Columbia CDVB SERIES Owner's manual

Co l u m b i a bo i l e r Co m p a n y
Main ofces and Factory: Pottstown, PA
P/N 37616101, Rev. C [02/09]
CDVB SERIES
Gas Fired Boilers For Forced Hot Water
INSTALLATION, OPERATION &
MAINTANANCE MANUAL

2
TABLE OF CONTENTS
KEEP THIS MANUAL NEAR BOILER AND
RETAIN FOR FUTURE REFERENCE.
GAS FIRED BOILERS FOR FORCED HOT WATER
Tested for 100 lbs.
ASME Working Pressure
H
C.S.A. Certied for
Natural gas or Propane
SAFETY SYMBOLS
IMPORTANT: Read the following instructions
COMPLETELY before installing!
The following dened symbols are used throughout this manual to notify the reader of potential hazards of varying
risk levels.
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
DANGER
!
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious
injury or substantial property damage.
WARNING
!
Indicates a potentially hazardous situation which,
if not avoided, could result in minor or moderate
injury or property damage.
CAUTION
!
Indicates special instructions on installation,
operation or maintenance which are important
but not related to personal injury hazards.
NOTICE
Introduction..........................................................................................................................................4
Boiler Ratings, Capacities & Dimensions ............................................................................................5
Ventilation & Combustion Air ...............................................................................................................7
Connecting Supply & Return Piping ..................................................................................................10
Applicable Federal Codes .................................................................................................................13
Vent System Modication ..................................................................................................................13
Connecting Gas Service....................................................................................................................14
Electrical Wiring.................................................................................................................................15
Lighting Instructions...........................................................................................................................17
Sequence of Operations....................................................................................................................18
General Instruction For Seasonal Startup & Maintenance ................................................................19
Replacement Parts............................................................................................................................22

3
NOTES:
• Greater clearances for access should supersede re pro-
tection clearances.
* For installation on combustible ooring Special Base MUST
BE USED. (See Replacement Parts Section)
1. Keep boiler area clear and free from combustible
materials, gasoline and other ammable vapors
and liquids.
2. DO NOT obstruct air openings to the boiler
room.
3. Modication, substitution or elimination of factory
equipped, supplied or specied components may
result in property damage, personal injury or the
loss of life.
4. TO THE OWNER: Installation and service of
this boiler must be performed by a qualified
installer.
5. TO THE INSTALLER: Leave all instructions with
the boiler for future reference.
6. When this product is installed in the Com-
monwealth of Massachusetts the installation
must be performed by a Licensed Plumber
or Licensed Gas Fitter.
Improper installation, adjustment, alteration,
service or maintenance can cause injury or
property damage.
INTRODUCTION
The installation must conform to the requirements of 1.
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.) Reference should also be made to local gas utility
regulations and other codes in effect in the area in which
the installation is to be made.
Where required by the authority having jurisdiction, the
2.
installation must conform to American Society of Me-
chanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME No.
CSD-1.
This boiler is classied as a Category I and III and vent
3.
installation shall be in accordance with the latest revision
of the National Fuel Gas Code, ANSI Z223.1 or applicable
provisions of the local building codes.
LOCATE BOILER on level, solid base as near the outside
4.
wall as possible and centrally located with respect to the
heat distribution system as practicable.
Allow 24 inches at the front and right side for servicing
5.
and cleaning.
When installed in utility room, the door should be wide
6.
enough to allow the largest boiler part to enter, or to
permit replacement of another appliance such as a water
heater.
The boiler shall be installed such that the gas ignition
7.
system components are protected from water, (dripping,
spraying, rain, etc.), during appliance operation and
service, (circulator replacement, condensate trap, control
replacement, etc.).
FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS
8.
ONLY. *The boiler must not be installed on carpeting.
Minimum clearances to combustible constructions are:
TOP ...................................................... 18 IN.
FRONT .....................................................6 IN.
FLUE CONNECTOR ...............................6 IN.
REAR........................................................4 IN.
CONTROL SIDE.......................................9 IN.
OTHER SIDE ...........................................3 IN.
VENT PIPE ..............................................6 IN.
WARNING
!
WARNING
!

4
ALL INSTALLATIONS OF BOILERS AND VENTING SHOULD BE DONE ONLY BY A QUALIFIED
EXPERT AND IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL. INSTALL-
ING 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 GASES SUCH AS CARBON MONOXIDE WHICH IS ODORLESS AND INVISIBLE.
BOILER RATINGS, CAPACITIES & DIMENSIONS
BOILER DIMENSIONS
DIMENSIONS FOR NATURAL GAS
Model # Natural
Gas Inlet
Dimensions Pump size
Supply
& Return
Tappings
Number
of
Burners
AFUE
Ratings
A B C D E
-50 ½" 11¼ 2⅛ 36⅜ 27 1¼" 1 83%
-100 ½" 15⅛ 4⅛ 36⅜ 27 1¼" 2 82%
-125 ½" 19 6 3 6⅜ 27 1¼" 3 82%
-150 ½" 19 6 4 6⅜ 27 1¼" 3 80%
-200 ½" 22⅞ 8 4 7 28 1¼" 4 80%
NOTE: For altitudes above 2,000 ft. ratings should be reduced at the rate of 4% for each 1,000 ft. above sea level.
WARNING
!

5
BOILER RATINGS, CAPACITIES & DIMENSIONS
Model #
A.G.A.
Input
Btu/Hr.
Heating
Capacity
Btu/Hr.
I=B=R
NetOutput
Btu/Hr
No.
of
Burners
Water
Content
(Gals.)
AFUE
Ratings
-50 50,000 42,000 37,000 1 2.4 83%
-100 100,000 82,000 71,000 2 4.0 82%
-125 125,000 103,000 90,000 3 5.6 82%
-150 150,000 122,000 106,000 3 5.6 80%
-200 199,999 160,000 139,000 4 7.2 80%
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 certied for installation on non-combustible oors. For installation on combustible oors, use
combustible oor kit.
This boiler is a Category III Designed Certied appliance which requires a special horizontal through the wall venting
system. Only HEAT-FAB SAF-T-VENT™, FLEX-L STAR-34™, ProTech™ FasNSeal, and Z-FLEX Z-VENT™ vent
material products shall be used.
Should a chimney installation be required, see venting addendum.
See venting addendum for maximum vent lengths and proper congurations.
MEA number for the boilers is 415-90-E.
Electric service to be 120 Volts, 15 Amps, 60 Hz.
**For equivalent square feet of radiation, divide I=B=R output by 150.

6
!!
VENTILATION & COMBUSTION AIR
COMBUSTION AIR REQUIREMENTS
(Minimum Square Inch Openings)
MODEL #
*UNCONFINED AREA **CONFINED AREA
OUTSIDE
COMBUSTION AIR
1 SQ. IN/5000 BTU/
HR (SEE Figure #2)
INSIDE
COMBUSTION AIR
1 SQ. IN. /1000
BTU/HR
(SEE Figure #1)
OUTSIDE COMBUSTION AIR
VERTICAL
DUCTS 1 SQ. IN.
/4000 BTU/HR
(SEE Figures #2
& 3)
HORIZONTAL
DUCTS 1 SQ. IN.
/2000 BTU/HR
(SEE Figure #4)
-50 10 100 13 25
-100 20 100 25 50
-125 25 125 32 63
-150 30 150 38 75
-200 40 200 50 100
* Unconned 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).
** Conned Area: A space whose volume
is 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).
Ventilation of the boiler room must be adequate to 1.
provide sufcient air to properly support combustion
per the latest revision of the National Fuel Gas Code,
ANSI Z223.1.
When a boiler is located in an unconned space in a
2.
building or conventional construction frame, masonry
or metal building, inltration normally is adequate to
provide air for combustion and ventilation. However, if
the equipment is located in a building of tight construction
(See the National Fuel Gas Code, ANSI Z223.1 latest
revision), the boiler area should be considered as a con-
ned space. In this case air for combustion and ventilation
shall be provided according to paragraph #5. If there is
any doubt, install air supply provisions in accordance with
the latest revision of the National Fuel Gas Code.
When a boiler is installed in an unconned space, in a
3.
building of unusually tight construction, air for combus-
tion and ventilation must be obtained from outdoors or
from spaces freely communicating with the outdoors.
A permanent opening or openings having a total free
area of not less than 1 square inch per 5,000 BTU per
hour of total input rating of all appliances shall be pro-
vided. Ducts may be used to convey makeup air from
the outdoors and shall have the same cross-sectional
area of the openings to which they are connected.
When air for combustion and ventilation is from inside
4.
WARNING
AIR OPENINGS TO COMBUSTIONAREAMUST NOT BE OBSTRUCTED.
BY FOLLOWING THE INSTRUCTIONS BELOW, ADEQUATE
COMBUSTION AIR CAN BE MAINTAINED.

7
VENTILATION & COMBUSTION AIR
buildings, the conned space shall be provided with
two permanent openings, one starting 12 inches from the
top and one 12 inches from the bottom of the enclosed
space. Each opening shall have a minimum free area
of 1 square inch per one thousand (1000) BTU per hour
of the total input rating of all appliances in the enclosed
space, but must not be less than one hundred (100)
square inches. These openings must freely communicate
directly with other spaces of sufcient volume so that the
combined volume of all spaces meets the criteria for an
unconned space. See
Figure #1.
VENT PIPE
BASEBOARD
VENTS
BOILER
12"
12"
Figure #1
When the boiler is installed in a conned space and all air 5.
is provided from the outdoors the conned 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 mini-
mum dimension of rectangular air ducts shall be not less
than 3 x 3 inches or 9 square inches.
When installing two openings, one must commence A.
within 12 inches from the top and the other within 12
inches from the bottom of the enclosure. The open-
ings shall communicate directly, or by ducts, with the
outdoors or spaces (crawl or attic) that freely commu-
nicate with the outdoors. One of the following methods
must be used to provide adequate air for ventilation
and combustion.
When directly communicating with the outdoors, each I.
opening shall have a minimum free area of 1 square
inch per 4,000 BTU per hour of total input rating of all
equipment in the enclosure. See
Figure #2 .
OUTLET
AIR
VENTILATION LOUVERS
(EACH END OF ATTIC)
INLET
AIR
VENTILATION
LOUVRES FOR
UNHEATED
CRAWL SPACE
Figure #2
When communicating with the outdoors by means of II.
vertical ducts, each opening shall have a minimum
free area 1 square inch per 4,000 BTU per hour of
total input rating of all appliances in the enclosed
space. See
gure #3 .
BOILER
OUTLET
AIR
VENTILATION LOUVERS
(EACH END OF ATTIC)
-- SLAB --
INLET AIR DUCT
12"
(DUCT ENDS 1 FT.
ABOVE THE FLOOR)
Figure #3

8
If horizontal ducts are used, each opening and duct III.
shall have a minimum free area 1 square inch per
2,000 BTU per hour of total input rating of all appli-
ances in the enclosed space. See
gure #4 .
BOILER
-- SLAB --
INLET AIR DUCT
12"
INLET AIR DUCT
12"
Figure #4
One permanent opening, commencing within 12 inches B.
of the top of the enclosure, shall be permitted where the
equipment has clearances of at least 1 inch from the
sides, 1 inch from the back, and 6 inches from the front
of the boiler. The opening shall directly communicate
with the outdoors or shall communicate through a verti-
cal or horizontal duct to the outdoors or spaces (crawl
or attic) that freely communicate with the outdoors. The
openings must have a minimum free area of 1 square
inch per 3000 Btu per hour of the total 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 connec-
tors in the conned space.
VENTILATION & COMBUSTION AIR
In calculating free area using louvers, grilles or screens 6.
for the above, consideration shall be given to their block-
ing 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 specied. If the design
and free area is not known, it may be assumed that wood
louvers will have 20-25% free area and metal louvers and
grilles will have 60-75% free area. Louvers and grilles
should be xed in the open position or interlocked with the
boiler so they are opened automatically during the boiler
operation.

9
CONNECTING SUPPLY & RETURN PIPING
Connect supply and return piping as suggested in 1. gure
#5
, when the boiler is used in connection with refriger-
ated systems.
The chilled medium MUST BE PIPED IN PARALLEL A.
with the boiler.
Use appropriate valves to prevent the chilled medium B.
from entering the heating boiler.
During heating cycle open valves A and B, close I.
valves C and D.
During cooling cycle, open valves C and D, close II.
valves A and B.
C. Maintain a minimum clearance of one inch to hot C.
water pipes.
When the boiler is connected to heating coils located in
2.
air handling units where they may be exposed to refrig-
erated air circulation, the boiler piping system MUST
BE supplied with ow control valves or other automatic
means to prevent gravity circulation of the boiler water
during the cooling cycle.
Hot water boilers installed above radiation level must be
3.
provided with a low water cut-off device.
When a boiler is connected to a heating system that
4.
utilizes multiple zoned circulators, each circulator must
be supplied with a ow control valve to prevent gravity
circulation.
Hot water boilers and system must be lled with water
5.
and maintained to a minimum pressure of 12 pounds per
square inch.
Bypass piping is an option which gives the ability to adjust
6.
the supply boiler water temperature to t the system or
the condition of the installation. This method of piping,
however, is not typically required for baseboard heat-
ing systems. Typical installations where bypass piping is
used are as follows:
This method is used to protect boilers from conden-A.
sation forming due to low temperature return water.
Generally noticed in large converted gravity systems or
other large water volume systems. See
gure #6 .
This method is used to protect systems using radiant B.
panels and the material they are encased in from high
temperature supply water from the boiler. And protect
the boiler from condensate. See
gure #7 and #8 .
IMPORTANT: Circulators in the following
illustrations are mounted on the system supply
side, but mounting on the system return side is
also acceptable practice.
CIRCULATOR
VA LVE
EXPANSION
TANK
VA LVE
RETURN
SUPPLY
12"
MAX.
CIRCULATOR
FLOW
VA LVE
SYSTEM
TEMPERATURE
GAUGE
"B"
"A"
SYSTEM
PRIMARY
6"
FEED
WATER
Figure #5
ZONE
CIR.
VA LVE
FLOW
VALVE
EXPANSION
TANK
VA LVE
SYSTEM
TEMPERATURE
GAUGE
RETURN
SUPPLY
"A"
"B"
6"
FEED
WATER
BYPASS PIPING
Figure #6
6"
EXPANSION
TANK
TEMPERATURE
SYSTEM
GAUGE
SUPPLY
RETURN
4 WAY MIXING
VALVE
ZONE
CIR.
WATER
FEED
MIXING VALVE PIPING
Figure #7

10
This method is used to protect boilers from condensate C.
forming as well as protecting the heating system from
high water temperatures, see
gure #8 .
NOTE #1: When using bypass piping, adjust
valves A and B until desired system temperature
is obtained.
NOTE #2: Bypass loop must be same size piping
as the supply and return piping.
Installation using circulators is shown in 7. gure #9 .
Installation using zone valves is shown in
8. gure #10 .
For further piping information refer to the I=B=R Installa-
9.
tion and Piping Guide.
CONNECTING SUPPLY & RETURN PIPING
CIRCULATOR
VALVE
EXPANSION
TANK
VALVE
RETURN
SUPPLY
12"
MAX.
CIRCULATOR
FLOW
VALVE
SYSTEM
TEMPERATURE
GAUGE
"B"
"A"
SYSTEM
PRIMARY
6"
FEED
WATER
PRIMARY SECONDARY PIPING WITH BYPASS
Figure #8

11
CONNECTING SUPPLY & RETURN PIPING
TANK
SYSTEM
CIRCULATOR
CIRCULATOR
REDUCED PRESSURE
BACKFLOW PREVENTER
FLOW CONTROL
OR CHECK VALVE
OUTLET
HOT WATER
TRAP
THERMAL
WIRING FOR
THERMOSTAT/
PUMP CONTROL
INLET
COLD WATER
RELIEF VALVE
DRAIN COCK
6" 6"
WATER
FEED
PRESSURE
REDUCING
VALVE
GATE
VALVE
Figure #9
CIRCULATOR
DRAIN COCK
RELIEF VALVE
HOT WATER
OUTLET
THERMAL
TRAP
PUMP CONTROL
WIRING FOR
THERMOSTAT/
SYSTEM RETURN
PIPING
INLET
COLD WATER
VALVE
TANK ZONE
6" 6"
PRESSURE
REDUCING
VALVE
BACKFLOW PREVENTER
REDUCED PRESSURE
GATE VALVE
Figure #10
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 APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUS
INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON
MONOXIDE WHICH IS ODORLESS AND INVISIBLE.
WARNING
!

12
APPLICABLE FEDERAL CODES
VENT 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. 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.
Seal an unused opening in the common venting system.
1.
Visually inspect the venting system for proper size and 2.
horizontal pitch and determine there is no blockage or re-
striction, leakage, corrosion and other deciencies which
could cause an unsafe condition.
Insofar as is practical, close all building doors and win-
3.
dows 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 replace dampers.
Place in operation the appliance being inspected. Follow
4.
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
Test for spillage at the draft hood relief opening after 5
5.
minutes of main burner operation. Use the ame of a
match or candle, or smoke from a cigarette, cigar or pipe.
After it has been determined that each appliance remain-
6.
ing connected to a common venting system properly
vents when tested as outlined above, return doors, win-
dows, exhaust fans, replace dampers and any other gas
burning appliances to their previous condition of use.
Any improper operation of the common venting system
7.
should be corrected so the installation conforms with
the latest revision of the National Fuel Gas Code, ANSI
Z223.1. 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 ap-
propriate tables in the latest revision of the National Fuel
Gas Code, ANSI Z223.1.
NFPA 54/ANSI Z223.1, National Fuel Gas Code and NFPA/
ANSI 211, Chimneys, Fireplaces, Vents and Solid Fuel Burning
Appliances. These codes contain information on special gas
vents for Category II, III and IV appliances, vent sizing, location,
air space clearances to combustibles and safe installation
practices. The gas vent installer should be familiar with these
Federal Codes as well as Local Codes and Regulations.
GENERAL INFORMATION GAS VENTS AND
APPLIANCES:
By Federal Codes, gas appliances are categorized by the
pressure and temperature of the ue gas vented from the
appliance. Category I and II appliances are natural draft (draft
hood) vented, with high ue gas temperatures (Category I), and
low ue gas temperatures (Category II). Category III and IV
appliances are fan forced vents with high temperature (Category
III) and low temperature (Category IV) ue gasses. Appliance
efciency is directly related to ue gas temperature. Higher
efciency appliances remove more heat from the gas, so they
Vents for Category I appliances may not be suitable
for use with Category II, III, or IV appliances because
condensate may corrode the vent.
WARNING
!
Vents for Category III appliances may not be suitable
for use with Category I appliances because ue gas
temperatures may be too high.
WARNING
!
will have lower temperature ue products. When ue gas
temperatures are lowered, corrosive condensates may form
in the gas vent or in the appliance. Condensates may form
in Category II, III, IV appliance vents, so special, corrosive
resistant venting systems are required for higher efciency
appliances.

13
CONNECTING GAS SERVICE
Connect gas service from meter to control assembly in 1.
accordance with 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 leg or trap must be
installed at the bottom of a vertical section of piping at the
inlet to the boiler. A pipe compound resistant to the action
of liquied petroleum gases must be used on all threaded
pipe connections. Check with the local utility for location
of manual shutoff valve if required. See
gure #11 .
The gas line should be of adequate size to prevent undue
2.
pressure drop and never smaller than the pipe size of the
main gas control valve. See chart below.
Maximum Capacity of Pipe in Cubic Feet of
Gas Per Hour
(Gas pressure = 0.5 psig or less,
pre sure drop = .5 in.w/c)
Nomi-
nal Iron
Pipe
Size
Length of Pipe (Feet)
10' 20' 30' 40' 60' 80' 100'
½" 175 120 97 82 66 57 50
¾" 360 250 200 170 138 118 103
1" 680 465 375 320 260 220 195
1¼" 1400 950 770 660 530 460 400
For additional information refer to the National Fuel
Gas Code Handbook, Latest Revision.
DO NOT USE AN OPEN FLAME.
WARNING
!
To check for leaks in gas piping, use a soap and water 3.
solution or other approved method.
Disconnect the boiler from the gas supply piping system
4.
during any pressure testing of the gas piping. After recon-
necting, leak test the gas connection and boiler piping
before placing the boiler back into operation.
PRESSURE GAS
NATURAL PROPANE
MIN. SUPPLY 5" w.c. 11" w.c.
MAX. SUPPLY 14" w.c. 14" w.c.
MANIFOLD 3.5" w.c. 10.5" w.c.
Figure #11

14
* NOT ALL COMPONENTS LISTED ARE USED IN ALL CON-
TROL SYSTEMS.
NOTES:
* Switches are shown in position during the heating
cycle.
* If any of the original wiring supplied with the boiler
is replaced it must be replaced with like wire size and
type of insulation or equivalent.
ELECTRICAL WIRING
Electrical wiring must conform with the latest revision of the
National Electrical Code, ANSI / NFPA No. 70 and/or local
authority having jurisdiction.
When an external electrical source is utilized, the boiler,
1.
when installed, MUST BE electrically grounded in accor-
dance with these requirements.
Install a fused disconnect switch between boiler and me-
2.
ter at a convenient location.
Hot water control and intermittent ignition wiring for boilers
with fail safe relay. See gure #12.
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
Pressure Switch PS
Manual Reset Pressure Sw. MR-PS
Control Terminal
Relay Coil 1K
Relay Contacts 1K1
Relay Contacts 1K2
Limit Switch LS
Manual Switch MS
Circulator CIR
Energy Cut-Off ECO
Pilot Safety Coil PSC
Wire Connection
Low Water Cut Off LWCO
Electric Water Feeder EWF
Power Generator PG
Roll-Out Switch RSW
COMPONENT AND WIRE CODING KEYS
The keys that follow pertain to the HOT WATER CON-
TROL AND INTERMITTENT IGNITION WIRING
diagrams.

15
HOT WATER CONTROL AND INTERMITTENT IGNITION WIRING
PILOT
PILOT
ELECTRICAL WIRING
Figure #12

16
IF YOU DO NOT FOLLOW THESE INSTRUCTIONS
EXACTLY, A FIRE OR EXPLOSION MAY RESULT
CAUSING PROPERTY DAMAGE, PERSONAL
INJURY OR LOSS OF LIFE.
Before operating, make certain the boiler and
system are full of water to minimum pressure
(this is usually 12 lbs. per square inch on most
systems) and system is vented of air. See the
operating and lighting instructions.
THERMOSTAT INSTALLATION
Thermostat should be installed on an inside wall about 1.
four feet above the oor.
Never install a thermostat on an outside wall.
2.
Check thermostat operation by raising and lowering ther- 3.
mostat setting as required to start and stop the burners.
Instructions for the nal adjustment of the thermostat are
4.
packaged with the thermostat (adjusting heating anticipa-
tor, calibration, etc.)
THINGS TO AVOID WHEN LOCATING THERMO-
STATS
DEAD SPOTS:
Corners and alcoves Behind doors
COLD SPOTS: HOT SPOTS:
Concealed pipes or
ducts
Concealed pipes
Fireplace
or chimney
Stairwells - drafts TV sets
Radios
Unheated rooms on
other side of wall
Lamps
Direct sunlight
Outside walls
Kitchens
This appliance is equipped with an ignition deviceA.
which automatically lights the pilot. Do not try to light
the pilot by hand.
BEFORE OPERATING smell all around the appli-B.
ance area for gas. Be sure to smell next to the oor
because some gas is heavier than air and will settle
on the oor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.•
Do not touch any electrical switch•
D• o not use any phone or mobile electronics 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 re de-•
partment.
Use only your hand to move the system control C.
switch. Never use tools. If the switch will not move
by hand, don’t try to repair it, call a qualied service
technician. Force or attempted repair may result in a
re or explosion.
Force or attempted repair may result in a
re or explosion.
WARNING
!
Do not use this appliance if any part has been under D.
water. Immediately call a qualied service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
FOR YOUR SAFETY READ BEFORE OPERATING
ELECTRICAL WIRING
LIGHTING INSTRUCTIONS
CAUTION
!
WARNING
!
If these instructions are not followed exactly, a
re or explosion may result causing property
damage, personal injury or loss of life.
WARNING
!

17
LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEM
STOP!
1. Read the safety information in the user’s informa-
tion manual.
Set thermostat to lowest setting.
2.
Turn off all electric power to the appliance. 3.
This appliance is equipped with an ignition device which 4.
automatically lights the burner. DO NOT try to light the
burner by hand.
Turn the gas control knob clockwise
5. to “OFF”. (See
Figure #13 )
Wait ve (5) minutes to clear out any gas. Then smell for
6.
gas, including near the oor. If you smell gas, STOP!
Follow “What To Do If You Smell Gas” in the safety infor-
mation section. If you don’t smell gas, go on to the next
step.
Turn the gas control knob counterclockwise
7. to “ON”.
Turn on all electrical power to the appliance.
8.
Set the thermostat to desired setting. 9.
If the appliance will not operate, follow the instructions “To 10.
Turn Off Gas To Appliance” and call your service techni-
cian or gas supplier.
TO TURN OFF GAS TO APPLIANCE
Set the thermostat to lowest setting. 1.
Turn off all electric power to the appliance if service is to 2.
be preformed.
Turn gas control knob clockwise
3. to “OFF” Do Not
Force.
ON A CALL FOR HEAT:
The thermostat will actuate, completing the circuit be- 1.
tween terminals T and T.
The R8222C relay coil will energize thus pulling in the
2.
relay contacts.
The circulator starts and power is switched to the limit.
3.
If limit circuit is closed the venter motor and TF-2 trans-
former are energized.
The venter motor starts and develops static pressure.
4.
When the static pressure is reached the pressure switch 5.
pulls in completing the circuit between TF-2 and the inter-
mittent ignition control.
The intermittent ignition control opens the pilot valve
6.
and ignites pilot. After pilot is proven the main burner will
ignite.
In the event the boiler water temperature exceeds the
7.
high limit setting the power will be interrupted to the ven-
ter motor, and TF-2 thus interrupting power to the ignition
system. Power will remain off until the water temperature
drops below the high limit setting. The circulator will con-
tinue to operate under this condition until the thermostat is
satised.
Should the air ow (static pressure) be interrupted (ex-
8.
ample blocked ue, etc.), the pressure switch will sense a
drop in pressure, opening the circuit between the igni-
tion system and TF-2. The venter motor will continue to
operate until static pressure is reached or thermostat is
satised.
In the event the ow of combustion products through
9.
any part of the boiler ueway becomes blocked, a ame
safety roll-out switch will shut off the main burners. If this
condition occurs, do not attempt to place the boiler back
operation.
When the thermostat is satised power is interrupted to
10.
the relay coil and the relay drops out cutting power to the
circulator, venter motor, and TF-2.
LIGHTING INSTRUCTIONS
SEQUENCE OF OPERATIONS
INLET OUTLET
Figure #13

18
GENERAL INSTRUCTION FOR SEASONAL STARTUP & MAINTENANCE
It is suggested that a qualied service agency be employed to
make an annual inspection of the boiler and the heating sys-
tem. They are experienced in making the inspection outlined
below.
In the event repairs or corrections are necessary they can
make the proper changes for safe operation of the boiler.
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
CAUTION
!
Verify proper operation after service.
If the venter has oil cups, lubricate venter motor once a month
during the heating season with a few drops of non-detergent
motor oil (SAE 20 or 30). Replace the rubber plugs when
nished.
DO NOT OVER OIL.
CAUTION
!
BEGINNING OF EACH HEATING SEASON
Before seasonal start-up, it is highly advisable to have a 1.
certied service agency inspect the system:
Check the boiler for soot and scale build up in the ues. A.
Clean the burners.B.
Check the gas input rate to maintain high operating ef-C.
ciency.
The service agency should make certain the system is
2.
lled with water to minimum pressure (approximately 12
pounds per square inch) and open air vents (if used) to
expel any air that may have accumulated in the system.
Check automatic air vents for leakage.
3.
Inspect venting system at the start of each heating sea- 4.
son. Check the pipe from the boiler for signs of deteriora-
tion and sagging joints. Repair if necessary. Remove the
vent pipe from the boiler and check for obstructions.
Clean condensate tee & trap. Periodic cleaning of the
5.
condensate collection system is required. When a con-
densate 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'
CONDENSATE TRAP
ASSY. NOTE, NOT REQUIRED ON
MODELS DV125 THRU 200.
CONDENSATE DRAIN
THE PROCEDURE FOR CLEANING THIS SYSTEM
FOLLOWS:
Remove tubing from condensate tee.A.
Empty all liquid from tubing.B.
Rinse tubing inside & out in a sink with water.C.
If tubing cannot be cleaned inside, the tubing should beD.
replaced with the same type and size of tubing.
Replace tubing as described inE.
gure #14 . (Fill trap
with water.)
Visually inspect entire piping system and if any leaks F.
appear, have them repaired as soon as possible. DO
NOT use petroleum based stop leak compounds.
Check venter assembly static pressure as fol-6.
lows:
With the boiler off, disconnect the white compression A.
tting on the pressure switch.
Connect a slope manometer to the compression tting B.
with additional tubing.
Turn the boiler on and read suction pressure on theC.
manometer. Reading should be negative (-) .55 ± .05
inches of water column or higher for the 50B thru 150B
and negative (-) .65 ± .05 inches of water column or
higher for the 200B.
If static pressures are not at the minimum allowable level
7.
(listed above), check vent pipe for obstructions.
Figure #14

19
The following procedure should be followed to clean and 8.
check the boiler ue passageways:
Remove the burners from the combustion chamber by A.
raising the burners up from the manifold orices and
pulling toward the front of the boiler. See
gure #15 .
GAS VALVE
ORIFICES
BURNERS
Figure #15
Disconnect the vent pipe from the vent adapter.B.
Remove the top jacket panel. See C.
Figure #16 .
COMBUSTION
BURNER
(REMOVED)
BURNERS GAS
VENT PIPE
CHAMBER
DOOR
VALVE
ADAPTER
ROLL-OUT SAFETY
BURNER
SWITCH
JACKET
FRONT
PANEL
Figure #16
Disconnect the white compression tting from the pres-D.
sure switch.
Disconnect venter wires from relay.E.
Remove the ue collector and venter from the boiler F.
castings by loosening the hold-down bolts located on
each side of the collector. See
gure #17 .
BURNERS
ORIFICES
GAS VALVE
HOLD DOWN
BOLT
FLUE
COLLECTOR
VENTER
ASSEMBLY
A1795
Figure #17
Visually inspect the venter assembly for any unusual G.
wear or dirt build up. Clean with vacuum if necessary.
Place a sheet of heavy paper or similar material over H.
the bottom of the combustion chamber and brush down
the ue passageways. The soot and scale will collect
on the paper and is easily removed with the paper.
Vacuum out base and ueways and reassemble the I.
boiler in reverse order.
Seal ue collector and vent adapter with high tempera-J.
ture silicone. (+400°)
Start boiler to ensure proper operating condition.K.
Keep the area around the boiler clean and free of com-
9.
bustible materials such as gasoline, paints, paint thinner
and other such ammable vapors and liquids.
The free ow of combustion and ventilating air to the
10.
boiler and boiler room must not be restricted or blocked.
Some circulators require periodic servicing. These circula-
11.
tors 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
GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE

20
The main burner ame should form a
sharp blue inner mantel with no yellow.
opening twice per year. DO NOT OVER OIL. Follow the
manufacturers instructions attached to the circulator.
When oil cups or holes are not provided, bearings are
either permanently lubricated or water lubricated.
Visually check the main burners and pilot ame at the
12.
start of each heating season and again midway through
the season.
Check the burner throats and burner orices for lint and A.
dust obstructions. See
gure #17 .
The main burner ame should have a well dened in-B.
ner blue mantel with a lighter blue outer mantel. See
gure #18 .
Figure #18
The pilot ame should envelop ⅜ to ½ inch of the tip of C.
the pilot sensing device. See
gure #19 .
IGNITION ELECTRODE
3/8” TO 1/2”
IN FLAME
Figure #19
Adjusting the pilot ame: 13.
Remove the pilot adjustment cover screw.A.
GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE
Turn inner screw (adjustment screw) clockwiseB. to
decrease and counterclockwise to increase the
pilot ame, see gure #20.
After adjustment, be sure to replace cover screw to C.
prevent possible gas leakage.
The main burners and the pilot burner should be D.
checked for signs of corrosion or scale build up.
Clean main burners and pilot burner with a steel bristle E.
brush.
CHECK GAS INPUT RATE TO BOILER
Maximum permissible gas supply pressure must not be 1.
higher and minimum supply pressure must not be lower
than what is specied on the rating plate.
To check for proper ow of natural gas to boiler using the
2.
gas meter, proceed as follows:
Turn off the gas supply to all other appliances, except A.
the boiler.
With the boiler operating, determine the ow of gas B.
through the meter for two minutes and multiply by 30 to
get the hourly rate (in cubic feet).
Divide the input rate shown on the rating plate by the C.
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.
If minor adjustment is necessary, adjust the pressure D.
regulator on the combination gas control. Increase or
decrease manifold pressure to obtain gas input required
as described on the rating plate. To increase, turn the
regulator adjusting screw clockwise or counter-
clockwise to decrease pressure, see Figure #20.
The manifold pressures are taken at the outlet side of
the gas valve.
Relight all the other appliances turned off in step "a."E.
above. Be sure all pilot burners are operating.
INLET OUTLET
Figure #20