U.S. Boiler Company ESC, ESC3C, ESC4C, ESC5C, ESC6C Installation, Operating And Service Instructions

...

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

ESC™

ENHANCED SEALED COMBUSTION

Gas - Fired Boiler

9700609

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

ESC_C

Heating Contractor Phone Number

Address

103788-03 - 9/13

Boiler Serial Number Installation Date

Price - $5.00

WARNINGS FOR THE HOMEOWNER

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 LEAK WATER at the end of

its useful life. Be sure to protect walls, carpets, and valuables from water that could leak from the

boiler.

PROTECT YOUR HOME IN FREEZING WEATHER. A power outage, safety lockout, or

component failure will prevent your boiler from lighting. In winter, your pipes may freeze and cause extensive property damage. If you must leave your home unattended for an extended time

when outdoor temperatures are below 32°F, rst

turn off your home’s main water supply and drain the water from all pipes.

DO NOT BLOCK AIR FLOW into or around the

boiler. Insufcient air may cause the boiler to produce carbon monoxide or start a re.

KEEP FLAMMABLE LIQUIDS AWAY from the

boiler, including paint, solvents, and gasoline. The boiler may ignite the vapors from the liquids causing explosion or re.

KEEP CHILDREN AND PETS away from hot

surfaces of the boiler, boiler piping, and vent pipe.

CARBON MONOXIDE (CO) is an odorless, deadly gas that may be introduced into your home by any malfunctioning fuel-burning product, including

your boiler. Consider installing CO alarms near

bedrooms in all levels of the building to warn you and your family of potential CO exposure.

WARNINGS foR the INStALLeR

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 rst verifying

that the system is cool and free of pressure and that your clothing will protect you from a release of hot water or steam. Do not rely solely on the boiler’s temperature and pressure gage when making this judgment.

USE PROPER PERSONAL PROTECTION EQUIPMENT when servicing or working near the

boiler. Materials of construction, ue products, and

fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, and/or other toxic or harmful substances that can are hazardous to health and life and that are known to the State of California to cause cancer, birth defects, and other reproductive harm.

INSTALL ALL GUARDS, cover plates, and enclosures before operating the boiler.

SIZE THE BOILER PROPERLY relative to the heat load. A grossly oversized boiler will cycle excessively and this will lead to premature failure of the boiler and its components. Our warranty does not apply to damage from excessive cycling.

ADHERE TO ALL LOCAL CODE REQUIREMENTS.

1. Installation must conform to requirements of authority having jurisdiction or, in the absence of such requirements, with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54.

2. Where required by authority having

jurisdiction, the installation must conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

3. ALL WIRING must be in accordance with requirements of authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code ANSI/NFPA 70.

INSTALLING CONTRACTOR IS RESPONSIBILITY to verify that all controls are correctly installed and are operating properly when installation is complete.

1. Limit Sensor Fully inserted.

Failure to properly install limit sensor may result in property damage, personal injury or loss of life due to elevated operating temperatures and/or pressures.

2. Safety relief valve installed in supply water

manifold.

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 grade, the following requirements shall be satised:

1. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the side wall horizontally vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts

State Building Code.

2. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the detector on the oor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment, the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector may be installed on the next adjacent habitable oor level. Such detector may be a battery operated carbon monoxide detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.

3. A metal or plastic identication plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. A nal inspection by the state or local gas inspector of the side wall horizontally vented equipment shall not be performed until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of carbon monoxide detectors and alarms as required above.

B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

C. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting

system design or venting system components with the equipment, the instructions for installation of the equipment and the venting system shall include:

1. A complete parts list for the venting system design or venting system; and

2. Detailed instructions for the installation of the venting system design or the venting system components.

D. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not

provide the parts for venting ue gases, but identies “special venting systems”, the following shall be satised:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

E. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment,

all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

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 available.

 • System-friendly – built-in protection from condensation and thermal shock.

*IQ Control System Overview

ESC Boiler uses a microprocessor based control system called the "IQ Control System". This "IQ Control System" consists of an Intelligent Hydronic Control Control (Control) and an IQ Option Panel (Option Panel) with optional "plug-in" IQ Option Cards (Option Card). The IQ Control System fully integrates both

factory and eld installed components, simplifying installation and troubleshooting. The IQ Control System is designed to efciently operate the entire boiler system to save energy, installation and setup time while

ensuring adequate supply of heat and domestic hot water.

What's in the crate?

1. ESC™ Boiler

2. Circulator & Gasket Kit

q Taco 007-2 (8056170)

qGrundfos UP-15 (102805-01)

qB & G NRF-22 (8056174)

3. Miscellaneous Parts Carton

Cartons Include: (1) Safety Relief Valve, Set at 30 PSI

(1) Pressure/Temperature Gauge (1) Water Manifold

(1) Circulator Harness (1) Vent Connector (1) Vent Terminal

(1) Air Intake Terminal

(1) Drain Valve

q ESC3/ ESC4: P/N 102648-01

q ESC5/ ESC6: P/N 102648-02

q ESC7: P/N 102648-03

q ESC8/ ESC9: P/N 102648-04

4. Instruction Envelope (103787-01)

q Instruction & Operation Manual (103788-03)

q Warranty Sheet (103203-01)

Ratings

SPECIFICATIONS

ESC Series

Boiler Model Input (MBH)

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 shown based on piping and pickup allowance of 1.15. Consult manufacturer before selecting boiler

for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

Heating Capacity

(MBH)

Net AHRI Rating, Water

(MBH)

(1)

AFUE (%)

Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A

Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi relief valved.

Dimensions, Weights and Connections

Boiler

Model

ESC3C 33 12¾ 41 1¼ 1¼ 3 3 ½ ¾ ¾ ESC4C 33 15½ 41 1¼ 1¼ 3 3 ½ ¾ ¾ ESC5C 33 18½ 41 1¼ 1¼ 3 4 ½ ¾ ¾ ESC6C 33 21½ 41 1¼ 1¼ 3 4 ½ ¾ ¾ ESC7C 33 24¾ 41 1¼ 1¼ 3 5 ¾ ¾ ¾ ESC8C 33 27¾ 41 1¼ 1¼ 4 5 ¾ ¾ ¾ ESC9C 33 30¾ 41 1¼ 1¼ 4 5 ¾ ¾ ¾

Depth Width Height

Supply NPT

(inch)

Return NPT

(inch)

Vent

(inch)

Air

Intake

(inch)

Gas NPT

(inch)

Relief Valve

NPT

(inch)

Drain

IPS

(inch)

Water Temperatures and Flows

Boiler Model

ESC3C 130-220 110 None <1 ESC4C 130-220 110 None <1 ESC5C 130-220 110 None <1 ESC6C 130-220 110 None <1 ESC7C 130-220 110 None <1 ESC8C 130-220 110 None <1 ESC9C 130-220 110 None <1

Allowable Supply Water

Temperature (°F)

Minimum Return Water

Temperature (°F)

Minimum Flow

(GPM)

Waterside Pressure Drop

at 20°F DT (Ft. of Head)

Weights and Volume

Boiler Model Shipping Weight (lbs) Empty Weight (lbs) Water Content (gal)

ESC3C 250 170 2 ESC4C 300 220 3 ESC5C 350 270 4 ESC6C 410 320 5 ESC7C 460 370 5 ESC8C 510 420 6 ESC9C 560 470 7

SPECIFICATIONS (continued)

Figure S-1: Minimum Clearances to Combustibles

BOILER QUICK-START

Installation:

1. Unpack the crate ............................................................................................. 9

2. Position the boiler ............................................................................................ 9

3. Provide combustion air .................................................................................. 10

4. Connect venting ............................................................................................. 10

5. Connect gas piping ........................................................................................ 12

6. Connect boiler water piping ........................................................................... 12

7. Connect electrical wiring ................................................................................ 14

8. Program the controls ..................................................................................... 15

9. Check for gas and water leaks ...................................................................... 18

10. Perform startup checks and adjustments ...................................................... 19

Annual Maintenance Checklist ............................................................................21

Troubleshooting .................................................................................................... 23

Repair Parts List ................................................................................................... 29

Internal Wiring ....................................................................................................... 37

Appendices:

A – Combustion Air................................................................................................. 41

B – Venting ............................................................................................................. 42

C – Gas Piping ....................................................................................................... 51

D – System Piping .................................................................................................. 53

E – Filling the System and Checking for Leaks ...................................................... 57

F – Adjusting Gas Input Rate ................................................................................. 58

G – Checking Draft and Combustion ...................................................................... 59

H – Operation ......................................................................................................... 60

I – IQ Control System ............................................................................................. 61

1. UNPACK THE CRATE

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).

4. Tip the boiler and shimmy it off the skid.

1-a

2. POSITION THE BOILER

WARNINGS

OBSERVE MINIMUM CLEARANCES to combustible walls and ceilings to avoid potential re hazard.

DO NOT INSTALL ON CARPET. This may cause a re.

INSTALLING THE BOILER NEAR A SOURCE OF FLAMMABLE LIQUIDS or gases may cause re or

explosion.

1. Slide the boiler into desired location.

2. Meet the minimum clearances to

combustible construction per the Speciﬁcation Section of this manual.

1-b

CLEAN BURNERS DAILY if operating the boiler in

a dusty environment.

PROTECT IGNITION SYSTEM COMPONENTS

from sources of water that may spray, drip, or rain on them during installation, operation and service.

3. Allow 24" service clearance in front and on

the left side of the boiler.

4. Level the boiler, using shims as necessary.

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 Z223.1/NFPA 54, or applicable provisions of the local building codes.

4. CONNECT VENTING

IMPROPER VENTING may result in

property damage and the release of

deadly carbon monoxide (CO) into the home.

Observe all general venting guidelines provided in Appendix B—Venting. Additionally:

Follow all instructions in Appendix B-2 Direct Vent

or B-3 Power Vent.

1. For the exhaust, attach special (Category

IV) gas vent to the fan outlet using a single sheetmetal screw (Figure 4-a).

2. Congure the air intake:

(1) To equip the ESC for outdoor

combustion air (direct vent), attach the

Like all fuel-burning appliances, boilers need air to

operate reliably and safely.

1. If equipping for direct vent (sealed

combustion), provide combustion air according to Appendix B2—Venting for

Direct Vent boilers.

2. If not equipping the ESC for direct vent,

provide combustion air from the boiler room according to Appendix A—Combustion Air.

plastic or metal intake air pipe to the inlet air duct.

(2) To equip the ESC for indoor combustion air (power vent), attach the air intake

terminal to the boiler's inlet air duct with a single sheetmetal screw (Figure 4-b).

3. For horizontal venting, follow the instructions

in Appendix B2 Direct Venting, Special

Instructions for Stainless Steel Venting

Horizontal Installations, Specically,

(1) Cut a hole in the exterior wall, large enough to t the wall thimble. Hole diameter for the ESC3-7 is 7", hole diameter for the ESC8-9 is 8".

(2) Install wall thimble.

4-a

4-b

4. CONNECT VENTING (continued)

(3) Install vent piping. (4) When conguring 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 nal installation should appear as in Figure 4-c.

4. For vertical venting, follow instructions in

Appendix B2  Direct Venting, Special Instructions for Stainless Steel Venting

Vertical Installations, Specically,

(1) Install re stops and wall thimbles. (2) Install vent piping and vert terminal. (3) Install condensate line.

(4) Install roof ashing and roof supports. (5) The nal installation should appear as in

Figure B-7 in Appendix B-2.

5. Do not use cellular core PVC (ASTM

F891), cellular core CPVC, or Radel®

(polyphenolsulfone).

6. Do not cover non-metallic vent pipe and

ttings with thermal insulation.

Note: Non-metallic vent cannot be used with

this boiler.

4-c

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 re or explosion.

SIZE GAS PIPING, regulators, valves, and meters so as to provide an adequate gas ow and pressure to the boiler during operation. Failure to do so may cause poor

combustion, noise, injury, or death.

1. Remove boiler door, locate gas valve and

remove plastic shipping plug.

2. Thread a ¾" x 1½" nipple, a 90° street

elbow, or a Honeywell ange onto the gas valve and pipe through the slot in the left jacket panel (Figure 5-a).

3. Pipe from the street elbow through the

left jacket panel, and complete drip leg as shown (Figure 5-a).

5-a

6. CONNECT BOILER WATER PIPING

General system piping guidelines are included in

Appendix D—System Piping.

Additionally, for this particular boiler install piping shown below (Figure 6-a).

6-a

1. Apply sealant to all threads.

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”.

relief valve is installed.

to a location where it will not harm people or damage property. The relief valve may discharge scalding hot water or steam.

result in boiler explosion.

This installation is not complete until the

PIPE THE RELIEF VALVE DISCHARGE

BLOCKING THE RELIEF VALVE may

5. Screw the temperature-pressure gage into

manifold tapping “G”.

6. CONNECT BOILER WATER PIPING (continued)

6. Connect the system supply to the open end

of the manifold "S" using a 1¼” male NPT tting.

7. Screw an installer-supplied 1¼” pipe or

nipple into the water return tapping “R”.

8. Screw the supplied drain valve into tapping

“D”.

9. See Figure 6b for suggested near boiler

piping of IQ Options.

10. Maintain minimum 1/2" clearance between

water piping and combustible construction.

6-b

Item Description 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 806601528

7. 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

CAREFULLY according to the boiler’s

wiring diagram and instructions

Refer to the Internal Wiring diagrams later in this manual.

1. Locate the wiring box on the left side of the

boiler and open the cover (Figure 7-a).

2. Install a 120V disconnect near the boiler.

3. Connect the 120V wiring from the disconnect

to the boiler's white (neutral), black (hot), and green (ground) labeled "120VAC Power supply". Do not reverse polarity.

4. Connect the 120V wiring from the circulator

to the white (neutral) yellow (hot) wires

marked "circulator".

7-a



3 T

5. Electrically bond to ground in accordance

with requirements of authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code, ANSI/NFPA 70.

WIRE AN ADDITIONAL SAFETY LIMIT

such as a low water cutoff or temperature limit device, other than an IQ Control™ device, in series with the 120V circuit used to power the boiler. Do not alter the boiler’s factory wiring when

adding an additional limit.

6. Connect the 24V wiring from the thermostat

to the "T-T" terminals on the Option Control

Panel.

7. To connect other external devices, refer to

the instructions included with these devices.

7-b

THE MAXIMUM ALLOWABLE

CURRENT for each circulator is 5 amps at

120V AC. For circulators with higher amp ratings, you must install a circulator relay or starter coil to provide line voltage to the circulator and connect only the relay or starter coil to boiler terminals. The combined boiler and circulator amperage must not exceed 12 amps. Install over-current protection in accordance with authority having jurisdiction or, in the absence of such requirements, follow the National Electric Code, ANSI/NFPA 70. Do not provide overcurrent protection greater than 15 amperes.

8. PROGRAM THE CONTROLS

Unit Display

Sample Display

1 sec

Using Intelligent Hydronic Control Display

The Intelligent Hydronic Control is located inside the boiler front door, just above the IQ Option Panel (Figure 8-a).

Intelligent

Hydronic Control

IQ Option Panel

8-a

The control display, along with Up ñ, Down ò, and “

I” keys may be used to view boiler operating

status (Figure 8-b). Please note that these keys

look similar to the keys on the IQ Option Panel

but are in a different orientation, and they perform different functions.

1. Press and release the “I” key on the IQ

control to change from one parameter to the next. Each setting will alternately ash between the relevant display code and its corresponding value.

Operating Mode Options

StA Status

bt Boiler Temperature SP Operating Setpoint (Outdoor Reset) HL High Limit Setting

HdF High Limit Differential

tt Heat Request Status

dh DHW Heat Request Status FLA Flame Current rUn Run Time Hours CYC Boiler Cycles Err Error (see Error Numbers)

The STA (status) display code has the below listed values. This list is also available on the control cover.

Status Code Displayed in STA Mode

1 Standby

2 Waiting for Pressure Switch to Open

3 Waiting for Pressure Switch to Close

4 Prepurge

6 Spark

7 Flame Proving

8 Running 10 Retry/Recycle Delay 11 Pressure Switch Failed to Open 12 Pressure Switch Failed to Close 13 Soft Lockout 14 Hard Lockout 15 Waiting for Limit to Close 16 Flame Present Out of Sequence 17 Self Test

Intelligent Hydronic Control

8-b

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:

For example, when the “I” key is pressed on the control until “bt” is displayed, it will then ash a three digit number (such as “180”) followed by either “F” (or “C”). This indicates that the boiler

water temperature is 180°F. Other operating parameters display the information in a similar fashion.

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 the Parameters such as High Limit Setpoint and High Limit Differential:

1. Access the adjustment mode by pressing

and holding the Up ñ, Down ò, and “I” keys simultaneously for three (3) seconds. This procedure is intended to discourage unauthorized changes or accidental changes

to limit settings.

2. Press the "I" key to display available

Adjustment Mode options. Select an option.

Adjustment Mode Options

HL_ dF_ Or_ PP_ St_ Pt_ dh_ rst f-C bac

3. Press the Up ñ and Down ò keys to adjust

140-220°F Adjust High Limit Setting

10-30°F Adjust High Limit Differential

0-10 minutes Circulator Overrun Time

2-20 minutes Circulator Pre-purge Time

140-180°F Start Temperature

On or off Priority time

dh or tt2 DH Terminal Function

Reset Lockout

F or C Select degrees F or C Mode

Back to Operating Mode

the displayed item to the desired value.

4. To return to the normal operating mode from

the Adjustment Mode, when the "bAc” option is displayed, press either the Up ñ or Down ò key. If no keys are pressed, after ve (5) minutes the control will automatically return

to the Operating Mode.

More Information about Adjustable Parameters

1. High Limit (HL_)

The control is factory programmed with a

High Limit Setpoint of 180°F. The burner turns "off" when the boiler temperature

(bt) is above Operating Setpoint. The Operating Setpoint (SP) will equal the High Limit Setpoint unless an Outdoor Reset IQ Option Card is installed. The Outdoor

Reset IQ Option Card reduces the Operating

Setpoint to regulate heat delivery, increase home comfort and save energy. Refer to the Appendix I for additional information. The High Limit setpoint is adjustable between 140° and 220°F.

2. Differential (df_)

The control is factory programmed with a

Differential of 15°F. The Differential is the

number of degrees the boiler temperature

must decrease below the Operating Setpoint before the boiler can restart. The differential is adjustable between 10° through 30°F.

3. Circulator Overrun Time (OR_)

The control is factory programmed with

a Circulator Overrun Time of 0 minutes. Circulator Overrun Time (also called “circulator off delay” or “circulator post purge”) continues circulator operation after a call for heat has ended, sending excess

heat from the boiler into the system. Ensure

system piping and zone panel settings allow water ow to the priority zone after the call for heat ends. The Circulator Overrun Time is adjustable between 0 through 10 minutes.

4. Circulator Pre-purge Time (PP_)

When the boiler is warm (boiler water

temperature higher than 140°F (adjustable

using Start Temperature parameter)) and

there is a thermostat call for heat, the system circulator is started and boiler ring is delayed Circulator Pre-purge minutes. If the temperature drops below 140°F or there is a DHW call for heat the boiler is started without delay. Additionally, the boiler is started without delay if the thermostat call

for heat is initiated when the boiler water

temperature is less than 140°F. This feature helps save energy by satisfying home

heating needs with residual boiler heat

rather than cycling the boiler. The Circulator Pre-purge time has a factory setting of 2 minutes and is eld 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)

Table 8a: Circulator Pre-purge Time example, (PP_ = 2 minutes)

Call for

Heat

Source

TT = on - <140 Start with no delay

TT = on - >140 Start after 2 minute delay DHW = on tt2 <140 Start with no delay DHW = on tt2 >140 Start after 2 minute delay DHW = on dh <140 Start with no delay DHW = on dh >140 Start with no delay

5. Start Temperature (St_)

DHW

Terminal

Selection

Boiler

Temperature

Burner Status

Amount of “Heat available” is calculated

by taking the difference between measured

boiler water temperature and the Start

Temperature setting. Useful “Heat Available” is dependent on the type of

heating emitter installed in the home.

Heat emitters require a certain minimum temperature to operate effectively. Our default settings reect cast iron radiators. Fan Coils may require a start temperature setting of 180°F or 160°F before providing

heat to the home. The Start Temperature

has a factory setting of 140°F and is eld adjustable between 140°F and 180°F.

6. Priority Time (Pt_)

When the Priority Time parameter is set

to “on” and Domestic Hot Water (DHW) call for heat is “on” the DHW demand will take “Priority” over home heating demand. During Priority Time the system circulator will be forced “off”. Priority Time ends and the system circulator is released to service home heating demand when Domestic Hot Water call for heat is over. When Priority Time parameter is set to “Off” the DHW call for heat does not force “off” the system circulator. The Priority Time has a factory setting of “On” and is eld adjustable between “On” and “Off” Refer to Table 8b.

7. Domestic Hot Water (DHW) Terminal

Function (dh_)

The control allows conguration 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 circulator or a second heating zone circulator. These applications are selected as follows:

a. When dh_ is set equal to Domestic Hot

Water Demand (h)

When there is an Indirect Water Heater

(IWH) the control provides “DHW” input terminals for the IWH Aquastat and “DHW Circulator” output terminals for the DHW Circulator. When there is a DHW call for heat, the System Circulator is “forced off”, the DHW Circulator terminal is energized and the circulator pre-purge time delay control logic is bypassed to allow the boiler to re without delay. When DHW demand ends the System Circulator “force off” is removed, the circulator can respond normally, and the DHW Circulator is de-energized. The DHW call for heat is detected by a voltage on

to the DHW terminal. When the Priority

Time parameter is set to “off” the System Circulator is not forced off for a DHW call

for heat. Refer to Table 8b.

Table 8b: DHW Terminal Function (dh_) Selection = Domestic Hot Water Demand, (Parameter dh_ = dh)

Call for Heat Circulator Status

T-T

Input

on off On on off

on on On off on

off on On off on

on off OFF on off

on on OFF on on

off on OFF off on

DHW

Input

Priority

Time (Pt_)

System

Circulator

Output

DHW

Circulator

Output

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 congured to control a second heating zone. This is particularly helpful when the home uses only two heating zones. The control replaces the need for a two circulator zone panel. When DHW Terminal Function (dh_) is set to “tt2" the control’s two circulator outputs are used to control two independent heating zones. Refer to Table 8c. A “TT” input causes a call for heat and energizes the “System Circulator” output to service heating zone 1 and a second zone's thermostat wired to the “DHW” input causes a call for heat and energizes heating zone 2 circulator wired to the "DHW Circulator" output.

When there is a Second Heating Zone

(call for heat) the boiler is started and the DHW Circulator terminal is energized. When Second Heating Zone is deenergized the call for heat is ended and the Second Heating Zone Circulator is de-energized. A Second Heating Zone is detected by sensing a voltage on the "DHW" terminal.

Using the IQ Option Panel

IQ Option Cards are available from U.S. Boiler

Company distributors and are the simplest way

to add functionality, safety and efciency to your heating system. The IQ Option Panel provides an easy and convenient means to "plug-in" an Auxiliary High Limit, Low Water Cut-off and/or Outdoor Reset function.

For installation, programming, and troubleshooting instructions, refer to the instructions supplied with those cards.

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 control and connected IQ Option Cards. All boiler settings, status and error codes are displayed in full text. All Outdoor Reset IQ Option Card parameters are adjustable with graphic and help information screens. The LCD Display Kit includes a mounting bracket and wiring harness to allow mounting in the ESC plastic hood above the front door. For installation, programming, and troubleshooting instructions, refer to the instructions supplied with the display.

Table 8c: DHW Terminal Function (dh_) Selection = Second Heating Zone, (Parameter dh_ = tt2)

Call for Heat Circulator Status

System

T-T

Input

off off off off

on off on off

on on on on

off on off on

DHW Input

Circulator

Output

(Zone 1)

Circulator

Output

(Zone 2)

9. CHECK FOR GAS AND WATER LEAKS

GAS LEAKS may result in re or

explosion.

WATER LEAKS may cause extensive

property damage.

DHW

Refer to Appendix E – Filling the System and Checking for Leaks

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 re.

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.

3. Adjust zone thermostat to maximum setting.

4. Allow gas line to purge of air.

q Boiler lights cleanly within 60 seconds.

5. Adjust gas input rate. See Appendix F –

Adjusting Gas Input Rate

q Pilot and main burner ﬂames appear

clean and blue.

10-a

6. Disconnect pilot lead wires from gas valve

(Figure 10-b).

q Boiler shuts off.

7. Reconnect pilot lead wires to gas valve.

q Boiler restarts.

8. Adjust zone thermostat to minimum setting.

q Boiler shuts off.

9. Adjust zone thermostat to maximum setting.

10. Observe temperature gage as boiler heats.

10-b

10-c

11. Adjust the high limit setting to its minimum

level (see "Programming High Limit" in Section 8).

q Boiler shuts off when temperature gage

reads within 15°F of high limit setting.

12. Return high limit to the desired setting (see

"Programming High Limit" in Section 8).

13. Check combustion in the vent stack and

record results in the spaces provided below.

_____ CO _____ O

(less than 7%)

(more than 9%)

_____ CO (less than 100 ppm, air free)

ANY FAILED STARTUP CHECK

Must be corrected before placing the boiler in service.

10. PERFORM STARTUP CHECKS AND ADJUSTMENTS (continued)

Figure 10-d: Operating Instructions

+ 44 hidden pages

U.S. Boiler Company ESC, ESC3C, ESC4C, ESC5C, ESC6C Installation, Operating And Service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual