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Summary of Contents for Columbia CDVB SERIES
- Page 1 CDVB SERIES Gas Fired Boilers For Forced Hot Water INSTALLATION, OPERATION & MAINTANANCE MANUAL olumbia oiler ompany Main offices and Factory: Pottstown, PA 37616101 , Rev. C [02/09]...
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Page 2: Table Of Contents
GAS FIRED BOILERS FOR FORCED HOT WATER KEEP THIS MANUAL NEAR BOILER AND RETAIN FOR FUTURE REFERENCE. TABLE OF CONTENTS Introduction ............................4 Boiler Ratings, Capacities & Dimensions ....................5 Ventilation & Combustion Air .......................7 Connecting Supply & Return Piping ....................10 Applicable Federal Codes .........................13 Vent System Modification ........................13 Connecting Gas Service ........................14 Electrical Wiring ..........................15... -
Page 3: Introduction
INTRODUCTION WARNING Allow 24 inches at the front and right side for servicing and cleaning. 1. Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors When installed in utility room, the door should be wide and liquids. -
Page 4: Boiler Ratings, Capacities & Dimensions
BOILER RATINGS, CAPACITIES & DIMENSIONS WARNING 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. - Page 5 BOILER RATINGS, CAPACITIES & DIMENSIONS 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 certified for installation on non-combustible floors. For installation on combustible floors, use combustible floor kit.
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Page 6: Ventilation & Combustion Air
VENTILATION & COMBUSTION AIR WARNING AIR OPENINGS TO COMBUSTION AREA MUST NOT BE OBSTRUCTED. BY FOLLOWING THE INSTRUCTIONS BELOW, ADEQUATE COMBUSTION AIR CAN BE MAINTAINED. COMBUSTION AIR REQUIREMENTS (Minimum square inch openings) *UNCONFINED AREA **CONFINED AREA INSIDE OUTSIDE COMBUSTION AIR OUTSIDE COMBUSTION AIR VERTICAL... - Page 7 VENTILATION & COMBUSTION AIR buildings, the confined space shall be provided with Figure #2 two permanent openings, one starting 12 inches from the top and one 12 inches from the bottom of the enclosed VENTILATION LOUVERS 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)
- Page 8 VENTILATION & COMBUSTION AIR III. If horizontal ducts are used, each opening and duct In calculating free area using louvers, grilles or screens shall have a minimum free area 1 square inch per for the above, consideration shall be given to their block- 2,000 BTU per hour of total input rating of all appli- ing effect.
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Page 9: Connecting Supply & Return Piping
CONNECTING SUPPLY & RETURN PIPING IMPORTANT: Circulators in the following Figure #5 illustrations are mounted on the system supply RETURN SYSTEM side, but mounting on the system return side is SYSTEM CIRCULATOR TEMPERATURE GAUGE also acceptable practice. 12" MAX. FLOW VALVE SUPPLY figure... - Page 10 CONNECTING SUPPLY & RETURN PIPING Figure #8 PriMarY seConDarY PiPinG wiTh BYPass RETURN SYSTEM SYSTEM CIRCULATOR TEMPERATURE GAUGE 12" MAX. FLOW VALVE SUPPLY "A" PRIMARY VALVE CIRCULATOR "B" VALVE FEED WATER EXPANSION TANK 6" This method is used to protect boilers from condensate forming as well as protecting the heating system from figure #8 high water temperatures, see...
- Page 11 CONNECTING SUPPLY & RETURN PIPING Figure #9 GATE VALVE SYSTEM CIRCULATOR REDUCED PRESSURE BACKFLOW PREVENTER FLOW CONTROL OR CHECK VALVE COLD WATER HOT WATER TANK INLET OUTLET CIRCULATOR PRESSURE REDUCING FEED VALVE WATER THERMAL RELIEF VALVE TRAP 6" 6" WIRING FOR THERMOSTAT/ PUMP CONTROL DRAIN COCK...
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Page 12: Applicable Federal Codes
APPLICABLE FEDERAL CODES will have lower temperature flue products. When flue gas NFPA 54/ANSI Z223.1, National Fuel Gas Code and NFPA/ temperatures are lowered, corrosive condensates may form ANSI 211, Chimneys, Fireplaces, Vents and Solid Fuel Burning in the gas vent or in the appliance. Condensates may form Appliances. -
Page 13: Connecting Gas Service
CONNECTING GAS SERVICE Connect gas service from meter to control assembly in 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 Figure #11 inlet to the boiler. -
Page 14: Electrical Wiring
ELECTRICAL WIRING Electrical wiring must conform with the latest revision of the * NOT ALL COMPONENTS LISTED ARE USED IN ALL CON- National Electrical Code, ANSI / NFPA No. 70 and/or local TROL SYSTEMS. authority having jurisdiction. When an external electrical source is utilized, the boiler, Hot water control and intermittent ignition wiring for boilers when installed, MUST BE electrically grounded in accor- with fail safe relay. - Page 15 ELECTRICAL WIRING Figure #12 hoT waTer ConTrol anD inTerMiTTenT iGniTion wirinG PILOT PILOT...
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Page 16: Lighting Instructions
ELECTRICAL WIRING THERMOSTAT INSTALLATION THINGS TO AVOID WHEN LOCATING THERMO- STATS Thermostat should be installed on an inside wall about four feet above the floor. DEAD SPOTS: Never install a thermostat on an outside wall. Corners and alcoves Behind doors COLD SPOTS: HOT SPOTS: Check thermostat operation by raising and lowering ther-... -
Page 17: Sequence Of Operations
LIGHTING INSTRUCTIONS LIGHTING PROCEDURE FOR BOILER WITH cian or gas supplier. INTERMITTENT PILOT SYSTEM TO TURN OFF GAS TO APPLIANCE STOP! Read the safety information in the user’s informa- Set the thermostat to lowest setting. tion manual. Turn off all electric power to the appliance if service is to Set thermostat to lowest setting. -
Page 18: General Instruction For Seasonal Startup & Maintenance
GENERAL INSTRUCTION FOR SEASONAL STARTUP & MAINTENANCE It is suggested that a qualified service agency be employed to THE PROCEDURE FOR CLEANING THIS SYSTEM make an annual inspection of the boiler and the heating sys- FOLLOWS: tem. They are experienced in making the inspection outlined below. - Page 19 GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE The following procedure should be followed to clean and Disconnect the white compression fitting from the pres- check the boiler flue passageways: sure switch. Remove the burners from the combustion chamber by raising the burners up from the manifold orifices and Disconnect venter wires from relay.
- Page 20 GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE Turn inner screw (adjustment screw) clockwise opening twice per year. DO NOT OVER OIL. Follow the decrease and counterclockwise to increase the manufacturers instructions attached to the circulator. pilot flame, see figure #20. When oil cups or holes are not provided, bearings are either permanently lubricated or water lubricated.
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Page 21: Replacement Parts
REPLACEMENT PARTS PILOT SPARK PILOT Item Part No. Description Qty. 109007296 PILOT BRACKET ASSEMBLY HW-005.01 BRACKET SCREW 240007093 SPARK CABLE PILOT TUBING, 1/8" x 24" 14615005 PB-001.02 Natural Gas Q345A PILOT 240007096 LP Q345A Pilot * Included with #3 - Pilot Tube Assembly Kit (above) ROLLOUT &... - Page 22 REPLACEMENT PARTS BASE Item Item Description Part # Qty. Description Part # Qty. BURNER TUBE 1 1/2" - -50 SCREW 3/8" HEX HW005.01 BURNER TUBE 1 1/2" - -100 GAS VALVE VR8204H-1006 - 50 - 150 SPARK 240005543 VG01101 BURNER TUBE 1 1/2" - -125 & 150 BURNER TUBE 1 1/2"...
- Page 23 REPLACEMENT PARTS JACKET PART NUM- ITEM DESCRIPTION OTY. PANEL - LEFT 50-200 3162702 PANEL - FRONT -50 315-2-19.01 PANEL - FRONT -100 315-2-19.02 PANEL - FRONT -125 & 150 315-2-19.03 PANEL - FRONT -200 315-2-19.04 PANEL - BASE -50 315-2-12.01 PANEL - BASE -100 315-2-12.02 PANEL - BASE -125 &...
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Page 24: Heat Exchanger
REPLACEMENT PARTS HEAT EXCHANGER Item DESCRIPTION Part Number Qty. LEFT HAND SECTION 100-2-2.01 CENTER SECTION, -100 CENTER SECTION, -125 100-2-1.01 CENTER SECTION, -150 CENTER SECTION, -200 RIGHT SECTION 100-2-3.01 COMPLETE HEAT EXCHANGER ASSEMBLY TIE ROD ¼ X 11½, -100 HW-011.01 HEAT EXCHANGER 3 SECTION -100 100-2-7.01 TIE ROD ¼... - Page 25 REPLACEMENT PARTS PIPING & CONTROLS ITEM DESCRIPTION QTY. HARNESS IGN/GV 36" 37413601 HARNESS - CIRCULATOR 72" 37519501 PIPE - NPL 1¼ X 4½ NPT 1 1310002 DRAIN - SHORT HW-016.03 PIPE - TEE 1¼ X ¾ X 1¼ 1510001 HARNESS- CONTROL/LIMIT 38" 37518901 GAUGE - THERALTIMETER 1260006...
- Page 26 REPLACEMENT PARTS ELECTRICAL ITEM DESCRIPTION QTY. CONTROL SUPPORT BRACKET 31522201 PLT SPARK CONTROL 14662070 WIRE ROLLOUT SWITCH 40" 37614501 TRANSFORMER - 40VA 550001339 CONTROL R8222C-1008 (RELAY) 1410001 9 TERM STRIP EF04001 SCREW 10-32X5/16 GREEN GROUND HW09001 PRESSURE SWITCH (FS6205A-2413) 50B - 150B SS00801 PRESSURE SWITCH (FS6273A-3065) 200B ONLY SS00802...
- Page 27 REPLACEMENT PARTS FLUE COLLECTOR & VENTER COMPONENTS ITEM DESCRIPTION QTY. FLUE COLLECTOR -50 34524802 FLUE COLLECTOR -100 34524804 FLUE COLLECTOR -125 34524805 FLUE COLLECTOR -150 34524806 FLUE COLLECTOR -200 34524808 VENT ADAPTER -50, -100, & -125 345-2-7.01 VENT ADAPTER -150 & -200 345-2-7.02 VENTER MOUNTING PLATE -50 ONLY 34524902...
- Page 28 COLUMBIA BOILER COMPANY Main offices and factory Pittstown, PA...
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