Columbia MCB50, MCB75, MCB100, MCB125, MCB150 Installation, Operation & Maintenance Manual

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Page 1

MODEL NUMBERS:

MCB50 MCB75 MCB100 MCB125 MCB150 MCB175 MCB200 MCB250 MCB300

MCB SERIES

Cast Iron Gas Fired Boilers

For Forced Hot Water

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Columbia Company

Main ofces and Factory: Pottstown, PA

P/N 37612101, Rev. E [05/2012]

Page 2

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Ratings & Data - Natural Gas & Propane Gas ...........3

Dimensions .........................................................4

Installation Procedure ..........................................5

Ventilation & Combustion Air .................................6

Connecting Supply and Return Piping .....................7

Connecting Supply and Return Piping .....................8

Vent Installation ................................................ 12

Vent System Modication .................................... 12

Vent Damper Installation & Instructions ................ 13

Connecting Gas Service ...................................... 14

Electrical Section ............................................... 15

Wiring Diagram - 24V Standing Pilot .................... 16

Wiring Diagram - Intermittent Ignition ................. 17

Lighting Instructions .......................................... 18

Normal Sequence of Operation ............................ 20

General Instructions .......................................... 20

Checking Gas Input Rate To Boiler ....................... 22

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

IMPORTANT: Read the following instructions COMPLETELY before installing!!

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 property damage,

personal injury or the loss of life.

TO THE OWNER - Installation and service of this boiler must be performed by a qualied installer.

Replacement Parts - Base ................................... 23

Safety Symbols & Warnings

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 or serious injury.

WARNING

Indicates a hazardous situation which, if

not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not

avoided, may result in minor or moderate injury.

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.

WARNING

All installations of boilers and venting shall be done only by a qualied expert and in accordance with appropriate 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.

NOTICE

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

C.S.A. Certied

For Natural Gas Or Propane

Tested For 100 psi.

ASME

Working Pressure

Page 3

RATINGS & DATA - NATURAL GAS & PROPANE GAS

Table 1 - Ratings and Capacities

(2)

Net Rating

Water

Mbh

108

124

143

178

214

No.

Burners

Boiler

No.

100

125

150

175

200

250

300

(1)

Input

Mbh

100

125

150

175

200

250

299

(1)

Heating

Capacity Mbh

104

124

143

165

205

243

EXPLANATORY NOTES

-- All boilers are design certied for installation on noncombustible oor.

-- For installation on combustible oors use combustible oor kit.

(3)

Recommended

Air Cushion

Tank

Water

Content

(Gals.)

2.4

4.0

5.6

7.2

8.8

10.4

High

Altitude

Input

45,000

67,500

90,000

112,500

135,000

157,000

180,000

225,000

270,000

-- Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be reduced to 10 feet. Refer to the latest revision of NFGC part 11.

-- Electric service to be 120 Volts, 15 Amps, 60 Hz.

-- The MEA number for the this boiler is 19-79-E.

(1) Input rating for sea level to 2,000 ft. (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 ft (610m) to 4500 (1350m) above sea level. Reduce input per table.

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

(2) Net Water Ratings shown based on piping and pickup allowance of 1.15. Consult manufacturer before

selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

For forced hot water systems where boiler and all piping within area to be heated, boiler may be selected on basis of its heating capacity.

(3) Tank sized for non-ferrous baseboard or radiant panel systems. Increase size for cast iron baseboard and radiation.

STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler Battery, High Limit Control, Vent Damper Relay, Theraltimeter Gauge, Circulator With Return Piping To Boiler, Main Gas Burners, Combination 24 Volt Gas Control (Includes Automatic Gas Valve, Gas Pressure Regulator, Automatic Pilot, Safety Shutoff, Pilot Flow Adjustment, Pilot Filter), A.S.M.E. Relief Valve, Drain Valve, Spill Switch, Rollout Switch, Automatic Vent Damper. Not Shown Are: Wiring Harness, Thermocouple, Non-linting Safety Pilot.

OPTIONAL EQUIPMENT: Intermittent Electric Ignition Pilot System.

Page 4

DIMENSIONS

Table 2 - Dimensions

Boiler No.

100

125

150

175

200

250

300

* Propane gas inlet, all units, 1/2"

Natural Gas

Inlet*

½"

¾"

11⅛"

18⅞"

30½"

Dimensions

⁄

13¼"

15¼"

30¾"

36¼"

37¾"

37¼"

37¾"

38¾"

40¾"

42¾"

6½"

10"

Pump size Supply &

Return Tappings

1¼"

Page 5

INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration,

service or maintenance can cause injury or property damage.

Installation must conform to the requirements of the authority having jurisdiction or, in the 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 the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically red Boilers, ANSI/ASME CSD-1.

This boiler series is classied as a Category I. Vent installation shall be in accordance with "Venting of Equipment ," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or "Venting Systems and Air Supply for Appliances," of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

This boiler has met safe lighting and other performance criteria with gas manifold and control assembly on the boiler per the latest revision of ANSI Z21.13/CGA 4.9.

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.).

Locate boiler on level, solid base as near the chimney as possible and centrally located with respect to the heat distribution system as practical.

Allow 24 inches (610mm) at front and right side for servicing and cleaning.

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

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY - For installation on combustible

ooring special base must be used. (See Replacement Parts Section.) Boiler can not be installed on carpeting. Minimum clearances to combustible construction are:

TOP ....................................18 IN. (457mm)

FRONT .........................................ALCOVE *

FLUE CONNECTOR ................. 6 IN. (152mm)

REAR ................................... 4 IN. (102mm)

CONTROL SIDE ..................... 9 IN. (229mm)

OTHER SIDE ........................... 3 IN. (76mm)

HOT WATER PIPING .............. 1/2 IN. (13mm)

NOTE: Greater clearances for access should supersede fire

protection clearances. * Denition of Alcove is three sided space with no wall in front of boiler. ANSI standard for alcove is 18 inches from front of appliance to leading edge of side walls as shown below.

Minimum Clearances to Combustible

Construction (as seen from above)

BOILER

18"

Page 6

VENTILATION & COMBUSTION AIR

Provide combustion air and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections

8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes.

Provide make-up air where exhaust fans, clothes dryers, and kitchen ventilation equipment interfere with proper operation.

National Fuel Gas Code recognizes several methods of obtaining adequate ventilation and combustion air. Requirements of the authority having jurisdiction may override these methods.

• Engineered Installations. Must be approved by authority having jurisdictions.

• Mechanical Air Supply. Provide minimum of 0.35 cfm per Mbh for all appliances located within space. Additional requirements where exhaust fans installed. Interlock each appliance to mechanical air supply system to prevent main burner operation when mechanical air supply system not operating.

• All Indoor Air. Calculate minimum volume for all appliances in space. Use a different method if minimum volume not available.

о Standard Method. Cannot be used if known air

inltration rate is less than 0.40 air changes per

National Gas and Propane Installation Code Requires providing air supply in accordance with:

hour. See Table 3 for space with boiler only. Use equation for multiple appliances.

Volume ≥ 50 ft3 x Total Input [Mbh]

о Known Air Inltration Rate. See Table 3 for

space with boiler only. Use equation for multiple appliances. Do not use an air inltration rate (ACH) greater than 0.60.

Volume ≥ 21 ft3/ACH x Total Input [Mbh]

о Refer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

• All Outdoor Air. Provide permanent opening(s) communicating directly or by ducts with outdoors.

о Two Permanent Opening Method. Provide opening

commencing within 12 inches of top and second opening commencing within 12 inches of bottom enclosure.

 Direct communication with outdoors or

communicating through vertical ducts. Provide minimum free area of 1 in2 per 4 Mbh of total input rating of all appliances in enclosure.

 Communicating through horizontal ducts.

Provide minimum free area of 1 in2 per 2 Mbh of total input rating of all appliances in

enclosure.

о One Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure. Provide minimum clearance of 1 inch on sides and back and 6 inches on front of boiler (does not supersede clearance to combustible materials).

о Combination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for additional requirements for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer to National Fuel Gas Code for application information.

• Section 8.2 and 8.3 when combination of appliances has a total input of up to and including 400 Mbh (120 kW).

• Section 8.4 when combination of appliances has total input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code for specic air supply requirements for enclosure or structure where boiler is installed, including air

supply openings and ducts.

Table 3

Input Mbh

Standard

Method

0.1 0.2 0.3 0.4 0.5 0.6

50 2500 10500 5250 3500 2625 2100 1750

75 3750 15750 7875 5250 3938 3150 2625

100 5000 21000 10500 7000 5250 4200 3500

125 6250 26250 13125 8750 6563 5250 4375

150 7500 31500 15750 10500 7875 6300 5250

175 8750 36750 18375 12250 9188 7350 6125

200 10000 42000 21000 14000 10500 8400 7000

250 12500 52500 26250 17500 13125 10500 8750

300 15000 63000 31500 21000 15750 12600 10500

Known Air Inltration Rate Method (Air Changes Per Hour)

Page 7

CONNECTING SUPPLY AND RETURN PIPING

WARNING

To avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation, a discharge line shall be installed to relief valve outlet connection.

Discharge line shall:

• connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum distance from oor or allowable safe point of discharge.

• be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge line;

• have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug or place any obstruction in discharge line.

• terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing;

• allow complete drainage of the valve and the discharge line;

• be independently supported and securely anchored to avoid applied stress on the relief valve;

• be as short and straight as possible;

• terminate with plain end (not threaded);

• be constructed of material suitable for exposure to temperatures of 375° F; or greater.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements.

RELIEF VALVE

DISCHARGE

LINE

Check local

codes for

maximum

distance

from oor

or allowable

safe point of

discharge.

RELIEF VALVE

Check local

codes for

maximum

distance

from oor

or allowable safe point of

discharge.

DISCHARGE

LINE

Page 8

AIR

SEPARATOR

CONNECTING SUPPLY AND RETURN PIPING

IMPORTANT: Circulators in the following illustrations are mounted on the system supply side, but mounting on the system return side is also acceptable practice.

Figure 5 - Circulators Mounted on System Supply

The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. See Figure 5.

The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with ow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

Hot water boilers installed above radiation level or as required by authority having jurisdiction must be provided with a low water cut-off device.

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.

Hot water boilers and system must be lled with water and maintained to a minimum pressure of 12 psi.

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

bypass piping is used are as follows: A. This method is used to protect boilers from con-

densation forming due to low temperature return water. Generally noticed in large converted gravity systems or other large water volume systems.

Figure 6 & 7.

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.

NOTE#1: When using bypass piping, adjust valves V1 & V2 until desired system temperature is obtained.

NOTE#2: Bypass loop must be same size piping as the supply and return piping.

Page 9

CONNECTING SUPPLY AND RETURN PIPING

Figure 6 - Bypass Piping Automatic Mixing Valve

TO SYSTEM

WATER INLET

EXPANSION

TANK

FROM SYSTEM

CIRCULATOR

SHUT-OFF VALV E

PRESSURE REDUCER VALVE

CHECK VALVE

BOILER

BALL VALVE

3 WAY MIXING VALV E

ALTERNATE

CIRCULATOR

LOCATION

AIR SEPARATOR

HOSE BIB

Figure 7 - Bypass Piping - Fixed Low Temp Only Automatic Mixing Valve

TO SYSTEM

WATER INLET

SYSTEM

CIRCULATOR

EXPANSION

TANK

V2V1

BOILER

FROM SYSTEM

ALTERNATE

CIRCULATOR

LOCATION

CIRCULATOR

SHUT-OFF VALV E

7. Installation using circulators and zone valves are

shown in Figures 8-11. For further piping information refer to I=B=R Installation and Piping Guide.

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

8. Install discharge piping from safety relief valve.

• Use ¾" or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C) or greater.

PRESSURE REDUCER VALVE

CHECK VALVE

BALL VALVE

ZONE VALVE

AIR SEPARATOR

• Individual boiler discharge piping shall be independent of other discharge piping.

• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

Page 10

CONNECTING SUPPLY AND RETURN PIPING

Figure 8 - Single Zone System With DHW Priority

Figure 9 - Multi Zone System With Circulators And DHW Priority

Page 11

CONNECTING SUPPLY AND RETURN PIPING

Figure 10 - Multi Zone System With Zone Valves And DHW Priority (With Circulator)

Figure 11 - Multi Zone System With Zone Valves And Dhw Priority (With Zone Valve)

Page 12

VENT INSTALLATION

WARNING

All installations of boilers and venting should be done only by a qualied expert and in accordance with the appropriate 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 with is odorless and invisible.

WARNING

This boiler shall not be connected to any

portion of a mechanical draft system operating under positive pressure.

The vent pipe must slope upward from the boiler not less then ¼ inch for every 1 foot (21mm/m) to vent terminal.

Horizontal portions of the venting system shall be supported rigidly every 5 feet and at the elbows. No portion of the vent pipe should have any dips or sags.

This boiler series is classied as a Category I. Vent installation shall be in accordance with "Venting of Equipment," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or "Venting Systems and Air Supply for Appliances," of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

Inspect chimney to make certain it is constructed according to NFPA 211. The vent or vent connector shall be Type B or metal pipe having resistance to heat and corrosion not less than that of galvanized sheet steel or aluminum not less than 0.016 inch thick (No. 28 Ga).

Connect ue pipe from draft hood to chimney. Bolt or screw joints together to avoid sags. Flue pipe should not extend beyond inside wall of chimney. Do not install manual damper in ue pipe or reduce size of ue outlet except as provided by the latest revision of ANSI Z223.13 or CAN/CSA B149.1. Protect combustible ceiling and walls near ue pipe with reproof insulation. Where two or more appliances vent into a common ue, the area of the common ue must be at least equal to the area of the largest ue plus 50 percent of the area of each additional ue.

VENT SYSTEM MODIFICATION

When an existing boiler is removed from a common venting system, the system is likely to be too large for the proper venting of the appliances sill 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 appliances remaining connected to the common venting system are not in operation.

Seal an unused opening in the common venting system.

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.

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 other appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they operate at maximum speed. Do not operate a summer exhaust fan. Close replace dampers.

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 appliances to their previous condition 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 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.

Page 13

VENT DAMPER INSTALLATION & INSTRUCTIONS

DAMPER INSTALLATION NOTE: Refer to Figure 11 for steps 1-6.

Figure 12 - Damper Motor Wiring

DAMPER INSTRUCTIONS

Figure 13 - Vent Damper Placement

Place Vent Damper on or as close to vent outlet of boiler as possible. Figure 13.

Remove Vent Damper Motor cover.

Feed damper wire harness connector through bracket hole on Damper Motor frame.

Tighten locknut onto Damper wire harness connector.

Plug Damper connector into socket on Damper Motor frame.

Replace Damper Motor cover and wire Damper in accordance with Figure 12.

Verify only boiler is serviced by Vent Damper. Figure

13.

Clearance of not less than 6 inches (152mm) between Vent Damper and combustible material must be maintained. Additional clearance should be allowed for service of Vent Damper.

Vent Damper must be in the open position when appliance main burners are operating.

The Vent Damper position indicator must be in a visible location following installation.

The thermostat's heat anticipator must be adjusted to match the total current draw of all controls associated with the boiler during a heating cycle.

Page 14

CONNECTING GAS SERVICE

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

Figure 14 - Gas Piping

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.

CAUTION

General

• 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

• Size and install gas piping system to provide sufcient gas supply to meet maximum input at not less than minimum supply pressure. See Table 5.

• Support piping with hooks straps, bands, brackets, hangers, or building structure components to prevent or dampen excessive vibrations and prevent strain on gas connection. Boiler will not support piping weight.

• Use thread (joint) compound (pipe dope) suitable for liqueed petroleum gas.

• Install eld sourced manual main shutoff valve, ground joint union, and sediment trap upstream of gas valve.

See Figure 14.

Table 5 Natural Gas Propane

Min. Supply Pressure 5" w.c. 11" w.c.

Max. Supply Pressure 13.5" w.c. 13.5" w.c.

Manifold Pressure 3.5" w.c. 10.5" w.c.

MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS/HOUR

(Gas Pressure = 0.5 psig or less, Pressure Drop = 5 in. w/c)

Table 4

Length of

Pipe (Feet)

10 175 360 680 1400

20 120 250 465 950

30 97 200 375 770

40 82 170 320 660

60 66 138 260 530

80 57 118 220 460

100 50 103 195 400

For additional information refer to the National Fuel Gas Code Handbook.

Nominal Iron Pipe Size

½” ¾” 1” 1¼”

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.

Leak Check 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.

•

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.

Page 15

ELECTRICAL SECTION

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.

ELECTRICAL WIRING See wiring diagrams on the following two pages for

details.

Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to:

• USA- National Electrical Code, ANSI/NFPA 70.

• Canada - Canadian Electrical Code, Part I, CSA C22.1: Safety Standard for Electrical Installations.

THERMOSTAT INSTALLATION

Thermostat should be installed on an inside wall about four feet above the oor.

NEVER install a thermostat on an outside wall.

Do not install a thermostat where it will be affected by drafts, hot or cold pipes, sunlight, lighting xtures, televisions, a replace, or a chimney.

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

Instructions for the nal adjustment of the thermostat are packaged with the thermostat (adjusting heating anticipator, calibration, etc.)

Page 16

WIRING DIAGRAM - 24V STANDING PILOT

VR8200

VR8300

Page 17

WIRING DIAGRAM - INTERMITTENT IGNITION

Page 18

LIGHTING INSTRUCTIONS

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 any procedures are attempted on this appliance, determine if ignition system is electric or standing pilot. If you are uncertain, contact manufacturer before proceeding.

WARNING

Before lighting any type of pilot burner (standing or intermittent), make certain the hot water boiler and system are full of water

to minimum pressure of 12 psi in the system, and also verify system is vented of air. Set operating control of thermostat to “below” normal setting. Refer to following appropriate lighting instruction.

D. Do not use this appliance if any part has been under

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

water.

OPERATING INSTRUCTIONS FOR INTERMITTENT PILOT SYSTEM

STOP! Read the safety information to the left.

Set the thermostat to lowest setting.

Turn off all electric power to the appliance.

This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the

pilot by hand.

Figure 15 - Intermittent Pilot

LIGHTING PROCEDURE FOR BOILER WITH INTERMITTENT PILOT SYSTEM

For Your Safety, Read Before Operating!!

A. This appliance is equipped with an ignition device which

automatically lights the pilot. Do not try to light the appliance 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.

CAUTION

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.

10.

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

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

Turn gas control knob clockwise to “OFF.” Wait (5) minutes to clear out any gas. If you then smell

gas, STOP! Follow “What To Do If You Smell Gas” in the safety information to the left. If you don’t smell gas, go on to the next step.

Turn gas control knob counterclockwise to “ON.” Turn on all electric power to the appliance. Set thermostat to desired setting. If the appliance will not operate, follow the instructions

“

To Turn Off Gas To Appliance

call a qualied service technician or your gas supplier.

” on next page, and

C. Use only your hand to push in or turn the gas control

knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it. Call a qualied service technician. Force or attempted repair may

result in a re or explosion.

Page 19

LIGHTING INSTRUCTIONS

LIGHTING PROCEDURE FOR BOILER WITH CONTINUOUS PILOT

For Your Safety, Read Before Lighting!!

Read the warning at the beginning of "

Instructions

This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.

Before lighting, 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. See section " page

Use only your hand to push in or turn gas control knob or reset button. Never use tools. If the knob or reset button will not push in or turn by hand, don’t try to repair it, call a qualied service technician. Force or attempted repair may result in a re or explosion.

Do not use this appliance if any part has been under water. Immediately call a qualied service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

LIGHTING INSTRUCTIONS FOR CONTINUOUS PILOT

STOP! Read the safety information above.

Set the thermostat to the lowest setting.

Turn off all electric power to the appliance.

Remove access panel and burner door.

Turn gas control knob clockwise to "OFF."

(Figures 16 and 17)

What To Do If You Smell Gas

Lighting

" on previous

Figure 17 - Continuous Pilot

NOTE: Some gas control knobs cannot be turned from

"PILOT" to "OFF" unless knob is pushed in slightly. DO NOT FORCE.

Wait (5) minutes to clear out any gas. If you then smell gas, STOP! Follow " on previous page. If you don't smell gas, go to the next step.

Find pilot. Follow metal tube from gas control. Depending on the model of the boiler, pilot is either mounted on the base or on one of the burner tubes.

Turn gas control knob counterclockwise to "PILOT."

Push in gas control knob or reset button if so equipped, all the way in and hold. Immediately light the pilot with a match. Continue to hold the gas control knob or reset button in for about 1 minute after the pilot is lit. Release knob or button, and it will pop up back up. Pilot should remain lit. If it goes out, repeat steps 5 through

• If knob or button does not pop up when released, stop and immediately call a qualied service technician or your gas supplier.

What To Do If You Smell Gas

Figure 16 - Gas Control Knob

INLET

• If the pilot will not stay lit after several tries, turn

the gas control knob clockwise to "OFF." Call a qualied service technician or your gas supplier.

10.

Replace burner door.

11.

Turn gas control knob counterclockwise to "ON."

12.

Replace access panel.

13.

Turn on all electric power to the appliance.

14.

Set thermostat to desired setting.

TO TURN OFF GAS TO THE APPLIANCE

Set the thermostat to lowest setting.

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

Push in gas control knob slightly and turn clockwise

to "OFF." DO NOT FORCE.

Call a qualied service technician.

Page 20

NORMAL SEQUENCE OF OPERATION

On a call for heat, the thermostat will actuate, completing the circuit to the control. The completed circuit to the control will rst activate the circulator and damper which will close an end switch inside the damper. This action will complete the circuit to the ignition system and ignition will take place.

In the event the boiler water temperature exceeds the high limit setting on the boiler mounted high limit control, power will be interrupted between the control system and the ignition system. The power will remain off until the boiler water temperature drops below the high limit setting. The circulator will continue to operate under this condition until the thermostat is satised.

In the event the ow of combustion products through the boiler venting system becomes blocked, the blocked vent safety switch will shut the main burner gas off. Similarly, if the boiler ue-way becomes blocked, a ame rollout safety switch will shut the main burner gas off. Figure

18. If either of these conditions occur, DO NOT ATTEMPT TO PLACE THE BOILER BACK INTO OPERATION. CONTACT A CERTIFIED SERVICE AGENCY.

Burners

Figure 18 - Blocked Vent Safety Switch, Roll-out Safety Switch

Intergral Draft Hood

Burner

Door

Orices

Manifold

Base

Jacket Base

Panel

Blocked Vent Safety Switch

Rollout Switch 4 Section Boiler

R o l l o u t S w i t c h

2,3,5,6,7

Section Boiler

GENERAL INSTRUCTIONS

Before seasonal start-up, have a certied service agency check the boiler for soot and scale in the ues, clean the burners and check the gas input rate to maintain high

operating efciency.

CAUTION

Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing The service agency or owner should make certain the

system is lled with water to minimum pressure and open air vents, if used, to expel any air that may have accumulated in the system. Check the entire piping system and, if any leaks appear, have them repaired.

Circulators need to be checked and maintained. Refer to the circulator manufacturer's instructions.

The venting system should be inspected at the start of each heating season. Check the vent pipe from the boiler to the chimney for signs of deterioration by rust or sagging joints. Repair if necessary. Remove the vent pipe at the base of the chimney or ue and using a mirror, check vent for obstruction and make certain the vent is in good working order.

The boiler ue gas passageways may be inspected by a light and mirror. Remove the burner door. a trouble lamp in the ue collector through the draft relief opening. With the mirror positioned above the burners, the

ue gas passageways can be checked for soot or scale. The following procedure should be followed to clean the

ue gas passageways:

Figure 21

Remove the burners from the combustion chamber by raising the burners up from the manifold orices and pulling toward the front of the boiler.

Disconnect the vent pipe from the draft hood.

Remove the top jacket panel.

Remove the combination ue collector and draft hood from the boiler castings by loosening the nuts on the hold down bolts located on each side of the collector.

Figure 17

Place a sheet of heavy paper or similar material over the bottom of the base and brush down the ue passageways. The soot and scale will collect on the paper and is easily removed with the paper.

With the paper still in place in the base, clean the top of the boiler castings of the boiler putty or silicone used to seal between the castings and ue collector. Make certain that chips are not lodged in the ue

passageways.

Figure 21

. Place

Page 21

GENERAL INSTRUCTIONS

When the cleaning process is complete, restore the boiler

Figure 21 - Gas Burner Pilot

components to their original position. Use IS-808 GE silicone (available from a distributor) to seal around the ue collector and boiler castings.

A visual check of the main burner and pilot ames should be made at the start of the heating season and again in mid-season. The main burner ame should have a well dened inner blue mantel with a lighter blue outer mantel. Check the burner throats and burner orices for lint or dust obstruction.

Figures 20 and 21

Figure 19 - Gas Burner Flame

To adjust the pilot ame, remove the pilot adjustment cover screw and turn the inner adjustment screw

counterclockwise to increase or clockwise to decrease pilot ame. Be sure to replace cover screw after adjustment to prevent possible gas leakage. Figures 15 -

Figure 20 - Gas Burner Orices

17 on previous pages.

The burners and pilot should be checked for signs of

The pilot ame should envelop ⅜ to ½ inch of the tip of the pilot thermocouple, ignition/sensing electrode or mercury

sensor.

Figure 21.

Figure 20 - Combustion Chamber

corrosion, rust or scale buildup. The area around the boiler must be kept clear and free of combustible materials, gasoline and other ammable vapors and liquids.

The free ow of combustion and ventilating air to the boiler and boiler room must not be restricted or blocked.

Inspect eld sourced low water cutoffs annually, or as recommended by low water cutoff manufacturer. Flush

BURNERS

oat type low water cutoffs per manufacturer's instructions.

It is recommended that a qualied service agency be employed to make an annual inspection of the boiler and heating system. They are experienced in making the inspections outlined above, and, in the event repairs or corrections are necessary, trained technicians can make the proper changes for safe operation of the boiler.

GAS VALVE

ORIFICES

Page 22

CHECKING GAS INPUT RATE TO BOILER

Gas input to the boiler can be adjusted by removing the protective cap on the pressure regulator, and turning

the screw clockwise to increase input and counterclockwise to decrease input. The manifold

pressures are taken at the outlet side of the gas valve. To check for proper ow of natural gas to the boiler, divide the input rate shown on the rating plate by the heating value of the gas obtained from the local gas company. This will determine the number of cubic feet of gas required per hour. With all other gas appliances off, determine the ow of gas through the meter for two minutes and multiply by 30 to get the hourly rate. Make minor adjustments to the gas input as described

above. Figures 15-17.

Burner orices should be changed if the nal manifold pressure varies more than plus or minus 0.3 inches water column from the specied pressure.

Primary air adjustment is not necessary, therefore air shutters are not furnished as standard equipment. Air shutters can be furnished on request where required by local codes or conditions.

Figure 22 - High Limit Control Location

HIGH LIMIT

AND OPERATING

CONTROL

BURNER ACCESS

DOOR

GAS VALVE

CHECK SAFETY CONTROL CIRCUIT. Ignition system safety shutoff device must be tested after placing boiler in operation. (Figures 15-17 on previous pages)

1. Pilot: With main burner operating, turn the pilot gas adjusting screw clockwise until pilot gas

is turned off. Within 90 seconds the main gas control should close, shutting off the gas to the main burner.

2. High Limit Control: Remove cover and note temperature setting. Decrease this setting to minimum and operate boiler. When the boiler water temperature exceeds the control temperature setting, the control will open the circuit, closing the automatic main gas valve. Figure 22.

Page 23

BOILER BASE

DRAWN BY:

DATE:

REPLACEMENT PARTS - BASE

UTICA BOILERS, INC.

VTB REV: 1 A1520

4/28/97

NOTE: DO NOT ALTER THIS MASTER

PART NO.:

Item

BURNER TUBE 1 1/2"

BASE W/INSUL

BURNER DOOR -

Description Part # Qty.

- 50

- 75, 100 2

- 125, 150 3

- 175, 200 4

- 250 5

- 300 6

- 50

- 75, 100

- 125, 150

- 175, 200

- 250

- 300

75, 100

125, 150

175, 200

250

300

MANIFOLD - 50 356-2-1.01

MANIFOLD - 75&100 356-2-1.02

MANIFOLD - 125&150 356-2-1.03

MANIFOLD - 175&200 356-2-1.04

MANIFOLD - 250 356-2-1.05

MANIFOLD - 300 356-2-1.06

240005543

5611601

5611602

3001823

5611604

5611605

5611606

3261201

3262701

109008513

109008514

109008515

109008516

Item

SCREW ¼ - 20 X ½ SELF TAP HW-005.01

GAS VALVE VR8200H

GAS VALVE VR8200H - 50 - 300 24V LP

GAS VALVE VR8204H - 50 - 150 SPARK NAT

GAS VALVE VR8304H4 - 175-300 SPARK NAT

GAS VALVE VR8304 - 50-300 SPARK LP

Description Part # Qty.

50 - 150 24V NAT VG-003.05

VG00307

VG01101

VG01103

VG01104

GAS VALVE VR8300H4 - 250 & 300 24V NAT VG01201

GAS VALVE VR8300H4 - 175 & 200 24V NAT VG01202

ORIFICE 3.2mm NAT - 50, 100, 150, 200, 250, & 300

240007406

ORIFICE 3.0mm NAT - 175 240007404

ORIFICE 2.9mm NAT - 125 240007403

ORIFICE 2.8mm NAT - 75

ORIFICE #45 LP - 50

ORIFICE #47 LP - 100, 150, 200, 250, & 300

ORIFICE #49 LP - 125 & 175 355-1-5.06

240007402

3551520

355-1-5.04

ORIFICE #50 LP - 75 355-1-5.07

COMBUSTIBLE BASE FLOORING - 50

COMBUSTIBLE BASE FLOORING - 75, 100

COMBUSTIBLE BASE FLOORING - 125, 150

COMBUSTIBLE BASE FLOORING - 175, 200

NOT SHOWN

COMBUSTIBLE BASE FLOORING - 250

COMBUSTIBLE BASE FLOORING - 300

Orice Quantities: Model 50 - qty 1; Model 75 & 100- qty 2; Model 125 & 150-

325-2-8.01

325-2-8.02

325-2-8.03

325-2-8.04

325-2-8.05

325-2-8.06

qty 3; Model 175 & 200- qty 4; Model 250- qty 5; Model 300- qty 6.

Page 24

HEAT EXCHANGER

REPLACEMENT PARTS - HEAT EXCHANGER

Fully Assembled Heat Exchangers

912000001 Heat Exchanger (2 Section)

912000002 Heat Exchanger (3 Section)

912000003 Heat Exchanger (4 Section)

912000004 Heat Exchanger (5 Section)

912000005 Heat Exchanger (6 Section)

912000006 Heat Exchanger (7 Section)

ROLLOUT & SPILL SWITCH

Item # Description Part # Qty.

2 SECTION TEMP. SENSOR BRACKET 32611001

3 SECTION TEMP. SENSOR BRACKET

4 SECTION TEMP. SENSOR BRACKET

5-7 SECTION TEMP. SENSOR BRACKET

CONTROL-FIXED TEMPERATURE THERMO

(ROLLOUT SWITCH)

SCREW - #6 X ¼ HEX HD HW06501

Rollout switch is located on base and ue collector. NOTE: Quantities above are for each switch.

3262001 1

109008517 1

109008518 1

AQ02101

Page 25

DATE:

DRAWN BY:

PART NO.:

NOTE: DO NOT ALTER THIS MASTER

REV:

UTICA BOILERS, INC.

4/24/97

VTB 1 A1518

BOILER JACKET

REPLACEMENT PARTS - JACKET

Item

DESCRIPTION Part Number Qty.

PANEL - TOP 50 31621501

PANEL - TOP 75 & 100 31621502

PANEL - TOP 125 31621503

PANEL - TOP 150 31621504

PANEL - TOP 175 & 200 31621505

PANEL - TOP & 250 31621506

PANEL - TOP & 300 31621507

PANEL - LEFT 250-300 3162704

PANEL - LEFT (L)50-200 3162706

PANEL - LEFT (L)250-300 3162707

PANEL - LEFT 50-200 3162708

DRAFT DEFLECTOR 50 3162501

DRAFT DEFLECTOR 75/100 3162502

DRAFT DEFLECTOR 125/150 3162503

DRAFT DEFLECTOR 175/200 3162504

DRAFT DEFLECTOR 250 3162505

DRAFT DEFLECTOR 300 3162506

PNL LWR ACCES 50 109008534

PNL LWR ACCES 75/100 109008535

PNL LWR ACCES 125/150 109008536

PNL LWR ACCES 175/200 109008537

PNL LWR ACCES 250 109008538

PNL LWR ACCES 300 109008539

PANEL - BASE 50 3161201

PANEL - BASE 75 & 100 3161202

PANEL - BASE 125 & 150 109008530

PANEL - BASE 175 & 200 109008531

PANEL - BASE 250 109008532

PANEL - BASE 300 109008533

Item

PANEL - RIGHT 50-200 3162705

PANEL - RIGHT 225-300 3162703

PANEL - REAR 50 3162601

PANEL - REAR 75 & 100 3162602

PANEL - REAR 125 & 150 3162603

PANEL - REAR 175 & 200 3162604

PANEL - REAR 250 3162605

PANEL - REAR 300 3162606

FLUE COL 50 3462101

FLUE COL 75 3462108

FLUE COL 100 3462102

FLUE COL 125 3462107

FLUE COL 150 3462103

FLUE COL 175 3462109

FLUE COL 200 3462104

FLUE COL 250 109008527

FLUE COL 300 3462106

DAMPER 4" 50 240006936

DAMPER 5" 75 240006937

DAMPER 6" 100 & 125 240006938

DAMPER 7" 150 & 175 240006939

DAMPER 8" 200 & 250 240006940

DAMPER 9" 300 240006941

PNL- UPPER ACCESS 50 31621201

PNL- UPPER ACCESS 75&100 31621202

PNL- UPPER ACCESS 125 31621203

PNL- UPPER ACCESS 150 31621204

PNL- UPPER ACCESS 175 & 200 31621205

PNL- UPPER ACCESS 225 & 250 31621206

PNL- UPPER ACCESS 275 & 300 31621207

DESCRIPTION Part Number Qt y.

Page 26

STANDING PILOT

REPLACEMENT PARTS - PILOT

Spark Pilot Kit - Natural Gas 550001911 Spark Pilot Kit - LP/Propane 550001912

CONTINUOUS PILOT

Item Description Qty.

1 PILOT BRACKET ASSEMBLY 1

2 BRACKET SCREW 2

3 SPARK CABLE 1

PILOT TUBING, 1/8" x 24"

Natural Gas Q345A PILOT

LP Q345A Pilot

6 Pilot Shield 1

* Included with #3 - Pilot Tube Assembly Kit (above)

Continuous Pilot Kit - Natural Gas 550001926

Continuous Pilot Kit - LP/Propane 550001927

Item Description Qty.

1 PILOT BRACKET ASSEMBLY 1

2 BRACKET SCREW 2

3 THERMOCOUPLE Q309 1

PILOT TUBING, 1/8" x 24"

Natural Gas Q314A PILOT

LP Q314A Pilot

* Included with #3 - Pilot Tube Assembly Kit (above)

Page 27

PIPING & CONTROLS

REPLACEMENT PARTS - PIPING & CONTROLS

ITEM DESCRIPTION P/N QTY.

1 WIRE ROLLOUT/SPILL 28" 37513301 2

2 HARNESS IGN TO G/V 18" 37413602 1

3 PILOT IGNITION CABLE 30" PB00702 1

4 PIPE - NPL 1.1/4X4.1/2 NPT PF-006.07 1

5 DRAIN - SHORT HW-016.03 1

6 PIPE - TEE 1.1/4X3/4X1.1/4 PF-008.03 1

7 PIPE - 1.1/4" CLOSE NPL PF-006.01 1

8 WIRE LOW VOLTAGE/DAMPER 375-1-14.01 1

9 HARNESS CIRCULATOR 72" 37519501 1

10 CONTROL L8148E1257 (AQUASTAT) 1010002 1

11 RELIEF VALVE 30# VR-001.01 1

12 WELL 3/4"X3" AQ-020.01 1

13 GAUGE - THERALTIMETER GA-001.00 1

14 PIPE - NPL 3/4"X4" PF-005.11 1

15 PIPE - ELBOW 3/4" 90° PF-002.04 1

16 CLAMP #3600 WHITE EF03601 2

17 PLT SPARK CTRL S8600 PB00604 1

Page 28

Columbia Company

Main ofces and factory

Pottstown, PA