INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR ESC™ ENHANCED SEALED COMBUSTION Gas - Fired Boiler 9700609 As an ENERGY STAR® Partner, U.S. Boiler Company has determined that this boiler meets the ENERGY STAR® guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
WARNINGS for the HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler. INSPECT THE BOILER ANNUALLY. To keep your boiler safe and efficient, have a service technician follow the Service checklist near the end of this manual. IF YOU ARE NOT QUALIFIED to install or service boilers, do not install or service this one. THE BOILER MAY LEAK WATER at the end of its useful life. Be sure to protect walls, carpets, and valuables from water that could leak from the boiler.
Special Installation Requirements for Massachusetts A. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the side wall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1.
Congratulations on your purchase of a new ESC™ boiler—designed and constructed to provide you with years of reliable service. • ENERGY STAR™ efficiency – friendly on the environment and your wallet. • Cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger made at Burnham Foundry, LLC in Zanesville, Ohio. • IQ Control™ – the most advanced and easiest to use control available. • System-friendly – built-in protection from condensation and thermal shock.
SPECIFICATIONS Ratings ESC Series Boiler Model Input (MBH) Output (MBH) ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 70 105 140 175 210 245 280 60 90 120 150 179 208 238 Net I=B=R Water (MBH) AFUE (%) 52 78 104 130 156 181 207 85.5 85.4 85.3 85.2 85.0 84.5* 84.
SPECIFICATIONS (continued) Figure S-1: Minimum Clearances to Combustibles
Boiler Quick-Start Installation: 1. Unpack the crate.............................................................................................. 8 2. Position the boiler............................................................................................. 8 3. Provide combustion air..................................................................................... 9 4. Connect venting................................................................................................ 9 5.
1. Unpack the Crate 4. Tip the boiler and shimmy it off the skid. THE BOILER IS TOP-HEAVY. Do not allow it to tip over. 1. Remove the sleeve. 2. Remove the contents from the skid, except the boiler. 3. Remove the four (4) hex-drive lag screws holding the boiler to the skid (Figure 1-a). 1-a 1-b 2. Position the Boiler WARNINGS OBSERVE MINIMUM CLEARANCES to combustible walls and ceilings to avoid potential fire hazard. DO NOT INSTALL ON CARPET. This may cause a fire.
3. Provide Combustion Air INSUFFICIENT COMBUSTION AIR SUPPLY may result in the production and release of deadly carbon monoxide (CO) into the home. 1. If equipping for direct vent (sealed Like all fuel-burning appliances, boilers need air to operate reliably and safely. 2. If not equipping the ESC for direct vent, combustion), provide combustion air according to Appendix B2—Venting for Direct Vent boilers. provide combustion air from the boiler room according to Appendix A—Combustion Air. 4.
4. Connect Venting (continued) (3) Install vent piping. (4) When configuring the ESC for Power Vent (indoor combustion air) install a 45° vent elbow, pointing downward. (5) Install vent terminal and seal around all exterior openings. (6) The final installation should appear as in Figure 4-c. 4.
5. Connect Gas Piping Size gas piping according to Appendix C – Gas Piping 3. Pipe from the street elbow through the left jacket panel, and complete drip leg as shown (Figure 5-a). SHUT OFF GAS SUPPLY before servicing the boiler. ALL GAS PIPING MUST BE GAS TIGHT. Use gas rated thread compound on all threaded joints to avoid leaks, which may result in fire or explosion. SIZE GAS PIPING, regulators, valves, and meters so as to provide an adequate gas flow and pressure to the boiler during operation.
6. Connect Boiler Water Piping (continued) 6. Connect the system supply to the open end 8. Screw the supplied drain valve into tapping of the manifold "S" using a 1¼” male NPT fitting. “D”. 9. See Figure 6b for suggested near boiler 7. Screw an installer-supplied 1¼” pipe or piping of IQ Options. nipple into the water return tapping “R”.
7. Connect Electrical Wiring DISCONNECT ELECTRICAL POWER to the boiler and heating system before servicing. Positively assure that no voltage is present. Lock electrical boxes to prevent someone from inadvertently restoring power before the heating system is safe to operate. NEVER DEFEAT OR JUMP OUT safety devices. device.
8. Program the Controls Viewing the Operating Mode Options Using IQ Boiler Control Display The IQ Boiler Control is located inside the boiler front door, just above the IQ Option Panel (Figure 8-a). In operating mode the user may view (but not change) boiler operating status, settings and troubleshooting information. To view IQ Boiler Control display information: 1. Press and release the “I” key on the IQ Boiler Control to change from one parameter to the next.
8. Program the Controls (continued) 1 sec Sample Display 1 sec Unit Display OR 1 sec Please note that in operating mode to hold the display on the value the user can press and hold either the Up ñ or Down ò keys and the value will be continuously shown. This may be helpful in watching a value “live”. Changing the Adjustable Parameters To adjust the High Limit setpoint, High Limit Differential or Pump Overrun time settings or setting the display for either °F or °C temperature readings: 1.
8. Program the Controls (continued) Using the Optional LCD Display Kit The LCD Display is an easy to use touch screen type display that allows a technician to monitor and adjust the IQ Boiler Control and connected IQ Option Cards. All boiler settings, status and error codes are displayed in full text. All Outdoor Reset IQ Option Card parameters are adjustable with graphic and help information screens.
10. Perform Startup Checks and Adjustments FAILURE TO PERFORM THESE CHECKS of the boiler's combustion and safety systems may result in serious property damage, injury, or death. IF YOU SMELL GAS, STOP and repair the leak. Lighting the boiler when gas is leaking may cause explosion or fire. Follow the checklist below: 1. Verify that the venting, water piping, gas piping, and electrical systems are properly installed and checked. 2. Apply power to the boiler. 3. Adjust zone thermostat to maximum setting. 4.
Annual Maintenance Checklist WARNINGS THE BOILER CONTAINS REFRACTORY CERAMIC FIBER, a possible human carcinogen. personal injury or death, and extensive property damage. USE A NIOSH APPROVED RESPIRATOR when servicing high-temperature insulation and gasket materials. Wash exposed skin gently with soap and water after contact Wash exposed clothing separate from normal laundry. TURN OFF ALL GAS AND ELECTRIC power supplies to the boiler before servicing.
Troubleshooting When a problem occurs with the boiler operation, the IQ Control System easily provides specific, valuable information to help resolve the issue quickly. The display on the IQ Boiler control should be the first place to check. If "Err" IS NOT displayed on the IQ Boiler Control: Use the following table to determine the problem and possible causes.
Troubleshooting (continued) If "Err" IS displayed on the IQ Boiler Control: "Err" flashes on the IQ Boiler control display followed by a number. Use the following table along with this error number to determine the problem and possible causes: IQ Boiler Control Error Codes (when "Err" is flashing) Display Status Boiler / Control Action(s) Blank Boiler and Circulator off No 120 Vac power at boiler, check breaker and wiring between breaker panel and boiler.
Troubleshooting (continued) If IQ Boiler Control Shows Status Code “STA 15": The IQ Boiler Control is “Waiting for Limit to Close” and the display on the IQ Option Panel should be the first place to check.
Repair Parts Key No.
Repair Parts (continued) Key No.
Repair Parts (continued) Key No.
Repair Parts (continued) Key No.
Repair Parts (continued) Key No.
Repair Parts (continued) Key No.
Repair Parts (continued) Key No.
Repair Parts (continued) Key No.
Internal Wiring 30 Figure IW-1: Wiring Diagram
Internal Wiring (continued) Figure IW-2: Wiring Diagram 31
Internal Wiring (continued) Figure IW-3: Single Zone System with Domestic Hot Water Tank 32 Figure IW-4: Multiple Zone System with Zone Circulators
Internal Wiring (continued) Figure IW-5: Multiple Zone System with Zone Valves Figure IW-6: Multiple Zone System with Zone Circulator Panel 33
Internal Wiring (continued) POWER SUPPLY 120/60/1 DHW AQUASTAT (L4006, L4080) (SUPPLIED BY OTHERS) L2 L1 THERMOSTAT THERMOSTAT THERMOSTAT 24V TRANSFORMER MODE ZONE 4 PRIORITY DOMESTIC HOT WATER PRIORITY IS SELECTED USING ZONE PANEL SWITCH NORMAL RESET OFF POWER IN T T ZONE 1 T T ZONE 2 FUSE (3 AMP MAX.
APPENDIX A – Combustion Air PROVIDE ENOUGH AIR to ventilate the boiler room, dilute the flue gases, and sustain combustion. Ignition failure, overheating, fire, carbon monoxide, and spillage of flue gases may result from poor air supply. If the boiler is a Direct Vent boiler and exchanges all combustion air and combustion products directly with the outdoors, there are no special requirements for providing combustion, ventilation, and dilution air.
APPENDIX B – Venting VENT THIS BOILER according to the instructions. Failure to do so may cause products of combustion to enter the building resulting in severe property damage, personal injury or death. Install this boiler according to this manual and the National Fuel Gas Code, ANSI Z223.1/NFPA 54, i the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
APPENDIX B1 INTENTIONALLY OMITTED 37
APPENDIX B2 – Direct Venting GENERAL WARNINGS for DIRECT VENT SYSTEMS DRAFTHOODS, VENT DAMPERS and other obstructions or openings in the vent system are prohibited. IF USING A CHIMNEY AS A CHASE for the vent, do not vent any other appliance into the space between the chimney wall and the vent. DO NOT REDUCE THE DIAMETER of the vent pipe. ELIMINATE LOW SPOTS in the vent where flue gas condensate may pool. MOISTURE AND ICE may collect around and below the vent terminal. Keep the area in good repair.
APPENDIX B2 – Direct Venting (continued) Figure B-2: Approved Terminal Locations 9. Locate the combustion air terminal on the same face of the building as the vent termination to prevent nuisance boiler shutdowns. 10. If the vent passes through interior spaces in floors above the boiler room, enclose the vent with material having a fire resistance rating at least equal to the rating of the adjoining floor or ceiling.
APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent USE STAINLESS STEEL VENTING only with boilers approved for use with stainless steel venting as noted in the Specifications Section of this manual. AL 29-4C® stainless steel vent systems resist the corrosive effects of high temperature acidic flue gas condensate and are leak-tight. Alternate stainless steel venting systems require special adaptors to connect to the parts supplied with the boiler.
APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) Vent/Combustion Air, Equivalent Length Work Sheet This sheet is supplied to assist in vent/combustion air, equivalent length calculating Combustion Air (PVC shown) 90° elbow(s) PVC Quantity = 90° elbow(s) x 5’ = equiv. ft. a. 45° elbow(s) PVC Quantity = Quantity = x 5’ = equiv. ft. a. x 5’ = equiv. ft. b x1= equiv. ft. c. x 2' = equiv. ft. d. x 7' = equiv. ft. e. 45° elbow(s) x 2.
APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) (1) Insert the wall thimble from the outside of the wall, and secure the outside flange to the wall using nails or screws. (2) Seal any exterior openings in the wall thimble, or between the thimble and the wall, using a weatherproof sealant. (3) Install the inside thimble flange and secure the flange to the inside wall using screws or nails. 3. Maintain 12" separation between vent and intake terminals.
APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) Figure B-6: Typical Vertical Stainless Steel Venting 6. Install the intake air terminal supplied with the boiler onto the outdoor end of the air intake pipe per the instructions in Connect Venting in this manual. 7. Install the vent terminal supplied with the boiler onto the outdoor end of the vent pipe per the boiler-specific instructions in Connect Venting in this manual.
APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) Figure B-7: Vertical Vent/Air Termination Details for Stainless Steel Direct Vent Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.
APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) Figure B-8: Vertical Air Intake Piping for Direct Venting 45
APPENDIX B3 – Power Venting Some direct vent boilers are also approved with use of indoor combustion air. If the boiler you are installing is approved for use with indoor combustion air, install the vent according to the instructions in Appendix B2 Direct Venting, but omit the “optional” indoor air piping and components. Specific instructions for configuring the boiler for indoor air appear in the boiler-specific instructions at the front of this manual.
APPENDIX C – Gas Piping (continued) ASSURE GAS PIPING IS LEAK FREE AND OF PROPER SIZE and type for the connected load. 4. For materials or conditions other than those listed above, refer to the National Fuel Gas Code, NFPA54/ANSI Z223.1, or size the system using standard engineering methods acceptable to authority having jurisdiction. SHUT OFF MAIN GAS SUPPLY prior to installing or servicing boiler gas piping. USE PROPER THREAD COMPONENTS on all gas connectors. 1.
APPENDIX D – System Piping USE PROPER DESIGN AND INSTALLATION PRACTICES and observe all local codes when installing system piping. Property damage and injury may result from an improperly piped or designed heating system. i Boiler damage caused by flawed system design or operation is excluded from our warranty. Training and experience is required to design and install a piping system that will protect the boiler and provide many years of comfort to the building occupants.
APPENDIX D – System Piping (continued) 7. Condensation (3) Do not allow chilled water to enter the boiler during the heating cycle, or heated water to enter chilled water coils during the cooling cycle. (1) Do not over-pump. Adhere to the design flow requirements for each zone. (2) Adhere to the boiler’s specific 8. Dry Fire minimum return water and supply water temperature requirements.
APPENDIX D – System Piping (continued) Figure D-0: Piping Schematic Symbols 50
APPENDIX D – System Piping (continued) Figure D-W1: Water Boiler, Series Loop Figure D-W2: Water Boiler, Two or More Zones 51
APPENDIX D – System Piping (continued) Figure D-W3: Water Boiler, Tankless Coil, Two or More Zones Figure D-W4: Water Boiler, Indirect Water Heater, Two or More Zones 52
APPENDIX D – System Piping (continued) Figure D-W5: Water Boiler, Indirect Water Heater Figure D-W6: Multiple Water Boilers, Indirect Water Heater, Two or More Zones 53
APPENDIX E – Filling the System and Checking for Leaks Fill entire heating system with water and vent air from system. Use the following procedure on a Series Loop or multi-zoned system installed as per the figure below. Remove air from system when filling. 1. Close full port ball valve located between vertical hose bib and air scoop in boiler supply piping (see Appendix D – System Piping. 11. Open the zone valve or shut-off valve for the next zone to be purged.
APPENDIX F – Adjusting Gas Input Rate Natural Gas Boilers: 1. Turn off gas supply to all appliances other than gas-fired boiler. 2. Note the rated manifold gas pressure listed on the boiler’s rating label. 3. Connect Manometer to manifold pressure tapping on Gas Valve (Figure F-1). F-2 8. Determine gas flow rate in Cubic Feet per Hour based on elapsed time for two revolutions. (Example: 70 Seconds for (2) Revolutions = 102.8 Cu. Ft. 9. When the clocked time falls between two F-1 4.
APPENDIX F – Adjusting Gas Input Rate (continued) Table F-1: Gas Flow Rate in Cu. Ft. / Hr. Seconds for Two (2) Revolutions (3) Reinstall gas orifices and main burner. Size of Gas Meter Dial One-Half Cu. Ft. One Two Cu. Ft. Cu. Ft. 24 150.0 300.0 450.0 26 138.4 276.9 415.3 28 128.5 257.1 385.7 30 120.0 240.0 360.0 1. Follow the procedure for gas boilers, except: 34 105.8 211.7 317.6 2. Adjust tank regulator for gas valve inlet 38 94.7 189.4 284.2 42 85.7 171.4 257.
APPENDIX G – CHECKING DRAFT AND COMBUSTION CHECK DRAFT (GAS BOILERS WITH DRAFT HOODS) 1. Insofar as is practical, close all doors and windows in the building. 2. Turn on all appliances not connected to the same venting system as the boiler being checked. 3. Turn on all exhaust fans (such as range hoods and bathroom exhausts) to their maximum speed. Do not turn on any summer exhaust fans. 4. Close all fireplace dampers. 5. Operate the appliance being checked. Follow lighting instructions. 6.
APPENDIX H – iq control system IQ Control System Overview The “IQ Control System” consists of an IQ Boiler Control and an IQ Option Panel with optional “plug in” cards: • Fully integrates both factory and field installed components, simplifying installation and troubleshooting. • Efficiently operates the entire boiler system to save energy. • Ensures adequate heat and supply of domestic hot water. • UL / CSA Listed or Recognized and tested as part of a complete system.
APPENDIX H – IQ Control System (continued) IQ Outdoor Reset Option Card: P/N 102723-01 Installing the IQ Outdoor Reset Option Card is the simplest way to maximize the efficiency of any ESC Boiler. The IQ Outdoor Reset Card is a microprocessorbased control that regulates the water temperature of the heating system based on the outdoor temperature.
APPENDIX H – IQ Control System (continued) IQ Hi Limit Option Card (Auto Reset): P/N 102717-01 IQ Hi Limit Option Card (Manual Reset): P/N 102720-01 IQ High Limit Option Cards add auxiliary temperature limit-rated controls to ESC Boilers. High Limit Option Cards plug into the IQ Option Panel and connect to a system-mounted probe with a single Molex connection. IQ High Limit Option Cards feature an adjustable set point and differential, as well as built-in diagnostics.
APPENDIX H – IQ Control System (continued) System Parts List Optional Components Part Number Item Description 102723-01 Outside Reset IQ Option Card, Domestic Hot Water Priority, for use with Option Control Panel, with Outside Air Temperature Sensor, Instructions, Unit Pack 102294-01 Outdoor Reset IQ Option Card, Domestic Hot Water Priority, for use with IQ Option Panel, less Sensor 102439-01 Outdoor Air Temperature Sensor, 12k ohm 102711-01 LWCO IQ Option Card kit, Hot Water LF Module, Automatic R
SERVICE RECORD DATE 62 SERVICE PERFORMED
SERVICE RECORD DATE SERVICE PERFORMED 63
U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 (717) 397-4701 www.usboiler.burnham.
