U.S. Boiler Company ENHANCED 2 Series, Installation, Operating And Service Instructions

Page 1: ...d Boiler 9700609 Price 5 00 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__ Boiler Serial Number Installation Date Heating Contractor Phone Number Address ...

Page 2: ...rty damage If you must leave your home unattended for an extended time when outdoor temperatures are below 32 F first turn off your home s main water supply and drain the water from all pipes DO NOT BLOCK OR OBSTRUCT flow of combustion and ventilation air into or around the boiler Insufficient air may cause the boiler to produce carbon monoxide or start a fire KEEP BOILER AREA CLEAR AND FREE from ...

Page 3: ...xcessively and this will lead to premature failure of the boiler and its components Our warranty does not apply to damage from excessive cycling ADHERE TO ALL LOCAL CODE REQUIREMENTS 1 Installation must conform to requirements of authority having jurisdiction or in the absence of such requirements with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or the Natural Gas and Propane Installation C...

Page 4: ... 01 q Circulator Mounting Hardware Kit 1 1 4 NPT 6056007 except less circulator q Drain Valve NPT 102802 01 q Safety Relief Valve 30 psi 81660363 q Water Manifold 80607001 5 q Instruction Envelope 103779 01 q Instruction Operation Manual 103780 06 q Boiler Warranty Sheet 103203 01 q Boiler Warranty Card 103204 02 What s in the crate IQ Control System Overview ES2 Boiler uses a microprocessor based...

Page 5: ... Water Temperature F Minimum Flow GPM Waterside Pressure Drop at 20 F DT Ft of Head ES23 130 220 110 None 1 ES24 130 220 110 None 1 ES25 130 220 110 None 1 ES26 130 220 110 None 1 ES27 130 220 110 None 1 ES28 130 220 110 None 1 ES29 130 220 110 None 1 Water Temperatures and Flows 1 Input ratings can be used for elevations up to 2000 ft 600 m Refer to Appendix F for elevations 2000 ft 600 m or high...

Page 6: ...ombustible Materials SPECIFICATIONS continued Weights and Volume Boiler Model Shipping Weight lbs Empty Weight lbs Water Content gal ES23 254 180 2 ES24 304 231 3 ES25 357 284 4 ES26 405 332 5 ES27 462 382 5 ES28 518 438 6 ES29 564 484 7 ...

Page 7: ...14 9 Check for gas and water leaks 17 10 Perform startup checks and adjustments 18 Annual Maintenance Checklist 19 Troubleshooting 22 Repair Parts List 28 Internal Wiring 34 Appendices A Combustion Air 38 B Venting 39 C Gas Piping 43 D System Piping 44 E Filling the System and Checking for Leaks 48 F Adjusting Gas Input Rate 49 G Checking Draft and Combustion 51 H Operation 52 I IQ Control System ...

Page 8: ...he 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 1 Unpack the Crate 4 Tip the boiler and shimmy it off the skid Figure 1 b 1 a 1 b ...

Page 9: ...ion CLEAN BURNERS DAILY if operating the boiler in a dusty environment PROTECT IGNITION SYSTEM COMPONENTS from sources of water that may spray drip or rain on them during installation or service 4 Level the boiler using shims as necessary 5 Assure that the front air dam applicable to 5 section thru 9 section boilers only is in place and undamaged See Figure 2 a 2 a WARNING Models ES25 ES26 ES27 ES...

Page 10: ... in accordance with local building codes or local authority having jurisdiction or Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 and or National Building Code of Canada Masonry chimney must be lined with listed chimney lining system Clay flue lined masonry chimneys do not meet venting requirements for this appliance c Do not use cellular core PVC ASTM F891 ...

Page 11: ...ters 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 1 Remove boiler door locate gas valve and remove plastic shipping plug 2 Thread a x 1 nipple a 90 street elbow or a Honeywell flange onto the gas valve and pipe through the slot in the left jacket panel Figure 5 a In Canada close nipples and street...

Page 12: ...itting 7 Screw an installer supplied 1 pipe or nipple into the water return tapping R 8 Screw the supplied drain valve into tapping D 9 See Figure 6b for suggested near boiler piping of IQ Options General system piping guidelines are included in Appendix D System Piping Additionally for this particular boiler install piping shown below Figure 6 a 1 Apply sealant to all threads 2 Screw the water su...

Page 13: ...ter cutoff or temperature limit device other than an IQ Control System in series with the 120V circuit used to power the boiler Do not alter the boiler s factory wiring when adding an additional limit 7 Connect Electrical Wiring 5 Connect the 24V wiring from the thermostat to the T T terminals on the Option Control Panel 6 Insert vent damper harness to vent damper 7 To connect other external devic...

Page 14: ... Status Code Displayed in STA Mode 1 Standby 4 Prepurge 6 Spark 7 Flame Proving 8 Running 10 Retry Recycle Delay 13 Soft Lockout 14 Hard Lockout 15 Waiting for Limit to Close 16 Flame Present Out of Sequence 17 Self Test 18 Waiting for Damper to Open 20 Damper Failure to Open For example when the I key is pressed on the control until bt is displayed it will then flash a three digit number such as ...

Page 15: ...s above this value The High Limit setpoint is adjustable between 140 and 220 F The Operating Setpoint SP will equal the High Limit Setpoint unless an Outdoor Reset IQ Option Card is installed The Outdoor Reset IQ Option Card reduces the Operating Setpoint to regulate heat delivery increase home comfort and save energy Refer to the Appendix I for additional information 2 Differential df_ The contro...

Page 16: ...Terminal Selection Boiler Temperature Burner Status TT on 140 Start with no delay TT on 140 Start after 2 minute delay DHW on tt2 140 Start with no delay DHW on tt2 140 Start after 2 minute delay DHW on dh 140 Start with no delay DHW on dh 140 Start with no delay 7 Domestic Hot Water DHW Terminal Function The control allows configuration of the DHW Circulator output functionality to help the boile...

Page 17: ...W Input System Circulator Output Zone 3 DHW Circulator Output Zone 2 off off off off on off on off on on on on off on off on Using the IQ Option Panel IQ Option Cards are available from U S Boiler Company 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 an Auxiliary High Limi...

Page 18: ...line to purge of air q Boiler lights cleanly within 60 seconds 5 Adjust gas input rate See Appendix F Adjusting Gas Input Rate Check main burner and pilot flames See Figures 10 a and 10 c 10 a q Pilot and main burner flames appear clean and blue 6 Disconnect pilot lead wires from gas valve Figure 10 b q Boiler shuts off 7 Reconnect pilot lead wires to gas valve q Boiler restarts 8 Adjust zone ther...

Page 19: ...d clothing separate from normal laundry CAUTION LABEL ALL WIRES prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation ATTENTION Au moment de l entretien des commandes étiquetez tous les fils avant de les débrancher Les erreurs de câblage peuvent nuire au bon fonctionnement et être dangereuses FAILURE TO MAINTAIN THE BOILER in proper working conditi...

Page 20: ... pilot lead wires at gas valve 4 Remove wires from flame roll out switch 5 Remove burner access panel 6 Mark location of the pilot main burner on the manifold if the marking on manifold is missing or obliterated 7 Hold burner at throat Lift front of burner to clear orifice Figure AM 1 The burner that holds the pilot can only be removed by first lifting the burner adjacent to its right 6 Perform St...

Page 21: ...21 Annual Maintenance Checklist continued Operating Instructions VR8204 and VR8304 Gas Valves AM 2 ...

Page 22: ...ent is generally the least likely cause Before replacing a component try to rule out all other possible causes 5 When checking voltage across wiring harness pins be careful not to insert the meter probes into the pins Doing so may damage the pin resulting in a loose connection when the harness is reconnected When error is shown Value Description 4 Flame current lower than threshold 6 Flame Out of ...

Page 23: ...ess is defective While the Err 56 is displayed by the control perform the following tasks Remove the call for heat adjust thermostat or remove wire from TT terminals Check for 24Vac between P6 5 and ground If voltage not present attempt to start boiler again If 24Vac is present unplug the vent damper harness from control With wire harness unplugged check for 24Vac between P6 5 on Control and groun...

Page 24: ... until the thermostat is turned off The source of blockage must be corrected by trained and skilled personnel from a qualified service agency before resetting switch Blocked Vents are caused by a collapsed chimney resulting in full or partial blockage chimney cross sectional area too small height insufficient or cold chimney causing sustained poor draft Always follow the recommendations in Section...

Page 25: ...e for proper operation Replace gas valve is problem persists Hard Lockout When a hard lockout occurs boiler shuts down Flame Out of Sequence If flame is detected in pre purge Control goes to Flame Out of Sequence Before trial and is reported The control gives a flame 10 seconds to disappear If flame goes away control resumes heating cycle from the beginning If it doesn t is cleared and is reported...

Page 26: ...y tubes of air b If no gas flow check the following 24 volts across PV and MV PV at gas valve if voltage ok replace defective gas valve Check for break in wiring harness to gas valve 24 volts across control connector P5 2 and P5 5 if no voltage at control replace defective control 3 Spark does Not Stop When Pilot Lights If the spark does not stop when the pilot lights check the following Loose con...

Page 27: ...el are not causing the open limit IQ Option Panel Display Shows ERR Display Status Boiler Control Action s Err 1 Low Input Voltage AC voltage is too low Err 2 card IQ Option Card Type Change without Re Learn Whenever a new IQ Option Card is first installed into the IQ Option Panel the IQ Option Panel automatically Learns the card This means it detects the specific card and lists it as a card numbe...

Page 28: ...102678 01 3 102678 01 4 102678 01 5 102678 01 6 102678 01 7 102678 01 8 102678 01 Blocked Vent Switch not shown 80160157 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 ...

Page 29: ...2705 06 102705 07 102705 08 102705 09 2E Burner Access Panel 102707 03 102707 04 102707 05 102707 06 102707 07 102707 08 102707 09 2F Base Gasket Kit 6206002 2G Base Side Insulation 2 72007001 2H Base Rear Insulation 72007031 72007041 72007051 72007061 72007071 72007081 72007091 2J Base Front Insulation 72007032 72007042 72007052 72007062 72007072 72007082 72007092 2K Base Leg Assembly 4 6186001 2...

Page 30: ...fold 82207031 82207041 82207051 82207061 N A Gas Manifold N A 82207071 82207081 82207091 3C Burner Orifices Natural Gas 47 4 822710 6 822710 8 822710 10 822710 12 822710 14 822710 16 822710 Burner Orifices LP Gas 1 20mm 4 822792 6 822792 8 822792 10 822792 12 822792 14 822792 16 822792 3D Pilot Burner 100147 01 3E Pilot Assembly Natural Gas 8236163 Pilot Assembly LP Gas 8236164 3F Main Burner 3 10...

Page 31: ...Key No Description Quantity Part Number ES23 ES24 ES25 ES26 ES27 ES28 ES29 4A Control 103660 01 4B IQ Option Panel 102291 01 4C Transformer 102516 01 4D Temperature Sensor 102411 01 Temperature Sensor Spring Clip not shown 102422 01 ...

Page 32: ...565 04 102565 05 102565 06 102565 07 102565 08 102565 09 5E Jacket Top Panel 102568 03 102568 04 102568 05 102568 06 102568 07 102568 08 102568 09 5F Jacket Front Door 102576 03 102576 04 103717 05 103717 06 103717 07 103717 08 103717 09 5G Jacket Rear Discharge 102549 03 102549 04 102549 05 102549 06 102549 07 102549 08 102549 09 5H Jacket Poly Front Cover 102600 03 102600 04 102600 05 102600 06 ...

Page 33: ...anifold 80607001 6B Temperature Pressure Gauge 100282 01 6C 30 PSI Relief Valve 81660363 6D Drain Valve 102802 01 6E Vent Damper 102284 01 102284 02 102284 03 102284 04 102284 05 Circulator not shown Taco 007 2 8056170 Grundfos UP 15 102805 02 B G NRF 22 8056174 Grundfos Alpha Available through Grundfos spare parts service ...

Page 34: ...34 Internal Wiring Figure IW 1 Wiring Diagram ...

Page 35: ...35 Internal Wiring continued Figure IW 2 Wiring Schematic ...

Page 36: ...36 Figure IW 3 Multiple Zone System with Zone Circulators Internal Wiring continued Figure IW 4 Multiple Zone System with Zone Valves ...

Page 37: ...4 N O COM N C ZONE 4 RELAY DHW CIRCULATOR SUPPLIED BY OTHERS JUMPER 3 4 2 WIRE ZONE VALVE NO END SWITCH 2 WIRE ZONE VALVE NO END SWITCH 1 4 WIRE ZONE VALVE POWER OPEN SELF CLOSING JUMPER 3 4 PRIORITY ZONE FUSE 3 AMP MAX 24V TRANSFORMER L1 POWER SUPPLY 120 60 1 L2 DHW AQUASTAT L4006 L4080 SUPPLIED BY OTHERS DOMESTIC HOT WATER PRIORITY IS SELECTED USING ZONE PANEL SWITCH SYSTEM CIRCULATOR SUPPLIED B...

Page 38: ...oom Proceed to Step 6 Is the boiler located in a building of unusually tight construction 5 If the answer to all of the three questions below is yes then you must provide outdoor air to the boiler room Do the walls and ceilings exposed to the outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed or sealed Yes No Are operable windows and do...

Page 39: ...m are not in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliance...

Page 40: ...une allumette ou d une chandelle ou la fumée d une cigarette d un cigare ou d une pipe APPENDIX B Venting continued 6 Une fois qu il a été déterminé selon la méthode indiquée ci dessus que chaque appareil raccordé au système d évacuation est mis à l air libre de façon adéquate Remettre les portes et les fenêtres les ventilateurs les registres de cheminées et les appareils au gaz à leur position or...

Page 41: ...r positive pressure DO NOT REDUCE THE DIAMETER of the vent connector between the boiler and the chimney It must not be smaller than the outlet on the draft hood damper or vent reducer supplied with the boiler Exception National Fuel Gas Code ANSI Z223 1 NFPA 54 and Natural Gas and Propane Installation Code CAN CSA B149 1 allow vent downsizing when vent size determined by their Vent Sizing Tables i...

Page 42: ...nshallbeinaccordancewith VentingofEquipment of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or Venting systems and Air Supply for Appliances of the Natural Gas and Propane Installation Code CAN CSA B149 1 or applicable provisions of the local building codes Clay flue lined masonry chimneys do not meet the venting requirements for this appliance ...

Page 43: ...0 1400 20 92 190 350 730 120 250 465 950 30 73 152 285 590 97 200 375 770 40 63 130 245 500 82 170 320 660 50 56 115 215 440 73 151 285 580 60 50 105 195 400 66 138 260 530 70 46 96 180 370 61 125 240 490 80 43 90 170 350 57 118 220 460 90 40 84 160 320 53 110 205 430 100 38 79 150 305 50 103 195 400 1 CFH of Natural Gas is approximately equal to 1000 BTU hr 1 CFH of LP is approximately equal to 2...

Page 44: ... the boiler and provide many years of comfort to the building occupants Be sure to protect the boiler from the following problems 1 Corrosion 1 Comply with the boiler s specific water quality requirements See the Specifications Section of this manual 2 Pressurize the system above the highest net positive suction head NPSH required for each circulator and ensure positive pressure at the uppermost p...

Page 45: ...1 Do not over pump Adhere to the design flow requirements for each zone 2 Adhere to the boiler s specific minimum return water and supply water temperature requirements Install a boiler bypass system bypass or primary secondary loop when needed to maintain water temperatures and flows within the specified limits 3 Do not allow chilled water to enter the boilerduringtheheatingcycle orheated water t...

Page 46: ... 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 ...

Page 47: ...47 APPENDIX D System Piping continued Figure D W3 Recommended Water Piping for Circulator Zoned Heating Systems ...

Page 48: ...convectors in the loop are purged of air 10 Close the opened zone valve or shut off valve for the zone being purged of air 11 Open the zone valve or shut off valve for the next zone to be purged Repeat the previous steps until all zones have been purged At completion open all zone valves or shut off valves 12 Close hose bib continue filling the system until the pressure gauge reads 12 psi Close fi...

Page 49: ...at the rate of 4 for each additional 1000 ft 300 m Boiler Model Input Mbh 0 2000 ft 0 600 m 2000 4500 ft 600 1350 m 5 000 ft 1500 m ES23 70 0 63 0 61 6 ES24 105 0 94 5 92 4 ES25 140 0 126 0 123 2 ES26 175 0 157 5 154 0 ES27 210 0 189 0 184 8 ES28 245 0 220 5 215 6 ES29 280 0 252 0 246 4 Check gas input rate to boiler Do not exceed input rate shown on rating label or reduced input required for elev...

Page 50: ...r alternate main burner orifices if outlet pressure is less than 3 2 inches water column or greater than 3 8 inches water column Provide current main burner orifice size outlet gas pressure and measured input rate 5 Recheck Main Burner Flame Leak Test Gas Piping The boiler and its gas connections must be leak tested and leak free before placing boiler in operation For leak testing over psig 3 5 kP...

Page 51: ...e required CO2 or O2 specified for the boiler If CO2 O2 or CO fall outside of the range specified for the boiler review the installation and startup instructions and make any necessary adjustments to the boiler or associated venting or piping systems i Note the gross flue gas temperature for future reference Significant changes in flue gas temperature can indicate changes in the boiler s operating...

Page 52: ...tion of the burners Boiler Fault In the event the boiler fails to start the control provides status information to help determine Status Codes displayed in STA Mode Status STA Description Standby Burner off Circulator off 1 No call for heat detected Circulator Pre purge burner off circulator on 1 Either condition is true a Call for heat detected and boiler temperature higher than operating setpoin...

Page 53: ...r Recognized and tested as part of a complete system Communicate with other EnviraCom enabled components to provide a complete system solution to maximize comfort and energy efficiency IQ Option Panel P N 102291 01 The heart of IQ Control System is the Intelligent Hydronic Control The control replaces the traditional separate ignition control primary boiler aquastat as well as the fan and circulat...

Page 54: ...oint The Operating Setpoint is set to the DHW Setpoint when the Control or Outdoor Reset Option Card DHW input is energized This setpoint is set equal to the Indirect Water Heater manufacturer s recommended water temperature High Boiler Water Temperature The High Boiler Water Temperature also known as the Boiler Water Design Temperature setpoint is set to the lowest boiler water temperature that w...

Page 55: ...ts the reset curve to save energy while the home is in a reduced room temperature mode Honeywell VisionPro IAQ Setback Thermostat Honeywell P N TH942lc1004 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 ES2 Boiler The Display Kit communicates with the control and all installed IQ Option Cards All boiler settings stat...

Page 56: ...pipe fittings are required 102717 01 Aquastat IQ Option Card 130 220 Deg F 15 Deg F Adjustable Differential Auto Reset for use with Option Control Panel Temperature Sensor with 36 inch lead Well Sensor Clip Instructions Unit Pack Additional pipe fittings are required 102292 01 Aquastat IQ Option Card 130 220 Deg F Manual Reset for use with IQ Option Panel less well Less Sensor 102293 01 Aquastat I...

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Page 60: ...60 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net ...