PeerlessBoilers Gas/Oil Boilers Installation & Maintenance Manual
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PeerlessBoilers Gas/Oil Boilers Installation & Maintenance Manual

Lc/lce series oil, gas & gas/oil boilers – water
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Series
LC/LCE
Oil, Gas &
Gas/Oil Boilers – Water
I n s t a l l a t i o n ,
O p e r a t i o n &
M a i n t e n a n c e
M a n u a l

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Summary of Contents for PeerlessBoilers Gas/Oil Boilers

  • Page 1 Series LC/LCE Oil, Gas & Gas/Oil Boilers – Water I n s t a l l a t i o n , O p e r a t i o n & M a i n t e n a n c e...

  • Page 2: Table Of Contents

    D. CHIMNEY OR VENT ....3 E. BOILER SETTING ..... .4 F.

  • Page 3: Using This Manual

    Throughout this manual you will see special attention boxes intended to supplement the instructions and make special notice of potential hazards. These categories mean, in the judgment of PB Heat, LLC: USING THIS MANUAL DANGER Indicates a condition or hazard which will cause severe personal injury, death or major property damage.

  • Page 4: Preinstallation

    Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ASME CSD-1. Carefully read these instructions before beginning work. Understand all aspects of the installation. Contact your PB Heat’s sales representative or customer service for help in answering questions.

  • Page 5: Clearance From Combustible Construction

    5. This boiler is designed to fire only with a pressurized fire box. The breeching and vent may be sized for negative, neutral or positive pressure (no more than 0.l inches water column at the boiler outlet) as...

  • Page 6: Boiler Setting

    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.

  • Page 7: Installation Survey

    INSTALLATION SURVEY 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 with your specific system and will provide an overview of hot water system operation in general.
  • Page 8 PREINSTALLATION...
  • Page 9 PREINSTALLATION...
  • Page 10 86036 LC-1017 86026 Table 1.5: Standard and Optional Jacket Cartons, 86030 Jacket Label 86059 86058 Note: Boilers with inspection tappings in front and back sections only use standard cartons. Boiler Model LC-05 LC-06 LC-07 LC-08 86069* 86069* 86069* 86074* 86069*...
  • Page 11 87034 87053 LCE-23 87034 87053 LCE-24 87034 87053 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 Model Water LC-04 Through...

  • Page 12: Place The Boiler

    1. Remove crate top and sides. Remove any loose cartons. Remove burner support pedestal and nipple, if supplied 2. Lift boiler off crate pallet. Move to location determined in Chapter 1: Preinstallation. 3. Remove lifting frame and hardware. 4. Re-install burner support pedestal and nipple if necessary.

  • Page 13: The Sections

    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 Figure 2.4.
  • Page 14 PLACE THE BOILER Figure 2.4: Install Additional Sections. Use level on each section as tie rod bolts are drawn up.
  • Page 15 PLACE THE BOILER Figure 2.5: Series LC Boiler Assembly – Right Side View...
  • Page 16 PLACE THE BOILER Figure 2.6: Series LCE Boiler Assembly – Right Side View...
  • Page 17 WARNING Do not exceed the manufacturer’s torque recommendations. Figure 2.7: Torque Specification/Procedure PLACE THE BOILER 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.
  • Page 18 PLACE THE BOILER Figure 2.9: LC/LCE Boiler Section Assembly Sequence...

  • Page 19: Install Coils Or Plates

    2. Provide a water supply line to the boiler. 3. Plug all open tappings in the boiler. 4. Provide a means to vent air as the boiler fills. 5. Fill the boiler with water, venting air as water level rises.

  • Page 20: Apply Cleanout Cover Plates

    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 “FRONT▼” for proper orientation. b) Secure the plate and compress using the 3/8" tie down assembly, nuts and washers provided.

  • Page 21: Install Flue Baffles

    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.

  • Page 22: Pipe The Boiler

    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.
  • Page 23 Figure 3.2: LC/LCE Boiler Piping Table 3.1: Boiler Supply and Return Connections & Recommended Header Sizing I=B=R Gross Model @ 20°F Output Rise LC-04 LC-05R LC-05 LC-06 LC-07 1029 LC-08 1189 LC-09 1350 LC-10 1511 LC-11 1672 LC-12 1832 LCE-13...
  • Page 24 (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.

  • Page 25: Chilled Water Systems

    1. For flow rates higher than given in Table 3.1, provide bypass piping around the boiler to limit the boiler flow to that given in the table or pipe the boiler in a secondary loop with its own pump as shown in Figure 3.3.
  • Page 26 PIPE THE BOILER Figure 3.6: Piping for Variable Low Temperature Systems, Single Boiler...
  • Page 27 PIPE THE BOILER Figure 3.7: Multiple Boiler Piping, System Return Temperature Above 130°F on Gas, 150°F on Oil...
  • Page 28 PIPE THE BOILER Figure 3.8: Piping for Variable Low Temperature Systems, Multiple Boilers...

  • Page 29: Assemble The Jacket

    Jacket Top Panel flanges, into the Jacket Side Panels. APPLY PLATES AND LABELS 1. Mount Boiler Rating Plates and Agency Plates on the Upper Jacket Front Panel as shown in Figure 4.1. 2. Secure metal plates with #6 x 1/4" sheet metal screws.
  • Page 30 ASSEMBLE THE JACKET Figure 4.2: Jacket Assembly...

  • Page 31: Venting

    5. VENTING Refer to Chapter 1, Preinstallation, Section D. Chimney or Vent for installation requirements. Refer to Chapter 9, Starting the Boiler, Section C. Run Burner Check Out for damper settings and draft requirements. 6. INSTALL THE BURNER A. BURNER APPLICATION 1.
  • Page 32 INSTALL THE BURNER Figure 6.1: Combustion Chamber Layout – See Table 6.1 for Dimensions Table 6.1: Combustion Chamber Dimensions Model LC-04 LC-05R LC-05 LC-06 LC-07 LC-08 LC-09 LC-10 LC-11 LC-12 LCE-13 LCE-14 LCE-15 LCE-16 LCE-17 LCE-18 LCE-19 LCE-20 LCE-21 LCE-22 LCE-23 LCE-24 Chamber...

  • Page 33: Connect Fuel Piping

    7. CONNECT FUEL PIPING A. GENERAL 1. Read the Burner Instruction Manual, supplied with the boiler or with the burner if purchased separately. Review applicable code requirements for burner and fuel piping installations. 2. Install piping to allow removal of burner and access to combustion chamber for cleaning or service.
  • Page 34 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 1-1/4" (Feet) Pipe 1050 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.

  • Page 35: Install Controls And Trim

    8. INSTALL CONTROLS AND TRIM A. INSTALL SAFETY RELIEF VALVE 1. Pipe the Safety Relief Valve off of the 2-1/2" tapping at the upper left side of the Rear Section. Make sure the relief valve sizing meets local code requirements. See Figure 8.1.

  • Page 36: Pipe Tankless Heaters If Used

    G. INSTALL CONTROL WIRING 1. Wire the boiler according to the wiring diagrams supplied with the burner and the boiler (in the Boiler Envelope). 2. Low Energy Safety Control wiring, if used, must follow the contour of the boiler. Some local codes may require that all wiring, even low voltage, be routed in conduit.
  • Page 37 INSTALL CONTROLS AND TRIM Figure 8.2: Control and Pipe Tapping Locations...
  • Page 38 INSTALL CONTROLS AND TRIM Figure 8.3: Suggested Piping – Single Tankless Coil Installation Figure 8.4: Suggested Piping – Dual Tankless Coil Installation...

  • Page 39: Starting The Boiler

    After the boiler is in operation, 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.

  • Page 40: Check Boiler Controls

    LCE-24 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.

  • Page 41: Maintenance

    MAINTENANCE 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.

  • Page 42: Placing Boiler In Operation

    Do not use this boiler if any part of it has been under water. Immediately call a qualified 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.

  • Page 43: Monthly Maintenance

    3. Inspect and check the operation of the venting system. E. DAILY MAINTENANCE 1. Inspect the boiler area to make sure the area is free from combustible or flammable materials and that there are not obstructions to the flow of air to the boiler or combustion air openings to the room.

  • Page 44: Boiler Ratings & Dimensions

    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 requirements, such as intermittent system operation, extensive piping systems, etc.
  • Page 45 BOILER RATINGS & DIMENSIONS Figure 11.2: Series LC Dimensional Diagram Figure 11.3: Series LCE Dimensional Diagram...
  • Page 46 BOILER RATINGS & DIMENSIONS...

  • Page 47: Repair Parts

    REPAIR PARTS 12. REPAIR PARTS Repair parts are available from your 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.
  • Page 48 REPAIR PARTS Table 12.1A: Series LC Repair Parts Item Description Front Section Intermediate Section w/1" Tapping Intermediate Section Back Section Tapped Intermediate Section Upper Flow Port Gasket Lower Flow Port Gasket Tie Rod 5/8" Diameter High Temp Rope Ceramic Fiber Base Liner Ceramic Fiber Target Wall Front Cleanout Plate (C.I.) 5/16"-18 x 1-1/4"...
  • Page 49 For Models LC-04 and LC-08 For Models LC-05, LC-08, LC-09 and LC-10 For Models LC-06, LC-10, LC-11 and LC-12 For Models LC-07 and LC-12 Specify Boiler Model Number Specify Boiler Model Number Specify Boiler Model Number Specify Boiler Model Number...

  • Page 50: Series Lce Boiler Assembly

    REPAIR PARTS Figure 12.2: Series LCE Boiler Assembly...
  • Page 51 Table 12.2A: Series LCE Repair Parts Item Description Front Section Top Flue Outlet Intermediate Section Intermediate Section w/1" Tapping Intermediate Section Back Section (Closed Back) Back Section w/Tankless Coil Opening Tapped Intermediate Section Upper Flow Port Gasket Lower Flow Port Gasket Tie Rod 5/8"...
  • Page 52 REPAIR PARTS Table 12.2B: Series LCE Repair Parts (continued) Item Description Top Jacket Panel LC-6004-2 Top Jacket Panel with Flue Opening LC-6022 Rear Top Jacket Panel LC-6006 Top Flue Outlet Plate (14" Flue) Top Flue Outlet Plate (16" Flue) 5/8" Diameter High Temperature Rope 3/8"...
  • Page 53 NOTES NOTES...
  • Page 54 NOTES...
  • Page 55 Series Oil, Gas & HI Division of gama PB HEAT, LLC PO BOX 447 • NEW BERLINVILLE, PA 19545-0447 ©2007 LC/LCE Gas/Oil Boilers Water I n s t a l l a t i o n , O p e r a t i o n &...

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