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ECR International PENNCO FSB 3 Series Installation, Operation & Maintenance Manual

Gas-fired hot water induced draft boilers
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Models
FSB-2
FSB-3
FSB-4
FSB-5
FSB-6
FSB SERIES 3
Gas-Fired Hot Water
Induced Draft Boilers
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
C.S.A. Certified
For Natural Gas Or Propane
Tested For 50 psi
ASME
Working Pressure
2201 Dwyer Avenue, Utica, NY 13501
www.ecrinternational.com
PN 240013101 REV. A [08/15/2020]
Manufactured by:
ECR International Inc.
Tel. 800 325 5479

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Summary of Contents for ECR International PENNCO FSB 3 Series

  • Page 1 FSB-2 FSB-3 FSB-4 FSB-5 FSB-6 Tested For 50 psi C.S.A. Certified ASME For Natural Gas Or Propane Working Pressure 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]...

  • Page 2: Table Of Contents

    TABEL OF CONTENTS 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 ��������������������������������������������������������������������������...
  • Page 3 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� ECR International reserves the right to discontinue, change, specifications or system design at any time without notice and without incurring any obligation, whatsoever.

  • Page 4: Physical Data

    1 - PHYSICAL DATA Model FSB-2 FSB-3 FSB-4 FSB-5 FSB-6 # Sections 11" 14-¹/4" 17-1/2" 20-3/4" 24" A Width 279 mm 362 mm 445 mm 527 mm 610 mm 29” 29” 29” 29” 29” B Height 737 mm 737 mm 737 mm 737 mm 737 mm...

  • Page 5: Safety Symbols And Warnings

    2 - SAFETY SYMBOLS AND WARNINGS FOR YOUR SAFETY READ BEFORE OPERATING 2�1� Safety Symbols & Warnings Boiler installation shall be completed by qualified agency. DANGER WARNING Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury.

  • Page 6: For Your Safety

    2 - SAFETY SYMBOLS AND WARNINGS WARNING WARNING Combustion chamber insulation in this product Fire, Explosion, Asphyxiation, Electrical shock contains ceramic fiber material. Ceramic fibers hazard! Flooding will result in damages such as can be converted to cristobalite in very high electrical problems, corrosion, inoperative parts, temperature applications.

  • Page 7: Locating The Boiler

    3 - LOCATING THE BOILER WARNING NOTICE Follow local regulations with respect to installation Fire hazard. Do not install boiler on combustible of CO detectors. flooring or carpeting. Refer to (Combustible Floor Addendum) included in literature envelope provide (Combustible Floor Addendum) included in literature with boiler.

  • Page 8: Boiler Location Considerations

    3 - LOCATING THE BOILER 3�2 Boiler Location Considerations • Horizontal run to chimney shall be as short as possible. • Ambient room temperature always above 32°F (0°C) to • System piping exposed to freezing conditions: Use prevent the potential of freezing. inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system.

  • Page 9: Connecting Supply And Return Piping

    4 - CONNECTING SUPPLY AND RETURN PIPING WARNING Figure 2 - Safety Relief Valve Discharge Piping Burn and scald hazard! Safety relief valve shall be installed with spindle in upright position only, following ASME BPV code. Failure to follow these ASME RELIEF VALVE instructions could result in death or serious injury.

  • Page 10: Supply And Return Requirements

    4 - CONNECTING SUPPLY AND RETURN PIPING Figure 3 - Forced Hot Water Typical Piping Figure 4 - Forced Hot Water Typical Piping With Zone Control Valve MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE LIMIT SENSOR MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE LIMIT SENSOR PN 240013101 Rev.
  • Page 11 4 - CONNECTING SUPPLY AND RETURN PIPING 4�2 Supply and Return Requirements WARNING Asphyxiation hazard! Gradual flueway blockage • Install radiation units (panels, radiators or cabinets) and resulting from condensate induced corrosion may supply and return mains first then make connections at block boiler passages, resulting in carbon monoxide boiler.

  • Page 12: Ventilation & Combustion Air

    5 - VENTILATION & COMBUSTION AIR 5�1 Requirements appliances. Do not use an air infiltration rate (ACH) greater than 0.60. WARNING Volume ≥ 21 ft /ACH x Total Input (Btu/hr)/1000 Asphyxiation Hazard! Provide enough air openings C. Refer to National Fuel Gas Code for opening to boiler/combustion area to dilute flue gases requirements between connected indoor spaces.

  • Page 13: Vent System Modification

    6 - VENT SYSTEM MODIFICATION 6�1 Removal of Existing Boiler From Venting After it has been determined that each appliance remaining connected to the common venting system System properly vents when tested as outlined above, return When an existing boiler is removed from a common doors, windows, exhaust fans, fireplace dampers and any venting system, the common venting system is likely to be other gas-burning appliance to their previous conditions...

  • Page 14: Vent Installation

    7 - VENT INSTALLATION Outside chimneys should not be used unless they are WARNING (choose one of the following): Boiler and venting installations shall be performed A. Enclosed in a chase by a qualified expert and in accordance with the B.
  • Page 15 7 - VENT INSTALLATION Figure 7 - Type B Gas Vent Vent pipe must be: At lease 2 ft. (610mm) higher than any part of the roof, but not Liner less than 3 ft. Chimney (915mm) tall, and within a 10 ft. within a 10 ft.

  • Page 16: Horizontal Venting (Category Iii)

    8 - HORIZONTAL VENTING INSTRUCTIONS INDUCED DRAFT HIGH EFFICIENCY BOILERS 8�1 Horizontal Venting (Category III) CHOICE OF VENT PIPE MATERIAL • U. L. Listed Z-Flex Z-Vent Stainless Steel Vent Pipe. Horizontal Requirements (Category III) venting systems must be installed in accordance with •...
  • Page 17 8 - HORIZONTAL VENTING INSTRUCTIONS Boilers may be vented horizontally as shown in Vent Termination Fitting: For all vent pipe materials, Figure 8� Vent pipe is pitched down from boiler to you may use either: vent termination. Do not connect other appliances to A.
  • Page 18 8 - HORIZONTAL VENTING INSTRUCTIONS Figure 9 - Horizontal Venting Clearances о United States - Terminate vent system at least D. Vent Termination 4 feet (1.22 m) horizontally from, and in no case above or below, unless a 4 feet (1.22m) о...
  • Page 19 8 - HORIZONTAL VENTING INSTRUCTIONS Joining and Sealing the Vent Pipe: B. For Heat-Fab Saf-T-Vent stainless steel vent pipe The vent pipe needs to be both watertight and gas use a high temperature silicone sealant rated for tight. Seal all joints and seams as follows: 550°F The outside of the male end and inside A.
  • Page 20 8 - HORIZONTAL VENTING INSTRUCTIONS D. For ProTech Systems FasNSeal stainless steel C. For Flex-L StaR-34 stainless steel vent pipe use vent pipe no cleaning fluid is required. For 3” a high temperature silicone sealant rated for vent pipe runs on 2, 3, 4 and 5 section boilers, 550°F.

  • Page 21: Optional Horizontal Venting Instruction

    8 - HORIZONTAL VENTING INSTRUCTIONS Support Spacing: If horizontal vent must go through a crawl space or other unheated space, cool temperatures will cause Do not restrict thermal expansion movement of the flue gases to continuously condense inside the vent vent.

  • Page 22: Gas Supply Piping

    10 - GAS SUPPLY PIPING 10�1 Connecting Gas Piping DANGER Fire Hazard. Do not use matches, candles, open Gas line enters boiler from right side. Flexible gas flames, or other methods providing ignition source. connectors must never breach any boiler openings. Failure to comply will result in death or serious •...
  • Page 23 10 - GAS SUPPLY PIPING Table 5 - NATURAL GAS Pipe Capacity - BTU Per Hour Input Length of Includes Fittings Pipe - Ft� ½" ¾" 1" 1¼" 92,000 190,000 350,000 625,000 63,000 130,000 245,000 445,000 50,000 105,000 195,000 365,000 Table 6 - PROPANE GAS Pipe Capacity - BTU Per Hour Input Length...

  • Page 24: Electrical Wiring

    11 - ELECTRICAL WIRING manufacturer instructions. WARNING Connect 115 volt power supply to terminals L1 (HOT) and Electrical shock hazard. Turn OFF electrical power L2 inside J box on right side panel. supply at service panel before making electrical Run 14 gauge or heavier copper wire from boiler to connections.

  • Page 25: Wiring Diagrams

    12 - WIRING DIAGRAMS Figure 12 - Control Module Damper is not an option. PN 240013101 Rev. A [08/15/2020]...

  • Page 26: Sequence Of Operation

    13 - SEQUENCE OF OPERATION 13�1 Sequence of Operation Thermostat calls for heat, control relay contacts. Circulator pump is powered through terminals C1 and C2. Control holds off burner and attempts to satisfy thermostat with residual boiler heat. Induced draft blower is powered. When blower gets up to speed and blower suction pressure reaches pressure switch set point, pressure switch contacts close sending 24 volts to pilot control...

  • Page 27: Starting Your Boiler

    14 - STARTING YOUR BOILER 14�1 Filling System • Close air vents on all radiation units. Open valves to these units. • Verify boiler and expansion tank drain valves are closed. Air bleed screw on tank drain fitting should be closed. •...

  • Page 28: Operating Instructions

    14 - STARTING YOUR BOILER LIGHTING PROCEDURE FOR BOILER WITH 14�2 Operating Instructions INTERMITTENT PILOT SYSTEM STOP! Read Safety Information on previous page. Set the thermostat to lowest setting. For Your Safety, Read Before Operating!! Turn off all electric power to the appliance. This appliance is equipped with an ignition device which WARNING automatically lights the burner.

  • Page 29: Checking And Adjusting

    15 - CHECKING AND ADJUSTING 15.1 Gas Valve Safety Shutdown Test Figure 14 - Automatic Gas Valve WARNING Electrical shock hazard. Follow instructions to turn off electric power. Failure to do so could result in death or serious injury. Ignition system safety shutoff device must be tested after placing boiler in operation.

  • Page 30: Thermostat Heat Anticipator Setting

    15 - CHECKING AND ADJUSTING 15�5 Thermostat Heat Anticipator Setting Set Heat anticipator at .2. Check thermostat operation. When set above temperature indicated on thermometer, boiler burners should ignite. Verify thermostat turns off boiler when room temperature reaches selected setting and starts boiler operating when room temperature falls few degrees.

  • Page 31: Maintaining Your Boiler

    16 - MAINTAINING YOUR BOILER 16�1 General Maintenance Cleaning Your Boiler And Burners Burners Flue passages between sections should be examined yearly Beginning of heating season visually check pilot and main and cleaned if necessary. burner flames. See Figures 15 & 16. To clean: •...

  • Page 32: Service Hints

    17 - 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.

  • Page 33: Boiler Ratings & Capacities

    18 - BOILER RATINGS & CAPACITIES Table 8 - RATINGS NATURAL AND PROPANE GASES Vent Diameter (Inches) Heating Model AFUE Input Capacity To Chimney Horizontal Vent AHRI Rating Water Btu/hr Btu/hr (Category I) (Category III) Btu/hr FSB-2 42,500 36,000 31,000 84.4 FSB-3 75,000...

  • Page 34: Appendix A - Control Module

    APPENDIX A - CONTROL MODULE A�1 Installation Environment Considerations A�3 Adjusting Settings To discourage unauthorized changing of settings, procedure WARNING to enter adjustment mode is required. If you do not follow these instructions To enter adjustment mode, press UP, DOWN, and I buttons exactly, a fire or explosion may result (see Figure 12) simultaneously for three seconds.

  • Page 35: Operation

    APPENDIX A - CONTROL MODULE A�5 Operation Control determines burner operation is required, module proceeds to start burner (see state codes list) Module continuously monitors boiler water temperature and and heats water in boiler until setpoint temperature is fires or shuts off burner based on this temperature data. achieved or thermostat is satisfied.

  • Page 36: Boiler High Limit Temperature Controller

    APPENDIX A - CONTROL MODULE A�6 Boiler High Limit Temperature Controller A�7 Troubleshooting • When water temperature reaches setpoint, controller • Following service procedures are provided as general ends heating cycle. guide. • When water temperature drops below setpoint minus •...

  • Page 37: Troubleshooting Error Codes

    APPENDIX A - CONTROL MODULE Table 10 - Operation Error Codes Error display clearing (once error condition has disappeared) Error Error Clears itself Up/down Code Description Cycle when Push any key when Power Explanation Things to look for root status is problem displayed resolved...

  • Page 38: Intermittent Pilot

    APPENDIX A - CONTROL MODULE A�9 Intermittent Pilot STEP 3: Check spark ignition circuit. WARNING Ignition System Checks Electrical shock hazard. Ignition circuit generates STEP 1: Check ignition cable. over 10,000 volts. Turn OFF electrical power supply at service panel before making electrical •...
  • Page 39 APPENDIX A - CONTROL MODULE • Recheck ignition sequence as follows. Figure 19 - Pilot Flame — Reconnect main valve wire. — Adjust thermostat above room temperature. — Verify ignition sequence at burner. — If spark does not stop after pilot lights, replace module.
  • Page 40 • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. 2201 Dwyer Avenue, Utica, NY 13501 All specifications subject to change without notice. Tel. 800 325 5479 ©2020 ECR International, Inc. www.ecrinternational.com BDR THERMEA GROUP...

This manual is also suitable for:

Pennco fsb-2Pennco fsb-3Pennco fsb-4Pennco fsb-5Pennco fsb-6

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