Electrical Connections - IBC SL 35-199 Operating Instructions Manual

Removing wiring box covers
Line voltage leads for power supply,
primary pump and VS output
Line voltage load pump terminals
CAUTION
The internal pump relays are
protected with 5 Amp fuses.
The maximum recommended
load on each fuse is 4 Amps
(80% of rating). The maximum
combined pump load is 10
Amps. Isolation relays or
contactors MUST be used if the
loads exceed these maximums.
1-26
SL 35-199, SL 45-260 MODULATING GAS BOILERS
1.8

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.
1.8.1 120VAC Line Voltage Hook-up
Line-voltage wiring is done within the field-wiring box. (Refer to Section
6.2.Wiring Diagram on page 6-4). Connect the boiler to the grid power using a
separate, fused circuit and on/off switch within sight of the boiler. Use 14-gauge
wire in BX cable or conduit properly anchored to the boiler case for mains supply
and pump circuits.
Connect a 120 VAC / 15 amp supply to the "AC IN" tagged leads in the wiring
box. The max. actual draw (with 5 typical residential size pumps) is less than 4
amps.
The 120 VAC power supply to the load pumps (P/V1, P/V2, P/V3, and P/V4) have
been factory installed and connected to P/V-L and P/V-N for your convenience.
If you are to use the P/V relay connections for zone valves then the 120 VAC
connections at P/V-L and P/V-N will have to be removed and properly capped
off. 24VAC can then be applied using an external transformer to supply power to
zone valves. The upper 4 pairs of contacts on this green connector strip are then
powered to manage up to 4 load pumps – the top pair for Load 1, the second pair
for #2 etc. Once the controller is programmed for the respective loads, the boiler
will manage all the loads without need of further relays (for loads up to 1/3 HP;
for more – use a protective relay).
The boiler (primary) pump is connected to the White/Yellow pair labeled Primary
Pump. This lead is factory wired to the controller (and its 120 VAC supply) at
the upper right backside of the controller board – do not attempt to connect the
primary pump to the Pump/Zone Valve Terminal Block along the controller's right
edge - this is for the secondary pumps and/or zone valves only. Connect the
pump's Black wire to the Yellow of this pair (switched Hot). The White/ Yellow pair
should be individually capped if the primary pump does not obtain its power from
this pair (e.g. if a variable speed primary pump is connected to the mains power).
Pumps can be switched on/off using the touch-screen, so there is no need
for temporary pump wiring during system filling / air purging. If pumps
are hard-wired to the panel during the system fill/purge phase, re-wire the
boiler pump to the Primary Pump leads inside the wiring box so the primary
pump purge function is active.
In a new construction application- use a construction thermostat – or jumper
with in-line on/off switch – for on/off management of the boiler. Do not
just pull power from the unit, or its moisture management routine will be
interrupted (fan turns at ultra low rpm for 90 minutes after burner shutdown).
Treat it like a computer, where you do not just pull the plug when done. If a "low
airflow / check vent" error signal shows, check for (and remove) any water in the
clear vinyl air reference tubes. This has been seen occasionally at construction
sites where the boiler has been repeatedly de-powered wet.
The combined current of all pumps connected through the on-board pump relays
should not exceed 10 amps. The control circuit board is protected using on-board
field replaceable fuses. Each pump is fused with a separate 5 Amp fuse. The
Alarm contact is fused with a 5 Amp fuse and the 24VAC boiler control circuit is
protected with a 2 Amp fuse.
INSTALLATION AND OPERATION INSTRUCTIONS