ECR International Dunkirk EXCELSIOR 3 Series Installation, Operation & Maintenance Manual Download Page 1

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High Efficiency

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]

Summary of Contents for Dunkirk EXCELSIOR 3 Series

Page 1: ...RATION 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 5...

Page 2: ...e right to discontinue change specifications 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 240013...

Page 3: ...tions Flue Size Inches cm Dimension A Inches cm Dimension B Inches cm Chimney Vent Direct Vent 4 5 13 18 46 6 1 32 19 5 5 13 21 54 8 1 32 19 6 5 13 24 63 1 1 32 19 7 6 15 28 71 3 19 N A DIMENSIONS PN...

Page 4: ...ILER 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...

Page 5: ...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...

Page 6: ...l Symbol alerts you to potential personal injury hazards Obey all safety messages potential personal injury hazards Obey all safety messages following this symbol to avoid possible injury or death fol...

Page 7: ...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 Inf...

Page 8: ...trols and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Additional manual reset low water cutoff and manual reset high limit may be required 2 6 Requirements for Commonwealth of Massa...

Page 9: ...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 o...

Page 10: ...ating called piping and pickup allowance 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 f...

Page 11: ...e 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...

Page 12: ...hut 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...

Page 13: ...square inch per 4 000 BTU per hour input of all equipment in space Duct cross sectional area shall be same as opening free area C Horizontal Ducts Minimum free area of 1 square inch per 2 000 BTU per...

Page 14: ...e Mesh Screen Wood Louvers Metal Louvers Btuh Btuh Btuh 3 x 12 144 000 36 000 108 000 8 x 8 256 000 64 000 192 000 8 x 12 384 000 96 000 288 000 8 x 16 512 000 128 000 384 000 Btuh British Thermal Uni...

Page 15: ...e pins on door into slotted mounting bracket holes Recommend hinges be on same side as flexible oil line in order to swing door open 6 Inspect Swing door insulation and rope gasket A Inspect fiber rop...

Page 16: ...s water tight 11 Install Limit control mounting plug in upper 3 4 NPT port facing front See Figure 7 12 Install Limit control harness assembly Loosen mounting screw on bottom of limit control A Mount...

Page 17: ...ing and Control Assembly LIMIT CONTROL WITH INTEGRAL LOW WATER CUT OFF THERMAL LWCO WIRE BURNER WIRING RELIEF VALVE BACK OF BOILER NOTICE Do not install valve between boiler and controls manifold or r...

Page 18: ...to grounding lug When installing wiring through hole in Limit use anti abrasion cable clamp Connect black hot wire to L1 of terminal block white N wire to L2 of terminal block 16 Install top panel Pl...

Page 19: ...e bolt first or tighten either piece of hardware 100 without using alternating tightening method described above 19 Install oil burner Check oil nozzle in burner for size angle and type inspect electr...

Page 20: ...is necessary per 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 in...

Page 21: ...21 Figure 17 Standard Near Boiler Piping Piping Diagram Legend 10 HYDRONIC PIPING PN 240013422 Rev A 08 15 2021...

Page 22: ...22 10 HYDRONIC PIPING DHW Heater Figure 18 Piping And Wiring Single Zone System With Domestic Hot Water DHW Priority PN 240013422 Rev A 08 15 2021...

Page 23: ...X CONTACT ZR ON PRIORITY PUMP PRIMARY PUMP PRIORITY ON STATUS OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY OPTION SWITCHES ZONE VALVE PUMP ZR ZC DPM 2 PRIORITY Figure 19 Multi Zone Piping and...

Page 24: ...CT ZR ON PRIORITY PUMP PRIMARY PUMP PRIORITY ON STATUS OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY OPTION SWITCHES ZONE VALVE PUMP ZR ZC DPM 2 PRIORITY Figure 20 Piping And Wiring Multizone S...

Page 25: ...25 10 HYDRONIC PIPING Figure 21 Piping and Wiring Multi Zone System With Circulators And Domestic Hot Water Priority PN 240013422 Rev A 08 15 2021...

Page 26: ...Figure 22 Primary Secondary Piping And Wiring With Circulators And Domestic Hot Water MAX 4 X DIAMETER CLOSELY SPACED TEES BOILER PUMP 26 10 HYDRONIC PIPING PN 240013422 Rev A 08 15 2021...

Page 27: ...27 10 HYDRONIC PIPING PN 240013422 Rev A 08 15 2021...

Page 28: ...M TANK PERFORMANCE CONSIDER USING ZONE CIRCULATOR BOILER PUMP MAX 4 X DIAMETER CLOSLEY SPACED TEES CONSULTER LA FIGURE 24 Figure 23 Piping And Wiring Primary Secondary Multi Zone System Piping With Zo...

Page 29: ...LER 120 VAC TO XFRM 24 VAC X X CONTACT ZR ON PRIORITY PUMP PRIMARY PUMP PRIORITY ON STATUS OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY OPTION SWITCHES ZONE VALVE PUMP ZR ZC DPM 2 PRIORITY 10...

Page 30: ...0 HYDRONIC PIPING Figure 24 Piping And Wiring Primary Secondary Piping With Zone Valves And Domestic Hot Water With Circulator ZONE VALVE MAX 4 X DIAMETER CLOSELY SPACED TEES PN 240013422 Rev A 08 15...

Page 31: ...ORITY PUMP FROM BOILER 120 VAC TO XFRM 24 VAC X X CONTACT ZR ON PRIORITY PUMP PRIMARY PUMP PRIORITY ON STATUS OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY OPTION SWITCHES ZONE VALVE PUMP ZR ZC...

Page 32: ...PARATOR ZONE VALVE EXPANSION TANK WATER INLET SYSTEM CIRCULATOR Figure 25 Bypass Piping Fixed Low Temperature Only Adjust two throttling valves to maintain at least 130 F 140 F in boiler return BOILER...

Page 33: ...VE 4 WAY MIXING VALVE EXPANSION TANK Figure 27 Bypass Piping 4 Way Valve Option with Circulator On Supply Side SHUT OFF VALVES SHUT OFF VALVES BOILER SUPPLY MAIN TO COMBINED HEATING COOLING SYSTEM RET...

Page 34: ...n 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 pump for fuel pump and by pass conne...

Page 35: ...or more and increase fuel consumption See Table 6 and 7 Table 6 BOILER WATER VOLUMES Number of Boiler Section Total Volume Gallons 4 3 6 5 4 3 6 5 1 7 5 9 Table 7 PIPING WATER VOLUMES PIPE SIZE COPPER...

Page 36: ...ith fused disconnect switch in this circuit Never jump out or make inoperative any safety or operating controls WARNING Electrical shock hazard Turn OFF electrical power supply at service panel before...

Page 37: ...into fireclay tile lined masonry chimney or type L vent or factory built chimney that complies with type HT requirements of UL103 See Figure 32 3 Chimney Inspection Prior to installation of any new o...

Page 38: ...and total volume of flue gases Operate boiler for at least 5 minutes before measuring draft Minimum Draft at Breech Draft induced by the chimney must create at least a neutral pressure of 0 zero inche...

Page 39: ...hest part of passage through roof Must be at least 2 FT higher than any neighboring object within 10 Ft Must have unobstructed top opening Must be at least 4 inches thick and be tight Must slope up at...

Page 40: ...ng E Open purge valve F Open shut off valve in cold water supply piping G When zone is completely purged of air close zone valve or shut off valve Open valve to next zone to be purged Repeat this step...

Page 41: ...sely 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 were not separated when wiring the cont...

Page 42: ...n a second time for 20 seconds 4 Display will read PURR OFF 16 7 Control Action On System Start Up At initial start up with economy feature active control establishes 145 F target temperature To test...

Page 43: ...rgeting function is active and limit control will reduce boiler temperature to conserve fuel Economy feature is activated using the Economy dial See How Thermal Targeting Works 16 8 page 42 16 OPERATI...

Page 44: ...Fire burn asphyxiation hazard Do not attempt to start burner when oil has accumulated in combustion chamber or unit is full of vapor or hot Check operation of all boiler controls before installation o...

Page 45: ...eliminary steps I Check wiring connections and power supply II Verify power is on to controls III Verify limit control is closed IV Check contacts between igniter and electrodes V Check piping to oil...

Page 46: ...e 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 Du...

Page 47: ...perature Table 12 Thermostat locations to Avoid DEAD SPOTS HOT SPOTS COLD SPOTS Behind doors Concealed pipes Concealed pipes or ducts Fireplace TV sets Stairwell drafts Corners alcoves Radios Door dra...

Page 48: ...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 AFG Burner with V1 Hea...

Page 49: ...KER 3 is aligned with correct index number as per Burner Settings Table B Tighten RETAINING NUT 1 NOTE Zero and four are scale indicators only From left to right first line is 4 and last line 0 On som...

Page 50: ...1 2 75M 2 625 1 65 V7 Hago 1 25 x 45B 175 2 4 10 87 0 7180 V1 2 75M 2 625 1 80 V7 Hago 1 35 x 45B 175 3 3 10 86 0 Timings Pre purge 15 seconds Post purge 15 seconds Table 13 Beckett Chimney Vent Preli...

Page 51: ...4 0 0 85 WC 6130 6 Slot 2 5 1 30 V6 Delavan 1 00x45B 175 2 0 0 65 WC Timings Pre purge 15 seconds Post purge 30 seconds Table 14 Beckett NX Direct Vent Preliminary Burner Settings TABLE14b BECKETT ECR...

Page 52: ...7 0 4090 Reverse 2 75 0 90 Oval Delavan 0 75 x 90B 140 2 3 5 86 0 5100 Standard 2 75 1 00 None Delavan 0 80 x 90B 180 0 2 75 87 0 5120 Standard 2 75 1 20 None Delavan 1 00 x 90B 190 0 5 9 86 0 6130 St...

Page 53: ...ing Rate GPH Combus tion Liner Nozzle Mfr Nozzle Type Pump Pressure PSI Head Setting Air Setting Pressure Switch Setpoint 4075 Reverse 2 75 0 75 Oval Delavan 0 65x60W 150 3 5 0 0 25 WC 5100 Standard 2...

Page 54: ...0 x 60B 160 1 22 87 0 4090 4 56 0 90 Oval Delavan 0 75 x 70A 145 2 28 86 0 5100 3 00 1 00 None Delavan 0 75 x 45B 175 0 75 36 87 0 5120 3 00 1 20 None Delavan 1 00 x 60A 165 0 85 1 00 40 86 0 6130 3 0...

Page 55: ...ring freezing weather Water left in system will freeze and crack pipes and or boiler 18 7 Oil Burner Maintenance Perform following preventative maintenance annually preferably prior to heating season...

Page 56: ...system including radiation Allow boiler water to reach operating temperature if possible Continue to circulate water for few hours Stop firing boiler Drain system in a manner and to a location that h...

Page 57: ...3rd pass Two inner flue ways B Inspect chimney and clean if necessary C Clean and re attach vent connector onto rear of the boiler with three screws NOTICE When securing burner swing door verify door...

Page 58: ...UM HOSE VACUUM HOSE BRISTLE BRUSH FLUE BRUSH FLUE BRUSH FRONT VIEW 3RD PASS COMBUSTION CHAMBER 2ND PASS Figure 46 Cleaning the Boiler 19 OIL BOILER BURNER CLEANING INSTRUCTIONS PN 240013422 Rev A 08 1...

Page 59: ...ot come on I No power to control II Control is in soft lockout or restricted mode Press reset button for more than 1 second to exit soft lockout If control has recycled three times within same call fo...

Page 60: ...low water to run and clear valve seat Water logged expansion tank Drain tank follow instructions to provide air buffer HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT LIMIT CO...

Page 61: ...ed after expansion tank This configuration allows circulator to pump away from expansion tank for improved air elimination and system performance Air eliminator fitting or air purger is not provided A...

Page 62: ...US GPM 5 10 15 20 m h 3 Head feet Model Watts Volts Amps Capacitor UP 15 42F 85 115 0 74 10 F 180 V Fourni avec la pompe Figure 47 Grundfos Pump Curve Figure 48 Taco 007e Pump Curve 21 EQUIPMENT AND A...

Page 63: ..._________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person Installation booklet affixed o...

Page 64: ...All specifications subject to change without notice 2021 ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com...

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