Pennco 15B045FE User Manual

15B SERIES II

Models

15B045FE
15B070FE
15B096FE

15B120FE
15B145FE
15B170FE

15B195FE
15B245FE
15B295FE

Cast Iron Gas Fired Boilers

For Forced Hot Water

INSTALLATION, OPERATION &

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 240009024, Rev. E [10/2014]

TABLE OF CONTENTS

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

2 - Dimensions .............................................................................................................5

3 - Installation Procedure ............................................................................................6

4 - Ventilation & Combustion Air ..................................................................................7

5 - Connecting Supply & Return Piping .........................................................................8

6 - Vent Installation ...................................................................................................14

7 - Vent System Modication ......................................................................................14

8 - Vent Damper Installation & Instructions ...............................................................15

9 - Connecting Gas Service .........................................................................................16

10 - Electrical Section .................................................................................................17

11 - Wiring Diagram ...................................................................................................18

12 - Lighting Instructions ...........................................................................................21

13 - Normal Sequence Of Operation ...........................................................................22

14 - General Instructions ...........................................................................................22

15 - Checking Gas Input Rate To Boiler ......................................................................24

Appendix A - Control Module ..................................................................................... 25

A.1 Installation Environment Considerations ................................................................ 25

A.2 Electrical Connections ......................................................................................... 25

A.3 Adjusting Settings .............................................................................................. 25

A.4 Display ............................................................................................................. 25

A.5 Operation .......................................................................................................... 26

A.6 Boiler High Limit Temperature Controller ................................................................ 27

A.8 Troubleshooting Error Codes ................................................................................ 27

A.9 Intermittent Pilot Ignition System Verication ......................................................... 28

2

SAFETY MESSAGES

IMPORTANT: Read the following instructions
COMPLETELY before installing!!

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.

NOTICE

Used to address practices not related to personal
injury.

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

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.

3

1 - RATINGS & DATA - NATURAL GAS & PROPANE GAS

Model No.

Input

Mbh

(1)

Table 1

Heating

Capacity

Mbh

- Ratings and Capacities

(1)

Net AHRI

Rating Water

Mbh

(2)

**

AFUE Elect.

Ign.

No. Of

Burners

Recommended Air

Cushion Tank

(3)

Water

Content

(Gals.)

15B045 45 37 32 82.0% 1 15 2.4

15B070 70 57 50 82.0% 2 15 4.0

15B096 96 79 69 82.0% 2 30 4.0

15B120 120 98 85 82.0% 3 30 5.6

15B145 145 119 103 82.0% 3 30 5.6

15B170 170 140 122 82.0% 4 30 7.2

15B195 195 160 139 82.0% 4 30 7.2

15B245 245 201 174 82.0% 5 30 8.8

15B295 295 242 210 82.0% 6 60 10.4

EXPLANATORY NOTES

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

-- 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 1,000 ft (304m) above sea
level.

(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, 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,, Non­linting Safety Pilot.

4

**

Dimensions

2 - DIMENSIONS

Table 2 - Dimensions

Model No.

Natural Gas

Inlet*

A B C D E F

15B045 ½" 11¼ 5⅝ 4 27⅛ 207/

Dimensions (Inches)

415/

16

15B070 ½" 15⅛ 7 5 28⅛ 2015/16415/
15B096 ½" 15⅛ 7 5 28⅛ 2015/16415/
15B120 ½" 19 9½ 6 29⅛ 217/1657/
15B145 ½" 19 9½ 6 29⅛ 217/1657/
15B170 ½" 22⅞ 113/
15B195 ½" 22⅞ 113/
15B245 ¾” 26¾ 136/
15B295 ¾” 30⅝ 155/

* Propane Gas Inlet (All Units) 1/2”

7 30⅛ 2115/16515/

16

7 30⅛ 2115/16515/

16

8 31⅛ 227/16615/

16

9 32⅛ 2215/16815/

16

** Minimum height for Low Water Cutoff installation.

5

Pump Size Supply &

Return Tappings

16

16

16

16

16

16

16

16

16

1¼"
1¼"
1¼"
1¼"
1¼"
1¼"
1¼"
1¼"
1¼"

TABLE OF CONTENTS

1 - Ratings & Data - Natural Gas & Propane Gas ...........................................................2

2 - Dimensions .............................................................................................................3

3 - Installation Procedure ............................................................................................6

4 - Ventilation & Combustion Air ..................................................................................7

5 - Connecting Supply & Return Piping .........................................................................8

6 - Vent Installation ...................................................................................................14

7 - Vent System Modication ......................................................................................14

8 - Vent Damper Installation & Instructions ...............................................................15

9 - Connecting Gas Service .........................................................................................16

10 - Electrical Section .................................................................................................17

11 - Wiring Diagram ...................................................................................................18

12 - Lighting Instructions ...........................................................................................20

13 - Normal Sequence Of Operation ...........................................................................21

14 - General Instructions ...........................................................................................21

15 - Checking Gas Input Rate To Boiler ......................................................................23

Appendix A - Control Module ..................................................................................... 24

A.1 Installation Environment Considerations ................................................................ 24

A.2 Electrical Connections ......................................................................................... 24

A.3 Adjusting Settings .............................................................................................. 24

A.4 Display ............................................................................................................. 24

A.5 Operation .......................................................................................................... 25

A.6 Boiler High Limit Temperature Controller ................................................................ 26

A.7 Troubleshooting.................................................................................................. 26

A.8 Troubleshooting Error Codes ................................................................................ 26

A.9 Intermittent Pilot Ignition System Verication ......................................................... 27

6

SAFETY MESSAGES

IMPORTANT: Read the following instructions
COMPLETELY before installing!!

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.

NOTICE

Used to address practices not related to personal
injury.

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

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.

7

3 - 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 authority having jurisdiction,
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 gas manifold and control assembly on
boiler per latest revision of ANSI Z21.13/CGA 4.9.

5.

Boiler shall be installed 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.

9.

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. Minimum clearances to combustible

construction are:

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

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

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

REAR....................................8 IN. (229mm)

CONTROL SIDE ................... ..9 IN. (76mm)

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

HOT WATER PIPING ................. 2 IN. (51mm)

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)

8"

3"

9"

Control

Side

BOILER

8

18"

Front

4 - 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 jurisdictions.

• 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 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

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.

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.

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).

о Combination Indoor and Outdoor Air. 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 1 - Minimum Room Volume, Indoor Air Only*

Input Mbh

45 2250 9450 4725 3150 2363 1890 1575

70 3500 14700 7350 4900 3675 2940 2450

96 4800 20160 10080 6720 5040 4032 3360

120 6000 25200 12600 8400 6300 5040 4200

145 7250 30450 15225 10150 7613 6090 5075

170 8500 35700 17850 11900 8925 7140 5950

195 9750 40950 20475 13650 10238 8190 6825

245 12250 51450 25725 17150 12863 10290 8575

295 14750 61950 30975 20650 15488 12390 10325

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

Standard

Method

0.1 0.2 0.3 0.4 0.5 0.6

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

9

5 - CONNECTING SUPPLY & 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:

• 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.

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

• have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug or
place any obstruction in discharge line.

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

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

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

• be as short and straight as possible;

• terminate with plain end (not threaded);

• 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 1 - Safety Relief Valve

Safety Relief Valve

Discharge Line

Check local codes
for maximum

distance from oor

or allowable safe
point of discharge.

10

5 - CONNECTING SUPPLY & RETURN PIPING

Hydronic Piping - General

• Install piping in accordance with authority having
jurisdiction.

• Support system piping and safety relief valve discharge
piping.

Special Conditions

• System piping exposed to freezing conditions: Use

inhibited proplyene glycol solutions certied by uid

manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.

• Boiler installed above radiation level (or as required by
authority having jurisdiction). Install low water cutoff.

• Boiler used in connection with refrigeration system.
Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.
See Figure 2, Page 10.

• System piping connected to heating coils located in air
handling unit exposed to refrigerated air circulation.

Install ow control valves or other automatic means to

prevent gravity circulation of boiler water during cooling
cycle.

Safety Relief Valve

!

WARNING

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

NOTICE

Boiler rated at 100 psig maximum allowable working
pressure. Boiler provided with 30 psig safety relief
valve. Field source safety relief valve for system
pressures greater than 30 psig. Temperature­pressure gauge provided with boiler is satisfactory
for 30-50 psig operation. Replace temperature­pressure gauge for system pressure over 50 psig.
Scale on dial must be graduated to not less than 1½
nor more than 3½ time safety relief valve pressure
settings.

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

• Systems with automatic ll valves require back ow
prevention device.

• Install discharge piping from safety relief valve. See
Warning, Page 8.

• When boiler is 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.

• Bypass piping is an option which gives ability to adjust

the supply boiler water temperature to t the 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 3 & 4, Page 11.

B. These methods are used to protect systems using

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

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

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

• Installation using circulators and zone valves are shown
in Figures 3-8 . For further piping information refer to
AHRI Installation and Piping Guide.

• For zone controls and indirect hot water, refer to
appropriate manufacturer instructions.

• For Low Water Cutoff, see Dimensions page 5 for
minimum height. Use kit number 550009885. Follow

instructions enclosed with the kit.

• For other LWCO's follow their specic manufacturer
instructions.

11

5 - CONNECTING SUPPLY AND RETURN PIPING

EXPANSION

TANK

CHECK
VALVE

B

D

FEED

WATER

C

RETURN PIPING

FROM HEATING
AND COOLING
ELEMENT

WATER
CHILLER

SUPPLY PIPING

TO HEATING

AND COOLING

ELEMENT

CIRCULATOR

A

PRESSURE
REDUCING
VALVE

PROPER
BACKFLOW
PROTECTION
DEVICE

GATE
VALVE

PURGE
VALVE

NOTICE

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

Figure 2 - Circulators Mounted on Supply System, Boiler Used In Conguration to Chiller System.

See Special Conditions, Page 9

12

5 - CONNECTING SUPPLY AND RETURN PIPING

Figure 3 - Bypass Piping -Automatic Mixing Valve, See Bypass Piping Options, Page 9

WATER INLET

TO SYSTEM

EXPANSION

CIRCULATOR

SHUT-OFF
VALV E

TANK

BOILER

PRESSURE
REDUCER VALVE

CHECK VALVE

ALTERNATE

CIRCULATOR

LOCATION

BALL VALVE

3 WAY MIXING
VALV E

FROM SYSTEM

Note: Bypass
connection not showing
primary/secondary
piping

AIR SEPARATOR

HOSE BIB

Figure 4 - Bypass Piping - Fixed Low Temp Only, See Bypass Piping Options, Page 9

TO SYSTEM

WATER INLET

SYSTEM

CIRCULATOR

V2V1

FROM SYSTEM

Note: Bypass
connection not showing

EXPANSION

CIRCULATOR

SHUT-OFF
VALV E

TANK

BOILER

PRESSURE
REDUCER VALVE

CHECK VALVE

ALTERNATE

CIRCULATOR

LOCATION

BALL VALVE

ZONE VALVE

primary/secondary
piping

AIR SEPARATOR

13

5 - CONNECTING SUPPLY AND RETURN PIPING

Figure 5 - Single Zone System With DHW Priority

Figure 6 - Multi-Zone System with Circulators and DHW Priority

14

5 - CONNECTING SUPPLY AND RETURN PIPING

Figure 7 -

Multi-zone System With Zone Valves And DHW Priority (With Circulator)

Figure 8 -

Multi-zone System With Zone Valves And DHW Priority (With Zone Valve)

15

6 - 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.

1.

Vent pipe must slope upward from boiler not less then
¼ inch per 1 foot to the vent terminal.

2.

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

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.

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).

5.

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.

7 - VENT SYSTEM MODIFICATION

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

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.

1.

Seal any unused opening 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 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.

4.

5.

6.

7.

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.

16

8 - VENT DAMPER INSTALLATION & INSTRUCTIONS

Figure 9 - Damper Installation Figure 10 - Damper Location

UN-ACCEPTABLE
DAMPER LOCATIONS

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

ACCEPTABLE VENT
DAMPER LOCATIONS

CHIMNEY

NOTE: Refer to Figure 9 for steps 1-6.

1.

Place Vent Damper on or as close to vent outlet of
boiler as possible. Do not modify draft hood or vent
damper during installation.

2.

Remove Vent Damper Motor cover.

3.

Feed damper wire harness connector through bracket
hole on damper motor frame.

4.

Tighten locknut onto Damper wire harness connector.

5.

Plug Damper connector into socket on damper motor
frame.

6.

Replace damper motor cover and wire damper as.

BOILER

1.

Verify only boiler is serviced by vent damper. See

HOT WATER HEATER

Figure 10 .

2.

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

3.

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

4.

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

5.

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

17

9 - CONNECTING GAS SERVICE

!

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.

Figure 11 - Drip Leg

General

• 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

• 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 3.

• 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.

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

liqueed petroleum gas.

• Install eld sourced manual main shutoff valve, ground
joint union, and sediment trap upstream of gas valve.
See Figure 11.

Table 3 - Gas Pressure

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 2 - Gas Piping

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.

Nominal Iron Pipe Size

½” ¾” 1” 1¼”

!

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, 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.

18

10 - 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

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.

Make following wiring connections:

1.

Spill switch inside ue collector. Use low voltage

harness.

2.

Vent damper connection.

3.

Circulator connection.

4.

Line power connections.

5.

LWCO kit 550002998 includes wiring instructions and
wiring diagrams. If using a different LWCO, refer to the

specic instructions provided with that unit.

See wiring diagrams on the following two pages for
details.

Thermostat Installation

1.

Install thermostat on inside wall about four feet above

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
burners.

5.

Instructions for nal adjustment of thermostat

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

19

11 - WIRING DIAGRAM

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.

20

I

11 - WIRING DIAGRAM

*

*

TRANSFORMER IS NOT SIZED TO ACCOMODATE VA REQUIREMENTS OF

ZONE VALVES OR SIMILAR ACCESSORIES.

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

21

12 - 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.

OPERATING INSTRUCTIONS FOR INTERMITTENT
PILOT SYSTEM

1.

STOP! Read the safety information to the left.

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 pilot by
hand. See Figure 14.

Figure 14 - Intermittent Pilot

NOTICE

Before lighting pilot burner, verify hot water boiler

5.

6.

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.

7.

8.

9.

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

• 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

10.

TO TURN OFF GAS TO THE APPLIANCE

1.

2.

3.

4.

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

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

22

13 - NORMAL SEQUENCE OF OPERATION

Thermostat actuates on call for heat, completing circuit

to control. Completed circuit to control will rst activate
circulator. Control will rst monitor water temperature

with circulator running to determine if thermostat can be

satisfed without ring burner; if not it will activate damper

which closes end switch inside damper. Action completes
circuit to ignition system and 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. See Figure 15. If either of these conditions occur,
do not attempt to place boiler back into operation.
Contact certied service agency.

Figure 15 - Blocked Vent Safety Switch, Roll-out

Safety Switch

Rollout Switch

2,3,5,6,7

Section Boiler

Rollout Switch 4
Section Boiler

14 - GENERAL INSTRUCTIONS

Before seasonal start-up, have 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

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

Verify proper operation after service.

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 piping system and, if
leaks are found, have them repaired immediately.

Check and maintain circulators. 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

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

Inspect boiler ue gas passageways by a light and mirror.
Remove burner door. Place trouble lamp in ue collector

through draft relief opening. With mirror positioned above

burners, ue gas passageways can be checked for soot or

scale. See Figure 15.

Follow the following procedure to clean ue gas

passageways:

1.

2.

3.

4.

5.

6.

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

silicone 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. See

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. See

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 17, Page 22

Figure 15

.

.

23

14 - GENERAL INSTRUCTIONS

• 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. See

• Pilot ame should envelop ⅜ to ½ inch of tip of ignition/
sensing electrode. See

• 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 14, Page 20.

• Check burners and pilot for signs of corrosion, rust or
scale buildup. Area around boiler must be kept clear
and free of combustible materials, gasoline and other

ammable vapors and liquids.

• Free ow of combustion and ventilating air to boiler and
boiler room must not be restricted or blocked.

• 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.

Figure 18

.

Figure 16

Figure 16 - Burner Flame

.

Figure 17 - Burner

Gas Control
Knob

Burners

• 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.

Burner Door

Figure 18 - Pilot Flame

24

15 - CHECKING GAS INPUT RATE TO BOILER

Gas input to boiler can be adjusted by removing protective
cap on pressure regulator

Figure 14, Page 20

and

Figure 19 - Boiler Right Side and Front

turning screw clockwise to increase input and
counterclockwise to decrease input. Manifold

pressures are taken at outlet side of gas valve. See
Figure 14, Page 20. 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
will determine number of cubic feet of gas required per

hour. With all other gas appliances off, determine ow of

gas through meter for two minutes and multiply by 30 to
get hourly rate. Make minor adjustments to gas input as
described above.

Burner orices should be changed if nal manifold pressure

varies more than plus or minus 0.3 inches water column

from specied pressure.

Primary air adjustment is not necessary, therefore air
shutters are not furnished as standard equipment. Air
shutters can be furnished on request where required by
local codes or conditions.

High Limit

Control

Front Lower
Jacket Panel

Gas Valve

CHECK SAFETY CONTROL CIRCUIT. Ignition system
safety shutoff device must be tested after placing boiler in
operation.

Intermittent Pilot: With main burner operating, turn
pilot gas adjusting screw clockwise until pilot gas is

turned off. See Figure 14, Page 20 Within 90 seconds main
gas control should close, shutting off gas to main burner.

High Limit Control (Figure 23): Remove cover and note
temperature setting. Decrease this setting to minimum
and operate boiler. When boiler water temperature exceeds
control temperature setting, control will open circuit,
closing automatic main gas valve.

25

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 13, Page 21

• 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 18.

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 20 - 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.

26

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.

Table 4 - Operation State Codes

State
Code

Number

1

4

6

7

8

9

10

13

14

15

16

17

18

19

20

21

Idle Standby - no call for heat

Circulator

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

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

Flame stabilization

Running System is running. Flame signal must be present.

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

Retry Recycle Delay

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

Hard lock-out Manual reset is required for hard lockout

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

Flame out of sequence

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

Current leakage detection

Wait for recovery

Wait for damper to open

Wait for damper to close

Wait for damper to open
(Failed close)

Wait for damper to close
(Failed open)

Denition Explanation

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 switch 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.

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.”

27

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 manual reset press any onboard button or cycle
power to reset.

Figure 21 - 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.

2.

Check troubleshooting guide to pinpoint cause of
problem. See Table 5, page 35.

3.

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

4.

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 5 shows codes that could arise on integrated display
during fault.

Suggestions are provided in Table 5 for servicing these
potential errors.

28

APPENDIX A - CONTROL MODULE

Table 5 - Troubleshooting Error Codes

Error
Code

Number

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

6

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

23

32

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

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

60

61

62

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

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

65

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

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

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.

Igniter ame rod shorted to burner ground

Applies only to thermostats having on-board transformer.
Polarity is wrong in this case.

Thermostat input higher than threshold.

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

Soft lockout: maximum number of retries exceeded.

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

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

Denition Consequence

Soft lockout

Soft lockout

Wait for recovery

Wait for recovery

Wait for recovery

Wait for recovery

Soft lockout

Soft lockout

A.9 Intermittent Ignition System

Verication

STEP 1: Check ignition cable.

• Verify ignition cable does not run in contact with 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.

29

STEP 2:

Verify ignition system grounding. Nuisance shutdowns are
often caused 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.

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 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 lightoff.

• 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.

— 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.

• 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 9, Page 35.

Figure 22 - 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.
Figure 22 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 14, 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 18, Page 22.

30

NOTES

PENNCO BOILERS

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com