PB Heat Boiler Gas Oil Boilers User Manual

Series LC/LCE

Oil, Gas & Gas/Oil Boilers – Water

Installation,

Operation &

Maintenance

Manual

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USING THIS MANUAL

A. INSTRUCTION MANUALS

DANGER

Indicates a condition or hazard which will cause

severe personal injury, death or major property

damage.

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)

WARNING

B. SPECIAL ATTENTION BOXES

Indicates a condition or hazard which may cause

severe personal injury, death or major property

damage.

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:

CAUTION

Indicates a condition or hazard which will or can

cause minor personal injury or property damage.

NOTICE

Indicates special attention is needed, but not directly

related to potential personal injury or property

damage.

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PREINSTALLATION

1. PREINSTALLATION

NOTICE

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.

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

c) For accessing and servicing of level controls and

A. ACCESSIBILITY CLEARANCES

inspection tappings (if used): provide 24"

minimum from the right side of the boiler to any

wall or obstruction.

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.

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.

a) For installing, removing and servicing the burner:

provide 48" between the front of the boiler and

any adjacent wall or other appliance.

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")].

b) For access to the top of the boiler for cleaning

flueways: provide 24" above top of jacket.

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PREINSTALLATION

B. CLEARANCE FROM COMBUSTIBLE

CONSTRUCTION

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.

Provide the following minimum clearances to

combustible construction. See Figure 1.1.

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

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"

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.

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.

4. If the vent terminates in an area where wind-

generated 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

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.

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.

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.

WARNING

Failure to provide adequate venting can result in

severe property damage, personal injury or death.

Figure 1.2: Motorized Vent Damper Interlock

Figure 1.3: Vent Termination, Typical

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PREINSTALLATION

Figure 1.4: Foundation Layout

8. Exterior Vents:

E. BOILER SETTING

a) Insulate sufficiently to ensure adequate draft and

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.

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.

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.

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.

WARNING

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.

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).

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.

c) The vent must be installed so it can be

disconnected and the Top Flue Outlet removed

for proper cleaning of the flueways.

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PREINSTALLATION

Table 1.1: Foundation Lengths

H. VERIFY COMPONENTS

Model

Foundation Length, Inches

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.

LC-04

LC-05

37¹⁵⁄₁₆

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

48¹⁄₁₆

53¹⁄₈

58⁵⁄₁₆

63³⁄₈

68⁷⁄₁₆

73¹⁄₂

78⁹⁄₁₆

83³⁄₄

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.

88¹³⁄₁₆

93⁷⁄₈

98¹⁵⁄₁₆

104¹⁄₈

109³⁄₁₆

114¹⁄₄

119⁷⁄₁₆

124¹⁄₂

129⁹⁄₁₆

134⁵⁄₈

139¹¹⁄₁₆

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 and rating label.

ii) LCE-21 through LCE-24: Baffles

f) Jacket Cartons: Include ASME plate

g) Draft Damper (LCE only)

h) Label Carton (LCE only)

i) Burner Mounting Plate

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.

j) Trim Carton: Includes safety relief valve and

temperature-pressure gage

k) Control Carton: Limit controls

l) Tankless Heater(s)

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.

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.

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.

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PREINSTALLATION

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PREINSTALLATION

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PREINSTALLATION

Table 1.3: Standard and Optional Sections for Knockdown Boilers

50 psig MAWP

80 psig MAWP

Sections

Standard

w/Inspection Tappings No Inspection Tappings w/Inspection Tappings

No Inspection Tappings

Front

Plain Interm.

Top Flue Interm. Part #/UPC LCE-1056

LWCO Interm. Part #/UPC LC-1000-1

3" Tap. Interm. Part #/UPC

Closed Back

Coil Back

Part #/UPC

LC-1001

LC-1000

86000

86004

86100

86005

86008

86022

86036

LC-1013

LC-1014

LCE-1064

LC-1014-2

LC-1015

LC-1016

LC-1017

86010

86014

86110

86092

86016

86018

86026

LC-1001-2

LC-1000-2

LCE-1056-1

LC-1000-3

LC-1003-2

LC-1007-2

LC-1002-2

86002

86006

86111

86007

86009

86024

86038

LC-1013-2

LC-1014-1

LCE-1064-1

LC-1014-3

LC-1015-1

LC-1016-2

LC-1017-2

86012

86015

86112

86093

86017

86020

86028

LC-1003

LC-1007

LC-1002

Part #/UPC

Table 1.4: Standard and Optional Jacket

Cartons, Front/Back Panels

Table 1.5: Standard and Optional Jacket Cartons,

Top/Side Panels

Standard

(No Inspection

Tappings)

Standard 50

86030

With Inspection

Jacket Label

psig MAWP

Tappings

30 psig MAWP

86059

86058

86031

86032

86033

86034

86094

86101

86102

86103

86104

86097

80 psig MAWP

Note: 80 psig MAWP not available in Canada.

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

standard cartons.

Table 1.6A: Burner Mounting Plates

Boiler Model

Model

LC-04

LC-05R

LC-05

LC-06

LC-07

LC-08

LC-09

LC-10

LC-11

LC-12

CF-800

CF-1400

CF-2300

301CRD

702CRD

801CRD

S4.2

R6.2

R6.3

R8.1

R8.2

R8.3

J15A

J30A

J50A

JB1

86070*

Beckett

Carlin

86069*

86074*

86069*

86074*

86073

86074*

86073

86074*

86073

86074*

86073

86070*

86069*

86078

86069*

86078

86071

86069*

Gordon

Piatt

86079

86071

86079

86076

86079

86076

86079

86076

86079

86076

86079

86076

86071

86072

86071

86072

86071

Power

Flame

86072

86071

86072

86071

86072

86071

86077

86075

86077

86075

86077

86075

86077

86075

86071

86075

Webster

* Standard Burner Mounting Plate

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PREINSTALLATION

Table 1.6B: Burner Mounting Plates

Boiler Model

Model

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

CF2300AKG

CF2300AKB

CF2500

CF3500AKM

CF3500AKL

801CRD

1050FFD

1150FFD

R10.9

86074*

86083* 86083*

Not

Beckett

Carlin

86074* 86074*

Available

86083* 86083* 86083*

86080* 86080*

86073

86088

86073

86088

86086

86088

86086

86088

N/A

86087

86088

86087

86088

86087

86088

86087

86088

86087

86088

86087

86088

86087

86088

R10

R10.1

R10.2

Gordon

Piatt

86088

JB2

86076

86081

86076

86081

86076

86081

Power

Flame

Webster

86080

86081

86080

86081

86080

86081

86080

86081

86080

86081

86080

86081

86080

86081

86080

86081

86080

86081

* Standard Burner Mounting Plate

Table 1.7: Trim Cartons

Output¹

50 psig

Model

30 psig

80 psig

LC-04

LC-05R

LC-05

LC-06

LC-07

LC-08

LC-09

LC-10

LC-11

87030

87031

87032

87033

87034

87050

87051

87052

87053

87080

87081

87082

87802

87082

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

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 1.8: Control Cartons

Model

Water

LC-04

Through

LCE-24

88510

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PLACE THE BOILER

2. PLACE THE BOILER

2. Remove lifting frame and hardware.

A. PACKAGED BOILER

3. Proceed to Section D: Install Coils or Plates

1. Remove crate top and sides. Remove any loose

cartons. Remove burner support pedestal and

nipple, if supplied

C. KNOCKDOWN BOILER

1. Place channel rails as shown in Figure 1.4.

2. Lift boiler off crate pallet. Move to location

determined in Chapter 1: Preinstallation.

2. Open the Section Assembly Kit cartons. These

cartons contain the parts needed for assembly of the

sections.

3. Remove lifting frame and hardware.

4. Re-install burner support pedestal and nipple if

necessary.

3. Place the Back Section on the floor as shown in

Figure 2.1.

5. Proceed to Chapter 3: Piping the Boiler.

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.

B. ASSEMBLED BLOCK BOILER

1. Move block to location determined in Chapter 1:

Preinstallation.

Figure 2.1: Lay Sections on Floor and Apply Rope Seal and Gaskets

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PLACE THE BOILER

WARNING

The sections are heavy and must be supported

securely.

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.

Figure 2.2: Flow Port Machining & Gasket

CAUTION

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.

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.

Figure 2.3: Apply Silcone Sealant

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PLACE THE BOILER

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

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PLACE THE BOILER

Figure 2.5: Series LC Boiler Assembly – Right Side View

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PLACE THE BOILER

Figure 2.6: Series LCE Boiler Assembly – Right Side View

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PLACE THE BOILER

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.

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.

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. Place the Intermediate Section with 3" top

tapping (Tapped Intermediate) in the position

given in Figure 2.9.

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.

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

i) First: Lower Top Port

ii) Second: Bottom Port

iii) Third: Upper Top Port

ii) The remaining intermediate sections are 3"

Tapped Intermediates or Plain Intermediates

as shown in Figure 2.8 and Figure 2.9.

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.

WARNING

Do not exceed the manufacturer’s torque

recommendations.

Figure 2.8: Section Positioning Numbering

Table 2.1: Section Numbering Sequence

Place a Tapped Intermediate

Model

Section at Position

(Numbered Rear to Front)

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

9, 16

9, 17

10, 18

10, 19

Figure 2.7: Torque Specification/Procedure

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PLACE THE BOILER

Figure 2.9: LC/LCE Boiler Section Assembly Sequence

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PLACE THE BOILER

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 2.10 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.

a) Maintain pressure while checking all joints and

fittings for leaks.

Figure 2.10: Tankless Coil Openings

7. After inspection is complete, drain the boiler and

remove plugs from tappings that are to be used.

Table 2.2: Tankless Coil Ratings

Heater No.

X-1020

Heater No.

X-1021

Heater No.

X-1022

Two Heaters No. Two Heaters No. Two Heaters No.

X-1020 X-1021 X-1022

Model

GPM Location GPM Location GPM Location GPM Location GPM Location GPM Location

LC-04

LC-05R

LC-05

LC-06

LC-07

LC-08

LC-09

LC-10

LC-11

5.5

5.62

5.75

6.25

6.5

7.0

7.25

7.5

8.0

–

6.5

7.0

7.75

8.5

9.25

10.0

10.75

11.50

12.25

–

8.0

9.0

10.0

12.0

13.0

14.0

14.5

15.0

16.0

–

1 & 2

–

9.5

10.5

13.0

15.5

17.5

20.0

21.5

23.5

24.5

1 & 2

–

13.0

13.75

14.5

15.5

16.5

17.5

18.0

18.75

19.5

15.5

18.0

20.0

22.5

24.5

27.0

31.5

33.5

35.5

37.5

39.5

1 & 2

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

–

Above heater ratings are based on intermittent demand for water from 40°F to 140°F with 200°F boiler water.

DANGER: Install mixing valve in hot water supply piping. Water temperature over 125°F can cause severe burns instantly or death from scalds.

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PLACE THE BOILER

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 1-1/2" 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 1-1/2" studs, flat washers and

nuts supplied.

Figure 2.11: Install Cleanout Cover Plates

c) Inspect the finished seal, particularly where the

plate crosses the section joints.

3. (LCE) Apply 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.

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

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.

• 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.

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

down assembly, nuts and washers provided. See

Figure 2.13.

Figure 2.12: Rear Flue Collar Attachment

Figure 2.13: Top Flue Collar Attachment

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PLACE THE BOILER

H. INSTALL FLUE BAFFLES

I. INSTALL CHAMBER LINER

1. Remove the Front Cleanout Plate from Front

Section.

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.

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 LCE-

20 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.

Figure 2.14: Flue Baffle Locations

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PIPE THE BOILER

3. PIPE THE BOILER

Lower flow rates (higher temperature rise) are

acceptable provided the return temperature to the

boiler is at least 130°F on gas boilers and 150°F on

oil boilers to prevent condensation of flue gases.

A. PREPARATION

1. Make sure the boiler has been pressure tested as

outlined in “Place the Boiler Sections” in this

manual.

3. Do not reduce the number or size of supply and

return connections given in Table 3.1. These are

required to control the flow velocities in the boiler

and maintain uniform distribution.

2. The Supply and Return piping can be installed

before installing the jacket. Use nipples long enough

to extend through the jacket.

4. When the boiler is connected to heating coils located

in air handling units, the boiler piping system must

be equipped with flow control valves or other

automatic devices to prevent gravity circulation of

the boiler water during the cooling cycle.

3. Install a pipe plug or nipple and cap in the 3”

tapping in the top of the tapped intermediate section

when necessary. Use only the lower side connection,

required for return piping as shown.

B. SUPPLY AND RETURN PIPING

C. LOW SYSTEM TEMPERATURE

1. Always locate the Supply and Return connections as

shown in Figure 3.1 and other illustrations in this

manual.

1. Low Return Temperature Piping, General

a) When the return temperature from the system

will be below 130°F on gas boilers or 150°F on

oil boilers for extended periods (heat pump

systems, outdoor reset, snow melt, etc.), provide

piping and controls to protect the boiler from

condensation. Condensation will damage the

boiler and will lead to shortened boiler life and

maintenance problems.

2. The suggested supply and return sizing in Table 3.1

and in the “Boiler Ratings and Dimensions” section

in this manual is based on a flow rate through the

boiler equivalent to a 20°F temperature rise (1 gpm

flow for each 10,000 Btu/Hr of boiler output). Using

higher flow rates is not recommended. This could

cause poor water flow distribution in the boiler.

Figure 3.1: Piping Detail, Supply and Return Connections

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PIPE THE BOILER

Figure 3.2: LC/LCE Boiler Piping

Table 3.1: Boiler Supply and Return Connections & Recommended Header Sizing

Suggested Supply

Connections – Top

Return Connections

I=B=R

Gross

Output

MBH

GPM

@ 20°F

Rise

Rear and Side

Model

Size

(Inches)

Header

(Inches)

Size

Header

(Inches)

Number

(Inches)

LC-04

LC-05R

LC-05

LC-06

LC-07

LC-08

LC-09

LC-10

LC-11

547

649

707

2-1/2

868

1029

1189

1350

1511

1672

1832

1966

2125

2284

2444

2603

2763

2922

3082

3256

3430

3604

3777

103

119

135

151

167

183

197

213

228

244

260

276

292

308

326

343

360

378

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

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PIPE THE BOILER

b) Temporary low temperature operation is

acceptable within limits. For occasional cold start-

ups condensation will occur, but will have limited

effects. If the system is frequently allowed to cool

to room temperature, such as on night set-back

systems or energy management systems, cold

start-ups will occur often. These systems require

a Variable Low Temperature piping and control

arrangement, described below.

2. Constant Low Temperature

a) For systems with a relatively constant low

operating temperature (such as heat pump

systems), you can pipe a fixed flow by-pass

arrangement as shown in Figure 3.3. This piping

will not work for variable low temperature

systems such as outdoor reset systems or

primary/secondary systems with a large primary

circuit temperature drop. See Figure 3.4 for

multiple boilers.

3. Variable Low Temperature

a) When the return water temperature from the

system will vary (outdoor reset, snow melt, etc.) a

fixed bypass will not work. Fixed bypass piping

works by setting a high temperature rise through

the boiler. As the system return temperature rises

(during primary heating months, for example)

the boiler will cycle on the limit control

Figure 3.3: Fixed By-Pass Piping, Single Boiler

frequently, causing poor performance and

excessive cycling. To protect the boiler and

provide proper operation, install a temperature

Figure 3.4: Fixed By-Pass Piping, Multiple Boilers

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PIPE THE BOILER

control valve and boiler circuit pump piped off of

the system as a secondary loop. See Figure 3.6

for a single boiler and Figure 3.7 for multiple

boilers.

F. MULTIPLE BOILER INSTALLATIONS

1. For multiple boiler installations, piping the boilers in

a secondary loop is recommended. Each boiler

should be provided with its own pump and piped off

of the secondary loop header. See Figure 3.7 for

systems with return temperature above 130°F on gas

boilers or 150°F on oil boilers. For low temperature

systems, see Figure 3.4 (constant low temperature

systems) or Figure 3.8 (variable low temperature

systems).

D. CHILLED WATER SYSTEMS

1. If the boiler will be used in conjunction with a

refrigeration system, the chilled medium must be

placed in parallel with the boiler and proper valves

applied to prevent the chilled medium from entering

the boiler. See Figure 3.5.

2. You can use alternative piping if desired, such as

parallel piping or series piping in the primary system

loop. But these systems are less versatile.

E. HIGH FLOW RATE PIPING

a) With parallel piping, for instance, the system flow

conditions change if one or more of the boiler

shut-off valves are closed. It is difficult to pipe

parallel boilers to protect the boiler from low

return temperatures.

1. For flow rates higher than given in Table 3.1, provide

bypass piping around the boiler to limit the boiler

flow to that given in the table or pipe the boiler in a

secondary loop with its own pump as shown in

Figure 3.3.

b) With series piping, temperature control to the

system is difficult because the temperature rise

equals the sum of the rises through each boiler.

Series piped boilers cannot be isolated for

servicing.

Figure 3.5: Piping to Isolate Boiler from Chilled Medium on Chiller Systems

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PIPE THE BOILER

Figure 3.6: Piping for Variable Low Temperature Systems, Single Boiler

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PIPE THE BOILER

Figure 3.7: Multiple Boiler Piping, System Return Temperature Above 130°F on Gas, 150°F on Oil

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PIPE THE BOILER

Figure 3.8: Piping for Variable Low Temperature Systems, Multiple Boilers

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ASSEMBLE THE JACKET

4. ASSEMBLE THE JACKET

2. Attach the Middle Front Panel and Lower Front Rail

in the same manner.

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 pre-

insulated.

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

2. Remove all needed knockouts from the jacket parts

before beginning assembly.

1. Attach the Rear Jacket Panel to the Jacket Side

Panels with #10 x 1/2" sheet metal screws.

B. APPLY JACKET SIDES AND CORNERS

E. APPLY JACKET TOP PANELS

1. See Figure 4.2 for details.

1. Attach the Top Front Panel to the Sides and Upper

Front Panel with #10 x 1/2" sheet metal screws.

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

the boiler.

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. 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.

3. Attach the Jacket Top Panel to the Jacket Top Front

Panel with #10 x 1/2" sheet metal screws.

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.

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.

6. Attach the Left Front Corner Panel to the Left Side

Panel with #10 x 1/2" sheet metal screws.

F. APPLY PLATES AND LABELS

7. Attach the Right Front Corner Panel to the Right

Side Panel with #10 x 1/2" sheet metal screws.

1. Mount Boiler Rating Plates and Agency Plates on the

Upper Jacket Front Panel as shown in Figure 4.1.

C. APPLY JACKET FRONT PANELS

2. Secure metal plates with #6 x 1/4" sheet metal

screws. Apply all adhesive-backed labels.

1. Attach the Upper Front Panel to the Right and Left

Front Corner Panels with #10 x 1/2" sheet metal

screws.

Table 4.1: Jacket Top & Side Panel Placement

Locate Jacket Top and Side Panels in

the Position Below

(Numbers are from Rear to Front)

Model

(Front)

(Rear)

LCE-13

LCE-14

LCE-15

LCE-16

LCE-17

LCE-18

LCE-19

LCE-20

LCE-21

LCE-22

LCE-23

LCE-24

–

Figure 4.1: Location of Rating, Agency and

Instruction Plates on Jacket Front

Top Panel

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ASSEMBLE THE JACKET

Figure 4.2: Jacket Assembly

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VENTING

5. VENTING

Refer to Chapter 1, Preinstallation, Section D. Chimney

or Vent for installation requirements. Refer to

Chapter 9, Starting the Boiler, Section C. Run Burner

Check Out for damper settings and draft requirements.

6. INSTALL THE BURNER

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

front section around the chamber opening.

A. BURNER APPLICATION

1. Refer to Burner Spec and Data Sheets for the Oil

and Gas/Oil Burners pre-tested with Series LC

boilers.

4. Secure the Burner Mounting Plate to the front

section with the flat washers and hex nuts.

2. Make sure the nozzle sizing and spray pattern match

C. MOUNT THE BURNER

those given in the spec and data sheets.

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

instructions.

3. See Figure 6.1 and Table 6.1 for combustion

chamber dimensions.

2. Insert (4) 3/8"-16 x 1 1/4" studs supplied with Burner

Mounting Plate into the front plate holes.

B. INSTALL BURNER MOUNTING PLATE

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.

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.

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.

2. Remove the Burner Mounting Plate and Hardware

Bag from the crate.

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INSTALL THE BURNER

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

Table 6.1: Combustion Chamber Dimensions

Chamber

Burner Front Plate Extension Past Jacket (Inches)

Length

“A”

Model

Gordon-

Piatt

Power

Flame

Beckett

Carlin

Webster

(Inches)

LC-04

LC-05R

LC-05

LC-06

LC-07

LC-08

LC-09

LC-10

LC-11

18⁷⁄₈

23¹⁵⁄₁₆

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

6¹⁄₈

1¹⁄₈

N/A

6¹⁄₈

1¹⁄₈

N/A

6¹⁄₈

1¹⁄₈

6¹⁄₈

1¹⁄₈

6¹⁄₈

1¹⁄₈

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

104¹⁵⁄₁₆

110

115¹⁄₁₆

120¹⁄₈

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CONNECT FUEL PIPING

7. CONNECT FUEL PIPING

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.

Figure 7.1: Gas Supply Connection to Boiler

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.

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.

5. Use only pipe joint compounds rated for use with

Liquefied Petroleum Gases.

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.

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.

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.

WARNING

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.

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.

Do not test gas supply piping with open flame. Use a

soap suds mixture brushed onto the pipe joints to

test for leaks.

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.

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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.

Pipe Length

(Feet)

1-1/4"

Pipe

1-1/2"

Pipe

2-1/2"

Pipe

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

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

100

150

870

710

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

0.50

1.10

0.55

1.04

0.60

1.00

0.65

0.70

Multiply Capacity by:

0.962

0.926

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INSTALL CONTROLS AND TRIM

8. INSTALL CONTROLS AND TRIM

A. INSTALL SAFETY RELIEF VALVE

C. INSTALL LOW WATER CUTOFFS

1. Pipe the Safety Relief Valve off of the 2-1/2" tapping

at the upper left side of the Rear Section. Make sure

the relief valve sizing meets local code requirements.

See Figure 8.1.

1. See Figure 8.2 for the locations of tappings for probe

type and float type low water cutoffs. The Front

Section has a 3/4" tapping for a probe type control.

The Rear Section has two 1" tappings for mounting a

float type control.

CAUTION

D. INSTALL CONTROLS & TRIM

Pipe the discharge of the Safety Relief Valve(s) away

from any traffic area, preferably to a floor drain. This

is necessary to prevent injury should the valve

discharge.

1. Install the Temperature-Pressure Gage in the 1/2"

tapping at the upper center of the Front Section. See

Figure 8.2.

Pipe the discharge full size of valve outlet.

2. Mount the Operating Temperature Limit Control bulb

well in the Coil Cover Plate at the upper right of the

Front Section. Place the well in the right side 3/4"

control tapping of the cover plate if a Tankless

Heater is not installed there. If a tankless heater is

installed at this location (Position 2), mount the well

in the center 3/4" control tapping of the coil. See

Figure 8.2.

B. INSTALL DRAIN VALVE

1. Install a 3/4" drain valve in the lower center tapping

in the Rear Section. See Figure 8.1 and Figure 8.2.

2. Pipe the valve discharge to a floor drain if available

or apply a nipple and cap to close off when not in

use.

Figure 8.1: Safety Relief Valve Piping

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INSTALL CONTROLS AND TRIM

3. Mount the High Limit Control bulb well in the left

side 3/4" tapping of the coil cover plate if a tankless

heater is not mounted in the upper right opening

(Position 2). If a coil is installed there, mount the well

in the 3/4" tapping to the left of the opening. See

Figure 8.2.

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.

CAUTION

3. Follow the instructions in the Burner Manual and the

Wiring Diagrams supplied with the burner and the

boiler.

Make sure that the gas ignition system components,

electrical controls, junction boxes and electrical

panels are protected from water (dripping, spraying,

rain, etc.) during boiler operation and service

(circulator or pump servicing, control replacements

or other).

G. INSTALL CONTROL WIRING

1. Wire the boiler according to the wiring diagrams

supplied with the burner and the boiler (in the Boiler

Envelope).

E. PIPE TANKLESS HEATERS IF USED

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.

1. Connect piping to any installed tankless heaters. See

Figure 8.3 for suggested piping for single coils and

Figure 8.4 for suggested piping for dual coils.

F. CONNECT SUPPLY WIRING

3. Install line voltage wiring in conduit.

1. Install all wiring in accordance with local codes, the

National Electrical Code and other controlling

agencies or governing bodies.

4. Do not install single pole switches, including safety

controls, in a grounded line.

2. Use #14 gauge or heavier wire for supply wiring.

Protect the circuit with a fused disconnect switch (by

others).

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INSTALL CONTROLS AND TRIM

Figure 8.2: Control and Pipe Tapping Locations

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INSTALL CONTROLS AND TRIM

Figure 8.3: Suggested Piping – Single Tankless Coil Installation

Figure 8.4: Suggested Piping – Dual Tankless Coil Installation

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STARTING THE BOILER

9. STARTING THE BOILER

•

If automatic fill is used, the system will have

to be checked periodically to make sure the

antifreeze concentration has not been diluted

below design level.

A. CHECK THE PIPING

1. Water Piping

a) The Boiler must have been hydrostatically tested.

•

Local codes may require the use of a

backflow preventer or manual fill only with

separation from the city supply.

b) Check the attached piping for joint tightness.

c) Continue monitoring as you proceed through

start up.

Consider the minimum temperature of

potential exposure for the system when

deciding on the antifreeze concentration. A

concentration of 50% generally provides

protection from freezing down to -30°F.

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

CAUTION

a soap suds solution.

The boiler gaskets will be damaged by petroleum or

its derivatives.

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

Gas Control Train.

Do not use petroleum based compounds in the

boiler, including petroleum-based stop-leak

compounds.

3. Oil Piping

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

are tight.

2. Purge the air from the system.

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

and return line pressures.

C. RUN BURNER CHECK-OUT

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.

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).

d) Excess pressure can cause pump seal failures.

Excess vacuum will cause fuel flow problems

with the burner oil pump.

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.

B. FILL THE BOILER

1. Fill the boiler and system.

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.

a) Fill the system with fresh water only. If the water

hardness is high, use water treatment to reduce

the deposition of minerals in the boiler.

CAUTION

Check the system for leaks and make sure the

automatic fill valve (if used) and the expansion tank

are operating correctly. Leakage or weeping of the

relief valve will cause make-up water to be added to

the system. Excessive make-up water will damage

the boiler and system components due to liming and

oxygen corrosion.

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.

CAUTION

b) If the system requires antifreeze, use only

antifreeze designed for hydronic systems. These

contain inhibitors to prevent corrosion of the

boiler and system components. Do not use

ethylene glycol or automotive antifreezes.

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.

•

Make sure the antifreeze supplier can provide

periodic inhibitor check service.

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STARTING THE BOILER

4. Adjust the burner as needed for a CO reading of:

2. Low Water Cutoffs

a) Oil burners: CO approximately 12.5% or 1%

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

Button.

less than the level at which the smoke reading

goes above a trace on the Bacharach scale.

b) Test float type controls. ASME CSD-1 requires

the control to be piped with Test-n-Check valves

in order to allow isolation for test.

b) Gas burners: 9% to 10% with CO less than 50

ppm.

c) Inspect all flue gas joints (sections, attachments,

breeching and vent) for gas tightness. Remove

the jacket panels in order to thoroughly inspect

all rope seal joints between the sections.

3. Follow additional instructions in the Burner Manual

for proving the burner component operation.

4. Check all controls to make sure they function

correctly.

D. CHECK BOILER CONTROLS

5. After all controls have been proven, set the

Operating and High Limit Temperature Controls to

the temperatures desired.

1. Limit and Operating Temperature Controls

a) Lower the setting of each control until the burner

shuts down.

Table 9.1: Typical Combustion Chamber Pressure and Boiler Draft Loss

Combustion Chamber Pressure

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

(Inches w.c.)

Boiler Draft Loss

(Inches w.c.)

Model

LC-04

LC-05R

LC-05

LC-06

LC-07

LC-08

LC-09

LC-10

LC-11

+ 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

+ 0.32

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

0.22

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

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.

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MAINTENANCE

10. MAINTENANCE

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:

Precautionary 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.

First 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.

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MAINTENANCE

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.

WARNING

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.

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.

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.

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.

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.

2. Inspect the Venting System

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

clean and free from cracks or potential leaks.

A. PLACING BOILER IN OPERATION

CAUTION

1. Start up the Burner/Boiler per the Burner Manual

and the instructions in this manual on starting the

boiler.

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.

2. Prove the correct operation of all controls on the

boiler and burner as outlined below.

• Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation. Verify proper

operation after servicing.

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.

b) All joints must be tight and sealed.

5. Inspect and test all low water cutoffs.

c) The vent connector must extend into, but not

beyond the inside edge of the chimney or vent.

6. Test the safety relief valve(s) using the procedure

given by the valve manufacturer on the valve tag.

3. Inspect the Boiler Area

7. Visually inspect the burner and pilot flames (if

applicable).

a) The boiler area must be clean and free from

combustible materials, gasoline or any other

flammable liquids or vapors.

B. TO SHUT DOWN THE BOILER

b) The combustion air openings and the area

around the boiler must be unobstructed.

1. Turn off Burner.

4. Inspect boiler flueways and burner for cleanliness. If

cleaning is required, use the following procedure.

2. Open main line power disconnect switch to

boiler/burner.

a) Turn off all electrical power to the boiler.

3. Close fuel shut-off valves.

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.

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.

c) Brush the boiler tube spaces both horizontally

(through cleanout openings on ends) and

vertically (from top of boiler through cleanout

openings at flueways).

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.

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MAINTENANCE

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. 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.

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.

2. Make sure there are no signs of abnormal operation,

such as overfilling or leakage.

CAUTION

f) Replace all Jacket Panels.

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.

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.

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.

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.

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BOILER RATINGS & DIMENSIONS

11. BOILER RATINGS & DIMENSIONS

Table 11.1: Series LC/LCE Boiler Ratings

SERIES LC/LCE BOILER RATINGS

Gross

I=B=R Burner Capacity

I=B=R Net Ratings

Combustion Efficiency

Boiler

Model

Number

I=B=R

Output

Mbh

Boiler

H.P.

Oil

Gas

MBH

Steam

Sq. Ft.

Steam

MBH

Water

MBH

GPH

Oil

Gas

LC-04

LC-05R

LC-05

LC-06

LC-07

LC-08

LC-09

LC-10

LC-11

547

649

707

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

686

808

881

1708

2029

2208

2713

3217

3717

4250

4804

5367

5917

6358

6875

7388

7908

8421

8938

9454

9971

10533

11096

11658

12217

410

487

530

651

772

476

564

615

755

895

83.7

83.6

83.5

83.6

83.7

81.2

81.1

81.0

81.1

81.2

868

1077

1273

1469

1664

1860

2056

2252

2464

2657

2850

3043

3236

3429

3622

3815

4027

4239

4451

4663

1029

1189

1350

1511

1672

1832

1966

2125

2284

2444

2603

2763

2922

3082

3256

3430

3604

3777

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

892

1034

1174

1314

1454

1593

1710

1848

1986

2125

2263

2403

2541

2680

2831

2983

3134

3284

1020

1153

1288

1420

1526

1650

1773

1898

2021

2145

2269

2393

2528

2663

2798

2932

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

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.

Figure 11.1: Tankless Coil Pressure Drops

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BOILER RATINGS & DIMENSIONS

Figure 11.2: Series LC Dimensional Diagram

Figure 11.3: Series LCE Dimensional Diagram

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BOILER RATINGS & DIMENSIONS

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REPAIR PARTS

12. REPAIR PARTS

Repair parts are available from your installer or by contacting PB Heat, LLC, New

Berlinville, PA. Use the Figures and Tables on pages 45-50 to assist in ordering parts.

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

Figure 12.1: Series LC Boiler Assembly

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REPAIR PARTS

Table 12.1A: Series LC Repair Parts

Item

Stock

Code

Description

No.

Part Selection Information

See Table 3 for Stock Code

Front Section

–

Intermediate Section w/1" Tapping

Intermediate Section

See Table 3 for Stock Code

2 Required per Flueway

–

Back Section

–

Tapped Intermediate Section

Upper Flow Port Gasket

–

51671

51672

51721

55723

50862

50854

51162

Lower Flow Port Gasket

1 Required per Flueway

Tie Rod

4 Required per Flueway

5/8" Diameter High Temp Rope

Ceramic Fiber Base Liner

13 Feet Required per Flueway

Models LC-04 through LC-12

Ceramic Fiber Target Wall

Front Cleanout Plate (C.I.)

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

Steel Cover Plate

4 Required

51776

51777

Steel Cover Plate

Tankless Heater Location 1

Tankless Heater Location 2

Rubber Gasket

Specify Heater Model Number

Specify Quantity

51800

90923

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

Specify Quantity

Specify Burner Model

7 Required

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

Flame 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 Box w/9" Flue Outlet

Rear Flue Box w/10" Flue Outlet

Rear Flue Box w/12" Flue Outlet

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

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

Side Jacket Panel LC-6000

Side Jacket Panel LC-6001

Side Jacket Panel LC-6002

Side Jacket Panel LC-6003

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

90922

4 Required

1 Required per Flueway

Models LC-04 and LC-05

Models LC-06, LC-07 and LC-08

Models LC-09, LC-10, LC-11 and LC-12

7 Required

51772

86040

86041

86042

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

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REPAIR PARTS

Table 12.1B: Series LC Repair Parts (continued)

Item

Stock

Code

Description

No.

Part Selection Information

For Models LC-04 and LC-08

Top Jacket Panel LC-6004

Top Jacket Panel LC6004-1

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

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

Specify Boiler Model Number

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REPAIR PARTS

Figure 12.2: Series LCE Boiler Assembly

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REPAIR PARTS

Table 12.2A: Series LCE Repair Parts

Item

Stock

Code

Description

No.

Part Selection Information

See Table for Stock Code

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

86022

86036

86008

51671

51672

51721

55723

50862

50854

51162

2 Required per Flueway

1 Required per Flueway

4 Required per Flueway

13 Feet Required per Flueway

For All LCE Boilers

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

4 Required

51776

51777

Steel Cover Plate

Tankless Heater Location 1

Tankless Heater Location 2

Tankless Heater Location 3

Rubber Gasket

Specify Heater Model Number

Not Used on Water

Specify Quantity

51800

90923

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

Specify Quantity

Specify Burner Model

7 Required

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

90922

4 Required

1 Required per Flueway

For All LCE Boilers

5 Required

51772

51131

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

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

Top Jacket Panel LC-6004-1

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

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REPAIR PARTS

Table 12.2B: Series LCE Repair Parts (continued)

Item

Stock

Code

Description

No.

Part Selection Information

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"

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

51132

51133

55723

51604

90523

90524

86113

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

Draft Damper, 16"

Baffles

Models LCE-21 through LCE-24 Only

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NOTES

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NOTES

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Series LC/LCE

Oil, Gas & Gas/Oil Boilers

Water

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

Qualified Service Agency.

HI Division

of gama

ASME

PB HEAT, LLC

PO BOX 447 • NEW BERLINVILLE, PA 19545-0447

LC8043 R8 (3/07-2M)

Printed in U.S.A.

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