ECR International Dunkirk EXCELSIOR EXB Series Instruction manual

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. [phone]
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.

3
DIMENSIONS
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]

4
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]

5
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]

6
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]

7
3.1 Installation and Operation
1. 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 o 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-ring 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 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.
9. 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.
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 ttings.
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 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]

8
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
of
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]

9
1. Boiler is suitable for installation on combustible
ooring. Do not install boiler on carpeting.
2. Locate boiler in front of nal 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 oor is not level, or if water may be
encountered on oor 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
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 .
6. 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.
7. Fresh air for combustion and ventilation must be
available 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.
9. 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”
15”
2
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
of
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]

10
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]