Dunkirk Excelsior EXB Series User manual

Dunkirk Excelsior EXB Series User manual
OIL-BURNING EQUIPMENT:
HIGH EFFICIENCY HOT-WATER BOILERS
HOMEOWNER And OPERATOR INSTRUCTIONS
P/N# 240007138 Rev A [04/08]
NOTICE
• READ AND SAVE THESE INSTRUCTIONS FOR
REFERENCE.
• USE ONLY NUMBER 2 FUEL OIL.
! CAUTION
• DO NOT USE GASOLINE, CRANKCASE DRAININGS,
OR ANY OIL CONTAINING GASOLINE.
• NEVER BURN GARBAGE OR PAPER IN THE UNIT,
AND NEVER LEAVE COMBUSTIBLE MATERIAL
AROUND IT.
! WARNING
• KEEP YOUR BOILER AND THE SPACE AROUND
THE APPLIANCE CLEAR OF DEBRIS. DO NOT
STACK ITEMS ON OR AROUND THE APPLIANCE
WITHIN THE REQUIRED CLEARANCES TO
COMBUSTIBLES.
• ENSURE THAT THE SUPPLY OF COMBUSTION
AIR TO THE APPLIANCE IS NOT OBSTRUCTED
OR CUT OFF. ENSURE THAT THE PROPER
VENTILATION TO THE APPLIANCE AREA IS
MAINTAINED.
INSTRUCTIONS TO OBTAIN PROPER
OPERATION OF THE BOILER
! CAUTION
• DO NOT SET COMBUSTION VISUALLY.
• DO NOT START THE BURNER UNLESS ALL
CLEAN-OUT DOORS ARE SECURED IN PLACE.
• DO NOT ATTEMPT TO START THE BURNER
WHEN EXCESS OIL HAS ACCUMULATED, WHEN
THE UNIT IS FULL OF VAPOR, OR WHEN THE
COMBUSTION CHAMBER IS VERY HOT.
Instruments are the only reliable method to determine proper
combustion adjustments. An improperly adjusted burner causes
soot and high fuel bills due to the incomplete combustion of the
fuel oil. This in turn may require excessive boiler maintenance,
service costs, and in some instances, house cleaning or redecorating. A competent service mechanic should be consulted to
make the proper adjustments with a smoke tester, CO2 indicator
and draft gauge. Bacharach or Dwyer test kits include these instruments.
A ¼” NPT plug is provided in the burner swing door to take draft
readings in the combustion chamber. A ¼” diameter hole will
be required in the flue pipe between the boiler and barometric
damper (if used) to take draft, CO2, smoke and temperature readings. Adjust air shutter on oil burner to obtain a “trace” of smoke.
Measure CO2 at this point. Increase air adjustment to lower CO2
approximately one (1) percent. Check to ensure zero (0) smoke
and correct draft is obtained for the unit installed (reference the
Boiler Installation Manual for correct draft settings). If the proper
draft can not be maintained, changes and/or modifications may
be required in the venting or the chimney.
3
SHUTTING DOWN THE BOILER FOR
EXTENDED PERIODS OF TIME
! CAUTION
ALWAYS KEEP THE OIL SUPPLY VALVE SHUT OFF
IF THE BURNER IS SHUT DOWN FOR AN EXTENDED
PERIOD OF TIME.
• Always turn off electrical power to the boiler via the field installed fused disconnect switch if the boiler is shut down for
an extended period of time.
• When restarting the boiler from an extended shutdown, follow the Operating Instructions in the Installation Manual and
Operating Instructions.
GENERAL MAINTENANCE DURING OPERATION
The following preventative maintenance should be performed by
a qualified service technician annually prior to the heating season.
Preventative maintenance of an oil fired boiler reduces operating
costs. The boiler and vent pipe should be inspected for accumulation of soot or scale deposits periodically but at least once every
year before the start of each heating season. When soot is present on the section walls and flue ways, improper combustion will
result, causing additional sooting and scaling until flue ways are
completely closed.
! WARNING
ALWAYS DISCONNECT POWER TO THE BOILER WITH
THE EMERGENCY POWER ISOLATION SWITCH WHEN
SERVICING THE BOILER. THE EMERGENCY POWER
ISOLATION SWITCH IS FIELD INSTALLED AND SHOULD
BE WITHIN 5 FEET OF THE BOILER.
4
Oil Burner Maintenance
1. Oil Burner Motor – Add two-three drops of non-detergent
electric motor oil to each oil cup located at the front and rear
of the motor if so equipped. Excessive oiling will shorten the
life expectancy of the motor.
2. Fuel Filter – This should be replaced so as to prevent contaminated fuel from reaching the nozzle. A partially blocked
fuel filter can cause premature failure of the fuel pump unit.
3. Fuel Pump Unit – Replace pump screen and clean pump
unit to maintain reliable fuel delivery to the nozzle.
4. Ignition Electrodes – Clean and adjust as per manufacturer’s recommendations, so as to maintain reliable ignition
of the oil.
5. Nozzle – Replace annually as to maintain safe and reliable
combustion efficiency.
6. Fan and Blower Housing – These must be kept clean, free
of dirt, lint and oil so as to maintain the proper amount of air
the fuel requires to burn.
Boiler Cleaning Instructions
Cleaning is to be performed by a qualified service technician.
1. Shut off all electrical power to the boiler/burner and shut off
fuel supply.
2. For access to the combustion chamber remove the 4 bolts. If
boiler is equipped with flexible fuel lines, swing door open.
3. Remove the vent connector.
4. Remove the baffles from the flue passages. There is a pair of
baffles in each boiler. The baffles are installed in the 3rd pass
(two inner flue ways.)
5. Clean the 3rd Pass – Insert a 2” dia. x 42” long wire or fiber
bristle brush into each of the two 3rd passes. Using long
strokes, push the brush all the way through the boiler until the
brush has exited the smoke box opening. Pull the brush all the
way forward until it has exited the front of the boiler. Continue
this operation for the entire length of the flue way until clean.
Repeat the operation for the other 3rd pass flue way.
5
Boiler cleaning instructions
6. Clean the 2nd Pass – Insert a 2” dia. x 42” long wire or fiber
bristle brush into each of the two 2nd passes. Using long
strokes, push the brush all the way through the boiler until
the brush hits the back wall of the reversing chamber. Pull
the brush all the way forward until it has exited the front of the
boiler. Continue this operation for the entire length of the flue
way until clean. Repeat the operation for the other 2nd pass
flue way.
7. Vacuum the loose debris in the bottom of the combustion
chamber and smoke box.
8. For more detailed instructions, see Installation, Operation &
Maintenance manual.
6
HOMEOWNER and OPERATOR INSTRUCTIONS
7
HOMEOWNER and OPERATOR INSTRUCTIONS
!
CAUTION
DO NOT TAMPER WITH the UNIT OR CONTROLS
– CALL YOUR QUALIFIED SERVICE TECHNICIAN.
Contact a qualified service technician before remodeling, for annual service/maintenance, before extended periods of shutdown,
and before start-up.
Service Personnel Information
Name:__________________________________________
Address: ________________________________________
Telephone Number: _______________________________
ECR INTERNATIONAL
2201 Dwyer Ave., Utica NY 13501
www.ecrinternational.com
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