ECR International Dunkirk WPSB 3 Series Installation, Operation & Maintenance Manual Download

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GAS-FIRED

HOT WATER BOILERS

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

WPSB SERIES 3

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

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]

Summary of Contents for Dunkirk WPSB 3 Series

Page 1: ...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 Tested For 50 psi ASME Working Pressure Manufactured by ECR International Inc 2201 Dwy...

Page 2: ...n 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 inc...

Page 3: ...7 Vent Damper Operation 17 8 Gas Supply Piping 18 9 Electrical Wiring 19 10 Wiring Diagram 20 11 General Instructions 21 12 Lighting Instructions 22 13 Operating Your Boiler 23 14 Service Hints 26 15...

Page 4: ...Dimensions 1 1 4 RETURN PN 240013090 REV C 10 01 2021 Dimensions BOILER MODEL NUMBER DIMENSIONS INCH Boiler Volume Gallon FLUE DIAMETER A WIDTH WPSB 3 5 11 3 30 WPSB 4 6 14 4 60 WPSB 5 6 17 6 00 WPSB...

Page 5: ...and all requirements before beginning installation FOR YOUR SAFETY READ BEFORE OPERATING Hot Water Can Scald Water heated to temperature for clothes washing dish washing and other sanitizing needs can...

Page 6: ...be found on the NIOSH website https www cdc gov niosh topics silica NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing...

Page 7: ...ting and other performance criteria with the gas manifold and control assembly on the boiler per the latest revision of ANSI Z21 13 CGA 4 9 5 Install boiler such that gas ignition system components ar...

Page 8: ...oric acid muriatic acid Cements adhesives and glues Photo processing plants Garages with workshops Furniture refinishing areas and establishments Laundry Chemicals Laundry detergents bleaches fabric s...

Page 9: ...iping Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate Run pipe as short and straight as possible t...

Page 10: ...herwise damage and or malfunction could be caused Recommended water quality is o Hardness Less than 150 mg L o Acidity level 7 8 pH o Sediments Particle size less than 50 micron If the water quality i...

Page 11: ...damage to boiler and venting system Minimum design return water temperature to prevent condensation in boiler and venting is 120 F Minimum high limit setting is 140 F 1 Boiler used in heating system w...

Page 12: ...12 Figure 5 Chilled Water Piping Figure 4 Typical Hot Water Piping 4 CONNECTING SUPPLY AND RETURN PIPING CIRCULATOR PUMP PN 240013090 REV C 10 01 2021...

Page 13: ...Bypass Piping Circulator On Supply Figure 7 Bypass Piping Circulator On Return Bypass Piping Required For High Mass Large Water Content Systems 4 CONNECTING SUPPLY AND RETURN PIPING PN 240013090 REV C...

Page 14: ...60 Volume 21 ft3 ACH x Total Input Mbh C Refer to National Fuel Gas Code for opening requirements between connected indoor spaces All Outdoor Air Provide permanent opening s communicating directly or...

Page 15: ...ent pipe should have any dips or sags Requirements 3 Boiler series is classified as a Category I Vent installation shall be in accordance with Venting of Equipment of the National Fuel Gas Code ANSI Z...

Page 16: ...ances remaining connected to it At time of removal of existing boiler following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while o...

Page 17: ...ition Turn thermostat or controller down again and check damper position indicator returns to closed position Vent Damper Manual Operation Vent damper may be placed in open position to permit burner o...

Page 18: ...regulation should be used by propane installer Propane gas piping should be checked out by propane installer CHECKING GAS PIPING DANGER Fire Hazard Do not use matches candles open flames or other meth...

Page 19: ...ighting fixtures televisions a fireplace or a chimney 4 Check thermostat operation by raising and lowering thermostat setting as required to start and stop the burners 5 Instructions for the final adj...

Page 20: ...2 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...

Page 21: ...p at highest unit in system If your units have automatic vents manual venting is unnecessary but it will speed up the proper filling of your system If your system is closed expansion tank system you m...

Page 22: ...ly and turn clockwise to OFF Do not force WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance...

Page 23: ...ostat to lowest setting for one minute then back to normal setting ADJUST PILOT BURNER Pilot flame should surround 3 8 to 1 2 of the pilot sensor See Figure 14 If flame needs adjusting do it as follow...

Page 24: ...t shuts off gas supply to burners Turn your thermostat up to call for heat and let boiler run until temperature of water reaches limit setting Gas valve should shut off and circulator running until th...

Page 25: ...rioritized If I1 I2 is not used turn Economy Feature OFF House will not get or stay warm 1 Check for air bound radiators 2 Check thermostat settings including heat anticipator settings common on non d...

Page 26: ...ol terminals and wire joints Rollout switch blown Have your service agent check heat exchanged for blockage Replace rollout switch with exact replacement Blocked vent blown Have your service agent che...

Page 27: ...and piping should be checked at least once a season If vent piping shows any sign of leaking replace immediately WATER SYSTEM If system is to remain out of service during freezing weather always drain...

Page 28: ...ter than calculated heat loss of the building Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements BOILERS FOR USE AT HIGH ALTITUDE Boiler is fa...

Page 29: ...It will remain lit until the water temperature falls 10 The Fuel SmartHydroStat prevents burner operation while this LED is on See Differential explanation on page 6 of Hydrolevel Manual LWCO ACTIVE I...

Page 30: ...position restore to correct position If this LED is blinking and the burner is not firing Make sure the plug connection or jumper on boilers where vent damper plug is not used is secure Make sure the...

Page 31: ...ting a Check pilot flame Verify it is blue steady and envelops 3 8 to 1 2 in 10 to 13 mm of flame rod See Figure A 1 for possible flame problems and causes b If necessary adjust pilot flame by turning...

Page 32: ...d position 4 Return thermostat to desired position 5 Place vent damper in open position to permit burner operation by using HOLD DAMPER OPEN switch located on damper controller 6 Thermostat controls b...

Page 33: ...ross orange and yellow wires in Molex plug see Figure 4 This will create bypass of the damper boiler should then ignite If boiler ignites Go to section B 4 Vent Damper Troubleshooting Guide If boiler...

Page 34: ...or heat 1 Thermostat not calling for heat 2 Burned out heat anticipator 3 Loose or broken connections 4 Off On operating limit pressure control or low water cut off 5 Off On blocked vent switch or fla...

Page 35: ...35 Company Address Phone Company Name Tech Initials Service Performed Date PN 240013090 REV C 10 01 2021...

Page 36: ...tion THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating l...

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