IBC Boilers SL 40-399 G3, SL 26-260 G3 Installation And Operating Instructions Manual

SL 26-260 G3, SL 40-399 G3

MODULATING GAS BOILERS

(Natural Gas or Propane)

WARNING: If the information in this manual is not followed exactly, a re or

explosion may result causing property damage, personal injury, or loss of life.

Do not store or use gasoline or other ammable vapors 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 re department.

Installation and service must be performed by a qualied installer, service

agency or the gas supplier.

This Manual is also available in French - contact IBC or visit our web site www.ibcboiler.com

INSTALLATION AND OPERATING INSTRUCTIONS

SL 40-399 G3

www.ibcboiler.com

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

WARNING

If the information in this manual

is not followed exactly, a re or

explosion may result causing property damage, personal injury, or loss of life.

SAFETY CONSIDERATIONS

Installation, start-up and servicing of IBC boilers must be performed by competent,

qualied, licensed and trained heating technicians.

Failure to read and comply with all instructions and applicable National and local codes may result in hazardous conditions that could result in property damage and injury to occupants which in extreme cases might result in death.

HAZARDS & PRECAUTIONS

DANGER

Points out an immediately hazardous situation which must

be avoided in order to prevent

serious injury or death.

WARNING

Points out a potentially hazardous situation which must

be avoided to prevent serious

injury or death.

CAUTION

Points out a potentially hazardous situation which must

be avoided to prevent possible

moderate injury and/or property damage

Supplied with the boiler - The IBC boiler is shipped with an accessory parts kit consisting of the following items:

• 1 x Wall mounting bracket

• 1 x Condensate trap assembly

• 1 x 30 psig pressure relief valve

• 1 x Outdoor temperature sensor

• 6 x 1/4” x 2 1/2” Lag screws/w at

washers

• Installation and Operating Instructions

• User Manual

• V10 Touchscreen Operating Instructions

NOTE

Points out installation, maintenance and operation details that will result in

enhanced efciency, longevity

and proper operation of your boiler.

Manual

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SPECIFICATIONS

SPECIFICATION SL 26-260 G3 SL 40-399 G3

CSA Input (Natural Gas or Propane) - MBH

CSA Input (Natural Gas or Propane) - kW

CSA Output - MBH

CSA Output - kW

A.F.U.E

Combustion Efciency BTS-2000 Thermal Efciency

Minimum gas supply pressure (Natural Gas or Propane) - inch w.c.

Maximum gas supply pressure (Natural Gas or Propane) - inch w.c.

Ambient temperature - Low °F / °C High °F / °C

Max. relative humidity (non-condensing)

Minimum water temp.

Maximum water temp. (electronic hi-limit)

Max. ΔT - supply/return (electronic fence)

Power use (120Vac/60Hz) @ full re - Watts

26 - 260

7.6 - 76.2

24.9 - 239

7.30 - 70.0

95%

32°F / 0°C

122°F / 50°C

90%

34°F / 1°C

190°F/ 88°C

40°F

127 (less pumps)

40 - 399

11.7 - 117

38.4 - 383

11.2 - 112

96% 96%

32°F / 0°C 122°F / 50°C

90%

34°F / 1°C

190°F/ 88°C

40°F

345 (less pumps)

Weight (empty) - lbs/Kg

Heating Surface Area - ft

Pressure vessel water content - USG/Litres

Maximum boiler ow rate - USgpm

Minimum boiler ow rate - USgpm

Maximum operating water pressure* - psig

Minimum water pressure - psig

Approved installation altitude - ASL

Maximum equivalent vent length Each side (Vent & Air Intake)) (Natural Gas or Propane) Air intake options: either direct vent or indoor supply

* boilers are shipped with 30 psig pressure relief valve.

/ m

162 / 74

22.71 / 2.11

5 / 19

0 - 12,000’

200’ (3")

240 / 110

36.56 / 3.40

7 / 26

0 - 12,000’

200’ (4")

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

THIS PAGE IS INTENTIONALLY LEFT BLANK.

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

Contents

1.0 INSTALLATION....................................................1-1

1.1 GENERAL........................................................1-1

1.2 CODE REQUIREMENTS ............................................1-3

1.3 LOCATION .......................................................1-3

1.4 EXHAUST VENTING AND AIR INTAKE .................................1-4

1.4.1 Applications ...................................................1-6

1.4.2 Exhaust Vent Material ...........................................1-6

1.4.3 Vent Travel ....................................................1-7

1.4.4 Venting Passage Through Ceiling and Floor ..........................1-9

1.4.5 Rooftop Vent Termination .........................................1-9

1.4.6 Sidewall Vent Termination .......................................1-10

1.4.7 “Direct Vent” Combustion Air Intake Piping ..........................1-15

1.4.8 “Indoor Air” Combustion Air Intake .................................1-16

1.4.9 Combustion Air Filtration ........................................1-17

1.4.10 Closet Installations ............................................1-17

1.5 CONDENSATE REMOVAL ..........................................1-18

1.5.1 Condensate Trap ..............................................1-18

1.5.2 Condensate Trap Assembly - Installation ............................1-18

1.5.3 Condensate Trap Assembly - cleaning procedure . . . . . . . . . . . . . . . . . . . . . 1-19

1.5.4 Further installation details .......................................1-19

1.6 WATER PIPING ..................................................1-21

1.6.1 General Piping Issues ..........................................1-21

1.6.2 Installation Rules ..............................................1-24

1.7 GAS PIPING .....................................................1-28

1.8 ELECTRICAL CONNECTIONS ......................................1-29

1.8.1 120 VAC Line Voltage Hook-up ...................................1-29

1.8.2 Power Quality and Electrical Protection .............................1-30

1.8.3 Zone Valve Hook-up............................................1-30

1.8.4 Thermostat / Sensor Wiring ......................................1-30

1.8.5 Other Wiring ..................................................1-30

1.8.6 Thermostat Heat Anticipator......................................1-31

2.0 IBC BOILER CONTROLLER .........................................2-1

2.1 GENERAL........................................................2-1

2.2 CONTROL .......................................................2-1

2.3 CONTROL INTERFACE .............................................2-2

3.0 STARTUP & COMMISSIONING .......................................3-1

3.1 BOILER SHUTDOWN & LIGHTING ....................................3-1

3.2 PRIOR TO START-UP ..............................................3-2

3.2.1 Pre-Ignition Checks .............................................3-2

3.2.2 Test Ignition Safety Shutoff .......................................3-2

3.3 COMMISSIONING .................................................3-2

3.3.1 Gas Valve and Fan Diagrams .....................................3-4

3.4 FUEL CONVERSION ...............................................3-5

3.4.1 Gaining access to combustion chamber and burner removal instructions....3-6

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

4.0 MAINTENANCE ...................................................4-1

4.1 BOILER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.1 General Care ..................................................4-1

4.1.2 Inspection.....................................................4-1

4.1.3 Venting .......................................................4-1

4.1.4 Condensate Traps ..............................................4-1

4.1.5 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.6 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.7 Pump ........................................................4-2

4.1.8 Gas Piping ....................................................4-2

4.1.9 Touchscreen Boiler Controller .....................................4-2

4.1.10 Water .......................................................4-2

4.1.11 Freeze Protection ..............................................4-2

4.1.12 Boiler Treatment...............................................4-2

4.1.13 Relief Valve - Maintenance and Testing .............................4-3

4.2 GEOGRAPHY & COMPONENTS......................................4-4

4.2.1 Fan and gas valve removal instructions..............................4-6

4.2.2 Fan and gas valve re-installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.2.3 Replacing the gas valve ..........................................4-8

5.0 TROUBLESHOOTING ..............................................5-1

5.1 PRELIMINARY CHECKS ............................................5-1

5.2 ELECTRONIC COMPONENTS .......................................5-2

5.2.1 Temperature Sensors............................................5-2

5.2.2 Fan ..........................................................5-3

5.2.3 Water Pressure Sensor ..........................................5-3

5.2.4 Safety and Ignition Module (SIM)...................................5-3

5.2.4.1 Low water cutoff function: reset and test............................5-4

5.2.4.2 Water Temperature function: reset and test .........................5-5

5.3 TROUBLESHOOTING ..............................................5-6

5.3.1 Using Control Module Errors Displayed ..............................5-6

5.3.2 Ignition Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.3.3 Cycling Problems ...............................................5-9

5.3.4 Temperature Problems..........................................5-10

5.3.5 Miscellaneous.................................................5-11

6.0 DIAGRAMS.......................................................6-1

6.1 PARTS DIAGRAMS ................................................6-2

6.2 WIRING DIAGRAMS ...............................................6-9

6.3 SEQUENCE OF OPERATION .......................................6-11

INSTALLATION & COMMISSIONING REPORT.............................6-12

INSTALLER SET-UP..................................................6-13

SERVICE RECORD ..................................................6-14

NOTES ....................................................6-15

REVISION HISTORY .................................................6-17

INSTALLATION AND OPERATION INSTRUCTIONS

DANGER

Should overheating occur or the

gas supply fails to shut off, do not turn off or disconnect the electrical supply to the pump. Instead shut off the gas supply at a location external to the appliance

WARNING

Do not use this boiler if any part has been under water.

Immediately call a qualied service technician to inspect the

boiler and to replace any part of the control system and any gas control that has been under water.

CAUTION

Care must be taken to properly size the boiler for its intended

use. Prolonged full re run time, over-sizing or under-sizing, and incorrect ow rates through

the boiler can lead to increased

maintenance costs, equipment

stress and premature failure.

WARNING

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

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 combustion air supply.

The Installer should do a pre-installation check to ensure that the following precautions can be observed:

• The boiler should be installed in areas where the combustion air source is not subject to chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes

such as chlorinated and/or uorinated hydrocarbons can reduce the life of a boiler.

Cleaners, bleaches, air fresheners, refrigerants, aerosol propellants, dry-cleaning

uids, de-greasers and paint-removers all contain vapors which can form corrosive acid compounds when burned in a gas ame. Airborne chlorides such as those

released with the use of laundry detergents are also to be avoided.

• The boiler should be located where water leakage will not result in damage to the area. If a location such as this cannot be found, a suitable drain pan should be installed under the appliance. The boiler is not to be installed above carpeting.

• At a new construction site, or during renovations, action must be taken to protect the boiler from drywall dust or other construction related 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

ring - allow for air circulation and ventilation in the immediate area.

• When the boiler is in operation, the impact of the steam plume normally experienced at the exhaust terminal of a condensing boiler should be assessed. Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location. Boiler condensate is corrosive. Protective measures must be taken to prevent corrosion damage to metal roofs or other metal building components in contact with the condensate. Keep exhaust plumes well away from all building air intakes including those of neighboring properties.

• The exhaust outlet should be placed so as to reach 12” minimum above the downturned intake - to avoid exhaust re-ingestion.

• For sidewall venting options: Both the inlet and exhaust terminations should normally be located on the same plane (side) of the building. The elevation of both pipes can be raised in “periscope style” after passing through the wall to gain required clearance above grade and snow level.

• If the indoor combustion air option is used, ensure combustion air openings to the boiler room remain unblocked and free of obstructions.

• Examine the condensate outlet to ensure proper disposal of condensate will occur during operation. If condensates are to be discharged into building drain piping materials that are subject to corrosion, a neutralization package must be used.

• Ensure that the pressure relief valve will be installed with no valves or other means of isolation between its inlet and the boiler. Make sure the relief valve outlet will be piped with unobstructed piping (minimum 3/4” diameter) to a safe discharge location.

If the boiler can become exposed

to uid temperatures below 34°F (1°C), a method of protection to prevent freezing of condensate

should be employed. Contact the factory for further information.

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

THIS PAGE IS INTENTIONALLY LEFT BLANK

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

1.0 INSTALLATION

1.1 GENERAL

The gas-red modulating boilers are low pressure, fully condensing units having a variable

input range. Approved as “Category IV” vented appliances, the boilers use either Direct Vent (sealed combustion) or indoor combustion air, providing a great degree of installation

exibility.

The following table displays the required connection specications for each model.

DESCRIPTION SL 26-260 G3 SL 40-399 G3

A Flue Outlet 3” Schedule 40 4" Schedule 40

B Combustion Air Inlet 3” Schedule 40 4" Schedule 40

C Safety Relief Valve and Air Vent 3/4" NPT - F 3/4" NPT - F

D Touchscreen display 2-1/4” x 4” 2-1/4" x 4"

E Water Outlet 1-1/2” NPT-M 1-1/2" NPT - M

F Water Inlet 1-1/2” NPT-M 1-1/2" NPT - M

G Knock-outs (8) 1/2” 1/2"

H Gas Inlet 3/4” NPT-F 3/4" NPT - F

I Condensate Outlet 3/4” Hose 3/4" Hose

Table 1: Connections

Figures 1A and 1B show outer case dimensions, piping and electrical holes. Refer to

these gures to help with nding a suitable location for the boiler. See also Section 1.3

Location.

INSTALLATION

1-1

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

Figure 1A: Dimensions / Connections for SL 26-260 G3

9.7in [246mm]

Figure 1B: Dimensions / Connections for SL 40-399 G3

1-2

INSTALLATION AND OPERATION INSTRUCTIONS

WARNING

Keep boiler area free and clear of combustible materials, gasoline,

and other ammable vapors and liquids.

WARNING

Combustion air must not be drawn from areas containing

corrosive air from swimming

pools or spas, including air directly next to outdoor pools and spas.

WARNING

The boiler shall not be exposed to water leaks from piping or

components located overhead.

This includes condensation dropping from un-insulated cold

water lines overhead.

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

1.2 CODE REQUIREMENTS

The boilers are tested and certied 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. Where required by jurisdiction, installation must conform to the Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1. If there is any conict, then the more

stringent requirement will apply.

1.3 LOCATION

The boilers are designed and approved for indoor installation (wall or rack mounting), with

signicant exibility of location provided with the available venting options. The boiler can

be placed in an alcove, basement, closet or utility room. Surrounding conditions shall be 32°F (0°C) to 122°F (50°C) and less than 90% relative humidity.

Install the boiler in areas where the combustion air source is not subject to chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes such as chlorinated

and/or uorinated hydrocarbons can reduce the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants, aerosol propellants, dry-cleaning uids, de-greasers and paint-

removers all contain vapors which can form corrosive acid compounds when burned in a

gas ame. Airborne chlorides such as those released with the use of laundry detergents

are also to be avoided. For this reason, the indoor air venting option using air surrounding the boiler should not be used in a laundry room. Similarly, ensure any direct vent air source is not adjacent to a clothes dryer exhaust terminal. Avoid agricultural applications where the boiler and/or the intake air source are affected by ammonia and/or dust.

Locate the boiler where water leakage will not result in damage to the area. If a location such as this cannot be found, a suitable drain pan should be installed under the appliance. The boiler is not to be installed above carpeting.

Boiler weight – without water and any effect of system piping and components – is up to approx. 240 lbs/110 kg. For support fasteners, use the supplied 6 x 1/4” x 2 1/2" long lag screws. Installer to supply 1/4" bolts if metal mounting systems are used. Fasteners are to be attached to solid material capable of supporting the combined weight of the boiler and piping assembly components.

Other factors to consider for mounting sites:

• Adhere to the minimum clearance requirements for combustible materials (see Table

2).

• A minimum 24" clearance at the front and 12” above the boiler is recommended for

adequate servicing. Check local codes for additional access and service clearance requirements.

WARNING

Ensure the gas ignition system components are protected from water (dripping, spraying, rain,

etc.) during appliance operation and when servicing (pump

replacement, condensate trap

servicing, control replacement, etc.)

INSTALLATION

1-3

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

WARNING

Exposed water piping and associated components

(relief valves, circulators, etc.) should not be in contact

with combustible materials.

Check local codes for required clearances and/or provide adequate insulation.

WARNING

DO NOT MOUNT THIS BOILER TO HOLLOW WALL STRUCTURES - The weight of the boiler alone is 240 pounds. The combined weight of the boiler, its water contents and associated piping components can exceed 300 pounds. Fasteners must be rated for this strain, and must

be rmly anchored into solid

material that will support this weight.

ring - allow for air circulation and ventilation in the immediate area.

SURFACE

Front 1" 24”

Rear 0" 0”

Left Side 1" 0” - (to non-combustibles)

Right Side 1" 4” (for electric and gas if required

Top 12” 12” (for vent connection)

Bottom 12" 12” (for condensate trap and piping)

Table 2 - Clearance from boiler cabinet

A minimum distance below the boiler of 12" is required to provide clearance for the supplied condensation trap assembly. More clearance will typically be required to accommodate associated water and gas piping.

DISTANCE FROM COMBUSTIBLES

DISTANCE FOR INSTALLATION AND SERVICE

Installers are to take all

necessary precautions to avoid

injury during the installation of this boiler.

DANGER

Do not common vent SL series

modulating boilers with any other existing or new appliance.

Figure 2: Wall mounting of boiler

1.4 EXHAUST VENTING AND AIR INTAKE

It is important to carefully plan the installation to ensure the appropriate vent materials,

travel and termination decisions are included. Specic attention is warranted to manage

the impact of the steam plume normally experienced at the exhaust terminal of a condensing boiler. Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location, to maximize customer satisfaction. Keep exhaust plumes well away from all building air intakes including those of neighboring properties.

1-4

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

WARNING

Venting, condensate drainage, and combustion air systems for all IBC boilers must be installed in compliance with all applicable codes and the instructions of

their respective Installation

Manuals.

Inspect nished vent and air

piping thoroughly to ensure all are airtight and comply with the

instructions provided and with all requirements of applicable

codes.

Failure to comply will result in

severe personal injury or death.

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 USA, the National Fuel Gas Code, ANSI 223.1, latest edition, prevails. Where there is a discrepancy between the installation instructions below, and the code requirements, the more stringent shall apply.

Figure 3: Flue gas venting

Provisions for the combustion and air ventilation must be in accordance with the section “Air for Combustion and Ventilation” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Clause 8.2, 8.3 or 8.4 of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

IMPORTANT:

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances that remain connected to it.

When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size using the appropriate tables in the National Fuel Gas Code, ANSI Z223.1 - latest edition. In Canada, use the B149.1 Installation Code.

At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

• Seal any unused opening in the common venting system.

• Visually inspect the venting system for proper size and horizontal pitch and determine

there is no blockage or restriction, leakage, corrosion and other deciencies that

could cause an unsafe condition.

• Insofar as is practical, close all building doors and windows and all doors between

the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum

speed. Do not operate a summer exhaust fan. Close replace dampers.

INSTALLATION

1-5

WARNING

Covering non-metallic vent pipe and ttings with thermal

insulation shall be prohibited.

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

• Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so that the appliance operates 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, replace dampers and any other gas-burning appliance to their

previous condition.

• Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 - latest edition. In Canada, all installations must conform with the current CAN/CGA - B149.1-10 Installation Code and/or local codes.

1.4.1 Applications

All SL series boilers are approved with alternative venting options: either 2-pipe Direct

Vent or Vent pipe with Indoor Air, offering exibility to meet the specic requirements of

the installation. With the Direct Vent case, combustion air is piped directly to the boiler’s air intake from outdoors (see Section 1.4.7 for air intake piping requirements). Using the indoor air alternative, air for combustion is drawn from the indoor air surrounding the boiler.

Provided the maximum overall vent length limit is not exceeded, the installer may choose to vent the boiler through the wall, directly through the roof, or upward using an existing

- but otherwise unused - chimney as a vent raceway.

WARNING

Condensate can cause corrosion

of metal roong components and other roong materials.

Check with the builder or

roong contractor to ensure

that materials will be resistant to

acidic condensate. pH levels can

be as low as 3.0

1.4.2 Exhaust Vent Material

Exhaust Vent Material – CANADA

Use PVC, CPVC or Polypropylene (PPs) vent component systems approved under ULC-S636 Standard for Type BH Gas Venting Systems, or stainless steel Type BH venting

systems*. The vent temperature is limited with the use of a ue temperature sensor

and software to ensure the maximum temperature of the PVC venting material is not exceeded. The temperatures are typically:

• ULC-S636 PVC: 158°F (70°C)

• ULC-S636 CPVC: 212°F (100°C)

• ULC-S636 PPs:- 249°F (120°C)

Exhaust Vent Material – USA

PVC, CPVC or PPs venting materials are approved for use with these boilers in the USA.

The vent temperature is limited with the use of ue temperature sensor and software to

ensure that the maximum temperature of the PVC venting material is not exceeded. PVC

venting material shall be certied to Sch. 40 ASTM D1785 or D2665. CPVC material shall be certied to Sch. 40/ASTM F441.

Do not use ABS or any cellular core pipe for exhaust venting.

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in venting systems shall be prohibited.

The boiler offers 3" or 4" venting connections. Fittings are to be used to adapt to the appropriate diameter – see Vent Travel below. Exhaust venting is to be inserted directly

into the 3" or 4" female stainless steel tting (see Figure 3).

1-6

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

WARNING

Do not mix PPs venting materials

from different Manufacturers.

These venting materials are

designed to be installed as part of a complete system.

Failure to comply may result in

severe personal injury or death.

WARNING

Fully insert the approved venting

material into the boilers exhaust outlet and tighten clamp to ensure

the venting connection is locked

in place.

For PPs material, use the transition / adaptor tting (Sch 40 to PPs) offered by the respective PPs manufacturers Centrotherm / Innoue

ISAA0404) or M&G Dura Vent / PolyPro

(# 3PPs-AD), (# 4PPs-AD) or Z-Flex/Z_DENS (#

(their part # ISAA0303 or #

2ZDCPVCG3). For PPs material exposed to outdoor weather, follow the venting supplier’s recommendations on UV protection.

Combustion air piping - if used - is inserted directly into the 3" or 4" female stainless steel

tting (see Section 1.4.7).

Venting shall be supported in accordance with the applicable code.

*Manufacturers of stainless steel Type BH venting systems must submit their approved

transition tting to IBC for evaluation and written approval.

1.4.3 Vent Travel

PVC/CPVC or PPs (Rigid Single Wall) or Schedule 40 approved piping is the standard venting option; with this, the boilers can be sited up to 200 equivalent feet from the vent

termination. The actual vent travel allowance is reduced for ttings in accordance with the

following tables. For example, for an SL 40-399 G3 using 6 x 90º CPVC vent elbows, the maximum lineal measure of pipe allowed is 152 feet (200' – (6 x 8' = 48) = 152').

SL 26-260 G3

EXHAUST PIPE SIZE MAXIMUM EQUIVALENT LENGTH

Sched.40; Rigid PPs

3" 200' (each side)

90° vent elbow allow 8' equivalent

90° long sweep elbow allow 5' equivalent

45° elbow allow 3' equivalent

PPs 87-90° elbows use 8' equivalent

3" Stainless Sidewall Terminal (SST)

IBC P/N 180-149 (P-257)

Flexible PPs

3" PPs Flexible 60' (max.) actual lineal x 3.33 = equivalent

allow 20' equivalent of 3" Sched. 40

INSTALLATION

Table 3A: Maximum Exhaust Venting Length for SL 26-260 G3

1-7

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

SL 40-399 G3

EXHAUST PIPE SIZE MAXIMUM EQUIVALENT LENGTH

Sched.40; Rigid PPs

4" CPVC / Rigid PPs 200' (each side)

90° vent elbow allow 8' equivalent

90° long sweep elbow allow 5' equivalent

45° elbow allow 3' equivalent

PPs 87-90° elbows use 8' equivalent

3" Stainless Sidewall Terminal (SST) IBC P/N 180-149 (P-257)

allow 65' equivalent

3" CPVC (to adapt to the SST) for each 1' allow 3.2' equivalent

Flexible PPs

4" PPs Flexible 160' max, using 1.2 x for equivalent length

Table 3B: Maximum Exhaust Venting Length for SL 40-399 G3

For Flexible PPs, up to 160 actual lineal feet are allowed in a nominally vertical orientation (>45°). The equivalent length of 4” Flex PPs shall be computed using a multiple of 1.2:1, e.g.80' x 1.2 = 96’ equivalent (with such use of 80' of 4" Flex, up to 104' equivalent of 4" Rigid PPs would still be allowed). PPs 87-90° elbows are considered equivalent to 8'.

NOTE: Unused intake travel cannot be added to the exhaust. Unequal intake and exhaust piping is allowed - see Section 1.4.8.

Exhaust venting must slope down towards the boiler with a pitch of at least 1/4" per foot (PPs vent: follow PPs manufacturer requirements for slope), so condensate runs back towards the trap. Support should be provided for intake and vent piping, particularly so for horizontal runs (follow local code).

Figure 4: Pipe and tting beveling

Ensure all venting components are clear of burrs/debris prior to assembly. Care is to be taken to avoid ingestion into the fan of plastic debris left in the combustion air piping.

All joints must be secured using appropriate solvent cement to bond the respective pipe material (Canada: CPVC cement approved under ULC-S636, in accordance with its manufacturer instructions; USA: PVC (ASTM D2564), or PVC/ABS (D2235)

- Use transition glue anywhere that PVC and CPVC are joined. Follow the cement

manufacturer’s instructions closely when joining various components. For PPs, connections shall be secured using approved retainer clips supplied by the respective PPs manufacturer.

1-8

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

WARNING

Follow all installation instructions supplied by the pipe

and tting manufacturer.

Figure 5A: 26-260 Fan control harness plug

Figure 5B: 40-399 Fan control harness plug

BEST PRACTICES

To reduce the possibility of expansion noise, allow a 1/4” gap around the exhaust and air intake piping.

WARNING

Condensate can cause corrosion

of metal roong components and other roong materials.

Check with the builder or

roong contractor to ensure

that materials will be resistant to

acidic condensate. pH levels can

be as low as 3.0

All vent connections must be liquid and pressure tight. Prior to ring 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 and water solution.

The installer must ll the condensate trap prior to testing.

To drive the fan into manual high speed operation for vent leak testing, unplug the fan control harness plug (see Figures 5A and 5B), and then block the vent outlet so that the vent run will be under maximum fan pressure. Paint all joints with an approved leak test solution just as you would joints in a gas line, and make sure there are no leaks. Good practice would suggest that the installer attach a tag on the vent line near the condensate drain tee indicating the type of test, the date and the installer’s name.

1.4.4 Venting Passage Through Ceiling and Floor

• Conrm material meets local codes including re stopping 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 liquid and pressure tight.

1.4.5 Rooftop Vent Termination

a) Rooftop vents must terminate as follows:

• The exhaust pipe can terminate in an open vertical orientation without concern about

rain inltration; rain will drain away through the condensate trap.

• Optional bird screen may be placed in a termination 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, direct vent congurations, including typical clearance requirements,

are shown in Figure 8.

• The intake air pipe is not typically drained, so it must be terminated with a down-turned

elbow (see Figure 8).

• The intake pipe does not need to penetrate the roof at the same elevation as the

exhaust (as shown); lower down on the roof is acceptable.

• For roof top venting of multiple boiler sets, group all intake terminals together for a

common penetration through a custom cap. Alternatively, place in the closest proximity

achievable using commonly available pipe ashing. Similarly group the exhaust pipes

and place the two separate groups of pipes at least 3' apart (the closest intake and exhaust pipes shall be 36", or more, apart). Use the same 12" (minimum) vertical separation for all termination options. For alternate group terminations, contact the IBC Factory for written guidance.

• Roof Top Concentric Termination kits are approved for use with the boiler model. The

installation of the vertical roof top concentric termination must follow the installation instructions supplied with the venting material manufacturer. Care must be taken to install the termination kit a minimum horizontal distance of 10’ (305cm) away from any portion of the building and a minimum of 2’ (61cm) above the roof line plus the anticipated snow line.

INSTALLATION

1-9

Figure 6: IBC recommended minimum vent terminal clearance

under ventilated soft

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

Figure 8: Rooftop vent terminal congurations

Figure 7: Prohibited installation

Rooftop vent termination with sidewall combustion air

1.4.6 Sidewall Vent Termination

a) Vent terminal clearance minimums are as follows:

• The exhaust vent terminal is to be placed 18” minimum (12” in USA) above the grade

or anticipated snow level.

• Clearance above grade, veranda, porch, deck or balcony – 12” (0.3m), but check local

code also (anticipated snow levels may supersede).

• Clearance to openable window or door – 36” (0.91m) (USA – 12”)

• Vertical clearance to ventilated soft located above the terminal - 48” (1.2m)See

Caution note in this section.

• Clearance to each side of centre line extended above meter/regulator assembly: - 3’

(0.91m) within a height of 15’ (4.6m) above the meter/regulator.

• Clearance to service regulator vent outlet: - 3’ (0.91m)

• Clearance to non-mechanical air supply inlet to building or the combustion air intake to

any other appliance: - 3’ (0.91m) (USA – 12” (0.3m))

• Clearance to a mechanical air supply inlet: - 6’ (1.82m) (USA - 3’ (0.91m) above if

within 10’ (3.1m) horizontally)

• Clearance above paved sidewalk or paved driveway located on public property: - 7’

(2.2m) Note: Cannot terminate directly above a paved sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings

• Clearance under veranda, porch, deck or balcony: - 12” (0.3m) IBC strongly

recommends a minimum of 24” with the boilers to avoid damage to the structure. Note:

Prohibited unless fully open on a minimum of two sides below the oor.

• Vents must be installed such that ue gas does not discharge towards neighbor’s

windows, or where personal injury or property damage can occur.

• It is important to ensure proper condensate management from vent terminations.

Condensate shall not be discharged in a manner that will cause damage to external

building nishes or components, or inltrate building envelopes, including adjacent

structures.

1-10

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

Figure 10: Vent terminal clearances

Figure 9: Sidewall vent termination indoor combustion air applications

CAUTION

Vent termination clearances in this section are code minimum, or IBC recommended minimum

requirements, and may be inadequate for your installation. Building envelope details must

be examined carefully, and ingress of moisture into building

structures is to be avoided.

Serious structural damage may

occur if adequate precautions

and clearances are not allowed for.

These precautions are to be

observed for neighboring

structures as well as for the

structure the boiler(s) are

installed in.

Figure 11: Vent terminal clearances

b) Sidewall vent termination for indoor combustion air applications shall be as follows:

• The vent shall be terminated with a tee tting as illustrated - See Figure 9.

• Bird screen of 1/4” stainless steel or plastic mesh (IPEX System 636 drain grate)

should be installed in both open ends of the tee.

INSTALLATION

1-11

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

WARNING

It is extremely important to maintain at least the minimum

separation of exhaust vent

termination from boiler intake

air as illustrated in gures 12

and 13. Failure to do so can result in a dangerous situation where exhaust gasses are reingested with combustion air. Damage to the boiler can result from a failure to maintain these

separations. Third party vent

termination kits and concentric wall penetration kits that do not maintain these minimum separations shall NOT be used. Improper installation will

void the warranty. Do not use

proprietary InnoFlue or PolyPro

PPs terminals available without specic approval from IBC.

•

Figure 12: Sidewall vent termination

c) Sidewall Direct Vent with separate vent and air pipes shall be terminated as follows:

• Both the intake air and exhaust vent terminations shall be located on the same plane

(side) of the building.

• The exhaust vent termination is to be placed so as to reach 12” minimum above the

down-turned intake to avoid exhaust re-ingestion.

• The elevation of both terminations can be raised in “periscope style” after passing

through the wall, then congured as in Figure 12 to gain the required clearance.

• Use a 45° elbow on the exhaust termination to launch the plume up and off the sidewall

(for protection of wall).

• Bird screen of 1/4" stainless steel or plastic mesh (IPEX System 636 drain grate) is

useful to guard against foreign objects.

Figure 13: Sidewall vent termination options - multiple vent piping congurations

1-12

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

WARNING

In areas of high snowfall, users

must be advised to check side wall vent and air intake

terminations on a regular basis to ensure blockage does not occur.

CAUTION

Take care installing Concentric Side Wall Termination kits. Blockage of the combustion air intake can occur when the outdoor temperature drops below 5°F/-15°C.

d) Sidewall Direct Vent with Stainless Sidewall Terminal shall be terminated as follows:

• The Stainless Sidewall Terminal (SST) 3 inch IBC part number 180-149 (sold

separately included with the IBC kit P-257 ), is the only direct vent sidewall terminal approved for use with the IBC boiler model.

• The boiler’s controller is required to be the Touchscreen type and have software

version 1.02.2 or later installed for SST to be used.

• The SST shall be installed in compliance with the minimum vent clearances listed in a)

above.

• The installation instructions included with the kit shall be carefully followed.

• The SST shall only be installed with the vent and intake pipes horizontally beside

each other or vertically with the vent pipe on top as shown in Figure 14. The vent pipe cannot be installed below the intake. The vent cap must be installed with the openings directed up and down, as shown in Figure 14, and not side to side.

• The SST vent/air connections t Sched. 40 three inch PVC/CPVC pipe. PPs pipe

cannot be used with the SST. The pipes must extend completely through the wall as shown in Figure 15 and immediately inside the wall adapt up to a 4 inch pipe using

a standard reducing coupling tting. Do not use a bushing. The SST is an external xture, and is not part of the sealed vent system that runs inside the building.

• Ensure that the vent termination location does not exceed the allowed maximum

equivalent vent length, including the allowance for the SST, dened in this document

section 1.4.3 Vent Travel and section 1.4.7 “Direct Vent” Combustion Air Intake Piping.

• Multiple vent SST installations must be installed level with one another, and maintain

at least the minimum separation distances shown in Figures 16 and 17. The Terminals shall not be stacked vertically.

•

The two basic methods for supplying combustion air to an IBC boiler are described in

sections 1.4.7 and 1.4.8.

e) Approved PVC Side Wall Termination kits are listed below:

• Ipex # 196984 2"

• Ipex # 196985 3"

• Ipex # 196986 4"

These kits are sold separately through the manufacturer.

INSTALLATION

Ipex # 196984 2" PVC, #196985 3" PVC, and # 196986 4" PVC

1-13

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

Figure 14: Allowed SST installation orientations

Figure 15: Pipes extend completely through the wall (Vertical orientation shown).

Figure 16: Minimum separation for multiple vent installation - vertical orientation

Figure 17: Minimum separations for multiple vent installation - horizontal orientation

1-14

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

WARNING

In addition to preventing

ingestion of chemical contaminants, care must be taken to ensure air intake terminals are not installed in locations where contamination might occur due to ingestion of particulate foreign material (dust,

dirt and debris).

WARNING

Intake air openings must be

congured such that rain or

other forms of moisture cannot enter the air intake piping system. Otherwise serious damage to the boiler may result.

NOTE

Care must be taken when installing air intake piping to ensure that a “trap” is not formed in the piping so as to allow a build-up of water, and blockage of intake air.

1.4.7 “Direct Vent” Combustion Air Intake Piping

The direct vent option uses piping from the outside to supply combustion air directly to the boiler’s combustion air connection.

Figure 18: Direct vent combustion air intake

SL 26-260 G3

Such blockage will result in a boiler safety shut-down.

NOTE

Combustion fan blockages

can occur when environmental

particulate and foreign matter

contaminants (leaves, dust, dandelion & cottonwood uff, etc) are drawn into the air intake.

In areas where this problem is suspected to be an issue,

intake air ltration should be

considered. Contact Factory.

Filters should be checked and cleaned or replaced on a regular

schedule based on the severity

of the problem.

INTAKE PIPE SIZE MAXIMUM EQUIVALENT LENGTH

Sched.40; Rigid PPs

3" 200' each side

90° vent elbow allow 8' equivalent

90° long sweep elbow allow 5' equivalent

45° elbow allow 3' equivalent

PPs 87-90° elbows use 8' equivalent

3" Stainless Sidewall Terminal IBC P/N 180-149 (P-257)

Flexible PPs

3" PPs Flexible (SL 26-260 G3)

Table 4A: Maximum Intake Pipe Venting Length for SL 26-260 G3

No additional allowance required

60' max., actual lineal x 3.33 = equivalent

INSTALLATION

1-15

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

NOTE

It is not permitted to add to the exhaust length by transfer of unused intake allowance.

NOTE

Combustion air piping - if used - is inserted directly into the 4” female

stainless steel tting on the top,

right side of the boiler and run horizontally or vertically to the outdoors. Screen material can be placed at the inlet as appropriate for the environment (e.g. insects, dust).

SL 40-399 G3

INTAKE PIPE SIZE MAXIMUM EQUIVALENT LENGTH

Sched.40; Rigid PPs

4" CPVC / Rigid PPs 200' (each side)

90° vent elbow allow 8' equivalent

90° long sweep elbow allow 5' equivalent

45° elbow allow 3' equivalent

PPs 87-90° elbows use 8' equivalent

3" Stainless Sidewall Terminal IBC P/N 180-149 (P-257)

3" PVC (to adapt to SST) for each 1' allow 3.2' equivalent

Flexible PPs

4" PPs Flexible 160' max, using 1.2 x for equivalent length

Table 4B: Maximum Intake Pipe Venting Length for SL 40-399 G3

For the inlet air – 4" Schedule 40 PVC, CPVC, ABS, or PPs piping of any type is permitted.

Care must be taken to ensure adequate separation is maintained between the air intake

inlet and the vent terminal. Refer to the vent terminal conguration drawings in the Vent

Termination section above.

Support should be provided for intake piping, particularly so for horizontal runs (follow local code).

No additional allowance required

WARNING

When using Indoor Air options, adequate combustion air must be supplied to the boiler room according to the requirements of all applicable codes.

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.

Figure 19: Indoor combustion air intake

1-16

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

To support combustion, an ample air supply is required. This may require direct openings in the boiler room to the outside. If the boiler is not in a room adjacent to an outside wall, air may be ducted from outside wall openings.

Provisions for combustion and ventilation air must be made as follows:

• in the USA, in accordance with the National Fuel Gas Code, ANSI Z223.1 (latest

edition), or applicable provisions of the local building codes

• in Canada, in compliance with B149.1

1.4.9 Combustion Air Filtration

If combustion air contamination from ingested particulate matter is a concern in any

installation, an optional air intake lter may be installed.

IMPORTANT: Under no circumstances should a third-party air lter be installed on

an IBC boiler without proper evaluation and written approval of the IBC Engineering Department.

Figure 20: Air Intake Filter Assembly P-172

INSTALLATION

Figure 21: Combustion air intake

1.4.10 Closet Installations

For installations in a conned space (such as a closet), ventilation openings may be

needed through a door or wall to prevent excessive heat from building up inside the space.

The boiler shall not be exposed to ambient conditions above 122°F (50°C) or below 32°F (0°C).

1-17

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

1. Install condensate

2. Slide retainer around trap and

4. Secure trap with nut and

SL 80-399 MODULATING GAS BOILER

WARNING

Fill trap with water before boiler

is rst red to prevent exhaust fumes from entering room. Never

operate the boiler unless the trap

is lled with water.

Failure to comply will result in

severe personal injury or death.

trap and tube.

slide retainer tabs into cabinet.

3. Pass tube through retainer.

1.5 CONDENSATE REMOVAL

IBC’s specied vent conguration promotes the safe drainage of moisture from the boiler and exhaust venting without owing liquids back through the heat exchanger (as done by

some other condensing boilers).

Reliable system operation requires (1) proper design and installation of exhaust venting to allow condensate to run back to the drain/trap; (2) acid neutralization as appropriate. To achieve these:

• Allow for a 1/4” per foot slope back to the vent connection, with appropriate hangers to maintain that gradient.

• Ensure the supplied trap is correctly installed and lled with water.

• When required, add (and maintain in good condition) a neutralization tank.

1.5.1 Condensate Trap

The condensate trap must be installed on the drain connection at the base of the boiler as shown in Figure 22.

1.5.2 Condensate Trap Assembly - Installation

1. Remove the boiler door and remove the condensate trap door by removing the 2 nuts and washers, lower the front of the trap door and slide forward. Undo the Drain Spout Compression Nut (E), remove the Drain Hose (G) from Trap Drain Outlet (F). Place

the Vacuum breaker cap (J) over the Vacuum breaker opening and push rmly home.

Remove the Upper Compression Nut and Washer (C) and slide over the Boiler Drain Outlet (A).

2. Fill the trap with water and slide the trap body (D) over the Boiler Drain Outlet (A) and tighten. Attach the Drain Hose (G) and tighten the Drain Spout Compression Nut (E).

3. Install the Condensate Trap Door and tighten the 2 hex screws. Check for leaks.

washer.

Figure 22: Condensate trap installation

WARNING

The Trap Door must be installed

as instructed and all trap ttings

must be tightened as instructed

to prevent leakage of ue gasses.

Failure to comply may result in

severe personal injury or death.

1-18

Condensate Trap, as shipped and disassembled

INSTALLATION AND OPERATION INSTRUCTIONS

NOTE

It is the responsibility of

the installing and/or service Contractor to advise and instruct

the end User in how to perform the Trap cleaning procedure,

and to advise that the Trap be checked at least every two months and cleaned as required.

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

INSTALLATION

1.5.3 Condensate Trap Assembly - cleaning procedure

1. Turn off the power to the boiler and allow it to cool down.

2. Remove the trap from the boiler (reverse the installation procedure above).

3. Remove the Trap Cleanout Assembly (H) from the Trap Body and clean and ush the

debris out.

4. Re-assemble the trap components, re-ll the trap, and replace on the boiler as

described in the installation instructions above.

1.5.4 Further installation details

• The condensate drain must be piped to within 1” of a drain or connected to a condensate pump.

• Drainage line must slope down to the drain at a pitch of 1/4” per foot so condensate runs towards the drain.

• Condensate traps should be checked every two months, and cleaned and relled as necessary.

1-19

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

Figure 23: Condensate trap disassembly for cleaning

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 must be measured on a regular schedule to ensure the neutralizing agent

is active and effective.

DANGER

The water in the condensate

neutralizer can cause severe

burns to the skin. Use extreme

caution when servicing the

condensate neutralizer. Wear

protective gloves and eyewear.

Figure 24 Condensate trap drainage

Figure 25: Condensate neutralization tank

1-20

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

WARNING

During operation, the relief valve

may discharge large amounts of steam and/or hot water. Therefore, to reduce the potential for bodily injury and property damage, a discharge line MUST be installed that it:

1. is connected from the

valve outlet with no intervening valve and directed downward

to a safe point of discharge.

2. allows complete drainage of both the valve and the discharge line.

3. is independently supported and securely

anchored so as to avoid applied stress on the valve.

4. is as short and straight as possible

5. terminates freely to atmosphere where any

discharge will be clearly visible

and is at no risk of freezing.

6. terminates with a plain end which is not threaded.

7. is constructed of a material suitable for exposure

to temperatures of 375°F or

greater.

8. is, over its entire length, of a pipe size equal to or greater than that of the valve

outlet.

1.6 WATER PIPING

1.6.1 General Piping Issues

Primary/secondary piping, or the use of a hydraulic separator is recommended for

maximum exibility in multi-load applications, but piping loads in parallel is also

encouraged in systems that only have two loads, or when loads are operating simultaneously. The extremely low pressure drop through the SL Series heat exchanger allows many options not available in other designs. 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.

SL 26-260 G3

These boilers are designed for use within a closed loop, forced circulation, low pressure

system. A 30 psi pressure relief valve (3/4” NPT) is supplied for eld installation at one

of the locations shown in the following illustrations. Relief valve discharge piping must

terminate between 6” (15cm) and 12” (30cm) above the oor or per local Code.

SL 40-399 G3

These boilers are designed for use within a closed loop, forced circulation, low pressure

system. A 30 psi pressure relief valve (3/4" NPT) is supplied for eld installation in the relief valve tting on top of the boiler. An optional 75 Psig relief valve can be used where

required on closed loop systems within multi-level buildings. Relief valve discharge piping

must terminate between 6" (15cm) and 12” (30cm) above the oor or per local Code.

DO NOT CAP, PLUG OR OTHERWISE OBSTRUCT THE DISCHARGE PIPE OUTLET!

CAUTION

Installers should inquire of local water purveyors as to the

suitability of their supply for use in hydronic heating systems.

If water quality is questionable,

a local water treatment expert must be consulted for testing,

assessment and, if required,

treatment.

Alternatively, water or hydronic uid of known quality can be

brought to the site.

INSTALLATION

Figure 26: Boiler trim options - Single boiler

System piping is connected to the boiler using the 1 1/2" NPT-M threaded ttings.

Unions and gate or ball valves at the boilers supply and return water connections are recommended to simplify servicing. Un-insulated hot water pipes must be installed with a minimum 1/4" clearance from combustible materials.

1-21

WARNING

Close ll valve after any addition

of water to the system, to reduce risk of water escapement.

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

Fluid ll is most often accomplished by using a boiler regulator & ll valve set at 12 psig or more, with the appropriate backow prevention device as required by local code. This is acceptable in areas where municipal water or well water has been treated and ltered

to remove excessive minerals and sediment, and water chemistry is known to be suitable for closed loop hydronic systems. In areas where water quality is in question, or when chemical treatment or glycol is required, other options should be considered. Follow the applicable codes and good piping practice.

There are a number of boiler feed and pressurization devices on the market today that

may be a better choice than a raw water ll from the mains. When regular maintenance

requires relief valve blow-off, the discharge may be directed back into the pressurization

unit for recycling of boiler uid and chemicals back into the system. In buildings that may be unoccupied for long periods of time, pressurization units are useful to prevent ood damage should leakage occur from any component in the system. An additional benet is that backow prevention devices are not required when using these devices.

Do not place any water connections above the boiler; leaks can damage the fan and

controls. If needed, create a shield over the top of the cover, but allow clearance for airow

and service access.

For best results, use a Primary/Secondary piping system, with a pumped boiler loop using 2" piping. Refer to Tables 5A and 5B for boiler head loss information.

Supply stack upper tapping - 3/4” FIP to accept relief valve and air vent assembly

Relief valve and air vent assembly

(recommended conguration)

For example, the minimum ow rate required through the heat exchanger is 20 gpm and a maximum of 45 gpm is allowed. Primary/Secondary piping ensures adequate ow and de-couples Δ°T issues (boiler vs. distribution). Aim for a 20° to 30° F Δ°T across the heat exchanger at high re (there is a boiler protection throttle fence limiting the Δ°T to 40°F).

NOTE

Full sized application drawings can be downloaded from our web site.

Figure 27: Primary/Secondary piping concept with hydraulic separator

The boilers can supply multiple heating loads with compatible supply temperature requirements. Always ensure that loads sensitive to high temperatures are protected using means such as mixing valves.

www.ibcboiler.com

1-22

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

WARNING

Water quality has a signicant

impact on the lifetime and performance of an IBC Boiler heat exchanger.

Improperly prepared water in a heating circuit may cause damage to the heat exchanger through corrosion or fouling. Repeated or uncontrolled water

lls will increase the potential

for damage.

High levels of dissolved solids

or minerals may precipitate

out of the uid onto the hottest

part of the heat exchanger, impairing heat transfer and

resulting in overheating and

premature failure. The amount of solids that may form on the heat exchanger will depend on the degree of hardness and

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

so as to remove all dissolved

solids. Other water chemistry allowable limits are as follows:

Acidity pH is to be between 6.6 and 8.5

Chloride is to be less than 125 mg/l

Iron is to be less than 0.3 mg/l

Cu less than 0.1 mg/l

Conductivity is to be less than 400μS/cm (at 77°F (25°C))

Hardness is to be 7 Grains or less

IMPORTANT: Ensure that these limits are acceptable for the other water-side components in the system.

BOILER HEAD LOSS

BOILER HEAD LOSS SL 26-260 G3

Flow rate (gpm) 6 10 15 20 25

Head @ ow (ft wc) 2’ 3.5’ 5.5’ 8’ 13’

Table 5A: Boiler Head Loss

BOILER HEAD LOSS - SL 40-399 G3

Flow rate (gpm) 20 25 30 35 40 45

Head @ ow (ft wc) 1 1.5 2 3 4 6

Table 5B: Boiler Head Loss

Ensure that the pump is rated for the design circulating water temperatures; some pumps have a minimum water temperature rating above the low temperature potential of the

boiler. Following installation, conrm the actual performance by measuring Δ°T (under high and low ow conditions) after establishing the correct ring rate.

We require water ow after burner shutdown to utilize legacy heat – this is signicant

due to the mass of the heat exchanger plus its internal water volume. Default software values will run the boiler’s primary pump for up to 5 minutes (300 seconds) after burner shutdown. Secondary pumps can be set to run up to 15 minutes after burner shutdown (for the last calling load). As shipped, the default software will run the Load 1 pump for 5 minutes to place the legacy heat where it is useful. Any secondary pump can be set to run for 0 – 900 seconds in the heat purge mode. Guard against deadheading pumps when all

zone valves are closed (see Section 2.7 Set Up & Load Denition).

The primary pump must be under the control of the boiler to allow pump purge after burner shut-down.

Schematics for several piping layouts are provided, and additional drawings are available at www.ibcboiler.com. Installers shall conform the piping design to one of the

provided congurations to simplify the control application, promote good loads and ow

management.

Propylene glycol solution is commonly used in a closed loop where freeze protection is required. Its density is lower than that of water, resulting in lower thermal performance at a

given ow and pressure. As a rule of thumb, a 50%:50% solution of propylene glycol and

water will require an increased system circulation rate (gpm up 10%), and system head (up 20%) to provide performance equivalent to straight water.

INSTALLATION

1-23

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

WARNING

Do not use automotive-type

ethylene or other types of

automotive glycol antifreeze,

or undiluted antifreeze of any kind. This may result in

severe boiler damage. It is the

responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials. Improper

mixtures and chemical additives

may cause damage to ferrous and non-ferrous components as well as non-metallic, wetted components, normally found in hydronic systems. Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation

location. For environmental

and toxicity reasons, IBC recommends only using nontoxic propylene glycol.

1.6.2 Installation Rules

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 entrance to the cool load (this will also

provide oor protection). This will permit immediate circulation of mixed ow into the cool

loop.

NOTE

The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with

appropriate valves to prevent the

chilled medium from entering the boiler.

NOTE

The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must

be equipped with ow control valves or other automatic means to prevent gravity circulation

of the boiler water during the cooling cycle.

Figure 28: Primary/Secondary piping concept with simultaneous setpoint calls. Always

ensure that loads sensitive to high temperatures (e.g. radiant oor) are protected using

appropriate means such as a manual mixing valve, or an aquastat (set to130°F, for example) wired to the boiler’s auxiliary interlocks.

Figure 29: Two pump, two load - parallel piping concept

1-24

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

Compared with the Primary/Secondary approach, the above design saves one pump. Lost

is the simplicity of constant head and ow at the boiler.

Check valves or thermal traps should be used to isolate both the supply and return piping

for each load - to avoid thermal siphoning and reverse ow.

To ensure adequate water ow through the boiler under high-head / single zone space

heating conditions, a pressure activated bypass or other means of bypass must be used

on any load where the ow rate might drop below minimum requirements (20 gpm).

For further information and details, consult our Application Notes – which provide detail on

specic single and multiple boiler applications “Piping”, “Wiring” and “Settings”. (available

at www.ibcboiler.com or from your IBC Representative).

INSTALLATION

1-25

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. We require that our boilers

be installed by licensed and experienced trades people who are familiar with the applicable local and national codes. System design is to be completed by an experienced hydronic designer or Engineer. It is necessary to carefully read and follow these installation instructions along with

the application drawing that ts

your system.

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

1-26

Figure 30: Trim for multiple boiler installations

Figure 31: Mulit-Plex Racking System

INSTALLATION AND OPERATION INSTRUCTIONS

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 energize an internal relay to operate the air handler circulator and its fan on a call for heat. This may result in operation of these components when other loads are running at a higher priority, resulting in cold air blowing, or robbing heat from another load.

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

Some wiring alteration may

be required to divorce both of

these functions from thermostat

control in favour of more effective control from the IBC

boiler.

NOTE

For further information and details regarding Multiple Boiler application, consult our

Technical Notes - Multiple Boiler Systems. These notes provide

necessary detail on specic

single and multiple boiler applications “Piping”, “Wiring”

and “Settings”. (available at

www.ibcboiler.com or from your

IBC Representative).

Figure 32: Multiple boiler piping

Figure 33: Jumper

INSTALLATION

Figure 34: Multiple boiler inter-wiring

1-27

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

NOTE

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

It is essential to check gas supply pressure to each boiler with a manometer or other high-

quality precision measuring device. Pressure should be monitored before ring the

boiler, when the regulator is in a “lock-up” condition and during operation, throughout the boiler’s full modulation range.

Pay special attention to retrot

situations where existing

regulators may have an oversized orice 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 specication at all ring rates,

and will not exceed the boiler’s maximum pressure rating when locked-up with no load.

1.7 GAS PIPING

The boilers require an inlet gas supply pressure of at least 4.0" w.c. for natural gas or

propane during high re operation. This will ensure that gas pressure measured at the gas valve inlet pressure tap does not droop below 3.5" w.c. at high re. For either fuel, the inlet pressure shall be no greater than 14.0" w.c. Conrm this pressure range is available with

your local gas supplier.

The inlet gas connection to the boiler is 3/4" NPT (female).

Adequate gas supply piping shall be provided with no smaller than 3/4" Sched 40 (e.g. Iron Pipe Size (IPS)) and using a 1" w.c. pressure drop, in accordance with the following chart:

MODEL

SL 26-260 G3 (Natural Gas) 20' 80' 300' 600'

SL 26-260 G3 (Propane) 70' 200' 800' 1600'

SL 40-399 G3 (Natural Gas) 10' 40' 150' 300'

SL 40-399 G3 (Propane) 30' 100' 400' 900'

Table 6: Maximum Pipe Length (ft)

Gas piping must have a sediment trap ahead of the boiler’s gas valve (see Figure 34). A manual shutoff valve must be located outside the boiler, in accordance with local codes/ standards. All threaded joints in gas piping should be made with an approved piping compound resistant to the action of natural gas/propane. Use proper hangers to support gas supply piping as per applicable codes.

The boiler must be disconnected or otherwise isolated from the gas supply during any pressure testing of the system at test pressures in excess of 1/2 psig. Dissipate test pressure prior to reconnecting. The boiler and its gas piping shall be leak tested before being placed into operation.

3/4" IPS

1" IPS 1 1/4" IPS 1 1/2" IPS

The gas valve is provided with pressure taps to measure gas pressure upstream (supply pressure) and downstream (manifold pressure) of the gas valve (see Figures 35A and

35B). Note that manifold pressure varies slightly in accordance with ring rates with the

modulating series boilers, but will always be close to 0” w.

Figure 35: Typical gas piping

1-28

INSTALLATION AND OPERATION INSTRUCTIONS

Line voltage leads for power supply, primary pump and VS output

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

1.8 ELECTRICAL CONNECTIONS

All electrical wiring to the boiler (including grounding) must conform to local electrical codes and/or to the National Electrical Code, ANS/NFPA No. 70 – latest edition, or to the Canadian Electrical Code, C22.1 - Part 1.

1.8.1 120 VAC Line Voltage Hook-up

Line-voltage wiring is done within the eld-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) has been factory installed and connected to P/V-L and P/V-N for your convenience. If you 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. 24 VAC 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 manages all the loads without need of further relays (for loads up to 1/3 HP; for more – use a protective relay).

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.

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 touchscreen controller, so there is no need for

temporary pump wiring during system lling / air purging. If pumps are hard-wired to the panel during the system ll/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 an 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 airow / 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 eld

replaceable fuses. Each pump is fused with a separate 5 Amp fuse. The Alarm contact is fused with a 5 Amp fuse and the 24 VAC boiler control circuit is protected with a 2 Amp fuse.

INSTALLATION

1-29

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

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 spikes, lightning strikes and

other forms of severe electrical

“noise”. Power conditioning

equipment (surge protectors, APC or UPS devices) may be required in areas where power quality is suspect.

1.8.2 Power Quality and Electrical Protection

In areas of unreliable power, appropriate surge protectors and or power conditioning equipment should be installed in powers supply wiring circuits.

1.8.3 Zone Valve Hook-up

If zone valves rather than pumps are used to manage multiple heating loads, then 24 VAC for the zone valves should be provided to the power contacts on the Pump/ Zone Valve Terminal Block. Disconnect the 120 VAC leads connected to PV-L/PV-N and cap off. Use a separate transformer – the 40 VA unit inside the wiring box is for internal systems only. The individual load/zone valves are then to be wired to their associated contacts on the secondary pump/zone valve connector. Do not confuse such “load/zone valves” with similar valves used to segregate a single load type (e.g. those used on a zoned radiant

oor) – see next section.

1.8.4 Thermostat / Sensor Wiring

Dry contacts for thermostats for each of the four loads are provided as marked on the lower connector strip (e.g. “Therm 1”). Gang lines from a multiple-zoned load (e.g. off

the end-switches for each radiant oor zone) present a common thermostat signal to the controller. Ensure that there are no disturbing inuences on the call-for-heat lines - e.g.,

that no coils to switch an air handler motor. Most power stealing thermostats can be connected directly to the Therm terminals. manual for

more detailed instructions.

See the

V-10 Touchscreen Boiler Controller

DANGER

Do not connect thermistor sensors to “Therm” terminals.

An overheating hazard can result

in serious personal injury and/or property damage. See Controller

Manual section 2.1.1 for detailed instructions.

NOTE

The IBC Touch-Screen controller has the ability to connect to most power stealing thermostats. See the V-10 Touchscreen Boiler Controller manual for details.

1.8.5 Other Wiring

Other optional low voltage connections to the control board include:

• Two auxiliary interlocks - for external safety devices as may be required by some jurisdictions, such as a low water cutoff or a low gas pressure cut-out (for off-grid

propane). A oor-protecting aquastat (water temperature control) can use one of these, to cause a full boiler shutdown in the case of excess oor temperature.

• Contacts for indoor and outdoor temperatures sensors associated with reset heating. A 10K ohm thermister (resistor dependent on temperature) for outdoor reset sensing is

supplied with the boiler for improved comfort and combustion efciency.

• One pair for a DHW tank sensor. Connect to “DHW S” (not the respective Therm. 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 connection – this is used for connecting multiple SL and/or VFC modulating units for autonomous staging.

• The bottom pair of contacts receives a 0-10VDC (default) or 4-20 mA signal from an external boiler controller for direct throttle control. The boiler’s own sensors act as high limits only. The user must enter maximum and minimum boiler supply temperatures.

NOTE: Sensors connected to any sensor input contacts must be of the NTC Thermister

type with a resistance of 10,000 ohms at 77°F (25°C) and β = 3892. We do not

recommend using 3rd party supplied sensors. Compatible water temperature sensors and outdoor sensors can be supplied by your IBC distributor.

1-30

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 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 be adjusted to the current draw of its associated zone valve.

BOILER SYSTEMS AND OPERATION

Figure 36 : Electric wiring connections (full-page wiring diagram on the back of this manual}

1-31

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

THIS PAGE IS INTENTIONALLY LEFT BLANK.

1-32

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

2.0 IBC BOILER CONTROLLER

2.1 GENERAL

This boiler is equipped with the V-10 Touchscreen controller. The controller simplies the programming of the boiler while providing greater exibility. For more detailed instructions,

reference the Touchscreen Boiler Controller manual.

The controller is equipped to provide:

• Control of up to 5 pumps – 1 boiler pump + 4 separate load pumps

• Outdoor Reset control

• Set Point temperature regulation

• Domestic Hot Water (DHW)

• External control via 0-10VDC or 4-20mA signaling

• Alarm dry contacts

• 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 touchscreen control include:

NOTE

No sharp or metallic object should be used on the touchscreen as this will cause damage. Use only a Stylus or a

clean nger.”

• Express Setup Menu for simple, quick programming

• Software updatable in the eld with an SD card or a USB stick

• Setup conguration back-up and cloning using an SD card or USB stick

• Superior warning messages while setting up the control

• Advanced Error messages with visual display on the Home Screen

• Internet/LAN connectivity

• BACnet (with activation)

2.2 CONTROL

When the boiler is rst energized, the controller will go through a power up sequence that

will take approximately 90 seconds. During this time the controller is completing a selfdiagnostic and loading all previous settings. In the event of a power interruption the boiler will automatically resume operation when power is restored with all the previously stored values. The controller provides overall management of the boiler operations including:

• Power-up, Self-diagnostics, easy Load parameter adjustments

• Burner operation, safety management systems, Call for Heat management and Load Priority

• Real time boiler data

• Temperature and throttle operation

• Maintenance of operational and error service logs

• 2-way communication between other IBC boilers and controls

Operational and historical data may be accessed at any time using the System Status

and Load Proles 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.

BOILER SYSTEMS AND OPERATION

2-1

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

2.3 CONTROL INTERFACE

The control interface is provided through a 2-1/4 x 4 inch, color touchscreen display. The

touchscreen responds to a light nger touch on the screen. You can also use a stylus or

similar device to operate the touch controls. Do not use a sharp or metallic object such as a screw driver to operate the control as it could damage the touchscreen.

The controller display is divided into two areas, the screen active area and the boiler status bar. All screens have an active area consisting of the screen title bar at the top and a border surrounding the active area. At the bottom of the display there is space reserved for the boiler status bar.

Prior to any interaction with the touchscreen, the display shows the Home screen details of the current boiler status. If the controller has been left on the Home screen long enough (user adjustable, 10 minutes by default) the display will be dimmed to save power.

The control will automatically return to the home screen if left unattended. The screens will step back one screen at a time in 10 minute increments if the touchscreen has not been touched. The pop-up windows will also step back automatically in 2 minute intervals.

The boiler status bar indicates if the boiler is in a normal, warning or alarm state. When no warning or alarm state is present, the bar will be green and the time will be displayed inside the green area. The bar can also be yellow or red corresponding a warning or alarm

state. Text inside the bar will indicate the specic warning or alarm present. If more than

one alarm is present the text display will slowly change, rotating though whatever alarms that are present.

2-2

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

3.0 STARTUP & COMMISSIONING

3.1 BOILER SHUTDOWN & LIGHTING

STARTUP AND COMMISSIONING

3-1

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

WARNING

Fill trap with water before boiler is

rst red to prevent exhaust fumes from entering room. Never operate the boiler unless the trap is lled

with water. Failure to comply will

result in severe personal injury or

death.

3.2 PRIOR TO START-UP

3.2.1 Pre-Ignition Checks

1. Ensure venting system is complete and seal tested. Conrm any common venting

system at the installation site is isolated and independent of the SL boiler. Also

conrm that any holes left from the removal of a previous boiler have been sealed, and that any resizing of the old ue has been done. Fill condensation trap.

2. Check that the water piping system is fully ushed and charged, and that all air has

been discharged through loosened bleed caps. Note it is possible to switch all pumps

on/off from the touchscreen – without a call for heat. This greatly simplies system lling and air bleeding (go to Installer Setup, System Settings, Site Settings, change

Manual Pump Purge to “ON”. When complete, return to Off, or this will automatically

occur with a call for heat). Use a minimum water pressure of 12 psig. And conrm that

the pressure relief valve is installed and safely drained.

3. Check to see that adequate gas pressure is present at the inlet gas supply test port. Open the test port by turning its center-screw one full turn counterclockwise, using a

small (1/8” or 3 mm) at screwdriver.. Connect a manometer and open the gas control

valve. Requirements are minimum 5” w.c and maximum 14” w.c. Check that there are no gas leaks.

4. Perform a nal check of electrical wiring, and provide power to the boiler to initialize operation.

Error displayed after testing ignition safety shut off

3.2.2 Test Ignition Safety Shutoff

With the boiler in operation, test the ignition system safety shutoff device by shutting the gas control valve immediately outside the boiler case. Ensure the boiler has shut off and the appropriate Error information is displayed on the Touchscreen. To restart the boiler, reset power or press “Clear Errors” in the Advanced Diagnostics section.

3.3 COMMISSIONING

The SL boilers are factory calibrated to operate with natural 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 must not be tampered with. The Low Fire (Zero Offset) screw is not to be adjusted in the eld. The High Fire (Gas:Air ratio) adjustment screw may have to be adjusted to attain optimum combustion results if required, however, no mixture adjustment shall be performed unless done by

a qualied technician using properly functioning and calibrated combustion analyzing

equipment.

The controller will automatically detect the installation's altitude and make the appropriate adjustments to operate the boiler up to 12,000 feet in elevation without de-ration. The boiler will automatically de-rate at altitudes above 12,000 feet. Refer to the IBC Altitude tables for further information.

3-2

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

DANGER

Making adjustments to the IBC

gas valve without a properly

calibrated gas combustion analyzer and by persons who are not trained and experienced in its use is forbidden. Failure to use an analyzer can result in an immediate hazard.

1. Turn off the gas supply. With a small (1/8” or 3 mm) at screwdriver, open the inlet gas

supply pressure test port by turning its center-screw one full turn counterclockwise. Attach a manometer to the pressure test port, and turn on the gas to the appliance. The static manometer reading should be ideally 7” w.c. for Natural Gas and 11” w.c. for Propane. Minimum and maximum static pressure should be between 4” and 14” w.c. Monitor pressure throughout the commissioning procedure. Pressure may drop up to 1”

to 2” w.c. at high re but under no circumstances should it drop below 4” w.c. at the gas

valve inlet test port.

2. Allow the boiler to ignite. Run against a large load, to maintain high re.

3. With a combustion analyzer probe in the ue gas test port, turn the High Fire (Gas:Air

Ratio) Adjustment screw (see Figure 37A and Figure 37B) (see Table 7 below for the corresponding CO

values - set the CO2 target at high re). This screw offers very ne

adjustment, and may require several turns.

NOTE: This screw has signicant backlash. When changing direction of turn, it may

take up to a full turn before any change is indicated on the analyzer reading. Clock

the gas meter to conrm full maximum rating plate input.

4. Conrm the minimum re level settings. Re-dene the load as “Manual Control”.

Use Heat Output in “Congure Load x” to control the output as needed. The reading should be within the Low re range. Re-test at high re.

5. Turn boiler off by removing the call for heat (use the Installer Setup screen to

turn load to off if no other ready means available). Turn off gas then remove the manometer connections, and turn the centre-screw in the manifold pressure test port clockwise until fully closed. Ensure fully closed, but not over-tightened. Restore gas and soap test for leaks.

MODEL C

RANGE TARGET RANGE TARGET

Natural Gas

Propane

Note: Low Fire CO

should be at least 0.5% lower than High Fire CO

9.0 – 10.0 9.5 8.2 – 9.2 8.7 < 150

10.3 – 11.3 10.8 9.3 – 10.3 9.8 < 250

Table 7: Combustion test target ranges - CO

HIGH FIRE LOW FIRE

/ Maximum CO

CO MAX

PPM

STARTUP AND COMMISSIONING

3-3

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

3.3.1 Gas Valve and Fan Diagrams

Figure 37A: Gas Valve and Pressure Reference System - SL 26-260 G3

Figure 37B: Gas Valve and Pressure Reference System - SL 40-399 G3

3-4

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

WARNING

Check the rating plate of the

boiler to ensure it is congured

for the fuel you are using. If the fuel is incorrect for the

appliance, a conversion kit must

be ordered from IBC and the

gas valve adjusted accordingly. Failure to perform the required fuel conversion can result in an

immediate hazard.

DANGER

Operating any IBC boiler using a fuel other than the fuel listed on its rating plate is prohibited. If the information in this section

related to conversion to

alternate fuels is not followed exactly, a dangerous situation

can result, leading to re or

explosion, which may cause property damage, personal injury, or loss of life.

3.4 FUEL CONVERSION

The SL boilers are factory re-tested to operate with natural gas 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 listed on the rating plate is prohibited

unless the following conversion procedure is completed by a qualied technician.

Refer to the previous section 3.3 - COMMISSIONING. The Low Fire (Zero offset) valve adjustment cap on the gas valve has been factory sealed using paint-seal compound. This cap must not be tampered with. The Low Fire (Zero offset) screw is not to be adjusted in

the eld.

The High Fire (Gas:Air ratio) adjustment screw will have to be adjusted to attain optimum combustion results whenever fuel conversion is undertaken, however, no mixture

adjustment shall be performed unless done by a qualied technician using properly

functioning and calibrated combustion analyzing equipment.

Fuel conversions must be carried out by a qualied technician:

1. Ensure you are installing the correct fuel conversion kit for your boiler. Compare the

boiler model number with the Kit # found in Table 8.

2. Read the fuel conversion instructions supplied with the fuel conversion kit.

3. Carefully follow the procedures of the fuel conversion instructions on:

• Fuel Conversion

• Combustion Testing and Adjustment

• Placing conversion labels associated with the new fuel onto the boiler.

4. Carefully follow the “Prior to Start-Up” – Section 3.2 and “Commissioning” – Section

3.3 procedures on the preceding pages 3-2 and 3-3.

Fuel Conversion Kit Part Numbers

MODEL NUMBER

SL 26-260 G3

SL 40-399 G3

Table 8: Fuel Conversion Kits

NATURAL GAS TO PROPANE

P-300 P-301

P-302 P-303

PROPANE TO NATURAL GAS

STARTUP AND COMMISSIONING

3-5

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

NOTE

The safety warning regarding burner refractory on page 4-2 of

this manual must be observed.

Heat Exchanger Lid removed

Refractory removed

3.4.1 Gaining access to combustion chamber and

burner removal instructions

SL 26-260 G3

1. Remove the fan and gas valve assembly. See “Fan and gas valve removal instructions” on page 4-6 of this manual.

2. Disconnect the igniter cable, gas valve cable and the two fan plugs, and move them out of the way.

3. Remove the two screws that secure the igniter to the lid using a # 2 Phillips screwdriver.

4. Carefully remove the igniter by sliding it straight up.

5. Remove the igniter gasket, and place the parts on a clean dry area.

6. Remove the 8 hex nuts that attach the heat exchanger lid to the heat exchanger with a 10 mm open-end wrench or socket.

7. With a permanent marker or equivalent, make an alignment mark between the lid, gasket, and heat exchanger.

8. Before removing the lid, it is important to be positioned directly above it to ensure a straight-up extraction. Failing to do this may result in refractory damage.

9. Slowly lift the lid-burner assembly off the heat exchanger. The refractory should remain in place in the combustion chamber shoulder. Note that there is less than 1/8” (3 mm) clearance between the burner walls and the refractory. Care must be observed to ensure minimal contact between these parts to prevent refractory cracking.

10. Place the lid with the burner attached, on a clean dry area.

11. With a permanent marker or equivalent, make an alignment mark on the refractory, lining it up with the same mark made earlier between the lid and heat exchanger.

12. Carefully remove the refractory, and place it in a clean dry area.

13. If the burner needs to be removed, gradually loosen the ve screws that secure the burner to the heat exchanger lid with a # 2 Phillips screwdriver. Then remove the screws and the burner.

Burner and Heat Exchanger Lid

3-6

SL 40-399 G3

1. Remove the fan and the gas valve assembly. See “Fan and gas valve removal instructions” on page 4-6 of this manual.

2. Disconnect the igniter cable, and move it out of the way.

3. Remove the two screws that secure the igniter to the lid with a # 2 Phillips screwdriver.

4. Carefully remove the igniter by sliding it straight up.

5. Remove the igniter gasket, and place the parts on a clean dry area.

6. Loosen the lid fasteners located around the top edge of the heat exchanger, and swing the bolts off the lid and let them hang down.

7. With a permanent marker or equivalent, make an alignment mark between the lid and heat exchanger.

8. Before removing the lid, it is important to be positioned directly above it to ensure a straight-up extraction. Failing to do this may result in refractory damage.

9. Carefully lift the lid-burner assembly straight up and out of the heat exchanger, being careful not to damage the refractory.

10. Place the lid with the burner attached, on a clean dry area.

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

11. With a permanent marker or equivalent, make an alignment mark on the refractory,

lining it up with the same mark made earlier between the lid and heat exchanger.

12. Carefully remove the refractory, and place in a clean dry area.

13. If the burner needs to be removed, gradually loosen the screws that secure the burner

to the heat exchanger lid with an M5 hex screwdriver. Then, remove the screws and the burner.

Re-assembly

SL 26-260 G3

1. Inspect the burner gasket: look for cracks, deterioration or signs of gas bypass.

Replace if necessary.

2. Place the heat exchanger lid on a at surface, and position the gasket on the lid,

aligning it with the screw holes.

3. Install the burner in place with its four screws, tightening the screws gradually and in a

cross sequence. Do not over tighten;

good seal and to prevent deformation of the burner ange.

4. Inspect the refractory for cracks, degradation and atness. If in doubt, replace with a

new one.

5. If installing a new refractory, rst place it onto the lid, aligning it at the igniter hole,

then make an alignment mark on the refractory to correspond with the previously made line on the lid.

6. Carefully insert the refractory into the heat exchanger combustion chamber, using the

alignment marks for proper positioning.

7. Ensure that the lid gasket is in good condition, and is in place and level.

8. Carefully insert the lid-burner assembly straight down. Ensure that there is limited

contact between the burner and the refractory as well as observe the alignment markings.

9. Install the 8 hex nuts to secure the lid in place; tighten by hand plus an extra 1/2 to 1

turn. Caution! Over-tightening these nuts will cause the lid to warp and possibly leak

fumes or ames.

10. Re-install the igniter, tightening its screws by hand plus an extra 1/8 of a turn.

11. Re-attach the igniter wire to the igniter, gas valve cable and the two fan plugs.

tighten by hand

plus an 1/8 of a turn to maintain a

MAINTENANCE

SL 40-399 G3

1. Inspect the burner gasket: look for cracks, deterioration or signs of gas bypass.

Replace if necessary.

2. Place the heat exchanger lid on a at surface and position the gasket on the lid,

aligning it with the screw holes.

3. Install the burner in place with its screws, tightening the screws gradually and in a cross

sequence. Do not over tighten;

tighten by hand

plus a 1/2 turn to maintain a good seal

and prevent deformation of the burner ange.

4. Inspect the refractory for cracks, degradation and atness. If in doubt, replace with a

new one.

5. If installing a new refractory, rst place it onto the lid, aligning it at the igniter hole,

then make an alignment mark on the refractory to correspond with the previously made marking on the lid.

6. Carefully insert the refractory onto the heat exchanger combustion chamber, using

the alignment marks for proper positioning.

3-7

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

7. Ensure that the lid (orange) gasket is in place and level.

8. Carefully insert the lid-burner assembly straight down. Ensure that there is limited contact between the burner and refractory, and observe the alignment markings.

9. Swing up the lid fasteners, ensuring the nuts and the washers are above the lid. Evenly tighten the nuts in a cross pattern, and ensure that the lid is securely

tightened. Test for leaks around the gasket seal to ensure there are no ue gas leaks.

10. Re-install the igniter, tightening its screws by hand plus an extra 1/2 a turn.

11. Re-attach the igniter wire to the igniter.

3-8

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

4.0 MAINTENANCE

4.1 BOILER MAINTENANCE

4.1.1 General Care

CAUTION

The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition.

CAUTION

Label all wires prior to

disconnection when servicing

controls. Wiring errors can cause improper and dangerous operation.

WARNING

Fill trap with water before boiler

is rst red to prevent exhaust fumes from entering room. Never

operate the boiler unless the trap

is lled with water.

Failure to comply will result in

severe personal injury or death.

WARNING

Whenever the burner is removed for inspection or boiler servicing,

the sealing gaskets must be examined and replaced if damaged. Upon re-assembly,

an approved leak test solution

must be applied around the

burner ange sealing area to

ensure there is no leakage of combustible gas/air premix.

• Keep combustible materials and ammable liquids and vapors away from the boiler.

• Keep vent terminals clear of obstructions (snow, dirt, etc.).

4.1.2 Inspection

Inspection of the boiler is to be performed annually by a qualied service technician.

4.1.3 Venting

• Remove any obstructions to vent terminals (e.g. leaves, dust, other debris).

• Clean or replace intake air lters or screens as required.

• Check for holes or leaks in venting. Replace venting as needed.

• Examine for any signs of moisture caused by sweating intake air pipes; insulate as

required.

• Ensure proper resealing or reinstallation of venting on each servicing.

4.1.4 Condensate Traps

• The condensate trap must be examined every two months to see if cleaning is

necessary (refer to trap cleaning instructions, section 1.5.3 of this manual). Ensure that

the trap has been re-lled completely before ring boiler.

• If condensate neutralization is used, check the pH level of condensate discharge.

4.1.5 Burner

• Annually, remove the burner to inspect for fouling (refer to the burner removal and

reassembly instructions, section 3.4.1 of this manual). Blow clear using compressed air. Evaluate the magnitude of clearing required, and establish a reasonable burner inspection schedule. Some boiler / locations may call for annual service, others showing clean burners will only need attention every 2 – 5 years. Consider adding air

ltration if the burner requires cleaning every year. In alternate years, visually inspect the burner through the sight glass. Ensure that the ame is stable and is without excessive uttering. Normal ame pattern is evenly distributed over the burner surface.

• If the burner is operating improperly, remove and clean or replace. Use a CO

to determine proper combustion. See Table 7 for correct values.

analyzer

4.1.6 Heat Exchanger

During annual inspection (with the burner removed), examine the heat exchanger for signs of contamination and clean if necessary. In areas of poor gas quality, there may be a buildup of black plaque (typically sulfur). Other fouling agents may include: airborne dust, debris and volatiles.

Refer to the burner removal instructions in Section 3.4.1 for access to combustion chamber and heat exchanger. Note that the safety warning regarding burner refractory on this page must be observed.

MAINTENANCE

4-1

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

WARNING

The IBC heat exchanger has a small amount of combustion

chamber insulation (refractory), which contains ceramic bers.

When exposed to extremely high

temperatures, the ceramic bers,

which contain crystalline silica,

can be converted into cristobalite - which is classied as a

possible human carcinogen.

Care should be taken to avoid

disturbing or damaging the refractory. If damage occurs, contact the factory for directions.

Avoid breathing and contact with

skin and eyes and follow these precautions:

1. For conditions of frequent use or heavy exposure, respirator protection is required. Refer

to the “NIOSH Guide to the Selection and Use of Particulate

Respirators Certied under 42

CFR 84” for selection and use of

respirators certied 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. Wear long sleeved, loose tting clothing, gloves and eyes

protection.

3. Assure adequate ventilation.

4. Wash with soap and water after contact.

5. Wash potentially contaminated clothes separately from other laundry and rinse washing machine thoroughly.

6. Discard used insulation in an air tight plastic bag.

NIOSH stated rst aid:

Eye contact - Irrigate and wash immediately.

Breathing - Provide fresh air.

4.1.7 Pump

Check that the pump is on in normal operation and that the water Δ°T is reasonable for a given ring rate.

4.1.8 Gas Piping

Check for damage or leaks and repair as needed.

4.1.9 Touchscreen Boiler Controller

• Check that the boiler operation is consistent with the steps in the Touchscreen Boiler

Controller manual.

• Check that the water temperature targets and setpoint are satisfactory and that they

have not been adversely amended.

• Check the operating history via the boilers Logs menu and the Error Logs menu. The

controller tracks the duty cycle of the boiler in each of the four loads separately. This information can be used to adjust the water temperatures of each load.

• If a problem exists with the control, consult the Troubleshooting section.

4.1.10 Water

• Check the water pressure and temperature. There should be no noticeable change if

the boiler is functioning normally. Check for any noise in the system.

• Check the water piping for damage or leaks. Repair as needed.

• Check for 12-15 psig in normal operation, and look to ensure pressure does not run up

toward 30 psig at high temperature. If pressure rises sharply, consider replacement of

the expansion tank. Check also for noise at high re, which may signal water quality

problems.

• Water chemistry shall be of a quality generally accepted as suitable for hydronic

applications.

• Ensure any direct “city ll” water connections are left in the closed position to minimize

exposure to leaks and ooding.

4.1.11 Freeze Protection

Check the freeze protection. Use only antifreeze made specically for hydronic systems.

Inhibited propylene glycol is recommended. Antifreeze volume must be between 25% and 50% of the total volume of water in the system.

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.

4-2

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

WARNING

Do not use automotive-type

ethylene or other types of

automotive glycol antifreeze,

or undiluted antifreeze of any kind. This may result in

severe boiler damage. It is the

responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials. Improper

mixtures and chemical additives

location. For environmental

and toxicity reasons, IBC recommends only using nontoxic propylene glycol.

4.1.13 Relief Valve - Maintenance and Testing

The relief valve manufacturer requires that under normal operating conditions a “try lever test” must be performed every two months. Under severe service conditions, or if corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be performed at the end of any non-service period.

Test at or near the maximum operating pressure by holding the test lever fully open for at

least 5 seconds to ush the valve seat free of sediment and debris. Then release the lever

and permit the valve to snap shut.

If the lever does not activate, or there is no evidence of discharge, discontinue use of

equipment immediately and contact a licensed contractor or qualied service personnel.

If the relief valve does not completely seal, and uid continues to leak from the discharge pipe - perform the test again to try and ush any debris that may be lodged in the valve. If repeated tries fail to stop the leakage, contact a licensed contractor or qualied service

personnel to replace the valve.

While performing a “try lever test”, a quantity of heat transfer uid will be discharged from the piping system and the system pressure will drop. This uid must be replaced. It is

highly recommended that a system pressurization unit, such as an Axiom Industries model

MF200 be employed to rell and pressurize your system. Capture the discharged uid

in a container and recycle it by returning it to the system feeder unit. This is particularly important when your system contains treatment chemicals or glycol solutions. If the

system employs plain water, the boiler auto ll valve must be turned on in order to recharge the lost uid.

CAUTION

Installers should inquire of local water purveyors as to the

suitability of their supply for use in hydronic heating systems.

If water quality is questionable,

a local water treatment expert must be consulted for testing,

assessment and, if required,

treatment.

Alternatively, water or hydronic uid of known quality can be

brought to the site.

CAUTION

Before testing the relief valve,

make certain the discharge pipe is properly connected to the

valve outlet and arranged to

contain and safely dispose of

equipment discharge.

MAINTENANCE

4-3

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

4.2 GEOGRAPHY & COMPONENTS

Components of the SL 26-260 G3

ITEM NO. COMPONENT ITEM NO. COMPONENT

4-4

Pressure Relief Valve

Combustion Test Port

Safety Ignition Module

Ignitor

Flue Gas Temperature Sensor

Low Water Cutoff Probe

Site Glass

Tridicator

Supply Water Pipe

Gas Valve

INSTALLATION AND OPERATION INSTRUCTIONS

Components of the SL 40-399 G3

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

ITEM NO. COMPONENT ITEM NO. COMPONENT

MAINTENANCE

Venturi Mixing Device

Fan

Supply Water Temperature Sensor

Air Intake Pipe

V-10 Touchscreen Controller

Water Pressure Sensor

Return Water Temperature Sensor

Return Water Pipe

Blocked Vent Pressure Switch

Vessel Hi-Limit Switch

4-5

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

4.2.1 Fan and gas valve removal instructions

SL 26-260 G3

1. Turn off the electric power and gas supply to the boiler.

2. Ensure the boiler cools down to the surrounding temperature. Do not drain the boiler unless freezing conditions are expected during this procedure.

3. Remove the front cover, and then remove the boiler upper-front cover by removing the screws at the top right and left corner of the boiler.

A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to connectors, screws or refractory may occur.

4. Unplug both electrical connectors from the fan.

5. Unplug the electrical connector from the gas valve.

6. Position the harnesses out of the way of the heat exchanger lid.

7. Undo the brass nut between the valve and the venturi mixing device.

8. Remove the four 8 mm hex bolts that attach the fan to the lid.

9. Remove the fan and air intake venturi assembly from the boiler.

10. Separate the fan and the venturi mixing device by removing the 3 Phillips head screws that attach the venturi mixing device to the fan.

11. Attach the venturi mixing device to the new fan.

12. Bolt the fan to the lid of the heat exchanger.

13. Attach the gas valve to the venturi mixing device with the brass coupler nut, ensuring that the gasket is in place.

14. Connect the electrical connectors to the fan and gas valve.

SL 40-399 G3

1. Turn off the electric power and gas supply to the boiler.

2. Ensure the boiler cools down to the surrounding temperature. Do not drain the boiler unless freezing conditions are expected during this procedure.

3. Remove the front cover, and then remove the boiler's upper-front cover by removing the two Phillips head screws at the top right and left corners of the boiler.

A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to connectors, screws or refractory may occur.

4. Unplug both the upper and lower electrical connectors from the fan.

5. Note the colors and positioning of the wire connectors, and then unplug the electrical connector from the gas valve by removing the 1/4” spade connectors.

6. Position the harnesses out of the way of the heat exchanger lid.

7. Remove the 4 hex head bolts using a 4 mm hex key that attaches the gas valve to

the venturi mixing device. These screws should be rst loosened slightly in a cross

sequence to prevent deformation of the mating parts.

8. With the corrugated stainless steel gas line still attached to the gas valve, the gas valve can now be separated from the venturi mixing device. There is an O-ring installed between the gas inlet block and gas valve, and it should remain positioned on the block’s groove. If it falls out it is important that it be positioned back on the groove or saved for re-assembly.

9. Remove the 4 hex nuts that attach the fan to the heat exchanger lid. A 7 mm openended wrench or socket is required.

4-6

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

10. With the venturi mixing device still attached, remove the fan by pulling straight up

ensuring that no wires are caught and that the gas line remains in place. Place the removed components in a clean, dry area.

11. Note how the venturi mixing device is positioned on the fan before removing it from

the fan. Remove the three Phillips head screws to separate the venturi mixing device from the fan.

12. Attach the venturi mixing device to the new fan.

4.2.2 Fan and gas valve re-installation

SL 26-260 G3

1. If the gas valve was removed from the venturi, ensure the gasket is in the proper

position.

2. Attach the gas valve to the venturi mixing device with the brass coupler nut.

3. Re-install the fan and gas valve assembly onto the lid using the four 8 mm hex bolts

removed earlier.

• Ensure the black gasket is installed between the fan outlet and the lid.

• Tighten by hand plus an extra 1/8 of a turn the 4 hex bolts.

• Test for leaks around the fan and lid gasket.

4. Re-attach both fan harness connectors.

5. Re-attach the gas valve connector.

6. If a new gas valve is being installed, remove the protective cover from the gas inlet

now.

7. Re-attach the gas supply line JIC connector (are-tting nut).

8. Open up the gas supply, and check for possible leaks.

9. Return the electric power to the boiler, and perform the startup routine.

10. Check for gas or fume leaks after 10 minutes of continuous operation.

SL 40-399 G3

1. If the gas valve has been removed, reattach it to the corrugated gas line.

2. Re-attach the venturi mixing device to the new fan, observing the alignment marks

made during disassembly.

3. Ensure that the fan gasket is in place (between the heat exchanger lid and the fan).

4. Re-install the fan and venturi assembly onto the heat exchanger lid, tightening the

four hex nuts by hand plus an extra 1/2 turn.

5. Plug in both the upper and lower fan harness connectors.

6. Plug in the gas valve connector.

7. If a new gas valve is being installed, remove the protective cover from the gas inlet

now.

8. Re-attach the gas inlet block onto the gas valve, ensuring that the O-ring seal is in

place. If this O-ring is lost, it must be replaced with a factory supplied O-ring.

9. Tighten by hand plus an extra 1/2 turn in cross sequence the 4 gas inlet block screws.

10. Open up the gas supply valve, and check for possible leaks.

11. Return the electric power to the boiler, and perform the startup routine.

12. Check for gas or fume leaks after 10 minutes of continuous operation.

TROUBLESHOOTING

4-7

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

4.2.3 Replacing the gas valve

SL 26-260 G3

1. Turn off the electric power and gas supply to the boiler.

2. Remove the electrical connection from the gas valve.

3. Ensure the boiler cools to the surrounding temperature. Do not drain the boiler unless freezing conditions are expected during this procedure.

4. Remove the front cover, and then remove the boiler's upper-front cover by removing the two Phillips head screws at the top right and left corners of the boiler.

A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view as damage to the connectors, screws, or refractory may occur.

5. Support the male compression coupling on the inlet of the gas valve, and with a

wrench, undo the compression tting to separate the gas valve from the gas supply

pipe.

6. To separate the gas valve from the venturi mixing device, unscrew the brass coupler nut and retain the gasket between the gas valve and the brass coupler.

7. Remove the male compression coupler from the old gas valve outlet, and install this

on the new gas valve outlet, using fuel-appropriate Teon tape on the threads.

8. Screw the brass coupler nut to the brass coupler ange on the left side of the gas valve. Ensure that the gasket is in place.

9. Supporting the male compression coupling on the outlet of the gas valve, with a

wrench, tighten the compression tting to secure the gas valve to the gas supply pipe.

SL 40-399 G3

1. Turn off the electric power and gas supply to the boiler.

2. Ensure that the boiler cools down to the surrounding temperature. Do not drain the boiler unless freezing conditions are expected during this procedure.

3. Remove the front cover, and then remove the boiler's upper-front cover by removing the two Phillips head screws at the top right and left corner of the boiler.

A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to connectors, screws or refractory may occur.

4. Noting the color and orientation of the connectors, unplug the 4 spade connectors from the gas valve.

5. To separate the aluminium gas block on the right side of the gas valve, remove the 4 hex head bolts with a 4 mm hex key.

6. To separate the gas valve from the venturi mixing device, remove the 4 hex head bolts on the left side of the gas valve with a 4 mm hex key.

7. Bolt the gas valve to the venturi mixing device ange with the 4 mm hex bolts, ensuring that the O-ring is positioned between the gas valve and the venturi mixing device.

8. Bolt the gas block to the gas valve outlet, ensuring that the O-ring is positioned between the gas block and the gas valve.

9. Connect the electrical connectors to the new gas valve.

4-8

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

NOTE

This boiler is equipped with a blocked vent shutoff system,

which closes the gas supply upon detection of an irregular

venting condition. In such event, the electronic controller

will automatically carry out a

reset/ retry every 5 minutes. See

Section 5.3.1 Airow Error for Troubleshooting steps.

5.0 TROUBLESHOOTING

The troubleshooting section is divided into 3 sections:

• Preliminary Checks

• Electronic Components

• Troubleshooting

Often, a problem can be identied and solved through simple checks of the basics: conrming the electrical power supply, gas ow and resetting the thermostat control. To

extend the cover of such preliminary checks, the boiler’s touchscreen controller offers a clear visual display of the status of the various control circuit components.

Should a problem remain unsolved after applying the preliminary checks, proceed to the detailed system review, using the Troubleshooting section. It covers potential error conditions grouped into the following categories:

• Using touchscreen controller errors displayed

• Ignition problems

• Cycling problems

• Temperature problems

• Miscellaneous

Below each section is a list of Symptoms, Diagnoses, and Remedies.

Also provided with this manual are a number of diagrams (see Section 6.0) for use with troubleshooting including:

• Electrical wiring diagrams

• Sequence of operations owchart

• Boiler component diagrams

5.1 PRELIMINARY CHECKS

The rst step in troubleshooting this system should be a review of the touchscreen

controller. There are a number of diagnostic features incorporated in the software that evaluate system integrity, display error conditions and provide initial remedial actions.

In addition to checking the display, the following list is a guideline for troubleshooting:

1. Conrm power to the boiler: check that the touchscreen controller display is on (e.g.

display is lit. The touchscreen controller’s display will be fully functional in 90 seconds after power is restored to the boiler.)

2. Check that the boiler is not in a safety lockout.

3. Ensure wiring is clean and secure.

4. Check that gas is reaching the unit.

5. Conrm that the water system is properly charged to 12 and that the pump is

serviceable.

TROUBLESHOOTING

5-1

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

5.2 ELECTRONIC COMPONENTS

This section details the method for troubleshooting the non-standard electronic components on the boiler.

5.2.1 Temperature Sensors

The 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 resistance (obtained by connecting a good quality test meter

capable of measuring up to 5,000 kΩ (5,000,000Ω) at the controller end of the sensor

lead).

To obtain a resistance reading, remove power to the boiler, and return water. For the supply water and vent temperature sensors, remove the wire leads by disconnecting their respective Molex connectors. Place multi-meter probes into the sensor’s female Molex connector socket. Do not apply voltage to the sensor as damage may result.

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE

°F °C Ω °F °C Ω

0 -18 85,362 100 38 5,828

5 -15 72,918 105 41 5,210

10 -12 62,465 110 43 4,665

15 -9 53,658 11 5 46 4,184

20 -7 42,218 120 49 3,760

25 -4 39,913 125 52 3,383

30 -1 34,558 130 54 3,050

35 2 29,996 135 57 2,754

40 4 26,099 140 60 2,490

45 7 22,763 145 63 2,255

50 10 19,900 150 66 2,045

55 13 17,436 155 68 1,857

60 16 15,311 160 71 1,689

65 18 13,474 165 74 1,538

70 21 11,883 170 77 1,403

75 24 10,501 175 79 1,281

80 27 9,299 180 82 1,172

85 29 8,250 185 85 1,073

90 32 7,334 190 88 983

95 35 6,532 195 91

903

Table 9: Temperature Sensor resistance values

5-2

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

5.2.2 Fan

Operating power is provided by means of a separate 120 VAC connector (white/black/ green). Control of the fan is provided via a four lead connector. This connector feeds a PWM control signal (black wire) from the controller and provides a tachometer signal (white wire) back from the fan. Unplugging the control connector will cause the fan to go to high speed and trigger a “Blocked Vent Error” within 6 seconds if the boiler is operating.

LEAD COLOR FUNCTION TROUBLESHOOTING

Red

Blue

Black Signal from controller

White Fan tach. 2 pulses/rev (freq x 30=rpm)

Table 10: Fan Operation

35 VDC Positive power terminal

35 VDC Negative power terminal

Fan will only operate at max. speed if disconnected.

5.2.3 Water Pressure Sensor

The water pressure sensor ensures that there is adequate pressure in the heating system for safe operation. The pressure is displayed in PSI as the default. If the system pressure

should drop below 8PSI the ring rate of the boiler is reduced. If the pressure drops to 4PSI or lower, the boiler will not re.

Check the operation of the sensor by isolating the boiler from its system piping, and close

the system ll valve, and then crack the pressure relief valve. The pressure displayed should reect declining pressure. If it remains “xed”, drain the boiler and replace the sensor, or

dislodge any blocking debris from the sensor inlet channel and reinsert.

5.2.4 Safety and Ignition Module (SIM)

The SIM is a safety control that is certied to conform to the UL 60730-5-5 and ANSI

Z21.20-2014 • CAN/CSA-C22.2 No. 60730-2-5-14 Standards. The low water cutoff function and the high-limit manual reset water temperature function also conform to these standards.

TROUBLESHOOTING

The SIM directly controls the boiler’s gas valve and provides:

• Direct spark automatic ignition

• Flame detection 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.

5-3

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

The SIM’s two status LEDs indicate the operating status as shown in the table below.

Status Indicators

LED 1 LED 2 STATE

DESCRIPTION, LED STATUS INDICATION

Rapid Flash Rapid Flash Power up or Resetting Startup checks and initialization

LED1 Off = No Flame or

Off Off Standby

Sparking

LED 2 = Burner-On Call state

LED1 Off = No Flame or Sparking

Off On Pre-Purge or Inter-Purge

On On Heating

LED 2 = Burner-On Call state

LED 1 On = Flame detected

LED 2 = Burner-On Call state

LED 1 ashing = Electrode

Rapid Flash On Igniting

Sparking, LED 2 = Burner-On Call state

An operating limit was exceeded

Off Flashing Lockout

or a sequence failed or an external sensor fault was detected.

Flash Alternately with LED 2

Flash Alternately with LED 1 Fail-Safe

A critical internal fault was detected.

The SIM is continuously communicating with the boiler’s main controller reporting sensor readings and status. The sensor readings and error status, if any are displayed on the boiler controller’s screen.

5.2.4.1 Low water cutoff function: reset and test

The low water cutoff (LWCO) function provides continuous protection against a low water incident.

If the SIM detects a low water incident, the boiler goes into a lockout condition.

Here, you will

need to reset the boiler. To test the LWCO on the boiler, you can also manually place the boiler in a lockout condition (locks).

Resetting the boiler after a LWCO lockout

Before you reset the boiler, ensure that the boiler is pressurized and that the air has been removed.

1. On the touchscreen controller, tap the Home screen.

2. On the Main Menu, tap the Diagnostics button.

3. Tap the Advanced Diagnostics button.

4. Tap the Clear Errors button.

5. Tap the Ye s radio button, and then tap OK.

The system clears the errors, and resets the boiler.

Testing the LWCO function

1. On the touchscreen controller, tap the Home screen.

2. On the Main Menu, tap the Diagnostics button.

3. Tap the SIM Module button.

5-4

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

4. Tap the LWCO Test button.

5. Disconnect the yellow wire from the LWCO function.

A message on the screen indicates that the boiler is in lockout mode.

6. To reset the boiler, reconnect the yellow wire to the LWCO function.

On the touchscreen controller, tap the Reset button.

The message: "The SIM Module has been reset" is displayed.

7. Tap the Close button, and then tap the Back button until you return to the Home

screen.

5.2.4.2 Water Temperature function: reset and test

The hi-limit temperature function monitors the hi-limit temperature set in the SIM. If the water temperature exceeds the hi-limit temperature, the boiler goes into a lockout condition (locks), requiring a manual reset. You can test the hi-limit cutoff temperature function on the boiler.

Resetting the boiler after a Hi-Limit lockout

Before you reset the boiler, ensure that the boiler is pressurized and that the air has been removed.

1. On the touchscreen controller, tap the Home screen.

2. On the Main Menu, tap the Diagnostics button.

3. Tap the Advanced Diagnostics button.

4. Tap the Clear Errors button.

5. Tap the Ye s radio button, and then tap OK.

The system clears the errors, and resets the boiler.

Testing the Hi-Limit cutoff temperature function

1. On the touchscreen controller, tap the Home screen.

2. On the Main Menu, tap the Diagnostics button.

3. Tap the SIM Module button.

4. Tap the Hi-Limit Test button.

You will need to enter a cutoff temperature below the Supply Temp. value currently displayed. For example, if the Supply Temp. value is 180°F, enter 170°F in the Cut Off Temp. box.

5. Tap inside the Cut-Off Temp. box, and then tap a number value.

6. Tap the OK button.

The message: "Hi-Limit Detected" is displayed.

TROUBLESHOOTING

7. To reset the boiler, select the Reset button.

The message: "The SIM module has been reset" is displayed.

8. Tap the Close button, and then tap the Back button until you return to the Home

screen.

5-5

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

5.3 TROUBLESHOOTING

WARNING

Never attempt to repair the control module (circuit board). If the control module is defective,

replace it immediately.

SYMPTOM DIAGNOSIS REMEDY

MAXIMUM IGNITION TRIALS ERROR

Touchscreen 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. Consult service

technician if error recurs.

5.3.1 Using Control Module Errors Displayed

The bottom line of the touchscreen is reserved for displaying the boiler's error status. The boiler status bar will normally be Green, but can change color to Yellow or Red. The colors represent the following boiler operating status. The text inside the bar will indicate the

specic warning or alarm. If there is more than one alarm present the text will scroll slowly

through all current alarm conditions.

• Green – Normal

• Yellow – Warning

• Red – Alarm

No spark when igniting.

Igniter probe/ame

sensor disconnected.

Manual gas shutoff is closed or gas line not fully purged.

Gap between igniter probe rods is too large or too small.

Check that igniter lead is secure at the touchscreen controller and at the probe.

Check for gas ow. Open manual gas shutoff and

reset boiler.

Adjust ignitor probe rod gap between 1/8th and 3/16th (3.2-4.7 mm)

HI LIMIT CUTOFF TEMPERATURE ERROR

Touchscreen message:

Error – Water High-Limit Exceeded

Spark, but no ignition.

Boiler ignites, but shuts off at the end of the ignition trial. Improperly

grounded pressure vessel/ burner or unserviceable

ignition lead or spark module.

Water temperature exceeds hi-limit. Boiler in hard lockout.

Check spark module is sending power to gas valve – close gas supply, then disconnect (black) electric housing from face of gas valve, gently spread plastic tabs to open, and look for 24vac voltage between blue and brown wires during an ignition cycle. Replace module if no current detected

• Ensure pressure vessel is grounded.

• Check the igniter probe/ame sensor is electrically

isolated from the vessel, and its ceramic insulator is intact.

• Replace ignition lead

• Replace spark module

See Section 5.2.4.

5-6

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

SYMPTOM DIAGNOSIS REMEDY

LOW WATER CUTOFF ERROR

Touchscreen message:

Error - Low Water Cutoff

The Safety and Ignition module has detected a low water condition.

See Section 5.2.4.

TROUBLESHOOTING

5-7

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

SYMPTOM DIAGNOSIS REMEDY

TEMPERATURE SENSOR ERROR

Touchscreen Message:

Error - Max. Inlet/Outlet Sensor Temp. Exceeded. -> Check water

ow

Current outlet temperature exceeds operating limit.

Defective or

disconnected temperature sensor.

• Check water ow.

• Check wiring to temperature sensor and control module.

• Check temperature sensor. See Section 5.2.1.

Water temperature signal not within acceptable range.

Potential ow or sensor failure. Consult service technician.

MISCELLANEOUS

Touchscreen Message :

• Check transformer; replace if damaged.

• Check circuit board for visible damage.

Blank – screen dark, but fan

running Indicative of power-

surge damage to appliance

5.3.2 Ignition Problems

SYMPTOM DIAGNOSIS REMEDY

NOISY SPARK WHEN IGNITING

BOILER RUMBLES WHEN IGNITING.

BOILER WILL NOT ATTEMPT TO IGNITE. FAN AND PUMP ARE OPERATING NORMALLY.

BOILER WILL NOT ATTEMPT TO IGNITE. FAN AND / OR PUMP ARE OFF DISPLAY NOT ILLUMINATED

Ignition lead is not rmly

Reconnect ignition lead.

connected.

Contaminants/moisture

on igniter probe/ame

Ensure probe is dry by re-running post-purge; otherwise, clean or replace igniter probe.

sensor.

Fluctuating gas

Check CO

level via analyzer.

pressure/ gas pressure too high/too low.

Check for proper gas

Check pressure with manometer during ignition.

piping.

No power to ignition control module.

Igniter probe/ame

• Check system wiring.

• Check air reference tubing.

Reconnect probe.

sensor disconnected.

Defective Control

Check ignition output from control module.

Module.

No power to boiler. Check line voltage.

Defective transformer. Check transformer. Reconnect or replace as needed.

5-8

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

5.3.3 Cycling Problems

SYMPTOM DIAGNOSIS REMEDY

RAPID CYCLING Improper values entered

via keypad.

Excess Condensate in

venting.

Obstruction in condensate trap.

Improper vent length or improper slope to vent.

Incorrect settings or

defective thermostat.

Air in system or marginal

water ow.

Slow combustion air blower.

Dirty burner/heat exchanger.

Low water ow due to

improper piping.

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 adequate)

Check venting slopes on horizontal runs. Look for sags.

Inspect and clean condensate trap.

Check venting. Compare vent length and diameter to Table 4A or Table 4B: Maximum Venting.

Check operation. Refer to manufacturer’s instructions. Check setting with ammeter.

Bleed/purge system as required. Conrm adequate

pump size and temp rise in HX.

Check that CO

level is within specication.

Check pressure drop.

Refer to recommended piping in Section 1.6

Low water ow due to

undersized pump.

Low water ow due to

restrictions in water

Check manufacturer’s rating charts/check temperature differential across heat exchanger.

Check temperature differential across zone/heat exchanger.

pipe.

Low radiation. Check actual amount of radiation per zone and refer

to manufacturer’s rating tables.

Unit over-red. Clock gas meter/check gas pressure with manometer/

check CO

level.

Unit Oversized. Check load calculation vs. min. boiler output.

Improperly set or

Check operation with ohmmeter/voltmeter.

defective operating/

safety controls.

TROUBLESHOOTING

5-9

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

5.3.4 Temperature Problems

SYMPTOM DIAGNOSIS REMEDY

LOW HEAT

Operating temperature

Increase temperature target.

too low.

Priority parameters

Review load conguration parameters.

or load conguration

improperly set up.

Unit undersized. Refer to Load Calculation vs. Boiler Output.

Air trapped within

Bleed system as required.

system.

Improper system

Refer to recommended piping in Section 1.6

piping.

System pump undersized.

Poor gas/air mixing. Check CO

Check pump manufacturer’s data/check temp differential across heat exchanger.

level.

Defective thermostat. Refer to manufacturer’s instructions.

Obstruction in

Inspect and clean condensate drain.

condensate drain.

Unit cycling on

Check operation with Ohmmeter/Voltmeter.

operating/ safety controls.

TEMPERATURE EXCEEDS THERMOSTAT SETTING

ONE OR MORE ZONES DO NOT HEAT PROPERLY

System radiation undersized.

Incorrect anticipator

Check manufacturer’s rating tables for capacity per foot.

Check with Ammeter.

setting.

Thermostat not level. Check level.

Air trapped within

Vent system/zone as required.

zone(s) piping

Low radiation/

excessive heat loss.

Low ow rate to

Check actual length of pipe using radiation / heat loss calculation.

Check temperature drop across zone.

zone(s).

Defective zone valve/

Check operation per manufacturer’s instructions.

zone circulator.

5-10

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

5.3.5 Miscellaneous

SYMPTOM DIAGNOSIS REMEDY

FUMES AND HIGH HUMIDITY

BOILER STUCK ON INITIALIZE

TOUCHSCREEN MESSAGE:

Unknown Error

BOILER REMAINS IN STANDBY DURING CALL FOR RESET HEATING OR SETPOINT (DHW OPERATION WORKS AS NORMAL). (5 BUTTON CONTROLLER)

‘GHOST’ CALL FOR HEAT.

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

Fan board failure Replace fan.

Temperature sensor input problem.

Test each temperature sensor for appropriate readings and Replace defective temperature sensor.

Boiler may be in Warm Weather Shut-down.

In Installer Setup / Heat Load Conguration / Congure Load (Heating) adjust Summer

Shutdown Temperature to a temperature above that registered by outdoor sensor.

Triac or ‘Power-robbing’ thermostat sending current to boiler.

Remove Therm. connections from boiler to conrm

that stray voltage, or current induced in thermostat wiring, is source of nuisance signal. Replace the Power Robbing thermostat, isolate the thermostat with a relay or install a properly sized resistor

(consult the thermostat manufacturer rst then IBC

for instructions).

ERROR: WATER HIGH LIMIT / LOW WATER CUTOFF WON’T CLEAR.

DHW TAKING TOO LONG TO HEAT.

BOILER OUTPUT NOT MODULATING UP TO MAXIMUM DESPITE TARGET NOT BEING REACHED.

PRIMARY PUMP RUNS BUT LOAD PUMPS DO NOT.

PRIMARY PUMP RUNS DURING PARALLEL-PIPED DHW CALL.

Boiler is in 1 hour safety lockout.

Sensor may be under-reading actual water temp.

Reset safety device and cycle boiler power off and on to reset error.

Check sensor engagement; note well is 15cm / almost 6 inches deep and sensor must be fully set to back. Check programmed settings boiler temp set too close to the required DHW temp

Possible ow issue: check for

35 or 40 degree F temperature difference between boiler

Conrm that primary pump is able to overcome

head loss of boiler and primary loop piping at the

required ow rate.

supply and return water

temperatures (evokes electronic fence).

Wiring not complete. Supply power to the PV/L and PV/N terminals

from the incoming power supply to the boiler. (Factory wired on boilers with a factory installed Touchscreen Controller)

Load denition as DHW. Re-dene DHW load as DHW Loop 2 (5 button

Controls) to turn off primary pump during domestic hot water calls. On Touchscreen Controllers set the boiler pump to off in the Installer Set-up Menu.

TROUBLESHOOTING

5-11

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

THIS PAGE IS INTENTIONALLY LEFT BLANK.

5-12

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

6.0 DIAGRAMS

This section includes:

• Parts diagrams

• Wiring diagrams

• The sequence of operation

DIAGRAMS

6-1

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

6.1 PARTS DIAGRAMS

SL 26-260 G3 Boiler - Parts assembly

Diagram 6.1-1: Boiler assembly parts - SL 26-260 G3

6-2

INSTALLATION AND OPERATION INSTRUCTIONS

Table : Boiler assembly parts list (refer to Diagram

Some parts are available only in Kits. Please visit www.ibcboiler. com for more information.

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

ITEM PART NUMBER DESCRIPTION QTY

10 240-113 FAN 1 20 150-073 MIXER O-RING 1 30 180-161 FUEL MIXER, NG 1

180-162 FUEL MIXER, LP 40 250-742 GASKET, GAS VALVE COUPLER 1 50 250-768 GAS VALVE COUPLER 1 60 250-741 NUT, GAS VALVE COUPLER 1 70 180-166 GAS VALVE 1 80 190-157 GAS LINE 1 90 190-162 AIR INTAKE ASSEMBLY 1

100 250-859 AIR INTAKE ASSEMBLY, MOUNTING CLIP 1 110 250-322 GASKET, FAN TO LID 1 120 250-050 GASKET, IGNITOR 1 130 240-002 IGNITOR 1 140 250-057 SIGHT GLASS HOUSING 1 150 255-025 GASKET, HOUSING-GLASS 1 160 250-059 SIGHT GLASS 1 170 255-023 GASKET, SIGHT GLASS-H.Ex. 1 180 255-026 GASKET, H.Ex. LID-H.Ex. 1 190 255-034 GASKET, BURNER-H.Ex. 1 200 180-186 BURNER 1 210 250-761 HEAT EXCHANGER REFRACTORY 1 220 500-044 V10.0 CONTROL MODULE 1 230 250-488 CONTROLLER, TERMINAL BLOCK COVER 1 240 500-021 DOOR ASSEMBLY 1 250 240-006 PRESSURE SENSOR, RETURN WATER 1 260 250-258 RETURN WATER PIPE 1 270 250-682 WATER PIPE SPACER 1 280 255-024 GASKET, WATER PIPE 2 290 180-013 CONDENSATE TRAP 1 300 250-664 CONDENSATE TRAP RETAINER 1 310 240-134 TEMPERATURE SENSOR, RETURN WATER 1 320 240-133 TEMPERATURE SENSOR, SUPPLY WATER 1 330 170-032 HEAT EXCHANGER 1 340 250-259 SUPPLY WATER PIPE 1 350 240-010 LOW WATER CUT OFF PROBE 1 360 180-005 PRESSURE RELIEF VALVE 1 370 250-187 RATING LABEL, PANEL 1 380 250-254 BRACKET, VESSEL LIMIT SWITCH 1

390 240-030 VESSEL TEMP. HIGH LIMIT SWITCH 1

DIAGRAMS

6-3

SL 80-399 MODULATING GAS BOILER

ITEM PART NUMBER DESCRIPTION QTY

400 250-867

BRACKET, BLOCKED VENT PRESS.

SWITCH 410 240-138 BLOCKED VENT PRESSURE SWITCH 1 420 240-008 TRANSFORMER 1 430 500-105 IGNITION MODULE 1 440 240-132 FLUE TEMPERATURE SENSOR 1 450 250-855 FLUE TEMPERATURE SENSOR FITTING 1 460 250-804 EXHAUST DUCT 1 470 250-856 INTAKE DUCT 1 480 250-800 ACCESS COVER 1

6-4

INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER

THIS PAGE IS INTENTIONALLY LEFT BLANK.

TROUBLESHOOTING

6-5

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 40-399 G3 Boiler - Parts assembly

Diagram 6.1-2: Boiler assembly parts - SL 40-399 G3

6-6

INSTALLATION AND OPERATION INSTRUCTIONS

Table : Boiler assembly parts list (refer to Diagram 6.1-2 on opposite page)

Some parts are available only in Kits. Please visit www.ibcboiler. com for more information.

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

ITEM PART # DESCRIPTION QTY

10 240-113 FAN 1 20 150-073 MIXER, NG 1

180-164 MIXER, LP 30 150-232 MIXER O-RING 1 40 190-160 GAS VALVE ELBOW 1 50 150-259 GAS VALVE ELBOW O-RING 1 60 250-869 NATURAL GAS ORIFICE 12.0 1

250-865 PROPANE ORIFICE 11.2 70 255-035 ORIFICE/COUPLER GASKET 2 80 180-150 GAS VALVE 1 90 250-755 GAS INLET BLOCK 1

100 150-001 GAS INLET BLOCK O-RING 1 110 250-794 GAS VALVE COUPLER ROTATION LOCK 1 120 250-793 GAS VALVE COUPLER BOTTOM PLATE 1 130 190-162 AIR INTAKE ASSEMBLY 1 140 250-859 AIR INTAKE MOUNTING CLIP 1 150 190-158 GAS LINE 1 160 250-322 FAN GASKET 1 170 240-002 IGNITER 1 180 250-050 IGNITER GASKET 1 190 250-057 SIGHT GLASS FRAME 1 200 255-023 SIGHT GLASS LOWER GASKET 1 210 250-059 SIGHT GLASS 1 220 255-025 SIGHT GLASS UPPER GASKET 1 230 255-048 BURNER GASKET 1 240 255-009 HEAT EXCHANGER LID GASKET 1 250 180-185 BURNER 1 260 250-753 HEAT EXCHANGER REFRACTORY 1 270 500-044 V10.0 CONTROL MODULE 1 280 250-488 CONTROLLER TERMINAL BLOCK COVER 1 290 500-079 DOOR ASSEMBLY 1 300 240-006 RETURN WATER PRESSURE SENSOR 1 310 250-748 RETURN WATER PIPE ASSEMBLY 1 320 255-027 GASKET, WATER PIPE 2

330 240-133

TEMPERATURE SENSOR, SUPPLY WATER

DIAGRAMS

340 240-134

TEMPERATURE SENSOR, RETURN WATER

350 180-065 CONDENSATE TRAP 1 360 250-664 CONDENSATE TRAP RETAINER 1 370 HEAT EXCHANGER 1

6-7

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

ITEM PART # DESCRIPTION QTY

170-028

80 PSI CAPACITY, 316Ti STAINLESS STEEL

170-029 80 PSI CAPACITY, 439 STAINLESS STEEL 380 250-853 SUPPLY WATER PIPE ASSEMBLY 1 390 180-189 TRIDICATOR 1 400 240-010 LOW WATER CUT-OFF SENSOR 1 410 180-005 PRESSURE RELIEF VALVE 30 PSIG 1 420 500-081 CABINET 1 430 240-008 TRANSFORMER 1 440 250-187 RATING LABEL PANEL 1 450 500-105 SAFETY IGNITION MODULE 1 460 240-132 FLUE TEMPERATURE SENSOR 1 470 250-024 EXHAUST DUCT 1 480 250-025 INTAKE DUCT 1 490 250-693 UPPER ACCESS PANEL 1 500 250-870 SWITCH BRACKET 1 510 240-138 BLOCKED VENT PRESSURE SWITCH 1 520 240-030 VESSEL TEMP. HIGH LIMIT SWITCH 1

6-8

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

6.2 WIRING DIAGRAMS

Diagram 6.2-1: Ladder wiring diagram

DIAGRAMS

6-9

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

Better Boilers

P 101

blue

red

blue

orange

blue

P 102

IBC Control Board

P 501

P 702

TB1

17 16

22 13

27 28

black

brown

black

white

yellow

orange

white black

white orange

white white

2 x plug

red white

red

yellow

black

yellow

black

Diagram 6.2-2: Internal wiring diagram

5 x plug

Exhaust

Pressure

Switch

VS Out 0-10VDC

NG150

Combustion

Transformer

24 Vac

Upper Vessel High Limit Switch

Inlet Water Temperature Sensor

Inlet Water

Pressure

Sensor

Fan

3 x plug

120 Vac

black

white

black

white

SL 40-399 G3 and SL 26-260 G3

INTERNAL WIRING DIAGRAM

Outlet Water

Temperature

Sensor

Flue Gas

Temperature

Sensor

black

white

black black black

green

brown

blue

Gas

Valve

green

white white

white

120Vac

Mains

Power Supply

yellow

To Boiler Pump

4 x plug

LWCO Probe

orange

Replacement internal wiring must meet or exceed the ratings of the wiring supplied from the factory.

green

green green

white

blue

white

red

yellow

green

brown

green green

red

1 2

white

3 4 5

blue

7 8 9

blue

Spark Electrode and Flame Sensing Rod Assembly

Grounded

to case

IBC SIM Ignition Module

T1b

100-025A

6-10

INSTALLATION AND OPERATION INSTRUCTIONS

SL 26-260 G3, SL 40-399 G3 MODULATING GAS BOILERS

SL 80-399 MODULATING GAS BOILER

6.3 SEQUENCE OF OPERATION

Diagram 6.3: Sequence of operation diagram

DIAGRAMS

6-11

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

Gas Supply Pressure (high re) _______ Inches w.c. Measured Rate of Input (high re) ____________ Btu/hr

Instructions).

Neutralization? Yes/No

µA

Combustion Readings:

Natural Gas Propane

Installation instructions have been followed and completed (Section 1 of Installation and Operating

Check-out procedures have been followed and completed (Section 3 of Installation and Operating

Leak testing completed gas piping venting system Fan and combustion components

System Cleaned and Flushed (type of cleaner used) ________________________________________________

System Filled (type/concentration of any glycol/chemicals used) _______________________________________

Air purge completed

Relief Valve correctly installed and piped

Condensate trap lled

Ignition Safety Shutoff test completed. Flame current reading - High re _______ µA - Low re _______

Owner advised and instructed in the safe operation and maintenance of the boiler and system.

Information regarding the unit and installation received and left with owner

Condensate drain clear and free owing Condensate

Relief valve “try lever” test performed

_____________ % O2 ______________ % CO ____________ ppm

Flue temperature _________ Return water temperature (measure simultaneously with ue temp.)

_______________

Installers: send this completed sheet - Fax to 604 877 0295 - or - scan and Email to info@ibcboiler.com, and earn an extra

year’s Parts Warranty coverage (User to submit corresponding Installation Record from User Guide).

Commissioning has been completed as listed on this report - Installer Signature _____________________________

INSTALLER SET-UP

Load Denition - Load #1 _______________________________________________________________________

Load Conguration - Load #1

_____________________________________________________________________________________________

Load Denition - Load #2 _______________________________________________________________________

Load Conguration - Load #2

_____________________________________________________________________________________________

Load Denition - Load #3 _______________________________________________________________________

Load Conguration - Load #3

_____________________________________________________________________________________________

Load Denition - Load #4 _______________________________________________________________________

Load Conguration - Load #4

_____________________________________________________________________________________________

SERVICE RECORD

DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE

NOTES

As referenced on page 2-7 of this manual, the following message is relevant to users in the USA:

IMPORTANT

This Boiler is equipped with a feature that saves energy by reducing the boiler water

temperature as the heating load decreases. This feature is equipped with an override

which is provided primarily to permit the use of an external energy management system

that serves 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 as the heating load decreases.

• This boiler is not used for any space heating.

• 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.

REVISION HISTORY

R1 (March 2017) Initial release

R2 (AVRIL 2017) Corrections to text (Specications table and part number tables)

IBC Technologies Inc.

8015 North Fraser Way

Burnaby, BC

Canada V5J 5M8

Tel: 604-877-0277

Fax: 604-877-0295

Toll Free: 1-844-432-8422

www.ibcboiler.com

April 2017

IBC Boilers SL 40-399 G3, SL 26-260 G3 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual