ECR PENNCO 16 Series Instruction manual

16 Series
GAS-FIRED
STEAM BOILERS
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
P/N 1305004, Rev. E [08/31/2016]
MODEL HSID
Electronic
Intermittent
Ignition
PENNCO BOILERS
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
MODELS
1603HSID
1604HSID
1605HSID
1606HSID
1607HSID
1608HSID
1609HSID

2
DIMENSIONS
Figure 1 - Dimensions
BOILER MODEL
NUMBER (1)
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
P/N 1305004, Rev. E [8/31/2016]

3
RATINGS AND CAPACITY
P/N 1305004, Rev. E [8/31/2016]
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.
Table 1 - Ratings and Capacities
BOILER MODEL
NUMBER
No. of
Sec.
†Natural Gas
Intermittent
Ignition w/Vent
Damper
Fuel Type Input
*MBTUH
Heating
Capacity
*MBTUH
AFUE(%) Net AHRI
Rating *Mbh
Net AHRI
Rating Sq. Ft.
(1) 1603HSID 3
Natural Gas 75 62 82.7 47 196
Propane 70 58 82.7 44 183
(1) 1604HSID 4
Natural Gas 112 91 82.0 68 283
Propane 105 85 80.4 64 267
(1) 1605HSID 5
Natural Gas 150 122 82.0 92 383
Propane 140 114 80.6 86 358
(1) 1606HSID 6
Natural Gas 187 153 82.0 115 479
Propane 175 143 80.9 107 446
(1) 1607HSID 7
Natural Gas 225 183 82.0 137 571
Propane 210 171 81.1 128 533
(1) 1608HSID 8
Natural Gas 262 214 82.0 161 671
Propane 245 200 81.3 150 625
(1) 1609HSID 9
Natural Gas 299 245 82.0 184 767
Propane 280 229 81.5 172 717
* 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 sufx 'P' for Propane Gas.

4
Dimensions................................................ 2
Ratings and Capacity .................................. 3
Safety Symbols .......................................... 5
Locating the Boiler...................................... 6
System Piping ............................................ 7
Installation - System Piping ........................10
Fresh Air for Combustion ............................11
Chimney and Vent Pipe Connection ..............12
Vent Damper Operation ..............................14
Gas Supply Piping......................................15
Electrical Wiring ........................................16
Operating Instructions................................17
Operating Your Boiler .................................18
Checking and Adjusting ..............................19
Start-up Cleaning ......................................21
General Maintenance .................................22
Service Hints ............................................23
Wiring Diagrams........................................24
Wiring Diagrams........................................25
Controls and Accessories ............................26
Appendix A-1 - Vent Damper Harness...........27
Appendix A-2 - Vent Damper Troubleshooting 28
Repair Parts..............................................31
TABLE OF CONTENTS
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
GAS FIRED STEAM BOILERS
Check our website frequently for updates: www.ecrinternational.com
Information and specications outlined in this manual in effect at the
time of printing of this manual. Manufacture reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
Introduction
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.
Prior to Installation
• Verify correct boiler for type of gas being used
natural or propane. See Rating Plate.
• Verify boiler size and dimensions. See Figure 1 page 2.
• Verify ratings and capacity data for natural gas. See
Table 1 page 3.
Installation Requirements
• 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.
P/N 1305004, Rev. E [8/31/2016]

5
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury.
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
CAUTION
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.
General
Boiler and venting installation shall be completed by
qualied agency.
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.
!
Become familiar with symbols identifying potential
hazards.
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.
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 re or to
asphyxiation from poisonous gases such as carbon
monoxide which is odorless and invisible.
!
WARNING
Fire, explosion, asphyxiation hazard. Keep boiler
area clear and free from combustible materials,
gasoline and other ammable vapors and liquids.
Modication, substitution or elimination of factory
equipped, supplied or specied components could
result in death or serious injury.
!
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.
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
tter.
P/N 1305004, Rev. E [8/31/2016]

6
LOCATING THE BOILER
Locating the Boiler
1. Select level location as centralized with piping system,
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
ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
!
3. Do not install boiler on carpeting. For installation
on non-combustible oors only. For installation on
combustible ooring, special base must be used. See
Repair Parts page 27.
4. Use metal shims under boiler base legs for nal leveling
if needed.
5. 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 inltration does not provide necessary
air.“Fresh Air for Combustion” on page 11.
6. Notify owner to keep air passages free of obstruction.
Ventilating and combustion air must enter boiler room
without restrictions.
7. Install boiler so automatic gas ignition system
components are protected from water (dripping,
spraying, rain, etc.) during appliance operation and
service.
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. Attach draft diverter,
and blocked vent switch. Mount vent damper. See
"Connecting Vent Damper and Vent Connector" page 12.
See Wiring Diagrams page 25.
Table 2 -
Minimum Clearance Dimensions
Top 6"
Rear 6"
Control Side 7"
Opposite Side 6"
Front Alcove
Flue/Vent
Connector
6"
P/N 1305004, Rev. E [8/31/2016]

7
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 safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum
distance from oor or allowable safe point of discharge.
• Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line.
• Have no intervening shutoff valve between safety 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 valve and discharge line.
• Install safety valve with spindle in vertical position.
• Do not install shutoff valve between boiler and safety valve.
• Support safety valve discharge piping.
• Be short and straight as possible.
• Terminate with plain end, not threaded.
• 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.
!
Check local codes
for maximum
distance from
oor or other
allowable safe
point of discharge
Safety Valve
Discharge
Piping
6" Above Floor
Figure 3 - Safety Valve
P/N 1305004, Rev. E [8/31/2016]

8
SYSTEM PIPING
Consider near boiler piping as part of the boiler for proper
water level control and to produce dry steam.
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.
• 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.”
13. For pumped return systems, follow the condensate
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.
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.
P/N 1305004, Rev. E [8/31/2016]

9
Figure 4 - Recommended Near Boiler Piping Using One Supply Tapping
SYSTEM PIPING
P/N 1305004, Rev. E [8/31/2016]

10
INSTALLATION - SYSTEM PIPING
Figure 6 - Chilled Water Piping
VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING
VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING
Figure 5 - Recommended Near Boiler Piping Using Two Supply Tappings
P/N 1305004, Rev. E [8/31/2016]

11
FRESH AIR FOR COMBUSTION
WARNING
Air openings to combustion area must not be
obstructed. Follow instructions below, to maintain
adequate 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
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 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.
• 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.
Room Volume is greater than 50 cubic feet multiplied
by Total Input [Mbh]
B. Known Air Inltration Rate. See Table 3 for
space with boiler only. Use equation for multiple
appliances. Do not use an air inltration rate air
changes per hour (ACH) greater than 0.60.
Room volume is greater than 21 cubic feet divided by
ACH (air changes per hour) x Total Input [Mbh]
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.
A. Two Permanent Opening Method. Provide opening
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom of
enclosure.
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.
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).
C. 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.
Table 3 - Minimum Room Volume, Indoor Air Only*
Input Mbh Standard
Method
Known Air Inltration Rate Method (Air Changes Per Hour)
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.
P/N 1305004, Rev. E [8/31/2016]

12
CHIMNEY AND VENT PIPE CONNECTION
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.
Connecting The Vent Damper And Vent Connector
Refer to Figure 1 for the size and location of the vent (ue
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 ue outlet
collar. Fasten damper securely to ue 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 ue 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 ue 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 replace ue.
9. End of vent pipe must be ush with inside face of
chimney ue. 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.
NOTICE
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 deciencies
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 replace dampers.
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 re or to
asphyxiation from poisonous gases such as carbon
monoxide which is odorless and invisible.
!
P/N 1305004, Rev. E [8/31/2016]

13
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 ame 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, replace 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.
Vent connectors serving appliances vented by natural draft shall
not be connected into any portion of mechanical draft systems
operating under positive pressure.
CHIMNEY AND VENT PIPE CONNECTION
3 FT (914mm)
MIN.
2 FT (610mm)
MIN.
Figure 7 - Typical Masonry Chimney Requirements
P/N 1305004, Rev. E [8/31/2016]

14
VENT DAMPER OPERATION
Figure 8 - Horizontal Installation
Check vent damper and all ue 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.
Inspect vent damper at least once a year by
trained service technician.
Manual Operation of Vent Damper
• Place vent damper in open position to permit burner
operation by using “HOLD DAMPER OPEN” switch,
located on damper controller.
• Thermostat controls burner ring as before, while
damper remains open.
• DO NOT turn damper open manually, motor damage
will result.
• Set switch to “AUTOMATIC OPERATION” to close vent
damper during burner off cycle.
• For further information, and for vent damper
troubleshooting guide, refer to manual packaged with
vent damper.
Horizontal Installation
To Boiler Vent Damper To
Chimney
NO
NO
YES YES
Flow
Install vent damper
with actuator to sides
of vent only. Do not
mount above or below
vent.
To
Chimney
Flow Vent Damper
To Boiler
Actuator may
be installer in
any position.
Figure 9 - Alternate Vent Damper Installation
Do Not
Install
Here
Caution: Do not
install Vent Damper
within 6" (152mm)
of combustible
material
Install Damper Here
Chimney
Boiler
Figure 10 - Vent Damper Position Indicator
Flue Gas
Flow
Flue Gas Flow
OPEN
CLOSED
ROTATION
CLOSED
OPEN
ROTATION
Damper Closed Damper Open
Showing Open and Closed Positions
Vent Damper Installation - Follow all cautions and
notes.
• Install vent damper to service only single appliance for
which it is intended.
• Do not install vent damper with 6" (15mm) of
combustible material.
• Do not install vent damper on vent pipe curve.
• Do not run wires near high temperature surfaces. Use
standoff brackets if necessary.
• Install vent damper with actuator to sides of vent only.
Do not mount above or below vent.
WARNING
Asphyxiation or burn hazard. Improper installation
and operation of vent damper could result in serious
injury or death due to re or to asphyxiation from
poisonous gases such as carbon monoxide which is
odorless and invisible.
!
P/N 1305004, Rev. E [8/31/2016]

15
GAS SUPPLY PIPING
P/N 1305004, Rev. E [8/31/2016]
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 re
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 sufcient
gas supply to meet maximum input at not less than
minimum supply pressure. See Tables 4a and 4b.
Table - 4a Gas Pipe Sizes - Natural Gas
Length
of Pipe
- Ft.
Pipe Capacity - BTU Per Hour Input
Includes Fittings
1/2" 3/4" 1" 1 -1/4"
20 92,000 190,000 350,000 625,000
40 63,000 130,000 245,000 445,000
60 50,000 105,000 195,000 365,000
Table - 4b Gas Pipe Sizes - Propane Gas
Length
of Pipe
- Ft.
Pipe Capacity - BTU Per Hour Input
Includes Fittings
5/8" 3/4" 1/2" 3/4"
20 131,000 216,000 189,000 393,000
40 90,000 145,000 129,000 267,000
60 72,000 121,000 103,000 217,000
* 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 liqueed petroleum gas.
• Install eld sourced manual main shutoff valve, ground
joint union, and sediment trap upstream of gas valve.
See Figure 11.
DANGER
Fire Hazard. Do not use matches, candles, open
ames, 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 uid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open ames, or other methods
providing ignition source.
• Correct leaks immediately and retest.
Figure 11 - Gas Piping At Boiler
3” Minimum
Sediment
Trap
Manifold
Floor Line
Automatic
Gas Valve
Ground
Joint
Union
Propane Installation
WARNING
Fire, explosion, asphyxiation hazard. Verify boiler
is equipped with propane gas orices and gas valve
is congured for propane. Failure to follow these
instructions may result in serious injury or death.
• Connections by licensed propane dealer only.
• Use two stage regulator provided by propane
supplier.
• Have propane supplier check piping.

16
ELECTRICAL WIRING
Figure 12a - Isolation Relay Wiring For Steam Boilers
With Float Type Low Water Cut Off And Use of
Electronic Thermostat
Figure 12b - Isolation Relay Wiring For Steam
Boilers With Probe Type Low Water Cut Off And Use
of Electronic Thermostat
WARNING
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.
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 oat 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
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 xtures,
televisions, replace, or chimney.
4. Check thermostat operation by raising and lowering
thermostat setting as required to start and stop
burners.
5. Instructions for nal adjustment of thermostat see
manufacturer's instructions.
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.
P/N 1305004, Rev. E [8/31/2016]

17
OPERATING INSTRUCTIONS
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
5. Remove lower front panel.
6. Rotate the gas control knob clockwise to“OFF”.
7. Wait ve (5) minutes to clear out any gas. Then smell
for gas, including near the oor. 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.
For Your Safety Read Before Operating
WARNING
If you do not follow these instructions
exactly, a re 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.
• Before operating smell all around appliance area
for gas. Be sure to smell next to oor because
some gas is heavier than air and will settle to the
oor.
• 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 qualied
service technician. Force or attempted repair may
result in re or explosion.
• Do not use this appliance if any part has
been under water. Immediately call a qualied
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 re
department.
!
P/N 1305004, Rev. E [8/31/2016]

18
OPERATING YOUR BOILER
Filling System With Water
Steam heating systems boiler is partially lled 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 ll valve. Allow water to run into boiler.
4. Allow boiler to ll until water runs out gauge drain
valve. Then close gauge drain valve.
5. Continue to ll boiler until water reaches indicated
water line about halfway up glass gauge.
Water Level
• Normal water level is 24" above the oor 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.
WARNING
Burn Hazard. Never run water into a hot empty
boiler. Failure to follow these instructions could
result in death or serious injury.
!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.
P/N 1305004, Rev. E [8/31/2016]

19
CHECKING AND ADJUSTING
Figure 14 - Igniter
Adjust Pilot Burner
Pilot ame should surround 3/8” to 1/2” of pilot sensor. See
Figure 15.
To adjust Flame.
1. Remove screw cover over pilot adjusting screw. See
Figure 13.
2. Insert small screwdriver and adjust ame as needed.
Turn screw counterclockwise to increase ame, clock-
wise to decrease.
3. Replace screw cover over pilot adjusting screw.
Main Burners
• Main burners do not require primary air adjustment and
are not equipped with primary air shutters.
• Main burner ames form sharp blue inner cones in
softer blue outer mantel, with no yellow. Remain still
when observing main burner ames.
• Check main burner orices, burner throat and ame
ports for dust and lint obstruction if ame appearance
is not correct.
• Remove rollout shield if necessary to observe main
burner ames.
• 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 ring, 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.
Figure 15 - Main Burner
P/N 1305004, Rev. E [8/31/2016]

20
CHECKING AND ADJUSTING
Adjust Steam Pressure Control
• 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 rere 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.
A. In typical single family residence with clean one-
pipe 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.
• Set differential adjustment at 1 psi, i.e. steam pressure
required in radiators. Results in cut-off setpoint of 1½
psi.
• 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.
• 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.
• 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.
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 :
• For Model 67D-1 oat type low water cutoffs - as
the water level raises the oat above the burner
cut off switch level, the burners should ignite. The
water feeder remains powered until the water
level raises the oat to the water feeder switch
level, satisfying the water feeder.
• 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.
I. In either case, one and two inches of water should
be visible in glass gauge when both water feeder is
satised, and burners are allowed to ignite.
• Time delays in feed cycles are designed to prevent
boiler from ooding due to slow return lines.
• 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.
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.
P/N 1305004, Rev. E [8/31/2016]