RBI LB 600, LB 225, LB 750, LB 1050, LB 1200 Installation & Operation Manual

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.

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: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

10/09

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 2

AVERTISSMENT. Assurez-vous de bien suivre les instructions données dans cette
notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter
tout dommoge matériel, toute blessure ou la mort

Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides infl ammables
à proximité de cet appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareil.

• Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans
le bâtiment.

• Appelez immédiatement votre fournisseur de gas depuis un voisin. Suivez les
intructions du fournisseur.

• Si vous ne purvez rejoindre le fournisseur, appelez le service des incendies.

L’installation et l’entretien doivent être assurés par un installateur ou un service
d’entretien qualifi é ou par le fournisseur de gaz.

CONTENTS

Before Your Start ................................................page 2

Ratings & Capacities .......................................... page 3

Boiler/Water Heater Location .............................page 3

Combustion Air & Ventilation ..............................page 3

General Venting Guidelines ................................ page 9

Venting Options ..................................................page 9

Vertical/Chimney Venting ...................................page 9

Horizontal Venting ............................................page 10

Outdoor Venting ...............................................page 11

Common Vent Systems ....................................page 12

General Piping Requirements ..........................page 13

Heating System Piping ..................................... page 14

Domestic Water Supply Piping .........................page 18

Gas Supply Piping ............................................page 21

Electrical Wiring ................................................page 22

General Operation ............................................page 22

Operating Instructions ......................................page 25

Checking & Adjustments ..................................page 28

Control Description ...........................................page 30

Maintenance ..................................................... page 31

Troubleshooting ................................................ page 34

Repair Parts ......................................................page 36

Start Up Sheet ..................................................page 44

Mass. Code .......................................................page 46

Warranty ...........................................................page 48

BEFORE YOU START

This manual covers the application, installation,
operation and maintenance of a LCD Series fi nned
copper heating boiler/water heater/pool heater.

To obtain the safe, dependable, effi cient operation and
long life for which this heating boiler/water heater was
designed, these instructions must be read, understood
and followed.

The LCD Series finned copper heating boiler/water
heaters have been design certifi ed by CSA for use with
natural and propane gas under the latest revision of
ANSI-Z21.10.3/CSA 4.3, Gas Water Heaters, and ANSI­Z21.13/CSA 4.9, Gas-Fired Low Pressure Steam and Hot
Water Boilers and CAN1-3.1 Industrial and Commercial
Gas Fired Boilers. Each unit has been constructed and
hydrostatically tested for a maximum working pressure of
160 psi, 1103 kPa in accordance with Section IV of the
A.S.M.E. Boiler and Pressure Vessel Code.

All aspects of the boiler/water heater installation must
conform to the requirements of the authority having
jurisdiction, or, in the absence of such requirements,
to the National Fuel Gas Code, ANSI Z223.1/NFPA 54­latest revision. Where required by the authority having
jurisdiction, the installation must conform to the Standard
for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1.

In Canada, the installation must be in accordance with
the requirements of CSA B149.1 or .2, Installation Code
for Gas Burning Appliances and Equipment.

If installed in the Commonwealth of Massachusetts, you
MUST FOLLOW the additional instructions located in the
back of this manual (MACODE-3).

The owner should maintain a record of all service work
performed with the date and a description of the work
done. Include the name of the service organization for
future reference.

Direct all questions to your RBI distributor or contact
the RBI Customer Service Department, 260 North Elm
Street, Westfi eld, MA 01085 for U.S. or 7555 Tranmere
Drive, Mississauga, ONT L5S 1L4 for Canada. Always
include the model and serial numbers from the rating
plate of the boiler/water heater in question.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 3

RATINGS & CAPACITIES

Before undertaking the installation of the LCD Series
boiler/water heater check the rating plate to ensure
that the unit has been sized properly for the job. The
“Net I=B=R Ratings” specify the equivalent amount
of direct cast iron radiation that the unit can supply
under normal conditions. Also ensure that the unit has
been set up for the type of gas available at the
installation site. Other important considerations are
the availability of an adequate electrical supply, fresh air
for combustion and a suitable chimney or vent system.

DO NOT place this boiler/water heater in a location

5.
that would restrict the introduction of combustion air
into the unit or subject the air inlet to a negative
pressure, see “GENERAL VENTING GUIDELINES”.

WARNING: Never store combustible materials,
gasoline or any product containing fl ammable
vapors or liquids in the vicinity of the boiler/
water heater. Failure to comply with this warning
can result in an explosion or fire causing
extensive property damage, severe personal
injury or death!

BOILER/WATER HEATER LOCATION

1. This boiler/water heater is suitable for indoor and
outdoor installations. Locate the boiler/water heater
in an area that provides good access to the unit.
Servicing may require the removal of jacket panels.
Allow the minimum clearances between adjacent
construction and the boiler/water heater as listed in
Table 1.

NOTE: Service clearances are not mandatory, but
are recommended to ensure ease of service should
it be required.

Table 1
Clearance to Service
Combustibles Clearance
in mm in mm

Top 6 153 20 508
Back 6 153 24 610
Left Side 6 153 24 610
Right Side 6 153 24 610
Front 6 153 30 762
Flue 6 153

2. An optimum site will be level, central to the piping
system, close to a chimney or outside wall and have
adequate fresh air for combustion. Ensure that the
boiler/water heater is level from front to back and
from side to side. Use metal shims to level the
boiler/water heater. Electrical and electronic
components must also be protected from exposure
to water during operation and maintenance. DO
NOT install this boiler/water heater in a location that
would subject any of the gas ignition components
to direct contact with water or excessive moisture
during operation or servicing.

3. Ensure that the fl oor is structurally sound and will
support the weight of the boiler/water heater.

NOTE: The LCD may be installed directly on
combustible fl ooring, but never on carpeting.

4. Locate the boiler/water heater in an area that will
prevent water damage to adjacent construction should
a leak occur or during routine maintenance. If such a
location doesn’t exist, a suitable drain pan that’s
adequately drained must be installed under the unit.

6. NEVER place this boiler/water heater in a location
that would subject it to temperatures at or near
freezing. See the “Freeze Protection Section” on
page 14.

CAUTION: Units installed outdoors MUST be
protected from ice and snow accumulation or the
unit will be damaged voiding the warranty!

COMBUSTION AIR & VENTILATION

WARNING: This boiler/water heater must be
supplied with combustion air in accordance with
Section 5.3, Air for Combustion & Ventilation, of
the latest revision of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and all applicable local
building codes. Canadian installations must
comply with CSA B149.1 or .2 Installation Code
for Gas Burning Appliances and Equipment, or
applicable provisions of the local building codes.
Failure to provide adequate combustion air for
this boiler/water heater can result in excessive
levels of carbon monoxide which can result in
severe personal injury or death!

To operate properly and safely this boiler/water
heater requires a continuous supply of air for
combustion. NEVER store objects on or around
the boiler/water heater!

CAUTION: Combustion air contaminated with
fl uorocarbons or other halogenated compounds
such as cleaning solvents and refrigerants will
result in the formation of acids in the combustion
chamber. These acids will cause premature failure
of the boiler/water heater voiding the warranty!

CAUTION: If the boiler/water heater is operated while
the building is under construction it MUST be
protected from wood, concrete, sheet rock and other
types of dust. Failure to properly protect the unit
from construction dust will damage the unit voiding
the warranty!

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 4

Buildings will require the installation of a fresh air duct
or other means of providing make-up air if the intake
air option isn’t used. Any building utilizing other gas
burning appliances, a fi replace, wood stove or any type
of exhaust fan must be checked for adequate
combustion air when all of these devices are in
operation at one time. Sizing of an outside air duct must
be done to meet the requirements of all such devices.

All Air From Inside The Building

If the LCD is to be located in a confi ned space the
minimum clearances listed in Table 1 must be
maintained between it and any combustible construction.
When installed in a confi ned space without the intake
air option, Figures 1, 2 & 3, two permanent openings
communicating with an additional room(s) are required.
The combined volume of these spaces must have
sufficient volume to meet the combustion air

WARNING: Never operate the LCD in an
environment subjected to a negative pressure
unless the air intake is connected to the
outdoors. Failure to comply with this warning
can result in excessive levels of carbon
monoxide causing severe personal injury or
death!

requirements of all gas utilization equipment. Fireplaces,
wood stoves or any type of exhaust fan must be
considered when making this determination. Each
opening must have a minimum free area of 1 in2/1000
Btu/hr, 2200 mm2/kW based on the total input rating of
ALL gas utilization equipment in the confi ned area. Each
opening must be no less than 100 in2, 64,516 mm2 in
size. The upper opening must be within 12 in, 305 mm
of, but not less than 3 in, 76 mm from, the top of the
enclosure. The bottom opening must be within 12 in,
305 mm of, but not less than 3 in, 76 mm from, the
bottom of the enclosure.

Figure 1 - Vertical Venting with a Metal Chimney System and Inside Air

10 FT

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

1.5 FT 0.5 m

1/4 IN. PER F00T 20 mm/m

Table 2

VENT PIPE DIAMETER

IN. mm FT mm

5" TO 10"

12" TO 18"

127 TO 254
305 TO 457

MINIMUM VERTICAL RISE

OFF THE TOP OF UNIT "A"

12"
24"

305
610

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 6

All Air From Outside The Building
When installed in a confi ned space without utilizing
the intake air option two permanent openings

communicating directly with, or by ducts to, the outdoors
or spaces that freely communicate with the outdoors must
be present. The upper opening must be within 12 in,
305 mm of, but not less than 3 in, 76 mm from, the top of
the enclosure. The bottom opening must be within 12 in,
305 mm of, but not less than 3 in, 76 mm from, the bottom
of the enclosure.

Where directly communicating with the outdoors
or communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area
of 1 in2/4000 Btu/hr, 550 mm2/kW of the total input
rating of all of the equipment in the enclosure.

Where communicating with the outdoors through
horizontal ducts, each opening shall have a minimum
free area of 1 in2/2000 Btu/hr, 1100 mm2/kW of the total
input rating of all of the equipment in the enclosure. When
louvers and screens are used, they must have the same
cross-sectional area as the free area of the opening to
which they connect.

When calculating the free area necessary to meet
the make-up air requirements of the enclosure,
consideration must be given to the blockage effects
of louvers, grills and screens. Screens must have a
minimum mesh size of 1/4 in, 6.4mm. If the free area
through a louver or grill is not known, ducts should be
sized per Table 3.

Table 3 - Make-up Air Louver Sizing

Required Cross Sectional Area

Input 1/4 in 6.4 mm
(MBH) Wire Screen
in

2

cm

75% Free Area 25% Free Area

Metal Louvers Wooden Louvers

2

in

2

cm

2

in

2

cm

2

225 57 363 75 484 225 1452
300 75 484 100 645 300 1935
399 100 645 133 858 399 2573
600 150 968 200 1290 600 3870
750 190 1210 250 1613 750 4840
1050 263 1696 350 2258 1050 6773
1200 300 1936 400 2580 1200 7740
1480 370 2388 494 3182 1480 9546
1650 413 2662 550 3548 1650 10,643
1970 493 3179 657 4236 1970 12,707
2300 575 3711 767 4945 2300 14,835

Canadian installations must comply with CSA B149.1
when air supply is provided by natural air fl ow from the
outdoors for natural draft, partial fan-assisted, fan­assisted, or power draft-assisted burners, there shall
be a permanent air supply opening(s) having a cross­sectional area of not less than 1 in2 per 7,000 Btuh
(310 mm2 per kW) up to and including 1 million Btuh,
plus 1 in2 per 14,000 Btuh (155 mm2 per kW) in excess

of 1 million Btuh.

Intake Air Option - General Guidelines

This confi guration provides combustion air directly to the
boiler/water heater’s air intake using a dedicated pipe
to obtain combustion air from the outdoors. Combustion
air can be drawn in horizontally through an outside wall
or vertically through the roof, see Figures 4, 5, 6 & 7.

WARNING: Common intake air systems may
be used to provide the common duct is sized
properly and an intake combustion air damper
is installed in the intake air pipe of each heater.
Improper installation can result in excessive
levels of carbon monoxide which can cause
severe personal injury or death!

Single wall galvanized smoke pipe, single wall aluminum
pipe or flexible aluminum pipe can be used for the
in-take air pipe. It must be sized per Table 4. All joints
in metal combustion air systems must be secured using
corrosion resistant fasteners and sealed using a suitable
Silicon caulk or tape. The combustion air system

MUST be supported by the building structure not
the boiler/water heater.

Table 4 - Combustion Air Pipe Sizing

Model Size Pipe Diameter
in mm
225 - 300 5 127
400 6 152
600 - 750 8 203
1050 10 254
1200 - 2300 12 305

CAUTION: A stack damper interlocked with the unit
should be installed in the intake air pipe when the
infi ltration of sub-freezing air could occur, otherwise
the unit could freeze up voiding the warranty!

Intake Air Option - Horizontal Guidelines

The maximum equivalent length for the horizontal
combustion air pipe on installations that used the Direct
Vent option is 35 ft, 10.8 m. The maximum equivalent
length for the horizontal combustion air pipe on
installations that use the Horizontal Vent option is 100 ft,

30.5 m. Each 90° elbow and the combustion air terminal

are equal to 10 linear ft, 3.0 m of pipe. If horizontal runs
exceed 5 ft, 1.5 m they must be supported at 3 ft, 0.9 m
intervals with overhead hangers. The certifi ed combustion
air terminal from RBI must be used and installed as
shown in Figures 4 and 5.

Intake Air Option - Vertical Guidelines

The maximum length for the vertical combustion air
pipe is 30 ft, 9.1 m plus two 90° elbows. A listed,
nonrestrictive combustion air cap must be used. The
combustion air cap must terminate as shown in Figure

6. The penetration point in the roof must be properly

fl ashed and sealed.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 7

Figure 4 - Horizontal Combustion Air and Venting for a Single Unit

16 FT 4.9 m

1.5 FT 0.5 m

1/4 IN. PER FOOT

20 mm/m

9

8

Y

7

,
e
c

6

na
t

5

s

iD

4

lac
i

3

t
r
e

2

V

1

0

05101520

Horiz ontal Distance , X

2000 & Larger

1201 To 2000

901 To 1200

200 To 900

1000 BTU'S

When running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals
must be installed on the same plane (outside wall) in order to prevent pressure differences due to prevailing winds.
In cold climates, double-wall or insulated inlet pipe recommended to prevent condensation.

Figure 5 - Horizontal Combustion Air and Venting for Multiple Units

2 IN. 5.0 cm

1.5 FT 0.5 m

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 8

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

1.5 FT

0.5 m

5 1/2 FT

1.7 m

5 FT

1.5 m

Figure 7 - Combination Air Intake And Venting, Masonry Chimney Shown

10 FT 3.1 m

3 FT 1 m

1.5 FT .5m

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 9

GENERAL VENTING GUIDELINES

WARNING: 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 applicable provisions
of the local building codes. Canadian
installations must comply with CSA B149.1 or
.2 Installation Code. Improper venting can result
in excessive levels of carbon monoxide which
can result in severe personal injury or death!

All vent systems must be fully supported by the building
structure and not by the boiler/water heater. Appropriate
thimbles and fi re-stops must be used where required.

WARNING: Common vent systems must be
properly engineered and sized to provide a
negative draft of 0.01 to 0.08 in, .25 to 2.0 mm
W.C. at the flue outlet! Common positive
pressure vent systems are not to be used.
Improper installation can result in excessive
levels of carbon monoxide which can cause
severe personal injury or death!

NOTE: A single acting barometric damper must be
installed directly to the boiler/water heater flue
outlet to ensure proper operation. This does not
apply to outdoor units or direct vent positive
pressure units.

NOTE: Some venting applications may require the stop
to be removed for smooth operation. The barometric
damper should be located after the fl ue collector, refer
to Figures 2, 7A and 8 for proper location. Be sure that
the damper is mounted horizontally (never vertically).
Carefully follow the instructions provided with the
barometric damper. Check with local codes for specifi c
requirements.

In Canada, B149 (7.25 Draft Regulators) states the
damper shall be of double-acting type.

WARNING: To avoid spillage into the room of
dangerous fl ue gas containing carbon monoxide,
the opening in damper must never face against the
fl ow of fl ue gas.

VENT SYSTEM OPTIONS

The LCD may be vented the following ways:

1) Vertical/Chimney Venting, Negative Pressure,

Category I - uses an approved metal chimney system
or properly lined masonry chimney. Combustion air is
obtained from the space in which the unit is installed or
from outdoors. A barometric damper must be installed
near the fl ue outlet when venting vertically. See Figures
6 and 7. This also applies to any fan-assisted chimneys
or vents.

2) Direct Vent, Positive Pressure, Category III - for

horizontal vent runs equivalent to 35 ft, 10.8 m or less.
A stainless steel vent system certifi ed to UL 1738 for
installations in the United States. ULC S636 for
installations in Canada must be used when combustion
air is ducted from outdoors, from the same wall.

3) Horizontal Vent, Negative Pressure, Category I -

for horizontal vent runs equivalent to more than 35 ft,

10.8 m (90 degree elbow equals 10 equivalent feet). A

dedicated wall mounted power venter must be used. The
vent system can be single wall galvanized steel or type
B vent pipe. Combustion air is obtained from the space
in which the unit is installed or from the outdoors.

A barometric damper must be installed when the
horzontal run is longer than 35 equivalent feet. (90 degree
elbow = 10 equivalent feet). If this is the case, a power
venter must also be used.

If horizontal run is less than 35 equivalent feet, do not
use a barometric damper. Follow applicable instructions
under the “COMBUSTION AIR & VENTILATION” section.

4) Outdoor Installation - uses the outdoor option kit.

Barometric damper is not required.

NOTE: All venting, combusiton air material supplied
by installer. All venting material must be approved
for the application. Consult the vent manufacturer’s
product literature

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 10

VERTICAL/CHIMNEY VENTING

The LCD is listed as a Category I appliance when vented
vertically into a metal chimney system or properly sized
masonry chimney, Figures 1, 2, 6 & 7. The chimney must
provide a negative pressure of 0.01 to 0.08 in, .25
to 2.0 mm W.C. at the boiler/water heater fl ue collar
with the unit running at full load. A barometric damper
must be installed between the fl ue collar and the vent
connector. Approved thimbles and fi re-stops must be
used when combustible construction is penetrated.

WARNING : If an appliance using any type of a
mechanical draft system operating under
positive pressure is connected to a chimney
fl ue, never connect any other appliances to this
fl ue. Doing so can result in excessive levels of
carbon monoxide which can cause severe
personal injury or death!

Chimney Inspection & Sizing

A thorough inspection of the masonry chimney must be
performed to ensure that the chimney is clean, properly
constructed, lined and sized. Exterior masonry chimneys
should not be used unless properly lined to prevent
condensation and draft problems. Table 5 lists the
equivalent breeching and fl ue sizes required for the
boiler/water heater. When more than one appliance is
connected to the same chimney fl ue, the fl ue must be
large enough to safely vent the combined output of all
of the appliances.

WARNING: Never install a vent pipe having a
diameter different than that of the boiler/water
heater fl ue collar. Failure to comply with this
warning can result in excessive levels of carbon
monoxide which can cause severe personal
injury or death.

Always provide a minimum clearance of 6 in, 152 mm
between single wall vent pipe and any combustible
materials. Type B1 vent may be used, clearance between
it and any combustible material must be as listed.

WARNING: Failure to maintain minimum
clearances between vent connectors and any
combustible material can result in a fi re causing
extensive property damage, severe personal
injury or death!

DIRECT VENT,
POSITIVE PRESSURE, CATEGORY III

In this confi guration the boiler/water heater blower is
used to push the fl ue products to the outdoors while
drawing combustion air from the outdoors. The equivalent
length of the vent and combustion air systems must not
exceed 35 ft, 10.7 m for each. The Intake Air Option
instructions under the “COMBUSTION AIR &
VENTILATION” section must be followed! The vent
system must be sized per Table 4.

Table 5 - Equivalent Breeching & Chimney Size

Model Size Pipe Diameter
in mm
225 5 127
300 - 400 6 152
600 - 750 8 203
1050 10 254
1200 - 1480 12 305
1650 - 2300 14 356

Note: These sizes are based on a 20 ft, 6.1m chimney height.

Vent Connections

Locate the boiler/water heater as close to the chimney
as possible. Use the shortest, straightest vent connector
possible for the installation. If horizontal runs exceed
5 ft, 1.5 m they must be supported at 3 ft, 0.9 m
intervals with overhead hangers. Use a type B, single
wall stainless or single wall galvanized steel vent pipe
the same diameter as the fl ue collar to connect the
boiler/water heater to a masonry chimney. When using
an approved metal chimney system use the appropriate
vent connector. The vent connector should be sloped up
toward the chimney at a minimum rate of 1/4 in/ft,
20 mm/m. On masonry chimneys the connector must
terminate fl ush with the inside of the chimney fl ue,
Figure 2. Fasten each single wall vent connection with
at least 3 corrosion resistant sheet metal screws.

Horizontal Direct Vent Systems - Figures 4 & 5

The vent materials used in horizontal vent systems
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.

The maximum equivalent length for the horizontal vent
and combustion air pipes is 35 ft, 10.8 m for each. Each
90˚ elbow and the intake air and vent terminals are
equal to 10 ft, 3.1 m of straight pipe. To maximize the
performance of single wall sheet metal vent systems
locate 90˚ elbows as far from the boiler as possible and
from one another. For best results, horizontal vent
systems should be as straight as possible.

The vent system must be both gas tight and watertight.
All seams and joints in metal pipes must be joined
and sealed in accordance with the vent system
manufacturer’s instructions.

When horizontal vent runs exceed 5 ft, 1.5 m they
must be supported at 3 ft, 0.9 m intervals with overhead
hangers. The vent system must be pitched down, toward
the vent terminal, 1/4 in/ft, 20 mm/m. If any part of a
single wall metal vent system passes through an
unheated space it must be insulated with insulation
rated for 400˚F, 204˚C.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 11

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
above any door, window or gravity air inlet into any
building. It must not terminate less than 4 ft, 1.2 m
horizontally from, and in no case above or below, unless
a 4 ft, 1.2 m horizontal distance is maintained, from
electric meters, gas meters, regulators and relief
equipment and not less than 7 ft, 2.1 m from any adjacent
public walkway. The bottom of the vent terminal(s) shall
be located at least 5 ft, 1.5 m above the air intake
terminal(s) unless there is a minimum 5 ft, 1.5 m
horizontal separation between them. Avoid terminal
locations likely to be affected by winds, snowdrifts, people
and pets. Protect building materials and vegetation from
degradation caused by the fl ue gases.

Vertical Direct Vent Systems - Figure 6

The maximum length for the vertical vent and
combustion air pipes is 35 ft, 10.7 m plus two 90˚
elbows. If any part of a single wall metal vent system
passes through an unheated space it must be insulated
with insulation rated for 400˚F, 204˚C. Structural
penetrations must be made using approved fi re-stops.

A listed, nonrestrictive vent cap must be used. The top
of a vertical vent system must extend at least 5 1/2 ft,

1.7 m above the roof surface that it passes through,

4 ft, 1.2 m above the intake air cap, see Figure 6.

HORIZONTAL VENT,
NEGATIVE PRESSURE, CATEGORY I

In this confi guration a wall-mounted power venter must
be used to pull the fl ue products horizontally from the
unit and vent them to the outdoors, see Figures 3, 4 &

5. The air for combustion is taken from the space in
which the unit is installed, or from the outdoors. The
applicable instructions under the “COMBUSTION AIR
& VENTILATION” section must be followed!

To maximize the performance of single wall sheet metal
vent systems locate 90˚ elbows as far from the boiler
as possible and from one another. For best results,
horizontal vent systems should be as short and straight
as possible.

When horizontal vent runs exceed 5 ft, 1.5 m they
must be supported at 3 ft, 0.9 m intervals with
overhead hangers. The vent system must be pitched
down, toward the vent terminal, 1/4 in/ft, 20 mm/m.
If any part of a single wall metal vent system passes
through an unheated space it must be insulated with
insulation rated for 400˚F, 204˚C.

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 above any door, window or gravity air inlet

into any building. It must not terminate less than
4 ft, 1.2 m horizontally from, and in no case above
or below, unless a 4 ft, 1.2 m horizontal distance
is maintained, from electric meters, gas meters,
regulators and relief equipment and not less than 7 ft,

2.3 m from any adjacent public walkway. The bottom

of the vent terminal(s) shall be located at least 5 ft, 1.5
m above the air intake terminal(s) unless there is
a minimum 5 ft, 1.5 m horizontal separation between
them. Avoid terminal locations likely to be affected by
winds, snowdrifts, people and pets. Protect building
materials and vegetation from degradation caused by
the fl ue gases.

To determine the appropriate power venter for the
boiler/water heater, see Table 6. Follow the power venter
manufacturer’s installation instructions.

Table 6 - Power Venter Sizes

LCD Power Venter Max. Pipe Length
Model Model FT m

225 - 300 HS-1 30* 9.3

400 HS-2 100 31.0
600 HS-2 67** 20.8
750 HS-3 100 31.0
1050-1200 HS-4 100 31.0
1480-2300 HS-5 100 31.0

*Choose HS-2 for 100 ft. Max. Pipe length
**Choose HS-3 for 100 ft. 31 m, Max. Pipe Length

OUTDOOR VENTING

When installed outdoors the LCD must be fi tted with
the factory supplied outdoor vent hood and air intake
hood, see Figure 8. Multiple units must be spaced per
Figure 9.

The boiler/water heater must be at least 10 ft, 3.1 m
from any door, window or gravity air inlet into any
building and at least 3 ft, 0.9 m from any overhang
unless local codes dictate differently.

Avoid locations where wind defl ection off of adjacent
walls, buildings or shrubbery might cause a downdraft.
The unit(s) should be located at least 3 ft, 0.9 m from
structures. Outdoor installations are not recommended
in areas where the danger of snow blockage exists.

CAUTION: Do not place the boiler/water heater in a
location that would subject it to runoff from adjacent
buildings or damage may occur voiding the
warranty!

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 12

Figure 8 - Outdoor Venting

Figure 9 - Multiple Outdoor Units

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 ciencies which could cause an unsafe condition.

Inspecter de façon visuelle le système d'évacu-ation

pour déterminer la grosser et l'inclinaison
horizontale qui conviennent et s'assurer que le
système est exempt d'obstruction, d'étranglement
de fruite, de corrosion et autres défaillances qui
pourraient présenter des risques.

c) Insofar as is practical, close all building doors and

windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn
on any exhaust fans, such as range hoods and
bathroom exhaust, so they will operate at maximum
speed. Do not operate a summer exhaust fan for a
boiler installation. Close fi replace dampers.

COMMON VENT SYSTEMS

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. At the time of removal of an
existing boiler/water heater, the following steps shall be
followed with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation.

Au moment du retrait d'une chaudière existante, les
mesures suivantes doivent être prises pour chaque
appareil toujours raccordé au système d'évacuation
commun et qui fonctionne alors que d'autres appareils
toujours raccordés au système d'évacuation ne fonction­nent pas: système d'évacuation

Dans la mesure du possible, fermer toutes les

portes et les fenêtres du bâtiment et toutes les
portes entre l'espace où les appareils toujours
raccordés du système d'évacuation sont installés et
les autres espaces du bâtiment. Mettre en marche
les sécheuses, tous les appareils non raccordés au
système d'évacuation commun et tous les
ventilateurs d'extraction comme les hottes de
cuisinère et les ventilateurs des salles de bain.
S'assurer que ces ventilateurs fonctionnent à la
vitesse maximale. Ne pas faire fonctionner les
ventilateurs d'été. Fermer les registres des
cheminées.

d) Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.

Mettre l'appareil inspecté en marche. Suivre les

instructions d'allumage. Régler le thermostat de
façon que l'appareil fonctionne de façon continue.

e) Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the fl ame
of a match or candle, or smoke from a cigarette,
cigar or pipe.

Faire fonctionner le brûleur principal pendant 5 min

ensuite, déterminer si le coupe-tirage déborde à
l'ouverture de décharge. Utiliser la fl amme d'une
allunette ou d'une chandelle ou la fumée d'une
cigarette, d'un cigare ou d'une pipe.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 13

f) After it has been determined that each appliance

remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fi replace dampers
and any other gas-burning appliance to their
previous condition of use.

Une fois qu'il a été d éterminé, selon la métode

indiquée ci-dessus, que chaque appareil raccordé
au système d'évacuation est mis à l'air libre de façor
adéquate. Remettre les portes et les fenêtres, les
ventilateurs, les registres de cheminées et les
appareils au gaz à leur position originale.

g) Any improper operation of the common venting

system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54. When resizing any portion of the
common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Appendix F in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and or CAN/CGA-B149 Installation
Codes.

Tout mauvais fonctionnement du systéme d'évacu-

tion commun devrait étré corrigé de façor que
l'installation soit conforme au National Fue Gas
Code, ANSI Z223.1/NFPA 54 et (ou) aux codes
d'installation CAN/CGA-B149. Si la grosseur d'une
section du système d' évacuation doit étré modifi ée,
le système devrait étré modifi é pour respecter les
valeurs minimales des tableaux pertinents de
l'appendice F du National Fuel Gas Code, ANSI
Z223.1/ NFPA 54 et (ou) des codes d'installation
CAN/CGA-B149.

GENERAL PIPING REQUIREMENTS

CAUTION: Improper piping of this boiler/water heater
will void the manufacturer's warranty and can cause
boiler failure resulting in fl ooding and extensive
property damage! Excessive water hardness causing
scaling in the copper heat exchanger tubes is NOT
covered under the manufacturer’s warranty.
Excessive pitting and erosion of the internal surface
of the copper heat exchanger tubes is NOT covered
under the manufacturer’s warranty if the result of
high water fl ow rates, see Table 7. Return water
temperatures below 125°F, 52°C will result in heat
exchanger damage from excessive condensation
voiding the manufacturer’s warranty, see Primary/
Secondary Piping Figure 11.

Table 7 - Temperature Rise Table

ΔT = 15 °F ΔT = 8.3 °C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa

225 24.6 0.18 1.6 0.5
300 32.8 0.31 2.1 0.9
400 43.7 0.70 2.8 2.1
600 65.6 1.84 4.1 5.4
750 82.0 3.32 5.2 9.8

ΔT = 20 °F ΔT = 11.1 °C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop

Number GPM Ft L/s kPa
300 24.6 0.18 1.6 0.5
400 32.8 0.41 2.1 1.2
600 49.2 1.08 3.1 3.2
750 61.5 1.95 3.9 5.7
1050 86.1 5.16 5.4 15.2
1200 98.4* 8.14 6.2 24.0
1480 121.4* 7.94 7.7 23.4

ΔT = 25 °F ΔT = 13.9 °C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop

Number GPM Ft L/s kPa
400 26.2 0.27 1.7 0.8
600 39.4 0.71 2.5 2.1
750 49.2 1.29 3.1 3.8
1050 68.9 3.41 4.3 10.1
1200 78.7 5.38 5.0 15.9
1480 97.1 5.25 6.1 15.5
1650 108.2 7.02 6.8 20.7

ΔT = 30 °F ΔT = 16.7 °C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop

Number GPM Ft L/s kPa
600 32.8 0.51 2.1 1.5
750 41.0 0.92 2.6 2.7
1050 57.4 2.44 3.6 7.2
1200 65.6 3.84 4.1 11.3
1480 80.9 3.75 5.1 11.0
1650 90.2 5.01 5.7 14.8
1970 107.7 8.75 6.8 25.8
2300 125.7* 12.45 7.9 36.7

ΔT = 35 °F ΔT = 19.4 °C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa

600 28.1 0.38 1.8 1.1
750 35.1 0.69 2.2 2.0
1050 49.2 1.83 3.1 5.4
1200 56.2 2.89 3.5 8.5
1480 69.3 2.82 4.4 8.3
1650 77.3 3.77 4.9 11.1
1970 92.3 6.58 5.8 19.4
2300 107.8 9.36 6.8 27.6
*Flow exceeds recommended maximum use a greater temperature
rise or consult manufacturer. Cupro-Nickel exchanger should be
considered.

NOTE: Shut off valves and unions should be
installed at the inlet and outlet connections of the
boiler/water heater to provide for isolation of the unit
should servicing be necessary.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 14

Freeze Protection

This boiler/water heater is CSA designed certifi ed for
outdoor installation. Outdoor installations in areas where
the danger of freezing exists are not recommended
unless proper freeze protection is provided. If the unit
is to be installed in such an area the following
precautions MUST be observed:

1. A continuous fl ow of water through the boiler/water
heater MUST be maintained! The pump responsible
for fl ow through the boiler/water heater must run
continuously!

2. An ethylene glycol/water mixture suitable for the
minimum temperature that the unit will be exposed

to must be used. The pump must be capable of

producing 15% more fl ow and overcoming a 20%
increase in head loss. Domestic water systems must
be isolated from the water heater by the use of a
heat exchanger or other approved method.

3. If the boiler/water heater must be shut off for any
reason the electric, gas and water supplies MUST
be shut off and the unit and its pump completely
drained.

CAUTION: Improper outdoor installation of this
boiler/water heater can cause boiler failure voiding
the manufacturer's warranty!

Relief Valve

Pipe the discharge of the pressure relief valve to prevent
scalding in the event of a discharge, see Figure 10. The
discharge piping must be sized the same as the pressure
relief valve outlet and installed to allow complete drainage
of both the relief valve and the discharge piping.

WARNING: Never install any type of valve
between the boiler/water heater and the relief
valve or an explosion causing extensive
property damage, severe personal injury or
death may occur!

Flow Switch

The fl ow switch supplied with the boiler/water heater must
be wired to the terminal strip in the control panel to
prevent the boiler from fi ring unless there’s adequate
water fl ow through the unit. The fl ow switch must be
installed in the supply piping adjacent to the boiler outlet
connection.

CAUTION: Failure to properly install the fl ow switch
may result in damage to the boiler/water heater heat
exchanger voiding the warranty!

HEATING SYSTEM PIPING

General Piping Requirements

All heating system piping must be installed by a qualifi ed
technician in accordance with the latest revision of the
ANSI/ASME Boiler and Pressure Vessel Code, Section
IV, and when required, ANSI/ASME CSD-1, Standard
for Controls and Safety Devices for Automatically Fired
Boilers. All applicable local codes and ordinances must
also be followed. A minimum clearance of 1 in, 25 mm
must be maintained between heating system pipes and
all combustible construction. All heating system piping
must be supported by suitable hangers not the boiler.

The thermal expansion of the system must be
considered when supporting the system. A minimum
system pressure of 12 psig, 82.7 kPa must be
maintained.

Figure 10 - Relief Valve Piping

Heating Boiler Piping Connections

The supply and return piping should be sized to suit the
system. The supply and return connection sizes are
listed in Table 8.

Table 8 - Supply & Return Connection Sizes

Model Size Supply Return
225 thru 300 1-1/2" NPT 1-1/2" NPT
400 thru 2300 2-1/2" NPT 2-1/2" NPT

Pump Requirements (Primary/Secondary)

This low mass boiler requires a continuous minimum
water fl ow for proper operation. The boiler pump must
be sized to overcome the head loss of the boiler and the
near piping in order to achieve the required temperature
rise. Table 7 provides the heat exchanger pressure drop
and temperature rise figures. The temperature rise
across the boiler must never exceed 35°F, 19.4°C.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 15

CAUTION: A temperature rise outside of the range
listed in Table 7 indicates that the fl ow rate through
the heat exchanger is incorrect which will damage
the heat exchanger voiding the warranty! The
maximum allowable temperature rise is 35°F, 19.4°C.

The maximum allowable fl ow rate through a LCD
boiler with copper heat exchanger is 92 GPM,

5.8 L/s on 225-1200 models and 115 GPM, 7.3 L/s

on 1480 to 2300 models. The cupro-nickel heat
exchanger allows for 100 GPM, 6.3 L/s on 225 to
1200 models and 125 GPM, 7.9 L/s on 1480 to 2300
models.

Low Water Cutoff

If a boiler is installed above any radiation elements it
must be fi tted with a low water cutoff device.

Refer to wiring diagram supplied with the boiler/water
heater for proper wiring connections.

Expansion Tank & Air Separator

An expansion tank or other means to control thermal
expansion must be installed in the heating system. An
expansion tank must be installed close to the boiler on
the suction side of the pump. An air scoop and
automatic air vent must also be installed to eliminate air
trapped in the system.

Low Return Water Temperatures

To prevent the problems associated with condensation
of the products of combustion due to low return water
temperatures a primary/secondary piping system with
a bypass and bypass valve must be installed, see Figure

12. The bypass and bypass valve must be sized the
same as the boiler piping. A balancing valve must
also be installed in the supply side of the boiler piping
downstream of the bypass. The balancing valve
should be adjusted to divert some of the heated
discharge water into the return water until the required
inlet water temperature is achieved. The primary and
secondary pumps should be sized to provide the
required fl ow through each system. The boiler piping
connections to the heating system piping must not be
more than 12 in, 305 mm apart to ensure zero pressure
drop. See Figure 12.

Multiple Boiler Systems

Systems using multiple boilers can also be installed
using a primary/secondary manifold system, Figure 13.

Piping For Use With Cooling Units

The boiler, when used in connection with a refrigeration
system, must be installed so the chilled medium is piped
in parallel with the boiler. Appropriate valves must be
used to prevent the chilled water from entering the
boiler.

Primary/Secondary Piping

Boilers connected to heating systems using zone valves,
zone pumps, or systems that have excessive fl ow rates
or return water temperatures less than 125°F, 52°C
must be isolated from these systems to protect the boiler.

Variable Water Flows

Figure 11 shows a typical primary/secondary piping
system. A dedicated pump is used to maintain a
constant water flow through the boiler. This boiler
pump is sized to overcome the head loss of the boiler
and near piping while supplying the flow rate
required to maintain the desired temperature rise
across the boiler heat exchanger. The system pump is
sized to provide the required fl ow to the heating system.
The boiler piping connections to the heating system
piping must not be more than 12 in, 305 mm apart to
ensure zero pressure drop. See Figure 11.

When a boiler is connected to a heating coil that may
be exposed to refrigerated air from an air handling
device, the piping system must be equipped with fl ow­control valves or some other automatic means of
preventing gravity circulation of the boiler water during
the cooling cycle.