Columbia CDVB SERIES Installation, Operation & Maintanance Manual
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17 LIGHTING PROCEDURE FOR BOILER WITH INTERMITTENT PILOT SYSTEM STOP! 1. Read the safety information in the user’s informa- tion manual. Set thermostat to lowest setting. 2. Turn off all electric power to the appliance. 3. This appliance is equipped with an ignition device which 4. automatically lights the burner. DO NOT try to light the burner by hand. Turn the
Columbia CDVB SERIES, 6 ! ! VENTILATION & COMBUSTION AIR COMBUSTION AIR REQUIREMENTS (Minimum Square Inch Openings) MODEL # *UNCONFINED AREA **CONFINED AREA OUTSIDE COMBUSTION AIR 1 SQ. IN/5000 BTU/ HR (SEE Figure #2) INSIDE COMBUSTION AIR 1 SQ. IN. /1000 BTU/HR (SEE Figure #1) OUTSIDE COMBUSTION AIR VERTICAL DUCTS 1 SQ. IN. /4000 BTU/HR (SEE Figures #2 & 3) HORIZONTAL DUCTS 1 SQ. IN. /2000 BTU/HR (SEE Figure #4) -50 10 100 13 25 -100 20 100 25 50 -125 25 125 32 63 -150 30 150 38 75 -200 40 200 50 100 * Unconned Area: A space whose volume is not less than 50 cubic feet per 1000 BTU per hour of all appliances
Columbia CDVB SERIES, 26 ELECTRICAL 4 5 1 6 8 9 7 2 3 ITEM DESCRIPTION P/N QTY. 1 CONTROL SUPPORT BRACKET 31522201 1 2 PLT SPARK CONTROL 14662070 1 3 WIRE ROLLOUT SWITCH 40" 37614501 1 4 TRANSFORMER - 40VA 550001339 2 5 CONTROL R8222C-1008 (RELAY) 1410001 1 6 9 TERM STRIP EF04001 1 7 SCREW 10-32X5/16 GREEN GROUND HW09001 1 8 PRESSURE SWITCH (FS6205A-2413) 50B - 150B SS00801 1 PRESSURE SWITCH (FS6273A-3065) 200B ONLY SS00802 1 9 HW TUBE SIL ORANGE 1/8ID HW09701 1 FULLY ASSEMBLED CONTROL BRACKET CONTROL BRACKET SUB-ASSY 50B - 150B 31522901 CONTROL BRACKET SUB
Columbia CDVB SERIES, 12 APPLICABLE FEDERAL CODES VENT SYSTEM MODIFICATION When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for the proper venting of the appliances remained connected to it. If this situation occurs, the following test procedure must be followed: REMOVAL OF BOILER FROM VENTING SYSTEM At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other app
21 1 2 3 ROLLOUT & SPILL SWITCH Item # Description Part # Qty. 1 TEMP. SENSOR BRACKET 3262001 1 2 CONTROL-FIXED TEMPERATURE THERMO (ROLLOUT SWITCH) AQ02101 1 3 SCREW - #6 X ¼ HEX HD HW06501 2 The rollout switch is located on the base. NOTE: The quantities above are for each switch. REPLACEMENT PARTS PILOT 2 5 1 4 3 SPARK PILOT Item Part No. Description Qty. 1 109007296 PILOT BRACKET ASSE
Columbia CDVB SERIES, 23 1 3 2 4 6 7 5 JACKET ITEM DESCRIPTION PART NUM- BER OTY. 1 PANEL - LEFT 50-200 3162702 1 2 PANEL - FRONT -50 315-2-19.01 1 PANEL - FRONT -100 315-2-19.02 PANEL - FRONT -125 & 150 315-2-19.03 PANEL - FRONT -200 315-2-19.04 3 PANEL - BASE -50 315-2-12.01 1 PANEL - BASE -100 315-2-12.02 PANEL - BASE -125 & 150 315-2-12.03 PANEL - BASE -200 315-2-12.04 4 PANEL - RIGHT -50-200 3162701 1 5 PANEL - SEPARATOR -50 31522401 1 PANEL - SEPARATOR -100 31522402 PANEL - SEPARATOR -125 & 150 31522403 PANEL - SEPARATOR -200 31522404 REPLACEMENT PARTS
Columbia CDVB SERIES, 7 VENTILATION & COMBUSTION AIR buildings, the conned space shall be provided with two permanent openings, one starting 12 inches from the top and one 12 inches from the bottom of the enclosed space. Each opening shall have a minimum free area of 1 square inch per one thousand (1000) BTU per hour of the total input rating of all appliances in the enclosed space, but must not be less than one hundred (100) square inches. These openings must freely communicate directly with other spaces of sufcient volume so that the combined volume of all spaces meets the criteria for an un
Columbia CDVB SERIES, 9 CONNECTING SUPPLY & RETURN PIPING Connect supply and return piping as suggested in 1. gure #5 , when the boiler is used in connection with refriger- ated systems. The chilled medium MUST BE PIPED IN PARALLEL A. with the boiler. Use appropriate valves to prevent the chilled medium B. from entering the heating boiler. During heating cycle open valves A and B, close I. valves C and D. During cooling cycle, open valves C and D, close II. valves A and B. C. Maintain a minimum clearance of one inch to hot C. water pipes. When the boiler is connected to heating coils located in 2. air handling units where they may be exposed
8 If horizontal ducts are used, each opening and duct III. shall have a minimum free area 1 square inch per 2,000 BTU per hour of total input rating of all appli- ances in the enclosed space. See gure #4 . BOILER -- SLAB -- INLET AIR DUCT 12" INLET AIR DUCT 12" Figure #4 One permanent opening, commencing within 12 inches B. of the top of the enclosure, shall be permitted wher
Columbia CDVB SERIES, 3 NOTES: • Greater clearances for access should supersede re pro- tection clearances. * For installation on combustible ooring Special Base MUST BE USED. (See Replacement Parts Section) 1. Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors and liquids. 2. DO NOT obstruct air openings to the boiler room. 3. Modication, substitution or elimination of factory equipped, supplied or specied components may result in property damage, personal injury or the loss of life.
Co l u m b i a bo i l e r Co m p a n y Main ofces and Factory: Pottstown, PA P/N 37616101, Rev. C [02/09] CDVB SERIES Gas Fired Boilers For Forced Hot Water INSTALLATION, OPERATION & MAINTANANCE MANUAL
Columbia CDVB SERIES, 20 The main burner ame should form a sharp blue inner mantel with no yellow. opening twice per year. DO NOT OVER OIL. Follow the manufacturers instructions attached to the circulator. When oil cups or holes are not provided, bearings are either permanently lubricated or water lubricated. Visually check the main burners and pilot ame at the 12. start of each heating season and again midway through the season. Check the burner throats and burner orices for lint and A. dust obstructions. See gure #17 . The main burner ame should have a well dened in-B. ner blue mantel with a lighter blue outer mantel. See gure #18 . Figure #18 The pilot
Columbia CDVB SERIES, 13 CONNECTING GAS SERVICE Connect gas service from meter to control assembly in 1. accordance with ANSI Z223.1 and local codes or utility. A ground joint union should be installed for easy removal of gas control for servicing. A drip leg or trap must be installed at the bottom of a vertical section of piping at the inlet to the boiler. A pipe compound resistant to the action of liquied petroleum gases must be used on all threaded pipe connections. Check with the local utility for location of manual shutoff valve if required. See gure #11 . The gas line sh
Columbia CDVB SERIES, 5 BOILER RATINGS, CAPACITIES & DIMENSIONS Model # A.G.A. Input Btu/Hr. Heating Capacity Btu/Hr. I=B=R NetOutput Btu/Hr No. of Burners Water Content (Gals.) AFUE Ratings -50 50,000 42,000 37,000 1 2.4 83% -100 100,000 82,000 71,000 2 4.0 82% -125 125,000 103,000 90,000 3 5.6 82% -150 150,000 122,000 106,000 3 5.6 80% -200 199,999 160,000 139,000 4 7.2 80% STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler Battery, Combination Aquastat Relay, Theraltimeter Gauge, Circulator, Main Gas Burners, Electric Ignition System, A.S.M.E relief Valve, Drain Valve, Induced Draft Fan, and Safety Pressure Switch All boilers are design certied for installation on non-combust
Columbia CDVB SERIES, 18 GENERAL INSTRUCTION FOR SEASONAL STARTUP & MAINTENANCE It is suggested that a qualied service agency be employed to make an annual inspection of the boiler and the heating sys- tem. They are experienced in making the inspection outlined below. In the event repairs or corrections are necessary they can make the proper changes for safe operation of the boiler. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. CAUTION ! Verify proper operation after service. If the
Columbia CDVB SERIES, 2 TABLE OF CONTENTS KEEP THIS MANUAL NEAR BOILER AND RETAIN FOR FUTURE REFERENCE. GAS FIRED BOILERS FOR FORCED HOT WATER Tested for 100 lbs. ASME Working Pressure H C.S.A. Certied for Natural gas or Propane SAFETY SYMBOLS IMPORTANT: Read the following instructions COMPLETELY before installing! The following dened symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels. Indicates an imminently hazardous situation which, if not avoided, will
Columbia CDVB SERIES, 10 This method is used to protect boilers from condensate C. forming as well as protecting the heating system from high water temperatures, see gure #8 . NOTE #1: When using bypass piping, adjust valves A and B until desired system temperature is obtained. NOTE #2: Bypass loop must be same size piping as the supply and return piping. Installation using circulators is shown in 7. gure #9 . Installation using zone valves is shown in 8. gure #10 . For further piping information refer to the I=B=R Installa- 9. tion and Piping Guide. CONNECTING SUPPLY & RETURN PIPING CIRCULATOR VALVE EXPANSION TANK VALVE RETURN
Columbia CDVB SERIES, 4 ALL INSTALLATIONS OF BOILERS AND VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL. INSTALL- ING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS ODORLESS AND INVISIBLE. BOILER RATINGS, CAPACITIES & DIMENSIONS BOILER DIMENSIONS DIMENSIONS FOR NATURAL GAS Model # Natural Gas Inlet Dimensions Pump size Supply
Columbia CDVB SERIES, 19 The following procedure should be followed to clean and 8. check the boiler ue passageways: Remove the burners from the combustion chamber by A. raising the burners up from the manifold orices and pulling toward the front of the boiler. See gure #15 . GAS VALVE ORIFICES BURNERS Figure #15 Disconnect the vent pipe from the vent adapter.B. Remove the top jacket panel. See C. Figure #16 . COMBUSTION BURNER (REMOVED) BURNERS GAS VENT PIPE CHAMBER DOOR VA LVE ADAPTER ROLL-OUT SAFETY BURNER SWITCH JACKET FRONT PANEL Figure #16 Disco
Columbia CDVB SERIES, 11 CONNECTING SUPPLY & RETURN PIPING TANK SYSTEM CIRCULATOR CIRCULATOR REDUCED PRESSURE BACKFLOW PREVENTER FLOW CONTROL OR CHECK VALVE OUTLET HOT WATER TRAP THERMAL WIRING FOR THERMOSTAT/ PUMP CONTROL INLET COLD WATER RELIEF VALVE DRAIN COCK 6" 6" WATER FEED PRESSURE REDUCING VALVE GATE VALVE Figure #9 CIRCULATOR DRAIN COCK RELIEF VALVE HOT WATER OUTLET THERMAL TRAP PUMP CONTROL WIRING FOR THERMOSTAT/ SYSTEM RETURN PIPING INLET COLD WATER VALVE TANK ZONE 6" 6" PRESSURE REDUCING VALVE BACKFLOW PREVEN
Columbia CDVB SERIES, 24 Item # DESCRIPTION Part Number Qty. 1 LEFT HAND SECTION 100-2-2.01 1 2 CENTER SECTION, -100 100-2-1.01 1 CENTER SECTION, -125 2 CENTER SECTION, -150 2 CENTER SECTION, -200 3 3 RIGHT SECTION 100-2-3.01 1 4 TIE ROD ¼ X 11½, -100 HW-011.01 2TIE ROD ¼ X 15½ -125 & 150 HW-011.03 TIE ROD 1/4X19.1/2 -200 HW-011.05 5 NUT 5/16-18 WISLOCK 6 1330001 6 PIPE FIT BUSH 3/4 X 1/4 NPT 1060002 1 PIPE-NPL 1.1/4X4.1/2 NPT 1310002 1 6 PUSH NIPPLE 2" MACH., -50 43300976 2 PUSH NIPPLE 2" MACH., -100 4 PUSH NIPPLE 2"
Columbia CDVB SERIES, 22 1 2 3 4 5 6 7 BASE Item # Description Part # Qty. 1 BURNER TUBE 1 1/2" - -50 240005543 1 BURNER TUBE 1 1/2" - -100 2 BURNER TUBE 1 1/2" - -125 & 150 3 BURNER TUBE 1 1/2" - -200 4 2 BASE W/INSUL - -50 5611607 1 BASE W/INSUL - -100 5611608 BASE W/INSUL - -125 & 150 5611609 BASE W/INSUL - -200 5611604 3 BURNER DOOR - -50 32512501 1 BURNER DOOR - -100 32523001 BURNER DOOR - -125 & 150 32523101 BURNER DOOR - -200 32523102 4 MANIFOLD - -50 356-2-1.01 1 MANIFOLD - -100 356-2-1.02 MANIFOLD - -125 &150 356-2-1.03 MANIFOLD - -200 356-2-1.0
Columbia CDVB SERIES, 16 IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. Before operating, make certain the boiler and system are full of water to minimum pressure (this is usually 12 lbs. per square inch on most systems) and system is vented of air. See the operating and lighting instructions. THERMOSTAT INSTALLATION Thermostat should be installed on an inside wall about 1. four feet above the oor. Never install a thermostat on an outside wall. 2. Check ther
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