ECR International MGB-50J, MGB-100J, MGB-125J, MGB-150J, MGB-75J Installation, Operation & Maintenance Manual

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MGB

CAST IRON GAS FIRED BOILERS

FOR FORCED HOT WATER

Models

MGB-50J

MGB-75J MGB-100J MGB-125J MGB-150J MGB-170J MGB-200J

with Honeywell Control

INSTALLATION, OPER ATION

& MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

C.S.A. Certied

For Natural Gas

Or Propane

Tested For 100 psi.

ASME

Working Pressure

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N 240011584, Rev. A [07/30/2016]

Figure 1 - Dimensions

DIMENSIONS

"E"

"F"

"B"

"A"

"C"

1¼" Supply

3½"

4¼"

14"

27"

5½"

1¼" Return

"D"**

2½"

4½"

Table 1 - Dimensions

½"

Dimensions

Boiler No.

100

125

150

170

200

* Propane gas inlet, all units, 1/2" ** D is minimum height for low water cutoff installation

Natural Gas

Inlet*

½"

11⅛"

15"

18⅞"

¾"

D**

30¾"

36¼"

37¾"

37¼"

37¾"

38¾"

5¾"

6¾"

7¾"

Pump size Supply &

Return Tappings

1¼"

P/N 240011584 Rev. A [07/30/2016]

SAFETY SYMBOLS AND WARNINGS

Dimensions ......................................................2

Safety Symbols and Warnings ............................ 3

Ratings & Data - Natural Gas & Propane Gas ........4

Installation Procedure .......................................5

Ventilation & Combustion Air ..............................6

Connecting Supply and Return Piping ..................7

Connecting Supply and Return Piping ..................8

Vent Installation ............................................. 12

Vent System Modication ................................. 12

Vent Damper Installation & Instructions ............. 13

Connecting Gas Service ................................... 14

Electrical Section ............................................ 15

Wiring Diagram ............................................. 16

Lighting Instructions ....................................... 18

Normal Sequence of Operation ......................... 19

General Instructions ....................................... 19

Checking Gas Input Rate To Boiler .................... 21

Appendix A - Control Module................. ........... 22

Appendix B-1 - Vent Damper Harness ............... 30

Appendix B-2 - Vent Damper Troubleshooting ..... 31

Safety Symbols & Warnings

The following dened symbols are used throughout this

manual to notify the reader of potential hazards of varying risk levels.

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, could result in minor or moderate injury.

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

IMPORTANT: Read the following instructions COMPLETELY before installing!!

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.

WARNING

Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors

and liquids. DO NOT obstruct air openings to the boiler room.

Modication, substitution or elimination of factory equipped, supplied or specied components may

result in personal injury or loss of life. TO THE OWNER - Installation and service of this

boiler must be performed by a qualied installer.

TO THE INSTALLER - Leave all instructions with boiler for future reference.

When this product is installed in the Commonwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter.

CAUTION

Laceration, burn hazard. Metal edges and parts may have sharp edges and/or hot. Use appropriate personal protection equipment to include safety glasses and gloves when installing or servicing this boiler. Failure to follow these instructions could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

P/N 240011584 Rev. A [07/30/2016]

RATINGS & DATA - NATURAL GAS & PROPANE GAS

Table 2 - Ratings and Capacities

Boiler

No. 50J

75J

100J 125J 150J 170J 200J

(1)

Input

Mbh

100 125 150 170 200

(1)

Heating

Capacity Mbh

83 104 124 139 165

(2)

Net AHRI

Rating Water

Mbh

90 108 121 143

AFUE

83.5

83.1

83.0

82.0

83.0

82.0

No.

Burners

2 3 3 4 4

(3)

Recommended

Air Cushion

Tank

30 30 30 30 30

Water

Content

(Gals.)

2.4

4.0

5.6

7.2

(1)

High

Altitude Input

Mbh

67.5

112.5 135 153 180

EXPLANATORY NOTES

-- All boilers are design certied for installation on noncombustible oor.

-- For installation on combustible oors use combustible oor kit.

-- Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be reduced to 10 feet. Refer to the latest revision of NFGC part 11.

-- Electric service to be 120 Volts, 15 Amps, 60 Hz.

-- The MEA number for the this boiler is 19-79-E.

(1) Input rating for sea level to 2,000 ft. (610m) above sea level.

United States, over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m) above sea level.

Canada, 2000 ft (610m) to 4500 (1350m) above sea level reduce input per table. Over 4500 ft (1350m) above sea level. Contact Provincial authority having jurisdiction.

(2) Net AHRI Water Ratings shown based on 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.

For forced hot water systems where boiler and all piping within area to be heated, boiler may be selected on basis of its heating capacity.

(3) Tank sized for non-ferrous baseboard or radiant panel systems. Increase size for cast iron baseboard and

radiation.

STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler Battery, High Limit Control, Intermittent Electric Ignition Pilot System, Vent Damper Relay, Theraltimeter Gauge, Circulator With Return Piping To Boiler, Main Gas Burners, Gas Control (Includes Automatic Gas Valve, Gas Pressure Regulator, Intermittent Pilot, Safety Shutoff, Pilot Flow Adjustment, Pilot Filter), A.S.M.E. Relief Valve, Drain Valve, Spill Switch, Rollout Switch, Combination Gas Control, Automatic Vent Damper. Not Shown Are: Wiring Harness, Thermocouple, Non-linting Safety Pilot.

P/N 240011584 Rev. A [07/30/2016]

INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration, service or maintenance could result in death or serious injury.

Installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1.

Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls

and Safety Devices for Automatically red Boilers,

ANSI/ASME CSD-1.

Boiler series is classied as a Category I. Vent

installation shall be in accordance with "Venting of Equipment ," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or "Venting Systems and Air Supply for Appliances," of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

Boiler has met safe lighting and other performance criteria with the gas manifold and control assembly on the boiler per the latest revision of ANSI Z21.13/CGA

4.9.

Install boiler such that gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service, (circulator replacement, condensate trap, control replacement, etc.).

Locate boiler on level, solid base as near chimney as possible and centrally located with respect to heat distribution system as practical.

Allow 24 inches (610mm ) at front and right side for servicing and cleaning.

When installed in utility room, door should be wide enough to allow largest boiler part to enter, or to permit replacement of another appliance such as water heater.

WARNING

Fire hazard. Do not install boiler on combustible

ooring or carpeting. Failure to follow these

instructions could result in death or serious injury.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS

ONLY - For installation on combustible ooring special

base must be used. (See Repair Parts, Optional Kits Manual). Do not install boiler on carpeting. Minimum clearances to combustible construction are:

TOP ....................................18 IN. (457mm)

FRONT .........................................ALCOVE *

FLUE CONNECTOR ................. 6 IN. (152mm)

REAR ................................... 4 IN. (102mm)

CONTROL SIDE ..................... 9 IN. (229mm)

OTHER SIDE ........................... 3 IN. (76mm)

HOT WATER PIPING ................ Per Local Code

NOTE: Greater clearances for access should supersede fire

protection clearances.

* Denition of Alcove is three sided space with no wall in

front of boiler. ANSI standard for alcove is 18 inches from front of appliance to leading edge of side walls as shown below.

Minimum Clearances to Combustible Construction

(as seen from above)

BOILER

Front

18"

P/N 240011584 Rev. A [07/30/2016]

VENTILATION & COMBUSTION AIR

Provide combustion air and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections

8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes.

Provide make-up air where exhaust fans, clothes dryers, and kitchen ventilation equipment interfere with proper operation.

National Fuel Gas Code recognizes several methods of obtaining adequate ventilation and combustion air. Requirements of the authority having jurisdiction may override these methods.

x Engineered Installations. Must be approved by

authority having jurisdictions.

x Mechanical Air Supply. Provide minimum of 0.35

cfm per Mbh for all appliances located within space. Additional requirements where exhaust fans installed. Interlock each appliance to mechanical air supply system to prevent main burner operation when mechanical air supply system not operating.

x All Indoor Air. Calculate minimum volume for all

appliances in space. Use a different method if minimum volume not available.

о Standard Method. Cannot be used if known air

inltration rate is less than 0.40 air changes per

National Gas and Propane Installation Code Requires providing air supply in accordance with:

hour. See Table 3 for space with boiler only. Use equation for multiple appliances.

Volume ≥ 50 ft3 x Total Input [Mbh]

о Known Air Inltration Rate. See Table 3 for

space with boiler only. Use equation for multiple

appliances. Do not use an air inltration rate

(ACH) greater than 0.60.

Volume ≥ 21 ft3/ACH x Total Input [Mbh]

о Refer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

x All Outdoor Air. Provide permanent opening(s)

communicating directly or by ducts with outdoors.

о Two Permanent Opening Method. Provide opening

commencing within 12 inches of top and second opening commencing within 12 inches of bottom enclosure.

 Direct communication with outdoors or

communicating through vertical ducts. Provide minimum free area of 1 in2 per 4 Mbh of total input rating of all appliances in enclosure.

 Communicating through horizontal ducts.

Provide minimum free area of 1 in2 per 2 Mbh of total input rating of all appliances in enclosure.

о One Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure. Provide minimum clearance of 1 inch on sides and back and 6 inches on front of boiler (does not supersede clearance to combustible materials).

x Refer to National Fuel Gas Code for additional

requirements for louvers, grilles, screens and air ducts.

x Combination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for application information.

x Section 8.2 and 8.3 when combination of appliances

has a total input of up to and including 400 Mbh (120 kW).

о Does not have draft control device.

x Section 8.4 when combination of appliances has total

input exceeding 400 Mbh (120 kW).

x Refer to Natural Gas and Propane Installation Code

for specic air supply requirements for enclosure

or structure where boiler is installed, including air supply openings and ducts.

Table 3 - Space With Boiler Only

Room Cubic Feet Volume

Input Mbh

50 2500 10500 5250 3500 2625 2100 1750

75 3750 15750 7875 5250 3938 3150 2625

100 5000 21000 10500 7000 5250 4200 3500

125 6250 26250 13125 8750 6563 5250 4375

150 7500 31500 15750 10500 7875 6300 5250

170 8500 35700 17850 11900 8925 7140 5950

200 10000 42000 21000 14000 10500 8400 7000

Standard

Method

0.1 0.2 0.3 0.4 0.5 0.6

Known Air Inltration Rate Method (ACH - Air Changes Per Hour)

P/N 240011584 Rev. A [07/30/2016]

CONNECTING SUPPLY AND RETURN 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:

x connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum

distance from oor or allowable safe point of discharge.

x be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge

line;

x have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug or

place any obstruction in discharge line.

x terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing;

x allow complete drainage of the valve and the discharge line;

x be independently supported and securely anchored to avoid applied stress on the relief valve;

x be as short and straight as possible;

x terminate with plain end (not threaded);

x be 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.

Figure 2 - Safety Relief Valve

RELIEF VALVE

DISCHARGE

LINE

Check local

codes for

maximum

distance

from oor

or allowable

safe point of

discharge.

P/N 240011584 Rev. A [07/30/2016]

AIR

SEPARATOR

CONNECTING SUPPLY AND RETURN PIPING

Circulators in following illustrations are mounted on system supply side, mounting on system return side is also acceptable practice.

Figure 3 See Special Conditions, Page 9

Circulators Mounted on Supply System, Boiler Used In Conguration with Chiller System.

Boiler used in connection with refrigeration system, install so chilled medium is piped in parallel with boiler with appropriate valves to prevent chilled medium from entering boiler. See Figure 3.

Boiler piping system of hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be

equipped with ow control valves or other automatic

means to prevent gravity circulation of boiler water during cooling cycle.

Hot water boilers installed above radiation level or as required by authority having jurisdiction must be provided with low water cut-off device.

Boiler connected to heating system utilizing multiple zoned circulators, each circulator must be supplied with

ow control valve to prevent gravity circulation.

Hot water boilers and system must be lled with water

and maintained to minimum pressure of 12 psi.

For Low Water Cutoff, see Figure 1 for minimum height. Use Kit #550002998 and follow instructions enclosed with kit. For other LWCO's follow their manufacture

specic instructions.

Bypass piping is optional which gives ability to

adjust supply boiler water temperature to t system

or condition of installation. This method of piping, however, is not typically required for baseboard heating systems. Typical installations where bypass piping is used are as follows:

A. This method is used to protect boilers from

condensation forming due to low temperature return water. Generally noticed in large converted gravity systems or other large water volume systems. Figures 4 and 5.

B. These methods are used to protect systems using

radiant panels and material they are encased in from high temperature supply water from boiler and protect boiler from condensation.

NOTE#1: When using bypass piping, adjust valves V1 & V2 until desired system temperature is obtained. See Figure 5, page 9.

NOTE#2: Bypass loop must be same size piping as supply and return piping.

P/N 240011584 Rev. A [07/30/2016]

CONNECTING SUPPLY AND RETURN PIPING

Figure 4 - Bypass Piping With Mixing Valve

TO SYSTEM

WATER INLET

EXPANSION

TANK

FROM SYSTEM

CIRCULATOR

SHUT-OFF VALV E

PRESSURE REDUCER VALVE

CHECK VALVE

BOILER

BALL VALVE

3 WAY MIXING VALV E

ALTERNATE

CIRCULATOR

LOCATION

Figure 5 - Bypass Piping - Fixed Low Temp Only With Zone Valve

TO SYSTEM

BOILER

V2V1

ALTERNATE

CIRCULATOR

LOCATION

SYSTEM

CIRCULATOR

WATER INLET

EXPANSION

TANK

AIR SEPARATOR

HOSE BIB

FROM SYSTEM

8. Installation using circulators and zone valves are

shown in Figures 6 through 9. For further piping information refer to AHRI Installation and Piping Guide.

CIRCULATOR

SHUT-OFF VALV E

PRESSURE REDUCER VALVE

CHECK VALVE

BALL VALVE

ZONE VALVE

AIR SEPARATOR

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

9. Install discharge piping from safety relief valve. See

Warning, Page 7 and Figure 2.

P/N 240011584 Rev. A [07/30/2016]

CONNECTING SUPPLY AND RETURN PIPING

Figure 6 - Single Zone System With DHW

Figure 7 - Multi Zone System With Circulators And DHW

P/N 240011584 Rev. A [07/30/2016]

CONNECTING SUPPLY AND RETURN PIPING

Figure 8 - Multi Zone System With Zone Valves And DHW (With Circulator)

Figure 9 - Multi Zone System With Zone Valves And DHW (With Zone Valve)

P/N 240011584 Rev. A [07/30/2016]

VENT INSTALLATION

WARNING

Boiler and venting installations shall be performed

by a qualied expert and in accordance with the

appropriate manual. Installing or venting boiler or other gas appliance with improper methods or materials may result in serious injury or death due

to re or to asphyxiation from poisonous gases such

as carbon monoxide with is odorless and invisible.

WARNING

Do not connect boiler to any portion of mechanical draft system operating under positive pressure.

Vent pipe must slope upward from the boiler not less then ¼ inch for every 1 foot (21mm/m) to vent terminal.

Horizontal portions of venting system shall be supported rigidly every 5 feet and at the elbows. No portion of vent pipe should have any dips or sags.

Boiler series is classied as a Category I. Vent

installation shall be in accordance with "Venting of Equipment," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or "Venting Systems and Air Supply for Appliances," of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

Inspect chimney. Verify chimney is constructed according to NFPA 211. Vent or vent connector shall be Type B or metal pipe having resistance to heat and corrosion not less than that of galvanized sheet steel or aluminum not less than 0.016 inch thick (No. 28 Ga).

Connect ue pipe from draft hood to chimney. Bolt or

screw joints together to avoid sags. Flue pipe should not extend beyond inside wall of chimney. Do not

install manual damper in ue pipe or reduce size of ue outlet except as provided by the latest revision of

ANSI Z223.13 or CAN/CSA B149.1. Protect combustible

ceiling and walls near ue pipe with reproof insulation.

Where two or more appliances vent into a common

ue, the area of the common ue must be at least equal to the area of the largest ue plus 50 percent of the area of each additional ue.

VENT SYSTEM MODIFICATION

When an existing boiler is removed from a common venting system, the system is likely to be too large for the proper venting of the appliances sill connected to it. If this situation occurs, the following test procedure must be followed:

REMOVAL OF BOILER FROM VENTING SYSTEM

At the time of removal of an existing boiler, the following steps shall be followed with each appliance 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.

Seal an unused opening in the common venting system.

Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion and other deciencies

which could cause an unsafe condition.

Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any other appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they operate at maximum speed. Do

not operate a summer exhaust fan. Close replace

dampers.

Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the ame of

a match or candle, or smoke from a cigarette, cigar or pipe.

After it has been determined that each appliance remaining connected to a common venting system properly vents when tested as outlined above, return

doors, windows, exhaust fans, replace dampers and

any other gas burning appliances to their previous condition of use.

Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.

P/N 240011584 Rev. A [07/30/2016]

VENT DAMPER INSTALLATION & INSTRUCTIONS

DAMPER INSTALLATION

Follow Damper installation instructions provided with damper. See Figure 10.

Figure 10 - Damper Motor Wiring

Vent Damper

Vent Outlet

Limit Control

Damper Motor

Damper Wire

Haness

DAMPER INSTRUCTIONS

Figure 11 - Vent Damper Placement

UN-ACCEPTABLE DAMPER LOCATIONS

REFER TO DAMPER MANUFACTURER'S INSTALLATION INSTRUCTIONS FOR POSITION OF DAMPER CONTROL BOX

ACCEPTABLE VENT DAMPER LOCATIONS

CHIMNEY

BOILER

Verify only boiler is serviced by Vent Damper. Figure

HOT WATER HEATER

11.

Clearance of not less than 6 inches (152mm) between Vent Damper and combustible material must be maintained. Additional clearance should be allowed for service of Vent Damper.

Vent Damper must be in the open position when appliance main burners are operating.

Vent Damper position indicator must be in visible location following installation.

Thermostat's heat anticipator must be adjusted to match total current draw of all controls associated with boiler during heating cycle.

P/N 240011584 Rev. A [07/30/2016]

CONNECTING GAS SERVICE

CAUTION

WHAT TO DO IF YOU SMELL GAS

x Do not try to light any appliance.

x Do not touch any electrical switch; do not use

any phone in your building.

x Immediately call your gas supplier from a

neighbor’s phone. Follow gas supplier’s instructions.

x If you cannot reach your gas supplier, call the re

department.

Figure 12 - Gas Piping

General

x Use piping materials and joining methods acceptable

to authority having jurisdiction. In absence of such requirements:

x USA - National Fuel gas Code, ANSI Z223.1/NFPA 54 x Canada - Natural Gas and Propane Installation Code,

CAN/CSA B149.1

x Size and install gas piping system to provide sufcient

gas supply to meet maximum input at not less than minimum supply pressure. See Table 4.

x Support piping with hooks straps, bands, brackets,

hangers, or building structure components to prevent or dampen excessive vibrations and prevent strain on gas connection. Boiler will not support piping weight.

x Use thread (joint) compound (pipe dope) suitable for

liqueed petroleum gas.

x Install eld sourced manual main shutoff valve, ground

joint union, and sediment trap upstream of gas valve. See Figure 12.

Table 5 Natural Gas Propane

Min. Supply Pressure 5" w.c. 11" w.c.

Max. Supply Pressure 13.5" w.c. 13.5" w.c.

Manifold Pressure 3.5" w.c. 10.5" w.c.

MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS/HOUR

(Gas Pressure = 0.5 psig or less, Pressure Drop = 5 in. w/c)

Table 4

Length of

Pipe (Feet)

10 175 360 680 1400

20 120 250 465 950

30 97 200 375 770

40 82 170 320 660

60 66 138 260 530

80 57 118 220 460

100 50 103 195 400

For additional information refer to the National Fuel Gas Code Handbook.

½” ¾” 1” 1¼”

Nominal Iron Pipe Size

DANGER

Fire Hazard. Do not use matches, candles, open

ames, or other methods providing ignition source.

Failure to comply will result in death or serious injury.

Leak Check Gas Piping

Pressure test boiler and gas connection before placing boiler in operation.

Pressure test over 1/2 psig (3.5 kPa). Disconnect boiler and its individual gas shutoff valve from gas supply system.

Pressure test at 1/2 psig (3.5 kPa) or less. Isolate boiler from gas supply system by closing manual gas shutoff valve.

Locate leakage using gas detector, non-corrosive

detection uid, or other leak detection method

acceptable to authority having jurisdiction. Do not

use matches, candles, open ames, or other methods

providing ignition source.

Correct leaks immediately and retest.

P/N 240011584 Rev. A [07/30/2016]

ELECTRICAL SECTION

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

ELECTRICAL WIRING See wiring diagrams on the following two pages for

details.

Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to:

x USA- National Electrical Code, ANSI/NFPA 70. x Canada - Canadian Electrical Code, Part I, CSA C22.1:

Safety Standard for Electrical Installations.

If using LWCO kit 550002998 wiring instructions and wiring diagram are included with the kit.

THERMOSTAT INSTALLATION

Thermostat should be installed on inside wall about

four feet above oor.

NEVER install thermostat on outside wall.

Do not install thermostat where it will be affected by

drafts, hot or cold pipes, sunlight, lighting xtures, televisions, replace, or chimney.

Check thermostat operation by raising and lowering thermostat setting as required to start and stop burners.

Instructions for nal adjustment of thermostat

are packaged with thermostat (adjusting heating anticipator, calibration, etc.)

P/N 240011584 Rev. A [07/30/2016]

WIRING DIAGRAM

Figure 13 -

Modication, substitution or elimination of factory equipped, supplied or specied components may

result in personal injury or loss of life.

Integrated High Limit Electronic Ignition Control

WARNING

P/N 240011584 Rev. A [07/30/2016]

WIRING DIAGRAM

Figure 14 -

Integrated High Limit Electronic Ignition Control

P/N 240011584 Rev. A [07/30/2016]

LIGHTING INSTRUCTIONS

WARNING

If you do not follow these instructions

exactly, a re or explosion may result

causing property damage, personal injury or loss of life.

x This appliance is equipped with an ignition device

which automatically lights burner. Do NOT try to

light this burner by hand.

x Before operating smell all around appliance area

for gas. Be sure to smell next to oor because

some gas is heavier than air and will settle to the

oor.

x Use only your hand to turn the gas shutoff

valve. Never use tools. If valve will not turn

by hand, do not try to repair it, call a qualied

service technician. Force or attempted repair may

result in re or explosion.

x Do not use this appliance if any part has

been under water. Immediately call a qualied

service technician to inspect appliance and to replace any part of control system and any gas control which has been under water.

OPERATING INSTRUCTIONS FOR INTERMITTENT PILOT SYSTEM

STOP! Read the safety information to the left.

Set the thermostat to lowest setting.

Turn off all electric power to the appliance.

This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

Figure 15 - Intermittent Pilot

NOTICE

Before lighting any type of pilot burner (standing or intermittent), verify the hot water boiler and system are full of water to minimum pressure of 12 psi in the system, also verify system is vented of air. Set operating control of thermostat to “below” normal setting. Refer to following appropriate lighting instruction.

LIGHTING PROCEDURE FOR BOILER WITH INTERMITTENT PILOT SYSTEM

A. This appliance is equipped with an ignition device which

automatically lights the pilot. Do not try to light the appliance by hand.

CAUTION

WHAT TO DO IF YOU SMELL GAS

x Do not try to light any appliance.

x Do not touch any electrical switches; do not use

any phone in your building.

x Immediately call your gas supplier from a

10.

TO TURN OFF GAS TO THE APPLIANCE

neighbor’s phone. Follow the gas supplier’s instructions.

Turn gas control knob clockwise to “OFF.” Wait (5) minutes to clear out any gas. If you then smell

gas, STOP! Follow “What To Do If You Smell Gas” in the safety information to the left. If you don’t smell gas, go on to the next step.

Turn gas control knob counterclockwise to “ON.” Turn on all electric power to the appliance. Set thermostat to desired setting. If the appliance will not operate, follow the instructions

“

To Turn Off Gas To Appliance

service technician or your gas supplier.

Set the thermostat to lowest setting. Turn off all electric power to the appliance if service is

to be performed. Push in gas control knob slightly and turn clockwise

to "OFF." DO NOT FORCE.

Call qualied service technician.

” , and call qualied

x If you cannot reach your gas supplier, call the re

department.

P/N 240011584 Rev. A [07/30/2016]

NORMAL SEQUENCE OF OPERATION

Thermostat actuates on call for heat, completing circuit to control. Completed

circuit to control will rst activate circulator

and damper which will close end switch inside damper. Completes circuit to ignition system, ignition takes place.

In event boiler water temperature exceeds high limit setting on boiler mounted high limit control, power is interrupted between control system and ignition system. Power remains off until boiler water temperature drops below high limit setting. Circulator continues to operate under this condition until thermostat is

satised.

In event ow of combustion products through

boiler venting system becomes blocked, blocked vent safety switch shuts main burner gas off.

Similarly, if boiler ue-way becomes blocked, ame rollout safety switch shuts main burner

gas off. occur, DO NOT ATTEMPT TO PLACE BOILER

BACK INTO OPERATION. CONTACT CERTIFIED SERVICE AGENCY.

Figure 16

. If either of these conditions

Intergral Draft Hood

Burner

Door

*Burners

Orices

Figure 16 - Blocked Vent Safety Switch, Roll-out Safety Switch

Blocked Vent Safety Switch

Rollout Switch 4 Section Boiler

Base

Jacket Base Panel

* Burner shipping retention clips (not shown) may be removed if desired.

Rollout Switch

2,3,5

Section Boiler

GENERAL INSTRUCTIONS

Before seasonal start-up, have a certied service agency check boiler for soot and scale in ues, clean burners and check gas input rate to maintain high operating efciency.

WARNING

This procedure should be followed to clean ue gas

passageways:

Label all wires prior to disconnection when servicing controls. Wiring errors could cause improper and dangerous operation.

Verify proper operation after servicing

Service agency will verify system is lled with water to

minimum pressure and open air vents, if used, to expel any air accumulated in the system. Check entire piping system and, if any leaks appear, have them repaired.

Circulators need to be checked and maintained. Refer to circulator manufacturer's instructions.

Inspect venting system at the start of each heating season. Check vent pipe from boiler to chimney for signs of deterioration by rust or sagging joints. Repair if necessary.

Remove vent pipe at base of chimney or ue and using a

mirror, check vent for obstruction and verify vent is in good working order.

Boiler ue gas passageways may be inspected by a light

and mirror. Remove burner door.

lamp in ue collector through draft relief opening. With mirror positioned above burners, ue gas passageways can

be checked for soot or scale.

Figure 16

. Place trouble

When cleaning process is complete, restore boiler components to their original position. Use IS-808 GE

silicone (available from distributor) to seal around ue

collector and boiler castings.

Remove burners from combustion chamber by raising

burners up from manifold orices and pulling toward

front of boiler.

Disconnect vent pipe from draft hood.

Remove top jacket panel.

Remove combination ue collector and draft hood from

boiler castings by loosening nuts on hold down bolts located on each side of collector.

Place sheet of heavy paper or similar material over

bottom of base and brush down ue passageways. Soot

and scale will collect on paper and is easily removed with the paper.

With paper still in place in base, clean top of boiler castings of boiler putty or silicone used to seal between

castings and ue collector. Verify chips are not lodged in ue passageways.

Figure 16

P/N 240011584 Rev. A [07/30/2016]

GENERAL INSTRUCTIONS

Figure 17 - Gas Burner Flame

Figure 18 - Combustion Chamber

BURNERS

ORIFICES

GAS VALVE

x Make visual inspection of main burner and pilot ames

at start of heating season and again in mid-season. Main

burner ame should have well dened inner blue mantel

with lighter blue outer mantel. Check burner throats and

burner orices for lint or dust obstruction.

Figures 17

and 18.

x Pilot ame should envelop ⅜ to ½ inch of tip of ignition/

sensing electrode. See

Figure 19.

x To adjust pilot ame, remove pilot adjustment cover

screw and turn inner adjustment screw counterclockwise

to increase or clockwise to decrease pilot

ame. Be sure to replace cover screw after adjustment to

prevent possible gas leakage. See Figure 15, Page 18.

x Check burners and pilot for signs of corrosion, rust or

scale buildup.

x Area around boiler must be kept clear and free of

combustible materials, gasoline and other ammable

vapors and liquids.

x Free ow of combustion and ventilating air to boiler and

boiler room must not be restricted or blocked.

x Inspect eld sourced low water cutoffs annually, or

as recommended by low water cutoff manufacturer.

Flush oat type low water cutoffs per manufacturer's

instructions.

x Employ a qualied service agency to make annual

inspection of boiler and heating system. They are experienced in making the inspections outlined above, and, in event repairs or corrections are necessary, trained technicians make the proper changes for safe operation of the boiler.

Figure 19 - Gas Burner Pilot

P/N 240011584 Rev. A [07/30/2016]

CHECKING GAS INPUT RATE TO BOILER

x Adjust gas input to boiler by removing protective cap on

Figure 20 - High Limit Control Location

pressure regulator, and turning screw clockwise to increase input and counterclockwise to decrease

input.

High Limit and

Operating Control

x Manifold pressures are taken at outlet side of gas

valve.

x To check for proper ow of natural gas to boiler, divide

input rate shown on rating plate by heating value of gas obtained from local gas company. This determines number of cubic feet of gas required per hour.

x With all other gas appliances off, determine ow of gas

through meter for two minutes and multiply by 30 to get hourly rate.

Burner Access

x Make minor adjustments to gas input as described

above. See Figure 15 page 18.

x Change burner orices if nal manifold pressure

varies more than plus or minus 0.3 inches water

column from specied pressure listed on boiler

rating plate.

x Primary air adjustment is not necessary, therefore

air shutters are not furnished as standard equipment.

Door

Gas Valve

CHECK SAFETY CONTROL CIRCUIT. Test ignition system safety shutoff device after placing boiler in operation.

Intermittent Pilot: With main burner operating, turn

Figure 16 page 19.

pilot gas adjusting screw clockwise until pilot gas is turned off. Within 90 seconds main gas control closes, shutting off gas to main burner.

High Limit Control: Remove plastic cover and note temperature setting. Refer to appendix A for adjustment procedure. Decrease setting to minimum and operate boiler. When boiler water temperature exceeds control temperature setting, control will open circuit, closing automatic main gas valve. Figure 20.

P/N 240011584 Rev. A [07/30/2016]

APPENDIX A - CONTROL MODULE

A.1 Installation Environment Considerations

WARNING

If you do not follow these instructions

exactly, a re or explosion may result

causing property damage, personal injury or loss of life.

x Do not use this appliance if any part has

been under water. Immediately call a qualied

service technician to inspect appliance and to replace any part of control system and any gas control which has been under water.

x Do not allow water to drip on controls. Prevent

condensation by allowing air circulation around module and gas control.

x Do not use corrosive chemicals around or on

module or gas control.

x Controls can be damaged by excessively high

temperatures. Verify adequate air circulation around control is maintained when installing boiler.

A.2 Electrical Connections Connect Module Connectors Figure 13, Page 16

x Connect L, N, G leads inside J box using wire nuts.

Secure J-box cover.

x Connect Circulator harness to circulator. Harness

comes plugged into module with Molex® plug.

x Connect thermostat connection to yellow wires

marked TT using wire nuts.

x Ensure remaining Molex® plug connectors have not

worked loose during transit.

A.3 Adjusting Settings

To discourage unauthorized changing of settings, procedure to enter adjustment mode is required.

To enter adjustment mode, press UP, DOWN, and I buttons simultaneously for three seconds. Press and release I button until parameter requiring adjustment is displayed.

See Figure 21 below.

о “SP_” Setpoint (180 °F default setting; adjustable

between 130 and 220 °F). Note: on some models this is "HL" High Limit.

о “Df_” Setpoint Differential (15 °F default setting;

adjustable between 10 and 30 °F)

о “°F_” Degrees Fahrenheit

Press UP or DOWN button until parameter has reached desired value. After 60 seconds without any button inputs,

control automatically returns to READ mode.

A.4 Display

In RUN mode, status items and parameters are viewable.

Example, to display setpoint, control ashes “sp” (setpoint)

followed by temperature (i.e., 135), followed by °F or °C.

To read settings, press and release I key to nd parameter

of interest. Example, press and release I until setpoint (sp) is

displayed, followed by three-digit number, i.e., 190, followed by °F or °C. Press I button again will display (S1T) Sensor 1 Temperature followed by three-digit number and corresponding degree designator.

See Display Readout.

Figure 21

- Display Readout

x Check sensing bulb is fully inserted in well and is not

loose.

x Verify vent damper connection is made. See page 13.

P/N 240011584 Rev. A [07/30/2016]

APPENDIX A - CONTROL MODULE

A.5 Operation

Module continuously monitors boiler water temperature and

res or shuts off burner based on this temperature data.

When “Call for Heat” occurs, control enables circulator and monitors boiler water temperature to determine

whether thermostat can be satised without ring

burners.

Table 6 - Vent Damper Models Operation State Codes

1. State code sequence through a normal heat cycle

State

Order

a 1 Idle There is no call for heat and or:

b 1 Circulator

Code

Number

Denition Explanation

Thermostat has call for heat. Control has activated system circulator pump and is

waiting to see if there is enough heat to satisfy the thermostat without ring the

burners. This may last as long as 2 minutes, but will typically be much less.

Control determines burner operation is required, module proceeds to start burner (see state codes list) and heats water in boiler until setpoint temperature is

achieved or thermostat is satised. .

Burner is de-activated, ignition module completes heating cycle, returns to idle and waits for temperature to drop again.

Circulator is turned on throughout “Call for Heat.”

c 17 Diagnostics Pilot valve diagnostics/current leakage detection. Typically a few seconds.

Vent damper should be closed while boiler is off to conserve energy. Now, the vent

d 18

e 17 Diagnostics

f 6 Spark

g 7 Flame stabilization

h 8 Running

Wait for damper to open

damper must open before burner can safely be lit. The vent damper must conrm it is

open (a switch closes to do this). The control is waiting for this to occur. This may last up to one minute. If the vent damper switch has not closed after one minute, ERR 55 will be displayed.

Another diagnostic check. The control will also check the safety switches (rollout and vent) are closed. This will be so quick the control may move on before the STA code is

ashed. Should the safety switches be detected open, the control will show STA15 for

as long as the switches are open.

Spark for ignition. There should be an audible sparking (buzzing ) noise. This will

last until the control detects a pilot ame, but not more than 30 seconds (90 for S9361A2095). (If no ame is detected after the trial period, sparking will cease, and

a 5 minute delay will occur before the control tries again. STA10 will be displayed during this period).

The pilot ame must be strong enough(1 µA) for the control to release the main burners. This will last up to 10 seconds. (If the ame is still not strong enough after

10 seconds, the control will shut off the pilot, wait 5 minutes, then try again. STA10 will be displayed during the 5 minute period).

Main burners are providing heat. This will continue as long as the thermostat requires. During this period, the control will monitor the pilot signal, boiler temperature, damper, and limit switches to assure safe operation.

g 1 Post operation

The damper will close again to conserve heat, and the circulator pumps will continue for a short time to deliver stored heat to the house before it has a chance to escape during the upcoming off period.

P/N 240011584 Rev. A [07/30/2016]

Table 6 conti. - Vent Damper Models Operation State Codes

State

Order

2. Other possible state codes

h 4 Pre-purge

i 9 Post-purge

j 10

Code

Number

Denition Explanation

Retry Recycle Delay

APPENDIX A - CONTROL MODULE

System is purging before ignition trial; includes Pilot Valve circuit diagnostics. On vent

damper models, this is so quick it will typically be over before the display can ash

this code, and therefore will rarely be visible.

System is purging after heat cycle. On vent damper models, this is so quick it will

typically be over before the display can ash this code, and therefore will rarely be

visible.

5 minute delay after pilot signal is lost. Either:

Control failed to detect ame after spark period. Check pilot for contamination, check ignition wire; check electrical ground; Check pilot ame.

Control lost pilot ame signal AFTER main burners were lit. Check for

adequate draft and combustion air. Check gas line for adequate pressure.

k 13 Soft lock out

l 14 Hard lock out

m 15

n 16

o 17 Diagnostics Onboard self check performed at various points during the operation sequence.

p 19

q 20

Wait for limit to close

Flame out of sequence

Wait for damper switch to close

Wait for damper to open (Failed close)

Soft lock out duration is one hour, may override with manual reset. Appropriate error

code will ash alternately.

Requires manual reset. Unacceptable high water temperature (err 65) and onboard electronics failure ( er 18) are the only two (2) hard lockouts on this model.

One of the safety limits - rollout, vent spill, or low water cutoff (if one is eld

installed on the 24V safety circuit) has been activated. Control will resume normal operation once limit is reset. Underlying cause why the limit switch opened MUST be investigated.

Flame signal sensed before trial ignition. Appropriate alarm is sent. OR Flame signal sensed out of sequence during post purge OR Flame signal present when not expected. Appropriate alarm is sent.

Damper is closed and control waits for damper switch to close. Checked at beginning of heat cycle before opening damper. If damper does not open in 60 seconds, control goes to State 20. Control may also be in state 15 if one of the safety limits is open.

Damper has not opened (end switch not closed) at beginning of heat cycle. Alarm message is sent, control is NOT in lockout. Control will resume normal operation once the damper opens.

r 21

Wait for damper to close (Failed open)

Damper has not closed despite actuator de-energized. Alarm message sent, control is NOT in lockout.

P/N 240011584 Rev. A [07/30/2016]

APPENDIX A - CONTROL MODULE

A.6 Boiler High Limit Temperature Controller

x When water temperature reaches setpoint, controller

ends heating cycle.

x When water temperature drops below setpoint minus

differential, controller restarts heat cycle to re-heat boiler water.

x If water temperature exceeds maximum allowed

temperature (220°F or 104°C), controller enters manual reset lockout state.

x For models having reset capability, press any onboard

button or cycle power to reset.

Figure 23 - Basic Control Algorithm Example

A.7 Troubleshooting

x Following service procedures are provided as general

guide.

x On lockout and retry models, meter readings between

gas control and ignition module must be taken within trial for ignition period. Once ignition module shuts off, lockout models must be reset through key buttons and display. On retry models, wait for retry or reset at thermostat.

x Check for correct installation and wiring before replacing

any component.

x Control module cannot be repaired. If it malfunctions, it

must be replaced.

x Use only qualied service agent to service ignition

systems.

Perform checkout as rst step in troubleshooting.

Check troubleshooting guide to pinpoint cause of problem. See Table 7 , page 26.

If troubleshooting indicates ignition problem, see Ignition System Checks to isolate and correct the problem.

Perform checkout procedure following troubleshooting guide again to verify system is operating normally.

A.8 Troubleshooting Error Codes

Integrated boiler control uses advanced diagnostic capability to assist in troubleshooting error conditions.

Table 7 shows codes that could arise on integrated display during fault.

Suggestions are provided in Table 6 page 23 and Table 7 page 26 for servicing these potential errors.

P/N 240011584 Rev. A [07/30/2016]

Error Code Number

18 Electronic failure

Denition

Flame current lower

than threshold

Flame sensed out of

normal sequence

Flame sensed

during Pre-purge

Flame sensed

during Post-purge

Temperature sensor

failure

APPENDIX A - CONTROL MODULE

Table 7 - Troubleshooting Error Codes

Error Display clearing ( once error condition has disappeared)

Clears itself

when root problem is

solved

Cycle

Power

OFF

 



 

  

Up/down

Push

key when

any

status is

key

displayed

 

Explanation Things to look for

Control requires a strong

enough signal to verify ame

is present. Signal too low.

Control circuit is sensing

ame rectication when there

should be none.

Control believes it is defective 1. Try reset by cycling power or push any

Primarily for induced draft models although present in vent damper software. Pilot is being sensed to soon in ignition sequence.

Primarily for induced draft models although present in vent damper software. Pilot is being sensed to late in shutdown sequence.

Temperature sensor is not providing expected reading.

1. Check pilot ame sense is clean.

2. Check for proper ground

3. Check wiring

4. Check for correct pilot orice

5. Check there are no gas leaks in pilot tubing

1. Check gas valve

2. Check all electrical connections are tight

key

2. Check wiring to pilot and main valve

3. Control requires replacement

1. Check gas valve

2. Check all electrical connections are tight

1. Check gas valve

2. Check all electrical connections are tight

1. Check sensor is plugged into control board

2. Check sensor wiring is not damaged

3. Scroll display reading to "bt" and hold sensor bulb securely in you hand. It should read a temperature close to body temperature. If not, replace sensor.

Damper end switch

Flame rod shorted

to burner ground

AC line frequency

failed to close

failed to open

error

 

Vent damper must conrm it

is open (switch closes to do this). Control did not receive this signal after waiting one minute, and is still waiting.

Vent damper must conrm

it is closed (switch opens to do this) after a heat call. The control did not receive this signal after waiting one minute, and is still waiting.

Control did not detect a voltage difference between

ame sense wire and ground.

AC frequency is incorrect or noisy.

1. Check vent damper harness is securely connected to both vent damper and control board.

2. Check vent damper harness is not damaged.

3. Check vent damper mechanism is operating freely.

4. See Appendix B

1. Check vent damper harness is connected to both vent damper and control board.

2. Check vent damper harness is not damaged.

3. Check vent damper mechanism is operating freely.

4. See Appendix B

1. Check ame sense wire on pilot

assembly is not frayed or damaged. If so, replace pilot assembly.

Note! These are high temperature wires.

DO NOT attempt eld repair.

2. Check there is no moisture collecting on the control board.

1. Some electric or electronic devices may generate electromagnetic interference. Verify none is present.

2. Check thermostat connection.

P/N 240011584 Rev. A [07/30/2016]

APPENDIX A - CONTROL MODULE

Table 7 - Troubleshooting Error Codes - conti.

Error Display clearing ( once error condition has disappeared)

Error Code Number

59 Line voltage error

Note: In event of multiple errors, the highest error number is displayed rst.

Note: Error codes 18 and 65 - Hard Lockout will not expire. Requires operator reset. No volatile memory (error will not be remembered if power is

off).

Error codes 6, 23, 62,63 and 64 - Soft Lockout of 1 hour durantion if not reset. Control will then resume normal operation. If source error is

still present a second soft lockout it possible.

All other codes - No lockout. Control will resume normal operation immediately when source error is resolved.

Denition

Thermostat input

higher than

threshold

Line Voltage

unstable

Soft Lockout-Max

retries exceeded

Soft Lockout - Max

recycles exceeded

Soft Lockout -

Internal failure

Hard Lockout -

Temperature above

limit

Clears itself

when root problem is

solved

 

Cycle

Power

OFF

 

Push

any key

Up/down key when

status is

displayed

Explanation Things to look for

Line voltage (or, possibly thermostat) is either to high or to low.

Some types of thermostat may not be compatible with control circuitry.

Unstable line voltage possibly to many heavy loads switching on and off.

Control sensed consecutive

instances of no ame signal

while trying to light pilot. Note: not present on S9261A2095.

Control sensed consecutive

instances of loss of pilot ame

signal AFTER main burners are lit. Note: not present on S9261A2095.

Control is sensing something wrong with electrical circuitry.

Control sensed water temperature too high for safe boiler operation

Source problem is likely in the electrical external to the boiler. Control will clear itself and resume normal operation once the situation is resolved. Check BOTH line power and thermostat wiring.

Verify boiler works properly by jumping yellow thermostat wires. If so, replace thermostat (or thermostat wires).

1. Check current draw on this branch circuit from house breaker box might have very heavy loads switching on or off.

2. Check power coming into the house. Source problem is likely in the electrical external to the boiler. Control will clear itself and resume normal operation once the situation is resolved.

1. Check control ground connection.

2. Check pilot ignition wire for good condition and connection.

3. Clean pilot tip.

4. Check pilot tube, assure no gas leaks.

5. Check correct pilot orice is being used.

6. Check gas line pressure.

1. Check gas valve & gas supply.

2. Check all electrical connections are tight.

3. Check pilot rod is clean.

4. Check for adequate draft.

5. Check for adequate combustion air.

1. Check all wiring is correct. Refer to wiring diagram.

2. Check there is a good ground to pilot bracket.

1. Check water is circulating properly through boiler.

2. Check there is not air in the system.

3. If pressure relief valve is opened,

there is denitely a problem with water

circulation!

4. If any of the above 3 are true, root problem is in the hot water circulation.

5. Scroll display reading to "bt" , and hold sensor bulb securely in your hand. It should read a temperature close to body temperature. If not, replace sensor.

P/N 240011584 Rev. A [07/30/2016]

APPENDIX A - CONTROL MODULE

A.9 Intermittent Pilot

Ignition System Checks

STEP 1: Check ignition cable.

x Verify ignition cable does not make contact with metal

surfaces.

x Verify only factory supplied Ignition cable (or approved

replacement) is used.

x Verify connections to ignition module and igniter or

igniter-sensor are clean and tight.

x Verify ignition cable provides good electrical continuity.

STEP 2:

Verify ignition system grounding. Nuisance shutdowns are often caused by poor or erratic grounding.

Common ground is required for module and pilot burner/ igniter sensor.

— Check for good metal-to-metal contact between pilot burner bracket and the main burner. — Check ground lead from GND (BURNER) terminal

on module to pilot burner. Verify connections are clean and tight. If wire is damaged or deteriorated, replace with No. 14-18 gauge, moisture-resistant, thermoplastic insulated wire with 105°C [221°F] minimum rating.

— Check ceramic ame rod insulator for cracks or

evidence of exposure to extreme heat, which can permit leakage to ground. Replace pilot burner/igniter sensor and provide shield if necessary.

— If ame rod or bracket is bent out of position, restore

to correct position.

P/N 240011584 Rev. A [07/30/2016]

APPENDIX A - CONTROL MODULE

STEP 3: Check spark ignition circuit.

Disconnect ignition cable at SPARK terminal on module.

WARNING

Electrical shock hazard. Ignition circuit generates over 10,000 volts. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

Energize module and listen for audible sparking noise. When operating normally, there should be a buzzing noise that turns on and off twice per second for duration of 1–7 seconds depending on model.

STEP 4: Verify pilot and main burner lightoff.

x Initiate call for heat. Turn thermostat above room

temperature. Ignition sequence may be delayed by thermal purge up to 2 minutes.

x Watch pilot burner during ignition sequence.

— Verify ignition spark continues after pilot is lit. — Verify pilot lights and spark stops, verify main

burner does not light.

x If so, ensure adequate ame current as follows.

x Recheck ignition sequence as follows.

— Reconnect main valve wire. — Adjust thermostat above room temperature. — Verify ignition sequence at burner. — If spark does not stop after pilot lights, replace

module.

— If main burner does not light or if main burner lights

and system locks out, check module, ground wire and gas control as described in troubleshooting table. See Table 7, Page 26.

Figure 24 - Troubleshooting Pilot Flame

— Turn off boiler at circuit breaker or fuse box.

— Clean ame rod with emery cloth.

— Verify electrical connections are clean and tight.

Replace damaged wire.

— Check for cracked ceramic insulator, which can

cause short to ground, and replace igniter-sensor if necessary.

— At gas valve, disconnect main valve wire from MV

terminal.

— Turn on power and set thermostat to call for heat. Pilot

should light, main burner will remain off because main valve actuator is disconnected.

— Check pilot ame. Verify it is blue, steady and

envelops 3/8 to 1/2 in. [10 to 13 mm] of ame rod. See Figure 24 for possible ame problems and causes.

— If necessary, adjust pilot ame by turning pilot

adjustment screw on gas control clockwise to decrease

or counterclockwise to increase pilot ame. Following

adjustment, always replace pilot adjustment cover

screw and tighten rmly to assure proper gas control

operation. Figure 19, page 20.

— Set temperature below room set-point to end call for

heat.

Correct Pilot Flame: 3/8 to 1/2 inch in ame.

See Figure 20, Page 20.

P/N 240011584 Rev. A [07/30/2016]

APPENDIX B - VENT DAMPER

B.1 Vent Damper Harness - Molex Plugs

WARNING

Do Not negate the action of any existing safety orperational controls. Avoidance of these instructions could result in death or serious injury.

Note

Check Molex Plugs on Vent Damper Harness:

Note

When servicing controls, all wires must be labeled prior to disconnection. Wiring errors can cause improper and dangerous operation. Do not turn damper open manually or motor damage will result and void all warranties, use the service switch.

DO NOT CUT PLUG OFF OF DAMPER MOTOR ASSEMBLY OR WARRANTY WILL BE VOID.

Damper wiring harness is made up of 4 individual colored wires, Brown, Black, Yellow, and Orange (refer to drawing below).

xIf boiler ignites: Go to section B.2 "Vent Damper Troubleshooting Guide". NOTE: Prior to replacing the damper, be sure the problem is not with wire connections between damper and wiring harness.

"V" Slot

Brown

Yellow

Orange

Black

Control End of wiring harness

Hold plug in hand with wiring harness behind Molex with “V” slot on top. Verify wires colors are in proper position

"V" Slot

Black

Yellow

Brown

Disconnect thermostat wires.

Use the two diagrams below to conrm the Molex plugs

on each end of the damper harness are wired and operating properly.

Damper end of wiring harness:

A. Hold plug in hand with wiring harness behind Molex

with “V” slot on top. Verify wire colors are in proper position.

B. Take reading across brown and black wires in Molex

plug, using test meter set for AC volts. 24 volts should be present.

i. IF NOT, source of the problem is not in

damper; check line voltage and 24 volt supply.

ii. If 24 volts is present across brown and black,

continue to step iii.

iii. Reconnect thermostat wires and turn up heat

setting.

iv. Check voltage across black and orange wires

in Molex plug. 24 volts AC should be present:

x IF NOT, source problem is not the damper.

x If 24 volts is present continue on to step v.

v. Place jumper wire across orange and yellow

wires in Molex plug (see Below). This will create bypass of the damper, boiler should then ignite.

xIF NOT, source problem is not the damper. Go

to “Aquastat end of wiring harness’

OPEN

Orange Black

A. Remove damper harness from control. Jump Molex

connector on control board between two center holes using ~18ga. thermostat wire.

i. If boiler ignites, replace damper harness ii. If boiler does not light, replace control.

P/N 240011584 Rev. A [07/30/2016]

APPENDIX B - VENT DAMPER TROUBLESHOOTING

B.2 Vent Damper Troubleshooting Guide

WARNING

Do Not negate the action of any existing safety orperational controls. Avoidance of these instructions could result in death or serious injury.

Note

labeled prior to disconnection. Wiring errors can cause improper and dangerous operation. Do not turn damper open manually or motor damage will result and void all warranties, use the service switch.

DO NOT CUT PLUG OFF OF DAMPER MOTOR ASSEMBLY OR WARRANTY WILL BE VOID.

Normal Sequence of Operation

When servicing controls, all wires must be

24 VAC

Power

Power ON Damper Position

4 & 1 All times Open or Closed

4 & 2 Calling for Heat Open or Opening

4 & 3 During combustion Damper Open

Vent

Damper

Plug

4 BLK

3 YLW

2 ORG

1 BRN

Trouble Shooting

Problem Possible Cause Recommended Solution

1. Off on limit (120VAC)

2. Bad transformer

NO POWER Between 4 & 1

NO POWER Between 4 & 2

POWER Between 4 & 1

When calling for heat

POWER Between 4 & 1 Between 4 & 2 DAMPER OPEN

3. Loose or broken connections

4. Blown fuse or circuit breaker

5. Disconnect switch off

6. Harness not plugged into receptacle

1. Thermostat not calling for heat

2. Burned out heat anticipator

3. Loose or broken connections

4. Off/On operating limit, or low water cut off

5. Off/On blocked vent switch or ame roll out

1. Loose or broken connection

2. Defective damper motor

1. turn limit on

2. Replace transformer

3. Tighten, repair, or replace connection

4. Replace fuse or reset circuit breaker

5. Turn switch on

6. Plug harness in

1. Turn thermostat up to call for heat

2. Replace thermostat

3. Tighten, repair, or replace connection

4. Turn operating limit, or low water cutoff ON

5. Reset or replace switch

1. Tighten, repair, or replace connection

2. Replace damper motor assembly

P/N 240011584 Rev. A [07/30/2016]

APPENDIX B - VENT DAMPER TROUBLESHOOTING

Note

open position. Use service switch to keep damper in open position. Place jumper between

2 & 3. If appliance res, remove jumper and

plug receptacle back into damper controller

plug. If appliance does not re, replace damper

motor assembly. Do not replace pipe assembly.

If damper motor assembly is not available, place service switch in hold open position. This should keep damper in open position and allow customer to have automatic heat. Return or replace the motor assembly at your convenience. Motor assembly carries 18 month limited commercial warranty from the original date of purchase. (Refer to form #4294 on website). Pipe assembly is not warranted.

Trouble Shooting with Jumper Wire In Place

For troubleshooting only. Verify damper is in

Problem Possible Cause Recommended Solution

NO POWER Between 4 & 1

Between 4 & 2 Between 4 & 3 Damper OPEN NO COMBUSTION

Damper Sticks

Damper Rotates Continuously

1. Is gas turned on

2. Operating limit, pressure control, low water cut off not on.

3. Blocked vent switch or ame roll out switch tripped

4. Loose or broken connection

5. Defective component in appliance after vent damper

1. Damper blade obstruction

2. Damper pipe egg shaped, out of round/binding.

3. Crimped end of vent piece inserted in to far

1. Defective damper motor assembly 1. Replace damper motor assembly

1. Verify gas is on

2. Verify operating limit, pressure control or low water cut off is on

3. Reset or replace blocked vent switch or ame roll out switch

4. Tighten, repair, or replace connection

5. Replace defective component in appliance

1. Clear the obstruction

2. Restore to damper pipe to round, verify not binding.

3. Correct the condition

P/N 240011584 Rev. A [07/30/2016]

NOTES

P/N 240011584 Rev. A [07/30/2016]

NOTES

P/N 240011584 Rev. A [07/30/2016]

Company Address & Phone #Company Name & Tech InitialsService PerformedDate

P/N 240011584 Rev. A [07/30/2016]

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the

use of an external energy management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS

TRUE:

x An external energy management system is installed that reduces the boiler water temperature as the heating load

decreases.

x This boiler is not used for any space heating

x This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

x This boiler is equipped with a tankless coil.

UTICA BOILERS

2201 Dwyer Avenue

Utica NY 13501

web site: www.ecrinternational.com

P/N 240011584 Rev. A [07/30/2016]

ECR International MGB-50J, MGB-100J, MGB-125J, MGB-150J, MGB-75J Installation, Operation & Maintenance Manual

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Frequently Asked Questions

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