Installation, Operating and Service Instructions for X-2 ...

1 installation , Operating and Service Instructions for X-2 TM. Water Boiler Cast Iron Chimney Vent Gas Fired Models: X-202. X-203. X-204. X-205. X-206. X-207. X-208. X-209. Manual Contents Page Dimensional and Physical Data.. 3. Pre- installation .. 5. Removing Existing Boiler.. 6. Unpack Boiler .. 6. Venting.. 7. Water Piping.. 10. Gas Piping.. 13. Electrical.. 14. System Start-Up and Checkout .. 18. Operation.. 23. Before Leaving Jobsite.. 27. Service and Maintenance.. 28. How It Works .. 32. Troubleshooting.. 34. Service Parts.. 39. Appendix .. 46. TO THE INSTALLER: Affix these Instructions adjacent to boiler.

2 9700609. Provide model number and serial number when seeking information and support. TO THE CONSUMER: Retain these Instructions for future reference. Contact heating contractor for all issues and support. ! WARNING. Improper installation , adjustment, alteration, Service , or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualified installer, Service agency or gas supplier. Read these Instructions carefully before installing. 106636-02 - 12/19. X-2 installation , Operating & Service Manual The City of New York requires a Licensed Master Plumber supervise the installation of this product.

3 The Massachusetts Board of Plumbers and Gas Fitters has listed the X-2TM series Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, for the latest Approval Code or ask your local Sales Representative. The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas fitter. The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. ! DANGER ! CAUTION. Indicates a hazardous situation that, if not Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

4 Avoided, could result in minor or moderate injury. ! WARNING NOTICE: Indicates special Instructions on Indicates a hazardous situation that, if not installation , operation, or Service which are avoided, could result in death or serious injury. important but not related to personal injury hazards. ! DANGER. Explosion Hazard. DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building.

5 Immediately, call the gas supplier from a remotely located phone. Follow the gas supplier's Instructions or if the supplier is unavailable, contact the fire department. ! WARNING. This boiler must only be serviced and repaired by skilled and experienced Service technicians. If any controls are replaced, they must be replaced with identical models. Read, understand and follow all the Instructions and warnings contained in all the sections of this manual. If any electrical wires are disconnected during Service , clearly label the wires and assure that the wires are reconnected properly.

6 Never jump out or bypass any safety or Operating control or component of this boiler. Assure that all safety and Operating controls and components are Operating properly before placing the boiler back in Service . Annually inspect all vent gaskets and replace any exhibiting damage or deterioration. 2 106636-02 - 12/19. X-2 installation , Operating & Service Manual 1 Dimensional and Physical Data Table 1-1: Dimensions and Connections Boiler Supply NPT Return NPT Vent Gas NPT Relief Valve Drain Depth Width Height Model (inch) (inch) (inch) (inch) NPT (inch) NPT (inch).

7 X-202 32 14 40 1 1 4 . X-203 32 14 40 1 1 4 . X-204 32 16 40 1 1 5 . X-205 32 19 40 1 1 6 . X-206 32 22 40 1 1 6 . X-207 32 25 40 1 1 7 . X-208 32 28 40 1 1 7 . X-209 32 31 40 1 1 8 . Table 1-2: Weights and Volume Boiler Shipping Weight Empty Weight Water Content Input (MBH) (1). Model (lbs) (lbs) (gal). X-202 38 202 143 1. X-203 70 254 180 2. X-204 105 304 231 3. X-205 140 357 284 4. X-206 175 405 332 5. X-207 210 462 382 6. X-208 245 518 438 7. X-209 280 564 484 8. (1). Input ratings can be used for elevations up to 2000 ft. Refer to System Start-up and Checkout Sections for elevations 2000 ft.

8 Or higher. Electrical Requirements: 120 VAC, 60 Hz, 1-ph, Less than 12A. Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi safety relief valve. 106636-02 - 12/19 3. X-2 installation , Operating & Service Manual 1 Dimensional and Physical Data (continued). Model "W". X-202 14". X-203 14". X-204 16". X-205 19". X-206 22". X-207 25". X-208 28". Figure 1-3: Minimum Closet Clearances Model "W". X-209 31". Figure 1-4: Minimum Alcove Clearances * Minimum radial clearance around vent pipe and breeching for single-wall metal pipe vent connector.

9 Otherwise, follow vent connector manufacturer's recommended clearances. ** Additional height required to maintain 6" clearance from all breeching components. Vent damper may be installed in vertical or horizontal section of vent connector within reach of vent damper harness. ** Area of each opening to be 1 sq. inch for each 1000 BTU/hr input - with minimum of 100 sq. inches. Height of opening should be half of width. 3" minimum dimension for air openings. 4 106636-02 - 12/19. X-2 installation , Operating & Service Manual 2 Pre- installation F. Install on level floor.

10 For basement installation ! WARNING provide concrete base if floor is not level or if Carefully read all Instructions before installing water may be encountered on floor around boiler. boiler. Failure to follow all Instructions in proper order can cause personal injury or death. ! WARNING. ASSURE THAT THE FRONT AIR DAM is in place and undamaged. A damaged front air dam will negatively A. Inspect shipment carefully for any signs of affect the performance of this boiler, which can cause damage. All equipment is carefully manufactured, serious property damage, personal injury or death.