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INSTALLATION AND OPERATION INSTRUCTIONS

1-28

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

1.8.6 Thermostat Heat Anticipator

IBC “Therm.” contacts draw no power, so an anticipator setting for the thermostat

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 room thermostat’s heat anticipator should

be adjusted to the current draw of its associated zone valve.

Figure 30: Electrical Wiring Connections (full page ladder diagram at back of this manual)

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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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