PLYMOUTH STEAM SERIES 2 GAS-FIRED STEAM BOILERS 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 INSTALLATION, OPERATION & MAINTENANCE MANUAL MODEL PSB Electronic Intermittent Ignition ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 www.ecrinternational.com An ISO 9001-2008 Certified Company P/N# 14683003, Rev.
DIMENSIONS Figure 1 - Dimensions BOILER MODEL NUMBER (1) Dimensions (Inches) Intermittent Ignition w/Vent Damper Flue Diameter "A" Width PSB-3D 5 11¼ PSB-4D 6 14½ PSB-5D 6 17¾ PSB-6D 7 21 PSB-7D 7 24¼ PSB-8D 7 27½ PSB-9D 7 30¾ Add 5½" to height for Vent Damper (1) Add model number suffix 'P' for Propane Gas.
RATINGS AND CAPACITY Table 1 - Ratings and Capacities BOILER MODEL NUMBER Intermittent Ignition w/Vent Damper (1) (1) (1) (1) (1) (1) (1) †Natural Gas No. of Sec. PSB-3D 3 PSB-4D 4 PSB-5D Input *MBTUH Heating Capacity *MBTUH Natural Gas 75 62 Propane 70 Natural Gas Net AHRI Rating *Mbh Net AHRI Rating Sq. Ft. 82.7 47 196 58 82.7 44 183 112 91 82.0 68 283 Propane 105 85 80.4 64 267 Natural Gas 150 122 82.0 92 383 Propane 140 114 80.
TABLE OF CONTENTS Introduction Dimensions................................................. 2 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. Ratings and Capacity................................... 3 Safety Symbols........................................... 5 Locating the Boiler.......................................
SAFETY SYMBOLS General Boiler and venting installation shall be completed by qualified agency. 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. ! WARNING 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.
LOCATING THE BOILER Locating the Boiler 1. Select level location as centralized with piping system, Table 2 Minimum Clearance Dimensions and as near chimney as possible. 2. Place crated boiler at selected location. Remove all crate material. Please recycle responsibly. ! WARNING Fire hazard. Do not install boiler on combustible flooring or carpeting. Failure to follow these instructions could result in death or serious injury. 5. 6. 7.
SYSTEM 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 safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum distance from floor 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.
SYSTEM PIPING 13. For pumped return systems, follow the condensate Consider near boiler piping as part of the boiler for proper water level control and to produce dry steam. pump or boiler feed pump manufacturer’s instructions for proper installation and hookup. 14. 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 at the pump.
SYSTEM PIPING Figure 4 - Recommended Near Boiler Piping Using One Supply Tapping 9
INSTALLATION - SYSTEM PIPING Figure 5 - Recommended Near Boiler Piping Using Two Supply Tappings Figure 6 - Chilled Water Piping VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING 10
FRESH AIR FOR COMBUSTION ! WARNING 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 air changes per hour (ACH) greater than 0.60. Air openings to combustion area must not be obstructed.
CHIMNEY AND VENT PIPE CONNECTION 9. End of vent pipe must be flush with inside face of ! WARNING chimney flue. Use sealed-in thimble for chimney connection. 10. Horizontal run should not be longer than 3/4 the chimney height (HT) Figure 7, page 13. Installing or venting a boiler or any other gas appliance with improper methods or materials could result in death or serious injury due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.
CHIMNEY AND VENT PIPE CONNECTION 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 flame of a match or candle, or smoke from a cigarette, cigar or pipe. 6.
VENT DAMPER OPERATION ! WARNING Figure 8 - Horizontal Installation Asphyxiation or burn hazard. Improper installation and operation of vent damper could result in serious injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible. Horizontal Installation Flow NO YES To Boiler Vent Damper Vent Damper Installation - Follow all cautions and notes. • Install vent damper to service only single appliance for which it is intended.
GAS SUPPLY PIPING ! CAUTION Propane Installation WARNING WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. Fire, explosion, asphyxiation hazard. Verify boiler is equipped with propane gas orifices and gas valve is configured for propane. Failure to follow these instructions may result in serious injury or death. • 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.
ELECTRICAL WIRING ! WARNING Electronic Thermostats A. Some electronic thermostats may lose their memory or shut down. With probe type low water cutoff, this may occur each time low water cutoff detects low water condition. If this is the case, an isolation relay is required for thermostat circuit. A 24 volt single pole single throw (SPST) normally open (N.O.) relay is required, such as Honeywell R8222A or equivalent. Wire as shown in Figure 12a or Figure 12b. B.
OPERATING INSTRUCTIONS For Your Safety Read Before Operating 1. STOP! Read the safety information on this page. ! WARNING 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance. 4. This appliance is equipped with an ignition device which If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. automatically lights the pilot. Do not try to light the pilot by hand.
OPERATING YOUR BOILER ! WARNING Thermostat A. Set thermostat to desired room temperature. B. Set thermostat to lower setting if heat is not required C. System is self-checking. If failure of any component system will not operate or will go into safety lockout. D. On call for heat, each component must function properly to permit operation. E. Turn thermostat to lowest setting for one minute and back to normal setting to reset on safety lockout. Burn Hazard. Never run water into a hot empty boiler.
CHECKING AND ADJUSTING Adjust Pilot Burner Pilot flame should surround 3/8” to 1/2” of pilot sensor. See Figure 15. To adjust Flame. 1. Remove screw cover over pilot adjusting screw. See Figure 13. 2. Insert small screwdriver and adjust flame as needed. Turn screw counterclockwise to increase flame, clockwise to decrease. 3. Replace screw cover over pilot adjusting screw. Figure 14 - Igniter Main Burners • Main burners do not require primary air adjustment and are not equipped with primary air shutters.
CHECKING AND ADJUSTING Adjust Steam Pressure Control Boiler Equipped With Optional WF-2U-24 Water Feeder E. Continue thermostat call for heat after low water cut off recognizes low water condition. F. One minute time delay, water feeder starts feeding water to boiler. G. Feeder feeds for one minute, and then goes into another one minute waiting period. H.
START-UP CLEANING ! WARNING • Maintain at least 180°F for 15 minutes to remove dissolved gasses from fresh water. Following service procedures must be performed by qualified service agent. Boiler owner shall not attempt these steps. Failure to do so could result in death or serious injury. • Shut off burners. 8. Allow system to operate for one week to give majority of system dirt a chance to work its way back to boiler. • Check water in gauge glass. Gauge glass should be dry above water line.
GENERAL MAINTENANCE Low Water Cut-Off Boiler Water Treatment Other Than Cleaners Low Water Cut-Off interrupts electrical current to burner when water line in boiler drops to low level. Check Low Water Cut-Off monthly to verify it is providing proper protection. See “Checking and Adjusting” on page 21. Remove Low Water Cut-Off probes beginning of each heating season for inspection and cleaning. More cleaning may be required on boilers requiring frequent additions of make up water.
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service. ! 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. • If you cannot reach your gas supplier, call the fire department. IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .
WIRING DIAGRAMS Figure 13 - Wiring Diagrams For Boilers With PS-802 Probe Type Low Water Cut-Off Shown PS802 Terminals PS802 To CG400 Cross Reference PS802 CG400 N 2 H 1 C P1 E P2 W A If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent.
WIRING DIAGRAMS Figure 17 - Wiring Diagrams For Boilers With 67D-1 Float Type Low Water Cut-Off If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C Thermoplastic wire or its equivalent.
CONTROLS AND ACCESSORIES SAFETY VALVE Safety valve is designed to open automatically if boiler steam pressure exceeds pressure rating of valve (15 psig). Should it fail to open under this condition, shut down your boiler. If valve discharge occurs, or valve fails to open as described above, contact a qualified service technician to replace safety valve and inspect heating system to determine cause, as this may indicate equipment malfunction.
REPAIR PARTS 27
REPAIR PARTS 28
REPAIR PARTS 29
REPAIR PARTS 14 11 Safety Relief Valve ½NPT X 4" Nipple PF-033.
Date Service Performed Company Name & Tech Initials Company Address & Phone #
DUNKIRK BOILERS 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.
