Weil-McLain LGB-5 Manuel utilisateur

Part Number 550-110-682/0304

LGB

Gas–fired boiler

CSD-1 Control System

Control Supplement

LGBLGB

LGB-5-5

-5-5

-5Series 2 – Propane gas

LGB-5 CSD-1 Series 2 Propane gas – Control Supplement

2Part Number 550-110-682/0304

The following terms are used throughout this Control Supplement to bring attention to the

presence of hazards of various risk levels or to important information concerning the life of the

product.

Indicates presence of hazards that will cause severe personal injury, death or

substantial property damage.

Indicates presence of hazards that can cause severe personal injury, death or

substantial property damage.

Indicates presence of hazards that will or can cause minor personal injury or

property damage.

Indicates special instructions on installation, operation or maintenance that

are important but not related to personal injury or property damage.

Hazard definitions

Please read this page first

Contents A ................ Installation & boiler assembly ..........................................4

B ................. Gas piping .......................................................................... 7

C ................. Water and steam trim components ................................ 7

D ................ Wiring................................................................................. 8

................... Wiring — sequence of operation ..................................... 9

................... Wiring diagrams & illustration ................................ 10–13

E ................. Leak test procedure ........................................................ 14

F ................. Operating instructions ................................................... 16

G. ............... Replacement parts .......................................................... 18

This Control Supplement must only be used by a qualified installer/service

technician. Read these instructions completely before beginning the

installation. Failure to follow these instructions can cause severe personal

injury, death or substantial property damage.

This Control Supplement is for CSD-1 controls on LGB-5 boilers only.

This document is only intended as a supplement to the LGB Installation •

Start-up •Service •Parts Manual (referred to in this Supplement as the

LGB Manual). Follow all instructions in the LGB Manual in addition to the

instructions in this Control Supplement.

The installation must conform to the requirements of the authority having

jurisdiction, or, in the absence of such requirements,to the National Fuel Gas

Code,ANSI Z-223.1/NFPA-54 (latest edition).Where required by the authority

having jurisdiction the installation must conform to the American Society of

Mechanical Engineers (ASME) Safety Code for Controls and Safety Devices

for Automatically-Fired Boilers, Number CSD-1.

To the installer . . .

LGB-5 CSD-1 Series 2 Propane gas – Control Supplement

Part Number 550-110-682/0304 3

Carton guide

Table 1 Boiler cartons

Verify that the correct cartons are available before beginning assembly.

LGB-5 CSD-1 Series 2 Propane gas – Control Supplement

4Part Number 550-110-682/0304

1. Remove all burners from base box assembly.

a. Remove 3.95 mm natural gas main burner

orifices in manifold.

b. Install 2.40 mm propane gas main burner

orifices.

Use pipe dope sparingly only on

male ends. Use pipe dope compatible

with propane gases. Do not

overtighten orifices. Failure to follow

these guidelines could result in severe

personal injury, death or substantial

property damage.

2. Install standing pilot on burner 2 from left. Install

electronic pilot on burner 5 from left. See Figures 1

and 2.

3. Remove pilot line components from pilot line elbow.

Replace elbow with tee supplied and reconnect pilot

line components. Install bushing, standing pilot

shutoff valve and brass tubing adapter on the other

side of the tee as shown in Figure 3 (page 6).

4. Attach pilot switch box to interior jacket panel. See

Figure 5 (page 12).

Figure 1

Pilot burner assembly

Locate electronic pilot burner

in 5th position from left, and

standing pilot burner in 2nd

position from left, as shown.

Installation & boiler assembly

Place the boiler

Refer to the LGB Manual and read through entire manual. Follow all guidelines in Sections I through VI.

Complete the following steps of Sections I through VI of the LGB Manual:

IPre-installation

II Boiler assembly (base, sections, pressure test and flue collector hood)

III Piping (boiler water or steam piping connections)

IV Jacket

VDraft hood

VI Install boiler controls (refer to this Supplement for the controls supplied with CSD-1 boilers and

requirements for installing them)

5. Connect thermocouple from standing pilot to switch

box. Cut 60” pilot tubing (provided) into 2 pieces to

make connections from pilot shutoff valve to pilot

switch box and from pilot switch box to standing

pilot. See Figure 3 (page 6).

6. Connect 125 °C ground wire (provided in control

carton) from pilot mounting bracket (per Figure 2)

to the ignition control module grounding screw on

the control panel after ignition control panel is

mounted per this Supplement.

7. Connect pilot spark and sense wires to the ignition

control (terminals SPARK and SENSE) after the

ignition control panel is mounted per this

Supplement.

8. Reinstall burner assembly. Make sure pilot(s) are

located in the positions shown in Figure 1.

9. Attach:

a. 550-223-710 label at boiler operating instruction

label. Place so that this label reads first.

b. 550-223-796 label at rating label.

c. Wiring diagram on jacket front panel.

Install pilot burners — NEW installation

LGB-5 CSD-1 Series 2 Propane gas – Control Supplement

Part Number 550-110-682/0304 5

Figure 2

Electronic pilot burner

assembly to main burner

1. These instructions are for use with the LGB-5

propane control carton only.

2. Remove jacket door and access panel.

3. Disconnect wiring and tubing from existing pilot

burner and main flame sensor.

4. Remove all burners.

a. Remove 3.95 mm natural gas main burner

orifices in manifold.

b. Install 2.40 mm propane gas main burner

orifices.

Use pipe dope sparingly only on

male ends. Use pipe dope compatible

with propane gases. Do not

overtighten orifices. Failure to follow

these guidelines could result in severe

personal injury, death or substantial

property damage.

5. Remove and discard existing electronic pilot burner

from pilot burner tube. Replace with electronic pilot

burner in carton.

6. Attach Q327 standing pilot to burner tube in kit.

Connect pilot tubing and thermocouple to pilot.

This conversion is to be installed by a Weil-McLain distributor or other qualified agency in accordance with the

manufacturer’s instructions and all codes and requirements of the authority having jurisdiction. Failure to follow

instructions could result in serious injury or property damage. The qualified agency performing this work assumes

responsibility for this conversion.

For your safety, turn off electrical power supply before

making any electrical connections to avoid possible

electrical shock hazard.

7. Reinstall burners. See Figures 1 and 2 for pilot burner

mounting and locations.

8. See Figure 3, page 6 for propane piping.

9. Replace elbow in pilot gas line with tee. Install pilot

shutoff valve for standing pilot in one side of tee and

electronic pilot shutoff valve in the other side, as

shown in Figure 3, page 6.

10. Attach pilot switch box to jacket. See Figure 5 (page

12). Connect thermocouple to pilot switch box. Cut

60” pilot tubing (provided) into 2 pieces to make

connections from tee in pilot line to pilot switch box

and from pilot switch box to standing pilot.

11. Remove natural gas valve train.

12. See following section in this Supplement for

installation of propane gas valve train.

13. Reinstall access panel.

14. Wire per wiring instructions and wiring diagrams in

this Supplement. Add splices as needed.

15. Attach:

a. 550-223-710 label at boiler operating instruction

label. Place so that this label reads first.

b. 550-223-796 label at rating label.

c. Wiring diagram over diagram on door (one on

each base).

16. To place in operation, follow instructions in the LGB

Manual and this Supplement.

Install pilot burners & orifices — EXISTING installation

LGB-5 CSD-1 Series 2 Propane gas – Control Supplement

6Part Number 550-110-682/0304

Connect gas train assembly to burner manifold by:

1. Apply pipe dope to burner manifold nipple (Figure 3, item 1).

Pipe joint compound used must be resistant to corrosive action of liquefied

petroleum gases. Apply sparingly only to male threads of pipe joints. Use of

excessive pipe joint compound can result in damage and possible failure of

gas train components.

2. Pipe lower half of gas train ground joint union to this nipple (Figure 3, item 2).

3. Knock out the gas valve opening on the left side of the boiler. The gas supply can only

enter from the left because of the length of the gas train.

4. Place gas train in position and hand-tighten the ground joint union. Position the gas train

assembly and tighten the union securely.

5. Connect vent lines (routed to outside per code requirements) to ¹⁄₄" tubing vent

connections on main gas valve and pilot gas pressure regulator (Figure 3, item 3).

6. Connect pilot gas tubing (¹⁄₈" aluminum) to adapter in pilot gas valve outlet (Figure 3,

item 4).

7. Crimp connect two ¹⁄₄" spade terminals to ends of pilot gas valve wires (Figure 3, item 5).

Install gas train

assembly

Figure 3

Gas train assembly

Installation & boiler assembly — cont.

LGB-5 CSD-1 Series 2 Propane gas – Control Supplement

Part Number 550-110-682/0304 7

1. Contact gas supplier to size pipes, tanks and regulator.

a. Inlet gas pressure to manual main shut-off gas valve —

minimum 11”W.C., maximum 13”W.C.

b. If pressure to gas valve exceeds 13”W.C., install 100% lockup gas pressure regulator

upstream of hand valve.

2. Remove gas supply knockout disc from left side jacket panel. Gas supply can only enter

from the left side because of the length of the CSD-1 gas train assembly.

3. Follow good piping practices.

Pipe joint compound used must be resistant to corrosive action of liquefied

petroleum gases. Apply sparingly only to male threads of pipe joints. Use of

excessive pipe joint compound can result in damage and possible failure of

gas train components.

4. Install drip leg and manual gas valve at inlet of gas connection to boiler. Where local utility

requires, extend drip leg to floor.

5. Install ground joint union when required for servicing.

6. Support piping by hangers, not by boiler or its accessories.

7. Purge all air from supply piping.

8. Before operating boiler, check boiler and its gas connections for leaks.

Do not check for gas leaks with an open flame — BUBBLE TEST. Failure to

use bubble test or test for leaks can cause severe personal injury, death or

substantial property damage.

a. Close manual main shutoff valve (exterior to jacket) during any pressure testing at less

than 13”W.C.

b. Disconnect boiler from gas supply piping during any pressure test greater than

13”W.C.

Gas piping

1. LGB-5 CSD-1 boilers are equipped with the following components, as required by the

ASME CSD-1. Consult local codes for any special or additional requirements.

a. LGB-5 CSD-1 water boilers include the following:

• a manual reset high temperature limit control and an automatic reset limit control.

• a manual reset low water cutoff (probe type supplied). Install the probe low water

cutoff in the supply or return piping, above the top of the boiler. The low water

cutoff must be mounted between the boiler and any isolation valve(s) installed in

the piping.

b. LGB-5 CSD-1 steam boilers include the following:

• a manual reset high pressure limit control and an automatic reset limit control.

• a manual reset float low water cutoff plus an automatic reset float low water

cutoff (gravity return steam boilers) or an automatic reset float low water cutoff/

pump control (pumped return steam boilers).

The controls may be mounted on either end of the boiler. All controls (and

the junction box) must be mounted on the same end.

Water and steam trim

components

LGB-5 CSD-1 Series 2 Propane gas – Control Supplement

8Part Number 550-110-682/0304

For your safety, turn off electrical

power supply before making any

electrical connections to avoid

possible shock hazard.

A strain relief bushing and adapter

must be used at each point where

wiring passes through the boiler

jacket or control cases to protect

wiring insulation.

The boiler limit controls and low

water cutoff(s) are exterior to the

boiler jacket, and must be wired per

N.E.C. class 1 in conduit. The wire

(No. 14 gauge or heavier) and

conduit for these controls is supplied

by the installer — it is not included

with the boiler.

Assembly illustration and wiring

diagrams

This Supplement contains a schematic and ladder

wiring diagram.

The diagrams show limit control and low water cutoff

connections for both water and steam boilers.

See Figure 5, pages 12 and 13 for a typical finished

assembly.

General

Refer to LGB Manual for further information.

All wiring must be installed in accordance with the

requirements of the National Electrical Code and any

additional national, state or local code requirements

having jurisdiction. All line voltage wiring external to

boiler jacket must be N.E.C. class 1.

Provide a separate electrical circuit with a fused

disconnect switch (15 amp recommended) to supply

the boiler. Wiring to the boiler must be No. 14 gauge

or heavier, installed in conduit.

The boiler must be electrically grounded in accordance

with the National Electrical Code,ANSI/NFPA No. 70,

latest edition.

Use 105 °C thermoplastic wire, or equivalent, if any

original wire must be replaced (except for pilot spark

and sense wires and 125 °C pilot burner ground wire).

Wiring procedure

1. Mount all controls as directed in Section C of this

Supplement. Refer to the assembly illustration,

Figure 5, page 12 for component locations.

2. Mount the junction box supplied with the boiler

on the inside left (or right) side of the jacket as

shown in the assembly illustration (using screws

and nuts provided). The junction box must be

mounted on the same end of the boiler as the

controls will be mounted.

3. Attach the transformer/relay to the junction box.

4. Mount the CSD-1 control panel on the jacket

interior panel as shown in the assembly

illustration, Figure 5, page 12 (using screws and

nuts provided).

5. Crimp connect ¹⁄₄" spade terminals (provided) to

the pilot gas valve wires (if not already done in

Section A of this Supplement). Connect the pilot

valve black wire to the ignition control PV

terminal. Connect the pilot valve white wire to the

main gas valve TR terminal.

6. Connect pilot burner ground wire, spark wire and

sense wire to ignition control as directed in wiring

diagram and Figure 2, page 5.

7. The main gas valve wires are pre-attached to the

CSD-1 control panel. Connect these wires as

shown in the wiring diagram.

8. Use minimum 14-gauge thermoplastic wire

(105 °C or better), supplied by installer, to

complete wiring of the remaining components

according to the appropriate wiring diagram and

the assembly illustration. Route all wiring to

external components (limit controls and low water

cutoffs) in conduit per N.E.C. class 1.

Wiring

LGB-5 CSD-1 Series 2 Propane gas – Control Supplement

Part Number 550-110-682/0304 9

General

The following sequence of operation applies to all wiring diagrams in this Supplement — both water and steam.

Call for heat

On a call for heat (from thermostat or operating control) —

1. Assumptions: Limit control and water level control contacts are closed and standing pilot is operating.

2. Ignition control checks for signal at electronic pilot. (No signal should be present.)

If no signal is sensed (normal condition):

a. Pilot solenoid opens.

b. Pilot ignition spark begins.

c. Pilot ignites.

d. Pilot proves.

If a signal is sensed (abnormal condition) by the ignition control, the control will lockout.

On failure to establish pilot flame signal within 15 seconds, the ignition control will turn off the

pilot gas valve. It will wait 5 minutes, then retry for ignition. If the second ignition attempt fails,

the ignition control will lockout and illuminate the red lockout light.

This will activate the alarm contact of the impulse relay, providing an isolated contact closure

across terminals A1 and A2 of the CSD-1 control panel terminal strip. The contact rating is 15

amps at 250 VAC.

To reset the boiler, push the red lockout button on the CSD-1 control panel.

3. Once pilot is proved the ignition control activates main gas valve. Main burners will ignite and boiler will

continue to fire until terminated by limit action or no call for heat.

Lockout modes

In addition to lockout on flame-sense failure, the boiler may also experience lockout due to shutdown of a manual

reset control.

The boiler is equipped with a manual reset limit control and a manual reset low water cutoff.

Should the limit control or the low water cutoff lockout, the boiler will only restart after the limit

control or low water cutoff reset switch is pressed.

Steam boilers — Do not substitute another manual reset low water cutoff for the one specified

and supplied with the boiler. Other controls may not operate as intended and could cause serious

operating problems or failures.

The boiler is equipped with a standing pilot as well as an electrically-ignited pilot. Should the

standing pilot thermocouple lose flame sense, the pilot switch box will open the electrical circuit,

shutting off the boiler. The pilot must be manually lighted in accordance with the lighting

instructions on the boiler label and in this Supplement in order to restart the boiler.

DWiring — sequence of operation

LGB-5 CSD-1 Series 2 Propane gas – Control Supplement

10 Part Number 550-110-682/0304

Wiring — diagrams

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