IBC Technologies SL 80-399 User manual

INSTALLATION AND OPERATING INSTRUCTIONS
www.ibcboiler.com
SL 80-399
MODULATING GAS BOILER
(Natural Gas or Propane)
WARNING: If the information in this manual is not followed exactly, a re or
explosion may result causing property damage, personal injury, or loss of life.
Do not store or use gasoline or other ammable vapours and liquids or other
combustible materials in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
•Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a nearby phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier, call the re department.
Installation and service must be performed by a qualied installer, service
agency or the gas supplier.
This Manual is also available in French - contact IBC or visit our web site www.ibcboiler.com

INSTALLATION AND OPERATION INSTRUCTIONS
SL 80-399 MODULATING GAS BOILER
SAFETY CONSIDERATIONS
SPECIFICATIONS
WARNING
If the information in this
manual is not followed
exactly, a re or explosion
may result causing property
damage, personal injury, or
loss of life.
Installation, start-up and servicing of IBC boilers must be done with due
care and attention, and should only be performed by competent, qualied,
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 prop-
erty damage and injury to occupants which in extreme cases might result
in death.
HAZARDS &
PRECAUTIONS
WARNING
Points out a potentially
hazardous situation which
must be avoided to prevent
serious injury or death.
CAUTION
Points out a potentially
hazardous situation which
must be avoided to prevent
possible moderate injury and/
or property damage
NOTE
Points out installation,
maintenance and operation
details that will result in
enhanced efciency, longevity
and proper operation of your
boiler.
DANGER
Points out an immediately
hazardous situation which
must be avoided in order
to prevent serious injury or
death.
Specication SL 80-399
CSA Input (Natural Gas or Propane) - MBH
CSA Input (Natural Gas or Propane) - kW
CSA Output - MBH
CSA Output - kW
80 - 399
23.4 - 117
77 - 382
22.6 - 112
Combustion Efciency (CSA 4.9 - 2010) 95.7%
Minimum gas supply pressure (Natural Gas or Pro-
pane) - inch w.c. 5
Maximum gas supply pressure (Natural Gas or Pro-
pane) - inch w.c. 14
Power use (115Vac/60Hz) @ full re - Watts 345 (less pumps)
Weight (empty) - lbs/Kg 240 / 110
Pressure vessel water content - USG/Litres 7 / 26
Maximum boiler ow rate - USgpm 45
Minimum boiler ow rate - USgpm 20
Maximum operating water pressure* - psig 30
Minimum water pressure - psig 8
Approved installation altitude - ASL 0 - 8,000’
Ambient temperature - Low/High (°F-°C) 34°F(1°C)/122(50)
Max. relative humidity (non-condensing) 90%
Minimum water temp. 34°F / 1.1°C
Maximum water temp. (electronic hi-limit) 185°F / 85°C
Maximum water temp. (mechanical hi-limit) 200°F / 93.3°C
Max. ΔT - supply/return (electronic fence) 35°F
Maximum equivalent vent length - 4”
Each side (Vent & Air Intake))
(Natural Gas or Propane)
Air intake options: either direct vent or indoor supply
150’
Supplied with the boiler - The IBC boiler is shipped with an accessory parts kit
consisting of the following items:
1 x Wall mounting bracket•
1 x Condensate trap assembly•
1 x 30 psig pressure relief valve•
1 x Outdoor temperature sensor•
6x1/4”x21/2”Lagscrews/watwashers•
* boilers are shipped with 30 psig pressure relief valve

INSTALLATION AND OPERATION INSTRUCTIONS
SL 80-399 MODULATING GAS BOILER
1.0 INSTALLATION....................................................1-1
1.1 GENERAL ...................................................1-1
1.2 CODE REQUIREMENTS ........................................1-2
1.3 LOCATION ...................................................1-2
1.4 EXHAUST VENTING AND AIR INTAKE.............................1-3
1.5 CONDENSATE REMOVAL......................................1-13
1.6 WATER PIPING ..............................................1-16
1.7 GAS PIPING.................................................1-22
1.8 ELECTRICAL CONNECTIONS ..................................1-23
2.0 BOILER SYSTEMS AND OPERATION .................................2-1
2.1 GENERAL ...................................................2-1
2.2 CONTROL ...................................................2-1
2.3 USER INTERFACE ............................................2-1
2.4 ACCESS LEVELS .............................................2-2
2.5 SEQUENCE OF OPERATION ....................................2-4
2.6 OTHER OPERATING FEATURES .................................2-6
2.7 SET UP & LOAD DEFINITION ...................................2-10
3.0 STARTUP AND COMMISSIONING ....................................3-1
3.1 LIGHTING AND SHUTTING DOWN THE BOILER ....................3-1
3.2 PRIOR TO START-UP ..........................................3-2
3.3 COMMISSIONING .............................................3-2
4.0 MAINTENANCE ...................................................4-1
4.1 BOILER MAINTENANCE ........................................4-1
4.2 GEOGRAPHY & COMPONENTS .................................4-4
5.0 TROUBLESHOOTING ..............................................5-1
5.1 PRELIMINARY CHECKS ........................................5-1
5.2 ELECTRONIC COMPONENTS ...................................5-2
5.3 TROUBLESHOOTING GUIDE....................................5-5
6.0 DIAGRAMS.......................................................6-1
6.1 PARTS DIAGRAMS ............................................6-2
6.2 WIRING DIAGRAMS ...........................................6-4
6.3 SEQUENCE OF OPERATIONS ...................................6-7
CONTENTS

INSTALLATION AND OPERATION INSTRUCTIONS
SL 80-399 MODULATING GAS BOILER
The Installer must carefully read this manual to ensure that all installation
details can be adhered to. Special attention is to be paid to clearances and
access, vent travel and termination, gas supply, condensate removal and
combustion air supply.
The Installer should do a pre-installation check the to ensure that the
following precautions can be observed:
• The boiler should be installed in areas where the combustion air source is
not subject to chemical fouling or agricultural vapours. Exposure to corrosive
chemicalfumessuchaschlorinatedand/oruorinatedhydrocarbonscan
reduce the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants,
aerosolpropellants,dry-cleaninguids,de-greasersandpaint-removersall
contain vapours which can form corrosive acid compounds when burned in a
gasame.Airbornechloridessuchasthosereleasedwiththeuseoflaundry
detergents are also to be avoided.
• The boiler should be located where water leakage will not result in damage
to the area. If a location such as this cannot be found, a suitable drain pan
should be installed under the appliance. The boiler is not to be installed above
carpeting.
• At a new construction site, or during renovations, action must be taken to
protect the boiler from drywall dust or other construction related contaminants;
combustion air should be drawn from a CLEAN source (e.g. outdoors) and the
boiler should be isolated from interior dust sources. Do not seal boiler case
openingsdirectlywhenring-allowforaircirculationandventilationinthe
immediate area.
• When the boiler is in operation, the impact of the steam plume normally
experienced at the exhaust terminal of a condensing boiler should be
assessed. Generally, intake and exhaust pipes should terminate at a rooftop
or sterile wall location. Boiler condensate is corrosive. Protective measures
must be taken to prevent corrosion damage to metal roofs or other metal
building components in contact with the condensate. Keep exhaust plumes
well away from all building air intakes including those of neighbouring
properties.
• The exhaust outlet should be placed so as to reach 24” minimum above the
down-turned intake - to avoid exhaust re-ingestion.
• For sidewall venting options: Both the inlet and exhaust terminations should
normally be located on the same plane (side) of the building. The elevation of
both pipes can be raised in “periscope style” after passing through the wall to
gain required clearance above grade and snow level.
• If the indoor combustion air option is used, ensure combustion air openings to
the boiler room remain unblocked and free of obstructions.
• Examine the condensate outlet to ensure proper disposal of condensate will
occur during operation. If condensates are to be discharged into building drain
piping materials that are subject to corrosion, a neutralization package must
be used.
• Ensure that the pressure relief valve will be installed with no valves or other
means of isolation between its inlet and the boiler. Make sure the relief valve
outlet will be piped with unobstructed piping (minimum 3/4” diameter) to a safe
discharge location.
WARNING
Do not use this boiler if any
part has been under water.
Immediately call a qualied
service technician to inspect
the boiler and to replace any
part of the control system and
any gas control that has been
under water.
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

1-1
INSTALLATION
SL 80-399 MODULATING GAS BOILER
INSTALLATION1.0
GENERAL
SL80-399gas-redmodulatingboilersarelowpressure,fullycondensing
units having a variable input range from 80 MBH to 399 MBH (0 to 8,000’). The
boilers are approved as “Category IV” vented appliances using either Direct
Vent (sealed combustion) or indoor combustion air, providing a great degree of
installationexibility.
Figure 1 shows outer case dimensions and piping and electrical holes. Use this
diagramtondasuitablelocationfortheboiler.SeealsoSection 1.3 Location.
DESCRIPTION SIZE
AFlue Outlet 4" O.D. CPVC/PVC Pipe
BCombustion Air Inlet 4" O.D. PVC/ABS/CPVC Pipe
CSafety Relief Valve 3/4" NPT
DLCD Display
EWater Outlet 1 1/2” NPT - M
FWater Inlet 1 1/2” NPT - M
GKnock-outs (6) 1/2”
HGas Inlet 3/4” NPT - M
ICondensate Outlet 3/4” Flexible Hose Barb Fitting
Table 1: Connections
1.1
Figure 1: Dimensions / Connections

INSTALLATION AND OPERATION INSTRUCTIONS
1-2
SL 80-399 MODULATING GAS BOILER
CODE REQUIREMENTS
TheSL80-399boilerwastestedtoandcertiedunderCSA4.9-2010/ANSI
Z21.13-2010.
Installation must conform to local codes, or in the absence of these, with the
latest editions of CAN/CGA B149 and the Canadian Electrical Code Part 1 CSA
C22.2 No. 1.
In the US, installations must conform to the current National Fuel Gas Code
ANSI Z223.1 and the National Electrical Code ANSI/NFPA 70. Where required
by jurisdiction, installation must conform to the Standard for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. If there is any
conict,thenthemorestringentrequirementwillapply.
LOCATION
The SL series boilers are designed and approved for indoor installation (wall or
rackmounting),withsignicantexibilityoflocationprovidedwiththeavailable
venting options. The boiler can be placed in an alcove, basement, closet or utility
room. Surrounding ambient conditions shall be 0°C to 50°C and less than 90%
relative humidity.
Install the boiler in areas where the combustion air source is not subject to
chemical fouling or agricultural vapours. Exposure to corrosive chemical
fumes such as chlorinated and/or uorinated hydrocarbons can reduce
the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants, aerosol
propellants,dry-cleaninguids,de-greasersandpaint-removersallcontain
vapourswhichcanformcorrosiveacidcompoundswhenburnedinagasame.
Airborne chlorides such as those released with the use of laundry detergents
are also to be avoided. For this reason, the indoor air venting option using air
surrounding the boiler should not be used in a laundry room. Similarly, ensure
any direct vent air source is not adjacent to a clothes dryer exhaust terminal.
Avoid agricultural applications where the boiler and/or the intake air source
are affected by ammonia and/or dust.
Locate the boiler where water leakage will not result in damage to the area. If a
location such as this cannot be found, a suitable drain pan should be installed
under the appliance. The boiler is not to be installed above carpeting.
Boiler weight – without water and any effect of system piping and components
– is approx. 240 lbs/110 kg. For support fasteners, use the supplied 6 x 1/4” x 2
1/2" long lag screws. Installer to supply 1/4" bolts if metal mounting systems are
used. Fasteners are to be attached to solid material capable of supporting the
combined weight of the boiler and piping assembly components.
Other factors affecting potential mounting sites:
•Ensure minimum clearance requirements for combustible materials (see
Table 2)aresatised.
•Minimum 24" clearance at the front and 12” above is recommended for
adequate servicing. Check local codes for additional access and service
clearance requirements.
•At a new construction site, or during renovations, action must be taken
to protect the boiler from drywall dust or other construction related
1.2
WARNING
Keep boiler area free
and clear of combustible
materials, gasoline, and
other ammable vapours
and liquids.
WARNING
Combustion air must not be
drawn from areas containing
corrosive air from swimming
pools or spas, including air
directly next to outdoor pools
and spas.
WARNING
The boiler shall not be
exposed to water leaks from
piping or components located
overhead. This includes
condensation dropping from
un-insulated cold water lines
overhead.
1.3

1-3
INSTALLATION
SL 80-399 MODULATING GAS BOILER
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 ring - allow for
air circulation and ventilation in the immediate area.
SURFACE DISTANCE FROM COMBUSTIBLE SURFACES
Front 1"
Rear 0"
Left Side 1"
Right Side 1"
Top 12”
Bottom 12"
Table 2 - Clearance from boiler cabinet
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.
EXHAUST VENTING AND AIR INTAKE
It is important to carefully plan the installation to ensure the appropriate
vent materials, travel and termination decisions are incorporated. Specic
attention is warranted to manage the impact of the steam plume normally
experienced at the exhaust terminal of a condensing boiler. Generally,
intake and exhaust pipes should terminate at a rooftop or sterile wall
location, to maximize customer satisfaction. Keep exhaust plumes
well away from all building air intakes including those of neighbouring
properties.
WARNING
DO NOT MOUNT THIS
BOILER TO HOLLOW
WALL STRUCTURES - The
combined weight of the
boiler, its water contents
and associated piping
components can exceed 300
pounds. Fasteners must be
rated for this strain, and must
be rmly anchored into solid
material that will support this
weight.
Installers are to take all
necessary precautions
to avoid injury during the
installation of this boiler.
1.4
DANGER
Do not common vent SL
series modulating boilers
with any other existing or new
appliance.
Figure 2: Wall mounting of boiler

INSTALLATION AND OPERATION INSTRUCTIONS
1-4
SL 80-399 MODULATING GAS BOILER
All venting must be installed in accordance with the requirements of the
jurisdiction having authority: in Canada, Part 8, Venting Systems of the B149.1-
10 Code and any other local building codes are to be followed. In the USA Part 7,
Venting of Equipment of the National Fuel Gas Code, ANSI 223.1, latest edition,
prevails. Where there is a discrepancy between the installation instructions
below, and the code requirements, the more stringent shall apply.
IMPORTANT
When an existing boiler is removed from a common venting system, the common
venting system is likely to be too large for proper venting of the appliances
remaining connected to it.
When resizing any portion of the common venting system, the common venting
system should be resized to approach the minimum size as determined using the
appropriate tables in the National Fuel Gas Code, ANSI Z223.1 - latest edition. In
Canada, use the B149.1-10.Installation Code.
At the time of removal of an existing boiler the following steps shall be followed
with each appliance remaining connected to the common venting system placed
in operation, while the other appliances remaining connected to the common
venting system are not in operation.
•Seal any unused opening in the common venting system.
•Visually inspect the venting system for proper size and horizontal pitch and
determine there is no blockage or restriction, leakage, corrosion and other
deciencieswhichcouldcauseanunsafecondition.
•Insofar as is practical, close all building doors and windows and all doors
between the space in which the appliances remaining connected to the
common venting system are located and other spaces of the building. Turn
on clothes dryers and any appliance not connected to the common venting
system. Turn on any exhaust fans, such as range hoods and bathroom
exhausts, so they will operate at maximum speed. Do not operate a summer
exhaustfan.Closereplacedampers.
WARNING
Venting, condensate
drainage, and combustion
air systems for all IBC
boilers must be installed in
compliance with all applicable
codes and the instructions of
their respective Installation
Manuals.
Inspect nished vent and air
piping thoroughly to ensure
all are airtight and comply
with the instructions provided
and with all requirements of
applicable codes.
Failure to comply will result
in severe personal injury or
death.
Figure 3: Flue gas venting

1-5
INSTALLATION
SL 80-399 MODULATING GAS BOILER
•Place in operation the appliance being inspected. Follow the lighting
instructions. Adjust thermostat so appliance will operate continuously.
•After it has been determined that each appliance remaining connected to the
common venting system properly vents when tested as outlined above, return
doors,windows,exhaustfans,replacedampersandanyothergas-burning
appliance to their previous conditions of use.
•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.
1.4.1 Applications
All SL series boilers are approved with alternative venting options: either 2-pipe
DirectVentorsinglepipe/IndoorAirventingcanbeusedofferingexibilityto
meetthespecicrequirementsoftheinstallation.WiththeDirectVentcase,
combustion air is piped directly to the boiler’s air intake from outdoors (see
Section 1.4.7 for air intake piping requirements). Using the indoor air alternative,
air for combustion is drawn from the indoor air surrounding the boiler.
Provided the maximum overall vent length limit is not exceeded, the installer may
choose to vent the boiler through the wall, directly through the roof or upward
using an existing - but otherwise unused - chimney as a vent raceway.
1.4.2 Exhaust Vent Material
EXHAUST VENT MATERIAL – CANADA
OnlyCPVCandPVC(withrestricteduetemperature)ventcomponentsystems
approved under ULC-S636 Standard for Type BH Gas Venting Systems, or
stainless steel Type BH venting systems* are to be used. Venting manufacturers,
such as IPEX Inc with their System 636™ line, establish exhaust temperature
limitations for their materials; it is the responsibility of the installer to ensure
that such limitations are taken into account in the selection of PVC vs. CPVC
vs.stainlesssteelsystems.Inthestandardconguration,SLseriesboilerscan
supply water temperatures up to 180°F, leaving stack temperatures above the
65°C (149°F) limit for System 636TM PVC”; use approved CPVC or stainless
steel systems.
For long vent runs with higher initial exhaust temperature, some jurisdictions may
allow the use of mixed materials for economy: CPVC for the initial run followed
by PVC to the termination (It is the responsibility of the Installer to conrm that
local codes will allow this option). Ensure appropriate transition glue is used. The
installerisresponsibletoensurethatsufcienttemperaturelossisallowedforin
the CPVC section to fall below the limit for PVC, taking into account the highest
possible ambient temperature in the area of vent travel (e.g. boiler room, attic
and/or chase).
EXHAUST VENT MATERIAL – USA
IBCstronglyrecommendsthatonlyCPVCandPVC(withrestrictedue
temperature) vent component systems approved under ULC-S636 Standard for
Type BH Gas Venting Systems, or stainless steel Type BH venting systems* are
to be used.
Many local jurisdictions in the USA however, still allow the use of PVC (Sch. 40
ASTMD1785orD2665andttings)orCPVC(Sch.40/ASTMF441withSch.80
ttings);orCSAapproved4"stainlessventsystems.

INSTALLATION AND OPERATION INSTRUCTIONS
1-6
SL 80-399 MODULATING GAS BOILER
Do not use ABS or any cellular core pipe for exhaust venting.
The boiler offers 4" venting connections. Fittings are to be used to adapt to the
appropriate diameter – see Vent Travel below. Exhaust venting is to be inserted
directlyintothe4"femalestainlesssteelttingonthetop,leftsideoftheboiler
(see Figure 2).
Combustion air piping - if used - is inserted directly into the 4” female stainless
steelttingonthetop,rightsideoftheboiler(see Section 1.4.7).
Venting shall be supported in accordance with applicable code.
*Manufacturers of stainless steel Type BH venting systems must submit
their approved transition tting to IBC for evaluation and written approval.
1.4.3 Vent Travel
4" CPVC or PVC ULC-S636 approved piping is the standard venting option; with
this, the SL 80-399 boiler can be sited up to 150 equivalent feet from the vent
termination.Theactualventtravelallowanceisreducedforttingsinaccordance
with Table 3. – e.g. for a SL 80-399 using 6 x 90º CPVC vent elbows, the
maximum lineal measure of pipe allowed is 102 feet (150' – (6 x 8' = 48) = 102').
EXHAUST PIPE SIZE MAXIMUM EQUIVALENT LENGTH
4" 150' (each side)
90° vent elbow allow 8’ equivalent
90° long sweep elbow allow 5’ equivalent
45° elbow allow 3' equivalent
Table 3: Maximum exhaust venting length
NOTE: Unused intake travel cannot be added to the exhaust. Unequal
intake and exhaust piping is allowed - see Section 1.4.8.
Exhaust venting must slope down towards the boiler with a pitch of at least
1/4" per foot so condensate runs back towards the trap. Support should be
provided for intake and vent piping, particularly so for horizontal runs (follow
local code). Insulate exhaust piping where it passes through unheated spaces or
underground, with appropriate pipe insulation to prevent freezing of condensates.
1.4.4 Venting Passage Through Ceiling and Floor
• Conrmmaterialmeetslocalcodesincludingrestoppingrequirements.
•Pipe clearances - no IBC requirements; follow local codes.
•All piping must be liquid and pressure tight.
Ensure all venting components are clean of burrs/debris prior to assembly.
Care is to be taken to avoid ingestion into the fan of plastic debris left in the
combustion air piping.
All joints must be secured using appropriate solvent cement to bond the
respective pipe material (Canada: PVC, CPVC or transition 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.

1-7
INSTALLATION
SL 80-399 MODULATING GAS BOILER
Allventconnectionsmustbeliquidandpressuretight.Priortoringtheboiler,
and before any of the venting run is concealed by the building construction, the
installer must test the exhaust joints under fan pressure with the vent blocked,
usingasoap/watersolution.Installermustllcondensatetrappriortotest.
Remove the fan control harness plug as illustrated in the photos, and then block
the vent outlet so that the vent run will be under maximum fan pressure. Paint all
joints with an approved leak test solution just as you would joints in a gas line,
and make sure there are no leaks. Good practice would suggest that the installer
attach a tag on the vent line near the condensate drain tee indicating the type of
test, the date and the installer’s name.
1.4.5 Rooftop Vent Termination
Rooftop vents must terminate as follows:
• The exhaust pipe can terminate in an open vertical orientation without concern
aboutraininltration;rainwilldrainawaythroughthecondensatetrap.
•If used, the intake air pipe is not typically drained, so it must be terminated
with a down-turned elbow (see Figure 4). The intake pipe does not need to
penetrate the roof at the same elevation as the exhaust (as shown); lower
down roof is OK.
• Optionalbirdscreenmaybeplacedinaterminationtting.Leaveunglued,
and hold in place with a short nipple. This permits easy access for cleaning.
•For roof top venting of multiple boiler sets, group all intake terminals together
for a common penetration through a custom cap. Alternatively, place in the
closestproximityachievableusingcommonlyavailablepipeashing.Similarly
group the exhaust pipes and place the 2 separate groups of pipes at least 3'
apart (the closest intake and exhaust pipes shall be 36" - or more - apart).
Use the same 24" (minimum) vertical separation for all termination options.
•DO NOT exhaust vent into a common venting system.
Fan control harness plug
Unplugging fan control harness plug
will drive the fan into manual high
speed operation for vent leak test
Figure 4: Rooftop vent terminal congurations
WARNING
Condensate can cause
corrosion of metal roong
components and other
roong materials. Check
with the builder or roong
contractor to ensure that
materials will be resistant to
acidic condensate. pH levels
can be as low as 3.0

INSTALLATION AND OPERATION INSTRUCTIONS
1-8
SL 80-399 MODULATING GAS BOILER
1.4.6 Sidewall Vent Termination
Sidewall direct vent applications shall be vented as follows:
• Both the inlet and exhaust terminations should normally be located on the
same plane (side) of the building.
•The exhaust outlet is to be placed so as to reach 24" minimum above the
down-turned intake - to avoid exhaust re-ingestion.
•The elevation of both pipes can be raised in “periscope style” after passing
throughthewall,thenconguredasinFigure 5, to gain required clearance.
•Use a 45° elbow on the exhaust termination to launch the plume up and off
the sidewall, for protection of wall.
•Bird screen of 1/4" stainless steel or plastic mesh (IPEX System 636 drain
grate) is useful to guard against foreign objects.
WARNING
It is extremely important to
maintain at least the minimum
separation of exhaust vent
termination from boiler intake
air as illustrated in gures
5, and 9. 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
shall NOT be used. Improper
installation will void the
warranty.
Figure 5: Sidewall vent termination - direct vent applications
Figure 6: Sidewall vent termination - indoor combustion air applications

1-9
INSTALLATION
SL 80-399 MODULATING GAS BOILER
Sidewall indoor combustion air applications shall be vented as follows:
•The exhaust outlet is to be placed 18” minimum (12” in USA) above the grade
or anticipated snow level.
• Theventshallbeterminatedwithateettingasillustrated-See Figure 6.
•Bird screen, as above, should be installed in both open ends of the tee.
For side venting of multiple boiler sets, group all intake terminals together with 6"
to 12" lateral spacing, and similarly group the exhaust pipes. Place the 2 groups
on the same plane of the building (e.g. north facing wall). Place the 2 groups of
pipes at least 3' apart (the closest intake and exhaust pipes shall be 36" - or more
– apart. Use same 24" (minimum) vertical separation.
Vent terminal clearance minimums are as follows:
•Clearance above grade, veranda, porch, deck or balcony – 12" (0.3m), but
check local code also (anticipated snow levels may supersede).
•Clearance to openable window or door – 36" (0.91m) (USA – 12”)
• Verticalclearancetoventilatedsoftlocatedabovetheterminal-48”(1.2m)
See Caution note in this section.
•Clearance to each side of centre line extended above meter/regulator
assembly: - 3' (0.91m) within a height of 15' (4.6m) above the meter/regulator.
•Clearance to service regulator vent outlet: - 3' (0.91m)
•Clearance to non-mechanical air supply inlet to building or the combustion air
intake to any other appliance: - 3' (0.91m) (USA – 12" (0.3m))
•Clearance to a mechanical air supply inlet: - 6’ (1.82m) (USA - 3’ (0.91m)
above if within 10’ (3.1m) horizontally)
•Clearance above paved sidewalk or paved driveway located on public
property: - 7' (2.2m) Note: Cannot terminate directly above a paved sidewalk
or paved driveway that is located between two single family dwellings and
serves both dwellings
• Clearance under veranda, porch, deck or balcony: - 12" (0.3m) IBC strongly
recommends a minimum of 48” with the SL 80-399 to avoid damage to
the structure. Note: Prohibited unless fully open on a minimum of two sides
below the oor.
Figure 9: Sidewall vent termination - multiple vent piping conguration
Figure 7: IBC recommended
minimum vent terminal clearance
under ventilated soft
Figure 8: Prohibited installation

INSTALLATION AND OPERATION INSTRUCTIONS
1-10
SL 80-399 MODULATING GAS BOILER
• Ventsmustbeinstalledsuchthatuegasdoesnotdischargetowards
neighbor’s windows, or where personal injury or property damage can occur.
•It is important to ensure proper condensate management from vent
terminations. Condensate shall not be discharged in a manner that will cause
damagetoexternalbuildingnishesorcomponents,orinltratebuilding
envelopes, including adjacent structures.
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.
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, and ingress of
moisture into building
structures is to be avoided.
Serious structural damage
may occur if adequate
precautions and clearances
are not allowed for.
These precautions are to be
observed for neighbouring
structures as well as for the
structure the boiler(s) are
installed in.
Figure 10: Vent terminal clearances
Figure 11: Vent terminal clearances

1-11
INSTALLATION
SL 80-399 MODULATING GAS BOILER
1.4.7 “Direct Vent” Combustion Air Intake Piping
There are two basic methods of supplying combustion air to an IBC boiler.
The direct vent option uses piping from the outside to supply combustion air
directly to the boiler’s combustion air connection.
INTAKE PIPE SIZE MAXIMUM EQUIVALENT LENGTH
4" 150' (each side)
90° vent elbow allow 8' equivalent
90° long sweep elbow allow 5’ equivalent
45° elbow allow 3’ equivalent
Air Intake Filter Contact Factory
Table 4: Maximum intake piping length
For the inlet air – 4” Schedule 40 PVC, CPVC or ABS piping of any type is
permitted.
NOTE: It is not permitted to add to the exhaust length by transfer of unused
intake allowance.
Combustion air piping - if used - is inserted directly into the 4” female stainless
steelttingonthetop,rightsideoftheboilerandrunhorizontallyorverticallyto
the outdoors. Screen material can be placed at the inlet as appropriate for the
environment (e.g. insects, dust).
Care must be taken to ensure adequate separation is maintained between the
airintakeinletandtheventterminal.Refertotheventterminalconguration
drawings in the Vent Termination section above.
Support should be provided for intake piping, particularly so for horizontal runs
(follow local code).
WARNING
In addition to preventing
ingestion of chemical
contaminants, care must
be taken to ensure air
intake terminals are not
installed in locations where
contamination might occur
due to ingestion of particulate
foreign material (dust, dirt
and debris).
Figure 12: Direct vent combustion air intake
NOTE
Care must be taken when
installing air intake piping to
ensure that a “trap” is not
formed in the piping so as to
allow a build-up of water, and
blockage of intake air.
Such blockage will result in a
boiler safety shut-down.
WARNING
Intake air openings must be
congured such that rain
or other forms of moisture
cannot enter the air intake
piping system. Otherwise
serious damage to the boiler
may result.

INSTALLATION AND OPERATION INSTRUCTIONS
1-12
SL 80-399 MODULATING GAS BOILER
1.4.8 “Indoor Air” Combustion Air Intake
An “Indoor Combustion Air installation”, as described herein, is one in which air
for combustion is taken from the ambient air around the boiler.
To support combustion, an ample air supply is required. This may require
direct openings in the boiler room to the outside. If the boiler is not in a room
adjacent to an outside wall, air may be ducted from outside wall openings.
Provisions for combustion and ventilation air must be made as follows:
• in the USA, in accordance with Section 5.3 Air for Combustion and
Ventilation of the National Fuel Gas Code, ANSI Z223.1 (latest edition), or
applicable provisions of the local building codes
• in Canada, in compliance with B149.
1.4.9 Combustion Air Filtration
If combustion air contamination from ingested particulate matter may be a
concerninanyinstallation,anoptionalairintakeltermaybeinstalled.
IMPORTANT NOTE: At the time of this printing, a combustion air lter for the
SL 80-399 model was not yet available. Contact the Factory if your application
requires air ltration. Under no circumstances should a third-party air lter be
installed on an IBC boiler without proper evaluation and written approval of the
IBC Engineering Department.
1.4.10 Closet Installations
Forinstallationsinaconned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 boiler shall not be exposed to ambient conditions above 122°F (50°C) or
below 32°F (0°C).
Figure 15: Indoor combustion air intake
WARNING
When using Indoor
Air options, adequate
combustion air must be
supplied to the boiler room
according to the requirements
of all applicable codes.
Figure 13: Reserved
Figure 14: Reserved

1-13
INSTALLATION
SL 80-399 MODULATING GAS BOILER
NOTE
Combustion fan
blockages can occur when
environmental particulate and
foreign matter contaminants
(leaves, dust, dandelion &
cottonwood uff, etc) are
drawn into the air intake. In
areas where this problem is
suspected to be an issue,
intake air ltration should be
considered. Contact Factory.
Filters should be checked
and cleaned or replaced on
a regular schedule based on
the severity of the problem.
WARNING
When using Indoor
Air options, adequate
combustion air must be
supplied to the boiler room
according to the requirements
of all applicable codes.
CONDENSATE REMOVAL
IBC’sspeciedventcongurationpromotesthesafedrainageofmoisture
fromtheboilerandexhaustventingwithoutowingliquidsbackthroughthe
heat exchanger (as done by some other condensing boilers). Reliable system
operation requires (1) proper design and installation of exhaust venting to
allow condensate to run back to the drain/trap; (2) acid neutralization as
appropriate. To achieve these:
1. Allow for a 1/4” per foot slope back to the vent connection, with
appropriate hangers to maintain that gradient.
2. Ensurethesuppliedtrapiscorrectlyinstalledandlledwithwater.
3. When required, add (and maintain in good condition) a neutralization
tank.
1.5.1 Condensate Trap
A condensate trap must be installed on the drain connection at the base of
the boiler as shown in Figure 16.
1.5
Figure 16: Condensate trap installation

INSTALLATION AND OPERATION INSTRUCTIONS
1-14
SL 80-399 MODULATING GAS BOILER
1.5.2 Condensate Trap Assembly Installation
1. Undo Drain Spout Compression Nut (D),remove Drain Spout (C) from
Condensate Drain Outlet (E) of Trap Body (A).
2. Loosen Upper Compression Nut (B) and place the Nut and Trap Body (A) over
Boiler Condensate Outlet (G) far enough to swing Trap Hook (F) down and
past the Drain Spout connection threads. Pull the trap slightly downward to
seat it against the hook.
3. UnscrewTrapBodyfromtraptoppiece,andllwithwater.ScrewTrapBody
back to top piece.
4. Hand Tighten Upper Compression Nut and secure Drain Hose to Drain Spout
barb connection. If the nut is removed, ensure the cone seal and backup
o-ring remain in the factory supplied position. Gently pull on all assembled
components to make sure they are secured in position.
1.5.3 Condensate Trap cleaning procedure
1. Turn off the power to the boiler and allow it to cool down.
2. Unscrew trap body (A) from trap top piece.
3. Unscrewtrapbottompiecefrommaintrapbodyandcleanandushdebris
from these components. In cases of severe fouling, Drain Spout may have
to be removed, and trap top piece removed from boiler condensate outlet for
further cleaning of those components.
4. Re-assembletrapcomponents,re-lltrap,andreplaceonboilerasdescribed
in the Condensate Trap Assembly Installation instructions above.
1.5.4 Further installation details
•Condensate drain must be piped to within 1” of a drain or be connected to a
condensate pump.
•Drainage line must slope down to the drain at a pitch of 1/4” per foot so
condensate runs towards the drain.
•Condensate traps should be checked every 2 months, and cleaned and
relledasnecessary.
WARNING
Fill trap with water before
boiler is rst red to prevent
exhaust fumes from entering
room. Never operate the
boiler unless the trap is lled
with water.
Failure to comply will result
in severe personal injury or
death.
Factory supplied condensate trap
with drain hose
Figure 17: Condensate trap
disassembly for cleaning

1-15
INSTALLATION
SL 80-399 MODULATING GAS BOILER
WARNING
If condensates are to be
discharged into building
drain piping materials that
are subject to corrosion, a
neutralization package must
be used.
CAUTION
When a condensate
neutralization package
is installed, the pH of the
condensate discharge must
be measured on a regular
schedule to ensure the
neutralizing agent is active
and effective.
Figure 19: Condensate neutralization tank
TO
DRAIN
FACTORY SUPPLIED
CONDENSATE TRAP
CONDENSATE DRAINAGE
Free flow of condensate from venting
system and pressure vessel must be
maintained at all times. Trap and
condensate drain piping must be
accessible to allow regular inspection
and cleaning.
IBC
SL 80-399
BOILER
IBC
CONDENSATE HOSE AND DRAIN
PIPING TO SLOPE TOWARD
DRAIN AND BE SECURED TO
PREVENT ACCIDENTAL DISASSEMBLY.
ATTACH HOSE
TO DRAINAGE PIPING
DRAIN MATERIALS SUBJECT TO
CORROSION MUST BE PROTECTED
BY ACID NEUTRALIZATION
WARNING: “Risk of damage to appliance”
All condensate discharge lines must be at
a lower elevation than the condensate
water line of the appliance.
CONDENSATE WATER LINE
FLUE GAS EXHAUST
CONDENSATE AND RAIN
WATER FLOWS BACK FROM
VENTING SYSTEM
TO DRAIN
1 1/2” FIP
OUTLET
1 1/2” FIP
INLET
MAINTENANCE DETAILS FOR
NT20 CONDENSATE
NEUTRALIZATION TANK
Refer to manufacturer’s maintenance
instructions for other makes and models
of condensate neutralization tanks
WARNING: “Risk of damage to appliance” Neutralization
tank inlet and discharge must be at a lower elevation than
the condensate water line of the appliance.
FLUE GAS EXHAUST
CONDENSATE AND RAIN
WATER FLOWS BACK FROM
VENTING SYSTEM
IBC
SL 80-399
BOILER
IBC
NOTE: 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 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
Figure 18: Condensate trap drainage

INSTALLATION AND OPERATION INSTRUCTIONS
1-16
SL 80-399 MODULATING GAS BOILER
WATER PIPING
1.6.1 General Piping Issues
The SL modulating series boilers are designed for use within a closed loop,
forced circulation, low pressure system. A 30 psi pressure relief valve (3/4" NPT)
issuppliedforeldinstallationinthereliefvalvettingontopoftheboiler.Relief
valve discharge piping must terminate between 6" (15cm) and 12” (30cm) above
theoororperlocalCode.
Systempipingisconnectedtotheboilerusingthe11/2"NPT-Mthreadedttings.
Unions and gate or ball valves at the boilers supply and return water connections
are recommended to simplify servicing. Un-insulated hot water pipes must be
installed with a minimum 1" clearance from combustible materials.
Fluidllismostoftenaccomplishedbyusingaboilerregulator&llvalveset
at12psigormore,withappropriatebackowpreventiondeviceasrequired
by local code. This is acceptable in areas where municipal water or well water
hasbeentreatedandlteredtoremoveexcessivemineralsandsediment,and
water chemistry is known to be suitable for closed loop hydronic systems. In
areas where water quality is in question, or when chemical treatment or glycol is
required, other options should be considered. Follow applicable Codes and good
piping practice.
There are a number of boiler feed and pressurization devices on the market
todaythatmaybeabetterchoicethanarawwaterllfromthemains.When
regular maintenance requires relief valve blow-off, the discharge may be directed
backintothepressurizationunitforrecyclingofboileruidandchemicals
back into the system. In buildings that may be unoccupied for long periods of
time,pressurizationunitsareusefultopreventooddamageshouldleakage
occurfromanycomponentinthesystem.Anadditionalbenetisthatbackow
prevention devices are not required when using these devices.
Figure 20: Boiler trim options - Single boiler
NOTE
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
uid of known quality can be
brought to the site.
WARNING
During operation, the relief
valve may discharge large
amounts of steam and/or hot
water. Therefore, to reduce
the potential for bodily
injury and property damage,
a discharge line MUST be
installed that it:
is connected from the valve outlet1.
with no intervening valve and
directed downward to a safe point of
discharge.
allows complete drainage of both the2.
valve and the discharge line.
is independently supported and3.
securely anchored so as to avoid
applied stress on the valve.
is as short and straight as possible4.
terminates freely to atmosphere5.
where any discharge will be clearly
visible and is at no risk of freezing.
terminates with a plain end which is6.
not threaded.
is constructed of a material suitable7.
for exposure to temperatures of
375°F or greater.
is, over its entire length, of a pipe size8.
equal to or greater than that of the
valve outlet.
DO NOT CAP, PLUG OR OTHERWISE
OBSTRUCT THE DISCHARGE PIPE
OUTLET!
1.6