Weil-McLain LGB-4 Bedienungsanleitung

Part Number 550-141-919/0304

LGLG

LGBB

Refer to

LGBLGB

LGB •Installation •

Start-Up •Service •

Parts Manual

for additional informatio

Control Supplement must only be used by a qualified installer/service

technician. Read all instructions before installing. Failure to follow all

instructions in proper order can cause severe personal injury, death or

substantial property damage.

Contents

Installation ....................... 2

Conversion (Natural/Propane) ... 2

Gas piping ......................... 3

Wiring ............................... 4

Operating instructions ..... 6

Verification testing .......... 7

Parts ................................. 8

These terms are used throughout this

manual to bring attention to the presence

of hazards of various risk levels or to

important information concerning the life

of the product.

Gas–fired boiler

Control SupplementControl Supplement

Control Supplement

LGBLGB

LGB-4-4

-4-4

-4 &LGBLGB

LGBLGB

LGB-5-5

-5-5

-5 Series 2 – Propane gas

Universal Control System

Indicates presence of hazards that can cause severe personal injury, death or

substantial property damage.

Indicates special instructions on installation, operation or maintenance that

are important but not related to personal injury or property.

LGBLGB

LGB-4-4

-4-4

-4 &55

•

Control Supplement

•

UCS

•

Propane

2Part Number 550-141-919/0304

1. Remove all burners from base box assembly. Remove 3.95 mm natural gas main burner orifices in manifold.

Install 2.40 mm propane main burner orifices. Use pipe dope sparingly only on male ends. Use pipe dope

compatible with propane gases. Do not overtighten orifices.

2. Install pilot burners. See Figure 1. Follow Table 1 for electronic pilot burner and standing pilot burner (Q327)

locations on manifold.

3. Install gas controls and ignition control as shown in Figure 3 on page 7 or Figure 4 on page 8. Use Propane

Control Carton, Number 4 and 5.

4. Attach pilot switch box to interior jacket panel (see Figure 3 or 4, pages 7 and 8). Connect thermocouple from

standing pilot to switch box. Cut 60" pilot tubing into 2 pieces to make connections from pilot valve to pilot

switch box and from pilot switch box to standing pilot.

5. Attach:

a. 550-223-710 label above or to the left of boiler operating instruction label. Place so that this label reads

first.

b. 550-223-796 label next to rating label.

c. Wiring diagram on door.

d. Canada only - mount rating plate on interior jacket panel.

6. Proceed to section III, Gas Piping.

1. These instructions are for use with Propane Control Carton Number 4 and 5.

2. Remove jacket door(s) and access panel.

3. Disconnect wiring and tubing from existing pilot burner.

4. Remove all burners. Remove 3.95 mm natural gas main burner orifices in manifold. Install 2.40 mm propane

main burner orifices. Use pipe dope sparingly only on male ends. Use pipe dope compatible with propane

gases. Do not overtighten orifices.

5. Remove and discard existing electronic pilot burner from pilot burner tube. Replace with electronic pilot

burner in carton.

6. Attach Q327 standing pilot to burner tube in kit. Connect pilot tubing and thermocouple to pilot.

7. Re-install burners. See Table 1 for location of pilot burners.

8. Attach pilot switch box to jacket. See Figure 3 or 4, pages 7 and 8. Connect thermocouple to pilot switch box.

Cut 60" pilot tubing into 2 pieces to make connections from tee in pilot line to pilot switch box and from pilot

switch box to standing pilot.

9. Remove natural gas valve train.

10. Install propane gas valve train and fittings from carton. (See paragraph 4, page 3 of this Supplement.)

11. Re-install access panel(s).

12. See Figure 3 or 4, pages 7 and 8, for propane piping.

13. Wire per wiring diagram, pages 4 – 5. Add splices as needed.

Attach:

a. 550-223-710 label above or to the left of boiler operating instruction label. Place so that this label reads

first.

b. 550-223-796 label next to rating label.

c. Wiring diagram over diagram on door (one on each base).

14. To place in operation,follow instructions on constant burner pilot light-up label and boiler operating label.

15. Replace jacket doors.

INew installation Conversion from natural gas to propane gas

II Existing installation Conversion from natural gas to propane gas

This conversion is to be installed by a Weil-McLain distributor or other qualified agency in

accordance with the manufacturer's instructions and all codes and requirements of the

authority having jurisdiction. Failure to follow instructions could result in serious injury or

property damage. The qualified agency performing this work assumes responsibility for this

conversion.

For your safety, turn off electrical power supply before making any electrical connections to

avoid possible electrical shock hazard.

LGBLGB

LGB-4-4

-4-4

-4 &55

•

Control Supplement

•

UCS

•

Propane

Part Number 550-141-919/0304

Figure 1

Pilot burner

assembly

Table 1

Pilot and

flame sensor

locations

1. Contact gas supplier to size pipes, tanks and regulator.

a. Inlet gas pressure to manual main shut-off gas valve minimum 11" W.C., maximum

13" W.C.

b. If pressure to gas valve exceeds 13" W.C., install 100% lock-up gas pressure regulator

upstream of hand valve.

2. Remove knockout disc from jacket panel side to which gas supply will be piped.

3. Follow good piping practices.

4. Pipe joint compound (pipe dope) must be resistant to corrosive action of liquefied petroleum

gases. Apply sparingly only to male threads of pipe joints.

5. Install drip leg at inlet of gas connection to boiler. Where local code/utility requires, extend

drip leg to floor.

6. Install ground joint union when required for servicing.

7. Support piping by hangers, not by boiler or its accessories.

8. Purge all air from supply piping.

9. Before operating boiler, check boiler and its gas connections for leaks.

Boiler

model

Electronic

pilot

burner *

Standing

pilot

burner *

Propane

carton

LGB-4 4 2 4 and 5

LGB-5 5 2 4 and 5

* Burner position, counting from left to right

III Gas piping

Do not check for gas leaks with an open flame - use bubble test. Failure to

use bubble test or check for leaks can cause severe personal injury, death or

substantial property damage.

a. Close manual main shut-off valve during any pressure testing greater than 13" W.C.

b. Disconnect boiler and gas valve from gas supply piping during any pressure test

greater than 13" W.C.

10. In Canada - manual main shut-off valve must be identified by installer.

LGBLGB

LGB-4-4

-4-4

-4 &55

•

Control Supplement

•

UCS

•

Propane

4Part Number 550-141-919/0304

IV Wiring

LGBLGB

LGB-4-4

-4-4

-4 &55

•

Control Supplement

•

UCS

•

Propane

Part Number 550-141-919/0304

All wiring must be installed according to requirements

of the National Electrical Code and any national, state

or local code requirements having jurisdiction. All

wiring external to boiler jacket must be N.E.C. Class 1.

The boiler must be electrically grounded according to

the National Electrical Code, ANSI/NFPA No. 70 latest

edition. Use 105oC thermoplastic wire, or equivalent, if

any original wire must be replaced. GND (burner)

lead wires must be 125oC wire.

Canadian installations must conform to CSA C22.1

Canadian Electrical Code Part 1 and any local or

provincial codes.

Wiring to boiler must be No. 14 gauge or heavier.

Install in conduit.

A separate electrical circuit with a fused disconnect

switch (15 amp. recommended) should be used for the

boiler.

• Determine right or left electrical supply wiring.

• Attach electrical junction box to inside jacket end

panel. Screws and nuts are provided.

• Attach control transformer to junction box.

• Complete wiring per wiring diagram, Figure 2,

pages 4 and 5.

• Install ignition control ground connection as

shown in Figure 1 and wiring diagram, Figure 2.

• In Canada — attach chain between junction box

and transformer with S-hooks.

Wiring

procedure

Wiring

requirements

a. Pilot gas valve opens (provided Pilot Switch

Box is satisfied of flame on standing pilot).

b. Pilot ignition spark begins.

c. Pilot ignites.

d. Pilot proves.

e. Main gas valve opens.

f. Main burners ignite.

3. Boiler shuts down when operating control satisfied.

Figure 2 Wiring diagram For your safety, turn off power supply before making

electrical connections to avoid possible electrical shock

hazard.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and

dangerous operation resulting in servere personal

injury, death or substantial property damage.

On failure to sense pilot flame, Ignition Control will

wait 5 minutes then retry for ignition. On failure of the

thermocouple to sense flame at the standing pilot, the

Pilot Switch Box will open the circuit, preventing

operation of the boiler and requiring the pilot to be

manually ignited before restarting.

"Hot" side of line voltage to boiler must be wired

directly to limit circuit, then fed to transformer

primary.

Sequence of

operation

1. Operating control begins start-up sequence.

a. Limit control contacts are closed.

2. Ignition control module energized.

LGBLGB

LGB-4-4

-4-4

-4 &55

•

Control Supplement

•

UCS

•

Propane

6Part Number 550-141-919/0304

A. This boiler is equipped with a pilot which must be lighted by hand. When lighting the

pilot, follow these instructions exactly. The gas supply to this pilot is controlled by the

Pilot Switch Box. This boiler is also equipped with an ignition device which automatically

lights a second pilot. The gas supply to this pilot is controlled by the Gas Control. Do not

try to light this pilot by hand.

B. BEFORE LIGHTING THE MANUAL PILOT, smell all around the appliance area for

gas. Be sure to smell next to the floor because some gas is heavier than air and will settle

on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor's phone. Follow the gas

supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to turn the gas control knob. Never use tools. If the knob will not

turn by hand, don't try to repair it, call a qualified service technician. Force or attempted

repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified

service technician to inspect the appliance and to replace any part of the control system

and any gas control, which has been under water.

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electrical power to the appliance.

4. Remove the Base Access Shield.

5. Close Pilot Shutoff Valve connected to Gas Hand Valve. Close Gas Hand

Valve.

6. Wait five (5) minutes to clear out any gas. Then smell for gas, including

near the floor. If you smell gas, STOP! Follow "B" in the safety

information above. If you don't smell gas, go to the next step.

7. Open Pilot Shutoff Valve.

8. Press and hold the reset lever on the Pilot Switch Box. Manually light

the pilot while holding the lever down. Air in the gas supply line will

have to purge through the line before sufficient gas will reach the pilot.

9. After purging all air, hold the Pilot Switch Box lever for about 1 minute

to heat the thermocouple.

10. Release the Pilot Switch Box lever. The pilot should remain lit.

11. Open the Gas Hand Valve and follow the sequence below.

12. This appliance is also equipped with an ignition device which

automatically lights the second pilot. Do not try to light this pilot by

hand.

13. Turn Gas Control knob clockwise to "OFF".

14. Wait five (5) minutes to clear out any gas. Then smell for gas, including

near the floor. If you smell gas, STOP! Follow "B" in the safety

information above on this label. If you don't smell gas, go to the next

step.

15. Turn Gas Control knob counterclockwise to "ON".

16. Turn on all electric power to the appliance.

17. Set thermostat to desired setting.

18. If the appliance will not operate, turn off gas to the boiler by closing the Gas Hand Valve and Pilot Shutoff

Valv e. Rotate the Gas Control knob clockwise to “OFF”. Call your service technician or gas supplier.

19. Replace Base Access Shield and Front Panel.

Starting

boiler

IV Operating instructions

LGBLGB

LGB-4-4

-4-4

-4 &55

•

Control Supplement

•

UCS

•

Propane

Part Number 550-141-919/0304

VVerification testing

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.

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.

Leak test automatic

gas valve

1. Close manual test firing valve.

2. Open the service valve. Press down and turn automatic gas valve knob (or lever) to

ON.

3. Install a hose barb into a pressure tap downstream of the 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. Remove the manometer and plug any open pressure taps.

5. Follow Operating Instructions to place boiler in service.

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 valve. Use a

voltmeter to verify voltage to automatic valve.

4. With no gas flow to the manifold, the boiler ignition controls should turn off the

automatic gas valve after main flame ignition trial. Use a voltmeter to verify voltage to

automatic valve is turned off.

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 automatic gas valve. 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 valve. Follow the procedures below.

LGBLGB

LGB-4-4

-4-4

-4 &55

•

Control Supplement

•

UCS

•

Propane

8Part Number 550-141-919/0304

Weil-McLain

500 Blaine Street

Michigan City, IN 46360-2388

http://www.weil-mclain.com

Figure 3

Control and gas

components

VI Parts list

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