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Secondary loop sensor to Master boiler

Check valve

Figure 46

Multiple boiler low loss header - piping concept

3.12 Gas piping

Note

Due to the precision of modern modulating boilers it is important to pay special
attention to gas pressure regulation.

Important:

Check gas supply pressure to each boiler with a manometer or other high-

quality precision measuring device. Pressure should be monitored before firing the
boiler, during operation throughout the boiler's full modulation range, and after the call
when the regulator is in a "lock-up" condition.

Pay special attention to retrofit situations where existing regulators may have an over-
sized orifice and/or worn seats, causing pressure “creep” and high lock-up pressures.

A high quality regulator will maintain constant pressure above the boiler’s minimum
specification at all firing rates, and will not exceed the boiler’s maximum pressure
rating when locked-up with no load.

56

Section: Installation

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Содержание SL SERIES

Страница 1: ...other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance If you smell gas Do not try to light any appliance Do not touch any electrical switch d...

Страница 2: ...the total water volume in the system A high water volume system with a low hardness count may cause as much damage as a system with less volume and higher hardness so it is recommended to treat water...

Страница 3: ...mply with all instructions and applicable national and local codes may result in hazardous conditions that could result in property damage and injury to occupants and in extreme cases to death Keep in...

Страница 4: ...e contained in component manufacturers manuals before installing starting up operating maintaining or servicing the appliance Warning Disconnect power supply before any wiring service is performed Fai...

Страница 5: ...g an existing boiler 15 3 3 Determining location of the appliance 16 Best installation conditions 17 3 4 Mounting the boiler 17 3 5 Connecting the vent and air intake pipes 18 3 6 Installation clearan...

Страница 6: ...65 Checklist for electrical conditions ducting and water connections 65 6 0 Boiler operation 67 6 1 Lighting and shutting down the boiler 67 6 2 Testing the ignition safety shutoff 68 6 3 Commissioni...

Страница 7: ...8 2 1 Maximum ignition trials error 93 8 2 2 Hi Limit cut off temperature error 94 8 2 3 Low Water Cut off error 94 8 2 4 Aux Interlock 1 or 2 94 8 3 Miscellaneous touchscreen controller errors 95 8...

Страница 8: ...Intentionally left empty...

Страница 9: ...0 Weight empty lbs Kg 85 39 85 39 102 46 3 152 69 Pressure vessel water content USG Litres 2 47 9 35 2 47 9 35 1 72 6 51 5 09 19 3 Maximum boiler flow rate USgpm 14 14 19 22 Minimum boiler flow rate U...

Страница 10: ...vent length each side vent air intake Natural gas or propane Air intake options either direct vent or indoor supply 100 2 240 3 100 2 240 3 35 2 170 3 Not applicable 150 3 Boilers are shipped with a...

Страница 11: ...Figure 2 Top view SL 10 85 G3 SL 14 115 G3 Figure 3 Bottom view SL 10 85 G3 SL 14 115 G3 SL 20 160 G3 Figure 4 Front and side view SL 20 160 G3 7 SL 20 160 G3...

Страница 12: ...Figure 5 Top view SL 20 160 G3 Figure 6 Bottom view SL 20 160 G3 SL 30 199 G3 Figure 7 Front and side view SL 30 199 G3 8 Section Specifications...

Страница 13: ...ications SL 10 85 G3 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 A Flue Outlet 3 Schedule 40 or 3 PPs 80mm B Combustion Air 3 Schedule 40 or 3 PPs 80mm C LCD Display 2 x 4 D Water Outlet 1 NPT M 1 NPT M 1...

Страница 14: ...Intentionally left empty...

Страница 15: ...from the front SL G3 residential boilers 1 1 Standard features and benefits High thermal efficiency Turn down ratio 10 to 1 Control of up to 5 pumps 1 boiler pump and 4 separate load pumps Outdoor re...

Страница 16: ...coverage 11 years 25 coverage IBC offers a limited heat exchanger warranty with no registration of 0 5 years 100 coverage For non residential applications IBC offers a 5 year warranty on all parts ag...

Страница 17: ...lt in damage to the area If there is no suitable location install a suitable drain pan under the boiler Do not install above carpeting At a new construction site or during renovations protect the appl...

Страница 18: ...eam plume normally at the exhaust terminal of a condensing boiler Generally intake and exhaust pipes should terminate at a rooftop or sterile wall location Boiler condensate is corrosive Protective me...

Страница 19: ...lers ANSI ASME CSD 1 If there is any conflict follow the more stringent regulations Table 2 Code requirements by country 3 2 Removing an existing boiler When an existing boiler is removed from a commo...

Страница 20: ...esigned and approved for indoor installation wall or rack mounting in areas such as an alcove basement or utility room These areas should have a surrounding temperature of 32 F 0 C to 122 F 50 C and l...

Страница 21: ...mer satisfaction Keep exhaust plumes well away from all building air intakes including those of neighboring properties Refer to Table 5 and Figure 19 in Sidewall vent termination on page 29 The minimu...

Страница 22: ...ket flange 4 Secure the lower part of the boiler to the wall with two field supplied bolts 3 5 Connecting the vent and air intake pipes These appliances offer 3 connections that accept standard 3 PVC...

Страница 23: ...tection Figure 11 Securing a pipe connection Warning Ensure that you lubricate the gasket with silicone grease before inserting the venting material Fully insert the approved venting material into the...

Страница 24: ...Venting condensate drainage and combustion air systems for all IBC boilers must be installed in compliance with all applicable codes and with instructions provided in the respective installation manu...

Страница 25: ...ilder or roofing contractor to ensure that materials are resistant to acidic condensate pH levels can be as low as 3 0 Covering non metallic vent pipe and fittings with thermal insulation is prohibite...

Страница 26: ...l general Use of cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenolsulfone in venting systems is prohibited Do not use ABS or any cellular core pipe for exhaust venting 3 7 4 Direct ve...

Страница 27: ...e g outdoors and the boiler should be isolated from interior dust sources Do not seal boiler case openings directly when firing See list of known contaminants on the Important safety instructions on p...

Страница 28: ...ping requirements Some local jurisdictions require a minimum initial length of pipe be exposed or accessible for inspection Pipe clearances no IBC requirements follow local codes All piping must be li...

Страница 29: ...ble pipe used for calculating total equivalent length are shown in the following table Vent Lengths Intake Exhaust Maximum Equivalent Length SL 10 85 G3 SL 14 115 G3 SL 20 160 G3 SL 30 199 G3 2 inch r...

Страница 30: ...xhaust Unequal intake and exhaust piping is allowed Support should be provided for intake and vent piping particularly for horizontal runs follow local code Example of equivalent length calculations f...

Страница 31: ...tting Leave unglued and hold in place with a short nipple This permits easy access for cleaning Do not exhaust vent into a common venting system b For rooftop direct vent systems Rooftop two pipe dire...

Страница 32: ...tration through a custom cap Alternatively place close together using commonly available pipe flashing Similarly group the exhaust pipes and place the two separate groups of pipes at least 3 feet apar...

Страница 33: ...ding envelope details must be examined carefully Take action to avoid moisture entering building structures Serious structural damage may occur if adequate precautions and clearances are not considere...

Страница 34: ...ce to each side of center line extended above meter regulator assembly 3 ft 91 cm within a height 15 ft above the meter regulator assembly I Clearance to service regulator vent outlet Above a regulato...

Страница 35: ...ure 21 Figure 22 and Figure 23 Failure to do so can result in a dangerous situation where exhaust gasses are re ingested with combustion air Damage to the boiler can result from a failure to maintain...

Страница 36: ...and off the sidewall for protection of wall A short piece of venting cut at 45 gives a horizontal termination protected from wind loads see Figure 20 Figure 21 and Figure 22 Recommend the use of a bir...

Страница 37: ...Figure 22 Sidewall vent termination configuration option 1 Figure 23 Sidewall vent termination configuration option 2 33 3 7 6 Sidewall vent termination...

Страница 38: ...minimum vent clearances listed in Table 5 Install the SST with the vent and intake pipes horizontally beside each other or vertically with the vent pipe on top see Figure 25 The vent pipe cannot be in...

Страница 39: ...ly Figure 27 Minimum separation for multiple vent installation vertical orientation Figure 28 Minimum separations for multiple vent installation horizontal orientation Caution Take care installing Con...

Страница 40: ...tdoors Combustion air in check air intake outside to make sure it is clear of obstructions Air intake filter check and clean air filter regularly Figure 30 Direct vent intake exhaust system with optio...

Страница 41: ...with water Failure to comply will result in severe personal injury or death Ensure the supplied trap is correctly installed and filled with water When required add and maintain in good condition a neu...

Страница 42: ...wing nuts and put aside 3 Fill the condensate trap with water and ensure that the bottom union cap is hand tightened to prevent leakage 4 Loosen the upper union nut and slide the trap over the boiler...

Страница 43: ...secure with the wing nuts 6 The drain hose should run to a suitable drain or condensate neutralizer Figure 31 Condensate trap drainage Flue gas exhaust Condensate and rain water flow back from venting...

Страница 44: ...nting systems and pressure vessel must be maintained at all times Trap and condensate drain piping must be accessible to allow regular inspection and cleaning 3 10 Installing a condensate neutralizer...

Страница 45: ...idic Do not use hands to stir material Refer to the neutralization instructions of the manufacturer Access to the discharge before the drain is necessary for proper maintenance in order to check the e...

Страница 46: ...tem with a low hardness count may cause as much damage as a system with less volume and higher hardness so it is recommended to treat water so as to remove all dissolved solids Other water chemistry a...

Страница 47: ...simplify the control application promote good loads and flow management installers must conform to the piping design configurations provided Propylene glycol usage Warning Do not use automotive type...

Страница 48: ...g Note The piping drawings in this manual are simple schematic guides to a successful installation For further information and details consult our concept drawings which provide detail on specific sin...

Страница 49: ...d by using a boiler regulator and fill valve set at 12 psig or more with the appropriate backflow prevention device as required by local code This is acceptable in areas where municipal water or well...

Страница 50: ...these devices Do not place any water connections above the boiler to avoid damage to the fan and controls If needed create a shield over the top of the cover but allow clearance for airflow and servic...

Страница 51: ...ependently supported and securely anchored so as to avoid applied stress on the valve Is as short and straight as possible Terminates freely to atmosphere where any discharge will be clearly visible a...

Страница 52: ...within the range 34 F to 180 F to meet three separately piped loads Use closely spaced tees to connect each pumped load e g DHW baseboards or radiant floor to the primary loop or employ the use of a h...

Страница 53: ...as close together as possible maximum four pipe diameters apart and there should be no restrictions between the fittings that would result in a pressure drop Heat Migration On secondary loops that ex...

Страница 54: ...itor the performance of system components when using the sequential load feature of the boiler to ensure that the components are compatible For instance many air handlers have a thermostat connection...

Страница 55: ...Optional Figure 38 Typical one temperature space heating piping concept Optional Thermostatic mixing valve Figure 39 Typical two temperature space heating piping concept 51 3 11 2 System piping...

Страница 56: ...ic tempering valve may be required by local code Indirect hot water tank Figure 40 Indirect domestic hot water piping concept Optional Thermostatic mixing valve Figure 41 Two sided piping DHW and spac...

Страница 57: ...piping concept 3 11 2 2 Parallel load piping Compared with the primary secondary approach the design below saves one pump Lost is the simplicity of constant head and flow at the boiler Air handler Fi...

Страница 58: ...Multiple IBC boilers can be installed in a single heating system to provide redundancy increased output and greater heating plant turn down capabilities Primary secondary piping must be employed and e...

Страница 59: ...and up to 23 additional boilers can be added to the system as Subordinate boilers by connecting a twisted pair of wires between the boilers No additional controls are needed Check valves are used in...

Страница 60: ...e should be monitored before firing the boiler during operation throughout the boiler s full modulation range and after the call when the regulator is in a lock up condition Pay special attention to r...

Страница 61: ...0 ft 600 ft SL 30 199 G3 Natural Gas 10 ft 40 ft 150 ft 600 ft SL 30 199 G3 Propane 30 ft 125 ft 400 ft 1 600 ft Table 9 Maximum Gas Pipe Length ft Gas piping must have a sediment trap ahead of the bo...

Страница 62: ...ld be installed in power supply wiring circuits Note The IBC boiler like any modern appliance that contains electronic equipment must have a clean power supply and is susceptible to power surges and s...

Страница 63: ...pumps the top pair for Load 1 the second pair for 2 etc Once the controller is programmed for the respective loads the boiler manages all the loads without need of further relays for loads up to 1 3...

Страница 64: ...m 1 2 3 4 location and the boiler automatically detects and calls a smart DHW routine One pair of contacts for remote secondary loop temperature control One pair marked BoilerNet for network connectio...

Страница 65: ...iant floor zone present a common thermostat signal to the controller Ensure that there are no disturbing influences on the call for heat lines for example that there are no coils to switch an air hand...

Страница 66: ...Figure 49 Electric wiring connections 62 Section Installation...

Страница 67: ...imultaneous operation of two similar water temperature loads Programmable setback override schedule The control can manage or operate in a network of up to 4 IBC boilers without additional controller...

Страница 68: ...s Do not use a sharp or metallic object such as a screw driver to operate the control as it could damage the touchscreen Prior to any interaction with the touchscreen the display shows the Home screen...

Страница 69: ...ore operating the appliance it is important to review the following checklist of precautions Checklist for electrical conditions ducting and water connections Checking electrical conditions Check Chec...

Страница 70: ...p is flowing in the correct direction Checking venting connections Check All connections are pressure tested and leak free All vent pipe is sized correctly and joints are sealed Powering on the boiler...

Страница 71: ...ocess see Sequence of Operation on page 103 6 1 Lighting and shutting down the boiler Start up Checklist Check Followed lighting and shutting down procedure Tested the ignition safety shutoff function...

Страница 72: ...shut off the gas control valve directly outside the boiler case 2 Ensure that the boiler has purged attempted to re light three times has shut off and the appropriate error information is displayed o...

Страница 73: ...r natural gas but needs to be converted to propane use the conversion kit sold separately by IBC to install the appropriate fitting s and adjust the gas valve accordingly See Table 10 for the required...

Страница 74: ...and O ring 7 Tighten the upper nut onto the gas valve 8 Place conversion labels associated with the new fuel onto the boiler 9 Turn on the gas supply and connect the electrical power 10 Check for gas...

Страница 75: ...oint or DHW This load should be large enough to allow the boiler to operate at high fire for over 10 minutes The gas pressure for natural gas should be around 7 w c at high fire and 11 w c for propane...

Страница 76: ...ake tiny adjustments may require several turns Turning the High Fire screw clockwise will lean out the flame 7 Set the heat out value in Test Operation mode to the minimum MBH for the boiler To do thi...

Страница 77: ...Low fire CO max PPM Range Target Range Target Natural Gas 9 0 10 0 9 5 8 2 9 2 8 7 150 Propane 10 3 11 3 10 8 9 3 10 3 9 8 250 Table 11 Combustion test target ranges CO2 Maximum CO Note Low Fire CO2 s...

Страница 78: ...Intentionally left empty...

Страница 79: ...r As needed Inspection of the boiler is to be performed annually by a qualified service technician Annually 7 2 Maintenance checklist for heating contractor Caution Label all wires prior to disconnect...

Страница 80: ...esult in a hazardous condition 7 2 2 General boiler maintenance Boiler Component Maintenance Required Frequency Check Condensate trap Remove and clean annually see Cleaning the condensate trap on page...

Страница 81: ...Other fouling agents include airborne dust debris and volatiles With the burner removed examine the heat exchanger for signs of contamination and clean if necessary Annually Boiler Pump Check that th...

Страница 82: ...nd non ferrous components as well as non metallic wet components normally found in hydronic systems Ethylene glycol is toxic and may be prohibited for use by codes applicable to your installation loca...

Страница 83: ...ain and safely dispose of equipment discharge The relief valve manufacturer requires that under normal operating conditions a try lever test must be performed every two months Under severe service con...

Страница 84: ...ssurize your system we recommend using a system pressurization appliance such as an Axiom Industries model SF100 series Capture the discharged fluid in a container and recycle it by returning it to th...

Страница 85: ...itor Fan coupler and gasket Screws nuts securing fan to fan coupler location of fan gasket Fan Upper nut orifice and O ring Lower nut behind bracket and gasket Gas valve electrical cable and screw Gas...

Страница 86: ...nd remove the orifice and O ring 7 To remove the gas valve unscrew the lower nut Ensure that the gasket remains inside the nut 8 Disconnect the electrical cable from the fan 9 Remove the screws or nut...

Страница 87: ...gas valve electrical cable remove the screw 5 Unscrew the upper nut of the gas valve 6 Carefully push down on the gas valve and remove the orifice and O ring 7 Unscrew the lower nut of the gas valve a...

Страница 88: ...irators Certified under 42 CFR 84 for selection and use of respirators certified by NIOSH For the most current information NIOSH can be contacted at 1 800 356 4676 or on the web at www cdc gov niosh 2...

Страница 89: ...e ignition cable and ground wire to the ignitor 4 Turn on the power and gas supply 5 Check for leaks 6 Tune the gas valve 7 4 Cleaning the condensate trap Warning If condensate neutralization is used...

Страница 90: ...s Note the orientation of the hose 2 Loosen the upper union nut and slide the condensate trap off the boiler drain outlet 3 Unscrew the condensate union cap at the base of the trap empty the water and...

Страница 91: ...over the boiler drain outlet and then tighten the upper union nut 7 To reinstall the trap pan tilt and slide the two tabs under the chassis of the boiler and secure with the two wing nuts 8 Ensure th...

Страница 92: ...Intentionally left empty...

Страница 93: ...he resistance of the temperature sensors varies inversely with temperature To test measure the temperature of the sensed environment and compare with the value derived from the measurement of the resi...

Страница 94: ...82 1 172 85 29 8 250 185 85 1 073 90 35 7 334 190 88 983 95 35 6 532 195 91 903 Table 12 Temperature sensor resistance values 10K ohms 8 1 2 Fan The fan is controlled via the SIM control The SIM provi...

Страница 95: ...and current measurement Supply water temperature sensing Flue gas temperature sensing Supply water maximum temperature shutdown Flue gas maximum temperature shutdown Low water cut off The SIM continu...

Страница 96: ...Troubleshooting error messages Warning Never attempt to repair the control module circuit board If the control module is defective replace it immediately Errors shown on the touchscreen controller are...

Страница 97: ...too small Adjust ignition probe rod gap between and 3 16th inch 3 2 4 7 mm Spark but no ignition Check that the spark module is sending power to the gas valve close the gas supply then disconnect the...

Страница 98: ...w Water Cut off error Low Water Cutoff Error Issue Diagnosis Fix Error Low Water Cutoff The Safety and Ignition module has detected a low water condition Refer to the V10 Touchscreen Controller manual...

Страница 99: ...Max Inlet Outlet Sensor Temp Exceeded Check water flow Water temperature signal not within acceptable range Potential flow or sensor failure Consult service technician Current outlet temperature exce...

Страница 100: ...l via analyzer Check for proper gas piping Check pressure with manometer during ignition Boiler will not attempt to ignite Fan and pump are operating normally No power to ignition control module Check...

Страница 101: ...evel Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain Appliance cycling on operating safety controls Check operation with Oh...

Страница 102: ...ostat manufacturer first then IBC for instructions Error Water High Limit Low Water Cutoff won t clear Boiler is in 1 hour safety lockout For instructions on clearing errors see the V10 Touchscreen Co...

Страница 103: ...red via keypad Check load maximum temps are above target temps by of the selected boiler differential Ensure boiler differential is OK 16 30 F is generally adequate Excess condensate in venting Check...

Страница 104: ...r pipe Check temperature differential across zone heat exchanger Low radiation Check actual amount of radiation per zone and refer to manufacturer s rating tables Appliance over fired Clock gas meter...

Страница 105: ...101 Appendices Wiring diagrams V 10 Controller electrical diagram Figure 52 Controller electrical diagram...

Страница 106: ...Internal wiring diagram Figure 53 Internal wiring diagram 102 Section Appendices...

Страница 107: ...Sequence of Operation Figure 54 Sequence of Operation 103 Sequence of Operation...

Страница 108: ...Duct 250 941 P 390 1 115 Intake Duct 250 942 P 391 1 120 Safety Ignition Module SIM 500 078 P 271B 1 125 Flue Temperature Sensor 240 132 P 361 1 135 Terminal Block Cover 250 825 1 140 V 10 Touchscree...

Страница 109: ...105 Exploded views of boiler parts...

Страница 110: ...212 Fan Gasket 250 627 1 215 Fan 240 114 P 310 1 216 Air Metering Insert 250 866 SL 10 85 G3 P 342 SL 14 115 G3 P 335 1 217 218 Venturi Insert SL 10 85 G3 240 123 SL 14 115 G3 240 124 1 220 Water Pipe...

Страница 111: ...ure Sensor Bushing 250 023 1 270 Return Water Pipe 250 454 1 275 Return Temperature Sensor 240 134 P 363 1 280 Condensate Trap 180 013 P 115 1 283 Condensate Trap Retainer 250 874 250 875 P 344 1 290...

Страница 112: ...ption Part Quantity 325 Ignitor Gasket 250 050 SL 10 85 G3 P 327 SL 14 115 G3 P 111B 1 330 331 Ignitor SL 10 85 G3 240 141 SL 14 115 G3 240 002 1 335 Ignitor Fan Coupler Screws 150 260 10 108 Section...

Страница 113: ...ke Duct 250 942 P 391 1 115 Safety Ignition Module SIM 500 078 P 271B 1 120 Flue Temperature Sensor 240 132 P 361 1 130 Side Terminal Block Cover 250 825 1 135 V 10 Touchscreen Controller 500 063 P 24...

Страница 114: ...110 Section Appendices...

Страница 115: ...0 555 1 225 Gas Tube 250 792 1 226 Orifice 650 NG 180 107 P 307 1 227 Orifice 505 LP 180 095 P 306 1 228 Orifice O ring 150 175 1 229 Gas Valve Union Nut 250 811 1 230 Water Pipe Gasket 250 458 2 235...

Страница 116: ...33 P 362 1 300 Refractory 250 762 P 317 1 305 High Limit Switch 240 030 1 315 Burner 180 187 P 313 1 320 Burner Gasket 255 069 P 378 1 325 Heat Exchanger Lid Gasket 255 029 P 374 1 330 Sight Glass Hou...

Страница 117: ...e Duct 250 942 P 391 1 116 Flue Temperature Sensor 240 132 P 361 1 120 Safety Ignition Module SIM 500 078 P 271B 1 135 Terminal Block Cover 250 825 1 140 V 10 Touchscreen Controller 500 063 P 242 1 14...

Страница 118: ...Item Description Part Quantity 200 Fan Coupler 250 749 P 347 1 205 Fan Coupler O ring 150 254 1 114 Section Appendices...

Страница 119: ...et 255 024 1 250 Venturi Insert 240 142 P 336 1 255 Gas Tube 250 792 1 265 Gas Valve 180 165 P 326B 1 266 Gas Line Gasket 150 271 1 275 Water Pipe Bracket 250 845 1 280 Return Water Pipe 250 834 P 370...

Страница 120: ...anger Lid Gasket 255 026 P 319 1 325 Refractory 250 761 1 330 Ignitor Gasket 250 050 P 111B 1 335 Ignitor 240 002 1 340 Sight Glass 250 059 P 107A 1 341 Sight Glass Gasket 255 025 1 342 Sight Glass Ho...

Страница 121: ...stem Filled type concentration of any glycol chemicals used _________________________ Air purge completed Relief Valve correctly installed and piped Relief valve try lever test performed Condensate tr...

Страница 122: ...Intentionally left empty...

Страница 123: ...s 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 water temperature a...

Страница 124: ...877 0277 T 856 877 0544 F 604 877 0295 F 856 735 5584 Toll Free 1 844 HEAT IBC 1 844 432 8422 www ibcboiler com Information in this document is subject to change without notice IBC assumes no responsi...

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