Olsen OMGC-8D, OMGC-8DP, OMGC-9DP, OMGC-9D Maintenance Manual

Models

OMGC SERIES II

GAS-FIRED

HOT WATER BOILERS

OMGC-8D

OMGC-8DP

OMGC-9D

OMGC-9DP

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

An ISO 9001-2008 Certified Company

C.S.A. Certied

For Natural Gas Or Propane

Tested For 50 psi.

ASME

Working Pressure

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N 240009270, Rev. E [10/2014]

Figure 1 - Dimensions

1 - DIMENSIONS

*

* Minimum acceptable height for Low Water Cutoff probe.

Table 1 - Dimensions

DIMENSIONS (INCH.)

BOILER
MODEL
NUMBER

OMGC-8 7 27½

OMGC-9 7 30¾

Add 5½” to height for vent Damper.

FLUE

DIAMETER

“A”

WIDTH

2

BOILER
MODEL
NUMBER

(1)

Input

(3)

Mbh

2 - BOILER RATINGS AND CAPACITIES

Table 2 - Ratings and Capacities

† NATURAL GAS † PROPANE GAS AFUE

(2)

Heating

Capacity

(3)

Mbh

NET AHRI

RATING

Water,

(3)

Mbh

*HIGH

ALTITUDE

INPUT

(3)

Mbh

INPUT

(3)

Mbh

HEATING

CAPACITY

(3)

Mbh

NET AHRI

RATING

*HIGH

ALTITUDE

INPUT

(3)

Mbh

INTERMITTENT

IGNITION WITH

VENT DAMPER

OMGC-8 262.5 220 191

OMGC-9

†

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

299 251 218

236

269

245 206 179

280 235 204

220

252

83.9

83.7

• 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.

+ Heating Capacity based on D.O.E. (Department of Energy) test procedure.

(1)

Add model number sufce ‘P’ for Propane.

(2)

Net AHRI Water rating 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.

(3)

Mbh = 1,000 Btuh = British Thermal Unit Per Hour

- Ratings marked “Net AHRI Ratings” indicate amount of remaining heat input used to heat radiation or terminal units. Net
AHRI Ratings shown are based on allowance of 1.15 in accordance with factors shown on AHRI Standard as published by
The Hydronics Institute.

- Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated heat loss of the
building.

- Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.

BOILERS FOR USE AT HIGH ALTITUDE

Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level.

For use at altitudes above 2,000 feet above sea level, input ratings are reduced by change in main burner orice size.

For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000 feet above

sea level. Consult National Fuel Gas Code, ANSI Z223.1/NFPA 54, or manufacturer for correct orice sizing information.

In Canada, a high altitude conversion kit is available to convert to altitudes of 2,000 to 4,500 feet above sea level. Please
consult your dealer.

3

3 - TABLE OF CONTENTS

1 - Dimensions .................................................... 2

2 - Ratings And Capacities ....................................3

3 - Table of Contents ............................................ 4

4 - Installation Procedure .....................................5

5 - Ventilation & Combustion Air ............................6

6 - Connecting Supply And Return Piping ................7

7 - Chimney And Vent Pipe Connection ................. 11

8 - Vent Damper Operation ................................. 14

9 - Gas Supply Piping ......................................... 15

10 - Electrical Wiring .......................................... 15

11 - Wiring Diagrams ......................................... 16

12 - General Instructions .................................... 19

13 - Lighting Instructions ................................... 20

14 - Operating Your Boiler .................................. 21

15 - Maintaining Your Boiler ................................ 23

16 - Service Hints .............................................. 24

17 - Equipment And Optional Accessories ............ 25

Appendix A - Control Module ............................... 27

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

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.

!

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.

NOTICE

Used to address practices not related to personal
injury.

4

4 - INSTALLATION PROCEDURE

!

WARNING

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

1.

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.

2.

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.

3.

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.

4.

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.

5.

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.).

6.

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

7.

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

8.

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.

1.

FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible

ooring special base must be used. (See Replacement

Parts Section.) Boiler can not be installed on
carpeting.

Table 3 -

Top 6” (152mm)

Rear 6” (152mm)

Control Side 7” (178mm)

Opposite Side 6” (152mm)

Front

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 1/2” (13mm)

NOTE: Greater clearances for access should supersede fire

* 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 CLEARANCE DIMENSIONS

Inches (mm)

18” (457mm)

protection clearances.

Minimum Clearances to Combustible

Construction (as seen from above)

6"

6"

BOILER

7"

Control

Side

Front

18"

5

5 - 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.

• Engineered Installations. Must be approved by
authority having jurisdiction.

• 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.

• All Indoor Air. Calculate minimum allowable room
volume for all appliances in space. Use a different
method if minimum volume not available.

A. Standard Method. Cannot be used if known air

inltration rate is less than 0.40 air changes per

hour. See Table 4 for space with boiler only. Use
equation for multiple appliances.

Volume ≥ 50 ft3 x Total Input [Mbh]

B. Known Air Inltration Rate. See Table 4 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]

C. Refer to National Fuel Gas Code for opening

requirements between connected indoor spaces.

Canada

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

• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.

A. Two Permanent Opening Method. Provide opening

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

B. One Permanent Opening Method. Provide opening

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

• Refer to National Fuel Gas Code for additional

requirements for louvers, grilles, screens and air
ducts.

• Combination Indoor and Outdoor Air. Refer to National
Fuel Gas Code for application information.

• Section 8.2 and 8.3 when combination of appliances

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

• Section 8.4 when combination of appliances has total

input exceeding 400 Mbh (120 kW).

• 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 4 - Minimum Room Volume, Indoor Air Only*

Input Mbh

Standard

Method

0.1 0.2 0.3 0.4 0.5 0.6

262.5 13125 55125 27563 18375 13781 11025 9188
299 14950 62790 31395 20930 15698 12558 10465

* Table values based on boiler only. Add volume for any additional appliances.

Room Cubic Feet Volume

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

6

6 - CONNECTING SUPPLY AND RETURN PIPING

!

WARNING

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

Figure 2 - Safety Relief Valve

RELIEF VALVE

1.

Refer to local codes and appropriate ASME Boiler
and Pressure Vessel Code for additional installation
requirements. Install safety relief valve using pipe

ttings provided with boiler. See Figure 2

2.

Install safety relief valve with spindle in vertical
position.

3.

Do not install shutoff valve between boiler and safety
relief valve.

4.

Install discharge piping from safety relief valve. See
Figure 2.

• Use ¾” or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C)
or greater.

• Individual boiler discharge piping shall be independent
of other discharge piping.

• Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping.

DISCHARGE

LINE

Check local

codes for

maximum

distance

from oor

or allowable

safe point of

discharge.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

7

6 - CONNECTING SUPPLY AND RETURN PIPING

!

WARNING

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

1.

Boiler is shipped assembled. Install discharge piping
from safety relief valve. See Warning, Page 7.

2.

Install temperature pressure gauge.

• Apply pipe sealant to threads on shaft of gauge.

• Thread gauge into supply water tee. See Figure 3.

NOTICE

DO NOT TIGHTEN GAUGE BY HAND!! Gauge should
be tightened using crescent wrench or 9/16” open
end wrench. See Figure 3.

3.

Connect supply and return lines to boiler. Connections

may require additional ttings and parts, as shown on

diagrams.

Verify clean water supply is available to water inlet
valve. Install sand strainer when water supply is from
a well or pump.

Install hot water boiler above radiation level or as
required by Authority having jurisdiction. Install low
water cutoff device at time of installation. See Figure
1 for minimum probe height. Use kit #550002998.
Follow instruction enclosed with kit. With other

LWCO’s use their manufacturer specic instructions.

Periodic inspection is necessary, as is ushing of oat
type devices, per manufacturers specic instruction.

FOR USE WITH COOLING UNITS

A. Boiler used in connection with refrigeration

system, must be installed so that chilled medium
is piped in parallel with heating boiler. Appropriate
valves must be used to prevent chilled medium
from entering heating boiler. See Figure 5 page 9.

B. Boiler connected to heating coils located in air

handling units where they may be exposed to
refrigerated air circulation, piping system shall

be equipped with ow control valves or other

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

Figure 3 - Temperature Pressure Gauge

LOW WATER TEMPERATURE AND LARGE WATER
CONTENT SYSTEM (See Figures 6 and 7, Page 10.)

Signicant condensation may form in boiler and/or

venting system if boiler is operated for long period of
time with return temperatures of less than 120° F.

Condensate is corrosive and can cause severe
damage to boiler and venting system. Minimum
design return water temperature to prevent
condensation in boiler and venting is 120°F.
Minimum high limit setting is 140°F.

1.

Boiler used in heating system where design water
temperatures below 140°F are desired (e.g. radiant

oor heating), 4-way mixing valve or suitable

alternative is required to prevent low temperature
return water from entering boiler. Follow mixing valve

manufacturer’s instructions.

2.

Boiler connected to system having large water content
(such as former gravity system), install system bypass.
See Figures 6 and 7, page 10.

3.

If boiler water reset control is used to operate boiler,
minimum reset supply water temperature setpoint
must be at least 140°F, unless mixing valve is used as
in (1) above.

8

6 - CONNECTING SUPPLY AND RETURN PIPING

Figure 4 - Typical Hot Water Piping

Figure 5 - Chilled Water Piping

9

6 - CONNECTING SUPPLY AND RETURN PIPING

Bypass Piping Required For High Mass (Large Water Content) Systems

Figure 6 - BYPASS PIPING - CIRCULATOR ON SUPPLY

Figure 7 - BYPASS PIPING - CIRCULATOR ON RETURN

10

7 - CHIMNEY AND VENT PIPE CONNECTION

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.

Boilers connecting to gas vents or chimneys, vent
installations 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.

Check Your Chimney

It must be clean, right size, properly constructed and
in good condition.

Chimney Sizing

Chimney sizing, and vent installation must be in
accordance with The National Fuel Gas Code, ANSI
Z223.1/NFPA 54 or CAN/CSA B149.1, or applicable
provisions of local building codes.

This is a high efciency boiler with low stack

temperature. Following recommendations are in
addition to requirements of the National Fuel Gas
Code.

1. Type B double wall vent pipe is recommended for
vent connector. Single wall vent connectors should
not be used unless following conditions are true:

a) Except for basement, boiler is not installed in

unheated space.

b) Total horizontal portion of vent connector, not

including elbows is less than 5 feet in length.

2. Outside chimneys (i.e. chimneys exposed to
outdoors below roof line) should not be used unless
they are:

a) enclosed in a chase, or

b) lined with type B vent pipe, or listed exible
vent liner, or other certied chimney lining system.

3. Where possible it is recommended to common vent
boiler and water heater.

4. For multiple boiler installations, consult boiler
manufacturer for venting recommendations.

Connecting The Vent Damper And Vent
Connector

Refer to Figure 1, page 2 for size and location of vent

(ue opening).

NOTICE

Damper blade on furnished vent damper has 1/2
square inch hole (approximately 3/4” diameter).
Boilers equipped with intermittent ignition, hole
should be plugged by using plug supplied with vent
damper.

1.

Position furnished vent damper on top of ue outlet
collar. Fasten damper securely to ue outlet collar with

sheet metal screws. Verify damper blade has clearance
to operate inside of diverter. Do not modify either draft
diverter or vent damper during installation.

As An Option

Damper may be installed in horizontal or vertical

position, closer to ue outlet collar preferred. See

Figures 8, 9 and 10 and enclosed vent damper
instructions.

2.

Install vent damper to service only single boiler for
which it is intended. Damper position indicator shall be
in visible location following installation. Locate damper
so it is accessible for servicing. See Figure 9.

3.

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

4.

Boiler is equipped with factory wired harness that plugs
into vent damper.

5.

Slope pipe up from boiler to chimney not less than 1/4”
per foot.

6.

Run pipe as directly as possible with as few elbows as
possible.

7.

Do not connect to replace ue.

8.

End of vent pipe must be ush with inside face of
chimney ue. Use a sealed-in thimble for chimney

connection.

Fasten sections of vent pipe with sheet metal screws
to make piping rigid. Support horizontal potions of
vent system to prevent sagging. Use stovepipe wires

every 5’ to support pipe from above. Use double wall

vent pipe if vent pipe must go through crawl space.
Where vent pipe passes through combustible wall
or partition, use ventilated metal thimble. Thimble
should be 4 inches larger in diameter than vent pipe.

11

7 - CHIMNEY AND VENT PIPE CONNECTION

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.

Minimum Vent Pipe Clearance

Wood and other combustible materials must not be
closer than 6” from any surface of single wall metal
vent pipe. Listed Type B vent pipe or other listed
venting systems shall be installed in accordance with
their listing.

Removing Existing Boiler From Common
Venting System

When an existing boiler is removed from common
venting system, common venting system is likely to be
too large for proper venting of appliances remaining
connected to it.

At time of removal of existing boiler, following steps
shall be followed with each appliance remaining
connected to the common venting system placed
in operation, while other appliances remaining
connected to common venting system are not in
operation.

1.

Seal any unused openings in the common venting
system.

2.

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.

3.

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 appliance not connected
to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they will operate at maximum speed. Do not operate a

summer exhaust fan. Close replace 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 ame of

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

6.

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

doors, windows, exhaust fans, replace dampers and

any other gas-burning appliance to their previous
conditions of use.

7.

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.

12

8 - VENT DAMPER OPERATION

Figure 8 - Vent Damper Installation Figure 9 - Vent Damper Placement

Annually check vent damper and all ue product

carrying areas of appliance, with particular attention
given to deterioration from corrosion or other
sources. If you see corrosion or other deterioration,
contact your heating contractor for repairs. Check
vent damper operation as follows:

• When boiler is off, check vent damper positions
indicator points to closed position, Figure 10.

• Turn thermostat or controller up to call for heat and
check vent damper indicator points to open position.

• Turn thermostat or controller down again and check
damper position indicator returns to closed position.

Vent Damper Manual Operation

Vent damper may be placed in open position to
permit burner operation by using “HOLD DAMPER
OPEN” switch, located on damper controller.

Thermostat will control burner ring as before, while

damper will remain open. DO NOT turn damper
open manually or motor damage will result. Set
switch to “AUTOMATIC OPERATION” to close vent
damper during burner off cycle.

For further information, and vent damper
troubleshooting guide, refer to manual packaged with
vent damper.

Inspect vent damper at least once a year by a

qualied service technician.

Figure 10 - Vent Damper Position Indicator

13

9 - GAS SUPPLY PIPING

3” Minimum

Sediment

Trap

Manifold

Floor Line

Automatic

Gas Valve

Ground

Joint

Union

!

CAUTION

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 re

department.

CHECK GAS SUPPLY

Gas pipe to your boiler must be correct size for
length of run and for total BTU per hour input of all
gas utilization equipment connected to it. See Table
5 for proper size. Be sure your gas line complies with
local codes and gas company requirements.

CONNECTING THE GAS PIPING See Figure 11.

Gas line enters boiler from right side.

• Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements:

• USA - National Fuel gas Code, ANSI Z223.1/NFPA 54

• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1

• Use pipe joint compound suitable for LP gas on male
threads only.

• Use ground joint unions.

• Install sediment trap upstream of gas controls.

• Use two pipe wrenches when making connection to gas
valve to keep it from turning.

• Install manual shut-off valve in vertical pipe about 5

feet above oor.

• Tighten all joints securely.

•

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, noncorrosive

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.

Table 5 - Gas Pipe Sizes

NATURAL GAS

Pipe Capacity - BTU Per Hour Input

Includes Fittings

Length of
Pipe - FT

20 92,000 190,000 350,000 625,000

40 63,000 130,000 245,000 445,000

60 50,000 105,000 195,000 365,000

Length of

Pipe - FT

20 131,000 216,000 189,000 393,000

40 90,000 145,000 129,000 267,000

60 72,000 121,000 103,000 217,000

* Outside diameter
Measure length of pipe or tubing from gas meter or

propane second stage regulator.

½” ¾” 1” 1¼”

PROPANE GAS

Pipe Capacity - BTU Per Hour Input

Includes Fittings

Copper Tubing * Iron Pipe

⅝” ¾” ½” ¾”

Figure 11 - Gas Piping

• Propane gas connections should only be made by
licensed propane installer.

• Two-stage regulation should be used by propane
installer.

• Propane gas piping should be checked out by propane
installer.

CHECKING GAS PIPING

!

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.

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

14

10 - ELECTRICAL WIRING

!

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.

NOTICE

Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.

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

• USA- National Electrical Code, ANSI/NFPA 70.

• Canada - Canadian Electrical Code, Part I, CSA C22.1:

Safety Standard for Electrical Installations.

ELECTRIC POWER SUPPLY

Run separate 120 volt circuit from separate over
current protective device in electrical service entrance
panel. This should be a 15 ampere circuit. Locate
shut-off switch at boiler. It must be turned off during
any maintenance. Connect 120 volt power supply to
control leads L1 (HOT) and L2.

LWCO kit 550002998 includes wiring instructions and

diagrams. If using another LWCO, refer to specic

manufacturer instructions supplied by appropriate
manufacturer.

Run a 14 gauge or heavier copper wire from boiler
to grounded connection in service panel or properly
driven and electrically grounded ground rod.

VENT DAMPER WIRING

Boiler is equipped with factory wired harness with 4 pin
molex plug, that plugs into 4 pin molex receptacle inside
vent damper operator.

Vent damper must be connected for boiler to operate.

If any of the original wire as supplied with this
appliance must be replaced,
It must be replaced with type 105°C thermoplastic
wire or its equivalent.

THERMOSTAT INSTALLATION

1.

Thermostat should be installed on an inside wall about

four feet above the oor.

2.

NEVER install thermostat on outside wall.

3.

Do not install a thermostat where it will be affected

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

4.

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

5.

Instructions for the nal adjustment of the thermostat

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

Set heat anticipator at .2 amps. 24 volt thermostat
connects to aquastat terminals T and TV.

15

11 - WIRING DIAGRAMS

Figure 12 - Integrated High Limit Electronic Ignition Control (240008781)

!

WARNING

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

result in personal injury or loss of life.

Inducer is not an option.

I

16

11 - WIRING DIAGRAMS

Figure 13 - Integrated High Limit Electronic Ignition Control (240008781)

PILOT / FLAME SENSOR

17

11 - WIRING DIAGRAMS

Figure 14 - Integrated High Limit Electronic Ignition Control (240008781)

!

WARNING

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

result in personal injury or loss of life.

18

12 -GENERAL INSTRUCTIONS

FILLING SYSTEM WITH WATER

• Close air vents on all radiation units. Open valves to

these units.

• Verify boiler and expansion tank drain valves are closed.

• Air bleed screw on tank drain tting should be closed.

• Open valve in line from boiler to expansion tank. Open

water inlet to your boiler and leave it open. Start with
lowest radiation unit. Open air vent on this unit. When

all air has escaped and water starts to ow from vent,

close it.

• Go to next radiation unit, and repeat this process.

Repeat until you have covered every radiation units in
the system (ending up at highest unit in system).

• If your units have automatic vents, manual venting is

unnecessary but it will speed up the proper lling of

your system.

• If your system is closed expansion tank system, you

may leave it open to rell system automatically as

needed.

• Check temperature pressure gauge. Not position of hand

indicating pressure. This should be between 10 and 15
psi. Any lowering of this movable hand below 10 psi.
Will indicate loss of water due to leakage. Automatic

ll valve should compensate for this. Instructions are

packaged with the valve.

NOTICE

Never run water in a hot empty boiler.

19

13 - 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.

• This appliance is equipped with an ignition device
which automatically lights burner. Do NOT try to

light this burner by hand.

• 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.

• 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.

• 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.

LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEM

For Your Safety, Read Before Operating!!

A. This appliance is equipped with an ignition device

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

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

5. Remove lower front panel.

6. Rotate the gas control knob clockwise to
“OFF”.

Figure 15 - Automatic Gas Valve

PRESSURE REGULATOR
(UNDER CAP SCREW)

INLET

PRESSURE

TAP

INLET

GAS CONTROL

KNOB

ADJUSTMENT

OFF

ON

PILOT ADJUSTMENT

(UNDER CAP SCREW)

7. Wait ve (5) minutes to clear out any gas. Then

smell for gas, including near the oor. If you smell

gas, STOP! Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s instructions.
If you don’t smell gas, go to next step.

8. Rotate gas control knob counterclockwise to

“ON”.

9. Replace lower front panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the

instructions “To Turn Off Gas To Appliance” and call
your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

WIRING
TERMINALS (2)

OUTLET
PRESSURE
TAP

GROUND
TERMINALS

(2)

OUTLET

PILOT
OUTLET

• Do not try to light any appliance.

• Do not touch any electrical switches; do not use
any phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the re
department.

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

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

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if
service is to be performed.

3. Push in gas control knob slightly and turn
clockwise to “OFF” Do not force.

20

14 - OPERATING YOUR BOILER

AUTOMATIC GAS VALVE

Automatic Gas Valve opens or closes according to
heat requirements of thermostat and temperature
limit control. It closes if pilot goes out. Each
individual control must be operating correctly before
any gas can pass to burners. Any one control can
hold gas supply from burner regardless of demand of
any other control.

SAFETY PILOT

Safety Pilot prevents ow of gas to burner if pilot

goes out, or will not ignite.

GAS VALVE SAFETY SHUTDOWN TEST

Ignition system safety shutoff device must be tested after
placing boiler in operation.

RELIGHT

Electric and gas shall be off for 5 minutes before
relighting.

THERMOSTAT

Keep it set at desired room temperature. If windows
are to be opened or heat is not needed, move
thermostat pointer to lower setting.

NOTICE

In event of failure of any component, system
will not operate or will go into safety lockout.
System is completely self-checking. On
every call for heat, each component must
be functioning properly to permit operation.
Safety lockout system has to be reset by
turning thermostat to lowest setting for one
minute, then back to normal setting.

Figure 16 - Pilot Flame

MAIN BURNER(S)

• Main burners do not require primary air adjustment and
are not equipped with primary air shutters.

• Main burner ames form sharp blue inner cones in softer
blue outer mantel, with no yellow.

• Puffs of air from blowing on ame or stamping on oor

will cause ames to turn orange momentarily. This is

not unusual. Remain still when observing main burner

ames.

• If ame appearance is not correct, check main burner
orices, burner throat and ame ports for dust and

lint obstruction. It may be necessary to remove rollout

shield to observe main burner ames. Replace rollout

shield after observation. Refer to Figure 17.

Figure 17 - Burner

ADJUST PILOT BURNER

Pilot ame should surround 3/8” to 1/2” of the pilot
sensor. See Figure 16. If ame needs adjusting, do it

as follows:

1.

Remove screw cover over pilot adjusting screw.

2.

Insert small screwdriver and adjust ame as needed.
Turn screw counterclockwise to increase ame, clockwise

to decrease.

3.

Replace screw cover over pilot adjusting screw.

ADJUST LIMIT CONTROLS

Instructions for each control are included with
controls. Settings can be changed. Refer to
Appendix A page 27 for information.

21

14 - OPERATING YOUR BOILER

CHECK THERMOSTAT OPERATION

A. When set above temperature indicated on

thermostat, boiler should ignite.

B. Verify thermostat turns boiler off when room

temperature reaches selected setting and starts
boiler operating when room temperature falls a
few degrees.

C. After setting limit control to limit setting, check to

see if it shuts off gas supply to burners. Turn your
thermostat up to call for heat and let boiler run
until temperature of water reaches limit setting.
Gas valve should shut off and circulator running

until thermostat is satised, or water cools enough

to restart burners through limit control.

D. Set thermostat for desired temperature. Conditions

in your home and location of thermostat will govern
this setting.

22

15 - MAINTAINING YOUR BOILER

BURNERS

Beginning of heating season visually check pilot and main

burner ames. See Figure 16.

SAFETY RELIEF VALVE

Refer to page 7 for important information. To test safety

relief valve refer to valve manufacturer’s instructions

packaged with relief valve. Call Technical Support if

manufacturer’s instruction are not located.

EXPANSION TANK

Tank may become waterlogged, or may receive excess
of air. Frequent automatic opening of safety relief
valve indicates water logging. High boiler temperature
accompanied by unusually low radiation unit temperature
(and “knocking”) indicates excess air in tank.

To correct:

1.

Close valve between boiler and tank. Drain tank until
empty.

2.

Check all tank plugs and ttings. Tighten as necessary.

3.

Open valve between boiler and tank. Water will rise to

normal height in tank if you have automatic ll valve
(otherwise, manually rell system).

CLEANING YOUR BOILER AND BURNERS

Flue passages between sections should be examined yearly
and cleaned if necessary.

To clean:

• Remove burners, pilot, and vent pipe.

• Remove top and front jacket panels.

• Remove two screws attaching intermediate front panel
to left and right side jacket panels.

• Remove draft diverter and intermediate front panel
together.

• Carefully remove cerafelt gasket strips.

• Clean passageways between sections with exible
handle wire brush. Remove dirt from bottom of boiler
and from between sections by vacuuming.

• Verify all ame ports in burners are open and clear.
Shake out or blow out all loose dirt in burners.

• Reseal seams between adjacent sections as necessary
with 400° F RTV silicone sealant.

• Reassemble all parts.

• Verify tightness of pilot connections and condition of

burner ames after reassembly. See Figures 16 and 17,

pages 21.

BOILER FLUE PASSAGES

Recommend following checked annually by qualied service

agent.

• ue passages

• burner adjustment

• operation of controls

Before start of each season (or whenever system has been
shut down for some time) recheck whole system for leaks
and recheck boiler and vent pipe for leaks. Replace or patch
any boiler seals that are faulty.

VENT PIPE

Venting and piping should be checked at least once a
season. If vent piping shows any sign of leaking, replace
immediately.

WATER SYSTEM

If system is to remain out of service during freezing weath­er, always drain it completely (water left in to freeze will
crack pipes and/or boiler).

HOUSEKEEPING

• Verify vent pipe connections to chimney are secure and
no obstructions are present.

• Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors and

liquids.

• Keep boiler area clear of debris and other materials

obstructing ow of combustion and ventilation air.

23

16 - SERVICE HINTS

EQUIPMENT AND OPTIONAL ACCESSORIES - WHAT THEY DO

!

CAUTION

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 the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the re
department.

IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .

You may avoid inconvenience and service calls by checking these points before you call for service.

Possible Cause What to do

Thermostat is not set correctly Reset thermostat above room temperature

Burner is not operating properly Check ame. If it is yellow, burner is not getting enough air.
Or, if ame is blue and noisy and seems to lift off burner,

burner is getting too much air. Contact your service technician.
No electric power to boiler Check over current protection. Verify electric power supply circuit is

“ON”.
Controls out of adjustment Reset according to instructions.

Radiators not heating Open radiator vents to expel air. Check ow control valve (if

used). It may be in closed position.
Circulating pump not running Check over current protection. Check relay operation.
Poor electrical contact Check all control terminals and wire joints.
Rollout switch blown Have your service agent check heat exchanged for blockage.

Replace rollout switch with exact replacement.
Blocked vent blown Have your service agent check venting system and chimney

for blockage, or down draft condition. Reset blocked vent.

Vent damper not operating Consult troubleshooting guide in Efkal manual, packaged with

vent damper.

Possible Cause What to do

Gas input amount is incorrect Contact your service agent.

Possible Cause What to do

Dirt on seat Open valve manually. Allow water to run and clear valve seat.
Water logged expansion tank Drain tank, see instructions.

HAVE YOUR SERVICE AGENT CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.

IF BURNER IS NOISY . . .

RELIEF VALVE LEAKING . . .

24

17 - EQUIPMENT AND OPTIONAL ACCESSORIES

EXPANSION TANK

Expanding water ows into expansion tank. Tank should
be correct size. Tank is lled with air. As water expands it

compresses air in the tank to form air pressure cushion.
This “spring-like” cushion serves to maintain correct
operating water pressure regardless of water temperature.
This assures “full measure” of water, even in highest
radiation unit of system. It also prevents blowing off of
safety relief valve. Air in tank in beginning (with system

lled with cold water) is sufcient for proper operation.

Tank also serves as trap for excess air in system. Air

would cause gurgling in pipes and in efcient circulation in

radiators if left in system.

It is possible for tank to become “waterlogged” (lled with
water). It can also become overlled with air. This can hap­pen after lling system with new water. Fittings provided on

tank and in line to tank are for bleeding off excess water or
air.

When installing this tank, it is important:

1.

Tank be higher than boiler top.

2.

Pipe to tank continuously rises up to tank (so air
can “bubble” up to it).

AUTOMATIC FILL VALVE

For a safe, efcient operation, hot water system must be

completely lled with water. Adding new water, when
needed can be done manually (by use of hand valve in

water supply line). Requires regular attention to system’s
needs. Automatic ll valve accomplishes this without atten-

tion. Install in supply line on hot water boilers only. Valve
operates through water pressure differentials. It does not
require electrical connection.

DRAIN VALVE

Manual valve provides means of draining all water from
boiler and system. It is often installed in 3/4” tapping at
bottom of end boiler section. Or it can be installed in tee
where return line enters boiler.

WATER TEMPERATURE CONTROL

Water temperature limit control in relay is adjustable
and may be set as necessary. It may be set as low as

104°F (40°C), or as high as 220°F (104°C). This depends
on type and amount of radiation involved and weather
conditions.

DIAPHRAGM TYPE EXPANSION TANK

Diaphragm type expansion tank takes place of conventional
expansion tank. Carefully read instructions packed with
your tank assembly.

Tank comes with 10-12 pounds per square inch air charge.
This is the same as pressure produced in system by

automatic ll valve. When system is rst lled, tank will

contain little or no water.
As water is heated its pressure increases. It expands into

tank, compressing air in tank. Compressed air cushion
permits water in system to expand as temperature
changes. Diaphragm type tank can be mounted on air

purger tting or at any convenient place in supply or return

line.

AIR ELIMINATING FITTING (AIR PURGER)

Air purger is used to remove excess air from system. It
is installed in supply line. It will eliminate air from water
before it reaches radiators and bleed off this air.

MAIN AIR VENT FOR DOWN FLOW SYSTEMS OR
DIAPHRAGM TYPE EXPANSION TANK

Before system is lled with water, there is air in pipes and

radiation units. Some of it will be trapped as system is

lled . It is possible to eliminate most of this air through

air vent on radiation units. Main air vent will speed and
simplify this. Install on highest point in supply main when
all radiation is below top of boiler.

CIRCULATING PUMP

Every forced hot-water system requires circulating pump.
Separate pump or zone valve is required for each zone,
if you have a two or more zone system. Pump must have
capacity to provide circulation required by your system.
Pump is connected into main just ahead of boiler. It is also
wired to electrical system.

VENT DAMPER

This product is automatic, motorized stack damper

developed to increase efciency of heating system by

reducing standby losses from heating apparatus and
conditioned air space. Damper closes chimney vent
when burner is off and fully opens it when combustion is
required.

25

17 - EQUIPMENT AND OPTIONAL ACCESSORIES

ROLLOUT SWITCH
(FLAME ROLLOUT SAFETY SHUTOFF)

Rollout switch is temperature-sensitive fuse link device.

Located on boiler base just outside re box. In event of
heat exchanger ueway blockage causing ame to roll
out of re box, fuse does not change in appearance when

blown.
If rollout switch blows, it must be replaced with exact

replacement. Check heat exchanger ueways for blockage

when restoring system to operating condition. DO NOT
operate system without rollout switch.

BLOCKED VENT SAFETY SWITCH
(BLOCKED VENT SAFETY SHUTOFF)

Blocked vent safety switch is manual reset disc thermostat

with xed setpoint (340°F (171°C)), and normally closed

contacts. It is located at relief opening of integral draft diverter.
In event of chimney or venting system blockage causing
products of combustion to spill out of relief opening, blocked
vent disc heats up and blocked vent contacts open, shutting

down ow of gas to main burners by removing power to gas

valve.
In event blocked vent contacts open, reset button on back

of switch will pop up. Blocked vent safety switch must be
reset manually, after switch has cooled off, by pushing
reset button down. Check venting system and chimney for
blockage when restoring system to operating condition. DO
NOT operate boiler without Blocked vent safety switch.

26

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.

• 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.

• Do not allow water to drip on controls. Prevent
condensation by allowing air circulation around
module and gas control.

• Do not use corrosive chemicals around or on
module or gas control.

• 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 14, Page 18

• L1& L2 leads inside J-box using wire nuts. Secure J-

box cover.

• Circulator harness to circulator. Harness comes

plugged into module with Molex® plug.

• Thermostat connection to yellow wires marked TT

using wire nuts.

• 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 12, page 16.

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 ashs “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 18

- Display Readout

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

loose.

• Refer to enclosed addendum for wiring instructions

when using indirect hot water heater.

27

APPENDIX A - CONTROL MODULE

A.5 Operation

Module continuously monitors boiler water temperature and

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

1.

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

whether thermostat can be satised without ring

burners.

2.

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. .

3.

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

4.

Circulator is turned on throughout “Call for Heat.”

Table 6 - Operation State Codes

State
Code

Number

1

4 Pre-purge System is purging before ignition trial; includes Pilot Valve circuit diagnostics.

6 Spark System sparking. Flame is not present up to 13 seconds

7 Flame stabilization

8 Running System is running. Flame signal must be present.

9 Post-Purge System is purging at end of call for heat

10

13 Soft lock-out Soft lockout duration is one hour, may override with manual reset.

14 Hard lock-out Manual reset is required for hard lockout

15 Wait for limit to close Possible thermostat call for heat; limit switch is open.

16 Flame out of sequence

17

18 Wait for damper to open

19 Wait for damper to close

20

21

Current leakage detection

Wait for damper to open

Wait for damper to close

Denition Explanation

Idle Standby - no call for heat

Circulator

Retry Recycle Delay

Pilot valve diagnostics Pilot valve circuitry diagnostics during pre-purge.

Wait for recovery

(Failed close)

(Failed open)

Heat request present. Boiler temperature sufciently high to run circulator

pump only.

Flame signal is being established. Variation in signal is allowed during this

state, ame must be stable at end of period

Successful ignition was not detected, and delay is called before retry.

Flame signal was lost during state 7 or 8, and delay is called before retry (32
second delay)

Flame signal sensed before trial for ignition. Appropriate alarm is sent.

OR

Flame signal sensed out of sequence during post purge. Appropriate alarm is
sent. OR

Flame signal present when not expected. Appropriate alarm is sent.

Self check performed at start up, again at beginning of heat cycle, and during
“Wait for Recovery “ State.

Self check performed at start up, again at beginning of heat cycle, and during
“Wait for Recovery “ State

Control has signaled damper/pressure switch
to close, and is waiting for completion.
If damper/pressure switch does not close within 60 seconds, control goes to
State 20.

Damper is closed and control waits for damper to open.
Checked at beginning of heat cycle before opening damper.
If damper does not open in 60 seconds, control goes to State 21.

Damper has not opened (end swich not closed) at beginning of heat cycle.
Alarm message is sent, control is NOT in lockout.

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

28

APPENDIX A - CONTROL MODULE

A.6 Boiler High Limit Temperature Controller

• When water temperature reaches setpoint, controller
ends heating cycle.

• When water temperature drops below setpoint minus
differential, controller restarts heat cycle to re-heat
boiler water.

• If water temperature exceeds maximum allowed
temperature (220°F or 104°C), controller enters manual
reset lockout state.

• For models having reset capability, press any onboard
button or cycle power to reset.

Figure 20 - Basic Control Algorithm Example

A.7 Troubleshooting

• Following service procedures are provided as general
guide.

• 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.

• Check for correct installation and wiring before replacing
any component.

• Control module cannot be repaired. If it malfunctions, it
must be replaced.

• Use only qualied service agent to service ignition
systems.

1.

Perform checkout as rst step in troubleshooting.

Check troubleshooting guide to pinpoint cause of problem.
See Table 7 , page 30.

2.

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

3.

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 6 page 28 shows codes that could arise on integrated
display during fault.

Suggestions are provided in Table 6 for servicing these
potential errors.

29

APPENDIX A - CONTROL MODULE

Table 7 - Troubleshooting Error Codes

Error
Code

Number

4 Flame current too low. Check for ame. Non critical alarm

6

Flame sensed out of normal sequence (before opening or after closing gas valve).

18 Gas valve relays welded. Five consecutive soft lockouts. Hard lockout

23

32

Flame sensed during prepurge ( before gas valve signaled opened).

Sensor 1 error. Temperature sensor in well is not reading correctly.
Verify it is connected to board. Replace if necessary.

55 Atmospheric damper end switch failed to close (end switch contacts stuck open). Wait for recovery

56 Atmospheric damper end switch failed to open (end switch contacts stuck close). Wait for recovery

57

Igniter ame rod shorted to burner ground

58 Igniter ame rod shorted to burner ground. Repair or replace igniter. Wait for recovery

59 Line Voltage error - voltage out of specication high or low (15-37V (44-66Hz)) Wait for recovery

Applies only to thermostats having on-board transformer.

60

Polarity is wrong in this case.

Thermostat input higher than threshold.

61

Line voltage unstable - possibly too may heavy loads switching on and off causing
erratic supply voltage.

Denition Consequence

Soft lockout

Soft lockout

Wait for recovery

Wait for recovery

Wait for recovery

Wait for recovery

62

Soft lockout: maximum number of retries exceeded.

Soft lockout is reset after one hour if alarm reason disappears.

63 Soft lockout: maximum number of recycles exceeded. Soft lockout

64 Soft Lockout - electronics failure. On-board self diagnostics detected error. Soft lockout

65

Over temperature error. Sensor measured temperature in excess of maximum
allowable limit.

Note: Soft lockout time is 1 hour or manual reset. Hard lockout requires manual reset.

A.9 Intermittent Pilot

Ignition System Checks

STEP 2:

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

STEP 1: Check ignition cable.

• Verify ignition cable does not touch metal surfaces.

• Verify only factory supplied Ignition cable (or approved
replacement) is used.

• Verify connections to ignition module and igniter or
igniter-sensor are clean and tight.

• Verify ignition cable provides good electrical continuity.

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.

Soft lockout

Soft lockout

30

APPENDIX A - CONTROL MODULE

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

to correct position.
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 buzzing noise
turns on and off twice per second for duration of 1–7
seconds, depending on model.

STEP 4: Verify pilot and main burner light-off.

• Initiate call for heat. Turn thermostat above room
temperature. Ignition sequence may be delayed by
thermal purge until boiler water temperature is below
140°F (60°C)

• Watch pilot burner during ignition sequence.

• 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 30.

Figure 19 - Troubleshooting Pilot Flame

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

burner does not light.

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

— 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 19 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 16, 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 16, Page 21.

31

ECR International

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com