U.S. Boiler Company ES2 Service manual

103780-05 - 8/14
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
ES2™
ENHANCED SERIES 2
Gas - Fired Boiler
9700609
Price - $5.00
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
ES2__
Boiler Serial Number Installation Date
Heating Contractor Phone Number
Address

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 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 OR OBSTRUCT ow of
combustion and ventilation air into or around the
boiler. Insufcient air may cause the boiler to
produce carbon monoxide or start a re.
KEEP BOILER AREA CLEAR AND FREE
from combustible materials, gasoline and other
ammable vapors and liquids.
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 or vent
system failure. 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 HOMEOWNER

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 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.
THIS INSTALLATION IS NOT COMPLETE until
the front air dam is installed (See Figure 2-a).
Product performance will be negatively affected if
the front air dam is not installed which can cause
serious property damage, personal injury or death.
SIZE THE BOILER PROPERLY relative to the
design heat load or, if using domestic hot water
priority, the peak hot water load, whichever
is larger. 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, and/or the Natural Gas and Propane
Installation Code, CAN/CSA B149.1.
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,
and/or the Canadian Electrical Code Part 1,
CSA C22.1, Electrical Code.
INSTALLING CONTRACTOR IS RESPONSIBLE
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.
3. Blocked vent switch installed on edge of
canopy/draft diverter.
WARNINGS FOR THE INSTALLER

4
Congratulations on your purchase of a new ES2 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.
1. q ES2™ Boiler
2. q Vent Damper w/ Carton
 4” Damper  ES23 (102284-01)
5” Damper  ES24 (102284-02)
6” Damper  ES25 & ES26 (102284-03)
 7” Damper  ES27 & ES28 (102284-04)
 8” Damper  ES29 (102284-05)
3. q Circulator & Gasket Kit
 Taco 007-2 (8056170)
 Grundfos UP-15 (102805-02)
 Grundfos Alpha (104935-01)
 B & G NRF-22 (8056174)
4. q Miscellaneous Parts Bag
q Temperature/Pressure Gage; ¼” NPT
(100282-01)
q Circulator Mounting Hardware Kit, 1- 1/4”
NPT (6056007) - except less circulator
q Drain Valve; ¾” NPT (102802-01)
q Safety Relief Valve; 30 psi (81660363)
q Water Manifold (80607001)
5. q Instruction Envelope (103779-01)
q Instruction & Operation Manual
(103780-05)
q Boiler Warranty Sheet (103203-01)
q Boiler Warranty Card (103204-02)
What's in the crate?
*IQ Control System Overview
ES2 Boiler uses a microprocessor based control system called the "IQ Control System". This "IQ Control
System" consists of an Intelligent Hydronic 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.

5
ES2 Series
Boiler Model Input (MBH) DOE Heating Capacity (MBH) Net AHRI Rating, Water
(MBH) (1) AFUE (%)
ES23 70 59 51 85
ES24 105 89 77 85
ES25 140 119 103 85
ES26 175 149 130 85
ES27 210 178 155 85
ES28 245 208 181 85
ES29 280 238 207 85
Ratings
SPECIFICATIONS
Boiler
Model Depth Width Height Supply NPT (inch)
Return NPT
(inch)
Vent
(inch)
Gas NPT
(inch)
Relief Valve
NPT (inch)
Drain
NPT (inch)
ES23 33 12¾ 41 1¼ 1¼ 4 ½ ¾ ¾
ES24 33 15½ 41 1¼ 1¼ 5 ½ ¾ ¾
ES25 33 18½ 41 1¼ 1¼ 6 ½ ¾ ¾
ES26 33 21½ 41 1¼ 1¼ 6 ½ ¾ ¾
ES27 33 24¾ 41 1¼ 1¼ 7 ¾ ¾ ¾
ES28 33 27¾ 41 1¼ 1¼ 7 ¾ ¾ ¾
ES29 33 30¾ 41 1¼ 1¼ 8 ¾ ¾ ¾
Dimensions and Connections
Boiler Model
Allowable Supply
Water Temperature
(°F)
Minimum Return
Water Temperature
(°F)
Minimum Flow
(GPM)
Waterside Pressure Drop
at 20°F DT
(Ft. of Head)
ES23 130-220 110 None <1
ES24 130-220 110 None <1
ES25 130-220 110 None <1
ES26 130-220 110 None <1
ES27 130-220 110 None <1
ES28 130-220 110 None <1
ES29 130-220 110 None <1
Water Temperatures and Flows
(1) Net AHRI Water Ratings shown are based on a 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.
Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A
Maximum Allowable Working Pressure: 50 psi. Boiler shipped from factory with a 30 psi safety relief valve.

6Figure S-1: Minimum Clearances to Combustible Materials
SPECIFICATIONS (continued)
Weights and Volume
Boiler
Model
Shipping Weight
(lbs)
Empty Weight
(lbs)
Water Content
(gal)
ES23 254 180 2
ES24 304 231 3
ES25 357 284 4
ES26 405 332 5
ES27 462 382 5
ES28 518 438 6
ES29 564 484 7

7
Installation:
1. Unpack the crate ............................................................................................. 8
2. Position the boiler ............................................................................................ 9
3. Provide combustion air .................................................................................. 10
4. Connect venting............................................................................................. 10
5. Connect gas piping........................................................................................ 11
6. Connect boiler water piping ........................................................................... 12
7. Connect electrical wiring................................................................................ 13
8. Program the controls ..................................................................................... 14
9. Check for gas and water leaks ...................................................................... 17
10. Perform startup checks and adjustments ...................................................... 18
Annual Maintenance Checklist............................................................................ 19
Troubleshooting.................................................................................................... 22
Repair Parts List................................................................................................... 28
Internal Wiring....................................................................................................... 34
Appendices:
A – Combustion Air..................................................................................................38
B – Venting..............................................................................................................39
C – Gas Piping ........................................................................................................43
D – System Piping...................................................................................................44
E – Filling the System and Checking for Leaks.......................................................48
F – Adjusting Gas Input Rate ..................................................................................49
G – Checking Draft and Combustion....................................................................... 50
H - Operation...........................................................................................................51
I – IQ Control System ..............................................................................................52
BOILER QUICK-START

8
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).
DO NOT DAMAGE front air dam. It is
required for proper operation of the boiler.
1. UNPACK THE CRATE
4. Tip the boiler and shimmy it off the skid
(Figure 1-b).
1-a 1-b

9
2. POSITION THE BOILER
WARNINGS
1. Slide the boiler into desired location.
2. Meet the minimum clearances to
combustible construction per the
Specification Section of this manual.
3. Allow 24" service clearance in front and on
the left side of the boiler.
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.
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 or service.
4. Level the boiler, using shims as necessary.
5. Assure that the front air dam (applicable to
5-section thru 9-section boilers only) is in
place and undamaged. See Figure 2-a.
2-a
WARNING
Models ES25, ES26, ES27, ES28 and ES29 only. Verify Front Air Dam is installed and undamaged
(Figure 2-a). A missing or damaged Front Air Dam will negatively affect the performance of this boiler,
which can cause serious property damage, personal injury or death.
NOTE: Front Air Dam not used on Models ES23 and ES24.

10
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.
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 Sections 8.2, 8.3 or 8.4
4. CONNECT VENTING
IMPROPERVENTINGmayresultinproperty
damage and the release of ue gases which
contain deadly carbon monoxide (CO) into the home,
which can cause severe personal injury, death or
substantial property damage.
INSPECT EXISTING CHIMNEY before
installing boiler. Failure to clean or replace
perforated pipe or tile lining will cause severe injury
or death.
Vent installation shall be in accordance with
"Venting of Equipment," of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54, or "Venting Systems
and Air Supply for Appliances," of the Natural Gas
and Propane Installation Code, CAN/CSA B149.1,
or applicable provisions of the local building codes.
Observe all general venting guidelines provided in
Appendix B—Venting. Additionally:
1. Install any of the following for this Category
I, draft hood equipped appliance:
a. Type B or Type L gas vent. Install
in accordance with listing and
manufacturer's instructions.
b. Masonry or metal chimney. Build
and install in accordance with local
building codes; or local authority having
jurisdiction; or Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning
Appliances, ANSI/NFPA 211 and/or
National Building Code of Canada.
Masonry chimney must be lined with listed
chimney lining system. Clay ue lined
masonry chimneys do not meet venting
requirements for this appliance.
c. Do not use cellular core PVC (ASTM
F891), cellular core CPVC, or Radel®
(polyphenolsulfone).
d. Do not cover non-metallic vent pipe and
ttings with thermal insulation.
Note: Non-metallic vent cannot be used
with this boiler.
2. Attach the vent damper with three
sheetmetal screws around the perimeter of
the ue collar (Figure 4-a). The vent damper
may also be mounted anywhere between the
ue outlet and the chimney within reach of
the electrical harness.
a. Do not modify either draft hood for vent
damper.
b. Maintain minimum 6" (152 mm)
between vent damper and combustible
construction.
c. Position indicator must be visible following
installation.
d. Provide access for service.
3. Vent connector shall be double-wall
insulated gas vent as supplied with this
boiler or Type B (double-wall) gas vent only.
Using sheetmetal screws, attach the vent
connector between the vent damper and the
vertical chimney (Figure 4-b).
of Natural Gas and Propane Installation Code,
CAN/CSA B149.1, or applicable provisions of the
local building codes.
Like all fuel-burning appliances, boilers need air to
operate reliably and safely.
Provide combustion air using the instructions in
Appendix A—Combustion Air.

11
4-a
DAMPER MUST BE OPEN when the main burner is ring.
4-b
4. CONNECT VENTING (continued)
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). In Canada, close
nipples and street ells are not approved for
use as gas piping.
3. Pipe through the left jacket panel, and
complete drip leg as shown (Figure 5-a).
5-a
Le registre doit être ouvert lorsque le brûleur principal de l’appareil
fonctionne.

12
6. CONNECT BOILER WATER PIPING
4. Screw the relief valve into manifold tapping
“RV”.
i This installation is not complete until the
relief valve is installed.
PIPE THE RELIEF VALVE DISCHARGE
to a location where it will not harm
people or damage property. The relief valve may
discharge scalding hot water or steam.
BLOCKING THE RELIEF VALVE may
result in boiler explosion.
5. Screw the temperature-pressure gage into
manifold tapping “G”.
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.
General system piping guidelines are included in
Appendix D—System Piping.
Additionally, for this particular boiler install piping
shown below (Figure 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.
6-a
RV
S
R
O
G
D
Item Description Part Number
1 1¼ x 1¼ x ½ Tee 806601021
2 Immersion Well, ½ NPT 80160456
3 1¼ x 6 Nipple 806600029
41¼ 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
6-b

13
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".
WIRE AN ADDITIONAL SAFETY LIMIT
such as a low water cutoff or temperature
limit device, other than an IQ Control System, in
series with the 120V circuit used to power the
boiler. Do not alter the boiler’s factory wiring when
adding an additional limit.
7. CONNECT ELECTRICAL WIRING
5. Connect the 24V wiring from the thermostat
to the "T-T" terminals on the Option Control
Panel.
6. Insert vent damper harness to vent damper.
7. To connect other external devices, refer to
the instructions included with these devices.
7-a
1

123 T T
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.
Electrically bond to ground and install over-current
protection in accordance with requirements of
authority having jurisdiction or, in the absence of
such requirements, with the National Electrical
Code, ANSI/NFPA 70, and/or the Canadian
Electrical Code Part 1, CSA C22.1, Electrical
Code. Do not provide over-current protection
greater than 15 amperes.

14
Using Intelligent Hydronic Control Display
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 control
display information:
1. Press and release the “I” key on the
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
4 Prepurge
6 Spark
7 Flame Proving
8 Running
10 Retry/Recycle Delay
13 Soft Lockout
14 Hard Lockout
15 Waiting for Limit to Close
16 Flame Present Out of Sequence
17 Self Test
18 Waiting for Damper to Open
20 Damper Failure to Open
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.
The Intelligent Hydronic Control (control) is located
inside the boiler front door, just above the IQ
Option Panel (Figure 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.
8-b
Intelligent
Hydronic Control
IQ Option Panel
8-a
Intelligent Hydronic Control

15
Unit Display
OR
Sample
Display
1 sec
1 sec
1 sec
Please note that in operating mode to hold the
display on the value the user can press and hold
either the Up ñor 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_ 140-220°F Adjust High Limit Setting
dF_ 10-30°F Adjust High Limit Differential
Or_ 0-10 minutes Circulator Overrun Time
PP_ 2-20 minutes Circulator Pre-purge Time
St_ 140-180°F Start Temperature
Pt_ On or off Priority time
dh_ dh or tt2 DH Terminal Function
rst Reset Lockout
f-C For C Select degrees F or C Mode
bac Back to Operating Mode
3. Press the Up ñand Down ò keys to adjust
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 ñor Down
ò key. If no keys are pressed, after ve (5)
minutes the control will automatically return
to the Operating Mode.
8. PROGRAM THE CONTROLS (continued)
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 this value. The High Limit setpoint
is adjustable between 140° and 220°F. 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.
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

16
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)
5. Start Temperature (St_)
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.
Table 8a: Circulator Pre-purge Time example,
(PP_ = 2 minutes)
Call for
Heat
Source
DHW
Terminal
Selection
Boiler
Temperature Burner Status
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
7. Domestic Hot Water (DHW) Terminal
Function (dh_)
The control allows conguration of the
DHW Circulator output functionality to help
the boiler 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
DHW
Input
Priority
Time
(Pt_)
System
Circulator
Output
DHW
Circulator
Output
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

17
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 de-
energized 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.
Table 8c: DHW Terminal Function (dh_)
Selection = Second Heating Zone,
(Parameter dh_ = tt2)
Call for Heat Circulator Status
T-T
Input
DHW
Input
System
Circulator
Output
(Zone 3)
DHW
Circulator
Output
(Zone 2)
off off off off
on off on off
on on on on
off on off on
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 ES2 plastic hood above
the front door. For installation, programming,
and troubleshooting instructions, refer to the
instructions supplied with the display.
9. CHECK FOR GAS AND WATER 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 for Leaks

18
10-b
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.
qBoiler lights cleanly within 60 seconds.
5. Adjust gas input rate. See Appendix F –
Adjusting Gas Input Rate. Check main
burner and pilot ames. See Figures 10-a
and 10-c.
10-a
qPilot and main burner flames appear
clean and blue.
6. Disconnect pilot lead wires from gas valve
(Figure 10-b).
qBoiler shuts off.
7. Reconnect pilot lead wires to gas valve.
qBoiler restarts.
8. Adjust zone thermostat to minimum setting.
qBoiler shuts off.
9. Adjust zone thermostat to maximum setting.
10. Observe temperature gage as boiler heats.
11. Adjust the high limit setting to its minimum
level (see "Programming High Limit" in
Section 8).
qBoiler shuts off when temperature gage
reads within 15°F of high limit setting.
10-c

19
12. Return high limit to the desired setting (see
"Programming High Limit" in Section 8).
13. Check draft. See Appendix G
– Checking Draft and Combustion.
qNo spillage observed.
14. Check combustion in the vent stack and
record results in the spaces provided below.
_____ CO2 (less than 7%)
_____ O2 (more than 9%)
_____ CO (less than 50 ppm, air free)
ANY FAILED STARTUP CHECK
Must be corrected before placing the boiler
in service.
10. PERFORM STARTUP CHECKS AND ADJUSTMENTS (continued)
WARNINGS
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.
CAUTION: LABEL ALL WIRES prior to
disconnection when servicing controls. Wiring
errors can cause improper and dangerous
operation.
ATTENTION. Au moment de l’entretien des
commandes, étiquetez tous les ls avant de les
débrancher. Les erreurs de câblage peuvent nuire
au bon fonctionnement et être dangereuses.
FAILURE TO MAINTAIN THE BOILER in proper
working condition may lead to re, explosion,
personal injury or death, and extensive property
damage.
TURN OFF ALL GAS AND ELECTRIC power
supplies to the boiler before servicing. Contact with
or release of dangerous ammable gas, electrical
voltage, moving parts, and very hot water under
pressure may cause serious personal injury,
property damage, or death.
LOCK ELECTRICAL BOXES AND GAS VALVES
CLOSED to prevent someone from inadvertently
restoring power or gas before the heating system is
safe to operate.
ANNUAL MAINTENANCE CHECKLIST

20
AM-1
Equipment you will need:
qSoft bristle brush
q Bristle ue brush
q Vacuum with brush attachment
Perform these tasks each year:
1. Clean low water cutoff probe (if applicable).
Flush oat-type low water cutoff (if
applicable).
2. Inspect vent for obstruction and signs of
condensation, distortion, overheating or gas
leakage.
3. Clean vent terminal and air intake screens.
4. Inspect boiler ue passages:
(1) Remove vent pipe, damper.
(2) Remove top panel and hood.
(3) Remove blocked vent switch and
canopy.
(4) Examine all ue passageways. Using
bristle ue brush and vacuum,
remove any soot or obstructions.
5. Remove and clean main burners:
(1) Remove jacket front panel.
(2) Disconnect pilot tubing at gas valve.
(3) Disconnect pilot lead wires at gas valve.
(4) Remove wires from ame roll-out switch.
(5) Remove burner access panel.
(6) Mark location of the pilot main burner on
the manifold if the marking on manifold
is missing or obliterated.
(7) Hold burner at throat. Lift front of burner
to clear orice (Figure AM-1). The
burner that holds the pilot can only be
removed by rst lifting the burner
adjacent to its right.
6. Perform Startup Checks and Adjustments
described earlier in this manual.
7. Check operation of airow sensing switches.
8. Check for water leaks on the boiler or water
pooling around boiler.
9. Manually operate the relief valve. If the
water is grey or black, there is excessive
oxygen in the system. Oxygen is corrosive
to boilers. Eliminate any source of oxygen.
10. Verify proper operation after servicing.
S’assurer que l’appareil fonctionne
adéquatement une fois l’entretien terminé.
ANNUAL MAINTENANCE CHECKLIST (continued)