ECR International Dunkirk PLYMOUTH STEAM 2 Series Installation, Operation & Maintenance Manual Download

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PLYMOUTH STEAM SERIES 2

GAS-FIRED

STEAM BOILERS

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

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

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 325 5479

www.ecrinternational.com

14683003 REV. O [10/01/2021]

Summary of Contents for Dunkirk PLYMOUTH STEAM 2 Series

Page 1: ...DEL 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 Manufactured by ECR International Inc 2201 Dwye...

Page 2: ...1 6 2 4 7 PSB 7D 7 24 7 4 5 7 PSB 8D 7 27 8 6 6 7 PSB 9D 7 30 9 5 7 7 Add 5 to height for Vent Damper 1 Add model number suffix P for Propane Gas 3 section only Figure 1 Dimensions LEFT SIDE FRONT RIG...

Page 3: ...er Fuel Type Input MBTUH Heating Capacity MBTUH AFUE Net AHRI Rating Mbh Net AHRI Rating Sq Ft 1 PSB 3D 3 Natural Gas 75 62 82 7 47 195 Propane 70 58 82 7 44 183 PSB 4D 4 Natural Gas 112 91 82 0 68 28...

Page 4: ...em design at any time without notice and without incurring any obligation whatsoever Introduction Boiler is designed for use in closed heating systems where all steam is returned as condensate and mak...

Page 5: ...Failure to follow these instructions could result in minor or moderate injury WARNING Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or serious inj...

Page 6: ...dish washing and other sanitizing needs can scald and cause permanent injury Children elderly and infirm or physically handicapped persons are more likely to be permanently injured by hot water Never...

Page 7: ...enting and maintenance of ambient temperature at safe limits under normal conditions of use Boiler location should not interfere with proper circulation of air Introduce outside air if normal infiltra...

Page 8: ...valve and discharge line Install safety valve with spindle in vertical position WARNING Burn and scald hazard Safety relief valve could discharge steam or hot water during operation Install discharge...

Page 9: ...ser s and header shall be 2 pipe size 10 Equalizer line shall be minimum 1 pipe size 11 The near boiler piping shall include a 2 tee with a plug located on the supply line as shown for skimming i e su...

Page 10: ...10 Figure 3 Recommended Near Boiler Piping Using One Supply Tapping 3 4 Section Sizes SYSTEM PIPING PN 14683003 Rev O 10 01 2021...

Page 11: ...LVES A B OPEN FOR HEATING CLOSE FOR COOLING VALVES C D CLOSE FOR HEATING OPEN FOR COOLING Figure 4 Recommended Near Boiler Piping Using Two Supply Tappings 5 thru 9 Sections Figure 5 Chilled Water Pip...

Page 12: ...lume shall be 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 13: ...wever not longer than 3 4 the chimney height HT Figure 6 page 14 Vent Pipe Fasten sections of vent pipe with 3 sheet metal screws at each joint to make piping rigid Support horizontal portions of vent...

Page 14: ...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 15: ...ing guide refer to manual Appendix A of this manual and literature packaged with vent damper Horizontal Installation To Boiler Vent Damper To Chimney NO NO YES YES Flow Install vent damper with actuat...

Page 16: ...0 Leak Check Gas Piping Pressure test boiler and gas connection before placing boiler in operation Avoid excessive pressure that could damage pressure regulators valves or meters Pressure test at 1 2...

Page 17: ...molex harness that plugs into 4 pin molex receptacle inside vent damper control Vent damper must be connected for boiler to operate Thermostat Installation 1 Install thermostat on inside wall per manu...

Page 18: ...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 19: ...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 20: ...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 no...

Page 21: ...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 22: ...w boiler to cool Add fresh water slowly up to normal water line Start burners Maintain at least 180 F for 15 minutes to remove dissolved gasses from fresh water Shut off burners 8 Allow system to oper...

Page 23: ...eassemble all parts 10 Check tightness of pilot connections and condition of burner flames after reassembly See Figures 14 and 15 Boiler Water Treatment Other Than Cleaners In steam systems where syst...

Page 24: ...ut 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 ch...

Page 25: ...Water Cut Off Shown CG400 PSE802 CG400 N 2 H 1 C P1 W A B P2 Terminals PSE802 To CG400 Cross Reference If any of the original wire as supplied with this appliance must be replaced it must be replaced...

Page 26: ...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 27: ...4 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 prevent...

Page 28: ...in Molex plug see Below This will create bypass of the damper boiler should then ignite IF NOT source problem is not the damper Go to Aquastat end of wiring harness Brown Yellow Orange Black V Slot Co...

Page 29: ...anticipator 3 Loose or broken connections 4 Off On operating limit or low water cut off 5 Off On blocked vent switch or flame roll out 1 Turn thermostat up to call for heat 2 Replace thermostat 3 Tig...

Page 30: ...n 2 Restore to damper pipe to round verify not binding 3 Correct the condition Damper Rotates Continuously 1 Defective damper motor assembly 1 Replace damper motor assembly Note For troubleshooting on...

Page 31: ...00814AC 42500815AC 42500816AC 42500817AC 42500818AC 42500819AC 13 Jacket Front Panel 42500811AC 42500804AC 42500805AC 42500806AC 42500807AC 42500808AC 42500809AC 14 Tie Rod Nut 14605001 14605002 14605...

Page 32: ...6 3 10 32 3 16 Hex Hd Screw 14695301 4 Gas Manifold 14616033 14616034 14616035 14616013 14616014 14616015 14616016 5 Main Burner Orifice 14615031 14615031 14615031 14615035 14615035 14615035 14615035...

Page 33: ...740 2 Pilot Tube 14615005 14615006 3 10 32 3 16 Hex Hd Screw 14695301 4 Gas Manifold 14616010 14616011 14616012 14616013 14616014 14616015 14616016 5 Main Burner Orifice 14615036 6 Main Burner Regular...

Page 34: ...0522 9B Probe only for Hydrolevel Cycle Guard 240010925 10 Intermittent Pilot Control 14662070 11 NPT x 4 Nipple PF 033 02 12 x x Brass Tee PS 802 only 14693051 13 Brass Coupling PS 802 only 14693052...

Page 35: ...____ Measured BTU HR input____________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person I...

Page 36: ...All specifications subject to change without notice 2021 ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com...

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