RBI LCD DOMINATOR Installation and Operation Instruction

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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: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782

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

75% Free Area 25% Free Area

Metal Louvers Wooden Louvers

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

, e c

na t

lac i

t r e

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

1.5 FT 0.5 m

2 IN. 5.0 cm

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.

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.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 16

Figure 11 - Typical Primary/Secondary Piping System

(See Notes)

NOTES:

1. Boiler circuit piping must be sized

large enough to handle maximum ﬂ ow through unit.

2. Boiler pump sized to boiler design ﬂ ow

requirements.

3. All boilers furnished with factory

mounted outlet water temperature gauge.

4. Boiler pump purging required. Use ter-

minals supplied.

Notice: These drawings show suggested piping conﬁ guration and valving. Check with local codes and ordinances for speciﬁ c requirements.

H-1 Rev 3

Pump

Gate Valve

Globe Valve

Angle Valve

Bufferfly Valve

Balance Valve

Ball Valve

Motorized Valve

Solenoid

Operated Valve

Self-Operated

Val ve

Figure 12 - Low Temperature Piping

(See Notes and Adjustment Procedures)

NOTES:

1. Boiler circuit piping must be large enough to handle

maximum ﬂ ow through unit.

2. Boiler pump sized to boiler design ﬂ ow requirements.

3. All boilers furnished with factory mounted outlet water

temperature gauge.

4. Boiler pump purging required. Use terminals supplied.

Notice: These drawings show suggested piping conﬁ guration and valving. Check with local codes and ordinances for speciﬁ c requirements.

Pressure

Reducing Valve

Check Valve

Pressure

Relief Valve

Flow Switch

Thermometer

Aquastat Union

Pressure Switch

Gas Pressure

Regulator

Automatic

Air Vent

H-3 Rev 5

BackflowPrevention

Adjustment Procedure To Maintain Inlet Temperature

Above Dew Point

T1-Temp-Min+110° For Atmospheric

T1-Temp-Min=125° Sealed Combusion

1. Turn heater on and open valves A & B.

2. After steady-state operation, if T1 is less than Temp-Min slowly close valve B until T1 climbs to desired operating temperature above Temp-Min.

3. If T1 is greater than desired operating temperature, slowly close valve A to adjust to lower desired temperature above Temp-Min.

4. Check after system operating temperature has stabiized. Make ﬁ nal adjustments.

5. Follow same adjustment procedure for sealed combustion.

Device

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

H-18 Rev 2

Figure 13 - Multiple Boiler Piping (See notes)

NOTES:

1. For pump selection consult factory.

2. Boiler pump sized to boiler and thermostatic 3-way valve design ﬂ ow requirements.

3. Boiler circuit piping must be sized large enough to handle maximum ﬂ ow through unit.

4. All boilers furnished with factory mounted outlet water temperature gauge.

5. Boiler pump purging required. Use terminals supplied.

6. Valve is precalibrated for 140°F return temperature.

Notice: These drawings show suggested piping conﬁ guration and valving. Check with local codes and ordinances for speciﬁ c requirements.

Angle Valve

Bufferfly Valve

Balance Valve

Ball Valve

Motorized Valve

Solenoid

Operated Valve

Self-Operated

Val ve

Pressure

Reducing Valve

Check Valve

Pressure

Relief Valve

Flow Switch

Thermometer

NOTES:

1. Boiler circuit piping must be large enough to handle maximum ﬂ ow through unit.

2. Boiler pump sized to boiler design ﬂ ow requirements.

3. All boilers furnished with factory mounted outlet water temperature gauge.

4. Boiler pump purging required. Use terminals supplied.

5. Secondary loop pipe diameter must be sized large enough to handle maximum ﬂ ow through all units.

Notice: These drawings show suggested piping conﬁ guration and valving. Check with local codes and ordinances for speciﬁ c requirements.

H-15 Rev 4

Aquastat Union

Pressure Switch

Gas Pressure

Regulator

Automatic

Air Vent

Backflow-

Prevention

Device

3-Way Valve

Expansion

Tan k

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 18

DOMESTIC WATER SUPPLY PIPING

CAUTION: Proper control settings must be used to prevent water supplied for domestic use from exceeding 130°F, 54°C or a scald injury will occur! When higher water temperatures are required for appliances such as a dishwasher, a mixing valve or some other tempering means must be installed. Households with small children may require water temperatures less than 120°F, 49°C. Local codes must be complied with!

General Piping Requirements

Ensure that the water heater is equipped with bronze headers. Piping and components connected to the water heater must be suitable for use with potable water. The water heater must not be connected to any heating system piping or components previously used with a nonpotable water heating appliance. No toxic chemicals, such as those used for boiler treatment, are to be introduced into the potable water used for space heating. If a hot water storage tank is used in the system it must be equipped with a temperature and pressure relief valve that complies with ANSI Z21.22 or CAN-4.4 and CAN-4.6.

NOTE: The storage tank must be located as close to the water heater as possible to prevent excessive head loss which will reduce ﬂ ow.

Water Chemistry

The required temperature rise across the water heater is based on water having a hardness between 8 and 18 grains per gallon with a level of dissolved solids not exceeding 350 ppm. Water having a hardness less than 8 grains can cause excessive errosion of the heat exchanger. Water that has a hardness greater than 18

grains per gallon and/or a level of dissolved solids exceeding 350 ppm will require a recalculation of the pump size and temperature rise.

A cupro-nickel heat exchanger may also be required. The manufacturer should be consulted when these water conditions are encountered. See Table 9A

CAUTION: a LCD water heater 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 125 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 variables of water conditions world wide it is necessary to consider pH values and water hardness in relationship to scaling. It is crucial to consider these two variables when making heat exchanger and pump selection. If local water conditions are extreme follow the guidelines in the Heat Exchanger Selection Table (Table 9A) and the Pumping Performance Table (Table 9B). Scale free operation can be achieved by using water with a hardness between 8 and 18 and by maintaining the pH between 5 and 9. Follow the conditions listed under NORMAL in the table. In some areas of the country additional precautions must be observed due to unusual characteristics of the local water supply. Call the nearest RBI representative for details.

To properly size the pump a grain hardness and pH test must be taken at the installation site before the order is placed. Proper pump sizing will improve heater performance and help ensure heater longevity.

The maximum allowable ﬂ ow rate through

Table 9A - LCD Heat Exchanger Selection Graph

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 19LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 19

Table 9B - LCD Pumping Performance Requirement

Expansion Tank

An expansion tank or other means to control thermal expansion must be installed in the water heating system if back ﬂ ow prevention devices are installed.

Cold Water Supply

The cold water supply must be piped to the water heater’s outlet piping between the water heater and the hot water storage tank. This will prevent untempered water from entering the water heater, see the Temperature Rise Control section below. A typical water heating system is shown in Figure 14 and 15.

Pump Requirements

This low-mass water heater requires a continuous minimum water ﬂ ow for proper operation. The low water ﬂ ow switch provided for this unit will shut down the water heater if ﬂ ow falls below the required minimum level. Table 9B provides the heat exchanger pressure drop chart and temperature rise table. The temperature rise

across the water heater must never exceed 35°F,

19.4°C.

Temperature Rise Control

Water returned to the water heater inlet must not be less than 125°F, 52°C or excessive condensation of the products of combustion will damage the water heater voiding the warranty. The method outlined below can be employed to prevent this condition from occurring.

A balancing valve should be installed on the outlet side of the water heater for purposes of adjusting the flow rate through the heat exchanger. Thermometers are installed on both the inlet and outlet of the water heater for determining the temperature rise through the unit. The proper velocity through the water heater must be maintained in accordance with Table 9B for efficient operation and long life. If the temperature rise through the water heater is lower than recommended the water velocity is too high. Premature erosion of the heat exchanger will occur. Conversely, if the temperature rise is higher than recommended in Table 9B the ﬂ ow rate is too low. Scaling and softening of the heat exchanger will occur.

Thermostatic Mixing Valve - Water Above 140°F, 60°C Water can be stored at temperatures above 140°F,

60°C provided that a thermostatically controlled mixing valve is used to temper the hot water to an acceptable temperature before it’s supplied for domestic use.

The mixing valve MUST be set to prevent a scald injury from occurring, see the caution against scalding above.

Storage of water for domestic use above 140°F, 60°C will provide an increased quantity of tempered water and help prevent growth of water born bacteria.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 20

(Typ.)

Figure 14 - Typical Water Heating Piping (LW Models Only)

(See Notes)

Attention:

Not all RBI stock storage tanks

incorporate this tapping: See Note 1.

Figure 15 - Multiple Water Heating Piping (LW Models Only)

(See Notes)

D-1 Rev 6

Pump

Valve

Globe Valve

Angle Valve

Bufferfly Valve

Balance Valve

Ball Valve

Motorized Valve

Solenoid

Operated Valve

Self-Operated

Valve

SELF BALANCIN G DOUBLE REVERSE RETURN MAKE-UP & SUPPLY, CIRCULATION

D-4 Rev 6

Attention:

Not all RBI stock storage tanks

incorporate this tapping: See Note 1.

NOTES:

1. Optional cold water make up and recirculation line location.

2. When using intermittent pump and pump delay, locate remote aquastat well in lower 1/3 of tank. Install aquastat with heat sensing compound.

3. Thermal expansion tank may be required, check local codes.

4. When using optional factory mounted pump, max pipe length 30’ total, 6-90° elbows, full pipe size.

5. CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE.

The pH and water hardness must be measured before selecting heat exchanger and pump. Consult the Heat Exchanger Graph and

Pumping Performance Table before making selection.

6. Common piping must be sized for maximum combined heater ﬂ ow.

7. Hot water tanks should be equipped with a combination temperature & pressure relief valve.

8. MA Code requires an 1/8” hole in check valve to compensate for thermal expansion.

Notice: These drawings show suggested piping conﬁ guration and valving. Check with local codes and ordinances for speciﬁ c requirements.

Pressure

Reducing Valve

Check Valve

Pressure

Relief Valve

Flow Switch

Thermometer

Aquastat Union

Pressure Switch

Gas Pressure

Regulator

Automatic

Air Vent

Temperature &

Pressure

Relief Valve

Vacuum

Relief Valve

Drain Valve

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 21

GAS SUPPLY PIPING

WARNING: Check the boiler/water heater rating plate to make sure that the boiler/water heater is for the type of gas that will be used. If it isn’t, do not connect the boiler/water heater to the gas supply. Gas supply piping must be in accordance with the National Fuel code, ANSI Z223.1-latest revision or applicable provisions of the local building codes. Canadian installations must comply with CAN/CGA B149.1 or .2 Installation Code. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

The LCD comes from the factory ready to be piped to the gas supply. If for any reason the boiler/water heater is not for the type of gas available at the installation site, call your RBI Water Heaters representative to resolve the problem.

Note: A minimum gas supply pressure of 6 in, 152 mm, W.C. natural or 11 in, 279 mm W.C. propane and maximum 14 in, 356 mm W.C. natural or propane, must be available at the safety shutoff valve inlet with the unit(s) operating.

Table 10 should be used to ensure that the gas supply piping is sized properly. If more than one appliance is supplied by the same supply pipe, the piping must be sized based on the maximum possible demand. Do not neglect the pressure drop due to pipe ﬁ ttings. Table 10 should be used in conjunction with Table 11 to ensure that the gas supply piping has the capacity to meet the demand.

Figure 16 depicts the proper way to connect the boiler/ water heater to the gas supply piping. The manual shutoff valve must be installed in the supply piping. It should be installed 5 ft, 1.5 m above the ﬂ oor where required by local codes. Provide a sediment trap at the bottom of the vertical section of the gas supply pipe upstream of the gas controls.

Table 10 - Gas Pipe Capacity

Maximum pipe capacity in ft at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.

Nominal Iron Pipe Size, (in)

Note: Multiply the gas volume by 0.62 for propane ﬂ ow capacity in

/hr. Multiply the propane ﬂ ow capacity by 2500 Btu/ft3 to determine

ft the propane Btu/hr capacity for a given pipe size and length.

10 20 30 40 50 60 80 100 150

278 190 152 130 115 105 90 79 64

/4ʺ

520 350 285 245 215 195 170 150 120

1ʺ

1050 730 590 500 440 400 350 305 250

11/4ʺ

1600 1100 890 760 670 610 530 460 380

11/2ʺ

3050 2100 1650 1450 1270 1150 990 870 710

2ʺ

4800 3300 2700 2300 2000 1850 1600 1400 1130

21/2ʺ

8500 5900 4700 4100 3600 3250 2800 2500 2000

3ʺ

/hr based on 0.60 speciﬁ c gravity gas

Pipe length in feet

Maximum gas volume of pipe, (ft3/hr)

Table 11 - Equivalent Pipe Length Chart

Nominal

Iron Pipe

Size, (in)

11/4ʺ 11/2ʺ

21/2ʺ

Notes: 1. For ﬂ ow through branch.

2. For ﬂ ow at full open.

90° Elbow Tee

2.6 5.2 0.6 1.5

1ʺ

3.5 6.9 0.8 1.9

4.0 8.0 0.9 2.3

5.2 10.3 1.2 3.0

2ʺ

6.2 12.3 1.4 3.7

7.7 15.3 1.8 4.5

3ʺ

Type of pipe ﬁ tting

Gas Valve2 Gas Cock

Equivalent pipe length, (ft)

CAUTION: Always use a wrench on the gas valve body when making gas connections to it. Never over-tighten the piping entering the gas valve body or gas valve failure may result!

Figure 16 - Gas Supply Piping

A ground joint union should be installed between the boiler gas controls and the supply piping. Each of these items are needed to ensure long life and ease of servicing. Always use a pipe sealant that is suitable for use with LP gas.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 22

When applicable, provisions for vent, bleed and gas relief lines must be made in accordance with the latest revision of ANSI Z223.1/NFPA 54.

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler. All gas connections MUST be leak tested before putting the boiler into operation.

WARNING: Never use an open ﬂ ame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

Whenever the gas supply piping is pressure tested the boiler/water heater gas controls must be protected. If the test pressure is equal to, or less than 1/2 psig, 3.5 kPa isolate the boiler/water heater by closing it's manual shut off valve, see Figure 16. If the test pressure is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect the boiler/water heater and its individual shut-off valve.

ELECTRICAL WIRING

Electrical Power Connections

CAUTION:Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing.

ATTENTION. Au moment de l'entretien des commandes, étiquetez tous les ﬁ ls avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S'assurer que l'appareil fonctionne adéquatement une fois l'entretirn terminé.

The electrical connections to this boiler/water heater must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code, ANSI/NFPA-70. Installation should also conform with CSA C22.1 Canadian Electrical Code Part I if installed in Canada.

Install a separate 120 volt 15 or 20 amp circuit breaker for the boiler/water heater and pump, see Table 12. A properly rated shut-off switch should be located at the boiler/water heater. The boiler/water heater must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical Code, ANSI/NFPA-70.

Table 12 - LCD Electrical Requirements

Recommended LCD Circuit Breaker *Running Model (Amps) Amps LB/LW 225-600 15 3.9 LB/LW 750 15 6.0 LB/LW 1050-1970 20 11.4 LB/LW 2300 20 14.4 *Use separate circuit breaker that is properly sized for pump and pump contactor.

Line voltage ﬁ eld wiring of any controls or other devices must conform to the temperature limitation of type T wire at 95°F, 35°C above room temperature. Use copper conductors with a minimum size of #14 awg. Use appropriate wiring materials for units installed outdoors. The wire size must be compatible with the total amp draw of the circuit.

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

GENERAL OPERATION

WARNING: Before proceeding read and fully understand the instructions contained in this manual. Do not attempt to operate this boiler/ water heater if it has not been installed in accordance with the guidelines set forth in this manual. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance. Do not interrupt water ﬂ ow through the boiler/ water heater.

En cas de surchauffe ou si l'alimentation en gaz ne s'arrête pas, fermez manuellement le robinet d'arrêt de l'admission de gaz.

Hydronic Heating Boilers

Open the make-up water valve and slowly ﬁ ll the boiler and all of the radiation with water. Ensure that all bleed and drain valves are closed.

Adjust the make-up water pressure regulator so a minimum 12 psig, 83 kPa system pressure is maintained at the highest point in the system piping. If a make-up water pump is used adjust it to maintain a minimum 12 psig, 83 kPa system pressure.

Open the system bleed and drain valves one at a time to purge the air trapped in the heating system piping.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 23

With the boiler off, run the system pump for at least 30 minutes and bleed the system piping using the bleed valves. If strainers are used in the system piping, the make-up water valve should be closed and the strainers checked and cleaned.

The system expansion tank should be checked to ensure that the correct water level in the tank is maintained. The tank should be less than half full of water with the system full and adjusted to the correct operating pressure.

Start the boiler as described in the “OPERATING INSTRUCTIONS”. Run the boiler for at least an hour. The system pump(s) and all radiation units must be operated during this time. Ensure that the make-up water valve is open.

Shut the boiler off and open the bleed valves to purge the air trapped in the heating system piping. Close the make-up water valve and check and clean the strainers and make-up water pressure reducing valve.

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/ off and 2-stage units depending on the model selected. The 225-400 models have on/off staging, while the 600 through 2300 models have a two stage option. Input staging is controlled from an aquastat controller that signals the relays to select the blower and gas valve modes. Table 13 identiﬁ es the stages and ﬁ ring modes associated with the standard single stage units. Table 14 identiﬁ es the stages and ﬁ ring modes associated with the two stage option.

The outlet water temperature is automatically controlled by the aquastat. The optional staging function is controlled by a return water aquastat. The return water aquastat utilizes inputs from the inlet water temperature sensors or optional tank sensors to stage the boiler/ water heater as required.

Pressure Switch Settings

Differential pressure switches are provided in the LCD to shut down gas ﬂ ow under a blocked ﬂ ue or inlet condition. A single pressure switch is used on the standard models. One low fire and one high fire pressure switch is used when the two-stage option is employed. The low ﬁ re pressure switch serves to shut down gas ﬂ ow if there is a blocked ﬂ ue or inlet condition during low ﬁ re operation. Similarly, the high ﬁ re switches will shut down gas ﬂ ow if there is a blocked ﬂ ue or inlet condition during high ﬁ re operation. The differential

pressure is taken between the air plenum and the pressure inside one of the main burners.

Pressure taps are provided in the control compartment for taking the differential pressure readings, Figure 17. Table 15 lists the differential pressure settings for all of the models.

Figure 17 - Pressure Switch Tap(s)

Table 13 - Firing Modes (L225-L2300)

Stage Firing Mode Off Off 1 On

Table 14 - Firing Modes (L600-L2300)

Stage Firing Mode Off Off 1 Low Fire 2 High Fire

Table 15 - Differential Pressure Settings (All Units)

Model High Fire Inches W.C. mm W.C. 225-300 1.0 - 1.1 25.4 - 27.9 400 0.7 - 0.8 17.8 - 20.3 600-2300 1.0 - 1.1 25.4 - 27.9

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 24

On all units, the pressure switch(es) will interrupt power to the control module under a blocked flue or inlet condition. This will cause the pilot and main gas valves to close. Tables 16 and 17 identify how pressure switch control changes during boiler/water heater staging. Tables 18 and 19 identify the control actions if a low air condition occurs at any stage.

Table 16 - Pressure Switch Control, L225-L400

Stage Pressure Switch Mode Off Off 1 High Fire

Table 17 - Pressure Switch Control, L600-L2300

Stage Pressure Switch Mode Off Off 1 Low Fire 2 High Fire

Table 18 - Low Air Condition Action, L225-L2300

Stage Control Action 1 No Power to Flame Sense Module

Table 19 - Low Air Condition Action, L600-L2300

Stage Control Action 1 No Power to Flame Sense Module 2 No Power to Flame Sense Module

Prepurge:

1. Blower delay timer TD3 energizes the high speed windings of the blower(s).

2. Air pressure in the combustion chamber is sensed. If the air pressure is sufﬁ cient, the pressure switch closes allowing the blower delay timer TD1 to start a 10 second pre-purge.

Ignition Trial:

1. Blower delay timer TD1 times out and the ﬂ ame sense module, FSM, is energized.

2. The FSM starts the 10-second ignition trial, energizing relay R7, the pilot solenoid valve and the spark generator.

3. The pilot valve and spark generator are energized for the 10-second ignition trial. When the pilot ﬂ ame is sensed, the 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.

If the pilot ﬂ ame isn’t sensed, the FSM de-energizes the PV terminal and waits 5 minutes before initiating the second ignition trial. The blower(s), pump(s) and optional power venter will remain on during this time.

5. On CSD-1 equipped units the blower(s) and optional power venter will shut down and the boiler/water heater will lock if the second ignition trial fails. The unit must then be manually reset by depressing the reset button on the left jacket panel.

6. On non-CSD-1 equipped units the FSM will wait 10 minutes after the second unsuccessful ignition attempt then begin the ignition process described in step 3 above. The FSM will continue to cycle the unit through steps 3, 4 and 6 until the unit lights or the demand for heat is removed.

OPERATION SEQUENCE, ON/OFF L225 through L2300

Note: Refer to the wiring diagram included with the unit for further control system info.

POWER ON: Demand for Heat:

1. The operator switch closes, energizing pump delay timer TD4 and the water pump(s).

2. Water ﬂ ow through the unit closes the water ﬂ ow switch contacts energizing blower delay timer TD3.

3. The system checks all primary limit(s) and other interlocks before starting pre-purge. The unit will not start if any switch is open.

Main Burner

Once the pilot is proven, the MV terminal on the FSM is energized sending 24VAC to the safety and main solenoid valves.

Normal Operation

On single stage units the blowers and gas valves operate at one input.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 25

Demand Satisﬁ ed:

1. When the demand for heat is satisﬁ ed the operator switch will open, de-energizing relay R8, TD1, TD3, TD4, the FSM, and the pilot, main and safety solenoid valves. The pilot and main flames are extinguished.

2. The blower delay timer TD3 starts the 80 second post-purge timing. The blower(s) shut(s) off when TD3 times out.

3. The pump delay timer TD4 starts the post-purge timing. The pump(s) remain on for 0.1 to 10 minutes then shut(s) off when TD4 times out.

High Limit, Low Water Flow, Low Gas Pressure, High Gas Pressure, Power Venter Interlock Faults

1. Electrical power to the gas valves, blower(s) and optional power venter will be interrupted if any safety is tripped.

2. The manual reset high limit can be reset by depressing the reset button on the left jacket panel.

Low Air (Blocked Flue/Air Inlet)

• The pressure switch will monitor blower airﬂ ow.

• Air monitoring will begin at pre-purge. If a low air

condition is present power will not be supplied to the FSM. The blower(s) will remain on.

Ignition Trial:

1. Blower delay timer TD1 times out and the ﬂ ame sense module, FSM, is energized.

2. The FSM starts the 10-second ignition trial, energizing relay R7, the pilot solenoid valve and the spark generator.

3. The pilot valve and spark generator are energized for the 10-second ignition trial. When the pilot ﬂ ame is sensed, the FSM sends 24VAC to its MV terminal energizing the safety and low ﬁ re-side of the main solenoid valves and relay R8, de-energizing R7 and the spark generator.

OPERATION SEQUENCE, 2 STAGE OPTION L600 through L2300

Note: Refer to the wiring diagram included with the unit for further control system info.

POWER ON:

Demand for Heat:

1. The low operator switch closes, energizing pump delay timer TD4 and the water pump(s).

2. Water ﬂ ow through the unit closes the water ﬂ ow switch contacts energizing blower delay timer TD3.

3. The system checks all primary limit(s) and other inter-locks before starting pre-purge. The unit will not start if any switch is open.

Prepurge:

1. Blower delay timer TD3 energizes the low speed windings of the blower(s).

2. Once sufficient air pressure in the combustion chamber is sensed the pressure switch closes allowing the blower delay timer TD1 to start a 10 second pre-purge.

Main Burner

Once the pilot is proven, the FSM sends 24VAC to its MV terminal energizing the safety and low-ﬁ re side of the main solenoid valves.

Normal Operation

• Staging is controlled by the return water aquastat. Relays R2 and R2R are energized by the return water aquastat when more heat input is required. The hi-speed windings of the blower(s) are energized.

• Relay R9 is energized when the hi-ﬁ re pressure switch senses adequate air pressure to sustain hi-fire combustion. R9 energizes the hi-ﬁ re side of the main solenoid valve.

• Stage 1 will operate ﬁ rst and last.

NOTE: For a change from stage 1 to 2, a 30 second time delay is provided in the pressure switch switching circuit. The time delay TD6 provides a hold state that allows the blower to reach full speed and close the high ﬁ re pressure switch before it is energized to conﬁ rm proper air ﬂ ow.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 26

Demand Satisﬁ ed:

1. When the demand for heat is satisfied the low operator switch will open, de-energizing relays R2, R2R, R8, R9, TD1, TD3, TD4, TD6, the FSM, and the pilot, main and safety solenoid valves. The pilot and main ﬂ ames are extinguished.

2. The blower delay timer TD3 starts the 80 second post-purge timing. The blower(s) shut(s) off when TD3 times out.

3. The pump delay timer TD4 starts the post-purge timing. The pump(s) remain on for 0.1 to 10 minutes then shut(s) off when TD4 times out.

High Limit, Low Water Flow, Low Gas Pressure, High Gas Pressure, Power Venter Interlock Faults

1. Electrical power to the gas valves, blower(s) and power venter will be interrupted if any safety is tripped.

2. The manual reset high limit can be reset by depressing the reset button on the left jacket panel.

Low Air (Blocked Flue/Air Inlet)

• The pressure switches will monitor blower airﬂ ow.

• Air monitoring will begin at pre-purge. If a low air

condition is present, power will not be supplied to the FSM. The blower(s) will remain on.

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN MARCHE

A. This appliance is equipped with an ignition device

which automatically lights the pilot. Do not try to light the pilot by hand.

Cet appareil est muni d’un dispositif d’allumage qui

allume automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse manuellement.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next to the ﬂ oor because some gas is heavier than air and will settle on the ﬂ oor.

DANGER: Propane gas may not always be detected by smell. Propane gas is heavier than air and can collect in low areas.

Propane gas can ignite or explode if an ignition source is present and result in death, serious injury and property damage!

FOR YOUR SAFETY

• Have only qualiﬁ ed licensed professionals install, service and maintain this appliance and your gas system in accordance with all applicable codes.

• Install a nationally listed combustible gas detector(s) in your home.

• If you suspect a leak:

1. Have everyone leave the building immediately.

2. Do not attempt to light any appliance.

3. Do not touch any electrical or electronic switches in the building.

4. Do not use any phone in the building.

5. Call your gas supplier from a phone outside of the building.

6. If you cannot reach your gas supplier call the ﬁ re department.

AVANT DE FAIRE FONCTIONNER, reniﬂ ez tout autour de l’appareil pour déceler une odeur de gaz. Reniﬂ ez près du plancher, car certains gaz sont plus lourds que l’air et peuvent s’accumuler au niveau du sol.

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 gaz depuis un voisin. Suives les instructions du fournisseur.

• Si vous ne pouvez rejoindre le fournisseur, appelez le service de incendies.

C. Do not use this appliance if any part has been

under water. Immediately call a qualiﬁ ed service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water.

N’utilisez pas cet appareil s’il a été plongé dans

l’eau, même partiellement. Faites inspecter l’appareil par un tecnicien qualifié et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans l’eau.

CAUTION: To prevent being burned, stand clear of the boiler during ignition and do not touch any hot metal parts.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 27

OPERATING INSTRUCTIONS

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”.

2. Set the operating control or thermostat to off or its lowest setting.

3. Turn off all electric power to the appliance.

Close the main manual gas shut-off valve, Figure 16.

5. Wait ﬁ ve (5) minutes to clear out any gas. Then smell for gas, including near the ﬂ oor. If you smell gas, STOP! Follow “B” in the safety information above (to the left) on this label. If you do not smell gas, go to the next step.

6. Remove the upper front jacket panel.

7. Turn the knob on the pilot valve to off, Figure 18.

8. Turn the knob on the main gas valve to off, 225 through 400 models, Figure 18. On 600 through 2300 models close the manual shutoff valve located in the control compartment, Figure 19.

9. Remove the plug(s) from the pilot and manifold pressure ﬁ tting(s), Figure 19.

10. Connect a manometer having a minimum capacity of 20 in, 508 mm W.C. to the pilot and manifold pressure fittings, Figure 19. Make sure the gas supply piping has been purged of air and all gas joints up to the gas valve have been thoroughly checked for leaks.

11. Remove plug(s) from the differential air pressure taps, Figure 17.

12. Connect both sides of a manometer to the pressure switch tee, Figure 17, going to one of the pressure switches.

Figure 18 - Pilot Valve (All Models) Main Valve (225 - 400 Models)

Figure 19 - Manual Valve & Manifold Pressure Tap

16. The pilot should automatically light. Do not try to light the pilot by hand!

17. The pilot pressures should match those listed in Table 20. To adjust the pilot gas pressure see the “PILOT ADJUSTMENT” instructions in the “CHECKING AND ADJUSTMENTS” section.

18. Distinguish pilot.

19. Turn the knob on the main gas valve to on, 225 through 400 models, Figure 18. On 600 through 2300 models open the manual shutoff valve located in the control compartment, Figure 19.

20. Recycle boiler.

21. The manifold pressures should match those listed in Table 20. To adjust the manifold gas pressure see the “GAS PRESSURE ADJUSTMENT” instructions in the “CHECKING AND ADJUSTMENTS” section.

22. Replace the upper front jacket panel.

23. Check all safety switches for proper operation before placing boiler on-line.

Required Gas Pressure

Provide gas supply pressure at inlet to boiler gas train as follows: LP Nat

Minimum (in W.C.) 11 6 Maximum (in W.C.) 14 14

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 control or thermostat to the desired setting.

15. With the unit operating at high purge the differential air pressure should match those listed in Table

15. To adjust the differential air pressure see the “AIRFLOW ADJUSTMENT” instructions in the “CHECKING AND ADJUSTMENTS” section.

Measure pressure when the boiler is ﬁ ring at full rate. Low gas pressure could indicate undersized gas line or insufﬁ cient gas supply.

Static and operating gas pressure required at the gas valve inlet is between 6" W.C. and 14" W.C. for natural gas and 11" W.C. and 14" W.C. for propane. If the gas pressure is above this limit, a lock-up style regulator suitable for dead end service such as an Equimeter or Fisher must be installed to prevent increase (creep) of gas pressure when the units are not operating. This pressure regulator (supplied by others) may be installed at the service entrance to each unit or a “master” regulator sized to handle multiple units may be utilized. Consult local gas utility or regulator manufacturer for recommendations to meet speciﬁ c job site requirements.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 28

Table 20 - Pilot & Manifold Pressures

On/Off inches W.C. mm W.C. Pilot - NG 2.5 ± .3 63.5 ± 7.6 Pilot - LP 7.0 ± 2 177.0 ± 50.0 Low Fire inches W.C. mm W.C. Manifold - NG 1.4 ± .2 35.5 ± 5.0 Manifold - LP 4.0 ± .5 101.6 ± 12.7 High Fire inches W.C. mm W.C. Manifold - NG 2.5 ± .2 63.5 ± 5.0 Manifold - LP 9.3 ± .3 236.2 ± 7.6

Table 21 - Combustion Readings

Natural Fuel Propane Fuel

7.0 – 7.5 (low) 8.2 – 8.8 (low)

CO2%

7.8 – 8.5 (high) 9.2 – 9.9 (high)

8.3 – 7.6 (low) 8.3 – 7.6 (low)

O2%

7.0 – 5.8 (high) 7.0 – 5.8 (high)

Instructions De Mise En Marche

1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion supérieure de cette étiquette.

2. Réglez le thermostat à la température la plus basse.

3. Coupez l’alimentation électrique de l’appareil.

4. Cet appareil est muni d’un dispositif d’allumage qui allume automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse manuellement.

5. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.

6. Attendre cinq (5) minutes pour laisser échapper tout le gaz. Reniﬂ ez tout autour de l’appareil, y compris près du plancher, pour déceler une odeur de gaz. Si vous sentez une odeur de gaz, ARRÊTEZ! Passez à l’étape B des instructions de sécurité sur la portion supérieure de cette étiquette. S’il n’y a pas d’odeur de gaz, passez à l’étape suivante.

7. Ouver la vanne manuelle d’arrêt d’alimintation de gaz.

8. Mettez l’appareil sous tension.

9. Réglez le thermostat à la température désirée.

10. Si l’appareil ne se met pas en marche, suivez les instructions intitulées couper l’admission de gaz de l’appareil et appelez un technicien qualiﬁ é ou le fournisseur de gaz.

To Turn Off Gas To Appliance

1. Set the operating control or thermostat to its lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Close the manual main valves.

COUPER L’ADMISSION DE GAZ DE L’APPAREIL

1. Réglez le thermostat à la température la plus basse.

2. Coupez l’alimentation électrique de l’appareil s’il faut procéder à l’entretien.

3. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.

CHECKING & ADJUSTMENTS

1. With the burners in operation, close the manual shutoff valve in the gas supply line. As soon as the main burner ﬂ ames go out, open the manual shutoff valve. A normal ignition sequence should take place. If the burners fail to light, the gas valves will close and the system will go into a 5-minute lock out period. The ﬂ ame sense module will then make a second ignition attempt. If the unit won’t light ensure that the gas piping is fully purged of air. Inspect the ignition system and ensure that it is operating properly.

2. To test the ignition safety shutoff device, close the manual shutoff valve in the gas supply line. Within 5 seconds of main burner ﬂ ame extinction, the main gas valve solenoid should close with an audible noise. After 10 seconds the module should lockout and the trial for ignition end. After 5 minutes a second trial for ignition should occur. Open the manual shutoff valve in the gas supply line and reset the ignition control system. A normal ignition sequence should take place.

3. With the burners in operation, interrupt the power to the control circuit by turning down the operator or thermostat. The boiler/water heater should shut down. Reset the operating control or thermostat. A normal ignition sequence should follow.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 29

Input Rate, Natural Gas

Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 5000 ft, 1524 m. At elevations above 5000 ft, 1524 m, input ratings should be reduced by 4% for each additional 1000 ft, 305 m.

Check the input rate as follows:

1. Turn off all other gas appliances that use the same gas meter as the boiler/water heater.

2. Call your gas supplier and ask for the heating value of the gas.

3. Connect a ﬂ ue gas analyzer to the vent pipe.

4. Start the boiler/water heater and let it run for 15 minutes.

5. Using the gas meter and a stopwatch, clock the time that it takes to burn 10 ft

, 0.28 m3 of gas and

divide this time by 10.

6. Insert the heating value and the time, in seconds, into the formula below.

Input = (heating value, Btu/hr)(3600)/(time, seconds)

8. If the computed rate deviates by more than 5% from the rated input value of the unit adjust the manifold pressure accordingly. DO NOT adjust the manifold pressure by more than 5%. If a proper rate cannot be maintained without adjusting the manifold pressure beyond the 5% limit, the main burner oriﬁ ces must be replaced. If the input rate is too low, go to the next lager size of main burner oriﬁ ces. If the input rate is too high, go to the next smaller size.

CAUTION: Never increase the input of the boiler/ water heater above that for which it is rated. Doing so can cause premature failure of the unit!

For L600-L2300:

1. Remove the upper front jacket panel.

2. Turn off main burner gas ﬂ ow by turning the manual gas valve(s) in the control compartment to the off position, see Figure 19.

3. Observe the pilot flame through one of the observation ports located at the left and right ends of the unit.

Pilot pressures will be set at the factory. However, if it is necessary to adjust the pilot pressure to match those in Table 20, take the following steps:

1. Remove the upper front jacket panel.

2. Remove the 1/8" plug from the pilot pressure test port and connect a 20 in, 508 mm W.C. manometer to it, see Figure 18.

3. Remove the gas pressure regulator cap from the pilot valve. See Figure 18 for the location of the regulator and cap.

4. Use a 3/32 hex wrench to turn the pressure regulator adjustment screw clockwise to increase the pilot pressure and counter clockwise to decrease it.

5. Replace the pressure regulator adjustment screw cap.

Gas Pressure Adjustment

CAUTION: The maximum inlet gas pressure listed on the rating plate must not be exceeded or damage to the boiler/water heater may occur voiding the warranty!

The minimum supply pressure listed on the rating plate is for input adjustment.

Pilot Adjustment

The pilot burner is actually an isolated main burner that’s controlled by a separate pilot valve. Pilot pressure settings are as shown in Table 20. These pressures are measured at the pilot pressure valve, see Figure 19. Tables 13 and 14 above list the ﬁ ring mode that is associated with each stage.

To view the pilot without main burner operation, take the following steps:

For L225-L400:

1. Remove the upper front jacket panel.

2. Turn off main burner gas ﬂ ow by turning the main burner gas valve knob to the off position, Figure 18.

3. Observe the pilot flame through one of the observation ports located at the left and right ends of the unit.

The manifold pressures should match those listed in Table 20. Pressures should not vary outside these ranges. Each gas valve pressure regulator has been preset at the factory. If neccessary, adjust the gas pressures to achieve the combustion results show in Table 21.

If adjustments are necessary the following steps must be followed:

1. Remove the 1/8" plug from the manifold pressure

tap valve. Connect 20 in, 508 mm W.C. manometers to it, see Figure 19.

2. Remove the regulator adjustment screw cap from the main gas valve.

3. Rotate the regulator adjustment screw clockwise to increase the manifold pressure, counter clockwise to decrease it.

4. Replace the regulator adjustment screw cap and manual shut off valve pressure tap plug.

CAUTION: Never force the regulator adjustment screw beyond the stop limits or damage to the regulator will occur!

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 30

PROPANE GAS: Optimum results are obtained when the boiler/water heater is operated with the manifold pressure(s) set per Table 20. If the manifold pressure is off by more than 5% adjust it according to steps 1 through 4 above.

Airﬂ ow Adjustment

1. Remove the upper front jacket panel.

2. Connect both sides of a manometer to the pressure switch tee, Figure 17, going to one of the pressure switches.

3. With the unit operating at high ﬁ re the differential pressure should match those listed in Table 15. Do not change air pressure in lower stages.

CONTROL DESCRIPTION

Boiler Thermostat

If a thermostat is to be used to control the boiler always follow the instructions included with the thermostat. Proper location of the thermostat will ensure efﬁ cient trouble-free operation of the boiler. Mount the thermostat to an inside wall at a height approximately ﬁ ve feet above the ﬂ oor.

The water heater high limit should be set a minimum of 20˚F, 11˚C higher than the operating control. Refer to the HOT WATER SUPPLY section for the proper supply water temperature.

Flow Switch

A ﬂ ow switch is provided in the water outlet piping to prevent the boiler/water heater from firing without adequate water ﬂ ow through the heat exchanger.

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. Wire the switch and any external controls in series to the “Interlock” contacts in the control box, see the wiring diagrams included with the unit for details. Ensure that the low water cutoff device(s) will function properly.

Flame Sense Module

The ﬂ ame sense module is located in the control box. It is an intermittent pilot control device that controls the pilot gas ﬂ ow, spark energy to ignite the pilot gas and the main valve(s) once pilot ignition has been proven.

Avoid placing the thermostat in areas that will not provide an accurate measurement of the room temperature. Locating the thermostat behind a door, in an alcove, close to a source of thermal radiation or in a drafty area will cause poor or sporadic heating.

For a thermostat that employs an adjustable heat anticipator, adjust the anticipator to match the current measured in the thermostat circuit. An increased anticipator setting may be necessary if the unit cycles frequently. If the room temperature over-shoots the thermostat setting, reduce the anticipator setting.

Operating Control

The preferred control setting for potable hot water is 130˚F, 54˚C. The operating control should be set to the lowest setting that will satisfy the consumer’s needs.

WARNING: Setting the thermostat or operation control too high can result in scalding resulting in severe personal injury!

High Limit (Aquastat)

The high limit is located in the top control area of the boiler/water heater. A remote capillary bulb is run to a well on the outlet side of the supply header. The high limit can be reset by depressing the reset button on the left jacket panel.

Two ﬂ ame failure alarm terminals are provided on the ﬂ ame sense module. For CSD-1 these terminals are utilized to shut the unit down in case of ﬂ ame failure. The two terminals are connected to a lockout control module located in the control box. This lockout control module contains a magnetic latch relay that requires manual reset when de-energized. To reset after ﬂ ame failure, push and release the momentary contact switch located on the left jacket panel.

Relay Board

The relay board is located in the control panel. It provides sequencing of the gas valves and blower(s) based on the staging controller's input. It also provides the following time delays for proper unit operation:

• A 10 second prepurge when stage 1 is energized.

• A 30 second pressure switch sequencing delay when the blowers switch from low ﬁ re to high ﬁ re. The delay enables the blower to come up to speed before the high pressure side of the pressure switch conﬁ rms proper air ﬂ ow.

These time delays are set within the separate time delay board connected to the relay board.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 31

Gas Pressure Switch

Optional low and/or high-pressure gas pressure switches will shut down the 24V circuit if excessively high or low gas pressure exists in the gas train or supply piping.

MAINTENANCE

WARNING: Disconnect electrical power and close the manual gas shut off valve before performing maintenance or severe personal injury may result!

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, exposure to hazardous materials or loss of life. Installation and service must be performed by a qualiﬁ ed installer, service agency or the gas supplier who must read and follow the supplied instructions before installing, servicing or removing this boiler. This boiler contains crystalline silica materials that have been identified as carcinogenic or possibly carcinogenic to humans when inhaled.

AVERTISSEMENT: Une installation, un réglage, une modiﬁ cation, une réparation ou un entretien non comforme aux normes peut entraîner des dommages matériels, des blessures, exposition à des matières dangereuses ou la mort. L’installation et l’entretien doivent être effectués par un installateur ou un service d’entretien qualiﬁ é ou le fournisseur de gaz qui doivent avoir lu les instructions fournies avant de faire l’installation, l’entretien ou l’enlèvement de la chaudière et les respecter, Cette chaudière contient des matériaux qui ont été identiﬁ és comme étant cancérogènes ou pouvant l’ être.

CAUTION: Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment can damage the boiler/water heater!

WARNING: The ceramic combustion chamber contains crystalline silica. Wear a tightly ﬁ tted dust mask when removing the burners or heat exchanger to prevent inhalation of airborne fibers. Crystalline silica fibers have been identified as carcinogenic, or possibly carcinogenic when inhaled.

The boiler/water heater should be cleaned and inspected once a year, before each heating season. Make sure that the burner and ignition components are free from dust, soot, dirt, corrosion or other deposits that would impair the boiler/water heater ‘s performance. Refer to page 36 for component identiﬁ cation.

Burner Inspection And Removal - Figure 20

1. Close the manual shutoff valves in the gas supply

lines and turn off electrical power to the boiler/water heater.

2. Remove the front jacket panels.

3. Disconnect the manifold gas piping at the ground

joint union(s). Also disconnect the pressure sensing lines, pilot tubing and ignition and sensing leads.

4. Remove the manifold(s).

5. Remove the burner(s) from the lower front combus-

tion chamber panel.

6. Inspect the burners for damage or signs of

deterioration. Use a brush or compressed air to remove any debris from the burner ports.

7. DO NOT install a damaged or badly corroded

burner replace it.

8. Install the burner(s) making sure that the burner

gasket is not torn or deteriorated. If it is replace it.

9. Reassemble the unit following the removal steps in

reverse order.

Heat Exchanger Inspection - Figure 20

1. Close the manual shutoff valve in the gas supply

line and turn off electrical power to the boiler/water heater.

2. Remove the jacket front panels.

3. Disconnect the gas piping at the ground joint

union(s). Also disconnect the pressure sensing lines, pilot tubing and ignition and sensing leads.

4. Remove the 1/4 inch nuts and washers holding the

upper combustion chamber front panel in place and carefully remove it.

5. Inspect the inside and outside of the heat exchanger

for signs of damage, sooting or corrosion.

6. The outside surfaces of the copper tubes should be

free of any soot deposits. A slight black smudge is normal with some types of gases. Black soot indicates poor combustion. Green deposits indicate condensation due to low return water temperatures. In either case the heat exchanger must be cleaned thoroughly and the problem resolved before the boiler/water heater is returned to service

7. If there are no signs of damage, sooting or corrosion

reassemble the unit following the previous steps in reverse order.

8. A badly corroded or damaged heat exchanger must

be replaced, see the Heat Exchanger Removal section.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 32

Heat Exchanger Removal, Cleaning & Replacement See Figure 20

1. Close the shut off valves in the inlet and outlet piping. On heating systems close the system ﬁ ll valve and relieve the system pressure from the boiler by carefully lifting the relief valve or opening the drain valve.

2. Drain the boiler/water heater and disconnect it from the system piping.

3. Remove the inlet/outlet and return headers.

4. Remove the jacket front panels.

5. Loosen, 4 turns, but don’t remove the 6 screws, (3 on each side) holding the heat exchanger upper rails in place, Figure 21.

6. Disconnect the gas piping at the ground joint unions. Also disconnect the pressure sensing lines, pilot tubing and ignition and sensing leads.

7. Remove the upper partition panel, 1050 through 2300 models.

8. Remove the 1/4 inch nuts and washers holding the upper combustion chamber front panel in place and carefully remove it.

9. Carefully slide the heat exchanger out of the unit.

10. Remove the “V” bafﬂ e straps and “V” bafﬂ es.

11. Thoroughly inspect the heat exchanger for signs of damage. If there is no damage, clean the heat exchanger with water from a high-pressure hose. Use a soft bristle brush if necessary.

CAUTION: Never clean the heat exchanger while it’s in the boiler/water heater or the combustion chamber will be destroyed!

12. Sagging or distorted heat exchanger tubes are an indication of low water ﬂ ow through the system. A leaking or otherwise damaged heat exchanger must be replaced and the condition that caused the damage resolved before the boiler/water heater is returned to service.

13. If the heat exchanger isn’t damaged rewire the heat exchanger baffles in place and slide the heat exchanger back into the unit.

14. Reinstall all of the other components in the reverse order of their removal.

15. The torque values for the bolts that secure the removable headers are 17-20 ft lbs. Once bolts have been started and secured the tightening sequence is as follows:

1) Middle Top

2) Middle Botom

3) Right Top

4) Left Bottom

5) Left Top

6) Right Bottom

Figure 20-Burner and Heat Exchanger Servicing

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 33

Figure 21- Heat Exchanger Upper Rail Screws

Vent System

Thoroughly inspect the vent system for any signs of blockage, corrosion or leakage. Immediately replace any unsound vent system piping.

Controls

Use the “BOILER/WATER HEATER OPERATION” and “CHECKING AND ADJUSTMENTS” sections of this manual for reference.

1. Check the thermostat or operating controls for proper operation.

2. A ﬂ oat type low water cutoff device must be ﬂ ushed out per the manufacturers’ instructions. The probe on a probe low water cut off must be cleaned and inspected per the manufacturers’ instructions. Ensure that the low water cutoffs operate properly. If not, replace them.

3. The ﬂ ow switch contacts must be open when water ﬂ ow is not present.

4. The relief valve should not weep or discharge water at normal system pressure. If it does contact a qualiﬁ ed service technician to have it inspected. NEVER try to clean or repair the relief valve! If the valve fails to operate properly, have it replaced!

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. The water temperature should never exceed the maximum set point of 240°F, 116°C. The aquastat high limit cannot be repaired. If it fails to function properly replace it.

6. Visually check the pilot and main burner ﬂ ames to ensure proper operation, see Figure 22.

WARNING: A yellow, ﬂ oating ﬂ ame indicates a lack of combustion air. A lifting ﬂ ame 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!

Figure 22 - Pilot & Main Burner Flame

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 34

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 • Reset limit or control or resolve

control/interlock open problem as applicable

• If not resolved, check wiring and condition of limit

Low water cutoff open • Check circulating pump

• Check pump contact in control box

• Check LWCO wiring and condition No Power to Pump Pump contact not wired Wire pump contact in control box Pump malfunctioning Replace pump Defective pump timer TD4 Replace pump timer TD4 No Power to Optional Power Venter Power venter not wired to Wire power venter as shown in

external power connection diagram Power venter fault Replace power venter Power Venter On, No Action Power venter interlock not wired Wire power venter interlock as

From Unit shown in connection diagram No Power To Blower(s) Blower(s) not plugged in Plug in blower(s) Defective blower timer TD3 Replace Blower Timer TD3 Blower(s) malfunctioning Replace blower(s) Unit Does Not Spark Incorrect spark gap or shorted Properly adjust igniter gap or

igniter lead correct short Bad ground on ﬂ ame sense Check ground connections,

module adjust as necessary Defective ﬂ ame sense module Replace ﬂ ame sense module Low air (blocked ﬂ ue/inlet) • If condition exists, check inlet,

condition ﬂ ue & chimney for blockage

• Check combustion air/ventilation openings in space

• Check inlet air ﬁ lter, clean/replace as necessary

Spark generator fault check spark generator wiring Defective air purge timer TD1 Replace Timer TD1 Unit Sparks But Will Not Fire Low gas pressure Check gas supply pressure during

ignition trial, adjust as necessary Pilot valve manual knob closed Open pilot valve manual knob Pilot valve not wired Connect pilot valve wires Low pilot pressure Check pilot pressure, adjust as

necessay Pilot valve malfunctioning Replace pilot valve

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 ame sense module Replace ﬂ ame sense module Manual valve(s) in air plenum Remove upper front jacket panel,

closed open manual valve(s) Main valve(s) not wired Wire main valve(s) Low manifold pressure Check manifold pressure during

ignition trial, adjust as necessary Main valve(s) malfunctioning Replace main valve(s) Insufﬁ cient Heating Operating control set too low Increase control temperature

setting Unit Consistently Shuts Down High limit set too low Increase high limit setting

On High Limit Bad Combustion Insufﬁ cient air • Check CO & CO2, adjust blower

(High CO, Yellow Flames) inlet damper(s) to increase airﬂ ow

• Check for plenum air leakage from lower front jacket panel seams, repair as necessary

Dirty inlet air ﬁ lter Remove, inspect and clean inlet air ﬁ lter as necessary

Too much air Check CO & CO2, adjust blower inlet damper(s) to decrease airﬂ ow

Gas Flow Shuts Off During Low air (blocked ﬂ ue/inlet) • If condition exists,check inlet, Operation (Blowers Remain On) condition ﬂ ue, chimney for blockage

• Check combustion air/ventilation openings in space

• Check inlet air ﬁ lter, clean/replace as necessary

• Check pressure switch for correct setting

Figure 23 - Exploded View

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 36

RIOM-23-REV. B

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 37

SERVICE AND REPLACEMENT PARTS LIST (MODELS 225-2300)

Ref # Name of Part

1 Jacket Lower Front Panel 70-2716 1 1 70-2717 1 70-2718 1 70-2719 1 70-2721 1 70-2722 1 1 70-2723 1 70-2724 1 70-2725 1 Jacket Lower Front Panel (SS)

Handle 20-0050 1 1 1 1 1 1 1 1 1 1 1 Deckplate 20-0062 1 1 1 1 1 1 1 2 Jacket Upper Front Panel 70-3101 1 1 70-3102 1 70-3103 1 70-3104 1 70-3106 1 70-3107 1 1 70-3108 1 70-3109 1 70-3110 1 Jacket Upper Front Panel (SS)

3 Jacket Left Panel 03-2155 1 1 1 1 1 1 1 03-1822 1 1 1 1 Jacket Left Panel (SS)

4 Junction Box Assembly 70-3113 1 1 1 Junction Box Assembly 5 Junction Box Cover 03-2036 1 1 1 1 1 1 1 1 1 1 1 6 Jacket Right Panel 03-2158 1 1 1 1 1 03-2159 1 1 03-1825 1 1 1 1 Jacket Right Panel (SS)

7 Combustion Air Inlet Assembly (Indoor) 70-2744 1 1 1 70-2746 1 1 70-2748 1 70-2749 1 1 1 1 1 Combustion Air Inlet Assembly (Outdoor) 70-2820 1 1 1 70-2821 1 1 70-2822 1 70-2823 1 1 1 1 1 8 Filter (Indoor) 09-0488 1 1 1 09-0489 1 1 09-0497 1 09-0498 1 1 1 1 1 Filter (Outdoor) 09-0490 1 1 1 1 1 09-0491 1 1 1 1 1 1

Part # 225 300 400 600 750 1050 1200 1480 1650 1970 2300

70-2716.1 70-2717.1 70-2718.1 70-2719.1 70-2721.1 70-2722.1 70-2723.1 70-2724.1 70-2725.1

70-3101.1 70-3102.1 70-3103.1 70-3104.1 70-3106.1 70-3107.1 70-3108.1 70-3109.1 70-3110.1

03-2155.1 03-1822.1

70-3113.1

03-2158.1 03-2159.1 03-1825.1

1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 38

Ref # Name of Part

9 Jacket Rear Panel 03-1811 1 1 03-1812 1 03-1813 1 03-1814 1 03-1816 1 03-1817 1 1 03-1818 1 03-1819 1 03-1820 1 Jacket Rear Panel (SS)

11 Jacket Top Panel 03-1801 1 1 03-1802 1 03-1803 1 03-1804 1 03-1806 1 03-1807 1 1 03-1808 1 03-1809 1 03-1810 1 Jacket Top Panel (SS)

Jacket Top Panel (Outdoor) 70-2969 1 1 70-2970 1 70-2971 1 70-2972 1 70-2974 1 70-2975 1 1 70-2976 1 70-2977 1 70-2978 1 NS Outdoor Hood Assembly 70-2951 1 1 70-2952 1 70-2953 1 70-2954 1 70-2956 1 70-2957 1 1 1 70-2958 1 1 12 Base Panel Legs 03-1862 2 2 2 2 2 4 4 4 4 4 4 13 Jacket Base Panel 03-1847 1 1 03-1848 1 03-1849 1 03-1850 1 03-1852 1 03-1853 1 1 03-1854 1 03-1855 1 03-1856 1

Part # 225 300 400 600 750 1050 1200 1480 1650 1970 2300

03-1811.1 03-1812.1 03-1813.1 03-1814.1 03-1816.1 03-1817.1 03-1818.1 03-1819.1 03-1820.1

03-1801.1 03-1802.1 03-1803.1 03-1804.1 03-1806.1 03-1807.1 03-1808.1 03-1809.1 03-1810.1

1 1 1 1 1 1 1 1 1 1 1

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 39

Ref # Name of Part

14 Combustion Chamber Base Panel 03-1974 1 1 03-1975 1 03-1976 1 03-1977 1 03-1979 1 03-1980 1 1 03-1981 1 03-1982 1 03-1983 1 Cerablanket Insulation 05-0103 3 3 4 4 6 8 8 10 10 12 12 Manning Glass Insulation (per square foot) 05-0104 3 3 4 4 6 8 8 10 10 12 12 15 Combustion Chamber Lower Front Panel 03-2170 1 03-1962 1 03-1963 1 03-1964 1 03-1965 1 03-1967 1 03-2171 1 03-1968 1 03-1969 1 03-1970 1 03-1971 1 16 Combustion Chamber Upper Front Panel 70-2775 1 1 70-2776 1 70-2777 1 70-2778 1 70-2780 1 70-2781 1 1 70-2782 1 70-2783 1 70-2784 1 17 Comb Chamber Lower Left Side Panel 70-2772 1 1 1 1 1 1 1 1 1 1 1 Comb Chamber Lower Right Side Panel 70-2773 1 1 1 1 1 1 1 1 1 1 1 18 Comb Chamber Upper Left Side Panel 70-2770 1 1 1 1 1 1 1 1 1 1 1 Comb Chamber Upper Right Side Panel 70-2771 1 1 1 1 1 1 1 1 1 1 1 19 Heat Exchanger Guide Rail 03-1938 4 4 4 4 4 4 4 4 4 4 4 20 Combustion Chamber Rear Panel 03-1904 1 1 03-1905 1 03-1906 1 03-1907 1 03-1909 1 03-1910 1 1 03-1911 1 03-1912 1 03-1913 1 Manning Glass Insulation (per square foot) 05-0104 2 2 3 3 4 5 6 7 7 8 9 21 Combustion Chamber Top Panel 70-2750 1 1 70-2751 1 70-2752 1 70-2753 1 70-2755 1 70-2756 1 1 70-2757 1 70-2758 1 70-2759 1 Manning Glass Insulation (per square foot) 05-0104 4 4 5 6 7 10 12 13 13 17 18 22 Flue Box Wrapper Assembly 70-2798 1 1 70-2799 1 70-2800 1 70-2801 1 70-2803 1 70-2804 1 1 1 70-2805 1 1

Part # 225 300 400 600 750 1050 1200 1480 1650 1970 2300

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 40

Ref # Name of Part

23 Flue Outlet Assembly 70-3117 1 70-2736 1 70-2737 1 70-2738 1 70-2739 1 70-2741 1 70-2742 1 1

70-2743 1 1 24, 25, Tile Kit 05-0212 1 27 05-0202 1 05-0203 1 05-0204 1 05-0205 1 05-0207 1 05-0213 1 05-0208 1 05-0209 1 05-0210 1 05-0211 1 26 End Refractory Panel, Right 05-0058 1 1 1 1 1 1 1 1 1 1 1 End Refractory Panel, Left 05-0107 1 1 1 1 1 1 1 1 1 1 1 28 Manifold 10-0470 1 10-0465 1 10-0466 1 10-0467 1 10-0468 1 70-3087 1 70-3088 1 70-3089 1 70-3090 1 70-3091 1 70-3092 1 29 Main Oriﬁ ce, NG 10-0087 2 3 7 9 13 15 17 19 25 27 Main Oriﬁ ce, LP 10-0088 2 3 7 9 13 15 17 19 25 27 Main Oriﬁ ce, NG 10-0115 5 Main Oriﬁ ce, LP 10-0116 5 NS Pilot Oriﬁ ce, NG 10-0089 1 1 1 1 1 1 1 1 1 1 Pilot Oriﬁ ce, LP 10-0090 1 1 1 1 1 1 1 1 1 1 Pilot Oriﬁ ce, NG 10-0093 1 Pilot Oriﬁ ce, LP 10-0120 1 30 Burner Tube 10-0275 2 3 5 7 9 13 15 17 19 25 27 Burner Tube w/hole for Pressure Switch 70-2898 1 1 1 1 1 1 1 1 1 1 1 Pilot Tube Assembly (tubing and ﬁ ttings) 70-2896 1 1 1 1 1 1 1 1 1 1 1 NS Burner Gasket 06-0020 3 4 6 8 10 14 16 18 20 26 28 31 NS Ignition Cable Assembly 44-0056 1 1 1 1 1 1 1 1 1 1 1 NS Heat Exchanger Assembly (Copper) 70-3001 1 1 (Cast Iron Headers) 70-3002 1 70-3003 1 70-3004 1 70-3006 1 70-3007 1 70-2832 1 70-2833 1 70-2834 1 70-2835 1 Heat Exchanger Assembly (Copper) 70-3023 1 1 (Bronze Headers) 70-3024 1 70-3025 1 70-3026 1 70-3028 1 70-3029 1 70-2852 1 70-2853 1 70-2854 1 70-2855 1

Spark Ignitor (*prior to 0205 - must order cable 44-0056)

Part # 225 300 400 600 750 1050 1200 1480 1650 1970 2300

70-2742.1

16-0327* 1 1 1 1 1 1 1 1 1 1 1

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 41

Ref # Name of Part

NS Heat Exchanger Assembly (Cupronickel) 70-3012 1 1 (Cast Iron Headers) 70-3013 1 70-3014 1 70-3015 1 70-3017 1 70-3018 1 70-2842 1 70-2843 1 70-2844 1 70-2845 1 Heat Exchanger Assembly (Cupronickel) 70-3034 1 1 (Bronze Headers) 70-3035 1 70-3036 1 70-3037 1 70-3039 1 70-3040 1 70-2862 1 70-2863 1 70-2864 1 70-2865 1 32 Tube Bundle (Copper) 70-3053 1 1 70-3054 1 70-3055 1 70-3056 1 70-3058 1 70-3059 1 70-2907 1 70-2908 1 70-2909 1 70-2910 1 Tube Bundle (Cupronickel) 70-3064 1 1 70-3065 1 70-3066 1 70-3067 1 70-3069 1 70-3070 1 70-2917 1 70-2918 1 70-2919 1 70-2920 1 34 V Bafﬂ e Hold-Down 03-2021 2 2 2 2 4 4 4 4 6 6 6 NS Heat Exchanger Support Channel 03-2022 1 03-2023 1 03-2024 1 NS Tube Replacement Assembly 70-3080 2 2 70-3081 2 70-3082 2 70-3083 2 70-3085 2 70-3086 2 36 O Ring, Inlet/Outlet & Return Headers 06-0001 16 16 16 16 16 16 16 20 20 20 20 37 Stud, Inlet/Outlet & Return Headers 57-0220 12 12 12 12 12 12 12 12 12 12 12 38 Nut, Inlet/Outlet & Return Headers 57-0492 12 12 12 12 12 12 12 12 12 12 12 39 Return Header, Bronze

Return Header, Cast Iron

40 Inlet/Outlet Header, Bronze

Inlet/Outlet Header, Cast Iron

41 Blower, Fasco 7062 12-0013 1 1 1 1 1 Blower, Fasco 7083 12-0014 1 2 2 2 2 2 2

Part # 225 300 400 600 750 1050 1200 1480 1650 1970 2300

01-0011S

1 1 1

01-0004S

1 1 1 1

01-0018S

1 1 1 1

01-0009S

1 1 1

01-0002S

1 1 1 1

01-0023S

1 1 1 1

01-0010S

1 1 1

01-0003S

1 1 1 1

01-0019S

1 1 1 1

01-0008S

1 1 1

01-0001S

1 1 1 1

01-0022S

1 1 1 1

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 42

Ref # Name of Part

42 Combustion Air Damper Assembly 70-2818 1 1 1 1 1 70-2819 1 2 2 2 2 2 2 43 Low Pressure Switch (.30 WC) 14-0059 1 1 Low Pressure Switch (.42 WC) 11-0417 1 1 1 Low Pressure Switch (.58 WC) 14-0058 1 1 1 High Pressure Switch (.58 WC) 14-0058 1 1 1 High Pressure Switch (.80 WC) 14-0061 1 1 1 1 1 1 1 1 44 High Limit (LB) 14-0009 1 1 1 1 1 1 1 1 1 1 1 High Limit (LW) 14-0008 1 1 1 1 1 1 1 1 1 1 1 NS High Limit Well, 3/8 x 2 13-0104 1 1 1 1 1 1 1 1 1 1 1 NS Operator (LB) 14-0007 1 1 1 1 1 1 1 1 1 1 1 Operator (LW) 14-0010 1 1 1 1 1 1 1 1 1 1 1 Operator, T6031A (pool heater) 14-0003 1 1 1 1 1 1 1 1 1 1 1 45 Firing Valve, 3/4" 11-0461 1 1 1 Firing Valve, 1" 11-0456 2 2 Firing Valve, 1 1/4" 11-0457 2 2 Firing Valve, 1 1/2" 11-0458 2 2 2 Firing Valve, 2" 11-0459 2 NS Manual Pilot "B" Valve 11-0031 1 1 1 1 1 1 1 1 1 1 1 46 Main Gas Valve, VR8304 11-0056 1 1 1 Main Gas Valve, V8944B, 1" 11-0171 1 1 Main Gas Valve, V8944B, 1 1/4" 11-0172 1 1 Main Gas Valve, V8944B, 1 1/2" 11-0173 1 1 1 Main Gas Valve, V8944B, 2" 11-0174 1 47 Safety Valve, V48A, 1" 11-0151 1 1 Safety Valve, V48A, 1 1/4" 11-0152 1 1 Safety Valve, V48A, 1 1/2" 11-0153 1 1 1 Safety Valve, V48A, 2" 11-0154 1 48 Pilot Valve, VR8304 11-0056 1 1 1 1 1 1 1 1 1 1 1 Natural to LP Conversion Spring, On/Off 11-0001 1 1 1 1 1 1 1 1 1 1 1 Natural to LP Conversion Spring, 2 Stage 11-0007 1 1 1 1 1 1 1 1 1 1 1 49 Manual Shut Off Valve, 1" 11-0465 1 1 Manual Shut Off Valve, 1 1/4" 11-0466 1 1 Manual Shut Off Valve, 1 1/2" 11-0467 1 1 1 Manual Shut Off Valve, 2" 11-0454 1 50 Flame Sensor, UTC 1003 Ignition Module 16-0059 1 1 1 1 1 1 1 1 1 1 1 NS Alarm Board, (CSD-1) 16-0023 1 1 1 1 1 1 1 1 1 1 1 51 Spark Generator, Q652B 16-0008 1 1 1 1 1 1 1 1 1 1 1 52 Transformer, 75 VA 15-0008 1 1 1 1 1 1 1 1 1 1 1 NS Pressure Relief Valve 50# 30-0360 1 1 1 1 1 1 Pressure Relief Valve 50# 13-0006 1 1 Pressure Relief Valve 50# 30-0374 1 Pressure Relief Valve 50# 30-0379 1 1 Pressure Relief Valve 125# 13-0009 1 1 1 1 1 1 1 1 1 1 1 NS Tridicator (LB) 13-0305 1 1 1 1 1 1 1 Tridicator (LB) 13-0308 1 1 1 1 Thermometer (LB) 13-0302 2 2 2 2 2 2 2 1 1 1 1 Thermometer (LW) 13-0302 2 2 2 2 2 2 2 1 1 1 1 NS Flow Switch 14-0203 1 1 1 1 1 1 1 1 1 1 1 Flow Switch (Outdoor) 14-0205 1 1 1 1 1 1 1 1 1 1 1 Flow Switch (Potter) 14-0201 1 1 1 1 1 1 1 1 1 1 1 Flow Switch (Outdoor Potter) 14-0202 1 1 1 1 1 1 1 1 1 1 1 NS Thermometer Well, 3/8 x 3 13-0102 1 1 1 1 1 1 1 1 1 1 1 NS Harness Kit (J1, J3, J4, J5, J6, J7, J8, J9 & J10) 40-0313 1 1 1 1 1 1 1 1 1 1 1 Valve Control (J2) Harness (On/Off) 40-0302 1 1 1 1 1 1 1 1 1 1 1 Valve Control (J2) Harness (2 Stage) 40-0303 1 1 1 1 1 1 1 1 1 1 1 Jumper Harness 40-0311 1 1 1 1 1 1 1 1 1 1 1 54 Main Board Assembly (On/Off) 70-2927 1 1 1 1 1 1 1 1 1 1 1 Main Board Assembly (2 Stage) 70-2928 1 1 1 1 1 1 1 1 NS Main Board 40-0074 1 1 1 1 1 1 1 1 1 1 1 NS Timer Board 40-0075 1 1 1 1 1 1 1 1 1 1 1 NS LED Indicator Board 40-0076 1 1 1 1 1 1 1 1 1 1 1 NS Ribbon Cable 44-0057 1 1 1 1 1 1 1 1 1 1 1 NS Relay, 2P, (On/Off) 15-0121 5 5 5 5 5 5 5 5 5 5 5

Part # 225 300 400 600 750 1050 1200 1480 1650 1970 2300

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 43

Ref # Name of Part

NS Relay, 2P, (2 Stage) 15-0121 8 8 8 8 8 8 8 8 NS Relay, 3P , (On/Off or 2 Stage) 15-0123 1 1 1 1 1 1 1 1 1 1 1 NS Relay, 24AC 15-0113 1 1 1 1 1 1 1 1 1 1 1 NS Pump Contactor 1PH (C2) 15-0118 1 1 1 1 1 1 1 1 1 1 1 NS Pump Contactor 3PH 15-0111 1 1 1 1 1 1 1 1 1 1 1 NS Low Gas Pressure Switch (Manual Reset) 11-0410 1 1 1 1 1 1 1 1 1 1 1 NS High Gas Pressure Switch (Manual Reset) 11-0411 1 1 1 1 1 1 1 1 1 1 1 NS Terminal Block 7P 48-0153 1 1 1 1 1 1 1 1 1 1 1 NS Terminal Block 10P 48-0156 1 1 1 1 1 1 1 1 1 1 1 NS PVC Gasket Foam 66-0103 24 24 28 32 36 40 40 40 48 48 56 NS Rating Plate 82-0054 1 1 1 1 1 1 1 1 1 1 1 NS Overlay 82-0188 1 1 1 1 1 1 1 1 1 1 1 NS Paint 66-0013 1 1 1 1 1 1 1 1 1 1 1 NS Silicone 66-0151 1 1 1 1 1 1 1 1 1 1 1 NS Sidewall Vent Kit, HS1 Sidewall Vent Kit, HS2 Sidewall Vent Kit, HS3 Sidewall Vent Kit, HS4 Sidewall Vent Kit, HS5 NS Sidewall Vent Kit (with air intake hood), HS1 Sidewall Vent Kit (with air intake hood), HS2 Sidewall Vent Kit (with air intake hood), HS2 Sidewall Vent Kit (with air intake hood), HS3 Sidewall Vent Kit (with air intake hood), HS4 Sidewall Vent Kit (with air intake hood), HS4 Sidewall Vent Kit (with air intake hood), HS5 Vent Termination Hood 6" 09-0112 1 1 1 Vent Termination Hood 7" 09-0140 1 Vent Termination Hood 8" 09-0113 1 Vent Termination Hood 10" 09-0115 1 Vent Termination Hood 12" 09-0116 1 1 Vent Termination Hood 14" 09-0141 1 1 1 NS Air Intake Hood 6" 09-0102 1 1 1 Air Intake Hood 8" 09-0103 1 1 Air Intake Hood 10" 09-0104 1 Air Intake Hood 12" 09-0105 1 1 1 1 1 NS Barometric Damper 6" 09-0405 1 1 1 Barometric Damper 7" 09-0409 1 Barometric Damper 8" 09-0404 1 Barometric Damper 10" 09-0403 1 Barometric Damper 12" 09-0401 1 1 Barometric Damper 14" 09-0402 1 1 1 NS Rack Assembly 70-2886 1 1 1 70-2888 1 1 70-2890 1 70-2892 1 1 70-2894 1 1 1

Part # 225 300 400 600 750 1050 1200 1480 1650 1970 2300

12-0009K1

1 1

12-0010K1

1 1

12-0011K1

12-0001K1

1 1 1

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Page 44

START UP FORM

Date of Start Up: Job Name: Model #: Serial Number #: Boiler Model:  Dominator  LCD Company Name Fuel Type:  Natural Gas  Propane Tech Name System Type:  Hydronic  Domestic Phone Number

PRE-START UP CHECK LIST

 ANY VISUAL DAMAGE TO UNIT?  INLET FILTER INSTALLED AND CLEAN?

 PIPING PROPERLY CONNECTED?  ALL WIRING CONNECTED PROPERLY?

 SYSTEM FLOODED AND FLOWING?  BOILER PUMP PUMPING INTO INLET?

 BOILER CIRCULATOR WIRED?  COMBUSTION AIR PROVIDED?

 VENT/STACK CONNECTED?  PROPER SERVICE CLEARANCE PROVIDED?

 IS VENT VERTICAL THROUGH THE ROOF?  OUTDOOR AIR SENSOR INSTALLED/WIRED?

 IS VENT THROUGH THE WALL?  ARE UNITS RACKED?

 IS POWER VENT INSTALLED AND WIRED?  IS RACK ASSEMBLED TIGHTLY?

 SEALED COMBUSTION?  NO HOLES SCREWED INTO CABINET?

ELECTRICAL/WIRING/CONTROL

Boiler Supply Voltage External BMS System Boiler Pump Supply Voltage Utilize Boiler BTC For Control Voltage Down Stream of Transformer

BTC CONTROL SET UP: (Not all settings are used for every mode. (Dominator Series Only))

: Mode : Boiler Max : Purge ΔT : Boiler Target : Boiler Min : Tank Target : Boiler Diff LCD ONLY : Tank Diff : Intr-Stg Diff : Operator (STG1) : Outdoor Start : Intr-Stg On Dly :

High Operator (STG 2) : Boiler Start : Intr-Stg Off Dly : High Limit : Pump Purge

COMBUSTION/SAFETY REPORT

Page 45

FACTORY FIRE TEST REPORT: Low Fire High Fire

Manifold Gas Pressure: "W.C." Air Differential Pressure: "W.C."

These results are afﬁ xed to the side of the heater on a small white label.

FIELD TEST REPORT IN STAGE: 1 2 3 4 Manifold Gas Pressure: "W.C." Air Differential Pressure: "W.C." Pilot Manifold Pressure: "W.C." CO2: Stack Temp. (Net): Efﬁ ciency @ °F Inlet Temp. CO (PPM): O2: Stack Draft (Must Be Negative): Pilot Signal:

SAFETY CONTROL CHECK:

Wired and Operating

Properly @ Setting:

Failed To Operate

Comment To Right Comments

Low Water Cut Off (PPM): Factory Flow Switch Operating Control High Limit Differential Air Switch STG. 1, 2 Differential Air Switch STG. 3, 4 Blocked Flu Switch Flame Failure Lockout (CSD-1) Pump Delay Combustion Air Damper Power Vent Proving Switch Barometric Damper

COMMISSIONING THE UNIT

Customer Instructed? Yes No All Covers Replaced? Yes No Wiring Secure/Tight? Yes No Customer Given Manual? Yes No Cabinet Air Leaks? Yes No Gas Leaks Detected? Yes No Unit Cycled Min. of 15 X? Yes No Temp. Set Per Customer? Yes No Left Maintenance Instruction? Yes No

Commissioned By:

(Signature)

The delta T between the heaters inlet and outlet is critical to proper ﬂ ow. Before you leave the job site you must record the delta T. This reading should not exceed 35°F, 19.4°C or be lower than 20°F, 11.1°C.

Inlet Temperature

Outlet Temperature

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 46

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 nished grade, in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisﬁ ed:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall

horizontal vented gas fueled equipment, the installing plumber or gasﬁ tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasﬁ tter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualiﬁ ed licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl

space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent ﬂ oor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of

installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in

accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certiﬁ ed.

3. SIGNAGE. A metal or plastic identiﬁ cation plate shall be permanently mounted to the exterior of the

building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment

shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

WARNING: Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

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. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most

current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or

structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system

components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ﬂ ue gases, but identiﬁ es “special venting systems”, the following requirements shall be satisﬁ ed by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or

equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that

system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

WARNING: Improper venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

LIMITED WARRANTY

Boilers/Water Heaters

Industrial, Commercial and Other Non-Residential Use

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 Boiler (the “Product”) will be free from defects in material or workmanship for ten (10) years from the date of installation. Additional twenty one (21) year thermal shock warranty on heat exchanger. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the 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.

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 material or workmanship for ﬁ ve (5) years from the date of installation. Additional twenty one (21) year thermal warranty on heat exchanger. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the 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.

This limited warranty does not apply: (a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has

not been installed, maintained or operated in accordance with the furnished written instructions, or has been altered or modiﬁ ed in any way.

These include but not limited to:

• Excessive water hardness causing a lime build-up in the heat exchanger tubes is not a fault of the equipment and is not covered under the manufacturer’s warranty.

• Excessive pitting and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and is not covered by the manufacturer’s warranty. (See Installation Instructions for proper pump performance.)

• Chemical corrosion, no corrosive chemical (freon, dry cleaning chemicals, degreasing liquids, chlorine or any chemicals that produce hydrochloric acid) can be present in the boiler room as it rapidly destroys the heating equipment and voids the warranty.

• All copper ﬁ n boilers should not operate with a return water temperature less than 110°F, 43°C atmospheric combustion, 125°F, 52°C fan assist combustion. If a lower temperature is required, an external bypass should be installed to prevent condensation. The manufacturer’s warranty does not cover damage done by condensation.

(b) to any expenses, including labor or material, incurred during removal or reinstallation of the Product or parts

thereof.

surrounding the Product.

(d) to any workmanship of any installer of the Product; or to Products installed outside the continental United

States or Canada.

This limited warranty is conditional upon: (a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned

with prior written approval from the Manufacturer. All returns must be freight prepaid.

(b) determination in the reasonable opinion of the Manufacturer that there exists a defect in material or

workmanship.

Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION.

260 North Elm Street  Westﬁ eld, MA 01085 Phone: (413) 568-9571  Fax: (413) 568-9613

7555 Tranmere Drive  Mississauga, Ontario L5S 1L4 Canada Phone: (905) 670-5888  Fax: (905) 670-5782

RBI LCD DOMINATOR Installation and Operation Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual