Dunkirk WPSB SERIES II Operation & Maintenance Manual

Dunkirk WPSB SERIES II Operation & Maintenance Manual

Gas-fired hot water boilers

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Models
WPSB-3D
WPSB-3DP
WPSB-4D
WPSB-4DP
WPSB-5D
WPSB-5DP
WPSB-6D
WPSB-6DP
WPSB-7D
WPSB-7DP
WPSB-8D
WPSB-8DP
WPSB-9D
WPSB-9DP
WPSB SERIES II
GAS-FIRED
HOT WATER BOILERS
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Tested For 50 psi.
ASME
Working Pressure
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N 240009047, Rev. D [03/09/2016]

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Table of Contents
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Summary of Contents for Dunkirk WPSB SERIES II

  • Page 1 WPSB SERIES II Models WPSB-3D GAS-FIRED WPSB-3DP HOT WATER BOILERS WPSB-4D WPSB-4DP WPSB-5D INSTALLATION, OPERATION & WPSB-5DP MAINTENANCE MANUAL WPSB-6D WPSB-6DP WPSB-7D WPSB-7DP WPSB-8D WPSB-8DP WPSB-9D WPSB-9DP Tested For 50 psi. ASME Working Pressure Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...
  • Page 2 DIMENSIONS DIMENSIONS CONTROL Dimensions DIMENSIONS (INCH.) BOILER Boiler MODEL Volume FLUE “A” NUMBER Gallon DIAMETER WIDTH WPSB-3 11¼ WPSB-4 14½ WPSB-5 17¾ WPSB-6 11.7 WPSB-7 24¼ 13.5 WPSB-8 27½ 15.3 WPSB-9 30¾ 17.2 Add 5½” to height for vent Damper.
  • Page 3 BOILER RATINGS AND CAPACITIES Table 1 - Ratings and Capacities † NATURAL GAS † PROPANE GAS AFUE BOILER (2) NET NET AHRI HEATING INTERMITTENT MODEL Input Heating INPUT AHRI RATING CAPACITY IGNITION NUMBER Capacity RATING Water, WITH VENT DAMPER WPSB-3 84.0 WPSB-4 112.5...
  • Page 4: Table Of Contents

    TABLE OF CONTENTS Table of Contents ..........4 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE Locating the Boiler ..........5 Ventilation & Combustion Air ........ 6 IMPORTANT: Read the following instructions COMPLETELY before installing!! Connecting Supply and Return Piping ....7 Chimney and Vent Pipe Connection ......11 WARNING Vent Damper Operation ........13...
  • Page 5: Locating The Boiler

    LOCATING THE BOILER WARNING WARNING Fire hazard. Shall not install boiler on combustible Improper installation, adjustment, alteration, service flooring or carpeting. Failure to follow these or maintenance could result in death or serious instructions could result in death or serious injury. injury.
  • Page 6: Ventilation & Combustion Air

    VENTILATION & COMBUSTION AIR Provide combustion air and ventilation air in accordance • All Outdoor Air. Provide permanent opening(s) with the section “Air for Combustion and Ventilation,” of communicating directly or by ducts with outdoors. the National Fuel Gas Code, ANSI Z223.1 / NFPA 54, or A.
  • Page 7: Connecting Supply And Return Piping

    CONNECTING SUPPLY AND RETURN PIPING WARNING Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation. Discharge line shall: •...
  • Page 8 CONNECTING SUPPLY AND RETURN PIPING Verify clean water supply is available to water inlet valve. WARNING Install sand strainer when water supply is from a well or Burn and scald hazard. Safety relief valve could pump. discharge steam or hot water during operation. Install hot water boiler above radiation level or as Install discharge piping per these instructions.
  • Page 9 CONNECTING SUPPLY AND RETURN PIPING Figure 3- Typical Hot Water Piping Figure 4 - Chilled Water Piping...
  • Page 10 CONNECTING SUPPLY AND RETURN PIPING BYPASS PIPING REQUIRED FOR HIGH MASS (LARGE WATER CONTENT) SYSTEMS Figure 5 - Bypass Piping - Circulator On Supply Control Figure 6 - Bypass Piping - Circulator On Return CONTROL...
  • Page 11: Chimney And Vent Pipe Connection

    CHIMNEY AND VENT PIPE CONNECTION Boilers connecting to gas vents or chimneys, vent Connecting The Vent Damper And Vent Connector Refer to Dimensions, page 2 for size and location of installations shall be in accordance with “Venting of vent (flue opening). Equipment”, of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, or applicable provisions of local building codes.
  • Page 12 CHIMNEY AND VENT PIPE CONNECTION Removing Existing Boiler From Common Venting Any improper operation of the common venting system System should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54. When an existing boiler is removed from common venting When re-sizing any portion of the common venting system, common venting system is likely to be too large for system, the common venting system should be re-sized...
  • Page 13: Vent Damper Operation

    VENT DAMPER OPERATION Figure 7 Figure 8 For safe, efficient operation, vent damper and all flue For further information, and vent damper product carrying areas of appliance must be checked troubleshooting guide, refer to manual packaged with annually, with particular attention given to deterioration vent damper.
  • Page 14: Gas Supply Piping

    GAS SUPPLY PIPING • Pressure test at 1/2 psig (3.5 kPa) or less. Isolate CAUTION boiler from gas supply system by closing manual gas WHAT TO DO IF YOU SMELL GAS shutoff valve. • Locate leakage using gas detector, noncorrosive •...
  • Page 15: Electrical Wiring

    ELECTRICAL WIRING VENT DAMPER WIRING WARNING Boiler is equipped with factory wired harness with 4 pin Electrical shock hazard. Turn OFF electrical power molex plug, that plugs into 4 pin molex receptacle inside supply at service panel before making electrical vent damper operator.
  • Page 16: Wiring Diagrams

    WIRING DIAGRAMS Figure 11 - Electronic Ignition Control WARNING Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life.
  • Page 17: Starting Your Boiler

    STARTING YOUR BOILER FILLING SYSTEM WITH WATER NOTICE • Close air vents on all radiation units. Open valves to Never run water in a hot empty boiler. these units. • Verify boiler and expansion tank drain valves are closed. • Close drain fitting on air bleed screw. •...
  • Page 18: Lighting Instructions

    LIGHTING INSTRUCTIONS F. Remove front panel. WARNING G. Rotate the gas control knob clockwise to “OFF”. If you do not follow these instructions exactly, a fire or explosion may result Figure 12 - Automatic Gas Valve causing property damage, personal injury or loss of life.
  • Page 19: Operating Your Boiler

    OPERATING YOUR BOILER AUTOMATIC GAS VALVE Figure 13 - Pilot Flame Automatic Gas Valve opens or closes according to heat requirements of thermostat and temperature limit control. It closes if pilot goes out. Each individual control must be operating correctly before any gas can pass to burners.
  • Page 20 OPERATING YOUR BOILER CHECK THERMOSTAT OPERATION A. When set above temperature indicated on thermostat, boiler should ignite. B. Verify thermostat turns boiler off when room temperature reaches selected setting and starts boiler operating when room temperature falls a few degrees. C.
  • Page 21: Operating The Boiler - System Start-Up

    OPERATING THE BOILER - SYSTEM START-UP HI TEMP illuminates when boiler water temperature reaches high limit setting. Remains lit until water temperature falls 10°. Prevents burner operation while this LED is on. LWCO Active Indicates low water cut-off (LWCO) function of limit control is active. When control is installed with a well, LED is on at all times when control is powered.
  • Page 22 OPERATING THE BOILER - SYSTEM START-UP Table 1 - Troubleshooting Burner Will Not Fire If installed with indirect water heater, insure end switch in relay box controlling indirect water No or Insufficient Domestic heater is properly connected to cable 2 (see wiring diagram). This insures domestic water calls Hot Water are prioritized.
  • Page 23: Service Hints

    SERVICE HINTS EQUIPMENT AND OPTIONAL ACCESSORIES - WHAT THEY DO You may avoid inconvenience and service calls by checking these points before you call for service. CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. •...
  • Page 24: Maintaining Your Boiler

    MAINTAINING YOUR BOILER BURNERS CLEANING YOUR BOILER AND BURNERS Beginning of heating season visually check pilot end main Flue passages between sections should be examined yearly burner flames. See page 19 and cleaned if necessary. To clean: SAFETY RELIEF VALVE •...
  • Page 25: Equipment And Optional Accessories

    EQUIPMENT AND OPTIONAL ACCESSORIES AIR ELIMINATING FITTING (AIR PURGER) WARNING Air purger is used to remove excess air from system. It Burn and scald hazard. Safety relief valve could is installed in supply line. It will eliminate air from water discharge steam or hot water during operation.
  • Page 26 EQUIPMENT AND OPTIONAL ACCESSORIES ROLLOUT SWITCH BLOCKED VENT SAFETY SWITCH (FLAME ROLLOUT SAFETY SHUTOFF) (BLOCKED VENT SAFETY SHUTOFF) Rollout switch is temperature-sensitive fuse link device. Blocked vent safety switch is manual reset disc thermostat Located on boiler base just outside fire box. In event of with fixed setpoint (340°F), and normally closed contacts.
  • Page 27 NOTES...
  • Page 28 • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. DUNKIRK BOILERS DUNKIRK BOILERS 2201 Dwyer Avenue, Utica NY 13501 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...

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