Instruction/ maintenance manual of the product Gas/Oil Boilers PB Heat
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LC/LCE Gas/Oil Boilers – W ater Series Oil, Gas & Installation, Operation & Maintenance Manual.
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 . .
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.
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.
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.
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) 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.
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.
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.
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.
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 LC.
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.
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.
12 PLA CE THE BOILER Figure 2.4: Install Additional Sections. Use level on each section as tie rod bolts are drawn up..
13 PLA CE THE BOILER Figure 2.5: Series LC Boiler Assembly – Right Side View.
14 PLA CE THE BOILER Figure 2.6: Series LCE Boiler Assembly – Right Side View.
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.
16 Figure 2.9: LC/LCE Boiler Section Assembly Sequence PLA CE THE BOILER.
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.
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.
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.
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.
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.
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.
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.
24 Figure 3.6: Piping for V ariable Low T emperature Systems, Single Boiler PIPE THE BOILER.
25 Figure 3.7: Multiple Boiler Piping , System Return T emperature Above 130°F on Gas, 150°F on Oil PIPE THE BOILER.
26 Figure 3.8: Piping for V ariable Low T emperature Systems, Multiple Boilers PIPE THE BOILER.
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.
28 ASSEMBLE THE JA CKET Figure 4.2: Jacket Assembly.
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.
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 LC.
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.
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.
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.
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.
35 INST ALL CONTROLS AND TRIM Figure 8.2: Control and Pipe T apping Locations.
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.
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.
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.
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.
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.
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.
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.
43 BOILER RA TINGS & DIMENSIONS Figure 11.2: Series LC Dimensional Diagram Figure 11.3: Series LCE Dimensional Diagram.
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.
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.
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" .
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 Jac.
48 REP AIR P ARTS Figure 12.2: Series LCE Boiler Assembly.
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 Interme.
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.
51 NOTES NOTES.
52 NOTES.
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.
An important point after buying a device PB Heat Gas/Oil Boilers (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought PB Heat Gas/Oil Boilers yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data PB Heat Gas/Oil Boilers - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, PB Heat Gas/Oil Boilers you will learn all the available features of the product, as well as information on its operation. The information that you get PB Heat Gas/Oil Boilers will certainly help you make a decision on the purchase.
If you already are a holder of PB Heat Gas/Oil Boilers, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime PB Heat Gas/Oil Boilers.
However, one of the most important roles played by the user manual is to help in solving problems with PB Heat Gas/Oil Boilers. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device PB Heat Gas/Oil Boilers along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
