IBC Technologies SL 30-175 Page 3 Installation And Operating Istructions Download

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INSTALLATION AND OPERATION INSTRUCTIONS

SL 30-175, SL 45-260 MODULATING GAS BOILERS

1.0 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Code reQuireMents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 loCation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 eXHaust Venting and air intaKe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 Condensate reMoVal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.6 Water PiPing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1.7 gas PiPing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1.8 eleCtriCal ConneCtions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

2.0 BOILER SYSTEMS AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

5.2 eleCtroniC CoMPonents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3 trouBlesHooting guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

6.0 DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Parts diagraMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Wiring diagraMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3 seQuenCe oF oPerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

CONTENTS

Summary of Contents for SL 30-175

Page 1: ...ombustible 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 buildi...

Page 2: ...Input Natural Gas or Propane kW CSA Output MBH CSA Output kW 30 175 8 8 51 3 29 161 8 4 47 2 45 260 13 2 76 2 43 2 239 12 7 70 0 AFUE 96 1 96 1 Minimum gas supply pressure Nat Gas or Propane inch w c...

Page 3: ...OL 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 SH...

Page 4: ...at a rooftop or sterile wall location Boiler condensate is corrosive Protective measures must be taken to prevent corrosion damage to metal roofs or other metal building components in contact with the...

Page 5: ...ealed combustion or indoor combustion air providing a great degree of installation flexibility Figure 1 shows outer case dimensions and piping and electrical holes Use this diagram to find a suitable...

Page 6: ...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...

Page 7: ...oiler 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...

Page 8: ...n while the other appliances remaining connected to the common venting system are not in operation Seal any unused opening in the common venting system Visually inspect the venting system for proper s...

Page 9: ...36 Standard for Type BH Gas Venting Systems or stainless steel Type BH venting systems Permitted PPs materials comprise Single Wall Rigid pipe and fittings and Flexible Ensure compliance with exhaust...

Page 10: ...to the same 200 equivalent length Flexible PPs both the SL 30 175 and SL 45 260 models are approved with up to 160 actual lineal feet of 4 Flex PPs in a nominally vertical orientation 45 The equivalen...

Page 11: ...otos and then block the vent outlet so that the vent run will be under maximum fan pressure Paint all joints with an approved leak test solution just as you would joints in a gas line and make sure th...

Page 12: ...nd 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 minimum above the down turned intake to avoid exhaust re...

Page 13: ...els 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 Fa...

Page 14: ...ed in a manner that will cause damage to external building finishes or components or infiltrate building envelopes including adjacent structures WARNING In areas of high snowfall Users must be advised...

Page 15: ...and debris Figure 12 Direct vent combustion air intake COMBUSTION AIR FROM OUTDOORS DIRECT VENT INSTALLATION CHECK AIR INTAKE OUTSIDE TO MAKE SURE IT IS CLEAR OF OBSTRUCTIONS FLUE GAS EXHAUST TO OUTD...

Page 16: ...stallation an optional air intake filter may be installed Important Note At the time of this printing a combustion air filter for the SL 45 260 model was not yet available Contact the Factory if your...

Page 17: ...t 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 O...

Page 18: ...boiler as described 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 m...

Page 19: ...ST BE PROTECTED BY ACID NEUTRALIZATION WARNING Risk of damage to appliance All condensate discharge lines must be at a lower elevation than the condensate water line of the appliance CONDENSATE WATER...

Page 20: ...r from any component in the system An additional benefit is that backflow prevention devices are not required when using these devices Figure 20 Boiler trim options Single boiler CAUTION Installers sh...

Page 21: ...ures are protected using means such as a mixing valve set for maximum limit say 140 F to protect radiant floors or an aquastat wired to the boiler s auxiliary interlocks A variety of application drawi...

Page 22: ...of water resulting in lower thermal performance at a given flow and pressure As a rule of thumb a 50 50 solution of propylene glycol and water will require an increased system circulation rate gpm up...

Page 23: ...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...

Page 24: ...people who are familiar with the applicable local and national codes System design is to be completed by an experienced hydronic designer or Engineer It is necessary to carefully read and follow these...

Page 25: ...175 SL 45 260 BOILER IBC IBC SL 30 175 SL 45 260 BOILER IBC IBC SL 30 175 SL 45 260 BOILER IBC IBC SL 30 175 SL 45 260 BOILER IBC NOTE For further information and details regarding Multiple Boiler ap...

Page 26: ...es The boiler must be disconnected or otherwise isolated from the gas supply during any pressure testing of the system at test pressures in excess of 1 2 psig Dissipate test pressure prior to reconnec...

Page 27: ...actory wired to the controller and its 120 VAC supply and is accessible in the field wiring box below the controller do not attempt to connect the primary pump to the Pump Zone Valve Terminal Block al...

Page 28: ...upplied 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...

Page 29: ...S DHW S Boiler Net Ext Cont White Green Black To From other IBC Boilers must be twisted pair wire Input from external controls by others 4 20 mA or 0 10VDC only NOTE All sensors are optional based on...

Page 30: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 26 SL 30 175 SL 45 260 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 31: ...4 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...

Page 32: ...ee load operation Legend RFl Radiant Floor 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 accessibl...

Page 33: ...s boiler 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 operatin...

Page 34: ...ure 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...

Page 35: ...ng cycle begins 2 5 4 Heating The heating cycle lasts until the Heating Enabled state ends or until water temperature exceeds the target temperature by of the supply differential for the last served l...

Page 36: ...ied 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 Er...

Page 37: ...is saves energy without sacrificing comfort When applied within a condensing boiler outdoor reset offers direct and significant combustion efficiency benefits by allowing generally lower circulating w...

Page 38: ...ed at the installation site 2 the Design Supply Temperature the desired boiler operating level to occur at that coldest day and 3 the Design Indoor Temp this is the value that anchors the reset curve...

Page 39: ...Heat Load Configuration then Configure Load use the load number tagged as Space Heating and drop down to Summer Shutdown Press Enter to select then use the keys to move the threshold temperature to t...

Page 40: ...e left hand key to move back to the Setup Heating Loads screen then move down to Configure Load 1 and hit enter 7 The screen will display the input fields appropriate to the nature of the load selecte...

Page 41: ...cycle off its software water high limit 12 Priority where more than one load is present it is critical that a value be entered to allow reasonable load scheduling see Section 2 6 1 13 At the lower en...

Page 42: ...piping structure and system wiring are configured appropriately refer to Section 1 6 2 Installation Rules page 1 20 for piping layouts and the Wiring Schematics on pages 6 4 and 6 5 Ensure that DHW a...

Page 43: ...ian Force or attempt ed repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified ser vice technician to inspect the appliance...

Page 44: ...g boilers are factory calibrated to 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 m...

Page 45: ...essure test port clockwise until fully closed Ensure fully closed but not over tightened Restore gas and soap test for leaks Model High fire low fire co max PPM Co2 range Co2 target Co2 range Co2 targ...

Page 46: ...screws 5 Separate and lift the gas valve up and away from the venturi assembly 6 If converting a Natural Gas boiler to Propane remove the brass Propane orifice from its packaging and seat the orifice...

Page 47: ...03 SCREWS EQUIPPED WITH GAS VALVE 3 180 043 or 180 045 VENTURI 1 Figure 33 Gas Valve dissassembly to install or remove propane orifice Remove three venturi mounting screws Separate gas valve from vent...

Page 48: ...to be removed gradually loosen up the 5 screws that secure the burner to the heat exchanger lid using a 2 Phillips screwdriver Re assembly 1 Inspect burner gasket Look for cracks deterioration or sig...

Page 49: ...compressed 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 on...

Page 50: ...run up toward 30 psig at high temperature If pressure rises sharply consider replacement or draining of expansion tank Check also for noise at high fire which may signal water quality problems Check w...

Page 51: ...ust 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 co...

Page 52: ...to loosen Cover tilts back then lift up and off Clear access to front components Clear access to top components Lift top cover up at front Top cover lifts up and out Gas Inlet Block air intake snorkle...

Page 53: ...tion chamber Lid Bolts 8 bolts Fan Flange Bolts Removal of vent stack to facilitate service of components located behind it Air intake snorkel inlet from cabinet behind the vent stack Air intake stack...

Page 54: ...etween the Venturi and Adaptor Plate this will be reused if undamaged 11 Remove the 3 Torx self tapping screws connecting the adaptor plate to the fan and carefully remove the adaptor plate and gasket...

Page 55: ...erature Problems 5 3 5 Miscellaneous Below each section is a list of Symptoms Diagnoses and Remedies Also provided with this manual are a number of diagrams see Section 6 0 for use with troubleshootin...

Page 56: ...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 a...

Page 57: ...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...

Page 58: ...e 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...

Page 59: ...the red lamp inside the LWCO Module is illuminated 3 Cycle the power to the boiler off and back on A red lamp will be illuminated when the LWCO confirms presence of water If the red light does not com...

Page 60: ...ion or repeated power interruptions Ensure 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...

Page 61: ...c voltage between blue and brown wires during an ignition cycle Replace module if no current detected Boiler ignites but shuts off at the end of the ignition trial Improperly grounded pressure vessel...

Page 62: ...locked b Check LCD screen for correct water pressure c Open water feed point boiler fill valve or boiler pressurization unit to make sure system is filled to operating pressure If the boiler loop is f...

Page 63: ...zer Check for proper piping Check pressure with manometer during ignition Boiler will not attempt to ignite Fan and pump are operating normally No power to ignition control module Check system wiring...

Page 64: ...mmeter 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...

Page 65: ...l Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain Unit cycling on operating safety controls Check operation with Ohmmeter V...

Page 66: ...BOILERS 5 3 5 Miscellaneous SYMPTOM DIAGNOSIS REMEDY Fumes and High Humidity Improperly installed condensate trap Refer to installation operation instructions Leak in vent piping Inspect using soap s...

Page 67: ...6 1 DIAGRAMS SL 30 175 SL 45 260 MODULATING GAS BOILERS 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS 6 3 SEQUENCE OF OPERATION...

Page 68: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 2 SL 30 175 SL 45 260 MODULATING GAS BOILERS 6 1 PARTS DIAGRAMS Diagram 6 1 1 Boiler assembly parts SL 30 175 SL 45 260 Modulating Boilers Parts assembly...

Page 69: ...6 3 DIAGRAMS SL 30 175 SL 45 260 MODULATING GAS BOILERS Diagram 6 1 2 Boiler assembly parts list refer to Diagram 6 1 1 on opposite page...

Page 70: ...te CB 2 CB 3 CB 4 P V Power L P V Power N P V3 N P V3 L P V1 N P V1 L P V2 N P V2 L CB Auxiliary Interlock L W C O Air Proving etc Jumper if not used Indoor Sensor Secondary Loop Sensor Domestic Hot W...

Page 71: ...15 O16 O17 O18 O19 O20 O21 O22 CB Input to Processor Input to Processor Call for Heat Jumper or connect to dry contacts of external control Outdoor Sensor Auxiliary Interlock L W C O Air Proving etc J...

Page 72: ...lack green black 80 089A T white white 2 x plug Outlet Water Temperature Sensor black blue blue white white black 2 3 4 5 6 10 SPARK RESISTIVE WIRE ONLY 24V GND VALVE VALVE GND GND BURNER P 101 7 3 4...

Page 73: ...6 7 DIAGRAMS SL 30 175 SL 45 260 MODULATING GAS BOILERS 6 3 SEQUENCE OF OPERATION Diagram 6 3 Sequence of operation diagram...

Page 74: ...ed and 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 Standby readin...

Page 75: ..._________________________________ Load Definition Load 2 _______________________________________________________________________ Load Configuration Load 2 _____________________________________________...

Page 76: ...NOTES...

Page 77: ...ergy 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 b...

Page 78: ...IBC Technologies Inc 1445 Charles Street Vancouver BC Canada V5L 2S7 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 156A R2 September 2012...

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