1. DL manuals
  2. U.S. Boiler Company
  3. Boiler
  4. ESC
  5. Installation, operating and service instructions

U.S. Boiler Company ESC Installation, operating and service instructions

Manual is about: ENHANCED SEALED COMBUSTION Gas - Fired Boiler

Summary of ESC

  • Page 1

    Installation, operating and service instructions for esc ™ enhanced sealed combustion gas - fired boiler 103788-03 - 9/13 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

    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 special installation requirements for massachusetts a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the side wall exhaust vent termination is less than seven (7) feet above ...

  • Page 5

    5 congratulations on your purchase of a new esc ™ 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 ...

  • Page 6

    6 esc series boiler model input (mbh) heating capacity (mbh) net ahri rating, water (mbh) (1) afue (%) esc3c 60.8 52 45 85.5 esc4c 91.2 78 68 85.4 esc5c 121.6 104 90 85.3 esc6c 152.0 130 113 85.2 esc7c 182.4 156 136 85.0 esc8c 212.8 180 157 84.5 esc9c 243.2 206 179 84.0 (1) net ahri water ratings sh...

  • Page 7

    7 figure s-1: minimum clearances to combustibles specifications (continued).

  • Page 8

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

  • Page 9

    9 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). 1. Unpack the crate 4. Tip the boiler and shimmy it off the skid. 2. Positio...

  • Page 10

    10 3. Provide combustion air insufficient combustion air supply may result in the production and release of deadly carbon monoxide (co) into the home. Provide combustion and ventilation air in accordance with the section "air for combustion and ventilation," of the national fuel gas code, ansi z223....

  • Page 11

    11 4. Connect venting (continued) (3) install vent piping. (4) when configuring the esc for power vent (indoor combustion air) install a 45° vent elbow, pointing downward. (5) install vent terminal and seal around all exterior openings. (6) the final installation should appear as in figure 4-c. 4. F...

  • Page 12

    12 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 joints to avoid leaks, which may result in fire or explosion. Size gas piping, regulators, va...

  • Page 13

    13 6. Connect the system supply to the open end of the manifold "s" using a 1¼” male npt fitting. 7. Screw an installer-supplied 1¼” pipe or nipple into the water return tapping “r”. 8. Screw the supplied drain valve into tapping “d”. 6. Connect boiler water piping (continued) 9. See figure 6b for s...

  • Page 14

    14 7. Connect electrical wiring 7-a 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 j...

  • Page 15

    15 8. Program the controls using intelligent hydronic control display 1 . Press and release the “ i ” key on the iq control to change from one parameter to the next. Each setting will alternately flash between the relevant display code and its corresponding value. Operating mode options sta status b...

  • Page 16

    16 8. Program the controls (continued) 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 parameters to adjust...

  • Page 17

    17 8. Program the controls (continued) 7. Domestic hot water (dhw) terminal function (dh_) the control allows configuration of the dhw circulator output functionality to help the esc integrate into each installation more effectively. The dhw circulator output can be connected to a domestic hot water...

  • Page 18

    18 9. Check for gas and water leaks gas leaks may result in fire or explosion. Water leaks may cause extensive property damage. Refer to appendix e – filling the system and checking for leaks 8. Program the controls (continued) b. When dh_ is set equal to second heating zone (tt2) when there is no i...

  • Page 19

    19 10. Perform startup checks and adjustments 10-b 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 20

    20 figure 10-d: operating instructions 10. Perform startup checks and adjustments (continued).

  • Page 21

    21 annual maintenance checklist important product safety information refractory ceramic fiber product warning: the repair parts list designates parts that contain refractory ceramic fibers (rcf). Rcf has been classified as a possible human carcinogen. When exposed to temperatures about 1805°f, such ...

  • Page 22

    22 label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation failure to maintain the boiler in proper working condition may lead to fire, explosion, personal injury or death, and extensive property damage. Turn off all gas and electric p...

  • Page 23

    23 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 24

    24 troubleshooting (continued) iq boiler control error codes (when "err" is flashing) display status boiler / control action(s) blank boiler and circulator off no 120 vac power at boiler, check breaker and wiring between breaker panel and boiler. Err 2 pressure switch failed to open while the blower...

  • Page 25

    25 troubleshooting (continued) 2. Circulator is on, but boiler is off display / status recommended corrective action sta1 circulator pre-purge burner off circulator on the boiler is warm and circulator is providing residual boiler heat to building: check boiler temperature - the boiler will not star...

  • Page 26

    26 troubleshooting (continued) 5. Circulator is on, blower is on 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 again....

  • Page 27

    27 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 28

    28 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: iq option panel displa...

  • Page 29

    29 repair parts key no. Description [quantity] part number esc3c esc4c esc5c esc6c esc7c esc8c esc9c 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 all e...

  • Page 30

    30 key no. Description [quantity] part number esc3c esc4c esc5c esc6c esc7c esc8c esc9c 2a canopy 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...

  • Page 31

    31 repair parts (continued) key no. Description [quantity] part number esc3c esc4c esc5c esc6c esc7c esc8c esc9c 3a base wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 3b base tray 102543-03 102543-04 102543-05 102543-06 102543-07 102543-08 102543-09 3c burner tray assembly 6...

  • Page 32

    32 repair parts (continued) key no. Description [quantity] part number esc3c esc4c esc5c esc6c esc7c esc8c esc9c 4a 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 33

    33 repair parts (continued) key no. Description [quantity] part number esc3c esc4c esc5c esc6c esc7c esc8c esc9c 5a air box assembly 61807032 61807042 61807052 61807062 61807072 61807082 61807092 5b air box door 71807034 71807044 71807054 71807064 71807074 71807084 71807094 5c combustion air diffuse...

  • Page 34

    34 repair parts (continued) key no. Description [quantity] part number esc3c esc4c esc5c esc6c esc7c esc8c esc9c 6a iq boiler control 103661-01 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...

  • Page 35

    35 key no. Description [quantity] part number esc3c esc4c esc5c esc6c esc7c esc8c esc9c 7a jacket left side panel 102566-01 7b jacket right side panel 102567-01 7c jacket rear panel 102587-03 102587-04 102587-05 102587-06 102587-07 102587-08 102587-09 7d jacket vestibule panel 102588-03 102588-04 10...

  • Page 36

    36 repair parts (continued) key no. Description [quantity] part number esc3c esc4c esc5c esc6c esc7c esc8c esc9c 8a water manifold 80607001 8b temperature/pressure gauge 100282-01 8c circulator wiring harness 6130701 8d 30 psi relief valve 81660363 8e drain valve 102802-01 8f vent terminal 8110701 8...

  • Page 37

    37 internal wiring figure iw-1: wiring diagram.

  • Page 38

    38 internal wiring (continued) figure iw-2: wiring diagram.

  • Page 39

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

  • Page 40

    40 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 41

    41 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 42

    42 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 43

    43 appendix b2 – direct venting planning a direct vent system 1. Avoid contact with plumbing or electrical wires. 2 . Horizontal vent pipe must maintain a minimum ¼ inch per foot slope down towards boiler. 3. Any condensate forming in the vent will return to the boiler. Provide for a condensate trap...

  • Page 44

    44 however, boiler may be installed with vertical venting and sidewall combustion air inlet or visa versa, if installation conditions do not allow alternate arrangement. 10. If the vent passes through interior spaces in floors above the boiler room, enclose the vent with material having a fire resis...

  • Page 45

    45 special instructions for stainless steel direct vent use stainless steel venting only with boilers approved for use with stainless steel venting as noted in the specifications section of this manual. Al 29-4c ® stainless steel vent systems resist the corrosive effects of high temperature acidic f...

  • Page 46

    46 combustion air (pvc shown) vent (stainless special gas vent) 90° elbow(s) pvc 90° elbow(s) quantity = x 5’ = equiv. Ft. A. Quantity = x 5’ = equiv. Ft. A. 45° elbow(s) pvc 45° elbow(s) quantity = x 2.5’ = equiv. Ft. B. Quantity = x 5’ = equiv. Ft. B straight pipe pvc straight pipe length ft. = x ...

  • Page 47

    47 figure b-4: separate horizontal air intake terminal installation figure b-5: optional separate horizontal vent terminal installation (1) insert the wall thimble from the outside of the wall, and secure the outside flange to the wall using nails or screws. (2) seal any exterior openings in the wal...

  • Page 48

    48 appendix b2 – direct venting (continued) special instructions for stainless steel direct vent (continued) 6. Install the intake air terminal supplied with the boiler onto the outdoor end of the air intake pipe per the instructions in connect venting in this manual. 7. Install the vent terminal su...

  • Page 49

    49 figure b-7: vertical vent/air termination details for stainless steel direct vent extend 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...

  • Page 50

    50 figure b-8: vertical air intake piping for direct venting appendix b2 – direct venting (continued) special instructions for stainless steel direct vent (continued).

  • Page 51

    51 appendix b3 – power venting some direct vent boilers are also approved with use of indoor combustion air. If the boiler you are installing is approved for use with indoor combustion air, install the vent according to the instructions in appendix b2 direct venting, but omit the “optional” indoor a...

  • Page 52

    52 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 4. For materials or conditions other than those listed above...

  • Page 53

    53 appendix d – system piping use proper design and installation practices and observe all local codes when installing system piping. Property damage and injury may result from an improperly piped or designed heating system. I boiler damage caused by flawed system design or operation is excluded fro...

  • Page 54

    54 appendix d – system piping (continued) water boiler, the use of the listed lwco control is permitted when it is installed according to the lwco manufacturer's instructions. 6. Thermal shock (1) do not over-pump. Adhere to the design flow requirements for each zone. (2) install a boiler bypass, sy...

  • Page 55

    55 appendix d – system piping (continued) figure d-2: recommended w ater piping for zone v alve zoned heating systems.

  • Page 56

    56 appendix d – system piping (continued) figure d-3: recommended w ater piping for circulator zoned heating systems.

  • Page 57

    57 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 figure below. Remove air from system when filling. 1. Close full port ball valve located b...

  • Page 58

    58 appendix f – adjusting gas input rate natural gas boilers: 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 se...

  • Page 59

    59 appendix g – checking draft and combustion 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 hoods and bathroom exhausts) to their maxi...

  • Page 60

    60 boiler sequence of operation normal operation 1. The esc boilers are equipped with an intelligent hydronic control (control). This control replaces the traditional separate ignition control, high limit switch, blower relay and circulator relay and adds energy saving thermal purge features. Energy...

  • Page 61

    61 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 62

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

  • Page 63

    63 appendix h – iq control system (continued) iq high limit option cards add auxiliary temperature limit-rated controls to esc 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 64

    64 appendix h – iq control system (continued) optional components sy stem parts list 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, instructions, unit pack 102294-01 outdoor res...