LCD-I0M-14

82-0278

Finned Copper Tube

Gas Boilers (LB) &
Water Heaters (LW)

Boiler Manual
Installation and Operation
Instructions

This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination
of the burner, resulting in possible severe personal injury, death or substantial property damage. The boiler can only be operated with
a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated
by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affix these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualified service
technician, and to follow all guidelines in the User’s Information Manual.

7/2024 Copyright 2014 Mestek, Inc.

 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

If the information in this manual is not followed BEFORE YOUR START . . . . . . . . . . . . . . . . PAGE 2
exactly, a fire or explosion may result causing property, RATINGS & CAPACITIES . . . . . . . . . . . . . . . PAGE 3
personal injury or loss of life.
BOILER/WATER HEATER LOCATION . . . . . . . . PAGE 3
Do not store or use gasoline or other flammable vapors COMBUSTION AIR & VENTILATION . . . . . . . . . PAGE 3
and liquids in the vicinity of this or any other appliance
GENERAL VENTING GUIDELINES . . . . . . . . . . PAGE 9
WHAT TO DO IF YOU SMELL GAS:
VENTING OPTIONS . . . . . . . . . . . . . . . . . . PAGE 9
• Do not try to light any appliance. VERTICAL/CHIMNEY VENTING . . . . . . . . . . .PAGE 13
• Do not touch any electrical switch. Do not use any HORIZONTAL VENTING . . . . . . . . . . . . . . .PAGE 14
phone in your building.
OUTDOOR VENTING . . . . . . . . . . . . . . . . PAGE 14
• Immediately call your gas supplier from a phone outside
COMMON VENT SYSTEMS . . . . . . . . . . . . . PAGE 15
the building. Follow the gas supplier’s instructions.
GENERAL PIPING REQUIREMENTS . . . . . . . . PAGE 16
• If you cannot reach your gas supplier, call the fire
department. HEATING SYSTEM PIPING . . . . . . . . . . . . . .PAGE 17

Installation and service must be performed by a qualified DOMESTIC WATER SUPPLY PIPING . . . . . . . . PAGE 21
installer, service agency or the gas supplier. GAS SUPPLY PIPING . . . . . . . . . . . . . . . . .PAGE 24

Assurez-vous de bien suivre les instructions données ELECTRICAL WIRING . . . . . . . . . . . . . . . . PAGE 25

dans cette notice pour réduire au minimum le risque GENERAL OPERATION . . . . . . . . . . . . . . . PAGE 25
d’incendie ou d’explosion ou pour éviter tout dommoge
OPERATING INSTRUCTIONS . . . . . . . . . . . . PAGE 29
matériel, toute blessure ou la mort
CHECKING & ADJUSTMENTS . . . . . . . . . . . .PAGE 31
Ne pas entreposer ni utiliser d’essence ou ni d’autres
vapeurs ou liquides inflammables à proximité de cet CONTROL DESCRIPTION . . . . . . . . . . . . . .PAGE 33
appareil ou de tout autre appareil. MAINTENANCE . . . . . . . . . . . . . . . . . . . .PAGE 34
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: TROUBLESHOOTING . . . . . . . . . . . . . . . . PAGE 37

• Ne pas tenter d’allumer d’appareil. REPAIR PARTS . . . . . . . . . . . . . . . . . . . .PAGE 39

START UP SHEET . . . . . . . . . . . . . . . . . . PAGE 47
• Ne touchez à aucun interrupteur; ne pas vous servir
des téléphones se trouvant dans le bâtiment. MASS. CODE . . . . . . . . . . . . . . . . . . . . .PAGE 49
• Appelez immédiatement votre fournisseur de gas depuis WARRANTY . . . . . . . . . . . . . . . . . . . . . .PAGE 50
un voisin. Suivez les intructions du fournisseur.
• Si vous ne purvez rejoindre le fournisseur, appelez le
service des incendies. BEFORE YOU START
L’installation et l’entretien doivent être assurés par un
installateur ou un service d’entretien qualifié ou par le This manual covers the application, installation, operation and
fournisseur de gaz. maintenance of a LCD Series finned copper heating boiler/water
heater.
Failure to properly vent this unit can cause excessive To obtain the safe, dependable, efficient operation and long life for
amounts of carbon monoxide resulting in severe which this heating boiler/water heater was designed, these instructions
personal injury or death! must be read, understood and followed.
DESIGNED AND TESTED ACCORDING TO A.S.M.E. The LCD Series finned copper heating boiler/water heaters have
BOILER AND PRESSURE VESSEL CODE, SECTION been design certified by CSA for use with natural and propane gas
IV FOR A MAXIMUM ALLOWABLE WORKING PRES- under the latest revision of ANSI-Z21.10.3/CSA 4.3, Gas Water
SURE OF 160 PSI, 1103 kPa WATER. Heaters, and ANSI-Z21.13/CSA 4.9, Gas-Fired Low Pressure Steam
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED and Hot Water Boilers. Each unit has been constructed and
ADJACENT TO THE HEATER . hydrostatically tested for a maximum working pressure of 160 psi,
1103 kPa in accordance with Section IV of the A.S.M.E. Boiler and
CONSUMER , RETAIN THESE INSTRUCTIONS FOR Pressure Vessel Code.
FUTURE REFERENCE PURPOSES.
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.
2
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

In Canada, the installation must be in accordance with the 2. An optimum site will be level, central to the piping system, close
requirements of CSA B149.1 or .2, Installation Code for Gas Burning to a chimney or outside wall and have adequate fresh air for
Appliances and Equipment. combustion. Ensure that the boiler/water heater is level from
front to back and from side to side. Use metal shims to level the
If installed in the Commonwealth of Massachusetts, you MUST boiler/water heater. Electrical and electronic components must
FOLLOW the additional instructions located in the back of this also be protected from exposure to water during operation and
manual (MACODE-3). maintenance. DO NOT install this boiler/water heater in a
The owner should maintain a record of all service work performed location that would subject any of the gas ignition components
with the date and a description of the work done. Include the name to direct contact with water or excessive moisture during
of the service organization for future reference. operation or servicing.
Direct all questions to your RBI distributor or contact the RBI Cus- 3. Ensure that the floor is structurally sound and will support the
tomer Service Department, 260 North Elm Street, Westfield, MA weight of the boiler/water heater.
01085 for U.S. or 7555 Tranmere Drive, Mississauga, ONT L5S 1L4 The LCD may be installed directly on combustible
for Canada. Always include the model and serial numbers from the flooring, but never on carpeting.
rating plate of the boiler/water heater in question.
4. Locate the boiler/water heater in an area that will prevent water
damage to adjacent construction should a leak occur or during
RATINGS & CAPACITIES routine maintenance. If such a location doesn’t exist, a suitable
drain pan that’s adequately drained must be installed under the
Before undertaking the installation of the LCD Series boiler/water unit.
heater check the rating plate to ensure that the unit has been sized 5. DO NOT place this boiler/water heater in a location that would
properly for the job. The “Net AHRI Ratings” specify the equivalent restrict the introduction of combustion air into the unit or subject
amount of direct cast iron radiation that the unit can supply under the air inlet to a negative pressure, see “GENERAL VENTING
normal conditions. Also ensure that the unit has been set up for the GUIDELINES”.
type of gas available at the installation site. Other important
considerations are the availability of an adequate electrical supply, Never store combustible materials, gasoline or any
fresh air for combustion and a suitable chimney or vent system. 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
BOILER/WATER HEATER LOCATION injury or death!

1. This boiler/water heater is suitable for indoor and outdoor 6. NEVER place this boiler/water heater in a location that would
installations. Locate the boiler/water heater in an area that subject it to temperatures at or near freezing. See the “Freeze
provides good access to the unit. Servicing may require the Protection Section” on page 17.
removal of jacket panels. Allow the minimum clearances between Units installed outdoors MUST be protected from ice
adjacent construction and the boiler/water heater as listed in and snow accumulation or the unit will be damaged
Table 1. voiding the warranty!
Service clearances are not mandatory, but are
recommended to ensure ease of service should it be
required.
COMBUSTION AIR & VENTILATION
Table 1 This boiler/water heater must be supplied with
Clearance to Service combustion air in accordance with Section 9.3, Air
Combustibles Clearance for Combustion & Ventilation, of the latest revision
in mm in mm of the National Fuel Gas Code, ANSI Z223.1/NFPA
Top 6 153 20 508 54 and all applicable local building codes. Canadian
Back 6 153 24 610 installations must comply with CSA B149.1 or .2
Left Side 6 153 24 610 Installation Code for Gas Burning Appliances and
Right Side 6 153 24 610 Equipment, or applicable provisions of the local
Front 6 153 30 762 building codes. Failure to provide adequate
Flue 6 153 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!

3
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Combustion air contaminated with fluorocarbons or All Air From Inside The Building
other halogenated compounds such as cleaning
solvents and refrigerants will result in the formation If the LCD is to be located in a confined space the minimum clearances
of acids in the combustion chamber. These acids will listed in Table 1 must be maintained between it and any combustible
cause premature failure of the boiler/water heater construction. When installed in a confined space without the
voiding the warranty! intake air option, Figures 1, 2 & 3, two permanent openings
communicating with an additional room(s) are required. The
If the boiler/water heater is operated while the building combined volume of these spaces must have sufficient volume to
is under construction it MUST be protected from meet the combustion air requirements of all gas utilization equipment.
wood, concrete, sheet rock and other types of dust. Fireplaces, wood stoves or any type of exhaust fan must be considered
Failure to properly protect the unit from construction when making this determination. Each opening must have a minimum
dust will damage the unit voiding the warranty! free area of 1 in2/1000 Btu/hr, 2200 mm2 kW based on the total
input rating of ALL gas utilization equipment in the confined area.
Buildings will require the installation of a fresh air duct or other Each opening must be no less than 100 in2, 64,516 mm2 in size. The
means of providing make-up air if the intake air option isn’t used. upper opening must be within 12 in, 305 mm of, but not less than
Any building utilizing other gas burning appliances, a fireplace, wood 3 in, 76 mm from, the top of the enclosure. The bottom opening
stove or any type of exhaust fan must be checked for adequate must be within 12 in, 305 mm of, but not less than 3 in, 76 mm
combustion air when all of these devices are in operation at one from, the bottom of the enclosure.
time. Sizing of an outside air duct must be done to meet the
requirements of all such devices.
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!

Figure 1 Vertical venting with a metal chimney system and inside air

10 FT

4
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Figure 2 Vertical venting using a masonry chimney system and inside air

Figure 3 Horizontal venting using inside air

1/4 IN. PER F00T 20 mm/m

1.5 FT 0.5 m

Table 2
MINIMUM VERTICAL RISE
VENT PIPE DIAMETER
OFF THE TOP OF UNIT "A"
IN. mm FT mm
5" TO 10" 127 TO 254 12" 305
12" TO 18" 305 TO 457 24" 610

5
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

All Air From Outside The Building Intake Air Option - General Guidelines
When installed in a confined space without utilizing the intake This configuration provides combustion air directly to the boiler/
air option two permanent openings communicating directly with, water heater’s air intake using a dedicated pipe to obtain combustion
or by ducts to, the outdoors or spaces that freely communicate with air from the outdoors. Combustion air can be drawn in horizontally
the outdoors must be present. The upper opening must be within 12 through an outside wall or vertically through the roof, see Figures
in, 305 mm of, but not less than 3 in, 76 mm from, the top of the 4, 5, 6 & 7.
enclosure. The bottom opening must be within 12 in, 305 mm of, Common intake air systems may be used to provide
but not less than 3 in, 76 mm from, the bottom of the enclosure. the common duct is sized properly and an intake
Where directly communicating with the outdoors or communicating combustion air damper is installed in the intake air
with the outdoors through vertical ducts, each opening shall have a pipe of each heater. Improper installation can result in
minimum free area of 1 in2/4000 Btu/hr, 550 mm2/kW of the excessive levels of carbon monoxide which can cause
total input rating of all of the equipment in the enclosure. severe personal injury or death!
Where communicating with the outdoors through horizontal Single wall galvanized smoke pipe, single wall aluminum pipe or
ducts, each opening shall have a minimum free area of 1 in2/2000 flexible aluminum pipe can be used for the in-take air pipe. It must
Btu/hr, 1100 mm2/kW of the total input rating of all of the be sized per Table 4. All joints in metal combustion air systems
equipment in the enclosure. When louvers and screens are used, they must be secured using corrosion resistant fasteners and sealed using
must have the same cross-sectional area as the free area of the a suitable Silicon caulk or tape. The combustion air system
MUST be supported by the building structure not the
opening to which they connect. boiler/water heater.
When calculating the free area necessary to meet the make-up air
requirements of the enclosure,consideration must be given to the Table 4 Combustion air pipe sizing
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 Pipe Diameter
Model Size
in mm
louver or grill is not known, ducts should be sized per Table 3.
400 6 152
600 - 750 8 203
Table 3 Make-up air louver sizing 1050 10 254
Required Cross Sectional Area 1200 - 2300 12 305
Input 1/4 in 6.4 mm 75% Free Area 25% Free Area
(MBH) Wire Screen Metal Louvers Wooden Louvers
A combustion air damper interlocked with the unit
in2 cm2 in2 cm2 in2 cm2
should be installed in the intake air pipe when the
399 100 645 133 858 399 2573
infiltration of sub-freezing air could occur, otherwise
600 150 968 200 1290 600 3870
the unit could freeze up voiding the warranty!
750 190 1210 250 1613 750 4840
1050 263 1696 350 2258 1050 6773
1200 300 1936 400 2580 1200 7740
1480 370 2388 494 3182 1480 9546
1650 413 2662 550 3548 1650 10,643
Intake Air Option - Horizontal Guidelines
1970 493 3179 657 4236 1970 12,707 The maximum equivalent length for the horizontal combustion
2300 575 3711 767 4945 2300 14,835 air pipe on installations that used the Direct Vent option is 35 ft,
10.8 m. The maximum equivalent length for the horizontal
combustion air pipe on installations that use the Horizontal Vent
option is 100 ft, 30.5 m. Each 90° elbow and the combustion air
Canadian installations must comply with CSA B149.1 when air terminal are equal to 10 linear ft, 3.0 m of pipe. If horizontal runs
supply is provided by natural air flow from the outdoors for natural exceed 5 ft, 1.5 m they must be supported at 3 ft, 0.9 m intervals
draft, partial fan-assisted, fan-assisted, or power draft-assisted with overhead hangers. The certified combustion air terminal from
burners, there shall be a permanent air supply opening(s) having RBI must be used and installed as shown in Figures 4 and 5.
a cross-sectional area of not less than 1 in2 per 7,000 Btuh
(310 mm2 per kW) up to and including 1 million Btuh, plus
1 in2 per 14,000 Btuh (155 mm2 per kW) in excess of 1 Intake Air Option - Vertical Guidelines
million Btuh. 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.

6
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Figure 4 Horizontal combustion air and venting for a single unit

9
8
7
Vertical Distance, Y

6 2000 & Larger

5 1201 To 2000
4 901 To 1200
3 200 To 900
400
2 1000 BTU'S
1
0
0 5 10 15 20
Horizontal Distance , X

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

Figure 5 Horizontal combustion air and venting for a multiple units

2 IN. 5.0 cm

1.5 FT 0.5 m

9
8 7
7
ce, Y

6
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Figure 6 Vertical combustion air and venting, metal chimney system shown
Locate exhaust terminal downwind from air intake to reduce potential for flue gas recirculation.

10 FT 3.1 m

4 FT
1.2 m 5 1/2 FT
1.7 m

1.5 FT
0.5 m

5 FT
1.5 m

Figure 7 Combination air intake and venting, masonry chimney shown

10 FT 3.1 m

3 FT 1 m

1.5 FT .5m

8
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

GENERAL VENTING GUIDELINES VENT SYSTEM OPTIONS

The vent installation must be in accordance with Part The LCD may be vented the following ways:
7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54-latest revision or 1) Vertical/Chimney Venting, Negative Pressure, Category
applicable provisions of the local building codes. I - uses an approved metal chimney system or properly lined
Canadian installations must comply with CSA B149.1 masonry chimney. Combustion air is obtained from the space
or .2 Installation Code. See Figure A for added clarity. in which the unit is installed or from outdoors. A barometric
Improper venting can result in excessive levels of carbon damper must be installed near the flue outlet when venting
monoxide which can result in severe personal injury vertically. See Figures 6 and 7. This also applies to any fan-assisted
or death! chimneys or vents.
All vent systems must be fully supported by the building structure 2) Direct Vent, Positive Pressure, Category III - for
and not by the boiler/water heater. Appropriate thimbles and fire- horizontal vent runs equivalent to 35 ft, 10.8 m or less.
stops must be used where required. A stainless steel vent system certified to UL 1738 for
Common vent systems must be properly engineered installations in the United States. ULC S636 for
and sized to provide a negative draft of 0.01 to 0.08 installations in Canada must be used when combustion air is
in, .25 to 2.0 mm WC at the flue outlet! Common ducted from outdoors, from the same wall.
positive pressure vent systems are not to be used. 3) Horizontal Vent, Negative Pressure, Category I -
Improper installation can result in excessive levels of for horizontal vent runs equivalent to more than 35 ft,
carbon monoxide which can cause severe personal 10.8 m (90° elbow equals 10 equivalent ft). A dedicated wall
injury or death! mounted power venter must be used. The vent system can be
single wall galvanized steel or type B vent pipe. Combustion
Multi-story, common venting systems shall be in air is obtained from the space in which the unit is installed or
accordance with the National Fuel Gas Code, ANSI from the outdoors.
Z223.1/NFPA 54 and/or the CSA B149.1, Natural
Gas and Propane Installation Code (Current Editions), A barometric damper must be installed when the horzontal run
local codes and vent manufacturer's installation is longer than 35 equivalent feet. (90° elbow = 10 equivalent
instructions. Size the chimney and breeching using ft). If this is the case, a power venter must also be used.
generally accepted engineering practices. (Consult 4) Outdoor Installation - uses the outdoor option kit. Barometric
factory for vertical heights beyond 60 ft.) damper is not required.
A single acting barometric damper must be All venting, combusiton air material supplied by
installed directly to the boiler/water heater flue installer. All venting material must be approved for the
outlet to ensure proper operation. This does not apply application. Consult the vent manufacturer’s product
to outdoor units or direct vent positive pressure units. literature.
Some venting applications may require the stop to be
removed for smooth operation. The barometric
damper should be located after the flue collector, refer
to Figures 2, 7A and 8 for proper location. Carefully
follow the instructions provided with the barometric
damper. Check with local codes for specific
requirements.
In Canada, B149 (7.25 Draft Regulators) states the
damper shall be of double-acting type.
To avoid spillage into the room of dangerous flue gas
containing carbon monoxide, the opening in damper
must never face against the flow of flue gas.
Boiler/Water Heater shall not be connected to a
chimney flue serving a separate appliance designed
to burn solid fuel.

9
 LCD Series
Torus Finned
Stainless SteelCopper Tube Gas
Condensing Boilers
Boilers & Water
& Water Heaters
Heaters – Boiler Manual
– Installation Manual

Figure A - Direct Vent Terminal Clearances

Canadian Installations¹ US Installations²

Clearance above grade, veranda, porch,
A= 12 in (30 cm) 12 in (30 cm)
deck, or balcony
6 in (15 cm) for appliances < 10,000 6 in (15 cm) for appliances < 10,000 Btuh
Btuh (3 kW); 12 in (30 cm) for appliances (3 kW); 9 in (23 cm) for appliances >
B= Clearance to window or door that may > 10,000 Btuh (3 kW) and < 100,000 10,000 Btuh (3 kW) and < 50,000 Btuh
be opened Btuh (30 kW); 36 in (91 cm) for (15 kW); 12 in (30 cm) for appliances >
appliances > 100,000 Btuh (30 kW) 50,000 Btuh (15 kW)
Clearance to permanently closed
C=
window
Vertical clearance to ventilated soffit
located above the terminal within a
D=
horizontal distance of 2 ft (61 cm) from
the center line of the terminal.
Per local installation codes
E= Clearance to unventilated soffit

F= Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line

H= extended above meter / regulator 3 ft (91 cm) within a height of 15 ft (4.6m)
assembly

Clearance to service regulator 3 ft (91 cm)

I=
vent outlet

6 in (15 cm) for appliances < 10,000 6 in (15 cm) for appliances < 10,000 Btuh
Clearance to nonmechanical air supply Btuh (3kW); 12 in (30 cm) for appliances (3kW); 9 in (23 cm) for appliances >
J= inlet to building or the combustion air > 10,000 Btuh (3 kW) and < 100,000 10,000 Btuh (3 kW) and < 50,000 Btuh (15
inlet to any other appliance Btuh (30 kW); 36 in (91 cm) for kW); 12 in (30 cm) for appliances > 50,000
appliances > 100,000 Btuh (30 kW) Btuh (15 kW)

10
 LCDStainless
Torus Series Finned Copper Tube
Steel Condensing Gas Boilers
Boilers & Water&Heaters
Water Heaters – Boiler
– Installation Manual
Manual

Figure A - Direct Vent Terminal Clearances - Concluded

Clearance to a mechanical air 3 ft (91 cm) above if within 10 ft (3 m)

K= 6 ft (1.83 m)
supply inlet horizontally
Clearance above paved sidewalk 7 ft (2.13 m) for mechanical draft systems
or paved driveway located on (Category I appliances). Vents for
L= public property 7 ft (2.13 m)† Category II and IV appliances cannot be
located above public walkways or other
areas where condensate or vapor can
cause a nuisance or hazard
Clearance under veranda, porch,
M= 12 in (30 cm)‡ Per local installation codes
deck, or balcony

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family
dwellings and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
NOTES:
1) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
3) If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearances must prevail.

Figure A - Other Than Direct Vent Terminal Clearances

Canadian Installations¹ US Installations²

Clearance above grade, veranda, porch, 12 in (30 cm) 12 in (30 cm)
A=
deck, or balcony
6 in (15 cm) for appliances < 10,000
Btuh (3 kW); 12 in (30 cm) for appliances
Clearance to window or door that may 4 ft (1.2 m) below or to side of opening;
B= > 10,000 Btuh (3 kW) and < 100,000
be opened 1 ft (300 mm) above opening
Btuh (30 kW); 36 in (91 cm) for
appliances > 100,000 Btuh (30 kW)
Clearance to permanently closed
C=
window
Vertical clearance to ventilated soffit
located above the terminal within a
D=
horizontal distance of 2 ft (61 cm)
from the center line of the terminal

E= Clearance to unventilated soffit

Per local installation codes
F= Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line

H= extended above meter/regulator 3 ft (91 cm) within a height of 15 ft (4.6m)
assembly

Clearance to service regulator vent 3 ft (91 cm)

I=
outlet

6 in (15 cm) for appliances < 10,000 4 ft (1.2 m) below or to side of opening;
Clearance to nonmechanical air supply Btuh (3kW); 12 in (30 cm) for appliances 1 ft (300 mm) above opening
J= inlet to building or the combustion air > 10,000 Btuh (3 kW) and < 100,000
inlet to any other appliance Btuh (30 kW); 36 in (91 cm) for
appliances > 100,000 Btuh (30 kW)

11
 Torus Stainless Steel Condensing Boilers & Water Heaters – Installation Manual

LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Figure A - Other Than Direct Vent Terminal Clearances - Concluded

Clearance to a mechanical air supply 6 ft (1.83 m) 3 ft (91 cm) above if within 10 ft (3 m)

K=
inlet horizontally
Clearance above paved sidewalk or 7 ft (2.13 m) for mechanical draft systems
paved driveway located on public (Category I appliances). Vents for
L= property Category II and IV appliances cannot be
7 ft (2.13 m)† located above public walkways or other
areas where condensate or vapor can
cause a nuisance or hazard

Clearance under veranda, porch, deck, 12 in (30 cm)‡

M= Per local installation codes
or balcony

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
NOTES:
1) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
3) If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearances must prevail.

12
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

VERTICAL/CHIMNEY VENTING Never install a vent pipe having a diameter different

than that of the boiler/water heater flue collar. Failure
The LCD is listed as a Category I appliance when vented vertically to comply with this warning can result in excessive
into a metal chimney system or properly sized masonry chimney, levels of carbon monoxide which can cause severe
Figures 1, 2, 6 & 7. The chimney must provide a negative pressure personal injury or death.
of 0.01 to 0.08 in, .25 to 2.0 mm WC at the boiler/water heater
flue collar with the unit running at full load. A barometric damper Always provide a minimum clearance of 6 in, 152 mm between
must be installed between the flue collar and the vent connector. single wall vent pipe and any combustible materials. Type B1 vent
Approved thimbles and fire-stops must be used when combustible may be used, clearance between it and any combustible material
construction is penetrated. must be as listed.
If an appliance using any type of a mechanical draft Failure to maintain minimum clearances between vent
system operating under positive pressure is connected connectors and any combustible material can result
to a chimney flue, never connect any other appliances in a fire causing extensive property damage, severe
to this flue. Doing so can result in excessive levels of personal injury or death!
carbon monoxide which can cause severe personal
injury or death!

DIRECT VENT, POSITIVE PRESSURE,

Chimney Inspection & Sizing
CATEGORY III
A thorough inspection of the masonry chimney must be performed
to ensure that the chimney is clean, properly constructed, lined and In this configuration the boiler/water heater blower is used to push
sized. Exterior masonry chimneys should not be used unless properly the flue products to the outdoors while drawing combustion air
lined to prevent condensation and draft problems. Table 5 lists the from the outdoors. The equivalent length of the vent and combustion
mimimum riser diameter connections, negative pressure for the air systems must not exceed 35 ft, 10.7 m for each. The Intake
boiler/water heater. When more than one appliance is connected Air Option instructions under the “COMBUSTION AIR &
to the same chimney flue, the flue must be large enough to safely VENTILATION” section must be followed! The vent system flue
vent the combined output of all of the appliances. pipe diameter must be sized per Table 5a.

Table 5 Minimum Riser Connection, Negative Pressure (Category I)

Horizontal Direct Vent Systems - Figures 4 & 5
Pipe Diameter The vent materials used in horizontal vent systems must be certified
Model Size
in mm to UL 1738 for installations in the United States, ULC S636 for
400 6 152 installations in Canada. The certified vent terminal from RBI must
600 7 178 also be used.
750 8 203
1050 10 254 The maximum equivalent length for the horizontal vent and
1200 - 1480 12 305 combustion air pipes is 35 ft, 10.8 m for each. Each 90° elbow
1650 - 2300 14 356 and the intake air and vent terminals are equal to 10 ft, 3.1 m of
straight pipe. To maximize the performance of single wall sheet
Note: Vent system must be sized per the tables contained in metal vent systems locate 90° elbows as far from the boiler as possible
NFPA 54 or an engineered system and from one another. For best results, horizontal vent systems
should be as straight as possible.
Vent Connections
The vent system must be both gas tight and watertight. All seams
Locate the boiler/water heater as close to the chimney as possible. and joints in metal pipes must be joined and sealed in accordance
Use the shortest, straightest vent connector possible for the with the vent system manufacturer’s instructions.
installation. If horizontal runs exceed 5 ft, 1.5 m they must be
supported at 3 ft, 0.9 m intervals with overhead hangers. Use a When horizontal vent runs exceed 5 ft, 1.5 m they must be supported
type B, single wall stainless or single wall galvanized steel vent pipe at 3 ft, 0.9 m intervals with overhead hangers. The vent system
the same diameter as the flue collar to connect the boiler/water must be pitched down, toward the vent terminal, 1/4 in/ft,
heater to a masonry chimney. When using an approved metal 20 mm/m. If any part of a single wall metal vent system passes
chimney system use the appropriate vent connector. The vent through an unheated space it must be insulated with insulation rated
connector should be sloped up toward the chimney at a minimum for 400°F, 204°C.
rate of 1/4 in/ft, 20 mm/m. On masonry chimneys the connector
must 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.

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 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Table 5a Category III Vent Pipe Diameter When horizontal vent runs exceed 5 ft, 1.5 m they must be supported
at 3 ft, 0.9 m intervals with overhead hangers. The vent system must
Pipe Diameter be pitched down, toward the vent terminal, 1/4 in/ft, 20 mm/m.
Model Size
in mm If any part of a single wall metal vent system passes through an
400 6 152 unheated space it must be insulated with insulation rated for 400°F,
600 - 750 8 203 204°C.
1050 10 254
1200 - 1480 12 305 Horizontal vent systems shall terminate at least 4 ft, 1.2 m below,
1650 - 2300 14 356 4 ft, 1.2 m horizontally from or 1 ft, 0.23 m above any door,
window or gravity air inlet into any building. It must not terminate
Note: Diameters based on a maximum 35 equivalent feet.
less than 4 ft, 1.2 m horizontally from, and in no case above
or below, unless a 4 ft, 1.2 m horizontal distance is maintained,
from electric meters, gas meters, regulators and relief equipment
Horizontal vent systems shall terminate at least 4 ft, 1.2 m below, and not less than 7 ft, 2.3 m from any adjacent public walkway.
4 ft, 1.2 m horizontally from or 1 ft, 0.23 m above any door, window Avoid terminal locations likely to be affected by winds, snowdrifts,
or gravity air inlet into any building. It must not terminate less than people and pets. Protect building materials and vegetation from
4 ft, 1.2 m horizontally from, and in no case above or below, unless degradation caused by the flue gases.
a 4 ft, 1.2 m horizontal distance is maintained, from electric meters,
gas meters, regulators and relief equipment and not less than 7 ft, To determine the appropriate power venter for the boiler/water
2.1 m from any adjacent public walkway. Avoid terminal locations heater, see Table 6. Follow the power venter manufacturer’s
likely to be affected by winds, snowdrifts, people and pets. Protect installation instructions.
building materials and vegetation from degradation caused by the
flue gases. Table 6 Power Venter Sizes
LCD Power Venter Max. Pipe Length
Vertical Direct Vent Systems - Figure 6 Model Model ft mm
400 HS-2 100 31.0
The maximum length for the vertical vent and combustion air pipes 600 HS-2 67** 20.8
is 35 ft, 10.7 m plus two 90° elbows. If any part of a single wall 750 HS-3 100 31.0
metal vent system passes through an unheated space it must be 1050-1200 HS-4 100 31.0
insulated with insulation rated for 400°F, 204°C. Structural 1480-2300 HS-5 100 31.0
penetrations must be made using approved fire-stops.
**Choose HS-3 for 100 ft, 31 m, Max. Pipe Length
A listed, nonrestrictive vent cap must be used. The top of a vertical
vent system must extend at least 5 1/2 ft, 1.7 m above the roof
surface that it passes through, 4 ft, 1.2 m above the intake air cap,
see Figure 6.
OUTDOOR VENTING
When installed outdoors the LCD must be fitted with the factory
HORIZONTAL VENT, NEGATIVE PRESSURE, supplied outdoor vent hood and air intake hood, see Figure 8.
Multiple units must be spaced per Figure 9.
CATEGORY I
The boiler/water heater must be at least 10 ft, 3.1 m from any
In this configuration a wall-mounted power venter must be used door, window or gravity air inlet into any building and at least
to pull the flue products horizontally from the unit and vent them 3 ft, 0.9 m from any overhang unless local codes dictate differently.
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 Avoid locations where wind deflection off of adjacent walls, buildings
outdoors. The applicable instructions under the “COMBUSTION or shrubbery might cause a downdraft. The unit(s) should be located
AIR & VENTILATION” section must be followed! at least 3 ft, 0.9 m from structures. Outdoor installations are not
recommended in areas where the danger of snow blockage exists.
To maximize the performance of single wall sheet metal vent systems
locate 90° elbows as far from the boiler as possible and from one Do not place the boiler/water heater in a location that
another. For best results, horizontal vent systems should be as short would subject it to runoff from adjacent buildings or
and straight as possible. damage may occur voiding the warranty!

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 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Figure 8 Outdoor venting 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 fonction-nent pas:
système d'évacuation
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. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhaust, so
they will operate at maximum speed. Do not operate a summer
exhaust fan for a boiler installation. Close fireplace dampers.
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.

15
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

e) Test for spillage at the draft hood relief opening after 5 minutes Table 7 Temperature Rise Table
of main burner operation. Use the flame of a match or candle,
or smoke from a cigarette, cigar or pipe. ∆T = 15°F ∆T = 8.3°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Faire fonctionner le brûleur principal pendant 5 min ensuite, Number GPM Ft L/s kPa
déterminer si le coupe-tirage déborde à l'ouverture de décharge. 400 44.7 0.73 2.8 2.1
Utiliser la flamme d'une allunette ou d'une chandelle ou la 600 67.2 1.92 4.1 5.4
fumée d'une cigarette, d'un cigare ou d'une pipe. 750 84.0 3.47 5.2 9.8
∆T = 20°F ∆T = 11.1°C
f) After it has been determined that each appliance remaining Model Flow Rate Pres. Drop Flow Rate Pres. Drop
connected to the common venting system properly vents when Number GPM Ft L/s kPa
tested as outlined above, return doors, windows, exhaust fans, 400 33.5 0.43 2.1 1.2
fireplace dampers and any other gas-burning appliance to their 600 50.4 1.13 3.1 3.2
750 63.0 2.04 3.9 5.7
previous condition of use. 1050 88.2 5.40 5.4 15.2
Une fois qu'il a été d éterminé, selon la métode indiquée ci- 1200 100.8* 8.51 6.2 24.0
dessus, que chaque appareil raccordé au système d'évacuation 1480 124.3* 8.30 7.7 23.4
est mis à l'air libre de façor adéquate. Remettre les portes et les ∆T = 25°F ∆T = 13.9°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
fenêtres, les ventilateurs, les registres de cheminées et les appareils Number GPM Ft L/s kPa
au gaz à leur position originale. 400 26.8 0.28 1.7 0.8
g) Any improper operation of the common venting system should 600 40.3 0.75 2.5 2.1
be corrected so the installation conforms with the National Fuel 750 50.4 1.35 3.1 3.8
1050 70.6 3.57 4.3 10.1
Gas Code, ANSI Z223.1/NFPA 54. When resizing any portion 1200 80.6 5.63 5.0 15.9
of the common venting system, the common venting system 1480 99.5 5.49 6.1 15.5
should be resized to approach the minimum size as determined 1650 110.9 7.34 6.8 20.7
using the appropriate tables in Appendix F in the National Fuel ∆T = 30°F ∆T = 16.7°C
Gas Code, ANSI Z223.1/NFPA 54 and or CAN/CGA-B149 Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Installation Codes. Number GPM Ft L/s kPa
600 33.6 0.53 2.1 1.5
Tout mauvais fonctionnement du systéme d'évacu-tion commun 750 42.0 0.96 2.6 2.7
devrait étré corrigé de façor que l'installation soit conforme au 1050 58.8 2.55 3.6 7.2
National Fue Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux 1200 67.2 4.01 4.1 11.3
codes d'installation CAN/CGA-B149. Si la grosseur d'une section 1480 82.9 3.92 5.1 11.0
du système d' évacuation doit étré modifiée, le système devrait 1650 92.4 5.24 5.7 14.8
étré modifié pour respecter les valeurs minimales des tableaux 1970 110.3 9.15 6.8 25.8
pertinents de l'appendice F du National Fuel Gas Code, ANSI ∆T = 35°F ∆T = 19.4°C
Z223.1/ NFPA 54 et (ou) des codes d'installation CAN/ Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
CGA-B149. 600 28.8 0.40 1.8 1.1
750 36.0 0.72 2.2 2.0
1050 43.2 1.18 3.1 5.4
1200 57.6 3.02 3.5 8.5
GENERAL PIPING REQUIREMENTS 1480 71.0 2.94 4.4 8.3
1650 79.2 3.94 4.9 11.1
Improper piping of this boiler/water heater will void 1970 94.6 6.88 5.8 19.4
the manufacturer's warranty and can cause boiler failure **Flow exceeds recommended maximum use a greater temperature
resulting in flooding and extensive property damage! rise or consult manufacturer. Cupro-nickel heat exchanger should be
considered.
Excessive water hardness causing scaling in the copper
heat exchanger tubes is NOT covered under the
manufacturer’s warranty. Excessive pitting and erosion
of the internal surface of the copper heat exchanger
tubes is NOT covered under the manufacturer’s
warranty if the result of high water flow rates, see Table
7. Return water temperatures below 125°F, 52°C will
result in heat exchanger damage from excessive
condensation voiding the manufacturer’s warranty, see
Primary/Secondary Piping Figure 11.
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.

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 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Freeze Protection Flow Switch

This boiler/water heater is CSA designed certified for outdoor The flow switch s provided to prove flow is present through the
installation. Outdoor installations in areas where the danger of boiler. The temperature rise across the primary heat exchanger must
freezing exists are not recommended unless proper freeze protection never exceed 35F, 19.4C.
is provided. If the unit is to be installed in such an area the following
precautions MUST be observed: Failure to properly install the flow switch may result
in damage to the boiler/water heater heat exchanger
1. A continuous flow of water through the boiler/water heater voiding the warranty!
MUST be maintained! The pump responsible for flow through
the boiler/water heater must run continuously!
2. A propylene 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
HEATING SYSTEM PIPING
overcoming a 20% increase in head loss. Domestic water systems
must be isolated from the water heater by the use of a heat General Piping Requirements
exchanger or other approved method.
3. If the boiler/water heater must be shut off for any reason the All heating system piping must be installed by a qualified technician
electric, gas and water supplies MUST be shut off and the unit in accordance with the latest revision of the ANSI/ASME Boiler
and its pump completely drained. and Pressure Vessel Code, Section IV, and when required, ANSI/
ASME CSD-1, Standard for Controls and Safety Devices for
Improper outdoor installation of this boiler/water heater Automatically Fired Boilers. All applicable local codes and ordinances
can cause boiler failure voiding the manufacturer's must also be followed. A minimum clearance of 1 in, 25 mm must
warranty! be maintained between heating system pipes and all combustible
construction. All heating system piping must be supported by suitable
hangers not the boiler.
Relief Valve
The thermal expansion of the system must be considered when
Pipe the discharge of the pressure relief valve to prevent scalding in supporting the system. A minimum system pressure of 12 psig,
the event of a discharge, see Figure 10. The discharge piping must be 82.7 kPa must be maintained.
sized the same as the pressure relief valve outlet and installed to allow
complete drainage of both the relief valve and the discharge piping.
Heating Boiler Piping Connections
Figure 10 Relief valve piping The supply and return piping should be sized to suit the system.
The supply and return connection sizes are listed in Table 8.

Table 8 Supply & return connection sizes

Model Size Supply Size Return Size
400 thru 1970 2 1/2” NPT 2 1/2” NPT

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!

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 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Pump Requirements (Primary/Secondary) Primary/Secondary Piping

This low mass boiler requires a continuous minimum water flow Boilers connected to heating systems using zone valves, zone pumps,
for proper operation. The boiler pump must be sized to overcome or systems that have excessive flow rates or return water temperatures
the head loss of the boiler and the near piping in order to achieve less than 125°F, 52°C must be isolated from these systems to protect
the required temperature rise. Table 7 provides the heat exchanger the boiler. Figure 11, shows a typical primary/secondary piping
pressure drop and temperature rise figures. The temperature rise system. A dedicated pump is used to maintain a constant water
across the boiler must never exceed 35°F, 19.4°C. flow through the boiler. This boiler pump is sized to overcome the
head loss of the boiler and near-boiler piping system while supplying
A temperature rise outside of the range listed in Table the flow rate required to maintain the desired temperature rise across
7 indicates that the flow rate through the heat exchanger the boiler heat exchanger. The system pump is sized to provide the
is incorrect which will damage the heat exchanger required flow to the heating system. The boiler piping connections
voiding the warranty! The maximum allowable to the heating system piping must be a maximum 10X pipe diameters
temperature rise is 35°F, 19.4°C. between centers to ensure zero pressure drop in the primary system.
Flow must be properly accounted for in the design of primary/
The maximum allowable flow rate through a LCD secondary systems. In order to prevent boiler(s) short cycling the
boiler with copper heat exchanger is 92 GPM, system flow must be equal to or higher than the boiler(s) local flow.
5.8 L/s on 400-1200 models and 115 GPM,
7.3 L/s on 1480 to 1970 models. The cupro-nickel
heat exchanger allows for 100 GPM, 6.3 L/s on 400 Low Return Water Temperatures
to 1200 models and 125 GPM, 7.9 L/s on 1480 to
1970 models. 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
Low Water Cutoff must be installed, see Figure 12 and 12A. The bypass and bypass
valve must be sized the same as the secondary piping. A balancing
If a boiler is installed above any radiation elements it must be fitted valve must also be installed in the supply side of the secondary
with a low water cutoff device. piping downstream of the bypass. The balancing valve should be
Refer to wiring diagram supplied with the boiler/water heater for adjusted to divert some of the heated discharge water into the return
proper wiring connections. 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
Expansion Tank & Air Separator the primary system piping must not be more than 10X pipe diameters
apart to ensure zero pressure drop in the primary system, see Figure
An expansion tank or other means to control thermal expansion 12 and 12A.
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 Multiple Boiler Systems
air trapped in the system.
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 flow-control valves or some other automatic
means of preventing gravity circulation of the boiler water during
the cooling cycle.

18
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Figure 11 Typical primary/secondary piping system

(See notes) Pump

Gate Valve

Globe Valve

Angle Valve

NOTES:
Bufferfly Valve
1. Boiler circuit piping must be sized
large enough to handle maximum
Balance Valve
flow through unit.
2. Boiler pump sized to boiler design
flow requirements.
Ball Valve
3. All boilers furnished with factory
mounted outlet water temperature
gauge. Motorized Valve
4. Boiler pump purging required.
Use terminals supplied.
Solenoid
Notice: These drawings show suggested Operated Valve
piping configuration and valving.
Check with local codes and ordinances for
specific requirements.
H-1 Rev 4
Self-Operated
Valve

Pressure
Figure 12 Low temperature piping Reducing Valve

(See notes and adjustment procedures)

Check Valve

Pressure
Relief Valve

Flow Switch

Thermometer

Aquastat Union

Pressure Switch

H-3 Rev 6
Gas Pressure
Regulator

Automatic
Air Vent

Backflow-
Prevention
Device

3-Way Valve
Adjustment Procedure To Maintain Inlet Temperature
Above Dew Point
T1-Temp-Min=110°F For Atmospheric
NOTES: T1-Temp-Min=125°F Sealed Combusion Expansion
Tank
1. Boiler circuit piping must be sized large enough to handle 1. Turn heater on and open valves A & B.
maximum flow through unit. 2. After steady-state operation, if T1 is less than Temp-Min
2. Boiler pump sized to boiler design flow requirements. slowly close valve B until T1 climbs to desired operating
3. All boilers furnished with factory mounted outlet water temperature above Temp-Min.
temperature gauge.
3. If T1 is greater than desired operating temperature, slowly
4. Boiler pump purging required. Use terminals supplied.
close valve A to adjust to lower desired temperature above
Notice: These drawings show suggested piping configuration and valving. Temp-Min.
Check with local codes and ordinances for specific requirements. 4. Check after system operating temperature has stabilized.
Make final adjustments.
5. Follow same adjustment procedure for sealed combustion.

19
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Figure 12A Low temperature piping with thermostatic valve

(See notes and adjustment procedures) Pump

Gate Valve

Globe Valve

Angle Valve
NOTES:
Bufferfly Valve
1. For pump selection consult factory.
2. Boiler pump sized to boiler and
thermostatic 3-way valve design flow Balance Valve
requirements.
3. Boiler circuit piping must be sized
large enough to handle maximum Ball Valve
flow through unit.
4. All boilers furnished with factory
Motorized Valve
mounted outlet water temperature
gauge.
5. Boiler pump purging required. Use
terminals supplied. Solenoid
Operated Valve
6. Valve is precalibrated for 140°F
return temperature.

Notice: These drawings show Self-Operated

Valve
suggested piping configuration and
H-18 Rev 3 valving. Check with local codes and
ordinances for specific requirements.
Pressure
Reducing Valve

Check Valve

Figure 13 Multiple Boiler Piping

(See Notes) Pressure
Relief Valve

Flow Switch

Thermometer

Aquastat Union

Pressure Switch

Gas Pressure
Regulator

Automatic
Air Vent

Backflow-
Prevention
Device

3-Way Valve

NOTES: Expansion
Tank

1. Boiler circuit piping must be sized large enough to handle

maximum flow through unit.
2. Boiler pump sized to boiler design flow requirements.
3. All boilers furnished with factory mounted outlet water
temperature gauge.
4. Boiler pump purging required. Use terminals supplied. H-15 Rev 5
5. Secondary loop pipe diameter must be sized large enough to
handle maximum flow through all units.

Notice: These drawings show suggested piping configuration and valving.

Check with local codes and ordinances for specific requirements.

20
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

DOMESTIC WATER SUPPLY PIPING 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
Proper control settings must be used to prevent water will improve heater performance and help ensure heater longevity.
supplied for domestic use from exceeding 130°F, 54°C
or a scald injury will occur! When higher water
temperatures are required for appliances such as a Expansion Tank
dishwasher, a mixing valve or some other tempering An expansion tank or other means to control thermal expansion
means must be installed. Households with small must be installed in the water heating system if back flow prevention
children may require water temperatures less than devices are installed.
120°F, 49°C. Local codes must be complied with!

Cold Water Supply

General Piping Requirements
The cold water supply must be piped to the water heater’s outlet
Ensure that the water heater is equipped with bronze headers. Piping piping between the water heater and the hot water storage tank.
and components connected to the water heater must be suitable for This will prevent untempered water from entering the water heater,
use with potable water. The water heater must not be connected to see the Temperature Rise Control section below. A typical water
any heating system piping or components previously used with a heating system is shown in Figure 14 and 15.
non-potable 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 Pump Requirements
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. This low-mass water heater requires a continuous minimum water
flow for proper operation. The low water flow switch provided for
The storage tank must be located as close to the water this unit will shut down the water heater if flow falls below the
heater as possible to prevent excessive head loss which required minimum level. Table 9B provides the heat exchanger
will reduce flow. pressure drop chart and temperature rise table. The temperature
rise across the water heater must never exceed 35°F, 19.4°C.

Water Chemistry
Temperature Rise Control
The required temperature rise across the water heater is based on
water having a hardness between 8 and 18 grains per gallon with Water returned to the water heater inlet must not be less than 125°F,
a level of dissolved solids not exceeding 350 ppm. Water having a 52°C or excessive condensation of the products of combustion will
hardness less than 8 grains can cause excessive errosion of the heat damage the water heater voiding the warranty. The method outlined
exchanger. Water that has a hardness greater than 18 grains per below can be employed to prevent this condition from occurring.
gallon and/or a level of dissolved solids exceeding 350 ppm will A balancing valve should be installed on the outlet side of the water
require a recalculation of the pump size and temperature rise. heater for purposes of adjusting the flow rate through the heat
A cupro-nickel heat exchanger may also be required. The exchanger. Thermometers are installed on both the inlet and outlet
manufacturer should be consulted when these water conditions are of the water heater for determining the temperature rise through the
encountered, see Table 9A. unit. The proper velocity through the water heater must be maintained
The maximum allowable flow rate through a LCD water in accordance with Table 9B for efficient operation and long life.
heater with copper heat exchanger is 92 GPM, 5.8 L/s If the temperature rise through the water heater is lower than
on 400 to1200 models and 115 GPM, 7.3 L/s on 1480 recommended the water velocity is too high. Premature erosion of
to 2300 models. The cupro-nickel heat exchanger allows the heat exchanger will occur. Conversely, if the temperature rise is
for 100 GPM, 6.3 L/s on 400 to 1200 models 125 higher than recommended in Table 9B the flow rate is too low. Scaling
GPM, 7.9 L/s on 1480 to 2300 models, see Table 9B. and softening of the heat exchanger will occur.

RBI water heaters are designed to run scale free. Due to the extreme
variables of water conditions world wide it is necessary to consider Thermostatic Mixing Valve -
pH values and water hardness in relationship to scaling. It is crucial Water Above 140°F, 60°C
to consider these two variables when making heat exchanger and
pump selection. If local water conditions are extreme follow the Water can be stored at temperatures above 140°F, 60°C provided
guidelines in the Heat Exchanger Selection Table (Table 9A) and the that a thermostatically controlled mixing valve is used to temper
Pumping Performance Table (Table 9B). Scale free operation can be the hot water to an acceptable temperature before it’s supplied for
achieved by using water with a hardness between 8 and 18 and by domestic use.
maintaining the pH between 5 and 9. Follow the conditions listed The mixing valve MUST be set to prevent a scald injury from
under NORMAL in the table. In some areas of the country additional occurring, see the caution against scalding above.
precautions must be observed due to unusual characteristics of the
local water supply. Call the nearest RBI representative for details. Storage of water for domestic use above 140°F, 60°C will provide
an increased quantity of tempered water and help prevent growth
of water born bacteria.
21
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Table 9A LCD Heat exchanger selection graph

Table 9B LCD Pumping performance requirement

22
 Motorized Valve

LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual Solenoid
Operated Valve

Self-Operated
Valve

Figure 14 Typical water heating piping (LW models only)

(See notes) Pressure
Reducing Valve
3
1
Check Valve

8
4
Pump
Pressure
7 Relief Valve
Valve

2
Flow Switch
Globe Valve

D-1 Rev 6 Thermometer

Angle Valve

Bufferfly Valve
Aquastat Union

Attention:
Not all RBI stock storage tanks Balance Valve
incorporate this tapping: See Note 1. Pressure Switch

Ball Valve Gas Pressure

Figure 15 Multiple water heating piping (LW models only) Regulator
(See notes)
Motorized Valve
Automatic
SELF BALANCING DOUBLE REVERSE Air Vent
RETURN MAKE-UP & SUPPLY, CIRCULATION
Solenoid
4 Operated Valve

3 Temperature &
Pressure
8 Relief Valve
6 Self-Operated
Valve
4

Vacuum
1
Relief Valve
7 Pressure
Reducing Valve

2
Check Valve Drain Valve
7
(Typ.)

2
Pressure
Relief Valve
D-4 Rev 6
6

Flow Switch

Attention:
Thermometer
Not all RBI stock storage tanks
NOTES: incorporate this tapping: See Note 1.

1. Optional cold water make up and recirculation line location. Aquastat Union
2. When using intermittent pump and pump delay, locate remote aquastat
well in lower 1/3 of tank. Install aquastat with heat sensing compound.
3. Thermal expansion tank may be required, check local codes.
Pressure Switch
4. When using optional factory mounted pump, max pipe length 30’ total, 6-90° elbows, full pipe size.
5. CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE.
The pH and water hardness must be measured before selecting heat exchanger and pump.
Consult the Heat Exchanger Graph and Pumping Performance Table before making selection. Gas Pressure
6. Common piping must be sized for maximum combined heater flow. Regulator
7. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
8. MA Code requires an 1/8” hole in check valve to compensate for thermal expansion.
9. Boilers may require a mixing application in order to prevent flue gas condensation and premature failure caused by fireside corrosion. See (Figure 12) -
Automatic
"Adjustment Procedure To Maintain Inlet Temperature Above Dew-point". Air Vent
10. A thermostatic mixing valve may be required at the outlet of the tank in order to limit the mixed water to a desirable temperature helping to prevent
scalding and injury. Consult local codes.

Notice: These drawings show suggested piping configuration and valving.

Check with local codes and ordinances for specific requirements. Temperature &
Pressure
Relief Valve
23
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

GAS SUPPLY PIPING Table 11 Equivalent pipe length chart

Nominal Type of pipe fitting
Check the boiler/water heater rating plate to make
Iron Pipe 90˚ Elbow Tee1 Gate Valve2 Gas Cock2
sure that the boiler/water heater is for the type of gas
Size Equivalent pipe length, (ft)
that will be used. If it isn’t, do not connect the boiler/
1" 2.6 5.2 0.6 1.5
water heater to the gas supply. Gas supply piping must
1 1/4" 3.5 6.9 0.8 1.9
be in accordance with the National Fuel code, ANSI
1 1/2" 4.0 8.0 0.9 2.3
Z223.1-latest revision or applicable provisions of the
2" 5.2 10.3 1.2 3.0
local building codes. Canadian installations must
2 1/2" 6.2 12.3 1.4 3.7
comply with CAN/CGA B149.1 or .2 Installation
3" 7.7 15.3 1.8 4.5
Code. Failure to comply with this warning can result
Notes: 1. For flow through branch.
in extensive property damage, severe personal injury 2. For flow at full open.
or death!
The LCD comes from the factory ready to be piped to the gas Always use a wrench on the gas valve body when
supply. If for any reason the boiler/water heater is not for the type making gas connections to it. Never over-tighten the
of gas available at the installation site, call your RBI Water Heaters piping entering the gas valve body or gas valve failure
representative to resolve the problem. may result!
A minimum gas supply pressure of 7 in, 178 mm,
WC natural or 11 in, 279 mm WC propane and Figure 16 Gas supply piping
maximum 14 in, 356 mm WC natural or propane,
must be available at the safety shutoff valve inlet with
the unit(s) operating.
Table 10 should be used to ensure that the gas supply piping is
sized properly. If more than one appliance is supplied by the same
supply pipe, the piping must be sized based on the maximum possible
demand. Do not neglect the pressure drop due to pipe fittings. Table
10 should be used in conjunction with Table 11 to ensure that the
gas supply piping has the capacity to meet the demand.
Figure 16 depicts the proper way to connect the boiler/
water heater to the gas supply piping. The manual shut-off valve
must be installed in the supply piping. It should be installed 5 ft,
1.5 m above the floor where required by local codes. Provide a
sediment trap at the bottom of the vertical section of the gas supply
pipe upstream of the gas controls.
A ground joint union should be installed between the boiler gas When applicable, provisions for vent, bleed and gas relief lines must
controls and the supply piping. Each of these items are needed to be made in accordance with the latest revision of ANSI Z223.1/
ensure long life and ease of servicing. Always use a pipe sealant that NFPA 54.
is suitable for use with LP gas.
Safe lighting and other performance criteria were met with the gas
Table 10 Gas pipe capacity
manifold and control assembly provided on the boiler. All gas
connections MUST be leak tested before putting the boiler into
Maximum pipe capacity in ft3/hr based on 0.60 specific gravity gas operation.
at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.
Nominal Pipe length in feet Never use an open flame to test for gas leaks. Always
Iron Pipe 10 20 30 40 50 60 80 100 150 use an approved leak detection method. Failure to
Size Maximum gas volume of pipe, (ft3/hr) comply with this warning can cause extensive property
3/4" 278 190 152 130 115 105 90 79 64 damage, severe personal injury or death!
1" 520 350 285 245 215 195 170 150 120
1 1/4" 1050 730 590 500 440 400 350 305 250
Whenever the gas supply piping is pressure tested the boiler/water
1 1/2" 1600 1100 890 760 670 610 530 460 380
heater gas controls must be protected. If the test pressure is equal
2" 3050 2100 1650 1450 1270 1150 990 870 710
to, or less than 1/2 psig, 3.5 kPa isolate the boiler/water heater
2 1/2" 4800 3300 2700 2300 2000 1850 1600 1400 1130
by closing it's manual shut off valve, see Figure 16. If the test
3" 8500 5900 4700 4100 3600 3250 2800 2500 2000
pressure is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect
the boiler/water heater and its individual shut-off valve.
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.

24
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

ELECTRICAL WIRING GENERAL OPERATION

Before proceeding read and fully understand the
Electrical Power Connections instructions contained in this manual. Do not attempt
to operate this boiler/water heater if it has not been
Label all wires prior to disconnection when servicing installed in accordance with the guidelines set forth
controls. Wiring errors can cause improper and in this manual. Failure to comply with this warning
dangerous operation! Verify proper operation after can result in extensive property damage, severe personal
servicing. injury or death!
Au moment de l'entretien des commandes, étiquetez Should overheating occur or the gas supply fail to shut off, turn off
tous les fils avant de les débrancher. Des erreurs de the manual gas control valve to the appliance. Do not interrupt
câblage peuvent entraîner un fonctionnement water flow through the boiler/water heater.
inadéquat et dangereux. S'assurer que l'appareil
fonctionne adéquatement une fois l'entretirn terminé. 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.
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 Hydronic Heating Boilers
also conform with CSA C22.1 Canadian Electrical Code Part I if Open the make-up water valve and slowly fill the boiler and all
installed in Canada. of the radiation with water. Ensure that all bleed and drain valves
Install a separate 120 volt 15 or 20 amp circuit breaker for the are closed.
boiler/water heater and pump, see Table 12. A properly rated shut- Adjust the make-up water pressure regulator so a minimum 12 psig,
off switch should be located at the boiler/water heater. The boiler/ 83 kPa system pressure is maintained at the highest point in the
water heater must be grounded in accordance with the authority system piping. If a make-up water pump is used adjust it to maintain
having jurisdiction, or if none, the latest revision of the National a minimum 12 psig, 83 kPa system pressure.
Electrical Code, ANSI/NFPA-70.
Open the system bleed and drain valves one at a time to purge the
air trapped in the heating system piping.
Table 12 LCD electrical requirements
Recommended
With the boiler off, run the system pump for at least 30 minutes
LCD Circuit Breaker *Running and bleed the system piping using the bleed valves. If strainers are
Model (Amps) Amps used in the system piping, the make-up water valve should be closed
400 - 600 15 3.9 and the strainers checked and cleaned.
750 15 6.0 The system expansion tank should be checked to ensure that the
1050 - 1970 20 11.4 correct water level in the tank is maintained. The tank should be
2300 20 14.4 less than half full of water with the system full and adjusted to the
*Use separate circuit breaker that is properly sized for pump and correct operating pressure.
pump contactor.
Start the boiler as described in the “OPERATING INSTRUCTIONS”.
Run the boiler for at least an hour. The system pump(s) and all
Line voltage field wiring of any controls or other devices must radiation units must be operated during this time. Ensure that the
conform to the temperature limitation of type T wire at 95°F, 35°C make-up water valve is open.
above room temperature. Use appropriate wiring materials for units Shut the boiler off and open the bleed valves to purge the air trapped
installed outdoors. The wire size must be compatible with the total in the heating system piping. Close the make-up water valve and
amp draw of the circuit. check and clean the strainers and make-up water pressure reducing
Refer to the wiring diagram supplied with the boiler/water heater valve.
for proper wiring connections and boiler full load amperage (FLA). 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.

25
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

BOILER/WATER HEATER OPERATION Figure 17 Pressure switch tap(s)

Staging Operation
The LCD boiler/water heater series is separated into on/off and
2-stage units depending on the model selected. The 400 model has
on/off staging, while the 600 through 2300 models have a two
stage option. Input staging is controlled from an aquastat controller
that signals the relays to select the blower and gas valve modes.The
boiler will not operate without the outdoor sensor installed. Table
13 identifies the stages and firing modes associated with the standard
single stage units. Table 14 identifies the stages and firing modes
associated with the two stage option.

Table 13 Firing modes (400-2300)

Stage Firing Mode
Off Off
1 On

Table 14 Firing modes (600-2300)

Stage Firing Mode
Off Off
1 Low Fire Table 15 Differential pressure settings (all units)
2 High Fire Differential Pressure
Requirement at High Fire
Model (All Units)
The outlet water temperature is automatically controlled by the Inches WC mm WC
aquastat. The optional staging function is controlled by a return 400 0.7 ± 0.8 17.8 ± 20.3
water aquastat. The return water aquastat utilizes inputs from the 600-2300 1.0 ± 1.1 25.4 ± 27.9
inlet water temperature sensors or optional tank sensors to stage
the boiler/water heater as required.

On all units, the pressure switch(es) will interrupt power to the

Pressure Switch Settings control module under a blocked flue or inlet condition. This will
Differential pressure switches are provided in the LCD to shut down cause the pilot and main gas valves to close. Tables 16 and 17 identify
gas flow under a blocked flue or inlet condition. A single pressure how pressure switch control changes during boiler/water heater
switch is used on the standard models. One low fire and one high staging. Tables 18 and 19 identify the control actions if a low air
fire pressure switch is used when the two-stage option is employed. condition occurs at any stage.
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, Table 16 Pressure switch control, 400
the high fire switches will shut down gas flow if there is a blocked Stage Pressure Switch Mode
flue or inlet condition during high fire operation. The differential
Off Off
pressure is taken between the air plenum and the pressure
inside one of the main burners. 1 High Fire

Pressure taps are provided in the control compartment for taking

the differential pressure readings, Figure 17. Table 15 lists the
Table 17 Pressure switch control, 600-2300
differential pressure settings for all of the models.
Stage Pressure Switch Mode
Off Off
1 Low Fire
2 High Fire

26
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

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
Table 18 Low air condition action, 400-2300 terminal and waits 5 minutes before initiating the second ignition
Stage Control Action trial. The blower(s), pump(s) and optional power venter will
1 No Power to Flame Sense Module 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
Table 19 Low air condition action, 600-2300 reset by depressing the reset button on the left jacket panel.
Stage Control Action 6. On non-CSD-1 equipped units the FSM will wait 10
1 No Power to Flame Sense Module minutes after the second unsuccessful ignition attempt then
2 No Power to Flame Sense Module
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

OPERATION SEQUENCE, ON/OFF Once the pilot is proven, the MV terminal on the FSM is energized
sending 24VAC to the safety and main solenoid valves.
400 THROUGH 2300
Normal Operation
Refer to the wiring diagram included with the unit
for further control system info. On single stage units the blowers and gas valves operate at one
input.
Demand Satisfied:
POWER ON:
1. When the demand for heat is satisfied the operator switch will
Demand for Heat: open, de-energizing relay R8, TD1, TD3, TD4, the FSM, and
1. The operator switch closes, energizing pump delay timer TD4 the pilot, main and safety solenoid valves. The pilot and main
and the water pump(s). flames are extinguished.
2. Water flow through the unit closes the water flow switch contacts 2. The blower delay timer TD3 starts the 80 second post-purge
energizing blower delay timer TD3. timing. The blower(s) shut(s) off when TD3 times out.
3. The system checks all primary limit(s) and other interlocks before 3. The pump delay timer TD4 starts the post-purge timing. The
starting pre-purge. The unit will not start if any switch is open. pump(s) remain on for 0.1 to 10 minutes then shut(s) off when
TD4 times out.
Prepurge:
High Limit, Low Water Flow, Low Gas Pressure, High Gas
1. Blower delay timer TD3 energizes the high speed windings of Pressure, Power Venter Interlock Faults
the blower(s).
1. Electrical power to the gas valves, blower(s) and optional power
2. Air pressure in the combustion chamber is sensed. If the air venter will be interrupted if any safety is tripped.
pressure is sufficient, the pressure switch closes allowing the
blower delay timer TD1 to start a 10 second pre-purge. 2. The manual reset high limit can be reset by depressing the reset
button on the left jacket panel.
Ignition Trial:
Low Air (Blocked Flue/Air Inlet)
1. Blower delay timer TD1 times out and the flame sense module,
FSM, is energized. • The pressure switch will monitor blower airflow.
2. The FSM starts the 10-second ignition trial, energizing relay • Air monitoring will begin at pre-purge. If a low air condition is
R7, the pilot solenoid valve and the spark generator. present power will not be supplied to the FSM. The blower(s)
will remain on.
3. The pilot valve and spark generator are energized for the
10-second ignition trial. When the pilot flame is sensed, the

27
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

OPERATION SEQUENCE, 2 STAGE OPTION Main Burner

600 THROUGH 2300 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.
Refer to the wiring diagram included with the unit
for further control system info. Normal Operation
• Staging is controlled by the return water aquastat. Relays R2
and R2R are energized by the return water aquastat when more
POWER ON: heat input is required. The hi-speed windings of the blower(s)
are energized.
Demand for Heat:
• Relay R9 is energized when the hi-fire pressure switch senses
1. The low operator switch closes, energizing pump delay timer adequate air pressure to sustain hi-fire combustion. R9 energizes
TD4 and the water pump(s). the hi-fire side of the main solenoid valve.
2. Water flow through the unit closes the water flow switch contacts • Stage 1 will operate first and last.
energizing blower delay timer TD3.
For a change from stage 1 to 2, a 30 second time delay
3. The system checks all primary limit(s) and other inter-locks is provided in the pressure switch switching circuit.
before starting pre-purge. The unit will not start if any switch The time delay TD6 provides a hold state that allows
is open. the blower to reach full speed and close the high fire
Prepurge: pressure switch before it is energized to confirm proper
air flow.
1. Blower delay timer TD3 energizes the low speed windings of
the blower(s). Demand Satisfied:
2. Once sufficient air pressure in the combustion chamber is sensed 1. When the demand for heat is satisfied the low operator switch
the pressure switch closes allowing the blower delay timer TD1 will open, de-energizing relays R2, R2R, R8, R9, TD1, TD3,
to start a 10 second pre-purge. TD4, TD6, the FSM, and the pilot, main and safety solenoid
Ignition Trial: valves. The pilot and main flames are extinguished.
1. Blower delay timer TD1 times out and the flame sense module, 2. The blower delay timer TD3 starts the 80 second post-purge
FSM, is energized. timing. The blower(s) shut(s) off when TD3 times out.
2. The FSM starts the 10-second ignition trial, energizing relay 3. The pump delay timer TD4 starts the post-purge timing. The
R7, the pilot solenoid valve and the spark generator. pump(s) remain on for 0.1 to 10 minutes then shut(s) off when
TD4 times out.
3. The pilot valve and spark generator are energized for the
10-second ignition trial. When the pilot flame is sensed, the High Limit, Low Water Flow, Low Gas Pressure, High Gas
FSM sends 24VAC to its MV terminal energizing the safety Pressure, Power Venter Interlock Faults
and low fire-side of the main solenoid valves and relay R8,
de-energizing R7 and the spark generator. 1. Electrical power to the gas valves, blower(s) and power venter
will be interrupted if any safety is tripped.
4. If the pilot flame isn’t sensed, the FSM de-energizes the PV
terminal and waits 5 minutes before initiating the second ignition 2. The manual reset high limit can be reset by depressing the reset
trial. The blower(s), pump(s) and optional power venter will button on the left jacket panel.
remain on during this time. Low Air (Blocked Flue/Air Inlet)
5. On CSD-1 equipped units the blower(s) and optional power • The pressure switches will monitor blower airflow.
venter will shut down and the boiler/water heater will lock if
the second ignition trial fails. The unit must then be manually • Air monitoring will begin at pre-purge. If a low air condition is
reset by depressing the reset button on the left jacket panel. present, power will not be supplied to the FSM. The blower(s)
will remain on.
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.

28
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

OPERATING INSTRUCTIONS C. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the
FOR YOUR SAFETY READ BEFORE OPERATING appliance and to replace any part of the control system and any
gas control that has been under water.
POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN N’utilisez pas cet appareil s’il a été plongé dans l’eau, même
MARCHE partiellement. Faites inspecter l’appareil par un tecnicien qualifié
et remplacez toute partie du système de contrôle et toute
A. This appliance is equipped with an ignition device which commande qui ont été plongés dans l’eau.
automatically lights the pilot. Do not try to light the pilot by To prevent being burned, stand clear of the boiler
hand. during ignition and do not touch any hot metal parts.
Cet appareil est muni d’un dispositif d’allumage qui allume
automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse
manuellement. Operating Instructions
1. STOP! Read the safety information above. If, at any time, the
B. BEFORE OPERATING smell all around the appliance area appliance will not operate properly, follow the instructions “TO
for gas. Be sure to smell next to the floor because some gas is TURN OFF GAS TO APPLIANCE”.
heavier than air and will settle on the floor. 2. Set the operating control or thermostat to off or its lowest setting.
Propane gas may not always be detected by smell. 3. Turn off all electric power to the appliance.
Propane gas is heavier than air and can collect in low 4. Close the main manual gas shut-off valve, Figure 16.
areas. 5. Wait five (5) minutes to clear out any gas. Then smell for gas,
Propane gas can ignite or explode if an ignition source is including near the floor. If you smell gas, STOP! Follow “B”
present and result in death, serious injury and property in the safety information above (to the left) on this label. If you
damage! do not smell gas, go to the next step.
6. Remove the upper front jacket panel.
7. Turn the knob on the pilot valve to off, Figure 18.
FOR YOUR SAFETY 8. Turn the knob on the main gas valve to off, 400 model, Figure 18.
• Have only qualified licensed professionals install, service and On 600 through 2300 models close the manual shutoff valve
maintain this appliance and your gas system in accordance with located in the control compartment, Figure 19.
all applicable codes. 9. Remove the plug(s) from the pilot and manifold pressure
• Install a nationally listed combustible gas detector(s) in your fitting(s), Figure 19.
home. 10. Connect a manometer having a minimum capacity of 20 in,
• If you suspect a leak: 508 mm WC to the pilot and manifold pressure fittings, Figure
1. Have everyone leave the building immediately. 19. Make sure the gas supply piping has been purged of air and
all gas joints up to the gas valve have been thoroughly checked
2. Do not attempt to light any appliance. for leaks.
3. Do not touch any electrical or electronic switches in the 11. Remove plug(s) from the differential air pressure taps, Figure 17.
building.
12. Connect both sides of a manometer to the pressure switch tee,
4. Do not use any phone in the building. Figure 17, going to one of the pressure switches.
5. Call your gas supplier from a phone outside of the building.
6. If you cannot reach your gas supplier call the fire department. Figure 18 Pilot valve (all models)
main valve (400 model)
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 servirdes
téléphones se trouvant dans le bâtiment.
• Appelez immédiatement votre fournisseur de gaz depuis un
voisin. Suives les instructions du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur, appelez le service
de incendies.

29
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

13. Turn the knob on the pilot valve to on, Figure 18. Required Gas Pressure
14. Turn on all electric power to the boiler and set the operating Provide gas supply pressure at inlet to boiler gas train as follows:
control or thermostat to the desired setting.
15. With the unit operating at high purge the differential air pressure
should match those listed in Table 15. To adjust the differential
air pressure see the “AIRFLOW ADJUSTMENT” instructions LP Nat
in the “CHECKING AND ADJUSTMENTS” section. Minimum (in WC) 11 7
Maximum (in WC) 14 14
Figure 19 Manual valve & manifold pressure tap

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 7 in WC and 14 in WC for natural gas and 11 in WC and
14 in WC 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 recommenda-
tions to meet specific job site requirements.

Table 20 Pilot & manifold pressures

16. The pilot should automatically light. Do not try to light the On/Off
pilot by hand! inches WC mm WC
17. The pilot pressures should match those listed in Table 20. To Pilot - NG 2.5 ± 0.3 63.5 ± 7.6
adjust the pilot gas pressure see the “PILOT ADJUSTMENT” Pilot - LP 7.0 ± 2.0 177.0 ± 50.0
instructions in the “CHECKING AND ADJUSTMENTS” Low Fire
section. inches WC mm WC
18. Distinguish pilot. Manifold - NG 1.4 ± 0.2 35.5 ± 5.0
19. Turn the knob on the main gas valve to on, 400 model, Figure Manifold - LP 4.0 ± 0.5 101.6 ± 12.7
18. On 600 through 2300 models open the manual shutoff High Fire
valve located in the control compartment, Figure 19. inches WC mm WC
20. Recycle boiler. Manifold - NG 2.5 ± 0.2 63.5 ± 5.0
21. The manifold pressures should match those listed in Table 20. Manifold - LP 9.3 ± 0.3 236.2 ± 7.6
To adjust the manifold gas pressure see the “GAS PRESSURE
ADJUSTMENT” instructions in the “CHECKING AND Table 21 Combustion readings
ADJUSTMENTS” section.
Natural Fuel Propane Fuel
22. Replace the upper front jacket panel. 7.0 - 7.5 (low) 8.2 - 8.8 (low)
23. Check all safety switches for proper operation before placing CO2 %
7.8 - 8.5 (high) 9.2 - 9.9 (high)
boiler on-line. 8.3 - 7.6 (low) 8.3 - 7.6 (low)
O2 %
7.0 - 5.8 (high) 7.0 - 5.8 (high)

30
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Instructions De Mise En Marche 2. To test the ignition safety shutoff device, close the manual shutoff
valve in the gas supply line. Within 5 seconds of main burner
1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion flame extinction, the main gas valve solenoid should close with
supérieure de cette étiquette. an audible noise. After 10 seconds the module should lockout
2. Réglez le thermostat à la température la plus basse. and the trial for ignition end. After 5 minutes a second trial for
3. Coupez l’alimentation électrique de l’appareil. ignition should occur. Open the manual shutoff valve in the
4. Cet appareil est muni d’un dispositif d’allumage qui allume gas supply line and reset the ignition control system. A normal
automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse ignition sequence should take place.
manuellement. 3. With the burners in operation, interrupt the power to the control
5. Fermer la vanne manuelle d’arrêt d’alimintation de gaz. circuit by turning down the operator or thermostat. The boiler/
water heater should shut down. Reset the operating control or
6. Attendre cinq (5) minutes pour laisser échapper tout le gaz. thermostat. A normal ignition sequence should follow.
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 Input Rate, Natural Gas
sur la portion supérieure de cette étiquette. S’il n’y a pas d’odeur
de gaz, passez à l’étape suivante. Gas appliances are rated based on sea level operation with no
adjustment required at elevations up to 5000 ft, 1524 m. At
7. Ouver la vanne manuelle d’arrêt d’alimintation de gaz. elevations above 5000 ft, 1524 m, input ratings should be reduced
8. Mettez l’appareil sous tension. by 4% for each additional 1000 ft, 305 m.
9. Réglez le thermostat à la température désirée. Check the input rate as follows:
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 1. Turn off all other gas appliances that use the same gas meter
technicien qualifié ou le fournisseur de gaz. 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.
To Turn Off Gas To Appliance
4. Start the boiler/water heater and let it run for 15 minutes.
1. Set the operating control or thermostat to its lowest setting. 5. Using the gas meter and a stopwatch, clock the time that it takes
2. Turn off all electric power to the appliance if service is to be to burn 10 ft3, 0.28 m3 of gas and divide this time by 10.
performed. 6. Insert the heating value and the time, in seconds, into the formula
3. Close the manual main valves. below.
7. Input = (heating value, Btu/hr)(3600)/(time, seconds)
COUPER L’ADMISSION DE GAZ DE L’APPAREIL 8. If the computed rate deviates by more than 5% from the rated
1. Réglez le thermostat à la température la plus basse. input value of the unit adjust the manifold pressure accordingly.
DO NOT adjust the manifold pressure by more than 5%. If a
2. Coupez l’alimentation électrique de l’appareil s’il faut procéder proper rate cannot be maintained without adjusting the manifold
à l’entretien. pressure beyond the 5% limit, the main burner orifices must
3. Fermer la vanne manuelle d’arrêt d’alimintation de gaz. 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.
CHECKING & ADJUSTMENTS Never increase the input of the boiler/water heater
1. With the burners in operation, close the manual shutoff valve above that for which it is rated. Doing so can cause
in the gas supply line. As soon as the main burner flames go premature failure of the unit!
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 won’t light ensure that the gas piping is fully purged
of air. Inspect the ignition system and ensure that it is operating
properly.

31
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Pilot Adjustment Gas Pressure Adjustment

The pilot burner is actually an isolated main burner that’s The maximum inlet gas pressure listed on the rating
controlled by a separate pilot valve. Pilot pressure settings are as plate must not be exceeded or damage to the boiler/
shown in Table 20. These pressures are measured at the pilot pressure water heater may occur voiding the warranty!
valve, see Figure 19. Tables 13 and 14 above list the firing mode
that is associated with each stage. The minimum supply pressure listed on the rating plate is for input
adjustment.
To view the pilot without main burner operation, take the following
steps: The manifold pressures should match those listed in Table 20.
Pressures should not vary outside these ranges. Each gas valve
For 400: pressure regulator has been preset at the factory. If neccessary, adjust
1. Remove the upper front jacket panel. the gas pressures to achieve the combustion results show in Table
21.
2. Turn off main burner gas flow by turning the main burner gas
valve knob to the off position, Figure 18. If adjustments are necessary the following steps must be followed:
3. Observe the pilot flame through one of the observation ports 1. Remove the 1/8 in plug from the manifold pressure tap valve.
located at the left and right ends of the unit. Connect 20 in, 508 mm WC manometers to it, see Figure 19.
For 600-2300: 2. Remove the regulator adjustment screw cap from the main gas
valve.
1. Remove the upper front jacket panel.
3. Rotate the regulator adjustment screw clockwise to increase the
2. Turn off main burner gas flow by turning the manual gas valve(s) manifold pressure, counter clockwise to decrease it.
in the control compartment to the off position, see Figure 19.
4. Replace the regulator adjustment screw cap and manual shut
3. Observe the pilot flame through one of the observation ports off valve pressure tap plug.
located at the left and right ends of the unit.
Never force the regulator adjustment screw beyond
Pilot pressures will be set at the factory. However, if it is necessary the stop limits or damage to the regulator will occur!
to adjust the pilot pressure to match those in Table 20, take the
following steps: PROPANE GAS: Optimum results are obtained when the
1. Remove the upper front jacket panel. boiler/water heater is operated with the manifold pressure(s) set
per Table 20. If the manifold pressure is off by more than 5% adjust
2. Remove the 1/8 in plug from the pilot pressure test port and it according to steps 1 through 4 above.
connect a 20 in, 508 mm WC 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. Airflow Adjustment
4. Use a 3/32 hex wrench to turn the pressure regulator adjustment 1. Remove the upper front jacket panel.
screw clockwise to increase the pilot pressure and counter 2. Connect both sides of a manometer to the pressure switch tee,
clockwise to decrease it. Figure 17, going to one of the pressure switches.
5. Replace the pressure regulator adjustment screw cap. 3. With the unit operating at high fire the differential pressure should
match those listed in Table 15. Do not change air pressure in
lower stages.

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 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

CONTROL DESCRIPTION Low Water Cutoff

If the boiler is to be installed above radiation or if required by other
codes or regulations, install a low water cutoff in appropriate piping.
Boiler Thermostat Wire the switch and any external controls in series to the “Interlock”
If a thermostat is to be used to control the boiler always follow the contacts in the control box, see the wiring diagrams included with
instructions included with the thermostat. Proper location of the the unit for details. Ensure that the low water cutoff device(s) will
thermostat will ensure efficient trouble-free operation of the boiler. function properly.
Mount the thermostat to an inside wall at a height approximately
five feet above the floor.
Flame Sense Module
Avoid placing the thermostat in areas that will not provide an accurate
measurement of the room temperature. Locating the thermostat The flame sense module is located in the control box. It is an
behind a door, in an alcove, close to a source of thermal radiation intermittent pilot control device that controls the pilot gas flow,
or in a drafty area will cause poor or sporadic heating. spark energy to ignite the pilot gas and the main valve(s) once pilot
ignition has been proven.
For a thermostat that employs an adjustable heat anticipator, adjust
the anticipator to match the current measured in the thermostat Two flame failure alarm terminals are provided on the flame sense
circuit. An increased anticipator setting may be necessary if the unit module. For CSD-1 these terminals are utilized to shut the unit
cycles frequently. If the room temperature over-shoots the thermostat down in case of flame failure. The two terminals are connected to
setting, reduce the anticipator setting. 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
Operating Control the momentary contact switch located on the left jacket panel.
The preferred control setting for potable hot water is 130°F, 54°C.
The operating control should be set to the lowest setting that will Relay Board
satisfy the consumer’s needs.
The relay board is located in the control panel. It provides sequencing
Setting the thermostat or operation control too high of the gas valves and blower(s) based on the staging controller's
can result in scalding resulting in severe personal injury! input. It also provides the following time delays for proper unit
operation:
• A 10 second prepurge when stage 1 is energized.
High Limit (Aquastat)
• A 30 second pressure switch sequencing delay when the blowers
The high limit is located in the top control area of the boiler/water switch from low fire to high fire. The delay enables the blower to
heater. A remote capillary bulb is run to a well on the outlet side come up to speed before the high pressure side of the pressure
of the supply header. The high limit can be reset by depressing the switch confirms proper air flow.
reset button on the left jacket panel.
These time delays are set within the separate time delay board
The water heater high limit should be set a minimum of 20°F, connected to the relay board.
11°C higher than the operating control. Refer to the HOT WATER
SUPPLY section for the proper supply water temperature.
Gas Pressure Switch
Flow Switch Optional low and/or high-pressure gas pressure switches will shut
down the 24V circuit if excessively high or low gas pressure exists
The flow switch is provided to prove flow is present through the in the gas train or supply piping.
boiler. The temperature rise across the primary heat exchanger must
never exceed 35F, 19.4C.

33
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

MAINTENANCE Burner Inspection And Removal - Figure 20

1. Close the manual shutoff valves in the gas supply lines and turn
Disconnect electrical power and close the manual gas off electrical power to the boiler/water heater.
shut off valve before performing maintenance or severe
personal injury may result! 2. Remove the front jacket panels.
3. Disconnect the manifold gas piping at the ground joint union(s).
Improper installation, adjustment, alteration, service Also disconnect the pressure sensing lines, pilot tubing and
or maintenance can cause property damage, personal ignition and sensing leads.
injury, exposure to hazardous materials or loss of life. 4. Remove the manifold(s).
Installation and service must be performed by a
qualified installer, service agency or the gas supplier 5. Remove the burner(s) from the lower front combustion chamber
who must read and follow the supplied instructions panel.
before installing, servicing or removing this boiler. 6. Inspect the burners for damage or signs of deterioration. Use a
This boiler contains crystalline silica materials that brush or compressed air to remove any debris from the burner
have been identified as carcinogenic or possibly ports.
carcinogenic to humans when inhaled. 7. DO NOT install a damaged or badly corroded burner replace
it.
AVERTISSEMENT: Une installation, un réglage, une
modification, une réparation ou un entretien non 8. Install the burner(s) making sure that the burner gasket is not
comforme aux normes peut entraîner des torn or deteriorated. If it is replace it.
dommages matériels, des blessures, exposition à des 9. Reassemble the unit following the removal steps in reverse order.
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 Heat Exchanger Inspection - Figure 20
qui doivent avoir lu les instructions fournies avant de 1. Close the manual shutoff valve in the gas supply line and turn
faire l’installation, l’entretien ou l’enlèvement de la off electrical power to the boiler/water heater.
chaudière et les respecter, Cette chaudière contient 2. Remove the jacket front panels.
des matériaux qui ont été identifiés comme étant
cancérogènes ou pouvant l’ être. 3. Disconnect the gas piping at the ground joint union(s). Also
disconnect the pressure sensing lines, pilot tubing and ignition
Servicing, inspection and adjustment must be done and sensing leads.
by a trained technician in accordance with all applicable 4. Remove the 1/4 in nuts and washers holding the upper
local and national codes. Improper servicing or combustion chamber front panel in place and carefully remove
adjustment can damage the boiler/water heater! it.
The ceramic combustion chamber contains crystalline 5. Inspect the inside and outside of the heat exchanger for signs
silica. Wear a tightly fitted dust mask when removing of damage, sooting or corrosion.
the burners or heat exchanger to prevent inhalation 6. The outside surfaces of the copper tubes should be free of any
of airborne fibers. Crystalline silica fibers have been soot deposits. A slight black smudge is normal with some types
identified as carcinogenic, or possibly carcinogenic of gases. Black soot indicates poor combustion. Green deposits
when inhaled. indicate condensation due to low return water temperatures. In
either case the heat exchanger must be cleaned thoroughly and
The boiler/water heater should be cleaned and inspected once a the problem resolved before the boiler/water heater is returned
year, before each heating season. Make sure that the burner and to service
ignition components are free from dust, soot, dirt, corrosion or other 7. If there are no signs of damage, sooting or corrosion reassemble
deposits that would impair the boiler/water heater ‘s performance. the unit following the previous steps in reverse order.
Refer to page 39 for component identification.
8. A badly corroded or damaged heat exchanger must be replaced,
see the Heat Exchanger Removal section.

34
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Heat Exchanger Removal, Cleaning 12. Sagging or distorted heat exchanger tubes are an indication of
low water flow through the system. A leaking or otherwise
& Replacement - See Figure 20 damaged heat exchanger must be replaced and the condition
1. Close the shut off valves in the inlet and outlet piping. On heating that caused the damage resolved before the boiler/water heater
systems close the system fill valve and relieve the system pressure is returned to service.
from the boiler by carefully lifting the relief valve or opening 13. If the heat exchanger isn’t damaged rewire the heat
the drain valve. exchanger baffles in place and slide the heat exchanger back
2. Drain the boiler/water heater and disconnect it from the system into the unit.
piping. 14. Reinstall all of the other components in the reverse order of
3. Remove the inlet/outlet and return headers. their removal.
4. Remove the jacket front panels. 15. The torque values for the bolts that secure the removable headers
5. Loosen, 4 turns, but don’t remove the 6 screws, (3 on each are 17-20 ft lbs. Once bolts have been started and secured the
side) holding the heat exchanger upper rails in place, Figure 21. tightening sequence is as follows:
6. Disconnect the gas piping at the ground joint unions. Also 1) Middle Top
disconnect the pressure sensing lines, pilot tubing and ignition 2) Middle Botom
and sensing leads. 3) Right Top
7. Remove the upper partition panel, 1050 through 1970 models. 4) Left Bottom
8. Remove the 1/4 in nuts and washers holding the upper 5) Left Top
combustion chamber front panel in place and carefully remove
it. 6) RightBottom
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.
Never clean the heat exchanger while it’s in the boiler/
water heater or the combustion chamber will be
destroyed!

Figure 20 Burner and heat exchanger servicing

35
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

Figure 21 Heat exchanger upper rail screws 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

Vent System
Thoroughly inspect the vent system for any signs of blockage,
corrosion or leakage and periodically clean screen in vent terminal
(where applicable). Immediately replace any unsound vent system
piping.

Controls
Use the “BOILER/WATER HEATER OPERATION” and
“CHECKING AND ADJUSTMENTS” sections of this manual
for reference.
1. Check the thermostat or operating controls for proper operation.
2. A 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 - this may be due to thermal expansion in
a closed water supply system. 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, for boilers and 210°F, 99°C for water heaters.
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.

36
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

TROUBLE-SHOOTING
SYMPTOM CHECK ACTION
1 No Power To Control Circiut 1. Power not connected 1. Wire unit to line voltage

2. External circuit breaker open 2. Reset breaker

3. Transformer circuit breaker open 3. Reset breaker

2 No Action On Call For Heat 1. Primary limit or other control/interlock 1. Reset limit or control or resolve problem
open as applicable

I f not resolved, check wiring and

condition of limit

2. Low water cutoff open 2. Check circulating pump

2. Check pump contact in control box

2. Check LWCO wiring and condition

3 No Power To Pump 1. Pump contact not wired 1. Wire pump contact in control box

2. Pump malfunctioning 2. Replace pump

3. Defective pump timer TD4 3. Replace pump timer TD4

4 No Power to Optional Power Venter 1. Power venter not wired to external power 1. Wire power venter as shown in
connection diagram

2. Power venter fault 2. Replace power venter

5 Power Venter On, No Action From Unit 1. Power venter interlock not wired 1. Wire power venter interlock as shown in
connection diagram

6 No Power To Blower(s) 1. Blower(s) not plugged in 1. Plug in blower(s)

2. Defective blower timer TD3 2. Replace blower timer TD3

3. Blower(s) malfunctioning 3. Replace blower(s)

7 Unit Does Not Spark 1. Incorrect spark gap or shorted ignitor lead 1. Properly adjust ignitor gap or correct
short

2. Bad ground on flame sense module 2. Check ground connections, adjust as

necessary

3. Defective flame sense module 3. Replace flame sense module

4. Low air (blocked flue/inlet) condition 4. If condition exists, check inlet, flue, &
chimney for blockage

Check combustion air/ventilation

opening in space

Check inlet air filter, clean/replace as

necessary

5. Spark generator fault 5. Check spark generator wiring

6. Defective air purge timer TD1 6. Replace timer TD1

8 Unit Sparks But Will Not Fire 1. Low gas pressure 1. Check gas supply pressure during inition
trial, adjust as necessary

2. Pilot valve manual knob closed 2. Open pilot valve manual knob

3. Pilot valve not wired 3. Connect pilot valve wires

4. Low pilot pressure 4. Check pilot pressure, adjust as necessary

5. Pilot valve malfunctioning 5. Replace pilot valve

37
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

TROUBLE-SHOOTING
SYMPTOM CHECK ACTION
9 Pilot Lights But Main Burners Will Not Fire 1. Bad flame sense lead from ignitor to 1. Check sense lead & ground connections,
flame sense module adjust as necessary

2. Defective flame sense module 2. Replace flame sense module

3. Manual valve(s) in air plenum closed 3. Remove upper front jacket panel, open
manual valve(s)

4. Main valves(s) not wired 4. Wire main valve(s)

5. Low manifold pressure 5. Check manifold pressure during ignition

trial, adjust as necessary

6. Main valve(s) malfunctioning 6. Replace main valve(s)

10 Insufficient Heating 1. Operating control set too low 1. Increase control temperature setting

11 Unit Consistently Shuts Down 1. High limit set to low 1. Increase high limit setting
On High Limit

12 Bad Combustion 1. Insufficient air 1. Check CO & CO2, adjust blower inlet
(High CO, Yellow Flames) damper(s) to increase airflow

Check for plenum air leakage from lower

front jacket panel seams, repair as
necessary
2. Dirty inlet air filter
2. Remove, inspect and clean inlet air filter
as necessary
3. Too much air
3. Check CO & CO2, adjust blower inlet
damper(s) to decrease airflow

13 Gas Flow Shuts Down During 1. Low air (blocked flue/inlet) condition 1. If condition exists, check inlet, flue,
Operation (Blowers Remain On) chimney for blockage

Check combustion air/ventilation

openings in space

Check inlet air filter, clean/replace as

necessary

Check pressure switch for correct setting

38
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

REPAIR PARTS

Figure 23 Exploded view

39
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 400 600 750 1050 1200 1480 1650 1970 2300
8 Filter (Indoor) 09-0488 1
09-0489 1 1
09-0497 1
09-0498 1 1 1 1 1
Filter (Outdoor) 09-0490 1 1 1
09-0491 1 1 1 1 1 1
NS Outdoor Hood Assembly 70-2952 1
70-2953 1
70-2954 1
70-2956 1
70-2957 1 1 1
70-2958 1 1
NS Cerablanket Insulation (white) 05-0103 4 6 8 10 12 14 14 16 18
Manning Glass Insulation (per sq ft) ) (silver) 05-0104 6 6 8 10 12 14 14 16 16
Manning Glass Tape (per ft) 66-0105 6 6 8 10 12 14 14 16 16
PVC Gasket Foam (per ft/per roll 50') 66-0103 50 50 50 50 50 50 50 50 50
2" Blanket Insulation (per sq ft) (yellow) 05-0200 20 22 24 30 34 36 36 44 44
Red Silicone Gasket (per ft/per 50' roll) 06-0146 50 50 50 50 50 50 50 50 50
15 Combustion Chamber Lower Front Panel 03-1963 1
03-1964 1
03-1965 1
03-1967 1
03-2171 1
03-1968 1
03-1969 1
03-1970 1
03-1971 1
16 Combustion Chamber Upper Front Panel 70-2776 1
70-2777 1
70-2778 1
70-2780 1
70-2781 1 1
70-2782 1
70-2783 1
70-2784 1
23 Flue Outlet Assembly 70-2737.1 1
70-2738.1 1
70-2739.1 1
70-2741.1 1
70-2742.1 1 1
70-2735.1 1
70-2743.1 1 1

40
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 400 600 750 1050 1200 1480 1650 1970 2300
24, 25, Tile Kit 05-0203 1
27 05-0204 1
05-0205 1
05-0207 1
05-0213K 1
05-0208 1
05-0209 1
05-0214K 1
05-0211 1
26 End Refractory Panel, Right 05-0058 1 1 1 1 1 1 1 1 1
End Refractory Panel, Left 05-0107 1 1 1 1 1 1 1 1 1
28 Manifold 10-0466 1
10-0467 1
10-0468 1
70-3087 1
70-3088 1
70-3089 1
70-3090 1
70-3091 1
70-3092 1
29 Main Orifice, NG 10-0087 7 9 13 15
10-0130 17 19 23 27
Main Orifice, LP 10-0088 7 9 13 15 17 19 23 27
Main Orifice, NG 10-0115 5
Main Orifice, LP 10-0116 5
NS Pilot Orifice, NG 10-0089 1 1 1 1
10-0132 1 1 1 1
Pilot Orifice, LP 10-0090 1 1 1 1 1 1 1 1
Pilot Orifice, NG 10-0093 1
Pilot Orifice, LP 10-0120 1
30 Burner Tube 10-0275 5 7 9 13 15 17 19 23 27
Burner Tube w/hole for Pressure Switch 70-2898 1 1 1 1 1 1 1 1 1
Pilot Tube Assembly (tubing and fittings) 70-2896 1 1 1 1 1 1 1 1 1
NS Burner Gasket (pkg of 10) 21-2011 1 1 1 2 2 2 2 3 3
NS Burner Support Rail 03-2091 1
03-2092 1
03-2093 1
03-2095 1
03-0296 1
03-2097 1 1
03-0298 1
03-0299 1
31 Spark Ignitor (*prior to 0206 - must order w/cable 44-0056) 16-0327* 1 1 1 1 1 1 1 1 1
NS Ignition Cable Assembly 44-0056 1 1 1 1 1 1 1 1 1

41
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 400 600 750 1050 1200 1480 1650 1970 2300
NS Heat Exchanger Assembly (Copper) Glass Line Headers 70-3002R 1
70-3003R 1
70-3004R 1
70-3006R 1
70-3007R 1
70-2832R 1
70-2833R 1
70-2834R 1
70-2835R 1
Heat Exchanger Assembly (Copper) Bronze Headers 70-3024R 1
70-3025R 1
70-3026R 1
70-3028R 1
70-3029R 1
70-2852R 1
70-2853R 1
70-2854R 1
70-2855R 1
Individual copper/cupronickel tubes (available for field repair) model and serial number required Call for pricing
Tube Expansion Tool 30-0761 1 1 1 1 1 1 1 1 1
Heat Exchanger Assembly (Cupronickel) Glass Line Headers 70-3013R 1
70-3014R 1
70-3015R 1
70-3017R 1
70-3018R 1
70-2842R 1
70-2843R 1
70-2844R 1
70-2845R 1
Heat Exchanger Assembly (Cupronickel) Bronze Headers 70-3035R 1
70-3036R 1
70-3037R 1
70-3039R 1
70-3040R 1
70-2862R 1
70-2863R 1
70-2864R 1
70-2865R 1

42
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 400 600 750 1050 1200 1480 1650 1970 2300
32 Tube Bundle (Copper) 70-3054 1
70-3055 1
70-3056 1
70-3058 1
70-3059 1
70-2907 1
70-2908 1
70-2909 1
70-2910 1
Tube Bundle (Cupronickel) 70-3065 1
70-3066 1
70-3067 1
70-3069 1
70-3070 1
70-2917 1
70-2918 1
70-2919 1
70-2920 1
NS Heat Exchanger "V" Baffles 03-2011 36
03-2012 7 36
03-2013 7
03-2014 7
03-2016 14
03-2017 18 18
03-2019 18
34 Hold-Down Clip 03-2164 14 14 14 28 36 36 72 36 72
NS Heat Exchanger Support Channel 03-2022 1
03-2023 1
03-2024 1
35 Tube Replacement Assembly (must be ordered with tile kit) 70-3081 2
70-3082 2
70-3083 2
70-3085 2
70-3086 2
36 O'Ring (pkg of 20) 21-2010 1 1 1 1 1 1 1 1 1
37 Stud, Inlet/Outlet & Return Headers ASME 57-0220 12 12 12 12 12 12 12 12 12
38 Nut, Inlet/Outlet & Return Headers ASME 57-0492 12 12 12 12 12 12 12 12 12
39 Return Header, Bronze 01-0011.1S 1
01-0004.1S 1 1 1 1
01-0018.1S 1 1 1 1
Return Header, Glass Lined 01-0009S 1
01-0002S 1 1 1 1
01-0023S 1 1 1 1

43
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 400 600 750 1050 1200 1480 1650 1970 2300
40 Inlet/Outlet Header, Bronze 01-0010.1S 1
01-0003.1S 1 1 1 1
01-0019.1S 1 1 1 1
Inlet/Outlet Header, Glass Lined 01-0008S 1
01-0001S 1 1 1 1
01-0022S 1 1 1 1
41 Blower, Fasco 7062 12-0013K 1 1
Blower, Fasco 7083 12-0014K 1 2 2 2 2 2 2
42 Combustion Air Damper Assembly 70-2818 1 1
70-2819 1 2 2 2 2 2 2
43 Low Pressure Switch (.30 WC) 14-0059 1 1
Low Pressure Switch (.42 WC) 11-0417 1 1 1
Low Pressure Switch (.58 WC) 14-0058 1 1 1
High Pressure Switch (.58 WC) 14-0058 1
High Pressure Switch (.80 WC) 14-0061 1 1 1 1 1 1 1 1
44 High Limit, (LB) 14-0009 1 1 1 1 1 1 1 1 1
High Limit, (LW) 14-0008 1 1 1 1 1 1 1 1 1
NS High Limit Well, 3/8 x 3 13-0104 1 1 1 1 1 1 1 1 1
NS BTC Outdoor Reset Control 14-0305
NS Operator (LB) 14-0007 1 1 1 1 1 1 1 1 1
Operator (LW) 14-0010 1 1 1 1 1 1 1 1 1
45 Firing Valve, 3/4" 11-0461 1
Firing Valve, 1" 11-0456 2 2
Firing Valve, 1 1/4" 11-0457 2 2
Firing Valve, 1 1/2" 11-0458 2 2 2
Firing Valve, 2" 11-0459 2
NS CSD-1 Leak Test Valve 11-0031 1 1 1 1 1 1 1 1 1
46 Main Gas Valve (NG), VR8304 11-0056 1
Main Gas Valve (NG), V8944B, 1" 11-0171 1 1
Main Gas Valve (NG), V8944B. 1 1/4" 11-0172 1 1
Main Gas Valve (NG), V8944B. 1 1/2" 11-0173 1 1 1
Main Gas Valve (NG), V8944B, 2" 11-0174 1
Main Gas Valve (LP), V8944C, 1
11-0176 1 1
(Models 400, Consult Factory)
Main Gas Valve (LP), V8944C. 1 1/4" 11-0177 1 1
Main Gas Valve (LP), V8944C. 1 1/2" 11-0178 1 1 1 1
47 Safety Valve (NG-LP), L8214G, 1" 11-0371 1 1
Safety Valve (NG-LP), L8214G, 1 1/4" 11-0364 1 1
Safety Valve (NG-LP), L8214G, 1 1/2" 11-0365 1 1 1
Safety Valve (NG-LP), L8214G, 2" 11-0366 1
48 Pilot Valve (NG), VR8304 11-0056 1 1 1 1 1 1 1 1 1
Natural to LP, Pilot Valve Conversion Spring, On/Off 11-0001 1 1 1 1 1 1 1 1 1
Natural to LP, Pilot Valve Conversion Spring, 2 Stage 11-0007 1 1 1 1 1 1 1 1
49 Manual Shut Off Valve, 1" 11-0465 1 1
Manual Shut Off Valve, 1 1/4" 11-0466 1 1
Manual Shut Off Valve, 1 1/2" 11-0467 1 1 1
Manual Shut Off Valve, 2" 11-0454 1

44
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 400 600 750 1050 1200 1480 1650 1970 2300
50 Flame Sensor, UTC 1003 - 61A Ignition Module 16-0059 1 1 1 1 1 1 1 1 1
NS Alarm Board, (CSD-1) 16-0023 1 1 1 1 1 1 1 1 1
Harness Kit (includes J1,J3,J5,J6,J7,J8,J9 & J10) 40-0313 1 1 1 1 1 1 1 1 1
J2 Valve Control 2 Stage Harness 40-0303 1 1 1 1 1 1 1 1 1
J2 Valve Control On/Off Harness 40-0302 1 1 1 1 1 1 1 1 1
51 Spark Generator 16-0036 1 1 1 1 1 1 1 1 1
52 Transformer, 75 VA 15-0008 1 1 1 1 1 1 1 1 1
NS Pressure Relief Valve 50# 13-0040 1 1 1
Pressure Relief Valve 50# 30-0360 1
Pressure Relief Valve 50# 30-0374 1 1
Pressure Relief Valve 50# 30-0379 1 1 1
Pressure Relief Valve 125# 30-0364 1 1 1 1 1 1 1 1 1
NS Tridicator 0 - 230 psi (Rating 75-150 psi) 13-0305 1 1 1 1 1
Tridicator 0 - 100 psi (Rating 30-60 psi) 13-0308 1 1 1 1
Thermometer 13-0302 2 2 2 2 2 1 1 1 1
NS Flow Switch 14-0203 1 1 1 1 1 1 1 1 1
Flow Switch (Outdoor) 14-0205 1 1 1 1 1 1 1 1 1
Flow Switch (Potter) Optional 14-0201 1 1 1 1 1 1 1 1 1
Flow Switch (Outdoor Potter) Optional 14-0202 1 1 1 1 1 1 1 1 1
NS Thermometer Well, 3/8 x 3 13-0104 1
Thermometer Well, 3/8 x 4 13-0105 1 1 1 1 1 1 1 1
54 Main Board Assembly (On/Off ) 70-2927R 1 1 1 1 1 1 1 1 1
Main Board Assembly (2 Stage) 70-2928R 1 1 1 1 1 1 1 1
NS Main Board 40-0074R 1 1 1 1 1 1 1 1 1
NS Timer Board 40-0075 1 1 1 1 1 1 1 1 1
NS LED Indicator Board 40-0076 1 1 1 1 1 1 1 1 1
NS Ribbon Cable 44-0057 1 1 1 1 1 1 1 1 1
NS Relay, 2P, (On/Of ) 15-0121 5 5 5 5 5 5 5 5 5
NS Relay, 2P (2 Stage) 15-0121 8 8 8 8 8 8 8 8
NS Relay, 3P (On/Off pr 2 Stage) 15-0123 1 1 1 1 1 1 1 1 1
NS Time Delay Relay 15-0113 1 1 1 1 1 1 1 1 1
NS Pump Contactor 1PH (C2) 15-0118 1 1 1 1 1 1 1 1 1
NS Low Gas Pressure Switch (Manual Reset) 11-0410 1 1 1 1 1 1 1 1
NS High Gas Pressure Switch (Manual Reset) 11-0411 1 1 1 1 1 1 1 1
NS Rating Plate 82-0054 1 1 1 1 1 1 1 1 1
NS Overlay 82-0188 1 1 1 1 1 1 1 1 1
NS Silicone 66-0151 1 1 1 1 1 1 1 1 1
NS Silicone Tubing 06-0051 2 2 2 2 2 2 2 2 2
Vent Termination Hood 6" 09-0112 1
Vent Termination Hood 7" 09-0140 1
Vent Termination Hood 8" 09-0113 1
Vent Termination Hood 10" 09-0115 1
Vent Termination Hood 12" 09-0116 1 1
Vent Termination Hood 14" 09-0141 1 1 1

45
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

REPAIR PARTS (CONTINUED)

Model Size with Item Quantities Below

Ref # Name of Part Part # 400 600 750 1050 1200 1480 1650 1970 2300
NS Air Intake Hood 6" 09-0102 1
Air Intake Hood 8" 09-0103 1 1
Air Intake Hood 10" 09-0104 1
Air Intake Hood 12" 09-0105 1 1 1 1 1
NS Barometric Damper 6" 09-0405 1
Barometric Damper 7" 09-0409 1
Barometric Damper 8" 09-0404 1
Barometric Damper 10" 09-0403 1
Barometric Damper 12" 09-0401 1 1
Barometric Damper 14" 09-0402 1 1 1
NS Rack Assembly 70-2886 1
70-2888 1 1
70-2890 1
70-2892 1 1
70-2894 1 1 1
N/S Blower Relay 15-0123 1 1 1 1 1 1 1 1 1
N/S Aquastat - 11D18-1 TANK STAT 14-0304 1 1 1 1 1 1 1 1 1
N/S Sight Glass - NEOCERAM 3/16 2 X 2 20-0005 2 2 2 2 2 2 2 2 2
N/S Site Glass Gasket 06-0013 2 2 2 2 2 2 2 2 2
N/S View Port Hold down 20-0008 2 2 2 2 2 2 2 2 2
N/S 24 Volt Freeze Protection Damper Motor Assembly 09-0427 1 1 1 1 1 1 1 1 1

46
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

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

PRE-START UP CHECK LIST

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

 PIPING PROPERLY CONNECTED?  ALL WIRING CONNECTED PROPERLY?

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

 BOILER CIRCULATOR WIRED?  COMBUSTION AIR PROVIDED?

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

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

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

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

 SEALED COMBUSTION?  NO HOLES SCREWED INTO CABINET?

ELECTRICAL/WIRING/CONTROL
Boiler Supply Voltage External BMS System
Boiler Pump Supply Voltage Utilize Boiler BTC For Control
Voltage Down Stream of Transformer
BTC CONTROL SET UP: (Not all settings are used for every mode. (Dominator Series Only))
: Mode : Boiler Max : Purge °T
: Boiler Target : Boiler Min
: Tank Target : Boiler Diff LCD ONLY
: Tank Diff : Intr-Stg Diff : Operator (STG1)
: Outdoor Start : Intr-Stg On Dly : High Operator (STG 2)
: Boiler Start : Intr-Stg Off Dly : High Limit
: Pump Purge

47
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

COMBUSTION/SAFETY REPORT

FACTORY FIRE TEST REPORT: Low Fire High Fire These results are affixed
Manifold Gas Pressure: "WC" to the side of the heater
Air Differential Pressure: "WC" on a small white label.

FIELD TEST REPORT IN STAGE: 1 2 3 4

Manifold Gas Pressure: "WC"
Air Differential Pressure: "WC"
Pilot Manifold Pressure: "WC"
CO2:
Stack Temp. (Net):
Efficiency @ °F Inlet Temp.
CO (PPM):
O2:
Stack Draft (Must Be Negative):
Pilot Signal:

Wired and Operating Failed To Operate

SAFETY CONTROL CHECK: Properly @ Setting: Comment To Right Comments
Low Water Cut Off (PPM):
Factory Flow Switch
Operating Control
High Limit
Differential Air Switch STG. 1, 2
Differential Air Switch STG. 3, 4
Blocked Flu Switch
Flame Failure Lockout (CSD-1)
Pump Delay
Combustion Air Damper
Power Vent Proving Switch
Barometric Damper

COMMISSIONING THE UNIT

Customer Instructed? Yes No
All Covers Replaced? Yes No The delta T between the heaters inlet and outlet
Wiring Secure/Tight? Yes No is critical to proper flow. Before you leave the
Customer Given Manual? Yes No job site you must record the delta T. This reading
Cabinet Air Leaks? Yes No should not exceed 35°F, 19.4°C or be lower than
20°F, 11.1°C.
Gas Leaks Detected? Yes No
Unit Cycled Min. of 15 X? Yes No
Temp. Set Per Customer? Yes No Inlet Temperature
Left Maintenance Instruction? Yes No
Outlet Temperature

Commissioned By:
(Signature)
Date:

48
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

NOTICE! Commonwealth of Massachusetts

Installation Requirements 

MACODE-3

In the Commonwealth of Massachusetts, the installa- Improper venting can result in excessive levels
tion must be performed by a licensed plumber or gas of carbon monoxide which can cause severe
fitter. personal injury or death!
1. For all side wall horizontally vented gas fueled equipment 2. Exemptions — The following equipment is exempt from
installed in every dwelling, building or structure used in whole 248 CMR 5.08(2)(a) 1 through 4:
or in part for residential purposes, including those owned or
a. The equipment listed in Chapter 10 entitled “Equipment
operated by the commonwealth and where the side wall exhaust
Not Required To Be Vented” in the most current edition of
vent termination is less than seven (7) feet above finished grade,
NFPA 54 as adopted by the Board; and
in the area of the venting, including but not limited to decks and
porches, the following requirements shall be satisfied: b. Product Approved side wall horizontally vented gas
fueled equipment installed in a room or structure
d. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the
separate from the dwelling, building or structure used in
time of installation of the side wall horizontal vented gas
whole or in part for residential purposes.
fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an 3. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING
alarm and battery back-up is installed on the floor level SYSTEM PROVIDED.
where the gas equipment is to be installed. In addition, the a. When the manufacturer of Product Approved side wall
installing plumber or gasfitter shall observe that a battery horizontally vented gas equipment provides a venting
operated or hard wired carbon monoxide detector with an system design or venting system components with the
alarm is installed on each additional level of the dwelling, equipment, the instructions provided by the manufacturer
building or structure served by the side wall horizontal for installation of the equipment and the venting system
vented gas fueled equipment. It shall be the responsibility of shall include:
the property owner to secure the services of qualified
licensed professionals for the installation of hard wired i. Detailed instructions for the installation of the venting
carbon monoxide detectors. system design or the venting system components; and
i. In the event that the side wall horizontally vented gas ii. A complete parts list for the venting system design or
fueled equipment is installed in a crawl space or an attic, venting system.
the hard wired carbon monoxide detector with alarm and 4. MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING
battery back-up may be installed on the next adjacent SYSTEM NOT PROVIDED.
floor level.
a. When the manufacturer of a Product Approved side wall
ii. In the event that the requirements of this subdivision can horizontally vented gas fueled equipment does not provide
not be met at the time of completion of installation, the the parts for venting the flue gases, but identifies “special
owner shall have a period of thirty (30) days to comply venting systems”, the following requirements shall be
with the above requirements; provided, however, that satisfied by the manufacturer:
during said thirty (30) day period, a battery operated
carbon monoxide detector with an alarm shall be i. The referenced “special venting system” instructions
installed. shall be included with the appliance or equipment
installation instructions; and
e. APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above ii. The “special venting systems” shall be Product
provisions shall comply with NFPA 720 and be ANSI/UL 2034 Approved by the Board, and the instructions for that
listed and IAS certified. system shall include a parts list and detailed installation
instructions.
f. SIGNAGE. A metal or plastic identification plate shall be
permanently mounted to the exterior of the building at a 5. A copy of all installation instructions for all Product Approved
minimum height of eight (8) feet above grade directly in line side wall horizontally vented gas fueled equipment, all
with the exhaust vent terminal for the horizontally vented gas venting instructions, all parts lists for venting instructions,
fueled heating appliance or equipment. The sign shall read, and/or all venting design instructions shall remain with the
in print size no less than one-half (1/2) inch in size, “GAS VENT appliance or equipment at the completion of the installation.
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. Improper venting can result in excessive levels of
g. INSPECTION. The state or local gas inspector of the side wall carbon monoxide which can cause severe personal
horizontally vented gas fueled equipment shall not approve injury or death!
the installation unless, upon inspection, the inspector
observes carbon monoxide detectors and signage installed
in accordance with the provisions of 248 CMR 5.08(2)(a)1
through 4.

49
 LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

LIMITED WARRANTY

Finned Copper Tube Boilers/Water Heaters

Industrial, Commercial and Other Non-Residential Use

The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other
Non-Residential Use Boiler (the “Product”) will be free from defects in material or workmanship for ten (10) years from the date of installation.
Additional twenty one (21) year thermal shock warranty on heat exchanger. If upon examination by the Manufacturer the Product is shown to
have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product
which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship for
one (1) year from date of installation or 18 months from date of shipment from RBI.

The “Manufacturer” warrants to the original owner at the original installation site that the heat exchanger of the Industrial, Commercial, and other
Non-Residential Use Water Heater (the “Product”) will be free from defects in material or workmanship for five (5) years from the date of
installation. Additional twenty one (21) year thermal warranty on heat exchanger. If upon examination by the Manufacturer the Product is shown
to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the
Product which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and
workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.

This limited warranty does not apply:

(a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has not been installed,
maintained or operated in accordance with the furnished written instructions, or has been altered or modified in any way.
These include but not limited to:
• Excessive water hardness causing a lime build-up in the heat exchanger tubes is not a fault of the equipment and is not covered
under the manufacturer’s warranty.
• Excessive pitting and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and
is not covered by the manufacturer’s warranty. (See Installation Instructions for proper pump performance.)
• Chemical corrosion, no corrosive chemical (freon, dry cleaning chemicals, degreasing liquids, chlorine or any chemicals that
produce hydrochloric acid) can be present in the boiler room as it rapidly destroys the heating equipment and voids the warranty.
• All copper fin boilers should not operate with a return water temperature less than 110°F, 43°C atmospheric combustion, (125°F,
52°C fan assist combustion - Dominator/LCD/Futera II), (140°F, 60°C fan assist combustion - Futera III/Futera XLF). If a lower
temperature is required, an external bypass should be installed to prevent condensation (bypass and valve arrangement included on
the Futera Fusion Series). The manufacturer’s warranty does not cover damage done by condensation.
(b) to any expenses, including labor or material, incurred during removal or reinstallation of the Product or parts thereof.
(c) to damage as a result of settlement, distortion, collapse, or cracking of any foundation area, beams or pipes surrounding the Product.
(d) to any workmanship of any installer of the Product; or to Products installed outside the continental United States or Canada.

This limited warranty is conditional upon:

(a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be returned with prior written approval from
the Manufacturer. All returns must be freight prepaid.
(b) determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship.

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

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

260 North Elm Street 7555 Tranmere Drive

Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (833) 265-5371 Phone: (905) 670-5888
www.rbiwaterheaters.com

50
LCD Series Finned Copper Tube Gas Boilers & Water Heaters – Boiler Manual

51
260 North Elm Street 7555 Tranmere Drive
Westfield, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (833) 265-5371 Phone: (905) 670-5888
www.rbiwaterheaters.com