GAS FIRED BOILERS FOR STEAM HEATING Columbia Boiler Company Main Offices and Factory: Pottstown, PA INST ALLA TION MANU AL AND OPERA TING INSTR UCTIONS INSTALLA ALLATION MANUAL OPERATING INSTRUCTIONS CEG-C
TABLE OF CONTENTS Safety Symbols & Warnings ................................................................................. Page 1 Installation Procedure ........................................................................................... Page 2 Ventilation and Combustion Air ...................................................................... Pages 3-4 Connecting Supply and Return Piping ............................................................... Page 5-6 Vent Installation ..................
Safety Symbols The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels. DANGER DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
INST ALLA TION PR OCEDURE INSTALLA ALLATION PROCEDURE WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. 1. The installation must conform to the requirements of the authority having jurisdiction or, in absence of such requirements, to the latest revision of the National Fuel Gas Code, ANSI Z223.1. (Available from the American Gas Association, Pleasant Valley Road, Cleveland, Ohio 44134.
VENTILA TION & COMB USTION AIR VENTILATION COMBUSTION WARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT BE OBSTRUCTED. BY FOLLOWING THE INSTRUCTIONS BELOW, ADEQUATE COMBUSTION AIR CAN BE MAINTAINED * Unconfined area: A space whose volume is not less than 50 cubic feet per 1000 BTU per hour of all appliances installed in that space (cubic feet of space = height x width x length).
5. When the boiler is installed in a confined space and all air is provided from the outdoors the confined space shall be provided with one or two permanent openings according to methods A or B. When ducts are used, they shall be of the same cross sectional area as the free area of the area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3 x 3 inches or 9 square inches. A.
input rating of all equipment located in the enclosure. The free area must be no less than the sum of the areas of all vent connectors in the confined space. 6. In calculating free area using louvers, grilles or screens for the above, consideration shall be given to their blocking effect. Screens used shall not be smaller than 1/4 inch mesh. If the free area through a design of louver or grill is known, it should be used in calculating the size opening required to provide the free area specified.
SUGGESTED PIPING FOR A MODULAR STEAM BOILERS PUMPED RETURNS FIGURE 6a GRAVITY RETURNS FIGURE 6b PAGE 6
VENT INST ALLA TION INSTALLA ALLATION WARNING: This boiler shall not be connected to any portion of a mechanical draft system operating under positive pressure. 1. The vent pipe must slope upward from the boiler not less than 1/4 inch for every 1 foot to the vent terminal. 2. Horizontal portions of the venting system shall be supported rigidly every 5 feet and at elbows. No portion of the vent pipe should have dips or sags. 3.
VENT SY STEM MODIFICA TION SYSTEM MODIFICATION When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for the proper venting of the appliances remained connected to it.
VENT D AMPER INST ALLA TION DAMPER INSTALLA ALLATION AND INSTRUCTIONS INSTALLATION NOTE: REFER TO FIGURE 8 BELOW FOR STEPS 1-7 1. Place Vent Damper on or as close to vent outlet of boiler as possible. 2. Remove Locknut from connector at the free end of the Damper wire harness. 3. Feed Damper connector and Damper wire harness through bracket hole on Damper Motor frame. 4. Replace and tighten locknut onto Damper wire harness connector. 5. Plug Damper connector into socket on Damper Motor frame.
CONNECTING GAS SER VICE SERVICE Connect gas service meter to control assembly in accordance with the latest revision of ANSI Z223.1 and local codes or utility. A ground joint union should be installed for easy removal of gas control for servicing. A drip or trap must be installed at the bottom of a vertical section of piping at the inlet to the gas valve. A pipe compound resistant to the action of liquefied petroleum gases must be used on all threaded pipe connections.
THERMOST AT INST ALLA TION THERMOSTA INSTALLA ALLATION 1. Thermostat should be installed on an inside wall at least two feet from an uninsulated or outside wall, approximately four feet above the floor. 2. NEVER install a thermostat on an outside wall. 3. Do not install a thermostat where it will be affected by: A. Drafts B. Hot or cold pipes C. Sun light D. Lighting fixtures E. Television F. Fireplace or chimneys 4.
C. Use only your hand to push in or turn 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 qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and gas control which has been under water.
E. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. CONTINUOUS PILOT GAS VALVE LIGHTING INSTRUCTIONS FOR CONTINUOUS PILOT SYSTEM 1. Stop! Read the safety information at the beginning of this manual. 2. Set thermostat to lowest setting. 3. Turn off all electric power to the appliance. FIGURE 12 4.
NORMAL SEQ UENCE OF OPERA TION SEQUENCE OPERATION On a call for heat: 1.) The thermostat will actuate completing the circuit between T and T. 2.) The damper will then open thus closing the end switch completing the circuit, and ignition will begin. 3.) In the event that the boiler steam pressure exceeds the pressure control setting, the pressure control will interrupt the circuit to the boiler ignition system. The power will remain off until the steam pressure drops below the pressure control setting. 4.
CONNECTING SUPPL Y AND SUPPLY RETURN PIPING PIPING,, WATER CHILLED MEDIUM 1. When the boiler is used in connection with refrigerated system, connect supply and return piping as suggested in figure 14 below. A. The chilled medium MUST BE IN PARALLEL with the boiler. B. Use appropriate valves to prevent the chilled medium from entering the heating boiler. a. During heating cycle open valves A and B. Close valves C and D. b. During cooling cycle open valves C and D. Close valves A and B. C.
GENERAL INSTRUCTIONS Before seasonal start up it is advisable to have a competent service agency check the boiler for soot and scale in the flues, clean the burners, and check the gas input rate to maintain high operating efficiency. On steam boilers make certain the boiler is filled to the water line as indicated in figure 15. The gauge cocks should be normally open. To remove dirt from the gauge glass the petcock may be opened to flush out the glass. WARNING: DISCHARGE WILL BE BOILING HOT WATER.
TO CLEAN THE BOILER FL UEW AYS: FLUEW UEWA 1. Remove the burners from the combustion chamber by raising the burners upward from the manifold orifices and pulling toward the front of the boiler. To remove the burner with the pilot burner attached, first disconnect the pilot line tubing and thermocouple or pilot generator leads at the main electric gas valve. Do not remove the pilot line tubing at the pilot as the pilot burner orifice may drop out and become damaged or lost. 2.
4. Electronic Low Water Cut-off: Operation may be checked by opening the drain valve in the back side of the boiler. This will drain the water from the boiler and break the electronic circuit to the automatic gas valve. IMPURITIES IN BOILER WATER of a steam boiler may cause foaming and an unsteady water line, or prevent steam generation. They may result in objectionable odors escaping from the vents on water boilers.
CHECKING AND ADJUSTING THE GAS IGNITION COMPONENTS The gas input to the boiler can be adjusted by removing the protective cap on the pressure regulator, see figure 16 on page 19 , and turning screw clockwise t o increase input and counterclockwise to decrease input. Natural gas manifold pressure should be set at approximately 3.5 inches water column. Propane gas manifold pressure should be set at approximately 10 inches water column.
The free flow of combustion and ventilation air to the boiler and boiler room should not be restricted or blocked. It is suggested that a qualified 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, can make the proper changes for safe operation of the boiler. Optional parts WC-001.00 WC-004.01 WC-005.
CEG-C REPLA CEMENT P AR TS - B ASE REPLACEMENT PAR ARTS BASE ITEM # PART # 1 3542202 3542203 3542204 3542205 3542206 3542207 VG-008.07 DESCRIPTION MANIFOLD CEG112C MANIFOLD CEG150C MANIFOLD CEG187C MANIFOLD CEG225C MANIFOLD CEG262C MANIFOLD CEG300C 2 GAS VALVE VR8200H-3000 CEG112 & 150 24V VG01102 GAS VALVE VR8204-3010 CEG112&150 SPARK VG01103 GAS VALVE VR8304H4206 CEG187 - 300 SPARK VG01201 VR8300H4006 CEG262C CEG187 - 300 24V 3 352-1-1.03 GAS ORIFICE #47-NATURAL 352-1-1.
CEG-C REPLA CEMENT P AR TS - J ACKETS REPLACEMENT PAR ARTS JA ITEM PART # NUMBER 1 2 3 4 5 31423001 31422802 31422803 31422804 31422805 31422806 31422807 31421002 31421003 31421004 31421005 31421006 31421007 31423002 3442702 3442703 3442704 3442705 3442706 3442707 DESCRIPTION OTY.
CEG-C REPLA CEMENT P AR TS - HEA T EX CHANGER REPLACEMENT PAR ARTS HEAT EXCHANGER ITEM PART # NUMBER 1 100-2-15.01 2 100-2-14.01 CEG112C - (2), CEG 225 -(5), DESCRIPTION OTY. E-Left Hand Section E-Center Section 1 CEG150 - (3), CEG262 - (6), CEG150 - (6), CEG262 - (12), DESCRIPTION OTY. 13 HW-003.02 NUT-1/4-20 HEX SLT 14 HW-008.01 WASH 5/16 FLAT STL ZP 4 2 (Fully assembled heat exchangers.
CEG-C REPLA CEMENT P AR TS - FR ONT P ANEL CONTR OLS REPLACEMENT PAR ARTS FRONT PANEL CONTROLS ITEM PART # NUMBER 1 GA-004.00 2 PF-033.02 3 WCO1901 DESCRIPTION GAUGE WTR LEVEL PIPE FIT NPL 1/2"X4" ELWCO PS-802U-24 WITH PROBE 4 HW-006.02 POP RIVIT FLUE 3/16" 5 32421901 SENSOR BRACKET 6 AQ02101 CONTROL FIXED TEMP (ONE ON DRAFT HOOD) 7 37513301 WIRE - ROLL OUT 8 HW06501 SCR 6X1/4" SLOT OTY. ITEM PART # NUMBER 1 1 1 2 1 2 1 2 9 10 11 12 13 14 15 16 17 FIGURE 24 PAGE 24 DESCRIPTION 753-1-3.
CEG-C REPLA CEMENT P AR TS - ELECTRICAL REPLACEMENT PAR ARTS ITEM NUMBER PART NUMBER DESCRIPTION OTY. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EF-013.01 37414401 37424501 PB00702 37413602 PB00604 37413201 37413801 EF03601 37413002 37413001 3641601 37413101 3641501 ELEC. J-BOX 4X4X1/2 WIRE PRES. SWITCH TO J-BOX 34" HARNESS-ELWCO TO J-BOX 18" IGN WIRE 30" CIDE MODELS ONLY HARNESS IGN. MOD.
37411601 PAGE 26 REV: 8, December 2001 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW *A.G.A Heating Net I=B=R** Gas Dimensions WATER CONTENT Annual Fuel Boiler Input Capacity Steam Rating Inlet (GALLON CAPACITY) Utilization Efficiency Number Btu/Hr. Btu/Hr. Btu/Hr. Sq. Ft. Size A B C D E F G To Water To LWCO (AFUE) & Damper & Damper Line Line Elect Ign Std. Pilot CEG112C 112,500 90,000 67,500 281 1/2 14.1/4 27.5/8 24.1/8 5 3.1/2 6 44.3/4 4.8 3.0 81.0 78 CEG150C 150,000 120,000 90,000 375 1/2 17.1/8 28.
