RBI LCD Series Installation & Operation Manual

LCD-IOM-1

7/1/02

LCD SERIES FINNED COPPER GAS BOILERS

& WATER HEATERS INSTALLATION

& OPERATION MANU AL

MEA#117-96-E

DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE
VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE
OF 160 PSI WATER.

WARNING: If the information in this manual is not followed exactly, a fire
or explosion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch. Do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or
the gas supplier.

WARNING: Failure to properly vent this unit can cause excessive amounts of carbon
monoxide resulting in severe personnal injury or death!

INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER/WATER HEATER.

CONSUMER: RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

260 North Elm Street 1300 Midway Boulevard
Westfield, MA 01085
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

Mississauga, Ontario L5T 2G8 Canada

䡲

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 inflammables
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 qualifié 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 V enting Guidelines................................page 9

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

V ertical/Chimney V enting ...................................page 9

Horizontal V enting ............................................page 10

Outdoor V enting ...............................................page 11

Common V ent Systems....................................page 12

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

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

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

Gas Supply Piping............................................page 22

Electrical Wiring ...............................................page 23

General Operation............................................page 23

Operating Instructions ......................................page 26

Checking & Adjustment....................................page 28

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

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

Trouble Shooting ..............................................page 34

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

BEFORE YOU START

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

To obtain the safe, dependable, efficient 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 certified 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. Each unit has been constructed and
hydrostatically tested for a maximum working pressure
of 160 psi,
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
54-latest 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.

In the Commonwealth of Massachusetts, the installation
must be performed by a licensed plumber or gas fitter.

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 Water Heaters distributor
or contact the RBI Customer Service Depar tment, 260
North Elm Street, Westfield, MA 01085. Always include
the model and serial numbers from the rating plate of
the boiler/water heater in question.

1103 kPa

in accordance with Section IV of

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.

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

Top 6
Back 6
Left Side 6
Right Side 6
Front 6
Flue 6

2. An optimum site will be level, central to the piping
system, close to a chimney or outside wall and hav e
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 floor is structurally sound and will
support the weight of the boiler/water heater.

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

4. Locate the boiler/water heater in an area that will
prevent w ater 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.

mm
153
153
153
153
153
153

in
20
24
24
24
30

mm
508
610
610
610
762

5. DO NOT place this boiler/water heater in a location
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 flammable
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!

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 & V entilation, 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 b uilding 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
fluorocarbons 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 fireplace, 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 confined space the
minimum clearances listed in Table 1 must be
maintained between it and any combustible construction.
When installed in a confined 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

ALL gas utilization equipment in the confined area. Each
opening must be no less than 100 in2,
size. The upper opening must be within 12 in,
of, but not less than 3 in,
enclosure. The bottom opening must be within 12 in,

305 mm

of, but not less than 3 in,

bottom of the enclosure.

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

based on the total input rating of

64,516 mm

2

in

305 mm

76 mm

from, the top of the

76 mm

from, the

10 FT 3.1m

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 5

Figure 2 - Vertical Venting using a Masonry Chimney and Inside Air

VENT PIPE DIAMETER

IN. mm FT mm

5" TO 10"

12" TO 18"

127 TO 254
305 TO 457

Figure 3 - Horizontal Venting using Inside Air
All Air From Outside The Building

4 FT

1.2 m

3 FT

0.9 m

MINIMUM VERTICAL RISE

OFF THE TOP OF UNIT "A"

12"
24"

305
610

1/4 IN. PER F00T 20 mm/m

1.5 FT 0.5 m

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 6

All Air From Outside The Building
When installed in a confined 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 m ust 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 in

/4000 Btu/hr,

550 mm2/kW

of the total input

2

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 in

2

/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 ha ve 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 the louver or grill
should be sized per Table 2.

Intake Air Option - General Guidelines

This configuration 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: Each boiler/water heater must have
it’s own intake air system. Common intake air
systems are not to be used! Improper
installation can result in excessive levels of
carbon monoxide which can cause severe
personal injury or death!

Single wall galvanized smok e pipe, single wall aluminum
pipe or flexible aluminum pipe can be used for the
in-take air pipe. It must be sized per Table 3. 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 3 - Combustion Air Pipe Sizing

Model Size Pipe Diameter

in

mm

225 - 300 5

400 6

600 - 750 8
900 - 1050 10
1200 - 2300 12

127
152
203
254
305

Table 2 - Make-up Air Louver Sizing

Required Cross Sectional Area

Input 1/4 in

(MBH) Wire Screen

225 57
300 75
399 100
600 150
750 190
900 225
1050 263
1200 300
1480 370
1650 413
1970 493
2300 575

in

6.4 mm

2

cm
363
484
645

968
1210
1451
1696
1936
2388
2662
3179
3711

75% Free Area 25% Free Area

Metal Louvers Wooden Louvers

2

2

in

75
100
133
200

250
300
350
400
494

3182

550

3548

657

4236

767

2

cm

484
645
858

1290

1613

1935
2258
2580

4945

in

225
300

399
600
750

900
1050
1200
1480
1650
1970
2300

2

2

cm
1452
1935

2573
3870
4840
5805
6773
7740
9546

10,643
12,707
14,835

Canadian installations must comply with CSA B149.1
when

air supply

outdoors for
assisted, or power draft-assisted
be a permanent

is provided by natural air flow from the

natural draft

air supply

, partial fan-assisted, fan-

burners

, there shall

opening(s) having a cross-

sectional area of not less than 1 in2 per 7,000 Btuh

(310 mm2 per kW)

plus 1 in2 per 14,000 Btuh

up to and including 1 million Btuh,

(155 mm2 per kW)

in e xcess

of 1 million Btuh.

CAUTION: A stack damper interlocked with the unit
should be installed in the intake air pipe when the
infiltration 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 V ent option is 100 ft ,

30.5 m

are equal to 10 linear ft,
exceed 5 ft,

. Each 90° elbow and the combustion air terminal

3.0 m

of pipe. If horizontal runs

1.5 m

they must be supported at 3 ft,

0.9 m

intervals with overhead hangers. The certified 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
flashed and sealed.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 7

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

4 FT

1.2 m

1/4 IN. PER FOOT

20 mm/m

3 FT 0.9 m

16 FT 4.9 m

5 FT 1.5 m

1.5 FT 0.5 m

5 FT 1.5 m

When running horizontal combustion air and venting for single or m ultiple 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

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 8

Figure 6 - Vertical Combustion Air and Venting, Metal Chimney System Shown

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

MINIMUM VERTICAL RISE

OFF THE TOP OF UNIT "A"

12"

24"

10 FT 3.1 m

VENT PIPE DIAMETER

IN. mm FT mm

5" TO 10"

12" TO 18"

3 FT 1 m

127 TO 254
305 TO 457

305
610

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 fire-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,
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 double acting
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.

barometric damper

.25 to 2.0 mm

must be

VENT SYSTEM OPTIONS

The LCD may be vented the following ways:

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. F ollow applicab le instructions
under the “COMBUSTION AIR & VENTILA TION” section.

4)

Outdoor Installation -

Barometric damper is not required.

NOTE: All venting, comb usiton air material supplied
by installer.

uses the outdoor option kit.

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,
flue collar with the unit running at full load. A barometric
damper must be installed between the flue collar and
the vent connector. Approved thimbles and fire-stops
must be used when combustible construction is
penetrated.

.25 to 2.0 mm

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

W.C. at the boiler/water heater

1)

Vertical/Chimney V enting -

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

2)

Direct Vent, Positive Pressure -

runs equivalent to 35 ft, 10.8 m or less. A stainless steel
vent system certified to UL 1738 for installations in the
United States. ULS636 for installations in Canada must
be used when combustion air is ducted from outdoors,
from the same wall.

3)

Horizontal Vent, Negative Pressure -

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.

uses an approved metal

for horizontal vent

for horizontal

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 4 lists the
equivalent breeching and flue sizes required for the
boiler/water heater. When more than one appliance is
connected to the same chimney flue the flue must be
large enough to safely vent the combined output of all
of the appliances.

Table 4 - Equivalent Breeching & Chimney Size

Model Size Pipe Diameter

in

mm

225 5
300 - 400 6
600 - 750 8

900 - 1050 10
1200 - 1480 12
1650 - 2300 14

Note: These sizes are based on a 20 ft,

6.1m

127
152
203
254
305
356

chimney height.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 10

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,
intervals with overhead hangers. Use a type B, single
wall stainless or single wall galvanized steel vent pipe
the same diameter as the flue 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,

2 cm/m

terminate flush with the inside of the chimney flue,
Figure 2. Fasten each single wall vent connection with
at least 3 corrosion resistant sheet metal screws.

Always provide a minimum clearance of 6 in,
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.

. On masonry chimneys the connector must

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

0.9 m

152 mm

Horizontal Direct Vent Systems - Figures 4 & 5

The vent materials used in horizontal vent systems
must be certified to UL 1738 for installations in the
United States, ULS636 for installations in Canada. The
certified vent terminal from RBI must also be used. The
following manufactures have systems that meet these
requirements:

Heat-Fab, Inc.
38 Hayward Street
Greenfield, MA 01301, [phone].

Z-Flex U.S., Inc.,
20 Commerce Park North
Bedford, NH 03110-6911, [phone].

Protech Systems Inc.
26 Gansevoort Street
Albany, NY 12202, [phone]

The maximum equivalent length for the horizontal vent
and combustion air pipes is 35 ft,

Each 90˚ elbow and the intake air and vent terminals
are equal to 10 ft,
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.

3.3 m

of straight pipe. To maximize

10.8 m

for each.

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

DIRECT VENT ,
POSITIVE PRESSURE

In this configuration the boiler/water heater blower is
used to push the flue 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,
instructions under the “COMBUSTION AIR &
VENTILATION SECTION” must be followed! The vent
system must be sized per Table 4.

10.8 m

for each. The Intake Air Option

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,
must be supported at 3 ft,
overhead hangers. The vent system must be pitched
down, toward the vent terminal, 1/4 in/ft,
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

0.98 m

.

1.5 m

they

intervals with

21 mm/m

.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 11

Horizontal vent systems shall terminate at least 4 ft,

1.3 m

below , 4 ft, 1.3 m horizontally from or 1 ft,
above any door, window or gravity air inlet into any
building. It must not terminate less than 4 ft,
horizontally from, and in no case above or below , unless
a 4 ft,
electric meters, gas meters, regulators and relief
equipment and not less than 7 ft,
public walkway. The bottom of the vent terminal(s) shall
be located at least 5 ft,
terminal(s) unless there is a minimum 5 ft,
horizontal separation between them. Avoid terminal
locations likely to be affected b y winds, snowdrifts, people
and pets. Protect building materials and vegetation from
degradation caused by the flue gases.

Vertical Direct Vent Systems - Figure 6

The maximum length for the vertical vent and
combustion air pipes is 35 ft,
elbows. If any par t of a single wall metal vent system
passes through an unheated space it must be insulated
with insulation rated for 400˚F,
penetrations must be made using approved fire-stops.

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

1.8 m

4 ft,

1.3 m

horizontal distance is maintained, from

2.3 m

from any adjacent

1.5 m

above the air intake

10.8 m

plus two 90˚

204˚C

above the roof surface that it passes through,

1.3 m

above the intake air cap, see Figure 6.

0.23 m

1.3 m

1.5 m

. Structural

HORIZONT AL VENT ,
NEGATIVE PRESSURE

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

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

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

When horizontal vent runs exceed 5 ft,
must be supported at 3 ft,
overhead hangers. The vent system must be pitched
down, toward the vent terminal, 1/4 in/ft,
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

0.98 m

.

1.5 m

they

intervals with

21 mm/m

Horizontal vent systems shall terminate at least 4 ft,

1.3 m

below, 4 ft,

0.23 m

into any building. It must not terminate less than
4 ft,
or below, unless a 4 ft,
is maintained, from electric meters, gas meters,
regulators and relief equipment and not less than 7 ft,

2.3 m

of the vent terminal(s) shall be located at least 5 ft,

m

a minimum 5 ft,
them. Avoid terminal locations likely to be affected by
winds, snowdrifts, people and pets. Protect building
materials and vegetation from degradation caused by
the flue gases.

To determine the appropriate power venter for the
boiler/water heater, see Table 5. Follow the power venter
manufacturer’s installation instructions.

Table 5 - Power Venter Sizes

*Choose HS115-2 for 100 ft. Max. Pipe length
**Choose HS-3 for 100 ft.

above any door, window or gravity air inlet

1.3 m

horizontally from, and in no case above

from any adjacent public walkway. The bottom

above the air intake terminal(s) unless there is

LCD Po wer 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

750-900 HS-3 100 31.0
1050-1200 HS-4 100 31.0
1480-2300 HS-5 100 31.0

1.3 m

horizontally from or 1 ft,

1.3 m

horizontal distance

1.5 m

horizontal separation between

31 m

, Max. Pipe Length

OUTDOOR VENTING

When installed outdoors the LCD must be fitted 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,
from any door, window or gravity air inlet into any
building and at least 3 ft,
unless local codes dictate differently.

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!

0.9 m

from any overhang

1.5

3.0 m

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
deficiencies 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. Tur n 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 maxim um
speed. Do not operate a summer exhaust fan for a
boiler installation. Close fireplace 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'év acuation

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.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 13

e) 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, fireplace 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.

f) 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 CSA B149 Installation
Codes.

Tout mauvais fonctionnement du systéme d'évacu­tion 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 modifiée,
le système devrait étré modifié 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
CSA-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 flooding and extensive
property damage! Excessive water hardness causing
scaling in the copper heat exchanger tubes is
covered under the manufacturer’s warranty.
Excessive pitting and erosion of the internal surface
of the copper heat exchanger tubes is

NOT

under the manufacturer’s warranty if the result of
high water flow rates, see Table 6. Return water
temperatures below 125°F,

52°C

will result in heat
exchanger damage from excessive condensation
voiding the manufacturer’s warranty, see Primar y/
Secondary Piping Figure 11.

NOT

covered

Table 6 - Temperature Rise Table

∆T = 15 °F ∆

Model Flow Rate Pres. Drop

Number GPM Ft

225 24.6 0.18
300 32.8 0.31
400 43.7 0.70
600 65.6 1.84
750 82.0 3.32
900 98.4 * 5.42

∆T = 20 °F ∆

Model Flow Rate Pres. Drop

Number GPM Ft

300 24.6 0.18
400 32.8 0.41
600 49.2 1.08
750 61.5 1.95

900 73.8 3.18
1050 86.1 5.16
1200 98.4* 8.14
1480 121.4* 7.94

∆T = 25 °F ∆

Model Flow Rate Pres. Drop

Number GPM Ft

400 26.2 0.27

600 39.4 0.71

750 49.2 1.29

900 59.0 2.10
1050 68.9 3.41
1200 78.7 5.38
1480 97.1 5.25
1650 108.2 7.02

∆T = 30 °F ∆

Model Flow Rate Pres. Drop

Number GPM Ft

600 32.8 0.51

750 41.0 0.92

900 49.2 1.50
1050 57.4 2.44
1200 65.6 3.84
1480 80.9 3.75
1650 90.2 5.01
1970 107.7 8.75
2300 125.7* 12.45

∆T = 35 °F ∆

Model Flow Rate Pres. Drop

Number GPM Ft

600 28.1 0.38

750 35.1 0.69

900 42.2 1.13
1050 49.2 1.83
1200 56.2 2.89
1480 69.3 2.89
1650 77.3 3.79
1970 92.3 6.58
2300 107.8 9.36

*Flow exceeds recommended maximum use a greater temperature
rise or consult manufacturer. Cupro-Nickel exchanger should be

considered.

T = 8.3 °C

Flow Rate Pres. Drop

L/s kPa

1.6 0.5

2.1 0.9

2.8 2.1

4.1 5.4

5.2 9.8

6.2 16.0
T = 11.1 °C

Flow Rate Pres. Drop

L/s kPa

1.6 0.5

2.1 1.2

3.1 3.2

3.9 5.7

4.7 9.4

5.4 15.2

6.2 24.0

7.7 23.4
T = 13.9 °C

Flow Rate Pres. Drop

L/s kPa

1.7 0.8

2.5 2.1

3.1 3.8

3.7 6.2

4.3 10.1

5.0 15.9

6.1 15.5

6.8 20.7
T = 16.7 °C

Flow Rate Pres. Drop

L/s kPa

2.1 1.5

2.6 2.7

3.1 4.4

3.6 7.2

4.1 11.3

5.1 11.0

5.7 14.8

6.8 25.8

7.9 36.7
T = 19.4 °C

Flow Rate Pres. Drop

L/s kPa

1.8 1.1

2.2 2.0

2.7 3.3

3.1 5.4

3.5 8.5

4.4 8.3

4.9 11.1

5.8 19.4

6.8 27.6

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 certified 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 flow of water through the boiler/water
heater MUST be maintained! The pump responsible
for flow 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 flow and overcoming a 20%
increase in head loss. Domestic w ater systems m ust
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 pre vent
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 dr ainage
of both the relief valve and the discharge piping.

Figure 10 - Relief Valve 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 flow switch supplied with the boiler/water heater must
be wired to the terminal strip in the control panel to
prevent the boiler from firing unless there’s adequate
water flow through the unit. The flow switch must be
installed in the supply piping adjacent to the boiler outlet
connection.

CAUTION: Failure to properly install the flow 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 qualified
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,
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,
maintained.

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 7.

82.7 kPa

25 mm

must be

Table 7 - 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

This low mass boiler requires a continuous minimum
water flow for proper operation. The system pump must
be sized to overcome the head loss of the boiler and
the heating system in order to achieve the required
temperature rise. Table 6 provides the heat exchanger
pressure drop and temperature rise figures.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 15

CAUTION: A temperature rise outside of the range
listed in Table 6 indicates that the flow rate through
the heat exchanger is incorrect which will damage
the heat exchanger voiding the warranty! The
maximum allowable temperature rise is 35°F,

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

5.8 L/s

on 1480 to 2300 models. The cupro-nickel heat
exchanger allows for 100 GPM,
1200 models and 125 GPM,
models.

Low Water Cutoff

If a boiler is installed above any radiation elements it
must be fitted 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.

Primary/Secondary Piping

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

Variab le 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.

on 225-1200 models and 115 GPM,

6.3 L/s

7.9 L/s

on 1480 to 2300

19.4°C

7.3 L/s

on 225 to

52°C

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 secondary piping.

A balancing valve must also be installed in the supply
side of the secondary 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 flow through each system. The
secondary piping connections to the primary system
piping must not be more than 12 in,
ensure zero pressure drop in the primary system, 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.

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 flow­control valves or some other automatic means of
preventing gravity circulation of the boiler water during
the cooling cycle.

305 mm

apart to

This secondary pump is sized to overcome the head
loss of the boiler and secondary piping system while
supplying the flow rate required to maintain the desired
temperature rise across the boiler. The primary pump
is sized to provide the required flow to the heating
system. The secondary piping connections to the
primary system piping must not be more than 12 in,

mm

apart to ensure zero pressure drop in the primar y

system, see Figure 11.

305

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 16

Figure 11 - Typical Primary/Secondary Piping System
See Notes

Figure 12 - Low Temperature Piping
See Notes and Adjustment Procedures

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 17

Figure 13 - Multiple Boiler Piping (See notes)

ax

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,
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,
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 flow.

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.

54°C

or a scald injury will occur!

49°C

. Local codes

A Cupro-Nickel heat exchanger may also be required.
The manufacturer should be consulted when these water
conditions are encountered.See Table 8A

CAUTION:
a LCD water heater with copper heat exchanger is
92 GPM,

L/s

on 1480 to 2300 models. The cupro-nickel heat
exchanger allows for 100 GPM,
models 125 GPM,
T able 8B .

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 follo w the guidelines in the Heat Exchanger
Selection Table (Table 8A) and the Pumping
Performance Table (Table 8B). 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 flow rate through

5.8 L/s

on 225-1200 models and 115 GPM,

6.3 L/s

on 225 to 1200

7.9 L/s

on 1480 to 2300 models, see

7.3

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 19

T able 8A - LCD Heat Exchanger Selection Graph

T able 8B - LCD Pumping Perf ormance Requirement

∆

∆

∆

∆

∆

∆

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 20

Expansion T ank

An expansion tank or other means to control thermal
expansion must be installed in the water heating system
if back flow 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 flow for proper operation. The low water
flow switch provided for this unit will shut down the water
heater if flow falls below the required minimum level.
Table 8A provides the heat exchanger pressure drop
chart and temperature rise table.

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 8B for efficient
operation and long life. If the temperature rise through the
water heater is lower than recommended the water v elocity
is too high. Premature erosion of the heat e xchanger will
occur. Con versely, if the temperature rise is higher than
recommended in Table 8B the flow 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.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 21

Figure 14 - Typical Water Heating Piping
See Notes

Figure 15 - Multiple Water Heating Piping
See Notes

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 22

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. 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,

and maximum 14 in,
propane, must be available at the safety shutoff
valve inlet with the unit(s) operating.

Table 9 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 fittings. Table 9
should be used in conjunction with Table 10 to ensure
that the gas supply piping has the capacity to meet the
demand.

W.C. natural or 11 in,

356 mm

279 mm

W .C. propane

W.C. natural or

Table 10 - Equivalent Pipe Length Chart

Nominal
Iron Pipe
Size, (in)

1″
11/4″
11/2″

2″
21/2″

3″

Notes: 1. For flow through branch.

90° Elbow Tee

2.6 5.2 0.6 1.5

3.5 6.9 0.8 1.9

4.0 8.0 0.9 2.3

5.2 10.3 1.2 3.0

6.2 12.3 1.4 3.7

7.7 15.3 1.8 4.5

2. For flow at full open.

Type of pipe fitting

1

Gas Valv e2Gas Cock

Equivalent pipe length, (ft)

2

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

Figure 16 depicts the proper way to connect the boiler/
water heater to the gas supply piping. Provide a
sediment trap at the bottom of the vertical section of the
gas supply pipe upstream of the gas controls.

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.

Table 9 - Gas Pipe Capacity

Maximum pipe capacity in ft3/hr based on 0.60 specific gravity gas
at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.

Nominal
Iron Pipe
Size, (in)

3

1″
11/4″
11/2″

2″
21/2″

3″

Note: Multiply the gas volume by 0.62 for propane flow capacity in
ft3/hr. Multiply the propane flow capacity by 2500 Btu/ft3 to determine
the propane Btu/hr capacity for a given pipe size and length.

10 20 30 40 50 60 80 100 150

Maximum gas volume of pipe, (ft3/hr)

278 190 152 130 115 105 90 79 64

/4″

520 350 285 245 215 195 170 150 120
1050 730 590 500 440 400 350 305 250
1600 1100 890 760 670 610 530 460 380
3050 2100 1650 1450 1270 1150 990 870 710
4800 3300 2700 2300 2000 1850 1600 1400 1130
8500 5900 4700 4100 3600 3250 2800 2500 2000

Pipe length in feet

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 flame 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.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 23

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 fils 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 amp circuit breaker for the
boiler/water heater and pump, see Table 11. 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.

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. F ailure 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 flow 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 fill 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,
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

83 kPa

system pressure is

system pressure.

Table 11 - LCD Electrical Requirements

Recommended

LCD Circuit Breaker *Running

Model (Amps) Amps
LB/LW 225-600 15 3.9
LB/LW 750-900 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 field wiring of any controls or other devices
must 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.

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

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.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 24

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 W A TER HEA TER
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 and 300 models have on/off staging, while the
400 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 12 identifies the stages and firing modes
associated with the standard single stage units. Table
13 identifies the stages and firing modes associated with
the two stage option.

Table 12 - Firing Modes (L225-L2300)

Stage Firing Mode

Off Off

1On

Table 13 - Firing Modes (L400-L2300)

Stage Firing Mode

Off Off

1 Low Fire
2 High Fire

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 flow under a blocked flue 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 fire pressure switch serves to shut
down gas flow if there is a blocked flue or inlet condition
during low fire operation. Similarly, the high fire switches
will shut down gas flow if there is a blocked flue or inlet
condition during high fire 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 14 lists the differential pressure settings for all of
the models.

Figure 17 - Pressure Switch Tap(s)

Table 14 - Differential Pressure Settings (All Units)

Firing Mode Differential Pressure

Inches W .C.

Optional Low Fire 0.7 ± 0.1

High Fire 1.0 ± 0.2

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 15 and 16 identify how pressure switch
control changes during boiler/water heater staging.
Tables 17 and 18 identify the control actions if a low air
condition occurs at any stage.

Table 15 - Pressure Switch Control,

L225-L300

Stage Pressure Switch Mode

Off Off

1 High Fire

Table 16 - Pressure Switch Control,

L400-L2300

Stage Pressure Switch Mode

Off Off

1 Low Fire
2 High Fire

Table 17 - Low Air Condition Action,

L225-L2300

Stage Control Action

1 No Power to Flame Sense Module

Table 18 - Low Air Condition Action,

L400-L2300

Stage Control Action

1 No Power to Flame Sense Module
2 No Power to Flame Sense Module

mm W .C .

16.8 ± 2.5

24.9 ± 5.1

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 25

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 w ater pump(s).

2. Water flow through the unit closes the water flow

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.

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 sufficient, the pressure switch
closes allowing the blower delay timer TD1 to start
a 7 second pre-purge.

Ignition T rial:

1. Blower delay timer TD1 times out and the flame

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 flame
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.

4. If the pilot flame 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.

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.

Demand Satisfied:

1. When the demand for heat is satisfied 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 star ts 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 saf ety
is tripped.

2. The manual reset high limit can be reset by
depressing the rubber plug in the front top jacket
panel.

Low Air (Blocked Flue/Air Inlet)

• The pressure switch will monitor blower airflow.

• 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.

OPERATION SEQUENCE, 2 STAGE
OPTION L400 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 w ater pump(s).

2. Water flow through the unit closes the water flow
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 7
second pre-purge.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 26

Ignition T rial:

1. Blower delay timer TD1 times out and the flame
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 flame
is sensed, the FSM sends 24VAC to its MV terminal
energizing the safety and low fire-side of the main
solenoid valves and relay R8, de-energizing R7 and
the spark generator.

4. If the pilot flame 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.

Demand Satisfied:

1. When the demand for heat is satisfied the operator
switch will open, de-energizing relays R2, R2R, R8,
R9, 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 star ts 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 rubber plug in the front top jacket
panel.

Low Air (Blocked Flue/Air Inlet)

• The pressure switches will monitor blower airflow.

• 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.

Main Burner

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

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-fire pressure switch
senses adequate air pressure to sustain hi-fire
combustion. R9 energizes the hi-fire side of the pilot
and main solenoid valves.

• Stage 1 will operate first and last.

NOTE: For a change from stage 1 to 2, a 7 second
LCD time delay is provided in the pressure switch
switching circuit (PD6). The time delay provides a
hold state that allows the blower to reach full speed
and close the high fire pressure switch before it is
energized to confirm proper air flow.

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

POUR VO TRE 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
floor because some gas is heavier than air and will
settle on the floor.

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 27

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 qualified 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 fire
department.

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

3. Turn off all electric power to the appliance.

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

5. Wait five (5) minutes to clear out any gas.

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. Locate pilot and manifold pressure taps in the
upper compartment. Remove the 1/8" screw plugs,
see Figure 19.

Figure 18 - Pilot Valve (All Models)

Main Valve (225 - 400 Models)

AVANT DE FAIRE FONCTIONNER, reniflez tout autour
de l’appareil pour déceler une odeur de gaz. Reniflez
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 four nisseur, appelez
le service de incendies.

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

under water. Immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any 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.

10. Connect a 20 in,

508 mm W.C

. manometer to each

valve, see Figure 19.

11. Turn the knob on the pilot valve to on, Figure 18.

12. 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.

13. Make sure that the gas supply piping has been
purged of air and that all gas joints up to the gas
valve have been thoroughly checked for leaks.

14. Turn on all electric power to the boiler.

Figure 19 - Manual Valve & Manifold Pressure Tap

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” and call your service technician or gas
supplier.

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 28

15. Set the operating control or thermostat to the
desired setting.

16. The pilot should automatically light. Do

not try to

light the pilot by hand!

17. The burners should light with proper boiler/water
heater operation.

18. The pilot and manifold pressures should
match those listed in Table 19. To adjust the
manifold gas pressure see the “GAS PRESSURE
ADJUSTMENT” instructions in the “CHECKING
AND ADJUSTMENT” section.

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

LP Nat
Minimum (in WC) 11 6
Maximum (in WC) 14 14

Measure pressure when the boiler is firing at full rate.
Low gas pressure could indicate undersized gas line or
insufficient 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 specific job site requirements.

Table 19 - Pilot & Manifold Pressures

LCD-225, 300 & LCD-400 to 1200

1480 to 2300

Natural Gas

inches W.C.

Low Fire* 1.3 ± 0.2
High Fire 2.5 ± 0.2

inches W.C.

Low Fire* 3.6 +/- 0.2
High Fire 8.0 +/- 0.2

*Optional

mm W.C .

33 ± 5
64 ± 5

LP Gas

mm W.C .

91 ± 5

204 ± 5

inches W.C.

1.6 ± 0.2

2.5 ± 0.2

inches W.C.

4.0 ± 0.2

8.0 ± 0.2

mm W.C .

41 ± 5
64 ± 5

mm W.C .

102 ± 5
204 ± 5

Instructions De Mise En Marche

1. ARRÊTEZ! Lisez les instructions de sécur ité 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. Reniflez 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 qualifié 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’APAREIL

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 & ADJUSTMENT

1. With the burners in operation, close the manual
shutoff valve in the gas supply line. As soon as the
main burner flames 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 flame sense module will then make a
second ignition attempt. If the unit w on’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 flame 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 flue 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 cubic feet of gas and
divide this time by 10.

6. Inser t the heating value and the time, in seconds,

into the formula below.

7. 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
orifices must be replaced. If the input rate is too low ,
go to the next lager size of main burner orifices. If
the input rate is too high, go to the next smaller size .

9. At full input the CO2 should be between 7.5% and

8.5% with a CO reading of less than 50 ppm.

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!

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 19. These pressures are
measured at the pilot pressure valve, see Figure 19.
Tables 12 and 13 above list the firing 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. Tur n off main burner gas flow 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.

For L600-L2300:

1. Remove the upper front jacket panel.

2. T urn off main burner gas flow 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 19, 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 counterclockwise 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.

NATURAL GAS: Optimum results are obtained when the
boiler/water heater is operated with the manifold
pressure(s) set per Table 19. The manifold pressure
should not vary outside these ranges. Each gas valve
pressure regulator has been preset at the factory. If
adjustment is necessary the following steps must be
followed:

1. Remove the 1/8" plug from the manifold pressure
tap valve. Connect 20 in,

508 mm

WC mano-meters

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 clock-wise
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 19. If the manifold pressure is
off by more than 5% adjust it according to steps 1
through 4 above.

Airflow Adjustment

1. Remove the upper front jacket panel.

2. Connect both sides of a manometer to the pressure
switch tee, Figure 18, going to one of the pressure
switches.

3. With the unit operating at high fire the differential
pressure should be between 0.6 and 0.8 in,

20 mm

W.C. Do not change air pressure in lower

15 and

stages.

4. To fine tune the air settings once the upper front
jacket panel is installed, remove the plastic plug(s)
on the upper front jacket panel. Use a Phillips
screwdriver to rotate the screw(s) to obtain the CO
and CO readings in the INPUT RATE section above.

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 efficient
trouble-free operation of the boiler. Mount the thermostat
to an inside wall at a height approximately five feet
above the floor. Avoid placing the thermostat in areas
that will not provide an accurate measurement of the
room temperature. Locating the ther mostat 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 operating control on the water heater is set to its
lowest setting when the water heater leaves the factory.
The preferred control setting for potable hot water is
130˚F,
lowest setting that will satisfy the consumer’s needs.

54˚C

. The operating control should be set to the

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 black rubber plug
in the front top jacket panel.

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

Low Water Cutoff

If the boiler is to be installed above radiation or if

2

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. Test in accordance with
the manufacturer’s instructions included with the
device(s).

Flame Sense Module

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

Two flame failure alarm terminals are provided on the
flame sense module. For CSD-1 these terminals are
utilized to shut the unit down in case of flame 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 flame
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 7 second prepurge when stage 1 is energized.

• A 7 second pressure switch sequencing delay when

the blowers switch from low fire to high fire. The
delay enables the blower to come up to speed before
the high pressure side of the pressure switch
confirms proper air flow.

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

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 31

Optional Gas Pressure Switches

Optional low and/or high-pressure gas pressure
switches will shut down the 24 VAC 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 qualified
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.

AVERTISSEMNET: Une installation, un réglage,
une modification, 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
qualifié 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 identifiés
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 voiding the warranty!

WARNING: The ceramic combustion chamber
contains crystalline silica. Wear a tightly fitted
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.

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 below.

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 fill
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” baffle straps and “V” baffles.

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 distor ted heat exchanger tubes are an
indication of low water flow 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.

Figure 20-Burner and Heat Exchanger Servicing

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 33

Vent System

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

Figure 21- Heat Exchanger Upper Rail

Controls

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

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

2. A float type low water cutoff device must be flushed
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 flow switch contacts must be open when water
flow is not present.

4. The relief valve should not weep or discharge water
at normal system pressure. If it does contact a
qualified 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 flames to
ensure proper operation, see Figure 22.

WARNING: A yellow, floating flame indicates a
lack of combustion air. A lifting flame indicates
too much combustion air. Do not operate the
boiler/water heater until the problem is solved
or severe personal injury or death may occur!

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 flame sense Check ground connections,

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

condition flue & chimney for blockage

• Check combustion air/ventilation
openings in space

•Check inlet air filter, 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 flame sense lead from igniter Check sense lead & ground ........

Will Not Fire to flame sense module connections, adjust as necessary

Defective flame sense module Replace flame sense module
Manual valve(s) in air plenum 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)

Insufficient 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 Insufficient air •Check CO & CO2, adjust blower
(High CO, Yellow Flames) inlet damper(s) to increase airflow

• Check for plenum air leakage

from lower front jacket panel

seams, repair as necessary
Dirty inlet air filter Remove, inspect and clean inlet air

filter as necessary
Too much air Check CO & CO2, adjust blower

inlet damper(s) to decrease airflow

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

•Check combustion air/ventilation
openings in space

•Check inlet air filter, clean/replace
as necessary

• Check pressure switch for correct

setting

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 36

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 37

SERVICE AND REPLACEMENT PARTS LIST (MODELS 225-2300)

Ref # Name of Part

1 Jacket Lower Front Panel Assembly 70-2716 1 1

2 Jacket Upper Front Panel Assembly 70-2706 1 1

3 Left Jacket Panel 70-3111 11111111

4 Control Box Assembly Standard 70-3113 111111111111

Control Box Assembly Optional 2 Stage 70-3114 1111111111
Control Box Assembly Standard CSD-1 70-3115 111111111111

Control Box Assembly 2 Stage CSD-1 70-3116 1111111111
5 Control Box Cover 03-2153 111111111111
6 Right Jacket Panel 03-2158 1111

7 Combustion Air Inlet Assembly (Indoor) 70-2744 1 1

Rear Intake Option available on 70-2746 1 1

750-2300 models only 70-2748 1 1

8 Combustion Air Inlet Assembly (Outdoor) 70-2820 1 1

9 Jacket Rear Panel 03-1811 1 1

10 Combustion Air Inlet Cover 03-1881 1

11 Jacket T op Panel 03-1801 1 1

Part # 225 300 400 600 750 900 1050 1200 1480 1650 1970 2300

70-2717 1
70-2718 1
70-2719 1
70-2720 1
70-2721 1
70-2722 1 1
70-2723 1
70-2724 1
70-2725 1

70-2707 1
70-2708 1
70-2709 1
70-2710 1
70-2711 1
70-2712 1 1
70-2713 1
70-2714 1
70-2715 1

70-3112 1111

03-2159 1111
03-1825 1111

70-2749 1111

70-2821 1 1
70-2822 1 1
70-2823 1111

03-1812 1
03-1813 1
03-1814 1
03-1815 1
03-1816 1
03-1817 1 1
03-1818 1
03-1819 1
03-1820 1

03-1882 1 1
03-1883 11111

03-1802 1
03-1803 1
03-1804 1
03-1805 1
03-1806 1
03-1807 1 1
03-1808 1
03-1809 1
03-1810 1

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 38

Ref # Name of Part

12 Base Panel Legs 03-1862 222222444444
13 Jacket Base Panel 03-1847 1 1

14 Combustion Chamber Base Panel 03-1974 1 1

15 Combustion Chamber Lower Front Panel 03-2170 1

16 Comb.Chamber Upper Front Panel 03-1939 1 1

17 Comb. Chamber Lower Left Side Panel 03-1936 111111111111

Comb.Chamber Lower Right Side Panel 03-1937 111111111111

18 Comb.Chamber Upper Left Side Panel 03-1934 111111111111

Comb. Chamber Upper Right Side Panel 03-1935 111111111111

19 Heat Exchanger Guide Rail 03-1938 444444444444
20 Combustion Chamber Rear Panel 03-1904 1

Part # 225 300 400 600 750 900 1050 1200 1480 1650 1970 2300

03-1848 1
03-1849 1
03-1850 1
03-1851 1
03-1852 1
03-1853 1 1
03-1854 1
03-1855 1
03-1856 1

03-1975 1
03-1976 1
03-1977 1
03-1978 1
03-1979 1
03-1980 1 1
03-1981 1
03-1982 1
03-1983 1

03-1962 1
03-1963 1
03-1964 1
03-1965 1
03-1966 1
03-1967 1
03-2171 1
03-1968 1
03-1969 1
03-2172 1
03-1971 1

03-1940 1
03-1941 1
03-1942 1
03-1943 1
03-1944 1
03-1945 1
03-1946 1
03-1947 1
03-1948 1

03-1905 1
03-1906 1
03-1907 1
03-1908 1
03-1909 1
03-1910 1 1
03-1911 1
03-1912 1
03-1913 1

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 39

Ref # Name of Part

21 Combustion Chamber Top Panel 03-1884 1 1

22 Flue Box Wrapper Assembly 70-2798 1 1

23 Flue Outlet Assembly 70-3117 1

24 Lower Front Refractory Panel 05-0110 1

Lower Left Front Refractory Panel 05-0091 1 1

Lower Right Front Refractory Panel 05-0096 1 1

Lower Center Front Refractory Panel 05-0151 1

25 Upper Front Refractory Panel 05-0070 1 1

Upper Left Front Refractory Panel 05-0075 1

Upper Right Front Refractory Panel 05-0080 1

Upper Center Front Refractory Panel 05-0085 1

26 End Refractory Panel, Left & Right 05-0058 111111111111

Part # 225 300 400 600 750 900 1050 1200 1480 1650 1970 2300

03-1885 1
03-1886 1
03-1887 1
03-1888 1
03-1889 1
03-1890 1 1
03-1891 1
03-1892 1
03-1893 1

70-2799 1
70-2800 1
70-2801 1
70-2802 1
70-2803 1
70-2804 1 1 1
70-2805 1 1

70-2736 1
70-2737 1
70-2738 1
70-2739 1
70-2740 1
70-2741 1
70-2742 1 1 1
70-2743 1 1

05-0086 1
05-0087 1
05-0088 1
05-0089 1
05-0090 1

05-0111 1
05-0092 1
05-0093 1
05-0112 1
05-0095 1

05-0113 1
05-0097 1
05-0098 1
05-0114 1
05-0100 1

05-0071 1
05-0072 1
05-0073 1
05-0074 1

05-0076 1 1
05-0077 1
05-0078 1
05-0079 1

05-0081 1 1
05-0082 1
05-0083 1
05-0084 1

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 40

Ref # Name of Part

27 Rear Refractory Panel 05-0059 1 1

Left & Right Rear Refractory Panel 05-0066 1

Center Rear Refractory Panel 05-0069 1

28 Manifold 10-0465 1 1

29 Main Orifice, Natural Gas 10-0087 2 3 7 9 11 13 15 17 19 25 27

Main Orifice, LP Gas 10-0088 2 3 7 9 11 13 15 17 19 25 27

Main Orifice, Natural Gas 10-0093 5

Main Orifice, LP Gas 10-0116 5

Pilot Orifice, Natural Gas 10-0089 1 1 111111111

Pilot Orifice, LP Gas 10-0090 1 1 111111111

Pilot Orifice, Natural Gas 10-0115 1

Pilot Orifice, LP Gas 10-0119 1

30 Main Burner Tube 10-0275 34681012141618202628

Pilot Burner Assembly (tubings and fittings) 70-2896 111111111111

31 Spark Ignitor 16-0327 111111111111

NS Heat Exchanger Assembly (Copper) 70-3001 1

(Cast Iron Headers) 70-3002 1

Heat Exchanger Assembly (Copper) 70-3025 1

(Bronze Headers) 70-3026 1

Part # 225 300 400 600 750 900 1050 1200 1480 1650 1970 2300

05-0060 1
05-0061 1
05-0062 1
05-0063 1
05-0064 1
05-0065 1 1

05-0067 1
05-0068 1

10-0466 1
10-0467 1
10-0468 1
10-0469 1
30-0746 1
30-0747 1
30-0748 1
30-0749 1
30-0750 1
30-0751 1

70-3003 1
70-3004 1
70-3005 1
70-3006 1
70-3007 1
70-3008 1
70-3009 1
70-3010 1
70-3011 1
70-3012 1

70-3027 1
70-3028 1
70-3029 1
70-3030 1
70-3031 1
70-3032 1
70-3033 1
70-3034 1
70-3035 1
70-3036 1

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 41

Ref # Name of Part

NS Heat Exchanger Assembly (Cupronickel) 70-3013 1

(Cast Iron Headers) 70-3014 1

Heat Exchanger Assembly (Cupronickel) 70-3037 1

(Bronze Headers) 70-3038 1

32 Tube Bundle (Copper) 70-3049 1

Tube Bundle (Cupronickel) 70-3061 1

33 Heat Exchanger "V" Baffle 03-2011 7 7 36

34 V Baffle Hold-down 03-2021 222244444666

NS Heat Exchanger Support Channel 03-2022 1

Part # 225 300 400 600 750 900 1050 1200 1480 1650 1970 2300

70-3015 1
70-3016 1
70-3017 1
70-3018 1
70-3019 1
70-3020 1
70-3021 1
70-3022 1
70-3023 1
70-3024 1

70-3039 1
70-3040 1
70-3041 1
70-0342 1
70-0343 1
70-0344 1
70-0345 1
70-0346 1
70-0347 1
70-0348 1

70-3050 1
70-3051 1
70-3052 1
70-3053 1
70-3054 1
70-3055 1
70-3056 1
70-3057 1
70-3058 1
70-3059 1
70-3060 1

70-3062 1
70-3063 1
70-3064 1
70-3065 1
70-3066 1
70-3067 1
70-3068 1
70-3069 1
70-3070 1
70-3071 1
70-3072 1

03-2012 7 36
03-2013 7
03-2014 7
03-2015 7
03-2016 7
03-2017 7 9
03-2018 9
03-2019 9
03-2020 9

03-2023 1
03-2024 1

LCD INSTALLATION AND OPERATION INSTRUCTIONSPage 42

Ref # Name of Part

35

Combustion Cham. Refr. Retainer (F/R Edge Baffle)

36 O Ring, Inlet/Outlet & Return Headers 06-0001 16 16 16 16 16 16 16 16 16 16 16 16
37 Stud, Inlet/Outlet & Return Headers 57-0223 666666666666
38 Nut, Inlet/Outlet & Return Headers 57-0492 666666666666
39 Return Header, Bronze

Return Header, Cast Iron

40 Inlet/Outlet Header, Bronze

Inlet/Outlet Header, Cast Iron

41 Blower, Fasco 70625413 12-0013 1 1 1 1

Blower, Fasco 70830370 12-0014 111222222

42 Combustion Air Damper Assembly 70-2818 1 1 1 1

43 Low Pressure Switch 14-0059 1111111111
43 High Pressure Switch 14-0061 111111111111
44 High Limit L4008E1305 (LB) 14-0112 111111111111

High Limit L4008E1313 (LW) 14-0105 111111111111

NS Operator L4008A1015 (LB) 14-0102 111111111111

Operator L6008A1242 (LW) 14-0106 111111111111

Operator L6008G1009 - 2 Stage 14-0107 1111111111

NS NG STD/FM Gas Train Assembly 73-0824 1

NS LP STD/FM Gas Train Assembly 73-0830 1

Part # 225 300 400 600 750 900 1050 1200 1480 1650 1970 2300

03-1972 111111111111

01-0011-1S
01-0004S
01-0018S

01-0009S
01-0002S
01-0022S
01-0010-1S
01-0003S
01-0019S
01-0008S
01-0001S
01-0023S

70-2819 111222222

73-0825 1
73-0826 1
73-0827 1
73-0828 1
73-0829 1
73-0776 1
73-0777 1
73-0778 1
73-0779 1
73-0780 1
73-0781 1

73-0831 1
73-0832 1
73-0833 1
73-0834 1
73-0835 1
73-0782 1
73-0783 1
73-0784 1
73-0785 1
73-0786 1
73-0787 1

111

11111

1111

111

11111

1111

111

11111

1111

111

11111

1111

LCD INSTALLATION AND OPERATION INSTRUCTIONS Page 43

Ref # Name of Part

45 Firing Valv e, 3/4" 11-0461 1 1 1

Firing Valve , 1" 11-0456 1 1 1
Firing Valve, 1 1/4" 11-0457 1 1
Firing Valve, 1 1/2" 11-0458 1 1
Firing Valve , 2" 11-0459 1 1

NS Manifold Pressure Valve 11-0031 111111111111

46 Main Gas Valve, VR8305 11-0087 1 1 1

Main Gas Valve, V8944B, 1" 11-0186 1 1 1
Main Gas Valve, V8944B, 1 1/4" 11-0187 1 1
Main Gas Valve, V8944B, 1 1/2" 11-0188 1 1
Main Gas Valve, V8944B, 2" 11-0174 1 1

47 Safety Valve, V48A, 1" 11-0151 1 1 1

Safety Valve, V48A, 1 1/4" 11-0152 1 1
Safety Valve, V48A, 1 1/2" 11-0153 1 1
Safety V alve , V48A, 2" 11-0154 1 1

48 Pilot Valve, VR8304M 11-0055 111111111111

Pilot Valve, VR8205Q 2 Stage 11-0086 1111111111
Manual Shut Off Valve, 1" 11-0465 1 1 1
Manual Shut Off Valve, 1 1/4" 11-0466 1 1
Manual Shut Off Valve, 1 1/2" 11-0467 1 1
Manual Shut Off Valve, 2" 11-0454 1 1

50

Flame Sensor UTC 1003-61A Ignition Module

51 Q652B1006, Spark Generator 16-0008 111111111111

NS Ignition Lead 16-0202 111111111111

52 Transformer, 75 VA 15-0008 111111111111
55 Relay, 9 Pin 15-0115 55555777777

Relay, 4 Pin 15-0116 22222222222

NS Manual Reset Board, CSD-1 16-0013 111111111111

Relief Valve 1" 50# (LB) 30-0379 111111111111
Relief Valve 3/4" 125# (LW) 30-0364 111111111111
Tridicator 0-100 PSI (LB) 13-0308 111111111111
Tridicator 0-230 PSI (LW) 13-0305 111111111111

NS On/Off Switch 48-0010 111111111111

Part # 225 300 400 600 750 900 1050 1200 1480 1650 1970 2300

16-0059 111111111111

260 North Elm Street 1300 Midway Boulevard
Westfield, MA 01085
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]

Mississauga, Ontario L5T 2G8 Canada

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