Instruction/ maintenance manual of the product ES2 ES2 Burnham
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As an ENERGY ST AR ® Partner , Burnham Hydronics has determined that this boiler meets the ENERGY ST AR ® guidelines for energy efciency 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 .
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 efcient, 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.
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.
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 24.
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.
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.
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.
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) .
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.
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.
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.
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 .
14 Unit D i splay 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”.
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 Us.
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.
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.
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 .
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 .
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.
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.
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.
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 G.
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 .
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 10256.
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 Circula.
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 .
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.
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.
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.
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.
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.
38 (2) Comply with the boiler’s specic water quality requirements. See the Specifications Section of this manual. (3) Comply with the boiler’s specic 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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
An important point after buying a device Burnham ES2 ES2 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Burnham ES2 ES2 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Burnham ES2 ES2 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Burnham ES2 ES2 you will learn all the available features of the product, as well as information on its operation. The information that you get Burnham ES2 ES2 will certainly help you make a decision on the purchase.
If you already are a holder of Burnham ES2 ES2, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Burnham ES2 ES2.
However, one of the most important roles played by the user manual is to help in solving problems with Burnham ES2 ES2. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Burnham ES2 ES2 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
