ECR International PENNCO FSB 3 Series Gebrauchsanweisung

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel.

800 325 5479

www.ecrinternational.com

PN 240013101 REV. A [08/15/2020]

FSB SERIES 3

Gas-Fired Hot Water

Induced Draft Boilers

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Models

FSB-2

FSB-3

FSB-4

FSB-5

FSB-6

Tested For 50 psi

ASME

Working Pressure



For Natural Gas Or Propane

1 - Physical Data �� 4

2 - Safety Symbols and Warnings �� 5

2.1. Safety Symbols & Warnings ......................................................................................5

2.2 For Your Safety ........................................................................................................6

3 - Locating the boiler �� 7

3.1 Installation Requirements ..........................................................................................7

3.2 Boiler Location Considerations....................................................................................8

4 - Connecting supply and return piping�� 9

4.1 Safety Relief Valve Installation ...................................................................................9

4.2 Supply and Return Requirements ..............................................................................10

5 - Ventilation & Combustion Air �� 12

6 - Vent system modification�� 13

7 - Vent Installation �� 14

7.1

Chimney Venting (Category I)

......................................................................................14

7.2 Minimum Vent Pipe Clearance ..................................................................................14

8 - Horizontal Venting (Category III) �� 16

9 -

Optional Horizontal Venting Instruction

�� 21

10 - Gas supply Piping�� 22

11 - Electrical Wiring�� 24

11.1 Electrical Wiring Requirements................................................................................24

11.2 Thermostat Installation..........................................................................................24

12 - Wiring Diagrams �� 25

13 - Sequence of Operation �� 26

14 - Starting Your Boiler�� 27

14.1 Filling System.......................................................................................................27

14.2 Operating Instructions...........................................................................................28

14.3 Turn Off Gas To Appliance ......................................................................................28

15 - Checking and Adjusting�� 29

15.1 Gas Valve Safety Shutdown Test .............................................................................29

15.2 Pilot Burner Adjustment.........................................................................................29

15.3 Main Burner(s) Inspection......................................................................................29

15.4 Adjusting Limit Controls.........................................................................................29

15.5 Thermostat Heat Anticipator Setting........................................................................30

16 - Maintaining Your Boiler�� 31

17 - Service Hints �� 32

18 - Boiler Ratings & Capacities �� 33

Appendix A - Control Module �� 34

A.1

Installation Environment Considerations

......................................................................34

A.2 Electrical Connections .............................................................................................34

A.3 Adjusting Settings ..................................................................................................34

A.4 Display .................................................................................................................34

A.5 Operation ..............................................................................................................35

A.6

Boiler High Limit Temperature Controller

......................................................................36

A.7 Troubleshooting......................................................................................................36

A.8 Troubleshooting Error Codes ....................................................................................37

A.9 Intermittent Pilot....................................................................................................38

TABEL OF CONTENTS

PN 240013101 Rev. A [08/15/2020]

VERIFY CONTENTS RECEIVED

Fully Assembled Boiler *Vent Adapter

*Fuse Link

Pump (Optional)

*Drain Valve *ASME Safety Relief Valve *Tridicator

*Black Iron Fittings

(see parts list for sizes

and use)

Includes Essential

Documents and Warranty

11x17 Wire Diagrams

Document Package

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE



time of printing of this manual� ECR International reserves the right to





* Items found in parts box included with your boiler.

PN 240013101 Rev. A [08/15/2020]



Check our website frequently for updates: www.ecrinternational.com

1 - PHYSICAL DATA

Model

FSB-2 FSB-3 FSB-4 FSB-5 FSB-6

# Sections 2 3 4 5 6

A Width 11"14-¹/"17-/""24"

279 mm 362 mm 445 mm 527 mm 610 mm

BHeight 29” 29” 29” 29” 29”

737 mm 737 mm 737 mm 737 mm 737 mm

CDepth     

591 mm 591 mm 591 mm 591 mm 591 mm

DVent Location 2-

/

"2-

/

”2-

/

”2-

/

”2-

/

”

59 mm 59 mm 59 mm 59 mm 59 mm

E Flue Diameter (Sidewall)

3” 3” 3” 3” 4”

76 mm 76 mm 76 mm 76 mm 102 mm

F Flue Diameter (Chimney)

    

102 mm 102 mm 102 mm 102 mm 102 mm

Supply & Return Tappings 1-

¹/

 1-

¹/

 1-

¹/

 1-

¹/

 1-

¹/



     

     

     

Heating Water Content, Gal (Liters) 1.75 (6.6) 3 (11.4) 4.25 (16.1) 5.5 (20.9) 6.75(25.6)

Boiler Weight, less pkg - Lbs (KG) 225 (102.1) 265 (120.2) 322 (146.1) 370 (167.8) 431 (195.5)

 

 





"

(313.1 mm)

"

(592.6 mm)



GAS SUPPLY



(184mm)



(83mm)

" (516 mm)

" (419 mm)

"

(117.8mm)

SUPPLY





ASME RELIEF

VALVE

PN 240013101 Rev. A [08/15/2020]

2 - SAFETY SYMBOLS AND WARNINGS

CAUTION

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate injury.

WARNING

Indicates a hazardous situation which, if not

avoided, could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not

avoided, WILL 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.

Become familiar with symbols identifying potential hazards.



WARNING

Do not tamper with or use this boiler for any

purpose other than its intended use. Failure to follow

these instructions could result in death or serious

injury. Use only manufacturer recommended parts

and accessories.

CAUTION

Laceration, burn hazard. Metal edges and parts

may have sharp edges and/or may be hot. Use

appropriate personal protection equipment to

include safety glasses and gloves when installing

or servicing this boiler. Failure to follow these

instructions could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal

injury.

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.

FOR YOUR SAFETY READ BEFORE OPERATING

Hot Water Can Scald!

Water heated to temperature for clothes washing,

dish washing and other sanitizing needs can scald and

cause permanent injury.



persons are more likely to be permanently injured by





tap or draw their own bath.



description, or if state laws or local codes require

certain water temperatures at hot water taps, you

must take special precautions:

• Use lowest possible temperature setting.

• Install some type of tempering device, such as

an automatic mixing valve, at hot water tap or

water heater. Automatic mixing valve must be

selected and installed according to manufacturer's

recommendations and instructions.

• Water passing out of drain valves may be

extremely hot. To avoid injury:

• Make sure all connections are tight.

• 

DANGER

Water

Temperature

Seng

1st Degree Burn

Exposure Time For

An Adult

2nd and 3rd Degree Burn

Exposure Time For An

Adult

120° F 1 minute 5 minutes

130° F 5 seconds 30 seconds

140° F 2 seconds 5 seconds

150° F 1 second 1.5 seconds

160° F Instantaneous 0.5 seconds

Note: Warning for Infants, Children, and Elderly:

Great care must be taken when exposing the

aforementioned groups to warm or hot water as they

can be badly burned in exposure times less than half

of the time for an adult.

2�1� Safety Symbols & Warnings

WARNING

Adding water to a hot boiler may result in heat



exchanger is not hot. Failure to follow these

instructions could result in death or serious injury.

PN 240013101 Rev. A [08/15/2020]

WARNING

Keep boiler area clear and free from combustible



liquids.







result in personal injury or loss of life.

Installation and service of this boiler shall be performed



When this product is installed in the Commonwealth

of Massachusetts the installation shall be performed

by a Licensed Plumber or Licensed Gas Fitter.

WARNING

Combustion chamber insulation in this product



can be converted to cristobalite in very high

temperature applications. The International Agency

for Research on Cancer (IARC) has concluded,

Crystalline silica inhaled in the form of quartz

or cristobalite from occupational sources is

carcinogenic to humans (Group1). Avoid breathing





respirator is based on the OSHA requirements

for cristobalite at the time this document was

written. Other types of respirators may be needed

depending on the job site conditions. Current



https://www.cdc.gov/niosh/topics/

silica/.

and phone numbers are also listed on this website.



and eye protection. Apply enough water to the

combustion chamber lining to prevent dust. Wash

potentially contaminated clothes separately from

other clothing. Rinse clothes washer thoroughly.



Breathing: Fresh air.

2 - SAFETY SYMBOLS AND WARNINGS

Manufacturer recommends a carbon monoxide detectorManufacturer recommends a carbon monoxide detector





jurisdictions may, by law, require.jurisdictions may, by law, require.

2�2 For Your Safety

WARNING

Fire, Explosion, Asphyxiation, Electrical shock

hazard! Flooding will result in damages such as

electrical problems, corrosion, inoperative parts,

mold and other unforeseen issues which can

occur over time. Any equipment determined by



as excess of water or other liquid, shall be

replaced. Failure to follow these directions will

result in a Hazardous Situation.

PN 240013101 Rev. A [08/15/2020]

3 - LOCATING THE BOILER

Installation must conform to requirements of authority

having jurisdiction or, in absence of such requirements,

to the National Fuel Gas Code

Where required by authority having jurisdiction,

installation must conform to the Standard for Controls









Equipment”, of the National Fuel Gas Code



building codes.

Boiler has met safe lighting and other performance

criteria with gas manifold and control assembly on



Install such that gas ignition system components are

protected from water (dripping, spraying, rain, etc.)

during appliance operation and service, (circulator

replacement, condensate trap, control replacement,

etc.).

Locate boiler on level, solid base as near chimney as

possible and centrally located with respect to heat

distribution system as practical.

Verify you have the right size boiler before starting

installation. See rating and capacity table.

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.

Boiler installed in building under construction, take

care to insure clean combustion air supply during

construction process. Airborne particulates such as



clog burner ports and cause incomplete combustion and

sooting.

10.

FOR INSTALLATION ON NON-COMBUSTIBLE

FLOORS ONLY - For installation on combustible



NOTICE

Follow local regulations with respect to installation

of CO detectors.

Table 1 - BOILER MINIMUM CLEARANCE TO

COMBUSTIBLES

Unit Minimum

Clearances

Top 6” (152 mm)

Rear 6” (152 mm)

Right 8” (203 mm)

Left 6” (152 mm)

Front (Alcove) 18” (457 mm)

Flue/Vent Connector 6” (152 mm)

 1” (24 mm)

Set unit on concrete or other noncombustible material base or

oor. DO NOT INSTALL ON CARPETING.

Figure 1 - Minimum Clearances To Combustible

Construction



front of boiler. ANSI standard for alcove is 18 inches from

front of appliance to leading edge of side walls as shown

above.

8”

Boiler

Rear

Front

Right

LEFT

18”

6” 8”

6”

CAUTION

Bolier weight exceeds 200 pounds (90.7 kg). Do not

lift boiler without assistance.

WARNING

Fire hazard. Do not install boiler on combustible



Addendum) included in literature envelope provide

with boiler. Failure to follow these instructions could

result in death or serious injury.

3�1 Installation Requirements

(Combustible Floor Addendum) included in literature

envelope provide with boiler and outlined in National

Fuel Gas CodeDo Not Install

Boiler on carpeting�

11.

Verify boiler is supplied with correct type of gas, fresh

air for combustion, and suitable electrical supply.

PN 240013101 Rev. A [08/15/2020]

3 - LOCATING THE BOILER

• Ambient room temperature always above 32°F (0°C) to

prevent the potential of freezing.

• Drainage of water (or water/ antifreeze solution) during

boiler service or from safety relief valve discharge.

• Access to system water piping, gas supply, and

electrical service.

• 

capable of supporting the weight of the boiler, water,

and equipment.

• 

wet.

• Water, gas, and electrical connect to right side of

boiler.

Table 2 - CONTAMINANTS

Items to Avoid Products Which May Contain These

Items Areas Where These Items May Be

Found

Chlorine, Fluorine, and Compounds



Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Swimming pool or spa chemicals

De-icing salts or chemicals

Carbon Tetrachloride

Swimming pools and pool storage areas





Airborne Particulates

Drywall dust

Road or gravel dust

Dryer lint

Cat litter





Acids, Solvents, etc.

Paint, Varnish, Turpentine, etc.

Cleaning Solvents

Hydrochloric acid/muriatic acid

Cements, adhesives and glues

Photo processing plants

Garages with workshops



establishments

Laundry Chemicals

Laundry detergents, bleaches, fabric

softeners, etc.

Antistatic fabric softeners (dryer sheets)

Dry cleaning/laundry areas and

establishments

Other

Permanent wave solutions

Refrigerants (Freon, etc) (only where

the refrigerant may be leaking from the

appliance)

Beauty shops

Refrigeration repair shops







passages possibly resulting in unsafe operation. In this case, unit servicing shall include





the room be generously ventilated (well in excess of combustible air requirements), and

homeowner seal laundry supply containers, and minimize room vapors.

. Piping allowing fresh air in should also be considered. See Section 5-1.

• Horizontal run to chimney shall be as short as possible.

• System piping exposed to freezing conditions: Use



manufacturer for use with closed water heating system.

Do not use automotive or ethylene glycol.

3�2 Boiler Location Considerations

PN 240013101 Rev. A [08/15/2020]

4 - CONNECTING SUPPLY AND RETURN PIPING

Check local codes

for maximum

distance from



allowable safe

point of discharge

ASME RELIEF VALVE

DISCHARGE

PIPING

Figure 2 - Safety Relief Valve Discharge Piping

Refer to local codes and appropriate ASME Boiler

and Pressure Vessel Code for additional installation

requirements. Install safety relief valve using pipe



Install safety relief valve with spindle in vertical

position.



relief valve.

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).

• Terminate pipe with plain end (not threaded).

WARNING

Burn and scald hazard! Safety relief valve shall be

installed with spindle in upright position only,

following ASME BPV code. Failure to follow these

instructions could result in death or serious injury.

4�1 Safety Relief Valve Installation

WARNING

Burn and scald hazard. Safety relief valve could

discharge steam or hot water during operation.

Install discharge piping per these instructions. Failure

to follow these instructions could result in death or

serious injury.

PN 240013101 Rev. A [08/15/2020]

LIMIT SENSOR

MINIMUM HEIGHT FOR

LOW WATER CUTOFF

PROBE

Figure 3 -

Forced Hot Water Typical Piping

LIMIT SENSOR

MINIMUM HEIGHT

FOR LOW WATER

CUTOFF PROBE

Figure 4 - Forced Hot Water Typical Piping

With Zone Control Valve

4 - CONNECTING SUPPLY AND RETURN PIPING

PN 240013101 Rev. A [08/15/2020]

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