Weil-McLain LGB-4 User Manual

Gas–fired boiler

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Page 1 LG B B B B B Gas–Fired Boiler Boiler Manual • Installation • Maintenance • Start-up • Parts Refer to Control Supplement for additional information Read all instructions before installing Leave all instructions with boiler for future reference. Installer Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Page 2 Gas-Fired Boiler — Boiler Manual Read this page first Hazard The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning the life of the definitions product.
Page 3: Table Of Contents
• Installation • Start-Up • Maintenance • Parts Contents Pre-installation Codes ..................4 Air openings ................4 Venting ..................6 Foundation .................. 8 Boiler assembly Base.....................9 Sections ..................10 Hydrostatic pressure test ............12 Cleanout plates .................14 Flue collector hood..............15 Piping Water boilers ................16 Steam boilers ................18 Multiple steam boilers ..............20 Jacket ....................21...
Page 4: Pre-Installation
Gas-Fired Boiler — Boiler Manual Pre-installation — air openings Codes Installations must comply with all local codes, laws, regulations and ordinances, also National Fuel Gas Code ANSI Z223.1–latest edition. When required, installations must conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
Page 5 • Installation • Start-Up • Maintenance • Parts Combustion air Air from inside building (boiler in interior room): and ventilation • Tightly constructed buildings must be provided with openings to outside for combustion and ventilation air. These openings must be sized to handle all fuel-burning appliances, openings exhaust and ventilation fans and fireplaces.
Page 6: Venting
Gas-Fired Boiler — Boiler Manual Pre-installation — venting Chimney or Vent Venting must be installed according to Part 7, Venting of Equipment, of National Fuel Gas Code, ANSI Z223.1–latest edition and applicable building codes. Canadian installations must comply with CAN/CGA B149.1 or B149.2 Installation Code. Breeching must not be connected to any portion of mechanical draft system that can operate under positive pressure.
Page 7 • Installation • Start-Up • Maintenance • Parts Figure 3 Figure 4 Individual Combined stub vents vents Vent caps Combined vent 3 ft length (Note 3) minimum 2 ft 5 ft Roof line minimum minimum Note 2 Note 1 20 ft Minimum effective chimney height Outside...
Page 8: Foundation
Use foundation with airways when concrete floor is “green”. Foundation, minimum 2" thick Figure 6 Boiler “W” Boiler “W” Model Inches Model Inches 1" Foundation Number Number LGB-4 LGB-14 LGB-5 LGB-15 46½" LGB-6 LGB-16 2" LGB-7 LGB-17 LGB-8 LGB-18 LGB-9 LGB-19 LGB-10...
Page 9: Boiler Assembly Base
Base Arrangement Table (Note 1) Figure 7 Boiler Base Size Boiler Base Size Model Model f r o Number Number Access shield LGB-4 LGB-14 (sizes D, E, F LGB-5 LGB-15 i n g and G i p p LGB-6 LGB-16 shown) LGB-7 LGB-17...
Page 10: Sections
Gas-Fired Boiler — Boiler Manual Boiler assembly — sections Section assembly Assembly may start at either end section. For easier assembly start with right end section. 1. Position right end section flush with right end of base. See on page 15. Figure 13 Sections are top- Sections are top heavy and will not stand individually without support.
Page 11 If corrections are made and gap still exists, contact your Weil-McLain distributor or sales office before continuing installation. Failure to correct this situation could cause seal failure, resulting in severe personal injury, death or substantial property damage.
Page 12: Hydrostatic Pressure Test
Gas-Fired Boiler — Boiler Manual Boiler assembly — pressure test Hydrostatic pressure Pressure test before connecting gas piping and electrical supply. test 1. Refer to for control tapping locations. Install: Figures 11a and 11b a. Boiler drain (not supplied). b. Water pressure gauge — for test only. Be sure gauge can handle test pressures. See Step 3 2.
Page 13 • Installation • Start-Up • Maintenance • Parts Hydrostatic pressure 4. Check for maintained gauge pressure and leaks. Repair if found. test 5. Drain boiler and remove plugs from tappings used for controls and accessories. (continued) Repair leaks Leaks must be repaired at once. Failure to do so can damage boiler, resulting at once in substantial property damage.
Page 14: Cleanout Plates
Gas-Fired Boiler — Boiler Manual Boiler assembly — cleanout plates Cleanout plates Assemble cleanout plates to section assembly as shown in Figure 12 Gas-tight seal Cleanout plates must be sealed gas-tight to prevent possibility of flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
Page 15: Flue Collector Hood
Apply retort cement between bottom of sections and top of base assembly. See Figure 13 Figure 13 Flue collector hood assembly and sealing the boiler Boiler Model Flue Collector Hood(s) Number (from left side of boiler) LGB-4 LGB-5 LGB-6 LGB-7 LGB-8 LGB-9 Flue collector hood LGB-10...
Page 16: Piping Water Boilers
186-14 Notes Models LGB-4 through LGB-12 only — alternate supply tapping for supply and return on same end. Models LGB-4 through LGB-12 only — alternate return tapping for supply and return on same end. Location for closed type expansion tanks only. Locate diaphragm type expansion tanks between boiler supply connection and circulator suction connection.
Page 17 • Installation • Start-Up • Maintenance • Parts Primary/secondary Weil-McLain recommends piping Figure 15 as shown in . For single Figure 15 piping 12 " maximum boilers, pipe as shown for one unit. (systems above 140°F) Size secondary boiler pump GPM for 20°F to 40°F temperature rise...
Page 18: Steam Boilers
Pipe the header at least 24 inches above the boiler water line. Weil-McLain recommends using a boiler feed system, with the pump operated by a level controller on the boiler. Weil-McLain does not recommend using a condensate return system on which the pump is operated by a receiver-mounted float switch.
Page 19 Steam Select minimum receiver capacity based on time Number Capacity Condensate receiver capacity (minutes), required for condensate to return to the receiver. (minimum) lbs/hour gallons/hour GPM @ 15 PSI LGB-4 324.0 LGB-5 421.2 LGB-6 526.5 LGB-7 631.8 LGB-8 737.1 LGB-9 842.4...
Page 20: Multiple Steam Boilers
Gas-Fired Boiler — Boiler Manual Piping — multiple steam boilers Figure 20 Piping multiple steam boilers f e e Steam supply Hartford Header loop detail 24" Boiler 2 to 4" Water line Water line trap 4" f e e Hartford loop tee Use only close nipple 33 7/16"...
Page 21: Jacket
Draft hood attachment Screws Screw Draft hood 186-21 Boiler Draft Hood Boiler Draft Hoods Model Model (from boiler left side — front view) Number Number LGB-4 LGB-13 LGB-5 LGB-14 LGB-6 LGB-15 LGB-7 LGB-16 LGB-8 LGB-17 LGB-9 LGB-18 LGB-10 LGB-19 LGB-11...
Page 22: Install Boiler Controls
Notes Other manufacturers’ controls providing similar function may be used, if properly located and selected to handle boiler evaporative capacity. Weil-McLain does not recommend using McDonnell & Miller Model 157 or 193. Cannot be used as backup water level controls.
Page 23 • Installation • Start-Up • Maintenance • Parts Nipple, 1" x 4", (2) Figure 22 Union, 1", (2) Steam boiler control installation Nipple, 1" x 2½", (2) Pressure operating and limit controls Cross, 1", (2) and pressure gauge Nipple, 1" x 2", (1) Nipple, 1"...
Page 24: Final Adjustment
Gas-Fired Boiler — Boiler Manual Final Adjustments — water boilers Water treatment Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe boiler damage will occur. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.
Page 25: Steam Boilers
• Installation • Start-Up • Maintenance • Parts Final Adjustments — steam boilers Water treatment Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe boiler damage will occur. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.
Page 26: Placing Boiler In Operation
Gas-Fired Boiler — Boiler Manual Placing boiler in operation To place boiler 1. Turn operating control to position or lowest position on dial. Be sure boiler has been correctly filled with water. in operation 2. Turn electric power. Before lighting Main shutoff gas valve must be closed for at least five (5) minutes before pilot lighting to prevent minor personal injury or property damage.
Page 27: Check-Out Procedure
• Installation • Start-Up • Maintenance • Parts Check-out procedure — check off steps as completed 1. System properly filled with water? 2. Automatic air vent, if used, open one turn (water boilers only)? 3. Air purged from system (water boilers only)? 4.
Page 28: Maintenance
Gas-Fired Boiler — Boiler Manual Maintenance — read this page first Also refer to additional instructions shipped with boiler for specific control Additional instructions operation and troubleshooting. Have your boiler inspected, cleaned and, if necessary, adjusted once a year Annual service by a qualified service agency.
Page 29 • Installation • Start-Up • Maintenance • Parts Maintenance — minimum schedule Beginning of each 1. Annual service call by a qualified service agency. heating season 2. Check burners and flueways and clean if necessary. Refer to Clean boiler heating surfaces , page 31.
Page 30: Burner Flame
Gas-Fired Boiler — Boiler Manual Maintenance — procedures Inspect base 1. Make sure base insulation is secure against all four base panels. insulation If base insulation material is damaged or displaced, call service technician immediately. Do not operate boiler. Operating boiler with damaged or displaced base insulation can result in severe personal injury, death or substantial property damage.
Page 31: Heating Surfaces
• Installation • Start-Up • Maintenance • Parts Inspect 1. Check venting system at least once a month during heating season. With boiler firing, hold candle or match below lower edge of draft hood “skirt”. If flame does not blow out, venting system but burns undisturbed, vent system is functioning properly.
Page 32: Replacement Parts
Gas-Fired Boiler — Boiler Manual Replacement parts Base Insulation Table Base Size Base Insulation Size (Note 1) (Note 2) A and K B and K A and J B and J Notes: 1. See page 9, Base Arrangement Table, to determine base size for your boiler.
Page 33 • Installation • Start-Up • Maintenance • Parts Item Description Size Weil-McLain Item Description Size Weil-McLain Part Number Part Number 443-300-098 Horizontal Draft Hood Screw, Hex Washer Head Slotted 10-32 x 443-400-099 Base Access Shield 450-003-606 443-300-100 450-003-607 443-300-101 450-003-582...
Page 34: Dimensions
Tappings Tappings Natural and Propane (Note 1) Outlet(s) Model Size Size 5" w.c. 7" w.c. Natural Size Number Trains Natural 11"-13" Propane LGB-4 6" 5" (1) 1" 10" (1) 1" LGB-5 6" 5" (1) 1" 12" (1) 1" LGB-6 6"...
Page 35: Equipment - Standard And Optional
Electronically Supervised Pilot Burner • Wire Harness Water boilers 1. Combination Operating and High Limit Temperature Control (LGB-4 through LGB-20 only) 2. Operating Temperature Control (LGB-21 through LGB-23 only) 3. High Limit Temperature Control (LGB-21 through LGB-23 only) 4. Combination Pressure/Temperature Gauge 5.
Page 36: Ratings
1.15. Steam ratings are based to the chimney or vent with not more than one (1) standard sloping-type 90° elbow. on the following allowances: LGB-4 through LGB-12 — 1.333, Consult the National Fuel Gas Code, ANSI Z223.1, for actual sizing. If individual vertical LGB-13 —...

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