Dunkirk EXCELSIOR EXB4075 Installation, Operation & Maintenance Manual Download Page 1

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Summary of Contents for EXCELSIOR EXB4075

Page 1: ...6145 EXB6165 EXB7165 EXB7180 EXB7190 EXCELS High Efficiency OilFiredHotWaterBoiler INSTALLATION OPERATION MAINTENANCE MANUAL r r 7_ US H Manufactured by ECR international Inc 220 DwyerAvenue Utica NY...

Page 2: ...eck 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 r...

Page 3: ...IS _k 1 _ _ J l __j1 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...

Page 4: ...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 St...

Page 5: ...r 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 Hydro...

Page 6: ...ct 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...

Page 7: ...erformance 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...

Page 8: ...f 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...

Page 9: ...i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i...

Page 10: ...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 shu...

Page 11: ...e opening within 12 inches of top of space Locate remaining opening within 12 inches of bottom of space Size each opening per the following A Direct communication with outdoors Minimum free area of 1...

Page 12: ...ructed Houses 3 V2 x 12 8 x 8 8 x 12 8 x 16 144 000 256 000 384 000 512 000 36 000 64 000 96 000 128 000 i08 000 192 000 288 000 384 000 Btuh British Thermal Units per hour based on opening covered by...

Page 13: ...gral cast hinge pins on door into slotted mounting bracket holes Recommend hinges be on same side as flexible oil line in order to swing door open Inspect Swing door insulation and rope gasket A Inspe...

Page 14: ...B Locate 3 4 NPT x 90 street elbow Install elbow using 3 4 NPT tapping in supply piping Install elbow with outlet facing directly up Install relief valve with outlet facing horizontally C Pipe dischar...

Page 15: ...i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i...

Page 16: ...f terminal block white N wire to L2 of terminal block Install top panel Place on top of side panels Position tabs in top panel into slots in side panels Push top panel toward back of boiler Install re...

Page 17: ...cannot be drawn to provide an air tight seal Applying excessive torque will only cause thread damage Fk ure 15 Limit Control Wirinc Ensure all conduit is secured to prevent contact with flue pipe THER...

Page 18: ...r manufacturer s specific instructions 6 When connecting cold water supply to pressure reducing valve make sure clean water supply is available When water supply is from well or pump install sand stra...

Page 19: ...BOILER CONTROL FROM SYSTEM FRONT OF BOILER TEMPERATURE PRESSURE DRAIN Piping Diagram Legend HOSE BIB J LOW CONTROL VAVLE DRAIN VALVE PRESSURE RELIEF VALVE CIRCULATOR _ PRESSUREREDUCER VALVE _ BALL v A...

Page 20: ...i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i...

Page 21: ...i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i...

Page 22: ...tNLET BOILER _USE FULL PORT ZONE VALVE CH ZONE 3 ZONE 2 DHW CIRCULATOR ZONE 1 PRIORITY ZONE I t I 120VAC HYDROSTA MODEL 3250 L N 24VAC FROM TRANSFORMER 120VAC TO TRANSFORMER TO OIL BURNER rll ZONE VA...

Page 23: ...rculators And Domestic Hot Water Priority ZONE 4 CIRC 4 _ ZONE 3 CIRC 3 ZONE 2 CIRC 2 DHW CIRCULATOR ZONE 1 PRIORY_Y ZONE EXPANSION TANK INDIRECT WATER HEATER AQUASTAT OR THERMOSTAT L 120 VAC N TO OIL...

Page 24: ...ZONE4_ ZONE3 _ ZONE2_ ZONE 1 PRIORITY ZONE i WATER INLE EXPANSION TANK...

Page 25: ...I INDIRECT WATER HEATER AQUASTAT OR THERMOSTAT DATA PORT o F_ J ARM 4P CONTROL WITH PRIORITY F_ kJ TOEXTRA ZONE MODULE 120 VAC TO OIL BURNER RELAY T 120VAC COl L 120VAC CONTACTS...

Page 26: ...r With Zone Valve ZONE 4 SYSTEM CI RCULATOR ZONE 2 ZONE 1 PRIORITY ZONE USE FULL PORT ZONE VALVE FOR OPTIMUM TAN_ PERFORMANCE CONSIDEF_ USING ZONE CIRCULATOR i SEE FIGURE 24 C 2 MAX APART I _ FLOW iN...

Page 27: ...C FROM TRANSFORMER 120VACTO TRANSFORMER TO OIL BURNER A 24VAC COIL 120VAC CONTACTS INDIRECT WATER H EATER AQUASTAT OR TH ERMOSTAT ON ZONE VALVE PUMF I II PRIORITY I1 1 ZR ZC I1 1 DPM 2 OPTION SWITCHES...

Page 28: ...4 Piping And Wiring Primary Secondary Piping With Zone Valves And Domestic Hot Water With Circulator _USE FULL PORT ZONE VALVE _ ZONE 4 ZONE 3 ZONE 2 CH CIRCULATORpuMP ZONE 1 PRIORITY ZONE DHW CIRCULA...

Page 29: ...24VACFROM TRANSFORMER 120VACTO TRANSFORMER ZONE VALVE PUMF INDIRECTWATER m m PRIORITY HEATER AQUASTAT _ ZR ZC ORTHERMOSTAT _ DPM 2 OPTION SWITCHES L 120 VAC...

Page 30: ...aintain at least 130 F 140 F in boiler return TO_SYSTEM E_ SYSTEM CIRCU LATOR WATER INLET EXPANSION TANK Vl V2 K BOILER FROM SYSTEM y I CIRCULATOR LOCATION Figure 25 Bypass Piping Automatic Hixing Val...

Page 31: ...ALTERNATE I CIRCULATOR __ LOCATION Figure 28 Recommended Piping for Combination Heating and Cooling Refrigeration System __A t __ WATER BOILER SHUTOFF v v s _i_ _ _ i m 1 m _1_ d AIR CUSHION TANK SUPP...

Page 32: ...n line often allow air to be drawn into fuel pump making it difficult to maintain oil pressure at nozzle Do not run overhead fuel lines from tank to oil burner Follow instructions attached to fuel pum...

Page 33: ...i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i...

Page 34: ...ii ii ii ii ii ii ii i i ii ii ii ii ii ii ii i i ii ii ii ii ii ii ii i i ii ii ii ii ii ii ii i i ii ii ii ii ii ii ii i i ii ii ii ii ii ii ii i i ii ii ii ii ii ii ii i i ii ii ii ii ii ii ii i i...

Page 35: ...ior to installation of any new or replacement fuel burning equipment chimney shall be inspected by qualified service agency A De rating may cause condensation on interior walls of chimney and boiler L...

Page 36: ...A 31 and CSA B139 for information for appropriate choice of venting materials Chimney may have to be lined to create sufficient draft or chimney may have to be lined to prevent corrosion of masonry ch...

Page 37: ...passage Lhrough roof Must be at least 2 FT higher than any neighboring object within 10 Ft Must have unobstructed top ii opening Must slope up at least 1 4 inch per foot of horizontal run _ smooth cor...

Page 38: ...pleted and fuses installed and oil tank is filled and oil lines have been tested Clean heating system if boiler water is dirty Refer to 18 Maintenance on page 52 for proper cleaning instructions for w...

Page 39: ...zone house turn dial to 2 or 1 Conversely if boiler provides adequate heat added fuel savings can be achieved by selecting higher setting example 4 or 5 If heating and indirect water heater signals w...

Page 40: ...rol will raise boilers target temperature to provide heat When outside temperature is mild heat demand is low Limit control will lower boiler s target temperature saving fuel i i i i i i i i i i i i i...

Page 41: ...hich point boiler will be allowed to fire again Note LED illuminates regularly during normal boiler operation TEST SETTINGS Button To Test Low Water Cut Off Press and hold Test Settings button for 5 s...

Page 42: ...oil pressure adjusting screw and turn screw to obtain proper pump pressure refer to 17 Oil Burner Nozzle Air Settings on page 46 Fire burn asphyxiation hazard Do not loosen or remove any oil line fitt...

Page 43: ...pleted by qualified agency Failure to do so could result in death or serious injury Control contains no field serviceable parts Do not attempt to take it apart Replace entire control if operation is n...

Page 44: ...alve is turned off and control delays turning motor off for set motor off delay time before control returns to standby I Pump Prime Igniter and motor are on with solenoid valve energized for 4 minutes...

Page 45: ...ble nozzle line electrode assembly and set electrode tip spacing Electrode tip spacing may need to be set prior to reassembling nozzle line electrode assembly Refer to figures on following pages for s...

Page 46: ...nd attach oil connector tube 2 Recheck Z dimension periodically when servicing to ensure escutcheon plate has not been moved Reset Z dimension if you replace air tube or nozzle line assembly Figure 42...

Page 47: ..._ 5ram 5164 _to 7 64 or 2 tO2 5ram I I L10 Turbulator Setting A Loosen nut 1 turn SCREW 2 until INDEX MARKER 3 is aligned with correct index number as per Burner Settings Table B Tighten RETAINING NU...

Page 48: ...60B 0 90x60B 0 85x60B 1 00x60B 1 10x60B 1 10x60AS 1 10x45AS 1 25x45AS 140 125 150 140 140 150 140 175 175 N A N A N A N A N A N A 0 2 2 x 86 0 85 0 84 0 86 5 85 0 84 0 86 5 85 0 86 0 Pre purge Post Pu...

Page 49: ...n 0 60x60B 150 2 5 0 95 Oval Hago 0 75x60B 155 2 5 1 00 None Delavan 0 75x45B 175 2 5 1 15 V5 Hago 1 00x60B 140 2 5 1 35 V5 Delavan 1 10x60B 150 2 5 1 30 V6 Danfoss 1 00x45B 175 Pre purge 15 seconds P...

Page 50: ...l Delavan 1 00x90B 125 i 2 75 1 00 None Delavan 0 75x603 175 1 1 75 1 15 None Delavan 1 00x80B 130 2 1 75 1 35 None Delavan 1 20x803 125 3 2 75 1 30 V6 Delavan 1 00x453 175 2 1 75 1 45 V6 Delavan 1 25...

Page 51: ...75 Oval Delavan 0 65x60W 0 95 Oval Delavan 0 75x90B 1 10 Oval Delavan 1 00x90B 1 00 None Delavan 0 75x60B 1 15 None Delavan 1 00x80B 1 35 None Delavan 1 20x80B 1 30 V6 Delavan 1 00x45B H 150 175 125...

Page 52: ...qualified service agency 18 3 Relief Valve Test relief valve for proper operation Refer to valve manufacturer s instructions packaged with relief valve 18 4 Conventional Expansion Tank See Equipment A...

Page 53: ...ow ready to be put into service 18 10 Frequent Water Addition Frequent water additions although unusual for water boiler are sign of leaky system Excessive amounts of make up water supplied to boiler...

Page 54: ...ay G Do not start burner unless burner swing door and vent connector are secured in place H Clean passage from combustion chamber to 2nd pass I Vacuum loose debris in bottom of combustion chamber and...

Page 55: ...Figure 45 Cleaning the Boiler FLUE BRUSH VACUUM HOSE FRONT VIEW FLUE BRUSH BRISTLE BRUSH COMBUSTION CHAMBER 2ND PASS...

Page 56: ...urner II Shortened electrodes Ill Clogged nozzles IV Airflow too high V Ignitor module defective VI CAD cell defective VII Oil valve stuck open or closed To isolate fuel problems disconnect fuel syste...

Page 57: ...t Waterlogged expansion tank Openvalvemanually Allow watertorunandclearvalveseat Drain tank followinstructions toprovide airbuffer Boiler is cold house is cold Boiler is hot house is cold Burner will...

Page 58: ...relief valve or other heating system problems It is important to install tank higher than top of boiler Connecting pipe from boiler to expansion tank shall rise continuously up to expansion tank so t...

Page 59: ...i _ _ _ I 4 _ _ 3 10 2 _5 Z _ _i i E _o_i I U US GPM 5 10 15 20 r_ m3 h I 2 3 4 5 Supplied with pump 10pF 180V Figure 47 Taco Pump Curve FLOW M H 1 2 3 4 5 7 8 9 I0 30 i S 2_ i S 20 5 5 0 0 5 10 15 20...

Page 60: ...DUNKIRK BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com...

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