ECR Pennco 15B045FE Installation, Operation & Maintenance Manual Download

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P/N 240009024, Rev. B [12/2013]

An ISO 9001-2008 Certified Company

15B SERIES

Cast Iron Gas Fired Boilers

For Forced Hot Water

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue,

Utica NY 13501

web site: www.ecrinternational.com

Models

15B045FE

15B070FE

15B096FE

15B120FE

15B145FE

15B170FE

15B195FE

15B245FE

15B295FE

Tested For

100 psi

ASME

Working Pressure

C.S.A. Certified

For Natural Gas Or Propane

Summary of Contents for Pennco 15B045FE

Page 1: ...ater INSTALLATION OPERATION MAINTENANCE MANUAL Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com Models 15B045FE 15B070FE 15B096FE 15B120FE 15B145FE 15B170FE 15B195FE 15B245FE 15B295FE Tested For 100 psi ASME Working Pressure C S A Certified For Natural Gas Or Propane ...

Page 2: ...ical Section 17 11 Wiring Diagram 18 12 Lighting Instructions 21 13 Normal Sequence Of Operation 22 14 General Instructions 22 15 Checking Gas Input Rate To Boiler 24 Appendix A Control Module 25 A 1 Installation Environment Considerations 25 A 2 Electrical Connections 25 A 3 Adjusting Settings 25 A 4 Display 25 A 5 Operation 26 A 6 Boiler High Limit Temperature Controller 27 A 8 Troubleshooting E...

Page 3: ...OR FUTURE REFERENCE WARNING Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids DO NOT obstruct air openings to the boiler room Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life TO THE OWNER Installation and service of this boiler must be performed by a q...

Page 4: ...ea level United States over 2000 ft 610m above sea level Reduce input rate 4 for every 1 000 ft 304m above sea level 2 Net AHRI Water Ratings shown based on piping and pickup allowance of 1 15 Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc For forced hot water systems wh...

Page 5: ...1 15B070 15 7 5 28 2015 16 415 16 1 15B096 15 7 5 28 2015 16 415 16 1 15B120 19 9 6 29 217 16 57 16 1 15B145 19 9 6 29 217 16 57 16 1 15B170 22 113 16 7 30 2115 16 515 16 1 15B195 22 113 16 7 30 2115 16 515 16 1 15B245 26 136 16 8 31 227 16 615 16 1 15B295 30 155 16 9 32 2215 16 815 16 1 Propane Gas Inlet All Units 1 2 2 DIMENSIONS Dimensions ...

Page 6: ...ical Section 17 11 Wiring Diagram 18 12 Lighting Instructions 20 13 Normal Sequence Of Operation 21 14 General Instructions 21 15 Checking Gas Input Rate To Boiler 23 Appendix A Control Module 24 A 1 Installation Environment Considerations 24 A 2 Electrical Connections 24 A 3 Adjusting Settings 24 A 4 Display 24 A 5 Operation 25 A 6 Boiler High Limit Temperature Controller 26 A 8 Troubleshooting E...

Page 7: ...OR FUTURE REFERENCE WARNING Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids DO NOT obstruct air openings to the boiler room Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life TO THE OWNER Installation and service of this boiler must be performed by a q...

Page 8: ...te boiler on level solid base as near chimney as possible and centrally located with respect to heat distribution system as practical 7 Allow 24 inches 610mm at front and right side for servicing and cleaning 8 When installed in utility room door should be wide enough to allow largest boiler part to enter or to permit replacement of another appliance such as water heater WARNING Fire hazard Do not...

Page 9: ... when mechanical air supply system not operating All Indoor Air Calculate minimum volume for all appliances in space Use a different method if minimum volume not available A Standard Method Cannot be used if known air infiltration rate is less than 0 40 air changes per hour See Table 1 for space with boiler only Use equation for multiple appliances Volume 50 ft3 x Total Input Mbh B Known Air Infil...

Page 10: ...ze equal to or greater than that of the relief valve outlet over the entire length of discharge line have no intervening shutoff valve between safety relief valve and discharge to atmosphere do not plug or place any 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 the valve and the dischar...

Page 11: ... 1 nor more than 3 time safety relief valve pressure settings Do not install shutoff valve between boiler and safety relief valve Systems with automatic fill valves require back flow prevention device Install discharge piping from safety relief valve See Warning Page 8 When boiler is connected to heating system utilizing multiple zoned circulators each circulator must be supplied with flow control...

Page 12: ...ND COOLING ELEMENT CIRCULATOR A PRESSURE REDUCING VALVE PROPER BACKFLOW PROTECTION DEVICE GATE VALVE PURGE VALVE NOTICE Circulators in following illustrations are mounted on system supply side mounting on system return side is also acceptable practice Figure 2 Circulators Mounted on Supply System Boiler Used In Configuration to Chiller System See Special Conditions Page 9 ...

Page 13: ...ass Piping Options Page 9 5 CONNECTING SUPPLY AND RETURN PIPING Figure 3 Bypass Piping Automatic Mixing Valve See Bypass Piping Options Page 9 BOILER WATER INLET ALTERNATE CIRCULATOR LOCATION TO SYSTEM FROM SYSTEM CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE 3 WAY MIXING VALVE AIR SEPARATOR HOSE BIB EXPANSION TANK Note Bypass connection not showing primary secondary pipi...

Page 14: ...14 5 CONNECTING SUPPLY AND RETURN PIPING Figure 5 Single Zone System With DHW Priority Figure 6 Multi Zone System with Circulators and DHW Priority ...

Page 15: ...15 5 CONNECTING SUPPLY AND RETURN PIPING Figure 7 Multi zone System With Zone Valves And DHW Priority With Circulator Figure 8 Multi zone System With Zone Valves And DHW Priority With Zone Valve ...

Page 16: ...tem 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 re sized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 1 Vent pipe must slope upward from boiler not less then in...

Page 17: ...icator must be in visible location following installation 5 Thermostat s heat anticipator must be adjusted to match total current draw of all controls associated with boiler during heating cycle 8 VENT DAMPER INSTALLATION INSTRUCTIONS Figure 9 Damper Installation Figure 10 Damper Location NOTE Refer to Figure 9 for steps 1 6 1 Place Vent Damper on or as close to vent outlet of boiler as possible D...

Page 18: ...traps bands brackets hangers or building structure components to prevent or dampen excessive vibrations and prevent strain on gas connection Boiler will not support piping weight Use thread joint compound pipe dope suitable for liquefied petroleum gas Install field sourced manual main shutoff valve ground joint union and sediment trap upstream of gas valve See Figure 11 Table 3 Gas Pressure Natura...

Page 19: ...isdiction Refer to National Electrical Code ANSI NFPA 70 Thermostat Installation 1 Install thermostat on inside wall about four feet above floor 2 NEVER install thermostat on outside wall 3 Do not install a thermostat where it will be affected by drafts hot or cold pipes sunlight lighting fixtures televisions a fireplace or a chimney 4 Check thermostat operation by raising and lowering thermostat ...

Page 20: ...M I Figure 12 Integrated High Limit Electronic Ignition Control 240008781 WARNING Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life ...

Page 21: ...21 11 WIRING DIAGRAM Figure 13 Integrated High Limit Electronic Ignition Control 240008781 PILOT FLAME SENSOR ...

Page 22: ...tructions To Turn Off Gas To Appliance and call qualified service technician or your gas supplier TO TURN OFF GAS TO THE APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Push in gas control knob slightly and turn clockwise to OFF DO NOT FORCE 4 Call qualified service technician WARNING If you do not follow these instruc...

Page 23: ...s are found have them repaired immediately Check and maintain circulators Refer to circulator manufacturer s instructions Inspect venting system at the start of each heating season Check vent pipe from boiler to chimney for signs of deterioration by rust or sagging joints Repair if necessary Remove vent pipe at base of chimney or flue and using mirror check vent for obstruction and verify vent is ...

Page 24: ...nd pilot for signs of corrosion rust or scale buildup Area around boiler must be kept clear and free of combustible materials gasoline and other flammable vapors and liquids Free flow of combustion and ventilating air to boiler and boiler room must not be restricted or blocked Inspect field sourced low water cutoffs annually or as recommended by low water cutoff manufacturer Flush float type low w...

Page 25: ...nus 0 3 inches water column from specified pressure Primary air adjustment is not necessary therefore air shut ters are not furnished as standard equipment Air shutters can be furnished on request where required by local codes or conditions CHECK SAFETY CONTROL CIRCUIT Ignition system safety shutoff device must be tested after placing boiler in operation Intermittent Pilot With main burner operati...

Page 26: ...heck sensing bulb is fully inserted in well and is not loose Refer to enclosed addendum for wiring instructions when using indirect hot water heater A 3 Adjusting Settings To discourage unauthorized changing of settings procedure to enter adjustment mode is required To enter adjustment mode press UP DOWN and I buttons simultaneously for three seconds Press and release I button until parameter requ...

Page 27: ...efore trial for ignition Appropriate alarm is sent OR Flame signal sensed out of sequence during post purge Appropriate alarm is sent OR Flame signal present when not expected Appropriate alarm is sent 17 Pilot valve diagnostics Pilot valve circuitry diagnostics during pre purge Current leakage detection Self check performed at start up again at beginning of heat cycle and during Wait for Recovery...

Page 28: ...ls must be reset through key buttons and display On retry models wait for retry or reset at thermostat Check for correct installation and wiring before replacing any component Control module cannot be repaired If it malfunctions it must be replaced Use only qualified service agent to service ignition systems 1 Perform checkout as first step in troubleshooting 2 Check troubleshooting guide to pinpo...

Page 29: ...lockout is reset after one hour if alarm reason disappears 63 Soft lockout maximum number of recycles exceeded Soft lockout 64 Soft Lockout electronics failure On board self diagnostics detected error Soft lockout 65 Over temperature error Sensor measured temperature in excess of maximum allowable limit Soft lockout Note Soft lockout time is 1 hour or manual reset Hard lockout requires manual rese...

Page 30: ...Replace damaged wire Check for cracked ceramic insulator which can cause short to ground and replace igniter sensor if necessary At gas valve disconnect main valve wire from MV terminal Turn on power and set thermostat to call for heat Pilot should light main burner will remain off because main valve actuator is disconnected Check pilot flame Verify it is blue steady and envelops 3 8 to 1 2 in 10 ...

Page 31: ...NOTES ...

Page 32: ...verride which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part o...

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