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LCD SERIES FINNED COPPER GAS BOILERS
& WATER HEATERS INSTALLATION
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 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 flammable 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 fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
WARNING: Failure to properly vent this unit can cause excessive amounts of carbon
monoxide resulting in severe personnal injury or death!
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER/WATER HEATER.
CONSUMER: RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
& OPERATION MANUAL
260 North Elm Street
Westfield, MA 01085
Phone: (413) 568-9571
Fax: (413) 568-9613
1300 Midway Boulevard
Mississauga, Ontario L5T 2G8 Canada
Phone: (905) 670-5888
Fax: (905) 670-5782
LCD-IOM-1
7/1/02
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Table of Contents
Troubleshooting
Related Manuals for RBI LCD Series
Summary of Contents for RBI LCD Series
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Page 1: Operation Manual
LCD-IOM-1 7/1/02 LCD SERIES FINNED COPPER GAS BOILERS & WATER HEATERS 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 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. -
Page 2: Table Of Contents
BEFORE YOU START This manual covers the application, installation, The owner should maintain a record of all service work operation and maintenance of a LCD Series finned performed with the date and a description of the work 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 or other means of providing make-up air if the intake If the LCD is to be located in a confined space the minimum clearances listed in Table 1 must be 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 MINIMUM VERTICAL RISE VENT PIPE DIAMETER OFF THE TOP OF UNIT "A" 5" TO 10" 127 TO 254 12" 12" TO 18" 305 TO 457 24"...
- Page 6 3182 9546 1480 1480 intervals with overhead hangers. The certified combustion 1650 2662 3548 1650 10,643 air terminal from RBI must be used and installed as 1970 3179 4236 1970 12,707 shown in Figures 4 and 5. 2300 3711 4945...
- Page 7 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 7 Figure 4 - Horizontal Combustion Air and Venting Figure 4 - Horizontal Combustion Air and Venting for a Single Unit 4 FT 1.2 m 1/4 IN. PER FOOT 20 mm/m 3 FT 0.9 m 16 FT 4.9 m 5 FT 1.5 m 5 FT 1.5 m...
- Page 8 Page 8 LCD INSTALLATION AND OPERATION INSTRUCTIONS Figure 6 - Vertical Combustion Air and Venting, Metal Chimney System Shown Figure 7 - Combination Air Intake And Venting, Masonry Chimney Shown MINIMUM VERTICAL RISE VENT PIPE DIAMETER OFF THE TOP OF UNIT "A" 5"...
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Page 9: General Venting Guidelines
LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 9 A barometric damper must be installed when the GENERAL VENTING GUIDELINES horzontal run is longer than 35 equivalent feet. (90 degree elbow = 10 equivalent feet). If this is the case, a power WARNING: The vent installation must be in venter must also be used. -
Page 10: Horizontal Venting
United States, ULS636 for installations in Canada. The 5 ft, 1.5 m they must be supported at 3 ft, 0.9 m certified vent terminal from RBI must also be used. The intervals with overhead hangers. Use a type B, single... -
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, 1.3 m below, 4 ft, 1.3 m horizontally from or 1 ft, 0.23 m 1.3 m below, 4 ft, 1.3 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 deficiencies which could cause an unsafe condition. -
Page 13: General Piping Requirements
LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 13 e) After it has been determined that each appliance Table 6 - Temperature Rise Table ∆T = 15 °F ∆ T = 8.3 °C remaining connected to the common venting system Model Flow Rate Pres. -
Page 14: Heating System Piping
Page 14 LCD INSTALLATION AND OPERATION INSTRUCTIONS Freeze Protection WARNING: Never install any type of valve This boiler/water heater is CSA designed certified for between the boiler/water heater and the relief outdoor installation. Outdoor installations in areas where valve or an explosion causing extensive the danger of freezing exists are not recommended property damage, severe personal injury or 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 6 indicates that the flow 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 Figure 12 - Low Temperature Piping See Notes and Adjustment Procedures...
- Page 17 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 17 Figure 13 - Multiple Boiler Piping (See notes)
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Page 18: Domestic Water Supply Piping
120°F, 49°C . Local codes Table 8B . must be complied with! RBI water heaters are designed to run scale free. Due General Piping Requirements to the extreme variables of water conditions world wide Ensure that the water heater is equipped with bronze it is necessary to consider pH values and water headers. - Page 19 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 19 Table 8A - LCD Heat Exchanger Selection Graph Table 8B - LCD Pumping Performance Requirement ∆ ∆ ∆ ∆ ∆ ∆...
- Page 20 Page 20 LCD INSTALLATION AND OPERATION INSTRUCTIONS 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 21 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 21 Figure 14 - Typical Water Heating Piping See Notes Figure 15 - Multiple Water Heating Piping See Notes...
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Page 22: Gas Supply Piping
If for any reason the boiler/water heater is not for the type of gas available at the installation site, CAUTION: Always use a wrench on the gas valve call your RBI Water Heaters representative to resolve body when making gas connections to it. Never the problem. -
Page 23: Electrical Wiring
LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 23 ELECTRICAL WIRING GENERAL OPERATION Electrical Power Connections WARNING: Before proceeding read and fully understand the instructions contained in this manual. Do not attempt to operate this boiler/ CAUTION:Label all wires prior to disconnection water heater if it has not been installed in when servicing controls. - Page 24 Page 24 LCD INSTALLATION AND OPERATION INSTRUCTIONS Figure 17 - Pressure Switch Tap(s) Open the make-up water valve and adjust the system pressure if necessary. The system should be checked and bled after three days of operation. BOILER WATER HEATER OPERATION Staging Operation The LCD boiler/water heater series is separated into on/...
- Page 25 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 25 OPERATION SEQUENCE, ON/OFF Normal Operation On single stage units the blowers and gas valves L225 through L2300 operate at one input. Note: Refer to the wiring diagram included with the Demand Satisfied: unit for further control system info. 1.
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Page 26: Operating Instructions
Page 26 LCD INSTALLATION AND OPERATION INSTRUCTIONS Ignition Trial: Demand Satisfied: 1. Blower delay timer TD1 times out and the flame 1. When the demand for heat is satisfied the operator sense module, FSM, is energized. switch will open, de-energizing relays R2, R2R, R8, 2. - Page 27 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 27 DANGER: Propane gas may not always be 2. Set the operating control or thermostat to off or its detected by smell. Propane gas is heavier than lowest setting. 3. Turn off all electric power to the appliance. air and can collect in low areas.
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Page 28: Checking & Adjustment
Page 28 LCD INSTALLATION AND OPERATION INSTRUCTIONS 15. Set the operating control or thermostat to the 6. Attendre cinq (5) minutes pour laisser échapper tout desired setting. le gaz. Reniflez tout autour de l’appareil, y compris 16. The pilot should automatically light. Do not try to près du plancher, pour déceler une odeur de gaz. - 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 flow by turning the manual 1524 m .
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Page 30: Control Description
Page 30 LCD INSTALLATION AND OPERATION INSTRUCTIONS PROPANE GAS: Optimum results are obtained when High Limit (Aquastat) the boiler/water heater is operated with the manifold The high limit is located in the top control area of the pressure(s) set per Table 19. If the manifold pressure is boiler/water heater. -
Page 31: Maintenance
LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 31 Optional Gas Pressure Switches 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 24 VAC 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 that... - Page 32 Page 32 LCD INSTALLATION AND OPERATION INSTRUCTIONS Heat Exchanger Removal, Cleaning & Replacement - 10. Remove the “V” baffle straps and “V” baffles. See Figure 20 11. Thoroughly inspect the heat exchanger for signs of 1. Close the shut off valves in the inlet and outlet damage.
- Page 33 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 33 Vent System 5. The aquastat high limit controls the maximum water Thoroughly inspect the vent system for any signs of temperature in the boiler. It should be set at least blockage, corrosion or leakage. Immediately replace any 20°F, 11°C above the operater setpoint.
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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: Troubleshooting
LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 35 TROUBLESHOOTING PROBLEM POSSIBLE CAUSES REMEDIES Pilot Lights But Main Burners Bad flame sense lead from igniter Check sense lead & ground ..Will Not Fire to flame sense module connections, adjust as necessary Defective flame sense module Replace flame sense module Manual valve(s) in air plenum... -
Page 36: Repair Parts
Page 36 LCD INSTALLATION AND OPERATION INSTRUCTIONS... - 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 Assembly 70-2716 70-2717 70-2718 70-2719 70-2720 70-2721 70-2722 70-2723 70-2724 70-2725 Jacket Upper Front Panel Assembly...
- Page 38 Page 38 LCD INSTALLATION AND OPERATION INSTRUCTIONS Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Base Panel Legs 03-1862 Jacket Base Panel 03-1847 03-1848 03-1849 03-1850 03-1851 03-1852 03-1853 03-1854 03-1855 03-1856 Combustion Chamber Base Panel 03-1974 03-1975 03-1976...
- Page 39 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 39 Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Combustion Chamber Top Panel 03-1884 03-1885 03-1886 03-1887 03-1888 03-1889 03-1890 03-1891 03-1892 03-1893 Flue Box Wrapper Assembly 70-2798 70-2799 70-2800 70-2801 70-2802...
- Page 40 Page 40 LCD INSTALLATION AND OPERATION INSTRUCTIONS Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Rear Refractory Panel 05-0059 05-0060 05-0061 05-0062 05-0063 05-0064 05-0065 Left & Right Rear Refractory Panel 05-0066 05-0067 05-0068 Center Rear Refractory Panel 05-0069 Manifold 10-0465...
- Page 41 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 41 Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Heat Exchanger Assembly (Cupronickel) 70-3013 (Cast Iron Headers) 70-3014 70-3015 70-3016 70-3017 70-3018 70-3019 70-3020 70-3021 70-3022 70-3023 70-3024 Heat Exchanger Assembly (Cupronickel) 70-3037 (Bronze Headers) 70-3038...
- Page 42 Page 42 LCD INSTALLATION AND OPERATION INSTRUCTIONS Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Combustion Cham. Refr. Retainer (F/R Edge Baffle) 03-1972 O Ring, Inlet/Outlet & Return Headers 06-0001 Stud, Inlet/Outlet & Return Headers 57-0223 Nut, Inlet/Outlet &...
- Page 43 LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 43 Ref # Name of Part Part # 1050 1200 1480 1650 1970 2300 Firing Valve, 3/4" 11-0461 Firing Valve, 1" 11-0456 Firing Valve, 1 1/4" 11-0457 Firing Valve, 1 1/2" 11-0458 Firing Valve, 2" 11-0459 Manifold Pressure Valve 11-0031...
- Page 44 260 North Elm Street 1300 Midway Boulevard Westfield, MA 01085 Mississauga, Ontario L5T 2G8 Canada Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782...