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40

HEAT EXCHANGER

COMPLETE HEAT EXCHANGER ASSEMBLY

HEAT EXCHANGER 2 SECTION - 50

912000001

HEAT EXCHANGER 3 SECTION - 100

912000002

HEAT EXCHANGER 4 SECTION - 125 &150

912000003

HEAT EXCHANGER 5 SECTION - 200

912000004

REPLACEMENT PARTS

Summary of Contents for CDVB-100

Page 1: ...Columbia Company Main offices and Factory Pottstown PA P N 37616101 Rev F 05 2012 CDVB SERIES Gas Fired Boilers For Forced Hot Water INSTALLATION OPERATION MAINTENANCE MANUAL ...

Page 2: ...dification 11 Horizontal Vent Pipe Installation Instructions 12 Vertical Vent Pipe Installation Instructions 22 Connecting Gas Service 28 Electrical Wiring 29 Lighting Instructions 31 Sequence Of Operation 32 General Instruction For Seasonal Startup Maintenance 33 Replacement Parts 37 GAS FIRED BOILERS FOR FORCED HOT WATER DANGER Indicates a hazardous situation which if not avoided WILL result in ...

Page 3: ...tts Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited to installation by licensed plumber or gas fitter 9 FOR INSTALLATION ON NON COMBUSTIBLE FLOORS ONLY Boiler must NOT be installed on carpeting 10 Minimum clearances to combustible constructions are TOP 18 in 457mm FRONT 6 in 152mm FLUE CONNECTOR 6 in 152mm REAR 4 in 102mm CONTROL SID...

Page 4: ...r each 1 000 ft above sea level BOILER RATINGS CAPACITIES DIMENSIONS WARNING All installations of boilers and venting should be done only by a qualified expert and in accordance with the appropriate utica boilers manual Installing or venting a boiler or any other gas appliance with improper methods or materials may result in serious injury or death due to fire or to asphyxiation from poisonous gas...

Page 5: ...tion extensive piping systems etc STANDARD EQUIPMENT Boiler Jacket Cast Iron Boiler Battery Combination Aquastat Relay Theraltimeter Gauge Circulator Main Gas Burners Electric Ignition System A S M E relief Valve Drain Valve Induced Draft Fan and Safety Pressure Switch All boilers are design certified for installation on non combustible floors For installation on combustible floors use combustible...

Page 6: ... Air Provide permanent opening s communicating directly or by ducts with outdoors о 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 encl...

Page 7: ...ity circulation 6 Hot water boilers and system must be filled with water and maintained to minimum pressure of 12 psi IMPORTANT Circulators in following illustrations are mounted on system supply side but mounting on system return side is also acceptable practice CONNECTING SUPPLY RETURN PIPING 7 Bypass piping is option which gives ability to adjust supply boiler water temperature to fit system or...

Page 8: ...GE SUPPLY RETURN 4 WAY MIXING VALVE ZONE CIR WATER FEED Figure 3 MIXING VALVE PIPING ZONE CIR VALVE FLOW VALVE EXPANSION TANK VALVE SYSTEM TEMPERATURE GAUGE RETURN SUPPLY A B 6 FEED WATER Figure 2 BYPASS PIPING CONNECTING SUPPLY RETURN PIPING ...

Page 9: ... using circulators is shown in figure 5 9 Installation using zone valves is shown in figure 6 10 For further piping information refer to the I B R Installation and Piping Guide CIRCULATOR VALVE EXPANSION TANK VALVE RETURN SUPPLY 12 MAX CIRCULATOR FLOW VALVE SYSTEM TEMPERATURE GAUGE B A SYSTEM PRIMARY 6 FEED WATER CONNECTING SUPPLY RETURN PIPING Figure 4 PRIMARY SECONDARY PIPING WITH BYPASS ...

Page 10: ... 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 WARNING Burn and scald hazard Safety relief valve could discharge steam or hot water during operation Install discharge piping per these instructions...

Page 11: ...OLD WATER VALVE TANK ZONE 6 6 PRESSURE REDUCING VALVE BACKFLOW PREVENTER REDUCED PRESSURE GATE VALVE CONNECTING SUPPLY RETURN PIPING Figure 5 Piping with Circulator Figure 6 Piping with Zone Valves WARNING All installations of boilers and venting should be done only by a qualified expert and in accordance with the appropriate installation manual Installing or venting a boiler or any other gas appl...

Page 12: ...g 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 resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code ANSI Z2...

Page 13: ...d may result in rapid deterioration of the venting system a potential health hazard 3 Faulty vent installation can allow toxic fumes to be released into living areas This may cause serious bodily injury or property damage Vent performance may also be affected by improper assembly 4 Install separate vents for forced exhaust appliances and natural draft appliances A common vent between natural draft...

Page 14: ...ow 5 ft 1 5m Example 20 feet 6m of vent pipe w 1 elbow is equivalent to 15 feet 4 6m of vent pipe w 2 elbows Note condensate trap is not required on models DV150 thru 200 E Slope horizontal runs upwards not less than 1 4 inch foot 21mm m from boiler to vent terminal F No portion of the vent pipe should have dips or sags where condensate could collect see figure 9 on page 14 for a typical vent syst...

Page 15: ...15 HORIZONTAL VENT INSTALLATION INSTRUCTIONS Figure 9 Figure 7a Vent Cap Figure 7b Figure 8 ...

Page 16: ...ondensate tee drain is only needed when horizontal vent lengths exceed 10 feet 3m 2 Insert vent pipe in boiler venter outlet vent adapter apply silicone completely around edge of outlet and tighten clamp HORIZONTAL VENT INSTALLATION INSTRUCTIONS ...

Page 17: ...1 Condensate tee drain is only needed when horizontal vent lengths exceed 10 feet 3m 2 Insert vent pipe in boiler venter outlet vent adapter apply silicone completely around edge of outlet and tighten clamp Figure 11 Flex L Star 34 Vent Pipe Components ...

Page 18: ...2 Heat Fab Saf T Vent Vent Pipe Components Notes 1 Condensate tee drain is only needed when horizontal vent lengths exceed 10 feet 3m 2 Insert vent pipe in boiler venter outlet vent adapter apply silicone completely around edge of outlet and tighten clamp ...

Page 19: ...e 13 Z Flex Z Vent Vent Pipe Components Notes 1 Condensate tee drain is only needed when horizontal vent lengths exceed 10 feet 3m 2 Insert vent pipe in boiler venter outlet vent adapter apply silicone completely around edge of outlet and tighten clamp ...

Page 20: ... Condensate tee drain is only needed when horizontal vent lengths exceed 10 feet 3m 2 Insert vent pipe in boiler venter outlet vent adapter apply silicone completely around edge of outlet and tighten clamp Figure 14 ProTech FasNSeal Vent Pipe Components ...

Page 21: ... 12 inches 30cm above finished grade or at least 12 inches 30cm 18 46cm Canada above the normally expected snow accumulation level in geographical areas where snow accumulates 4 feet 1 2m away from and not above any doors or windows At least 3 feet 0 9m above any forced air inlet located within 6 feet 1 8m horizontally At least 6 feet 1 8m from combustion air intake of another appliance Vent termi...

Page 22: ...22 HORIZONTAL VENT INSTALLATION INSTRUCTIONS Figure 16 Termination Clearances ...

Page 23: ...t possible for best performance The designer must consider the building s orientation answering these questions Ref pages 24 27 A Will the vent terminate outside the building where its operation could be adversely affected by winds B Could any adjacent buildings adversely affect vent operation C Allowing for these factors can reduce the possibility of downdraft conditions If your local experience ...

Page 24: ...g in damage injury or death WARNING Do not use unlined masonry chimneys These increase risk of condensate formation which may cause chimney to deteriorate allowing combustion products to collect in structure resulting in damage injury or death G VENT TERMINATION Terminate all vertical vents with a listed vent cap or roof assembly unless local codes require otherwise See vent cap or roof assembly m...

Page 25: ...ge Table 4 Roof Pitch Chart Roof Pitch Height Above Roof Brace Flat to 7 12 1 0 ft 0 3m Over 7 12 to 8 12 1 5 ft 0 5m Over 8 12 to 9 12 2 0 ft 0 6m Over 9 12 to 10 12 2 5 ft 0 8m Brace to Roof at top Over 10 12 to 11 12 3 3 ft 1 0m Over 11 12 to 12 12 4 0 ft 1 2m Over 12 12 to 14 12 5 0 ft 1 5m Brace to Roof at Top and Mid Point Over 14 12 to 16 12 6 0 ft 1 8m Over 16 12 to 18 12 7 0 ft 2 1m Over ...

Page 26: ...ry chimneys previously used for venting equipment should be suitably per NFGC standard Also provide an accessible clean out per the latest revision of the NFGC ANSI Z2231 AND NFPA 54 1 1 Vent Inspection A Make sure existing vent or chimney is the proper size and construction for appliances that will use it The best way to do this is to size as if it were a new installation Compare the existing ven...

Page 27: ...atural Draft Water Heater 40 000BTU Hr MODEL D1 D2 D2 MIN MAX DV50 4 4 4 DV100 4 5 6 DV125 150 4 6 8 DV175 200 4 7 8 NOTE Information contained in this figure is only one of many possible vertical venting configurations Follow appropriate sections of NFGC for proper venting practice for category 1 appliances ...

Page 28: ...28 Figure 24 Category I Vent Using Hart Cooley Type B Gas Vent or Equivalent VERTICAL VENT PIPE INSTALLATION INSTRUCTIONS ...

Page 29: ... 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 ...

Page 30: ...d intermittent ignition wiring for boilers with fail safe relay See figure 26 WIRING CODE KEY LINE VOLTAGE BY FACTORY LOW VOLTAGE BY FACTORY LINE VOLTAGE BY INSTALLER LOW VOLTAGE BY INSTALLER COMPONENT KEY CODING Thermostat millivolt TH 1 Thermostat 24 Volt TH 2 Thermostat Line Voltage TH 3 Transformer 120V 24V 40VA TR 1 Transformer 120V 24V 50VA TR 2 24 Volt Gas Valve LGV 24 Volt Gas Valve LGV 1 ...

Page 31: ...31 PILOT PILOT ELECTRICAL WIRING Figure 26 HOT WATER CONTROL AND INTERMITTENT IGNITION WIRING ...

Page 32: ...switch Do not use any phone in your building 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 fire department C Use only your hand to move the system control switch Never use tools If the switch will not move by hand don t try to repair it call a qualified service technician Force or attempted repair ma...

Page 33: ...e limit If limit circuit is closed the venter motor and TF 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 TF 2 and the intermittent ignition control 6 The intermittent ignition control opens the pilot valve and ignites pilot After pilot is proven the main burner wil...

Page 34: ...necessary Remove the vent pipe from the boiler and check for obstructions 5 Clean condensate tee trap Periodic cleaning of the condensate collection system is required When a condensate collection system is installed in a venting system it is recommended that the cleaning become a part of the annual servicing VENT PIPE ELBOW VENT SYSTEM FOR LENGTHS 15 AND UNDER VENT SYSTEM FOR LENGTHS OVER 15 COND...

Page 35: ...ts paint thinner and other such flammable vapors and liquids 10 The free flow of combustion and ventilating air to the boiler and boiler room must not be restricted or blocked 11 Some circulators require periodic servicing These circulators usually have oil cups or openings at each end of the motor and one for the shaft bearing Put about one teaspoon of SAE 20 or 30 non detergent motor oil in each...

Page 36: ...ff the gas supply to all other appliances except the boiler B With the boiler operating determine the flow of gas through the meter for two minutes and multiply by 30 to get the hourly rate in cubic feet C Divide the input rate shown on the rating plate by the heating value of the gas as obtained from the local gas company This will determine the number of cubic feet of gas required per hour D If ...

Page 37: ...UT SWITCH AQ02101 1 3 SCREW 6 X HEX HD HW06501 2 The rollout switch is located on the base NOTE The quantities above are for each switch PILOT Spark Pilot Kit Natural Gas 550001911 Spark Pilot Kit LP Propane 550001912 Item Description Qty 1 PILOT BRACKET ASSEMBLY 1 2 BRACKET SCREW 2 3 SPARK CABLE 1 4 PILOT TUBING 1 8 x 24 1 5 NATURAL GAS Q345A PILOT 1 LP Q345A PILOT 6 PILOT TEMPERATURE SHIELD 1 In...

Page 38: ...2 1 01 1 MANIFOLD 100 356 2 1 02 MANIFOLD 125 150 356 2 1 03 MANIFOLD 200 356 2 1 04 Item Description Part Qty 5 SCREW 3 8 HEX HW005 01 4 6 GAS VALVE VR8204H 1006 50 150 SPARK NAT VG01101 1 GAS VALVE VR8304H 4206 200 SPARK NAT VG01103 GAS VALVE VR83043216 50 200 LP VG01104 7 ORIFICE3 2mm 50 100 150 200 240007406 ORIFICE 2 9mm 125 240007404 ORIFICE 47 LP 50 100 150 200 240007403 ORIFICE 49 LP 125 2...

Page 39: ...FRONT 125 150 315 2 19 03 PANEL FRONT 200 315 2 19 04 3 PANEL BASE 50 315 2 12 01 1 PANEL BASE 100 315 2 12 02 PANEL BASE 125 150 315 2 12 03 PANEL BASE 200 315 2 12 04 4 PANEL RIGHT 50 200 3162701 1 5 PANEL SEPARATOR 50 31522401 1 PANEL SEPARATOR 100 31522402 PANEL SEPARATOR 125 150 31522403 PANEL SEPARATOR 200 31522404 REPLACEMENT PARTS ...

Page 40: ...NGER COMPLETE HEAT EXCHANGER ASSEMBLY HEAT EXCHANGER 2 SECTION 50 912000001 HEAT EXCHANGER 3 SECTION 100 912000002 HEAT EXCHANGER 4 SECTION 125 150 912000003 HEAT EXCHANGER 5 SECTION 200 912000004 REPLACEMENT PARTS ...

Page 41: ... X 4 NPT 1 1310002 1 4 DRAIN SHORT HW 016 03 1 5 PIPE TEE 1 X X 1 1510001 1 6 HARNESS CONTROL LIMIT 38 37518901 1 7 GAUGE THERALTIMETER 1260006 1 8 CONTROL L4080B AQ02201 1 9 WELL X 3 AQ 020 01 1 10 RELIEF VALVE 30 VR 001 01 1 11 PIPE ELBOW 90 1190001 1 12 PIPE NPL X 4 1310001 1 3 4 5 7 8 9 10 11 12 6 2 1 REPLACEMENT PARTS ...

Page 42: ...ELAY 1410001 1 6 9 TERM STRIP EF04001 1 7 SCREW 10 32X5 16 GREEN GROUND HW09001 1 8 PRESSURE SWITCH FS6205A 2413 50B 150B SS00801 1 PRESSURE SWITCH FS6273A 3065 200B ONLY SS00802 1 9 HW TUBE SIL ORANGE 1 8ID HW09701 1 FULLY ASSEMBLED CONTROL BRACKET CONTROL BRACKET SUB ASSY 50B 150B 31522901 CONTROL BRACKET SUB ASSY 200B 31522902 P N 31522901 31522902 INCLUDE PART 1 8 ALL WIRING REPLACEMENT PARTS ...

Page 43: ...ECTOR 100 34524804 FLUE COLLECTOR 125 34524805 FLUE COLLECTOR 150 34524806 FLUE COLLECTOR 200 34524808 2 VENT ADAPTER 50 100 125 345 2 7 01 1 VENT ADAPTER 150 200 345 2 7 02 3 VENTER MOUNTING PLATE 50 ONLY 34524902 1 4 HW SCR 20x HW 005 01 5 5 VENTER 50 200 DC00402 1 6 BOLT 5 16 18 x 1 14695039 2 REPLACEMENT PARTS ...

Page 44: ...Columbia Company Main offices and factory Pottstown PA ...

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