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
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