ECR International Pennco FSB II Series Gebrauchsanweisung

FSB Series II

Gas-Fired Hot Water

Induced Draft Boilers

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

P/N 240009022 Rev. B [04/2012]

An ISO 9001-2008 Certified Company

Tested for 50 psi.

ASME Working

Pressure

C.S.A. Certiﬁed for

Natural gas or

Propane

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13504-4729

web site: www.ecrinternational.com

Models

FSB-2

FSB-3

FSB-4

FSB-5

FSB-6

FSB-7

TABLE OF CONTENTS

Safety Symbols & Warnings

The following deﬁned symbols are used throughout this

manual to notify the reader of potential hazards of varying

risk levels.

NOTICE

Used to address practices not related to personal

injury.

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

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

WARNING

Keep boiler area clear and free from combustible

materials, gasoline and other ﬂammable vapors

and liquids.

DO NOT obstruct air openings to the boiler room.

Modiﬁcation, substitution or elimination of factory

equipped, supplied or speciﬁed components may

result in personal injury or loss of life.

TO THE OWNER - Installation and service of this

boiler must be performed by a qualiﬁed 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

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.

Boiler Ratings & Capacities...................... 3

Dimensions ............................................. 4

Installation Procedure............................. 5

Ventilation & Combustion Air .................. 6

Installation System Piping ...................... 7

Vent Installation ................................... 10

Horizontal Venting Instructions .......... 13

Optional Horizontal Venting Instruction 18

Gas supply Piping .................................. 19

Electrical Wiring .................................... 21

Sequence of Operation .......................... 22

Wiring Diagrams ................................... 23

Starting Your Boiler............................... 24

Checking and Adjusting......................... 26

Maintaining Your Boiler ......................... 28

Service Hints ......................................... 29

Equipment & Optional Accessories ........ 30

Appendix A - Control Module ................. 32

A.1 Installation Environment Considerations.32

A.2 Electrical Connections.......................... 32

A.3 Adjusting Settings............................... 32

A.4 Display .............................................. 32

A.5 Operation .......................................... 33

A.6 Boiler High Limit Temperature Controller 34

A.7 Troubleshooting .................................. 34

A.8 Troubleshooting Error Codes................. 34

A.9 Intermittent Pilot ................................ 35

New York City MEA Number 484-84-E Vol. IV.

BOILER RATINGS & CAPACITIES

Table 1 - RATINGS NATURAL AND PROPANE GASES

Model

Input

*Mbh

Heating

Capacity

*Mbh

**Net

AHRI Rating

Water

*Mbh

AFUE

Vent Diameter (Inches)

To Chimney

(Category I)

Horizontal Vent

(Category III)

FSB-2 42.5 36 31 84.4 4 3

FSB-3 75.0 63 55 83.4 4 3

FSB-4 112.5 94 82 83.0 4 3

FSB-5 150.0 125 109 82.7 4 3

FSB-6 187.5 155 135 82.3 4 4

FSB-7 225.0 186 162 82.0 4 4

* MBH = 1,000 Btuh = British Thermal Unit Per Hour. Boilers are equipped for altitudes up to 2,000 feet only. U.S.A.

Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each 1,000 feet above

sea level. Canada Only - Boilers may be used at high altitude (2,000-4500 feet/640-1350m) by using a certiﬁed

ﬁeld conversion kit, resulting in a 10% de-rate. Contact Provincial authority having jurisdiction for installations

above 4500 ft (1350m)above sea level.+ Heating Capacity based on D.O.E. (Department of Energy) test

procedure.

**Net AHRI Water Ratings i

ndicate amount of remaining heat input that can be used to heat the radiation

or terminal units. Net AHRI Ratings shown are based on an allowance of 1.15 Selection of

boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated

heat loss of building.

Manufacturer should be consulted before selecting a boiler for installations having unusual piping

and pickup requirements.

This boiler cannot be used with all types of chimneys. Read these instructions carefully before installing.

These Gas-Fired Hot Water Boilers are low pressure, sectional cast iron boilers Design Certiﬁed by C.S.A. (Canadian

Standards Association) for use with Natural and Propane Gases. Constructed and hydrostatically tested for maximum

working pressure of 50 psi in accordance with A.S.M.E. Boiler and Pressure Vessel Code Section IV Standards for cast iron

heating boilers.

Boilers must stand on noncombustible ﬂoor. If installed on combustible ﬂoor, please refer to Repair Parts manual for

appropriate Combustible Floor Base part number.

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 oriﬁce size. U.S.A. 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

(NFPA54/ANSI Z223.1), or manufacturer for correct oriﬁce sizing information. High altitude oriﬁces are available from

boiler manufacturer.

DIMENSIONS

Model Width (A)

FSB-2

FSB-3

14-1/4

FSB-4

17-1/2

FSB-5

20-3/4

FSB-6

FSB-7

27-1/4

INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration, service

or maintenance could result in death or serious

injury.

Installation must conform to requirements of authority

having jurisdiction or, in absence of such requirements,

to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

Where required by authority having jurisdiction,

installation must conform to the Standard for Controls

and Safety Devices for Automatically ﬁred Boilers,

ANSI/ASME CSD-1.

Boiler series is classiﬁed as 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 local

building codes.

Boiler has met safe lighting and other performance

criteria with gas manifold and control assembly on

boiler per latest revision of ANSI Z21.13/CGA 4.9.

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

from drywall dust and from ﬁberglass insulation can

clog burner ports and cause incomplete combustion and

sooting.

WARNING

Fire hazard. Do not install boiler on combustible

ﬂooring or carpeting. Failure to follow these

instructions could result in death or serious injury.

10.

FOR INSTALLATION ON NON-COMBUSTIBLE

FLOORS ONLY - For installation on combustible

ﬂooring special base must be used. (See Replacement

Parts Section.) Do Not Install Boiler on carpeting.

11.

Verify boiler is supplied with correct type of gas, fresh

air for combustion, and suitable electrical supply.

NOTICE

Follow local regulations with respect to installation

of CO detectors.

Table 1 - BOILER MINIMUM CLEARANCE TO

COMBUSTIBLES

Unit Minimum

Clearances

Top 6” (152mm)

Rear 6” (152mm)

Control Side 8” (203mm)

Opposite Side 6” (152mm)

Front (Alcove) 18” (457mm)

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 1” (24mm)

Set unit on concrete or other noncombustible material

base or ﬂoor. DO NOT INSTALL ON CARPETING.

Figure 1 - Minimum Clearances To Combustible

Construction

8”

Boiler

Rear

Front

Control Side

Opposite Side

18”

6”

6” 8”

VENTILATION & COMBUSTION AIR

Provide combustion air and ventilation air in accordance

with the section “Air for Combustion and Ventilation,” of the

National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections

8.2, 8.3 or 8.4 of Natural Gas and Propane Installation

Code, CAN/CSA B149.1, or applicable provisions of local

building codes.

Provide make-up air where exhaust fans, clothes dryers,

and kitchen ventilation equipment interfere with proper

operation.

National Fuel Gas Code recognizes several methods

of obtaining adequate ventilation and combustion air.

Requirements of the authority having jurisdiction may

override these methods.

• Engineered Installations. Must be approved by

authority having jurisdictions.

• Mechanical Air Supply. Provide minimum of 0.35

cfm per Mbh for all appliances located within space.

Additional requirements where exhaust fans installed.

Interlock each appliance to mechanical air supply

system to prevent main burner operation when

mechanical air supply system not operating.

• All Indoor Air. Calculate minimum volume for all

appliances in space. Use a different method if

minimum volume not available.

оStandard Method. Cannot be used if known air

inﬁltration rate is less than 0.40 air changes per

hour. See Table 3 for space with boiler only. Use

equation for multiple appliances.

Volume ≥50 ft3x Total Input [Mbh]

оKnown Air Inﬁltration Rate. See Table 3 for

space with boiler only. Use equation for multiple

appliances. Do not use an air inﬁltration rate

(ACH) greater than 0.60.

Volume ≥15 ft3/ACH x Total Input [Mbh]

оRefer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

• All Outdoor Air. Provide permanent opening(s)

communicating directly or by ducts with outdoors.

оTwo Permanent Opening Method. Provide opening

commencing within 12 inches of top and second

opening commencing within 12 inches of bottom

enclosure.

Direct communication with outdoors or

communicating through vertical ducts. Provide

minimum free area of 1 in2per 4 Mbh of total

input rating of all appliances in enclosure.

Communicating through horizontal ducts.

Provide minimum free area of 1 in2per 2

Mbh of total input rating of all appliances in

enclosure.

оOne Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure.

Provide minimum clearance of 1 inch on sides

and back and 6 inches on front of boiler (does not

supersede clearance to combustible materials).

оCombination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for additional requirements

for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for application information.

National Gas and Propane Installation Code Requires

providing air supply in accordance with:

• Section 8.2 and 8.3 when combination of appliances

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

kW).

оDoes not have draft control device.

• Section 8.4 when combination of appliances has total

input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code

for speciﬁc air supply requirements for enclosure

or structure where boiler is installed, including air

supply openings and ducts.

Table 2 - Air Inﬁltration

Input Mbh Standard

Method

Known Air Inﬁltration Rate Method (Air Changes Per Hour)

0.1 0.2 0.3 0.4 0.5 0.6

42.5 2125 6375 3188 2125 1594 1275 1063

75 3750 11250 5625 3750 2813 2250 1875

112.5 5625 16875 8438 5625 4219 3375 2813

150 7500 22500 11250 7500 5625 4500 3750

187.5 9375 28125 14063 9375 7031 5625 4688

225 11250 33750 16875 11250 8438 6750 5625

Refer to local codes and appropriate ASME Boiler

and Pressure Vessel Code for additional installation

requirements.

Install relief valve on 3/4” pipe nipple in tapped boiler

opening.

A. Pipe discharge line following guidelines in preceding

Warning. See Figure 2, Page 7.

B. Discharge line pipe size shall be equal or greater

than that of relief valve outlet over entire length

of discharge line with no intervening shutoff valve

between safety relief valve and discharge to

atmosphere.

C. Discharge line shall terminate with plain end to

atmosphere where any discharge will be clearly

visible and is at no risk of freezing.

D. Discharge line shall be independently supported to

avoid applied stress on relief valve.

E. Installation shall allow complete drainage of relief

valve and discharge line.

Install Drain Valve on lower left side of boiler as

marked.

Install Temperature and Pressure Gauge into ¼”

bushing threaded in tee furnished with supply piping.

See

Figure 3 & 4.

Connect Supply and Return Lines to boiler. See Figures

3 and 4. Connections may require certain additional

ﬁttings and parts.

INSTALLATION SYSTEM PIPING

WARNING

Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns,

scalding, or water damage due to discharge of steam and/or hot water during operation.

Discharge line shall:

• connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum

distance from ﬂoor or allowable safe point of discharge.

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

line;

• have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug or

place any obstruction in discharge line.

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

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

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

• be as short and straight as possible;

• terminate with plain end (not threaded);

• be constructed of material suitable for exposure to temperatures of 375° F; or greater.

Refer to local codes and appropriate ANSI/ASME Boiler and Pressure Vessel Code, Section IV, or Boiler,

Pressure Vessel and Pressure Piping Code, CSA B51 for additional installation requirements.

Check local codes

for maximum

distance from

ﬂoor or other

allowable safe

point of discharge

RELIEF VALVE

DISCHARGE

PIPING

Figure 2 - Safety Relief Valve Discharge Piping

INSTALLATION SYSTEM PIPING

Figure 3 -

Forced Hot Water Typical Piping

Figure 4 - Forced Hot Water Typical Piping

With Zone Control Valve

• Install radiation units (panels, radiators or cabinets) and

supply and return mains ﬁrst then make connections at

boiler.

• Verify clean water supply is available when connecting

cold water supply to water valve. Install sand strainer at

pump when water supply is from well or pump.

• Provide low water cutoff device when boiler is installed

above radiation level or as required by the Authority

having jurisdiction, either provide as part of boiler

or at time of boiler installation. Periodic inspection

is necessary, as is ﬂushing of ﬂoat type devices, per

manufacturers speciﬁc instructions.

• Boiler used in connection with refrigeration systems

shall be installed so chilled medium is piped in parallel

with heating boiler with appropriate valves to prevent

chilled medium from entering heating boiler. See

Figure

• Boiler connected to heating coils located in air handling

units exposed to refrigerated air circulation, piping

system shall be equipped with ﬂow control valves or

other automatic means to prevent gravity circulation of

boiler water during cooling cycle.

INSTALLATION SYSTEM PIPING

Figure 5

- Piping Arrangements For Boiler When

Used In Connection With Refrigeration

System

Low Design Water Temperature Systems (Below

140°F) And Large Water Content Systems

Condensation is corrosive and can eventually 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.

• Boiler used in heating systems where design water

temperatures below 140°F are desired (e.g. radiant ﬂoor

heating), a 3-way or 4-way mixing valve or suitable

alternative is required to prevent low temperature return

water from entering boiler. When using mixing valve,

follow manufacturer’s installation instructions.

• Boiler connected to system having large water content

(such as former gravity system), suggest use of bypass

piping. See

Figure

Figure 6

- Bypass Piping

Check Your Chimney

Chimney must be clean, right size, 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.

Boiler’s induced draft blower has 3” outlet. 3” X

4” increaser ﬁtting is included in parts bag. Locate

increaser ﬁtting on outlet of induced draft blower, and

secure gas-tight with bead of furnished silicone sealant.

Increaser ﬁtting is required on this boiler for Category I

venting, and 4” is minimum permissible vent diameter.

This does not imply vent connector is intended to be 4”

diameter pipe. Vent connector shall be sized according

to appropriate venting tables in the National Fuel

Gas Code and may be required to be larger than 4”

diameter.

NOTICE

Boiler installation for chimney venting is not

complete unless increaser ﬁtting is located and

secured.

These are high efﬁciency boilers with low stack or

exhaust temperature.

Venting into masonry chimney without liner, line

chimney from top to bottom with either:

A. Listed Type B vent pipe

B. Listed ﬂexible vent liner

C. Poured ceramic liner.

Outside chimneys should not be used unless they are

(choose one of the following):

A. Enclosed in a chase

B. Lined with Type B vent pipe

C. Use listed ﬂexible vent liner

D. Use certiﬁed chimney lining system

Vent connector from boiler to chimney should run as

directly as possible with as few elbows as possible.

Where possible, it is recommended to common vent

water heater and boiler. Consult appropriate Vent

Sizing Tables in National Fuel Gas Code for speciﬁc

requirements of multiple appliance venting.

Boiler is only appliance connected to vent, Type B vent

pipe is recommended for vent connector.

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

per foot (21mm/m).

10.

End of vent pipe must be ﬂush with inside face of

chimney ﬂue. Use sealed-in thimble for chimney

connection.

11.

Fasten sections of vent pipe with sheet metal screws to

make piping rigid. Use stovepipe wires to support pipe

from above.

12.

Do not connect to ﬁreplace ﬂue.

13.

Do not install damper on this boiler.

Minimum Vent Pipe Clearance

• Use Type B vent pipe through crawl space. Where vent

pipe passes through combustible wall or partition, use

ventilated metal thimble. Thimble should be 4 inches

larger in diameter than vent pipe.

• Boiler installed with single wall vent, must have 6”

clearance between its surface and any combustible

material. New Type B gas vent or ﬂexible liner must be

installed in accordance with instructions furnished with

vent. Maintain clearances as speciﬁed for vent pipe.

• Verify vent pipe is ﬁre-stopped where it goes through

ﬂoor or ceiling. It should have approved vent cap with

clearances from roof. If clearances are less than shown,

have vent checked by local authorities. Figure 7, Page 11.

• Vent connectors serving appliances vented by natural

draft shall not be connected into any portion of

mechanical draft systems operating under positive

pressure.

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