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RBI LCD Series User Manual

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

General IconGeneral
BrandRBI
ModelLCD Series
CategoryWater Heater
LanguageEnglish

Summary

LCD SERIES FINNED COPPER GAS BOILERS (MODEL LB) & WATER HEATERS (MODEL LW) INSTALLATION & OPERATION MANUAL

BEFORE YOU START

RATINGS & CAPACITIES

BOILER/WATER HEATER LOCATION

COMBUSTION AIR & VENTILATION

All Air From Inside The Building

GENERAL VENTING GUIDELINES

VENT SYSTEM OPTIONS

Vertical/Chimney Venting, Negative Pressure, Category I

Uses an approved metal chimney or lined masonry chimney. Combustion air from space or outdoors.

Direct Vent, Positive Pressure, Category III

Stainless steel vent system certified to UL 1738. For installations in US/Canada.

Horizontal Vent, Negative Pressure, Category I

Wall-mounted power venter used to pull flue products horizontally.

Outdoor Installation

Uses the factory supplied outdoor vent hood and air intake hood.

VERTICAL/CHIMNEY VENTING

DIRECT VENT, POSITIVE PRESSURE, CATEGORY III

HORIZONTAL VENT, NEGATIVE PRESSURE, CATEGORY I

OUTDOOR VENTING

COMMON VENT SYSTEMS

GENERAL PIPING REQUIREMENTS

Freeze Protection

Relief Valve

Flow Switch

HEATING SYSTEM PIPING

General Piping Requirements

All heating system piping must be installed by a qualified technician.

Heating Boiler Piping Connections

The supply and return piping should be sized to suit the system.

Pump Requirements (Primary/Secondary)

Low mass boiler requires a continuous minimum water flow for proper operation.

Low Return Water Temperatures

Multiple Boiler Systems

Piping For Use With Cooling Units

DOMESTIC WATER SUPPLY PIPING

General Piping Requirements

Ensure that the water heater is equipped with bronze headers and uses potable water components.

Water Chemistry

Discusses water hardness and its impact on heat exchangers and pump selection.

Expansion Tank

Cold Water Supply

Pump Requirements

Temperature Rise Control

GAS SUPPLY PIPING

Maximum pipe capacity

Table 10 provides gas pipe capacity based on size, length, and gas type.

Equivalent Pipe Length Chart

Table 11 details equivalent pipe lengths for fittings and valves.

ELECTRICAL WIRING

Electrical Power Connections

Details wiring requirements according to electrical codes for safe installation.

GENERAL OPERATION

Hydronic Heating Boilers

Instructions for filling and purging the heating system with water.

BOILER/WATER HEATER OPERATION

Staging Operation

Explains on/off and two-stage firing modes controlled by aquastats.

Pressure Switch Settings

Details differential pressure switch settings for safety and operation.

OPERATION SEQUENCE, ON/OFF L225 through L2300

POWER ON

Describes the sequence of events when power is applied and heat is demanded.

Prepurge

Explains the blower operation and pressure sensing during the prepurge cycle.

Ignition Trial

Details the pilot ignition sequence, including safety checks and lockouts.

Main Burner

Describes the activation of the main burner after pilot ignition is proven.

Normal Operation

Explains single-stage operation with blowers and gas valves at one input.

OPERATION SEQUENCE, 2 STAGE OPTION L600 through L2300

POWER ON

Outlines the initial sequence when power is applied and heat is requested.

Prepurge

Describes the prepurge phase, including blower speed and pressure switch activation.

Ignition Trial

Details the pilot ignition process, including safety module functions and trials.

Main Burner

Explains the main burner activation after successful pilot ignition for two-stage units.

Normal Operation

Describes how staging is controlled by a return water aquastat for two-stage units.

OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING

General Safety Precautions

Emphasizes reading instructions, smelling for gas, and avoiding water damage.

Gas Leak Detection and Response

Provides critical steps to take if a gas leak is suspected.

OPERATING INSTRUCTIONS

Preparation Steps

Covers safety stops, power off, gas shutoff, and waiting period before operation.

Pilot and Manifold Pressure Setup

Details connecting manometers and checking pilot/manifold pressures.

Required Gas Pressure

Specifies required gas supply pressures for natural gas and propane.

CHECKING & ADJUSTMENTS

Ignition Safety Shutoff Test

Describes testing the safety shutoff device by momentarily interrupting the flame.

Control Circuit Interruption Test

Details testing the control circuit shutdown by turning down the thermostat.

Pilot Adjustment

Pilot Observation

Steps to observe the pilot flame without main burner operation.

Pilot Pressure Adjustment

Instructions for adjusting pilot pressure using a manometer and hex wrench.

Gas Pressure Adjustment

Manifold Pressure Adjustment

Steps to adjust manifold pressure to match table values using a manometer.

CONTROL DESCRIPTION

Boiler Thermostat

Guidelines for thermostat installation and anticipator adjustment for accurate room temperature.

Operating Control

Recommends setting the operating control for potable hot water to 130°F.

High Limit (Aquastat)

Explains the function and setting of the high limit aquastat to control maximum water temperature.

Flow Switch

Describes the function of the flow switch to prevent firing without adequate water flow.

Low Water Cutoff

Advises on installing and wiring low water cutoff devices if required.

Flame Sense Module

Explains the role of the flame sense module in controlling pilot and main burner ignition.

Relay Board

Details the relay board's function in sequencing gas valves and blowers, including time delays.

MAINTENANCE

Burner Inspection And Removal

Step-by-step guide for inspecting, removing, and reinstalling burners.

Heat Exchanger Inspection

Instructions for inspecting the heat exchanger for damage, sooting, or corrosion.

Heat Exchanger Removal, Cleaning & Replacement

General Cleaning and Inspection

Steps for removing, cleaning, and inspecting the heat exchanger.

Controls

Thermostat/Operating Controls Check

Checking operation of thermostat and operating controls.

Low Water Cutoff Flushing and Cleaning

Procedures for flushing and cleaning low water cutoff devices.

Flow Switch Contact Check

Verifying flow switch contacts are open when no water flow is present.

Relief Valve Inspection

Checking the relief valve for weeping or discharge at normal pressure.

Aquastat High Limit Function

Verifying the aquastat high limit controls maximum water temperature.

Pilot and Main Burner Flame Check

Visually checking pilot and main burner flames for proper operation.

TROUBLESHOOTING

No Power To Control Circuit

Addresses issues related to no power reaching the control circuit.

No Action On Call For Heat

Troubleshooting steps when the unit does not respond to a call for heat.

No Power to Pump

Diagnosing and resolving issues related to no power reaching the pump.

No Power to Optional Power Venter

Troubleshooting steps for no power to the optional power venter.

Power Venter On, No Action From Unit

Addresses situations where the power venter is on but the unit shows no action.

No Power To Blower(s)

Resolving issues where the blower(s) receive no power.

Unit Does Not Spark

Troubleshooting ignition issues when the unit does not spark.

Unit Sparks But Will Not Fire

Diagnosing why the unit sparks but fails to ignite the flame.

TROUBLESHOOTING (continued)

Pilot Lights But Main Burners Will Not Fire

Troubleshooting when the pilot lights but the main burners do not ignite.

Insufficient Heating

Addresses causes and solutions for inadequate heating output.

Unit Consistently Shuts Down On High Limit

Diagnosing and resolving consistent shutdowns due to high limit activation.

Bad Combustion (High CO, Yellow Flames)

Troubleshooting issues related to poor combustion, high CO, and yellow flames.

Gas Flow Shuts Off During Operation (Blowers Remain On)

Investigating why gas flow stops while blowers continue running.

START UP FORM

PRE-START UP CHECK LIST

A checklist of essential items to verify before starting the unit.

ELECTRICAL/WIRING/CONTROL

Section for recording electrical and control system parameters.

BTC CONTROL SET UP

Configuration settings for the Boiler Temperature Control (BTC) system.

COMBUSTION/SAFETY REPORT

FACTORY FIRE TEST REPORT

Records factory fire test results for manifold and air differential pressures.

FIELD TEST REPORT IN STAGE

Fields for recording test results during installation stages (CO2, Stack Temp, etc.).

SAFETY CONTROL CHECK

Verification of safety control functions like low water cutoff, flow switch, and high limit.

COMMISSIONING THE UNIT

Checklist for final unit commissioning, including customer instruction and leak checks.

NOTICE!

Commonwealth of Massachusetts Installation Requirements

Requirements for carbon monoxide detectors and signage for horizontally vented equipment.

NOTICE! (continued)

Commonwealth of Massachusetts Installation Requirements (continued)

Requirements for installation by licensed plumbers/fitters and venting system documentation.

LIMITED WARRANTY

Boilers/Water Heaters Industrial, Commercial and Other Non-Residential Use

Details the warranty for boilers and water heaters for industrial/commercial use.

Warranty Exclusions

Lists conditions under which the limited warranty does not apply.

Warranty Conditions

Outlines conditions for warranty claims, including shipment of defective parts.

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