Dunkirk PSB-3D Installation, Operation & Maintenance Manual
Plymouth steam series 2 gas-fired steam boilers
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- Installation instructions manual (29 pages) ,
- Installation, operation & maintenance manual (32 pages)
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An ISO 9001-2008 Certified Company
PLYMOUTH STEAM SERIES 2
STEAM BOILERS
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
MODEL PVSB
Continuous Pilot
ECR International, Inc.
2201 Dwyer Avenue,
Utica NY 13504-4729
www.ecrinternational.com
GAS-FIRED
MODEL PSB
Electronic
Intermittent
Ignition
H
P/N# 14683003, Rev. A [07/2011]
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Summary of Contents for Dunkirk PSB-3D
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Page 1: Steam Boilers
PLYMOUTH STEAM SERIES 2 GAS-FIRED STEAM BOILERS INSTALLATION, OPERATION & MAINTENANCE MANUAL MODEL PVSB Continuous Pilot MODEL PSB Electronic Intermittent Ignition ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13504-4729 www.ecrinternational.com P/N# 14683003, Rev. A [07/2011] An ISO 9001-2008 Certified Company... -
Page 2: Table Of Contents
TABLE OF CONTENTS Safety Symbols ......................3 Boiler Ratings And Capacities ................... 4 Before You Start ......................5 Locating The Boiler ......................5 Fresh Air For Combustion....................6 Installation - System Piping ..................... 7 Chimney And Vent Pipe Connection ................. 10 Vent Damper Operation .................... -
Page 3: Safety Symbols
SAFETY SYMBOLS The following defi ned symbols are used throughout this READ ALL INSTRUCTIONS BEFORE INSTALLING. manual to notify the reader of potential hazards of varying risk levels. WARNING DANGER Keep boiler area clear and free from Indicates a hazardous situation which, if combustible materials, gasoline and other not avoided, WILL result in death or serious fl... -
Page 4: Boiler Ratings And Capacities
Capacity Rating w/Vent *MBH Rating Rating Sq. *MBH Rating Diameter Width Vent Damper *MBH *MBH Sq. Ft. Damper *MBH *MBH Radiation PSB-3D PVSB-3D 11¼ PSB-4D PVSB-4D 112.5 14½ PSB-5D PVSB-5D 17¾ PSB-6D PVSB-6D 187.5 PSB-7D PVSB-7D 24¼ PSB-8D PVSB-8D 262.5 27½... -
Page 5: Before You Start
BEFORE YOU START Check to be sure you have the right size boiler before These boilers are designed for use in closed heating systems starting the installation. See rating and capacity table on where all of the steam is returned to the boiler as condensate previous page. -
Page 6: Fresh Air For Combustion
FRESH AIR FOR COMBUSTION Known Air Infi ltration Rate. See Table 1 for WARNING space with boiler only. Use equation for multiple appliances. Do not use an air infi ltration rate Air openings to combustion area must not (ACH) greater than 0.60. be obstructed. -
Page 7: Installation - System Piping
INSTALLATION - SYSTEM PIPING • Use pipe suitable for temperatures of 375°F (191°C) WARNING or greater. Burn and scald hazard. Safety valve could • Individual boiler discharge piping shall be discharge steam or hot water during independent of other discharge piping. operation. - Page 8 INSTALLATION - SYSTEM PIPING Recommended near boiler piping for gravity return System takeoffs from the header must never be bull- systems is shown in Figure 5. This confi guration uses headed. If the steam main goes in two directions, there one supply and one return tapping.
- Page 9 INSTALLATION - SYSTEM PIPING For gravity return systems, the bottom of the lowest Figure 4 - Chilled Water Piping steam carrying pipe, be it a dry return, or the end of the steam main, must be at least 28” above the normal water level line on the right side of the boiler.
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Page 10: Chimney And Vent Pipe Connection
CHIMNEY AND VENT PIPE CONNECTION For boilers for connection to gas vents or chimneys, Do not connect to fi replace fl ue. vent installations shall be in accordance with "Venting of End of vent pipe must be fl ush with inside face of Equipment", of the National Fuel Gas Code, ANSI Z223.1/ chimney fl... -
Page 11: Vent Damper Operation
CHIMNEY AND VENT PIPE CONNECTION Test for spillage at the draft hood relief opening after Figure 5 - Typical Masonry Chimney Requirements 5 minutes of main burner operation. Use the fl ame of a match or candle, or smoke from a cigarette, cigar or pipe. -
Page 12: Gas Supply Piping
VENT DAMPER OPERATION For safe, effi cient operation, the vent damper and all DO NOT turn damper open manually or motor fl ue product carrying areas of the appliance must be damage will result. Set switch to “AUTOMATIC checked annually by you, with particular attention OPERATION”... - Page 13 GAS SUPPLY PIPING Propane Installation Figure 9 - Gas Piping At Boiler • Connections by licensed propane dealer only. • Use two stage regulator provided by propane supplier. • Propane supplier should check piping. Leak Check Gas Piping Pressure test boiler and gas connection before placing boiler in operation.
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Page 14: Electrical Wiring
ELECTRICAL WIRING ELECTRIC POWER SUPPLY Set heat anticipator at 0.4 amps for boilers equipped with standing pilot, and at 0.6 amps for boilers equipped with All electrical work must conform to local codes, as well as the intermittent ignition. The 24 volt thermostat leads shall be National Electrical Code, ANSI/NFPA-70. - Page 15 ELECTRICAL WIRING Figure 10A - Isolation Relay Wiring For Steam Figure 10B - Isolation Relay Wiring For Steam Boilers With Float Type Low Water Cut Off And Using Boilers With Probe Type Low Water Cut Off And An Electronic Thermostat Using An Electronic Thermostat...
- Page 16 ELECTRICAL WIRING Figure 11 - Wiring Diagrams For Boilers With PS-802 Probe Type Low Water Cut-Off INTERMITTENT IGNITION If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent.
- Page 17 ELECTRICAL WIRING Figure 12 - Wiring Diagrams For Boilers With PS-802 Probe Type Low Water Cut-Off STANDING PILOT If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent.
- Page 18 ELECTRICAL WIRING Figure 13 - Wiring Diagrams For Boilers With 67D-1 Float Type Low Water Cut-Off INTERMITTENT IGNITION If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent.
- Page 19 ELECTRICAL WIRING Figure 14 - Wiring Diagrams For Boilers With 67D-1 Float Type Low Water Cut-Off STANDING PILOT If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent.
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Page 20: Controls And Accessories
CONTROLS AND ACCESSORIES SAFETY VALVE LOW WATER CUT-OFF 1. Model 67D-1 The safety valve should open automatically if the boiler steam pressure exceeds the pressure rating of the valve This is a fl oat operated switch which shuts down the gas (15 psig). - Page 21 CONTROLS AND ACCESSORIES SPILL SWITCH (BLOCKED VENT SAFETY SHUTOFF) The spill switch is a manual reset disc thermostat with a fi xed setpoint (280° F), and normally closed contacts. It is located at the relief opening of the draft diverter. In the event of chimney or venting system blockage causing products of combustion to spill out of the relief opening, the spill switch disc heats up and the spill switch contacts will...
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Page 22: Operating Instructions
OPERATING INSTRUCTIONS For Your Safety Read Before Operating Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or WARNING turn by hand, don’t try to repair it, call a qualifi ed ser- vice technician. -
Page 23: Continuous Pilot Boiler - Vr8200A/Vr8300A Gas Valve Operating Instructions
CONTINUOUS PILOT BOILER - VR8200A/VR8300A GAS VALVE OPERATING INSTRUCTIONS STOP! Read the safety information on page 22. Figure 15 - Lighting Pilot Set the thermostat to lowest setting. Turn off all electric power to the appliance. Remove lower front panel. Rotate gas control knob slightly and turn clockwise to “OFF”... -
Page 24: Operating Instructions
OPERATING YOUR BURNER HOW A STEAM SYSTEM OPERATES THERMOSTAT The water in the boiler is heated until it reaches the boil- Keep it set at a desired room temperature. If windows ing point. As the water boils it turns into steam. The steam are to be opened or heat is not needed, move thermostat rises from the top of the water through the supply main to pointer to a lower setting. -
Page 25: Checking And Adjusting
CHECKING AND ADJUSTING ADJUST PILOT BURNER ADJUST STEAM PRESSURE CONTROL Pilot fl ame should surround 3/8” to 1/2” of the pilot sensor. The steam pressure limit control (pressuretrol) shuts off the gas to the main burners when the steam pressure in Refer to Fig. - Page 26 CHECKING AND ADJUSTING If your boiler is equipped with the optional WF-2U-24 Figure 19 - Igniter water feeder, continue to keep the thermostat calling for heat after the low water cut off recognizes the low water condition. After a one minute time delay, the water feeder should start feeding water to the boiler.
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Page 27: Cleaning Your Boiler
CLEANING YOUR BOILER It is very important to clean a new steam boiler after it has Now, let the boiler steam for a few days, to give the majority been installed and put into continuous operation. This must of the system dirt a chance to work its way back to the be done to remove any accumulation of oil, grease, sludge, boiler. -
Page 28: Maintaining Your Boiler
MAINTAINING YOUR BOILER Keep boiler area clear and free from combustible materials, NOTE: Opening blow-off valve checks cut-off operation gasoline and other fl ammable vapors and liquids. Keep too. As fl oat drops with falling water level, burners will shut boiler are clear and free of obstructions to fl... - Page 29 MAINTAINING YOUR BOILER FOAMING, PRIMING OR SURGING BOILER WATER TREATMENT (Other Than Cleaners) In steam systems where the system is tight, free from leaks, These terms are used to describe a fl uctuating water line - and all the steam is returned to the boiler as condensate, when water leaves the boiler with the steam.
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Page 30: Service Hints
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service. FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS 1. Do Not try to light any appliance. 2. Do not touch any electric switch, do not use the phone. -
Page 31: Repair Parts
REPAIR PARTS... - Page 32 REPAIR PARTS...
- Page 33 REPAIR PARTS...
- Page 34 REPAIR PARTS...
- Page 36 ECR INTERNATIONAL, INC. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...
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Questions and answers
Can't see water level in clear tube
To fix the issue of not seeing the water level in the clear tube of the Dunkirk PSB-3D boiler, follow these steps:
1. Check Water Level: Ensure the boiler has the correct water level as stamped on the side jacket panel.
2. Inspect Gauge Glass: Verify that the glass water level gauge is properly installed in the three designated holes on the right side jacket panel.
3. Flush Sediment: Open the blow-off valve at the bottom of the control to flush away sediment. Drain until the water is clear, then close the valve.
4. Restore Water Level: If the water level in the gauge glass has dropped, add water to the boiler to restore it.
5. Check for Blockages: Ensure the passageways are clear by cleaning between sections with a flexible wire brush and vacuuming out dirt.
6. Consult Manufacturer Instructions: If the issue persists, refer to the low water cut-off manufacturer’s instructions included with the boiler.
Following these steps should help restore visibility of the water level in the gauge glass.
This answer is automatically generated