ECR Dunkirk PWB-5D - User Manual

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Summary

Boiler Ratings and Capacities

Boilers for Use at High Altitude

Information regarding boiler input ratings adjustments for altitudes above 2,000 feet.

Before You Start

Locating the Boiler

Guidance on selecting boiler location and required installation clearances.

Fresh Air for Combustion

Ventilation Requirements

Methods for providing adequate combustion air: indoor, outdoor, or combined.

Installation - System Piping

Safety Relief Valve Installation

Steps for installing the safety relief valve and its discharge piping.

Low Design Water Temperature Systems

Requirements for systems below 140°F, including mixing valve use.

Use with Cooling Units

Guidelines for connecting the boiler to cooling systems.

Chimney and Vent Pipe Connection

Connecting the Vent Damper and Vent Connector

Procedure for attaching the vent damper to the boiler's flue outlet.

Removing Boiler from Common Venting

Steps for safely removing a boiler from a shared venting system.

Vent Damper Operation

Manual Operation of the Vent Damper

Instructions for manually opening and closing the vent damper.

Gas Supply Piping

Connecting the Gas Piping

Guidelines for connecting the gas line, including fittings and safety rules.

Electrical Wiring

Install Your Thermostat

Guidance on thermostat location and wiring to the boiler's aquastat.

Vent Damper Wiring

Information on connecting the vent damper to the boiler's wiring harness.

Wiring Diagrams for Hot Water Boilers

Intermittent Ignition Wiring

Detailed wiring diagram for intermittent ignition systems.

Standing Pilot Wiring

Wiring diagram for standing pilot ignition systems.

Equipment and Optional Accessories

Safety Relief Valve

Explanation of the safety relief valve's function and importance.

Expansion Tank

Details on the function and installation of expansion tanks.

Circulating Pump

Information on the role and connection of the circulator pump.

Vent Damper

Description of the vent damper's purpose in improving efficiency.

Starting Your Boiler

Filling System with Water

Step-by-step guide for filling the boiler and radiation units with water.

Safety Before Operating

What to Do If You Smell Gas

Emergency procedures for detecting a gas leak.

Intermittent Ignition Boiler Operation

Step-by-step guide for starting and operating intermittent ignition boilers.

Continuous Pilot Boiler Operation

Operating Your Boiler

General operation of automatic gas valve, safety pilot, and system self-checking.

To Turn Off Gas to Appliance

Procedure for safely shutting off the gas supply.

Operating Your Boiler

Adjust Pilot Burner

Instructions for adjusting the pilot burner flame.

Main Burner(s)

Guidance on observing main burner flames for proper combustion.

Recommended Boiler Water Temperatures

Recommended limit control settings for different heating units.

Maintaining Your Boiler

Safety Relief Valve Maintenance

Instructions for testing and maintaining the safety relief valve.

Boiler Flue Passages Check

Recommendations for checking flue passages and controls annually.

Vent Pipe Inspection

Importance of checking the vent pipe seasonally for leaks.

Service Hints

Troubleshooting No Heat

Diagnosing and resolving common heating issues.

Troubleshooting Noisy Burner

Diagnosing and resolving noisy burner operation.

Troubleshooting Relief Valve Leak

Steps for fixing a leaking relief valve.

Repair Parts

Jacket, Section and Base Parts

List of parts for the boiler jacket, sections, and base assembly.

Burner & Manifold Parts

List of replacement parts for the burner assembly and gas manifold.

Boiler Controls and Piping Parts

Part numbers for boiler controls, safety devices, and piping components.

The provided manual describes the Dunkirk PWB Series Gas-Fired Hot Water Boilers, available in both Continuous Pilot (PVWB) and Electronic Intermittent Ignition (PWB) models. These boilers are designed for heating hot water in residential and commercial applications.

Function Description

The Dunkirk PWB Series boilers are gas-fired appliances that heat water for hydronic heating systems. They are equipped with either a continuous pilot or an electronic intermittent ignition system to ignite the main burners. The heated water is then circulated through a piping system to radiation units (e.g., radiators, baseboards, convector radiators) to provide space heating. The system includes safety features such as a safety relief valve, rollout switch, and spill switch to ensure safe operation. A vent damper is integrated to improve efficiency by reducing standby losses when the burner is off.

Important Technical Specifications

The boilers are available in 2 to 9 sections, with varying input MBH, heating capacity MBH, and Net I=B=R Rating MBH.

Input MBH (1,000 Btuh):

2-section: 37.5 MBH
3-section: 70 MBH
4-section: 105 MBH
5-section: 140 MBH
6-section: 175 MBH
7-section: 210 MBH
8-section: 245 MBH
9-section: 280 MBH

Heating Capacity MBH (D.O.E. test procedure):

2-section: 30 MBH
3-section: 57 MBH
4-section: 85 MBH
5-section: 113 MBH
6-section: 142 MBH
7-section: 170 MBH
8-section: 198 MBH
9-section: 226 MBH

Net I=B=R Rating MBH (based on 1.15 piping and pickup allowance):

2-section: 26 MBH
3-section: 50 MBH
4-section: 74 MBH
5-section: 98 MBH
6-section: 123 MBH
7-section: 148 MBH
8-section: 172 MBH
9-section: 197 MBH

Dimensions (Inches):

Flue Diameter: 3" (2-section), 5" (3-section), 6" (4-5 section), 7" (6-9 section)
"A" Width: 8" (2-section), 11¼" (3-section), 14½" (4-section), 17¾" (5-section), 21" (6-section), 24¼" (7-section), 27½" (8-section), 30⅝" (9-section)
Add 5½" to height for vent damper.

Boiler Volume (Cu. Ft.):

2-section: 3.8
3-section: 5.4
4-section: 7.0
5-section: 8.5
6-section: 10.1
7-section: 11.7
8-section: 13.2
9-section: 14.8

Electrical Supply: Separate 120 volt circuit, 15 ampere, 14 gauge or heavier copper wire. Thermostat: 24 volt, heat anticipator set at .2 amps. Gas Pipe Sizes: Refer to tables for Natural Gas and Propane Gas pipe capacity based on length and BTU per hour input. Altitude Deration: For altitudes above 2,000 ft., input ratings are reduced by 4% for each 1,000 ft.

Usage Features

Ignition Systems: Available with either a continuous pilot (manual lighting required) or electronic intermittent ignition (automatic lighting).
Vent Damper: Automatic, motorized stack damper to increase efficiency by reducing standby losses. It closes when the burner is off and fully opens when combustion is required. Can be manually set to "HOLD DAMPER OPEN" for servicing.
Low Design Water Temperature Systems: For systems below 140°F (e.g., radiant floor heating), a 3-way or 4-way mixing valve (or suitable alternative) must be installed to prevent low temperature return water from entering the boiler.
Cooling Unit Connection: When used with a refrigeration system, the chilled medium must be piped in parallel with the heating boiler, using appropriate valves to prevent chilled medium from entering the boiler. Flow control valves are required for heating coils in air handling units exposed to refrigerated air circulation to prevent gravity circulation during the cooling cycle.
Automatic Fill Valve: An optional feature that automatically refills the system as needed, maintaining correct operating water pressure.
Drain Valve: Manual valve for draining water from the boiler and system.
Water Temperature Control: Adjustable limit control (140°F to 240°F) to set desired water temperature.
Circulating Pump: Required for forced hot-water systems, connected to the main just ahead of the boiler and wired to the electrical system.
Expansion Tank: Conventional or diaphragm type (EX-TROL) to accommodate water expansion and maintain pressure.
Air Eliminating Fitting (Air Purger): Removes excess air from the system, installed in the supply line.
Main Air Vent: Speeds up air elimination, especially for down flow systems or with diaphragm type expansion tanks.

Maintenance Features

Annual Visual Check: Pilot and main burner flames should be checked annually, preferably at the beginning of the heating season.
Safety Relief Valve Test: Must be tested monthly during boiler operation and at the beginning and end of any extended non-service period. Hold the trip lever fully open for at least five seconds to flush sediment.
Expansion Tank Maintenance: If waterlogged or overfilled with air (indicated by frequent relief valve opening or low radiation unit temperature with knocking), close the valve to the boiler, drain the tank, check plugs/fittings, and refill.
Flue Passages, Burner Adjustment, and Controls Check: Recommended annually by a competent Service Technician to ensure trouble-free operation.
Boiler and Vent Pipe Leak Check: Recheck for leaks before each season or after any shutdown. Replace or patch faulty boiler seals.
Vent Pipe Inspection: Check at least once a season for leaks and replace immediately if any are found.
Cleaning Boiler and Burners: Flue passages should be examined and cleaned yearly if necessary. This involves removing burners, pilot, vent pipe, jacket panels, draft diverter, and cerafelt gasket strips. Clean passageways with a wire brush, vacuum dirt, and ensure flame ports are clear. Reseal seams with 400°F RTV silicone sealant.
Circulator Pump Isolation Valves: Operate manually once or twice a year to prevent sticking.
Housekeeping: Keep the boiler area clear of combustible materials, flammable vapors, and obstructions to combustion and ventilation air.
Vent Damper Inspection: Must be inspected at least once a year by a trained service technician. Check indicator points for open/closed positions.
Troubleshooting Guide: Provides steps for common issues like "System Not Heating," "Burner Is Noisy," and "Relief Valve Leaking."