Columbia CEGDID075D Gebrauchsanweisung

GAS-FIRED STEAM BOILERS

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

P/N# 240009573, Rev. D [08/2012]

MODEL

CEGDID

Electronic

Intermittent

Ignition

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13504-4729

web site: www.ecrinternational.com

Models

CEGDID075D

CEGDID112D

CEGDID150D

CEGDID187D

CEGDID225D

CEGDID262D

CEGDID299D

OLUMBIA

OMPANY

Main ofﬁces and Factory:

Pottstown, PA

Figure 1 - Dimensions

Table 1 - Physical Data

Models 075 112 150 187 225 262 299

Width (A) 10 7/814 1/817 3/820 5/823 7/827 1/830 3/8

Height (B) 35 7/8

Depth (C) 28 3/828 3/829 3/830 3/830 3/830 3/830 3/8

Gas

Connection Size (G) ½ NPT ½ NPT ½ NPT ¾NPT ¾NPT ¾NPT ¾NPT

Flue Diameter

5" 5" 6" 7" 7" 7" 7"

DIMENSIONS

2" NPT

½" NPT

Plug

2" NPT

Safety

Relief

Valve

Floor

5½"

Depth C

29"

25"

12⅜"

16⅝"

13½"

2" NPT

Table 2

Ratings and Capacities

Natural Gas & Propane (LP)

Boiler Model

Number Input

MBH (1)

Heating

Capacity

MBH (1)

Net AHRI Rating (2)

AFUE, % No. of

Sections Vent Pipe

Size

Steam,

MBH Steam,

Sq. Ft.

CEG075DID 75 62 47 195 82.2 3 5"

CEG112DID 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 83.2 8 7"

CEG299DID 299 250 188 782 83.4 9 7"

Heating Capacity and AFUE are based on DOE (Department of Energy) test procedures.

1. Input rating for sea level to 2,000 ft. above sea level.

Altitudes over 2000 ft. above sea

level, reduce input rate 4% for every 1000 ft.

2. Net AHRI steam ratings shown are based on a piping and pickup allowance of 1.333.

Consult manufacturer before selecting a boiler for installations having unusual piping

and pickup requirements, such as intermittent system operation, extensive piping

systems, etc.

BOILER RATINGS AND CAPACITIES

Important Safety Information....................... 5

Locating the Boiler...................................... 6

Hydronic Piping .......................................... 7

Fresh Air for Combustion ............................11

Chimney and Vent Pipe Connection ..............12

Vent Damper Operation ..............................14

Gas Supply Piping......................................15

Electrical Wiring ........................................16

Operating Instructions................................17

Operating Your Boiler .................................18

Checking and Adjusting ..............................19

Start-up Cleaning ......................................21

General Maintenance .................................22

Troubleshooting.........................................23

Wire Diagrams ..........................................24

Optional Hydronic Piping.............................27

TABLE OF CONTENTS

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

GAS FIRED STEAM BOILERS

Check our website frequently for updates: www.ecrinternational.com

Information and speciﬁcations outlined in this manual in effect at the

time of printing of this manual. ECR International reserves the right to

discontinue, change speciﬁcations or system design at any time without

notice and without incurring any obligation, whatsoever.

Introduction

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.

Prior to Installation

• Verify correct boiler for type of gas being used

natural or propane. See Rating Plate.

• Verify boiler size and dimensions. See Figure 1 and

Table 1, page 2.

• Verify ratings and capacity data for natural gas. See

Table 2.

Installation Requirements

• Supply boiler with correct gas (natural or propane),

fresh air for combustion, and suitable electrical supply.

• Connect boiler to adequate venting and piping

systems.

• Provide boiler with properly located and adjusted

thermostat.

Installation of boiler in building under construction, use

precaution to insure clean combustion air supply during

construction process. Airborne particulate from construction

materials can clog burner ports and cause incomplete

combustion and sooting.

Complete all steps for safe and proper heating system

operation.

IMPORTANT SAFETY INFORMATION

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

may result in minor or moderate injury.

NOTICE

Used to address practices not related to personal

injury.

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.

WARNING

Fire, explosion, asphyxiation hazard. Keep boiler area

clear and free from combustible materials, gasoline

and other ﬂammable vapors and liquids.

Modiﬁcation, substitution or elimination of factory

equipped, supplied or speciﬁed components could

result in death or serious injury.

General

Boiler and venting installation shall be completed by

qualiﬁed agency.

WARNING

Fire, explosion, asphyxiation and electrical shock

hazard. Improper installation could result in death

or serious injury. Read this manual and understand

all requirements before beginning installation.

Become familiar with symbols identifying potential

hazards.

This is the safety alert symbol. Symbol alerts you to

potential personal injury hazards. Obey all safety messages

following this symbol to avoid possible injury or death.

Installation shall conform to requirements of

authority having jurisdiction or in absence of such

requirements to the National Fuel Gas Code,

ANSI Z223.1/NFPA 54.

Where required by authority having

jurisdiction, installation shall conform to

Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1.

Controls can be added to make this boiler CSD-

1 compliant. Check with your local codes for

requirements.

Requirements for Commonwealth of Massachusetts:

Boiler installation must conform to Commonwealth of

Massachusetts code 248 CMR which includes but is

not limited to installation by licensed plumber or gas

ﬁtter.

LOCATING THE BOILER

Locating the Boiler

Select level location as centralized with piping system,

and as near chimney as possible.

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.

Do not install boiler on carpeting. For installation

on non-combustible ﬂoors only. For installation on

combustible ﬂooring, special base must be used. (See

Replacement Parts Manual.)

Use metal shims under boiler base legs for ﬁnal leveling

if needed.

Install boiler in location that permits satisfactory

combustion of gas, proper venting, and maintenance

of ambient temperature at safe limits under normal

conditions of use. Boiler location should not interfere

with proper circulation of air. Introduce outside air

if normal inﬁltration does not provide necessary

air.“Fresh Air for Combustion” on page 11.

Notify owner to keep air passages free of obstruction.

Ventilating and combustion air must enter boiler room

without restrictions.

Table 3 -

Minimum Clearance Dimensions

Top 6"

Rear 6"

Control Side 7"

Opposite Side 6"

Front Alcove

Flue/Vent

Connector 6"

Near Boiler Piping 1/2"

Install boiler so automatic gas ignition system

components are protected from water (dripping,

spraying, rain, etc.) during appliance operation and

service.

Draft Hood Installation

WARNING

Asphyxiation, carbon monoxide hazard. Failure to

follow these instructions could result in improper

combustion and possible leakage of combustion

products into the living space.

Follow directions given in Figure 3. Attach draft diverter,

and blocked vent switch. Mount vent damper. See

"Connecting Vent Damper and Vent Connector" page 12.

See Wiring Diagrams pages 24 and 25.

7”

6”

Boiler

Rear

Front

Control Side

Opposite Side

ALCOVE

6”

Figure 2 - Minimum Clearances To Combustible

Construction

Figure 3 - Draft Hood Installation

Lift up then off to remove front panel.

Remove top jacket panel (4 screws).

Slide draft hood over ﬂue collector.

Secure with 1 or 2 screws, based on boiler size.

Replace top jacket panel (4 screws).

Replace front panel.

Draft Hood

Screws

Front Panel

Lift Up

Then Off

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.

• Have no intervening shutoff valve between safety valve and discharge to atmosphere. Do not plug or

place any obstruction in discharge line.

• Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing.

• Allow complete drainage of valve and discharge line.

• Install safety valve with spindle in vertical position.

• Do not install shutoff valve between boiler and safety valve.

• Support safety valve discharge piping.

• Be short and straight as possible.

• Terminate with plain end, not threaded.

• Constructed of material suitable for exposure to temperatures of 375° F (191°C); or greater.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation

requirements.

Check local codes

for maximum

distance from

ﬂoor or other

allowable safe

point of discharge

Safety Valve

Discharge

Piping

6" Above Floor

Figure 4 - Safety Valve

HYDRONIC PIPING

Consider near boiler piping as part of the boiler for proper

water level control and to produce dry steam.

Correct near boiler piping is crucial to proper operation of

boiler and heating system.

Follow these recommendations carefully.

Place boiler in selected location as near chimney as

possible.

Install safety valve. Figure 4 and Warning on Page 7.

• Install union, if used, close to safety valve outlet.

• Install elbows close to safety valve outlet and

downstream of union (if used).

Boiler is equipped with two 2" supply connections and

two 2" return connections, one each on both left and

right sides of boiler. Plug unused connections with

furnished 2" plug and 2 x ¾" bushing for drain valve.

When using both supply tappings to pipe system.

Figure 5b , Page 9

• Fit headers with header offsets, swing joints, or equip

with expansion joints, so thermal expansion and

contraction of header does not damage boiler. Do not

weld headers.

• Place system takeoffs from header between equalizer

and riser to header nearest equalizer. System takeoffs

must never be between two risers. If steam main goes

in two directions, place two takeoffs from header, one

for each main.

Recommended near boiler piping for gravity return

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.

Equip all boilers in gravity return systems with Hartford

Loop as shown in Figure 5a and 5b page 9.

Piping vertical risers from boiler to header, risers must

be minimum of 24" high above water line..

Steam riser(s) and header shall be 2" pipe size.

Equalizer line shall be minimum 1-1/2" pipe size.

10.

Near boiler piping shall include 2" tee with female

adapter and cap located on supply line as shown for

skimming (i.e. surface blow-down).

11.

For pumped return systems, follow condensate pump

or boiler feed pump manufacturer’s instructions for

proper installation and hookup. See Table 3 and Figure

6 page 10.

12.

Connecting cold water supply to water inlet valve,

verify clean water supply is available. When water

supply is from well or pump, install sand strainer at

pump.

Table 3 - Steam Flow Rates (Gross)

Sections Flow Rates LBS/HR

363.4 LBS/HR

4 94.7 LBS/HR

5 126.8 LBS/HR

6 158.1 LBS/HR

7 190.2 LBS/HR

8 221.5 LBS/HR

9 252.8 LBS/HR

Figure 5b - Recommended Near Boiler Piping Using Two Supply Tappings

HYDRONIC PIPING

Floor

Sections Risers Headers Equalizers

32"2" 1½

42"2" 1½

Water Line

28"

Main Vent

Equalizer 1½"

Close Nipple

Header

24"

Figure 5a - Recommended Near Boiler Piping Using One Supply Tapping

For Alternate Piping

Conﬁgurations See Page 27

Sections Risers Headers Equalizers

5 (2) 2" 2" 1½

6 (2) 2" 2" 1½

7 (2) 2" 2½" 1½

8 (2) 2" 3 1½

9 (2) 2" 3 1½

Water Line

28"

Main Vent

24"

Equalizer 1½"

Close Nipple

Header

Floor

24"

Cap To

Skimmer Tee

Cap To

Skimmer Tee

For Alternate Piping

Conﬁgurations See Page 27

HYDRONIC PIPING

Figure 6 - Recommended Near Boiler Piping For Pumped Return Systems

Figure 7 - Recommended Near Boiler Piping For Gravity Return Systems

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