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MODEL NUMBERS:
15B045, 15B070, 15B096,
15B120, 15B145, 15B175,
15B195, 15B245, 15B295
An ISO 9001-2000 Certified Company
INSTALLATION, OPERATION &
PENNCO BOILERS
85 Middle Rd.
Dunkirk, NY 14048
R
www.ecrinternational.com
15B SERIES
Cast Iron Gas Fired Boilers
For Forced Hot Water
MAINTANANCE MANUAL
P/N 1305026, Rev. B [02/09]
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Summary of Contents for ECR PENNCO 15B Series
- Page 1 15B SERIES Cast Iron Gas Fired Boilers For Forced Hot Water INSTALLATION, OPERATION & MAINTANANCE MANUAL MODEL NUMBERS: 15B045, 15B070, 15B096, 15B120, 15B145, 15B175, 15B195, 15B245, 15B295 PENNCO BOILERS 85 Middle Rd. Dunkirk, NY 14048 An ISO 9001-2000 Certified Company www.ecrinternational.com P/N 1305026, Rev.
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Page 2: Table Of Contents
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS TABLE OF CONTENTS IMPORTANT: Read the following instruc- Ratings & Data - Natural Gas & Propane Gas ...3 tions COMPLETELY before installing!! Installation Procedure .........4 Ventilation & Combustion Air ......5 WARNING Connecting Supply & Return Piping ....7 Vent Installation .......... -
Page 3: Ratings & Data - Natural Gas & Propane Gas
RATINGS & DATA - NATURAL GAS & PROPANE GAS Recommended Water AFUE Model A.G.A. Input Heating Capacity I=B=R NetOutput NetRating Sq. Ft. No. Of AFUE Air Cushion Content Elect. Btu/Hr. Btu/Hr. Btu/Hr. HW @ 170° Burners Stdg. Pilot Tank (Gals.) Ign. -
Page 4: Installation Procedure
INSTALLATION PROCEDURE WARNING Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. The installation must conform to the requirements of the FOR INSTALLATION ON NON-COMBUSTIBLE authority having jurisdiction or, in the absence of such FLOORS ONLY - For installation on combustible flooring special base must be used. -
Page 5: Ventilation & Combustion Air
VENTILATION & COMBUSTION AIR WARNING Air openings to combustion area must not be obstructed. By following the instructions below, adequate combustion air can be maintained. In this case air for combustion and ventilation shall be COMBUSTION AIR REQUIREMENTS provided according to Step 5. If there is any doubt, install (Minimum Square Inches Requirement) Unconfined Area* Confined Area**... - Page 6 VENTILATION AND COMBUSTION AIR If horizontal ducts are used, each opening and duct shall When directly communicating with the outdoors, each have a minimum free area 1 square inch per 2,000 Btu opening shall have a minimum free area of 1 square inch per hour of total input rating of all appliances in the en- closed space.
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Page 7: Connecting Supply & Return Piping
CONNECTING SUPPLy & RETURN PIPING IMPORTANT: Circulators in the following illustrations are mounted on the system supply side, but mounting on the system return side is also acceptable practice. Figure #5 PRESSURE REDUCING VALVE GATE VALVE SUPPLY PIPING TO HEATING AND COOLING ELEMENT CIRCULATOR... - Page 8 CONNECTING SUPPLy AND RETURN PIPING Figure #6 TO SYSTEM FROM SYSTEM WATER INLET EXPANSION TANK BYPASS PIPING - AUTOMATIC MIXING VALVE BOILER ALTERNATE CIRCULATOR LOCATION PRESSURE BALL VALVE AIR SEPARATOR CIRCULATOR REDUCER VALVE SHUT-OFF 3 WAY MIXING CHECK VALVE HOSE BIB VALVE VALVE FROM SYSTEM...
- Page 9 CONNECTING SUPPLy AND RETURN PIPING Figure #7 SINGLE ZONE SYSTEM WITH CH CIRCULATOR DHW PRIORITY WATER INLET EXPANSION TANK CIRCULATOR BOILER PRIORITY ZONE PRESSURE BALL VALVE CIRCULATOR HOSE BIB REDUCER VALVE AIR SEPARATOR FLOW CONTROL SHUT-OFF ZONE VALVE VAVLE CHECK VALVE VALVE Figure #8 ZONE 4...
- Page 10 CONNECTING SUPPLy AND RETURN PIPING Figure #9 ZONE 4 MULTIZONE SYSTEM WITH ZONE VALVES AND DHW PRIORITY (WITH CIRCULATOR) ZONE 3 *USE FULL PORT ZONE VALVE. ZONE 2 CIRCULATOR ZONE 1 (PRIORITY ZONE) WATER INLET CIRCULATOR EXPANSION BOILER TANK PRESSURE BALL VALVE AIR SEPARATOR CIRCULATOR...
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Page 11: Vent Installation
VENT INSTALLATION WARNING All installations of boilers and venting should be done only by a qualified expert and in accordance with the appropriate manual. Installing or venting a boiler or any other gas appliance with improper methods or materials may result in serious injury or death due to fire or to asphyxiation from poison- ous gases such as carbon monoxide with is odorless and invisible. -
Page 12: Vent Damper Installation & Instructions
VENT SySTEM MODIFICATION should be corrected so the installation conforms with the latest revision of the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the ap- propriate tables in the latest revision of the National Fuel Gas Code, ANSI Z223. -
Page 13: Connecting Gas Service
CONNECTING GAS SERVICE Connect gas service from meter to control assembly in accordance with ANSI Z223.1 and local codes or utility. MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS/HOUR A ground joint union should be installed for easy removal (Gas Pressure = 0.5 psig or less, Pressure Drop = 5 in. -
Page 14: Wiring Diagram - 24V Standing Pilot
WIRING DIAGRAM - 24V STANDING PILOT... -
Page 15: Wiring Diagram - Intermittent Ignition
WIRING DIAGRAM - INTERMITTENT IGNITION... -
Page 16: Lighting Instructions
LIGhTING INSTRUCTIONS WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. Before any procedures are attempted on this appliance, it is necessary to determine if the ignition system is electric or standing pilot. - Page 17 LIGhTING INSTRUCTIONS LIGHTING PROCEDURE FOR BOILER WITH Figure #16 CONTINUOUS PILOT PRESSURE REGULATOR ADJUSTMENT BENEATH INLET OUTLET For Your Safety, Read Before Lighting!! COVER SCREW PRESSURE PRESSURE Read the warning at the beginning of " Lighting Instruc- tions." TH/TR This appliance has a pilot which must be lighted by hand. OUTLET INLET When lighting the pilot, follow these instructions exactly.
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Page 18: Normal Sequence Of Operation
NORMAL SEqUENCE OF OPERATION Figure #17 On a call for heat, the thermostat will actuate, completing the circuit to the control. The completed circuit to the control will first activate the circulator and damper which will close an end switch inside the damper. - Page 19 GENERAL INSTRUCTIONS bottom of the base and brush down the flue passage- The pilot flame should envelop ⅜ to ½ inch of the tip of the ways. The soot and scale will collect on the paper and is pilot thermocouple, ignition/sensing electrode or mercury sen- easily removed with the paper.
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Page 20: Checking Gas Input Rate To Boiler
ChECkING GAS INPUT RATE TO BOILER Gas input to the boiler can be adjusted by removing the protective cap on the pressure regulator (Figures #14-#16) and turning the screw clockwise to increase input and Figure #22 counterclockwise to decrease input. The manifold pressures are taken at the outlet side of the gas valve. -
Page 21: Boiler Exploded View
BOILER ExPLODED VIEW Item Description Item Description Item Description Jacket Front Lower 13 Draft Hood 25 Pipe Nipple Control 14 Restrictor 26 Pilot Spark Control Jacket Front Upper 15 Jacket Back 27 Theraltimeter Gauge Jacket Side Right 16 Right End Section 28 High Limit Control Left End Section 17 Jacket Side Left... - Page 22 REPLACEMENT PARTS - BASE Item Part No. Description QTY. Item Part No. Description Qty. Burner Tube 1½” (045) 356-2-1.03 Manifold (120, 145) Burner Tube 1½” (070, 096) 356-2-1.04 Manifold (175, 195) Burner Tube 1½” (120, 145) 356-2-1.05 Manifold (245) 240005543 Burner Tube 1½”...
- Page 23 REPLACEMENT PARTS - hEAT ExChANGER Item Part No. Description Qty. Item Part No. Description Qty. HW06901 Nut - 18 Wislock 100-2-2.01 B - Left Hand Section 14605001 Tie Rod - ¼” x 7¼” (045) Push Nipple 2” Mach. (045) Push Nipple 2” Mach. (070, 096) HW-011.01 Tie Rod - ¼”...
- Page 24 REPLACEMENT PARTS - JACkET Description Part No. Description Qty. Item Qty. Item Part No. 240006936 4” Damper (045) 34620501 Flue Collector (045) 240006937 5” Damper (070, 096) 34620502 Flue Collector (070, 096) 240006938 6” Damper (120, 145) 34620503 Flue Collector (120, 145) 240006939 7”...
- Page 25 REPLACEMENT PARTS - PILOT SPARK PILOT Item Part No. Description Qty. 109007296 PILOT BRACKET ASSEMBLY HW-005.01 BRACKET SCREW 240007093 SPARK CABLE 14615005 PILOT TUBING, 1/8" x 24" PB-001.02 Natural Gas Q345A PILOT 240007096 LP Q345A Pilot * Included with #3 - Pilot Tube Assembly Kit (above) CONTINUOUS PILOT Item Part No.
- Page 26 REPLACEMENT PARTS - PIPING & CONTROLS Item Part No. Description Qty. Item Part No. Description Qty. AQ-020.01 Well ¾” x 3” 1516001 Pipe - Tee 1¼” x ¾” x 1¼” Pilot Ignition Cable 30” AQ02201 High Limit Control 240007093 1310001 Pipe - Nipple ¾”...
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Page 27: Conversion Kits
CONVERSION kITS LP TO NATURAL GAS Model Part No. Description 15B045 550001270 Kit, Conversion, LP to Natural 15B070 550001271 Kit, Conversion, LP to Natural 15B096 550001272 Kit, Conversion, LP to Natural 15B120 550001273 Kit, Conversion, LP to Natural 15B145 550001274 Kit, Conversion, LP to Natural 15B175 550001275... - Page 28 85 Middle Rd. Dunkirk, NY 14048...
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