Strange XG2000 behavior

John Mills_5

Tech finds no spark so replaces ignition module. Then gets spark and fire but after 30 seconds or so, some relay on the logic board arcs like crazy, the fire drops out, relights and the problem repeats again. Of course no boards to be had.

But it gets stranger. I came by, thought maybe we'd run just the pump to keep water circulating since it is barely above zero. To keep the fire off, I yanked a wire from the spill switch. But burners fire right up but Mr. Relay doesn't do his chattering routine at all. Great, we can get the guy heat for now. But when the limit opened, the inducer shut down but the burners didn't. Ooops. So this board must really be messed up. Anybody see anything like this before?

Not sure the bypass is working right either. The boiler shut up to 190 very fast but no hot water leaving it. The bypass stayed cold. Suddenly we had hot water heading out to the loops and back. Shouldn't hot water have been recirculated back through the bypass pipe?

JaredM

John, Not sure about the board problem...but I would make sure you don't have a short or fault somewhere on that boiler before replacing the board. Chattering relays could also be caused by an intermittent contact of one of the things in the limit string. You can go down the chain of things that the board looks at to try to narrow it down. That board is really just a junction point for all the limits and safeties with corresponding leds. Couldn't bring up a wiring diagram at Burnham's website.

On the bypass...it sounds like the bypass element is sticking closed not allowing flow through the boiler...a common mode of failure for that part. The element is available as a replcement part and it's a pretty simple repair IF you have isolation valves around the boiler. It looks very similar to an automotive thermostat and works much the same way.

Been a while buddy!

-JaredM

Unknown

John

The VizLogic Module that was used on the XG2000 series boilers was really quite ahead of its time as far as technology goes. They were quite easy to troubleshoot by simply following the sequence of the LED's. Where the lights stopped is where the problem usually occured. They were prone to the same problems that many other solid state circuitry devices are also prone to such as ground faults and voltage spikes. They are obtainable via UPS Next Day Air from our parts warehouse just as are all of the other parts for our boilers. These boilers have been out of production for many years now (replaced by the Revolution boiler) and spare boards are rarely kept by the distributors anymore. It sounds as though the thermostatic element in the bypass housing has also failed in the bypass position. These elements are also obtainable from our warehouse overnight. A word of caution though when changing the element. Go easy on the access cover for the element whem trying to get it off. Hope this helps.

Glenn Stanton

Manager of Training

Burnham Hydronics

U.S. Boiler Co., Inc.

John Mills_5

Thanks gentlemen

I think I'll have our best tech do some snooping on it. If it weren't for the strange behavior with the spill switch open, I'd suspect the board for sure. And have him see why no water goes through the bypass.

Jared, has been a long time. I see you pop up on H-Talk occasionally, visit more. Glenn, hope you are doing fine now. We could use another training class here soon!

John Mills_5

getting more confused

Our best tech checked it out and came to the same conclusion we did, bad board. But the new board does the exact same thing! So he's still playing.

I sat on hold at Burnham's tech support for 45 minutes this AM and for 1 hour 45 minutes today. The recording kept talking about how great Burnham's support was. I finally decided they were closed for President's Day, why I don't know. Seems to me they should have a recording saying they are closed not that they will be with me shortly. I didn't have 2 1/2 hour to be glued to the phone today

John Mills_5

Final answer

Turns out when our tech replaced the spark module, he wired something wrong causing all this. He's a big guy and it was murder to get to so I can relate.

But Glenn, please suggest that support and the main number put a message on when you are closed. Whoda thunk a boilermaker would close on President's Day! And come back to Indy with another seminar soon!

Unknown

John

I had given some thought to the miswiring possibility that seems to occur from time to time, particularly with the Universal replacement ignition modules. If I remember correctly, wasn't the XG2000 equipped with a Johnson G60 module originally?

Today was President's Day and our offices were closed, but Technical Services is still manned on these holidays with half of the staff though. That would account for the waiting period as well as the lack of a message on that toll free line stating we were closed.

Glenn Stanton

Manager of Training

Burnham Hydronics

U.S. Boiler Co., Inc.

John Mills_5

not a G60

it was a blue plastic control. Senior tech said it had to have 24v hot all the time and the tech that installed the Honeywell didn't catch it. Somehow the 24v fed back into the logic board and drove it crazy.

Unknown

Still a Johnson

Still a Johnson but probably the G770 or G775 module. It does require a constant power wire and as I stated, that's the common mistake I see when changing them out with the S8610U Honeywell Universal control. The other error I see involves the Penn Pilot assembly being connected incorrectly to the Honeywell control. There is a very small notation in the Honeywell indtructions that highlights that but for some reason it usually gets missed.

Glenn Stanton

Manager of Training

Burnham Hydronics

U.S. Boiler Co., Inc.