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Series LC/LCE
Oil, Gas & Gas/Oil Boilers – Water
Installation,
Operation &
Maintenance
Manual
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TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 1 5. VENTING 29 A. INSTRUCTION MANUALS . . . . . . . . . . . . . . .1 6. INSTALL THE BURNER 29 B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1 A. BURNER APPLICATION . . . . . . . . . . . . . . . .29 1. PREINSTALLATION 2 B. INSTALL BURNER MOUNTING PLATE . . . .29 C. MOUNT THE BURNER . . . . . . . . . . . . . . . . .29 A. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 B. CLEARANCE FROM COMBUSTIBLE 7. CONNECT FUEL PIPING 31 CONSTRUCTION . .
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USING THIS MANUAL USING THIS MANUAL A. INSTRUCTION MANUALS DANGER The Series LC/LCE Installation, Operation & Indicates a condition or hazard which will cause Maintenance Manual is divided into four basic sections: severe personal injury, death or major property 1. Preinstallation (Section 1) damage. 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,
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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 r
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PREINSTALLATION B. CLEARANCE FROM COMBUSTIBLE D. CHIMNEY OR VENT CONSTRUCTION 1. Inspect the existing chimney or vent system. Make sure it is in good condition. Inspect chimney liner Provide the following minimum clearances to and repair or replace if necessary. combustible construction. See Figure 1.1. 2. The vent system and installation must be in 1. Sides: 6" accordance with the current edition of the American 2. Rear of Jacket: 6" National Standard ANSI/NFPA 211, “Chimneys, 3. Front of Jacke
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PREINSTALLATION Figure 1.4: Foundation Layout 8. Exterior Vents: E. BOILER SETTING a) Insulate sufficiently to ensure adequate draft and to prevent vent damage due to condensation. 1. If the boiler room floor is not level or if additional structural support is needed, provide a good, level 9. Vent Connection to Boiler: foundation for the boiler with the minimum dimensions given in Table 1.1. The flooring and a) Support the weight of the vent system structural support system must be suitable for
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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 LC-04 37¹⁵⁄₁₆ dampers, may also be shipped separately. LC-05 43 LC-06 48¹⁄₁₆ 2. Knockdown: All components shipped for field LC-07 53¹⁄₈ assembly. See Table 1.2 for standard components. LC-08 58⁵⁄₁₆ See Tables 1.3 through 1.8 for optional components. LC
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PREINSTALLATION 6 Table 1.2A: Series LC Shipping List Standard Sections (See Table 1.3 for Options) Assembly Kit Ctns. Flue Ctn. Jacket Cartons (Tbl 1.4, 1.5 Options) Top/Side Boiler Channel 1" Contents Contents Front/Rear Panels Model Rail Plain LWCO 3" Tap. Baffle See Below See Below Panels Hardware Number Bundle Front Back Interm. Interm. Interm. Carton Item 1 Item 2 Hardware Chamber Liner LC-04 Quantity 1 1 1 1 1 1 1 1 1 1 Part No. LC-1001 LC-1007 LC-1000 LC-1000-1 LC-1023 LC-1022 LC-5004 LC
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PREINSTALLATION 7 Table 1.2B: Series LCE Shipping List Standard Sections (See Table 1.3 for Options) Assembly Kit Cartons Flue Ctn. Jacket Cartons (See Table 1.4, 1.5 for Options) Lbl. Ctn. Top/Side Boiler Channel Top 1" Flow Port Gaskets, Silicone Sealant, Contents Front/Rear Panels Model Rail Flue LWCO 3" Tap. Plain Baffle Tie Rods, Washers, Tie Rod Nuts, Section Seal Rope, Draft See Below Panels Hardware Rating Spray Adhesive, Cleanout Plates, Mounting Hardware Number Bundle Front Interm. Int
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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 Part #/UPC LC-1001 86000 LC-1013 86010 LC-1001-2 86002 LC-1013-2 86012 Plain Interm. Part #/UPC LC-1000 86004 LC-1014 86014 LC-1000-2 86006 LC-1014-1 86015 Top Flue Interm. Part #/UPC LCE-1056 86100 LCE-1064 86110 LCE-1056-1 86111 LCE-1064-1 86112 LWCO Interm. Part #/UPC LC-1000-
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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 86074* CF2300AKB 86083* 86083* Not Beckett CF2500 86074* 86074* Available CF3500AKM 86083* 86083* 86083* CF3500AKL 86080* 86080* 801CRD 86073 86073 Carlin 1050FFD 86086 86086 N/A 1150FFD 86087 86087 86087 86087 86087 86087 86087 R10.9 86088 R10 86088 86088 86088 86088 86088 Gordon Piatt R10.1 86088 86088 86088 86088 R10.2 86088 8608
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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 C. KNOCKDOWN BOILER nipple, if supplied 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
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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 Intermed
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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. 12
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PLACE THE BOILER Figure 2.5: Series LC Boiler Assembly – Right Side View 13
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PLACE THE BOILER Figure 2.6: Series LCE Boiler Assembly – Right Side View 14
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PLACE THE BOILER 16. To properly assemble LC/LCE sections in the field, 17. Repeat with the remaining sections. the following steps must be followed to ensure that a. Save the LWCO Intermediate with two 1" no damage occurs to the tie rod lugs. A 0-100 ft-lbs tappings (for level control) for use as the section torque wrench is required. closest to the front section. a. Use a spirit level as shown in Figure 2.4 to check b. Place the Intermediate Section with 3" top the alignment of the sections as
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PLACE THE BOILER Figure 2.9: LC/LCE Boiler Section Assembly Sequence 16
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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, Tapp
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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 bras
