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Energy Star ESC Installation Operating And Maintenance Istructions

Enhanced sealed combustion gas - fired boiler
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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
ENHANCED SEALED COMBUSTION
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.
Boiler Model Number
ESC
Heating Contractor
Address
102601-02 - 9/11
ESC™
Gas - Fired Boiler
Boiler Serial Number
9700609
Installation Date
Phone Number
Price - $5.00

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  • Page 1 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).
  • Page 2 WARNINGS foR the hoMeoWNeR when outdoor temperatures are below 32°F, first FOLLOW ALL INSTRUCTIONS and warnings turn off your home’s main water supply and drain printed in this manual and posted on the boiler. the water from all pipes. INSPECT THE BOILER ANNUALLY. To keep your DO NOT BLOCK AIR FLOW into or around the boiler safe and efficient, have a service technician boiler.
  • Page 3 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.
  • Page 4 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.

  • Page 5: Specifications

    ESC5 85.3 ESC6 85.2 ESC7 85.0 ESC8 84.5* ESC9 84.0* * Do not meet ENERGY STAR requirements Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A Dimensions, Weights and Connections Relief Valve Drain Boiler Supply NPT Return Vent Gas NPT Depth Width Height...
  • Page 6 SPECIFICATIONS (continued) Figure S-1: Minimum Clearances to Combustibles...

  • Page 7: Table Of Contents

    BOILER QUICk-START Installation: Unpack the crate ..................... 8 Position the boiler .................... 8 Provide combustion air ..................9 Connect venting ....................9 Connect gas piping ..................11 Connect boiler water piping ................11 Connect electrical wiring ................13 Program the controls ..................14 Check for gas and water leaks ..............

  • Page 8: Unpack The Crate

    1. UNPACk THE CRATE Tip the boiler and shimmy it off the skid. THE BOILER IS TOP-HEAVY. Do not allow it to tip over. Remove the sleeve. Remove the contents from the skid, except the boiler. Remove the four (4) hex-drive lag screws holding the boiler to the skid (Figure 1-a).

  • Page 9: Provide Combustion Air

    Appendix B2—Venting for release of deadly carbon monoxide (CO) into the Direct Vent boilers. home. If not equipping the ESC for direct vent, Like all fuel-burning appliances, boilers need air to provide combustion air from the boiler room operate reliably and safely.
  • Page 10 . CONNECT VENTING (continued) (3) Install vent piping. Instructions for Stainless Steel Venting Vertical Installations, Specifically, (4) When configuring the ESC for Power Vent (indoor combustion air) install a 45° (1) Install fire stops and wall thimbles. vent elbow, pointing downward.

  • Page 11: Connect Gas Piping

    5. CONNECT GAS PIPING Size gas piping according to Appendix C – Gas Pipe from the street elbow through the Piping 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.
  • Page 12 6. CONNECT BOILER WATER PIPING (continued) Connect the system supply to the open end Screw the supplied drain valve into tapping of the manifold "S" using a 1¼” male NPT “D”. fitting. See Figure 6b for suggested near boiler Screw an installer-supplied 1¼” pipe or piping of IQ Options.

  • Page 13: Connect Electrical Wiring

    . 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.

  • Page 14: Program The Controls

    . PROGRAM THE CONTROLS Viewing the operating Mode options Using IQ Boiler Control Display In operating mode the user may view (but not The IQ Boiler Control is located inside the boiler change) boiler operating status, settings and front door, just above the IQ Option Panel (Figure troubleshooting information.
  • Page 15 . PROGRAM THE CONTROLS (continued) with a High Limit Setpoint of 180°F. The Unit Display 1 sec 1 sec boiler turns "off" when the supply water temperature is above this value. The High 1 sec Sample Limit setpoint is adjustable between 130° Display and 220°F.

  • Page 16: Check For Gas And Water Leaks

    LCD Display Kit includes a mounting bracket The LCD Display is an easy to use touch screen and wiring harness to allow mounting in the ESC type display that allows a technician to monitor plastic hood above the front door. For installation,...

  • Page 17: Perform Startup Checks And Adjustments

    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.

  • Page 18: Annual Maintenance Checklist

    ANNUAL MAINTENANCE CHECkLIST WARNINGS THE BOILER CONTAINS REFRACTORY personal injury or death, and extensive property CERAMIC FIBER, a possible human carcinogen. damage. USE A NIOSH APPROVED RESPIRATOR when TURN OFF ALL GAS AND ELECTRIC power servicing high-temperature insulation and gasket supplies to the boiler before servicing.

  • Page 19: Troubleshooting

    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.
  • Page 20 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: "Err" IQ Boiler Control Error Codes (when is flashing) Display...
  • Page 21 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. The IQ Option Panel display (lower display) will show one of the following status codes: IQ Option Panel Display Shows “ERR"...

  • Page 22: Repair Parts List

    REPAIR PARTS [Quantity] Part Number Description ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 Block Assembly 102287-03 102287-04 102287-05 102287-06 102287-07 102287-08 102287-09 Flue Baffle 71107002 71107002 71107002 71107002 71107002 71107002 71107002...
  • Page 23 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 Canopy Assembly - Sea Level 102594-03 102594-04 102594-05 102594-06 102594-07 102594-08 102594-09 Canopy Assembly - High Altitude 102594-13 102594-14 102594-15 102594-16 102594-17 102594-18 102594-19 Canopy Gasket Kit 6206001 Fan Gasket 8206085...
  • Page 24 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 Base Wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 Base Tray 102543-03 102543-04 102543-05 102543-06 102543-07 102543-08 102543-09 Burner Tray Assembly 61807031 61807041 61807051 61807061 61807071 61807081 61807091 Base Front Panel...
  • Page 25 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 Gas Valve (Natural Gas), 81660282 Honeywell VR8204P1171 Gas Valve (Natural Gas), 81660283 Honeywell VR8304P4496 Gas Valve (LP Gas), Honeywell 81660146 VR8204C3015 Gas Valve (LP Gas), Honeywell 81660181 VR8304P4280 ½"...
  • Page 26 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 Air Box Assembly 61807032 61807042 61807052 61807062 61807072 61807082 61807092 Air Box Door 71807034 71807044 71807054 71807064 71807074 71807084 71807094 Combustion air diffuser 71807049 71807059 71807069 71807079 71807089 71807099...
  • Page 27 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 IQ Boiler Control 102290-01 IQ Option Panel 102291-01 Transformer 102516-01 Temperature Sensor 102411-01 Differential Pressure Switch 80160762 80160761 80160760 80160759 80160760 Sea Level 0' - 4999' High Altitude - 5000' - 10,000' 80160759 80160763...
  • Page 28 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 Jacket Left Side Panel 102566-01 Jacket Right Side Panel 102567-01 Jacket Rear Panel 102587-03 102587-04 102587-05 102587-06 102587-07 102587-08 102587-09 Jacket Vestibule Panel 102588-03 102588-04 102588-05 102588-06 102588-07 102588-08...
  • Page 29 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 Water Manifold 80607001 Temperature/Pressure Gauge 100282-01 Circulator Wiring Harness 6130701 Safety Relief Valve 81660363 Drain Valve 102802-01 Vent Terminal 8110701 8110702 Air Intake Terminal (Not Shown) 6116045 6116044 6116063...

  • Page 30: Internal Wiring

    INTERNAL WIRING Figure IW-1: Wiring Diagram...
  • Page 31 INTERNAL WIRING (continued) Figure IW-2: Wiring Diagram...
  • Page 32 INTERNAL WIRING (continued) Figure IW-: Single Zone System with Domestic Hot Water Tank Figure IW-: Multiple Zone System with Zone Circulators...
  • Page 33 INTERNAL WIRING (continued) Figure IW-5: Multiple Zone System with Zone Valves Figure IW-6: Multiple Zone System with Zone Circulator Panel...
  • Page 34 INTERNAL WIRING (continued) DHW AQUASTAT (L4006, L4080) POWER (SUPPLIED BY OTHERS) SUPPLY 120/60/1 THERMOSTAT THERMOSTAT THERMOSTAT TRANSFORMER DOMESTIC HOT WATER PRIORITY IS SELECTED USING ZONE PANEL SWITCH MODE ZONE 4 PRIORITY NORMAL RESET IQ OPTION PANEL POWER IN ZONE 1 ZONE 2 ZONE 3 ZONE 4...

  • Page 35: Appendices: A - Combustion Air

    APPENDIX A – COMBUSTION AIR If the Floorspace from Step 1 is less than the PROVIDE ENOUGH AIR to ventilate the Minimum Floorspace from Step 3, then you boiler room, dilute the flue gases, and must provide outdoor air to the boiler room. sustain combustion.

  • Page 36: B - Venting

    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.
  • Page 37 APPeNDIX B1 INteNtIoNALLY oMItteD...
  • Page 38 APPENDIX B2 – DIRECT VENTING GeNeRAL WARNINGS foR DIReCt VeNt SYSteMS DRAFTHOODS, VENT DAMPERS and other IF USING A CHIMNEY AS A CHASE for the vent, do not vent any other appliance into the space obstructions or openings in the vent system are prohibited.
  • Page 39 APPENDIX B2 – Direct Venting (continued) Figure B-2: Approved Terminal Locations Locate the combustion air terminal on walls. The fire stop must close the opening the same face of the building as the vent between the vent and/or air intake pipe and termination to prevent nuisance boiler the structure.
  • Page 40 APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent Table B-1: Vent System and Air Intake USE STAINLESS STEEL VENTING System Components only with boilers approved for use with stainless steel venting as noted in the Vent System Component Part Number Specifications Section of this manual.
  • Page 41 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) Vent (stainless special gas vent) 90°...
  • Page 42 APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) (1) Insert the wall thimble from the outside opening with weatherproof sealant (Figure of the wall, and secure the outside B-4). flange to the wall using nails or screws. To install a vertical “snorkel”...
  • Page 43 APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) Figure B-6: Typical Vertical Stainless Steel Venting Install the intake air terminal supplied with Apply Dow Corning Silastic 732 RTV Sealant the boiler onto the outdoor end of the air between the vent pipe and the storm collar intake pipe per the instructions in Connect to provide a watertight and heat-resistant...
  • Page 44 APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) Figure B-: 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.
  • Page 45 APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) Figure B-: Vertical Air Intake Piping for Direct Venting...

  • Page 46: C - Gas Piping

    APPENDIX B – POWER VENTING Some direct vent boilers are also approved with the “optional” indoor air piping and components. use of indoor combustion air. If the boiler you Specific instructions for configuring the boiler for are installing is approved for use with indoor indoor air appear in the boiler-specific instructions combustion air, install the vent according to the at the front of this manual.
  • Page 47 APPENDIX C – Gas Piping (continued) For materials or conditions other than those ASSURE GAS PIPING IS LEAK FREE listed above, refer to the National Fuel Gas AND OF PROPER SIZE and type for the Code, NFPA54/ANSI Z223.1, or size the connected load.

  • Page 48: D - System Piping

    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. 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.
  • Page 49 APPENDIX D – System Piping (continued) Condensation (3) Do not allow chilled water to enter the boiler during the heating cycle, or heated Do not over-pump. Adhere to the design water to enter chilled water coils during flow requirements for each zone. the cooling cycle.
  • Page 50 APPENDIX D – System Piping (continued) Figure D-0: Piping Schematic Symbols...
  • Page 51 APPENDIX D – System Piping (continued) Figure D-W1: Water Boiler, Series Loop Figure D-W2: Water Boiler, Two or More Zones...
  • Page 52 APPENDIX D – System Piping (continued) Figure D-W: Water Boiler, Tankless Coil, Two or More Zones Figure D-W: Water Boiler, Indirect Water Heater, Two or More Zones...
  • Page 53 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 54: E - Filling The System And Checking For Leaks

    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. Close full port ball valve located between Open the zone valve or shut-off valve vertical hose bib and air scoop in boiler...

  • Page 55: F - Adjusting Gas Input Rate

    APPENDIX F – ADjUSTING GAS INPUT RATE Natural Gas Boilers: Turn off gas supply to all appliances other than gas-fired boiler. Note the rated manifold gas pressure listed on the boiler’s rating label. Connect Manometer to manifold pressure tapping on Gas Valve (Figure F-1). Determine gas flow rate in Cubic Feet per Hour based on elapsed time for two revolutions.
  • Page 56 APPENDIX F – Adjusting Gas Input Rate (continued) Table F-1: Gas Flow Rate in Cu. Ft. / Hr. Reinstall gas orifices and main burner. Repeat procedure to measure input rate. Size of Gas Meter Dial Seconds for Two Recheck Main Burner Flame. One-Half (2) Revolutions Cu.

  • Page 57: G - Checking Draft And Combustion

    APPENDIX G – CHECkING DRAFT AND COMBUSTION CHECK DRAFT (GAS BOILERS WITH DRAFT HOODS) After 5 minutes of main burner operation, Insofar as is practical, close all doors and test for spillage at the draft hood relief windows in the building. opening, using a lighted match, candle, Turn on all appliances not connected to the cigarette, etc.

  • Page 58: H - Burnham® Iq Control System

    APPENDIX H – IQ CONTROL SYSTEM IQ Control System overview • Ensures adequate heat and supply of domestic hot water. The “IQ Control System” consists of an IQ Boiler Control and an IQ Option Panel with optional “plug • UL / CSA Listed or Recognized and tested in”...
  • Page 59 IQ LWCo option Card (Auto Reset): P/N 102711-01 IQ LWCo option Card (Manual Reset): P/N 102714-01 IQ LWCO Option Cards add a low water cut-off function to ESC Boilers. LWCO Option Cards plug into the IQ Option Panel and connect to the system-mounted sensor with a single-wire connection.
  • Page 60 The Display Kit provides a 3.5” LCD multi-color Touch Screen display for mounting in the plastic “hood” above the front door of any ESC Boiler. The Display Kit communicates with the IQ Boiler Control and all installed IQ Option Cards. All boiler settings, status, and errors are displayed in full text on the bright, backlit display.
  • Page 61 APPENDIX H – IQ Control System (continued) stem Parts List Optional Components Part Number Item Description Outside Reset IQ Option Card, Domestic Hot Water Priority, for use with Option Control Panel, with Outside 102723-01 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...

  • Page 62: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 63 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 64 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 (717) 397-4701 www.usboiler.burnham.com...

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