIMENSIONS 42 12 REPAIR PARTS 45 A SERIES LC BOILER ASSEMBLY 45 SERIES LCE BOILER ASSEMBLY 48 USING THIS MANUAL A INSTRUCTIO
32. a Support the weight of the vent system independently of the boiler flue connection b Provide support of the vent connector breeching at maximum 12 foot intervals to prevent sagging and to provide a minimum upward slope of 1 4 per foot 10 Do not vent natural draft appliances in a combined vent which operates under positive pressure 11 Draft Regulator Install a barometric draft regulator where using high chimney or any high draft vent This is needed to prevent causing negative draft in the boiler Excess draft will cause flame lifting and possible impingement 12 The Draft Damper for the LCE boiler is a separate piece shipped in the Top Flue Outlet Carton a Install the Draft Damper as close as possible to the boiler flue outlet It can be installed vertically or horizontally provided that the connecting vent piping and fittings are designed and installed for pressurized service b Secure the damper to the vent with screws and seal the joints with a bead of high temperature silicone sealant found in Section Assembly Kits c The vent must be installed so it can be disconnected and the Top Flue Outlet removed for proper cleaning of the flueways gt 6 01 lt 9 lt 92 593140 s3903 Jals1No LANOVE NOILVANNOJ us L lt gt 9 4 E BOILER SETTING 1 If the boiler room floor is not level or if additional structural support is needed provide a
33. ack Section Closed Back 86022 Back Section w Tankless Coil Opening 86036 5 Tapped Intermediate Section 86008 Upper Flow Port Gasket 2 Reguired per Flueway 51671 Lower Flow Port Gasket 1 Reguired per Flueway 51672 6 Tie Rod 4 Reguired per Flueway 51721 5 8 Diameter High Temp Rope 13 Feet Reguired per Flueway 55723 Ceramic Fiber Base Liner For All LCE Boilers 50862 Ceramic Fiber Target Wall 50854 Front Cleanout Plate C 1 51162 10 5 16 18 x 1 1 4 Studs w Brass Nuts 4 Reguired 11 Steel Cover Plate 51776 12 Steel Cover Plate 51777 13 Tankless Heater Location 1 Specify Heater Model Number 14 Tankless Heater Location 2 Specify Heater Model Number 15 Tankless Heater Location 3 Not Used on Water 16 Rubber Gasket Specify Quantity 51800 17 3 8 16 x 3 4 SS Hex Head Cap Screw Specify Quantity 18 Rear Observation Assembly 90923 19 5 16 18 x 3 4 Hex Head Cap Screw Specify Quantity 20 Burner Mounting Plate Specify Burner Model 21 3 8 16 x 2 1 4 Studs with Nuts 7 Required 22 Front Observation Assembly 90922 23 3 8 16 x 1 Studs for Burner Mounting 4 Required 24 1 4 20 x 1 2 Hex Head Machine Screw 4 Required 25 Cleanout Cover Plate Steel 1 Required per Flueway 51772 26 Rear Flue Cover Plate For All LCE Boilers 51131 27 Rear Flue Cover Stud 5 16 18 x 1 1 2 5 Required 28 Rear Flue Cover Hi Temp Rope 1 4 Dia x 65 Long 29 Side Jacket Panel LC 6000 For Models LCE 13 17 20 amp 21 Side Jacket Panel LC 6001 For Models
34. al components 6876 a Channel Rails 73 b Sections 78946 33 Assembly Kit Carton s Includes flow port 881346 gaskets tie rods with hardware high temperature 93 rope and cleanout cover plates 981546 d Flue Box Carton Includes flue box rear flue 104 cover plate LCE only rear observation 109346 assembly and port cover plates 114 11996 e Baffle Carton 124 i LC Includes baffles combustion chamber 129946 liner and rating label 134 z isdi ii LCE 21 through LCE 24 Baffles f Jacket Cartons Include ASME plate b If the foundation must be a concrete slab use g Draft Damper LCE only air cell high temperature insulating board at least h Label Carton LCE only 1 2 inch thick with aluminum backing aluminum side up 1 2 inch thick high temperature millboard with aluminum backing is acceptable as well Place the insulating board on the slab between the steel channels i Burner Mounting Plate j Trim Carton Includes safety relief valve and temperature pressure gage k Control Carton Limit controls F INSTALLATION SURVEY I Tankless Heater s For new and existing installations a Water Installation Survey is available from PB Heat LLC The survey will provide information on how a hot water boiler works 3 with your specific system and will provide an overview of hot water system operation in general m Additional controls and fittings Assembled Block Same as knockdown except channel
35. ast 12 from the left side of the boiler to any wall or obstruction More clearance may be needed for longer boilers unless the jacket is pre assembled before placing the boiler For installation and removal of tankless heaters provide 45 between the end of the boiler and any adjacent wall of obstruction This provides for all available tankless coils The spacing can be closer for Heater Number X 1020 allow 30 or Heater Number X 1021 allow 35 PREINSTALLATION B CLEARANCE FROM COMBUSTIBLE CONSTRUCTION Provide the following minimum clearances to combustible construction See Fiaure 1 1 6 C COMBUSTION AND VENTILATION AIR 1 PB E Sides 6 Rear of Jacket 6 Front of Jacket 24 Top of Jacket 24 Hot Water Pipes 6 Vent or Chimney Connector 18 The installation must provide adeguate air for combustion and ventilation Unless the boiler room construction and natural air infiltration are sure to provide all the air needed provide an opening or duct to the outside with a free cross sectional area of at least 1 square inch per 4000 Btuh input for all installed appliances At high altitude increase this reguirement 4 for each 1000 feet above sea level The boiler room must never be under negative pressure If exhaust fans or other equipment can cause a negative pressure in the boiler room the air openings and eguipment design must be engineered to assure a neutral or slightly positive pre
36. ating value of 140 000 Btu per aallon 2 Net B R water ratings based on an allowance of 1 15 3 Net I B R steam ratings based on an allowance for LC 04 to LC 08 1 333 LC 09 1 323 LC 10 1 310 LC 11 1 298 LC 12 1 290 LCE 13 to LCE 24 1 288 4 Consult factory before selecting a boiler for installations having unusual piping and pickup reguirements such as intermittent system operation extensive piping systems etc 5 Combustion efficiency determined in accordance with The Hydronics Institute s Testing and Rating Standard for Heating Boilers 60 30 Pressure Drop PSI 20 0 2 4 6 8 10 12 14 16 18 20 Coil Flow Rate GPM Figure 11 1 Tankless Coil Pressure Drops 42 Connection BOILER RATINGS amp DIMENSIONS O 4 Supply Tappings te Maximum Burner Lengths 2 3 Rear Return Tapping 5 3 Intermediate Supply Tap when required 8 3 Side Return when reguired Rear Observation Port BECKETT 26 CARLIN 26 POWERFLAME C 36 J 29 GORDON 8 PIATT 54 26 R 32 WEBSTER J 31 Figure 11 2 Series LC Dimensional Diagram 2 9 18 suppose O 4 Supply Tappings 2 3 Rear Return Tapping 3 3 Side Return Tapping s 4 Rear Observation Port 5 3 Tapping s Not Used Plug 4e Og 37 Figure 11 3 Series LCE Dimensional Diagram RIGHT SIDE Maximum Burner Length Beckett 26 Carlin 26
37. e 2 4 Place a block under the pipe as shown in the figure and use as a brace during assembly 12 Place a Plain Intermediate Section on the floor and prepare as above 13 Carefully place the Intermediate Section against the Rear Section and visually line up the flow ports as close as possible 14 Insert a tie rod with one nut and washer applied into each of the four tie rod lugs See Figures 2 5 and 2 6 15 Place the nut and washer on the other end of the tie rod and draw finger tight gasket in machined groove Apply bead of silicone about 1 8 inch thick around the outside of gasketias shown Do not get sealant Om surface of gasket Figure 2 3 Apply Silcone Sealant 11 PLACE THE BOILER WARNING SECTIONS ARE TOP HEAVY HANDLE WITH CARE TO AVOID TIPPING OR FALLING Intermediate Section Level Each Section Place the first intermediate section next to the rear section as shown Use spirit level to make sure the sections are plumb Check the level as each additional intermediate section is added Rear Section Temporary Support Pipe Screw a 3 pipe at least 30 inches long into the lower return tapping in the rear section k 7 Support Block Figure 2 4 Install Additional Sections Use level on each section as tie rod bolts are drawn up 12 PLACE THE BOILER Rear Flue Box In m Lom HIR 0
38. e 4 2 for details 1 Attach the Top Front Panel to the Sides and Upper Position the Jacket Assembly with the front panels 2 The Side Panels can be used on either side of Front Panel with 10 x 1 2 sheet metal screws the boiler 2 Models LC 08 through LC 12 use two Jacket Top 3 Place the Jacket Side Panels on each side leaned Panels Place them on top with the seam at the same against the Boiler Sections point as the side panels Join them at their seam 4 On Models LC 08 through LC 12 each side uses with 410 1 2 sheet metal screws On LCE models two panels Place the panels so the seam is centered place panels in the sequence shown in Table 4 1 on the Tapped Intermediate Section On LCE models place panels in the sequence shown in 3 Attach the Jacket Top Panel to the Jacket Top Front Table 4 1 Panel with 10 x 1 2 sheet metal screws 5 On boilers with two or more Jacket Side Panels per 4 Attach the To AK n Rear Panel to the Jacket Top Panel side join the panels together with 10 x 1 2 sheet with 10 x 1 2 sheet metal screws metal screws Also attach the Jacket Side Panel Reinforcing Angle inside the jacket at the bottom of ihe seam 5 Finish by placing 10 x 1 2 sheet metal screws in the remaining holes along the Jacket Top Panel 6 Attach the Left Front Corner Panel to the Left Side flanges into the Jacket Side Panels Panel with 710 x 1 2 sheet metal screws 7 Attach the Right Front Corner Panel
39. e antifreeze supplier can provide periodic inhibitor check service If automatic fill is used the system will have to be checked periodically to make sure the antifreeze concentration has not been diluted below design level Local codes may require the use of a backflow preventer or manual fill only with separation from the city supply Consider the minimum temperature of potential exposure for the system when deciding on the antifreeze concentration A concentration of 50 generally provides protection from freezing down to 30 A CAUTION The boiler gaskets will be damaged by petroleum or its derivatives Do not use petroleum based compounds in the boiler including petroleum based stop leak compounds 2 Purge the air from the system C RUN BURNER CHECK OUT 1 Before firing the burner slide the Slide Gate Damper on the rear flue box all the way down full open on LC s or open the LCE Draft Damper until the handle is parallel to the vent pipe full open 2 Follow the instructions in the Burner Manual for starting the burner adjusting air openings and fuel rates Perform ignition system and flame supervisory control test and checkout as described in the manual 3 After burner is set at rate close the damper until the pressure reading at the test opening in the rear flue box or draft damper is between 0 wc and 0 1 wc positive See Table 9 1 for typical overfire pressure measured at the burne
40. ese systems reguire a Variable Low Temperature piping and control arrangement described below 2 Constant Low Temperature a For systems with a relatively constant low operating temperature such as heat pump systems you can pipe a fixed flow by pass arrangement as shown in Figure 3 3 This piping will not work for variable low temperature systems such as outdoor reset systems or primary secondary systems with a large primary circuit temperature drop See Figure 3 4 for multiple boilers 3 Variable Low Temperature a When the return water temperature from the system will vary outdoor reset snow melt etc a fixed bypass will not work Fixed bypass piping works by setting a high temperature rise through the boiler As the system return temperature rises during primary heating months for example the boiler will cycle on the limit control frequently causing poor performance and excessive cycling To protect the boiler and provide proper operation install a temperature 24 0 max H E NW Balancing Valves H V T x Z O nen Figure 3 3 Fixed By Pass Piping Single Boiler 24 tp 220 Valves b 144 Fill Line EXPANSION TANK Figure 3 4 Fixed By Pass Piping Multiple Boilers 22 Dh wa Balancing Valves Ka t PIPE THE BOILER control valve and boiler circuit pump piped off of F MULTIPLE BOI
41. f the vent terminates in an area where wind generated downdrafts are likely install a suitable vent cap which can control wind effects This boiler is designed to fire only with pressurized fire box The breeching and vent may be sized for negative neutral or positive pressure no more than 0 1 inches water column at the boiler outlet as desired But negative pressure overfire can cause lifting of the flame and poor combustion or overheating of the boiler crown sheet Forced draft breechings and vents must be sealed and of heavy gauge steel construction and must comply with all applicable codes of construction The vent diameter and minimum height for stub vents are listed in the Ratings and Dimensions Section of this manual Always extend vent terminations at least 3 feet above the roof line See Figure 1 3 A WARNING Failure to provide adequate venting can result in severe property damage personal injury or death gt PA LCE Only gt 3 feet min gt 4E gt Draft Regula lt Vent Typical 3 gt Instal Figure 1 3 Vent Termination Typical PREINSTALLATION lt FOUNDATION LENGTH gt 6 lt JACKET LENGTH gt 76 SECTION LENGTH Steel Channels Supplied in Baffle Carton Figure 1 4 Foundation Layout 8 Exterior Vents a Insulate sufficiently to ensure adequate draft and to prevent vent damage due to condensation 9 Vent Connection to Boiler
42. for return piping as shown B SUPPLY AND RETURN PIPING 1 Always locate the Supply and Return connections as shown in Figure 3 1 and other illustrations in this manual 2 The suggested supply and return sizing in Table 3 1 and in the Boiler Ratings and Dimensions section in this manual is based on a flow rate through the boiler equivalent to a 20 F temperature rise 1 flow for each 10 000 Btu Hr of boiler output Using higher flow rates is not recommended This could cause poor water flow distribution in the boiler BOILER HEADER Pipe with offset to allow for header expansion Use threaded fittings for swing joints Lower flow rates higher temperature rise are acceptable provided the return temperature to the boiler is at least 130 F on gas boilers and 150 F on oil boilers to prevent condensation of flue gases 3 Do not reduce the number or size of supply and return connections given in Table 3 1 These are required to control the flow velocities in the boiler and maintain uniform distribution 4 When the boiler is connected to heating coils located in air handling units the boiler piping system must be equipped with flow control valves or other automatic devices to prevent gravity circulation of the boiler water during the cooling cycle C LOW SYSTEM TEMPERATURE 1 Low Return Temperature Piping General a When the return temperature from the system will be below 130 F on gas boilers or 15
43. g temperature control to the system is difficult because the temperature rise equals the sum of the rises through each boiler Series piped boilers cannot be isolated for servicing VENT AIR SEPARATOR X X SUPPLY N PUMP EXPANSION TANK BOILER BALANCING CHECK RETURN VALVE VALVE Figure 3 5 Piping to Isolate Boiler from Chilled Medium on Chiller Systems 23 PIPE THE BOILER 28 D Boiler Loop Circulator lt T i pt j 2 Check Valve 4 3 System Pump 4 0 4 Air Separator Fillline X 5 Expansion Tank 1 M 4 6 Mixing Valve 150 Set Point gt 7 7 Mixing Valve Temperature Sensor PIPING FOR VARIABLE SYSTEM RETURN TEMP BELOW 130 F FOR GAS 150 F FOR OIL Figure 3 6 Piping for Variable Low Temperature Systems Single Boiler 24 Nun 138 ANAL MO1 GOH L3A AHVONOO3S ABV Wild TVYOIdAL DNidid 931109 e NOISNVdX3 21 t ES TT 9 Josuag aunje1eduuja BUIXIIN 195 3 091 BUIXIIN yue uoisuedx3 ce GD I 0000000 7 N 010 10je1edog E 2 257556 5009 9000000009 x A 211 dung tu ls s 42949 s 1ej10g 7 1274 gt i CI Np Ya EC a ON D 5 iy
44. good level foundation for the boiler with the minimum dimensions given in Table 1 1 The flooring and structural support system must be suitable for the operating weight of the boiler and any connected piping Place the Steel Channels on the foundation as shown in Fiaure 1 4 Do not operate the boiler until the foundation if new concrete has thoroughly cured The concrete might be damaged if heated too quickly due to the entrained moisture remaining A WARNING Do not install this boiler on carpeting or any combustible flooring A significant fire hazard could result with potential for property damage personal injury or death 3 If the boiler is installed in a penthouse or if wiring of any sort is run underneath the boiler foundation construct the foundation with provision for air flow underneath between the main floor and the top of the boiler foundation a An acceptable foundation would be concrete blocks laid with the openings lined up PREINSTALLATION Table 1 1 Foundation Lengths Model Foundation Length Inches H VERIFY COMPONENTS 1 Packaged All components should be inside crate In some cases the burner may be shipped separatelv 37546 Optional equipment such as barometric draft 43 dampers may also be shipped separatelv 48 EL 2 Knockdown All components shipped for field 58546 assembly See Table 1 2 for standard components 63 See Tables 1 3 through 1 8 for option
45. he Rear Flue Cover Plate to the Rear Section with 5 16 x 1 1 2 studs flat washers and nuts supplied 3 LCE Apply spray adhesive supplied in Section Assembly Kits to the rope groove on the bottom of the Top Flue Outlet Plate Place the high temperature rope seal in the aroove overlapping at the ends for a good seal a Place the plate over the opening provided by the three top flue intermediate sections at the front of the boiler NOTE Top flue outlet plate is marked FRONTY for proper orientation b Secure the plate and compress using the 3 8 tie down assembly nuts and washers provided See Figure 2 13 Figure 2 12 Rear Flue Collar Attachment 18 Cleanout Cover Plate With Insulation Carriage Bolt Brass Hex Nut 546 UNC x 134 Long Steel Hex Nut Flat Washers SIDE VIEW Figure 2 11 Install Cleanout Cover Plates c Inspect the finished seal particularly where the plate crosses the section joints d The correct Top Flue Outlet Plate for the LCE boiler is LCE 13 thru LCE 17 use the 14 flue opening part number LCE 5007 Carton D LCE 18 thru LCE 24 use the 16 flue opening part number LCE 5007 1 Carton E 4 Attach the Rear Observation Door to the Rear Section with four 4 5 16 18 x 3 4 hex head bolts provided Figure 2 13 Top Flue Collar Attachment PLACE THE BOILER H INSTALL FLUE BAFFLES 1 4 Aluminized Steel Baffle Stainless
46. l tapping of the cover plate if a Tankless Heater is not installed there If a tankless heater is installed at this location Position 2 mount the well in the center 3 4 control tapping of the coil See Figure 8 2 Pipe Safety Valve Discharge to safe location preferably to a floor drain Safety Relief Valve b Return 33 INSTALL CONTROLS AND TRIM 3 Mount the High Limit Control bulb well in the left VN CAUTION side 3 4 tapping of the coil cover plate if a tankless heater is not mounted in the upper right opening The boiler burner must be electrically grounded in Position 2 If a coil is installed there mount the well accordance with the reguirements of the authority in the 3 4 tapping to the left of the opening See having jurisdiction or in the absence of such Figure 8 2 reguirements with the current edition of the National Electrical Code ANSI NFPA Number 70 CAUTION Make sure that the gas ignition system components electrical controls junction boxes and electrical panels are protected from water dripping spraying rain etc during boiler operation and service circulator or pump servicing control replacements G INSTALL CONTROL WIRING or other E PIPE TANKLESS HEATERS IF USED 1 Connect piping to any installed tankless heaters See 2 Figure 8 3 for suggested piping for single coils and Figure 8 4 for suggested piping for dual F CONNECT SUPPLY WIRING 3 1 Install a
47. ll wiring in accordance with local codes the 4 National Electrical Code and other controlling agencies or governing bodies 2 Use 14 gauge or heavier wire for supply wiring Protect the circuit with a fused disconnect switch by others 34 1 3 Follow the instructions in the Burner Manual and the Wiring Diagrams supplied with the burner and the boiler Wire the boiler according to the wiring diagrams supplied with the burner and the boiler in the Boiler Envelope Low Energy Safety Control wiring if used must follow the contour of the boiler Some local codes may reguire that all wiring even low voltage be routed in conduit Install line voltage wiring in conduit Do not install single pole switches including safety controls in grounded line INSTALL CONTROLS AND TRIM E 2 15 Li o e 8 x 1 4 NPT Supply Tapping Front Section 8 Probe LWCO Tapping 3 4 NPT 5 F Alternate High Temp Limit Location 2 4 NPT Supply Tapping Rear Section 9 3 4 NPT Tapping 3 NPT Return Tapping Rear Section 10 Not used on water 3 4 NPT Plug Tapping 4 Pressure Temp Gauge 1 2 Tappping Float LWCO Tappings 1 5 Not Used on Water 1 2 Plug Tapping 13 Drain Valve Connection 3 4 i L 6 Tankless Coil Temp Control Tapping 14 Not Shown 1 NPT Tapping in Side and 3 4 Not Used on Water
48. n reguirements Refer to Chapter 9 Starting the Boiler Section C Run Burner Check Out for damper settings and draft reguirements 6 INSTALL THE BURNER BURNER APPLICATION 3 Screw 7 3 8 16 x 2 1 4 studs into the holes in the front section around the chamber opening 1 Refer to Burner Spec and Data Sheets for the Oil and Gas Oil Burners pre tested with Series LC 4 Secure the Burner Mounting Plate to the front boilers section with the flat washers and hex nuts 2 Make sure the nozzle sizing and spray pattern match C MOUNT THE BURNER those given in the spec and data sheets 1 Remove the Burner from its crate Read the burner 3 See 6 1 and Table 6 1 for combustion instructions chamber dimensions 2 Insert 4 3 8 16 x 1 1 4 studs supplied with Burner B INSTALL BURNER MOUNTING PLATE Mounting Plate into the front plate holes 3 Place the high temperature gasket on the burner front plate and secure the burner to the front plate with 3 8 flat washers and hex nuts 1 The Burner Mounting Plate is made to fit the burner being used Burners vary in bolt pattern for the flange burner tube diameter insertion length and near tube configuration Make sure the front plate is correct for your burner if purchased separately from the boiler 4 If the burner is supplied with a pedestal install it to the burner per the Burner Manufacturer s Instructions The pedestal provides additional 2 Remove the Burner M
49. om combustible materials gasoline or any other flammable liquids or vapors b The combustion air openings and the area around the boiler must be unobstructed 4 Inspect boiler flueways and burner for cleanliness If cleaning is required use the following procedure a Turn off all electrical power to the boiler b Remove Jacket Middle Front Panel and Jacket Top Panels Remove Front Cleanout Plate and Cleanout Cover Plates on each flueway On LCE boilers remove the top flue outlet plate and vent piping as necessary to access the top of the sections c Brush the boiler tube spaces both horizontally through cleanout openings on ends and vertically from top of boiler through cleanout openings at flueways MAINTENANCE d Remove the Burner and Burner Mounting Plate E DAILY MAINTENANCE Remove any scale or soot from the combustion chamber by means of vacuum cleaning or other 1 Inspect the boiler area to make sure the area is free available means Take care not to damage the from combustible or flammable materials and that chamber floor liner or target wall liner there are not obstructions to the flow of air to the e Replace the Front Cleanout Plate Burner boiler or combustion air openings to the room Mounting Plate Burner and all Cleanout Cover Plates on top of the sections Make sure all sealing rope and seals are in good condition Replace sealing rope if necessary 2 Make sure there are no signs of abnormal ope
50. ounting Plate and Hardware support and prevents the burner from sagging Bag from the crate 29 INSTALL THE BURNER 247 12 1 2 6 Figure 6 1 Combustion Chamber Layout See Table 6 1 for Dimensions Table 6 1 Combustion Chamber Dimensions Chamber Length A Inches Beckett Carlin Burner Front Plate Extension Past Jacket Inches Gordon Power Piatt Flame Webster 18 231546 231546 104546 110 115 6 120 30 the boiler or with the burner if purchased separatelv Review applicable code reguirements for burner and fuel piping installations Install piping to allow removal of burner and access to combustion chamber for cleaning or service B INSTALL FUEL OIL PIPING 1 Place the fuel oil tank and install the piping in accordance with NFPA 31 and all other applicable codes General Guidelines for Oil Piping a Follow the guidelines in the Burner Manual for sizing oil lines Never use smaller than 1 2 OD copper tubing b Install manual shut off valves on the suction line at the burner and at the oil line entrance to the building If installing a shut off valve on the return line you must provide an oil pressure relief valve piped ahead of the shut off valve and discharged to the tank to prevent over pressure conditions c Install a two pipe oil distribution system when possible It will improve the
51. p water supply b Open main line power disconnect switch to boiler burner Remove the fuses or secure the switch so that the power cannot be turned on accidentally 40 MAINTENANCE c Be certain that the boiler and system are refilled before returning to service Follow the Instructions in this manual and the Lighting Instructions to operate d The system may be filled with a 5096 inhibited propylene glycol solution for protection down to 35 Use only antifreeze solutions specifically designed for hydronic use C MAINTENANCE ANNUAL 1 Before the start of each heating season inspect and make all necessary adjustments to insure proper boiler and burner operation Use the maintenance and inspection procedures following 2 Inspect the Venting System a Check the chimney or vent to make sure it is clean and free from cracks or potential leaks A CAUTION Before servicing the boiler Turn off all electrical power to the boiler Close the Gas Service Valve and Oil Shut Off Valve Allow the boiler to cool if it has been operating Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing b All joints must be tight and sealed c The vent connector must extend into but not beyond the inside edge of the chimney or vent 3 Inspect the Boiler Area a The boiler area must be clean and free fr
52. r front plate and boiler draft loss When a barometric draft regulator is installed in the venting system adjust the boiler damper for 0 wc pressure reading at the damper Adjust the draft regulator for 0 05 wc draft between the boiler damper and the draft regulator A CAUTION On installations with high draft do not leave the boiler with a negative draft reading at the rear flue box or draft damper High negative draft can pull the flame up into the boiler crown sheet and overheat the iron This can result in cracked sections or shortened boiler life 37 STARTING THE BOILER 4 Adjust the burner as needed for a reading of 2 Low Water Cutoffs a Oil burners approximately 12 5 or 1 a Test probe type controls by using the Push to Test less than the level at which the smoke reading Button goes above a trace on the Bacharach scale b Test float type controls ASME CSD 1 reguires b Gas burners 9 to 10 with CO less than 50 the control to be piped with Test n Check valves ppm in order to allow isolation for test c Inspect all flue gas joints sections attachments breeching and vent for gas tightness Remove 3 Follow additional instructions in the Burner Manual the jacket panels in order to thoroughly inspect for proving the burner component operation all rope seal joints between the sections 4 Check all controls to make sure they function correctly D CHECK BOILER CONTROLS
53. rails sections and assembly kit cartons are assembled into a block as a single shipping level component You can also use this survey to locate system problems which will have to be corrected To obtain copies of the Water Installation Survey contact vour PB Heat representative or download it from PeerlessBoilers com G PLANNING THE LAYOUT Prepare sketches and notes of the layout to minimize the possibility of interferences with new or existing equipment piping venting and wiring Sununoy sec 1840 1840 Ajquiassy ees n sJu juoO anjj Z erempier 521914 Inoue o eas SMN 75098 55098 05098 27098 29098 29098 21088 80098 50098 70098 22098 00098 poy spoy PULLS euooi IS sjexsec slu juoO suolen Ajquiassy I POD 42015 9 9 9 6 1109 21 2 1109 21 9109 27 000551 20 1 2 2201 31 8 6201 21 8001 27 T 0001 91 0001 07 1001 31 TOOT O1 Hed 1 1 22098 1 02098 1 27098 24098 11068 80098 50098 8 70098 22098 00098 yuen 2015 9 9 9 15502 2 1109 21 9109 97 2
54. ration such as or leakage A CAUTION f Replace all Jacket Panels Be very careful when adding water to a hot boiler 5 Inspect the boiler and piping for signs of leaks Add very slowly or if possible allow the boiler to Check to see if there are signs of heavy make up cool naturally before adding water water addition to the system If an excessive loss of water occurs check for a leak 6 When placing boiler into operation follow Burner in the piping and correct the problem Excessive Manual all instructions supplied with the boiler and make up water will cause corrosion and damage to the instructions in this chapter the boiler 7 Test the operation of all limit controls float controls and ignition components as described in Part A Placing Boiler in Operation of this chapter D MONTHLY MAINTENANCE 1 Inspect the burner and pilot flames as for the annual inspection 2 Inspect the boiler and system for any signs of leakage or excessive make up water usage 3 Inspect and check the operation of the venting system 41 11 BOILER RATINGS amp DIMENSIONS Table 11 1 Series LC LCE Boiler Ratings SERIES LC LCE BOILER RATINGS I B R Burner Capacity 1 B R Net Ratings Combustion Efficiency Boiler Model Oil Gas Steam Number P GPH MBH MBH Oil Gas 1 Burner input based on No 2 fuel oil with a he
55. rner Mounting Plates CF 800 Table 1 5 LC 1002 2 Top Side Panels Jacket Label Standard No Inspection Tappings LC 1017 2 Standard and Optional Jacket Cartons With Inspection Tappings Note Boilers with inspection tappings in front and back sections only use standard cartons Boiler Model 86070 86070 LC 07 LC 08 Beckett CF 1400 86069 86069 86069 CF 2300 301CRD 86070 86070 86074 86074 86074 86074 86074 Carlin 702CRD 86069 86069 86069 86069 801CRD 86073 86073 86073 86073 Webster Standard Burner Mounting Plate PREINSTALLATION Table 1 6B Burner Mounting Plates Boiler Model LCE 13 LCE 14 LCE 15 LCE 16 LCE 17 LCE 18 LCE 19 LCE 20 LCE 21 LCE 22 LCE 23 LCE 24 86074 86083 86083 Not Beckett 86074 86074 Available 86083 86083 86083 86080 86080 Carlin Power Flame Webster Standard Burner Mounting Plate Table 1 7 Trim Cartons 1 Safety Relief Valve selection based on capacity determined by boiler output Gross I B R Output Applies to most locations in United States and Canada Table 1 8 Control Cartons LC 04 Through LCE 24 2 PLACE THE B
56. ssure in the boiler room at all times of operation If the equipment design and air openings cannot assure this then the boiler must be located in an isolated room Using combustion air dampers a If motorized dampers are used on the combustion and ventilation air openings wire them such that they must open when the boiler tries to operate They must include a switch which prevents the boiler from operating if they do not open See Figure 1 2 K Motorized Combustion Air Damper Typical Burner Wired to Open Damper End Switch End Switch Proves Damper Open on Call for Heat Then Allows Burner to Start Figure 1 2 Motorized Vent Damper Interlock D CHIMNEY OR VENT 1 Inspect the existing chimney or vent system Make sure it is in good condition Inspect chimney liner and repair or replace if necessary The vent system and installation must be in accordance with the current edition of the American National Standard ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances or applicable provisions of the local building codes The venting requirements for the LCE are the same as for the LC Figure 1 3 shows the top flue outlet required on LCE boilers Chimney Vent Operation The vent system must be sized and installed to remove all combustion products If the vent system is not sized properly the burner may not operate properly This can cause poor combustion or sooting to occur I
57. t Corner Panel LC 6011 Right Front Jacket Corner Panel LC 6010 Upper Front Jacket Panel LC 6007 Middle Front Jacket Panel LC 6008 Lower Front Jacket Rail LC 6009 Back Jacket Panel LC 6012 Side Jacket Panel Support Angle LC 6014 46 Front Top Jacket Panel LC 6005 REPAIR PARTS Table 12 1B Series LC Repair Parts continued Top Jacket Panel LC 6004 For Models LC 04 and LC 08 Top Jacket Panel LC6004 1 For Models LC 05 LC 08 LC 09 and LC 10 Top Jacket Panel LC 6004 2 For Models LC 06 LC 10 LC 11 and LC 12 Top Jacket Panel LC 6004 3 For Models LC 07 and LC 12 39 Rear Top Jacket Panel LC 6006 Single Rib Flue Baffle Aluminized Steel LC 1018 Specify Boiler Model Number Triple Rib Flue Baffle Aluminized Steel LC 1019 Specify Boiler Model Number Single Rib Flue Baffle Stainless Steel LC 1020 Specify Boiler Model Number Triple Rib Flue Baffle Stainless Steel LC 1021 Specify Boiler Model Number 47 REPAIR PARTS Figure 12 2 Series LCE Boiler Assembly 48 REPAIR PARTS Table 12 2A Series LCE Repair Parts Item DEP Stock 1 Front Section See Table for Stock Code 2 Top Flue Outlet Intermediate Section Intermediate Section w 1 Tapping 3 Intermediate Section 4 B
58. tion Burner Figure 2 9 LC LCE Boiler Section Assembly Sequence 16 PLACE THE BOILER 1 E HYDROSTATIC TEST THE BOILER T ao N D Remove the coil cover plates gaskets and mounting hardware located in the Flue Box Carton Install tankless heaters if used in openings 1 and 2 See Figure 2 10 and Table 2 2 Place the cover plates and gaskets over any unused heater openings Place the cover plate with two 3 4 NPT tappings on the upper flow port opening Position 2 of the Front Section Install a drain valve in the Rear Section Tapping 13 See Figure 8 2 Provide a water supply line to the boiler Plug all open tappings in the boiler Provide a means to vent air as the boiler fills Fill the boiler with water venting air as water level rises Pressurize boiler to 75 psig for 50 psig sections 120 psig for 80 psig sections DO NOT EXCEED THESE PRESSURES a Maintain pressure while checking all joints and fittings for leaks After inspection is complete drain the boiler and remove plugs from tappings that are to be used Table 2 2 Tankless Coil Ratings Heater No X 1021 Heater No X 1020 Figure 2 10 Tankless Coil Openings Heater No X 1022 Two Heaters No X 1020 Two Heaters No X 1021 Two Heaters No X 1022 Location GPM Location Location Location GPM Location Location PDN K KIK tS N N
59. uondo ST PT R SUOMI poef A quiassy Na 7019101 del L 70119101 OOMT ul 7019101 Neg T 3511 Buiddiys seues VZ L eiqer suondo 10 T ees 15 lpung Jauueuj 1 qumN PPoW Sununoy sj ysen s le d A quiessy 0 adoy ang Y and doy sju juoO I 55098 05098 21198 22098 00198 00098 pois a El 2997 209 201 2 1109 907 T 109 301 9109 3901 2109301 HLOT IOT 4001 21 9901 3071 1001 21 ON Hed 2 I I I I Kmueno 55098 05098 21198 22098 00198 pois 19997 2 1109 401 1 1109 901 9109 3071 HLOT IOT 4001 21 9901 3071 1001 21 ON Hed I I I T 55098 05098 21198 22098 00198 pois 9997 L LI09 301 9109 401 HLOT IOT 4001 21 9901 3071 1001 21 Hed v I I I 1 fgguenp 12088 55098 16098 05098 21198 22098 00198 pois 9 Y 2997 8 8208 301 T 109 4O1 4109 307 9109301 HLOT IOT LOOT DT 9901 3071 1001 21 ON Hed 1 1 1 1 1 55098 16098 05098 22098 00198 pois Y 9997 L LI09 301 4109 307 9109301 1001 21 9901 3071 1001 21 ON Hed 2 I I I Kmueno 55098
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