A.O. Smith XB-101 Instruction Manual

XP BOILERInstruction ManualPRINTED IN THE U.S.A. 0711 320741-002Thank you for buying this energy efcient boiler. We appreciate your conde

10FEATURES AND COMPONENTSFIGURE 3. SINGLE HEAT EXCHANGER BOILER COMPONENTS

11FIGURE 4. DOUBLE HEAT EXCHANGER BOILER COMPONENTS

12COMPONENT DESCRIPTION1. Front access door: Provides access to the gas train, burner controllers and the heat exchanger. 2. Air Filter Box:Allows f

13FIGURE 7. LOW/HIGH GAS PRESSURE SWITCHGAS VALVEThe gas valve is a normally closed servo regulated gas valve. The valve opens only when energiz

14FLAME SENSOREach burner is equipped with a ame sensor to detect the presence of the burner ames at high and low re conditions. If no a

15GENERALIf 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

16CIRCULATING PUMPA circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the boiler.

17A discharge pipe from the relief valve should terminate at an adequate oor drain. Do not thread, plug, or cap the end of drain

18TABLE 8. SINGLE UNIT INSTALLATION, SUGGESTED GAS PIPE SIZING. MAXIMUM EQUIVALENT PIPE LENGTH (IN FEET).BTUInput2” 2-1/2” 3” 4”Nat Pro Nat Pro Nat

19• Auto body shops • Plastic manufacturing plants • Furniture renishing areas and establishments • New building construction • Remodeling areas

2TABLE OF CONTENTSTABLE OF CONTENTS ... 2SAFE INSTALLATION, USE AND SERVICE...

20TABLE 10. SUGGESTED PIPE SIZE FOR MULTIPLE GAS APPLIANCES (NATURAL GAS) Nominal Maximum Capacity of Pipe in BTU/hr and kW for Gas Pressures of 14

21GENERAL REQUIREMENTSREQUIRED ABILITYInstallation or service of this boiler requires ability equivalent to that of a licensed trades man in the eld

22LEVELINGBecause this unit is a Category IV appliance it produces some amounts of condensation. The unit has a condensation disposal system that requ

23CONFINED SPACEA 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 inpu

24The 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

25VENTINGVent sizing, installation and termination should be in accordance with this installation manual. This boiler must be vented using P

26VENT AND AIR PIPE INSTALLATION1. Measure from the boiler level to vent. Refer to the Table 14 on Page 36 for the allowable lengths.2. Prepare pipe

27(30.5 m). A maximum of three 90° elbows can be used. Minimum vertical vent is 7 equivalent feet (2.1 m) for direct vent install

28FIGURE 25. VERTICAL VENTING FIGURE 26. HORIZONTAL VENTINGMODELS (XB/XW)VENT KIT NUMBERS (RAIN CAP)1000 320884-0001300 320884-0011700 320884-00120

29FIGURE 27. DIRECT VENT HORIZONTALFIGURE 28. DIRECT VENT VERTICALMODELS (XB/XW)VENT KIT NUMBERS (TEE)AIR INTAKE KIT NUMBERS (ELBOW)1000 321765-00

3The proper installation, use and servicing of this boiler is extremely important to your safety and the safety of others.Many safety-related messages

30FIGURE 29. DIRECT VENT, VERTICAL VENT HORIZONTAL INTAKEFIGURE 30. DIRECT VENT, HORIZONTAL VENT VERTICAL INTAKEMODELS (XB/XW)VENT KIT NUMBERS (RAI

31TERMINATION CLEARANCES SIDEWALL POWER VENTV XVENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTEDvvAGVFIXEDCLOSEDFIXEDCLOSEDOPERABLEOP

32TERMINATION CLEARANCES SIDEWALL DIRECT VENTFIGURE 32. DIRECT VENTVent terminal clearances for “Direct Vent” installations. Direct Vent conguration

33For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwellin

34DIRECT VENT: HORIZONTAL TERMINATIONGas vent extending through an exterior wall must not terminate adjacent to a wall or below building extensions su

35DIRECT VENTING: VERTICAL TERMINATIONInstallation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 fo

36ALL VENT PIPE MATERIALS AND FITTINGS MUST COMPLY WITH THE FOLLOWING:ITEM MATERIAL STANDARDS FOR INSTALLATION IN:UNITED STATES CANADAVent pipe and t

37CONDENSATE NEUTRALIZERThe condensate drains from the boiler have pH levels between 4.3 and 5.0. The pH measurement of a uid is an indicator

386. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not blo

39PIPE SIZES FOR PROPANE GASMake sure to contact the gas supplier for pipe sizes, tanks, and 100% lockup gas pressure regulator.PURGING GAS LINEGas li

4GROUNDING INSTRUCTIONSThis boiler must be grounded in accordance with the National Electrical Code, Canadian Electrical Code and/or lo

40BOILER START UP AND OPERATIONSIMPORTANTOnly an A.O. Smith Certied Start-up agent must perform the initial ring of the boiler. At this ti

41TABLE 18. WATER HARDNESS MEDIUM (0-12 GRAINS PER GALLON)XW MODEL NO.∆T ºF GPM ∆P FEET1000 25 76 17.51300 25 99 221700 25 129 232000 25 152 17.5260

42LIGHTING AND OPERATING INSTRUCTIONS

43Click on Operation button, and under the Modulation Menu, set the required Firing rate (High/Low) by setting the RPM.On the Firing Rate page, set th

44TABLE 19. HIGH FIRE RATETABLE 20. LOW FIRE RATEHIGH FIRING RATE SETTINGSet the boiler to the high ring rate by setting the High Firing Rate RPM a

453. Three Pump Outputs with 5 selectable operation modes.4. 24VAC:• Output control of gas valve (Pilot and Main) and External Ignition Transformer

46CSD-1 Acceptable.Meets CSD-1 section CF-300 requirements as a Primary Safety Control.Meets CSD-1 section CW-400 requirements as a Temperature Ope

47GENERAL OPERATIONAL SEQUENCEINITIATEThe R7910 enters the Initiate sequence on Initial Power up or:• Voltage uctuations vary less than 20VAC or gre

48LEAD LAG (LL) MASTER GENERAL OPERATIONThe XP Boiler is a multiple burner application and it works on the basis of the Lead Lag Operat

49For example:— If its add-stage action has been triggered, it will remain in this condition until either a stage has been added,Or— The criteria for

5This Instruction Manual covers XP Boiler models XB/XW 1000, 1300, 1700, 2000, 2600, 3400 - Series 100/101. The instructions and illustrations contain

5010. Drill 1/4 in. holes through the panel at the marked locations and secure the power supply with the two #6-32 screws and nuts provided.11. Remo

51On System applications, each Burner Control System is represented on the Home page by an icon and name. Pressing the icon allows the user

52FIGURE 53. S7999B DISPLAY PAGE FLOW

53FIGURE 54. SUMMARY STATUS PAGECONFIGURE BUTTONPressing the Congure button (bottom left) on the Status page opens the Conguration page. The S7999B

54KEYBOARDSome pages request user entry of characters. When this type of input is required, a keyboard page appears, as shown in Figure 58. The text b

55Note: When the installer proceeds with the safety parameter conguration, the control unlocks the safety parameters in this group and ma

56FAULT/ALARM HANDLINGEach Burner Control reports to the OI display when a safety lockout or an Alert occurs.Safety lockouts are indicated o

57Note: The system time can be set in the OI display to ensure that correct timestamps are given to the controls’ lockouts and alerts. Power interrupt

58OPERATION BUTTONThe operation button displays the Burner Control running operation, including setpoint and ring rate values. From this page

59SYSTEM CONFIGURATION (S7999B OI DISPLAY ONLY)The OI Display has some functions related to general conguration for the control in the end us

6DIMENSIONS AND CAPACITY DATATABLE 1. ROUGH IN DIMENSIONS (SINGLE)Models XB/XW-1000 XB/XW-1300 XB/XW-1700Dimensions inches mm inches mm inches mmFlue

60CONFIGURATIONThe Burner Control can be congured from the OI Display. The control conguration is grouped into the functional groups as show

61To support the recommended Troubleshooting, the R7910 has an Alert File. Review the Alert history for possible trends that may have been occurring p

62CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE30 Internal fault: Flame bias shorted to adjacent pin Internal Fault.1. Reset Modu

63CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE67 ILK OFF 1. Check wiring and correct any possible shorts.2. Check Interlock (IL

64CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE94 Header sensor fault 1. Check wiring and correct any possible errors.2. Replace

65CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE124 High re switch OFF 1. Check wiring and correct any potential wiring errors.2.

66CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE150 Flame not detected OEM Specic1. Sequence returns to standby and restarts sequ

67CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE164 Block intake ON OEM Specic1. Check wiring and correct any errors.2. Inspect

68CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE212 Invalid Preignition time setting 1. Return to Conguration mode and recheck se

69CODE DESCRIPTION37 Program Module application parameter revision differs from application processor38 Program Module safety parameter revision diffe

7TABLE 3. ROUGH IN DIMENSIONS (DOUBLE)Models XB/XW-2000 XB/XW-2600 XB/XW-3400Dimensions inches mm inches mm inches mmFlue Outlet Diameter 8 203 8 203

70CODE DESCRIPTION114 MIX modulation range (max minus min) was too small (< 4% or 40 RPM)Modulation Operation Faults115 Fan was limited to its mini

71CODE DESCRIPTION191 Lead Lag base load common setting was invalid192 Lead Lag DHW demand switch setting was193 Lead Lag Mix demand switch setting wa

72CODE DESCRIPTION274 Abnormal Recycle: Demand off during Pilot Flame Establishing Period275 Abnormal Recycle: LCI off during Drive to Purge Rate276 A

73CODE DESCRIPTION341 Abnormal Recycle: Hardware SLO electronics342 Abnormal Recycle: Hardware processor clock343 Abnormal Recycle: Hardware AC phase3

74CODE DESCRIPTION482 Internal error: Safety key bit 4 was incorrect483 Internal error: Safety key bit 5 was incorrect484 Internal error: Safety key b

75CODE DESCRIPTION571 Heat exchanger high limit response was invalid572 Heat exchanger high limit was exceeded573 Heat exchanger high limit wasn'

76INSPECT BOILER AREA1. Verify that boiler area is free of any combustible materials, gasoline and other ammable vapors and liquids. 2. Verify that

775. Loosen the seven bolts on the blower adapter at the base and move the burner ground wire (Green) aside.6. Lift the blower adapter and remove th

781. Turn off the electrical power, and manual gas shut-off. • Allow boiler parts to cool before disassembly.2. Remove the vent pipe. • Check p

79HANDLING CERAMIC FIBER MATERIALSRemoval of combustion chamber lining:The combustion chamber insulation in this boiler contains ceramic ber material

8MODELS (XB/XW)INPUT MBHGROSS OUTPUT MBH (NOTE 1)NET I=B=R RATINGS WATER MBH (NOTE 2)MAX MIN1000 920 100 856 7441300 1300 130 1209 10511700 1700 170 1

80PIPING DIAGRAMSFIGURE 78. PRIMARY/SECONDARY PIPING SYSTEMNOTES:1. Preferred piping diagram.2. The temperature and pressure relief valve setting

81AOSSTORAGE TANKHOT WATERTO FIXTURESFINISHED FLOOREXPANSIONTANKALTERNATE CONNECTIONCOLD WATERSUPPLYSYSTEMRETURNNOTES:1. Preferred piping diagram.2.

82LIMITED WARRANTYA. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this boiler:1. If within TEN years a

8325589 Highway 1, McBee, SC 29101Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306www.hotwater.com

9FLOW, HEAD AND TEMPERATURE RISETABLE 7. XB MODELS - FLOW, HEAD AND TEMPERATURE RISEModelsInput(Btu/hr)Output(Btu/hr)Water FlowTemperature Rise - ΔT