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  5. Installation, Operating And Service Instructions

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

Manual is about: ENHANCED SERIES 2 Gas - Fired Boiler

Summary of ES2

  • Page 1

    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 ...

  • Page 2

    2 follow all instructions and warnings printed in this manual and posted on the boiler. Inspect the boiler annually. To keep your boiler safe and efficient, have a service technician follow the service checklist near the end of this manual. If you are not qualified to install or service boilers, do ...

  • Page 3

    3 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 ve...

  • Page 4

    4 congratulations on your purchase of a new es2 boiler—designed and constructed to provide you with years of reliable service. • cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger. • iq control™ system– the most advanced and easiest to use control ava...

  • Page 5

    5 es2 series boiler model input (mbh) doe heating capacity (mbh) net ahri rating, water (mbh) (1) afue (%) es23 70 59 51 85 es24 105 89 77 85 es25 140 119 103 85 es26 175 149 130 85 es27 210 178 155 85 es28 245 208 181 85 es29 280 238 207 85 ratings specifications boiler model depth width height sup...

  • Page 6

    6 figure s-1: minimum clearances to combustible 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.

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    7 installation: 1. Unpack the crate ............................................................................................. 8 2. Position the boiler ............................................................................................ 9 3. Provide combustion air ...........................

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    8 the boiler is top-heavy. Do not allow it to tip over. 1. Remove the sleeve. 2. Remove the 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 boil...

  • Page 9

    9 2. Position the boiler warnings 1. Slide the boiler into desired location. 2. Meet the minimum clearances to combustible construction per the specification section of this manual. 3. Allow 24" service clearance in front and on the left side of the boiler. Observe minimum clearances to combustible ...

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    10 3. Provide combustion air insufficient combustion air supply may result in the production and release of deadly carbon monoxide (co) into the home which can cause severe personal injury or death. Provide combustion and ventilation air in accordance with the section "air for combustion and ventila...

  • Page 11

    11 4-a damper must be open when the main burner is firing. 4-b 4. Connect venting (continued) 5. Connect gas piping size gas piping according to appendix c – gas piping shut off gas supply before servicing the boiler. All gas piping must be gas tight. Use gas rated thread compound on all threaded jo...

  • Page 12

    12 6. Connect boiler water piping 4. Screw the relief valve into manifold tapping “rv”. I this installation is not complete until the relief valve is installed. Pipe the relief valve discharge to a location where it will not harm people or damage property. The relief valve may discharge scalding hot...

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    13 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. Protect e...

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    14 using intelligent hydronic control display 8. Program the controls viewing the operating mode options in operating mode the user may view (but not change) boiler operating status, settings and troubleshooting information. To view control display information: 1 . Press and release the “ i ” key on...

  • Page 15

    15 unit display or sample display 1 sec 1 sec 1 sec please note that in operating mode to hold the display on the value the user can press and hold either the up ñ or down ò keys and the value will be continuously shown. This may be helpful in watching a value “live”. Changing the adjustable paramet...

  • Page 16

    16 circulator pre-purge time has a factory setting of 2 minutes and is field adjustable between 2 and 20 minutes. When reset card is installed, pre-purge time may be adjusted down to zero (0) minutes. Refer to table 8a. 8. Program the controls (continued) 5. Start temperature (st_) amount of “heat a...

  • Page 17

    17 8. Program the controls (continued) b. When dh_ is set equal to second heating zone (tt2) when there is no iwh the “dhw circulator” output may be configured to control a second heating zone. This is particularly helpful when the home uses only two heating zones. The control replaces the need for ...

  • Page 18

    18 10-b 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. F...

  • Page 19

    19 12. Return high limit to the desired setting (see "programming high limit" in section 8). 13. Check draft. See appendix g – checking draft and combustion. Q no spillage observed. 14. Check combustion in the vent stack and record results in the spaces provided below. _____ co 2 (less than 7%) ____...

  • Page 20

    20 am-1 equipment you will need: q soft bristle brush q bristle flue brush q vacuum with brush attachment perform these tasks each year: 1. Clean low water cutoff probe (if applicable). Flush float-type low water cutoff (if applicable). 2. Inspect vent for obstruction and signs of condensation, dist...

  • Page 21

    21 annual maintenance checklist (continued) operating instructions, vr8204 and vr8304 gas valves am-2.

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    22 troubleshooting before troubleshooting the following pages contain trouble shooting tables for use in diagnosing control problems. When using these tables the following should be kept in mind: 1. This information is only meant to be used by a professional heating technician as an aid in diagnosin...

  • Page 23

    23 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 displa...

  • Page 24

    24 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 / status recommended corrective action sta1 standby burner off circulator off the boiler has ...

  • Page 25

    25 troubleshooting (continued) 6. Circulator is on, damper is open but boiler fails to start display / status description sta 10 retry / recycle delay 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 agai...

  • Page 26

    26 troubleshooting (continued) display / status recommended corrective action sta 10 retry / recycle delay sta 13 soft lockout 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 ...

  • Page 27

    27 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: if iq option panel dis...

  • Page 28

    28 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 103860-08 102554-09 1d flue baffl...

  • Page 29

    29 repair parts list (continued) key no. Description [quantity] part number es23 es24 es25 es26 es27 es28 es29 2a base wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 2b base tray 102543-03 102543-04 102543-05 102543-06 102543-07 102543-08 102543-09 2c burner tray assembly 618...

  • Page 30

    30 repair parts list (continued) key no. Description [quantity] part number es23 es24 es25 es26 es27 es28 es29 3a gas valve (natural gas), honeywell vr8204p1171 81660282 n/a gas valve (natural gas), honeywell vr8304p4496 n/a 81660283 gas valve (lp gas), honeywell vr8204c3015 81660146 n/a gas valve (...

  • Page 31

    31 repair parts list (continued) 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

    32 repair parts list (continued) key no. Description [quantity] part number es23 es24 es25 es26 es27 es28 es29 5a jacket left side panel 102566-01 5b jacket right side panel 102567-01 5c jacket rear panel 102569-03 102569-04 102569-05 102569-06 102569-07 102569-08 102569-09 5d jacket vestibule panel...

  • Page 33

    33 repair parts list (continued) key no. Description [quantity] part number es23 es24 es25 es26 es27 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 102284-04 102...

  • Page 34

    34 internal wiring figure iw-1: wiring diagram.

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    35 internal wiring (continued) figure iw-2: wiring schematic.

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    36 figure iw-3: multiple zone system with zone circulators internal wiring (continued) figure iw-4: multiple zone system with zone valves.

  • Page 37

    37 figure iw-5: multiple zone system with zone circulator panel internal wiring (continued) t stat 1 valve 1 t stat 2 valve 2 t stat 3 off on zone 4 priority taco zvc 404 (or eqiv.) four zone zone valve control with optional priority thermostat boiler jacket panel 1 2 3 t t 1 1 4 2 3 5 6 7 8 2 3 lin...

  • Page 38

    38 appendix a – combustion air provide enough air to ventilate the boiler room, dilute the flue gases, and sustain combustion. Ignition failure, overheating, fire, carbon monoxide, and spillage of flue gases may result from poor air supply. If the boiler is a direct vent boiler and exchanges all com...

  • Page 39

    39 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. I install this boiler according to this manual and the national fuel gas code, ansi z223.1/nf...

  • Page 40

    40 au moment du retrait d’une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’evacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas: (1) sceller toutes les ouv...

  • Page 41

    41 appendix b1 – atmospheric venting figure b-1: typical atmospheric vent installation general warnings for atmospheric venting systems use atmospheric venting only with boilers approved for atmospheric venting as noted in the specifications section of this manual. Inspect existing chimney for obstr...

  • Page 42

    42 n’Évacuez les produits de la combustion du gaz dans l’atmosphÈre que dans le cas de chaudières approuvées pour cela comme le stipule la section spécifications de ce manuel. VÉrifier si la cheminÉe existante n’est pas obstruée ou détériorée et la réparer ou la chemiser avant de mettre la chaudière...

  • Page 43

    43 appendix c – gas piping assure gas piping is leak free and of proper size and type for the connected load. Shut off main gas supply prior to installing or servicing boiler gas piping. 1. Determine the boiler’s maximum gas demand and minimum gas supply pressure (printed on the boiler’s rating labe...

  • Page 44

    44 5. Bond all above-ground gas piping to a grounding electrode and ensure the piping is electrically continuous. Do not use gas piping as a grounding electrode. Refer to national electrical code, nfpa 70. 6. Install sediment trap, ground-joint union and manual shut-off valve upstream of boiler gas ...

  • Page 45

    45 3. Overpressure (1) install a properly sized expansion tank. (2) do not exceed the boiler’s specific requirements for maximum allowable working pressure. (3) do not plug or block the relief valve. 4. Freezing (1) run all portions of the system piping inside a heated space unless the system is pro...

  • Page 46

    46 appendix d – system piping (continued) figure d-w2: recommended w ater piping for zone v alve zoned h eating systems 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...

  • Page 47

    47 appendix d – system piping (continued) figure d-w3: recommended w ater piping for circulator zoned h eating systems.

  • Page 48

    48 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 figures in appendix d. Remove air from system when filling. 1. Close full port ball valve ...

  • Page 49

    49 appendix f – adjusting gas input rate check manifold pressure: 1. Note the rated manifold gas pressure listed on the boiler’s rating label. 2. Connect manometer to manifold pressure tapping on gas valve (figure f-1). 3. Light main burners by adjusting thermostat to highest setting. 4. Gas valve h...

  • Page 50

    50 appendix g – checking draft and combustion check draft (gas boilers with draft hoods) 1. Insofar as is practical, close all doors and windows in the building. 2. Turn on all appliances not connected to the same venting system as the boiler being checked. 3. Turn on all exhaust fans (such as range...

  • Page 51

    51 appendix h – operation boiler sequence of operation normal operation 1. The es2 boilers are equipped with an intelligent hydronic control (control). This control replaces the traditional separate ignition control, high limit switch and circulator relay and adds energy saving thermal purge feature...

  • Page 52

    52 appendix i – iq control system iq control system overview the “iq control system” consists of a control and an iq option panel with optional “plug in” cards: • fully integrates both factory and field installed components, simplifying installation and troubleshooting. • efficiently operates the en...

  • Page 53

    53 appendix i – iq control system (continued) iq outdoor reset option card kit: p/n 102723-01 installing the iq outdoor reset option card is the simplest way to maximize the efficiency of any es2 boiler. The iq outdoor reset card is a microprocessor- based control that regulates the water temperatur...

  • Page 54

    54 appendix i – iq control system (continued) iq high limit option cards add auxiliary temperature limit-rated controls to es2 boilers. High limit option cards plug into the iq option panel and connect to a system-mounted probe with a single molex connection. Iq high limit option cards feature an ad...

  • Page 55

    55 appendix i – iq control system (continued) part number item description 102723-01 outside reset iq option card, domestic hot water priority, for use with option control panel, with outside air temperature sensor with 60 inch lead, instructions, unit pack. No additional pipe fittings required. 102...

  • Page 56

    56 u.S. Boiler company, inc. P.O. Box 3020 lancaster, pa 17604 1-888-432-8887 www.Usboiler.Net.