Page 2 - TABLE OF CONTENTS
2 TABLE OF CONTENTS TABLE OF CONTENTS .......................................................................... 2 SAFE INSTALLATION, USE AND SERVICE .......................................... 3 GENERAL SAFETY ................................................................................ 4 INTRODU...
Page 3 - IMPORTANT DEFINITIONS; offer service and inspection of appliances within the building.; SAFE INSTALLATION, USE AND SERVICE
3 The proper installation, use and servicing of this boiler is extremely important to your safety and the safety of others.Many safety-related messages and instructions have been provided in this manual and on your boiler to warn you and others of a potential injury hazard. Read and obey all safety ...
Page 4 - GENERAL SAFETY
4 GROUNDING INSTRUCTIONS This boiler must be grounded in accordance with the National Electrical Code, Canadian Electrical Code and/or local codes. Boiler is polarity sensitive; correct wiring is imperative for proper operation. This boiler must be connected to a grounded metal, permanent wiring sys...
Page 5 - INTRODUCTION; QUALIFICATIONS; QUALIFIED INSTALLER OR SERVICE AGENCY
5 This Instruction Manual covers XP Boiler models XB/XW 1000, 1300, 1700, 2000, 2600, 3400 - Series 100/101. The instructions and illustrations contained in this Instruction manual will provide you with troubleshooting procedures to diagnose and repair common problems and verify proper operation. MO...
Page 6 - DIMENSIONS AND CAPACITY DATA; TABLE 2. OPERATING CHARACTERISTICS; FIGURE 1. SINGLE HEAT EXCHANGER BOILER
6 DIMENSIONS AND CAPACITY DATA TABLE 1. ROUGH IN DIMENSIONS (SINGLE) Models XB/XW-1000 XB/XW-1300 XB/XW-1700 Dimensions inches mm inches mm inches mm Flue Outlet Diameter 6 152 8 152 8 203 Air Intake Diameter 6 152 6 152 8 203 Water Inlet 2 inch NPT 2 1/2 inch NPT Water Outlet 2 inch NPT 2 1/2 inch ...
Page 8 - RATINGS; TABLE 5. IBR RATINGS; with a grounded neutral should be provided to supply; ELECTRICAL REQUIREMENTS; TABLE 6. ELECTRICAL REQUIREMENTS
8 MODELS (XB/XW) INPUT MBH GROSS OUTPUT MBH (NOTE 1) NET I=B=R RATINGS WATER MBH (NOTE 2) MAX MIN 1000 920 100 856 744 1300 1300 130 1209 1051 1700 1700 170 1581 1375 2000 2000 100 1860 1617 2600 2600 130 2418 2103 3400 3400 212 3162 2750 RATINGS TABLE 5. IBR RATINGS Notes: 1. The ratings are based ...
Page 9 - FLOW, HEAD AND TEMPERATURE RISE; Temperature Rise - ΔT °F
9 FLOW, HEAD AND TEMPERATURE RISE TABLE 7. XB MODELS - FLOW, HEAD AND TEMPERATURE RISE Models Input (Btu/hr) Output (Btu/hr) Water Flow Temperature Rise - ΔT °F Flow Rate 20 30 40 Maximum Minimum XB-1000 920,000 855,600 GPM 86 56 43 86 43 LPM 325 211 162 325 162 ΔP FT 26 12 7 26 7 ΔP M 7.9 3.7 2.1 7...
Page 10 - FEATURES AND COMPONENTS; FIGURE 3. SINGLE HEAT EXCHANGER BOILER COMPONENTS
10 FEATURES AND COMPONENTS FIGURE 3. SINGLE HEAT EXCHANGER BOILER COMPONENTS
Page 11 - FIGURE 4. DOUBLE HEAT EXCHANGER BOILER COMPONENTS
11 FIGURE 4. DOUBLE HEAT EXCHANGER BOILER COMPONENTS
Page 12 - COMPONENT DESCRIPTION; Do not use this switch for
12 COMPONENT DESCRIPTION 1. Front access door: Provides access to the gas train, burner controllers and the heat exchanger. 2. Air Filter Box: Allows for the connection of the PVC air intake pipe to the boiler through a standard PVC adapter. It uses a filter to prevent dust and debris from entering ...
Page 13 - FIGURE 9. WATER FLOW SWITCH; THE CONTROL SYSTEM; FIGURE 5. BURNER CONTROL SYSTEM; SPARK IGNITER; FIGURE 6. SPARK IGNITER; LOW/HIGH GAS PRESSURE SWITCH; CONTROL COMPONENTS
13 FIGURE 7. LOW/HIGH GAS PRESSURE SWITCH GAS VALVE The gas valve is a normally closed servo regulated gas valve. The valve opens only when energized by the burner control and closes when the power is removed. The burner control supplies 24 volts to the gas valve during operation. FIGURE 8. GAS VALV...
Page 15 - BOILER INSTALLATION CONSIDERATIONS
15 GENERAL If the system is to be filled with water for testing or other purposes during cold weather and before actual operation, care must be taken to prevent freezing of water in the system. Failure to do so may cause the water in the system to freeze with resulting damage to the system. Damage d...
Page 17 - XW HOT WATER BOILERS,; of; GAS CONNECTIONS; CAUTION; Pressure Relief Valve discharge pipe must; Water Damage Hazard; Explosion Hazard
17 A discharge pipe from the relief valve should terminate at an adequate floor drain. Do not thread, plug, or cap the end of drain line. The Discharge Pipe: • Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions. • Shall not be pl...
Page 18 - CORROSIVE MATERIALS AND CONTAMINATION; Refrigeration repair shops; GAS SUPPLY LINE SIZING
18 TABLE 8. SINGLE UNIT INSTALLATION, SUGGESTED GAS PIPE SIZING. MAXIMUM EQUIVALENT PIPE LENGTH (IN FEET). BTU Input 2” 2-1/2” 3” 4” Nat Pro Nat Pro Nat Pro Nat Pro 920,000 70 150 175 ----- ----- ----- ----- ----- 1,300,000 40 100 100 200 ----- ----- ----- ----- 1,700,000 20 60 70 150 200 ----- ----...
Page 19 - FIELD WIRING
19 • Auto body shops • Plastic manufacturing plants • Furniture refinishing areas and establishments • New building construction • Remodeling areas Common household products, pool and laundry products may contain fluorine or chlorine compounds. When these chemicals come in contact with the boiler, t...
Page 21 - GENERAL REQUIREMENTS; REQUIRED ABILITY; are not in operation.
21 GENERAL REQUIREMENTS REQUIRED ABILITY Installation or service of this boiler requires ability equivalent to that of a licensed trades man in the field involved. Plumbing, air supply, venting, gas supply, and electrical work are re quired. LOCATION When installing the boiler, consideration must be...
Page 22 - Breathing Hazard - Carbon Monoxide Gas; Rear
22 LEVELING Because this unit is a Category IV appliance it produces some amounts of condensation. The unit has a condensation disposal system that requires this unit to be level to properly drain. Each unit should be checked to be certain that it is level prior to starting the unit. If the unit is ...
Page 23 - CONFINED SPACE; DIRECT VENT APPLIANCES; FRESH AIR OPENINGS FOR CONFINED SPACES; FIGURE 17. OUTDOOR AIR THROUGH TWO OPENINGS
23 CONFINED SPACE A confined space is one whose volume is less than 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space.Openings must be installed to provide fresh air for combustion, ventilation and dilution in confined spaces....
Page 24 - FIGURE 19. OUTDOOR AIR THROUGH TWO HORIZONTAL
24 The confined space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The vertical ducts shall communicate directly with the outdoors. See Figure 20.Each duct opening...
Page 25 - VENTING; VENT INSTALLATION CONSIDERATIONS
25 VENTING Vent sizing, installation and termination should be in accordance with this installation manual. This boiler must be vented using PVC/CPVC or Stainless Steel materials.All electrical power and gas must be turned off prior to any installation of the venting system. VENT INSTALLATION CONSID...
Page 26 - FIGURE 22. PVC/CPVC VENTING WITH ADAPTER
26 VENT AND AIR PIPE INSTALLATION 1. Measure from the boiler level to vent. Refer to the Table 14 on Page 36 for the allowable lengths. 2. Prepare pipes to the required lengths and deburr the inside and outside of the pipe ends. Chamfer outside the pipe end to ensure even cement distribution when jo...
Page 28 - MODELS
28 FIGURE 25. VERTICAL VENTING FIGURE 26. HORIZONTAL VENTING MODELS (XB/XW) VENT KIT NUMBERS (RAIN CAP) 1000 320884-000 1300 320884-001 1700 320884-001 2000 320884-001 2600 320884-001 3400 320884-002 MODELS (XB/XW) VENT KIT NUMBERS (TEE) 1000 321765-000 1300 321765-001 1700 321765-001 2000 321765-00...
Page 31 - TERMINATION CLEARANCES SIDEWALL POWER VENT; POWER VENT; FIGURE 31. POWER VENT
31 TERMINATION CLEARANCES SIDEWALL POWER VENT V X VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED v v A G V FIXED CLOSED FIXED CLOSED OPERABLE OPERABLE V C B B B B F B V V A J V H M X X V V K B E D L POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT...
Page 32 - TERMINATION CLEARANCES SIDEWALL DIRECT VENT; FIGURE 32. DIRECT VENT; DIRECT VENT
32 TERMINATION CLEARANCES SIDEWALL DIRECT VENT FIGURE 32. DIRECT VENT Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion. CANADIAN INSTALLATIONS 1 US INSTALLATIONS 2 CANADIAN INSTALLATIONS 1 US INSTALLATIONS 2 A Clearance above grade, ...
Page 33 - as adopted by the Board and
33 For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side ...
Page 34 - DIRECT VENT: HORIZONTAL TERMINATION; TERMINATION
34 DIRECT VENT: HORIZONTAL TERMINATION Gas vent extending through an exterior wall must not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage. Install...
Page 35 - DIRECT VENTING: VERTICAL TERMINATION; PREPARE ROOF/WALL PENETRATIONS; VERTICAL
35 DIRECT VENTING: VERTICAL TERMINATION Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. VENT/AIR TERMINATION LOCATIONS: Follow these guidelines for locating the vent/air terminations: 1...
Page 36 - TABLE 14. DIRECT VENT ALLOWABLE AIR/VENT LENGTHS
36 ALL VENT PIPE MATERIALS AND FITTINGS MUST COMPLY WITH THE FOLLOWING: ITEM MATERIAL STANDARDS FOR INSTALLATION IN: UNITED STATES CANADA Vent pipe and fittings PVC schedule 40 ANSI/ASTM D1785 CPVC and PVC venting must be ULC-S636 Certified. CPVC schedule 40/80 ANSI/ASTM F441 Pipe cement/primer PVC ...
Page 37 - CONDENSATE NEUTRALIZER; CONDENSATE DISPOSAL; CONDENSATE TRAP
37 CONDENSATE NEUTRALIZER The condensate drains from the boiler have pH levels between 4.3 and 5.0. The pH measurement of a fluid is an indicator of the acidity or alkalinity. Neutral fluids have pH of 7.0. Acid fluids have pH below 7. Some local codes may require the use of a condensate neutralizer...
Page 38 - GAS PRESSURE REQUIREMENTS; GAS SUPPLY CONNECTIONS; GAS SUPPLY PIPE CONNECTIONS; FIGURE 41. GAS SUPPLY PIPING
38 6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow. Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property dam...
Page 40 - BOILER START UP AND OPERATIONS; FIGURE 42. GAS TRAIN ASSEMBLY
40 BOILER START UP AND OPERATIONS IMPORTANT Only an A.O. Smith Certified Start-up agent must perform the initial firing of the boiler. At this time the user should not hesitate to ask the start-up agent any questions regarding the operation and maintenance of the unit. If you still have questions, p...
Page 41 - FREEZE PROTECTION (HYDRONIC HEATING; HOT WATER CAN SCALD:; CHECK/CONTROL WATER HARDNESS
41 TABLE 18. WATER HARDNESS MEDIUM (0-12 GRAINS PER GALLON) XW MODEL NO. ∆T ºF GPM ∆P FEET 1000 25 76 17.5 1300 25 99 22 1700 25 129 23 2000 25 152 17.5 2600 25 198 22 3400 25 258 23 ∆T ºF = Temperature rise ºF at the specified GPM. GPM = Flow rate in gallons per minute. ∆P = Pressure loss through t...
Page 42 - LIGHTING AND OPERATING INSTRUCTIONS
Page 43 - FIGURE 43. BURNER HOME SCREEN
43 Click on Operation button, and under the Modulation Menu, set the required Firing rate (High/Low) by setting the RPM. On the Firing Rate page, set the Firing rate RPM by selecting the Manual in Run check box. ADJUSTMENT There must be sufficient load to operate the boiler at high fire to perform t...
Page 44 - counterclockwise rotation decreases gas flow.
44 TABLE 19. HIGH FIRE RATE TABLE 20. LOW FIRE RATE HIGH FIRING RATE SETTING Set the boiler to the high firing rate by setting the High Firing Rate RPM as described below. Check combustion readings using a combustion analyzer. If combustion readings are not in accordance with the chart below adjust ...
Page 45 - CONTROL SYSTEM; BURNER CONTROL SYSTEM
45 3. Three Pump Outputs with 5 selectable operation modes. 4. 24VAC: • Output control of gas valve (Pilot and Main) and External Ignition Transformer. • Digital inputs for room limit control, high limit control, Gas pressure switch, low water cutoff. 5. External spark transformer. 6. Flame Sensor. ...
Page 46 - BURNER CONTROL OPERATION; SAFETY SHUTDOWN OF BURNER CONTROL FUNCTIONS; COMMUNICATIONS AND DISPLAYS
46 CSD-1 Acceptable. Meets CSD-1 section CF-300 requirements as a Primary Safety Control. Meets CSD-1 section CW-400 requirements as a Temperature Operation control. Meets CSD-1 section CW-400 requirements as a Temperature High Limit Control when configured for use with 10 kohm NTC sensors. Federal ...
Page 47 - GENERAL OPERATIONAL SEQUENCE; INITIATE
47 GENERAL OPERATIONAL SEQUENCE INITIATE The R7910 enters the Initiate sequence on Initial Power up or: • Voltage fluctuations vary less than 20VAC or greater than 30VAC. • Frequency fluctuations vary +/-5% (57 to 63 Hz).• If Demand, LCI, or Stat interrupt (open) during the Prepurge Period. • After ...
Page 48 - DOMESTIC HOT WATER; LEAD LAG
48 LEAD LAG (LL) MASTER GENERAL OPERATION The XP Boiler is a multiple burner application and it works on the basis of the Lead Lag Operation. The XB Boiler is factory configured for Hydronic/Central Heating application, whereas the XW Boiler is factory configured for Domestic Hot Water application. ...
Page 49 - LOCAL OPERATOR INTERFACE: DISPLAY SYSTEM; FIGURE 49. BURNER CONTROL S7999B DISPLAY SYSTEM
49 For example:— If its add-stage action has been triggered, it will remain in this condition until either a stage has been added, Or — The criteria for its being in an add-stage condition is no longer met; only then will it take another look around to see what state it should go to next. DEFINITION...
Page 50 - FIGURE 50. S7999B OI DISPLAY CONNECTOR TERMINALS; SPECIFICATIONS; MOUNTING THE S7999B OI DISPLAY AND POWER SUPPLY
50 10. Drill 1/4 in. holes through the panel at the marked locations and secure the power supply with the two #6-32 screws and nuts provided. 11. Remove the 9-pin connector plug from the back of the OI Display. 12. Wire the connector to the power supply and the RS-485 cables. 13. Ensure the 9-pin co...
Page 51 - PAGE NAVIGATION; COMMON OI DISPLAY PAGE SYMBOLS; the user to the previous page.; STARTING UP THE S7999B OI DISPLAY
51 On System applications, each Burner Control System is represented on the Home page by an icon and name. Pressing the icon allows the user to zoom in on that boiler and see its specific details. These details are provided on a new page, which can include additional buttons that display additional ...
Page 53 - FIGURE 54. SUMMARY STATUS PAGE; CONFIGURE BUTTON
53 FIGURE 54. SUMMARY STATUS PAGE CONFIGURE BUTTON Pressing the Configure button (bottom left) on the Status page opens the Configuration page. The S7999B Configuration page does not have a “Display Setup” button. The configuration page allows the user to view and set parameters that define how the ...
Page 56 - Run Hours
56 FAULT/ALARM HANDLING Each Burner Control reports to the OI display when a safety lockout or an Alert occurs.Safety lockouts are indicated on each configuration page as an alarm bell symbol. At the status page (for S7999B), the History button turns red. If the S7999B is displaying the system statu...
Page 58 - OPERATION BUTTON; The operation button displays the Burner Control running; FIGURE 68. CONTROL EXPANDED ALERT DETAIL
58 OPERATION BUTTON The operation button displays the Burner Control running operation, including setpoint and firing rate values. From this page the user can change setpoints, manually control the boiler’s firing rate, manually turn pumps on, view annunciation information, and switch between hydron...
Page 60 - DHW Storage; SYSTEM SYNCHRONIZATION (S7999B OI DISPLAY ONLY)
60 CONFIGURATION The Burner Control can be configured from the OI Display. The control configuration is grouped into the functional groups as shown in Table 23. HYDRONIC CONTROL System Identification and Access CH - Central Heat Outdoor Reset DHW - Domestic Hot Water DHW Storage DHW Plate Warm Weath...
Page 61 - starts; TROUBLESHOOTING; TABLE 24. TROUBLESHOOTING CODES
61 To support the recommended Troubleshooting, the R7910 has an Alert File. Review the Alert history for possible trends that may have been occurring prior to the actual Lockout. Note Column: H= Hold message; L=Lockout message; H or L= either Hold or Lockout depending on Parameter Configuration. COD...
Page 63 - for proper operation.
63 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 67 ILK OFF 1. Check wiring and correct any possible shorts. 2. Check Interlock (ILK) switches to assure proper function. 3. Verify voltage through the interlock string to the interlock input with a voltmeter. 4. If steps 1-3 are c...
Page 67 - setting
67 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES NOTE 164 Block intake ON OEM Specific 1. Check wiring and correct any errors. 2. Inspect the Block Intake Switch to make sure it is working correctly. 3. Reset and sequence the module. 4. During Standby and Purge, measure the voltage a...
Page 69 - rate; CODE
69 CODE DESCRIPTION 37 Program Module application parameter revision differs from application processor 38 Program Module safety parameter revision differs from safety processor 39 PCB incompatible with product contained in Program Module 40 Parameter PCB in Program Module is too large for product 4...
Page 70 - greater than setpoint
70 CODE DESCRIPTION 114 MIX modulation range (max minus min) was too small (< 4% or 40 RPM)Modulation Operation Faults 115 Fan was limited to its minimum duty cycle 116 Manual rate was > CH max modulation rate 117 Manual rate was > DHW max modulation rate 118 Manual rate was < min modula...
Page 71 - setpoint
71 CODE DESCRIPTION 191 Lead Lag base load common setting was invalid 192 Lead Lag DHW demand switch setting was 193 Lead Lag Mix demand switch setting was invalid 194 Lead Lag modulation sensor setting was invalid 195 Lead Lag backup modulation sensor setting was invalid 196 Lead Lag slave mode set...
Page 75 - response
75 CODE DESCRIPTION 571 Heat exchanger high limit response was invalid 572 Heat exchanger high limit was exceeded 573 Heat exchanger high limit wasn't allowed due to stack limit setting 574 Heat exchanger high limit wasn't allowed due to stack connector setting 575 Heat exchanger high limit delay wa...
Page 76 - FIGURE 77. BURNER FLAMES; MAIN BURNER; MAINTENANCE PROCEDURES; tight; End of season months:
76 INSPECT BOILER AREA 1. Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids. 2. Verify that air intake area is free of any of the contaminants. If any of these are present in the boiler intake air vicinity, they must be removed. If they can...
Page 79 - Water Products Company, 500 Tennessee Waltz Parkway,
79 HANDLING CERAMIC FIBER MATERIALSRemoval of combustion chamber lining: The combustion chamber insulation in this boiler contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has...
Page 80 - PIPING DIAGRAMS; FIGURE; XP; LEGEND
80 PIPING DIAGRAMS FIGURE 78. PRIMAR Y/SECONDAR Y PIPING SYSTEM NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However , local codes shall govern...
Page 82 - LIMITED WARRANTY
82 LIMITED WARRANTY A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this boiler: 1. If within TEN years after initial installation of the boiler, a heat exchanger or gas burner should prove upon examination by the warrantor to be defective in material o...
