IBC Technologies SL 80-399 Installation And Operating Instructions Manual
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IBC Technologies SL 80-399 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 80-399
(Natural Gas or Propane)
www.ibcboiler.com

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  • Page 1 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 gasoline or other flammable vapours and liquids or other combustible materials in the vicinity of this or any other appliance.

  • Page 2: Safety Considerations

    SL 80-399 MODULATING GAS BOILER SAFETY CONSIDERATIONS Installation, start-up and servicing of IBC boilers must be done with due WARNING care and attention, and should only be performed by competent, qualified, licensed and trained heating technicians. If the information in this...

  • Page 3: Table Of Contents

    SL 80-399 MODULATING GAS BOILER CONTENTS INSTALLATION........... . 1-1 general .
  • Page 4 SL 80-399 MODULATING GAS BOILER The Installer must carefully read this manual to ensure that all installation DANGER details can be adhered to. Special attention is to be paid to clearances and access, vent travel and termination, gas supply, condensate removal and Should overheating occur combustion air supply.

  • Page 5: Installation

    SL 80-399 MODULATING GAS BOILER INSTALLATION general SL 80-399 gas-fired modulating boilers are low pressure, fully condensing 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 (sealed combustion) or indoor combustion air, providing a great degree of installation flexibility.

  • Page 6: Code Requirements

    SL 80-399 MODULATING GAS BOILER Code reQuireMents The SL 80-399 boiler was tested to and certified under CSA 4.9-2010 / 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 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 7: Exhaust Venting And Air Intake

    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 immediate area.
  • Page 8 SL 80-399 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 Part 7, Venting, condensate Venting of Equipment of the national Fuel gas Code, ansi 223.1, latest edition,...
  • Page 9 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 properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous conditions of use.
  • Page 10 80-399 boiler can be sited up to 150 equivalent feet from the vent termination. The actual vent travel allowance is reduced for fittings in accordance with Table 3. – e.g. for a sl 80-399 using 6 x 90º CPVC vent elbows, the maximum lineal measure of pipe allowed is 102 feet (150' – (6 x 8' = 48) = 102').
  • Page 11 SL 80-399 MODULATING GAS BOILER 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 must test the exhaust joints under fan pressure with the vent blocked, using a soap/water solution. Installer must fill condensate trap prior to test. remove the fan control harness plug as illustrated in the photos, and then block the vent outlet so that the vent run will be under maximum fan pressure.
  • Page 12 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 outlet is to be placed so as to reach 24" minimum above the down-turned intake - to avoid exhaust re-ingestion.
  • Page 13 • Clearance under veranda, porch, deck or balcony: - 12" (0.3m) IBC strongly recommends a minimum of 48” with the SL 80-399 to avoid damage to Figure 8: Prohibited installation the structure. Note: Prohibited unless fully open on a minimum of two sides below the floor.
  • Page 14 SL 80-399 MODULATING GAS BOILER • Vents must be installed such that flue gas does not discharge towards WARNING neighbor’s windows, or where personal injury or property damage can occur. In areas of high snowfall, • it is important to ensure proper condensate management from vent Users must be advised to terminations.
  • Page 15 SL 80-399 MODULATING GAS BOILER 1.4.7 “Direct Vent” Combustion Air Intake Piping WARNING In addition to preventing there are two basic methods of supplying combustion air to an iBC boiler. ingestion of chemical the direct vent option uses piping from the outside to supply combustion air contaminants, care must directly to the boiler’s combustion air connection.

  • Page 16: Closet Installations

    At the time of this printing, a combustion air filter for the IMPORTANT NOTE: SL 80-399 model was not yet available. Contact the Factory if your application requires air filtration. Under no circumstances should a third-party air filter be installed on an IBC boiler without proper evaluation and written approval of the IBC Engineering Department.

  • Page 17: Condensate Removal

    SL 80-399 MODULATING GAS BOILER Condensate reMoVal IBC’s specified vent configuration promotes the safe drainage of moisture NOTE from the boiler and exhaust venting without flowing liquids back through the heat exchanger (as done by some other condensing boilers). reliable system Combustion fan operation requires (1) proper design and installation of exhaust venting to blockages can occur when allow condensate to run back to the drain/trap; (2) acid neutralization as environmental particulate and appropriate.
  • Page 18 SL 80-399 MODULATING GAS BOILER 1.5.2 Condensate Trap Assembly Installation WARNING undo drain spout Compression nut (d),remove drain spout (C) from Fill trap with water before Condensate drain outlet (e) of trap Body (a). boiler is first fired to prevent...
  • Page 19 SL 80-399 MODULATING GAS BOILER FLUE GAS EXHAUST WARNING CONDENSATE AND RAIN WATER FLOWS BACK FROM If condensates are to be VENTING SYSTEM CONDENSATE DRAINAGE discharged into building drain piping materials that Free flow of condensate from venting are subject to corrosion, a...

  • Page 20: Water Piping

    SL 80-399 MODULATING GAS BOILER Water PiPing 1.6.1 General Piping Issues WARNING the sl modulating series boilers are designed for use within a closed loop, During operation, the relief forced circulation, low pressure system. a 30 psi pressure relief valve (3/4" nPt) valve may discharge large is supplied for field installation in the relief valve fitting on top of the boiler. Relief...
  • Page 21 For best results, use a Primary: Secondary piping system, with a pumped boiler system, to reduce risk of loop using 2" piping for the sl 80-399. Heat exchanger head is only 2’ at 30 gpm water escapement. and approx. 4' at 40 gpm.
  • Page 22 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).
  • Page 23 SL 80-399 MODULATING GAS BOILER if the installation involves small loads, as in typical zoned baseboard heating NOTE 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 The Primary (boiler) pump entrance to the cool load (this will also provide floor protection). This will permit...
  • Page 24 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 clarity.
  • Page 25 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...

  • Page 26: Gas Piping

    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. Confirm this pressure range is available with your local gas supplier. the inlet gas connection of the boiler’s gas valve is 3/4" nPt (male).

  • Page 27: Electrical Connections

    SL 80-399 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 28 SL 80-399 MODULATING GAS BOILER 1.8.3 Zone Valve Hook-up NOTE if 24Vac zone valves rather than pumps are used to manage multiple heating The IBC boiler (like any loads (must be three-way diverting valves to maintain boiler flow), then the modern appliance that 115Vac wires on the Pump terminal Block (terminals 11 and 12) must be...
  • Page 29 SL 80-399 MODULATING GAS BOILER Figure 30: Electrical Wiring Connections (full page ladder diagram at back of this manual) 1-25 INSTALLATION...
  • Page 30 SL 80-399 MODULATING GAS BOILER THIS PAGE INTENTIONALLY LEFT BLANK 1-26 INSTALLATION AND OPERATION INSTRUCTIONS...

  • Page 31: Boiler Systems And Operation

    SL 80-399 MODULATING GAS BOILER BOILER SYSTEMS AND OPERATION 2.1 general the sl 80-399 modulating boiler is designed to service light-to-medium WARNING commercial space and domestic water heating loads. typically, a single space heating load will be managed using either set-Point or reset parameters, or If the boiler can become if two loads are paired (e.g.

  • Page 32: Access Levels

    SL 80-399 MODULATING GAS BOILER 2.3.2 LCD Display Upon power-up, the LCD screen initially flashes a software release number then switches to a Standby- display mode, showing real time data plus key temperature target settings. When there is a call for heat from any load, that load is identified at the Status line (e.g. Heating – BBd - for baseboards with reset - in place of Standby). the target temperature for the relevant load is conspicuously displayed while that load is being handled.

  • Page 33: Advanced Setup

    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 provides access to the time & date fields, provides the means to toggle between C° / F° plus allows...

  • Page 34: Sequence Of Operation

    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: standby cycle Purging ignition cycle Heating cycle Circulating cycle error mode Each state is explained below. A flow chart for the sequence of operation can be found in the back of the manual.
  • Page 35 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 specific band limit, the postpurge will continue as normal, but the boiler will enter the circulating mode.

  • Page 36: Other Operating Features

    VFC 15-150 and 45-225 models remain within the sl 80-399 code set, but sequential load management operation is not normally recommended with this larger model. load scheduling allows adjustable prioritization across loads 1, 2, and 3, with settable values from 20 to 90. note: these values do not represent percentages and do not add up to 100;...
  • Page 37 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. Following such initial cycle, the clashing loads will switch back and forth after further 10 min.
  • Page 38 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 make no further difference to the delivered temperature if the floor slab has stabilized at the boiler temperature served up by the reset curve.
  • Page 39 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.

  • Page 40: Set Up & Load Definition

    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: in the Standby mode, start by pressing any key to call up the Main Menu.
  • Page 41 SL 80-399 MODULATING GAS BOILER use the Summer Shutdown field to enter a threshold temperature for the 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 Temp. field to optimize boiler run times on low mass loads. Finned tube baseboards sink very little heat when operated below 100°F;...
  • Page 42 SL 80-399 MODULATING GAS BOILER 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. to enact the control arrangements as input, it is necessary that the piping structure and system wiring are configured appropriately (refer to Section 1.6.2 Installation Rules, page 1-20 for piping layouts and the Wiring...

  • Page 43: Startup And Commissioning

    SL 80-399 MODULATING GAS BOILER STARTUP AND COMMISSIONING 3.1 ligHting and sHutting doWn tHe Boiler STARTUP AND COMMISSIONING...

  • Page 44: Prior To Start-Up

    CoMMissioning the sl 80-399 modulating boiler is factory calibrated to operate with natural gas (or propane if so ordered) at sea level. the relevant valve adjustment screws have been factory sealed using loctite thread-lock compound, which can be broken where required.
  • Page 45 SL 80-399 MODULATING GAS BOILER With a combustion analyzer probe in the flue gas test port, turn the Gas:Air DANGER 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). Making adjustments to This screw offers very fine adjustment, and may require several turns. the IBC gas valve without This screw has significant backlash. When changing direction of turn,...
  • Page 46 SL 80-399 MODULATING GAS BOILER 3.3.1 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 47: Maintenance

    SL 80-399 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 48: Heat Exchanger

    SL 80-399 MODULATING GAS BOILER 4.1.6 Heat Exchanger WARNING 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 (typically sulfur). other fouling agents: The IBC heat exchanger has a airborne dust, debris and volatiles.

  • Page 49: Boiler Treatment

    SL 80-399 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 50: Geography & Components

    SL 80-399 MODULATING GAS BOILER geograPHY & CoMPonents Remove top cover button bolts Gas Inlet Block Turn cover button Counter Clock Wise to loosen Lift top cover up at front Gas Valve Body Top cover lifts up and out Cover tilts back, then lift up and off...
  • Page 51 SL 80-399 MODULATING GAS BOILER Burner Flange Bolts Tridicator Gauge on Supply Riser Low Water Cut-Off Module behind Control Panel Fan Flange Bolts Manual Reset Water High Limit Switch on Upper Vessel High Limit Switch on Supply Riser (red button is reset)
  • Page 52 SL 80-399 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 53: 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, a problem can be identified and solved through simple checks of the basics: confirming the electrical power supply, gas flow and resetting the thermostat control. to extend the cover of such preliminary checks, the boiler’s control module offers a clear visual display of the status of the various control circuit components.

  • Page 54: Electronic Components

    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 Temperature Sensors the resistance of the temperature sensors varies inversely with temperature. to...
  • Page 55 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 signal (black wire) from the controller and provides a tachometer signal (white wire) back from the fan.

  • Page 56: Water Pressure Sensor

    SL 80-399 MODULATING GAS BOILER Next, confirm that the circuit is properly powered. The supply voltage to the 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 into the harness / connectors). see previous page for a presentation of the measurement points.

  • Page 57: Troubleshooting Guide

    SL 80-399 MODULATING GAS BOILER 5.3 trouBlesHooting guide 5.3.1 Using Control Module Errors Displayed SYMPTOM DIAGNOSIS REMEDY Check fan operation • Check lead is attached at fan. AIRFLOW ERROR • Cycle power off/on; listen for fan initialization. LCD Screen Message: if no action, focus your attention on the fan itself. Error – Insufficient Air Flow Check for fouled • Check clear vinyl air pressure line for...
  • Page 58 SL 80-399 MODULATING GAS BOILER SYMPTOM DIAGNOSIS REMEDY No spark when Check that igniter lead is secure at the control MAxIMUM IGNITION TRIALS igniting. Igniter module and at the probe. ERROR probe/flame sensor LCD Screen Message: disconnected. Error – Ignition Failure after 3 Manual gas shutoff is Check for gas flow. Open manual gas shutoff...
  • Page 59 SL 80-399 MODULATING GAS BOILER SYMPTOM DIAGNOSIS REMEDY Indicates one or both • Check wiring to ensure switches are properly VENT HI-LIMIT ERROR switches has tripped. connected to control module. LCD Screen Message: • Check for evidence of any damage to vent Error - Vessel/Vent High-Limit system and signs of excess heat near Exceeded *** Call for service! switches.

  • Page 60: Ignition Problems

    SL 80-399 MODULATING GAS BOILER 5.3.2 Ignition Problems SYMPTOM DIAGNOSIS REMEDY Ignition lead is not reconnect ignition lead. NOISY SPARK WHEN firmly connected. IGNITING Contaminants/ ensure probe is dry by re-running post-purge; moisture on igniter otherwise, clean or replace igniter probe.
  • Page 61 SL 80-399 MODULATING GAS BOILER 5.3.3 Cycling Problems SYMPTOM DIAGNOSIS REMEDY Improper values Check load maximum temps are above target RAPID CYCLING entered via keypad. temps, by 1/2 of the selected boiler differential. ensure boiler differential is oK (16-30°F is...
  • Page 62 SL 80-399 MODULATING GAS BOILER 5.3.4 Temperature Problems SYMPTOM DIAGNOSIS REMEDY Operating increase temperature target. see Section 2.7 INSUFFICIENT HEAT temperature too low. Priority parameters Review load configuration parameters. See or load configuration Section 2.7 improperly set up. Unit undersized. refer to load Calculation vs. Boiler output.
  • Page 63 SL 80-399 MODULATING GAS BOILER 5.3.5 Miscellaneous SYMPTOM DIAGNOSIS REMEDY Improperly installed refer to installation/operation instructions FUMES AND HIGH HUMIDITY condensate trap Leak in vent piping inspect using soap solution Flue gas leak within Visually inspect all mechanical connections boiler...
  • Page 64 SL 80-399 MODULATING GAS BOILER THIS PAGE INTENTIONALLY LEFT BLANK 5-12 INSTALLATION AND OPERATION INSTRUCTIONS...

  • Page 65: Diagrams

    SL 80-399 MODULATING GAS BOILER 6.0 DIAGRAMS 6.1 - Parts diagraMs 6.2 - Wiring diagraMs 6.3 - seQuenCe oF oPeration DIAGRAMS...

  • Page 66: Parts Diagrams

    SL 80-399 MODULATING GAS BOILER 6.1 Parts diagraMs SL 80-399 Modulating Boiler - Parts assembly Diagram 6.1-1: Boiler assembly parts INSTALLATION AND OPERATION INSTRUCTIONS...
  • Page 67 SL 80-399 MODULATING GAS BOILER Diagram 6.1-2: Boiler assembly parts list (refer to Diagram 6.1-1 on opposite page DIAGRAMS...

  • Page 68: Wiring Diagrams

    SL 80-399 MODULATING GAS BOILER 6.2 Wiring diagraMs Diagram 6.2-1: Ladder wiring diagram INSTALLATION AND OPERATION INSTRUCTIONS...
  • Page 69 SL 80-399 MODULATING GAS BOILER Diagram 6.2-2: Multi-boiler “boiler net” wiring diagram DIAGRAMS...
  • Page 70 SL 80-399 MODULATING GAS BOILER Diagram 6.2-3: Internal wiring diagram INSTALLATION AND OPERATION INSTRUCTIONS...

  • Page 71: Sequence Of Operations

    SL 80-399 MODULATING GAS BOILER 6.3 seQuenCe oF oPeration Diagram 6.3: Sequence of operation diagram DIAGRAMS...
  • Page 72 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 73: Service Record

    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 _____________________________________________________________________________________________ serViCe reCord DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...
  • 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...

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