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ation SERVICE MANUAL / PARTS LIST MODEL XSG-5 1055 Mendell Davis Drive s Jackson MS 39272 888-994-7636 s 601-372-3903 s Fax 888-864-7636 unifiedbrands.net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or Gas Model, Manual Filling 67$5783 :KHQWKHSRZHUFRUGLVSOXJJHGLQWKHUHLV$&SRZHUWRWHUPLQDO+27DQGWHUPLQDO1HXWUDORQ WKHFKRNHWLPHU :KHQWKH212))VZLWFKLVDFWLYDWHGWHUPLQDORQWKHFKRNHWLPHULVHQHUJL]HGVWDUWLQJWKHFKRNHWLPHU VHTXHQFH7KHFKRNHVROHQRLGLVHQHUJL]HGIRUVHFRQGV7KHKLJKOLPLWLVDOVRHQHUJL]HGVHQGLQJ SRZHUWRWKHFRPPRQWHUPLQDORIWKH//&2FRQWDFWVRQWKH:DWHU/HYHO&RQWURO7KHZDWHUOHYHOERDUG LVDOVRHQHUJL]HGFDXVLQJWKH+/+LJK/RZFRQWDFWVRQWKH:DWHU/HYHO&RQWUROERDUGWRVZLWFK 0DQXDOILOOLQJRIWKHVWHDPHULVQRZUHTXLUHG2QFHWKHZDWHUOHYHOLQWKHVWHDPHUUHDFKHVWKHORZHU SUREHWKH//&2FRQWDFWVVZLWFKVHQGLQJSRZHUWRWKHFRPPRQWHUPLQDORIWKH+/FRQWDFWVFDXVLQJ WKHDGGZDWHUOLJKWDQGEX]]HUWRFRPHRQ :KHQWKHVWHDPHUFDYLW\LVILOOHGZLWKHQRXJKZDWHUWRKLWWKHKLJKSUREHWKH+/FRQWDFWVVZLWFKDQG SRZHULVVHQWGRZQWRWKHKHDWFLUFXLWU\ :KLOHWKDWLVRFFXUULQJ\RXDUHVWLOOWLPLQJWKHFKRNHWLPHURQFHWKHFKRNHWLPHUKDVUXQLWVVHTXHQFH LWFDQRQO\EHUHHQHUJL]HGE\WXUQLQJWKH212))VZLWFK2))DQGWKHQEDFN213UHILOOLQJWKH VWHDPHUFDYLW\EHIRUHDFWLYDWLQJWKH212))VZLWFKLVUHFRPPHQGHGRQPDQXDOILOOPRGHOV ,IWKHSUHVVXUHVZLWFKLVFORVHG&RQWURO5HOD\ZLOOHQHUJL]HVHQGLQJSRZHUWRWKHEXUQHUEORZHU WLPHUHQHUJL]LQJWKHEXUQHUEORZHU :KHQWKHEORZHUFRPHVXSWRVSHHGLWSXOOVDYDFXXPFORVLQJ96WXUQLQJWKH+HDW/DPS21DQG HQHUJL]LQJWKHLJQLWLRQFRQWUROOHU7KHLJQLWLRQFRQWUROOHUSHUIRUPVDVHOIGLDJQRVWLFVRQSRZHUXS$IWHU DSUHSXUJHRIVHFRQGVWKHPDLQJDVYDOYHLVHQHUJL]HGDQGWKH,JQLWHUFRPPHQFHVWRVSDUNXQWLOD IODPHLVGHWHFWHGRUWKH7ULDOIRU,JQLWLRQSHULRGRIVHFRQGVH[SLUHV2QFHWKHIODPHLVGHWHFWHGWKH VSDUNLVVKXWRIIDQGWKHPDLQJDVYDOYHUHPDLQVHQHUJL]HG6KRXOGWKHEXUQHUIDLOWROLJKWRUIODPHLV QRWGHWHFWHGGXULQJWKHILUVWWULDOIRULJQLWLRQSHULRGWKHJDVYDOYHLVGHHQHUJL]HGDQGWKHFRQWUROVWDUWV WKHLQWHUSXUJHVHTXHQFHRIVHFRQGVEHIRUHDWWHPSWLQJDQRWKHU7ULDOIRU,JQLWLRQ7KHFRQWUROZLOO PDNHWZRDGGLWLRQDODWWHPSWVDQGLIXQVXFFHVVIXOZLOOJRLQWRORFNRXW/RFNRXW5HFRYHU\LVDFFRP SOLVKHGE\WXUQLQJWKHSRZHUVZLWFKWRWKH2))SRVLWLRQ:DLWLQJDPLQLPXPRIVHFRQGVWKHQUHWXUQ WKHSRZHUVZLWFKWRWKH21SRVLWLRQ 7+(7,0(5 ,Q6WDQGE\0RGH&RQWURO5HOD\LVGHHQHUJL]HGWKH,QWHUQDO&RQYHFWLRQ)DQ0RWRUDQGWKH&RRN /DPSDUH2))DQG6WDQGE\/DPSLV21 ,Q7LPHG0RGHWLPHUWXUQHGWRDQ\WLPHGVHTXHQFHRU8QWLPHG&RRN0RGHIXOORQFRQWUROUHOD\LV HQHUJL]HGWXUQLQJRQWKH&RRN/DPS7KH,QWHUQDO&RQYHFWLRQ)DQLVHQHUJL]HGDQG6WDQGE\/DPSLV2)) 7LPH0RGH&RQWLQXHG7LPHUZLOOWLPHGRZQXQWLOWKHEX]]HUVRXQGV7XUQLQJWKHEX]]HURIIZLOO DFWLYDWHWKH6WDQGE\0RGHXQOHVVWKHWLPHULVUHVHWWRD7LPHGRU8QWLPHG&RRNSRVLWLRQ $'':$7(5/,*+7 ,IWKHZDWHUOHYHOGURSVEHORZWKHKLJKSUREHWKHKHDWLQJFLUFXLWLVGHHQHUJL]HGDQGWKH$GG:DWHU /LJKWDQG%X]]HUZLOOFRPH21 ,IWKHZDWHUOHYHOFRQWLQXHVWRGURSEHORZWKHORZSUREHWKHXQLWZLOOFRPSOHWHO\VKXWGRZQ +,*+/,0,7 7KH+LJK/LPLWXVHVD7\SH.WKHUPRFRXSOHWRPRQLWRUH[FHVVLYHKHDWLQWKHFRPEXVWLRQFKDPEHU :KHQDWHPSHUDWXUHH[FHHGLQJ)LVGHWHFWHGWKHFRQWUROZLOOVKXWGRZQWKHKHDWLQJFLUFXLW7KH FRQWUROKDVDQDXWRUHVHWIXQFWLRQDQGZLOODXWRPDWLFDOO\UHVHWZKHQWKHGHWHFWHGWHPSHUDWXUHGURSV EHORZWKHVHWSRLQW 4 SM-XSG-5 OPERATING SUMMARY - 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ITEM PART # 1 14 1 15 DESCRIPTION TERMINAL BLOCK, 2 NT1624 POSITION NT1523 TIMER, 60 MINUTE, 120V QTY. 2 1 1 16 17 18 H1178 KNOB NT1557 LAMP, AMBER, 120V NT1628 LAMP, BLUE, 120V 1 1 1 1 19 NT1556 LAMP, RED, 120V 2 1 1 20 21 NT1565 ON/OFF SWITCH NT1088 MOUNTING LATCH 1 1 1 22 NT1090 CONTACT, ON SWITCH 1 1 23 NT1612 VACCUUM SWITCH 1 1 24 NT1606 BLOWER MOTOR 1 2 2 25 26 NT1746 SOLENOID NT1578 IGNITOR/SENSOR PROBE 1 1 1 1 7 SM-XSG-5 XSG-5 PLUMBING SIDE COMPONENTS (Shown with Auto-Fill Option) 7 8 6 9 10 5 11 4 12 13 14 3 15 2 16 19 1 ITEM PART # 1 DESCRIPTION NT1555 3/4 MP x HB 90 DEG. FITTING 18 17 QTY. ITEM PART # 1 11 DESCRIPTION NT1140 3/8 BRASS NIPPLE QTY. 1 2 NT1138 3/8 NPT LOCKNUT 1 12 NT1139 3/8 NPT UNION 1 3 NT1127 1 1/2 BALL VALVE DRAIN 1 13 NT1278 MANIFOLD 1 4 NT1134 3/4 ELBOW 2 14 NT1721 AUTO-FILL VALVE 1 5 NT1502 CHECK VALVE ASSEMBLY 2 15 NT1474 90 ELBOW 1 6 NT1132 3/4 HOSE 1 16 1 7 NT1091 PRESSURE SWITCH 1 17 NT1479 TEFLON TUBING LEVEL PROBES NT1566 WATER (INCLUDES CONTROLLER) NT1203 5/16 HOSE 8 NT1202 1/2 x 1/8 BRASS REDUCER BUSHING 1 18 9 NT1200 BRASS TEE 1 19 10 NT1201 1/2 x 3/8 BRASS REDUCER BUSHING 1 G1562 INFRARED BURNER NT1820 3RD WATER LEVEL PROBE (AUTO-FILL ONLY) 2 1 1 1 8 SM-XSG-5 XSG-5 DOOR COMPONENTS 2 3 4 5 11 1 6 12 7 8 9 10 NT1115 NT1106 NT1511 NT1508 NT1050 NT1144 NT1545 NT1538 NT1509 NT1539 NT1179 NT1161 Door Insulation (not shown): NT1729 9 SM-XSG-5 XSG-5 STANDARD WIRING DIAGRAM 10 SM-XSG-5 ;6*67$1'$5'7528%/(6+227,1* 6<037203266,%/(&$86( 8QLWGRHVQRWWXUQ´21µQRSRZHU 3UREOHPZLWKIDFLOLW\EUHDNHU 1RZDWHULQFKDPEHU %ORZQIXVH)) )DXOW\VHOHFWRUVZLWFK66 )DXOW\ORZHUZDWHUSUREH )DXOW\ZDWHUOHYHOFRQWURO )DXOW\KLJKOLPLWFRQWURO 1RLJQLWLRQKHDWOLJKW´21µ *DVVXSSO\WRXQLWLV´2))µ )DXOW\LJQLWLRQFRQWURO )DXOW\LJQLWHUSUREH )DXOW\JDVVROHQRLGYDOYH 1RLJQLWLRQKHDWOLJKW´2))µ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´21µGRHVQRWF\FOH 1RUPDOZKHQGRRURSHQ )DXOW\SUHVVXUHVZLWFK36 )DXOW\JDVVROHQRLGYDOYH ([FHVVLYHVWHDPOHDNLQJSDVWGRRUVHDO $GGZDWHUOLJKWLOOXPLQDWHVZLWKZDWHULQXQLW )DXOW\'LUW\XSSHUZDWHUSUREH )DXOW\ZDWHUOHYHOFRQWURO FOR SERVICE SUPPORT CALL: 888-994-7636 SM-XSG-5 11 XSG-5 AUTO-FILL WIRING DIAGRAM 12 SM-XSG-5 XSG-5 AUTO-FILL TROUBLESHOOTING 6<037203266,%/(&$86( 8QLWGRHVQRWWXUQ´21µQRSRZHU 3UREOHPZLWKIDFLOLW\EUHDNHU 1RZDWHULQFKDPEHU %ORZQIXVH)) )DXOW\VHOHFWRUVZLWFK66 )DXOW\ORZHUZDWHUSUREH )DXOW\ZDWHUOHYHOFRQWURO )DXOW\KLJKOLPLWFRQWURO 1RLJQLWLRQKHDWOLJKW´21µ *DVVXSSO\WRXQLWLV´2))µ )DXOW\LJQLWLRQFRQWURO )DXOW\LJQLWHUSUREH )DXOW\JDVVROHQRLGYDOYH 1RLJQLWLRQKHDWOLJKW´2))µ )DXOW\SUHVVXUHVZLWFK3636 )DXOW\EXUQHUEORZHUPRWRU )DXOW\FRQWUROUHOD\&5 )DXOW\EORZHUWLPHU +HDWVWD\V´21µGRHVQRWF\FOH 1RUPDOZKHQGRRURSHQ )DXOW\SUHVVXUHVZLWFK36 )DXOW\JDVVROHQRLGYDOYH ([FHVVLYHVWHDPOHDNLQJSDVWGRRUVHDO $GGZDWHUOLJKWLOOXPLQDWHVZLWKZDWHULQXQLW )DXOW\'LUW\XSSHUZDWHUSUREH )DXOW\ZDWHUOHYHOFRQWURO 8QLWLVVORZWRSUHKHDWDQGVORZWRUHFRYHU )DXOW\SUHVVXUHVZLWFK36 6WHDPRULILFHREVWUXFWHG :URQJVL]HJDVRULILFH :URQJJDVVXSSO\ ,QFRUUHFWSUHVVXUHDWVXSSO\ )DXOW\JDVEXUQHU 8QLWVKXWVGRZQGXULQJSUHKHDWDQGRUQRUPDO RSHUDWLRQ /LPHEXLOGXSRQFKDPEHUERWWRP )DXOW\KLJKOLPLWFRQWURO )DXOW\KLJKOLPLWFRQWURO )DXOW\KLJKOLPLWWKHUPRFRXSOH )DXOW\ORZHUZDWHUSUREH )DXOW\ZDWHUOHYHOFRQWURO 8QLWGRHVQRWILOODWLQLWLDOVWDUW :DWHUOHYHOFRQWURO3&% :DWHULQOHWYDOYH62/ 8QLWGRHVQRWUHILOOGXULQJQRUPDORSHUDWLRQ :DWHUOHYHOFRQWURO3&% 'HIHFWLYHGLUW\PLGGOHZDWHUOHYHOSUREH :DWHULQOHWYDOYH62/ 8QLWRYHUILOOV :DWHUOHYHOFRQWURO3&% 'HIHFWLYHGLUW\XSSHUZDWHUOHYHOSUREH :DWHULQOHWYDOYH62/ FOR SERVICE SUPPORT CALL: 888-994-7636 SM-XSG-5 13 DO NOT remove either chimney assembly at any time during installation. STEP 1) Prior to stand mounting, remove exhaust deflectors from both units by removing (3) 10-24 x 1/2 truss-head phillips screws (THPS) at indicated locations. Original exhaust deflectors will not be re-used. 10-24 screws 3 locations, each unit Tools required for installation: Phillips screwdrivers Rubber mallet (possibly) 7/16 wrench or 7/16 socket with ratchet 3 locations 10-24 screws Leave aluminized steel sheet metal chimney of upper unit in place. STEP 3) Remove (3) 10-24 x 1/2 THPS at indicated locations. stainless steel outer shroud aluminized steel chimney Questions? Call 1-888-994-7636 XSG-5 Double-Stack Chimney Kit Installation (Rev. A 1/10) This shroud will not be re-used. STEP 2) Remove stainless steel outer shroud from upper unitONLY by removing (1) 10-24 x 3/4 THPS and nylon spacer at indicated location. Pull straight up on shroud to release (8) tabs from slots. upper unit ONLY 10-24 screw Estimated time for installation: 20 minutes exhaust deflectors BOTH STEAMERS MUST BE PROPERLY MOUNTED IN STAND BEFORE BEGINNING INSTALLATION OF CHIMNEY KIT Both units should be secured to stand with (4) 1/4-20 x 3/4 bolts and lock washers, finger-tight. NOTE: Stand brace is not shown in illustration SM-XSG-5 14 relief 3 locations 10-24 screws NOTE: This is a cutaway view 8 tabs 4 each side side flanges 10-24 screws 2 each side NOTE: Stand brace is not shown in illustration STEP 6) Attach second piece of lower unit chimney extension (M1602) by aligning 8 slots with tabs of chimney brace AND 8 tabs (4 each side) with slots in the upper unit's chimney assembly. The side flanges of this piece need to be on the outside of the extension piece installed in step 5. Once lined up, slide down forcefully to lock in place until screw holes line up. Use (4) 10-24 x 1/2 THPS at indicated locations to secure. Chimney Extension Part 2, M1602 8 slots XSG-5 Double-Stack Chimney Kit Installation (Rev. A 1/10) Chimney Extension Part 1, M1601 STEP 5) Attach first piece of lower unit chimney extension (M1601) as shown using (3) 10-24 x 1/2 THPS at indicated locations. Questions? Call 1-888-994-7636 chimney brace 2 locations 10-24 screws STEP 4) Attach chimney brace (M1600) as shown, with tabs facing up, using (3) 10-24 x 1/2 THPS. Remove (2) remaining screws at indicated location for next step. It is critical to install this piece correctly! All flanges must be in the air space between the aluminized steel chimney and the surrounding stainless steel. Extension has relief area specifically to assist in installation. (See detail views) It may be necessary to move upper unit slightly to allow screw holes to line up. SM-XSG-5 15 Questions? Call 1-888-994-7636 8 tabs 4 each side 10-24 screws 1 each side NOTE: Stand brace is not shown in illustration Complete installation by tightening (8) 1/4-20 x 3/4 bolts (4 each unit) that secure steamers to stand. STEP 9) Position stainless steel inner shroud (M1609) between steamers and attach to outer shroud using (2) 10-24 x 1/2 THPS at indicated locations. stainless steel inner shroud XSG-5 Double-Stack Chimney Kit Installation (Rev. A 1/10) 10-24 screws 3 locations NOTE: Stand brace is not shown in illustration STEP 8) Insert new exhaust deflector (M1610) on the inside of new stainless steel outer shroud as shown, spanning both chimneys. Attach using (3) 10-24 x 1/2 THPS at indicated locations. stainless steel outer shroud STEP 7) Attach new stainless steel outer shroud (M1608) by aligning 8 tabs with remaining slots in the upper unit's chimney assembly as shown. Slide down to lock in place. No screws are required to secure this piece in place. NOTE: Stand brace is not shown in illustration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eptember 27, 2011 "#&#!#"#!" $##!"!! $! 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