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SL 80-399 MODULATING GAS BOILER1.01.1INSTALLATIONGENERALSL 80-399 gas-fired modulating boilers are low pressure, fully condensingunits having a variable input range from 80 MBH to 399 MBH (0 to 8,000’). Theboilers are approved as “Category IV” vented appliances using either DirectVent (sealed combustion) or indoor combustion air, providing a great degree ofinstallation flexibility.Figure 1 shows outer case dimensions and piping and electrical holes. Use thisdiagram to find a suitable location for the boiler. See also Section 1.3 Location.DESCRIPTIONSIZEA Flue Outlet 4" O.D. CPVC/PVC PipeB Combustion Air Inlet 4" O.D. PVC/ABS/CPVC PipeC Safety Relief Valve 3/4" NPTDLCD DisplayE Water Outlet 1 1/2” NPT - MF Water Inlet 1 1/2” NPT - MG Knock-outs (6) 1/2”H Gas Inlet 3/4” NPT - MI Condensate Outlet 3/4” Flexible Hose Barb FittingTable 1: ConnectionsFigure 1: Dimensions / ConnectionsINSTALLATION1-1

SL 80-399 MODULATING GAS BOILER1.2CODE REQUIREMENTSThe SL 80-399 boiler was tested to and certified under CSA 4.9-2010 / ANSIZ21.13-2010.Installation must conform to local codes, or in the absence of these, with thelatest editions of CAN/CGA B149 and the Canadian Electrical Code Part 1 CSAC22.2 No. 1.In the US, installations must conform to the current National Fuel Gas CodeANSI Z223.1 and the National Electrical Code ANSI/NFPA 70. Where requiredby jurisdiction, installation must conform to the Standard for Controls and SafetyDevices for Automatically Fired Boilers, ANSI/ASME CSD-1. If there is anyconflict, then the more stringent requirement will apply.1-2WARNINGKeep boiler area freeand clear of combustiblematerials, gasoline, andother flammable vapoursand liquids.WARNINGCombustion air must not bedrawn from areas containingcorrosive air from swimmingpools or spas, including airdirectly next to outdoor poolsand spas.WARNING1.3The boiler shall not beexposed to water leaks frompiping or components locatedoverhead. This includescondensation dropping fromun-insulated cold water linesoverhead.LOCATIONThe SL series boilers are designed and approved for indoor installation (wall orrack mounting), with significant flexibility of location provided with the availableventing options. The boiler can be placed in an alcove, basement, closet or utilityroom. Surrounding ambient conditions shall be 0°C to 50°C and less than 90%relative humidity.Install the boiler in areas where the combustion air source is not subject tochemical fouling or agricultural vapours. Exposure to corrosive chemicalfumes such as chlorinated and/or fluorinated hydrocarbons can reducethe life of a boiler. Cleaners, bleaches, air fresheners, refrigerants, aerosolpropellants, dry-cleaning fluids, de-greasers and paint-removers all containvapours which can form corrosive acid compounds when burned in a gas flame.Airborne chlorides such as those released with the use of laundry detergentsare also to be avoided. For this reason, the indoor air venting option using airsurrounding the boiler should not be used in a laundry room. Similarly, ensureany direct vent air source is not adjacent to a clothes dryer exhaust terminal.Avoid agricultural applications where the boiler and/or the intake air sourceare affected by ammonia and/or dust.Locate the boiler where water leakage will not result in damage to the area. If alocation such as this cannot be found, a suitable drain pan should be installedunder the appliance. The boiler is not to be installed above carpeting.Boiler weight – without water and any effect of system piping and components– is approx. 240 lbs/110 kg. For support fasteners, use the supplied 6 x 1/4” x 21/2" long lag screws. Installer to supply 1/4" bolts if metal mounting systems areused. Fasteners are to be attached to solid material capable of supporting thecombined weight of the boiler and piping assembly components.Other factors affecting potential mounting sites:• Ensure minimum clearance requirements for combustible materials (seeTable 2) are satisfied.• Minimum 24" clearance at the front and 12” above is recommended foradequate servicing. Check local codes for additional access and serviceclearance requirements.• At a new construction site, or during renovations, action must be takento protect the boiler from drywall dust or other construction relatedINSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERcontaminants; combustion air should be drawn from a CLEAN source(e.g. outdoors) and the boiler should be isolated from interior dustsources. Do not seal boiler case openings directly when firing - allow forair circulation and ventilation in the immediate area.SurfaceFront 1"Rear 0"Left Side 1"Right Side 1"Top 12”Bottom 12"Table 2 - Clearance from boiler cabinetDistance from Combustible SurfacesWARNINGDO NOT MOUNT THISBOILER TO HOLLOWWALL STRUCTURES - Thecombined weight of theboiler, its water contentsand associated pipingcomponents can exceed 300pounds. Fasteners must berated for this strain, and mustbe firmly anchored into solidmaterial that will support thisweight.Installers are to take allnecessary precautionsto avoid injury during theinstallation of this boiler.Figure 2: Wall mounting of boilerA minimum distance below the boiler of 12" is required to provideclearance for the supplied condensation trap assembly. More clearance willtypically be required to accommodate associated water and gas piping.1.4EXHAUST Venting and AIR INTAKEDANGERDo not common vent SLseries modulating boilerswith any other existing or newappliance.It is important to carefully plan the installation to ensure the appropriatevent materials, travel and termination decisions are incorporated. Specificattention is warranted to manage the impact of the steam plume normallyexperienced at the exhaust terminal of a condensing boiler. Generally,intake and exhaust pipes should terminate at a rooftop or sterile walllocation, to maximize customer satisfaction. Keep exhaust plumeswell away from all building air intakes including those of neighbouringproperties.INSTALLATION1-3

SL 80-399 MODULATING GAS BOILERDo not use ABS or any cellular core pipe for exhaust venting.The boiler offers 4" venting connections. Fittings are to be used to adapt to theappropriate diameter – see Vent Travel below. Exhaust venting is to be inserteddirectly into the 4" female stainless steel fitting on the top, left side of the boiler(see Figure 2).Combustion air piping - if used - is inserted directly into the 4” female stainlesssteel fitting on the top, right side of the boiler (see Section 1.4.7).Venting shall be supported in accordance with applicable code.*Manufacturers of stainless steel Type BH venting systems must submittheir approved transition fitting to IBC for evaluation and written approval.1.4.3 Vent Travel4" CPVC or PVC ULC-S636 approved piping is the standard venting option; withthis, the SL 80-399 boiler can be sited up to 150 equivalent feet from the venttermination. The actual vent travel allowance is reduced for fittings in accordancewith Table 3. – e.g. for a SL 80-399 using 6 x 90º CPVC vent elbows, themaximum lineal measure of pipe allowed is 102 feet (150' – (6 x 8' = 48) = 102').EXHAUST Pipe Size4" 150' (each side)90° vent elbow allow 8’ equivalent90° long sweep elbow allow 5’ equivalent45° elbow allow 3' equivalentTable 3: Maximum exhaust venting lengthMaxIMUM EquivAlEnt LengthNote: Unused intake travel cannot be added to the exhaust. Unequalintake and exhaust piping is allowed - see Section 1.4.8.Exhaust venting must slope down towards the boiler with a pitch of at least1/4" per foot so condensate runs back towards the trap. Support should beprovided for intake and vent piping, particularly so for horizontal runs (followlocal code). Insulate exhaust piping where it passes through unheated spaces orunderground, with appropriate pipe insulation to prevent freezing of condensates.1.4.4 Venting Passage Through Ceiling and Floor• Confirm material meets local codes including fire stopping requirements.• Pipe clearances - no IBC requirements; follow local codes.• All piping must be liquid and pressure tight.Ensure all venting components are clean of burrs/debris prior to assembly.Care is to be taken to avoid ingestion into the fan of plastic debris left in thecombustion air piping.All joints must be secured using appropriate solvent cement to bond therespective pipe material (Canada: PVC, CPVC or transition cement approvedunder ULC-S636, in accordance with its manufacturer instructions; USA: PVC(ASTM D2564), or PVC/ABS (D2235) Use transition glue anywhere that PVC andCPVC are joined. Follow the cement manufacturer’s instructions closely whenjoining various components.1-6INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERAll vent connections must be liquid and pressure tight. Prior to firing the boiler,and before any of the venting run is concealed by the building construction, theinstaller must test the exhaust joints under fan pressure with the vent blocked,using a soap/water solution. Installer must fill condensate trap prior to test.Remove the fan control harness plug as illustrated in the photos, and then blockthe vent outlet so that the vent run will be under maximum fan pressure. Paint alljoints 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 installerattach a tag on the vent line near the condensate drain tee indicating the type oftest, the date and the installer’s name.1.4.5 Rooftop Vent TerminationFan control harness plugUnplugging fan control harness plugwill drive the fan into manual highspeed operation for vent leak testRooftop vents must terminate as follows:• The exhaust pipe can terminate in an open vertical orientation without concernabout rain infiltration; rain will drain away through the condensate trap.• If used, the intake air pipe is not typically drained, so it must be terminatedwith a down-turned elbow (see Figure 4). The intake pipe does not need topenetrate the roof at the same elevation as the exhaust (as shown); lowerdown roof is OK.• Optional bird screen may be placed in a termination fitting. Leave unglued,and hold in place with a short nipple. This permits easy access for cleaning.• For roof top venting of multiple boiler sets, group all intake terminals togetherfor a common penetration through a custom cap. Alternatively, place in theclosest proximity achievable using commonly available pipe flashing. Similarlygroup the exhaust pipes and place the 2 separate groups of pipes at least 3'apart (the closest intake and exhaust pipes shall be 36" - or more - apart).Use the same 24" (minimum) vertical separation for all termination options.• DO NOT exhaust vent into a common venting system.WARNINGCondensate can causecorrosion of metal roofingcomponents and otherroofing materials. Checkwith the builder or roofingcontractor to ensure thatmaterials will be resistant toacidic condensate. pH levelscan be as low as 3.0Figure 4: Rooftop vent terminal configurationsINSTALLATION1-7

SL 80-399 MODULATING GAS BOILERSidewall indoor combustion air applications shall be vented as follows:• The exhaust outlet is to be placed 18” minimum (12” in USA) above the gradeor anticipated snow level.• The vent shall be terminated with a tee fitting as illustrated - See Figure 6.• Bird screen, as above, should be installed in both open ends of the tee.For side venting of multiple boiler sets, group all intake terminals together with 6"to 12" lateral spacing, and similarly group the exhaust pipes. Place the 2 groupson the same plane of the building (e.g. north facing wall). Place the 2 groups ofpipes at least 3' apart (the closest intake and exhaust pipes shall be 36" - or more– apart. Use same 24" (minimum) vertical separation.Figure 9: Sidewall vent termination - multiple vent piping configurationVent terminal clearance minimums are as follows:Figure 7: IBC recommendedminimum vent terminal clearanceunder ventilated soffitFigure 8: Prohibited installationINSTALLATION• Clearance above grade, veranda, porch, deck or balcony – 12" (0.3m), butcheck local code also (anticipated snow levels may supersede).• Clearance to openable window or door – 36" (0.91m) (USA – 12”)• Vertical clearance to ventilated soffit located above the terminal - 48” (1.2m)See Caution note in this section.• Clearance to each side of centre line extended above meter/regulatorassembly: - 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 airintake to any other appliance: - 3' (0.91m) (USA – 12" (0.3m))• Clearance to a mechanical air supply inlet: - 6’ (1.82m) (USA - 3’ (0.91m)above if within 10’ (3.1m) horizontally)• Clearance above paved sidewalk or paved driveway located on publicproperty: - 7' (2.2m) Note: Cannot terminate directly above a paved sidewalkor paved driveway that is located between two single family dwellings andserves both dwellings• Clearance under veranda, porch, deck or balcony: - 12" (0.3m) IBC stronglyrecommends a minimum of 48” with the SL 80-399 to avoid damage tothe structure. Note: Prohibited unless fully open on a minimum of two sidesbelow the floor.1-9

SL 80-399 MODULATING GAS BOILERWARNINGIn areas of high snowfall,Users must be advised tocheck side wall vent andair intake terminations ona regular basis to ensureblockage does not occur.• Vents must be installed such that flue gas does not discharge towardsneighbor’s windows, or where personal injury or property damage can occur.• It is important to ensure proper condensate management from ventterminations. Condensate shall not be discharged in a manner that will causedamage to external building finishes or components, or infiltrate buildingenvelopes, including adjacent structures.CAUTIONVent termination clearancesin this section arecode minimum, or IBCrecommended minimumrequirements, and maybe inadequate for yourinstallation. Building envelopedetails must be examinedcarefully, and ingress ofmoisture into buildingstructures is to be avoided.Serious structural damagemay occur if adequateprecautions and clearancesare not allowed for.These precautions are to beobserved for neighbouringstructures as well as for thestructure the boiler(s) areinstalled in.Figure 10: Vent terminal clearancesFigure 11: Vent terminal clearances1-10INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERWARNINGIn addition to preventingingestion of chemicalcontaminants, care mustbe taken to ensure airintake terminals are notinstalled in locations wherecontamination might occurdue to ingestion of particulateforeign material (dust, dirtand debris).1.4.7 “Direct Vent” Combustion Air Intake PipingThere are two basic methods of supplying combustion air to an IBC boiler.The direct vent option uses piping from the outside to supply combustion airdirectly to the boiler’s combustion air connection.WARNINGIntake air openings must beconfigured such that rainor other forms of moisturecannot enter the air intakepiping system. Otherwiseserious damage to the boilermay result.Figure 12: Direct vent combustion air intakeNOTECare must be taken wheninstalling air intake piping toensure that a “trap” is notformed in the piping so as toallow a build-up of water, andblockage of intake air.Such blockage will result in aboiler safety shut-down.INTAKE Pipe SizeMaxIMUM EquivAlEnt Length4" 150' (each side)90° vent elbow allow 8' equivalent90° long sweep elbow allow 5’ equivalent45° elbow allow 3’ equivalentAir Intake FilterContact FactoryTable 4: Maximum intake piping lengthFor the inlet air – 4” Schedule 40 PVC, CPVC or ABS piping of any type ispermitted.Note: It is not permitted to add to the exhaust length by transfer of unusedintake allowance.Combustion air piping - if used - is inserted directly into the 4” female stainlesssteel fitting on the top, right side of the boiler and run horizontally or vertically tothe outdoors. Screen material can be placed at the inlet as appropriate for theenvironment (e.g. insects, dust).Care must be taken to ensure adequate separation is maintained between theair intake inlet and the vent terminal. Refer to the vent terminal configurationdrawings in the Vent Termination section above.Support should be provided for intake piping, particularly so for horizontal runs(follow local code).INSTALLATION1-11

SL 80-399 MODULATING GAS BOILER1.4.8 “Indoor Air” Combustion Air IntakeWARNINGWhen using IndoorAir options, adequatecombustion air must besupplied to the boiler roomaccording to the requirementsof all applicable codes.An “Indoor Combustion Air installation”, as described herein, is one in which airfor combustion is taken from the ambient air around the boiler.Figure 15: Indoor combustion air intakeTo support combustion, an ample air supply is required. This may requiredirect openings in the boiler room to the outside. If the boiler is not in a roomadjacent to an outside wall, air may be ducted from outside wall openings.Figure 13: ReservedProvisions for combustion and ventilation air must be made as follows:• in the USA, in accordance with Section 5.3 Air for Combustion andVentilation of the National Fuel Gas Code, ANSI Z223.1 (latest edition), orapplicable provisions of the local building codes• in Canada, in compliance with B149.1.4.9 Combustion Air FiltrationIf combustion air contamination from ingested particulate matter may be aconcern in any installation, an optional air intake filter may be installed.Important Note: At the time of this printing, a combustion air filter for theSL 80-399 model was not yet available. Contact the Factory if your applicationrequires air filtration. Under no circumstances should a third-party air filter beinstalled on an IBC boiler without proper evaluation and written approval of theIBC Engineering Department.1.4.10 Closet InstallationsFigure 14: ReservedFor installations in a confined space (such as a closet), ventilation openings maybe needed through a door or wall to prevent excessive heat from building upinside the space.The boiler shall not be exposed to ambient conditions above 122°F (50°C) orbelow 32°F (0°C).1-12INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERNOTE1.5Combustion fanblockages can occur whenenvironmental particulate andforeign matter contaminants(leaves, dust, dandelion &cottonwood fluff, etc) aredrawn into the air intake. Inareas where this problem issuspected to be an issue,intake air filtration should beconsidered. Contact Factory.Filters should be checkedand cleaned or replaced ona regular schedule based onthe severity of the problem.CONDENSATE REMOVALIBC’s specified vent configuration promotes the safe drainage of moisturefrom the boiler and exhaust venting without flowing liquids back through theheat exchanger (as done by some other condensing boilers). Reliable systemoperation requires (1) proper design and installation of exhaust venting toallow condensate to run back to the drain/trap; (2) acid neutralization asappropriate. To achieve these:1. Allow for a 1/4” per foot slope back to the vent connection, withappropriate hangers to maintain that gradient.2. Ensure the supplied trap is correctly installed and filled with water.3. When required, add (and maintain in good condition) a neutralizationtank.1.5.1 Condensate TrapA condensate trap must be installed on the drain connection at the base ofthe boiler as shown in Figure 16.WARNINGWhen using IndoorAir options, adequatecombustion air must besupplied to the boiler roomaccording to the requirementsof all applicable codes.Figure 16: Condensate trap installationINSTALLATION1-13

SL 80-399 MODULATING GAS BOILERWARNINGFill trap with water beforeboiler is first fired to preventexhaust fumes from enteringroom. Never operate theboiler unless the trap is filledwith water.Failure to comply will resultin severe personal injury ordeath.1.5.2 Condensate Trap Assembly Installation1. Undo Drain Spout Compression Nut (D),remove Drain Spout (C) fromCondensate Drain Outlet (E) of Trap Body (A).2. Loosen Upper Compression Nut (B) and place the Nut and Trap Body (A) overBoiler Condensate Outlet (G) far enough to swing Trap Hook (F) down andpast the Drain Spout connection threads. Pull the trap slightly downward toseat it against the hook.3. Unscrew Trap Body from trap top piece, and fill with water. Screw Trap Bodyback to top piece.4. Hand Tighten Upper Compression Nut and secure Drain Hose to Drain Spoutbarb connection. If the nut is removed, ensure the cone seal and backupo-ring remain in the factory supplied position. Gently pull on all assembledcomponents to make sure they are secured in position.Factory supplied condensate trapwith drain hose1.5.3 Condensate Trap cleaning procedure1. Turn off the power to the boiler and allow it to cool down.2. Unscrew trap body (A) from trap top piece.3. Unscrew trap bottom piece from main trap body and clean and flush debrisfrom these components. In cases of severe fouling, Drain Spout may haveto be removed, and trap top piece removed from boiler condensate outlet forfurther cleaning of those components.4. Re-assemble trap components, re-fill trap, and replace on boiler as describedin the Condensate Trap Assembly Installation instructions above.1.5.4 Further installation detailsFigure 17: Condensate trapdisassembly for cleaning1-14• Condensate drain must be piped to within 1” of a drain or be connected to acondensate pump.• Drainage line must slope down to the drain at a pitch of 1/4” per foot socondensate runs towards the drain.• Condensate traps should be checked every 2 months, and cleaned andrefilled as necessary.INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERWARNINGIf condensates are to bedischarged into buildingdrain piping materials thatare subject to corrosion, aneutralization package mustbe used.CONDENSATE DRAINAGEFree flow of condensate from ventingsystem and pressure vessel must bemaintained at all times. Trap andcondensate drain piping must beaccessible to allow regular inspectionand cleaning.WARNING: “Risk of damage to appliance”All condensate discharge lines must be ata lower elevation than the condensatewater line of the appliance.FLUE GAS EXHAUSTCONDENSATE AND RAINWATER FLOWS BACK FROMVENTING SYSTEMIBCSL 80-399BOILERCONDENSATE WATER LINEIBCFACTORY SUPPLIEDCONDENSATE TRAPATTACH HOSETO DRAINAGE PIPINGCONDENSATE HOSE AND DRAINPIPING TO SLOPE TOWARDDRAIN AND BE SECURED TOPREVENT ACCIDENTAL DISASSEMBLY.TODRAINFigure 18: Condensate trap drainageDRAIN MATERIALS SUBJECT TOCORROSION MUST BE PROTECTEDBY ACID NEUTRALIZATIONCAUTIONWhen a condensateneutralization packageis installed, the pH of thecondensate discharge mustbe measured on a regularschedule to ensure theneutralizing agent is activeand effective.MAINTENANCE DETAILS FORNT20 CONDENSATENEUTRALIZATION TANKRefer to manufacturer’s maintenanceinstructions for other makes and modelsof condensate neutralization tanksWARNING: “Risk of damage to appliance” Neutralizationtank inlet and discharge must be at a lower elevation thanthe condensate water line of the appliance.FLUE GAS EXHAUSTCONDENSATE AND RAINWATER FLOWS BACK FROMVENTING SYSTEMIBCSL 80-399BOILERNOTE: Access to the discharge before the drain isnecessary for proper maintenance in order to check theeffectiveness of the neutralizing agent. A simple pH testshould be performed annually to ensure neutralizing agentis still effective. If pH falls below 6.5 the neutralizing materialshould be replaced. The agent (limestone chips with aminimum calcium carbonate content of 85%) can bepurchased from a local supplierIBC1 1/2” FIPOUTLET1 1/2” FIPINLETTO DRAINFigure 19: Condensate neutralization tankINSTALLATION1-15

SL 80-399 MODULATING GAS BOILER1.6Water PipingWARNINGDuring operation, the reliefvalve may discharge largeamounts of steam and/or hotwater. Therefore, to reducethe potential for bodilyinjury and property damage,a discharge line MUST beinstalled that it:1.6.1 General Piping IssuesThe 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 field installation in the relief valve fitting on top of the boiler. Reliefvalve discharge piping must terminate between 6" (15cm) and 12” (30cm) abovethe floor or per local Code.1. is connected from the valve outletwith no intervening valve anddirected downward to a safe point ofdischarge.2. allows complete drainage of both thevalve and the discharge line.3. is independently supported andsecurely anchored so as to avoidapplied stress on the valve.4. is as short and straight as possible5. terminates freely to atmospherewhere any discharge will be clearlyvisible and is at no risk of freezing.6. terminates with a plain end which isnot threaded.7. is constructed of a material suitablefor exposure to temperatures of375°F or greater.8. is, over its entire length, of a pipe sizeequal to or greater than that of thevalve outlet.DO NOT CAP, PLUG OR OTHERWISEOBSTRUCT THE DISCHARGE PIPEOUTLET!NOTEInstallers should inquire oflocal water purveyors as tothe suitability of their supplyfor use in hydronic heatingsystems.If water quality is questionable,a local water treatment expertmust be consulted for testing,assessment and, if required,treatment.Alternatively, water or hydronicfluid of known quality can bebrought to the site.Figure 20: Boiler trim options - Single boilerSystem piping is connected to the boiler using the 1 1/2" NPT-M threaded fittings.Unions and gate or ball valves at the boilers supply and return water connectionsare recommended to simplify servicing. Un-insulated hot water pipes must beinstalled with a minimum 1" clearance from combustible materials.Fluid fill is most often accomplished by using a boiler regulator & fill valve setat 12 psig or more, with appropriate backflow prevention device as requiredby local code. This is acceptable in areas where municipal water or well waterhas been treated and filtered to remove excessive minerals and sediment, andwater chemistry is known to be suitable for closed loop hydronic systems. Inareas where water quality is in question, or when chemical treatment or glycol isrequired, other options should be considered. Follow applicable Codes and goodpiping practice.There are a number of boiler feed and pressurization devices on the markettoday that may be a better choice than a raw water fill from the mains. Whenregular maintenance requires relief valve blow-off, the discharge may be directedback into the pressurization unit for recycling of boiler fluid and chemicalsback into the system. In buildings that may be unoccupied for long periods oftime, pressurization units are useful to prevent flood damage should leakageoccur from any component in the system. An additional benefit is that backflowprevention devices are not required when using these devices.1-16INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERWARNINGClose fill valve after anyaddition of water to thesystem, to reduce risk ofwater escapement.Do not place any water connections overhead the boiler; leaks can damagethe fan & controls. If needed, create a shield over the top of the cover, but allowclearance for airflow and service access.For best results, use a Primary: Secondary piping system, with a pumped boilerloop using 2" piping for the SL 80-399. Heat exchanger head is only 2’ at 30 gpmand approx. 4' at 40 gpm.The minimum flow rate required through the heat exchanger is 20 gpm and amaximum of 45 gpm is allowed. Primary/Secondary piping ensures adequateflow and de-couples Δ°T issues (boiler vs. distribution). Aim for a 20° to 30° F Δ°Tacross the heat exchanger at high fire (there is a boiler protection throttle fencelimiting the Δ°T to 35°F).Table 5: ReservedFigure 21: Primary/Secondary piping concept with hydraulic separatorThe SL modulating series boilers can supply multiple heating loads withcompatible supply temperature requirements. Always ensure that loads sensitiveto high temperatures are protected using means such as a mixing valves.A variety of application drawings showing basic design options are available fromthe IBC web site at: www.ibcboiler.comNOTEFull sized applicationdrawings can be downloadedfrom our web site.www.ibcboiler.comPRESSURE VESSEL HEADFlow rate (gpm) 20 35 30 35 40 45Head @ flow (ft wc) 1 1.5 2 3 4 6Table 6: Pressure Vessel HeadWe require water flow after burner shutdown to utilize legacy heat – this issignificant due to the mass of the heat exchanger (50 Kg) plus its 26L internalwater volume. Default software values will run the boiler’s primary pump for upto 5 minutes (300 seconds) after burner shutdown. Secondary pumps can beset to run up to 5 minutes after burner shutdown (for the last calling load). Asshipped, the default software will run the Load 1 pump for 5 minutes to place theINSTALLATION1-17

SL 80-399 MODULATING GAS BOILERlegacy heat where it is useful. Any secondary pump can be set to run for 0 – 300seconds in the heat purge mode. Guard against deadheading pumps when allzone valves are closed (see Section 2.7 Set Up & Load Definition).The primary pump must be under the control of the boiler, to allow the boiler’sflow proving routine to run. The boiler control looks for flow/no flow during apump on / off check on each start up. Ensure that temporarily wired primary orsecondary pumps (e.g. wired externally during the system fill/purge phase) arereturned to the boiler’s control terminals. A “No Water Flow” error message willotherwise be experienced on start-up.Schematics for several piping layouts are provided, and additional drawings areavailable at www.ibcboiler.com. Installers shall conform the piping design to oneof the provided configurations to simplify the control application, promote goodloads and flow management.WARNINGDo not use automotive-typeethylene or other types ofautomotive glycol antifreeze,or undiluted antifreeze ofany kind. This may resultin severe boiler damage. Itis the responsibility of theInstaller to ensure that glycolsolutions are formulated toinhibit corrosion in hydronicheating systems of mixedmaterials. Improper mixturesand chemical additives maycause damage to ferrous andnon-ferrous components aswell as non-metallic, wettedcomponents, normally foundin hydronic systems. Ethyleneglycol is toxic, and may beprohibited for use by codesapplicable to your installationlocation. For environmentaland toxicity reasons, IBCrecommends only using nontoxicpropylene glycol.Propylene glycol solution is commonly used in a closed loop where freezeprotection is required. Its density is lower than that of water, resulting inlower thermal performance at a given flow and pressure. As a rule of thumb,a 50%:50% solution of propylene glycol and water will require an increasedsystem circulation rate (gpm up 10%), and system head (up 20%) to provideperformance equivalent to straight water.1.6.2 Installation RulesThe boiler control hardware used is common to the smaller VFC 15-150 and45-225 models; these smaller models feature IBC’s hallmark 3-load loadmanagement system. However, as it would normally be inappropriate to applythat sequential load run strategy on larger commercial-scale loads, the 80-399software has been changed – specifically covering temperature transition duringload switching – to discourage diverse multiple load applications. Where Factoryapproval is granted, traditional 3-load code will be made available.Figure 22: Primary/Secondary piping concept with simultaneous setpoint calls1-18INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERNOTEThe Primary (boiler) pumpmust be under the controlof the boiler and wired tothe correct yellow and whitewires labelled “Primary” inthe wiring box.Failure to do so will resultin a no heat condition as theboiler will interrupt start-upwith a “No Water Flow” error.If the installation involves small loads, as in typical zoned baseboard heatingapplications, use of a buffer tank is recommended. To aid in temperaturetransition from hot to cool loads, a 3-way mixing valve can be placed at theentrance to the cool load (this will also provide floor protection). This will permitimmediate circulation of mixed flow into the cool loop. See separate publicationApplication Notes for more detail (available at www.ibcboiler.com or from yourIBC Representative).Always ensure that loads sensitive to high temperatures (e.g. radiant floor)are protected using appropriate means such as a manual mixing valve, or anaquastat (set to130°F, for example) wired to the boiler’s auxiliary interlocks.Figure 23: Two pump, two load - parallel piping conceptCompared with the Primary/Secondary approach, the above design saves onepump. Lost is the simplicity of constant head and flow at the boiler.Wiring: In these parallel pumping applications, disconnect the wire from thePump Block, terminal 11 (P/V Power - L), and isolate it using a wire nut, crimpconnector or other secure means to prevent the bare wire from contactinganything. Install a wire into the Power Block, terminal 1 (BP - L), and jumper upto Pump Block, terminal 11 (P/V Power - L). This procedure will allow the boilerto operate the load pumps through the Boiler Pump contacts, in order to provideflow proving operation.Check valves or thermal traps should be used to isolate both the supply andreturn piping for each load - to avoid thermal siphoning and reverse flow.To ensure adequate water flow through the boiler under high-head / singlezone space heating conditions, a pressure activated bypass or other means ofbypass must be used on any load where the flow rate might drop below minimumrequirements (20 gpm).For further information and details, consult our Application Notes – which providedetail on specific single and multiple boiler applications “Piping”, “Wiring” and“Settings”. (available at www.ibcboiler.com or from your IBC Representative).INSTALLATION1-19

SL 80-399 MODULATING GAS BOILERNOTEThis piping drawings in thismanual are simple schematicguides to a successfulinstallation. There are manynecessary components notshown, and details such asthermal traps are left out sothe drawings have greaterclarity. We require thatour boilers be installed bylicensed and experiencedtrades people who are familiarwith the applicable localand national codes. Systemdesign is to be completedby an experienced hydronicdesigner or Engineer. It isnecessary to carefully readand follow these installationinstructions along with theapplication drawing that fitsyour system.Figure 24: Trim for multiple boiler installationsFigure 25: Multi boiler rack mountingFigure 26: Front view rack mounting1-20INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERNOTEWhen using the sequentialload feature of the IBC boiler,attention must be paid tothe operation of systemcomponents in order toensure they are compatible.Many air handlers (fancoils) for instance have athermostat connection thatwill energize an internal relayto operate the air handlercirculator and its fan ona call for heat. This mayresult in operation of thesecomponents when otherloads are running at a higherpriority, resulting in cold airblowing, or robbing heat fromanother load.Some wiring alteration maybe required to divorce bothof these functions fromthermostat control in favourof more effective control fromthe IBC boiler.Figure 27: Multiple boiler pipingFigure 28: Multiple boiler inter-wiringINSTALLATION1-21

SL 80-399 MODULATING GAS BOILER1.7Gas PipingThe boiler requires an inlet gas pressure of at least 5.0" w.c. for natural gas orpropane. For either fuel, the inlet pressure shall be no greater than 14.0" w.c.Confirm this pressure range is available with your local gas supplier.The inlet gas connection of the boiler’s gas valve is 3/4" NPT (male).Adequate gas supply piping shall be provided with no smaller than 3/4" Sched 40(e.g. Iron Pipe Size (IPS)) and using a 1" w.c. pressure drop, in accordance withthe following chart:Model 3/4" IPS 1" IPS 1 1/4" IPS 1 1/2" IPSSL 80-399 (Natural Gas) 10 40 150 350SL 80-399 (Propane) 30 100 400 900Table 7: Maximum Pipe Length (ft)Gas piping must have a sediment trap ahead of the boiler’s gas valve (see Figure29). A manual shutoff valve must be located outside the boiler, in accordance withlocal codes/standards. All threaded joints in gas piping should be made with anapproved piping compound resistant to the action of natural gas/propane. Useproper hangers to support gas supply piping as per applicable codes.The boiler must be disconnected or otherwise isolated from the gas supplyduring 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 shallbe 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 (seeFigure 32). Note that manifold pressure varies slightly in accordance with firingrates with the modulating series boilers, but will always be close to 0” w.c.Figure 29: Typical gas piping1-22INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER1.8Electrical ConnectionsAll Electrical wiring to the boiler (including grounding) must conform to localelectrical codes and/or National Electrical Code, ANS/NFPA No. 70 – latestedition, or The Canadian Electrical Code, C22.1 - Part 1.1.8.1 115Vac Line Voltage Hook-upRemoving wiring box coverLine-voltage wiring is done within the field-wiring box. (Refer to Section6.2.Wiring Diagram on page 6-4). Connect the boiler to the grid power using aseparate, fused circuit and on/off switch within sight of the boiler. Use 14-gaugewire in BX cable or conduit properly anchored to the boiler case for mains supplyand pump circuits.Connect a 115 VAC / 15 amp supply to the power block terminal strip (terminals 3and 4) in the wiring box. The max. actual draw shall not exceed 12 amps.If primary / secondary piping is used, with pumps to manage multiple loads,connect them to the pump terminal block located above the power block. Theupper 3 pairs of contacts on this block are powered to manage up to 3 loadpumps – the top pair for Load 1, the second pair for #2 etc. Once the controlleris programmed for the respective loads, the boiler will manage all the loadswithout need of further relays (maximum pump electrical draw up to 1/3 HP. Useprotective relays for higher draws).Line voltage power block terminalsLine voltage pump block terminalsCAUTIONThe internal pump relays in theIBC control have a maximumrating of 5 Amps or 1/3 H.P.each, with a maximum totalallowable draw of 10 amps.Isolation contactors MUST beused if electrical loads exceedthese maximums.The boiler pump is connected to the power block (terminals 1 and 2). Theseterminals are factory wired to the controller (and its 115 Vac supply).Pumps can be switched on/off using the keypad, so there is no need fortemporary pump wiring during system filling / air purging. If pumps are hardwiredto the panel during the system fill/purge phase, re-wire the boiler pump tothe Primary Pump leads inside the wiring box, to enable the water flow provingroutine to run.In a new construction application- use a construction thermostat – or jumperwith in-line on/off switch – for on/off management of the boiler. Do notjust pull power from the unit, or its moisture management routine will beinterrupted (fan turns at ultra low rpm for 90 minutes after burner shutdown).Treat it like a computer, where you do not just pull the plug when done. If an“Insufficient airflow / check vent” error signal shows, check for (and remove) anywater in the clear vinyl air reference tubes. This has been seen occasionally atconstruction sites where the boiler has been repeatedly de-powered wet.The combined current of all pumps connected through the on-board pump relaysshould not exceed 10 amps. The control circuit board is protected using on-boardfield replaceable fusing.1.8.2 Power Quality and Electrical ProtectionIn areas of unreliable power, appropriate surge protectors and or powerconditioning equipment should be installed in powers supply wiring circuits.INSTALLATION1-23

SL 80-399 MODULATING GAS BOILERNOTEThe IBC boiler (like anymodern appliance thatcontains electronicequipment), must have a“clean” power supply, and issusceptible to power surgesand spikes, lightning strikesand other forms of severeelectrical “noise”. Powerconditioning equipment(surge protectors, APC orUPS devices) may be requiredin areas where power qualityis suspect.1.8.3 Zone Valve Hook-upIf 24Vac zone valves rather than pumps are used to manage multiple heatingloads (must be three-way diverting valves to maintain boiler flow), then the115Vac wires on the Pump Terminal Block (Terminals 11 and 12) must bedisconnected and electrically isolated (using wire nuts or other acceptableinsulation method). Externally supplied 24VAC for the zone valves should beprovided to the power contacts (Terminal 11 & 12) on the Pump Terminal Block.Use a separate transformer of adequate capacity. The 40VA transformer insidethe wiring box is for internal systems only. The individual load/zone valves arethen to be wired to their associated contacts on the Pump Terminal Block.1.8.4 Thermostat / Sensor WiringDry contacts (eg. thermostats, aquastats or relay contacts) for each of 3 loadsare provided as marked on the Sensor Terminal Block (e.g. “Therm 1”). Requiredinput for enabling the IBC boiler is a dry / mechanical contact; ensure that triac orother parasitically-powered units are not used.1.8.5 Other WiringOther optional low voltage connections to the control board include:Terminal Block for: Thermostat& Switch Inputs, Sensor inputs,Auxiliary Interlocks, Network Wiring,External Control SignalDANGERDo not connect thermistorsensors to “Therm” terminals.An overheating hazard canresult in serious personalinjury and/or propertydamage.NOTEThe IBC control onlyrecognizes a true dry contactclosure as a call for heat onterminals “Therm. 1, Therm. 2or Term. 3. Thermostats andother devices that use a “Triac”output cannot be used as a callfor heat without the installationof an intervening relay with drycontacts to connect to the IBCterminal strip.• Two auxiliary interlocks - for external safety devices as may be required bysome jurisdictions, such as a low water cut-off or a low gas pressure cut-out(for off-grid propane).• Contacts for indoor and outdoor temperatures sensors associated with ResetHeating. A 10K ohm thermister for outdoor reset sensing is supplied with theboiler, to encourage use of this temperature compensating space heatingtechnique for improved comfort and combustion efficiency.• One pair for a DHW tank sensor. Connect to “DHW S” (not the respectiveTherm. 1,2,3 location) and the boiler will automatically notice and go to asmart DHW routine• One pair of contacts for remote secondary loop temperature control.• One pair (marked BoilerNet) for network connection – this is used forconnecting multiple SL and/or VFC modulating units for autonomous staging.See separate Technical Memo for guidance.• A final pair of contacts, to receive a 4-20 mA (default) or 0-10VDC signalfrom an external boiler controller- for direct throttle control. The boiler’s ownsensors act as high limits only. User must enter maximum and minimum boilersupply temperatures.Note: Sensors connected to any sensor input contacts must be of NTCThermister - type with a resistance of 10,000 ohms at 25°C and β = 3892. We donot recommend using 3rd party supplied sensors. Compatible water temperaturesensors and outdoor sensors can be supplied by your IBC distributor.1.8.6 Thermostat Heat AnticipatorIBC “Therm.” contacts draw no power, so an anticipator setting for the thermostatis not applicable with the SL modulating series boilers. In the case of a singletemperature / heat load where zone valves are used to manage individualthermostatically controlled zones, each room thermostat’s heat anticipator shouldbe adjusted to the current draw of its associated zone valve.1-24INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERFigure 30: Electrical Wiring Connections (full page ladder diagram at back of this manual)INSTALLATION1-25

SL 80-399 MODULATING GAS BOILERTHIS PAGE INTENTIONALLY LEFT BLANK1-26INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER2.0BOILER SYSTEMS AND OPERATION2.1 GENERALWARNINGIf the boiler can becomeexposed to fluid temperaturesbelow 34°F (1°C), a method ofprotection to prevent freezingof condensate should beemployed. Contact the factoryfor further information.The SL 80-399 modulating boiler is designed to service light-to-mediumcommercial space and domestic water heating loads. Typically, a single spaceheating load will be managed using either Set-Point or Reset parameters, orif two loads are paired (e.g. space and indirect DHW) these should be run inparallel on set-point operation. External load controls can be added to provideremote/active mixing as required.Accordingly, the boiler is shipped with pre-programmed values for set-pointoperation on Load 1, while Loads 2 and 3 are set to “Off”.The boiler control hardware used is common to the smaller VFC 15-150 and45-225 models; these smaller models feature IBC’s hallmark 3-load managementsystem. However, as it would normally be inappropriate to apply that sequentialload run strategy on larger commercial-scale loads, the 80-399 software hasbeen changed – specifically covering temperature transition during load switching– to discourage diverse multiple load applications. Where Factory approval isgranted, traditional 3-load code will be made available.2.2CONTROLThe control unit provides overall management of boiler operations, including:1. Power-up / set-up / boiler state machine (standby / heat call management etc).2. Burner, pumps (primary + external) and/or zone valve management.3. Temperature and throttle operation.4. Maintenance of a service log with diagnostics.5. 2 way communications.Operating and historical data may be accessed at any time, using the Log andAdvanced Settings fields, available using the permanently lit LCD screen. Seebelow. Data includes the following:• Ignition counter• Time records, including burn time by load and the throttle duty cycle• Error log2.3USER INTERFACE2.3.1 Keypad FunctionsA five button keypad is provided for intuitive navigation around the screen. Thefour outer keys are used to move the cursor up or down, and side to side. Thecentre button is used to make selections and confirm inputs. The left hand keyis also used to back-step to the previous screen; multiple key stokes are used towithdraw back to the operating status screen.BOILER SYSTEMS AND OPERATION2-1

SL 80-399 MODULATING GAS BOILER2.3.2 LCD DisplayUpon power-up, the LCD screen initially flashes a software release numberthen switches to a Standby- display mode, showing real time data plus keytemperature target settings.When there is a call for heat from any load, that load is identified at the Statusline (e.g. Heating – BBd - for baseboards with reset - in place of Standby). TheTarget temperature for the relevant load is conspicuously displayed while thatload is being handled.Note: The Status line displays those loads that are heating or calling forheat. In this instance (“Heating 3DHW”), Load 3 has been set up as DHW andis actively heating, with no other loads calling for heat. If you saw (“Heating3DHW C:1RFL”), it would indicate Load 3 DHW is actively heating, while Load1 (Radiant Floor heating with Reset) is shown as requiring heat but awaitingits turn. If a third load has been implemented and is also calling, the Statusline display would expand to show the relevant details. Note: See 2.1 General,regarding limitations of three load operation.Legend:• RFl: Radiant Floor with Reset• CIR: Cast Iron Radiators w/ Reset• BBd: Baseboards w/ Reset• AIR: Air Handler w/ Reset• StP: Set Point• DHW: Domestic Hot WaterOther information is accessible using a menu based system – described in thefollowing sections.2.4ACCESS LEVELSThe controller provides for the display of further information (via the LoadStatus Screen) plus three levels of access for the adjustment of control settings.This is done to simplify the control interface for the user while retaining fieldaccess to the full functionality of the system for the appropriately trainedheating professional. The split access feature offers a layer of security againstadventurous “finger trouble”, including accidental adjustment to settings that couldlead to inefficient operation (e.g. excessive cycling) or dangerous conditions.To access the Main Menu, touch any key. Move the cursor up or down using thetop and bottom keys.The Load Status Screen offers a comprehensive summary of all settings andactual readings for each heating load, eliminating a need to jump betweenscreens while doing an extended watch of boiler operation.Note: where the word “more” is displayed at the bottom or top of a screen, it ispossible to see more lines by moving the cursor in that direction.2-2INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER2.4.1 User setupThe occupant has access to a number of practical settings. The most meaningfulinclude adjustment of the indoor temperature target plus the temperature setbackand occupied / unoccupied modes. The User Menu also provides access to thetime & date fields, provides the means to toggle between C° / F° plus allowsadjustment of the screen image itself (“Contrast Adjustment”).2.4.2 Installer SetupThe installer has access to all “User” adjustable fields plus a much widerselection of inputs. Loads can be declared and configured, with temperaturesettings appropriate to the characteristics of the heating system.Key issues here are selection of appropriate boiler supply temperature criteria forthe type of emitter, and the establishment of practical temperature differentials(e.g. DHW tank target vs. boiler supply). A record of the service history is alsoavailable for onscreen access.2.4.3 Advanced DiagnosticsNot an access level, this field allows a view into detailed sensor readings andoperating parameters such as fan rpm. This screen is useful for advancedtroubleshooting of pressure sensors, etc.2.4.4 Advanced SetupThis access level is set for the sole use of factory representatives and ispermanently password protected.2.4.5 PasswordsA Password access feature is loaded on the controller, for use in situations wherethere is exposure to unauthorized and / or uneducated adjustment. The installeris encouraged to consult with the user to determine the need for ongoing accessto settings. In risk situations, the password feature can be invoked by selecting“Password On/Off” and toggling to “On” in either or both of the User and Installermenus.Pre-set passwords are used:• For the User the code is “11111” followed by “enter”• A common “installer” code is also used, to ensure continuing access even witha change in service personnel. Contact IBC for access to this password.BOILER SYSTEMS AND OPERATION2-3

SL 80-399 MODULATING GAS BOILER2.5SEQUENCE OF OPERATIONThe control module has 5 cycles during normal operation, as well as an errormode for problem detection:1. Standby cycle2. Purging3. Ignition cycle4. Heating cycle5. Circulating cycle6. Error modeEach state is explained below. A flow chart for the sequence of operation can befound in the back of the manual.GLOSSARY OF TERMSThis glossary briefly defines some terms used in the Sequence discussion.• Call for Heat: The thermostat indicates that room temperature is below thethermostat setting.• Heat Required: Temperature sensors on the boiler indicate that watertemperature is below the water temperature target or setpoint.• Heating Enabled: The boiler is powered and there is a Call for Heat, Heat isRequired. The boiler will start and enter the Heating Cycle unless it is in anerror mode.2.5.1 StandbyWaiting for a Heating Enabled signal. The burner and boiler pump are off duringthis time.2.5.2 PurgingPrepurgeOn a Heating Enabled signal, the boiler automatically enters a prepurge cycle.The fan starts and automatically adjusts to a level suitable for ignition. Tenseconds later, the pump starts. After a total of 15 seconds, the ignition cyclebegins.InterpurgeThe boiler enters an interpurge cycle if ignition is unsuccessful. The fan andpump continue to run, and ignition is delayed by an additional 15 seconds.PostpurgeThe fan remains on for 20 seconds and then reduces airflow to an ultra low flowmode for 90 minutes unless preempted.2-4INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERThe pump remains on for 5 minutes (adjustable) after the heating cycle ends.If the heating cycle ends as a result of water temperature exceeding the loadspecific band limit, the postpurge will continue as normal, but the boiler will enterthe circulating mode.The cut off temperature levels are specific for each load; they are determinedusing the preset target plus ½ of the supply differential entered. Default valuesfor such differentials are 20°F (+/- 10°F) for space heating with outdoor reset and16°F ( +/- 8°F) for DHW and other set point loads,If there is a Heating Enabled signal any time during this cycle, the postpurgeends, and a prepurge begins, otherwise the boiler will enter Standby mode.2.5.3 IgnitionAfter the prepurge, the gas valve opens for 4.0 seconds.If no flame is detected at the end of the trial, the interpurge cycle is entered. Ifignition fails 3 times successively, the boiler locks out for a 1 hour long interval,after which the ignition cycle is refreshed (e.g. for 3 further attempts). Alternately,the boiler can be powered down and restarted to accelerate the re-try sequence.The homeowner should follow up persistent recurrence of the 1 hour resetroutine by contacting a qualified service technician, to evaluate the cause of suchignition irregularity.With a successful ignition, the output of the boiler decreases immediately to a lowlevel, and the heating cycle begins.2.5.4 HeatingThe heating cycle lasts until the Heating Enabled state ends, or until watertemperature exceeds the target temperature by ½ of the supply differential for thelast served load and the throttle has fallen to the minimum output. At the end ofthe heating cycle, the boiler enters a postpurge.During the heating cycle, the boiler addresses the multiple defined loadsin accordance with its Prioritization algorithm. See Section 2.6.1. Boileroutput changes to meet heating demands as indicated by the temperaturecharacteristics of the boiler supply and return water. Boiler supply watertemperature targets vary according to the set up parameters entered, and aresubject to further variation for loads where Outdoor Reset has been selected.Where thermal loads are within the boiler’s 80 to 399 MBH throttle range, thecontrol algorithm seeks to regulate the boiler supply temperature within ±3°Fof the target temperature. On/Off differentials apply to loads below the 80 MBHminimum input rating.2.5.5 CirculatingThis cycle operates when water temperature exceeds target by 1/2 of the supplydifferential for that load at minimum output, and call for heat is still present. Afterentering a postpurge, the system pump remains on until water temperature is1/2 of the supply differential below setpoint temperature.In a two load system, Circulating mode will also run during transition from anyhigh temperature load (e.g. DHW at 180°F) to the cooler target (e.g. baseboardson Outdoor Reset, at perhaps 130°F). In the case where the boiler looptemperature is outside the applicable differentials, the burner will shut off whileBOILER SYSTEMS AND OPERATION2-5

SL 80-399 MODULATING GAS BOILERthe pump remains on until the loop drops ½ the differential below the new loadtarget temperature. Note: if there is no place to sink heat during such Circ. mode,this phase will continue indefinitely, affecting heat delivery.Thermal shock avoidance is key. Wherever two or more loads are used, andsettings could permit supply temperature differences greater than 20°F, external3-way motorized or injection mixing is called for.A thermal shock avoidance routine is employed to avoid undesirable effects oflarge temperature swings: the hot load pump remains on until the boiler’s returnwater sensor detects temperature stability - to sink excess heat. For example,upon satisfaction of a DHW call the DHW load pump will remain running until theboiler return water temperature falls to the DHW tank target temperature. Thisdeposits legacy heat from the primary loop into the water tank before activationof a cooler load.Always ensure that loads sensitive to high temperatures are protected usingappropriate means - e.g. a three way mixing valve set to restrict entering watertemperature to 130°F.2.5.6 - Error ModeThe controller continually checks sensors to see that they are operating withinnormal parameters. If sensors indicate the boiler is operating outside it limits, itwill declare an error condition.Two types of error conditions can occur:• Soft Errors: result when an abnormal condition exists which does not presentan immediate safety hazard. The boiler enters an extended purge, followedby the error cycle of 5 minutes for all conditions other than Maximum IgnitionTrials (a modified Hard Error which locks out for 1 hour after 3 unsuccessfulignition attempts). Following the purge, the fan and pump are stopped untilthe end of the error cycle. Normal operation then resumes.• Hard Errors: result when a condition exists that may be a safety hazard.The boiler enters an extended purge then the fan and pump are stopped.The boiler is in a lockout, and must be checked and restarted by a servicetechnician.See Section 5.3.1 Control Panel for a list of hard and soft errors and theirlikely causes. Note that other problems such as disconnected wires or defectivesensors may be the cause of the error. Always check connections and wiring first.2.6OTHER OPERATING FEATURES2.6.1 PrioritizationThe control module hosts a scheduling routine to manage the boiler’s operationwhen more than one load has been defined. The load scheduling features asdeveloped for the smaller VFC 15-150 and 45-225 models remain within theSL 80-399 code set, but sequential load management operation is not normallyrecommended with this larger model. Load scheduling allows adjustableprioritization across Loads 1, 2, and 3, with settable values from 20 to 90. Note:these values do not represent percentages and do not add up to 100; rather, theyare used to set relative importance of loads. To avoid instability, do not equalpriorities - spread loads by 10 points or more. A setting of “90” gives absolutepriority; otherwise, the difference between settings equals the run time (in2-6INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERminutes, for the initial cycle) of the higher load setting before switch-over to thesimultaneously calling load, e.g. DHW with priority set to 80 will run for approx.35 min. before switching to a clashing load set with priority 45. Following suchinitial cycle, the clashing loads will switch back and forth after further 10 min.intervals pending satisfaction of one or both loads.To cause repeated unequal run times (for example, constant 35 vs 5 min. runs) itis necessary to integrate an external load removing relay or timer on one of theheat calls (contact the Factory for details).2.6.2 Reset HeatingThe boiler offers Outdoor Reset control as standard equipment; this coordinatesthe control of boiler supply water temperature for space heating with the outdoortemperature. Outdoor Reset offers enhanced comfort and efficiency by usingvariable water temperatures to compensate for the differing rates of heat loss thata building faces as outdoor temperature changes. At any outdoor temperatureabove the coldest day expected, it automatically uses lower heating temperaturesthan would otherwise be used. This saves energy without sacrificing comfort.Figure 31: Outdoor reset curvesWhen applied within a condensing boiler, outdoor reset offers direct andsignificant combustion efficiency benefits by allowing generally lower circulatingwater temperature. This provides cooler return water to the boiler, promotingmore condensation (= energy capture).Contacts are provided for connection of an outdoor sensor (a tekmar 070 orsimilar sensor is shipped with each boiler) to be placed in an appropriate outdoorposition. The temperature management algorithm flexes the boiler supplytemperature according to characterized heating curves that are automaticallycalled up through the load declaration process. Curves are provided for eachof the radiation terminal types offered - e.g. high or low mass radiant floor, airhandler, finned tube baseboards etc.In an “open loop” reset system, a room or zone thermostat is used to send a callfor heat over a 24VAC lead; this opens the respective zone valve, and signalsthe boiler to fire using onward leads to the boiler’s dry contacts (use one of thepairs marked “Therm 1, 2 or 3” on the Sensor Block terminal strip. Gang suchleads in parallel from multiple zone valves for single connection to the boiler.BOILER SYSTEMS AND OPERATION2-7

SL 80-399 MODULATING GAS BOILERNote that typical room thermostats simply provide a call for heat, they do notcontrol the circulating water temperature from the boiler in an open loop resetsystem. Adjustment of a room thermostat from 23°C to 30°C will make no furtherdifference to the delivered temperature if the floor slab has stabilized at the boilertemperature served up by the reset curve.Where Outdoor Reset is applied without the indoor sensor feedback option, somemanual adjustment may be required to achieve the desired comfort level. Fineadjustment can be made at the keypad using the Indoor Setpoint Temperaturevariable, located as Line 1 in the User screen. To increase heat (e.g. from 72°F to73°) - move the Indoor value upward (warmer) from the level otherwise chosen.This shifts the position of the reset curve, will amend the boiler water temperatureby a similar amount. Do not adjust the Design Indoor Temp. value - a movementupward in concert with Line 1 adjustment will have the effect of neutralizing theintended effect.An optional indoor temperature feedback routine can be activated (with fieldinstallation of an indoor sensor, connected to the contacts located on thecontroller) to automate adjustment of the Outdoor Reset routine.The key inputs on initial set up are (1) Design Outdoor Temperature – the coldestexpected weather typically experienced at the installation site; (2) the DesignSupply Temperature – the desired boiler operating level to occur at that coldestday; and (3) the Design Indoor Temp. - this is the value that anchors the resetcurve. The Indoor Set Point Temp. variable is the primary means for the user to“bias” the outdoor reset routine to add or reduce heat.If outdoor reset is selected and there is no signal received from the sensor,the controller assigns a provisional 0°C value and will adopt the appropriatetemperature target from the relevant reset curve.See Section 2.7 Set Up & Load Definition for activation procedure.2.6.3 Variable Speed PumpingThe controller provides an electrical signal (4-20mA) for connection to pumps thatare capable of using this signal to vary their rotational speed.ΔT° management across the majority of the boiler’s operating range can beachieved with proper piping and control configuration, but this feature is currentlynot supported without direct consultation with the IBC Factory.Where a conventional pump is correctly wired in accordance with the wiringdiagram, the pump will operate at a single, high speed.2.6.4 Temperature SetbackFor heating loads declared as Space Heating (e.g. with Outdoor Reset) and/or DHW (where a thermistor probe is used), there are provisions for enteringtemperature setback intervals. During the setback period, the boiler supplywater temperature target is adjusted from the pre-set fixed or floating (withOutdoor Reset) levels. There is a simultaneous movement in the Indoor SetpointTemperature or DHW Tank Setpoint, to yield a consistent spread and avoidundesirable cycling. Normally users would apply this feature to achieve fuelsavings during night-or-away hours. It is also possible to use the feature toset forward (up) the temperature; this may be of use for certain commercialapplications where short-term high temperature DHW service is desired.Up to 56 events / week can be programmed for each eligible load – for example,DHW can be set back twice and returned (twice) each day. The routine can beapplied by specific day (Mon-Sun).2-8INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERThe automated setback feature cannot be applied to setpoint loads, includingDHW with simple aquastat control. This is due to the lack of linkage with thethermostat; setback without linkage could lead to unacceptable cycling.Access is via the User Setup screen.2.6.5 Unoccupied ModeUsers can further reduce energy consumption by switching the boiler to theunoccupied mode during holidays or other away periods.While in the Unoccupied mode, the DHW load is turned off, while Space Heatingloads for which Outdoor Reset is activated will drop both the circulating water andthe indoor setpoint temperature parameters to 50°F. Set Point controlled loadsare not adjusted through this process, to avoid the potential for boiler cycling asthere is no linkage with the relevant thermostat.On the main User Setup Menu, select “Occupancy Status”, then toggle betweenOccupied (top button) and Unoccupied (lower button) as desired.2.6.6 Summer ShutdownDuring the Installer set up process, a cut-off level for outdoor temperature can beselected - to curtail any further space heating. This is typically used to turn off anOutdoor Reset enabled load once the outdoor temperature reaches a thresholdlevel e.g. 60°F. The load will be automatically reactivated once the weatherreturns to levels below the selected threshold. Use of this feature with a value 5°- 10°F below the Indoor Setpoint Temperature is strongly recommended to avoidshort cycling of the boiler during very marginal heating conditions.From the main Installer Setup Menu, select “Heat Load Configuration”, then“Configure Load (use the load number tagged as Space Heating)”, and dropdown to “Summer Shutdown”. Press Enter to select, then use the keys to movethe threshold temperature to the desired level, and press the centre key again torecord. The controller must receive a valid signal from the tekmar 070 outdoorsensor, supplied with the boiler, to operate.2.6.7 Remote / Subordinate ModeInstallers have the option of placing the control of the boiler under an externalelectronic controller (such as a tekmar 265). Connections are provided toreceive a 0-10vDC or 4-20 mA signal for throttle management. The defaultconfiguration is 4-20mA; to switch over to 0-10V, remove the electrical boxcorner cover to provide access to the slotted clearance hole on the lower rightcorner of the control module; use needle-nose pliers to move the plastic jumpertab from the right two terminals to the left two terminals accessible throughthe slotted clearance hole. Where the IBC controller senses a signal on theremote connections, it automatically subordinates its internal throttle logic, andadopts the external signal. In such slave mode, temperature management isalso surrendered to the external controller’s sensors. The installer only entersMaximum Boiler Supply and On/Off Differential temperatures; the boiler willrespond to these as high limit switches.From the main Installer Setup Menu, select “Define Load (with desired #)”, thenlocate and enter “External Control”. Next, configure the load with the Maximumand Differential temperature values.BOILER SYSTEMS AND OPERATION2-9

SL 80-399 MODULATING GAS BOILER2.7SET UP & LOAD DEFINITIONAfter the boiler is powered up, the installer can use the keypad and display tocharacterize the application, as follows:1. In the Standby mode, start by pressing any key to call up the Main Menu.2. Using the directional keys, move the cursor to Installer Setup, then depressthe centre (Enter) key. See Section 2.4.5. Passwords if these are in use ordesired.3. Select Date & Time (and Enter), then move the cursor about to adjust time(on a 24:00 hour basis), date and invoke Daylight Savings if appropriate. Usethe upper key to increase a value (e.g. date, time, temperature), the bottomkey to reduce. Note that it is often possible to move in steps of 10 or 100 bymoving the cursor right or left once a field has been selected for adjustment.Hit the Enter key to record the desired / amended information after eachvalue has been selected.4. Use the left-most key to step back to the Installer Setup screen, and selectHeat Load Configuration for input of the load characteristics.5. Each of the boiler’s 3 Load positions can be configured for any type ofheating. VFC boilers are factory shipped with default settings as follows:Load 1 set as Space Heating or Reset Heating, with High Mass RadiantFloor set as the terminal type; Load 2 as Set Point; and Load 3 as DHW. Thefactory defaults can be changed using the Define Load 1-2-3 lines to reversethe order, turn off a Load or do whatever the installer desires.6. Once the appropriate Loads are set, use the left-hand key to move back to theSetup Heating Loads screen, then move down to Configure Load 1 (and hit enter).7. The screen will display the input fields appropriate to the nature of the loadselected, e.g. Design Outdoor Temp. for a Space Heating (or Reset Heating)load. Note: these fields are pre-loaded with default values that are to bealtered to reflect the desired parameters.8. For reset loads, the initial selection to be made addresses the “emitter” type– choices include H(high) Mass Radiant, L(ow) Mass Radiant, Baseboard, AirHandler etc. An appropriate reset curve is called up through this procedure.Reset loads carry a default value for Design Outdoor Temp. of -10°F (-23°C).Raise or lower this as appropriate – e.g. for Vancouver or Seattle, use 19°to 25°F, while for Edmonton or Fargo -30°F would be more appropriate.Note: - for some users, this adjustment may seem counter-intuitive. Movingthe setting toward a colder design value will have the effect of reducing theboiler’s target temperature for any given weather, because a given currentcondition is relatively warmer than the designated “coldest” day.Moving down the screen, set the Design Supply Temperature – the targetedtemp. for circulating water on the coldest day. For an in-slab radiant floorthis would typically be 125°F (50°C). For finned tube baseboards typicallydriven at 180°F, try 160°F max. instead, to promote combustion efficiency.For air handlers, try running 20°F lower than typically used. Of course, theappropriate setting will depend on the characteristics of the emitter and thebuilding but in general the SL modulating boiler’s large throttle turndown willallow better average temp. control, permitting lower maximums.9. For Reset Loads, move down the screen again to display more lines;2-10INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERUse the Summer Shutdown field to enter a threshold temperature for theavoidance of heating during warmer times. This is typically set at 60° to 65°Fso as to eliminate excessive boiler cycling in marginal heating conditions.Use the Minimum Temp. field to optimize boiler run times on low mass loads.Finned tube baseboards sink very little heat when operated below 100°F;application of a “full reset curve” (e.g. 160°F right down to a 70°F roomtarget) would cause boiler cycling in light-to-moderate heating conditions.Set baseboard minimums at 100-120°F and aim for 4 or less cycles/hr. Aminimum setting can also be used to enhance home comfort with single orexcessive speed air handlers to avoid the cool blast effect. Set the lowestpossible level for combustion efficiency.10. For all loads, select and enter a Maximum allowable temperature and on/off Supply Differential Temp. Note these values must be input; they are notautomatically assigned as done within some boiler controls. Ensure theMaximum takes account of the construction and safety requirements of eachapplication – e.g., 140°F max. for typical in-slab radiant floor, for avoidance ofthermal stress. The Differential shall be set to offer a reasonable temperaturecontrol range (suggested values: 20°F for high mass radiant // 30°F for lowmass baseboards // 16°F for DHW). Ensure that the spread between theTarget and Maximum temps is greater than one half of the Differential (e.g.for a radiant floor Design Supply Temperature of 125°F and a Maximum of140°F, a differential of 20°F (half of which is 10°F) fits nicely.11. Avoid situations where the Maximum is close or below the potential Target, orthe boiler will cycle off its (software) water high limit.12. Priority:- where more than one load is present, it is critical that a value beentered to allow reasonable load scheduling (see Section 2.6.1).13. At the lower end of the Load 1-2-3 setup screen, there are 4 lines availablefor “mapping” of sensor inputs.. For example, “Indoor Temp. from …..Indoor”indicates that the boiler will look for a signal from an indoor sensor on theIndoor Sensor wiring contacts. Failing a valid signal, the screen will display“Indoor Temp. …..Open”, and there will be no effective indoor trim of thereset curve. These lines do not require amendment at most installation sites.The mapping feature allows reassignment of the sensor contacts to supportnon-standard functions. For example, re-allocation of the Water Temp. signalfrom “(boiler) Outlet” to “Secondary Loop” will allow the throttle managementroutine to manage a secondary loop temperature rather than the boiler’s owndirect supply temperature. Use this when injecting into a commercial heating:cooling loop. Another possibility: two separate reset channels – each with itsown indoor trim. Sensor ports open for such re-assignment are DHW, Indoor,Outdoor and Secondary Loop.14. The final 3 lines are for the motorized mixing valve option. See separatedocumentation for this.15. To compensate for altitude at the installation site, use the Altitude adjustmentfeature, found in the front Installer Setup menu (several lines below “HeatLoad Configuration”. Key in the altitude – in hundreds of feet above sealevel. For example, an installation at 2,860 feet should be entered as “29” (asrounded to the nearest hundred).16. Two lines below Altitude adjustment is the field for amendment of the primarypump heat purge time. To shorten the 5 minute post-firing period, reduce the300 second interval to as low as 60 sec. Similar adjustment of secondarypump run time can be made in the Heat Load Configuration / Configure Load1,2,3 fields (down to zero sec.= off).BOILER SYSTEMS AND OPERATION2-11

SL 80-399 MODULATING GAS BOILER17. Upon completion of the input of load parameters, use the left button to stepback through the menu system to return to the Operating Status screen.18. To enact the control arrangements as input, it is necessary that the pipingstructure and system wiring are configured appropriately (refer to Section1.6.2 Installation Rules, page 1-20 for piping layouts and the WiringSchematics on pages 6-4 and 6-5). Ensure that DHW aquastat or thermistorprobe leads, thermostat and pump (or zone valve) leads are connected attheir respective contact points on the terminal block.19. Forced shutdown: – use the Heat Load Configuration screen to switch offload(s) to remove a call for heat, if no other means are readily available.Simple removal of power to boiler is to be avoided – this interruptsthe moisture management routine. Treat the unit as you would treat acomputer, allowing an orderly shutdown.2-12INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER3.0STARTUP AND COMMISSIONING3.1 LIGHTING AND SHUTTING DOWNTHE BOILERSTARTUP AND COMMISSIONING3-1

SL 80-399 MODULATING GAS BOILER3.2 PRIOR TO START-UPWARNINGFill trap with water beforeboiler is first fired to preventexhaust fumes from enteringroom. Never operate theboiler unless the trap is filledwith water.Failure to comply will resultin severe personal injury ordeath.3.2.1 Pre-Ignition Checks1. Ensure venting system is complete and seal tested. Confirm any commonventing system at the installation site is isolated and independent of the SLboiler, that any holes left from removal of a previous boiler have been sealed,and that any resizing of the old flue has been done. Fill condensation trap.2. Check water piping system is fully flushed and charged, and that all air hasbeen discharged through loosened bleed caps. Note it is possible to switchall pumps on/off from the keypad – without a call for heat. This greatlysimplifies system filling and air bleeding (go to Installer Setup, drop downto Pump Purge and toggle to On. When complete, return to Off, or this willautomatically occur with a call for heat). Use a minimum water pressure of 12psig. And confirm pressure relief valve is installed and safely drained.3. Perform a final check of electrical wiring.4. Using a manometer, check to see that adequate gas pressure is presentat the inlet gas supply test port. Requirements are minimum 5” w.c andmaximum 14” w.c.3.2.2 Test Ignition Safety ShutoffError displayed after testing ignitionsafety shut offWith the boiler in operation, test the ignition system safety shutoff device byshutting the manual gas valve immediately outside the boiler case. Ensureboiler has shut off and the appropriate Error information is displayed on the LCDscreen. To restart boiler, reset power.3.3commissioningThe SL 80-399 modulating boiler is factory calibrated to operate with naturalgas (or propane if so ordered) at sea level. The relevant valve adjustmentscrews have been factory sealed using Loctite thread-lock compound, whichcan be broken where required. However, no mixture adjustment shall beperformed unless done by a qualified technician using properly functioningcombustion analyzing equipment.Inlet gas supply pressure test portUpon initial set up, the installer can enter the site elevation to compensatefor altitude. Without such intervention, the gas valve will automatically de-ratethe maximum input in accordance with the density altitude, by approximately 2%per 1,000’ above sea level. The gas valve’s zero governor will ensure that thegas:air mixture is not affected at altitude.To verify the proper operation of the gas valve in the field, the following procedurecan be carried out by a qualified technician (see Figure 28).Manifold pressure test port3-21. with a small (1/8" or 3 mm) flat screwdriver, open the manifold pressuretest port by turning its centre- screw 1 full turn counterclockwise. Attach amanometer between the manifold pressure test port and the reference line.2. Allow the boiler to ignite / run against a large load, to maintain high fire3. With the boiler at maximum output, use a 2 mm hex key to adjust the zerooffset(see Figure 28, “A”) as required to achieve 0” wc. This adjustment isonly necessary if this screw has been tampered with.INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERDANGERMaking adjustments tothe IBC gas valve withouta properly calibrated gascombustion analyzer and bypersons who are not trainedand experienced in its useis forbidden. Failure to usean analyzer can result in animmediate hazard.4. With a combustion analyzer probe in the flue gas test port, turn the Gas:AirRatio Adjustment screw (see Figure 28, “B”) to achieve 25% excess air(corresponding CO2 values are 9.4% for natural gas and 10.7% for propane).This screw offers very fine adjustment, and may require several turns.Note: This screw has significant backlash. When changing direction of turn,it may take up to a full turn before any change is indicated on the analyzerreading. Clock the gas meter to confirm full maximum rating plate input.5. To confirm or adjust the minimum fire level settings, Re-define the load as“Manual Control”. Use Heat Output in “Configure Load x” to control the outputas needed.6. At the minimum firing rate, adjust the zero-offset screw (see Figure 28, “A”)to obtain 25% excess air. It may be necessary to reduce the output in stagesif this adjustment has been tampered with.7. Turn boiler off by removing the call for heat (use the Heat Load Configurationscreen to turn load to off if no other ready means available), then remove themanometer connections, and turn the centre-screw in the manifold pressuretest port 1 full turn clockwise. Ensure fully closed, but not over-tightened.Zero-offset adjustment screwRemoval of flue gas test port plugInsertion of flue gas analyzer probeGas:Air ratio adjustment screwFlue gas test port plugFigure 32: Gas Valve and Pressure Reference SystemSTARTUP AND COMMISSIONING3-3

SL 80-399 MODULATING GAS BOILERNOTEThe safety warning regardingburner refractory on page4-2 of this manual must beobserved.3.3.1 Gaining access to combustion chamber, burnerremoval instructions1. Remove fan and gas valve assembly. See “Fan and gas valve removalinstructions” on page 4-6 of this manual.2. Disconnect the igniter cable and move it out of the way.3. Remove the two screws that secure the igniter to the lid using a # 2 Phillipsscrewdriver.4. Carefully remove the igniter by sliding it straight up.5. Remove the igniter gasket and place parts on a clean dry area.6. Remove the 6 hex nuts that attach the heat exchanger lid to the heatexchanger. A 10 mm open end wrench or socket will be required.7. With a permanent marker or equivalent, make an alignment mark betweenthe lid and heat exchanger.8. Before removing the lid, it is important to be positioned directly above it to ensurea straight up extraction. Failing to do this may result in refractory damage.9. Slowly lift the lid-burner assembly off the heat exchanger. The refractoryshould remain in place in the combustion chamber shoulder. Note thatthere is less than 1/8” (3 mm) clearance between the burner walls and therefractory. Care must be observed to ensure minimal contact between theseparts to prevent refractory cracking.10. Place the lid with the burner attached, on a clean dry area.11. With a permanent marker or equivalent, make an alignment mark on therefractory lining it up with the same mark made earlier between the lid andheat exchanger.12. Carefully remove the refractory and place in a clean dry area.13. If burner needs to be removed, gradually loosen up the 8 screws that securethe burner to the heat exchanger lid using a #2 Phillips screwdriver. Removescrews and burner.Re-assembly1. Inspect burner gasket. Look for cracks, deterioration or signs of gas bypass.Replace if necessary.2. Place heat exchanger lid on a flat surface and position the gasket on the lid,aligning it with the screw holes.3. Install the burner in place with its 8 screws, tightening the screws gradually andin a cross sequence. Do not over tighten, hand tight plus 1/2 turn should besufficient to maintain a good seal and prevent deformation of the burner flange.4. Inspect refractory for cracks, degradation and flatness. If in doubt, replacewith a new one.5. If installing a new refractory, first place it onto the lid, aligning it at the igniterhole, then make an alignment mark on the refractory to coincide with thepreviously made line on the lid.6. Carefully insert refractory onto heat exchanger combustion chamber, usingthe alignment marks for proper positioning.7. Ensure that the lid (orange) gasket is in place and flat.8. Carefully insert the lid-burner assembly straight down ensuring limited contactbetween burner and refractory and observing the alignment markings.9. Install the 6 hex nuts to secure the lid in place, tighten by hand, then anextra 1/2 turn. Caution! Over-tightening these nuts will cause lid to warp andpossibly leak fumes or flames.10. Re-install igniter, tightening its screws by hand, then an extra 1/2 turn.11. Re-attach igniter wire to igniter.3-4INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER4.04.1MAINTENANCEBOILER MAINTENANCECAUTIONThe owner is responsible forgeneral care of the boiler.Improper maintenance ofthe boiler may result in ahazardous condition.CAUTIONLabel all wires prior todisconnection when servicingcontrols. Wiring errorscan cause improper anddangerous operation.WARNINGFill trap with water beforeboiler is first fired to preventexhaust fumes from enteringroom. Never operate theboiler unless the trap is filledwith water.Failure to comply will resultin severe personal injury ordeath.WARNINGWhenever the burner isremoved for inspection orboiler servicing, the sealinggaskets must be examinedand replaced if damaged.Upon re-assembly, anapproved leak test solutionmust be applied around theburner flange sealing area toensure there is no leakage ofcombustible gas/air premix.4.1.1 General Care• Keep combustible materials and flammable liquids and vapours away from theboiler.• Keep vent terminals clear of obstructions (snow, dirt, etc.).4.1.2 InspectionInspection of the boiler is to be performed annually by a qualified servicetechnician.4.1.3 Venting• Check vent terminals for and remove any obstructions (e.g. leaves, dust,other debris).• Check, and clean or replace intake air filters or screens as required.• Check for holes or leaks in venting. Replace venting as needed.• Examine for any signs of moisture caused by sweating intake air pipes;insulate as required.4.1.4 Condensate Traps• Condensate trap must be examined every two months to see if cleaning isnecessary (refer to trap cleaning instructions on page 1-14 of this manual).Ensure that trap has been re-filled completely before firing boiler.• If condensate neutralization is used, check pH level of condensate discharge.4.1.5 Burner• Annually, remove burner to inspect for extent of fouling (refer to burnerremoval and reassembly instructions on page 3-4, adjacent page). Blowclear using compressed air. Evaluate the magnitude of clearing required, andestablish a reasonable burner inspection schedule. Some boiler / locationsmay call for annual service, others showing clean burners will only needattention every 2 – 5 years. Consider adding air filtration if burner requirescleaning every year. In alternate years, visually inspect burner through sightglass. Ensure flame is stable and without excessive fluttering. Normal flamepattern is evenly distributed over the burner surface.• If burner is operating improperly, remove and clean or replace. Use a CO2analyzer to determine proper combustion. CO2 level should be 9.4% (fornatural gas) or 10.7% (propane).MAINTENANCE4-1

SL 80-399 MODULATING GAS BOILERWARNINGThe IBC heat exchanger has asmall amount of combustionchamber insulation (refractory),which contains ceramic fibers.When exposed to extremely hightemperatures, the ceramic fibers,which contain crystalline silica,can be converted into cristobalite- which is classified as apossible human carcinogen.Care should be taken to avoiddisturbing or damaging the refractory.If damage occurs, contactthe factory for directions.Avoid breathing and contact withskin and eyes and follow theseprecautions:1. For conditions of frequentuse or heavy exposure, respiratorprotection is required. Referto the “NIOSH Guide to theSelection and Use of ParticulateRespirators Certified under 42CFR 84” for selection and use ofrespirators certified by NIOSH.For the most current information,NIOSH can be contacted at1-800-356-4676 or on the web atwww.cdc.gov/niosh.2. Wear long sleeved, loose fittingclothing, gloves and eyesprotection.3. Assure adequate ventilation.4. Wash with soap and waterafter contact.5. Wash potentially contaminatedclothes separately fromother laundry and rinse washingmachine thoroughly.6. Discard used insulation in anair tight plastic bag.NIOSH stated first aid:Eye contact - Irrigate and washimmediately.Breathing - Provide fresh air.4.1.6 Heat ExchangerDuring annual inspection (with the burner removed), examine the heat exchangerfor signs of contamination and clean if neccessary. In areas of poor gas quality,there may be a buildup of black plaque (typically sulfur). Other fouling agents:airborne dust, debris and volatiles.Refer to burner removal instructions on page 3-4 for access to combustionchamber and heat exchanger. Note that the safety warning regarding burnerrefractory on page 4-2 on this page must be observed.4.1.7 PumpCheck that the pump is on in normal operation and that the water Δ°T isreasonable for a given firing rate (e.g. 10°F between supply and return whenfiring at 200,000 Btu/hr.).4.1.8 Gas PipingCheck for damage or leaks and repair as needed.4.1.9 Control Module• Check that boiler operation is consistent with the steps in Section 2.5Sequence of Operation.• Check that water temperature targets and setpoint is satisfactory and havenot been adversely amended.• Check the operating history using the screen: - use Installer Setup // Logs, toscan for hours of service, cycles per hour, and any logged errors. One methodis to use the graphical presentation of the duty cycle by load – go to Logs,move the cursor to a load and push “Enter” to access. This gives a profile ofthe boiler’s duty cycle by throttle level.• If a problem exists with the control, consult troubleshooting guide.4.1.10 Water• Check water pressure and temperature. There should be no noticeablechange if boiler is functioning normally. Check for any noise in the system.• Check water piping for damage or leaks and repair as needed.• Check for 12-15 psig in normal operation, and look to ensure pressure doesnot run up toward 30 psig at high temperature. If pressure rises sharply,consider replacement of expansion tank. Check also for noise at high fire,which may signal water quality problems.• Check water piping for damage or leaks and repair as needed.• Water chemistry shall be of a quality generally accepted as suitable forhydronic applications.• Ensure any direct “city fill” water connections are left in the closed position tominimize exposure to leaks and flooding.4.1.11 Freeze ProtectionCheck freeze protection. Use only antifreeze made specifically for hydronicsystems. Inhibited propylene glycol is recommended. Antifreeze volume must notexceed 50% of the total volume of water in the system.4-2INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERWARNINGDo not use automotive-typeethylene or other types ofautomotive glycol antifreeze,or undiluted antifreeze ofany kind. This may resultin severe boiler damage. Itis the responsibility of theInstaller to ensure that glycolsolutions are formulated toinhibit corrosion in hydronicheating systems of mixedmaterials. Improper mixturesand chemical additives maycause damage to ferrous andnon-ferrous components aswell as non-metallic, wettedcomponents, normally foundin hydronic systems. Ethyleneglycol is toxic, and may beprohibited for use by codesapplicable to your installationlocation. For environmentaland toxicity reasons, IBCrecommends only using nontoxicpropylene glycol.NOTEInstallers should inquire oflocal water purveyors as tothe suitability of their supplyfor use in hydronic heatingsystems.If water quality isquestionable, a local watertreatment expert mustbe consulted for testing,assessment and, if required,treatment.Alternatively, water or hydronicfluid of known quality can bebrought to the site.4.1.12 Boiler Treatment• Check consistency of any boiler treatment used, for appropriate mixture.Chemical inhibitors are consumed over time, lowering their density.• Verify proper operation after servicing.4.1.13 Relief Valve - Maintenance and TestingThe relief valve manufacturer requires that under normal operating conditionsa “try lever test” must be performed every two months. Under severe serviceconditions, 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 performedat the end of any non-service period.Test at or near maximum operating pressure by holding the test lever fully openfor at least 5 seconds to flush the valve seat free of sediment and debris. Thenrelease the lever and permit the valve to snap shut.If the lever does not activate, or there is not evidence of discharge, discontinueuse of equipment immediately and contact a licensed contractor or qualifiedservice personnel.If the relief valve does not completely seal, and fluid continues to leak from thedischarge pipe - perform the test again to try and flush any debris that may belodged in the valve. If repeated tries fail to stop the leakage, contact a licensedcontractor or qualified service personnel to replace the valve.While performing a “try lever test”, a quantity of heat transfer fluid will bedischarged from the piping system and the system pressure will drop. This fluidmust be replaced. It is highly recommended that a system pressurization unit,such as an Axiom Industries model MF200 be employed to refill and pressurizeyour system. Capture the discharged fluid in a container and recycle it byreturning it to the system feeder unit. This is particularly important when yoursystem contains treatment chemicals or glycol solutions. If the system employsplain water, the boiler auto fill valve must be turned on in order to recharge thelost fluid.CAUTIONBefore testing the relief valve,make certain the dischargepipe is properly connected tothe valve outlet and arrangedto contain and safely disposeof equipment discharge.MAINTENANCE4-3

SL 80-399 MODULATING GAS BOILER4.2GEOGRAPHY & COMPONENTSRemove top cover button boltsGas Inlet BlockTurn cover button Counter ClockWise to loosenLift top cover up at frontGas Valve BodyCover tilts back, then lift up and offTop cover lifts up and outFan Swirl plate (Air Inlet) between Fan andGas ValveClear access to top componentsClear access to front componentsFan air pressure reference tube4-4INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERBurner Flange BoltsTridicator Gauge on Supply RiserLow Water Cut-Off Module behind ControlPanelFan Flange BoltsManual Reset Water High Limit Switch onSupply Riser (red button is reset)Upper Vessel High Limit Switch onpressure vessel upper support bracketIgnitor Cable connected to IgnitorSight glass (inspection port)Low Water Cut-Off Probe on Supply RiserFlue Temperature Sensor on the ventbehind the Supply RiserMAINTENANCE4-5

SL 80-399 MODULATING GAS BOILER4.2.1 Fan and gas valve removal instructions1. Turn off electric power and gas supply to the boiler.2. Ensure boiler cools down to ambient temperature. Do not drain the boilerunless freezing conditions are expected during this procedure.3. Remove front cover, then remove boiler upper-front cover by removing thetwo yellow thumbscrews at the top right and left corner of the boiler. No toolsare required.4. A ladder or step may be required to have a clear vertical view of the workarea. Do not attempt to reach from the front without a clear view, as damageto connectors, screws or refractory may occur.5. Unplug both upper and lower electrical connectors from the fan.6. Unplug the electrical connector from the gas valve by removing the 1/4”connector attaching screw.7. Position the harnesses out of the way of the heat exchanger lid.8. Unplug the clear tube from the swirl plate pressure reference port.9. Remove the 4 hex head socket screws that attach the gas inlet block to thegas valve using a 4 mm hex (Allen) key or driver. These screws should befirst loosened up slightly in cross sequence to prevent deformation of themating parts.10. With the yellow flexible gas line still attached, the gas inlet block is now freeto move but should only be separated from the gas valve a maximum of 1inch (25 mm), which is sufficient for fan and gas valve removal. There isan o-ring installed between the gas inlet block and gas valve, and it shouldremain positioned on the block’s groove. If it falls out it is important that it bepositioned back on the groove or saved for re-assembly.11. Remove the 4 hex nuts that attach the fan to the heat exchanger lid. A 10mm open end wrench or socket will be required.12. With the gas valve and swirl plate still attached, remove the fan by pullingstraight up ensuring that no wires are caught and that the gas line remains inplace. Place the removed components in a clean, dry area.13. If the fan is being replaced: With a permanent marker or equivalent, makean alignment mark between the fan and swirl plate adapter and use a 6 mmhex (Allen) key or driver, remove the 3 screws that attach the gas valve/swirlplate assembly to the fan.4-64.2.2 Fan and gas valve re-installation1. If the gas valve has been removed, reattach it to the swirl plate.2. Re-attach gas valve and swirl plate assembly onto fan observing thealignment marks made during disassembly.3. Ensure that fan (orange) gasket is in place.4. Re-install f an-gas valve assembly onto heat exchanger lid tightening the 4hex nuts by hand then an extra 1/2 turn.5. Re-plug both upper and lower fan harness connectors.6. Re-plug gas valve connector and tighten up retaining screw.7. If a new gas valve is being installed, remove the protective cover from thegas inlet now.8. Re-attach gas inlet block onto gas valve ensuring that the o-ring seal is inplace. If this O-ring is lost, it must be replaced with a factory supplied O-ring.9. Tighten up the 4 gas inlet block screws in cross sequence, first hand tightand then an extra 1/2 turn.10. Re-connect clear pressure reference tube onto swirl plate port.11. Open up gas valve and check for possible leaks.12. Return electric power to the boiler and perform start up routine.13. Check for gas or fumes leaks after 10 minutes of continuous operation.INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER5.0 TROUBLESHOOTINGThe troubleshooting section is divided into 3 sections:5.1 Preliminary Checks5.2 Electronic Components5.3 Troubleshooting GuideOften, a problem can be identified and solved through simple checks of thebasics: confirming the electrical power supply, gas flow and resetting thethermostat control. To extend the cover of such preliminary checks, the boiler’scontrol module offers a clear visual display of the status of the various controlcircuit components.Should a problem remain unsolved after applying the preliminary checks,proceed to the detailed system review, using the Troubleshooting Guide. TheGuide covers potential error conditions as grouped into the following categories:5.3.1 Using Control Module Errors Displayed5.3.2 Ignition Problems5.3.3 Cycling Problems5.3.4 Temperature Problems5.3.5 MiscellaneousBelow each section is a list of Symptoms, Diagnoses, and Remedies.Also provided with this manual are a number of diagrams (see Section 6.0) foruse with troubleshooting including:• Electrical Wiring Diagrams• Sequence of Operations Flowchart• Boiler Component Layout Diagrams5.1Preliminary ChecksThe first step in troubleshooting this system should be a review of the Controller’sLCD screen. There are a number of diagnostic features incorporated in thesoftware that evaluate system integrity, display error conditions and provide initialsuggested remedial actions (see Section 2.5.6 Error Mode.)In addition to checking the display, the following list is a guideline fortroubleshooting:1. Confirm power to the boiler: check that control module display is on (e.g.display is lit).2. Check that boiler is not in a safety lockout.3. Ensure wiring is clean and secure.4. Check that gas is reaching the unit.5. Confirm water system is properly charged to 12 psig and pump isserviceable.TROUBLESHOOTING5-1

SL 80-399 MODULATING GAS BOILER5.2Electronic ComponentsThis section details the method for troubleshooting the non-standard electroniccomponents on the boiler including the electronic differential air pressure sensorand the temperature sensors.5.2.1 Temperature SensorsThe resistance of the temperature sensors varies inversely with temperature. Totest, measure the temperature of the sensed environment and compare with thevalue derived from the measurement of the resistance (obtained by connecting agood quality test meter capable of measuring up to 5,000 kΩ (5,000,000Ω) at thecontroller end of the sensor lead).To obtain a resistance reading, remove power to the boiler. For the supply waterand vent temperature sensors, remove the wire leads by disconnecting theirrespective Molex connectors. Place multi-meter probes into sensor’s femaleMolex connector socket. Do not apply voltage to the sensor (damage may result).Return water temperature sensorFor the return water temperature sensor, locate the blue 2-wire leads comingfrom the strap on sensor on the return pipe. Disconnect the Molex connectorlocated approx. 6" from the sensor. Place multi-meter probes into the sensor’sfemale Molex connector socket. Do not apply voltage.Supply water temperature sensor10KΩ sensors supplied with boiler2 x Water temperature sensors1 x Outdoor sensor (shown above)1 x Vent temperature sensorSee table #8 for resistance valuesTEMPERATURE RESISTANCE TEMPERATURE RESISTANCE°F °C Ω °F °C Ω0 -18 85,362 100 38 5,8285 -15 72,918 105 41 5,21010 -12 62,465 110 43 4,66515 -9 53,658 115 46 4,18420 -7 42,218 120 49 3,76025 -4 39,913 125 52 3,38330 -1 34,558 130 54 3,05035 2 29,996 135 57 2,75440 4 26,099 140 60 2,49045 7 22,763 145 63 2,25550 10 19,900 150 66 2,04555 13 17,436 155 68 1,85760 16 15,311 160 71 1,68965 18 13,474 165 74 1,53870 21 11,883 170 77 1,40375 24 10,501 175 79 1,28180 27 9,299 180 82 1,17285 29 8,250 185 85 1,07390 32 7,334 190 88 98395 35 6,532 195 91 903Table 8: Temperature Sensor resistance values5-2INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER5.2.2 Fan/BlowerOperating power is provided by means of a separate 115 VAC connector at thebottom of the fan (white/black/green). Control of the fan is provided via a fourlead connector at the top of the fan. This connector feeds a PWM control signal(black wire) from the controller and provides a tachometer signal (white wire)back from the fan. Unplugging the control connector will cause the fan to go tohigh speed and trigger a “Blocked Vent Error” within 6 seconds if the boiler isoperating.Control wire plugLead Color Function TroubleshootingRedBlueBlack35 VDC Positive powerterminal35 VDC Negative powerterminalSignal from controllerFan will only operate at max.speed if disconnected.Fan will only operate at max.speed if disconnected.Fan will only operate at max.speed if disconnected.White Fan tach. 2 pulses/rev (freq x 30=rpm)Table 9: Fan Operation5.2.3 Differential Air Pressure SensorUnplug to run fan full speedGo to the Advanced Diagnostics screen, and with the fan off (“Fan Duty Cycle =0) look for a Fan Pressure reading of 102 +/-5. Next check with fan in operation,and look for an increased Fan Pressure value. In normal operation, the FanPressure reading should move toward the Required Pressure value. A backwardmovement in Fan Pressure indicates the clear vinyl air pressure line has beenconnected to the wrong port on the sensor body.Removing circuit board terminalcoverCircuit boardFigure 29 (right): Testpoints on circuit boardfor air pressure sensorvoltage readingsRemove terminal plugs, then circuitboard coverTROUBLESHOOTING5-3

SL 80-399 MODULATING GAS BOILERNext, confirm that the circuit is properly powered. The supply voltage to thesensor should be 13.8 VDC; to check, the simplest technique is to measure thecircuit on the face of the controller circuit board (vs. an attempt to splice into theharness / connectors). See previous page for a presentation of the measurementpoints.Air pressure sensor mountingFinally, to measure the sensor output, connect a DC volt meter between points“J501-33” (located on the footprint of the 34 pin connector – immediately belowthe right leg of the LCD display - second pin from bottom right) and GND (seeabove). With the fan off, the measure should read 0.5VDC. With a Fan Pressureof approx. 300, the meter will read 1.5v (approx.). Note:- this component is asensor, not a switch; do not over-pressurize by blowing into the air referencelines. Maximum pressure capacity is 40” w.c. @ 20 C but only 10” w.c. @ 5C.5.2.4 Water Pressure SensorGo to the Advanced Diagnostics screen, and check the top display line — InletPressure. With the pumps at rest and system pressure of 12.5 psi, the InletPressure sensor value should read 235 +/- 5.Do not blow into sensor portsCheck operation of the sensor by isolating the boiler from its system piping,closing the system fill valve then cracking the pressure relief valve; the signalshould reflect declining pressure. If it remains “fixed”, drain boiler and replacesensor, or dislodge any blocking debris from sensor inlet channel and reinsert.5.2.5 Hi-Limit Switches (water and vent UVHL)Check resistance between leads. If resistance is very low, temperature shouldbe acceptable. If resistance is very high, temperature should be out of bounds.A simple means of checking whether a high limit switch is open is by measuringthe AC voltage across the device. If the reading is 24 VAC the switch is open. If a0VAC reading is shown, it is closed. NEVER connect an ohm-meter or continuitychecker across a live circuit.5.2.6 Fenwal Ignition ModuleWater pressure sensorWhen the boiler fails to ignite, or the flame ignites, but goes out at the end of theignition trial, the problem could be in the flame sensing circuit.Connect an electrical test meter - set to read Microamps (symbol μA) to the twotest pins at the top right of the ignition module. Recycle the boiler so it entersanother trial for ignition and monitor the flame current reading. When the burnerignites, a steady reading of between [3 and 5] Microamps should be measuredby your meter. The control will lock out if the reading drops below 0.7 Microamps.(see Section 5.3.1 - “Control Module - Maximum ignition trials error”, and Section5.3.2 - “Ignition problems”).Fenwal ignition module - Microamp(μA) test points are shown at topleftt corner of module (beside redL.E.D.)5-4INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER5.3 troubleshooting GUIDE5.3.1 Using Control Module Errors DisplayedSYMPTOM DIAGNOSIS REMEDYAirflow ErrorLCD Screen Message:Error – Insufficient Air FlowInsufficient combustion airflow;soft error; will retry in 5 minutesWARNINGNever attempt to repairthe control module (circuitboard). If the control moduleis defective, replace itimmediately.Check fan operation • Check lead is attached at fan.• Cycle power off/on; listen for fan initialization.If no action, focus your attention on the fanitself.Check for fouledreference lines and airsensorCheck achieved fanpower• Check clear vinyl air pressure line forpresence of water. After disconnecting fromblack air pressure sensor, blow clear (do notblow into sensor). Check for exhaust reingestion,or repeated power interruptions .• Ensure condensate trap is not blocked.• Go to Advanced Diagnostics and checkdifferential air pressure sensor (at rest andwith fan on). See Section 5.2.3.In Advanced Diagnostics, during Pre-purge, FanPressure (FP) should move close to RequiredPressure (RP); if FP only 120-150 vs. RP of[250 or 300], then check for actual vent systemblockage: (a) disconnect intake within boilercase; (b) open burner then fan/gas valve lookingfor debris.Water noise in vent.Excess condensate inventing.• Check condensate trap for obstructions.Remove obstructions and refill condensatetrap with water.• Check vent length, size and configuration.TROUBLESHOOTING5-5

SL 80-399 MODULATING GAS BOILERSYMPTOM DIAGNOSIS REMEDYMaximum Ignition TrialsErrorLCD Screen Message:Error – Ignition Failure after 3triesBoiler has failed to ignite on 3successive attempts. Boiler inlockout for 1 hour, then repeats3-try seq. Consult servicetechnician if error recurs.Hi Limit ErrorLCD Screen Message:Error – Water High-Limit/LWCOWater temperature exceeds hilimitor water level is low. Boilerin hard lockout. Will reset in 1hour. Consult service technician.No spark whenigniting. Igniterprobe/flame sensordisconnected.Manual gas shutoff isclosed or gas line notfully purged.Gap between igniterprobe rods is toolarge or too small.Spark, but no ignition.Boiler ignites, butshuts off at theend of the ignitiontrial. Improperlygrounded pressurevessel/burner orunserviceable ignitionlead or spark module.Check for illuminatedred light on LWCOControl Module.Check that igniter lead is secure at the controlmodule and at the probe.Check for gas flow. Open manual gas shutoffand reset boiler.Adjust gap between igniter probe rods tobetween 1/8” and 3/16".Check spark module is sending power to gasvalve – close gas supply, then disconnect(black) electric housing from face of gas valve,gently spread plastic tabs to open, and look for24vac voltage between blue and brown wiresduring an ignition cycle. Replace module if nocurrent detected• Ensure pressure vessel is grounded.• Check the igniter probe/flame sensor iselectrically isolated from the vessel, and itsceramic insulator is intact.• Replace ignition lead• Replace spark moduleRed light onWater level OK - check manual reset water highlimit:a) Check for any evidence of actual excesstemperatureb) Check temperature sensorsc) Check for flow problemsd) Push reset button (cycle power off and backon after pushing reset button)Red light offWater level low:a) Check air vent at top of boiler to ensure it isworking and boiler is not air lockedb) Check tridicator for correct water pressurec) Open water feed point (boiler fill valve orboiler pressurization unit) to make sure systemis filled to operating pressure.If boiler is filled but red light does not come on,check for power at LWCO control module (24Vac between terminals 1 (yellow) and 3 (blue).Replace LWCO control module as required.5-6INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERSYMPTOM DIAGNOSIS REMEDYVent Hi-Limit ErrorLCD Screen Message:Error - Vessel/Vent High-LimitExceeded *** Call for service!Vent temperature has exceededthe vent limit switch or theupper vessel high limit hasbeen tripped. Boiler in lockout.Consult service technician.Temperature SensorErrorLCD Screen Message:Error - Max. In-Out Temp.Exceed. -> Check water flowWater temperature signalnot within acceptable range.Potential flow or sensor failure.Consult service technician.MiscellaneousLCD Screen Message :Blank – screen dark, but fanrunning Indicative of powersurgedamage to applianceIndicates one or bothswitches has tripped.Current outlettemperature exceedsoperating limit.Defective ordisconnectedtemperature sensor.• Check wiring to ensure switches are properlyconnected to control module.• Check for evidence of any damage to ventsystem and signs of excess heat nearswitches.• Push manual reset button(s), maintainconstant watch during boiler operationto evaluate vent/cabinet temperatures atmaximum operating settings. Ensure nounsafe condition exists, e.g. max flue temp.or heat escapement at the burner flange.• Check water flow.• Check wiring to temperature sensor andcontrol module.• Check temperature sensor. See Section5.2.1.• Check transformer; replace if damaged.• Check circuit board for visible damage.TROUBLESHOOTING5-7

SL 80-399 MODULATING GAS BOILER5.3.2 Ignition ProblemsSYMPTOM DIAGNOSIS REMEDYNoisy spark whenignitingBoiler rumbles whenigniting.Boiler will not attemptto ignite. Fan and pumpare operating normally.Ignition lead is notfirmly connected.Contaminants/moisture on igniterprobe/flame sensor.Fluctuating gaspressure/ gaspressure too high/toolow.Check for properpiping.No power to ignitioncontrol module.Igniter probe/flamesensor disconnected.Blown fuse in ignitionmodule.Reconnect ignition lead.Ensure probe is dry by re-running post-purge;otherwise, clean or replace igniter probe.Check CO2 level via analyzer.Check pressure with manometer during ignition.• Check system wiring.• Check air reference tubing.Reconnect probe.Check fuse. If blown, replace.Defective ControlModule.Check ignition output from control module.Boiler will not attemptto ignite. Fan and / orpump are off Displaynot illuminatedNo power to boiler. Check line voltage .Defective transformer.Check transformer. Reconnect or replace asneeded.5-8INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER5.3.3 Cycling ProblemsSYMPTOM DIAGNOSIS REMEDYRapid CyclingImproper valuesentered via keypad.Excess Condensate inventing.Obstruction incondensate trap.Improper vent lengthor improper slope tovent.Incorrect settings ordefective thermostat.Air in system ormarginal water flow.Slow combustion airblower.Dirty burner/heatexchanger.Insufficient waterflow due to improperpiping.Insufficient water flowdue to undersizedpump.Insufficient water flowdue to restrictions inwater pipe.Insufficient radiation.Unit over-fired.Unit Oversized.Improperly set ordefective operating/safety controls.Check load maximum temps are above targettemps, by 1/2 of the selected boiler differential.Ensure boiler differential is OK (16-30°F isgenerally adequate)Check venting slopes on horizontal runs. Lookfor sags.Inspect and clean condensate trap.Check venting. Compare vent length anddiameter to Table 3: Maximum Venting.Check operation. Refer to manufacturer’sinstructions. Check setting with ammeter.Bleed/purge system as required. Confirmadequate pump size and temp rise in HXCheck that CO2 level is OK 9.4% nat. gas(10.7% for propane).Check pressure drop.Refer to recommended piping in Section 1.6Check manufacturer’s rating charts/checktemperature differential across heat exchanger.Check temperature differential across zone/heatexchanger.Check actual amount of radiation per zone andrefer to manufacturer’s rating tables.Clock gas meter/check gas pressure withmanometer/ check CO2 level.Check load calculation vs. min. boiler output.Check operation with ohmmeter/voltmeter.TROUBLESHOOTING5-9

SL 80-399 MODULATING GAS BOILER5.3.4 Temperature ProblemsSymptom Diagnosis RemedyInsufficient heatTemperature exceedsthermostat settingOne or more zones donot heat properlyOperatingtemperature too low.Priority parametersor load configurationimproperly set up.Unit undersized.Air trapped withinsystem.Improper systempiping.System pumpundersized.Poor gas/air mixing.Defective thermostat.Obstruction incondensate drain.Unit cycling onoperating/ safetycontrols.System radiationundersized.Incorrect anticipatorsetting.Thermostat not level.Air trapped withinzone(s) pipingInsufficient radiation/excessive heat loss.Insufficient flow rateto zone(s).Defective zone valve/zone circulator.increase temperature target. See Section 2.7Review load configuration parameters. SeeSection 2.7Refer to Load Calculation vs. Boiler Output.Bleed system as required.Refer to recommended piping in Section 1.6Check pump manufacturer’s data/check tempdifferential across heat exchanger.Check CO2 level.Refer to manufacturer’s instructions.Inspect and clean condensate drain.Check operation with Ohmmeter/Voltmeter.Check manufacturer’s rating tables for capacityper foot.Check with Ammeter.Check level.Vent system/zone as required.Check actual length of pipe using radiation / heatloss calculation.Check temperature drop across zone.Check operation per manufacturer’s instructions.5-10INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER5.3.5 MiscellaneousSYMPTOM DIAGNOSIS REMEDYFumes and High HumidityImproperly installedcondensate trapLeak in vent pipingFlue gas leak withinboilerRefer to installation/operation instructionsInspect using soap solutionVisually inspect all mechanical connectionsTROUBLESHOOTING5-11

SL 80-399 MODULATING GAS BOILERTHIS PAGE INTENTIONALLY LEFT BLANK5-12INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER6.0 DIAGRAMS6.1 - PARTS DIAGRAMS6.2 - WIRING DIAGRAMS6.3 - SEQUENCE OF OPERATIONDIAGRAMS6-1

SL 80-399 MODULATING GAS BOILER6.1 PARTS DIAGRAMSSL 80-399 Modulating Boiler - Parts assemblyDiagram 6.1-1: Boiler assembly parts6-2INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERDiagram 6.1-2: Boiler assembly parts list (refer to Diagram 6.1-1 on opposite pageDIAGRAMS6-3

SL 80-399 MODULATING GAS BOILER6.2 WIRING DIAGRAMSDiagram 6.2-1: Ladder wiring diagram6-4INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILERDiagram 6.2-2: Multi-boiler “boiler net” wiring diagramDIAGRAMS6-5

SL 80-399 MODULATING GAS BOILERDiagram 6.2-3: Internal wiring diagram6-6INSTALLATION AND OPERATION INSTRUCTIONS

SL 80-399 MODULATING GAS BOILER6.3 SEQUENCE OF OPERATIONDiagram 6.3: Sequence of operation diagramDIAGRAMS6-7

INSTALLATION & COMMISSIONING REPORTBoiler Details:Model Number _____________________ Serial Number ______________________________________________Date of Installation ______________ Address of installation _______________________________________________________________________________________________________________________________________User contact information _______________________________________________________________________Installer Information Company ___________________________________________________________________Address ______________________________________________________________________________________Phone/Fax/E mail ______________________________________________________________________________Fuel Natural Gas PropaneGas Supply Pressure (high fire) _______ Inches w.c. Measured Rate of Input (high fire) ____________ Btu/hrInstallation 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 componentsSystem Cleaned and Flushed (type of cleaner used) ________________________________________________System Filled (type/concentration of any glycol/chemicals used) _______________________________________Air purge completed (go to Installer Setup - - Pump Purge - - On, and operate pumps until air has been ejected)Relief Valve correctly installed and piped Relief valve “try lever” test performedCondensate trap filled Condensate drain clear and free flowing Condensate Neutralization? Yes/NoIgnition Safety Shutoff test completed. Flame current reading - High fire _______ µA - Low fire _______ µAStandby readings from IBC display screen - (remove all heat calls) - Outdoor Temperature ________ TankTemperature _______ Outlet Temperature _________ Outlet Pressure __________ Heat Output ___________Load Status Screen readings - Load 1 _______________ Load 2 _______________ Load 3 _______________From Installer Setup Menu (scroll down) - Altitude ______________ Prim. Pump Purge Time _______________Multiboiler Config. ______ (go to Installer Setup - - enter - this setting should be “Off” except for Master Boiler)Advanced Diagnostic Menu readings - boiler in Standby - (remove all heat calls)Outdoor Temperature _______ Inlet Pressure _______ Outlet Pressure _________ Delta Pressure __________Flow Rate __________ Fan Speed __________ Required Pressure ___________ Fan Pressure ____________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 ownerCombustion Readings - recommended, but optional (required for fuel conversion):CO2 _____________ % O2 ______________ % CO ____________ ppmFlue temperature _________ Return water temperature (measure simultaneously with flue temp.) _______________Installers: send this completed sheet - Fax to 604 877 0295 - or - scan and Email to info@ibcboiler.com, and earnan extra year’s Parts Warranty coverage (User to submit corresponding Installation Record from User Guide).Commissioning has been completed as listed on this report - Installer Signature _____________________________

Installer set-upLoad Definition - Load #1 _______________________________________________________________________Load Configuration - Load #1_____________________________________________________________________________________________Load Definition - Load #2 _______________________________________________________________________Load Configuration - Load #2_____________________________________________________________________________________________Load Definition - Load #3 _______________________________________________________________________Load Configuration - Load #3_____________________________________________________________________________________________SERVICE RECORDDATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE

NOTES

NOTES

IBC Technologies Inc.1543 Venables Street,Vancouver, BCCanada V5L 2G8Tel: 604.877.0277Fax: 604.877.0295www.ibcboiler.com120-111E-A-R2