Dunkirk EXCELSIOR EXB4075 Installation, Operation & Maintenance Manual
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Dunkirk EXCELSIOR EXB4075 Installation, Operation & Maintenance Manual

High efficiency oil fired hot water boiler
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Models
EXB4075
EXB4095
EXB4110
EXB5100
EXB5115
EXB5135
EXB6130
EXB6145
EXB6165
EXB7165
EXB7180
EXB7190
An ISO 9001-2008 Certified Company
EXCELSIOR
High Efficiency
Oil Fired Hot Water Boiler
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N 240009348, Rev. E [12/2014]

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Summary of Contents for Dunkirk EXCELSIOR EXB4075

  • Page 1 EXCELSIOR High Efficiency Oil Fired Hot Water Boiler Models EXB4075 INSTALLATION, OPERATION & EXB4095 MAINTENANCE MANUAL EXB4110 EXB5100 EXB5115 EXB5135 EXB6130 EXB6145 EXB6165 EXB7165 EXB7180 EXB7190 Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com An ISO 9001-2008 Certified Company P/N 240009348, Rev.
  • Page 2 EXCELSIOR OIL-FIRED CAST IRON HOT WATER BOILER Models EXB5100 EXB6130 Per Energy Star specifications, AFUE is rounded to the nearest whole percentage point. As such, these products qualify for Energy Star. Check our website frequently for updates: www.ecrinternational.com Information and specifications outlined in this manual in effect at the time of printing of this manual.
  • Page 3 DIMENSIONS DIMENSIONS Dimension Flue Size Sections Inches Inches (cm) (cm) 5 (13) 18 3/8 (46) 5 (13) 21 5/8 (56) 5 (13) 24 7/8 (64) 6 (15) 28 1/8 (72)

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 1 - Introduction ......................5 2 - Safety Information..................... 6 3 - Before You Start ......................7 4 - Ratings & Capacities ....................8 5 - Locating The Boiler ....................9 6 - Installation Requirements ..................10 7 - Fresh Air For Combustion ..................

  • Page 5: Introduction

    1 - INTRODUCTION WARNING NOTICE Installations of boilers and venting shall be done Surface rust on cast iron sections may be attributed only by a qualified expert and in accordance with to manufacturing process as well as condensation this manual. Installing or venting a boiler or any during storage.

  • Page 6: Safety Information

    2 - SAFETY INFORMATION 2.1 General WARNING Boiler installation shall be completed by qualified agency. Construction materials of appliance and products of combustion and fuel contain alumina, silica, WARNING heavy metals, carbon monoxide, nitrogen oxides, aldehydes and /or other toxic or harmful Fire, explosion, asphyxiation and electrical shock substances which can cause death or serious injury hazard.

  • Page 7: Before You Start

    3 - BEFORE YOU START 3.1 Installation and Operation 3.2 Prior To Installing The Boiler • Verify you have selected right size boiler with proper Do not operate unit if any control, switch, components capacity. AHRI rating of boiler selected should be greater or devices have been underwater or subject to water than or equal to calculated peak heating load (heat loss) damage.

  • Page 8: Ratings & Capacities

    4 - RATINGS & CAPACITIES Table 1 RATINGS & CAPACITIES OIL-FIRED HOT WATER BOILERS Chimney Min. relief Chimney Max. Number Firing Heating *MAWP Liner Flue Input AHRI AFUE Valve Liner Size Water Rate Capacity Water Size Size [Mbh] Rating Capacity Round Temp Sections...

  • Page 9: Locating The Boiler

    5 - LOCATING THE BOILER Fresh air for combustion and ventilation must be avail- WARNING able at boiler. Ventilating and combustion air must Fire hazard. Do not be install on carpeting. Failure enter boiler room without restrictions. to follow these instructions could result in death or Installation shall conform to requirements of authority serious injury.

  • Page 10: Installation Requirements

    6 - INSTALLATION REQUIREMENTS Figure 2 - General Requirements For A Typical Installation LIMIT RELIEF VALVE CHECK LOCAL CODES FOR MAXIMUM DISTANCE FROM FLOOR, OR OTHER ALLOWABLE SAFE POINT OF DISCHARGE. NOTICE Shut off manual fuel supply valve if burner is shut down for extended period of time.

  • Page 11: Fresh Air For Combustion

    7 - FRESH AIR FOR COMBUSTION Alternate method for boiler located within WARNING confined space: Use indoor air if two permanent Asphyxiation, fire hazard. Do not obstruct air openings communicate directly with additional space(s) openings to combustion area. Follow instructions of sufficient volume such that the combined volume of all spaces meet criteria for unconfined space.
  • Page 12 7 - FRESH AIR FOR COMBUSTION Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In Tightly Constructed Houses Table 3 - FRESH AIR DUCT CAPACITIES THROUGH LOUVERS ¼” Mesh Wood Metal Fresh Air Screen Louvers Louvers Duct Size (Btuh)* (Btuh)* (Btuh)*...

  • Page 13: Boiler Assembly

    8 - BOILER ASSEMBLY Remove Crate Figure 5 - Reversible Hinge A. Remove all fasteners at crate skid. B. Lift outside container and remove all other inside protective spacers and bracing. Remove burner and miscellaneous parts boxes. Remove Boiler from skid. Boiler is secured to base with 4 screws.
  • Page 14 8 - BOILER ASSEMBLY NOTICE Figure 8 - Grommet Do not install valve between boiler and controls manifold or relief valve. Locate cast 1 1/4 x 1 1/4 x 3/4 tee and assemble on long female adapter with 3/4” tapping facing toward front of boiler and joint is water tight.
  • Page 15 8 - BOILER ASSEMBLY Figure 10 - Supply Piping and Control Assembly NOTICE Do not install valves between boiler and controls manifold or relief valve. LIMIT CONTROL WITH INTEGRAL LOW WATER CUT OFF THERMAL/ LWCO WIRE BURNER WIRING RELIEF VALVE BACK OF BOILER...
  • Page 16 8 - BOILER ASSEMBLY Figure 11 - Oval Liner Connect Field Wiring. See “13 - Electrical Connections” on page 34. A. Route wire harness from burner to Limit control through rear jacket panel. See Figure 15, Page 17. Connect molex plug on burner wire harness to its receptacle on limit control.
  • Page 17 8 - BOILER ASSEMBLY B. Use hand wrench to tighten door hardware and start Figure 14 - Circulator Wiring with non-hinged side. Use alternating tightening method from non-hinged side to hinged side to tighten door equally until sealed without applying excessive torque.

  • Page 18: Boiler System Piping

    9 - BOILER SYSTEM PIPING Connect System Supply And Return Piping 9.2 Bypass Piping To Boiler See Piping Diagrams for illustrations for this section. Connect system supply and return piping to correct Bypass piping may be required for applications listed boiler fittings.

  • Page 19: Hydronic Piping

    10 - HYDRONIC PIPING Figure 17 - Standard Near Boiler Piping Piping Diagram Legend...
  • Page 20 10 - HYDRONIC PIPING Figure 18 - Piping and Wiring Single Zone System With Domestic Hot Water DHW Priority DHW Heater FIGURE 18 INDIRECT WATER TANK HEATER, AQUASTAT CONTROL OR THERMOSTAT T-STAT THERMOSTAT PRIORITY ZONE 2 ZONE COMMON DATA PORT ELECTRONIC 24 VAC @ 1 VA FUSE...

  • Page 21: Zone Valve

    10 - HYDRONIC PIPING Figure 19 - Multi-Zone Piping and Wiring With Zone Valves And Domestic Hot Water Priority (With Zone Valve) (SEE FIGURE 20) ZONE VALVE / PUMP FIGURE 19 INDIRECT WATER PRIORITY HEATER, AQUASTAT ZR-ZC OR THERMOSTAT DPM-2 OPTION SWITCHES TANK T-STAT...
  • Page 22 10 - HYDRONIC PIPING Figure 20 - Piping and Wiring Multizone System With Zone Valves And Domestic Hot Water Priority (With Circulator) ZONE VALVE / PUMP FIGURE 20 INDIRECT WATER PRIORITY HEATER, AQUASTAT ZR-ZC OR THERMOSTAT DPM-2 OPTION SWITCHES TANK T-STAT CONTROL T-STAT...
  • Page 23 10 - HYDRONIC PIPING Figure 21 - Piping and Wiring Multi-Zone System With Circulators And Domestic Hot Water Priority FIGURE 21 INDIRECT WATER TANK HEATER, AQUASTAT CONTROL OR THERMOSTAT T-STAT T-STAT T-STAT THERMOSTATS DATA PORT PRIORITY ZONE 2 ZONE 3 ZONE 4 ZONE COMMON...
  • Page 24 10 - HYDRONIC PIPING Figure 22 - Primary/Secondary Piping And Wiring With Circulators And Domestic Hot Water MAX = 4 X DIAMETER CLOSELY - SPACED TEES BOILER PUMP...
  • Page 25 10 - HYDRONIC PIPING FIGURE 22 INDIRECT WATER TANK HEATER, AQUASTAT CONTROL OR THERMOSTAT T-STAT T-STAT T-STAT THERMOSTATS DATA PORT PRIORITY ZONE 2 ZONE 3 ZONE 4 ZONE COMMON ELECTRONIC FUSE 24 VAC @ 1VA 24AC PRIORITY ON HYDROSTAT 30 VA MODEL 3250 TO EXTRA ZONE MODULE...
  • Page 26 10 - HYDRONIC PIPING Figure 23 - Piping and Wiring Primary/Secondary Multi Zone System Piping With Zone Valves And Domestic Hot Water (With Zone Valve) ZONE 1 (PRIORITY ZONE)* * USE FULL PORT ZONE VALVE. FOR OPTIMUM TANK PERFORMANCE, CONSIDER USING ZONE SEE FIGURE 24 CIRCULATOR.
  • Page 27 10 - HYDRONIC PIPING ZONE VALVE / PUMP FIGURE 23 INDIRECT WATER PRIORITY HEATER, AQUASTAT ZR-ZC OR THERMOSTAT DPM-2 OPTION SWITCHES TANK T-STAT CONTROL T-STAT T-STAT 24VAC FROM TRANSFORMER 24 VAC TO DPM-2 STATUS HYDROSTAT PRIORITY ON PRIMARY PUMP MODEL 3250 PRIORITY PUMP X-X CONTACT ZR ON...
  • Page 28 10 - HYDRONIC PIPING Figure 24 - Piping And Wiring Primary/Secondary Piping With Zone Valves And Domestic Hot Water (With Circulator) ZONE VALVE MAX = 4 X DIAMETER CLOSELY - SPACED TEES...
  • Page 29 10 - HYDRONIC PIPING ZONE VALVE / PUMP FIGURE 24 INDIRECT WATER PRIORITY HEATER, AQUASTAT ZR-ZC OR THERMOSTAT DPM-2 OPTION SWITCHES TANK T-STAT CONTROL T-STAT T-STAT 24VAC FROM TRANSFORMER 24 VAC TO DPM-2 STATUS HYDROSTAT PRIORITY ON PRIMARY PUMP MODEL 3250 PRIORITY PUMP X-X CONTACT ZR ON...
  • Page 30 10 - HYDRONIC PIPING Figure 26 Bypass Piping (Fixed Low Temperature Only) Adjust two throttling valves to maintain at least 130°F - 140°F in boiler return. FROM SYSTEM TO SYSTEM SYSTEM CIRCULATOR WATER INLET EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION Figure 25 - Bypass Piping Automatic Mixing Valve PRESSURE BALL VALVE...
  • Page 31 10 - HYDRONIC PIPING Figure 27 - Bypass Piping (4-Way Valve Option With Circulator On Supply Side) TO SYSTEM FROM SYSTEM WATER INLET EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION Figure 28 - Recommended Piping for Combination Heating and Cooling (Refrigeration) System PRESSURE BALL VALVE AIR SEPARATOR...

  • Page 32: Fuel Supply Piping

    11 - FUEL SUPPLY PIPING 11.1 Installation of oil tank and piping shall conform Figure 30 - Double Pipe Oil Line to requirements of authority having jurisdiction or in absence of such requirements National Board of Fire Underwriters . In addition, refer to NFPA 31 (U.S.) or CSA B139 (Canada) Installation of oil storage tank, vent, fill pipe and caps shall conform to requirements of authority...

  • Page 33: Antifreeze In The System

    12 - ANTIFREEZE IN THE SYSTEM 12.1 Antifreeze added to boilers must be nontoxic, and must be of type specifically intended for use in closed hydronic heating systems. Under no circumstances should automotive antifreeze be used. Antifreeze used in any boiler may reduce capacity by 10% or more and increase fuel consumption.

  • Page 34: Electrical Connections

    13 - ELECTRICAL CONNECTIONS 13.1 Electrical wiring shall conform to requirements WARNING of authority having jurisdiction or in absence of such Electrical shock hazard. Turn OFF electrical power requirements ANSI/NFPA No. 70, in Canada shall supply at service panel before making electrical be in accordance with the Canadian Electrical Code C22.2.

  • Page 35: Chimney And Venting Connections

    14 - CHIMNEY AND VENTING CONNECTIONS 14.1 Chimney Venting Chimney Inspection – Prior to installation of any new or replacement fuel burning equipment chimney shall be Oil fired boilers with connections to vents or chimneys, inspected by qualified service agency. vent installation shall conform to requirements of A.

  • Page 36: Stack Temperature

    14 - CHIMNEY AND VENTING CONNECTIONS 14.2 Vent and Vent Connector Pressure Drop Table 9 - Between Vent connector should be kept as short as possible. Over-Fire & Breech Horizontal length of vent connector should not be Sections Inches WC greater than 10 feet.
  • Page 37 14 - CHIMNEY AND VENTING CONNECTIONS Figure 31 - Proper Draft Regulator Locations Figure 32 - Typical Chimney Locations Figure 33 - Pressure Tapping for Checking Draft Minimum height must be at least 3 Ft higher than highest part of passage through roof.

  • Page 38: Filling Boiler

    15 - FILLING BOILER WARNING NOTICE Boiler maximum operating pressure is posted on Fire, burn, asphyxiation hazard. Turn off service ASME data label located on front lower leg of boiler. switch to boiler to prevent accidental firing of burner outside combustion chamber. Disconnect Never exceed this pressure.

  • Page 39: Operating The Boiler - System Start-Up

    16 - OPERATING THE BOILER - SYSTEM START-UP 16.1 Setting The Limit Control Figure 34 - Limit Setting can be verified using TEST/SETTINGS button. See Page 41. 16.2 Setting High Limit To adjust, turn HI TEMP dial until desired setting is displayed.
  • Page 40 16 - OPERATING THE BOILER - SYSTEM START-UP 16.6 Activating Thermal Pre-Purge (optional) Activation of this feature is not recommended for boilers with tankless coils. • Limit has thermal pre-purge feature to maximize efficiency. When activated, control will purge higher boiler temperatures down to 135°F at start of any thermostat call and supply latent energy in boiler to heating zone calling.
  • Page 41 16 - OPERATING THE BOILER - SYSTEM START-UP ECONOMY TARGET Economy feature is active, Figure 36 - LED Legend limit control continually sets target temperatures below high limit setting to maximize fuel efficiency. When boiler water reaches target temperature, LED illuminates and burner shuts down.
  • Page 42 16 - OPERATING THE BOILER - SYSTEM START-UP 16.9 Oil Burner - Beckett AFG WARNING NOTICE Fire, burn, asphyxiation hazard. Do not loosen or remove any oil line fittings while burner is in Instructions are for Beckett AFG with Beckett operation.
  • Page 43 16 - OPERATING THE BOILER - SYSTEM START-UP IV. After 60 second recycle period, control will try to CAUTION restart system. Do not run boiler unattended until following procedure V. After 15 second lockout time, control will lock out is completed. Failure to follow these instructions could burner and reset button will flash.
  • Page 44 16 - OPERATING THE BOILER - SYSTEM START-UP E. Ignition Carry-over. Once flame is established, Figure 38 - Sequence of Operation igniter remains on for 10 additional seconds to ensure flame stability. F. Run. Flame is sustained until call for heat is satisfied. Burner is then sent to Motor-Off Delay, if applicable, or it is shut down and sent to Standby.
  • Page 45 16 - OPERATING THE BOILER - SYSTEM START-UP C. After installing nozzle, reassemble nozzle line NOTICE electrode assembly and set electrode tip spacing. D. Electrode tip spacing may need to be set prior to Before starting or resetting control from restricted reassembling nozzle line electrode assembly.

  • Page 46: Oil Burner, Nozzle, & Air Settings

    17 - OIL BURNER, NOZZLE, & AIR SETTINGS Figure 40 - Beckett Electrode Tip Adjustments Figure 39 - Beckett Electrode Tip Adjustments Standard Dimensions (L2) Heads Standard Dimensions (L1, V1) Heads Figure 42 - Beckett Check/Adjust ‘Z’ Dimension - Figure 41 - Beckett Check/Adjust “Z”...
  • Page 47 17 - OIL BURNER, NOZZLE, & AIR SETTINGS Figure 44 -Riello Turbulator Setting Figure 43 - Riello Electrode Setting Turbulator Setting A. Loosen nut (1) turn SCREW (2) until INDEX MARKER (3) is aligned with correct index number as per Burner Settings Table.
  • Page 48 17 - OIL BURNER, NOZZLE, & AIR SETTINGS Table 13 - Beckett Chimney Vent Preliminary Burner Settings Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments. TABLE 13a: BECKETT CHIMNEY PRELIMINARY BURNER SETTINGS Rated Inser- Firing...
  • Page 49 17 - OIL BURNER, NOZZLE, & AIR SETTINGS Table 14 - Beckett NX (Direct Vent) Preliminary Burner Settings Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments. TABLE 14a: BECKETT DIRECT VENT PRELIMINARY BURNER SETTINGS Rated Firing Pump...
  • Page 50 17 - OIL BURNER, NOZZLE, & AIR SETTINGS Table 15 - Riello 40F Chimney Vent Preliminary Burner Settings Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments. TABLE 15: RIELLO 40F CHIMNEY VENT PRELIMINARY BURNER SETTINGS Pump Rated Inser-...
  • Page 51 17 - OIL BURNER, NOZZLE, & AIR SETTINGS Table 16 - Riello 40BF (DIRECT VENT) Preliminary Burner Settings Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments. Table 16: RIELLO 40BF DIRECT VENT PRELIMINARY BURNER SETTINGS Pump Rated Inser-...
  • Page 52 17 - OIL BURNER, NOZZLE, & AIR SETTINGS Table 17 - Carlin (CHIMNEY VENT) Preliminary Burner Settings Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments. TABLE 1 - CARLIN SETTINGS Rated INSER- COMBUS- PUMP...

  • Page 53: Maintenance

    18 - MAINTENANCE 18.3 Relief Valve DANGER • Test relief valve for proper operation. Refer to valve Before servicing, turn off electrical power to boiler manufacturer’s instructions packaged with relief valve. at service switch. Turn off fuel supply to burner Failure to comply will result in death or serious 18.4 Conventional Expansion Tank injury.

  • Page 54: Oil Boiler /Burner Cleaning Instructions

    18 - MAINTENANCE Steps to inspect, clean and/or replace control well: • Continue to circulate water for few hours. • Stop firing boiler. Turn off electric service to boiler controls. • Drain system in manner and to location that hot water Drain boiler water to level below tapping for control can be discharged safely.
  • Page 55 19 - OIL BOILER / BURNER CLEANING INSTRUCTIONS Clean combustion chamber and baffles. Use wire DANGER or fiber bristle brush to clean surfaces of combustion Before servicing, turn off electrical power to boiler chamber and baffles. Vacuum all of loose debris in at service switch.
  • Page 56 19 - OIL BOILER/BURNER CLEANING INSTRUCTIONS Figure 46 - Cleaning the Boiler FLUE BRUSH VACUUM 3RD PASS HOSE FLUE BRUSH BRISTLE BRUSH VACUUM HOSE COMBUSTION CHAMBER & 2ND PASS FRONT VIEW...

  • Page 57: Troubleshooting

    20 - TROUBLESHOOTING 20.1 Combustion I. No oil to burner. II. Shortened electrodes A. Nozzles- See “17 - Oil Burner, Nozzle, & Air Settings” on page 46. III. Clogged nozzles. B. Fuel leaks - Any fuel leak between pump and nozzle IV.
  • Page 58 20 - TROUBLESHOOTING IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . . POSSIBLE CAUSE WHAT TO DO Thermostat is not set correctly Reset thermostat Burner is not operating properly Adjust burner per instructions. Check over-current protection. Check to be sure electric power supply cir- No electric power to boiler cuit is “ON”.

  • Page 59: Equipment And Accessories

    21 - EQUIPMENT AND ACCESSORIES 21.6 Conventional Expansion Tank (Not 21.1 Limit Relay Control (provided) Provided) Water temperature limit control in limit relay is adjustable. See Limit instructions for how to set limit temperature. In a properly assembled system, expanding water flows into an expansion tank.
  • Page 60 21 - EQUIPMENT AND ACCESSORIES Figure 47 - Grundfos Pump Curve US GPM m /h Model Watts Volts Amps Capacitor UP 15-42F 0.74 10µF/180V* *Supplied with pump Figure 48 - Taco Pump Curve Model Volts Amps Capacitor 007-F5 0.70 Supplied w/ pump...
  • Page 61 NOTES...

  • Page 62: Parts List

    NOTES...
  • Page 63 SERVICE RECORD...
  • Page 64 DUNKIRK BOILERS DUNKIRK BOILERS 2201 Dwyer Avenue, Utica NY 13501 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com web site: www.ecrinternational.com...

This manual is also suitable for:

Excelsior exb4095Excelsior exb4110Excelsior exb5100Excelsior exb5115Excelsior exb5135Excelsior exb6130 ... Show all

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