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Columbia HERITAGE series, Installation, Operating And Service Instructions

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Columbia HERITAGE series Installation, Operating And Service Instructions Download Page 1

105266-01 - 7/14

9700609

INSTALLATION, OPERATING

AND

SERVICE INSTRUCTIONS

HERITAGE™ SERIES

CAST IRON GAS-FIRED BOILER

For service or repairs to boiler, call your heating contractor.  When seeking information on boiler, 

provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
   HG0 _ _

 

 Boiler Serial Number

  Installation Date

Heating Contractor

  Phone Number

Address

Summary of Contents for HERITAGE series

Page 1: ...RON GAS FIRED BOILER For service or repairs to boiler call your heating contractor When seeking information on boiler provide Boiler Model Number and Serial Number as shown on Rating Label Boiler Model Number HG0 _ _ Boiler Serial Number Installation Date Heating Contractor Phone Number Address ...

Page 2: ... HG02 37 5 30 26 82 HG03 62 50 44 82 HG04 96 78 68 82 HG05 130 106 92 82 HG06 164 134 116 82 1 Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1 15 Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc The City of New York requires a Licensed Master P...

Page 3: ...3 Figure 1 Minimum Clearance to Combustible Materials Boiler Model Shipping Weight lbs Water Content gal HG02 220 2 4 HG03 270 3 2 HG04 320 4 0 HG05 370 4 7 HG06 420 5 5 Table 1C Weights and Volume ...

Page 4: ...ith the section Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or applicable provisions of local building codes WARNING Adequate combustion and ventilation air must be provided to assure proper combustion The following guideline is based on the National Fuel Gas Code ANSI Z223 1 NFPA 54 1 Determine volume of space boiler room Rooms communicating directly with ...

Page 5: ...nst floor A Move boiler to approximate installed position B Remove all crate fasteners C Lift outside container and remove with all other inside protective spacers and bracing Save two of the wooden slats from the container sleeve for use in Steps E and F D Remove all boiler hold down fasteners E Tilt the boiler to one side and slide a wooden slat under the two raised feet F Tilt the boiler to the...

Page 6: ...g must be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during operation of cooling system G Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered i e converted gravity circulation system etc Remove circulator and install pipe ...

Page 7: ...7 Figure 4 Recommended Water Piping for Zone Valve Zoned Heating Systems III Water Piping and Trim continued ...

Page 8: ...8 Figure 5 Recommended Water Piping for Circulator Zoned Heating Systems III Water Piping and Trim continued ...

Page 9: ...action of liquefied petroleum gas 3 Install sediment trap ground joint union and manual shut off valve upstream of boiler gas control valve See Figure 6 IV Gas Piping Figure 6 Pilot and Gas Piping 4 All above ground gas piping upstream from manual shut off valve must be electrically continuous and bonded to a grounding electrode Do not use gas piping as grounding electrode Refer to National Electr...

Page 10: ...pliances or fireplaces DANGER Inspect existing chimney before installing boiler Failure to clean or replace perforated pipe or tile lining will cause severe injury or death C Install Vent Damper OPEN the VENT DAMPER CARTON and remove the Installation Instructions READ THE INSTALLATION INSTRUCTIONS THOROUGHLY before proceeding The automatic gas control valve supplied on each Heritage Series boiler ...

Page 11: ...nce 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 V Venting continued a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other d...

Page 12: ...C 60 hertz less than 15 amperes A separate electrical circuit must be run from the main electrical service with an over current device disconnect in the circuit A service switch is recommended and may be required by some local jurisdictions Connect to L1 L2 and green ground screw See Figures 8 and 9 D For installations using zone valves provide separate transformer for zone valve wiring Consult zo...

Page 13: ...13 Figure 8 Wiring Connection Diagram VI Electrical continued ...

Page 14: ...14 Figure 9 Schematic Ladder Diagram VI Electrical continued ...

Page 15: ...inutes and vent damper has been in the open position 4 Turn OFF the electric switch serving boiler 5 Open valve on main gas line at meter 6 Purge air from gas piping Adequate ventilation must be provided and no smoking or open flame permitted 7 Turn ON electric switch serving boiler 8 Open Manual Shut off Valve upstream of Combination Gas Valve 9 Loosen or remove Inlet Pressure Tap Plug in Combina...

Page 16: ...ystem Safety Shut off Device Remove 3 wire plug from gas valve If burners do not shut down determine cause of malfunction Replace necessary items and check operation Figure 12 Pilot Burner Flame G Check Vent Damper Operation Vent Damper must be in open position when main burners are operating H Check High Limit Control Jumper Thermostat connections T and TV in HydroStat Control See Figures 8 and 9...

Page 17: ...ARK 1 Flame Current Measurement Procedure See Figure 14 Measuring pilot flame current with micro ammeter a Pilot flame current in micro amps can be measured using any standard micro ammeter by inserting the meter probes into the module holes labeled FLAME CURRENT as shown in Figure 14 b Flame current must be measured with pilot valve open pilot lit but the main valve closed c Disconnect MV lead wi...

Page 18: ...ut of sequence remains longer than 10 seconds control will resume normal operation 1 hour after error is corrected Check for pilot flame Replace gas valve if pi lot flame present If no pilot flame cycle Call for Heat If error repeats replace control 6 Control Internal Error Control remains in wait mode When the fault corrects control resumes normal operation Cycle Call for Heat If error repeats re...

Page 19: ...d respirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silic...

Page 20: ...20 Figure 15 Operating Instructions IX Service and Maintenance continued ...

Page 21: ...Section XI Repair Parts Install canopy 7 Install Jacket Top Panel Blocked Vent Switch Vent Damper and vent pipe D Clean Main Burners and Firebox 1 To remove burners for cleaning changing orifices or repairs a Remove Jacket Lower Front Panel b Disconnect pilot tubing at gas valve c Disconnect 3 wire plug at the gas valve d Remove wires to flame rollout switch e Remove the burner access panel f Mark...

Page 22: ...2 X Troubleshooting A Temperature Limit LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions B Electronic Ignition Module see Figure 16 ...

Page 23: ...NOTE IT MAY BE NECESSARY TO RECYCLE THE CALL FOR HEAT MORE THAN ONCE TO CLEAR THE PILOT SUPPLY TUBES OF AIR NOTE IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE CLEAN FLAME ROD CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS S...

Page 24: ...ck Assembly 763820 763821 763822 763823 763824 1B Canopy Gasket Kit 763825 1C Canopy Assembly 763826 763827 763828 763829 763830 Blocked Vent Switch Assembly not shown 763831 All Heritage Repair Parts may be obtained through TDC Manufacturing Inc 155 Route 61 South Schuylkill Haven PA 17972 ...

Page 25: ...9 763840 763841 2C Burner Tray Assembly 763842 763843 763844 763845 763846 2D Base Front Panel 763847 763848 763849 763850 763851 2E Burner Access Panel 763852 763853 763854 763855 763856 2F Base Gasket Kit 763857 2G Base Side Insulation 763858 2H Base Rear Insulation 763859 763860 763861 763862 763863 2J Base Leg Assembly 763864 Flame Rollout Switch Assembly not shown 763865 ...

Page 26: ...70 763871 763872 3C Burner Orifices Natural Gas 47 2 763873 Burner Orifices Natural Gas 45 3 763874 5 763874 7 763874 9 763874 Burner Orifices LP Gas 1 25mm 2 763875 5 763875 7 763875 9 763875 Burner Orifices LP Gas 55 3 763876 3D Pilot Burner 763877 3E Pilot Assembly Natural Gas 763878 Pilot Assembly LP Gas 763879 3F Main Burner 1 763880 2 763880 4 763880 6 763880 8 763880 3G Pilot Tubing 763881 ...

Page 27: ...27 XI Repair Parts continued Key No Description Quantity Part Number HG02 HG03 HG04 HG05 HG06 4A HydroStat 3200 Plus w Sensor 763883 4B Honeywell S8610M EI Module 763884 ...

Page 28: ...rts continued Key No Description Quantity Part Number HG02 HG03 HG04 HG05 HG06 5 Complete Jacket Kit 763885 763886 763887 763888 763889 Jacket Horizontal Clip not shown 2 763890 Jacket Vertical Clip not shown 2 763891 ...

Page 29: ...r HG02 HG03 HG04 HG05 HG06 6A Circulator Harness 763892 6B Temperature Pressure Gauge 763896 763897 6C 30 PSI Relief Valve 575021 6D Drain Valve 763898 6E Vent Damper 763893 763894 763895 Taco 007 Circulator not shown 535030 Circulator Flange Kit 1 1 4 not shown 535038 ...

Page 30: ...ed Vent Switch Assembly 763831 Natural Gas Pilot Assembly Honeywell Q3481B1206 36 Lead 763878 Propane Gas Pilot Assembly Honeywell Q3481B1420 36 Lead 763879 Natural Gas Valve Honeywell VR8204C3007 763866 Propane Gas Valve Honeywell VR8204C3015 763867 Ground Wire for Pilot 763882 XI Repair Parts continued Common Replacement Parts All Sizes ...

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