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.

1. Connectgas servicefrom meterto controlas-
semblyin accordancewithANSIZ223.1andlocal
codesor utility.A groundjoint unionshouldbe in-
stalledforeasyremovalofgascontrolforservicing.
Adriplegor trapmustbe installedatthebottomof
averticalsectionofpipingatthe inletto theboiler.
Apipecompoundresistanttothe actionof liquified
petroleumgasesmustbeusedonallthreadedpipe
connections.Checkwiththelocalutilityfor location
ofmanualshutoffvalveif required.(Figure 13)
INS IALL MANUAL VALVE %,/2/ HIM
6 #_. (183cm) EJ]F FH_ BOILER Z_ND
b £t (]5_crn) AB_VE T,_ FL NrqR
_/'FIE_E REOUIRED BY LEI]CAL CE]DE3
.3" (8 c_,)
_--- DRIP LEG
GAS CDNTRD ZNi ET
[Fl U .Sq
MINUMUM
2. The gas line should be of adequate size to prevent
undue pressure drop and neversmalter than the pipe
size of the main gas control valve. (See Chart)
MAXIMUM CAPACITY OF PiPE IN CUBIC FEET OF GAS/HOUR
(Gas Pressure = 0.5 psig or less, Pressure Drop = 5 in. w/c)
I0 175 360 680 1400
20 120 250 465 950
30 97 200 375 770
40 82 170 320 660
60 66 138 260 530
80 57 118 220 460
100 50 I03 195 400
Foradditionalinformation referto"Table C"ofthe National Fuel Gas
Code Handbook.
3. To check for leaks in gas piping, use a soap and
water solution or other approved method.
4. Disconnect boiler from gas supply piping system
during any pressure testing of the gas piping. After
reconnecting, leak test gas connection and boiler
piping before placing boiler back into operation.
SEE WIRING DIAGRAMS ON THE FOLLOWING_
WO PAGES FOR DETAILS. j/
Electrical wiring must conform with the National
Electrical Code, ANSI/NFPA No. 70-1990 when
installed in the United states, the CSAC22.1 Canadian
Electrical Code, Part 1, when installed in Canada
and/or the local authority having jurisdiction.
_h
IMPORTANT: Install a fused disconnect switchh
Lbetween boiler and meter at a convenient location S
1. Thermostat should be installed on an inside wall
about four feet above the floor.
2. NEVER install a thermostat on an outside wall.
3. Do not install a thermostat where it witl 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 setting as required to start and stop the
burners.
5. Instructions for the final adjustment of the thermostat
are packaged with the thermostat (adjusting heating
anticipator, calibration, etc.)

THERMOSTAT
L 7 r J
I
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I
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I
0 I
I
HONEYWELL
L4080B
--1_ TR
vtA E
CAMPER CONTROL
BOARD
NEUTRAL 115 VAC
POWER
HOT SUPPLY
OVER CURRENT & PROTECTED
DESCONNECT

HONEYWELL
L4OSOB v 1 V_aR2°4
THERMOSTAT_ _>_P
L]'_]rJ I1_ vR°3°°
O ssw RSW
_oo.
NEUTRAL 115 VAC
POWER
__ HOT SUPPLY
OVER CURRENT & PROTECTED
DISCONNECT
--4<
--X<
<4
--<4
1
L
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b
L
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INTERMITTENT PILOT CONTROL
11234 s 6 9I
RToT_I_KT_TIBK _09_TO PILOT
| | J w l_ wl,u: J GAS VALVE
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_ VR8304M

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. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.
For Your Safety, Read Before Operating!!
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
the appliance by hand.
B. Before operating, smell all around the appliance
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle
on the floor. JA CAUT,O.
WHAT TO DO IF YOU SMELL GAS
* Do not try to light any appliance.
* Do not touch any electrical switches; do not
use any phones in your building.
*Immediately 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.
C. Use only your hand to push in or turn the gas 6. Turn
control knob. Never use tools. If the knob wilt not "OFF."
1. STOP! Read the safety information in the User's
information Manual.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
the pilot by hand. (Figure 14)
(i:/_ _ iN[ :-"
INLI [ F RE S?UI_E
G F'_._
I]LJ I I2 I
gas control knob clockwise_ to

6. Wait (5) minutes to clear out any gas. If you then
smell gas, STOP! Follow "What To Do If You Smell
Gas" in the safety information above. If you don't
smell gas, go on to the next step.
7. Turn gas control knob counterctockwisef-'_,,
to "ON."
1. STOP! Read the safety information at the beginning
of these instructions.
2. Set the thermostat to the lowest setting.
8. Turn on all electric power to the appliance. 3. Turn off all electric power to the appliance.
9. Set thermostat to desired setting.
10. If the appliance wilt not operate, follow the
instructions "To Turn Off Gas To Appliance" on page
13 and call a qualified service technician or your
gas supplier.
A. Read the warning at the beginning of "Lighting
Instructions" on page 15.
B. This appliance has a pilot which must be lighted by
hand. When lighting the pilot, follow these instructions
exactly.
C. Before lighting, smell all around the appliance area
for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
See page 15 for "What To Do If You Smell Gas."
D. Use only your hand to push in or turn gas control
knob or reset button. Never use tools. If the knob or
reset button 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.
E. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.
4. Remove access panel and burner door.
5. Turn gas control knob clockwise i_to "OFF."
(Figures 15 and 16)
/i//
FIGURE t5]
PRESSURE RE@ULATOR
INLET OUTLET
PRESSURE PRESSURE
TAP\ TAP
GA£
GAS NUT FT
INLET
PILOT FLOW ADS SCREW
BENEATH COVER SCRE%J
@AS CONTROL KNOB
IFIGURE 161
NOTE: Some gas control knobs cannot be turned
from "PILOT" to "OFF" unless knob is pushed in
slightly. DO NOT FORCE,
6. Wait (5) minutes to clear out any gas. If you then
smell gas, STOP! Follow "What To Do IfYou Smell
Gas" on page 15. If you don't smell gas, go to the
next step.

7. Find pilot. Followmetaltube from gas control.
Dependingonthemodeloftheboiler,pilotiseither
mountedon the base or on one of the burner
tubes.
8. Turn gas control knob counterclockwise f'_'_,
to "PILOT."
9. Push in gas control knob or reset button if so
equipped, all the way in and hold. Immediately light
the pilot with a match. Continue to hold the gas control
knob or reset button in for about 1 minute after the
pilot is lit. Release knob or button, and it will pop up
back up. Pilot should remain lit. If it goes out, repeat
steps 5 through 9.
* If knob or button does not pop up when released,
stop and immediately call a qualified service
technician or your gas supplier.
* If the pilot will not stay lit after several tries, turn
the gas control knob clockwise ,_'_tto "OFF."
See note on page 16 and call a qualified service
technician or your gas supplier.
10. Replace burner door.
11. Turn gas control knob counterclockwise f_"_'\
to "ON."
12. Replace access panel.
13. Turn on all electric power to the appliance.
14. Set thermostat to desired setting.
1. Set the thermostat to lowest setting.
2. Turn offatl 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 a qualified service technician.
On a call for heat, the thermostat will actuate,
completing the circuit to the control. The completed
circuit to the control will first activate the circulator
and damper which will close an end switch inside
the damper. This action will complete the circuit to
the ignition system and ignition wilt take place.
In the event the boiler water temperature exceeds
the high limit setting on the boiler mounted high
limit control, power will be interrupted between the
control system and the ignition system. The power
will remain off until the boiler water temperature
drops below the high limit setting. The circulator wilt
continue to operate under this condition until the
thermostat is satisfied.
In the event the flow of combustion products through
the boiler venting system becomes blocked, the
blocked vent safety switch will shut the main burner
gas off. Similarly, if the boiler flueway becomes
blocked, a flame rollout safety switch will shut the
main burner gas off. (Figure 17) If either of these
conditions occur, DO NOT ATTEMPT TO PLACE
THE BOILER BACK INTO OPERATION. CONTACT
A QUALIFIED SERVICE AGENCY.
FOR MODELS:
i5123 THRCL, GH 15275
FOR h,/ODEL3:
15045 THROUGH 1509_
"\ "\\BLOCKED VENT
5A_EIY 5WIICd
INTEGR/\L D R/_ FT /_
H ( ):1[
BASE.
FOR MODELS: 150 8 &152P5 //
IACKET BAS
PANEL
\. "\MAN FCLD
ROLL OdT 3A_ ETI'j /
SWITCH
IFIGURE 171

Before seasonal start-up, have a competent service
agency check the boiler for soot and scale in the
flues, clean the burners and check the gas input rate
to maintain high operating efficiency.
iAc o,,o.Ai
abel all wires prior to disconnection when I
ervicing controls. Wiring errors can cause I
proper and dangerous operation.
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 system. Check the entire
piping system and, if any leaks appear, have them
repaired.
Many circulators like the one pictured in Figure 18
require periodic servicing. The motor usually has
openings at each end to lubricate the bearings.
Put about one half teaspoon of SAE 20 or 30 non-
detergent motor oil in each opening twice a year.
The venting system should be inspected at the start
of each heating season. Check the vent pipe from
the boiler to the chimney for signs of deterioration by
rust or sagging joints. Repair if necessary. Remove
the vent pipe at the base of the chimney or flue and
using a mirror, check vent for obstruction and make
certain the vent is in good working order.
The boiler flue gas passageways may be inspected
by a light and mirror. Remove the burnerdoor. (Figure
17) Place a trouble lamp in the flue collector through
the draft relief opening. With the mirror positioned
above the burners, the flue gas passageways can
be checked for soot or scale.
The following procedure should be followed to clean
the flue gas passageways:
1. Remove the burners from the combustion
chamber by raising the burners up from the
manifold orifices and pulling toward the front of
the boiler. (Figure 17)
2. Disconnect the vent pipe from the draft
hood.
FIGURE 18J
Do Not Over Oil!!
Many circulators have an oil opening for the shaft
bearing. This should be oiled at the same time for quiet
operation. Follow the manufacturer's instructions for
oiling the shaft bearing.
3. Remove the top jacket panel.
4. Remove the combination flue collector and
draft hood from the boiler castings by loosening
the nuts on the hold down bolts located on each
side of the collector. (Figure 17)
5. Place a sheet of heavy paper or similar
material over the bottom of the base and brush
down the flue passageways. The soot and scale
will collect on the paper and is easily removed
with the paper.
With the paper still in place in the base, clean
the top of the boiler castings of the boiler putty
or silicone used to seal between the castings
and flue collector. Make certain that chips are
not lodged in the flue passageways.
When the cleaning process is complete, restore the
boiler components to their original position. Use
boiler putty or IS-808 GE silicone (available from a
Pennco distributor) to seal around the flue collector
and boiler castings.

Avisualcheckof themainburnerandpilotflames
shouldbe madeatthestartof the heatingseason
and againin mid-season.The mainburnerflame
shouldhaveaweltdefinedinnerbluemantelwitha
lighterblueoutermantel,Checktheburnerthroats
andbumerorificesforlintordustobstruction.(Figures
19 and 20)
LIGHT BLUE OUTER MANTEL
FIGURE 19]
\
iFIGURE 20]
The pilot flame should envelop _8 to ½ inch of the tip
of the pilot thermocoupte, ignition/sensing electrode
or mercury sensor, (Figure 21)
PZLOT FLAME MAKN :BURNER
/
FIGURE I8]
To adjust the pitot flame, remove the pilot adjustment
cover screw (Figures 14-16 on pages 15-16) and
turn the inner adjustment screw counterclockwise
f_'_ to increase or clockwise _"_ to decrease
pilot flame, Be sure to replace cover screw after
adjustment to prevent possible gas leakage,
The burners and pilot should be checked for signs
of corrosion, rust or scale buildup. The area around
the boiler must be kept clear and free of combustible
materials, gasoline and other flammabte vapors and
liquids.
The free flow of combustion and ventilating air to
the boiler and boiler room must not be restricted or
blocked,
It is recommended that a qualified service agency
be employed to make an annual inspection of the
boiler and heating system, They are experienced in
making the inspections outlined above, and, in the
event repairs or corrections are necessary, trained
technicians can make the proper changes for safe
operation of the boiler,

Gas input to the boiler can be adjusted by removing the
protective cap on the pressure regulator (Figures 14-
16 on pages 15-16) and turning the screw clockwise
_"_to increase input and counterclockwise
f-'_'-, to decrease input. Natural gas manifold
pressure should be set at approximately 3.5 inches
water column. Propane gas manifold pressure should
be set at approximately 11 inches water column.
These manifold pressures are taken at the outlet
side of the gas valve. (Figures 15 and 17 on pages
16-17) To check for proper flow of natural gas to the
boiler, divide the input rate shown on the rating plate
by the heating value of the gas obtained from the
local gas company. This will determine the number
of cubic feet of gas required per hour. With all other
gas appliances off, determine the flow of gas through
the meter for two minutes and multiply by 30 to get
the hourly rate. Make minor adjustments to the gas
input as described above.
Burner orifices should be changed ifthe 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 satisfactory operation.
1. Pilot: With main burner operating, turn the
pilot gas adjusting screw clockwise _
until pilot gas is turned off. (Figures 14-16 on
pages 15-16) Within 90 seconds the main gas
control should close, shutting off the gas to the
main burner.
2. High Limit Control (Figure 22): Remove
cover and note temperature setting. Decrease
this setting to minimum and operate boiler. When
the boilerwater temperature exceeds the control
temperature setting, the control will open the
circuit, closing the automatic main gas valve.
Front Lower
Gas Valve
IFIGURE 221

I Jacket Front Lower
2 Control
3 Jacket Front Upper
4 Jacket Side Right
5 Left End Section
6 Push Nipple
7 Jacket Top
8 Damper
9 Baffle
I0 Center Section
I1 Jacket Back To Flue
I2 Flue Coltecter
13 3raft Hood
14 Restrictor
15 Jacket Back
16 Right End Section
17 Jacket Side Left
18 Relief Valve
19 Dipe Nipple
20 _ipe Elbow
21 .Circulator
22 nipe Nipple
23 nipe Tee
24 3rain Cock
25 Pipe Nipple
26 Pilot Spark Control
27 Therattimeter Gauge
28 High Limit Control
29 Pipe Bushing
30 ¢7elt
31 Tray
32 Base
33 Burner Door
34 Gas Valve
35 Manifold
36 Burner Tube