AO Smith Boiler 2000 User Manual

Instruction Manual  
XP BOILER  
MODELS: XB/XW  
1000, 1300, 1700  
2000, 2600, 3400  
SERIES 100/101  
INSTALLATION - OPERATION -  
MAINTENANCE - LIMITED WARRANTY  
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.  
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-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  
hazardous situation which, if not avoided,  
will result in injury or death.  
DANGER  
WARNING indicates a potentially hazardous  
situation which, if not avoided, could result  
in injury or death.  
WARNING  
CAUTION indicates a potentially hazardous  
situation which, if not avoided, could result in  
minor or moderate injury.  
CAUTION  
CAUTION used without the safety alert  
symbol indicates a potentially hazardous  
CAUTION  
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  
Rated inputs are suitable up to 2000 feet (610 m) elevation. Consult  
If the unit is exposed to the following, do not operate until all the factory for installation at altitudes over 2000 feet (610 m).  
corrective steps have been made by a qualified service agent:  
FIELD INSTALLED COMPONENTS  
1. Exposure to fire.  
2. If damaged.  
3. Firing without water.  
4. Sooting.  
When installing the boiler, the following components must be  
installed:  
Circulating Pump (Hydronic)  
If the boiler has been exposed to flooding, it must be replaced.  
Remote Temperature Sensor/Header Sensor  
Storage Tank (Temperature & Pressure Relief Valve)  
LIQUEFIED PETROLEUM GAS MODELS  
Boilers for propane or liquefied petroleum gas (LPG) are different  
from natural gas models.Anatural gas boiler will not function safely  
on LP gas 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.  
4
INTRODUCTION  
This Instruction Manual covers XP Boiler models XB/XW 1000,  
QUALIFICATIONS  
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.  
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.  
MODEL IDENTIFICATION  
Check the rating plate affixed to the Boiler. The following  
information describes the model number structure:  
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.”  
SERIES-100/101 DESIGNATION:  
• 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  
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.  
FUEL:  
This product requires a formal Start-Up by an authorized service/  
start-up provider that has been approved by the manufacturer for  
this specific 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,  
efficient operation.  
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.  
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.  
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  
5
DIMENSIONS AND CAPACITY DATA  
FIGURE 1. SINGLE HEAT EXCHANGER BOILER  
TABLE 1. ROUGH IN DIMENSIONS (SINGLE)  
Models  
XB/XW-1000  
inches  
XB/XW-1300  
inches  
XB/XW-1700  
inches  
Dimensions  
Flue Outlet Diameter  
Air Intake Diameter  
Water Inlet  
mm  
152  
152  
mm  
152  
152  
mm  
203  
203  
6
6
8
6
8
8
2 inch NPT  
2 inch NPT  
2 inch NPT  
2 1/2 inch NPT  
Water Outlet  
2 1/2 inch NPT  
2 inch NPT  
Gas Inlet  
A
B
C
D
E
F
47  
67  
29  
37  
23  
9
1199  
1702  
737  
49  
68  
29  
38  
23  
9
1245  
1727  
737  
57  
76  
29  
37  
24  
9
1448  
1930  
737  
940  
610  
229  
940  
965  
584  
584  
229  
229  
G
H
J
34  
44  
6
864  
1118  
152  
279  
34  
45  
6
864  
1143  
152  
34  
45  
6
864  
1143  
152  
K
11  
11  
279  
11  
279  
L
12  
305  
11  
279  
12  
305  
TABLE 2. OPERATING CHARACTERISTICS  
Manifold Pressure  
Inches W.C.  
Maximum Supply Pressure Minimum Supply Pressure  
Models  
(XB/XW)  
Type of Gas  
kPa  
Inches W.C.  
kPa  
Inches W.C.  
kPa  
Min Fire -0.2 to -0.3 -0.05 to -0.07  
Max Fire -3.0 to -3.9 -0.75 to -0.97  
Min Fire -0.1 to -0.3 -0.025 to -0.07  
Natural  
14.0  
3.49  
4.0  
1.0  
1000, 1300, 1700  
2000, 2600, 3400  
Propane  
14.0  
3.49  
4.0  
2.0  
Max Fire -3.6 to -4.9 -0.90 to -1.22  
6
 
FIGURE 2. DOUBLE HEAT EXCHANGER BOILER  
TABLE 3. ROUGH IN DIMENSIONS (DOUBLE)  
Models  
XB/XW-2000  
inches  
XB/XW-2600  
inches  
XB/XW-3400  
inches  
Dimensions  
mm  
203  
203  
mm  
203  
203  
mm  
254  
254  
Flue Outlet Diameter  
8
8
8
8
10  
10  
Air Intake Diameter  
Water Inlet  
Water Outlet  
Gas Inlet  
3 inch NPT  
3 inch NPT  
2 inch NPT  
4 inch NPT  
4 inch NPT  
3 inch NPT  
A
47  
1194  
49  
1245  
57  
1448  
B
C
D
E
F
78  
36  
22  
40  
7
1981  
914  
80  
37  
22  
41  
6
2032  
940  
91  
37  
22  
41  
6
2311  
940  
559  
559  
559  
1016  
178  
1041  
152  
1041  
152  
G
10  
254  
10  
254  
10  
254  
H
J
4
102  
508  
305  
4
102  
483  
305  
4
102  
483  
330  
20  
12  
19  
12  
19  
13  
K
TABLE 4. RECOVERY CAPACITIES  
Temperature Rise - ΔT °F (°C)  
Input Rating Output Rating Water  
Models  
40  
(22)  
60  
(33)  
70  
(39)  
80  
(44)  
90  
(50)  
100  
(56)  
120  
(67)  
140  
(78)  
(Btu/hr)  
(Btu/hr)  
Flow  
GPH  
LPH  
GPH  
LPH  
GPH  
LPH  
2,593  
9,815  
3,664  
13,868  
4,791  
1,728  
6,543  
2,442  
9,246  
3,194  
1,482  
5,608  
2,094  
7,925  
2,738  
1,296  
4,907  
1,832  
6,934  
2,395  
9,068  
1,152  
4,362  
1,628  
6,164  
2,129  
8,060  
1,037  
3,926  
1,465  
5,547  
1,916  
7,254  
864  
3,272  
1,221  
4,623  
1,597  
6,045  
741  
2,804  
1,047  
3,962  
1,369  
5,182  
XW-1000  
920,000  
854,680  
XW-1300 1,300,000  
1,207,700  
XW-1700 1,700,000  
XW-2000 2,000,000  
XW-2600 2,600,000  
1,579,300  
1,858,000  
2,415,400  
18,136  
12,090  
10,363  
GPH  
LPH  
GPH  
LPH  
GPH  
5,636  
21,336  
7,327  
27,737  
9,582  
3,758  
14,224  
4,885  
18,491  
6,388  
3,221  
12,192  
4,187  
15,850  
5,475  
2,818  
10,668  
3,664  
13,868  
4,791  
2,505  
9,483  
3,257  
12,327  
4,259  
2,255  
8,534  
2,931  
11,095  
3,833  
1,879  
7,112  
2,442  
9,246  
3,194  
1,610  
6,096  
2,094  
7,925  
2,738  
XW-3400 3,400,000  
3,158,600  
LPH  
36,271  
24,181  
20,726  
18,136  
16,121  
14,508  
12,090 10,363  
7
RATINGS  
TABLE 5. IBR RATINGS  
MODELS  
(XB/XW)  
INPUT  
MBH  
GROSS  
OUTPUT MBH  
NET I=B=R RATINGS WATER MBH  
(NOTE 2)  
(NOTE 1)  
MAX  
MIN  
1000  
1300  
920  
100  
130  
856  
744  
1300  
1209  
1051  
1700  
2000  
2600  
3400  
1700  
2000  
2600  
3400  
170  
100  
130  
212  
1581  
1860  
2418  
3162  
1375  
1617  
2103  
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  
30  
A dedicated, single phase, 30/60 amp circuit breaker  
with a grounded neutral should be provided to supply  
power to the boiler.  
1300  
120  
60  
1700  
2000  
2600  
3400  
120  
120  
120  
120  
60  
60  
60  
60  
30  
60  
60  
60  
A dedicated, single phase, 60/60 amp circuit breaker  
with a grounded neutral should be provided to supply  
power to the boiler.  
8
 
FLOW, HEAD AND TEMPERATURE RISE  
TABLE 7. XB MODELS - FLOW, HEAD AND TEMPERATURE RISE  
Temperature Rise - ΔT °F  
Flow Rate  
Input  
(Btu/hr)  
Output  
(Btu/hr)  
Water  
Flow  
Models  
20  
30  
40  
Maximum  
Minimum  
GPM  
LPM  
ΔP FT  
ΔP M  
GPM  
LPM  
ΔP FT  
ΔP M  
GPM  
LPM  
86  
325  
26  
7.9  
120  
453  
32.5  
9.9  
156  
592  
56  
211  
12  
3.7  
80  
302  
15  
4.6  
104  
395  
43  
162  
7
2.1  
60  
226  
8
2.4  
78  
86  
325  
26  
7.9  
120  
453  
32.5  
9.9  
156  
592  
43  
162  
7
2.1  
60  
226  
8
2.4  
78  
XB-1000  
XB-1300  
920,000  
855,600  
1,300,000  
1,209,000  
296  
296  
XB-1700  
1,700,000  
1,581,000  
ΔP FT  
ΔP M  
35  
14  
8
35  
8
10.7  
4.3  
2.4  
10.7  
2.4  
GPM  
LPM  
ΔP FT  
ΔP M  
GPM  
LPM  
ΔP FT  
ΔP M  
GPM  
LPM  
184  
696  
26  
7.9  
239  
905  
32.5  
9.9  
313  
1184  
123  
464  
12  
3.7  
159  
604  
15  
4.6  
209  
789  
92  
348  
7
2.1  
120  
453  
8
2.4  
156  
592  
184  
696  
26  
7.9  
239  
905  
32.5  
9.9  
313  
1184  
92  
348  
7
2.1  
120  
453  
8
2.4  
156  
592  
XB-2000  
XB-2600  
2,000,000  
2,600,000  
1,860,000  
2,418,000  
XB-3400  
3,400,000  
3,162,000  
ΔP FT  
ΔP M  
35  
14  
8
35  
8
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