Hamilton Engineering XL800, Installing, Operating & Maintaining

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TABLE OF CONTENTS
TABLE OF CONTENTS
USING THIS MANUAL ..................................................... 2
TABLE OF CONTENTS ......................................................3
PART 1. GENERAL INFORMATION ........................ 4–17
A. How it Operates ..................................................................... 4–7
B. Appliance Controls ......................................................................8
C. Appliance Control Board (Bcb) Screens ...................9–10
D. Cascade Display Functions ........................................... 11–13
E. Glossary .........................................................................................14
F. Dimensions .......................................................................... 15–16
G. Pre-Installation Requirements .................................... 16–17
H. Pressure Relief Valve ............................................................... 17
PART 2. ELECTRICAL .............................................. 18–21
A. Electrical Connection/Requirements ...............................18
B. Internal Wiring Connection ..........................................18–21
PART 3. GAS CONNECTION ...................................22–27
A. Gas Connection and Inspection ......................................... 22
B. Gas Piping .................................................................................... 22
C. Gas Tables .................................................................................... 23
D. Gas Valve Setup ................................................................23–24
E. Setting the Maximum Load ........................................25–26
F. Setting the Minimum Load.................................................. 26
G. Gas Conversion ..........................................................................27
PART 4. VENTING ................................................... 28–38
A. Approved Venting Materials ............................................... 28
B. Venting the Appliance....................................................29–36
C. Inlet Air Vent ................................................................................37
D. Venting Runs that Exceed
Maximum Combined Length...............................................37
E. Condensate Requirements .................................................. 38
PART 5. PIPING ........................................................ 39–47
A. Hydronic Heating Boiler Piping .......................................... 39
B. Boiler Schematic Drawings ..................................................40
C. Fill & Purge Heating System .................................................41
D. Water Heating Piping ............................................................. 42
E. Water Heating Schematic Drawings .......................43–47
PART 6. START-UP PROCEDURES ..................... 48–56
A. Items to be Checked Before Lighting the Appliance .....48
B. Lighting Instructions ...................................................... 48–49
C. Operating Instructions ........................................................... 49
D. INI Process and Service Procedures ....................... 49–51
E. Adjusting the Temp on the Appliance Display ...52–53
F. Sequence of Operation..........................................................54
G. 0–10v Direct Control .................................................... 54–55
H. Outdoor Reset Function ........................................................ 56
PART 7. SERVICE AND MAINTENANCE ............57–63
A. Servicing the Appliance ..........................................................57
B. Placing the Appliance into Normal Operation .............57
C. Testing the Manual Reset High Limit .....................57–58
D. Soft Lockout Codes ........................................................ 59–60
E. Appliance Hard Lockout Codes ..........................................61
F. To Turn Off Gas to the Appliance ...................................... 62
G. Pump & Wiring Control ......................................................... 62
H. Status Readings ........................................................................ 63
I. Appliance Sensor Resistance Table ................................. 63
PART 8. MAINTENANCE ....................................... 64–66
A. Periodic Maintenance And Inspections .........................64
B. Annual Inspection .................................................................... 65
C. Heat Exchanger Anti-Scaling Prevention Feature ... 66
PART 9. SPECIAL INSTALLATION REQS ........... 67–68
A. Installation Requirements—Massachusetts ..................67
B. Installation at High Altitudes ................................................68
PART 10. PARTS BREAKDOWN ........................... 69–71
PART 11. WARRANTY INFORMATION ...................... 72
A. Warranty Contact Information .............................................72