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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
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).
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102538-01R4-2/10
ES2™
ENHANCED SERIES 2
Gas - Fired Boiler
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Summary of Contents

  • Page 1

    INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR ENHANCED SERIES 2 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). ®...

  • Page 2

    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.

  • Page 3

    Congratulations on your purchase of a new Burnham 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.

  • Page 4

    Ratings Input (MBH) Boiler Model ES23 ES24 ES25 ES26 ES27 ES28 ES29 Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A Dimensions and Connections Boiler Depth Width Height Model ES23 12¾ ES24 15½ ES25 18½ ES26 21½ ES27 24¾ ES28 27¾ ES29 30¾...

  • Page 5

    SPeCIfICAtIoNS (continued) Figure S-1: Minimum Clearances to Combustibles and Closet Dimensions...

  • Page 6: Table Of Contents

    Position the boiler ... 7 Provide combustion air ... 8 Connect venting ... 8 Connect gas piping ... 10 Connect boiler water piping ... 10 Connect electrical wiring ... 12 Program the controls ... 13 Check for gas and water leaks ... 15 Perform startup checks and adjustments ...

  • Page 7: Unpack The Crate, Position The Boiler

    Meet the minimum clearances to combustible construction per the Specification Section of this manual. 1. UNPACk THE CRATE Tip the boiler and shimmy it off the skid. 2. POSITION THE BOILER WARNINGS CLEAN BURNERS DAILY if operating the boiler in a dusty environment.

  • Page 8: Provide Combustion Air, Connect Venting

    Vent connector shall be double-wall insulated gas vent as supplied with this boiler or Type B (double-wall) gas vent only. Using sheetmetal screws, attach the vent connector between the vent damper and the vertical chimney (Figure 4-b). Do not exceed the maximum vent connector length in Table 4.1.

  • Page 9

    4. CoNNeCt VeNtING (continued) Table 4.1: ES2 Vent Connector - Horizontal Length Restrictions (ft) Model ES23 Input (MBH) Minimum Vent Diameter (in) Vent Height (ft) ES24 ES25 ES26 With B-Vent (double wall) Vent Connector ES27 ES28 ES29...

  • Page 10: Connect Gas Piping, Connect Boiler Water Piping

    SIZE GAS PIPING, regulators, valves, and meters so as to provide an adequate gas flow and pressure to the boiler during operation. Failure to do so may cause poor combustion, noise, injury, or death. Remove boiler door, locate gas valve and remove plastic shipping plug.

  • Page 11

    1¼ x 1¼ x ½ Tee Immersion Well, ½ NPT 1¼ x 6 Nipple 1¼ Tee 1¼ x ¾ Bushing LWCO Sensor, ¾ NPT 1¼ x 3 Nipple 1¼ Elbow Burnham Part Number 806601021 80160456 806600029 806601030 806600504 102305-01 806600005...

  • Page 12: Connect Electrical Wiring

    IQ™ Control device, in series with the 120V circuit used to power the boiler. Do not alter the boiler’s factory wiring when adding an additional limit. ...

  • Page 13: Program The Controls

    IQ option Panel The IQ Boiler Control display, along with Up ñ, Down ò, and “I” keys may be used to view boiler operating status (Figure 8-b). Please note that these keys look similar to the keys on the IQ Option Panel but are in a different orientation, and they perform different functions.

  • Page 14

    Unit Display 1 sec Using the IQ option Panel IQ Option Cards are available from Burnham distributors and are the simplest way to add functionality, safety and efficiency to your heating system. The IQ Option Panel provides an easy and convenient means to "plug-in"...

  • Page 15: Check For Gas And Water Leaks

    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 .

  • Page 16: Perform Startup Checks And Adjustments

    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: Verify that the venting, water piping, gas piping, and electrical systems are properly installed and checked.

  • Page 17: Annual Maintenance Checklist

    Perform Startup Checks and Adjustments described earlier in this manual. Check operation of airflow sensing switches. Check for water leaks on the boiler or water pooling around boiler. Manually operate the relief valve. If the water is grey or black, there is excessive oxygen in the system.

  • Page 18: 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.

  • Page 19

    An alarm message is sent but the control is not in lockout. 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...

  • Page 20

    Option Card installed in Slot 1. For example, if, while the boiler has a Heat Request, and the Aquastat IQ Option Card installed in Slot 1 has a sensor failure the IQ Option Panel displays OL-C1 (Open Limit Card Slot 1). To investigate the status of option card C1: Press the “I”...

  • Page 21: Repair Parts List

    Description Block Assembly 102287-03 Canopy Gasket Kit Canopy Assembly 102554-03 Flue Baffle 102678-01 Blocked Vent Switch (not shown) REPAIR PARTS LIST [Quantity] Part Number ES23 ES24 ES25 102287-04 102287-05 102554-04 102554-05 102678-01 102678-01 ES26 ES27 ES28 102287-06 102287-07 102287-08 6206001 102554-06 102554-07 102554-08...

  • Page 22

    Description Base Wrapper Base Tray Burner Tray Assembly Base Front Panel Burner Access Panel Base Gasket Kit Base Side Insulation Base Rear Insulation Base Front Insulation Base Leg Assembly Flame Roll-out Switch Manifold Support Bracket RePAIR PARtS LISt (continued) [Quantity] Part Number ES23 ES24 ES25...

  • Page 23

    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 1.20mm Pilot Burner Pilot Assembly - Natural Gas Pilot Assembly - LP Gas...

  • Page 24

    Description IQ Boiler Control IQ Option Panel Transformer Temperature Sensor RePAIR PARtS LISt (continued) ES23 ES24 [Quantity] Part Number ES25 ES26 ES27 ES28 102289-01 102291-01 102516-01 102411-01 ES29...

  • Page 25

    RePAIR PARtS LISt (continued) Description Jacket Left Side Panel Jacket Right Side Panel Jacket Rear Panel 102569-03 Jacket Vestibule Panel 102565-03 Jacket Top Panel 102568-03 Jacket Front Door 102576-03 Jacket Rear Discharge 102549-03 Jacket Poly Front Cover 102600-03 Upper Poly Grille Lower Poly Grille [Quantity] Part Number ES23...

  • Page 26

    Description Supply Water Manifold Temperature/Pressure Gauge Circulator Wiring Harness 30 PSI Relief Valve Drain Valve Vent Damper Circulator (not shown): Taco 007-2 Grundfos UP-15 B & G NRF-22 RePAIR PARtS LISt (continued) [Quantity] Part Number ES23 ES24 ES25 102284-01 102284-02 ES26 ES27 ES28...

  • Page 27: Internal Wiring

    INTERNAL WIRING Figure IW-1: Wiring Diagram...

  • Page 28

    INteRNAL WIRING (continued) Figure IW-2: Wiring Schematic...

  • Page 29

    INteRNAL WIRING (continued) Figure IW-3: Single Zone System with Domestic Hot Water Tank Figure IW-4: Multiple Zone System with Zone Circulators...

  • Page 30

    INteRNAL WIRING (continued) Figure IW-5: Multiple Zone System with Zone Valves Figure IW-6: Multiple Zone System with Zone Circulator Panel...

  • Page 31

    SELECTED USING ZONE PANEL SWITCH ZONE 4 PRIORITY IQ OPTION PANEL T STAT 1 VALVE 1 T STAT 2 VALVE 2 T STAT 3 VALVE 3 T STAT 4 VALVE 4 POWER ZONE 4 JUMPER 3 & 4 PRIORITY ZONE BOILER JACKET PANEL...

  • Page 32: A – Combustion Air

    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.

  • Page 33: B – Venting

    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.

  • Page 34

    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. FIREPLACES AND FAN-ASSISTED GAS APPLIANCES must not be vented into the same chimney space as this boiler.

  • Page 35

    thIS PAGe INteNtIoNALLY Left BLANK...

  • Page 36: C – Gas Piping

    Determine the boiler’s maximum gas demand and minimum gas supply pressure (printed on the boiler’s rating label) and the demand of other gas appliances served by the same gas meter. Ensure that gas piping, fittings, and gas...

  • Page 37: D – System Piping

    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. Be sure to protect the boiler from the following...

  • Page 38

    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.

  • Page 39

    APPeNDIX D – System Piping (continued) Figure D-0: Piping Schematic Symbols...

  • Page 40

    APPeNDIX D – System Piping (continued) Figure D-W1: Water Boiler, Series Loop Figure D-W2: Water Boiler, Two or More Zones...

  • Page 41

    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...

  • Page 42

    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...

  • Page 43: E – Filling The System And Checking For Leaks

    Series Loop or multi-zoned system installed as per the figure below. Remove air from system when filling. Close full port ball valve located between vertical hose bib and air scoop in boiler supply piping (see Appendix D – System Piping.

  • Page 44: F – Adjusting Gas Input Rate

    If input is too high, reduce input rate by decreasing manifold pressure. Do not reduce more than 0.3” w.c. Instead, contact Burnham for an orifice replacement kit. If input is below 98% of Rating Label input, increase manifold gas pressure no more than 0.3 inches w.c.

  • Page 45

    CONNECTIONS must be leak tested and FOR LEAK TESTING OVER ½ PSIG, disconnect boiler and its individual shut- For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler’s individual manual shut-off valve. Check for gas leaks in all piping joints,...

  • Page 46: G – Checking Draft And Combustion

    , CO, and flue gas temperature. For oil boilers, also use a smoke tester with smoke test paper. Operate the boiler at its rated (high fire) input. With the analyzer, check the CO CO and temperature of the flue gases exiting the boiler.

  • Page 47: H – Iq Control System

    • Efficiently operates the entire boiler system to save energy. IQ Boiler Control: The heart of Burnham’s IQ Control System is the IQ Boiler Control. The IQ Boiler Control replaces the traditional separate ignition control, primary boiler aquastat, as well as the fan and circulator relays.

  • Page 48

    The Low Water Cutoff (LWCO) IQ Option Cards are advanced devices that detect the absence of water in the boiler. LWCO IQ Option Cards use patented signal processing to identify when the probe signal levels have decreased due to fouling, permitting extended operation for probe impedances up to 40K Ohms.

  • Page 49

    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. enviraCoM thermostats: Standard EnviraCOM thermostats provide “heat demand”...

  • Page 50

    Trail, Aquastat Limit Control, 130-220 Deg F, 15 Deg F Adjustable Differential, Auto Reset, less Well, less Sensor, 120 Vac Circulator Control Relay IQ Option Panel with three slots “plug-in” option card slots, suitable for gas or oil fired boiler applications, 102291-01...

  • Page 51

    SERVICE RECORD DATE SERVICE PERFORMED...

  • Page 52

    Burnham Repair Parts Pricing where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger.

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