IBC SL SERIES Installation & Operating Manual

SL 10-85 G3 SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. If you smell gas: Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a nearby phone. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier.

exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage. High levels of dissolved solids or minerals may precipitate out of the fluid onto the hottest part of the heat exchanger, impairing heat transfer and resulting in overheating and premature failure. The amount of solids that may form on the heat exchanger will depend on the degree of hardness and the total water volume in the system. A high water volume system with a low hardness count may cause as much damage as a system with less volume and higher hardness, so it is recommended to treat water so as to remove all dissolved solids. Other water chemistry allowable limits are as follows: Acidity pH is to be between 6.6 and 8.5 Chloride is to be less than 125 mg/l Iron is to be less than 0.3 mg/l Cu less than 0.1 mg/l Conductivity is to be less than 400μS/cm (at 77°F [25°C]) 7 grains/ gal (120 ppm) Important: Ensure that these limits are acceptable for the other water-side components in the system. Shipped with the boiler: 1 x Wall mounting bracket 1 x Condensate trap assembly 1 x 30 psig pressure relief valve 1 x Outdoor temperature sensor 2 x ¼" x 2 ½" Lag screws/w flat washers 1 x Propane fuel conversion kit

Danger Points out an immediate hazardous situation that must be avoided to prevent serious injury or death. Warning Points out a potential hazardous situation that must be avoided to prevent serious injury or death. Caution Points out a potential hazardous situation that must be avoided to prevent possible moderate injury and/or property damage. Note Points out installation, maintenance and operational notes to enhance efficiency, longevity and proper operation of the boiler. Important safety instructions Installation, start-up and servicing of IBC boilers must be performed by competent, qualified, licensed and trained heating technicians. Failure to read and comply with all instructions and applicable national and local codes may result in hazardous conditions that could result in property damage and injury to occupants, and in extreme cases to death. Keep instructions near the air handling appliance for future reference. Danger Should overheating occur or the gas supply fails to shut off, do not turn off or disconnect the electrical supply to the pump. Instead shut off the gas supply at a location external to the appliance. Danger Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, do not try to operate any appliance - do not touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a phone located remotely. Follow the gas supplier’s instructions, or if the supplier is unavailable, contact the fire department. 3 Safety information

to prevent freezing of condensate. Contact the factory for further information. Warning Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water. Warning Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, or loss of life. Read and understand the entire manual before attempting installation, start-up, operation, or service. Installation and service must be performed only by an experienced, skilled installer or service agency. Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers’ manuals before installing, starting up, operating, maintaining, or servicing the appliance. Warning Disconnect power supply before any wiring/service is performed. Failure to do so could result in damage to appliance and/or electric shock. Caution The boiler must be installed so that electrical components are not exposed to water during operation. Known Corrosive Contaminants to Avoid Cements and glues Refrigerant leaks from cracks in coils Paint or varnish removers Sodium chloride or potassium chloride used for water softening Adhesives used to fasten building products and other similar products Chemicals in perming solutions Chlorinated waxes or cleaners Chlorofluorocarbon chemicals found in spray cans Chlorine-based swimming pool chemicals Antistatic dryer sheets in clothes dryers Hydrochloric acid or muriatic acid used in household cleaning and stain removal Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms Calcium chloride used for snow clearing 4 Section: Safety information

3 Important safety instructions 3 Specifications 5 Cabinet dimensions 6 SL 10-85 G3, SL 14-115 G3 6 SL 20-160 G3 7 SL 30-199 G3 8 Connection specifications 9 1.0 Introduction 11 1.1 Standard features and benefits 11 1.2 Warranty 12 2.0 Before installation 13 3.0 Installation 15 3.1 Code requirements 15 3.2 Removing an existing boiler 15 3.3 Determining location of the appliance 16 Best installation conditions 17 3.4 Mounting the boiler 17 3.5 Connecting the vent and air intake pipes 18 3.6 Installation clearances 19 3.7 Exhaust venting and air intake 20 3.7.1 Venting code 20 3.7.2 Venting options 21 3.7.3 Exhaust vent material 21 3.7.4 Direct vent 22 3.7.5 Rooftop vent termination 26 3.7.6 Sidewall vent termination 29 3.7.7 Combustion air filtration system 36 3.8 Closet installations 36 3.9 Installing the condensate trap 37 3.10 Installing a condensate neutralizer 40 1

42 3.11.1 General piping best practices 44 3.11.2 System piping 44 3.12 Gas piping 56 3.12.1 Gas pressure 57 3.13 Electrical connections 58 3.13.1 Power management, quality and electrical protection 58 3.13.2 120VAC line-voltage hook-up 59 3.13.3 Other wiring 60 3.13.4 Zone valve hook-up 60 3.13.5 Thermostat / sensor wiring 61 3.13.6 Thermostat heat anticipator 61 4.0 About the boiler controller 63 4.1 Controller 63 4.2 Control interface 64 5.0 Before operating the boiler 65 Important pre-ignition checks 65 Checklist for electrical conditions, ducting and water connections 65 6.0 Boiler operation 67 6.1 Lighting and shutting down the boiler 67 6.2 Testing the ignition safety shutoff 68 6.3 Commissioning 68 6.3.1 Checking a boiler's fuel source 69 6.3.2 Performing a fuel conversion 69 6.3.3 Adjusting the gas valve 70 7.0 Service and maintenance 75 7.1 Maintenance checklist for homeowner 75 7.2 Maintenance checklist for heating contractor 75 7.2.1 Touchscreen boiler controller 76 7.2.2 General boiler maintenance 76 7.3 Replacing the fan, gas valve, and burner 80 7.3.1 Replacing the fan on the SL 85, 115, 160 and 199 G3 boilers 82 7.3.2 Replacing the gas valve on the SL 85, 115, 160 and 199 G3 boilers 83 2 Section: Contents

84 7.4 Cleaning the condensate trap 85 8.0 Troubleshooting 89 8.1 Electronic components 89 8.1.1 Temperature sensors 89 8.1.2 Fan 90 8.1.3 Water pressure sensor 90 8.1.4 Safety and Ignition Module (SIM+) 91 8.2 Troubleshooting error messages 92 8.2.1 Maximum ignition trials error 93 8.2.2 Hi Limit cut-off temperature error 94 8.2.3 Low Water Cut-off error 94 8.2.4 Aux. Interlock 1 or 2 94 8.3 Miscellaneous touchscreen controller errors 95 8.3.1 Ignition issues 96 8.3.2 Temperature issues 97 8.3.3 Miscellaneous issues 98 8.3.4 Cycling issues 99 Appendices 101 Wiring diagrams 101 V-10 Controller electrical diagram 101 Internal wiring diagram 102 Sequence of Operation 103 Exploded views of boiler parts 104 Installation & Commissioning Report 117 3

SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 CSA Input (Natural Gas or Propane) - MBH CSA Input (Natural Gas or Propane) - kW CSA Output - MBH CSA Output - kW 10.6 - 85 3.1 - 24.9 10.1 - 79 2.96 - 23.1 14 - 115 4.1 - 33.7 13.3 - 109 3.9 - 32 20 - 160 5.86 - 46.9 19 - 147 5.57 - 43.1 32 - 199 9.37 - 58.3 30 - 181.3 8.8 - 53.1 A.F.U.E 96% 95% 95% 95% Minimum gas supply pressure (Natural Gas or Propane) - inch w.c. 4 4 4 4 Maximum gas supply pressure (Natural Gas or Propane) - inch w.c. 14 14 14 14 Power use (120Vac/60Hz) @ full fire - Watts (less pumps) 54 72 82 100 Weight (empty) - lbs/Kg 85 / 39 85 / 39 102 / 46.3 152 / 69 Pressure vessel water content - USG/Litres 2.47 / 9.35 2.47 / 9.35 1.72 / 6.51 5.09 / 19.3 Maximum boiler flow rate - USgpm 14 14 19 22 Minimum boiler flow rate - USgpm 2 2 4 6 Maximum operating water pressure* - psig 30 30 30 30 Minimum water pressure - psig 8 8 8 8 Approved installation altitude - ASL 0 - 12,000’ 0 - 12,000’ 0 - 12,000’ 0 - 12,000’ Ambient temperature Low °F / °C High °F / °C 32°F / 0°C 122°F / 50°C 32°F / 0°C 122°F / 50°C 32°F / 0°C 122°F / 50°C 32°F / 0°C 122°F / 50°C Max. relative humidity (non- condensing) 90% 90% 90% 90% Minimum water temp. 34°F / 1°C 34°F / 1°C 34°F / 1°C 34°F / 1°C Maximum water temp. (electronic hi-limit) 190°F / 88°C 190°F / 88°C 190°F / 88°C 190°F / 88°C Max. Water Temperature Lockout 201°F / 94°C 201°F / 94°C 201°F / 94°C 201°F / 94°C

SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 Limit Max. ΔT - supply/return (electronic fence) 40°F 40°F 40°F 40°F Maximum equivalent vent length , each side (vent & air intake) (Natural gas or propane) Air intake options: either direct vent or indoor supply 100’ (2") 240’ (3") 100’ (2") 240’ (3") 35’ (2") 170’ (3") Not applicable 150’ (3") * Boilers are shipped with a 30 psig pressure relief valve. Cabinet dimensions SL 10-85 G3, SL 14-115 G3 Figure 1 : Front and side view - SL 10-85 G3, SL 14-115 G3 6 Section: Specifications

Figure 3 : Bottom view - SL 10-85 G3, SL 14-115 G3 SL 20-160 G3 Figure 4 : Front and side view - SL 20-160 G3 7 SL 20-160 G3

Figure 6 : Bottom view - SL 20-160 G3 SL 30-199 G3 Figure 7 : Front and side view - SL 30-199 G3 8 Section: Specifications

Figure 9 : Bottom view - SL 30-199 G3 Connection specifications The following table displays the required connection specifications. SL 10-85 G3, SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 A Flue Outlet 3" Schedule 40 or 3" PPs (80mm) B Combustion Air 3" Schedule 40 or 3" PPs (80mm) C LCD Display 2¼" x 4" D Water Outlet 1" NPT-M 1" NPT-M 1¼” NPT-M E Water Inlet 1" NPT-M 1" NPT-M 1¼” NPT-M F Knock-outs (8) ½" G Gas Inlet ½" NPT-F H Condensate Outlet ¾" Hose Table 1 Connections 9 Connection specifications

Approved as “Category IV” vented appliances, the boilers use direct vent (sealed combustion) or indoor combustion air. Figure 10 View from the front - SL G3 residential boilers 1.1 Standard features and benefits High thermal efficiency Turn-down ratio 10 to 1 Control of up to 5 pumps – 1 boiler pump and 4 separate load pumps Outdoor reset control Load combining – simultaneous operation of two similar water temperature loads Load zoning – simultaneous operation of up to four loads with the same control settings Ability to manage and/or operate in a network of up to 24 IBC SL boilers

Portal BACnet over IP compatible Easy-to-use touchscreen 1.2 Warranty For residential applications, IBC offers a 5-year warranty on all parts against defects in materials or workmanship and failures due to thermal shock. In addition, IBC offers a heat exchanger limited warranty with registration, according to the following terms: 0 - 10 years (100% coverage) 11+ years (25% coverage). IBC offers a limited heat exchanger warranty with no registration of 0-5 years (100% coverage). For non-residential applications, IBC offers a 5-year warranty on all parts against defects in materials or workmanship and failures due to thermal shock. In addition, IBC offers a heat exchanger limited 10 year warranty with registration, according to the following terms: 0 - 5 years (100% coverage) 6 - 7 years (50% coverage) 8 years (40% coverage) 9 years (30% coverage) 10 years (20% coverage). To view the full warranty statement for the SL G3 series and to register your product, go to ibcboiler.com. 12 Section: Introduction

Before installing the appliance, it is important to review and observe the following checklist of precautions: Precautions Check Care must be taken to properly size the boiler for its intended use. Prolonged full fire run time, over-sizing or under-sizing, and incorrect flow rates through the appliance can lead to increased maintenance costs, equipment stress and premature failure. □ Ensure you install the appliance where the combustion air source is not subject to chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants, aerosol propellants, dry-cleaning fluids, de-greasers and paint-removers all contain vapors that can form corrosive acid compounds when burned in a gas flame. Airborne chlorides such as those released with the use of laundry detergents are also to be avoided. □ Locate the appliance where water leakage will not result in damage to the area. If there is no suitable location, install a suitable drain pan under the boiler. Do not install above carpeting. □ At a new construction site, or during renovations, protect the appliance from drywall dust or other construction related contaminants. Draw combustion air from a clean source (e.g., outdoors) and isolate the boiler from interior dust sources. Do not seal boiler case openings directly when firing - allow for air circulation and ventilation in the immediate area. □ Place the exhaust outlet 12" minimum above the down-turned intake to avoid exhaust re- ingestion. □ For sidewall venting options, place the inlet and exhaust terminations on the same side of the building. The elevation of both pipes can be raised in “periscope style” after passing through the wall to gain required clearance above grade and snow level. □ If using the indoor combustion air option, ensure combustion air openings to the boiler room remain unblocked and free of obstructions. □ Examine the condensate outlet to ensure proper disposal of condensate will occur during operation. If condensates are to be discharged into building drain piping materials that are subject to corrosion, a neutralization package must be used. □

between its inlet and the boiler. Make sure the relief valve outlet is piped with unobstructed piping (minimum ¾" diameter) to a safe discharge location. □ If the appliance is likely to be exposed to fluid temperatures below 34° F (1° C), a method of protection to prevent freezing of condensate should be employed. Contact the factory for further information. □ When the appliance is in operation, assess the impact of the steam plume normally at the exhaust terminal of a condensing boiler. Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location. Boiler condensate is corrosive. Protective measures must be taken to prevent corrosion damage to metal roofs or other metal building components in contact with the condensate. Keep exhaust plumes well away from all building air intakes including those of neighboring properties. □ Caution Care must be taken to properly size the boiler for its intended use. Prolonged full fire run time, over-sizing or under-sizing, and incorrect flow rates through the boiler can lead to increased maintenance costs, equipment stress and premature failure. 14 Section: Before installation

drawings to find a suitable location for the appliance. 3.1 Code requirements The appliances are tested and certified under CSA 4.9 / ANSI Z21.13. Below are the code requirements for every installation. Canada US Conform to local codes, or in the absence of these, with the latest editions of CAN/CGA B149.1 and the Canadian Electrical Code Part 1 CSA C22.2 No. 1. Where required by jurisdiction, installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. If there is any conflict, follow the more stringent regulations. Conform to the current National Fuel Gas Code ANSI Z223.1 and the National Electrical Code ANSI/NFPA 70. Where required by jurisdiction, installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. If there is any conflict, follow the more stringent regulations. Table 2 Code requirements by country 3.2 Removing an existing boiler When an existing boiler is removed from a common venting system, the common venting system may be too large for proper venting of the appliances that remain connected to it. When resizing any portion of the common venting system, use the minimum size according to the appropriate tables in the National Fuel Gas Code, ANSI Z223.1 - latest edition. In Canada, follow the B149.1 Installation Code. When removing an existing boiler, the following checks must be carried out for each of the appliances still connected to the common exhaust system, by operating them one at a time: Seal any unused opening in the common venting system. Visually inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies that could cause an unsafe condition. (Where practical) Close all building doors and windows such as doors adjacent to appliances remaining connected to the common venting system and other spaces.

system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so that they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so that the appliance operates continuously. After determining that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition. Any improper operation of the common venting system should be corrected, so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 - latest edition. In Canada, all installations must conform with the current CAN/CGA - B149.1-10 Installation Code and/or local codes. 3.3 Determining location of the appliance The boilers are designed and approved for indoor installation (wall or rack mounting) in areas such as an alcove, basement, or utility room. These areas should have a surrounding temperature of 32 °F (0°C) to 122 °F (50 °C) and less than 90% relative humidity. Danger Do not common vent appliances with other existing appliances or with a new appliance. Warnings Keep the area around a boiler clear of combustible materials, gasoline, and other flammable vapors and liquids. Ensure combustion air is not drawn from areas containing corrosive air such as swimming pools or spas, including air directly next to outdoor pools and spas. Ensure that a boiler is not exposed to water leaks from piping or components located overhead, including condensation from uninsulated cold water lines overhead. Protect the gas ignition system components from water (dripping, spraying, rain, etc.) during appliance operation and when servicing (pump replacement, condensate trap servicing, control replacement, etc.). Ensure that combustible materials do not make contact with exposed water piping and associated components (relief valves, circulators, etc.). Check local codes for required clearances and/or provide adequate insulation. 16 Section: Installation

Below are some factors to consider for best installation conditions: Install the boiler in areas where the combustion air source is not subject to chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a boiler. See list of known contaminants on the Important safety instructions on page 3. For this reason, do not use the indoor air venting option (using air surrounding the boiler) in a laundry room. Similarly, ensure any direct vent air source is not near a clothes dryer exhaust terminal. Avoid agricultural applications where the boiler and/or the intake air source are affected by ammonia and/or dust. Avoid installing a boiler where water leakage will cause damage; for example, above carpeting. If unavoidable, install a suitable drain pan under the appliance. Vent location - An important consideration is managing the impact of the steam plume normally at the exhaust terminal of a condensing boiler. Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location to maximize customer satisfaction. Keep exhaust plumes well away from all building air intakes including those of neighboring properties. Refer to Table 5 and Figure 19 in Sidewall vent termination on page 29. The minimum clearance requirements for combustible materials (see Table 3 ). For adequate servicing, we recommend a minimum 24" clearance at the front and 6" above the boiler. Check local codes for additional access and service clearance requirements. At a new construction site, or when renovating: Protect the boiler from drywall dust or other construction related contaminants. Ensure combustion air is drawn from a clean source (e.g., outdoors). Isolate the boiler from interior dust sources. 3.4 Mounting the boiler You must attach fasteners to solid material capable of supporting the combined weight of the boiler and piping assembly components. Boiler weight – without water, system piping and components – is approximately 150 lbs / 69 kg. Warning Do not mount the appliance to hollow wall structures - The combined weight of the boiler, its water content and associated piping components can exceed 150 pounds. Fasteners must be rated for this strain, and must be firmly anchored into solid material that will support this weight. Installers must take necessary precautions to avoid injury during the installation of this boiler. 17 Best installation conditions

wall studs using the supplied ¼" x 2½" long lag screws (min. 4) with ¼" flat washers. 2. Hook the boiler tab (located on back of boiler) over the support bracket flange. 3. Ensure that the boiler tab is flush against the mounting bracket flange. 4. Secure the lower part of the boiler to the wall with two field-supplied ¼" bolts. 3.5 Connecting the vent and air intake pipes These appliances offer 3" connections that accept standard 3" PVC/CPVC pipe (3.5" OD) and 3" nominal PPs (80 mm) pipe. Use standard vent pipe fittings to adapt to smaller diameter pipe if appropriate . Venting must be supported in accordance with the applicable code and instructions supplied by the manufacturers. 18 Section: Installation

2.5” beyond the first 3” PVC/CPVC sized gasket that will seal to standard 80 mm PPs pipe. Care should be taken to ensure that PPs pipe is installed so that it extends past this second gasket. If using combustion air piping, insert directly into the connector on the right. PPs pipe should be inserted firmly into the connector until it cannot go further. The pipe must be secured with the built-in clamp. For PPs material exposed to outdoor conditions, follow the venting supplier’s recommendations on UV protection. Figure 11 Securing a pipe connection Warning Ensure that you lubricate the gasket with silicone grease before inserting the venting material. Fully insert the approved venting material into the boiler's exhaust outlet, and tighten clamp to ensure the venting connection is locked in place (as shown above). Warning Do not mix venting materials from different manufacturers. These venting materials are designed to be installed as part of a complete system. Failure to comply may result in severe personal injury or death. 3.6 Installation clearances Warning Exposed water piping and associated components (relief valves, circulators, etc.,) should not be in contact with combustible materials. Check local codes for required clearances and / or provide adequate insulation. 19 3.6 Installation clearances

Surface Minimum distance from combustible surfaces Recommended distance from installation and service Front 2" 24" Rear 0 0 Left side 1" 4" (allow access to water connections) Right side 1" 4" (water, electric, and gas connections) Top 2" 6" (vent connection) Bottom 0 12" (for condensate trap) Table 3 Clearance distances for boiler mounting sites A minimum distance below the boiler of 12" is required to provide clearance for the supplied condensation trap assembly. More clearance will typically be required to accommodate associated water and gas piping. 3.7 Exhaust venting and air intake When planning a boiler's installation, consider the appropriate vent materials, travel and termination. Warning Venting, condensate drainage, and combustion air systems for all IBC boilers must be installed in compliance with all applicable codes and with instructions provided in the respective installation manuals. Inspect finished vent and air piping thoroughly to ensure all are airtight, and comply with the instructions provided as well as with the requirements of applicable codes. Failure to comply will result in severe personal injury or death. 3.7.1 Venting code All venting must be installed in accordance with the requirements of the jurisdiction having authority: in Canada, Part 8, Venting Systems of the CAN/CSA B149.1 Code and any other local building codes are to be followed. In the USA, the National Fuel Gas Code, ANSI Z223.1/NFPA 54, latest edition prevails. Where there is a discrepancy between the installation instructions provided and the code requirements, apply the more stringent. 20 Section: Installation

These appliances are approved with alternative venting options: either 2-pipe direct vent or vent pipe with indoor air. With direct vent, combustion air is piped directly to the boiler’s air intake from outdoors. Using the indoor air alternative, air for combustion is drawn from the indoor air surrounding the boiler. Provided the maximum overall vent length limit is not exceeded, the boiler may be vented through the wall, directly through the roof, or upward using an existing, but otherwise unused, chimney as a vent raceway. Figure 12 Flue gas exhaust to outdoors 3.7.3 Exhaust vent material Warnings Condensate can cause corrosion of metal roofing components and other roofing materials. Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate. pH levels can be as low as 3.0. Covering non-metallic vent pipe and fittings with thermal insulation is prohibited. Exhaust vent material – Canada Use PVC, CPVC, or Polypropylene (PPs) vent component systems approved under ULC-S636 Standard for Type BH Gas Venting Systems, or stainless steel Type BH venting systems1. ULC- S636 components are certified as systems including pipe, fittings and cement/primer for PVC/CPVC and must be installed in strict accordance with manufacturers' instructions. The vent temperature is limited by the boiler controller with the use of a flue temperature sensor to ensure the maximum temperature of the PVC venting material is not exceeded. 1Manufacturers of stainless steel Type BH venting systems must submit their approved transition fitting to IBC for evaluation and written approval. 21 3.7.2 Venting options

PVC, CPVC, or PPs venting materials are approved for use with these boilers in most of the USA. Check local codes to determine if any materials are prohibited. The vent temperature is limited with the use of the flue temperature sensor and software to ensure that the maximum temperature of the PVC venting material is not exceeded. PVC venting material shall be certified to Sch. 40 ASTM D1785 or D2665. CPVC material shall be certified to Sch. 40/ASTM F441. Exhaust vent material - general Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in venting systems is prohibited. Do not use ABS or any cellular core pipe for exhaust venting. 3.7.4 Direct vent Direct vent is a two-pipe system that draws combustion air (air intake) from outdoors, and discharges exhaust gases to the outdoors. Ensure that adequate separation is maintained between the air intake inlet and the exhaust vent terminal. Refer to the vent terminal configuration drawings in the "Vent Termination" sections. Flue gas exhaust to outdoors Combustion air from outdoors. "Direct Vent" installation: check air intake outside is clear of obstructions. Figure 13 Direct vent 22 Section: Installation

An “Indoor Combustion Air installation” can be described as air for combustion that is taken from the air surrounding the boiler. Flue gas exhaust to outdoors Combustion air from boiler room. For indoor air installation, check air intake and boiler room combustion air opening(s) to ensure they are clear of obstructions. Figure 14 Indoor combustion air intake Warning When using indoor air options, supply adequate combustion air to the boiler room according to the requirements of all applicable codes. At a new construction site, or during renovations, action must be taken to protect the boiler from drywall dust or other construction related contaminants; combustion air should be drawn from a clean source (e.g. outdoors) and the boiler should be isolated from interior dust sources. Do not seal boiler case openings directly when firing (See list of known contaminants on the Important safety instructions on page 3). Warnings In addition to preventing ingestion of chemical contaminants, ensure air intake terminals are not installed in locations where contamination might occur due to ingestion of particulate foreign material (dust, dirt and debris). Configure intake air openings, so that rain or other forms of moisture cannot enter the air intake piping system. Otherwise serious damage to the boiler may result. Notes When installing air intake piping, ensure that a "trap" is not formed in the piping causing a build-up of water and blockage of intake air. Such blockages will cause a boiler safety shut-down. Filters require checking and cleaning or replacing on a regular schedule based on the severity of the problem. 23 3.7.4 Direct vent

Exhaust venting must slope down towards the boiler with a pitch of at least ¼" per foot (PPs vent: follow PPs manufacturer requirements for slope), so condensate runs back towards the trap. Support should be provided for intake and vent piping where it passes through unheated spaces or underground, with appropriate pipe insulation to prevent freezing of condensates. Certain installations of the SL models can employ 2" vent options. We caution installers when using horizontal runs of 2" pipe. Air friction from the fast moving exhaust during long burner runs at high-fire in a 2" pipe can overcome gravity on ¼" per foot vent slope, leaving a pool of condensate at the next upturned elbow. Pooling can impair the achievement of full high-fire rating plate performance. Ensure pipe and fittings are beveled for trouble-free insertion through exhaust and intake pipe gaskets. Wet gaskets and pipe before insertion. Figure 15 Pipe and fitting beveling Exhaust piping is inserted directly into the left connector on the top of the boiler, then runs horizontally or vertically to the outdoors. Screen material can be placed at the outlet as appropriate for the environment (e.g., insects, dust). Check that material meets local codes including fire stopping requirements. Some local jurisdictions require a minimum initial length of pipe be exposed or accessible for inspection. Pipe clearances - no IBC requirements; follow local codes. All piping must be liquid and pressure tight. Ensure all venting components are clear of burrs/debris prior to assembly. Clear plastic debris left in the combustion air piping to avoid intake into the fan. Secure joints using appropriate solvent cement to bond the respective pipe material (Canada: CPVC cement approved under ULC-S636, in accordance with its manufacturer instructions; USA: PVC (ASTM D2564), or PVC/ABS (D2235) - Use transition glue anywhere that PVC and CPVC are joined. Follow the cement manufacturer’s instructions closely when joining various components. For PPs, connections shall be secured using approved retainer clips supplied by the respective PPs manufacturer. Check that vent connections are liquid and pressure tight. Prior to firing the boiler, and before any of the venting run is concealed by the building construction, test the exhaust joints under fan pressure with the vent blocked, using a soap and water solution. The installer must fill the condensate trap prior to testing. Coat all joints with an approved leak test solution just as you would joints in a gas line, and make sure that there are no leaks. We suggest attaching a tag on the vent line near the condensate drain tee with the type of test, the date and the installer’s name. 24 Section: Installation

Confirm material meets local codes including fire stopping requirements. Check the local jurisdiction on the minimum initial length of pipe that should be exposed or accessible for inspection. Follow the local codes for pipe clearances - no IBC requirements. Ensure that piping is liquid and pressure tight. 3.7.4.1 Air intake and exhaust vent length allowance Warning Follow all installation instructions supplied by the piping and fitting manufacturer. Ensure that adequate separation is maintained between the air intake inlet and the exhaust vent terminal. The pipe length and allowance for pipe fittings, terminations and flexible pipe used for calculating total equivalent length are shown in the following table: Vent Lengths Intake/Exhaust Maximum Equivalent Length SL 10-85 G3 SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 2-inch rigid pipe 100 ft 100 ft 35 ft n/a 3-inch rigid pipe 240 ft 240 ft 170 ft 150 ft 90° elbow allow 8 ft for each elbow 90° long sweep elbow allow 5 ft for each elbow 45° elbow allow 3 ft for each elbow PPs 87-90° elbows allow 8 ft for each elbow (Intake only) Air Intake Filter (IBC part P-357) allow 8 ft 2-inch Stainless Sidewall Terminal (IBC part P-256) Intake: No additional allowance Exhaust: Allow 20 ft equivalent of 2- inch Sched. 40 Intake: No additional allowance Exhaust: Allow 20 ft equivalent of 2- inch Sched. 40 Not allowed Not allowed 3-inch Stainless Sidewall Terminal Intake: No additional allowance Exhaust: Allow 20 ft equivalent of 3-inch Sched. 40 25 3.7.4 Direct vent

SL 10-85 G3 SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 (IBC part P-257) 3-inch PPs flexible pipe Limited to 45 ft maximum Limited to 45 ft maximum Limited to 45 ft maximum Limited to 30 ft maximum Allow 1.2 x actual length (e.g., 10 feet of 3-inch flexible pipe x 1.2 = 12 feet of rigid pipe) Allow 1.2 x actual length (e.g., 10 feet of 3-inch flexible pipe x 1.2 = 12 feet of rigid pipe) Allow 1.2 x actual length (e.g., 10 feet of 3-inch flexible pipe x 2 = 20 feet of rigid pipe) Allow 3.3 x actual length (e.g., 10 feet of 3-inch flexible pipe x 3.3 = 33 feet of rigid pipe) Table 4 Maximum air intake pipe and maximum exhaust vent length Notes Unused intake travel cannot be added to the exhaust. Unequal intake and exhaust piping is allowed. Support should be provided for intake and vent piping, particularly for horizontal runs (follow local code). Example of equivalent length calculations for an SL 14-115 G3: An SL 14-115 G3 can be sited up to 240 feet (actual vent length allowance) from the vent termination using 3-inch pipe. For 6 x 90º elbows, the maximum lineal (straight) length of pipe allowed is 192 feet (240’ – (6 x 8' = 48) = 192'). For 3-inch flexible PPS pipe, up to 45 linear feet is allowed in vertical orientation (> 45 °). The equivalent length of 3-inch flexible PPS pipe should be calculated using a multiple of 1.2 (e.g., 10' x 1.2 = 12'). 3.7.5 Rooftop vent termination Warning Condensate can cause corrosion of metal roofing components and other roofing materials. Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate. pH levels can be as low as 3.0. 26 Section: Installation

The exhaust pipe can terminate in an open vertical orientation without concern about rain infiltration; rain will drain away through the condensate trap. Optional bird screen may be placed in a termination fitting. Leave unglued, and hold in place with a short nipple. This permits easy access for cleaning. Do not exhaust vent into a common venting system. b. For rooftop direct vent systems: Rooftop, two pipe, direct vent configurations, including typical clearance requirements are shown below in the following images. Figure 16 Rooftop vent terminal configurations Figure 17 Rooftop vent termination with sidewall combustion air 27 3.7.5 Rooftop vent termination

Exhaust Vent screen Inlet Flashing Figure 18 Rooftop vent terminal vent screen and retainer The intake air pipe is not typically drained, so it must be terminated with a down- turned elbow as shown. The intake pipe does not need to penetrate the roof at the same elevation as the exhaust (as shown); lower down on the roof is acceptable. Best Practice: To reduce the possibility of expansion noise, allow a ¼ inch gap around the exhaust and air intake piping. For roof top venting of multiple boiler sets, group all intake terminals together for a common penetration through a custom cap. Alternatively, place close together using commonly available pipe flashing. Similarly, group the exhaust pipes and place the two separate groups of pipes at least 3 feet apart (the closest intake and exhaust pipes must be 36 inches, or more, apart). Use the same 12-inch (minimum) vertical separation for all termination options. For alternate group terminations, contact the IBC factory for written guidance. Roof top concentric termination kits are approved for use with the boiler model. Installation of the vertical roof top termination must follow the installation instructions supplied with the venting material manufacturer. Care must be taken to install the termination kit a minimum horizontal distance of 10' (305 cm) away 28 Section: Installation

plus the anticipated snow line. 3.7.6 Sidewall vent termination Caution Vent termination clearances in this section are code minimum, or IBC-recommended minimum requirements, and may be inadequate for your installation. Building envelope details must be examined carefully. Take action to avoid moisture entering building structures. Serious structural damage may occur if adequate precautions and clearances are not considered. These precautions apply to neighboring structures as well as to the structure the boiler(s) are installed in. Vent terminal Air supply inlet Area where terminal is not permitted Figure 19 Minimum clearances from vent/air inlet terminations (see legend on adjacent page) 29 3.7.6 Sidewall vent termination

Canadian Installations 2, 33 A Clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) B Clearance to window or door that may be opened 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 12 in (30 cm) for appliances > 10,000 Btuh (3 kW) and ≤ 100,000 Btuh (30 kW), 36 in (91 cm) for appliances >100,000 Btuh (30 kW) 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 9 in (23 cm) for appliances > 10,000 Btuh (3 kW) and ≤ 50,000 Btuh (15 kW), 12 in (30 cm) for appliances > 50,000 Btuh (15 kW) C Clearance to permanently closed window * * D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2ft (61 cm) from the center line of the terminal * * E Clearance to unventilated soffit * * F Clearance to outside corner * * G Clearance to inside corner * * H Clearance to each side of center line extended above meter/regulator assembly 3 ft (91 cm) within a height 15 ft above the meter/ regulator assembly * I Clearance to service regulator vent outlet Above a regulator within 3 ft (91 cm) horizontally of the vertical center line of the regulator vent outlet to a maximum vertical distance of 15 ft (4.5 m) * 1In accordance with the current CAN/CSA-B149 Installation Codes. 2If locally adopted installation codes specify clearances different than those illustrated, then the most stringent shall apply. 3In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code. *Clearances in accordance with local installation codes and the requirements of the gas supplier. The minimum distance from adjacent public walkways, adjacent buildings, openable windows, and building openings shall not be less than those values specified in the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, CSA 8149.1. 30 Section: Installation

Canadian Installations 2, 33 J Clearance to non- mechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 12 in (30 cm) for appliances > 10,000 Btuh (3 kW) and ≤ 100,000 Btuh (30 kW), 36 in (91 cm) for appliances >100,000 Btuh (30 kW) 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 9 in (23 cm) for appliances > 10,000 Btuh (3 kW) and ≤ 50,000 Btuh (15 kW), 12 in (30 cm) for appliances > 50,000 Btuh (15 kW) K Clearance to mechanical air supply inlet 6 ft (1.83 m) 3 ft (91 cm) above if within 10 ft (3 m) horizontally L Do not terminate above paved sidewalk or paved driveway 7 ft (2.13 m) 4 Vents cannot be located above public walkways or other areas where condensate or vapor can cause a nuisance or hazard* M Clearance under veranda, porch, deck or balcony 12 in (30 cm)5 * Table 5 Vent/air inlet termination clearances Warning Important!: Maintain at least the minimum separation of exhaust vent termination from boiler intake air as illustrated in Figure 20 , Figure 21 , Figure 22 and Figure 23 . Failure to do so can result in a dangerous situation where exhaust gasses are re-ingested with combustion air. Damage to the boiler can result from a failure to maintain these separations. Third party vent termination kits and concentric wall penetration kits that do not maintain these minimum separations must not be used. Improper installation will void the warranty. Do not use proprietary InnoFlue or PolyPro PPs terminals without specific approval from IBC. Sidewall direct vent with separate vent and air pipes must be terminated as follows: Locate the intake air and exhaust vent terminations on the same plane (side) of the building. 1In accordance with the current CAN/CSA-B149 Installation Codes. 2If locally adopted installation codes specify clearances different than those illustrated, then the most stringent shall apply. 3In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code. 4 A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. 5 Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. 31 3.7.6 Sidewall vent termination

turned intake to avoid exhaust re-ingestion. (Optionally) Raise the elevation of both terminations in “periscope style” after passing through the wall, then to gain the required clearance configure as shown in Figure 20 , Figure 21 , and Figure 22 . Use a 45° elbow on the exhaust termination to launch the plume up and off the sidewall (for protection of wall). A short piece of venting cut at 45° gives a horizontal termination protected from wind loads (see Figure 20 , Figure 21 , and Figure 22 ). Recommend the use of a bird screen of ¼" stainless steel or plastic mesh (IPEX System 636 drain grate) to guard against foreign objects. Caution Refer to local code requirements or restrictions when installing concentric side wall termination kits. Ensure that the termination and venting slope back to the appliance. Figure 20 Vent termination clearance Figure 21 Vent termination clearances 32 Section: Installation

Figure 23 Sidewall vent termination configuration option 2 33 3.7.6 Sidewall vent termination

Warning In areas of high snowfall, users must be advised to check side wall vent and air intake terminations on a regular basis to ensure blockage does not occur. Sidewall direct vent with stainless sidewall terminal must be terminated as follows: The Stainless Sidewall Terminal (SST) 2 inch (IBC kit P-256) and 3 inch (IBC kit P-257) are approved for use with this appliance. Install the SST to comply with the minimum vent clearances listed in Table 5 . Install the SST with the vent and intake pipes horizontally beside each other or vertically with the vent pipe on top (see Figure 25 ). The vent pipe cannot be installed below the intake. The vent cap must be installed with the openings directed up and down (see Figure 25 ), and not side to side. Figure 25 Allowed SST installation orientations The SST vent/air connections fit Sched. 40 two inch or three inch PVC/CPVC pipe. PPs pipe cannot be used with the SST. The pipes must extend completely through the wall as shown below. The SST is an external fixture, and is not part of the sealed vent system that runs inside the building. 34 Section: Installation

Ensure that the vent termination location does not exceed the allowed maximum equivalent vent length, including the allowance for the SST. Install multiple vent SST installations level with one another and maintain at least the minimum separation distances shown below. The terminals shall not be stacked vertically. Figure 27 : Minimum separation for multiple vent installation - vertical orientation Figure 28 : Minimum separations for multiple vent installation - horizontal orientation Caution Take care installing Concentric Side Wall Termination kits when the outdoor temperature drops below 5°F/-15°C. Possible blockage of the combustion air intake can occur when the outdoor temperature drops below this temperature. Approved PVC Side Wall Termination kits are listed below: Ipex # 196984 2 inch Ipex # 196985 3 inch Figure 29 Approved PVC Side Wall Termination configuration 35 3.7.6 Sidewall vent termination

If combustion air contamination from ingested particulate matter is a concern in any installation, an optional air intake filter may be installed. IBC-supplied air intake filters have a known pressure drop and fouling factor and should be used as a component of the combustion air system according to the allowable intake length in Table 4 . Flue gas exhaust to outdoors Combustion air in - check air intake outside to make sure it is clear of obstructions. Air intake filter - check and clean air filter regularly Figure 30 Direct vent - intake, exhaust system with optional air intake filter (filtration may also be used on indoor air applications as required) 3.8 Closet installations For installations in a confined space (such as a closet), ventilation openings may be needed through a door or wall to prevent excessive heat from building up inside the space. The appliance must not be exposed to surrounding air above 122°F (50°C) or below 32°F (0°C). 36 Section: Installation

IBC’s specified vent configuration promotes the safe drainage of moisture from the boiler and exhaust venting without flowing liquids back through the heat exchanger (as done by some other condensing boilers). Warning Fill the trap with water before initially firing the boiler to prevent exhaust fumes from entering the room. Never operate the boiler unless the trap is filled with water. Failure to comply will result in severe personal injury or death. Ensure the supplied trap is correctly installed and filled with water. When required, add (and maintain in good condition) a neutralization tank. For installation information, see Installation on page 15. The condensate trap must be installed on the drain connection at the base of the boiler. The condensate drain must be piped to within 1 inch of a drain or connected to a condensate pump. The drainage line must slope down to the drain at a pitch of ¼ inch per foot so condensate runs towards the drain. 37 3.9 Installing the condensate trap

2. To remove the condensate retainer, undo the two wing nuts, and put aside. 3. Fill the condensate trap with water, and ensure that the bottom union cap is hand-tightened to prevent leakage. 4. Loosen the upper union nut, and slide the trap over the boiler drain outlet, and then tighten the upper union nut. 38 Section: Installation

the retainer to enable you to slide the two tabs under the chassis of the boiler, and secure with the wing nuts. 6. The drain hose should run to a suitable drain or condensate neutralizer. Figure 31 Condensate trap drainage Flue gas exhaust: Condensate and rain water flow back from venting system Warning: Risk of damage to appliance. Ensure rainwater is prevented from entering air 39 3.9 Installing the condensate trap

Warning: Risk of damage to appliance. All condensate discharge lines must be at a lower elevation than the condensate water line of the appliance. Affix hose to plastic piping Factory-supplied condensate trap Confirm slope. Condensate hose and drain piping to slope toward drain and be secured to prevent accidental disassembly . To drain. Drain materials subject to corrosion must be protected by acid neutralization. Condensate drainage: Free flow of condensate from venting systems and pressure vessel must be maintained at all times. Trap and condensate drain piping must be accessible to allow regular inspection and cleaning. 3.10 Installing a condensate neutralizer If discharging condensate into building drain piping materials that are subject to corrosion, use a neutralization package. Caution After installing a condensate neutralization package, the pH of the condensate discharge must be measured on a regular schedule to ensure the neutralizing agent is active and effective. Danger The water in the condensate neutralizer can cause severe burns to the skin. Wear protective gloves and eye wear when servicing the condensate neutralizer. 40 Section: Installation

Condensate water line: Warning - Risk of damage to appliance. All condensate discharge lines, including neutralization tank inlet, must be at a lower elevation than the condensate water line of the appliance. Factory-supplied condensate trap Plastic piping Condensate neutralizer NT-1S: Drain materials subject to corrosion must be protected by acid neutralization. Warning - Risk of injury. Tank fluid can be highly acidic. Do not use hands to stir material. Refer to the neutralization instructions of the manufacturer. Access to the discharge, before the drain, is necessary for proper maintenance in order to check the effectiveness of the neutralizing agent. A simple pH test should be performed annually to ensure neutralizing agent is still effective. If the pH falls below 6.5 the neutralizing material should be replaced. The agent (limestone chips with a minimum calcium carbonate content of 85%) can be purchased from a local supplier. ¾ inch 14 NPT inlet and outlet. Unions for ease of maintenance. (Shipped with NT-1S) To drain 41 3.10 Installing a condensate neutralizer

Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage. High levels of dissolved solids or minerals may precipitate out of the fluid onto the hottest part of the heat exchanger, impairing heat transfer and resulting in overheating and premature failure. The amount of solids that may form on the heat exchanger will depend on the degree of hardness and the total water volume in the system. A high water volume system with a low hardness count may cause as much damage as a system with less volume and higher hardness, so it is recommended to treat water so as to remove all dissolved solids. Other water chemistry allowable limits are as follows: Acidity pH is to be between 6.6 and 8.5 Chloride is to be less than 125 mg/l Iron is to be less than 0.3 mg/l Cu less than 0.1 mg/l Conductivity is to be less than 400μS/cm (at 77°F [25°C]) 7 grains/ gal (120 ppm) Important: Ensure that these limits are acceptable for the other water-side components in the system. Boiler Head Loss - SL 10-85 G3, SL 14-115 G3 Flow rate (gpm) 2 4 6 8 10 12 14 Head @ flow (ft wc) 0.5 1.5 2.5 3.0 4.0 4.5 6.0 Table 6 SL 10-85 G3, SL 14-115 G3 Boiler Head Loss Boiler Head Loss - SL 20-160 G3 Flow rate (gpm) 4 6 8 10 12 14 16 Head @ flow (ft wc) 0.5 1.0 1.5 2.0 3.0 4.0 5.0 Table 7 SL 20-160 G3 Boiler Head Loss 42 Section: Installation

Flow rate (gpm) 6 10 15 20 22 Head @ flow (ft wc) 2.0 3.5 5.5 8.0 13.0 Table 8 SL 30-199 G3 Boiler Head Loss Ensure that the pump is rated for the design circulating water temperatures; some pumps have a minimum water temperature rating above the low temperature potential of the boiler. Following installation, confirm the actual performance by measuring Δ°T (under high and low flow conditions) after establishing the correct firing rate. To use legacy heat, we recommend water flow after burner shutdown. There can be significant build- up of energy due to the volume of heated water in the system. Default load settings will run the boiler’s primary pump for up to 15 minutes (900 seconds) after burner shutdown. Secondary pumps can be set to run up to 5 minutes after burner shutdown (for the last calling load). As shipped, the default settings will run the boiler pump for 5 minutes to place the legacy heat where it is useful. To allow pump purge after burner shut-down, the primary pump must be under the control of the boiler. To simplify the control application, promote good loads and flow management, installers must conform to the piping design configurations provided. Propylene glycol usage Warning Do not use automotive-type ethylene or other types of automotive glycol antifreeze, or undiluted antifreeze of any kind. This may result in severe boiler damage. Installers must ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials. Improper mixtures and chemical additives may cause damage to ferrous and non-ferrous components as well as non-metallic, wetted components, normally found in hydronic systems. Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation location. For environmental and toxicity reasons, IBC recommends only using non-toxic propylene glycol. Propylene glycol solution is commonly used in a closed loop where freeze protection is required. Its density is lower than that of water, resulting in lower thermal performance at a given flow and pressure. Generally, a 50%:50% solution of propylene glycol and water requires an increased system circulation rate (gpm up 10%), and system head (up 20%) to provide performance equivalent to straight water. 43 3.11 Water Piping

Primary/secondary piping, or the use of a hydraulic separator (such as the Caleffi 549 SEP4™ 4-in-1 Magnetic Hydraulic Separators) is recommended for maximum flexibility in multi-load applications. Piping loads in parallel is also encouraged in systems that only have two loads, or when loads are operating simultaneously. The extremely low pressure drop through the heat exchanger affords more flexible options unavailable in other designs. Caution Contact local water purveyors about the suitability of the supply for use in hydronic heating systems. If unsure about water quality, request testing and assessment (and treatment, if required) from a local water treatment expert. Alternatively, water or hydronic fluid of known quality can be brought to the site. 3.11.2 System piping Note The piping drawings in this manual are simple schematic guides to a successful installation. For further information and details, consult our concept drawings – which provide detail on specific single and multiple boiler applications (available in IBC's Technical portal). There are many necessary components not shown, and details such as thermal traps are left out so the drawings have greater clarity. Our boilers must be installed by licensed and experienced heating professionals familiar with the applicable local and national codes. System design is to be completed by an experienced hydronic designer or engineer. You should carefully read and follow the installation instructions along with the application drawing that fits your system. System piping is connected to the boiler using 1 inch NPT-Male threaded fittings on the right or left side connection ports. To simplify servicing, we recommend using unions or ball valves at the boiler's supply and return water connections. 44 Section: Installation

Microbubble air eliminators are best installed where the fluid is at the highest temperature and lowest pressure. Expansion tank connection (point of no pressure change) should be on the suction side of the circulator, with minimal pressure drop between. Fill station with isolation valve closed, or fill tank. Dirt separator recommended Figure 33 Basic boiler trim options Fluid fill is most often accomplished by using a boiler regulator and fill valve set at 12 psig or more, with the appropriate backflow prevention device as required by local code. This is acceptable in areas where municipal water or well water has been treated and filtered to remove excessive minerals and sediment, and water chemistry is known to be suitable for closed loop hydronic systems. In areas where water quality is in question, or when chemical treatment or glycol is required, other options should be considered. Follow the applicable codes and good piping practice. Warning Close the fill valve after any addition of water to the system, to reduce risk of water escaping. 45 3.11.2 System piping

be a better choice than a raw water fill from the mains. When regular maintenance requires relief valve blow-off, the discharge may be directed back into the pressurization appliance for recycling of boiler fluid and chemicals back into the system. In buildings that may be unoccupied for long periods of time, pressurization appliances are useful to prevent flood damage should leakage occur from any component in the system. An additional benefit is that backflow prevention devices are not required when using these devices. Do not place any water connections above the boiler to avoid damage to the fan and controls. If needed, create a shield over the top of the cover, but allow clearance for airflow and service access. Heating supply and return Auto air vent or flushing valve Figure 34 Consideration for left-side only piping Note that the supply pipe off the right-hand side of the heat exchanger carries the LWCO device. If all heating loads are on the left-hand side only, ensure that the right-hand supply connections use an auto air vent or a flushing valve. Due to the various piping options available, positioning the pressure relief valve can vary. When piping from either side, the relief valve is installed in the upper port opposite the supply outlet, using the fittings provided. 46 Section: Installation

A 30 psi pressure relief is supplied for field installation in the relief valve fitting on the boiler. Relief valve discharge piping must terminate between 6 inches (15 cm) and 12 inches (30 cm) above the floor or per local code. Warning During operation, the relief valve may discharge large amounts of steam and/or hot water. To reduce the potential for bodily injury and property damage, install a discharge line that: Is connected from the valve outlet with no intervening valve and directed downward to a safe point of discharge. Allows complete drainage of both the valve and the discharge line. Is independently supported and securely anchored, so as to avoid applied stress on the valve. Is as short and straight as possible. Terminates freely to atmosphere where any discharge will be clearly visible and is at no risk of freezing. terminates with a plain end which is not threaded. Is constructed of a material suitable for exposure to temperatures of 375° F or greater. Is, over its entire length, of a pipe size equal to or greater than that of the valve outlet. Do not cap, plug or obstruct the discharge pipe outlet. If piping from both sides at the same time, a tee must be installed on either supply outlet, immediately on exiting the boiler so that there is no possibility of installing an isolation valve between the pressure vessel and the relief valve. Pressure relief valve locations (pick one) No shut-off valve Figure 35 Relief piping with dual side piping connections 47 3.11.2 System piping

For optimal performance, place pumps on the supply side of secondary loops to facilitate air evacuation. Use pumps with internal check valves to avoid ghost flows and thermal siphoning. Primary/Secondary piping ensures adequate flow and de-couples Δ°T issues (boiler vs. distribution). It also adds to the system's thermal buffering, to assist in handling small loads and temperature transition. Aim for a 20 °F to 30 °F Δ°T across the heat exchanger at high fire (there is a boiler protection throttle fence limiting the Δ °T to 40 °F). A primary-secondary piping configuration requires an extra pump, independent from any secondary load pumps. The controller hosts wiring terminals and integral relays to simplify installation and operation of this preferred layout, offsetting such costs. For best results regarding the SL 14-115 G3, use a Primary/Secondary piping system with a pumped boiler loop (using 1” piping). Heat exchanger head is only 1.5’ at 4 USgpm and approximately 4’ at 10 USgpm. The minimum flow rate required through the heat exchanger is listed in Table 6 ,Table 6 , and Table 6 . To ensure adequate water flow through the boiler under high-head / single zone space heating conditions, a pressure activated bypass or other means of bypass must be used on any load where the flow rate might drop below minimum requirements. These boilers are designed to supply three different heating loads with temperatures within the range 34°F to 180°F - to meet three separately piped loads. Use closely spaced tees to connect each pumped “load” (e.g. DHW, baseboards or radiant floor) to the primary loop, or employ the use of a hydraulic separator to isolate the boiler loop from the system and pipe the system from the secondary side of the separator. Twoload systems may be piped with a variant of parallel piping commonly used, including our unique dual side piping configuration. Ensure that the pump is rated for the design circulating water temperatures; some pumps have a minimum water temperature rating above the low temperature potential of the boiler. Following installation, confirm the actual performance by measuring Δ°T (under high and low flow conditions). Check valves or thermal traps should be used to isolate both the supply and return piping for each load - to avoid thermal siphoning and reverse flow. To ensure adequate water flow through the boiler under high-head / single zone space heating conditions, a pressure activated bypass or other means of bypass must be used on any load where the flow rate might drop below minimum requirements. Boilers can be connected directly to a floor of non-oxygen barrier polybutylene material (PB tubing). For maintenance of warranty on such systems, all loops must be flushed thoroughly, and a dirt separator or side stream filter must be installed. After the retrofit, a separator / filter maintenance routine must be performed, with filter clearing after the first day, first week, month, and annually thereafter. Ferrous fitting and pumps must not be used on non-oxygen barrier tube systems. 48 Section: Installation

straight piping a minimum of 8 pipe diameters upstream and 4 pipe diameters downstream, with no elbow or other component that may create turbulent flow. Tees should be as close together as possible (maximum four pipe diameters apart) and there should be no restrictions between the fittings that would result in a pressure drop. Heat Migration: On secondary loops that extend vertically to a load that is above the primary loop, use check valves on both supply and return of secondary piping. Check valves or zone valves on return. Figure 36 Primary-secondary piping details with closely-spaced tees 49 3.11.2 System piping

so that the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. The boiler piping system of a hot water boiler connected to the heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle. Monitor the performance of system components when using the sequential load feature of the boiler to ensure that the components are compatible. For instance, many air handlers have a thermostat connection that will energize an internal relay to operate the air handler circulator and its fan on a call for heat. This may result in the air handler components operating when other loads are operating at a higher priority, resulting in cold air blowing, or heat robbed from another load. Some wiring alterations may be required to separate these functions from the thermostat control in favor of more effective control from the boiler. Closely-spaced tees Optional Figure 37 One-temperature space heating - tees on secondary piping 50 Section: Installation

Optional Thermostatic mixing valve Figure 39 Typical two-temperature space heating piping concept. 51 3.11.2 System piping

local code. Indirect hot water tank Figure 40 Indirect domestic hot water - piping concept Optional Thermostatic mixing valve Figure 41 Two sided piping, DHW and space heating - piping concept 52 Section: Installation

3.11.2.2 Parallel load piping Compared with the primary-secondary approach, the design below saves one pump. Lost is the simplicity of constant head and flow at the boiler. Air handler Figure 43 One pump parallel piping concept 53 3.11.2 System piping

local code. Indirect hot water tank Figure 44 Two pump, two load parallel piping concept 3.11.2.3 Multiple-boiler piping Multiple IBC boilers can be installed in a single heating system to provide redundancy, increased output, and greater heating plant turn-down capabilities. Primary-secondary piping must be employed, and each boiler must be installed with its own pump as illustrated below. This approach provides constant head and flow at each boiler, regardless of flow variations in the main building loop. 54 Section: Installation

saves electricity by reducing the pumping power required as load conditions are reduced. One boiler control is set up as a "Master" boiler, and up to 23 additional boilers can be added to the system as "Subordinate" boilers by connecting a twisted pair of wires between the boilers. No additional controls are needed. Check valves are used in each boiler's piping to prevent reverse flow when the boiler is off. Secondary loop sensor to Master boiler To building Closely spaced tees From building Check valve Figure 45 Multiple boiler piping concept 55 3.11.2 System piping

Check valve Figure 46 Multiple boiler low loss header - piping concept 3.12 Gas piping Note Due to the precision of modern modulating boilers it is important to pay special attention to gas pressure regulation. Important: Check gas supply pressure to each boiler with a manometer or other high- quality precision measuring device. Pressure should be monitored before firing the boiler, during operation throughout the boiler's full modulation range, and after the call when the regulator is in a "lock-up" condition. Pay special attention to retrofit situations where existing regulators may have an over- sized orifice and/or worn seats, causing pressure “creep” and high lock-up pressures. A high quality regulator will maintain constant pressure above the boiler’s minimum specification at all firing rates, and will not exceed the boiler’s maximum pressure rating when locked-up with no load. 56 Section: Installation

The boilers require a minimum inlet gas supply pressure of 4.0" w.c. for natural gas or propane during high fire operation. For either fuel, the inlet pressure shall be no greater than 14.0" w.c. Confirm this pressure range is available with your local gas supplier. The inlet gas connection to the boiler is ½" NPT (female). Adequate gas supply piping must be installed with no smaller than ½" Schedule 40 (e.g., Iron Pipe Size (IPS) and using a 1" w.c. pressure drop, in accordance with the following table. Maximum Pipe Length (ft) Model ½ inch IPS ¾ inch IPS 1 inch IPS 1¼ inch IPS SL 10-85 G3, SL 14-115 G3 (Natural Gas) 30 ft 125 ft 400 ft - SL 10-85 G3, SL 14-115 G3 (Propane) 90 ft 350 ft 1,000 ft - SL 20-160 G3 (Natural Gas) 10 ft 70 ft 200 ft - SL 20-160 G3 (Propane) 50 ft 200 ft 600 ft - SL 30-199 G3 (Natural Gas) 10 ft 40 ft 150 ft 600 ft SL 30-199 G3 (Propane) 30 ft 125 ft 400 ft 1,600 ft Table 9 Maximum Gas Pipe Length (ft) Gas piping must have a sediment trap ahead of the boiler’s gas valve. A manual shutoff valve must be located outside the boiler, in accordance with local codes or standards. All threaded joints in gas piping should be made with an approved piping compound resistant to the action of natural gas or propane. Use proper hangers to support gas supply piping as per applicable codes. Figure 47 Typical gas piping Install manual shut-off valve. Check local code for height requirement Full-sized sediment trap Union The boiler must be disconnected or otherwise isolated from the gas supply during any pressure testing of the system at test pressures in excess of ½ psig. Dissipate test pressure prior to reconnecting. The boiler and its gas piping must be leak-tested before being placed into operation. 57 3.12.1 Gas pressure

pressure) and downstream (manifold pressure) of the gas valve. Note that manifold pressure varies slightly in accordance with firing rates with the modulating series boilers, but will always be close to 0" wc. 3.13 Electrical connections All electrical wiring to the boiler (including grounding) must conform to local electrical codes and/or to the National Electrical Code, ANSI/NFPA No. 70 – latest edition, or to the Canadian Electrical Code, C22.1 - Part 1. 3.13.1 Power management, quality and electrical protection In areas of unreliable power, appropriate surge protectors and or power conditioning equipment should be installed in power supply wiring circuits. Note The IBC boiler (like any modern appliance that contains electronic equipment) must have a “clean” power supply, and is susceptible to power surges and spikes, lightning strikes and other forms of severe electrical “noise”. Power conditioning equipment (surge protectors, APC or UPS devices) may be required in areas where power quality is suspect. In temporary or manual operation, for example in new construction heating, use a construction thermostat or jumper with an in-line on/off switch for on/off management of the boiler. Do not turn off the heat by removing power to the boiler. This will interrupt the moisture management routine (fan turns at ultra low rpm for 90 minutes after burner shutdown) resulting in serious damage to the boiler. Treat the boiler like a computer, where you do not just pull the plug when done. 58 Section: Installation

Line-voltage wiring is done within the field-wiring box (see Wiring diagrams on page 101). Connect the boiler to the grid power using a separate, fused circuit and on/off switch within sight of the boiler. Use 14-gauge wire in BX cable or conduit properly anchored to the boiler case for mains supply and pump circuits. Figure 48 Line voltage load pump terminals Caution The on-board controller load pump relays are protected with 5 Amp fuses. The maximum recommended load on each fuse is 4 Amps (80% of rating). The maximum combined pump load is 10 Amps. Isolation relays or contactors must be used if the loads exceed these maximums. Connect a 120 VAC / 15 amp supply to the "AC IN" tagged leads in the wiring box. The maximum actual draw (with 5 typical residential size pumps) is less than 4 amp. 3.13.2.1 Load pumps The 120 VAC power supply to the load pumps (P/V1, P/V2, P/V3, and P/V4) has been factory installed and connected to P/V-L and P/V-N for your convenience. The upper 4 pairs of contacts on this green connector strip are then powered to manage up to 4 load pumps – the top pair for Load 1, the second pair for #2 etc. Once the controller is programmed for the respective loads, the boiler manages all the loads without need of further relays (for loads up to 1/3 HP for more – use a protective relay). 3.13.2.2 Boiler pump The boiler pump (primary pump) is powered by the white/yellow wire from the pair labeled "Boiler Pump" (Primary Pump). This lead is factory wired to the controller (and its 120 VAC supply) at the upper right backside of the controller board. Do not attempt to connect the primary pump to the pump/zone valve terminal block along the controller’s right edge - this is for the secondary pumps and/or zone valves only. Connect the pump’s black wire to the yellow of this pair (switched Hot). The white/yellow pair should be individually capped if the primary pump does not obtain its power from this pair (e.g. if a variable speed primary pump is connected to the mains power). Pumps can be switched on/off using the touchscreen controller, so there is no need for temporary pump wiring during system filling / air purging. The combined current of all load pumps connected through the on-board pump relays should not exceed 10 amps. The control circuit board is protected using on-board field replaceable fuses. Each 59 3.13.2 120VAC line-voltage hook-up

24 VAC boiler control circuit is protected with a 2 Amp fuse. The VS output leads are not commonly used except when providing a variable speed signal to the fan in an IBC air handler. 3.13.3 Other wiring Danger Do not connect sensors to “Therm” terminals. Overheating components can result in serious personal injury and/or property damage. Other optional low voltage connections to the control board include: Two auxiliary Interlocks - for external safety devices as may be required by some jurisdictions, such as an external low-water cutoff. Contacts for indoor and outdoor temperatures sensors associated with reset heating. A 10K ohm thermister (resistor dependent on temperature) for outdoor reset sensing is supplied with the boiler for improved comfort and combustion efficiency. One pair for a DHW tank sensor. Connect to "DHW S" (not the respective Therm. 1,2,3,4 location) and the boiler automatically detects and calls a smart DHW routine. One pair of contacts for remote secondary loop temperature control. One pair (marked BoilerNet) for network connection – this is used for connecting multiple IBC modulating appliances for autonomous staging. The bottom pair of contacts (labeled 'External Control') receives a 0-10VDC (default) or 4-20 mA signal from an external boiler controller for direct throttle control. The boiler’s own sensors act as high limits only. The user must enter maximum and minimum boiler supply temperatures. Note Sensors connected to any sensor input contacts must be of the NTC Thermister type with a resistance of 10,000 ohms at 77°F (25°C) and β = 3892. We do not recommend using 3rd party supplied sensors. Compatible water temperature sensors and outdoor sensors can be supplied by your IBC distributor. 3.13.4 Zone valve hook-up If using zone valves instead of pumps to manage multiple heating loads: 1. Provide 24VAC for the zone valves to the power contacts on the Pump/ Zone Valve terminal block. 2. Disconnect the 120VAC leads connected to PV-L/PV-N and cap off. 60 Section: Installation

systems only. 4. Wire individual load/zone valves to their associated contacts on the secondary pump/zone valve connector. Do not confuse such “load/zone valves” with similar valves used to segregate a single load type (e.g., those used on a zoned radiant floor) – see the next section. 3.13.5 Thermostat / sensor wiring Each of the four loads has dry contacts for thermostats as marked on the lower connector strip (e.g., "Therm 1"). Gang lines from a multiple-zoned load (e.g., off the end-switches for each radiant floor zone) present a common thermostat signal to the controller. Ensure that there are no disturbing influences on the call-for-heat lines - for example, that there are no coils to switch an air handler motor. Most power stealing thermostats can be connected directly to the Therm terminals. Consult the Controller manual for more detailed instructions. 3.13.6 Thermostat heat anticipator IBC “Therm” contacts draw no power, so an anticipator setting for the thermostat is not applicable with these appliances. In the case of a single temperature / heat load where zone valves are used to manage individual thermostatically controlled zones, each room thermostat’s heat anticipator should be adjusted to the current draw of its associated zone valve. 61 3.13.5 Thermostat / sensor wiring

This boiler is equipped with a touchscreen controller for programming the boiler. For detailed instructions on using the controller, see the Touchscreen Controller manual. Note Use only a stylus or a clean finger to interact with the touchscreen. Using sharp or metallic objects will cause damage. The controller is equipped to provide: Control of up to 5 pumps – 1 boiler pump + 4 separate load pumps Outdoor Reset control Set Point temperature regulation Domestic Hot Water (DHW) External control via 0-10VDC or 4-20mA signaling Manual control of firing rate for gas valve calibration Alarm dry contacts Zoning - simultaneous operation of up to four pumps Load Combining – simultaneous operation of two similar water temperature loads Programmable setback / override schedule The control can manage or operate in a network of up to 4 IBC boilers without additional controller.  Some of the new features available in the touchscreen control include: Setup Menu for simple, quick programming Portal connectivity for remote monitoring and programming Superior warning messages while setting up the control Advanced Error messages with visual display on the Home Screen Internet/LAN connectivity 4.1 Controller When the boiler is first energized, the controller will go through a power up sequence that will take approximately 60 seconds. During this time the controller is completing a self-diagnostic and loading all previous settings. In the event of a power interruption the boiler will automatically resume operation when power is restored with all the previously stored values.

Power-up, self-diagnostics, easy Load parameter adjustments Burner operation, safety management systems, call-for-heat management and load priority Real time boiler data Temperature and throttle operation Maintenance of operational and error service logs 2-way communication between other IBC boilers and controls Internet connection and communication Operational and historical data may be accessed from the Status menu > Load Status > Load Profiles and Load Statistics screens. Also in the Status menu, you can view error logs, including records of all errors since original power-up complete with the date and time of the error. 4.2 Control interface The control interface is provided through a color touchscreen display. The touchscreen responds to a light finger touch on the screen. You can also use a stylus, pencil, or similar device to operate the touch controls. Do not use a sharp or metallic object such as a screw driver to operate the control as it could damage the touchscreen. Prior to any interaction with the touchscreen, the display shows the Home screen details of the current boiler status. If the controller has been left on, the Home screen long enough (user adjustable, 10 minutes by default) the display dims to save power. The control automatically returns to the home screen if left unattended. The screens will step back one screen at a time in 10-minute increments if the touchscreen has not been touched. The pop- up windows will also step back automatically in 2-minute intervals. The boiler status bar indicates if the boiler is in a normal, warning or alarm state. When no warning or alarm state is present, the bar will be green and the time will be displayed inside the green area. The bar can also be yellow or red corresponding a warning or alarm state. Text inside the bar will indicate the specific warning or alarm present. If more than one alarm is present the text display will slowly change, rotating though whatever alarms that are present. 64 Section: About the boiler controller

Danger Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, do not try to operate any appliance - do not touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a phone located remotely. Follow the gas supplier’s instructions, or if the supplier is unavailable, contact the fire department. Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water. Should overheating occur or the gas supply fails to shut off, do not turn off or disconnect the electrical supply to the pump. Instead shut off the gas supply at a location external to the appliance. Important pre-ignition checks Once installation of the appliance is completed, and before operating the appliance, it is important to review the following checklist of precautions: Checklist for electrical conditions, ducting and water connections Checking electrical conditions Check Check all line voltage electrical connections to ensure all connections are correct and tight. □ Check thermostat connections. □ Thermostat in a suitable location. □ Checking piping connections Check Ensure venting system is complete and seal tested. □ Confirm any common venting system at the installation site is isolated and independent of the boiler. □ Confirm that any holes left from the removal of a previous boiler have been sealed, and that any resizing of the old flue has been done. □ Check that the water piping system is fully flushed and charged, and that all air has been discharged through loosened bleed caps. Note that it is possible to switch all pumps on/off from the touchscreen – without a call for heat. This simplifies system filling and air bleeding (refer to "Performing a manual pump purge" in the Controller manual). Load must be assigned. Use a minimum water pressure of 12 psig. And confirm that the pressure relief valve is installed and safely drained. □

Check Check to see that adequate gas pressure is present at the inlet gas supply test port. □ Connect a manometer and open the gas control valve. Requirements are minimum 4" w.c and maximum 14" w.c. □ Check that there are no gas leaks. □ All connections are pressure tested and leak free. □ All piping flushed to ensure all air is removed. □ Check valve is installed and the external pump is flowing in the correct direction. □ Checking venting connections Check All connections are pressure tested and leak free. □ All vent pipe is sized correctly and joints are sealed. □ Powering on the boiler Check Perform a final check of electrical wiring, and provide power to the boiler to initialize operation. □ Warning Fill the condensate trap with water before you first fire the boiler to prevent exhaust fumes from entering the room. Never operate the boiler unless the trap is filled with water. Failure to comply will result in severe personal injury or death. 66 Section: Before operating the boiler

Before operating the appliance, there are some important pre-igntion checks that need to be performed. For more information, see Before operating the boiler on page 65. To understand the boiler start-up process, see Sequence of Operation on page 103. 6.1 Lighting and shutting down the boiler Start-up Checklist Check Followed lighting and shutting down procedure. □ Tested the ignition safety shutoff function (see Testing the ignition safety shutoff on page 68). □ Checked the appliance's fuel source, and if necessary, performed a fuel conversion using the appropriate P-kit. □ Performed gas pressure test by measuring the inlet gas pressure. □

combustion test and adjustment. □ Tested the low water cutoff function to check that the LWCO sensor is working. Refer to "Testing the LWCO function" in the Controller manual. □ Tested the high limit temperature function to check that the High limit temperature sensor is working. Refer to "Testing the Hi-Limit cutoff temperature function" in the Controller manual. □ 6.2 Testing the ignition safety shutoff To test the ignition system safety shutoff function: 1. With the boiler in operation, shut off the gas control valve directly outside the boiler case. 2. Ensure that the boiler has purged, attempted to re-light three times, has shut off and the appropriate error information is displayed on the controller. 3. The error is displayed after testing the ignition safety shutoff. 4. To restart the boiler, reset the power or on the touchscreen controller tap (Status)> Clear Errors > Yes. 6.3 Commissioning The appliances are factory calibrated to operate with natural gas (or propane if desired) at sea level. The gas-air ratio or zero-offset adjustment screw may need adjusting to attain optimum combustion results. Note that only qualified technicians using properly functioning and calibrated combustion analyzing equipment should perform a mixture adjustment. 68 Section: Boiler operation

Danger Operating any IBC appliance using a fuel other than the fuel listed on its rating plate is prohibited. Failure to follow the instructions on converting to alternate fuels can result in a fire or explosion, which may cause property damage, personal injury, or loss of life. Check the rating plate of the appliance to ensure it is configured for the fuel you are using. If the fuel is incorrect for the appliance, a conversion kit must be ordered from IBC and the gas valve adjusted accordingly. Failure to perform the required fuel conversion can result in an immediate hazard. This boiler model can burn either natural gas or propane if equipped with the correct fuel-air metering device. Examine the rating plate of the boiler to ensure it is configured for the fuel you are using. For example, if the boiler is configured for natural gas, but needs to be converted to propane, use the conversion kit (sold separately by IBC) to install the appropriate fitting(s) and adjust the gas valve accordingly. See Table 10 for the required conversion kit. The touchscreen controller will automatically detect the installation’s altitude and make the appropriate adjustments to operate the boiler up to 4,500 feet in elevation without de-ration. The boiler will automatically de-rate at altitudes above 4,500 feet. Fuel conversion kit numbers Compare the boiler model number with the Kit # found in the table below: Model Number Natural Gas to Propane Propane to Natural Gas SL 10-85 G3, SL 14-115 G3 P-304 P-305 SL 20-160 G3 P-306 P-307 SL 30-199 G3 P-308 P-309 Table 10 Fuel Conversion Kits 6.3.2 Performing a fuel conversion You must be a qualified heating professional to perform this procedure. In this fuel conversion, you will be replacing the orifice, located between the gas valve and gas line to the fan, with the fuel-appropriate orifice supplied in the kit. 69 6.3.1 Checking a boiler's fuel source

1. Before you disconnect the electrical power, ensure that the gas supply is turned off at the gas shut-off valve. 2. Remove the front door. 3. Undo the nut at the top of the gas valve. 4. Push down on the gas valve, and remove the orifice and O-ring. 5. Insert the fuel-appropriate orifice (from kit) into the O-ring. 6. Reinstall the orifice and O-ring. 7. Tighten the upper nut onto the gas valve. 8. Place conversion labels associated with the new fuel onto the boiler. 9. Turn on the gas supply and connect the electrical power. 10. Check for gas leaks. 11. Tune the gas valve (see "Adjusting the gas valve" below). 6.3.3 Adjusting the gas valve Danger Making adjustments to the IBC gas valve without a properly calibrated gas combustion analyzer and by persons who are not trained and experienced in its use is forbidden. Failure to use an analyzer can result in an immediate hazard. Figure 50 Gas valve and fan components 70 Section: Boiler operation

Gas valve inlet Inlet gas pressure port Manifold pressure port Low fire (offset pressure) 6.3.3.1 Measuring the inlet gas pressure To perform a gas pressure test, you will need to use a Torx 15 screwdriver and a manometer. 1. Shut off the gas supply. You will be measuring the inlet gas supply from the test port. Do not perform a test from the manifold gas pressure test port. 2. On the gas valve, loosen the inlet gas pressure test port screw counter-clockwise. 3. Attach the manometer to the inlet gas pressure test port. 4. To measure the inlet gas pressure, switch on the gas supply. 5. When the boiler is operating at high fire, measure the gas pressure. Ensure that you have a load configured (reset heating, set point, or DHW). This load should be large enough to allow the boiler to operate at high fire for over 10 minutes. The gas pressure for natural gas should be around 7" w.c. at high fire and 11" w.c. for propane. 6. After completing the inlet gas pressure test, switch off the gas supply. 7. Remove the manometer from the inlet gas pressure test port. 8. Tighten the inlet gas pressure test port screw. 9. Switch on the gas supply, and soap test for leaks before returning the boiler to normal operation. 6.3.3.2 Performing a combustion test and adjustment The High Fire (gas-air ratio) adjustment screw will have to be adjusted to attain optimum combustion results whenever fuel conversion is undertaken, however, no mixture adjustment must be performed unless done by a qualified technician using properly functioning and calibrated combustion analyzing equipment. 1. Turn off the boiler’s external gas shut-off valve. 2. Give the boiler a call for heat. 71 6.3.3 Adjusting the gas valve

by turning its center-screw one full turn counterclockwise. 4. Attach a manometer to the inlet pressure test port and turn on gas to appliance. Static manometer reading should be ideally 7" w.c. for Natural Gas and 11" w.c. for Propane. Minimum and maximum static pressure should be between 4" and 14" w.c. Monitor pressure throughout the commissioning (start-up) procedure. Pressure may drop up to 1" to 2" w.c. at high fire. 5. To run the boiler at high fire, you can set the heat-out value in Test Operation mode to the maximum MBH for the boiler. To do this, on the controller, go to (More) > Test Operation > In the Fan Test: Heat Out field, tap 0 MBtu, then enter the maximum MBH. When the boiler reaches high fire, insert the combustion analyzer test probe into the flue gas test port. Then verify that the CO2 reading is within the combustion test targets at Table 11 values. 6. Adjust the high fire according to values in Table 11 using the high fire adjustment screw . Make tiny adjustments (may require several turns). Turning the High Fire screw clockwise will lean out the flame. 7. Set the heat-out value in Test Operation mode to the minimum MBH for the boiler. To do this, go to (More) > Test Operation > In the Fan Test: Heat Out field, tap 0 MBtu, then enter the minimum MBH. 8. Adjust the low fire according to values in Table 11 using the low fire adjustment screw. Turn the screwdriver clockwise to raise the CO2% (to richen). Turn counter-clockwise to lower CO2%. Start with ⅛ of a turn until you see the analyzer measure a change then only make 1/16 adjustments. If changing direction on this adjustment, you may notice a significant backlash. 9. Check the results and confirm the correct settings when you return the boiler to high fire, and then to low fire. Note Clock the gas meter to confirm full maximum rating plate input. 10. To exit the Test Operation screen, select Back. 11. Remove the call for heat. 12. If a manometer is connected to the gas valve inlet gas pressure port: a. Turn off the gas supply at the external gas shut-off valve. b. Disconnect the manometer. c. Tighten the inlet pressure port screw with a Torx 15 screwdriver. 13. Remove the analyzer probe, and install the test port plug. 72 Section: Boiler operation

Fuel High fire Low fire CO max PPM Range % Target % Range % Target % Natural Gas 9.0 - 10.0 9.5 8.2 - 9.2 8.7 <150 Propane 10.3 - 11.3 10.8 9.3 -10.3 9.8 < 250 Table 11 Combustion test target ranges - CO2 / Maximum CO Note: Low Fire CO2 should be at least 0.5% lower than High Fire CO2 73 6.3.3 Adjusting the gas valve

Inspection of the boiler is to be performed annually by a qualified service technician. Caution The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition. 7.1 Maintenance checklist for homeowner Maintenance Required Frequency Check Inspect system for unusual noises. Call your local heating contractor for service if needed As needed □ Keep vent terminals clear of obstructions (snow, dirt, etc.). As needed □ Keep combustible materials and flammable liquids and vapors away from the boiler. As needed □ Inspection of the boiler is to be performed annually by a qualified service technician. Annually □ 7.2 Maintenance checklist for heating contractor Caution Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Maintenance Required Check Remove any obstructions (e.g. leaves, dust, other debris) from vent terminals □ Check and clean or replace intake air filters or screens as required. □ Check for holes or leaks in venting. Replace venting as needed. □ Examine for any signs of moisture caused by sweating intake air pipes; insulate as required. □ Ensure proper resealing or re-installation of venting on each servicing. □ Check the pressure switch tubing for signs of brittleness or cracks. Replace using IBC part P-382. □

Maintenance Required for Boiler Controller Frequency Check Check that boiler operation is consistent with the steps in the Touchscreen Boiler Controller Manual. Annually □ Check that water temperature targets and setpoint is satisfactory and have not been adversely amended. Annually □ Check the operating history using the boiler's Logs menu and Error Logs menu. The controller tracks the duty cycle of the boiler in each of the 4 loads separately. This information can be used to adjust the water temperatures of each load. Annually □ Caution The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition. 7.2.2 General boiler maintenance Boiler Component Maintenance Required Frequency Check Condensate trap Remove and clean annually (see Cleaning the condensate trap on page 85). Ensure that the trap has been re-filled completely before firing the boiler. Annually □ If condensate neutralization is used, check the pH level of condensate discharge. Annually □ Burner Warning When removing the burner for inspection or boiler servicing, examine the sealing gaskets and replace if damaged. Upon re-assembly, test all sealing areas to ensure there is no leakage of combustible gas/air premix. Remove the burner to inspect for extent of fouling (see Replacing the burner on the SL 85, 115, 160 and 199 G3 boilers on page 84. a. Wash the burner from outside with a domestic water pressure, and dry using compressed air. As needed □ 76 Section: Service and maintenance

establish a reasonable burner inspection schedule. Some boiler / locations may call for annual service, others showing clean burners will only need attention every 2 – 5 years. c. Reassemble. Visually inspect the burner through sight glass. Ensure the flame is stable, without excessive fluttering. Normal flame pattern is evenly distributed over the burner surface. If the burner is operating improperly, remove and clean or replace. Use a CO2 analyzer to determine proper combustion. See Combustion test target ranges - CO2 / Maximum CO on page 73 for correct values. Annually □ Heat exchanger In areas of poor gas quality, there may be a build-up of black plaque (typically sulfur). Other fouling agents include: airborne dust, debris and volatiles. With the burner removed, examine the heat exchanger for signs of contamination and clean if necessary. Annually □ Boiler Pump Check that the pump is on in normal operation and that the water Δ°T is reasonable for a given firing rate. Annually □ Gas Piping Check for damage or leaks and repair as needed. Annually □ Boiler treatment Check consistency of any boiler treatment used, for appropriate mixture. Chemical inhibitors are consumed over time, lowering their density. Annually □ Verify proper operation after servicing. Caution Installers should inquire of local water purveyors as to the suitability of their supply for use in hydronic heating systems. If water quality is questionable, a local water treatment expert must be consulted for testing, assessment and, if required, treatment. Alternatively, water or hydronic fluid of known quality can be brought to the site. Annually □ 77 7.2.2 General boiler maintenance

only antifreeze made specifically for hydronic systems. Inhibited propylene glycol is recommended. Antifreeze volume must be between 25% and 50% of the total volume of water in the system. Warning Do not use automotive-type ethylene or other types of automotive glycol antifreeze, or undiluted antifreeze of any kind. This may result in severe boiler damage. It is the responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials. Improper mixtures and chemical additives may cause damage to ferrous and non-ferrous components as well as non-metallic, wet components, normally found in hydronic systems. Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation location. For environmental and toxicity reasons, IBC recommends only using non-toxic propylene glycol. Annually □ Water Caution Installers should inquire of local water purveyors as to the suitability of their supply for use in hydronic heating systems. If water quality is questionable, a local water treatment expert must be consulted for testing, assessment and, if required, treatment. Alternatively, water or hydronic fluid of known quality can be brought to the site. □ Check water pressure and temperature. There should be no noticeable change if boiler is functioning normally. Check for any noise in the system. Annually □ Check water piping for damage or leaks and repair as Annually □ 78 Section: Service and maintenance

when the boiler is firing and the water temperature is rising. If pressure rises sharply, consider replacement of expansion tank. Annually □ Check also for noise at high fire, which may signal water quality problems. Annually □ Water chemistry shall be of a quality generally accepted as suitable for hydronic applications. Annually □ Ensure any direct “city fill” water connections are left in the closed position to minimize exposure to leaks and flooding. Annually □ Relief valve - maintenance and testing Caution Before testing the relief valve, ensure the discharge pipe is properly connected to the valve outlet and arranged to contain and safely dispose of equipment discharge. The relief valve manufacturer requires that under normal operating conditions a “try lever test” must be performed every two months. Under severe service conditions, or if corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be performed at the end of any non-service period. Annually □ Test at or near the maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of sediment and debris. Then release the lever and allow the valve to snap shut. If the lever does not activate, or if there is no sign of discharge, discontinue use of equipment immediately and contact a licensed contractor or qualified service personnel. If the relief valve does not completely seal, and fluid continues to leak from the discharge pipe - perform the 79 7.2.2 General boiler maintenance

in the valve. If repeated tries fail to stop the leakage, contact a licensed contractor or qualified service personnel to replace the valve. While performing a "try lever test", a quantity of heat transfer fluid will be discharged from the piping system and the system pressure will drop. This fluid must be replaced. To refill and pressurize your system, we recommend using a system pressurization appliance such as an Axiom Industries model SF100 series. Capture the discharged fluid in a container and recycle it by returning it to the system feeder appliance. This is particularly important when your system contains treatment chemicals or glycol solutions. If the system employs plain water, the boiler auto fill valve must be turned on in order to recharge the lost fluid. 7.3 Replacing the fan, gas valve, and burner This section documents the following maintenance procedures: Replacing the fan Replacing the gas valve Replacing the burner. 80 Section: Service and maintenance

Ignition cable, ground wire, ignitor Fan coupler and gasket Screws/nuts securing fan to fan coupler (location of fan gasket) Fan Upper nut, orifice and O-ring Lower nut (behind bracket) and gasket Gas valve electrical cable and screw Gas valve support bracket 81 7.3 Replacing the fan, gas valve, and burner

boilers For reference, see Figure 51 Removing the fan 1. Turn off the electric power and gas supply to the boiler. 2. Ensure the boiler cools down to the surrounding temperature. Do not drain the boiler unless freezing conditions are expected during this procedure. 3. Remove the door. A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to connectors or screws may occur. 4. To disconnect the gas valve electrical cable , remove the screw. 5. Unscrew the upper nut of the gas valve. 6. Carefully push down the gas valve, and remove the orifice and O-ring. 7. To remove the gas valve, unscrew the lower nut . Ensure that the gasket remains inside the nut. 8. Disconnect the electrical cable from the fan. 9. Remove the screws or nuts securing the fan to the coupler. 10. Remove the fan and fan gasket. Installing the new fan 1. Install the new fan gasket and fan. 2. Secure the fan to the coupler using the two screws. 3. Reconnect the electrical cable to the fan. 4. Insert the lower part of the gas valve so that it is supported by the gas valve bracket, then tighten with the lower nut. Ensure that the lower gas valve gasket is in place. 5. Ensure that the gas valve orifice and O-ring are in place before you tighten the upper nut. 6. Reconnect the gas valve electrical cable with the screw. 7. Turn on the power and gas supply. 8. Check for gas leaks. 9. Tune the gas valve. 82 Section: Service and maintenance

boilers For reference, see Figure 51 Removing the gas valve 1. Turn off the electric power and gas supply to the boiler. 2. Ensure that the boiler cools down to the surrounding temperature. Do not drain the boiler unless freezing conditions are expected during this procedure. 3. Remove the door and the top cover/lid. A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to connectors or screws may occur. 4. To disconnect the gas valve electrical cable , remove the screw. 5. Unscrew the upper nut of the gas valve. 6. Carefully push down on the gas valve, and remove the orifice and O-ring. 7. Unscrew the lower nut of the gas valve, and remove from the gas valve bracket. Ensure that the gasket remains inside the nut. Installing the new gas valve 1. Position the lower part of the new gas valve so that it is supported by the gas valve bracket, then tighten with the lower nut. Ensure that the gasket is in place. 2. Ensure that the gas valve orifice and O-ring are in place before you tighten the upper nut. 3. Reconnect the gas valve electrical cable with the screw. 4. Turn on the power and gas supply. 5. Check for gas leaks. 6. Tune the gas valve. 83 7.3.2 Replacing the gas valve on the SL 85, 115, 160 and 199 G3 boilers

boilers Warning The IBC heat exchanger has a small amount of combustion chamber insulation (refractory), which contains ceramic fibers. When exposed to extremely high temperatures, the ceramic fibers that contain crystalline silica can be converted into cristobalite, classified as a possible human carcinogen. Avoid disturbing or damaging the refractory. If damage occurs, contact the factory for directions. Avoid breathing and contact with skin and eyes and follow these precautions: 1. For conditions of frequent use or heavy exposure, respirator protection is required. Refer to the “NIOSH Guide to the Selection and Use of Particulate Respirators Certified under 42 CFR 84” for selection and use of respirators certified by NIOSH. For the most current information, NIOSH can be contacted at 1-800-356-4676 or on the web at www.cdc.gov/niosh. 2. Wear long sleeved, loose fitting clothing, gloves and eyes protection. 3. Assure adequate ventilation. 4. Wash with soap and water after contact. 5. Wash potentially contaminated clothes separately from other laundry and rinse washing machine thoroughly. 6. Discard used insulation in an air tight plastic bag. NIOSH stated first aid: Eye contact - Irrigate and wash immediately. Breathing - Provide fresh air. For reference, see Figure 51 Removing the burner 1. Turn off the electric power and gas supply to the boiler. 2. Ensure that the boiler cools down to the surrounding temperature. Do not drain the boiler unless freezing conditions are expected during this procedure. 84 Section: Service and maintenance

A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to connectors, screws or refractory may occur. 4. Disconnect the ignition cable and ground wire from the ignitor. 5. Remove the fan coupler screws , and put aside along with the coupler and gasket. 6. Remove the burner and burner gasket. Installing the new burner and new burner gasket 1. Insert the new gasket and new burner. 2. Reinstall the coupler gasket and coupler, using a criss-cross pattern to tighten the screws. 3. Reconnect the ignition cable and ground wire to the ignitor. 4. Turn on the power and gas supply. 5. Check for leaks. 6. Tune the gas valve. 7.4 Cleaning the condensate trap Warning If condensate neutralization is used, check the pH level of condensate before and after neutralization to verify effectiveness and ensure that the discharge has neutral pH levels. Never operate the boiler unless the trap is filled with water. Failure to comply will result in severe personal injury or death. Condensate traps should be checked every year, cleaned and refilled as necessary. Before cleaning the condensate trap, you must turn off the power to the boiler, and allow it to cool down. Important: Installers or service contractors should ensure that the end user is instructed on cleaning and refilling the trap. 85 7.4 Cleaning the condensate trap

down. 1. To remove the trap pan, undo the two wing nuts. Note the orientation of the hose. 2. Loosen the upper union nut, and slide the condensate trap off the boiler drain outlet. 3. Unscrew the condensate union cap at the base of the trap, empty the water and flush the trap with water. 4. Fill the condensate trap to the top with water and replace the union cap and gasket 86 Section: Service and maintenance

water and replace the union cap and gasket. 6. Loosen the upper union, and slide the trap over the boiler drain outlet, and then tighten the upper union nut. 7. To reinstall the trap pan, tilt and slide the two tabs under the chassis of the boiler, and secure with the two wing nuts. 8. Ensure that the bottom union cap is hand-tightened to prevent leakage. Do not use tools and over-torque. 87 7.4 Cleaning the condensate trap

identified and solved through basic checks: confirming the electrical power supply, gas flow and resetting the thermostat control. Below are some common troubleshooting issues including fixes. 8.1 Electronic components This section details the method for troubleshooting the non-standard electronic components on the boiler. 8.1.1 Temperature sensors The resistance of the temperature sensors varies inversely with temperature. To test, measure the temperature of the sensed environment and compare with the value derived from the measurement of the resistance (obtained by connecting a good quality test meter capable of measuring up to 5,000 kΩ (5,000,000Ω) at the controller end of the sensor lead). To obtain a resistance reading, remove power to the boiler. For the supply water, return water, and vent temperature sensors, remove the wire leads by disconnecting their respective Molex connectors. Place multi-meter probes into the sensor’s female Molex connector socket. Do not apply voltage to the sensor as damage may result.

Temp. °F/°C Resist. Ω – Ohm 0 / -18 85,362 100 / 38 5,828 5 / -15 72,918 105 / 41 5,210 10 / -12 62,465 110 / 43 4,665 15 / -9 53,658 115 / 46 4,184 20 / -7 42,218 120 / 49 3,760 25 / -4 39,913 125 / 52 3,383 30 / -1 34,558 130 / 54 3,050 35 / 2 29,996 135 / 57 2,754 40 / 4 26,099 140 / 60 2,490 45 / 7 22,763 145 / 63 2,255 50 / 10 19,900 150 / 66 2,045 55 / 13 17,436 155 / 68 1,857 60 / 16 15,311 160 / 71 1,689 65 / 18 13,474 165 / 74 1,538 70 / 21 11,883 170 / 77 1,403 75 / 24 10,501 175 / 79 1,281 80 / 27 9,299 180 / 82 1,172 85 / 29 8,250 185 / 85 1,073 90 / 35 7,334 190 / 88 983 95 / 35 6,532 195 / 91 903 Table 12 Temperature sensor resistance values - 10K ohms 8.1.2 Fan The fan is controlled via the SIM+ control. The SIM+ provides electronic commutating power to the fan motor coilers determining the fan speed and power usage. 8.1.3 Water pressure sensor The water pressure sensor ensures that there is adequate pressure in the heating system for safe operation. The pressure is displayed in PSI as the default. If the system pressure should drop below 8 PSI the firing rate of the boiler is reduced. If the pressure drops to 4 PSI or lower, the boiler will not fire. 90 Section: Troubleshooting

fill valve, and then crack the pressure relief valve. The pressure displayed should reflect declining pressure. If it remains “fixed”, drain the boiler and replace the sensor, or dislodge any blocking debris from the sensor inlet channel and reinsert. 8.1.4 Safety and Ignition Module (SIM+) The SIM+ is a safety control, certified to conform to the UL 60730-5-5 and ANSI Z21.20 • CAN/CSA- C22.2 No. 60730-2-5-14 standards. The module controls the boiler’s combustion fan, gas valve, sensors, safety and ignition functions including: Direct spark automatic ignition Flame detection and current measurement Supply water temperature sensing Flue gas temperature sensing Supply water maximum temperature shutdown Flue gas maximum temperature shutdown Low water cut-off. The SIM+ continuously communicates with the boiler’s main controller reporting sensor readings and status. The sensor readings and error status, if any are displayed on the boiler controller’s screen. 8.1.4.1 Table showing LED operating status Its two status LEDs indicate the operating status as shown in the table below. SIM+ Status Indicators LED 1 LED 2 State Description, LED status indication Rapid flash Rapid flash Power up or resetting Startup checks and initialization Off Off Standby LED 1 Off = No flame or sparking LED 2 = Burner-on call state Off On Pre-purge or inter-purge LED 1 Off = No flame or sparking LED 2 = Burner-on call state 91 8.1.4 Safety and Ignition Module (SIM+)

LED 1 LED 2 State Description, LED status indication On On Heating LED 1 On = Flame detected LED 2 = Burner-on call state Rapid flash On Igniting LED 1 Flashing - Electrode sparking LED 2 = Burner-on call state Off Flashing Lockout Possible errors: An operating limit was exceeded A sequence failed An external sensor fault was detected. Flash alternately with LED 2 Flash alternately with LED 1 Fail-safe An error was detected - the boiler requires a power cycle Table 13 SIM+ LED status Indicators 8.2 Troubleshooting error messages Warning Never attempt to repair the control module (circuit board). If the control module is defective, replace it immediately. Errors shown on the touchscreen controller are described below as well as diagnoses and fixes. The bottom line of the touchscreen displays the boiler's error status. The following colors represent the boiler's operating status: Green – Normal Yellow – Warning Red – Alarm The text inside the bar will indicate the specific warning or alarm. If there is more than one alarm present the text will scroll slowly through all current alarm conditions. Besides the errors listed below, see also Miscellaneous touchscreen controller errors on page 95. 92 Section: Troubleshooting

Maximum Ignition Trials Error Issue Diagnosis Fix Error – Ignition Failure after 3 tries boiler has failed to ignite on 3 successive attempts. Boiler is in lockout for 1 hour, then repeats 3-try sequence. Consult service technician if error recurs. No spark when igniting. Ignition probe/flame sensor disconnected. Check that ignition lead is secure at the control module and at the probe. Manual gas shutoff is closed or gas line not fully purged. Check for gas flow. Open manual gas shutoff and reset boiler. Gap between ignition probe rods is too large or too small. Adjust ignition probe rod gap between ⅛ and 3/16th inch (3.2-4.7 mm). Spark, but no ignition Check that the spark module is sending power to the gas valve - close the gas supply, then disconnect the (black) electric housing from the face of the gas valve. Gently spread the plastic tabs to open. Look for 24 VAC voltage during an ignition cycle. Replace the module if there is no current detected. Boiler ignites, but shuts off at the end of the ignition trial. Improperly grounded pressure vessel/burner or unserviceable ignition lead or spark module. Ensure the pressure vessel is grounded. Check the ignition probe/flame sensor is electrically isolated from the vessel, and its ceramic insulator is intact. Replace ignition lead Replace spark module. 93 8.2.1 Maximum ignition trials error

Hi Limit cutoff temperature Error Issue Diagnosis Fix Error – Water High-Limit Exceeded Water temperature exceeds hi-limit. Boiler is in hard lockout mode. Refer to the V10 Touchscreen Controller manual for information on resetting a boiler after a hi-limit temperature lockout. 8.2.3 Low Water Cut-off error Low Water Cutoff Error Issue Diagnosis Fix Error - Low Water Cutoff The Safety and Ignition module has detected a low water condition. Refer to the V10 Touchscreen Controller manual for information on resetting a boiler after a LWCO lockout. 8.2.4 Aux. Interlock 1 or 2 Aux. Interlock 1 or 2 Issue Diagnosis Fix Interlock 1 or 2 terminals are open. Jumper lead is loose or compromised. Replace the jumper lead. External safety is in an alarm state. Inspect the external safety devices. 94 Section: Troubleshooting

Miscellaneous errors Issue Diagnosis Fix “ Loop/Indoor Sensor” “Insufficient Air Flow” “Insufficient Water Pressure” The sensor plug is not engaged. Check the P501 plug is fully engaged in the back of the controller board. “Unknown Error” The sensor plug is not engaged. Check the P501 plug is fully engaged in the back of the controller board. Temperature sensor input problem. Test each temperature sensor for appropriate readings and Replace defective temperature sensor. Error - Max. Inlet/Outlet Sensor Temp. Exceeded. > Check water flow Water temperature signal not within acceptable range. Potential flow or sensor failure. Consult service technician. Current outlet temperature exceeds operating limit. Check water flow. Defective or disconnected temperature sensor. Check wiring to temperature sensor and control module. Check temperature sensor. Blank – screen dark, but fan running Indicative of power-surge damage to appliance Check transformer; replace if damaged. Check circuit board for visible damage. Controller is stuck in "service" mode after software update. If update fails or no updates applied. Restarting returns the boiler to normal operation. 95 8.3 Miscellaneous touchscreen controller errors

Ignition issues Issue Diagnosis Fix Noisy spark when igniting Ignition lead is not firmly connected. Reconnect ignition lead. Contaminants/moisture on igniter probe/flame sensor. Ensure probe is dry by re-running post-purge; otherwise, clean or replace igniter probe. Boiler rumbles when igniting. Fluctuating gas pressure/ gas pressure too high/too low. Check CO2 level via analyzer. Check for proper gas piping Check pressure with manometer during ignition. Boiler will not attempt to ignite. Fan and pump are operating normally. No power to ignition control module. Check system wiring. Check air reference tubing. Igniter probe/flame sensor disconnected. Reconnect probe. Defective Control Module. Check ignition output from control module. Boiler will not attempt to ignite. Fan and / or pump are off. Display not illuminated No power to boiler. Check line voltage. Defective transformer. Check transformer. Reconnect or replace as needed. 96 Section: Troubleshooting