RBI LCD OMINATOR Series Installation And Operation Instructions Manual
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RBI LCD OMINATOR Series Installation And Operation Instructions Manual

RBI LCD OMINATOR Series Installation And Operation Instructions Manual

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-10
82-0278
9/2021 Copyright 2014 Mestek, Inc.

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  • Page 1 LCD-I0M-10 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

    LCD Series 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.

  • 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 LCD Series 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 LCD Series 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 LCD Series 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 LCD Series 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

    LCD Series 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 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances Canadian Installations¹ US Installations² Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm) deck, or balcony...
  • Page 11 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual Figure A - Direct Vent Terminal Clearances - Concluded Clearance to a mechanical air 3 ft (91 cm) above if within 10 ft (3 m) 6 ft (1.83 m) supply inlet horizontally...
  • Page 12 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual Figure A - Other Than Direct Vent Terminal Clearances - Concluded Clearance to a mechanical air supply 3 ft (91 cm) above if within 10 ft (3 m) 6 ft (1.83 m) inlet...

  • Page 13: Vertical/Chimney Venting

    The vent materials used in horizontal vent systems must be certified Model Size to UL 1738 for installations in the United States, ULC S636 for installations in Canada. The certified vent terminal from RBI must also be used. The maximum equivalent length for the horizontal vent and 1050 combustion air pipes is 35 ft, 10.8 m for each.

  • Page 14: Horizontal Venting

    LCD Series 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 15: Common Vent Systems

    LCD Series 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 16: General Piping Requirements

    LCD Series 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 17: Heating System Piping

    LCD Series 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 18 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual Pump Requirements (Primary/Secondary) Primary/Secondary Piping This low mass boiler requires a continuous minimum water flow Boilers connected to heating systems using zone valves, zone pumps, for proper operation. The boiler pump must be sized to overcome or systems that have excessive flow rates or return water temperatures the head loss of the boiler and the near piping in order to achieve less than 125°F, 52°C must be isolated from these systems to protect...
  • Page 19 LCD Series 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 20 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual Low temperature piping with thermostatic valve Figure 12A (See notes and adjustment procedures) Pump Gate Valve Globe Valve Angle Valve NOTES: Bufferfly Valve 1. For pump selection consult factory. 2.

  • Page 21: 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 22 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual Table 9A LCD Heat exchanger selection graph Table 9B LCD Pumping performance requirement...
  • Page 23 Globe Valve D-1 Rev 6 Thermometer Angle Valve Bufferfly Valve Aquastat Union Attention: Not all RBI stock storage tanks Balance Valve Pressure Switch incorporate this tapping: See Note 1. Ball Valve Gas Pressure Multiple water heating piping (LW models only)

  • Page 24: 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 25: Electrical Wiring

    LCD Series 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 26 LCD Series 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 27 LCD Series 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 28 LCD Series 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 29: Operating Instructions

    LCD Series 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 30 LCD Series 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 31: Checking & Adjustments

    LCD Series 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 32 LCD Series 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 33: Control Description

    LCD Series 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 34: Maintenance

    LCD Series 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 35 LCD Series 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 36 LCD Series 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 37: Troubleshooting

    LCD Series 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.
  • Page 38 LCD Series 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 39: Repair Parts

    LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual REPAIR PARTS Exploded view Figure 23...
  • Page 40 LCD Series 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)
  • Page 41 LCD Series 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...
  • Page 42 LCD Series 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...
  • Page 43 LCD Series 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) 70-3035R (Bronze Headers) 70-3036R...
  • Page 44 LCD Series 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 01-0011.1S 01-0004.1S 01-0018.1S Return Header, Cast Iron...
  • Page 45 LCD Series 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 46 LCD Series 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"...

  • Page 47: Start Up Sheet

    LCD Series 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...
  • Page 48 LCD Series 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 49: Mass Code

    LCD Series 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 50: 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 51 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual...
  • Page 52 260 North Elm Street 7555 Tranmere Drive Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada Phone: (833) 265-5371 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com...

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