Columbia LV Series Installation Operation Maintenance Manual

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[Page 1] Columbia LV Series

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

[Page 2] Columbia LV Series

Homeowner / Installer Policy We at Columbia Boiler Company would like to “Thank You” for choosing our top of the line LV Series Boiler. At Columbia Boiler we take pride in the serviceability and the quality construction of our products. We have...

[Page 3] Columbia LV Series

Contents Homeowner / Installer Policy i Product Features 1 Model Specifications 2 Model Dimensions 2 Installation 3 Operation 13 Maintenance 16 Trouble Shooting 17 Preliminary Settings 23 Parts List 27 Burner Service Set-Up Records 28 Product Feature...

[Page 4] Columbia LV Series

2 Component Arrangement SPECIFICATIONS LV-75 LV-100 LV-110 LV-125 LV-135 LV-150 HEATING CAPACITY BTU/HR 89,355 118,300 128,600 150,000 160,000 174,000 IBR NET RATING BTU/HR 77,700 102,900 118,000 130,500 139,100 151,300 INPUT BTU/HR 105,000 140,000 1...

[Page 5] Columbia LV Series

3 Installation I GENERAL This Series hot water steel boilers are high quality oil fired heating units. The installation of the unit shall be in accordance with state and local regulations. Refer to local Installation Codes for Oil Burning Equipment,...

[Page 6] Columbia LV Series

4 c) Stand two of the legs up along the short side the top on the outside of the top. Fasten the cross braces through the legs and tighten all bolts. Repeat for the other side. d) Assemble the long side braces to the legs and themselves. Place the t...

[Page 7] Columbia LV Series

5 C) Special Conditions When a boiler is located in an area where exhaust fans, kitchen ventilation systems, clothes dryers, or fireplaces may create conditions of unsatisfactory combustion or venting, special provisions should be made for additional...

[Page 8] Columbia LV Series

6 Relief valve discharges and drain valve piping must be piped to a safe place of discharge. All plugs and water connections should be checked for leaks upon installation and annually. This series of boilers virtually eliminates all standby losses wi...

[Page 9] Columbia LV Series

7 n l m n n n n n k k RETURN THERMOSTATIC OR MANUAL BYPASS STOP VALVE FILL VALVE DRAIN VALVE RELIEF VALVE AQUASTAT FLOW CONTROL VALVE SUPPLY CIRCULATOR AIR VENT OR EXPANSION TANK T & A GAUGE n BURNER DOOR FIGURE 2 - PIPING LAYOUT PREFERR...

[Page 10] Columbia LV Series

8 ELECTRICAL DIAGRAM FOR LV SERIES BOILERS TO CONNECT BURNER TO AQUASTAT (APPLIES TO BECKETT CHIMNEY VENT BURNERS) ELECTRICAL DIAGRAM FOR LV SERIES BOILERS TO CONNECT BURNER TO AQUASTAT (APPLIES TO RIELLO CHIMNEY VENT BURNERS) ...

[Page 11] Columbia LV Series

9 ELECTRICAL DIAGRAM FOR LV SERIES BOILERS TO CONNECT BURNER TO AQUASTAT (APPLIES TO CARLIN CHIMNEY VENT BURNERS) ELECTRICAL DIAGRAM FOR LVD SERIES BOILERS TO CONNECT BURNER TO AQUASTAT (APPLIES TO BECKETT DIRECT VENT BURNERS) ...

[Page 12] Columbia LV Series

10 ELECTRICAL DIAGRAM FOR LVD SERIES BOILERS TO CONNECT BURNER TO AQUASTAT (APPLIES TO RIELLO DIRECT VENT BURNERS) ELECTRICAL DIAGRAM FOR LVD SERIES BOILERS TO CONNECT BURNER TO AQUASTAT (APPLIES TO CARLIN DIRECT VENT BURNERS) ...

[Page 13] Columbia LV Series

11 The primary control will stop the oil burner within a predetermined number of seconds if the fuel fails to ignite or if the flame goes out during operation. The oil burner will remain off until the reset button on the relay has been pushed. THE RE...

[Page 14] Columbia LV Series

12 It is recommended that the indirect water heater be wired so that when its thermostat calls for heat the flow of heat to the rest of the house is turned off. Consult the wiring diagrams from the indirect hot water heater manufacturer for wiring de...

[Page 15] Columbia LV Series

13 E) Vent Cap Install a U.L. listed vent cap where the possibility of down drafts exist. F) Boiler Venting This boiler must be vented into a properly sized chimney, or into an Underwriters Laboratories Inc. list- ed venting device which is capable o...

[Page 16] Columbia LV Series

14 II ST ART UP ADJUSTMENTS A) Equipment Required 1. CO2 analyzer 2. Draft gauge. 3. Fuel pressure gauge. 4. Stack thermometer. 5. Smoke tester. B) Burner Adjustments Allow the burner to operate steadily for at least 15 minutes. Check the burner set...

[Page 17] Columbia LV Series

15 D) Fan and Blower Housing The fan and blower housing should be kept clean from lint and dirt. If the boiler is located near an unvented dryer, special care must be taken so that lint does not block air passages in the burner and proper combustion ...

[Page 18] Columbia LV Series

16 Maintenance I VENT SYSTEM ESCAPING GASES ARE DANGEROUS. THE ENTIRE FLUE AND VENTING SYSTEM SHOULD BE INSPECTED AT LEAST ONCE A YEAR BY A QUALIFIED SERVICEMAN. II OIL FIL TER The oil filter cartridge should be replaced annually. III CLEANING At...

[Page 19] Columbia LV Series

17 Troubleshooting Guide TROUBLE: BURNER DOES NOT START SOURCE PROCEDURE CAUSES REMEDY Thermostat Check Thermostat Thermostat set too low. Turn thermostat up. Thermostat on “off ”or “cool.” Switch to heat. Open thermostat wires. Repair or rep...

[Page 20] Columbia LV Series

18 Oil Supply Check tank for oil. Check for water in oil tank using a dip stick coated with litmus paste. Listen for pump whine. Oil Line Open pump bleed port and start and Filter burner. Milky oil or no oil indicates loss of prime. Listen for pump w...

[Page 21] Columbia LV Series

19 Cad Cell Check cad cell with ohmmeter. If more than 2000 ohms, cad cell is defective or dirty. Primary After burner fires, open cad cell Control circuit if flame looks OK. If burner continues to operate, fault is in primary control. Heat Inspect h...

[Page 22] Columbia LV Series

20 Poor Fire Inspect flame for stability. Oil Supply If burner loses flame prior to the primary control locking out, fault is in fuel system. Combustion Reduce combustion air supply. Air Pump Install pressure gauge in gauge port of fuel pump. Pressur...

[Page 23] Columbia LV Series

21 Draft Take a draft reading. Draft should be according to installer/ serviceman labels for Series I & II boiler located at the end of this manual, in the stack. Draft Inspect draft regulator for correct Regulator location on flue system. Comb...

[Page 24] Columbia LV Series

22 Circulator Check if circulator is operational. Check if circulator is correct size. Check if circulator is up to speed; check if voltage to circulator is sufficient. Thermostat Check thermostat settings. Check thermostat location. Check thermostat...

[Page 25] Columbia LV Series

23 INSTALLER/SERVICEMAN Model Number LV-75 LV-100 LV-110 Burner Type Riello Riello Riello Burner Model F5 F5 F5 Nozzle Type .65 60W .85 60w .90 60W Pump Pressure PSI 150 150 150 Head/Pin Position 2.0 2.0 2.0 Air Band N/A N/A N/A Air Shutter 1.75 3.0 ...

[Page 26] Columbia LV Series

24 INSTALLER/SERVICEMAN Model Number LVD-75 LVD-100 LVD-110 Burner Type Riello Riello Riello Burner Model BF5 BF5 BF5 Nozzle Type .65 60W .85 60W .90 60W Pump Pressure PSI 150 150 150 Head/Pin Position 2.0 2.0 2.0 Air Band N/A N/A N/A Air Shutter 3.2...

[Page 27] Columbia LV Series

25 INSTALLER/SERVICEMAN Model Number LV-125 LV-135 LV-150 Burner Type Riello Riello Riello Burner Model F5 F5 F5 Nozzle Type 1.00 60A 1.10 60A 1.25 60A Pump Pressure PSI 150 150 150 Head/Pin Position 2.0 3.0 4.0 Air Band N/A N/A N/A Air Shutter 3.5 3...

[Page 28] Columbia LV Series

INSTALLER/SERVICEMAN Model Number LVD-125 LVD-125 LVD-125 Burner Type Beckett Carlin* Riello Burner Model AFII EZ-1 BF5 Nozzle Type 1.00 60°B 1.00 60°B 1.00 60°B Pump Pressure PSI 140 140 150 Head/Pin Position 8 110-125 1.0 Air Band N/A N/A N/A Ai...

[Page 29] Columbia LV Series

Parts List LV75/110 and LV125/150 Boilers Item Description Part Number Part Number No. LV75/110 LV125/150 1 Heat Exchanger 280000 280002 2 Fire Tuber Baffle 280275 280274 3 Combustion Liner 337804 337804 4 Insulation for Steel Burner Door 337803 33...

[Page 30] Columbia LV Series

28 Initial Set Up 1 2 3 4 5 1. Date 2. Model Number 3. Firing Rate 4. Pump Pressure* 5. CO2 6. “0” Smoke 7. Gross Stack°F 8. Draft Over Fire 9. Replaced Filter Yes/No 10. Replaced Nozzle Yes/No 11. Clean Pump Filter Yes/No 12. Inspect Coil Gaske...

[Page 31] Columbia LV Series

29 6 7 8 9 10 1. Date 2. Model Number 3. Firing Rate 4. Pump Pressure* 5. CO2 6. “0” Smoke 7. Gross Stack°F 8. Draft Over Fire 9. Replaced Filter Yes/No 10. Replaced Nozzle Yes/No 11. Clean Pump Filter Yes/No 12. Inspect Coil Gasket 13. Check fo...

[Page 32] Columbia LV Series

11 12 13 14 15 1. Date 2. Model Number 3. Firing Rate 4. Pump Pressure* 5. CO2 6. “0” Smoke 7. Gross Stack°F 8. Draft Over Fire 9. Replaced Filter Yes/No 10. Replaced Nozzle Yes/No 11. Clean Pump Filter Yes/No 12. Inspect Coil Gasket 13. Check f...