IBC SL 40-399 G3 Installation And Operating Instructions Manual Download Page 85

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Summary of Contents for SL 40-399 G3

Page 1: ...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 gas supplier from a nearby phone Follow the gas sup...

Page 2: ...potentially hazardous situation which must be avoided to prevent serious injury or death CAUTION Points out a potentially hazardous situation which must be avoided to prevent possible moderate injury...

Page 3: ...x relative humidity non condensing 90 90 Minimum water temp 34 F 1 C 34 F 1 C Maximum water temp electronic hi limit 190 F 88 C 190 F 88 C Max T supply return electronic fence 40 F 40 F Power use 120V...

Page 4: ...INSTALLATION AND OPERATION INSTRUCTIONS 4 SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 5: ...tallation 1 18 1 5 3 Condensate Trap Assembly cleaning procedure 1 19 1 5 4 Further installation details 1 19 1 6 WATER PIPING 1 21 1 6 1 General Piping Issues 1 21 1 6 2 Installation Rules 1 24 1 7 G...

Page 6: ...as valve re installation 4 7 4 2 3 Replacing the gas valve 4 8 5 0 TROUBLESHOOTING 5 1 5 1 PRELIMINARY CHECKS 5 1 5 2 ELECTRONIC COMPONENTS 5 2 5 2 1 Temperature Sensors 5 2 5 2 2 Fan 5 3 5 2 3 Water...

Page 7: ...asures 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 8: ...INSTALLATION AND OPERATION INSTRUCTIONS 8 SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 9: ...cifications for each model Figures 1A and 1B show outer case dimensions piping and electrical holes Refer to these figures to help with finding a suitable location for the boiler See also Section 1 3...

Page 10: ...STALLATION AND OPERATION INSTRUCTIONS 1 2 SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS Figure 1A Dimensions Connections for SL 26 260 G3 9 7in 246mm Figure 1B Dimensions Connections for SL 40 399...

Page 11: ...ing air surrounding the boiler should not be used in a laundry room Similarly ensure any direct vent air source is not adjacent to a clothes dryer exhaust terminal Avoid agricultural applications wher...

Page 12: ...to carefully plan the installation to ensure the appropriate vent materials travel and termination decisions are included Specific attention is warranted to manage the impact of the steam plume norma...

Page 13: ...Installation Code At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the...

Page 14: ...unused chimney as a vent raceway 1 4 2 Exhaust Vent Material Exhaust Vent Material CANADA Use PVC CPVC or Polypropylene PPs vent component systems approved under ULC S636 Standard for Type BH Gas Vent...

Page 15: ...can be sited up to 200 equivalent feet from the vent termination The actual vent travel allowance is reduced for fittings in accordance with the following tables For example for an SL 40 399 G3 using...

Page 16: ...are considered equivalent to 8 NOTE Unused intake travel cannot be added to the exhaust Unequal intake and exhaust piping is allowed see Section 1 4 8 Exhaust venting must slope down towards the boile...

Page 17: ...ate trap Optional bird screen may be placed in a termination fitting Leave unglued and hold in place with a short nipple This permits easy access for cleaning DO NOT exhaust vent into a common venting...

Page 18: ...e 3 0 91m USA 12 0 3m Clearance to a mechanical air supply inlet 6 1 82m USA 3 0 91m above if within 10 3 1m horizontally Clearance above paved sidewalk or paved driveway located on public property 7...

Page 19: ...should be installed in both open ends of the tee Figure 9 Sidewall vent termination indoor combustion air applications CAUTION Vent termination clearances in this section are code minimum or IBC reco...

Page 20: ...ch the plume up and off the sidewall for protection of wall Bird screen of 1 4 stainless steel or plastic mesh IPEX System 636 drain grate is useful to guard against foreign objects Figure 13 Sidewall...

Page 21: ...rough the wall as shown in Figure 15 and immediately inside the wall adapt up to a 4 inch pipe using a standard reducing coupling fitting Do not use a bushing The SST is an external fixture and is not...

Page 22: ...ATING GAS BOILERS Figure 14 Allowed SST installation orientations Figure 15 Pipes extend completely through the wall Vertical orientation shown Figure 17 Minimum separations for multiple vent installa...

Page 23: ...of chemical contaminants care must be taken to ensure air intake terminals are not installed in locations where contamination might occur due to ingestion of particulate foreign material dust dirt and...

Page 24: ...intake inlet and the vent terminal Refer to the vent terminal configuration drawings in the Vent Termination section above Support should be provided for intake piping particularly so for horizontal...

Page 25: ...h B149 1 1 4 9 Combustion Air Filtration If combustion air contamination from ingested particulate matter is a concern in any installation an optional air intake filter may be installed IMPORTANT Unde...

Page 26: ...uts and washers lower the front of the trap door and slide forward Undo the Drain Spout Compression Nut E remove the Drain Hose G from Trap Drain Outlet F Place the Vacuum breaker cap J over the Vacuu...

Page 27: ...n 2 Remove the trap from the boiler reverse the installation procedure above 3 Remove the Trap Cleanout Assembly H from the Trap Body and clean and flush the debris out 4 Re assemble the trap componen...

Page 28: ...corrosion a neutralization package must be used 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 29: ...he floor or per local Code Figure 26 Boiler trim options Single boiler System piping is connected to the boiler using the 1 1 2 NPT M threaded fittings Unions and gate or ball valves at the boilers su...

Page 30: ...stem An additional benefit is that backflow prevention devices are not required when using these devices Do not place any water connections above the boiler leaks can damage the fan and controls If ne...

Page 31: ...shall conform the piping design to one of the provided configurations to simplify the control application promote good loads and flow management Propylene glycol solution is commonly used in a closed...

Page 32: ...diluted antifreeze of any kind This may result in severe boiler damage It is the responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating...

Page 33: ...avoid thermal siphoning and reverse flow To ensure adequate water flow through the boiler under high head single zone space heating conditions a pressure activated bypass or other means of bypass must...

Page 34: ...wn and details such as thermal traps are left out so the drawings have greater clarity We require that our boilers be installed by licensed and experienced trades people who are familiar with the appl...

Page 35: ...in operation of these components when other loads are running at a higher priority resulting in cold air blowing or robbing heat from another load Some wiring alteration may be required to divorce bot...

Page 36: ...Use proper hangers to support gas supply piping as per applicable codes The boiler must be disconnected or otherwise isolated from the gas supply during any pressure testing of the system at test pres...

Page 37: ...the primary pump 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 pai...

Page 38: ...strip e g Therm 1 Gang lines from a multiple zoned load e g off the end switches for each radiant floor zone present a common thermostat signal to the controller Ensure that there are no disturbing i...

Page 39: ...ing 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...

Page 40: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 32 SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 41: ...th visual display on the Home Screen Internet LAN connectivity BACnet with activation 2 2 CONTROL When the boiler is first energized the controller will go through a power up sequence that will take a...

Page 42: ...raction 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...

Page 43: ...3 1 STARTUP AND COMMISSIONING SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS 3 0 STARTUP COMMISSIONING 3 1 BOILER SHUTDOWN LIGHTING...

Page 44: ...provide power to the boiler to initialize operation 3 2 2 Test Ignition Safety Shutoff With the boiler in operation test the ignition system safety shutoff device by shutting the gas control valve im...

Page 45: ...significant backlash When changing direction of turn it may take up to a full turn before any change is indicated on the analyzer reading Clock the gas meter to confirm full maximum rating plate inpu...

Page 46: ...INSTRUCTIONS 3 4 SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS 3 3 1 Gas Valve and Fan Diagrams Figure 37B Gas Valve and Pressure Reference System SL 40 399 G3 Figure 37A Gas Valve and Pressure Ref...

Page 47: ...e correct fuel conversion kit for your boiler Compare the boiler model number with the Kit found in Table 8 2 Read the fuel conversion instructions supplied with the fuel conversion kit 3 Carefully fo...

Page 48: ...burner walls and the refractory Care must be observed to ensure minimal contact between these parts to prevent refractory cracking 10 Place the lid with the burner attached on a clean dry area 11 With...

Page 49: ...the alignment marks for proper positioning 7 Ensure that the lid gasket is in good condition and is in place and level 8 Carefully insert the lid burner assembly straight down Ensure that there is lim...

Page 50: ...t between the burner and refractory and observe the alignment markings 9 Swing up the lid fasteners ensuring the nuts and the washers are above the lid Evenly tighten the nuts in a cross pattern and e...

Page 51: ...on if the burner requires cleaning every year In alternate years visually inspect the burner through the sight glass Ensure that the flame is stable and is without excessive fluttering Normal flame pa...

Page 52: ...e to leaks and flooding 4 1 11 Freeze Protection Check the freeze protection Use only antifreeze made specifically for hydronic systems Inhibited propylene glycol is recommended Antifreeze volume must...

Page 53: ...tries model MF200 be employed to refill and pressurize your system Capture the discharged fluid in a container and recycle it by returning it to the system feeder unit This is particularly important w...

Page 54: ...RS Components of the SL 26 260 G3 ITEM NO COMPONENT ITEM NO COMPONENT 1 Pressure Relief Valve 6 Low Water Cutoff Probe 2 Combustion Test Port 7 Site Glass 3 Safety Ignition Module 8 Tridicator 4 Ignit...

Page 55: ...PONENT 11 Venturi Mixing Device 16 Water Pressure Sensor 12 Fan 17 Return Water Temperature Sensor 13 Supply Water Temperature Sensor 18 Return Water Pipe 14 Air Intake Pipe 19 Blocked Vent Pressure S...

Page 56: ...ct the electrical connectors to the fan and gas valve SL 40 399 G3 1 Turn off the electric power and gas supply to the boiler 2 Ensure the boiler cools down to the surrounding temperature Do not drain...

Page 57: ...ive cover from the gas inlet now 7 Re attach the gas supply line JIC connector flare fitting nut 8 Open up the gas supply and check for possible leaks 9 Return the electric power to the boiler and per...

Page 58: ...f the gas valve Ensure that the gasket is in place 9 Supporting the male compression coupling on the outlet of the gas valve with a wrench tighten the compression fitting to secure the gas valve to th...

Page 59: ...th troubleshooting including Electrical wiring diagrams Sequence of operations flowchart Boiler component diagrams 5 1 PRELIMINARY CHECKS The first step in troubleshooting this system should be a revi...

Page 60: ...water For the supply water and vent temperature sensors remove the wire leads by disconnecting their respective Molex connectors Place multi meter probes into the sensor s female Molex connector sock...

Page 61: ...eration The pressure is displayed in PSI as the default If the system pressure should drop below 8PSI the firing rate of the boiler is reduced If the pressure drops to 4PSI or lower the boiler will no...

Page 62: ...een removed 1 On the touchscreen controller tap the Home screen 2 On the Main Menu tap the Diagnostics button 3 Tap the Advanced Diagnostics button 4 Tap the Clear Errors button 5 Tap the Yes radio bu...

Page 63: ...t Before you reset the boiler ensure that the boiler is pressurized and that the air has been removed 1 On the touchscreen controller tap the Home screen 2 On the Main Menu tap the Diagnostics button...

Page 64: ...tween blue and brown wires during an ignition cycle Replace module if no current detected Boiler ignites but shuts off at the end of the ignition trial Improperly grounded pressure vessel burner or un...

Page 65: ...NG GAS BOILER SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS SYMPTOM DIAGNOSIS REMEDY LOW WATER CUTOFF ERROR Touchscreen message Error Low Water Cutoff The Safety and Ignition module has detected a...

Page 66: ...for visible damage 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 flam...

Page 67: ...structions Check setting with 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...

Page 68: ...t exchanger Poor gas 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 s...

Page 69: ...te the thermostat with a relay or install a properly sized resistor consult the thermostat manufacturer first then IBC for instructions ERROR WATER HIGH LIMIT LOW WATER CUTOFF WON T CLEAR Boiler is in...

Page 70: ...INSTALLATION AND OPERATION INSTRUCTIONS 5 12 SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 71: ...6 1 DIAGRAMS SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS 6 0 DIAGRAMS This section includes Parts diagrams Wiring diagrams The sequence of operation...

Page 72: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 2 SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS 6 1 PARTS DIAGRAMS SL 26 260 G3 Boiler Parts assembly Diagram 6 1 1 Boiler assembly parts SL 26 260 G3...

Page 73: ...025 GASKET HOUSING GLASS 1 160 250 059 SIGHT GLASS 1 170 255 023 GASKET SIGHT GLASS H Ex 1 180 255 026 GASKET H Ex LID H Ex 1 190 255 034 GASKET BURNER H Ex 1 200 180 186 BURNER 1 210 250 761 HEAT EXC...

Page 74: ...00 250 867 BRACKET BLOCKED VENT PRESS SWITCH 1 410 240 138 BLOCKED VENT PRESSURE SWITCH 1 420 240 008 TRANSFORMER 1 430 500 105 IGNITION MODULE 1 440 240 132 FLUE TEMPERATURE SENSOR 1 450 250 855 FLUE...

Page 75: ...6 5 TROUBLESHOOTING SL 80 399 MODULATING GAS BOILER THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 76: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 6 SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS SL 40 399 G3 Boiler Parts assembly Diagram 6 1 2 Boiler assembly parts SL 40 399 G3...

Page 77: ...LER BOTTOM PLATE 1 130 190 162 AIR INTAKE ASSEMBLY 1 140 250 859 AIR INTAKE MOUNTING CLIP 1 150 190 158 GAS LINE 1 160 250 322 FAN GASKET 1 170 240 002 IGNITER 1 180 250 050 IGNITER GASKET 1 190 250 0...

Page 78: ...189 TRIDICATOR 1 400 240 010 LOW WATER CUT OFF SENSOR 1 410 180 005 PRESSURE RELIEF VALVE 30 PSIG 1 420 500 081 CABINET 1 430 240 008 TRANSFORMER 1 440 250 187 RATING LABEL PANEL 1 450 500 105 SAFETY...

Page 79: ...6 9 DIAGRAMS SL 80 399 MODULATING GAS BOILER SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS 6 2 WIRING DIAGRAMS Diagram 6 2 1 Ladder wiring diagram...

Page 80: ...placement internal wiring must meet or exceed the ratings of the wiring supplied from the factory green Transformer green green white white black Upper Vessel High Limit Switch white yellow white red...

Page 81: ...6 11 DIAGRAMS SL 80 399 MODULATING GAS BOILER SL 26 260 G3 SL 40 399 G3 MODULATING GAS BOILERS 6 3 SEQUENCE OF OPERATION Diagram 6 3 Sequence of operation diagram...

Page 82: ...g Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner used ________________________________________________ System Fi...

Page 83: ...uration Load 2 _____________________________________________________________________________________________ Load Definition Load 3 ____________________________________________________________________...

Page 84: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Page 85: ...NOTES...

Page 86: ...t system that serves 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...

Page 87: ...REVISION HISTORY R1 March 2017 Initial release R2 AVRIL 2017 Corrections to text Specifications table and part number tables...

Page 88: ...IBC Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Tel 604 877 0277 Fax 604 877 0295 Toll Free 1 844 432 8422 www ibcboiler com April 2017 IBC Technologies Inc 2017...

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