IBC SL Series Installation & Operating Manual
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IBC SL Series Installation & Operating Manual

Commercial condensing boiler
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INSTALLATION &
OPERATING MANUAL
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.
Commercial Condensing Boiler
SL 26-260 G3
SL 40-399 G3
WARNING

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  • Page 1 INSTALLATION & OPERATING MANUAL Commercial Condensing Boiler SL 26-260 G3 SL 40-399 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.
  • Page 2 Water quality Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage.
  • Page 3 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.
  • Page 4 Section: Safety information Warning If the boiler is likely to be exposed to fluid temperatures below 34°F (1°C), use a method to prevent freezing of condensate. Contact the factory for further information. Warning Do not use this boiler if any part has been 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.

  • Page 5: Table Of Contents

    Contents Safety information Manual safety markings Important safety instructions Specifications Cabinet dimensions SL 26-260 G3 SL 40-399 G3 Connection specifications 1.0 Introduction 1.1 Standard features and benefits 1.2 Warranty 2.0 Before installation 3.0 Installation 3.1 Code requirements 3.2 Removing an existing boiler 3.3 Determining location of the appliance Best installation conditions 3.4 Mounting the boiler...
  • Page 6 Section: Contents 3.11.1 General piping best practices 3.11.2 System piping 3.12 Gas piping 3.12.1 Gas pressure 3.13 Electrical connections 3.13.1 Power management, quality and electrical protection 3.13.2 120VAC line-voltage hook-up 3.13.3 Other wiring 3.13.4 Zone valve hook-up 3.13.5 Thermostat / sensor wiring 3.13.6 Thermostat heat anticipator 4.0 About the boiler controller 4.1 Controller...

  • Page 7: Safety Information

    7.4 Cleaning the condensate trap 8.0 Troubleshooting 8.1 Electronic components 8.1.1 Temperature sensors 8.1.2 Fan 8.1.3 Water pressure sensor 8.1.4 Safety and Ignition Module (SIM) 8.2 Troubleshooting error messages 8.2.1 Maximum ignition trials error 8.2.2 Hi Limit cut-off temperature error 8.2.3 Low Water Cut-off error 8.2.4 Aux.
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  • Page 9: Specifications

    Specifications Boiler Specification SL 26-260 G3 SL 40-399 G3 26 - 260 MBH CSA Input (Natural Gas or Propane) 40 - 399 MBH CSA Input (Natural Gas or Propane) 7.6 - 76.2 kW 11.7 - 117 kW 38.4 - 383 MBH CSA Output 24.9 - 239 MBH CSA Output...

  • Page 10: Cabinet Dimensions

    Section: Specifications Ignition Stages Timings Fan Pre-purge 15 seconds Trial for Ignition 4 seconds Flame Failure Response <0.8 second Table 1 Ignition stages timings Cabinet dimensions SL 26-260 G3 Figure 1 : Front and side view - SL 26-260 G3...

  • Page 11: 40-399 G3

    SL 40-399 G3 Figure 2 : Top view - SL 26-260 G3 Figure 3 : Bottom view - SL 26-260 G3 SL 40-399 G3 Figure 4 : Front and side view - SL 40-399 G3...
  • Page 12 Section: Specifications Figure 5 : Top view - SL 40-399 G3 Figure 6 : Bottom view - SL 40-399 G3...

  • Page 13: Connection Specifications

    Connection specifications Connection specifications The following table displays the required connection specifications. SL 26-260 G3 SL 40-399 G3 Flue Outlet 3" Schedule 40 4" Schedule 40 Combustion Air Inlet 3" Schedule 40 4" Schedule 40 Safety Relief Valve and Air ¾"...
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  • Page 15: Introduction

    1.0 Introduction The gas-fired modulating boilers are low pressure, fully condensing units with a variable input range. Approved as “Category IV” vented appliances, the boilers use direct vent (sealed combustion) or indoor combustion air. Figure 7 View from the front - SL 26-260 G3 Figure 8 View from the front - SL 40-399 G3...

  • Page 16: Standard Features And Benefits

    Load zoning – simultaneous operation of up to four loads with the same control settings Ability to manage and/or operate in a network of up to 24 IBC SL boilers Internet/LAN connectivity for software updates and remote access through the IBC V-10...

  • Page 17: Before Installation

    2.0 Before installation 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.
  • Page 18 Section: Before installation Precautions Check 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.

  • Page 19: Installation

    3.0 Installation Refer to the Specifications section for dimensional drawings and connection specifications. Use these drawings to find a suitable location for the appliance. 3.1 Code requirements The appliances are tested and certified under CSA 4.9 / ANSI Z21.13. Below are the code requirements for every installation.

  • Page 20: Determining Location Of The Appliance

    Section: Installation Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

  • Page 21: Best Installation Conditions

    Best installation conditions Best installation conditions Below are some factors to consider for best installation conditions: Install the boiler in areas where the combustion air source is not subject to chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a boiler.

  • Page 22: Connecting The Vent And Air Intake Pipes

    Section: Installation Attach the support bracket (supplied) to Hook the boiler tab (located on the wall studs using the supplied ¼" x back of boiler) over the support 2½" long lag screws (min. 4) with ¼" flat bracket flange. washers. Ensure that the boiler tab is flush against Secure the lower part of the the mounting bracket flange.

  • Page 23: Installation Clearances

    (as shown above). *Manufacturers of stainless steel Type BH venting systems must submit their approved transition fitting to IBC for evaluation and written approval. Figure 9 Securing vent connection Warning Do not mix PP venting materials from different manufacturers.

  • Page 24: 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.

  • Page 25: Venting Code

    PVC, CPVC, or PP venting materials are approved for use with these boilers in most of the USA. Check local codes to determine if any materials are prohibited. The vent temperature is limited Manufacturers of stainless steel Type BH venting systems must submit their approved transition fitting to IBC for evaluation and written approval.

  • Page 26: Direct Vent

    Section: Installation with the use of the flue temperature sensor and software to ensure that the maximum temperature of the PVC venting material is not exceeded. PVC venting material shall be certified to Sch. 40 ASTM D1785 or D2665. CPVC material shall be certified to Sch. 40/ASTM F441.
  • Page 27 3.7.4 Direct vent Air intake installation 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;...
  • Page 28 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.
  • Page 29 PP 87-90° elbows allow 8 ft for each elbow 3-inch Stainless Sidewall Intake: No additional allowance required Terminal IBC (P-257) Exhaust: Allow 20 ft 3-inch PP flexible pipe Limited to a maximum of 60 ft Allow 3.3 x actual length (e.g., 10 feet of 3-inch flexible pipe x 3.3 = 33 feet of rigid pipe)
  • Page 30 Section: Installation termination using 4-inch pipe. For 6 x 90º elbows, the maximum lineal (straight) length of pipe allowed is 152 feet (200’ – (6 x 8' = 48) = 152'). For 4-inch flexible PP pipe, up to 160 linear feet is allowed in vertical orientation (> 45 °).

  • Page 31: Rooftop Vent Termination

    3.7.5 Rooftop vent termination 3.7.5 Rooftop vent termination Warning Condensate can cause corrosion of metal roofing components and other roofing materials. Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate. pH levels can be as low as 3.0. a.
  • Page 32 36", or more, apart). Use the same 12" (minimum) vertical separation for all termination options. For alternate group terminations, contact the IBC factory for written guidance. Roof top concentric termination kits are approved for use with the boiler model.

  • Page 33: Sidewall Vent Termination

    3.7.6 Sidewall vent termination 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.
  • Page 34 Section: Installation Canadian Description US Installations Installations Clearance above grade, 12 in (30 cm) 12 in (30 cm) veranda, porch, deck, or balcony Clearance to window or 36 in (91 cm) for 12 in (30 cm) for door that may be opened appliances >100,000 Btuh appliances >...
  • Page 35 3.7.6 Sidewall vent termination Canadian Description US Installations Installations Clearance to mechanical 6 ft (1.83 m) 3 ft (91 cm) above if within air supply inlet 10 ft (3 m) horizontally Do not terminate above 7 ft (2.13 m) Vents cannot be located paved sidewalk or paved above public walkways or driveway...
  • Page 36 Improper installation will void the warranty. Do not use proprietary InnoFlue or PolyPro PP terminals without specific approval from IBC. Caution Take care installing Concentric Side Wall Termination kits when the outdoor temperature drops below 5°F/-15°C.
  • Page 37 3.7.6 Sidewall vent termination Figure 18 Vent termination clearance, stacked Figure 19 Vent termination clearances, stacked, side view Figure 20 Sidewall multi-vent terminations, stacked option...
  • Page 38 Sidewall multi-vent terminations, side-by-side option Sidewall direct vent with stainless sidewall terminal must be terminated as follows: The Stainless Sidewall Terminal (SST) 3 inch (IBC kit P-257) is approved for use with this appliance. Install the SST to comply with the minimum vent clearances listed in...
  • Page 39 3.7.6 Sidewall vent termination Figure 22 Allowed SST installation orientations The SST vent/air connections fit Sched. 40 three inch PVC/CPVC pipe. PP pipe cannot be used with the SST. The pipes must extend completely through the wall as shown below, and immediately inside the wall, adapt up to a 4 inch pipe using a standard reducing coupling fitting.
  • Page 40 Section: Installation Warning In areas of high snowfall, users must be advised to check side wall vent and air intake terminations on a regular basis to ensure blockage does not occur. Where an exhaust passes through a sidewall too close to a soffit, the venting must extend past the soffit by transitioning to vertical as shown in Figure Figure 27...

  • Page 41: Combustion Air Filtration System

    The appliance must not be exposed to surrounding air above 122°F (50°C) or below 32°F (0°C). 3.9 Installing the condensate trap IBC’s specified vent configuration promotes the safe drainage of moisture from the boiler and exhaust venting without flowing liquids back through the heat exchanger (as done by some other condensing boilers).
  • Page 42 Section: Installation Ensure the supplied trap is correctly installed and filled with water. When required, add (and maintain in good condition) a neutralization tank. For information on installing a condensate neutralizer, see Installation on page The condensate trap must be installed on the drain connection at the base of the boiler.
  • Page 43 3.9 Installing the condensate trap Fill the condensate trap with water, and Loosen the upper union nut, and slide ensure that the bottom union cap is the trap over the boiler drain outlet, and hand-tightened to prevent leakage. then tighten the upper union nut. To reinstall the condensate retainer, tilt The drain hose should run to a suitable the retainer to enable you to slide the...
  • Page 44 Section: Installation Flue gas exhaust: condensate and rain water, flow back from the venting system. Warning - Risk of damage to appliance. Ensure that rain water is prevented from entering air intake piping. 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.

  • Page 45: Installing A Condensate Neutralizer

    3.10 Installing a condensate neutralizer 3.10 Installing a condensate neutralizer If discharging condensate into building drain piping materials that are subject to corrosion, use a neutralization package. 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.

  • Page 46: Water Piping

    Section: Installation Free flow of condensate from venting systems and the pressure vessel must be maintained at all times. Trap and condensate drain piping must be accessible to allow regular inspection and cleaning. Condensate neutralizer NT-25: Drain materials subject to corrosion must be protected by acid neutralization.
  • Page 47 3.11 Water Piping Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage.
  • Page 48 (gpm up 10%), and system head (up 20%) to provide performance equivalent to straight water. IBC boilers are designed for use within a closed loop, forced circulation, low pressure system. A 30 psi pressure relief is supplied for field installation in the relief valve fitting on the boiler. For the SL 40-399 G3, optional relief valves up to 75 psi can be used where required on closed loop systems within multi-level buildings.
  • Page 49 3.11 Water Piping 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.

  • Page 50: General Piping Best Practices

    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.
  • Page 51 3.11.2 System piping Pressure relief valve (shipped with the boiler): no isolation valve permitted between boiler and relief valve Air vent purchased separately Microbubble air eliminators are best installed where the fluid is at the highest temperature and lowest pressure, on boiler outlet at expansion tank connection. Expansion tank connection (point of no pressure change) should be on the suction side of the circulator, with minimal pressure drop between.
  • Page 52 Section: Installation Fluid fill is most often accomplished by using a boiler regulator and fill valve set at 12 psig or more, with the appropriate backflow prevention device as required by local code. This is acceptable in areas where municipal water or well water has been treated and filtered to remove excessive minerals and sediment, and water chemistry is known to be suitable for closed loop hydronic systems.
  • Page 53 3.11.2 System piping Closely-spaced tees: To avoid induced flow, each set of tees should be installed with straight piping a minimum of 8 pipe diameters upstream and 4 pipe diameters downstream, with no elbow or other component that may create turbulent flow. Tees should be as close together as possible (maximum four pipe diameters apart) and there should be no restrictions between the fittings that would result in a pressure drop.
  • Page 54 Section: Installation Note The boiler, when used in connection with a refrigeration system, must be installed so that the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. The boiler piping system of a hot water boiler connected to the heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to...
  • Page 55 3.11.2 System piping Figure 34 Two pump, two load - parallel piping Compared with the Primary-Secondary approach, the above design saves one pump. Use check valves or thermal traps to isolate both the supply and return piping for each load. This avoids thermal siphoning and reverse flow.
  • Page 56 Section: Installation Figure 35 Primary-secondary piping concept with hydraulic separator Pressure relief valve (shipped with boiler): no isolation valve permitted between boiler and relief valve. Hydraulic separator. Expansion tank connection (point of no pressure change) should be on the suction side of the circulator, with minimal pressure drop between.
  • Page 57 External devices shown on this drawing are not supplied by IBC as standard equipment except for the pressure relief valve and internal LWCO. The other devices can be provided by your IBC distributor or by special order from IBC. Figure 36...
  • Page 58 Section: Installation Optional external tridicator gauge: An internally mounted tridicator is factory-installed. An external tridicator can be fitted if required by local jurisdiction. Flow direction: To supply manifold Flow direction: From return manifold Drain with cap Figure 37 Multiple boiler piping - four staged boilers, single load Supply to heating system.

  • Page 59: Gas Piping

    3.12 Gas piping 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.

  • Page 60: Electrical Connections

    Section: Installation Gas piping must have a sediment trap ahead of the boiler’s gas valve. A manual shutoff valve must be located outside the boiler, in accordance with local codes or standards. All threaded joints in gas piping should be made with an approved piping compound resistant to the action of natural gas or propane.

  • Page 61: Power Management, Quality And Electrical Protection

    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.

  • Page 62: Other Wiring

    Each pump is fused with a separate 5 Amp fuse. The Alarm contact is fused with a 5 Amp fuse and the 24VAC boiler control circuit is protected with a 2 Amp fuse. The VS output leads are not commonly used except when providing a variable speed signal to the fan in an IBC air handler. 3.13.3 Other wiring Danger Do not connect sensors to “Therm”...

  • Page 63: Zone Valve Hook-Up

    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...
  • Page 64 Section: Installation Figure 40 Electric wiring connections...

  • Page 65: About The Boiler Controller

    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:...

  • Page 66: Control Interface

    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 >...

  • Page 67: Before Operating The Boiler

    5.0 Before operating the boiler Danger Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, do not try to operate any appliance - do not touch any electrical switch or use any phone in the building.
  • Page 68 Section: Before operating the boiler Checking piping connections 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"...

  • Page 69: Boiler Operation

    6.0 Boiler operation Before operating the appliance, there are some important pre-igntion checks that need to be performed. For more information, see Before operating the boiler on page 63. To understand the boiler start-up process, see Sequence of Operation on page 107.

  • Page 70: Testing The Ignition Safety Shutoff

    Section: Boiler operation Start-up Checklist Check □ Tested efficiency of the appliance and made necessary adjustments by Performing a combustion test and adjustment. □ Tested the low water cutoff function to check that the LWCO sensor is working. Refer to "Testing the LWCO function"...

  • Page 71: Checking A Boiler's Fuel Source

    6.3.1 Checking a boiler's fuel source Danger Operating any IBC appliance using a fuel other than the fuel listed on its rating plate is prohibited. Failure to follow the instructions on converting to alternate fuels can result in a fire or explosion, which may cause property damage, personal injury, or loss of life.
  • Page 72 Section: Boiler operation To perform a fuel conversion on an SL 26-260 G3: Removing the Venturi mixing device 1. Before you disconnect the electrical power, ensure that the gas supply is turned off at the gas shut-off valve. 2. Change the gas fuel source. 3.

  • Page 73: Adjusting The Gas Valve

    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.
  • Page 74 Section: Boiler operation 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.
  • Page 75 6.3.3 Adjusting the gas valve 9. Check the results and confirm the correct settings when you return the boiler to high fire, and then to low fire. Note For natural gas, clock the gas meter to confirm full maximum rating plate input. 10.
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  • Page 77: Service And Maintenance

    7.0 Service and maintenance 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...

  • Page 78: Touchscreen Boiler Controller

    Section: Service and maintenance 7.2.1 Touchscreen boiler controller Maintenance Required for Boiler Controller Frequency Check □ Annually 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.
  • Page 79 7.2.2 General boiler maintenance Boiler Maintenance Required Frequency Check Component 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.
  • Page 80 Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation location. For environmental and toxicity reasons, IBC recommends only using non-toxic propylene glycol. □ Water...
  • Page 81 7.2.2 General boiler maintenance Boiler Maintenance Required Frequency Check Component needed. □ Annually Check the water pressure. Pressure should be stable when the boiler is firing and the water temperature is rising. If pressure rises sharply, consider replacement of expansion tank. □...

  • Page 82: Replacing The Fan, Gas Valve, And Burner

    Section: Service and maintenance Boiler Maintenance Required Frequency Check Component test again to try and flush any debris that may be lodged in the valve. If repeated tries fail to stop the leakage, contact a licensed contractor or qualified service personnel to replace the valve.
  • Page 83 7.3 Replacing the fan, gas valve, and burner Combustion fan Venturi mixing device Gas valve coupler and gasket High fire (gas:air) adjustment Gas valve inlet compression coupling/ nut On-Off switch Inlet gas pressure port Manifold pressure port (not used) Low fire (offset pressure) Fan gasket Figure 41 Gas valve and fan components - SL 26-260 G3...

  • Page 84: Replacing The Fan

    Section: Service and maintenance Gas valve outlet connector Location of gas valve O-ring. Bolts Low fire offset pressure adjustment Outlet pressure port (not used) Inlet gas pressure port High fire (gas:air) adjustment Venturi mixing device Combustion fan Aluminum gas block (gas inlet) Figure 42 Gas valve and fan components - SL 40-399 G3 7.3.1 Replacing the fan...
  • Page 85 7.3.1 Replacing the fan Replacing the fan on the SL 26-260 G3 For reference, see Figure 41 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.

  • Page 86: Replacing The Gas Valve

    Section: Service and maintenance 3. Remove the cabinet door, and then remove the top cover/lid. A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to wires or screws may occur.
  • Page 87 7.3.2 Replacing the gas valve 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.
  • Page 88 Section: Service and maintenance Installing the new gas valve 1. Secure the new gas valve to the gas valve connector with the 4 bolts, ensuring that the O-ring is in place. 2. Attach the aluminum gas block to the new gas valve, ensuring that the O-ring is in place.

  • Page 89: Replacing The Burner

    7.3.3 Replacing the burner 7.3.3 Replacing the burner Warning The IBC heat exchanger has a small amount of combustion chamber insulation (refractory), which contains ceramic fibers. When exposed to extremely high temperatures, the ceramic fibers that contain crystalline silica can be converted into cristobalite, classified as a possible human carcinogen.
  • Page 90 Section: Service and maintenance Warning Wear gloves and a suitable protective mask to avoid ingesting particles from the refractory. 4. Disconnect the ignitor and gas valve wires, and the two electrical fan plugs. 5. To access the fan / Venturi mixing device assembly, unscrew the gas valve coupler nut Retain the gasket.
  • Page 91 7.3.3 Replacing the burner Replacing the burner on the SL 40-399 G3 For reference, see Figure 42 To remove the burner: 1. 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.
  • Page 92 Section: Service and maintenance To install the new burner: 1. Install the new burner and gasket, tightening the screws evenly in a criss-cross pattern. Do not over tighten; tighten by hand plus a ½ turn to maintain a good seal and prevent deformation of the burner flange.

  • Page 93: Cleaning The Condensate Trap

    7.4 Cleaning the condensate trap 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.
  • Page 94 Section: Service and maintenance To remove the condensate Loosen the upper union nut, and retainer, undo the two wing slide the condensate trap off the nuts. Note the orientation of the boiler drain outlet. drain hose. Unscrew the union cap at the base Replace the union cap and gasket and of the trap, and empty and flush the hand-tighten to prevent leakage, and fill...
  • Page 95 7.4 Cleaning the condensate trap Slide the condensate trap over the To reinstall the condensate retainer, tilt boiler drain outlet, and then tighten and slide the two retainer tabs under the the upper union nut. chassis of the boiler, and secure with the two wing nuts.
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  • Page 97: Troubleshooting

    8.0 Troubleshooting This section includes various conditions as well as possible solutions. Often, a problem can be identified and solved through basic checks: confirming the electrical power supply, gas flow and resetting the thermostat control. Below are some common troubleshooting issues including fixes. 8.1 Electronic components This section details the method for troubleshooting the non-standard electronic components on the boiler.

  • Page 98: Fan

    Section: Troubleshooting Resist. Resist. Temp. °F/°C Temp. °F/°C Ω – Ohm 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...

  • Page 99: Water Pressure Sensor

    8.1.3 Water pressure sensor Lead Color Function Troubleshooting 35 VDC Positive power terminal Fan will only operate at max speed if disconnected Blue 35 VDC Negative power terminal Fan will only operate at max speed if disconnected Black Signal from controller Fan will only operate at max speed if disconnected White Fan tach.

  • Page 100: Troubleshooting Error Messages

    Section: Troubleshooting 8.1.4.1 Table showing LED operating status Its two status LEDs indicate the operating status as shown in the table below. SIM Status Indicators Description, LED status LED 1 LED 2 State indication Rapid flash Rapid flash Power up or Startup checks and initialization resetting Standby...

  • Page 101: Maximum Ignition Trials Error

    8.2.1 Maximum ignition trials error The bottom line of the touchscreen displays the boiler's error status. The following colors represent the boiler's operating status: Green – Normal Yellow – Warning Red – Alarm The text inside the bar will indicate the specific warning or alarm. If there is more than one alarm present the text will scroll slowly through all current alarm conditions.

  • Page 102: Low Water Cut-Off Error

    Section: Troubleshooting 8.2.3 Low Water Cut-off error Low Water Cutoff Error Issue Diagnosis Error - Low Water Cutoff The Safety and Ignition Refer to the V10 Touchscreen module has detected a low Controller manual for water condition. information on resetting a boiler after a LWCO lockout.

  • Page 103: Ignition Issues

    8.3.1 Ignition issues Miscellaneous errors Issue Diagnosis Error - Max. Inlet/Outlet Sensor Temp. Current outlet Check water flow. Exceeded. > Check water flow Water temperature temperature signal not within acceptable range. exceeds Potential flow or sensor failure. Consult service operating limit. technician.
  • Page 104 Section: Troubleshooting Ignition issues Issue Diagnosis Igniter probe/flame Reconnect probe. sensor disconnected. Defective Control Check ignition output from control Module. module. Boiler will not attempt to ignite. No power to boiler. Check line voltage. Fan and / or pump are off. Display Defective transformer.

  • Page 105: Temperature Issues

    8.3.2 Temperature issues 8.3.2 Temperature issues Temperature issues Issue Diagnosis Low heat Operating temperature too low. Increase temperature target. Increase temperature target. Priority parameters or load Review load configuration parameters. configuration improperly set up. Appliance undersized. Refer to Load Calculation vs. Boiler Output.

  • Page 106: Miscellaneous Issues

    Replace the Power Robbing boiler. thermostat, isolate the thermostat with a relay or install a properly sized resistor (consult the thermostat manufacturer first then IBC for instructions). Error: Water Boiler is in 1-hour For instructions on clearing errors, see the V10 High Limit / safety lockout.

  • Page 107: Cycling Issues

    8.3.4 Cycling issues 8.3.4 Cycling issues Cycling issues Issue Diagnosis Rapid Improper values entered via Check load maximum temps are above target temps, by ½ Cycling keypad. of the selected boiler differential. Ensure boiler differential is OK (16 - 30 °F is generally adequate) Excess condensate in Check venting slopes on horizontal runs.
  • Page 108 Intentionally left empty...

  • Page 109: Appendices

    Appendices Wiring diagrams V-10 Controller electrical diagram Figure 45 Controller electrical diagram...

  • Page 110: Internal Wiring Diagram

    Section: Appendices Internal wiring diagram Figure 46 Internal wiring diagram...

  • Page 111: Sequence Of Operations

    Sequence of operations Sequence of operations Figure 47 Sequence of Operation...

  • Page 112: Exploded Views Of Boiler Parts

    Section: Appendices Exploded views of boiler parts Boiler part diagrams - SL 26-260 G3 Item # Description Part ID Kit # Quantity Top access cover/lid 250-800 P-415 Exhaust duct 250-804 P-393 Intake duct 250-856 P-435 Safety Ignition Module 500-105 P-270B Ignition cable only 200-154 P-358...
  • Page 113 Boiler part diagrams - SL 26-260 G3 Item # Description Part ID Kit # Quantity Fan or 240-113 P-311...
  • Page 114 Section: Appendices Item # Description Part ID Kit # Quantity VG145 Alternative Fan 240-172 P-311 Gas Valve Coupler Gasket 250-742 P-329 Gas Valve Coupler Nut 250-741 P-329 Gas Valve Coupler 250-768 P-329 Gas Valve 180-166 P-329 Gas Line Pipe 190-157 P-419 Sight Glass Frame 250-057...

  • Page 115: Boiler Part Diagrams - Sl 40-399 G3

    Boiler part diagrams - SL 40-399 G3 Item # Description Part ID Kit # Quantity Fuel Mixer LP 180-162 P-300 Mixer O-Ring 150-073 P-389 Fan Gasket 250-322 P-389 Vessel High-Limit Switch 240-030 P-9070 Wiring Harness 200-157 P-431 Boiler part diagrams - SL 40-399 G3...
  • Page 116 Section: Appendices Item Description Part ID Kit # Quantity Exhaust Duct 250-024 P-384 Top Access Cover 250-693 P-420 Intake Duct 250-025 P-9154 Safety Ignition Module 500-105 P-270B Ignition cable only 200-154 P-358 Air pressure switch (blocked vent) 240-138 P-337 Pressure switch Bracket 250-870 P-422 Vessel Temperature High Limit Switch...
  • Page 117 Boiler part diagrams - SL 40-399 G3 Item # Description Part ID Kit # Quantity Heat Exchanger Lid Gasket 255-009 P-365 240-113 P-311 VG145 Alternative Fan 240-172 P-311 Mixer O-Ring 150-073 P-387B Fuel Mixer LP 500-114 P-302B Fuel Mixer NG 500-113 P-303B Gas Valve Coupler Gasket...
  • Page 118 Section: Appendices Item # Description Part ID Kit # Quantity Gas Valve 180-150 P-330 Gas Inlet Block 250-755 P-423 Gas Line 190-158 P-364 Water Pressure Sensor 240-006 P-9057 Return Water Pipe 250-748 P-424 Water Pipe Gasket 255-027 P-387B Return Water Temperature Sensor 240-134 P-363 Condensate Retainer...

  • Page 119: Installation & Commissioning Report

    Installation & Commissioning Report Installation & Commissioning Report Model Number _____________________ Serial Number ________________________________ Date of Installation ________ Address of installation ____________________________________ User contact information __________________________________________________________ Installer Information (Company & Address)_____________________________________________ Phone/Fax/E-mail ________________________________________________________________ □ □ Fuel: Natural Gas Propane Gas Supply Pressure (high fire) ____ Inches w.c. Measured Rate of Input (high fire) _____Btu/hr □...
  • Page 120 This boiler is not used for any space heating. This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. This boiler is equipped with a tankless coil (not applicable to these boilers). US installers should contact IBC for any further information required.
  • Page 121 856-735-5584 Toll Free: 1-844-HEAT-IBC/ 1-844-432-8422 www.ibcboiler.com Information in this document is subject to change without notice. IBC assumes no responsibility for changes made to the manual due to clerical errors, to regulation changes, or to product development. September 23, 2022 120-270E10 ©...

This manual is also suitable for:

Sl 26-260 g3Sl 40-399 g3

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