ECR International PENNCO FSB 3 Series Instruction manual

Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. [phone]
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

2
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]

3
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

4
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]

5
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]

6
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]

7
3 - LOCATING THE BOILER
1. Installation must conform to requirements of authority
having jurisdiction or, in absence of such requirements,
to the National Fuel Gas Code
2. Where required by authority having jurisdiction,
installation must conform to the Standard for Controls


3. 

Equipment”, of the National Fuel Gas Code

building codes.
4. Boiler has met safe lighting and other performance
criteria with gas manifold and control assembly on

5. 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.).
6. Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.
7. Verify you have the right size boiler before starting
installation. See rating and capacity table.
8. When installed in utility room, door should be wide
enough to allow largest boiler part to enter, or to
permit replacement of another appliance such as water
heater.
9. 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]

8
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]

9
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
1. Refer to local codes and appropriate ASME Boiler
and Pressure Vessel Code for additional installation
requirements. Install safety relief valve using pipe

2. Install safety relief valve with spindle in vertical
position.
3. 
relief valve.
4. Install discharge piping from safety relief valve. See
Figure 2.
• Use ¾” or larger pipe.
• Use pipe suitable for temperatures of 375°F (191°C)
or greater.
• Individual boiler discharge piping shall be independent
of other discharge piping.
• Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping.
• Install union, if used, close to safety relief valve outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• 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]

10
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]