PeerlessBoilers LCE Series Installation, Operation & Maintenance Manual

LC/LCE

Gas/Oil Boilers – Steam

Series

Oil, Gas &

Installation,
Operation &
Maintenance
Manual

USING THIS MANUAL

A. INSTRUCTION MANUALS . . . . . . . . . . . . . . .1

B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1

1. PREINSTALLATION

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

A. PACKAGED BOILER . . . . . . . . . . . . . . . . . . .10

B. ASSEMBLED BLOCK BOILER . . . . . . . . . . .10

C. KNOCKDOWN BOILER – PLACING

THE SECTIONS . . . . . . . . . . . . . . . . . . . . . .10

D. INSTALL COILS OR PLATES . . . . . . . . . . . .17

E. HYDROSTATIC TEST THE BOILER . . . . . . .17

F. APPLY CLEANOUT COVER PLATES . . . . . .19

G. INSTALL FLUE COLLAR . . . . . . . . . . . . . . . .19

H. INSTALL FLUE BAFFLES . . . . . . . . . . . . . . .20

I. INSTALL CHAMBER LINER . . . . . . . . . . . . .20

3. PIPE THE BOILER

A. PREPARATION . . . . . . . . . . . . . . . . . . . . . . .21

B. SUPPLY AND RETURN PIPING . . . . . . . . . .21

C. LOW SYSTEM TEMPERATURE . . . . . . . . . .21

D. MULTIPLE BOILER INSTALLATIONS . . . . . .22

4. ASSEMBLE THE JACKET

A. PREPARE THE PARTS . . . . . . . . . . . . . . . . .25

B. APPLY JACKET SIDES AND CORNERS . . .25

C. APPLY JACKET FRONT PANELS . . . . . . . . .25

D. APPLY JACKET REAR PANEL . . . . . . . . . . .25

E. APPLY JACKET TOP PANELS . . . . . . . . . . .25

F. APPLY PLATES AND LABELS . . . . . . . . . . .25

5. VENTING 27

6. INSTALL THE BURNER

A. BURNER APPLICATION . . . . . . . . . . . . . . . .27

B. INSTALL BURNER MOUNTING PLATE . . . .27

C. MOUNT THE BURNER . . . . . . . . . . . . . . . . .27

7. CONNECT FUEL PIPING

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .29

B. INSTALL FUEL OIL PIPING . . . . . . . . . . . . .29

C. INSTALL GAS SUPPLY PIPING . . . . . . . . . .29

D. TEST GAS SUPPLY PIPING . . . . . . . . . . . . .29

8. INSTALL CONTROLS AND TRIM

A. INSTALL SAFETY VALVES . . . . . . . . . . . . .31

B. INSTALL BLOWDOWN VALVE . . . . . . . . . . .31

C. INSTALL LOW WATER CUTOFF(S) . . . . . . .31

D. INSTALL PRESSURE CONTROLS . . . . . . . .31

E. PIPE TANKLESS HEATERS(S) . . . . . . . . . . .31

F. CONNECT SUPPLY WIRING . . . . . . . . . . . .31

G. INSTALL CONTROL WIRING . . . . . . . . . . . .32

9. STARTING THE BOILER

A. CHECK THE PIPING . . . . . . . . . . . . . . . . . . .39

B. FILL THE BOILER . . . . . . . . . . . . . . . . . . . . .39

C. RUN BURNER CHECK-OUT . . . . . . . . . . . . .39

D. CHECK BOILER CONTROLS . . . . . . . . . . . .39

E. CLEAN THE BOILER . . . . . . . . . . . . . . . . . . .39

10. MAINTENANCE

A. PLACING BOILER IN OPERATION . . . . . . . .42

B. TO SHUT DOWN THE BOILER . . . . . . . . . .42

C. MAINTENANCE – ANNUAL . . . . . . . . . . . . .42

D. MONTHLY MAINTENANCE . . . . . . . . . . . . .43

E. DAILY MAINTENANCE . . . . . . . . . . . . . . . . .43

11. BOILER RATINGS & DIMENSIONS 44

12. REPAIR PARTS

A. SERIES LC BOILER ASSEMBLY . . . . . . . . .47

B. SERIES LCE BOILER ASSEMBLY . . . . . . . .50

TABLE OF CONTENTS

TABLE OF CONTENTS

1

A. INSTRUCTION MANUALS

The Series LC/LCE 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.

NOTICE

Indicates a condition or hazard which will or can
cause minor personal injury or property damage.

CAUTION

DANGER

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.

WARNING

A. ACCESSIBILITY CLEARANCES

1. Clearances for service and from combustible surfaces
are the same for the LCE as for the LC. 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.

NOTICE

PREINSTALLATION

1. PREINSTALLATION

Carefully read these instructions before beginning work. Understand all aspects of the installation. Contact your PB Heat, LLC
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, correctly.

Figure 1.1: Clearance Requirements

2

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. Steam and 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:

a) 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. The venting requirements for the
LCE are the same as for the LC. Figure 1.3 shows
the top flue outlet required on LCE boilers.

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.

3

PREINSTALLATION

Figure 1.2: Motorized Vent Damper Interlock Figure 1.3: Vent Termination, Typical

Failure to provide adequate venting can result in
severe property damage, personal injury or death.

WARNING

4

8. Exterior Vents:
a) 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.

12. The Draft Damper for the LCE boiler is a separate

piece, shipped in the Top Flue Outlet Carton.

a) Install the Draft Damper as close as possible to

the boiler flue outlet. It can be installed vertically
or horizontally provided that the connecting vent
piping and fittings are designed and installed for
pressurized service.

b) Secure the damper to the vent with screws and

seal the joints with a bead of high temperature
silicone sealant (found in Section Assembly Kits).

c) The vent must be installed so it can be

disconnected and the Top Flue Outlet removed
for proper cleaning of the flueways.

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.

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.

WARNING

Figure 1.4: Foundation Layout

PREINSTALLATION

5

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.

F. INSTALLATION SURVEY

For new and existing installations, a Steam Installation
Survey is available from PB Heat, LLC. The survey will
provide information on how a steam boiler works with
your specific system and will provide an overview of
steam 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
Steam 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 1.7 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 flue

cover plate (LCE only), rear observation
assembly and port cover plates.

e) Baffle Carton

i) LC: Includes baffles, combustion chamber

liner, rating label

ii) LCE-21 through LCE-24: Baffles

f) Jacket Cartons: Includes ASME plate

g) Draft Damper (LCE only)

h) Label Carton (LCE only)

i) Burner Mounting Plate

j) Trim Carton: Includes safety relief valve and

temperature-pressure gage

k) Control Carton: Limit controls

l) Tankless Heater(s)

m) 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.

Table 1.1: Foundation Lengths

LC-04
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
LCE-22
LCE-23
LCE-24

Model

Foundation Length, Inches

37¹⁵⁄₁₆

43

48¹⁄₁₆

53¹⁄₈

58⁵⁄₁₆

63³⁄₈

68⁷⁄₁₆

73¹⁄₂

78⁹⁄₁₆

83³⁄₄

88¹³⁄₁₆

93⁷⁄₈
98¹⁵⁄₁₆
104¹⁄₈

109³⁄₁₆

114¹⁄₄

119⁷⁄₁₆

124¹⁄₂

129⁹⁄₁₆

134⁵⁄₈

139¹¹⁄₁₆

PREINSTALLATION

6

PREINSTALLATION

Table 1.2A: Series LC Shipping List

Panels

Top/Side

Hardware

Panels

Front/Rear

Contents

See Below

Contents

See Below

Assembly Kit Ctns. Jacket Cartons (Tbl 1.4 Options)Flue Ctn.

Baffle

3" Tap.

1"

LWCO

Chamber Liner

1

LC-6017

1

LC-6016

Hardware

1

Item 2

LC-5004

Item 1

1

LC-1022

1

LC-1023

Carton

Interm.

1

Interm.

LC-1000-1

A

A

A

LC-04

86031

86030

86040

86050

85004

86005

1

1

1

1

1

1

B

LC-6017-1

LC-6016

A

LC-5004

B

LC-1022-1

LC-05

LC-1023

LC-1000-1

86032

86030

86040

86051

85105

86005

1

1

1

1

1

1

B

LC-6017-1

LC-6016

A

LC-5004

B

LC-1022-1

LC-05

LC-1023-1

LC-1000-1

86032

86030

86040

86051

85005

86005

1

1

1

1

1

1

C

LC-6017-2

LC-6016

B

LC-5004-1

C

LC-1022-2

LC-06

LC-1023-2

LC-1000-1

86033

86030

86041

86052

85006

86005

1

1

1

1

1

1

D

LC-6017-3

LC-6016

B

LC-5004-1

D

LC-1022-3

LC-07

LC-1023-3

LC-1000-1

86034

86030

86041

86053

85007

86005

1

1

1

1

1

1

1

1

B

LC-6017-1

A

LC-6017

LC-6016

B

LC-5004-1

B

LC-1022-1

A

LC-1022

LC-08

LC-1023-4

LC-1000-1

86032

86031

86030

86041

86051

86050

85008

86005

2

1

1

2

1

1

B

LC-6017-1

LC-6016

C

LC-5004-2

B

LC-1022-1

LC-09

LC-1023-5

LC-1000-1

86032

86030

86042

86051

85009

86005

1

1

1

1

1

1

1

1

C

LC-6017-2

B

LC-6017-1

LC-6016

C

LC-5004-2

C

LC-1022-2

B

LC-1022-1

LC-10

LC-1023-6

LC-1000-1

86033

86032

86030

86042

86052

86051

85010

86005

2

1

1

2

1

1

1

C

LC-6017-2

LC-6016

C

LC-5004-2

C

LC-1022-2

LC-11

LC-1023-7

LC-1003

LC-1000-1

86033

86030

86042

86052

85011

86008

86005

1

1

1

1

1

1

1

1

1

D

LC-6017-3

C

LC-6017-2

LC-6016

C

LC-5004-2

D

LC-1022-3

C

LC-1022-2

LC-12

LC-1023-8

LC-1003

LC-1000-1

86034

86033

86030

86042

86053

86052

85012

86008

86005

Plain

Interm.

Back

Standard Sections (See Table 1.3 for Options)

Front

Rail

Bundle

Channel

Boiler

Model

Number

1

1

1

1

Quantity

LC-1000

LC-1007

LC-1001

Label

Par t N o.

86004

86022

86000

90160

Stock Code

LC-04

2

LC-1000

1

LC-1007

1

LC-1001

1

Par t N o.

Quantity

LC-05R

Label

2

86004

1

86022

1

86000

1

90161

Quantity

Stock Code

LC-05

LC-1000

LC-1007

LC-1001

Label

Par t N o.

3

86004

1

86022

1

86000

1

90161

Quantity

Stock Code

LC-06

LC-1000

LC-1007

LC-1001

Label

Par t N o.

4

86004

1

86022

1

86000

1

90162

Quantity

Stock Code

LC-07

LC-1000

LC-1007

LC-1001

Label

Par t N o.

5

86004

1

86022

1

86000

1

90163

Quantity

Stock Code

LC-08

LC-1000

LC-1007

LC-1001

Label

Par t N o.

6

86004

1

86022

1

86000

1

90164

Quantity

Stock Code

LC-09

LC-1000

LC-1007

LC-1001

Label

Par t N o.

7

86004

1

86022

1

86000

1

90165

Quantity

Stock Code

LC-10

LC-1000

LC-1007

LC-1001

Label

Par t N o.

7

86004

1

86022

1

86000

1

90166

Quantity

Stock Code

LC-11

LC-1000

LC-1007

LC-1001

Label

Par t N o.

8

86004

1

86022

1

86000

1

90167

Quantity

Stock Code

LC-12

LC-1000

LC-1007

LC-1001

Label

Par t N o.

86004

86022

86000

90168

Stock Code

Mounting Hardware

1 Assembly Kit Cartons Contents: Flow Port Gaskets, Silicone Sealant, Tie Rods, Washers, Tie Rod Nuts, Section Seal Rope, Rope Adhesive or Spray Adhesive, Cleanout Plates,

2 Flue Box Carton Contents: Flue Box, Seal Rope, Observation Assembly, Coil Cover Plates, Cover Plate Gaskets, Mounting Hardware

7

PREINSTALLATION

Table 1.2B: Series LCE Shipping List

85013

LCE-8028

A

90523

S-5007-3

E

86094

LCE-6023

B

86032

LCE-6017-1

A

86031

LCE-6017

86030

LCE-6016

D

86043

LC-5011

E

86054

C

86052

1

1

1

2

1

1

1

1

1

Label

Rating

1

Draft

Damper

1

1

Panels

Top/Side

Hardware

Chamber Liner

1

1

Panels

Hardware

Front/Rear

1

Item 1

Contents

See Below

1

Mounting Hardware

Assembly Kit Cartons Jacket Cartons (See Table 1.4 for Options)Flue Ctn. Lbl. Ctn.

Flow Port Gaskets, Silicone Sealant,

1

Rope Adhesive or Spray Adhesive, Cleanout Plates,

Tie Rods, Washers, Tie Rod Nuts, Section Seal Rope,

85014

LCE-8028-1

A

90523

S-5007-3

E

86094

LCE-6023

B

86032

LCE-6017-1

86030

LCE-6016

D

86043

LC-5011

E

86054

D

86053

1

LCE-8028-2

1

S-5007-3

1

LCE-6023

1

LCE-6017-2

1

LCE-6017-1

1

LCE-6016

1

LC-5011

1

1

1

85016

LCE-8028-3

A

90523

S-5007-3

E

86094

LCE-6023

C

86033

LCE-6017-2

86030

LCE-6016

D

86043

LC-5011

E

86054

B

86051

1

1

1

2

1

1

1

1

1

1

1

85015

1

A

90523

1

E

86094

C

86033

2

B

86032

1

86030

1

D

86043

E

86054

1

B

86051

2

A

86050

85017

LCE-8028-4

A

90523

S-5007-3

E

86094

LCE-6023

B

86032

LCE-6017-1

A

86031

LCE-6017

86030

LCE-6016

D

86043

LC-5011

E

86054

C

86052

B

86051

1

1

1

3

1

1

1

2

85018

LCE-8028-5

B

90524

S-5007-4

E

86094

LCE-6023

B

86032

LCE-6017-1

86030

LCE-6016

E

86044

LC-5012

E

86054

C

86052

1

1

1

1

2

1

1

1

1

1

85019

LCE-8028-6

B

90524

S-5007-4

E

86094

LCE-6023

C

86033

LCE-6017-2

B

86032

LCE-6017-1

86030

LCE-6016

E

86044

LC-5012

E

86054

D

86053

C

86052

1

1

1

2

2

1

1

1

2

85020

LCE-8028-7

B

90524

S-5007-4

E

86094

LCE-6023

B

86032

LCE-6017-1

A

86031

LCE-6017

86030

LCE-6016

E

86044

LC-5012

E

86054

D

86053

1

1

1

3

1

1

1

1

1

1

1

85021

LCE-8028-8

B

90524

S-5007-4

E

86094

LCE-6023

B

86032

LCE-6017-1

A

86031

LCE-6017

86030

LCE-6016

E

86044

LC-5012

E

86054

D

86053

B

86051

A

86050

1

1

1

4

1

1

1

1

2

85022

LCE-8028-9

B

90524

S-5007-4

E

86094

LCE-6023

B

86032

LCE-6017-1

86030

LCE-6016

E

86044

LC-5012

E

86054

D

86053

B

86051

1

1

1

1

3

1

1

1

1

1

1

85023

LCE-8028-10

B

90524

S-5007-4

E

86094

LCE-6023

C

86033

LCE-6017-2

B

86032

LCE-6017-1

86030

LCE-6016

E

86044

LC-5012

E

86054

D

86053

C

86052

B

86051

1

LCE-8028-11

1

S-5007-4

1

LCE-6023

2

LCE-6017-2

2

LCE-6017-1

1

LCE-6016

1

LC-5012

1

1

2

85024

B

90524

E

86094

C

86033

B

86032

86030

E

86044

E

86054

D

86053

C

86052

Baffle

Carton

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

86022

6

86004

2

86008

1

86005

3

86100

1

86000

2

90169

Quantity

Stock Code

LCE-14

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Par t No.

1

6

Plain

Interm. Back

1

3" Tap.

Interm.

1

1"

LWCO

Interm.

3

Top

Flue

Interm.

Standard Sections (See Table 1.3 for Options)

1

Front

2

Rail

Bundle

Channel

Quantity

Boiler

Model

Number

LCE-13

Label

1

86022

7

86004

2

86008

1

86005

3

86100

1

86000

2

90162

Quantity

Stock Code

LCE-15

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

86022

8

86004

2

86008

1

86005

3

86100

1

86000

2

90163

Quantity

Stock Code

LCE-16

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

86022

8

86004

3

86008

1

86005

3

86100

1

86000

2

90163

Quantity

Stock Code

LCE-17

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

86022

9

86004

3

86008

1

86005

3

86100

1

86000

2

90164

Quantity

Stock Code

LCE-18

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

86022

10

86004

3

86008

1

86005

3

86100

1

86000

2

90164

Quantity

Stock Code

LCE-19

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

86022

10

86004

4

86008

1

86005

3

86100

1

86000

2

90165

Quantity

Stock Code

LCE-20

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

1

86022

11

86004

4

86008

1

86005

3

86100

1

86000

2

90165

Quantity

Stock Code

LCE-21

LCE-1074

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

86113

1

86022

12

86004

4

86008

1

86005

3

86100

1

86000

2

90166

Quantity

Stock Code

LCE-22

LCE-1074

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

86113

1

86022

13

86004

4

86008

1

86005

3

86100

1

86000

2

90166

Quantity

Stock Code

LCE-23

LCE-1074

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

1

86113

1

86022

14

86004

4

86008

1

86005

3

86100

1

86000

2

90167

Quantity

Stock Code

LCE-24

LCE-1074

LC-1007

LC-1000

LC-1003

LC-1000-1

LCE-1056

LC-1001

Label

Par t No.

86113

86022

86004

86008

86005

86100

86000

90167

Stock Code

1 Flue Box Carton Contents: Top Flue Plate, Rear Flue Cover, Seal Rope, Observation Assembly, Coil Cover Plates, Cover Plate, Gaskets, Mounting Hardware

8

PREINSTALLATION

Note: Boilers with inspection tappings in front and back sections only use
standard cartons.

Table 1.4: Standard and Optional Jacket Cartons,

Top/Side Panels

A
B
C
D

E

Jacket Label

86031
86032
86033
86034
86094

Standard

(No Inspection

Tappings)

86101
86102
86103
86104
86097

With Inspection

Tappings

Table 1.3: Standard and Optional Sections for Knockdown Boilers

Table 1.5A: 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

Sections

15 psig Steam MAWP

Standard w/Inspection Tappings

Par t # Stock Code Part # ITP Stock Code

Front

LC-1001 86000 LC-1013 86010

Intermediate

LC-1000 86004 LC-1014 86014

LWCO Intermediate

LC-1000-1 86005 LC-1014-2 86092

Top Flue Intermediate

LCE-1056 86100 LCE-1064 86110

3" Tapped Intermediate

LC-1003 86008 LC-1015 86016

Closed Back

LC-1007 86022 LC-1016 86018

Coil Back

LC-1002 86036 LC-1017 86026

9

PREINSTALLATION

Table 1.7: Control Cartons

Table 1.6: 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.

Table 1.5B: Burner Mounting Plates

Model

CF2300AKG

CF2300AKB

CF2500

CF3500AKM

CF3500AKL

801CRD
1050FFD
1150FFD

R10.9

R10
R10.1
R10.2

C2
C3

JB2

Boiler Model

86074*

86073

86088

86076

86081

LCE-13

86083*

86073

86088

86076

86081

LCE-14

86083*

86086

86088

86076

86081

LCE-15

86074*

86086

86088

86080
86081

LCE-16

86074*

86087

86088

86080
86081

LCE-17

86083*

86087

86088

86080
86081

LCE-18

86083*

86087

86088

86080
86081

LCE-19

86083*

86087

86088

86080
86081

LCE-20

86080*

86087

86088

86080
86081

LCE-21

86080*

86087

86088

86080
86081

LCE-22

86087

86088

86080
86081

LCE-23

N/A

86088

86080
86081

LCE-24

Beckett

Carlin

Gordon

Piatt

Power

Flame

Webster

* Standard Burner Mounting Plate

Not

Available

Model

Stock

Code

Label

LC-04

LC-05R

LC-05

87000
87000
87000

A
A

A
LC-06
LC-07
LC-08

87000
87000
87000

A

A

A
LC-09
LC-10
LC-11
LC-12

87001
87001
87001
87001

B

B

B

B

LCE-13
LCE-14
LCE-15

87002
87002
87002

C

C

C

LCE-16
LCE-17
LCE-18

87002
87003
87003

C

D

D

LCE-19
LCE-20
LCE-21

87003
87003
87003

D

D

D

LCE-22
LCE-23
LCE-24

87003
87004
87004

D

E

E

Model Stock Code Label

LC-04

Through

LCE-24

88511 Steam

10

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

11

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 rope adhesive or 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 Figures 2.5
and 2.6.

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.

CAUTION

Figure 2.2: Flow Port Machining & Gasket

The sections are heavy and must be supported
securely.

WARNING

12

Figure 2.4: Install Additional Sections. Use level on each section as tie rod bolts are drawn up.

PLACE THE BOILER

13 13

PLACE THE BOILER

Figure 2.5: Series LC Boiler Assembly – Right Side View

14

PLACE THE BOILER

Figure 2.6: Series LCE Boiler Assembly – Right Side View

15

16. To 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 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 2.7
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 2.9.

c. LCE ONLY. Save the (3) Top Flue Outlet

Intermediates (with wide opening in top of the
flue collector) for use as the sections closest to
the LWCO Intermediate Section. See Figure 2.9.

i) The sequence from Front to Rear is:

• Front Section

• 1" Low Water Cut-off Intermediate

• Three (3) Top Flue Outlet Intermediates

ii) The remaining intermediate sections are 3"

Tapped Intermediates or Plain Intermediates
as shown in Figure 2.8 and Figure 2.9.

Do not exceed the manufacturer’s torque
recommendations.

WARNING

PLACE THE BOILER

Figure 2.7: Torque Specification/Procedure

Figure 2.8: Section Positioning Numbering

Table 2.1: Section Numbering Sequence

LC-04
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
LCE-22
LCE-23
LCE-24

Model

Place a Tapped Intermediate

Section at Position

(Numbered Rear to Front)

NA
NA
NA
NA
NA
NA
NA

6
6
8

5, 9
6, 10
6, 11

5, 9, 12
5, 9, 13

5, 9, 14
5, 9, 12, 15
5, 9, 13, 16
5, 9, 13, 17

6, 10, 14, 18
6, 10, 14, 19

16

Figure 2.9: LC/LCE Boiler Section Assembly Sequence

PLACE THE BOILER

17

D. INSTALL COILS OR PLATES

1. Remove the coil cover plates, gaskets and mounting
hardware, located in the Flue Box Carton.

2. 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.

3. Install tankless heaters, if used, in openings #1 and
#3. (Optional on Rear Section)

4. See Figure 2.10.

5. Steam boilers may have up to two coils installed
when supplied with special tankless coil rear seciton.

6. Standard Rear Sections do not have a tankless
opening (position #3). This is available only as
optional construction. This special rear section is
needed to install two coils on a steam boiler.

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:

• 45 psig

• DO NOT EXCEED THESE PRESSURES.

a) 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.

PLACE THE BOILER

Figure 2.10: Tankless Coil Openings

18

Table 2.2: Tankless Coil Ratings

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
LCE-22
LCE-23
LCE-24

Model

GPM Location

5.5

5.62

5.75

6.25

6.5

7.0

7.25

7.5

8.0
–
–
–
–
–
–
–
–
–
–
–
–
–

1
1
1
1
1
1
1
1
1
–
–
–
–
–
–
–
–
–
–
–
–
–

GPM Location

–

6.5

7.0

7.75

8.5

9.25

10.0

10.75

11.50

12.25
13
13
13
13
13
13
13
13
13
13
13
13

–
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

GPM Location

–
–
–
–

13.0

13.75

14.5

15.5

16.5

17.5

18.0

18.75

19.5
20
20
20
20
20
20
20
20
20

–
–
–

–
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

GPM Location

–
–
–
–
–
–

14.5

15.0

16.0
–
–
–
–
–
–
–
–
–
–
–
–
–

–
–
–
–
–

–
1 & 3
1 & 3
1 & 3

–

–

–

–

–

–

–

–

–

–

–

–

–

GPM Location

–
–
–
–
–
–
–

21.5

23.5

24.5
26
26
26
26
26
26
26
26
26
26
26
26

–
–
–
–
–
–

–
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3

GPM Location

–
–
–
–
–
–
–
–
–
–
–
–

33.5

35.5

37.5

39.5
40
40
40
40
40
40

–
–
–
–
–
–
–
–
–
–
–

–
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3
1 & 3

Heater No.

X-1020

Heater No.

X-1021

Heater No.

X-1022

Two Heaters No.

X-1020

Two Heaters No.

X-1021

Two Heaters No.

X-1022

Above heater ratings are based on intermittent demand for water from 40

°F to 140°F with 200°F boiler water.

Steam boilers require a special rear section with coil opening in order to use two tankless heaters.
DANGER: Install mixing valve in hot water supply piping. Water temperature over 125°F can cause severe burns instantly or death from scalds.

PLACE THE BOILER

19

F. APPLY CLEANOUT COVER PLATES

1. Apply the Cleanout Cover Plates on the tops of the
section joints as shown in Figure 2.11.

2. Pre-assemble a steel flat washer and steel nut on the
carriage bolts. Place a carriage bolt into each side of
the cleanout opening as shown in the figure.

3. Tighten the lower nut securely.

4. Press the Cleanout Plate with insulation over the
protruding carriage bolts until the insulation lays
flush against the cast iron.

5. Apply a flat washer and brass nut to the carriage
bolt. Draw the brass nuts down until the insulation
presses firmly against the iron.

G. INSTALL FLUE COLLAR

1. (LC) Remove the Flue Collar and Rear Observation
Door Assembly from the LC Rear Flue Box Carton.
(LCE) Remove the Top Flue Outlet Plate, the Rear
Flue Cover Plate and the Rear Observation Door
Assembly from the LCE Top Flue Outlet Carton.

2. (LC) Attach the Flue Collar to the Back Section with
5/16" x 1¹⁄₂" studs, flat washers and hex nuts
supplied. See Figure 2.12.
(LCE) Attach the Rear Flue Cover Plate to the Rear
Section with 5/16" x 1¹⁄₂" studs, flat washers and nuts
supplied.

3. (LCE) Apply high tack adhesive or spray adhesive
(supplied in Section Assembly Kits) to the rope groove
on the bottom of the Top Flue Outlet Plate. Place the
high temperature rope seal in the groove, overlapping
at the ends for a good seal.

a) Place the plate over the opening provided by the

three top flue intermediate sections at the front of
the boiler. NOTE: Top flue outlet plate is marked
“FRONT▼” for proper orientation.

b) Secure the plate and compress using the 3/8" tie

down assembly, nuts and washers provided. See
Figure 2.13.

c) Inspect the finished seal, particularly where the

plate crosses the section joints.

d) The correct Top Flue Outlet Plate for the LCE

boiler is:

• LCE-13 thru LCE-17 use the 14" flue opening,
part number LCE-5007, Carton D

• LCE-18 thru LCE-24 use the 16" flue opening,
part number LCE-5007-1, Carton E

4. Attach the Rear Observation Door to the Rear
Section with four (4) 5/16"-18 x 3/4" hex head bolts
provided.

PLACE THE BOILER

Figure 2.12: Rear Flue Collar Attachment Figure 2.13: Top Flue Collar Attachment

Figure 2.11: Install Cleanout Cover Plates

20

H. INSTALL FLUE BAFFLES

1. Remove the Front Cleanout Plate from Front
Section.

2. Open Baffles carton. Remove Baffles. For LC Only –
Save Ceramic Fiber Liner for Section I. Save Rating
Label for Chapter 4. Models LCE-13 through LCE­20 do not require baffles.

3. Place baffles as shown in Figure 2.14. Three of these
are special stainless steel baffles, identified with a
1/4" hole punched in each end. These baffles must
be placed in the lowest row of tubes.

4. Install the Front Cleanout Plate.

I. INSTALL CHAMBER LINER

1. (LCE) Remove Ceramic Fiber Liner from Jacket
Carton E. Place the liner on the floor of the
combustion chamber. Place the front end of the liner
flush with the inside of the Front Section. The liner is
24 inches wide. It will not extend all the way to the
rear of the boiler on all boiler sizes. No adhesive is
required, just press the liner down firmly.

PLACE THE BOILER

Figure 2.14: Flue Baffle Locations

21

A. PREPARATION

1. The boiler must be pressure tested as outlined in the
chapter “Place the Boiler Sections” of this manual.

2. The Supply and Return piping can be installed
before installing the jacket. Use nipples long enough
to extend through the jacket.

B. SUPPLY AND RETURN PIPING

1. See Figure 3.3 for piping illustration.

2. Install Top connections sized per Table 3.1.

a) Model LC-04 requires one riser off the Rear

Section. Plug the 4" tapping in the top of the
Front Section.

b) Models LC-05 through LC-10 require two risers,

one off the Front and one off the Rear Section.

c) Models LC-11 and LC-12 require three risers,

one each off the Front and Rear Sections plus
one off the Tapped Intermediate Section.

d) LCE models require three or more risers.

3. Size the Header per Table 3.1. Pipe the header at
least 24 inches above the normal boiler water line.
See Figure 3.1. This is required to prevent water
from carrying over into the header and then to the
system.

4. Figure 3.3 shows the Supply and Return piping for
Parallel Flow Gravity systems and all Pumped Return
Systems.

5. Counterflow Gravity systems require the boiler steam
line to enter the top of the steam main. See
Figure 3.2 for this special case.

6. Do not reduce the size or number of risers
shown. These are required for reliable operation of
the boiler. If the risers are undersized or incorrectly
placed, a sloped water line can occur in the boiler,
causing possible overheating of some sections.

7. Pipe the Header with an offset as shown in the
drawings. This offset prevents the expansion and
contraction of the Header from damaging the boiler
sections.

8. Always locate the Steam Supply take-off

between the Equalizer and the last Boiler
Riser. (See PB Heat, LLC's “Steam Installation

Survey” for discussion). Locating the steam supply
between the risers will cause water carryover to the
system.

9. Do not use a bull head tee to provide steam supply
and equalizer connections. This will cause water level
bounce and carryover.

C. LOW SYSTEM TEMPERATURE

1. The use of a Hartford loop is recommended in all
installations. See Figure 3.1. The loop provides
additional reliability for the system.

2. A check valve must still be installed on the pump
discharge of all pumped return systems.

3. PIPE THE BOILER

Figure 3.1: Supply and Return Connections, Skim Piping, Hartford Loop

PIPE THE BOILER

22

3. On pumped return systems, install a boiler cock after
the pump to allow throttling of the pump discharge.
The pressure after the boiler cock should be no more
than 5 psig above the boiler operating pressure.
Pumping the water into the boiler too fast will cause
collapse of the water level and level control problems.

4. Size the equalizer per Table 3.1. Models LC-11, LC­12 and LCE-13 through LCE 24 require two return
connections to the boiler off of the equalizer line.

5. Pipe the Hartford loop tee so the inside top of the
close nipple is 2 to 4 inches below the normal boiler
water line. See Figure 3.1.

6. If the pump discharge is looped overhead, above the
boiler water line, install spring-loaded check valves at
both the pump discharge and the connection to the
boiler return.

D. MULTIPLE BOILER INSTALLATIONS

1. Figure 3.4 shows typical piping for multiple boiler
Gravity Return systems. Figure 3.5 show typical
piping for multiple boiler Pumped Return Systems.

2. Provide separate feed lines for multiple boiler
pumped return systems. Use either separate feed
pumps or solenoid or motorized valves to isolate
feeding of the boilers. This is needed to provide
reliable level control and avoid nuisance
performance problems.

3. Condensate return units are not effective for multiple
boiler installations since they do not respond to the
needs of the boilers. always use Boiler Feed Units.

4. Install a Float and Thermostatic trap at the boiler
water level on each of the mulitple boilers on a
pumped return system. This prevents flooding of idle
boilers due to condensation of steam.

Figure 3.2: Supply and Return Piping –

Counterflow Gravity Systems

PIPE THE BOILER

Table 3.1: Header, Risers & Equalizer Sizing

Model

I=B=R

Gross

Output

MBH

End Section

Risers

Intermediate Section

Risers

Equalizer

(Inches)

Header

Size

(inches)

Number

Size

(inches)

Number

Size

(inches)

LC-04

LC-05R

LC-05

547
649
707

1
2
2

4
3
3

–
–
–

–
–
–

2
2
2

4
5

5
LC-06
LC-07
LC-08

868
1029
1189

2
2
2

4
4
4

–
–
–

–
–
–

2
2¹⁄₂
2¹⁄₂

5
5

6
LC-09
LC-10
LC-11
LC-12

1350
1511
1672
1832

2
2
2
2

4
4
4
4

–
–
1
1

–

–
3
3

2¹⁄₂
2¹⁄₂

3
3

6
6
6

6
LCE-13
LCE-14
LCE-15

1966
2125
2284

2
2
2

4
4
4

1
2
2

3
3
3

3
3
3

6

8

8
LCE-16
LCE-17
LCE-18

2444
2603
2763

2
2
2

4
4
4

2
3
3

3
3
3

3
4
4

8

8

8
LCE-19
LCE-20
LCE-21

2922
3082
3256

2
2
2

4
4
4

3
4
4

3
3
3

4
4
4

8

8

8
LCE-22
LCE-23
LCE-24

3430
3604
3777

2
2
2

4
4
4

4
4
4

3
3
3

4
4
4

8

8

8

23

PIPE THE BOILER

Figure 3.3: Supply and Return Piping – Pumped Return and Parallel Flow Gravity Systems

24

PIPE THE BOILER

Figure 3.5: Piping Multiple Boilers, Typical, Pumped Return Systems

Figure 3.4: Piping Multiple Boilers, Typical, Gravity Return Systems

25

A. PREPARE THE PARTS

1. Collect all the jacket cartons: Jacket Front & Back
Carton plus Jacket Side & Top Cartons. See

the Shipping List in the front of this manual for the
jacket cartons required. The cartons contain the
jacket parts and screws. The jacket panels are pre­insulated.

2. Remove all needed knockouts from the jacket parts
before beginning assembly.

B. APPLY JACKET SIDES AND CORNERS

1. See Figure 4.2 for details.

2. The Side Panels can be used on either side of
the boiler.

3. Place the Jacket Side Panels on each side leaned
against the Boiler Sections.

4. On Models LC-08 through LC-12, each side uses
two panels. Place the panels so the seam is centered
on the Tapped Intermediate Section. On LCE
models, place panels in the sequence shown in
Table 4.1.

5. On boilers with two or more Jacket Side Panels per
side, join the panels together with #10 x 1/2" sheet
metal screws. Also attach the Jacket Side Panel
Reinforcing Angle inside the jacket at the bottom of
the seam.

6. Attach the Left Front Corner Panel to the Left Side
Panel with #10 x 1/2" sheet metal screws.

7. Attach the Right Front Corner Panel to the Right
Side Panel with #10 x 1/2" sheet metal screws.

C. APPLY JACKET FRONT PANELS

1. Attach the Upper Front Panel to the Right and Left
Front Corner Panels with #10 x 1/2" sheet metal
screws.

2. Attach the Middle Front Panel and Lower Front Rail
in the same manner.

3. Position the Jacket Assembly with the front panels
pushed up against the front section. You will need
the jacket in this position to install the Burner Front
Plate.

D. APPLY JACKET REAR PANEL

1. Attach the Rear Jacket Panel to the Jacket Side
Panels with #10 x 1/2" sheet metal screws.

E. APPLY JACKET TOP PANELS

1. Attach the Top Front Panel to the Sides and Upper
Front Panel with #10 x 1/2" sheet metal screws.

2. Models LC-08 through LC-12 use two Jacket Top
Panels. Place them on top with the seam at the same
point as the side panels. Join them at their seam
with #10 x 1/2" sheet metal screws. On LCE models,
place panels in the sequence shown in Table 4.1.

3. Attach the Jacket Top Panel to the Jacket Top Front
Panel with #10 x 1/2" sheet metal screws.

4. Attach the Top Rear Panel to the Jacket Top Panel
with #10 x 1/2" sheet metal screws.

5. Finish by placing #10 x 1/2" sheet metal screws in
the remaining holes along the Jacket Top Panel
flanges, into the Jacket Side Panels.

F. APPLY PLATES AND LABELS

1. Mount Boiler Rating Plates and Agency Plates on the
Upper Jacket Front Panel as shown in Figure 4.1.

2. Secure metal plates with #6 x 1/4" sheet metal
screws. Apply all adhesive-backed labels.

4. ASSEMBLE THE JACKET

Figure 4.1: Location of Rating, Agency and

Instruction Plates on Jacket Front
Top Panel

Table 4.1: Jacket Top & Side Panel Placement

LCE-13
LCE-14
LCE-15
LCE-16
LCE-17
LCE-18
LCE-19
LCE-20
LCE-21
LCE-22
LCE-23
LCE-24

Model

Locate Jacket Top and Side Panels in

the Position Below

(Numbers are from Rear to Front)

5

(Front)

432

1

(Rear)

–
–
–
–
–
–
–
E
E
E
E
E

–
–
–
–
E
E

E
A
A
B
B
C

E
E
E
E
A
B
C
A
B
B
B
B

B
B
B
C
B
B
B
B
B
B
B
B

A
B
C
C
B
B
B
B
B
B
C
C

ASSEMBLE THE JACKET

26

ASSEMBLE THE JACKET

Figure 4.2: Jacket Assembly

27

VENTING/INSTALL THE BURNER

5. VENTING

Refer to Chapter 1, P

reinstallation, Section D. Chimney
or Vent for installation requirements. Refer to
Chapter 9, Star

ting the Boiler, Section C. Run Burner

Check Out

for damper settings and draft requirements.

6. INSTALL THE BURNER

A. BURNER APPLICATION

1. Refer to Burner Spec and Data Sheets for the Oil
and Gas/Oil Burners pre-tested with Series LC/LCE
boilers.

2. Make sure the nozzle sizing and spray pattern match
those given in the spec and data sheets.

3. See Figure 6.1 and Table 6.1 for combustion
chamber dimensions.

B. INSTALL BURNER MOUNTING PLATE

1. The Burner Mounting Plate is made to fit the burner
being used. Burners vary in bolt pattern for the
flange, burner tube diameter, insertion length and
near-tube configuration. Make sure the front plate is
correct for your burner if purchased separately from
the boiler.

2. Remove the Burner Mounting Plate and Hardware
Bag from the crate.

3. Screw (7) 3/8"-16 x 2 1/4" studs into the holes in the
front section around the chamber opening.

4. Secure the Burner Mounting Plate to the front
section with the flat washers and hex nuts.

C. MOUNT THE BURNER

1. Remove the Burner from its crate. Read the burner
instructions.

2. Insert (4) 3/8"-16 x 1 1/4" studs supplied with Burner
Mounting Plate into the front plate holes.

3. Place the high temperature gasket on the burner
front plate and secure the burner to the front plate
with 3/8" flat washers and hex nuts.

4. If the burner is supplied with a pedestal, install it to
the burner per the Burner Manufacturer’s
Instructions. The pedestal provides additional
support and prevents the burner from sagging.

28

INSTALL THE BURNER

Figure 6.1: Combustion Chamber Layout – See Table 6.1 for Dimensions

Table 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
LCE-13
LCE-14
LCE-15
LCE-16
LCE-17
LCE-18
LCE-19
LCE-20
LCE-21
LCE-22
LCE-23
LCE-24

Model

Chamber

Length

“A”

(Inches)

Burner Front Plate Extension Past Jacket (Inches)

Beckett Carlin

Gordon-

Piatt

Power

Flame

Webster

18⁷⁄₈
23¹⁵⁄₁₆
23¹⁵⁄₁₆

29

34¹⁄₁₆

39¹⁄₈

44³⁄₁₆

49¹⁄₄

54⁵⁄₁₆

59³⁄₈

64⁷⁄₁₆

69¹⁄₂

74⁹⁄₁₆

79⁵⁄₈
84¹¹⁄₁₆

89³⁄₄
94¹³⁄₁₆

99⁷⁄₈

104¹⁵⁄₁₆

110

115¹⁄₁₆

120¹⁄₈

6¹⁄₈
6¹⁄₈
6¹⁄₈
6¹⁄₈
6¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈

1¹⁄₈
N/A
N/A

6¹⁄₈
6¹⁄₈
6¹⁄₈
6¹⁄₈
6¹⁄₈
6¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈

N/A

6¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈

6¹⁄₈
6¹⁄₈
6¹⁄₈
6¹⁄₈
6¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈

6¹⁄₈
6¹⁄₈
6¹⁄₈
6¹⁄₈
6¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈
1¹⁄₈

29

A. GENERAL

1. Read the Burner Instruction Manual, supplied with
the boiler or with the burner if purchased separately.
Review applicable code requirements for burner and
fuel piping installations.

2. Install piping to allow removal of burner and access
to combustion chamber for cleaning or service.

B. INSTALL FUEL OIL PIPING

1. Place the fuel oil tank and install the piping in
accordance with NFPA-31 and all other applicable
codes.

2. General Guidelines for Oil Piping

a) Follow the guidelines in the Burner Manual for

sizing oil lines. Never use smaller than 1/2" OD
copper tubing.

b) Install manual shut-off valves on the suction line

at the burner and at the oil line entrance to the
building. If installing a shut-off valve on the
return line, you must provide an oil pressure
relief valve piped ahead of the shut-off valve and
discharged to the tank to prevent over-pressure
conditions.

c) Install a two-pipe oil distribution system when

possible. It will improve the reliability of the oil
delivery to the burner.

d) Use flare fittings when using copper tubing.

e) Provide an oil line filter in the suction line. Size

the filter for the suction gear capacity of the
burner oil pump if running a two-pipe system.

f) If burner is above the top of the fuel oil tank,

install a check valve on the oil suction line at the
burner to prevent oil from evacuating the line. If
burner is below the top of the tank, install an
anti-siphon device to prevent oil flow should the
oil line break.

C. INSTALL GAS SUPPLY PIPING

1. Size the piping as required by the National Fuel Gas
Code, ANSI Z223.1 or as required by local codes.

a) Use Table 7.1 for sizing of natural gas for a

system pressure drop of 0.3 inch water column.

2. The standard gas train is designed for a maximum
pressure of 1/2 psig (14 inches water column). Make
sure the system regulator will not allow a higher
pressure to the Gas Control Train under any
conditions.

3. The minimum gas supply pressure is listed on the
Burner Rating Plate. Make sure the system regulator
and the piping are sized and adjusted properly to
provide this pressure under all conditions.

4. Install a Service Valve, Sediment Trap and Ground
Joint Union at the supply connection to the Gas
Control Train as shown in Figure 7.1. These are not
supplied with the boiler. Install them in accordance
with local codes.

5. Use only pipe joint compounds rated for use with
Liquefied Petroleum Gases.

D. TEST GAS SUPPLY PIPING

1. ISOLATE THE BOILER GAS CONTROL TRAIN
FROM THE SYSTEM DURING TEST:

a) Test pressure 1/2 psig or less – Close the Manual

Shut-Off Valve on the Boiler Gas Control Train.

b) Test pressure over 1/2 psig – Disconnect the gas

supply piping upstream of the Boiler Manual
Shut-Off Valve.

CONNECT FUEL PIPING

7. CONNECT FUEL PIPING

Figure 7.1: Gas Supply Connection to Boiler

Do not expose the Gas Control Train to excessive
pressure. The gas valves can be damaged. This could
result in explosion hazard and severe personal injury
or death.

Do not test gas supply piping with open flame. Use a
soap suds mixture brushed onto the pipe joints to
test for leaks.

WARNING

30

CONNECT FUEL PIPING

Table 7.1: Capacity of Gas Supply Pipe in Cubic Feet Per Hour of Natural Gas for Pressure Drop of

0.3 inch Water Column.

10

20

30

40

50

60

70

90

100

150

1050

730

590

500

440

400

350

320

305

250

1600

1100

890

760

670

610

560

490

460

380

3050

2100

1650

1450

1270

1150

1050

930

870

710

4800

3300

2700

2300

2000

1850

1700

1500

1400

1130

8500

5900

4700

4100

3600

3250

3000

2600

2500

2000

17500

12000

9700

8300

7400

6800

6200

5400

5100

4100

44000

31000

25000

22000

20000

18000

17000

15000

14000

11500

Pipe Length

(Feet)

1-1/4"

Pipe

1-1/2"

Pipe

2"

Pipe

2-1/2"

Pipe

3"

Pipe

4"

Pipe

6"

Pipe

Above ratings based on natural gas with specific gravity of 0.60 allowing pressure drop of 0.3 inches water column. No allowance is needed for
pipe fittings. Use the following multipliers on above capacities for specific gravity other than 0.60:

Specific Gravity

Multiply Capacity by: 1.10

0.50

1.04

0.55

1.00

0.60

0.962

0.65

0.926

0.70

31

A. INSTALL SAFETY VALVES

1. Pipe the Pop Safety Valve on a tee mounted in the
2¹⁄₂" tapping located on the upper left side of the
Rear Section. Make sure the relief valve sizing meets
local code requirements.

2. Install a 2" ball valve for skimming off the end of the
tee as shown in the piping drawings in this manual.

B. INSTALL BLOWDOWN VALVES

1. Install a 1¹⁄₂" full port ball valve off of the return
connection as shown in the “Pipe the Boiler” section
of this manual. See Figure 8.1.

2. Pipe the valve discharge to a floor drain if available
or apply a nipple and cap to close off when not in
use.

C. INSTALL LOW WATER CUTOFF(S)

1. Mount a float type Low Water Cutoff and Gauge
Glass in the tappings provided in the side of the front
section or the side and top of the first intermediate
section.

2. Do not apply piping which would raise or lower the
location of the cutoff relative to the tappings in the
boiler. Raising the water level over the design height
will cause water carryover to the system.

3. For correct location of typical low water cutoff/feeder
or low water cutoff/pump control, see Figures 8.4
through 8.7.

4. See Figure 8.2 for the location of control connection
tappings.

5. Provide each float low water cutoff with a blowdown
valve. Pipe the blowdown away from traffic to a floor
drain if available. The blowdown valve is required
for proper maintenance of the control.

6. Maintain a height of 46¹⁄₂" from boiler foundation to
the normal water level.

7. When using Multiple Float Type Controls: Always
pipe the controls off of the same tappings to the
boiler. Do not mount on different ends of the boiler
or in different tappings. This can cause erratic
operation and nuisance problems with the controls.

D. INSTALL PRESSURE CONTROLS

1. Pipe the Steam Pressure Gauge and Boiler Limit and
Operating Pressure Controls as shown in Figure 8.3.
Connect the control assembly to the 1/2" tapping in
the front section.

E. PIPE TANKLESS HEATER(S)

1. Connect piping to any installed tankless heaters. See
Figure 8.8 for suggested piping for single coils and
Figure 8.9 for suggested piping for dual coils.

F. CONNECT SUPPLY WIRING

1. Install all wiring in accordance with local codes, the
National Electrical Code and other controlling
agencies or governing bodies.

2. Use #14 gauge or heavier wire for supply wiring.
Protect the circuit with a fused disconnect switch (by
others) and a grounded neutral.

3. Mount an electrical junction box on the boiler Front
Panel for connection of supply wiring and
distribution to the boiler controls.

4. Follow the instructions in the Burner Manual and the
Wiring Diagrams supplied with the burner and the
boiler.

INSTALL CONTROLS, TRIM & WIRING

8. INSTALL CONTROLS, TRIM & WIRING

Pipe the discharge of the Safety Relief Valve away
from any traffic area, preferably to a floor drain. This
is necessary to prevent injury should the valve
discharge.

Pipe the discharge full size of valve outlet.

CAUTION

Make sure that the ignition system components,
electrical controls, junction boxes and electrical
panels are protected from water (dripping, spraying,
rain, etc.) during boiler operation and service (trap
servicing, control replacements or other).

CAUTION

The boiler/burner must be electrically grounded in
accordance with the requirements of the authority
having jurisdiction, or in the absence of such
requirements, with the current edition of the National
Electrical Code, ANSI/NFPA Number 70.

NOTICE

32

G. INSTALL CONTROL WIRING

1. Wire the boiler according to the wiring diagrams
supplied with the burner and the boiler (in the Boiler
Envelope).

2. Low Energy Safety Control wiring, if used, must
follow the contour of the boiler. Some local codes
may require that all wiring, even low voltage, be
routed in conduit.

3. Install line voltage wiring in conduit.

4. Do not install single pole switches, including safety
controls, in a grounded line.

INSTALL CONTROLS, TRIM & WIRING

Figure 8.1: Blowdown Valve, Safety Valve and Skim Valve Piping

33

INSTALL CONTROLS, TRIM & WIRING

Figure 8.2: Control and Pipe Tapping Locations

34

INSTALL CONTROLS, TRIM & WIRING

Figure 8.3: Control and Pipe Tapping Locations

35

INSTALL CONTROLS, TRIM & WIRING

Figure 8.5: Optional Model 47-2 Low Water Cutoff/Feeder – Use only up to Model LC-07

Figure 8.4: Optional Model 67PE2 Float Low Water Cutoff

36

INSTALL CONTROLS, TRIM & WIRING

Figure 8.6: Optional Float Type Pump Control/Low Water Cutoff, Model 157

37

INSTALL CONTROLS, TRIM & WIRING

Figure 8.7: Optional Feeder/Low Water Cutoff, Type 51-2

38

INSTALL CONTROLS, TRIM & WIRING

Figure 8.9: Suggested Piping – Dual Tankless Coil Installation

Figure 8.8: Suggested Piping – Single Tankless Coil Installation

39

A. CHECK THE PIPING

1. Steam Piping
a) The Boiler must have been hydrostatically tested.

b) Check the attached piping for joint tightness.

c) Continue monitoring as you proceed through

start up.

2. Gas Piping
a) Make sure the gas system piping and the

connections to the boiler Gas Control Train(s)
have been leak tested.

b) After the boiler is in operation, check the

tightness of all joints in the boiler gas piping with
a soap suds solution.

c) Purge the gas piping of all air up to the boiler

Gas Control Train.

3. Oil Piping
a) Check the oil piping visually. Make sure all joints

are tight.

b) When the burner is firing, check the suction line

and return line pressures.

c) If the pressure exceeds the allowable pressure in

the Burner Manual or if the suction line vacuum
is higher than allowable, correct the piping as
needed to bring the suction line and return line
pressures within acceptable range.

d) Excess pressure can cause pump seal failures.

Excess vacuum will cause fuel flow problems
with the burner oil pump.

B. FILL THE BOILER

1. Fill the boiler to the normal water line.
a) Gravity Systems and Pumped Return with

Condensate Units – Fill to 46¹⁄₂" above the boiler
foundation (center of gauge glass).

b) Pumped Return with Boiler Feed Unit - Fill the

boiler using the boiler feed unit. Fill level will
depend on the control being used, but should be
46¹⁄₂" above the boiler foundation (just below
center of gauge glass) when the pump stops.

C. RUN BURNER CHECK-OUT

1. Before firing the burner, slide the Slide Gate Damper

on the rear flue box all the way down (full open) on
LC’s or open the LCE Draft Damper until the handle
is parallel to the vent pipe (full open).

2. Follow the instructions in the Burner Manual for

starting the burner, adjusting air openings and fuel
rates. Perform ignition system and flame supervisory
control test and checkout as described in the manual.

3. After burner is set at rate, close the damper until the

pressure reading at the test opening in the rear flue box
or draft damper is between 0" wc and 0.1" wc positive.
See Table 9.1 for typical overfire pressure (measured
at the burner front plate) and boiler draft loss.

When a barometric draft regulator is installed in the
venting system, adjust the boiler damper for 0" wc
pressure reading at the damper. Adjust the draft
regulator for -0.05" wc draft between the boiler
damper and the draft regulator.

4. Adjust the burner as needed for a CO

2

reading of:

a) Oil burners: 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.

5. Inspect all flue gas joints (sections, attachments,
breeching and vent) for gas tightness. Remove the
jacket panels in order to thoroughly inspect all rope
seal joints between the sections.

D. CHECK BOILER CONTROLS

1. Limit and Operating Temperature Controls

a) Lower the setting of each control until the burner

shuts down.

2. Low Water Cutoffs

a) Test probe type controls by using the Push-to-Test

Button.

b) Test float type controls.

3. Follow additional instructions in the Burner Manual
for proving the burner component operation.

4. Check all controls to make sure they function
correctly.

5. After all controls have been proven, set the
Operating and High Limit Temperature Controls to
the temperatures desired.

E. CLEAN THE BOILER

1. Clean the boiler as described below no later than
one week after the initial start-up. Cleaning will be
more effective if the boiler operates a day or two to
loosen sediment and impurities in the system.

9. STARTING THE BOILER

STARTING THE BOILER

Cleaning the boiler requires the use of very hot water
and corrosive chemicals. Use care when handling to
prevent injury.

WARNING

On installations with high draft, do not leave the
boiler with a negative draft reading at the rear flue
box or draft damper. High negative draft can pull the
flame up into the boiler crown sheet and overheat the
iron. This can result in cracked sections or shortened
boiler life.

CAUTION

40

2. The boiler must be cleaned to remove any
accumulation of oil, grease, sludge, etc. that may be
in the system. These substances can cause foaming
and surging of the boiler water, producing unstable
water line and water carryover to the system.

3. The piping for a 2" Skim Valve must be done as
shown in this manual, with the skim valve mounted
off the Pop Safety Valve tee on the rear of the boiler.

4. Use common washing soda (such as Arm and Hammer
Super Washing Soda). Mix the soda with water in a 10
quart pail. Use a proportion of one pound of washing
soda for each 800 square feet EDR net boiler rating.
Remove the Pop Safety Valve and pour the washing
soda solution into the boiler through the Pop Safety
Valve tee. Replace Pop Safety Valve.

5. Connect a 2 inch drain line off of the Skim Valve,
run to a point of safe discharge.

6. Close all valves to the system. Provide a means of
continuous fresh water to the boiler for the cleaning
process.

7. Open the Skim Valve. Fill the boiler until water
begins to flow out of the valve.

8. Turn burner on and allow the boiler water to heat up
to just below steaming (180° to 200° F). Cycle the
burner to maintain temperature during skimming. Do
not allow the boiler to steam. Steaming mixes up the
contaminants in the water instead of floating them at
the surface.

9. Open the make-up water valve to continuously feed
water to the boiler. Allow water to flow out the skim
tapping.

10. Continue skimming the boiler until the water flowing
from the skim tapping flows clear. This will take
some time, possibly several hours for a dirty system.

11. After skimming is complete, close the skim valve and
turn off the boiler.

12. Close the make-up water valve and open the boiler
blowdown valves.

13. Drain the boiler completely, then refill and drain
again one or two times to make sure all of the soda
has been washed out.

14. Restore piping to normal. Pipe a nipple and cap in
the skim valve.

15. Note: If the gauge glass becomes dirty again, this
indicates more contaminants have worked loose in
the system. Repeat the cleaning and skimming
process as needed to clean the system.

STARTING THE BOILER

Table 9.1: Typical Combustion Chamber Pressure and Boiler Draft Loss

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
LCE-22
LCE-23
LCE-24

+ 0.22
+ 0.22
+ 0.24
+ 0.26
+ 0.27
+ 0.28
+ 0.29
+ 0.30
+ 0.31
+ 0.32
+ 0.24
+ 0.25
+ 0.26
+ 0.27
+ 0.28
+ 0.29
+ 0.30
+ 0.31
+ 0.31
+ 0.31
+ 0.32
+ 0.32

Model

Boiler Draft Loss

(Inches w.c.)

Combustion Chamber Pressure

with 0.1" w.c. at Rear Flue Box Test Port

(Inches w.c.)

0.12

0.12

0.14

0.16

0.17

0.18

0.19

0.20

0.21

0.22

0.14

0.15

0.16

0.17

0.18

0.19

0.20

0.21

0.21

0.21

0.22

0.22

NOTE: Actual chamber pressure and draft loss readings may vary with each boiler and installation due to variation in the heat exchanger,
deposits in the flueways, actual burner firing rate and excess air conditions. Use the above numbers as a general guide only. If the measured draft
loss is considerably higher than the above, check the flueways for deposits and confirm the burner firing rate.

Do not leave the boiler unattended while firing.

Take great care not to allow the water level to drop
below the bottom of the gauge glass or to allow fresh
water make-up to flow in too fast. This will avoid the
possibility of causing the boiler sections to fracture.

CAUTION

WARNING

Product Safety Information

Refractory Ceramic Fiber Product

This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF,
when inhaled, have been classified by the International Agency for Research on Cancer
(IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to
temperatures above 1800°F (982°C), they can change into crystalline silica, which has been
classified by the IARC as carcinogenic to humans. If particles become airborne during
service or repair, inhalation of these particles may be hazardous to your health.

Avoid Breathing Fiber Particulates and Dust

Suppliers of RCF recommend the following precautions be taken when handling these
materials:

Precautionar

y Measures:
Provide adequate ventilation.
Wear a NIOSH/MSHA approved respirator.
Wear long sleeved, loose fitting clothing and gloves to prevent skin contact.
Wear eye goggles.
Minimize airborne dust prior to handling and removal by water misting the material and
avoiding unnecessary disturbance of materials.
Wash work clothes separately from others. Rinse washer thoroughly after use.
Discard RCF materials by sealing in an airtight plastic bag.

Fir

st Aid Procedures:
Inhalation: If breathing difficulty or irritation occurs, move to a location with fresh clean air.
Seek immediate medical attention if symptoms persist.
Skin Contact: Wash affected area gently with a mild soap and warm water. Seek immediate
medical attention if irritation persists.
Eye Contact: Flush eyes with water for 15 minutes while holding eyelids apart. Do not rub
eyes. Seek immediate medical attention if irritation persists.
Ingestion: Drink 1 to 2 glasses of water. Do not induce vomiting. Seek immediate medical
attention.

41

10. MAINTENANCE

MAINTENANCE

42

A. PLACING BOILER IN OPERATION

1. Start up the Burner/Boiler per the Burner Manual
and the instructions in this manual on starting 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.

4. Test the limit and operating controls to assure they
are operating correctly.

5. Inspect and test all low water cutoffs.

6. Test the safety relief valve(s) using the procedure
given by the valve manufacturer on the valve tag.

7. Visually inspect the burner and pilot flames (if
applicable).

B. TO SHUT DOWN THE BOILER

1. Turn off Burner.

2. Open main line power disconnect switch to
boiler/burner.

3. Close fuel shut-off valves.

4. To take boiler out of service if the boiler and system
are not to be used when temperatures are below
freezing:

a) Drain the boiler and system completely and shut

off make-up water supply.

b) Open main line power disconnect switch to

boiler/burner. Remove the fuses or secure the
switch so that the power cannot be turned on
accidentally.

c) Be certain that the boiler and system are refilled

before returning to service. Follow the
Instructions in this manual and the Lighting
Instructions to operate.

d) The system may be filled with a 50% inhibited

propylene glycol solution for protection down to

-35°F. Use only antifreeze solutions specifically
designed for hydronic use.

C. MAINTENANCE – ANNUAL

1. Before the start of each heating season, inspect
and make all necessary adjustments to insure proper
boiler and burner operation. Use the maintenance
and inspection procedures following.

2. Inspect the Venting System

a) Check the chimney or vent to make sure it is

clean and free from cracks or potential leaks.

b) All joints must be tight and sealed.

c) The vent connector must extend into, but not

beyond the inside edge of the chimney or vent.

3. Inspect the Boiler Area

a) The boiler area must be clean and free from

combustible materials, gasoline or any other
flammable liquids or vapors.

b) The combustion air openings and the area

around the boiler must be unobstructed.

4. Inspect boiler flueways and burner for cleanliness. If
cleaning is required, use the following procedure.

a) Turn off all electrical power to the boiler.

b) Remove Jacket Middle Front Panel and Jacket

Top Panels. Remove Front Cleanout Plate and
Cleanout Cover Plates on each flueway. On LCE
boilers, remove the top flue outlet plate and vent
piping as necessary to access the top of the
sections.

c) Brush the boiler tube spaces both horizontally

(through cleanout openings on ends) and
vertically (from top of boiler through cleanout
openings at flueways).

MAINTENANCE

Do not store or allow combustible or flammable
materials near the boiler. Substantial fire or explosion
hazard could result, causing risk of personal injury,
death or property damage.

Do not use this boiler if any part of it has been under
water. Immediately call a qualified service technician
to inspect the boiler. Any part of the control system,
any gas control or any burner or gas component
which has been under water must be replaced.

Should overheating occur or the fuel supply fail to
shut off: Shut off the fuel supply at a location
external to the boiler. Do not turn off or disconnect
the electrical supply to the pump. Immediately call a
qualified service technician to inspect the boiler for
damage and defective components.

WARNING

Before servicing the boiler:

• Turn off all electrical power to the boiler.

• Close the Gas Service Valve and Oil Shut-Off Valve.

• Allow the boiler to cool if it has been operating.

• Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper
operation after servicing.

CAUTION

43

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. Take care not to damage the
chamber floor liner or target wall liner.

e) Replace the Front Cleanout Plate, Burner

Mounting Plate, Burner and all Cleanout Cover
Plates on top of the sections. Make sure all
sealing rope and seals are in good condition.
Replace sealing rope if necessary.

f) Replace all Jacket Panels.

5. Inspect the boiler and piping for signs of leaks.
Check to see if there are signs of heavy make-up
water addition to the system.

6. When placing boiler into operation, follow Burner
Manual, all instructions supplied with the boiler and
the instructions in this chapter.

7. Test the operation of all limit controls, float controls
and ignition components as described in Part A,
“Placing Boiler in Operation”, of this chapter.

D. MONTHLY MAINTENANCE

1. Inspect the burner and pilot flames as for the annual
inspection.

2. Inspect the boiler and system for any signs of
leakage or excessive make-up water usage.

3. Inspect and check the operation of the venting
system.

E. DAILY MAINTENANCE

1. Inspect the boiler area to make sure the area is free
from combustible or flammable materials and that
there are not obstructions to the flow of air to the
boiler or combustion air openings to the room.

2. Make sure there are no signs of abnormal operation,
such as overfilling or leakage.

MAINTENANCE

Be very careful when adding water to a hot boiler.
Add very slowly or, if possible, allow the boiler to
cool naturally before adding water.

If an excessive loss of water occurs, check for a leak
in the piping and correct the problem. Excessive
make-up water will cause corrosion and damage to
the boiler.

CAUTION

44

BOILER RATINGS & DIMENSIONS

11. BOILER RATINGS & DIMENSIONS

Table 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 1.15.
3 Net I=B=R steam ratings based on an allowance for LC-04 to LC-08=1.333, LC-09=1.323, LC-10=1.310, LC-11=1.298, LC-12=1.290,

LCE-13 to LCE-24=1.288.

4 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping

systems, etc.

5 Combustion efficiency determined in accordance with The Hydronics Institute’s Testing and Rating Standard for Heating Boilers.

Gross

I=B=R

Output

Mbh

Boiler

Model

Number

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
LCE-22
LCE-23
LCE-24

547
649
707

868
1029
1189
1350
1511
1672
1832
1966
2125
2284
2444
2603
2763
2922
3082
3256
3430
3604
3777

16.3

19.4

21.1

25.7

30.7

35.5

40.3

45.1

49.9

54.7

58.7

63.5

68.2

73.0

77.8

82.5

87.3

92.1

97.3

102.5

107.7

112.8

4.75

5.60

6.10

7.50

8.80

10.20

11.60

12.80

14.20

15.60

17.00

18.40

19.80

21.00

22.50

24.00

25.00

26.50

28.00

29.50

31.00

32.50

Boiler

H.P.

Oil

GPH

I=B=R Burner Capacity

686
808

881
1077
1273
1469
1664
1860
2056
2252
2464
2657
2850
3043
3236
3429
3622
3815
4027
4239
4451
4663

Gas
MBH

1708
2029
2208
2713
3217
3717
4250
4804
5367
5917
6358
6875
7388
7908
8421
8938
9454

9971
10533
11096
11658
12217

Steam

Sq. Ft.

I=B=R Net Ratings

410
487
530
651
772

892
1020
1153
1288
1420
1526
1650
1773
1898
2021
2145
2269
2393
2528
2663
2798
2932

Steam

MBH

476
564
615
755

895
1034
1174
1314
1454
1593
1710
1848
1986
2125
2263
2403
2541
2680
2831
2983
3134
3284

Water

MBH

83.7

83.7

83.7

83.7

83.6

83.6

83.6

83.6

83.6

83.6

83.5

83.5

83.5

83.5

83.5

83.5

83.5

83.5

83.6

83.6

83.7

83.7

Oil

Combustion Efficiency

81.2

81.2

81.2

81.1

81.1

81.1

81.1

81.1

81.1

81.1

81.0

81.0

81.0

81.0

81.0

81.0

81.0

81.0

81.1

81.1

81.2

81.2

Gas

SERIES LC/LCE BOILER RATINGS

Figure 11.1: Tankless Coil Pressure Drops

BOILER RATINGS & DIMENSIONS

Figure 11.2: Series LC Dimensional Diagram

Figure 11.3: Series LCE Dimensional Diagram

45

46

BOILER RATINGS & DIMENSIONS

SERIES LC/LCE BOILER DIMENSIONS

Boiler

Model

Number

Jacket Supply Piping

Return

Piping

Riser Tapping Locations*

Burner

Center

Line

Vent Location Vent

Width

“A”

Length

“B”

Height

“C”

Risers Size

Recom.

Header

End Sect.

Tappings

Intermediate Section Tapping

“D” “E”

Diameter

“F”

Minimum

Height

Equalizer “G1” “G2” “G3” “G4”

LC-04 37" 25-15/16" 63" 1 4" 4" 2" 16-1/2" – – – – 18-1/2" 18-1/4" 54-1/8" 9" 3'

LC-05R 37" 31" 63" 2 3" 5" 2" 21-9/16" – – – – 18-1/2" 18-1/4" 54-1/8" 9" 3'

LC-05 37" 31" 63" 2 3" 5" 2" 21-9/16" – – – – 18-1/2" 18-1/4" 54-1/8" 9" 3'

LC-06 37" 36-1/16" 63" 2 4" 5" 2" 26-5/8" – – – – 18-1/2" 18-1/4" 54-1/8" 10" 3'

LC-07 37" 41-1/8" 63" 2 4" 5" 2-1/2" 31-11/16" – – – – 18-1/2" 18-1/4" 54-1/8" 10" 3'

LC-08 37" 46-5/16" 63" 2 4" 6" 2-1/2" 36-13/16" – – – – 18-1/2" 18-1/4" 54-1/8" 10" 3'

LC-09 37" 51-3/8" 63" 2 4" 6" 2-1/2" 41-7/8" – – – – 18-1/2" 18-1/4" 54-1/8" 12" 3'

LC-10 37" 56-7/16" 63" 2 4" 6" 2-1/2" 46-15/16" – – – – 18-1/2" 18-1/4" 54-1/8" 12" 3'

LC-11 37" 61-1/2" 63" 2, 1 4", 3" 6" 3" (2 Ret.) 52" 26" – – – 18-1/2" 18-1/4" 54-1/8" 12" 3'

LC-12 37" 66-9/16" 63" 2, 1 4", 3" 6" 3" (2 Ret.) 57-1/8" 26" – – – 18-1/2" 18-1/4" 54-1/8" 12" 3'

LCE-13 37" 71-3/4" 63" 2, 1 4", 3" 6" 3" 62-3/16" 36-3/16" – – – 18-1/2" 16" 20-1/2" 14" 3'

LCE-14 37" 76-13/16" 63" 2, 2 4", 3" 8" 3" 67-1/4" 20-15/16" 20-5/16" – – 18-1/2" 16" 20-1/2" 14" 3'

LCE-15 37" 81-7/8" 63" 2, 2 4", 3" 8" 3" 72-5/16" 26" 20-5/16" – – 18-1/2" 16" 20-1/2" 14" 3'

LCE-16 37" 86-15/16" 63" 2, 2 4", 3" 8" 3" 77-7/16" 26" 25-7/16" – – 18-1/2" 16" 20-1/2" 14" 3'

LCE-17 37" 92-1/8" 63" 2, 3 4", 3" 8" 4" 82-1/2" 20-15/16" 20-5/16" 15-1/4" – 18-1/2" 16" 20-1/2" 14" 3'

LCE-18 37" 97-3/16" 63" 2, 3 4", 3" 8" 4" 87-9/16" 20-15/16" 20-5/16" 20-5/16" – 18-1/2" 16" 20-1/2" 16" 3'

LCE-19 37" 102-1/4" 63" 2, 3 4", 3" 8" 4" 92-5/8" 20-15/16" 20-5/16" 25-7/16" – 18-1/2" 16" 20-1/2" 16" 3'

LCE-20 37" 107-7/16" 63" 2, 4 4", 3" 8" 4" 97-3/4" 20-15/16" 20-5/16" 15-1/4" 15-1/4" 18-1/2" 16" 20-1/2" 16" 3'

LCE-21 37" 112-1/2" 63" 2, 4 4", 3" 8" 4" 102-3/16" 20-15/16" 20-5/16" 20-5/16" 15-1/4" 18-1/2" 16" 20-1/2" 16" 3'

LCE-22 37" 117-9/16" 63" 2, 4 4", 3" 8" 4" 107-7/8" 20-15/16" 20-5/16" 20-5/16" 20-5/16" 18-1/2" 16" 20-1/2" 16" 3'

LCE-23 37" 122-5/8" 63" 2, 4 4", 3" 8" 4" 112-15/16" 26" 20-5/16" 20-5/16" 20-5/16" 18-1/2" 16" 20-1/2" 16" 3'

LCE-24 37" 127-11/16" 63" 2, 4 4", 3" 8" 4" 118-1/16" 26" 20-5/16" 20-5/16" 26" 18-1/2" 16" 20-1/2" 16" 3'

*These dimensions are approximate.

Table 11.2: Series LC/LCE Boiler Dimensions

47

REPAIR PARTS

12. REPAIR PARTS

Figure 12.1: Series LC Boiler Assembly

Repair parts are available from your installer or by contacting PB Heat, LLC, P.O. Box
447, New Berlinville, PA 19545-0447. Use the Figures and Tables on pages 47-52 to
assist in ordering parts.

Note: Remember to include boiler model number and serial number when ordering parts.

48

REPAIR PARTS

Table 12.1A: Series LC Repair Parts

Item

No.

Description Part Selection Information

Stock

Code

1 Front Section See Table 1.3 for Stock Code

2 Intermediate Section w/1" Tapping See Table 1.3 for Stock Code

3 Intermediate Section See Table 1.3 for Stock Code

4 Back Section See Table 1.3 for Stock Code

5 Tapped Intermediate Section See Table 1.3 for Stock Code

Upper Flow Port Gasket 2 Required per Flueway 51671

Lower Flow Port Gasket 1 Required per Flueway 51672

6 Tie Rod 4 Required per Flueway 51721

5/8" Diameter High Temp Rope 13 Feet Required per Flueway 55723

7 Ceramic Fiber Base Liner Models LC-04 through LC-12 50862

8 Ceramic Fiber Target Wall 50854

9 Front Cleanout Plate (C.I.) 51162

10 5/16"-18 x 1-1/4" Studs w/Brass Nuts 4 Required

11 Steel Cover Plate 51776

12 Steel Cover Plate 51777

13 Tankless Heater Location 1 Specify Heater Model Number

14 Tankless Heater Location 2 Not Used On Steam

15 Tankless Heater Location 3 Specify Heater Model Number

16 Rubber Gasket Specify Quantity 51800

17 3/8"-16 x 3/4" SS Hex Head Cap Screw Specify Quantity

18 Rear Observation Assembly 90923

19 5/16"-18 x 3/4" Hex Head Cap Screw Specify Quantity

20 Burner Mounting Plate Specify Burner Model

21 3/8"-16 x 2-1/4" Studs with Nuts

22 Flame Observation Assembly 90922

23 3/8"-16 x 1" Studs for Burner Mounting 4 Required

24 1/4"-20 x 1/2" Hex Head Machine Screw 4 Required

25 Cleanout Cover Plate (Steel) 1 Required per Flueway 51772

26 Rear Flue Box w/9" Flue Outlet Models LC-04 and LC-05 86040

Rear Flue Box w/10" Flue Outlet Models LC-06, LC-07 and LC-08 86041

Rear Flue Box w/12" Flue Outlet Models LC-09, LC-10, LC-11 and LC-12 86042

27 Rear Flue Box Stud 5/16"-18 x 1-1/2" 7 Required

28 Rear Flue Box Hi Temp Rope, 1/4" Diameter x 65" Long

29 Side Jacket Panel LC-6000 For Models LC-04 and LC-08

Side Jacket Panel LC-6001 For Models LC-05, LC-08, LC-09 and LC-10

Side Jacket Panel LC-6002 For Models LC-06, LC-10, LC-11 and LC-12

Side Jacket Panel LC-6003 For Models LC-07 and LC-12

30 Left Front Jacket Corner Panel LC-6011

31 Right Front Jacket Corner Panel LC-6010

32 Upper Front Jacket Panel LC-6007

33 Middle Front Jacket Panel LC-6008

34 Lower Front Jacket Rail LC-6009

35 Back Jacket Panel LC-6012

36 Side Jacket Panel Support Angle LC-6014

37 Front Top Jacket Panel LC-6005

49

REPAIR PARTS

Table 12.1B: Series LC Repair Parts (continued)

38

39

Top Jacket Panel LC-6004

Top Jacket Panel LC6004-1

Top Jacket Panel LC-6004-2

Top Jacket Panel LC-6004-3

Rear Top Jacket Panel LC-6006

Single Rib Flue Baffle, Aluminized Steel LC-1018

Triple Rib Flue Baffle, Aluminized Steel LC-1019

Single Rib Flue Baffle, Stainless Steel LC-1020

Triple Rib Flue Baffle, Stainless Steel LC-1021

Item

No.

Description

For Models LC-04 and LC-08

For Models LC-05, LC-08, LC-09 and LC-10

For Models LC-06, LC-10, LC-11 and LC-12

For Models LC-07 and LC-12

Specify Boiler Model Number

Specify Boiler Model Number

Specify Boiler Model Number

Specify Boiler Model Number

Part Selection Information

Stock

Code

50

REPAIR PARTS

Figure 12.2: Series LCE Boiler Assembly

51

REPAIR PARTS

Table 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

Front Section

Top Flue Outlet Intermediate Section

Intermediate Section w/1" Tapping

Intermediate Section

Back Section (Closed Back)

Back Section w/Tankless Coil Opening

Tapped Intermediate Section

Upper Flow Port Gasket

Lower Flow Port Gasket

Tie Rod

5/8" Diameter High Temp Rope

Ceramic Fiber Base Liner

Ceramic Fiber Target Wall

Front Cleanout Plate (C.I.)

5/16"-18 x 1-1/4" Studs w/Brass Nuts

Steel Cover Plate

Steel Cover Plate

Tankless Heater Location 1

Tankless Heater Location 2

Tankless Heater Location 3

Rubber Gasket

3/8"-16 x 3/4" SS Hex Head Cap Screw

Rear Observation Assembly

5/16"-18 x 3/4" Hex Head Cap Screw

Burner Mounting Plate

3/8"-16 x 2-1/4" Studs with Nuts

Front Observation Assembly

3/8"-16 x 1" Studs for Burner Mounting

1/4"-20 x 1/2" Hex Head Machine Screw

Cleanout Cover Plate (Steel)

Rear Flue Cover Plate

Rear Flue Cover Stud 5/16"-18 x 1-1/2"

Rear Flue Cover Hi Temp Rope, 1/4" Dia. x 65" Long

Side Jacket Panel LC-6000

Side Jacket Panel LC-6001

Side Jacket Panel LC-6002

Left Front Jacket Corner Panel LC-6011

Right Front Jacket Corner Panel LC-6010

Upper Front Jacket Panel LC-6007

Middle Front Jacket Panel LC-6008

Lower Front Jacket Rail LC-6009

Back Jacket Panel LC-6012

Side Jacket Panel Support Angle LC-6014

Front Top Jacket Panel LC-6005

Top Jacket Panel LC-6004

Top Jacket Panel LC-6004-1

Item

No.

Description

86022

86036

86008

51671

51672

51721

55723

50862

50854

51162

51776

51777

51800

90923

90922

51772

51131

See Table for Stock Code

2 Required per Flueway

1 Required per Flueway

4 Required per Flueway

13 Feet Required per Flueway

For All LCE Boilers

4 Required

Specify Heater Model Number

Not Used On Steam

Specify Heater Model Number

Specify Quantity

Specify Quantity

Specify Quantity

Specify Burner Model

7 Required

4 Required

4 Required

1 Required per Flueway

For All LCE Boilers

5 Required

For Models LCE-13, -17, -20 & -21

For Models LCE-13 to LCE-15, LCE-17 to LCE-24

For All LCE Boilers

For Models LCE-13, -17, -20 & -21

For Models LCE-13 to LCE-15, LCE-17 to LCE-24

Part Selection Information

Stock

Code

52

REPAIR PARTS

Table 12.2B: Series LCE Repair Parts (continued)

38

40

39

41

42

43

44

Top Jacket Panel LC-6004-2

Top Jacket Panel with Flue Opening LC-6022

Rear Top Jacket Panel LC-6006

Top Flue Outlet Plate (14" Flue)

Top Flue Outlet Plate (16" Flue)

5/8" Diameter High Temperature Rope

3/8" Diameter Tie Down Assembly

Draft Damper, 14"

Draft Damper, 16"

Baffles

Item

No.

Description

51132

51133

55723

51604

90523

90524

86113

For Models LCE-15, -16, -19, -23 & -24

For All LCE Boilers

For Models LCE-13 through LCE-17

For Models LCE-18 and Larger

For Top Flue Outlet Plate, 6 Feet

For Top Flue Outlet Plate, 4 Required

For Models LCE-13 through LCE-17

For Models LCE-18 and Larger

Models LCE-21 through LCE-24 Only

Part Selection Information

Stock

Code

LC/LCE

Gas/Oil Boilers
Steam

Series

Oil, Gas &

Installation,
Operation &
Maintenance
Manual

TO THE INSTALLER:

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.

LC8046 R6 (4/06-1.5M)

Printed in U.S.A.

©2006

HI Division

of gama

ASME

PB HEAT, LLC

PO BOX 447 • NEW BERLINVILLE, PA 19545-0447