ECR International Dunkirk WPSB II Series Gebrauchsanweisung

Models

WPSB..-3D

WPSB--3DP

WPSB-4D

WPSB-41.DP

WPSB-SD

WPSB-SDP

WPSB-6D

WPSB-6DP

WPSB-7D

WPSB-7DP

WPSB.-.8D

WPSB--8DP "

WPSB-,gD

WPSB-9DP

WPSB SERIES II

HOT GAS=FIRED

WATER BOILERS

INSTALLATION,OPERATION&

MAINTENANCEMANUAL

+. °,,,- o ,, I% l

US H

Tested For 50 psi

ASrqE

Working Pressure

Manufactured by:

ECR |nternationa|, |nc.

220! Dwyer Avenue. Utica NY 13501

web site www ecnnternatlonal coin P/N 240009047, Rev B [08/2012]

DIMENSIONS

[

AS ME

qELIEF VENT DAMPER

[2 1/2" NPT I \o

[

SPILL

DRA[NV L_'E

LEFT SIDE

TEM P,iPR ESS.GAUGE

|I[

LJ J_L_

R:OLLOUT

@,A_iTCH

FRONT

INT, PILOT r,_u,NTRuL_,

RIGHT SIDE

CONTROL

DIMENSIONS (INCH.)

BOILER II[Boiler

MODEL FLUE "A" Volume

NUMBER ( DIAMETER WIDTH Gallon

I = I

WPSB=3 5 111/4 6.3

WPSB=4 6 141/2 8.1

WPSB-5 6 173/4 9.9

WPSB-6 7 21 11.7

WPSB-7 7 241/4 13.5

WPSB-8 7271/2 15.3

WPSB=9 7 303/4 17.2

Add 51/2" to height for vent Damper.

tNATURAL GAS i % PROPANE GAS IAFUE

III I

BOILER i (2) (2)NET I

NET AHRI HEATING AHRI INTERMITTENT

MODEL Input Heating RATING INPUT CAPACITY

NUMBER (I) I (3)--_h Capacity I _._p I (3)M_ hI ,_, RATING I IGNITION

M ....... ,"'" _°) (3) I WITH VENT

I (3)HLh I I J IBH

1) (3) Mbh _ I Hbh ! DAHPER

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 1i0 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

t 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 suffix'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

orifice 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 orifice sizing information.

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

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 Certificate ........................................ 38

SAFETY SYMBOLS &WARNINGS

The following defined symbols are used throughout this

manual to notify the reader of potential hazards of varying

risk levels,

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury

KEEP THIS HANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

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.

Keep boiler area clear and free from combustible

materials, gasoline and other flammable vapors

and liquids.

DO NOT obstruct air openings to the boiler room.

Modification, substitution or elimination of factory

equipped, supplied or specified components may

result in personal injury or loss of life.

TO THE OWNER - Installation and service of this

boiler must be performed by a qualified 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.

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.

Used to address practices not related to personal

injury.

Improperinstallation,adjustment,alteration,service

or maintenancecouldresult in deathor serious

injury.

Fire hazard. Do not install boiler on combustible

flooring or carpeting. Failure to follow these

instructions 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 fired Boilers,

ANSI/ASME CSD-I.

3. Boiler series is classified 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 fiberglass 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 fire

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 infiltration 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.

11. FOR INSTALLATION ON NON=COMBUSTIBLE

FLOORS ONLY = Forinstallationon combustible

flooringspecialbase must be used.(See Replacement

PartsSection.)Do Not installBoileron carpeting,

Minimum Clearance Dimensions

Table Hinimum Clearances

Top 6" (152mm)

Rear 6" (152mm)

Control Side 7" (178mm)

Opposite Side 6" (152mm)

Front 18" (457mm)

Flue/Vent Connector 6" (152mm)

Near Boiler Piping 2" (51mm)

NOTE: Greater clearances for access should supersede fire

protection clearances.

* Definition 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. Hinimum Clearances to Combustible

Construction (as seen from above)

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 Nbh 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

infiltration 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 Infiltration Rate. See Table 3 for

space with boiler only. Use equation for multiple

appliances. Do not use an air infiltration rate

(ACH) greater than 0.60.

Volume > 21 ftVACH 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 in 2 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 require-

ments 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 Hbh (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 specific 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

Known Air Infiltration Rate Method AC. (Air Changes Per Hour)

Method 0.1 0.2 0.3 0.4 0.5 0.6

3750

5625

7500

9375

11250

13125

14950

112.5

150

187.5

255

262.5

299

15750

23625

31500

39375

47250

55125

62790

7875

11813

15750

19688

23625

27563

31395

5250

7875

10500

13090

15750

18375

20930

3938

5906

7875

9844

11813

13781

15698

3150

4725

6300

7875

9450

11025

12558

2625

3938

5250

6563

7875

9188

10465

Table values based on boiler only. Add volume for any additional appliances.

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 floor 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 ASIV]E Boiler and Pressure Vessel Code for additional installation

requirements.

Figure 1. = Safety Relief Valve

DISCHARGE

LINE

RELIEF VALVE

Check local

codes for

maximum

distance

from floor

or allowable

safe point of

discharge.

Burn and scald hazard. Safety relief valve could

discharge steam or hot water during operation. In-

stall 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.

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 fittings 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 flushing of float type

devices, per manufacturers specific 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 flow 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.)

Significant 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 ° E

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°E

Minimum high limit setting is 140°E

1, Boiler used in heating system where design water

temperatures below 140°F are desired (e.g. radiant

floor 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.

CONNECTINGSUPPLYANDRETURNPIPING........................

Figure 3 =Typical Hot Water Piping

Figure 4 =Chilled Water Piping

VALVES A &

DPEN FBR

CLBSE FOR

VALVES: C

CL,BSE FOR

DPEN FDR

CONNECTING SUPPLY AND RETURN PIPING

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

Figure 5=Bypass Piping =Circulator On Supply

Return From System

Thro_Hng

VaJve

Shutoff

Valve

Circulator l

Shutoff Pump Throttling

Valve Valve

Suppiy

Control Water To System

Feed

._rmometer

FiHtroi With

Air Purger

[ A_ust the two throttling valves to maintain

at least 120°F in the boiler return.

Figure 6 =Bypass Piping =Circulator On Return

,l Y_LVZ _HRO_TL,I_

F_LLT_DL V%_TH

_IR P JR:GER

I A_,JIJ_T THE T'_ T_m_it,_G I

VALVES TO N_'_TAIR _T L_AST

!20 F _N THE BOIER F_gJ_,

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