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  • COMMERCIAL BOILERS/WATER HEATERS

    Service Handbook

    PRINTED IN THE U.S.A. 0513 320822-003

    SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT

    FOR MODELS: XB/XWH 1000, 1300, 1700 2000, 2600, 3400SERIES 100/101

    INSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS - BOILER/WATER HEATER CONSTRUCTION -

    OPERATION & SERVICE - TROUBLESHOOTING

    25589 Highway 1McBee, SC 29101

  • 2 Servicing should only be performed by a Qualified Service Agent

  • 3Servicing should only be performed by a Qualified Service Agent

    TABLE OF CONTENTSTABLE OF CONTENTS .......................................................................... 3INTRODUCTION .................................................................................... 4

    Qualifications ..................................................................................... 4Service Warning ................................................................................ 4Service Reminder .............................................................................. 4Tools Required ................................................................................... 4

    INSTALLATION CONSIDERATIONS ..................................................... 5Instruction Manual ............................................................................. 5Closed Water Systems ...................................................................... 5Thermal Expansion ............................................................................ 5Air Requirements ............................................................................... 5Contaminated Air ............................................................................... 5Venting ............................................................................................... 6General Venting Information .............................................................. 6Water Piping ...................................................................................... 6Temperature Rise & Flow Rate .......................................................... 6Boiler/Water Heater Controls ............................................................. 7Primary System Control ..................................................................... 7Installation Checklist .......................................................................... 8

    FEATURES AND COMPONENTS ......................................................... 9OPERATION AND SERVICE ................................................................11

    Modulating Fire Operation ................................................................11Combustion Blower ..........................................................................11Heat Exchanger Assembly .............................................................. 12Venturi And Gas Train Assembly ..................................................... 14Burner Assembly ............................................................................. 15Flame Sensor .................................................................................. 17Spark Igniter .................................................................................... 18Gas Valve ........................................................................................ 19Temperature Sensors ...................................................................... 20Air Filter Assembly ........................................................................... 21Control Panel Assembly .................................................................. 22Control Board Assembly .................................................................. 25Display System (Touch Screen Display) .......................................... 29Connector Terminals ........................................................................ 29

    START UP AND OPERATIONS ........................................................... 31Prior To Start Up .............................................................................. 31General ............................................................................................ 31Filling And Purging of Boiler/Water Heater Installation .................... 31Filling Boiler/Water Heater Installation ............................................. 31Inlet Gas Pressure ........................................................................... 31Manifold Pressure Connections ....................................................... 32Water Temperature Regulation ........................................................ 32Check/Control Water Hardness ....................................................... 33Freeze Protection (Hydronic Heating Installation) ........................... 33Inspect/Fill Condensate System ...................................................... 33

    LIGHTING AND OPERATING INSTRUCTIONS .................................. 34Adjustment ....................................................................................... 35Setting Of The Test Mode ................................................................ 35

    CONTROL SYSTEM OPERATIONS .................................................... 38Burner Control System .................................................................... 38Overview .......................................................................................... 38

    Burner Control Operation ................................................................ 40General Operational Sequence ....................................................... 41Lead Lag .......................................................................................... 42Local operator interface: display system ......................................... 44Installation Instructions (S7999D OI Display) .................................. 45Page Navigation .............................................................................. 48

    TROUBLESHOOTING ......................................................................... 58Poor Combustion - Ignition Failure - Rough Start/Operation ........... 58

    TROUBLESHOOTING CODES ............................................................ 60PIPING DIAGRAMS ............................................................................. 75

  • 4 Servicing should only be performed by a Qualified Service Agent

    This Service Manual covers the models and series numbers listed on the front cover only. The instructions and illustrations contained in this manual will provide you with troubleshooting procedures to verify proper operation and diagnose and repair common service problems.

    QUALIFICATIONSQUALIFIED INSTALLER OR SERVICE AGENCYInstallation and service of this boiler/water heater 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 Z223.1 2006 Sec. 3.3.83: Qualified Agency - Any individual, firm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction. If you are not qualified (as defined by ANSI above) and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this Service Manual. If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual.This product requires start-up certification by an qualified service agent that has been trained by the factory for this specific product. Call 1-800-527-1953 to locate the nearest qualified service agency and arrange a factory certified start-up.

    SERVICE WARNINGIf you are not qualified (as defined by ANSI above) and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual. If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual.

    SERVICE REMINDERWhen performing any troubleshooting step outlined in this manual always consider the wiring and connectors between components. Perform a close visual inspection of all wiring and connectors to and from a given component before replacement. Ensure wires were stripped before being crimped in a wire connector, ensure wires are crimped tightly in their connectors, ensure connection pins in sockets and plugs are not damaged or worn, ensure plugs and sockets are mating properly and providing good contact.Failure to perform this critical step or failing to perform this step thoroughly often results in needless down time, unnecessary parts replacement, and customer dissatisfaction.

    TOOLS REQUIRED Instruction Manual that came with the boiler/water heater. All hand tools common to installation and service of commercial water heaters and boilers such as torch, pipe wrenches etc. TORX T40 or 5 mm hex wrench - for setting gas mixture at gas valve. 3 mm or 7/64 inch hex (Allen) wrench - for setting gas mixture at gas valve. 6 mm allen key, Long (8-10) T handle 1/8 inch hex (allen key) wrench for Blower removal and installation. Hex (Allen) wrench sizes: 1/2, 5/32, 1/8, 1/4 and 5/16" or TORX T25/T40 - for Burner, and 24V Gas Valve removal and

    installation. Two Manometers or Pressure Gauges.

    One -