Dunkirk EXCELSIOR Series Instruction manual

Hodels
EXB4075
EXB4095
EXB4110
EXB5100
EXB5115
EXB5135
EXB6130
EXB6145
EXB6165
EXB7165
EXB7180
EXB7190
EXCELS
High Efficiency
OilFiredHotWaterBoiler
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
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Manufactured by:
ECR international, Inc.
220! DwyerAvenue. Utica NY 13501
web site www ecnntemational corn PIN 240009348, Rev C [08/2012]

Hodels
EXB40751
EXB4095
EXB5100
EXB5115
EXB6130
EXB6145
EXB6165
EXB7165
EXB7180
Heet Energy Star requirements
for Energy Efficiency
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,

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4
5
6
7
5 (13)
5 (13)
5 (13)
6 (15)
18 3/8 (46)
21 5/8 (56)
24 7/8 (64)
28 1/8 (72)

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 ......................................................................................................... 52
19 - Oil Boiler/Burner Cleaning Instructions .................................................................... 54
20 - Troubleshooting ..................................................................................................... 56
21 - Equipment And Accessories .................................................................................... 58
Parts List ..................................................................................................................... 62
Warranty ..................................................................................................................... 68
Check Out Certificate .................................................................................................... 70

Installationsof boilersandventingshall bedone
only bya qualifiedexpert and in accordancewith
this manual.Installing or ventinga boiler or any
other oil appliancewith improper methodsor
materialsmayresult in seriousinjury or deathdue
to fire or to asphyxiationfrom poisonousgases
suchascarbonmonoxidewhichisodorlessand
invisible.
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
affect performance or life of boiler.
1,1 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 fired natural draft (chimney vented)
oil fired hot water boiler comprised of cast iron sections,
available with 4, 5, 6 or 7 sections. Sections are held
together by push nipples and threaded rods.
4,5 and some 6 section boilers may be factory equipped for
direct vent installations. Direct vent instructions are cov-
ered in a separate supplemental instructions document.
Boiler models are capable of firing #2 fuel oil from 0.75
gph up to 1.90 gph.
Boilers include -
• Limit, 220 °F maximum, operating control with integral
low water cut off.
• Temperature and pressure gauge
• 30 psi relief valve
• Drain valve

2.1 General
Boiler installation shall be completed by qualified agency.
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.
Modification, substitution or elimination of factory
equipped, supplied or specified components could
result in death or serious injury.
Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury.
2,2 Become Familiar With Symbols Identifying
Potential Hazards.
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,
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.
Product contains fiberglass wool and refractory
ceramic fibers. Possible cancer hazard. May cause
irritation to skin, eyes and respiratory tract. To
avoid this hazard, wear a dust mask and gloves
when handling fiberglass and ceramic fibers.
IHPORTANT: Read the following instructions
COHPLETELY before installing!!
2.3 Installation shah 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.
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
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-I.
Additional manual reset low water cutoff 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:
Used to address practices not related to personal • Installation by licensed plumber or gas fitter.
injury.

3.1 Installation and Operation
]. Do not operate unit if any control, switch, components
or devices have been underwater or subject to water
damage.
2. Before servicing, allow boiler to cool. Always shut off any
electricity and oil supply to boiler when working on it.
3. Inspect oil line and connections for leaks,
4. Verify oil burner nozzle is proper size, Over-firing will
result in early failure of boiler sections, and result in a
potentially dangerous situation,
5. Never vent boiler into enclosed space. Always vent to
the outside, Never vent to another room or inside a
building,
6. Verify adequate air supply for complete combustion,
7. 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.
8. Consider system total water volume, temperature,
initial fill 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,
9. Boiler manufacturer recommends initial fill pressure of
10-12 psi, For higher fill pressures increase expansion
tank's air charge to match fill pressure.
10. Purge heating system of air and gases is critical for
proper circulation and quiet performance, Once the air
is purged, for boiler installations using float 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 Figure 1, Page 8
• Boiler must be supplied with proper oil supply and oil
piping, sufficient 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 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,
1. Causes of oxygen contamination may be:
A, Addition of excessive make up water as a result of
leaks,
B, Absorption through open tanks and fittings,
C, Oxygen permeable materials in the distribution
system,
2. 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 fittings which allow oxygen
absorption,
D, Use non-permeable materials in the heating system,

4 _ _TING5 & CAPACITI£5
Table % RATINGS & CAPACITIES
OIL-FIRED HOT WATER BOILERS
=J I Net I Min relief Max JChimney Chimney
Heat ng MAvvv "Liner FlueNumberFiring In ut ' ' I
.AHRI . . AFUE Valve Water Liner Size
of Rate :MPh. _apacIzy vvazer o , , Size Size
Sections [GPH] [ J rMbh] Rating r_s _ [ Yo] Capacty Temp Round [Square , [Inches]
! ! L J . [Mbh] . L_ J . i. [Mbh] . [°F] . [Inches] Inches]
4
4
4
5
5
5
6
6
6
7
7
7
0.75 105
0.95 133
i.i0 154
1.00 140
1.15 161
1.35 189
1,30 182
1.45 203
1,65 231
1,65 231
1,80 252
1,90 266
91
114
132
122
139
161
159
176
198
201
217
228
79
99
115
106
121
140
138
153
172
175
189
198
65 86.0 91 250
65 85.0 115 250
65 84.0 132 250
65 86.5 122 250
65 85,0 139 250
65 84,0 161 250
65 86,5 159 250
65 85.0 176 250
65 84,0 198 250
65 86,0 201 250
65 85.0 217 250
65 84.0 227 250
6
6
6
6
6
7
6
7
7
7
7
8
6 3/4 5
6 3/4 5
6 3/4 5
6 3/4 5
6 3/4 5
6 3/4 5
6 3/4 5
6 3/4 5
6 3/4 5
6 3/4 6
6 3/4 6
6 3/4 6
GPH =U.5. Gallons per Hour
Mbh =i 000 Btu (British thermal units) per hour.
psi =Pounds per square inch
*MAWP = Maximum allowable working pressure. This low pressure oil fired hot water boiler is constructed and
hydrostatically tested for maximum working pressure of 65 psi in accordance with the latest revision of the A.5. M.E.
(American 5ociety of Mechanical Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating boilers.
AFUE= Annual Fuel Utilization Efficiency
Heating Capacity and AFUE based on i3.i% CO2(i3.5% C02at 0.95 GPH and i.i0 GPH), -0.02" w.c. draft in breech, and
#i 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. Smafl portion is heat from jacket and surfaces of boiler and this heat stays in structure. Net AHRI rating
represents portion of remaining heat appfied to heat radiation or terminal units (i.e. finned tube baseboard, cast iron
radiators, radiant floor, etc.). Difference between Heating Capacity and Net AHRI Rating, cafled piping and pickup
aflowance, establishes reserve for heating volume of water in system and offsetting heat losses from system piping. Net
AHRI ratings shown are based on piping and pickup factor of i5% 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.

Fire hazard. Do not be install on carpeting. Failure
to follow these instructions could result in death or
serious injury.
I. Boiler is suitable for installation on combustible floor-
ing. Do not install boiler on carpeting.
2. Locate boiler in front of final position before removing
crate.
3. Locate unit so vent pipe connection to chimney will be
short and direct.
4. For basement installation, provide solid elevated base,
such as concrete, if floor is not level, or if water may be
encountered on floor around boiler,
5. 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
12" 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.
6. Minimum clearances to combustible material see
Figure 1 and Table2.
7. Fresh air for combustion and ventilation must be avail-
able at boiler. Ventilating and combustion air must
enter boiler room without restrictions.
8. 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. In Canada, use CSA B 139, latest
revision.
9. Clearance to venting is for single wall flue pipe. If Type
L vent is used, clearance may be reduced to minimum
required by vent pipe manufacturer.
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 See Flue 18" (46 cm)
Flue 9" (23 cm) 9" (23 cm)
All distancesmeasuredfromtheboilerjacket orflue.
Figure i- Clearances to Combustible Construction
See 24"
Table 2
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Figure 2 - General Requirements For A Typical Installation
EXPAN8 ON TANK
OI_L LINES ......
VALVE
T
CHECK LOCAL CODES FOR
MAXIMUM DISTANCE FROM
FLOOR, OR OTHER ALLOWABLE
SAFE POINT OF DISCHARGE.
Shut off manual fuel supply valve if burner is shut
down for extended period of time.