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PB Heat Gas/Oil Boilers manual

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Table of contents for the manual

  • Page 1

    LC/LCE Gas/Oil Boilers – W ater Series Oil, Gas & Installation, Operation & Maintenance Manual[...]

  • Page 2

    USING THIS MANUAL 1 A . INSTRUCTION MANUALS . . . . . . . . . . . . . . .1 B . SPECIAL A TTENTION BOXES . . . . . . . . . . . .1 1. PREINST ALLA TION 2 A . ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 B . CLEARANCE FROM COMBUSTIBLE CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . .3 C. COMBUSTION AND VENTILA TION AIR . . . .3 D . CHIMNEY O[...]

  • Page 3

    1 A. INSTRUCTION MANUALS The Series LC/LCE Installation, Operation & Maintenance Manual is divided into four basic sections: 1. Pr einstallation (Section 1) 2. Installation (Sections 2 through 8) 3. Star t-Up (Section 9) 4. Maintenance (Section 10) B. SPECIAL A TTENTION BO XES Throughout this manual you will see special attention bo xes intende[...]

  • Page 4

    A. ACCESSIBILITY CLEARANCES 1. Clearances for ser vice and from combustible surfaces are the same for the LCE as for the LC. The following recommendations allow for r easonable access to the boiler . F ollow local codes and requir ements when setting actual layout. See Figur e 1.1. a) F or installing, r emoving and ser vicing the burner: provide 48[...]

  • Page 5

    B. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION Provide the following minimum clearances to combustible construction . See Figur e 1.1. 1. Sides: 6" 2. Rear of Jacket: 6" 3. F ront of Jacket: 24" 4. T op of Jacket: 24" 5. Hot W ater P ipes: 6" 6. V ent or Chimney Connector: 18" C. COMBUSTION AND VENTILA TION AIR 1. The inst[...]

  • Page 6

    4 8. Exterior V ents: a) Insulate sufficiently to ensure adequate draft and to prevent vent damage due to condensation. 9. V ent Connection to Boiler: a) Suppor t 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 prov[...]

  • Page 7

    b) If the foundation must be a concr ete slab, use an air cell high temperature insulating board, at least 1/2 inch thick, with aluminum backing, aluminum side up. 1/2 inch thick high temperature millboard with aluminum backing is acceptable as well. Place the insulating board on the slab between the steel channels. F . INST ALLA TION SURVEY F or n[...]

  • Page 8

    6 PREINST ALLA TION T able 1.2A: Series LC Shipping List Channel Rail Bundle F ront Back Plain Interm. 1" L WCO Interm. 3" T ap. Interm. Baffle Carton Contents See Below Item 1 Contents See Below Item 2 F ront/Rear P anels Hardware T op/Side P anels Hardware Chamber Liner Standard Sections (See T able 1.3 for Options) Assembly Kit Ctns. J[...]

  • Page 9

    7 PREINST ALLA TION T able 1.2B: Series LCE Shipping List Channel Rail Bundle F ront To p Flue Interm. 1" L WCO Interm. 3" T ap. Interm. Plain Interm. Back Baffle Carton Flow P ort Gaskets, Silicone Sealant, Tie Rods, W ashers, Tie Rod Nuts, Section Seal Rope, Spray Adhesive, Cleanout Plates, Mounting Hardware Contents See Below Item 1 Fr[...]

  • Page 10

    P ar t #/UPC P ar t #/UPC P ar t #/UPC P ar t #/UPC P ar t #/UPC P ar t #/UPC P ar t #/UPC 8 PREINST ALLA TION Note: 80 psig MA WP not available in Canada. Note: Boilers with inspection tappings in front and back sections only use standard cartons. T able 1.5: Standard and Optional Jack et Cartons, T op/Side Panels F ront Plain Interm. T op Flue In[...]

  • Page 11

    9 PREINST ALLA TION T able 1.8: Control Cartons T able 1.7: T rim Cartons 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 Model 87030 87030 87030 87030 87031 87031 87032 87032 87032 87032 87032 87033 87033 87033 87033 87033 87034 87034 87034 87034 87034[...]

  • Page 12

    A. P ACK A GED BOILER 1. Remove crate top and sides. Remove any loose car tons. Remove burner suppor t 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 suppor t pedestal and nipple if necessary . 5. Proceed to Chapt[...]

  • Page 13

    5. Clean the area around the flow ports and in the seal recess. Use solvent and a clean cloth to thoroughly clean all of the sealing surfaces. Remove all foreign matter to assure a water tight seal when the sections are drawn together . 6. Place a Flow P ort Gasket in each of the three flow por t r ecesses as shown in Figur es 2.1 and 2.2. 7. Apply[...]

  • Page 14

    12 PLA CE THE BOILER Figure 2.4: Install Additional Sections. Use level on each section as tie rod bolts are drawn up.[...]

  • Page 15

    13 PLA CE THE BOILER Figure 2.5: Series LC Boiler Assembly – Right Side View[...]

  • Page 16

    14 PLA CE THE BOILER Figure 2.6: Series LCE Boiler Assembly – Right Side View[...]

  • Page 17

    16. T o 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 r equir ed. a. Use a spirit level as shown in F igur e 2.4 to check the alignment of the sections as the nuts are drawn up. Keep the sections plumb. b. Draw the sections to[...]

  • Page 18

    16 Figure 2.9: LC/LCE Boiler Section Assembly Sequence PLA CE THE BOILER[...]

  • Page 19

    D . INST ALL COILS OR PLA TES 1. Remove the coil cover plates, gaskets and mounting hardware, located in the Flue Bo x Car ton. 2. Install tankless heaters, if used, in openings #1 and #2. See Figur e 2.10 and T able 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 [...]

  • Page 20

    F . APPL Y CLEANOUT CO VER PLA TES 1. Apply the Cleanout Cover Plates on the tops of the section joints as shown in Figur e 2.11. 2. Pr e-assemble a steel flat washer and steel nut on the carriage bolts. Place a car riage bolt into each side of the cleanout opening as shown in the figure. 3. Tighten the lower nut secur ely . 4. Pr ess the Cleanout [...]

  • Page 21

    H. INST ALL FLUE BAFFLES 1. Remove the F ront Cleanout Plate from Front Section. 2. Open Baffles car ton. Remove Baffles. F or LC Only – Save Ceramic Fiber Liner for Section I. Save Rating Label for Chapter 4. Models LCE-13 through LCE- 20 do not requir e baffles. 3. Place baffles as shown in Figur e 2.14. Thr ee of these are special stainless st[...]

  • Page 22

    A. PREP ARA TION 1. Make sure the boiler has been pr essur e tested as outlined in “Place the Boiler Sections” in this manual. 2. The Supply and Return piping can be installed before installing the jacket. Use nipples long enough to e xtend through the jacket. 3. Install a pipe plug or nipple and cap in the 3” tapping in the top of the tapped[...]

  • Page 23

    21 Figure 3.2: LC/LCE Boiler Piping PIPE THE BOILER T able 3.1: Boiler Supply and Return Connections & Recommended Header Sizing 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 Model 547 649 707 868 1029 1189 1350 1511 1672 1832 1966 2125 2284 2444 [...]

  • Page 24

    b) T emporary low temperature operation is acceptable within limits. F or occasional cold star t- ups 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 star t-ups will occur often. These systems r equire a V a[...]

  • Page 25

    control valve and boiler circuit pump piped off of the system as a secondary loop. See Figure 3.6 for a single boiler and Figur e 3.7 for multiple boilers. D . CHILLED W A TER 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 p[...]

  • Page 26

    24 Figure 3.6: Piping for V ariable Low T emperature Systems, Single Boiler PIPE THE BOILER[...]

  • Page 27

    25 Figure 3.7: Multiple Boiler Piping , System Return T emperature Above 130°F on Gas, 150°F on Oil PIPE THE BOILER[...]

  • Page 28

    26 Figure 3.8: Piping for V ariable Low T emperature Systems, Multiple Boilers PIPE THE BOILER[...]

  • Page 29

    A. PREP ARE THE P ARTS 1. Collect all the jacket car tons: Jack et F ront & Back Carton plus Jacket Side & T op Cartons . See the Shipping List in the front of this manual for the jacket car tons r equired. The cartons contain the jacket par ts and scr ews. The jacket panels are pr e- insulated. 2. Remove all needed knockouts from the jacke[...]

  • Page 30

    28 ASSEMBLE THE JA CKET Figure 4.2: Jacket Assembly[...]

  • Page 31

    29 VENTING 5. VENTING Refer to Chapter 1, P r einstallation , Section D. Chimney or V ent for installation requir ements. Refer to Chapter 9, Star ting the Boiler, Section C. Run Burner Check Out for damper settings and draft requir ements. 6. INST ALL THE BURNER A. BURNER APPLICA TION 1. Refer to Burner Spec and Data Sheets for the Oil and Gas/Oil[...]

  • Page 32

    30 INST ALL THE BURNER Figure 6.1: Combustion Chamber Layout – See T able 6.1 for Dimensions T able 6.1: Combustion Chamber Dimensions 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 Model Chamber Length “A” (Inches) Burner Front Plate Extension P[...]

  • Page 33

    A. GENERAL 1. Read the Burner Instruction Manual, supplied with the boiler or with the burner if purchased separately . Review applicable code requir ements for burner and fuel piping installations. 2. Install piping to allow removal of burner and access to combustion chamber for cleaning or ser vice. B. INST ALL FUEL OIL PIPING 1. Place the fuel o[...]

  • Page 34

    32 CONNECT FUEL PIPING T able 7.1: Capacity of Gas Supply P ipe in Cubic Feet P er Hour of Natural Gas for Pressure Drop of 0.3 inch W ater Column. 10 20 30 40 50 60 70 90 100 150 1050 730 590 500 440 400 350 320 305 250 1600 1100 890 760 670 610 560 490 460 380 3050 2100 1650 1450 1270 1150 1050 930 870 710 4800 3300 2700 2300 2000 1850 1700 1500 [...]

  • Page 35

    A. INST ALL SAFETY RELIEF V AL VE 1. Pipe the Safety Relief V alve 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 r equir ements. See Figur e 8.1. B. INST ALL DRAIN V AL VE 1. Install a 3/4" drain valve in the lower center tapping in the Rear Section. See Figur e 8.[...]

  • Page 36

    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 (P osition 2). If a coil is installed there, mount the well in the 3/4" tapping to the left of the opening. See Figur e 8.2. E. PIPE T ANKLESS HEA TERS IF USED 1. Connect piping to [...]

  • Page 37

    35 INST ALL CONTROLS AND TRIM Figure 8.2: Control and Pipe T apping Locations[...]

  • Page 38

    36 INST ALL CONTROLS AND TRIM Figure 8.4: Suggested Piping – Dual T ankless Coil Installation Figure 8.3: Suggested Piping – Single T ankless Coil Installation[...]

  • Page 39

    A. CHECK THE PIPING 1. W ater Piping a) The Boiler must have been hydrostatically tested. b) Check the attached piping for joint tightness. c) Continue monitoring as you proceed through star t up. 2. Gas Piping a) Make sure the gas system piping and the connections to the boiler Gas Control T rain(s) have been leak tested. b) After the boiler is in[...]

  • Page 40

    4. Adjust the burner as needed for a CO 2 reading of: a) Oil bur ners: CO 2 approximately 12.5% or 1% less than the level at which the smoke reading goes above a trace on the Bacharach scale. b) Gas burners: 9% to 10% with CO less than 50 ppm. c) Inspect all flue gas joints (sections, attachments, breeching and vent) for gas tightness. Remove the j[...]

  • Page 41

    39 MAINTENANCE 10. MAINTENANCE W ARNING Product Saf ety Inf ormation Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fiber s (RCF). Airborne RCF , when inhaled, have been c lassified by the International Agency f or Research on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials[...]

  • Page 42

    40 A. PLACING BOILER IN OPERA TION 1. Star t up the Burner/Boiler per the Bur ner Manual and the instructions in this manual on star ting the boiler . 2. Prove the correct operation of all controls on the boiler and burner as outlined below . 3. Check the operation of the ignition and flame proving controls as described in the Burner Manual. 4. T e[...]

  • Page 43

    41 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. T ake care not to damage the chamber floor liner or target wall liner . e) Replace the F ront Cleanout Plate, Bur ner Mounting Plate, Burner and all Cleanout Cover Plates on top of the section[...]

  • Page 44

    42 BOILER RA TINGS & DIMENSIONS 11. BOILER RA TINGS & DIMENSIONS T able 11.1: Series LC/LCE Boiler Ratings 1 Burner input based on No. 2 fuel oil with a heating value of 140,000 Btu per gallon. 2 Net I=B=R water ratings based on an allowance of 1.15. 3 Net I=B=R steam ratings based on an allowance for LC-04 to LC-08=1.333, LC-09=1.323, LC-1[...]

  • Page 45

    43 BOILER RA TINGS & DIMENSIONS Figure 11.2: Series LC Dimensional Diagram Figure 11.3: Series LCE Dimensional Diagram[...]

  • Page 46

    44 BOILER RA TINGS & DIMENSIONS T able 11.2: Series LC/LCE Boiler Dimensions Width “A” Length “B ” Height “C” Number Size Recom. Header Number Size Recom. Header Ends “G” “ G1” “G2” Burner Center Line “D ” “E” Diameter Minimum Height SERIES LC/LCE BOILER DIMENSIONS Jacket Supply Piping Return Piping Riser T appin[...]

  • Page 47

    45 REP AIR P ARTS 12. REP AIR P ARTS Figure 12.1: Series LC Boiler Assembly Repair par ts are available from your installer or by contacting PB Heat, LLC, New Berlinville, P A. Use the Figur es and T ables on pages 45-50 to assist in ordering par ts. Note: Remember to include boiler model number and serial number when ordering par ts.[...]

  • Page 48

    46 REP AIR P ARTS T able 12.1A: Series LC Repair Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 F ront Section Intermediate Section w/1" T apping Intermediate Section Back Section T apped Intermediate Section Upper Flow P or t Gasket Lower Flow P or t Gasket Tie Rod 5/8" Diameter H[...]

  • Page 49

    47 REP AIR P ARTS T able 12.1B: Series LC Repair P arts (continued) 38 39 T op Jacket P anel LC-6004 T op Jacket P anel LC6004-1 T op Jacket P anel LC-6004-2 T op Jacket P anel LC-6004-3 Rear T op Jacket P anel LC-6006 Single Rib Flue Baffle, Aluminized Steel LC-1018 T riple Rib Flue Baffle, Aluminized Steel LC-1019 Single Rib Flue Baffle, Stainles[...]

  • Page 50

    48 REP AIR P ARTS Figure 12.2: Series LCE Boiler Assembly[...]

  • Page 51

    49 REP AIR P ARTS T able 12.2A: Series LCE Repair Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 F ront Section T op Flue Outlet Intermediate Section Intermediate Section w/1" T apping Intermediate Section Back Section (Closed Back) Back Section w/T ankless Coil Opening T apped In[...]

  • Page 52

    50 REP AIR P ARTS T able 12.2B: Series LCE Repair P arts (continued) 38 40 39 41 42 43 44 T op Jacket P anel LC-6004-2 T op Jacket P anel with Flue Opening LC-6022 Rear T op Jacket P anel LC-6006 T op Flue Outlet Plate (14" Flue) T op Flue Outlet Plate (16" Flue) 5/8" Diameter High T emperature Rope 3/8" Diameter Tie Down Assemb[...]

  • Page 53

    51 NOTES NOTES[...]

  • Page 54

    52 NOTES[...]

  • Page 55

    LC/LCE Gas/Oil Boilers W ater Series Oil, Gas & Installation, Operation & Maintenance Manual TO THE INST ALLER: This manual is the property of the owner and must be affixed near the boiler for future reference. TO THE OWNER: This boiler should be inspected annually by a Qualified Service Agency. LC8043 R8 (3/07-2M) Printed in U .S.A. ©2007[...]