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ECR Dunkirk PWB Series - User Manual

ECR Dunkirk PWB Series
28 pages
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GAS-FIRED
HOT WATER BOILERS
P/N 14683002, Rev. A [8/2011]
PWB SERIES
An ISO 9001-2008 Certified Company
ECR International, Inc.
2201 Dwyer Avenue,
Utica NY 13501
www.ecrinternational.com
MODEL PWB
Electronic
Intermittent Ignition
MODEL PVWB
Continuous Pilot
H
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ECR Dunkirk PWB Series Specifications

General IconGeneral
BrandECR
ModelDunkirk PWB Series
CategoryBoiler
LanguageEnglish

Summary

Dunkirk PWB Series Gas-Fired Hot Water Boilers

Model PVWB: Continuous Pilot Operation

Details the PVWB model with continuous pilot ignition for gas-fired hot water boilers.

Model PWB: Electronic Ignition

Describes the PWB model featuring electronic intermittent ignition for gas-fired hot water boilers.

Boiler Ratings and Capacities

Natural and Propane Gas Boiler Ratings

Lists input, heating capacity, and net I=B=R ratings for models based on section count.

High Altitude Boiler Performance

Explains input rating reductions for altitudes above 2,000 ft and general guidance for high altitude use.

Pre-Installation Checks and Boiler Location

Initial Setup and Safety Preparations

Covers essential pre-installation checks for gas type, air, electrical, venting, and thermostat placement.

Boiler Placement and Clearances

Guidelines for selecting a boiler location, required clearances, and ventilation needs.

Combustible Material Clearances

Specifies minimum distances from the boiler to combustible materials for safe operation.

Combustion Air Requirements

Ventilation and Combustion Air Methods

Details methods for providing combustion air: indoor air (standard/infiltration) and outdoor air (two/one opening).

Indoor Air Volume Calculation

Provides a table and formula for calculating minimum room volume for indoor air based on input MBH and ACH.

System Piping Installation

Safety Relief Valve Installation Guide

Instructions for installing the safety relief valve and its discharge piping to a drain.

Temperature Pressure Gauge Installation

Steps for correctly installing the temperature pressure gauge onto the boiler's supply water tee.

Piping for Special Systems

Low Temperature Water Systems

Recommends mixing valves for systems below 140°F to prevent low temperature return water.

Boilers with Cooling Units

Guidelines for integrating the boiler with refrigeration systems and air handling units.

Chimney and Vent Pipe Connection

Chimney Inspection and Sizing Requirements

Emphasizes checking chimney condition, size, and construction for proper venting of combustion gases.

Vent Damper Installation Procedures

Details vent damper installation, including placement, fastening, and adapter use for 2-section boilers.

Vent Pipe Clearances and Common Venting

Minimum Vent Pipe Clearance Rules

Specifies the required minimum clearance between single-wall metal vent pipe and combustible materials.

Common Venting System Procedures

Outlines steps for safely removing a boiler from a common venting system and verifying remaining appliances.

Vent Damper Operation and Control

Damper Installation and Functional Checks

Explains how to check vent damper operation and provides instructions for manual control.

Gas Supply Piping Installation

Gas Pipe Sizing and Connection Guidelines

Details sizing gas pipes by length and BTU input, and rules for connecting gas piping to the boiler.

Gas Piping Safety and Testing

Essential safety warnings and procedures for checking gas piping, including leak detection and pressure testing.

Electrical Wiring and Connections

Power Supply and Grounding

Outlines requirements for the 120-volt power supply circuit, including amperage, shut-off, and grounding.

Thermostat and Control Wiring

Guides on thermostat location selection and wiring to aquastat terminals, plus vent damper/circulator wiring.

Intermittent Ignition Wiring Diagram

Intermittent Ignition Control Wiring

Details wiring for intermittent ignition systems: thermostat, aquastat, pilot control, gas valve, and vent damper.

Standing Pilot Wiring Diagram

Standing Pilot Control Wiring

Details wiring for standing pilot systems: thermostat, aquastat, pilot, gas valve, and vent damper.

Boiler Components and Accessories

Key Component Functions Explained

Explains the functions of safety relief valve, expansion tank, air purger, automatic fill valve, drain valve, and temperature control.

Circulator Pump and Vent Damper Roles

Describes the function of the circulating pump for system circulation and the vent damper for efficiency.

Safety Devices and System Startup

Rollout and Spill Safety Switches

Explains the function of the rollout switch (flame rollout) and spill switch (blocked vent).

Boiler System Operation and Filling

Details how a hot-water system operates and the procedure for filling it with water.

Critical Safety and Operating Instructions

General Safety Warnings and Gas Leaks

Provides critical warnings about fire/explosion, smelling gas, and handling submerged appliances.

Intermittent Ignition Boiler Startup

Step-by-step instructions for operating an intermittent ignition boiler, including starting and shutting down.

Continuous Pilot Boiler Operation

Continuous Pilot Startup and Shutdown

Step-by-step guide for operating a continuous pilot boiler, including lighting and shutdown procedures.

Automatic Gas Valve and Safety Pilot Testing

Explains automatic gas valve, safety pilot function, and gas valve safety shutdown test procedures.

Boiler Adjustments and Temperature Settings

Pilot and Main Burner Adjustments

Instructions for adjusting pilot burner flame and checking main burner flame appearance for proper operation.

Limit Control and Water Temperature Settings

Guides on adjusting limit controls and recommended boiler water temperatures for different heating units.

Boiler Maintenance Procedures

Annual Boiler Inspection and Cleaning

Details annual checks for burners, flue passages, vent pipe, and instructions for cleaning the boiler and burners.

Safety Valve Testing and System Care

Covers testing the safety relief valve, managing expansion tank issues, draining the system, and servicing circulator pump valves.

Boiler Service Hints and Troubleshooting

Troubleshooting Heating Performance

Provides potential causes and solutions for common heating issues like thermostat problems, power loss, or poor radiator heat.

Addressing Noisy Burners and Leaks

Offers troubleshooting advice for noisy burners, relief valve leaks, and water-logged expansion tanks.

Repair Parts: Jacket, Section, and Base

Jacket, Section, and Base Components List

Lists part numbers for jacket, section, and base components for various boiler sizes, 2 to 9 sections.

Repair Parts: Burner and Manifold

Burner and Manifold Parts List

Lists part numbers for burner and manifold components, including gas valves, orifices, and pilot burners.

Repair Parts: Boiler Controls and Piping

Controls and Piping Components List

Lists part numbers for boiler controls (aquastats, pilot controls) and various piping fittings and valves.

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