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

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Page 1

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]

Page 2

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

Boiler

Volume

Gallon

Page 3

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.

Page 4

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.

Page 5

LOCATING THE BOILER

WARNING

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

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.

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.

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.

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.

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.).

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

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.

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.

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)

BOILER

Front

Control

Side

18"

Page 6

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)

Page 7

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

Page 8

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.

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

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.

Connect supply and return lines to boiler. Connections

may require additional ttings and parts, as shown on

diagrams.

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.

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.

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

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.

Page 9

CONNECTING SUPPLY AND RETURN PIPING

Figure 3- Typical Hot Water Piping

Figure 4 - Chilled Water Piping

Page 10

CONTROL

Control

CONNECTING SUPPLY AND RETURN PIPING

BYPASS PIPING REQUIRED FOR HIGH MASS (LARGE WATER CONTENT) SYSTEMS

Figure 5 - Bypass Piping - Circulator On Supply

Figure 6 - Bypass Piping - Circulator On Return

Page 11

CHIMNEY AND VENT PIPE CONNECTION

Boilers connecting 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 local building codes.

Check Your Chimney

It must be clean, right size, properly constructed and in good condition.

Chimney Sizing

Chimney sizing, and vent installation must be in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of local building codes.

Connecting The Vent Damper And Vent Connector

Refer to Dimensions, page 2 for size and location of

vent (ue opening).

Damper blade on furnished vent damper has 1/2

square inch hole (approximately 3/4” diameter).

Boilers equipped with intermittent ignition, hole should be plugged by using plug supplied with vent damper.

This is a high efciency boiler with low stack temperature.

Following recommendations are in addition to requirements of the National Fuel Gas Code.

1. Type B double wall vent pipe is recommended for vent connector. Single wall vent connectors should not be used unless following conditions are true:

a) Except for basement, boiler is not installed in

unheated space.

b) Total horizontal portion of vent connector, not

including elbows is less than 5 feet in length.

2. Outside chimneys (i.e. chimneys exposed to

outdoors below roof line) should not be used unless they are:

a) enclosed in a chase, or

b) lined with type B vent pipe, or listed exible vent liner, or other certied chimney lining system.

3. Where possible it is recommended to common vent boiler and water heater.

4. For multiple boiler installations, consult boiler manufacturer for venting recommendations.

NOTICE

Position furnished vent damper on top of ue outlet collar. Fasten damper securely to ue outlet collar with

sheet metal screws. Verify damper blade has clearance to operate inside of diverter. Do not modify either draft diverter or vent damper during installation.

As An Option

Damper may be installed in a horizontal or

vertical position, closer to ue outlet collar

preferred. See Figures 7, 8 and 9, and Vent Damper Instructions.

Install vent damper to service only single boiler for which it is intended. Damper position indicator shall be in visible location following installation. Locate damper so it is accessible for servicing.

Damper must be in the open position when appliance main burners are operating.

Boiler is equipped with factory wired harness that plugs into vent damper.

Slope pipe up from boiler to chimney not less than 1/4” per foot.

Run pipe as directly as possible with as few elbows as possible.

Do not connect to replace ue.

End of vent pipe must be ush with inside face of chimney ue. Use a sealed-in thimble for chimney

connection.

Sections of vent pipe should be fastened with sheet metal screws to make piping rigid. Horizontal potions of vent system must be supported to prevent sagging. Use

stovepipe wires every 5’ to support pipe from above. If

vent pipe must go through crawl space, double wall vent pipe should be used. Where vent pipe passes through combustible wall or partition, use ventilated metal thimble. Thimble should be 4 inches larger in diameter than 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.

Page 12

CHIMNEY AND VENT PIPE CONNECTION

Removing Existing Boiler From Common Venting System

When an existing boiler is removed from common venting

system, common venting system is likely to be too large for proper venting of appliances 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 other appliances remaining connected to common venting system are not in operation.

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 de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 replace dampers.

Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the ame of

a match or candle, or smoke from a cigarette, cigar or pipe.

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, replace dampers and

any other gas-burning appliance to their previous conditions of use.

Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

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. When re-sizing any portion of the common venting system, the common venting system should be re-sized 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.

Page 13

VENT DAMPER OPERATION

Figure 7 Figure 8

For safe, efcient operation, vent damper and all ue

product carrying areas of appliance must be checked annually, with particular attention given to deterioration from corrosion or other sources. If you see corrosion or other deterioration, contact your heating contractor for repairs. Check vent damper operation as follows:

• When boiler is off, check vent damper positions indicator points to closed position. See Figure 9.

• Turn thermostat or controller up to call for heat and check vent damper indicator points to open position. See Figure 9.

• 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 operation by using “HOLD DAMPER OPEN” switch, located on damper controller. Thermostat will control

burner ring as before, while damper will remain open.

DO NOT turn damper open manually or motor damage will result. Set switch to “AUTOMATIC OPERATION” to close vent damper during burner off cycle.

For further information, and vent damper troubleshooting guide, refer to manual packaged with vent damper.

Inspect vent damper at least once a year by a

qualied service technician.

Figure 9 - Vent Damper Position Indicator

Page 14

GAS SUPPLY PIPING

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow gas supplier’s

instructions.

•

Pressure test at 1/2 psig (3.5 kPa) or less. Isolate boiler from gas supply system by closing manual gas shutoff valve.

•

Locate leakage using gas detector, noncorrosive

detection uid, or other leak detection method

acceptable to authority having jurisdiction. Do

not use matches, candles, open ames, or other

methods providing ignition source.

•

Correct leaks immediately and retest.

• If you cannot reach your gas supplier, call the re

department.

Check Gas Supply

Gas pipe to your boiler must be correct size for length of run and for total BTU per hour input of all gas utilization equipment connected to it. Be sure your gas line complies with local codes and gas company requirements. See Table 4 for proper pipe size.

Connecting The Gas Piping

Gas line enters boiler from right side.

• Use only piping materials and joining methods listed as acceptable by the authority having jurisdiction, or in the absence of such requirements, by the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

• Use pipe joint compound suitable for LP gas on male threads only.

• Use ground joint unions.

• Install sediment trap upstream of gas controls.

• Use two pipe wrenches when making connection to gas valve to keep it from turning.

• Install manual shut-off valve in vertical pipe about 5

feet above oor.

• Tighten all joints securely.

• Propane gas connections should only be made by licensed propane installer.

• Two-stage regulation should be used by propane installer.

• Propane gas piping should be checked out by propane installer.

Table 4 - GAS PIPE SIZES

NATURAL GAS

Pipe Capacity - BTU Per Hour Input

Includes Fittings

Length of Pipe - FT

20 92,000 190,000 350,000 625,000

40 63,000 130,000 245,000 445,000

60 50,000 105,000 195,000 365,000

Length of

Pipe - FT

20 131,000 216,000 189,000 393,000

40 90,000 145,000 129,000 267,000

60 72,000 121,000 103,000 217,000

* Outside diameter Measure length of pipe or tubing from gas meter or

propane second stage regulator.

Figure 10 - Gas Piping

½” ¾” 1” 1¼”

PROPANE GAS

Pipe Capacity - BTU Per Hour Input

Includes Fittings

Copper Tubing * Iron Pipe

⅝” ¾” ½” ¾”

CHECKING GAS PIPING

DANGER

Fire Hazard. Do not use matches, candles, open

ames, or other methods providing ignition source.

Failure to comply will result in death or serious injury.

Pressure test boiler and gas connection before placing boiler in operation.

•

Pressure test over 1/2 psig (3.5 kPa). Disconnect boiler and its individual gas shutoff valve from gas supply system.

Page 15

ELECTRICAL WIRING

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to National Electrical Code, ANSI/NFPA 70.

ELECTRIC POWER SUPPLY

Run separate 120 volt circuit from separate over current protective device in electrical service entrance panel. This should be a 15 ampere circuit. Locate shut-off switch at boiler. It must be turned off during any maintenance. Connect 120 volt power supply to control leads L1 (HOT) and L2.

Run a 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod.

THERMOSTAT INSTALLATION

Thermostat should be installed on an inside wall about

four feet above the oor.

NEVER install a thermostat on an outside wall.

Do not install a thermostat where it will be affected

by drafts, hot or cold pipes, sunlight, lighting xtures, televisions, a replace, or a chimney.

Check thermostat operation by raising and lowering thermostat setting as required to start and stop the burners.

Instructions for the nal adjustment of the thermostat

are packaged with the thermostat (adjusting heating anticipator, calibration, etc.)

VENT DAMPER WIRING

Boiler is equipped with factory wired harness with 4 pin

molex plug, that plugs into 4 pin molex receptacle inside

vent damper operator. Vent damper must be connected for boiler to operate.

NOTICE

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

If original wire as supplied with this appliance must be replaced, replace with type 105°C thermoplastic wire or its equivalent.

Set heat anticipator at .2 amps. 24 volt thermostat connects to aquastat terminals T and TV.

Page 16

WIRING DIAGRAMS

Figure 11 - Electronic Ignition Control

WARNING

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

result in personal injury or loss of life.

Page 17

STARTING YOUR BOILER

FILLING SYSTEM WITH WATER

• Close air vents on all radiation units. Open valves to

these units.

• Verify boiler and expansion tank drain valves are closed.

• Close drain tting on air bleed screw.

• Open valve in line from boiler to expansion tank. Open

water inlet to your boiler and leave it open. Start with lowest radiation unit. Open air vent on this unit. When

all air has escaped and water starts to ow from vent,

close it.

• Go to next radiation unit, and repeat process. Repeat

until you have covered every radiation units in the system

(ending up at highest unit in system).

• If your units have automatic vents, this manual venting is

unnecessary but it will speed up the proper lling of your

system.

• If your system is closed expansion tank system, you may

leave it open to rell system automatically as needed.

• Check temperature pressure gauge. Not position of hand indicating pressure. This should be between 10 and 15 psi. Any lowering of this movable hand below 10 psi. indicates

loss of water due to leakage. Automatic ll valve should

compensate for this. Instructions are packaged with valve.

NOTICE

Never run water in a hot empty boiler.

Page 18

LIGHTING INSTRUCTIONS

WARNING

If you do not follow these instructions

exactly, a re or explosion may result

causing property damage, personal injury or loss of life.

• This appliance is equipped with an ignition device which automatically lights burner. Do NOT try to

light this burner by hand.

• Before operating smell all around appliance area

for gas. Be sure to smell next to oor because

some gas is heavier than air and will settle to the

oor.

• Use only your hand to turn the gas shutoff valve. Never use tools. If valve will not turn

by hand, do not try to repair it, call a qualied

service technician. Force or attempted repair may

result in re or explosion.

• Do not use this appliance if any part has been under water. Immediately call a qualied

service technician to inspect appliance and to replace any part of control system and any gas control which has been under water.

F. Remove front panel.

G. Rotate the gas control knob clockwise to “OFF”.

Figure 12 - Automatic Gas Valve

PRESSURE REGULATOR (UNDER CAP SCREW)

INLET

PRESSURE

TAP

INLET

GAS CONTROL

KNOB

ADJUSTMENT

OFF

PILOT ADJUSTMENT

(UNDER CAP SCREW)

WIRING TERMINALS (2)

OUTLET PRESSURE TAP

GROUND TERMINALS

(2)

OUTLET

PILOT OUTLET

H. Wait ve (5) minutes to clear out any gas. Then

smell for gas, including near the oor. If you smell

gas, STOP! Follow the safety information “What To Do

If You Smell Gas”. If you don’t smell gas, go to next

step.

I. Rotate gas control knob counterclockwise to

“ON”.

LIGHTING PROCEDURE FOR BOILER WITH INTERMITTENT PILOT SYSTEM

For Your Safety, Read Before Operating!!

A. This appliance is equipped with an ignition device

which automatically lights the pilot. Do not try to light appliance by hand.

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switches; do not use any phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the re department.

B. STOP! Read the safety information above.

J. Turn on all electric power to the appliance.

K. Set thermostat to desired setting.

L. If appliance will not operate, follow the instructions

“To Turn Off Gas To Appliance” and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Push in gas control knob slightly and turn

clockwise to “OFF” Do not force.

C. Set the thermostat to lowest setting.

D. Turn off all electric power to the appliance.

E. This appliance is equipped with an ignition device which

automatically lights the pilot. Do not try to light the pilot by hand.

Page 19

OPERATING YOUR BOILER

AUTOMATIC GAS VALVE

Automatic Gas Valve opens or closes according to heat requirements of thermostat and temperature limit control. It closes if pilot goes out. Each individual control must be operating correctly before any gas can pass to burners. Any one control can hold gas supply from burner regardless of demand of any other control.

SAFETY PILOT

Safety Pilot prevents ow of gas to burner if pilot

goes out, or will not ignite.

GAS VALVE SAFETY SHUTDOWN TEST

Ignition system safety shutoff device must be tested after placing boiler in operation.

RELIGHT

Electric and gas shall be off for 5 minutes before relighting.

THERMOSTAT

Keep it set at desired room temperature. If windows are to be opened or heat is not needed, move thermostat pointer to lower setting.

NOTICE

In event of failure of any component, system will not operate or will go into safety lockout. System is completely self-checking. On every call for heat, each component must be functioning properly to permit operation. Safety lockout system has to be reset by turning thermostat to lowest setting for one minute, then back to normal setting.

Figure 13 - Pilot Flame

MAIN BURNER(S)

• Main burners do not require primary air adjustment and are not equipped with primary air shutters.

• Main burner ames form sharp blue inner cones in softer blue outer mantel, with no yellow.

• Puffs of air from blowing on ame or stamping on oor

will cause ames to turn orange momentarily. This is

not unusual. Remain still when observing main burner

ames.

• If ame appearance is not correct, check main burner orices, burner throat and ame ports for dust and

lint obstruction. It may be necessary to remove rollout

shield to observe main burner ames. Replace rollout

shield after observation. Refer to Figure 14.

Figure 14 - Burner

ADJUST PILOT BURNER

Pilot ame should surround 3/8” to 1/2” of the pilot sensor. See Figure 16. If ame needs adjusting, do it

as follows:

Remove screw cover over pilot adjusting screw.

Insert small screwdriver and adjust ame as needed. Turn screw counterclockwise to increase ame, clockwise

to decrease.

Replace screw cover over pilot adjusting screw.

ADJUST LIMIT CONTROLS

Instructions for each control are included with controls. Settings can be changed.

See Control Section page 24.

Page 20

OPERATING YOUR BOILER

CHECK THERMOSTAT OPERATION

A. When set above temperature indicated on

thermostat, boiler should ignite.

B. Verify thermostat turns boiler off when room

temperature reaches selected setting and starts boiler operating when room temperature falls a few degrees.

C. After setting limit control to limit setting, check to

see if it 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 thermostat is satised, or water cools enough

to restart burners through limit control.

D. Set thermostat for desired temperature. Conditions

in your home and location of thermostat will govern this setting.

Page 21

OPERATING THE BOILER - SYSTEM START-UP

HI TEMP illuminates when boiler water temperature

reaches high limit setting. Remains lit until water

temperature falls 10°. Prevents burner operation while this

LED is on.

LWCO Active Indicates low water cut-off (LWCO) function of limit control is active. When control is installed with a well, LED is on at all times when control is powered.

Important: If control is installed with a well other than Electro-Well, LED will not illuminate indicating control is not providing low water cut-off functionality.

WARNING

Burn and scald hazard. Do not add water until boiler has fully cooled. Failure to follow these instructions could result in death or serious injury.

LWCO Low Water illuminates if boiler is in low water

condition. Limit control prevents burner operation during this condition.

Important: Have system checked by qualied service

agency prior to resuming operation.

ECONOMY Active Indicates thermal targeting function

is active and limit control is reducing boiler temperature to conserve fuel. Economy feature is activated using Economy dial.

ECONOMY TARGET Economy feature is active, limit

control continually sets target temperatures below high

limit setting to maximize fuel efciency. When boiler water

reaches target temperature, LED illuminates and burner shuts down. Boiler water will continue to circulate and heat the house as long as thermostat call continues. LED will stay lit until boiler temperature drops below differential set

point at which point boiler will be allowed to re again.

Note: LED illuminates regularly during normal boiler operation.

LWCO TEST Button To Test Low Water Cut-Off: Press and hold Test/Settings

button for 5 seconds. Display will read LWCO. LWCO TEST

Red Low Water light will illuminate and burner circuit (B1 and B2) will de-energize.

Note: Control must be installed with Electro-Well for low water cut-off functionality.

LCO

Page 22

Burner Will Not Fire

No or Insufcient Domestic

Hot Water

If installed with indirect water heater, insure end switch in relay box controlling indirect water

heater is properly connected to cable 2 (see wiring diagram). This insures domestic water calls are prioritized. If cable 2 is not used, turn Economy Feature OFF.

House will not get or stay

warm

OPERATING THE BOILER - SYSTEM START-UP

Table 1 - Troubleshooting

Check for air bound radiators. Check thermostat settings including heat anticipator settings (common on non-digital

thermostats. Check Economy settings. Economy feature, much like outdoor reset controls, lowers

average boiler temperature, can slow or prevent the house from coming up to temperature. Move to lower setting.

Page 23

SERVICE HINTS

You may avoid inconvenience and service calls by checking these points before you call for service.

Possible Cause What to do

EQUIPMENT AND OPTIONAL ACCESSORIES - WHAT THEY DO

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the re department.

IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .

Thermostat is not set correctly

Burner is not operating properly

No electric power to boiler

Controls out of adjustment

Radiators not heating

Circulating pump not running

Poor electrical contact

Rollout switch blown

Blocked vent safety switch blown

Vent damper not operating

Gas input amount is incorrect

Reset thermostat above room temperature

Check ame. If it is yellow, burner is not getting enough air. Or, if ame is blue and noisy and seems to lift off burner, burner is getting

too much air. Contact your service technician.

Check over current protection. Verify electric power supply circuit is “ON”.

Reset according to instructions.

Open radiator vents to expel air. Check ow control valve (if used). It

may be in closed position.

Check over current protection. Check relay operation.

Check all control terminals and wire joints.

Have your service agent check heat exchanged for blockage. Replace rollout switch with exact replacement.

Have your service agent check venting system and chimney for blockage, or down draft condition. Reset blocked vent safety switch.

Consult troubleshooting guide in Efkal manual, packaged with vent

damper.

IF BURNER IS NOISY . .

Contact your service agent.

Dirt on seat

Water logged expansion tank

HAVE YOUR SERVICE AGENT CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.

RELIEF VALVE LEAKING . . .

Open valve manually. Allow water to run and clear valve seat.

Drain tank, see instructions.

Page 24

MAINTAINING YOUR BOILER

BURNERS

Beginning of heating season visually check pilot end main

burner ames. See page 19

SAFETY RELIEF VALVE

Test safety relief valve for proper operation. Refer to valve

manufacturer’s instructions packaged with relief valve. Call Technical Support if manufacturer’s instruction are not

located.

EXPANSION TANK

Tank may become waterlogged, or may receive excess

of air. Frequent automatic opening of safety relief valve indicates water logging. High boiler temperature accompanied by unusually low radiation unit temperature

(and “knocking”) indicates excess air in tank.

To correct:

Close valve between boiler and tank. Drain tank until empty.

Check all tank plugs and ttings. Tighten as necessary.

Open valve between boiler and tank. Water will rise to

normal height in tank if you have automatic ll valve (otherwise, manually rell system).

BOILER FLUE PASSAGES

Recommend following checked annually by qualied service

agent.

• ue passages

• burner adjustment

• operation of controls

Before start of each season (or whenever system has been shut down for some time) recheck whole system for leaks and recheck boiler and vent pipe for leaks. Replace or patch any boiler seals that are faulty.

VENT PIPE

Venting and piping should be checked at least once a season. If vent piping shows any sign of leaking, replace immediately.

CLEANING YOUR BOILER AND BURNERS

Flue passages between sections should be examined yearly

and cleaned if necessary. To clean:

CIRCULATOR PUMP ISOLATION VALVES

Operate isolation valves in circulator pump anges

manually once or twice per year to prevent valves from becoming stuck in open position

Rotate valves from open position to closed position and back to open position.

HOUSEKEEPING

• Remove burners, pilot, and vent pipe.

• Remove top and front jacket panels.

• Remove two screws attaching intermediate front panel to left and right side jacket panels.

• Remove draft diverter and intermediate front panel as a unit.

• Carefully remove cerafelt gasket strips.

• Clean passageways between sections with exible handle wire brush. Remove dirt from bottom of boiler and from between sections by vacuuming.

• Verify all ame ports in burners are open and clear. Shake out or blow out all loose dirt in burners.

• Reseal seams between adjacent sections as necessary with 400° F RTV silicone sealant.

• Reassemble all parts.

• Verify tightness of pilot connections and condition of

burner ames after reassembly. See Figures 15 and 16.

• Verify vent pipe connections to chimney are secure and no obstructions are present.

• Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors and

liquids.

• Keep boiler area clear of debris and other materials

obstructing ow of combustion and ventilation air.

WATER SYSTEM

If system is to remain out of service during freezing weather, always drain it completely (water left in to freeze will crack pipes and/or boiler).

Page 25

EQUIPMENT AND OPTIONAL ACCESSORIES

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation.

AIR ELIMINATING FITTING (AIR PURGER)

Air purger is used to remove excess air from system. It

is installed in supply line. It will eliminate air from water before it reaches radiators and bleed off this air.

Install discharge piping per these instructions.

SAFETY RELIEF VALVE

Safety relief valve is required on your boiler. Water expands as it is heated. If there is no place for water to expand

into, water pressure will build up inside boiler and system. Should this happen, safety relief valve will automatically open at predetermined pressure. This will relieve the strain on boiler and system. Run pipe from relief valve outlet (pipe must be same size as outlet and open end must not be threaded) to open drain, tub or sink, or other suitable drainage point not subject to freezing. Failure to do so may cause water damage or injury should safety relief valve release.

EXPANSION TANK

Expanding water ows into expansion tank. Tank should be correct size. Tank is lled with air. As water expands it

compresses air in the tank to form air pressure cushion. This “spring-like” cushion serves to maintain correct operating water pressure regardless of water temperature. This assures “full measure” of water, even in highest radiation unit of system. It also prevents blowing off of safety relief valve. Air in tank in beginning (with system

lled with cold water) is sufcient for proper operation. Tank also serves as trap for excess air in system. Air would cause gurgling in pipes and in efcient circulation in

radiators if left in system.

It is possible for tank to become “waterlogged” (lled with water). It can also become overlled with air. This can happen after lling system with new water. Fittings

provided on tank and in line to tank are for bleeding off

excess water or air.

When installing this tank, it is important:

Tank be higher than boiler top.

Pipe to tank continuously rises up to tank (so air can “bubble” up to it).

MAIN AIR VENT FOR DOWN FLOW SYSTEMS OR DIAPHRAGM TYPE EXPANSION TANK

Before system is lled with water, there is air in pipes and

radiation units. Some of it will be trapped as system is

lled . It is possible to eliminate most of this air through

air vent on radiation units. Main air vent will speed and simplify this. Install on highest point in supply main when all radiation is below top of boiler.

AUTOMATIC FILL VALVE

For a safe, efcient operation, hot water system must be

completely lled with water. Adding new water, when needed can be done manually (by use of hand valve in

water supply line). Requires regular attention to system’s needs. Automatic ll valve accomplishes this without

attention. Install in supply line on hot water boilers only. Valve operates through water pressure differentials. It does not require electrical connection.

DRAIN VALVE

Manual valve provides means of draining all water from boiler and system. It is often installed in 3/4” tapping at bottom of end boiler section. Or it can be installed in tee where return line enters boiler.

CIRCULATING PUMP

Every forced hot-water system requires circulating pump. Separate pump or zone valve is required for each zone, if you have a two or more zone system. Pump must have capacity to provide circulation required by your system. Pump is connected into main just ahead of boiler. It is also wired to electrical system.

DIAPHRAGM TYPE EXPANSION TANK

Diaphragm type expansion tank takes place of conventional expansion tank. Carefully read instructions packed with

your tank assembly. Tank comes with 10-12 pounds per square inch air charge.

This is the same as pressure produced in system by

automatic ll valve. When system is rst lled, tank will

contain little or no water.

As water is heated its pressure increases. It expands into

tank, compressing air in tank. Compressed air cushion

permits water in system to expand as temperature

changes. Diaphragm type tank can be mounted on air

purger tting or at any convenient place in supply or return

line.

VENT DAMPER

This product is automatic, motorized stack damper

developed to increase efciency of heating system by

reducing standby losses from heating apparatus and conditioned air space. Damper closes chimney vent when burner is off and fully opens it when combustion is required.

Page 26

EQUIPMENT AND OPTIONAL ACCESSORIES

ROLLOUT SWITCH (FLAME ROLLOUT SAFETY SHUTOFF)

Rollout switch is temperature-sensitive fuse link device.

Located on boiler base just outside re box. In event of heat exchanger ueway blockage causing ame to roll out of re box, fuse does not change in appearance when

blown.

If rollout switch blows, it must be replaced with exact replacement. Check heat exchanger ueways for blockage

when restoring system to operating condition. DO NOT operate system without rollout switch.

BLOCKED VENT SAFETY SWITCH (BLOCKED VENT SAFETY SHUTOFF)

Blocked vent safety switch is manual reset disc thermostat

with xed setpoint (340°F), and normally closed contacts. It

is located at relief opening of integral draft diverter. In event of chimney or venting system blockage causing products of combustion to spill out of relief opening, blocked vent safety switch disc heats up and blocked vent safety switch contacts

open, shutting down ow of gas to main burners by removing

power to gas valve. In event blocked vent safety switch contacts open, reset

button on back of switch will pop up. Blocked vent safety switch must be reset manually, after switch has cooled off, by pushing reset button down. Check venting system and chimney for blockage when restoring system to operating condition. DO NOT operate boiler without blocked vent safety switch.

Page 27

NOTES

Page 28

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. 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 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 load decreases.

• This boiler is not used for any space heating

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

DUNKIRK BOILERS

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com