Energy Star ESC Installation Operating And Maintenance Istructions Download

Page: 28 / 64

Key

No.

Description

[Quantity] Part Number

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 102588-09

Jacket Top Panel

102586-03 102586-04 102586-05 102586-06 102586-07 102586-08 102586-09

Jacket Front Door

102661-03 102661-04 102661-05 102661-06 102661-07 102661-08 102661-09

Jacket Poly Front Cover

102600-03 102600-04 102600-05 102600-06 102600-07 102600-08 102600-09

Upper Poly Grille

102621-01

Lower Poly Grille

102622-01

Air Intake Collar Assembly

102582-01

102582-02

102582-03

REPAIR PARTS (continued)

Summary of Contents for ESC

Page 1: ...NSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR ESC ENHANCED SEALED COMBUSTION Gas Fired Boiler 102601 02 9 11 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 Boiler Serial Number Installation Date Heating Contractor Phone Number Address 9700609 Price 5...

Page 2: ...ay 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 hot water or steam Do not rely solely on the boiler s temperature and pressure gage when making this judgment USE PROPER PERSONAL PROTECTION EQU...

Page 3: ...l be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 A final inspection by the state or local gas in...

Page 4: ...and thermal shock 1 ESC Boiler 2 Circulator Gasket Kit q Taco 007 2 8056170 q Grundfos UP 15 102805 01 q B G NRF 22 8056174 3 Miscellaneous Parts Carton Cartons Include 1 Safety Relief Valve Set at 30 PSI 1 Pressure Temperature Gauge 1 Water Manifold 1 Circulator Harness 1 Vent Connector 1 Vent Terminal 1 Air Intake Terminal 1 Drain Valve q ESC3 ESC4 P N 102648 01 q ESC5 ESC 6 P N 102648 02 q ESC7...

Page 5: ...1 41 1 1 3 4 ESC7 33 24 41 1 1 3 5 ESC8 33 27 41 1 1 4 5 ESC9 33 30 41 1 1 4 5 Dimensions Weights 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 ESC3 130 220 110 None 1 ESC4 130 220 110 None 1 ESC5 130 220 110 None 1 ESC6 130 220 110 Non...

Page 6: ... Figure S 1 Minimum Clearances to Combustibles SPECIFICATIONS continued ...

Page 7: ...s 14 9 Check for gas and water leaks 16 10 Perform startup checks and adjustments 17 Annual Maintenance Checklist 18 Troubleshooting 19 Repair Parts List 22 Internal Wiring 30 Appendices A Combustion Air 35 B Venting 36 C Gas Piping 46 D System Piping 48 E Filling the System and Checking for Leaks 54 F Adjusting Gas Input Rate 55 G Checking Draft and Combustion 57 H Burnham IQ Control System 58 Bo...

Page 8: ...O 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 of water that may spray drip or rain on them during installation or service 1 a 1 b 1 Slide the boiler into desired location 2 Meet the minimum c...

Page 9: ...endix B Venting Additionally Follow all instructions in Appendix B 2 Direct Vent or B 3 Power Vent 1 For the exhaust attach special Category IV gas vent to the fan outlet using a single sheetmetal screw Figure 4 a 2 Configure the air intake 1 To equip the ESC for outdoor combustion air direct vent attach the 4 a 4 b plastic or metal intake air pipe to the inlet air duct 2 To equip the ESC for indo...

Page 10: ...he final installation should appear as in Figure 4 c 4 For vertical venting follow instructions in Appendix B2 Direct Venting Special Instructions for Stainless Steel Venting Vertical Installations Specifically 1 Install fire stops and wall thimbles 2 Install vent piping and vert terminal 3 Install condensate line 4 Install roof flashing and roof supports 5 The final installation should appear as ...

Page 11: ...street ells are not approved for use as gas piping 3 Pipe from the street elbow through the left jacket panel and complete drip leg as shown Figure 5 a 6 Connect Boiler Water Piping General system piping guidelines are included in Appendix D System Piping Additionally for this particular boiler install piping shown below Figure 6 a 6 a 5 a 1 Apply sealant to all threads 2 Screw the water supply ma...

Page 12: ...Connect Boiler Water Piping continued 8 Screw the supplied drain valve into tapping D 9 See Figure 6b for suggested near boiler piping of IQ Options 6 b Item Description 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 13: ...e of the boiler and open the cover 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 c...

Page 14: ...ng for Pressure Switch to Open 3 Waiting for Pressure Switch to Close 4 Prepurge 6 Spark 7 Flame Proving 8 Running 9 Postpurge 10 Retry Recycle Delay 11 Pressure Switch Failed to Open 12 Pressure Switch Failed to Close 13 Soft Lockout 14 Hard Lockout 15 Waiting for Limit to Close 16 Flame Present Out of Sequence 17 Self Test For example when the I key is pressed on the IQ Boiler Control until bt i...

Page 15: ... 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 energy Re...

Page 16: ...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 with graphic and help information screens The LCD Display Kit includes a mounting bracket and wiring harness to allow mounting in the ESC plastic hood above the front door For installation programming an...

Page 17: ...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 Boiler shuts off when temperature gage reads within 15 F of high limit setting 12 Return high l...

Page 18: ... q Vacuum with brush attachment Perform these tasks each year 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 2 Remove top panel and hood 3 Remove canopy 4 Examine all flue passageways Using bristle flue brush and...

Page 19: ...elay IQ Control will attempt to light the burner again If the burner loses flame during running mode code 8 during the next six recycles IQ Control will progress to a soft lockout 11 Pressure Switch Failed to Open The blower is still off and the pressure switch has not opened at the beginning of the heat cycle An alarm message is sent but the control is not in lockout 12 Pressure Switch Failed to ...

Page 20: ... signaled opened Err 29 Pressure Switch Failed to Close While the blower is on the pressure switch failed to close check wiring check that the blower is running and check pressure switch Err 32 Temperature Sensor Failure Temperature sensor or interface failure open or short connection increased connection resistance dual sensor mismatch or control hardware failure Err 57 Flame Rod Shorted to Burne...

Page 21: ...ersists 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 Internal IQ Option Panel Error Replace the IQ Option Panel Err 8 Limit Output ON in OFF State Check limit string wiring replace the IQ Option Panel Err 9 Hard lockout due to repeated Err 8 Check limit string wiring replace the IQ Option Pane...

Page 22: ... Quantity Part Number ESC3 ESC4 ESC5 ESC6 ESC7 ESC8 ESC9 1A Block Assembly 102287 03 102287 04 102287 05 102287 06 102287 07 102287 08 102287 09 1B Flue Baffle 2 71107002 3 71107002 4 71107002 5 71107002 6 71107002 7 71107002 8 71107002 ...

Page 23: ...anopy 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 2B Canopy Gasket Kit 6206001 2C Fan Gasket 8206085 2D Fan 81161512 Repair Parts continued ...

Page 24: ...807061 61807071 61807081 61807091 3D Base Front Panel 102705 03 102705 04 102705 05 102705 06 102705 07 102705 08 102705 09 3E Burner Access Panel 102707 03 102707 04 102707 05 102707 06 102707 07 102707 08 102707 09 3F Base Gasket Kit 6206002 3G Base Side Insulation 2 72007001 3H Base Rear Insulation 72007031 72007041 72007051 72007061 72007071 72007081 72007091 3J Base Front Insulation 72007032 ...

Page 25: ...60181 4B Gas Manifold 82207031 82207041 82207051 82207061 Gas Manifold 82207071 82207081 82207091 4C Burner Orifices Natural Gas 47 4 822710 6 822710 8 822710 10 822710 12 822710 14 822710 16 822710 Burner Orifices LP Gas 120mm 4 822792 6 822792 8 822792 10 822792 12 822792 14 822792 16 822792 4D Pilot Burner 100147 01 4E Pilot Assembly Natural Gas 102592 01 Pilot Assembly LP Gas 102593 01 4F Main...

Page 26: ... 61807032 61807042 61807052 61807062 61807072 61807082 61807092 5B Air Box Door 71807034 71807044 71807054 71807064 71807074 71807084 71807094 5C Combustion air diffuser N A 71807049 71807059 71807069 71807079 71807089 71807099 5D Pilot Tube Gasket Cover Plate 7096002 5E Pilot Tube Gasket 8206038 5F Window Plug 102202 01 ...

Page 27: ... ESC8 ESC9 6A IQ Boiler Control 102290 01 6B IQ Option Panel 102291 01 6C Transformer 102516 01 6D Temperature Sensor 102411 01 6E Differential Pressure Switch Sea Level 0 4999 80160762 80160761 80160760 80160759 80160760 High Altitude 5000 10 000 80160759 80160763 80160764 80160765 80160764 ...

Page 28: ...02588 04 102588 05 102588 06 102588 07 102588 08 102588 09 7E Jacket Top Panel 102586 03 102586 04 102586 05 102586 06 102586 07 102586 08 102586 09 7F Jacket Front Door 102661 03 102661 04 102661 05 102661 06 102661 07 102661 08 102661 09 7G Jacket Poly Front Cover 102600 03 102600 04 102600 05 102600 06 102600 07 102600 08 102600 09 7H Upper Poly Grille 102621 01 7J Lower Poly Grille 102622 01 7...

Page 29: ...SC8 ESC9 8A Water Manifold 80607001 8B Temperature Pressure Gauge 100282 01 8C Circulator Wiring Harness 6130701 8D Safety Relief Valve 81660363 8E Drain Valve 102802 01 8F Vent Terminal 8110701 8110702 8G Air Intake Terminal Not Shown 6116045 6116044 6116063 8H Vent Connector 8110703 8110704 ...

Page 30: ...30 Internal Wiring Figure IW 1 Wiring Diagram ...

Page 31: ...31 Internal Wiring continued Figure IW 2 Wiring Diagram ...

Page 32: ...32 Figure IW 3 Single Zone System with Domestic Hot Water Tank Figure IW 4 Multiple Zone System with Zone Circulators Internal Wiring continued ...

Page 33: ...33 Figure IW 5 Multiple Zone System with Zone Valves Figure IW 6 Multiple Zone System with Zone Circulator Panel Internal Wiring continued ...

Page 34: ...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 35: ... 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 36: ...steel pipe or by the combustion air pipe in a concentric polypropylene vent system B3 Power Vent Similar to Direct Vent but some or all combustion air is drawn from inside the building May draw air directly from the boiler room without the use of a combustion air pipe If you are removing an existing boiler from a gas vent or chimney that is also used to vent other gas appliances 1 Seal any unused ...

Page 37: ...37 APPENDIX B1 INTENTIONALLY OMITTED ...

Page 38: ... B 2 1 Minimum twelve 12 inches above grade plus normally expected snow accumulation level or seven 7 feet above grade if located adjacent to public walkway Do not install over public walkway where local experience indicates appliance flue gas vapor or condensate creates a nuisance or hazard 2 Minimum three 3 feet above any forced draft combustion air intake located within ten 10 feet 3 Minimum fo...

Page 39: ...ir intake passes through floors ceilings or framed Figure B 2 Approved Terminal Locations walls The fire stop must close the opening between the vent and or air intake pipe and the structure 2 Size roof opening to allow easy insertion of vent and air intake piping to allow proper installation of flashing and storm collar to prevent moisture from entering the structure 3 Use appropriately designed ...

Page 40: ...th is required there are two options 1 Select adjustable length pipe from Table B 1 The pipe adjusts 7 from 12 to 19 Or 2 Cut the non gasketed end of a standard straight length Make a square cut and file the end smooth Table B 1 Vent System and Air Intake System Components Vent System Component Part Number 3 Dia Pipe x 1 Ft 8116296U 4 Dia Pipe x 1 Ft 100176 01 3 Dia Pipe x 3 Ft 8116298U 4 Dia Pipe...

Page 41: ...ft x 2 equiv ft d Vertical drain tee Length ft x 7 equiv ft e Total a b c equiv ft Total a b c d e equiv ft Total cannot exceed 60 equiv ft length Vent and combustion air terminals do not count towards total equiv ft Vent Combustion Air Equivalent Length Work Sheet This sheet is supplied to assist in vent combustion air equivalent length calculating APPENDIX B2 Direct Venting continued Special Ins...

Page 42: ...de wall using screws or nails 3 Maintain 12 separation between vent and intake terminals Where the intake air pipe penetrates the external wall seal the opening with weatherproof sealant Figure B 4 4 To install a vertical snorkel exterior to the building refer to Figure B 5 or B 6 5 An optional concentric adapter kit P N 61106012 is available for 3 4 stainless steel vents to provide a single exter...

Page 43: ...h the boiler 1 Install vent and intake piping per Figures B 6 thru B 8 2 Install the storm collar onto the vent pipe immediately above the flashing 3 Apply Dow Corning Silastic 732 RTV Sealant between the vent pipe and the storm collar to provide a watertight and heat resistant seal 4 Install the vent terminal per the boiler specific instructions in Connect Venting in this manual 5 Install the air...

Page 44: ...Vent Air Intake Piping to maintain minimum vertical X and minimum horizontal Y distance of twelve 12 inches from roof surface Allow additional vertical X distance for expected snow accumulation APPENDIX B2 Direct Venting continued Special Instructions for Stainless Steel Direct Vent continued ...

Page 45: ...45 Figure B 8 Vertical Air Intake Piping for Direct Venting APPENDIX B2 Direct Venting continued Special Instructions for Stainless Steel Direct Vent continued ...

Page 46: ...Pressure Drop 0 5 w c Pressure Drop 1 1 1 1 10 132 278 520 1050 175 360 680 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 ...

Page 47: ...er and its individual shut off valve from the gas supply piping 2 When testing at psig or less isolate boiler from gas supply piping by closing boiler s individual manual shut off valve 3 Locate leaks using approved combustible gas detector or nonflammable non corrosive leak detection solution DO NOT CHECK FOR LEAKS USING OPEN FLAMES such as matches or candles or devices that spark 8 Repair any de...

Page 48: ...If filling the boiler with softened water test regularly the water softener regularly to ensure that brine solution is not entering the boiler s water supply 2 Lime scale 1 Repair leaking pipes fittings and vents to minimize the need to add makeup water 2 Comply with the boiler s specific water quality requirements See the Specifications Section of this manual 3 Comply with the boiler s specific r...

Page 49: ... Fire Install a low water cutoff when the boiler is installed above the level of the lowest radiator and when required by local code i 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 ins...

Page 50: ...50 Figure D 0 Piping Schematic Symbols APPENDIX D System Piping continued ...

Page 51: ...51 Figure D W1 Water Boiler Series Loop APPENDIX D System Piping continued Figure D W2 Water Boiler Two or More Zones ...

Page 52: ...52 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 53: ...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: ...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 55: ...ypically labeled or 1 cubic foot per 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...

Page 56: ...Reinstall gas orifices and main burner Repeat procedure to measure input rate 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...

Page 57: ...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 58: ... the optional Outdoor Air Reset Card is installed in the IQ Option Panel the Operating Setpoint temperature is automatically adjusted according to the outdoor temperature For example as the outdoor temperature increases the Operating Setpoint temperature is reduced from the High Limit Setting to save energy while improving home comfort By better matching boiler heat supply to actual home heat dema...

Page 59: ...Setpoint The Operating Setpoint is set to the DHW Setpoint when the 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 will hea...

Page 60: ...et 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 ESC Boiler The Display Kit communicates with the IQ Boiler Control and all installed IQ Option Cards All boiler settings stat...

Page 61: ...ol Panel Temperature Sensor Well Sensor Clip Instructions Unit Pack 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 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...

Page 62: ...62 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 63: ...63 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 64: ...64 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 717 397 4701 www usboiler burnham com ...

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