HomeMy WebLinkAboutLCD IOM (LCD-IOM-7)05/14 Copyright 2014 Mestek, Inc.
LCD-I0M-7
82-0278
Boiler Manual
Installation and Operation
Instructions
Th is manual is intended only for use by a qualifi ed 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. Th e 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.
Affi x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualifi ed service
technician, and to follow all guidelines in the User’s Information Manual.
Finned Copper Tube
Gas Boilers (LB) &
Water Heaters (LW)
Finned copper tube gas boilers & water heaters – Boiler Manual
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BEFORE YOUR START. . . . . . . . . . . . . . . . . PAGE 2
RATINGS & CAPACITIES. . . . . . . . . . . . . . . . PAGE 3
BOILER/WATER HEATER LOCATION . . . . . . . . . PAGE 3
COMBUSTION AIR & VENTILATION. . . . . . . . . . PAGE 3
GENERAL VENTING GUIDELINES. . . . . . . . . . . PAGE 9
VENTING OPTIONS . . . . . . . . . . . . . . . . . . PAGE 9
VERTICAL/CHIMNEY VENTING . . . . . . . . . . . PAGE 10
HORIZONTAL VENTING . . . . . . . . . . . . . . . PAGE 11
OUTDOOR VENTING . . . . . . . . . . . . . . . . PAGE 11
COMMON VENT SYSTEMS . . . . . . . . . . . . . PAGE 12
GENERAL PIPING REQUIREMENTS . . . . . . . . PAGE 13
HEATING SYSTEM PIPING . . . . . . . . . . . . . PAGE 14
DOMESTIC WATER SUPPLY PIPING . . . . . . . . PAGE 18
GAS SUPPLY PIPING . . . . . . . . . . . . . . . . PAGE 21
ELECTRICAL WIRING . . . . . . . . . . . . . . . . PAGE 22
GENERAL OPERATION . . . . . . . . . . . . . . . PAGE 22
OPERATING INSTRUCTIONS . . . . . . . . . . . . PAGE 26
CHECKING & ADJUSTMENTS. . . . . . . . . . . . PAGE 28
CONTROL DESCRIPTION . . . . . . . . . . . . . . PAGE 30
MAINTENANCE . . . . . . . . . . . . . . . . . . . PAGE 31
TROUBLESHOOTING . . . . . . . . . . . . . . . . PAGE 34
REPAIR PARTS. . . . . . . . . . . . . . . . . . . . PAGE 36
START UP SHEET . . . . . . . . . . . . . . . . . . PAGE 44
MASS. CODE. . . . . . . . . . . . . . . . . . . . . PAGE 46
WARRANTY . . . . . . . . . . . . . . . . . . . . . PAGE 47
BEFORE YOU START
Th is manual covers the application, installation, operation and
maintenance of a LCD Series fi nned copper heating boiler/water
heater/pool heater (Canada only).
To obtain the safe, dependable, effi cient operation and long life for
which this heating boiler/water heater was designed, these instructions
must be read, understood and followed.
Th e LCD Series fi nned copper heating boiler/water heaters have been
design certifi ed by CSA for use with natural and propane gas under
the latest revision of ANSI-Z21.10.3/CSA 4.3, Gas Water Heaters, and
ANSI-Z21.13/CSA 4.9, Gas-Fired Low Pressure Steam and Hot
Water Boilers and CAN1-3.1 Industrial and Commercial Gas Fired
Boilers. Each unit has been constructed and hydrostatically tested for
a maximum working pressure of 160 psi, 1103 kPa in accordance
with Section IV of the A.S.M.E. Boiler and Pressure Vessel Code.
All aspects of the boiler/water heater installation must conform
to the requirements of the authority having jurisdiction, or, in the
absence of such requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 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.
If the information in this manual is not followed
exactly, a fire or explosion may result causing property,
personal injury or loss of life.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any
phone in your building.
• Immediately call your gas supplier from a phone outside
the building. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
Assurez-vous de bien suivre les instructions données
dans cette notice pour réduire au minimum le risque
d’incendie ou d’explosion ou pour éviter tout dommoge
matériel, toute blessure ou la mort
Ne pas entreposer ni utiliser d’essence ou ni d’autres
vapeurs ou liquides inflammables à proximité de cet
appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous servir
des téléphones se trouvant dans le bâtiment.
• Appelez immédiatement votre fournisseur de gas depuis
un voisin. Suivez les intructions du fournisseur.
• Si vous ne purvez rejoindre le fournisseur, appelez le
service des incendies.
L’installation et l’entretien doivent être assurés par un
installateur ou un service d’entretien qualifié ou par le
fournisseur de gaz.
Failure to properly vent this unit can cause excessive
amounts of carbon monoxide resulting in severe
personal injury or death!
DESIGNED AND TESTED ACCORDING TO A.S.M.E.
BOILER AND PRESSURE VESSEL CODE, SECTION
IV FOR A MAXIMUM ALLOWABLE WORKING PRES-
SURE OF 160 PSI, 1103 kPa WATER.
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED
ADJACENT TO THE HEATER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE PURPOSES.
Finned copper tube gas boilers & water heaters – Boiler Manual
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In Canada, the installation must be in accordance with the
requirements of CSA B149.1 or .2, Installation Code for Gas Burning
Appliances and Equipment.
If installed in the Commonwealth of Massachusett s, you MUST
FOLLOW the additional instructions located in the back of this
manual (MACODE-3).
Th e owner should maintain a record of all service work performed
with the date and a description of the work done. Include the name
of the service organization for future reference.
Direct all questions to your RBI distributor or contact the RBI Cus-
tomer Service Department, 260 North Elm Street, Westfi eld, MA
01085 for U.S. or 7555 Tranmere Drive, Mississauga, ONT L5S 1L4
for Canada. Always include the model and serial numbers from the
rating plate of the boiler/water heater in question.
RATINGS & CAPACITIES
Before undertaking the installation of the LCD Series boiler/water
heater check the rating plate to ensure that the unit has been sized
properly for the job. Th e “Net AHRI Ratings” specify the equivalent
amount of direct cast iron radiation that the unit can supply under
normal conditions. Also ensure that the unit has been set up for the
type of gas available at the installation site. Other important
considerations are the availability of an adequate electrical supply,
fresh air for combustion and a suitable chimney or vent system.
BOILER/WATER HEATER LOCATION
1. Th is boiler/water heater is suitable for indoor and outdoor
installations. Locate the boiler/water heater in an area that
provides good access to the unit. Servicing may require the
removal of jacket panels. Allow the minimum clearances between
adjacent construction and the boiler/water heater as listed in
Table 1.
Service clearances are not mandatory, but are
recommended to ensure ease of service should it be
required.
Table 1
Clearance to
Combustibles
Service
Clearance
in mm in mm
Top 6 153 20 508
Back 6 153 24 610
Left Side 6 153 24 610
Right Side 6 153 24 610
Front 6 153 30 762
Flue 6 153
2. An optimum site will be level, central to the piping system, close
to a chimney or outside wall and have adequate fresh air for
combustion. Ensure that the boiler/water heater is level from
front to back and from side to side. Use metal shims to level the
boiler/water heater. Electrical and electronic components must
also be protected from exposure to water during operation and
maintenance. DO NOT install this boiler/water heater in a
location that would subject any of the gas ignition components
to direct contact with water or excessive moisture during
operation or servicing.
3. Ensure that the fl oor is structurally sound and will support the
weight of the boiler/water heater.
Th e LCD may be installed directly on combustible
fl ooring, but never on carpeting.
4. Locate the boiler/water heater in an area that will prevent water
damage to adjacent construction should a leak occur or during
routine maintenance. If such a location doesn’t exist, a suitable
drain pan that’s adequately drained must be installed under the
unit.
5. DO NOT place this boiler/water heater in a location that would
restrict the introduction of combustion air into the unit or subject
the air inlet to a negative pressure, see “GENERA L VENTING
GUIDELINES”.
Never store combustible materials, gasoline or any
product containing fl ammable vapors or liquids in the
vicinity of the boiler/water heater. Failure to comply
with this warning can result in an explosion or fi re
causing extensive property damage, severe personal
injury or death!
6. NEVER place this boiler/water heater in a location that would
subject it to temperatures at or near freezing. See the “Freeze
Protection Section” on page 14.
Units installed outdoors MUST be protected from ice
and snow accumulation or the unit will be damaged
voiding the warranty!
COMBUSTION AIR & VENTILATION
Th is boiler/water heater must be supplied with
combustion air in accordance with Section 5.3, Air
for Combustion & Ventilation, of the latest revision
of the National Fuel Gas Code, ANSI Z223.1/NFPA
54 and all applicable local building codes. Canadian
installations must comply with CSA B149.1 or .2
Installation Code for Gas Burning Appliances and
Equipment, or applicable provisions of the local
building codes. Failure to provide adequate
combustion air for this boiler/water heater can result
in excessive levels of carbon monoxide which can
result in severe personal injury or death!
To operate properly and safely this boiler/water heater requires a
continuous supply of air for combustion. NEVER store objects on
or around the boiler/water heater!
Finned copper tube gas boilers & water heaters – Boiler Manual
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Combustion air contaminated with fl uorocarbons or
other halogenated compounds such as cleaning
solvents and refrigerants will result in the formation
of acids in the combustion chamber. Th ese acids will
cause premature failure of the boiler/water heater
voiding the warranty!
If the boiler/water heater is operated while the building
is under construction it MUST be protected from
wood, concrete, sheet rock and other types of dust.
Failure to properly protect the unit from construction
dust will damage the unit voiding the warranty!
Buildings will require the installation of a fresh air duct or other
means of providing make-up air if the intake air option isn’t used.
Any building utilizing other gas burning appliances, a fi replace, wood
stove or any type of exhaust fan must be checked for adequate
combustion air when all of these devices are in operation at one
time. Sizing of an outside air duct must be done to meet the
requirements of all such devices.
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!
All Air From Inside The Building
If the LCD is to be located in a confi ned space the minimum clearances
listed in Table 1 must be maintained between it and any combustible
construction. When installed in a confi ned space without the
intake air option, Figures 1, 2 & 3, two permanent openings
communicating with an additional room(s) are required. Th e
combined volume of these spaces must have suffi cient volume to
meet the combustion air requirements of all gas utilization equipment.
Fireplaces, wood stoves or any type of exhaust fan must be considered
when making this determination. Each opening must have a minimum
free area of 1 in2/1000 Btu/hr, 2200 mm2 kW based on the total
input rating of ALL gas utilization equipment in the confi ned area.
Each opening must be no less than 100 in2, 64,516 mm2 in size. Th e
upper opening must be within 12 in, 305 mm of, but not less than
3 in, 76 mm from, the top of the enclosure. Th e bott om opening
must be within 12 in, 305 mm of, but not less than 3 in, 76 mm
from, the bott om of the enclosure.
Figure 1 Vertical venting with a metal chimney system and inside air
10 FT
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Figure 2 Vertical venting using a masonry chimney system and inside air
Figure 3 Horizontal venting using inside air
305 TO 457
127 TO 254
VENT PIPE DIAMETER
5" TO 10"
12" TO 18"
MINIMUM VERTICAL RISE
OFF THE TOP OF UNIT "A"
IN.mm FT mm
12"
24"
305
610
1.5 FT 0.5 m
1/4 IN. PER F00T 20 mm/m
Table 2
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All Air From Outside The Building
When installed in a confi ned space without utilizing the intake
air option two permanent openings communicating directly with,
or by ducts to, the outdoors or spaces that freely communicate with
the outdoors must be present. Th e upper opening must be within 12
in, 305 mm of, but not less than 3 in, 76 mm from, the top of the
enclosure. Th e bott om opening must be within 12 in, 305 mm of,
but not less than 3 in, 76 mm from, the bott om of the enclosure.
Where directly communicating with the outdoors or communicating
with the outdoors through vertical ducts, each opening shall have a
minimum free area of 1 in2/4000 Btu/hr, 550 mm2/kW of the
total input rating of all of the equipment in the enclosure.
Where communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of 1 in2/2000
Btu/hr, 1100 mm2/kW of the total input rating of all of the
equipment in the enclosure. When louvers and screens are used, they
must have the same cross-sectional area as the free area of the
opening to which they connect.
When calculating the free area necessary to meet the make-up air
requirements of the enclosure,consideration must be given to the
blockage eff ects of louvers, grills and screens. Screens must have a
minimum mesh size of 1/4 in, 6.4mm. If the free area through a
louver or grill is not known, ducts should be sized per Table 3.
Table 3 Make-up air louver sizing
Required Cross Sectional Area
Input
(MBH)
1/4 in 6.4 mm
Wire Screen
75% Free Area
Metal Louvers
25% Free Area
Wooden Louvers
in2 cm2 in2 cm2 in2 cm2
225 57 363 75 484 225 1452
300 75 484 100 645 300 1935
399 100 645 133 858 399 2573
600 150 968 200 1290 600 3870
750 190 1210 250 1613 750 4840
1050 263 1696 350 2258 1050 6773
1200 300 1936 400 2580 1200 7740
1480 370 2388 494 3182 1480 9546
1650 413 2662 550 3548 1650 10,643
1970 493 3179 657 4236 1970 12,707
2300 575 3711 767 4945 2300 14,835
Canadian installations must comply with CSA B149.1 when air
supply is provided by natural air fl ow from the outdoors for natural
draft , partial fan-assisted, fan-assisted, or power draft -assisted
burners, there shall be a permanent air supply opening(s) having
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
million Btuh.
Intake Air Option - General Guidelines
Th is confi guration provides combustion air directly to the boiler/
water heater’s air intake using a dedicated pipe to obtain combustion
air from the outdoors. Combustion air can be drawn in horizontally
through an outside wall or vertically through the roof, see Figures
4, 5, 6 & 7.
Common intake air systems may be used to provide
the common duct is sized properly and an intake
combustion air damper is installed in the intake air
pipe of each heater. Improper installation can result in
excessive levels of carbon monoxide which can cause
severe personal injury or death!
Single wall galvanized smoke pipe, single wall aluminum pipe or
fl exible aluminum pipe can be used for the in-take air pipe. It must
be sized per Table 4. All joints in metal combustion air systems
must be secured using corrosion resistant fasteners and sealed using
a suitable Silicon caulk or tape. Th e combustion air system
MUST be supported by the building structure not the
boiler/water heater.
Table 4 Combustion air pipe sizing
Model Size Pipe Diameter
in mm
225 - 300 5 127
400 6 152
600 - 750 8 203
1050 10 254
1200 - 2300 12 305
A combustion air damper interlocked with the unit
should be installed in the intake air pipe when the
infi ltration of sub-freezing air could occur, otherwise
the unit could freeze up voiding the warranty!
Intake Air Option - Horizontal Guidelines
Th e maximum equivalent length for the horizontal combustion
air pipe on installations that used the Direct Vent option is 35 ft ,
10.8 m. Th e maximum equivalent length for the horizontal
combustion air pipe on installations that use the Horizontal Vent
option is 100 ft , 30.5 m. Each 90° elbow and the combustion air
terminal are equal to 10 linear ft , 3.0 m of pipe. If horizontal runs
exceed 5 ft , 1.5 m they must be supported at 3 ft , 0.9 m intervals
with overhead hangers. Th e certifi ed combustion air terminal from
RBI must be used and installed as shown in Figures 4 and 5.
Intake Air Option - Vertical Guidelines
Th e 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. Th e combustion air cap must terminate as shown
in Figure 6. Th e penetration point in the roof must be properly
fl ashed and sealed.
Finned copper tube gas boilers & water heaters – Boiler Manual
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Figure 4 Horizontal combustion air and venting for a single unit
Figure 5 Horizontal combustion air and venting for a multiple units
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 diff erences due to prevailing winds. In cold climates, double-
wall or insulated inlet pipe recommended to prevent condensation.
1.5 FT 0.5 m
2 IN.5.0 cm
0
1
2
3
4
5
6
7
8
9
0 5 1 0 1 5 2 0
H o r i z o n t a l D i s t anc e , X Y , e c n a t s i D l a c i t r e V 2 0 0 0 & L a r g e r
1 2 0 1 T o 2 0 0 0
9 0 1 To 1 2 0 0
2 0 0 To 9 0 0
1000 B T U ' S
Finned copper tube gas boilers & water heaters – Boiler Manual
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Figure 6 Vertical combustion air and venting, metal chimney system shown
Locate exhaust terminal downwind from air intake to reduce potential for fl ue gas recirculation.
Figure 7 Combination air intake and venting, masonry chimney shown
10 FT 3.1 m
4 FT
1.2 m
5 FT
1.5 m
1.5 FT
0.5 m
5 1/2 FT
1.7 m
1.5 FT .5m
10 FT 3.1 m
3 FT 1 m
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GENERAL VENTING GUIDELINES
Th e vent installation must be in accordance with Part
7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54-latest revision or
applicable provisions of the local building codes.
Canadian installations must comply with CSA B149.1
or .2 Installation Code. Improper venting can result
in excessive levels of carbon monoxide which can result
in severe personal injury or death!
All vent systems must be fully supported by the building structure
and not by the boiler/water heater. Appropriate thimbles and fi re-
stops must be used where required.
Common vent systems must be properly engineered
and sized to provide a negative draft of 0.01 to 0.08
in, .25 to 2.0 mm WC at the fl ue outlet! Common
positive pressure vent systems are not to be used.
Improper installation can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
A single acting barometric damper must be
installed directly to the boiler/water heater fl ue
outlet to ensure proper operation. Th is does not apply
to outdoor units or direct vent positive pressure units.
Some venting applications may require the stop to be
removed for smooth operation. Th e barometric
damper should be located aft er the fl ue collector, refer
to Figures 2, 7A and 8 for proper location. Be sure that
the damper is mounted horizontally (never vertically).
Carefully follow the instructions provided with the
barometric damper. Check with local codes for specifi c
requirements.
In Canada, B149 (7.25 Draft Regulators) states the
damper shall be of double-acting type.
To avoid spillage into the room of dangerous fl ue gas
containing carbon monoxide, the opening in damper
must never face against the fl ow of fl ue gas.
VENT SYSTEM OPTIONS
Th e LCD may be vented the following ways:
1) Vertical/Chimney Venting, Negative Pressure, Category
I - uses an approved metal chimney system or properly lined
masonry chimney. Combustion air is obtained from the space
in which the unit is installed or from outdoors. A barometric
damper must be installed near the fl ue outlet when venting
vertically. See Figures 6 and 7. Th is also applies to any fan-assisted
chimneys or vents.
2) Direct Vent, Positive Pressure, Category III - for
horizontal vent runs equivalent to 35 ft , 10.8 m or less.
A stainless steel vent system certifi ed to UL 1738 for
installations in the United States. ULC S636 for
installations in Canada must be used when combustion air is
ducted from outdoors, from the same wall.
3) Horizontal Vent, Negative Pressure, Category I -
for horizontal vent runs equivalent to more than 35 ft ,
10.8 m (90° elbow equals 10 equivalent ft ). A dedicated wall
mounted power venter must be used. Th e vent system can be
single wall galvanized steel or type B vent pipe. Combustion
air is obtained from the space in which the unit is installed or
from the outdoors.
A barometric damper must be installed when the horzontal run
is longer than 35 equivalent feet. (90° elbow = 10 equivalent
ft ). If this is the case, a power venter must also be used.
If horizontal run is less than 35 equivalent ft , do not use a
barometric damper. Follow applicable instructions under the
“COMBUSTION AIR & VENTILATION” section.
4) Outdoor Installation - uses the outdoor option kit. Barometric
damper is not required.
All venting, combusiton air material supplied by
installer. All venting material must be approved for the
application. Consult the vent manufacturer’s product
literature.
Finned copper tube gas boilers & water heaters – Boiler Manual
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VERTICAL/CHIMNEY VENTING
Th e LCD is listed as a Category I appliance when vented vertically
into a metal chimney system or properly sized masonry chimney,
Figures 1, 2, 6 & 7. Th e chimney must provide a negative pressure
of 0.01 to 0.08 in, .25 to 2.0 mm WC at the boiler/water heater
fl ue collar with the unit running at full load. A barometric damper
must be installed between the fl ue collar and the vent connector.
Approved thimbles and fi re-stops must be used when combustible
construction is penetrated.
If an appliance using any type of a mechanical draft
system operating under positive pressure is connected
to a chimney fl ue, never connect any other appliances
to this fl ue. Doing so can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
Chimney Inspection & Sizing
A thorough inspection of the masonry chimney must be
performed to ensure that the chimney is clean, properly constructed,
lined and sized. Exterior masonry chimneys should not be used
unless properly lined to prevent condensation and draft problems.
Table 5 lists the equivalent breeching and fl ue sizes required for
the boiler/water heater. When more than one appliance is connected
to the same chimney fl ue, the fl ue must be large enough to safely
vent the combined output of all of the appliances.
Table 5 Equivalent Breeching & Chimney Size (Category I)
Model Size Pipe Diameter
in mm
225 5 127
300 - 400 6 152
600 - 750 8 203
1050 10 254
1200 - 1480 12 305
1650 - 2300 14 356
Note: These sizes are based on 20 ft, 6.1 m chimney height.
Vent Connections
Locate the boiler/water heater as close to the chimney as possible.
Use the shortest, straightest vent connector possible for the
installation. If horizontal runs exceed 5 ft , 1.5 m they must be
supported at 3 ft , 0.9 m intervals with overhead hangers. Use a
type B, single wall stainless or single wall galvanized steel vent pipe
the same diameter as the fl ue collar to connect the boiler/water
heater to a masonry chimney. When using an approved metal
chimney system use the appropriate vent connector. Th e vent
connector should be sloped up toward the chimney at a minimum
rate of 1/4 in/ft , 20 mm/m. On masonry chimneys the connector
must terminate fl ush with the inside of the chimney fl ue, Figure 2.
Fasten each single wall vent connection with at least 3 corrosion
resistant sheet metal screws.
Never install a vent pipe having a diameter diff erent
than that of the boiler/water heater fl ue collar. Failure
to comply with this warning can result in excessive
levels of carbon monoxide which can cause severe
personal injury or death.
Always provide a minimum clearance of 6 in, 152 mm between
single wall vent pipe and any combustible materials. Type B1 vent
may be used, clearance between it and any combustible material
must be as listed.
Failure to maintain minimum clearances between vent
connectors and any combustible material can result
in a fi re causing extensive property damage, severe
personal injury or death!
DIRECT VENT, POSITIVE PRESSURE,
CATEGORY III
In this confi guration the boiler/water heater blower is used to push
the fl ue products to the outdoors while drawing combustion air
from the outdoors. Th e equivalent length of the vent and combustion
air systems must not exceed 35 ft , 10.7 m for each. Th e Intake
Air Option instructions under the “COMBUSTION AIR &
VENTILATION” section must be followed! Th e vent system fl ue
pipe diameter must be sized per Table 5a.
Horizontal Direct Vent Systems - Figures 4 & 5
Th e vent materials used in horizontal vent systems must be certifi ed
to UL 1738 for installations in the United States, ULC S636 for
installations in Canada. Th e certifi ed vent terminal from RBI must
also be used.
Th e maximum equivalent length for the horizontal vent and
combustion air pipes is 35 ft , 10.8 m for each. Each 90° elbow
and the intake air and vent terminals are equal to 10 ft , 3.1 m of
straight pipe. To maximize the performance of single wall sheet
metal vent systems locate 90° elbows as far from the boiler as possible
and from one another. For best results, horizontal vent systems
should be as straight as possible.
Th e vent system must be both gas tight and watertight. All seams
and joints in metal pipes must be joined and sealed in accordance
with the vent system manufacturer’s instructions.
When horizontal vent runs exceed 5 ft , 1.5 m they must be supported
at 3 ft , 0.9 m intervals with overhead hangers. Th e vent system
must be pitched down, toward the vent terminal, 1/4 in/ft ,
20 mm/m. If any part of a single wall metal vent system passes
through an unheated space it must be insulated with insulation rated
for 400°F, 204°C.
Finned copper tube gas boilers & water heaters – Boiler Manual
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Table 5a Category III Vent Pipe Diameter
Model Size Pipe Diameter
in mm
225 5 127
300 - 400 6 152
600 - 750 8 203
1050 10 254
1200 - 1480 12 305
1650 - 2300 14 356
Note: Diameters based on a maximum 35 equivalent feet.
Horizontal vent systems shall terminate at least 4 ft , 1.2 m below,
4 ft , 1.2 m horizontally from or 1 ft , 0.23 m above any door, window
or gravity air inlet into any building. It must not terminate less than
4 ft , 1.2 m horizontally from, and in no case above or below, unless
a 4 ft , 1.2 m horizontal distance is maintained, from electric meters,
gas meters, regulators and relief equipment and not less than 7 ft ,
2.1 m from any adjacent public walkway. Th e bott om of the vent
terminal(s) shall be located at least 5 ft , 1.5 m above the air intake
terminal(s) unless there is a minimum 5 ft , 1.5 m horizontal separation
between them. Avoid terminal locations likely to be aff ected by winds,
snowdrift s, people and pets. Protect building materials and vegetation
from degradation caused by the fl ue gases.
Vertical Direct Vent Systems - Figure 6
Th e maximum length for the vertical vent and combustion air pipes
is 35 ft , 10.7 m plus two 90° elbows. If any part of a single wall
metal vent system passes through an unheated space it must be
insulated with insulation rated for 400°F, 204°C. Structural
penetrations must be made using approved fi re-stops.
A listed, nonrestrictive vent cap must be used. Th e top of a vertical
vent system must extend at least 5 1/2 ft , 1.7 m above the roof
surface that it passes through, 4 ft , 1.2 m above the intake air cap,
see Figure 6.
HORIZONTAL VENT, NEGATIVE PRESSURE,
CATEGORY I
In this confi guration a wall-mounted power venter must be used
to pull the fl ue products horizontally from the unit and vent them
to the outdoors, see Figures 3, 4 & 5. Th e air for combustion is
taken from the space in which the unit is installed, or from the
outdoors. Th e applicable instructions under the “COMBUSTION
AIR & VENTILATION” section must be followed!
To maximize the performance of single wall sheet metal vent systems
locate 90° elbows as far from the boiler as possible and from one
another. For best results, horizontal vent systems should be as short
and straight as possible.
When horizontal vent runs exceed 5 ft , 1.5 m they must be supported
at 3 ft , 0.9 m intervals with overhead hangers. Th e vent system must
be pitched down, toward the vent terminal, 1/4 in/ft , 20 mm/m.
If any part of a single wall metal vent system passes through an
unheated space it must be insulated with insulation rated for 400°F,
204°C.
Horizontal vent systems shall terminate at least 4 ft , 1.2 m below,
4 ft , 1.2 m horizontally from or 1 ft , 0.23 m above any door,
window or gravity air inlet into any building. It must not terminate
less than 4 ft , 1.2 m horizontally from, and in no case above
or below, unless a 4 ft , 1.2 m horizontal distance is maintained,
from electric meters, gas meters, regulators and relief equipment
and not less than 7 ft , 2.3 m from any adjacent public walkway.
Th e bott om of the vent terminal(s) shall be located at least 5 ft ,
1.5 m above the air intake terminal(s) unless there is a minimum
5 ft , 1.5 m horizontal separation between them. Avoid terminal
locations likely to be aff ected by winds, snowdrift s, people and pets.
Protect building materials and vegetation from degradation caused
by the fl ue gases.
To determine the appropriate power venter for the boiler/water
heater, see Table 6. Follow the power venter manufacturer’s
installation instructions.
Table 6 Power Venter Sizes
LCD Power Venter Max. Pipe Length
Model Model ft mm
225-300 HS-1 30* 9.3
400 HS-2 100 31.0
600 HS-2 67**20.8
750 HS-3 100 31.0
1050-1200 HS-4 100 31.0
1480-2300 HS-5 100 31.0
*Choose HS-2 for 100 ft, Max. Pipe Length
**Choose HS-3 for 100 ft, 31 m, Max. Pipe Length
OUTDOOR VENTING
When installed outdoors the LCD must be fi tt ed with the factory
supplied outdoor vent hood and air intake hood, see Figure 8.
Multiple units must be spaced per Figure 9.
Th e boiler/water heater must be at least 10 ft , 3.1 m from any
door, window or gravity air inlet into any building and at least
3 ft , 0.9 m from any overhang unless local codes dictate diff erently.
Avoid locations where wind defl ection off of adjacent walls, buildings
or shrubbery might cause a downdraft . Th e unit(s) should be located
at least 3 ft , 0.9 m from structures. Outdoor installations are not
recommended in areas where the danger of snow blockage exists.
Do not place the boiler/water heater in a location that
would subject it to runoff from adjacent buildings or
damage may occur voiding the warranty!
Finned copper tube gas boilers & water heaters – Boiler Manual
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Figure 8 Outdoor venting
Figure 9 Multiple outdoor units
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
a) Seal any unused openings in the common venting system.
Sceller toutes les ouvertures non utilisées du sys-tème d'évacuation.
b) Visually inspect the venting system for proper size and horizontal
pitch and determine if there is no blockage or restriction, leakage,
corrosion and other defi ciencies which could cause an unsafe
condition.
Inspecter de façon visuelle le système d'évacu-ation pour
déterminer la grosser et l'inclinaison horizontale qui conviennent
et s'assurer que le système est exempt d'obstruction, d'étranglement
de fruite, de corrosion et autres défaillances qui pourraient
présenter des risques.
c) Insofar as is practical, close all building doors and windows and
all doors between the space in which the appliances remaining
connected to the common venting system are located and other
spaces of the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhaust, so
they will operate at maximum speed. Do not operate a summer
exhaust fan for a boiler installation. Close fi replace dampers.
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. Mett re en marche les sécheuses,
tous les appareils non raccordés au système d'évacuation commun
et tous les ventilateurs d'extraction comme les hott es 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.
Mett re l'appareil inspecté en marche. Suivre les instructions
d'allumage. Régler le thermostat de façon que l'appareil
fonctionne de façon continue.
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e) Test for spillage at the draft hood relief opening aft er 5 minutes
of main burner operation. Use the fl ame of a match or candle,
or smoke from a cigarett e, cigar or pipe.
Faire fonctionner le brûleur principal pendant 5 min ensuite,
déterminer si le coupe-tirage déborde à l'ouverture de décharge.
Utiliser la fl amme d'une allunett e ou d'une chandelle ou la
fumée d'une cigarett e, d'un cigare ou d'une pipe.
f) Aft er it has been determined that each appliance remaining
connected to the common venting system properly vents when
tested as outlined above, return doors, windows, exhaust fans,
fi replace dampers and any other gas-burning appliance to their
previous condition of use.
Une fois qu'il a été d éterminé, selon la métode indiquée ci-
dessus, que chaque appareil raccordé au système d'évacuation
est mis à l'air libre de façor adéquate. Remett re les portes et les
fenêtres, les ventilateurs, les registres de cheminées et les appareils
au gaz à leur position originale.
g) Any improper operation of the common venting system should
be corrected so the installation conforms with the National Fuel
Gas Code, ANSI Z223.1/NFPA 54. When resizing any portion
of the common venting system, the common venting system
should be resized to approach the minimum size as determined
using the appropriate tables in Appendix F in the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 and or CAN/CGA-B149
Installation Codes.
Tout mauvais fonctionnement du systéme d'évacu-tion commun
devrait étré corrigé de façor que l'installation soit conforme au
National Fue Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux
codes d'installation CAN/CGA-B149. Si la grosseur d'une section
du système d' évacuation doit étré modifi ée, le système devrait
étré modifi é pour respecter les valeurs minimales des tableaux
pertinents de l'appendice F du National Fuel Gas Code, ANSI
Z223.1/ NFPA 54 et (ou) des codes d'installation CAN/
CGA-B149.
GENERAL PIPING REQUIREMENTS
Improper piping of this boiler/water heater will void
the manufacturer's warranty and can cause boiler failure
resulting in fl ooding and extensive property damage!
Excessive water hardness causing scaling in the copper
heat exchanger tubes is NOT covered under the
manufacturer’s warranty. Excessive pitt ing and erosion
of the internal surface of the copper heat exchanger
tubes is NOT covered under the manufacturer’s
warranty if the result of high water fl ow rates, see Table
7. Return water temperatures below 125°F, 52°C will
result in heat exchanger damage from excessive
condensation voiding the manufacturer’s warranty, see
Primary/Secondary Piping Figure 11.
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.
Table 7 Temperature Rise Table
ΔT = 15°F ΔT = 8.3°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
225 24.6 0.18 1.6 0.5
300 32.8 0.31 2.1 0.9
400 43.7 0.70 2.8 2.1
600 65.6 1.84 4.1 5.4
750 82.0 3.32 5.2 9.8
ΔT = 20°F ΔT = 11.1°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
300 24.6 0.18 1.6 0.5
400 32.8 0.41 2.1 1.2
600 49.2 1.08 3.1 3.2
750 61.5 1.95 3.9 5.7
1050 86.1 5.16 5.4 15.2
1200 98.4* 8.14 6.2 24.0
1480 121.4* 7.94 7.7 23.4
ΔT = 25°F ΔT = 13.9°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
400 26.2 0.27 1.7 0.8
600 39.4 0.71 2.5 2.1
750 49.2 1.29 3.1 3.8
1050 68.9 3.41 4.3 10.1
1200 78.7 5.38 5.0 15.9
1480 97.1 5.25 6.1 15.5
1650 108.2 7.02 6.8 20.7
ΔT = 30°F ΔT = 16.7°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
600 32.8 0.51 2.1 1.5
750 41.0 0.92 2.6 2.7
1050 57.4 2.44 3.6 7.2
1200 65.6 3.84 4.1 11.3
1480 80.9 3.75 5.1 11.0
1650 90.2 5.01 5.7 14.8
1970 107.7 8.75 6.8 25.8
2300 125.7* 12.45 7.9 36.7
ΔT = 35°F ΔT = 19.4°C
Model Flow Rate Pres. Drop Flow Rate Pres. Drop
Number GPM Ft L/s kPa
600 28.1 0.38 1.8 1.1
750 35.1 0.69 2.2 2.0
1050 49.2 1.83 3.1 5.4
1200 56.2 2.89 3.5 8.5
1480 69.3 2.82 4.4 8.3
1650 77.3 3.77 4.9 11.1
1970 92.3 6.58 5.8 19.4
2300 107.8 9.36 6.8 27.6
**Flow exceeds recommended maximum use a greater temperature
rise or consult manufacturer. Cupro-nickel heat exchanger should be
considered.
Finned copper tube gas boilers & water heaters – Boiler Manual
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Freeze Protection
Th is boiler/water heater is CSA designed certifi ed for outdoor
installation. Outdoor installations in areas where the danger of
freezing exists are not recommended unless proper freeze protection
is provided. If the unit is to be installed in such an area the following
precautions MUST be observed:
1. A continuous fl ow of water through the boiler/water heater
MUST be maintained! Th e pump responsible for fl ow through
the boiler/water heater must run continuously!
2. An ethylene glycol/water mixture suitable for the minimum
temperature that the unit will be exposed to must be used. Th e
pump must be capable of producing 15% more fl ow and
overcoming a 20% increase in head loss. Domestic water systems
must be isolated from the water heater by the use of a heat
exchanger or other approved method.
3. If the boiler/water heater must be shut off for any reason the
electric, gas and water supplies MUST be shut off and the unit
and its pump completely drained.
Improper outdoor installation of this boiler/water heater
can cause boiler failure voiding the manufacturer's
warranty!
Relief Valve
Pipe the discharge of the pressure relief valve to prevent scalding in
the event of a discharge, see Figure 10. Th e discharge piping must be
sized the same as the pressure relief valve outlet and installed to allow
complete drainage of both the relief valve and the discharge piping.
Figure 10 Relief valve piping
Never install any type of valve between the boiler/
water heater and the relief valve or an explosion causing
extensive property damage, severe personal injury or
death may occur!
Flow Switch
Th e fl ow switch supplied with the boiler/water heater must be wired
to the terminal strip in the control panel to prevent the boiler from
fi ring unless there’s adequate water fl ow through the unit. Th e fl ow
switch must be installed in the supply piping adjacent to the boiler
outlet connection.
Failure to properly install the fl ow switch may result
in damage to the boiler/water heater heat exchanger
voiding the warranty!
HEATING SYSTEM PIPING
General Piping Requirements
All heating system piping must be installed by a qualifi ed technician
in accordance with the latest revision of the ANSI/ASME Boiler
and Pressure Vessel Code, Section IV, and when required, ANSI/
ASME CSD-1, Standard for Controls and Safety Devices for
Automatically Fired Boilers. All applicable local codes and ordinances
must also be followed. A minimum clearance of 1 in, 25 mm must
be maintained between heating system pipes and all combustible
construction. All heating system piping must be supported by suitable
hangers not the boiler.
Th e thermal expansion of the system must be considered when
supporting the system. A minimum system pressure of 12 psig,
82.7 kPa must be maintained.
Heating Boiler Piping Connections
Th e supply and return piping should be sized to suit the system.
Th e supply and return connection sizes are listed in Table 8.
Table 8 Supply & return connection sizes
Model Size Supply Size Return Size
225 thru 300 1 1/2” NPT 1 1/2” NPT
400 thru 2300 2 1/2” NPT 2 1/2” NPT
Finned copper tube gas boilers & water heaters – Boiler Manual
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Pump Requirements (Primary/Secondary)
Th is low mass boiler requires a continuous minimum water fl ow
for proper operation. Th e boiler pump must be sized to overcome
the head loss of the boiler and the near piping in order to achieve
the required temperature rise. Table 7 provides the heat exchanger
pressure drop and temperature rise fi gures. Th e temperature rise
across the boiler must never exceed 35°F, 19.4°C.
A temperature rise outside of the range listed in Table
7 indicates that the fl ow rate through the heat exchanger
is incorrect which will damage the heat exchanger
voiding the warranty! Th e maximum allowable
temperature rise is 35°F, 19.4°C.
Th e maximum allowable fl ow rate through a LCD
boiler with copper heat exchanger is 92 GPM,
5.8 L/s on 225-1200 models and 115 GPM,
7.3 L/s on 1480 to 2300 models. Th e cupro-nickel
heat exchanger allows for 100 GPM, 6.3 L/s on 225
to 1200 models and 125 GPM, 7.9 L/s on 1480 to
2300 models.
Low Water Cutoff
If a boiler is installed above any radiation elements it must be fi tt ed
with a low water cutoff device.
Refer to wiring diagram supplied with the boiler/water heater for
proper wiring connections.
Expansion Tank & Air Separator
An expansion tank or other means to control thermal expansion
must be installed in the heating system. An expansion tank must
be installed close to the boiler on the suction side of the pump. An
air scoop and automatic air vent must also be installed to eliminate
air trapped in the system.
Primary/Secondary Piping
Boilers connected to heating systems using zone valves, zone pumps,
or systems that have excessive fl ow rates or return water temperatures
less than 125°F, 52°C must be isolated from these systems to protect
the boiler.
Variable Water Flows
Figure 11 shows a typical primary/secondary piping system. A
dedicated pump is used to maintain a constant water fl ow through
the boiler. Th is boiler pump is sized to overcome the head loss of
the boiler and near piping while supplying the fl ow rate required
to maintain the desired temperature rise across the boiler heat
exchanger. Th e system pump is sized to provide the required fl ow
to the heating system.
Low Return Water Temperatures
To prevent the problems associated with condensation of the
products of combustion due to low return water temperatures a
primary/secondary piping system with a bypass and bypass valve
must be installed, see Figure 12 and 12A. Th e bypass and bypass
valve must be sized the same as the boiler piping. A balancing valve
must also be installed in the supply side of the boiler piping
downstream of the bypass. Th e balancing valve should be adjusted
to divert some of the heated discharge water into the return water
until the required inlet water temperature is achieved. Th e primary
and secondary pumps should be sized to provide the required fl ow
through each system.
Multiple Boiler Systems
Systems using multiple boilers can also be installed using a primary/
secondary manifold system, Figure 13.
Piping For Use With Cooling Units
Th e 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 fl ow-control valves or some other
automatic means of preventing gravity circulation of the boiler water
during the cooling cycle.
Finned copper tube gas boilers & water heaters – Boiler Manual
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H-1 Rev 4
NOTES:
1. Boiler circuit piping must be sized
large enough to handle maximum
fl ow through unit.
2. Boiler pump sized to boiler design
fl ow requirements.
3. All boilers furnished with factory
mounted outlet water temperature
gauge.
4. Boiler pump purging required.
Use terminals supplied.
Notice: These drawings show suggested
piping confi guration and valving.
Check with local codes and ordinances for
specifi c requirements.
Adjustment Procedure To Maintain Inlet Temperature
Above Dew Point
T1-Temp-Min=110°F For Atmospheric
T1-Temp-Min=125°F Sealed Combusion
1. Turn heater on and open valves A & B.
2. After steady-state operation, if T1 is less than Temp-Min
slowly close valve B until T1 climbs to desired operating
temperature above Temp-Min.
3. If T1 is greater than desired operating temperature, slowly
close valve A to adjust to lower desired temperature above
Temp-Min.
4. Check after system operating temperature has stabilized.
Make fi nal adjustments.
5. Follow same adjustment procedure for sealed combustion.
H-3 Rev 6
NOTES:
1. Boiler circuit piping must be sized large enough to handle
maximum fl ow through unit.
2. Boiler pump sized to boiler design fl ow requirements.
3. All boilers furnished with factory mounted outlet water
temperature gauge.
4. Boiler pump purging required. Use terminals supplied.
Notice: These drawings show suggested piping confi guration and valving.
Check with local codes and ordinances for specifi c requirements.
Operated Valve
Air Vent
Pressure Switch
Aquastat Union
Gas Pressure
Regulator
Automatic
Thermometer
Flow Switch
Pressure
Relief Valve
Reducing Valve
Self-Operated
Check Valve
Pressure
Valve
Pump
Motorized Valve
Solenoid
Ball Valve
Bufferfly Valve
Angle Valve
Gate Valve
Globe Valve
Balance Valve
Backflow-
Prevention
Device
Expansion
Tank
Figure 11 Typical primary/secondary piping system
(See notes)
Figure 12 Low temperature piping
(See notes and adjustment procedures)
Finned copper tube gas boilers & water heaters – Boiler Manual
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Operated Valve
Air Vent
Pressure Switch
Aquastat Union
Gas Pressure
Regulator
Automatic
Thermometer
Flow Switch
Pressure
Relief Valve
Reducing Valve
Self-Operated
Check Valve
Pressure
Valve
Pump
Motorized Valve
Solenoid
Ball Valve
Bufferfly Valve
Angle Valve
Gate Valve
Globe Valve
Balance Valve
Backflow-
Prevention
Device
3-Way Valve
Expansion
Tank
H-18 Rev 3
NOTES:
1. For pump selection consult factory.
2. Boiler pump sized to boiler and
thermostatic 3-way valve design fl ow
requirements.
3. Boiler circuit piping must be sized
large enough to handle maximum
fl ow through unit.
4. All boilers furnished with factory
mounted outlet water temperature
gauge.
5. Boiler pump purging required. Use
terminals supplied.
6. Valve is precalibrated for 140°F
return temperature.
Notice: These drawings show
suggested piping confi guration and
valving. Check with local codes and
ordinances for specifi c requirements.
H-15 Rev 5
NOTES:
1. Boiler circuit piping must be sized large enough to handle
maximum fl ow through unit.
2. Boiler pump sized to boiler design fl ow requirements.
3. All boilers furnished with factory mounted outlet water
temperature gauge.
4. Boiler pump purging required. Use terminals supplied.
5. Secondary loop pipe diameter must be sized large enough to
handle maximum fl ow through all units.
Notice: These drawings show suggested piping confi guration and valving.
Check with local codes and ordinances for specifi c requirements.
Figure 12A Low temperature piping with thermostatic valve
(See notes and adjustment procedures)
Figure 13 Multiple Boiler Piping
(See Notes)
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DOMESTIC WATER SUPPLY PIPING
Proper control sett ings must be used to prevent water
supplied for domestic use from exceeding 130°F, 54°C
or a scald injury will occur! When higher water
temperatures are required for appliances such as a
dishwasher, a mixing valve or some other tempering
means must be installed. Households with small
children may require water temperatures less than
120°F, 49°C. Local codes must be complied with!
General Piping Requirements
Ensure that the water heater is equipped with bronze headers. Piping
and components connected to the water heater must be suitable for
use with potable water. Th e water heater must not be connected to
any heating system piping or components previously used with a
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
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.
Th e storage tank must be located as close to the water
heater as possible to prevent excessive head loss which
will reduce fl ow.
Water Chemistry
Th e required temperature rise across the water heater is based on
water having a hardness between 8 and 18 grains per gallon with
a level of dissolved solids not exceeding 350 ppm. Water having a
hardness less than 8 grains can cause excessive errosion of the heat
exchanger. Water that has a hardness greater than 18 grains per
gallon and/or a level of dissolved solids exceeding 350 ppm will
require a recalculation of the pump size and temperature rise.
A cupro-nickel heat exchanger may also be required. The
manufacturer should be consulted when these water conditions are
encountered, see Table 9A.
Th e maximum allowable fl ow rate through a LCD water
heater with copper heat exchanger is 92 GPM, 5.8 L/s
on 225 1200 models and 115 GPM, 7.3 L/s on 1480 to
2300 models. Th e cupro-nickel heat exchanger allows for
100 GPM, 6.3 L/s on 225 to 1200 models 125 GPM,
7.9 L/s on 1480 to 2300 models, see Table 9B.
RBI water heaters are designed to run scale free. Due to the extreme
variables of water conditions world wide it is necessary to consider
pH values and water hardness in relationship to scaling. It is crucial
to consider these two variables when making heat exchanger and
pump selection. If local water conditions are extreme follow the
guidelines in the Heat Exchanger Selection Table (Table 9A) and the
Pumping Performance Table (Table 9B). Scale free operation can be
achieved by using water with a hardness between 8 and 18 and by
maintaining the pH between 5 and 9. Follow the conditions listed
under NORMAL in the table. In some areas of the country additional
precautions must be observed due to unusual characteristics of the
local water supply. Call the nearest RBI representative for details.
To properly size the pump a grain hardness and pH test must be taken
at the installation site before the order is placed. Proper pump sizing
will improve heater performance and help ensure heater longevity.
Expansion Tank
An expansion tank or other means to control thermal expansion
must be installed in the water heating system if back fl ow prevention
devices are installed.
Cold Water Supply
Th e cold water supply must be piped to the water heater’s outlet
piping between the water heater and the hot water storage tank.
Th is will prevent untempered water from entering the water heater,
see the Temperature Rise Control section below. A typical water
heating system is shown in Figure 14 and 15.
Pump Requirements
Th is low-mass water heater requires a continuous minimum water
fl ow for proper operation. Th e low water fl ow switch provided for
this unit will shut down the water heater if fl ow falls below the
required minimum level. Table 9B provides the heat exchanger
pressure drop chart and temperature rise table. Th e temperature
rise across the water heater must never exceed 35°F, 19.4°C.
Temperature Rise Control
Water returned to the water heater inlet must not be less than 125°F,
52°C or excessive condensation of the products of combustion will
damage the water heater voiding the warranty. Th e method outlined
below can be employed to prevent this condition from occurring.
A balancing valve should be installed on the outlet side of the water
heater for purposes of adjusting the fl ow rate through the heat
exchanger. Th ermometers are installed on both the inlet and outlet
of the water heater for determining the temperature rise through the
unit. Th e proper velocity through the water heater must be maintained
in accordance with Table 9B for effi cient operation and long life.
If the temperature rise through the water heater is lower than
recommended the water velocity is too high. Premature erosion of
the heat exchanger will occur. Conversely, if the temperature rise is
higher than recommended in Table 9B the fl ow rate is too low. Scaling
and soft ening of the heat exchanger will occur.
Thermostatic Mixing Valve -
Water Above 140°F, 60°C
Water can be stored at temperatures above 140°F, 60°C provided
that a thermostatically controlled mixing valve is used to temper
the hot water to an acceptable temperature before it’s supplied for
domestic use.
Th e mixing valve MUST be set to prevent a scald injury from
occurring, see the caution against scalding above.
Storage of water for domestic use above 140°F, 60°C will provide
an increased quantity of tempered water and help prevent growth
of water born bacteria.
Finned copper tube gas boilers & water heaters – Boiler Manual
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Table 9A LCD Heat exchanger selection graph
Table 9B LCD Pumping performance requirement
Finned copper tube gas boilers & water heaters – Boiler Manual
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D-4 Rev 6
D-1 Rev 6
NOTES:
1. Optional cold water make up and recirculation line location.
2. When using intermittent pump and pump delay, locate remote aquastat
well in lower 1/3 of tank. Install aquastat with heat sensing compound.
3. Thermal expansion tank may be required, check local codes.
4. When using optional factory mounted pump, max pipe length 30’ total, 6-90° elbows, full pipe size.
5. CAUTION: MEASURE WATER HARDNESS AND pH AT JOB SITE.
The pH and water hardness must be measured before selecting heat exchanger and pump.
Consult the Heat Exchanger Graph and Pumping Performance Table before making selection.
6. Common piping must be sized for maximum combined heater fl ow.
7. Hot water tanks should be equipped with a combination temperature & pressure relief valve.
8. MA Code requires an 1/8” hole in check valve to compensate for thermal expansion.
Notice: These drawings show suggested piping confi guration and valving.
Check with local codes and ordinances for specifi c requirements.
Operated Valve
Reducing Valve
Self-Operated
Check Valve
Pressure
Valve
Pump
Motorized Valve
Solenoid
Ball Valve
Bufferfly Valve
Angle Valve
Valve
Globe Valve
Balance Valve
2
3
1
4
7
8
Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
SELF BALANCING DOUBLE REVERSE
RETURN MAKE-UP & SUPPLY, CIRCULATION
1
2
3
2
7
7
6
6 8
4
4
Attention:
Not all RBI stock storage tanks
incorporate this tapping: See Note 1.
Air Vent
Pressure Switch
Aquastat Union
Gas Pressure
Regulator
Automatic
Thermometer
Flow Switch
Pressure
Relief Valve
Vacuum
Relief Valve
Temperature &
Pressure
Relief Valve
Drain Valve
(Typ.)
Figure 14 Typical water heating piping (LW models only)
(See notes)
Figure 15 Multiple water heating piping (LW models only)
(See notes)
Finned copper tube gas boilers & water heaters – Boiler Manual
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F
GAS SUPPLY PIPING
Check the boiler/water heater rating plate to make
sure that the boiler/water heater is for the type of gas
that will be used. If it isn’t, do not connect the boiler/
water heater to the gas supply. Gas supply piping must
be in accordance with the National Fuel code, ANSI
Z223.1-latest revision or applicable provisions of the
local building codes. Canadian installations must
comply with CAN/CGA B149.1 or .2 Installation
Code. Failure to comply with this warning can result
in extensive property damage, severe personal injury
or death!
Th e LCD comes from the factory ready to be piped to the gas
supply. If for any reason the boiler/water heater is not for the type
of gas available at the installation site, call your RBI Water Heaters
representative to resolve the problem.
A minimum gas supply pressure of 6 in, 152 mm,
WC natural or 11 in, 279 mm WC propane and
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 fi tt ings. 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. Th e manual shut-off valve
must be installed in the supply piping. It should be installed 5 ft ,
1.5 m above the fl oor where required by local codes. Provide a
sediment trap at the bott om of the vertical section of the gas supply
pipe upstream of the gas controls.
A ground joint union should be installed between the boiler gas
controls and the supply piping. Each of these items are needed to
ensure long life and ease of servicing. Always use a pipe sealant that
is suitable for use with LP gas.
Table 10 Gas pipe capacity
Maximum pipe capacity in ft3/hr based on 0.60 specifi c gravity gas
at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.
Nominal
Iron Pipe
Size
Pipe length in feet
10 20 30 40 50 60 80 100 150
Maximum gas volume of pipe, (ft3/hr)
3/4" 278 190 152 130 115 105 90 79 64
1" 520 350 285 245 215 195 170 150 120
1 1/4" 1050 730 590 500 440 400 350 305 250
1 1/2" 1600 1100 890 760 670 610 530 460 380
2" 3050 2100 1650 1450 1270 1150 990 870 710
2 1/2" 4800 3300 2700 2300 2000 1850 1600 1400 1130
3" 8500 5900 4700 4100 3600 3250 2800 2500 2000
Note: Multiply the gas volume by 0.62 for propane fl ow capacity in ft3/hr.
Multiply the propane fl ow capacity by 2500 Btu/ft3 to determine
the propane Btu/hr capacity for a given pipe size and length.
Table 11 Equivalent pipe length chart
Nominal
Iron Pipe
Size
Type of pipe fi tting
90˚ Elbow Tee
1 Gate Valve2 Gas Cock2
Equivalent pipe length, (ft)
1" 2.6 5.2 0.6 1.5
1 1/4" 3.5 6.9 0.8 1.9
1 1/2" 4.0 8.0 0.9 2.3
2" 5.2 10.3 1.2 3.0
2 1/2" 6.2 12.3 1.4 3.7
3" 7.7 15.3 1.8 4.5
Notes: 1. For fl ow through branch.
2. For fl ow at full open.
Always use a wrench on the gas valve body when
making gas connections to it. Never over-tighten the
piping entering the gas valve body or gas valve failure
may result!
Figure 16 Gas supply piping
When applicable, provisions for vent, bleed and gas relief lines must
be made in accordance with the latest revision of ANSI Z223.1/
NFPA 54.
Safe lighting and other performance criteria were met with the gas
manifold and control assembly provided on the boiler. All gas
connections MUST be leak tested before putt ing the boiler into
operation.
Never use an open fl ame to test for gas leaks. Always
use an approved leak detection method. Failure to
comply with this warning can cause extensive property
damage, severe personal injury or death!
Whenever the gas supply piping is pressure tested the boiler/water
heater gas controls must be protected. If the test pressure is equal
to, or less than 1/2 psig, 3.5 kPa isolate the boiler/water heater
by closing it's manual shut off valve, see Figure 16. If the test
pressure is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect
the boiler/water heater and its individual shut-off valve.
Finned copper tube gas boilers & water heaters – Boiler Manual
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F
ELECTRICAL WIRING
Electrical Power Connections
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation! Verify proper operation aft er
servicing.
Au moment de l'entretien des commandes, étiquetez
tous les fi ls avant de les débrancher. Des erreurs de
câblage peuvent entraîner un fonctionnement
inadéquat et dangereux. S'assurer que l'appareil
fonctionne adéquatement une fois l'entretirn terminé.
Th e electrical connections to this boiler/water heater must be made
in accordance with all applicable local codes and the latest revision
of the National Electrical Code, ANSI/NFPA-70. Installation should
also conform with CSA C22.1 Canadian Electrical Code Part I if
installed in Canada.
Install a separate 120 volt 15 or 20 amp circuit breaker for the
boiler/water heater and pump, see Table 12. A properly rated shut-
off switch should be located at the boiler/water heater. Th e boiler/
water heater must be grounded in accordance with the authority
having jurisdiction, or if none, the latest revision of the National
Electrical Code, ANSI/NFPA-70.
Table 12 LCD electrical requirements
Recommended
LCD Circuit Breaker *Running
Model (Amps) Amps
LB/LW 250 - 600 15 3.9
LB/LW 750 15 6.0
LB/LW 1050 - 1970 20 11.4
LB/LW 2300 20 14.4
*Use separate circuit breaker that is properly sized for pump and
pump contactor.
Line voltage fi eld wiring of any controls or other devices must
conform to the temperature limitation of type T wire at 95°F, 35°C
above room temperature. Use copper conductors with a minimum
size of #14 awg. Use appropriate wiring materials for units installed
outdoors. Th e wire size must be compatible with the total amp
draw of the circuit.
Refer to the wiring diagram supplied with the boiler/water heater
for proper wiring connections.
GENERAL OPERATION
Before proceeding read and fully understand the
instructions contained in this manual. Do not att empt
to operate this boiler/water heater if it has not been
installed in accordance with the guidelines set forth
in this manual. Failure to comply with this warning
can result in extensive property damage, severe personal
injury or death!
Should overheating occur or the gas supply fail to shut off , turn off
the manual gas control valve to the appliance. Do not interrupt
water fl ow through the boiler/water heater.
En cas de surchauff e ou si l'alimentation en gaz ne s'arrête pas, fermez
manuellement le robinet d'arrêt de l'admission de gaz.
Hydronic Heating Boilers
Open the make-up water valve and slowly fi ll the boiler and all
of the radiation with water. Ensure that all bleed and drain valves
are closed.
Adjust the make-up water pressure regulator so a minimum 12 psig,
83 kPa system pressure is maintained at the highest point in the
system piping. If a make-up water pump is used adjust it to maintain
a minimum 12 psig, 83 kPa system pressure.
Open the system bleed and drain valves one at a time to purge the
air trapped in the heating system piping.
With the boiler off , run the system pump for at least 30 minutes
and bleed the system piping using the bleed valves. If strainers are
used in the system piping, the make-up water valve should be closed
and the strainers checked and cleaned.
Th e system expansion tank should be checked to ensure that the
correct water level in the tank is maintained. Th e tank should be
less than half full of water with the system full and adjusted to the
correct operating pressure.
Start the boiler as described in the “OPERA TING INSTRUCTIONS”.
Run the boiler for at least an hour. Th e system pump(s) and all
radiation units must be operated during this time. Ensure that the
make-up water valve is open.
Shut the boiler off and open the bleed valves to purge the air trapped
in the heating system piping. Close the make-up water valve and
check and clean the strainers and make-up water pressure reducing
valve.
Open the make-up water valve and adjust the system pressure if
necessary. Th e system should be checked and bled aft er three days
of operation.
Finned copper tube gas boilers & water heaters – Boiler Manual
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F
BOILER/WATER HEATER OPERATION
Staging Operation
Th e LCD boiler/water heater series is separated into on/off and
2-stage units depending on the model selected. Th e 225-400 models
have on/off staging, while the 600 through 2300 models have a
two stage option. Input staging is controlled from an aquastat
controller that signals the relays to select the blower and gas valve
modes. Per DOE mandate, the (LB225/300) operator control
incorporates an automatic means (outdoor reset) of adjusting the
boiler water temperature for hot water heating. Th e boiler will not
operate without the outdoor sensor installed. Table 13 identifi es
the stages and fi ring modes associated with the standard single stage
units. Table 14 identifi es the stages and fi ring modes associated
with the two stage option.
Table 13 Firing modes (L225-L2300)
Stage Firing Mode
Off Off
1On
Table 14 Firing modes (L600-L2300)
Stage Firing Mode
Off Off
1Low Fire
2 High Fire
Th e outlet water temperature is automatically controlled by the
aquastat. Th e optional staging function is controlled by a return
water aquastat. Th e return water aquastat utilizes inputs from the
inlet water temperature sensors or optional tank sensors to stage
the boiler/water heater as required.
Pressure Switch Settings
Diff erential pressure switches are provided in the LCD to shut down
gas fl ow under a blocked fl ue or inlet condition. A single pressure
switch is used on the standard models. One low fi re and one high
fi re pressure switch is used when the two-stage option is employed.
Th e low fi re pressure switch serves to shut down gas fl ow if there
is a blocked fl ue or inlet condition during low fi re operation. Similarly,
the high fi re switches will shut down gas fl ow if there is a blocked
fl ue or inlet condition during high fi re operation. Th e diff erential
pressure is taken between the air plenum and the pressure
inside one of the main burners.
Pressure taps are provided in the control compartment for taking
the diff erential pressure readings, Figure 17. Table 15 lists the
diff erential pressure sett ings for all of the models.
Figure 17 Pressure switch tap(s)
Table 15 Differential pressure settings (all units)
Model
Diff erential Pressure
Requirement at High Fire
(All Units)
Inches WC mm WC
225-300 1.0 ± 1.1 25.4 ± 27.9
400 0.7 ± 0.8 17.8 ± 20.3
600-2300 1.0 ± 1.1 25.4 ± 27.9
On all units, the pressure switch(es) will interrupt power to the
control module under a blocked fl ue or inlet condition. Th is will
cause the pilot and main gas valves to close. Tables 16 and 17 identify
how pressure switch control changes during boiler/water heater
staging. Tables 18 and 19 identify the control actions if a low air
condition occurs at any stage.
Table 16 Pressure switch control, L225-L400
Stage Pressure Switch Mode
Off Off
1 High Fire
Table 17 Pressure switch control, L600-L2300
Stage Pressure Switch Mode
Off Off
1Low Fire
2 High Fire
Finned copper tube gas boilers & water heaters – Boiler Manual
24
F
Table 18 Low air condition action, L225-L2300
Stage Control Action
1 No Power to Flame Sense Module
Table 19 Low air condition action, L600-L2300
Stage Control Action
1 No Power to Flame Sense Module
2 No Power to Flame Sense Module
OPERATION SEQUENCE, ON/OFF
L225 THROUGH L2300
Refer to the wiring diagram included with the unit
for further control system info.
POWER ON:
Demand for Heat:
1. Th e operator switch closes, energizing pump delay timer TD4
and the water pump(s).
2. Water fl ow through the unit closes the water fl ow switch contacts
energizing blower delay timer TD3.
3. Th e system checks all primary limit(s) and other interlocks before
starting pre-purge. Th e unit will not start if any switch is open.
Prepurge:
1. Blower delay timer TD3 energizes the high speed windings of
the blower(s).
2. Air pressure in the combustion chamber is sensed. If the air
pressure is suffi cient, the pressure switch closes allowing the
blower delay timer TD1 to start a 10 second pre-purge.
Ignition Trial:
1. Blower delay timer TD1 times out and the fl ame sense module,
FSM, is energized.
2. Th e FSM starts the 10-second ignition trial, energizing relay
R7, the pilot solenoid valve and the spark generator.
3. Th e pilot valve and spark generator are energized for the
10-second ignition trial. When the pilot fl ame is sensed, the
FSM sends 24VAC to its MV terminal energizing the safety
and main solenoid valves and relay R8, de-energizing relay R7
and the spark generator.
4. If the pilot fl ame isn’t sensed, the FSM de-energizes the PV
terminal and waits 5 minutes before initiating the second ignition
trial. Th e blower(s), pump(s) and optional power venter will
remain on during this time.
5. On CSD-1 equipped units the blower(s) and optional power
venter will shut down and the boiler/water heater will lock if
the second ignition trial fails. Th e unit must then be manually
reset by depressing the reset butt on on the left jacket panel.
6. On non-CSD-1 equipped units the FSM will wait 10
minutes aft er the second unsuccessful ignition att empt then
begin the ignition process described in step 3 above. Th e FSM
will continue to cycle the unit through steps 3, 4 and 6 until
the unit lights or the demand for heat is removed.
Main Burner
Once the pilot is proven, the MV terminal on the FSM is energized
sending 24VAC to the safety and main solenoid valves.
Normal Operation
On single stage units the blowers and gas valves operate at one
input.
Demand Satisfi ed:
1. When the demand for heat is satisfi ed the operator switch will
open, de-energizing relay R8, TD1, TD3, TD4, the FSM, and
the pilot, main and safety solenoid valves. Th e pilot and main
fl ames are extinguished.
2. Th e blower delay timer TD3 starts the 80 second post-purge
timing. Th e blower(s) shut(s) off when TD3 times out.
3. Th e pump delay timer TD4 starts the post-purge timing. Th e
pump(s) remain on for 0.1 to 10 minutes then shut(s) off when
TD4 times out.
High Limit, Low Water Flow, Low Gas Pressure, High Gas
Pressure, Power Venter Interlock Faults
1. Electrical power to the gas valves, blower(s) and optional power
venter will be interrupted if any safety is tripped.
2. Th e manual reset high limit can be reset by depressing the reset
butt on on the left jacket panel.
Low Air (Blocked Flue/Air Inlet)
• Th e pressure switch will monitor blower airfl ow.
• Air monitoring will begin at pre-purge. If a low air condition is
present power will not be supplied to the FSM. Th e blower(s)
will remain on.
Finned copper tube gas boilers & water heaters – Boiler Manual
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F
OPERATION SEQUENCE, 2 STAGE OPTION
L600 THROUGH L2300
Refer to the wiring diagram included with the unit
for further control system info.
POWER ON:
Demand for Heat:
1. Th e low operator switch closes, energizing pump delay timer
TD4 and the water pump(s).
2. Water fl ow through the unit closes the water fl ow switch contacts
energizing blower delay timer TD3.
3. Th e system checks all primary limit(s) and other inter-locks
before starting pre-purge. Th e unit will not start if any switch
is open.
Prepurge:
1. Blower delay timer TD3 energizes the low speed windings of
the blower(s).
2. Once suffi cient air pressure in the combustion chamber is sensed
the pressure switch closes allowing the blower delay timer TD1
to start a 10 second pre-purge.
Ignition Trial:
1. Blower delay timer TD1 times out and the fl ame sense module,
FSM, is energized.
2. Th e FSM starts the 10-second ignition trial, energizing relay
R7, the pilot solenoid valve and the spark generator.
3. Th e pilot valve and spark generator are energized for the
10-second ignition trial. When the pilot fl ame is sensed, the
FSM sends 24VAC to its MV terminal energizing the safety
and low fi re-side of the main solenoid valves and relay R8,
de-energizing R7 and the spark generator.
4. If the pilot fl ame isn’t sensed, the FSM de-energizes the PV
terminal and waits 5 minutes before initiating the second ignition
trial. Th e blower(s), pump(s) and optional power venter will
remain on during this time.
5. On CSD-1 equipped units the blower(s) and optional power
venter will shut down and the boiler/water heater will lock if
the second ignition trial fails. Th e unit must then be manually
reset by depressing the reset butt on on the left jacket panel.
6. On non-CSD-1 equipped units the FSM will wait 10 minutes
aft er the second unsuccessful ignition att empt then begin the
ignition process described in step 3 above. Th e FSM will continue
to cycle the unit through steps 3, 4 and 6 until the unit lights
or the demand for heat is removed.
Main Burner
Once the pilot is proven, the FSM sends 24VAC to its MV terminal
energizing the safety and low-fi re side of the main solenoid valves.
Normal Operation
• Staging is controlled by the return water aquastat. Relays R2
and R2R are energized by the return water aquastat when more
heat input is required. Th e hi-speed windings of the blower(s)
are energized.
• Relay R9 is energized when the hi-fi re pressure switch senses
adequate air pressure to sustain hi-fi re combustion. R9 energizes
the hi-fi re side of the main solenoid valve.
• Stage 1 will operate fi rst and last.
For a change from stage 1 to 2, a 30 second time delay
is provided in the pressure switch switching circuit.
Th e time delay TD6 provides a hold state that allows
the blower to reach full speed and close the high fi re
pressure switch before it is energized to confi rm proper
air fl ow.
Demand Satisfi ed:
1. When the demand for heat is satisfi ed the low operator switch
will open, de-energizing relays R2, R2R, R8, R9, TD1, TD3,
TD4, TD6, the FSM, and the pilot, main and safety solenoid
valves. Th e pilot and main fl ames are extinguished.
2. Th e blower delay timer TD3 starts the 80 second post-purge
timing. Th e blower(s) shut(s) off when TD3 times out.
3. Th e pump delay timer TD4 starts the post-purge timing. Th e
pump(s) remain on for 0.1 to 10 minutes then shut(s) off when
TD4 times out.
High Limit, Low Water Flow, Low Gas Pressure, High Gas
Pressure, Power Venter Interlock Faults
1. Electrical power to the gas valves, blower(s) and power venter
will be interrupted if any safety is tripped.
2. Th e manual reset high limit can be reset by depressing the reset
butt on on the left jacket panel.
Low Air (Blocked Flue/Air Inlet)
• Th e pressure switches will monitor blower airfl ow.
• Air monitoring will begin at pre-purge. If a low air condition is
present, power will not be supplied to the FSM. Th e blower(s)
will remain on.
Finned copper tube gas boilers & water heaters – Boiler Manual
26
F
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN
MARCHE
A. Th is appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot by
hand.
Cet appareil est muni d’un dispositif d’allumage qui allume
automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse
manuellement.
B. BEFORE OPERA TING smell all around the appliance area
for gas. Be sure to smell next to the fl oor because some gas is
heavier than air and will sett le on the fl oor.
Propane gas may not always be detected by smell.
Propane gas is heavier than air and can collect in low
areas.
Propane gas can ignite or explode if an ignition source is
present and result in death, serious injury and property
damage!
FOR YOUR SAFETY
• Have only qualifi ed licensed professionals install, service and
maintain this appliance and your gas system in accordance with
all applicable codes.
• Install a nationally listed combustible gas detector(s) in your
home.
• If you suspect a leak:
1. Have everyone leave the building immediately.
2. Do not att empt to light any appliance.
3. Do not touch any electrical or electronic switches in the
building.
4. Do not use any phone in the building.
5. Call your gas supplier from a phone outside of the building.
6. If you cannot reach your gas supplier call the fi re department.
AVANT DE FAIRE FONCTIONNER, renifl ez tout autour de
l’appareil pour déceler une odeur de gaz. Renifl ez près du plancher,
car certains gaz sont plus lourds que l’air et peuvent s’accumuler
au niveau du sol.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareil.
• Ne touchez à aucun interrupteur; ne pas vous 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.
C. Do not use this appliance if any part has been under water.
Immediately call a qualifi ed service technician to inspect the
appliance and to replace any part of the control system and any
gas control that has been under water.
N’utilisez pas cet appareil s’il a été plongé dans l’eau, même
partiellement. Faites inspecter l’appareil par un tecnicien qualifi é
et remplacez toute partie du système de contrôle et toute
commande qui ont été plongés dans l’eau.
To prevent being burned, stand clear of the boiler
during ignition and do not touch any hot metal parts.
Operating Instructions
1. STOP! Read the safety information above. If, at any time, the
appliance will not operate properly, follow the instructions “TO
TURN OFF GAS TO APPLIANCE”.
2. Set the operating control or thermostat to off or its lowest sett ing.
3. Turn off all electric power to the appliance.
4. Close the main manual gas shut-off valve, Figure 16.
5. Wait fi ve (5) minutes to clear out any gas. Th en smell for gas,
including near the fl oor. If you smell gas, STOP! Follow “B”
in the safety information above (to the left ) on this label. If you
do not smell gas, go to the next step.
6. Remove the upper front jacket panel.
7. Turn the knob on the pilot valve to off , Figure 18.
8. Turn the knob on the main gas valve to off , 225 through 400
models, Figure 18. On 600 through 2300 models close the
manual shutoff valve located in the control compartment, Figure
19.
9. Remove the plug(s) from the pilot and manifold pressure
fi tt ing(s), Figure 19.
10. Connect a manometer having a minimum capacity of 20 in,
508 mm WC to the pilot and manifold pressure fi tt ings, Figure
19. Make sure the gas supply piping has been purged of air and
all gas joints up to the gas valve have been thoroughly checked
for leaks.
11. Remove plug(s) from the diff erential air pressure taps, Figure 17.
12. Connect both sides of a manometer to the pressure switch tee,
Figure 17, going to one of the pressure switches.
Figure 18 Pilot valve (all models)
main valve (225 - 400 models)
Finned copper tube gas boilers & water heaters – Boiler Manual
27
F
13. Turn the knob on the pilot valve to on, Figure 18.
14. Turn on all electric power to the boiler and set the operating
control or thermostat to the desired sett ing.
15. With the unit operating at high purge the diff erential air pressure
should match those listed in Table 15. To adjust the diff erential
air pressure see the “AIRFLOW ADJUSTMENT” instructions
in the “CHECKING AND ADJUSTMENTS” section.
Figure 19 Manual valve & manifold pressure tap
16. Th e pilot should automatically light. Do not try to light the
pilot by hand!
17. Th e pilot pressures should match those listed in Table 20. To
adjust the pilot gas pressure see the “PILOT ADJUSTMENT”
instructions in the “CHECKING AND ADJUSTMENTS”
section.
18. Distinguish pilot.
19. Turn the knob on the main gas valve to on, 225 through 400
models, Figure 18. On 600 through 2300 models open the
manual shutoff valve located in the control compartment, Figure
19.
20. Recycle boiler.
21. Th e manifold pressures should match those listed in Table 20.
To adjust the manifold gas pressure see the “GAS PRESSURE
ADJUSTMENT” instructions in the “CHECKING AND
ADJUSTMENTS” section.
22. Replace the upper front jacket panel.
23. Check all safety switches for proper operation before placing
boiler on-line.
Required Gas Pressure
Provide gas supply pressure at inlet to boiler gas train as follows:
LP Nat
Minimum (in WC) 11 6
Maximum (in WC) 14 14
Measure pressure when the boiler is fi ring at full rate. Low gas
pressure could indicate undersized gas line or insuffi cient gas supply.
Static and operating gas pressure required at the gas valve inlet is
between 6 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. Th is 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 specifi c job site requirements.
Table 20 Pilot & manifold pressures
On/Off
inches WC mm WC
Pilot - NG 2.5 ± 0.3 63.5 ± 7.6
Pilot - LP 7.0 ± 2.0 177.0 ± 50.0
Low Fire
inches WC mm WC
Manifold - NG 1.4 ± 0.2 35.5 ± 5.0
Manifold - LP 4.0 ± 0.5 101.6 ± 12.7
High Fire
inches WC mm WC
Manifold - NG 2.5 ± 0.2 63.5 ± 5.0
Manifold - LP 9.3 ± 0.3 236.2 ± 7.6
Table 21 Combustion readings
Natural Fuel Propane Fuel
CO2 %7.0 - 7.5 (low) 8.2 - 8.8 (low)
7.8 - 8.5 (high) 9.2 - 9.9 (high)
O2 %8.3 - 7.6 (low) 8.3 - 7.6 (low)
7.0 - 5.8 (high) 7.0 - 5.8 (high)
Finned copper tube gas boilers & water heaters – Boiler Manual
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F
Instructions De Mise En Marche
1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion
supérieure de cett e étiquett e.
2. Réglez le thermostat à la température la plus basse.
3. Coupez l’alimentation électrique de l’appareil.
4. Cet appareil est muni d’un dispositif d’allumage qui allume
automatiquement la veilleuse. Ne tentez pas d’allumer la veilleuse
manuellement.
5. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
6. Att endre cinq (5) minutes pour laisser échapper tout le gaz.
Renifl ez tout autour de l’appareil, y compris près du plancher,
pour déceler une odeur de gaz. Si vous sentez une odeur de
gaz, ARRÊTEZ! Passez à l’étape B des instructions de sécurité
sur la portion supérieure de cett e étiquett e. S’il n’y a pas d’odeur
de gaz, passez à l’étape suivante.
7. Ouver la vanne manuelle d’arrêt d’alimintation de gaz.
8. Mett ez l’appareil sous tension.
9. Réglez le thermostat à la température désirée.
10. Si l’appareil ne se met pas en marche, suivez les instructions
intitulées couper l’admission de gaz de l’appareil et appelez un
technicien qualifi é ou le fournisseur de gaz.
To Turn Off Gas To Appliance
1. Set the operating control or thermostat to its lowest sett ing.
2. Turn off all electric power to the appliance if service is to be
performed.
3. Close the manual main valves.
COUPER L’ADMISSION DE GAZ DE L’APPAREIL
1. Réglez le thermostat à la température la plus basse.
2. Coupez l’alimentation électrique de l’appareil s’il faut procéder
à l’entretien.
3. Fermer la vanne manuelle d’arrêt d’alimintation de gaz.
CHECKING & ADJUSTMENTS
1. With the burners in operation, close the manual shutoff valve
in the gas supply line. As soon as the main burner fl ames go
out, open the manual shutoff valve. A normal ignition sequence
should take place. If the burners fail to light, the gas valves will
close and the system will go into a 5-minute lock out period.
Th e fl ame sense module will then make a second ignition att empt.
If the unit won’t light ensure that the gas piping is fully purged
of air. Inspect the ignition system and ensure that it is operating
properly.
2. To test the ignition safety shutoff device, close the manual shutoff
valve in the gas supply line. Within 5 seconds of main burner
fl ame extinction, the main gas valve solenoid should close with
an audible noise. Aft er 10 seconds the module should lockout
and the trial for ignition end. Aft er 5 minutes a second trial for
ignition should occur. Open the manual shutoff valve in the
gas supply line and reset the ignition control system. A normal
ignition sequence should take place.
3. With the burners in operation, interrupt the power to the control
circuit by turning down the operator or thermostat. Th e boiler/
water heater should shut down. Reset the operating control or
thermostat. A normal ignition sequence should follow.
Input Rate, Natural Gas
Gas appliances are rated based on sea level operation with no
adjustment required at elevations up to 5000 ft , 1524 m. At
elevations above 5000 ft , 1524 m, input ratings should be reduced
by 4% for each additional 1000 ft , 305 m.
Check the input rate as follows:
1. Turn off all other gas appliances that use the same gas meter
as the boiler/water heater.
2. Call your gas supplier and ask for the heating value of the gas.
3. Connect a fl ue gas analyzer to the vent pipe.
4. Start the boiler/water heater and let it run for 15 minutes.
5. Using the gas meter and a stopwatch, clock the time that it takes
to burn 10 ft 3, 0.28 m3 of gas and divide this time by 10.
6. Insert the heating value and the time, in seconds, into the formula
below.
7. Input = (heating value, Btu/hr)(3600)/(time, seconds)
8. If the computed rate deviates by more than 5% from the rated
input value of the unit adjust the manifold pressure accordingly.
DO NOT adjust the manifold pressure by more than 5%. If a
proper rate cannot be maintained without adjusting the manifold
pressure beyond the 5% limit, the main burner orifi ces must
be replaced. If the input rate is too low, go to the next lager size
of main burner orifi ces. If the input rate is too high, go to the
next smaller size.
Never increase the input of the boiler/water heater
above that for which it is rated. Doing so can cause
premature failure of the unit!
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Pilot Adjustment
Th e pilot burner is actually an isolated main burner that’s
controlled by a separate pilot valve. Pilot pressure sett ings are as
shown in Table 20. Th ese pressures are measured at the pilot pressure
valve, see Figure 19. Tables 13 and 14 above list the fi ring mode
that is associated with each stage.
To view the pilot without main burner operation, take the following
steps:
For L225-L400:
1. Remove the upper front jacket panel.
2. Turn off main burner gas fl ow by turning the main burner gas
valve knob to the off position, Figure 18.
3. Observe the pilot fl ame through one of the observation ports
located at the left and right ends of the unit.
For L600-L2300:
1. Remove the upper front jacket panel.
2. Turn off main burner gas fl ow by turning the manual gas valve(s)
in the control compartment to the off position, see Figure 19.
3. Observe the pilot fl ame through one of the observation ports
located at the left and right ends of the unit.
Pilot pressures will be set at the factory. However, if it is necessary
to adjust the pilot pressure to match those in Table 20, take the
following steps:
1. Remove the upper front jacket panel.
2. Remove the 1/8 in plug from the pilot pressure test port and
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.
4. Use a 3/32 hex wrench to turn the pressure regulator adjustment
screw clockwise to increase the pilot pressure and counter
clockwise to decrease it.
5. Replace the pressure regulator adjustment screw cap.
Gas Pressure Adjustment
Th e maximum inlet gas pressure listed on the rating
plate must not be exceeded or damage to the boiler/
water heater may occur voiding the warranty!
Th e minimum supply pressure listed on the rating plate is for input
adjustment.
Th e manifold pressures should match those listed in Table 20.
Pressures should not vary outside these ranges. Each gas valve
pressure regulator has been preset at the factory. If neccessary, adjust
the gas pressures to achieve the combustion results show in Table
21.
If adjustments are necessary the following steps must be followed:
1. Remove the 1/8 in plug from the manifold pressure tap valve.
Connect 20 in, 508 mm WC manometers to it, see Figure 19.
2. Remove the regulator adjustment screw cap from the main gas
valve.
3. Rotate the regulator adjustment screw clockwise to increase the
manifold pressure, counter clockwise to decrease it.
4. Replace the regulator adjustment screw cap and manual shut
off valve pressure tap plug.
Never force the regulator adjustment screw beyond
the stop limits or damage to the regulator will occur!
PROPANE GAS: Optimum results are obtained when the
boiler/water heater is operated with the manifold pressure(s) set
per Table 20. If the manifold pressure is off by more than 5% adjust
it according to steps 1 through 4 above.
Airfl ow Adjustment
1. Remove the upper front jacket panel.
2. Connect both sides of a manometer to the pressure switch tee,
Figure 17, going to one of the pressure switches.
3. With the unit operating at high fi re the diff erential pressure should
match those listed in Table 15. Do not change air pressure in
lower stages.
Finned copper tube gas boilers & water heaters – Boiler Manual
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CONTROL DESCRIPTION
Boiler Thermostat
If a thermostat is to be used to control the boiler always follow the
instructions included with the thermostat. Proper location of the
thermostat will ensure effi cient trouble-free operation of the boiler.
Mount the thermostat to an inside wall at a height approximately
fi ve feet above the fl oor.
Avoid placing the thermostat in areas that will not provide an accurate
measurement of the room temperature. Locating the thermostat
behind a door, in an alcove, close to a source of thermal radiation
or in a draft y area will cause poor or sporadic heating.
For a thermostat that employs an adjustable heat anticipator, adjust
the anticipator to match the current measured in the thermostat
circuit. An increased anticipator sett ing may be necessary if the unit
cycles frequently. If the room temperature over-shoots the thermostat
sett ing, reduce the anticipator sett ing.
Operating Control
Th e preferred control sett ing for potable hot water is 130°F, 54°C.
Th e operating control should be set to the lowest sett ing that will
satisfy the consumer’s needs.
Sett ing the thermostat or operation control too high
can result in scalding resulting in severe personal injury!
High Limit (Aquastat)
Th e high limit is located in the top control area of the boiler/water
heater. A remote capillary bulb is run to a well on the outlet side
of the supply header. Th e high limit can be reset by depressing the
reset butt on on the left jacket panel.
Th e water heater high limit should be set a minimum of 20°F,
11°C higher than the operating control. Refer to the HOT WATER
SUPPLY section for the proper supply water temperature.
Flow Switch
A fl ow switch is provided in the water outlet piping to prevent the
boiler/water heater from fi ring without adequate water fl ow through
the heat exchanger.
Low Water Cutoff
If the boiler is to be installed above radiation or if required by other
codes or regulations, install a low water cutoff in appropriate piping.
Wire the switch and any external controls in series to the “Interlock”
contacts in the control box, see the wiring diagrams included with
the unit for details. Ensure that the low water cutoff device(s) will
function properly.
Flame Sense Module
Th e fl ame sense module is located in the control box. It is an
intermitt ent pilot control device that controls the pilot gas fl ow,
spark energy to ignite the pilot gas and the main valve(s) once pilot
ignition has been proven.
Two fl ame failure alarm terminals are provided on the fl ame sense
module. For CSD-1 these terminals are utilized to shut the unit
down in case of fl ame failure. Th e two terminals are connected to
a lockout control module located in the control box. Th is lockout
control module contains a magnetic latch relay that requires manual
reset when de-energized. To reset aft er fl ame failure, push and release
the momentary contact switch located on the left jacket panel.
Relay Board
Th e relay board is located in the control panel. It provides sequencing
of the gas valves and blower(s) based on the staging controller's
input. It also provides the following time delays for proper unit
operation:
• A 10 second prepurge when stage 1 is energized.
• A 30 second pressure switch sequencing delay when the blowers
switch from low fi re to high fi re. Th e delay enables the blower to
come up to speed before the high pressure side of the pressure
switch confi rms proper air fl ow.
Th ese time delays are set within the separate time delay board
connected to the relay board.
Gas Pressure Switch
Optional low and/or high-pressure gas pressure switches will shut
down the 24V circuit if excessively high or low gas pressure exists
in the gas train or supply piping.
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MAINTENANCE
Disconnect electrical power and close the manual gas
shut off valve before performing maintenance or severe
personal injury may result!
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury, exposure to hazardous materials or loss of life.
Installation and service must be performed by a
qualifi ed installer, service agency or the gas supplier
who must read and follow the supplied instructions
before installing, servicing or removing this boiler.
Th is boiler contains crystalline silica materials that
have been identifi ed as carcinogenic or possibly
carcinogenic to humans when inhaled.
AVERTISSEMENT: Une installation, un réglage, une
modifi cation, une réparation ou un entretien non
comforme aux normes peut entraîner des
dommages matériels, des blessures, exposition à des
matières dangereuses ou la mort. L’installation et
l’entretien doivent être eff ectués par un installateur ou
un service d’entretien qualifi é ou le fournisseur de gaz
qui doivent avoir lu les instructions fournies avant de
faire l’installation, l’entretien ou l’enlèvement de la
chaudière et les respecter, Cett e chaudière contient
des matériaux qui ont été identifi és comme étant
cancérogènes ou pouvant l’ être.
Servicing, inspection and adjustment must be done
by a trained technician in accordance with all applicable
local and national codes. Improper servicing or
adjustment can damage the boiler/water heater!
Th e ceramic combustion chamber contains crystalline
silica. Wear a tightly fi tt ed dust mask when removing
the burners or heat exchanger to prevent inhalation
of airborne fi bers. Crystalline silica fi bers have been
identifi ed as carcinogenic, or possibly carcinogenic
when inhaled.
Th e boiler/water heater should be cleaned and inspected once a
year, before each heating season. Make sure that the burner and
ignition components are free from dust, soot, dirt, corrosion or other
deposits that would impair the boiler/water heater ‘s performance.
Refer to page 36 for component identifi cation.
Burner Inspection And Removal - Figure 20
1. Close the manual shutoff valves in the gas supply lines and turn
off electrical power to the boiler/water heater.
2. Remove the front jacket panels.
3. Disconnect the manifold gas piping at the ground joint union(s).
Also disconnect the pressure sensing lines, pilot tubing and
ignition and sensing leads.
4. Remove the manifold(s).
5. Remove the burner(s) from the lower front combustion chamber
panel.
6. Inspect the burners for damage or signs of deterioration. Use a
brush or compressed air to remove any debris from the burner
ports.
7. DO NOT install a damaged or badly corroded burner replace
it.
8. Install the burner(s) making sure that the burner gasket is not
torn or deteriorated. If it is replace it.
9. Reassemble the unit following the removal steps in reverse order.
Heat Exchanger Inspection - Figure 20
1. Close the manual shutoff valve in the gas supply line and turn
off electrical power to the boiler/water heater.
2. Remove the jacket front panels.
3. Disconnect the gas piping at the ground joint union(s). Also
disconnect the pressure sensing lines, pilot tubing and ignition
and sensing leads.
4. Remove the 1/4 in nuts and washers holding the upper
combustion chamber front panel in place and carefully remove
it.
5. Inspect the inside and outside of the heat exchanger for signs
of damage, sooting or corrosion.
6. Th e outside surfaces of the copper tubes should be free of any
soot deposits. A slight black smudge is normal with some types
of gases. Black soot indicates poor combustion. Green deposits
indicate condensation due to low return water temperatures. In
either case the heat exchanger must be cleaned thoroughly and
the problem resolved before the boiler/water heater is returned
to service
7. If there are no signs of damage, sooting or corrosion reassemble
the unit following the previous steps in reverse order.
8. A badly corroded or damaged heat exchanger must be replaced,
see the Heat Exchanger Removal section.
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Heat Exchanger Removal, Cleaning
& Replacement - See Figure 20
1. Close the shut off valves in the inlet and outlet piping. On heating
systems close the system fi ll valve and relieve the system pressure
from the boiler by carefully lift ing the relief valve or opening
the drain valve.
2. Drain the boiler/water heater and disconnect it from the system
piping.
3. Remove the inlet/outlet and return headers.
4. Remove the jacket front panels.
5. Loosen, 4 turns, but don’t remove the 6 screws, (3 on each
side) holding the heat exchanger upper rails in place, Figure 21.
6. Disconnect the gas piping at the ground joint unions. Also
disconnect the pressure sensing lines, pilot tubing and ignition
and sensing leads.
7. Remove the upper partition panel, 1050 through 2300 models.
8. Remove the 1/4 in nuts and washers holding the upper
combustion chamber front panel in place and carefully remove
it.
9. Carefully slide the heat exchanger out of the unit.
10. Remove the “V” baffl e straps and “V” baffl es.
11. Th oroughly 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!
12. Sagging or distorted heat exchanger tubes are an indication of
low water fl ow through the system. A leaking or otherwise
damaged heat exchanger must be replaced and the condition
that caused the damage resolved before the boiler/water heater
is returned to service.
13. If the heat exchanger isn’t damaged rewire the heat
exchanger baffl es in place and slide the heat exchanger back
into the unit.
14. Reinstall all of the other components in the reverse order of
their removal.
15. Th e torque values for the bolts that secure the removable headers
are 17-20 ft lbs. Once bolts have been started and secured the
tightening sequence is as follows:
1) Middle Top
2) Middle Botom
3) Right Top
4) Left Bott om
5) Left Top
6) RightBott om
Figure 20 Burner and heat exchanger servicing
Finned copper tube gas boilers & water heaters – Boiler Manual
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Figure 21 Heat exchanger upper rail screws
Vent System
Th oroughly inspect the vent system for any signs of blockage,
corrosion or leakage. Immediately replace any unsound vent system
piping.
Controls
Use the “BOILER/WATER HEATER OPERA TION” and
“CHECKING AND ADJUSTMENTS” sections of this manual
for reference.
1. Check the thermostat or operating controls for proper operation.
2. A fl oat type low water cutoff device must be fl ushed out per
the manufacturers’ instructions. Th e probe on a probe low water
cut off must be cleaned and inspected per the manufacturers’
instructions. Ensure that the low water cutoff s operate properly.
If not, replace them.
3. Th e fl ow switch contacts must be open when water fl ow is not
present.
4. Th e relief valve should not weep or discharge water
at normal system pressure. If it does contact a qualifi ed service
technician to have it inspected. NEVER try to clean or repair
the relief valve! If the valve fails to operate properly, have it
replaced!
5. Th e 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 . Th e water
temperature should never exceed the maximum set point of
240°F, 116°C. Th e aquastat high limit cannot be repaired. If
it fails to function properly replace it.
6. Visually check the pilot and main burner fl ames to ensure proper
operation, see Figure 22.
A yellow, fl oating fl ame indicates a lack of combustion
air. A lift ing fl ame indicates too much combustion air.
Do not operate the boiler/water heater until the
problem is solved or severe personal injury or death
may occur!
Figure 22 Pilot & main burner fl ame
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TROUBLE-SHOOTING
SYMPTOM CHECK ACTION
1 No Power To Control Circiut 1. Power not connected
2. External circuit breaker open
3. Transformer circuit breaker open
1. Wire unit to line voltage
2. Reset breaker
3. Reset breaker
2 No Action On Call For Heat 1. Primary limit or other control/interlock
open
2. Low water cutoff open
1. Reset limit or control or resolve problem
as applicable
If not resolved, check wiring and
condition of limit
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
2. Pump malfunctioning
3. Defective pump timer TD4
1. Wire pump contact in control box
2. Replace pump
3. Replace pump timer TD4
4 No Power to Optional Power Venter 1. Power venter not wired to external power
2. Power venter fault
1. Wire power venter as shown in
connection diagram
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
2. Defective blower timer TD3
3. Blower(s) malfunctioning
1. Plug in blower(s)
2. Replace blower timer TD3
3. Replace blower(s)
7 Unit Does Not Spark 1. Incorrect spark gap or shorted ignitor lead
2. Bad ground on fl ame sense module
3. Defective fl ame sense module
4. Low air (blocked fl ue/inlet) condition
5. Spark generator fault
6. Defective air purge timer TD1
1. Properly adjust ignitor gap or correct
short
2. Check ground connections, adjust as
necessary
3. Replace fl ame sense module
4. If condition exists, check inlet, fl ue, &
chimney for blockage
Check combustion air/ventilation
opening in space
Check inlet air fi lter, clean/replace as
necessary
5. Check spark generator wiring
6. Replace timer TD1
8 Unit Sparks But Will Not Fire 1. Low gas pressure
2. Pilot valve manual knob closed
3. Pilot valve not wired
4. Low pilot pressure
5. Pilot valve malfunctioning
1. Check gas supply pressure during inition
trial, adjust as necessary
2. Open pilot valve manual knob
3. Connect pilot valve wires
4. Check pilot pressure, adjust as necessary
5. Replace pilot valve
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SYMPTOM CHECK ACTION
9 Pilot Lights But Main Burners Will Not Fire 1. Bad fl ame sense lead from ignitor to
fl ame sense module
2. Defective fl ame sense module
3. Manual valve(s) in air plenum closed
4. Main valves(s) not wired
5. Low manifold pressure
6. Main valve(s) malfunctioning
1. Check sense lead & ground connections,
adjust as necessary
2. Replace fl ame sense module
3. Remove upper front jacket panel, open
manual valve(s)
4. Wire main valve(s)
5. Check manifold pressure during ignition
trial, adjust as necessary
6. Replace main valve(s)
10 Insuffi cient Heating 1. Operating control set too low 1. Increase control temperature setting
11 Unit Consistently Shuts Down
On High Limit
1. High limit set to low 1. Increase high limit setting
12 Bad Combustion
(High CO, Yellow Flames)
1. Insuffi cient air
2. Dirty inlet air fi lter
3. Too much air
1. Check CO & CO2, adjust blower inlet
damper(s) to increase airfl ow
Check for plenum air leakage from lower
front jacket panel seams, repair as
necessary
2. Remove, inspect and clean inlet air fi lter
as necessary
3. Check CO & CO2, adjust blower inlet
damper(s) to decrease airfl ow
13 Gas Flow Shuts Down During
Operation (Blowers Remain On)
1. Low air (blocked fl ue/inlet) condition 1. If condition exists, check inlet, fl ue,
chimney for blockage
Check combustion air/ventilation
openings in space
Check inlet air fi lter, clean/replace as
necessary
Check pressure switch for correct setting
TROUBLE-SHOOTING
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F
Figure 23 Exploded view
REPAIR PARTS
Finned copper tube gas boilers & water heaters – Boiler Manual
37
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REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part #225 300 400 600 750 1050 1200 1480 1650 1970 2300
8 Filter (Indoor)09-0488 1 1 1
09-0489 1 1
09-0497 1
09-0498 11111
Filter (Outdoor)09-0490 11111
09-0491 111111
NS Outdoor Hood Assembly 70-2951 1 1
70-2952 1
70-2953 1
70-2954 1
70-2956 1
70-2957 1 1 1
70-2958 1 1
NS Cerablanket Insulation (per square foot)05-0103 444468810101212
Manning Glass Insulation (per square foot)05-0104 66668101012121414
Manning Glass Tape (per ft) 66-0105 44468141416161818
PVC Gasket Foam (per ft / per roll 50')66-0103 50 50 50 50 50 50 50 50 50 50 50
2" Blanket Insulation (per sq ft) 05-0200 16 18 20 22 24 30 34 36 36 44 46
Red Silicone Gasket (per ft / per roll 50')06-0146 50 50 50 50 50 50 50 50 50 50 50
15 Combustion Chamber Lower Front Panel 03-2170 1
03-1962 1
03-1963 1
03-1964 1
03-1965 1
03-1967 1
03-2171 1
03-1968 1
03-1969 1
03-1970 1
03-1971 1
16 Combustion Chamber Upper Front Panel 70-2775 1 1
70-2776 1
70-2777 1
70-2778 1
70-2780 1
70-2781 1 1
70-2782 1
70-2783 1
70-2784 1
23 Flue Outlet Assembly 70-3117.1 1
70-2736.1 1
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
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REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part #225 300 400 600 750 1050 1200 1480 1650 1970 2300
24, 25, Tile Kit *(prior to 0211) 05-0212 1
27 (tube replacement assembly (ref #35) 05-0202 1
must also be ordered on sizes 225 - 1200)05-0203 1
05-0204 1
05-0205 1
05-0207 1
05-0213K* 1
05-0213 1
05-0208 1
05-0209 1
05-0214K* 1
05-0214 1
05-0211 1
26 End Refractory Panel, Right 05-0058 11111111111
End Refractory Panel, Left 05-0107 11111111111
28 Manifold 10-0470 1
10-0465 1
10-0466 1
10-0467 1
10-0468 1
70-3087 1
70-3088 1
70-3089 1
70-3090 1
70-3091 1
70-3092 1
29 Main Orifi ce, NG 10-0087 2 3 7 9 13 15
10-0130 17 19 23 27
Main Orifi ce, LP 10-0088 2 3 7 9 13 15 17 19 23 27
Main Orifi ce, NG 10-0115 5
Main Orifi ce, LP 10-0116 5
NS Pilot Orifi ce, NG 10-0089 1 1 1111
10-0132 1111
Pilot Orifi ce, LP 10-0090 1 1 11111111
Pilot Orifi ce, NG 10-0093 1
Pilot Orifi ce, LP 10-0120 1
30 Burner Tube 10-0275 23579131517192327
Burner Tube w/hole for Pressure Switch 70-2898 11111111111
Pilot Tube Assembly (tubing and fi ttings)70-2896 11111111111
NS Burner Gasket (pkg of 10) 21-2011 11111222233
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REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part #225 300 400 600 750 1050 1200 1480 1650 1970 2300
NS Burner Support Rail 03-2090 1 1
03-2091 1
03-2092 1
03-2093 1
03-2095 1
03-2096 1
03-2097 1 1
03-2098 1
03-2099 1
31 Spark Ignitor (*prior to 0205 - must order cable 44-0056)16-0327*11111111111
NS Ignition Cable Assembly 44-0056 11111111111
NS Heat Exchanger Assembly (Copper) 70-3001 1 1
(Cast Iron Headers) 70-3002 1
70-3003 1
70-3004 1
70-3006 1
70-3007 1
70-2832 1
70-2833 1
70-2834 1
70-2835 1
Heat Exchanger Assembly (Copper) 70-3023 1 1
(Bronze Headers) 70-3024 1
70-3025 1
70-3026 1
70-3028 1
70-3029 1
70-2852 1
70-2853 1
70-2854 1
70-2855 1
Individual copper/cupronickel tubes* available for fi eld repair *model and serial number required
Tube Expansion Tool 30-0761 11111111111
Heat Exchanger Assembly (Cupronickel) 70-3012 1 1
(Cast Iron Headers) 70-3013 1
70-3014 1
70-3015 1
70-3017 1
70-3018 1
70-2842 1
70-2843 1
70-2844 1
70-2845 1
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REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part #225 300 400 600 750 1050 1200 1480 1650 1970 2300
Heat Exchanger Assembly (Cupronickel)70-3034 1 1
(Bronze Headers) 70-3035 1
70-3036 1
70-3037 1
70-3039 1
70-3040 1
70-2862 1
70-2863 1
70-2864 1
70-2865 1
32 Tube Bundle (Copper)70-3053 1 1
70-3054 1
70-3055 1
70-3056 1
70-3058 1
70-3059 1
70-2907 1
70-2908 1
70-2909 1
70-2910 1
Tube Bundle (Cupronickel)70-3064 1 1
70-3065 1
70-3066 1
70-3067 1
70-3069 1
70-3070 1
70-2917 1
70-2918 1
70-2919 1
70-2920 1
NS Heat Exchanger ”V“ Baffl es 03-2011 7 7 36
03-2012 7 36
03-2013 7
03-2014 7
03-2016 14
03-2017 18 18
03-2019 18
34 Hold-Down Clips 03-2164 14 14 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 70-3080 2 2
(must be ordered with tile kit) 70-3081 2
70-3082 2
70-3083 2
70-3085 2
70-3086 2
Finned copper tube gas boilers & water heaters – Boiler Manual
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REPAIR PARTS (CONTINUED)
Model Size with Item Quantities Below
Ref # Name of Part Part #225 300 400 600 750 1050 1200 1480 1650 1970 2300
36 O Ring (pkg of 20) 21-2010 11111111111
37 Stud, Inlet/Outlet & Return Headers ASME 57-0220 12 12 12 12 12 12 12 12 12 12 1.38
38 Nut, Inlet/Outlet & Return Headers ASME 57-0492 12 12 12 12 12 12 12 12 12 12 0.10
39 Return Header, Bronze 01-0011.1 1 1 1
01-0004.1 1111
01-0018.1 1111
Return Header, Cast Iron 01-0009S 1 1 1
01-0002S 1111
01-0023S 1111
40 Inlet/Outlet Header, Bronze 01-0010.1 1 1 1
01-0003.1 1111
01-0019.1 1111
Inlet/Outlet Header, Cast Iron 01-0008S 1 1 1
01-0001S 1111
01-0022S 1111
41 Blower, Fasco 7062 12-0013 1111 1
Blower, Fasco 7083 12-0014 1222222
42 Combustion Air Damper Assembly 70-2818 1111 1
70-2819 1222222
43 Low Pressure Switch (.30 WC) 14-0059 1 1
Low Pressure Switch (.42 WC) 11-0417 1 1 1
Low Pressure Switch (.58 WC) 14-0058 1 1 1
High Pressure Switch (.58 WC) 14-0058 1 1 1
High Pressure Switch (.80 WC) 14-0061 11111111
44 High Limit (LB) 14-0009 11111111111
High Limit (LW) 14-0008 11111111111
NS High Limit Well, 3/8 x 3 13-0104 11111111111
NS BTC Outdoor Reset Control 14-0305 1 1
NS Operator (LB) 14-0007 11111111111
Operator (LW) 14-0010 11111111111
Operator, T6031A (pool heater) 14-0003 11111111111
45 Firing Valve, 3/4" 11-0461 1 1 1
Firing Valve, 1" 11-0456 2 2
Firing Valve, 1-1/4" 11-0457 2 2
Firing Valve, 1-1/2" 11-0458 2 2 2
Firing Valve, 2" 11-0459 2
NS Manual Pilot “B” Valve 11-0031 11111111111
46 Main Gas Valve, VR8304 11-0056 1 1 1
Main Gas Valve, V8944B, 1" 11-0171 1 1
Main Gas Valve, V8944B, 1-1/4" 11-0172 1 1
Main Gas Valve, V8944B, 1-1/2" 11-0173 1 1 1
Main Gas Valve, V8944B, 2" 11-0174 1
47 Safety Valve, L8214G, 1" 11-0371 1 1
Safety Valve, L8214G, 1-1/4" 11-0364 1 1
Safety Valve, L8214G, 1-1/2" 11-0365 1 1 1
Safety Valve, L8214G, 2" 11-0366 1
Finned copper tube gas boilers & water heaters – Boiler Manual
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Model Size with Item Quantities Below
Ref # Name of Part Part #225 300 400 600 750 1050 1200 1480 1650 1970 2300
48 Pilot Valve, VR8304 11-0056 11111111111
Natural to LP Conversion Spring, On/Off 11-0001 11111111111
Natural to LP Conversion Spring, 2 Stage 11-0007 11111111111
49 Manual Shut Off Valve, 1" 11-0465 1 1
Manual Shut Off Valve, 1-1/4" 11-0466 1 1
Manual Shut Off Valve, 1-1/2" 11-0467 1 1 1
Manual Shut Off Valve, 2" 11-0454 1
50 Flame Sensor, UTC 1003 Ignition Module 16-0059 11111111111
NS Alarm Board, (CSD-1) 16-0023 11111111111
Harness Kit (includes J1, J3, J5, J6, J7, J8, J9 & J10)40-0313 11111111111
J2 Valve Control 2 Stage Harness 40-0303 11111111111
J2 Valve Control On/Off Harness 40-0302 11111111111
51 Spark Generator 16-0036 11111111111
52 Transformer, 75 VA 15-0008 11111111111
NS Pressure Relief Valve 50# 30-0360 111111
Pressure Relief Valve 50# 13-0006 1 1
Pressure Relief Valve 50# 30-0374 1
Pressure Relief Valve 50# 30-0379 1 1
Pressure Relief Valve 125# 13-0009 11111111111
NS Tridicator (LB) 13-0305 1111111
Tridicator (LB) 13-0308 1111
Thermometer (LB) 13-0302 22222221111
Thermometer (LW) 13-0302 22222221111
NS Flow Switch 14-0203 11111111111
Flow Switch (Outdoor) 14-0205 11111111111
Flow Switch (Potter) 14-0201 21111111111
Flow Switch (Outdoor Potter) 14-0202 31111111111
NS Thermometer Well, 3/8 x 3" 13-0104 1 1 1
NS Thermometer Well, 3/8 x 4" 13-0105 11111111
54 Main Board Assembly (On/Off ) 70-2927R 11111111111
Main Board Assembly (2 Stage) 70-2928R 11111111
NS Main Board 40-0074R 11111111111
NS Timer Board 40-0075 11111111111
NS LED Indicator Board 40-0076 11111111111
NS Ribbon Cable 44-0057 11111111111
NS Relay, 2P, (On/Off ) 15-0121 55555555555
NS Relay, 2P, (2 Stage) 15-0121 88888888
NS Relay, 3P , (On/Off or 2 Stage) 15-0123 11111111111
NS Relay, 24AC 15-0113 11111111111
NS Pump Contactor 1PH (C2) 15-0118 11111111111
NS Low Gas Pressure Switch (Manual Reset)11-0410 11111111111
NS High Gas Pressure Switch (Manual Reset)11-0411 11111111111
NS Rating Plate 82-0054 11111111111
NS Overlay 82-0188 11111111111
NS Silicone 66-0151 11111111111
REPAIR PARTS (CONTINUED)
Finned copper tube gas boilers & water heaters – Boiler Manual
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Model Size with Item Quantities Below
Ref # Name of Part Part #225 300 400 600 750 1050 1200 1480 1650 1970 2300
NS Silicone Tubing 06-0051 22222222222
Vent Termination Hood 6" 09-0112 1 1 1
Vent Termination Hood 7" 09-0140 1
Vent Termination Hood 8" 09-0113 1
Vent Termination Hood 10" 09-0115 1
Vent Termination Hood 12" 09-0116 1 1
Vent Termination Hood 14" 09-0141 1 1 1
NS Air Intake Hood 6" 09-0102 1 1 1
Air Intake Hood 8" 09-0103 1 1
Air Intake Hood 10" 09-0104 1
Air Intake Hood 12" 09-0105 11111
NS Barometric Damper 6" 09-0405 1 1 1
Barometric Damper 7" 09-0409 1
Barometric Damper 8" 09-0404 1
Barometric Damper 10" 09-0403 1
Barometric Damper 12" 09-0401 1 1
Barometric Damper 14" 09-0402 1 1 1
NS Rack Assembly 70-2886 1 1 1
70-2888 1 1
70-2890 1
70-2892 1 1
70-2894 1 1 1
REPAIR PARTS (CONTINUED)
Finned copper tube gas boilers & water heaters – Boiler Manual
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START UP FORM
Date of Start Up: Job Name:
Model #: Serial Number #:
Boiler Model: Dominator LCD Company Name
Fuel Type: Natural Gas Propane Tech Name
System Type: Hydronic Domestic Phone Number
PRE-START UP CHECK LIST
ANY VISUAL DAMAGE TO UNIT? INLET FILTER INSTALLED AND CLEAN?
PIPING PROPERLY CONNECTED? ALL WIRING CONNECTED PROPERLY?
SYSTEM FLOODED AND FLOWING? BOILER PUMP PUMPING INTO INLET?
BOILER CIRCULATOR WIRED? COMBUSTION AIR PROVIDED?
VENT/STACK CONNECTED? PROPER SERVICE CLEARANCE PROVIDED?
IS VENT VERTICAL THROUGH THE ROOF? OUTDOOR AIR SENSOR INSTALLED/WIRED?
IS VENT THROUGH THE WALL? ARE UNITS RACKED?
IS POWER VENT INSTALLED AND WIRED? IS RACK ASSEMBLED TIGHTLY?
SEALED COMBUSTION? NO HOLES SCREWED INTO CABINET?
ELECTRICAL/WIRING/CONTROL
Boiler Supply Voltage External BMS System
Boiler Pump Supply Voltage Utilize Boiler BTC For Control
Voltage Down Stream of Transformer
BTC CONTROL SET UP: (Not all settings are used for every mode. (Dominator Series Only))
: Mode : Boiler Max : Purge ΔT
: Boiler Target : Boiler Min
: Tank Target : Boiler Diff LCD ONLY
: Tank Diff : Intr-Stg Diff : Operator (STG1)
: Outdoor Start : Intr-Stg On Dly : High Operator (STG 2)
: Boiler Start : Intr-Stg Off Dly : High Limit
: Pump Purge
Finned copper tube gas boilers & water heaters – Boiler Manual
45
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COMBUSTION/SAFETY REPORT
FACTORY FIRE TEST REPORT: Low Fire High Fire
Manifold Gas Pressure: "WC"
Air Differential Pressure: "WC"
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):
Effi ciency @ °F Inlet Temp.
CO (PPM):
O2:
Stack Draft (Must Be Negative):
Pilot Signal:
SAFETY CONTROL CHECK:
Low Water Cut Off (PPM):
Factory Flow Switch
Operating Control
High Limit
Differential Air Switch STG. 1, 2
Differential Air Switch STG. 3, 4
Blocked Flu Switch
Flame Failure Lockout (CSD-1)
Pump Delay
Combustion Air Damper
Power Vent Proving Switch
Barometric Damper
COMMISSIONING THE UNIT
Customer Instructed? Yes No
All Covers Replaced? Yes No
Wiring Secure/Tight? Yes No
Customer Given Manual? Yes No
Cabinet Air Leaks? Yes No
Gas Leaks Detected? Yes No
Unit Cycled Min. of 15 X? Yes No
Temp. Set Per Customer? Yes No
Left Maintenance Instruction? Yes No
Commissioned By:
(Signature)
Date:
The delta T between the heaters inlet and outlet
is critical to proper fl ow. Before you leave the
job site you must record the delta T. This reading
should not exceed 35°F, 19.4°C or be lower than
20°F, 11.1°C.
Inlet Temperature
Outlet Temperature
Wired and Operating
Properly @ Setting:
Failed To Operate
Comment To Right Comments
These results are affi xed
to the side of the heater
on a small white label.
Finned copper tube gas boilers & water heaters – Boiler Manual
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F
NOTICE! Commonwealth of Massachusetts
Installation Requirements MACODE-3
In the Commonwealth of Massachusetts, the installa-
tion must be performed by a licensed plumber or gas
fi tter.
1. For all side wall horizontally vented gas fueled equipment
installed in every dwelling, building or structure used in whole
or in part for residential purposes, including those owned or
operated by the commonwealth and where the side wall exhaust
vent termination is less than seven (7) feet above fi nished grade,
in the area of the venting, including but not limited to decks and
porches, the following requirements shall be satisfi ed:
d. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the
time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gasfi tter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the fl oor level
where the gas equipment is to be installed. In addition, the
installing plumber or gasfi tter shall observe that a battery
operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal
vented gas fueled equipment. It shall be the responsibility of
the property owner to secure the services of qualifi ed
licensed professionals for the installation of hard wired
carbon monoxide detectors.
i. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an attic,
the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent
fl oor level.
ii. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply
with the above requirements; provided, however, that
during said thirty (30) day period, a battery operated
carbon monoxide detector with an alarm shall be
installed.
e. APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above
provisions shall comply with NFPA 720 and be ANSI/UL 2034
listed and IAS certifi ed.
f. SIGNAGE. A metal or plastic identification plate shall be
permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in line
with the exhaust vent terminal for the horizontally vented gas
fueled heating appliance or equipment. The sign shall read,
in print size no less than one-half (1/2) inch in size, “GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
g. INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve
the installation unless, upon inspection, the inspector
observes carbon monoxide detectors and signage installed
in accordance with the provisions of 248 CMR 5.08(2)(a)1
through 4.
Improper venting can result in excessive levels
of carbon monoxide which can cause severe
personal injury or death!
2. Exemptions — The following equipment is exempt from
248 CMR 5.08(2)(a) 1 through 4:
a. The equipment listed in Chapter 10 entitled “Equipment
Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
b. Product Approved side wall horizontally vented gas
fueled equipment installed in a room or structure
separate from the dwelling, building or structure used in
whole or in part for residential purposes.
3. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM PROVIDED.
a. When the manufacturer of Product Approved side wall
horizontally vented gas equipment provides a venting
system design or venting system components with the
equipment, the instructions provided by the manufacturer
for installation of the equipment and the venting system
shall include:
i. Detailed instructions for the installation of the venting
system design or the venting system components; and
ii. A complete parts list for the venting system design or
venting system.
4. MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED.
a. When the manufacturer of a Product Approved side wall
horizontally vented gas fueled equipment does not provide
the parts for venting the fl ue gases, but identifi es “special
venting systems”, the following requirements shall be
satisfi ed by the manufacturer:
i. The referenced “special venting system” instructions
shall be included with the appliance or equipment
installation instructions; and
ii. The “special venting systems” shall be Product
Approved by the Board, and the instructions for that
system shall include a parts list and detailed installation
instructions.
5. A copy of all installation instructions for all Product Approved
side wall horizontally vented gas fueled equipment, all
venting instructions, all parts lists for venting instructions,
and/or all venting design instructions shall remain with the
appliance or equipment at the completion of the installation.
Improper venting can result in excessive levels of
carbon monoxide which can cause severe personal
injury or death!
47
260 North Elm Street 7555 Tranmere Drive
Westfi eld, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com
LIMITED WARRANTY
Boilers/Water Heaters
Industrial, Commercial and Other Non-Residential Use
Th e “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.
Th e “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.
Th is 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 writt en instructions, or has been altered or modifi ed in any way.
Th ese 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 pitt ing and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and
is not covered by the manufacturer’s warranty. (See Installation Instructions for proper pump performance.)
• Chemical corrosion, no corrosive chemical (freon, dry cleaning chemicals, degreasing liquids, chlorine or any chemicals that
produce hydrochloric acid) can be present in the boiler room as it rapidly destroys the heating equipment and voids the warranty.
• All copper fi n boilers should not operate with a return water temperature less than 110°F, 43°C atmospheric combustion, 125°F, 52°C fan
assist combustion. If a lower temperature is required, an external bypass should be installed to prevent condensation. Th e 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 sett lement, 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.
Th is 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 writt en 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.
Copyright 2012 Mestek, Inc.
260 North Elm Street 7555 Tranmere Drive
Westfi eld, MA 01085 Mississauga, Ontario L5S 1L4 Canada
Phone: (413) 568-9571 Phone: (905) 670-5888
Fax: (413) 568-9613 Fax: (905) 670-5782
www.rbiwaterheaters.com