Gems Lattner Instruction Manual
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Gems Lattner Instruction Manual

Wlf steam boilers
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Instruction Manual – WLF Steam Boilers
2006 to 2007

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  • Page 1 Instruction Manual – WLF Steam Boilers 2006 to 2007...

  • Page 2: Table Of Contents

    Index General Description …………………………………………………………………………….Page 4 A. Boiler Design ……………………………………………………………………………………4 B. Boiler Connections ……………………………………………………………………………………4 C. Boiler Trim ……………………………………………………………………………………5 D. Fuel Burning System ……………………………………………………………………………………5 E. Fuel Train ……………………………………………………………………………………6 F. Control Panel ……………………………………………………………………………………6 G. Combustion Safeguard ……………………………………………………………………………………6 H. Guarantees ……………………………………………………………………………………6 Factory Tests ……………………………………………………………………………………7 J.
  • Page 3 J. Auxiliary Low Water Cut-Off ………………………………………………………………………………….24 Probe Cleaning Section IV: Troubleshooting …………………………………………………………………………..Page 25 A. Normal Operation ………………………………………………………………………………….25 B. Basic Service Tools ………………………………………………………………………………….25 C. Before You Begin ………………………………………………………………………………….25 Lattner Boiler Limited Warranty …………………………………………………………………………..Page 28 Standard Terms & Conditions …………………………………………………………………………..Page 29 .......................Page 30 Product Support Literature...

  • Page 4: General Description

    General Description WARNING: All installation procedures must be followed completely by a competent installer familiar with boilers and boiler accessories. CAUTION: Read and follow all instructions before installing any boiler equipment. All cover plates, enclosures and guards must be maintained and in place at all times, except during maintenance and servicing. A.

  • Page 5: Boiler Trim

    Boiler Blowdown Valve/Drain 5. Auxiliary Low Water Cut-Off A boiler blowdown valve is provided on the front right An additional control, separate from the primary low side of the pressure vessel to completely drain the boiler water control is provided to prevent burner operation if a as required, and for periodic bottom blowdown.

  • Page 6: Fuel Train

    Ignition/Pilot 2. Pump ON/OFF Switch Gas-fired units are equipped with a spark ignited gas Provided to isolate the pump control circuit. pilot assembly. The gas pilot assembly includes a pilot gas cock, gas pressure regulator, ignition transformer, 3. Terminals and pilot solenoid valve. Provided for the connection of the 120/1/60 volt supply Forced Draft Fan and for external connections for field wiring.

  • Page 7: Factory Tests

    Vessel Inspectors. The original copy is archive at along with the boiler serial number, year built, maximum Lattner. boiler output and minimum safety valve capacity. This information is stamped on the top head of the pressure 2.

  • Page 8: Section I: Installation

    Use the following chart to determine vent size for into place. If the unit is dragged, attach chains to the base Lattner boilers. Chart based on a minimum of 1 sq. in. frame only. per 4,000 BTU input. Ideal is 1 sq. in. per 2,000 BTU input.

  • Page 9: Stack

    Specifications 1. Pipe Size Install all stacks in compliance with state and local codes. Lattner recommends double wall stack per ANSI Size steam pipe according to system requirements. Z2231.1, appliance category III for positive vent pressure systems for boilers operating with a maximum continuous 2.

  • Page 10: Safety Valve

    Connect cold water supply pipe to aftercooler. Automatic Bottom Blowdown 11. Dead Boiler Drain Valve A Lattner automatic bottom blowdown valve may be used in place of one of the manual blowdown valves. For draining the boiler when it is cool and not under...

  • Page 11: Boiler Feed Systems

    Diaphragm Gas Valve Make-Up Water Supply This valve is the main gas valve. A separate gas Connect city water line to the float valve provided pressure regulator must be used to regulate main burner with the boiler feed system. pressure. LV5 through LV35 use 1/2”...

  • Page 12: Electrical Connections

    If the boiler was shipped with controls removed, re- connect the wires according to the wiring diagram. All All Lattner steam boilers will have at least two pressure wires that need to be reconnected will have a tag switches, a "controller" and a "limit”.

  • Page 13: Start Up Of Standard Burners

    *For warranty validation, complete start up check list (included with boiler) and return it to Lattner. Failure to return check list may void warranty. 14. Burner Head Pressure Check gas pressure at burner head. Burner head pressure should be as specified in the burner manual.
  • Page 14 16. Check for Gas Leaks 19. Pressuretrols Allow the boiler to reach its operating pressure. Check Brush a soapy water solution on each connection in the the pressuretrols to be certain they’re are set as main gas and pilot gas lines. Look for bubbles. If there described and functioning properly.

  • Page 15: Section Ii: Boiler Care

    To remove oil and grease from a new boiler, use the supply of Lattner Boiler Compound D. Water Treatments & Chemicals sent with the boiler.

  • Page 16: Water Treatment Summary

    This is done by blowdown. Blowdown removes a portion of It is normal for the water line of Lattner boilers to the water in the boiler in order to reduce the amount of fluctuate about one inch.

  • Page 17: Burner Adjustment

    the vent pipe from the condensate return tank. If there is The boiler and the boiler level controls should be blown an abnormally high steam flow from the vent, either the down at least DAILY. traps or check valves are leaking. A thermal sensor may be used to help detect which traps External Inspections are malfunctioning.

  • Page 18: Internal Inspections

    Always be certain the sight glass is cut to proper length. Make sure the fixtures are plumb. If these two conditions are not checked, the glass may crack. M. Internal Inspections Gaskets Purpose of Inspections The hand hole gaskets and the McDonnell Miller head gasket must be replaced after each internal inspection.

  • Page 19: Section Iii: Maintenance

    Do the following every 6 to 12 months depending but the blowdown lines must be piped to a safe location. on water quality: Lattner recommends blowing down at 30 psi. Remove hand hole plate and clean inside Boiler Blowdown boiler.

  • Page 20: D. Table 1: Recommended Testing

    D. Table 1: Recommended Testing Schedule Item Frequency Responsibility Remarks Gauges and Sight Glass Daily Operator Make visual inspection and record readings in a log. Instrument and Boiler Settings Daily Operator Make visual check against manufacturer’s recommended specifications. Refer to product literature sheets.

  • Page 21: Hand Hole Plate Removal & Re

    Hand Hole Plate Removal & Re-Installation Disconnect all power to the boiler. The boiler must be cool and drained of all water. See assembly print for hand hole location. Remove the hand hole plate nut. Use a 7/8" socket. Remove arch over hand hole plate. Remove hand hole plate.
  • Page 22 Sight Glass Removal & Re-Installation Boiler and pump should be switched off. Boiler should be cool and the water level should be below the lower water gauge fixture. Close the upper and lower water gauge valves. Loosen both sight glass packing nuts (top and bottom) with a wrench.

  • Page 23: H. Cleaning Interconnecting Pipe

    G. McDonnell Miller Servicing 16. Flush out all piping with water after cleaning. Disconnect all power to the boiler. 17. Replace all pipe plugs and pipe caps. Tighten with The boiler should be cool and drained of all water a wrench enough to prevent water or steam leaks. just below the McDonnell Miller control.

  • Page 24: I. Warrick Relay Replacement

    Warrick Relay Replacement Auxiliary Low Water Cut-Off Probe Cleaning Disconnect all power to the boiler. Disconnect all power to the boiler. 2. Pull relay out by hand. This may take a little Remove the four screws on top of the probe enclosure with a Phillips screwdriver.

  • Page 25: A. Normal Operation

    10. If the boiler has optional controls, refer to the wiring diagram. B. Basic Service Tools The following basic equipment will aid in troubleshooting Lattner boilers. Not all equipment is needed for every repair: Schematic diagram of the boiler Volt/ohm meter Ammeter...
  • Page 26 Possible Boiler Problems Possible Causes Boiler and pump switch are ON, Circuit breaker is tripped or fuse is blown. pump does not run and low water McDonnell Miller piping is plugged. level in boiler. McDonnell Miller float is stuck. McDonnell Miller is wired incorrectly. Pump or solenoid water valve is wired incorrectly.
  • Page 27 Burner motor runs and pilot lights but Check flame strength signal (digital display module). If low, adjust pilot gas pressure main gas valve does not open. and air settings for improved readings. Possible dirty scanner lens. Check gas valve circuit, both main valve and proof of closure switch (if so equipped). Main valve opening too slow.

  • Page 28: Lattner Boiler Limited Warranty

    Purchaser the benefit of such adjustment as it can make with the manufacturer of such items. Lattner shall not be liable for special, indirect, or consequential damages. Lattner shall not be liable for any loss or damage resulting, directly or indirectly, from the use or loss of use of the boiler. This exclusion from liability includes the Purchaser’s expenses for downtime or for making up downtime, damages for which the Purchaser...
  • Page 29 EXCLUSION OF OTHER TERMS Subsequent to the receipt of Purchaser’s Purchase Order and the This constitutes an offer on behalf of Lattner Boiler Manufacturing (the Company’s issued order acknowledgement, the Purchaser may not Company); to sell the goods described in the quotation, exclusively on change or cancel the order in whole or in part without the written the terms and conditions stated.
  • Page 30 Lattner Boiler Company Instruction Manual – WLF Models February 2005...
  • Page 31 We disclaim any responsibility. 1224 North Utica Tulsa, OK 74110-4682 1-800-587-7123 918-587-6649 Fax: 918-587-6961 topogesales@topog-e.com Lattner Boiler Company Instruction Manual – WLF Models February 2005 Page 31...
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  • Page 46 KUNKLE PRESSURE RELIEF VALVES Installation and Operating Instructions Pre-Installation Handling This pressure relief valve is designed to protect equipment from overpressure. The valve should be handled with care, not subjected to heavy shock loads, and protected to prevent contamination from getting inside. It should be installed correctly per A.S.M.E.

  • Page 47: Pressure Regulators

    BULLETIN MS2056- 04/04 Gas Appliance Pressure Regulators Straight-Thru-Flow Design RV52, RV53, RV61, RV81, RV91, RV111, and RV131 1/2", 3/4", 1", 1¼", 1½", 2", 2½", 3" & 4" design certified Maximum Pressure CSA Rated (except RV131) ..1/2 psi (35 mbar) Maxitrol Tested* RV52 &...
  • Page 48 Straight-Thru-Flow Design RV52, RV53, RV61, RV81, series RV91, RV111, and RV131 FEATURES • Greater accuracy—higher pressure drop capacity • Outlet pressures available to 42” w.c. • Available in full range of pipe sizes from 1/2" to 4" • All models tapped with NPT vent bosses •...
  • Page 49 Capacities and Pressure Drop CAPACITIES—expressed in CFH (m /h)—0.64 sp gr gas Pressure DropÑinches w.c. (mbar) Model A.G.A. Number and Pipe Size 1/2 x 1/2 RV52 3/4 x 3/4 (12.7) (4.2) (6.1) (7.4) (8.5) (9.5) (10.5) (11.3) (12.1) (12.8) (13.5) (19.1) (23.4) (27.1)
  • Page 50 Dimensions and Spring Ranges RV81 & 91 RV52 & 53 R V 6 1 DIMENSIONS*—inches (millimeters) R V 1 1 1 Model & Call-Outs Vent Swing Illustration Radius Number 1/8" 3.25 1.25 RV52 (91) (124) (81) (83) (32) 1/8" 3.75 RV53 (99) (132)
  • Page 51 BULLETIN MI2010-5/00 SAFETY WARNING INSTRUCTIONS INSTRUCCIONES PARA PRECAUCIONES DE SEGURIDAD FOR MAXITROL GAS PRESSURE REGULATORS PARA REGULADORES DE PRESION DE GAS NOTE: GAS PRESSURE REGULATORS WILL NOT MAXITROL TURN OFF THE FLOW OF GAS. SPECIAL WARNINGS NOTA: LOS REGULADORES DE PRESION DE GAS NO CORTAN EL FLUJO DE GAS IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY...
  • Page 52 6. La ventilación deberá estar controlada de acuerdo con los códigos y reglamentos 6. Venting must be controlled in accordance with government and plumbing gubernamentales de plomería para evitar el peligro de que se escape el gas en caso codes and regulations to avoid the danger of escaping gas should there be de una fuga interna.
  • Page 53 Installation & Maintenance Instructions MM-217(F) Series 150 and 157 ® (Mercury Switch) Series 150S and 157S (Snap Switch, All Models except 157S-RB-P) Low Water Cut-Off/Pump Controllers For Steam Boilers and Other Level Control Applications Series 150 and 150S Typical Applications: –...
  • Page 54 OPERATION Maximum Pressure: 150 psi (10.5 kg/cm Electrical Ratings Alarm Circuit Rating Motor Horsepower PumpCircuit Rating (Amperes) Voltage Amps Voltage Voltage Full Load Locked Rotor Pilot Duty 120 VAC 120 VAC 120 VAC 44.4 345 VA at 120 or 240 VAC 240 VAC 22.2 240 VAC...
  • Page 55 Settings and Differential Pressures (continued) Values are ± 8” (3.2mm). Model 158/158S Model 158-MD/158S-MD Approximate Approximate Distance Above Distance Above Cast Line Differential Cast Line Differential Pressure Setting In. (mm) In. (mm) Pressure Setting In. (mm) In. (mm) Motorized (24) Pump Off (24) 0 psi...
  • Page 56 Settings and Differential Pressures (continued) Values are ± 8” (3.2mm). Model 159/159S Approximate Distance Above Cast Line Differential Setting In. (mm) In. (mm) Pressure Pump #1 Off (24) 0 psi Pump #1 On (16) (0 kg/ Pump #2 Off (16) (16) Pump #2 On (6.4)
  • Page 57 INSTALLATION TOOLS NEEDED: IMPORTANT: Follow the boiler manufacturer's Two (2) pipe wrenches, one (1) flathead screw instructions along with all applicable codes and driver, and pipe sealing compound. ordinances for piping, blow down valve and water gauge glass requirements. STEP 1 - Determine the Elevation at Which the Low Water Cut-Off/Pump Controller Must be Installed STEAM EQUALIZING PIPE If the control will be the primary low...
  • Page 58 b. For Models 150-B and 150S-B and Series Models 150-B and 150S-B Series 157 and 157S 157 and 157S (For all other models, proceed to Step 3). Screw the w” NPT steel plug (C) (provided) in tapping (A). CAUTION The plug must be reinstalled before control is shipped installed on the boiler, and removed when boiler is installed after shipment.
  • Page 59 STEP 4 - Electrical Wiring WARNING • To prevent a fire, do not use this product to switch currents over 7.4A, 1/3 Hp at 120 VAC or 3.7A, 1/3 Hp at 240 VAC, unless a starter or relay is used in conjunction with it. •...

  • Page 60: Manual Reset

    b. Following the appropriate wiring diagram, (refer IMPORTANT: There must be to page 9) based on your application require- a minimum space of 1/2” ments, and using BX armored cable or Thinwall (13mm) between connector electrical metal tubing connector fittings, make fittings and electrical live electrical connections to the junction box (L).

  • Page 61: Wiring Diagrams

    WIRING DIAGRAMS For Motorized Valves, refer to the valve manufacturer's wiring instructions. Low Water Cut-Off Only 1. Main Line Switch - For burner circuits within the 2. Pilot Switch - To holding coil of a starter when switch’s electrical rating. the burner circuit exceeds the switch’s electrical rating.
  • Page 62 6. Re-attach the junction box cover (K). Note: Cover must be installed correctly as shown STEP 5 - Testing This control is factory calibrated for specific applications. The following testing procedure is only meant to serve as a verification of proper operating sequence. Dimensions provided are typical for a boiler not being fired and/or not at pressure.
  • Page 63 c. For automatic reset models only. When the water Snap Switch Models level reaches approximately d” (22mm) above the horizontal cast line (lower for MD models) the burner should come on (pump #2 should shut off with Models 159 and 159S). For manual reset models only.
  • Page 64 MAINTENANCE SCHEDULE: BLOW DOWN PROCEDURE: • Blow down control as follows when boiler is in operation. CAUTION – Daily if operating pressure is above 15 psi. To prevent serious personal injury from steam – Weekly if operating pressure is below 15 psi. pipe blow down, connect a drain pipe to the control opening to avoid exposure to steam NOTE...
  • Page 65 This bulletin should be used by experienced personnel as a guide to the installation of series 26M controls. Selection or installation of equipment should always be accompanied by competent technical assistance. We encourage you to contact Gems Sensors or its local representative if further information is required. Specifications...

  • Page 66: Wiring Diagram

    Enclosure: 0=None, 1=NEMA 1, 4=NEMA 4 Socket Style: A=11 Pin Octal, B=DIN mount, M=None,module only Supply Voltage: 1=120VAC, 2=240VAC, 3=24VAC, 8=208/240VAC Sensitivity : A=4.7K, B=10K, C=26K, D=50K, E=100K No Option Gems Sensors Inc. One Cowles Road Plainville, CT 06062-1198 Tel: 860-793-4579 Page 66...

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