ECR International Dunkirk PLYMOUTH STEAM 2 Series Gebrauchsanweisung

PLYMOUTH STEAM SERIES 2

GAS-FIRED

STEAM BOILERS

INSTALLATION, OPER ATION &

MAINTENANCE MANUAL

MODEL PSB

Electronic

Intermittent

Ignition

MODELS

PSB-3D

PSB-3DP

PSB-4D

PSB-4DP

PSB-5D

PSB-5DP

PSB-6D

PSB-6DP

PSB-7D

PSB-7DP

PSB-8D

PSB-8DP

PSB-9D

PSB-9DP

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 325 5479

www.ecrinternational.com

14683003 REV. O [10/01/2021]

DIMENSIONS

BOILER MODEL NUMBER

(1) Dimensions (Inches) Boiler Water Volume

Intermittent

Ignition w/Vent Damper Flue Diameter "A" Width*

Maximum

Boiler Water

Volume

Gallons

Minimum

"Below" Low

Water Cuto

Gallons

(1) PSB-3D 5 11¼ 2.6 1.8

PSB-4D 6 14½ 3.8 2.7

PSB-5D 6 17¾ 5 3.7

PSB-6D 7 21 6.2 4.7

PSB-7D 7 24¼ 7.4 5.7

PSB-8D 7 27½ 8.6 6.7

PSB-9D 7 30¾ 9.5 7.7

*Add 5½" to height for Vent Damper

(1) Add model number sux 'P' for Propane Gas 3 section only.

Figure 1 - Dimensions

LEFT SIDE FRONT RIGHT SIDE

Gas Line

Rollout

Switch

Low Water

Cuto Probe

Spill

Switch

Pressure

Gauge

Water

Line

Low Water

Cuto

Glass

Gauge

Gas

Valve

2.5 OD

2.5 ODTransformer

24.00"

36.375"

Pressure

Limit

Control

26.50"

4.75"

*Vent

Damper

ASME

Relief

Valve

12.25"

29"

PN 14683003 Rev. O [10/01/2021]

RATINGS AND CAPACITY

Net AHRI steam Ratings shown are based on a piping and pickup allowance of 1.333.

Base selection of boiler size on "Net AHRI Rating" being equal to or greater than installed radiation in square feet.

Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements,such as

intermittent system operation, exhaust piping systems, etc.

Table 1 - Ratings and Capacities

BOILER MODEL

NUMBER

No. of

Sec.

†Natural Gas

Intermittent

Ignition w/Vent Damper Fuel Type Input

*MBTUH

Heating

Capacity

*MBTUH

AFUE(%) Net AHRI

Rating *Mbh

Net AHRI

Rating Sq. Ft.

(1)PSB-3D 3

Natural Gas 75 62 82.7 47 195

Propane 70 58 82.7 44 183

PSB-4D 4 Natural Gas 112 91 82.0 68 283

PSB-5D 5 Natural Gas 150 122 82.0 92 383

PSB-6D 6 Natural Gas 187 153 82.0 115 479

PSB-7D 7 Natural Gas 225 183 82.0 137 570

PSB-8D 8 Natural Gas 262 214 82.0 161 670

PSB-9D 9 Natural Gas 299 245 82.0 184 766

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

† For altitudes above 2,000 ft. reduce input rate 4% for each 1,000 ft. above sea level.

Heating Capacity is based on DOE (Department of Energy) test procedure.

(1) Add model number sux 'P' for Propane Gas 3 Section Only.

PN 14683003 Rev. O [10/01/2021]

Dimensions................................................ 2

Ratings and Capacity .................................. 3

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

Important Safety Information....................... 5

Locating the Boiler...................................... 7

System Piping ............................................ 8

Installation - System Piping ........................11

Fresh Air for Combustion ............................12

Chimney and Vent Pipe Connection ..............13

Vent Damper Operation ..............................15

Gas Supply Piping......................................16

Electrical Wiring ........................................17

Operating Instructions................................18

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

Checking and Adjusting ..............................20

Start-up Cleaning ......................................22

General Maintenance .................................23

Service Hints ............................................24

Wiring Diagrams........................................25

Controls and Accessories ............................27

Appendix A - Vent Damper ........................... 28

Appendix A - Vent Damper TroubleShooting. 29

Repair Parts ................................................. 31

Check Out Certicate.................................... 35

TABLE OF CONTENTS

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

GAS FIRED STEAM BOILERS

Check our website frequently for updates: www.ecrinternational.com

Information and specications outlined in this manual in eect at the

time of printing of this manual. Manufacturer reserves the right to

discontinue, change specications or system design at any time without

notice and without incurring any obligation, whatsoever.

Introduction

Boiler is designed for use in closed heating systems where

all steam is returned as condensate and make-up water is

minimal. Boiler is not designed for or intended for use in

open systems using 100% make-up water.

Prior to Installation

• Verify correct boiler for type of gas being used

natural or propane. See Rating Plate.

• Verify boiler size and dimensions. See Figure 1 page 2.

• Verify ratings and capacity data for natural gas. See

Table 1 page 3.

Installation Requirements

• Supply boiler with correct gas (natural or propane),

fresh air for combustion, and suitable electrical supply.

• Connect boiler to adequate venting and piping

systems.

• Provide boiler with properly located and adjusted

thermostat.

Installation of boiler in building under construction, use

precaution to insure clean combustion air supply during

construction process. Airborne particulate from construction

materials can clog burner ports and cause incomplete

combustion and sooting.

Complete all steps for safe and proper heating system

operation.

PN 14683003 Rev. O [10/01/2021]

IMPORTANT SAFETY INFORMATION

General

Boiler and venting installation shall be completed by

qualied agency.

Become familiar with symbols identifying potentialBecome familiar with symbols identifying potential

hazards.hazards.

This is the safety alert symbol. Symbol alerts you to This is the safety alert symbol. Symbol alerts you to

potential personal injury hazards. Obey all safety messages potential personal injury hazards. Obey all safety messages

following this symbol to avoid possible injury or death.following this symbol to avoid possible injury or death.

Installation shall 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 shall conform to Standard for Controls

and Safety Devices for Automatically Fired Boilers,

ANSI/ASME CSD-1. Controls can be added to make

this boiler CSD-1 compliant. Check with your local

codes for requirements.

Requirements for Commonwealth of Massachusetts:

Boiler installation must conform to Commonwealth of

Massachusetts code 248 CMR which includes but is

not limited to installation by licensed plumber or gas

tter.

CAUTION

Laceration, burn hazard. Metal edges and parts

may have sharp edges and/or hot. Use appropriate

personal protection equipment to include safety

glasses and gloves when installing or servicing this

boiler. Failure to follow these instructions could result

in minor or moderate injury.

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

Installing or venting a boiler or any other gas

appliance with improper methods or materials could

result in death or serious injury due to re or to

asphyxiation from poisonous gases such as carbon

monoxide which is odorless and invisible.

WARNING

Fire, explosion, asphyxiation hazard. Keep boiler

area clear and free from combustible materials,

gasoline and other ammable vapors and liquids.

Modication, substitution or elimination of factory

equipped, supplied or specied components could

result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

may result in minor or moderate injury.

NOTICE

Used to address practices not related to personal

injury.

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.

WARNING

Fire, Explosion, Asphyxiation, Electrical shock

hazard! Flooding will result in damages such as

electrical problems, corrosion, inoperative parts,

mold and other unforeseen issues which can

occur over time. Any equipment determined by

a professional as damaged by a ood, dened

as excess of water or other liquid, shall be

replaced. Failure to follow these directions will

result in a Hazardous Situation.

PN 14683003 Rev. O [10/01/2021]

WARNING

Combustion chamber insulation in this product

contains ceramic ber material. Ceramic bers can

be converted to cristobalite in very high temperature

applications. The International Agency for Research

on Cancer (IARC) has concluded, Crystalline silica

inhaled in the form of quartz or cristobalite from

occupational sources is carcinogenic to humans

(Group1). Avoid breathing dust and contact with

skin and eyes. Use NIOSH certied dust respirator

(N95). This type of respirator is based on the OSHA

requirements for cristobalite at the time this document

was written. Other types of respirators may be

needed depending on the job site conditions. Current

NIOSH recommendations can be found on the NIOSH

website http://www.cdc.gov/niosh/homepage.html.

NIOSH approved respirators, manufacturers, and

phone numbers are also listed on this website. Wear

long-sleeved, loose tting clothing, gloves, and eye

protection. Apply enough water to the combustion

chamber lining to prevent dust. Wash potentially

contaminated clothes separately from other clothing.

Rinse clothes washer thoroughly.

NIOSH stated First Aid. Eye: Irrigate immediately.

Breathing: Fresh air.

FOR YOUR SAFETY READ BEFORE OPERATING

Hot Water Can Scald!

Water heated to temperature for clothes washing,

dish washing and other sanitizing needs can scald

and cause permanent injury.

Children, elderly, and inrm or physically

handicapped persons are more likely to be

permanently injured by hot water. Never leave

them unattended in bathtub or shower. Never allow

small children to use a hot water tap or draw their

own bath.

If anyone using hot water in the building ts the

above description, or if state laws or local codes

require certain water temperatures at hot water

taps, you must take special precautions:

• Use lowest possible temperature setting.

• Install some type of tempering device, such

as an automatic mixing valve, at hot water

tap or water heater. Automatic mixing valve

must be selected and installed according

to manufacturer's recommendations and

instructions.

• Water passing out of drain valves may be

extremely hot. To avoid injury:

• Make sure all connections are tight.

• Direct water ow away from any person.

DANGER

Water

Temperature

Seng

1st Degree Burn

Exposure Time For

An Adult

2nd and 3rd Degree Burn

Exposure Time For An

Adult

120° F 1 minute 5 minutes

130° F 5 seconds 30 seconds

140° F 2 seconds 5 seconds

150° F 1 second 1.5 seconds

160° F Instantaneous 0.5 seconds

Note: Warning for Infants, Children, and Elderly:

Great care must be taken when exposing the

aforementioned groups to warm or hot water as they

can be badly burned in exposure times less than half

of the time for an adult.

IMPORTANT SAFETY INFORMATION

PN 14683003 Rev. O [10/01/2021]

LOCATING THE BOILER

Locating the Boiler

Select level location as centralized with piping system,

and as near chimney as possible.

Place crated boiler at selected location. Remove all

crate material. Please recycle responsibly.

WARNING

Fire hazard. Do not install boiler on combustible

ooring or carpeting. Failure to follow these

instructions could result in death or serious injury.

FOR INSTALLATION ON NON-COMBUSTIBLE

FLOORS ONLY - For installation on combustible

ooring special base shall be used. Please refer to

(Combustible Floor Addendum) included in literature

envelope provided with boiler and outlined in National

Fuel Gas Code, ANSI Z223.1/NFPA 54. Do Not Install

Boiler on carpeting.

Use metal shims under boiler base legs for nal leveling

if needed.

Install boiler in location that permits satisfactory

combustion of gas, proper venting, and maintenance

of ambient temperature at safe limits under normal

conditions of use. Boiler location should not interfere

with proper circulation of air. Introduce outside air

if normal inltration does not provide necessary

air.“Fresh Air for Combustion” on page 12.

Notify owner to keep air passages free of obstruction.

Ventilating and combustion air must enter boiler room

without restrictions.

Install boiler so automatic gas ignition system

components are protected from water (dripping,

spraying, rain, etc.) during appliance operation and

service.

Draft Hood Installation

WARNING

Asphyxiation, carbon monoxide hazard. Failure to

follow these instructions could result in improper

combustion and possible leakage of combustion

products into the living space.

Table 2 - Minimum Clearance Dimensions

Top 6"

Rear 6"

Control Side 7"

Opposite Side 6"

Front Alcove

Flue/Vent

Connector 6"

Follow directions given in Figure 7, Mount vent damper. See

"Connecting Vent Damper and Vent Connector" page 15.

See Wiring Diagrams page 26.

PN 14683003 Rev. O [10/01/2021]

SYSTEM PIPING

Check local codes

for maximum

distance from

oor or other

allowable safe

point of discharge

SAFETY VALVE

DISCHARGE

PIPING

6" Above Floor

Figure 2 - Safety Valve

Safety Relief Valve Installation instructions:

• Connect to safety valve outlet. Piped down to safe

point of disposal. Check local codes for maximum

distance from oor or allowable safe point of discharge.

• Pipe size be of equal to or greater than of safety valve

outlet over entire length of discharge line.

• Have no intervening shuto valve between safety valve

and discharge to atmosphere. Do not plug or place any

obstruction in discharge line.

• Size and arrange discharge piping to avoid reducing

safety relief valve relieving capacity below minimum

relief valve capacity stated on rating plate.

• Terminate freely to atmosphere where any discharge

will be clearly visible and at no risk of freezing.

• Allow complete drainage of valve and discharge line.

• Install safety valve with spindle in vertical position.

WARNING

Burn and scald hazard. Safety relief valve could

discharge steam or hot water during operation.

Install discharge piping per the following instructions.

Failure to follow these instructions could result in death

or serious injury .

!• Do not install shuto valve between boiler and safety

valve.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve

outlet and downstream of union (if used)

• Support safety valve discharge piping.

• Run pipe as short and straight as possible to location

protecting user from scalding and properly drain piping.

• Terminate with plain end, not threaded.

• Size and arrange discharge piping to avoid reducing

safety relief valve relieving capacity below minimum

relief valve capacity stated on rating plate.

• 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.

PN 14683003 Rev. O [10/01/2021]

SYSTEM PIPING

Consider near boiler piping as part of the boiler for proper

water level control and to produce dry steam.

Correct near boiler piping is crucial to proper operation of

boiler and heating system.

Follow these recommendations carefully:

Single riser installations are not recommended for

boiler sizes 5-9 sections. Use double riser piping for

boiler sizes 5-9 sections.

Place boiler in selected location as near chimney as

possible.

Install safety valve. Figure 2 and Warning on Page 8.

• Install union, if used, close to safety valve outlet.

• Install elbows close to safety valve outlet and

downstream of union (if used).

Boiler is equipped with two 2½" supply connections

and two 2½" return connections, one each on both left

and right sides of boiler. Plug unused connections with

furnished 2½" plug (furnished).

When using both supply tappings to pipe system as

shown in Figure 4, Page 11.

• Fit headers with header osets, swing joints, or equip

with expansion joints, so thermal expansion and

contraction of header does not damage boiler. Do not

weld headers.

• Place system takeos from header between equalizer

and riser to header nearest equalizer. System takeos

must never be between two risers. If steam main goes

in two directions, place two takeos from header, one

for each main.

System takeos from the header must never be

bullheaded. If the steam main goes in two directions,

there must be two takeos from the header, one for each

main.

All boilers in gravity return systems shall be equipped

with a Hartford Loop as shown in Figures 3 & 4.

When piping the vertical risers from the boiler to the

header, the bottom of the header must be a minimum

of 24 inches above the water level line on the right side

of the boiler.

Steam riser(s) and header shall be 2½” pipe size.

10.

Equalizer line shall be minimum 1½” pipe size.

11.

The near boiler piping shall include a 2½” tee with a

plug located on the supply line as shown for skimming

(i.e. surface blowdown).

12.

The near boiler piping shall include a 1-1/2 ball valve

in the return piping as shown for bottom blowdown and

draining.

13.

For gravity return systems, the bottom of the lowest

steam carrying pipe, be it a dry return, or the end of the

steam main, must be at least 28” above the normal water

level line on the right side of the boiler. This is known as

“Dimension A.”

14.

For pumped return systems, follow the condensate

pump or boiler feed pump manufacturer’s instructions

for proper installation and hookup.

15.

In connecting the cold water supply to the water inlet

valve, make sure that a clean water supply is available.

When the water supply is from a well or pump, a sand

strainer should be installed before the pump.

For Use With Cooling Units

Install boiler, when used in connection with refrigeration

system, so chilled medium is piped in parallel with boiler

with appropriate valves to prevent chilled medium from

entering the boiler. See Figure 5 page 11.

PN 14683003 Rev. O [10/01/2021]

Installation

Design and install boiler and system piping to prevent

oxygen contamination of boiler water.

Sources of oxygen contamination are system leaks

requiring addition of makeup water, ttings, and oxygen

permeable materials in distribution system.

Eliminate oxygen contamination by repairing system leaks,

repair ttings, use non-permeable materials in distribution

system, and eliminate open tanks in the system, or isolate

boiler from system with heat exchanger.

Water Quality

• Do not use softened water in steam boilers. Accelerated

boiler corrosion will result.

• Consult local water treatment companies for unusually

hard water area (above 7 grains hardness) or low

pH water conditions. Boiler water pH of 7 to 8.5 is

manufacturer recommended.

Figure 3 - Recommended Near Boiler Piping Using One Supply Tapping [3 & 4 Section Sizes]

SYSTEM PIPING

PN 14683003 Rev. O [10/01/2021]

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