Peerless LC Series Operation manual
LC
™
Gas/Oil Boilers – Water
Series
Oil, Gas &
Installation,
Operation &
Maintenance
Manual
USING THIS MANUAL 1
A. INSTRUCTION MANUALS . . . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . .3
C. COMBUSTION AND VENTILATION AIR . . . .3
D. CHIMNEY OR VENT . . . . . . . . . . . . . . . . . . . .3
E. BOILER SETTING . . . . . . . . . . . . . . . . . . . . . .4
F. INSTALLATION SURVEY . . . . . . . . . . . . . . . .5
G. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .5
H. VERIFY COMPONENTS . . . . . . . . . . . . . . . . .5
2. PLACE THE BOILER 9
A. PACKAGED BOILER . . . . . . . . . . . . . . . . . . . .9
B. ASSEMBLED BLOCK BOILER . . . . . . . . . . . .9
C. KNOCKDOWN BOILERS . . . . . . . . . . . . . . . .9
D. INSTALL COILS OR PLATES . . . . . . . . . . . .13
E. HYDROSTATIC TEST THE BOILER . . . . . . .13
F. APPLY CLEANOUT COVER PLATES . . . . . .15
G. INSTALL FLUE COLLAR . . . . . . . . . . . . . . . .16
H. INSTALL FLUE BAFFLES . . . . . . . . . . . . . . .16
3. PIPE THE BOILER 17
A. PREPARATION . . . . . . . . . . . . . . . . . . . . . . .17
B. SUPPLY AND RETURN PIPING . . . . . . . . . .17
C. LOW SYSTEM TEMPERATURE . . . . . . . . . .17
D. CHILLED WATER SYSTEMS . . . . . . . . . . . .20
E. HIGH FLOW RATE PIPING . . . . . . . . . . . . . .20
F. MULTIPLE BOILER INSTALLATIONS . . . . . .20
4. ASSEMBLE THE JACKET 24
A. PREPARE THE PARTS . . . . . . . . . . . . . . . . .24
B. APPLY JACKET SIDES AND CORNERS . . .24
C. APPLY JACKET FRONT PANELS . . . . . . . . .24
D. APPLY JACKET REAR PANEL . . . . . . . . . . .24
E. APPLY JACKET TOP PANELS . . . . . . . . . . .24
F. APPLY PLATES AND LABELS . . . . . . . . . . .24
5. VENTING 26
6. INSTALL THE BURNER 26
A. BURNER APPLICATION . . . . . . . . . . . . . . . .26
B. INSTALL BURNER MOUNTING PLATE . . . .26
C. MOUNT THE BURNER . . . . . . . . . . . . . . . . .26
7. CONNECT FUEL PIPING 28
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .28
B. INSTALL FUEL OIL PIPING . . . . . . . . . . . . .28
C. INSTALL GAS SUPPLY PIPING . . . . . . . . . .28
D. TEST GAS SUPPLY PIPING . . . . . . . . . . . . .28
8. INSTALL CONTROLS AND TRIM 30
A. INSTALL SAFETY RELIEF VALVE . . . . . . . .30
B. INSTALL DRAIN VALVE . . . . . . . . . . . . . . . .30
C. INSTALL LOW WATER CUTOFFS . . . . . . . .30
D. INSTALL CONTROLS & TRIM . . . . . . . . . . .30
E. PIPE TANKLESS HEATERS IF USED . . . . . .31
F. CONNECT SUPPLY WIRING . . . . . . . . . . . .31
G. INSTALL CONTROL WIRING . . . . . . . . . . . .31
9. STARTING THE BOILER 34
A. CHECK THE PIPING . . . . . . . . . . . . . . . . . . .34
B. FILL THE BOILER . . . . . . . . . . . . . . . . . . . . .34
C. RUN BURNER CHECK-OUT . . . . . . . . . . . . .34
D. CHECK BOILER CONTROLS . . . . . . . . . . . .35
10. MAINTENANCE 37
A. PLACING BOILER IN OPERATION . . . . . . . .37
B. TO SHUT DOWN THE BOILER . . . . . . . . . .37
C. MAINTENANCE – ANNUAL . . . . . . . . . . . . .37
D. MONTHLY MAINTENANCE . . . . . . . . . . . . .38
E. DAILY MAINTENANCE . . . . . . . . . . . . . . . . .38
11. BOILER RATINGS & DIMENSIONS 39
12. REPAIR PARTS 42
13. STARTUP AND SERVICE REPORT 44
TABLE OF CONTENTS
TABLE OF CONTENTS
A. INSTRUCTION MANUALS
The Series LC™ Installation, Operation & Maintenance
Manual is divided into four basic sections:
1. Preinstallation (Section 1)
2. Installation (Sections 2 through 8)
3. Start-Up (Section 9)
4. Maintenance (Section 10)
B. SPECIAL ATTENTION BOXES
Throughout this manual you will see special attention
boxes intended to supplement the instructions and make
special notice of potential hazards. These categories
mean, in the judgment of PB Heat, LLC:
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
USING THIS MANUAL
USING THIS MANUAL
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
1
⚠
DANGER
⚠
WARNING
⚠
CAUTION
⚠
NOTICE
A. ACCESSIBILITY CLEARANCES
1. The following recommendations allow for reasonable
access to the boiler. Follow local codes and
requirements when setting actual layout. See
Figure 1.1.
a) For installing, removing and servicing the burner:
provide 48" between the front of the boiler and
any adjacent wall or other appliance.
b) For access to the top of the boiler for cleaning
flueways: provide 24" above top of jacket.
c) For accessing and servicing of level controls and
inspection tappings (if used): provide 24"
minimum from the right side of the boiler to any
wall or obstruction.
d) For installation of jacket: provide at least 12"
from the left side of the boiler to any wall or
obstruction. More clearance may be needed for
longer boilers unless the jacket is pre-assembled
before placing the boiler.
e) For installation and removal of tankless heaters:
provide 45" between the end of the boiler and
any adjacent wall of obstruction. [This provides
for all available tankless coils. The spacing can
be closer for Heater Number X-1020 (allow 30")
or Heater Number X-1021 (allow 35")].
The equipment must be installed in accordance with installation requirements of the authority having
jurisdiction or, in the absence of such requirements, to the current edition of the
National Fuel Gas Code
, ANSI
Z223.1/NFPA 54.
Where required by the authority having jurisdiction, the installation must conform to
American Society of
Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers,
ASME CSD-1.
PREINSTALLATION
1. PREINSTALLATION
Carefully read these instructions before beginning work. Understand all aspects of the installation. Contact your PB Heat’s sales
representative or customer service for help in answering questions.
This boiler must be installed by a qualified contractor. The boiler warranty can be voided if the boiler is not installed, maintained
and serviced correctly.
Figure 1.1: Clearance Requirements
2
⚠
NOTICE
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION
Provide the following minimum clearances to
combustible construction. See Figure 1.1.
1. Sides: 6"
2. Rear of Jacket: 6"
3. Front of Jacket: 24"
4. Top of Jacket: 24"
5. Hot Water Pipes: 6"
6. Vent or Chimney Connector: 18"
C. COMBUSTION AND VENTILATION AIR
1. The installation must provide adequate air for
combustion and ventilation.
2. Unless the boiler room construction and natural air
infiltration are sure to provide all the air needed,
provide an opening or duct to the outside with a free
cross sectional area of at least 1 square inch per
4000 Btuh input for all installed appliances. At high
altitude, increase this requirement 4% for each 1000
feet above sea level.
3. The boiler room must never be under negative
pressure. If exhaust fans or other equipment can
cause a negative pressure in the boiler room, the air
openings and equipment design must be engineered
to assure a neutral or slightly positive pressure in the
boiler room at all times of operation. If the
equipment design and air openings cannot assure
this, then the boiler must be located in an isolated
room.
4. Using combustion air dampers:
If motorized dampers are used on the combustion
and ventilation air openings, wire them such that
they must open when the boiler tries to operate.
They must include a switch which prevents the boiler
from operating if they do not open. See Figure 1.2.
D. CHIMNEY OR VENT
1. Inspect the existing chimney or vent system. Make
sure it is in good condition. Inspect chimney liner
and repair or replace if necessary.
2. The vent system and installation must be in
accordance with the current edition of the American
National Standard ANSI/NFPA 211, “Chimneys,
Fireplaces, Vents, and Solid Fuel Burning
Appliances”, or applicable provisions of the local
building codes.
3. Chimney/Vent Operation: The vent system must be
sized and installed to remove all combustion
products. If the vent system is not sized properly, the
burner may not operate properly. This can cause
poor combustion or sooting to occur.
4. If the vent terminates in an area where windgenerated downdrafts are likely, install a suitable vent
cap which can control wind effects.
5. This boiler is designed to fire only with a pressurized
fire box. The breeching and vent may be sized for
negative, neutral or positive pressure (no more than
0.l inches water column at the boiler outlet) as
desired. But negative pressure overfire can cause
lifting of the flame and poor combustion or
overheating of the boiler crown sheet.
6. Forced draft breechings and vents must be sealed
and of heavy gauge steel construction and must
comply with all applicable codes of construction.
7. The vent diameter and minimum height for stub
vents are listed in the Ratings and Dimensions
Section of this manual. Always extend vent
terminations at least 3 feet above the roof line. See
Figure 1.3.
PREINSTALLATION
Figure 1.2: Motorized Vent Damper Interlock
Failure to provide adequate venting can result in
severe property damage, personal injury or death.
Figure 1.3: Vent Termination, Typical
3
⚠
WARNING
8. Exterior Vents:
Insulate sufficiently to ensure adequate draft and to
prevent vent damage due to condensation.
9. Vent Connection to Boiler:
a) Support 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 provide a minimum
upward slope of 1/4" per foot.
10. Do not vent natural draft appliances in a combined
vent which operates under positive pressure.
11. Draft Regulator: Install a barometric draft regulator
where using high chimney or any high draft vent.
This is needed to prevent causing negative draft in
the boiler. Excess draft will cause flame lifting and
possible impingement.
E. BOILER SETTING
1. If the boiler room floor is not level or if additional
structural support is needed, provide a good, level
foundation for the boiler with the minimum
dimensions given in Table 1.1. The flooring and
structural support system must be suitable for the
operating weight of the boiler and any connected
piping. Place the Steel Channels on the foundation
as shown in Figure 1.4.
2. Do not operate the boiler until the foundation, if new
concrete, has thoroughly cured. The concrete might
be damaged if heated too quickly due to the
entrained moisture remaining.
3. If the boiler is installed in a penthouse or if wiring of
any sort is run underneath the boiler foundation,
construct the foundation with provision for air flow
underneath between the main floor and the top of
the boiler foundation.
a) An acceptable foundation would be concrete
blocks laid with the openings lined up.
b) If the foundation must be a concrete 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.
Do not install this boiler on carpeting or any
combustible flooring. A significant fire hazard could
result, with potential for property damage, personal
injury or death.
Figure 1.4: Foundation Layout
PREINSTALLATION
4
⚠
WARNING
F. INSTALLATION SURVEY
For new and existing installations, a Water Installation
Survey is available from PB Heat, LLC. The survey will
provide information on how a hot water boiler works
with your specific system and will provide an overview
of hot water system operation in general.
You can also use this survey to locate system problems
which will have to be corrected. To obtain copies of the
Water Installation Survey, contact your PB Heat
representative or download it from PeerlessBoilers.com.
G. PLANNING THE LAYOUT
Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring.
H. VERIFY COMPONENTS
1. Packaged: All components should be inside crate. In
some cases the burner may be shipped separately.
Optional equipment, such as barometric draft
dampers, may also be shipped separately.
2. Knockdown: All components shipped for field
assembly. See Table 1.2 for standard components.
See Tables 1.3 through 1.8 for optional components.
a) Channel Rails
b) Sections
c) Assembly Kit Carton(s): Includes flow port
gaskets, tie rods with hardware, high temperature
rope, and cleanout cover plates.
d) Flue Box Carton: Includes flue box, rear
observation assembly and port cover plates.
e) Baffle Carton: Includes baffles, combustion
chamber liner and rating label.
f) Jacket Cartons: Includes ASME plate
g) Burner Mounting Plate
h) Trim Carton: Includes safety relief valve and
temperature-pressure gage
i) Control Carton: Limit controls
j) Tankless Heater(s)
k) Additional controls and fittings
3. Assembled Block: Same as knockdown except
channel rails, sections and assembly kit cartons are
assembled into a block as a single shipping level
component.
PREINSTALLATION
Table 1.1: Foundation Lengths
Model Foundation Length, Inches
LC-04 37-15/16
LC-05 43
LC-06 48-1/16
LC-07 53-1/8
LC-08 58-5/16
LC-09 63-3/8
LC-10 68-7/16
LC-11 73-1/2
LC-12 78-9/16
5
6
PREINSTALLATION
Table 1.2: Series LC™ Shipping List
Channel
Rail
Bundle
Front
Back
Plain
Interm.
1"
LWCO
Interm.
3" Tap.
Interm.
Baffle
Carton
Contents
See Below
Item 1
Contents
See Below
Item 2
Front/Rear
Panels
Hardware
Top/Side
Panels
Hardware
Chamber Liner
Standard Sections (See Table 1.3 for Options)
Assembly Kit Ctns. Jacket Cartons
(Tbl 1.4, 1.5 Options)Flue Ctn.
Boiler
Model
Number
LC-04
LC-05R
LC-05
LC-06
LC-07
LC-08
LC-09
LC-10
LC-11
LC-12
Quantity
Par t N o.
Label
Stock Code
Quantity
Par t N o.
Label
Stock Code
Quantity
Par t N o.
Label
Stock Code
Quantity
Par t N o.
Label
Stock Code
Quantity
Par t N o.
Label
Stock Code
Quantity
Par t N o.
Label
Stock Code
Quantity
Par t N o.
Label
Stock Code
Quantity
Par t N o.
Label
Stock Code
Quantity
Par t N o.
Label
Stock Code
Quantity
Par t N o.
Label
Stock Code
1
90160
1
90161
1
90161
1
90162
1
90163
1
90164
1
90165
1
90166
1
90167
1
90168
1
LC-1001
86000
1
LC-1001
86000
1
LC-1001
86000
1
LC-1001
86000
1
LC-1001
86000
1
LC-1001
86000
1
LC-1001
86000
1
LC-1001
86000
1
LC-1001
86000
1
LC-1001
86000
1
LC-1007
86022
1
LC-1007
86022
1
LC-1007
86022
1
LC-1007
86022
1
LC-1007
86022
1
LC-1007
86022
1
LC-1007
86022
1
LC-1007
86022
1
LC-1007
86022
1
LC-1007
86022
1
LC-1000
86004
2
LC-1000
86004
2
LC-1000
86004
3
LC-1000
86004
4
LC-1000
86004
4
LC-1000
86004
5
LC-1000
86004
6
LC-1000
86004
7
LC-1000
86004
8
LC-1000
86004
1
LC-1000-1
86005
1
LC-1000-1
86005
1
LC-1000-1
86005
1
LC-1000-1
86005
1
LC-1000-1
86005
1
LC-1000-1
86005
1
LC-1000-1
86005
1
LC-1000-1
86005
1
LC-1000-1
86005
1
LC-1000-1
86005
1
LC-1003
86008
1
LC-1003
86008
1
LC-1003
86008
1
LC-1003
86008
1
LC-1003
86008
1
LC-1023
LC-04
85004
1
LC-1023
LC-05
85105
1
LC-1023-1
LC-05
85005
1
LC-1023-2
LC-06
85006
1
LC-1023-3
LC-07
85007
1
LC-1023-4
LC-08
85008
1
LC-1023-5
LC-09
85009
1
LC-1023-6
LC-10
85010
1
LC-1023-7
LC-11
85011
1
LC-1023-8
LC-12
85012
1
LC-1022
A
86050
1
LC-1022-1
B
86051
1
LC-1022-1
B
86051
1
LC-1022-2
C
86052
1
LC-1022-3
D
86053
1
LC-1022
A
86050
2
LC-1022-1
B
86051
1
LC-1022-1
B
86051
2
LC-1022-2
C
86052
1
LC-1022-2
C
86052
1
LC-1022-1
B
86051
1
LC-1022-2
C
86052
1
LC-1022-3
D
86053
1
LC-5004
A
86040
1
LC-5004
A
86040
1
LC-5004
A
86040
1
LC-5004-1
B
86041
1
LC-5004-1
B
86041
1
LC-5004-1
B
86041
1
LC-5004-2
C
86042
1
LC-5004-2
C
86042
1
LC-5004-2
C
86042
1
LC-5004-2
C
86042
1
LC-6016
86030
1
LC-6016
86030
1
LC-6016
86030
1
LC-6016
86030
1
LC-6016
86030
1
LC-6016
86030
1
LC-6016
86030
1
LC-6016
86030
1
LC-6016
86030
1
LC-6016
86030
1
LC-6017
A
86031
1
LC-6017-1
B
86032
1
LC-6017-1
B
86032
1
LC-6017-2
C
86033
1
LC-6017-3
D
86034
1
LC-6017
A
86031
2
LC-6017-1
B
86032
1
LC-6017-1
B
86032
2
LC-6017-2
C
86033
1
LC-6017-2
C
86033
1
LC-6017-1
B
86032
1
LC-6017-2
C
86033
1
LC-6017-3
D
86034
1 Assembly Kit Cartons Contents: Flow Port Gaskets, Silicone Sealant, Tie Rods, Washers, Tie Rod Nuts, Section Seal Rope, Spray Adhesive, Cleanout Plates, Mounting Hardware
2 Flue Box Carton Contents: Flue Box, Seal Rope, Observation Assembly, Coil Cover Plates, Cover Plate Gaskets, Mounting Hardware
7
PREINSTALLATION
Note: 80 psig MAWP not available in Canada.
Table 1.5: Standard and Optional Jacket Cartons,
Top/Side Panels
Table 1.6: Burner Mounting Plates
Model
CF-800
CF-1400
CF-2300
301CRD
702CRD
801CRD
S4.2
R6.2
R6.3
R8.1
R8.2
R8.3
C1
C2
J15A
J30A
J50A
JB1
Boiler Model
86070*
86070*
86070*
86071
86072
86071
LC-04
86070*
86070*
86070*
86071
86072
86071
LC-05R
86069*
86069*
86078
86071
86072
86071
LC-05
86069*
86069*
86078
86071
86072
86071
LC-06
86069*
86069*
86079
86071
86072
86071
LC-07
86074*
86069*
86079
86076
86077
86075
LC-08
86074*
86073
86079
86076
86077
86075
LC-09
86074*
86073
86079
86076
86077
86075
LC-10
86074*
86073
86079
86076
86077
86075
LC-11
86074*
86073
86079
86076
86075
LC-12
Beckett
Carlin
Gordon
Piatt
Power
Flame
Webster
* Standard Burner Mounting Plate
Table 1.4: Standard and Optional Jacket Cartons,
Front/Back Panels
Table 1.3: Standard and Optional Sections for Knockdown Boilers
Standard 50
psig MAWP
86030
30 psig MAWP 86059
80 psig MAWP 86058
Sections
50 psig MAWP 80 psig MAWP
Standard
No Inspection Tappings
w/Inspection Tappings No Inspection Tappings w/Inspection Tappings
Front Part #/UPC LC-1001 86000 LC-1013 86010 LC-1001-2 86002 LC-1013-2 86012
Plain Interm. Part #/UPC LC-1000 86004 LC-1014 86014 LC-1000-2 86006 LC-1014-1 86015
LWCO Interm. Part #/UPC LC-1000-1 86005 LC-1014-2 86092 LC-1000-3 86007 LC-1014-3 86093
3" Tap. Interm. Part #/UPC LC-1003 86008 LC-1015 86016 LC-1003-2 86009 LC-1015-1 86017
Closed Back Part #/UPC LC-1007 86022 LC-1016 86018 LC-1007-2 86024 LC-1016-2 86020
Coil Back Part #/UPC LC-1002 86036 LC-1017 86026 LC-1002-2 86038 LC-1017-2 86028
Jacket Label
Standard
(No Inspection
Tappings)
With Inspection
Tappings
A 86031 86101
B 86032 86102
C 86033 86103
D 86034 86104
E 86094 86097
Note: Boilers with inspection tappings in front and back sections only use
standard cartons.
PREINSTALLATION
Table 1.8: Control Cartons
Model Stock Code Label
LC-04
Through
LC-12
88511 Water
Table 1.7: Trim Cartons
1 Safety Relief Valve selection based on capacity determined by boiler output
(Gross I=B=R Output). Applies to most locations in United States and
Canada.
Model
Output¹
30 psig 50 psig 80 psig
LC-04 87030 87050 87080
LC-05R 87030 87050 87080
LC-05 87030 87050 87080
LC-06 87030 87050 87080
LC-07 87031 87050 87080
LC-08 87031 87050 87080
LC-09 87032 87051 87080
LC-10 87032 87051 87081
LC-11 87032 87051 87081
LC-12 87032 87051 87081
8
A. PACKAGED BOILER
1. Remove crate top and sides. Remove any loose
cartons. Remove burner support 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 support pedestal and nipple if
necessary.
5. Proceed to Chapter 3: Piping the Boiler.
B. ASSEMBLED BLOCK BOILER
1. Move block to location determined in Chapter 1:
Preinstallation.
2. Remove lifting frame and hardware.
3. Proceed to Section D: Install Coils or Plates
C. KNOCKDOWN BOILER
1. Place channel rails as shown in Figure 1.4.
2. Open the Section Assembly Kit cartons. These
cartons contain the parts needed for assembly of the
sections.
3. Place the Back Section on the floor as shown in
Figure 2.1.
4. The Back Section combustion chamber area is lined
with a ceramic fiber blanket liner. Make sure the liner
is in good condition. Minor tears are not a problem,
but there should be no holes in the insulation.
PLACE THE BOILER
2. PLACE THE BOILER
Figure 2.1: Lay Sections on Floor and Apply Rope Seal and Gaskets
9
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 Port Gasket in each of the three flow
port recesses as shown in Figures 2.1 and 2.2.
7. Apply spray adhesive in the rope groove around the
perimeter of the section.
8. Place the sealing rope completely around the rope
groove, being careful not to stretch the rope. Extend
the rope from 1/4" to 1/2" past the end of the groove
on both sides of the cleanout opening on top of the
section. This will assure a gas tight seal when the
cleanout cover plate is applied.
9. Apply a bead of silicone sealant around each flow
port as shown in Figure 2.3. Do not get sealant on
the flow port gaskets.
10. Lift up the Rear Section and move into position on
the steel channels on the boiler foundation.
11. Screw a 3" pipe at least 30 inches long into the
lower 3" tapping on the back of the Rear Section as
shown in Figure 2.4. Place a block under the pipe as
shown in the figure and use as a brace during
assembly.
12. Place a Plain Intermediate Section on the floor and
prepare as above.
13. Carefully place the Intermediate Section against the
Rear Section and visually line up the flow ports as
close as possible.
14. Insert a tie rod with one nut and washer applied
into each of the four tie rod lugs. See Figure 2.5.
15. Place the nut and washer on the other end of the tie
rod and draw finger tight.
PLACE THE BOILER
Figure 2.3: Apply Silcone Sealant
Gaskets will be damaged by petroleum or its
derivatives. Completely remove all solvent residue
before placing gaskets.
Do not use petroleum based compounds in the
boiler.
Figure 2.2: Flow Port Machining & Gasket
The sections are heavy and must be supported
securely.
10
⚠
WARNING
⚠
CAUTION
PLACE THE BOILER
Figure 2.4: Install Additional Sections. Use level on each section as tie rod bolts are drawn up.
11
PLACE THE BOILER
Figure 2.5: Series LC™ Boiler Assembly – Right Side View
12
16. To properly assemble LC™ 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 required.
a. Use a spirit level as shown in Figure 2.4 to check
the alignment of the sections as the nuts are
drawn up. Keep the sections plumb.
b. Draw the sections together evenly, in three
rotations. Torque each port to 20 ft-lbs for the
first rotation, then to 40 ft-lbs for the second
rotation, then to 60 ft-lbs for the third rotation.
Use the following sequence until all three ports
touch metal-to-metal at 60 ft-lbs. See Figure 2.6
for port reference.
i) First: Lower Top Port
ii) Second: Bottom Port
iii) Third: Upper Top Port
c. Tighten these (3) three locations only to a torque
value of 60 ft-lbs. DO NOT EXCEED.
d. After the three ports have been tightened to 60
ft-lbs, tighten the draw rod at the bumping pads
until metal-to-metal contact is reached. This will
assure a proper gas tight seal and prevent the
products of combustion from migrating into the
boiler room.
17. Repeat with the remaining sections.
a. Save the LWCO Intermediate with two 1"
tappings (for level control) for use as the section
closest to the front section.
b. Place the Intermediate Section with 3" top
tapping (Tapped Intermediate) in the position
given in Figure 2.7.
D. INSTALL COILS OR PLATES
1. Remove the coil cover plates, gaskets and mounting
hardware, located in the Flue Box Carton.
2. Install tankless heaters, if used, in openings #1 and
#2. See Figure 2.8 and Table 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 the upper flow port opening
(Position #2) of the Front Section.
E. HYDROSTATIC TEST THE BOILER
1. Install a drain valve in the Rear Section, Tapping 13.
See Figure 8.2.
2. Provide a water supply line to the boiler.
3. Plug all open tappings in the boiler.
4. Provide a means to vent air as the boiler fills.
5. Fill the boiler with water, venting air as water level
rises.
6. Pressurize boiler to:
• 75 psig for 50 psig sections.
• 120 psig for 80 psig sections.
• DO NOT EXCEED THESE PRESSURES.
Maintain pressure while checking all joints and
fittings for leaks.
7. After inspection is complete, drain the boiler and
remove plugs from tappings that are to be used.
Do not exceed the manufacturer’s torque
recommendations.
PLACE THE BOILER
Figure 2.6: Torque Specification/Procedure
Table 2.1: Section Numbering Sequence
Model
Place a Tapped Intermediate
Section at Position
(Numbered Rear to Front)
LC-04 N/A
LC-05 N/A
LC-06 N/A
LC-07 N/A
LC-08 4
LC-09 5
LC-10 5
LC-11 6
LC-12 6
13
⚠
WARNING
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