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Burnham ES2, Installation & Service Instructions Manual

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Burnham ES2 Installation & Service Instructions Manual Download Page 21

21

Key 

No.

Description

[Quantity] Part Number 

ES23

ES24

ES25

ES26

ES27

ES28

ES29

1A

Block Assembly

102287-03

102287-04

102287-05 102287-06 102287-07 102287-08 102287-09

1B

Canopy Gasket Kit

6206001

1C

Canopy Assembly

102554-03

102554-04

102554-05 102554-06 102554-07 102554-08 102554-09

1D

Flue Baffle

[2]

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

Summary of Contents for ES2

Page 1: ...c g n i t a e h r u o y l l a c r e l i o b o t s r i a p e r r o e c i v r e s r o F l e b a L g n i t a R n o n w o h s s a r e b m u N l a i r e S d n a r e b m u N l e d o M r e l i o B e d i v o r p r e l i o b r e b m u N l e d o M r e l i o B 2 S E r e b m u N l a i r e S r e l i o B e t a D n o i t a l l a t s n I r o t c a r t n o C g n i t a e H r e b m u N e n o h P s s e r d d A INSTAL...

Page 2: ...R 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...

Page 3: ...mper w Carton 4 Damper ES23 102284 01 5 Damper ES24 102284 02 6 Damper ES25 ES26 102284 03 7 Damper ES27 ES28 102284 04 8 Damper ES29 102284 05 3 q Circulator Gasket Kit Taco 007 2 8056170 Grundfos UP 15 8056173 B G NRF 22 8056174 4 q Miscellaneous Parts Bag 102627 01 q Temperature Pressure Gage NPT 100282 01 q Circulator Mounting Hardware Kit 1 1 4 NPT 6056007 q Circulator Wiring Harness 6130701 ...

Page 4: ... 41 1 1 7 ES28 33 27 41 1 1 7 ES29 33 30 41 1 1 8 Dimensions and Connections Electrical Requirements 120VAC 60 Hz 1 ph 15A Boiler Model Allowable Supply Water Temperature F Minimum Return 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 ...

Page 5: ... Figure S 1 Minimum Clearances to Combustibles and Closet Dimensions SPECIFICATIONS continued ...

Page 6: ... Check for gas and water leaks 15 10 Perform startup checks and adjustments 16 Annual Maintenance Checklist 17 Troubleshooting 18 Repair Parts List 21 Internal Wiring 27 Appendices A Combustion Air 32 B Venting 33 C Gas Piping 36 D System Piping 37 E Filling the System and Checking for Leaks 43 F Adjusting Gas Input Rate 44 G Checking Draft and Combustion 46 H IQ Control System 47 Warranty Back Co...

Page 7: ...ction per the Specification Section of this manual OBSERVE MINIMUM CLEARANCES to combustible walls and ceilings to avoid potential fire hazard DO NOT INSTALL ON CARPET This may cause a fire INSTALLING THE BOILER NEAR A SOURCE OF FLAMMABLE LIQUIDS or gases may cause fire or explosion CLEAN BURNERS DAILY if operating the boiler in a dusty environment PROTECT IGNITION SYSTEM COMPONENTS from sources o...

Page 8: ... Category I appliances If venting this appliance into a masonry chimney the chimney must be lined with a listed chimney lining system DAMPER MUST BE OPEN when the main burner is firing 4 b i e Type B gas vent or flexible metal as required by NFPA 54 and applicable local codes Clay flue lined masonry chimneys do not meet the venting requirements for this appliance 2 Attach the vent damper with thre...

Page 9: ... Diameter in 4 5 6 6 7 7 8 Vent Height ft With B Vent double wall Vent Connector 6 0 0 6 0 4 0 2 8 8 8 8 2 8 2 8 10 10 10 10 10 10 10 10 15 15 15 15 15 15 15 15 20 20 20 20 20 20 20 20 30 20 30 30 30 30 30 30 50 20 30 30 30 30 30 30 100 20 30 30 30 50 50 50 Table 4 1 ES2 Vent Connector Horizontal Length Restrictions ft ...

Page 10: ...AS PIPING MUST BE GAS TIGHT Use gas rated thread compound on all threaded joints to avoid leaks which may result in fire or explosion 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 1 Remove boiler door locate gas valve and remove plastic shipping plug 2 T...

Page 11: ...onnect Boiler Water Piping continued 9 See Figure 6b for suggested near boiler piping of IQ Options 6 b Item Description Burnham Part Number 1 1 x 1 x Tee 806601021 2 Immersion Well NPT 80160456 3 1 x 6 Nipple 806600029 4 1 Tee 806601030 5 1 x Bushing 806600504 6 LWCO Sensor NPT 102305 01 7 1 x 3 Nipple 806600005 8 1 Elbow 806601528 ...

Page 12: ...er Figure 7 a 2 Install a 120V disconnect near the boiler 3 Connect the 120V wiring from the disconnect to the boiler s white neutral black hot and green ground labeled 120VAC Power supply Do not reverse polarity 4 Connect the 120V wiring from the circulator to the white neutral yellow hot wires marked circulator WIRE AN ADDITIONAL SAFETY LIMIT such as a low water cutoff or temperature limit devic...

Page 13: ...ator running 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 19 Waiting for Damper to Close 20 Damper Failure to Open 21 Damper Failure to Close For example when the I key is pressed on the IQ Boiler Control until bt is displayed it will then...

Page 14: ...imit Setpoint of 180 F The boiler turns off when the supply water temperature is above this value The High Limit setpoint is adjustable between 130 and 220 F The Operating Setpoint SP will equal the High Limit Setpoint unless an IQ 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 energ...

Page 15: ...itor 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 8 Program the Controls continued with graphic and help information screens The LCD Display Kit includes a mounting bracket and wiring harness to allow mounting in the ES2 plastic hood above the front doo...

Page 16: ...an 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 thermostat to minimum setting q Boiler shuts off 9 Adjust zone thermostat to maximum setting 10 Observe temperature gage as boiler heats 11 Adjust the high limit setting to its minimum level see Programming High Limit in Section 8 q Boile...

Page 17: ...1 Clean low water cutoff probe 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 3 Remove blocked vent switch and canopy 4 Examine all flue passageways Using bristle flue brush and vacuum remove any soot or obst...

Page 18: ...t is corrected and the one hour time delay is completed Boiler can be restarted sooner than the time delay by using Adjustment Mode function and manually resetting boiler see Adjustment Mode instructions 14 Hard Lockout When a hard lockout occurs boiler shuts down Boiler will NOT automatically restart once the condition that caused the lockout is corrected It will be necessary to go to Adjustment ...

Page 19: ... Atmospheric Damper End Switch failed to open end switch contacts stuck closed Err 57 Flame Rod Shorted to Burner Ground Flame Rod shorted to burner ground this can result from excessive flue gas condensation Err 58 AC Line Frequency Error AC Signal is too noisy or frequency is incorrect Err 59 Line Voltage Error AC voltage out of specification high or low Err 60 Thermostat Input Higher than Thres...

Page 20: ...ther card slot and reinstall card If problem persists replace card Err 5 Limit Output OFF in ON State Check limit string wiring replace the IQ Option Panel Err 6 Incorrect Wiring Check boiler wiring Err 7 Limit Output ON in OFF State Check limit string wiring replace the IQ Option Panel Err 8 8 Internal IQ Option Panel Error Replace the IQ Option Panel If IQ Option Panel Display Shows OL The OL ca...

Page 21: ...287 05 102287 06 102287 07 102287 08 102287 09 1B Canopy Gasket Kit 6206001 1C Canopy Assembly 102554 03 102554 04 102554 05 102554 06 102554 07 102554 08 102554 09 1D Flue Baffle 2 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 ...

Page 22: ...807071 61807081 61807091 2D Base Front Panel 71807035 71807045 71807055 71807065 71807075 71807085 71807095 2E Burner Access Panel 71807036 71807046 71807056 71807066 71807076 71807086 71807096 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 72007...

Page 23: ...160 3B Gas Manifold 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 102592 01 Pilot Assembly LP Gas 102593 01 ...

Page 24: ...Parts LIST continued Key No Description Quantity Part Number ES23 ES24 ES25 ES26 ES27 ES28 ES29 4A IQ Boiler Control 102289 01 4B IQ Option Panel 102291 01 4C Transformer 102516 01 4D Temperature Sensor 102411 01 ...

Page 25: ...02565 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 102576 05 102576 06 102576 07 102576 08 102576 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 102600 07 102600 0...

Page 26: ...Supply Water Manifold 80607001 6B Temperature Pressure Gauge 100282 01 6C Circulator Wiring Harness 6130701 6D 30 PSI Relief Valve 81660363 6E Drain Valve 806603012 6F Vent Damper 102284 01 102284 02 102284 03 102284 04 102284 05 Circulator not shown Taco 007 2 8056170 Grundfos UP 15 8056173 B G NRF 22 8056174 ...

Page 27: ...27 Internal Wiring Figure IW 1 Wiring Diagram ...

Page 28: ...28 Internal Wiring continued Figure IW 2 Wiring Schematic ...

Page 29: ...29 Figure IW 3 Single Zone System with Domestic Hot Water Tank Figure IW 4 Multiple Zone System with Zone Circulators Internal Wiring continued ...

Page 30: ...30 Figure IW 5 Multiple Zone System with Zone Valves Figure IW 6 Multiple Zone System with Zone Circulator Panel Internal Wiring continued ...

Page 31: ...HERS 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 BY OTHERS WIRING USED WHEN DOMESTIC HOT WATER PRIORITY IS...

Page 32: ... 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 gasket or sealed Yes No Are operable windows and doors weatherstripped Yes...

Page 33: ...sually 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 Resize the common venting system to approach the minimum size as determined using the National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 1 Installation Codes 4 Check the draft of each remaining ...

Page 34: ...not be vented into the same chimney space as this boiler 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 drafthood damper or vent reducer supplied with the boiler UNLISTED VENT DAMPERS AND OBSTRUCTIONS in the vent pipe are prohibited THE VENT DAMPER supplied with the boiler shall not be used to block the vent of any ...

Page 35: ...35 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 36: ...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 37: ...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 problems 1 Corrosion 1 Comply with the boiler s specific water quality requirements See the Specifications Section of thi...

Page 38: ...or primary secondary loop when needed to avoid returning large volumes of cold water directly to a hot boiler 7 Condensation 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...

Page 39: ...39 Figure D 0 Piping Schematic Symbols APPENDIX D System Piping continued ...

Page 40: ...40 Figure D W1 Water Boiler Series Loop APPENDIX D System Piping continued Figure D W2 Water Boiler Two or More Zones ...

Page 41: ...41 Figure D W3 Water Boiler Tankless Coil Two or More Zones APPENDIX D System Piping continued Figure D W4 Water Boiler Indirect Water Heater Two or More Zones ...

Page 42: ...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: ...convector and repeat procedure until all 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...

Page 44: ... revolution on a residential gas meter 8 Determine gas flow rate in Cubic Feet per Hour based on elapsed time for two revolutions Example 70 Seconds for 2 Revolutions 102 8 Cu Ft 9 When the clocked time falls between two table values Table F 1 add the table values shown above and below your clocked reading and divide by 2 Example 68 Seconds for 2 Revolutions 110 7 102 8 2 106 7 Cu Ft Hr 10 Obtain ...

Page 45: ...F Adjusting Gas Input Rate continued 15 Recheck Main Burner Flame 16 Return other gas fired appliances to previous condition of use LP Propane Gas Boilers 1 Follow the procedure for gas boilers except 2 Adjust tank regulator for gas valve inlet pressure of 13 5 inches w c or less but not less than 11 5 inches w c 3 Gas valve has step opening regulator which initially opens to 1 4 to 2 5 inches w c...

Page 46: ...iler at its rated high fire input 4 With the analyzer check the CO2 or O2 CO and temperature of the flue gases exiting the boiler 5 For two stage or modulating boilers also check the CO2 or O2 CO and temperature of the flue gases at low fire 6 Confirm that the measured CO2 or O2 matches the required CO2 or O2 specified for the boiler 7 For oil boilers also take a smoke measurement of the flue gase...

Page 47: ...al connections with no screws required along with the power and interconnection wiring into the IQ Boiler System Only wiring from field installed sensors is required The IQ Option Panel includes a dedicated digital readout that provides option card status information diagnostics and setup functions when necessary Ensures adequate heat and supply of domestic hot water UL CSA Listed or Recognized an...

Page 48: ...tomatic or manual reset models Automatic reset versions automatically reset when temperature return to safe levels Manual reset 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...

Page 49: ...play 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 to the IQ Boiler Control and alerts the home owner of a boiler control faults Connected thermostats provide a red LED and display the IQ Boiler Control or IQ Option Card Error Codes A home owner is alerted to a problem even...

Page 50: ...Aquastat IQ Option Card 130 220 Deg F Manual Reset for use with IQ Option Panel less well Less Sensor 102293 01 Aquastat IQ Option Card 130 220 Deg F 15 Deg F Adjustable Differential Auto Reset for use with IQ Option Panel less Well less Sensor 102295 01 Limit Rated Temperature Sensor 36 inch length 102296 01 Limit Rated Temperature Sensor 48 inch length 102728 01 IQ LCD Display Boiler Exterior Mo...

Page 51: ...51 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 52: ...the cost of removing and reinstalling the alleged defective part or its replacement and all labor and material connected therewith and transportation to and from U S Boiler Company Inc b Components that are part of the heating system but were not furnished by U S Boiler Company Inc as part of the residential boiler c Improper burner adjustment control settings care or maintenance d This warranty c...

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