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  5. Installation And Operating Instructions Manual

IBC Technologies SL 80-399 Installation And Operating Instructions Manual

Manual is about: Modulating (Natural Gas or Propane)

Summary of SL 80-399

  • Page 1

    Inst alla tion and opera ting instr uctions www.Ibcboiler.Com sl 80-399 modulating gas boiler (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 gas...

  • Page 2: Safety Considerations

    Installation and operation instructions sl 80-399 modulating gas boiler safety considerations specifications 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. Installation, start-up and servici...

  • Page 3: Contents

    Installation and operation instructions sl 80-399 modulating gas boiler 1.0 installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 4

    Installation and operation instructions sl 80-399 modulating gas boiler the installer must carefully read this manual to ensure that all installation details can be adhered to. Special attention is to be paid to clearances and access, vent travel and termination, gas supply, condensate removal and c...

  • Page 5: Installation

    1-1 installation sl 80-399 modulating gas boiler installation 1.0 general sl80-399gas-firedmodulatingboilersarelowpressure,fullycondensing units having a variable input range from 80 mbh to 399 mbh (0 to 8,000’). The boilers are approved as “category iv” vented appliances using either direct vent (s...

  • Page 6

    Installation and operation instructions 1-2 sl 80-399 modulating gas boiler code requirements thesl80-399boilerwastestedtoandcertifiedundercsa4.9-2010/ansi z21.13-2010. Installation must conform to local codes, or in the absence of these, with the latest editions of can/cga b149 and the canadian ele...

  • Page 7

    1-3 installation sl 80-399 modulating gas boiler contaminants; combustion air should be drawn from a clean source (e.G. Outdoors) and the boiler should be isolated from interior dust sources. Do not seal boiler case openings directly when firing - allow for air circulation and ventilation in the imm...

  • Page 8

    Installation and operation instructions 1-4 sl 80-399 modulating gas boiler all venting must be installed in accordance with the requirements of the jurisdiction having authority: in canada, part 8, venting systems of the b149.1- 10 code and any other local building codes are to be followed. In the ...

  • Page 9

    1-5 installation sl 80-399 modulating gas boiler • place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. • after it has been determined that each appliance remaining connected to the common venting system properl...

  • Page 10

    Installation and operation instructions 1-6 sl 80-399 modulating gas boiler do not use abs or any cellular core pipe for exhaust venting. The boiler offers 4" venting connections. Fittings are to be used to adapt to the appropriate diameter – see vent travel below. Exhaust venting is to be inserted ...

  • Page 11

    1-7 installation sl 80-399 modulating gas boiler allventconnectionsmustbeliquidandpressuretight.Priortofiringtheboiler, and before any of the venting run is concealed by the building construction, the installer must test the exhaust joints under fan pressure with the vent blocked, usingasoap/waterso...

  • Page 12

    Installation and operation instructions 1-8 sl 80-399 modulating gas boiler 1.4.6 sidewall vent termination sidewall direct vent applications shall be vented as follows: • both the inlet and exhaust terminations should normally be located on the same plane (side) of the building. • the exhaust outle...

  • Page 13

    1-9 installation sl 80-399 modulating gas boiler sidewall indoor combustion air applications shall be vented as follows: • the exhaust outlet is to be placed 18” minimum (12” in usa) above the grade or anticipated snow level. • theventshallbeterminatedwithateefittingasillustrated-see figure 6. • bir...

  • Page 14

    Installation and operation instructions 1-10 sl 80-399 modulating gas boiler • ventsmustbeinstalledsuchthatfluegasdoesnotdischargetowards neighbor’s windows, or where personal injury or property damage can occur. • it is important to ensure proper condensate management from vent terminations. Conden...

  • Page 15

    1-11 installation sl 80-399 modulating gas boiler 1.4.7 “direct vent” combustion air intake piping there are two basic methods of supplying combustion air to an ibc boiler. The direct vent option uses piping from the outside to supply combustion air directly to the boiler’s combustion air connection...

  • Page 16

    Installation and operation instructions 1-12 sl 80-399 modulating gas boiler 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 around the boiler. To support combustion, an ample air ...

  • Page 17

    1-13 installation sl 80-399 modulating gas boiler note combustion fan blockages can occur when environmental particulate and foreign matter contaminants (leaves, dust, dandelion & cottonwood fluff, etc) are drawn into the air intake. In areas where this problem is suspected to be an issue, intake ai...

  • Page 18

    Installation and operation instructions 1-14 sl 80-399 modulating gas boiler 1.5.2 condensate trap assembly installation 1. Undo drain spout compression nut (d),remove drain spout (c) from condensate drain outlet (e) of trap body (a). 2. Loosen upper compression nut (b) and place the nut and trap bo...

  • Page 19

    1-15 installation sl 80-399 modulating gas boiler warning if condensates are 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 condensate discharge m...

  • Page 20

    Installation and operation instructions 1-16 sl 80-399 modulating gas boiler water piping 1.6.1 general piping issues the sl modulating series boilers are designed for use within a closed loop, forced circulation, low pressure system. A 30 psi pressure relief valve (3/4" npt) issuppliedforfieldinsta...

  • Page 21

    1-17 installation sl 80-399 modulating gas boiler do not place any water connections overhead the boiler; leaks can damage the fan & controls. If needed, create a shield over the top of the cover, but allow clearanceforairflowandserviceaccess. For best results, use a primary: secondary piping system...

  • Page 22

    Installation and operation instructions 1-18 sl 80-399 modulating gas boiler legacy heat where it is useful. Any secondary pump can be set to run for 0 – 300 seconds in the heat purge mode. Guard against deadheading pumps when all zone valves are closed (see section 2.7 set up & load definition). Th...

  • Page 23

    1-19 installation sl 80-399 modulating gas boiler if the installation involves small loads, as in typical zoned baseboard heating applications, use of a buffer tank is recommended. To aid in temperature transition from hot to cool loads, a 3-way mixing valve can be placed at the entrancetothecoolloa...

  • Page 24

    Installation and operation instructions 1-20 sl 80-399 modulating gas boiler note this piping drawings in this manual are simple schematic guides to a successful installation. There are many necessary components not shown, and details such as thermal traps are left out so the drawings have greater c...

  • Page 25

    1-21 installation sl 80-399 modulating gas boiler note when using the sequential load feature of the ibc boiler, attention must be paid to the operation of system components in order to ensure they are compatible. Many air handlers (fan coils) for instance have a thermostat connection that will ener...

  • Page 26

    Installation and operation instructions 1-22 sl 80-399 modulating gas boiler gas piping the boiler requires an inlet gas pressure of at least 5.0" w.C. For natural gas or propane. For either fuel, the inlet pressure shall be no greater than 14.0" w.C. Confirmthispressurerangeisavailablewithyourlocal...

  • Page 27

    1-23 installation sl 80-399 modulating gas boiler removing wiring box cover line voltage power block terminals line voltage pump block terminals electrical connections all electrical wiring to the boiler (including grounding) must conform to local electrical codes and/or national electrical code, an...

  • Page 28

    Installation and operation instructions 1-24 sl 80-399 modulating gas boiler 1.8.3 zone valve hook-up if 24vac zone valves rather than pumps are used to manage multiple heating loads(mustbethree-waydivertingvalvestomaintainboilerflow),thenthe 115vac wires on the pump terminal block (terminals 11 and...

  • Page 29

    1-25 installation sl 80-399 modulating gas boiler figure 30: electrical wiring connections (full page ladder diagram at back of this manual).

  • Page 30

    Installation and operation instructions 1-26 sl 80-399 modulating gas boiler this page intentionally left blank.

  • Page 31: Boiler Systems and Operation

    2-1 boiler systems and operation sl 80-399 modulating gas boiler boiler systems and operation 2.0 2.1 general the sl 80-399 modulating boiler is designed to service light-to-medium commercial space and domestic water heating loads. Typically, a single space heating load will be managed using either ...

  • Page 32

    Installation and operation instructions 2-2 sl 80-399 modulating gas boiler 2.3.2 lcd display uponpower-up,thelcdscreeninitiallyflashesasoftwarereleasenumber then switches to a standby- display mode, showing real time data plus key temperature target settings. Whenthereisacallforheatfromanyload,that...

  • Page 33

    2-3 boiler systems and operation sl 80-399 modulating gas boiler 2.4.1 user setup the occupant has access to a number of practical settings. The most meaningful include adjustment of the indoor temperature target plus the temperature setback and occupied / unoccupied modes. The user menu also provid...

  • Page 34

    Installation and operation instructions 2-4 sl 80-399 modulating gas boiler sequence of operation the control module has 5 cycles during normal operation, as well as an error mode for problem detection: 1. Standby cycle 2. Purging 3. Ignition cycle 4. Heating cycle 5. Circulating cycle 6. Error mode...

  • Page 35

    2-5 boiler systems and operation sl 80-399 modulating gas boiler the pump remains on for 5 minutes (adjustable) after the heating cycle ends. If the heating cycle ends as a result of water temperature exceeding the load specificbandlimit,the postpurge will continue as normal, but the boiler will ent...

  • Page 36

    Installation and operation instructions 2-6 sl 80-399 modulating gas boiler the pump remains on until the loop drops ½ the differential below the new load target temperature. Note: if there is no place to sink heat during such circ. Mode, thisphasewillcontinueindefinitely,affectingheatdelivery. Ther...

  • Page 37

    2-7 boiler systems and operation sl 80-399 modulating gas boiler minutes, for the initial cycle) of the higher load setting before switch-over to the simultaneously calling load, e.G. Dhw with priority set to 80 will run for approx. 35 min. Before switching to a clashing load set with priority 45. F...

  • Page 38

    Installation and operation instructions 2-8 sl 80-399 modulating gas boiler note that typical room thermostats simply provide a call for heat, they do not control the circulating water temperature from the boiler in an open loop reset system. Adjustment of a room thermostat from 23°c to 30°c will ma...

  • Page 39

    2-9 boiler systems and operation sl 80-399 modulating gas boiler the automated setback feature cannot be applied to setpoint loads, including dhw with simple aquastat control. This is due to the lack of linkage with the thermostat; setback without linkage could lead to unacceptable cycling. Access i...

  • Page 40

    Installation and operation instructions 2-10 sl 80-399 modulating gas boiler set up & load definition after the boiler is powered up, the installer can use the keypad and display to characterize the application, as follows: 1. In the standby mode, start by pressing any key to call up the main menu. ...

  • Page 41

    2-11 boiler systems and operation sl 80-399 modulating gas boiler use the summer shutdownfieldtoenterathresholdtemperatureforthe avoidance of heating during warmer times. This is typically set at 60° to 65°f so as to eliminate excessive boiler cycling in marginal heating conditions. Use the minimum ...

  • Page 42

    Installation and operation instructions 2-12 sl 80-399 modulating gas boiler 17. Upon completion of the input of load parameters, use the left button to step back through the menu system to return to the operating status screen. 18. To enact the control arrangements as input, it is necessary that th...

  • Page 43: Startup and Commissioning

    3-1 startup and commissioning sl 80-399 modulating gas boiler startup and commissioning 3.0 3.1 lighting and shutting down the boiler.

  • Page 44

    Installation and operation instructions 3-2 sl 80-399 modulating gas boiler 3.2 prior to start-up 3.2.1 pre-ignition checks 1. Ensureventingsystemiscompleteandsealtested.Confirmanycommon venting system at the installation site is isolated and independent of the sl boiler, that any holes left from re...

  • Page 45

    3-3 startup and commissioning sl 80-399 modulating gas boiler 4. Withacombustionanalyzerprobeinthefluegastestport,turnthegas:air ratio adjustment screw (see figure 28, “b”) to achieve 25% excess air (corresponding co2 values are 9.4% for natural gas and 10.7% for propane). Thisscrewoffersveryfineadj...

  • Page 46

    Installation and operation instructions 3-4 sl 80-399 modulating gas boiler 3.3.1 gaining access to combustion chamber, burner removal instructions 1. Remove fan and gas valve assembly. See “fan and gas valve removal instructions” on page 4-6 of this manual. 2. Disconnect the igniter cable and move ...

  • Page 47: Maintenance

    4-1 maintenance sl 80-399 modulating gas boiler maintenance 4.0 boiler maintenance 4.1.1 general care • keepcombustiblematerialsandflammableliquidsandvapoursawayfromthe boiler. • keep vent terminals clear of obstructions (snow, dirt, etc.). 4.1.2 inspection inspection of the boiler is to be performe...

  • Page 48

    Installation and operation instructions 4-2 sl 80-399 modulating gas boiler 4.1.6 heat exchanger during annual inspection (with the burner removed), examine the heat exchanger for signs of contamination and clean if neccessary. In areas of poor gas quality, there may be a buildup of black plaque (ty...

  • Page 49

    4-3 maintenance sl 80-399 modulating gas boiler 4.1.12 boiler treatment • check consistency of any boiler treatment used, for appropriate mixture. Chemical inhibitors are consumed over time, lowering their density. • verify proper operation after servicing. 4.1.13 relief valve - maintenance and test...

  • Page 50

    Installation and operation instructions 4-4 sl 80-399 modulating gas boiler geography & components 4.2 fan air pressure reference tube turn cover button counter clock wise to loosen cover tilts back, then lift up and off clear access to front components clear access to top components lift top cover ...

  • Page 51

    4-5 maintenance sl 80-399 modulating gas boiler sight glass (inspection port) burner flange bolts fan flange bolts tridicator gauge on supply riser upper vessel high limit switch on pressure vessel upper support bracket ignitor cable connected to ignitor manual reset water high limit switch on suppl...

  • Page 52

    Installation and operation instructions 4-6 sl 80-399 modulating gas boiler 4.2.1 fan and gas valve removal instructions 1. Turn off electric power and gas supply to the boiler. 2. Ensure boiler cools down to ambient temperature. Do not drain the boiler unless freezing conditions are expected during...

  • Page 53: 5.0 Troubleshooting

    5-1 troubleshooting sl 80-399 modulating gas boiler 5.0 troubleshooting the troubleshooting section is divided into 3 sections: 5.1 preliminary checks 5.2 electronic components 5.3 troubleshooting guide often,aproblemcanbeidentifiedandsolvedthroughsimplechecksofthe basics:confirmingtheelectricalpowe...

  • Page 54

    Installation and operation instructions 5-2 sl 80-399 modulating gas boiler electronic components this section details the method for troubleshooting the non-standard electronic components on the boiler including the electronic differential air pressure sensor and the temperature sensors. 5.2.1 temp...

  • Page 55

    5-3 troubleshooting sl 80-399 modulating gas boiler 5.2.2 fan/blower operating power is provided by means of a separate 115 vac connector at the bottom of the fan (white/black/green). Control of the fan is provided via a four lead connector at the top of the fan. This connector feeds a pwm control s...

  • Page 56

    Installation and operation instructions 5-4 sl 80-399 modulating gas boiler next,confirmthatthecircuitisproperlypowered.Thesupplyvoltagetothe sensor should be 13.8 vdc; to check, the simplest technique is to measure the circuit on the face of the controller circuit board (vs. An attempt to splice in...

  • Page 57

    5-5 troubleshooting sl 80-399 modulating gas boiler 5.3 troubleshooting guide symptom diagnosis remedy airflow error lcd screen message: error – insufficient air flow insufficient combustion airflow; soft error; will retry in 5 minutes check fan operation • checkleadisattachedatfan. • cyclepoweroff/...

  • Page 58

    Installation and operation instructions 5-6 sl 80-399 modulating gas boiler symptom diagnosis remedy maximum ignition trials error lcd screen message: error – ignition failure after 3 tries boiler has failed to ignite on 3 successive attempts. Boiler in lockout for 1 hour, then repeats 3-try seq. Co...

  • Page 59

    5-7 troubleshooting sl 80-399 modulating gas boiler symptom diagnosis remedy vent hi-limit error lcd screen message: error - vessel/vent high-limit exceeded *** call for service! Vent temperature has exceeded the vent limit switch or the upper vessel high limit has been tripped. Boiler in lockout. C...

  • Page 60

    Installation and operation instructions 5-8 sl 80-399 modulating gas boiler 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-running post-purge; otherwise...

  • Page 61

    5-9 troubleshooting sl 80-399 modulating gas boiler 5.3.3 cycling problems symptom diagnosis remedy rapid cycling improper values entered via keypad. Check load maximum temps are above target temps, by 1/2 of the selected boiler differential. Ensure boiler differential is ok (16-30°f is generally ad...

  • Page 62

    Installation and operation instructions 5-10 sl 80-399 modulating gas boiler symptom diagnosis remedy insufficient heat operating temperature too low. Increase temperature target. See section 2.7 priority parameters or load configuration improperly set up. Reviewloadconfigurationparameters.See secti...

  • Page 63

    5-11 troubleshooting sl 80-399 modulating gas boiler 5.3.5 miscellaneous symptom diagnosis remedy fumes and high humidity improperly installed condensate trap refer to installation/operation instructions leak in vent piping inspect using soap solution flue gas leak within boiler visually inspect all...

  • Page 64

    Installation and operation instructions 5-12 sl 80-399 modulating gas boiler this page intentionally left blank.

  • Page 65: 6.0 Diagrams

    6-1 diagrams sl 80-399 modulating gas boiler 6.0 diagrams 6.1 - parts diagrams 6.2 - wiring diagrams 6.3 - sequence of operation.

  • Page 66

    Installation and operation instructions 6-2 sl 80-399 modulating gas boiler 6.1 parts diagrams diagram 6.1-1: boiler assembly parts sl 80-399 modulating boiler - parts assembly.

  • Page 67

    6-3 diagrams sl 80-399 modulating gas boiler diagram 6.1-2: boiler assembly parts list (refer to diagram 6.1-1 on opposite page.

  • Page 68

    Installation and operation instructions 6-4 sl 80-399 modulating gas boiler 6.2 wiring diagrams diagram 6.2-1: ladder wiring diagram.

  • Page 69

    6-5 diagrams sl 80-399 modulating gas boiler diagram 6.2-2: multi-boiler “boiler net” wiring diagram.

  • Page 70

    Installation and operation instructions 6-6 sl 80-399 modulating gas boiler diagram 6.2-3: internal wiring diagram.

  • Page 71

    6-7 diagrams sl 80-399 modulating gas boiler 6.3 sequence of operation diagram 6.3: sequence of operation diagram.

  • Page 72

    Installation & commissioning report boiler details: model number _____________________ serial number ______________________________________________ date of installation ______________ address of installation __________________________________________ _________________________________________________...

  • Page 73

    Service record date licensed contractor description of work done installer set-up load definition - load #1 _______________________________________________________________________ load configuration - load #1 ___________________________________________________________________________________________...

  • Page 74

    Notes.

  • Page 75

    Notes.

  • Page 76

    Ibc technologies inc. 1543 venables street, vancouver, bc canada v5l 2g8 tel: 604.877.0277 fax: 604.877.0295 www.Ibcboiler.Com 120-111e-a-r2.