PENNCO 15045 Technical Document

SERIES 15B CAST iRON GAS FIRED BOILERS
MODEL NUMBERS:
15045,15070,15096,
15120,15145,15175,
15195,15245,15295
FOR FORCED HOT WATER
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
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
idicates 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)
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.
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. J
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
- o¢®@
(if _" ,,_ ,,
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
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%
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"
.oi
5j ......
-o i
col
U U
'_D"
25 5/16"
"Z'
4"
. ,1 d ,
1 ]/4 IIREURN %1 1/4"
t
t
-oi
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. 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 1 and
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.).
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.
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)
_ 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
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,
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.
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)
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)
CH MNEY VENTLATON LOUVERS
(EACH ENDQF ATTIC:}
OUTLET/J
AIR
VENTFIPE
............... VENTLATIOn
LOUVEnSFort
\
IFGORE21
2. When communicating with the outdoors by
means of vertical ducts, each opening shall
have a minimum free area of 1square inch per
4,000 BTU per hour of total input rating of all
appliances in the enclosed space. (Figure 3)
CHIMNEY
VFNT LAT ON LOUVERS
(EACH END OF ATTIC} ....
[]ZI } i IZ] _ZZZIiZiZZZI i IZ] IZZZI LZI i !
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
i • y" i_ii
".......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.
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
i
:E:
vA,_ ,
_'_tE E _SCN
,,_TE
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•
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
........' :i_ii _ESSU_E
,'_V,kp,'E
.... :ii ....
::. , :: ,
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)
2. When the boiler isconnected 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.
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
"/AL_'E
GATE
,h,ALVE
4; -.
i
,_L',
PURaE _1
[ FIGURE 7]
PRIMARY SECONDARY PIPING WITH BYPASS
M_x _ TE_IPERATURE
a£uaE
C_RCU_£TC,_ _LC,W
V£LVE _,
S_ST_4
,_LVE P ESSdRE
R_DUO O
VA:,
O_E
_L,'E
FIGURE 8 ]
PURGE
V£LVE
BOILER INSTALLATION WITH CIRCULATORS
> i
FLO'A
CONTRC L
/_L FS :4:#. PRESSiJRL
REDdCING
GATe /VALVE
/VALVE
(OLD %ATER
HOT ¢_/_TER INLET
OJTLET x
THER /_L
TR/_p
qRING FOR
THER; O TAT
Pur!P "_O TROL
T/_NK CR
S_STEM
RETgRN
PrPiNG
] RELEF VALVE
PURG
V_LvE
FEED
,',ATER ilia'ZZZZZ£
pL_iRC_E ,_
t FIGURE 9 J
BOILER INSTALLATION WITH ZONE VALVES
PRcSSiJRE
REDUCING
GATe /VALVE
/VALVE
HOT CATER
OUTLET
COLD W_TER
INLET
f\
THERMAL
TR#P
CRNG FOR
THERMOSTAT /
PUMP CONTROL
T_NK ZONE
,_L'E
S_'3TEM
RETdRN
PIPING
C:_R ,!
PURGE
'/_L' E
RELIEF /_L,E
FIGURE I0]
FEED
(,_TER
/
CHECK
VALVE [ \ /
EXDA 51ON
TANK
ill
PURGE
ALE

II installations of boilers and venting should be done only by a qualified expert and in accordance
ith the appropriate Utica Boilers manual. Installing or venting aboiler or any other gas appliance
ith improper methods or materials may result in serious injury or death due to fire otto asphyxiation
om poisonous gases such as carbon monoxide with is odorless and invisible. J
his boiler shall not be connected to any portion of a mechanical draft system operating und
_positive pressure.
1 The vent pipe must slope upward from the boiler
not less then I/4 inch for every 1 foot to the vent
terminal
2 Horizontal portions of the venting system shall
be supported rigidly every 5 feet and at the elbows
No portion of the vent pipe should have any dips
or sags
3 This boiler series is classified as a Category 1
and the vent mstallahon shall be m accordance with
chapter 7 and 10 of the Nahonal Fuel Gas Code
noted above or apphcable provisions of the local
building codes
4 Inspect chimney to make certain it is constructed
according to NFPA 211 The vent or vent collector
shall be Type B or metal pipe having resistance to
heat and corrosion not less than that of galvanized
sheet steel or aluminum not less than 0 016 inch
thick (No 28 Ga)
5 Connect flue pipe from draft hood to chimney
Bolt or screw joints together to avoid sags Flue pipe
should not extend beyond reside wall of chimney
Do not install manual damper in flue pipe or reduce
size of flue outlet except as prowded by the latest
rewslon ofANSIZ223 1 Protect combustible celhng
and walls near flue pipe with fireproof insulation
Where two or more apphances vent into a common
flue, the area of the common flue must be at least
equal to the area of the largest flue plus 50 percent
of the area of each additional flue
When an existing boiler is removed from a common
venting system, the system is hkely to be too large
for the proper venting of the apphances still con-
nected to it If this situation occurs, the following test
procedure must be followed
At the time of removal of an existing boiler, the fol-
lowing steps shall be followed with each appliance
remaining connected tothe common venting system
placed m operation, while the other apphances re-
maining connected to the common venting system
are not in operation
A Seal an unused opening in the common
venting system
B Visually mspectthe venting system for proper
size and horizontal pitch and determine there
is no blockage or restriction, leakage, corrosion
and other deficiencies which could cause an
unsafe condition
C Insofar as is practical, close all building doors
and windows and all doors between the space
in which the appliances remaining connected
to the common venting system are located and
other spaces of the building Turn on clothes
dryers and any other apphance not connected
tothe common venting system Turn on any ex-
haust fans, such as range hoods and bathroom
exhausts, so they operate at maximum speed
Do not operate a summer exhaust fan Close
fireplace dampers
D Place in operation the apphance being re-
spected Follow the hghtmg mstruchons Adjust
thermostat so apphance will operate continu-
ously

E. Test for spitlage atthe draft hood retief opening
after 5 minutes of main burner operation. Use
the flame of a match or candle, or smoke from
a cigarette, cigar or pipe.
F. After it has been determined that each appli-
ance remaining connected to a common venting
system properly vents when tested as outlined
above, return doors, windows, exhaust fans,
fireplace dampers and any other gas burning
appliances to their previous condition of use.
G. Any improper operation of the common vent-
ing system should be corrected so the installation
conforms with the latest revision of the National
Fuel Gas Code, ANSI Z223.1. When resizing
any portion of the common venting system, the
common venting system should be resized to
approach the minimum size as determined us-
ing the appropriate tables in appendix G in the
latest revision of the National Fuel Gas Code,
ANSI Z223.
NOTE: Refer to Figure 11 for steps 1-7.
!NSTALL R
HOOK JP
DAMPR
,MOTOR
VENT
• DAM_'ER
VENT
OI.TLET
INSTALL R
OOK U?
/"
CONTROL
VENT DAMPER
HAR ESS
H! LIM,F _'_
CONTROL
I FIGURE 111
FACTORY WRD
1. Place Vent Damper on or as close to vent outlet
of boiler as possible. (Figure 12)
2. Remove Vent Damper Motor cover.
3. Remove Iocknut from connector at the end of the
Damper wire harness.
4. Feed Damper and Damperwire harness connectors
through bracket hole on Damper Motor frame.
5. Replace and tighten Iocknut onto Damper wire
harness connector.
6. Plug Damper connector into socket on Damper
Motor frame.
7. Replace Damper Motor cover and wire Damper
in accordance with Figure 11.
1. Ensure that only the boiler is serviced by the Vent
Damper. (Figure 12)
LJIX #C:C:EPT,_ BLE
E)#I PER LOC#T ONS
HOT d'/ATER HEATER
IFIGURE 121
2. Clearance of not less than 6 inches between Vent
Damper and combustible material must be main-
tained. Additional clearance should be allowed for
service of Vent Damper.
3. Vent Damper must be in the open position when
appliance main burners are operating.
4. The Vent Damper position indicator must be in a
visible location following installation.
5. The thermostat's heat anticipator must be adjusted
to match the total current draw of all controls associ-
ated with the boiler during a heating cycle.