IBC Sl Series Installation & Operating Manual
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IBC Sl Series Installation & Operating Manual

Residential 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.
Residential Condensing Boiler
SL 10-85 G3
SL 14-115 G3
SL 20-160 G3
SL 30-199 G3
WARNING

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  • Page 1 INSTALLATION & OPERATING MANUAL Residential Condensing Boiler 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.
  • 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 10-85 G3, SL 14-115 G3 SL 20-160 G3 SL 30-199 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...
  • Page 6 Section: Contents 3.11 Water Piping 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...

  • Page 7: Safety Information

    7.3.3 Replacing the burner on the SL 85, 115, 160 and 199 G3 boilers 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...
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  • Page 9: Specifications

    Specifications Boiler Specification SL 10-85 G3 SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 CSA Input (Natural Gas or 10.6 - 85 14 - 115 20 - 160 32 - 199 Propane) - MBH 3.1 - 24.9 4.1 - 33.7 5.86 - 46.9 9.37 - 58.3 CSA Input (Natural Gas or...

  • Page 10: Cabinet Dimensions

    Section: Specifications Boiler Specification SL 10-85 G3 SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 Limit Max. ΔT - supply/return (electronic 40°F 40°F 40°F 40°F fence) Maximum equivalent vent length , 100’ (2") 100’ (2") 35’ (2") Not applicable each side (vent & air intake) (Natural gas or propane) 240’...

  • Page 11: 20-160 G3

    SL 20-160 G3 Figure 2 : Top view - SL 10-85 G3, SL 14-115 G3 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...

  • Page 12: 30-199 G3

    Section: Specifications Figure 5 : Top view - 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...

  • Page 13: Connection Specifications

    Connection specifications Figure 8 : Top view - SL 30-199 G3 Figure 9 : Bottom view - SL 30-199 G3 Connection specifications The following table displays the required connection specifications. SL 10-85 G3, SL 20-160 G3 SL 30-199 G3 SL 14-115 G3 Flue Outlet 3" Schedule 40 or 3" PPs (80mm) Combustion Air 3"...
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  • Page 15: Introduction

    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...

  • Page 16: Warranty

    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).

  • 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 □ Ensure that the pressure relief valve is installed with no valves or other means of isolation 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.

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

  • Page 23: Installation Clearances

    3.6 Installation clearances For PPs, no transition adapter is required. The vent connection has a second gasket approximately 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.

  • 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 Options

    PVC venting material is not exceeded. 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 Exhaust vent material – U.S.A 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.
  • Page 27 3.7.4 Direct vent Air intake 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.
  • 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 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.

  • Page 30: Rooftop Vent Termination

    Section: Installation Vent Lengths Maximum Equivalent Length Intake/Exhaust SL 10-85 G3 SL 14-115 G3 SL 20-160 G3 SL 30-199 G3 (IBC part P-257) 3-inch PPs Limited to 45 ft Limited to 45 ft Limited to 45 ft Limited to 30 ft flexible pipe maximum maximum...
  • Page 31 3.7.5 Rooftop vent termination a. Rooftop vents must terminate as follows: 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.
  • Page 32 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.

  • Page 33: 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 Installations Description US Installations Clearance above grade, 12 in (30 cm) 12 in (30 cm) veranda, porch, deck, or balcony Clearance to window or 6 in (15 cm) for appliances 6 in (15 cm) for appliances door that may be opened ≤...
  • Page 35 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.
  • Page 36 Section: Installation Place the exhaust vent termination, so that it reaches 12" minimum above the down- 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...
  • Page 37 3.7.6 Sidewall vent termination Figure 22 Sidewall vent termination configuration option 1 Figure 23 Sidewall vent termination configuration option 2...
  • Page 38 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.
  • Page 39 3.7.6 Sidewall vent termination Figure 26 Pipes extend completely through the wall (Vertical orientation shown) 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.

  • Page 40: Combustion Air Filtration System

    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...

  • Page 41: Installing The Condensate Trap

    3.9 Installing the condensate trap 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 Remove the boiler door. To remove the condensate retainer, undo the two wing nuts, and put aside. Fill the condensate trap with water, and Loosen the upper union nut, and ensure that the bottom union cap is slide the trap over the boiler drain hand-tightened to prevent leakage.
  • Page 43 3.9 Installing the condensate trap To reinstall the condensate retainer, tilt The drain hose should run to a suitable the retainer to enable you to slide the drain or condensate neutralizer. two tabs under the chassis of the boiler, and secure with the wing nuts. Figure 31 Condensate trap drainage Flue gas exhaust: Condensate and rain water flow back from venting system...

  • Page 44: Installing A Condensate Neutralizer

    Section: Installation intake piping. Condensate water line. 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 .
  • Page 45 3.10 Installing a condensate neutralizer Figure 32 Condensate neutralization tank 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...

  • Page 46: Water Piping

    Section: Installation 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 47 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.

  • Page 48: 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 49 3.11.2 System piping No isolation valve permitted between boiler and relief valve 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.
  • Page 50 Section: Installation Today, there are a number of boiler feed and pressurization devices on the market that may 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.
  • Page 51 3.11.2 System piping These 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. Relief valve discharge piping must terminate between 6 inches (15 cm) and 12 inches (30 cm) above the floor or per local code.
  • Page 52 Section: Installation 3.11.2.1 Primary-Secondary 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.
  • 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 Notes 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 Optional Figure 38 Typical one-temperature space heating piping concept Optional Thermostatic mixing valve Figure 39 Typical two-temperature space heating piping concept.
  • Page 56 Section: Installation Optional Domestic water, hot and cold: A thermostatic tempering valve may be required by 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...
  • Page 57 3.11.2 System piping Figure 42 Basic primary-secondary piping with hydraulic separator - piping concept 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...
  • Page 58 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.
  • Page 59 3.11.2 System piping Each boiler will control its own pump, turning it off or on when heat is required. This approach saves electricity by reducing the pumping power required as load conditions are reduced. One boiler control is set up as a "Master" boiler, and up to 23 additional boilers can be added to the system as "Subordinate"...

  • Page 60: Gas Piping

    Section: Installation Secondary loop sensor to Master boiler 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.

  • Page 61: Gas Pressure

    3.12.1 Gas pressure 3.12.1 Gas pressure 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.

  • Page 62: Electrical Connections

    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 63: 120Vac Line-Voltage Hook-Up

    3.13.2 120VAC line-voltage hook-up 3.13.2 120VAC line-voltage hook-up 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.

  • Page 64: Other Wiring

    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.

  • Page 65: Thermostat / Sensor Wiring

    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...
  • Page 66 Section: Installation Figure 49 Electric wiring connections...

  • Page 67: 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 68: 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 > 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.

  • Page 69: 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 70 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 71: 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 65. To understand the boiler start-up process, see Sequence of Operation on page 103.

  • Page 72: 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 73: 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 74: 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 75 6.3.3 Adjusting the gas valve Combustion fan Fan plug High fire (gas:air ratio) adjustment 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.
  • Page 76 Section: Boiler operation 3. With a small (1/8" or 3 mm) flat screwdriver, open the inlet gas supply pressure test port 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"...
  • Page 77 6.3.3 Adjusting the gas valve 14. Turn on the gas supply shut off valve, and soap test for leaks. CO max Fuel High fire Low fire Range % Target % Range % Target % Natural Gas <150 9.0 - 10.0 8.2 - 9.2 Propane <...
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  • Page 79: Service And Maintenance

    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.

  • Page 80: 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 81 7.2.2 General boiler maintenance Boiler Maintenance Required Frequency Check Component b. Evaluate the magnitude of clearing required, and establish a reasonable burner inspection schedule. Some boiler / locations may call for annual service, others showing clean burners will only need attention every 2 – 5 years. c.
  • Page 82 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 83 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 84: 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 85 7.3 Replacing the fan, gas valve, and burner Figure 51 Gas valve and fan components Ignition cable, ground wire, ignitor Fan coupler and gasket Screws/nuts securing fan to fan coupler (location of fan gasket) Upper nut, orifice and O-ring Lower nut (behind bracket) and gasket Gas valve electrical cable and screw Gas valve support bracket...

  • Page 86: Replacing The Fan On The Sl 85, 115, 160 And 199 G3 Boilers

    Section: Service and maintenance 7.3.1 Replacing the fan on the SL 85, 115, 160 and 199 G3 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.

  • Page 87: Replacing The Gas Valve On The Sl 85, 115, 160 And 199 G3 Boilers

    7.3.2 Replacing the gas valve on the SL 85, 115, 160 and 199 G3 boilers 7.3.2 Replacing the gas valve on the SL 85, 115, 160 and 199 G3 boilers For reference, see Figure 51 Removing the gas valve 1. Turn off the electric power and gas supply to the boiler. 2.

  • Page 88: Replacing The Burner On The Sl 85, 115, 160 And 199 G3 Boilers

    7.3.3 Replacing the burner on the SL 85, 115, 160 and 199 G3 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.

  • Page 89: Cleaning The Condensate Trap

    7.4 Cleaning the condensate trap 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, screws or refractory may occur.
  • Page 90 Section: Service and maintenance Warning Before replacing the condensate trap, turn off the power to the boiler and allow to cool down. To remove the trap pan, undo the Loosen the upper union nut, two wing nuts. Note the orientation of and slide the condensate trap the hose.
  • Page 91 7.4 Cleaning the condensate trap Fill the condensate trap to the top with Loosen the upper union, and slide water and replace the union cap and the trap over the boiler drain outlet, gasket. and then tighten the upper union nut. To reinstall the trap pan, tilt and slide the Ensure that the bottom union two tabs under the chassis of the boiler,...
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  • Page 93: 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 94: 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 95: Safety And Ignition Module (Sim+)

    8.1.4 Safety and Ignition Module (SIM+) Check the operation of the sensor by isolating the boiler from its system piping, and close the system 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.

  • Page 96: Troubleshooting Error Messages

    Section: Troubleshooting SIM+ Status Indicators LED 1 LED 2 State Description, LED status indication Heating LED 1 On = Flame detected LED 2 = Burner-on call state Rapid flash Igniting LED 1 Flashing - Electrode sparking LED 2 = Burner-on call state Flashing Lockout Possible errors:...

  • Page 97: Maximum Ignition Trials Error

    8.2.1 Maximum ignition trials error 8.2.1 Maximum ignition trials error Maximum Ignition Trials Error Issue Diagnosis Error – Ignition Failure No spark when Check that ignition lead is secure at the after 3 tries boiler has igniting. Ignition control module and at the probe. failed to ignite on 3 probe/flame sensor successive attempts.

  • Page 98: Hi Limit Cut-Off Temperature Error

    Section: Troubleshooting 8.2.2 Hi Limit cut-off temperature error Hi Limit cutoff temperature Error Issue Diagnosis Error – Water High-Limit Water temperature exceeds Refer to the V10 Touchscreen Exceeded hi-limit. Boiler is in hard Controller manual for lockout mode. information on resetting a boiler after a hi-limit temperature lockout.

  • Page 99: Miscellaneous Touchscreen Controller Errors

    8.3 Miscellaneous touchscreen controller errors 8.3 Miscellaneous touchscreen controller errors Miscellaneous errors Issue Diagnosis The sensor Check the P501 plug is “ Loop/Indoor Sensor” plug is not fully engaged in the back engaged. of the controller board. “Insufficient Air Flow” “Insufficient Water Pressure” “Unknown Error”...

  • Page 100: Ignition Issues

    Section: Troubleshooting 8.3.1 Ignition issues Ignition issues Issue Diagnosis Noisy spark when igniting Ignition lead is not firmly Reconnect ignition lead. connected. Contaminants/moisture Ensure probe is dry by re-running on igniter probe/flame post-purge; otherwise, clean or sensor. replace igniter probe. Boiler rumbles when igniting.

  • Page 101: 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 102: Miscellaneous Issues

    Power Robbing thermostat, isolate the current to thermostat with a relay or install a boiler. properly sized resistor (consult the thermostat manufacturer first then IBC for instructions). Error: Water High Limit / Low Water Boiler is in 1- For instructions on clearing errors, see Cutoff won’t clear.

  • Page 103: Cycling Issues

    8.3.4 Cycling issues Miscellaneous issues Issue Diagnosis Boiler pump runs but load pumps do Wiring not Supply power to the PV/L and PV/N not. complete. terminals from the incoming power supply to the boiler. (Factory wired on boilers with a factory installed touchscreen controller) Boiler stuck on initialize Fan board...
  • Page 104 Section: Troubleshooting Cycling issues Issue Diagnosis to improper piping. Low water flow due Check manufacturer’s rating charts/check temperature differential to undersized across heat exchanger. pump. Low water flow due Check temperature differential across zone/heat exchanger. to restrictions in water pipe. Low radiation.

  • Page 105: Appendices

    Appendices Wiring diagrams V-10 Controller electrical diagram Figure 52 Controller electrical diagram...

  • Page 106: Internal Wiring Diagram

    Section: Appendices Internal wiring diagram Figure 53 Internal wiring diagram...

  • Page 107: Sequence Of Operation

    Sequence of Operation Sequence of Operation Figure 54 Sequence of Operation...

  • Page 108: Exploded Views Of Boiler Parts

    Section: Appendices Exploded views of boiler parts Boiler part diagrams - SL 10-85 G3, SL 14-115 G3 Item # Description Part # P-kit Quantity Top Access Cover 250-818 Exhaust Duct 250-941 P-390 Intake Duct 250-942 P-391 Safety Ignition Module+ (SIM+) 500-078 P-271B Flue Temperature Sensor 240-132 P-361...
  • Page 109 Exploded views of boiler parts...
  • Page 110 Section: Appendices Item # Description Part # Quantity Sight Glass Housing 250-057 P-107A Sight Glass 250-059 Sight Glass Gasket 255-025 Sight Glass to Lid Gasket 255-023 Fan Coupler 250-749 P-347 Fan Coupler O-ring 150-254 Burner Gasket 255-069 P-378 Heat Exchanger Lid 170-041 P-394 Fan Gasket...
  • Page 111 Exploded views of boiler parts Item # Description Part # Quantity Gas Valve 180-165 P-326B Gas Line Gasket 150-271 Flexible Gas Line 190-159 Water Pressure Sensor 240-006 Water Pipe Bracket 250-592 Pressure Sensor Bushing 250-023 Return Water Pipe 250-454 Return Temperature Sensor 240-134 P-363 Condensate Trap...
  • Page 112 Section: Appendices Item # Description Part # Quantity Ignitor Gasket 250-050 SL 10-85 G3: P-327 SL 14-115 G3: 330, Ignitor SL 10-85 G3: 240- 111B SL 14-115 G3: 240- Ignitor / Fan Coupler Screws 150-260...
  • Page 113 Exploded views of boiler parts Boiler part diagrams - SL 20-160 G3 Item # Description Part # P-kit Quantity Top Access Cover 250-850 Exhaust Duct 250-941 P-390 Intake Duct 250-942 P-391 Safety Ignition Module+ (SIM+) 500-078 P-271B Flue Temperature Sensor 240-132 P-361 Side Terminal Block Cover 250-825...
  • Page 114 Section: Appendices...
  • Page 115 Exploded views of boiler parts Item # Description Part # Quantity Fan Coupler 250-749 P-347 Fan Coupler O-ring 150-254 Heat Exchanger Lid 170-042 P-395 Fan Gasket 250-627 240-114 P-310 Venturi 240-124 P-335 LWCO Probe 240-010 Supply Water Pipe, 1" 250-555 Gas Tube 250-792 Orifice 650 - NG 180-107...
  • Page 116 Section: Appendices Item # Description Part # Quantity Condensate Trap Retainer 250-874, 250-875 P-344 Condensate Trap 180-013 P-115 Return Temperature Sensor 240-134 P-363 Heat Exchanger 170-034 P-322 Supply Duplex Temperature Sensor 240-133 P-362 Refractory 250-762 P-317 High Limit Switch 240-030 Burner 180-187 P-313...
  • Page 117 Exploded views of boiler parts Boiler part diagrams - SL 30-199 G3 Item # Description Part # P-kit Quantity Top Access Cover 250-840 Exhaust Duct 250-943 Intake Duct 250-942 P-391 Flue Temperature Sensor 240-132 P-361 Safety Ignition Module+ (SIM+) 500-078 P-271B Terminal Block Cover 250-825 V-10 Touchscreen Controller...
  • Page 118 Section: Appendices Item Description Part # Quantity Fan Coupler 250-749 P-347 Fan Coupler O- 150-254 ring...
  • Page 119 Exploded views of boiler parts Item Description Part # Quantity Heat Exchanger 170-043 P-396 Burner 180-056 P-346 Burner Gasket 255-034 P-375 Fan Gasket 250-627 240-114 P-310 LWCO Probe 240-010 Supply Water 250-833 P-379 Pipe Water Pipe 255-024 Gasket Venturi Insert 240-142 P-336 Gas Tube 250-792...
  • Page 120 Section: Appendices Item Description Part # Quantity Heat Exchanger 170-035 P-323 Heat Exchanger 255-026 P-319 Lid Gasket Refractory 250-761 Ignitor Gasket 250-050 111B Ignitor 240-002 Sight Glass 250-059 107A Sight Glass 255-025 Gasket Sight Glass 250-057 Housing Sight Glass to 255-023 Lid Gasket...

  • Page 121: 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 122 Intentionally left empty...
  • Page 123 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 124 856-735-5584 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. August, 2021 120-276E8 ©...

This manual is also suitable for:

Sl 10-85 g3Sl 14-115 g3Sl 20-160 g3Sl 30-199 g3

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