Columbia CSC SERIES Instruction manual

P/N 37711701, Rev. C [05/2012]
Columbia Company
Main ofces and Factory:
Pottstown, PA
CSC SERIES
Direct Vent
Gas Fired Hot Water Boiler
INSTALLATION, OPER ATION &
MAINTENANCE MANUAL
C.S.A. Certied
For Natural Gas Or Propane
Tested For 100 psi.
ASME
Working Pressure
H

2
SAFETY SYMBOLS
The following dened symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
IMPORTANT: Read the following instructions COMPLETELY
before installing!
!
DANGER
Indicates a hazardous situation which, if not
avoided, WILL result in death, serious injury.
!
WARNING
Indicates a hazardous situation which, if not
avoided, may result in death, serious injury.
!
CAUTION
Indicates a hazardous situation which, if not
avoided, may result in injury.
NOTICE
Indicates information which should be
followed to ensure proper installation and
operation.
Introduction................................................................................................................................ 3
Boiler Ratings, Capacities & Dimensions.......................................................................................... 4
Connecting Supply And Return Piping ............................................................................................. 5
General Information Gas Vents And Appliances ................................................................................ 8
Vent Pipe Modication .................................................................................................................. 9
Connect Gas Service ...................................................................................................................10
Electrical Wiring .........................................................................................................................12
Operating Instructions.................................................................................................................13
Sequence Of Operation................................................................................................................14
General Instruction For Seasonal Start Up And Maintenance .............................................................15
Venting Instructions....................................................................................................................19
Condensate Drains......................................................................................................................24
Replacement Parts......................................................................................................................32
Relief Valve Piping Supplemental Installation Instructions ................................................................40
TABLE OF CONTENTS
Keep This Manual Near Boiler And
Retain For Future Reference.
!
WARNING
Keep boiler area clear and free from
combustible materials, gasoline and other
ammable vapors and liquids.
Do not obstruct air openings to the boiler
room.
Modication, substitution or elimination
of factory equipped, supplied or specied
components may result in personal injury or
the loss of life.
To the installer: Leave all instructions with the boiler for
future reference.
When this product is installed in the Commonwealth of
Massachusetts the installation must be performed by a
Licensed Plumber or Licensed Gas Fitter.
To the owner: Installation and service of this boiler must
be performed by a qualied installer.

3
• The installation must conform to the requirements of
the authority having jurisdiction or, in absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, and/or Natural Gas and Propane
Installation Code, CAN/CSA B149.1.
• Where required by Authority having jurisdiction,
installation must conform to Standard for Controls and
Safety Devices for Automatically Fired Boilers, ANSI/
ASME CSD-1.
• LOCATE BOILER on level, solid base as near the outside
wall as possible and centrally located with respect to the
heat distribution system as practicable.
• Allow 24 inches (61cm) at front and right side for
servicing and cleaning.
• When installed in utility room, the door should be wide
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
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 oors only.
The boiler must not be installed on carpeting (for
installation on combustible ooring special base
part no.325-2-8.00 Must be used). Minimum
clearances to combustible constructions are:
TOP 18 in. (46 cm)
FLUE CONNECTOR 2 in. (5 cm)
FRONT 6 in. (15 cm)
REAR 4 in. (10 cm)
RIGHT SIDE 9 in. (23 cm)
LEFT SIDE 3 in. (8 cm)
Refer to Figure 1. Greater clearances for access should super-
sede re protection clearances.
6" (15.2 cm) MIN.
9"
(22.9 cm)
MIN.
3"
(7.6 cm)
MIN.
4" (10.2 cm)
MIN.
FRONT OF
BOILER
!
WARNING
Improper installation, adjustment, alteration,
service or maintenance can cause injury or
property damage.
Figure 1 - Min. Clearances To Combustible Materials
!
WARNING
All installations of boilers and venting should
be done only by a qualied expert and in
accordance with the appropriate boiler
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 re or to asphyxiation from poisonous
gases such as carbon monoxide which is
odorless and invisible.
INTRODUCTION

4
Boiler Ratings, Capacities & Dimensions
Boiler
No.
Input
Btu/Hr.
Heating
Capacity
Btu/Hr.
Net Output
Btu/Hr.
Natural
Gas
Inlet
Dimensions Supply &
Return
Tappings
No. Of
Burners
Water
Content
AFUE
Ratings
A B C D
3
Section
50,000
(14.7 KW)
44,000
(12.9 KW)
38,000
(11.1 KW)
1/2"
(1.27 cm)
15.1/8"
(38 cm)
3.1/2"
(9 cm)
3.1/2"
(9 cm)
5"
(12.7 cm)
1.1/4"
(3.2 cm) 24.0 gals (15.14 liters) 87%
4
Section
100,000
(29.3 KW)
87,000
(25.5 KW)
76,000
(22.3 KW)
1/2"
(1.27 cm)
19"
(48 cm)
3.1/2"
(9 cm)
3.1/2"
(9 cm)
6.1/2"
(16.5 cm)
1.1/4"
(3.2 cm) 35.6 gals (21.20 liters) 87%
5
Section
140,000
(41.0 KW)
122,000
(35.7 KW)
107,000
(31.3 KW)
1/2"
(1.27 cm)
22.7/8"
(58 cm)
4.1/4"
(11 cm)
4.1/8"
(11 cm)
8.3/8"
(21.3 cm)
1.1/4"
(3.2 cm) 47.2 gals (27.25 liters) 87%
NOTE: Input rating for applications 0-2000 ft ( 0-610m) above sea level.
United States: Over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m) above sea level.
Canada: 2000-4500 ft (610-1350m) above sea level. Reduce input rate 10%.
Canada over 4500 ft (1350m) above sea level. Contact Provincial authority having jurisdiction.
STANDARD EQUIPMENT:
Boiler Jacket, Cast Iron Boiler Battery, Limit Control, Re-
movable Transformers, Plug in Relay, Theraltimeter Gauge,
Circulator (eld mounted), Main Gas Burners, Hot Surface
Pilot; A.S.M.E Relief Valve, Drain Valve, Induced Draft Fan,
Safety Pressure Switch, and Combination Intake/Exhaust
Termination Kit.
All boilers are design certied for installation on non-com-
bustible oors. For installation on combustible oors, use
combustible oor kit.
This boiler is a Direct Vent Designed Certied appliance
which requires a special horizontal through the wall venting
system.
Use ONLY the venting material products listed below:
• HEAT-FAB® SAF-T-VENT™
• FLEX-L® STAR-34™
• ProTech™ FasNSeal®
• Z-FLEX® Z-VENT™
Consult venting addendum for maximum vent lengths and
proper congurations.
Electrical service to be 120 Volts, 15 Amps, 60 Hz.
BOILER RATINGS, CAPACITIES & DIMENSIONS

5
1. See Relief Valve Piping Supplemental Installation
Instructions located on page 40 of this manual.
2. Connect supply and return piping as suggested in
Figure 1 below when the boiler is used in connection
with refrigerated systems:
A. Boiler used in connection with refrigeration
system. Install piping in parallel with boiler, with
appropriate valves to prevent chilled medium from
entering boiler. See gure 2.
B. System piping connected to heating coils located
in air handling unit exposed to refrigerated air
circulation. Install ow control valves or other
automatic means to prevent gravity circulation of
boiler water during cooling cycle.
EXPANSION
TANK
B
A
D
CHECK
VALVE
CIRCULATOR
FROM HEATING
AND COOLING
ELEMENT
SUPPLY PIPING
TO HEATING
AND COOLING
ELEMENT
WATER
CHILLER
C
RETURN PIPING
FEED
WATER
NOTICE
Reduced pressure back ow preventer must
be used under provisions required by the
Environmental Protection Agency, (EPA).
3. Maintain a minimum clearance of 1 inch (2.54cm) to
hot water pipes.
4. Hot water boilers installed above radiation level or
as required by Authority having jurisdiction must be
provided with a low water cut-off device at the time of
boiler installation.
5. When a boiler is connected to a heating system that
utilizes multiple zoned circulators, each circulator must
be supplied with a ow control valve to prevent gravity
circulation.
Figure 1 - Near Boiler Supply & Return Piping
CONNECTING SUPPLY AND RETURN PIPING

6
6. Bypass piping is an option which
gives the ability to adjust the
supply boiler water temperature
to t the system or condition of
the installation. This method of
piping is not typically required for
baseboard heating systems.
A. This method is used
to protect boilers from
condensate forming due to
low temperature return water.
Generally noticed in large
converted gravity systems
or other large water volume
systems. See Figure 3.
B. These methods are used to
protect systems using radiant
panels and the material they
are encased in from high
temperature supply water
from the boiler and protect the
boiler from condensation. See
Figures 4 & 5.
7. NOTE: When using bypass piping,
adjust valves A and B, in Figures
3 & 5, until desired system
temperature is obtained.
8. NOTE: When using a 4-way
mixing valve, set control knob until
desired temperatures are met. See
instruction supplied with valve.
9. Bypass loop piping must be the
same size piping as the supply and
the return.
10. Typical installation using circulators
is shown in Figure 6 on following
page.
11. Typical installation using zone
valves is shown in Figure 7 on
following page.
12. For further piping information
refer to the I=B=R installation and
piping guide.
ZONE
CIR.
VALVE
FLOW
VALVE
EXPANSION
TANK
VALVE
SYSTEM
TEMPERATURE
GAUGE
RETURN
SUPPLY
"A"
"B"
WATER
FEED
ZONE
CIR.
EXPANSION
TANK
SYSTEM
TEMPERATURE
GAUGE
RETURN
SUPPLY
4 WAY MIXING
VALVE
WATER
FEED
Figure 3 - Bypass Piping
Figure 3 - Mixing Valve Piping
CONNECTING SUPPLY AND RETURN PIPING

7
CIRCULATOR
VALVE
EXPANSION
TANK
VALVE
RETURN
SUPPLY
(31 cm)
MAX.
CIRCULATOR
FLOW
VALVE
SYSTEM
TEMPERATURE
GAUGE
"B"
"A"
SYSTEM
PRIMARY
12"
FEED
WATER
Figure 5 - Primary Secondary Piping with Bypass
Figure 6 - Typical Installation Using Circulators
CONNECTING SUPPLY AND RETURN PIPING

8
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), or low ue gas temperatures (Category
II).
• Category III and IV appliances are fan forced vents with
high temperature (Category III) or 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 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.
• Proper operation of the vent system and appliance is
dependent upon the use of all parts specied by the
manufacturer for use in the particular installation.
Appliance and vent system performance may be affected
by improper assembly.
• Vents for Category I appliances may not be suitable
for use with Category II, III, or IV appliances because
condensate may corrode the vent.
• Vents for Category III appliances may not be suitable
for use with Category I appliances because ue gas
temperatures may be too high.
Figure 7 - Typical Installation Using Zone Valves
CONNECTING SUPPLY AND RETURN PIPING
GENERAL INFORMATION GAS VENTS AND APPLIANCES

9
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 remaining
connected to it.
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.
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deciencies
which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and
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. Close replace dampers.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
5. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the ame of
a match or candle, or smoke from a cigarette, cigar or
pipe.
6. After it has been determined that each appliance
remaining connected to a common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, replace dampers and
any other gas burning appliance to their previous
conditions of use.
7. Any improper operation of the common venting 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 re-sizing any portion of the
common venting system, the common venting system
should be re-sized to approach the minimum size as
determined using the appropriate tables in Chapter 13
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
and/or the Natural Gas and Propane Installation Code,
CAN/CSA B149.1.
VENT PIPE MODIFICATION

10
Figure 8 - Manual Gas Shutoff Valve
CONNECT GAS SERVICE
!
CAUTION
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switches; do
not use any phones 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 re department.
The following rules apply:
1. Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements:
USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54
Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
2. All pipe compound must be resistant to liqueed
petroleum gas.
3. Install ground joint union in gas supply line between
shut-off valve and boiler controls.
4. Install a sediment trap upstream of gas controls.
5. Use two pipe wrenches when making the connection to
the gas valve to keep it from turning.
6. Install manual shut-off valve in vertical pipe about 5
feet (1.5m) above oor.
7. Tighten all joints securely.
8. Propane gas connections should only be made by a
licensed propane installer.
9. Two-stage regulation should be used by the propane
installer.
10. Propane gas piping should be checked out by the
propane installer.
!
DANGER
Fire Hazard. Do not use matches, candles,
open ames, or other methods providing
ignition source. Failure to comply will result in
death or serious injury.
Checking The 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. See Figure 8.
• Locate leakage using gas detector, noncorrosive
detection uid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open ames, or other methods
providing ignition source.
• Correct leaks immediately and retest.

11
The boiler, when installed, must be electrically bonded
to ground in accordance with the requirements of the
authority having jurisdiction or, in the absence of such
requirements, with the National Electrical code, ANSI/NFPA
70, and/or the Canadian Electrical Code Part I, CSA C22.1,
Electrical Code.
!
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.
Component And Wire Coding Keys
• The keys that follow pertain to the HOT WATER
CONTROL AND HOT SURFACE PILOT WIRING FOR
SEALED COMBUSTION SERIES (diagrams on following
page).
• 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.
COMPONENT KEY CODING
Thermostat (24 Volt) TH-2
Transformer (120V/24V 40VA) TR-1
Transformer (120V/24V 40VA) TR-2
24 Volt Gas Valve SV9501H
Pressure Switch PS
Control Terminal
Relay Coil 1K
Relay Contacts 1K1
Relay Contacts 1K2
Limit Switch LS
Circulator CIR
Wire Connection
Not all components listed are used in all control
systems.
WIRING CODE KEY
LINE VOLTAGE BY FACTORY
LOW VOLTAGE BY FACTORY
LINE VOLTAGE BY INSTALLER
LOW VOLTAGE BY INSTALLER
THINGS TO AVOID WHEN
LOCATING THERMOSTATS
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 wall Kitchens
ELECTRICAL WIRING
!
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
Install Your Thermostat
• The thermostat location has an important effect on the
operation of your boiler system.
• BE SURE TO FOLLOW THE INSTRUCTIONS INCLUDED
WITH YOUR THERMOSTAT.
• Locate the thermostat about four feet (4’) above the
oor on an inside wall.
• Check thermostat operation by raising and lowering
thermostat setting as required to start and stop burners.

12
120V
60HZ
SUPPLY
C
NO
INDUCED
DRAFT
BLOWER
TH-2
R8222C
1 4
3 6
CIR
L1 L2 C2 LM FT TV T
VM/LM
VM C1
1K
BLUE
TR-2TR-1
BLUE
L4080B
LS
PS
B
RED
GREEN
AND
WHITE
SV9501H
Q3450B
ORANGE
IGNITION
CONTROL
Honeywell
ORANGE
GREEN
120V
60HZ
SUPPLY
C
INDUCED
DRAFT
BLOWER
TH-2
1 4
3 6
CIR
1K1
1K2
1K
L1 L2 C2 LM
FT
TV
T
VM
VM
C1
L4080B
LS
PS
B
NO
LM
GREEN
AND
WHITE
SV9501H
Q3450B
Honeywell
CONTROL IGNITION
WHITE
WHITE
BLUE
BLUE
GREEN
YELLOW
YELLOW
RED
BLACK
RED
BLACK
RED
ORG
BLUE
BLUE
ORG
ORG
ELECTRICAL WIRING
HOT WATER CONTROL AND HOT SURFACE PILOT WIRING

13
FOR BOILER WITH A HOT SURFACE PILOT SYSTEM
!
WARNING
If you do not follow these instructions exactly,
a re or explosion may result causing property
damage, personal injury or loss of life.
FOR YOUR SAFETY, READ BEFORE OPERATING!
OPERATING INSTRUCTIONS
Before operating, make certain the boiler and system are
full of water to minimum pressure (this is usually 12 psig
on most systems) and system is vented of air. See the
operating and lighting instructions.
!
WARNING
A. This appliance is equipped with an ignition
device which automatically lights the
burner. Do not attempt to light the burner
by hand.
B. BEFORE OPERATING smell all around the
appliance 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; 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 re department.
C. Use only your hand to push down or turn
the knob. Never use tools. If the knob will
not operate by hand, don’t try to repair it,
call a qualied service technician. Force
or attempted repair may result in re or
explosion.
D. Do not use this appliance if any part
has been underwater. Immediately call
a qualied service technician to inspect
the appliance and to replace any part of
control system and any gas control which
has been under water.

14
On a call for heat:
1. The thermostat will actuate, completing the circuit
between terminals T and T.
2. The R8222C relay coil will energize thus pulling in the
relay contacts.
3. The circulator starts and power is switched to the limit.
If limit circuit is closed the venter motor and TR-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 TR-2 and the
SV9501H gas valve system.
6. The SV9501H opens the pilot valve and ignites pilot.
After pilot is proven the main burner will ignite.
7. In the event the boiler water temperature exceeds the
high limit setting the power will be interrupted to the
venter motor, and TR-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 continue to operate under this condition
until the thermostat is satised.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information on previous page.
2. Set thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which
automatically lights the pilot. DO NOT try to light the
pilot by hand.
5. Move the ignition system control switch to the "OFF"
position. See Figure 10.
6. Wait ve (5) minutes to clear out any gas. If you then
smell gas, STOP. Follow "What To Do If You Smell Gas"
on previous page. If you don't smell gas, go to next
step.
7. Move the ignition system control switch to the "ON"
position. See Figure 10.
8. Turn on all electric power to the appliance.
9. Set thermostat to desired setting.
10. If the appliance will not operate, follow the instructions
"To Turn Off Gas To Appliance" to right and call a
qualied service technician or your gas supplier.
8. Should the air ow (static pressure) be interrupted (ie.
blocked ue), the pressure switch will sense a drop
in pressure, opening the circuit between the ignition
system and TR-2. The venter motor will continue to
operate until static pressure is reached or thermostat is
satised.
9. In the event the ow of combustion products through
the boiler ue-ways becomes reduced or blocked, the
Q34505 pilot will lose ame rectication and shut off
the main burners. The boiler will try for ignition but
will not light. If this condition occurs, turn off the main
power and do not put the unit into operation.
10. When the thermostat is satised power is interrupted to
the relay coil and the relay drops out cutting power to
the circulator, venter motor, and TR-2.
ON OFF
GAS
GAS
PRESSURE REGULATOR
ADJUSTMENT BENEATH
COVER SCREW
PILOT FLOW ADJ.
SCREW BENEATH
CONTROL
IGNITER
IGNITION SYSTEM
COVER SCREW
CONTROL SWITCH
PRESSURE
TAP
OUTLET INLET
TO TURN OFF GAS TO APPLIANCE
1. Set thermostat to lowest setting.
2. Turn o all electric power to the appliance if service is to
be performed.
3. Move the ignition system control switch to the "OFF"
position. DO NOT FORCE
Figure 10 - Gas Control Screw
OPERATING INSTRUCTIONS
SEQUENCE OF OPERATION

15
BEGINNING OF EACH HEATING SEASON
1. Before seasonal start up it is advisable to have a
competent service agency check the boiler for soot and
scale in the ues, clean the burners and check the gas
input rate to maintain high operating efciency and
safe operation.
2. The service agency should make certain the system
is lled with water to minimum pressure and open
air vents - if used - to expel any air that may have
accumulated in the system.
3. Check automatic air vents for leakage.
4. Inspect the venting system at the start of each heating
season. Check the pipe from the boiler for signs of
deterioration and sagging joints. Repair if necessary.
Remove the vent pipe from the boiler and check for
obstructions.
5. Clean condensate tee & trap.
6. Periodically check the condensate trap for water/
condensate. The trap should always have water in it.
Rell the trap if it runs dry. If the trap runs dry then
ue gasses can escape.
7. Inspect eld sourced low water cutoff(s) annually or
as recommended by low water cutoff manufacturer.
Flush oat type low water cutoff per manufacturer's
instructions.
It is suggested that a qualied service agency be employed
to make an annual inspection of the boiler and the heating
system. .
In the event repairs or corrections are necessary they can
make the proper changes for safe operation of the boiler.
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. The procedure for
cleaning this system is as follows:
1. Remove tubing from condensate tee.
2. Empty all liquid from tubing.
3. Rinse tubing inside & out in a sink with water.
4. If the inside of the tubing cannot be cleaned, the tubing
should be replaced with the same type and size of
tubing.
5. Add water to trap before replacing.
6. Replace tubing as described in Figure 11 .
7. Visually inspect entire piping system and if any leaks
appear, have them repaired as soon as possible. DO
NOT use petroleum based stop leak compounds.
!
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after service.
Figure 11 - Condensate Collection System
GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE

16
The following procedure should be followed to clean
and check the ue gas passageways:
1. Turn off gas to the boiler at the manual gas
2. Remove the jacket front panel. See Figure 12 .
3. Disconnect the vent pipe from the vent pipe adapter.
4. Disconnect the air inlet pipe from the coupling. See
Figure 13 for coupling location.
5. Remove the air box covers. See Figure 13 .
6. Remove the burners from the combustion chamber by
raising the burners up from the manifold orices and
pulling toward the front of the boiler. See Figure 14 .
7. Remove top panel. See Figure 12 .
8. Remove the ue collector and venter assembly from
the boiler castings by removing the hold-down screws
located on each side of the ue collector. See Figure
15 .
9. Remove the bafes from the heat exchanger. See
Figure 13.
10. Visually inspect bafes for any unusual wear or soot
build up. Clean if necessary.
11. Visually inspect venter assembly for any unusual wear
or dirt build up. Vacuum if necessary.
12. Place a sheet of heavy paper or similar material in
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.
13. Replace the Flue Collector using the hold down screws
and silicone in place with GE IS 808 silicone or similar.
See Figure 15 .
14. Repeat steps 1-5 in reverse order to reassemble the
boiler.
Figure 12 - Front Panel
Figure 14 - Main Gas Burner Tubes
Figure 13 - Air Box Cover
Figure 15 - Flue Collector and Venter Assembly
GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE

17
15. Start boiler to insure proper operating condition.
16. Keep area around boiler clean and free of combustible
materials such as gasoline, paints, paint thinner and
other such ammable vapors and liquids.
17. The free ow of combustion and ventilating air to boiler
and boiler room must not be restricted or blocked.
18. 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 opening twice per year. DO NOT
OVER OIL. Follow manufacturer's instructions attached
to 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 start of each heating season and again midway
through the season.
A. Check the burner throats and burner orices for lint
and dust obstructions. See Figure 15.
B. The main burner ame should have a well dened
inner blue mantel with a lighter blue outer mantel.
See Figure 16.
C. The pilot ame should envelop 3/8" (0.95 cm)
to 1/2" (1.27 cm) of the tip of the pilot sensing
device. See Figure 17.
The main burner ame should form a sharp blue inner
mantel with no yellow.
Figure 16 - Gas Burner Flame
Figure 17 - Gas Burner Pilot
GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE

18
Adjusting the pilot ame:
1. Remove pilot adjustment cover screw.
2. Turn inner screw (adjustment screw) clockwise to
decrease and counterclockwise to increase pilot
ame. See Figure 10.
3. Replace cover screw to prevent possible gas leakage.
4. Main burners and pilot burner should be checked for
signs of corrosion or scale build up.
5. Clean main burners and pilot burner with a steel bristle
brush.
Check Venter Static Pressure
Refer to Figure 18 for the following instructions.
1. With boiler off, disconnect orange and white tubing
from pressure switch on air box and venter motor.
2. Install 3/16" (.48 cm) plastic barbed tee between slope
manometer and pressure switch.
3. The other part of tee goes to air box and venter
pressure taps.
A. Orange being high negative.
B. White being low negative.
4. Turn boiler back on and read static pressure. Reading
should be -.55 ±.05 inches water column or higher for
Sealed Combustion series boilers.
5. If static pressures are not at minimum allowable level,
check intake and exhaust pipes for obstructions or
damage.
6. To reassemble, remove tees and additional tubing
and replace orange tube to venter tap, and white
tube to air box tap.
7. Do not cut original tubing. Additional tubing is
required. If tubing is cut, replace it only with
O.E.M. high temperature silicone tubing. Do not
replace with vinyl or plastic tubing because it will
melt.
Figure 18 - Checking Static Pressure
CHECK GAS INPUT RATE TO BOILER
1. Maximum permissible gas supply pressure must not
be higher and minimum supply pressure must not be
lower than what is specied on the rating plate.
2. To check for proper ow of natural gas to boiler using
the gas meter, proceed as follows:
A. Turn off gas supply to all other appliances, except
boiler.
B. With boiler operating, determine ow of gas
through meter for two minutes and multiply by 30
to get hourly rate.
C. Divide input rate shown on rating plate by heating
value of gas obtained from local gas company. This
will determine number of cubic feet of gas required
per hour.
D. If minor adjustment is necessary, install manom-
eter on outlet side of gas valve. Adjust pressure
regulator on combination gas control. Increase
or decrease manifold pressure to obtain gas input
required as described on rating plate. To increase,
turn regulator adjusting screw clockwise or
counterclockwise to decrease pressure. See
Figure 10.
E. After adjustment has been completed, turn boiler
off and remove manometer and shut-off valve.
F. Relight all other appliances turned off in step A
above. Be sure all pilot burners are operating.
GENERAL INSTRUCTION FOR SEASONAL START UP AND MAINTENANCE

19
Ventilation & Combustion Air
!
WARNING
Air openings to combustion area must not
be obstructed. By following the chart above,
adequate combustion air can be maintained.
Closet Installation: Vent opening must be placed in wall
or door directly across from front of boiler with minimum
opening as listed above. Vent opening must be located 28"
(71.12 cm) up from oor. See Figure 19.
Note: If covering hole with screen or using louvers, opening
must have same free owing area as opening in wall with
no screen or louvers.
Figure 19 - Closet Installation
Venting Requirements Combustion Air
Requirements
Boiler Size Vent Opening
Dimensions 3" (8cm) Inlet Pipe length
3 Section 5" X 5" (13 cm x 13 cm) 30 Ft (914cm) with 2 Elbows
4 Section 8" x 8" (20 cm x 20 cm) 30 Ft (914cm) with 2 Elbows
5 Section 9" x 9" (23 cm x 23 cm) 20 Ft (610 cm) with 2 Elbows
Installation Requirements Specic To State Of
Massachusetts For Direct Vent, Mechanical Vent, and
Domestic Hot Water Appliances
In the State of Massachusetts, boiler installation must
conform to state code 248 CMR which includes but is not
limited to:
VENTING INSTRUCTIONS
• This product must be installed by a licensed
Plumber or Gas Fitter.
• When exible connectors are used, the maximum
length shall not exceed 36 inches.
• When lever type gas shutoffs are used, they shall
be T-handle type.
For all side wall horizontally vented gas fueled equipment
installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the commonwealth and where the
side wall exhaust vent termination is less than seven
(7) feet above nished grade in the area of the venting
including but not limited to, decks and porches, the
following requirements shall be satised:
1. Installation of carbon monoxide detectors :
At the time of installation of the side wall horizontal
vented gas fueled equipment, the installing plumber
or gas-tter shall observe that a hard wired carbon
monoxide detector with an alarm and battery back-
up is installed on the oor level where the gas
equipment is to be installed. In addition, the installing
plumber or gas-tter shall observe that a battery
operated or hard wired carbon monoxide detector
with an alarm is installed on each additional level of
the dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment. It shall
be the responsibility of the property owner to secure
the services of qualied licensed professionals for the
installation of hard wired carbon monoxide detectors.
A. In the event that the side wall horizontally vented
gas fueled equipment is installed in a crawl space
or an attic, the hard wired carbon monoxide
detector with alarm and battery back-up may be
installed on the next adjacent oor level.
B. In the event that the requirements of this
subdivision can not be met at the time of
completion of installation, the owner shall have a
period of thirty (30) days to comply with the above
requirements; provided, however, that during said
thirty (30) day period, a battery operated carbon
monoxide detector with an alarm shall be installed.
2. Approved carbon monoxide detectors: Each
carbon monoxide detector as required in accordance
with the above provisions shall comply with NFPA 720
and be ANSI/UL 2034 listed and IAS certied.

20
3. Signage : A metal or plastic identication plate shall
be permanently mounted to the exterior of the building
at a minimum height of eight (8) feet above grade
directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print size no less
than one-half (1/2) inch in size,
GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS.
4. Inspection : The state or local gas inspector of the
side wall horizontally vented gas fueled equipment shall
not approve the installation unless, upon inspection,
the inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions of
248 CMR 5.08(2)(a)1 through 4.
5. Product-approved vent/air intake : A product-
approved vent terminal must be used and, if
applicable, a product-approved air intake must be
used. Installation shall be in strict compliance with the
manufacturer’s instructions.
6. Installation instructions : A copy of all installation
instructions for all Product Approved side wall
horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/
or all venting design instructions shall remain with
the appliance or equipment at the completion of the
installation.
VENTING INSTRUCTIONS
Vent Pipe Installation Instructions
This boiler is design certied for use with following venting
systems.
Company Product
HEAT-FAB®SAF-T-VENT™
FLEX-L®STAR-34™
Z-FLEX®Z-VENT™
ProTech®FasNSeal™
!
WARNING
Read and understand these instructions, for
correct installation of vent system.
Failure to use this venting system will void
manufacturer’s warranty and may result in
rapid deterioration of venting system, a
potential health hazard.
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.
Vent connectors serving appliances vented by
natural draft shall not be connected into any
portion of mechanical draft systems operating
under positive pressure
!
WARNING
All installations of boilers and venting
should be done by a qualied expert and in
accordance with these instructions Installing
or venting a boiler or any other gas appliance
with improper methods or materials may
result in serious injury or death due to re or
to asphyxiation from poisonous gases such
as carbon monoxide which is odorless and
invisible.
!
CAUTION
The above vent pipe and ttings are used
for venting gas burning category III, IV, and
direct vent appliances. Do not use this vent
pipe or ttings for venting appliances burning
fuels such as wood, oil, kerosene or coal.
Do not use this vent pipe and ttings for
venting incinerators of any kind.