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INSTALLATION

SL 35-199, SL 45-260 MODULATING GAS BOILERS

NOTE

The IBC Touch-Screen 

controller has the ability 

to connect to most power 

stealing thermostats. See the 

Wiring Diagram for details.

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. See Controller 

Manual section 2.1.1 for 

detailed instructions.

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. Disconnect the 120 Vac leads connected to PV-L/PV-N 

and cap off. 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 4 loads are provided as marked on the 

lower 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. Most power 

stealing thermostats can be connected directly to the Therm terminals. 

See 

Controller Manual section 2.1.1 for more detailed instructions.

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. 1,2,3,4 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. 

  The bottom 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 35-199

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: ...llowing items 1 x Wall mounting bracket 1 x Condensate trap assembly 1 x 30 psig pressure relief valve 1 x Outdoor temperature sensor 6 x 1 4 x 2 1 2 Lag screws w flat washers WARNING If the informati...

Page 3: ...5 Minimum boiler flow rate USgpm 6 6 Maximum operating water pressure psig 30 30 Minimum water pressure psig 8 8 Approved installation altitude ASL 0 12 000 0 12 000 Ambient temperature Low F C Ambien...

Page 4: ...INSTALLATION AND OPERATION INSTRUCTIONS 4 SL 35 199 SL 45 260 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 5: ...ER CONTROLLER 2 1 2 1 GENERAL 2 1 2 2 CONTROL 2 1 2 3 CONTROL INTERFACE 2 1 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...

Page 6: ...ng 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 sidew...

Page 7: ...egree 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 DESCRIP...

Page 8: ...ent 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 w...

Page 9: ...ally 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...

Page 10: ...steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in...

Page 11: ...ved under ULC S636 Standard for Type BH Gas Venting Systems or stainless steel Type BH venting systems are to be used Permitted PPs materials comprise Single Wall Rigid pipe and fittings and Flexible...

Page 12: ...0 equivalent feet from the vent termination using 3 The actual vent travel allowance is reduced for fittings in accordance with Table 3 e g for SL 35 199 and SL 45 260 boilers using 6 x 90 CPVC elbows...

Page 13: ...components For PPs connections shall be secured using approved retainer clips supplied by the respective PPs manufacturer All vent connections must be liquid and pressure tight Prior to firing the bo...

Page 14: ...to a common venting system Roof Top Concentric Termination Kits are approved for use with this boiler model The installation of the vertical roof top concentric termination must follow the installatio...

Page 15: ...ll Place the 2 groups of pipes at least 3 apart the closest intake and exhaust pipes shall be 36 or more apart Use same 24 minimum vertical separation Alternately as long as the boilers are identical...

Page 16: ...centre 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 supp...

Page 17: ...l building 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...

Page 18: ...ot permitted to add to the exhaust length by transfer 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 t...

Page 19: ...ke filter may be installed IBC supplied 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 intak...

Page 20: ...ompression 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 B...

Page 21: ...ribed 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...

Page 22: ...sed 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 Fig...

Page 23: ...elief valve 3 4 NPT is supplied for field installation at one of the locations shown in the following illustrations Relief valve discharge piping must terminate between 6 15cm and 12 30cm above the fl...

Page 24: ...r from any component in the system An additional benefit is that backflow prevention devices are not required when using these devices Do not place any water connections overhead the boiler leaks can...

Page 25: ...L internal water volume Default software values will 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...

Page 26: ...r clarity We require that our boilers be installed by licensed and experienced trades people who are familiar with the applicable local and national codes System design is to be completed by an experi...

Page 27: ...1 21 INSTALLATION SL 35 199 SL 45 260 MODULATING GAS BOILERS Figure 25 Basic Primary Secondary piping with hydraulic separator concept Figure 26 Primary Secondary with Indirect Domestic Hot Water...

Page 28: ...t and potentially lengthen the duration of the transition from hot to cool loads SL modulating series boilers can be connected directly to a floor of non oxygen barrier polybutylene material PB tubing...

Page 29: ...ed using appropriate means such as a manual mixing valve or an aquastat set to130 F for example wired to the boiler s auxiliary interlocks PARALLEL LOAD PIPING BENEFITS AND INSTALLATION RULES Compared...

Page 30: ...llustrated below This approach provides constant head and flow at each boiler regardless of flow variations in the main building loop Each boiler will control its own pump turning it off or on when he...

Page 31: ...excess of 1 2 psig Dissipate test pressure prior to reconnecting The boiler and its gas piping shall be leak tested before being placed into operation The gas valve is provided with pressure taps to m...

Page 32: ...to the Pump Zone Valve Terminal Block along the controller s right edge this is for the secondary pumps and or zone valves only Connect the pump s Black wire to the Yellow of this pair switched Hot T...

Page 33: ...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...

Page 34: ...hermostat is not applicable with the SL modulating series boilers In the case of a single temperature heat load where zone valves are used to manage individual thermostatically controlled zones each r...

Page 35: ...p configuration back up and cloning using SD card or USB stick Superior warning messages while setting up the control Advanced Error messages with visual display on the Home Screen Internet LAN connec...

Page 36: ...d a boarder surrounding the active area At the bottom of the display there is space reserved for the boiler status bar Prior to any interaction with the touch screen the display will be showing the Ho...

Page 37: ...3 1 STARTUP AND COMMISSIONING SL 35 199 SL 45 260 MODULATING GAS BOILERS STARTUP AND COMMISSIONING 3 0 3 1 LIGHTING AND SHUTTING DOWN THE BOILER clockwise open close...

Page 38: ...se Ensure boiler has shut off and the appropriate Error information is displayed on the Touch Screen To restart boiler reset power or press Clear Errors in the Advanced Diagnostics section COMMISSIONI...

Page 39: ...ustment screw see Figure 31a for the SL 35 199 Gas Valve and Figure 31b for the SL 45 260 Gas Valve to achieve results listed in Table 7 below Check and adjust if necessary the high fire CO2 levels fi...

Page 40: ...INSTALLATION AND OPERATION INSTRUCTIONS 3 4 SL 35 199 SL 45 260 MODULATING GAS BOILERS Figure 31a SL 35 199 Gas Valve Adjust Figure 31b SL 45 260 Gas Valve Adjust...

Page 41: ...lly 3 The gas supply shall be shut off prior to disconnecting the electrical power and before proceeding with the conversion Ensure that the gas supply is turned off at the gas shut off valve 4 Using...

Page 42: ...exchanger 12 Carefully remove the refractory and place in a clean dry area 13 If burner needs to be removed gradually loosen up the 3 screws that secure the burner to the heat exchanger lid using a 2...

Page 43: ...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 onl...

Page 44: ...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 o...

Page 45: ...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 46: ...cover Gas inlet connection on side Gas valve Gas supply line Ignition wire boot Fan housing Fan pressure sensor Fan motor Ignition module Sight glass burner observation port GEOGRAPHY COMPONENTS 4 2 N...

Page 47: ...switch Vent temperature sensor bracket Inlet return water temperature sensor Removing vent stack test port plug Water pressure sensor Water temperature high limit switch Combustion air intake riser R...

Page 48: ...turi are one unit and must not be separated The gas valve can be removed from the fan venturi assembly by removing the three T25 Torks screws Take care not to misplace or damage the gasket between the...

Page 49: ...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 sho...

Page 50: ...ove the wire leads by disconnecting their respective Molex connectors Place multi meter probes into sensor s female Molex connector socket Do not apply voltage to the sensor damage may result TEMPERAT...

Page 51: ...ed in the advanced diagnostics section of the controller In general the Fan Pressure and the Required Pressure should be very close to each other while the boiler is in operation If the required press...

Page 52: ...to Ignite After 3 Attempts the Capable Controls module provides a single flash at the start of each Purge and Interpurge cycle continuous rapid flashes during the 4 second spark interval solid illumi...

Page 53: ...E LWCO MODULE Before resetting the LWCO module ensure that the system if fully charged with water and that all the air has been bled To reset the LWCO module press the reset button The red LED will il...

Page 54: ...ing Pre purge Fan Pressure FP should move close to Required Pressure RP if FP is not within 30 of RP and getting closer then check for actual vent system blockage a disconnect intake within boiler cas...

Page 55: ...off at the end of the ignition trial Improperly grounded pressure vessel burner or unserviceable ignition lead or spark module Ensure pressure vessel is grounded Check the igniter probe flame sensor i...

Page 56: ...e 5 3 2 Ignition Problems SYMPTOM DIAGNOSIS REMEDY NOISY SPARK WHEN IGNITING Ignition lead is not firmly connected Reconnect ignition lead Contaminants moisture on igniter probe flame sensor Ensure pr...

Page 57: ...ith 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 D...

Page 58: ...s air mixing Check CO2 level Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain Unit cycling on operating safety controls Chec...

Page 59: ...th a relay or install a properly sized resistor consult the thermostat manufacturer first then IBC for instructions ERROR WATER HIGH LIMIT LOW WATER CUT OFF WON T CLEAR Boiler is in 1 hour safety lock...

Page 60: ...INSTALLATION AND OPERATION INSTRUCTIONS 5 12 SL 35 199 SL 45 260 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 61: ...6 1 DIAGRAMS SL 35 199 SL 45 260 MODULATING GAS BOILERS 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS 6 3 SEQUENCE OF OPERATION...

Page 62: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 2 SL 35 199 SL 45 260 MODULATING GAS BOILERS 6 1 PARTS DIAGRAMS Diagram 6 1 1 SL 35 199 Boiler assembly parts SL 35 199 Modulating Boiler Parts assembly...

Page 63: ...H 1 200 500 044 V10 0 CONTROL MODULE 1 210 250 488 CONTROLLER TERMINAL BLOCK COVER 1 220 500 021 DOOR ASSEMBLY 1 230 240 006 PRESSURE SENSOR RETURN WATER 1 240 250 258 RETURN WATER PIPE 1 250 240 009...

Page 64: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 SL 35 199 SL 45 260 MODULATING GAS BOILERS Diagram 6 1 4 SL 45 260 Boiler assembly parts SL 45 260 Modulating Boiler Parts assembly...

Page 65: ...SWITCH 1 200 500 044 V10 0 CONTROL MODULE 1 210 250 488 CONTROLLER TERMINAL BLOCK COVER 1 220 500 021 DOOR ASSEMBLY 1 230 240 006 PRESSURE SENSOR RETURN WATER 1 240 250 258 RETURN WATER PIPE 1 250 24...

Page 66: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 6 SL 35 199 SL 45 260 MODULATING GAS BOILERS Diagram 6 2 1 Ladder wiring diagram 6 2 WIRING DIAGRAMS...

Page 67: ...ite white black black Vent High Limit Switch Upper Vessel High Limit Switch Water High Limit Switch white yellow black yellow red white red white white white white white black yellow yellow black blac...

Page 68: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 8 SL 35 199 SL 45 260 MODULATING GAS BOILERS 6 3 SEQUENCE OF OPERATION Diagram 6 3 Sequence of operation diagram...

Page 69: ...g Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner used ________________________________________________ System Fi...

Page 70: ...uration Load 2 _____________________________________________________________________________________________ Load Definition Load 3 ____________________________________________________________________...

Page 71: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Page 72: ...NOTES...

Page 73: ...NOTES...

Page 74: ...E 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 T...

Page 75: ...REVISION HISTORY R1 AUGUST 2014 Initial release SL 35 199 Incorporate the SL 45 260 model R2 MAY 2015 Address update...

Page 76: ...IBC Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 207E A R2 May 2015 IBC Technologies Inc 2015...

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