ECR International Dunkirk EXCELSIOR 3 Series Gebrauchsanweisung

High E󱐰ciency

Oil Fired Hot Water Boiler

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

EXCELSIOR Series 3

Models

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]

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. ECR International reserves the right to

discontinue, change specications or system design at any time without

notice and without incurring any obligation, whatsoever.

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

For Parts lists see manual 240013423 included with your boiler literature package.

*ENERGY STAR LISTED

EXCELSIOR OIL-FIRED CAST IRON HOT WATER BOILEREXCELSIOR OIL-FIRED CAST IRON HOT WATER BOILER

Models

*EXB4075

*EXB5100

*EXB6130

*EXB7165

DIMENSIONS

Sections

Flue Size

Inches

(cm)

Dimension

"A"

Inches

(cm)

Dimension

"B"

Inches

(cm)

Chimney

Vent

D i r e c t

Vent

4 5 (13) 18 ⅜(46.6) 1 ⅛ (32) ¾ (19)

5 5 (13) 21 ⅝(54.8) 1 ⅛ (32) ¾ (19)

6 5 (13) 24 ⅞(63.1) 1 ⅛ (32) ¾ (19)

7 6 (15) 28 ⅛(71.3) ¾ (19) N/A

DIMENSIONS

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

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 ................................................................................................. 15

9 - BOILER SYSTEM PIPING.......................................................................................... 20

10 - HYDRONIC PIPING................................................................................................ 21

11 - FUEL SUPPLY PIPING ............................................................................................ 34

12 - ANTIFREEZE IN THE SYSTEM................................................................................. 35

13 - ELECTRICAL CONNECTIONS .................................................................................. 36

14 - CHIMNEY AND VENTING CONNECTIONS................................................................. 37

15 - FILLING BOILER ................................................................................................... 40

16 - OPERATING THE BOILER - SYSTEM START-UP ........................................................ 41

17 - OIL BURNER, NOZZLE, & AIR SETTINGS................................................................. 48

18 - MAINTENANCE ..................................................................................................... 55

19 - OIL BOILER / BURNER CLEANING INSTRUCTIONS................................................... 57

20 - TROUBLESHOOTING ............................................................................................. 59

21 - EQUIPMENT AND ACCESSORIES ............................................................................ 61

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

1. Oil Fired Boilers

Boiler is low pressure, sectional cast iron constructed

and tested for maximum working pressure of 65 psi in

accordance with A.S.M.E. (American Society of Mechanical

Engineers) Section IV Standards for cast iron heating

boilers. Capacity rated in accordance with AHRI (Hydronics

Institute).

Boiler is pressure red natural draft (chimney vented)

oil red hot water boiler comprised of cast iron sections,

available with 4, 5, 6 or 7 sections. Sections are held

together by metal push nipples and threaded rods.

4, 5 and 6 section boilers may be eld equipped for direct

vent installations with use of direct vent burner and venting

kits. Direct vent instructions are covered in a separate

supplemental instruction document included with direct

vent venting kit.

Boiler models are capable of ring #2 fuel oil from 0.75

gph up to 1.80 gph.

Boilers include -

• Limit, 220° F maximum, operating control with integral

low water cut o

• Temperature and pressure gauge

• 30 psi relief valve

• Drain valve

WARNING

Installations of boilers and venting shall be done

by a qualied 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 re

or to asphyxiation from poisonous gases such as

carbon monoxide which is odorless and invisible.

1 - INTRODUCTION

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

2.2 General

Boiler installation shall be completed by qualied agency.

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.

Modication, substitution or elimination of factory

equipped, supplied or specied components could

result in death or serious injury.

Improper installation, adjustment, alteration, service

or maintenance could result in death or serious

injury.

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 instructions could result in

death or serious injury.

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 toThis is the safety alert symbol. Symbol alerts you to

potential personal injury hazards. Obey all safety messagespotential 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.

2.1 Become Familiar With Symbols Identifying

Potential Hazards.

NOTICE

Used to address practices not related to personal

injury.

2 - SAFETY INFORMATION

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.

Children, elderly, and inrm or physically

handicapped 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.

If anyone using hot water in the building ts the

above 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.

• Direct water ow away from any person.

DANGER

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

WARNING

Construction materials of appliance and products

of combustion and fuel contain alumina, silica,

heavy metals, carbon monoxide, nitrogen

oxides, aldehydes and /or other toxic or harmful

substances which can cause death or serious injury

and which are known to the State of California to

cause cancer, birth defects and other reproductive

harm. Always use proper safety clothing,

respirators and equipment when servicing or

working nearby the appliance.

WARNING

Combustion chamber insulation in this product

contains ceramic ber material. Ceramic bers 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 certied dust

respirator (N95). This type of 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/.

approved

respirators, manufacturers, and phone numbers are

also listed on this website. Wear long-sleeved, loose

tting 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.

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.

2 - SAFETY INFORMATION

WARNING

This prod

uct contains Fibrous glass. Fibrous

glass is a synthetic ber made from tiny particles

of glass. Fibrous glass has been classied as a

possible human carcinogen. When disturbed as a

result of servicing or repair, brous glass becomes

airborne and, if inhaled, may be hazardous to

your health. It can harm the eyes, skin, and the

lungs. Airborne bers from these materials have

been listed by the State of California as a possible

cause of cancer through inhalation. Adhere

to the following precautions and procedures.

Avoid breathing dust and contact with skin and

eyes. Use NIOSH certied dust respirator (e.g.,

N95). 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/. Approved

respirators, manufacturers, and phone numbers

are also listed on this website. Wear appropriate

personal protective clothing to prevent skin contact,

as well as gloves and eye protection. Wash skin

daily at end of each work shift, and prior to eating,

drinking, smoking, etc. Workers whose clothing

may have been contaminated should change into

uncontaminated clothing before leaving the work

premises. Wash potentially contaminated clothes

separately from other clothing. Rinse clothes washer

thoroughly. Follow all Local, State and Federal

guidelines for disposal.

NIOSH stated First Aid. Eye: Irrigate immediately.

Breathing: Fresh air.

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

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

2.3

Installation Shall Conform To Requirements

Of Authority Having Jurisdiction Or In Absence

Of Such Requirements To ANSI/NFPA 31,

“Installation Of Oil Burning Equipment”. In

Canada, Current Edition Of Canadian Standards

Association CSA B139, Installation Code For

Oil Burning Equipment” For Recommended

Installation Practices. Such Applicable

Requirements Take Precedence Over General

Instructions Of This Manual.

2.4 Current Edition of American National Standard

ANSI/NFPA 211 “Chimneys, Fireplaces, Vents and

Solid Fuel Burning Appliances” for venting.

2.5

Where required by authority having

jurisdiction, installation shall conform to Standard

for Controls and Safety Devices for Automatically

Fired Boilers, ANSI/ASME CSD-1.

Additional manual reset low water cuto and manual reset

high limit may be required.

2.6 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.

NOTICE

Surface rust on cast iron sections may be attributed

to manufacturing process as well as condensation

during storage. Surface rust is normal and does not

aect performance or life of boiler.

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.

2 - SAFETY INFORMATION

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

3.1 Installation and Operation

Do not operate unit if any control, switch, components

or devices have been underwater or subject to water

damage.

Before servicing, allow boiler to cool. Always shut o any

electricity and oil supply to boiler when working on it.

Inspect oil line and connections for leaks.

Verify oil burner nozzle is proper size. Over-ring could

result in early failure of boiler sections, and result in a

potentially dangerous situation.

Never vent boiler into enclosed space. Always vent to

the outside. Never vent to another room or inside a

building.

Verify adequate air supply for complete combustion.

Relief valve automatically lifts open when system

pressure exceeds 30 psi. Before installing relief valve

read manufacturer’s instructions. Pipe relief valve to a

safe location. Check with authorities having jurisdiction.

Consider system total water volume, temperature,

initial ll pressure and arrangement when sizing and

installing expansion tank. Improperly installed and

sized expansion tank may result in frequent lifting of

relief valve or other heating system problems. Follow

expansion tank manufacturer guidelines for installation,

and sizing.

Boiler manufacturer recommends initial ll pressure of

10-12 psi. For higher ll pressures increase expansion

tank’s air charge to match ll pressure.

10.

Purging heating system of air and gases is critical for

proper circulation and quiet performance. Once the air

is purged, for boiler installations using oat type vents,

air vents should be closed for normal operation. If air

is heard or noticed by loss of heat, purge system and

open vents for short period of time.

3.2 Prior To Installing The Boiler

• Verify you have selected right size boiler with proper

capacity. AHRI rating of boiler selected should be greater

than or equal to calculated peak heating load (heat loss)

for building or area(s) served by boiler and associated

hot water heating systems. Use heat loss calculations

based on approved methods. See Table 1.

• Boiler must be supplied with proper oil supply and oil

piping, sucient fresh combustion air, and suitable

electrical supply.

• Connect boiler to suitable venting and piping systems

adequate to distribute heating load.

• Installation is not complete unless pressure relief valve

is installed in 3/4” tapping located in supply piping.

• Thermostat must be properly located and installed

• Failure to pipe boiler correctly may result in excessive

noise or other related problems.

Existing Water System Evaluation

A good system will prevent oxygen contamination of boiler

water.

Causes of oxygen contamination may be:

A. Addition of excessive make up water as a result of

leaks.

B. Absorption through open tanks and ttings.

C. Oxygen permeable materials in the distribution

system.

To insure long product life, oxygen sources must be

eliminated.

Take the following measures:

A. Repair system leaks.

B. Eliminate open tanks from the system.

C. Eliminate and/or repair ttings which allow oxygen

absorption.

D. Use non-permeable materials in the heating system.

3 - BEFORE YOU START

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

GPH = U.S. Gallons per Hour

Mbh = 1000 Btu (British thermal units) per hour.

psi = Pounds per square inch

*MAWP = Maximum allowable working pressure. This low pressure oil red hot water boiler is constructed and

hydrostatically tested for maximum working pressure of 65 psi in accordance with the latest revision of the A.S.M.E.

(American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating boilers.

AFUE= Annual Fuel Utilization Eciency

Heating Capacity and AFUE based on 13.1% CO2 (13.5% CO2 at 0.90 GPH, 13.2% CO2 at 1.65 GPH), -0.02” w.c. draft in

breech, and # 1 smoke or less. Testing is done in accordance with U.S. DOE (Department of Energy) test procedure.

Heating Capacity indicates amount of heat available after subtracting losses up the stack. Remaining heat is available

to heat water. Small portion is heat from jacket and surfaces of boiler and this heat stays in structure. Net AHRI rating

represents portion of remaining heat applied to heat radiation or terminal units (i.e. nned tube baseboard, cast iron

radiators, radiant oor, etc.). Dierence between Heating Capacity and Net AHRI Rating, called piping and pickup

allowance, establishes reserve for heating volume of water in system and osetting heat losses from system piping. Net

AHRI ratings shown are based on piping and pickup factor of 15% in accordance with AHRI Standard as published by

Hydronics Institute.

Net AHRI rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building

or area(s) served by boiler and associated hot water heating systems. Consult manufacturer before selecting boiler for

installations having unusual piping and pickup requirements.

Table 1 - RATINGS & CAPACITIES

OIL-FIRED HOT WATER BOILERS

Models

Number

Sections

Firing

Rate

[GPH]

Input

[Mbh]

Heating

Capacity

[Mbh]

Net

AHRI

Rating

[Mbh]

*MAWP

Water

[psi]

AFUE

[%]

M i n .

Relief

Valve

Capacity

[Mbh]

M a x .

Water

Temp

[°F]

Chimney

Liner

Size

Round

[Inches]

Chimney

Liner

Size

Square

[Inches]

Flue

Size

[Inches]

EXB4075 4 0.75 105 92 80 65 87.0 140 250 6 6¾ 5

EXB4090 4 0.90 126 110 96 65 86.0 140 250 6 6¾ 5

EXB5100 5 1.00 140 123 107 65 87.0 175 250 6 6¾ 5

EXB5120 5 1.20 168 148 129 65 86.0 175 250 6 6¾ 5

EXB6130 6 1.30 182 160 139 65 87.0 210 250 6 6¾ 5

EXB6145 6 1.45 203 178 155 65 86.0 210 250 6 6¾ 5

EXB7165 7 1.65 231 202 176 65 87.0 245 250 7 6¾ 6

EXB7180 7 1.80 252 220 191 65 86.0 245 250 7 6¾ 6

4 - RATINGS & CAPACITIES

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

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