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Instruction Manual
XP BOILER
MODELS: XB/XW
1000, 1300, 1700
2000, 2600, 3400
SERIES 100/101
INSTALLATION - OPERATION -
25589 Highway 1
McBee, SC 29101 MAINTENANCE - LIMITED WARRANTY
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 SMEL
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TABLE OF CONTENTS TABLE OF CONTENTS .......................................................................... 2 SAFE INSTALLATION, USE AND SERVICE.......................................... 3 GENERAL SAFETY................................................................................ 4 INTRODUCTION .................................................................................... 5 Model Identification ............................................................................ 5 Abbreviatio
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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, o
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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
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INTRODUCTION This Instruction Manual covers XP Boiler models XB/XW 1000, QUALIFICATIONS 1300, 1700, 2000, 2600, 3400 - Series 100/101. The instructions QUALIFIED INSTALLER OR SERVICE AGENCY and illustrations contained in this Instruction manual will provide you with troubleshooting procedures to diagnose and repair Installation and service of this boiler requires ability equivalent common problems and verify proper operation. to that of a Qualified Agency, as defined by ANSI below. In the
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DIMENSIONS AND CAPACITY DATA FIGURE 1. SINGLE HEAT EXCHANGER BOILER TABLE 1. ROUGH IN DIMENSIONS (SINGLE) Models XB/XW-1000 XB/XW-1300 XB/XW-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 22
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FIGURE 2. DOUBLE HEAT EXCHANGER BOILER TABLE 3. ROUGH IN DIMENSIONS (DOUBLE) Models XB/XW-2000 XB/XW-2600 XB/XW-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
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RATINGS TABLE 5. IBR RATINGS MODELS INPUT GROSS NET I=B=R RATINGS WATER MBH (XB/XW) MBH OUTPUT MBH (NOTE 2) (NOTE 1) MAX MIN 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 sufficient quantity for the requirements of the building a
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FLOW, HEAD AND TEMPERATURE RISE TABLE 7. XB MODELS - FLOW, HEAD AND TEMPERATURE RISE Temperature Rise - ΔT °F Flow Rate Input Output Water Models (Btu/hr) (Btu/hr) Flow 20 30 40 Maximum Minimum GPM 86 56 43 86 43 LPM 325 211 162 325 162 XB-1000 920,000 855,600 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 XB-1300 1,300,000 1,209,000 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 XB-1700 1,700,000 1,581,000
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FEATURES AND COMPONENTS FIGURE 3. SINGLE HEAT EXCHANGER BOILER COMPONENTS 10
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FIGURE 4. DOUBLE HEAT EXCHANGER BOILER COMPONENTS 11
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19. Heat exchanger access covers COMPONENT DESCRIPTION Allows access to the combustion side of the heat exchanger 1. Front access door: coils. Provides access to the gas train, burner controllers and the heat 20. High gas pressure switch exchanger. Switch provided to detect excessive supply gas pressure. 2. Air Filter Box: 21. Spark Igniter Allows for the connection of the PVC air intake pipe to the boiler Provides direct spark for igniting the burners. through a standard PVC adapter. I
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CONTROL COMPONENTS THE CONTROL SYSTEM The R7910A1138 is a burner control system that provides heat control, flame supervision, circulation pump control, fan control, boiler control sequencing, and electric ignition function. It will also provide status and error reporting. FIGURE 7. LOW/HIGH GAS PRESSURE SWITCH GAS VALVE The gas valve is a normally closed servo regulated gas valve. The valve opens only when energized by the burner control and FIGURE 5. BURNER CONTROL SYSTEM closes when the
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FLAME SENSOR WATER TEMPERATURE SENSORS Each burner is equipped with a flame sensor to detect the presence of the burner flames at high and low fire conditions. If no flame is sensed, the gas valve will close automatically. The voltage sensed by the flame sensor will also be displayed on the Burner Screen. FIGURE 12. WATER TEMPERATURE SENSORS Temperature sensors are threaded immersion probes. Temperature probes have embedded temperature sensors FIGURE 10. FLAME SENSOR (thermistors). The boi
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BOILER INSTALLATION CONSIDERATIONS If the system is of the open type, a pressure reducing valve will not GENERAL be required as the water supply to the system will be controlled by a manually operated valve. An overhead surge tank is required. A If the system is to be filled with water for testing or other purposes minimum pressure of 15 psi (100 kPa) must be maintained on the during cold weather and before actual operation, care must be taken boiler at all times to ensure avoidance of po
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CIRCULATING PUMP HOT WATER BOILER SYSTEM - GENERAL WATER LINE CONNECTIONS A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the boiler. Install in accordance with the current edition of the National Piping diagrams will serve to provide the installer with a reference for the materials and methods of piping necessary for Electrical Code, NFPA 70 or the Canadian Electrical Code, installation. It is essential that all wat
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In addition, a CSA design-certified and ASME-rated temperature and pressure (T&P) relief valve must be installed on each and every water storage tank in hot water supply system. The T&P relief valve must comply with appli cable construction provisions Explosion Hazard of Standard for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 or CSA 4.4. T&P re lief valve must be of automatic reset Relief Valve must comply with type and not embody a single-use type fusible plug, cartridge or
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It is important to guard against gas valve fouling from TABLE 8. SINGLE UNIT INSTALLATION, SUGGESTED GAS PIPE contaminants in the gas ways. Such fouling may cause improper SIZING. MAXIMUM EQUIVALENT PIPE LENGTH (IN FEET). operation, fire or explosion. If copper supply lines are used they must be approved for gas service. 2” 2-1/2” 3” 4” BTU When local codes require a main manual shut-off valve outside Input Nat Pro Nat Pro Nat Pro Nat Pro the boiler jacket, a suitable main manual shut-off
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LOW VOLTAGE CONTROL WIRING • Auto body shops 1. Header Terminals: In case of Hydronic Boilers, the header • Plastic manufacturing plants terminals are connected to the hydronic loop header sensor. • Furniture refinishing areas and establishments Whereas in case of Hot water Boilers the header terminals • New building construction are connected to the tank sensor where the temperature can • Remodeling areas be sensed. See Figure 15. Common household products, pool and laundry products ma
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20 TABLE 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 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 (3.05) 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
