RBI LCD-I0M-8R Installation And Operation Instructions Manual
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RBI LCD-I0M-8R Installation And Operation Instructions Manual

RBI LCD-I0M-8R Installation And Operation Instructions Manual

Lcdominator series finned copper tube gas boilers (lb) & water heaters (lw)
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This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction.
of the burner, resulting in possible severe personal injury, death or substantial property damage. The boiler can only be operated with
a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated
by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affix these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualified service
technician, and to follow all guidelines in the User' s Information Manual.
Finned Copper Tube
Gas Boilers (LB) &
Water Heaters (LW)
Boiler  Manual

Installation and Operation

Instructions
Construction dust and particulate, particularly drywall dust, will cause contamination
LCD-I0M-8R
82-0278
06/15 Copyright 2014 Mestek, Inc.

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Summary of Contents for RBI LCD-I0M-8R

  • Page 1: Installation And Operation

    LCD-I0M-8R 82-0278 Finned Copper Tube Gas Boilers (LB) & Water Heaters (LW) Boiler  Manual Installation and Operation Instructions This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these instructions.

  • Page 2: Table Of Contents

    Finned copper tube gas boilers & water heaters – Boiler Manual If the information in this manual is not followed Before Your Start page 2 exactly, a fire or explosion may result causing property, ratingS & CapaCitieS page 3 personal injury or loss of life. Boiler/Water Heater loCation page 3 Do not store or use gasoline or other flammable vapors...

  • Page 3: Ratings & Capacities

    3. Ensure that the floor is structurally sound and will support the Direct all questions to your RBI distributor or contact the RBI Cus- weight of the boiler/water heater. tomer Service Department, 260 North Elm Street, Westfield, MA 01085 for U.S.
  • Page 4 Finned copper tube gas boilers & water heaters – Boiler Manual All Air From Inside The Building Combustion air contaminated with fluorocarbons or other halogenated compounds such as cleaning If the LCD is to be located in a confined space the minimum clearances solvents and refrigerants will result in the formation listed in Table 1 must be maintained between it and any combustible of acids in the combustion chamber.
  • Page 5 Finned copper tube gas boilers & water heaters – Boiler Manual Vertical venting using a masonry chimney system and inside air Figure 2 Horizontal venting using inside air Figure 3 1/4 IN. PER F00T 20 mm/m 1.5 FT 0.5 m Table 2 MINIMUM VERTICAL RISE VENT PIPE DIAMETER...
  • Page 6 The certified combustion air terminal from draft, partial fan-assisted, fan-assisted, or power draft-assisted RBI must be used and installed as shown in Figures 4 and 5. burners, there shall be a permanent air supply opening(s) having a cross-sectional area of not less than 1 in...
  • Page 7 Finned copper tube gas boilers & water heaters – Boiler Manual Horizontal combustion air and venting for a single unit Figure 4 2 0 0 0 & L a r g e r 1 2 0 1 T o 2 0 0 0 9 0 1 To 1 2 0 0 2 0 0 To 9 0 0 1000 B T U ' S...
  • Page 8 Finned copper tube gas boilers & water heaters – Boiler Manual Vertical combustion air and venting, metal chimney system shown Figure 6 Locate exhaust terminal downwind from air intake to reduce potential for flue gas recirculation. 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT...

  • Page 9: General Venting Guidelines

    Finned copper tube gas boilers & water heaters – Boiler Manual GENERAL VENTING GUIDELINES VENT SYSTEM OPTIONS The LCD may be vented the following ways: The vent installation must be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest revision or 1) Vertical/Chimney Venting, Negative Pressure, Category applicable provisions of the local building codes.

  • Page 10: Vertical/Chimney Venting

    Horizontal Direct Vent Systems - Figures 4 & 5 The vent materials used in horizontal vent systems must be certified to UL 1738 for installations in the United States, ULC S636 for installations in Canada. The certified vent terminal from RBI must 1050 also be used.

  • Page 11: Horizontal Venting

    Finned copper tube gas boilers & water heaters – Boiler Manual When horizontal vent runs exceed 5 ft, 1.5 m they must be supported Table 5a Category III Vent Pipe Diameter at 3 ft, 0.9 m intervals with overhead hangers. The vent system must Pipe Diameter be pitched down, toward the vent terminal, 1/4 in/ft, 20 mm/m.

  • Page 12: Common Vent Systems

    Finned copper tube gas boilers & water heaters – Boiler Manual COMMON VENT SYSTEMS Outdoor venting Figure 8 If an existing boiler/water heater is removed from a common venting system, the common venting system may then be too large for the proper venting of the remaining appliances connected to it.

  • Page 13: General Piping Requirements

    Finned copper tube gas boilers & water heaters – Boiler Manual e) Test for spillage at the draft hood relief opening after 5 minutes Table 7 Temperature Rise Table of main burner operation. Use the flame of a match or candle, ∆T = 15°F ∆T = 8.3°C or smoke from a cigarette, cigar or pipe.

  • Page 14: Freeze Protection

    Finned copper tube gas boilers & water heaters – Boiler Manual Freeze Protection Flow Switch This boiler/water heater is CSA designed certified for outdoor The flow switch supplied with the boiler/water heater must be wired installation. Outdoor installations in areas where the danger of to the terminal strip in the control panel to prevent the boiler from freezing exists are not recommended unless proper freeze protection firing unless there’...
  • Page 15 Finned copper tube gas boilers & water heaters – Boiler Manual Pump Requirements (Primary/Secondary) Variable Water Flows This low mass boiler requires a continuous minimum water flow Figure 11 shows a typical primary/secondary piping system. A for proper operation. The boiler pump must be sized to overcome dedicated pump is used to maintain a constant water flow through the head loss of the boiler and the near piping in order to achieve the boiler.
  • Page 16 Finned copper tube gas boilers & water heaters – Boiler Manual Typical primary/secondary piping system Figure 11 (See notes) Pump Gate Valve Globe Valve Angle Valve NOTES: Bufferfly Valve 1. Boiler circuit piping must be sized large enough to handle maximum Balance Valve flow through unit.
  • Page 17 Finned copper tube gas boilers & water heaters – Boiler Manual Low temperature piping with thermostatic valve Figure 12A (See notes and adjustment procedures) Pump Pump Gate Valve Gate Valve Globe Valve Globe Valve Angle Valve NOTES: Angle Valve Bufferfly Valve 1.

  • Page 18: Domestic Water Supply Piping

    GPm, 7.9 L/s on 1480 to 2300 models, see Table 9B. RBI water heaters are designed to run scale free. Due to the extreme Thermostatic Mixing Valve - variables of water conditions world wide it is necessary to consider Water Above 140°F, 60°C...
  • Page 19 Finned copper tube gas boilers & water heaters – Boiler Manual Table 9A LCD Heat exchanger selection graph Table 9B LCD Pumping performance requirement...
  • Page 20 Angle Valve D-1 Rev 6 Bufferfly Valve Aquastat Union Balance Valve Attention: Pressure Switch Not all RBI stock storage tanks incorporate this tapping: See Note 1. Ball Valve Gas Pressure Regulator Multiple water heating piping (LW models only) Figure 15...

  • Page 21: Gas Supply Piping

    If for any reason the boiler/water heater is not for the type making gas connections to it. Never over-tighten the of gas available at the installation site, call your RBI Water Heaters piping entering the gas valve body or gas valve failure representative to resolve the problem.

  • Page 22: Electrical Wiring

    Finned copper tube gas boilers & water heaters – Boiler Manual ELECTRICAL WIRING GENERAL OPERATION Before proceeding read and fully understand the Electrical Power Connections instructions contained in this manual. Do not attempt to operate this boiler/water heater if it has not been Label all wires prior to disconnection when servicing installed in accordance with the guidelines set forth controls.
  • Page 23 Finned copper tube gas boilers & water heaters – Boiler Manual BOILER/WATER HEATER OPERATION Pressure switch tap(s) Figure 17 Staging Operation The LCD boiler/water heater series is separated into on/off and 2-stage units depending on the model selected. The 400 model has on/off staging, while the 600 through 2300 models have a two stage option.
  • Page 24 Finned copper tube gas boilers & water heaters – Boiler Manual FSM sends 24VAC to its MV terminal energizing the safety and main solenoid valves and relay R8, de-energizing relay R7 and the spark generator. 4. If the pilot flame isn’t sensed, the FSM de-energizes the PV Table 18 Low air condition action, 400-2300 terminal and waits 5 minutes before initiating the second ignition trial.
  • Page 25 Finned copper tube gas boilers & water heaters – Boiler Manual OPERATION SEQUENCE, 2 STAGE OPTION Main Burner 600 THROUGH 2300 Once the pilot is proven, the FSM sends 24VAC to its MV terminal energizing the safety and low-fire side of the main solenoid valves. Refer to the wiring diagram included with the unit Normal Operation for further control system info.

  • Page 26: Operating Instructions

    Finned copper tube gas boilers & water heaters – Boiler Manual OPERATING INSTRUCTIONS 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 FOR YOUR SAFETY READ BEFORE OPERATING gas control that has been under water.
  • Page 27 Finned copper tube gas boilers & water heaters – Boiler Manual Required Gas Pressure 13. Turn the knob on the pilot valve to on, Figure 18. 14. Turn on all electric power to the boiler and set the operating Provide gas supply pressure at inlet to boiler gas train as follows: control or thermostat to the desired setting.

  • Page 28: Checking & Adjustments

    Finned copper tube gas boilers & water heaters – Boiler Manual Instructions De Mise En Marche 2. To test the ignition safety shutoff device, close the manual shutoff valve in the gas supply line. Within 5 seconds of main burner 1.

  • Page 29: Pilot Adjustment

    Finned copper tube gas boilers & water heaters – Boiler Manual Pilot Adjustment Gas Pressure Adjustment The pilot burner is actually an isolated main burner that’s The maximum inlet gas pressure listed on the rating controlled by a separate pilot valve. Pilot pressure settings are as plate must not be exceeded or damage to the boiler/ shown in Table 20.

  • Page 30: Control Description

    Finned copper tube gas boilers & water heaters – Boiler Manual CONTROL DESCRIPTION Low Water Cutoff If the boiler is to be installed above radiation or if required by other codes or regulations, install a low water cutoff in appropriate piping. Boiler Thermostat Wire the switch and any external controls in series to the “Interlock”...

  • Page 31: Maintenance

    Finned copper tube gas boilers & water heaters – Boiler Manual MAINTENANCE Burner Inspection And Removal - Figure 20 1. Close the manual shutoff valves in the gas supply lines and turn Disconnect electrical power and close the manual gas off electrical power to the boiler/water heater.
  • Page 32 Finned copper tube gas boilers & water heaters – Boiler Manual Heat Exchanger Removal, Cleaning 12. Sagging or distorted heat exchanger tubes are an indication of low water flow through the system. A leaking or otherwise & Replacement - See Figure 20 damaged heat exchanger must be replaced and the condition 1.

  • Page 33: Vent System

    Finned copper tube gas boilers & water heaters – Boiler Manual A yellow, floating flame indicates a lack of combustion Heat exchanger upper rail screws Figure 21 air. A lifting flame indicates too much combustion air. Do not operate the boiler/water heater until the problem is solved or severe personal injury or death may occur! Pilot &...

  • Page 34: Troubleshooting

    Finned copper tube gas boilers & water heaters – Boiler Manual TROUBLE-SHOOTING SYMPTOM CHECK ACTION No Power To Control Circiut 1. Power not connected 1. Wire unit to line voltage 2. External circuit breaker open 2. Reset breaker 3. Transformer circuit breaker open 3.
  • Page 35 Finned copper tube gas boilers & water heaters – Boiler Manual TROUBLE-SHOOTING SYMPTOM CHECK ACTION Pilot Lights But Main Burners Will Not Fire 1. Bad flame sense lead from ignitor to 1. Check sense lead & ground connections, flame sense module adjust as necessary 2.

  • Page 36: Repair Parts

    Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS Exploded view Figure 23...
  • Page 37 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (ConTinueD) Model Size with Item Quantities Below Ref # Name of Part Part # 750 1050 1200 1480 1650 1970 2300 Filter (Indoor) 09-0488 09-0489 09-0497 09-0498 Filter (Outdoor) 09-0490 09-0491...
  • Page 38 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (ConTinueD) Model Size with Item Quantities Below Ref # Name of Part Part # 750 1050 1200 1480 1650 1970 2300 24, 25, Tile Kit 05-0203 05-0204 05-0205 05-0207 05-0213...
  • Page 39 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (ConTinueD) Model Size with Item Quantities Below Ref # Name of Part Part # 750 1050 1200 1480 1650 1970 2300 Burner Support Rail 03-2090 03-2091 03-2092 03-2093 03-2095 03-2096...
  • Page 40 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (ConTinueD) Model Size with Item Quantities Below Ref # Name of Part Part # 750 1050 1200 1480 1650 1970 2300 Heat Exchanger Assembly (Cupronickel) 70-3035 (Bronze Headers) 70-3036 70-3037 70-3039...
  • Page 41 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (ConTinueD) Model Size with Item Quantities Below Ref # Name of Part Part # 750 1050 1200 1480 1650 1970 2300 Return Header, Bronze 01-0011.1 01-0004.1 01-0018.1 Return Header, Cast Iron 01-0009S 01-0002S...
  • Page 42 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (ConTinueD) Model Size with Item Quantities Below Ref # Name of Part Part # 750 1050 1200 1480 1650 1970 2300 Manual Shut Off Valve, 1" 11-0465 Manual Shut Off Valve, 1-1/4"...
  • Page 43 Finned copper tube gas boilers & water heaters – Boiler Manual REPAIR PARTS (ConTinueD) Model Size with Item Quantities Below Ref # Name of Part Part # 750 1050 1200 1480 1650 1970 2300 Vent Termination Hood 8" 09-0113 Vent Termination Hood 10" 09-0115 Vent Termination Hood 12"...

  • Page 44: Start Up Sheet

    Finned copper tube gas boilers & water heaters – Boiler Manual STarT UP FOrM Date of Start Up: Job Name: Model #: Serial Number #: Boiler Model: Company Name  Dominator  LCD Fuel Type: Tech Name  Natural Gas  Propane System Type: Phone Number  Hydronic  Domestic...
  • Page 45 Finned copper tube gas boilers & water heaters – Boiler Manual COMBUSTION/SaFETY rEPOrT FaCTOrY FIrE TEST rEPOrT: Low Fire High Fire These results are affixed to the side of the heater Manifold Gas Pressure: "WC" on a small white label. Air Differential Pressure: "WC"...

  • Page 46: Mass Code

    Finned copper tube gas boilers & water heaters – Boiler Manual NOTICE! Commonwealth of Massachusetts Installation requirements MACODE-3 In the Commonwealth of Massachusetts, the installa- Improper venting can result in excessive levels tion must be performed by a licensed plumber or gas of carbon monoxide which can cause severe fitter.

  • Page 47: Warranty

    Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.
  • Page 48 260 North Elm Street 7555 Tranmere Drive Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com...

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