INSTALLATION
AND
OPERATOR’S MANUAL
EMERALD SERIES
EM-85
THRU
EM-200
OIL FIRED PACKAGED BOILER BURNER UNIT
COLUMBIA
®
COLUMBIA BOILER CO. OF POTTSTOWN
POTTSTOWN, PENNSYLVANIA 19464
FL
UE
BO
X
Homeowner / Installer Policy
We at Columbia Boiler Company would like to “Thank You” for choosing our top of the
line Emerald Series Boiler. At Columbia Boiler we take pride in the serviceability and the
quality construction of our products. We have built trusting relationships that date back
through our company’s history to 1936. We believe that personal service is the best service and our customers agree.
We would like to offer you a few helpful service points to insure your family years of trouble free comfort. In order to maintain peak performance of your boiler, it is recommended that your boiler be maintained annually. Servicing of your appliance must be
performed by a qualified oil heating technician. A properly trained oil technician will be
prepared to set your boiler/burner combination with the proper tools necessary to
achieve your maximum comfort and efficiency.
As a family owned business, we are happy to have you as one of our many satisfied
homeowners who have been choosing Columbia boilers for over 70 years. We look forward to a long and continued relationship.
Rosemarie Bartchak
Sales and Marketing Manager
Columbia Boiler Residential Sales
TABLE OF CONTENTS
Page
Emerald Series Boiler Ratings and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation and Operating Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Burner Service Set-Up Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Emerald Series Boiler/Burner Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EMERALD
PACKAGED,
HYDRONIC
HEATING BOILERS
SERIES
IBR/DOE RATINGS AND DATA
Boiler Model No.
EM-85
Firing Rate -- #2 Fuel
Input -- MBTU/Hr.
DOE Heating Capacity MBTU/Hr.
Net IBR Rating MBTU/Hr.
GPM Tankless Coil
DIMENSIONS (INCHES)
EM-100 EM-3100 EM-110 EM-125 EM-3125 EM-135 EM-150 EM-165 EM-175 EM-200
.85
119
101
88
3
1.00
140
118
103
5
1.00
140
119
103
5
1.10
154
130
113
5
1.25
175
148
129
5
1.25
175
146
127
5
1.35
189
159
138
5
1.50
210
176
153
5
1.65
231
183
168
5
1.75
245
205
178
5
2.00
280
234
203
5
EM-85
EM-100
EM-3100
EM-110
EM-125
EM-3125
EM-135
EM-150
EM-165
EM-175
EM-200
A
C
D
Length
Height
Width
20"
37-1/4"
19-1/2"
20"
37-1/4"
19-1/2"
21"
46"
21"
20"
37-1/4"
19-1/2"
20"
37-1/4"
19-1/2"
21"
46"
21"
21"
46"
21"
21"
46"
21"
21"
46"
21"
21"
46"
21"
21"
46"
21"
E
F
G
Height
Diameter
Base Hgt.
34-3/8"
16-3/4"
17"
34-3/8"
16-3/4"
17"
43-3/8"
18-3/4"
20-1/2"
34-3/8"
16-3/4"
17"
34-3/8"
16-3/4"
17"
43-3/8"
18-3/4"
20-1/2"
43-3/8"
18-3/4"
20-1/2"
43-3/8"
18-3/4"
20-1/2"
43-3/8"
18-3/4"
20-1/2"
43-3/8"
18-3/4"
20-1/2"
43-3/8"
18-3/4"
20-1/2"
Size
Height
C.L. to Rear
6"
37-1/2"
9"
6"
37-1/2"
9"
6"
47"
10-1/2"
6"
37-1/2"
9"
6"
37-1/2"
9"
6"
47"
10-1/2"
8"
47"
10-1/2"
8"
47"
10-1/2"
8"
47"
10-1/2"
8"
47"
10-1/2"
8"
47"
10-1/2"
Size
Supply L Height
Outlet M C.L. to Outlet
1-1/4"
35-1/4"
9"
1-1/4"
35-1/4"
9"
1-1/4"
45"
8-3/8"
1-1/4"
35-1/4"
9"
1-1/4"
35-1/4"
9"
1-1/4"
45"
8-3/8"
1-1/4"
45"
8-3/8"
1-1/4"
45"
8-3/8"
1-1/4"
45"
8-3/8"
1-1/4"
45"
8-3/8"
1-1/4"
45"
8-3/8"
Feed/
Drain
Size
Height
1-1/4"
19-1/4"
1-1/4"
19-1/4"
1-1/4"
22-3/4"
1-1/4"
19-1/4"
1-1/4"
19-1/4"
1-1/4"
22-3/4"
1-1/4"
22-3/4"
1-1/4"
22-3/4"
1-1/4"
22-3/4"
1-1/4"
22-3/4"
1-1/4"
22-3/4"
Return Q
Inlet
S
Size
C.L. to Inlet
Height
1-1/4"
20"
19"
1-1/4"
20"
19"
1-1/4"
20"
22-1/2"
1-1/4"
20"
19"
1-1/4"
20"
19"
1-1/4"
20"
22-1/2"
1-1/4"
20"
22-1/2"
1-1/4"
20"
22-1/2"
1-1/4"
20"
22-1/2"
1-1/4"
20"
22-1/2"
1-1/4"
20"
22-1/2"
Coil
Conn. U
Nominal Size
Height
1/2"
32-1/4"
1/2"
32-1/4"
1/2"
42"
1/2"
32-1/4"
1/2"
32-1/4"
1/2"
42"
1/2"
42"
1/2"
42"
1/2"
42"
1/2"
42"
1/2"
42"
Casing
Boiler
H
Flue
I
Outlet J
O
COLUMBIA BOILER CO.
OF POTTSTOWN
BOX G, POTTSTOWN, PA 19464
ASME
Construction
1
Emerald Series Installation and Operators Manual
COLUMBIA
COLUMBIA BOILER CO. OF POTTSTOWN
Box G, Pottstown, Pennsylvania 19464
A Message to: Installer, Serviceman, Homeowner:
Over sixty years of engineering and product development have gone into your new Columbia oil fired
boiler. It’s quality and design are unsurpassed. Properly installed and maintained, it will provide many years
of efficient and dependable operation. Please read this Instruction Manual carefully. The information contained within is designed to help you maintain peak performance from your boiler/burner unit.
A. Installation Instructions
CAUTION:
1. Installer must be a trained, experienced serviceman.
2. Inspect the boiler, jacket and all components to be sure damage has not occurred in shipment. If
damage is evident you must file a claim with the freight carrier immediately.
3. Disconnect power supply before connecting wiring.
4. Refer to local installation codes for oil burning equipment, for recommended installation practice.
5. A complete heat loss calculation is necessary to choose the proper size unit to install. The boiler
should be sized to within 25% of the actual heat loss of the structure.
6. Conduct thorough checkout when installation is complete.
Figure 1. The nuts that secure the tankless
coil flange should be tightened before the
boiler is filled with water, after initial firing
and once a year during the annual maintenance. DETERIORATION DUE TO COIL
GASKET LEAKS WILL VOID THE WARRANTY.
1) Place the boiler on a level non-combustible
floor, preferably raised and as close to the
chimney as possible. The following minimum
clearances must be adhered to during installation and maintained thereafter to properly
clean, inspect and service your boiler: sides
and back - 6"; front - 24" and vent connector
- 18". Reduced clearance installations must
follow NFPA-31 guidelines.
3a) This style of boiler is equipped with a built in
“Air Scoop System.” This feature allows
quiet air free operation of your hot water system by assuring the removal of air pockets
without the installation of Air Scoops to trap
noisy air.
2) For location of piping refer to the installation
drawing in Figure 1. The burner, aquastat
and circulator are wired at the factory. For
power and thermostat (not supplied) wiring
connections see the control manuals provided along with this manual. For piping and
wiring of other system components see the
manufacturers installation manuals.
The 1-1/4" supply line or Riser tapping in the
top of the boiler extends approximately 1"
below the top or waterline of the boiler, thus
allowing only air free water to enter the supply to the heating system. The air trapped in
the top of the boiler is then purged through a
3/4" vent tapping to be released with an (1)
automatic float vent (2) a manual vent or (3)
piped into a conventional type expansion
tank.
3) The tankless water heater may be piped as
shown in Figure 1. A mixing valve, not supplied, must be used to reduce the water
temperature at kitchen or bathroom taps.
High temperature water for a dishwasher
may be obtained by piping as shown in
2
type of installation for these conditions. Manual
venting of the fuel unit is usually required on initial start-up. Failure to vent air could result in an
air lock/oil starvation condition. (One pipe)
Relief valve discharges and drain valve piping should be piped to a safe place of discharge. All plugs and water connections
should be checked for leaks upon installation and annually.
Fuel supply below the level of burner: Use a
single stage fuel unit in lift conditions of up to 10
ft., and a two stage fuel unit when the lift
exceeds 10 ft. Both conditions require the use of
a return line which helps to purge the fuel unit of
air returning it to the fuel tank. The “by-pass”
plug must be inserted into the fuel unit when
installing a return line. (Two pipe)
4) Be certain the chimney is clean and free of
obstructions. Connect boiler flue outlet to
chimney using galvanized smoke pipe. The
flue pipe should be pitched upward at least
1/4" per foot of run. Refer to Page 1 in this
manual for proper size flue pipe for your
model boiler. Use only elbows and straight
sections. Tees may be used in a straight section in conjunction with a barometric draft
regulator; however, they must not be used
for a 90° turn. Each joint should be securely
fastened with sheet metal screws. The flue
pipe must not be inserted beyond the inside
wall of the chimney. Install barometric draft
regulator in the horizontal or vertical section
of the flue pipe.
Fuel line installation: Continuous lengths of
heavy wall copper tubing are recommended and
should be installed under the floor when possible.
Always use flare fittings. Always install fittings in
accessible locations. Never use teflon tape on
any fuel fitting. Use of teflon will void any pump
warranty. Fuel lines should not run against the
appliance or the ceiling joists.
5) The boiler room must be well ventilated to
allow sufficient make-up air to support combustion. Lack of adequate combustion air
may result in erratic operation of the burner,
noisy combustion or fuel odors. Remember
your need for outside air will be greatly
increased if you have a vented dryer in the
basement or other venting fans in the home.
Boilers located in confined spaces shall be
provided with two permanent openings, one
near the top and one near the bottom of the
enclosure. Each opening shall have a free
area of not less than one square inch per
1000 BTU per hour input rating of the boiler,
freely communicating with interior areas having adequate infiltration from the outside.
Fuel line valve and filter: Install two high
quality shutoff valve(s) in accessible locations on
the oil supply line. Locate one close to the tank
and the other close to the burner ahead of the filter. Some filters come with built-in shutoff valves.
Install a generous capacity filter inside the building between the fuel tank shutoff valve and the
burner locating both the filter and the valve close
to the burner for ease of servicing.
Always use flare fittings.
Never use compression fittings.
IMPORTANT
All oil feed lines to burners must be air tight.
Use only flare fittings when assembling oil lines
since the slightest air leak, caused by loose fittings, bad gaskets or any other reason, can
cause a foaming oil stream which will cause any
of the following conditions:
6) Fill boiler and system with water. Be sure
entire system has been purged of air and the
desired pressure is obtained.
a) Intermittent firing, causing safety shutdown
7) Connect burner to oil supply. Refer to fuel
unit manufacturer literature for piping, connections, lift and tank installation. If such
information is unavailable use the following
guidelines.
b) Poor starts
c) Smokey starts
d) Continual sooting of boiler and burner
parts including the cad cell
FUEL UNITS/FUEL LINES
e) Reduced firing rate, inefficient operation
and erratic fire pattern
Fuel supply “level with” or “above” burner: A
single stage fuel unit connected to the fuel supply with a single supply line is the most common
3
temperature is normally maintained at 160°F
around the tankless coil by the operating
control so that an abundance of hot water is
available. If the boiler water temperature
should fall below the operating control setting (160°F) the oil burner will be started
again by that control (and the circulating
pump will be prevented from operating) until
the operating control setting is satisfied. See
control manufacturers literature included in
the data package for detailed wiring, operating and safety instructions.
f) A dangerous combustion condition, allowing the firebox to fill with a lean mixture
(too much air in the oil stream) which could
cause a delay in ignition of the fuel mixture
until the danger point has been reached.
Suction vacuum must be held to acceptable
limits. The vacuum test is worth the time required
to make it. This problem becomes proportionately larger with underground tanks. If the following
procedures are followed, burner related problems
will be minimized:
a) Connect vacuum gauge to oil pump.
Suction vacuum must not exceed 10 inches of mercury for single stage pumps and
15 inches for two stage pumps. It is preferable to stay below these limitations.
2) Boilers Less Tankless Coil - This boiler is
equipped with a high limit aquastat control
which should be set at 180° by the installer.
The oil burner is operated in an identical
sequence as 1), except that the boiler water
temperature need not be maintained at a
160°F low limit setting since there is no
domestic hot water load to protect. See control manufacturers literature included in the
data package for detailed wiring, operating
and safety instructions.
b) When the suction line is tight and properly
installed the pump will hold its vacuum for
a minimum of 60 minutes after shutdown.
c) Installation of a check valve in the suction
line of a two pipe system is advisable
under all circumstances. Be sure the check
valve fittings are airtight.
3) A cadmium sulfide flame scanner (cad cell)
and relay are provided with the oil burner.
The cad cell 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 red reset button on the relay has been
pushed. RESET MUST NEVER BE
PRESSED MORE THAN ONCE DURING A
SINGLE FLAME FAILURE.
d) Connect the electric supply to the boiler as
indicated on the wiring diagrams. The
wiring must be installed in accordance with
the National Electrical Code and any other
state and local codes.
C. Operational Sequence
1) Boilers with Tankless Coil - This boiler is
equipped with a combination aquastat control which has high and low limits to be set
at 180° and 160° respectively by the installer.
When room temperature falls below thermostat setting, thermostat calls for heat starting
the burner and circulating pump. The burner
and pump continue to operate until room
heating requirements are satisfied (thermostat setting is reached), or until boiler water
temperature reaches the high limit control
temperature setting. If the high limit control
temperature setting is reached, the burner
shuts off and the circulating pump continues
to operate until the room heating requirements are satisfied. If the thermostat continues to call for heat after the boiler water
temperature has dropped below the temperature setting of the high limit control, the oil
burner will start again, while the circulating
pump will continue to run. The boiler water
D. Start-Up and Check-Out Procedure
CAUTION
Only a trained, experienced serviceman should
attempt the checkout procedure outlined below.
Read the burner manufacturers instructions for
start-up for special instructions and special features of the burner and control.
1) Combustion test equipment required for
proper burner adjustment:
a)
b)
c)
d)
e)
f)
4
CO2 Analyzer
Draft Gauge
Oil Pressure Gauge 0-200 PSI
Stack Thermometer
Smoke Test Gun
Vacuum Gauge 0-30 in. of Hg
ter so that the CO2 measured in the stack
ahead of the draft control should be a minimum of 10% and a maximum of 12%. At the
same time the draft should be adjusted to .01"-.02" W.C. over the fire. Install a second
barometric draft control if necessary to
reduce excessive draft. The smoke should
also be checked with a smoke gun and
found to be zero.
2) In order to take flue gas samples for combustion testing a 1/4" hole must be drilled
in the flue pipe between the boiler and the
barometric draft regulator.
3) Open all shut-off valves in the oil supply line
to the burner.
4) Set thermostats substantially above room
temperature.
11) Check operation of the cad cell relay by
removing one cad cell wire from external terminal during the flame cycle. The relay
should cut the burner off in approximately 15
to 45 seconds, depending on the control
provided. See the burner manufacturers
manual provided in the data pack.
5) Check electrode settings and readjust air setting if required. Electrode settings are shown
in the burner manual provided along with this
manual. Burner settings are listed on the
Service Man’s Label attached to the boiler
and on the Burner Unit specifications provided along with this manual.
E. Servicing the Boiler/Burner Unit
6) Install pressure gauge in the 1/8" gauge port
of the oil pump.
1) Burner Components: If replacement of burner
parts is necessary, always use parts recommended by the manufacturer. Specify part
number and description when ordering.
7) Turn on switch to start burner. If burner does
not start immediately, you may need to reset
the burner control. See the burner manufac
turers instructions for control and reset
features.
2) Electrode settings are important for reliable
ignition of the oil. Check to be sure the settings are in accordance with the instructions
provided in the burner manual.
8) On one pipe systems bleed the oil pump as
soon as burner motor starts. To bleed, attach
a length of 1/4" O.D. clear plastic tubing to
the end of the bleed plug and then loosen
plug while holding an empty container under
the tubing to catch all of the expelled oil.
Bleed for at least 15 seconds after the oil
stream is free of all air. If air is still evident in
the bleed line you must check the oil lines,
all fittings, filters and any other connections
for tightness. Kinks in the oil lines will create
undue high vacuum therefore they must be
eliminated. When you are sure all air has
been eliminated then close the bleed valve.
Ignition should be instantaneous following
the closing of this valve. If it is not, proceed
to the trouble shooting guide to determine
why the oil did not ignite.
3) Nozzles: The nozzle specifications listed in
the manual are the result of years of exhaustive engineering testing. ANY NOZZLE
REPLACEMENT SHOULD BE OF THE
EXACT TYPE AS LISTED IN THE SPECIFICATIONS. Use extreme care in handling nozzles to avoid scratches or dirt that could
cause leaks or affect the oil spray pattern.
4) Fan and blower housing should be kept clean
of dirt and lint. If heating unit is located near
an unvented dryer, special care must be
taken so that lint does not clog the burner air
inlets.
5) Replace the oil filter cartridge annually.
6) Cleaning the Boiler: Cleaning should be done
only by a trained, experienced serviceman.
Turn power off to the boiler. To clean the
boiler, remove the flue pipe, jacket top and
flue collector. Remove the baffles then clean
the tubes with a soft 2" flue brush. Reinstall
parts, readjust and clean the burner if
required.”
9) Be sure the oil pump discharge pressure is
adjusted to 140 PSI. If it is not refer to the oil
pump manufacturer’s instruction sheet for
pressure adjustment procedure.
10) FINAL ADJUSTMENTS OF THE BURNER
MUST BE MADE USING PROPER COMBUSTION TEST EQUIPMENT. The air supply
should be adjusted by loosening the lock
screw and moving the bulk air band or shut5
FIGURE 1
6
Troubleshooting Guide
TROUBLE: BURNER DOES NOT START
SOURCE
PROCEDURE
CAUSES
REMEDY
Power
Check boiler disconnect
and main disconnect switch
Switch open.
Close switch.
Tripped breaker or blown fuse
Reset breaker or replace fuse
Thermostat set too low.
Thermostat on “off” or “cool”
Thermostat not level
Turn up thermostat
Switch to heat
Level thermostat
Open thermostat wires
Repair or replace wires
Loose thermostat connectors
Faulty thermostat
Tighten connection
Replace thermostat
Check burner motor overload
switch, if equipped
Check primary control safety
switch.
Burner motor tripped on
overload
Primary tripped on safety
Press reset button
Press reset button
Check limit settings versus
boiler water temperature
Check for voltage at L1 and
L2
Jump TT terminals on aquastat
then check for voltage at
terminals B1 and B2
Burner off on limit
Adjust limit settings
Open safety switch, tripped
breaker or blown fuse
No voltage indicates defective
control
Close switch, reset breaker
or replace fuse
Replace control
Check for voltage between
the black and white leads. No
voltage indicates no power to
the control. Make sure the
the jumper on TT terminals
is installed
Aquastat limit control
switch open
Check limit setting.
Open circuit between limit
control and primary control
if voltage is present at B1
and B2 of aquastat
Repair circuit.
Check for voltage burner
motor. Voltage indicates
power to motor and a fault
in the burner.
Pump seized.
Turn off power to burner.
Rotate blower by hand,
check for excessive drag.
Replace fuel unit or blower
wheel.
Replace burner motor
Thermostat
Check thermostat settings
Jump TT terminals on
aquastat control. If burner
starts, fault is in the
thermostat circuit
Circuit
Resets
Aquastat
Control
Primary
Control
Burner
Blower wheel binding
Burner motor defective
7
TROUBLE: BURNER STARTS BUT DOES NOT ESTABLISH FLAME
SOURCE
PROCEDURE
CAUSES
REMEDY
Oil Supply
Check tank for oil
Check for water in oil tank
using a dip stick coated
with litmus paste
Listen for pump whine.
Empty tank.
Water in oil tank
Fill tank.
Strip tank of water
Fuel supply valve closed
Oil filter plugged
Plugged pump strainer
Restriction in oil line
Air leak in fuel system
Open valve
Replace filter cartridge
Clean strainer
Repair oil line
Repair leak. The use of flare
fittings is strongly recommended. Do not use Teflon
tape on oil fittings
Pump discharge pressure
set too low
Set pressure at 140 PSI
Coupling worn or broken
Pump worn - low pressure
motor overloads
Replace coupling
Replace pump
Combustion
Check air shutter and
Air
air band
Requirements
Improper air adjustment
Adjust air as indicated in
manual. Set CO2 to 10%
min - 12% max with zero
smoke
Ignition
Electrodes
Incorrect electrode settings
eroded electrode tips
Carboned and shorted
electrodes
Cracked porcelain insulators
Dress up tips and reset
electrodes
Clean electrodes
Open pump bleed port and
start burner. Milky oil or no
oil indicates loss of prime
Oil Pump
Install pressure gauge in port
of fuel pump. Pressure should
be 140 PSI
Remove and inspect nozzle
line assembly
Replace electrodes
Nozzle
Inspect nozzle for plugged
orifice and distributor slots
Inspect nozzle for correct
size and specifications
Plugged orifice or distributor
or strainer
Incorrect nozzle installed
Replace nozzle with nozzle
specified in this manual and
on the boiler lower jacket
panel
Ignitor
Connect ignitor leads to
line voltage. Listen for spark.
Check that ignitor
terminals are not arcing with
buss bars.
No spark or weak spark
Replace ignitor
8
TROUBLE: BURNER FIRES, BUT THEN FAILS ON SAFETY
SOURCE
PROCEDURE
CAUSES
REMEDY
Cad Cell
Check cad cell with ohmmeter.
If more than 1500 ohms, cad
cell is defective or dirty
Faulty or dirty cad cell
Clean or replace cad cell
Primary
Control
See Control Manual
Faulty primary control
Replace primary control
Poor Fire
Inspect flame for stability
Wrong nozzle
Replace nozzle with
type specified
Adjust draft to -.01-.02 W.C.
overfire
Adjust air for a CO2 of 10%
min. to 12% max. and zero
smoke
Repair leaky fittings
Improper draft
Improper air adjustment
Air in oil supply
Oil Supply
If burner loses flame prior
to the primary control
locking out, fault is in the
fuel system
Air leak to fuel system
Restriction in oil line
Plugged fuel filter
Plugged pump strainer
Cold oil
Repair leak. The use of
flare fittings is recommended.
Clear oil line restriction. Replace filter cartridge. Clean
strainer use #1 heating oil
or additive to thin oil
Pump
Install pressure gauge in
gauge port of oil pump
Pressure should be 140 PSI
Pump discharge pressure
incorrectly set
Coupling worn or broken
Pump worn
Set pressure at 140 PSI
Burner motor overloads.
Turn off power and rotate
blower by hand to check
for excessive drag
Pump or blower
overloading motor
Replace blower or pump
Faulty motor
Replace motor
Burner
Motor
Replace coupling
Replace pump
TROUBLE: HIGH NET STACK TEMPERATURES
SOURCE
PROCEDURE
CAUSES
REMEDY
Nozzle
Inspect nozzle for correct
size and type
Check pump pressure with
pump gauge
Incorrect nozzle
Nozzle overfiring due to
high pump pressure
Replace nozzle with nozzle
specified
Reduce pump pressure to
140 PSI
Heat exchanger fouled
Clean heat exchanger
Heat
Exchanger
Check heat exchanger surfaces
for soot or scale fouling
9
TROUBLE: BURNER FIRES BUT PULSATES
SOURCE
PROCEDURE
CAUSES
REMEDY
Draft
Take a draft reading. Draft
should be -.01"-.02" W.C.
overfire
Insufficient draft
Increase draft setting. Be
sure chimney is clean and
meets the minimum size
requirements.
Reduce draft settings. Install
second draft regulator if
necessary
Excessive draft
Draft
Regulator
Inspect draft regulator for
correct location
Improper installation
Move draft regulator to
correct location
Combustion
Air
Inspect installation for
adequate incoming make-up
air
Adjust combustion air
and take a CO2 reading
Insufficient amount of make-up
air in boiler room
Provide openings that freely
communicate with outside.
Improper air intake
adjustment
Adjust CO2 level to 10% min.
12% max. and zero smoke
Oil Supply
Bleed pump and inspect for
air
Air leak in fuel system
Repair air leak
Use flare fittings only
Pump
Pressure
Install pressure gauge in
port of oil pump. Pressure
should be 140 PSI
Pump discharge pressure
incorrectly set
Set pressure at 140 PSI
Coupling worn or broken
Replace coupling
Plugged orifice or distributor
Plugged nozzle strainer
Replace nozzle with
correct nozzle as specified
Nozzle
Inspect nozzle for plugged
orifice and distributor slots
TROUBLE: TOO MUCH HEAT
SOURCE
PROCEDURE
CAUSES
REMEDY
Circulator
Check to see if operating
control is working properly
Circulator does not stop
running
Repair operating control
Thermostat
Check thermostat settings
and calibration
Thermostat set too high
Reset thermostat
Thermostat defective
Thermostat out of calibration
Replace thermostat.
Recalibrate.
Flow valve/zone valve dirty
and stuck
Replace zone valve
Replace flow valve
Flow or
Zone Valve
Check to see if flow valve/
zone valve is operating
properly
10
TROUBLE: INSUFFICIENT HEAT
SOURCE
PROCEDURE
CAUSES
REMEDY
Circulator
Check if circulator is
operational.
Pump binding
Replace pump
Circulator motor burned out
Wiring from operating
control defective
Operating control defective
Replace circulator motor
Repair wiring
Check thermostat settings
Settings too low
Increase setting
Check thermostat location
Bad location due to heat
build up
Out of calibration
Move thermostat to a
better location
Recalibrate
Thermostat
Check thermostat calibration
Repair or replace operating
control
Flow Valve/
Zone Valve
Check flow valve/zone valve
for sticking in partially
closed position
Flow valve/zone valve not
opening fully
Clean or replace flow
valve/zone valve
Radiation
Check for air in radiators
Check to see if radiators are
sized properly
Radiators airbound
Radiators inadequate
Bleed radiators
Install adequate radiation
Tankless
Coil
Check usage of domestic
hot water
Demand too large
Install flow regulator
Additional boiler capacity
required
Heat
Exchanger
Check heat exchanger for soot
or scale accumulation
Insufficient heat transfer
Clean heat exchanger
Burner
Check pump pressure with
pressure gauge
Insufficient pump pressure
Increase pressure to 140 PSI
Nozzle
Check nozzle for size and
spray angle
Check nozzle for plugged
orifice, scoured surface
Wrong nozzle installed
Install specified nozzle
Nozzle underfiring due to
defective nozzle
Replace nozzle
TROUBLE: INSUFFICIENT DOMESTIC HOT WATER
SOURCE
PROCEDURE
CAUSES
REMEDY
Tankless Coil
Analyze capacity vs. usage
Check coil for fouling
Insufficient coil capacity
Hard water scaling
Install larger coil
Install soft water system
Clean coil
Operating
Control
Check operating control
setting
Setting too low
Set operating control
low limit to 160°F
Heat
Exchanger
Inspect coils for fouled surfaces and/or flow restrictions
Flow restriction
Remove restriction
Fouled surfaces or heat
exchanger
Clean heat exchanger
surfaces
11
12
(APPLIES TO CARLIN CHIMNEY VENT AND RIELLO CHIMNEY VENT BURNERS)
ELECTRICAL DIAGRAM FOR EM SERIES BOILERS
TO CONNECT BURNER TO AQUASTAT
13
(APPLIES TO BECKETT CHIMNEY VENT BURNERS)
ELECTRICAL DIAGRAM FOR EM SERIES BOILERS
TO CONNECT BURNER TO AQUASTAT
BURNER SERVICE SET-UP RECORDS
1
2
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 for Leaks @ plugs/fittings
14. Brush Clean Flue Tube Passages
15. Vacuum Chamber/Flue Tubes
16. Clean Blower Wheel
17. Check/Set Electrodes
14
3
4
5
BURNER SERVICE SET-UP RECORDS
6
7
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 for Leaks @ plugs/fittings
14. Brush Clean Flue Tube Passages
15. Vacuum Chamber/Flue Tubes
16. Clean Blower Wheel
17. Check/Set Electrodes
15
8
9
10
Columbia Emerald
Boiler/Burner
Unit Specifications
BOILER/BURNER UNIT SPECIFICATIONS - BECKETT AFG
Pump
Boiler Model
Pressure PSI
Burner
Hd.
Delavan
Nozzle
EM - 85
EM-100
EM-3100
EM-110
EM-3125
EM-125
EM-135
EM-150
EM-165
EM-175
EM-200
140
140
140
140
140
140
140
140
140
140
140
F-3
F-3
F-3
F-6
F-6
F-6
F-6
F-12
F-12
F-12
F-22
.65 80°B
.75 80°B
.85 80°B
.85 80°B
1.00 80°B
1.00 80°B
1.10 80°A
1.25 80°A
1.35 80°A
1.50 80°A
1.65 80°A
Approximate Air Setting
Shutter
Band
8
10
10
10
10
10
10
9
10
10
10
0
0
0
0
2
2
2
0
0
1
2
BOILER/BURNER UNIT SPECIFICATIONS - RIELLO 5F BURNER
Boiler Model
Pump
Pressure PSI
Delavan
Nozzle
Approximate Air Setting
Band
EM - 85
EM-100
EM-110
EM-125
EM-135
EM-150
EM-165
EM-175
EM-200
150
150
150
150
150
150
150
150
150
.65 60°A
.75 60°A
.85 60°A
1.00 60°A
1.10 80°A
1.25 80°A
1.35 80°A
1.50 80°A
1.65 80°B
1.75
1.75
2.25
2.75
3.25
3.8
2.0
2.8
2.75
BOILER/BURNER UNIT SPECIFICATIONS - CARLIN EZ-1 BURNER
Boiler Model
Pump
Pressure PSI
Delavan
Nozzle
Approximate Air Setting
Band
EM - 85
EM-100
EM-110
EM-125
EM-135
EM-150
EM-165
EM-175
EM-200
140
140
140
140
140
140
140
140
140
.65 70°A
.75 70°A
.85 70°A
1.00 60°B
1.10 60°B
1.25 60°B
1.35 60°B
1.50 70°A
1.65 70°A
.65
.65
.75
.85
.90
1.25
1.35
2.00
2.00
Notice: All settings are approximate. Check the Installer Serviceman Label on the boiler for updates and use instruments
to make final settings in accordance with the procedure in this manual.
16
OIL BURNER
BECKETT AFG BURNER (PART NO. 540120)
CARLIN EZ-1 BURNER (PART NO. 542210)
RIELLO F-5 BURNER (PART NO. 541152)
NOTES:
1. KNOCKDOWN BOILERS SUPPLIED WITH THREE (3) PIECE
SIDE/REAR JACKET.
2. BASE ASSEMBLY FOR UNITS PRODUCED PRIOR TO 1999
CONSISTING OF BASE, CHAMBER WRAPPER, FRONT
PANEL, PEEP SIGHT, CHAMBER SUPPORT BLOCK AND FIRE
CHAMBER (PART NO. 790416).
3. BASE ASSEMBLY FOR UNITS PRODUCED AFTER 1999
CONSISTING OF BASE, CHAMBER WRAPPER, FRONT
PANEL, PEEP SIGHT, CHAMBER SUPPORT BLOCK AND FIRE
CHAMBER (PART NO. 790415).
CC-7821
CBC P/N 595850
10/08 - 500