Columbia CSVB-2 Installation, Operation & Maintenance Manual

Text of Columbia CSVB-2 User Guide:

• Columbia CSVB-2, 20 GAS SUPPLY PIPING *Outside diameter: Measure length of pipe or tubing from gas meter or propane second stage regulator. Table 5 - NATURAL GAS Length of Pipe - Ft. Pipe Capacity - BTU Per Hour Input Includes Fittings ½" ¾" 1" 1¼" 20 92,000 190,000 350,000 625,000 40 63,000 130,000 245,000 445,000 60 50,000 105,000 195,000 365,000 Table 6 - PROPANE GAS Length of Pipe - Ft. Pipe Capacity - BTU Per Hour Input Includes Fittings Copper Tubing* Iron Pipe ⅝"¾"½"¾" 20 131,000 216,000 189,000 393,000 40 90,000 145,000 129,000 267,000 60 72,000 121,000 103,

• Columbia CSVB-2, CHECK YOUR CHIMNEY For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with “Venting of Equipment”, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes. Figure 7 - Type B Gas Vent 11 VENT INSTALLATION

• Columbia CSVB-2, 32 APPENDIX A - CONTROL MODULE A.1 Installation Environment Considerations WARNING If you do not follow these instructions exactly, a fi re or explosion may result causing property damage, personal injury or loss of life. • Do not use this appliance if any part has been under water. Immediately call a qualifi ed service technician to inspect appliance and to replace any part of control system and any gas control which has been under water. • Do not allow water to drip on controls. Prevent con

• Columbia CSVB-2, 7 1. Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements. 2. Install relief valve on 3/4” pipe nipple in tapped boiler opening. A. Pipe discharge line following guidelines in preceding Warning. See Figure 2, Page 7 . B. Discharge line pipe size shall be equal or greater than that of relief valve outlet over entire length of discharge line with no intervening shutoff valve between safety relief valve and discharge to atmosphere. C. Discharge line shall terminate with plain end to atmosphere

• 30 SAFETY RELIEF VALVE [ Figure 2, Page 7 ] Safety relief valve is required on your boiler. Water expands as it is heated. If there is no place for water to expand into, water pressure will build up inside boiler and system. Should this happen, safety relief valve will automatically open at predetermined pressure. This will relieve the strain on boiler and syste

• Columbia CSVB-2, 27 CHECKING AND ADJUSTING Main burner fl ame should form sharp blue inner mantel with no yellow. Figure 16 - Main Burner Flame Adjust Thermostat Heat Anticipator Instruction for fi nal adjustment of thermostat are packaged with thermostat. 1. Set Heat anticipator at .2. 2. Check thermostat operation. When set above temperature indicated on thermometer, boiler burners should ignite. Verify thermostat turns off boiler when room temperature reaches selected setting and starts boiler operating when room temper

• Columbia CSVB-2, CSVB Series II Gas-Fired Hot Water Induced Draft Boilers INSTALLATION, OPERATION & MAINTENANCE MANUAL P/N 240009363 Rev. B [04/2012] An ISO 9001-2008 Certified Company Tested for 50 psi. ASME Working Pressure C.S.A. Certifi ed for Natural gas or Propane 2201 Dwyer Avenue, Utica NY 13504-4729 web site: www.ecrinternational.com Models CSVB-2 CSVB-3 CSVB-4 CSVB-5 CSVB-6 CSVB-7

• Columbia CSVB-2, 26 Figure 14 - Automatic Gas Valve Gas Valve Safety Shutdown Test WARNING Electrical shock hazard. Follow instructions to turn off electric power. Failure to do so could result in death or serious injury. ! Ignition system safety shutoff device must be tested after placing boiler in operation. With main burners fi ring, disconnect ignition cable from intermittent pilot control box. Gas valve should shut off main burners. TURN OFF ELECTRIC POWER to boiler before reconnecting ignition cable, to prevent electric shock. Adjust Pilot Burner 1. Remove screw cover over pilot adjusting screw. 2. Inser

• 16 8. Joining and Sealing the Vent Pipe: The vent pipe needs to be both watertight and gas tight. Seal all joints and seams as follows: A. For Z-Flex Z-Vent stainless steel vent pipe use a high temperature silicone sealant rated for 550°F. The outside of the male end and inside of the female end of the pipe must be

• 13 Horizontal (Category III) venting systems must be installed in accordance with these instructions. Maximum Horizontal Vent Length For Stainless Steel Vent Pipe - 30’ Plus One 90º Elbow Plus Vent Terminal. Minimum Horizontal Vent Length - 2’ Plus One 90º Elbow Vent Termination. Additional elbows are equivalent to 6 feet of straight pipe for 4” diameter 90° elb

• Columbia CSVB-2, 17 C. For Flex-L StaR-34 stainless steel vent pipe use a high temperature silicone sealant rated for 550°F. Before applying silicone, the outside of the male end and inside of the female end of the pipe must be cleaned using a cleaner, such as methyl ethyl ketone (MEK) or naphtha. For 3” vent pipe runs, begin with the male end of the vent pipe over the boiler’s induced draft blower outlet. For 4” vent pipe runs begin with a StaR-34 3” to 4” increaser fi tting over the boiler’s induced draft blower outlet. For both 3” an

• Columbia CSVB-2, 25 Operating Instructions. 1. STOP! Read Safety Information on previous page. 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance. 4. This appliance is equipped with an ignition device which automatically lights the burner. Do not attempt to light pilot by hand. 5. Remove burner access panel. OFF ON INLET GAS CONTROL KNOB SHOWN IN "ON" POSITION 6. Depress gas control knob slightly and turn clockwise to “OFF” position. 7. Wait fi ve (5) minutes to clear out any gas. If you then smell gas STOP! Follow WHAT TO DO IF YOU SMELL GAS. If you don’t smell gas, go to next step. 8. Turn gas control k

• Columbia CSVB-2, 18 9. Support Spacing: Do not restrict thermal expansion movement of the vent. The vent pipe must expand and contract freely with temperature change. Each run of vent piping shall be supported as follows: A. Z-Flex stainless steel vent piping requires a loose fi tting metal strap or similar support at each joint at a maximum of 4 feet between supports. B. Heat-Fab stainless steel vent piping requires a support for every 6 feet of horizontal piping run. The support must be secured using at least #10 fasteners to a s

• Columbia CSVB-2, 21 ELECTRICAL WIRING Electrical Wiring See wiring diagram Figure 12, Page 23 for details. Refer to Ladder Diagram from document envelope received with boiler. Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to National Electrical Code, ANSI/NFPA 70. If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C thermoplastic wire or its equivalent Circulator harness is factory wired to control module. Connect harness to circulator in fi eld. See Figure 11 . WARNING Electrical shock hazard. Turn OFF electrical power supply at service panel

• Columbia CSVB-2, 35 APPENDIX A - CONTROL MODULE Table 8 - Troubleshooting Error Codes Error Code Number Defi nition Consequence 2 Pressure switch failed to open (stuck closed). Wait for recovery 4 Flame current too low. Check for fl ame. Non critical alarm 6 Flame sensed out of normal sequence (before opening or after closing gas valve). Soft lockout 18 Gas valve relays welded. Five consecutive soft lockouts. Hard lockout 23 Flame sensed during prepurge ( before gas valve signaled opened). Soft lockout 24 Flame sensed during postpurge (after gas valve signaled closed). Soft lockout 29 Pressure switch failed to close (Contacts stuck open) Wait for recovery 32 Sensor 1 error.

• Columbia CSVB-2, 9 • Install radiation units (panels, radiators or cabinets) and supply and return mains fi rst then make connections at boiler. • Verify clean water supply is available when connecting cold water supply to water valve. Install sand strainer at pump when water supply is from well or pump. • Provide low water cutoff device when boiler is installed above radiation level or as required by the Authority having jurisdiction, either provide as part of boiler or at time of boiler installation.

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