ECR PENNCO 16 Series, Installation, Operation & Maintenance Manual

Page 1: ...ERATION 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 ...

Page 2: ...EL NUMBER 1 Dimensions Inches Intermittent Ignition w Vent Damper Flue Diameter A Width 1603HSID 5 11 1604HSID 6 14 1605HSID 6 17 1606HSID 7 21 1607HSID 7 24 1608HSID 7 27 1609HSID 7 30 Add 5 to height for Vent Damper P N 1305004 Rev E 8 31 2016 ...

Page 3: ... 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 1...

Page 4: ...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 Pla...

Page 5: ...s appliance with improper methods or materials could result in death or serious injury due to fire 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 flammable vapors and liquids Modification substitution or elimination of factory equ...

Page 6: ... use Boiler location should not interfere with proper circulation of air Introduce outside air if normal infiltration 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 wate...

Page 7: ...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...

Page 8: ...der 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 2 pipe size 9 Equalizer line shall be minimum 1 pipe size 10 The...

Page 9: ...9 Figure 4 Recommended Near Boiler Piping Using One Supply Tapping SYSTEM PIPING P N 1305004 Rev E 8 31 2016 ...

Page 10: ... 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 ...

Page 11: ... 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 ...

Page 12: ...nger 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...

Page 13: ...g 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 Nati...

Page 14: ...nt 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 in...

Page 15: ...ents 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 liquefied petroleum gas Install field 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 flames or other me...

Page 16: ...ires 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 insid...

Page 17: ...tly and turn clockwise to OFF Do not force For Your Safety Read Before Operating WARNING If you do not follow these instructions exactly a fire 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 fo...

Page 18: ...de 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 d...

Page 19: ...n softer blue outer mantel with no yellow Remain still when observing main burner flames Check main burner orifices burner throat and flame ports for dust and lint obstruction if flame appearance is not correct Remove rollout shield if necessary to observe main burner flames Replace rollout shield after observation Gas Valve Safety Shutdown Test 1 Test ignition system safety shutoff device after p...

Page 20: ...urn 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 min...

Page 21: ...nnection from boiler drain valve to safe discharge point outside Shut off gas burners open drain valve allow all of water in boiler to drain out Close drain valve Allow boiler to cool slowly refill boiler to water line Repeat this step as many times as necessary until blow down water is clear 7 Following final blow down allow boiler to cool Add fresh water slowly up to normal water line Start burn...

Page 22: ...F RTV silicone to four mounting surface flanges of flue collector Mount flue collector on heat exchanger Tighten nuts and bolts 6 Seal front edge and four corners of flue collector to heat exchanger with silicone sealant 7 Use flashlight to verify there are no gaps in silicone seal 8 Install draft diverter vent damper vent pipe and jacket top and front cover 9 Reassemble all parts 10 Check tightne...

Page 23: ...out switch blown Have your service technician check heat exchanger for blockage Chimney flue is blocked Spill switch contacts open requiring manual reset of spill switch Have your service technician check and correct chimney problem Vent damper not operating Consult troubleshooting guide packaged with vent damper IF BURNER IS NOISY Gas input amount is incorrect Contact your service technician IF W...

Page 24: ...ust be replaced it must be replaced with type 105 C Thermoplastic wire or its equivalent Figure 13 Wiring Diagrams For Boilers With CG400 Probe Type Low Water Cut Off Shown CG400 PS802 CG400 N 2 H 1 C P1 W P2 B A Terminals PS802 To CG400 Cross Reference P N 1305004 Rev E 8 31 2016 ...

Page 25: ...ginal wire as supplied with this appliance must be replaced it must be replaced with type 105 C Thermoplastic wire or its equivalent Figure 17 Wiring Diagrams For Boilers With 67D 1 Float Type Low Water Cut Off P N 1305004 Rev E 8 31 2016 ...

Page 26: ...24 water feeder maybe used with either of the low water cutoffs listed Water feeder maintains safe minimum water level Keeps boiler running by compensating for minor evaporative steam leaks and prevents freeze ups if homeowners are away and return line leaks McDonnell and Miller Model 101 water feeders may be used however water feed rates are too high and need to be regulated or throttled and wiri...

Page 27: ...for AC volts 24 volts should be present i IF NOT source of the problem is not in damper check line voltage and 24 volt supply ii If 24 volts is present across brown and black continue to step iii iii Reconnect thermostat wires and turn up heat setting iv Check voltage across black and orange wires in Molex plug 24 volts AC should be present IF NOT source problem is not the damper If 24 volts is pr...

Page 28: ...le Cause Recommended Solution NO POWER Between 4 1 1 Off on limit 120VAC 2 Bad transformer 3 Loose or broken connections 4 Blown fuse or circuit breaker 5 Disconnect switch off 6 Harness not plugged into receptacle 1 turn limit on 2 Replace transformer 3 Tighten repair or replace connection 4 Replace fuse or reset circuit breaker 5 Turn switch on 6 Plug harness in NO POWER Between 4 2 POWER Betwee...

Page 29: ...to far 1 Clear the obstruction 2 Restore to damper pipe to round verify not binding 3 Correct the condition Damper Rotates Continuously 1 Defective damper motor assembly 1 Replace damper motor assembly Note For troubleshooting only Verify damper is in open position Use service switch to keep damper in open position Place jumper between 2 3 If appliance fires remove jumper and plug receptacle back ...

Page 30: ...30 REPAIR PARTS P N 1305004 Rev E 8 31 2016 ...

Page 31: ...31 REPAIR PARTS P N 1305004 Rev E 8 31 2016 ...

Page 32: ...11102 240011102 Rollout Shield 425 00 933 425 00 934 425 00 935 425 00 936 425 00 937 425 00 938 425 00 939 ALTERNATE PARTS OF CONTINUOUS PILOT 24 VOLT 1 24 Volt Gas Vlave Continuous Pilot 146 62 051 146 62 051 146 62 051 146 62 060 146 62 060 146 62 060 146 62 060 3 10 32 3 16 Hex Hd Screw 2 req d 146 95 301 146 95 301 146 95 301 146 95 301 146 95 301 146 95 301 146 95 301 7 Pilot Burner 146 62 0...

Page 33: ...33 REPAIR PARTS Safety Relief Valve 14 11 NPT X 4 Nipple PF 033 02 CG400 LOW WATER CUT OFF 240009340 P N 1305004 Rev E 8 31 2016 ...

Page 34: ...34 NOTES P N 1305004 Rev E 8 31 2016 ...

Page 35: ...35 Date Service Performed Company Name Tech Initials Company Address Phone P N 1305004 Rev E 8 31 2016 ...

Page 36: ...PENNCO BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...