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IBC SL 10-85 G3, Installation & Operating Manual

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IBC SL 10-85 G3 Installation & Operating Manual Download Page 41

3.9 Installing the condensate trap

IBC’s specified vent configuration promotes the safe drainage of moisture from the boiler and
exhaust venting without flowing liquids back through the heat exchanger (as done by some other
condensing boilers).

Warning

Fill the trap with water before initially firing the boiler to prevent exhaust fumes from
entering the room. Never operate the boiler unless the trap is filled with water. Failure to
comply will result in severe personal injury or death.

Ensure the supplied trap is
correctly installed and filled with
water.

When required, add (and maintain
in good condition) a neutralization
tank. For installation information,
see

Installation on page 15

.

The condensate trap must be
installed on the drain connection at
the base of the boiler. The
condensate drain must be piped to
within 1 inch of a drain or
connected to a condensate pump.
The drainage line must slope
down to the drain at a pitch of ¼
inch per foot so condensate runs
towards the drain.

37

3.9 Installing the condensate trap

Summary of Contents for SL 10-85 G3

Page 1: ... other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance 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 Insta...

Page 2: ... the total water volume in the system A high water volume system with a low hardness count may cause as much damage as a system with less volume and higher hardness so it is recommended to treat water so as to remove all dissolved solids Other water chemistry allowable limits are as follows Acidity pH is to be between 6 6 and 8 5 Chloride is to be less than 125 mg l Iron is to be less than 0 3 mg ...

Page 3: ...omply with all instructions and applicable national and local codes may result in hazardous conditions that could result in property damage and injury to occupants and in extreme cases to death Keep instructions near the air handling appliance for future reference Danger Should overheating occur or the gas supply fails to shut off do not turn off or disconnect the electrical supply to the pump Ins...

Page 4: ...se contained in component manufacturers manuals before installing starting up operating maintaining or servicing the appliance Warning Disconnect power supply before any wiring service is performed Failure to do so could result in damage to appliance and or electric shock Caution The boiler must be installed so that electrical components are not exposed to water during operation Known Corrosive Co...

Page 5: ...ng an existing boiler 15 3 3 Determining location of the appliance 16 Best installation conditions 17 3 4 Mounting the boiler 17 3 5 Connecting the vent and air intake pipes 18 3 6 Installation clearances 19 3 7 Exhaust venting and air intake 20 3 7 1 Venting code 20 3 7 2 Venting options 21 3 7 3 Exhaust vent material 21 3 7 4 Direct vent 22 3 7 5 Rooftop vent termination 26 3 7 6 Sidewall vent t...

Page 6: ...s 65 Checklist for electrical conditions ducting and water connections 65 6 0 Boiler operation 67 6 1 Lighting and shutting down the boiler 67 6 2 Testing the ignition safety shutoff 68 6 3 Commissioning 68 6 3 1 Checking a boiler s fuel source 69 6 3 2 Performing a fuel conversion 69 6 3 3 Adjusting the gas valve 70 7 0 Service and maintenance 75 7 1 Maintenance checklist for homeowner 75 7 2 Mai...

Page 7: ...2 8 2 1 Maximum ignition trials error 93 8 2 2 Hi Limit cut off temperature error 94 8 2 3 Low Water Cut off error 94 8 2 4 Aux Interlock 1 or 2 94 8 3 Miscellaneous touchscreen controller errors 95 8 3 1 Ignition issues 96 8 3 2 Temperature issues 97 8 3 3 Miscellaneous issues 98 8 3 4 Cycling issues 99 Appendices 101 Wiring diagrams 101 V 10 Controller electrical diagram 101 Internal wiring diag...

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Page 9: ...00 Weight empty lbs Kg 85 39 85 39 102 46 3 152 69 Pressure vessel water content USG Litres 2 47 9 35 2 47 9 35 1 72 6 51 5 09 19 3 Maximum boiler flow rate USgpm 14 14 19 22 Minimum boiler flow rate USgpm 2 2 4 6 Maximum operating water pressure psig 30 30 30 30 Minimum water pressure psig 8 8 8 8 Approved installation altitude ASL 0 12 000 0 12 000 0 12 000 0 12 000 Ambient temperature Low F C H...

Page 10: ...nt vent length each side vent air intake Natural gas or propane Air intake options either direct vent or indoor supply 100 2 240 3 100 2 240 3 35 2 170 3 Not applicable 150 3 Boilers are shipped with a 30 psig pressure relief valve Cabinet dimensions SL 10 85 G3 SL 14 115 G3 Figure 1 Front and side view SL 10 85 G3 SL 14 115 G3 6 Section Specifications ...

Page 11: ...Figure 2 Top view SL 10 85 G3 SL 14 115 G3 Figure 3 Bottom view SL 10 85 G3 SL 14 115 G3 SL 20 160 G3 Figure 4 Front and side view SL 20 160 G3 7 SL 20 160 G3 ...

Page 12: ...Figure 5 Top view SL 20 160 G3 Figure 6 Bottom view SL 20 160 G3 SL 30 199 G3 Figure 7 Front and side view SL 30 199 G3 8 Section Specifications ...

Page 13: ...fications SL 10 85 G3 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 A Flue Outlet 3 Schedule 40 or 3 PPs 80mm B Combustion Air 3 Schedule 40 or 3 PPs 80mm C LCD Display 2 x 4 D Water Outlet 1 NPT M 1 NPT M 1 NPT M E Water Inlet 1 NPT M 1 NPT M 1 NPT M F Knock outs 8 G Gas Inlet NPT F H Condensate Outlet Hose Table 1 Connections 9 Connection specifications ...

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Page 15: ...w from the front SL G3 residential boilers 1 1 Standard features and benefits High thermal efficiency Turn down ratio 10 to 1 Control of up to 5 pumps 1 boiler pump and 4 separate load pumps Outdoor reset control Load combining simultaneous operation of two similar water temperature loads Load zoning simultaneous operation of up to four loads with the same control settings Ability to manage and or...

Page 16: ...0 coverage 11 years 25 coverage IBC offers a limited heat exchanger warranty with no registration of 0 5 years 100 coverage For non residential applications IBC offers a 5 year warranty on all parts against defects in materials or workmanship and failures due to thermal shock In addition IBC offers a heat exchanger limited 10 year warranty with registration according to the following terms 0 5 yea...

Page 17: ...ult in damage to the area If there is no suitable location install a suitable drain pan under the boiler Do not install above carpeting At a new construction site or during renovations protect the appliance from drywall dust or other construction related contaminants Draw combustion air from a clean source e g outdoors and isolate the boiler from interior dust sources Do not seal boiler case openi...

Page 18: ...team plume normally at the exhaust terminal of a condensing boiler Generally intake and exhaust pipes should terminate 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 condensate Keep exhaust plumes well away from all building air intakes including...

Page 19: ...ilers ANSI ASME CSD 1 If there is any conflict follow the more stringent regulations Table 2 Code requirements by country 3 2 Removing an existing boiler When an existing boiler is removed from a common venting system the common venting system may be too large for proper venting of the appliances that remain connected to it When resizing any portion of the common venting system use the minimum siz...

Page 20: ...designed and approved for indoor installation wall or rack mounting in areas such as an alcove basement or utility room These areas should have a surrounding temperature of 32 F 0 C to 122 F 50 C and less than 90 relative humidity Danger Do not common vent appliances with other existing appliances or with a new appliance Warnings Keep the area around a boiler clear of combustible materials gasolin...

Page 21: ...omer satisfaction Keep exhaust plumes well away from all building air intakes including those of neighboring properties Refer to Table 5 and Figure 19 in Sidewall vent termination on page 29 The minimum clearance requirements for combustible materials see Table 3 For adequate servicing we recommend a minimum 24 clearance at the front and 6 above the boiler Check local codes for additional access a...

Page 22: ...cket flange 4 Secure the lower part of the boiler to the wall with two field supplied bolts 3 5 Connecting the vent and air intake pipes These appliances offer 3 connections that accept standard 3 PVC CPVC pipe 3 5 OD and 3 nominal PPs 80 mm pipe Use standard vent pipe fittings to adapt to smaller diameter pipe if appropriate Venting must be supported in accordance with the applicable code and ins...

Page 23: ...otection Figure 11 Securing a pipe connection Warning Ensure that you lubricate the gasket with silicone grease before inserting the venting material Fully insert the approved venting material into the boiler s exhaust outlet and tighten clamp to ensure the venting connection is locked in place as shown above Warning Do not mix venting materials from different manufacturers These venting materials...

Page 24: ...g Venting condensate drainage and combustion air systems for all IBC boilers must be installed in compliance with all applicable codes and with instructions provided in the respective installation manuals Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided as well as with the requirements of applicable codes Failure to comply will re...

Page 25: ...uilder or roofing contractor to ensure that materials are resistant to acidic condensate pH levels can be as low as 3 0 Covering non metallic vent pipe and fittings with thermal insulation is prohibited Exhaust vent material Canada Use PVC CPVC or Polypropylene PPs vent component systems approved under ULC S636 Standard for Type BH Gas Venting Systems or stainless steel Type BH venting systems1 UL...

Page 26: ...al general Use of cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenolsulfone in venting systems is prohibited Do not use ABS or any cellular core pipe for exhaust venting 3 7 4 Direct vent Direct vent is a two pipe system that draws combustion air air intake from outdoors and discharges exhaust gases to the outdoors Ensure that adequate separation is maintained between the air intak...

Page 27: ... e g outdoors and the boiler should be isolated from interior dust sources Do not seal boiler case openings directly when firing See list of known contaminants on the Important safety instructions on page 3 Warnings In addition to preventing ingestion of chemical contaminants ensure air intake terminals are not installed in locations where contamination might occur due to ingestion of particulate ...

Page 28: ...pping requirements Some local jurisdictions require a minimum initial length of pipe be exposed or accessible for inspection Pipe clearances no IBC requirements follow local codes All piping must be liquid and pressure tight Ensure all venting components are clear of burrs debris prior to assembly Clear plastic debris left in the combustion air piping to avoid intake into the fan Secure joints usi...

Page 29: ...ible pipe used for calculating total equivalent length are shown in the following table Vent Lengths Intake Exhaust Maximum Equivalent Length SL 10 85 G3 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 2 inch rigid pipe 100 ft 100 ft 35 ft n a 3 inch rigid pipe 240 ft 240 ft 170 ft 150 ft 90 elbow allow 8 ft for each elbow 90 long sweep elbow allow 5 ft for each elbow 45 elbow allow 3 ft for each elbow PPs...

Page 30: ...xhaust Unequal intake and exhaust piping is allowed Support should be provided for intake and vent piping particularly for horizontal runs follow local code Example of equivalent length calculations for an SL 14 115 G3 An SL 14 115 G3 can be sited up to 240 feet actual vent length allowance from the vent termination using 3 inch pipe For 6 x 90º elbows the maximum lineal straight length of pipe al...

Page 31: ...itting Leave unglued and hold in place with a short nipple This permits easy access for cleaning Do not exhaust vent into a common venting system b For rooftop direct vent systems Rooftop two pipe direct vent configurations including typical clearance requirements are shown below in the following images Figure 16 Rooftop vent terminal configurations Figure 17 Rooftop vent termination with sidewall...

Page 32: ...etration through a custom cap Alternatively place close together using commonly available pipe flashing Similarly group the exhaust pipes and place the two separate groups of pipes at least 3 feet apart the closest intake and exhaust pipes must be 36 inches or more apart Use the same 12 inch minimum vertical separation for all termination options For alternate group terminations contact the IBC fa...

Page 33: ...lding envelope details must be examined carefully Take action to avoid moisture entering building structures Serious structural damage may occur if adequate precautions and clearances are not considered These precautions apply to neighboring structures as well as to the structure the boiler s are installed in Vent terminal Air supply inlet Area where terminal is not permitted Figure 19 Minimum cle...

Page 34: ...nce to each side of center line extended above meter regulator assembly 3 ft 91 cm within a height 15 ft above the meter regulator assembly I Clearance to service regulator vent outlet Above a regulator within 3 ft 91 cm horizontally of the vertical center line of the regulator vent outlet to a maximum vertical distance of 15 ft 4 5 m 1In accordance with the current CAN CSA B149 Installation Codes...

Page 35: ...gure 21 Figure 22 and Figure 23 Failure to do so can result in a dangerous situation where exhaust gasses are re ingested with combustion air Damage to the boiler can result from a failure to maintain these separations Third party vent termination kits and concentric wall penetration kits that do not maintain these minimum separations must not be used Improper installation will void the warranty D...

Page 36: ... and off the sidewall for protection of wall A short piece of venting cut at 45 gives a horizontal termination protected from wind loads see Figure 20 Figure 21 and Figure 22 Recommend the use of a bird screen of stainless steel or plastic mesh IPEX System 636 drain grate to guard against foreign objects Caution Refer to local code requirements or restrictions when installing concentric side wall ...

Page 37: ...Figure 22 Sidewall vent termination configuration option 1 Figure 23 Sidewall vent termination configuration option 2 33 3 7 6 Sidewall vent termination ...

Page 38: ... minimum vent clearances listed in Table 5 Install the SST with the vent and intake pipes horizontally beside each other or vertically with the vent pipe on top see Figure 25 The vent pipe cannot be installed below the intake The vent cap must be installed with the openings directed up and down see Figure 25 and not side to side Figure 25 Allowed SST installation orientations The SST vent air conn...

Page 39: ...lly Figure 27 Minimum separation for multiple vent installation vertical orientation Figure 28 Minimum separations for multiple vent installation horizontal orientation Caution Take care installing Concentric Side Wall Termination kits when the outdoor temperature drops below 5 F 15 C Possible blockage of the combustion air intake can occur when the outdoor temperature drops below this temperature...

Page 40: ...utdoors Combustion air in check air intake outside to make sure it is clear of obstructions Air intake filter check and clean air filter regularly Figure 30 Direct vent intake exhaust system with optional air intake filter filtration may also be used on indoor air applications as required 3 8 Closet installations For installations in a confined space such as a closet ventilation openings may be ne...

Page 41: ... with water Failure to comply will result in severe personal injury or death Ensure the supplied trap is correctly installed and filled with water When required add and maintain in good condition a neutralization tank For installation information see Installation on page 15 The condensate trap must be installed on the drain connection at the base of the boiler The condensate drain must be piped to...

Page 42: ... wing nuts and put aside 3 Fill the condensate trap with water and ensure that the bottom union cap is hand tightened to prevent leakage 4 Loosen the upper union nut and slide the trap over the boiler drain outlet and then tighten the upper union nut 38 Section Installation ...

Page 43: ... secure with the wing nuts 6 The drain hose should run to a suitable drain or condensate neutralizer Figure 31 Condensate trap drainage Flue gas exhaust Condensate and rain water flow back from venting system Warning Risk of damage to appliance Ensure rainwater is prevented from entering air 39 3 9 Installing the condensate trap ...

Page 44: ...enting systems and pressure vessel must be maintained at all times Trap and condensate drain piping must be accessible to allow regular inspection and cleaning 3 10 Installing a condensate neutralizer If discharging condensate into building drain piping materials that are subject to corrosion use a neutralization package Caution After installing a condensate neutralization package the pH of the co...

Page 45: ...cidic Do not use hands to stir material Refer to the neutralization instructions of the manufacturer Access to the discharge before the drain is necessary for proper maintenance in order to check the effectiveness of the neutralizing agent A simple pH test should be performed annually to ensure neutralizing agent is still effective If the pH falls below 6 5 the neutralizing material should be repl...

Page 46: ...stem with a low hardness count may cause as much damage as a system with less volume and higher hardness so it is recommended to treat water so as to remove all dissolved solids Other water chemistry allowable limits are as follows Acidity pH is to be between 6 6 and 8 5 Chloride is to be less than 125 mg l Iron is to be less than 0 3 mg l Cu less than 0 1 mg l Conductivity is to be less than 400μ...

Page 47: ...To simplify the control application promote good loads and flow management installers must conform to the piping design configurations provided Propylene glycol usage Warning Do not use automotive type ethylene or other types of automotive glycol antifreeze or undiluted antifreeze of any kind This may result in severe boiler damage Installers must ensure that glycol solutions are formulated to inh...

Page 48: ...ng Note The piping drawings in this manual are simple schematic guides to a successful installation For further information and details consult our concept drawings which provide detail on specific single and multiple boiler applications available in IBC s Technical portal There are many necessary components not shown and details such as thermal traps are left out so the drawings have greater clar...

Page 49: ...ed by using a boiler regulator and fill valve set at 12 psig or more with the appropriate backflow prevention device as required by local code This is acceptable in areas where municipal water or well water has been treated and filtered to remove excessive minerals and sediment and water chemistry is known to be suitable for closed loop hydronic systems In areas where water quality is in question ...

Page 50: ... these devices Do not place any water connections above the boiler to avoid damage to the fan and controls If needed create a shield over the top of the cover but allow clearance for airflow and service access Heating supply and return Auto air vent or flushing valve Figure 34 Consideration for left side only piping Note that the supply pipe off the right hand side of the heat exchanger carries th...

Page 51: ...dependently supported and securely anchored so as to avoid applied stress on the valve Is as short and straight as possible Terminates freely to atmosphere where any discharge will be clearly visible and is at no risk of freezing terminates with a plain end which is not threaded Is constructed of a material suitable for exposure to temperatures of 375 F or greater Is over its entire length of a pi...

Page 52: ...es within the range 34 F to 180 F to meet three separately piped loads Use closely spaced tees to connect each pumped load e g DHW baseboards or radiant floor to the primary loop or employ the use of a hydraulic separator to isolate the boiler loop from the system and pipe the system from the secondary side of the separator Twoload systems may be piped with a variant of parallel piping commonly us...

Page 53: ...e as close together as possible maximum four pipe diameters apart and there should be no restrictions between the fittings that would result in a pressure drop Heat Migration On secondary loops that extend vertically to a load that is above the primary loop use check valves on both supply and return of secondary piping Check valves or zone valves on return Figure 36 Primary secondary piping detail...

Page 54: ...nitor the performance of system components when using the sequential load feature of the boiler to ensure that the components are compatible For instance many air handlers have a thermostat connection that will energize an internal relay to operate the air handler circulator and its fan on a call for heat This may result in the air handler components operating when other loads are operating at a h...

Page 55: ...Optional Figure 38 Typical one temperature space heating piping concept Optional Thermostatic mixing valve Figure 39 Typical two temperature space heating piping concept 51 3 11 2 System piping ...

Page 56: ...tic tempering valve may be required by local code Indirect hot water tank Figure 40 Indirect domestic hot water piping concept Optional Thermostatic mixing valve Figure 41 Two sided piping DHW and space heating piping concept 52 Section Installation ...

Page 57: ...r piping concept 3 11 2 2 Parallel load piping Compared with the primary secondary approach the design below saves one pump Lost is the simplicity of constant head and flow at the boiler Air handler Figure 43 One pump parallel piping concept 53 3 11 2 System piping ...

Page 58: ... Multiple IBC boilers can be installed in a single heating system to provide redundancy increased output and greater heating plant turn down capabilities Primary secondary piping must be employed and each boiler must be installed with its own pump as illustrated below This approach provides constant head and flow at each boiler regardless of flow variations in the main building loop 54 Section Ins...

Page 59: ...r 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 used in each boiler s piping to prevent reverse flow when the boiler is off Secondary loop sensor to Master boiler To building Closely spaced tees From building Check valve Figure 45 Multiple boiler piping c...

Page 60: ...re should be monitored before firing the boiler during operation throughout the boiler s full modulation range and after the call when the regulator is in a lock up condition Pay special attention to retrofit situations where existing regulators may have an over sized orifice and or worn seats causing pressure creep and high lock up pressures A high quality regulator will maintain constant pressur...

Page 61: ...00 ft 600 ft SL 30 199 G3 Natural Gas 10 ft 40 ft 150 ft 600 ft SL 30 199 G3 Propane 30 ft 125 ft 400 ft 1 600 ft Table 9 Maximum Gas Pipe Length ft Gas piping must have a sediment trap ahead of the boiler s gas valve A manual shutoff valve must be located outside the boiler in accordance with local codes or standards All threaded joints in gas piping should be made with an approved piping compoun...

Page 62: ...uld be installed in power supply wiring circuits 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 In temporar...

Page 63: ...d pumps the top pair for Load 1 the second pair for 2 etc Once the controller is programmed for the respective loads the boiler manages all the loads without need of further relays for loads up to 1 3 HP for more use a protective relay 3 13 2 2 Boiler pump The boiler pump primary pump is powered by the white yellow wire from the pair labeled Boiler Pump Primary Pump This lead is factory wired to t...

Page 64: ...m 1 2 3 4 location and the boiler automatically detects and calls 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 IBC modulating appliances for autonomous staging The bottom pair of contacts labeled External Control receives a 0 10VDC default or 4 20 mA signal from an extern...

Page 65: ...diant floor zone present a common thermostat signal to the controller Ensure that there are no disturbing influences on the call for heat lines for example that there are no coils to switch an air handler motor Most power stealing thermostats can be connected directly to the Therm terminals Consult the Controller manual for more detailed instructions 3 13 6 Thermostat heat anticipator IBC Therm co...

Page 66: ...Figure 49 Electric wiring connections 62 Section Installation ...

Page 67: ...simultaneous operation of two similar water temperature loads Programmable setback override schedule The control can manage or operate in a network of up to 4 IBC boilers without additional controller Some of the new features available in the touchscreen control include Setup Menu for simple quick programming Portal connectivity for remote monitoring and programming Superior warning messages while...

Page 68: ...ls Do not use a sharp or metallic object such as a screw driver to operate the control as it could damage the touchscreen Prior to any interaction with the touchscreen the display shows the Home screen details of the current boiler status If the controller has been left on the Home screen long enough user adjustable 10 minutes by default the display dims to save power The control automatically ret...

Page 69: ...fore operating the appliance it is important to review the following checklist of precautions Checklist for electrical conditions ducting and water connections Checking electrical conditions Check Check all line voltage electrical connections to ensure all connections are correct and tight Check thermostat connections Thermostat in a suitable location Checking piping connections Check Ensure venti...

Page 70: ...mp is flowing in the correct direction Checking venting connections Check All connections are pressure tested and leak free All vent pipe is sized correctly and joints are sealed Powering on the boiler Check Perform a final check of electrical wiring and provide power to the boiler to initialize operation Warning Fill the condensate trap with water before you first fire the boiler to prevent exhau...

Page 71: ...rocess see Sequence of Operation on page 103 6 1 Lighting and shutting down the boiler Start up Checklist Check Followed lighting and shutting down procedure Tested the ignition safety shutoff function see Testing the ignition safety shutoff on page 68 Checked the appliance s fuel source and if necessary performed a fuel conversion using the appropriate P kit Performed gas pressure test by measuri...

Page 72: ...n shut off the gas control valve directly outside the boiler case 2 Ensure that the boiler has purged attempted to re light three times has shut off and the appropriate error information is displayed on the controller 3 The error is displayed after testing the ignition safety shutoff 4 To restart the boiler reset the power or on the touchscreen controller tap Status Clear Errors Yes 6 3 Commission...

Page 73: ...or natural gas but needs to be converted to propane use the conversion kit sold separately by IBC to install the appropriate fitting s and adjust the gas valve accordingly See Table 10 for the required conversion kit The touchscreen controller will automatically detect the installation s altitude and make the appropriate adjustments to operate the boiler up to 4 500 feet in elevation without de ra...

Page 74: ...e and O ring 7 Tighten the upper nut onto the gas valve 8 Place conversion labels associated with the new fuel onto the boiler 9 Turn on the gas supply and connect the electrical power 10 Check for gas leaks 11 Tune the gas valve see Adjusting the gas valve below 6 3 3 Adjusting the gas valve Danger Making adjustments to the IBC gas valve without a properly calibrated gas combustion analyzer and b...

Page 75: ...point or DHW This load should be large enough to allow the boiler to operate at high fire for over 10 minutes The gas pressure for natural gas should be around 7 w c at high fire and 11 w c for propane 6 After completing the inlet gas pressure test switch off the gas supply 7 Remove the manometer from the inlet gas pressure test port 8 Tighten the inlet gas pressure test port screw 9 Switch on the...

Page 76: ...Make tiny adjustments may require several turns Turning the High Fire screw clockwise will lean out the flame 7 Set the heat out value in Test Operation mode to the minimum MBH for the boiler To do this go to More Test Operation In the Fan Test Heat Out field tap 0 MBtu then enter the minimum MBH 8 Adjust the low fire according to values in Table 11 using the low fire adjustment screw Turn the scr...

Page 77: ... Low fire CO max PPM Range Target Range Target Natural Gas 9 0 10 0 9 5 8 2 9 2 8 7 150 Propane 10 3 11 3 10 8 9 3 10 3 9 8 250 Table 11 Combustion test target ranges CO2 Maximum CO Note Low Fire CO2 should be at least 0 5 lower than High Fire CO2 73 6 3 3 Adjusting the gas valve ...

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Page 79: ...er As needed Inspection of the boiler is to be performed annually by a qualified service technician Annually 7 2 Maintenance checklist for heating contractor Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Maintenance Required Check Remove any obstructions e g leaves dust other debris from vent terminals Check and clea...

Page 80: ...result in a hazardous condition 7 2 2 General boiler maintenance Boiler Component Maintenance Required Frequency Check Condensate trap Remove and clean annually see Cleaning the condensate trap on page 85 Ensure that the trap has been re filled completely before firing the boiler Annually If condensate neutralization is used check the pH level of condensate discharge Annually Burner Warning When r...

Page 81: ... Other fouling agents include airborne dust debris and volatiles With the burner removed examine the heat exchanger for signs of contamination and clean if necessary Annually Boiler Pump Check that the pump is on in normal operation and that the water Δ T is reasonable for a given firing rate Annually Gas Piping Check for damage or leaks and repair as needed Annually Boiler treatment Check consist...

Page 82: ...and non ferrous components as well as non metallic wet components normally found in hydronic systems Ethylene glycol is toxic and may be prohibited for use by codes applicable to your installation location For environmental and toxicity reasons IBC recommends only using non toxic propylene glycol Annually Water Caution Installers should inquire of local water purveyors as to the suitability of the...

Page 83: ...tain and safely dispose of equipment discharge The relief valve manufacturer requires that under normal operating conditions a try lever test must be performed every two months Under severe service conditions or if corrosion and or deposits are noticed within the valve body testing must be performed more often A try lever test must also be performed at the end of any non service period Annually Te...

Page 84: ...essurize your system we recommend using a system pressurization appliance such as an Axiom Industries model SF100 series Capture the discharged fluid in a container and recycle it by returning it to the system feeder appliance This is particularly important when your system contains treatment chemicals or glycol solutions If the system employs plain water the boiler auto fill valve must be turned ...

Page 85: ...nitor Fan coupler and gasket Screws nuts securing fan to fan coupler location of fan gasket Fan Upper nut orifice and O ring Lower nut behind bracket and gasket Gas valve electrical cable and screw Gas valve support bracket 81 7 3 Replacing the fan gas valve and burner ...

Page 86: ...and remove the orifice and O ring 7 To remove the gas valve unscrew the lower nut Ensure that the gasket remains inside the nut 8 Disconnect the electrical cable from the fan 9 Remove the screws or nuts securing the fan to the coupler 10 Remove the fan and fan gasket Installing the new fan 1 Install the new fan gasket and fan 2 Secure the fan to the coupler using the two screws 3 Reconnect the ele...

Page 87: ... gas valve electrical cable remove the screw 5 Unscrew the upper nut of the gas valve 6 Carefully push down on the gas valve and remove the orifice and O ring 7 Unscrew the lower nut of the gas valve and remove from the gas valve bracket Ensure that the gasket remains inside the nut Installing the new gas valve 1 Position the lower part of the new gas valve so that it is supported by the gas valve...

Page 88: ...pirators Certified under 42 CFR 84 for selection and use of respirators certified by NIOSH For the most current information NIOSH can be contacted at 1 800 356 4676 or on the web at www cdc gov niosh 2 Wear long sleeved loose fitting clothing gloves and eyes protection 3 Assure adequate ventilation 4 Wash with soap and water after contact 5 Wash potentially contaminated clothes separately from oth...

Page 89: ...he ignition cable and ground wire to the ignitor 4 Turn on the power and gas supply 5 Check for leaks 6 Tune the gas valve 7 4 Cleaning the condensate trap Warning If condensate neutralization is used check the pH level of condensate before and after neutralization to verify effectiveness and ensure that the discharge has neutral pH levels Never operate the boiler unless the trap is filled with wa...

Page 90: ...ts Note the orientation of the hose 2 Loosen the upper union nut and slide the condensate trap off the boiler drain outlet 3 Unscrew the condensate union cap at the base of the trap empty the water and flush the trap with water 4 Fill the condensate trap to the top with water and replace the union cap and gasket 86 Section Service and maintenance ...

Page 91: ...p over the boiler drain outlet and then tighten the upper union nut 7 To reinstall the trap pan tilt and slide the two tabs under the chassis of the boiler and secure with the two wing nuts 8 Ensure that the bottom union cap is hand tightened to prevent leakage Do not use tools and over torque 87 7 4 Cleaning the condensate trap ...

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Page 93: ...he 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 boile...

Page 94: ...80 82 1 172 85 29 8 250 185 85 1 073 90 35 7 334 190 88 983 95 35 6 532 195 91 903 Table 12 Temperature sensor resistance values 10K ohms 8 1 2 Fan The fan is controlled via the SIM control The SIM provides electronic commutating power to the fan motor coilers determining the fan speed and power usage 8 1 3 Water pressure sensor The water pressure sensor ensures that there is adequate pressure in ...

Page 95: ...n and current measurement Supply water temperature sensing Flue gas temperature sensing Supply water maximum temperature shutdown Flue gas maximum temperature shutdown Low water cut off The SIM continuously communicates with the boiler s main controller reporting sensor readings and status The sensor readings and error status if any are displayed on the boiler controller s screen 8 1 4 1 Table sho...

Page 96: ... Troubleshooting error messages Warning Never attempt to repair the control module circuit board If the control module is defective replace it immediately Errors shown on the touchscreen controller are described below as well as diagnoses and fixes The bottom line of the touchscreen displays the boiler s error status The following colors represent the boiler s operating status Green Normal Yellow ...

Page 97: ...r too small Adjust ignition probe rod gap between and 3 16th inch 3 2 4 7 mm Spark but no ignition Check that the spark module is sending power to the gas valve close the gas supply then disconnect the black electric housing from the face of the gas valve Gently spread the plastic tabs to open Look for 24 VAC voltage during an ignition cycle Replace the module if there is no current detected Boile...

Page 98: ...ow Water Cut off error Low Water Cutoff Error Issue Diagnosis Fix Error Low Water Cutoff The Safety and Ignition module has detected a low water condition Refer to the V10 Touchscreen Controller manual for information on resetting a boiler after a LWCO lockout 8 2 4 Aux Interlock 1 or 2 Aux Interlock 1 or 2 Issue Diagnosis Fix Interlock 1 or 2 terminals are open Jumper lead is loose or compromised...

Page 99: ...r Max Inlet Outlet Sensor Temp Exceeded 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 Blank screen dark but fan running Indi...

Page 100: ...el via analyzer Check for proper gas 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 Check air reference tubing Igniter probe flame sensor disconnected Reconnect probe Defective Control Module Check ignition output from control module Boiler will not attempt to ignite ...

Page 101: ...level Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain Appliance cycling on operating safety controls Check operation with Ohmmeter Voltmeter System radiation undersized Check manufacturer s rating tables for capacity per foot Temperature exceeds thermostat setting Incorrect anticipator setting Check with Ammeter Thermosta...

Page 102: ...mostat manufacturer first then IBC for instructions Error Water High Limit Low Water Cutoff won t clear Boiler is in 1 hour safety lockout For instructions on clearing errors see the V10 Touchscreen Controller manual DHW taking too long to heat Sensor may be under reading actual water temp Check sensor engagement note well is 15 cm almost 6 inches deep and sensor must be fully set to back Check pr...

Page 103: ...ered via keypad Check load maximum temps are above target temps by of the selected boiler differential Ensure boiler differential is OK 16 30 F is generally adequate Excess condensate in venting Check venting slopes on horizontal runs Look for sags Obstruction in condensate trap Inspect and clean condensate trap Improper vent length or improper slope to vent Check venting Compare vent length and d...

Page 104: ...er pipe Check temperature differential across zone heat exchanger Low radiation Check actual amount of radiation per zone and refer to manufacturer s rating tables Appliance over fired Clock gas meter check gas pressure with manometer check CO2 level Appliance Oversized Check load calculation vs minimum boiler output Improperly set or defective controls Check operation with ohmmeter voltmeter 100 ...

Page 105: ...101 Appendices Wiring diagrams V 10 Controller electrical diagram Figure 52 Controller electrical diagram ...

Page 106: ...Internal wiring diagram Figure 53 Internal wiring diagram 102 Section Appendices ...

Page 107: ...Sequence of Operation Figure 54 Sequence of Operation 103 Sequence of Operation ...

Page 108: ...t Duct 250 941 P 390 1 115 Intake Duct 250 942 P 391 1 120 Safety Ignition Module SIM 500 078 P 271B 1 125 Flue Temperature Sensor 240 132 P 361 1 135 Terminal Block Cover 250 825 1 140 V 10 Touchscreen Controller 500 063 P 242 1 145 Transformer 240 008 1 150 Front Access Cover door assembly 500 096 P 331 1 155 Thumb screw 250 275 2 104 Section Appendices ...

Page 109: ...105 Exploded views of boiler parts ...

Page 110: ... 212 Fan Gasket 250 627 1 215 Fan 240 114 P 310 1 216 Air Metering Insert 250 866 SL 10 85 G3 P 342 SL 14 115 G3 P 335 1 217 218 Venturi Insert SL 10 85 G3 240 123 SL 14 115 G3 240 124 1 220 Water Pipe Gasket 250 458 2 221 Gas Tube 250 792 1 222 Gas Valve Union Nut 250 811 1 223 Orifice O ring 150 175 1 224 Orifice 725 NG 180 108 P 305 1 225 Orifice 480 LP 180 119 P 304 1 227 LWCO Probe 240 010 1 ...

Page 111: ...sure Sensor Bushing 250 023 1 270 Return Water Pipe 250 454 1 275 Return Temperature Sensor 240 134 P 363 1 280 Condensate Trap 180 013 P 115 1 283 Condensate Trap Retainer 250 874 250 875 P 344 1 290 Heat Exchanger 170 033 P 321 1 300 Temperature Switch 240 030 1 305 Heat Exchanger Lid Gasket 255 021 P 372 1 310 Burner 180 191 P 312 1 320 Refractory 250 763 P 327 1 107 Exploded views of boiler pa...

Page 112: ...iption Part Quantity 325 Ignitor Gasket 250 050 SL 10 85 G3 P 327 SL 14 115 G3 P 111B 1 330 331 Ignitor SL 10 85 G3 240 141 SL 14 115 G3 240 002 1 335 Ignitor Fan Coupler Screws 150 260 10 108 Section Appendices ...

Page 113: ...ake Duct 250 942 P 391 1 115 Safety Ignition Module SIM 500 078 P 271B 1 120 Flue Temperature Sensor 240 132 P 361 1 130 Side Terminal Block Cover 250 825 1 135 V 10 Touchscreen Controller 500 063 P 242 1 140 Transformer 240 008 1 150 Front Access Cover door assembly 500 097 P 332 1 155 Thumb screw 250 275 2 109 Exploded views of boiler parts ...

Page 114: ...110 Section Appendices ...

Page 115: ...50 555 1 225 Gas Tube 250 792 1 226 Orifice 650 NG 180 107 P 307 1 227 Orifice 505 LP 180 095 P 306 1 228 Orifice O ring 150 175 1 229 Gas Valve Union Nut 250 811 1 230 Water Pipe Gasket 250 458 2 235 Gas Valve 180 165 P 326B 1 240 Gas Line Gasket 150 271 2 241 Flexible Gas Line 190 159 1 250 Water Pressure Sensor 240 006 1 255 Pressure Sensor Bushing 250 023 1 260 Water Pipe Bracket 250 592 2 265...

Page 116: ...133 P 362 1 300 Refractory 250 762 P 317 1 305 High Limit Switch 240 030 1 315 Burner 180 187 P 313 1 320 Burner Gasket 255 069 P 378 1 325 Heat Exchanger Lid Gasket 255 029 P 374 1 330 Sight Glass Housing 250 057 P 107A 1 331 Sight Glass 250 059 1 332 Sight Glass Gasket 255 025 1 333 Sight Glass to Lid Gasket 255 023 1 335 Ignitor Gasket 250 050 P 317 1 336 Ignitor 240 141 1 337 Ignitor Fan Coupl...

Page 117: ...ke Duct 250 942 P 391 1 116 Flue Temperature Sensor 240 132 P 361 1 120 Safety Ignition Module SIM 500 078 P 271B 1 135 Terminal Block Cover 250 825 1 140 V 10 Touchscreen Controller 500 063 P 242 1 145 Transformer 240 008 1 150 Front Access Cover door assembly 500 098 P 333 1 155 Thumb screw 250 275 2 113 Exploded views of boiler parts ...

Page 118: ...Item Description Part Quantity 200 Fan Coupler 250 749 P 347 1 205 Fan Coupler O ring 150 254 1 114 Section Appendices ...

Page 119: ...ket 255 024 1 250 Venturi Insert 240 142 P 336 1 255 Gas Tube 250 792 1 265 Gas Valve 180 165 P 326B 1 266 Gas Line Gasket 150 271 1 275 Water Pipe Bracket 250 845 1 280 Return Water Pipe 250 834 P 370 1 285 Water Pressure Sensor 240 006 1 300 Condensate Trap Retainer 250 874 250 875 P 344 1 305 Condensate Trap 180 013 P 115 1 310 Return Temperature Sensor 240 134 P 363 1 311 Supply Duplex Tempera...

Page 120: ...hanger Lid Gasket 255 026 P 319 1 325 Refractory 250 761 1 330 Ignitor Gasket 250 050 P 111B 1 335 Ignitor 240 002 1 340 Sight Glass 250 059 P 107A 1 341 Sight Glass Gasket 255 025 1 342 Sight Glass Housing 250 057 1 343 Sight Glass to Lid Gasket 255 023 1 116 Section Appendices ...

Page 121: ...stem Filled type concentration of any glycol chemicals used _________________________ Air purge completed Relief Valve correctly installed and piped Relief valve try lever test performed Condensate trap filled Condensate drain clear and free flowing Condensate Neutralization Ignition Safety Shutoff test completed Flame current High fire _____ µA Low fire _____ µA Owner advised and instructed in th...

Page 122: ...Intentionally left empty ...

Page 123: ...es the same 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 ...

Page 124: ... 877 0277 T 856 877 0544 F 604 877 0295 F 856 735 5584 Toll Free 1 844 HEAT IBC 1 844 432 8422 www ibcboiler com Information in this document is subject to change without notice IBC assumes no responsibility for changes made to the manual due to clerical errors to regulation changes or to product development August 2021 120 276E8 IBC Technologies Inc 2021 ...

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