Burnham ES2 manual

As an ENERGY ST AR ® Partner , Burnham Hydronics has determined that this boiler meets the ENERGY ST AR ® guidelines for energy efciency established by the United States Environmental Protection Agency (EP A). 102538-01R4-2/10 n o n o i t a m r o f n i g n i k e e s n e h W . r o t c a r t n o c g n i t a e h r u o y l l a c , r e l i o b o t [...]

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 efcient, 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 not install or service this one. THE BOILER MAY L[...]

3 5 2 1 3 4 Congratulations on your purchase of a new Burnham ® boiler—designed and constructed to provide you with years of reliable service. • ENERGY ST AR™ efficiency – friendly on the environment and your wallet. • Cast iron heat e xchanger – for reliability and durability, nothing beats a cast iron heat exchanger. Ours is made pr[...]

4 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 1 18 102 85 ES26 175 147 128 85 ES27 210 176 153 85 ES28 245 206 179 85 ES29 280 235 205 85 Ratings SPECIFICA TIONS Boiler Model Depth Width Height Supply NPT (inch) Return NPT (inch) V ent (inch) Gas NPT (inc[...]

5 Figure S-1: Minimum Clearances to Combustibles and Closet Dimensions SPECIFICA TIONS (continued)[...]

6 Installation: 1. Unpack the crate ............................................................................................. 7 2. Position the boiler ............................................................................................ 7 3. Provide combustion air ..........................................................................[...]

7 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. UNP ACK THE CRA TE 4. Tip the boiler and shimmy it off the skid. 2. POSITION THE BOILER W ARNINGS 1. Slide the boiler into [...]

8 4-a 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. 4. CONNECT VENTING IMPROPER VENTING may result in property damage and the release of ue gases which contain deadly carbon monoxide (CO) into the [...]

9 4. CONNECT VENTING (continued) Model ES23 ES24 ES25 ES26 ES27 ES28 ES29 Input (MBH) 70 105 140 175 210 245 280 Minimum V ent Diameter (in) 4 5 6 6 7 7 8 V ent Height (ft) With B-V ent (double wall) V ent 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 [...]

10 2. Screw the water supply manifold into the boiler outlet tapping “O.” 3. Orient the manifold with the relief valve on top. 4. Screw the relief valve into manifold tapping “RV”. i This installation is not complete until the relief v alve is installed. PIPE THE RELIEF VALVE DISCHARGE to a location where it will not harm people or damage p[...]

1 1 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 W A TER PIPING (contin ued) 9. See Figure 6b for suggested near boiler piping of IQ Options. 6-b Item Description Burnham Part Number 1 1¼ x 1¼ x ½ T ee 806601021 2 Immersion We[...]

12 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-curr[...]

13 Using IQ Boiler Control Displa y 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 IQ Boiler Control display information: 1 . Press and release the “ I ” key on the IQ Boiler Control to change from one para[...]

14 Unit D isplay OR Samp le Di spl ay 1 s ec 1 s ec 1 s ec 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 P arameters To adjust the High Limit setpoin[...]

15 9. CHECK FOR GAS AND W A TER LEAKS GAS LEAKS may result in re or explosion. WATER LEAKS may cause extensive property damage. Refer to Appendix E – Filling the System and Checking f or Leaks Using the Optional LCD Display Kit The LCD Display is an easy to use touch screen type display that allows a technician to monitor and adjust the IQ Boi[...]

16 10-b 10. PERFORM ST ARTUP 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 re. Follow the checklist below: 1. Verify that t[...]

17 ANNUAL MAINTENANCE CHECKLIST W ARNINGS THE BOILER CONTAINS REFRACTORY CERAMIC FIBER , a possible human carcinogen Use a NIOSH approved respirator when servicing high-temperature insulation and gasket materials. Wash exposed skin gently with soap and water after contact Wash exposed clothing separate from normal laundry. LABEL ALL WIRES prior to [...]

18 TROUBLESHOOTING IQ Boiler Control Status Codes (when " Err " is not displayed) Display Status Boiler / Control Action(s) Blank Boiler and Circulator off No 120 V ac power at boiler , check breaker and wiring between breaker panel and boiler . 1 Boiler not responding to Heat Request Boiler is not seeing Heat Request. Check thermostat or[...]

19 If "Err" IS display ed on the IQ Boiler Control: " Err " ashes on the IQ Boiler control display followed by a number. Use the following table along with this error number to determine the problem and possible causes: IQ Boiler Control Error Codes (when " Err " is ashing) Display Status Boiler / Control Action([...]

20 TR OUBLESHOO TING (continued) If IQ Boiler Control Sho ws 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 rst place to check. The IQ Option Panel display (lower display) will show one of the following status codes: IQ Option Panel Display Shows “ E[...]

21 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 102554-08 102554-09 1D Flue Bafe [2] 102678-01 [3] 102678-01 [4] 102678-01 [5] 1[...]

22 REP AIR P AR TS 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 T ray 102543-03 102543-04 102543-05 102543-06 102543-07 102543-08 102543-09 2C Burner T ray Assembly 61807031 61807041 61807051 61807061 61807071 618[...]

23 REP AIR P AR TS LIST (continued) Key No. Description [Quantity] Part Number ES23 ES24 ES25 ES26 ES27 ES28 ES29 3A Gas V alve (Natural Gas), Honeywell VR8204P1 171 81660282 N/A Gas V alve (Natural Gas), Honeywell VR8304P4496 N/A 81660283 Gas V alve (LP Gas), Honeywell VR8204C3015 81660146 N/A Gas V alve (LP Gas), Honeywell VR8304P4314 N/A 8166016[...]

24 REP AIR P AR TS LIST (continued) Key No. Description [Quantity] Part Number ES23 ES24 ES25 ES26 ES27 ES28 ES29 4A IQ Boiler Control 102289-01 4B IQ Option Panel 102291-01 4C T ransformer 102516-01 4D T emperature Sensor 10241 1-01[...]

25 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 V estibule Panel 102565-03 102565-04 102565-05 102565-06 102565-07 102565-08 102565-09 5E Jacke[...]

26 REP AIR P AR TS LIST (continued) Key No. Description [Quantity] Part Number ES23 ES24 ES25 ES26 ES27 ES28 ES29 6A Supply W ater Manifold 80607001 6B T emperature/Pressure Gauge 100282-01 6C Circulator Wiring Harness 6130701 6D 30 PSI Relief V alve 81660363 6E Drain V alve 806603012 6F V ent Damper 102284-01 102284-02 102284-03 102284-04 102284-0[...]

27 INTERNAL WIRING Figure IW-1: W iring Diagram[...]

28 INTERNAL WIRING (continued) Figure IW-2: W iring Schematic[...]

29 Figure IW-3: Single Zone System with Domestic Hot W ater T ank Figure IW-4: Multiple Zone System with Zone Circulators INTERNAL WIRING (continued)[...]

30 Figure IW-5: Multiple Zone System with Zone V alves Figure IW-6: Multiple Zone System with Zone Circulator Panel INTERNAL WIRING (continued)[...]

31 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 LINE VOLTAGE FACTORY WIRING SIZE 14 AWG TYPE TW OR TEW/AWM WIRE LINE VOLTAGE FIELD WIRING VALVE 3 T STAT 4 VALVE 4 POWER POWER IN T T ZONE 1 T[...]

32 APPENDIX A – COMBUSTION AIR PROVIDE ENOUGH AIR to ventilate the boiler room, dilute the ue gases, and sustain combustion. Ignition failure, overheating, re, carbon monoxide, and spillage of ue gases may result from poor air supply. If the boiler is a Direct Vent boiler and exchanges all combustion air and combustion products directly [...]

33 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/NFP A 54, the Natural Gas and Propane Installation[...]

34 APPENDIX B1 – A TMOSPHERIC VENTING Figure B-1: T ypical Atmospheric V ent Installation GENERAL W ARNINGS FOR A TMOSPHERIC 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 obstructions and deterioration and repair or li[...]

35 THIS P A GE INTENTIONALL Y LEFT BLANK[...]

36 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 label) and the demand of other gas appliances se[...]

37 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 control valve and outside jacket. 7. When the pipi[...]

38 (2) Comply with the boiler’s specic water quality requirements. See the Specifications Section of this manual. (3) Comply with the boiler’s specic requirements for minimum water ow through the boiler, installing a system bypass or primary-secondary loop if necessary to maintain ow through the boiler when serving small zones. 3. [...]

39 Figure D-0: Piping Schematic Symbols APPENDIX D – System Piping (continued)[...]

40 Figure D-W1: W ater Boiler , Series Loop APPENDIX D – System Piping (continued) Figure D-W2: W ater Boiler , T wo or More Zones[...]

41 Figure D-W3: W ater Boiler , T ankless Coil, T wo or More Zones APPENDIX D – System Piping (continued) Figure D-W4: W ater Boiler , Indirect W ater Heater , T wo or More Zones[...]

42 APPENDIX D – System Piping (continued) Figure D-W5: W ater Boiler , Indirect W ater Heater Figure D-W6: Multiple W ater Boilers, Indirect Water Heater , T wo or More Zones[...]

43 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 gure below. Remove air from system when lling. 1. Close full port ball valve located between vertical hose bib and air scoop in boil[...]

44 APPENDIX F – ADJUSTING GAS INPUT RA TE Natural Gas Boilers: 1. Turn off gas supply to all appliances other than gas-red boiler. 2. Note the rated manifold gas pressure listed on the boiler’s rating label. 3. Connect Manometer to manifold pressure tapping on Gas Valve (Figure F-1). 4. Light main burners by adjusting thermostat to highest s[...]

45 Seconds for T wo (2) Revolutions Size of Gas Meter Dial One-Half Cu. Ft. One Cu. Ft. T wo Cu. Ft. 24 150.0 300.0 450.0 26 138.4 276.9 415.3 28 128.5 257.1 385.7 30 120.0 240.0 360.0 34 105.8 21 1.7 317.6 38 94.7 189.4 284.2 42 85.7 171.4 257.1 46 78.2 156.5 234.7 50 72.0 144.0 216.0 55 65.4 130.9 196.3 60 60.0 120.0 180.0 65 55.3 1 10.7 166.1 70[...]

46 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 hoods and bathroom exhausts) to their maximum s[...]

47 The IQ Boiler Control stores two boiler supply temperature setpoints in its memory; one setpoint is for the High Limit Setting and the second is for the Operating Setpoint. APPENDIX H – IQ CONTROL SYSTEM IQ Control System Overvie w The “IQ Control System” consists of an IQ Boiler Control and an IQ Option Panel with optional “plug in” c[...]

48 APPENDIX H – IQ Contr ol System (continued) IQ Option Cards: For example, if additional safety limits are required, select Manual or Automatic Reset Aquastat or Low Water Cutoff IQ Option Cards. Additionally, if energy savings and improved home comfort is desired, select an Outdoor Reset IQ Option Card. The Outdoor Reset IQ Option Card regulat[...]

49 The LCD Display kit includes a mounting bracket and wiring harness to allow simple physical installation and “plug-in” style electrical connection. This intuitive display reduces setup and troubleshooting time by providing the user adjustment and alarm focused “help” and “information” screens. APPENDIX H – IQ Contr ol System (conti[...]

50 APPENDIX H – IQ Contr ol System (continued) Burnham Part Number Item Description 102723-01 Outside Reset IQ Option Card, Domestic Hot W ater Priority , for use with Option Control Panel, with Outside Air T emperature Sensor with 60 inch lead, Instructions, Unit Pack. No additional pipe ttings required. 102294-01 Outdoor Reset IQ Option Card[...]

51 SER VICE RECORD DA TE SERVICE PERFORMED[...]

52 L L i i m m i i t t e e d d W W a a r r r r a a n n t t y y F F o o r r R R e e s s i i d d e e n n t t i i a a l l G G r r a a d d e e W W a a t t e e r r a a n n d d S S t t e e a a m m B B o o i i l l e e r r s s Using Cast Iron, Carbon Steel, Cast Aluminum, or Stainless Steel Heat Exchangers a a n n d d P P a a r r t t s s / / A A c c c c e [...]