A.O. Smith XB-100 Instruction Manual Download Page 30

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FIGURE 29. DIRECT VENT, VERTICAL VENT HORIZONTAL INTAKE

FIGURE 30. DIRECT VENT, HORIZONTAL VENT VERTICAL INTAKE

MODELS

(XB/XW)

VENT

KIT NUMBERS

(RAIN CAP)

AIR INTAKE

KIT NUMBERS

(ELBOW)

1000

320884-000

321764-000

1300

320884-001

321764-000

1700

320884-001

321764-001

2000

320884-001

321764-001

2600

320884-001

321764-001

3400

320884-002

321764-002

MODELS

(XB/XW)

VENT

KIT NUMBERS

(TEE)

AIR INTAKE

KIT NUMBERS

(ELBOW)

1000

321765-000

321764-000

1300

321765-001

321764-000

1700

321765-001

321764-001

2000

321765-001

321764-001

2600

321765-001

321764-001

3400

321765-002

321764-002

Summary of Contents for XB-100

Page 1: ...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 supp...

Page 2: ...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 ...

Page 3: ...ert symbol indicates a potentially hazardous situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances kn...

Page 4: ...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 ...

Page 5: ...ion Institute INTRODUCTION QUALIFICATIONS QUALIFIED INSTALLER OR SERVICE AGENCY Installation and service of this boiler requires ability equivalent to that of a Qualified Agency as defined by ANSI below In the field involved Installation skills such as plumbing air supply venting gas supply and electrical supply are required in addition to electrical testing skills when performing service ANSI Z21...

Page 6: ...37 D 37 940 38 965 37 940 E 23 584 23 584 24 610 F 9 229 9 229 9 229 G 34 864 34 864 34 864 H 44 1118 45 1143 45 1143 J 6 152 6 152 6 152 K 11 279 11 279 11 279 L 12 305 11 279 12 305 Table 2 OPERATING CHARACTERISTICS Models XB XW Manifold Pressure Maximum Supply Pressure Minimum Supply Pressure Type of Gas Inches W C kPa Inches W C kPa Inches W C kPa 1000 1300 1700 2000 2600 3400 Natural Min Fire...

Page 7: ...0 50 100 56 120 67 140 78 XW 1000 920 000 854 680 GPH 2 593 1 728 1 482 1 296 1 152 1 037 864 741 LPH 9 815 6 543 5 608 4 907 4 362 3 926 3 272 2 804 XW 1300 1 300 000 1 207 700 GPH 3 664 2 442 2 094 1 832 1 628 1 465 1 221 1 047 LPH 13 868 9 246 7 925 6 934 6 164 5 547 4 623 3 962 XW 1700 1 700 000 1 579 300 GPH 4 791 3 194 2 738 2 395 2 129 1 916 1 597 1 369 LPH 18 136 12 090 10 363 9 068 8 060 ...

Page 8: ... 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 MODELS XB XW SUPPLY VOLTAGE VOLTS FREQUENCY HZ CURRENT AMPS ELECTRICAL NOTES 1000 120 60 30 A dedicated single phase 30 60 amp circuit breaker with a grounded neutral should be provided to supply ...

Page 9: ...P M 9 9 4 6 2 4 9 9 2 4 XB 1700 1 700 000 1 581 000 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 XB 2000 2 000 000 1 860 000 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 XB 2600 2 600 000 2 418 000 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 XB 3400 3 400 ...

Page 10: ...10 FEATURES AND COMPONENTS Figure 3 SINGLE HEAT EXCHANGER BOILER COMPONENTS ...

Page 11: ...11 Figure 4 DOUBLE HEAT EXCHANGER BOILER COMPONENTS ...

Page 12: ... 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...

Page 13: ...sion 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 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 burne...

Page 14: ...TURE 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 and has four leads The control system displays the Inlet and Outlet water temp...

Page 15: ...ng 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...

Page 16: ...s to heat exchanger failure All hot water heating systems should be completely flushed 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 flush contaminants from a system can cause solids to form on the inside of boiler exchangers create excessive blockage of water circulation ...

Page 17: ... have a temperature rating of 210 F 99 C a pressure rating not exceeding lowest rated working pressure of any system compo nent and a discharge capacity exceeding total input of water boilers supply ing water to storage tank Locate the T P relief valve a in the top of the tank or b in the side of the tank on a centerline within the upper 6 inches 152 mm of the top of the tank see Figure 78 and Fig...

Page 18: ... 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 significant 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...

Page 19: ...y are correct and that an adequate ground connection is present by performing the three voltage tests below See Figure 14 for wiring references Confirm 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 14 FIELD WIRING LOW VOLTAGE CONTROL WIRING 1 Header Terminals In case of Hydronic Boilers the header terminals are ...

Page 20: ... 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 11 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 Specific Gravity Gas w Heating Value of 1 000 BTU s Ft3 Size Length of Pipe in Feet Meters Inches 10 3 ...

Page 21: ...tem for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and deficiencies 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 dr...

Page 22: ...tilation and dilution of flue 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 Confined Space section that follows PANELS AND COVERS All panels and covers e g control and junction box covers front side and rear panels of boiler must be in place afte...

Page 23: ... 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 fixed in the open position 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 ven...

Page 24: ...inimum 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 OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS The confined space shall be provided with two permanent horizontal ducts one commencing within 12 inches 300 mm of the top and one commencing within 12 inc...

Page 25: ... specified in this manual to make the vent connections Failure to follow this warning could result in fire personal injury or death Note Make sure that for PVC venting installation the first 10 feet of vent must be CPVC or stainless steel and the set point temperature of the boiler must not exceed 200 F STAINLESS STEEL INSTALLATION Installations must comply with applicable national state and local...

Page 26: ...roper volume Failure to properly seal all joints and seams may result in flue gas recirculation spillage of flue products and carbon monoxide emissions causing severe personal injury or death AIR INLET PIPE MATERIALS Make sure the air inlet pipe s are sealed The acceptable air inlet pipe materials are PVC CPVC AL 29 4C An adapter is provided for transition between the air inlet connection on the b...

Page 27: ...ons specified by the instruction sheet provided in the kit The following are requirements for the Air Intake Terminal AIT 1 The Air Intake System AIS must ter minate with the venting equipment pro vided with the boiler 2 The AIT should not be located less than 3 feet 1 0 m below any exhaust vent within 10 feet 3 0 m 3 The total horizontal distance of the AIS from the boiler s Blower Adapter to the...

Page 28: ...DELS XB XW VENT KIT NUMBERS RAIN CAP 1000 320884 000 1300 320884 001 1700 320884 001 2000 320884 001 2600 320884 001 3400 320884 002 MODELS XB XW VENT KIT NUMBERS TEE 1000 321765 000 1300 321765 001 1700 321765 001 2000 321765 001 2600 321765 001 3400 321765 002 ...

Page 29: ...0 321765 001 321764 000 1700 321765 001 321764 001 2000 321765 001 321764 001 2600 321765 001 321764 001 3400 321765 002 321764 002 MODELS XB XW VENT KIT NUMBERS RAIN CAP AIR INTAKE KIT NUMBERS ELBOW 1000 320884 000 321764 000 1300 320884 001 321764 000 1700 320884 001 321764 001 2000 320884 001 321764 001 2600 320884 001 321764 001 3400 320884 002 321764 002 ...

Page 30: ...0 320884 000 321764 000 1300 320884 001 321764 000 1700 320884 001 321764 001 2000 320884 001 321764 001 2600 320884 001 321764 001 3400 320884 002 321764 002 MODELS XB XW VENT KIT NUMBERS TEE AIR INTAKE KIT NUMBERS ELBOW 1000 321765 000 321764 000 1300 321765 001 321764 000 1700 321765 001 321764 001 2000 321765 001 321764 001 2600 321765 001 321764 001 3400 321765 002 321764 002 ...

Page 31: ...inlet into building or combustion air inlet to any other appliance 6 inches 15 cm for appliances up to 10 000 Btu hr 3 kW 12 inches 30 cm for appliances between 10 000 Btu hr 3 kW and 100 000 Btu hr 30kW 36 inches 91cm for appliances above 100 000 Btu hr 30 kW 4 feet 1 2 m below or to side of opening 1 foot 30 cm above opening D Vertical clearance to ventilated soffit located above the terminal wi...

Page 32: ...inches 15 cm for appliances up to 10 000 Btu hr 3 kW 9 inches 23 cm for appliances between 10 000 Btu hr 3 kW and 50 000 Btu hr 15 kW 12 inches 30 cm for appliances above 50 000 Btu hr 15 kW D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61 cm from the center line of the terminal 12 inches 30 cm 12 inches 30 cm K Clearance to a mechanica...

Page 33: ...the horizontally vented gas fueled heating appliance or equipment The sign should read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment should not approve the installation unless upon inspection the inspector observes carbon monoxide detec...

Page 34: ...t and air inlet terminations must terminate in the same pressure zone Do not terminate above any door or window where condensate can freeze causing ice formations Locate or monitor the vent to prevent condensate damage to exterior finishes 3 The air piping must terminate in a down turned elbow using a mesh screen This setup will avoid recirculation of flue products into the combustion air stream S...

Page 35: ...t to buildup of leaves or sediment and also not blocked or restricted by snow accumulation 6 If installing both intake air and vent piping in a Direct Vent configuration vertically through the roof ensure that all exterior vertical clearance requirements shown in Figure 35 are being maintained These clearances and those cited by local and national codes must be maintained Note On flat roof install...

Page 36: ...ETER INCH AIR INTAKE MIN LENGTH FT AIR INTAKE MAX LENGTH FT VENT DIAMETER INCH VENT MIN LENGTH FT VENT MAX LENGTH FT XP 1000 6 12 100 6 12 100 XP 1300 6 12 100 8 12 100 XP 1700 8 12 100 8 12 100 XP 2000 8 12 100 8 12 100 XP 2600 8 12 100 8 12 100 XP 3400 10 12 100 10 12 100 Table 15 ROOM AIR ALLOWABLE VENT LENGTHS MODEL VENT DIAMETER INCH VENT MIN LENGTH FT VENT MAX LENGTH FT XP 1000 6 12 100 XP 1...

Page 37: ...ry installed condensate trap Install a commercially available neutralizing kit if required by the local codes The boiler is factory fitted with a 24V condensate trap connected to the controller For safety reasons if the condensate drain is blocked the control system will turn off all the firing burners and bring the boiler to a safe shut down If there is an air blockage in the line vent out the ai...

Page 38: ...inal supply pressure setting of 7 inches w c 1 7 kPa while the boiler is operating is recommended and will generally provide good boiler operation Some addition adjustment maybe required later to maintain a steady gas supply pressure 4 When installing multiple boilers in the same gas supply system it is recommended that individual positive lock up gas pressure regulators be installed at each unit ...

Page 39: ...or the manometer tubing Place the tubing of the manometer over the tap once the 1 8 fitting is installed 4 Slowly turn on the gas supply 5 Ensure inlet pressure is within specified range 6 If the gas pressure is out of range contact the gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control CHECK FOR GAS LEAKS B...

Page 40: ... to purge system of air Provisions should be made to permit manual venting of radiators or convectors FILLING HOT WATER SUPPLY BOILER INSTALLATION 1 Close the system s drain valve by turning handle clockwise 2 Open a nearby hot water faucet to permit the air to escape 3 Fully open the cold water inlet pipe valve allowing the boiler and piping to be filled 4 Close the hot water faucet as water star...

Page 41: ...satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally disabled If anyone using hot water in your home fits into one of theses groups or if there is a local code or state law requ...

Page 42: ...42 LIGHTING AND OPERATING INSTRUCTIONS ...

Page 43: ...ed gas air control and gas safety shut off control valves The valve functions in parallel with the variable speed combustion blower to supply the correct gas air ratio for optimum performance and efficiency The combustion blower speed is controlled automatically and determines the amount of negative pressure experienced by the gas safety shut off control valves The gas air regulator adjusts gas fl...

Page 44: ...g the Low Firing Rate RPM as described below Check combustion readings using a combustion analyzer If combustion readings are not in accordance with the chart shown below adjust as follows remove the cap on the gas regulator using a slotted screwdriver This will expose the offset adjustment screw Using a TORX T40 or a 5 mm hex wrench carefully adjust the low fire gas setting to achieve the CO2 lev...

Page 45: ... electric ignition function 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 efficient costs less reduces emissions improves load control and is more flexible than the traditional large boiler Control System consists of R7910A1138 Control Device S7999B Touchs...

Page 46: ... Pilot Valve terminal is not energized c No flame is present at the end of the PFEP or after programmed number of retry attempts d Main valve terminal is energized e Internal system fault occurred COMMUNICATIONS AND DISPLAYS Two modes of communications are available to the R7910 1 The R7910 has two RS485 communication ports for ModBus that allows for interfacing to one or all R7910s of a system an...

Page 47: ... complete 14 A new CH request is blocked for the forced off time set by the Anti Short Cycle if enabled 15 The pump stays on during the pump overrun time if enabled 16 At the end of the pump overrun time the pump will be switched off 6 MAIN FLAME ESTABLISHING PERIOD MFEP a Lockout Interlock opens if enabled b Pilot valve terminal is not energized c Main valve terminal is not energized d No flame p...

Page 48: ... 1 LL master does not prevent it and more important 2 It will not confuse the LL master because it is implemented as a state machine that is in only one state at a time DOMESTIC HOT WATER Start up sequence DHW request system in standby 1 Heat request detected either DHW Sensor Only DHW Sensor and Remote Command or DHW Switch and Inlet Sensor whichever applies 2 The pump is switched on after the DH...

Page 49: ...untime or Use Last If one or more Control Systems are in the Use First category then one of these the one with the lowest sequence number will always be the first boiler to fire If there is no Control System in the Use First category and one or more are in the Equalize Runtime category then the First boiler is also the Lead boiler LOCAL OPERATOR INTERFACE DISPLAY SYSTEM Figure 49 BURNER CONTROL S7...

Page 50: ...ONS 1 Electrical Ratings 12 VDC input maximum of 500 mA current drain Included Power Supply for S7999B Inputs 85 to 264 VAC 47 to 63 Hz 120 to 370 VDC Output 12 VDC 0 to 2 1 A Power 25 W 2 Operating Temperature 32 F to 122 F 0 C to 50 C 3 Storage Shipping Temperature 40 F to 158 F 40 C to 70 C 4 Humidity 85 maximum relative humidity 5 Approvals FCC Part 15 Class A Digital Device Underwriter s Labo...

Page 51: ...sired Function see Figure 53 The page descriptions are provided below so that you can understand the purpose of each and view the selections parameters and information that is available or required on each COMMON OI DISPLAY PAGE SYMBOLS Most pages have a Home button in the top left corner of the screen and a Back button in the top right corner of the screen The Home button returns the user to the ...

Page 52: ...52 Figure 53 S7999B DISPLAY PAGE FLOW ...

Page 53: ...eters The parameter name is displayed on the left and the current setting is displayed in the text box on the right STATUS OR HOME PAGE A status summary page Figure 54 is displayed when the S7999B display is connected This status page appears on the S7999B when the Burner control icon is pressed on the Home page The status page displays the current condition of the burner control and displays some...

Page 54: ... password Three levels of access to Burner Control parameters are permitted Each access level has defined rights when interfacing with configuration and status parameters within the controls End user The end user can read or view the control parameters and be allowed to change some operating parameters CH setpoint as an example Installer The installer can read all control parameters and change def...

Page 55: ...all parameters in each safety block must be verified to save them in the control When the installer is done changing safety parameters pressing the Verify button on the configuration screen begins the Verification process The settings for all safety parameters in each changed block are presented and Verified by the installer see Figure 62 on Page 56 VERIFY Pressing the Verify button displays safet...

Page 56: ...e time when the alert occurred refer to Table 22 DATA COMMENT Alert Line Set by display Alert Code Unique Code defining which fault occured Description Alert description HISTORY BUTTON The History button on the Home page serves not only as a button but also displays Burner Control lockouts holds and alerts as they occur The History button can be selected at any time regardless of which type of inf...

Page 57: ...n the history page lockout history and alert log The entire 15 fault code history is displayed in a scrollable list with the most recent fault displayed first followed by the next most recent fault Summary information is displayed for each fault entry including the burner cycle count fault code and fault number with description Detailed information for a specific fault entry that also includes bur...

Page 58: ...unciation information and switch between hydronic heating loops Central Heat and Domestic Hot Water as shown in Figure 69 If a password is required to change any of the settings on this page the user can press the Login button to enter the password Annunciation information is shown in Figure 70 and Figure 71 Figure 68 CONTROL EXPANDED ALERT DETAIL Figure 69 HYDRONIC OPERATION PAGE Figure 70 PROGRA...

Page 59: ...tal I O status of the Burner Control A snapshot of the diagnostic status is displayed and updated once per second as it changes in the control The digital I O data is displayed as LEDs that are either on green or off red See Figure 72 Not all digital I O can be displayed at the same time on the page so a horizontal scroll bar is used to move the view left and right to show all digital I O data The...

Page 60: ...layed on the Configuration menu page Parameters in functional groups that are not applicable for the installation can be ignored In some cases features in a functional group are disabled by default and are enabled when needed for the installation SYSTEM SYNCHRONIZATION S7999B OI DISPLAY ONLY The user can manually synchronize configuration data from the connected controls at any time A new control ...

Page 61: ...id processor clock H 7 Internal fault Safety relay drive error H 8 Internal fault Zero crossing not detected H 9 Internal fault Flame bias out of range H 10 Internal fault Invalid Burner control state L 11 Internal fault Invalid Burner control state flag L 12 Internal fault Safety relay drive cap short H 13 Internal fault PII shorted to ILK H or L 14 Internal fault HFS shorted to LCI H or L 15 Int...

Page 62: ... not match application s model ID Contact the service professional L 55 Application configuration data block CRC errors Contact the service professional L 56 57 RESERVED 58 Internal fault HFS shorted to IAS Internal Fault 1 Reset Module 2 If fault repeats replace module L 59 Internal Fault Mux pin shorted L Normal Event Status 60 Internal Fault HFS shorted to LFS L 61 Anti short cycle Will not be ...

Page 63: ... and Outlet sensors and pump circuits for proper operation 2 Recheck the Delta T Limit to confirm proper setting 3 If previous steps are correct and fault persists replace the module H or L 82 Stack limit 1 Check wiring and correct any possible errors 2 Replace the Stack high limit 3 If previous steps are correct and fault persists replace the module H or L 83 Delta T exchanger outlet limit Not Ap...

Page 64: ...hat the flame detector is wired to the correct terminal 3 Make sure the F G wires are protected from stray noise pickup 4 Reset and sequence the module if code reappears replace the flame detector 5 Reset and sequence the module if code reappears replace the module H or L 106 Flame lost in MFEP 1 Check pilot valve Main Valve for DSI wiring and operation correct any errors 2 Check the fuel supply 3...

Page 65: ...g ignition H or L 131 Fan movement detected during standby H 132 Fan speed failed during run H 133 135 RESERVED Start Check Faults 136 Interrupted Airflow Switch failed to close 1 Check wiring and correct any possible wiring errors 2 Check Interrupted Airflow switch es to assure proper function 3 Verify voltage through the airflow switch to the IAS input with a voltmeter 4 If steps 1 3 are correct...

Page 66: ...e present If not the lockout switch is defective and needs replacing 5 If the fault persists replace the relay module H or L 153 Combustion pressure Off H or L 154 Purge Fan switch On OEM Specific 1 Purge fan switch is on when it should be off H or L 155 Purge Fan switch Off H 156 Combustion pressure and Flame ON OEM Specific 1 Check that flame is not present in the combustion chamber Correct any ...

Page 67: ...tting L 186 Invalid Delta T limit response setting L 187 Invalid DHW high limit enable setting L 188 Invalid DHW high limit response setting L 189 Invalid Flame sensor type setting L 190 Invalid interrupted air switch enable setting L 191 Invalid interrupted air switch start check enable setting L 192 Invalid igniter on during setting L 193 Invalid ignite failure delay setting L 194 Invalid ignite...

Page 68: ...Invalid Outlet high limit enable setting Contact the service professional L 235 Invalid Outlet connector type setting Contact the service professional L 236 Invalid Inlet connector type setting Contact the service professional L 237 Invalid DHW connector type setting Contact the service professional L 238 Invalid Stack connector type setting Contact the service professional L 239 Invalid S2 J8 6 c...

Page 69: ... overridden due to sensor fault 70 No demand source was set due to demand priority conflicts 71 73 RESERVED CODE DESCRIPTION EE Management Faults 0 None No alert 1 Alert PCB was restored from factory defaults 2 Safety configuration parameters were restored from factory defaults 3 Configuration parameters were restored from factory defaults 4 Invalid Factory Invisibility PCB was detected 5 Invalid ...

Page 70: ...t source parameter was invalid 151 Minimum water temperature parameter was greater than setpoint CODE DESCRIPTION Fan Parameter Errors 74 Periodic Forced Recycle 75 Absolute max fan speed was out of range 76 Absolute min fan speed was out of range 77 Fan gain down was invalid 78 Fan gain up was invalid 79 Fan minimum duty cycle was invalid 80 Fan pulses per revolution was invalid 81 Fan PWM freque...

Page 71: ... 225 226 RESERVED 227 DHW priority override time was not derated due to invalid outdoor temperature 228 Warm weather shutdown was not checked due to invalid outdoor temperature 229 Lead Lag slave communication timeout 230 RESERVED CODE DESCRIPTION 152 Minimum water temperature parameter was greater than time of day setpoint 153 Minimum pressure parameter was greater than setpoint 154 Minimum press...

Page 72: ...2 Abnormal Recycle Ignition failed due to interrupted air flow switch was off 303 Abnormal Recycle ILK off during Drive to Purge Rate CODE DESCRIPTION 231 Lead Lag CH setpoint was invalid 232 Lead Lag CH time of day setpoint was invalid 233 LL outdoor temperature was invalid 234 Lead Lag ODR time of day setpoint was invalid 235 Lead Lag ODR time of day setpoint exceeded normal setpoint 236 Lead La...

Page 73: ...ycle Hardware flame bias dynamic low 380 Abnormal Recycle Fan Speed Not Proven 381 Abnormal Recycle Fan Speed Range Low CODE DESCRIPTION 304 Abnormal Recycle ILK off during Measured Purge Time 305 Abnormal Recycle ILK off during Drive to Lightoff Rate 306 Abnormal Recycle ILK off during Pre Ignition test 307 Abnormal Recycle ILK off during Pre Ignition time 308 Abnormal Recycle ILK off during Main...

Page 74: ...1 Mix S10 J10 7 temperature was invalid 522 Mix outlet temperature was invalid 523 Mix inlet temperature was invalid 524 Mix S5 J8 11 temperature was invalid 525 Mix modulation sensor type was invalid 526 Mix ODR min water temperature setpoint was invalid CODE DESCRIPTION 382 Abnormal Recycle Fan Speed Range High 383 450 RESERVED Circulator Errors 451 Circulator control was invalid 452 Circulator ...

Page 75: ...valid 541 Delta T exchanger outlet enable was invalid 542 Delta T inlet exchanger enable was invalid 543 Delta T inlet outlet degrees was out of range 544 Delta T exchanger outlet degrees was out of range 545 Delta T inlet exchanger degrees was out of range 546 Delta T response was invalid 547 Delta T inversion limit response was invalid 548 Delta T rate limit enable was invalid 549 Delta T exchan...

Page 76: ...t operation during initial ignition operation and extinction Cause no excessive lifting of flame from burner ports MAINTENANCE PROCEDURES MAINTENANCE SCHEDULES Yearly procedures for Service Technician Check for reported problems Check the interior clean and vacuum if needed Clean the condensate trap and fill with fresh water Check for water gas flue condensate leaks Ensure flue and air lines in go...

Page 77: ... main burners from unit 3 Check that burner ports are free of foreign matter 4 Clean burner with vacuum cleaner Do not distort burner ports 5 Reinstall burners in unit Ensure that all the screws on the burner flange are tightened securely so that the gasket will provide a good seal 6 Also check for good flow of combustion and ventilating air to the unit After placing the boiler in operation check ...

Page 78: ...condensate drains and tubes at least once a month and insure they will allow the free flow of condensate at all times The system must be inspected more frequently in cold weather if the drain system is located in an area such as along the floor where freezing tempera tures are likely to occur The conden sate drain system must be protected against freezing Contact a qualified service agent to inspe...

Page 79: ...on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection 2 Apply enough water to the combustion chamber lining to prevent airborne dust 3 Remove the combustion chamber lining from the boiler and place it in a plastic bag for disposal 4 Wa...

Page 80: ...PRIMARY SECONDARY HYDRONIC PIPING SYSTEM LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS MODEL INLET DIA OUTLET DIA XB 1000 2 2...

Page 81: ... the storage tank Applications in excess of these recommendations shall require a licensed engineer for design assistance XP BOILERS 1000 3400 ONE BOILER VERTICAL STORAGE TANK RECOVERY SYSTEM ONE TEMPERATURE LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS ...

Page 82: ...ate or provincial law are limited to one 1 year duration for the boiler or any of its parts Some states and provinces do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you 5 CLAIM PROCEDURE Any claim under this warranty should be initiated with the dealer who sold the boiler or with any other dealer handling the warrantor s products If this is ...

Page 83: ...83 25589 Highway 1 McBee SC 29101 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com ...

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