Gas–fired boiler
LGB
Control Supplement
Series 2 – Propane gas
CSD-1 Control System
Contents
I. New installation .......... 2
II. Existing installation .... 4
III. Water and steam trim
components .................. 4
IV. Gas piping ................... 5
V. Wiring ........................... 5
Sequence of operation ..... 8
Wiringprocedure .............. 8
VI. Leaktestprocedure ... 10
VII. Operating instructions ..... 11
VIII.Parts list ..................... 12
Indicates presence of hazards that can cause severe personal injury,death or
substantial property damage.
These terms are used throughout this
manual to bring attention to the
presence of hazards of various risk
levels or to important information
concerning the life of the product.
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 550-141-816/0798
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CSD-1ControlSystem–Propanegas
I
New installation
– continued
Figure 1
Pilot burner assembly, typical
Figure 2
Main flame sensor assembly
Part Number 550-141-816/0798
3
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LGB-6 to LGB-20 Series 2 – Control Supplement
II
Existing installation Conversion from natural gas to propane gas
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.
1. These instructions are for use with Propane Control Cartons as listed in Gas Control
Arrangement, Table 2 (page 2).
2. Remove jacket door(s) and access panel(s).
3. Disconnect wiring and tubing from existing pilot burner and main flame sensor.
4. Remove all burners. Remove 3.95 mm natural gas main burner orifices in manifold. 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.
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.
7. Re-install burners. See Table 1 (page 2) for location of pilot burners and flame sensor(s).
8. Attach pilot switch box to jacket. See Figure 6 (page 12). Connect thermocouple to pilot
switch box. Cut 60” pilot tubing into 2 pieces to make connections from tee in pilot line to
pilot switch box and from pilot switch box to standing pilot.
9. Remove natural gas valve train.
10. Install propane gas valve train and fittings from carton (See page 5, section IV, paragraph
4 of this Supplement).
11. Re-install access panel(s).
12. See Figure 6, page 12 for propane piping.
13. Wire per wiring instructions and wiring diagrams, pages 5-9. Add splices as needed.
14. 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).
15. To place in operation, follow instructions on constant burner pilot light-up label and
boiler operating label.
16. Replace jacket doors.
III
Water and steam trim components
1. Install water or steam trim components as required by CSD-1 latest edition. See the boiler
manual for tapping locations.
a. Water boilers require:
•
a manual reset high temperature limit control in addition to the standard
automatic reset limit control.
•
a manual reset low water cutoff.
b. Steam boilers require:
•
a manual reset high pressure limit control in addition to the standard automatic
reset limit control.
•
a manual reset low water cutoff in addition to the standard automatic reset low
water cutoff.
4
Part Number 550-141-816/0798
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CSD-1ControlSystem–Propanegas
IV
Gas piping
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% lock-up gas pressure regulator
upstream of hand valve.
2. Remove gas supply knockout disc from jacket panel.
3. Follow good piping practices.
4. Pipe joint compound (pipe dope) must be resistant to corrosive action of liquefied
petroleum gases. Apply sparingly only to male threads of pipe joints.
5. Install drip leg at inlet of gas connection to boiler. Where local utility requires, extend drip
leg to floor.
6. Install ground joint union when required for servicing.
7. Support piping by hangers, not by boiler or its accessories.
8. Purge all air from supply piping.
9. 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 shut-off valve during any pressure testing at less than 13”W.C.
b. Disconnect boiler and gas valve from gas supply piping during any pressure test
greater than 13”W.C.
Wiring
V
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.
5. Refer to wiring diagrams, Figure 3 (pages 6 and 7) and Figure 5 (page 9). See section,
“Wiring procedure” on page 8.
6. Figure 5 on page 9 is the Field Wiring Diagram. See Figure 3, pages 6 and 7, for the
schematic and ladder wiring diagrams.
Part Number 550-141-816/0798
5
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LGB-6 to LGB-20 Series 2 – Control Supplement
CSD-1ControlSystem–Propanegas
Figure 3
Wiring diagram
EQUIPMENT
GROUND
(NOTE 9)
LADDER WIRING DIAGRAM
H
SCHEMATIC WIRING DIAGRAM
N
STEAM
120 V.A.C.
MANUAL
RESET
LOW WATER
CUT-OFF
MANUAL
RESET
LWCO
NO.1 RED FLAME FAILURE LAMP
LIMIT CIRCUIT
HIGH
LIMIT
SERVICE SWITCH
(BY OTHERS)
OPERATING
CONTROL
MANUAL
MANUAL
RESET
HIGH LIMIT
(STEAM ONLY)
LOW WATER RESET
CUT-OFF LWCO
OPERATING
CONTROL
HIGH
LIMIT HIGH LIMIT
PRIMARY
MAIN FLAME
PROVING MODULE
PILOT PROVING
MODULE
MOMENTARY
SWITCH
R
C
MV
MV/PV
PV
MV
MV/PV
PV
24 V.A.C.
PRIMARY
PILOT
SWITCH
BOX
R
IMPULSE
RELAY
ALARM
ALARM
24 V
ALARM
ALARM
24 V
R
C
24 V.A.C.
MAIN FLAME
SENSOR
WIRE NUTS (4)
JUNCTION
BOX
MAIN GAS VALVE HIGH FIRE
OPERATOR (NOTE 5)
FIRING RATE CONTROL
(WHEN USED)
PILOT
(NOTE 8)
24V (GND)
SENSE
24V (GND)
SENSE
MV
MV/PV
PV
MV
MAIN GAS VALVE LOW FIRE OPERATOR
MV/PV
A1
A2
WATER
LIMIT CIRCUIT
SEE
NOTE 11
N/A
SPARK
FROM TRANSFORMER
THERMOCOUPLE
R
MANUAL
RESET
LWCO
MANUAL
RESET
HIGH LIMIT
MV/PV
(NOTE 5)
PV
ALARM
ALARM
24V
HIGH GAS
PRESSURE
SWITCH
MV/PV
PV
1
WIRE TIE
CLIP
SECONDARY GAS VALVE
(WHEN USED)
TERMINAL
BLOCK
HIGH GAS
PRESSURE
SWITCH
PILOT
SWITCH
BOX
1
2
A1
A2
(WHEN USED)
24V
(GND)
PRE-WIRED PANEL
TEMPERATURE
OPERATING/LIMIT
COMBINATION
CONTROL
MAIN FLAME SENSOR
NOTE 6
BK
FIRING RATE CONTROL
(WHEN USED)
SENSE
MV
BL
W
NO. 1 BASE
MAIN FLAME PROVING MODULE
THERMOCOUPLE
NOTE 11
MV/PV
PV
PILOT SOLENOID VALVE
R
STANDING
PILOT
MAIN GAS VALVE - TWO
STAGE COMBINATION
VALVE W/REGULATOR
MV
MV/PV
PV
BL
MV
PV
BL
PILOT
SOLENOID
VALVE
MV/PV
W
ALARM
FROM TRANSFORMER
SECONDARY
GAS VALVE
W
BK
ALARM
24V
NO. 1 BASE WIRING
(SIZES 6 THRU 20)
PILOT
SWITCH
BOX
24V
(GND)
NO.2 RED FLAME FAILURE LAMP
2
TO LIMIT CIRCUIT
PILOT FLAME SENSOR
SERVICE SWITCH
(BY OTHERS)
SENSE
SPARK
MAIN FLAME
PROVING MODULE
PILOT PROVING
MODULE
TRANSFORMER
BK
MOMENTARY
SWITCH
H
PILOT BURNER
(NOTE 8)
MV
MV/PV
PV
MV
MV/PV
PV
NO. 1 BASE
PILOT PROVING MODULE
FROM
FUSED
R
IMPULSE
RELAY
R
C
DISCONNECT
120
V.A.C.
24
V.A.C.
ALARM
ALARM
24 V
ALARM
ALARM
24 V
N
THERMOCOUPLE
MAIN GAS VALVE HIGH FIRE
OPERATOR (NOTE 5)
FIRING RATE CONTROL
(WHEN USED)
W
MAIN FLAME
SENSOR
MV
MV/PV
PV
MV
MAIN GAS VALVE LOW FIRE OPERATOR
MV/PV
PILOT
(NOTE 8)
A1
A2
SEE
NOTE 11
24V (GND)
SENSE
24V (GND)
SENSE
R
WIRE NUTS (3)
N/A
SPARK
MV/PV
PV
(NOTE 5)
ALARM
ALARM
24V
HIGH GAS
PRESSURE
SWITCH
PILOT
SWITCH
BOX
MV/PV
EQUIPMENT
GROUND
(NOTE 9)
PV
1
SECONDARY GAS VALVE
(WHEN USED)
HIGH GAS
PRESSURE
SWITCH
WIRE TIE
CLIP
TERMINAL
BLOCK
24V
(GND)
(WHEN USED)
MAIN FLAME SENSOR
1
2
A1
A2
SENSE
MV
MV/PV
PV
PRE-WIRED PANEL
NO. 2 BASE
MAIN FLAME PROVING MODULE
NOTE 6
BK
FIRING RATE CONTROL
(WHEN USED)
PILOT SOLENOID VALVE
BL
THERMOCOUPLE
W
NOTE 11
BK
STANDING
PILOT
R
ALARM
R
C
MAIN GAS VALVE - TWO
STAGE COMBINATION
VALVE W/REGULATOR
MV
MV/PV
PV
BL
MV
PV
BL
120
V.A.C.
24
V.A.C.
PILOT
SOLENOID
VALVE
ALARM
24V
MV/PV
W
SECONDARY
GAS VALVE
W
W
BK
NO. 2 BASE WIRING
24V
(GND)
2
WIRE NUTS (2)
(SIZES 13 THRU 20)
TRANSFORMER
PILOT FLAME SENSOR
SENSE
SPARK
LOW VOLTAGE FIELD
HIGH VOLTAGE FIELD
4. REFER TO CONTROL COMPONENT INSTRUCTIONS PACKED WITH BOILER FOR
APPLICATION INFORMATION.
ELECTRICAL SHOCK HAZARD, CAN CAUSE SEVERE INJURY OR DEATH.
DISCONNECT POWER BEFORE INSTALLING AND/OR SERVICING.
THERMOCOUPLE LEAD
LOW VOLTAGE FACTORY
HIGH VOLTAGE FACTORY
IGNITION/SENSING CABLE
PILOT BURNER
(NOTE 8)
MV/PV
NO. 2 BASE
PILOT PROVING MODULE
5.
TERMINAL ON MAIN GAS VALVE IS A SINGLE TERMINAL (COMMON)
FOR LOW AND HIGH FIRE OPERATORS.
NOTES:
6. REFER TO CONTROL SUPPLEMENT FOR GROUND LEADWIRE ATTACHMENT.
IF ORIGINAL GROUND LEADWIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED,
TYPE 125 C OR ITS EQUIVALENT MUST BE USED.
FACTORY WIRED TO CONTROL -
FIELD WIRED TO GAS VALVE OR FIRING
RATE CONTROL.
1. ALL WIRING MUST BE INSTALLED IN ACCORDANCE WITH:
A. U.S.A. - NATIONAL ELECTRICAL CODE AND ANY OTHER NATIONAL, STATE, OR LOCAL
CODE REQUIREMENTS.
Intermittent Pilot
MAIN GAS VALVE TERMINAL.
CONTROL MODULE TERMINAL.
B. CANADA - C.S.A. C22.1 CANADIAN ELECTRICAL CODE PART 1 AND ANY OTHER
NATIONAL, PROVINCIAL, OR LOCAL CODE REQUIREMENTS.
7. WIRES ARE FACTORY INSTALLED TO CONTROL PANEL, BUT MUST BE FIELD
CONNECTED TO GAS VALVES AND FIRING RATE CONTROL TERMINALS (WHEN USED).
A United Dominion Company
CSD-1 Control System
Steam or Water
6 thru 20
LGB
8. PILOT LEADWIRES ARE NOT FIELD REPLACEABLE. REPLACE PILOT ASSEMBLY IF NECESSARY.
Weil-McLain
500 Blaine St.
Michigan City, IN 46360-2388
2. ALL WIRING EXTERNAL TO BOILER JACKET MUST BE:
A. U.S.A. - N.E.C. CLASS 1.
B. CANADA - C.S.A. C22.1 C.E.C. PART 1.
IGNITION CONTROL PANEL TERMINAL.
TRANSFORMER TERMINAL.
PANEL LAMP
Propane Gas
9.
DENOTES FIELD INSTALLED CHASSIS GROUND.
10. ALL CONTACTS SHOWN WITHOUT POWER APPLIED - OFF SHELF CONDITION.
11. ALARM CONTACT RATINGS - 15 AMP @ 250 VAC.
550-141-835/0798WM
PART NUMBER
3. IF ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, TYPE
105 DEGREES C OR ITS EQUIVALENT MUST BE USED. EXCEPTION, SEE NOTE 6.
6
Part Number 550-141-816/0798
Part Number 550-141-816/0798
7
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LGB-6 to LGB-20 Series 2 – Control Supplement
Wiring
– continued
V
Sequence of operation
1. Operating control begins startup sequence.
a. Limit control contacts are closed.
2. Pilot proving module energized.
a. Pilot solenoid opens.
b. Pilot ignition spark begins.
c. Pilot ignites.
d. Pilot proves.
On failure to sense pilot flame, the pilot-proving module will wait 5
minutes, then retry for ignition. Upon 2 consecutive pilot flame failures,
the control will lockout and illuminate the red lockout light.
3. Main flame proving module energized from pilot proving module.
a. Secondary gas valve opens.
b. Main gas valve opens to low fire position.
c. Main burners ignite at low fire.
d. Main flame sensor proves low fire carryover.
e. Main gas valve opens to high fire position.
f. Main burners increase to high fire.
On failure to sense main flame, the main flame-proving module will
lockout and illuminate the red lockout light.
4. For dual base assembly - operating control energizes controls for each base assembly at the
same time. See steps 1 through 3 above.
5. Boiler shuts down when operating control satisfied.
If the boiler locks out, the alarm contacts on the terminal strip (terminals
A1 and A2) close. These contacts are rated to 15 amps, 250 V. To reset the
boiler, push the red lockout button.
1. Determine right or left electrical supply wiring.
Wiring procedure
Figure 4
2. Attach electrical junction box(es) to inside jacket end
panel. Screws and nuts are provided. For dual base
boilers, use offset nipples (provided) to connect
junction boxes together (as at right), then hang
junction boxes by screwing top box to boiler jacket.
See Figure 4.
Junction box assembly
dual base boilers
3. Attach control transformer(s) to junction box(es).
4. Drill 1/8” hole in interior jacket panel midway between
ignition control panel and left jacket panel. Mount
wire support clip using sheet metal screw (furnished).
5. Complete wiring per diagrams, Figure 3 (pages 6
and 7) and Figure 5 (page 9).Terminate at secondary
gas valve in valve junction box with wirenuts and
strain relief provided.
“Hot” side of line voltage to boiler
must be wired directly to limit
circuit, then fed to transformer
primary(ies).
Dual Base:“R”terminal of
secondaries are to supply power
to bases independently of each
other. Do not wire“R”terminals
together.
6. Install pilot proving and main flame proving ground
connections as shown in Figures 1 and 2 and wiring
diagram. Route wires through wire support clip.
8
Part Number 550-141-816/0798
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CSD-1ControlSystem–Propanegas
Figure 5
Field wiring diagram
Part Number 550-141-816/0798
9
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LGB-6 to LGB-20 Series 2 – Control Supplement
VI
Leak test procedure
1. Remove red (MV) and blue (PV) wires from main gas valve.
2. Close main test firing valve attached to the manifold.
3. Check that both leak test valves are closed and remove plugs.
4. Attach manometer to first leak test valve.
5. Open first leak test valve and check for pressure.
6. Close first leak test valve and remove manometer.
7. Attach manometer to second leak test valve.
8. Apply call for heat to boiler.
9. Check that electronic pilot proves.
10. Open second leak test valve and check for pressure.
11. Close second leak test valve and remove manometer.
12. Remove call for heat to boiler.
13. Reinstall plugs on leak test valves.
14. Connect wiring to main gas valve.
15. Open main test firing valve attached to the manifold.
When checking for pressure at the leak test valves, any small pressure
reading is normal. If the pressure continues to increase after opening the
leak test valve, the upstream valve is leaking and should be replaced.
10
Part Number 550-141-816/0798
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CSD-1ControlSystem–Propanegas
VII
Operating instructions
A. This boiler is equipped with a pilot which must be lighted by hand. When lighting the
pilot, follow these instructions exactly. The gas supply to this pilot is controlled by Pilot
switch box. This boiler is also equipped with an ignition device which automatically lights a
second pilot. The gas supply to this pilot is controlled by the Gas control. Do not try to
light this pilot by hand.
B. BEFORE OPERATING THE MANUAL PILOT, smell all around the appliance area for gas.
Be sure to smell next to the floor because some gas is heavier than air and will settle on the
floor.
WHAT TO DO IFYOU SMELL GAS
•
•
•
Do not try to light any appliance.
Do not touch any electric switch; do not use any phone in your building.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
•
If you cannot reach your gas supplier, call the fire department.
C. Do not use this appliance if any part has been under water. Immediately call a qualified
service technician to inspect the appliance and to replace any part of the control system
and any gas control, which has been under water.
This document is intended only as a supplement to the LGB Gas-Fired Boiler Manual. Follow
all instructions in the Manual, including those regarding start-up (found in Section VIII,
“Placing boiler in operation”).
Starting
boiler
1. STOP! Read the safety information above.
2. Set the Operating control to lowest setting.
3. Turn off all electrical power to the appliance.
4. Remove the Base access shield.
5. Close the Pilot shut-off valve connected to Manual main shut-off valve.
Close Manual main shut-off valve.
6. Wait five (5) minutes to clear out any gas. Then smell for gas, including
near the floor.If you smell gas,STOP! Follow“B”in the safety information
above. If you don’t smell gas, go to the next step.
7. Open the Pilot shut-off valve.
8. Press and hold the reset lever on the Pilot switch box. Manually light the
pilot while holding the lever down. Air in the gas supply line will have to
purge through the line before sufficient gas will reach the pilot.
9. After purging all air,hold the Pilot switch box lever for about 1 minute to
heat the thermocouple.
10. Release the Pilot switch box lever. The pilot should remain lit.
11. Open the Manual main shut-off valve and follow the sequence below.
12. This appliance is also equipped with an ignition device which automatically
lights the second pilot. Do not try to light this pilot by hand.
13. Turn on all electric power to the appliance.
14. Set Operating control to desired setting.
15. If the appliance will not operate, turn off gas to the appliance by closing
the Manual main shut-off valve and Pilot shut-off valve. Call your service
technician or gas supplier.
16. Replace Base access shield and Front panel.
Part Number 550-141-816/0798
11
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LGB-6 to LGB-20 Series 2 – Control Supplement
VIII
Parts
list
Figure 6
Ref. No.
Description
Size
Vendor/Part Number
Weil-McLain Part Number
1
Main flame sensor
Main burner with pilot bracket
Main flame sensor bracket
Honeywell 392956
Weil-McLain
Weil-McLain
Kinco-Balon 500
511-724-274
512-200-055
423-300-420
511-246-325
511-246-330
511-044-191
511-044-192
511-044-346
511-044-218
383-300-410
383-300-411
512-200-055
460-005-624
511-330-086
511-330-085
510-350-226
2
1"
1 ¼"
1"
1 ¼"
1"
3
4
5
Manual main shut-off valve
Secondary gas valve
Main gas valve
Kinco-Balon 600
Honeywell V8943A1003
Honeywell V8943A1111
Honeywell V8944L1033
Honeywell V8944L1041
Weil-McLain
Weil-McLain
Weil-McLain
Weil-McLain
United Technologies 1003-615
United Technologies 1003-60
Potter-Brumfield S89R-11ABD1-24
Honeywell AML21CBA2AA
Eaton Controls ZZ1K11810K
Honeywell AML51-C10R
Eaton Controls ZZ0PM0ZA
TI-¾ #85 (Available at Local Supply House)
Honeywell V8046C1014
Johnson Controls H91ABG
Kinco-Balon P2R
Johnson Controls L62GB-3C
Honeywell Q309A
Watts FBV3-06
Watts FBV3-07
Watts FBV3-08
1 ¼"
6
7
Pilot burner, standing-repair kit propane
Pilot burner, electronic-repair kit propane
Main burner with pilot bracket
Pilot burner bracket
Pilot proving module
Main flame proving module
Impulse relay
8
9
10
11
12
Push-button switch
511-624-580
511-624-581
13
14
15
Lens cover
Light bulb
Pilot solenoid
511-044-039
16
17
18
Pilot shut-off valve
Pilot switch box
Thermocouple
511-246-340
511-330-229
511-724-245
511-246-290
511-246-292
511-246-294
511-246-340
48"
1"
1 ¼"
1 ½"
19
Firing valve
20
21
22
Leak test valve
Pilot tubing, alum. ¼ O.D. x .032-20" long
Pilot tubing, alum. ¼ O.D. x .032-60" long
Kinco-Balon P2R
Available at Local Supply House
*Contact local Weil-McLain distributor/agent for current replacement part and order number.
Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
12
Part Number 550-141-816/0798
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