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Columbia LV Series, Installation, Operation & Maintenance Manual

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Columbia LV Series Installation, Operation & Maintenance Manual Download Page 3

Contents

Homeowner / Installer Policy

i

Product Features

1

Model Specifications

2

Model Dimensions

2

Installation

3

Operation

13

Maintenance

16

Trouble Shooting

17

Preliminary Settings

23

Parts List

27

Burner Service Set-Up Records

28

Product Features

•  ASME Coded Boiler Registered with National Board
•

Fully Insulated Heat Exchanger with Powder-Coated Cabinet

•

Available with Burner Swing Door

•

Equipped with Triple Aquastat, Circulator, and Temperature / Altitude Gauge

•

Outfitted with Additional Nozzles to Achieve a Variety of Heat Inputs

•

Provided with a Lifetime Limited Warranty

Figure 1

Summary of Contents for LV Series

Page 1: ...Low Volume Boiler LV Boiler LVD Direct Vent Boiler Installation Operation Maintenance Manual COLUMBIA COLUMBIA BOILER CO OF POTTSTOWN POTTSTOWN PENNSYLVANIA 19464 LV Series COLUMBIA ...

Page 2: ...years of trouble free comfort In order to maintain peak performance of your boiler it is recommended that your boiler be maintained annually Servicing of your appliance must be performed by a qualified oil heating technician A properly trained oil technician will be prepared to set your boiler burner combination with the proper tools necessary to achieve your maximum comfort and efficiency As a fa...

Page 3: ...s List 27 Burner Service Set Up Records 28 Product Features ASME Coded Boiler Registered with National Board Fully Insulated Heat Exchanger with Powder Coated Cabinet Available with Burner Swing Door Equipped with Triple Aquastat Circulator and Temperature Altitude Gauge Outfitted with Additional Nozzles to Achieve a Variety of Heat Inputs Provided with a Lifetime Limited Warranty Figure 1 ...

Page 4: ...DRAFT LOSS INCHES 05 08 10 0 05 0 065 0 08 WATER CONTENT 5 5 GAL 5 5 GAL 5 5 GAL 8 GAL 8 GAL 8 GAL BOILER HEIGHT w AQUASTAT 25 25 25 25 25 25 JACKET WIDTH 19 1 8 19 1 8 19 1 8 19 1 8 19 1 8 19 1 8 HYDRONIC SUPPLY HEIGHT 20 1 2 20 1 2 20 1 2 20 1 2 20 1 2 20 1 2 BURNER HEIGHT TO 9 3 8 9 3 8 9 3 8 9 3 8 9 3 8 9 3 8 HYDRONIC RETURN HEIGHT 5 5 5 5 5 5 FLUE OUTLET DIAMETER 5 5 5 5 5 5 A JACKET DEPTH 25...

Page 5: ...tructure Over sizing will result in short cycling and inefficient operation IV BOILER LOCATION A Boiler to be installed in a level position with clearances in accordance with NFPA 31 Table 10 6 1 STANDARD CLEARANCES Model LV 75 100 110 LV125 135 150 Front 12 24 Sides 12 6 Rear 2 6 Chimney Connector 2 18 Floor Approved for installation on combustible flooring B Reduced clearance installations shall...

Page 6: ... CHIMNEY VENT APPLICATIONS The unit must be installed where provisions exist for combustion and ventilation air Ordinarily provisions may be furnished by the following methods A Utility Room or Closet In buildings of tight construction including most modern homes you should provide an opening connecting to a well ventilated attic crawl space or directly with the outdoors The opening should have a ...

Page 7: ...e of discharge b Install the limit control in the 3 4 fitting provided in the boiler c Install the altitude temperature gauge in the 1 4 fitting provided in the coil plate B Packaged Boiler Controls are installed and pre wired at the factory Burners on models 75 100 110 are shipped in a separate box To install the burner follow the burner manufacturer s instructions included with the burner then c...

Page 8: ... of the house is turned off Always consult the tank water heaters installation and operation manual for proper supply piping sizes location of T P relief valve and any other information relating to the proper installation of the tank A thermal expansion tank may be required on those tanks which are equipped with check valves or back flow preventers on the cold water supply X BURNER AND CONTROLS A ...

Page 9: ...SED FOR A BALANCING VALVE 4 THE FLOW CONTROL VALVE MAY BE REPLACED BY ZONE VALVES 5 ALL PIPING MUST COMPLY WITH ALL STATE AND LOCAL CODES 6 CONSULT HOT WATER TANK MANUFACTURERS LITERATURE FOR TANK PIPING n l m n n n n k k n BURNER DOOR T A GAUGE RELIEF VALVE AQUASTAT AIR VENT OR EXPANSION TANK DRAIN VALVE FILL VALVE STOP VALVE CIRCULATOR RETURN THERMOSTATIC OR MANUAL BYPASS SUPPLY FLOW CONTROL VAL...

Page 10: ...AL DIAGRAM FOR LV SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO BECKETT CHIMNEY VENT BURNERS ELECTRICAL DIAGRAM FOR LV SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO RIELLO CHIMNEY VENT BURNERS ...

Page 11: ...AL DIAGRAM FOR LV SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO CARLIN CHIMNEY VENT BURNERS ELECTRICAL DIAGRAM FOR LVD SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO BECKETT DIRECT VENT BURNERS ...

Page 12: ...CAL DIAGRAM FOR LVD SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO RIELLO DIRECT VENT BURNERS ELECTRICAL DIAGRAM FOR LVD SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO CARLIN DIRECT VENT BURNERS ...

Page 13: ...tting In no case should the post purge timing be reduced to less than 1 minute Length of Vent Kit Minimum Post Purge Time 0 10 Feet 1 Minute 10 1 15 Feet 1 Minute 15 1 20 Feet 2 Minutes Times are approximate and should be considered minimum settings for the length of intake pipe installed The length of post purge may be increased on those units using the Beckett AFII or Riello BF 5 oil burners to ...

Page 14: ...ints should be avoided C In Line Oil Filter The oil filter should be of a generous capacity It should be located inside the building between the tank shut off valve and the burner A shut off valve and the oil filter should be located as close to the burner as possible for ease of servicing D Oil Shut Off Valve Install manual oil shut off valves at the burner and near the tank on the supply line Bo...

Page 15: ... sunlight Connect the thermostat leads to the TT terminals on the circulator control XV WARRANTY The limited warranty is not applicable unless these installation instructions are followed Operation I START UP DO NOT START UNLESS CLEAN OUT DOORS ARE IN PLACE A Make sure service switch to boiler is off B Make sure boiler has been filled with enough water until the entire system has been purged and d...

Page 16: ...n Air Reduce the air supply to allow just sufficient air for clean combustion This is accomplished by loosening the lock screws on the air shutter and closing the air shutter until a trace of smoke is recorded Take a CO2 sample Open the air shutter lowering CO2 about 1 1 2 to 2 A zero smoke reading should result If this adjustment cannot be obtained refer to the trouble shooting section in this ma...

Page 17: ...s not available erratic operation noisy combustion and fuel odors in the air may result Remember that venting fans or a vented dryer will greatly increase the need for outside air C Filter Replace the cartridge filter in the line every year to avoid fuel unit and nozzle contamination D Area Around Boiler The area around the boiler should be kept clean and free of any combustible materials particul...

Page 18: ... scale and any soot deposits with a flexible 2 flue brush Be careful not to damage the front or rear insulation F Replace the fire tube baffles G Reinstall the door and tighten with the 8 brass nuts H Reinstall the jacket panel I Turn on all electrical power to the boiler DO NOT REMOVE THE REAR COVER AND REAR REFRACTORY FOR NORMAL MAINTENANCE SOOT OR SCALE MUST BE REMOVED FROM THE FRONT BURNER OPE...

Page 19: ...sistance across cad cell Primary Check for line voltage between Control the black and white leads No voltage indicates no power to the control Check for line voltage between orange and white leads No voltage indicates a faulty control Burner Check for voltage at the black and white leads to the burner motor Voltage indicates power to motor and a fault in the burner Open cad cell wires Dirty cell f...

Page 20: ...ure Motor overloads Coupling worn or broken Pump discharge pressure set too low No spark or weak spark Line voltage below 102V Carboned and shorted electrodes Eroded electrode tips Incorrect electrode settings Cracked porcelain insulators Plugged orifice or distributor Plugged nozzle strainer Poor spray pattern Incorrect nozzle installed Air shutter open too far Air band open too far Fill tank Str...

Page 21: ...ontrol is working properly Thermostat Check thermostat settings and calibration FlowValve Check to see if flow valve is operating properly Circulator does not stop running Thermostat set too high Thermostat defective Thermostat out of calibration Flow valve dirty and stuck Flow valve defective Repair operating control Reset thermostat Replace thermostat Recalibrate Check level Clean flow valve Rep...

Page 22: ... tank Fuel supply valve closed Restriction in oil line Plugged fuel filter Plugged pump strainer Cold oil Too much combustion air Pump discharge pressure incorrectly set Coupling worn or broken Pump worn low pressure motor overloads Incorrect draft setting Leak in flue system Weak fluid Plugged orifice or distributor Plugged nozzle strainer Poor spray pattern Replace nozzle with specified nozzle R...

Page 23: ...allation Improper adjustment Air leak in fuel system Compression fittings Water in oil tank Pump discharge pressure incorrectly set Coupling worn or broken Pump worn low pressure motor overloads Plugged orifice or distributor Plugged nozzle strainer Poor spray pattern Plugged heat exchanger Install vent cap Increase draft setting Reduce draft settings install second draft regulator if necessary Mo...

Page 24: ... control defective Circulator too small Circulator defective Insufficient voltage Settings too low Bad location due to heat build up Out of calibration Flow valve not opening fully Radiators airbound Radiators inadequate Boiler too small Piping inadequate Insufficient heat transfer Insufficient pump pressure Wrong nozzle installed Nozzle underfiring due to defective nozzle Replace coupling Replace...

Page 25: ...___ ________________________ ________________________ INSTALLER SERVICEMAN Model Number LV 75 LV 100 LV 110 Burner Type Beckett Beckett Beckett Burner Model AFG AFG AFG Nozzle Type 65 80A 85 80A 90 80A Pump Pressure PSI 140 140 140 Head Pin Position F 3 F 4 F 6 Air Band 1 1 1 5 Air Shutter 10 OPEN 10 OPEN 10 OPEN Draft Over Fire 0 to 1 0 to 1 0 to 1 Draft In Stack 0 02 0 02 0 02 CO2 Reading 10 11 ...

Page 26: ... ________________________ ________________________ ________________________ INSTALLER SERVICEMAN Model Number LVD 75 LVD 100 LVD 110 Burner Type Carlin Carlin Carlin Burner Model EZ 1 EZ 1 EZ 1 Nozzle Type 65 60 A 85 60 A 90 60 A Pump Pressure PSI 140 140 140 Head Pin Position 0 75 0 85 1 00 1 10 1 25 Air Band 0 50 0 85 0 75 Air Shutter N A N A N A Draft Over Fire 0 to 1 0 to 1 0 to 1 Draft In Sta...

Page 27: ..._____________________ ________________________ ________________________ ________________________ INSTALLER SERVICEMAN Model Number LV 125 LV 135 LV 150 Burner Type Carlin Carlin Carlin Burner Model EZ 1 EZ 1 EZ 1 Nozzle Type 1 00 60B 1 10 60B 1 25 60B Pump Pressure PSI 140 140 140 Head Pin Position 1 1 1 25 1 35 1 5 1 35 1 5 Air Band 1 25 1 35 1 50 Air Shutter N A N A N A Draft Over Fire 0 to 1 0 ...

Page 28: ...oke Reading ZERO NOTICE Above settings are approximate Final adjustments to be made with proper test equipment Be sure all oil lines are air free and the use of flare fittings is recommended See installation ser vice manual for detailed information ________________________ ________________________ ________________________ ________________________ ________________________ ________________________ _...

Page 29: ...hown Burner Door Cast Door Complete 280260 280260 Not Shown Insulation for Cast Burner Door 337810 337810 Not Shown Cast Frame Gasket 337811 337811 6 Target Wall Insulation 337816 337816 7 Rear Door 280269 280269 8 Front Jacket Panel 501070 Kit 502280 9 Rear Jacket Panel 501080 10 Left Jacket Panel 501100 11 Right Jacket Panel 501090 12 Top Jacket Panel 501065 13 Aquastat 552110 552110 14 Temperat...

Page 30: ...ed Nozzle Yes No 11 Clean Pump Filter Yes No 12 Inspect Coil Gasket 13 Check for Leaks plugs fittings 14 Brush Clean Flue Tube Passages 15 Vacuum Chamber Flue Tubes 16 Clean Blower Wheel 17 Check Set Electrodes See pump pressure according to the installer serviceman labels for Series I and II boilers located at the end of this manual BURNER SERVICE SET UP RECORDS ...

Page 31: ...le Yes No 11 Clean Pump Filter Yes No 12 Inspect Coil Gasket 13 Check for Leaks plugs fittings 14 Brush Clean Flue Tube Passages 15 Vacuum Chamber Flue Tubes 16 Clean Blower Wheel 17 Check Set Electrodes See pump pressure according to the installer serviceman labels for Series I and II boilers located at the end of this manual BURNER SERVICE SET UP RECORDS ...

Page 32: ...o 11 Clean Pump Filter Yes No 12 Inspect Coil Gasket 13 Check for Leaks plugs fittings 14 Brush Clean Flue Tube Passages 15 Vacuum Chamber Flue Tubes 16 Clean Blower Wheel 17 Check Set Electrodes See pump pressure according to the installer serviceman labels for Series I and II boilers located at the end of this manual BURNER SERVICE SET UP RECORDS CC 5106 01 08 250 ...

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