16 Series
GAS-FIRED
STEAM BOILERS
MODELS
1603HSID
1604HSID
1605HSID
1606HSID
1607HSID
1608HSID
1609HSID
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
MODEL HSID
Electronic
Intermittent
Ignition
PENNCO BOILERS
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N 1305004, Rev. F [04/30/2017]
DIMENSIONS
Figure 1 - Dimensions
Vent
Damper
Pressure
Gauge
ASME
Relief
Valve
26.50"
Pressure
Limit
Control
4.75"
Spill
Switch
Water
Line
Transformer
2.5 OD
Glass
Gauge
Low Water
Cutoff Probe
36.375"
2.5 OD
Low Water
Cutoff
29"
Rollout
Switch
24.00"
CG400
12.25"
Gas
Valve
Gas Line
A
LEFT SIDE
FRONT
BOILER MODEL
NUMBER (1)
RIGHT SIDE
Dimensions (Inches)
Intermittent
Ignition w/Vent
Damper
Flue Diameter
"A" Width
1603HSID
5
11¼
1604HSID
6
14½
1605HSID
6
17¾
1606HSID
7
21
1607HSID
7
24¼
1608HSID
7
27½
1609HSID
7
30¾
Add 5½" to height for Vent Damper
2
P/N 1305004, Rev. F [04/30/2017]
RATINGS AND CAPACITY
Table 1 - Ratings and Capacities
BOILER MODEL
NUMBER
Intermittent
Ignition w/Vent
Damper
(1)
(1)
(1)
(1)
(1)
(1)
(1)
†Natural Gas
No. of
Sec.
1603HSID
3
1604HSID
4
1605HSID
5
1606HSID
6
1607HSID
Input
*MBTUH
Heating
Capacity
*MBTUH
Natural Gas
75
62
Propane
70
Natural Gas
Net AHRI
Rating *Mbh
Net AHRI
Rating Sq. Ft.
82.7
47
196
58
82.7
44
183
112
91
82.0
68
283
Propane
105
85
80.4
64
267
Natural Gas
150
122
82.0
92
383
Propane
140
114
80.6
86
358
Natural Gas
187
153
82.0
115
479
Propane
175
143
80.9
107
446
Natural Gas
225
183
82.0
137
571
Propane
210
171
81.1
128
533
Natural Gas
262
214
82.0
161
671
Propane
245
200
81.3
150
625
Natural Gas
299
245
82.0
184
767
Propane
280
229
81.5
172
717
Fuel Type
AFUE(%)
7
1608HSID
8
1609HSID
9
* MBH = 1,000 Btuh. Btuh = British Thermal Unit Per Hour.
† For altitudes above 2,000 ft. reduce input rate 4% for each 1,000 ft. above sea level.
Heating Capacity is based on DOE (Department of Energy) test procedure.
(1)
Add model number suffix 'P' for Propane Gas.
Net AHRI steam Ratings shown are based on a piping and pickup allowance of 1.333.
Base selection of boiler size on "Net AHRI Rating" being equal to or greater than installed radiation in square feet.
Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements,such as
intermittent system operation, exhaust piping systems, etc.
3
P/N 1305004, Rev. F [04/30/2017]
TABLE OF CONTENTS
Introduction
Dimensions................................................. 2
Boiler is designed for use in closed heating systems where
all steam is returned as condensate and make-up water is
minimal. Boiler is not designed for or intended for use in
open systems using 100% make-up water.
Ratings and Capacity................................... 3
Table of Contents......................................... 4
Safety Symbols........................................... 5
Locating the Boiler....................................... 6
Prior to Installation
System Piping............................................. 7
Installation - System Piping.........................10
•Verify correct boiler for type of gas being used
natural or propane. See Rating Plate.
Fresh Air for Combustion.............................11
•Verify boiler size and dimensions. See Figure 1 page 2.
Chimney and Vent Pipe Connection...............12
•Verify ratings and capacity data for natural gas. See
Table 1 page 3.
Vent Damper Operation...............................14
Gas Supply Piping.......................................15
Installation Requirements
Electrical Wiring.........................................16
•Supply boiler with correct gas (natural or propane),
fresh air for combustion, and suitable electrical supply.
•Connect boiler to adequate venting and piping
systems.
•Provide boiler with properly located and adjusted
thermostat.
Installation of boiler in building under construction, use
precaution to insure clean combustion air supply during
construction process. Airborne particulate from construction
materials can clog burner ports and cause incomplete
combustion and sooting.
Complete all steps for safe and proper heating system
operation.
Operating Instructions.................................17
Operating Your Boiler..................................18
Checking and Adjusting........................... 1920
Start-up Cleaning.......................................21
General Maintenance..................................22
Service Hints.............................................23
Wiring Diagrams.........................................24
Controls and Accessories.............................26
Appendix A - Vent Damper............................ 27
Appendix A - Vent Damper TroubleShooting.. 28
Repair Parts.................................................. 31
Warranty....................................................... 36
Check Out Certificate..................................... 39
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
GAS FIRED STEAM BOILERS
Check our website frequently for updates: www.ecrinternational.com
Information and specifications outlined in this manual in effect at the
time of printing of this manual. reserves the right to
discontinue, change specifications or system design at any time without
notice and without incurring any obligation, whatsoever.
4
P/N 1305004, Rev. F [04/30/2017]
SAFETY SYMBOLS
General
! WARNING
Boiler and venting installation shall be completed by
qualified agency.
Installing or venting a boiler or any other gas
appliance with improper methods or materials could
result in death or serious injury due to fire or to
asphyxiation from poisonous gases such as carbon
monoxide which is odorless and invisible.
! 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
Fire, explosion, asphyxiation hazard. Keep boiler
area clear and free from combustible materials,
gasoline and other flammable vapors and liquids.
Become familiar with symbols identifying potential
hazards.
Modification, substitution or elimination of factory
equipped, supplied or specified components could
result in death or serious injury.
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
!
! CAUTION
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury.
Laceration, burn hazard. Metal edges and parts
may have sharp edges and/or hot. Use appropriate
personal protection equipment to include safety
glasses and gloves when installing or servicing this
boiler. Failure to follow these instructions could result
in minor or moderate injury.
! WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
! CAUTION
Installation shall conform to requirements of
authority having jurisdiction or in absence of such
requirements to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54.
Indicates a hazardous situation which, if not avoided,
may result in minor or moderate injury.
NOTICE
Used to address practices not related to personal
injury.
Where required by authority having jurisdiction,
installation shall conform to Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1. Controls can be added to make
this boiler CSD-1 compliant. Check with your local
codes for requirements.
Requirements for Commonwealth of Massachusetts:
Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is
not limited to installation by licensed plumber or gas
fitter.
5
P/N 1305004, Rev. F [04/30/2017]
LOCATING THE BOILER
Locating the Boiler
1. Select level location as centralized with piping system,
Table 2 Minimum Clearance Dimensions
and as near chimney as possible.
2. Place crated boiler at selected location. Remove all
crate material. Please recycle responsibly.
! WARNING
Fire hazard. Do not install boiler on combustible
flooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
5.
6.
7.
6"
Rear
6"
Control Side
7"
Opposite Side
6"
Front
Flue/Vent
Connector
3. Do not install boiler on carpeting. For installation
4.
Top
on non-combustible floors only. For installation on
combustible flooring, special base must be used. See
Repair Parts page 31.
Use metal shims under boiler base legs for final leveling
if needed.
Install boiler in location that permits satisfactory
combustion of gas, proper venting, and maintenance
of ambient temperature at safe limits under normal
conditions of use. Boiler location should not interfere
with proper circulation of air. Introduce outside air
if normal infiltration does not provide necessary
air.“Fresh Air for Combustion” on page 11.
Notify owner to keep air passages free of obstruction.
Ventilating and combustion air must enter boiler room
without restrictions.
Install boiler so automatic gas ignition system
components are protected from water (dripping,
spraying, rain, etc.) during appliance operation and
service.
Alcove
6"
Draft Hood Installation
! WARNING
Asphyxiation, carbon monoxide hazard. Failure to
follow these instructions could result in improper
combustion and possible leakage of combustion
products into the living space.
Follow directions given in Figure 8 page 14. Mount
vent damper. See "Connecting Vent Damper and Vent
Connector" page 12. See Wiring Diagrams page 24.
6
P/N 1305004, Rev. F [04/30/2017]
SYSTEM PIPING
! WARNING
•Do not install shutoff valve between boiler and safety
valve.
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per the following instructions.
Failure to follow these instructions could result in death
or serious injury .
•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)
•Support safety valve discharge piping.
Safety Relief Valve Installation instructions:
•Run pipe as short and straight as possible to location
protecting user from scalding and properly drain piping.
•Connect to safety valve outlet. Piped down to safe
point of disposal. Check local codes for maximum
distance from floor or allowable safe point of discharge.
•Terminate with plain end, not threaded.
•Pipe size be of equal to or greater than of safety valve
outlet over entire length of discharge line.
•Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
•Have no intervening shutoff valve between safety valve
and discharge to atmosphere. Do not plug or place any
obstruction in discharge line.
•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.
•Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
•Terminate freely to atmosphere where any discharge
will be clearly visible and at no risk of freezing.
•Allow complete drainage of valve and discharge line.
•Install safety valve with spindle in vertical position.
Figure 3 - Safety Valve
SAFETY VALVE
DISCHARGE
PIPING
Check local codes
for maximum
distance from
floor or other
allowable safe
point of discharge
6" Above Floor
7
P/N 1305004, Rev. F [04/30/2017]
SYSTEM PIPING
13. For pumped return systems, follow the condensate
Consider near boiler piping as part of the boiler for proper
water level control and to produce dry steam.
pump or boiler feed pump manufacturer’s instructions
for proper installation and hookup.
14. In connecting the cold water supply to the water inlet
valve, make sure that a clean water supply is available.
When the water supply is from a well or pump, a sand
strainer should be installed at the pump.
Correct near boiler piping is crucial to proper operation of
boiler and heating system.
Follow these recommendations carefully.
1. Place boiler in selected location as near chimney as
possible.
2. Install safety valve. Figure 3 and Warning on Page 7.
For Use With Cooling Units
Install boiler, when used in connection with refrigeration
system, so chilled medium is piped in parallel with boiler
with appropriate valves to prevent chilled medium from
entering the boiler. See Figure 6.
•Install union, if used, close to safety valve outlet.
•Install elbows close to safety valve outlet and
downstream of union (if used).
3. Boiler is equipped with two 2½" supply connections
and two 2½" return connections, one each on both left
and right sides of boiler. Plug unused connections with
furnished 2½" plug (furnished).
4. When using both supply tappings to pipe system as
shown in Figure 5, Page 10.
•Fit headers with header offsets, swing joints, or equip
with expansion joints, so thermal expansion and
contraction of header does not damage boiler. Do not
weld headers.
•Place system takeoffs from header between equalizer
and riser to header nearest equalizer. System takeoffs
must never be between two risers. If steam main goes
in two directions, place two takeoffs from header, one
for each main.
5. System takeoffs from the header must never be
bullheaded. If the steam main goes in two directions,
there must be two takeoffs from the header, one for each
main.
6. All boilers in gravity return systems must be equipped
with a Hartford Loop as shown in Figure 5.
7. When piping the vertical risers from the boiler to the
header, the bottom of the header must be a minimum
of 24 inches above the water level line on the right side
of the boiler.
8. Steam riser(s) and header shall be 2½” pipe size.
9. Equalizer line shall be minimum 1½” pipe size.
10. The near boiler piping shall include a 2½” tee with a
plug located on the supply line as shown for skimming
(i.e. surface blowdown).
11. The near boiler piping shall include a 1-1/2 ball valve
in the return piping as shown for bottom blowdown and
draining.
12. For gravity return systems, the bottom of the lowest
steam carrying pipe, be it a dry return, or the end of the
steam main, must be at least 28” above the normal water
level line on the right side of the boiler. This is known as
“Dimension A.”
8
P/N 1305004, Rev. F [04/30/2017]
SYSTEM PIPING
Figure 4 - Recommended Near Boiler Piping Using One Supply Tapping
9
P/N 1305004, Rev. F [04/30/2017]
INSTALLATION - SYSTEM PIPING
Figure 5 - Recommended Near Boiler Piping Using Two Supply Tappings
Figure 6 - Chilled Water Piping
VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING
VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING
10
P/N 1305004, Rev. F [04/30/2017]
FRESH AIR FOR COMBUSTION
! WARNING
B. Known Air Infiltration Rate. See Table 3 for
space with boiler only. Use equation for multiple
appliances. Do not use an air infiltration rate air
changes per hour (ACH) greater than 0.60.
Air openings to combustion area must not be
obstructed. Follow instructions below, to maintain
adequate combustion air
Room volume is greater than 21 cubic feet divided by
ACH (air changes per hour) x Total Input [Mbh]
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.
C. Refer to National Fuel Gas Code for opening
requirements between connected indoor spaces.
•All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.
Provide make-up air where exhaust fans, clothes dryers,
and kitchen ventilation equipment interfere with proper
operation.
A. Two Permanent Opening Method. Provide opening
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom of
enclosure.
National Fuel Gas Code recognizes several methods
of obtaining adequate ventilation and combustion air.
Requirements of the authority having jurisdiction may
override these methods.
…… 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.
•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.
…… 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).
•All Indoor Air. Calculate minimum volume for all
appliances in space. Use a different method if minimum
volume not available.
A. Standard Method. See Table 3 for space with natural
gas boiler only. Use equation for multiple appliances
and/or propane.
C. Refer to National Fuel Gas Code for additional
requirements for louvers, grilles, screens and air
ducts.
Room Volume is greater than 50 cubic feet multiplied
by Total Input [Mbh]
•Combination Indoor and Outdoor Air. Refer to National
Fuel Gas Code for application information.
Table 3 - Minimum Room Volume, Indoor Air Only*
Known Air Infiltration Rate Method (Air Changes Per Hour)
Input Mbh
Standard
Method
0.1
0.2
0.3
0.4
0.5
0.6
75
3750
15750
7875
5250
3938
3150
2625
112.5
5625
23625
11813
7875
5906
4725
3938
150
7500
31500
15750
10500
7875
6300
5250
187
9350
39270
19635
13090
9818
7854
6545
225
11250
47250
23625
15750
11813
9450
7875
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.
11
P/N 1305004, Rev. F [04/30/2017]
CHIMNEY AND VENT PIPE CONNECTION
! WARNING
Installing or venting a boiler or any other gas
appliance with improper methods or materials could
result in death or serious injury due to fire or to
asphyxiation from poisonous gases such as carbon
monoxide which is odorless and invisible.
9. End of vent pipe must be flush with inside face of
chimney flue. Use sealed-in thimble for chimney
connection.
10. Horizontal run should not be longer than 3/4 the
chimney height (HT) Figure 7, page 13.
Vent Pipe
• Fasten sections of vent pipe with 3 sheet metal screws
at each joint to make piping rigid.
• Support horizontal portions of vent system to prevent
sagging.
• Use stovepipe wires or metal strapping every 5’ to
support pipe from above.
• Vent pipe through crawl space, use double wall vent
pipe.
• Vent pipe passing through combustible wall or partition,
use ventilated metal thimble. Thimble should be 4"
larger in diameter than vent pipe.
Boiler and venting installations shall be performed
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.
Chimney Inspection
Chimney must be clean, sized correctly, properly
constructed and in good condition.
Installation must conform to requirements of the authority
having jurisdiction or, in absence of such requirements, to
the National Fuel Gas Code, ANSI Z223.1/NFPA 54. See
Figure 7, page 13.
NOTICE
Connecting The Vent Damper And Vent Connector
Refer to Figure 1 for the size and location of the vent (flue
opening). Use a 28 gauge (minimum) galvanized pipe to
connect to the chimney.
Furnished vent damper blade has 1/2 square inch hole
(approximately 3/4” diameter). Boilers equipped with
intermittent ignition, plug hole using plug supplied with
vent damper.
1. Position furnished vent damper on top of flue outlet
collar. Fasten damper securely to flue outlet collar
with sheet metal screws. Make sure damper blade has
clearance to operate inside of diverter. Do not modify
draft diverter or vent damper
As An Option
Damper may be installed in any horizontal or vertical
position, closer to flue outlet collar preferred. See
Figures 7, 8 and 9.
2. Install vent damper to service single boiler only 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 open position when appliance main
burners are operating.
4. Boiler is equipped with factory wired harness that plugs
into vent damper. Connect thermostat to black wires
marked 24 volt thermostat on boiler.
5. Vent pipe must be same size as flue outlet collar.
6. Slope pipe up from boiler to chimney not less than 1/4”
per foot.
7. Run pipe as directly as possible with as few elbows as
possible.
8. Do not connect to fireplace flue.
Minimum Vent Pipe Clearance - Wood and other
combustible materials must not be closer than 6” from
any surface of single wall metal vent pipe. Listed Type
B vent pipe or other listed venting systems shall be
installed in accordance with their listing.
Removing Existing Boiler From Common Venting
System
When an existing boiler is removed from a common
venting system, the common venting system is likely to be
too large for proper venting of the appliances remaining
connected to it.
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 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 deficiencies
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 fireplace dampers.
12
P/N 1305004, Rev. F [04/30/2017]
CHIMNEY AND VENT PIPE CONNECTION
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 flame 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, fireplace 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 resized
to approach the minimum size as determined using the
appropriate tables in Chapter 13 of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
Figure 7 - Typical Masonry Chimney Requirements
2 FT (610mm)
MIN.
3 FT (914mm)
MIN.
Vent connectors serving appliances vented by natural draft shall
not be connected into any portion of mechanical draft systems
operating under positive pressure.
13
P/N 1305004, Rev. F [04/30/2017]
VENT DAMPER OPERATION
! WARNING
Figure 8 - Horizontal Installation
Asphyxiation or burn hazard. Improper installation
and operation of vent damper could result in serious
injury or death due to fire or to asphyxiation from
poisonous gases such as carbon monoxide which is
odorless and invisible.
Horizontal Installation
Flow
NO
YES
To Boiler Vent Damper
Vent Damper Installation - Follow all cautions
and notes.
To
Chimney
NO
Install vent damper
with actuator to sides
of vent only. Do not
mount above or below
vent.
To
Chimney
•Install vent damper to service only single appliance for
which it is intended.
YES
•Do not install vent damper with 6" (15mm) of
combustible material.
•Do not install vent damper on vent pipe curve.
Vent Damper
Flow
•Do not run wires near high temperature surfaces. Use
standoff brackets if necessary.
Actuator may
be installer in
any position.
To Boiler
•Install vent damper with actuator to sides of vent only.
Do not mount above or below vent.
Check vent damper and all flue product carrying
areas of boiler annually for deterioration from
corrosion or other sources. If you see corrosion or
other deterioration, contact your service agent for
repairs.
Check vent damper operation as follows:
1. When boiler is off, check vent damper positions
indicator points to closed position. See Figure 10.
2. Turn thermostat or controller up to call for heat and
check vent damper indicator points to open position
See Figure 10.
3. Turn thermostat or controller down again and check
damper position indicator returns to closed position.
4. Return thermostat to desired position.
Figure 9 - Alternate Vent Damper Installation
Caution: Do not
install Vent Damper
within 6" (152mm)
of combustible
material
Do Not
Install
Here
Install Damper Here
Inspect vent damper at least once a year by
trained service technician.
Chimney
Manual Operation of Vent Damper
Boiler
• Place vent damper in open position to permit burner
operation by using “HOLD DAMPER OPEN” switch,
located on damper controller.
Figure 10 - Vent Damper Position Indicator
ROTATION
Damper Closed
OPEN
Flow
CLOSED
• For further information, and for vent damper
troubleshooting guide, refer to manual packaged with
vent damper.
Flue Gas Flow
• Set switch to “AUTOMATIC OPERATION” to close vent
damper during burner off cycle.
CLOSED
Flue Gas
• DO NOT turn damper open manually, motor damage
will result.
ROTATION
OPEN
• Thermostat controls burner firing as before, while
damper remains open.
Damper Open
Showing Open and Closed Positions
14
P/N 1305004, Rev. F [04/30/2017]
GAS SUPPLY PIPING
! CAUTION
Propane Installation
WARNING
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
Fire, explosion, asphyxiation hazard. Verify boiler
is equipped with propane gas orifices and gas valve
is configured for propane. Failure to follow these
instructions may result in serious injury or death.
• 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.
•Connections by licensed propane dealer only.
•Use two stage regulator provided by propane
supplier.
•Have propane supplier check piping.
• If you cannot reach your gas supplier, call the fire
department.
!
General
•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.
•Size and install gas piping system to provide sufficient
gas supply to meet maximum input at not less than
minimum supply pressure. See Tables 4a and 4b.
Table - 4a
Length
of Pipe
- Ft.
20
40
60
Table - 4b
Length
of Pipe
- Ft.
20
40
60
DANGER
Fire Hazard. Do not use matches, candles, open
flames, 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. Avoid excessive pressure that could
damage pressure regulators, valves, or meters.
•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 fluid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open flames, or other methods
providing ignition source.
•Correct leaks immediately and retest.
Gas Pipe Sizes - Natural Gas
Pipe Capacity - BTU Per Hour Input
Includes Fittings
1/2"
3/4"
1"
1 -1/4"
92,000 190,000 350,000 625,000
63,000 130,000 245,000 445,000
50,000 105,000 195,000 365,000
Gas Pipe Sizes - Propane Gas
Pipe Capacity - BTU Per Hour Input
Includes Fittings
5/8"
3/4"
1/2"
3/4"
131,000 216,000 189,000 393,000
90,000 145,000 129,000 267,000
72,000 121,000 103,000 217,000
Figure 11 - Gas Piping At Boiler
* Outside diameter
Length of pipe or tubing should be measured from the gas meter
or propane second stage regulator.
•Support piping with hooks straps, bands, brackets,
hangers, or building structure components to prevent or
dampen excessive vibrations and prevent strain on gas
connection. Gas valve will not support piping weight.
•Use thread (joint) compound (pipe dope) suitable for
natural and liquefied petroleum gas.
•Install field sourced manual main shutoff valve, ground
joint union, and sediment trap upstream of gas valve.
See Figure 11.
Manifold
Floor Line
15
Automatic
Gas Valve
Ground
Joint
Union
3” Minimum
Sediment
Trap
P/N 1305004, Rev. F [04/30/2017]
ELECTRICAL WIRING
! WARNING
Electronic Thermostats
A. Some electronic thermostats may lose their
memory or shut down. With probe type low water
cutoff, this may occur each time low water cutoff
detects low water condition. If this is the case, an
isolation relay is required for thermostat circuit. A
24 volt single pole single throw (SPST) normally
open (N.O.) relay is required, such as Honeywell
R8222A or equivalent. Wire as shown in Figure 12a
or Figure 12b.
B. Some electronic thermostats are not acceptable
for use with steam systems, check manufacturer
suggested use.
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.
Electric Power Supply
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to
National Electrical Code, ANSI/NFPA 70.
Figure 12a - Isolation Relay Wiring For Steam
Boilers With Float Type Low Water Cut Off And
Use of Electronic Thermostat
Line Voltage Connections
A. Provide individual 120V, 15 amp circuit
(recommended) with fused disconnect or service
switch as required by authority having jurisdiction.
B. Locate a shut-off switch at the boiler.
C. Connect 115V electrical supply to primary leads on
24 volt transformer. Securely fasten with wire nuts.
D. Set heat anticipator at 0.6 amps for boilers
equipped with intermittent ignition. Connect 24
volt thermostat leads to two wires tagged “24 volt
thermostat” on boiler.
E. Boilers with 67D-1 float type low water cut-off, two
wires are black. One wire is located on secondary
of 24 volt transformer, second wire is located on
pressure limit control.
F. Boilers with CG400 probe type low water cut-off,
one wire is green and is located on terminal P2
of CG400 , second wire is black and located on
pressure limit control.
VENT DAMPER
Figure 12b - Isolation Relay Wiring For Steam
Boilers With Probe Type Low Water Cut Off And
Use of Electronic Thermostat
Boiler is equipped with factory wired 4 pin molex harness,
that plugs into 4 pin molex receptacle inside vent damper
control.
Vent damper must be connected for boiler to operate.
Thermostat Installation
1. Install thermostat on inside wall per manufacturer's
instructions.
2. NEVER install thermostat on outside wall.
3. Do not install thermostat where it will be affected by
drafts, hot or cold pipes, sunlight, lighting fixtures,
televisions, fireplace, or chimney.
4. Check thermostat operation by raising and lowering
thermostat setting as required to start and stop
burners.
5. Instructions for final adjustment of thermostat see
manufacturer's instructions.
16
P/N 1305004, Rev. F [04/30/2017]
OPERATING INSTRUCTIONS
For Your Safety Read Before Operating
! WARNING
If you do not follow these instructions
exactly, a fire 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.
1. STOP! Read the safety information on this page.
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.
Figure 13 - Gas Valve
•Before operating smell all around appliance area
for gas. Be sure to smell next to floor because
some gas is heavier than air and will settle to the
floor.
•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 qualified
service technician. Force or attempted repair may
result in fire or explosion.
•Do not use this appliance if any part has
been under water. Immediately call a qualified
service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.
! 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 fire
department.
5. Remove lower front panel.
6. Rotate the gas control knob clockwise
to“OFF”.
7. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas,
STOP! Follow “B” in the safety information on this page
If you don’t smell gas, go to next step.
8. Rotate the 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.
17
P/N 1305004, Rev. F [04/30/2017]
OPERATING YOUR BOILER
! WARNING
Thermostat
A. Set thermostat to desired room temperature.
B. Set thermostat to lower setting if heat is not
required
C. System is self-checking. If failure of any component
system will not operate or will go into safety
lockout.
D. On call for heat, each component must function
properly to permit operation.
E. Turn thermostat to lowest setting for one minute
and back to normal setting to reset on safety
lockout.
Burn Hazard. Never run water into a hot empty
boiler. Failure to follow these instructions could
result in death or serious injury.
Filling System With Water
Steam heating systems boiler is partially filled with water.
Fill boiler to correct level for proper system operation.
Correct water level is about halfway up glass water level
gauge as marked on boiler jacket.
1. Close boiler drain valve.
2. Open valves at top and bottom of glass water level
gauge.
3. Open fill valve. Allow water to run into boiler.
4. Allow boiler to fill until water runs out gauge drain
valve. Then close gauge drain valve.
5. Continue to fill boiler until water reaches indicated
water line about halfway up glass gauge.
Water Level
• Normal water level is 24" above the floor as shown on
left side of boiler.
• Determine water level when boiler is off and cold, when
all water in the system is inside the boiler and return
piping below water line, and everything above water
line is air, no steam.
• When boiler is making steam, water level drops two to
three inches below normal water line.
18
P/N 1305004, Rev. F [04/30/2017]
CHECKING AND ADJUSTING
Adjust Pilot Burner
Pilot flame should surround 3/8” to 1/2” of pilot sensor. See
Figure 14.
To adjust Flame.
1. Remove screw cover over pilot adjusting screw. See
Figure 13.
2. Insert small screwdriver and adjust flame as needed.
Turn screw counterclockwise to increase flame, clockwise to decrease.
3. Replace screw cover over pilot adjusting screw.
Figure 14 - Igniter
Main Burners
• Main burners do not require primary air adjustment and
are not equipped with primary air shutters.
• Main burner flames form sharp blue inner cones in
softer blue outer mantel, with no yellow. Remain still
when observing main burner flames.
• Check main burner orifices, burner throat and flame
ports for dust and lint obstruction if flame appearance
is not correct.
• Remove rollout shield if necessary to observe main
burner flames.
Figure 15 - Main Burner
• Replace rollout shield after observation.
Gas Valve Safety Shutdown Test
1. Test ignition system safety shutoff device after placing
boiler in operation.
2. Boilers equipped with intermittent ignition, with
main burners firing, disconnect ignition cable from
intermittent pilot control box. Gas valve will shut off
main burners.
3. TURN OFF ELECTRIC POWER to boiler before
reconnecting ignition cable, to prevent electric shock.
19
P/N 1305004, Rev. F [04/30/2017]
CHECKING AND ADJUSTING
Adjust Steam Pressure Control
Boiler Equipped With Optional WF-2U-24 Water
Feeder
E. Continue thermostat call for heat after low water
cut off recognizes low water condition.
F. One minute time delay, water feeder starts feeding
water to boiler.
G. Feeder feeds for one minute, and then goes into
another one minute waiting period.
H. Cycle of alternately waiting and feeding will repeat
until :
• Steam pressure limit control (pressuretrol) shuts
off gas to main burners when steam pressure in
boiler reaches cut-off setpoint (i.e. sum of cut-in and
differential setpoints).
• Burners refire when steam pressure drops to cut-in
setpoint.
• System pressure requirements are based on size and
condition of pipes, and load.
• Cut-in setting of pressuretrol should never be less than
twice system pressure drop for good system operation.
•For Model 67D-1 float type low water cutoffs - as
the water level raises the float above the burner
cut off switch level, the burners should ignite. The
water feeder remains powered until the water
level raises the float to the water feeder switch
level, satisfying the water feeder.
A. In typical single family residence with clean onepipe heating system and cast iron radiation, cut-in
is usually set at minimum setting, i.e. 1/2 psi.
• Steam radiation is sized based on square feet of
equivalent direct radiation (EDR). This is based on
steam pressure in the radiator of just less than 2 psi.
•For probe type low water cutoffs - the water level
will rise until water in the boiler makes contact
with the probe, satisfying the water feeder, and
igniting the burners.
• Set differential adjustment at 1 psi, i.e. steam pressure
required in radiators. Results in cut-off setpoint of 1½
psi.
I. In either case, one and two inches of water should
be visible in glass gauge when both water feeder is
satisfied, and burners are allowed to ignite.
• Larger systems or other types of systems such as two
pipe systems, or systems with convectors or fan coil
units, pressuretrol settings need to be determined on
system-by-system basis.
•Time delays in feed cycles are designed to prevent
boiler from flooding due to slow return lines.
• Cut-in setpoint is determined by system pressure drop
to furthest radiator or terminal unit. Double system
pressure drop as safety factor, resulting in the rule
cut-in setting should never be less than twice system
pressure drop.
•To check pressure limit, run boiler until pressure
reaches system demand. Turn pressure screw and drop
pressure setting until boiler shuts down. This shows the
pressure limit is operating properly.
•Refer to control manufacturer’s instructions for more
information.
• Differential setpoint is steam pressure required at
terminal heating units.
Boiler will now operate in correct pressure range. It
maintains enough steam pressure to send steam out to
furthest radiator, and not go over optimum steam pressure
required at the radiators.
Checking Controls
Low Water Cut-Off
A. Turn off power to boiler or turn thermostat down to
lowest setting.
B. Drain water to below visible bottom of water gauge
glass. Turn power on and turn thermostat to call for
heat.
C. Gas valve opens for approximately 10 seconds
(time delay on probe type LWCO), gas valve will
close and red indicator illuminates on LWCO.
D. When water is restored, it waits 30 seconds before
reactivating burner circuit.
Check Thermostat Operation
Thermostat set above temperature indicated on
thermometer, boiler should ignite.
Verify thermostat turns boiler off when room temperature
reaches selected setting and starts boiler operating when
room temperature falls few degrees.
Set thermostat for desired temperature. Conditions in your
home and location of thermostat will govern this setting.
20
P/N 1305004, Rev. F [04/30/2017]
START-UP CLEANING
! WARNING
•Maintain at least 180°F for 15 minutes to remove
dissolved gasses from fresh water.
Following service procedures must be performed
by qualified service agent. Boiler owner shall not
attempt these steps. Failure to do so could result in
death or serious injury.
•Shut off burners.
8. Allow system to operate for one week to give majority
of system dirt a chance to work its way back to boiler.
•Check water in gauge glass. Gauge glass should be
dry above water line.
It is very important to clean a new steam boiler after it has
been installed and put into continuous operation.
This must be done to remove any accumulation of oil,
grease, sludge, etc., that may have be present in system.
These substances may cause boiler water to foam and
surge, producing an unsteady water line, throwing
water into steam header, and possibly preventing steam
generation.
Follow skimming and blow-down steps in order to remove
contaminants.
•Water line should not bounce more than one inch
when boiler is steaming.
•If you see water droplets carrying over from top of
gauge glass, or excessive bouncing of water line,
boiler needs further cleaning.
•Take water sample and boil it on stove to see if it
foams. If it does, this indicates boiler needs to be
cleaned.
NOTICE
Skimming and Blow-down
Clean water with no additives is essential to proper
operation of your boiler and heating system. Boiler
cleaners and chemical cleaning, if used and not
rinsed properly, may be harmful to the system.
! WARNING
Burn Scald Hazard. Water temperatures in excess
of 125°F. Failure to follow these instructions could
result in death or serious injury.
New boilers must be skimmed at time of installation to
remove threading oil and other impurities that float on
surface of water.
1. Remove cap from skimmer female adapter tee and pipe
to floor drain or bucket. See Figures 4 and 5 page 9.
Raise water level to skimmer tapping.
2. Fire burners to maintain water temperature of 180200°F.
3. Feed water to boiler to maintain water level. Adjust
water feed rate to maintain continuous flow of 1 gallon
per minute. Do not allow boiler to steam.
4. Continue skimming until water runs clear. This may
take several hours.
5. Drain boiler completely to remove any foreign material.
6. Fill boiler to water line.
•Fire burners, allow normal steam pressure to build up.
If cleaning is necessary, repeat skimming and blow-down
procedure above. A long skim will be all you need to clean
the boiler.
In more troublesome cases it may be desirable to flush the
system while, in very extreme cases, it may be necessary
to chemically clean and flush heating system.
Consult boiler manufacturer before introducing any
chemicals into boiler.
Check water level frequently. Be sure top and bottom
valves on gauge are always open so actual water level is
shown at all times.
•Run connection from boiler drain valve to safe
discharge point outside.
•Shut off gas burners, open drain valve, allow all of
water in boiler to drain out.
•Close drain valve.
•Allow boiler to cool, slowly refill boiler to water line.
•Repeat this step as many times as necessary until
blow-down water is clear.
7. Following final blow-down, allow boiler to cool.
•Add fresh water slowly up to normal water line.
•Start burners.
21
P/N 1305004, Rev. F [04/30/2017]
GENERAL MAINTENANCE
Low Water Cut-Off
Boiler Water Treatment Other Than Cleaners
Low Water Cut-Off interrupts electrical current to burner
when water line in boiler drops to low level.
Check Low Water Cut-Off monthly to verify it is providing
proper protection. See “Checking and Adjusting” on page
21.
Remove Low Water Cut-Off probes beginning of each
heating season for inspection and cleaning. More cleaning
may be required on boilers requiring frequent additions of
make up water.
In steam systems where system is tight, free from leaks,
and all steam is returned to boiler as condensate, amount
of make up water is small. Water treatment is generally not
required.
In steam systems with less than 90% of steam being
returned as condensate, or with very hard or corrosive
make up water, treatment may be desirable. Follow
recommendations of your local boiler water treatment
specialist.
Boiler Flue Passages and Burners
Beginning of heating season visually check pilot and main
burner flames. See page 19.
Recommend you have flue passages, burner adjustment,
and operation of controls checked once each year by
trained Service Technician.
Before start of each season or whenever system has been
shut down for some time, check system, boiler and vent
pipe for leaks.
Foaming, Priming, or Surging
These terms are used to describe a fluctuating water line
when water leaves boiler with steam. It is caused by any
combination of following:
1. Threading oil and organic matter in boiler water. Follow
instructions under “Start-up Cleaning.”
2. Faulty quick vents that do not release air until sizeable
pressure is built up - if old style, replace - if dirty, clean
until you can easily blow through valve.
3. Adjustment of steam limit control to wide differential
increases difficulty if quick vents are old style, slowreleasing type or dirty. Always set steam limit control
differential as low as possible.
4. Soap and chemicals in boiler water cause extreme
surging. Boiler cleaners and chemical cleaning additives
are not recommended. If used and not rinsed properly,
may be harmful to the system.
Vent Pipe
Check vent piping at lease once a season. Verify vent pipe
connections to chimney are secure and no obstructions
are present. If vent piping shows sign of leaking, replace it
immediately.
Safety Valve
See Manufacturer's Instructions.
Cleaning Boiler Flue Passages and Burners
1. Remove burners, pilot, vent pipe, top and front jacket
panels. Remove hold-down nuts and bolts from flue
collector.
2. Use putty knife to cut through silicone. Lift flue collector
off boiler sections. Remove old silicone material.
3. Clean passageways between sections with flue brush.
Remove dirt from bottom of boiler and from between
sections by vacuuming.
4. Verify all flame ports in burners are open and clear.
Shake or blow out loose dirt in burners.
5. Apply generous bead of 400°F RTV silicone to four
mounting surface flanges of flue collector. Mount flue
collector on heat exchanger. Tighten nuts and bolts.
6. Seal front edge and four corners of flue collector to
heat exchanger with silicone sealant.
7. Use flashlight to verify there are no gaps in silicone
seal.
8. Install draft diverter, vent damper, vent pipe, and
jacket top and front cover.
9. Reassemble all parts.
10.Check tightness of pilot connections and condition of
burner flames after reassembly. See Figures 14 and 15.
22
P/N 1305004, Rev. F [04/30/2017]
SERVICE HINTS
You may avoid inconvenience and service calls by checking these points before you call for 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 fire
department.
IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .
Possible Cause
What to do
Thermostat is not set correctly
Reset thermostat above room temperature.
Burner is not operating properly
Inspect flame. If yellow, burner is not getting enough air. If blue and noisy and
seems to lift off burner, burner is getting too much air. Contact service technician.
No electric power to boiler
Verify electric power supply circuit is “ON”. Contact your service technician to
verify over current protection.
Controls out of adjustment
Reset according to instructions.
Radiators not heating
Inspect steam air vents for proper operation. Contact service technician to inspect for faulty
steam traps.
Poor electrical contact
Contact your service technician to inspect all control terminals and wire joints.
Rollout switch blown
Have your service technician check heat exchanger for blockage.
Chimney flue is blocked
Spill switch contacts open, requiring manual reset of spill switch. Have your service
technician check and correct chimney problem.
Vent damper not operating
Consult troubleshooting guide, packaged with vent damper. IF BURNER IS NOISY . . .
Gas input amount is incorrect
Contact your service technician.
IF WALLS OR WINDOWS SWEAT . . .
Not enough ventilation
Contact your service technician
Chimney flue is blocked
Contact service technician to inspect and correct, if necessary.
Air in system
refer to "Radiators Not Heating" above
Dirt on seat
Contact service technician.
IF RADIATORS ARE NOISY . . .
SAFETY VALVE LEAKING . . .
HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.
23
P/N 1305004, Rev. F [04/30/2017]
WIRING DIAGRAMS
Figure 13 - Wiring Diagrams For Boilers With CG400 Probe Type Low Water Cut-Off
Shown CG400
Terminals
PS802 To CG400
Cross Reference
PS802
CG400
N
2
H
1
C
P1
W
P2
B
A
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.
24
P/N 1305004, Rev. F [04/30/2017]
WIRING DIAGRAMS
Figure 17 - Wiring Diagrams For Boilers With 67D-1 Float Type Low Water Cut-Off
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.
25
P/N 1305004, Rev. F [04/30/2017]
CONTROLS AND ACCESSORIES
SAFETY VALVE
Safety valve is designed to open automatically if boiler steam
pressure exceeds pressure rating of valve (15 psig). Should
it fail to open under this condition, shut down your boiler. If
valve discharge occurs, or valve fails to open as described
above, contact a qualified service technician to replace safety
valve and inspect heating system to determine cause, as this
may indicate equipment malfunction.
WATER FEEDER (Optional)
Model WF-2U-24 water feeder maybe used with either
of the low water cutoffs listed. Water feeder maintains
safe minimum water level. Keeps boiler running by
compensating for minor evaporative steam leaks, and
prevents freeze-ups if homeowners are away and return
line leaks.
McDonnell and Miller Model 101 water feeders may be
used, however water feed rates are too high and need to
be regulated or throttled and wiring will have to be revised.
Consult boiler manufacturer before using these or any
other non-standard types of controls.
STEAM PRESSURE GAUGE
Boiler is equipped with pressure gauge installed. Gauge
enables monitoring of the pressure in the system. If safety
devices fail to shut off your boiler at proper settings, notify
your serviceman immediately.
WATER LEVEL GAUGE
Boiler water level can be seen through glass tube in water
level gauge at side of boiler. Correct cold boiler water level
is stamped on side jacket panel. Check water level regularly
for proper level.
Located on right side of boiler jacket panel, there are three
holes for glass water level gauge. Top hole is common for
both types of low water cut off, and is used for upper gauge
glass fitting. Middle hole, 9” down from top hole, is used for
bottom gauge glass fitting for the Model 67D-1 and 47-2
float type low water cut off. Lowest hole, 121/4” down from
top hole, is used for bottom gauge glass fitting for Model
CG400 probe type low water cut off. Cover unused with
sheet metal knockout.
STEAM PRESSURE CONTROL
Steam pressure limit control (pressuretrol) shuts off gas to
main burners when steam pressure in boiler reaches cutoff setpoint (i.e. sum of cut-in and differential setpoints).
Burners refire when steam pressure drops to cut-in
setpoint. System pressure requirements are based on size
and condition of pipes, and load.
LOW WATER CUT-OFF
Model 67D-1
Float operated switch which shuts down gas burner if water
falls below visible bottom of gauge glass.
Probe Type Models
Electronic probe type LWCO. Probe is located inside boiler.
LWCO will shut down burners if water loses contact with
probe for 10 seconds.
Refer to manufacturer’s instructions (enclosed) for more
information.
Automatic water feeder is safety device, not convenience
item. It is not designed to maintain “normal” water line.
Water feeder does not take place of responsible person
monitoring and maintaining normal water line. Steam
boilers require attention.
VENT DAMPER
Automatic, motorized stack damper developed to increase
efficiency of heating systems by reducing standby losses
from boiler and conditioned air space. Damper closes
chimney vent when burner is off and fully opens it when
combustion is required.
ROLLOUT SWITCH
(FLAME ROLLOUT SAFETY SHUTOFF)
Rollout switch is temperature-sensitive fuse link device.
Located on boiler base just outside fire box. In event of heat
exchanger flueway blockage causing flame to roll out of
fire box, fuse will blow, shutting down flow of gas to main
burners. Fuse does not change in appearance when blown.
If rollout switch blows, replace with exact replacement.
Check heat exchanger flueways for blockage when
restoring system to operating condition. Do not operate
system without rollout switch.
SPILL SWITCH
(BLOCKED VENT SAFETY SHUTOFF)
Spill switch is manual reset disc thermostat with fixed
setpoint (280° F), and normally closed contacts. It is located
at relief opening of 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 flow 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. Manually reset spill switch after switch has
cooled off, push reset button down. Check venting system
and chimney for blockage when restoring system to operating
condition. DO NOT operate boiler without spill switch.
26
P/N 1305004, Rev. F [04/30/2017]
APPENDIX A - VENT DAMPER
A.1 Vent Damper Harness - Molex Plugs
•If boiler ignites: Go to section B.2
"Vent Damper Troubleshooting Guide".
NOTE: Prior to replacing the damper, be sure the
problem is not with wire connections between damper
and wiring harness.
! WARNING
Do Not negate the action of any existing safety
orperational controls. Avoidance of these instructions
could result in death or serious injury.
Note
"V" Slot
When servicing controls, all wires must be
labeled prior to disconnection. Wiring errors
can cause improper and dangerous operation.
Do not turn damper open manually or motor
damage will result and void all warranties, use
the service switch.
Brown
Orange
Yellow
Black
DO NOT CUT PLUG OFF OF DAMPER MOTOR
ASSEMBLY OR WARRANTY WILL BE VOID.
Control End of wiring harness
Hold plug in hand with wiring harness behind Molex with
“V” slot on top. Verify wires colors are in proper position
Check Molex Plugs on Vent Damper Harness:
Note
"V" Slot
Damper wiring harness is made up of 4
individual colored wires, Brown, Black, Yellow,
and Orange (refer to drawing below).
Yellow
Brown
Black
1. Disconnect thermostat wires.
2. Use the two diagrams below to confirm the Molex plugs
on each end of the damper harness are wired and
operating properly.
Damper end of wiring harness:
A. Hold plug in hand with wiring harness behind Molex
with “V” slot on top. Verify wire colors are in
proper position.
B. Take reading across brown and black wires in Molex
plug, using test meter set for AC volts. 24 volts
should be present.
i. IF NOT, source of the problem is not in
damper; check line voltage and 24 volt supply.
ii. If 24 volts is present across brown and black,
continue to step iii.
iii. Reconnect thermostat wires and turn up heat
setting.
iv. Check voltage across black and orange wires
in Molex plug. 24 volts AC should be present:
•IF NOT, source problem is not the damper.
•If 24 volts is present continue on to step v.
v. Place jumper wire across orange and yellow
wires in Molex plug (see Below). This will
create bypass of the damper, boiler should
then ignite.
OPEN
Orange
Black
A. Remove damper harness from control. Jump Molex
connector on control board between two center
holes using ~18ga. thermostat wire.
i. If boiler ignites, replace damper harness
ii. If boiler does not light, replace control.
•IF NOT, source problem is not the damper. Go to
“Aquastat end of wiring harness’
27
P/N 1305004, Rev. F [04/30/2017]
APPENDIX A - VENT DAMPER TROUBLESHOOTING
A.2 Vent Damper Troubleshooting Guide
! WARNING
Do Not negate the action of any existing safety
orperational controls. Avoidance of these instructions
could result in death or serious injury.
Note
When servicing controls, all wires must be
labeled prior to disconnection. Wiring errors
can cause improper and dangerous operation.
Do not turn damper open manually or motor
damage will result and void all warranties, use
the service switch.
DO NOT CUT PLUG OFF OF DAMPER MOTOR
ASSEMBLY OR WARRANTY WILL BE VOID.
Normal Sequence of Operation
24 VAC
Power
Power ON
Damper Position
4&1
All times
Open or Closed
4&2
Calling for Heat
Open or Opening
4&3
During combustion
Damper Open
Vent
Damper
Plug
4 BLK
2 ORG
3 YLW
1 BRN
Trouble Shooting
Problem
Possible Cause
Recommended Solution
NO POWER
Between 4 & 1
1.
2.
3.
4.
5.
6.
Off on limit (120VAC)
Bad transformer
Loose or broken connections
Blown fuse or circuit breaker
Disconnect switch off
Harness not plugged into receptacle
1.
2.
3.
4.
5.
6.
turn limit on
Replace transformer
Tighten, repair, or replace connection
Replace fuse or reset circuit breaker
Turn switch on
Plug harness in
1.
2.
3.
4.
5.
Thermostat not calling for heat
Burned out heat anticipator
Loose or broken connections
Off/On operating limit, or low water cut off
Off/On blocked vent switch or flame roll out
1.
2.
3.
4.
5.
Turn thermostat up to call for heat
Replace thermostat
Tighten, repair, or replace connection
Turn operating limit, or low water cutoff ON
Reset or replace switch
NO POWER
Between 4 & 2
POWER
Between 4 & 1
When calling for
heat
POWER
Between 4 & 1
Between 4 & 2
DAMPER OPEN
1. Loose or broken connection
2. Defective damper motor
1. Tighten, repair, or replace connection
2. Replace damper motor assembly
28
P/N 1305004, Rev. F [04/30/2017]
APPENDIX A - VENT DAMPER TROUBLESHOOTING
Note
For troubleshooting only. Verify damper is in
open position. Use service switch to keep
damper in open position. Place jumper between
2 & 3. If appliance fires, remove jumper and
plug receptacle back into damper controller
plug. If appliance does not fire, replace damper
motor assembly. Do not replace pipe assembly.
If damper motor assembly is not available,
place service switch in hold open position. This
should keep damper in open position and allow
customer to have automatic heat. Return or
replace the motor assembly at your convenience.
Motor assembly carries 18 month limited
commercial warranty from the original date of
purchase. (Refer to form #4294 on vent damper
manufacturers website). Pipe assembly is not
warranted.
Trouble Shooting with Jumper Wire In Place
Problem
NO POWER
Between 4 & 1
Between 4 & 2
Between 4 & 3
Damper OPEN
NO COMBUSTION
Damper Sticks
Possible Cause
Recommended Solution
1.
2.
3.
4.
5.
1. Verify gas is on
2. Verify operating limit, pressure control or low water cut off is
on
3. Reset or replace blocked vent switch or flame roll out switch
4. Tighten, repair, or replace connection
5. Replace defective component in appliance
Is gas turned on
Operating limit, pressure control, low water cut off not on.
Blocked vent switch or flame roll out switch tripped
Loose or broken connection
Defective component in appliance after vent damper
1. Damper blade obstruction
2. Damper pipe egg shaped, out of round/binding.
3. Crimped end of vent piece inserted in too far
1. Clear the obstruction
2. Restore to damper pipe to round, verify not binding.
3. Correct the condition
1. Defective damper motor assembly
1. Replace damper motor assembly
Damper Rotates
Continuously
29
P/N 1305004, Rev. F [04/30/2017]
REPAIR PARTS
30
P/N 1305004, Rev. F [04/30/2017]
REPAIR PARTS
31
P/N 1305004, Rev. F [04/30/2017]
REPAIR PARTS
32
P/N 1305004, Rev. F [04/30/2017]
REPAIR PARTS
33
P/N 1305004, Rev. F [04/30/2017]
REPAIR PARTS
14
11
240009340
½ NPT X 4" Nipple
PF-033.02
34
P/N 1305004, Rev. F [04/30/2017]
INSTALLATION AND CHECK-OUT CERTIFICATE
Boiler Model
Serial #
Date Installed___________
Measured BTU/HR input____________
Installation instructions have been followed
Checkout procedure and adjustments performed
Maintenance and Service issues reviewed with owner/ maintenance person
Installation booklet affixed on or adjacent to boiler
Installer (Company)
Address
Phone
Installer’s Name
Signature
PENNCO BOILERS
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
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