Columbia CSC SERIES Installation, Operation & Maintenance Manual
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Columbia CSC SERIES Installation, Operation & Maintenance Manual

Csc series direct vent gas fired hot water boiler
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CSC SERIES

Direct Vent

Gas Fired Hot Water Boiler
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
H
Tested For 100 psi.
C.S.A. Certified
ASME
For Natural Gas Or Propane
Working Pressure
C
C
olumbia
ompany
Main offices and Factory:
Pottstown, PA
37711701
P/N
, Rev. C [05/2012]

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  • Page 1: Direct Vent

    CSC SERIES Direct Vent Gas Fired Hot Water Boiler INSTALLATION, OPERATION & MAINTENANCE MANUAL Tested For 100 psi. C.S.A. Certified ASME For Natural Gas Or Propane Working Pressure olumbia ompany Main offices and Factory: Pottstown, PA 37711701 , Rev. C [05/2012]...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Introduction ..........................3 Boiler Ratings, Capacities & Dimensions ..................4 Connecting Supply And Return Piping ..................... 5 General Information Gas Vents And Appliances ................8 Vent Pipe Modification ........................9 Connect Gas Service ........................10 Electrical Wiring .........................12 Operating Instructions .........................13 Sequence Of Operation........................14 General Instruction For Seasonal Start Up And Maintenance .............15...

  • Page 3: Introduction

    INTRODUCTION WARNING WARNING Improper installation, adjustment, alteration, All installations of boilers and venting should service or maintenance can cause injury or be done only by a qualified expert and in property damage. accordance with the appropriate boiler manual. Installing or venting a boiler or any •...

  • Page 4: Boiler Ratings, Capacities & Dimensions

    BOILER RATINGS, CAPACITIES & DIMENSIONS Boiler Ratings, Capacities & Dimensions Dimensions Heating Natural Supply & Boiler Input No. Of Water AFUE Capacity Net Output Return Btu/Hr. Burners Content Ratings Btu/Hr. Btu/Hr. Inlet Tappings 50,000 44,000 38,000 1/2" 15.1/8" 3.1/2" 3.1/2" 5"...

  • Page 5: Connecting Supply And Return Piping

    CONNECTING SUPPLY AND RETURN PIPING See Relief Valve Piping Supplemental Installation Maintain a minimum clearance of 1 inch (2.54cm) to Instructions located on page 40 of this manual. hot water pipes. Connect supply and return piping as suggested in Hot water boilers installed above radiation level or Figure 1 below when the boiler is used in connection as required by Authority having jurisdiction must be provided with a low water cut-off device at the time of...
  • Page 6 CONNECTING SUPPLY AND RETURN PIPING Bypass piping is an option which Figure 3 - Bypass Piping gives the ability to adjust the supply boiler water temperature SUPPLY to fit the system or condition of the installation. This method of SYSTEM piping is not typically required for TEMPERATURE GAUGE...
  • Page 7 CONNECTING SUPPLY AND RETURN PIPING Figure 5 - Primary Secondary Piping with Bypass RETURN SYSTEM SYSTEM CIRCULATOR TEMPERATURE 12" GAUGE (31 cm) FLOW MAX. VALVE SUPPLY "A" VALVE PRIMARY CIRCULATOR "B" VALVE FEED EXPANSION WATER TANK Figure 6 - Typical Installation Using Circulators...

  • Page 8: General Information Gas Vents And Appliances

    CONNECTING SUPPLY AND RETURN PIPING Figure 7 - Typical Installation Using Zone Valves GENERAL INFORMATION GAS VENTS AND APPLIANCES By Federal Codes, gas appliances are categorized by the • Proper operation of the vent system and appliance is pressure and temperature of the flue gas vented from the dependent upon the use of all parts specified by the manufacturer for use in the particular installation.

  • Page 9: Vent Pipe Modification

    VENT PIPE MODIFICATION When an existing boiler is removed from a common venting Place in operation the appliance being inspected. Follow system, the common venting system is likely to be too the lighting instructions. Adjust thermostat so appliance large for the proper venting of the appliances remaining will operate continuously.

  • Page 10: Connect Gas Service

    CONNECT GAS SERVICE Tighten all joints securely. CAUTION Propane gas connections should only be made by a WHAT TO DO IF YOU SMELL GAS licensed propane installer. Do not try to light any appliance. Two-stage regulation should be used by the propane installer.
  • Page 11 ELECTRICAL WIRING The boiler, when installed, must be electrically bonded to ground in accordance with the requirements of the COMPONENT KEY CODING authority having jurisdiction or, in the absence of such TH-2 Thermostat (24 Volt) requirements, with the National Electrical code, ANSI/NFPA 70, and/or the Canadian Electrical Code Part I, CSA C22.1, Transformer (120V/24V 40VA) TR-1...

  • Page 12: Electrical Wiring

    ELECTRICAL WIRING HOT WATER CONTROL AND HOT SURFACE PILOT WIRING Q3450B INDUCED DRAFT L4080B BLOWER 120V GREEN 60HZ SUPPLY WHITE ORANGE GREEN ORANGE CONTROL IGNITION Honeywell SV9501H TH-2 TR-1 TR-2 R8222C Q3450B 120V L4080B 60HZ INDUCED SUPPLY DRAFT BLOWER GREEN WHITE GREEN CONTROL...

  • Page 13: Operating Instructions

    OPERATING INSTRUCTIONS FOR BOILER WITH A HOT SURFACE PILOT SYSTEM FOR YOUR SAFETY, READ BEFORE OPERATING! WARNING WARNING A. This appliance is equipped with an ignition If you do not follow these instructions exactly, device which automatically lights the a fire or explosion may result causing property burner.

  • Page 14: Sequence Of Operation

    OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS Figure 10 - Gas Control Screw PILOT FLOW ADJ. STOP! Read the safety information on previous page. SCREW BENEATH COVER SCREW Set thermostat to lowest setting. Turn off all electric power to the appliance. IGNITION SYSTEM CONTROL SWITCH This appliance is equipped with an ignition device which automatically lights the pilot.

  • Page 15: General Instruction For Seasonal Start Up And Maintenance

    GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE Periodic cleaning of the condensate collection system is It is suggested that a qualified service agency be employed required. When a condensate collection system is installed to make an annual inspection of the boiler and the heating in a venting system, it is recommended that the cleaning system.
  • Page 16 GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE The following procedure should be followed to clean Figure 13 - Air Box Cover and check the flue gas passageways: Turn off gas to the boiler at the manual gas Remove the jacket front panel. See Figure 12. Disconnect the vent pipe from the vent pipe adapter.
  • Page 17 GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE Start boiler to insure proper operating condition. Figure 16 - Gas Burner Flame Keep area around boiler clean and free of combustible materials such as gasoline, paints, paint thinner and other such flammable vapors and liquids. The free flow of combustion and ventilating air to boiler and boiler room must not be restricted or blocked.
  • Page 18 GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE Do not cut original tubing. Additional tubing is Adjusting the pilot flame: required. If tubing is cut, replace it only with Remove pilot adjustment cover screw. O.E.M. high temperature silicone tubing. Do not replace with vinyl or plastic tubing because it will Turn inner screw (adjustment screw) clockwise melt.

  • Page 19: Venting Instructions

    VENTING INSTRUCTIONS Combustion Air Venting Requirements Requirements Vent Opening Boiler Size 3" (8cm) Inlet Pipe length Dimensions 3 Section 5" X 5" (13 cm x 13 cm) 30 Ft (914cm) with 2 Elbows 4 Section 8" x 8" (20 cm x 20 cm) 30 Ft (914cm) with 2 Elbows 5 Section 9"...
  • Page 20 VENTING INSTRUCTIONS Signage: A metal or plastic identification plate shall WARNING be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade Read and understand these instructions, for directly in line with the exhaust vent terminal for the correct installation of vent system.
  • Page 21 VENTING INSTRUCTIONS Figure 2 - Horizontal Vent Piping (Typical Installation) Notes: • Condensate tee/drain is only needed when horizontal vent lengths exceed 10 feet. • Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp.
  • Page 22 VENTING INSTRUCTIONS Horizontal Vent Pipe Lengths Boiler Size Vent Pipe Diameter Max Vent Length* Min Vent Length* Inlet Pipe 30 ft (914 cm) 2 ft (61 cm) 30 ft (914 cm) 3 Section 3" (8 cm) with with 1 elbow with 2 elbows condensate tee &...
  • Page 23 VENTING INSTRUCTIONS Install vent termination assembly through opening and Figure 3 - Front View Of Termination Kit secure to outside wall. Install PVC pipe from vent termination assembly to boilers air inlet. Assemble and install vent pipe according to vent pipe manufacturers instructions.

  • Page 24: Condensate Drains

    VENTING INSTRUCTIONS For vent pipe installation refer to the vent pipe manufacturers instructions. Figure 6 - Vent System For All Models Figure 7 - RECOMMENDED TERMINATION TEE THIMBLE VENT PIPE VENT CONDENSATE TRAP ASSY NOTE: REFER TO “VENT CONDENSATE PIPE LENGTHS” FOR DRAIN USAGE.
  • Page 25 VENTING INSTRUCTIONS Figure 9 - Vent Clearances Note: If there is a potential for excessive winds, special consideration should be given to locate the vent termination away from the windward side of the building. Vent Cap must be at least 7’...
  • Page 26 VENTING INSTRUCTIONS Figure 10 - Flex-L Star-34 Vent Pipe Components ® ™ Notes: • Condensate tee/drain is only needed when horizontal vent lengths exceed 10 feet. • Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp.
  • Page 27 VENTING INSTRUCTIONS Figure 12 - Z-Flex Z-vent Vent Pipe Components ® ™ Notes: • Condensate tee/drain is only needed when horizontal vent lengths exceed 10 feet. • Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp.
  • Page 28 VENTING INSTRUCTIONS Figure 14 - Vertical Vent Piping Typical Installation Notes: • Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp. Vent Pipe Lengths Installation Procedure For Vertical Venting • Vent Pipe Diameter: 3" (76 mm) Do not insulate or other wise wrap vent pipe or fittings.
  • Page 29 VENTING INSTRUCTIONS Figure 15 - Vertical Drain Tee Figure 16 - Vent Air Intake Figure 18 - Termination More than 10 Ft (3.05 m) Figure 17 - Termination 10 Ft (3.05 m) or Less From from Ridge Ridge...
  • Page 30 VENTING INSTRUCTIONS Figure 19 - Flex-L Star-34 Vent Pipe Components ® ™ Figure 20 - Z-Flex Z-vent Vent Pipe Components ® ™...
  • Page 31 VENTING INSTRUCTIONS Figure 21 - Heat Fab Saf-T Vent Vent Pipe Components ® ™ Figure 20 - ProTech FasNSeal Vent Pipe Components ® ™...

  • Page 32: Replacement Parts

    REPLACEMENT PARTS HEAT EXCHANGER FULLY ASSEMBLED HEAT EXCHANGERS 912000002 Heat Exchanger 3 Section 912000003 Heat Exchanger 4 Section 912000004 Heat Exchanger 5 Section...
  • Page 33 REPLACEMENT PARTS BASE ITEM ITEM PART # DESCRIPTIONS QTY. PART # DESCRIPTIONS QTY. Burner Tube 3 Section 3272101 Air Box Wrapper 3 Section Burner Tube 4 Section 240005543 3272102 Air Box Wrapper 4 Section Burner Tube 5 Section 3272103 Air Box Wrapper 5 Section 240007769 Pilot Grommet 5611602 Kit - Base With Insul 3 Section...
  • Page 34 REPLACEMENT PARTS AIR BOX COVERS ITEM ITEM PART # DESCRIPTIONS QTY. PART # DESCRIPTIONS QTY. HW10301 Hose Clamp Sst 3572401 Insul Frt Cov. 3 Section 3271601 Air Intake Adapter 3572402 Insul Frt Cov. 4 Section 3271203 Air Intake Sleeve 3572403 Insul Frt Cov.
  • Page 35 REPLACEMENT PARTS PIPING & CONTROLS TO GAS VALVE ITEM PART # DESCRIPTIONS QTY. 3772301 WIRE HARNESS - GAS VALVE 28" 37519501 HARNESS CIRCULATOR 72" 1310002 PIPE - NIPPLE 1.1/4 X 4.1/2 NPT DRAIN SHORT 016.03 1510001 PIPE FIT TEE - 1.1/4X3/4X1.1/4 PF-006.01 PIPE FIT NIPPLE 1.1/4 CLOSE 37518901...
  • Page 36 REPLACEMENT PARTS ELECTRICAL ITEM # PART # DESCRIPTIONS QTY. SS00801 PRESSURE SWITCH (FS6205A) 3171101 TERMINAL STRIP COVER 550001339 TRANSFORMERS - 40VA 1410001 CONTROL R8222C-1008 HW09601 TUBING - SILICON - CLEAR 12" EF04001 9 TERM STRIP HW09701 TUBING - SILICON - ORANGE 17"...
  • Page 37 REPLACEMENT PARTS PILOT ITEM PART # DESCRIPTION QTY. Pilot Q3450b 1039 HW NAT (For PBO1401 Natural Gas Only) Pilot Q3450b 1112 LP (For Pro- PB01402 pane Gas Only) 3771101 Pilot Assembly HW-024.01 Screw #10 32x3/16 43300201 Pilot Tube 1/8"X24" Aluminum FLUE COLLECTOR &...
  • Page 38 REPLACEMENT PARTS TERMINATION KIT ITEM # PART # DESCRIPTIONS QTY. 34721501 VENT TERMINATION THIMBLE PLATE ASSY 34721002 TERMINATION ASSEMBLY 34721401 VENT TERMINATION DEFLECTOR 1330006 NUT #10-24 HEX 30A004312 SCREW #10-24 X 1.1/2" ROUND HEAD 3471701 DRAW COLLAR - HW-009.01 SCR #8-18X1/2" SLT HX WASH 3471901 VENT TEMPLATE 5612601...
  • Page 39 REPLACEMENT PARTS JACKET ITEM # PART # DESCRIPTION QTY. 31710202 Panel - Left Hand Side 3172801 Panel - Front 3 Section 3172802 Panel - Front 4 Section 3172803 Panel - Front 5 Section 3172401 Panel - Separator Plate 3 Section 3172402 Panel - Separator Plate 4 Section 3172403...

  • Page 40: Relief Valve Piping Supplemental Installation Instructions

    SUPPLEMENTAL INSTRUCTIONS RELIEF VALVE PIPING Supplemental Installation Instructions IMPORTANT: THIS MANUAL MUST BE KEPT NEAR THE BOILER FOR FUTURE REFERENCE!! WARNINGS AND SAFETY SYMBOLS DANGER CAUTION Indicates an imminently hazardous situation Indicates an imminently hazardous situation which, if not avoided, WILL result in death, which, if not avoided, may result in injury .
  • Page 41 SUPPLEMENTAL INSTRUCTIONS Relief Valve and Discharge Line Piping Installation Install relief valve on pipe nipple in tapped boiler opening. Discharge line shall be independently supported to avoid Pipe discharge line following guidelines in preceding applied stress on relief valve. Installation shall allow Warning.
  • Page 42 NOTES...
  • Page 44 Columbia Company Main offices and factory Pottstown, PA...

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