INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR ES2™ ENHANCED SERIES 2 Gas - Fired Boiler As an ENERGY STAR® Partner, Burnham Hydronics has determined that this boiler meets the ENERGY STAR® guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). F o r s e rvi c e o r r e p a i rs to b o i le r, c a ll yo ur he a ti ng c o ntra c to r.
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.
Congratulations on your purchase of a new Burnham® 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. Ours is made proudly by our foundry in Zanesville, Ohio. • IQ Control™ – the most advanced and easiest to use control available.
SPECIFICATIONS Ratings ES2 Series Input (MBH) Boiler Model ES23 ES24 ES25 ES26 ES27 ES28 ES29 DOE Heating Capacity (MBH) Net I=B=R Rating (MBH) 70 105 140 175 210 245 280 59 88 118 147 176 206 235 AFUE (%) 51 77 102 128 153 179 205 85 85 85 85 85 85 85 Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A Dimensions and Connections Boiler Model Depth ES23 ES24 ES25 ES26 ES27 ES28 ES29 33 33 33 33 33 33 33 Width Height 12¾ 15½ 18½ 21½ 24¾ 27¾ 30¾ 41 41 41 41 41 41 41 Supply NPT Return NPT Vent Gas
SPECIFICATIONS (continued) Figure S-1: Minimum Clearances to Combustibles and Closet Dimensions
Boiler Quick-Start Installation: 1. Unpack the crate.............................................................................................. 7 2. Position the boiler............................................................................................. 7 3. Provide combustion air..................................................................................... 8 4. Connect venting................................................................................................ 8 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 which can cause severe personal injury or death. Like all fuel-burning appliances, boilers need air to operate reliably and safely. Provide combustion air using the instructions in Appendix A—Combustion Air. 4.
4. Connect Venting (continued) Table 4.
5. Connect Gas Piping Size gas piping according to Appendix C – Gas Piping SHUT OFF GAS SUPPLY before servicing the boiler. nipples and street ells are not approved for use as gas piping. 3. Pipe through the left jacket panel, and complete drip leg as shown (Figure 5-a). 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.
6. Connect Boiler Water Piping (continued) 7. Screw an installer-supplied 1¼” pipe or 9. See Figure 6b for suggested near boiler nipple into the water return tapping “R”. piping of IQ Options. 8. Screw the supplied drain valve into tapping “D”.
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 Using IQ Boiler Control Display Viewing the Operating Mode Options The IQ Boiler Control is located inside the boiler front door, just above the IQ Option Panel (Figure 8-a). IQ Boiler Control 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.
Annual Maintenance Checklist WARNINGS THE BOILER CONTAINS REFRACTORY CERAMIC FIBER, a possible human carcinogen 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. LABEL ALL WIRES prior to disconnection when servicing controls.
Troubleshooting When a problem occurs with the boiler operation, the Burnham 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) IQ Boiler Control Status Codes (when "Err" is not displayed) - continued Display 20 21 Status Boiler / Control Action(s) Damper Failed Open Damper Failed Closed The damper end switch has not closed (damper end switch is open) at the beginning of the heat cycle. An alarm message is sent but the control is not in lockout. The damper end switch has not opened (damper end switch is closed) at the beginning of the heat cycle.
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 LIST Key No.
Repair Parts LIST (continued) Key No.
Repair Parts LIST (continued) Key No. 3A 3B 3C 3D 3E Description Gas Valve (Natural Gas), Honeywell VR8204P1171 Gas Valve (Natural Gas), Honeywell VR8304P4496 Gas Valve (LP Gas), Honeywell VR8204C3015 Gas Valve (LP Gas), Honeywell VR8304P4314 ½" Gas Manifold ¾" Gas Manifold Burner Orifices - Natural Gas #47 Burner Orifices - LP Gas 1.
Repair Parts LIST (continued) Key No.
Repair Parts LIST (continued) Key No.
Repair Parts LIST (continued) Key No.
Internal Wiring Figure IW-1: Wiring Diagram 27
Internal Wiring (continued) 28 Figure IW-2: Wiring Schematic
Internal Wiring (continued) Figure IW-3: Single Zone System with Domestic Hot Water Tank Figure IW-4: Multiple Zone System with Zone Circulators 29
Internal Wiring (continued) Figure IW-5: Multiple Zone System with Zone Valves 30 Figure IW-6: Multiple Zone System with Zone Circulator Panel
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, the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
APPENDIX B1 – Atmospheric Venting GENERAL WARNINGS for ATMOSPHERIC VENTING SYSTEMS USE ATMOSPHERIC VENTING only with boilers approved for atmospheric venting as noted in the Specifications Section of this manual. INSPECT EXISTING CHIMNEY for obstructions and deterioration and repair or line the chimney prior to placing the boiler in service. UNLINED MASONRY CONSTRUCTION is prohibited for use as a chimney.
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APPENDIX C – Gas Piping Table C-3: Specific Gravity Correction Factors For Natural Gas ASSURE GAS PIPING IS LEAK FREE AND OF PROPER SIZE and type for the connected load. SHUT OFF MAIN GAS SUPPLY prior to installing or servicing boiler gas piping. Specific Gravity Correction Factor Specific Gravity Correction Factor 0.50 1.10 0.85 0.81 0.55 1.04 0.90 0.82 0.60 1.00 1.00 0.78 0.65 0.96 1.10 0.74 0.70 0.93 1.20 0.71 0.75 0.90 1.30 0.68 0.80 0.87 1.40 0.66 1.
APPENDIX C – Gas Piping (continued) 5. Bond all above-ground gas piping to a grounding electrode and ensure the piping is electrically continuous. DO NOT USE GAS PIPING AS A GROUNDING ELECTRODE. Refer to National Electrical Code, NFPA 70. 6. Install sediment trap, ground-joint union and manual shut-off valve upstream of boiler gas control valve and outside jacket. 7. When the piping is completed, test it for leaks.
APPENDIX D – System Piping (continued) (2) Comply with the boiler’s specific or radiator. Also add a low-water cutoff when required by local code requirements. water quality requirements. See the Specifications Section of this manual. (3) Comply with the boiler’s specific requirements for minimum water flow through the boiler, installing a system bypass or primary-secondary loop if necessary to maintain flow through the boiler when serving small zones. 6. Thermal shock (1) Do not over-pump.
APPENDIX D – System Piping (continued) Figure D-0: Piping Schematic Symbols 39
APPENDIX D – System Piping (continued) Figure D-W1: Water Boiler, Series Loop 40 Figure D-W2: Water Boiler, Two or More Zones
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 41
APPENDIX D – System Piping (continued) Figure D-W5: Water Boiler, Indirect Water Heater 42 Figure D-W6: Multiple Water Boilers, Indirect Water Heater, Two or More Zones
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 15. Recheck Main Burner Flame. Size of Gas Meter Dial 16. Return other gas-fired appliances to 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 34 105.8 211.7 317.6 38 94.7 189.4 284.2 42 85.7 171.4 257.1 46 78.2 156.5 234.7 50 72.0 144.0 216.0 55 65.4 130.
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 Option Cards: A variety of IQ Option Cards are available to enhance the features of a standard boiler. For example, if additional safety limits are required, select Manual or Automatic Reset Aquastat or Low Water Cutoff IQ Option Cards. Additionally, if energy savings and improved home comfort is desired, select an Outdoor Reset IQ Option Card.
APPENDIX H – IQ Control System (continued) IQ 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. The LCD Display kit includes a mounting bracket and wiring harness to allow simple physical installation and “plug-in” style electrical connection.
APPENDIX H – IQ Control System (continued) System Parts List Factory Mounted Components Burnham Part Number Item Description 102289-01 IQ Boiler Control, Vent Damper, 24 Vac Ignition Control, with Prepurge, Continuous Retry, 90 Second Ignition Trail, Aquastat Limit Control, 130-220 Deg F, 15 Deg F Adjustable Differential, Auto Reset, less Well, less Sensor, 120 Vac Circulator Control Relay 102291-01 IQ Option Panel with three slots “plug-in” option card slots, suitable for gas or oil fired boiler appli
SERVICE RECORD DATE SERVICE PERFORMED 51
Limited Warranty For Residential Grade Water and Steam Boilers Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water or steam boiler or U.S. Boiler Company, Inc. supplied parts and/or accessories manufactured and shipped on or after July 1, 2008: ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE BOILERS AND PARTS / ACCESSORIES SUPPLIED BY U.S.
