A.O. Smith 1000, 1300, 1700, 2000, 2600 User Manual

...

Instruction Manual

XB BOILER

MODELS: XB 1000, 1300, 1700 2000, 2600, 3400

SERIES 100/101

25589 Highway 1

McBee, SC 29101

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

MAINTENANCE - LIMITED WARRANTY

INSTALLATION - OPERATION -

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 efcient boiler. We appreciate your condence in our products.

PRINTED IN THE U.S.A. 0513 320741-005

TABLE OF CONTENTS ..........................................................................2

SAFE INSTALLATION, USE AND SERVICE.......................................... 3

GENERAL SAFETY................................................................................ 4

INTRODUCTION .................................................................................... 5

Model Identication ............................................................................ 5

Abbreviations Used ........................................................................... 5

Qualications ..................................................................................... 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 Conned Spaces ....................................... 23

VENTING .............................................................................................. 25

Vent Installation Considerations ...................................................... 25

CONDENSATE DISPOSAL .................................................................. 38

GAS SUPPLY CONNECTIONS ........................................................... 39

BOILER START UP AND OPERATIONS ............................................. 41

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 ....................................... 48

Installation Instructions (S7999D OI Display) .................................. 49

Starting Up The S7999D OI Display ................................................ 49

Page Navigation .............................................................................. 50

TROUBLESHOOTING ......................................................................... 59

MAINTENANCE PROCEDURES ......................................................... 74

Maintenance Schedules .................................................................. 74

General Maintenance ...................................................................... 74

Burner Maintenance ........................................................................ 75

Venting Maintenance ....................................................................... 76

Heat Exchanger Maintenance ......................................................... 76

Handling Ceramic Fiber Materials ................................................... 77

Replacement Parts .......................................................................... 77

PIPING DIAGRAMS ............................................................................. 78

LIMITED WARRANTY .......................................................................... 79

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-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 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

WARNING

CAUTION

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

WARNING indicates a potentially hazardous situation which, if not avoided, could result in injury or death.

CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION used without the safety alert

CAUTION

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.

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.

symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

IMPORTANT DEFINITIONS

APPROVALS

GENERAL SAFETY

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 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

For hot water heating systems using the XB model, the circulating pump is NOT provided on standard models (optional) and must be eld installed.

CORRECT GAS

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

PRECAUTIONS

If the unit is exposed to the following, do not operate until all corrective steps have been made by a qualied service technician:

1. Exposure to re.

2. If damaged.

3. Firing without water.

4. Sooting.

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

LIQUEFIED PETROLEUM GAS MODELS

Boilers for propane or liqueed petroleum gas (LPG) are different from natural gas models. A natural gas boiler will not function safely on propane (LP) gas and no attempt should be made to convert a boiler from natural gas to propane (LP) gas.

HIGH ALTITUDE INSTALLATIONS

Rated inputs are suitable up to 2000 feet (610 m) elevation for Propane and 10,100 feet (3079 m) for Natural gas. Consult the factory for Propane installation at altitudes over 2000 feet (610 m).

FIELD INSTALLED COMPONENTS

When installing the boiler, the follow ing compo nents must be installed:

• Circulating Pump (Hyd ronic)

• Remote Temperature Sensor/Header Sensor

• Storage Tank (Temperature & Pressure Relief Valve)

Propane (LP) gas must be used with great caution. It is highly explosive and heavier than air. It collects rst in the low areas making its odor difcult to detect at nose level. If propane (LP) gas is present or even suspected, do not attempt to nd the cause yourself. Leave the building, leaving doors open to ventilate, then call your gas supplier or qualied agency. Keep area clear until a service call has been made.

At times you may not be able to smell an propane (LP) gas leak. One cause is odor fade, which is a loss of the chemical odorant that gives propane (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 qualied service technician. Only trained propane (LP) gas professionals should conduct the required safety checks in accordance with industry standards.

INTRODUCTION

This Instruction Manual covers XP Boiler models XB 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 afxed to the Boiler. The following information describes the model number structure:

SERIES-100/101 DESIGNATION:

• XP = Extreme Performance

MODEL (APPLICATION):

• XB = Hydronic Heating Boiler

SIZE:

• 1000 = 920,000 Btu/hr input

• 1300 = 1,300,000 Btu/hr input

• 1700 = 1,700,000 Btu/hr input

• 2000 = 1,999,900 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) XB models can be special ordered with a factory installed pump. These factory congurations can also be changed in the eld by installing circulation pumps and changing pressure relief valves to accommodate 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 SERVICE TECHNICIAN OR QUALIFIED AGENCY

Installation and service of this boiler requires ability equivalent to that of a Qualied Agency, as dened by ANSI below. In the eld 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: “Qualied Agency” - “Any individual, rm, 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 qualied (as dened by ANSI above) and licensed or certied 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-Up by an authorized service/ start-up provider that has been approved by the manufacturer for this specic product. Call 1-800-527-1953 to locate the nearest authorized start-up provider and arrange a factory start-up. Please provide as much notice as possible, preferably 2 weeks. Please have the model and serial number ready when you call. This start-up is required to activate the warranty and ensure safe, efcient 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-up provider.

DIMENSIONS AND CAPACITY DATA

L B

AIR INTAKE

FLUE OUTLET

55 1/2"

7 7/8"

31 3/8"

FIGURE 1. SINGLE HEAT EXCHANGER BOILER

TABLE 1. ROUGH IN DIMENSIONS (SINGLE)

Models XB-1000 XB-1300 XB-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 44 111 8 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

(XB)

Type of Gas Inches W.C. kPa Inches W.C. kPa Inches W.C. kPa

Manifold Pressure Maximum Supply Pressure Minimum Supply Pressure

Min Fire -0.2 to - 0.3 -0.05 to - 0.07

1000, 1300, 1700 2000, 2600, 3400

Natural

Max Fire -3.0 to -3.9 -0.75 to -0.97

Min Fire -0.1 to - 0.3 -0.025 to -0.07

Propane

14.0 3.49 4.0 1.0

Max Fire -3.6 to -4.9 -0.90 to -1.22

FLUE OUTLET

AIR INTAKE

34 1/4"

31 7/8"

7 7/8"

55 7/8"

66 1/8"

10"

31 3/8"

FIGURE 2. DOUBLE HEAT EXCHANGER BOILER

TABLE 3. ROUGH IN DIMENSIONS (DOUBLE)

Models XB-2000 XB-2600 XB-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

86 1/4"

26 3/4"

RATINGS

TABLE 4. IBR RATINGS

MODELS

(XB)

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 sufcient 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 conrmed by the Hydronics Institute, Section of AHRI.

INPUT

MBH

MAX MIN

GROSS

OUTPUT MBH

(NOTE 1)

NET I=B=R RATINGS WATER MBH

(NOTE 2)

ELECTRICAL REQUIREMENTS

TABLE 5. ELECTRICAL REQUIREMENTS

MODELS

(XB)

1000 120 60 30 15 A dedicated, single phase, 30 amp circuit

1300 120 60 30 15

1700 120 60 30 15

2000 120 60 60 30 A dedicated, single phase, 60 amp circuit

2600 120 60 60 30

3400 120 60 60 30

SUPPLY VOLTAGE

(VOLTS)

FREQUENCY

(HZ)

CURRENT (AMPS)

WITH

PUMP

W/O

PUMP

ELECTRICAL NOTES

breaker with a grounded neutral should be provided to supply power to the boiler.

FLOW, HEAD AND TEMPERATURE RISE

TABLE 6. XB MODELS - FLOW, HEAD AND TEMPERATURE RISE

Models

XB-1000 920,000 855,600

XB-1300 1,300,000 1,209,000

XB-1700 1,700,000 1,581,000

XB-2000 1,999,900 1,860,000

XB-2600 2,600,000 2,418,000

XB-3400 3,400,000 3,162,000

Input

(Btu/hr)

Output

(Btu/hr)

Temperature Rise - ΔT °F Flow Rate

Water

Flow

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 7.9 2.1

GPM 120 80 60 120 60

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

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

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

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

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

20 30 40 Maximum Minimum

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

FEATURES AND COMPONENTS

3627

FIGURE 3. SINGLE HEAT EXCHANGER BOILER COMPONENTS

1913

FIGURE 4. DOUBLE HEAT EXCHANGER BOILER COMPONENTS

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 lter to prevent dust and debris from entering the boiler.

3. Automatic air vents: Designed to remove trapped air from the heat exchanger coils.

4. Blowers: The blowers pull in air and gas through the venturis. Air and gas mix inside the venturi and are pushed into the burners, where they burn inside the combustion chamber.

5. Boiler inlet temperature sensors These sensors monitor system return water temperature.

6. Boiler outlet temperature sensors/High Limits These sensors monitor boiler outlet water temperature. The boiler modulates based on the Lead Lag Sensor connected to the tank.

7. Burners Made with metal ber and stainless steel construction, the burners use pre-mixed air and gas and provide a wide range of ring rates.

8. Condensate Trap Disposes the condensate produced from heat exchanger and houses a switch that detects in case of blockage.

9. Control modules The control modules respond to internal and external signals and control the blowers, gas control valves, and pumps to meet the heating demand.

10. Touch Screen Display Digital controls with touch screen technology and full color display.

11. Sight glass The quartz sight glass provides a view of the ame for inspection

purposes.

12. Flame sensors

This is used by the control module to detect the presence of burner ame.

13. Flap valves Prevents recirculation of ue products when only one burner is

running.

14. Flue gas sensors (not visible)

These sensors monitor the ue gas exit temperature. The control modules will modulate and shut down the boiler if the ue gas temperature gets too hot. This protects the ue pipe from

overheating.

15. Flue pipe adapter (not visible)

Allows for the connection of the PVC vent pipe system to the boiler.

16. Gas shutoff valves (Internal unit) Manual valves used to isolate the gas control valves from the

burners.

17. Main gas shutoff valve (External unit)

Manual valve used to isolate the boiler from the gas supply.

18. Automatic modulating gas valve The gas valve with the addition of venturi and blower are used for modulating premix appliances.

19. Heat exchanger access covers Allows access to the combustion side of the heat exchanger coils.

20. High gas pressure switch Switch provided to detect excessive supply gas pressure.

21. Spark Igniter

Provides direct spark for igniting the burners.

22. Boiler power supply terminals (not visible) The main power to the boiler is supplied through the terminals housed inside the high voltage junction box.

23. Low gas pressure switch Switch provided to detect low gas supply pressure.

24. High voltage connection box This box has terminals for connecting the main power supply (120V) to the boiler and outputs power supply (120V) for the pumps from the boiler control. This box has terminals for low voltage devices such as condensate trap and ow switch.

25. Sensors/Communication Box Connects sensors to tank sensor/header sensor and external connections to building managements systems through MODBUS.

26. Low water cutoff board and sensor probe (LWCO) Device used to ensure adequate water is supplied to the boiler. In the event of inadequate water levels, LWCO will ensure boiler shut down. LWCO board is connected to the electronic panel, whereas the sensor probe is connected to the heat exchanger.

27. Main power supply switch Turns 120 VAC ON/OFF to the boiler.

28. Pump relay The pump relays are used for providing power to the Boiler models.

29. Pressure relief valve Protects the heat exchangers from an over pressure condition. The relief valve will be set at particular PSI, depending on models.

30. Reset switch (optional) (not visible) Reset switch for the low water cutoff.

31. Stainless steel heat exchangers Allows system water to ow through specially designed coils.

32. Venturi The venturi is a gas/air mixing unit that allows modulation of a premix burner with constant gas/air ratio.

33. Water inlet Water connection that return water from the system to the heat exchangers.

34. Water outlets A NPT water connection that supplies hot water to the system.

35. Enable/Disable Switch This is an emergency boiler turn off switch which disconnects the interlock voltage to the control board, hence turning off the power supply to the gas control valves. Do not use this switch

for turning off the boiler, this should be done from the touch screen display, using the Operational Switch on the Lead Lag screen.

36. Vent outlet Provides an outlet for combustion gases to outdoor.

CONTROL COMPONENTS

THE CONTROL SYSTEM

The R7910A1138 is a burner control system that provides heat control, ame supervision, circulation pump control, fan control, boiler control sequencing, and electric ignition function. It will also provide status and error reporting.

FIGURE 5. BURNER CONTROL SYSTEM

SPARK IGNITER

FIGURE 7. LOW/HIGH GAS PRESSURE SWITCH

GAS CONTROL VALVE

The gas control valve is a normally closed servo regulated gas control 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 control valve during

operation.

The spark igniter is a device that ignites the main burner. When power is supplied to the igniter electrode, an electric arc is created between the electrode and the ground terminal which ignites the main burner.

FIGURE 6. SPARK IGNITER

LOW/HIGH GAS PRESSURE SWITCH

This XB boiler is equipped with a low gas pressure switch which meets the CSD-1 code requirements.

The Low Gas Pressure Switch is normally open and remains open if the pressure is below the preset pressure. It closes as soon as the gas supply pressure is above the minimum supply

pressure.

The High Gas Pressure Switch is normally closed and is used to detect excessive gas pressure.

HIGH FIRING

RATE SETTING

LOW FIRING

RATE SETTING

FIGURE 8. GAS CONTROL VALVE

WATER FLOW SWITCH

The water ow switch activates when sufcient water ow has been established. Switch will not close when water ow is not

present.

FIGURE 9. WATER FLOW SWITCH

FLAME SENSOR

Each burner is equipped with a ame sensor to detect the presence of the burner ames at high and low re conditions. If no ame is sensed, the gas control valve will close automatically. The voltage sensed by the ame sensor will also be displayed on the Burner Screen.

FIGURE 10. FLAME SENSOR

WATER TEMPERATURE LIMIT CONTROLS

The XB models incorporate an outlet water sensor having dual sensors, that are factory set at 210°F (99°C).

MAIN POWER SUPPLY SWITCH

The main power supply switch is a padlockable switch. This switch pro vides 120V from the power supply to the boiler.

This switch needs to be turned off when servicing the boiler. NOTE: The Enable/Disable (Interlock) Switch on the front of the boiler does not interrupt electrical power to the boiler.

WATER TEMPERATURE SENSORS

FIGURE 12. WATER TEMPERATURE SENSORS

Temperature sensors are threaded immersion probes. Temperature probes have embedded temperature sensors (thermistors). The boiler’s control system monitors these sensors to determine water temperature at various points in the system.

INLET AND OUTLET TEMPERATURE SENSORS

All models have two inlet and two outlet temperature sensors for each heat exchanger, factory installed to monitor the water temperature entering and leaving the boiler. The Inlet Probe is a temperature sensor only and has two leads. The Outlet probe also contains the manual reset high temperature limit switch on the display and has four leads. The control system displays the Inlet and Outlet water temperatures sensed from these two sensors on the default Temperatures screen.

REMOTE SENSORS

All models are supplied from the factory with a remote sensor. The remote sensor is used to control system water temperature for a single boiler in the return line from a primary/secondary hydronic heating system.

The boiler will modulate its ring rate in response to the actual system temperature and load conditions. The control system displays the temperature sensed from the remote sensor as the “Lead Lag” temperature on the default Temperatures screen.

FIGURE 11. MAIN POWER SUPPLY SWITCH

LOW WATER CUTOFF DEVICE (LWCO)

Low water cutoff device is normally a closed switch that opens when water drops below a preset level. Each model is equipped with a factory installed LWCO. LWCO board is connected to the electronic panel, whereas the sensor probe is connected to the heat exchanger.

FIGURE 13. LWCO BOARD AND PROBE

BOILER INSTALLATION CONSIDERATIONS

GENERAL

If the system is to be lled 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 due to freezing is not covered by the warranty.

Figure 75 on Page 78 shows a typical primary, secondary piping method. This is the preferred piping method for most stainless steel boilers. Other piping methods, however, may provide good system operation. A prime concern when designing heating systems is the maintenance of proper ow through the unit during boiler operation. The secondary pump should be sized per the recommended ow rate of the boiler, see Dimension and Capacity Data section in this manual.

Before locating the boiler:

1. Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the boiler so that if water connections should leak,

water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the boiler. The pan must not restrict combustion air ow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this boiler, or any of its components.

3. Check area around the boiler. Remove any combustible

materials, gasoline and other ammable liquids.

4. Make sure the gas control system components are protected

from dripping or spraying water or rain during operation or service.

5. If a new boiler will replace an existing boiler, check for and

correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

• Lack of freeze protection in boiler water causing system and boiler to freeze and leak.

HYDRONIC SYSTEM

The following is a brief description of the equipment required for the installations noted in this manual. All installations must comply with local code.

WATER SUPPLY LINE

These boilers can be used only in a forced circulation hot water heating system. Since most forced circulation systems will be of the closed type, install the water supply line as shown on piping

diagram.

Fast lling of large pipe, old radiator installations and pressure purging of series loop systems (where high pressures are not available) requires bypassing of the pressure reducing valve.

Gener ally, pressure purging is not possible with a well pump system. High point air venting is essential.

If the system is of the open type, a pressure reducing valve will not be required as the water supply to the system will be controlled by a manu ally operated valve. An overhead surge tank is required. A minimum pressure of 15 psi (100 kPa) must be maintained on the boiler at all times to ensure avoidance of potential damage to the boiler which may not be covered by the warranty.

EXPANSION TANK

If the system is of the closed type, install an expansion tank. The sizing of the expansion tank for a closed system is very important and is directly related to the total water volume of the system.

An air separator as shown in the piping diagrams is recommended especially for modern commercial hydronic systems. See Figure 75

on Page 78.

VENT VALVES

It is recommended that automatic, loose key or screw-driver type vent valves be installed at each convector or radiator.

SYSTEM HEADERS

Split systems with individual supply and return lines from the boiler room should normally have this piping connected to supply and return manifold headers near the boiler. To achieve good water distribution with maximum pressure drop for sever al circuits, manifolds should be larger than system mains.

The circuits should be spaced on the heater at a minimum of 3” (76 mm) center to center. Install a balancing cock in each return line.

Manifold headers are recommended for split systems with or without zone valves and also those installations with zone circulating pumps. If the system is to be split at remote points, good practice requires special attention be given to main pipe sizing to allow balancing of water ow.

CHECK VALVES

Check valves must be installed to isolate each boiler in installations where multiple boilers/pumps are installed in the same zone.

COOLING PIPING

When the boiler is used in conjunction with a refrigeration system it must be installed so that the chilled medium is piped in parallel with the boiler. Appropriate ow control valves, manual or motorized, must be provided to prevent the chilled medium from entering the boiler.

If the boiler is connected to chilled water piping or its heating coils are exposed to refrigerated air, the boiler piping system must be equipped with ow valves or other automatic means to prevent gravity circulation through the boiler during the cooling cycle.

Primary/secondary pumping of both the chiller(s) and the boiler(s) is an excellent winter-summer change-over method, because cooling ow rates are so much more than heating ow rates. In this way each system (heating or cooling) is circulated independently.

CIRCULATING PUMP

A circulating pump is used when a system requires a circulating loop or there is a buffer tank used in conjunction with the boiler. Install in accordance with the current edition of the National Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1. All bronze circulating pumps are recommended for use with commercial boilers. Some circulating pumps are manufactured with sealed bearings and do not require further lubrication. Some circulating pumps must be periodically oiled. Refer to the pump manufacturer’s instructions for lubrication requirements.

XB HYDRONIC BOILERS: The circulating pump is not provided on standard models (optional) and must be obtained and installed in the eld.

PRIMARY SYSTEM CONTROL

All XB boiler installations require a “Primary System Control” that senses and reacts to water temperature inside the return line on primary/secondary hydronic heating systems. The Primary System Control will activate and deactivate boiler heating cycles based on its setpoint and current system water temperature. There are three suitable methods to congure a Primary System Control. One of these three methods must be used.

1. The Primary System Control can be the boiler’s control system working with the factory supplied Header Sensor, installed in the return line on primary/secondary hydronic heating systems.

2. Alternatively, the Burner Control system can be used as a Primary System Control. It will also provide boiler status and error reporting. Multiple boilers can be joined together to heat a system instead of a single, larger burner or boiler. Using boilers in parallel is more efcient, costs less, reduces emissions, improves load control, and is more exible than the traditional large boiler.

3. MB2 and COM2 ports can be used for Building Management Systems.

HOT WATER BOILER SYSTEM - GENERAL WATER LINE CONNECTIONS

Piping diagrams will serve to provide the installer with a reference for the materials and methods of piping necessary for installation. It is essential that all water piping be installed and connected as shown on the diagrams. Check the diagrams to be used thoroughly before starting installation to avoid possible errors and to minimize time and material cost. It is essential that all water piping be installed and connected as shown on the diagrams. See Figure 75 on Page 78.

CLOSED WATER SYSTEMS

Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back ow preventers. Devices such as these cause the water system to be a closed system.

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed system the volume of water will increase when it is heated. As the volume of water increases there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent Temperature-Pressure Relief Valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The Temperature-Pressure Relief Valve is not intended for the constant relief of thermal expansion.

A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local plumbing service agency to have a thermal expansion tank installed.

INTERNAL CONTAMINANTS

The hydronic system must be internally cleaned and ushed after a new or replacement boiler has been installed, to remove contaminants that may have accumulated during installation. This is extremely important when a replacement boiler is installed into an existing system where Stop Leak or other boiler additives have been used.

Failure to clean and ush the system can produce acid concentrations that become corrosive, and leads to heat exchanger failure.

All hot water heating systems should be completely ushed with a grease removing solution to assure trouble-free opera tion. Pipe joint compounds, soldering paste, grease on tubing and pipe all tend to contaminate a system

Failure to ush contaminants from a system can cause solids to form on the inside of boiler exchangers, create excessive blockage of water circulation, deterioration of the pump seals and impellers.

PRESSURE RELIEF VALVE

An ASME rated pressure relief valve is furnished with the boiler. A tting for the relief valve is provided in the top of the boiler. Never operate the heating elements without being certain the boiler is lled with water and a properly sized pressure relief valve is installed in the relief valve opening provided.

The pressure rating of the relief valve should be equal to or less than the rated pressure capacity of any component in the system including the boiler. Should the valve need to be replaced, call the toll free phone number listed on the back of this manual for further technical assistance

CAUTION

•

Pressure Relief Valve discharge pipe must

terminate at adequate drain.

Water Damage Hazard

Explosion Hazard

Relief Valve must comply with ASME code.

Properly sized Relief Valve must be installed in opening provided.

Can result in overheating and excessive tank pressure.

Can cause serious injury or death.

A discharge pipe from the relief valve should terminate at an adequate oor 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 plugged or blocked.

• Shall not be exposed to freezing temperatures.

• Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both the relief valve and the discharge pipe.

• Must terminate a maximum of six inches above a oor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.

• Shall not have any valve or other obstruction between the relief valve and the drain.

Once the boiler is installed and lled with water and the system is pressurized, manually test the operation of the pressure relief valve. See the Maintenance Procedures section of this manual for instructions.

Your local code authority may have other specic safety relief valve requirements not covered below. If any pressure relief valve is re placed, the replace ment valve must com ply with the current version of the ASME Boiler and Pressure Vessel Code, Section IV (“HEATING BOILERS”).

XB HYDRONIC BOILERS, are shipped with a 50 psi (345 kPa) pressure relief valve. This relief valve must be in stalled in the water outlet as near to the boiler as possi ble.

This ASME-rated valve has a discharge capacity that exceeds maximum boiler input rating and a pres sure rating that does not exceed maxi mum working pres sure shown on boiler rating plate.

GAS CONNECTIONS

Make sure the gas on which boiler is to operate is same as that specied on the rating plate. Do not install boiler if equipped for a different type of gas. Consult your gas supplier.

This boiler is not intended to operate at gas supply pressure other than shown on the rating plate. A lock-up or positive shutoff type regulator must be installed in gas supply line. For proper gas regulation the lock-up style regulators must be installed no closer than a minimum of 3 feet (0.9 m) from the boiler and a maximum of 8 feet (2.4 m) away from the boiler. Exposure to higher gas supply pressure may cause damage to gas control valves which can result in re or explosion. If overpressure has occurred such as through improper testing of gas lines or emergency malfunction of supply system, the gas control valves must be checked for safe operation. Make sure that the outside vents on supply regulators and the safety vent valves are protected against blockage. These are parts of the gas supply system, not boiler. Vent blockage may occur during ice build-up or snowstorms.

The boiler must be isolated from the gas supply piping system by closing its main manual gas shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig.

Disconnect the boiler and its main manual gas shut-off valve from the gas supply piping during any pressure testing of the gas supply system over 1/2 psig. The gas supply line must be capped when not connected to the boiler.

It is important to guard against gas control valve fouling from contaminants in the gas ways. Such fouling may cause improper operation, re or explosion. If copper supply lines are used they must be approved for gas service.

When local codes require a main manual shut-off valve outside the boiler jacket, a suitable main manual shut-off valve must be installed in a location complying with those codes.

Before attaching gas line be sure that all gas pipe is clean on inside. To trap any dirt or foreign material in the gas supply line, a sediment trap must be incorporated in piping. The sediment trap must be readily accessible and not subject to freezing conditions. Install in accordance with recommendations of serving gas supplier. Refer to the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code, CAN/CSA B149.1

Size of gas supply piping may be larger than heater connection on installations where a signicant run of piping is required.

To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to boiler gas inlet. When installing and tightening gas piping use a second wrench to hold the gas control valve to keep the valve from turning. To prevent damage to the gas control valve do not use pipe wrench on the valve body.

Fittings and unions in gas line must be of metal to metal type. Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compound to the rst two threads. Use compounds resistant to the action of liqueed petroleum gases. The boiler and its gas connection must be leak tested before placing the boiler in operation.

GAS SUPPLY LINE SIZING

The gas piping installation must be capable of supplying the maximum probable gas demand without excessive pressure loss. Depending on local practices, the ALLOWABLE PRESSURE LOSS between the gas meter, or service regulator and each appliance is generally 0.3 or 0.5 inches of water column (0.075 or 0.124 kPa).

For single boiler installation, refer to Table 7 and Table 8 to size iron pipe or equivalent gas supply line size to be used with single

unit.

For multiple boiler installation or installations of a single boiler with other gas appliances, please refer to Table 9 and Table 10 on Page 20 to size iron pipe or equivalent gas supply line. These tables are taken from the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.

• Table 9 is based on a pressure drop of 0.5 inches water column (0.124 kPa), and a gas with a specic gravity of

0.60 and a heating value of 1,000 BTU/ft3, approximately that of Natural Gas.

• Table 10 is based on a pressure drop of 0.5 inches water column (0.124 kPa), and a gas with a specic gravity of

1.53 and a heating value of 2,500 BTU/ft3, approximately

that of Propane Gas.

Where it is necessary to use more than the average number of ttings (i.e., elbows, tees and valves in gas supply line) use a pipe larger than specied to compensate for increased pressure drop.

Table 7 and Table 8 shows the maximum equivalent gas pipe length for a single unit installation. It does not take into account other appliances that may be connected to the gas line. For installation of multiple units, or instances where several appliances are connected to the same line, use Table 9 and Table 10 for proper sizing.

TABLE 7.

SINGLE UNIT INSTALLATION, SUGGESTED GAS PIPE

SIZING. MAXIMUM EQUIVALENT PIPE LENGTH (IN FEET).

BTU

Input

920,000 70 150 175 ----- ----- ----- ----- -----

1,300,000 40 100 100 200 ----- ----- ----- -----

1,700,000 20 60 70 150 200 ----- ----- -----

1,999,900 20 50 50 100 150 ----- ----- -----

2,600,000 10 30 30 70 90 200 ----- -----

3,400,000 ----- ----- 20 40 50 125 200 -----

Natural gas 1000 Btu/ft^3, 0.60 specic gravity @ 0.3 in. w.c. pressure drop. Propane gas 2500 Btu/ft^3, 1.50 specic gravity @ 0.3 in. w.c. pressure drop.

2” 2-1/2” 3” 4”

Nat Pro Nat Pro Nat Pro Nat Pro

SINGLE UNIT INSTALLATION, SUGGESTED GAS PIPE

TABLE 8.

SIZING. MAXIMUM EQUIVALENT PIPE LENGTH (IN FEET).

BTU

Input

920,000 125 200 200 ----- ----- ----- ----- -----

1,300,000 80 175 175 ----- ----- ----- ----- -----

1,700,000 40 100 100 ----- ----- ----- ----- -----

1,999,900 30 80 80 200 200 ----- ----- -----

2,600,000 20 50 50 125 150 ----- ----- -----

3,400,000 10 30 30 70 90 200 ----- -----

Natural gas 1000 Btu/ft^3, 0.63 specic gravity @ 0.5 in. w.c. pressure drop. Propane gas 2500 Btu/ft^3, 1.50 specic gravity @ 0.5 in. w.c. pressure drop.

2” 2-1/2” 3” 4”

Nat Pro Nat Pro Nat Pro Nat Pro

CORROSIVE MATERIALS AND CONTAMINATION SOURCES

Products to avoid: (Not all inclusive list)

• Spray cans containing chloro/uorocarbons

• Permanent wave solutions

• Chlorinated waxes/cleaners

• Chlorine-based swimming pool chemicals

• Calcium chloride used for thawing

• Sodium chloride used for water softening

• Refrigerant leaks

• Paint or varnish removers

• Hydrochloric acid/muriatic acid

• Cements and glues

• Antistatic fabric softeners used in clothes dryers

• Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

• Adhesives used to fasten building products and other similar products

Areas likely to have contaminants:

• Dry cleaning/laundry areas and establishments

• Swimming pools

• Metal fabrication plants

• Beauty shops

• Refrigeration repair shops

• Photo processing plants

• Auto body shops

• Plastic manufacturing plants

• Furniture renishing areas and establishments

• New building construction

• Remodeling areas

Common household products, pool and laundry products may contain uorine or chlorine compounds. When these chemicals come in contact with the boiler, they react and can form strong acids. The acid can spoil the boiler wall, causing serious damage and may result in ue gas spillage or boiler water leakage into the building.

If the above mentioned contaminants and corrosive materials chemicals are present near the location of the boiler, make sure to remove the boiler permanently or relocate air inlet and vent terminations to other areas.

FIELD WIRING

120 VAC POWER SUPPLY WIRING

A dedicated, single phase, 30-60 amp (refer to Table 5 on Page

8) circuit breaker with a grounded neutral should be provided to supply power to the boilers. Use #10 AWG wire for the 120 VAC power supply to the boiler. All 120 VAC power supply connections must be made as shown in Figure 14. These connections should be made at the rear of the unit where a wiring junction box is provided. Field installed power supply wiring to the boiler should be installed in conduit. This conduit and wiring should be separate from any other conduit/wiring to guard against EMI (electromagnetic interference).

POWER SUPPLY CHECK

To reduce the possibility of electrical interference with the boiler’s control system the power supply voltage, polarity and ground must be checked. Using an AC volt meter check the 120 VAC power supply wiring from the breaker prior to making power supply connections at the boiler. Conrm the power supply voltage & polarity are correct and that an adequate ground connection is present by performing the three voltage tests below. See Figure 14 for wiring references.

Conrm RMS voltage between:

• H and GND = 108 VAC minimum, 132 VAC maximum.

• N and H = 108 VAC minimum, 132 VAC maximum.

• N and GND = < 1 VAC maximum.

FIGURE 15. LOW VOLTAGE CONTROL WIRING

All low voltage control wiring connections must be made as shown in Figure 14. These connections should be made at the rear of the unit where a wiring junction box is provided. Field installed wiring inside 1/2 inch conduit is installed between the junction box on the back of the boiler and the temperature probe and/or eld supplied external control being used. This conduit and wiring should be separate from any other conduit/wiring to guard against EMI (electromagnetic interference).

FIGURE 14. FIELD WIRING

LOW VOLTAGE CONTROL WIRING

1. Header Terminals: In case of Hydronic Boilers, the header

terminals are connected to the hydronic loop header sensor. Whereas in case of Hot water Boilers the header terminals are connected to the tank sensor where the temperature can be sensed. See Figure 15.

2. Outdoor Terminals: In case of Hydronic Boilers, they are

connected to the outdoor sensors. But in case of Hot water Boilers, they are not connected. See Figure 15. The outdoor sensors must be mounted with cable inlet facing down as shown in Figure 16. The maximum length of the wire connecting from the boiler to the outdoor sensor must be no more than 50 feet (15.2 m).

3. MB2 and COM2 terminals are meant for building

management systems.

CABLE INLET

FIGURE 16. OUTDOOR SENSOR

The outdoor sensor must be mounted in a shaded location, to avoid direct sunlight. It must be at least 3 feet (0.9 m) away from any exhaust, dryer, bathroom or other building vents. It must be located on the north side of the building, above the expected snow line where ice and debris cannot cover it. NOTE: By default the "Outdoor Reset Function" is disabled in the Control panel, it can be turned ON from the master boiler under lead lag settings. Once turned ON the outdoor sensor becomes active and senses temperature, until then it remains idle even though connected to the back of the boiler.

TABLE 9. SUGGESTED PIPE SIZE FOR MULTIPLE GAS APPLIANCES (NATURAL GAS)

Nominal Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14 in. W.C. (0.5 psi) or Less and

Iron Pipe a Pressure Drop of 0.5 in. W.C. (based on 0.60 Specic Gravity Gas w/Heating Value of 1,000 BTU’s/Ft3)

Size Length of Pipe in Feet (Meters)

(Inches) 10 (3.05) 20 (6.1) 30 (9.14) 40 (12.19) 50 (15.24) 60 (18.29) 70 (21.34) 80 (24.38) 90 (27.43) 100 (30.48) 125 (38.1) 150 175 200

1 1/2 BTU/hr 2,100,000 1,460,000 1,180,000 990,000 900,000 810,000 750,000 690,000 650,000 620,000 550,000 500,000 460,000 —

kW 615 428 346 290 264 237 220 202 190 182 161 146 135 —

2 BTU/hr 3,950,000 2,750,000 2,200,000 1,900,000 1,680,000 1,520,000 1,400,000 1,300,000 1,220,000 1,150,000 1,020,000 950,000 850,000 800,000

kW 1,157 805 644 556 492 445 410 381 357 337 299 278 249 234

2 1/2 BTU/hr 6,300,000 4,350,000 3,520,000 3,000,000 2,650,000 2,400,000 2,250,000 2,050,000 1,950,000 1,850,000 1,650,000 1,500,000 1,370,000 1,280,000

kW 1,845 1,274 1,031 879 776 703 659 600 571 542 483 439 401 375

3 BTU/hr 11,000,000 7,700,000 6,250,000 5,300,000 4,750,000 4,300,000 3,900,000 3,700,000 3,450,000 3,250,000 2,950,000 2,650,000 2,450,000 2,280,000

kW 3,222 2,255 1,830 1,552 1,391 1,259 1,142 1,084 1,010 952 864 776 718 668

4 BTU/hr 23,000,000 15,800,000 12,800,000 10,900,000 9,700,000 8,800,000 8,100,000 7,500,000 7,200,000 6,700,000 6,000,000 5,500,000 5,000,000 4,600,000

kW 6,736 4,627 3,749 3,192 2,841 2,577 2,372 2,197 2,109 1,962 1,757 1,611 1,464 1,347

TABLE 10. SUGGESTED PIPE SIZE FOR MULTIPLE GAS APPLIANCES (PROPANE GAS)

Nominal Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14 in. W.C. (0.5 psi) or Less and

Iron Pipe a Pressure Drop of 0.5 in. W.C. (based on 0.60 Specic Gravity Gas w/Heating Value of 1,000 BTU’s/Ft3)

Size Length of Pipe in Feet (Meters)

(Inches) 10 (3.05) 20 (6.1) 30 (9.14) 40 (12.19) 50 (15.24) 60 (18.29) 70 (21.34) 80 (24.38) 90 (27.43) 100 (30.48) 125 (38.1) 150 175 200

1 1/2 BTU/hr 3,276,000 2,277,600 1,840,800 1,544,400 1,404,000 1,263,600 1,170,000 1,076,400 1,014,000 967,200 858,000 780,000 717,600 670,800

kW 959 667 539 452 411 370 343 315 297 283 251 228 210 196

2 BTU/hr 6,162,000 4,290,000 3,432,000 2,964,000 2,620,800 2,371,200 2,184,000 2,028,000 1,903,200 1,794,000 1,591,200 1,482,000 1,326,000 1,248,000

kW 1,805 1,256 1,005 868 768 694 640 594 557 525 466 434 388 366

2 1/2 BTU/hr 9,828,000 6,786,000 5,491,200 4,680,000 4,134,000 3,744,000 3,510,000 3,198,000 3,042,000 2,886,000 2,574,000 2,340,000 2,137,200 1,999,800

kW 2,878 1,987 1,608 1,371 1,211 1,097 1,028 937 891 845 754 685 626 585

3 BTU/hr 17,160,000 12,012,000 9,750,000 8,268,000 7,410,000 6,708,000 6,084,000 5,772,000 5,382,000 5,070,000 4,602,000 4,134,000 3,822,000 3,556,800

kW 5,026 3,518 2,856 2,421 2,170 1,965 1,782 1,690 1,576 1,485 1,348 1,211 1,119 1,042

4 BTU/hr 35,880,000 24,648,000 19,968,000 17,004,000 15,132,000 13,728,000 12,636,000 11,700,000 11,232,000 10,452,000 9,360,000 8,580,000 7,800,000 7,176,000

kW 10,508 7,219 5,848 4,980 4,432 4,021 3,701 3,427 3,290 3,061 2,741 2,513 2,284 2,102

GENERAL REQUIREMENTS

REQUIRED ABILITY

Installation or service of this boiler requires ability equivalent to that of a qualied service technician in the eld involved. Plumbing, air supply, venting, gas supply, and electrical work are re quired.

LOCATION

When installing the boiler, consideration must be given to proper location. The location selected should provide ade quate air supply and be as centralized with the piping system as possible.

REPLACING EXISTING COMMON VENTED BOILER

NOTE: This section does not describe a method for common venting XB units. It describes what must be done when a unit is removed from a common vent system. The XB units require special vent systems and fans for common vent.

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing boiler, the following steps should be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system

are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and deciencies which could cause an unsafe condition.

3. In so far as it is practical, close all building doors and

windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close replace dampers.

4. Place in operation the appliance being inspected. Follow the

lighting instructions. Adjust thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the ame of a match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each appliance remaining

connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, replace dampers and any other gas-burning appliance to their previous condition of use.

7. Any improper operation of the common venting system

should be corrected so that the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/ or CSA B149.1, Installation Codes. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables and guidelines in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Installation Codes.

This boiler is intended for Indoor Installation only, and should not be installed where freezing temperatures or any moisture could damage the external components of the boiler.

PANELS AND COVERS

LEVELING

All panels and covers (e.g. control and junction box covers; front, side and rear panels of boiler) must be in place after service and/ or before opera tion of boiler. This will ensure that all gas ignition components will be protected from water.

The XB is a low-pressure boiler (Category IV) to be used in hot water heating (hydronic) application. Category IV appli ances are often termed “High Ef ciency” appliances.

CHEMICAL VAPOR CORROSION

Boiler corrosion and component failure can be caused by the he a ting an d br eakd own of air b o r ne chemic a l vapors. Spray ca n propellants, cleaning sol vents, refrigerator and air conditioning refrig erants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive. These materials are corrosive at very low concentration levels with little or no odor to reveal their presence.

Products of this sort should not be stored near boiler. Also, air which is brought in contact with boiler should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. Failure to observe this requirement will void warranty.

INSTALLATION CLEARANCES

This boiler is approved for installation in an alcove with minimum clearances to combustibles.

TABLE 11. INSTALLATION CLEARANCES

RECOMMENDED

SERVICE

CLEARANCES

Front 30" (762 mm) 8" (203 mm)

Rear 36" (610 mm) 24" (610 mm)

Left 24 " (610 mm) 1" (25.4 mm)

Right 24 " (610 mm) 2" (51 mm)

Top 24" (610 mm) 6" (152 mm)

2” (51 mm) clearance is allowable from combustible construction

for hot water pipes.

Sufcient area should be provided at the front and rear of the unit for prop er servicing. In a utility room installa tion, the door opening should be wide enough to allow the boiler to enter or to permit the replacement of another appli ance such as a boiler.

FLOORING AND FOUNDATION:

All models are approved for installation on combustible ooring, but must never be installed on carpeting. Do not install the boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

If ooding is possible, elevate the boiler sufciently to prevent water from reaching the boiler.

CLEARANCES FROM

COMBUSTIBLE

MATERIALS

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 not level, obtain and insert shims under the feet at the frame base to correct this condition.

AIR REQUIREMENTS

Breathing Hazard - Carbon Monoxide Gas

Install appliance in accordance with the Instruction Manual and NFPA 54 or CAN/CSA-B149.1.

To avoid injury, combustion and ventilation air must be taken from outdoors.

Do not place chemical vapor emitting products near water heater.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

For safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided.

An insufcient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life. Such a condition often will result in a yellow, luminous burner ame, causing sooting of the combustion chamber, burners and ue tubes and creates a risk of asphyxiation.

Do not install the boiler in a conned space unless an adequate supply of air for combustion and ventilation is brought in to that space using the methods described in the Conned Space section that follows.

Never obstruct the ow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a re or explosion and cause property damage, serious bodily injury or death.

UNCONFINED SPACE

An unconned space is one whose volume is not 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. Rooms communicating directly with the space, in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconned space.

Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers and replaces shall also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air.

UNUSUALLY TIGHT CONSTRUCTION

In unconned spaces in buildings, inltration may be adequate to provide air for combustion, ventilation and dilution of ue gases. However, in buildings of unusually tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.) additional air must be provided using the methods described in the Conned Space section that follows.

CONFINED SPACE

A conned 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 conned spaces. The required size for the openings is dependent on the method used to provide fresh air to the conned space and the total Btu/hr input rating of all appliances installed in the space.

DIRECT VENT APPLIANCES

Appliances installed in a direct vent conguration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total appliance input Btu/ hr calculations used to determine the size of openings providing fresh air into conned spaces.

EXHAUST FANS

Where exhaust fans are installed, additional air shall be provided to replace the exhausted air. When an exhaust fan is installed in the same space with a water heater, sufcient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan. Undersized openings will cause air to be drawn into the room through the water heater’s vent system causing poor combustion. Sooting, serious damage to the water heater and the risk of re or explosion may result. It can also create a risk of asphyxiation.

LOUVERS AND GRILLES

The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers, grilles or screens in the openings.

The required size of openings for combustion, ventilation and dilution air shall be based on the “net free area” of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size of opening required to provide the free area specied. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25% free area and metal louvers and grilles will have 75% free area. Non motorized louvers and grilles shall be xed in the open position.

OUTDOOR AIR THROUGH TWO OPENINGS

FIGURE 17. OUTDOOR AIR THROUGH TWO OPENINGS

The conned space shall be provided with two permanent openings, 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 openings shall communicate directly with the outdoors. See Figure 17.

Each opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure. Each opening shall not be less than 100 square inches (645 cm2).

OUTDOOR AIR THROUGH ONE OPENING

FRESH AIR OPENINGS FOR CONFINED SPACES

The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in conned spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into conned spaces only. Do not refer to these illustrations for the purpose of vent installation. See Venting section on Page 25 for complete venting installation instructions.

FIGURE 18. OUTDOOR AIR THROUGH ONE OPENING

Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided. See Figure 18. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following:

1. 1 square inch per 3000 Btu/hr (700 mm2 per kW) of the total

input rating of all appliances located in the enclosure, and

2. Not less than the sum of the areas of all vent connectors in

the space.

OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS

FIGURE 19. OUTDOOR AIR THROUGH TWO HORIZONTAL

DUCTS

The conned space shall be provided with two permanent horizontal 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 horizontal ducts shall communicate directly with the outdoors. See Figure 19.

Each duct opening shall have a minimum free area of 1 square inch per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure.

When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3 inches.

OUTDOOR AIR THROUGH TWO VERTICAL DUCTS

The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into conned spaces only.

Do not refer to these illustrations for the purpose of vent installation.

The conned 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 shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure.

AIR FROM OTHER INDOOR SPACES

FIGURE 21. AIR FROM OTHER INDOOR SPACES

Each opening shall communicate directly with an additional room(s) of sufcient volume so that the combined volume of all spaces meets the criteria for an Unconned Space.

Each opening shall have a minimum free area of 1 square inch per 1,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of all appliances installed in the enclosure. Each opening shall not be less than 100 square inches (645 cm2).

FIGURE 20. OUTDOOR AIR THROUGH TWO VERTICAL

DUCTS

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