GAS-FIRED STEAM BOILERS COLUMBIA COMPANY Main offices and Factory: Pottstown, PA INSTALLATION, OPERATION & MAINTENANCE MANUAL Models CEGDID075D CEGDID112D CEGDID150D CEGDID187D CEGDID225D CEGDID262D CEGDID299D MODEL CEGDID Electronic Intermittent Ignition Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13504-4729 web site: www.ecrinternational.com P/N# 240009573, Rev.
DIMENSIONS Figure 1 - Dimensions A 25" Depth C Safety Relief Valve 2" NPT 2" NPT ½" NPT Plug 16⅝" 2" NPT 2" NPT 29" B 12⅜" 5½" 13½" Floor Table 1 - Physical Data Models 075 112 150 187 225 262 299 Width (A) 10 7/8 14 1/8 17 3/8 20 5/8 23 7/8 27 1/8 30 3/8 35 7/8 Height (B) Depth (C) Gas Connection Size (G) Flue Diameter 28 3/8 28 3/8 29 3/8 30 3/8 30 3/8 30 3/8 30 3/8 ½ NPT ½ NPT ½ NPT ¾ NPT ¾ NPT ¾ NPT ¾ NPT 5" 5" 6" 7" 7" 7" 7" 2
BOILER RATINGS AND CAPACITIES Table 2 Ratings and Capacities Natural Gas & Propane (LP) Boiler Model Number Input MBH (1) Heating Capacity MBH (1) CEG075DID 75 CEG112DID Net AHRI Rating (2) Steam, MBH Steam, Sq. Ft. AFUE, % No. of Sections Vent Pipe Size 62 47 195 82.2 3 5" 112 93 70 292 82.4 4 6" CEG150DID 150 125 94 391 82.6 5 6" CEG187DID 187 156 117 488 82.8 6 7" CEG225DID 225 188 141 587 83.0 7 7" CEG262DID 262 219 164 685 83.
TABLE OF CONTENTS Important Safety Information....................... 5 Introduction Locating the Boiler ...................................... 6 Boiler is designed for use in closed heating systems where all steam is returned as condensate and make-up water is minimal. Boiler is not designed for or intended for use in open systems using 100% make-up water. Hydronic Piping .......................................... 7 Fresh Air for Combustion ............................
IMPORTANT SAFETY INFORMATION General Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements to the National Fuel Gas Code, Boiler and venting installation shall be completed by qualified agency. ANSI Z223.1/NFPA 54. ! WARNING Where required by authority having jurisdiction, installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
LOCATING THE BOILER Locating the Boiler 1. Select level location as centralized with piping system, Figure 2 - Minimum Clearances To Combustible Construction 6” and as near chimney as possible. 2. Place crated boiler at selected location. Remove all crate material. Please recycle responsibly. ! WARNING Fire hazard. Do not install boiler on combustible flooring or carpeting. Failure to follow these instructions could result in death or serious injury. Boiler Opposite Side 7” 3.
HYDRONIC 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 safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum distance from floor or allowable safe point of discharge. • Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line.
HYDRONIC PIPING 5. Recommended near boiler piping for gravity return Consider near boiler piping as part of the boiler for proper water level control and to produce dry steam. systems is shown in Figure 7 page 10. For gravity return systems, bottom of lowest steam carrying pipe, dry return or end of steam main, must be at least 28” above normal water level line on left side of boiler. 6. Equip all boilers in gravity return systems with Hartford Loop as shown in Figure 5a and 5b page 9. 7.
HYDRONIC PIPING Figure 5a - Recommended Near Boiler Piping Using One Supply Tapping Main Vent Sections Risers Headers Equalizers 3 2" 2" 1½ 4 2" 2" 1½ Header 28" 24" Cap To Skimmer Tee Water Line 2" Close Nipple 24" Equalizer 1½" For Alternate Piping Floor Configurations See Page 27 Figure 5b - Recommended Near Boiler Piping Using Two Supply Tappings Main Vent Header 28" Sections Risers Headers Equalizers 5 (2) 2" 2" 1½ 6 (2) 2" 2" 1½ 7 (2) 2" 2½" 1½ 8 (2) 2" 3 1½
HYDRONIC PIPING Figure 6 - Recommended Near Boiler Piping For Pumped Return Systems Figure 7 - Recommended Near Boiler Piping For Gravity Return Systems 10
FRESH AIR FOR COMBUSTION ! WARNING C. Refer to National Fuel Gas Code for opening requirements between connected indoor spaces. Air openings to combustion area must not be obstructed. Follow instructions below, to maintain adequate combustion air • All Outdoor Air. Provide permanent opening(s) communicating directly or by ducts with outdoors. A. Two Permanent Opening Method. Provide opening commencing within 12 inches of top and second opening commencing within 12 inches of bottom of enclosure.
CHIMNEY AND VENT PIPE CONNECTION 4. Boiler is equipped with factory wired harness that plugs ! WARNING Installing or venting a boiler or any other gas appliance with improper methods or materials could result in death or serious injury due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible. 5. 6. 7. Boiler and venting installations shall be performed in accordance with "Venting of Equipment", of the National Fuel Gas Code, ANSI Z223.
CHIMNEY AND VENT PIPE CONNECTION 3. Insofar as is practical, close all building doors and 4. 5. 6. 7. 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 appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan.
VENT DAMPER OPERATION Check vent damper and all flue product carrying areas of boiler annually for deterioration from corrosion or other sources. If you see corrosion or other deterioration, contact your service agent for repairs. Check vent damper operation as follows: 1. When boiler is off, check vent damper positions indicator points to closed position. See Figure 11. 2. Turn thermostat or controller up to call for heat and check vent damper indicator points to open position See Figure 11. 3.
GAS SUPPLY PIPING ! CAUTION ! WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. Fire Hazard. Do not use matches, candles, open flames, or other methods providing ignition source. Failure to comply will result in death or serious injury. • 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.
ELECTRICAL WIRING Thermostat Installation 1. Install thermostat on inside wall per manufacturer's ! 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. instructions. 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 fixtures, televisions, fireplace, or chimney.
OPERATING INSTRUCTIONS For Your Safety Read Before Operating 1. STOP! Read the safety information on this page. ! WARNING 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 If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. automatically lights the pilot. Do not try to light the pilot by hand.
OPERATING YOUR BOILER Thermostat ! WARNING A. Set thermostat to desired room temperature. B. Set thermostat to lower setting if heat is not required C. System is self-checking. If failure of any component system will not operate or will go into safety lockout. D. On call for heat, each component must function properly to permit operation. E. Turn thermostat to lowest setting for one minute and back to normal setting to reset on safety lockout. Burn Hazard. Never run water into a hot empty boiler.
CHECKING AND ADJUSTING Adjust Pilot Burner Figure 14 - Pilot Burner Pilot flame should surround 3/8” to 1/2” of pilot sensor. See Figure 14. To adjust Flame. 1. Remove screw cover over pilot adjusting screw. See Figure 13. 2. Insert small screwdriver and adjust flame as needed. Turn screw counterclockwise to increase flame, clockwise to decrease. 3. Replace screw cover over pilot adjusting screw.
CHECKING AND ADJUSTING Adjust Steam Pressure Control Checking Controls • Steam pressure limit control (pressuretrol) shuts off gas to main burners when steam pressure in boiler reaches cut-off setpoint (i.e. sum of cut-in and differential setpoints). Low Water Cut-Off A. Turn off power to boiler or turn thermostat down to lowest setting. B. Drain water to below visible bottom of water gauge glass. Turn power on and turn thermostat to call for heat. C.
START-UP CLEANING 8. Following final blow-down, allow boiler to cool. ! WARNING • Add fresh water slowly up to normal water line. Following service procedures must be performed by qualified service agent. Boiler owner shall not attempt these steps. Failure to do so could result in death or serious injury. • Start burners. • Maintain at least 180°F for 15 minutes to remove dissolved gasses from fresh water. • Shut off burners.
GENERAL MAINTENANCE Low Water Cut-Off Boiler Water Treatment Other Than Cleaners Low Water Cut-Off interrupts electrical current to burner when water line in boiler drops to low level. Check Low Water Cut-Off monthly to verify it is providing proper protection. See “Checking and Adjusting” on page 20. Remove Low Water Cut-Off probes beginning of each heating season for inspection and cleaning. More cleaning may be required on boilers requiring frequent additions of make up water.
TROUBLESHOOTING You may avoid inconvenience and service calls by checking these points before you call for 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 fire department.
WIRE DIAGRAMS Figure 16 - Isolation Relay Wiring For Steam Boilers With Probe Type Low Water Cut Off And Using An Electronic Thermostat - Optional C R W TO BLOCKED VENT SWITCH Figure 17 - Water Feeder Connection - Optional Optional water feeder connection. • Connect feeder N to terminal 2. • Connect feeder H to terminal 1. • Connect "FEED" or "W" to terminal A. • For water feeders with 2 leads, connect feeder common to terminal 2 and feeder hot to terminal A.
WIRE DIAGRAMS (For full-sized Wire Diagrams, see Literature Envelope.) Figure 18 - Wiring Diagram For Boilers With CG 400-2060 Probe Type Low Water Cut-Off 4 YEL 3 2 BLK BRN 1 ORG VENT DAMPER LOW WATER CUT OFF BLK BRN (W) T YEL ORG WHT (R) T BLK JP2 JP1 2 P1 FACTORY INSTALLED JUMPER 1 NEC CLASS 2 NEC CLASS 2 LOW VOLTAGE LOW VOLTAGE FIELD SUPPLIED FIELD SUPPLED THERMOSTAT THERMOSTAT P2 A BURNER BLOCKED VENT SWITCH PROBE WHT BLK WHT BLK PRESSURETROL CUT IN WHT BLK .1 KG/2 CM 2 0.
WIRE DIAGRAMS (For full-sized Wire Diagrams, see Literature Envelope.
OPTIONAL PIPING HYDRONIC PIPING Figure 20 - Counter Flow Steam Systems 2" Pipe 28" 24" Water Line 48" 24" Floor Floor Figure 21 - Drop Header for True Swing Joint 28" 24" Water Line Hartford Loop 24" Floor 27
Columbia Company Main offices and factory Pottstown, PA
