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Home My WebLink AboutSL_115_160_199_85G3_InstManual_English_R5_email.pdfINSTALLATION AND OPERATING INSTRUCTIONSwww.ibcboiler.com SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS (Natural Gas or Propane) :$51,1*,IWKHLQIRUPDWLRQLQWKLVPDQXDOLVQRWIROORZHGH[DFWO\D¿UHRU explosion may result causing property damage, personal injury, or loss of life. 'RQRWVWRUHRUXVHJDVROLQHRURWKHUÀDPPDEOHYDSRXUVDQGOLTXLGVRURWKHU FRPEXVWLEOHPDWHULDOVLQWKHYLFLQLW\RIWKLVRUDQ\RWKHUDSSOLDQFH WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a nearby phone. Follow the gas supplier’s instructions. • ,I\RXFDQQRWUHDFK\RXUJDVVXSSOLHUFDOOWKH¿UHGHSDUWPHQW • ,QVWDOODWLRQDQGVHUYLFHPXVWEHSHUIRUPHGE\DTXDOL¿HGLQVWDOOHUVHUYLFH agency or the gas supplier. This Manual is also available in French - contact IBC or visit our web site www.ibcboiler.com INSTALLATION AND OPERATION INSTRUCTIONS2 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS SAFETY CONSIDERATIONS WARNING If the information in this manual LVQRWIROORZHGH[DFWO\D¿UHRU explosion may result causing property damage, personal injury, or loss of life. ,QVWDOODWLRQVWDUWXSDQGVHUYLFLQJRI,%&ERLOHUVPXVWEHGRQHZLWKGXHFDUHDQG DWWHQWLRQDQGVKRXOGRQO\EHSHUIRUPHGE\FRPSHWHQWTXDOL¿HGOLFHQVHGDQG trained heating technicians. Failure to read and comply with all instructions and applicable National and local codes may result in hazardous conditions that could result in property damage and injury to occupants which in extreme cases might result in death. HAZARDS & PRECAUTIONS WARNING Points out a potentially hazardous situation which must EHDYRLGHGWRSUHYHQWVHULRXV injury or death. CAUTION Points out a potentially hazardous situation which must EHDYRLGHGWRSUHYHQWSRVVLEOH moderate injury and/or property damage NOTE Points out installation, maintenance and operation details that will result in HQKDQFHGHI¿FLHQF\ORQJHYLW\ and proper operation of your boiler. DANGER Points out an immediately hazardous situation which must EHDYRLGHGLQRUGHUWRSUHYHQW serious injury or death. Supplied with the boiler - The IBC boiler is shipped with an accessory parts kit consisting of the following items: • 1 x Wall mounting bracket • 1 x Condensate trap assembly • 1 x 30 psig pressure relief valve • 1 x Outdoor temperature sensor • [´[´/DJVFUHZVZÀDWZDVKHUV 3INSTALLATION AND OPERATING INSTRUCTIONS SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS SPECIFICATIONS SPECIFICATION SL 10-85 G3 SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 &6$,QSXW1DWXUDO*DVRU3URSDQH 0%+ &6$,QSXW1DWXUDO*DVRU3URSDQH N: &6$2XWSXW0%+ &6$2XWSXWN: 10.6 - 85 3.10 - 24.9 10.1 - 79 2.96 - 23.1 14 - 115 4.10 - 33.7 13.3 - 109 3.90 - 32.0 20 - 160 5.86 - 46.9 19.0 - 147 5.57 - 43.1 32 - 199 9.37 - 58.3 30 - 181.3 8.8 - 53.1 A.F.U.E. 96% 95% 95%95% 0LQLPXPJDVVXSSO\SUHVVXUH1DWXUDO*DVRU3UR- SDQHLQFKZF 4444 0D[LPXPJDVVXSSO\SUHVVXUH1DWXUDO*DVRU 3URSDQHLQFKZF 14 14 14 14 3RZHUXVH9DF+]#IXOO¿UH:DWWVZLWKRXW SXPSV 54 72 82 100 :HLJKWHPSW\OEV.J 85 / 39 85 / 39 102 / 46.3 152 / 69 3UHVVXUHYHVVHOZDWHUFRQWHQW86*/LWUHV 2.47 / 9.35 2.47 / 9.35 1.72 / 6.51 5.09 / 19.3 0D[LPXPERLOHUÀRZUDWH86JSP 14 14 19 22 0LQLPXPERLOHUÀRZUDWH86JSP 2246 0D[LPXPRSHUDWLQJZDWHUSUHVVXUHSVLJ 30 30 30 30 0LQLPXPZDWHUSUHVVXUHSVLJ 8888 $SSURYHGLQVWDOODWLRQDOWLWXGH$6/0 - 12,000’ 0 - 12,000’0 - 12000’ 0 - 12,000’ $PELHQWWHPSHUDWXUH/RZ)& $PELHQWWHPSHUDWXUH+LJK)& 32°F / 0°C 122°F / 50°C 32°F / 0°C 122°F / 50°C 32°F / 0°C 122°F / 50°C 32°F / 0°C 122°F / 50°C 0D[UHODWLYHKXPLGLW\QRQFRQGHQVLQJ90% 90%90% 90% 0LQLPXPZDWHUWHPS34°F / 1°C 34°F / 1°C 34°F / 1°C 34°F / 1°C 0D[LPXPZDWHUWHPSHOHFWURQLFKLOLPLW190°F / 88°C 190°F / 88°C 190°F / 88°C 190°F / 88°C 0D[LPXPZDWHUWHPSORFNRXWOLPLW 201°F / 94°C 201°F / 94°C 201°F / 94°C 201°F / 94°C 0D[ǻ7VXSSO\UHWXUQHOHFWURQLFIHQFH40°F 40°F 40°F 40°F 0D[LPXPHTXLYDOHQWYHQWOHQJWKHDFKVLGHYHQW DQGDLULQWDNH´ 1DWXUDO*DVRU3URSDQH´ $LULQWDNHRSWLRQVHLWKHUGLUHFWYHQWRULQGRRUVXS- ply 100’ 240’ 100’ 240’ 35’ 170’ N/A 150’ INSTALLATION AND OPERATION INSTRUCTIONS4 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK 5INSTALLATION AND OPERATING INSTRUCTIONS SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS Contents 1.0 INSTALLATION .....................................................1-1 1.1 GENERAL........................................................1-1 1.2 CODE REQUIREMENTS ............................................1-3 1.3 LOCATION of a boiler...............................................1-3 1.4 EXHAUST VENTING & AIR INTAKE ...................................1-4 1.4.1 Applications ...................................................1-6 1.4.2 Exhaust Vent Material ...........................................1-6 1.4.3 Vent Travel....................................................1-7 1.4.4 Venting Passage Through Ceiling and Floor ..........................1-8 1.4.5 Rooftop Vent Termination.........................................1-8 1.4.6 Sidewall Vent Termination ........................................1-9 1.4.7 “Direct Vent” Combustion Air Intake Piping ..........................1-14 1.4.8 “Indoor Air” Combustion Air Intake .................................1-15 1.4.9 Combustion Air Filtration ........................................1-16 1.4.10 Closet Installations ............................................1-16 1.5 CONDENSATE REMOVAL..........................................1-17 1.5.1 Condensate Trap ..............................................1-17 1.5.2 Condensate Trap Assembly - Installation............................1-17 1.5.3 Condensate Trap Assembly - cleaning procedure . . . . . . . . . . . . . . . . . . . . . 1-18 1.5.4 Further installation details .......................................1-18 1.6 WATER PIPING ..................................................1-20 1.6.1 General Piping Issues ..........................................1-20 1.6.2 Basic System Piping Arrangements ................................1-25 1.7 GAS PIPING.....................................................1-31 1.8 ELECTRICAL CONNECTIONS ......................................1-32 1.8.1 120 VAC Line Voltage Hook-up ...................................1-32 1.8.2 Power Quality and Electrical Protection .............................1-33 1.8.3 Zone Valve Hook-up............................................1-33 1.8.4 Thermostat / Sensor Wiring ......................................1-33 1.8.5 Other Wiring..................................................1-34 1.8.6 Thermostat Heat Anticipator......................................1-34 2.0 IBC BOILER CONTROLLER.................................................2-1 2.1 GENERAL........................................................2-1 2.2 CONTROL .......................................................2-1 2.3 CONTROL INTERFACE.............................................2-2 3.0 STARTUP & COMMISSIONING.........................................3-1 3.1 LIGHTING & BOILER SHUTDOWN ...................................3-1 3.2 PRIOR TO START-UP ..............................................3-2 3.2.1 Pre-Ignition Checks .............................................3-2 3.2.2 Test Ignition Safety Shutoff .......................................3-2 3.3 COMMISSIONING .................................................3-2 3.4 FUEL CONVERSION ...............................................3-4 3.4.1 Gaining access to the combustion chamber ..........................3-5 3.4.2 Removing the burner ............................................3-6 3.4.2.1 Removing the burner - SL 10-85 G3, SL 14-115 G3, SL 20-160 G3.....3-6 INSTALLATION AND OPERATION INSTRUCTIONS6 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 3.4.2.2 Removing the burner - SL 30-199 G3 ............................3-6 3.4.3 Installing the burner .............................................3-7 3.4.3.1 Installing the burner - SL 10-85 G3, SL 14-115 G3, SL 20-160 G3 ......3-7 3.4.3.2 Installing the burner - SL 30-199 G3 .............................3-7 4.0 MAINTENANCE.....................................................4-1 4.1 BOILER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4.1.1 General Care ..................................................4-1 4.1.2 Inspection.....................................................4-1 4.1.3 Venting.......................................................4-1 4.1.4 Condensate Traps ..............................................4-1 4.1.5 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4.1.6 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4.1.7 Pump ........................................................4-2 4.1.8 Gas Piping ....................................................4-2 4.1.9 Touchscreen Controller ..........................................4-2 4.1.10 Water .......................................................4-2 4.1.11 Freeze Protection..............................................4-2 4.1.12 Boiler Treatment...............................................4-2 4.1.13 Relief Valve - Maintenance and Testing .............................4-3 4.2 GEOGRAPHY & COMPONENTS......................................4-4 4.2.1 Fan and gas valve removal instructions..............................4-5 4.2.2 Fan and gas valve re-assembly instructions ..........................4-5 5.0 TROUBLESHOOTING ................................................5-1 5.1 PRELIMINARY CHECKS ............................................5-1 5.2 ELECTRONIC COMPONENTS .......................................5-2 5.2.1 Temperature Sensors............................................5-2 5.2.2 Fan..........................................................5-3 5.2.3 Water Pressure Sensor ..........................................5-3 5.2.4 Safety and Ignition Module (SIM+) ..................................5-3 5.2.4.1 Low water cutoff function: reset and test ..........................5-4 5.2.4.2 Hi-limit temperature manual reset function: reset and test ............5-5 5.3 TROUBLESHOOTING ................................................5-6 5.3.1 Using Control Module Errors Displayed ..............................5-6 5.3.2 Ignition Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 5.3.3 Cycling Problems ...............................................5-9 5.3.4 Temperature Problems..........................................5-10 5.3.5 Miscellaneous.................................................5-11 6.0 DIAGRAMS ........................................................6-1 6.1 PARTS DIAGRAMS ................................................6-2 6.2 WIRING DIAGRAMS ...............................................6-8 6.3 SEQUENCE OF OPERATION .......................................6-10 INSTALLATION & COMMISSIONING REPORT ..............................6-11 INSTALLER SETUP....................................................6-12 SERVICE RECORD....................................................6-13 NOTES .........................................................6-14 REVISION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 7INSTALLATION AND OPERATING INSTRUCTIONS SL 20-115 G2 MODULATING GAS BOILERSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS The Installer must carefully read this manual to ensure that all installation details can be adhered to. Special attention is to be paid to clearances and access, vent travel and termination, gas supply, condensate removal and combustion air supply. The Installer should do a pre-installation check the to ensure that the following precautions can be observed: • The boiler should be installed in areas where the combustion air source is not subject to chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes VXFKDVFKORULQDWHGDQGRUÀXRULQDWHGK\GURFDUERQVFDQUHGXFHWKHOLIHRIDERLOHU Cleaners, bleaches, air fresheners, refrigerants, aerosol propellants, dry-cleaning ÀXLGVGHJUHDVHUVDQGSDLQWUHPRYHUVDOOFRQWDLQYDSRUVZKLFKFDQIRUPFRUURVLYH DFLGFRPSRXQGVZKHQEXUQHGLQDJDVÀDPH$LUERUQHFKORULGHVVXFKDVWKRVH released with the use of laundry detergents are also to be avoided. • The boiler should be located where water leakage will not result in damage to the area. If a location such as this cannot be found, a suitable drain pan should be installed under the appliance. The boiler is not to be installed above carpeting. • At a new construction site, or during renovations, action must be taken to protect the boiler from drywall dust or other construction related contaminants; combustion air should be drawn from a CLEAN source (e.g. outdoors) and the boiler should be isolated from interior dust sources. • When the boiler is in operation, the impact of the steam plume normally experienced at the exhaust terminal of a condensing boiler should be assessed. Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location. Boiler condensate is corrosive. Protective measures must be taken to prevent corrosion damage to metal roofs or other metal building components in contact with the condensate. Keep exhaust plumes well away from all building air intakes including those of neighboring properties. • In sealed combustion applications, the exhaust outlet should be placed so as to reach 12” minimum above the down-turned intake - to avoid exhaust re-ingestion. • For sidewall venting options: Both the inlet and exhaust terminations should normally be located on the same plane (side) of the building. The elevation of both pipes can be raised in “periscope style” after passing through the wall to gain required clearance above grade and snow level. • If the indoor combustion air option is used, ensure combustion air openings to the boiler room remain unblocked and free of obstructions. • Examine the condensate outlet to ensure proper disposal of condensate will occur during operation. If condensates are to be discharged into building drain piping materials that are subject to corrosion, a neutralization package must be used. • Ensure that the pressure relief valve will be installed with no valves or other means of isolation between its inlet and the boiler. Make sure the relief valve outlet will be piped with unobstructed piping (minimum 3/4” diameter) to a safe discharge location. • In locations where power supply quality varies or is unstable, installation of surge protection and power conditioners up to and including battery back-up uninterrupted power supply devices should be considered. WARNING Do not use this boiler if any part has been under water. ,PPHGLDWHO\FDOODTXDOL¿HG VHUYLFHWHFKQLFLDQWRLQVSHFWWKH boiler and to replace any part of the control system and any gas control that has been under water. DANGER 6KRXOGRYHUKHDWLQJRFFXURUWKH 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 CAUTION &DUHPXVWEHWDNHQWRSURSHUO\ size the boiler for its intended XVH3URORQJHGIXOO¿UHUXQWLPH RYHUVL]LQJRUXQGHUVL]LQJDQG LQFRUUHFWÀRZUDWHVWKURXJK the boiler can lead to increased PDLQWHQDQFHFRVWVHTXLSPHQW stress and premature failure. WARNING If the boiler can become exposed WRÀXLGWHPSHUDWXUHVEHORZ) &DPHWKRGRISURWHFWLRQWR SUHYHQWIUHH]LQJRIFRQGHQVDWH VKRXOGEHHPSOR\HG&RQWDFWWKH factory for further information. INSTALLATION AND OPERATION INSTRUCTIONS8 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK 1-1INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.0 INSTALLATION 1.1 GENERAL 6/6HULHVJDV¿UHGPRGXODWLQJERLOHUVDUHORZSUHVVXUHIXOO\FRQGHQVLQJXQLWVKDYLQJ variable input ranges VHHVSHFL¿FDWLRQFKDUWLQVLGHIURQWFRYHU Approved as “Category IV” vented appliances, the boilers use either Direct Vent (sealed combustion) or indoor FRPEXVWLRQDLUSURYLGLQJDJUHDWGHJUHHRILQVWDOODWLRQÀH[LELOLW\ Figures 1a,and 1b show outer case dimensions and piping and electrical holes. Refer to WKHDSSOLFDEOHGLDJUDPVWRKHOS¿QGDVXLWDEOHORFDWLRQIRUWKHERLOHU6HHDOVR6HFWLRQ /RFDWLRQ )LJXUH'LPHQVLRQV&RQQHFWLRQVIRU6/6/*6/*)URQWYLHZVLGHYLHZWRSYLHZDQGERWWRPYLHZ DESCRIPTION SL 10-85 G3/ SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 A Exhaust Outlet 3” Schedule 40 3” Schedule 40 3” Schedule 40 %Combustion Air 3” Schedule 40 3” Schedule 40 3” Schedule 40 &LCD Display 2-1/4” x 4” 2-1/4” x 4” 2-1/4” x 4” D Water Outlet 1” NPT-M 1” NPT-M 1-1/4” NPT-M E Water Inlet 1” NPT-M 1” NPT-M 1-1/4” NPT-M F Knock-outs (8) 1/2” 1/2” 1/2” G Gas Inlet 1/2” NPT-F 1/2” NPT-F 1/2” NPT-F +Condensate Outlet 3/4” Hose 3/4” Hose 3/4” Hose 7DEOH&RQQHFWLRQV INSTALLATION AND OPERATION INSTRUCTIONS1-2 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )LJXUH'LPHQVLRQV&RQQHFWLRQVIRU6/*)URQWYLHZVLGHYLHZWRSYLHZDQGERWWRPYLHZ )LJXUH'LPHQVLRQV&RQQHFWLRQVIRU6/*)URQWYLHZVLGHYLHZWRSYLHZDQGERWWRPYLHZ 1-3INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.2 CODE REQUIREMENTS 7KH6/PRGHOVZHUHWHVWHGWRDQGFHUWL¿HGXQGHU&6$$16,= Installation must conform to local codes, or in the absence of these, with the latest editions of CAN/CGA B149.1 and the Canadian Electrical Code Part 1 CSA C22.2 No. 1. In the US, installations must conform to the current National Fuel Gas Code ANSI Z223.1 and the National Electrical Code ANSI/NFPA 70. Where required by jurisdiction, installation must conform to the Standard for Controls and Safety Devices for $XWRPDWLFDOO\)LUHG%RLOHUV$16,$60(&6',IWKHUHLVDQ\FRQÀLFWWKHQWKHPRUH stringent requirement will apply. 1.3 LOCATION OF A BOILER The boilers are designed and approved for indoor installation (wall or rack mounting), with ÀH[LELOLW\RIORFDWLRQSURYLGHGZLWKWKHDYDLODEOHYHQWLQJRSWLRQV7KHERLOHUFDQEHSODFHG in an alcove, basement, closet or utility room. Surrounding conditions need to be 0°C to 50°C DQGOHVVWKDQUHODWLYHKXPLGLW\ Install the boiler in areas where the combustion air source is not subject to chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes such as chlorinated DQGRUÀXRULQDWHGK\GURFDUERQVFDQUHGXFHWKHOLIHRIDERLOHU&OHDQHUVEOHDFKHVDLU IUHVKHQHUVUHIULJHUDQWVDHURVROSURSHOODQWVGU\FOHDQLQJÀXLGVGHJUHDVHUVDQGSDLQW removers all contain vapors which can form corrosive acid compounds when burned in a JDVÀDPH$LUERUQHFKORULGHVVXFKDVWKRVHUHOHDVHGZLWKWKHXVHRIODXQGU\GHWHUJHQWV are also to be avoided. 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 adjacent to a clothes dryer exhaust terminal. Avoid agricultural applications where the boiler and/or the intake air source are affected by ammonia and/or dust. Avoid installing a boiler where water leakage will cause damage; for example, above carpeting. If unavoidable, install a suitable drain pan under the appliance. Boiler Weight – up to 150 lbs / 68 kg. For support fasteners, use the supplied 6 x 1/4” x 2 1/2” long lag screws. Installer to supply 1/4” bolts if metal mounting systems are used. Fasteners are to be attached to solid material capable of supporting the combined weight of the boiler and piping assembly components. Other factors to consider for potential mounting sites: • The minimum clearance requirements for combustible materials (see 7DEOH. • A minimum 24" clearance at the front and 10” above the boiler is recommended for adequate servicing. Check local codes for additional access and service clearance requirements. • 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. WARNING .HHSDERLOHUDUHDIUHHDQG clear of combustible materials, JDVROLQHDQGRWKHUÀDPPDEOH YDSRUVDQGOLTXLGV WARNING Ensure combustion air is not drawn from areas containing FRUURVLYHDLUIURPVZLPPLQJ pools or spas, including air directly next to outdoor pools and spas. WARNING Ensure a boiler is not exposed WRZDWHUOHDNVIURPSLSLQJRU FRPSRQHQWVORFDWHGRYHUKHDG including condensation from un-insulated cold water lines RYHUKHDG WARNING Protect the gas ignition system FRPSRQHQWVIURPZDWHUGULSSLQJ VSUD\LQJUDLQHWFGXULQJ appliance operation and when VHUYLFLQJSXPSUHSODFHPHQW FRQGHQVDWHWUDSVHUYLFLQJFRQWURO UHSODFHPHQWHWF INSTALLATION AND OPERATION INSTRUCTIONS1-4 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS SURFACE DISTANCE FROM COMBUSTIBLE SURFACES RECOMMENDED DISTANCE FOR INSTALLATION AND SERVICE Front 2” 24” Rear 0” 0” Left Side 1” 4” (allow access to water connections) Right Side 1” 4” (water, electric and gas connections) Top 2” 6” (for vent connection) Bottom 0” 12” (for condensate trap) 7DEOH&OHDUDQFHIURPERLOHUFDELQHW 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. 1.4 EXHAUST VENTING & AIR INTAKE It is important to carefully plan the installation to ensure the appropriate vent materials, WUDYHODQGWHUPLQDWLRQGHFLVLRQVDUHLQFOXGHG6SHFL¿FDWWHQWLRQLVZDUUDQWHGWRPDQDJH the impact of the steam plume normally experienced at the exhaust terminal of a condensing boiler. Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location, to maximize customer satisfaction. Keep exhaust plumes well away from all building air intakes including those of neighboring properties. All venting must be installed in accordance with the requirements of the jurisdiction having authority: in Canada, Part 8, Venting Systems of the B149.1-10 Code and any other local building codes are to be followed. In the USA the National Fuel Gas Code, ANSI 223.1, latest edition, prevails. Where there is a discrepancy between the installation instructions below, and the code requirements, the more stringent shall apply. IMPORTANT When an existing boiler is removed from a common venting system, the common venting WARNING Ensure that combustible PDWHULDOVGRQRWPDNHFRQWDFW with exposed water piping and associated components UHOLHIYDOYHVFLUFXODWRUVHWF &KHFNORFDOFRGHVIRUUHTXLUHG FOHDUDQFHVDQGRUSURYLGH DGHTXDWHLQVXODWLRQ DANGER 'RQRWFRPPRQYHQWWKH6/ modulating series boilers with any other existing or new appliance. WARNING '2127028177+,6 %2,/(572+2//2::$// 6758&785(67KHFRPELQHG weight of the boiler, its water contents and associated piping FRPSRQHQWVFDQH[FHHG pounds. Fasteners must be rated IRUWKLVVWUDLQDQGPXVWEH¿UPO\ anchored into solid material that will support this weight. ,QVWDOOHUVDUHWRWDNHDOO QHFHVVDU\SUHFDXWLRQVWRDYRLG injury during the installation of this boiler. Figure 3: Wall mounting of boiler 1-5INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS system is likely to be too large for the proper venting of the appliances that remain connected to it. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size using the appropriate tables in the National Fuel Gas Code, ANSI Z223.1 - latest edition. In Canada, use the B149.1-10 Installation Code. At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. • Seal any unused opening in the common venting system. • Visually inspect the venting system for proper size and horizontal pitch and determine WKHUHLVQREORFNDJHRUUHVWULFWLRQOHDNDJHFRUURVLRQDQGRWKHUGH¿FLHQFLHVWKDWFRXOG cause an unsafe condition. • Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not RSHUDWHDVXPPHUH[KDXVWIDQ&ORVH¿UHSODFHGDPSHUV • Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so that appliance will operate continuously. • After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, H[KDXVWIDQV¿UHSODFHGDPSHUVDQGDQ\RWKHUJDVEXUQLQJDSSOLDQFHWRWKHLUSUHYLRXV condition. • Any improper operation of the common venting system should be corrected, so that the installation conforms to 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. WARNING 9HQWLQJFRQGHQVDWHGUDLQDJH and combustion air systems for DOO,%&ERLOHUVPXVWEHLQVWDOOHG in compliance with all applicable codes and the instructions of WKHLUUHVSHFWLYH,QVWDOODWLRQ 0DQXDOV ,QVSHFW¿QLVKHGYHQWDQGDLU piping thoroughly to ensure all are airtight and comply with the LQVWUXFWLRQVSURYLGHGDQGZLWK DOOUHTXLUHPHQWVRIDSSOLFDEOH codes. Failure to comply will result in VHYHUHSHUVRQDOLQMXU\RUGHDWK )LJXUH%DVLFH[KDXVWYHQWDVVHPEO\ INSTALLATION AND OPERATION INSTRUCTIONS1-6 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.4.1 Applications All SL series boilers are approved with alternative venting options: either 2-pipe Direct 9HQWRU9HQWSLSHZLWK,QGRRU$LURIIHULQJÀH[LELOLW\WRPHHWWKHVSHFL¿FUHTXLUHPHQWVRI the installation. With the Direct Vent case, combustion air is piped directly to the boiler’s air intake from outdoors VHH6HFWLRQIRUDLULQWDNHSLSLQJUHTXLUHPHQWV Using the indoor air alternative, air for combustion is drawn from the indoor air surrounding the boiler. Provided the maximum overall vent length limit is not exceeded, the installer may choose to vent the boiler through the wall, directly through the roof or upward using an existing, but otherwise unused, chimney DVDYHQWUDFHZD\ 1.4.2 Exhaust Vent Material Exhaust Vent Material – CANADA Use PVC, CPVC or Polypropylene (PPs) vent component systems approved under ULC-S636 Standard for Type BH Gas Venting Systems, or stainless steel Type BH venting V\VWHPV 7KHYHQWWHPSHUDWXUHLVOLPLWHGZLWKWKHXVHRIDÀXHWHPSHUDWXUHVHQVRU and software to ensure the maximum temperature of the PVC venting material is not exceeded. Exhaust Vent Material – USA PVC, CPVC or PPs venting materials are approved for use with these boilers in the USA. 7KHYHQWWHPSHUDWXUHLVOLPLWHGZLWKWKHXVHRIÀXHWHPSHUDWXUHVHQVRUDQGVRIWZDUHWR ensure that the maximum temperature of the PVC venting material is not exceeded. PVC YHQWLQJPDWHULDOVKDOOEHFHUWL¿HGWR6FK$670'RU'&39&PDWHULDOVKDOO EHFHUWL¿HGWR6FK$670) Exhaust Vent Material - OTHER COUNTRIES Do not use ABS or any cellular core pipe for exhaust venting. Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in venting systems shall be prohibited. The boiler offers 3” venting connections. Fittings are to be used to adapt to the appropriate diameter VHH9HQW7UDYHOEHORZ7KHUHDUHWZRVWDLQOHVVVWHHOJDVNHWHG¿WWLQJVRQWKH top of the boiler. Exhaust venting is to be inserted directly into the 3” female stainless steel ¿WWLQJRQWKHOHIWVHH)LJXUH )RU33VPDWHULDOXVHWKH´WUDQVLWLRQDGDSWRU¿WWLQJ6FKWR33VRIIHUHGE\WKH respective PPs manufacturers Centrotherm / ,QQRÀXHTM (their part # ISAA0303) or M&G Dura Vent /PolyPro (#3PPS-AD) or Z-Flex/Z_DENS (#2ZDCPVCG3). For 2” venting, use ,QQRÀXHSDUW,65'RU3RO\3UR # 3PPS-R2 (within the PPs piping, after adapting with #3PPS-AD) or Z-DENS #2ZDR32 (within the PPs piping, after adapting with #2ZDCPVCG3). For PPs material exposed to outdoor weather, follow the venting suppliers’ recommendations on UV protection. &RPEXVWLRQDLUSLSLQJLIXVHGLVLQVHUWHGGLUHFWO\LQWRWKH´IHPDOHVWDLQOHVVVWHHO¿WWLQJ on the right VHH6HFWLRQ Venting shall be supported in accordance with the applicable code. Manufacturers of stainless steel Type BH venting systems must submit their approved WUDQVLWLRQ¿WWLQJWR,%&IRUHYDOXDWLRQDQGZULWWHQDSSURYDO WARNING &RYHULQJQRQPHWDOOLFYHQW SLSHDQG¿WWLQJVZLWKWKHUPDO insulation shall be prohibited. 1-7INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.4.3 Vent Travel PVC, CPVC or PPs (Rigid Single Wall) piping is the standard venting option; the SL 14-115 G3 boiler, for example, can be sited up to 100 equivalent feet from the vent termination using 2” or up to 240’ using 3”. The actual vent travel allowance is reduced for ¿WWLQJVLQDFFRUGDQFHZLWK7DEOH. – e.g. for an SL 14-115 G3 using 6 x 90º CPVC elbows, the maximum lineal measure of pipe allowed using 2” pipe is 52 feet (100’ – (6 x 8' = 48) = 52’). The same boiler using 3” pipe can have up to 192 feet (240’ – (6 x 8’ = 48) = 192’). For 3” Flexible PPs, up to 45 actual lineal feet are allowed in a nominally vertical orientation (>45°). The equivalent length of 3” Flex PPs shall be computed using a multiple of 1.2:1, e.g. 45’ x 1.2 = 54’ equiv. PPs 87-90° elbows are considered to be equivalent to 8’. 7DEOH0D[LPXPH[KDXVWYHQWLQJOHQJWK Note: Unused intake travel cannot be added to the exhaust. Unequal intake and exhaust piping is allowed (see Section 1.4.8). Exhaust venting must slope down towards the boiler with a pitch of at least 1/4” per foot (PPs vent: follow PPs manufacturer requirements) so condensate runs back towards the trap. Support should be provided for intake and vent piping, particularly so for horizontal runs (follow local code). Insulate exhaust piping where it passes through unheated spaces or underground, with appropriate pipe insulation to prevent freezing of condensates. &HUWDLQLQVWDOODWLRQVRIWKH6/PRGHOVFDQHPSOR\WKH´YHQWRSWLRQV We caution LQVWDOOHUVZKHQXVLQJKRUL]RQWDOUXQVRI´SLSH. Reason: air friction from the fast moving H[KDXVWGXULQJORQJEXUQHUUXQVDWKLJK¿UHLQD´SLSHFDQRYHUFRPHJUDYLW\RQ´IRRW vent slope – leaving a pool of condensate at the next upturned elbow. Pooling can impair WKHDFKLHYHPHQWRIIXOOKLJK¿UHUDWLQJSODWHSHUIRUPDQFH ([KDXVWSLSLQJLVLQVHUWHGGLUHFWO\LQWRWKH´IHPDOHVWDLQOHVVVWHHO¿WWLQJRQWKHWRSOHIW side of the boiler and run horizontally or vertically to the outdoors. Screen material can be placed at the outlet as appropriate for the environment (e.g. insects, dust). WARNING 'RQRWPL[YHQWLQJPDWHULDOV IURPGLIIHUHQW0DQXIDFWXUHUV 7KHVHYHQWLQJPDWHULDOVDUH designed to be installed as part of a complete system. Failure to comply may result in VHYHUHSHUVRQDOLQMXU\RUGHDWK WARNING )XOO\LQVHUWWKHDSSURYHGYHQWLQJ material into the boilers exhaust outlet and tighten clamp to ensure WKHYHQWLQJFRQQHFWLRQLVORFNHG in place. EXHAUST PIPE SIZE MAXIMUM EQUIVALENT LENGTH Sched.40; Rigid PPs SL 10-85 G3 SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 2"100' 100' 35’ Not applicable 3" 240' 240' 170’ 150' 90° vent elbow allow 8' equivalent allow 8' equivalent allow 8’ equivalent allow 8’ equivalent 90° long sweep elbow allow 5' equivalent allow 5' equivalent allow 5’ equivalent allow 5’ equivalent 45° elbow allow 3' equivalent allow 3' equivalent allow 3’ equivalent allow 3’ equivalent PPs 87-90° elbows use 8’ equivalent use 8’ equivalent use 8’ equivalent use 8’ equivalent 2" Stainless Sidewall Terminal IBC P/N 180-148 (P-256) allow 20' equivalent of 2" Sched. 40 allow 20' equivalent of 2" Sched. 40 Not allowed Not allowed 3" Stainless Sidewall Terminal IBC P/N 180-149 (P-257) allow 20' equivalent of 3" Sched. 40 allow 20' equivalent of 3" Sched. 40 allow 20’ equivalent of 3” Sched. 40 allow 20’ equivalent of 3” Sched. 40 Flexible PPs 3" Flexible 45’ (max.) actual lineal x 1.2 = equivalent 45' (max.) actual lineal x 1.2 = equivalent 45’ (max.) actual lineal x 2 = equivalent 30’ (max.) actual lineal x 3.3 = equivalent INSTALLATION AND OPERATION INSTRUCTIONS1-8 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )ROORZDOOLQVWDOODWLRQLQVWUXFWLRQVVXSSOLHGE\WKHSLSHDQG¿WWLQJPDQXIDFWXUHU Ensure all venting components are clear of burrs/debris prior to assembly. Care is to be taken to avoid ingestion into the fan of PVC/ABS debris left in the combustion air piping. All joints must be secured using appropriate solvent cement to bond the respective pipe material (Canada: CPVC cement approved under 8/&6LQDFFRUGDQFH ZLWKLWVPDQXIDFWXUHULQVWUXFWLRQV USA: PVC (ASTM D2564), or PVC/ABS (D2235) - Use transition glue anywhere that PVC and CPVC are joined. Follow the cement manufacturer’s instructions closely when joining various components. For PPs, connections shall be secured using approved retainer clips supplied by the respective PPs manufacturer. $OOYHQWFRQQHFWLRQVPXVWEHOLTXLGDQGSUHVVXUHWLJKW3ULRUWR¿ULQJWKHERLOHUDQGEHIRUH any of the venting run is concealed by the building construction, the installer must test the exhaust joints under fan pressure with the vent blocked, using a soap and water solution. ,QVWDOOHUPXVW¿OOFRQGHQVDWHWUDSSULRUWRWHVW Paint all joints with an approved leak test solution just as you would joints in a gas line, and make sure there are no leaks. Good practice would suggest that the installer attach a tag on the vent line near the boiler vent connection indicating the type of test, the date and the installer’s name. 1.4.4 Venting Passage Through Ceiling and Floor • &RQ¿UPPDWHULDOPHHWVORFDOFRGHVLQFOXGLQJ¿UHVWRSSLQJUHTXLUHPHQWV • Some local jurisdictions require a minimum initial length of pipe be exposed or accessible for inspection. • Pipe clearances - no IBC requirements, but best practice allows a minimum 1/4” open annulus around the pipe to prevent binding and expansion noise; follow local codes. • All piping must be liquid and pressure tight. 1.4.5 Rooftop Vent Termination D5RRIWRSYHQWVPXVWWHUPLQDWHDVIROORZV • The exhaust pipe can terminate in an open vertical orientation without concern about UDLQLQ¿OWUDWLRQUDLQZLOOGUDLQDZD\WKURXJKWKHFRQGHQVDWHWUDS • 2SWLRQDOELUGVFUHHQPD\EHSODFHGLQDWHUPLQDWLRQ¿WWLQJ/HDYHXQJOXHGDQGKROGLQ place with a short nipple. This permits easy access for cleaning. • DO NOT exhaust vent into a common venting system. BEST PRACTICES 7RUHGXFHWKHSRVVLELOLW\RI H[SDQVLRQQRLVHDOORZD´JDS DURXQGWKHH[KDXVWDQGDLULQWDNH piping. )LJXUH3LSHDQG¿WWLQJEHYHOLQJ 1-9INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS E)RU5RRIWRS'LUHFW9HQWV\VWHPV • 5RRIWRSWZRSLSHGLUHFWYHQWFRQ¿JXUDWLRQVLQFOXGLQJW\SLFDOFOHDUDQFHUHTXLUHPHQWV areVKRZQLQ)LJXUH • The intake air pipe is not typically drained, so it must be terminated with a down-turned elbowVHH)LJXUH • The intake pipe does not need to penetrate the roof at the same elevation as the exhaust (as shown); lower down on the roof is acceptable. • For roof top venting of multiple boiler sets, group all intake terminals together for a common penetration through a custom cap. Alternatively, place in the closest proximity DFKLHYDEOHXVLQJFRPPRQO\DYDLODEOHSLSHÀDVKLQJ6LPLODUO\JURXSWKHH[KDXVWSLSHV and place the two separate groups of pipes at least 3’ apart (the closest intake and exhaust pipes shall be 36”, or more, apart). Use the same 12” (minimum) vertical separation for 2 pipe option. For alternate group terminations, contact the IBC Factory for written guidance. • Roof Top Concentric Termination kits are approved for use with the boiler model. The installation of the vertical roof top concentric termination must follow the installation instructions supplied with the venting material manufacturer. Care must be taken to install the termination kit a minimum horizontal distance of 10’ (305cm) away from any portion of the building and a minimum of 2’ (61cm) above the roof line plus the anticipated snow line. 1.4.6 Sidewall Vent Termination D9HQWWHUPLQDOFOHDUDQFHPLQLPXPVDUHDVIROORZV • The exhaust vent terminal is to be placed 18” minimum (12” in USA) above the grade or anticipated snow level. • Clearance above grade, veranda, porch, deck or balcony – 12” (0.3m), but check local code also (anticipated snow levels may supersede). • Clearance to openable window or door – 36” (0.91m) (USA – 12”). • 9HUWLFDOFOHDUDQFHWRYHQWLODWHGVRI¿WORFDWHGDERYHWKHWHUPLQDO´P6HHWKH &DXWLRQQRWHLQWKLVVHFWLRQ • Clearance to each side of centre line extended above meter/regulator assembly: - 3’ (0.91m) within a height of 15’ (4.6m) above the meter/regulator. • Clearance to service regulator vent outlet: - 3’ (0.91m). • Clearance to non-mechanical air supply inlet to building or the combustion air intake to any other appliance: - 3’ (0.91m) (USA – 12” (0.3m)). WARNING &RQGHQVDWHFDQFDXVHFRUURVLRQ RIPHWDOURR¿QJFRPSRQHQWV DQGRWKHUURR¿QJPDWHULDOV &KHFNZLWKWKHEXLOGHURU URR¿QJFRQWUDFWRUWRHQVXUH that materials will be resistant to DFLGLFFRQGHQVDWHS+OHYHOVFDQ EHDVORZDV )LJXUH5RRIWRSYHQWWHUPLQDOFRQ¿JXUDWLRQV )LJXUH5RRIWRSYHQW WHUPLQDWLRQZLWKVLGHZDOO FRPEXVWLRQDLU INSTALLATION AND OPERATION INSTRUCTIONS1-10 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS • Clearance to a mechanical air supply inlet: - 6’ (1.82m) (USA - 3’ (0.91m) above if within 10’ (3.1m) horizontally). • Clearance above paved sidewalk or paved driveway located on public property: - 7’ (2.2m) Note: Cannot terminate directly above a paved sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings • Clearance under veranda, porch, deck or balcony: - 12” (0.3m) IBC strongly recommends a minimum of 24” with the SL boilers to avoid damage to the structure. 1RWH3URKLELWHGXQOHVVIXOO\RSHQRQDPLQLPXPRIWZRVLGHVEHORZWKHÀRRU • 9HQWVPXVWEHLQVWDOOHGVXFKWKDWÀXHJDVGRHVQRWGLVFKDUJHWRZDUGVQHLJKERU¶V windows, air intakes, and/or where personal injury or property damage can occur. • It is important to ensure proper condensate management from vent terminations. Condensate shall not be discharged in a manner that will cause damage to external EXLOGLQJ¿QLVKHVRUFRPSRQHQWVRULQ¿OWUDWHEXLOGLQJHQYHORSHVLQFOXGLQJDGMDFHQW structures. )LJXUH6LGHZDOOYHQWWHUPLQDWLRQ LQGRRUFRPEXVWLRQDLUDSSOLFDWLRQV Figure 11: Vent terminal clearances )LJXUH3URKLELWHGLQVWDOODWLRQ )LJXUH,%&UHFRPPHQGHG PLQLPXPYHQWWHUPLQDOFOHDUDQFH XQGHUYHQWLODWHGVRI¿W Figure 12 Vent terminal clearances 1-11INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS E6LGHZDOOYHQWWHUPLQDWLRQIRULQGRRUFRPEXVWLRQDLUDSSOLFDWLRQVVKDOOEHDV follows: • 7KHYHQWVKDOOEHWHUPLQDWHGZLWKDWHH¿WWLQJDVLOOXVWUDWHGVHH)LJXUH • Bird screen of 1/4” stainless steel or plastic mesh (IPEX System 636 drain grate) should be installed in both open ends of the tee. )LJXUH6LGHZDOOYHQWWHUPLQDWLRQSLSLQJFRQ¿JXUDWLRQ F6LGHZDOO'LUHFW9HQWZLWKVHSDUDWHYHQWDQGDLUSLSHVVKDOOEHWHUPLQDWHGDV follows: • Both the inlet and exhaust terminations shall be located on the same plane (side) of the building. • The exhaust vent termination is to be placed so as to reach 12” minimum above the down-turned intake - to avoid intake re-ingestion of exhaust gases. • The elevation of both terminations can be raised in “periscope style” after passing WKURXJKWKHZDOOWKHQFRQ¿JXUHGDVLQ)LJXUH, to gain the required clearance. • Use a 45° elbow on the exhaust termination to launch the plume up and off the sidewall (to protect the wall). • Bird screen of 1/4” stainless steel or plastic mesh eg. (IPEX System 636 drain grate for CPVC systems) is useful to guard against foreign objects. CAUTION 9HQWWHUPLQDWLRQFOHDUDQFHVLQ this section are code minimum, RU,%&UHFRPPHQGHGPLQLPXP UHTXLUHPHQWVDQGPD\EH LQDGHTXDWHIRU\RXULQVWDOODWLRQ %XLOGLQJHQYHORSHGHWDLOVPXVW be examined carefully, and ingress of moisture into building VWUXFWXUHVLVWREHDYRLGHG Serious structural damage may RFFXULIDGHTXDWHSUHFDXWLRQV and clearances are not allowed for. 7KHVHSUHFDXWLRQVDUHWREH REVHUYHGIRUQHLJKERULQJ structures as well as for the VWUXFWXUHWKHERLOHUVDUH installed in. WARNING It is extremely important to maintain at least the minimum VHSDUDWLRQRIH[KDXVWYHQW WHUPLQDWLRQIURPERLOHULQWDNH DLUDVLOOXVWUDWHGLQ¿JXUHV DQG)DLOXUHWRGRVRFDQ 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 VHSDUDWLRQV7KLUGSDUW\YHQW WHUPLQDWLRQNLWVDQGFRQFHQWULF ZDOOSHQHWUDWLRQNLWVWKDWGR not maintain these minimum separations shall 127 be used. ,PSURSHULQVWDOODWLRQZLOOYRLGWKH warranty. Do not use proprietary ,QQRÀXHRU3RO\3URVLGHZDOO WHUPLQDOVZLWKRXWVSHFL¿FZULWWHQ DSSURYDOIURP,%& INSTALLATION AND OPERATION INSTRUCTIONS1-12 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS G6LGHZDOO'LUHFW9HQWZLWK6WDLQOHVV6LGHZDOO7HUPLQDOVKDOOEHWHUPLQDWHGDV follows: • The Stainless Sidewall Terminal (SST), 2 inch IBC part number 180-148 (sold separately included with the IBC kit P-256 ) or 3 inch IBC part number 180-149 (sold separately included with the IBC kit P-257 ), are approved for use with the this IBC boiler model. • The boiler’s controller is required to be the touchscreen type and have software version 1.02.0 or later installed for SST to be used. • Install the SST to comply with the minimum vent clearances listed in a) above. • The installation instructions included with the kit shall be carefully followed. • The SST shall only be installed with the vent and intake pipes horizontally beside each other or vertically with the vent pipe on top DVVKRZQLQ)LJXUH. The vent pipe cannot be installed below the intake. The vent cap must be installed with the openings directed up and down, DVVKRZQLQ)LJXUH, and not side to side. • 7KH667YHQWDLUFRQQHFWLRQV¿W6FKHGWZRLQFKRUWKUHHLQFK39&&39&SLSH PPs pipe cannot be used with the SST. The pipes must extend completely through the ZDOODVVKRZQLQ)LJXUH7KH667LVDQH[WHUQDO¿[WXUHDQGLVQRWSDUWRIWKHVHDOHG vent system that runs inside the building. • Ensure that the vent termination location does not exceed the allowed maximum HTXLYDOHQWYHQWOHQJWKLQFOXGLQJWKHDOORZDQFHIRUWKH667GH¿QHGLQWKLVGRFXPHQW section 1.4.3 Vent Travel and section 1.4.7 “Direct Vent” Combustion Air Intake Piping. • Install multiple vent SST installations level with one another and maintain at least the minimum separation distances VKRZQLQ)LJXUHVDQG. The Terminals shall not be stacked vertically. e)$SSURYHG39&6LGH:DOO7HUPLQDWLRQNLWVDUHOLVWHGEHORZ • Ipex # 196984 2” • Ipex # 196985 3” • Ipex # 196986 4” )LJXUH6LGHZDOOYHQWWHUPLQDWLRQPXOWLSOHYHQWSLSLQJFRQ¿JXUDWLRQ WARNING In areas of high snowfall, users PXVWEHDGYLVHGWRFKHFN VLGHZDOOYHQWDQGDLULQWDNH terminations on a regular basis WRHQVXUHEORFNDJHGRHVQRW occur. NOTE These kits are sold separately through the manufacturer. CAUTION 7DNHFDUHLQVWDOOLQJ&RQFHQWULF 6LGH:DOO7HUPLQDWLRQNLWV when the outdoor temperature GURSVEHORZ°F°C. Possible bORFNDJHRIWKHFRPEXVWLRQ DLULQWDNHFDQRFFXUZKHQWKH outdoor temperature drops below this temperature. 1-13INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )LJXUH$OORZHG667LQVWDOODWLRQRULHQWDWLRQV )LJXUH0LQLPXPVHSDUDWLRQVIRUPXOWLSOHYHQWLQVWDOODWLRQKRUL]RQWDORULHQWDWLRQ )LJXUH0LQLPXPVHSDUDWLRQIRUPXOWLSOHYHQWLQVWDOODWLRQYHUWLFDORULHQWDWLRQ )LJXUH3LSHVH[WHQGFRPSOHWHO\WKURXJKWKHZDOO9HUWLFDORULHQWDWLRQVKRZQ • 2 “ IBC part number 180-148 • 3 “ IBC part number 180-149 INSTALLATION AND OPERATION INSTRUCTIONS1-14 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.4.7 “Direct Vent” Combustion Air Intake Piping There are two basic methods of supplying combustion air to an IBC boiler. The direct vent option uses piping from the outside to supply combustion air directly to the boiler’s combustion air connection. 7DEOH0D[LPXPLQWDNHSLSLQJOHQJWK NOTE: It is not permitted to add to the exhaust length by transfer of unused intake allowance. WARNING ,QDGGLWLRQWRSUHYHQWLQJ ingestion of chemical contaminants, care must be WDNHQWRHQVXUHDLULQWDNH terminals are not installed in locations where contamination might occur due to ingestion of SDUWLFXODWHIRUHLJQPDWHULDOGXVW GLUWDQGGHEULV )LJXUH'LUHFWYHQWFRPEXVWLRQDLULQWDNH WARNING ,QWDNHDLURSHQLQJVPXVWEH FRQ¿JXUHGVXFKWKDWUDLQRU other forms of moisture cannot HQWHUWKHDLULQWDNHSLSLQJ V\VWHP2WKHUZLVHVHULRXV damage to the boiler may result. NOTE &DUHPXVWEHWDNHQZKHQ LQVWDOOLQJDLULQWDNHSLSLQJWR HQVXUHWKDWD³WUDS´LVQRWIRUPHG in the piping so as to allow a EXLOGXSRIZDWHUDQGEORFNDJH RILQWDNHDLU 6XFKEORFNDJHZLOOUHVXOWLQD boiler safety shut-down. INTAKE PIPE SIZE MAXIMUM EQUIVALENT LENGTH Sched.40; Rigid PPs SL 10-85 G3 SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 2"100' 100' 35’ Not applicable 3" 240' 240' 170’ 150’ 90° vent elbow allow 8' equivalent allow 8' equivalent allow 8’ equivalent allow 8’ equivalent 90° long sweep elbow allow 5' equivalent allow 5' equivalent allow 5’ equivalent allow 5’ equivalent 45° elbow allow 3' equivalent allow 3' equivalent allow 3’ equivalent allow 3’ equivalent PPs 87-90° elbows use 8' equivalent use 8' equivalent use 8’ equivalent use 8’ equivalent Air Intake Filter (Part #103) allow 8' equivalent allow 8' equivalent 2” Stainless Sidewall Terminal IBC P/N 180-148 (P-256) No additional allowance No additional allowance Not allowed Not allowed 3” Stainless Sidewall Terminal IBC P/N 180-149 (P-257) No additional allowance No additional allowance No additional allowance No additional allowance Flexible PPs 3” Flexible 45’ (max.) lineal x 3.33 = equivalent 45’ (max.) lineal x 3.33 = equivalent 45’ (max.) actual lineal x 3.33 = equivalent 30’ (max.) actual lineal x 3.3 = equivalent 1-15INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS &RPEXVWLRQDLUSLSLQJLIXVHGLVLQVHUWHGGLUHFWO\LQWRWKH´IHPDOHVWDLQOHVVVWHHO¿WWLQJ on the top, right side of the boiler and run horizontally or vertically to the outdoors. Screen material can be placed at the inlet as appropriate for the environment (e.g. insects, dust). Care must be taken to ensure adequate separation is maintained between the air intake LQOHWDQGWKHYHQWWHUPLQDO5HIHUWRWKHYHQWWHUPLQDOFRQ¿JXUDWLRQGUDZLQJVLQWKH9HQW Termination section above. Support should be provided for intake piping, particularly so for horizontal runs (follow local code). 1.4.8 “Indoor Air” Combustion Air Intake An “Indoor Combustion Air installation”, as described herein, is one in which air for combustion is taken from the ambient air around the boiler. To support combustion, an ample air supply is required. This may require direct openings in the boiler room to the outside. If the boiler is not in a room adjacent to an outside wall, air may be ducted from outside wall openings. Provisions for combustion and ventilation air must be made as follows: • in the USA, in accordance with the National Fuel Gas Code, ANSI Z223.1 (latest edition), or applicable provisions of the local building codes • in Canada, in compliance with B149.1-10 WARNING When using Indoor Air options, DGHTXDWHFRPEXVWLRQDLUPXVW be supplied to the boiler room DFFRUGLQJWRWKHUHTXLUHPHQWVRI all applicable codes.)LJXUH,QGRRUFRPEXVWLRQDLULQWDNH INSTALLATION AND OPERATION INSTRUCTIONS1-16 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.4.9 Combustion Air Filtration If combustion air contamination from ingested particulate matter is a concern in any LQVWDOODWLRQDQRSWLRQDODLULQWDNH¿OWHUPD\EHLQVWDOOHG,%&VXSSOLHGDLULQWDNH¿OWHUV have a known pressure drop and fouling factor and should be used as a component of the combustion air system according to the allowable intake length in 7DEOH IMPORTANT: 8QGHUQRFLUFXPVWDQFHVVKRXOGDWKLUGSDUW\DLU¿OWHUEHLQVWDOOHGRQ DQ,%&ERLOHUZLWKRXWSURSHUHYDOXDWLRQDQGZULWWHQDSSURYDORIWKH,%&(QJLQHHULQJ 'HSDUWPHQW 1.4.10 Closet Installations )RULQVWDOODWLRQVLQDFRQ¿QHGVSDFHVXFKDVDFORVHWYHQWLODWLRQRSHQLQJVPD\EH needed through a door or wall to prevent excessive heat from building up inside the space. The boiler shall not be exposed to ambient conditions above 122°F (50°C) or below 32°F (0°C). NOTE &RPEXVWLRQIDQEORFNDJHV FDQRFFXUZKHQHQYLURQPHQWDO particulate and foreign matter FRQWDPLQDQWVOHDYHVGXVW GDQGHOLRQ FRWWRQZRRGÀXII HWFDUHGUDZQLQWRWKHDLULQWDNH In areas where this problem is suspected to be an issue, our RSWLRQDODLULQWDNH¿OWHUVKRXOGEH installed. )LOWHUVVKRXOGEHFKHFNHGDQG cleaned or replaced on a regular VFKHGXOHEDVHGRQWKHVHYHULW\ of the problem. )LJXUH'LUHFWYHQWLQWDNHH[KDXVWV\VWHPZLWKRSWLRQDODLULQWDNH¿OWHU¿OWUDWLRQPD\ DOVREHXVHGRQLQGRRUDLUDSSOLFDWLRQVDVUHTXLUHG 1-17INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.5 CONDENSATE REMOVAL ,%&¶VVSHFL¿HGYHQWFRQ¿JXUDWLRQSURPRWHVWKHVDIHGUDLQDJHRIPRLVWXUHIURPWKHERLOHU DQGH[KDXVWYHQWLQJZLWKRXWÀRZLQJOLTXLGVEDFNWKURXJKWKHKHDWH[FKDQJHUDVGRQHE\ some other condensing boilers). Reliable system operation requires (1) proper design and installation of exhaust venting to allow condensate to run back to the drain/trap; (2) acid neutralization as appropriate. To achieve these: 1. Allow for a 1/4” per foot slope back to the vent connection, with appropriate hangers to maintain that gradient. 2. (QVXUHWKHVXSSOLHGWUDSLVFRUUHFWO\LQVWDOOHGDQG¿OOHGZLWKZDWHU 3. When required, add (and maintain in good condition) a neutralization tank. 1.5.1 Condensate Trap A condensate trap must be installed on the drain connection at the base of the boiler as shown in )LJXUH 1.5.2 Condensate Trap Assembly - Installation 1. Undo the Drain Spout Compression Nut (E), remove Drain Hose (G) from the Trap Drain Outlet (F). Place the Vacuum breaker cap (J) over the Vacuum breaker opening DQGSXVK¿UPO\KRPH5HPRYHWKH8SSHU&RPSUHVVLRQ1XWDQG:DVKHU&DQG slide over the Boiler Drain Outlet (A). 2. Fill Trap with water, and slide Trap Body (D) over Boiler Drain Outlet (A) - (see Figure 22). 3. Tighten the upper compression nut and washer to the boiler drain outlet. 4. Attach the Drain Hose (G), and then tighten the Drain Spout Compression Nut (E). 5. Install the condensate trap retainer as indicated on the instructions provided separately. )LJXUH&RQGHQVDWHWUDS installation WARNING 7KHWUDSUHWDLQHUPXVWEH installed as instructed and all WUDS¿WWLQJVPXVWEHWLJKWHQHGDV LQVWUXFWHGWRSUHYHQWOHDNDJHRI ÀXHJDVVHV Failure to comply may result in VHYHUHSHUVRQDOLQMXU\RUGHDWK WARNING Fill trap with water before boiler LV¿UVW¿UHGWRSUHYHQWH[KDXVW IXPHVIURPHQWHULQJURRP1HYHU operate the boiler unless the trap LV¿OOHGZLWKZDWHU Failure to comply will result in VHYHUHSHUVRQDOLQMXU\RUGHDWK &RQGHQVDWH7UDSDVVKLSSHG&RQGHQVDWH7UDSGLVDVVHPEOHG 1. Install condensate trap and tube. 2. Slide retainer around trap and slide retainer tabs into cabinet. 3. Pass tube through retainer. 4. Secure trap with nut and washer. Boiler drain outlet INSTALLATION AND OPERATION INSTRUCTIONS1-18 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.5.3 Condensate Trap Assembly - cleaning procedure 1. Turn off the power to the boiler and allow it to cool down. 2. Remove the trap from the boiler (reverse the installation procedure above). 3. 5HPRYHWKH7UDS&OHDQRXW$VVHPEO\+IURPWKH7UDS%RG\DQGFOHDQDQGÀXVKWKH debris out. 4. 5HDVVHPEOHWUDSFRPSRQHQWVUH¿OOWUDSDQGUHSODFHRQERLOHUDVGHVFULEHGLQWKH installation instructions above. 1.5.4 Further installation details • Condensate drain must be piped to within 1” of a drain or be connected to a condensate pump. • Drainage line must slope down to the drain at a pitch of 1/4” per foot so condensate runs towards the drain. • &RQGHQVDWHWUDSVVKRXOGEHFKHFNHGHYHU\PRQWKVDQGFOHDQHGDQGUH¿OOHGDV necessary. NOTE It is the responsibility of WKHLQVWDOOLQJDQGRUVHUYLFH &RQWUDFWRUWRDGYLVHDQGLQVWUXFW the end User in how to perform WKH7UDSFOHDQLQJSURFHGXUH DQGWRDGYLVHWKDWWKH7UDS EHFKHFNHGDWOHDVWHYHU\WZR PRQWKVDQGFOHDQHGDVUHTXLUHG $VVHPEOHGFRQGHQVDWHWUDS 1-19INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )LJXUH&RQGHQVDWHWUDSGUDLQDJH )LJXUH&RQGHQVDWHQHXWUDOL]DWLRQWDQN )LJXUH&RQGHQVDWHWUDS GLVDVVHPEO\IRUFOHDQLQJ WARNING If condensates are to be discharged into building drain piping materials that are subject to corrosion, a neutralization SDFNDJHPXVWEHXVHG CAUTION When a condensate QHXWUDOL]DWLRQSDFNDJH LVLQVWDOOHGWKHS+RIWKH condensate discharge must be measured on a regular schedule to ensure the neutralizing agent LVDFWLYHDQGHIIHFWLYH DANGER 7KHZDWHULQWKHFRQGHQVDWH QHXWUDOL]HUFDQFDXVHVHYHUH EXUQVWRWKHVNLQ8VHH[WUHPH FDXWLRQZKHQVHUYLFLQJWKH condensate neutralizer. Wear SURWHFWLYHJORYHVDQGH\HZHDU INSTALLATION AND OPERATION INSTRUCTIONS1-20 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.6 WATER PIPING 1.6.1 General Piping Issues The SL boilers were designed to be easy to install in almost any application. Its unique multi-port piping design allows connection from either side or both sides at once. Primary/secondary piping, or the use of a hydraulic separator is recommended for PD[LPXPÀH[LELOLW\LQPXOWLORDGDSSOLFDWLRQVEXWSLSLQJORDGVLQSDUDOOHOLVDOVR encouraged in systems that only have two loads, or when loads are operating simultaneously. The extremely low pressure drop through the SL Series heat exchanger allows many options not available in other designs. In short – IBC has built a boiler that will allow you to pipe the system the way you prefer, rather than try and dictate your piping practices from boiler to radiator. There are some important details to consider however, and this section of the Installation and Operating Manual will walk you through them so you can enjoy a trouble-free installation. )LJXUH2YHUYLHZRISLSLQJRSWLRQV 1-21INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )LJXUH&RQVLGHUDWLRQIRUOHIWVLGHRQO\SLSLQJ Note that the supply pipe off the right-hand side of the heat exchanger carries the LWCO device. If all heating loads are on the left-hand side only, ensure that the right-hand supply FRQQHFWLRQVXVHDQDXWRDLUYHQWRUDÀXVKLQJYDOYH The SL modulating series boilers are designed for use within a closed loop, forced circulation, low pressure system. A 30 psi pressure relief valve (3/4” NPT) is supplied for ¿HOGLQVWDOODWLRQDWRQHRIWKHORFDWLRQVVKRZQLQWKHIROORZLQJLOOXVWUDWLRQV5HOLHIYDOYH GLVFKDUJHSLSLQJPXVWWHUPLQDWHEHWZHHQ´FPDQG´FPDERYHWKHÀRRURUSHU local Code. Due to the various piping options available, positioning the pressure relief valve can vary. When piping from either side, the relief valve is installed in the upper port opposite the VXSSO\RXWOHWXVLQJWKH¿WWLQJVSURYLGHGVHH)LJXUH If piping from both sides at the same time, a tee must be installed on either supply outlet, immediately on exiting the boiler so that there is no possibility of installing an isolation valve between the pressure vessel and the relief valve. CAUTION ,QVWDOOHUVVKRXOGLQTXLUHRI ORFDOZDWHUSXUYH\RUVDVWRWKH suitability of their supply for use in hydronic heating systems. ,IZDWHUTXDOLW\LVTXHVWLRQDEOH a local water treatment expert must be consulted for testing, DVVHVVPHQWDQGLIUHTXLUHG treatment. $OWHUQDWLYHO\ZDWHURUK\GURQLF ÀXLGRINQRZQTXDOLW\FDQEH brought to the site. WARNING 'XULQJRSHUDWLRQWKHUHOLHIYDOYH may discharge large amounts of steam and/or hot water. 7KHUHIRUHWRUHGXFHWKHSRWHQWLDO for bodily injury and property GDPDJHDGLVFKDUJHOLQH0867 be installed that it: 1. is connected from the valve outlet with no intervening valve and directed downward to a safe point of discharge. 2. allows complete drainage of both the valve and the discharge line. 3. is independently supported and securely anchored so as to avoid applied stress on the valve. 4. is as short and straight as possible 5. terminates freely to atmosphere where any discharge will be clearly visible and is at no risk of freezing. 6. terminates with a plain end which is not threaded. 7. is constructed of a material suitable for exposure to temperatures of 375°F or greater. 8. is, over its entire length, of a pipe size equal to or greater than that of the valve outlet. '2127&$33/8*2527+(5:,6( 2%6758&77+(',6&+$5*(3,3( 287/(7 INSTALLATION AND OPERATION INSTRUCTIONS1-22 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )LJXUH5HOLHISLSLQJZLWKGXDOVLGHFRQQHFWLRQV )LJXUH5HOLHISLSLQJZLWKVLQJOHVLGHSLSLQJFRQQHFWLRQV 1-23INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 6\VWHPSLSLQJLVFRQQHFWHGWRWKHERLOHUXVLQJWKH´1370DOHWKUHDGHG¿WWLQJVRQWKH right or left side connection ports. Unions and gate or ball valves at the boilers supply and return water connections are recommended to simplify servicing. Un-insulated hot water pipes must be installed with a minimum 1” clearance from combustible materials. )OXLG¿OOLVPRVWRIWHQDFFRPSOLVKHGE\XVLQJDERLOHUUHJXODWRU ¿OOYDOYHVHWDWSVLJ RUPRUHZLWKWKHDSSURSULDWHEDFNÀRZSUHYHQWLRQGHYLFHDVUHTXLUHGE\ORFDOFRGH7KLV LVDFFHSWDEOHLQDUHDVZKHUHPXQLFLSDOZDWHURUZHOOZDWHUKDVEHHQWUHDWHGDQG¿OWHUHG to remove excessive minerals and sediment, and water chemistry is known to be suitable for closed loop hydronic systems. In areas where water quality is in question, or when chemical treatment or glycol is required, other options should be considered. Follow applicable codes and good piping practice. There are a number of boiler feed and pressurization devices on the market today that PD\EHDEHWWHUFKRLFHWKDQDUDZZDWHU¿OOIURPWKHPDLQV:KHQUHJXODUPDLQWHQDQFH requires relief valve blow-off, the discharge may be directed back into the pressurization XQLWIRUUHF\FOLQJRIERLOHUÀXLGDQGFKHPLFDOVEDFNLQWRWKHV\VWHP,QEXLOGLQJVWKDWPD\ EHXQRFFXSLHGIRUORQJSHULRGVRIWLPHSUHVVXUL]DWLRQXQLWVDUHXVHIXOWRSUHYHQWÀRRG GDPDJHVKRXOGOHDNDJHRFFXUIURPDQ\FRPSRQHQWLQWKHV\VWHP$QDGGLWLRQDOEHQH¿WLV WKDWEDFNÀRZSUHYHQWLRQGHYLFHVDUHQRWUHTXLUHGZKHQXVLQJWKHVHGHYLFHV Do not place any water connections above the boiler. Leaks can damage the fan and FRQWUROV,IQHHGHGFUHDWHDVKLHOGRYHUWKHWRSRIWKHFRYHUEXWDOORZFOHDUDQFHIRUDLUÀRZ and service access. For best results regarding the SL 14-115 G3, use a Primary/Secondary piping system with a pumped boiler loop (using 1” piping). Heat exchanger head is only 1.5’ at 4 USgpm and approximately 4’ at 10 USgpm. 7KHPLQLPXPÀRZUDWHUHTXLUHGWKURXJKWKHKHDWH[FKDQJHULVOLVWHGLQ7DEOHV$DQG% 3ULPDU\6HFRQGDU\SLSLQJHQVXUHVDGHTXDWHÀRZDQGGHFRXSOHVǻ7LVVXHVERLOHUYV GLVWULEXWLRQ$LPIRUDWR)ǻ7DFURVVWKHKHDWH[FKDQJHUDWKLJK¿UHWKHUHLVD ERLOHUSURWHFWLRQWKURWWOHIHQFHOLPLWLQJWKHǻ7WR) 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 JLYHQÀRZDQGSUHVVXUH$VDUXOHRIWKXPEDVROXWLRQRISURS\OHQHJO\FRODQG water will require an increased system circulation rate (gpm up 10%), and system head (up 20%) to provide performance equivalent to straight water. )LJXUH%RLOHUWULPEDVLFRSWLRQV WARNING &ORVH¿OOYDOYHDIWHUDQ\DGGLWLRQ of water to the system, to reduce ULVNRIZDWHUHVFDSHPHQW NOTE Full sized application drawings can be downloaded from our web site. www.ibcboiler.com NOTE 7KHERLOHUZKHQXVHGLQ connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with DSSURSULDWHYDOYHVWRSUHYHQWWKH chilled medium from entering the boiler. NOTE 7KHERLOHUSLSLQJV\VWHPRIDKRW water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must EHHTXLSSHGZLWKÀRZFRQWURO YDOYHVRURWKHUDXWRPDWLFPHDQV WRSUHYHQWJUDYLW\FLUFXODWLRQ of the boiler water during the cooling cycle. INSTALLATION AND OPERATION INSTRUCTIONS1-24 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS The SL series modulating boilers are designed to supply three different heating loads with temperatures within the range 34°F to 180°F - to meet three separately piped loads. Use closely spaced tees to connect each pumped “load” (e.g. DHW, baseboards or radiant ÀRRUWRWKHSULPDU\ORRSRUHPSOR\WKHXVHRIDK\GUDXOLFVHSDUDWRUWRLVRODWHWKHERLOHU loop from the system and pipe the system from the secondary side of the separator. Two- load systems may be piped with a variant of parallel piping commonly used, including our XQLTXHGXDOVLGHSLSLQJFRQ¿JXUDWLRQ 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 ERLOHU)ROORZLQJLQVWDOODWLRQFRQ¿UPWKHDFWXDOSHUIRUPDQFHE\PHDVXULQJǻ7XQGHUKLJK DQGORZÀRZFRQGLWLRQV A variety of application drawings showing basic design options are available from the IBC web site at: www.ibcboiler.com BOILER HEAD LOSS BOILER HEAD LOSS SL 10-85 G3, SL 14-115 G3 Flow rate (gpm)24681012 14 +HDGORVV#ÀRZIWZF0.5’ 1.5’ 2.5’ 3.0’ 4.0’ 4.5’ 6.0’ 7DEOH$%RLOHU+HDG/RVV 6/*/6/* BOILER HEAD LOSS SL 20-160 G3 Flow rate (gpm)468101214 16 +HDGORVV#ÀRZIWZF0.5’ 1.0’ 1.5’ 2.0’ 3.0’ 4.0’ 5.0’ 7DEOH%%RLOHU+HDG/RVV6/* BOILER HEAD LOSS SL 30-199 G3 Flow rate (gpm) 6 10 15 20 22 +HDGORVV#ÀRZIWZF2’ 3.5’ 5.5’ 8’ 13’ 7DEOH&%RLOHU+HDG/RVV6/* :HUHFRPPHQGZDWHUÀRZDIWHUEXUQHUVKXWGRZQWRXWLOL]HOHJDF\KHDW±WKLVLVGXHWR the mass of the heat exchanger plus its water volume. Default software values will run the boiler’s primary pump for up to 15 minutes (900 seconds) after burner shutdown. Secondary pumps can be set to run up to 5 minutes after burner shutdown (for the last calling load). As shipped, the default software will run the Boiler pump for 5 minutes to place the legacy heat where it is useful. The primary pump must be under the control of the boiler to allow pump purge after burner shut-down. Schematics for several piping layouts are provided herein, and additional drawings are available at www.ibcboiler.com. Installers shall conform the piping design to one of the SURYLGHGFRQ¿JXUDWLRQVWRVLPSOLI\WKHFRQWURODSSOLFDWLRQSURPRWHJRRGORDGVDQGÀRZ management. WARNING :DWHUTXDOLW\KDVDVLJQL¿FDQW impact on the lifetime and SHUIRUPDQFHRIDQ,%&%RLOHU heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through corrosion or fouling. Repeated or uncontrolled water ¿OOVZLOOLQFUHDVHWKHSRWHQWLDO for damage. +LJKOHYHOVRIGLVVROYHGVROLGV or minerals may precipitate RXWRIWKHÀXLGRQWRWKHKRWWHVW part of the heat exchanger, impairing heat transfer and UHVXOWLQJLQRYHUKHDWLQJDQG SUHPDWXUHIDLOXUH7KHDPRXQW of solids that may form on the heat exchanger will depend on the degree of hardness and WKHWRWDOZDWHUYROXPHLQWKH V\VWHP$KLJKZDWHUYROXPH system with a low hardness count may cause as much damage as a system with less YROXPHDQGKLJKHUKDUGQHVVVR it is recommended to treat water VRDVWRUHPRYHDOOGLVVROYHG VROLGV2WKHUZDWHUFKHPLVWU\ allowable limits are as follows: $FLGLW\S+LVWREHEHWZHHQ DQG &KORULGHLVWREHOHVVWKDQ mg/l ,URQLVWREHOHVVWKDQPJO &XOHVVWKDQPJO &RQGXFWLYLW\LVWREHOHVVWKDQ ȝ6FPDW& +DUGQHVVLVWREH*UDLQVRU less IMPORTANT: Ensure that these limits are acceptable for the other water-side components in the system. 1-25INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS WARNING 'RQRWXVHDXWRPRWLYHW\SH ethylene or other types of DXWRPRWLYHJO\FRODQWLIUHH]H or undiluted antifreeze of DQ\NLQG7KLVPD\UHVXOWLQ VHYHUHERLOHUGDPDJH,WLVWKH responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials. Improper PL[WXUHVDQGFKHPLFDODGGLWLYHV may cause damage to ferrous and non-ferrous components as well as non-metallic, wetted components, normally found in hydronic systems. Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation ORFDWLRQ)RUHQYLURQPHQWDO DQGWR[LFLW\UHDVRQV,%& recommends only using non- toxic propylene glycol. The SL series modulating boilers offer exceptional matching of heat generation to UDGLDWLRQ7KHORZPLQLPXP¿ULQJLVEHWWHUVXLWHGWRORZWKHUPDOORDGVSUHVHQWHGLQD typical multi-zoned radiation system. However, where individual zones in a heating system KDYHORDGVXQGHU%WXKUWKHV\VWHPZLOOVWLOOEHQH¿WWKURXJKXVHRIDEXIIHUWDQNWR ensure a controlled supply temperature, and to prevent short cycling. Buffering should be added on the secondary piping of the relevant load, to avoid bulking up the thermal mass of the primary piping circuit (and potentially lengthen the duration of the transition from hot to cool loads). 6/PRGXODWLQJVHULHVERLOHUVFDQEHFRQQHFWHGGLUHFWO\WRDÀRRURIQRQR[\JHQEDUULHU polybutylene material (PB tubing). For maintenance of warranty on such systems, we UHTXLUHHYLGHQFHRIDWKRURXJKÀXVKLQJRIDOOORRSVSOXVLQVWDOODWLRQRIDGLUWVHSDUDWRU RUVLGHVWUHDP¿OWHU$VHSDUDWRU¿OWHUPDLQWHQDQFHURXWLQHVKDOOEHFDUULHGRXWDIWHUWKH UHWUR¿WZLWK¿OWHUFOHDULQJDIWHUWKHVWGD\VWZHHNPRQWKDQGDQQXDOO\WKHUHDIWHU&DUH LVWREHWDNHQWRDYRLGXVHRIIHUURXV¿WWLQJVDQGSXPSVRQ1RQ2[\JHQ%DUULHUWXEH systems. 1.6.2 Basic System Piping Arrangements 3ULPDU\6HFRQGDU\SLSLQJ%HQHÀWVDQGLQVWDOODWLRQUXOHV 1. *RRGFLUFXODWLQJZDWHUÀRZWKURXJKWKHERLOHULUUHVSHFWLYHRIORDGRUUDGLDWLRQV\VWHP head 2. $OORZVÀH[LEOHǻ7FRQWUROLQVHFRQGDU\ORRSV 3. Adds to the system’s thermal buffering, to assist in handling small loads and temperature transition. $3ULPDU\6HFRQGDU\SLSLQJFRQ¿JXUDWLRQUHTXLUHVDQH[WUDSXPSLQGHSHQGHQWIURPDQ\ secondary load pumps. The SL series modulating boilers’ controller hosts wiring terminals and integral relays to simplify installation and operation of this preferred layout, offsetting such costs. For optimal performance, place pumps on the supply side of secondary loops to facilitate DLUHYDFXDWLRQ8VHSXPSVZLWKLQWHUQDOFKHFNYDOYHVWRDYRLGJKRVWÀRZVDQGWKHUPDO siphoning. )LJXUH,PSRUWDQWSULPDU\VHFRQGDU\SLSLQJGHWDLOVZLWKFORVHO\VSDFHGWHHV INSTALLATION AND OPERATION INSTRUCTIONS1-26 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )LJXUH7\SLFDORQHWHPSHUDWXUHVSDFHKHDWLQJSLSLQJFRQFHSW )LJXUH2QHWHPSHUDWXUHVSDFHKHDWLQJSLSLQJFRQFHSWWHHVRQVHFRQGDU\SLSLQJ 1-27INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS NOTE /RDG&RPELQLQJLVQRZDYDLODEOH WRRSHUDWHFRPSDWLEOHZDWHU temperature loads at the same time. :KHQXVLQJWKHVHTXHQWLDO ORDGIHDWXUHRIWKH,%&ERLOHU attention must be paid to the operation of system components in order to ensure they are compatible. 0DQ\DLUKDQGOHUVIDQFRLOV IRULQVWDQFHKDYHDWKHUPRVWDW connection that will energize an internal relay to operate the air handler circulator and its fan on DFDOOIRUKHDW7KLVPD\UHVXOWLQ operation of these components when other loads are running at a higher priority, resulting in cold air blowing, or robbing heat from another load. Some wiring alteration may EHUHTXLUHGWRGLYRUFHERWKRI these functions from thermostat FRQWUROLQIDYRXURIPRUH HIIHFWLYHFRQWUROIURPWKH,%& boiler. )LJXUH7\SLFDOWZRWHPSHUDWXUHVSDFHKHDWLQJSLSLQJFRQFHSW INSTALLATION AND OPERATION INSTRUCTIONS1-28 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )LJXUH,QGLUHFW'RPHVWLF+RW:DWHUSLSLQJFRQFHSW )LJXUH%DVLF3ULPDU\6HFRQGDU\SLSLQJZLWKK\GUDXOLFVHSDUDWRUFRQFHSW NOTE 7KHSLSLQJGUDZLQJVLQWKLV manual are simple schematic guides to a successful LQVWDOODWLRQ7KHUHDUHPDQ\ necessary components not shown, and details such as thermal traps are left out so the GUDZLQJVKDYHJUHDWHUFODULW\ :HUHTXLUHWKDWRXUERLOHUV be installed by licensed and experienced trades people who are familiar with the applicable local and national codes. System design is to be completed by an experienced hydronic designer or Engineer. It is necessary to carefully read and follow these installation instructions along with the application drawing that ¿WV\RXUV\VWHP )LJXUH7ZRVLGHGSLSLQJ'+:DQGVSDFHKHDWLQJSLSLQJFRQFHSW 1-29BOILER SYSTEMS AND OPERATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 3DUDOOHOORDGSLSLQJ%HQHÀWVDQGLQVWDOODWLRQUXOHV Compared with the Primary/Secondary approach, the design below saves one pump. Lost LVWKHVLPSOLFLW\RIFRQVWDQWKHDGDQGÀRZDWWKHERLOHU )LJXUH2QHSXPSSDUDOOHOSLSLQJFRQFHSW )LJXUH7ZRSXPSWZRORDGSDUDOOHOSLSLQJFRQFHSW INSTALLATION AND OPERATION INSTRUCTIONS1-30 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS Check valves or thermal traps should be used to isolate both the supply and return piping IRUHDFKORDGWRDYRLGWKHUPDOVLSKRQLQJDQGUHYHUVHÀRZ 7RHQVXUHDGHTXDWHZDWHUÀRZWKURXJKWKHERLOHUXQGHUKLJKKHDGVLQJOH]RQHVSDFH heating conditions, a pressure activated bypass or other means of bypass must be used RQDQ\ORDGZKHUHWKHÀRZUDWHPLJKWGURSEHORZPLQLPXPUHTXLUHPHQWV For further information and details, consult our $SSOLFDWLRQ1RWHV – which provide detail on VSHFL¿FVLQJOHDQGPXOWLSOHERLOHUDSSOLFDWLRQV³3LSLQJ´³:LULQJ´ and ³6HWWLQJV´DYDLODEOH DWZZZLEFERLOHUFRPRUIURP\RXU,%&5HSUHVHQWDWLYH 0XOWLSOHERLOHUSLSLQJ%HQHÀWVDQGLQVWDOODWLRQUXOHV Multiple IBC boilers can be installed in a single heating system to provide redundancy, increased output, and greater heating plant turn-down capabilities. Primary/Secondary piping must be employed, and each boiler must be installed with its own pump as LOOXVWUDWHGEHORZ7KLVDSSURDFKSURYLGHVFRQVWDQWKHDGDQGÀRZDWHDFKERLOHU UHJDUGOHVVRIÀRZYDULDWLRQVLQWKHPDLQEXLOGLQJORRS Each boiler will control its own pump, turning it off or on when heat is required. This approach saves electricity by reducing the pumping power required as load conditions are reduced. One boiler control is set up as a “Master” boiler, and up to 23 additional boilers can be added to the system as “Subordinate” boilers by connecting a twisted pair of wires between the boilers. No additional controls are needed. &KHFNYDOYHVDUHWREHXVHGLQHDFKERLOHUVSLSLQJWRSUHYHQWUHYHUVHÀRZZKHQWKHERLOHU is off. For further information and details, consult our $SSOLFDWLRQ1RWHV – which provide detail on VSHFL¿FVLQJOHDQGPXOWLSOHERLOHUDSSOLFDWLRQV³3LSLQJ´³:LULQJ´ and ³6HWWLQJV´DYDLODEOH DWZZZLEFERLOHUFRPRUIURP\RXU,%&5HSUHVHQWDWLYH NOTE For further information and GHWDLOVUHJDUGLQJ0XOWLSOH %RLOHUDSSOLFDWLRQFRQVXOWRXU Technical Notes - Multiple Boiler Systems.7KHVHQRWHVSURYLGH QHFHVVDU\GHWDLORQVSHFL¿F single and multiple boiler DSSOLFDWLRQV³3LSLQJ´³:LULQJ´ DQG³6HWWLQJV´DYDLODEOHDW www.ibcboiler.com or from your ,%&5HSUHVHQWDWLYH )LJXUH0XOWLSOHERLOHUSLSLQJFRQFHSW 1-31BOILER SYSTEMS AND OPERATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.7 GAS PIPING The boiler requires an inlet gas pressure of at least 4.0" w.c. for natural gas or propane. )RUHLWKHUIXHOWKHLQOHWSUHVVXUHVKDOOEHQRJUHDWHUWKDQZF&RQ¿UPWKLVSUHVVXUH range is available with your local gas supplier. The inlet gas connection of the boiler’s gas valve is 1/2" NPT (female). Adequate gas supply piping shall be provided with no smaller than a 1/2" Iron Pipe Size (e.g. Iron Pipe Size (IPS) and using a 1” w.c. pressure drop, in accordance with the following chart: 7DEOH0D[LPXP3LSH/HQJWKIW6FKHGXOHVWHHO NOTE ,WLVHVVHQWLDOWRFKHFNJDV supply pressure to each boiler with a manometer or RWKHUKLJKTXDOLW\SUHFLVLRQ PHDVXULQJGHYLFH3UHVVXUH should be monitored before ¿ULQJWKHERLOHUZKHQWKH UHJXODWRULVLQD³ORFNXS´ condition and during operation, throughout the boiler’s full modulation range. 3D\VSHFLDODWWHQWLRQWRUHWUR¿W situations where existing UHJXODWRUVPD\KDYHDQRYHU VL]HGRUL¿FHDQGRUZRUQVHDWV FDXVLQJSUHVVXUH³FUHHS´DQG KLJKORFNXSSUHVVXUHV )LJXUH0XOWLSOHERLOHUORZORVVKHDGHUSLSLQJFRQFHSW MODEL 1/2" IPS 3/4" IPS 1" IPS 1-1/4” IPS SL 10-85 G3/ SL 14-115 G3 (Natural Gas)30’ 125’ 400’ SL 14-115 G3, SL 10-85 G3 (Propane)90’ 350’ 1,000’ SL 20-160 G3 (Natural Gas) 10’ 70’ 200’ SL 20-160 G3 (Propane) 50’ 200’ 600’ SL 30-199 G3 (Natural Gas) 10’ 40’ 150’ 600’ SL 30-199 G3 (Propane) 30’ 125’ 400’ 1,600’ INSTALLATION AND OPERATION INSTRUCTIONS1-32 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS Gas piping must have a sediment trap ahead of the boiler’s gas valve VHH)LJXUH. A manual shutoff valve must be located outside the boiler, in accordance with local codes/ standards. All threaded joints in gas piping should be made with an approved piping compound resistant to the action of natural gas/propane. Use proper hangers to support gas supply piping as per applicable codes. The boiler must be disconnected or otherwise isolated from the gas supply during any pressure testing of the system at test pressures in excess of 1/2 psig. Dissipate test pressure prior to reconnecting. The boiler and its gas piping shall be leak tested before being placed into operation. The gas valve is provided with pressure taps to measure gas pressure upstream (supply pressure) and downstream (manifold pressure) of the gas valve VHH)LJXUH Note that PDQLIROGSUHVVXUHYDULHVVOLJKWO\LQDFFRUGDQFHZLWK¿ULQJUDWHVZLWKWKHPRGXODWLQJVHULHV boilers, but will always be close to 0” w.c. )LJXUH7\SLFDOJDVSLSLQJFRQQHFWLRQ 1.8 ELECTRICAL CONNECTIONS All electrical wiring to the boiler (including grounding) must conform to local electrical codes and/or the National Electrical Code, ANS/NFPA No. 70 – latest edition, or the Canadian Electrical Code, C22.1 - Part 1. 1.8.1 120 VAC Line Voltage Hook-up /LQHYROWDJHZLULQJLVGRQHZLWKLQWKH¿HOGZLULQJER[5HIHUWR6HFWLRQ:LULQJ'LDJUDP RQSDJH Connect the boiler to the grid power using a separate, fused circuit and on/off switch within sight of the boiler. Use 14-gauge wire in BX cable or conduit properly anchored to the boiler case for mains supply and pump circuits. Connect a 120 VAC / 15 amp supply to the ³$&,1´tagged leads in the wiring box. The max. actual draw (with 5 typical residential size pumps) is less than 4 amps. The 120 VAC power supply to the load pumps (P/V1, P/V2, P/V3, and P/V4) has been factory installed and connected to P/V-L and P/V-N for your convenience. The upper 4 pairs of contacts on this green connector strip are then powered to manage up to 4 load pumps – the top pair for Load 1, the second pair for #2 etc. Once the controller is programmed for the respective loads, the boiler manages all the loads without need of further relays (for loads up to 1/3 HP for more – use a protective relay). /LQHYROWDJHOHDGVIRUSRZHUVXSSO\ SULPDU\SXPSDQG96RXWSXW /LQHYROWDJHORDGSXPSWHUPLQDOV CAUTION 7KHLQWHUQDOSXPSUHOD\VDUH SURWHFWHGZLWK$PSIXVHV7KH maximum recommended load RQHDFKIXVHLV$PSVRI UDWLQJ7KHPD[LPXPFRPELQHG SXPSORDGLV$PSV,VRODWLRQ UHOD\VRUFRQWUDFWRUV0867EH used if the loads exceed these maximums. 1-33INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS NOTE 7KH,%&ERLOHUOLNHDQ\PRGHUQ appliance that contains HOHFWURQLFHTXLSPHQWPXVWKDYH D³FOHDQ´SRZHUVXSSO\DQGLV YXQHUDEOHWRSRZHUVXUJHVDQG VSLNHVOLJKWQLQJVWULNHVDQG RWKHUIRUPVRIVHYHUHHOHFWULFDO ³QRLVH´3RZHUFRQGLWLRQLQJ HTXLSPHQWVXUJHSURWHFWRUV $3&RU836GHYLFHVPD\EH UHTXLUHGLQDUHDVZKHUHSRZHU TXDOLW\LVVXVSHFW DANGER Do not connect thermistor VHQVRUVWR³7KHUP´WHUPLQDOV $QRYHUKHDWLQJKD]DUGFDQUHVXOW in serious personal injury and/or property damage. The boiler (primary) pump is connected to the White/Yellow pair labeled Primary Pump This lead is factory wired to the controller (and its 120 VAC supply) at the upper right backside of the controller board. Do not attempt to connect the primary pump to the Pump/ Zone Valve Terminal Block along the controller’s right edge - this is for the secondary pumps and/or zone valves only. Connect the pump’s Black wire to the Yellow of this pair (switched Hot). The White/ Yellow pair should be individually capped if the primary pump does not obtain its power from this pair (e.g. if a variable speed primary pump is connected to the mains power). Pumps can be switched on/off using the touchscreen controller, so there is no need for WHPSRUDU\SXPSZLULQJGXULQJV\VWHP¿OOLQJDLUSXUJLQJ In a new construction application, use a construction thermostat, or jumper with an in-line on/off switch – for on/off management of the boiler. Do not just remove power from the unit, or its moisture management routine will be interrupted (fan turns at ultra low rpm for 90 minutes after burner shutdown). Treat it like a computer, where you do not just pull the SOXJZKHQGRQH,IDQ³,QVXI¿FLHQWDLUÀRZFKHFNYHQW´HUURUVLJQDOVKRZVFKHFNIRUDQG remove) any water in the clear vinyl air reference tubes. This has been seen occasionally at construction sites where the boiler has been repeatedly de-powered wet. The combined current of all pumps connected through the on-board pump relays VKRXOGQRWH[FHHGDPSV7KHFRQWUROFLUFXLWERDUGLVSURWHFWHGXVLQJRQERDUG¿HOG replaceable fuses. Each pump is fused with a separate 5 Amp fuse. The Alarm contact is fused with a 5 Amp fuse and the 24 VAC boiler control circuit is protected with a 2 Amp fuse. The VS output leads are not commonly used, except when providing a variable speed signal to the fan in an IBC Air Handler. 1.8.2 Power Quality and Electrical Protection In areas of unreliable power, appropriate surge protectors and or power conditioning equipment should be installed in powers supply wiring circuits. 1.8.3 Zone Valve Hook-up If zone valves rather than pumps are used to manage multiple heating loads, then 24 VAC for the zone valves should be provided to the power contacts on the Pump/ Zone Valve Terminal Block. Disconnect the 120 Vac leads connected to PV-L/PV-N and cap off. Use a separate transformer – the 40 VA unit inside the wiring box is for internal systems only. The individual load/zone valves are then to be wired to their associated contacts on the secondary pump/zone valve connector. Do not confuse such “load/zone valves” with similar YDOYHVXVHGWRVHJUHJDWHDVLQJOHORDGW\SHHJWKRVHXVHGRQD]RQHGUDGLDQWÀRRU±see WKHQH[WVHFWLRQ 1.8.4 Thermostat / Sensor Wiring Dry contacts for thermostats for each of the four loads are provided as marked on the lower connector strip (e.g. “Therm 1”). Gang lines from a multiple-zoned load (e.g. off the end- VZLWFKHVIRUHDFKUDGLDQWÀRRU]RQHSUHVHQWDFRPPRQWKHUPRVWDWVLJQDOWRWKHFRQWUROOHU (QVXUHWKHUHDUHQRGLVWXUELQJLQÀXHQFHVRQWKHFDOOIRUKHDWOLQHVHJQRFRLOVWRVZLWFK an air handler motor. Most power stealing thermostats can be connected directly to the Therm terminals. 6HHWKH 97RXFKVFUHHQ%RLOHU&RQWUROOHU manual for more detailed instructions. NOTE 7KH,%&7RXFK6FUHHQFRQWUROOHU has the ability to connect to most power stealing thermostats. See the V-10 Touchscreen Boiler Controller manual for details. INSTALLATION AND OPERATION INSTRUCTIONS1-34 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 1.8.5 Other Wiring Other optional low voltage connections to the control board include: • Two auxiliary interlocks - for external safety devices as may be required by some jurisdictions, such as a low water cut-off or a low gas pressure cut-out (for off-grid propane). • Contacts for indoor and outdoor temperature sensors associated with reset heating. A 10K ohm thermister for outdoor reset sensing is supplied with the boiler for improved FRPIRUWDQGFRPEXVWLRQHI¿FLHQF\ • One pair for a DHW tank sensor. Connect to “DHW S” (not the respective Therm. 1,2,3,4 location), and the boiler automatically detects and calls a smart DHW routine. • One pair of contacts for remote secondary loop temperature control. • One pair (marked BoilerNet) for network connection – this is used for connecting multiple SL and/or VFC modulating units for autonomous staging. • The bottom pair of contacts receives a 0-10VDC (default) or 4-20 mA signal from an external boiler controller for direct throttle control. The boiler’s own sensors act as high limits only. The user must enter maximum and minimum boiler supply temperatures. NOTE: Sensors connected to any sensor input contacts must be of the NTC Thermister W\SHZLWKDUHVLVWDQFHRIRKPVDW&DQGȕ :HGRQRWUHFRPPHQGXVLQJ 3rd party supplied sensors. Compatible water temperature sensors and outdoor sensors can be supplied by your IBC distributor. 1.8.6 Thermostat Heat Anticipator IBC “Therm.” contacts draw no power, so an anticipator setting for the thermostat is not applicable with the SL modulating series boilers. In the case of a single temperature / heat load where zone valves are used to manage individual thermostatically controlled zones, each room thermostat’s heat anticipator should be adjusted to the current draw of its associated zone valve. 1-35INSTALLATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERSSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )LJXUH(OHFWULFDO:LULQJ&RQQHFWLRQVIXOOSDJHODGGHUGLDJUDPDWEDFNRIWKLVPDQXDO INSTALLATION AND OPERATION INSTRUCTIONS1-36 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK 2-1BOILER SYSTEMS AND OPERATION SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 2.0 IBC BOILER CONTROLLER 2.1 GENERAL 7KLVERLOHULVHTXLSSHGZLWKWKH9WRXFKVFUHHQFRQWUROOHU7KHFRQWUROOHUVLPSOL¿HVWKH SURJUDPLQJRIWKHERLOHUZKLOHSURYLGLQJJUHDWHUÀH[LELOLW\)RUPRUHGHWDLOHGLQVWUXFWLRQV reference the 7RXFK6FUHHQ%RLOHU&RQWUROOHU manual. The controller is equipped to provide: • Control of up to 5 pumps – 1 boiler pump + 4 separate load pumps • Outdoor Reset control • Set Point temperature regulation • Domestic Hot Water (DHW) • External control via 0-10VDC or 4-20mA signaling • Alarm dry contacts • Load Combining – simultaneous operation of 2 similar water temperature loads • The control can manage and/or operate in a network of up to 24 IBC VFC or SL boilers Some of the new features available in the touch screen control include: • Express Setup Menu for simple, quick programing • 6RIWZDUHXSGDWDEOHLQWKH¿HOGZLWKDQ6'FDUGRUD86%VWLFN • 6HWXSFRQ¿JXUDWLRQEDFNXSDQGFORQLQJXVLQJDQ6'FDUGRU86%VWLFN • Superior warning messages while setting up the control • Advanced Error messages with visual display on the Home Screen • Internet/LAN connectivity • BACnet (with activation) 2.2 CONTROL :KHQWKHERLOHULV¿UVWHQHUJL]HGWKHFRQWUROOHUZLOOJRWKURXJKDSRZHUXSVHTXHQFHWKDW will take approximately 90 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. The controller provides overall management of the boiler operations including; • Power-up, Self-diagnostics, easy Load parameter adjustments • Burner operation, safety management systems, Call for Heat management and Load Priority • Real time boiler data • Temperature and throttle operation • Maintenance of operational and error service logs • 2-way communication between other IBC boilers and controls WARNING No sharp or metallic object should be used on the touch screen as this will cause damage. Use only a Stylus or a FOHDQ¿QJHU´ INSTALLATION AND OPERATION INSTRUCTIONS2-2 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS Operational and historical data may be accessed at any time using the System Status DQG/RDG3UR¿OHVVHFWLRQVRIWKHFRQWURO(UURUORJVDUHDYDLODEOHLQWKH'LDJQRVWLFV section and the controller is capable of recording any or all errors since original power-up complete with the date and time of the error. 2.3 CONTROL INTERFACE The control interface is provided through a 2-1/4 x 4 inch, color touchscreen display. The WRXFKVFUHHQUHVSRQGVWRDOLJKW¿QJHUWRXFKRQWKHVFUHHQ<RXFDQDOVRXVHDVW\OXVRU similar device to operate the touch controls. Do not use a sharp or metallic object such as a screw driver to operate the control as it could damage the touch screen. The controller display is divided into two areas, the screen active area and the boiler status bar. All screens have an active area consisting of the screen title bar at the top and a border surrounding the active area. At the bottom of the display there is space reserved for the boiler status bar. Prior to any interaction with the touch screen, the display shows the Home screen with 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 with be dimmed to save power. The control will automatically return to the home screen if left unattended. The screens will step back one screen at a time in 10 minute increments if the touch screen 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 VWDWH7H[WLQVLGHWKHEDUZLOOLQGLFDWHWKHVSHFL¿FZDUQLQJRUDODUPSUHVHQW,IPRUHWKDQ one alarm is present the text display will slowly change, rotating though whatever alarms that are present. 3-1STARTUP AND COMMISSIONING SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 3.0 STARTUP & COMMISSIONING 3.1 LIGHTING & BOILER SHUTDOWN INSTALLATION AND OPERATION INSTRUCTIONS3-2 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 3.2 PRIOR TO START-UP 3.2.1 Pre-Ignition Checks 1. (QVXUHYHQWLQJV\VWHPLVFRPSOHWHDQGVHDOWHVWHG&RQ¿UPDQ\FRPPRQYHQWLQJ system at the installation site is isolated and independent of the SL boiler. Also FRQ¿UPWKDWDQ\KROHVOHIWIURPUHPRYDORIDSUHYLRXVERLOHUKDYHEHHQVHDOHGDQG WKDWDQ\UHVL]LQJRIWKHROGÀXHKDVEHHQGRQH)LOOWKHFRQGHQVDWLRQWUDS 2. &KHFNWKDWWKHZDWHUSLSLQJV\VWHPLVIXOO\ÀXVKHGDQGFKDUJHGDQGWKDWDOODLUKDV been discharged through loosened bleed caps. Note that it is possible to switch all SXPSVRQRIIIURPWKHNH\SDG±ZLWKRXWDFDOOIRUKHDW7KLVJUHDWO\VLPSOL¿HVV\VWHP ¿OOLQJDQGDLUEOHHGLQJJRWRInstaller Setup, drop down to Pump Purge and toggle to 2Q. When complete, return to 2II, or this will automatically occur with a call for heat). 8VHDPLQLPXPZDWHUSUHVVXUHRISVLJ$QGFRQ¿UPWKDWWKHSUHVVXUHUHOLHIYDOYH is installed and safely drained. 3. Check to see that adequate gas pressure is present at the inlet gas supply test SRUW2SHQWKHWHVWSRUWXVLQJDVPDOO´RUPPÀDWVFUHZGULYHUE\WXUQLQJLWV center-screw one full turn counterclockwise. Connect a manometer and open the gas control valve. Requirements are minimum 4” w.c and maximum 14” w.c. Check to ensure that there are no gas leaks. 4. 3HUIRUPD¿QDOFKHFNRIWKHHOHFWULFDOZLULQJDQGSURYLGHSRZHUWRWKHERLOHUWR initialize operation. 3.2.2 Test Ignition Safety Shutoff With the boiler in operation, test the ignition system safety shutoff device by shutting the gas control valve immediately outside the boiler case. Ensure boiler has shut off and the appropriate Error information is displayed on the Touch Screen. To restart boiler, reset power or press “Clear Errors” in the Advanced Diagnostics section. 3.3 COMMISSIONING The SL modulating boilers are factory calibrated to operate with natural gas (or propane if so ordered) at sea level. The Zero-offset valve adjustment cap has been factory sealed using red paint-seal compound. This cap must not be tampered with. The Zero-offset VFUHZLVQRWWREHDGMXVWHGLQWKH¿HOG The Gas:Air ratio adjustment screw may have to be adjusted to attain optimum combustion results if required, however, no mixture DGMXVWPHQWVKDOOEHSHUIRUPHGXQOHVVGRQHE\DTXDOL¿HGWHFKQLFLDQXVLQJSURSHUO\ functioning and calibrated combustion analyzing equipment. This boiler model can burn either Natural gas or Propane if equipped with the correct RUL¿FH([DPLQHWKHUDWLQJSODWHRIWKHERLOHUWRHQVXUHLWLVFRQ¿JXUHGIRUWKHIXHO\RXDUH XVLQJ,IWKHERLOHULVFRQ¿JXUHGIRUQDWXUDOJDVEXWQHHGVWREHFRQYHUWHGWRSURSDQHXVH WKHFRQYHUVLRQNLWLQFOXGHGZLWKWKHERLOHUWRLQVWDOOWKHDSSURSULDWH¿WWLQJVDQGDGMXVW the gas valve accordingly. See Table 8 to check that you have the correct conversion kit. The controller will automatically detect the installation’s altitude and make the appropriate adjustments to operate the boiler up to 4,500 feet in elevation without de-ration. The boiler will automatically de-rate at altitudes above 4,500 feet. Refer to the IBC Altitude tables for further information. WARNING Fill trap with water before boiler is ¿UVW¿UHGWRSUHYHQWH[KDXVWIXPHV IURPHQWHULQJURRP1HYHURSHUDWH WKHERLOHUXQOHVVWKHWUDSLV¿OOHG with water. Failure to comply will UHVXOWLQVHYHUHSHUVRQDOLQMXU\RU death. (UURUGLVSOD\HGDIWHUWHVWLQJLJQLWLRQ VDIHW\VKXWRII 3-3STARTUP AND COMMISSIONING SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 7RYHULI\WKHSURSHURSHUDWLRQRIWKHJDVYDOYHLQWKH¿HOGWKHIROORZLQJSURFHGXUHPXVW EHFDUULHGRXWE\DTXDOL¿HGWHFKQLFLDQVHH)LJXUHIRUGHWDLOVRIWKHJDVYDOYHDQG SUHVVXUHV\VWHP 1. :LWKDVPDOO´RUPPÀDWVFUHZGULYHURSHQWKHLQOHWJDVVXSSO\SUHVVXUHWHVW port by turning its center-screw one full turn counterclockwise. Attach a manometer to the pressure test port and turn on the gas to the appliance. The static manometer reading should be ideally 7” w.c. for Natural Gas and 11” w.c. for Propane. Minimum and maximum static pressure should be between 5” and 14” w.c. Monitor pressure throughout the commissioning procedure. Pressure may droop up to 1” to 2” w.c. at KLJK¿UHEXWXQGHUQRFLUFXPVWDQFHVVKRXOGLWGURSEHORZ´ZFDWWKHJDVYDOYH inlet test port. 2. $OORZWKHERLOHUWRLJQLWHUXQDJDLQVWDODUJHORDGWRPDLQWDLQKLJK¿UH <RXFDQWHPSRUDULO\GH¿QHDORDGDV0DQXDOIRUGLUHFWFRQWURORIWKHERLOHU¿ULQJUDWH as long as the load number is associated with a pump that can remove the heat. &ORVLQJWKHFRUUHVSRQGLQJ7KHUPFRQQHFWLRQLQLWLDWHVPDQXDO¿ULQJ 3. :LWKDFRPEXVWLRQDQDO\]HUSUREHLQWKHÀXHJDVWHVWSRUWWXUQWKH*DV$LU5DWLR Adjustment screw VHH)LJXUH to achieve results (VHH7DEOHbelow for the corresponding CO2 values - set the CO2WDUJHWDWKLJK¿UH7KLVVFUHZRIIHUVYHU\¿QH adjustment, and may require several turns. Note:7KLVVFUHZKDVVLJQL¿FDQWEDFNODVK:KHQFKDQJLQJGLUHFWLRQRIWXUQLWPD\ take up to a full turn before any change is indicated on the analyzer reading. Clock WKHJDVPHWHUWRFRQ¿UPIXOOPD[LPXPUDWLQJSODWHLQSXW 4. &RQ¿UPWKHPLQLPXP¿UHOHYHOVHWWLQJV5HGH¿QHWKHORDGDV³0DQXDO&RQWURO´ 8VH+HDW2XWSXWLQ³&RQ¿JXUH/RDG[´WRFRQWUROWKHRXWSXWDVQHHGHG7KHUHDGLQJ VKRXOGEHZLWKLQWKH/RZ¿UHUDQJH5HWHVWDWKLJK¿UH 5. 7XUQERLOHURIIE\UHPRYLQJWKHFDOOIRUKHDWXVHWKH+HDW/RDG&RQ¿JXUDWLRQVFUHHQ to turn load to off if no other ready means available), then remove the manometer connections, and turn the centre-screw in the manifold pressure test port 1 full turn clockwise. Ensure fully closed, but not over-tightened. Restore gas and soap test for leaks. FUEL HIGH FIRE LOW FIRE CO MAX PPM RANGE TARGET RANGE TARGET 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 Note: Low Fire CO2 should be at least 0.5% lower than High Fire CO2 7DEOH&RPEXVWLRQWHVWWDUJHWUDQJHV&220D[LPXP&2 DANGER 0DNLQJDGMXVWPHQWVWRWKH,%&JDV YDOYHZLWKRXWDSURSHUO\FDOLEUDWHG 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. WARNING &KHFNWKHUDWLQJSODWHRIWKH ERLOHUWRHQVXUHLWLVFRQ¿JXUHG for the fuel you are using. If the fuel is incorrect for the appliance, DFRQYHUVLRQNLWPXVWEHRUGHUHG IURP,%&DQGWKHJDVYDOYH adjusted accordingly. )DLOXUHWRSHUIRUPWKHUHTXLUHG IXHOFRQYHUVLRQFDQUHVXOWLQDQ immediate hazard. INSTALLATION AND OPERATION INSTRUCTIONS3-4 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 3.4 FUEL CONVERSION 7KH6/PRGXODWLQJERLOHUVDUHIDFWRU\¿UHWHVWHGWRRSHUDWHZLWKQDWXUDOJDVRUSURSDQH as ordered. The rating plate will be marked to indicate which fuel the particular boiler has been set up with. Firing a boiler with a fuel other than what is listed on the rating SODWHLVSURKLELWHGXQOHVVWKHIROORZLQJFRQYHUVLRQSURFHGXUHLVFRPSOHWHGE\DTXDOL¿HG technician. Refer to the preceding section 3.3 - COMMISSIONING. The Zero-offset valve adjustment cap on the gas valve has been factory sealed using red paint-seal compound. This cap PXVWQRWEHWDPSHUHGZLWK7KH=HURRIIVHWVFUHZLVQRWWREHDGMXVWHGLQWKH¿HOG )XHOFRQYHUVLRQUHTXLUHVKDUGZDUHDGMXVWPHQWVRUL¿FHLQVHUWLRQRUUHPRYDODVZHOODV measurement and possible tuning of the gas:air mixture. Detailed instructions including parts and labeling are found in the Fuel Conversion kits. )XHOFRQYHUVLRQVPXVWEHFDUULHGRXWE\DTXDOL¿HGWHFKQLFLDQ 1. Ensure you are installing the correct fuel conversion kit for your boiler. Compare the boiler model number with the Kit # found in Table 8. 2. Read the fuel conversion instructions supplied with the fuel conversion kit. 3. Carefully follow the procedures of the fuel conversion instructions on: • Fuel Conversion • Combustion Testing and Adjustment • Placing conversion labels associated with the new fuel onto the boiler. 4. Carefully follow the ³3ULRUWR6WDUW8S´±6HFWLRQDQG³&RPPLVVLRQLQJ´±6HFWLRQ SURFHGXUHVRQWKHSUHFHGLQJSDJHVDQG Fuel Conversion Kit Part Numbers MODEL NUMBER NATURAL GAS TO PROPANE PROPANE TO NATURAL GAS SL 10-85 G3/ SL 14-115 G3 P-304 P-305 SL 20-160 G3 P-306 P-307 SL 30-199 G3 P-308 P-309 7DEOH)XHO&RQYHUVLRQ.LWV DANGER 2SHUDWLQJDQ\,%&ERLOHUXVLQJ a fuel other than the fuel listed on its rating plate is prohibited. If the information in this section UHODWHGWRFRQYHUVLRQWR alternate fuels is not followed exactly, a dangerous situation FDQUHVXOWOHDGLQJWR¿UHRU explosion, which may cause property damage, personal injury, or loss of life. 3-5STARTUP AND COMMISSIONING SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS )LJXUH*DV9DOYHDQG3UHVVXUH5HIHUHQFH6\VWHP 3.4.1 Gaining access to the combustion chamber 1. Remove the fan and gas valve assembly. 6HH³)DQDQGJDVYDOYHUHPRYDO LQVWUXFWLRQV´RQSDJHRIWKLVPDQXDO 2. Disconnect the igniter cable, and move it out of the way. 3. Remove the two screws that secure the igniter to the lid. 4. Carefully remove the igniter by sliding it straight up. 5. Remove the igniter gasket, and place the parts on a clean dry area. 6. Remove the 6 hex nuts that attach the heat exchanger lid to the heat exchanger with a 10 mm open-end wrench or socket. 7. With a permanent marker, make an alignment mark between the lid, gasket, and heat exchanger. Before removing the lid, it is important to be positioned directly above it to ensure a straight-up extraction. Failing to do this may result in refractory damage. 8. Slowly lift the lid-burner assembly off the heat exchanger. The refractory should remain in place in the combustion chamber shoulder. Note that there is less than a 1/8” (3 mm) clearance between the burner walls and the refractory. Care must be observed to ensure minimal contact between these parts to prevent refractory cracking. 9. Place the lid with the burner attached on a clean dry area. 10. (To help later in re-assembling) With a permanent marker or equivalent, make an alignment mark on the refractory, lining it up with the same mark made earlier between the lid and heat exchanger. 11. Carefully remove the refractory, and place it in a clean dry area. INSTALLATION AND OPERATION INSTRUCTIONS3-6 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS NOTE 7KHVDIHW\ZDUQLQJUHJDUGLQJ EXUQHUUHIUDFWRU\RQSDJHRI WKLVPDQXDOPXVWEHREVHUYHG Re-assembly 1. ,QVSHFWWKHUHIUDFWRU\IRUFUDFNVGHJUDGDWLRQDQGÀDWQHVV,ILQGRXEWUHSODFHZLWKD new one. 2. ,ILQVWDOOLQJDQHZUHIUDFWRU\¿UVWSODFHLWRQWRWKHOLGDOLJQLQJLWDWWKHLJQLWHUKROH then make an alignment mark on the refractory to correspond with the previously made line on the lid. 3. Carefully insert the refractory into the heat exchanger combustion chamber, using the alignment marks for proper positioning. 4. Ensure that the lid gasket is in good condition, and is in place and level. 5. Carefully insert the lid-burner assembly straight down, ensuring limited contact between the burner and refractory and observing the alignment markings. 6. Install the six hex nuts to secure the lid in place. Tighten by hand, and then tighten with an extra 1/2 to 1 turn. Caution! Over-tightening these nuts will cause the lid to ZDUSDQGSRVVLEO\OHDNIXPHVRUÀDPHV 7. Re-install the igniter. Tighten the screws by hand, and then tighten with an extra 1/8 of a turn. 8. Re-attach the igniter wire to the igniter. 3.4.2 Removing the burner 3.4.2.1 Removing the burner - SL 10-85 G3, SL 14-115 G3, SL 20-160 G3 1. Turn off the power and the gas supply to the boiler. 2. Remove the front cover, and allow the boiler to cool down to the surrounding temperature. 3. Remove the 8 Torx screws around the fan coupler, and lift off the fan coupler carefully. Note: The fan coupler seals against the heat exchanger lid with a high temperature silicone O-ring. If the O-ring is damaged in any way it must be replaced. 4. Carefully pull the burner straight up. The burner is sealed to the heat exchanger lid with a graphite gasket. If the graphite gasket is damaged in any way it must be replaced. 3.4.2.2 Removing the burner - SL 30-199 G3 1. Turn off the power and the gas supply to the boiler. 2. Remove the front cover, and allow the boiler to cool down to the surrounding temperature. 3. Disconnect the igniter cable. 4. Remove the two screws that secure the igniter to the lid using a # 15 TORX screwdriver. 5. Carefully remove the igniter by sliding it straight up. 6. Remove the igniter gasket, and place the parts on a clean dry area. 7. Remove the two screws that attach the fan to the heat exchanger lid. 8. Remove the 8 hex nuts that attach the heat exchanger lid to the heat exchanger with a 10 mm open-end wrench or socket. 9. With a permanent marker or equivalent, make an alignment mark between the lid, gasket, and heat exchanger. 10. Before removing the lid, it is important to be positioned directly above it to ensure a straight-up extraction. Failing to do this may result in refractory damage. 11. Slowly lift the lid-burner assembly off the heat exchanger. The refractory should remain in place in the combustion chamber shoulder. Note that there is less than 1/8” (3 mm) clearance between the burner walls and the refractory. Care must be observed to ensure minimal contact between these parts to prevent refractory 3-7MAINTENANCE SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS cracking. 12. Place the lid with the burner attached, on a clean dry area. 13. With a permanent marker or equivalent, make an alignment mark on the refractory, lining it up with the same mark made earlier between the lid and heat exchanger. 14. Carefully remove the refractory, and place it in a clean dry area. 15. ,IWKHEXUQHUQHHGVWREHUHPRYHGJUDGXDOO\ORRVHQWKH¿YHVFUHZVWKDWVHFXUHWKH burner to the heat exchanger lid with a # 15 TORX screwdriver. Then remove the screws and the burner. 3.4.3 Installing the burner 3.4.3.1 Installing the burner - SL 10-85 G3, SL 14-115 G3, SL 20-160 G3 1. Place the burner gasket onto the heat exchanger lid in the recess. Note: The burner gasket has a notch that needs to be matched to the key in the recess. 2. Place the burner into the heat exchanger lid on top of the gasket. Note: The notch in the burner must match the key in the gasket. 3. Ensure that the O-ring is seated in the groove of the fan coupler, and place the fan coupler onto the heat exchanger lid. 4. Install the 8 fan coupler screws loosely, then tighten them slowly in a cross pattern so that the fan coupler is tightened to the lid evenly. 5. Turn on the power and the gas supply to the boiler. 6. Create a call for heat and inspect the fan coupler gasket for leaks. 7. Install the boiler door. 3.4.3.2 Installing the burner - SL 30-199 G3 1. Inspect the burner gasket: look for cracks, deterioration or signs of gas bypass. Replace if necessary. 2. 3ODFHWKHKHDWH[FKDQJHUOLGRQDÀDWVXUIDFHDQGSRVLWLRQWKHJDVNHWRQWKHOLG aligning it with the screw holes. 3. Install the burner in place with its four screws, tightening the screws gradually and in a cross sequence. Do not over tighten; tighten by hand plus an 1/8 of a turn to maintain a JRRGVHDODQGWRSUHYHQWGHIRUPDWLRQRIWKHEXUQHUÀDQJH 4. ,QVSHFWWKHUHIUDFWRU\IRUFUDFNVGHJUDGDWLRQDQGÀDWQHVV,ILQGRXEWUHSODFHZLWKD new one. 5. ,ILQVWDOOLQJDQHZUHIUDFWRU\¿UVWSODFHLWRQWRWKHOLGDOLJQLQJLWDWWKHLJQLWHUKROH then make an alignment mark on the refractory to correspond with the previously made line on the lid. 6. Carefully insert the refractory into the heat exchanger combustion chamber, using the alignment marks for proper positioning. 7. Ensure that the lid gasket is in good condition, and is in place and level. 8. Carefully insert the lid-burner assembly straight down. Ensure that there is limited contact between the burner and the refractory as well as observe the alignment markings. 9. Install the 8 hex nuts to secure the lid in place: a. 7LJKWHQWKHQXWVHYHQO\IROORZLQJWKHGLUHFWLRQDODUURZVVKRZQLQ¿JXUH b. Tighten by hand (until all nuts are equally snug) plus an extra 1/2 to 1 turn. Caution! Over-tightening these nuts will cause the lid to warp and possibly leak fumes or ÀDPHV 10. Re-install the igniter, tightening its screws by hand plus an extra 1/8 of a turn. 11. Re-attach the igniter wire to the igniter, gas valve cable and the two fan plugs.)LJXUH7LJKWHQLQJSDWWHUQ INSTALLATION AND OPERATION INSTRUCTIONS3-8 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK 4-1MAINTENANCE SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 4.0 MAINTENANCE 4.1 BOILER MAINTENANCE 4.1.1 General Care • .HHSFRPEXVWLEOHPDWHULDOVDQGÀDPPDEOHOLTXLGVDQGYDSRUVDZD\IURPWKHERLOHU • Keep vent terminals clear of obstructions (snow, dirt, etc.). 4.1.2 Inspection ,QVSHFWLRQRIWKHERLOHULVWREHSHUIRUPHGDQQXDOO\E\DTXDOL¿HGVHUYLFH technician. 4.1.3 Venting • Remove any obstructions from the vent terminals (e.g. leaves, dust, other debris). • &OHDQRUUHSODFHLQWDNHDLU¿OWHUVRUVFUHHQVDVUHTXLUHG • Check for holes or leaks in venting. Replace venting as needed. • Examine for any signs of moisture caused by sweating intake air pipes; insulate as required. • Ensure proper resealing or reinstallation of venting on each servicing. 4.1.4 Condensate Traps • The condensate trap must be examined every two months to see if cleaning is necessary UHIHUWRWUDSFOHDQLQJLQVWUXFWLRQVVHFWLRQRIWKLVPDQXDOEnsure that WKHWUDSKDVEHHQUH¿OOHGFRPSOHWHO\EHIRUH¿ULQJERLOHU • If condensate neutralization is used, check the pH level of condensate discharge. 4.1.5 Burner • Annually, remove the burner to inspect for fouling UHIHUWRWKHEXUQHUUHPRYDODQG UHDVVHPEO\LQVWUXFWLRQVVHFWLRQRIWKLVPDQXDO Blow clear using compressed air. Evaluate the magnitude of clearing required, and establish a reasonable burner inspection schedule. Some boiler / locations may call for annual service, others showing clean burners will only need attention every 2 – 5 years. Consider adding air ¿OWUDWLRQLIWKHEXUQHUUHTXLUHVFOHDQLQJHYHU\\HDU,QDOWHUQDWH\HDUVYLVXDOO\LQVSHFW WKHEXUQHUWKURXJKWKHVLJKWJODVV(QVXUHWKDWWKHÀDPHLVVWDEOHDQGLVZLWKRXW H[FHVVLYHÀXWWHULQJ1RUPDOÀDPHSDWWHUQLVHYHQO\GLVWULEXWHGRYHUWKHEXUQHUVXUIDFH • If the burner is operating improperly, remove and clean or replace. Use a CO2 analyzer to determine proper combustion. 6HH7DEOHIRUWKHFRUUHFWYDOXHV 4.1.6 Heat Exchanger During annual inspection (with the burner removed), examine the heat exchanger for signs of contamination and clean if necessary. In areas of poor gas quality, there may be a buildup of black plaque (typically sulfur). Other fouling agents may consist of: airborne dust, debris and volatiles. 5HIHUWR*DLQLQJDFFHVVWRWKHFRPEXVWLRQFKDPEHU6HFWLRQfor instructions on accessing to the combustion chamber and heat exchanger. Note that the safety warning regarding burner refractory on this page must be observed. WARNING /DEHODOOZLUHVSULRUWR GLVFRQQHFWLRQZKHQVHUYLFLQJ controls. Wiring errors can cause improper and dangerous operation. CAUTION 7KHRZQHULVUHVSRQVLEOHIRU general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition. WARNING :KHQHYHUWKHEXUQHULVUHPRYHG IRULQVSHFWLRQRUERLOHUVHUYLFLQJ WKHVHDOLQJJDVNHWVPXVWEH examined and replaced if damaged. Upon re-assembly, DQDSSURYHGOHDNWHVWVROXWLRQ must be applied around the EXUQHUÀDQJHVHDOLQJDUHDWR HQVXUHWKHUHLVQROHDNDJHRI combustible gas/air premix. WARNING Fill trap with water before boiler LV¿UVW¿UHGWRSUHYHQWH[KDXVW IXPHVIURPHQWHULQJURRP1HYHU operate the boiler unless the trap LV¿OOHGZLWKZDWHU Failure to comply will result in VHYHUHSHUVRQDOLQMXU\RUGHDWK INSTALLATION AND OPERATION INSTRUCTIONS4-2 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 4.1.7 Pump &KHFNWKDWWKHSXPSLVRQLQQRUPDORSHUDWLRQDQGWKDWWKHZDWHUǻ7LVUHDVRQDEOHIRUD JLYHQ¿ULQJUDWHHJ)EHWZHHQVXSSO\DQGUHWXUQZKHQ¿ULQJDW%WXKU 4.1.8 Gas Piping Check for damage or leaks and repair as needed. 4.1.9 Touchscreen Controller • Check that the boiler operation is consistent with the steps in the Touch Screen Boiler Controller manual. • Check that the water temperature targets and set-point are satisfactory and that they have not been adversely amended. • Check the operating history via the boiler’s Logs menu and the Error Logs menu. The controller tracks the duty cycle of the boiler in each of the four loads separately. This information can be used to adjust the water temperatures of each load • If a problem exists with the controller, consult the Troubleshooting section. 4.1.10 Water • Check the water pressure and temperature. There should be no noticeable change if the boiler is functioning normally. Check for any noise in the system. • Check the water piping for damage or leaks. Repair as needed. • Check for 12-15 psig in normal operation, and look to ensure pressure does not run up toward 30 psig at high temperature. If pressure rises sharply, consider replacement of WKHH[SDQVLRQWDQN&KHFNDOVRIRUQRLVHDWKLJK¿UHZKLFKPD\VLJQDOZDWHUTXDOLW\ problems. • Water chemistry shall be of a quality generally accepted as suitable for hydronic applications. 6HH6HFWLRQIRUGHWDLOV • (QVXUHDQ\GLUHFW³FLW\¿OO´ZDWHUFRQQHFWLRQVDUHOHIWLQWKHclosed position to minimize H[SRVXUHWROHDNVDQGÀRRGLQJ 4.1.11 Freeze Protection &KHFNWKHIUHH]HSURWHFWLRQ8VHRQO\DQWLIUHH]HPDGHVSHFL¿FDOO\IRUK\GURQLFV\VWHPV Inhibited propylene glycol is recommended. Antifreeze volume must not exceed 50% of the total volume of water in the system. 4.1.12 Boiler Treatment • Check consistency of any boiler treatment used, for appropriate mixture. Chemical inhibitors are consumed over time, lowering their density. • Verify proper operation after servicing. CAUTION 7KHKHDWH[FKDQJHUKDVDVPDOO amount of combustion chamber LQVXODWLRQUHIUDFWRU\ZKLFK FRQWDLQVFHUDPLF¿EHUV When exposed to extremely high WHPSHUDWXUHVWKHFHUDPLF¿EHUV which contain crystalline silica, FDQEHFRQYHUWHGLQWRFULVWREDOLWH ZKLFKLVFODVVL¿HGDVDSRVVLEOH human carcinogen. &DUHVKRXOGEHWDNHQWRDYRLG disturbing or damaging the refractory. If damage occurs, contact the factory for directions. $YRLGEUHDWKLQJDQGFRQWDFWZLWK VNLQDQGH\HVDQGIROORZWKHVH precautions: )RUFRQGLWLRQVRIIUHTXHQW XVHRUKHDY\H[SRVXUH UHVSLUDWRUSURWHFWLRQLVUHTXLUHG 5HIHUWRWKH³1,26+*XLGHWRWKH Selection and Use of Particulate 5HVSLUDWRUV&HUWL¿HGXQGHU &)5´IRUVHOHFWLRQDQGXVHRI UHVSLUDWRUVFHUWL¿HGE\1,26+ For the most current information, 1,26+FDQEHFRQWDFWHGDW RURQWKHZHEDW ZZZFGFJRYQLRVK :HDUORQJVOHHYHGORRVH ¿WWLQJFORWKLQJJORYHVDQGH\HV protection. $VVXUHDGHTXDWHYHQWLODWLRQ :DVKZLWKVRDSDQGZDWHU after contact. :DVKSRWHQWLDOO\FRQWDPLQDWHG clothes separately from other laundry and rinse washing machine thoroughly. 'LVFDUGXVHGLQVXODWLRQLQDQ air tight plastic bag. 1,26+VWDWHG¿UVWDLG Eye contact - Irrigate and wash immediately. %UHDWKLQJ3URYLGHIUHVKDLU 4-3MAINTENANCE SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 4.1.13 Relief Valve - Maintenance and Testing The relief valve manufacturer requires that under normal operating conditions a “try lever test” must be performed every two months. Under severe service conditions, or if corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be performed at the end of any non-service period. Test at or near the maximum operating pressure by holding the test lever fully open for at OHDVWVHFRQGVWRÀXVKWKHYDOYHVHDWIUHHRIVHGLPHQWDQGGHEULV7KHQUHOHDVHWKHOHYHU and permit the valve to snap shut. If the lever does not activate, or there is no evidence of discharge, discontinue use of HTXLSPHQWLPPHGLDWHO\DQGFRQWDFWDOLFHQVHGFRQWUDFWRURUTXDOL¿HGVHUYLFHSHUVRQQHO ,IWKHUHOLHIYDOYHGRHVQRWFRPSOHWHO\VHDODQGÀXLGFRQWLQXHVWROHDNIURPWKHGLVFKDUJH SLSHSHUIRUPWKHWHVWDJDLQWRWU\DQGÀXVKDQ\GHEULVWKDWPD\EHORGJHGLQWKHYDOYH ,IUHSHDWHGWULHVIDLOWRVWRSWKHOHDNDJHFRQWDFWDOLFHQVHGFRQWUDFWRURUTXDOL¿HGVHUYLFH personnel to replace the valve. :KLOHSHUIRUPLQJD³WU\OHYHUWHVW´DTXDQWLW\RIKHDWWUDQVIHUÀXLGZLOOEHGLVFKDUJHGIURP WKHSLSLQJV\VWHPDQGWKHV\VWHPSUHVVXUHZLOOGURS7KLVÀXLGPXVWEHUHSODFHG,WLV highly recommended that a system pressurization unit, such as an $[LRP,QGXVWULHVPRGHO 0)EHHPSOR\HGWRUH¿OODQGSUHVVXUL]H\RXUV\VWHP&DSWXUHWKHGLVFKDUJHGÀXLG in a container and recycle it by returning it to the system feeder unit. This is particularly important when your system contains treatment chemicals or glycol solutions. If the V\VWHPHPSOR\VSODLQZDWHUWKHERLOHUDXWR¿OOYDOYHPXVWEHWXUQHGRQLQRUGHUWR UHFKDUJHWKHORVWÀXLG CAUTION %HIRUHWHVWLQJWKHUHOLHIYDOYH PDNHFHUWDLQWKHGLVFKDUJHSLSH is properly connected to the YDOYHRXWOHWDQGDUUDQJHGWR contain and safely dispose of HTXLSPHQWGLVFKDUJH INSTALLATION AND OPERATION INSTRUCTIONS4-4 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 4.2 GEOGRAPHY & COMPONENTS 1 Safety Ignition Module 7 Gas Valve 13 Supply Water Pipe 2 Ignitor 8 Air pressure switch (behind bracket)14 Combustion Test Port 3 Site Glass 9 Touchscreen controller 15 Fan Coupler 4 Combustion Fan 10 Return Water Temperature Sensor 16 Return Water Pipe (behind - on the right side) 5 Flue Gas Temperature Sensor (behind the combustion fan)11 Low Water Cutoff Probe 17 Gas Tube 6 Supply Water Temperature Sensor 12 Water Pressure Sensor (behind the touchscreen controller) 4-5MAINTENANCE SL 20-115 G2 MODULATING GAS BOILERSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 4.2.1 Fan and gas valve removal instructions 1. Turn off the power and the gas supply to the boiler. 2. Remove the front cover, and allow the boiler to cool down. 3. Disconnect the electrical plug attached to the fan. 4. Undo the union nut at the gas valve outlet (see Figures 45 and 46). Carefully remove WKHRUL¿FHDQG2ULQJDQGNHHSWKHPLQDVDIHSODFHIRUUHLQVWDOODWLRQODWHU(QVXUH you protect the gas valve outlet from dust and debris. 5. Remove the two hex nuts connecting the fan to the fan coupler, and carefully remove WKHIDQ<RXZLOO¿QGDJDVNHWDWWDFKHGWRWKHIDQ 6. If the removed fan is to be re-installed, ensure the fan and venturi are clean and dust free. 7. Remove the electrical connection from the gas valve. 8. To remove the gas valve, undo the union nut on the inlet of the gas valve. 9. Retain the gasket. 10. To install the new gas valve, with the gasket in position, tighten the union nut to the inlet of the gas valve. 4.2.2 Fan and gas valve re-assembly instructions 1. Place the fan gasket on the outlet of the fan coupler. 2. Attach the fan to the burner housing, and install the two hex nuts. Tighten the two hex nuts with a wrench. 3. ,QVHUWWKHRUL¿FHDQG2ULQJEHWZHHQWKHJDVYDOYHRXWOHWDQGWKHJDVOLQHWRWKHIDQ Tighten the gas valve union nut with a wrench. Ensure the gas valve inlet (lower) nut is tight. 4. Connect the electrical plug to the fan. 5. Restore the gas supply to the boiler, and test the gas valve inlet for gas leaks. 6. Restore power to the boiler and create a call for heat or hot water. 7. Check for leaks at the gas valve outlet and the connection between the fan and the burner housing. 8. Install the cover to the boiler. 9. Reset the boiler to normal operation. DANGER :KHQUHSODFLQJWKHIDQWKHYHQ- WXULPXVWEHPRYHGIURPWKHROG fan to the new fan. Failure to relocate these parts to the new fan may cause an immediately hazardous situation, which must be DYRLGHGLQRUGHUWRSUHYHQW serious injury or death )LJXUH*DV9DOYHDQG)DQFRPSRQHQWV INSTALLATION AND OPERATION INSTRUCTIONS4-6 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK 5-1TROUBLESHOOTING SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 5.0 TROUBLESHOOTING The troubleshooting section is divided into 3 sections: • 5.1 Preliminary Checks • 5.2 Electronic Components • 5.3 Troubleshooting Guide 2IWHQDSUREOHPFDQEHLGHQWL¿HGDQGVROYHGWKURXJKVLPSOHFKHFNVRIWKHEDVLFV FRQ¿UPLQJWKHHOHFWULFDOSRZHUVXSSO\JDVÀRZDQGUHVHWWLQJWKHWKHUPRVWDWFRQWURO7R extend the cover of such preliminary checks, the boiler’s touchscreen controller offers a clear visual display of the status of the various control circuit components. Should a problem remain unsolved after applying the preliminary checks, proceed to the detailed system review, using the Troubleshooting section. It covers potential error conditions grouped into the following categories: • 5.3.1 Using Control Module Errors Displayed • 5.3.2 Ignition Problems • 5.3.3 Cycling Problems • 5.3.4 Temperature Problems • 5.3.5 Miscellaneous Below each section is a list of Symptoms, Diagnoses, and Remedies. Also provided with this manual are a number of diagrams VHH6HFWLRQ for use with troubleshooting including: • Electrical Wiring Diagrams • Sequence of Operations Flowchart • Boiler Component Layout Diagrams 5.1 PRELIMINARY CHECKS 7KH¿UVWVWHSLQWURXEOHVKRRWLQJWKLVV\VWHPVKRXOGEHDUHYLHZRIWKHFRQWUROOHU¶V touchscreen. There are a number of diagnostic features incorporated in the software that evaluate system integrity, display error conditions, and provide initial remedial actions. In addition to checking the display, the following list is a guideline for troubleshooting: 1. &RQ¿UPSRZHUWRWKHERLOHUFKHFNWKDWWKHWRXFKVFUHHQFRQWUROOHULVRQHJGLVSOD\ is lit. The touchscreen controller’s display will be fully functional in 90 seconds after power is restored to the boiler.) 2. Check that the boiler is not in a safety lockout. 3. Ensure wiring is clean and secure. 4. Check that gas is reaching the unit. 5. &RQ¿UPWKDWWKHZDWHUV\VWHPLVSURSHUO\FKDUJHGWRSVLJDQGWKDWWKHSXPSLV serviceable. NOTE 7KLVERLOHULVHTXLSSHGZLWKD EORFNHGYHQWVKXWRIIV\VWHP which closes the gas supply upon detection of an irregular YHQWLQJFRQGLWLRQ,QVXFKHYHQW the electronic controller will automatically carry out a reset/ UHWU\HYHU\PLQXWHV INSTALLATION AND OPERATION INSTRUCTIONS5-2 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 5.2 ELECTRONIC COMPONENTS This section details the method for troubleshooting the non-standard electronic components on the boiler including the electronic differential air pressure sensor and the temperature sensors. 5.2.1 Temperature Sensors The resistance of the temperature sensors varies inversely with temperature. To 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 FDSDEOHRIPHDVXULQJXSWRNȍȍDWWKHFRQWUROOHUHQGRIWKHVHQVRU lead). To obtain a resistance reading, remove power to the boiler. For the supply water and return water temperature sensors, remove the wire leads by disconnecting their respective Molex connectors. Place multi-meter probes into the sensor’s female Molex connector socket. Do not apply voltage to the sensor as damage may result. TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE °F °C ȍ °F °C ȍ 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 32 7,334 190 88 983 95 35 6,532 195 91 903 7DEOH7HPSHUDWXUH6HQVRUUHVLVWDQFHYDOXHV 5-3TROUBLESHOOTING SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 5.2.2 Fan The fan is controlled by the SIM+, and powered via one cable. 5.2.3 Water Pressure Sensor The water pressure sensor ensures that there is adequate pressure in the heating system for safe operation. The pressure is displayed in PSI as the default. If the system pressure VKRXOGGURSEHORZ36,WKH¿ULQJUDWHRIWKHERLOHULVUHGXFHG,IWKHSUHVVXUHGURSVWR 36,RUORZHUWKHERLOHUZLOOQRW¿UH Check operation of the sensor by isolating the boiler from its system piping. Close the V\VWHP¿OOYDOYHDQGWKHQFUDFNWKHSUHVVXUHUHOLHIYDOYH7KHSUHVVXUHGLVSOD\HGVKRXOG UHÀHFWGHFOLQLQJSUHVVXUH,ILWUHPDLQV³¿[HG´GUDLQWKHERLOHUDQGUHSODFHWKHVHQVRURU dislodge any blocking debris from the sensor inlet channel and reinsert. 5.2.4 Safety and Ignition Module (SIM+) The SIM+LVDVDIHW\FRQWUROWKDWLVFHUWL¿HGWRFRQIRUPWRWKH8/DQG$16, Z21.20-2014 • CAN/CSA-C22.2 No. 60730-2-5-14 Standards. The low water cutoff function and the high temperature manual reset function also conform to these standards. The SIM+ directly controls the boiler’s gas valve and provides: • Direct spark automatic ignition • Flame detection and current measurement • Supply water temperature sensing • Flue gas temperature sensing • Supply water maximum temperature shutdown • Flue gas maximum temperature shutdown • Low water cut-off. INSTALLATION AND OPERATION INSTRUCTIONS5-4 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS The SIM’s two status LEDs indicate the operating status as shown in the table below. Status Indicators 7DEOH6WDWXVLQGLFDWRUV The SIM is continuously communicating with the boiler’s main controller reporting sensor readings and status. The sensor readings and error status (if any) are displayed on the boiler controller’s screen. 5.2.4.1 Low water cutoff function: reset and test The low water cutoff (LWCO) function provides continuous protection against a low water incident. If the SIM detects a low water incident, the boiler goes into a lockout condition. Here, you will need to reset the boiler. To test the LWCO on the boiler, you can also manually place the boiler in a lockout condition. Resetting the boiler after a LWCO lockout Before you reset the boiler, ensure that the boiler is pressurized and that the air has been removed. 1. On the touchscreen controller, tap the Home screen. 2. On the Main Menu, tap the Diagnostics button. 3. Tap the Advanced Diagnostics button. 4. Tap the Clear Errors button. 5. Tap the Yes radio button, and then tap OK. The system clears the errors, and resets the boiler. Testing the LWCO function 1. On the touchscreen controller, tap the Home screen. 2. On the Main Menu, tap the Diagnostics button. LED 1 LED 2 STATE DESCRIPTION, LED STATUS INDICATION Rapid Flash Rapid Flash Power up or Resetting Startup checks and initialization Off Off Standby LED1 Off = No Flame or Sparking LED 2 = Burner-On Call state Off On Pre-Purge or Inter-Purge LED1 Off = No Flame or Sparking LED 2 = Burner-On Call state On On Heating LED 1 On = Flame detected LED 2 = Burner-On Call state Rapid Flash On Igniting /('ÀDVKLQJ (OHFWURGH6SDUNLQJ LED 2 = Burner-On Call state Off Flashing Lockout An operating limit was exceeded or a sequence failed or an external sensor fault was detected. Flash Alternately with LED 2 Flash Alternately with LED 1 Fail-Safe A critical internal fault was detected. 5-5TROUBLESHOOTING SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 3. Tap the SIM Module button. 4. Tap the LWCO Test button. 5. Disconnect the yellow wire from the LWCO function. A message on the screen indicates that the boiler is in lockout mode. 6. To reset the boiler, reconnect the yellow wire to the LWCO function. 7. On the touchscreen controller, tap the Reset button. The message: “The SIM Module has been reset” is displayed. 8. Tap the Close button, and then tap the Back button until you return to the Home screen. 5.2.4.2 Hi-limit temperature manual reset function: reset and test The hi-limit temperature function monitors the hi-limit temperature set in the SIM. If the water temperature exceeds the hi-limit temperature, the boiler goes into a lockout condition, requiring a manual reset. You can test the hi-limit cutoff temperature function on the boiler. Resetting the boiler after a Hi-Limit lockout Before you reset the boiler, ensure that the boiler is pressurized and that the air has been removed. 1. On the touchscreen controller, tap the Home screen. 2. On the Main Menu, tap the Diagnostics button. 3. Tap the Advanced Diagnostics button. 4. Tap the Clear Errors button. 5. Tap the Yes radio button, and then tap OK. The system clears the errors, and resets the boiler. Testing the Hi-Limit cutoff temperature function 1. On the touchscreen controller, tap the Home screen. 2. On the Main Menu, tap the Diagnostics button. 3. Tap the SIM Module button. 4. Tap the Hi-Limit Test button. You will need to enter a cutoff temperature below the Supply Temp. value currently displayed. For example, if the Supply Temp. value is 180°F, enter 170°F in the Cut Off Temp. box. 5. Tap inside the Cut-Off Temp. box, and then tap a number value. 6. Tap the OK button. The message: “Hi-Limit Detected” is displayed. 7. To reset the boiler, select the Reset button. The message: “The SIM module has been reset” is displayed. 8. Tap the Close button, and then tap the Back button until you return to the Home screen. INSTALLATION AND OPERATION INSTRUCTIONS5-6 SL 20-115 G2 MODULATING GAS BOILERSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 5.3 TROUBLESHOOTING SYMPTOM DIAGNOSIS REMEDY MAXIMUM IGNITION TRIALS ERROR 7RXFK6FUHHQ0HVVDJH (UURU±,JQLWLRQ)DLOXUHDIWHU tries %RLOHUKDVIDLOHGWRLJQLWHRQ VXFFHVVLYHDWWHPSWV%RLOHULQ ORFNRXWIRUKRXUWKHQUHSHDWV WU\VHT&RQVXOWVHUYLFH WHFKQLFLDQLIHUURUUHFXUV 1RVSDUNZKHQLJQLWLQJ ,JQLWHUSUREHÀDPH sensor disconnected. Check that igniter lead is secure at the control module and at the probe. 0DQXDOJDVVKXWRIILV closed or gas line not fully purged. &KHFNIRUJDVÀRZ2SHQPDQXDOJDVVKXWRIIDQG reset boiler. Gap between igniter probe rods is too large or too small. Adjust ignitor probe rod gap between 1/8th and 3/16th (3.2-4.7mm). 6SDUNEXWQRLJQLWLRQCheck spark module is sending power to gas valve – close gas supply, then disconnect (black) electric housing from face of gas valve, gently spread plastic tabs to open, and look for 24vac voltage during an ignition cycle. Replace module if no current detected %RLOHULJQLWHVEXWVKXWV off at the end of the ignition trial. Improperly JURXQGHGSUHVVXUHYHVVHO EXUQHURUXQVHUYLFHDEOH LJQLWLRQOHDGRUVSDUN module. • Ensure pressure vessel is grounded. • &KHFNWKHLJQLWHUSUREHÀDPHVHQVRULVHOHFWULFDOO\ isolated from the vessel, and its ceramic insulator is intact. • Replace ignition lead • Replace spark module HI LIMIT CUTOFF TEMPERATURE ERROR 7RXFKVFUHHQPHVVDJH (UURU±:DWHU+LJK/LPLW Exceeded Water temperature H[FHHGVKLOLPLW%RLOHULV LQKDUGORFNRXWPRGH See Section 5.2.4. LOW WATER CUTOFF ERROR 7RXFKVFUHHQPHVVDJH (UURU/RZ:DWHU&XWRII 7KH6DIHW\DQG,JQLWLRQ module has detected a low water condition. See Section 5.2.4. 5.3.1 Using Control Module Errors Displayed WARNING 1HYHUDWWHPSWWRUHSDLUWKH FRQWUROPRGXOHFLUFXLWERDUG,I WKHFRQWUROPRGXOHLVGHIHFWLYH replace it immediately. 5-7TROUBLESHOOTING SL 20-115 G2 MODULATING GAS BOILERSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS SYMPTOM DIAGNOSIS REMEDY TEMPERATURE SENSOR ERROR 7RXFK6FUHHQ0HVVDJH (UURU0D[,Q2XW7HPS([FHHG !&KHFNZDWHUÀRZ :DWHU WHPSHUDWXUHVLJQDOQRWZLWKLQ DFFHSWDEOHUDQJH3RWHQWLDOÀRZ RUVHQVRUIDLOXUH&RQVXOWVHUYLFH WHFKQLFLDQ &XUUHQWRXWOHW temperature exceeds operating limit. • &KHFNZDWHUÀRZ 'HIHFWLYHRU disconnected temperature sensor. • Check wiring to temperature sensor and control module. • Check temperature sensor. 6HH6HFWLRQ MISCELLANEOUS 7RXFK6FUHHQ0HVVDJH %ODQN±VFUHHQGDUNEXWIDQ UXQQLQJ ,QGLFDWLYHRISRZHUVXUJH GDPDJHWRDSSOLDQFH • Check transformer; replace if damaged. • Check circuit board for visible damage. INSTALLATION AND OPERATION INSTRUCTIONS5-8 SL 20-115 G2 MODULATING GAS BOILERSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 5.3.2 Ignition Problems SYMPTOM DIAGNOSIS REMEDY NOISY SPARK WHEN IGNITING ,JQLWLRQOHDGLVQRW¿UPO\ connected. Reconnect ignition lead. &RQWDPLQDQWVPRLVWXUH RQLJQLWHUSUREHÀDPH sensor. Ensure probe is dry by re-running post-purge; otherwise, clean or replace igniter probe. BOILER RUMBLES WHEN IGNITING. Fluctuating gas pressure/ gas pressure too high/too low. Check CO2 level via analyzer. &KHFNIRUSURSHUJDV piping. Check pressure with manometer during ignition. BOILER WILL NOT ATTEMPT TO IGNITE. FAN AND PUMP ARE OPERATING NORMALLY. No power to ignition control module. • Check system wiring. • Check air reference tubing. ,JQLWHUSUREHÀDPH sensor disconnected. Reconnect probe. 'HIHFWLYH&RQWURO 0RGXOH Check ignition output from control module. BOILER WILL NOT ATTEMPT TO IGNITE. FAN AND / OR PUMP ARE OFF DISPLAY NOT ILLUMINATED No power to boiler.Check line voltage . 'HIHFWLYHWUDQVIRUPHUCheck transformer. Reconnect or replace as needed. 5-9TROUBLESHOOTING SL 20-115 G2 MODULATING GAS BOILERSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 5.3.3 Cycling Problems SYMPTOM DIAGNOSIS REMEDY RAPID CYCLING ,PSURSHUYDOXHVHQWHUHG YLDNH\SDG Check load maximum temps are above target temps, by 1/2 of the selected boiler differential. Ensure boiler differential is OK (16-30°F is generally adequate) ([FHVV&RQGHQVDWHLQ YHQWLQJ Check venting slopes on horizontal runs. Look for sags. 2EVWUXFWLRQLQ condensate trap. Inspect and clean condensate trap. ,PSURSHUYHQWOHQJWKRU LPSURSHUVORSHWRYHQW Check venting. Compare vent length and diameter to 7DEOH0D[LPXP9HQWLQJ Incorrect settings or GHIHFWLYHWKHUPRVWDW Check operation. Refer to manufacturer’s instructions. Check setting with ammeter. Air in system or marginal ZDWHUÀRZ %OHHGSXUJHV\VWHPDVUHTXLUHG&RQ¿UPDGHTXDWH pump size and temp rise in HX Slow combustion air blower. Check that CO2OHYHOLVZLWKLQVSHFL¿FDWLRQ Dirty burner/heat exchanger. Check pressure drop. ,QVXI¿FLHQWZDWHUÀRZ due to improper piping. Refer to recommended piping in 6HFWLRQ RAPID CYCLING ,QVXI¿FLHQWZDWHUÀRZ due to undersized pump. Check manufacturer’s rating charts/check temperature differential across heat exchanger. ,QVXI¿FLHQWZDWHUÀRZ due to restrictions in water pipe. Check temperature differential across zone/heat exchanger. ,QVXI¿FLHQWUDGLDWLRQCheck actual amount of radiation per zone and refer to manufacturer’s rating tables. 8QLWRYHU¿UHGClock gas meter/check gas pressure with manometer/ check CO2 level. 8QLW2YHUVL]HGCheck load calculation vs. min. boiler output. Improperly set or GHIHFWLYHRSHUDWLQJ safety controls. Check operation with ohmmeter/voltmeter. INSTALLATION AND OPERATION INSTRUCTIONS5-10 SL 20-115 G2 MODULATING GAS BOILERSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 5.3.4 Temperature Problems SYMPTOM DIAGNOSIS REMEDY INSUFFICIENT HEAT 2SHUDWLQJWHPSHUDWXUH too low. Increase temperature target. Priority parameters RUORDGFRQ¿JXUDWLRQ improperly set up. 5HYLHZORDGFRQ¿JXUDWLRQSDUDPHWHUV Unit undersized.Refer to Load Calculation vs. Boiler Output. Air trapped within system. Bleed system as required. Improper system piping. Refer to recommended piping in 6HFWLRQ System pump undersized. Check pump manufacturer’s data/check temp differential across heat exchanger. Poor gas/air mixing.Check CO2 level. 'HIHFWLYHWKHUPRVWDWRefer to manufacturer’s instructions. 2EVWUXFWLRQLQ condensate drain. Inspect and clean condensate drain. Unit cycling on operating/ safety controls. Check operation with Ohmmeter/Voltmeter. System radiation undersized. Check manufacturer’s rating tables for capacity per foot. TEMPERATURE EXCEEDS THERMOSTAT SETTING Incorrect anticipator setting. Check with Ammeter. 7KHUPRVWDWQRWOHYHOCheck level. ONE OR MORE ZONES DO NOT HEAT PROPERLY Air trapped within ]RQHVSLSLQJ Vent system/zone as required. ,QVXI¿FLHQWUDGLDWLRQ H[FHVVLYHKHDWORVV Check actual length of pipe using radiation / heat loss calculation. ,QVXI¿FLHQWÀRZUDWHWR ]RQHV Check temperature drop across zone. 'HIHFWLYH]RQHYDOYH zone circulator. Check operation per manufacturer’s instructions. 5-11TROUBLESHOOTING SL 20-115 G2 MODULATING GAS BOILERSL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 5.3.5 Miscellaneous SYMPTOM DIAGNOSIS REMEDY FUMES AND HIGH HUMIDITY Improperly installed condensate trap Refer to installation/operation instructions /HDNLQYHQWSLSLQJ Inspect using soap solution )OXHJDVOHDNZLWKLQERLOHU Visually inspect all mechanical connections BOILER STUCK ON INITIALIZE Fan board failure Replace fan. ‘GHOST’ CALL FOR HEAT.7ULDFRUµ3RZHUUREELQJ¶ thermostat sending current to boiler. 5HPRYH7KHUPFRQQHFWLRQVIURPERLOHUWRFRQ¿UP that stray voltage, or current induced in thermostat wiring, is source of nuisance signal. Replace the Power Robbing thermostat, isolate the thermostat with a relay or install a properly sized resistor FRQVXOWWKHWKHUPRVWDWPDQXIDFWXUHU¿UVWWKHQ,%& for instructions). ERROR: WATER HIGH LIMIT / LOW WATER CUT-OFF WON’T CLEAR. %RLOHULVLQKRXUVDIHW\ ORFNRXW Reset safety device and clear the error in the Advanced Diagnostics menu. DHW TAKING TOO LONG TO HEAT. Sensor may be under-reading actual water temp. Check sensor engagement; note well is 15cm / almost 6 inches deep and sensor must be fully set to back. Check programmed settings boiler temp is not set too close to the required DHW temp BOILER OUTPUT NOT MODULATING UP TO MAXIMUM DESPITE TARGET NOT BEING REACHED. 3RVVLEOHÀRZLVVXHFKHFNIRU RUGHJUHH)WHPSHUDWXUH difference between boiler supply and return water WHPSHUDWXUHVHYRNHV HOHFWURQLFIHQFH &RQ¿UPWKDWSULPDU\SXPSLVDEOHWRRYHUFRPH head loss of boiler and primary loop piping at the UHTXLUHGÀRZUDWH PRIMARY PUMP RUNS BUT LOAD PUMPS DO NOT. Wiring not complete.Supply power to the PV/L and PV/N terminals from the incoming power supply to the boiler. (Factory wired on boilers with a factory installed Touch Screen Controller) PRIMARY PUMP RUNS DURING PARALLEL-PIPED DHW CALL. %RLOHUSXPSVHWWRRQ5HGH¿QH'+:ORDGDV'+:/RRSEXWWRQ Controls) to turn off primary pump during domestic hot water calls. On Touch Screen Controllers set the boiler pump to off in the Installer Set-up Menu. INSTALLATION AND OPERATION INSTRUCTIONS5-12 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS THIS PAGE IS INTENTIONALLY LEFT BLANK 6-1DIAGRAMS SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 6.0 DIAGRAMS This section includes: • Parts diagrams • Wiring diagrams • Sequence of operation INSTALLATION AND OPERATION INSTRUCTIONS6-2 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 6.1 PARTS DIAGRAMS 'LDJUDP%RLOHUDVVHPEO\SDUWV SL 10-85 G3/ SL 14-115 G3 Modulating Boiler - Parts assembly 6-3DIAGRAMS SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS INSTALLATION AND OPERATION INSTRUCTIONS6-4 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS SL 20-160 G3 Modulating Boiler - Parts assembly 'LDJUDP%RLOHUDVVHPEO\SDUWV 6-5DIAGRAMS SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS INSTALLATION AND OPERATION INSTRUCTIONS6-6 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS SL 30-199 G3 Modulating Boiler - Parts assembly 'LDJUDP%RLOHUDVVHPEO\SDUWV 6-7DIAGRAMS SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS INSTALLATION AND OPERATION INSTRUCTIONS6-8 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 'LDJUDP/DGGHUZLULQJGLDJUDP 6.2 WIRING DIAGRAMS 6-9DIAGRAMS SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 'LDJUDP,QWHUQDOZLULQJGLDJUDP ! ! "#! $ % & '( ) * +",- , . / 0 ! ! . / & / 1" -/(&$ !"#!$"!"%&&'() ) ) ) &%%(*+ ) ) ) ) , ) 1"1" 1, , ($ 2#3 4 51" %--' '.* %-/' /'$0 INSTALLATION AND OPERATION INSTRUCTIONS6-10 SL 10-85 G3, SL 14-115 G3, SL 20-160 G3, SL 30-199 G3 MODULATING GAS BOILERS 6.3 SEQUENCE OF OPERATION 'LDJUDP6HTXHQFHRIRSHUDWLRQGLDJUDP INSTALLATION & COMMISSIONING REPORT Boiler Details: 0RGHO1XPEHU _____________________ Serial Number ______________________________________________ Date of Installation ______________ Address of installation __________________________________________ _____________________________________________________________________________________________ User contact information _______________________________________________________________________ Installer Information Company ___________________________________________________________________ Address ______________________________________________________________________________________ Phone/Fax/E mail ______________________________________________________________________________ Fuel Natural Gas Propane *DV6XSSO\3UHVVXUHKLJK¿UH _______ Inches w.c. 0HDVXUHG5DWHRI,QSXWKLJK¿UH ____________ Btu/hr Installation instructions have been followed and completed (Section 1 of Installation and Operating Instructions). Check-out procedures have been followed and completed (Section 3 of Installation and Operating Instructions). Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed (type of cleaner used) ________________________________________________ System Filled (type/concentration of any glycol/chemicals used) _______________________________________ Air purge completed Relief Valve correctly installed and piped Relief valve “try lever” test performed &RQGHQVDWHWUDS¿OOHG &RQGHQVDWHGUDLQFOHDUDQGIUHHÀRZLQJ Condensate Neutralization? Yes/No ,JQLWLRQ6DIHW\6KXWRIIWHVWFRPSOHWHG)ODPHFXUUHQWUHDGLQJ+LJK¿UHBBBBBBB$/RZ¿UHBBBBBBB$ Owner advised and instructed in the safe operation and maintenance of the boiler and system. Information regarding the unit and installation received and left with owner Combustion Readings: CO2 _____________ % O2 ______________ % CO ____________ ppm )OXHWHPSHUDWXUHBBBBBBBBB5HWXUQZDWHUWHPSHUDWXUHPHDVXUHVLPXOWDQHRXVO\ZLWKÀXHWHPSBBBBBBBBBBBBBBB ,QVWDOOHUVVHQGWKLVFRPSOHWHGVKHHW)D[WRRUVFDQDQG(PDLOWRLQIR#LEFERLOHUFRPDQGHDUQDQH[WUD \HDU¶V3DUWV:DUUDQW\FRYHUDJH8VHUWRVXEPLWFRUUHVSRQGLQJ,QVWDOODWLRQ5HFRUGIURP8VHU*XLGH &RPPLVVLRQLQJKDVEHHQFRPSOHWHGDVOLVWHGRQWKLVUHSRUW - Installer Signature _____________________________ INSTALLER SETUP /RDG'H¿QLWLRQ/RDG _______________________________________________________________________ /RDG&RQ¿JXUDWLRQ/RDG _____________________________________________________________________________________________ /RDG'H¿QLWLRQ/RDG _______________________________________________________________________ /RDG&RQ¿JXUDWLRQ/RDG _____________________________________________________________________________________________ /RDG'H¿QLWLRQ/RDG _______________________________________________________________________ /RDG&RQ¿JXUDWLRQ/RDG _____________________________________________________________________________________________ /RDG'H¿QLWLRQ/RDG _______________________________________________________________________ /RDG&RQ¿JXUDWLRQ/RDG _____________________________________________________________________________________________ SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE NOTES NOTES As referenced on page 2-7 of this manual, the following message is relevant to users in the USA: IMPORTANT This Boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: • An external energy management system is installed that reduces the boiler water temperature as the heating load decreases. • This boiler is not used for any space heating. • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil (not applicable to IBC’s SL boilers). 86LQVWDOOHUVVKRXOGFRQWDFW,%&IRUDQ\IXUWKHULQIRUPDWLRQUHTXLUHG REVISION HISTORY R1 (MARCH 2017) Initial release 5$35,/ 5HYLVLRQRI)LJXUHVDQG&RUUHFWLRQVWRWH[W6SHFL¿FDWLRQVWDEOHDQGSDUWQXPEHUV R3 (MAY 2017) Corrections to tables and part numbers. R4 (July 2017) Inclusion of information relating to the SL 30-199 G3 boiler. R5 (September 2017) Inclusion of information relating to the SL 10-85 G3 boiler. IBC Technologies Inc. 8015 North Fraser Way Burnaby, BC Canada V5J 5M8 Tel: 604.877.0277 Fax: 604.877.0295 Toll Free: 1-844-432-8422 www.ibcboiler.com September 2017 © IBC Technologies Inc. 2017