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U.S. Boiler Company ESC Installation, Operating And Service Instructions

Esc series enhanced sealed combustion gas - fired boiler
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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
ENHANCED SEALED COMBUSTION
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
ESC_C
Heating Contractor
Address
103788-03 - 9/13
ESC™
Gas - Fired Boiler
Boiler Serial Number
Installation Date
Phone Number
Price - $5.00

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  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR ESC™ ENHANCED SEALED COMBUSTION 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.
  • Page 2 WARNINGS foR the hoMeoWNeR FOLLOW ALL INSTRUCTIONS and warnings when outdoor temperatures are below 32°F, first printed in this manual and posted on the boiler. turn off your home’s main water supply and drain the water from all pipes. INSPECT THE BOILER ANNUALLY. To keep your boiler safe and efficient, have a service technician DO NOT BLOCK AIR FLOW into or around the follow the Service checklist near the end of this...
  • Page 3 WARNINGS foR the INStALLeR READ THIS ENTIRE MANUAL before attempting ADHERE TO ALL LOCAL CODE REQUIREMENTS. installation, start-up, or service. Improper 1. Installation must conform to requirements of installation, adjustment, alteration, service, or authority having jurisdiction or, in the maintenance may cause serious property damage, absence of such requirements, with the personal injury, or death.
  • Page 4 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 5 • System-friendly – built-in protection from condensation and thermal shock. IQ Control System Overview ESC Boiler uses a microprocessor based control system called the "IQ Control System". This "IQ Control System" consists of an Intelligent Hydronic Control Control (Control) and an IQ Option Panel (Option Panel) with optional "plug-in"...

  • Page 6: Specifications

    SPECIFICATIONS Ratings ESC Series Heating Capacity Net AHRI Rating, Water Boiler Model Input (MBH) AFUE (%) (MBH) (MBH) ESC3C 60.8 85.5 ESC4C 91.2 85.4 ESC5C 121.6 85.3 ESC6C 152.0 85.2 ESC7C 182.4 85.0 ESC8C 212.8 84.5 ESC9C 243.2 84.0 Net AHRI Water Ratings shown based on piping and pickup allowance of 1.15. Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.
  • Page 7 SPECIFICATIONS (continued) Figure S-1: Minimum Clearances to Combustibles...

  • Page 8: Table Of Contents

    BOILER QUICk-START Installation: Unpack the crate ..................... 9 Position the boiler .................... 9 Provide combustion air .................. 10 Connect venting ..................... 10 Connect gas piping ..................12 Connect boiler water piping ................12 Connect electrical wiring ................14 Program the controls ..................15 Check for gas and water leaks ..............

  • Page 9: 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 10: Provide Combustion Air

    Direct Vent boilers. accordance with the section "Air for Combustion and Ventilation," of the National Fuel Gas Code, If not equipping the ESC for direct vent, ANSI Z223.1/NFPA 54, or applicable provisions of provide combustion air from the boiler room the local building codes.
  • Page 11 4. CONNECT VENTING (continued) (3) Install vent piping. (4) Install roof flashing and roof supports. (4) When configuring the ESC for Power (5) The final installation should appear as in Vent (indoor combustion air) install a 45° Figure B-7 in Appendix B-2.

  • Page 12: 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 13 6. CONNECT BOILER WATER PIPING (continued) Connect the system supply to the open end See Figure 6b for suggested near boiler of the manifold "S" using a 1¼” male NPT piping of IQ Options. fitting. Maintain minimum 1/2" clearance between Screw an installer-supplied 1¼”...

  • Page 14: Connect Electrical Wiring

    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.

  • Page 15: Program The Controls

    8. PROGRAM THE CONTROLS Using Intelligent hydronic Control Display . Press and release the “I” key on the IQ control to change from one parameter to The Intelligent Hydronic Control is located inside the next. Each setting will alternately flash the boiler front door, just above the IQ Option between the relevant display code and its Panel (Figure 8-a).
  • Page 16 8. PROGRAM THE CONTROLS (continued) Please note that in operating mode to hold the Setpoint to regulate heat delivery, increase display on the value the user can press and hold home comfort and save energy. Refer to the either the Up ñ or Down ò keys and the value Appendix I for additional information.
  • Page 17 The control allows configuration of the Call for Boiler DHW Circulator output functionality to help Heat Terminal Burner Status Temperature the ESC integrate into each installation Source Selection more effectively. The DHW Circulator TT = on <140 Start with no delay TT = on >140...

  • Page 18: Check For Gas And Water Leaks

    (call for heat) the boiler is started and the includes a mounting bracket and wiring harness DHW Circulator terminal is energized. to allow mounting in the ESC plastic hood above When Second Heating Zone is de- the front door. For installation, programming,...

  • Page 19: 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 20 10. PERFORM STARTUP CHECkS AND ADjUSTMENTS (continued) Figure 10-d: Operating Instructions...

  • Page 21: Annual Maintenance Checklist

    ANNUAL MAINTENANCE CHECkLIST Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 22 ANNUAL MAINTENANCE CHECkLIST (continued) WARNINGS LABEL ALL WIRES prior to disconnection when TURN OFF ALL GAS AND ELECTRIC power servicing controls. Wiring errors can cause supplies to the boiler before servicing. Contact with improper and dangerous operation or release of dangerous flammable gas, electrical voltage, moving parts, and very hot water under FAILURE TO MAINTAIN THE BOILER in proper pressure may cause serious personal injury,...

  • Page 23: Troubleshooting

    TROUBLESHOOTING wiring diagram in Figures IW-1 and IW-2. Before troubleshooting Ensure that incoming 120 Vac power polarity The following pages contain trouble shooting is correct and that the boiler is properly tables for use in diagnosing control problems. grounded. Further, ensure that the control When using these tables the following should power supply is 24 VAC (minimum 18 VAC be kept in mind:...
  • Page 24 TROUBLESHOOTING (continued) Use Control Display ERR (error) Number to Direct troubleShooting efforts If the control detects an error it will flash “Err” (error) followed by a number. Use this number to identify the boiler problem and corrective action in the table below. If there is no Err display proceed to next Section: IQ Boiler Control Error Codes (when "Err"...
  • Page 25 TROUBLESHOOTING (continued) Use STA (status) Number to guide troubleShooting The control will flash “STA” followed by a number. Use this number to identify the boiler problem in the table below: 1. Boiler and Circulator off Display / Recommended Corrective Action Status The boiler has not detected a call for heat (tt = off and dh = off).
  • Page 26 TROUBLESHOOTING (continued) 5. Circulator is On, Blower is On but Boiler Fails to Start Display / Status Description The Boiler is in “Retry Delay”: - The burner failed to light (no flame signal). After a 5 minute delay, control will attempt to light the burner STA 10 again.
  • Page 27 TROUBLESHOOTING (continued) Display / Status Recommended Corrective Action 1. No Spark a. Can you hear sparking while STA 6 is displayed? - If there is no spark noise replace the control. b. If you can hear spark noise check the following: - Loose connection in ignition cable or ground wire - Continuity of ignition cable - Break in ignition cable insulation...
  • Page 28 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. The IQ Option Panel display (lower display) will show one of the following status codes: IQ Option Panel Display Shows “ERR"...

  • Page 29: Repair Parts List

    REPAIR PARTS All ESC™ 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.
  • Page 30 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3C ESC4C ESC5C ESC6C ESC7C ESC8C ESC9C 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 31 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3C ESC4C ESC5C ESC6C ESC7C ESC8C ESC9C 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 32 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3C ESC4C ESC5C ESC6C ESC7C ESC8C ESC9C 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 81660160 VR8304P4280 ½"...
  • Page 33 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3C ESC4C ESC5C ESC6C ESC7C ESC8C ESC9C 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 34 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3C ESC4C ESC5C ESC6C ESC7C ESC8C ESC9C IQ Boiler Control 103661-01 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 35 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3C ESC4C ESC5C ESC6C ESC7C ESC8C ESC9C 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 36 REPAIR PARTS (continued) [Quantity] Part Number Description ESC3C ESC4C ESC5C ESC6C ESC7C ESC8C ESC9C Water Manifold 80607001 Temperature/Pressure Gauge 100282-01 Circulator Wiring Harness 6130701 30 PSI Relief Valve 81660363 Drain Valve 102802-01 Vent Terminal 8110701 8110702 Vent Connector 8110703 Vent Tee AL294C, 3" 8116310 Vent Tee AL294C, 4"...

  • Page 37: Internal Wiring

    INTERNAL WIRING Figure IW-1: Wiring Diagram...
  • Page 38 INTERNAL WIRING (continued) Figure IW-2: Wiring Diagram...
  • Page 39 INTERNAL WIRING (continued) Figure IW-3: Multiple Zone System with Zone Circulators Figure IW-4: Multiple Zone System with Zone Valves...
  • Page 40 INTERNAL WIRING (continued) Figure IW-5: Multiple Zone System with Zone Circulator Panel 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...

  • Page 41: 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 42: 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, or applicable provisions of the local building codes.
  • Page 43 APPENDIX B2 – DIRECT VENTING GeNeRAL WARNINGS foR DIReCt VeNt SYSteMS DRAFT HOODS, VENT DAMPERS and other IF USING A CHIMNEY AS A CHASE for the vent, obstructions or openings in the vent system are do not vent any other appliance into the space prohibited.
  • Page 44 APPENDIX B2 – Direct Venting (continued) Figure B-2: Approved Terminal Locations However, boiler may be installed with Planning Vertical Installations – vertical venting and sidewall combustion air Install fire stop where vent and air intake inlet or visa versa, if installation conditions passes through floors, ceilings or framed do not allow alternate arrangement.
  • Page 45 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 46 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 47 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 48 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 49 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.
  • Page 50 APPENDIX B2 – Direct Venting (continued) Special Instructions for Stainless Steel Direct Vent (continued) Figure B-8: Vertical Air Intake Piping for Direct Venting...

  • Page 51: C - Gas Piping

    APPENDIX B3 – POWER VENTING Some direct vent boilers are also approved with Locate vent terminal at least 4 ft. below, 4 ft. use of indoor combustion air. If the boiler you horizontally from, or 1 ft above any door, operable are installing is approved for use with indoor window, or gravity air inlet.
  • Page 52 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, ANSI Z223.1/NFPA 54, or size the connected load.

  • Page 53: 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 54 APPENDIX D – System Piping (continued) water boiler, the use of the listed LWCO Combination Heating and Cooling Systems control is permitted when it is installed If this boiler is used in connection with according to the LWCO manufacturer's refrigeration systems, the boiler must be instructions.

  • Page 57: 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 58: F - Adjusting Gas Input Rate

    APPENDIX F – ADjUSTING GAS INPUT RATE Natural Gas Boilers: Check Manifold Pressure: 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). Light main burners by adjusting thermostat to highest setting.

  • Page 59: G - Checking Draft And Combustion

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

  • Page 60: H - Operation

    Table 4: Sequence of Operation Boiler Sequence of operation Status Codes displayed in STA Mode NORMAL OPERATION Status Description The ESC Boilers are equipped with an Standby Intelligent Hydronic Control (control). This (Burner off No call for heat detected control replaces the traditional separate...

  • Page 61: I - Iq Control System

    APPENDIX I – IQ CONTROL SYSTEM IQ Control System overview • Ensures adequate heat and supply of domestic hot water. The “IQ Control System” consists of a control and an IQ Option Panel with optional “plug in” cards: • UL / CSA Listed or Recognized and tested as part of a complete system.
  • Page 62 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 63 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 control and all installed IQ Option Cards. All boiler settings, status, and errors are displayed in full text on the bright, backlit display.
  • Page 64 IQ LCD Display, Boiler Exterior Mounted, STN Monochrome, White/Red backlight, 5Vdc Power Supply, 102728-01 RS422 (RS485) Communication, Pure Black Bezel with Gateway, Wire Harness, Mounting Bracket, ESC Logo Plates and Instructions IQ LCD Display, Boiler Exterior Mounted, STN Monochrome, White/Red backlight, 5Vdc Power Supply,...

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