Hamilton Engineering XL800 Wiring diagram

INSTALLING, OPERATING & MAINTAINING
800–1500 High Eciency
Water Heaters and Heating Boilers
800–1500
795,000 BTU/hr
999,999 BTU/hr
1,475,000 BTU/hr
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 SMELL GAS:
• Do not try to light any appliance
• Do not touch any electrical switch
• Do not use any phone in your building
Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier instructions. If you cannot
reach your gas supplier, call the fire department.
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or death.
WARNING
New York Massachusetts SCAQMD CEC Listed
MEA 425-05-E C1-0319-441 Compliant Rule1146.2 California Energy Commission
WARNING
These appliances MUSTbe installed by a properly licensed individual in
the City and State which the unit is being installed.All start up adjustments
and subsequent service workmust be done by a similarly licensed
contractoror a factory trained service individual. Failure to comply could
result in loss ofwarranty and or severe personal injury, death and or
substantial property damage. These instructions are required to be
kept with the appliance on the left side, in the pocket provided.
ANSI Z21.10.3/CSA 4.3-2019,
ANSI Z21.13/CSA 4.9-2017,
UL 795-2016, CGA 3.4-2020

2USING THIS MANUAL
USINGTHIS MANUAL
Throughout this manual youwill see these special attention boxes similarto those below, which are intended to
supplement the instructions and make special notice ofpotential hazards. These categories are in the judgment of
the Manufacturer.
Indicates a condition or hazard which MAY
cause severe personal injury, death, or
major property damage.
DANGER
Indicates a condition or hazard which MAY
cause severe personal injury, death, or
major property damage.
CAUTION
Indicates a condition or hazard which MAY
cause severe personal injury, death, or
major property damage.
WARNING
WARNING
• THE VENTSYSTEM IS RATEDAND DESIGNEDTO BE 2 PIPE
SEALED COMBUSTION ONLY, POLYPROPYLENE PP, PVC SCH 40
OR CPVC SCH 40 OR 80 ORAL 29-4C STAINLESSVENTING FOR
ALLMODELS. AFACTORYENGINEEREDVENTING SYSTEM MAY
ALLOW FOR EXCEPTIONS; CONSULTFACTORYFOR DETAILS.
• THIS APPLIANCE INSTALLATION MUSTCONFORMTOTHE LATEST
EDITION OFTHE “NATIONALFUELGAS CODE”ANSI Z223.1 NFPA
54 AND/OR CAN/CGAB149 INSTALLATION CODES. STATEAND
LOCALCODES MIGHTALSOAPPLYTO INSTALLATION.
• WHERE REQUIRED BYTHEAUTHORITYHAVINGJURISDICTION,
THE INSTALLATION MUSTCONFORMTOTHE STANDARDS FOR
CONTROLSAND SAFETYDEVICES FORAUTOMATICALLY FIRED
APPLIANCES, ANSI/ASME APPLIANCEAND PRESSURE VESSEL
CODE, SECTION IV,ALONGWITH CSD-1.
• THE APPLIANCE, GAS PIPING,WATER PIPING, VENTINGAND
ELECTRICALMUSTBE INSTALLED BYTRAINED & QUALIFIED
PERSONNELFAMILIAR WITH INSTALLATION PRACTICES, LOCAL
CODE,AND LICENSING REQUIREMENTS.
• IFTHE INFORMATION IN THESE INSTRUCTIONSARE NOT
FOLLOWED EXACTLY,A FIRE OR EXPLOSION MAYRESULT,
CAUSING PROPERTYDAMAGE, PERSONALINJURY, OR DEATH.
• DO NOTSTORE OR USE GASOLINE OR OTHER FLAMMABLE
VAPORSAND LIQUIDS IN THEVICINITYOFTHIS OR ANYOTHER
APPLIANCE.

3
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 ReliefValve...............................................................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. GasTables....................................................................................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. ApprovedVenting Materials...............................................28
B. Venting theAppliance....................................................29–36
C. InletAirVent................................................................................37
D. Venting Runs that Exceed
Maximum Combined Length...............................................37
E. Condensate Requirements..................................................38
PART 5. PIPING........................................................ 3947
A. Hydronic Heating BoilerPiping..........................................39
B. BoilerSchematic 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 tobe CheckedBefore Lighting theAppliance.....48
B. Lighting Instructions......................................................48–49
C. Operating Instructions...........................................................49
D. INI Process and Service Procedures.......................49–51
E. Adjusting theTemp 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 theAppliance..........................................................57
B. Placing theAppliance 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 O 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 MaintenanceAnd Inspections.........................64
B. Annual Inspection....................................................................65
C. Heat ExchangerAnti-Scaling Prevention Feature...66
PART 9. SPECIAL INSTALLATION REQS........... 6768
A. Installation Requirements—Massachusetts..................67
B. Installation at HighAltitudes................................................68
PART 10. PARTS BREAKDOWN........................... 6971
PART 11. WARRANTY INFORMATION...................... 72
A. Warranty Contact Information.............................................72

4PART 1. GENERAL INFORMATION
PART1. GENERALINFORMATION
A. HOW IT OPERATES
The appliance product line is a high
eciency water heating product,
requiring special venting and
condensate removal precautions.
All high eciency condensing
appliances will require more
maintenance (cleaning) than their
non-condensing counterparts.
Failure to do so may result in
damage to the appliance that is not
covered underwarranty. Failure
to follow all of the instructions
contained in this manual may also
cause premature productfailure that
may not be covered underwarranty.
This appliance has built-infreeze
protection, automatically activating
the circulation pump when the
internal water temperature drops
below 41°F. If the internal water
temperature drops to 37°F, a burn
cycle will be initiated andwill shut
down as soon as the supply water
temperature has reached 50°F.
Power and gas must be left on for
this function to operate.
The appliance’s primary controller
is the HOT™ control platform.The
HOT™ controlleruses BCB and
BDB boards to operate allfunctions
ofneeded control and safety. It
contains sophisticated logic that
allows it to operate at very precise
temperatures while minimizing
burner on/o cycling. When multiple
units are operated as a Cascade to
handle a common load, the control
logic contains the ability to control
all ofthe units as eciently as one.
Cascade operation is afactory-
installed and programmed option,
requiring a field wiring connection
between appliances for operation.
BCB=
the internal Boiler Control Board.
BDB =
the Boiler Display Board;
human interface.
CCB =
the internal Cascade Control Board.
CDB =
the Cascade Display Board, human
interface located in the face of the
cabinet.

5
PART 1. GENERAL INFORMATION
BDB—Boiler Display Board
CDB - Cascade Display Board
BCB—Boiler Control Board
CCB – Cascade Control Board
EDB – Eeprom Data Board – contains all operating parameters of CCB and BCB
TYPICAL APPLIANCE DISPLAY
AS PART OF A CASCADE
Typical Cascade display—Heating and Indirect
Hot Water applications Typical stand-alone appliance display— Heating and Indirect Hot Waterapplications
TYPICAL CASCADE DISPLAY TYPICAL STAND ALONE APPLIANCE DISPLAY
The bottom of the display contains a scrolling message related to the current status of the system (Cascade Display), or the appliance

6PART 1. GENERAL INFORMATION
As a Stand
Alone Appliance
HOT™ CONTROL
MENU NAVIGATION

7
PART 1. GENERAL INFORMATION
Appliance as
Part of a Cascade
HOT™ CONTROL
MENU NAVIGATION

8PART 1. GENERAL INFORMATION
Standby Status
Normal Operating Status in Cascade
Normal Operating Status
in single appliance
B. APPLIANCE CONTROLS
FIGURE 11
APPLIANCE CONTROL PANEL
1) POWER on/o switch
2) Display/Interface
The following components arefound on the
control panel on thefront ofthe appliance.
Press simultaneously while in SETUP area to activate Password Keyboard

9
PART 1. GENERAL INFORMATION
C. APPLIANCE CONTROL BOARD (BCB) SCREENS
In the main screen it is possible to
see:
• Set point value
• Type ofsystem (icons)
• Date and time
• Labels for navigation through the
controller(STATUS, SET POINT,
HISTORY, SETUP)
• Information and tips
• Alarms (soft lockout yellow and
hard lockout red)
Navigation and settings are allowed
by using the arrow, √ and BACK
buttons.
SLO Warning and Pump On Icon:
Stand-By Mode:
Burner On (flame icon):
HLO Warning and Pump On Icon: Entering SETUP functions area:
Operating Mode:

10 PART 1. GENERAL INFORMATION
In case offault indication (SLO or
HLO), the main page shows the
code ofthe fault occurred.To see
the extended description you have
to go into HISTORYmenu, where
a new item “ACTUALFAULT”will
be displayed. In case an appliance
RESETis required (HLO fault), it
is possible to activate the RESET
procedure entering theACTUAL
FAULTpage and selecting the
corresponding item.
HISTORY then SYSTEM INFO:
HISTORY then to view ACTUAL FAULT:
LAST 10 FAULTS (SLO):Click √ button to RESET fault:
SETUP then enter password mode:
PASSWORD entered then DONE: Options in PASSWORD MODE: Home screen during INI process:
After reaching the letter you need, press the
√ button then move to next
Press and hold simultaneously as shown
PASSWORD Keyboard:Press to enter password mode:
ACTUAL FAULT (HLO):
C. APPLIANCE CONTROL BOARD (BCB) SCREENS (continued)