ECR International Dunkirk EXCELSIOR EXB Series Gebrauchsanweisung

High E󱐰ciency

Oil Fired Hot Water Boiler

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

EXCELSIOR

Models

EXB4075

EXB4095

EXB4110

EXB5100

EXB5115

EXB5135

EXB6130

EXB6145

EXB6165

EXB7165

EXB7180

EXB7190

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 253 7900

www.ecrinternational.com

PN 240009348 REV. K [08/01/2018]

EXCELSIOR OIL-FIRED CAST IRON HOT WATER BOILER

Models

EXB4075

EXB5100

EXB6130

EXB7165

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.

DIMENSIONS

Sections

Flue Size

Inches

(cm)

Dimension

"A"

Inches

(cm)

Dimension

"B"

Inches

(cm)

Chimney

Vent

Direct

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 240009348, Rev. K [08/01/2018]

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.......................................................................................... 11

8 - Boiler Assembly....................................................................................................... 13

9 - Boiler System Piping ................................................................................................ 18

10 - Hydronic Piping ..................................................................................................... 19

11 - Fuel Supply Piping ................................................................................................. 32

12 - Antifreeze In The System ....................................................................................... 33

13 - Electrical Connections............................................................................................. 34

14 - Chimney And Venting Connections ........................................................................... 35

15 - Filling Boiler .......................................................................................................... 38

16 - Operating The Boiler - System Start-Up ................................................................... 39

17 - Oil Burner, Nozzle, & Air Settings ............................................................................. 46

18 - Maintenance ......................................................................................................... 53

19 - Oil Boiler / Burner Cleaning Instructions.................................................................... 55

20 - Troubleshooting ..................................................................................................... 57

21 - Equipment And Accessories .................................................................................... 59

TABLE OF CONTENTS

PN 240009348, Rev. K [08/01/2018]

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 some 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 1.65 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

only 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 may result in serious injury or death due

to re or to asphyxiation from poisonous gases

such as carbon monoxide which is odorless and

invisible.

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.

1 - INTRODUCTION

PN 240009348, Rev. K [08/01/2018]

2.1 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.

WARNING

Modication, substitution or elimination of factory

equipped, supplied or specied components could

result in death or serious injury.

WARNING

Improper installation, adjustment, alteration, service

or maintenance 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 to

potential personal injury hazards. Obey all safety messages

following this symbol to avoid possible injury or death.

2.2 Become Familiar With Symbols Identifying

Potential Hazards.

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”.

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.

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

Product contains berglass wool and refractory

ceramic bers. Possible cancer hazard. May cause

irritation to skin, eyes and respiratory tract. To

avoid this hazard, wear a dust mask and gloves

when handling berglass and ceramic bers.

NOTICE

Used to address practices not related to personal

injury.

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 240009348, Rev. K [08/01/2018]

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 will

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, Page 8.

• 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 240009348, Rev. K [08/01/2018]

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 0.95 GPH and 1.10 GPH, 13.2% CO2 on 7 section 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

Number

Sections

Firing

Rate

[GPH]

Input

[Mbh]

Heating

Capacity

[Mbh]

Net

AHRI

Rating

[Mbh]

*MAWP

Water

[psi]

AFUE

[%]

Min.

relief

Valve

Capacity

[Mbh]

M a x .

Water

Temp

[°F]

Chimney

Liner

Size

Round

[Inches]

Chimney

Liner

Size

Square

[Inches]

Flue

Size

[Inches]

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

4 0.95 133 114 99 65 85.0 115 250 6 6¾ 5

4 1.10 154 132 115 65 84.0 132 250 6 6¾ 5

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

5 1.15 161 139 121 65 85.0 139 250 6 6¾ 5

5 1.35 189 161 140 65 84.0 161 250 7 6¾ 5

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

6 1.45 203 176 153 65 85.0 176 250 7 6¾ 5

6 1.65 231 198 172 65 84.0 198 250 7 6¾ 5

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

7 1.80 252 217 189 65 85.0 217 250 7 6¾ 5

7 1.90 266 228 198 65 84.0 227 250 8 6¾ 5

4 - RATINGS & CAPACITIES

PN 240009348, Rev. K [08/01/2018]

Boiler is suitable for installation on combustible

ooring. Do not install boiler on carpeting.

Locate boiler in front of nal position before removing

crate.

Locate unit so vent pipe connection to chimney will be

short and direct.

For basement installation, provide solid elevated base,

such as concrete, if oor is not level, or if water may be

encountered on oor around boiler.

Provide recommended service clearance, if applicable,

as follows:

• Clearance from Jacket Front Panel

24” for servicing burner

• Clearance from Jacket Side Panels

24” for burner swing door, if opened fully with burner

mounted, otherwise 2” with burner removed.

• Clearance From Jacket Rear Panel

24” minimum for rear smoke box cleaning. (Note:

this dimension will also be controlled by horizontal to

vertical to horizontal smoke pipe arrangement. See

Figure 1

Minimum clearances to combustible material see

Figure 1 and Table 2.

Table 2 - BOILER CLEARANCES

Unit Combustible

Clearance

Accessibility,

Cleaning,

and Servicing

Top 12” (32 cm) 24” (61 cm)

Right Side 2” (5 cm) 24” (61 cm)

Left Side 2” (5 cm) 24” (61 cm)

Floor Combustible No Requirement

Front 17” (43 cm) 24” (61 cm)

Back 9” (23 cm) 24” (61 cm)

Flue 9” (23 cm) 9” (23 cm)

All distances measured from the boiler jacket or ue.

Fresh air for combustion and ventilation must be

available at boiler. Ventilating and combustion air must

enter boiler room without restrictions.

Installation shall conform to requirements of authority

having jurisdiction or in absence of such requirements

in United States, follow NFPA 31 Installation of Oil

Burning Equipment.

Clearance to venting is for single wall ue pipe. If Type

L vent is used, clearance may be reduced to minimum

required by vent pipe manufacturer.

15”

Figure 1 - Clearances to Combustible Construction

WARNING

Fire hazard. Do not be install on carpeting. Failure

to follow these instructions could result in death or

serious injury.

Table 1 - RATINGS & CAPACITIES

OIL-FIRED HOT WATER BOILERS

Number

Sections

Firing

Rate

[GPH]

Input

[Mbh]

Heating

Capacity

[Mbh]

Net

AHRI

Rating

[Mbh]

*MAWP

Water

[psi]

AFUE

[%]

Min.

relief

Valve

Capacity

[Mbh]

M a x .

Water

Temp

[°F]

Chimney

Liner

Size

Round

[Inches]

Chimney

Liner

Size

Square

[Inches]

Flue

Size

[Inches]

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

4 0.95 133 114 99 65 85.0 115 250 6 6¾ 5

4 1.10 154 132 115 65 84.0 132 250 6 6¾ 5

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

5 1.15 161 139 121 65 85.0 139 250 6 6¾ 5

5 1.35 189 161 140 65 84.0 161 250 7 6¾ 5

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

6 1.45 203 176 153 65 85.0 176 250 7 6¾ 5

6 1.65 231 198 172 65 84.0 198 250 7 6¾ 5

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

7 1.80 252 217 189 65 85.0 217 250 7 6¾ 5

7 1.90 266 228 198 65 84.0 227 250 8 6¾ 5

5 - LOCATING THE BOILER

PN 240009348, Rev. K [08/01/2018]

NOTICE

Shut o manual fuel supply valve if burner is shut

down for extended period of time.

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.

6 - INSTALLATION REQUIREMENTS

PN 240009348, Rev. K [08/01/2018]

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