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INSTALLATION AND OPERATION INSTRUCTIONS

4-4

SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS

4.2 GEOGRAPHY & COMPONENTS

Safety Ignition Module

Gas Valve

Supply Water Pipe

Ignitor

Air pressure switch (behind
bracket)

Combustion Test Port

Site Glass

Touchscreen controller

Fan Coupler

Combustion Fan

Return Water Temperature Sensor

Return Water Pipe (behind - on

the right side)

Flue Gas Temperature Sensor (behind
the combustion fan)

Low Water Cutoff Probe

Gas Tube

Supply Water Temperature Sensor

Water Pressure Sensor (behind

the touchscreen controller)

Содержание SL 14-115 G3

Страница 1: ...or other combustible 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 y...

Страница 2: ...hich in extreme cases might result in death HAZARDS PRECAUTIONS WARNING Points out a potentially hazardous situation which must be avoided to prevent serious injury or death CAUTION Points out a poten...

Страница 3: ...vessel water content USG Litres 2 47 9 35 1 72 6 51 5 09 19 3 Maximum boiler flow rate USgpm 14 19 22 Minimum boiler flow rate USgpm 2 4 6 Maximum operating water pressure psig 30 30 30 Minimum water...

Страница 4: ...INSTALLATION AND OPERATION INSTRUCTIONS 4 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 5: ...allation 1 17 1 5 3 Condensate Trap Assembly cleaning procedure 1 18 1 5 4 Further installation details 1 18 1 6 WATER PIPING 1 20 1 6 1 General Piping Issues 1 20 1 6 2 Basic System Piping Arrangemen...

Страница 6: ...an and gas valve re assembly instructions 4 5 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 Pressure Sensor 5...

Страница 7: ...ilding air intakes including those of neighboring properties In sealed combustion applications the exhaust outlet should be placed so as to reach 12 minimum above the down turned intake to avoid exhau...

Страница 8: ...INSTALLATION AND OPERATION INSTRUCTIONS 8 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 9: ...ns and piping and electrical holes Refer to the applicable diagrams to help find a suitable location for the boiler See also Section 1 3 Location Figure 1 Dimensions Connections for SL 14 115 G3 Front...

Страница 10: ...4 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS Figure 2 Dimensions Connections for SL 20 160 G3 Front view side view top view and bottom view Figure 3 Dimensions Connections for SL 30 199 G...

Страница 11: ...sure any direct vent 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 Lo...

Страница 12: ...lumes well away from all building air intakes including those of neighboring properties All venting must be installed in accordance with the requirements of the jurisdiction having authority in Canada...

Страница 13: ...ces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maxim...

Страница 14: ...e use of flue temperature sensor and software to ensure that the maximum temperature of the PVC venting material is not exceeded PVC venting material shall be certified to Sch 40 ASTM D1785 or D2665 C...

Страница 15: ...installers when using horizontal runs of 2 pipe Reason air friction from the fast moving exhaust during long burner runs at high fire in a 2 pipe can overcome gravity on 1 4 foot vent slope leaving a...

Страница 16: ...ater solution Installer must fill condensate trap prior to test Paint all joints with an approved leak test solution just as you would joints in a gas line and make sure there are no leaks Good practi...

Страница 17: ...lation instructions supplied with the venting material manufacturer Care must be taken to install the termination kit a minimum horizontal distance of 10 305cm away from any portion of the building an...

Страница 18: ...ith the SL boilers to avoid damage to the structure Note Prohibited unless fully open on a minimum of two sides below the floor Vents must be installed such that flue gas does not discharge towards ne...

Страница 19: ...the wall Bird screen of 1 4 stainless steel or plastic mesh eg IPEX System 636 drain grate for CPVC systems is useful to guard against foreign objects CAUTION Vent termination clearances in this secti...

Страница 20: ...nnections fit Sched 40 two inch or three inch PVC CPVC pipe PPs pipe cannot be used with the SST The pipes must extend completely through the wall as shown in Figure 16 The SST is an external fixture...

Страница 21: ...G3 MODULATING GAS BOILERS Figure 15 Allowed SST installation orientations Figure 18 Minimum separations for multiple vent installation horizontal orientation Figure 17 Minimum separation for multiple...

Страница 22: ...enter the air intake piping system Otherwise serious damage to the boiler may result NOTE Care must be taken when installing air intake piping to ensure that a trap is not formed in the piping so as t...

Страница 23: ...for horizontal runs follow local code 1 4 8 Indoor Air Combustion Air Intake An Indoor Combustion Air installation as described herein is one in which air for combustion is taken from the ambient air...

Страница 24: ...n approval of the IBC Engineering Department 1 4 10 Closet Installations For installations in a confined space such as a closet ventilation openings may be needed through a door or wall to prevent exc...

Страница 25: ...Installation 1 Undo the Drain Spout Compression Nut E remove Drain Hose G from the Trap Drain Outlet F Place the Vacuum breaker cap J over the Vacuum breaker opening and push firmly home Remove the U...

Страница 26: ...components re fill trap and replace on boiler as described in the installation instructions above 1 5 4 Further installation details Condensate drain must be piped to within 1 of a drain or be connec...

Страница 27: ...to be discharged into building drain piping materials that are subject to corrosion a neutralization package must be used CAUTION When a condensate neutralization package is installed the pH of the c...

Страница 28: ...flexibility in multi load applications but piping loads in parallel is also encouraged in systems that only have two loads or when loads are operating simultaneously The extremely low pressure drop t...

Страница 29: ...purveyors as to the suitability of their supply for use in hydronic heating systems If water quality is questionable a local water treatment expert must be consulted for testing assessment and if req...

Страница 30: ...ices Do not place any water connections above the boiler Leaks can damage the fan and controls If needed create a shield over the top of the cover but allow clearance for airflow and service access Fo...

Страница 31: ...oftware values will run the boiler s primary pump for up to 15 minutes 900 seconds after burner shutdown Secondary pumps can be set to run up to 5 minutes after burner shutdown for the last calling lo...

Страница 32: ...oid bulking up the thermal mass of the primary piping circuit and potentially lengthen the duration of the transition from hot to cool loads SL modulating series boilers can be connected directly to a...

Страница 33: ...LATION SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS Figure 34 Typical one temperature space heating piping concept Figure 33 One temperature space heating piping concept tees on secon...

Страница 34: ...ible Many air handlers fan coils for instance 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...

Страница 35: ...components not shown 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 fami...

Страница 36: ...G3 MODULATING GAS BOILERS Parallel load piping Benefits and installation rules Compared with the Primary Secondary approach the design below saves one pump Lost is the simplicity of constant head and...

Страница 37: ...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 Each boiler will control its own pump turni...

Страница 38: ...hart Table 6 Maximum Pipe Length ft Schedule 40 steel NOTE It is essential to check gas supply pressure to each boiler with a manometer or other high quality precision measuring device Pressure should...

Страница 39: ...cal codes and or the National Electrical Code ANS NFPA No 70 latest edition or the Canadian Electrical Code C22 1 Part 1 1 8 1 120 VAC Line Voltage Hook up Line voltage wiring is done within the field...

Страница 40: ...seen occasionally at construction sites where the boiler has been repeatedly de powered wet The combined current of all pumps connected through the on board pump relays should not exceed 10 amps The...

Страница 41: ...used for connecting multiple SL and or VFC modulating units for autonomous staging The bottom pair of contacts receives a 0 10VDC default or 4 20 mA signal from an external boiler controller for direc...

Страница 42: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 34 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS Figure 44 Electrical Wiring Connections full page ladder diagram at back of this manual...

Страница 43: ...B stick Setup configuration back up and cloning using an SD card or USB stick Superior warning messages while setting up the control Advanced Error messages with visual display on the Home Screen Inte...

Страница 44: ...itle bar at the top and a border 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 s...

Страница 45: ...3 1 STARTUP AND COMMISSIONING SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS 3 0 STARTUP COMMISSIONING 3 1 LIGHTING BOILER SHUTDOWN...

Страница 46: ...tside the boiler case 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...

Страница 47: ...adjustment and may require several turns Note This screw has significant backlash When changing direction of turn it may take up to a full turn before any change is indicated on the analyzer reading C...

Страница 48: ...Fuel Conversion kits Fuel conversions must be carried out by a qualified technician 1 Ensure you are installing the correct fuel conversion kit for your boiler Compare the boiler model number with the...

Страница 49: ...arker make an alignment mark between the lid gasket and heat exchanger Before removing the lid it is important to be positioned directly above it to ensure a straight up extraction Failing to do this...

Страница 50: ...turn 8 Re attach the igniter wire to the igniter 3 4 2 Removing the burner 1 Turn off the power and the gas supply to the boiler 2 Remove the front cover and allow the boiler to cool down to the surr...

Страница 51: ...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 pattern is...

Страница 52: ...nnections are left in the closed position to minimize exposure to leaks and flooding 4 1 11 Freeze Protection Check the freeze protection Use only antifreeze made specifically for hydronic systems Inh...

Страница 53: ...pletely seal and fluid continues to leak from the discharge pipe perform the test again to try and flush any debris that may be lodged in the valve If repeated tries fail to stop the leakage contact a...

Страница 54: ...8 Air pressure switch behind bracket 14 Combustion Test Port 3 Site Glass 9 Touchscreen controller 15 Fan Coupler 4 Combustion Fan 10 Return Water Temperature Sensor 16 Return Water Pipe behind on the...

Страница 55: ...th the gasket in position tighten the union nut to the inlet of the gas valve 4 2 2 Fan and gas valve re assembly instructions 1 Place the fan gasket on the outlet of the fan coupler 2 Attach the fan...

Страница 56: ...INSTALLATION AND OPERATION INSTRUCTIONS 4 6 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 57: ...l are a number of diagrams see Section 6 0 for use with troubleshooting including Electrical Wiring Diagrams Sequence of Operations Flowchart Boiler Component Layout Diagrams 5 1 PRELIMINARY CHECKS Th...

Страница 58: ...sistance reading remove power to the boiler For the supply water and return water temperature sensors remove the wire leads by disconnecting their respective Molex connectors Place multi meter probes...

Страница 59: ...rack the pressure relief valve The pressure displayed should reflect declining pressure If it remains fixed drain the boiler and replace the sensor or dislodge any blocking debris from the sensor inle...

Страница 60: ...ssurized 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 3 Tap the Advanced Diagnostics button 4 Tap the Clear Error...

Страница 61: ...er after a Hi Limit lockout 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 t...

Страница 62: ...wer to gas valve close gas supply then disconnect black electric housing from face of gas valve gently spread plastic tabs to open and look for 24vac voltage during an ignition cycle Replace module if...

Страница 63: ...ptable 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 t...

Страница 64: ...IGNITING Fluctuating gas pressure gas pressure too high too low Check CO2 level via analyzer Check for proper gas piping Check pressure with manometer during ignition BOILER WILL NOT ATTEMPT TO IGNIT...

Страница 65: ...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 is within specification...

Страница 66: ...heat 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 operati...

Страница 67: ...evice and clear the error in the Advanced Diagnostics menu DHW TAKING TOO LONG TO HEAT Sensor may be under reading actual water temp Check sensor engagement note well is 15cm almost 6 inches deep and...

Страница 68: ...INSTALLATION AND OPERATION INSTRUCTIONS 5 12 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 69: ...6 1 DIAGRAMS SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS 6 0 DIAGRAMS This section includes Parts diagrams Wiring diagrams Sequence of operation...

Страница 70: ...TALLATION AND OPERATION INSTRUCTIONS 6 2 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS 6 1 PARTS DIAGRAMS Diagram 6 1 1 Boiler assembly parts SL 14 115 G3 Modulating Boiler Parts assem...

Страница 71: ...6 3 DIAGRAMS SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS...

Страница 72: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS SL 20 160 G3 Modulating Boiler Parts assembly Diagram 6 1 2 Boiler assembly parts...

Страница 73: ...6 5 DIAGRAMS SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS...

Страница 74: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 6 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS SL 30 199 G3 Modulating Boiler Parts assembly Diagram 6 1 3 Boiler assembly parts...

Страница 75: ...6 7 DIAGRAMS SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS...

Страница 76: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 8 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS Diagram 6 2 1 Ladder wiring diagram 6 2 WIRING DIAGRAMS...

Страница 77: ...n green green black Upper Vessel High Limit Switch white yellow white red white white yellow brown black blue orange orange blue Inlet Water Pressure Sensor white white black yellow To Boiler Pump gre...

Страница 78: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 10 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 MODULATING GAS BOILERS 6 3 SEQUENCE OF OPERATION Diagram 6 3 Sequence of operation diagram...

Страница 79: ...g Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner used ________________________________________________ System Fi...

Страница 80: ...ration Load 2 _____________________________________________________________________________________________ Load Definition Load 3 _____________________________________________________________________...

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

Страница 82: ...NOTES...

Страница 83: ...NOTES...

Страница 84: ...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...

Страница 85: ...l release R2 APRIL 2017 Revision of Figures 33 and 34 Corrections to text Specifications table and part numbers R3 MAY 2017 Corrections to tables and part numbers R4 July 2017 Inclusion of information...

Страница 86: ...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 July 2017 IBC Technologies Inc 2017...

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