Weil-McLain LGB-4 User manual

Part Number 550-141-919/0304
LGLG
LGLG
LGBB
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B
Refer to
LGBLGB
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 SupplementControl Supplement
Control Supplement
LGBLGB
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
LGBLGB
LGB-4-4
-4-4
-4 &55
55
5
• 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
LGBLGB
LGB-4-4
-4-4
-4 &55
55
5
• Control Supplement • UCS • Propane
3
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
LGBLGB
LGB-4-4
-4-4
-4 &55
55
5
• Control Supplement • UCS • Propane
4Part Number 550-141-919/0304
IV Wiring

LGBLGB
LGBLGB
LGB-4-4
-4-4
-4 &55
55
5
• Control Supplement • UCS • Propane
5
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
LGBLGB
LGB-4-4
-4-4
-4 &55
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• 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
LGBLGB
LGB-4-4
-4-4
-4 &55
55
5
• Control Supplement • UCS • Propane
7
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
LGBLGB
LGB-4-4
-4-4
-4 &55
55
5
• 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