Boiler Assembly - Dunkirk EXCELSIOR EXB4075 Installation, Operation & Maintenance Manual

1.
Remove Crate
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.
2.
Remove Boiler from skid. Boiler is secured to base
with 4 screws. Remove all securing hardware.
3.
Move boiler into permanent position by sliding or
walking into place.
4.
Do not drop boiler. Do not bump boiler jacket
against floor.
5.
Open burner swing door. Proper method to closing
and securing burner swing door opened for inspection,
cleaning or field service.
A. Loosen and remove non-hinged side latching
hardware.
B. Remove hinged side latching hardware.
C. Door can be swung to full open position
approximately 90 to 120 degrees with the burner
mounted providing there is 22" of clearance to the
adjacent wall.
NOTICE
Burner door may come off hinges if lifted when
opened.
If reduced clearance prevents door from opening fully, one
of the following can provide full access:
• Burner can be removed to allow full rotation of door.
Door with burner mounted can be lifted off hinges and
set aside during servicing.
• Door mounting hardware is reversible from left side
hinge (as shipped) to right side hinge. To reverse hinge
arrangement. See Figure 5.
• Lift door off mounting eye bolts and set aside. Remove
mounting eye bolts from left side. Move door mounting
eye bolts to right side. Tighten both sets of hardware.
Lift door and place integral cast hinge pins on door into
slotted mounting bracket holes.
Recommend hinges be on same side as flexible oil line in
order to swing door open.
6.
Inspect Swing door insulation and rope gasket.
A. Inspect fiber rope located on swing door. Evenly
distribute rope around perimeter of door groove
do not bunch or overhang. There must not be
a gap where two ends of rope meet. Repair or
replace if rope is damaged or if there is gap
between ends.
B. Inspect burner swing door insulation for damage.
C. Combustion chamber and raised portion between
2nd and 3rd pass flue ways make an impression
in door insulation as designed.
D. Do not close and secure door at this time.

8 - BOILER ASSEMBLY

Figure 5 - Reversible Hinge
For purpose of these instructions, all pipe
connections shall use pipe dope or Teflon tape to
assure water tight connections unless otherwise
instructed. Steps 6 thru 16, Figure 10, Page 15.
7.
Open accessory carton and remove contents. Identify
components using illustrations throughout this section
applicable to your installation.
8.
Remove top panel. Remove sheet metal screws
securing top panel to jacket rear panel. Slide top panel
towards front of boiler and lift off of side panel.
9.
Locate shorter of two 1 1/4" adapters. Thread thru
insulation slot into supply port in rear of boiler. Locate
1 1/4 x 3/4 x 1 1/4 elbow and assemble onto adapter.
Verify connections are tight with outlet facing directly
up. See Figure 6.
10.
Locate longer of the two 1 1/4" adapters. Assemble
onto elbow.
Figure 6 - Adapter Assembled Onto Elbow
1 1/4" ADAPTER
1 1/4 x 3/4 x 1 1/4
13
NOTICE
ELBOW
EYEBOLT & NUT
AS HINGE
5/8 BOLT
(BOLT INTO FRONT SECTION)
EYEBOLT & NUT
AS HINGE
RELIEF VALVE