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Columbia HERITAGE series Installation, Operating And Service Instructions

Cast iron gas-fired boiler
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INSTALLATION, OPERATING
SERVICE INSTRUCTIONS
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 _ _
Heating Contractor
Address
105266-01 - 7/14
HERITAGE™ SERIES
Boiler Serial Number
AND
9700609
Installation Date
Phone Number

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  • Page 1 INSTALLATION, OPERATING SERVICE INSTRUCTIONS HERITAGE™ SERIES CAST IRON GAS-FIRED BOILER 9700609 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 Boiler Serial Number Installation Date HG0 _ _...

  • Page 2: Table Of Contents

    The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the Heritage™ Series Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.
  • Page 3 Table 1C: Weights and Volume Boiler Shipping Weight Water Content Model (lbs) (gal) HG02 HG03 HG04 HG05 HG06 Figure 1: Minimum Clearance to Combustible Materials...

  • Page 4: Pre-Installation

    I. Pre-Installation WARNING WARNING Adequate combustion and ventilation air must be Carefully read all instructions before installing provided to assure proper combustion. boiler. Failure to follow all instructions in proper order can cause personal injury or death. The following guideline is based on the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

  • Page 5: Unpack Boiler

    I. Pre-Installation (continued) a. Direct communication with outdoors. Minimum and rodents. Louvers and grilles must be fixed in free area of 1 square inch per 4,000 Btu per hour open position or interlocked with equipment to open input of all equipment in space. automatically before burner operation.

  • Page 6: Water Piping And Trim

    III. Water Piping and Trim appropriate valves to prevent chilled medium from WARNING entering boiler. See Figure 3. Failure to properly pipe boiler may result in If boiler is connected to heating coils located in improper operation and damage to boiler or air handling units where they may be exposed to building.

  • Page 9: Gas Piping

    IV. Gas Piping Size gas piping. Design system to provide adequate gas 4. All above ground gas piping upstream from manual supply to boiler. Consider these factors: shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas 1.

  • Page 10: Venting

    Equipment" of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of local building codes. Install any of the following for this Heritage Series Category I, draft hood equipped appliance: 1. Type B or Type L gas vent. Install in accordance with listing and manufacturer's instructions.
  • Page 11 V. Venting (continued) a. Seal any unused openings in the common venting Install Vent Connector system. 1. Install vent connector from vent damper outlet to b. Visually inspect the venting system for proper chimney. size and horizontal pitch and determine there is no 2.

  • Page 12: Electrical

    VI. Electrical General. Install wiring and electrically bond boiler to For installations using zone valves provide separate ground in accordance with requirements of authority transformer for zone valve wiring. Consult zone valve having jurisdiction, or in absence of such requirements, manufacturer for assistance.
  • Page 13 VI. Electrical (continued) Figure 8: Wiring Connection Diagram...
  • Page 14 VI. Electrical (continued) Figure 9: Schematic Ladder Diagram...

  • Page 15: System Start-Up And Checkout

    VII. System Start-up and Checkout 9. Loosen or remove Inlet Pressure Tap Plug in . Main Burner Check - Check main burners to see Combination Gas Valve and when purging is that they were not dislodged during shipment. Rear complete, tighten or replace plug. (See Figure 10). of burners should be in the vertical slots in the rear of burner tray and the front of the burners should be seated completely on the orifices.
  • Page 16 VII. System Start-up and Checkout (continued) 5. Natural Gas Input a. Approx. Input - Adjust regulator on Gas Valve so that manifold pressure is 3½ inches water column. Turning Regulator Adjusting Screw Clockwise increases pressure, Counter-clockwise rotation decreases pressure. Check Main Burner Flame. See Figure 11. Flame should have a clearly defined inner cone with no yellow tipping.

  • Page 17: Operation

    VIII. Operation Temperature Limit/LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. Electronic Ignition Module See Figure 13 for electronic ignition (EI). Electronic Ignition Modules with LED indicators. Table 2 cross- references the ignition module terminal designations to the ignition terminal numbers in the wiring ladder diagrams.
  • Page 18 VIII. Operation (continued) v. Check the pilot flame. It must be blue, Check the pilot burner operation/ignition steady and envelop the flame sensing rod sequence during ignition cycle: 3/8” to ½”. i. Restore boiler power at circuit breaker or vi. If needed, adjust pilot flame by fuse box.

  • Page 19: Service And Maintenance

    IX. Service and Maintenance Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 20 IX. Service and Maintenance (continued) Figure 15: Operating Instructions...
  • Page 21 IX. Service and Maintenance (continued) WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors and liquids.

  • Page 22: Troubleshooting

    X. Troubleshooting Temperature Limit/LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. Electronic Ignition Module (see Figure 16)
  • Page 23 X. Troubleshooting (continued) "CALL FOR HEAT." POWER TO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, MODULE? (24 V CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) NOMINAL) IS MADE.

  • Page 24: Repair Parts

    XI. Repair Parts All Heritage Repair Parts may be obtained through TDC Manufacturing, Inc., 155 Route 61 South, Schuylkill Haven, PA 17972. [Quantity] Part Number Description HG02 HG03 HG04 HG05 HG06 Block Assembly 763820 763821 763822 763823 763824 Canopy Gasket Kit 763825 Canopy Assembly 763826...
  • Page 25 XI. Repair Parts (continued) [Quantity] Part Number Description HG02 HG03 HG04 HG05 HG06 Base Wrapper 763832 763833 763834 763835 763836 Base Tray 763837 763838 763839 763840 763841 Burner Tray Assembly 763842 763843 763844 763845 763846 Base Front Panel 763847 763848 763849 763850 763851...
  • Page 26 XI. Repair Parts (continued) [Quantity] Part Number Description HG02 HG03 HG04 HG05 HG06 Gas Valve (Natural Gas), 763866 Honeywell VR8204C3007 Gas Valve (LP Gas), 763867 Honeywell VR8204C3015 ½" Gas Manifold 763868 763869 763870 763871 763872 Burner Orifices - Natural Gas #47 [2] 763873 —...
  • Page 27 XI. Repair Parts (continued) [Quantity] Part Number Description HG02 HG03 HG04 HG05 HG06 HydroStat 3200 Plus w/Sensor 763883 Honeywell S8610M EI Module 763884...
  • Page 28 XI. Repair Parts (continued) [Quantity] Part Number Description HG02 HG03 HG04 HG05 HG06 Complete Jacket Kit 763885 763886 763887 763888 763889 Jacket Horizontal Clip (not shown) [2] 763890 Jacket Vertical Clip (not shown) [2] 763891...
  • Page 29 XI. Repair Parts (continued) [Quantity] Part Number Description HG02 HG03 HG04 HG05 HG06 Circulator Harness 763892 Temperature/Pressure Gauge 763896 763897 30 PSI Relief Valve 575021 Drain Valve 763898 Vent Damper 763893 763894 763895 Taco 007 Circulator (not shown) 535030 Circulator Flange Kit 1-1/4" 535038 (not shown)
  • Page 30 XI. Repair Parts (continued) Common Replacement Parts ( All Sizes) Description Part Number HydroStat 3200 Plus w/Sensor 763883 Honeywell S8610M EI Module 763884 Flame Rollout Switch Assembly 763865 Blocked Vent Switch Assembly 763831 Natural Gas Pilot Assembly - Honeywell Q3481B1206, 36" Lead 763878 Propane Gas Pilot Assembly - Honeywell Q3481B1420, 36"...

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