Columbia CSC SERIES Installation, Operation & Maintenance Manual

CSC SERIES

H

Direct Vent

Gas Fired Hot Water Boiler

INSTALLATION, OPER ATION &

MAINTENANCE MANUAL

C.S.A. Certied

For Natural Gas Or Propane

Columbia Company

Main ofces and Factory:
Pottstown, PA

Tested For 100 psi.

ASME

Working Pressure

P/N 37711701, Rev. C [05/2012]

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 Modication .................................................................................................................. 9

Connect Gas Service ...................................................................................................................10

Electrical Wiring .........................................................................................................................12

Operating Instructions .................................................................................................................13

Sequence Of Operation................................................................................................................14

General Instruction For Seasonal Start Up And Maintenance .............................................................15

Venting Instructions ....................................................................................................................19

Condensate Drains......................................................................................................................24

Replacement Parts ......................................................................................................................32

Relief Valve Piping Supplemental Installation Instructions ................................................................40

SAFETY SYMBOLS

The following dened symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.

DANGER

!

Indicates a hazardous situation which, if not
avoided, WILL result in death, serious injury.

WARNING

!

Indicates a hazardous situation which, if not
avoided, may result in death, serious injury.

CAUTION

!

Indicates a hazardous situation which, if not
avoided, may result in injury.

Keep This Manual Near Boiler And

Retain For Future Reference.

WARNING

Keep boiler area clear and free from
combustible materials, gasoline and other
ammable vapors and liquids.

Do not obstruct air openings to the boiler

!

room.

Modication, substitution or elimination
of factory equipped, supplied or specied
components may result in personal injury or
the loss of life.

To the installer: Leave all instructions with the boiler for
future reference.

When this product is installed in the Commonwealth of
Massachusetts the installation must be performed by a
Licensed Plumber or Licensed Gas Fitter.

To the owner: Installation and service of this boiler must
be performed by a qualied installer.

NOTICE

Indicates information which should be
followed to ensure proper installation and
operation.

IMPORTANT: Read the following instructions COMPLETELY
before installing!

2

INTRODUCTION

WARNING

Improper installation, adjustment, alteration,

!

service or maintenance can cause injury or
property damage.

• The installation must conform to the requirements of
the authority having jurisdiction or, in absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, and/or Natural Gas and Propane
Installation Code, CAN/CSA B149.1.

• Where required by Authority having jurisdiction,
installation must conform to Standard for Controls and
Safety Devices for Automatically Fired Boilers, ANSI/
ASME CSD-1.

• LOCATE BOILER on level, solid base as near the outside
wall as possible and centrally located with respect to the
heat distribution system as practicable.

• Allow 24 inches (61cm) at front and right side for
servicing and cleaning.

• When installed in utility room, the door should be wide
enough to allow the largest boiler part to enter, or to
permit replacement of another appliance such as a
water heater.

Figure 1 - Min. Clearances To Combustible Materials

WARNING

All installations of boilers and venting should
be done only by a qualied expert and in
accordance with the appropriate boiler
manual. Installing or venting a boiler or any

!

other gas appliance with improper methods or
materials may result in serious injury or death
due to re or to asphyxiation from poisonous
gases such as carbon monoxide which is
odorless and invisible.

4" (10.2 cm)

MIN.

• The boiler shall be installed such that the gas ignition
system components are protected from water, (dripping,
spraying, rain, etc.), during appliance operation and
service, (circulator replacement, condensate trap,

control replacement, etc.).

• For installation on non-combustible oors only.
The boiler must not be installed on carpeting (for
installation on combustible ooring special base
part no.325-2-8.00 Must be used). Minimum
clearances to combustible constructions are:

TOP 18 in. (46 cm)

FLUE CONNECTOR 2 in. (5 cm)

FRONT 6 in. (15 cm)

REAR 4 in. (10 cm)

RIGHT SIDE 9 in. (23 cm)

LEFT SIDE 3 in. (8 cm)

Refer to Figure 1. Greater clearances for access should super­sede re protection clearances.

3"

(7.6 cm)

MIN.

6" (15.2 cm)

MIN.

9"

(22.9 cm)

MIN.

FRONT OF

BOILER

3

BOILER RATINGS, CAPACITIES & DIMENSIONS

Boiler Ratings, Capacities & Dimensions

Boiler

No.

3

Section

4

Section

5

Section

NOTE: Input rating for applications 0-2000 ft ( 0-610m) above sea level.

United States: Over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m) above sea level.

Canada: 2000-4500 ft (610-1350m) above sea level. Reduce input rate 10%.

Canada over 4500 ft (1350m) above sea level. Contact Provincial authority having jurisdiction.

Input

Btu/Hr.

50,000

(14.7 KW)

100,000

(29.3 KW)

140,000

(41.0 KW)

Heating

Capacity

Btu/Hr.

44,000

(12.9 KW)

87,000

(25.5 KW)

122,000

(35.7 KW)

Net Output

Btu/Hr.

38,000

(11.1 KW)

76,000

(22.3 KW)

107,000

(31.3 KW)

Natural

Gas

Inlet

1/2"

(1.27 cm)

1/2"

(1.27 cm)

1/2"

(1.27 cm)

A B C D

15.1/8"

(38 cm)

19"

(48 cm)

22.7/8"

(58 cm)

STANDARD EQUIPMENT:

Boiler Jacket, Cast Iron Boiler Battery, Limit Control, Re­movable Transformers, Plug in Relay, Theraltimeter Gauge,
Circulator (eld mounted), Main Gas Burners, Hot Surface
Pilot; A.S.M.E Relief Valve, Drain Valve, Induced Draft Fan,
Safety Pressure Switch, and Combination Intake/Exhaust
Termination Kit.

All boilers are design certied for installation on non-com­bustible oors. For installation on combustible oors, use

combustible oor kit.

Dimensions

3.1/2"

(9 cm)

3.1/2"

(9 cm)

4.1/4"

(11 cm)

3.1/2"

(9 cm)5"(12.7 cm)

3.1/2"

(9 cm)

4.1/8"

(11 cm)

6.1/2"

(16.5 cm)

8.3/8"

(21.3 cm)

This boiler is a Direct Vent Designed Certied appliance
which requires a special horizontal through the wall venting
system.

Use ONLY the venting material products listed below:

• HEAT-FAB® SAF-T-VENT

• FLEX-L® STAR-34™

• ProTech™ FasNSeal

• Z-FLEX® Z-VENT™

Consult venting addendum for maximum vent lengths and
proper congurations.

Supply &

Return

Tappings

1.1/4"

(3.2 cm)

1.1/4"

(3.2 cm)

1.1/4"

(3.2 cm)

®

™

No. Of

Burners

2

3

4

Water

Content

4.0 gals

(15.14 liters)

5.6 gals

(21.20 liters)

7.2 gals

(27.25 liters)

AFUE

Ratings

87%

87%

87%

Electrical service to be 120 Volts, 15 Amps, 60 Hz.

4

CONNECTING SUPPLY AND RETURN PIPING

1.

See Relief Valve Piping Supplemental Installation
Instructions located on page 40 of this manual.

2.

Connect supply and return piping as suggested in
Figure 1 below when the boiler is used in connection

with refrigerated systems:

A. Boiler used in connection with refrigeration

system. Install piping in parallel with boiler, with
appropriate valves to prevent chilled medium from
entering boiler. See gure 2.

B. System piping connected to heating coils located

in air handling unit exposed to refrigerated air
circulation. Install ow control valves or other
automatic means to prevent gravity circulation of

boiler water during cooling cycle.

3.

Maintain a minimum clearance of 1 inch (2.54cm) to
hot water pipes.

4.

Hot water boilers installed above radiation level or
as required by Authority having jurisdiction must be
provided with a low water cut-off device at the time of
boiler installation.

5.

When a boiler is connected to a heating system that
utilizes multiple zoned circulators, each circulator must
be supplied with a ow control valve to prevent gravity

circulation.

NOTICE

Reduced pressure back ow preventer must
be used under provisions required by the
Environmental Protection Agency, (EPA).

Figure 1 - Near Boiler Supply & Return Piping

A

EXPANSION

TANK

B

FEED

WATER

CHECK

VALV E

C

CHILLER

D

CIRCULATOR

SUPPLY PIPING

TO HEATING

AND COOLING

ELEMENT

WATER

RETURN PIPING

FROM HEATING

AND COOLING

ELEMENT

5

ZONE

CIR.

VALV E

FLOW

VALVE

EXPANSION

TANK

VALV E

SYSTEM
TEMPERATURE

GAUGE

RETURN

SUPPLY

"A"

"B"

WATER

FEED

ZONE

CIR.

EXPANSION

TANK

SYSTEM

TEMPERATURE

GAUGE

RETURN

SUPPLY

4 WAY MIXING

VALV E

WATER

FEED

Figure 3 - Bypass Piping

CONNECTING SUPPLY AND RETURN PIPING

6.

Bypass piping is an option which
gives the ability to adjust the
supply boiler water temperature
to t the system or condition of
the installation. This method of
piping is not typically required for
baseboard heating systems.

A. This method is used

to protect boilers from
condensate forming due to
low temperature return water.
Generally noticed in large
converted gravity systems
or other large water volume
systems. See Figure 3.

B. These methods are used to

protect systems using radiant
panels and the material they
are encased in from high
temperature supply water
from the boiler and protect the
boiler from condensation. See

Figures 4 & 5.

Figure 3 - Mixing Valve Piping

7.

NOTE: When using bypass piping,
adjust valves A and B, in Figures
3 & 5, until desired system
temperature is obtained.

8.

NOTE: When using a 4-way
mixing valve, set control knob until
desired temperatures are met. See
instruction supplied with valve.

9.

Bypass loop piping must be the
same size piping as the supply and
the return.

10.

Typical installation using circulators
is shown in Figure 6 on following
page.

11.

Typical installation using zone
valves is shown in Figure 7 on
following page.

12.

For further piping information
refer to the I=B=R installation and
piping guide.

6

CONNECTING SUPPLY AND RETURN PIPING

Figure 5 - Primary Secondary Piping with Bypass

SYSTEM

TEMPERATURE

GAUGE

SUPPLY

FLOW

VALV E

PRIMARY

CIRCULATOR

"B"

VALV E

RETURN

SYSTEM
CIRCULATOR

12"

(31 cm)

MAX.

"A"

VALV E

EXPANSION

TANK

Figure 6 - Typical Installation Using Circulators

FEED

WATER

7

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
pressure and temperature of the ue gas vented from the

appliance.

• Category I and II appliances are natural draft (draft

hood) vented, with high ue gas temperatures
(Category I), or low ue gas temperatures (Category
II).

• Category III and IV appliances are fan forced vents with

high temperature (Category III) or low temperature
(Category IV) ue gasses. Appliance efciency is directly
related to ue gas temperature. Higher efciency
appliances remove more heat from the gas, so they will
have lower temperature ue products.

• When ue gas temperatures are lowered, corrosive

condensates may form in the gas vent or in the
appliance. Condensates may form in Category II, III, IV
appliance vents, so special corrosive resistant venting
systems are required for higher efciency appliances.

8

• Proper operation of the vent system and appliance is
dependent upon the use of all parts specied by the
manufacturer for use in the particular installation.
Appliance and vent system performance may be affected
by improper assembly.

• Vents for Category I appliances may not be suitable
for use with Category II, III, or IV appliances because
condensate may corrode the vent.

• Vents for Category III appliances may not be suitable
for use with Category I appliances because ue gas
temperatures may be too high.

VENT PIPE 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 remaining
connected to it.

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 appliances remaining connected
to the common venting system are not in operation.

1.

Seal any unused openings in the common venting
system.

2.

Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deciencies
which could cause an unsafe condition.

3.

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 exhausts, so
they will operate at maximum speed. Do not operate a
summer exhaust fan. Close replace dampers.

4.

5.

6.

7.

Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.

Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the ame of
a match or candle, or smoke from a cigarette, cigar or
pipe.

After it has been determined that each appliance
remaining connected to a common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, replace dampers and
any other gas burning appliance to their previous
conditions of use.

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,
and/or the Natural Gas and Propane Installation Code,
CAN/CSA B149.1. When re-sizing any portion of the
common venting system, the common venting system
should be re-sized to approach the minimum size as
determined using the appropriate tables in Chapter 13
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
and/or the Natural Gas and Propane Installation Code,
CAN/CSA B149.1.

9

CONNECT GAS SERVICE

CAUTION

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switches; do
not use any phones in your building.

!

Immediately call your gas supplier from
a neighbor’s phone. Follow gas supplier’s
instructions.

If you cannot reach your gas supplier, call
the re department.

The following rules apply:

1.

Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements:

USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54

Canada - Natural Gas and Propane Installation Code,

CAN/CSA B149.1

2.

All pipe compound must be resistant to liqueed
petroleum gas.

3.

Install ground joint union in gas supply line between
shut-off valve and boiler controls.

4.

Install a sediment trap upstream of gas controls.

5.

Use two pipe wrenches when making the connection to
the gas valve to keep it from turning.

6.

Install manual shut-off valve in vertical pipe about 5
feet (1.5m) above oor.

7.

Tighten all joints securely.

8.

Propane gas connections should only be made by a
licensed propane installer.

9.

Two-stage regulation should be used by the propane
installer.

10.

Propane gas piping should be checked out by the
propane installer.

DANGER

Fire Hazard. Do not use matches, candles,

!

open ames, or other methods providing
ignition source. Failure to comply will result in
death or serious injury.

Checking The Gas Piping

Pressure test boiler and gas connection before placing
boiler in operation.

• Pressure test over 1/2 psig (3.5 kPa). Disconnect
boiler and its individual gas shutoff valve from gas
supply system.

• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
shutoff valve. See Figure 8.

• Locate leakage using gas detector, noncorrosive
detection uid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open ames, or other methods
providing ignition source.

• Correct leaks immediately and retest.

Figure 8 - Manual Gas Shutoff Valve

10

ELECTRICAL WIRING

The boiler, when installed, must be electrically bonded
to ground in accordance with the requirements of the
authority having jurisdiction or, in the absence of such
requirements, with the National Electrical code, ANSI/NFPA
70, and/or the Canadian Electrical Code Part I, CSA C22.1,

Electrical Code.

WARNING

Electrical shock hazard. Turn OFF electrical

!

power supply at service panel before making
electrical connections. Failure to do so could
result in death or serious injury.

Component And Wire Coding Keys

• The keys that follow pertain to the HOT WATER
CONTROL AND HOT SURFACE PILOT WIRING FOR
SEALED COMBUSTION SERIES (diagrams on following
page).

• If any of the original wiring supplied with the boiler is
replaced it must be replaced with like wire size and type
of insulation or equivalent.

COMPONENT KEY CODING

Thermostat (24 Volt)

Transformer (120V/24V 40VA)

Transformer (120V/24V 40VA)

24 Volt Gas Valve

Pressure Switch

Control Terminal

Relay Coil

Relay Contacts

Relay Contacts

Limit Switch

Circulator

Wire Connection

TH-2

TR-1

TR-2

SV9501H

PS

1K
1K1
1K2

LS
CIR

Not all components listed are used in all control

systems.

WIRING CODE KEY

CAUTION

Label all wires prior to disconnection when

!

servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.

Install Your Thermostat

• The thermostat location has an important effect on the
operation of your boiler system.

• BE SURE TO FOLLOW THE INSTRUCTIONS INCLUDED
WITH YOUR THERMOSTAT.

• Locate the thermostat about four feet (4’) above the
oor on an inside wall.

• Check thermostat operation by raising and lowering
thermostat setting as required to start and stop burners.

LINE VOLTAGE BY FACTORY

LOW VOLTAGE BY FACTORY

LINE VOLTAGE BY INSTALLER

LOW VOLTAGE BY INSTALLER

THINGS TO AVOID WHEN

LOCATING THERMOSTATS

DEAD SPOTS:

Corners and alcoves Behind doors

COLD SPOTS: HOT SPOTS:

Concealed pipes or ducts

Stairwells - drafts

Unheated rooms on
other side of wall

Outside wall

Concealed pipes

Fireplace or chimney

TV sets

Radios

Lamps

Direct sunlight

Kitchens

11

ELECTRICAL WIRING

HOT WATER CONTROL AND HOT SURFACE PILOT WIRING

SV9501H

GREEN

AND

WHITE

CONTROL

Honeywell

Q3450B

IGNITION

RED

ORANGE

GREEN

120V

60HZ

SUPPLY

INDUCED

LM

DRAFT

BLOWER

LS

L4080B

BLUE

FT

TV

T

BLUE

NO

CIR

L1

L2

C2

C

PS

VM

B

C1

ORANGE

VM/LM

3 6

1K

TH-2

1 4

TR-2TR-1

R8222C

GREEN

AND

WHITE

CONTROL

Honeywell

Q3450B

SV9501H

IGNITION

GREEN

RED

ORG

120V

60HZ

SUPPLY

PS

NO

ORG

WHITE

C

BLACK

YELLOW

CIR

L1

WHITE

LS

L4080B

INDUCED

DRAFT

BLOWER

BLUE

VM

RED

FT

LM

3 6

1K1

1 4

L2

C2

VM

LM

C1

BLACK

RED

YELLOW

B

T

TV

BLUE

1K

BLUE

TH-2

ORG

1K2

BLUE

12

OPERATING INSTRUCTIONS

FOR BOILER WITH A HOT SURFACE PILOT SYSTEM

FOR YOUR SAFETY, READ BEFORE OPERATING!

WARNING

If you do not follow these instructions exactly,

!

a re 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 psig
on most systems) and system is vented of air. See the
operating and lighting instructions.

WARNING

A. This appliance is equipped with an ignition

device which automatically lights the
burner. Do not attempt to light the burner
by hand.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell
next to the oor because some gas is
heavier than air and will settle on the
oor.

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 neighbor’s phone. Follow gas supplier’s
instructions.

• If you cannot reach your gas supplier, call
the re department.

C. Use only your hand to push down or turn

the knob. Never use tools. If the knob will
not operate by hand, don’t try to repair it,
call a qualied service technician. Force
or attempted repair may result in re or
explosion.

D. Do not use this appliance if any part

has been underwater. Immediately call
a qualied service technician to inspect
the appliance and to replace any part of
control system and any gas control which
has been under water.

13

ON

OFF

GAS

GAS

PRESSURE REGULATOR

ADJUSTMENT BENEATH

COVER SCREW

PILOT FLOW ADJ.
SCREW BENEATH

CONTROL

IGNITER

IGNITION SYSTEM

COVER SCREW

CONTROL SWITCH

PRESSURE

TAP

OUTLET

INLET

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS

1.

STOP! Read the safety information on previous page.

2.

Set 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 pilot. DO NOT try to light the
pilot by hand.

5.

Move the ignition system control switch to the "OFF"
position. See Figure 10.

6.

Wait ve (5) minutes to clear out any gas. If you then
smell gas, STOP. Follow "What To Do If You Smell Gas"
on previous page. If you don't smell gas, go to next
step.

7.

Move the ignition system control switch to the "ON"
position. See Figure 10.

8.

Turn on all electric power to the appliance.

9.

Set thermostat to desired setting.

10.

If the appliance will not operate, follow the instructions
"To Turn Off Gas To Appliance" to right and call a

qualied service technician or your gas supplier.

Figure 10 - Gas Control Screw

TO TURN OFF GAS TO APPLIANCE

1.

Set thermostat to lowest setting.

2.

Turn o all electric power to the appliance if service is to
be performed.

3.

Move the ignition system control switch to the "OFF"
position. DO NOT FORCE

SEQUENCE OF OPERATION

On a call for heat:

1.

The thermostat will actuate, completing the circuit
between terminals T and T.

2.

The R8222C relay coil will energize thus pulling in the
relay contacts.

3.

The circulator starts and power is switched to the limit.
If limit circuit is closed the venter motor and TR-2
transformer are energized.

4.

The venter motor starts and develops static pressure.

5.

When the static pressure is reached the pressure switch
pulls in completing the circuit between TR-2 and the
SV9501H gas valve system.

6.

7.

The SV9501H opens the pilot valve and ignites pilot.
After pilot is proven the main burner will ignite.

In the event the boiler water temperature exceeds the
high limit setting the power will be interrupted to the
venter motor, and TR-2, thus interrupting power to the
ignition system. Power will remain off until the water
temperature drops below the high limit setting. The
circulator will continue to operate under this condition
until the thermostat is satised.

8.

Should the air ow (static pressure) be interrupted (ie.
blocked ue), the pressure switch will sense a drop
in pressure, opening the circuit between the ignition
system and TR-2. The venter motor will continue to
operate until static pressure is reached or thermostat is
satised.

9.

In the event the ow of combustion products through
the boiler ue-ways becomes reduced or blocked, the
Q34505 pilot will lose ame rectication and shut off
the main burners. The boiler will try for ignition but
will not light. If this condition occurs, turn off the main
power and do not put the unit into operation.

10.

When the thermostat is satised power is interrupted to
the relay coil and the relay drops out cutting power to
the circulator, venter motor, and TR-2.

14