RBI LCD Series Installation & Operation Manual
RBI LCD Series Installation & Operation Manual

RBI LCD Series Installation & Operation Manual

Lcd series finned copper gas boilers (model lb) & water heaters (model lw)
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LCD SERIES FINNED COPPER
GAS BOILERS (MODEL LB) &
WATER HEATERS (MODEL LW)
INSTALLATION & OPERATION MANUAL
MEA#117-96-E
DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE
VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE
OF 160 PSI, 1103 kPa WATER.
WARNING: If the information in this manual is not followed exactly, a fire
or explosion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical 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 fi re department.
Installation and service must be performed by a qualifi ed installer, service agency or
the gas supplier.
WARNING: Failure to properly vent this unit can cause excessive amounts of carbon
monoxide resulting in severe personal injury or death!
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER/WATER HEATER.
CONSUMER: RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
260 North Elm Street
7555 Tranmere Drive
Westfi eld, MA 01085
Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571
Phone: (905) 670-5888
Fax: (413) 568-9613
Fax: (905) 670-5782
LCD-IOM-4
82-0278
7/1/02
10/09

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Summary of Contents for RBI LCD Series

  • Page 1 LCD-IOM-4 82-0278 7/1/02 LCD SERIES FINNED COPPER GAS BOILERS (MODEL LB) & WATER HEATERS (MODEL LW) INSTALLATION & OPERATION MANUAL MEA#117-96-E DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF 160 PSI, 1103 kPa WATER.
  • Page 2: Table Of Contents

    This manual covers the application, installation, done. Include the name of the service organization for operation and maintenance of a LCD Series fi nned future reference. copper heating boiler/water heater/pool heater.
  • Page 3: Ratings & Capacities

    5. DO NOT place this boiler/water heater in a location RATINGS & CAPACITIES that would restrict the introduction of combustion air Before undertaking the installation of the LCD Series into the unit or subject the air inlet to a negative boiler/water heater check the rating plate to ensure pressure, see “GENERAL VENTING GUIDELINES”.
  • Page 4 Page 4 LCD INSTALLATION AND OPERATION INSTRUCTIONS All Air From Inside The Building Buildings will require the installation of a fresh air duct If the LCD is to be located in a confi ned space the or other means of providing make-up air if the intake air option isn’t used.
  • Page 5 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 5 Figure 2 - Vertical Venting using a Masonry Chimney and Inside Air Figure 3 - Horizontal Venting using Inside Air 1/4 IN. PER F00T 20 mm/m 1.5 FT 0.5 m Table 2 MINIMUM VERTICAL RISE VENT PIPE DIAMETER OFF THE TOP OF UNIT "A"...
  • Page 6 1650 10,643 intervals with overhead hangers. The certifi ed combustion 1970 3179 4236 1970 12,707 air terminal from RBI must be used and installed as 2300 3711 4945 2300 14,835 shown in Figures 4 and 5. Canadian installations must comply with CSA B149.1 Intake Air Option - Vertical Guidelines when air supply is provided by natural air fl...
  • Page 7 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 7 Figure 4 - Horizontal Combustion Air and Venting for a Single Unit 1/4 IN. PER FOOT 20 mm/m 16 FT 4.9 m 1.5 FT 0.5 m 2000 & Larger 1201 To 2000 901 To 1200 200 To 900 1000 BTU'S Horizontal Distance, X...
  • Page 8 Page 8 LCD INSTALLATION AND OPERATION INSTRUCTIONS Figure 6 - Vertical Combustion Air and Venting, Metal Chimney System Shown Note: Locate exhaust terminal down wind to reduce fl ue gas recirculation. 10 FT 3.1 m 4 FT 1.2 m 5 1/2 FT 1.7 m 1.5 FT 0.5 m...
  • Page 9: General Venting Guidelines

    LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 9 GENERAL VENTING GUIDELINES VENT SYSTEM OPTIONS The LCD may be vented the following ways: WARNING: The vent installation must be in accordance with Part 7, Venting of Equipment, 1) Vertical/Chimney Venting, Negative Pressure, of the National Fuel Gas Code, ANSI Z223.1/ Category I - uses an approved metal chimney system NFPA 54-latest revision or applicable provisions...
  • Page 10: Horizontal Venting

    Pipe Diameter must be certifi ed to UL 1738 for installations in the United States, ULC S636 for installations in Canada. The certifi ed vent terminal from RBI must also be used. 300 - 400 600 - 750 The maximum equivalent length for the horizontal vent 1050 and combustion air pipes is 35 ft, 10.8 m for each.
  • Page 11: Outdoor Venting

    LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 11 Horizontal vent systems shall terminate at least 4 ft, Horizontal vent systems shall terminate at least 4 ft, 1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft, 0.23 m 1.2 m below, 4 ft, 1.2 m horizontally from or 1 ft, above any door, window or gravity air inlet into any 0.23 m above any door, window or gravity air inlet building.
  • Page 12: Common Vent Systems

    Page 12 LCD INSTALLATION AND OPERATION INSTRUCTIONS Figure 8 - Outdoor Venting a) Seal any unused openings in the common venting system. Sceller toutes les ouvertures non utilisées du sys- tème d'évacuation. b) Visually inspect the venting system for proper size and horizontal pitch and determine if there is no blockage or restriction, leakage, corrosion and other defi...
  • Page 13: General Piping Requirements

    LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 13 After it has been determined that each appliance Table 7 - Temperature Rise Table ΔT = 15 °F ΔT = 8.3 °C remaining connected to the common venting system Model Flow Rate Pres. Drop Flow Rate Pres.
  • Page 14: Heating System Piping

    Page 14 LCD INSTALLATION AND OPERATION INSTRUCTIONS Freeze Protection This boiler/water heater is CSA designed certifi ed for WARNING: Never install any type of valve outdoor installation. Outdoor installations in areas where between the boiler/water heater and the relief the danger of freezing exists are not recommended valve or an explosion causing extensive unless proper freeze protection is provided.
  • Page 15 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 15 CAUTION: A temperature rise outside of the range Low Return Water Temperatures listed in Table 7 indicates that the fl ow rate through To prevent the problems associated with condensation the heat exchanger is incorrect which will damage of the products of combustion due to low return water the heat exchanger voiding the warranty! The temperatures a primary/secondary piping system with...
  • Page 16 Page 16 LCD INSTALLATION AND OPERATION INSTRUCTIONS Figure 11 - Typical Primary/Secondary Piping System (See Notes) Pump Gate Valve Globe Valve NOTES: Angle Valve 1. Boiler circuit piping must be sized large enough to handle maximum fl ow through unit. Bufferfly Valve 2.
  • Page 17 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 17 Figure 12A - Low Temperature Piping with Thermostatic Piping (See notes and adjustment procedures) Pump Gate Valve Globe Valve Angle Valve NOTES: Bufferfly Valve 1. For pump selection consult factory. 2. Boiler pump sized to boiler and thermostatic 3-way valve design Balance Valve fl...
  • Page 18: Domestic Water Supply Piping

    Piping and components connected to the water heater must be suitable for use with potable water. The RBI water heaters are designed to run scale free. Due water heater must not be connected to any heating to the extreme variables of water conditions world wide...
  • Page 19 Page 19 LCD INSTALLATION AND OPERATION INSTRUCTIONS LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 19 Table 9B - LCD Pumping Performance Requirement Expansion Tank A balancing valve should be installed on the outlet side of An expansion tank or other means to control thermal the water heater for purposes of adjusting the flow rate expansion must be installed in the water heating system through the heat exchanger.
  • Page 20 Bufferfly Valve Balance Valve D-1 Rev 6 Ball Valve Motorized Valve Attention: Not all RBI stock storage tanks incorporate this tapping: See Note 1. Solenoid Operated Valve Figure 15 - Multiple Water Heating Piping (LW Models Only) Self-Operated (See Notes)
  • Page 21: Gas Supply Piping

    If for any reason the boiler/water heater Table 11 - Equivalent Pipe Length Chart is not for the type of gas available at the installation site, call your RBI Water Heaters representative to resolve Type of pipe fi tting Nominal the problem.
  • Page 22: Electrical Wiring

    Page 22 LCD INSTALLATION AND OPERATION INSTRUCTIONS When applicable, provisions for vent, bleed and gas Table 12 - LCD Electrical Requirements relief lines must be made in accordance with the latest Recommended revision of ANSI Z223.1/NFPA 54. Circuit Breaker *Running Model (Amps) Amps...
  • Page 23: Operating Instructions

    LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 23 With the boiler off, run the system pump for at least 30 The outlet water temperature is automatically controlled minutes and bleed the system piping using the bleed by the aquastat. The optional staging function is valves.
  • Page 24 Page 24 LCD INSTALLATION AND OPERATION INSTRUCTIONS Prepurge: On all units, the pressure switch(es) will interrupt power to the control module under a blocked flue or inlet 1. Blower delay timer TD3 energizes the high speed windings of the blower(s). condition.
  • Page 25 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 25 Demand Satisfi ed: Ignition Trial: 1. When the demand for heat is satisfi ed the operator 1. Blower delay timer TD1 times out and the fl ame switch will open, de-energizing relay R8, TD1, TD3, sense module, FSM, is energized.
  • Page 26: Operating Instructions

    Page 26 LCD INSTALLATION AND OPERATION INSTRUCTIONS Demand Satisfi ed: DANGER: Propane gas may not always be 1. When the demand for heat is satisfied the low detected by smell. Propane gas is heavier than operator switch will open, de-energizing relays R2, air and can collect in low areas.
  • Page 27 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 27 OPERATING INSTRUCTIONS Figure 19 - Manual Valve & Manifold Pressure Tap 1. STOP! Read the safety information above. If, at any time, the appliance will not operate properly, follow the instructions “TO TURN OFF GAS TO APPLIANCE”.
  • Page 28: Checking & Adjustments

    Page 28 LCD INSTALLATION AND OPERATION INSTRUCTIONS Table 20 - Pilot & Manifold Pressures To Turn Off Gas To Appliance 1. Set the operating control or thermostat to its lowest On/Off setting. inches W.C. mm W.C. 2. Turn off all electric power to the appliance if service Pilot - NG 2.5 ±...
  • Page 29 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 29 For L600-L2300: Input Rate, Natural Gas Gas appliances are rated based on sea level operation 1. Remove the upper front jacket panel. with no adjustment required at elevations up to 5000 ft, 2. Turn off main burner gas fl ow by turning the manual gas valve(s) in the control compartment to the off 1524 m.
  • Page 30: Control Description

    Page 30 LCD INSTALLATION AND OPERATION INSTRUCTIONS PROPANE GAS: Optimum results are obtained when The water heater high limit should be set a minimum of the boiler/water heater is operated with the manifold 20˚F, 11˚C higher than the operating control. Refer to pressure(s) set per Table 20.
  • Page 31: Maintenance

    LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 31 Gas Pressure Switch The boiler/water heater should be cleaned and Optional low and/or high-pressure gas pressure inspected once a year, before each heating season. switches will shut down the 24V circuit if excessively Make sure that the burner and ignition components are high or low gas pressure exists in the gas train or supply free from dust, soot, dirt, corrosion or other deposits...
  • Page 32 Page 32 LCD INSTALLATION AND OPERATION INSTRUCTIONS Heat Exchanger Removal, Cleaning & Replacement - CAUTION: Never clean the heat exchanger while it’s See Figure 20 in the boiler/water heater or the combustion 1. Close the shut off valves in the inlet and outlet chamber will be destroyed! piping.
  • Page 33 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 33 Figure 21- Heat Exchanger Upper Rail Screws 5. The aquastat high limit controls the maximum water temperature in the boiler. It should be set at least 20°F, 11°C above the operater setpoint. If the water temperature reaches the set temperature before the demand for heat has been met, the aquastat high limit should shut the boiler off.
  • Page 34: Troubleshooting

    Page 34 LCD INSTALLATION AND OPERATION INSTRUCTIONS TROUBLESHOOTING PROBLEM POSSIBLE CAUSES REMEDIES No Power To Control Circuit Power not connected Wire unit to line voltage External circuit breaker open Reset breaker Transformer circuit breaker open Reset breaker No Action On Call For Heat Primary limit or other •...
  • Page 35 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 35 TROUBLESHOOTING PROBLEM POSSIBLE CAUSES REMEDIES Pilot Lights But Main Burners Bad fl ame sense lead from igniter Check sense lead & ground ..Will Not Fire to fl ame sense module connections, adjust as necessary Defective fl...
  • Page 36: Repair Parts

    Page 36 LCD INSTALLATION AND OPERATION INSTRUCTIONS Figure 23 - Exploded View...
  • Page 37 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 37 SERVICE AND REPLACEMENT PARTS LIST (MODELS 225-2300) Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Jacket Lower Front Panel 70-2716 70-2717 70-2718 70-2719 70-2721 70-2722 70-2723 70-2724 70-2725 Jacket Lower Front Panel (SS) 70-2716.1 70-2717.1...
  • Page 38 Page 38 LCD INSTALLATION AND OPERATION INSTRUCTIONS Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Jacket Rear Panel 03-1811 03-1812 03-1813 03-1814 03-1816 03-1817 03-1818 03-1819 03-1820 Jacket Rear Panel (SS) 03-1811.1 03-1812.1 03-1813.1 03-1814.1 03-1816.1 03-1817.1 03-1818.1...
  • Page 39 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 39 Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Combustion Chamber Base Panel 03-1974 03-1975 03-1976 03-1977 03-1979 03-1980 03-1981 03-1982 03-1983 Cerablanket Insulation 05-0103 Manning Glass Insulation (per square foot) 05-0104 Combustion Chamber Lower Front Panel 03-2170...
  • Page 40 Page 40 LCD INSTALLATION AND OPERATION INSTRUCTIONS Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Flue Outlet Assembly 70-3117 70-2736 70-2737 70-2738 70-2739 70-2741 70-2742 70-2742.1 70-2743 24, 25, Tile Kit 05-0212 05-0202 05-0203 05-0204 05-0205 05-0207 05-0213...
  • Page 41 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 41 Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Heat Exchanger Assembly (Cupronickel) 70-3012 (Cast Iron Headers) 70-3013 70-3014 70-3015 70-3017 70-3018 70-2842 70-2843 70-2844 70-2845 Heat Exchanger Assembly (Cupronickel) 70-3034 (Bronze Headers) 70-3035...
  • Page 42 Page 42 LCD INSTALLATION AND OPERATION INSTRUCTIONS Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Combustion Air Damper Assembly 70-2818 70-2819 Low Pressure Switch (.30 WC) 14-0059 Low Pressure Switch (.42 WC) 11-0417 Low Pressure Switch (.58 WC) 14-0058 High Pressure Switch (.58 WC) 14-0058...
  • Page 43 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 43 Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Relay, 2P, (2 Stage) 15-0121 Relay, 3P , (On/Off or 2 Stage) 15-0123 Relay, 24AC 15-0113 Pump Contactor 1PH (C2) 15-0118 Pump Contactor 3PH 15-0111...
  • Page 44: Start Up Sheet

    Page 44 START UP FORM Date of Start Up: Job Name: Model #: Serial Number #: Boiler Model: Company Name Dominator Fuel Type: Tech Name Natural Gas Propane System Type: Phone Number Hydronic Domestic PRE-START UP CHECK LIST ANY VISUAL DAMAGE TO UNIT? INLET FILTER INSTALLED AND CLEAN? PIPING PROPERLY CONNECTED? ALL WIRING CONNECTED PROPERLY?
  • Page 45 Page 45 COMBUSTION/SAFETY REPORT FACTORY FIRE TEST REPORT: Low Fire High Fire These results are affi xed to the side of the heater Manifold Gas Pressure: "W.C." on a small white label. Air Differential Pressure: "W.C." FIELD TEST REPORT IN STAGE: Manifold Gas Pressure: "W.C."...
  • Page 46: Mass. Code

    Page 46 LCD INSTALLATION AND OPERATION INSTRUCTIONS MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above fi...
  • Page 47: Commonwealth Of Massachusetts

    LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 47 MACODE-3 NOTICE! Commonwealth of Massachusetts Installation Requirements In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas fi tter. (b) Exemptions The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4: 1.
  • Page 48: Warranty

    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. The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other Non-Residential Use Water Heater (the “Product”) will be free from defects in...

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