Weil McLain Boiler LGB 23 User Manual

1
Part Number 550-141-916/1001  
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Part Number 550-141-916/1001  
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LG B-6 t o LG B-2 3 Series 2 – Control Supplement  
II  
Ga s p ip in g  
1. Size gas piping considering —  
a. Diameter and length of gas supply piping.  
b. Number of fittings.  
c. Maximum gas consumption (including any possible future expansion).  
d. Allowable pressure drop from gas meter outlet to boiler. For pressure drops, see  
ANSI-Z223.1 – latest edition. Canadian installations must comply with B149.1 or  
B149.2 Installation Code.  
2. Size natural gas piping from Table 3, below. Size piping to provide proper inlet pressure to  
gas valve when operating at rated input.  
a. Inlet gas pressure to manual main shut-off gas valve —  
minimum 7" W.C. standard (5" on special order) – maximum 13" W.C.  
b. If pressure to gas valve exceeds 13" W.C., install positive dead-end lockup gas pressure  
regulator upstream of hand valve.  
c. To obtain approximate cubic feet per hour, divide input (BTU/HR) by 1000.  
3. Remove gas supply knockout disc from jacket panel.  
4. Follow good piping practices.  
5. Pipe joint compound (pipe dope) must be resistant to corrosive action of liquefied  
petroleum gases. Apply sparingly only to male threads of pipe joints.  
6. Install drip leg at inlet of gas connection to boiler. Where local utility requires,extend drip  
leg to floor.  
7. Install ground joint union when required for servicing.  
8. Support piping by hangers, not by boiler or its accessories.  
9. Purge all air from supply piping.  
10. Before operating boiler,check boiler and its gas connections for leaks.  
Do not check for gas leaks with an open flame – BUBBLE TEST. Failure to  
use bubble test or test for leaks can cause severe personal injury, death or  
substantial property damage.  
a. Close manual main shut-off valve during any pressure testing at less than 13" W.C.  
b. Disconnect boiler and gas controls from gas supply piping during any pressure test  
greater than 13" W.C.  
11. Set gas pressure switch as follows or to local inspectors requirements (LGB-21 through  
LGB-23 only):  
a. High – 14" W.C.  
12. Canada only - manual main shut-off valve must be identified by installer.  
Pipe  
Size  
1 ¼"  
1 ½"  
2"  
2 ½"  
3"  
4"  
*Pipe length, in feet (Natural Gas capacities, listed in MBH)  
Table 3  
10  
20  
30  
40  
50  
75  
100  
150  
250  
380  
710  
1,130  
2,000  
4,100  
Natural gas supply pipe sizing  
1,050  
1,600  
3,050  
4,800  
8,500  
17,500  
730  
590  
500  
440  
360  
305  
1,100  
2,100  
3,300  
5,900  
12,000  
890  
760  
670  
545  
460  
870  
1,400  
2,500  
5,100  
1,650  
2,700  
4,700  
9,700  
1,450  
2,300  
4,100  
8,300  
1,270  
2,000  
3,600  
7,400  
1,020  
1,650  
2,900  
6,000  
*Include measured length of gas supply piping and allowance in feet for number and size of fittings.  
4
Part Number 550-141-916/1001  
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UniversalControlSystem Naturalgas  
III  
Wirin g  
For your safety, turn off electrical power supply before making any electrical  
connections to avoid possible electrical shock hazard.  
1. All wiring must be installed in accordance with the requirements of the National Electrical  
Code and any additional national, state or local code requirements having jurisdiction. All  
wiring must be N.E.C. Class 1.  
2. The boiler must be electrically grounded in accordance with the National Electrical Code,  
ANSI/NFPA No. 70-latest edition. Use 105 °C. thermoplastic wire, or equivalent, if any of  
the original wire must be replaced (except for pilot spark, sense and ground wires).  
3. Canadian installations must conform to CSA C22.1 Canadian Electrical Code Part 1 and  
any local or provincial codes.  
4. Supply wiring to the boiler must be No. 14 gauge or heavier. Install in conduit.  
5. A separate electrical circuit with a fused disconnect switch (15 amp. recommended) should  
be used for the boiler.  
Sequence of operation  
1. Operating control begins start-up sequence.  
a. Limit control contacts are closed.  
2. Pilot-proving module energized.  
On failure to sense pilot flame or main flame, control will wait 5 minutes  
then retry for ignition.  
a. Pilot solenoid opens.  
b. Pilot ignition spark begins.  
c. Pilot ignites.  
d. Pilot proves.  
3. Main flame-proving module energized from pilot-proving module.  
a. Secondary gas valve opens.  
b. Main gas valve opens to low fire position.  
c. Main burners ignite at low fire.  
d. Main flame sensor proves low fire carryover.  
e. Main gas valve opens to high fire position.  
f. Main burners increase to high fire.  
4. Dual base assembly (LGB-13 through LGB-23) - operating control energizes controls for  
both base assemblies at the same time. See steps 1 through 3 above.  
5. Boiler shuts down when operating control is satisfied.  
Part Number 550-141-916/1001  
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LG B-6 t o LG B-2 3 Series 2 – Control Supplement  
III  
Wirin g  
– continued  
SCHEMATIC WIRING DIAGRAM  
STEAM  
LIMIT CIRCUIT  
WATER  
LIMIT CIRCUIT  
HIGH  
LIMIT  
CONTROL  
OPERATING  
CONTROL  
LOW WATER  
CUT-OFF  
LOW WATER  
CUT-OFF  
MAIN FLAME  
PROVING MODULE  
PILOT PROVING  
MODULE  
MV  
MV/PV  
MV  
MV/PV  
(NOTE 7)  
PV  
PV  
TEMPERATURE  
GND(BURNER)  
GND(BURNER)  
(NOTE 8)  
G
G
OPERATING/LIMIT  
COMBINATION  
CONTROL  
24V (GND)  
24V  
24V (GND)  
24V  
THESE TERMINALS  
TO BE JUMPERED  
WHEN L.W.C.O. IS  
NOT USED  
JUNCTION  
BOX  
MAIN FLAME  
SENSOR  
(NOTE 7)  
WIRE NUTS (4)  
PILOT  
(NOTE 9)  
SENSE  
SPARK  
SENSE  
SPARK  
FROM TRANSFORMER  
FROM TRANSFORMER  
TO LIMIT CIRCUIT  
UNIVERSAL  
SPARK  
IGNITION  
CONTROL  
SERVICE SWITCH  
(BY OTHERS)  
HIGH GAS  
PRESSURE  
SWITCH  
(WHEN USED)  
(NOTE 5)  
TERMINAL  
BLOCK  
WIRE TIE CLIP  
TRANSFORMER  
R
1
2
R
H
PRE-WIRED PANEL  
FROM  
FUSED  
DISCONNECT  
BK  
FIRING RATE CONTROL  
(WHEN USED)  
W
BL  
120  
V.A.C.  
24  
V.A.C.  
BK  
PILOT SOLENOID  
VALVE  
N
C
MV  
PV  
BL  
MV  
PV  
BL  
W
MV/PV  
MV/PV  
W
MAIN GAS VALVE - TWO  
STAGE COMBINATION  
VALVE W/REGULATOR  
SECONDARY  
GAS VALVE  
W
BK  
NO. 1 BASE WIRING  
WIRE NUTS (3)  
(SIZES 6 THRU 23)  
EQUIPMENT  
GROUND  
(NOTE 10)  
MAIN FLAME  
PROVING MODULE  
PILOT PROVING  
MODULE  
MV  
MV/PV  
MV  
MV/PV  
(NOTE 7)  
PV  
PV  
GND(BURNER)  
GND(BURNER)  
G
G
(NOTE 8)  
24V (GND)  
24V  
24V (GND)  
24V  
MAIN FLAME  
SENSOR  
(NOTE 7)  
PILOT  
(NOTE 9)  
SENSE  
SPARK  
SENSE  
SPARK  
UNIVERSAL  
SPARK  
HIGH GAS  
PRESSURE  
SWITCH  
(WHEN USED)  
(NOTE 5)  
IGNITION  
CONTROL  
TERMINAL  
BLOCK  
WIRE TIE CLIP  
1
2
R
PRE-WIRED PANEL  
BK  
FIRING RATE CONTROL  
(WHEN USED)  
R
C
W
BL  
BK  
120  
V.A.C.  
24  
V.A.C.  
PILOT SOLENOID  
VALVE  
MAIN GAS VALVE - TWO  
STAGE COMBINATION  
VALVE W/REGULATOR  
MV  
PV  
BL  
MV  
MV/PV  
W
PV  
BL  
W
MV/PV  
SECONDARY  
GAS VALVE  
W
TRANSFORMER  
WIRE NUTS (2)  
BK  
NO. 2 BASE WIRING  
(SIZES 13 THRU 23)  
LOW VOLTAGE FIELD  
HIGH VOLTAGE FIELD  
LOW VOLTAGE FACTORY  
HIGH VOLTAGE FACTORY  
ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE INJURY OR DEATH.  
DISCONNECT POWER BEFORE INSTALLING AND/OR SERVICING.  
IGNITION/SENSING CABLE  
NOTES:  
5. STANDARD EQUIPMENT FOR LGB-21 THRU LGB-23.  
MV/PV  
1. ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH:  
A. U.S.A. - NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL, STATE, OR LOCAL  
CODE REQUIREMENTS.  
B. CANADA - C.S.A. C22.1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER  
NATIONAL, PROVINCIAL, OR LOCAL CODE REQUIREMENTS.  
MAIN GAS VALVE TERMINAL.  
CONTROL MODULE TERMINAL.  
6.  
TERMINAL ON MAIN GAS VALVE IS A SINGLE TERMINAL (COMMON)  
FOR LOW AND HIGH FIRE OPERATORS.  
7. REFER TO CONTROL SUPPLEMENT FOR GROUND LEADWIRE ATTACHMENT.  
IF ORIGINAL GROUND LEADWIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED,  
TYPE 125 C OR ITS EQUIVALENT MUST BE USED.  
2. ALL WIRING EXTERNAL TO BOILER JACKET MUST BE:  
A. U.S.A. - N.E.C. CLASS 1.  
B. CANADA - C.S.A. C22.1 C.E.C. PART 1.  
IGNITION CONTROL  
PANEL TERMINAL.  
8. WIRES ARE FACTORY INSTALLED TO CONTROL PANEL, BUT MUST BE FIELD  
CONNECTED TO GAS VALVES AND FIRING RATE CONTROL TERMINALS (WHEN USED).  
TRANSFORMER TERMINAL.  
3. IF ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, TYPE 105 C OR  
ITS EQUIVALENT MUST BE USED. EXCEPTION, SEE NOTE 7.  
9. PILOT LEADWIRES ARE NOT FIELD REPLACEABLE. REPLACE PILOT ASSEMBLY IF NECESSARY.  
FACTORY WIRED TO CONTROL -  
FIELD WIRED TO GAS  
VALVE OR FIRING RATE CONTROL.  
10.  
DENOTES FIELD INSTALLED CHASSIS GROUND.  
4. REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR  
APPLICATION INFORMATION.  
11. ALL CONTACTS SHOWN WITHOUT POWER APPLIED - OFF SHELF CONDITION.  
6
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UniversalControlSystem Naturalgas  
EQUIPMENT  
GROUND  
(NOTE 10)  
Figure 3  
Wiring diagram  
LADDER WIRING DIAGRAM  
H
N
120 V.A.C.  
HIGH  
LIMIT  
CONTROL  
SERVICE SWITCH  
(BY OTHERS)  
OPERATING  
CONTROL  
LOW WATER  
CUT-OFF  
PRIMARY  
R
C
24 V.A.C.  
PRIMARY  
R
24 V.A.C.  
MAIN GAS VALVE HIGH FIRE  
OPERATOR (NOTE 6)  
FIRING RATE CONTROL  
(WHEN USED)  
MV  
MV  
MAIN GAS VALVE LOW FIRE OPERATOR  
MV/PV  
MV/PV  
PV  
MV/PV  
PV  
GND  
(NOTE 6)  
(BURNER)  
PV  
MV/PV  
24V  
(GND)  
SECONDARY GAS VALVE  
24V  
MAIN FLAME SENSOR  
SENSE  
SPARK  
NO. 1 BASE  
MAIN FLAME PROVING MODULE  
MV  
MV/PV  
PILOT SOLENOID VALVE  
PV  
HIGH GAS  
PRESSURE  
SWITCH  
(WHEN USED)  
(NOTE 5)  
GND  
(BURNER)  
24V  
(GND)  
2
24V  
1
PILOT FLAME SENSOR  
SENSE  
SPARK  
PILOT BURNER  
(NOTE 9)  
NO. 1 BASE  
PILOT PROVING MODULE  
MAIN GAS VALVE HIGH FIRE  
OPERATOR (NOTE 6)  
FIRING RATE CONTROL  
(WHEN USED)  
MV  
MV  
MAIN GAS VALVE LOW FIRE OPERATOR  
MV/PV  
MV/PV  
PV  
PV  
MV/PV  
GND  
(BURNER)  
(NOTE 6)  
PV  
MV/PV  
24V  
(GND)  
SECONDARY GAS VALVE  
24V  
MAIN FLAME SENSOR  
SENSE  
SPARK  
NO. 2 BASE  
MAIN FLAME PROVING MODULE  
MV  
MV/PV  
PILOT SOLENOID VALVE  
PV  
GND  
(BURNER)  
24V  
(GND)  
2
24V  
1
PILOT FLAME SENSOR  
HIGH GAS  
PRESSURE  
SWITCH  
SENSE  
SPARK  
(WHEN USED)  
(NOTE 5)  
PILOT BURNER  
(NOTE 9)  
NO. 2 BASE  
PILOT PROVING MODULE  
Intermittent Pilot  
A United Dominion Company  
Universal Control System  
Steam or Water  
6 thru 23  
LGB  
Weil-McLain  
500 Blaine St.  
Michigan City, IN 46360-2388  
Natural Gas  
550-101-131/0798WM  
PART NUMBER  
Part Number 550-141-916/1001  
7
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LG B-6 t o LG B-2 3 Series 2 – Control Supplement  
III  
Wirin g  
– continued  
Wiring Procedure  
1. Determine right or left electrical supply wiring.  
2. Attach electrical junction box(es) to inside jacket end panel. Screws and nuts are provided.  
For dual base boilers,use offset nipples (provided) to connect junction boxes together,  
then hang junction boxes by screwing top box to boiler jacket.See Figure 4,below.  
3. Attach control transformer(s) to junction box(es).  
4. Drill 1/8" hole in interior jacket panel midway between ignition control panel and left jacket  
panel. Mount wire support clip using sheet metal screw (furnished).  
5. Complete wiring per wiring diagram, Figure 3 (pages 6 and 7).  
“Hot” side of line voltage to boiler must be wired directly to limit circuit,  
then fed to transformer primary(ies). Dual Base:“Rterminal of  
secondaries are to supply power to bases independently of each other. Do  
not wire“Rterminals together.  
6. Install pilot proving and main flame proving ground connections as shown in Figures 1  
and 2 (page 3) and Figure 3 (pages 6 and 7). Route wires through wire support clip.  
7. Canada only - attach chain between junction box(es) and transformer with S-hooks.  
Figure 4  
Junction box assembly  
Screw Holes  
dual base boilers  
Junction Box  
to Mount  
Ba se 1  
Junction Box  
to Ja cket  
Offset Nipples  
(2)  
Junction Box  
Ba se 2  
911BGLr0  
8
Part Number 550-141-916/1001  
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UniversalControlSystem Naturalgas  
IV  
Op e ra t in g in s t ru c t io n s  
Part Number 550-141-916/1001  
9
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LG B-6 t o LG B-2 3 Series 2 – Control Supplement  
V
Ve rific a t io n t e s t in g  
Before starting boiler for the first time and at least annually (during annual inspection and  
start-up), follow the procedures below to verify boiler controls are operating correctly and  
that automatic gas valve properly shuts off gas flow. Failure to verify boiler operation  
could result in severe personal injury, death or substantial property damage.  
Manual test firing  
valve  
This boiler is equipped with a manual test firing valve — the manual gas valve piped  
between the gas manifold and the first automatic gas valve in the gas train. Closing the  
manual test firing valve allows verification of proper boiler operation without allowing  
gas flow to the manifold and allows leak testing of the automatic gas valves. Follow the  
procedures below.  
Verify boiler control  
sequence  
1. Follow the Operating Instructions in this Supplement to start the boiler, but do not  
open the manual test firing valve. Open all other manual gas valves as instructed.  
Leave the manual test firing valve closed.  
2. The automatic pilot burner should light.  
3. After the pilot lights, the boiler controls should activate the automatic gas valves. Use a  
voltmeter to verify voltage to automatic valves.  
4. With no gas flow to the manifold, the boiler ignition controls should turn off the  
automatic gas valves after main flame ignition trial. Use a voltmeter to verify voltage to  
automatic valves is turned off.  
Leak test automatic  
gas valve  
1. Close manual test firing valve.  
2. Open the service valve and gas hand valve.  
3. Install a hose barb into a pressure tap downstream of the first automatic gas valve.  
Allow any accumulated gas in the line to vent off. Then connect a U-tube manometer.  
If the valve seals properly, there should be no gas pressure present. Remove manometer  
and hose barb and replace pipe plug in pressure tap.  
4. Connect the manometer downstream of the second automatic gas valve. Temporarily  
remove the power leads to the first automatic gas valve. Then connect 24 volt power to  
the first automatic gas valve terminals to open it. If the second valve seals properly,  
there should be no pressure at the manometer.  
5. Remove the temporary power supply to the automatic gas valve. Reconnect its power  
leads. Remove the manometer and plug any open pressure taps.  
6. Follow Operating Instructions to place boiler in service.  
Replace any defective components. Do not attempt to operate boiler or leave boiler in  
operation if any component is found to be defective or to operate incorrectly. Failure to  
comply could result in severe personal injury, death, or substantial property damage.  
10  
Part Number 550-141-916/1001  
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UniversalControlSystem Naturalgas  
VI  
Pa rt s lis t  
– continued  
Figure 5  
Parts  
drawing  
8
9
7
12  
14  
3
1
4
5
11  
13  
10  
6
2
91601  
Part Number 550-141-916/1001  
11  
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LG B-6 t o LG B-2 3 Series 2 – Control Supplement  
Weil-McLain  
500 Blaine Street  
Michigan City, IN 46360-2388  
12  
Part Number 550-141-916/1001  
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