A.O. Smith 2000 User Manual
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Instruction Manual

 

 

 

 

 

 

 

 

 

 

 

 

 

XP BOILER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MODELS: XB/XW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1000, 1300, 1700

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2000, 2600, 3400

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SERIES 100/101

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INSTALLATION - OPERATION -

 

 

 

 

 

 

25589

Highway

1

 

 

 

 

 

 

 

 

 

McBee,

SC 29101

 

 

 

MAINTENANCE - LIMITED WARRANTY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

Thank you for buying this energy efficient boiler.

We appreciate your confidence in our products.

PRINTED IN THE U.S.A. 0711

320741-002

TABLE OF CONTENTS

TABLE OF CONTENTS 2

SAFE INSTALLATION, USE AND SERVICE 3

GENERAL SAFETY 4

INTRODUCTION 5

Model Identification 5

Abbreviations Used 5

Qualifications 5

DIMENSIONS AND CAPACITY DATA 6

FEATURES AND COMPONENTS 10

Component Description 12

CONTROL COMPONENTS 13

BOILER INSTALLATION CONSIDERATIONS 15

Hydronic System 15

Hot water boiler system - general water line connections 16

GENERAL REQUIREMENTS 21

Location 21

Fresh air openings for confined spaces 23

VENTING 25

Vent Installation Considerations 25

Venting Supports 27

CONDENSATE DISPOSAL 37

GAS SUPPLY CONNECTIONS 38

BOILER START UP AND OPERATIONS 40

LIGHTING AND OPERATING INSTRUCTIONS 42

CONTROL SYSTEM 45

Burner Control System 45

Burner control operation 46

General operational sequence 47

Local operator interface: display system 49

Installation instructions (S7999B OI Display) 50

Starting up the S7999B OI Display 51

Page Navigation 51

TROUBLESHOOTING 61

MAINTENANCE PROCEDURES 76

Maintenance schedules 76

General maintenance 76

Burner maintenance 77

Venting maintenance 78

Heat exchanger maintenance 78

Handling ceramic fiber materials 79

Replacement parts 79

PIPING DIAGRAMS 80

LIMITED WARRANTY 82

2

SAFE INSTALLATION, USE AND SERVICE

The proper installation, use and servicing of this boiler is extremely important to your safety and the safety of others.

Many safety-relatedmessages 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 messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this boiler.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently

DANGER hazardous situation which, if not avoided, will result in injury or death.

WARNING indicates a potentially hazardous

WARNING situation which, if not avoided, could result in injury or death.

CAUTION indicates a potentially hazardous

CAUTION situation which, if not avoided, could result in minor or moderate injury.

CAUTION used without the safety alert CAUTION symbol indicates a potentially hazardous

situation which, if not avoided, could result in property damage.

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and how to avoid the risk of injury.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This boiler can cause low level exposure to some of the substances listed in the Act.

IMPORTANT DEFINITIONS

Gas Supplier:

The

Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning

appliances

within

this

application. The gas

supplier typically has responsibility for the inspection and

code approval of

gas piping

up to

and including the Natural

Gas meter or Propane storage tank of a building. Many

gas suppliers also

offer service and inspection of appliances within the building.

APPROVALS

3

 

GENERAL SAFETY

GROUNDING INSTRUCTIONS

 

 

HIGH ALTITUDE INSTALLATIONS

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 system, or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the boiler.

INLET WATER CONSIDERATIONS

Circulating water through the boiler and to the remote storage tank (if applicable)­ is accomplished by a pump on XW models only. For hot water heating systems using the XB model, the circulating pump is NOT provided on standard models (optional) and must be field installed.

CORRECT GAS

Make sure the gas on which the boiler will operate is the same as that specified­ on the boiler rating plate. Do not install the boiler if equipped for a different type of gas; consult­ your supplier.

PRECAUTIONS

If the unit is exposed to the following, do not operate until all corrective steps have been made by a qualified service agent:

1.Exposure to fire.

2.If damaged.

3.Firing without water.

4.Sooting.

If the boiler has been exposed to flooding, it must be replaced.

LIQUEFIED PETROLEUM GAS MODELS

Boilers for propane or liquefied petroleum gas (LPG) are different fromnaturalgasmodels.Anaturalgasboilerwillnotfunctionsafely on LPgas and no attempt should be made to convert a boiler from natural gas to LP gas.

LP gas must be used with great caution. It is highly explosive and heavier than air. It collects first in the low areas making its odor difficult to detect at nose level. If LP gas is present or even suspected, do not attempt to find the cause yourself. Leave the building, leaving doors open to ventilate, then call your gas supplier or service agent. Keep area clear until a service call has been made.

At times you may not be able to smell an LP gas leak. One cause is odor fade, which is a loss of the chemical odorant that gives LP gas its distinctive smell. Another cause can be your physical condition, such as having a cold or diminishing sense of smell with age. For these reasons, the use of a propane gas detector is recommended.

If you experience an out of gas situation, do not try to relight appliances yourself. Call your local service agent. Only trained LP professionals should conduct the required safety checks in accordance with industry standards.

Rated inputs are suitable up to 2000 feet (610 m) elevation. Consult the factory for installation at altitudes over 2000 feet (610 m).

FIELD INSTALLED COMPONENTS

When installing the boiler, the follow­ing components­ must be installed:

Circulating Pump (Hydronic)­

Remote Temperature Sensor/Header Sensor

Storage Tank (Temperature & Pressure Relief Valve)

4

INTRODUCTION

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.

MODEL IDENTIFICATION

Check the rating plate affixed to the Boiler. The following information describes the model number structure:

SERIES-100/101DESIGNATION:

• XP = Extreme Performance

MODEL (APPLICATION):

XB = Hydronic Heating Boiler

XW = Domestic Hot Water Supply Boiler

SIZE:

1000 = 920,000 Btu/hr input

1300 = 1,300,000 Btu/hr input

1700 = 1,700,000 Btu/hr input

2000 = 2,000,000 Btu/hr input

2600 = 2,600,000 Btu/hr input

3400 = 3,400,000 Btu/hr input

FUEL:

N = Natural gas P = Propane

NOTE:

XB models are equipped with 50 psi pressure relief valve. (pump is optionally installed)

XW models are factory installed circulating pump (standard), with 125 psi pressure relief valve.

XB models can be special ordered with a factory installed pump and XW models can be special ordered without the factory installed pump. These factory configurations can also be changed in the field by installing circulation pumps and changing pressure relief valves to accommodate domestic and hydronic hot water system requirements.

Properly installed and maintained, it should give you years of trouble free service.

ABBREVIATIONS USED

Abbreviations found in this Instruction Manual include :

ANSI - American National Standards Institute

ASME - American Society of Mechanical Engineers

NEC - National Electrical Code

NFPA - National Fire Protection Association

UL - Underwriters Laboratory

CSA - Canadian Standards Association

AHRI - Air-Conditioning,Heating and Refrigeration Institute

QUALIFICATIONS

QUALIFIED INSTALLER OR SERVICE AGENCY

Installation and service of this boiler requires ability equivalent to that of a Qualified Agency, as defined by ANSI below. In the field involved. Installation skills such as plumbing, air supply, venting, gas supply and electrical supply are required in addition to electrical testing skills when performing service.

ANSI Z21.13 - CSA 4.9: “Qualified Agency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”

If you are not qualified (as defined by ANSI above) and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual. If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual.

This product requires a formal Start-Upby an authorized service/start-upprovider that has been approved by the manufacturer for this specific product. Call1-800-527-1953to locate the nearest authorizedstart-upprovider and arrange a factorystart-up.Please provide as much notice as possible, preferably 2 weeks. Please have the model and serial number ready when you call. Thisstart-upis required to activate the warranty and ensure safe, efficient operation.

Warranty on this product is limited and could be void in the event the unit is not installed per the instructions in this manual and/or not started up by an authorized factory trained service/start-upprovider.

5

DIMENSIONS AND CAPACITY DATA

Figure 1.  SINGLE HEAT EXCHANGER BOILER

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 NPT

 

 

 

 

 

 

 

 

 

 

Gas Inlet

 

 

2 inch NPT

 

2 inch NPT

 

 

 

 

 

 

 

 

 

 

 

A

47

1199

 

49

1245

57

 

1448

B

67

1702

 

68

1727

76

 

1930

C

29

737

 

29

737

29

 

737

D

37

940

 

38

965

37

 

940

E

23

584

 

23

584

24

 

610

F

9

229

 

9

229

9

 

229

G

34

864

 

34

864

34

 

864

H

44

1118

 

45

1143

45

 

1143

J

6

152

 

6

152

6

 

152

K

11

279

 

11

279

11

 

279

L

12

305

 

11

279

12

 

305

Table 2.  OPERATING CHARACTERISTICS

Models

 

Manifold Pressure

 

Maximum Supply Pressure

Minimum Supply Pressure

(XB/XW)

Type of Gas

 

Inches W.C.

kPa

Inches W.C.

kPa

Inches W.C.

kPa

 

Natural

Min Fire

-0.2to - 0.3

-0.05to - 0.07

14.0

3.49

4.0

1.0

 

 

 

 

1000, 1300, 1700

Max Fire

-3.0to-3.9

-0.75to-0.97

 

 

 

 

 

2000, 2600, 3400

 

 

 

 

 

 

 

 

Propane

Min Fire

-0.1to - 0.3

-0.025to-0.07

14.0

3.49

4.0

2.0

 

 

 

 

 

 

Max Fire

-3.6to-4.9

-0.90to-1.22

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

Figure 2.  DOUBLE HEAT EXCHANGER BOILER

Table 3.  ROUGH IN DIMENSIONS (DOUBLE)

Models

XB/XW-2000

 

 

XB/XW-2600

XB/XW-3400

 

 

 

 

 

 

 

 

 

 

Dimensions

inches

mm

 

 

inches

mm

inches

 

mm

Flue Outlet Diameter

8

203

 

8

203

10

 

254

 

 

 

 

 

 

 

 

 

 

Air Intake Diameter

8

203

 

8

203

10

 

254

 

 

 

 

 

 

 

 

 

 

Water Inlet

 

 

3 inch NPT

 

4 inch NPT

 

Water Outlet

 

 

3 inch NPT

 

4 inch NPT

 

Gas Inlet

 

 

2 inch NPT

 

3 inch NPT

 

A

47

1194

 

49

1245

57

 

1448

B

78

1981

 

80

2032

91

 

2311

C

36

914

 

37

940

37

 

940

D

22

559

 

22

559

22

 

559

E

40

1016

 

41

1041

41

 

1041

F

7

178

 

6

152

6

 

152

G

10

254

 

10

254

10

 

254

H

4

102

 

4

102

4

 

102

J

20

508

 

19

483

19

 

483

K

12

305

 

12

305

13

 

330

Table 4.  RECOVERY CAPACITIES

 

Input Rating

Output Rating

Water

 

 

Temperature Rise - ΔT °F (°C)

 

 

Models

 

 

 

 

 

 

 

 

40

60

70

80

90

100

120

140

 

(Btu/hr)

(Btu/hr)

Flow

 

 

 

 

(22)

(33)

(39)

(44)

(50)

(56)

(67)

(78)

 

 

 

 

 

 

 

 

 

 

 

 

XW-1000

920,000

854,680

GPH

2,593

1,728

1,482

1,296

1,152

1,037

864

741

LPH

9,815

6,543

5,608

4,907

4,362

3,926

3,272

2,804

 

 

 

XW-1300

1,300,000

1,207,700

GPH

3,664

2,442

2,094

1,832

1,628

1,465

1,221

1,047

LPH

13,868

9,246

7,925

6,934

6,164

5,547

4,623

3,962

 

 

 

XW-1700

1,700,000

1,579,300

GPH

4,791

3,194

2,738

2,395

2,129

1,916

1,597

1,369

LPH

18,136

12,090

10,363

9,068

8,060

7,254

6,045

5,182

 

 

 

XW-2000

2,000,000

1,858,000

GPH

5,636

3,758

3,221

2,818

2,505

2,255

1,879

1,610

LPH

21,336

14,224

12,192

10,668

9,483

8,534

7,112

6,096

 

 

 

XW-2600

2,600,000

2,415,400

GPH

7,327

4,885

4,187

3,664

3,257

2,931

2,442

2,094

LPH

27,737

18,491

15,850

13,868

12,327

11,095

9,246

7,925

 

 

 

XW-3400

3,400,000

3,158,600

GPH

9,582

6,388

5,475

4,791

4,259

3,833

3,194

2,738

LPH

36,271

24,181

20,726

18,136

16,121

14,508

12,090

10,363

 

 

 

7

RATINGS

Table 5.  IBR RATINGS

MODELS

INPUT

GROSS

NET I=B=R RATINGS WATER MBH

(XB/XW)

 

MBH

OUTPUT MBH

(NOTE 2)

 

MAX

 

MIN

(NOTE 1)

 

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

Notes:

1.The ratings are based on standard test procedures prescribed by the United States Department of Energy.

2.Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

3.Ratings have been confirmed by the Hydronics Institute, Section of AHRI.

ELECTRICAL REQUIREMENTS

Table 6.  ELECTRICAL REQUIREMENTS

MODELS

SUPPLY VOLTAGE

FREQUENCY

CURRENT

ELECTRICAL NOTES

(XB/XW)

(VOLTS)

(HZ)

(AMPS)

 

1000

120

60

30

A dedicated, single phase, 30/60 amp circuit breaker

1300

120

60

30

with a grounded neutral should be provided to supply

power to the boiler.

 

 

 

 

1700

120

60

30

 

2000

120

60

60

A dedicated, single phase, 60/60 amp circuit breaker

 

 

 

 

with a grounded neutral should be provided to supply

2600

120

60

60

power to the boiler.

3400

120

60

60

 

8

FLOW, HEAD AND TEMPERATURE RISE

Table 7.  XB MODELS - FLOW, HEAD AND TEMPERATURE RISE

 

Input

Output

Water

Temperature Rise - ΔT °F

Flow Rate

Models

 

 

 

 

 

 

 

 

 

 

(Btu/hr)

(Btu/hr)

Flow

20

30

40

Maximum

Minimum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GPM

86

56

43

86

43

XB-1000

920,000

855,600

LPM

325

211

162

325

162

ΔP FT

26

12

7

26

7

 

 

 

 

 

 

ΔP M

7.9

3.7

2.1

7.9

2.1

 

 

 

GPM

120

80

60

120

60

XB-1300

1,300,000

1,209,000

LPM

453

302

226

453

226

ΔP FT

32.5

15

8

32.5

8

 

 

 

 

 

 

ΔP M

9.9

4.6

2.4

9.9

2.4

 

 

 

GPM

156

104

78

156

78

XB-1700

1,700,000

1,581,000

LPM

592

395

296

592

296

ΔP FT

35

14

8

35

8

 

 

 

 

 

 

ΔP M

10.7

4.3

2.4

10.7

2.4

 

 

 

GPM

184

123

92

184

92

XB-2000

2,000,000

1,860,000

LPM

696

464

348

696

348

ΔP FT

26

12

7

26

7

 

 

 

 

 

 

ΔP M

7.9

3.7

2.1

7.9

2.1

 

 

 

GPM

239

159

120

239

120

XB-2600

2,600,000

2,418,000

LPM

905

604

453

905

453

ΔP FT

32.5

15

8

32.5

8

 

 

 

 

 

 

ΔP M

9.9

4.6

2.4

9.9

2.4

 

 

 

GPM

313

209

156

313

156

XB-3400

3,400,000

3,162,000

LPM

1184

789

592

1184

592

ΔP FT

35

14

8

35

8

 

 

 

 

 

 

ΔP M

10.7

4.3

2.4

10.7

2.4

Note: Head Loss shown is through the boiler only and allows for no additional piping.

9

FEATURES AND COMPONENTS

Figure 3.  SINGLE HEAT EXCHANGER BOILER COMPONENTS

10