U.S. Boiler Company ES2 Installation, Operating And Service Instructions Download

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103780-05 - 8/14

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

ES2

™

ENHANCED SERIES 2

Gas - Fired 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

Summary of Contents for ES2

Page 1: ...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...

Page 2: ...ty 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 BL...

Page 3: ...sign heat load or if using domestic hot water priority the peak hot water load whichever is larger A grossly oversized boiler will cycle excessively and this will lead to premature failure of the boil...

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 1037...

Page 5: ...r 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...

Page 6: ...mbustible 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...

Page 7: ...4 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...

Page 8: ...e 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 boi...

Page 9: ...on 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 Leve...

Page 10: ...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...

Page 11: ...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 s...

Page 12: ...n 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 pipi...

Page 13: ...er 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...

Page 14: ...r 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...

Page 15: ...ve 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 R...

Page 16: ...erminal 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 o...

Page 17: ...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 Comp...

Page 18: ...ine 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...

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 entreti...

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...

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

Page 22: ...defective control or component 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...

Page 23: ...licate Zone Alarm Refer to IQ Zone Panel Instructions Err 55 Damper Failed to Open Atmospheric Damper End Switch failed to close end switch contacts stuck open Refer to Troubleshooting Section 5 Err 5...

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 colla...

Page 25: ...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...

Page 26: ...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 co...

Page 27: ...l 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...

Page 28: ...02678 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 Bo...

Page 29: ...705 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...

Page 30: ...old 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 Orif...

Page 31: ...ey 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...

Page 32: ...65 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 05 103...

Page 33: ...27 ES28 ES29 6A Supply Water Manifold 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 1...

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: ...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 Z...

Page 38: ...om 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...

Page 39: ...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 restricti...

Page 40: ...d charge Utiliser la flamme d une allumette ou d une chandelle ou la fum e d une cigarette d un cigare ou d une pipe APPENDIX B Venting continued 6 Une fois qu il a t d termin selon la m thode indiqu...

Page 41: ...into any portion of mechanical draft systems operating under positive pressure DO NOT REDUCE THE DIAMETER of the vent connector between the boiler and the chimney It must not be smaller than the outl...

Page 42: ...ndecemanuel danslecodelocaletleNationalFuelGasCodeouCAN CSAB149 1 Leschemin es en ma onnerie rev tues int rieurement d argile ne respectent pas les exigences d vacuation de cet appareil NE PAS R DUIRE...

Page 43: ...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...

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 requireme...

Page 45: ...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 b...

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 installa...

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

Page 48: ...onvectors 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...

Page 49: ...t screw clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure Figure F 2 Several turns may be required Do not force the adjustment screw Do not exceed the boiler s...

Page 50: ...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 t...

Page 51: ...ion 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 Burne...

Page 52: ...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...

Page 53: ...int 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 recomm...

Page 54: ...s 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 colo...

Page 55: ...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 Cl...

Page 56: ...56 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...

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