Well-mcLain LGB 3 Series User manual

LGB
Series 3
Commercial Gas-Fired
Steam and Water Boilers
Manual Part Number 550-100-206/0123
!
WARNING
Installation and service of the boiler must be performed by a qualied installer or service technician.
Read all instructions, including this manual and all other information shipped with the boiler, before
installation or operation. Perform steps in the order given. Failure to comply could result in severe
personal injury, death or substantial property damage.
Boiler Manual

2550-100-206/0123
  3 
Contents
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Abbreviations . . . . . . . . . . . . . . . . . . . . . . 4
- 
Safety Signals . . . . . . . . . . . . . . . . . . . . . . 5
Please Read Before Proceeding . . . . . . . . . . . . 5
Servicing a Boiler. . . . . . . . . . . . . . . . . . . . . . . .5
Boiler Operation . . . . . . . . . . . . . . . . . . . . . . . .6
Boiler Water . . . . . . . . . . . . . . . . . . . . . . . . . .6
Commonwealth of Massachusetts . . . . . . . . . . . . . . .6
Freeze Protection Fluids . . . . . . . . . . . . . . . . . . . .6
Damage from Water Contact . . . . . . . . . . . . . . . . . .6
Frozen Water Damage . . . . . . . . . . . . . . . . . . . . .6
- 
Prepare Boiler Location. . . . . . . . . . . . . . . . . 7
Installation Compliance Requirements . . . . . . . . . . . . . 7
Checks Before Boiler Installation. . . . . . . . . . . . . . . .7
Flooring and Foundation . . . . . . . . . . . . . . . . . . . .8
Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Boiler Assembly . . . . . . . . . . . . . . . . . . . . 10
Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . 10
Single Base Boilers. . . . . . . . . . . . . . . . . . . . . . 10
Dual Base Assembly . . . . . . . . . . . . . . . . . . . . .10
Base Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . 12
Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydrostatic Pressure Test . . . . . . . . . . . . . . . . . . 16
Flue Collector Hood Installation . . . . . . . . . . . . . . . 17
Inducer Assembly. . . . . . . . . . . . . . . . . . . . . . . 19
Jacket Installation Guidelines . . . . . . . . . . . . . . . . 20
Single Base Jacket Installation (Models 4R-12) . . . . . . .20
Dual Base Jacket Installation (Models 14-20) . . . . . . . . 22
Pilot and Main Flame Sensor Installation. . . . . . . . . . . 24
Gas Train Installation for Single Bases . . . . . . . . . . . . 26
Gas Train Installation for Dual Bases. . . . . . . . . . . . . 26
Control Installation . . . . . . . . . . . . . . . . . . . . . .27
Boiler Conversion . . . . . . . . . . . . . . . . . . . 30
Gas Orice and Pressure Switch Conversion . . . . . . . . 30
Water Boiler Piping . . . . . . . . . . . . . . . . . . 31
Water Piping Installation . . . . . . . . . . . . . . . . . . .31
General Piping Information . . . . . . . . . . . . . . . . . . 32
Relief Valve Installation. . . . . . . . . . . . . . . . . . . . 33
Primary/Secondary Piping . . . . . . . . . . . . . . . . . .34
Refrigeration System Piping . . . . . . . . . . . . . . . . .34
Steam Boiler Piping . . . . . . . . . . . . . . . . . . 35
Steam Piping Installation . . . . . . . . . . . . . . . . . . . 35
Condensate Return. . . . . . . . . . . . . . . . . . . . . . 36
Piping Multiple Steam Boilers . . . . . . . . . . . . . . . . 37
Commonwealth of Massachusetts Installations. . . . . 38
Venting and Combustion Air - General. . . . . . . . 39
Code Compliance . . . . . . . . . . . . . . . . . . . . . . 39
Venting System Category . . . . . . . . . . . . . . . . . . 39
Combustion Air Provision. . . . . . . . . . . . . . . . . . . 39
Combustion Air Contamination . . . . . . . . . . . . . . . . 39
Sizing Combustion Air Openings . . . . . . . . . . . . . . . 40
Special Considerations . . . . . . . . . . . . . . . . . . . . 40
Existing Vent System . . . . . . . . . . . . . . . . . . . . . 42
Existing Vent System Test Procedure . . . . . . . . . . . . 42
Steam Boiler Venting - Category I . . . . . . . . . . 43
Chimney Draft Venting . . . . . . . . . . . . . . . . . . . .43
Condensate Drain Plug Installation. . . . . . . . . . . . . . 44
Water Boiler Venting - Category II . . . . . . . . . . 46
Category II Requirements . . . . . . . . . . . . . . . . . . 46
Using a Chimney . . . . . . . . . . . . . . . . . . . . . . .46
Condensate Drain Trap Construction. . . . . . . . . . . . . 49
Install Boiler Controls. . . . . . . . . . . . . . . . . . . . . . . 50
General Boiler Controls. . . . . . . . . . . . . . . . . . . . 50
Water Boiler Controls. . . . . . . . . . . . . . . . . . . . . 50
Steam Boiler Controls . . . . . . . . . . . . . . . . . . . . 50
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . 52
Gas Supply Piping Connection . . . . . . . . . . . . . . . . 52
Check Natural Gas Supply Pressure . . . . . . . . . . . . . 52
Gas Train Diagram . . . . . . . . . . . . . . . . . . . . . .53
Pipe Sizing for Natural Gas. . . . . . . . . . . . . . . . . . 54
Multiple Boiler Applications - Manifolded Gas Supply Lines . . . . . 54
Gas Pressure Switches (CSD-1 only) . . . . . . . . . . . . 54
- 
Electrical - General . . . . . . . . . . . . . . . . . . 55
Power Requirements . . . . . . . . . . . . . . . . . . . . . 56
Power Supply Connections. . . . . . . . . . . . . . . . . . 56
Field Wiring . . . . . . . . . . . . . . . . . . . . . . 57
LGB 4R, 4-12 - Single Base Schematic and Ladder Diagrams. . 58
LGB 14-20 - Dual Base Schematic and Ladder Diagrams . . 60
A. Power Supply — REQUIRED . . . . . . . . . . . . . . . 62
B. Circulator / Powered Outlet . . . . . . . . . . . . . . . .62
C. MODBUS and Shield. . . . . . . . . . . . . . . . . . . . . .62
D. Forced High Fire . . . . . . . . . . . . . . . . . . . . . . . .62
E. Enable/Disable (CH TT Input) . . . . . . . . . . . . . . . . .63
F. Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . .63
G. Spare Analog Input . . . . . . . . . . . . . . . . . . . . . . .63
H. Manual and Auto Limits . . . . . . . . . . . . . . . . . . . . . . . 63

3550-100-206/0123
 3  
- 
Control Operation . . . . . . . . . . . . . . . . . . . 65
User Interface . . . . . . . . . . . . . . . . . . . . . . . . 65
Display and Keypad . . . . . . . . . . . . . . . . . . . . . 65
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . 66
User Menu . . . . . . . . . . . . . . . . . . . . . . . . . .67
Advanced Menu . . . . . . . . . . . . . . . . . . . . . . . 67
Display Screens . . . . . . . . . . . . . . . . . . . . . . . 68
Control Settings . . . . . . . . . . . . . . . . . . . . . . . 69
Sequence of Operations . . . . . . . . . . . . . . . . . . .70
Ignition Process for Single Bases . . . . . . . . . . . . . . 70
Ignition Process for Dual Bases (LGB 14-20) . . . . . . . . 71
Startup - Fill the System . . . . . . . . . . . . . . . 73
Freeze Protection. . . . . . . . . . . . . . . . . . . . . . . 73
Clean the System. . . . . . . . . . . . . . . . . . . . . . . 73
Antifreeze — Water Boilers. . . . . . . . . . . . . . . . . . 74
Water Chemistry . . . . . . . . . . . . . . . . . . . . . . .74
Fill and Test Water Boilers . . . . . . . . . . . . . . . . . .74
Check Concentrations Annually . . . . . . . . . . . . . . . 74
Recommended Inhibitor . . . . . . . . . . . . . . . . . . . 75
Purge Air from Water Boilers . . . . . . . . . . . . . . . . . 75
Fill and Test Steam Boilers . . . . . . . . . . . . . . . . . . 75
Skimming Procedure for Steam Boilers . . . . . . . . . . . 75
Startup - Final Checks. . . . . . . . . . . . . . . . . 76
Check for Gas Leaks . . . . . . . . . . . . . . . . . . . . . 76
Check Thermostat Circuits . . . . . . . . . . . . . . . . . .76
Inspect the Condensate System — Category II Vent Systems . . 76
Inspect the Pressure Switch Hoses . . . . . . . . . . . . . 78
Final Checks Before Starting the Boiler . . . . . . . . . . . 78
Startup Procedure . . . . . . . . . . . . . . . . . . . 79
Starting the Boiler . . . . . . . . . . . . . . . . . . . . . . 79
Troubleshooting Startup Issues . . . . . . . . . . . . . . . 79
Check Flame and Combustion . . . . . . . . . . . . . . . .79
Gas Valve Adjustment . . . . . . . . . . . . . . . . . . . . 80
Maximum and Minimum Final Check. . . . . . . . . . . . . 81
Check Ignition System Safety Shuto󰀨 Device . . . . . . . . 81
Check the System for Leaks . . . . . . . . . . . . . . . . .81
Gas Valve Leakage Testing . . . . . . . . . . . . . . . . . 82
Verication Check List . . . . . . . . . . . . . . . . . . . . 82
- 
Maintenance - General . . . . . . . . . . . . . . . . 83
Handling Ceramic Fiber Materials . . . . . . . . . . . . . . 83
Perform Startup and Checkout . . . . . . . . . . . . . . . . 83
Annual Inspection . . . . . . . . . . . . . . . . . . . 84
First-Year Special Inspection . . . . . . . . . . . . . . . . . 84
General Information . . . . . . . . . . . . . . . . . . . . . 84
Inspect the Base Insulation. . . . . . . . . . . . . . . . . . 85
Service and Maintenance Schedules. . . . . . . . . . . . . 85
Annual Startup. . . . . . . . . . . . . . . . . . . . . 86
Check Air Openings . . . . . . . . . . . . . . . . . . . . . 86
Flue Vent System. . . . . . . . . . . . . . . . . . . . . . . 86
Check the Water System . . . . . . . . . . . . . . . . . . . 86
Check the Boiler Relief Valve. . . . . . . . . . . . . . . . . 86
Check the Expansion Tank . . . . . . . . . . . . . . . . . . 87
Inspect the Pilot and Main Flame Sensor Assemblies . . . . 87
Inspect and Clean the Burner and Combustion Chamber . .88
Cleaning the Heat Exchanger Block . . . . . . . . . . . . .89
Reinstall All Components . . . . . . . . . . . . . . . . . . . 89
Inspect the Flue Pressure Switch . . . . . . . . . . . . . . 89
Check Boiler Wiring . . . . . . . . . . . . . . . . . . . . . 89
Check Control Settings . . . . . . . . . . . . . . . . . . . . 89
Perform Startup and Checks . . . . . . . . . . . . . . . . .90
Check Main Burner and Pilot Burner Flame . . . . . . . . .90
Check the Flame Signal . . . . . . . . . . . . . . . . . . . 91
High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . 91
Reinstall the Jacket Door After Servicing. . . . . . . . . . . 91
Review with the Owner . . . . . . . . . . . . . . . . . . . . 91
- 
Troubleshooting - General . . . . . . . . . . . . . . 93
Errors and Lockouts . . . . . . . . . . . . . . . . . 93
Control Display . . . . . . . . . . . . . . . . . . . . . . . .93
Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . 93
Fault and Action Items . . . . . . . . . . . . . . . . . . . . 94
- 
Miscellaneous Parts. . . . . . . . . . . . . . . . . . 99
Ordering . . . . . . . . . . . . . . . . . . . . . . . . 99
The LGB Commercial Boiler. . . . . . . . . . . . . . . 100
Replacement Parts . . . . . . . . . . . . . . . . . . 102
Dimensions . . . . . . . . . . . . . . . . . . . . . . 106
- 
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . 107
Derate Information . . . . . . . . . . . . . . . . . . . . . 107
Boiler Ratings. . . . . . . . . . . . . . . . . . . . . . . . 108
Maintenance Log . . . . . . . . . . . . . . . . . . . 109
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Installation and Service Certicate. . . . . . . . . . 111

4550-100-206/0123
  3 
Abbreviation Description
AMP Ampere or Amperage
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
BTUH British Thermal Unit per Hour
CH Central Heat
CO Carbon Monoxide
CO2Carbon Dioxide
CP Consumer Protection
CPVC Chlorinated Polyvinyl Chloride
CSA Canadian Standards Association
CSD-1 Controls and Safety Devices
DHW Domestic Hot Water
LP Liqueed Petroleum (Propane)
LWCO Low Water Cut-O󰀨
MBH Thousands of Btuh
NFPA National Fire and Protection Agency
NG Natural Gas
NIOSH National Institute for Occupational Safety
and Health
NTC Negative Temperature Coe󰀩cient
O2Oxygen
P/T Pressure and Temperature
SCFM Standard Cubic Feet per Minute
ULC Underwriters Laboratories of Canada
VAC Volts Alternating Current
VDC Volts Direct Current
W.C. Water Column

Table 2 Common abbreviations
Tools Needed Purpose
1/16" at blade
screwdriver Wiring on terminal blocks.
Allen wrench -
small
LGB 4R, 4, & 5 gas valve
adjustment.
T40 bit LGB 6-20 gas valve adjustment.
7/16" wrench Gas orice installation.
Collector hood j-hook installation.
1/2" wrench and
socket Collector hood j-hook installation.
5/16" socket Burner access shield screws.
Phillips head
screwdriver Jacket screws.
Pipe wrenches Gas train installation.
9/16" wrench and
socket Base panels.
15/16" wrench and
socket Casting draw rod nuts.
Manometer
(inclined or digital)
Measuring the gas pressure
coming to the boiler.
Torque wrench Casting draw rods.
Collector hood bolts.
Level Casting block assembly.
Collector hood assembly.
Scissors Cutting berglass rope and tape
seals.
Table 1 Common tools needed
Tools

5550-100-206/0123
 3  
1
2
3
4
5
6
7
8
This section is intended to provide safety information.
Section Contents
Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . .5
Please Read Before Proceeding . . . . . . . . . . . . . . . .5

The following dened terms are used throughout this
manual to bring attention to the presence of hazards
or other important information.
DANGER
!
Danger indicates the presence of hazards that
will result in severe personal injury, death, or
substantial property damage.
!
WARNING
Warning indicates the presence of hazards that
can result in severe personal injury, death, or
substantial property damage.
CAUTION
!
Caution indicates the presence of hazards that
will or can result in minor personal injury or
property damage.
NOTICE
Notice indicates additional information that may be
related to property damage, but is not related to
personal injury.
IMPORTANT
Important indicates additional information that is
important, but is not related to personal injury or
property damage.

!
WARNING
Adhere to all following guidelines and
instructions in this section. Failure to adhere to
these guidelines can result in severe personal
injury, death, or substantial property damage.
Installer: Read all instructions, including this manual
and all other information shipped with the boiler,
before installation. Perform steps in the order given.
Consider piping and installation when determining
boiler location.
User: This manual is for use only by a qualied
heating installer or service technician. Refer to the
User Manual for your reference. A qualied service
technician should inspect and service this boiler at
least once per year.
Write the Consumer Protection (CP) number and
serial number in the space provided on the Installation
and Service Certicate on page 111. The CP number
can be found on the boiler jacket.
Please include the boiler model number, CP
number, and serial number when inquiring about the
boiler. The model number can be found on the boiler
rating label.
IMPORTANT
Any claims for damage or shortage in shipment
must be led immediately against the transportation
company by the consignee.
Servicing a Boiler
• To avoid electric shock, disconnect all electrical
supplies to the boiler before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
• This boiler contains ceramic ber and berglass
materials. Refer to the warning and instructions on
page 83.



6550-100-206/0123
  3 
1
2
3
4
5
6
7
8
Boiler Operation
• Do not block ow of combustion or ventilation air
to boiler.
• Should overheating occur, or gas supply fail to
shut o󰀨, do not turn o󰀨 or disconnect electrical
supply to pump. Shut o󰀨 the gas supply at a
location external to the appliance.
Boiler Water
• The water chemistry for the boiler must be
checked. Chemical treatment may be required. See
pages 73-75 for details.
• Before connecting the boiler, thoroughly ush the
system to remove sediment. Install a strainer or other
sediment removal equipment if necessary.
• Do not use petroleum-based cleaning or sealing
compounds in the boiler system. Gaskets and seals
in the system may be damaged, which can result in
substantial property damage.
• Continual fresh make-up water will reduce boiler
life. Mineral buildup in the heat exchanger reduces
heat transfer, overheats the heat exchanger, and
causes failure. Addition of oxygen carried in by
make-up water can cause internal corrosion. Leaks
in the boiler or piping must be repaired at once to
prevent make-up water. Use this boiler ONLY in a
closed-loop system.
• Do not add cold water to a hot boiler. Thermal
shock can cause the heat exchanger to crack.
Commonwealth of Massachusetts
When the boiler is installed within the Commonwealth
of Massachusetts:
• This product must be installed by a licensed
plumber or gas tter.
• If antifreeze is used, a reduced pressure back-ow
preventer device shall be used.
Freeze Protection Fluids
NEVER use automotive or standard glycol antifreeze.
Use only freeze-protection uids recommended in
this manual. See page 74 for more information.
Thoroughly clean and ush any replacement boiler
system that has used glycol before installing the new
LGB boiler.
Damage from Water Contact
DANGER
!
DO NOT attempt to operate any boiler if any
part of the boiler, burner, or controls has been
partially or fully sprayed with or submerged
under water. The boiler must either be replaced
or completely repaired and inspected. The boiler
and all components must be in good condition
and fully reliable before operation.
If these requirements are not met, operating
the boiler will cause re, explosion, and electrical
shock hazards, leading to serious injury, death,
or substantial property damage.
Saltwater damage: The immediate e󰀨ects of
saltwater damage are like those of freshwater,
with electrical components shorting out and the
removal of critical lubricants. However, salt and other
contaminants left behind can lead to long term issues
due to the conductive and corrosive nature of salt
residue. WM Technologies equipment contaminated
with saltwater or polluted water will no longer be
covered under warranty and should be replaced.
Electrical damage: If any electrical component or
wiring has, or is suspected to have come into contact
with water, replace the boiler.
Frozen Water Damage
Power outages, unattended residences or buildings,
boiler component failures, or other electrical system
failures in cold weather could result in frozen plumbing
and water damage in a matter of hours. Consult with
a boiler contractor or a home security agent to take
preventative actions, such as installing a security
system that operates during power outages, senses
low temperature, and initiates an e󰀨ective action.


7550-100-206/0123
 3  
1
2
3
4
5
6
7
8
This section is intended to provide installation
instructions for qualied heating installers.
Section Contents
Prepare Boiler Location . . . . . . . . . . . . . . . . . . . . 7
Boiler Assembly . . . . . . . . . . . . . . . . . . . . . . . 10
Boiler Conversion. . . . . . . . . . . . . . . . . . . . . . . 30
Water Boiler Piping . . . . . . . . . . . . . . . . . . . . . . 31
Steam Boiler Piping . . . . . . . . . . . . . . . . . . . . . 35
Commonwealth of Massachusetts Installations . . . . . . . 38
Venting and Combustion Air - General . . . . . . . . . . . .39
Steam Boiler Venting - Category I . . . . . . . . . . . . . . 43
Water Boiler Venting - Category II . . . . . . . . . . . . . .46
Install Boiler Controls. . . . . . . . . . . . . . . . . . . . . 50
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . .52

Installation Compliance Requirements
• Local, state, provincial, and national codes, laws,
regulations, and ordinances.
• National Fuel Gas Code, ANSI Z223.1/NFPA 54
latest edition.
• National Electrical Code ANSI/NFPA 70 latest
edition. For Canada, electrical installation and
grounding must be in accordance with CSA C22.1,
Part 1, Canadian Electrical Code and local codes.
• For Canada only: CAN/CSA B149.1, Natural Gas and
Propane Installation Code and local codes.
• Where required by the authority having
jurisdiction, the installation must conform to the
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
IMPORTANT
The LGB boiler manifold and controls met safe
lighting and other performance criteria when the
boiler underwent tests specied in ANSI Z21.13 latest
edition.
Checks Before Boiler Installation
1. Check for nearby connections to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical Power
• Location of drain for condensate
2. Check area around boiler. Remove any
combustible materials, gasoline, and other
ammable liquids.
!
WARNING
Failure to keep boiler area clear and free of
combustible materials, gasoline, and other
ammable liquids and vapors can create an
explosion hazard, which can result in severe
personal injury, death, or substantial property
damage.
3. Check the boiler location to ensure it protects the
gas control system components from dripping
or spraying water and rain during operation or
service.
4. If a new boiler is replacing the existing boiler,
check for and correct system problems:
• System leaks causing oxygen corrosion or heat
exchanger cracks from hard water deposits.
• Incorrect expansion tank sizing.
• Lack of freeze protection in boiler water.



8550-100-206/0123
  3 
1
2
3
4
5
6
7
8
Flooring and Foundation
!
WARNING
Do not install the boiler on combustible ooring
or carpeting even if a foundation is used. Failure
to comply can cause a re, which can result in
severe personal injury, death, or substantial
property damage.
!
WARNING
Do not route wiring, telephone cables, or piping
in the oor below the boiler. Overheating could
occur, which can result in severe personal injury,
death, or substantial property damage.
1. The boiler mounting surface must be level and
suitable for the load.
2. Provide a solid foundation pad at least 2" (51 mm)
above the oor if any of the following is true:
• Floor can become ooded.
• Floor is dirt, sand, gravel, or other loose material.
• Boiler mounting area is severely uneven or sloped.
3. Foundation must be brick or concrete
construction. The minimum foundation
dimensions are shown in Figure 1. The width (W)
from Figure 1 is listed in Table 3 for each model.
4. If ooding is possible, elevate the boiler su󰀩ciently
to prevent water from reaching the boiler.
Openings
Openings in oors, walls, ceilings, or roofs must be
designed for re stopping as required by local codes.
Vent pipe openings through combustible materials
must be 3/8" (9.5 mm) larger in diameter than the pipe.
!
WARNING
Pipe openings that do not have the required
diameter can cause a re, which can result in
severe personal injury, death, or substantial
property damage.
Air Openings: Follow all applicable codes to size and
verify size of the combustion and ventilation air openings
into the space. Follow the National Fuel Gas Code
ANSI Z223.1/NFPA 54, latest edition for the U.S.
Follow the Natural Gas and Propane Installation
Code CAN/CSA B149.1 for Canada.
The LGB boiler requires a special vent system.
See the Venting and Combustion Air sections starting
on page 39 for required air openings and sizing for
direct exhaust installations.
Air openings into the room must be sized to
handle the LGB boiler and any other appliances.
See pages 40-41 for required combustion air
openings.
!
WARNING
Provide combustion air openings correctly sized
for all appliances in the room, INCLUDING the
LGB boiler. Failure to comply can result in severe
personal injury, death, or substantial property
damage.

Figure 1 Minimum foundation and boiler placement
dimensions
Table 3 Minimum foundation width dimensions
Boiler
Model
Minimum
Width (W)
(inches)
Boiler
Model
Minimum
Width (W)
(inches)
LGB-4 21 LGB-11 56
LGB-5 26 LGB-12 61
LGB-6 31 LGB-14 71
LGB-7 36 LGB-16 81
LGB-8 41 LGB-18 91
LGB-9 46 LGB-20 101
LGB-10 51
220179
46½"
1/4"
2"
Base end panel
Foundation, minimum 2" thick
W

9550-100-206/0123
 3  
1
2
3
4
5
6
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8
Clearances
See Figure 2 for required and recommended
clearances. Install the boiler in a large space in
comparison with the boiler.
IMPORTANT
Without the recommended minimum clearances for
service access, it may not be possible to service the
boiler without removing it from the space.
Figure 2 Clearances for LGB Boilers
220188
Top
Top
Left
Side
Left
Side
Edge of opening within 12 inches of floor.
Edge of opening within 12 inches of floor.
Air openings
(when required)
Air openings
(when required)
Controls end
Front
Controls end
Front
Right
Side
Right
Side
Edge of opening within 12 inches of ceiling.
Edge of opening within 12 inches of ceiling.
Piping end
Piping end
Vent
pipe
Vent
pipe
Ensure that the installation complies with all state, local, and applicable codes.
Clearance from:
Minimum clearances to
combustible surfaces
(inches)
Minimum allowable
service clearances
(inches)
Recommended minimum service
access clearances
(inches)
Controls end (Front) 24 24 35
Left side 24 24 24
Right side 24 24 24
Piping end 24 24 35
(Measured from jacket, not pipes)
Top 24 24 24
Floor N/A* — —
Vent pipe 6 — —
Hot water pipes 6 — —
* Non-combustible ooring only.

10 550-100-206/0123
  3 
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
Base Assembly
!
WARNING
The boiler contains ceramic ber and berglass
materials. Use care when handling these materials
per instructions on page 83. Failure to comply
can result in severe personal injury or death.
IMPORTANT
Ensure the assembly and base assembly boxes are
on hand before beginning this section. See the Parts
section starting on page 99 for more information.
Before assembling the base, relocate the access
shield from the lower shipping holes to the upper
mounting holes using a 5/16" nut driver. See
Figure 3. Remove the burner shipping bracket from
the rear burner rest as shown in Figure 4.
Single Base Boilers
Single base boiler bases are shipped complete and
need no further modication. Proceed to Base Seal
Installation on page 12.
Dual Base Assembly
IMPORTANT
Base assembly must be installed in the order shown
in Figure 5 to ensure correct positioning of the
components.
Dual base boiler bases are shipped individually and
must be modied before section assembly.
1. Remove the right end panel from the left base
(Base 1) after removing the four bolts with a 9/16”
wrench and ratchet. Discard the bolts and nuts.
2. Temporarily remove the two rightmost burners on
Base 1.
3. Remove the two bolts and nuts securing the
combustion air ba󰀪e to the cross tie on the right
side of Base 1 with a 1/2” wrench and ratchet.
Discard the bolts and nuts. Ensure spacers
remain installed in cross ties.
4. Remove the left end panel from the right base
(Base 2) after removing the four bolts with a 9/16”
wrench and ratchet. Set aside the bots and nuts
to reuse later.
5. Temporarily remove the two leftmost burners on
Base 2.
6. Remove the two bolts and nuts securing the
combustion air ba󰀪e to the cross tie on the left
side of Base 2 with a 1/2” wrench and ratchet.
Discard the bolts and nuts. Ensure spacers
remain installed in cross ties.
Trim refractory insulation ush with the anges on the
right side of Base 1 and the left side of Base 2.
220182
Base front panel
Mounting hole
Mounting hole
Shipping hole
Base access shield
Screw
W
asher
Figure 3 Access shield relocation
Figure 4 Shipping bracket removal
220241

11550-100-206/0123
 3  
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Figure 5 Dual base assembly (LGB-14 shown)
220183
For dual base only
Trim insulation flush with flanges
where the two bases connect
Boiler Model
Number
Base
Size
Boiler Model
Number
Base
Size
LGB-4 4/4R LGB-11 F —
LGB-5 5 LGB-12 G —
LGB-6 A LGB-14 B C
LGB-7 B LGB-16 D C
LGB-8 C LGB-18 D E
LGB-9 D LGB-20 F E
LGB-10 E
(continued on the next page)
220243
220183b
220244
Back JacketBack Jacket
Splice BracketsSplice Brackets
Combustion Air Ba󰀪eCombustion Air Ba󰀪e Front InteriorFront Interior
Splice BracketsSplice Brackets

12 550-100-206/0123
  3 
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
Dual Base Assembly, continued
7. Align jacket brackets in the top holes of the base
anges as shown in Figure 5, page 11.
8. Align Base 1 and Base 2 together; secure with
the four bolts set aside in step 4 using a 9/16”
wrench and ratchet.
9. Align the combustion air ba󰀪es and cross ties of
Base 1 and Base 2 and secure with the provided
bolts and nuts using a 1/2” wrench and ratchet.
See Figure 5, page 11.
10. Reinstall all removed burners.
Check the gas orice to ensure proper sizing. See
Table 4 for correct orice sizes per model and altitude.
!
WARNING
The orice size marking must match the required
boiler orice size. Incorrect sizing can cause leaking
gas fumes, which can result in severe personal
injury, death, or substantial property damage.
!
WARNING
Failure to properly seat and level the burners
can result in severe personal injury, death, or
substantial property damage.
Burners must be properly seated in the locating
slots with the openings facing up. Level and straighten
the burners to avoid misring. The front of the burners
must rest fully over the main burner orices. Gas
orices must inject down the center of the burners.
If installing a boiler in an altitude 2,000 feet or
higher, follow instructions in the Gas Orice and
Pressure Switch Conversion procedure on page 30.
Base Seal Installation
!
WARNING
Fiber glass tape seal must be installed before
section installation. Failure to install seal can
result in severe personal injury, death, or
substantial property damage.
Retrieve base seal from the assembly box. Seal
should be cut after installation.
Install seal as shown in Figure 6 or Figure 7,
ensuring seal edges connect with no overlap or gap.
Table 4 Orice sizes
Orice sizes per model and altitude
Boiler
Models
Standard
(below 2,000 ft.)
High Altitude
(2,000-6,999 ft.)
High Altitude
(7,000-10,000 ft.)
LGB 4*
(see note) 3.95 mm #27 #30
LGB 4R #25 #27 #30
LGB 5-20 3.95 mm #27 #30
*Note: LGB-4 bases are shipped as LGB-4R bases with #25 orices
installed. Follow steps 6-8 on page 30 to install 3.95 mm orices.
Figure 6 Single base seal
Figure 7 Dual base seal
220245
220246220246

13550-100-206/0123
 3  
1
2
3
4
5
6
7
8
Section Assembly
IMPORTANT
The LGB Series 3 castings are not compatible with
the Series 2 castings.
Ensure all boiler sections and Assembly Boxes
are on hand before beginning this section. Boiler
Base must be constructed and in place. See the
Parts section starting on page 99 for details of
components required for each boiler model.
Prepare sections:
1. With a caulking gun, apply 1/8" continuous bead
of sealing rope adhesive in the sealing grooves of
a section. See Figure 8.
2. Place 1/2" rope in the groove. When working around
curves, grasp the rope at 1" intervals and push
together. Do not stretch. Rope MUST be continuous.
Cut the rope as each section is completed. Do not
precut rope used for sections. DO NOT use multiple
pieces of rope in a single rope groove.
!
WARNING
Do not precut the rope for the casting sections. A
gas-tight seal must be maintained to prevent ue
gas spillage and carbon monoxide emissions,
which can result in personal injury or death.
IMPORTANT
Before cutting the rope for section assembly,
reference Table 5, page 17 for the required rope
length for collector hoods. Set aside the required
rope length for the collector hood before proceeding
to ensure sucient remaining rope for the hood.
!
WARNING
Port opening sealing surfaces must be clear of
all grit and rust. Do not use petroleum-based
cleaning or sealing compounds in the boiler
system. Failure to comply can cause seal failure,
which can result in severe personal injury, death,
or substantial property damage.
3. Remove any grit or rust from port opening sealing
surfaces with a clean rag.
4. Place sealing rings into port openings (Figure 8).
5. Repeat steps 1-4 for all sections. Additionally,
discard any 3/8” diameter shipping tie rods; do
not use these to draw sections together.
(continued on the next page)
Figure 8 Sealing rope, seals, and draw rod tightening sequence
9" Elastomer
sealing ring
6" Elastomer
sealing ring
Sealing
rope
220185

14 550-100-206/0123
  3 
1
2
3
4
5
6
7
8
Section Assembly, continued
Install the Sections:
Assembly may start with either end section. For
easier assembly, these instructions start with the right
end section.
6. Install two retaining brackets over the base seal on
the right side of the assembled base. Use screws
and a Phillips head screwdriver. See Figure 9.
7. Position the right end section up against the
retaining bracket. Ensure the casting parting lines
are aligned with the base brackets as shown
in Figure 10. Make sure to keep the section
supported.
!
WARNING
Sections are top-heavy and will not stand
individually without support. Failure to support
the sections can result in severe personal injury,
death, or substantial property damage.
NOTICE
End section must be plumb. After erecting the rst
intermediate section, check both sections for plumb.
Failure to plumb sections may cause misaligned
piping and breech, resulting in property damage.
8. Position intermediate sections so the alignment
lugs t into the sockets of the placed section.
Refer to Figure 12, page 15.
9. Install a section onto the base assembly. Ensure
that the section is straight and properly aligned
using the alignment lugs.
10. Oil threads on all draw rods. Install a washer and
nut on the end being tightened. Use only a nut on
the opposite end.

220184
220184
Figure 10 Section assembly
Figure 9 Retaining brackets
220247
5 13/16" 2" 2"
1/2"
1/2"
Top View



15550-100-206/0123
 3  
1
2
3
4
5
6
7
8
Section Assembly, continued
11. Insert the draw rods. Tighten the rear and lower
front draw rods uniformly. Do not torque until all
sections are installed. Do not tighten the front
upper draw rods. See Figure 11.
CAUTION
!
The front upper draw rods must remain loose
until the lower front and rear draw rods are
tightened to the proper torque or misalignment
may occur.
12. Repeat steps 8 to 11 for all sections.
13. Uniformly draw sections together, starting at the
washer with nut end. Torque the rear then lower
front draw rods to a range of 100-120 ft-lbs.
Progress through every section to the end. Do not
back o󰀨 the draw rods once tightened.
14. Ensure that metal-to-metal contact is achieved
around the port opening. See Figure 12.
a. If a gap exists around the port opening, use
a feeler gauge to make sure it does not
exceed .032". If the gap is greater than .032",
check for rope extending from rope grooves, dirt
on port openings or sockets, or misaligned lugs.
b. If a gap exceeding .032" still exists after
corrections are made, or nothing needs to
be corrected, contact your WM Technologies
distributor before continuing installation.
!
WARNING
Failure to correct a gap around the port opening
that exceeds .032" could cause seal failure, which
can result in severe personal injury, death, or
substantial property damage.
15. Tighten the upper front draw rods just enough
to produce good, equal compression along the
length of the rope. DO NOT torque the upper front
draw rods.
!
WARNING
Check the sealing rope of each section before
proceeding to the next section. The boiler must
be sealed gas-tight to prevent possible ue gas
spillage and carbon monoxide emissions, which
can result in severe personal injury or death.
Figure 11 Draw rods
220249
220248

Metal-to-metal
contact
Metal-to-metal
contact
Section
Section
Elastomer
sealing ring
Elastomer
sealing ring
Alignment
lug
Alignment
lug
Socket
Socket
220186
Figure 12 Sealing ring installation and port alignment

16 550-100-206/0123
  3 
1
2
3
4
5
6
7
8

Hydrostatic Pressure Test
Perform a pressure test on the boiler before
connecting gas piping and electrical supply or
installing the jacket.
1. Install the following items. Refer to the gures
and tables in this section for tapping locations.
• Boiler drain (supplied by installer).
• Water pressure gauge (for test only). Be sure
the gauge can handle the test pressures stated
in Step 3.
2. Plug all remaining tappings.
!
WARNING
Do not leave the boiler unattended during the test.
Cold water ll could expand and cause excess
pressure, which can result in severe personal
injury, death, or substantial property damage.
NOTICE
Do not pressure test with any controls installed or
damage could occur.
3. Fill the boiler and vent all air. Pressure-test the
boiler for more than 10 minutes.
• Steam boilers: between 45-55 psig.
• Water boilers: 1.5 times the maximum working
pressure stated on the castings and boiler
nameplate.
4. Check for maintained gauge pressure and repair
any leaks.
5. Drain the boiler.
6. Remove plugs from the tappings used for controls
and accessories. Leave all other plugs installed.
Figure 13 Section end tappings
J1
J1
6" Supply
6" Supply
5" Return
5" Return
F1F1
C1
C1
M2
M2
E2
E2
D2
D2
H2
H2
H1
H1
K1
K1
G1
G1
E1
E1
D1
D1
M1
M1
220187
J2
J2
6" Supply
6" Supply
5" Return
5" Return
F2
F2
C2
C2
M4
M4
E4
E4
D4
D4
H4
H4
H3
H3
K2
K2
G2
G2
E3
E3
D3
D3
M3
M3
Legend - Figure 13
Tapping Size (in.) Steam Boilers Water Boilers[3]
C1, C2 1 1/4 Boiler drain Boiler drain
D1, D2,
D3, D4 1/2 Gauge glass [2] —
E1, E2,
E3, E4 1Low water cuto󰀨 [2] Optional low water
cuto󰀨
E1, E3 1
Pressure operating
and limit controls and
pressure gauge
—
F1, F2 1 — To expansion tank or
automatic air vent [4]
G1, G2 1/2 — Operating and high limit
control [4]
H1, H2,
H3, H4 [1] 3/8 Tri-cock —
J1, J2 2Steam relief valve and
skim tapping
Water relief valve and
skim tapping
K1, K2 1/2 — Pressure and
temperature gauge [4]
M1, M2,
M3, M4 1Optional low water cuto󰀨 [2]
Optional low water
cuto󰀨
M1, M3 1Firing rate control
(when used) Probe low water cuto󰀨
1. Available on special request only.
2. Must be on the same side as steam equalizer piping.
3. Additional controls for water boilers may be placed in supply piping.
4. Must be on the same side as supply to the system.



17550-100-206/0123
 3  
1
2
3
4
5
6
7
8
Flue Collector Hood Installation
Install the collector hood only after the pressure test
has been completed.
Ensure the collector hood, jacket, and assembly
boxes are on hand before beginning this section. See
the Parts section starting on page 99 for details of
components required for each boiler model.
1. Install the two alignment brackets to the upper
front draw rods.
a. Install each bracket on the second casting
from each end (Item 1).
b. Do not remove nuts from the draw rods; use
the provided, additional nuts (Item 2).
2. Thread two screws (Item 3) into the alignment
brackets. Leave 1/2" gap between the screw
heads and the brackets.
3. Apply silicone bead around the top of the section
assembly block as shown in Figure 15.
4. Retrieve rope previously set aside. Lay rope on the
sealant shown in Figure 15. Refer to Table 5 for
rope lengths.
5. Mount the ue collector hood on the section
assembly and over rope, aligning the front with
the alignment brackets. The ue collector hood
should be centered from left to right on the
section assembly.
(continued on the next page)
Figure 15 Silicone and berglass pattern
Table 5 Rope seal lengths
220251
Figure 14 Alignment brackets
220250
220250
Boiler
Model Size
Rope
Length
(in)
Boiler
Model Size
Rope Length (in)
Base 1 Base 2
LGB 4R / 4 90 LGB 11 195 —
LGB 5 105 LGB 12 210 —
LGB 6 120 LGB 14 135 150
LGB 7 135 LGB 16 165 150
LGB 8 150 LGB 18 165 180
LGB 9 165 LGB 20 195 180
LGB 10 180
Figure 16 Flue collector hood assembly
220252
1
2
3

18 550-100-206/0123
  3 
1
2
3
4
5
6
7
8
Flue Collector Hood Installation, continued
6. Use J hooks to attach the ue hood to the draw
rods at the top of the block. Refer to Figure 17
and Figure 18.
a. Secure the front brackets of the collector hood
to the front top draw rods as shown in Figure
18 using items 1-3.
b. Secure the rear brackets of the collector hood
to the rear top draws rods as shown in Figure
19 using items 4-9.
c. Di󰀨erent boiler models have collector hoods
with a varying number of brackets; each
bracket should be secured. Tight nuts and
bolts with a 1/2" wrench or ratchet.
7. Ensure the ue collector hood is level after
installation is complete.
!
WARNING
The hood and boiler assembly must be sealed
gas-tight to prevent the possibility of ue gas
spillage and carbon monoxide emissions, which
can result in severe personal injury or death.

Figure 17 J hooks front installation
Figure 18 J hooks back installation
220253
220253
220254
220254
Legend - Figure 17 & Figure 18
Item No. Description
1J-bolts
2Lock washers
3Nuts
4J-bolts
5Nuts
6Coupling nuts
7Lock washers
8Leveling washers
9Bolts
3
2
1
5
6
4
9
8
7

19550-100-206/0123
 3  
1
2
3
4
5
6
7
8
Inducer Assembly
Inducer orice plates and bolts are shipped with the
ue collector hood and must be removed before
proceeding with installation. Orice plates are marked
to indicate correct boiler application. Ensure the
correct orice plate is installed for each boiler.
For LGB water boilers and LGB 4R steam boilers
only, refer to the following instructions and Figure 19
for typical installation.
1. Install a gasket (item 1) on the ue collector hood.
2. Install the orice plate (item 2) on the installed
gasket.
3. Install a gasket (item 3) over the orice plate.
4. Install the inducer (item 4) onto the gasket.
5. Secure the inducer with provided 1/4-20 stainless
steel bolts (item 5) using a 1/2” ratchet. Ensure all
bolts are installed.
For LGB Steam boilers only (except model 4R),
refer to the following instructions and Figure 20 for
typical installation.
1. Install the gasket (item 6) on the ue collector
hood
2. Install the inducer (item 7) onto the gasket.
3. Secure the inducer with provided 1/4-20 stainless
steel bolts (item 8) using a 1/2” ratchet. Ensure all
bolts are installed.
Figure 19 Inducer installation – water and 4R steam
220255
220255
220256
220256


Figure 20 Inducer installation – steam boilers (except 4R)



Figure 21 Example orice plate
220278
4
3
2
1
5(x4)
8(x4)
7
6

20 550-100-206/0123
  3 
1
2
3
4
5
6
7
8
Jacket Installation Guidelines
Ensure the jacket and assembly boxes are on hand
before beginning this section. See the Parts section
starting on page 99 for details of components
required for each boiler model.
1. The following must be done before jacket
installation:
• Boiler must be pressure tested
• Plugs must be installed in unused tappings
• Flue collector hood
• Water boilers only: temperature sensor installed
2. The following must be done after installing the
side panels, but before installing the top panel:
• Control panel
• Routing inducer power wires, ue temperature
switch wires, and ue pressure switch tubing
through the wire chase.
3. The following may be on the boiler before jacket
installation:
• Supply and return piping
• Gas control assembly
• Compression tank piping
• Pilot line tubing
4. The following must be o the boiler before jacket
installation:
• Relief valves
• P/T gauge
• Steam or water gauges
• Limit control
• LWCO
• Gauge glass cocks and gauge glass
• Siphon
• Tri-cocks (if used)
• Drain cock
• Gas supply piping
• Control tray
5. Leave jacket parts in the cartons until needed to
avoid damage.
6. Remove the required jacket knockout discs.
Single Base Jacket Installation (Models 4R-12)
The recommended order of jacket installation for single
bases is shown in Figure 22, page 21. Jacket screws
are #10 x 1/2” Type AB Phillips head screws unless
otherwise noted. All installation screws are provided.
1. Attach four support brackets (item 1) to the side
panels using provided 10-32 x 1/2” screws and a
Phillips head screwdriver.
2. Hang the front top interior panel (Item 2) on
alignment bracket screws through the slots. See
Figure 23, page 21.
3. Set the side panels (Items 3-6) into the support
brackets.
a. Secure the left front panel (Item 3) to the left
back panel (Item 4) (5 locations).
b. Secure the left front panel (Item 3) to the front
top interior panel (Item 2) (3 locations).
c. Repeat steps a-b for the right side panels
(Items 5-6).
4. To install the wire chase (Item 7), ensure
insulating berglass tape is adhered to the bottom
of the chase. See Figure 24, page 21. Secure
the chase to the front top interior panel (item 2) (2
locations).
5. To install the back panel (item 8), set the panel
on top of the rear bracket as shown in Figure 25,
page 21. Secure the back panel to the left back
panel and the right back panel (12 locations).
!
WARNING
The back panel must be installed on top of the
rear bracket or air openings may be blocked.
Blocked air openings can cause incomplete
combustion, which can result in severe personal
injury or death.
6. Install the front bottom interior panel (Item 9):
a. Secure to the front top interior panel (3
locations).
b. Secure to the front left and right panels (4
locations).
7. Secure the front cross tie (Item 10) to the front left
and right panels (2 locations).
8. Install the top panel:
a. Secure to the front top interior panel (3
locations).
b. Secure to the side panels (10 locations).
c. Secure to the back panel (4 locations)
d. Secure to the wire chase (2 locations).
9. Secure the inducer cover (Item 12) to the top
panel.
10. Mark the correct model size and orice size on
the rating label.
