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APPROVED BLD2022-1512+Manufacturer_Specifications_and_Installation_Instructions+10.24.2022_12.23.19_PM+3181302BLD2022-1512 INSTALLATION & OPERATING MANUAL : 1i vvm,�Mmm Work Address Owner Approve Buildiri RECEIVED 11 /3/22� r °� CITY OF EDMONDS'9 PLANNING & DEVELOPMENT City 9 BOIL 1 HIGHWAY 99 If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. If you smell gas: " Do not try to light any appliance. >> Do not touch any electrical switch; do not use any phone in your building. >> Immediately call your gas supplier from a nearby phone. Follow the gas supplier's instructions. >> If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. c �jI us � SME Intertek H Water quality Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage. High levels of dissolved solids or minerals may precipitate out of the fluid 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 reduce dissolved solids to 30 ppm. 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/I Iron is to be less than 0.3 mg/I Cu less than 0.1 mg/I Conductivity is to be less than 400pS/cm at 77°F (25°C) 7 grains/ gal (120 ppm) Important: Ensure that these limits are acceptable for the other water -side components in the system. Shipped with the boiler: 1 x Wall mounting bracket (P-9100) 1 x Condensate trap assembly 1 x 30 psig pressure relief valve 1 x Outdoor temperature sensor �� 6 x'/4" x 2'/2" Lag screws/w flat washers Safety information Manual safety markings Danger Points out an immediate hazardous situation that must be avoided to prevent serious injury or death. OCaution t Points out a potential hazardous situation that must be avoided to prevent possible moderate injury and/or property damage. Important safety instructions Safety information Warning t Points out a potential hazardous situation that must be avoided to prevent serious injury or death. Note Points out installation, maintenance and operational notes to enhance efficiency, longevity and proper operation of the boiler. Installation, start-up and servicing of IBC boilers must be performed by competent, qualified, 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, and in extreme cases to death. Keep instructions near the air handling appliance for future reference. 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. Danger Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, do not try to operate any appliance - do not touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a phone located remotely. Follow the gas supplier's instructions, or if the supplier is unavailable, contact the fire department. Section: Safety information Warning If the boiler is likely to be exposed to fluid temperatures below 34°F (VC), use a method to prevent freezing of condensate. Contact the factory for further information. Warning Do not use this boiler if any part has been underwater. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been underwater. Warning Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, or loss of life. Read and understand the entire manual before attempting installation, start-up, operation, or service. Installation and service must be performed only by an experienced, skilled installer or service agency. Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers' manuals before installing, starting up, operating, maintaining, or servicing the appliance. J Warning Disconnect power supply before any wiring/service is performed. Failure to do so could result in damage to appliance and/or electric shock. OCaution The boiler must be installed so that electrical components are not exposed to water during operation. Cements and glues Refrigerant leaks from cracks in coils Paint or varnish removers Sodium chloride or potassium chloride used for water softening Adhesives used to fasten building products Chemicals in perming solutions and other similar products Chlorinated waxes or cleaners Chlorofluorocarbon chemicals found in spray cans Chlorine -based swimming pool chemicals Hydrochloric acid or muriatic acid used in household cleaning and stain removal Calcium chloride used for snow clearing Antistatic dryer sheets in clothes dryers Chlorine -type bleaches, detergents, and cleaning solvents found in household laundry rooms Contents Safetyinformation.................................................................................. 3 Manual safety markings......................................................................... 3 Important safety instructions.................................................................... 3 Specifications....................................................................................... 5 Cabinet dimensions............................................................................. 6 S L 2 6-2 6 0 G 3............................................................................... 6 S L 40-3 9 9 G 3............................................................................... 7 Connection specifications...................................................................... 9 1.0 Introduction.....................................................................................1 1 1.1 Standard features and benefits............................................................12 1.2 Warranty.....................................................................................1 2 2.0 Before installation............................................................................. 13 3.0 Installation...................................................................................... 15 3.1 Code requirements......................................................................... 15 3.2 Removing an existing boiler................................................................1 5 3.3 Determining location of the appliance.....................................................16 Best installation conditions................................................................ 17 3.4 Mounting the boiler......................................................................... 17 3.5 Connecting the vent and air intake pipes ................................................. 18 3.6 Installation clearances......................................................................1 9 3.7 Exhaust venting and air intake.............................................................20 3.7.1 Venting code......................................................................... 21 3.7.2 Venting options.......................................................................2 1 3.7.3 Exhaust vent material............................................................... 21 3.7.4 Direct vent............................................................................ 22 3.7.5 Rooftop vent termination............................................................ 27 3.7.6 Sidewall vent termination........................................................... 29 3.7.7 Combustion air filtration system....................................................37 3.8 Closet installations..........................................................................3 7 3.9 Installing the condensate trap............................................................. 37 3.10 Installing a condensate neutralizer...................................................... 41 3.11 Water Piping............................................................................... 42 d Section: Contents 3.11.1 General piping best practices ................................................. 46 3.11.2 System piping...................................................................46 3.12 Gas piping..............................................................................55 3.12.1 Gas pressure....................................................................55 3.13 Electrical connections.................................................................56 3.13.1 Power management, quality and electrical protection ...................... 57 3.13.2 120VAC line -voltage hook-up ................................................. 57 3.13.3 Other wiring..................................................................... 58 3.13.4 Zone valve hook-up............................................................ 59 3.13.5 Thermostat / sensor wiring.....................................................59 3.13.6 Thermostat heat anticipator................................................... 59 4.0 About the boiler controller............................................................... 61 4.1 Controller .......................................................................61 4.2 Control interface..........................................................62 5.0 Before operating the boiler...............................................................63 Important pre-ignition checks.............................................................. 63 Checklist for electrical conditions, ducting and water connections ................ 63 6.0 Boiler operation............................................................................ 65 6.1 Lighting and shutting down the boiler ................................................. 65 6.2 Testing the ignition safety shutoff ......................................................66 6.3 Commissioning..........................................................................66 6.3.1 Checking a boiler's fuel source ................................................. 67 6.3.2 Performing a fuel conversion....................................................67 a q '4 Adjusting the gas valve.......................................................... 69 7.0 Service and maintenance.................................................................73 7.1 Maintenance checklist for homeowner................................................73 7.2 Maintenance checklist for heating contractor ........................................ 73 7.2.1 Touchscreen boiler controller ................................................... 74 7.2.2 General boiler maintenance.....................................................74 7.3 Replacing the fan, gas valve, and burner ............................................. 78 7.3.1 Replacing the fan.................................................................80 7.3.2 Replacing the gas valve......................................................... 82 7.3.3 Replacing the burner.............................................................85 I 7.4 Cleaning the condensate trap............................................................. 89 8.0 Troubleshooting............................................................................... 93 8.1 Electronic components.....................................................................93 8.1.1 Temperature sensors................................................................93 8.1.2 Fan.................................................................................... 94 8.1.3 Water pressure sensor.............................................................. 95 8.1.4 Safety and Ignition Module (SIM)...................................................95 8.2 Troubleshooting error messages..........................................................96 8.2.1 Maximum ignition trials error........................................................9 7 8.2.2 Hi Limit cut-off temperature error ................................................... 97 8.2.3 Low Water Cut-off error............................................................. 98 8.2.4 Aux. Interlock 1 or 2..................................................................98 8.3 Miscellaneous touchscreen controller errors.............................................98 8.3.1 Ignition issues........................................................................ 99 8.3.2 Temperature issues................................................................101 8.3.3 Miscellaneous issues.............................................................. 102 8.3.4 Cycling issues...................................................................... 103 Appendices........................................................................................ 105 Wiringdiagrams................................................................................1 05 V-10 Controller electrical diagram.......................................................105 Internal wiring diagram ................................................................... 106 Sequence of operations..................................................................107 Exploded views of boiler parts................................................................108 Boiler part diagrams - SL 26-260 G3....................................................108 Boiler part diagrams - SL 40-399 G3....................................................111 Installation & Commissioning Report........................................................ 115 3 Intentionally left empty Specifications CSA Input (Natural Gas or Propane) CSA Input (Natural Gas or Propane) CSA Output CSA Output A.F.U.E Combustion Efficiency Thermal Efficiency (ANSI/AHRI-1500) Minimum gas supply pressure (Natural Gas or Propane) Maximum gas supply pressure (Natural Gas or Propane) Minimum Ambient temperature Maximum Ambient temperature Max. relative humidity (non -condensing) Minimum water temp. Maximum water temp. (electronic hi -limit) Max. AT - supply/return (electronic fence) Max. Water Temperature Lockout Limit Power use (120Vac/60Hz) @ full fire (less pumps) Weight (empty) Heating Surface Area Pressure vessel water content Maximum boiler flow rate Minimum boiler flow rate Maximum operating water pressure* Minimum water pressure 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 a 30 psig pressure relief valve. 26 - 260 MBH 7.6 - 76.2 kW 24.9 - 239 MBH 7.31 - 70.0 kW 95% 4" w.c. 14" w.c. 32°F / 0°C 122°F / 50°C 90% 34°F / VC 190°F / 88°C 40°F 201 °F / 94°C 127 W 162 Ibs / 74 Kg 22.71 ft2/ 2.11 m2 4.64 USG/ 17.6 L 25 USgpm 6 USgpm 30 psig/ 206 kPa 8 psig / 55 kPa 0-12,000' 200' (3") 40 - 399 MBH 11.7-117kW 38.4 - 383 MBH 11.2-112kW 96% 96% 4" w.c. 14" w.c. 32°F / 0°C 122°F / 50°C 90% 34°F / VC 190°F / 88°C 40°F 201 °F / 94°C 190 W 240 Ibs /110 Kg 36.56 ft2/ 3.40 m2 6.66 USG/ 25.2 L 45 USgpm 20 USgpm 80psig/ 551 kPa 8 psig / 55 kPa 0-12,000' 200' (4") Section: Specifications Fan Pre -purge Trial for Ignition 15 seconds 4 seconds Flame Failure Response <0.8 second Table 1 Ignition stages timings Cabinet dimensions SL 26-260 G3 2.2in FRONT COVER LATCH F [55mm] 35 6in [903mm] D G 18.Oin [458mm] 6.3in I I I 17.1 [159mm] JI4,IR [ 447mi 25.Oin [634mm] SUPPLIED WITH 314"x24" CONDENSATE FLEX HOSE Figure 1 : Front and side view- SL 26-260 G3 4.5in [114mm , 13.5in [343m m] C 9.7in [247mm] Figure 2 : Top view- SL 26-260 G, SL 40-399 G3 2.1in [53mm] SL 40-399 G3 4.8in 1 5.7in [122mm] [400mm] 9.7in 6.0in [246mm] [1531 3.9in E [98m m] B \—A 13.4in [341mm] 7.1in [181 mm]41 1 H 3.3in [85mm] Figure 3 : Bottom view - SL 26-260 G3 FRONT COVER LATCH 0 Q;n D 39.9in [ 1013mm] 18.Oin [457mm] 9.7in [246mm 27.Oin [686mm ] Lyy4rTim j SUPPLIED WITH 314" x 24" CONDENSATE FLEX HOSE Figure 4 : Front and side view - SL 40-399 G3 7 9.9in [252mm] j 5.4in [ 138mm ] 15.2in [ 387mm ] I A� 20.1 in [511mm] 8.0in [ 202 mm ] 10.2in [ 259mm ] 5.1in [129mm] 15.2in [ 387mm ] Section: Specifications 11.1in [283mm ] 15_gin Figure 5 : Top view - SL 40-399 G3 Figure 6 : Bottom view - SL 40-399 G3 Connection specifications The following table displays the required connection specifications. A Flue Outlet B Combustion Air Inlet C Safety Relief Valve and Air Vent D LCD Display E Water Outlet F Water Inlet G Knock -outs (8) H Gas Inlet I Condensate Outlet Table 2 Connections Connection specifications 3" Schedule 40 4" Schedule 40 3" Schedule 40 4" Schedule 40 3/" NPT - F 2'/4 x 4" 1'/2" NPT-M 1'/2" NPT-M 1/2" 3/4" NPT-F 3/" Hose Intentionally left empty 1.0 Introduction The gas -fired modulating boilers are low pressure, fully condensing units with a variable input range. Approved as "Category IV" vented appliances, the boilers use direct vent (sealed combustion) or indoor combustion air. Pressure Relief Valve Safety Ignition Module (SIM) Supply Water Heat Exchanger Figure 7 View from the front - SL 26-260 G3 Safety Ignition Module (SIM) Lsupply Water Heat Exchanger Figure 8 View from the front - SL 40-399 G3 Gas Valve Fan Controller Return Water Gas Valve L Fan Controller Return Water Section: Introduction 1.1 Standard features and benefits High thermal efficiency Turn -down ratio 10 to 1 Control of up to 5 pumps —1 boiler pump and 4 separate load pumps Outdoor reset control Load combining —simultaneous operation of two similar water temperature loads Load zoning — simultaneous operation of up to four loads with the same control settings Ability to manage and/or operate in a network of up to 24 IBC SL boilers Internet/LAN connectivity for software updates and remote access through the IBC V-10 Portal BACnet over IP compatible Easy -to -use touchscreen 1.2 Warranty For residential applications, IBC offers a 5-year warranty on all parts against defects in materials or workmanship and failures due to thermal shock. In addition, IBC offers a heat exchanger limited warranty with registration, according to the following terms: 0 - 10 years (100% coverage) 11 + years (25% coverage). IBC offers a limited heat exchanger warranty with no registration of 0-5 years (100% coverage). For non-residential applications, IBC offers a 5-year warranty on all parts against defects in materials or workmanship and failures due to thermal shock. In addition, IBC offers a heat exchanger limited 10 year warranty with registration, according to the following terms: 0 - 5 years (100% coverage) 6 - 7 years (50% coverage) 8 years (40% coverage) 9 years (30% coverage) 10 years (20% coverage). To view the full warranty statement for the SL 26-260 G3 and the SL 40-399 G3, and to register your product, go to ibcboiler.com. 12 2.0 Before installation Before installing the appliance, it is important to review and observe the following checklist of precautions: Care must be taken to properly size the boiler for its intended use. Prolonged full fire run ❑ time, over -sizing or under -sizing, and incorrect flow rates through the appliance can lead to increased maintenance costs, equipment stress and premature failure. Ensure you install the appliance where the combustion air source is not subject to ❑ chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants, aerosol propellants, dry-cleaning fluids, de -greasers and paint -removers all contain vapors that can form corrosive acid compounds when burned in a gas flame. Airborne chlorides such as those released with the use of laundry detergents are also to be avoided. Locate the appliance where water leakage will not result in damage to the area. If there is ❑ no suitable location, install a suitable drain pan under the boiler. Do not install above carpeting. At a new construction site, or during renovations, protect the appliance from drywall dust or ❑ other construction related contaminants. Draw combustion air from a clean source (e.g., outdoors) and isolate the boiler from interior dust sources. Do not seal boiler case openings directly when firing - allow for air circulation and ventilation in the immediate area. Place the exhaust outlet 12" minimum above the down -turned intake to avoid exhaust re- ❑ ingestion. For sidewall venting options, place the inlet and exhaust terminations on the same 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 using the indoor combustion air option, 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 is installed with no valves or other means of isolation ❑ between its inlet and the boiler. Make sure the relief valve outlet is piped with unobstructed piping (minimum'/4" diameter) to a safe discharge location. If the appliance is likely to be exposed to fluid temperatures below 34' F (1 ° C), a method ❑ of protection to prevent freezing of condensate should be employed. Contact the factory for further information. When the appliance is in operation, assess the impact of the steam plume typical of a ❑ condensing boiler's exhaust terminal. Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location. Boiler condensate is corrosive. Protective Section: Before installation 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. OCaution Care must be taken to properly size the boiler for its intended use. Prolonged full fire run time, over -sizing or under -sizing, and incorrect flow rates through the boiler can lead to increased maintenance costs, equipment stress and premature failure. 14 3.0 Installation Refer to the Specifications section for dimensional drawings and connection specifications. Use these drawings to find a suitable location for the appliance. 3.1 Code requirements The appliances are tested and certified under CSA 4.9 / ANSI Z21.13. Below are the code requirements for every installation. Conform to local codes, or in the absence of Conform to the current National Fuel Gas Code these, with the latest editions of CAN/CGA ANSI Z223.1 and the National Electrical Code B149.1 and the Canadian Electrical Code Part 1 ANSI/NFPA 70. CSA C22.2 No. 1. Where required by jurisdiction, installation must Where required byjurisdiction, installation must conform to the Standard for Controls and Safety conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. If there is any conflict, follow the more stringent regulations. Table 3 Code requirements by country ANSI/ASME CSD-1 If there is any conflict, follow the more stringent regulations. 3.2 Removing an existing boiler When an existing boiler is removed from a common venting system, the common venting system may be too large for proper venting of the appliances that remain connected to it. When resizing any portion of the common venting system, use the minimum size according to the appropriate tables in the National Fuel Gas Code, ANSI Z223.1 - latest edition. In Canada, follow the B149.1 Installation Code. When removing an existing boiler, the following checks must be carried out for each of the appliances still connected to the common exhaust system, by operating them one at a time: Seal any unused opening in the common venting system. Visually inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies that could cause an unsafe condition. (Where practical) Close all doors and windows such as doors adjacent to appliances remaining connected to the common venting system and other spaces of the building. Section: Installation 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 fireplace dampers. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so that the appliance operates continuously. After determining that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas -burning appliance to their previous 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. 3.3 Determining location of the appliance The boilers are designed and approved for indoor installation (wall or rack mounting) in areas such as an alcove, basement, or utility room. These areas should have a surrounding temperature of 32 °F (0°C) to 122 °F (50 °C) and less than 90% relative humidity. Danger Do not common vent appliances with other existing appliances or with a new appliance. Warnings Keep the area around a boiler clear of combustible materials, gasoline, and other flammable vapors and liquids. Ensure combustion air is not drawn from areas containing corrosive air such as swimming pools or spas, including air directly next to outdoor pools and spas. Ensure that a boiler is not exposed to water leaks from piping or components located overhead, including condensation from uninsulated cold water lines overhead. Protect the gas ignition system components from water (dripping, spraying, rain, etc.) during appliance operation and when servicing (pump replacement, condensate trap servicing, control replacement, etc.). Ensure that combustible materials do not make contact with exposed water piping and associated components (relief valves, circulators, etc.). Check local codes for required clearances and/or provide adequate insulation. 16 Best installation conditions Best installation conditions Below are some factors to consider for best installation conditions: 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 fluorinated hydrocarbons can reduce the life of a boiler. See list of known contaminants on the Important safety instructions on page 3. For this reason, do not use the indoor air venting option (using air surrounding the boiler) in a laundry room. Similarly, ensure any direct vent air source is not near a clothes dryer exhaust terminal. Avoid agricultural applications where the boiler and/or the intake air source are affected by ammonia and/or dust. Avoid installing a boiler where water leakage will cause damage; for example, above carpeting. If unavoidable, install a suitable drain pan under the appliance. Vent location - An important consideration is managing the impact of the steam plume typical of a condensing boiler's exhaust terminal. 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. Refer to Table 7 and Figure 15 in Sidewall vent termination on page 29. The minimum clearance requirements for combustible materials (see Table 4 ). For adequate servicing, we recommend a minimum 24" clearance at the front and 12" above the boiler. Check local codes for additional access and service clearance requirements. At anew construction site, or when renovating: Protect the boiler from drywall dust or other construction related contaminants. Ensure combustion air is drawn from a clean source (e.g., outdoors). Isolate the boiler from interior dust sources. 3.4 Mounting the boiler You must attach fasteners to solid material capable of supporting the combined weight of the boiler and piping assembly components. The SL40-399 boiler weight — without water, system piping and components — is approximately 240 Ibs/ 110 kg. Q7 Warning Do not mount the appliance to hollow wall structures - The combined weight of the boiler, its water content and associated piping components can exceed 300 pounds. Fasteners must be rated for this strain, and must be firmly anchored into solid material that will support this weight. Installers must take necessary precautions to avoid injury during the installation of this boiler. Section: Installation 1 Attach the support bracket (supplied) to 2. Hook the boiler tab (located on the wall studs using the supplied 1/4" x back of boiler) over the support 21/2" long lag screws (min. 4) with flat bracket flange. washers. 3. Ensure that the boiler tab is flush against 4. Secure the lower part of the the mounting bracket flange. boiler to the wall with a minimum of two field-supplied'/4' bolts. 3.5 Connecting the vent and air intake pipes These appliances offer 3 or 4-inch connections that accept standard 3 or 4 inch PVC/CPVC and (with adapter) PP pipe. Use available pipe -reducer fittings (not bushings) to adapt to smaller diameter pipe. Insert PVC/CPVC pipe directly into the female fitting, and secure with the built-in clamp (see image below). Venting must be supported in accordance with the applicable code. 18 3.6 Installation clearances For PP, use the transition / adapter fitting (Sch 40 to PP) offered by the respective PP manufacturers Centrotherm / InnoflueTM (their part #ISAA0303 or #ISAA0404) or M&G Dura Vent / PolyProTM (#3PPS-AD), (#4PPS-AD) orZ-Flex/Z-DENS (#2ZDCPVCG3). PVC/CPVC Combustion air piping - if used - is inserted directly into the 3" or 4" connector. For PP material exposed to outdoor conditions, follow the venting supplier's recommendations on UV protection. Warning Ensure that you lubricate the gasket with silicone grease before inserting the venting material. Fully insert the approved venting material into the boiler's exhaust outlet, and tighten clamp to ensure the venting connection is locked in place (as shown above). *Manufacturers of stainless steel Type BH venting systems must submit their approved transition fitting to IBC for evaluation and written approval. Figure 9 Securing vent connection 73 Warning Do not mix PP 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. 3.6 Installation clearances 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. Section: Installation Front 2" 24" 2" 24" Rear 0" 0" 0" 0" Left side 1" 0" (non- 1" 0" (non - combustibles) combustibles) Right side 1" 4" (for electric 1" 4"(for electric connections) connections) Top 2" 6" (vent connection) 12" 12" (vent connection) Bottom 0" 12" (for condensate 12" 12" (for condensate trap and piping) trap and piping) Table 4 Clearance distances for boiler mounting sites 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. 3.7 Exhaust venting and air intake When planning a boiler's installation, consider the appropriate vent materials, travel and termination. Warning Venting, condensate drainage, and combustion air systems for all IBC boilers must be installed in compliance with all applicable codes and with instructions provided in the respective installation manuals. Inspect finished vent and air piping thoroughly to ensure all are airtight, and comply with the instructions provided as well as with the requirements of applicable codes. Failure to comply will result in severe personal injury or death. 20 3.7.1 Venting code 3.7.1 Venting code All venting must be installed in accordance with the requirements of the jurisdiction having authority: in Canada, Part 8, Venting Systems of the CAN/CSA B149.1 Code and any other local building codes are to be followed. In the USA, the National Fuel Gas Code, ANSI Z223.1/NFPA 54, latest edition prevails. Where there is a discrepancy between the installation instructions provided and the code requirements, apply the more stringent. 3.7.2 Venting options These appliances are approved with alternative venting options: either 2-pipe direct vent or vent pipe with indoor air. With direct vent, combustion air is piped directly to the boiler's air intake from outdoors. 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 boiler may be vented through the wall, directly through the roof, or upward using an existing, but otherwise unused, chimney as a vent raceway. 3.7.3 Exhaust vent material Warnings Condensate can cause corrosion of metal roofing components and other roofing materials. Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate. pH levels can be as low as 3.0. Covering non-metallic vent pipe and fittings with thermal insulation is prohibited. Exhaust vent material — Canada Use PVC, CPVC, or Polypropylene (PP) vent component systems approved under ULC-S636 Standard for Type BH Gas Venting Systems, or stainless steel Type BH venting systemsl. ULC- S636 components are certified as systems including pipe, fittings and cement/primer for PVC/CPVC and must be installed in strict accordance with manufacturers' instructions. The vent temperature is limited by the boiler controller with the use of a flue temperature sensor to ensure the maximum temperature of the PVC venting material is not exceeded. Exhaust vent material — U.S.A PVC, CPVC, or PP venting materials are approved for use with these boilers in most of the USA. Check local codes to determine if any materials are prohibited. The vent temperature is limited 1 Manufacturers of stainless steel Type BH venting systems must submit their approved transition fitting to IBC for evaluation and written approval. Section: Installation with the use of the flue temperature sensor and software to ensure that the maximum temperature of the PVC venting material is not exceeded. PVC venting material shall be certified to Sch. 40 ASTM D1785 or D2665. CPVC material shall be certified to Sch. 40/ASTM F441. Exhaust vent material - general Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in venting systems is prohibited. Do not use ABS or any cellular core pipe for exhaust venting. 3.7.4 Direct vent Direct vent is a two -pipe system that draws combustion air (air intake) from outdoors, and discharges exhaust gases to the outdoors. Ensure that adequate separation is maintained between the air intake inlet and the exhaust vent terminal. Refer to the vent terminal configuration drawings in the "Vent Termination" sections. it t I SC SL-26-260 I BC SL-00-399 M OFlue gas exhaust to outdoors 2 Combustion air from outdoors. "Direct Vent" installation: check air intake outside is clear of obstructions. Figure 10 Direct vent 22 3.7.4 Direct vent Air intake installation ZyWarning When using indoor air options, supply adequate combustion air to the boiler room according to the requirements of all applicable codes. 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 firing (See list of known contaminants on the Important safety instructions on page 3). For inlet air, 4" Schedule 40 PVC, CPVC, ABS, or PP piping of any type is permitted. Warnings In addition to preventing ingestion of chemical contaminants, ensure air intake terminals are not installed in locations where contamination might occur due to ingestion of particulate foreign material (dust, dirt and debris). Configure intake air openings, so that rain or other forms of moisture cannot enter the air intake piping system. Otherwise serious damage to the boiler may result. Note --- When installing air intake piping, ensure that a "trap" is not formed in the piping causing a build-up of water and blockage of intake air. Such blockages will cause a boiler safety shut -down. Filters require checking and cleaning or replacing on a regular schedule based on the severity of the problem. Exhaust venting installation Exhaust venting must slope down towards the boiler with a pitch of at least'/4' per foot (PP vent: follow PP manufacturer requirements for slope), so condensate runs back towards the trap. 1 Ensure pipe and fittings are beveled for trouble -free insertion through exhaust and intake pipe gaskets Figure 11 Pipe and fitting beveling Exhaust piping is inserted directly into the left connector on the top of the boiler, then runs horizontally or vertically to the outdoors. Screen material can be placed at the outlet as appropriate for the environment (e.g., insects, dust). Section: Installation Check that material meets local codes including fire 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. Ensure all venting components are clear of burrs/debris prior to assembly. Clear plastic debris left in the combustion air piping to avoid intake into the fan. Secure joints using appropriate solvent cement to bond the respective pipe material (CPVC cement approved under ULC-S636, in accordance with its manufacturer instructions; 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 PP, connections shall be secured using approved retainer clips supplied by the respective PP manufacturer. Check that vent connections are liquid and pressure tight. Prior to firing the boiler, and before any of the venting run is concealed by the building construction, test the exhaust joints under fan pressure with the vent blocked, using a soap and water solution. The installer must fill the condensate trap prior to testing. Coat all joints with an approved leak test solution just as you would joints in a gas line, and make sure that there are no leaks. We suggest attaching a tag on the vent line near the condensate drain tee with the type of test, the date and the installer's name. Re: venting passage through ceiling and floor: Confirm material meets local codes including fire stopping requirements. Check the local jurisdiction on the minimum initial length of pipe that should be exposed or accessible for inspection. Follow the local codes for pipe clearances - no IBC requirements. Ensure that piping is liquid and pressure tight. Air intake and exhaust vent length allowance Warning Follow all installation instructions supplied by the piping and fitting manufacturer. The maximum vent lengths shown are separate for the intake and exhaust. For example, for a maximum vent length of 200 ft, the exhaust can travel a maximum of 200 equivalent ft and the intake can travel a maximum of 200 equivalent ft. Any unused vent lengths used on one side can not be added to the other. Equivalent feet of any elbows, termination kits, or flexible pipe must be subtracted from the maximum length using the appropriate table below: 3-inch rigid pipe 200 ft (max.) each side 90' elbow allow 8 ft for each elbow 90' long sweep elbow allow 5 ft for each elbow 24 3.7.4 Direct vent 45' elbow allow 3 ft for each elbow PP 87-90' elbows allow 8 ft for each elbow 3-inch Stainless Sidewall Intake: No additional allowance required Terminal IBC (P-257) Exhaust: Allow 20 ft 3-inch PP flexible pipe Limited to a maximum of 60 ft Allow 3.3 x actual length (e.g., 10 feet of 3-inch flexible pipe x 3.3 = 33 feet of rigid pipe) Table 5 Maximum air intake pipe and maximum exhaust vent length - SL 26-260 G3 4-inch rigid pipe 200 ft (each side) 90' elbow allow 8 ft for each elbow 90' long sweep elbow 45' elbow PP 87-90' elbows allow 5 ft for each elbow allow 3 ft for each elbow allow 8 ft for each elbow 3-inch Stainless Sidewall Terminal Intake: No additional allowance required (SST) IBC P-257 Exhaust: Allow 65 ft 3-inch CPVC (to adapt to the SST) for each 1 ft allow 3.2 ft equivalent 4-inch PP flexible pipe Limited to 160 ft maximum Allow 1.2 x actual length (e.g., 10 feet of 4-inch flexible pipe x 1.2 = 12 feet of rigid pipe) Table 6 Maximum air intake pipe and maximum exhaust vent length - SL 40-399 G3 . Notes Unused intake travel cannot be added to the exhaust. Unequal intake and exhaust piping is allowed. Support should be provided for intake and vent piping, particularly for horizontal runs (follow local code). Example of equivalent length calculations for an SL 40-399: An SL 40-399 G3 can be sited up to 200 feet (actual vent length allowance) from the vent Section: Installation termination using 4-inch pipe. For 6 x 901 elbows, the maximum lineal (straight) length of pipe allowed is 152 feet (200' — (6 x 8' = 48) = 152'). For 4-inch flexible PP pipe, up to 160 linear feet is allowed in vertical orientation (> 45 °). The equivalent length of 4-inch flexible PP pipe should be calculated using a multiple of 1.2 (e.g., 45'x 1.2 = 54'). 26 3.7.5 Rooftop vent termination 3.7.5 Rooftop vent termination Warning Condensate can cause corrosion of metal roofing components and other roofing materials. Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate. pH levels can be as low as 3.0. a. Rooftop vents must terminate as follows: The exhaust pipe can terminate in an open vertical orientation without concern about rain infiltration; rain will drain away through the condensate trap. Optional bird screen may be placed in a termination fitting. 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 configurations, including typical clearance requirements are shown below in the following images. 12' 13us mml min. Snow t 12' {305 mm} min. Figure 12 Rooftop vent terminal configurations 121. nmj 1 12" j MIN. Figure 13 Rooftop vent termination with sidewall combustion air Section: Installation Vent screen retainer OExhaust O3 Vent screen O4 Inlet O5 Flashing Figure 14 Rooftop vent terminal vent screen and retainer The intake air pipe is not typically drained, so it must be terminated with a down -turned elbow as shown. 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. Best Practice: To reduce the possibility of expansion noise, allow a'/4' gap around the exhaust and air intake piping. For roof top venting of multiple boiler sets, group all intake terminals together for a common penetration through a custom cap. Alternatively, place close together using commonly available pipe flashing. Similarly, group the exhaust pipes and place the two separate groups of pipes at least 3' apart (the closest intake and exhaust pipes must 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. Installation of the vertical roof top 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' (305 cm) away from any portion of the building and a minimum of 2 feet (61 cm) above the roof line plus the anticipated snow line. W 3.7.6 Sidewall vent termination 3.7.6 Sidewall vent termination O 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. Take action to avoid moisture entering building structures. Serious structural damage may occur if adequate precautions and clearances are not considered. These precautions apply to neighboring structures as well as to the structure the boiler(s) are installed in. M V y F C K y� QL-�Wwwmffi �1 PEN - :I ilm -- e L r I'mis Vent terminal Air supply inlet Area where terminal is not permitted Figure 15 Minimum clearances from vent/airinlet terminations Section: Installation A Clearance above grade, 12 in (30 cm) 12 in (30 cm) veranda, porch, deck, or balcony B Clearance to window or 36 in (91 cm) for 12 in (30 cm) for door that may be opened appliances >100,000 Btuh appliances > 50,000 Btuh (30 kW) (15 kW) C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2ft (61 cm) from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner 4 ft (1.22 m) 4 ft (1.22 m) H Clearance to each side of 3 ft (91 cm) within a height * center line extended 15 ft above the meter/ above meter/regulator regulator assembly assembly I Clearance to service Above a regulator within 3 * regulator vent outlet ft (91 cm) horizontally of the vertical center line of the regulator vent outlet to a maximum vertical distance of 15 ft (4.5 m) J Clearance to non- 36 in (91 cm) for 12 in (30 cm) for mechanical air supply inlet appliances >100,000 Btuh appliances > 50,000 Btuh to building or the (30 kW) (15 kW) combustion air inlet to any other appliance 1In accordance with the current CAN/CSA-B149 Installation Codes. 2If locally adopted installation codes specify clearances different than those illustrated, then the most stringent shall apply. 3In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code. Clearances in accordance with local installation codes and the requirements of the gas supplier. The minimum distance from adjacent public walkways, adjacent buildings, openable windows, and building openings shall not be less than those values specified in the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, CSA8149.1. 30 K Clearance to mechanical 6 ft (1.83 m) air supply inlet L Do not terminate above 7 ft (2.13 m) 4 paved sidewalk or paved driveway M Clearance under veranda, 12 in (30 cm) 5 porch, deck or balcony Table 7 Vent/air inlet termination clearances 3.7.6 Sidewall vent termination 3 ft (91 cm) above if within 10 ft (3 m) horizontally Vents cannot be located above public walkways or other areas where condensate or vapor can cause a nuisance or hazard* * Sidewall direct vent with separate vent and air pipes must be terminated as follows: Locate the intake air and exhaust vent terminations on the same plane (side) of the building. Place the exhaust vent termination so that it reaches minimum 12" above the down -turned intake to avoid exhaust re -ingestion. (Optionally) Raise the elevation of exhaust termination "periscope style" after passing through the wall, to gain the required clearance as shown in Figure 16 and Figure 17. Use a 45' elbow on the exhaust termination to launch the plume up and off the sidewall (for protection of wall). A short piece of venting cut at 45° gives a horizontal termination protected from wind loads (see Figure 17, and Figure 19). Recommended: the use of a bird screen of/4' stainless steel or plastic mesh (IPEX System 636 drain grate) to guard against foreign objects. OCaution Refer to local code requirements or restrictions when installing concentric side wall termination kits. Ensure that the termination and venting slope back to the appliance. 1In accordance with the current CAN/CSA-B149 Installation Codes. 2If locally adopted installation codes specify clearances different than those illustrated, then the most stringent shall apply. 3In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code. 4A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. 5Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. Section: Installation Warning Important!: Maintain at least the minimum separation of exhaust vent termination from boiler intake air as illustrated in Figure 16, Figure 17, Figure 18 and Figure 19 . Failure to do so can result in a dangerous situation where exhaust gasses are re - ingested 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 must not be used. Improper installation will void the warranty. Do not use proprietary InnoFlue or PolyPro PP terminals without specific approval from IBC. OCaution Take care installing Concentric Side Wall Termination kits when the outdoor temperature drops below 5°F/-15°C. Possible blockage of the combustion air intake can occur when the outdoor temperature drops below this temperature. C 12" (' 3 m} MIN. 12'[0.3m1 MIN. 12' (0.3m) MIN. 1 Z (03m) MI N. ABOVE ANTICIPATED ABOVE ANTICIPATED SNOW LINE. SNOWLINE I FL-1 Figure 16 Vent termination clearance, side -by- Figure 17 Vent termination clearances, side -by - side perforations side perforations, side view 32 ■■■ EM ■ A ■ ADMAN■ ■ ■■ N • . ■■I MI j■ ■ ■■I I Figure 18 Vent termination clearance, stacked 3.7.6 Sidewall vent termination IrpR 12'0 nDM� sn Figure 19 Vent termination clearances, stacked, side view A- M CIL, r at rt� +� rr a�rr r� Figure 20 Sidewall multi -vent terminations, stacked option 12' (03m) MIN. 12"(0.3m)MIN. ABOVE ANTICIPATE ❑ SNOW LINE. - 3" (0.075m) MIN. (edge to edge) 12" (0.3m) MIN. E ANTICIPATED Fresh Air Intake Bank SNOW LINE. fir^ T Section: Installation L Exhaust Vent Bank Lff min.Cr' VY(0.075m)MIN. Figure 21 Sidewall multi -vent terminations, side -by -side option Sidewall direct vent with stainless sidewall terminal must be terminated as follows: The Stainless Sidewall Terminal (SST) 3 inch (IBC kit P-257) is approved for use with this appliance. Install the SST to comply with the minimum vent clearances listed in Table 7. Install the SST with the vent and intake pipes horizontally beside each other or vertically with the vent pipe on top. The vent pipe cannot be installed below the intake. The vent cap must be installed with the openings directed up and down (see Figure 22), and not side to side. 34 3.7.6 Sidewall vent termination Figure 22 Allowed SST installation orientations The SST vent/air connections fit Sched. 40 three inch PVC/CPVC pipe. PP pipe cannot be used with the SST. The pipes must extend completely through the wall as shown below, and immediately inside the wall, adapt up to a 4 inch pipe using a standard reducing coupling fitting. Do not use a bushing. The SST is an external fixture, and is not part of the sealed vent system that runs inside the building. Figure 23 Pipes extend completely through the wall (Vertical orientation shown) Ensure that the vent termination location does not exceed the allowed maximum equivalent vent length, including the allowance for the SST. Install multiple vent SST installations level with one another and maintain at least the minimum separation distances shown below. The terminals shall not be stacked vertically. 12" MIN 12" MIN 12'MIN 12'MIN LP - - J'- Figure 24 : Minimum separation for multiple Figure 25 : Minimum separations for multiple vent vent installation - vertical orientation installation - horizontal orientation Approved PVC Side Wall Termination kits are listed below: Ipex # 196985 3" (SL 26-260 G3) [] 0 Ipex # 196986 4" (SL 40-399 G3) Figure 26 Approved PVC Side Wall Termination configuration C§) Section: Installation 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. Where an exhaust passes through a sidewall too close to a soffit, the venting must extend past the soffit by transitioning to vertical as shown in Figure 27. Figure 27 Side wall vent termination transition to vertical to clearsoffit This illustrates the scenario where indoor air is used for combustion. Where combustion air is drawn from outdoors, combustion venting should also transition to vertical and terminations should observe the limitations set out in Fig. 5. 36 3.7.7 Combustion air filtration system 3.7.7 Combustion air filtration system If contamination from particulate matter in room -supplied combustion air is a concern, an optional air intake filter may be t installed. The P-172 Air Filter kit has a 4" base for the combustion air fitting of the SL 399 G3. See left for adaptation for SL 26-260 G3 Iff 3 1 Flue gas exhaust to 3 outdoors 2 P-172A Air intake filter SL zs-zso 3 Field -supplied 4X3 mechanical joint coupling and a - short piece of 3-inch schedule 40 pipe Figure 28 Adaptation ofP-172 filterto 3"intake on SL 26-260 G3. 3.8 Closet installations For installations in a confined 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 appliance must not be exposed to surrounding air above 122°F (50°C) or below 32°F (0°C). 3.9 Installing the condensate trap IBC's specified vent configuration promotes the safe drainage of moisture from the boiler and exhaust venting without flowing liquids back through the heat exchanger (as done by some other condensing boilers). JWarning Fill the trap with water before initially firing the boiler to prevent exhaust fumes from entering the room. Never operate the boiler unless the trap is filled with water. Failure to comply will result in severe personal injury or death. Upper Union am Nut Union Nut O-ring Condensate Trap Union Cap cuse for lean -out Vacuum Breaker Cap Trap Drain Outlet Drain Compression Nut Section: Installation Ensure the supplied trap is correctly installed and filled with water. When required, add (and maintain in good condition) a neutralization tank. For information on installing a condensate neutralizer, see Installation on page 15. Drain The condensate trap must be Hvse installed on the drain connection at the base of the boiler. The condensate drain must be piped to within 1 " of a drain or connected to a condensate pump. The drainage line must slope down to the drain at a pitch of/4' per foot so condensate runs towards the drain. 1 . Remove the boiler door. 2. To remove the condensate retainer, undo the two wing nuts. Retain for later. 38 3. Fill the condensate trap with water, and ensure that the bottom union cap is hand -tightened to prevent leakage. 3.9 Installing the condensate trap 4. Loosen the upper union nut, and slide the trap over the boiler drain outlet, and then tighten the upper union nut. 5 ■ To reinstall the condensate retainer, tilt 6 ■ The drain hose should run to a suitable the retainer to enable you to slide the drain or condensate neutralizer. two tabs under the chassis of the boiler, and secure with the wing nuts. .M Section: Installation ------------/ 1 Flue gas exhaust: condensate and rain water, flow back from the venting system. Warning - Risk of damage to appliance. Ensure that rain water is prevented from entering air intake piping. 2 Condensate water line Warning - Risk of damage to appliance. All condensate discharge lines, including neutralization tank inlet, must be at a lower elevation than the condensate water line of the appliance. C3�,; Affix hose to drainage piping C4 Factory -supplied condensate trap C5 ; Confirm slope. Condensate hose and drain piping to slope toward drain and be secured to prevent accidental disassembly. ODrain materials subject to corrosion must be protected by acid neutralization, CTo drain. Figure 29 Condensate trap drainage Free flow of condensate from venting systems and pressure vessel must be maintained at all times. Trap and condensate drain piping must be accessible to allow regular inspection and cleaning. 40 3.10 Installing a condensate neutralizer 3.10 Installing a condensate neutralizer If discharging condensate into building drain piping materials that are subject to corrosion, use a neutralization package. OCaution After installing a condensate neutralization package, 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. Wear protective gloves and eye wear when servicing the condensate neutralizer. 1 2 J 6 5 5 4 7 FFL OY: Flue gas exhaust: condensate, and potentially rain water, flow back from the venting system. Air intake piping: Warning - Risk of damage to appliance. Ensure that rain water is prevented from entering. Condensate water line: Warning - Risk of damage to appliance. All condensate discharge lines, including neutralization tank inlet, must be at a lower elevation than the condensate water line of the appliance. Section: Installation Free flow of condensate from venting systems and the pressure vessel must be maintained at all times. Trap and condensate drain piping must be accessible to allow regular inspection and cleaning. Condensate neutralizer NT-25: Drain materials subject to corrosion must be protected by acid neutralization. Warning - Risk of injury. Tank fluid can be highly acidic. Do not use hands to stir material. Refer to the neutralization instructions of the manufacturer. Access to the discharge, before the drain, is necessary for proper maintenance in order to check the effectiveness of the neutralizing agent. A simple pH test should be performed annually to ensure neutralizing agent is still effective. If the pH falls below 6.5 the neutralizing material should be replaced. The agent (limestone chips with a minimum calcium carbonate content of 85%) can be purchased from a local supplier. 1" FPT inlet and outlet. Unions for ease of maintenance. To drain. Confirm slope. Slope the condensate hose and drain piping toward the drain and secure to prevent accidental disassembly. Figure 30 Condensate neutralization tank 3.11 Water Piping 42 3.11 Water Piping Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage. High levels of dissolved solids or minerals may precipitate out of the fluid 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 reduce dissolved solids to 30 ppm. 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/I Iron is to be less than 0.3 mg/I Cu less than 0.1 mg/I Conductivity is to be less than 400pS/cm at 77°F (25°C) 7 grains/ gal (120 ppm) Important: Ensure that these limits are acceptable for the other water -side components in the system. Flow rate (gpm) 6 10 15 20 Head @ flow (ft wc) 2 3.5 5.5 8 Table 8 SL 26-260 G3 Boiler Head Loss 25 13 Flow rate (gpm) 20 25 30 35 40 45 Head @ flow (ft wc) 1 1.5 2 3 4 6 Table 9 SL 40-399 G3 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, confirm the actual performance by measuring 0°T (under high and low flow conditions) after establishing the correct firing rate. Section: Installation To use legacy heat, we recommend water flow after burner shutdown. There can be significant build-up of energy due to the volume of heated water in the system. Default load settings 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 settings will run the Load 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. To guard against deadheading pumps when all zone valves are closed, set the load Pump Post Purge (sec) to'0'. To allow pump purge after burner shut -down, the primary pump must be under the control of the boiler. To simplify the control application, promote good loads and flow management, installers must conform to the piping design configurations provided. Propylene glycol usage 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. Installers must 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 non -toxic propylene glycol. 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 flow and pressure. Generally, a 50%:50% solution of propylene glycol and water requires an increased system circulation rate (gpm up 10%), and system head (up 20%) to provide performance equivalent to straight water. IBC boilers are designed for use within a closed loop, forced circulation, low pressure system. A 30 psi pressure relief is supplied for field installation in the relief valve fitting on the boiler. For the SL 40-399 G3, optional relief valves up to 75 psi can be used where required on closed loop systems within multi -level buildings. Relief valve discharge piping must terminate between 6" (15 cm) and 12" (30 cm) above the floor or per local code. 44 3.11 Water Piping Q� Warning 1 During operation, the relief valve may discharge large amounts of steam and/or hot water. To reduce the potential for bodily injury and property damage, install a discharge line that: Is connected from the valve outlet with no intervening valve and directed downward to a safe point of discharge. Allows complete drainage of both the valve and the discharge line. Is independently supported and securely anchored, so as to avoid applied stress on the valve. Is as short and straight as possible. Terminates freely to atmosphere where any discharge will be clearly visible and is at no risk of freezing. terminates with a plain end which is not threaded. Is constructed of a material suitable for exposure to temperatures of 375' F or greater. Is, over its entire length, of a pipe size equal to or greater than that of the valve outlet. Do not cap, plug or obstruct the discharge pipe outlet. Section: Installation 3.11.1 General piping best practices Primary/secondary piping, or the use of a hydraulic separator (such as the Caleffi 549 SEP4TM 4-in-1 Magnetic Hydraulic Separators) is recommended for maximum flexibility in multi -load applications. 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 heat exchanger affords more flexible options unavailable in other designs. OCaution Contact local water purveyors about the suitability of the supply for use in hydronic heating systems. If unsure about water quality, request testing and assessment (and treatment, if required) from a local water treatment expert. Alternatively, water or hydronic fluid of known quality can be brought to the site. 3.11.2 System piping = Note The piping drawings in this manual are simple schematic guides to a successful installation. For further information and details, consult our concept drawings — which provide detail on specific single and multiple boiler applications (available in IBC's Technical portal). There are many necessary components not shown, and details such as thermal traps are left out so the drawings have greater clarity. Our boilers must be installed by licensed and experienced heating professionals familiar with the applicable local and national codes. System design is to be completed by an experienced hydronic designer or engineer. You should carefully read and follow the installation instructions along with the application drawing that fits your system. System piping is connected to the boiler using 1'/2" NPT-Male threaded fittings. To simplify servicing, we recommend using unions at the boiler's supply and return water connections. 46 6 1 2 1 IBC Boiler L�J 3 � 4 W, 1r. L, .J a,. 7 3.11.2 System piping OPressure relief valve (shipped with the boiler): no isolation valve permitted between boiler and relief valve OAir vent purchased separately Microbubble air eliminators are best installed where the fluid is at the highest temperature and lowest pressure, on boiler outlet at expansion tank connection. 4 Expansion tank connection (point of no pressure change) should be on the suction side of the circulator, with minimal pressure drop between. O Boiler (primary) pump n To/ from load �7 Dirt separator recommended Fill station with isolation valve closed, or fill tank. Figure 31 Boiler trim options -single boiler Section: Installation Fluid fill is most often accomplished by using a boiler regulator and fill valve set at 12 psig or more, with the appropriate backflow prevention device as required by local code. This is acceptable in areas where municipal water or well water has been treated and filtered 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. Warning Close the fill valve after any addition of water to the system, to reduce risk of water escaping. Today, there are a number of boiler feed and pressurization devices on the market that may be a better choice than a raw water fill from the mains. When regular maintenance requires relief valve blow -off, the discharge may be directed back into the pressurization appliance for recycling of boiler fluid and chemicals back into the system. In buildings that may be unoccupied for long periods of time, pressurization appliances are useful to prevent flood damage should leakage occur from any component in the system. An additional benefit is that backflow prevention devices are not required when using these devices. Do not place any water connections above the boiler to avoid damage to the fan and controls. If needed, create a shield over the top of the cover, but allow clearance for airflow and service access. Primary -Secondary piping For best results, use a primary/secondary piping system, with a pumped boiler loop using 2" piping. Primary/Secondary piping ensures adequate flow and de -couples A°T issues (boiler vs. distribution). Aim for a 20 °F to 30 °F A'T across the heat exchanger at high fire (there is a boiler protection throttle fence limiting the A °T to 40 °F). For the SL 40-399 G3 model, the minimum flow rate required through the heat exchanger is 20 gpm and a maximum of 45 gpm. To ensure adequate water flow through the boiler under high -head / single zone space heating conditions, you must use a pressure activated bypass or other means of bypass on any load where the flow rate might drop below minimum requirements ( 20 gpm). 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 flow. 48 • !BC 5L 40-399 G3 � u >8: 0 <40 an >40 2 3.11.2 System piping 1. Closely -spaced tees: To avoid induced flow, each set of tees should be installed with straight piping a minimum of 8 pipe diameters upstream and 4 pipe diameters downstream, with no elbow or other component that may create turbulent flow. Tees should be as close together as possible (maximum four pipe diameters apart) and there should be no restrictions between the fittings that would result in a pressure drop. OHeat Migration: On secondary loops that extend vertically to a load that is above the primary loop, steps must be taken such as fabricating a thermal trap in the return piping - minimum 18" (46 cm) drop- to prevent thermal siphoning and heat migration to the load when there is no demand for heat to that loop. Alternatively, use check valves on both supply and return of secondary piping. Figure 32 Primary -secondary piping details with closely -spaced tees Section: Installation Note The boiler, when used in connection with a refrigeration system, must be installed so that the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. The boiler piping system of a hot water boiler connected to the heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle. Monitor the performance of system components when using the sequential load feature of the boiler to ensure that the components are compatible. For instance, many air handlers 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 the air handler components operating when other loads are operating at a higher priority, resulting in cold air blowing, or heat robbed from another load. Some wiring alterations may be required to separate these functions from the thermostat control in favor of more effective control from the boiler. Figure 33 Primary -secondary piping with simultaneous heating calls. Always ensure that loads sensitive to high temperatures (e.g., radiant floors), are protected using appropriate means such as a manual mixing valve, or an aquastat (set to 130T, for example) wired to the boiler's auxiliary interlocks. 50 3.11.2 System piping Figure 34 Two pump, two load - parallel piping Compared with the Primary -Secondary approach, the above design saves one pump. Use check valves or thermal traps to isolate both the supply and return piping for each load. This avoids thermal siphoning and reverse flow. In order to ensure appropriate flow of water through the boiler in the case of high pressure drops or heating of a single zone, it may be necessary to install a pressure -activated bypass device on any circuit where the flow rate could drop below the minimum requirements. Section: Installation 1 A Figure 35 Primary -secondary piping concept with hydraulic separator OPressure relief valve (shipped with boiler): no isolation valve permitted between boiler and relief valve. OHydraulic separator. O3 Expansion tank connection (point of no pressure change) should be on the suction side of the circulator, with minimal pressure drop between. O4 Fill station with isolation valve closed, or fill tank. Supply piping to load 1, load 2, load 3, load 4. OReturn from loads. O7 Boiler (primary) pump. g Air vent (available separately as P-195). 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. 52 3.11.2 System piping IBC uea3% It 0 a ■ 2=7M, o - Note External devices shown on this drawing are not supplied by IBC as standard equipment except for the pressure relief valve and internal LWCO. The other devices can be provided by your IBC distributor or by special order from IBC. Figure 36 Trim for multiple boilerinstallations OPressure relief valve (supplied by IBC) Auto air vent with isolation valve (available separately as P-195) O Pipe to drain (_4Low water cut-off: An internally mounted UL 353 Certified Low Water Cut -Off (LWCO) is factory -installed. In some instances, an external device may be required by local jurisdiction, which may have specific installation requirements not illustrated. When required, consult with IBC or the LWCO manufacturer for proper application. 5 Optional external water high limit (manual reset): An internally mounted manual reset mechanical water temperature high limit is factory -installed. An external manual reset mechanical water temperature high limit can be fitted if required by local jurisdiction. Section: Installation Optional external tridicator gauge: An internally mounted tridicator is factory -installed. An external tridicator can be fitted if required by local jurisdiction. Flow direction: To supply manifold g Flow direction: From return manifold `9 Drain with cap ----------------------- i 1 4 4 4 3 Figure 37 Multiple boiler piping - four staged boilers, single load O Supply to heating system. OSecondary loop sensor (to master boiler). D3 Closely -spaced tees are a maximum of four pipe diameters apart, with a minimum of eight pipe diameters of straight piping upstream of the first tee and a minimum of four pipe diameters of straight piping downstream of the second tee. 4 Return from heating system. 54 3.12 Gas piping 3.12 Gas piping Due to the precision of modern modulating boilers it is important to pay special attention to gas pressure regulation. Important: Check gas supply pressure to each boiler with a manometer or other high - quality precision measuring device. Pressure should be monitored before firing the boiler, during operation throughout the boiler's full modulation range, and after the call when the regulator is in a "lock -up" condition. Pay special attention to retrofit situations where existing regulators may have an over- sized orifice 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 specification at all firing rates, and will not exceed the boiler's maximum pressure rating when locked -up with no load. 3.12.1 Gas pressure The boilers require a minimum inlet gas supply pressure of 4.0" w.c. for natural gas or propane during high fire operation. For either fuel, the inlet pressure shall be no greater than 14.0" w.c. Confirm this pressure range is available with your local gas supplier. The inlet gas connection to the boiler is 3/4' NPT (female). Adequate gas supply piping must be installed with no smaller than 3/4" Schedule 40 (e.g., Iron Pipe Size (IPS) and using a 1" w.c. pressure drop, in accordance with the following table. SL 26-260 G3 (Natural Gas) 20' 80, 300' 600' SL 26-260 G3 (Propane) SL 40-399 G3 (Natural Gas) SL 40-399 G3 (Propane) Table 10 Maximum Gas Pipe Length (ft) 70' 200' 800' 1600' 10, 40' 150' 300' 30' 100, 400' 900, Section: Installation Gas piping must have a sediment trap ahead of the boiler's gas valve. A manual shutoff valve must be located outside the boiler, in accordance with local codes or standards. All threaded joints in gas piping should be made with an approved piping compound resistant to the action of natural gas or propane. Use proper hangers to support gas supply piping as per applicable codes. If 2 CInstall manual shut-off valve. Check local code for height requirement CFull-sized sediment trap CUnion Figure 38 Typical gas piping 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/z psig. Dissipate test pressure prior to reconnecting. The boiler and its gas piping must be leak -tested before being placed into operation. The gas valve is provided with pressure taps to measure gas pressure upstream (supply pressure) and downstream (manifold pressure) of the gas valve. Note that manifold pressure varies slightly in accordance with firing rates with the modulating series boilers, but will always be close to 0" wc. 3.13 Electrical connections All electrical wiring to the boiler (including grounding) must conform to local electrical codes and/or to the National Electrical Code, ANSI/NFPA No. 70 — latest edition, or to the Canadian Electrical Code, C22.1 - Part 1. 56 3.13.1 Power management, quality and electrical protection 3.13.1 Power management, quality and electrical protection In areas of unreliable power, appropriate surge protectors and or power conditioning equipment should be installed in power supply wiring circuits. 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. In temporary or manual operation, for example in new construction heating, use a construction thermostat orjumper with an in -line on/off switch for on/off management of the boiler. Do not turn off the heat by removing power to the boiler. This will interrupt the moisture management routine (fan turns at ultra low rpm for 90 minutes after burner shutdown) resulting in serious damage to the boiler. Treat the boiler like a computer, where you do not just pull the plug when done. 3.13.2 120VAC line -voltage hook-up D Line -voltage wiring is done within the field -wiring box (see Wiring 1 diagrams on page 105). 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. Figure 39 Line voltage load pump terminals Caution The on -board controller load 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. Connect a 120VAC / 15 amp supply to the "AC IN" tagged leads in the wiring box. The maximum actual draw (with 5 typical residential size pumps) is less than 4 amp. 3.13.2.1 Load pumps 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. 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, Section: Installation 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). 3.13.2.2 Boiler pump The boiler (primary) pump is powered by the white/yellow wire from the pair labeled "Boiler 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 filling / air purging. The combined current of all load pumps connected through the on -board pump relays should not exceed 10 amps. The control circuit board is protected using on -board field replaceable fuses. Each pump is fused with a separate 5 Amp fuse. The Alarm contact is fused with a 5 Amp fuse and the 24VAC boiler control circuit is protected with a 2 Amp fuse. The VS output leads are not commonly used except when providing a variable speed signal to the fan in an IBC air handler. 3.13.3 Other wiring Danger Do not connect sensors to "Therm" terminals. Overheating components can result in serious personal injury and/or property damage. Other optional low voltage connections to the control board include: Two auxiliary Interlocks -for external safety devices as maybe required by some jurisdictions, such as an external low-water cutoff. Contacts for indoor and outdoor temperatures sensors associated with reset heating. A 1 OK ohm thermister (resistor dependent on temperature) for outdoor reset sensing is supplied with the boiler for improved comfort and combustion efficiency. 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. 58 3.13.4 Zone valve hook-up One pair (marked BoilerNet) for network connection — this is used for connecting multiple IBC modulating appliances for autonomous staging. The bottom pair of contacts (labeled 'External Control') 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 R = 3892. We do not recommend using 3rd party supplied sensors. Compatible water temperature sensors and outdoor sensors can be supplied by your IBC distributor. 3.13.4 Zone valve hook-up If using zone valves instead of pumps to manage multiple heating loads: Provide 24VAC for the zone valves to the power contacts on the Pump/ Zone Valve terminal block. 2. Disconnect the 120VAC leads connected to PV-L/PV-N and cap off. Use a separate transformer— the 40 VA appliance inside the wiring box is for internal systems only. Wire individual load/zone valves 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 floor) — see the next section. 3.13.5 Thermostat / sensor wiring Each of the four loads has dry contacts for thermostats 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 zone valve) present a common thermostat signal to the controller. Ensure that there are no disturbing influences on the call -for -heat lines - for example, that there are no coils to switch an air handler motor. Most power stealing thermostats can be connected directly to the Therm terminals. Consult the Controller manual for more detailed instructions. 3.13.6 Thermostat heat anticipator IBC "Therm" contacts draw no power, so an anticipator setting for the thermostat is not applicable with these appliances. 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. Section: Installation IBC Cammllar V10.0 - Etectrlcal Ladder Ofayram L ■ 120Vac p N lac CG°1lral awre • a ' FsSR PA•,-N •--', Punn Iwo-11 lwdt'1.^° Load P m P " 0.va- Fur Sti `we4Pu • e 1N • • tiu�ry�mv10.'//.GO..+r v�•�p.v�1•�p+e mt we A1vlrr Monet rl' aaeG�-M Amnµ Mc1 •.MOR f m! uvd hermo tat �a iFrm wee3Tnennceml n"""' A°kr l°murud k. v°+.� o-wrrcns . • anaas..o. awns..°. Sensors000 BNW MI,• WL iptpl.q,ry G ��qu P9 °&92Ua�v�1 ' F1un�Caw[M- �, lipn lvn-"— ,ca�ma @r mv�o-,wOC orf+epMvi%I �. Sq lutm, ConscV I,PO'vdc !ltcl Figure 40 Electric wiring connections 9 4.0 About the boiler controller This boiler is equipped with a touchscreen controller for programming the boiler. For detailed instructions on using the controller, see the Touchscreen Controller manual. N ott Use only a stylus or a clean finger to interact with the touchscreen. Using sharp or metallic objects will cause damage. 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 Manual control of firing rate for gas valve calibration Alarm dry contacts Zoning - simultaneous operation of up to four pumps Load Combining — simultaneous operation of two similar water temperature loads Programmable setback / override schedule The control can manage or operate in a network of up to 4 IBC boilers without additional controller. Some of the new features available in the touchscreen control include: Setup Menu for simple, quick programming Portal connectivity for remote monitoring and programming Superior warning messages while setting up the control Advanced Error messages with visual display on the Home Screen Internet/LAN connectivity 4.1 Controller When the boiler is first energized, the controller will go through a power up sequence that will take approximately 60 seconds. During this time the controller is completing a self -diagnostic 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. Section: About the boiler controller The controller provides overall management of the boiler operations includi 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 Internet connection and communication Operational and historical data may be accessed from the I I Status menu > Load Status > Load Profiles and Load Statistics screens. Also in the Status menu, you can view error logs, including records of all errors since original power -up complete with the date and time of the error. 4.2 Control interface 08:33 The control interface is provided through a color touchscreen display. The touchscreen responds to a light finger touch on the screen. You can also use a stylus, pencil, or similar device to operate the touch controls. Do not use a sharp or metallic object such as a screw driver as it could damage the touchscreen. 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 dims to save power. The control automatically returns 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 specific warning or alarm present. If more than one alarm is present the text display will rotate though the alarms that are present. 62 5.0 Before operating the boiler Danger Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, do not try to operate any appliance - do not touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a phone located remotely. Follow the gas supplier's instructions, or if the supplier is unavailable, contact the fire department. Do not use this boiler if any part has been underwater. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been underwater. 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. Important pre-ignition checks Once installation of the appliance is completed, and before operating the appliance, it is important to review the following checklist of precautions: Checklist for electrical conditions, ducting and water connections Check all line voltage electrical connections to ensure all connections are correct and tight. ❑ Check thermostat connections. ❑ Thermostat in a suitable location. ❑ Ensure venting system is complete and seal tested. ❑ Confirm any common venting system at the installation site is isolated and independent of ❑ the boiler. Confirm that any holes left from the removal of a previous boiler have been sealed, and ❑ that any resizing of the old flue has been done. Check that the water piping system is fully flushed and charged, and that all air has been ❑ discharged through loosened bleed caps. Note that it is possible to run all pumps from the touchscreen — without a call for heat. This simplifies system filling and air bleeding (refer to "Performing a manual pump purge" in the Control/ermanual). Load must be assigned. Use a minimum water pressure of 12 psig and confirm that the pressure relief valve is installed and safely drained. Section: Before operating the boiler Check to see that adequate gas pressure is present at the inlet gas supply test port. ❑ Connect a manometer and open the gas control valve. Requirements are minimum 4" w.c ❑ and maximum 14" w.c. Check that there are no gas leaks. All connections are pressure tested and leak free. All piping flushed to ensure all air is removed. Check valve is installed and the external pump is flowing in the correct direction All connections are pressure tested and leak free. ❑ All vent pipe is sized correctly and joints are sealed. ❑ Perform a final check of electrical wiring, and provide power to the boiler to initialize ❑ operation. Warning Fill the condensate trap with water before you first fire the boiler to prevent exhaust fumes from entering the room. Never operate the boiler unless the trap is filled with water. Failure to comply will result in severe personal injury or death. IN n 64 6.0 Boiler operation Before operating the appliance, there are some important pre-igntion checks that need to be performed. For more information, see Before operating the boiler on page 63. To understand the boiler start-up process, see Sequence of Operation on page 107. 6.1 Lighting and shutting down the boiler FOR YOUR SAFETY READ BEFORE OPERATING ■ WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electric switch, do not use any phone in your building. • Immediately call your gas supplier from a neighbour's phone. Follow the gas supplier's instructions • If you cannot reach your gas supplier, call the fire department. C. Use only your hand to turn the gas control valve. Never force using tools. If the valve will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance If any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. OPERATING INSTRUCTIONS 1. STOP( Read the safety information above on this label before doing anything. 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance by selecting main Power switch to OFF. 4. This appliance is equipped with an ignition device which auto- matically lights the burner. Do not try to light the burner by hand. 5. Locate manual gas shutoff valve (see pictures below) and turn clockwise to "CLOSE". 8. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow step "B" in the safety information above on this label. If you don't smell gas, go to the next step. 7. Turn gas control valve to OPEN. 8. Turn on electric power to appliance by selecting main power switch to ON. 9. Set thermostat to desired setting. 10.1f the appliance will not operate, follow the mstrucbons "TO TURN OFF GAS APPLIANCE" and call your service technician or gas supplier. TO TURN OFF GAS APPLIANCE 1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance by selecting main Power switch to OFF. 3. Turn gas control valve to CLOSE. Openrouved �• clockwiser r=; tl Sens horaire LGI Oo r 0 00 , ClosecTanne POUR VOTRE SECURITE, LISEZ AVANT DE METTRE EN MARCHE AVERTISSEMENT : Ouieonque ne respect pas a Is lettre lea instructions tle Is presente notice risque tle tleclencher un incentlie ou no explosion on entrainont des dommoges, this blessure5 ou la mort. A. Cat appareil ne comporte pas de veilleuse. II est mum d'un dispositif d'allumage automatique du bruleur. Ne tentez pas d'allumer Is breleur manuellement. B. AVANT DE FAI RE FONCTIONNER, reniflez tout autour de ('appareil pour deceler une occur de gaz. Remftez pres du plancher, car certa'ms gaz sont plus lourds qua fair of peuvent s'accumuler au niveau du sol. OUE FAIRE SI VOUS SENTEZ LINE ODEUR DE GAZ: • Ne pas tenter d'allumer I'appareil. • Ne touchez a aucun interrupteur; ne pas vous servir des telephones se trou-11 dans le bAtiment. • Appel immedlatement whe foumisseur de gaz depuis un voisin. Suivez les instructions du fournisseur. • Si vous ne pouvez pas rejoindre le fournisseur, appelez Is service des incendies. C. Ne poussez ou tournez la manette d'admission du gaz qu'A Is main; ne jamais utiliser d'outils. Si la manette reste coincee, ne pas tenter de Is reparer, appelez un technician qualifie. Le fait de forcer la manette ou tle le reparer pout declencher une explosion ou un incentlie. D. IN utilisez pas cat appareil s d a ate plonge dans 1'eau, meme partiellement. Faltes nspecter I'appareil par un technician qualifie et remplacez toute partie du systeme de contr8le et I qui ant ate plonges Bans ('eau. INSTRUCTIONS DE MISE EN MARCHE 1. EZ I Lisez lea instructions de secunte sur Is portion supeneure de cette etiquette. 2. Reglez Is thermostat a Is temperature Is plus basse. 3. Coupez ('alimentation electnque de ('appareil. 4. Cat appareil est dote d'un mecanisme d'allumage automatique. Ne pas tenter d'allumer Is veilleuse a la main. 5. Reperer Is valve de termeture manuelle du gaz (voir images a-dessous) et toumer dans le lens des aiguilles dune montre pour FERMER 8. Attendre cinq (5) minutes pour laisser echapper tout le gaz. Reniflez tout autor tle I'appareil, y compris pre du plancer, pour deceler une otleur tle gaz. Si vous sentez une otleur de gaz, ARRETEZ I Passez a 1'etape B des instructions de securite sur Is portion supeneur tle cette etiquette. S'il n'y a pas d'odeur de gaz, passez A 1'etape suivante. 7. Regler la position de Is valve de contoble du gaz a OUVERT. 8. Mettez I'appared sous tension. 9. Reglez Is thermostat a Is temperature desiee. 10.Si I'appariel ne se met pas an mamhe, suivez lea instructions intitulees COMMENT COUPER UADMISSION DE GAZ DA 1'1 PPAREIL et appelez un technician qualifie ou le foumisseur de gaz. COMMENT COUPER L'ADMISSION DE GAZ DE L'APPAREIL 1. Reglez Is thermostat a Is temperature Is plus basse. 2. Coupez ('alimentation elechique de 1'aptnuoil s'll taut proceder a I'entretien 3. Regler Ia position de la1alve tle centrble tlu gala FERMER. Mallow Opaniou"aI 010e16s«nl, Dpen000t 00'adr- Followed lighting and shutting down procedure. 41 Tested the ignition safety shutoff function (see Testing the ignition safety shutoff on page ❑ 66). Checked the appliance's fuel source, and if necessary, performed a fuel conversion using ❑ the appropriate P-kit. Performed gas pressure test by measuring the inlet gas pressure. ❑ Section: Boiler operation Tested efficiency of the appliance and made necessary adjustments by Performing a ❑ combustion test and adjustment. Tested the low water cutoff function to check that the LWCO sensor is working. Refer to ❑ "Testing the LWCO function" in the V10 Touchscreen Controller manual. Tested the high limit temperature function to check that the High limit temperature sensor ❑ is working. Refer to "Testing the Hi -Limit cutoff temperature function" in the V10 Touchscreen Controller manual. 6.2 Testing the ignition safety shutoff To test the ignition system safety shutoff function: 1. With the boiler in operation, shut off the gas control valve directly outside the boiler case. 2. Ensure that the boiler has purged, attempted to re -light three times, has shut off and the appropriate error information is displayed on the controller. 3. The error is displayed after testing the ignition safety shutoff. 4. To restart the boiler, reset the power or on the touchscreen controller tap' I (Status)> Clear Errors > Yes. 6.3 Commissioning The appliances are factory calibrated to operate with natural gas (or propane if desired) at sea level. The gas -air ratio or zero -offset adjustment screw may need adjusting to attain optimum combustion results. Note that only qualified technicians using properly functioning and calibrated combustion analyzing equipment should perform a mixture adjustment. 6.3.1 Checking a boiler's fuel source 6.3.1 Checking a boiler's fuel source Danger Operating any IBC appliance using a fuel other than the fuel listed on its rating plate is prohibited. Failure to follow the instructions on converting to alternate fuels can result in a fire or explosion, which may cause property damage, personal injury, or loss of life. Check the rating plate of the appliance to ensure it is configured 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. This boiler model can burn either natural gas or propane if equipped with the correct fuel -air metering device. Examine the rating plate of the boiler to ensure it is configured for the fuel you are using. For example, if the boiler is configured for natural gas, but needs to be converted to propane, use the conversion kit (sold separately by IBC) to install the appropriate fitting(s) and adjust the gas valve accordingly. See Table 11 for the required conversion kit. The touchscreen 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. Fuel conversion kit numbers Compare the boiler model number with the Kit # found in the table below: SL 26-260 G3 P-300 P-301 SL 40-399 G3 P-302B P-303B Table 11 Fuel Conversion Kits 6.3.2 Performing a fuel conversion You must be a qualified heating professional to perform this procedure. In this fuel conversion, you will be replacing the Venturi mixing device, located between the gas valve and gas line to the fan. Section: Boiler operation To perform a fuel conversion on an SL 26-260 G3: Removing the Venturi mixing device 1. Before you disconnect the electrical power, ensure that the gas supply is turned off at the gas shut-off valve. 2. Change the gas fuel source. 3. Remove the front door cover and the top cover/panel. To view the gas valve components for the SL 26-260 G3, see Gas valve and fan components - SL 26-260 G3 on page 79. 4. Undo the brass coupling nut between the gas valve and the Venturi mixing device. 5. Move the gas valve to the side. 6. Note the orientation and the positions of the Venturi mixing device Hex bolts. 7. Remove the bolts and the Venturi mixing device from the fan. 8. Ensure that the fan O-Ring is not damaged and is seated in the groove. Installing the new Venturi mixing device 1. Install the new fuel -appropriate Venturi mixing device with the Hex bolts. 2. Check that the gasket is in place between the gas valve and the Venturi mixing device. 3. Connect the gas valve to the Venturi mixing device using the brass coupler nut. 4. Place the conversion labels associated with the new fuel onto the boiler. 5. Turn on the gas supply and connect the electrical power. 6. Check for gas leaks. 7. Tune the gas valve (see Adjusting the gas valve on page 69). To perform a fuel conversion on an SL 40-399 G3: Removing the Venturi mixing device Note If a downturned elbow is installed on the old venturi, it should not be transferred to the new venturi. 1. Before you disconnect the electrical power, ensure that the gas supply is turned off at the gas shut-off valve. 2. Change the gas fuel source. 3. Remove the front door cover and the top cover/panel. To view the gas valve components for the SL 40-399 G3, see Gas valve and fan components - SL 40-399 G3 on page 80. 4. To remove the four bolts of the gas valve -gas valve elbow, use an Allen key. 5. Separate the gas valve from the elbow, and retain the O-ring. 6.3.3 Adjusting the gas valve 6. To detach the Venturi mixing device from the fan, remove the three bolts (noting the location of the bolts). 7. Ensure that the fan O-ring is not damaged, and is seated in the groove. Installing the new Venturi mixing device 1. Attach the new Venturi mixing device to the fan with the three bolts. 2. When securing the gas valve to the new Venturi mixing device with the four bolts, ensure that the O-ring is installed. OCaution Failure to position the 0-ring as indicated will result in a gas leak. 3. Place conversion labels associated with the new fuel onto the boiler. 4. Check for gas leaks. 5. Tune the gas valve (see Adjusting the gas valve on page 69). 6.3.3 Adjusting the gas valve 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. To view illustrations of the gas valve and its components, see Figure 41 and Figure 42. 6.3.3.1 Measuring the inlet gas pressure To perform a gas pressure test, you will need to use a Torx 15 screwdriver and a manometer. 1. Shut off the gas supply. You will be measuring the inlet gas supply from the test port. Do not perform a test from the manifold gas pressure test port. 2. On the gas valve, loosen the inlet gas pressure test port screw counter -clockwise. 3. Attach the manometer to the inlet gas pressure test port. 4. To measure the inlet gas pressure, switch on the gas supply. 5. When the boiler is operating at high fire, measure the gas pressure. Ensure that you have a load configured (reset heating, set point, or DHW). This load should be large enough to allow the boiler to operate at high fire for over 10 minutes. The gas pressure for natural gas should be around 7" w.c. at high fire and 11" w.c. for propane. 6. After completing the inlet gas pressure test, switch off the gas supply. Section: Boiler operation 7. Remove the manometer from the inlet gas pressure test port. 8. Tighten the inlet gas pressure test port screw. Switch on the gas supply, and soap test for leaks before returning the boiler to normal operation. 6.3.3.2 Performing a combustion test and adjustment 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 must be performed unless done by a qualified technician using properly functioning and calibrated combustion analyzing equipment. 1. Turn off the boiler's external gas shut-off valve. 2. Give the boiler a call for heat. 3. With a small (1/8" or 3 mm) flat screwdriver, open the inlet gas supply pressure test port by turning its center -screw one full turn counterclockwise. 4. Attach a manometer to the inlet pressure test port and turn on gas to appliance. 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 (start-up) procedure. Pressure may drop up to 1" to 2" w.c. at high fire. 5. Torun the boiler at high fire, you can set the heat -out value in Test Operation mode to the maximum MBH for the boiler. To do this, on the controller, go to • • • (More) > Test Operation > In the Fan Test: Heat Out field, tap 0 MBtu, then enter the maximum MBH. When the boiler reaches high fire, insert the combustion analyzer test probe into the flue gas test port. Then verify that the CO2 reading is within the combustion test targets at Table 12 values. 6. Adjust the high fire according to values in Table 12 using the high fire adjustment screw . Make tiny adjustments (may require several turns). Turning the High Fire screw clockwise will lean out the flame. Set the heat -out value in Test Operation mode to the minimum MBH for the boiler. To do this, go to • • • (More) > Test Operation > In the Fan Test: Heat Out field, tap 0 MBtu, then enter the minimum MBH. 8. Adjust the low fire according to values in Table 12 using the low fire adjustment screw. Turn the screwdriver clockwise to raise the CO2% (to richen). Turn counter -clockwise to lower CO2%. Start with % of a turn until you see the analyzer measure a change then only make 1/16 adjustments. If changing direction on this adjustment, you may notice a significant backlash. 70 6.3.3 Adjusting the gas valve 9. Check the results and confirm the correct settings when you return the boiler to high fire, and then to low fire. Note For natural gas, clock the gas meter to confirm full maximum rating plate input. 10. To exit the Test Operation screen, select Back. 11. Remove the call for heat. 12. If a manometer is connected to the gas valve inlet gas pressure port: a. Turnoff the gas supply at the external gas shut-off valve. b. Disconnect the manometer. c. Tighten the inlet pressure port screw with a Torx 15 screwdriver. 13. Remove the analyzer probe, and install the test port plug. 14. Turn on the gas supply shut off valve, and soap test for leaks. Natural Gas 9.0 - 10.0 9.5 8.2 - 9.2 8.7 <150 Propane 10.3 - 11.3 10.8 9.3 -10.3 9.8 < 250 Table 12 Combustion test target ranges - CO21Maximum CO Note: Low Fire CO2 should be at least 0.5% lower than High Fire CO2 Intentionally left empty 7.0 Service and maintenance Inspection of the boiler is to be performed annually by a qualified service technician. OCaution The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition. 7.1 Maintenance checklist for homeowner Inspect system for unusual noises. Call your local heating contractor for As needed ❑ service if needed Keep vent terminals clear of obstructions (snow, dirt, etc.). As needed ❑ Keep combustible materials and flammable liquids and vapors away from As needed ❑ the boiler. Inspection of the boiler is to be performed annually by a qualified service Annually ❑ technician. 7.2 Maintenance checklist for heating contractor OCaution Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Remove any obstructions (e.g. leaves, dust, other debris) from vent terminals ❑ Check and clean or replace intake air filters 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 re -installation of venting on each servicing. ❑ Section: Service and maintenance 7.2.1 Touchscreen boiler controller Check that boiler operation is consistent with the steps in the Annually ❑ Touchscreen Boiler Controller Manual. Check that water temperature targets and setpoint is satisfactory and Annually ❑ have not been adversely amended. Check the operating history using the boiler's Logs menu and Error Annually ❑ Logs menu. The controller tracks the duty cycle of the boiler in each of the loads separately. This information can be used to adjust the water temperatures of each load. OCaution The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition. 7.2.2 General boiler maintenance Condensate Remove and clean annually (see Cleaning the Annually ❑ trap condensate trap on page 89). Ensure that the trap has been re -filled completely before firing the boiler. If condensate neutralization is used, check the pH level Annually ❑ of condensate discharge. Burner Warning When removing the burner for inspection or boiler servicing, examine the sealing gaskets and replace if damaged. Upon re -assembly, test all sealing areas to ensure there is no leakage of combustible gas/air premix. Remove the burner to inspect for extent of fouling (see Replacing the burner on page 85. a. Wash the burner from outside with a domestic water pressure, and dry using compressed air. b. Evaluate the magnitude of clearing required, and As needed ❑ 74 7.2.2 General boiler maintenance 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. c. Reassemble. Visually inspect the burner through sight glass. Ensure the flame is stable, without excessive fluttering. Normal flame pattern is evenly distributed over the burner surface. If the burner is operating improperly, remove and clean Annually ❑ or replace. Use a CO2 analyzer to determine proper combustion. See Combustion test target ranges - CO2 / Maximum CO on page 71 for correct values. Heat In areas of poor gas quality, there may be a build-up of Annually ❑ exchanger black plaque (typically sulfur). Other fouling agents include: airborne dust, debris and volatiles. With the burner removed, examine the heat exchanger for signs of contamination and clean if necessary. Boiler Pump Check that the pump is on in normal operation and that Annually ❑ the water 0°T is reasonable for a given firing rate. Gas Piping Check for damage or leaks and repair as needed. Annually ❑ Boiler Check consistency of any boiler treatment used, for Annually ❑ treatment appropriate mixture. Chemical inhibitors are consumed overtime, lowering their density. Verify proper operation after servicing. Annually ❑ OCaution 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 fluid of known quality can be brought to the site. Section: Service and maintenance ComponentBoiler Maintenance Required 1=0 Freeze Check the effectiveness of the glycol in the system. Use Annually ❑ protection only antifreeze made specifically 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. 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, wet 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 non -toxic propylene glycol. Water O 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 fluid of known quality can be brought to the site. Check water pressure and temperature. Annually ❑ There should be no noticeable change if boiler is functioning normally. Check for any noise in the system. Check water piping for damage or leaks and repair as Annually ❑ 76 7.2.2 General boiler maintenance needed. Check the water pressure. Pressure should be stable Annually ❑ when the boiler is firing and the water temperature is rising. If pressure rises sharply, consider replacement of expansion tank. Check also for noise at high fire, which may signal water Annually ❑ quality problems. Water chemistry shall be of a quality generally accepted Annually ❑ as suitable for hydronic applications. Ensure any direct "city fill" water connections are left in Annually ❑ the closed position to minimize exposure to leaks and flooding. Relief valve - Annually ElCaution maintenance O and testing Lo Before testing the relief valve, ensure the discharge pipe is properly connected to the valve outlet and arranged to contain and safely dispose of equipment discharge. 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 flush the valve seat free of sediment and debris. Then release the lever and allow the valve to snap shut. If the lever does not activate, or if there is no sign of discharge, discontinue use of equipment immediately and contact a licensed contractor or qualified service personnel. If the relief valve does not completely seal, and fluid continues to leak from the discharge pipe - perform the Section: Service and maintenance test again to try and flush any debris that may be lodged in the valve. If repeated tries fail to stop the leakage, contact a licensed contractor or qualified service personnel to replace the valve. While performing a "try lever test', a quantity of heat transfer fluid will be discharged from the piping system and the system pressure will drop. This fluid must be replaced. To refill and pressurize your system, we recommend using a system pressurization appliance such as an Axiom Industries model series. Capture the discharged fluid in a container and recycle it by returning it to the system feeder appliance. This is particularly important when your system contains treatment chemicals or glycol solutions. If the system employs plain water, the boiler auto fill valve must be turned on in order to recharge the lost fluid. 7.3 Replacing the fan, gas valve, and burner This section documents the following maintenance procedures: Replacing the fan Replacing the gas valve. Replacing the burner. 78 7.3 Replacing the fan, gas valve, and burner 1, M Combustion fan OVenturi mixing device 3 . Gas valve coupler and gasket C High fire (gas:air) adjustment C; Gas valve inlet compression coupling/ nut C On -Off switch 7 . Inlet gas pressure port CManifold pressure port (not used) C: Low fire (offset pressure) 10 Fan gasket Figure 41 Gas valve and fan components - SL 26-260 G3 CI Gas valve outlet connector OLocation of gas valve 0-ring. C Bolts ()Low fire offset pressure adjustment C; Outlet pressure port (not used) Inlet gas pressure port C High fire (gas:air) adjustment Cg Venturi mixing device C; Combustion fan 10 Aluminum gas block (gas inlet) Figure 42 Gas valve and fan components - SL 40-399 G3 7.3.1 Replacing the fan Section: Service and maintenance M 7.3.1 Replacing the fan Replacing the fan on the SL 26-260 G3 For reference, see Figure 41 . Removing the fan 1. Turnoff 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 cabinet door, and then remove the top cover/lid. 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 or screws may occur. 4. Disconnect the electrical wires from the fan. 5. Remove the electrical wire from the gas valve. 6. Undo the coupler nut 3 , and retain the gasket. 7. Remove the four nuts that attach the fan to the heat exchanger lid. 8. Carefully remove the fan and Venturi mixing device assembly, and then the fan gasket. 9. Separate the fan from the Venturi mixing device by removing the three screws. Installing the new fan 1. Attach the Venturi mixing device to the new fan with the screws and washers, ensuring that the new fan O-Ring is well seated in the groove of the fan. 2. Install the new fan and fan gasket onto the heat exchanger lid, and secure with the four nuts. 3. Secure the gas valve to the Venturi mixing device with the coupler nut 3 , ensuring that the gasket is in place. 4. Reattach the electrical wires to the gas valve and fan. 5. Open the gas supply, and check for gas leaks. 6. Tune the gas valve. Replacing the fan on the SL 40-399 G3 For reference, see Figure 42. Removing the fan 1. Turnoff 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. Section: Service and maintenance 3. Remove the cabinet door, and then remove the top cover/lid. 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 wires or screws may occur. 4. Unplug both electrical wires from the gas valve. 5. Remove the 4 bolts 3 that attach the gas valve to the Venturi mixing device, and move the gas valve out of the way. A��PPPPPP 6. Examine the gas valve gasket and replace if necessary.. 7. Disconnect the electrical wires from the fan. 8. Remove the nuts that attach the fan to the heat exchanger lid. 9. Remove the fan and Venturi mixing device assembly. 10. To separate the Venturi mixing device from the fan, remove the screws and washers. You should note the position of the Venturi mixing device on the fan before removing it. 11. Examine the fan gasket and replace if necessary. 9 p Installing the new fan 1. Attach the Venturi mixing device to the new fan, ensuring that the fan gasket is well seated in the groove. 2. Install the new fan and Venturi assembly onto the heat exchanger lid, tightening the four nuts by hand plus an extra '/z turn. Ensure that the fan gasket is in place (between the heat exchanger lid and the fan). 3. Reattach the electrical wires to the fan. 4. Ensure that the gas valve gasket is in place before you reattach the gas valve to the fan and Venturi assembly. 5. Attach the gas valve wires. 6. Open the gas supply, and check for gas leaks. 7. Tune the gas valve. 7.3.2 Replacing the gas valve Replacing the gas valve on an SL 26-260 G3 For reference, see Figure 41 . 82 7.3.2 Replacing the gas valve Removing the gas valve 1. Turnoff 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 cabinet door, and then remove the top cover/lid. 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 or screws may occur. 4. Disconnect the electrical wire from the gas valve. 5. Using a wrench to support the compression coupling (�), unscrew the compression nut. This allows you to separate the gas line pipe from the gas valve. 6. Unscrew the coupler nut 3 , and remove the gas valve and gasket. Retain the gasket for the new gas valve. 7. Install the new gas valve and gasket with the coupler nut 3 . 8. Using a wrench to support the compression coupling, screw on the compression nut 5 . 9. Reattach the electrical wire to the gas valve. 10. Open the gas supply, and check for gas leaks. 11. Tune the gas valve. Replacing the gas valve on an SL 40-399 G3 For reference, see Figure 42. Removing the gas valve 1. Turnoff 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 cabinet door, and then remove the top cover/lid. 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 or screws may occur. 4. Note the colors and orientation of the electrical wires before disconnecting them from the gas valve. 5. Separate the aluminum gas block (gas inlet) 10 from the gas valve by removing the 4 bolts. Retain the O-ring, or replace if worn. 6. To remove the gas valve, remove the 4 bolts from the outlet connector, . Retain the 0- ring, or replace if worn. Section: Service and maintenance Installing the new gas valve 1. Secure the new gas valve to the gas valve connector 1 with the 4 bolts, ensuring that the O-ring is in place. 2. Attach the aluminum gas block 10 to the new gas valve, ensuring that the O-ring is in place. If this O-ring is lost, it must be replaced with a factory supplied O-ring. Tighten by hand the 4 gas inlet block screws plus an extra '/z turn in a criss-cross pattern. 3. Connect the wires to the gas valve. 4. Open up the gas supply valve, and check for leaks. 5. Tune the gas valve. 84 7.3.3 Replacing the burner 7.3.3 Replacing the burner Warning The IBC heat exchanger has a small amount of combustion chamber insulation (refractory), which contains ceramic fibers. When exposed to extremely high temperatures, the ceramic fibers that contain crystalline silica can be converted into cristobalite, classified as a possible human carcinogen. 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 Certified under 42 CFR 84" for selection and use of respirators certified 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 fitting 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 airtight plastic bag. NIOSH stated first aid: Eye contact- Irrigate and wash immediately. Breathing - Provide fresh air. Replacing the burner on the SL 26-260 G3 For reference, see Figure 41 . To remove the burner: 1. Turnoff 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 cabinet door, and then remove the top cover/lid. Section: Service and maintenance Warning Wear gloves and a suitable protective mask to avoid ingesting particles from the refractory. 4. Disconnect the ignitor and gas valve wires, and the two electrical fan plugs. 5. To access the fan / Venturi mixing device assembly, unscrew the gas valve coupler nut 3 . Retain the gasket. 6. Remove the nuts of the heat exchanger lid. 7. Carefully remove - lift off and rotate - the fan -heat exchanger lid assembly. The burner is attached to the underside of the heat exchanger lid. 8. Remove the heat exchanger lid gasket. Replace if damaged. 9. To remove the ignitor and gasket, remove the two screws, and carefully lift the ignitor straight up. 10. Place the fan -heat exchanger lid -burner assembly upside down on a clean dry surface. 11. Carefully remove the refractory. Inspect for damage and replace if necessary. 12. Remove the burner screws and then the burner. To install the new burner: 1. Inspect the burner gasket, and replace if damaged. 2. Install the new burner, tightening the screws evenly in a criss-cross pattern. 3. Reinstall the refractory, lining up the holes with the holes on the heat exchanger lid. 4. Turn over the fan -heat exchanger lid -burner assembly, and reinstall the ignitor gasket and ignitor (tightening its screws by hand plus an extra 1/8 of a turn). 5. Reinstall the heat exchanger lid gasket. 6. Reinstall the fan -heat exchanger lid -burner assembly, tightening the nuts as shown below. 7. Reassemble components in the reverse order. 8. Open up the gas supply valve, and check for leaks. 9. Tune the gas valve. 6� J Figure 43 Order for tightening screws - SL 26-260 G3 7.3.3 Replacing the burner Replacing the burner on the SL 40-399 G3 For reference, see Figure 42. To remove the burner: 1. Turnoff 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 cabinet door, and then remove the top cover/lid. Q" Warning Wear a suitable protective mask to avoid ingesting particles from the refractory. 4. Note the colors and orientation of the electrical wires before disconnecting them from the gas valve. 5. Remove the 4 bolts on the gas valve connector outlet, and move the gas valve out of the way. Retain the O-ring, or replace if worn. 6. Disconnect the electrical wires of the fan. 7. Remove the 4 nuts securing the fan to the heat exchanger lid. 8. Remove the fan and the fan gasket. 9. Remove the wires attached to the ignitor. 10. Remove the ignitor and gasket. 11. 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. 12. Remove the heat exchanger lid -burner assembly, and place upside down on a clean dry surface. 13. Remove the heat exchanger lid gasket. 14. Wearing a mask and gloves, carefully remove the refractory. Inspect for damage and replace if necessary. 15. When separating the burner from the heat exchanger lid, gradually loosen the mounting screws in a criss-cross pattern. 16. Remove the burner gasket. Replace if damaged or worn. Section: Service and maintenance To install the new burner: 1. Install the new burner and gasket, tightening the screws evenly in a criss-cross pattern. Do not over tighten; tighten by hand plus a'/2 turn to maintain a good seal and prevent deformation of the burner flange. 2. Reinstall the refractory, lining up the ignitor holes with the holes on the heat exchanger lid. 3. Turn over the burner -lid assembly, and install the ignitor gasket and ignitor (tightening its screws by hand plus an extra 1 /8 of a turn). 4. Reinstall the heat exchanger lid gasket. Ensure that the lid gasket is in good condition, and is in place and level. 5. Reinstall the heat exchanger lid -burner assembly. 6. Replace the lid fasteners. Evenly tighten the bolts in a criss-cross pattern. 7. Reattach the ignitor wires. 8. Reinstall the fan gasket and fan, securing with the four nuts. 9. Reconnect the fan electrical wires. 10. Ensure that the gas valve O-ring is installed before reattaching the gas valve to the gas valve connector 1 with the 4 bolts. 11. Reconnect the electrical wires (paired colors in correct orientation) to the gas valve. 12. Open up the gas supply valve, and check for leaks. 13. Tune the gas valve. 2 4) C 5 8 3 2 6 6 1 i i 4 7 3. 6 Figure 44 Order for tightening screws - SL 40-399 G3 7.4 Cleaning the condensate trap 7.4 Cleaning the condensate trap Q� Warning If condensate neutralization is used, check the pH level of condensate before and after neutralization to verify effectiveness and ensure that the discharge has neutral pH levels. Never operate the boiler unless the trap is filled with water. Failure to comply will result in severe personal injury or death. Upper Union CM Nut Union Nut ❑-ring Condensate Trap — — L� Union Cap - use for clean -out Vacuum Breaker Cap Drain Compression Nut Trap Drain cutlet Drain Hose Condensate traps should be checked every year, cleaned and refilled as necessary. Before cleaning the condensate trap, you must turn off the power to the boiler, and allow it to cool down. Important: Installers or service contractors should ensure that the end user is instructed on cleaning and refilling the trap. Warning Before replacing the condensate trap, turn off the power to the boiler and allow to cool down. 89 Section: Service and maintenance 1 To remove the condensate 2 Loosen the upper union nut, and retainer, undo the two wing slide the condensate trap off the nuts. Note the orientation of the boiler drain outlet. drain hose. 3 Unscrew the union cap at the base 4 Replace the union cap and gasket and of the trap, and empty and flush the hand -tighten to prevent leakage, and fill trap with water. the condensate trap with water. M .o] 7.4 Cleaning the condensate trap 5 Slide the condensate trap over the 6 To reinstall the condensate retainer, tilt boiler drain outlet, and then tighten and slide the two retainer tabs under the the upper union nut. chassis of the boiler, and secure with the two wing nuts. 91 Intentionally left empty 8.0 Troubleshooting This section includes various conditions as well as possible solutions. Often, a problem can be identified and solved through basic checks: confirming the electrical power supply, gas flow and resetting the thermostat control. Below are some common troubleshooting issues including fixes. DI Preliminary checks 1. Confirm power to the boiler: check that the touchscreen controller is on (for example, display is lit.) 2. Check the controller's display for diagnostic error conditions. 3. Check that the boiler is not in a safety lockout. 4. Ensure wiring is clean and secure. 5. Check that gas is reaching the unit. 6. Confirm that the water system is properly charged within specifications, and that the pump is serviceable. Electronic component checks © See sections on checking the status of various control circuit components such as: - Temperature sensors -testing and measuring. - Fan: checking fan cable. - Water pressure sensor: checking water pressure sensor - Safety ignition module: -Checking LED status: - Low water cutoff error - Hi -limit temperature error 8.1 Electronic components Symptoms, Diagnoses and Fixes See sections covering diagnoses and fixes for the controller's error messages including: - Ignition issues Cycling issues Temperature issues Miscellaneous issues This section details the method for troubleshooting the non-standard electronic components on the boiler. 8.1.1 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 kQ (5,000,OOO1)) at the controller end of the sensor lead). To obtain a resistance reading, remove power to the boiler. For the supply water, return 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. The supply water and vent temperature sensors each contain two separate circuits. Test each pair. Both circuits must deliver accurate (although not necessarily identical) readings. Note that failures may occur only within certain temperature ranges. Section: Troubleshooting 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 53,658 115 / 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 / 35 7,334 190 / 88 983 95 / 35 6,532 195 / 91 903 Table 13 Temperature sensor resistance values - 10K ohms 8.1.2 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. 94 8.1.3 Water pressure sensor Red 35 VDC Positive power terminal Fan will only operate at max speed if disconnected Blue 35 VDC Negative power terminal Fan will only operate at max speed if disconnected Black Signal from controller Fan will only operate at max speed if disconnected White Fan tach. 2 pulses/rev (freq x3 0=rpm) 8.1.3 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 8PS1 the firing rate of the boiler is reduced. If the pressure drops to 4PS1 or lower, the boiler will not fire. Check the operation of the sensor by isolating the boiler from its system piping, and close the system fill valve, and then crack the pressure relief valve. The pressure displayed should reflect declining pressure. If it remains "fixed", drain the boiler and replace the sensor, or dislodge any blocking debris from the sensor inlet channel and reinsert. 8.1.4 Safety and Ignition Module (SIM) The SIM is a safety control, certified to conform to the UL 60730-5-5 and ANSI Z21.20 • CAN/CSA- C22.2 No. 60730-2-5-14 standards. The module controls the boiler's combustion fan, gas valve, sensors, safety and ignition functions including, and provides: Direct spark ignition Flame detection and current measurement Flue gas temperature sensing Supply water maximum temperature shutdown Flue gas maximum temperature shutdown �� Low water cut-off. Section: Troubleshooting 8.1.4.1 Table showing LED operating status Its two status LEDs indicate the operating status as shown in the table below. Rapid flash Off Off On Rapid flash Off Rapid flash Off On On On Flashing Power up or resetting Standby Pre -purge or inter -purge Heating Igniting Lockout Flash alternately Flash alternately Fail-safe with LED 2 with LED 1 Table 14 SIM+ LED status Indicators Startup checks and initialization LED 1 Off = No flame or sparking LED 2 = Burner -on call state LED 1 Off = No flame or sparking LED 2 = Burner -on call state LED 1 On = Flame detected LED 2 = Burner -on call State LED 1 Flashing - Electrode sparking LED 2 = Burner -on call state Possible errors: An operating limit was exceeded A sequence failed An external sensor fault was detected. An error was detected - the boiler requires a power cycle 8.2 Troubleshooting error messages Warning Never attempt to repair the control module (circuit board). If the control module is defective, replace it immediately. Errors shown on the touchscreen controller are described below as well as diagnoses and fixes. 0. 8.2.1 Maximum ignition trials error The bottom line of the touchscreen displays the boiler's error status. The following colors represent the boiler's operating status: Green — Normal Yellow —Warning Red —Alarm The text inside the bar will indicate the specific warning or alarm. If there is more than one alarm present the text will scroll slowly through all current alarm conditions. Besides the errors listed below, see also Miscellaneous touchscreen controller errors on page 98. 8.2.1 Maximum ignition trials error Error— Ignition Failure after 3 tries boiler has failed to ignite on 3 successive attempts. Boiler is in lockout for 1 hour, then repeats 3-try sequence. Consult service technician if error recurs. No spark when igniting. Check that ignition lead is secure Ignition probe/flame at the control module and at the sensor disconnected. probe. Manual gas shutoff is Check for gas flow. Open manual closed or gas line not fully gas shutoff and reset boiler. purged. Gap between ignition Adjust ignition probe rod gap probe rods is too large or between % and 3/16th inch (3.2- too small. 4.7 mm). Boiler ignites, but shuts off at the end of the ignition trial. Improperly grounded pressure vessel/burner or unserviceable ignition lead or spark module. 8.2.2 Hi Limit cut-off temperature error Ensure the pressure vessel is grounded. Check the ignition probe/flame sensor is electrically isolated from the vessel, and its ceramic insulator is intact. Replace ignition lead Replace spark module. Error— Water High -Limit Water temperature exceeds Refer to the VI Touchscreen Exceeded hi -limit. Boiler is in hard lockout Controller manual for mode. information on resetting a boiler after a hi -limit temperature lockout. Section: Troubleshooting 8.2.3 Low Water Cut-off error Error - Low Water Cutoff The Safety and Ignition Refer to the VI Touchscreen module has detected a low Controller manual for water condition. information on resetting a boiler after a LWCO lockout. 8.2.4 Aux. Interlock 1 or 2 Interlock 1 or 2 terminals are Jumper lead is loose or Replace the jumper lead. open. compromised. External safety is in an alarm Inspect the external safety state. devices. 8.3 Miscellaneous touchscreen controller errors " Loop/Indoor Sensor" "Insufficient Air Flow" "Insufficient Water Pressure" "Unknown Error" Mom©■ The sensor Check the P501 plug is plug is not fully engaged in the back engaged. of the controller board. The sensor Check the P501 plug is plug is not fully engaged in the back engaged. of the controller board. Temperature Test each temperature sensor input sensor for appropriate problem. readings and Replace defective temperature sensor. 8.3.1 Ignition issues Error -Max. In Sensor Temp. Current outlet Check water flow. Exceeded. > Check water flow Water temperature temperature signal not within acceptable range. exceeds Potential flow or sensor failure. Consult service operating limit. technician. Defective or Check wiring to disconnected temperature sensor and temperature control module. sensor. Check temperature sensor. Blank — screen dark, but fan running Indicative of Check transformer; power -surge damage to appliance replace if damaged. Check circuit board for visible damage. Controller is stuck in "service" mode after If update fails Restarting returns the software update. or no updates boiler to normal applied. operation. 8.3.1 Ignition issues Noisy spark when igniting Ignition lead is not firmly Reconnect ignition lead. connected. Boiler rumbles when igniting Boiler will not attempt to ignite Fan and pump are operating normally. Contaminants/moisture on ignitor probe/flame sensor. Fluctuating gas pressure/ gas pressure too high/too low. Check for proper gas piping No power to ignition control module. Ensure probe is dry by re -running post -purge; otherwise, clean or replace ignitor probe. Check CO2 level via analyzer. Check pressure with manometer during ignition. Check system wiring. Check air reference tubing. Section: Troubleshooting Igniter probe/flame Reconnect probe. sensor disconnected. Defective Control Module. Boiler will not attempt to ignite. No power to boiler. Fan and / or pump are off. Display Defective transformer not illuminated Check ignition output from control module. Check line voltage. Check transformer. Reconnect or replace as needed. 8.3.2 Temperature issues Low heat Operating temperature too low. Increase temperature target. Priority parameters or load configuration improperly set up. Appliance undersized. Air trapped within system Improper system piping. System pump undersized. Poor gas: air mixing. Defective thermostat. Obstruction in condensate drain. 8.3.2 Temperature issues Increase temperature target. Review load configuration parameters. Refer to Load Calculation vs. Boiler Output. Bleed system as required. Refer to recommended piping guidelines for the respective boiler model. Check pump manufacturer's data/check temp differential across heat exchanger. Check CO2 level. Refer to manufacturer's instructions. Inspect and clean condensate drain. Appliance cycling on operating/ Check operation with safety controls. Ohmmeter/Voltmeter. System radiation undersized Temperature Incorrect anticipator setting. exceeds thermostat setting Thermostat not level. One or more zones Air trapped within zone(s) do not heat properly piping Low radiation/ excessive heat loss. Low flow rate to zone(s). Defective zone valve/ zone circulator. Check manufacturer's rating tables for capacity per foot. Check with Ammeter. Check level. Vent system/zone as required. Check actual length of pipe using radiation / heat loss calculation. Check temperature drop across zone. Check operation per manufacturer's instructions. Section: Troubleshooting 8.3.3 Miscellaneous issues Fumes and Improperly installed Refer to installation/operation instructions. High condensate trap Humidity Leak in vent piping Inspect using soap solution. Flue gas leak within Visually inspect all mechanical connections. boiler `Ghost' call Triac or `Power- Remove Therm. connections from boiler to confirm that for heat. robbing' thermostat stray voltage, or current induced in thermostat wiring, is sending current to source of nuisance signal. Replace the Power Robbing boiler. thermostat, isolate the thermostat with a relay or install a properly sized resistor (consult the thermostat manufacturer first then IBC for instructions). Error: Water Boiler is in 1-hour For instructions on clearing errors, see the V10 High Limit / safety lockout. Touchscreen Controller manual. Low Water Cutoff won't clear. DHW taking Sensor maybe under- Check sensor engagement; note well is 15 cm / almost 6 too long to reading actual water inches deep and sensor must be fully set to back. Check heat. temp. programmed settings boiler temp set too close to the required DHW temperature. Boiler output Possible flow issue: not check for 35 or 40 T modulating temperature up to difference between maximum boiler supply and despite return water target not temperatures (evokes being electronic fence). reached. Confirm that primary pump is able to overcome head loss of boiler and primary loop piping at the required flow rate. Primary Wiring not complete. Supply power to the PV/L and PV/N terminals from the Pump runs incoming power supply to the boiler. (Factory wired on but load boilers with a factory installed touchscreen controller) pumps do not. 102 8.3.4 Cycling issues 8.3.4 Cycling issues Rapid Improper values entered via Check load maximum temps are above target temps, by Cycling keypad. of the selected boiler differential. Ensure boiler differential is OK (16 - 30 T is generally adequate) 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 flow. Check venting slopes on horizontal runs. Look for sags. Inspect and clean condensate trap. Check venting. Compare vent length and diameter. Check operation. Refer to manufacturer's instructions. Check setting with ammeter. Bleed/purge system as required. Confirm adequate pump size and temp rise in the heat exchanger. Slow combustion air blower. Check that CO2 level is within specification. Dirty burner/heat exchanger. Low water flow due to improper piping. Low water flow due to undersized pump. Low water flow due to restrictions in water pipe Low radiation. Appliance over -fired Appliance Oversized Improperly set or defective controls. Check pressure drop. Refer to recommended piping for the respective boiler model. Check manufacturer's rating charts/check temperature differential across heat exchanger. Check temperature differential across zone/heat exchanger. Check actual amount of radiation per zone and refer to manufacturer's rating tables. Clock gas meter/check gas pressure with manometer/ check CO2 level. Check load calculation vs. minimum boiler output. Check operation with ohmmeter/voltmeter. Intentionally left empty Appendices Wiring diagrams V-10 Controller electrical diagram L 4 120Vac o N G IBC Control Board 1 Black ce Wh119 ! ( Rbi) gaiter Pump Fuse - SA 7B1 Fuse - 5A Fuse -5A 1 -- v PNl -L PN1 - N ° ► Load 1 Pump P•V2-L PN2 • N. Load 2 Pump PN3-L PN3 - ry '�► Load 3 Pump P.•N4 - L PN4 - N. Load 4 Pump PN•L Power PN -N Power 2 3 4 5 Fuse - 5A Fuse - 5A 5 7 B 9 10 Tg2 1 Interlock 1 2 AuxAlary Interlock R1 �L-W-G-O_ Alr Proving, etc-j • dumper if not usedInIerIDCk 2 _ a Auxillary Interlock ArtLW-C-O-, Alr Proving, elc-1 • Jumper if not used - Load 1 Thermostat Therm. 2 T Load 2 Thgrmp5}al 6 Therm. 3 Load 3 Thermostal 9 GThem1.4 w Therm, GNO a LWp 4 Thowntal Reler to manual tw possible 000neclion,s 10 It 1 P IL Outdoor Sensor a Ouldoar Sensor 13 � = I.1d0or Sen so IntlOr Sensor 5 16 2rld Loop Sense: Secondary Loop Sensor 17 1$ —DKw Sensor Domestic Not Water Sensor 19 Boiler Net • - 2g TolFrom Omer IBC Boilers (oat Aing mum be Conco AT-HOM 29 NS320 or equivalenl) 21 2P Exlemdl Canvas- ■ — Input from exlemal controls (fry others, 0.10VDC or 4.2OmA only) 1 Ta3 F„ee - ca Alarm CAnWCIe (120V2C Max.) Figure 45 Controller electrical diagram 105 Internal wiring diagram Figure 46 Internal wiring diagram ToHoWilmV P*,w5e Section: Appendices 106 Sequence of operations Standby Cycle Yes Fan off & ler countdown complete. Pump off No Heating enabled? LYes Prepurge Cycle 0- Fan starts at ignition level 5 second delay Pump starts 10 second delay Interpurge Cycle Fan and pump continue operating 15 second delay Figure 47 Sequence of Operation Ignition Cycle Open gas valve Spark for 4 seconds Flame r niti sls?\ Error time-out for one hour Sequence of operations Heating Cycle More heat No Less heat No required? required? VYesower outputNledifferentialnt? Yes Postpurge Cycle Fan output set to E purge speed 20 second delay Fan output set to minimum speed Set 150 minute time (pump off after 5 minutes) Yes No close gas valve water temp. 1/2 'I below setpoi I AND meat required? NO Yes Exploded views of boiler parts Boiler part diagrams - SL 26-260 G3 Description 100 Top access cover/lid 250-800 P-415 105 Exhaust duct 250-804 P-393 110 Intake duct 250-856 P-435 115 Safety Ignition Module 500-105 P-270B Ignition cable only 200-154 P-358 120 Flue temperature sensor 240-132 P-361 125 Transformer 240-008 P-9059 130 V-10 Touchscreen controller 500-044 P-242 135 Terminal block cover 250-488 P-418 140 Cabinet door 500-021 P-334 Section: Appendices 1 1 1 1 1 1 1 1 1 1 108 Boiler part diagrams - SL 26-260 G3 275 280 315 310 305 30fl kilo 200 Fan or 240-113 P-311 1 Section: Appendices VG145 Alternative Fan 240-172 P-311 205 Gas Valve Coupler Gasket 250-742 P-329 210 Gas Valve Coupler Nut 250-741 P-329 211 Gas Valve Coupler 250-768 P-329 215 Gas Valve 180-166 P-329 220 Gas Line Pipe 190-157 P-419 230 Sight Glass Frame 250-057 P-107A 235 Sight Glass Upper Gasket 255-025 P-107A 240 Sight Glass 250-059 P-107A 245 Sight Glass Lower Gasket 255-023 P-107A 250 Heat Exchanger Lid 170-044 P-397 255 Heat Exchanger Lid Gasket 255-026 P-426 260 Burner Gasket 255-034 P-9217 265 Burner 180-186 P-314 270 Heat Exchanger Refractory 250-761 P-386 275 Pressure Switch Bracket 250-867 P-414 280 Air pressure switch (blocked vent) 240-138 P-337B 285 Pressure sensor silicone tube 190-308 P-382 288 Water Pipe Gasket 255-024 P-389 289 Water Pressure Sensor 240-006 P-9057 290 Return Water Pipe 250-258 P-9147 300 Condensate Trap Retainer 250-664 P-345 305 Condensate Trap 180-013 P-318 310 Return water temperature sensor 240-134 P-363 315 Heat Exchanger 170-032 P-324 320 Supply Water Pipe Gasket 255-024 P-389 325 Supply Water Pipe 250-259 P-9148 330 Low Water Cutoff Probe 240-010 P-9061 345 Pressure Relief Valve 30 PSI 180-005 P-9009 350 Supply Water Temperature Sensor 240-133 P-362 355 Ignitor 240-002 P-111B 356 Ignitor Gasket 250-050 P-111 B 370 Fuel Mixer NG 180-161 P-301 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Boiler part diagrams - SL 40-399 G3 371 Fuel Mixer LP 180-162 P-300 1 375 Mixer O-Ring 150-073 P-389 1 380 Fan Gasket 250-322 P-389 1 390 Vessel High -Limit Switch 240-030 P-9070 1 Wiring Harness 200-157 P-431 1 Boiler part diagrams - SL 40-399 G3 Section: Appendices 100 Exhaust Duct 250-024 P-384 105 Top Access Cover 250-693 P-420 110 Intake Duct 250-025 P-9154 115 Safety Ignition Module 500-105 P-270B Ignition cable only 200-154 P-358 120 Air pressure switch (blocked vent) 240-138 P-337 125 Pressure switch Bracket 250-870 P-422 130 Vessel Temperature High Limit Switch 240-030 P-9070 135 Transformer 240-008 P-9059 145 Controller V-10 500-044 P-242 Controller cover only P-418 150 Front Access Cover - door assembly 500-079 P-341 1 1 1 1 1 1 1 1 1 1 1 1 112 Boiler part diagrams - SL 40-399 G3 265 P16 11 220 225 230 231 235 23fi366 ��T 000a36035 3 250 q3203400 335 330 31 325 18 180 Heat Exchanger Lid Gasket 255-009 P-365 1 200 Fan 240-113 P-311 1 VG145 Alternative Fan 240-172 P-311 1 205 Mixer O-Ring 150-073 P-38713 1 210 Fuel Mixer LP 500-114 P-302B 1 211 Fuel Mixer NG 500-113 P-303B 1 220 Gas Valve Coupler Gasket 250-035 P-330 1 225 O-Ring 150-259 P-330 1 230 Orifice NG -no longer used n/a n/a 1 231 Orifice Propane -no longer used n/a n/a 1 Section: Appendices 235 Gas Valve 180-150 P-330 236 Gas Inlet Block 250-755 P-423 250 Gas Line 190-158 P-364 260 Water Pressure Sensor 240-006 P-9057 265 Return Water Pipe 250-748 P-424 270 Water Pipe Gasket 255-027 P-387B 275 Return Water Temperature Sensor 240-134 P-363 280 Condensate Retainer 250-664 P-345 285 Condensate Trap 180-013 P-318 290 Heat Exchanger 170-029 P-325 Heat exchanger lid 170-040 P-398 295 Pressure Sensor silicone tube 190-308 P-382 300 Supply Water Pipe 250-853 P-425 305 Tridicator 180-019 P-9014 310 Water Pipe Gasket 255-027 P-387B 311 Low Water Cutoff Probe 240-010 P-9061 315 Flue Gas Temperature Sensor 240-132 P-361 320 Pressure Relief Valve 180-005 P-9009 325 Heat Exchanger Refractory 250-753 P-325 330 Burner 180-185 P-315 335 Burner Gasket 255-048 P-376 340 Fan Gasket 250-322 P-387B 345 Sight Glass Frame 255-025 P-107A 350 Sight Glass Upper Gasket 255-060 P-107A 355 Sight Glass 255-059 P-107A 360 Sight Glass Lower Gasket 255-023 P-107A 365 Ignitor 240-002 P-111B 366 Ignitor gasket 250-050 P-111 B Wiring harness P-432 Supply water temperature sensor (not 240-133 P-362 shown) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 114 Installation & Commissioning Report Installation & Commissioning Report Model Number Serial Number Date of Installation Address of installation User contact information Installer Information (Company & Address Phone/Fax/E-mail Fuel: ❑ Natural Gas ❑ Propane Gas Supply Pressure (high fire) Inches w.c. Measured Rate of Input (high fire) Btu/hr ❑ Leak testing completed ❑ Gas piping ❑ Venting system ❑ Fan ❑ 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 Relief valve "try lever" test performed ❑ Condensate trap filled Condensate drain clear and free flowing Condensate Neutralization. ❑ Ignition Safety Shutoff test completed. Flame current - High fire pA - Low fire pA ❑ Owner advised and instructed in the safe operation and maintenance of the boiler and system. ❑ Information regarding the appliance and installation received and left with owner Combustion Readings: CO2 % 02 % CO Flue temperature _ Return water temperature (measure simultaneously with flue temp.) Commissioning has been completed as listed on this report - Installer's Signature Installers: send this completed sheet - Fax to 604 877 0295 - or - scan and Email to info@ibcboiler.com. ppm The following message is relevant to users in the USA: OImportant 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 of 300,000 BTU/hr or greater. This boiler is equipped with a tankless coil (not applicable to these boilers). US installers should contact IBC for any further information required. CAN IBC Technologies Inc. A 8015 North Fraser Way Burnaby, BC Canada V5J 5M8 T 604-877-0277 F 604-877-0295 Toll Free: 1-844-HEAT-IBC/ 1-844-432-8422 www.ibcboiler.com USA IBC Technologies USA Inc A 121 Walter Gaines Way Lawnside, NJ 08045 USA T 856-877-0544 F 856-735-5584 Information in this document is subject to change without notice. IBC assumes no responsibility for changes made to the manual due to clerical errors, to regulation changes, or to product development. September 23, 2022 1 120-270E10 ©IBC Technologies Inc. 2022 IBC