IBC SFC-99 Installation And Operating Instructions Manual Download

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INSTALLATION AND OPERATION INSTRUCTIONS

5-2

SFC COMBI BOILERS SFC-99, SFC-125

5.2 ELECTRONIC COMPONENTS

This section details the method for troubleshooting the non-standard electronic

components on the unit, including the electronic water pressure sensor-type

LWCO and the temperature sensors.

5.2.1 Temperature Sensors

The resistance of the temperature sensors varies inversely with temperature. To

test, measure the temperature of the sensed environment and compare with the

value derived from the measurement of the resistance (obtained by connecting a

good quality test meter capable of measuring up to 5,000 KΩ (5,000,000Ω) at the

controller end of the sensor lead).
To obtain a resistance reading, remove power to the unit. For the supply water

and return water temperature sensors, remove the wire leads by disconnecting

their respective Molex connectors. Place multi-meter probes into the sensor’s

male Molex connector socket. Do not apply voltage to the sensor as damage

may result.

12KΩ temperature sensors are supplied with the unit. See Table 15 for resistance

values.

SENSOR

TYPE

PURPOSE

LOCATION

NTC 12KΩ

Heat Exchanger

Temperature

Upper Left of Heat

Exchanger

NTC 12KΩ

Heating Supply

Temperature

Heating Supply Pipe

NTC 12KΩ

Domestic Hot Water

DHW Supply Pipe

NTC 10KΩ

Hot Water Tank

External Water Heater

NTC 12KΩ

Outdoor Sensor

Outdoors (North side)

NTC 12KΩ

Flue Gas Temperature

Top of rear Flue passage

Water Pressure

Heating Supply Pipe

Table 14: Temperature and Pressure Sensors

Figure 48: Water temperature

sensor

TEMPERATURE RESISTANCE

F / C

Ω - ohm

F / C

Ω - ohm

F / C

Ω - ohm

5F / -15C

76,020

77F / 25C

12,000

149F / 65C

2,752

14F / -10C

58,880

86F / 30C

9,805

158F / 70C

2,337

23F / -5C

45,950

95F / 35C

8,055

167F / 75C

1,994

32F / 0C

36,130

104F / 40C

6,653

176F / 80C

1,707

41F / 5C

28,600

113F / 45C

5,522

185F / 85C

1,467

50F / 10C

22,800

122F / 50C

4,609

194F / 90C

1,266

59F / 15C

18,300

131F / 55C

3,863

203F / 95C

1,096

68F / 20C

14,770

140F / 60C

3,253

212F / 100C

952

Table 15: Temperature Sensor Resistance Values – 12KΩ sensors.

Figure 47: Heat exchanger

temperature sensor

Summary of Contents for SFC-99

Page 1: ...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...

Page 2: ...ure Relief valve NPT 30psi 1 x Outdoor Temperature Sensor IBC part P 732 1 x SFC Installation Operating Instructions 1 x SFC SFB Controller Manual 1 x Propane Conversion Kit P 804 SFC 99 or P 806 SFC...

Page 3: ...ating Coil psig 43 5 Max Operating Pressure Domestic Hot Water Coil psig 150 Minimum water pressure psig 8 Approved installation altitude ASL 10 000 ft Ambient Temperature Low F C 32 0 Ambient Tempera...

Page 4: ...SI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 as applicable Failure to correctly install and operate this appliance can result in severe personal injury or death Th...

Page 5: ...18 1 5 4 Further Installation Details 1 18 1 6 Water Piping SPACE HEATING 1 20 1 6 1 General Piping Considerations 1 20 1 6 2 Basic Heating Piping Arrangements 1 24 1 7 Domestic Hot Water System 1 29...

Page 6: ...5 Burner 4 1 4 1 6 Heat Exchanger 4 2 4 1 7 Pump 4 2 4 1 8 Gas Piping 4 2 4 1 9 Control Module 4 2 4 1 10 Water Heating System 4 2 4 1 11 Freeze Protection 4 2 4 1 12 System Treatment 4 3 4 1 13 Reli...

Page 7: ...ating does not reach the correct temperature 5 8 5 4 3 Central heating system remains too warm 5 9 5 4 4 No domestic hot water DHW 5 9 5 4 5 Domestic hot tap water does not reach the correct temperatu...

Page 8: ...including those of neighbouring properties Place the exhaust outlet so it to reaches 12 minimum above the down turned intake Avoid exhaust re ingestion For sidewall venting options Both the inlet and...

Page 9: ...s usage of 4000 m3 for natural gas or 1500 m3 for propane The units are approved as Category IV vented appliances using Direct Vent sealed combustion Figures 1a and 1b show outer case dimensions and p...

Page 10: ...haust Outlet 3 Schedule 40 B Combustion Air 3 Schedule 40 C Cold Domestic Water Connection 1 2 Male NPT D Hot Domestic Water Connection 1 2 Male NPT E Heating Water Inlet Return 3 4 Male NPT F Heating...

Page 11: ...o avoid airborne chlorides such as those released with the use of laundry detergents Avoid installing the unit where water leakage may damage the area for example above carpeting If a location such as...

Page 12: ...two lower screws washers and anchors are field supplied 1 3 1 Mobile Home Installations Units installed in a mobile or manufactured home must conform to the local building codes WARNINGS Exposed water...

Page 13: ...Gas and Propane Installation Code CAN CSA B149 1 or applicable provisions of the local building codes IMPORTANT When an existing unit is removed from a common venting system the common venting system...

Page 14: ...s and any other gas burning appliance to their previous conditions of use Correct any improper operation of the common venting system to ensure that the installation conforms to the National Fuel Gas...

Page 15: ...option that enables units to be vented up to 120 equivalent feet from the vent termination using 3 The actual vent travel allowance is reduced for fittings in accordance with Table 3 Example For the m...

Page 16: ...bird screen of 1 4 stainless steel or plastic mesh e g IPEX System 636 drain grate for CPVC systems to guard against foreign objects Figure 4 Secure joints using appropriate solvent cement to bond the...

Page 17: ...and hold in place with a short nipple to allow easy access for cleaning For roof top venting of multiple unit sets group all intake terminals together for a common penetration through a custom cap Al...

Page 18: ...p Concentric Termination kits are approved for use with this unit For vertical roof top concentric terminations you must follow the installation instructions supplied with the venting material manufac...

Page 19: ...nation piping configuration Figure 9 Top view minimum distance of exhaust vent to inside and outside corners DIRECT VENT SIDE WALL TERMINATION KITS The Side Wall Termination kits approved for use with...

Page 20: ...ile termination kit Ipex 196985 3 PVC low profile termination kit Figure 10 Non Concentric kits Ipex 196984 2 PVC and 196985 3 PVC Figure 11a Horizontal Concentric Termination Two Kits Figure 11b Hori...

Page 21: ...Side Wall Termination kits On the same horizontal line not stacked With a minimum vertical separation of 12 center to center Use caution when installing Concentric Side Wall Termination kits when the...

Page 22: ...combustion air inlet to any other appliance 6 in 15 cm for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW...

Page 23: ...e 8 2 8 3 or 8 4 of Natural Gas and Propane Installation Code CAN CSA B149 1 or applicable provisions of the local building codes Figure 16 Direct vent combustion air intake V V V V V V V V V X X F C...

Page 24: ...e Schedule 40 PVC CPVC ABS or PPs piping of any type Use the same diameter as vent piping Insert combustion air piping directly into the 3 female plastic fitting on the top of the unit and run it hori...

Page 25: ...ondensate Trap The condensate trap cup must be installed on the drain connection at the base of the unit 1 5 2 Installing the Condensate Trap 1 Fill the condensate trap cup with water 2 Place the cond...

Page 26: ...and refill with water Inspect the trap and clean the interior portion of the trap attached to the unit 4 Re install the condensate trap cup and twist to the right 1 5 4 Further Installation Details Pi...

Page 27: ...corrosion you must use a neutralization package CAUTION When a condensate neutralization package is installed the pH of the condensate discharge must be measured on a regular schedule to ensure the ne...

Page 28: ...lti zone load applications Piping loads in parallel is only acceptable in systems where the minimum flow rate is guaranteed to be higher than the minimum for the unit and where the unit s pump is adeq...

Page 29: ...or closed loop hydronic systems When water quality is unknown or when chemical treatment or glycol is required you should consider other options Follow applicable Codes and good piping practice Other...

Page 30: ...ischarge 2 Allows complete drainage of both the valve and the discharge line 3 Is independently supported and securely anchored to avoid applied stress on the valve 4 Is as short and straight as possi...

Page 31: ...rs The installer designer must ensure that if the integral pump is used for the space heating emitters it is powerful enough for system distribution Avoid D where an external pump is placed in series...

Page 32: ...n the supply side of secondary loops to facilitate air evacuation Use pumps with internal check valves to avoid ghost flows and thermal siphoning The SFC series units are designed to be piped in a pri...

Page 33: ...types of automotive glycol antifreeze or undiluted antifreeze of any kind This may result in severe unit damage It is the responsibility of the Installer to ensure that glycol solutions are formulate...

Page 34: ...LERS SFC 99 SFC 125 Figure 27 Space heating piping concept with closely spaced tees on secondary loop Figure 26 Typical one temperature space heating piping concept with direct domestic hot water conc...

Page 35: ...rature space heating piping concept with domestic hot water concept drawing This drawing is only a simple schematic guide Figure 29 Air handler and direct domestic hot water parallel piping for low lo...

Page 36: ...LLATION AND OPERATION INSTRUCTIONS 1 28 SFC COMBI BOILERS SFC 99 SFC 125 Figure 30 Air handler and direct domestic hot water primary secondary concept drawing This drawing is only a simple schematic g...

Page 37: ...anual before operating the relief valve The unit requires a pressure relief valve identified with the ASME V or HV symbol and set to relieve at or below 150psi of domestic water pressure and a minimum...

Page 38: ...Table 6 Domestic Water Quality Guidelines 1 7 2 Domestic Hot Water Piping The domestic water piping connections are located at the bottom of the unit see Figure 1b The connections are 1 2 male NPT thr...

Page 39: ...mestic water pressure required is 40PSI and recommended to be 50PSI or higher Generating domestic hot water with a water pressure lower than 40PSI reduces the amount of hot water generated and increas...

Page 40: ...emperature rise SFC 99 2 4 GPM SFC 125 3 2 GPM CAUTION The field supplied thermostatic mixing valve may be installed on the direct domestic hot water piping connections at the unit or at the outlet of...

Page 41: ...valve during any pressure testing of the gas supply piping system at test pressures equal to or greater than 1 2 psi 3 5 kPa Dissipate test pressure prior to reconnecting The gas valve is provided wi...

Page 42: ...supplied appliance plug in a separate fused circuit and on off switch within sight of the unit The unit is equipped with 3 x 1 2 electrical knock outs for control wiring located behind the power suppl...

Page 43: ...lex BX connector 10 Install the junction box cover Note If the junction box is installed AC power must be supplied to the SFC series boiler through the junction box Do not plug the unit in elsewhere N...

Page 44: ...ips on a low water condition the power supply to the unit is interrupted Figure 37 External Probe Type Low Water Cutoff Device 1 9 2 Power Quality and Electrical Protection In areas of unreliable powe...

Page 45: ...perate as a set point unit and operate at its design supply temperature If outdoor reset functionality and the summer shut down feature are desired connect the supplied Outdoor sensor to X13 terminals...

Page 46: ...0V X15 X15 Blower 300 0 mm 95 0 mm Notes Original wiring as supplied with the appliance must be replaced with type T wire or its equivalent The wiring for the 120V field connections to the appliance s...

Page 47: ...nit pump operates for 10 seconds every 24 hours to prevent it from seizing The pump is energized 24 hours after the last call for heat and every 24 hours after that until the next call for heat The SF...

Page 48: ...or F Radiator Heating Indicator G Wrench Service Reset H Return Arrow Enter Save I Numerical Display Service Display Table 9 Controller Indicators and Touch Pad 2 3 INSTALLER INTERFACE 2 3 1 Turning A...

Page 49: ...er Menu code 15 a Master Installer Menu code 20 RF Menu code 30 See separate publication SFC controller manual for details Adjusting the Space Heating Water Temperature To access the main menu 1 Touch...

Page 50: ...Plus or Minus buttons 2 To alter this value touch the Plus or Minus buttons 4 To Save the changes touch the Return button Exit without saving the changes touch the area above the NOTE The domestic ho...

Page 51: ...s heat exchanger will not maintain its domestic hot water temperature between demands for hot water Comfort Mode ON The water heater s heat exchanger is maintained at the DHW temperature ECO Comfort...

Page 52: ...operly sized pump must also be installed between the unit and the indirect tank 2 6 SPACE HEATING 2 6 1 Overview The SFC series unit is designed to be installed in a primary secondary type piping syst...

Page 53: ...s still a call for heat or hot water the burner will turn off integral pump runs unless call is on demand DHW Service Display 1 6 After the call for heat is satisfied the unit s pump will operate for...

Page 54: ...INSTALLATION AND OPERATION INSTRUCTIONS 2 8 SFC COMBI BOILERS SFC 99 SFC 125 PAGE INTENTIONALLY LEFT EMPTY...

Page 55: ...3 1 STARTUP AND COMMISSIONING SFC COMBI BOILERS SFC 99 SFC 125 3 0 STARTUP COMMISSIONING 3 1 LIGHTING SHUTTING DOWN THE UNIT...

Page 56: ...rate with natural gas at sea level High Fire adjustment is required only if the calorific value of the fuel is out of the normally expected range NG range 950 1100 BTU Ft3 Consult your local fuel prov...

Page 57: ...s against Table 12 High Fire If the results are outside the permitted range check the inlet pressure and confirm that the correct orifice and venturi are installed For areas of lower calorific value n...

Page 58: ...ure must be carried out by a qualified technician 1 Ensure that the gas supply is turned off at the manual gas valve 2 Disconnect the electrical power 3 Disconnect the nut at the gas valve outlet top...

Page 59: ...ower switch to the unit 2 Turn off the gas supply valve to the unit There is no need to drain the unit unless the unit will be exposed to freezing conditions while off 3 Remove the front cover and all...

Page 60: ...f necessary inspect and clean the gasket mating surface 2 Place the heat exchanger cover onto the heat exchanger and loosely install the 6mm Allen bolts removed in step 6 Tighten the 6mm hex bolts in...

Page 61: ...the magnitude of clearing required and establish a reasonable burner inspection schedule Some installations may call for annual service others showing clean burners will only need attention every 2 y...

Page 62: ...t run up toward 30 psig at high temperature If pressure rises sharply consider replacement of the expansion tank Check also for noise at high fire that may signal water quality problems Water chemistr...

Page 63: ...ssurize your system Capture the discharged fluid in a container and recycle it by returning it to the system feeder unit This is particularly important when your system contains treatment chemicals or...

Page 64: ...items in a safe place for re installation 6 If the removed fan is to be re installed ensure the fan and venturi are clean and dust free 4 1 16 Fan and gas valve re assembly instructions 1 Place the f...

Page 65: ...eating 5 4 6 Indoor Temperature Does Not Reach Desired Temperature 5 4 7 No Hot Water DHW 5 4 8 Hot Water Does Not Reach Temperature Below each section is a list of symptoms diagnoses and solutions So...

Page 66: ...age to the sensor as damage may result 12K temperature sensors are supplied with the unit See Table 15 for resistance values SENSOR TYPE PURPOSE LOCATION S0 NTC 12K Heat Exchanger Temperature Upper Le...

Page 67: ...rate When the water pressure is less than 8psi the unit restricts its firing rate If the pressure is less than 4psi then the unit will not fire at all To test the operation of the pressure sensor type...

Page 68: ...rn off the cold and hot water valves below the unit release the water pressure and then drain the domestic hot water circuit Leave the drain valves open 5 2 7 Domestic Hot Water Sensor The SFC Series...

Page 69: ...TEMPERATURE RESISTANCE F C F C 0 18 85 362 100 38 5 828 5 15 72 918 105 41 5 210 10 12 62 465 110 43 4 665 15 9 53 658 115 46 4 184 20 7 42 218 120 49 3 760 25 4 39 913 125 52 3 383 30 1 34 558 130 5...

Page 70: ...w Check whether heating supply temperature sensor S1 is installed correctly Check for the correct operation of heating supply temperature sensor S1 Replace the heating supply temperature sensor S1 F00...

Page 71: ...ectly Mount the sensor correctly F016 Mounting fault S3 Domestic hot water sensor S3 is not mounted correctly Mount the sensor correctly F018 Flue and or air supply duct is blocked Check the flue and...

Page 72: ...es Check the wiring according to the schematic Check Connector X13 5 4 2 Central heating does not reach the correct temperature POSSIBLE CAUSES ANALYSIS POSSIBLE SOLUTION Water pressure in the system...

Page 73: ...5 gpm Yes No Increase the domestic hot water flow Domestic hot water sensor S3 is defective Yes No Replace the domestic hot water sensor S3 No electricity on the flow sensor 5V DC Yes Check the wiring...

Page 74: ...gnition distance is incorrect Yes No Replace the ignitor including the ignition cable Gas air control is not correctly adjusted Yes Check and or replace the ignition cable Replace the ignition unit in...

Page 75: ...6 1 DIAGRAMS SFC COMBI BOILERS SFC 99 SFC 125 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS...

Page 76: ...NS 6 2 SFC COMBI BOILERS SFC 99 SFC 125 6 1 PARTS DIAGRAMS Diagram 6 1 1 Unit assembly parts SFC Series modulating unit Parts assembly For information on the contents of P kits visit the Technical Inf...

Page 77: ...Gasket 150 312 Flue Pipe Outlet Gasket 150 313 90 Flue gas temperature sensor 180 205 P 814 NTC shaft 1 8 SW15 150 314 100 Ignitor and cable 240 115 P 815 110 Ignitor gasket 250 622A1 120 Burner 180 1...

Page 78: ...P 839 Alternative low calorific Natural Gas Orifice SFC 125 490 180 266 P 840 260 Supply pipe cold 180 240 P 826 DHW Flow sensor housing propeller 180 241 P 827 270 DHW Flow Sensor 240 122 P 849 280 D...

Page 79: ...1 X2 X2 X3 X3 X4 X4 X5 X5 X8 X8 X9 X9 X14 X14 Power Plug 120V X15 X15 Blower 300 0 mm 95 0 mm Notes Original wiring as supplied with the appliance must be replaced with type T wire or its equivalent T...

Page 80: ...3 of Installation and Operating Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner used ____________________________...

Page 81: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Page 82: ...me 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 unit s water temperature as the he...

Page 83: ...ences to maintaining the units R3 JUNE 2019 Updated drawings and made minor textual changes R4 NOVEMBER 2019 Concept drawings and tables on water quality R5 MARCH 2020 Updated table 5 figures 1b 2 36...

Page 84: ...5M8 Toll Free 1 844 432 8422 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 236 R6 84100406 August 2020 IBC Technologies Inc 2020 IBC Technologies USA Inc 1702 Taylors Lane Cinnaminson NJ 08...

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