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INST

ALLA

TION AND OPERA

TING INSTR

UCTIONS

www.ibcboiler.com

SL 35-199, SL 45-260

MODULATING GAS BOILERS 

(Natural Gas or Propane)

WARNING: If the information in this manual is not followed exactly, a fire or 

explosion may result causing property damage, personal injury, or loss of life.

Do not store or use gasoline or other flammable vapours and liquids 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 your building.

• 

Immediately call your gas supplier from a nearby phone. Follow the gas 

supplier’s instructions.

• 

If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service 

agency or the gas supplier.

This Manual is also available in French - contact IBC or visit our web site www.ibcboiler.com

Содержание SL 35-199

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 72: ...NOTES...

Страница 73: ...NOTES...

Страница 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...

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

Страница 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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