ECR PENNCO 15B Series, Installation, Operation & Maintenance Manual

Page 1: ...nkirk NY 14048 www ecrinternational com R An ISO 9001 2000 Certified Company 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 ...

Page 2: ...upplied or specified components may result in property damage personal injury or the loss of life 4 TO THE OWNER Installation and service of this boiler must be performed by a qualified installer 5 TO THE INSTALLER Leave all instructions with the boiler for future reference 6 When this product is installed in the Common wealth of Massachusetts the installation must be performed by a Licensed Plumb...

Page 3: ...ors 3 Tank sized for non ferrous baseboard or radiant panel systems Increase size for cast iron baseboard and radiation Net I B R ratings include 15 allowance for normal piping and pick up load Manufacturer should be consulted on installations having other than normal piping and pick up requirements For equivalent square feet of radiation divide I B R output by 150 STANDARD EQUIPMENT Boiler Jacket...

Page 4: ...e lighting and other performance 4 criteria with the gas manifold and control assembly on the boiler per the latest revision of ANSI Z21 13 CGA 4 9 The boiler shall be installed such that the gas ignition 5 system components are protected from water drip ping spraying rain etc during appliance operation and service circulator replacement condensate trap control replacement etc Locate boiler on lev...

Page 5: ... National Fuel Gas Code When a boiler is installed in an unconfined space in a 3 building of tight construction air for combustion and ven tilation must be obtained from outdoors or from spaces freely communicating with the outdoors A permanent opening or openings having a total free area of not less than 1 square inch per 5000 Btu per hour of total input rating of all appliances shall be provided...

Page 6: ...inch from the back and 6 inches from the front of the boiler The opening shall directly communicate with the outdoors or shall communicate through a verti cal or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors The openings must have a minimum free area of 1 square inch per 3000 Btu per hour of the total input rating of all equipment located in the...

Page 7: ...eating boiler During heating cycle open valves A and B close valves C and D During cooling cycle open valves C and D close valves A and B Maintain a minimum clearance of one inch to hot water C pipes When the boiler is connected to heating coils located in air 2 handling units where they may be exposed to refrigerated air circulation the boiler piping system MUST BE sup plied with flow control val...

Page 8: ...ation This method of piping however is not typically required for baseboard heat ing systems Typical installations where bypass piping is used are as follows This method is used to protect boilers from condensation A forming due to low temperature return water Generally noticed in large converted gravity systems or other large water volume systems Figure 6 These methods are used to protect systems...

Page 9: ...ALVE HOSE BIB FLOW CONTROL VALVE EXPANSION TANK BOILER DHW CIRCULATOR CH CIRCULATOR PRIORITY ZONE CIRCULATOR EXPANSION TANK WATER INLET FLOW CONTROL VAVLE SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB SINGLE ZONE SYSTEM WITH DHW PRIORITY MULTIZONE SYSTEM WITH CIRCU LATORS AND DHW PRIORITY CONNECTING SUPPLY AND RETURN PIPING Figure 7 Figure 8 ...

Page 10: ...PRIORITY ZONE BOILER WATER INLET CH DHW SYSTEM CIRCULATOR USE FULL PORT ZONE VALVE FOR OPTIMUM TANK PERFORMANCE CONSIDER USING ZONE CIRCULATOR SEE FIGURE 5 ZONE 4 CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE EXPANSION TANK AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE Figure 9 Figure 10 CONNECTING SUPPLY AND RETURN PIPING MULTIZONE SYSTEM WITH ZONE VALVES AND DHW PRIORITY WI...

Page 11: ...turn doors win dows exhaust fans fireplace dampers and any other gas burning appliances to their previous condition of use Any improper operation of the common venting system 7 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 m...

Page 12: ...ctor through bracket 3 hole on Damper Motor frame Tighten locknut onto Damper wire harness connector 4 Plug Damper connector into socket on Damper Motor 5 frame Replace Damper Motor cover and wire Damper in accor 6 dance with Figure 11 DAMPER INSTRUCTIONS Ensure that only the boiler is serviced by the Vent Damp 1 er Figure 12 REFER TO DAMPER MANUFACTURER S INSTALLATION INSTRUCTIONS FOR POSITION OF...

Page 13: ... piping system during 4 any pressure testing of the gas piping After reconnecting leak test gas connection and boiler piping before placing boiler back into operation Natural Gas Propane Min Supply Pressure 5 w c 11 w c Max Supply Pressure 14 w c 14 w c Manifold Pressure 3 5 w c 10 5 w c ELECTRICAL WIRING See wiring diagrams on the following two pages for details Electrical wiring must conform wit...

Page 14: ...14 Wiring Diagram 24V Standing Pilot ...

Page 15: ...15 Wiring Diagram Intermittent Ignition INTERMITTENT PILOT CONTROL PILOT J BOX L2 W Y Y BK L1 HOT 120V 60 HZ SUPPLY LWCO R R W W B B ...

Page 16: ...call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department CAUTION C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it Call a qualified service technician Force or attempted repair may result in a fire or explosion D ...

Page 17: ...H COVER SCREW OUTLET PRESSURE TAP TAP PRESSURE INLET GAS INLET GAS OUTLET TH TR ON OFF PILOT Figure 16 NOTE Somegascontrolknobscannotbeturnedfrom PILOT to OFF unless knob is pushed in slightly DO NOT FORCE Wait 5 minutes to clear out any gas If you then smell 6 gas STOP Follow What To Do If You Smell Gas If you don t smell gas go to the next step Find pilot Follow metal tube from gas control Depen...

Page 18: ...oper and dangerous operation CAUTION Verify proper operation after service The service agency or owner should make certain the system is filled with water to minimum pressure and open air vents if used to expel any air that may have accumulated in the sys tem Check the entire piping system and if any leaks appear have them repaired Circulators need to be checked and maintained Refer to the circula...

Page 19: ...ES BURNERS Figure 20 BURNER DOOR The pilot flame should envelop to inch of the tip of the pilot thermocouple ignition sensing electrode or mercury sen sor Figure 21 IGNITION ELECTRODE 3 8 TO 1 2 IN FLAME Figure 21 To adjust the pilot flame remove the pilot adjustment cover screw Figures 14 16 on previous pages and turn the inner adjustment screw counterclockwise to increase or clockwise to decreas...

Page 20: ...s should be changed if the final manifold pressure varies more than plus or minus 0 3 inches water column from the specified pressure Primary air adjustment is not necessary therefore air shutters are not furnished as standard equipment Air shutters can be furnished on request where required by local codes or conditions Check Safety Control Circuit after burner adjustments are made for satisfactor...

Page 21: ...altimeter Gauge 4 Jacket Side Right 16 Right End Section 28 High Limit Control 5 Left End Section 17 Jacket Side Left 29 Pipe Bushing 6 Push Nipple 18 Relief Valve 30 Well 7 Jacket Top 19 Pipe Nipple 31 Tray 8 Damper 20 Pipe Elbow 32 Base 9 Baffle 21 Circulator 33 Burner Door 10 Center Section 22 Pipe Nipple 34 Gas Valve 11 Jacket Back To Flue 23 Pipe Tee 35 Manifold 12 Flue Collecter 24 Drain Coc...

Page 22: ...raight Flange NPT 175 195 245 295 LP ONLY 1 6 VG 006 00 Internal Bushing x ALL LP 1 7 356 2 1 01 Manifold 045 1 356 2 1 02 Manifold 070 096 Item Part No Description Qty 7 356 2 1 03 Manifold 120 145 1 356 2 1 04 Manifold 175 195 356 2 1 05 Manifold 245 356 2 1 06 Manifold 295 8 HW 005 01 Screw 20 x Self Tap 4 9 240007406 Orifice 3 2mm Nat 096 2 Orifice 3 2mm Nat 145 3 Orifice 3 2mm Nat 195 4 Orifi...

Page 23: ...96 1 B Center Section 120 145 2 B Center Section 175 195 3 B Center Section 245 4 B Center Section 295 6 Item Part No Description Qty 7 100 2 2 01 B Left Hand Section 1 8 43300976 Push Nipple 2 Mach 045 2 Push Nipple 2 Mach 070 096 4 Push Nipple 2 Mach 120 145 6 Push Nipple 2 Mach 175 195 8 Push Nipple 2 Mach 245 10 Push Nipple 2 Mach 295 12 9 3461601 Baffle 045 Only 2 Fully Assembled Heat Exchang...

Page 24: ...1702 Flue Collector Restrictor 070 3461703 Flue Collector Restrictor 096 3461704 Flue Collector Restrictor 295 Item Part No Description Qty 8 34620501 Flue Collector 045 1 34620502 Flue Collector 070 096 34620503 Flue Collector 120 145 34620504 Flue Collector 175 195 34620505 Flue Collector 245 34620506 Flue Collector 295 9 31623301 Jkt Back Panel 045 1 31623302 Jkt Back Panel 070 096 31623303 Jkt...

Page 25: ... 02 Natural Gas Q345A PILOT 1 240007096 LP Q345A Pilot Included with 3 Pilot Tube Assembly Kit above CONTINUOUS PILOT Item Part No Description Qty 1 109007296 PILOT BRACKET ASSEMBLY 1 2 HW 005 01 BRACKET SCREW 2 3 1520001 THERMOCOUPLE Q309 1 4 14615005 PILOT TUBING 1 8 x 24 1 5 14662098 Natural Gas Q314A PILOT 1 240007285 LP Q314A Pilot Included with 3 Pilot Tube Assembly Kit above 1 1 5 5 3 4 4 2...

Page 26: ...e 18 1 5 1190001 Pipe Elbow 90 1 14 37513301 Wire Rollout Spill 28 2 6 1260006 Gauge Theraltimeter 1 15 14662070 Pilot Spark Control 1 7 37519501 Harness Circulator 72 1 16 EF03601 Clamp 3600 White 2 8 1310002 Pipe Nipple 1 x 4 NPT 1 17 Z99 Control Vent Damper 1 9 HW 016 03 Drain Valve 1 18 240004779 Wire 2 Cond Bonded 18 1 ITEM PART NO DESCRIPTION QTY 1a 32611001 Temp Sensor Bracket Base 1 1b 346...

Page 27: ...sion LP to Natural 15B245 550001277 Kit Conversion LP to Natural 15B295 550001278 Kit Conversion LP to Natural NATURAL GAS TO LP Model Part No Description 15B045 550001279 Kit Conversion Natural to LP 15B070 550001280 Kit Conversion Natural to LP 15B096 550001281 Kit Conversion Natural to LP 15B120 550001282 Kit Conversion Natural to LP 15B145 550001283 Kit Conversion Natural to LP 15B175 55000128...

Page 28: ...85 Middle Rd Dunkirk NY 14048 ...