ECR International Dunkirk PLYMOUTH STEAM 2 Series Instruction manual

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. [phone]
www.ecrinternational.com
14683003 REV. O [10/01/2021]

2
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"
A
PN 14683003 Rev. O [10/01/2021]

3
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]

4
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]

5
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]