Utica Boilers MGB, II-MGC Installation Manual

Models

MGC SERIES

GAS-FIRED

HOT WATER BOILERS

MGC-8D

MGC-8DP

MGC-9D

MGC-9DP

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

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 240009268, Rev. D [10/2014]

Figure 1 - Dimensions

1 - DIMENSIONS

*

* Minimum acceptable height for Low Water Cutoff probe.

Table 1 - Dimensions

DIMENSIONS (INCH.)

BOILER
MODEL
NUMBER

MGC-8 7 27½

MGC-9 7 30¾

Add 5½” to height for vent Damper.

FLUE

DIAMETER

“A”

WIDTH

2

2 - BOILER RATINGS AND CAPACITIES

Table 2 - Ratings and Capacities

† NATURAL GAS † PROPANE GAS AFUE

(2)

BOILER

MODEL

NUMBER

(1)

Input

Mbh

(3)

(1)

Heating

Capacity

(3)

Mbh

MGC-8 262.5 220 191 245 206 179 83.9

MGC-9 299 251 218 280 235 204 83.7

†

Input rating for sea level to 2,000 ft. (610m) above sea level. Over 2000 ft (610m) above sea level.
Reduce input rate 4% for every 1000 ft (304m) above sea level.
+ 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

NET AHRI

RATING

Water,

(3)

Mbh

INPUT

MBH

(3)

HEATING

CAPACITY

MBH

(3)

NET AHRI

RATING

INTERMITTENT

IGNITION WITH

VENT DAMPER

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.

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.

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 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 2” (51mm)

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

Front

7"

Control

Side

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

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.

• 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.

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.

Table 4 - Minimum Room Volume, Indoor Air Only*

Room Cubic Feet Volume

Input

Mbh

Standard

Method

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

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.

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.

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.

• 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).

Figure 2 - Safety Relief Valve

RELIEF VALVE

DISCHARGE

LINE

Check local

codes for

maximum

distance

from oor

or allowable

safe point of

discharge.

• 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 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 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.

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 p

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.

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. 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.

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.

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.

•

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.

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

Gas line enters boiler from right side.

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

Code, ANSI Z223.1/NFPA 54

• 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.

• 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.

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

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 National Electrical Code, ANSI/NFPA 70.

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

• 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.

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

WIRING
TERMINALS (2)

OUTLET
PRESSURE
TAP

GROUND
TERMINALS

(2)

OUTLET

PILOT
OUTLET

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

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.

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.

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.

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.

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 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 end

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).

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.

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
as a unit.

• 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, page 21.

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

HOUSEKEEPING

• 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.

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).

23

16 - SERVICE HINTS

EQUIPMENT AND OPTIONAL ACCESSORIES - WHAT THEY DO

• 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.

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

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.

Spill switch blown Have your service agent check venting system and chimney
for blockage, or down draft condition. Reset spill switch.

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

vent damper.

IF BURNER IS NOISY . . .

Possible Cause What to do

Gas input amount is incorrect Contact your service agent.

RELIEF VALVE LEAKING . . .

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.

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).

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 sys-

tem 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.

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 attention. 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.

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.

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.

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, spill switch disc heats up and spill

switch contacts open, shutting down ow of gas to main

burners by removing power to gas valve.
In event spill switch 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.

• 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.

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; ad-

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

о “Df_” Setpoint Differential (15 °F default set-

ting; 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

27

APPENDIX A - CONTROL MODULE

2.

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.

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

perature 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

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.

System is purging before ignition trial; includes Pilot Valve circuit

diagnostics.

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

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

23

32

55

56

57

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

59

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.

Atmospheric damper end switch failed to close (end switch contacts stuck
open).

Atmospheric damper end switch failed to open (end switch contacts stuck
close).

Igniter ame rod shorted to burner ground

Line Voltage error - voltage out of specication high or low (15-37V (44-

66Hz))

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

Wait for recovery

Wait for recovery

Wait for recovery

Soft lockout

Soft lockout

A.9 Intermittent Pilot

Ignition System Checks

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.

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.

STEP 3: Check spark ignition circuit.

30

APPENDIX A - CONTROL MODULE

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.

— 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.

• 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

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

See Figure 16, Page 21.

31

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and

Conservation Act, this boiler is equipped with a feature that saves energy

by reducing the boiler water temperature as the heating load decreases.

This feature is equipped with an override which is provided primarily to

permit the use of an external energy management system that serves the

same function.

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

FOLLOWING CONDITIONS IS TRUE:

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

• This boiler is not used for any space heating

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

• This boiler is equipped with a tankless coil.

UTICA BOILERS

2201 Dwyer Avenue

Utica NY 13501

web site: www.ecrinternational.com