Dunkirk WPSB-3D, WPSB-4D, WPSB-4DP, WPSB-3DP, WPSB-5D Operation & Maintenance Manual

Models

WPSB-3D

WPSB-3DP

WPSB SERIES II

GAS-FIRED

WPSB-4D

WPSB-4DP

WPSB-5D

WPSB-5DP

WPSB-6D

WPSB-6DP

WPSB-7D

WPSB-7DP

WPSB-8D

WPSB-8DP

WPSB-9D

WPSB-9DP

HOT WATER BOILERS

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Tested For 50 psi.

ASME

Working Pressure

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N 240009047, Rev. D [03/09/2016]

DIMENSIONS

DIMENSIONS

CONTROL

BOILER

MODEL

NUMBER

WPSB-3 5 11¼ 6.3

WPSB-4 6 14½ 8.1

WPSB-5 6 17¾ 9.9

WPSB-6 7 21 11.7

WPSB-7 7 24¼ 13.5

WPSB-8 7 27½ 15.3

WPSB-9 7 30¾ 17.2

Add 5½” to height for vent Damper.

Dimensions

DIMENSIONS (INCH.)

FLUE

DIAMETER

“A”

WIDTH

2

Boiler

Volume

Gallon

BOILER RATINGS AND CAPACITIES

Table 1 - Ratings and Capacities

† NATURAL GAS † PROPANE GAS AFUE

BOILER
MODEL
NUMBER

(1)

Input

(3)

Mbh

Heating

Capacity

(3)

Mbh

(2)

NET AHRI

RATING

Water,

(3)

Mbh

INPUT

(3)

Mbh

HEATING

CAPACITY

(3)

MBH

(2) NET

AHRI

RATING

(3)

Mbh

INTERMITTENT

IGNITION

WITH VENT

DAMPER

WPSB-3 75 63 55 70 59 51 84.0

WPSB-4 112.5 94 82 105 88 77 84.0

WPSB-5 150 126 110 140 118 103 84.1

WPSB-6 187.5 157 137 175 147 128 84.1

WPSB-7 225 188 163 210 176 153 84.0

WPSB-8 262.5 220 191 245 206 179 83.9

WPSB-9 299 251 218 280 235 204 83.7

† For altitudes above 2,000 ft. rating should be reduced at the rate of 4% for each 1,000 ft. above sea level.

Heating Capacity is based on D.O.E. (Department of Energy) test procedure.

(1)

Add model number sufx ‘P’ for Propane.

(2)

Net AHRI Water rating shown based on piping and pickup allowance of 1.15. Consult manufacturer before

selecting boiler for installations having unusual piping and pickup requirements, such as intermittent

system operation, extensive piping systems, etc.

(3)

MBH = 1,000 Btuh = British Thermal Unit Per Hour

- Ratings marked “Net AHRI Ratings” indicate amount of remaining heat input used to heat radiation or
terminal units. Net AHRI Ratings shown are based on allowance of 1.15 in accordance with factors shown on
AHRI Standard as published by The Hydronics Institute.

- Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater 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 factory equipped for use at altitudes of 0-2,000 feet above sea level.
For use at altitudes above 2,000 feet above sea level, input ratings are reduced by change in main burner

orice size.

For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000
feet above sea level. Consult National Fuel Gas Code (NFPA54/ANSI Z223.1-latest edition), or manufacturer

for correct orice sizing information.

3

TABLE OF CONTENTS

Table of Contents ................................................ 4

Locating the Boiler .............................................. 5

Ventilation & Combustion Air ................................ 6

Connecting Supply and Return Piping .................... 7

Chimney and Vent Pipe Connection ......................11

Vent Damper Operation ......................................13

Gas Supply Piping ..............................................14

Electrical Wiring ................................................15

Wiring Diagrams ................................................16

Starting Your Boiler ............................................17

Lighting Instructions ..........................................18

Operating Your Boiler .........................................19

Operating The Boiler - System Start-Up ...............21

Service Hints ....................................................23

Maintaining Your Boiler .......................................24

Equipment and Optional Accessories ...................25

SAFETY SYMBOLS & WARNINGS

The following dened symbols are used throughout this

manual to notify the reader of potential hazards of varying
risk levels.

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

IMPORTANT: Read the following instructions
COMPLETELY before installing!!

!

WARNING

Fire, explosion, asphyxiation and electrical shock

hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.

!

WARNING

Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors and

liquids.
DO NOT obstruct air openings to the boiler room.

Modication, substitution or elimination of factory
equipped, supplied or specied components may

result in personal injury or loss of life.
TO THE OWNER - Installation and service of this

boiler must be performed by a qualied installer.

TO THE INSTALLER - Leave all instructions with
boiler for future reference.

When this product is installed in the Commonwealth
of Massachusetts the installation must be performed
by a Licensed Plumber or Licensed Gas Fitter.

!

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, could result in minor or moderate injury.

NOTICE

Indicates information which should be followed to
ensure proper installation and operation.

4

LOCATING THE BOILER

!

WARNING

Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury.

1.

Installation must conform to requirements of authority
having jurisdiction or, in absence of such requirements,
to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

2.

Where required by authority having jurisdiction,
installation must conform to the Standard for Controls

and Safety Devices for Automatically red Boilers,

ANSI/ASME CSD-1.

3.

Boiler series is classied as Category I. Vent

installation shall be in accordance with "Venting of
Equipment ," of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or applicable provisions of local
building codes.

4.

Boiler installed in building under construction; take
care to insure clean combustion air supply during
construction process. Airborne particulates from drywall

dust and berglass insulation can clog burner ports and

cause incomplete combustion and sooting.

5.

Boiler shall be installed such that gas ignition system
components are protected from water (dripping,
spraying, rain, etc.) during appliance operation and
service, (circulator replacement, condensate trap,
control replacement, etc.).

6.

Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.

7.

When installed in utility room, door should be wide
enough to allow largest boiler part to enter, or to
permit replacement of another appliance such as water
heater.

8.

Accessibility clearances take precedence over re

protection clearances. An 18-inch clearance should be
maintained on any side where passage is required to
access another side for cleaning, servicing, inspection
or replacement of any part that may need attention. An
18-inch clearance is recommended on the control side
for servicing.

9.

Locate equipment which allows the facilities for
ventilation 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 inltration does

not provide the necessary air, outside air shall be
introduced (See “Fresh Air for Combustion”).

10.

Keep air passages free of obstructions. Ventilation
and combustion air must enter boiler room without
restrictions.

!

WARNING

Fire hazard. Shall not install boiler on combustible

ooring or carpeting. Failure to follow these

instructions could result in death or serious injury.

11.

FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible

ooring special base must be used. (See Replacement

Parts Section.) Do Not install Boiler on carpeting.

Minimum Clearance Dimensions

Table 2 - Minimum Clearances

Alcove

Top 6” (152mm)

Rear 6” (152mm)

Control Side 7” (178mm)

Opposite Side 6” (152mm)

Front

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 2” (51mm)

NOTE: Greater clearances for access should supersede fire

protection clearances.

* Denition of Alcove is three sided space with no wall in

front of boiler. ANSI standard for alcove is 18 inches from
front of appliance to leading edge of side walls as shown
below.

18” (457mm)

Minimum Clearances to Combustible

Construction (as seen from above)

6"

6"

BOILER

Front

7"

Control

Side

18"

5

VENTILATION & COMBUSTION AIR

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.

A. Standard Method. Cannot be used if known air

inltration rate is 0.40 air changes per hour. See

Table 3 for space with boiler only. Use equation for
multiple appliances.

Volume ≥ 50 ft3 x Total Input [Mbh]

B. Known Air Inltration Rate. See Table 3 for

space with boiler only. Use equation for multiple

appliances. Do not use an air inltration rate

(ACH) greater than 0.60.

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 by ducts with outdoors.

A. Two Permanent Opening Method. Provide opening

commencing within 12 inches of top and second
opening commencing within 12 inches of bottom of
enclosure.

 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.

B. One Permanent Opening Method. Provide opening

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
requirements for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer to National
Fuel Gas Code for application information.

National Gas and Propane Installation Code Requires
providing air supply in accordance with:

• Section 8.2 and 8.3 when combination of appliances

has a total input of up to and including 400 Mbh (120
kW).

• Section 8.4 when combination of appliances has total

input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code

for specic air supply requirements for enclosure

or structure where boiler is installed, including air
supply openings and ducts.

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

187.5 9375 39375 19688 13090 9844 7875 6563
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 Inltration Rate Method ACH (Air Changes Per Hour)

6

CONNECTING SUPPLY AND RETURN PIPING

!

WARNING

Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns,
scalding, or water damage due to discharge of steam and/or hot water during operation.

Discharge line shall:

• Connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum

distance from oor or allowable safe point of discharge.

• Be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge
line.

• Have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug
or place any obstruction in discharge line.

• Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing.

• Allow complete drainage of the valve and the discharge line.

• Be independently supported and securely anchored to avoid applied stress on the relief valve.

• Be as short and straight as possible.

• Terminate with plain end (not threaded).

• Be constructed of material suitable for exposure to temperatures of 375°F (191°C); or greater.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation
requirements.

Figure 1 - Safety Relief Valve

DISCHARGE

LINE

Check local

codes for

maximum

distance

from oor

or allowable
safe point of

discharge.

RELIEF VALVE

7

CONNECTING SUPPLY AND RETURN PIPING

!

WARNING

Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.

1.

Install discharge piping from safety relief valve. See
Warning, Page 7.

2.

Install temperature pressure gauge.

• Apply pipe sealant to threads on shaft of gauge.

• Thread gauge into supply water tee. See Figure 2.

NOTICE

Do not tighten gauge by hand. Gauge should be
tightened using crescent wrench or 9/16” open end
wrench. See Figure 2.

3.

Connect supply and return lines to boiler. Connections

may require additional ttings and parts, as shown on

diagrams.

4.

Boiler is equipped with 1 1/4” supply and return
connections on both left and right sides of boiler.

Verify clean water supply is available to water inlet valve.
Install sand strainer when water supply is from a well or
pump.

Install hot water boiler above radiation level or as
required by Authority having jurisdiction install low water
cutoff device at time of installation. Periodic inspection

is necessary, as is ushing of oat type devices, per
manufacturers specic instruction.

FOR USE WITH COOLING UNITS

A. Boiler used in connection with refrigeration system,

must be installed so that chilled medium is piped in
parallel with heating boiler. Appropriate valves must be
used to prevent chilled medium from entering heating
boiler. See Figure 4 page 9.

B. Boiler connected to heating coils located in air handling

units where they may be exposed to refrigerated air
circulation, piping system shall be equipped with ow

control valves or other automatic means to prevent
gravity circulation of boiler water during cooling cycle.

LOW WATER TEMPERATURE AND LARGE WATER
CONTENT SYSTEM (See Figures 5 and 6, Page 10.)

Signicant condensation may form in boiler and/or

venting system if boiler is operated for long period of
time with return temperatures of less than 120° F.

Figure 2 - Temperature Pressure Gauge

Condensate is corrosive and can cause severe
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 where design water

temperatures below 140°F are desired (e.g. radiant
oor heating), 4-way mixing valve or suitable

alternative is required to prevent low temperature low

return water from entering boiler. Follow mixing valve
manufacturer’s instructions.

2.

Boiler connected to system having large water content
(such as former gravity system), install system bypass.
See Figures 5 and 6, page 10.

3.

Boiler water reset control is used to operate boiler,
minimum reset supply water temperature setpoint

must be at least 140°F, unless mixing valve is used as

in (1) above.

8

CONNECTING SUPPLY AND RETURN PIPING

Figure 3- Typical Hot Water Piping

Figure 4 - Chilled Water Piping

9