Dunkirk PSB-3D, PSB-6D, PSB-5D, PSB-4D, PSB-7D Installation, Operation & Maintenance Manual
...
PLYMOUTH STEAM SERIES 2
GAS-FIRED
STEAM BOILERS
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
MODEL PVSB
Continuous Pilot
An ISO 9001-2008 Certified Company
ECR International, Inc.
2201 Dwyer Avenue,
Utica NY 13504-4729
www.ecrinternational.com
MODEL PSB
Electronic
Intermittent
Ignition
H
P/N# 14683003, Rev. A [07/2011]
TABLE OF CONTENTS
Safety Symbols ..............................................................................................................3
Boiler Ratings And Capacities ...........................................................................................4
Before You Start .............................................................................................................5
Locating The Boiler .........................................................................................................5
Fresh Air For Combustion.................................................................................................6
Installation - System Piping .............................................................................................7
Chimney And Vent Pipe Connection ................................................................................. 10
Vent Damper Operation ................................................................................................. 11
Gas Supply Piping .........................................................................................................12
Electrical Wiring ........................................................................................................... 14
Controls And Accessories ............................................................................................... 20
Operating Instructions ................................................................................................... 22
Intermittent Ignition Boiler - VR8204A/VR8304M Gas Valve Operating Instructions ................ 22
Continuous Pilot Boiler - VR8200A/VR8300A Gas Valve Operating Instructions ...................... 23
Operating Instructions ................................................................................................... 24
Checking and Adjusting ................................................................................................. 25
Cleaning Your Boiler ...................................................................................................... 27
Maintaining Your Boiler .................................................................................................. 28
Service Hints ...............................................................................................................30
Repair Parts ................................................................................................................. 31
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
SERIES 2
GAS FIRED BOILERS
STEAM BOILERS
H
2
SAFETY SYMBOLS
The following defi ned symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
DANGER
!
Indicates a hazardous situation which, if
not avoided, WILL result in death or serious
injury.
WARNING
!
Indicates a hazardous situation which, if
not avoided, could result in death or serious
injury.
CAUTION
!
Indicates a hazardous situation which, if not
avoided, may result in minor or moderate
injury.
NOTICE
READ ALL INSTRUCTIONS BEFORE INSTALLING.
WARNING
Keep boiler area clear and free from
combustible materials, gasoline and other
fl ammable vapors and liquids.
DO NOT obstruct air openings to the boiler
room.
Modifi cation, substitution or elimination
of factory equipped, supplied or specifi ed
components may result in property damage,
personal injury or the loss of life.
!
To the owner: Installation and service of
this boiler must be performed by a qualifi ed
installer.
To the installer: Leave all instructions with the
boiler for future reference.
Indicates information which should be
followed to ensure proper installation and
operation.
When this product is installed in the
Commonwealth of Massachusetts the
installation must be performed by a Licensed
Plumber or Licensed Gas Fitter.
WARNING
All installations of boilers and venting should
be done only by a qualifi ed expert and in
accordance with the appropriate Installation,
Operation and Maintenance manual.
!
Installing or venting a boiler or any other gas
appliance with improper methods or materials
may result in serious injury or death due to
fi re or to asphyxiation from poisonous gases
such as carbon monoxide which is odorless
and invisible.
3
Figure 1 - Dimensions
BOILER RATINGS AND CAPACITIES
Table 1 - Ratings and Capacities
BOILER MODEL NUMBER
Intermittent
Ignition w/
Vent Damper
(1)
Standing
Pilot
w/Vent
Damper
No. of
Sections
Input
*MBH
PSB-3D PVSB-3D 3 75 62 47 196 70 58 44 183 5 11¼
PSB-4D PVSB-4D 4 112.5 91 68 283 105 85 64 267 6 14½
PSB-5D PVSB-5D
5
150 122 92 383 140 114 86 358 6 17¾
PSB-6D PVSB-6D 6 187.5 153 115 479 175 143 107 446 7 21
PSB-7D PVSB-7D 7 225 183 137 571 210 171 128 533 7 24¼
PSB-8D PVSB-8D 8 262.5 214 161 671 245 200 150 625 7 27½
PSB-9D PVSB-9D 9 299 245 184 767 280 229 172 717 7 30¾
* MBH = 1,000 Btuh. Btuh = British Thermal Unit Per Hour.
** Add 5½" to height for Vent Damper
† For altitudes above 2,000 ft. reduce input rate 4% for each 1,000 ft. above sea level.
Heating Capacity is based on DOE (Department of Energy) test procedure.
(1)
Add model number suffi x 'P' for Propane Gas.
†Natural Gas †Propane Gas Dimensions
Heating
Capacity
*MBH
Net
I=B-R
Rating
*MBH
Net
I=B=R
Rating Sq.
Ft.
Input
*MBH
Heating
Capacity
*MBH
Net
I=B=R
Rating
*MBH
Net
I=B=R
Rating
Sq. Ft.
Radiation
Flue
Diameter
(Inches)
"A"
Width
The net I=B=R steam Ratings shown are based on a piping
and pickup allowance of 1.333.
Base selection of boiler size on "Net I=B=R Rating"
being equal to or greater than installed radiation in
square feet. Consult manufacturer before selecting a
boiler for installations having unusual piping and pickup
requirements,such as intermittent system operation,
exhaust piping systems, etc.
Specifi cations and dimensions are subject to change
without notice.
4
BEFORE YOU START
Check to be sure you have the right size boiler before
starting the installation. See rating and capacity table on
previous page. Also be sure the new boiler is for the type of
gas you are using. Check the rating plate on the right side of
the boiler.
You must see that the boiler is supplied with the correct type
of gas, fresh air for combustion, and a suitable electrical
supply. Also, the boiler must be connected to a suitable
venting system and an adequate piping system. Finally, a
thermostat, properly located, is needed for control of the
heating system. If you have any doubts as to the various
requirements, check with local authorities and obtain
professional help where needed. Take the time to complete
all of the steps for SAFE and PROPER operation of the heating
system.
If this boiler is installed in a building under construction,
special care must be taken to insure a clean combustion air
supply during the construction process. Airborne particulates
such as from drywall dust and from fi berglass insulation can
clog the burner ports and cause incomplete combustion and
sooting.
These boilers are designed for use in closed heating systems
where all of the steam is returned to the boiler as condensate
and the amount of make-up water required is minimal.
These boilers are not designed for or intended for use in
open systems of process applications using 100% make-up
water. Damage to the boiler resulting from such use shall
not be covered under the warranty.
Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls and
Safety Devices for Automatically fi red Boilers, ANSI/ASME
CSD-1.
The installation must conform to the requirements of the authority
having jurisdiction or, in the absence of such requirements, to
the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
The following steps are all necessary for proper installation
and safe operation of your boiler.
1. LOCATING THE BOILER 5. GAS SUPPLY PIPING
2. FRESH AIR FOR COMBUSTION 6. ELECTRICAL WIRING
3. INSTALLATION - SYSTEM PIPING 7. CHECKING & ADJUSTING
4. CHIMNEY & VENT PIPE CONNECTION
LOCATING THE BOILER
Select level location as centralized with piping system,
1.
and as near chimney as possible.
Place crated boiler at selected location, remove crate
2.
by pulling crate sides from top and bottom boards.
Combustible fl oors: When boiler is to be installed on a
combustible fl oor, a Special Base Plate must be used -
146-14-031 (2-6 Section) or 146-14-032 (7-9 Section).
This boiler must not be installed on carpeting.
Boiler is to be level. Metal shims may be used under
3.
base legs for fi nal leveling.
Equipment shall be installed in a location in which the
4.
facilities for ventilation permit satisfactory combustion
of gas, proper venting, and maintenance of ambient
temperature at safe limits under normal conditions of
use. Equipment shall be located so as not to interfere
with proper circulation of air. When normal infi ltration
does not provide the necessary air, outside air shall be
introduced (See Page 6 - “Fresh Air for Combustion”).
Advise owner to keep air passages free of obstructions.
5.
Ventilating and combustion air must enter boiler room
without restrictions.
The boiler shall be installed such that the automatic
6.
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation and service (condensate trap, control
replacement, etc.).
Table - 2 Minimum Clearance
Dimensions
Top 6"
Rear 6"
Control Side 7"
Opposite Side 6"
Front Alcove
Flue/Vent Connector 6"
Near Boiler Piping 1"
Unit must be set on a concrete or
other non-combustible material base
or fl oor.
5
FRESH AIR FOR COMBUSTION
WARNING
!
Air openings to combustion area must not
be obstructed. Following instructions below,
adequate combustion air can be maintained.
Provide combustion air and ventilation air in accordance
with the section “Air for Combustion and Ventilation,” of
the National Fuel Gas Code, ANSI Z223.1 / NFPA 54, or
applicable provisions of local building codes.
Provide make-up air where exhaust fans, clothes dryers,
and kitchen ventilation equipment interfere with proper
operation.
National Fuel Gas Code recognizes several methods
of obtaining adequate ventilation and combustion air.
Requirements of the authority having jurisdiction may
override these methods.
Engineered Installations. Must be approved by •
authority having jurisdiction.
Mechanical Air Supply. Provide minimum of 0.35 •
cfm per Mbh for all appliances located within space.
Additional requirements where exhaust fans installed.
Interlock each appliance to mechanical air supply
system to prevent main burner operation when
mechanical air supply system not operating.
All Indoor Air. Calculate minimum volume for all •
appliances in space. Use a different method if
minimum volume not available.
Standard Method. Cannot be used if known air A.
infi ltration rate is 0.40 air changes per hour. See
Table 1 for space with natural gas boiler only. Use
equation for multiple appliances and/or propane.
Volume ≥ 50 ft3 x Total Input [Mbh]
Known Air Infi ltration Rate. See Table 1 for B.
space with boiler only. Use equation for multiple
appliances. Do not use an air infi ltration rate
(ACH) greater than 0.60.
Volume ≥
Refer to National Fuel Gas Code for opening C.
requirements between connected indoor spaces.
All Outdoor Air. Provide permanent opening(s) •
communicating directly or by ducts with outdoors.
Two Permanent Opening Method. Provide opening A.
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom of
enclosure.
One Permanent Opening Method. Provide opening B.
commencing within 12 inches of top of enclosure.
Provide minimum clearance of 1 inch on sides/back
and 6 inches on front of boiler (does not supersede
clearance to combustible materials).
Refer to National Fuel Gas Code for additional C.
requirements for louvers, grilles, screens and air
ducts.
Combination Indoor and Outdoor Air. Refer to National •
Fuel Gas Code for application information.
21 ft3⁄ACH x Total Input [Mbh]
Direct communication with outdoors or
communicating through vertical ducts. Provide
minimum free area of 1 in² per 4 Mbh of total
input rating of all appliances in enclosure.
Communicating through horizontal ducts.
Provide minimum free area of 1 in² per 2
Mbh of total input rating of all appliances in
enclosure.
Table 3 - Minimum Room Volume, Indoor Air Only*
Input Mbh
Standard
Method
0.1 0.2 0.3 0.4 0.5 0.6
75 3750 15750 7875 5250 3938 3150 2625
112.5 5625 23625 11813 7875 5906 4725 3938
150 7500 31500 15750 10500 7875 6300 5250
187 9350 39270 19635 13090 9818 7854 6545
255 11250 47250 23625 15750 11813 9450 7875
262.5 13125 55125 27563 18375 13781 11025 9188
299 14950 62790 31395 20930 15698 12558 10465
* Table values based on boiler only. Add volume for any additional appliances.
Known Air Infi ltration Rate Method (Air Changes Per Hour)
6
INSTALLATION - SYSTEM PIPING
WARNING
Burn and scald hazard. Safety valve could
!
discharge steam or hot water during
operation. Install discharge piping per these
instructions
Near boiler piping, that is the piping around boiler, must be
considered as part of boiler for proper water level control,
and to produce dry steam. Correct near boiler piping is
crucial to the proper operation of the boiler and the heating
system. Follow these recommendations carefully.
Place boiler in selected location, as near chimney as
1.
possible.
Install safety valve, using furnished 3/4” coupling, into
2.
3/4” pipe nipple on top of boiler.
Install safety valve with spindle in vertical position.•
Do no install shutoff valve between boiler and safety •
valve.
Install discharge piping from safety valve. See Figure •
2.
Use 3/4" or larger pipe.•
3.
Use pipe suitable for temperatures of 375°F (191°C) •
or greater.
Individual boiler discharge piping shall be •
independent of other discharge piping.
Size and arrange discharge piping to avoid reducing •
safety valve relieving capacity below minimum relief
valve capacity stated on rating plate.
Run pipe as short and straight as possible to location •
protecting user from scalding and properly drain
piping.
Install union, if used, close to safety valve outlet.•
Install elbow(s), if used, close to safety valve outlet •
and downstream of union (if used).
Terminate pipe with plain end (not threaded).•
This boiler is equipped with two 2-1/2” supply
connections and two 2-1/2” return connections, one
each on both the left and right sides of the boiler.
Unused connections must be plugged with the 2-1/2”
plugs (furnished).
Figure 2 - Recommended Near Boiler Piping Using One Supply Tapping
7
INSTALLATION - SYSTEM PIPING
Recommended near boiler piping for gravity return
4.
systems is shown in Figure 5. This confi guration uses
one supply and one return tapping. This setup can be
used on any size boiler in this series. The supply and
return connections may be piped both into the same
side (either left or right) or one into each side of the
boiler.
5.
For installers choosing to use both supply tappings,
Figure 6A shows the correct way to pipe this system.
Figure 6B shows the wrong way to pipe a header with
two risers.
Headers must be fi tted with header offsets or swing •
joints, or be equipped with expansion joints, so that
thermal expansion and contraction of the header will
not damage the boiler. Headers shall not be welded.
System takeoffs from the header must be between •
the equalizer and the riser to the header nearest the
equalizer. System takeoffs must never be between
two risers.
System takeoffs from the header must never be bull-
6.
headed. If the steam main goes in two directions, there
must be two takeoffs from
the header, one for each
main.
All boilers in gravity return systems
7.
with a Hartford Loop as shown in Figures 2 and 3A.
When piping the vertical risers from the boiler to the
8.
header, the bottom of the header must be a minimum
of 24 inches above the water level line on the right side
of the boiler.
Steam riser(s) and header shall be 2-1/2” pipe size.
9.
Equalizer line shall be minimum 1-1/2” pipe size.
10.
The near boiler piping shall include a 2-1/2” tee with a
11.
plug located on the supply line as shown for skimming
(i.e. surface blowdown).
The near boiler piping shall include a 1-1/2 ball valve
12.
in the return piping as shown for bottom blowdown and
draining.
must be equipped
Figure 3A - Recommended Near Boiler Piping Using One Supply Tapping
8
INSTALLATION - SYSTEM PIPING
For gravity return systems, the bottom of the lowest
13.
steam carrying pipe, be it a dry return, or the end of the
steam main, must be at least 28” above the normal water
level line on the right side of the boiler. This is known as
“Dimension A.”
14.
For pumped return systems, follow the condensate
pump or boiler feed pump manufacturer’s instructions
for proper installation and hookup.
In connecting the cold water supply to the water inlet
15.
valve, make sure that a clean water supply is available.
When the water supply is from a well or pump, a sand
strainer should be installed at the pump.
FOR USE WITH COOLING UNITS
The boiler, when used in connection with a A.
refrigeration system, must be installed so the chilled
medium is piped in parallel with the boiler with
appropriate valves to prevent the chilled medium
from entering the boiler. See Figure 4.
Figure 3B - Common Near Boiler Piping Mistakes
Figure 4 - Chilled Water Piping
VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING
VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING
9
CHIMNEY AND VENT PIPE CONNECTION
For boilers for connection to gas vents or chimneys,
vent installations shall be in accordance with "Venting of
Equipment", of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54, or applicable provisions of the local building
codes.
CHECK YOUR CHIMNEY
This is a very important part of your heating system. It
must be clean, the right size, properly constructed and in
GOOD CONDITION. No boiler can function properly with
a bad chimney. Inspect the chimney and verify that the
construction and size of the chimney meets all applicable
provisions of the National Fuel Gas Code and local building
codes. Figure 4 gives you an idea how a boiler might be
vented to a chimney. Note that the height (HT) is measured
from the vent pipe to the top.
CONNECTING THE VENT DAMPER AND VENT
CONNECTOR
Refer to Fig. 1 and Table 1 for the size and location of the
vent (fl ue opening). Use a 28 gauge (minimum) galvanized
pipe to connect to the chimney.
IMPORTANT - The damper blade on the furnished vent
damper has a 1/2 square inch hole (approximately 3/4”
diameter). On boilers equipped with standing pilot, the hole
must be left open. On boilers equipped with intermittent
ignition, the hole should be plugged by using the plug
supplied with the vent damper.
1.
Position furnished vent damper on top of fl ue outlet
collar. Fasten damper securely to fl ue outlet collar
with sheet metal screws. Make sure damper blade has
clearance to operate inside of diverter. Do not modify
draft diverter or vent damper
As An Option
The damper may be installed in any horizontal or
vertical position, closer to the fl ue outlet collar
preferred. Follow the diagrams - Figures 6, 7 and 8.
Install the vent damper to service only the single boiler
2.
for which it is intended. The damper position indicator
shall be in a visible location following installation.
Locate the damper so that it is accessible for servicing.
The damper must be in the open position when
3.
appliance main burners are operating.
The boiler is equipped with a factory wired harness
4.
that plugs into the vent damper. The thermostat
must be connected to the black wires marked 24 volt
thermostat on the boiler.
Vent pipe must be same size as the fl ue outlet collar.
5.
Slope pipe up from boiler to chimney not less than 1/4”
6.
per foot.
Run pipe as directly as possible with as few elbows as
7.
possible.
8.
9.
10.
The sections of vent pipe should be fastened with sheet
metal screws to make the piping rigid. Horizontal portions
of the vent system must be supported to prevent sagging.
Use stovepipe wires every 5’ to support the pipe from above.
If the vent pipe must go through a crawl space, double wall
vent pipe should be used. Where vent pipe passes through a
combustible wall or partition, use a ventilated metal thimble.
The thimble should be 4 inches larger in diameter than the
vent pipe.
MINIMUM VENT PIPE CLEARANCE
Wood and other combustible materials must not be closer
than 6” from any surface of single wall metal vent pipe.
Listed Type B vent pipe or other listed venting systems shall
be installed in accordance with their listing.
REMOVING EXISTING BOILER FROM COMMON
VENTING SYSTEM
When an existing boiler is removed from a common venting
system, the common venting system is likely to be too large
for proper venting of the appliances remaining connected to
it.
At the time of removal of an existing boiler , the following steps
shall be followed with each appliance remaining connected
to the common venting system placed in operation, while
the other appliances remaining connected to the common
venting system are not in operation.
1.
2.
3.
4.
Do not connect to fi replace fl ue.
End of vent pipe must be fl ush with inside face of
chimney fl ue. Use a sealed-in thimble for the chimney
connection.
Horizontal run should not be longer than 3/4 the
chimney height (HT) (Fig.5).
Seal any unused openings in the common venting
system.
Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other defi ciencies
which could cause an unsafe condition.
Insofar as is practical, close all building doors and
windows and all doors between the space in which the
appliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they will operate at maximum speed. Do not operate a
summer exhaust fan. Close fi replace dampers.
Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
10
CHIMNEY AND VENT PIPE CONNECTION
Test for spillage at the draft hood relief opening after
5.
5 minutes of main burner operation. Use the fl ame of
a match or candle, or smoke from a cigarette, cigar or
pipe.
6.
After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fi replace dampers and
any other gas-burning appliance to their previous
conditions of use.
Any improper operation of the common venting system
7.
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
When resizing any portion of the common venting
system, the common venting system should be resized
to approach the minimum size as determined using the
appropriate tables in Chapter 13 of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of mechanical
draft systems operating under positive pressure.
Figure 5 - Typical Masonry Chimney Requirements
Figure 6 - Horizontal Installation
VENT DAMPER OPERATION
Figure 7 - Alternate Vent Damper Installation
TYPICAL INSTALLATION FOR VENT DAMPER
NOTE CAUTION AND FOOTNOTES
Install the vent damper to service only the single
1.
appliance for which it is intended. If improperly
installed, a hazardous condition, such as an explosion
or carbon monoxide poisoning, could result.
Do not install the vent damper on vent pipe curve.
2.
Do not run wires near high temperature surfaces.
3.
Use stand-off brackets if necessary.
11
Loading...