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INSTALLATION AND OPERATING INSTRUCTIONS

SL 28-160 MODULATING GAS BOILER

1.0 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 CODE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 EXHAUST VENTING AND AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 CONDENSATE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.6 WATER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1.7 GAS PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

1.8 ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

2.0 IBC BOILER 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 FUEL CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

4.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 BOILER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 GEOGRAPHY & COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

5.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 ELECTRONIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3 TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

6.0 DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 PARTS DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

CONTENTS

Содержание SL 28-160

Страница 1: ...tible 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 building Im...

Страница 2: ...tput kW 28 160 8 2 47 26 2 147 7 7 43 A F U E 95 Minimum gas supply pressure Natural Gas or Propane inch w c 5 Maximum gas supply pressure Natural Gas or Propane inch w c 14 Power use 120Vac 60Hz full...

Страница 3: ...NTROLLER 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 3 2 3...

Страница 4: ...se 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 sidewall ve...

Страница 5: ...ding a great degree 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 Lo...

Страница 6: ...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 where the boiler and or the intake air source...

Страница 7: ...rranted to manage the impact of the steam plume normally experienced at the exhaust terminal of a condensing boiler Generally intake and exhaust pipes should terminate at a rooftop or sterile wall loc...

Страница 8: ...enting system placed in operation while the other appliances remaining connected to the common venting system are not in operation Seal any unused opening in the common venting system Visually inspect...

Страница 9: ...6 PPs 110 C 230 F For long vent runs with higher initial exhaust temperature some jurisdictions may allow the use of mixed materials for economy CPVC for the initial run followed by ULC S636 approved...

Страница 10: ...sing a multiple of 2 1 eg 45 x 2 90 equivalent With 45 of 3 flex up to 116 equivalent of 3 rigid PPs would still be allowed 2 flexible PPs is not allowed EXHAUST PIPE SIZE MAXIMUM EQUIVALENT LENGTH Sc...

Страница 11: ...spective PPs manufacturer All vent connections must be liquid and pressure tight Prior to firing the boiler and before any of the venting run is concealed by the building construction the installer mu...

Страница 12: ...r a common penetration through a custom cap Alternatively place in the closest proximity achievable using commonly available pipe flashing Similarly group the exhaust pipes and place the 2 separate gr...

Страница 13: ...ithin 10 3 1m horizontally Clearance above paved sidewalk or paved driveway located on public property 7 2 2m Note Cannot terminate directly above a paved sidewalk or paved driveway that is located be...

Страница 14: ...ances Figure 10 Sidewall vent termination piping configuration CAUTION Vent termination clearances in this section are code minimum or IBC recommended minimum requirements and may be inadequate for yo...

Страница 15: ...th the vent pipe on top as shown in Figure 12 The vent pipe cannot be installed below the intake The vent cap must be installed with the openings directed up and down as shown in Figure 12 and not sid...

Страница 16: ...12 Allowed SST installation orientations Figure 15 Minimum separations for multiple vent installation horizontal orientation Figure 14 Minimum separation for multiple vent installation vertical orient...

Страница 17: ...PPs 3 Flexible 98 max actual lineal x 1 2 equivalent Table 4 Maximum exhaust venting length WARNING In addition to preventing ingestion of chemical contaminants care must be taken to ensure air intake...

Страница 18: ...ed herein is one in which air for combustion is taken from the ambient air around the boiler To support combustion an ample air supply is required This may require direct openings in the boiler room t...

Страница 19: ...e combustion air system according to the allowable intake length in Table 4 1 4 10 Closet Installations For installations in a confined space such as a closet ventilation openings may be needed throug...

Страница 20: ...ssion 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 Boiler...

Страница 21: ...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 to t...

Страница 22: ...AUTION 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 Figure 2...

Страница 23: ...ms that only have two loads or when loads are operating simultaneously The extremely low pressure drop through the SL Series heat exchanger allows many options not available in other designs In short...

Страница 24: ...quality is questionable a local water treatment expert must be consulted for testing assessment and if required treatment Alternatively water or hydronic fluid of known quality can be brought to the s...

Страница 25: ...ur 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...

Страница 26: ...pumps can be set to run up to 5 minutes after burner shutdown for the last calling load As shipped the default software will run the Boiler pump for 5 minutes to place the legacy heat where it is usef...

Страница 27: ...quire 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 experienced hydronic...

Страница 28: ...LATION AND OPERATION INSTRUCTIONS 1 24 SL 28 160 MODULATING GAS BOILER Figure 30 Primary Secondary with Indirect Domestic Hot Water Figure 29 Basic Primary Secondary piping with hydraulic separator co...

Страница 29: ...engthen 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 For maintenance of...

Страница 30: ...protected 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...

Страница 31: ...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 heat is requi...

Страница 32: ...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 measure gas pressure upstream supply pressur...

Страница 33: ...alve 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 The White Yellow pai...

Страница 34: ...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 switc...

Страница 35: ...plicable 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 he...

Страница 36: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 32 SL 28 160 MODULATING GAS BOILER THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 37: ...iguration 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 connectivity...

Страница 38: ...arder 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 Home scr...

Страница 39: ...3 1 STARTUP AND COMMISSIONING SL 28 160 MODULATING GAS BOILER STARTUP AND COMMISSIONING 3 0 3 1 LIGHTING AND SHUTTING DOWN THE BOILER clockwise open close...

Страница 40: ...in operation test the ignition system safety shutoff device by shutting the gas control valve immediately outside the boiler case Ensure boiler has shut off and the appropriate Error information is di...

Страница 41: ...corresponding CO2 values set for CO2 target at high fire 4 Confirm the minimum fire level settings Re define the load as Manual Control Use Heat Output in Configure Load x to control the output as nee...

Страница 42: ...refully 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 Us...

Страница 43: ...2 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 Phillips sc...

Страница 44: ...INSTALLATION AND OPERATION INSTRUCTIONS 3 6 SL 28 160 MODULATING GAS BOILER THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 45: ...essed 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 only nee...

Страница 46: ...der 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 of a qu...

Страница 47: ...e 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 contain...

Страница 48: ...ver Gas inlet connection on side Gas valve Gas supply line Ignition wire boot Fan housing Fan pressure sensing tube Fan pressure sensor Fan motor Ignition module Sight glass burner observation port GE...

Страница 49: ...re sensor bracket Inlet return water temperature sensor Ignition electrode flame sensor Removing vent stack test port plug Water pressure sensor Water temperature high limit switch Combustion air inta...

Страница 50: ...nd venturi 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 betwe...

Страница 51: ...n 6 0 for use with troubleshooting including Electrical Wiring Diagrams Sequence of Operations Flowchart Boiler Component Layout Diagrams PRELIMINARY CHECKS The first step in troubleshooting this syst...

Страница 52: ...rs remove 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 TE...

Страница 53: ...re should be very close to each other while the boiler is in operation If the required pressure is higher than the actual pressure there are several possible causes Exhaust and or Air Intake piping in...

Страница 54: ...gnite 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 illuminatio...

Страница 55: ...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 case b open burner th...

Страница 56: ...shuts 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 s...

Страница 57: ...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 probe is dry by re...

Страница 58: ...tting 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 specific...

Страница 59: ...CO2 level Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain Unit cycling on operating safety controls Check operation with O...

Страница 60: ...stat with 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 safe...

Страница 61: ...6 1 DIAGRAMS SL 28 160 MODULATING GAS BOILER 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS 6 3 SEQUENCE OF OPERATION...

Страница 62: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 2 SL 28 160 MODULATING GAS BOILER 6 1 PARTS DIAGRAMS Diagram 6 1 1 Boiler assembly parts SL 28 160 Modulating Boiler Parts assembly...

Страница 63: ...CLAMP 1 170 240 030 TEMPERATURE SWITCH MANUAL RESET 2 180 250 592 WATER PIPE BRACKET 2 190 250 452 SUPPLY PIPE 1 200 250 458 WATER PIPE GASKET 2 210 250 513 TEMPERATURE SWITCH BRACKET 1 220 240 031 T...

Страница 64: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 SL 28 160 MODULATING GAS BOILER Diagram 6 2 1 Ladder wiring diagram 6 2 WIRING DIAGRAMS...

Страница 65: ...hite 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 black bla...

Страница 66: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 6 SL 28 160 MODULATING GAS BOILER 6 3 SEQUENCE OF OPERATION Diagram 6 3 Sequence of operation diagram...

Страница 67: ...g Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner used ________________________________________________ System Fi...

Страница 68: ...uration Load 2 _____________________________________________________________________________________________ Load Definition Load 3 ____________________________________________________________________...

Страница 69: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Страница 70: ...NOTES...

Страница 71: ...NOTES...

Страница 72: ...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...

Страница 73: ...REVISION HISTORY R1 JULY 2014 Initial release R2 MAY 2015 Address update R3 FEBRUARY 2016 Added Stainless Sidewall Terminal direct venting details and Z DENS PPs appliance adapter information...

Страница 74: ...IBC Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 200E A R3 February 2016 IBC Technologies Inc 2016...

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