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Columbia CSC SERIES, Installation, Operation & Maintenance Manual

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Columbia CSC SERIES Installation, Operation & Maintenance Manual Download Page 12

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

BL

UE

TR-2

TR-1

BL

UE

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

BL

UE

BL

UE

GREEN

YELLOW

YELLOW

RED

BLA

CK

RED

BLACK

RED

ORG

BL

UE

BL

UE

OR

G

OR

G

ELECTRICAL WIRING

HOT WATER CONTROL AND HOT SURFACE PILOT WIRING

Summary of Contents for CSC SERIES

Page 1: ...lumbia Company Main offices and Factory Pottstown PA CSC SERIES Direct Vent Gas Fired Hot Water Boiler INSTALLATION OPERATION MAINTENANCE MANUAL C S A Certified For Natural Gas Or Propane Tested For 100 psi ASME Working Pressure H ...

Page 2: ... 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...

Page 3: ...eration and service circulator replacement condensate trap control replacement etc For installation on non combustible floors only The boiler must not be installed on carpeting for installation on combustible flooring 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 ...

Page 4: ...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 field mounted Main Gas Burners Hot Surface Pilot A S M E Relief Valve Drain Valve Ind...

Page 5: ...r 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 flow 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 i...

Page 6: ... 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 ...

Page 7: ...LVE 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 ...

Page 8: ...tes 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 efficiency appliances Proper operation of the vent system and appliance is dependent upon the use of all parts specified by the manufacturer for use in the particular installation Appliance and vent system performance may...

Page 9: ...ans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace 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 flame of a ma...

Page 10: ...keep it from turning 6 Install manual shut off valve in vertical pipe about 5 feet 1 5m above floor 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 flames or...

Page 11: ...e 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...

Page 12: ... 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 ...

Page 13: ...rea for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor 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 fire depart...

Page 14: ...o 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 qualified service technician or your gas supplier 8 Sho...

Page 15: ...per manufacturer s instructions It is suggested that a qualified 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 ventin...

Page 16: ...ated on each side of the flue collector See Figure 15 9 Remove the baffles from the heat exchanger See Figure 13 10 Visually inspect baffles 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 f...

Page 17: ...low 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 flame at the start of each heating season and again midway through the season A Check the burner throats and burner orifices for lint and dust obstructions See Figure 15 B The main burner flame should...

Page 18: ...ubing 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 specified on the rating plate 2 To check for proper fl...

Page 19: ... exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 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 fitter shall observe that a hard wired carbon mon...

Page 20: ...NG INSTRUCTIONS Vent Pipe Installation Instructions This boiler is design certified 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 o...

Page 21: ...eded when horizontal vent lengths exceed 10 feet Insert vent pipe in boiler venter outlet vent adapter apply silicone completely around edge of outlet and tighten clamp Figure 2 Horizontal Vent Piping Typical Installation VENTING INSTRUCTIONS ...

Page 22: ... ft 61 cm with 1 elbow 20 ft 610 cm with 2 elbows Example 20 ft 610 cm of vent pipe with 1 elbow is equivalent to 15 ft 457 cm of vent pipe with 2 elbows Note A condensate trap is only required on models over 10 ft 305 cm of horizontally run vent piping WARNING Do not insulate or otherwise wrap vent pipe or fittings Follow vent pipe manufacturers installation instructions for horizontal venting Lo...

Page 23: ...ns 7 Install vent pipe through termination assembly and extend it 3 7 6 cm beyond termination assembly Figures 5a and 5b 8 Install termination wind deflector with four 4 screws provided Figures 5a and 5b 9 Install draw collar around pipe and tighten nut and bolt until tightly secured Figures 5a and 5b 10 Secure termination tee according to vent pipe manufacturers instructions Figure 5a Top View Of...

Page 24: ...PE CONDENSATE DRAIN TERMINATION TEE CONDENSATE TRAP ASSY NOTE REFER TO VENT PIPE LENGTHS FOR USAGE VENT 12 30 5 cm MINIMUM TEE Figure 6 Vent System For All Models Figure 8 UNACCEPTABLE Figure 7 RECOMMENDED VENTING INSTRUCTIONS CONDENSATE DRAINS Flexible Tubing Condensate Drain Installation Install tee with run outlet in vent and close to appliance Install condensate drain in down outlet with high ...

Page 25: ...4 1 2m from or below any doors windows or gravity air inlet Locate vent cap to allow 12 300mm min above grade Vent cap must be at least 4 1 2m horizontally from any electric meters gas meters or relief equipment Vent cap must be at least 4 1 2m horizontally from any electric meters gas meters or relief equipment Direct combustion air intake air inlet permanently fastened to the boiler for combusti...

Page 26: ...ely around edge of outlet and tighten clamp Figure 10 Flex L Star 34 Vent Pipe Components VENTING INSTRUCTIONS Figure 11 Heat Fab Saf T Vent Vent Pipe Components Notes Condensate tee drain is only needed when horizontal vent lengths exceed 10 feet Insert vent pipe in boiler venter outlet vent adapter apply silicone completely around edge of outlet and tighten clamp ...

Page 27: ...ent pipe in boiler venter outlet vent adapter apply silicone completely around edge of outlet and tighten clamp Figure 13 ProTech FasNSeal Vent Pipe Components Notes Condensate tee drain is only needed when horizontal vent lengths exceed 10 feet Insert vent pipe in boiler venter outlet vent adapter apply silicone completely around edge of outlet and tighten clamp ...

Page 28: ...Figures 17 18 D Use vent pipe manufacturer s vent cap fire stop support collar roof flushing and storm collar E Install vertical vent drain tee Figure 15 See Condensate drain installation section of this manual F Fill the 3 8 flexible tubing with water before firing 2 Configuration of vent air intake see Figure 16 Installation Procedure For Vertical Venting NOTICE Boiler installation must use 90 e...

Page 29: ...29 Figure 15 Vertical Drain Tee Figure 16 Vent Air Intake VENTING INSTRUCTIONS Figure 17 Termination 10 Ft 3 05 m or Less From Ridge Figure 18 Termination More than 10 Ft 3 05 m from Ridge ...

Page 30: ...30 Figure 19 Flex L Star 34 Vent Pipe Components VENTING INSTRUCTIONS Figure 20 Z Flex Z vent Vent Pipe Components ...

Page 31: ...31 Figure 21 Heat Fab Saf T Vent Vent Pipe Components VENTING INSTRUCTIONS Figure 20 ProTech FasNSeal Vent Pipe Components ...

Page 32: ...32 HEAT EXCHANGER FULLY ASSEMBLED HEAT EXCHANGERS 912000002 Heat Exchanger 3 Section 912000003 Heat Exchanger 4 Section 912000004 Heat Exchanger 5 Section REPLACEMENT PARTS ...

Page 33: ...ifold 5 Section ITEM PART DESCRIPTIONS QTY 5 3272101 Air Box Wrapper 3 Section 1 3272102 Air Box Wrapper 4 Section 3272103 Air Box Wrapper 5 Section 6 240007769 Pilot Grommet 1 7 HW10201 Manifold Grommet 1 8 3271901 Air Box Wrapper Gskt Bot 3 Section 2 3271902 Air Box Wrapper Gskt Bot 4 Section 3271903 Air Box Wrapper Gskt Bot 5 Section 9 3271801 Air Box Wrapper Gasket 2 10 FOR NATURAL GAS ONLY VG...

Page 34: ... 3272703 Air Box Frt Pnl Assy 5 Section Includes Obs Window 9 Insul 11 ITEM PART DESCRIPTIONS QTY 8 3572401 Insul Frt Cov 3 Section 1 3572402 Insul Frt Cov 4 Section 3572403 Insul Frt Cov 5 Section 9 HW10001 Air Box Tap 2230 Rl 1 10 3572304 Insul Air Box Cover 2 11 3272401 Air Box Cover Assy 3 Section 1 3272402 Air Box Cover Assy 4 Section 3272403 Air Box Cover Assy 5 Section Includes Insulation 1...

Page 35: ... 4 1 2 NPT 1 4 HW 016 03 DRAIN SHORT 1 5 1510001 PIPE FIT TEE 1 1 4X3 4X1 1 4 1 6 PF 006 01 PIPE FIT NIPPLE 1 1 4 CLOSE 1 7 37518901 HARNESS CONTROL TO LIMIT 1 8 1260006 GAUGE THERALTIMETER 1 9 AQ02201 CONTROL LIMIT L4080B 1212 HW 1 10 AQ 020 01 WELL 3 4 X 3 HW 1 11 VR 001 01 RELIEF VALVE 30 3 4 1 12 1190001 PIPE FIT ELBOW 3 4 NPT 90 1 13 1310001 PIPE NIPPLE 3 4 X 4 NPT 1 REPLACEMENT PARTS ...

Page 36: ...339 TRANSFORMERS 40VA 2 4 1410001 CONTROL R8222C 1008 1 5 HW09601 TUBING SILICON CLEAR 12 6 EF04001 9 TERM STRIP 1 7 HW09701 TUBING SILICON ORANGE 17 8 HW09001 SCREW 10 32X5 16 GREEN GROUND 1 9 3172701 PANEL CONTROL SUPPORT BRACKET 1 3772201 COMPLETE CONTROL BRACKET ASSEMBLY THIS INCLUDES PART 1 2 3 5 7 8 ALL WIRING 1 REPLACEMENT PARTS ...

Page 37: ...EW 1 4 20X1 2 SELF TAP 5 4 DC00402 VENTER JAKEL 1 5 3571501 GASKET VENTER 1 6 14695039 BOLT 5 16 18X1 1 2 TYPE F 2 REPLACEMENT PARTS FLUE COLLECTOR VENTER COMPONENTS ITEM PART DESCRIPTION QTY 1 PBO1401 Pilot Q3450b 1039 HW NAT For Natural Gas Only 1 PB01402 Pilot Q3450b 1112 LP For Pro pane Gas Only 2 3771101 Pilot Assembly 1 3 HW 024 01 Screw 10 32x3 16 1 4 43300201 Pilot Tube 1 8 X24 Aluminum 1 ...

Page 38: ...SSY 1 2 34721002 TERMINATION ASSEMBLY 1 3 34721401 VENT TERMINATION DEFLECTOR 1 4 1330006 NUT 10 24 HEX 1 5 30A004312 SCREW 10 24 X 1 1 2 ROUND HEAD 1 6 3471701 DRAW COLLAR 1 7 HW 009 01 SCR 8 18X1 2 SLT HX WASH 8 8 3471901 VENT TEMPLATE 1 5612601 TERMINATION KIT INCLUDES ALL OF THE ABOVE REPLACEMENT PARTS ...

Page 39: ...ion 3 3172401 Panel Separator Plate 3 Section 1 3172402 Panel Separator Plate 4 Section 3172403 Panel Separator Plate 5 Section 4 31721101 Panel Right Hand Side 1 5 31721401 Panel Rear 3 Section 1 31721402 Panel Rear 4 Section 31721403 Panel Rear 5 Section 6 3172201 Panel Top 3 Section 1 3172202 Panel Top 4 Section 3172203 Panel Top 5 Section REPLACEMENT PARTS ...

Page 40: ... and or hot water during operation a discharge line shall be installed to relief valve outlet connection Discharge line shall connect to relief valve outlet and piped down to safe point of disposal Check local codes for maximum distance from floor or allowable safe point of discharge be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge line h...

Page 41: ...l be clearly visible and is at no risk of freezing Discharge line shall be independently supported to avoid applied stress on relief valve Installation shall allow complete drainage of relief valve and discharge line Discharge line shall be as short and straight as possible and constructed of material suitable for exposure to temperatures of 375 F or greater Refer to local codes and appropriate AS...

Page 42: ...NOTES ...

Page 43: ...Date Service Performed Company Name Tech Initials Company Address Phone ...

Page 44: ...Columbia Company Main offices and factory Pottstown PA ...

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