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Dunkirk PSB-3D, Installation, Operation & Maintenance Manual, Page: 1 / 32

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PLYMOUTH STEAM SERIES 2

GAS-FIRED

STEAM BOILERS

INSTALLATION, OPERATION & 

MAINTENANCE MANUAL

 P/N 14683003, Rev. D [08/03/2015]

ECR International, Inc.

2201 Dwyer Avenue, 

Utica NY 13501

www.ecrinternational.com

MODEL PSB

Electronic

Intermittent

Ignition

MODELS

PSB-3D

PSB-3DP

PSB-4D

PSB-4DP

PSB-5D

PSB-5DP

PSB-6D

PSB-6DP

PSB-7D

PSB-7DP

PSB-8D

PSB-8DP

PSB-9D

PSB-9DP

Summary of Contents for PSB-3D

Page 1: ...NANCE MANUAL P N 14683003 Rev D 08 03 2015 ECR International Inc 2201 Dwyer Avenue Utica NY 13501 www ecrinternational com MODEL PSB Electronic Intermittent Ignition MODELS PSB 3D PSB 3DP PSB 4D PSB 4...

Page 2: ...sions Inches Intermittent Ignition w Vent Damper Flue Diameter A Width PSB 3D 5 11 PSB 4D 6 14 PSB 5D 6 17 PSB 6D 7 21 PSB 7D 7 24 PSB 8D 7 27 PSB 9D 7 30 Add 5 to height for Vent Damper 1 Add model n...

Page 3: ...et AHRI Rating Mbh Net AHRI Rating Sq Ft 1 PSB 3D 3 Natural Gas 75 62 82 7 47 196 Propane 70 58 82 7 44 183 1 PSB 4D 4 Natural Gas 112 91 82 0 68 283 Propane 105 85 80 4 64 267 1 PSB 5D 5 Natural Gas...

Page 4: ...urring any obligation whatsoever Introduction Boiler is designed for use in closed heating systems where all steam is returned as condensate and make up water is minimal Boiler is not designed for or...

Page 5: ...appliance with improper methods or materials could result in death or serious injury due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible WARNING...

Page 6: ...se Boiler location should not interfere with proper circulation of air Introduce outside air if normal infiltration does not provide necessary air Fresh Air for Combustion on page 11 6 Notify owner to...

Page 7: ...struction in discharge line Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing Allow complete drainage of valve and discharge line Install safety val...

Page 8: ...r one for each main 6 All boilers in gravity return systems must be equipped with a Hartford Loop as shown in Figure 5 7 When piping the vertical risers from the boiler to the header the bottom of the...

Page 9: ...9 Figure 4 Recommended Near Boiler Piping Using One Supply Tapping SYSTEM PIPING P N 14683003 Rev D 08 03 2015...

Page 10: ...IPING Figure 6 Chilled Water Piping VALVES A B OPEN FOR HEATING CLOSE FOR COOLING VALVES C D CLOSE FOR HEATING OPEN FOR COOLING Figure 5 Recommended Near Boiler Piping Using Two Supply Tappings P N 14...

Page 11: ...oom volume is greater than 21 cubic feet divided by ACH air changes per hour x Total Input Mbh C Refer to National Fuel Gas Code for opening requirements between connected indoor spaces All Outdoor Ai...

Page 12: ...er than 3 4 the chimney height HT Figure 7 page 13 Vent Pipe Fasten sections of vent pipe with 3 sheet metal screws at each joint to make piping rigid Support horizontal portions of vent system to pre...

Page 13: ...appliance to their previous conditions of use 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54...

Page 14: ...damper troubleshooting guide refer to manual packaged with vent damper Horizontal Installation To Boiler Vent Damper To Chimney NO NO YES YES Flow Install vent damper with actuator to sides of vent o...

Page 15: ...ssive vibrations and prevent strain on gas connection Gas valve will not support piping weight Use thread joint compound pipe dope suitable for natural and liquefied petroleum gas Install field source...

Page 16: ...es are black One wire is located on secondary of 24 volt transformer second wire is located on pressure limit control F Boilers with CG400 probe type low water cut off one wire is green and is located...

Page 17: ...y and turn clockwise to OFF Do not force For Your Safety Read Before Operating WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal i...

Page 18: ...of boiler Determine water level when boiler is off and cold when all water in the system is inside the boiler and return piping below water line and everything above water line is air no steam When b...

Page 19: ...softer blue outer mantel with no yellow Remain still when observing main burner flames Check main burner orifices burner throat and flame ports for dust and lint obstruction if flame appearance is not...

Page 20: ...n thermostat to call for heat C Gas valve opens for approximately 10 seconds time delay on probe type LWCO gas valve will close and red indicator illuminates on LWCO D When water is restored it waits...

Page 21: ...ection from boiler drain valve to safe discharge point outside Shut off gas burners open drain valve allow all of water in boiler to drain out Close drain valve Allow boiler to cool slowly refill boil...

Page 22: ...RTV silicone to four mounting surface flanges of flue collector Mount flue collector on heat exchanger Tighten nuts and bolts 6 Seal front edge and four corners of flue collector to heat exchanger wit...

Page 23: ...t switch blown Have your service technician check heat exchanger for blockage Chimney flue is blocked Spill switch contacts open requiring manual reset of spill switch Have your service technician che...

Page 24: ...t be replaced it must be replaced with type 105 C Thermoplastic wire or its equivalent Figure 13 Wiring Diagrams For Boilers With CG400 Probe Type Low Water Cut Off Shown CG400 PS802 CG400 N 2 H 1 C P...

Page 25: ...nal wire as supplied with this appliance must be replaced it must be replaced with type 105 C Thermoplastic wire or its equivalent Figure 17 Wiring Diagrams For Boilers With 67D 1 Float Type Low Water...

Page 26: ...water feeder maybe used with either of the low water cutoffs listed Water feeder maintains safe minimum water level Keeps boiler running by compensating for minor evaporative steam leaks and prevents...

Page 27: ...27 REPAIR PARTS P N 14683003 Rev D 08 03 2015...

Page 28: ...28 REPAIR PARTS P N 14683003 Rev D 08 03 2015...

Page 29: ...29 REPAIR PARTS P N 14683003 Rev D 08 03 2015...

Page 30: ...30 REPAIR PARTS Safety Relief Valve 14 11 NPT X 4 Nipple PF 033 02 CG400 LOW WATER CUT OFF 240009340 P N 14683003 Rev D 08 03 2015...

Page 31: ...31 Date Service Performed Company Name Tech Initials Company Address Phone P N 14683003 Rev D 08 03 2015...

Page 32: ...reases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLE...

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