Series LC/LCE Oil, Gas & Gas/Oil Boilers – Water Installation, Operation & Maintenance Manual
TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 1 A. INSTRUCTION MANUALS . . . . . . . . . . . . . . .1 B. 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 VENT . . . . . . . . . . . . . . . . . . . .3 E. BOILER SETTING . . . . . . . . . . . . . . . . . . . . . .4 F.
USING THIS MANUAL USING THIS MANUAL A. INSTRUCTION MANUALS The Series LC/LCE Installation, Operation & Maintenance Manual is divided into four basic sections: 1. 2. 3. 4. Preinstallation (Section 1) Installation (Sections 2 through 8) Start-Up (Section 9) Maintenance (Section 10) B. SPECIAL ATTENTION BOXES Throughout this manual you will see special attention boxes intended to supplement the instructions and make special notice of potential hazards.
PREINSTALLATION 1. PREINSTALLATION NOTICE The equipment must be installed in accordance with installation requirements of the authority having jurisdiction or, in the absence of such requirements, to the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54. Where required 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.
PREINSTALLATION B. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION D. CHIMNEY OR VENT Provide the following minimum clearances to combustible construction. See Figure 1.1. 1. Inspect the existing chimney or vent system. Make sure it is in good condition. Inspect chimney liner and repair or replace if necessary. 1. 2. 3. 4. 5. 6. 2.
PREINSTALLATION 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: 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.
PREINSTALLATION Table 1.1: Foundation Lengths H. VERIFY COMPONENTS Model Foundation Length, Inches LC-04 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 37¹⁵⁄₁₆ 43 48¹⁄₁₆ 53¹⁄₈ 58⁵⁄₁₆ 63³⁄₈ 68⁷⁄₁₆ 73¹⁄₂ 78⁹⁄₁₆ 83³⁄₄ 88¹³⁄₁₆ 93⁷⁄₈ 98¹⁵⁄₁₆ 104¹⁄₈ 109³⁄₁₆ 114¹⁄₄ 119⁷⁄₁₆ 124¹⁄₂ 129⁹⁄₁₆ 134⁵⁄₈ 139¹¹⁄₁₆ 1. Packaged: All components should be inside crate. In some cases the burner may be shipped separately.
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PREINSTALLATION Table 1.3: Standard and Optional Sections for Knockdown Boilers 50 psig MAWP Sections Front Plain Interm. Top Flue Interm. LWCO Interm. 3" Tap. Interm.
PREINSTALLATION Table 1.6B: Burner Mounting Plates Boiler Model 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 CF2300AKG 86074* CF2300AKB CF2500 Beckett CF3500AKM CF3500AKL 801CRD 86073 1050FFD Carlin 1150FFD R10.9 86088 R10 Gordon Piatt R10.1 R10.
PLACE THE BOILER 2. PLACE THE BOILER A. PACKAGED 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. 2. Remove lifting frame and hardware. 3. Proceed to Section D: Install Coils or Plates C. KNOCKDOWN BOILER 1. Place channel rails as shown in Figure 1.4. 3. Remove lifting frame and hardware. 2. Open the Section Assembly Kit cartons.
PLACE THE BOILER 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 Figure 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.
PLACE THE BOILER Figure 2.4: Install Additional Sections. Use level on each section as tie rod bolts are drawn up.
PLACE THE BOILER Figure 2.
PLACE THE BOILER Figure 2.
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. A 0-100 ft-lbs 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.
PLACE THE BOILER Figure 2.
PLACE THE BOILER D. INSTALL COILS OR PLATES 1. Remove the coil cover plates, gaskets and mounting hardware, located in the Flue Box Carton. 2. Install tankless heaters, if used, in openings #1 and #2. See Figure 2.10 and Table 2.2. 3. 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. E. HYDROSTATIC TEST THE BOILER 1. Install a drain valve in the Rear Section, Tapping 13.
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 the Cleanout Plate with insulation over the protruding carriage bolts until the insulation lays flush against the cast iron. 5.
PLACE THE BOILER H. INSTALL FLUE BAFFLES 1. Remove the Front Cleanout Plate from Front Section. 2. Open Baffles carton. Remove Baffles. For LC Only – Save Ceramic Fiber Liner for Section I. Save Rating Label for Chapter 4. Models LCE-13 through LCE20 do not require baffles. I. INSTALL CHAMBER LINER 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.
PIPE THE BOILER 3. 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. A. PREPARATION 1. Make sure the boiler has been pressure tested as outlined in “Place the Boiler Sections” in this manual. 3. Do not reduce the number or size of supply and return connections given in Table 3.1.
PIPE THE BOILER Figure 3.2: LC/LCE Boiler Piping Table 3.
PIPE THE BOILER b) Temporary low temperature operation is acceptable within limits. For occasional cold startups condensation will occur, but will have limited effects. If the system is frequently allowed to cool to room temperature, such as on night set-back systems or energy management systems, cold start-ups will occur often. These systems require a Variable Low Temperature piping and control arrangement, described below. 2.
PIPE THE BOILER control valve and boiler circuit pump piped off of the system as a secondary loop. See Figure 3.6 for a single boiler and Figure 3.7 for multiple boilers. D. CHILLED WATER SYSTEMS 1. If the boiler will be used in conjunction with a refrigeration system, the chilled medium must be placed in parallel with the boiler and proper valves applied to prevent the chilled medium from entering the boiler. See Figure 3.5. E. HIGH FLOW RATE PIPING 1. For flow rates higher than given in Table 3.
PIPE THE BOILER Figure 3.
PIPE THE BOILER Figure 3.
PIPE THE BOILER Figure 3.
ASSEMBLE THE JACKET 4. ASSEMBLE THE JACKET 2. Attach the Middle Front Panel and Lower Front Rail in the same manner. A. PREPARE THE PARTS 1. Collect all the jacket cartons: Jacket Front & Back Carton plus Jacket Side & Top Cartons. See the Shipping List in the front of this manual for the jacket cartons required. The cartons contain the jacket parts and screws. The jacket panels are preinsulated. 3. Position the Jacket Assembly with the front panels pushed up against the front section.
ASSEMBLE THE JACKET Figure 4.
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. Refer to Burner Spec and Data Sheets for the Oil and Gas/Oil Burners pre-tested with Series LC boilers. 2. Make sure the nozzle sizing and spray pattern match those given in the spec and data sheets. 3. See Figure 6.1 and Table 6.
INSTALL THE BURNER Figure 6.1: Combustion Chamber Layout – See Table 6.1 for Dimensions Table 6.
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. 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. 2.
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.
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. C. INSTALL LOW WATER CUTOFFS 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.
INSTALL CONTROLS AND TRIM 3. Mount the High Limit Control bulb well in the left side 3/4" tapping of the coil cover plate if a tankless heater is not mounted in the upper right opening (Position 2). If a coil is installed there, mount the well in the 3/4" tapping to the left of the opening. See Figure 8.2.
INSTALL CONTROLS AND TRIM Figure 8.
INSTALL CONTROLS AND TRIM Figure 8.3: Suggested Piping – Single Tankless Coil Installation Figure 8.
STARTING THE BOILER 9. STARTING THE BOILER A. CHECK THE PIPING 1. Water Piping a) The Boiler must have been hydrostatically tested. b) Check the attached piping 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, check the tightness of all joints in the boiler gas piping with a soap suds solution.
STARTING THE BOILER 4. Adjust the burner as needed for a CO2 reading of: a) Oil burners: CO2 approximately 12.5% or 1% less than the level at which the smoke reading goes above a trace on the Bacharach scale. 2. Low Water Cutoffs a) Test probe type controls by using the Push-to-Test Button. b) Test float type controls. ASME CSD-1 requires the control to be piped with Test-n-Check valves in order to allow isolation for test. b) Gas burners: 9% to 10% with CO less than 50 ppm.
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.
MAINTENANCE WARNING Do not store or allow combustible or 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. 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.
MAINTENANCE d) Remove the Burner and Burner Mounting Plate. Remove any scale or soot from the combustion chamber by means of vacuum cleaning or other available means. Take care not to damage the chamber floor liner or target wall liner. e) Replace the Front Cleanout Plate, Burner 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. f) Replace all Jacket Panels. 5.
BOILER RATINGS & DIMENSIONS 11. BOILER RATINGS & DIMENSIONS Table 11.1: Series LC/LCE Boiler Ratings SERIES LC/LCE BOILER RATINGS Boiler Model Number Gross I=B=R Output Mbh Boiler H.P. Oil GPH Gas MBH Steam Sq. Ft. Steam MBH Water MBH Oil Gas 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-24 547 649 707 868 1029 1189 1350 1511 1672 1832 1966 2125 2284 2444 2603 2763 2922 3082 3256 3430 3604 3777 16.
BOILER RATINGS & DIMENSIONS Figure 11.2: Series LC Dimensional Diagram Figure 11.
44 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 37″ 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 25¹⁵⁄₁₆″ 31″ 31″ 36¹⁄₁₆″ 41¹⁄₈″ 46⁵⁄₁₆″ 51³⁄₈″ 56⁷⁄₁₆″ 61¹⁄₂″ 66⁹⁄₁₆″ 71³⁄₄″ 76¹³⁄₁₆″ 81⁷⁄₈″ 86¹⁵⁄₁₆″ 92¹⁄₈″ 97³⁄₁₆″ 102¹⁄₄″ 107⁷⁄₁₆″ 112¹⁄₂″ 117⁹⁄₁₆″ 122⁵⁄₈″ 127¹¹⁄₁₆″ Length “B” *These dimensions are approximate.
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. Figure 12.
REPAIR PARTS Table 12.1A: Series LC Repair Parts Item No.
REPAIR PARTS Table 12.1B: Series LC Repair Parts (continued) Item No.
REPAIR PARTS Figure 12.
REPAIR PARTS Table 12.2A: Series LCE Repair Parts Item No.
REPAIR PARTS Table 12.2B: Series LCE Repair Parts (continued) Item No.
NOTES NOTES 51
NOTES 52
Series LC/LCE Oil, Gas & Gas/Oil Boilers Water Installation, Operation & Maintenance Manual TO T H E I N S TA L L E R : This manual is the property of the owner and must be affixed near the boiler for future reference. TO T H E O W N E R : This boiler should be inspected annually by a Qualified Service Agency. HI Division of gama ASME PB HEAT, LLC PO BOX 447 • NEW BERLINVILLE, PA 19545-0447 ©2007 LC8043 R8 (3/07-2M) Printed in U.S.A.
