IBC Technologies SL 20-115 Installation And Operating Instructions Manual Download

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INSTALLATION AND OPERATION INSTRUCTIONS

1-30

SL 20-115 MODULATING GAS BOILER

NOTE

The IBC control only

recognizes a true dry contact

closure as a call for heat on

terminals “Therm. 1, Therm. 2

or Term. 3. Thermostats and

other devices that use a “Triac”

output cannot be used as a call

for heat without the installation

of an intervening relay with dry

contacts to connect to the IBC

terminal strip.

NOTE

The IBC boiler (like any

modern appliance that

contains electronic

equipment), must have a

“clean” power supply, and is

susceptible to power surges

and spikes, lightning strikes

and other forms of severe

electrical “noise”. Power

conditioning equipment

(surge protectors, APC or

UPS devices) may be required

in areas where power quality

is suspect.

DANGER

Do not connect thermistor

sensors to “Therm” terminals.

An overheating hazard can

result in serious personal

injury and/or property damage.

Terminal Strip for:

• Thermostat/switch Inputs

• Sensor inputs

• Auxiliary Interlocks

• Network Wiring

• External Control Signal

1.8.2 Power quality and Electrical Protection

in areas of unreliable power, appropriate surge protectors and or power

conditioning equipment should be installed in powers supply wiring circuits.

1.8.3 Zone valve Hook-up

if zone valves rather than pumps are used to manage multiple heating loads, then

24VaC for the zone valves should be provided to the power contacts on the Pump/

Zone Valve terminal Block. use a separate transformer – the 40Va unit inside the

wiring box is for internal systems only. the individual load/zone valves are then to

be wired to their associated contacts on the secondary pump/zone valve connector.

do not confuse such “load/zone valves” with similar valves used to segregate a

single load type (e.g. those used on a zoned radiant floor) –

see next section.

1.8.4 Thermostat / Sensor Wiring

dry contacts for thermostats for each of 3 loads are provided as marked on the

lower / orange connector strip (e.g. “therm 1”). gang lines from a multiple-zoned

load (e.g. off the end-switches for each radiant floor zone) to present a common

thermostat signal to the controller. Ensure there are no disturbing influences

on the call-for-heat lines - e.g. no coils to switch an air handler motor. Where

these zone valves are of a non-isolated 3-wire configuration, the zone valve end

contacts must be isolated from the load’s controller thermostat terminal using an

appropriate relay. required input for enabling the iBC boiler is a dry / mechanical

contact; ensure that triac or other parasitically-powered units are not used.

1.8.5 Other Wiring

other optional low voltage connections to the control board include:

•

two auxiliary interlocks - for external safety devices as may be required by

some jurisdictions, such as a low water cut-off or a low gas pressure cut-out

(for off-grid propane). A floor-protecting aquastat can use one of these, to

cause a full boiler shutdown in the case of excess floor temperature.

•

Contacts for indoor and outdoor temperatures sensors associated with reset

Heating. a 10K ohm thermister for outdoor reset sensing is supplied with the

boiler, to encourage use of this temperature compensating space heating

technique for improved comfort and combustion efficiency.

•

one pair for a dHW tank sensor. Connect to “dHW s” (not the respective

therm. 1,2,3 location) and the boiler will automatically notice and go to a

smart dHW routine

•

one pair of contacts for remote secondary loop temperature control.

•

one pair (marked Boilernet) for network connection – this is used for

connecting multiple sl and/or VFC modulating units for autonomous staging.

See separate Technical Memo for guidance.

•

A final pair of contacts, to receive a 0-10VDC (default) or 4-20 mA signal

from an external boiler controller- for direct throttle control. the boiler’s own

sensors act as high limits only. user must enter maximum and minimum boiler

supply temperatures.

NOTE:

sensors connected to any sensor input contacts must be of ntC

Thermister - type with a resistance of 10,000 ohms at 25°C and β = 3892. We do

not recommend using 3rd party supplied sensors. Compatible water temperature

sensors and outdoor sensors can be supplied by your iBC distributor.

Summary of Contents for SL 20-115

Page 1: ...stible materials 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 nearby phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed b...

Page 2: ...Natural Gas or Propane MBH CSA Input Natural Gas or Propane kW CSA Output MBH CSA Output kW 20 115 6 34 19 109 5 5 32 A F U E 96 1 Minimum gas supply pressure Natural Gas or Propane inch w c 5 Maximum gas supply pressure Natural Gas or Propane inch w c 14 Power use 120Vac 60Hz full fire Watts without pumps 54 Weight empty lbs Kg 115 52 Pressure vessel water content USG Litres 2 9 11 Maximum boiler...

Page 3: ...2 1 2 3 USER INTERFACE 2 1 2 4 ACCESS LEVELS 2 2 2 5 SEQUENCE OF OPERATION 2 4 2 6 OTHER OPERATING FEATURES 2 6 2 7 SET UP LOAD DEFINITION 2 10 3 0 STARTUP AND COMMISSIONING 3 1 3 1 LIGHTING AND SHUTTING DOWN THE BOILER 3 1 3 2 PRIOR TO START UP 3 2 3 3 COMMISSIONING 3 2 4 0 MAINTENANCE 4 1 4 1 BOILER MAINTENANCE 4 1 4 2 GEOGRAPHY COMPONENTS 4 4 5 0 TROUBLESHOOTING 5 1 5 1 PRELIMINARY CHECKS 5 1 5...

Page 4: ...ontact with the condensate Keep exhaust plumes well away from all building air intakes including those of neighbouring properties In sealed combustion applications the exhaust outlet should be placed so as to reach 24 minimum above the down turned intake to avoid exhaust re ingestion For sidewall venting options Both the inlet and exhaust terminations should normally be located on the same plane s...

Page 5: ...oviding a great degree of installation flexibility Figure 1 shows outer case dimensions and piping and electrical holes Use this diagram to find a suitable location for the boiler See also Section 1 3 Location DESCRIPTION SL 20 115 A Exhaust Outlet 3 Schedule 40 B Combustion Air 3 Schedule 40 C LCD Display 2 3 4 x 1 1 2 D Water Outlet 1 NPT F E Water Inlet 1 NPT F F Knock outs 6 1 2 G Gas Inlet 1 ...

Page 6: ...be avoided For this reason the indoor air venting option using air surrounding the boiler should not be used in a laundry room Similarly ensure any direct vent air source is not adjacent to a clothes dryer exhaust terminal Avoid agricultural applications where the boiler and or the intake air source are affected by ammonia and or dust Locate the boiler where water leakage will not result in damage...

Page 7: ...arranted to manage the impact of the steam plume normally experienced at the exhaust terminal of a condensing boiler Generally intake and exhaust pipes should terminate at a rooftop or sterile wall location to maximize customer satisfaction Keep exhaust plumes well away from all building air intakes including those of neighbouring properties WARNING Exposed water piping and associated components r...

Page 8: ... system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes...

Page 9: ...230 F For long vent runs with higher initial exhaust temperature some jurisdictions may allow the use of mixed materials for economy CPVC for the initial run followed by ULC S636 approved PVC to the termination It is the responsibility of the Installer to confirm that local codes will allow this option Ensure appropriate transition glue is used The installer is responsible to ensure that sufficien...

Page 10: ... e g 45 x 1 4 63 equiv With 45 of 2 Flex up to 37 equivalent of 2 Rigid PPs would still be allowed For 3 flex PPs the maximum lineal vertical travel is 98 and the factor to compute equivalent length for 3 Flex is 1 2 1 PPs 87 90 elbows are considered to be 8 equivalent EXHAUST Pipe Size MaxIMUM EquivAlEnt Length Sched 40 Rigid PPs 2 100 3 240 90 long sweep elbow allow 5 equivalent 90 vent elbow al...

Page 11: ...ips supplied by the respective PPs manufacturer All vent connections must be liquid and pressure tight Prior to firing the boiler and before any of the venting run is concealed by the building construction the installer must test the exhaust joints under fan pressure with the vent blocked using a soap water solution Installer must fill condensate trap prior to test Remove the fan control harness p...

Page 12: ...l termination options For alternate group terminations contact the IBC Factory for written guidance DO NOT exhaust vent into a common venting system 1 4 6 Sidewall Vent Termination Sidewall direct vent applications shall be vented as follows Both the inlet and exhaust terminations should normally be located on the same plane side of the building The exhaust outlet is to be placed so as to reach 24...

Page 13: ...ely as long as the boilers are identical models intake and exhaust terminals can maintain a minimum of 12 of separation horizontally from any exhaust or inlet termination of an adjacent boiler For alternate group terminations contact the IBC Factory for written guidance Figure 5 Sidewall vent termination piping configuration Figure 6 Sidewall vent termination indoor combustion air applications WAR...

Page 14: ...re line extended above meter regulator assembly 3 0 91m within a height of 15 4 6m above the meter regulator Clearance to service regulator vent outlet 3 0 91m Clearance to non mechanical air supply inlet to building or the combustion air intake to any other appliance 3 0 91m USA 12 0 3m Clearance to a mechanical air supply inlet 6 1 82m USA 3 0 91m above if within 10 3 1m horizontally Figure 8 Pr...

Page 15: ...finishes or components or infiltrate building envelopes including adjacent structures 1 4 7 Direct Vent Combustion Air Intake Piping There are two basic methods of supplying combustion air to an IBC boiler The direct vent option uses piping from the outside to supply combustion air directly to the boiler s combustion air connection WARNING In addition to preventing ingestion of chemical contaminan...

Page 16: ...ansfer of unused intake allowance Combustion air piping if used is inserted directly into the 3 female stainless steel fitting on the top right side of the boiler and run horizontally or vertically to the outdoors Screen material can be placed at the inlet as appropriate for the environment e g insects dust Care must be taken to ensure adequate separation is maintained between the air intake inlet...

Page 17: ... air intake filters have a known pressure drop and fouling factor and should be used as a component of the combustion air system according to the allowable intake length in Table 4 1 4 10 Closet Installations For installations in a confined space such as a closet ventilation openings may be needed through a door or wall to prevent excessive heat from building up inside the space The boiler shall n...

Page 18: ...ession Nut E remove Drain Hose G from Trap Drain Outlet F Place Vacuum breaker cap J over the Vacuum breaker opening and push firmly home Remove Upper Compression Nut and Washer C and slide over Boiler Drain Outlet A Insert one Trap Hook barb into the back mounting hole 2 Fill Trap with water and slide Trap Body D over Boiler Drain Outlet A Swing Trap Hook B around the Drain Outlet F connection th...

Page 19: ...d in the installation instructions above 1 5 4 Further installation details Condensate drain must be piped to within 1 of a drain or be connected to a condensate pump Drainage line must slope down to the drain at a pitch of 1 4 per foot so condensate runs towards the drain Condensate traps should be checked every 2 months and cleaned and refilled as necessary NOTE It is the responsibility of the i...

Page 20: ...tes are to be discharged into building drain piping materials that are subject to corrosion a neutralization package must be used CAUTION When a condensate neutralization package is installed the pH of the condensate discharge must be measured on a regular schedule to ensure the neutralizing agent is active and effective Figure 17 Condensate trap disassembly for cleaning ...

Page 21: ...ecommended for maximum flexibility in multi load applications but piping loads in parallel is also encouraged in systems that only have two loads or when loads are operating simultaneously The extremely low pressure drop through the SL Series heat exchanger allows many options not available in other designs In short IBC has built a boiler that will allow you to pipe the system the way you prefer r...

Page 22: ...der fitting Follow the instructions that come with the connection kit Instructions can also be accessed on line from www ibcboiler com CAUTION Installers should inquire of local water purveyors as to the suitability of their supply for use in hydronic heating systems If water quality is questionable a local water treatment expert must be consulted for testing assessment and if required treatment A...

Page 23: ... relief valve blow off the discharge may be directed back into the pressurization unit for recycling of boiler fluid and chemicals back into the system In buildings that may be unoccupied for long periods of time pressurization units are useful to prevent flood damage should leakage occur from any component in the system An additional benefit is that backflow prevention devices are not required wh...

Page 24: ...ll run the boiler s primary pump for up to 5 minutes 300 seconds after burner shutdown Secondary pumps can be set to run up to 5 minutes after burner shutdown for the last calling load As shipped the default software will run the Load 1 pump for 5 minutes to place the legacy heat where it is useful Any secondary pump can be set to run for 0 300 seconds in the heat purge mode Guard against deadhead...

Page 25: ...ondary piping details with closely spaced tees NOTE This piping drawings in this manual are simple schematic guides to a successful installation There are many necessary components not shown and details such as thermal traps are left out so the drawings have greater clarity We require that our boilers be installed by licensed and experienced trades people who are familiar with the applicable local...

Page 26: ...AND OPERATION INSTRUCTIONS 1 22 SL 20 115 MODULATING GAS BOILER Figure 28 Important Primary Secondary piping details with hydraulic separator Figure 27 Basic Primary Secondary piping with hydraulic separator concept ...

Page 27: ...1 23 INSTALLATION SL 20 115 MODULATING GAS BOILER Figure 29 Primary Secondary piping to a hydraulic separator distribution manifold Figure 30 Parallel piping connection to one side ...

Page 28: ...al multi zoned radiation system However where individual zones in a heating system have loads under 10 000 Btu hr the system will still benefit through use of a buffer tank to ensure a controlled supply temperature and to prevent short cycling Buffering should be added on the secondary piping of the relevant load to avoid bulking up the thermal mass of the primary piping circuit and potentially le...

Page 29: ...ves small loads as in typical zoned baseboard heating applications use of a buffer tank is recommended To aid in temperature transition from hot to cool loads a 3 way mixing valve can be placed at the entrance to the cool load this will also provide floor protection This will permit immediate circulation of mixed flow into the cool loop See separate publication Application Notes for more detail av...

Page 30: ...11 P V Power L This procedure will allow the boiler to operate the load pumps through the Boiler Pump contacts Check valves or thermal traps should be used to isolate both the supply and return piping for each load to avoid thermal siphoning and reverse flow To ensure adequate water flow through the boiler under high head single zone space heating conditions a pressure activated bypass or other me...

Page 31: ...ontrol is set up as a Master boiler and up to 23 additional boilers can be added to the system as Subordinate boilers by connecting a twisted pair of wires between the boilers No additional controls are needed Check valves are to be used in each boilers piping to prevent reverse flow when the boiler is off For further information and details consult our Application Notes which provide detail on sp...

Page 32: ... being placed into operation The gas valve is provided with pressure taps to measure gas pressure upstream supply pressure and downstream manifold pressure of the gas valve see Figure 38 Note that manifold pressure varies slightly in accordance with firing rates with the modulating series boilers but will always be close to 0 w c Figure 35 Typical gas piping connection Natural gas burner left Prop...

Page 33: ...and or zone valves only Connect the pump s Black wire to the Yellow of this pair switched Hot The White Yellow pair should be individually capped if the primary pump does not obtain its power from this pair e g if a variable speed primary pump is connected to the mains power If a parallel pump piping configuration is used rather than primary secondary loop the White Yellow Primary Pump pair up to ...

Page 34: ...oad e g off the end switches for each radiant floor zone to present a common thermostat signal to the controller Ensure there are no disturbing influences on the call for heat lines e g no coils to switch an air handler motor Where these zone valves are of a non isolated 3 wire configuration the zone valve end contacts must be isolated from the load s controller thermostat terminal using an approp...

Page 35: ...a single temperature heat load where zone valves are used to manage individual thermostatically controlled zones each room thermostat s heat anticipator should be adjusted to the current draw of its associated zone valve Figure 36 Electrical Wiring Connections full page ladder diagram at back of this manual A 2 5 mm Slot screwdriver is required for the bottom terminal strip Broader or narrower bla...

Page 36: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 32 SL 20 115 MODULATING GAS BOILER ...

Page 37: ...e 34 F to 180 F CONTROL The control unit provides overall management of boiler operations including 1 Power up set up boiler state machine standby heat call management etc 2 Burner pumps primary external and or zone valve management 3 Temperature and throttle operation 4 Maintenance of a service log with diagnostics 5 2 way communications Operating and historical data may be accessed at any time u...

Page 38: ... with Reset CIR Cast Iron Radiators w Reset BBd Baseboards w Reset AIR Air Handler w Reset StP Set Point DHW Domestic Hot Water Other information is accessible using a menu based system described in the following sections ACCESS LEVELS The controller provides for the display of further information via the Load Status Screen plus three levels of access for the adjustment of control settings This is...

Page 39: ...iler supply A record of the service history is also available for onscreen access 2 4 3 Advanced Diagnostics Not an access level this field allows a view into detailed sensor readings and operating parameters such as fan rpm This screen is useful for advanced troubleshooting of pressure sensors etc 2 4 4 Advanced Setup This access level is set for the sole use of factory representatives and is per...

Page 40: ...is below the water temperature target or setpoint Heating Enabled The boiler is powered and there is a Call for Heat Heat is Required The boiler will start and enter the Heating Cycle unless it is in an error mode 2 5 1 Standby Waiting for a Heating Enabled signal The burner and boiler pump are off during this time 2 5 2 Purging Prepurge On a Heating Enabled signal the boiler automatically enters ...

Page 41: ...begins 2 5 4 Heating The heating cycle lasts until the Heating Enabled state ends for all loads or until water temperature exceeds the target temperature by of the supply differential for the last served load and the throttle has fallen to the minimum output At the end of the heating cycle the boiler enters a postpurge During the heating cycle the boiler addresses the multiple defined loads in acc...

Page 42: ...mmediate safety hazard The boiler enters an extended purge followed by the error cycle of 5 minutes for all conditions other than Maximum Ignition Trials a modified Hard Error which locks out for 1 hour after 3 unsuccessful ignition attempts Following the purge the fan and pump are stopped until the end of the error cycle Normal operation then resumes Hard Errors result when a condition exists tha...

Page 43: ...y set to 80 will run for approx 35 min before switching to a clashing load set with priority 45 Following such initial cycle the clashing loads will switch back and forth after further 10 min intervals pending satisfaction of one or both loads To cause repeated unequal run times for example constant 35 vs 5 min runs it is necessary to integrate an external load removing relay or timer on one of th...

Page 44: ...erence to the delivered temperature if the floor slab has stabilized at the boiler temperature served up by the reset curve Where Outdoor Reset is applied without the indoor sensor feedback option some manual adjustment may be required to achieve the desired comfort level Fine adjustment can be made at the keypad using the Indoor Setpoint Temperature variable located as Line 1 in the User screen T...

Page 45: ...ied by specific day Mon Sun The automated setback feature cannot be applied to setpoint loads including DHW with simple aquastat control This is due to the lack of linkage with the thermostat setback without linkage could lead to unacceptable cycling Access is via the User Setup screen 2 6 6 Unoccupied Mode Users can further reduce energy consumption by switching the boiler to the unoccupied mode ...

Page 46: ... the external signal In such slave mode temperature management is also surrendered to the external controller s sensors The installer only enters Maximum Boiler Supply and On Off Differential temperatures the boiler will respond to these as high limit switches From the main Installer Setup Menu select Define Load with desired then locate and enter External Control Next configure the load with the ...

Page 47: ...ed tube baseboards typically driven at 180 F try 160 F max instead to promote combustion efficiency For air handlers try running 20 F lower than typically used Of course the appropriate setting will depend on the characteristics of the emitter and the building but in general the SL modulating boiler s large throttle turndown will allow better average temp control permitting lower maximums 9 For Re...

Page 48: ...tion site use the Altitude adjustment feature found in the front Installer Setup menu several lines below Heat Load Configuration Key in the altitude in hundreds of feet above sea level For example an installation at 2 860 feet should be entered as 29 as rounded to the nearest hundred 16 Two lines below Altitude adjustment is the field for amendment of the primary pump heat purge time To shorten t...

Page 49: ...3 1 STARTUP AND COMMISSIONING SL 20 115 MODULATING GAS BOILER STARTUP AND COMMISSIONING 3 0 3 1 LIGHTING AND SHUTTING DOWN THE BOILER ...

Page 50: ...o operate with natural gas or propane if so ordered at sea level The Zero offset valve adjustment cap has been factory sealed using red paint seal compound This cap must not be tampered with The Zero offset screw is not to be adjusted in the field The Gas Air ratio adjustment screw may have to be adjusted to attain optimum combustion results if required however no mixture adjustment shall be perfo...

Page 51: ...nfirm the minimum fire level settings Re define the load as Manual Control Use Heat Output in Configure Load x to control the output as needed Reading should be within Low fire range Re test at high fire 5 Turn boiler off by removing the call for heat use the Heat Load Configuration screen to turn load to off if no other ready means available then remove the manometer connections and turn the cent...

Page 52: ...and heat exchanger 12 Carefully remove the refractory and place in a clean dry area 13 If burner needs to be removed gradually loosen up the 4 screws that secure the burner to the heat exchanger lid using a 2 Phillips screwdriver Remove screws and burner Re assembly 1 Inspect burner gasket Look for cracks deterioration or signs of gas bypass Replace if necessary 2 Place heat exchanger lid on a fla...

Page 53: ...ressed air Evaluate the magnitude of clearing required and establish a reasonable burner inspection schedule Some boiler locations may call for annual service others showing clean burners will only need attention every 2 5 years Consider adding air filtration if burner requires cleaning every year In alternate years visually inspect burner through sight glass Ensure flame is stable and without exc...

Page 54: ...amage or leaks and repair as needed Check for 12 15 psig in normal operation and look to ensure pressure does not run up toward 30 psig at high temperature If pressure rises sharply consider replacement of expansion tank Check also for noise at high fire which may signal water quality problems Check water piping for damage or leaks and repair as needed Water chemistry shall be of a quality general...

Page 55: ...of heat transfer fluid will be discharged from the piping system and the system pressure will drop This fluid must be replaced It is highly recommended that a system pressurization unit such as an Axiom Industries model MF200 be employed to refill and pressurize your system Capture the discharged fluid in a container and recycle it by returning it to the system feeder unit This is particularly imp...

Page 56: ...bottom Gas valve connection block Gas valve Gas supply line Ignition wire boot Fan housing Fan pressure sensing tube Fan pressure sensor Fan motor Ignition module Sight glass burner observation port Combustion air intake riser GEOGRAPHY COMPONENTS 4 2 Note Vent stack piping and air intake riser have been removed in some of these photos for clarity ...

Page 57: ...Vent temperature sensor bracket Inlet return water temperature sensor Ignition electrode flame sensor Removing vent stack test port plug Fan coupler block Water pressure sensor Water temperature high limit switch Control Module removal Combustion air intake riser Removing combustion air intake riser Removing vent stack ...

Page 58: ...ight out ensuring that no wires are caught Place the removed components in a clean dry area 12 If the fan is being replaced With a permanent marker or equivalent make an alignment mark between the fan and swirl plate adapter and remove the screws that attach the gas valve swirl plate assembly to the fan 4 2 2 Fan and gas valve re installation 1 If the gas valve has been removed reattach it to the ...

Page 59: ...is manual are a number of diagrams see Section 6 0 for use with troubleshooting including Electrical Wiring Diagrams Sequence of Operations Flowchart Boiler Component Layout Diagrams Preliminary Checks The first step in troubleshooting this system should be a review of the Controller s LCD screen There are a number of diagnostic features incorporated in the software that evaluate system integrity ...

Page 60: ... not apply voltage to the sensor damage may result For the return water temperature sensor locate the blue 2 wire leads coming from the strap on sensor on the return pipe Disconnect the Molex connector located approx 6 from the sensor Place multi meter probes into the sensor s female Molex connector socket Do not apply voltage TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE F C Ω F C Ω 0 18 85 362 1...

Page 61: ...rminal Fan will only operate at max speed if disconnected Black Signal from controller Fan will only operate at max speed if disconnected White Fan tach 2 pulses rev freq x 30 rpm Table 10 Fan Operation 5 2 3 Differential Air Pressure Sensor Go to the Advanced Diagnostics screen and with the fan off Fan Duty Cycle 0 look for a Fan Pressure reading of 102 5 Next check with fan in operation and look...

Page 62: ...erature should be out of bounds A simple means of checking whether a high limit switch is open is by measuring the AC voltage across the device If the reading is 24 VAC the switch is open If a 0VAC reading is shown it is closed NEVER connect an ohm meter or continuity checker across a live circuit 5 2 6 Ignition Module There are two approved ignition modules Fenwal grey and Capable Controls white ...

Page 63: ...re condensate trap is not blocked Go to Advanced Diagnostics and check differential air pressure sensor at rest and with fan on See Section 5 2 3 Check achieved fan power In Advanced Diagnostics during Pre purge Fan Pressure FP should move close to Required Pressure RP if FP only 120 150 vs RP of 190 300 then check for actual vent system blockage a disconnect intake within boiler case b open burne...

Page 64: ...heck the igniter probe flame sensor is electrically isolated from the vessel and its ceramic insulator is intact Replace ignition lead Replace spark module Hi Limit Error On boilers equipped with both Water high limit AND factory installed LWCO LCD Screen Message Error Water High Limit LWCO Water temperature exceeds hi limit or water level is low Boiler in hard lockout Will reset in 1 hour Consult...

Page 65: ...In Out Temp Exceed Check water flow Water temperature signal not within acceptable range Potential flow or sensor failure Consult service technician Current outlet temperature exceeds operating limit Check water flow Defective or disconnected temperature sensor Check wiring to temperature sensor and control module Check temperature sensor See Section 5 2 1 Miscellaneous LCD Screen Message Blank sc...

Page 66: ...ufacturer s instructions Check setting with ammeter Air in system or marginal water flow Bleed purge system as required Confirm adequate pump size and temp rise in HX Slow combustion air blower Check that CO2 level is within specification Dirty burner heat exchanger Check pressure drop Insufficient water flow due to improper piping Refer to recommended piping in Section 1 6 SYMPTOM DIAGNOSIS REMED...

Page 67: ...er voltmeter 5 3 4 Temperature Problems Symptom Diagnosis Remedy Insufficient heat Operating temperature too low increase temperature target See Section 2 7 Priority parameters or load configuration improperly set up Review load configuration parameters See Section 2 7 Unit undersized Refer to Load Calculation vs Boiler Output Air trapped within system Bleed system as required Improper system pipi...

Page 68: ...chanical connections Symptom Diagnosis Remedy Temperature exceeds thermostat setting Incorrect anticipator setting Check with Ammeter Thermostat not level Check level One or more zones do not heat properly Air trapped within zone s piping Vent system zone as required Insufficient radiation excessive heat loss Check actual length of pipe using radiation heat loss calculation Insufficient flow rate ...

Page 69: ...6 1 DIAGRAMS SL 20 115 MODULATING GAS BOILER 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS 6 3 SEQUENCE OF OPERATION ...

Page 70: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 2 SL 20 115 MODULATING GAS BOILER 6 1 PARTS DIAGRAMS Diagram 6 1 1 Boiler assembly parts SL 20 115 Modulating Boiler Parts assembly ...

Page 71: ...PLER 1 141 250 225 INLET COUPLER 1 145 180 005 PRESSURE RELIEF VALVE 3 4 NPT 30 p s i 1 155 250 196 OUTLET PIPE 1 160 250 204 INLET PIPE 1 161 250 023 SENSOR BUSHING 1 162 240 006 RETURN WATER PRESSURE SENSOR 1 170 250 191 INLET OUTLET FLANGE 2 175 250 179 HEAT EXCHANGER CLAMP 1 180 204 030 TEMPERATURE SWITCH 2 190 250 171 CABINET ACCESS COVER 1 200 500 016 DOOR ASSEMBLY 1 210 500 001 CONTROLLER A...

Page 72: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 SL 20 115 MODULATING GAS BOILER 6 2 WIRING DIAGRAMS Diagram 6 2 1 Pictorial wiring diagram ...

Page 73: ...6 5 DIAGRAMS SL 20 115 MODULATING GAS BOILER Diagram 6 2 2 Ladder wiring diagram ...

Page 74: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 6 SL 20 115 MODULATING GAS BOILER Diagram 6 2 3 Internal wiring diagram ...

Page 75: ...6 7 DIAGRAMS SL 20 115 MODULATING GAS BOILER 6 3 SEQUENCE OF OPERATION Diagram 6 3 Sequence of operation diagram ...

Page 76: ...nd piped Relief valve try lever test performed Condensate trap filled Condensate drain clear and free flowing Condensate Neutralization Yes No Ignition Safety Shutoff test completed Flame current reading High fire _______ µA Low fire _______ µA Standby readings from IBC display screen remove all heat calls Outdoor Temperature ________ Tank Temperature _______ Outlet Temperature _________ Inlet Pre...

Page 77: ...__________________________________ Load Definition Load 2 _______________________________________________________________________ Load Configuration Load 2 _____________________________________________________________________________________________ Load Definition Load 3 _______________________________________________________________________ Load Configuration Load 3 _____________________________...

Page 78: ...NOTES ...

Page 79: ...ame function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped...

Page 80: ...IBC Technologies Inc 1445 Charles Street Vancouver BC Canada V5L 2S7 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 116E A R2 September 2012 ...

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