Table of Contents
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16 Series
GAS-FIRED
STEAM BOILERS
MODELS
INSTALLATION, OPERATION &
1603HSID
MAINTENANCE MANUAL
1604HSID
1605HSID
1606HSID
1607HSID
1608HSID
1609HSID
MODEL HSID
Electronic
Intermittent
Ignition
PENNCO BOILERS
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N 1305004, Rev. D [08/03/2015]
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Summary of Contents for PENNCO 1603HSID
- Page 1 16 Series GAS-FIRED STEAM BOILERS MODELS INSTALLATION, OPERATION & 1603HSID MAINTENANCE MANUAL 1604HSID 1605HSID 1606HSID 1607HSID 1608HSID 1609HSID MODEL HSID Electronic Intermittent Ignition PENNCO BOILERS 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com P/N 1305004, Rev. D [08/03/2015]...
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Page 2: Dimensions
DIMENSIONS Figure 1 - Dimensions BOILER MODEL Dimensions (Inches) NUMBER Intermittent Ignition w/Vent Flue Diameter "A" Width Damper 1603HSID 11¼ 1604HSID 14½ 1605HSID 17¾ 1606HSID 1607HSID 24¼ 1608HSID 27½ 1609HSID 30¾ Add 5½" to height for Vent Damper Add model number suffix 'P' for Propane Gas. -
Page 3: Table Of Contents
Input Net AHRI Net AHRI Ignition w/Vent Fuel Type Capacity AFUE(%) *MBTUH Rating *Mbh Rating Sq. Ft. Damper *MBTUH Natural Gas 82.7 1603HSID Propane 82.7 Natural Gas 82.0 1604HSID Propane 80.4 Natural Gas 82.0 1605HSID Propane 80.6 Natural Gas 82.0... - Page 4 TABLE OF CONTENTS Introduction Dimensions ..........2 Boiler is designed for use in closed heating systems where Ratings and Capacity ........3 all steam is returned as condensate and make-up water is Safety Symbols .......... 5 minimal. Boiler is not designed for or intended for use in open systems using 100% make-up water.
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Page 5: Safety Symbols
SAFETY SYMBOLS General Installation shall conform to requirements of authority having jurisdiction or in absence of such Boiler and venting installation shall be completed by requirements to the National Fuel Gas Code, ANSI qualified agency. Z223.1/NFPA 54. WARNING Where required by authority having jurisdiction, Fire, explosion, asphyxiation and electrical shock installation shall conform to Standard for Controls hazard. -
Page 6: Locating The Boiler
LOCATING THE BOILER Locating the Boiler Select level location as centralized with piping system, Table 2 - and as near chimney as possible. Minimum Clearance Dimensions Place crated boiler at selected location. Remove all 6" crate material. Please recycle responsibly. Rear 6"... -
Page 7: System Piping
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 floor or allowable safe point of discharge. -
Page 8: Hsid
SYSTEM PIPING Consider near boiler piping as part of the boiler for proper For pumped return systems, follow the condensate water level control and to produce dry steam. pump or boiler feed pump manufacturer’s instructions for proper installation and hookup. Correct near boiler piping is crucial to proper operation of In connecting the cold water supply to the water inlet boiler and heating system. -
Page 9: Hsid
SYSTEM PIPING Figure 4 - Recommended Near Boiler Piping Using One Supply Tapping P/N 1305004, Rev. D [18/03/2015]... -
Page 10: Installation - System Piping
INSTALLATION - SYSTEM PIPING Figure 5 - Recommended Near Boiler Piping Using Two Supply Tappings Figure 6 - Chilled Water Piping VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING P/N 1305004, Rev. -
Page 11: Fresh Air For Combustion
FRESH AIR FOR COMBUSTION WARNING B. Known Air Infiltration Rate. See Table 3 for space with boiler only. Use equation for multiple Air openings to combustion area must not be appliances. Do not use an air infiltration rate air obstructed. Follow instructions below, to maintain changes per hour (ACH) greater than 0.60. -
Page 12: Chimney And Vent Pipe Connection
CHIMNEY AND VENT PIPE CONNECTION End of vent pipe must be flush with inside face of WARNING chimney flue. Use sealed-in thimble for chimney Installing or venting a boiler or any other gas connection. appliance with improper methods or materials could Horizontal run should not be longer than 3/4 the result in death or serious injury due to fire or to chimney height (HT) Figure 7, page 13. - Page 13 CHIMNEY AND VENT PIPE CONNECTION Place in operation the appliance being inspected. Follow Figure 7 - Typical Masonry Chimney Requirements the lighting instructions. Adjust thermostat so appliance will operate continuously. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation.
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Page 14: Vent Damper Operation
VENT DAMPER OPERATION WARNING Figure 8 - Horizontal Installation Asphyxiation or burn hazard. Improper installation Horizontal Installation and operation of vent damper could result in serious Flow injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is To Boiler Vent Damper odorless and invisible. -
Page 15: Gas Supply Piping
GAS SUPPLY PIPING Propane Installation CAUTION WARNING WHAT TO DO IF YOU SMELL GAS Fire, explosion, asphyxiation hazard. Verify boiler • Do not try to light any appliance. is equipped with propane gas orifices and gas valve • Do not touch any electrical switch; do not use is configured for propane. -
Page 16: Electrical Wiring
ELECTRICAL WIRING Electronic Thermostats WARNING A. Some electronic thermostats may lose their Electrical shock hazard. Turn OFF electrical power memory or shut down. With probe type low water supply at service panel before making electrical cutoff, this may occur each time low water cutoff connections. -
Page 17: Operating Instructions
OPERATING INSTRUCTIONS For Your Safety Read Before Operating STOP! Read the safety information on this page. WARNING Set the thermostat to lowest setting. Turn off all electric power to the appliance. If you do not follow these instructions This appliance is equipped with an ignition device which exactly, a fire or explosion may result automatically lights the pilot. -
Page 18: Operating Your Boiler
OPERATING YOUR BOILER Thermostat WARNING A. Set thermostat to desired room temperature. Burn Hazard. Never run water into a hot empty B. Set thermostat to lower setting if heat is not boiler. Failure to follow these instructions could required result in death or serious injury. C. -
Page 19: Checking And Adjusting
CHECKING AND ADJUSTING Adjust Pilot Burner Figure 14 - Igniter Pilot flame should surround 3/8” to 1/2” of pilot sensor. See Figure 15. To adjust Flame. Remove screw cover over pilot adjusting screw. See Figure 13. Insert small screwdriver and adjust flame as needed. Turn screw counterclockwise to increase flame, clock- wise to decrease. - Page 20 CHECKING AND ADJUSTING Adjust Steam Pressure Control Boiler Equipped With Optional WF-2U-24 Water Feeder • Steam pressure limit control (pressuretrol) shuts E. Continue thermostat call for heat after low water off gas to main burners when steam pressure in cut off recognizes low water condition. boiler reaches cut-off setpoint (i.e.
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Page 21: Start-Up Cleaning
START-UP CLEANING • Maintain at least 180°F for 15 minutes to remove WARNING dissolved gasses from fresh water. Following service procedures must be performed • Shut off burners. by qualified service agent. Boiler owner shall not Allow system to operate for one week to give majority attempt these steps. -
Page 22: General Maintenance
GENERAL MAINTENANCE Low Water Cut-Off Boiler Water Treatment Other Than Cleaners Low Water Cut-Off interrupts electrical current to burner In steam systems where system is tight, free from leaks, when water line in boiler drops to low level. and all steam is returned to boiler as condensate, amount of make up water is small. -
Page 23: Service Hints
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 24: Wiring Diagrams
WIRING DIAGRAMS Figure 13 - Wiring Diagrams For Boilers With CG400 Probe Type Low Water Cut-Off Shown CG400 Terminals PS802 To CG400 Cross Reference PS802 CG400 If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent. -
Page 25: Wiring Diagrams
WIRING DIAGRAMS Figure 17 - Wiring Diagrams For Boilers With 67D-1 Float Type Low Water Cut-Off If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent. P/N 1305004, Rev. -
Page 26: Controls And Accessories
CONTROLS AND ACCESSORIES SAFETY VALVE WATER FEEDER (Optional) Safety valve is designed to open automatically if boiler steam Model WF-2U-24 water feeder maybe used with either pressure exceeds pressure rating of valve (15 psig). Should of the low water cutoffs listed. Water feeder maintains it fail to open under this condition, shut down your boiler. -
Page 27: Repair Parts
REPAIR PARTS P/N 1305004, Rev. D [18/03/2015]... - Page 28 REPAIR PARTS P/N 1305004, Rev. D [18/03/2015]...
- Page 29 REPAIR PARTS P/N 1305004, Rev. D [18/03/2015]...
- Page 30 REPAIR PARTS Safety Relief Valve CG400 LOW WATER CUT OFF 240009340 ½ NPT X 4" Nipple PF-033.02 P/N 1305004, Rev. D [18/03/2015]...
- Page 31 P/N 1305004, Rev. D [18/03/2015]...
- Page 32 • 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. PENNCO BOILERS 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...