Weil McLain FLAME GUARDIAN WMBC 1A User Manual

Gas–fired boiler  
LGB  
Control Supplement  
Flame Guardian WMBC-1A  
RM7895C Controller Electronic Pilot System  
IRI  
Contents  
I. Installation ..................... 2  
II. Gas piping ...................... 5  
III. Wiring ............................. 5  
IV.Startup ......................... 10  
V. Sequence of operation 11  
VI.Parts list ....................... 12  
Indicates presence of hazards that can cause severe personal injury,death or  
substantial property damage.  
Indicates special instructions on installation, operation or maintenance that  
are important but not related to personal injury or property damage.  
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.  
Part Number 550-141-807/0298  
 
Flame Guardian WMBC-1A Electronic Pilot System – IRI  
I
Installation continued  
Sensor  
Q179 Pilot  
Burner  
10-32 x 5/16“  
Machine Screws(2)  
Figure 2  
Igniter  
Q179 pilot burner assembly  
Locating Slot  
Ground Leadwire:  
Connect to WMBC  
Panel Terminal G2  
(Ground Terminal)  
Pilot Mounting  
Bracket  
Burner Support Bar  
Pilot Line Tubing  
Sensor Lead  
10-32 x 1/4“  
Machine Screws (2)  
Main Burner  
(with Pilot  
Mounting  
Bracket)  
Compression  
Union  
Igniter Lead  
LGB-A56  
6-32 x 5/16“ Type ”F”  
Self Tapping Screws(2)  
Figure 3  
Flame  
Sensor  
Locating Slot  
Main flame sensor assembly  
10-32 x 5/16“  
Machine Screws(2)  
Ground Leadwire:  
Connect to Main Flame  
Proving Module  
24 V (GND) terminal  
Burner Support Bar  
Flame Sensor  
Mounting Bracket  
Sensor Lead  
Main Burner  
(with Pilot  
Mounting  
Bracket)  
LGB-A85  
Part Number 550-141-807/0298  
3
LGB (Series 2) — Control Supplement  
I
Installation continued  
Figure 4  
IRI gas train schematic  
3
5
7
6
Boiler Jacket  
18  
12  
2
18  
4
17  
9
11  
10  
1
8
13  
14  
15  
16  
GAS PIPING DIAGRAM - LGB (Series 2)  
IRI Gas Train  
1
2
3
4
5
6
7
8
9
Manual main shut-off gas valve  
Low gas pressure switch  
10 Manual leak checking gas valve  
11  
Regulating diaphragm gas valve (two stage)  
12 High gas pressure switch  
Pilot manual shut-off valve  
Motorized gas valve w/ on/off actuator  
Pilot gas pressure regulator  
Normally open solenoid vent valve  
Pilot solenoid gas valve  
13  
14  
15  
Main flame sensor  
Main burner with main flame sensor bracket  
Pilot burner  
16 Main burner with pilot burner bracket  
Test cock  
Adapter, for N. O. vent valve  
Pipe flanges  
17  
18  
Second motorized gas valve w/ on/off actuator  
4
Part Number 550-141-807/0298  
Flame Guardian WMBC-1A Electronic Pilot System – IRI  
II  
Gas piping  
1. Size gas piping considering:  
a. Diameter and length of gas supply piping.  
b. Number of fittings.  
c. Maximum gas consumption (including any possible future expansion).  
d. Allowable pressure drop from gas meter outlet to boiler. For pressure drops, see ANSI-Z223.1 – latest  
edition.  
2. Size natural gas piping from table below. Size piping to provide proper inlet pressure to gas valve when operating  
at rated input.  
a. Inlet gas pressure to manual main shutoff gas valve minimum 7” W.C. standard (5½” on special order) –  
maximum 13W.C.  
b. If pressure to gas valve exceeds 13W.C., install positive dead-end lockup gas pressure regulator up stream of  
hand valve.  
c. To obtain approximate cubic feet per hour, divide input (BTU/HR) by 1000.  
3. Remove gas supply knockout disc from jacket panel.  
4. Follow good piping practices.  
5. Pipe joint compound (pipe dope) must be resistant to corrosive action of liquefied petroleum gases. Apply  
sparingly only to male threads of pipe joints.  
6. Install drip leg at inlet of gas connection to boiler. Where local utility requires, extend drip leg to floor.  
7. Install ground joint union when required for servicing.  
8. Support piping by hangers, not by boiler or its accessories.  
9. Purge all air from supply piping.  
10. Check all 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 during any pressure testing at less than 14.0 inches water column.  
b. Disconnect boiler and gas controls from gas supply piping during any pressure test greater than 14.0 inches  
water column.  
11. Set gas pressure switches as follows or to local inspector’s requirements:  
a. Low – 3.0W.C.  
b. High – 14.0W.C  
PIPE  
SIZE  
PIPE LENGTH, FEET (NATURAL GAS CAPACITIES, LISTED IN MBH)  
(Specific Gravity 0.60 @ Pressure Loss of 0.30" w.c.)  
Table 2  
Natural gas  
supply pipe  
sizing  
10’  
1,050  
20’  
730  
30’  
590  
40’  
500  
50’  
440  
75’  
360  
100’  
305  
460  
150’  
250  
380  
1¼"  
1½"  
2"  
2½"  
3"  
1,600  
3,050  
4,800  
8,500  
17,500  
1,100  
2,100  
3,300  
5,900  
12,000  
890  
1,650  
2,700  
4,700  
9,700  
760  
1,450  
2,300  
4,100  
8,300  
670  
1,270  
2,000  
3,600  
7,400  
545  
1,020  
1,650  
2,900  
6,000  
870  
710  
1,400  
2,500  
5,100  
1,130  
2,000  
4,100  
4"  
* Include measured length of gas supply piping and allowance in feet for number and size of fittings.  
III  
Wiring  
For your safety, turn off electrical power supply before making any electrical connections to avoid possible electrical  
shock hazard.  
1. 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 wiring must be N.E.C. Class 1.  
2. 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 of the original wire must be replaced (except  
for pilot spark, sense and ground wires).  
3. Supply wiring to the boiler must be No. 14 gauge or heavier. Install in conduit.  
4. A separate electrical circuit with a fused disconnect switch (15 amp. recommended) should be used for the boiler.  
Part Number 550-141-807/0298  
5
LGB (Series 2) — Control Supplement  
Flame Guardian WMBC-1A Electronic Pilot System – IRI  
Figure 5 — WMBC-1A panel wiring schematic  
6
Part Number 550-141-807/0298  
Part Number 550-141-807/0298  
7
LGB (Series 2) — Control Supplement  
Figure 6 — WMBC-1A panel wiring diagram – factory wiring  
8
Part Number 550-141-807/0298  
Flame Guardian WMBC-1A Electronic Pilot System – IRI  
Figure 7 — WMBC-1A field wiring diagram  
Part Number 550-141-807/0298  
9
LGB (Series 2) — Control Supplement  
IV  
Start-up  
Turn off electrical power supply and gas supply to boiler before making the following connections  
and adjustment. Failure to do so can cause severe personal injury, death or substantial property  
damage.  
1. Disable high fire by disconnecting the blue wire in the two-stage gas valve.  
2. Connect manometer to gas manifold (manometer must be capable of measuring 0” to 14”  
W.C.).  
3. Turn on electrical power supply and gas supply to boiler.  
4. Fire boiler, which will light off and remain on low fire.  
5. While reading manometer,turn low fire adjustment screw clockwise (Figure 5) until pressure  
reading is 1.2W.C.  
6. Turn off boiler.  
Turn off electrical power supply and gas supply to boiler before the following steps. Failure to  
do so can cause severe personal injury, death or substantial property damage.  
7. Remove manometer from manifold and plug the tapping.  
8. Reconnect the blue wire in the two-stage gas valve junction box.  
9. Turn on electrical power supply and gas supply to boiler.  
10. Follow operating instructions label on boiler to set boiler in operation.  
Figure 8  
Low fire adjustment  
Low Fire Adjustment  
10  
Part Number 550-141-807/0298  
Flame Guardian WMBC-1A Electronic Pilot System – IRI  
V
Sequence of operation  
1. Operating control begins startup sequence:  
a. Limit control contacts are closed.  
b. Purge timer is energized.  
2. Flame safeguard control pilot circuit energizes after 2.0 seconds.  
a. Pilot gas valve opens.  
b. Ignition transformer energizes.  
c. Yellowpilot onlamp lights.  
d. Pilot ignition spark begins.  
e. Pilot ignites.  
f. Pilot flame proves.  
3. Flame safeguard control energizes main flame circuit:  
a. Bluegas valve onlamp lights.  
b. Gas control train energizes.  
c. Downstream gas valve opens to low-fire position.  
d. Main burners ignite, operate at low fire.  
4. Ignition transformer de-energizes after 10-second trial for ignition.  
5. Pilot de-energizes after 10-second trial for main flame. Yellowpilot onlamp goes out.  
6. Main flame sensor proves main burner operation at low fire.  
7. Flame safeguard control energizes downstream gas valve to high-fire (through firing rate  
control, when used):  
a. Main burners operate at high fire.  
b. Main burners operate at low fire when water temperature or pressure reaches setting of  
firing rate control, when used.  
8. Boiler shuts down when operating control satisfied.  
9. Flame safeguard control lockout circuit energized if pilot is not proved during start-up or if  
main flame is not proved during run sequence.  
a. Flame safeguard control locks out on safety.  
b. Red “alarm” lamp, alarm relay, and alarm bell energize. Silencing switch can shut off  
alarm bell.  
c. Alarm relay de-energizes purge timer.  
d. Press reset button on flame safeguard control to permit normal start-up after correcting  
lockout condition.  
e. Normal start-up resumes after purge timer automatically resets (5 minute enforced  
wait).  
Part Number 550-141-807/0298  
11  
LGB (Series 2) — Control Supplement  
VI  
Parts list – Table 3  
Description  
Size  
Vendor/Part Number  
Honeywell RM7895C1012  
Honeywell ST7800A1005  
Honeywell R7847A1033  
Sylv. 120MB/CHI Min. CM8-967  
Bussman MTH-6  
Weil-McLain Part Number  
Primary Control  
510-350-431  
Prepurge Timing Card 2.0 Seconds  
Flame Amplifier  
510-350-432  
510-350-434  
Electric Bulb 120V  
Fuse 6 Amp.  
*
*
Relay 120V DPDT  
Control Timer  
Honeywell R4222D1013  
SSAC EDRM427  
510-311-012*  
510-350-430  
Gas Cock, ¼ M x ¼ F  
Pilot Regulator, ¼ NPT  
Pilot Solenoid  
Conbraco 53-300-01  
*
*
Maxitrol RV20A  
¼"  
¼"  
Honeywell V4046C  
511-044-040*  
Johnson Controls H91ABA  
Brass Union, 1/8 NPT x 1/4cc  
Low Gas Pressure Switch  
High Gas Pressure Switch  
Gauge Cock  
*
Honeywell C645A1030  
Honeywell C645B1013  
Conbraco 41-560-05  
Honeywell Q179C1009  
Weil-McLain  
511-624-550*  
511-624-555*  
511-210-415*  
511-330-181*  
460-005-624  
511-724-274  
423-300-420  
512-200-055  
511-802-014*  
*
Pilot Burner  
Pilot Bracket  
Main Flame Sensor  
Main Flame Sensor Bracket  
Main Burner with Bracket  
Ignition Transformer  
Honeywell 392956  
Weil-McLain  
Weil-McLain  
Honeywell Q624A1014  
Essex 500  
1"  
1 ¼"  
1 ½"  
2"  
Essex 600  
*
Hand Valve  
Conbraco 50-603  
Conbraco 50-703  
*
*
Valve Body  
(small - up to 2" Pipe Flanges)  
Honeywell V5097A  
510-744-315  
1"  
1 ¼"  
1 ½"  
2"  
Honeywell 32000109-002  
Honeywell 32000109-003  
Honeywell 32000109-004  
Honeywell 32000109-005  
Honeywell V4055A  
511-044-170  
511-044-171  
511-044-172  
511-044-173  
510-744-317  
511-046-340  
511-046-342  
Pipe Flanges (for Valve Body)  
Actuator For Valve Body (On/Off)  
¾"  
1"  
Honeywell V4295S  
Solenoid Vent Valve  
(Normally Open)  
Honeywell V4295S  
Adapter for small valve body  
(for vent valve)  
Honeywell 32002513  
511-044-176  
1"  
1 ¼"  
1 ½"  
2"  
Honeywell V4944N1011  
Honeywell V4944N1029  
Honeywell V4944N1037  
Honeywell V4944N1045  
511-048-503  
511-048-502  
511-048-501  
511-048-500  
Gas Valve with Regulator  
* Listed part can be purchased at local supply house  
Weil-McLain  
500 Blaine Street  
Michigan City, IN 46360-2388  
12  
Part Number 550-141-807/0298  

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