Ao-smith 3400 Manuel d'utilisateur

XB BOILERInstruction ManualPRINTED IN THE U.S.A. 0513 320741-005Thank you for buying this energy efcient boiler. We appreciate your conde

10FEATURES AND COMPONENTSFIGURE 3. SINGLE HEAT EXCHANGER BOILER COMPONENTS721111219132016642692831235183262524362717293483321035132

11FIGURE 4. DOUBLE HEAT EXCHANGER BOILER COMPONENTS27103512524273629343381731523321828269418616203261913211112

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 CONTROL VALVEThe gas control valve is a normally closed servo regulated gas control valve. The valve

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 buffer 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 l

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

19FIELD WIRING120 VAC POWER SUPPLY WIRINGA dedicated, single phase, 30-60 amp (refer to Table 5 on Page 8) circuit breaker with a grounded neutral sho

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

20TABLE 9. 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 qualied service t

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

25PVC/CPVC INSTALLATION:Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CS

26SUPPLIED VENT KIT:VENT PIPEVENT CONDENSATE TRAPFUSED ELBOWPVC/CPVC ADAPTERVENT PIPEFUSED ELBOWVENT CONDENSATE TRAPFIGURE 22. POLYPROPYLENE INSTALLA

27VENT AND AIR PIPE INSTALLATION1. Measure from the boiler level to vent. Refer to the Table 13 on Page 37 for the allowable lengths.2. Prepare pipe

28HORIZONTAL INSTALLATION REQUIREMENTS1. The vent system must terminate with the Through-the-Wall Termination (TWT) kits. Do not locate the terminal

29FIGURE 24. VERTICAL VENTING/ TERMINATION FIGURE 25. HORIZONTAL VENTING/ TERMINATIONMODELS (XB)RAIN CAP (PVC/CPVC)1000 320884-0001300 320884-001170

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 26. DIRECT VENT HORIZONTALFIGURE 27. DIRECT VENT VERTICALMODELS (XB)TEE VENTTERMINATIONS (PVC/CPVC)TEE VENTTERMINATIONS(POLYPROPYLENE)AIR I

31FIGURE 28. DIRECT VENT, VERTICAL VENT HORIZONTAL INTAKEFIGURE 29. DIRECT VENT, HORIZONTAL VENT VERTICAL INTAKEMODELS (XB)RAIN CAP(PVC/CPVC)AIR INT

32TERMINATION CLEARANCES SIDEWALL POWER VENTV XVENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTEDvvAGVFIXEDCLOSEDFIXEDCLOSEDOPERABLEOP

33TERMINATION CLEARANCES SIDEWALL DIRECT VENTFIGURE 31. DIRECT VENTVent terminal clearances for “Direct Vent” installations. Direct Vent conguration

34For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwellin

35DIRECT VENT: HORIZONTAL TERMINATIONGas vent extending through an exterior wall must not terminate adjacent to a wall or below building extensions su

36DIRECT VENTING: VERTICAL TERMINATIONInstallation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 fo

37ALL VENT PIPE MATERIALS AND FITTINGS MUST COMPLY WITH THE FOLLOWING:ITEM MATERIAL STANDARDS FOR INSTALLATION IN:UNITED STATES CANADAVent pipe and t

38CONDENSATE NEUTRALIZERThe condensate drains from the boiler have pH levels between 4.3 and 5.0. The pH measurement of a uid is an indicator

396. 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

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

40PIPE SIZES FOR PROPANE GASMake sure to contact the gas supplier for pipe sizes, tanks, and 100% lockup gas pressure regulator.PURGING GAS LINEGas li

41BOILER START UP AND OPERATIONSIMPORTANTOnly an A. O. Smith Certied Start-up agent must perform the initial ring of the boiler. At this time

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

44HIGH FIRING RATE SETTINGSet the boiler to the high ring rate by setting the High Firing Rate RPM as described below. Check combustion readings usin

454. 24VAC:• Output control of gas control valve (Pilot and Main) and External Ignition Transformer.• Digital inputs for room limit control, high l

465. PILOT FLAME ESTABLISHING PERIOD (PFEP):a. Lockout Interlock opens (if enabled).b. Pilot Valve terminal is not energized.c. No ame is presen

47LEAD LAGBurner Control System devices contain the ability to be a stand-alone control, operate as a Lead Lag Master control (which also uses the b

48If any slave under LL Master control is in a Run-Limited condition, then for some algorithms the LL master can apportion to that stage th

49FIGURE 48. S7999D OI DISPLAY CONNECTOR TERMINALSQUICK SETUP (S7999D OI DISPLAY)1. Make sure the S7999D 8-pin connector is properly aligned and pre

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

50The Home page also includes buttons for Lead Lag conguration when lead lag master and slave in the Burner control is enabled. Pressing th

51FIGURE 51. S7999D DISPLAY PAGE FLOW

52• Installer: The installer can read all control parameters and change default allowed parameters. This access level is used to customize the contro

53VERIFYPressing the Verify button displays safety conguration parameters for an additional verication step to commit the changes.Safe

54Press the Yes button to conrm each safety parameter block. If the No button is selected, the safety parameter block remains unconrmed and

55The date and time that each fault occurred is displayed in the lockout history. The lockout timestamp displays in both the lockou

56OPERATION BUTTONThe operation button displays the Burner Control running operation, including setpoint and ring rate values. From th

57FIGURE 68. PROGRAMMABLE ANNUNCIATION CONT.DIAGNOSTICS BUTTONThe Diagnostics button displays analog and digital I/O status of the Burner

58FIGURE 72. SYSTEM CONFIGURATION PAGESYSTEM SYNCHRONIZATION (S7999D OI DISPLAY ONLY)The user can manually synchronize conguration data from the con

59To support the recommended Troubleshooting, the R7910 has an Alert File. Review the Alert history for possible trends that may have been occurring p

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

60CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE30 Internal fault: Flame bias shorted to adjacent pin Internal Fault.1. Reset Modu

61CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE67 ILK OFF 1. Check wiring and correct any possible shorts.2. Check Interlock (IL

62CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE94 Header sensor fault 1. Check wiring and correct any possible errors.2. Replace

63CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE122 Lightoff rate proving failed 1. Check wiring and correct any potential wiring

64CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE149 Flame detected OEM Specic1. Holds if ame detected during Safe Start check up

65CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE164 Block intake ON OEM Specic1. Check wiring and correct any errors.2. Inspect

66CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODESNOTE212 Invalid Preignition time setting 1. Return to Conguration mode and recheck se

67CODE DESCRIPTION37 Program Module application parameter revision differs from application processor38 Program Module safety parameter revision diffe

68CODE DESCRIPTION114 MIX modulation range (max minus min) was too small (< 4% or 40 RPM)Modulation Operation Faults115 Fan was limited to its mini

69CODE DESCRIPTION191 Lead Lag base load common setting was invalid192 Lead Lag DHW demand switch setting was193 Lead Lag Mix demand switch setting wa

7TABLE 3. ROUGH IN DIMENSIONS (DOUBLE)Models XB-2000 XB-2600 XB-3400Dimensions inches mm inches mm inches mmFlue Outlet Diameter 8 203 8 203 10 254Ai

70CODE DESCRIPTION274 Abnormal Recycle: Demand off during Pilot Flame Establishing Period275 Abnormal Recycle: LCI off during Drive to Purge Rate276 A

71CODE DESCRIPTION341 Abnormal Recycle: Hardware SLO electronics342 Abnormal Recycle: Hardware processor clock343 Abnormal Recycle: Hardware AC phase3

72CODE DESCRIPTION482 Internal error: Safety key bit 4 was incorrect483 Internal error: Safety key bit 5 was incorrect484 Internal error: Safety key b

73CODE DESCRIPTION571 Heat exchanger high limit response was invalid572 Heat exchanger high limit was exceeded573 Heat exchanger high limit wasn'

74INSPECT BOILER AREA1. Verify that boiler area is free of any combustible materials, gasoline and other ammable vapors and liquids. 2. Verify that

755. 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

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

77HANDLING CERAMIC FIBER MATERIALSRemoval of combustion chamber lining:The combustion chamber insulation in this boiler contains ceramic ber material

78PIPING DIAGRAMSFIGURE 75. PRIMARY/SECONDARY PIPING SYSTEMNOTES:1. Preferred piping diagram.2. The temperature and pressure relief valve setting

79LIMITED WARRANTYA. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this boiler:1. If within TEN years a

8MODELS (XB)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 1581

25589 Highway 1, McBee, SC 29101Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306www.hotwater.comCopyright © 2013 A. O. Sm

9FLOW, HEAD AND TEMPERATURE RISETABLE 6. XB MODELS - FLOW, HEAD AND TEMPERATURE RISEModelsInput(Btu/hr)Output(Btu/hr)Water FlowTemperature Rise - ΔT