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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
ES2™
ENHANCED SERIES 2
Gas - Fired Boiler
®
As an ENERGY STAR Partner, Burnham Hydronics has determined that this boiler meets the ENERGY
®
STAR guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
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 B
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WARNINGS foR the hoMeo WNeR FOLLOW ALL INSTRUCTIONS and warnings outdoor temperatures are below 32°F, first turn off printed in this manual and posted on the boiler. your home’s main water supply and drain the water from all pipes. INSPECT THE BOILER ANNUALLY. To keep your boiler safe and efficient, have a service technician DO NOT BLOCK AIR FLOW into or around the follow the Service checklist near the end of this boiler. Insufficient air may cause the boiler to manual. produce carbon m
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® Congratulations on your purchase of a new Burnham boiler—designed and constructed to provide you with years of reliable service. • ENERGY STAR™ efficiency – friendly on the environment and your wallet. • Cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger. Ours is made proudly by our foundry in Zanesville, Ohio. • IQ Control™ – the most advanced and easiest to use control available. • System-friendly – built-in protection from condens
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SPECIFICATIONS Ratings ES2 Series Boiler Model Input (MBH) DOE Heating Capacity (MBH) Net I=B=R Rating (MBH) AFUE (%) ES23 70 59 51 85 ES24 105 88 77 85 ES25 140 118 102 85 ES26 175 147 128 85 ES27 210 176 153 85 ES28 245 206 179 85 ES29 280 235 205 85 Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A Dimensions and Connections Boiler Supply NPT Return NPT Vent Gas NPT Relief Valve Drain Depth Width Height Model (inch) (inch) (inch) (inch) NPT (inch) NPT (inch) ES23 33 12¾ 41 1¼ 1¼ 4 ½ ¾ ¾ ES24
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SPeCIfICA tIoNS ( continued) Figure S-1: Minimum Clearances to Combustibles and Closet Dimensions 5
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Boiler Quick-Start Installation: 1. Unpack the crate ............................................................................................. 7 2. Position the boiler ............................................................................................ 7 3. Provide combustion air .................................................................................... 8 4. Connect venting ...........................................................................................
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1. UNPACk THE CRATE 4. Tip the boiler and shimmy it off the skid. 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-a 1-b 2. POSITION THE BOILER WARNINGS OBSERVE MINIMUM CLEARANCES to CLEAN BURNERS DAILY if operating the boiler in combustible walls and ceilings to avoid potential a dusty environme
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3. PROVIDE COMBUSTION AIR Like all fuel-burning appliances, boilers need air to INSUFFICIENT COMBUSTION AIR operate reliably and safely. SUPPLY may result in the production and release of deadly carbon monoxide (CO) into the Provide combustion air using the instructions in home which can cause severe personal injury or Appendix A—Combustion Air. death. 4. CONNECT VENTING (i.e. Type B gas vent or flexible metal) as IMPROPER VENTING may result in required
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4. CoNNeCt VeNtING ( continued) Table 4.1: ES2 Vent Connector - Horizontal Length Restrictions (ft) Model ES23 ES24 ES25 ES26 ES27 ES28 ES29 Input (MBH) 70 105 140 175 210 245 280 Minimum Vent 4 5 6 6 7 7 8 Diameter (in) 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
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5. CONNECT GAS PIPING Size gas piping according to Appendix C – Gas nipples and street ells are not approved for Piping use as gas piping. SHUT OFF GAS SUPPLY before 3. Pipe through the left jacket panel, and servicing the boiler. complete drip leg as shown (Figure 5-a). 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, valves,
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6. CoNNeCt BoILeR W AteR PIPING (continued) 7. Screw an installer-supplied 1¼” pipe or 9. See Figure 6b for suggested near boiler nipple into the water return tapping “R”. piping of IQ Options. 8. Screw the supplied drain valve into tapping “D”. 6-b Item Description Burnham Part Number 1 1¼ x 1¼ x ½ Tee 806601021 2 Immersion Well, ½ NPT 80160456 3 1¼ x 6 Nipple 806600029 4 1¼ Tee 806601030 5 1¼ x ¾ Bushing 806600504 6 LWCO Sensor, ¾ NPT 102305-01 7 1¼ x 3 Nipple 806600005 8 1¼ Elbow 8066015
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. CONNECT ELECTRICAL WIRING 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 EACH BOILER circuit with a properly sized over-current protection device. MAKE ELECTRICAL CONNECTIONS CARE
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8. PROGRAM THE CONTROLS Using IQ Boiler Control Display Viewing the operating Mode options In operating mode the user may view (but not The IQ Boiler Control is located inside the boiler change) boiler operating status, settings and front door, just above the IQ Option Panel (Figure troubleshooting information. To view IQ Boiler 8-a). Control display information: 1. Press and release the “I” key on the IQ Boiler Control to change from one parameter to the next. Each setting will alterna
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8. PRoGRAM the CoNtR oLS ( continued) with a High Limit Setpoint of 180°F. The Unit Display 1 sec 1 sec boiler turns "off" when the supply water 1 sec OR temperature is above this value. The High Sample Limit setpoint is adjustable between 130° Display and 220°F. The Operating Setpoint (SP) will equal the High Limit Setpoint unless an IQ Please note that in operating mode to hold the Outdoor Reset IQ Option Card is installed. display on the value the user can press and hold The
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8. PRoGRAM the CoNtR oLS ( continued) Using the optional LCD Display Kit The LCD Display is an easy to use touch screen with graphic and help information screens. The LCD Display Kit includes a mounting bracket type display that allows a technician to monitor and wiring harness to allow mounting in the ES2 and adjust the IQ Boiler Control and connected IQ Option Cards. All boiler settings, status and plastic hood above the front door. For installation, error codes are displayed in full
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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. Follow the checklist below: 1. Verify that the venting, water piping, gas piping, and electrical systems are properly installed and checked. 2. Apply power to the boiler.
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ANNUAL MAINTENANCE CHECkLIST WARNINGS personal injury or death, and extensive property THE BOILER CONTAINS REFRACTORY damage. CERAMIC FIBER, a possible human carcinogen Use a NIOSH approved respirator when servicing TURN OFF ALL GAS AND ELECTRIC power high-temperature insulation and gasket materials. supplies to the boiler before servicing. Contact with Wash exposed skin gently with soap and water or release of dangerous flammable gas, electrical after contact Wash exposed clothing
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TROUBLESHOOTING When a problem occurs with the boiler operation, the Burnham IQ Control System easily provides specific, valuable information to help resolve the issue quickly. The display on the IQ Boiler control should be the first place to check. If "Err" IS Not displayed on the IQ Boiler Control: Use the following table to determine the problem and possible causes. IQ Boiler Control Status Codes (when "Err" is not displayed) Display Status Boiler / Control Action(s) Boiler and Blank No
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tR oUBLeShootING (continued) IQ Boiler Control Status Codes (when "Err" is not displayed) - continued Display Status Boiler / Control Action(s) Damper Failed The damper end switch has not closed (damper end switch is open) at the beginning of 20 Open the heat cycle. An alarm message is sent but the control is not in lockout. Damper Failed The damper end switch has not opened (damper end switch is closed) at the 21 Closed beginning of the heat cycle. An alarm message is sent but the contr
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tR oUBLeShootING (continued) If IQ Boiler Control Shows Status Code “STA 15": The IQ Boiler 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 Display Shows “ERR" Display Status Boiler / Control Action(s) Err 1 Low Input Voltage AC voltage is too low Whenever a new IQ Option Card is first installed into the IQ Option Panel,
