Pennco 15096HWD, 15045HWD Installation Guide

SERIES 15B CAST iRON GAS FIRED BOILERS

FOR FORCED HOT WATER

MODEL NUMBERS:
15045,15070,15096,

15120,15145,15175,
15195,15245,15295

PENNCO BOILERS
85 Middle Rd.
Dunkirk. NY 14048
Ph: (7161 366-5500

Fax: [phone]

www. ecrinternational.com

R International Brand Ic_/

An/SO 9001-2000 Certified Company

F N 1305026, Rev. 1.1 [03/05]

P/N# 1305026, Rev 1 1 [03/05] • Printed in USA. Made In USA

Safety Symbols and Warnings 3
Ratings and Data 4

Installation Procedure 5

Ventilation and Combustion Air 6
Connecting Supply and Return Piping 8

Vent Installation 10
Vent System Modification 10

Vent Damper Installation and Instructions 11
Connecting Gas Service 12
Electrical Wiring 12

Thermostat Installation 12
Lighting Instructions 15

Normal Sequence of Operation 17
General Instructions 18

Checking Gas Input Rate to Boiler 20
Boiler Exploded View 21
Replacement Parts Lists 22

Conversion Kits 27

MPORTANT: Read the following mstructlon_

OMPLETELY before mstalhngll

1. Keep boilerarea clear and free from combus-
tible materials, gasoline and other flammable
vapors and liquids.

2. DO NOT obstruct air openings to the boiler

room.

3. Modification, substitution or elimination

of factory equipped, supplied 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 quali-

fied installer.

KEEP THIS MANUAL NEAR BOILER )

, RETAIN FOR FUTURE REFERENCE

The following defined symbols are used throughout
this manual to notify the reader of potential hazards
of varying risk levels

nediCates an imminently hazardous situation_

hich, if not avoided, WiLL result in death or I

dicates a potentially hazardous situation I

hich, if not avoided, COULD result in death I

serious injury, j

5. TO THE INSTALLER - Leave all instructions
with the boiler for future reference.

6. When this product is installed in the Corn=
monwealth of Massachusetts the installation

must be performed by a Licensed Plumber or

k,Licensed Gas Fitter.

All installations of boilers and venting should
be done only by a qualified expert and in
accordance with the appropriate Pennco
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
poisonous gases such as carbon monoxide

which is odorless and invisible.

_J

J

i

dicates a potential hazardous situation I

hich, if not avoided, MAY result in minor or I

oderate injury. It may also be used to alert I

gainst unsafe practices, j)

(if _" ,,_ ,,

- o¢®@

C S A Certified Tested For 100 LBS

For Natural Gas Or Propane ASME

/_,,orkln g Pressure

15045 45,000 37,000 32,000 243 1 15
15070 70,000 57,000 50,000 365 2 15
15096 96,000 79,000 69,000 481 2 30
15120 120,000 98,000 85,000 603 3 30
15145 145,000 119,000 I03,000 7t9 3 30

15175 175,000 141,000 I23,000 829 4 30 31 49 7.2 80.5% 80%
15195 195,000 157,000 137,000 957 4 30 30 47 7.2 80.5% 80%
15245 245,000 197,000 171,000 1,t89 5 30 30 47 8.8 80.5% 80%
15295 295,000 237,000 206,000 1,368 6 60 30 47 I0.4 80.5% 80%

HAll boilers are design certified for installation on noncombustible floor.

--For installation on combustible floors use combustible floor kit

--Recommended chimney height 20 feet In special cases where conditions permit, chimney height may be reduced to 10 feet Refer to the latest revision of
NFGC part 11.

--Electric service to be 120 Volts, 15 Am ps, 60 Hz

--The MEA number for the this boiler is 39-86-E Vol VIII

§ For elevations above 2000 feet, ratings should be reduced at a rate of 4% for each 1000 feet above sea level
1 Base on 170° temperature in radiators

:1: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, Cast Iron Boiler Battery, High Limit Control, Vent Damper Relay, Theraltimeter Gauge, Circulator With Return Piping To Boiler,
Main Gas Burners, Combination 24 Volt Gas Control dnciudes Automatic Gas Valve, Gas Pressure Regulator, Automatic Pilot, Safety Shutoff, Pilot Flow Adjustment, Pilot

Filter), A.S.M.E. Relief Valve, Drain Cock, Spill Switch, Rollout Switch, Automatic Vent Damper Not Shown Are: Wiring Harness, Thermocouple, Nondinting Safety Pilot.
OPTIONAL EQUIPMENT: Intermittent Electbc Ignition PHot System.

"A"

.....kB" _

"C"

30 47 2.4 82% 80%
33 50 4.0 82% 80%
30 47 4.0 82% 80%
31 49 5.6 82% 80%

30 47 5.6 82% 80%

'_D"

25 5/16"

"Z'

. ,1 d ,

.oi

4"

5j ......

-o i

col

1 ]/4IIREURN

%

t

U U

15045 ½" 11.250 5.625 4.000 27.125 20.469 4.969 1¼"
15070 ½" 15.125 7.562 5.000 28.125 20.969 4.969 1¼"
15096 ½" 15.125 7.562 5.000 28.125 20.969 4.969 1¼"
15120 ½" 19.000 9.500 6.000 29.125 21.469 5.469 1¼"
15145 ½" 19.000 9.500 6.000 29.125 21.469 5.469 1¼"

15175 ½" 22.875 11.438 7.000 30.125 21.969 5.969 1¼"
15195 ½" 22.875 11.438 7.000 30.125 21.969 5.969 1¼"
15245 ¾" 26.750 13.375 8.000 31.125 22.469 6.969 1¼"
15295 ¾" 30.625 15.312 9.000 32.125 22.969 8.969 1¼"

* Propane Gas Inlet (All Units) 1/2"

1 1/4"

t

-oi

1. The installation must conform to the requirements
of the authority having jurisdiction or, in the absence
of such requirements, to the latest revision of the
National Fuel Gas Code, ANSI Z223. (Available from
the American Gas Association, 8501 E. Pleasant

Valley Road, Cleveland, Ohio 44134). Reference
should also be made to local gas utility regulations

and other codes in effect in the area in which the
installation is to be made. When installed in Canada:

The latest revision of the CAN 1-B 149.1 and/or B 149.2

Installation Codes for Gas-Burning Equipment and/or

local codes.

2. Where required bythe authority having jurisdiction,
the installation must conform to American Society

of Mechanical Engineers Safety Code for Controls
and Safety Devices ForAutomaticatly Fired Boilers,

ANSI/ASME No.CSD-1.

3. This boiler series is classified as a Category 1and
the vent installation shall be in accordance with Part

7 of the National Fuel Gas Code noted above when
installed in the United States. In Canada refer to

the CAN1-B149.1 and or B149.2 Installation Codes
for Gas-Burning Equipment. Also refer to applicable
provisions of the local building codes.

4. This boiler has met safe lighting and other
performance criteria with the gas manifold and control

assembly on the boiler per the latest revision of ANSI
Z21.13/CGA 4.9.

5. The boiler shall be installed such that the gas
ignition system components are protected from

water(dripping, spraying, rain, etc.)during appliance
operation and service, (circulator replacement,
condensate trap, control replacement, etc.).

7. Allow 24 inches at the front and right side for
servicing and cleaning.

8. When installed in a utility room, the door shoutd be

wide enough to allow the largest boiler part to enter,
or to permit replacement of another appliance such

as a water heater.

9. FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible

flooring special base part no. 325-2-8.00 must be

used. The boiler can not be installed on carpeting.
Minimum clearances to combustible construction

are:

TOP ................................................... 18 IN.

FRONT ...................................... ALCOVE *

FLUE CONNECTOR ........................... 6 IN.

REAR ................................................... 8 IN.

CONTROL SIDE .................................. 9 IN.

OTHER SIDE ....................................... 3 IN.

NOTE: Greater clearances for access should

supersede fire protection clearances.

* The definition of an Alcove is a three sided space with

no wall in front of the boiler. TheANSI standard for an
alcove is 18 inches from the front of an appliance to

the leading edge of the side walls as shown below.

MINIMUM CLEARANCES TO COMBUSTIBLE CON-

STRUCTION (AS SEEN FROM ABOVE)

6. Locate boiler on level, solid base as near the
chimney as possible and centrally located with respect

to the heat distribution system as practical.

_ 9"_ 3"

18"

1

COMBUSTION AIR REQUIREMENTS
(Minimum Square Inches Requirement)

i iii ,ii!o iiiB

15045 I00 10 I3 25
15070 I00 15 I9 38

15096 I00 20 25 50
15120 I25 25 32 63
15145 I50 30 38 75

15175 I75 35 44 88
15195 200 40 50 I00

15245 250 50 63 I25
15295 300 60 75 150

* A space whose volume is not less than 50 cubic feet per 1000 BTU per hour of all
appliances installed in that space (cubic feet of space = height x width x length)

** A space whose volume is less than 50 cubic feet per 1000 BTU per hour of a!t
appliances installed in that space (cubic feet of space = height x width x length)

1. Ventilation of the boiler room must be adequate to
provide sufficient air to properly support combustion
per the latest revision of the National Fuel Gas Code,

ANSI Z223.1 section 5.3.

i c,R

i3

4. When air for combustion and ventilation is from
inside buildings, the confined space shall be provided

with two permanent openings, one starting 12 inches
from the top and one 12 inches from the bottom of the
enclosed space. Each opening shall have a minimum
free area of I square inch per 1000 BTU per hour of

the total input rating of all appliances in the enclosed
space, but must not be less than 100 square inches.
These openings must freely communicate directly
with other spaces of sufficient volume so that the

combined volume of all spaces meets the criteria

for an unconfined space. (Figure 1)

ANSI Z223.1 section 1.7), the boiler area
should be considered as a confined space.

In this case air for combustion and ventilation

shall be provided according to Step 5. Ifthere

is any doubt, install air supply provisions in

accordance with the latest revision of the

National Fuel Gas Code.

3. When a boiler is installed in an unconfined
space in a building of unusually tight

construction, air for combustion and
ventilation 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.
Ducts may be used to convey makeup air

from the outdoors and shall have the same
cross-sectional area of the openings to which

they are connected.

I FIGURE 1 !

2. When a boiler is located in an unconfined space in a
building or conventional construction frame, masonry
or metal building, infiltration normally is adequate to
provide air for combustion and ventilation. However,
if the equipment is located in a building of unusually
tight construction (See the National Fuel Gas Code,

5. When the boiler is installed in a confined space
and all air is provided from the outdoors the confined

space shall be provided with one or two permanent
openings according to methods A or B. When ducts

are used, they shall be of the same cross sectional
area as the free area of the area of the openings

to which they connect. The minimum dimension of

rectangular air ducts shall be not less than 3 x 3
inches or 9 square inches.

A. When installing two openings, one must

commence within 12 inches from the top and

the other within 12 inches from the bottom of
the enclosure. The openings shall communicate

directly, or by ducts, with the outdoors or spaces
(crawl or attic) that freely communicate with the
outdoors. One of the following methods must

be used to provide adequate air for ventilation
and combustion.

1. When directly communicating with the

outdoors, each opening shall have a minimum

free area of 1 square inch per 4,000 BTU per

hour of total input rating of all equipment in
the enclosure. (Figure 2)

3. If horizontal ducts are used, each opening
and duct shall have a minimum free area 1

square inch per 2,000 BTU per hour of total
input rating of all appliances in the enclosed
space. (Figure 4)

CHIMNEY

OR

GAS VENT

CH MNEY

OUTLET/ J

AIR

VENTFIPE

............... VENTLATIOn

VENTLATON LOUVERS

(EACH ENDQF ATTIC:}

LOUVEnSFort

\

IFGORE21

2. When communicating with the outdoors by
means of vertical ducts, each opening shall

have a minimum free area of 1 square inch per

4,000 BTU per hour of total input rating of all

appliances in the enclosed space. (Figure 3)

VFNT LAT ON LOUVERS

(EACH END OF ATTIC} ....

CHIMNEY

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".......ii ii

i!i}!}i}i}iEJ}i:}iii!iiiiii}!iiiiiiii¸:}i!}i}i}i}i:}ii{¸i¸i!!i¸ii! iiii!i!!iiiiiE!i}iiikfi!!¸U}:}i!}:::i

B. One permanent opening, commencing within
12 inches of the top of the enclosure, shall be
permitted where the equipment has clearances

of at least 1 inch from the sides, 1 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

vertical 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 I square inch per 3000 Btu
per hour of the total input rating of all equipment

located in the enclosure. The free area must
be no less than the sum of the areas of all vent

connectors in the confined space.

[]ZI } i IZ]_ZZZIiZiZZZI i IZ]IZZZILZI i !

6. In calculating free area using louvers, grilles or

screens for the above, consideration shall be given
to their blocking effect. Screens used shall not be

smatter than 1/4 inch mesh. If the free area through

a design of louver or grill is known, it should be used
in calculating the size opening required to provide

the free area specified. If the design and free area

is not known, it may be assumed that wood louvers

will have 20-25% free area and metal louvers and
grilles will have 60-75% free area. Louvers and grilles

should be fixed in the open position or interlocked
with the boiler so they are opened automatically
during the boiler operation.

MPORTANT: Circulators in the foltowing"_

tustrations are mounted on the system supply I
ide, but mounting on the system return side is I

!soaccep!ab!ep! e: )

1. Connect supply and return piping as suggested in
Figure 5 when the boiler is used in connection with

refrigerated systems•

P_ESSU_E

/ VALVE

G_TE

,,VALVE

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i

,,_TE

:E:

vA,_ ,

E _SCN

5. Hot water boilers and system must be filled with

water and maintained to a minimum pressure of 12

pounds per square inch.

6. Bypass piping is an option which gives the ability

to adjust the supply boiler water temperature to fit
the system or the condition of the installation• This

method of piping, however, is not typically required

for baseboard heating systems• Typical installations
where bypass piping is used are as follows:

A. This method is used to protect boilers from

condensation forming due to low temperature
return water• Generally noticed in large converted

gravity systems or other large water volume

systems• (Figure 6)

BYPASS PIPING

suPP

FIGURE 5 I

A. The chilled medium MUST BE PIPED IN
PARALLEL with the boiler•

B. Use appropriate valves to prevent the chilled
medium from entering the heating 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.

C. Maintain a minimum clearance of one inch
to hot water pipes•

2. When the boiler is connected to heating coils located
in air handling units where they may be exposed to

refrigerated air circulation, the boiler piping system

MUST BE supplied with flow control valves or other

automatic means to prevent gravity circulation of the
boiler water during the cooling cycle.

........' :i_ii

_ESSU_E

,'_V,kp,'E

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::. , :: ,

B

_ALTE C _

PUROE
V_LVE

IF'GURE01

B. These methods are used to protect systems
using radiant panels and the material they
are encased in from high temperature supply

water from the boiler and protect the boiler from

condensation. (Figures 7-8)

NOTE#l: When using bypass piping, adjust

vatvesAand B until desired system temperature

is obtained•

NOTE#2: Bypass loop must be same size piping
as the supply and return piping.

3. Hot water boilers installed above radiation level
must be provided with a low water cut-off device•

4. When a boiler is connected to a heating system

that utilizes multiple zoned circulators, each circulator

must be supplied with a flow control valve to prevent

gravity circulation•

7. Installation using circulators and zone valves are
shown in Figures 9-10. Forfurther piping information
refer to the I=B=R Installation and Piping Guide•

MIXING VALVE PIPING

FL

S,STEr4

, T=_,IPE_£TURE

S,sUC_=

=r,ESSURE

_EDU,S,r_a

GATE

,h,ALVE

4; -.

,_L',

"/AL_'E

i

PRIMARY SECONDARY PIPING WITH BYPASS

C_RCU_£TC,_

S_ST_4

M_x _ TE_IPERATURE

,_LVE

_LC,W
V£LVE _,

a£uaE

_L,'E

O_E

P ESSdRE
R_DUO O

VA:,

[ FIGURE 7]

HOT ¢_/_TER INLET
OJTLET x

THER /_L
TR/_p

qRING FOR
THER; O TAT

Pur!P "_O TROL

(OLD %ATER

PURaE _1

BOILER INSTALLATION WITH CIRCULATORS

FLO'A

CONTRC L

/_L FS

] RELEFVALVE

PURG
V_LvE

> i

T/_NK CR

S_STEM
RETgRN

PrPiNG

t FIGURE 9 J

:4:#.

FEED

,',ATER

GATe /VALVE

/VALVE

FIGURE 8 ]

PRESSiJRL

REDdCING

ilia'ZZZZZ£

pL_iRC_E ,_

V£LVE

PURGE

HOT CATER
OUTLET

THERMAL
TR#P

f\

CRNG FOR

THERMOSTAT /
PUMP CONTROL

BOILER INSTALLATION WITH ZONE VALVES

COLD W_TER

INLET

PURGE

'/_L' E

T_NK ZONE

,_L'E

RELIEF /_L,E

S_'3TEM

RETdRN
PIPING

FIGURE I0]

C:_R ,!

FEED

(,_TER

PRcSSiJRE

GATe /VALVE

/VALVE

REDUCING

/

CHECK

VALVE [ \ /

EXDA 51ON

TANK

ill

PURGE
ALE