Columbia MCB-50J, MCB-75J, MCB-100J, MCB-125J, MCB-150J Installation, Operation & Maintenance Manual

Models

MCB-50J

MCB- 7 5J
MCB- 1 00J
MCB- 1 25J
MCB- 1 50J
MCB- 1 7 0J
MCB-200J

MCB SERIES II

Cast Iron Gas Fired Boilers

For Forced Hot Water

INST ALLATION, OPERA TION &

MAINTENANCE MANUAL

C.S.A. Certifi ed

For Natural Gas Or Propane

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com

Tested For 100 psi

Working Pressure

ASME

P/N 240009038, Rev. B [04/2012]

Figure 1 - Dimensions

DIMENSIONS

Table 1 - Dimensions

Boiler No.

50 ½" 11⅛"5½" 4" 30¾" 36¼" 5¾" 1¼"

75

100 ½" 15 7½" 6" 30¾" 37¼" 6" 1¼"
125 ½" 18⅞"9½" 6" 30¾" 37¼" 6" 1¼"
150 ½" 18⅞"9½" 7" 30¾" 37¾" 6¾" 1¼"
170 ½" 22¾"11½" 7" 30¾" 38¾" 6¾" 1¼"

200

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

Natural Gas

Inlet*

½" 15 7½" 5" 30¾" 37¾" 5¾" 1¼"

½" 22¾"11½" 8" 30¾" 38¾" 7¾" 1¼"

ABCDEF

Dimensions

Pump size Supply &

Return Tappings

2

TABLE OF CONTENTS

!

1 - Ratings & Data - Natural Gas & Propane Gas ..... 4

2 - Installation Procedure .................................... 5

3 - Ventilation & Combustion Air ........................... 6

4 - Connecting Supply and Return Piping ............... 7

5 - Vent Installation ...........................................12

6 - Vent System Modifi cation ...............................12

7 - Vent Damper Installation & Instructions ...........13

8 - Connecting Gas Service .................................14

9 - Electrical Section ..........................................15

10 - Wiring Diagram .........................................16

11 - Lighting Instructions ...................................17

12 - Normal Sequence of Operation .....................18

13 - General Instructions ....................................18

14 - Checking Gas Input Rate To Boiler .................20

15 - Control Function .........................................21

Safety Symbols & Warnings

The following defi 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

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

IMPORTANT: Read the following instructions
COMPLETELY before installing!!

WARNING

!

Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.

WARNING

!

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

DO NOT obstruct air openings to the boiler room.
Modifi cation, substitution or elimination of factory

equipped, supplied or specifi ed components may
result in personal injury or loss of life.

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

TO THE INSTALLER - Leave all instructions with
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

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

!

CAUTION

Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal
injury.

3

1 - RATINGS & DATA - NATURAL GAS & PROPANE GAS

Table 2 - Ratings and Capacities

Boiler

No.

(1)

Input

Mbh

(1)

Heating

Capacity Mbh

(2)

Net AHRI

Rating Water

Mbh AFUE

No.

of

Burners

(3)

Recommended

Air Cushion

Tank

Water

Content

(Gals.)
50J 50 52 36.3 83.5 1 15 2.4
75J 75 63 54.8 83.1 2 15 4.0

100J 100 83 72 83.0 2 30 4.0
125J 125 104 90 82.0 3 30 5.6
150J 150 124 107.8 83.0 3 30 5.6
170J 170 139 121 82.0 4 30 7.2
200J 200 165 143.4 82.0 4 30 7.2

EXPLANATORY NOTES

-- All boilers are design certifi ed for installation on noncombustible fl oor.

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

-- 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.

(2) Net AHRI 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, Intermittent Electric Ignition Pilot

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

4

2 - INSTALLATION PROCEDURE

!

WARNING

Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury

.

1.

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.

2.

Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically fi red Boilers,
ANSI/ASME CSD-1.

3.

Boiler series is classifi 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 applicable provisions of the local
building codes.

4.

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

4.9.

5.

Install boiler such that gas ignition system components
are protected from water (dripping, spraying, rain,
etc.) during appliance operation and service, (circulator
replacement, condensate trap, control replacement,
etc.).

6.

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

7.

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

8.

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.

!

WARNING

Fire hazard. Do not install boiler on combustible
fl ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.

9.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS
ONLY - For installation on combustible fl ooring special
base must be used. (See Repair Parts, Optional Kits
Manual). Do not install boiler 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 ................. 2 IN. (51mm)

NOTE: Greater clearances for access should supersede fire

protection clearances.
* Defi 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)

4"

9"

BOILER

Front

18"

5

3"

3 - 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
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

infi ltration rate is less than 0.40 air changes per
hour. See Table 3 for space with boiler only. Use
equation for multiple appliances.

3

Volume ≥ 50 ft

x Total Input [Mbh]

о Known Air Infi ltration Rate. See Table 3 for

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

• 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 in

2

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).

• 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.

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

о Refer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

Table 3 - Space With Boiler Only

Room Cubic Feet Volume

Input Mbh

Standard

Method

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

170 8500 35700 17850 11900 8925 7140 5950

200 10000 42000 21000 14000 10500 8400 7000

Known Air Infi ltration Rate Method (ACH - Air Changes Per Hour)

0.1 0.2 0.3 0.4 0.5 0.6

6

4 - CONNECTING SUPPLY AND RETURN PIPING

!

WARNING

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

Discharge line shall:

• connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum
distance from fl 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 (191°C); or greater.

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

Figure 2 - Safety Relief Valve

RELIEF VALVE

DISCHARGE

LINE

Check local

codes for

maximum

distance

from fl oor

or allowable

safe point of

discharge.

7

4 - CONNECTING SUPPLY AND RETURN PIPING

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

Figure 3 ­See Special Conditions, Page 9

Circulators Mounted on Supply System, Boiler Used In Confi guration with Chiller System.

1.

Boiler used in connection with refrigeration system,
install so chilled medium is piped in parallel with boiler
with appropriate valves to prevent chilled medium from
entering boiler. See Figure 2.

2.

Boiler piping system of 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 fl ow control valves or other automatic
means to prevent gravity circulation of boiler water
during cooling cycle.

3.

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

4.

Boiler connected to heating system utilizing multiple
zoned circulators, each circulator must be supplied with
fl ow control valve to prevent gravity circulation.

5.

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

6.

Bypass piping is optional which gives ability to
adjust supply boiler water temperature to fi t system
or condition of 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

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

systems. Figures 4 and 5.

B. These methods are used to protect systems using

radiant panels and material they are encased in
from high temperature supply water from boiler

and protect boiler from condensation.

NOTE#1: When using bypass piping, adjust

valves V1 & V2 until desired system temperature
is obtained. See Figure 5, page 9.

NOTE#2: Bypass loop must be same size piping

as supply and return piping.

8

4 - CONNECTING SUPPLY AND RETURN PIPING

Figure 4 - Bypass Piping With Mixing Valve

TO SYSTEM

WATER INLET

EXPANSION

TANK

FROM SYSTEM

CIRCULATOR

SHUT-OFF
VALVE

PRESSURE
REDUCER VALVE

CHECK VALVE

BOILER

BALL VALVE

3 WAY MIXING
VALVE

ALTERNATE

CIRCULATOR

LOCATION

Figure 5 - Bypass Piping - Fixed Low Temp Only With Zone Valve

TO SYSTEM

BOILER

V2V1

ALTERNATE

CIRCULATOR

LOCATION

SYSTEM

CIRCULATOR

WATER INLET

EXPANSION

TANK

AIR SEPARATOR

HOSE BIB

FROM SYSTEM

CIRCULATOR

SHUT-OFF
VALVE

7. Installation using circulators and zone valves are

shown in Figures 6 through 9. For further piping
information refer to AHRI Installation and Piping
Guide.

PRESSURE
REDUCER VALVE

CHECK VALVE

BALL VALVE

ZONE VALVE

AIR SEPARATOR

!

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. See

Warning, Page 7.

9

4 - CONNECTING SUPPLY AND RETURN PIPING

Figure 6 - Single Zone System With DHW

Figure 7 - Multi Zone System With Circulators And DHW

10

4 - CONNECTING SUPPLY AND RETURN PIPING

Figure 8 - Multi Zone System With Zone Valves And DHW (With Circulator)

Figure 9 - Multi Zone System With Zone Valves And DHW (With Zone Valve)

11

5 - VENT INSTALLATION

WARNING

!

Boiler and venting installations shall be performed
by a qualifi ed expert and in accordance with the
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
to fi re or to asphyxiation from poisonous gases such
as carbon monoxide with is odorless and invisible.

!

WARNING

Do not connect boiler to any portion of mechanical
draft system operating under positive pressure.

1.

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

2.

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

3.

Boiler series is classifi 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 applicable provisions of the local
building codes.

4.

Inspect chimney. Verify chimney is constructed
according to NFPA 211. 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).

5.

Connect fl 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 fl ue pipe or reduce size of
fl ue outlet except as provided by the latest revision of
ANSI Z223.13. Protect combustible ceiling and walls
near fl ue pipe with fi reproof insulation. Where two or
more appliances vent into a common fl ue, the area of
the common fl ue must be at least equal to the area
of the largest fl ue plus 50 percent of the area of each
additional fl ue.

6 - 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.

1.

Seal an unused opening 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 defi 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 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 fi 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 fl 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, fi 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.
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.

12

7 - VENT DAMPER INSTALLATION & INSTRUCTIONS

DAMPER INSTALLATION

Follow Damper installation instructions provided with

damper. See Figure 10.

Figure 10 - Damper Motor Wiring

DAMPER INSTRUCTIONS

Figure 11 - Vent Damper Placement

UN-ACCEPTABLE
DAMPER LOCATIONS

REFER TO DAMPER MANUFACTURER'S
INSTALLATION INSTRUCTIONS FOR
POSITION OF DAMPER
CONTROL BOX

ACCEPTABLE VENT
DAMPER LOCATIONS

CHIMNEY

BOILER

1.

Verify only boiler is serviced by Vent Damper. Figure

HOT WATER HEATER

11.

2.

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.

3.

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

4.

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

5.

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

13

8 - CONNECTING GAS SERVICE

!

!

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.

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

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

Figure 12 - Gas Piping

General

• Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements National Fuel gas Code, ANSI Z223.1/
NFPA 54

• Size and install gas piping system to provide suffi cient
gas supply to meet maximum input at not less than
minimum supply pressure. See Table 4.

• 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
liquefi ed petroleum gas.

• Install fi eld sourced manual main shutoff valve, ground
joint union, and sediment trap upstream of gas valve.
See Figure 12.

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.

½” ¾” 1” 1¼”

Nominal Iron Pipe Size

!

DANGER

Fire Hazard. Do not use matches, candles, open
fl 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 fl uid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open fl ames, or other methods
providing ignition source.

•

Correct leaks immediately and retest.

14

9 - 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
National Electrical Code, ANSI/NFPA 70.

THERMOSTAT INSTALLATION

1.

Thermostat should be installed on inside wall about
four feet above fl oor.

2.

NEVER install thermostat on outside wall.

3.

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

4.

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

5.

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

15

10 - WIRING DIAGRAM

Figure 13 -

Modifi cation, substitution or elimination of factory
equipped, supplied or specifi ed components may
result in personal injury or loss of life.

Integrated High Limit Electronic Ignition Control (240008781)

!

WARNING

16

11 - LIGHTING INSTRUCTIONS

!

!

WARNING

If you do not follow these instructions
exactly, a fi re or explosion may result
causing property damage, personal injury
or loss of life.

• This appliance is equipped with an ignition device

which automatically lights burner. Do NOT try to

light this burner by hand.

• Before operating smell all around appliance area
for gas. Be sure to smell next to fl oor because
some gas is heavier than air and will settle to the
fl oor.

• Use only your hand to turn the gas shutoff
valve. Never use tools. If valve will not turn

by hand, do not try to repair it, call a qualifi ed
service technician. Force or attempted repair may
result in fi re or explosion.

• Do not use this appliance if any part has
been under water. Immediately call a qualifi ed

service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.

OPERATING INSTRUCTIONS FOR INTERMITTENT
PILOT SYSTEM

1.

STOP! Read the safety information to the left.

2.

Set the thermostat to lowest setting.

3.

Turn off all electric power to the appliance.

4.

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

Figure 16 - Intermittent Pilot

NOTICE

5.

6.

Before lighting any type of pilot burner (standing or
intermittent), verify the hot water boiler and system
are full of water to minimum pressure of 12 psi in
the system, also verify system is vented of air. Set
operating control of thermostat to “below” normal
setting. Refer to following appropriate lighting
instruction.

LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEM

A. This appliance is equipped with an ignition device which

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

!

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 phone in your building.

• Immediately call your gas supplier from a

7.

8.

9.

10.

TO TURN OFF GAS TO THE APPLIANCE

1.

2.

3.

4.

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

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

service technician or your gas supplier.

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 qualifi ed service technician.

” , and call qualifi ed

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

17

12 - NORMAL SEQUENCE OF OPERATION

Thermostat actuates on call for heat,
completing circuit to control. Completed
circuit to control will fi rst activate circulator
and damper which will close end switch inside
damper. Completes circuit to ignition system,
ignition takes place.

In event boiler water temperature exceeds
high limit setting on boiler mounted high limit
control, power is interrupted between control
system and ignition system. Power remains
off until boiler water temperature drops below
high limit setting. Circulator continues to
operate under this condition until thermostat is
satisfi ed.

In event fl ow of combustion products through
boiler venting system becomes blocked, blocked
vent safety switch shuts main burner gas off.
Similarly, if boiler fl ue-way becomes blocked,
fl ame rollout safety switch shuts main burner

gas off. Figure 16. If either of these conditions
occur, DO NOT ATTEMPT TO PLACE BOILER

BACK INTO OPERATION. CONTACT
CERTIFIED SERVICE AGENCY.

Intergral Draft
Hood

Burner

Door

Burners

Orifi ces

Figure 17 - Blocked Vent Safety Switch, Roll-out
Safety Switch

Blocked Vent
Safety Switch

Rollout Switch
4 Section Boiler

Base

Jacket Base
Panel

Rollout Switch

2,3,5

Section Boiler

13 - GENERAL INSTRUCTIONS

Before seasonal start-up, have a certifi ed service agency
check boiler for soot and scale in fl ues, clean burners and
check gas input rate to maintain high operating effi ciency.

!

WARNING

This procedure should be followed to clean fl ue gas
passageways:

1.

Label all wires prior to disconnection when servicing
controls. Wiring errors could cause improper and
dangerous operation.

Verify proper operation after servicing
Service agency will verify system is fi lled with water to

minimum pressure and open air vents, if used, to expel any
air accumulated in the system. Check entire piping system
and, if any leaks appear, have them repaired.

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

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

Boiler fl ue gas passageways may be inspected by a light
and mirror. Remove burner door.
lamp in fl ue collector through draft relief opening. With
mirror positioned above burners, fl ue gas passageways can
be checked for soot or scale.

Figure 17

. Place trouble

2.

3.

4.

5.

6.

When cleaning process is complete, restore boiler
components to their original position. Use IS-808 GE
silicone (available from distributor) to seal around fl ue
collector and boiler castings.

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

Disconnect vent pipe from draft hood.

Remove top jacket panel.

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

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

With paper still in place in base, clean top of boiler
castings of boiler putty or silicone used to seal between
castings and fl ue collector. Verify chips are not lodged
in fl ue passageways.

Figure 19

.

Figure 17

.

18

13 - GENERAL INSTRUCTIONS

Figure 18 - Gas Burner Flame

Figure 19 - Combustion Chamber

BURNERS

ORIFICES

GAS VALVE

• Make visual inspection of main burner and pilot fl ames
at start of heating season and again in mid-season. Main
burner fl ame should have well defi ned inner blue mantel
with lighter blue outer mantel. Check burner throats and
burner orifi ces for lint or dust obstruction.

Figures 18

and 19.

• Pilot fl ame should envelop ⅜ to ½ inch of tip of ignition/
sensing electrode. See

Figure 20.

• To adjust pilot fl ame, remove pilot adjustment cover
screw and turn inner adjustment screw counterclockwise

to increase or clockwise to decrease pilot
fl ame. Be sure to replace cover screw after adjustment to
prevent possible gas leakage. See Figure 16, Page 19.

• Check burners and pilot for signs of corrosion, rust or
scale buildup.

• Area around boiler must be kept clear and free of
combustible materials, gasoline and other fl ammable
vapors and liquids.

• Free fl ow of combustion and ventilating air to boiler and
boiler room must not be restricted or blocked.

• Inspect fi eld sourced low water cutoffs annually, or
as recommended by low water cutoff manufacturer.
Flush fl oat type low water cutoffs per manufacturer's
instructions.

• Employ a qualifi ed service agency to make annual
inspection of boiler and heating system. They are
experienced in making the inspections outlined above,
and, in event repairs or corrections are necessary,
trained technicians make the proper changes for safe
operation of the boiler.

Figure 20 - Gas Burner Pilot

19

14 - CHECKING GAS INPUT RATE TO BOILER

• Adjust gas input to boiler by removing protective cap on
pressure regulator
increase input and counterclockwise

,

and turning screw clockwise to

to decrease

input.

• Manifold pressures are taken at outlet side of gas
valve.

• To check for proper fl ow of natural gas to boiler, divide
input rate shown on rating plate by heating value of
gas obtained from local gas company. This determines
number of cubic feet of gas required per hour.

• With all other gas appliances off, determine fl ow of gas
through meter for two minutes and multiply by 30 to
get hourly rate.

• Make minor adjustments to gas input as described
above. See Figure 16 page 18.

• Change burner orifi ces if fi nal manifold pressure
varies more than plus or minus 0.3 inches water
column from specifi ed pressure listed on boiler
rating plate.

• Primary air adjustment is not necessary, therefore
air shutters are not furnished as standard
equipment.

Figure 21 - High Limit Control Location

HIGH LIMIT

AND OPERATING

CONTROL

BURNER ACCESS

DOOR

GAS VALVE

CHECK SAFETY CONTROL CIRCUIT. Test ignition

system safety shutoff device after placing boiler in
operation.

1.

Intermittent Pilot: With main burner operating, turn

Figure 15 page 19.

pilot gas adjusting screw clockwise until pilot
gas is turned off. Within 90 seconds main gas control
closes, shutting off gas to main burner.

2.

High Limit Control: Remove plastic cover and

note temperature setting. Refer to appendix A for
adjustment procedure. Decrease setting to minimum
and operate boiler. When boiler water temperature
exceeds control temperature setting, control will open

circuit, closing automatic main gas valve. Figure 21.

20

15 - CONTROL FUNCTION

1

HI TEMP illuminates when boiler water temperature

reaches high limit setting and remains lit until water
temperature falls 10°. Prevents burner operation while this
LED is on.

2

LWCO Active Indicates low water cut-off (LWCO)

function of limit control is active. When control is installed

with a well, LED is on at all times when control is powered.

Important: If control is installed with a well other than
Electro-Well, LED will not illuminate indicating control is not
providing low water cut-off functionality.

!

WARNING

Burn and scald hazard. Do not add water until boiler
has fully cooled. Failure to follow these instructions
could result in death or serious injury.

LWCO Low Water illuminates if boiler is in low water

3

condition. Limit control prevents burner operation during
this condition.

Important: Have system checked by qualifi ed service
agency prior to resuming operation.

ECONOMY Active Indicates thermal targeting function

4

is active and limit control is reducing boiler temperature to
conserve fuel. Economy feature is activated using Economy
dial.

ECONOMY TARGET Economy feature is active, limit

5

control continually sets target temperatures below high
limit setting to maximize fuel effi ciency. When boiler water
reaches target temperature, LED illuminates and burner
shuts down. Boiler water will continue to circulate and heat
the house as long as thermostat call continues. LED will
stay lit until boiler temperature drops below differential set
point at which point boiler will be allowed to fi re again.

Note: LED illuminates regularly during normal boiler
operation.

6

LWCO TEST Button

To Test Low Water Cut-Off: Press and hold Test/Settings
button for 5 seconds. Display will read LWCO.

LWCO TEST
Red Low Water light will illuminate and burner circuit (B1

and B2) will de-energize.
Note: Control must be installed with Electro-Well for low

water cut-off functionality.

LCO

21

NOTES

Date Service Performed Company Name & Tech Initials Company Address & Phone #

COLUMBIA BOILER COMPANY

Main offi ces and factory

Pittstown, PA