Dunkirk WPSB Series II User Manual

WPSB SERIES II

GAS-FIRED

Models

WPSB-3D

WPSB-3DP

WPSB-4D

WPSB-4DP

WPSB-5D

WPSB-5DP

WPSB-6D

WPSB-6DP

WPSB- 7 D

WPSB-7 DP

WPSB-8D

WPSB-8DP

WPSB-9D

HOT WATER BOILERS

INSTALLATION,OPERATION&

MAINTENANCEMANUAL

WPSB-9DP

Tested For 50 psi.

ASME

Working Pressure

An ISO 9001-2008 Certified Company

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com

P/N 240009047, Rev. B [08/2012]

DIMENSIONS

DIMENSIONS

CONTROL

Dimensions

DIMENSIONS (INCH.)

BOILER

MODEL

NUMBER

FLUE

DIAMETER

“A”

WIDTH

Boiler

Volume

Gallon

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.

2

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 suffi 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
orifi 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 orifi ce sizing information.

3

TABLE OF CONTENTS

!

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

Parts, Kits and Accessories ................................. 29

Warranty ......................................................... 36

Check Out Certifi cate ........................................ 38

SAFETY SYMBOLS & WARNINGS

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

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 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 personal injury or 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
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.

!

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

Used to address practices not related to personal
injury.

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 fi red Boilers,
ANSI/ASME CSD-1.

3.

Boiler series is classifi 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 fi 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 fi 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 infi 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. Do not install boiler on combustible
fl 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

fl 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.

* Defi 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

infi ltration rate is 0.40 air changes per hour. See
Table 3 for space with boiler only. Use equation for
multiple appliances.

3

Volume ≥ 50 ft

B. Known Air Infi ltration Rate. See Table 3 for

space with boiler only. Use equation for multiple
appliances. Do not use an air infi 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.

x Total Input [Mbh]

• 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 specifi 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

Known Air Infi ltration Rate Method ACH (Air Changes Per Hour)

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.

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 fl 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 fl 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 fi 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.

Figure 2 - Temperature Pressure Gauge

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 fl ushing of fl oat type
devices, per manufacturers specifi 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 fl 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.)

Signifi 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.

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
fl 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

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

10

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 (fl 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.

1.

This is a high effi 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 fl exible

vent liner, or other certifi 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.

2.

3.

4.

5.

6.

7.

8.

NOTICE

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

11

CHIMNEY AND VENT PIPE CONNECTION

Removing Existing Boiler F rom C ommon V enting
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.

1.

Seal any unused openings in the common venting
system.

2.

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.

3.

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.

4.

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

5.

Test for spillage at the draft hood relief opening after
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.

7.

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.

12

VENT DAMPER OPERATION

Figure 7 Figure 8

For safe, effi cient operation, vent damper and all fl 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 fi 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
qualifi ed service technician.

Figure 9 - Vent Damper Position Indicator

13

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 fl uid, or other leak detection method
acceptable to authority having jurisdiction. Do
not use matches, candles, open fl ames, or other
methods providing ignition source.

•

Correct leaks immediately and retest.

• If you cannot reach your gas supplier, call the fi 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 fl 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
fl 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.

14

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

1.

Thermostat should be installed on an inside wall about
four feet above the fl oor.

2.

NEVER install a thermostat on an outside wall.

3.

Do not install a thermostat where it will be affected
by drafts, hot or cold pipes, sunlight, lighting fi xtures,
televisions, a fi replace, or a chimney.

4.

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

5.

Instructions for the fi 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.

15

WIRING DIAGRAMS

Figure 11 - Electronic Ignition Control

WARNING

!

Modifi cation, substitution or elimination of factory
equipped, supplied or specifi ed components may
result in personal injury or loss of life.

16

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 fi 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 fl 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 fi lling of your
system.

• If your system is closed expansion tank system, you may
leave it open to refi 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 fi ll valve should
compensate for this. Instructions are packaged with valve.

NOTICE

Never run water in a hot empty boiler.

17

LIGHTING INSTRUCTIONS

!

!

WARNING

If you do not follow these instructions
exactly, a fi 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 fl oor because
some gas is heavier than air and will settle to the
fl 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 qualifi ed
service technician. Force or attempted repair may
result in fi re or explosion.

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

ON

PILOT ADJUSTMENT

(UNDER CAP SCREW)

WIRING
TERMINALS (2)

OUTLET
PRESSURE
TAP

GROUND
TERMINALS

(2)

OUTLET

PILOT
OUTLET

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

smell for gas, including near the fl 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 fi 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.

18

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 fl 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.

Figure 13 - Pilot Flame

MAIN BURNER(S)

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 14 - Burner

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

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

• Puffs of air from blowing on fl ame or stamping on fl oor
will cause fl ames to turn orange momentarily. This is
not unusual. Remain still when observing main burner
fl ames.

• If fl ame appearance is not correct, check main burner
orifi ces, burner throat and fl ame ports for dust and
lint obstruction. It may be necessary to remove rollout
shield to observe main burner fl ames. Replace rollout
shield after observation. Refer to Figure 14.

ADJUST PILOT BURNER

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

1.

Remove screw cover over pilot adjusting screw.

2.

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

3.

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.

19

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 satisfi 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.

20

OPERATING THE BOILER - SYSTEM START-UP

1

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.

2

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

3

condition. Limit control prevents burner operation during
this condition.

Important: Have system checked by qualifi ed service
agency prior to resuming operation.

ECONOMY Active Indicates thermal targeting function

4

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

5

control continually sets target temperatures below high
limit setting to maximize fuel effi 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 fi re again.

Note: LED illuminates regularly during normal boiler
operation.

6

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

21

Burner Will Not Fire

No or Insuffi cient Domestic

Hot Water

House will not get or stay

warm

OPERATING THE BOILER - SYSTEM START-UP

Table 1 - Troubleshooting

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.

1.

Check for air bound radiators.

2.

Check thermostat settings including heat anticipator settings (common on non-digital
thermostats.

3.

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.

22

SERVICE HINTS

!

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

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 fi re
department.

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

Possible Cause What to do

Thermostat is not set correctly Reset thermostat above room temperature
Burner is not operating properly Check fl ame. If it is yellow, burner is not getting enough air.

Or, if fl ame is blue and noisy and seems to lift off burner,
burner is getting too much air. Contact your service technician.

No electric power to boiler Check over current protection. Verify electric power supply circuit is
“ON”.

Controls out of adjustment Reset according to instructions.
Radiators not heating Open radiator vents to expel air. Check fl ow control valve (if

used). It may be in closed position.
Circulating pump not running Check over current protection. Check relay operation.
Poor electrical contact Check all control terminals and wire joints.
Rollout switch blown Have your service agent check heat exchanged for blockage.

Replace rollout switch with exact replacement.
Blocked vent safety switch blown Have your service agent check venting system

and chimney for blockage, or down draft condi­tion. Reset blocked vent safety switch.

Vent damper not operating Consult troubleshooting guide in Effi kal manual, packaged with
vent damper.

IF BURNER IS NOISY . . .

Possible Cause What to do

Gas input amount is incorrect Contact your service agent.

Possible Cause What to do

Dirt on seat Open valve manually. Allow water to run and clear valve seat.
Water logged expansion tank Drain tank, see instructions.

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

RELIEF VALVE LEAKING . . .

23

MAINTAINING YOUR BOILER

BURNERS

Beginning of heating season visually check pilot end main
burner fl 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:

1.

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

2.

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

3.

Open valve between boiler and tank. Water will rise to
normal height in tank if you have automatic fi ll valve
(otherwise, manually refi ll system).

BOILER FLUE PASSAGES

Recommend following checked annually by qualifi ed service
agent.

• fl 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 fl anges manu-
ally 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 fl exible
handle wire brush. Remove dirt from bottom of boiler
and from between sections by vacuuming.

• Verify all fl 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

• Reassemble all parts.

• Verify tightness of pilot connections and condition of
burner fl 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 fl ammable vapors and
liquids.

• Keep boiler area clear of debris and other materials
obstructing fl ow of combustion and ventilation air.

°

F RTV silicone sealant.

WATER SYSTEM

If system is to remain out of service during freezing weath-

er, always drain it completely (water left in to freeze will

crack pipes and/or boiler).

24

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 fl ows into expansion tank. Tank should
be correct size. Tank is fi 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
fi lled with cold water) is suffi cient for proper operation.
Tank also serves as trap for excess air in system. Air
would cause gurgling in pipes and in effi cient circulation in
radiators if left in system.

It is possible for tank to become “waterlogged” (fi lled with
water). It can also become overfi lled with air. This can hap-
pen after fi 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:

1.

Tank be higher than boiler top.

2.

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

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 fi ll valve. When system is fi rst fi 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 fi tting
or at any convenient place in supply or return line.

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

Before system is fi lled with water, there is air in pipes and
radiation units. Some of it will be trapped as system is
fi 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, effi cient operation, hot water system must be

completely fi 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 fi ll valve accomplishes this without atten-
tion. 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.

VENT DAMPER

This product is automatic, motorized stack damper
developed to increase effi 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.

25

EQUIPMENT AND OPTIONAL ACCESSORIES

ROLLOUT SWITCH
(FLAME ROLLOUT SAFETY SHUTOFF)

Rollout switch is temperature-sensitive fuse link device.
Located on boiler base just outside fi re box. In event of
heat exchanger fl ueway blockage causing fl ame to roll
out of fi re box, fuse does not change in appearance when
blown.

If rollout switch blows, it must be replaced with exact
replacement. Check heat exchanger fl 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 fi 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 fl 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.

26

NOTES

DUNKIRK BOILERS

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com