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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 3
HOT WATER BOILERS
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Tested For 50 psi.
ASME
Working Pressure
GAS-FIRED
2201 Dwyer Avenue, Utica, NY 13501
PN 240013090 REV. C [10/01/2021]
Manufactured by:
ECR International Inc.
Tel. 800 325 5479
www.ecrinternational.com
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Table of Contents
Related Manuals for ECR International Dunkirk WPSB 3 Series
Summary of Contents for ECR International Dunkirk WPSB 3 Series
- Page 1 MAINTENANCE MANUAL WPSB-4DP WPSB-5D WPSB-5DP 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 Tel. 800 325 5479 www.ecrinternational.com PN 240013090 REV. C [10/01/2021]...
- Page 2 RETAIN FOR FUTURE REFERENCE Information and specifications outlined in this manual in effect at the time of printing of this manual. ECR International, Inc. reserves the right to discontinue, change specifications or system design at any time without notice and without incurring any obligation, whatsoever.
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Page 3: Table Of Contents
TABLE OF CONTENTS 1 - Dimensions ................4 2 - Safety Symbols And Warnings ............5 3 - Locating The Boiler ..............7 4 - Connecting Supply And Return Piping..........9 5 - Ventilation & Combustion Air ............14 6 - Chimney And Vent Pipe Connection..........15 7 - Vent Damper Operation ..............17 8 - Gas Supply Piping ..............18 9 - Electrical Wiring .................19... -
Page 4: Dimensions
1 - DIMENSIONS Dimensions DIMENSIONS (INCH.) BOILER Boiler MODEL Volume FLUE “A” NUMBER Gallon DIAMETER WIDTH WPSB-3 11¼ 3.30 WPSB-4 14½ 4.60 WPSB-5 17¾ 6.00 WPSB-6 7.40 WPSB-7 24¼ 8.75 WPSB-8 27½ 10.10 WPSB-9 30¾ 11.60 Add 5½” to height for vent Damper. Figure 1 - Dimensions Figure 1 - Dimensions 1 1/4”... -
Page 5: Safety Symbols And Warnings
2 - SAFETY SYMBOLS AND WARNINGS FOR YOUR SAFETY READ BEFORE OPERATING Become familiar with symbols identifying potential hazards. DANGER This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death. - Page 6 2 - SAFETY SYMBOLS AND WARNINGS WARNING WARNING Combustion chamber insulation in this product Fire, Explosion, Asphyxiation, Electrical shock contains ceramic fiber material. Ceramic fibers hazard! Flooding will result in damages such as can be converted to cristobalite in very high electrical problems, corrosion, inoperative parts, temperature applications.
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Page 7: Locating The Boiler
3 -LOCATING THE BOILER FOR INSTALLATION ON NON-COMBUSTIBLE WARNING FLOORS ONLY - For installation on combustible Fire hazard. Do not install boiler on combustible flooring special base shall be used. Please refer to flooring or carpeting. Failure to follow these (Combustible Floor Addendum) included in literature envelope provided with boiler and outlined in National instructions could result in death or serious injury. - Page 8 3 - LOCATING THE BOILER 3.3 Boiler Location Considerations • Horizontal run to chimney shall be as short as possible. • Ambient room temperature always above 32°F (0°C) to • System piping exposed to freezing conditions: Use prevent the potential of freezing. inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system.
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Page 9: Connecting Supply And Return Piping
4 - CONNECTING SUPPLY AND RETURN PIPING WARNING Figure 2 - Safety Relief Valve Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. RELIEF VALVE DISCHARGE WARNING LINE Burn and scald hazard. - Page 10 4 - CONNECTING SUPPLY AND RETURN PIPING 4.4 Water Treatment WARNING Manufacturer recommends a water analysis be done on • Poison hazard. Ethylene glycol is toxic. Do not water used to fill the system. Treatment may be required use ethylene glycol. based on the analysis results.
- Page 11 4 - 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 pump. Burn and scald hazard. Safety relief valve could Install hot water boiler above radiation level or as required discharge steam or hot water during operation.
- Page 12 4 - CONNECTING SUPPLY AND RETURN PIPING Figure 4 - Typical Hot Water Piping CIRCULATOR PUMP Figure 5 - Chilled Water Piping PN 240013090 REV. C [10/01/2021]...
- Page 13 4 - CONNECTING SUPPLY AND RETURN PIPING Bypass Piping Required For High Mass (Large Water Content) Systems Figure 6 - Bypass Piping - Circulator On Supply Figure 7 - Bypass Piping - Circulator On Return PN 240013090 REV. C [10/01/2021]...
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Page 14: Ventilation & Combustion Air
5 - 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 the communicating directly or by ducts with outdoors. National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Natural A. -
Page 15: Chimney And Vent Pipe Connection
6 - CHIMNEY AND VENT PIPE CONNECTION Boiler series is classified as a Category I. Vent WARNING installation shall be in accordance with “Venting of Boiler and venting installations shall be performed Equipment,” of the National Fuel Gas Code, ANSI by a qualified expert and in accordance with the Z223.1/NFPA 54, or “Venting Systems and Air Supply for Appliances,”... - Page 16 6 - CHIMNEY AND VENT PIPE CONNECTION Connecting The Vent Damper And Vent Connector WARNING Refer to Figure 1, page 4 for size and location of vent (flue Do not connect boiler to any portion of mechanical opening). draft system operating under positive pressure. NOTICE Removing Existing Boiler From Common Venting Damper blade on furnished vent damper has 1/2...
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Page 17: Vent Damper Operation
7 - VENT DAMPER OPERATION Figure 8 - Vent Damper Installation Figure 9 - Vent Damper Placement Annually check vent damper and all flue product carrying For further information, and vent damper troubleshooting areas of appliance, with particular attention given to guide, refer to manual packaged with vent damper and deterioration from corrosion or other sources. -
Page 18: Gas Supply Piping
8 - GAS SUPPLY PIPING • Pressure test over 1/2 psig (3.5 kPa). Disconnect CAUTION boiler and its individual gas shutoff valve from gas WHAT TO DO IF YOU SMELL GAS supply system. • Pressure test at 1/2 psig (3.5 kPa) or less. Isolate •... -
Page 19: Electrical Wiring
9 - ELECTRICAL WIRING molex plug, that plugs into 4 pin molex receptacle inside WARNING vent damper operator. Electrical shock hazard. Turn OFF electrical power Vent damper must be connected for boiler to operate. supply at service panel before making electrical connections. -
Page 20: Wiring Diagram
10 - WIRING DIAGRAM Figure 12 - Integrated High Limit Electronic Ignition Control WARNING Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life. PN 240013090 REV. C [10/01/2021]... -
Page 21: General Instructions
11 -GENERAL INSTRUCTIONS WARNING Adding water to hot boiler may result in heat exchanger failure. Before filling boiler verify heat exchanger is not hot. Failure to follow these instructions could result in death or serious injury. FILLING SYSTEM WITH WATER •... -
Page 22: Lighting Instructions
12 - LIGHTING INSTRUCTIONS 5. Remove lower front panel. WARNING 6. Rotate the gas control knob clockwise to “OFF”. If you do not follow these instructions exactly, a fire or explosion may result Figure 13 - Automatic Gas Valve causing property damage, personal injury or loss of life. -
Page 23: Operating Your Boiler
13 - OPERATING YOUR BOILER AUTOMATIC GAS VALVE Figure 14 - 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 24 13 - OPERATING YOUR BOILER- SYSTEM START-UP CHECK THERMOSTAT OPERATION For Control Functions and Settings see Appendix A 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.
- Page 25 13 - OPERATING YOUR BOILER Table 6 - Troubleshooting Burner Will Not Fire If installed with indirect water heater, insure switch controlling indirect water heater is properly No or Insufficient Domestic connected to I1-I2 (see wiring diagram). This insures domestic water calls are prioritized. Hot Water If I1-I2 is not used, turn Economy Feature OFF.
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Page 26: Service Hints
14 - SERVICE HINTS EQUIPMENT AND OPTIONAL ACCESSORIES - WHAT THEY DO CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. •... -
Page 27: Maintaining Your Boiler
15 - MAINTAINING YOUR BOILER BURNERS CLEANING YOUR BOILER AND BURNERS Beginning of heating season visually check pilot and main Flue passages between sections should be examined yearly burner flames. See Page 23. and cleaned if necessary. To clean: SAFETY RELIEF VALVE •... -
Page 28: Boiler Ratings And Capacities
17 - BOILER RATINGS AND CAPACITIES Table 1 - Ratings and Capacities † NATURAL GAS † PROPANE GAS AFUE (2) NET BOILER NET AHRI HEATING INPUT AHRI MODEL Heating INTERMITTENT Input RATING CAPACITY NUMBER Capacity IGNITION WITH RATING Water, VENT DAMPER WPSB-3 84.0 WPSB-4... -
Page 29: Appendix A - Control Function
APPENDIX A - CONTROL FUNCTION WARNING ECONOMY Target When the Economy feature is active, the Fuel Smart HydroStat continually sets Burn and scald hazard. Do not add water until boiler target temperatures below the high limit setting has fully cooled. Failure to follow these instructions to maximize fuel efficiency. - Page 30 APPENDIX A - CONTROL FUNCTION A-1. Intermittent Pilot If this LED is blinking and the burner is not firing: Make sure the plug connection (or jumper, on boilers where Ignition System Checks vent damper plug is not used) is secure. Make sure the plug connection at the vent damper end is STEP 1: Check ignition cable.
- Page 31 APPENDIX A - CONTROL FUNCTION STEP 3: Check spark ignition circuit. Recheck ignition sequence as follows: a. Adjust thermostat above room temperature. b. Verify ignition sequence at burner. WARNING Electrical shock hazard. Ignition circuit generates over 10,000 volts. Turn OFF electrical power Figure A-1 - Troubleshooting Pilot Flame supply at service panel before making electrical connections.
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Page 32: Appendix B - Vent Damper Installation
APPENDIX B - VENT DAMPER INSTALLATION WARNING Figure 1a - Horizontal Installations Flow Asphyxiation, burn hazard. Improper operation of vent damper may result in serious injury or death due to fire or to asphyxiation from poisonous gases Vent Damper To Boiler o Chimney such as carbon monoxide which is odorless and Install vent damper with actuator to sides of... - Page 33 APPENDIX B - VENT DAMPER INSTALLATION B.3 Vent Damper Harness - Molex Plugs Figure 4 WARNING Follow all instructions regarding safety operational controls in this manual. Failure to follow these instructions could result in death or serious injury. When servicing controls, all wires must be Note labeled prior to disconnection.
- Page 34 APPENDIX B - VENT DAMPER INSTALLATION B.4 Vent Damper Troubleshooting Guide Normal Sequence of Operation WARNING 24 VAC Power ON Damper Position Power Follow all instructions regarding safety operational 4 & 1 All times Open or Closed controls in this manual. Failure to follow these instructions could result in death or serious injury.
- Page 35 PN 240013090 REV. C [10/01/2021]...
- Page 36 • 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. 2201 Dwyer Avenue, Utica, NY 13501 All specifications subject to change without notice. Tel. 800 325 5479 ©2021 ECR International, Inc. www.ecrinternational.com...