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Troubleshooting
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Summary of Contents for ECR PENNCO 41J Series
- Page 1 41J Series Cast Iron Commercial Steam Boiler INSTALLATION, OPERATION & MAINTENANCE MANUAL Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 An ISO 9001-2008 Certified Company web site: www.ecrinternational.com P/N# 240009242 Rev. B [06/2013...
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Page 2: Table Of Contents
CAST IRON HOT WATER OR STEAM BOILER INSTALLATION MANUAL AND OPERATING INSTRUCTIONS SAFETY SYMBOLS TABLE OF CONTENTS Safety Symbols ..........2 Boiler Ratings & Capacities ........3 DANGER Rules For Safe Installation & Operation ....4 Locating The Boiler ..........5 Indicates a hazardous situation which, if not Combustion Air, Chimney &... -
Page 3: Boiler Ratings & Capacities
RATINGS AND CAPACITIES Ratings and Capacities - Chart 1 Pressure Drop Net AHRI Flue Outlet No. Chimney Output (1) Flue Thru Water Ratings (2) & Size Size (6) Horsepower Input/Size Collector Therm. Boiler (5) Gross (Mbh) Gross Size to Eff. Output (4) Steam Steam... -
Page 4: Rules For Safe Installation & Operation
SAFETY INFORMATION When Your Boiler Arrives Safety Information When boiler arrives be sure to save and refer to IMPORTANT: Read the following instructions instructions. COMPLETELY before installing!! Inspect each item received for visible damage. If any parts are damaged, report this to freight company WARNING immediately and request them to call and make Fire, explosion, asphyxiation and electrical shock... -
Page 5: Locating The Boiler
BEFORE INSTALLING Minimum Vent Pipe Clearance Boiler Location If the vent pipe must go through a crawl space, double Locate boiler on level, non-combustible foundation as near wall vent pipe should be used. Where vent passes through to chimney or fl ue as possible. Allow 24 inches at front and a combustible wall or partition, use a ventilated metal sides of boiler for servicing and cleaning. -
Page 6: Ventilation And Combustion Air
VENTILATION AND COMBUSTION AIR WARNING WARNING Asphyxiation hazard. Ensure enough air is available Air openings to combustion area must not be for proper combustion, avoiding hazard due to lack obstructed. Follow Chart 2 to insure adequate of oxygen. combustion air is maintained. COMBUSTION AIR REQUIREMENTS –... - Page 7 VENTILATION AND COMBUSTION AIR Figure 1 Figure 2 Combustion Air Combustion Openings with Motorized Dampers Openings Vent-Piping Vent-Piping Combustion Air supplied from Combustion Air supplied from inside the building outside the building Important Vent-Piping Note: Sloped vent pipe at least 1/4” for every 1’ to the vent terminal. Provide combustion and ventilation air in accordance When air for combustion and ventilation is from inside with the section “Air for Combustion and Ventilation”,...
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Page 8: Vent Installation
VENTILATION AND COMBUSTION AIR A. When installing two openings, one must commence B. One permanent opening, commencing within 12 within 12 inches from top and other within 12 inches of top of enclosure, shall be permitted where inches from bottom of enclosure. Openings shall equipment has clearances of at least 1 inch from communicate directly, or by ducts, with outdoors sides, 1 inch from back, and 6 inches from front... - Page 9 VENT INSTALLATION Flue Connection And Venting - Continued Figure 3 Simple vent system consists of 6-foot minimum vertical rise immediately off draft-hood, as shown in Figure 3. Terminate this vertical fl ue above building roof with suitable rain cap at least 2 feet above surrounding obstructions, i.e., parapets, adjacent buildings, penthouses, etc.
- Page 10 VENT INSTALLATION Removing Existing Boiler From Common Venting Figure 6 System When existing boiler is removed from common venting system, common venting system is likely to be too large for proper venting of appliances remaining connected to it. At time of removal of existing boiler, following steps shall be followed with each appliance remaining connected to common venting system placed in operation, while other appliances remaining connected to common venting system...
- Page 11 BOILER DIMENSIONS Left Side View Front View Supply Supply Water Line 38” 29” Floor Line Top View Flue Nutlets Return Return ALL SUPPLY AND RETURN CONNECTIONS ARE 4 INCH Supply Supply Chart 3 Water Content Boiler Shipping A Jacket in Gallons Base &...
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Page 12: Assembly Of Bases, Starting Section Assembly
INSTALLATION – ASSEMBLY Base Assembly Section Assembly The 300, 400 and 500 boilers are the basic models. The 300 The sections may be started from either the left or right end model has (6) burners, the 400 model has (8) burners and of the base. -
Page 13: Attaching Draft Hoods
INSTALLATION – ASSEMBLY Place nipples in ports taking care to seat them squarely to Attaching Draft Hoods prevent cocking. Figure 10. Attach the draft hoods to the boiler sections after applying boiler putty to the top of the boiler sections When pulling sections together with tie rods, always insert where the hoods and sections meet. -
Page 14: Installing Boiler Jacket Panels
INSTALLATION – ASSEMBLY Installing Boiler Jacket Panels Position top/front intermediate panel so back edge of top hangs on adjustable clips on front of draft hood(s); left NOTE: Jacket assembly must start at the left side of boiler. edge hangs on bracket on left upper jacket end panel; Attach lower jacket end panel (left) to two Z-bars on and right edge with integral bracket hangs on tie rod(s). - Page 15 INSTALLATION – ASSEMBLY Installing Boiler Jacket Panels - Continued end panel with lower behind middle and lining up holes. Use (5) #10 x ½” screws. Attach lower jacket end Attach upper jacket end panel (right) so left edge hangs panel to two Z-bars on base end closures through two on bracket on top/front intermediate panel.
- Page 16 INSTALLATION – ASSEMBLY boiler base. Each boiler base also includes data plate Attach burner door knobs with #8-32 x ¼” screws and indicating required gas type, fi ring rate, and gas #8-32 hex nuts. Slide bottom of lower access door(s) in slots on top of manifold brackets.
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Page 17: Control Mounting And Installation
INSTALLATION – ASSEMBLY Control Mounting And Installation Orient harness of control panel assembly so correct (female) plug is toward j-box and will connect to NOTE: Electrical controls (j-box, transformer, etc. can j-box harness. Figure 27A. Secure harness to control be mounted on either left or right jacket end panel. panel with zip-ties and #10 x ½”... - Page 18 INSTALLATION – ASSEMBLY Control Mounting And Installation Figure 27A Figure 29A Figure #27A Figure 27B Figure 29B Figure 28...
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Page 19: Tappings
TAPPINGS Illustration shows the end section and the various tap- Figure 29 pings provided. Tappings are the same in both right and left end sections. OPENING SIZE STEAM WATER Supply and 4” Supply and Return Return P r i m a r y LW C O a n d ½”... -
Page 20: Boiler Piping
BOILER PIPING PIPE SIZING BOILERS USED WITH REFRIGERATION SYSTEM Piping connection sizes are important to control proper When the boiler is installed in connection with a water velocity at the inlet and outlet connections to refrigeration system, it must be piped so that the the water boiler. -
Page 21: Piping Diagrams
BOILER PIPING Figure 33 STEAM BOILERS - SERIES S BOILER TAPPINGS ARE AVAILABLE FOR ALL CONNECTIONS SHOWN NOTE: Mount electrical supply on opposite side. CITY WATER SUPPLY CITY WATER SUPPLY WATER WATER WATER LINE LINE LINE 1.1/2 TO RETURN TO RETURN NO. - Page 22 BOILER PIPING Figure 35 STEAM BOILER PIPING SAFETY VALVE SHOULD BE FIELD INSTALLED AS CLOSE AS POSSIBLE TO BOILER STEAM BOILER PIPING Figure 35 WARNING Full size steam header is recommended on all steam Do not install shut-off or steam valve between systems as shown above.
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Page 23: Connecting Gas Service
CONNECTING GAS SERVICE • Connect gas service from meter to control assembly(s) in accordance with ANSI Z223.1 and local codes or Chart 4 utility. On multiple base boilers, connect gas service Minimum Gas Supply Pressure with branch lines from common main. Individual branch 5.0 inches w.c. -
Page 24: Electrical Wiring
ELECTRICAL WIRING Adjust Thermostat Heat Anticipator WARNING Suggested heat anticipator setting is .90 amps (set Electrical shock hazard. Turn OFF electrical power accordingly). Then follow instructions packaged with supply at service panel before making any line thermostat for fi nal adjustment, checking thermostat voltage connections. -
Page 25: Wiring Diagrams
WIRING DIAGRAMS Commercial Boiler, 1, 2 & 3 Base LOW VOLTAGE WIRING... - Page 26 WIRING DIAGRAMS Commercial Boiler, 4, 5 & 6 Base LOW VOLTAGE WIRING...
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Page 27: Operation And Service
OPERATION AND SERVICE Control Functions And Operation System Troubleshooting The control module performs the following basic functions: Start system by setting thermostat or controller above room temperature and observe system response. Opens and closes the fi rst (pilot) operator of the gas valve. -
Page 28: Startup & Checkout, Start System
OPERATION AND SERVICE NOTE: Light-off may not be satisfactory until the gas input CAUTION and combustion air have been adjusted. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. DANGER Do not touch any electrical switch; do not use any Fire Hazard. -
Page 29: Pilot System Troubleshooting Table
PILOT SYSTEM TROUBLESHOOTING TABLE NOTE: Before troubleshooting, familiarize yourself with the startup and check procedure. Turn gas supply OFF. Turn thermostat (controller) to call for heat. Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Also, check air proving switch on combustion air Power to module (24V module) blower system (if used) and that vent damper (if used) is open and end switch is made. -
Page 30: Checking & Adjusting
CHECKING AND ADJUSTING This valve should be tested every month during periods NOTICE of boiler operation, and at the beginning and end of any Do not exceed the Input rate stamped on the extended non-service period. Prior to testing, make cer- tain discharge pipe is properly connected to valve outlet nameplate of boiler located on End Jacket Panel. -
Page 31: Cleaning And Maintenance
CHECKING AND ADJUSTING VENTING SYSTEM AT LEAST ONCE A MONTH DURING HEATING SEASON Vent system is very important part of heating system. check to see that sections of vent pipe are secure at all No boiler, however effi cient its design, can perform joints and fi... - Page 32 PENNCO BOILERS 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...
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