U.S. Boiler Company ESC Service manual

INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
ESC™
ENHANCED SEALED COMBUSTION
Gas - Fired Boiler
103788-03 - 9/13
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
Boiler Serial Number Installation Date
Heating Contractor Phone Number
Address
9700609
Price - $5.00

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 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 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.
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.
WARNINGS foR the INStALLeR

4
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.

5
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.
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)
What's in the crate?
*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.

6
ESC Series
Boiler Model Input (MBH) Heating Capacity
(MBH)
Net AHRI Rating, Water
(MBH) (1) AFUE (%)
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.
Ratings
SPECIFICATIONS
Boiler
Model Depth Width Height Supply NPT (inch)
Return NPT
(inch)
Vent
(inch)
Air
Intake
(inch)
Gas NPT
(inch)
Relief Valve
NPT
(inch)
Drain
IPS
(inch)
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
Dimensions, Weights and Connections
Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A
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)
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
Water Temperatures and Flows
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
Weights and Volume
Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi relief valved.

7
Figure S-1: Minimum Clearances to Combustibles
SPECIFICATIONS (continued)

8
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
BOILER QUICK-START

9
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. UNPACK THE CRATE
4. Tip the boiler and shimmy it off the skid.
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.
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.
1-a 1-b
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.
4. Level the boiler, using shims as necessary.

10
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.
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.
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
4-a 4-b
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.

11
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

12
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).
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
5-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”.
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”.
RV
S
R
O
G
D

13
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”.
6. CONNECT BOILER WATER PIPING (continued)
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
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

14
7. CONNECT ELECTRICAL WIRING
7-a
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".
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.
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.
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 over-
current protection greater than 15 amperes.

15
8. PROGRAM THE CONTROLS
Using Intelligent Hydronic Control Display 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
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 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-a
IQ Option Panel
Intelligent
Hydronic Control
8-b
Intelligent Hydronic Control
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:
Unit Display
OR
Sample
Display
1 sec
1 sec
1 sec

16
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 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.
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.

17
8. PROGRAM THE CONTROLS (continued)
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 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
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 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

18
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
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 1)
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 ESC plastic hood above
the front door. For installation, programming,
and troubleshooting instructions, refer to the
instructions supplied with the display.

19
10. PERFORM STARTUP CHECKS AND ADJUSTMENTS
10-b
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
qPilot and main burner flames appear
clean and blue.
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.
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.
_____ CO2 (less than 7%)
_____ O2 (more than 9%)
_____ CO (less than 100 ppm, air free)
ANY FAILED STARTUP CHECK
Must be corrected before placing the boiler
in service.
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.
10-c
10-a

20
Figure 10-d: Operating Instructions
10. PERFORM STARTUP CHECKS AND ADJUSTMENTS (continued)