ECR International Dunkirk EXCELSIOR 3 Series Installation, Operation & Maintenance Manual
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ECR International Dunkirk EXCELSIOR 3 Series Installation, Operation & Maintenance Manual

High efficiency oil fired hot water boiler
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EXCELSIOR Series 3
High Efficiency
Oil Fired Hot Water Boiler
INSTALLATION, OPERATION &
Models
MAINTENANCE MANUAL
EXB4075
EXB4090
EXB5100
EXB5120
EXB6130
EXB6145
EXB7165
EXB7180
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 325 5479
www.ecrinternational.com
PN 240013422 REV. A [08/15/2021]

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Summary of Contents for ECR International Dunkirk EXCELSIOR 3 Series

  • Page 1 Oil Fired Hot Water Boiler INSTALLATION, OPERATION & Models MAINTENANCE MANUAL EXB4075 EXB4090 EXB5100 EXB5120 EXB6130 EXB6145 EXB7165 EXB7180 Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 325 5479 www.ecrinternational.com PN 240013422 REV. A [08/15/2021]...
  • Page 2 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. ECR International reserves the right to discontinue, change specifications or system design at any time without notice and without incurring any obligation, whatsoever.
  • Page 3 DIMENSIONS DIMENSIONS DIMENSIONS Dimension "B" Dimension Flue Size Inches "A" Sections Inches (cm) Inches (cm) (cm) Chimney Direct Vent Vent ⅜ ⅛ (32) 5 (13) (46.6) ¾ (19) ⅝ ⅛ (32) 5 (13) ¾ (19) (54.8) ⅞ ⅛ (32) 5 (13) ¾...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 1 - INTRODUCTION .......................5 2 - SAFETY INFORMATION ....................6 3 - BEFORE YOU START ....................9 4 - RATINGS & CAPACITIES ..................10 5 - LOCATING THE BOILER ................... 11 6 - INSTALLATION REQUIREMENTS ................12 7 - FRESH AIR FOR COMBUSTION ................. 13 8 - BOILER ASSEMBLY ....................

  • Page 5: Introduction

    1 - INTRODUCTION WARNING Installations of boilers and venting shall be done by a qualified expert and in accordance with this manual. Installing or venting a boiler or any other oil appliance with improper methods or materials could result in serious injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.

  • Page 6: Safety Information

    2 - SAFETY INFORMATION 2.1 Become Familiar With Symbols Identifying FOR YOUR SAFETY READ BEFORE OPERATING DANGER Potential 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.
  • Page 7 2 - SAFETY INFORMATION WARNING WARNING Combustion chamber insulation in this product Construction materials of appliance and products contains ceramic fiber material. Ceramic fibers can of combustion and fuel contain alumina, silica, be converted to cristobalite in very high temperature heavy metals, carbon monoxide, nitrogen applications.
  • Page 8 2 - SAFETY INFORMATION 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.

  • Page 9: 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 10: Ratings & Capacities

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

  • Page 11: Locating The Boiler

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

  • Page 12: Installation Requirements

    6 - INSTALLATION REQUIREMENTS Figure 2 - General Requirements For A Typical Installation 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 13: 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 14 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 15: 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 16 8 - BOILER ASSEMBLY Figure 8 - Grommet NOTICE 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 1-1/4" x 10" nipple with 3/4” tapping facing toward front of boiler and joint is water tight.
  • Page 17 8 - BOILER ASSEMBLY Figure 10 - Supply Piping and Control Assembly NOTICE Do not install valve 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 PN 240013422, Rev.
  • Page 18 8 - BOILER ASSEMBLY Connect Field Wiring. See “13 - Electrical Figure 11 - Oval Liner Connections”. A. Route wire harness from burner to Limit control through rear jacket panel. See Figure 10. Connect molex plug on burner wire harness to its receptacle on limit control.
  • Page 19 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 20: 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 boiler Bypass piping may be required for applications listed fittings.

  • Page 21: Hydronic Piping

    10 - HYDRONIC PIPING Figure 17 - Standard Near Boiler Piping Piping Diagram Legend PN 240013422, Rev. A [08/15/2021]...
  • Page 22 10 - HYDRONIC PIPING Figure 18 Piping And Wiring Single Zone System With Domestic Hot Water DHW Priority DHW Heater PN 240013422, Rev. A [08/15/2021]...
  • Page 23 10 - HYDRONIC PIPING Figure 19 - Multi-Zone Piping and Wiring With Zone Valves And Domestic Hot Water Priority (With Zone Valve) SEE FIGURE 20 (CONSULTER LA FIGURE 20) ZONE VALVE / PUMP PRIORITY ZR-ZC DPM-2 OPTION SWITCHES 24 VAC STATUS PRIORITY ON PRIMARY PUMP...
  • Page 24 10 - HYDRONIC PIPING Figure 20 - Piping And Wiring Multizone System With Zone Valves And Domestic Hot Water Priority (With Circulator) ZONE VALVE / PUMP PRIORITY ZR-ZC DPM-2 OPTION SWITCHES 24 VAC STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON ZONE VALVE / PUMP...
  • Page 25 10 - HYDRONIC PIPING Figure 21 - Piping and Wiring Multi-Zone System With Circulators And Domestic Hot Water Priority PN 240013422, Rev. A [08/15/2021]...
  • Page 26 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 PN 240013422, Rev. A [08/15/2021]...
  • Page 27 10 - HYDRONIC PIPING PN 240013422, Rev. A [08/15/2021]...
  • Page 28 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 CONSULTER LA FIGURE 24. PERFORMANCE, CONSIDER USING ZONE CIRCULATOR.
  • Page 29 10 - HYDRONIC PIPING ZONE VALVE / PUMP PRIORITY ZR-ZC DPM-2 OPTION SWITCHES 24 VAC STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON ZONE VALVE / PUMP PRIORITY ZR-ZC DPM-2 OPTION SWITCHES 120 VAC TO XFRM PRIMARY PRIORITY 120VAC FROM BOILER...
  • Page 30 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 PN 240013422, Rev. A [08/15/2021]...
  • Page 31 10 - HYDRONIC PIPING ZONE VALVE / PUMP PRIORITY ZR-ZC DPM-2 OPTION SWITCHES 24 VAC STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON ZONE VALVE / PUMP PRIORITY ZR-ZC DPM-2 OPTION SWITCHES 120 VAC TO XFRM PRIMARY PRIORITY 120VAC FROM BOILER...
  • Page 32 10 - HYDRONIC PIPING Figure 25 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 26 - Bypass Piping Automatic Mixing Valve PRESSURE BALL VALVE...
  • Page 33 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 Colling (Refrigeration) System PRESSURE BALL VALVE AIR SEPARATOR...

  • Page 34: 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.).

  • Page 35: 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 36: 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. supply at service panel before making electrical Run separate electrical circuit from entry box with connections.

  • Page 37: 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 inspected by qualified service agency. chimneys, vent installation shall conform to A.
  • Page 38 14 - CHIMNEY AND VENTING CONNECTIONS 14.2 Chimney and Chimney Connector • Minimum Draft at Breech – Draft induced by the chimney must create at least a neutral pressure of 0 Chimney connector should be kept as short as possible. (zero) inches water column (INWC) at breech.
  • Page 39 14 - CHIMNEY AND VENTING CONNECTIONS Figure 31 - Proper Draft Regulator Locations Figure 33 - Pressure Tapping for Checking Figure 32 - Typical Chimney Locations Draft Minimum height must be at least 3 Ft higher than highest part of passage through roof.

  • Page 40: 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 41: 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 43. 16.2 Setting High Limit To adjust, turn HI TEMP dial until desired setting is displayed.
  • Page 42 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 43 16 - OPERATING THE BOILER - SYSTEM START-UP Figure 36 - LED Legend ECONOMY TARGET Economy feature is active, 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 44 16 - OPERATING THE BOILER - SYSTEM START-UP WARNING NOTICE Fire, burn, asphyxiation hazard. Do not loosen Instructions are for Beckett AFG with Beckett or remove any oil line fittings while burner is in Genisys primary control. For other burners, refer to operation.
  • Page 45 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 After 15 second lockout time, control will lock out is completed. Failure to follow these instructions could burner and reset button will flash.
  • Page 46 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 47 16 - OPERATING THE BOILER - SYSTEM START-UP C. After installing nozzle, reassemble nozzle line NOTICE electrode assembly and set electrode tip spacing. Before starting or resetting control from restricted D. Electrode tip spacing may need to be set prior to lockout state, troubleshoot heating system for root reassembling nozzle line electrode assembly.

  • Page 48: Oil Burner, Nozzle, & Air Settings

    17 - OIL BURNER, NOZZLE, & AIR SETTINGS Figure 39 - Beckett NX Electrode Tip Adjustments Figure 40 - Beckett AFG Electrode Tip Adjustments for Three Pass Boilers Three Pass Boilers 1/4” 3/32” For detailed setup and adjustment instructions for Beckett NX Oil Burner, refer to Beckett NX Oil Burner Manual provided with boiler.
  • Page 49 17 - OIL BURNER, NOZZLE, & AIR SETTINGS Figure 43 - Riello Electrode Setting Figure 44 -Riello Turbulator 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 50 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 VENT PRELIMINARY BURNER SETTINGS Insertion Firing Com-...
  • Page 51 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 Firing Pump Pressure...
  • Page 52 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 Rated Firing Pump...
  • Page 53 17 - OIL BURNER, NOZZLE, & AIR SETTINGS Table 16 - Riello 40F (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 Firing Pump Pressure...
  • Page 54 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 17- CARLIN CHIMNEY VENT PRELIMINARY BURNER SETTINGS Rated Pump Boiler...

  • Page 55: 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 18.4 Conventional Expansion Tank Failure to comply will result in death or serious injury.
  • Page 56 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 a manner and to a location that hot Drain boiler water to level below tapping for control water can be discharged safely.

  • Page 57: Oil Boiler / Burner Cleaning Instructions

    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 58 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 PN 240013422, Rev. A [08/15/2021]...

  • Page 59: Troubleshooting

    20 - TROUBLESHOOTING 20.1 Combustion C. Control locks out after trial for Ignition. (TFI) A. Nozzles - See “17 - Oil Burner, Nozzle, & Air No oil to burner. Settings”. II. Shortened electrodes B. Fuel leaks - Any fuel leak between pump and nozzle is detrimental to good combustion results.
  • Page 60 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 61: Equipment And Accessories

    21 - EQUIPMENT AND ACCESSORIES 21.1 Limit Relay Control (provided) 21.6 Conventional Expansion Tank (Not 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 62 21 - EQUIPMENT AND ACCESSORIES Figure 47 - Grundfos Pump Curve US GPM m /h Model Watts Volts Amps Capacitor UP 15-42F 0.74 10 µF/180 V* *Fourni avec la pompe Figure 48 - Taco 007e Pump Curve PN 240013422, Rev. A [08/15/2021]...
  • Page 63 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________  Installation instructions have been followed  Checkout procedure and adjustments performed  Maintenance and Service issues reviewed with owner/ maintenance person  Installation booklet affixed on or adjacent to boiler Installer (Company) Address Phone...
  • Page 64 All specifications subject to change without notice. 2201 Dwyer Avenue, Utica, NY 13501 ©2021 ECR International, Inc. Tel. 800 325-5479 www.ecrinternational.com...

This manual is also suitable for:

Dunkirk excelsior exb4075Dunkirk excelsior exb4090Dunkirk excelsior exb5100Dunkirk excelsior exb5120Dunkirk excelsior exb6130Dunkirk excelsior exb6145 ... Show all

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