IBC SL 30-175 Installation And Operating Instructions Manual
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IBC SL 30-175 Installation And Operating Instructions Manual

Modulating gas boiler (natural gas or propane)
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MODULATING GAS BOILER
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
SL 30-175
(Natural Gas or Propane)
www.ibcboiler.com

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  • Page 1 • 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 www.ibcboiler.com...
  • Page 2 Supplied with the boiler - The IBC boiler is shipped with an accessory parts kit consisting of the following items: • 1 x Wall mounting bracket •...
  • Page 3 SL 30-175 MODULATING GAS BOILER SPECIFICATIONS SPECIFICATION SL 30-175 CSA Input (Natural Gas or Propane*) - MBH 30 - 175 CSA Input (Natural Gas or Propane*) - kW 8.8 - 51.3 CSA Output - MBH 29 - 161 CSA Output - kW 8.4 - 47.2...
  • Page 4 SL 30-175 MODULATING GAS BOILER THIS PAGE INTENTIONALLY LEFT BLANK INSTALLATION AND OPERATION INSTRUCTIONS...

  • Page 5: Table Of Contents

    IBC BOILER CONTROLLER ........
  • Page 6 SL 30-175 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 combustion air supply.

  • Page 7: Installation

    2-1/4” x 4” Water Outlet 1-1/2” NPT-M Water Inlet 1-1/2” NPT-M Knock-outs (8) 1/2” Gas Inlet 3/4” NPT-F Condensate Outlet 3/4” Hose Table 1: Connections Figure 1a: Dimensions / Connections for SL 30-175 Figure 1b: Dimensions / Connections for SL 30-175 INSTALLATION...

  • Page 8: Code Requirements

    SL 30-175 MODULATING GAS BOILER CODE REQUIREMENTS The SL 30-175 model was tested to and certified under CSA 4.9-2014 / ANSI Z21.13-2014. Installation must conform to local codes, or in the absence of these, with the latest editions of CAN/CGA B149.1 and the Canadian Electrical Code Part 1 CSA C22.2 No. 1. In the US, installations must conform to the current National Fuel Gas Code ANSI Z223.1 and the National Electrical Code ANSI/NFPA 70.

  • Page 9: Exhaust Venting And Air Intake

    SL 30-175 MODULATING GAS BOILER DISTANCE FROM RECOMMENDED DISTANCE FOR WARNING SURFACE COMBUSTIBLE INSTALLATION AND SURFACES SERVICE Exposed water piping and associated components Front 2" 24" (relief valves, circulators, etc.) Rear 0" 0" should not be in contact with Left Side 1"...
  • Page 10 SL 30-175 MODULATING GAS BOILER All venting must be installed in accordance with the requirements of the WARNING 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 USA Venting, condensate the National Fuel Gas Code, ANSI 223.1, latest edition, prevails.
  • Page 11 (e.g. boiler room, attic and/or chase). EXHAUST VENT MATERIAL – USA IBC strongly recommends that only CPVC or PPs vent component systems approved under UL1738 (Standard for Venting Sustens for Gas Burning Appliances, Categories II, III and IV), ULC-S636 Standard for Type BH Gas Venting Systems, or stainless steel Type BH venting systems* are to be used but many local jurisdictions in the USA still allow the use of PVC (Sch.
  • Page 12 SL 30-175 boiler, for example, can be sited up to 200 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 the SL 30-175 boiler using 6 x 90º CPVC elbows, the maximum lineal measure of pipe allowed using 3” pipe is 152 feet (200’...
  • Page 13 Some local jurisdictions require a minimum initial length of pipe be exposed or accessible for inspection. • Pipe clearances - no IBC requirements, but best practice allows a minimum 1/4” open gap around the pipe to prevent binding and expansion noise; follow local codes.
  • Page 14 3’ apart (the closest intake and exhaust pipes shall be 36” - or more - apart). Use the same 24” (minimum) vertical separation for 2 pipe option. For alternate group terminations, contact the IBC Factory for written guidance. • DO NOT exhaust vent into a common venting system.
  • Page 15 SL 30-175 MODULATING GAS BOILER • The exhaust outlet is to be placed so as to reach 24” minimum above the WARNING down-turned intake - to avoid intake re-ingestion of exhaust gases. It is extremely important • The elevation of both pipes can be raised in “periscope style” after passing to maintain at least the through the wall, then configured as in Figure 5, to gain required clearance.
  • Page 16 SL 30-175 MODULATING GAS BOILER Figure 9: Sidewall vent termination - multiple vent piping configuration Vent terminal clearance minimums are as follows: • Clearance above grade, veranda, porch, deck or balcony – 12” (0.3m), but check local code also (anticipated snow levels may supersede).
  • Page 17 • Clearance under veranda, porch, deck or balcony: - 12” (0.3m) IBC strongly recommends a minimum of 24” with the SL 30-175 to avoid damage to the structure. Note: Prohibited unless fully open on a minimum of two sides below the floor.
  • Page 18 SL 30-175 MODULATING GAS BOILER EXHAUST PIPE SIZE MAXIMUM EQUIVALENT LENGTH Sched.40; Rigid PPs 3” 200’ 4” 200’ 90° long sweep elbow allow 5’ equivalent 90° vent elbow allow 8’ equivalent 45° elbow allow 3’ equivalent PPs 87-90° elbows use 8’ equivalent Flexible PPs 3”...
  • Page 19 SL 30-175 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. NOTE To support combustion, an ample air supply is required. This may require Combustion fan direct openings in the boiler room to the outside.

  • Page 20: Condensate Removal

    SL 30-175 MODULATING GAS BOILER CONDENSATE REMOVAL IBC’s specified vent configuration promotes the safe drainage of moisture from WARNING the boiler and exhaust venting without flowing liquids back through the heat exchanger (as done by some other condensing boilers). Fill trap with water before Reliable system operation requires (1) proper design and installation of exhaust boiler is first fired to prevent venting to allow condensate to run back to the drain/trap;...
  • Page 21 SL 30-175 MODULATING GAS BOILER 1.5.3 Condensate Trap Assembly - cleaning procedure Turn off the power to the boiler and allow it to cool down. Remove the trap from the boiler (reverse the installation procedure above). Remove the Trap Cleanout Assembly (H), from the Trap Body and clean and flush the debris out.
  • Page 22 SL 30-175 MODULATING GAS BOILER Figure 16: Condensate trap disassembly for cleaning Figure 17: Condensate trap drainage WARNING If condensates are to be discharged into building drain piping materials that are subject to corrosion, a neutralization package must be used.

  • Page 23: Water Piping

    In short – IBC has built a boiler that will allow you to pipe the system the way you prefer, rather than try and dictate your piping practices from boiler to radiator.
  • Page 24 For best results, use a Primary: Secondary piping system, with a pumped boiler flow control valves or other loop using 1-1/2” piping for the SL 30-175. Heat exchanger head is only 2’ at 6 automatic means to prevent USgpm and approximately 13’ at 25 USgpm.
  • Page 25 SL 30-175 MODULATING GAS BOILER The minimum flow rate required through the heat exchanger is 6 USgpm with a WARNING maximum of 25 USgpm allowed. Primary/Secondary piping ensures adequate flow and de-couples Δ°T issues (boiler vs. distribution). Aim for a 20° to 30° F Δ°T Water quality has a significant across the heat exchanger at high fire (there is a boiler protection throttle fence impact on the lifetime and limiting the Δ°T to 40°F). performance of an IBC Boiler heat exchanger. The SL Series modulating boilers are designed to supply four different heating loads with temperatures within the range 34°F to 185°F - to meet four separately...
  • Page 26 SL 30-175 MODULATING GAS BOILER NOTE The 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 clarity.
  • Page 27 SL 30-175 MODULATING GAS BOILER Figure 25: Basic Primary/Secondary piping with hydraulic separator concept Figure 26: Primary/Secondary with Indirect Domestic Hot Water 1-21 INSTALLATION...
  • Page 28 SL 30-175 MODULATING GAS BOILER Propylene glycol solution is commonly used in a closed loop where freeze WARNING protection is required. Its density is lower than that of water, resulting in lower thermal performance at a given flow and pressure. As a rule of thumb, Do not use automotive-type a 50%:50% solution of propylene glycol and water will require an increased...
  • Page 29 SL 30-175 MODULATING GAS BOILER The use of the multi-temperature modulating system is optimized when the need NOTE to shutdown the boiler is reduced or eliminated during the transitional period. System design enhancements: (a) keep a relatively low thermal mass in the Load Combining is now primary loop, and (b) incorporate a 3-way mixing valve on the “cool”...
  • Page 30 MULTIPLE BOILER PIPING - BENEFITS AND INSTALLATION RULES (available at www.ibcboiler. com or from your IBC Multiple IBC boilers can be installed in a single heating system to provide Representative). redundancy, increased output, and greater heating plant turn-down capabilities. Primary/Secondary piping must be employed, and each boiler must be installed with its own pump as illustrated below.

  • Page 31: Gas Piping

    SL 30-175 MODULATING GAS BOILER 1.7 GAS PIPING The boiler should have an inlet gas pressure of at least 5.0" w.c. for natural gas WARNING or propane. For either fuel, the inlet pressure shall be no greater than 14.0" w.c.

  • Page 32: Electrical Connections

    SL 30-175 MODULATING GAS BOILER ELECTRICAL CONNECTIONS All Electrical wiring to the boiler (including grounding) must conform to local electrical codes and/or National Electrical Code, ANS/NFPA No. 70 – latest edition, or The Canadian Electrical Code, C22.1 - Part 1.
  • Page 33 Sensors connected to any sensor input contacts must be of NTC to connect to most power Thermister - type with a resistance of 10,000 ohms at 25°C and β = 3892. We do stealing thermostats. See the not recommend using 3rd party supplied sensors. Compatible water temperature Wiring Diagram for details. sensors and outdoor sensors can be supplied by your IBC distributor. 1-27 INSTALLATION...
  • Page 34 SL 30-175 MODULATING GAS BOILER 1.8.6 Thermostat Heat Anticipator IBC “Therm.” contacts draw no power, so an anticipator setting for the thermostat 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 room thermostat’s heat anticipator should...

  • Page 35: Ibc Boiler Controller

    Load Combining – simultaneous operation of 2 similar water temperature loads • The control can manage and/or operate in a network of up to 24 IBC VFC or SL boilers Some of the new features available in the touch screen control include: •...

  • Page 36: Control Interface

    SL 30-175 MODULATING GAS BOILER Operational and historical data may be accessed at any time using the System Status and Load Profiles sections of the control. Error logs are available in the Diagnostics section and the controller is capable of recording any or all errors since original power-up complete with the date and time of the error.

  • Page 37: Startup And Commissioning

    SL 30-175 MODULATING GAS BOILER STARTUP AND COMMISSIONING 3.1 LIGHTING AND SHUTTING DOWN THE BOILER clockwise open close STARTUP AND COMMISSIONING...

  • Page 38: Prior To Start-Up

    Error displayed after testing ignition safety shut off COMMISSIONING The SL 30-175 modulating boiler is factory calibrated to operate with natural DANGER gas (or propane if so ordered) at sea level. The Low Fire (Zero Offset) valve adjustment cap has been factory sealed using paint-seal compound. This cap Making adjustments to must not be tampered with.
  • Page 39 SL 30-175 (Natural Gas) CO 9.1 – 9.7 8.4 – 9.0 SL 30-175 (Propane) CO 10.5 – 11.1 10.8 9.4 – 10.2 Table 7: Combustion test target ranges - CO / Maximum CO Figure 31: SL 30-175 Gas Valve Adjust STARTUP AND COMMISSIONING...

  • Page 40: Fuel Conversion

    SL 30-175 MODULATING GAS BOILER FUEL CONVERSION The SL 30-175 modulating boiler is factory fire-tested to operate with natural gas, WARNING or propane as ordered. The rating plate will be marked to indicate which fuel the particular boiler has been set up with. Firing a boiler with a fuel other than what is...
  • Page 41 SL 30-175 MODULATING GAS BOILER 3.4.1 Gaining access to combustion chamber, burner NOTE removal instructions The safety warning regarding Remove fan and gas valve assembly. See “Fan and gas valve removal burner refractory on page instructions” on page 4-6 of this manual.
  • Page 42 SL 30-175 MODULATING GAS BOILER PAGE INTENTIONALLY LEFT BLANK INSTALLATION AND OPERATION INSTRUCTIONS...

  • Page 43: Maintenance

    SL 30-175 MODULATING GAS BOILER MAINTENANCE BOILER MAINTENANCE 4.1.1 General Care CAUTION • Keep combustible materials and flammable liquids and vapours away from the The owner is responsible for boiler. general care of the boiler. • Keep vent terminals clear of obstructions (snow, dirt, etc.). Improper maintenance of the boiler may result in a hazardous condition.
  • Page 44 SL 30-175 MODULATING GAS BOILER 4.1.6 Heat Exchanger CAUTION During annual inspection (with the burner removed), examine the heat exchanger The heat exchanger has a for signs of contamination and clean if necessary. In areas of poor gas quality, small amount of combustion there may be a buildup of black plaque (typically sulfur).
  • Page 45 SL 30-175 MODULATING GAS BOILER 4.1.12 Boiler Treatment WARNING • Check consistency of any boiler treatment used, for appropriate mixture. Do not use automotive-type Chemical inhibitors are consumed over time, lowering their density. ethylene or other types of • Verify proper operation after servicing.

  • Page 46: Geography & Components

    SL 30-175 MODULATING GAS BOILER GEOGRAPHY & COMPONENTS NOTE Vent stack piping and air intake riser have been removed in some of these photos for clarity Fan housing Removing front cover Gas valve Fan motor Removing top service cover Ignition module...
  • Page 47 SL 30-175 MODULATING GAS BOILER Vent temperature sensor bracket Removing vent stack test port plug Combustion air intake riser Water pressure sensor Water temperature high limit switch Removing combustion air intake riser Upper vessel high limit switch Control Module disconnection...
  • Page 48 SL 30-175 MODULATING GAS BOILER 4.2.1 Fan and gas valve removal instructions Turn off electric power and gas supply to the boiler. Ensure boiler cools down to ambient temperature. Do not drain the boiler unless freezing conditions are expected during this procedure.

  • Page 49: Troubleshooting

    SL 30-175 MODULATING GAS BOILER 5.0 TROUBLESHOOTING The troubleshooting section is divided into 3 sections: NOTE 5.1 Preliminary Checks This boiler is equipped with a 5.2 Electronic Components blocked vent shutoff system, 5.3 Troubleshooting Guide which closes the gas supply...
  • Page 50 SL 30-175 MODULATING GAS BOILER 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 Temperature Sensors The resistance of the temperature sensors varies inversely with temperature. To...
  • Page 51 SL 30-175 MODULATING GAS BOILER 5.2.2 Fan/Blower Operating power is provided by means of a separate 120 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 signal (black wire) from the controller and provides a tachometer signal (white wire) back from the fan.
  • Page 52 SL 30-175 MODULATING GAS BOILER 5.2.5 Hi-Limit Switches (water and UVHL) Check resistance between leads. If resistance is very low, temperature should be acceptable. If resistance is very high, temperature should be out of bounds. A simple means of checking whether a high limit switch is open is by measuring the AC voltage across the device.
  • Page 53 SL 30-175 MODULATING GAS BOILER 5.2.7 Optional Low Water Cut Off The boiler can be ordered with a UL 353 certified probe-type low water cut off (LWCO) device factory installed or a Field Installed retrofit kit (boiler model specific) can be ordered from your local wholesaler. The LWCO option has a test and reset button located above and to the left of the controller. The LWCO module will automatically reset after a power interruption and the boiler will continue to operate as long as the boiler was not in a low water condition prior to the power outage.

  • Page 54: Troubleshooting Guide

    SL 30-175 MODULATING GAS BOILER 5.3 TROUBLESHOOTING GUIDE 5.3.1 Using Control Module Errors Displayed The bottom line of the Touch Screen is reserved for displaying the boilers error status. The boiler status bar will normally be Green but can change colour to Yellow or Red.
  • Page 55 SL 30-175 MODULATING GAS BOILER SYMPTOM DIAGNOSIS REMEDY MAXIMUM IGNITION TRIALS No spark when igniting. Check that igniter lead is secure at the control ERROR Igniter probe/flame module and at the probe. sensor disconnected. Touch Screen Message: Manual gas shutoff is Check for gas flow. Open manual gas shutoff...
  • Page 56 SL 30-175 MODULATING GAS BOILER SYMPTOM DIAGNOSIS REMEDY • TEMPERATURE SENSOR Current outlet Check water flow. ERROR temperature exceeds operating limit. Touch Screen Message: • Defective or Error - Max. Inlet/Outlet Sensor Check wiring to temperature sensor and disconnected Temp. Exceeded. -> Check control module.
  • Page 57 SL 30-175 MODULATING GAS BOILER 5.3.3 Cycling Problems SYMPTOM DIAGNOSIS REMEDY RAPID CYCLING Improper values Check load maximum temps are above target entered via keypad. temps, by 1/2 of the selected boiler differential. Ensure boiler differential is OK (16-30°F is...
  • Page 58 SL 30-175 MODULATING GAS BOILER 5.3.4 Temperature Problems SYMPTOM DIAGNOSIS REMEDY LOW HEAT Operating increase temperature target. temperature too low. Priority parameters Review load configuration parameters. or load configuration improperly set up. Unit undersized. Refer to Load Calculation vs. Boiler Output. Air trapped within Bleed system as required.
  • Page 59 SL 30-175 MODULATING GAS BOILER 5.3.5 Miscellaneous SYMPTOM DIAGNOSIS REMEDY FUMES AND HIGH HUMIDITY Improperly installed Refer to installation/operation instructions condensate trap Leak in vent piping Inspect using soap solution Flue gas leak within boiler Visually inspect all mechanical connections...
  • Page 60 SL 30-175 MODULATING GAS BOILER THIS PAGE INTENTIONALLY LEFT BLANK 5-12 INSTALLATION AND OPERATION INSTRUCTIONS...

  • Page 61: Diagrams

    SL 30-175 MODULATING GAS BOILER 6.0 DIAGRAMS 6.1 - PARTS DIAGRAMS 6.2 - WIRING DIAGRAMS 6.3 - SEQUENCE OF OPERATION DIAGRAMS...
  • Page 62 SL 30-175 MODULATING GAS BOILER 6.1 PARTS DIAGRAMS SL 30-175 Modulating Boiler - Parts assembly Diagram 6.1-4: SL 30-175 Boiler assembly parts INSTALLATION AND OPERATION INSTRUCTIONS...
  • Page 63 AIR PRESSURE SENSOR 240-004 IGNITION MODULE 250-277 BRACKET, TEMP. LIMIT SWITCH 240-009 FLUE TEMPERATURE SENSOR (OPTIONAL) 250-260 EXHAUST DUCT 250-373 AIR INTAKE DUCT 250-248 ACCESS COVER Diagram 6.1-5: SL 30-175 Boiler assembly parts list (refer to Diagram 6.1-1 on opposite page) DIAGRAMS...
  • Page 64 SL 30-175 MODULATING GAS BOILER 6.2 WIRING DIAGRAMS Diagram 6.2-1: Ladder wiring diagram INSTALLATION AND OPERATION INSTRUCTIONS...
  • Page 65 SL 30-175 MODULATING GAS BOILER INTERNAL WIRING DIAGRAM Better Boilers brown Combustion Valve blue blue 5 x plug blue blue orange green orange Transformer blue blue brown black Vent High black Limit black orange Switch Upper Vessel yellow High Limit...
  • Page 66 SL 30-175 MODULATING GAS BOILER 6.3 SEQUENCE OF OPERATION Diagram 6.3: Sequence of operation diagram INSTALLATION AND OPERATION INSTRUCTIONS...
  • Page 67 INSTALLATION & COMMISSIONING REPORT Boiler Details: Model Number _____________________ Serial Number ______________________________________________ Date of Installation ______________ Address of installation __________________________________________ _____________________________________________________________________________________________ User contact information _______________________________________________________________________ Installer Information Company ___________________________________________________________________ Address ______________________________________________________________________________________ Phone/Fax/E mail ____________________________________________________________________________ Fuel Natural Gas Propane Gas Supply Pressure (high fire) _______ Inches w.c. Measured Rate of Input (high fire) ____________ Btu/hr Installation instructions have been followed and completed (Section 1 of Installation and Operating Instructions).
  • Page 68 INSTALLER SET-UP Load Definition - Load #1 _______________________________________________________________________ Load Configuration - Load #1 _____________________________________________________________________________________________ Load Definition - Load #2 _______________________________________________________________________ Load Configuration - Load #2 _____________________________________________________________________________________________ Load Definition - Load #3 _______________________________________________________________________ Load Configuration - Load #3 _____________________________________________________________________________________________ Load Definition - Load #4 _______________________________________________________________________ Load Configuration - Load #4 _____________________________________________________________________________________________...
  • Page 69 SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...
  • Page 70 NOTES...
  • Page 71 • This boiler is part of a modular or multiple boiler system having a total input 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil (not applicable to IBC’s SL boilers). US installers should contact IBC for any further information required.
  • Page 72 REVISION HISTORY R1 (SEPTEMBER 2014) Addition of V10.0 Touch Screen Controller...
  • Page 74 IBC Technologies Inc. 1445 Charles Street, Vancouver, BC Canada V5L 2S7 Tel: 604.877.0277 Fax: 604.877.0295 www.ibcboiler.com 120-213E-A-R1 September 2014 © IBC Technologies Inc. 2014...

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