ECR International Dunkirk WPSB 3 Series Instruction manual

GAS-FIRED
HOT WATER BOILERS
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
WPSB SERIES 3
Models
WPSB-3D
WPSB-3DP
WPSB-4D
WPSB-4DP
WPSB-5D
WPSB-5DP
WPSB-6D
WPSB-6DP
WPSB-7D
WPSB-7DP
WPSB-8D
WPSB-8DP
WPSB-9D
WPSB-9DP
Tested For 50 psi.
ASME
Working Pressure
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. [phone]
www.ecrinternational.com
PN 240013090 REV. C [10/01/2021]

2
Fully Assembled Boiler Vent Damper Pump (Optional) *Drain Valve
*ASME Safety Relief
Valve *Tridicator *Fuse Link w/ Instruction Tag *Nipple 3/4”x6-1/2 “
Includes Essential
Documents and Warranty
11x17 Wire Diagrams
Document Package *Circulator Harness
Information and specications outlined in this manual in eect at the
time of printing of this manual. ECR International, Inc. reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
* Items found in parts box included with your boiler.
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
For Parts lists see manual 240013149included with your boiler literature package.
ITEMS INCLUDED WITH YOUR BOILER
PN 240013090 REV. C [10/01/2021]

3
1 - Dimensions................................................................................ 4
2 - Safety Symbols And Warnings ...................................................... 5
3 - Locating The Boiler ..................................................................... 7
4 - Connecting Supply And Return Piping.............................................9
5 - Ventilation & Combustion Air .......................................................14
6 - Chimney And Vent Pipe Connection...............................................15
7 - Vent Damper Operation ..............................................................17
8 - Gas Supply Piping ......................................................................18
9 - Electrical Wiring.........................................................................19
10 - Wiring Diagram........................................................................20
11 - General Instructions .................................................................21
12 - Lighting Instructions.................................................................22
13 - Operating Your Boiler................................................................23
14 - Service Hints ...........................................................................26
15 - Maintaining Your Boiler .............................................................27
16 - Boiler Ratings And Capacities.....................................................28
Appendix A - Control Function ..........................................................29
Appendix B - Vent Damper Installation...............................................32
TABLE OF CONTENTS
PN 240013090 REV. C [10/01/2021]

4
1 - DIMENSIONS
Figure 1 - Dimensions

Figure 1 - Dimensions
*
1 1/4” RETURN
PN 240013090 REV. C [10/01/2021]
Dimensions
BOILER
MODEL
NUMBER
DIMENSIONS (INCH.)
Boiler
Volume
Gallon
FLUE
DIAMETER
“A”
WIDTH
WPSB-3 5 11¼ 3.30
WPSB-4 6 14½ 4.60
WPSB-5 6 17¾ 6.00
WPSB-6 7 21 7.40
WPSB-7 7 24¼ 8.75
WPSB-8 7 27½ 10.10
WPSB-9 7 30¾ 11.60
Add 5½” to height for vent Damper.

5
2 - SAFETY SYMBOLS AND WARNINGS
CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
!
WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not
avoided, WILL result in death or serious injury.
!
This is the safety alert symbol. Symbol alerts
you to potential personal injury hazards. Obey all
safety messages following this symbol to avoid
possible injury or death.
Become familiar with symbols identifying potential hazards.

2.1. Safety Information
WARNING
Do not tamper with or use this boiler for any
purpose other than its intended use. Failure to follow
these instructions could result in death or serious
injury. Use only manufacturer recommended parts
and accessories.
!
CAUTION
Laceration, burn hazard. Metal edges and parts
may have sharp edges and/or may be 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.
!!
NOTICE
Used to address practices not related to personal
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.
!
FOR YOUR SAFETY READ BEFORE OPERATING
Hot Water Can Scald!
Water heated to temperature for clothes washing,
dish washing and other sanitizing needs can scald and
cause permanent injury.

persons are more likely to be permanently injured by
hot water. Never leave them unattended in bathtub or
shower. Never allow small children to use a hot water
tap or draw their own bath.

description, or if state laws or local codes require
certain water temperatures at hot water taps, you
must take special precautions:
• Use lowest possible temperature setting.
• Install some type of tempering device, such as
an automatic mixing valve, at hot water tap or
water heater. Automatic mixing valve must be
selected and installed according to manufacturer's
recommendations and instructions.
• Water passing out of drain valves may be
extremely hot. To avoid injury:
• Make sure all connections are tight.
• 
DANGER
!
Water
Temperature
Seng
1st Degree Burn
Exposure Time For
An Adult
2nd and 3rd Degree Burn
Exposure Time For An
Adult
120° F 1 minute 5 minutes
130° F 5 seconds 30 seconds
140° F 2 seconds 5 seconds
150° F 1 second 1.5 seconds
160° F Instantaneous 0.5 seconds
Note: Warning for Infants, Children, and Elderly:
Great care must be taken when exposing the
aforementioned groups to warm or hot water as they
can be badly burned in exposure times less than half
of the time for an adult.
PN 240013090 REV. C [10/01/2021]

6
WARNING
Keep boiler area clear and free from combustible

liquids.
DO NOT obstruct air openings to the boiler room.


result in personal injury or loss of life.
Installation and service of this boiler shall be performed

When this product is installed in the Commonwealth
of Massachusetts the installation shall be performed
by a Licensed Plumber or Licensed Gas Fitter.
!
WARNING
Combustion chamber insulation in this product

can be converted to cristobalite in very high
temperature applications. The International Agency
for Research on Cancer (IARC) has concluded,
Crystalline silica inhaled in the form of quartz
or cristobalite from occupational sources is
carcinogenic to humans (Group1). Avoid breathing
dust and contact with skin and eyes. Use NIOSH

respirator is based on the OSHA requirements
for cristobalite at the time this document was
written. Other types of respirators may be
needed depending on the job site conditions.
Current NIOSH recommendations can be found
on the NIOSH website https://www.cdc.gov/
niosh/topics/silica/. NIOSH approved respirators,
manufacturers, and phone numbers are also listed

clothing, gloves, and eye protection. Apply enough
water to the combustion chamber lining to prevent
dust. Wash potentially contaminated clothes
separately from other clothing. Rinse clothes
washer thoroughly.
NIOSH stated First Aid. Eye: Irrigate immediately.
Breathing: Fresh air.
2.2 For Your Safety 2.2 For Your Safety
Manufacturer recommends a carbon monoxide detectorManufacturer recommends a carbon monoxide detector


jurisdictions may, by law, require.jurisdictions may, by law, require.
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

excess of water or other liquid, shall be replaced.
Failure to follow these directions will result in a
Hazardous Situation.
!!
2 - SAFETY SYMBOLS AND WARNINGS
To Installer leave all instructions with boiler for future
reference.
PN 240013090 REV. C [10/01/2021]

7
3 -LOCATING THE BOILER
Table 2 - MINIMUM CLEARANCE DIMENSIONS
Inches (mm)
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.

front of boiler. ANSI standard for alcove is 18 inches from
front of appliance to leading edge of side walls as shown
below.
1. Installation shall conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, and/or Natural Gas and Propane
Installation Code, CAN/CSA B149.1.
2. Where required by the authority having jurisdiction, the
installation shall conform to the Standard for Controls

ANSI/ASME CSD-1.
3. 
installation shall be in accordance with "Venting of
Equipment”, of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or "Venting Systems and Air Supply
for Appliances," of the Natural Gas and Propane
Installation Code, CAN/CSA B149.1, or applicable
provisions of the local building codes.
4. Boiler has met safe lighting and other performance
criteria with the gas manifold and control assembly on
the boiler per the latest revision of ANSI Z21.13/CGA
4.9.
5. Install boiler 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. Allow 24 inches (610mm) at front and right side for
servicing and cleaning.
8. 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.
Minimum Clearances to Combustible
Construction (as seen from above)
6"
BOILER
18"
6"
Front
7"
Control
Side
9. FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible

(Combustible Floor Addendum) included in literature
envelope provided with boiler and outlined in National
Fuel Gas Code, ANSI Z223.1/NFPA 54. Do Not Install
Boiler on carpeting.
3.1 Installation Requirements
CAUTION
Boiler weight exceeds 200 pounds (90.7 kg). Do not
lift boiler without assistance.
!
WARNING
Fire hazard. Do not install boiler on combustible

instructions could result in death or serious injury.
!
PN 240013090 REV. C [10/01/2021]

8
3.3 Boiler Location Considerations
• Ambient room temperature always above 32°F (0°C) to
prevent the potential of freezing.
• Drainage of water (or water/ antifreeze solution) during
boiler service or from safety relief valve discharge.
• Access to system water piping, gas supply, and
electrical service.
• 
capable of supporting the weight of the boiler, water,
and equipment.
• 
wet.
3 - LOCATING THE BOILER
Items to Avoid Products Which May Contain These
Items Areas Where These Items May Be Found
Chlorine, Fluorine, and Compounds

Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Swimming pool or spa chemicals
De-icing salts or chemicals
Carbon Tetrachloride
Swimming pools and pool storage areas


Airborne Particulates
Drywall dust
Road or gravel dust
Dryer lint
Cat litter


Acids, Solvents, etc.
Paint, Varnish, Turpentine, etc.
Cleaning Solvents
Hydrochloric acid/muriatic acid
Cements, adhesives and glues
Photo processing plants
Garages with workshops

establishments
Laundry Chemicals
Laundry detergents, bleaches, fabric
softeners, etc.
Antistatic fabric softeners (dryer sheets)
Dry cleaning/laundry areas and
establishments
Other
Permanent wave solutions
Refrigerants (Freon, etc) (only where
the refrigerant may be leaking from the
appliance)
Beauty shops
Refrigeration repair shops
Notes:


passages possibly resulting in unsafe operation. In this case, unit servicing shall include


the room be generously ventilated (well in excess of combustible air requirements), and
homeowner seal laundry supply containers, and minimize room vapors.
. Piping allowing fresh air in should also be considered. See Section 5-1.
Table 3-1: CONTAMINANTS
• Horizontal run to chimney shall be as short as possible.
• System piping exposed to freezing conditions: Use

manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
PN 240013090 REV. C [10/01/2021]

9
4 - CONNECTING SUPPLY AND RETURN PIPING
RELIEF VALVE
DISCHARGE
LINE
Check local
codes for
maximum
distance
from oor
or allowable
safe point of
discharge.
Figure 2 - Safety Relief Valve
1. Refer to local codes and appropriate ASME Boiler
and Pressure Vessel Code for additional installation
requirements. Install safety relief valve using pipe

2. Install safety relief valve with spindle in vertical
position.
3. 
relief valve.
4. Install discharge piping from safety relief valve. See
Figure 2.
• Use ¾” or larger pipe.
• Use pipe suitable for temperatures of 375°F (191°C)
or greater.
• Individual boiler discharge piping shall be independent
of other discharge piping.
• Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping.
• Install union, if used, close to safety relief valve outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).
• Terminate freely to atmosphere where discharge is
clearly visible and no risk of freezing.
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!
WARNING
Burn and scald hazard. Safety relief valve shall be
installed with spindle in upright position only,
following ASME BPV code. Failure to follow these
instructions could result in death or serious injury.
!
PN 240013090 REV. C [10/01/2021]

10
4.3 Flush and Rinse System
Flush the entire system and rinse thoroughly to ensure no
sludge will be introduced into the heating body of the boiler.
NOTICE
If damage due to frozen pipes is a possibility, install
appropriate safeguards and alarms on the heating
system to prevent property damage due to frozen
and burst pipes should the boiler heating system
become inoperative due to a power outage, safety
lockout or component failure.
4.4 Water Treatment
Manufacturer recommends a water analysis be done on

based on the analysis results. For extremely hard water or
pH below 7.0 consult your local water treatment company.
Manufacturer recommends a water analysis be done on

based on the analysis results.
For extremely hard water or pH below 7.0 consult your
local water treatment company.
• If CH water is very hard or full of impurities, it must be

or malfunction could be caused. Recommended water
quality is :
o Hardness Less than 150 mg/L
o Acidity level 7-8 pH
o Sediments Particle size less than 50 micron
• If the water quality is outside these ranges, consult a local
water treatment specialist for recommendations.
• If the water is treated, do not use petroleum based
products or products containing mineral oil or hydrocarbons
in order to avoid likely damage to parts made from rubber
compounds (o-rings).
4 - CONNECTING SUPPLY AND RETURN PIPING
WARNING
• Poison hazard. Ethylene glycol is toxic. Do not
use ethylene glycol.
• Never use automotive or standard glycol
antifreeze, even ethylene glycol made for hydronic
systems.
• Ethylene glycol can attack gaskets and seals used
in hydronic systems.
• Do not use petroleum based cleaning or sealing
compounds boiler system.
• 
water.
• Use only inhibited propylene glycol solutions

use with closed water heating system.
• 
glycol before installing new Boiler.
• Provide user with Material Safety Data Sheet

!
PN 240013090 REV. C [10/01/2021]