INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR ES2™ ENHANCED SERIES 2 Gas - Fired Boiler 9700609 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. Boiler Model Number ES2__ Heating Contractor Boiler Serial Number Installation Date Phone Number Address 103780-05 - 8/14 Price - $5.
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.
WARNINGS for the INSTALLER READ THIS ENTIRE MANUAL before attempting installation, start-up, or service. Improper installation, adjustment, alteration, service, or maintenance may cause serious property damage, personal injury, or death. DO NOT DISCONNECT PIPE FITTINGS on the boiler or in the heating system without first verifying that the system is cool and free of pressure and that your clothing will protect you from a release of hot water or steam.
Congratulations on your purchase of a new ES2 boiler—designed and constructed to provide you with years of reliable service. • Cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger. • IQ Control™ System– the most advanced and easiest to use control available. • System-friendly – built-in protection from condensation and thermal shock. *IQ Control System Overview ES2 Boiler uses a microprocessor based control system called the "IQ Control System".
SPECIFICATIONS Ratings ES2 Series (1) Boiler Model Input (MBH) DOE Heating Capacity (MBH) ES23 ES24 ES25 ES26 ES27 ES28 ES29 70 105 140 175 210 245 280 59 89 119 149 178 208 238 Net AHRI Rating, Water (MBH) (1) AFUE (%) 51 77 103 130 155 181 207 85 85 85 85 85 85 85 Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15.
Weights and Volume SPECIFICATIONS (continued) Boiler Shipping Weight Empty Weight Water Content Model (lbs) (lbs) (gal) ES23 ES24 ES25 ES26 ES27 ES28 ES29 6 254 304 357 405 462 518 564 180 231 284 332 382 438 484 2 3 4 5 5 6 7 Figure S-1: Minimum Clearances to Combustible Materials
Boiler Quick-Start Installation: 1. Unpack the crate.............................................................................................. 8 2. Position the boiler............................................................................................. 9 3. Provide combustion air................................................................................... 10 4. Connect venting.............................................................................................. 10 5.
1. Unpack the Crate THE BOILER IS TOP-HEAVY. Do not allow it to tip over. 4. Tip the boiler and shimmy it off the skid (Figure 1-b). 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). DO NOT DAMAGE front air dam. It is required for proper operation of the boiler.
2. Position the Boiler WARNINGS OBSERVE MINIMUM CLEARANCES to combustible walls and ceilings to avoid potential fire hazard. CLEAN BURNERS DAILY if operating the boiler in a dusty environment. DO NOT INSTALL ON CARPET. This may cause a fire. PROTECT IGNITION SYSTEM COMPONENTS from sources of water that may spray, drip, or rain on them during installation or service. INSTALLING THE BOILER NEAR A SOURCE OF FLAMMABLE LIQUIDS or gases may cause fire or explosion. 1. Slide the boiler into desired location.
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. Provide combustion and ventilation air in accordance with the section "Air for Combustion and Ventilation," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
4. Connect Venting (continued) 4-a 4-b DAMPER MUST BE OPEN when the main burner is firing. Le registre doit être ouvert lorsque le brûleur principal de l’appareil fonctionne. 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.
6. Connect Boiler Water Piping General system piping guidelines are included in Appendix D—System Piping. 4. Screw the relief valve into manifold tapping “RV”. Additionally, for this particular boiler install piping shown below (Figure 6-a). RV i This installation is not complete until the relief valve is installed. PIPE THE RELIEF VALVE DISCHARGE to a location where it will not harm people or damage property. The relief valve may discharge scalding hot water or steam.
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. PROTECT EACH BOILER circuit with a properly sized over-current protection device.
8. Program the Controls Using Intelligent Hydronic Control Display The Intelligent Hydronic Control (control) is located inside the boiler front door, just above the IQ Option Panel (Figure 8-a). Intelligent Hydronic Control IQ Option Panel 8-a The control display, along with Up ñ, Down ò, and “I” keys may be used to view boiler operating status (Figure 8-b).
8. Program the Controls (continued) 1 sec 1 sec Unit Display OR Sample Display 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 Parameters such as High Limit Setpoint and High Limit Differential: 1.
8. Program the Controls (continued) Circulator Pre-purge time has a factory setting of 2 minutes and is field adjustable between 2 and 20 minutes. When reset card is installed, pre-purge time may be adjusted down to zero (0) minutes. Refer to Table 8a. 7. Domestic Hot Water (DHW) Terminal Function () The control allows configuration of the DHW Circulator output functionality to help the boiler integrate into each installation more effectively.
8. Program the Controls (continued) b. When is set equal to Second Heating Zone () When there is no IWH the “DHW Circulator” output may be configured to control a second heating zone. This is particularly helpful when the home uses only two heating zones. The control replaces the need for a two circulator zone panel. When DHW Terminal Function () is set to “" the control’s two circulator outputs are used to control two independent heating zones. Refer to Table 8c.
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.
10. Perform Startup Checks and Adjustments (continued) 12. Return high limit to the desired setting (see "Programming High Limit" in Section 8). 14. Check combustion in the vent stack and record results in the spaces provided below. _____ CO2 (less than 7%) – Checking Draft and Combustion. _____ O2 (more than 9%) q No spillage observed. _____ CO (less than 50 ppm, air free) 13. Check draft. See Appendix G ANY FAILED STARTUP CHECK Must be corrected before placing the boiler in service.
Annual Maintenance Checklist (continued) Equipment you will need: q Soft bristle brush q Bristle flue brush q Vacuum with brush attachment Perform these tasks each year: 1. Clean low water cutoff probe (if applicable). Flush float-type low water cutoff (if applicable). 2. Inspect vent for obstruction and signs of condensation, distortion, overheating or gas leakage. 3. Clean vent terminal and air intake screens. 4. Inspect boiler flue passages: (1) Remove vent pipe, damper. (2) Remove top panel and hood.
Annual Maintenance Checklist (continued) AM-2 Operating Instructions, VR8204 and VR8304 Gas Valves 21
Troubleshooting wiring diagram in Figures IW1 and IW2. Ensure that incoming 120 Vac power polarity is correct and that the boiler is properly grounded. Further, ensure that the control power supply is 24 VAC (minimum 18 VAC to maximum 30 VAC) and polarity is correct. Before troubleshooting The following pages contain trouble shooting tables for use in diagnosing control problems. When using these tables the following should be kept in mind: 1.
Troubleshooting (continued) Use Control Display (error) Number To Direct Troubleshooting Efforts If the control detects an error it will flash “” (error) followed by a number. Use this number to identify the boiler problem and corrective action in the table below.
Troubleshooting (continued) Use STA (status) Number To Guide Troubleshooting The control will flash “” followed by a number. Use this number to identify the boiler problem in the table below: 1. Boiler and Circulator Off Display / Status Recommended Corrective Action The boiler has not detected a call for heat (tt = off and dh = off).
Troubleshooting (continued) 5. Circulator is On But Damper is Not Open Display / Status Recommended Corrective Action The control is waiting for the damper to open. Damper end switch has failed to close (end switch contact is stuck open). Combustion can never take place unless the damper blade is in the fully open position. Check the following: STA 20 Damper Failed to Open STA 21 Damper Failed to Closed - During status “STA18" or “STA 20” the control terminal “P6 - 5” (yellow wire) is energized.
Troubleshooting (continued) 6. Circulator is On, Damper is Open But Boiler Fails to Start (continued) Display / Status Recommended Corrective Action 1. No Spark a. Can you hear sparking while is displayed? - If there is no spark noise replace the control. b.
Troubleshooting (continued) If Control Shows Status Code “STA 15": The 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 All ES2™ Repair Parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should you require assistance in locating a U.S. Boiler Company Distributor in your area, or have questions regarding the availability of U.S. Boiler Company products or repair parts, please contact U.S. Boiler Company Customer Service at (717) 481-8400 or Fax (717) 481-8408. 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 34 Figure IW-1: Wiring Diagram
Internal Wiring (continued) Figure IW-2: Wiring Schematic 35
Internal Wiring (continued) Figure IW-3: Multiple Zone System with Zone Circulators Figure IW-4: Multiple Zone System with Zone Valves 36
Internal Wiring (continued) Figure IW-5: Multiple Zone System with Zone Circulator Panel 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, Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the i the local building codes.
APPENDIX B – Venting (continued) (1) (2) (3) (4) (5) 40 Au moment du retrait d’une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’evacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas: Sceller toutes les ouvertures non utilisées du système d’évacuation.
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.
APPENDICE B1 – SYSTÈMES D’ÉVACUATION DES PRODUITS DE LA COMBUSTION DU GAZ DANS L’ATMOSPHÈRE AVERTISSEMENTS GÉNÉRAUX POUR LES SYSTÈMES D’ÉVACUATION DES PRODUITS DE LA COMBUSTION DU GAZ DANS L’ATMOSPHÈRE N’ÉVACUEZ LES PRODUITS DE LA COMBUSTION DU GAZ DANS L’ATMOSPHÈRE que dans le cas de chaudières approuvées pour cela comme le stipule la section Spécifications de ce manuel. VÉRIFIER SI LA CHEMINÉE EXISTANTE n’est pas obstruée ou détériorée et la réparer ou la chemiser avant de mettre la chaudière en service.
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. (1) When testing over ½ psig (3.5 kPa), (2) When testing at ½ psig (3.
APPENDIX D – System Piping (continued) 3. Overpressure (1) Install a properly sized expansion tank. (2) Do not exceed the boiler’s specific requirements for maximum allowable working pressure. (3) Do not plug or block the relief valve. 4. Freezing (1) Run all portions of the system piping inside a heated space unless the system is properly protected with an inhibited antifreeze solution. 5. Overheating (1) Comply with the boiler’s specific requirement for minimum water flow through the boiler.
APPENDIX D – System Piping (continued) The following system diagrams are intended to provide a minimum level of guidance for a successful and trouble-free installation of the boiler in common applications. They do not substitute for proper design, evaluation, and installation by a trained and qualified installer using the proper tools, techniques, and design expertise. Not all options are available with every boiler.
Figure D-W3: Recommended Water Piping for Circulator Zoned Heating Systems APPENDIX D – System Piping (continued) 47
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 Figures in Appendix D. 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. 2. Isolate all zones by closing zone valves or the previous steps until all zones have been purged.
APPENDIX F – Adjusting Gas Input Rate Check Manifold Pressure: 1. Note the rated manifold gas pressure listed on the boiler’s rating label. 2. Connect Manometer to manifold pressure tapping on Gas Valve (Figure F-1). 3. Light main burners by adjusting thermostat to highest setting. F-2 Do not exceed the boiler’s rated gas input. 6. Recheck Main Burner Flame. Leak Test Gas Piping: F-1 4.
APPENDIX G – CHECKING DRAFT AND COMBUSTION CHECK DRAFT (GAS BOILERS WITH DRAFT HOODS) 6. After 5 minutes of main burner operation, 1. Insofar as is practical, close all doors and test for spillage at the draft hood relief opening, using a lighted match, candle, cigarette, etc. windows in the building. 2. Turn on all appliances not connected to the same venting system as the boiler being checked. 7. Repeat this test for each appliance connected to the common venting system. 3.
APPENDIX H – OPERATION Boiler Sequence of Operation NORMAL OPERATION 1. The ES2 Boilers are equipped with an Intelligent Hydronic Control (control). This control replaces the traditional separate ignition control, high limit switch and circulator relay and adds energy saving thermal purge features. Energy is saved by starting the circulator and delaying the burner start when there is residual heat available in the boiler. the cause of the problem.
APPENDIX I – iq control system IQ Control System Overview The “IQ Control System” consists of a 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 I – IQ Control System (continued) IQ Outdoor Reset Option Card Kit: P/N 102723-01 Installing the IQ Outdoor Reset Option Card is the simplest way to maximize the efficiency of any ES2 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 I – IQ Control System (continued) IQ Hi Limit Option Card (Auto Reset) Kit: P/N 102717-01 IQ Hi Limit Option Card (Manual Reset) Kit: P/N 102720-01 IQ High Limit Option Cards add auxiliary temperature limit-rated controls to ES2 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 I – 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 with 60 inch lead, Instructions, Unit Pack. No additional pipe fittings required. 102294-01 Outdoor Reset IQ Option Card, Domestic Hot Water Priority, for use with IQ Option Panel, less Sensor.
U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.
