IBC SL SERIES Istruzioni per l'installazione

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.

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.

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.

High levels of dissolved solids or minerals may precipitate out of the fluid onto the hottest part

of the heat exchanger, impairing heat transfer and resulting in overheating and premature

failure. The amount of solids that may form on the heat exchanger will depend on the degree

of hardness and the total water volume in the system. A high water volume system with a low

hardness count may cause as much damage as a system with less volume and higher

hardness, so it is recommended to treat water so as to remove all dissolved solids. Other

water chemistry allowable limits are as follows:

Acidity pH is to be between 6.6 and 8.5

Chloride is to be less than 125 mg/l

Iron is to be less than 0.3 mg/l

Cu less than 0.1 mg/l

Conductivity is to be less than 400μS/cm (at 77°F [25°C])

7 grains/ gal (120 ppm)

Important: Ensure that these limits are acceptable for the other water-side components in

the system.

Shipped with the boiler:

1 x Wall mounting bracket

1 x Condensate trap assembly

1 x 30 psig pressure relief valve

1 x Outdoor temperature sensor

2 x ¼" x 2 ½" Lag screws/w flat washers

1 x Propane fuel conversion kit

Safety information

Manual safety markings

Danger

Points out an immediate hazardous

situation that must be avoided to

prevent serious injury or death.

Warning

Points out a potential hazardous

situation that must be avoided to

prevent serious injury or death.

Caution

Points out a potential hazardous

situation that must be avoided to

prevent possible moderate injury

and/or property damage.

Note

Points out installation, maintenance and

operational notes to enhance efficiency,

longevity and proper operation of the

boiler.

Important safety instructions

Installation, start-up and servicing of IBC boilers must be performed by competent, qualified, licensed

and trained heating technicians.

Failure to read and comply with all instructions and applicable national and local codes may result in

hazardous conditions that could result in property damage and injury to occupants, and in extreme

cases to death. Keep instructions near the air handling appliance for future reference.

Danger

Should overheating occur or the gas supply fails to shut off, do not turn off or disconnect

the electrical supply to the pump. Instead shut off the gas supply at a location external to

the appliance.

Danger

Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or

any other appliance. If you smell gas vapors, do not try to operate any appliance - do not

touch any electrical switch or use any phone in the building. Immediately, call the gas

supplier from a phone located remotely. Follow the gas supplier’s instructions, or if the

supplier is unavailable, contact the fire department.

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.

Warning

Improper installation, adjustment, alteration, service or maintenance can cause

property damage, personal injury, or loss of life. Read and understand the entire

manual before attempting installation, start-up, operation, or service. Installation and

service must be performed only by an experienced, skilled installer or service agency.

Failure to follow all instructions in the proper order can cause personal injury or death.

Read all instructions, including all those contained in component manufacturers’

manuals before installing, starting up, operating, maintaining, or servicing the

appliance.

Warning

Disconnect power supply before any wiring/service is performed. Failure to do so could

result in damage to appliance and/or electric shock.

Caution

The boiler must be installed so that electrical components are not exposed to water

during operation.

Known Corrosive Contaminants to Avoid

Cements and glues Refrigerant leaks from cracks in coils

Paint or varnish removers Sodium chloride or potassium chloride used for

water softening

Adhesives used to fasten building products

and other similar products

Chemicals in perming solutions

Chlorinated waxes or cleaners Chlorofluorocarbon chemicals found in spray cans

Chlorine-based swimming pool chemicals Antistatic dryer sheets in clothes dryers

Hydrochloric acid or muriatic acid used in

household cleaning and stain removal

Chlorine-type bleaches, detergents, and cleaning

solvents found in household laundry rooms

Calcium chloride used for snow clearing

Section: Safety information

Contents

Safety information 3

Manual safety markings 3

Important safety instructions 3

Specifications 5

Cabinet dimensions 6

SL 10-85 G3, SL14-115 G3 6

SL20-160 G3 7

SL30-199 G3 8

Connection specifications 9

1.0 Introduction 11

1.1 Standard features and benefits 11

1.2 Warranty 12

2.0 Before installation 13

3.0 Installation 15

3.1 Code requirements 15

3.2 Removing an existing boiler 15

3.3 Determining location of the appliance 16

Best installation conditions 17

3.4 Mounting the boiler 17

3.5 Connecting the vent and air intake pipes 18

3.6 Installation clearances 19

3.7 Exhaust venting and air intake 20

3.7.1 Venting code 20

3.7.2 Venting options 21

3.7.3 Exhaust vent material 21

3.7.4 Direct vent 22

3.7.5 Rooftop vent termination 26

3.7.6 Sidewall vent termination 29

3.7.7 Combustion air filtration system 36

3.8 Closet installations 36

3.9 Installing the condensate trap 37

3.10 Installing a condensate neutralizer 40

3.11 Water Piping 42

3.11.1 General piping best practices 44

3.11.2 System piping 44

3.12 Gas piping 56

3.12.1 Gas pressure 57

3.13 Electrical connections 58

3.13.1 Power management, quality and electrical protection 58

3.13.2 120VAC line-voltage hook-up 59

3.13.3 Other wiring 60

3.13.4 Zone valve hook-up 60

3.13.5 Thermostat / sensor wiring 61

3.13.6 Thermostat heat anticipator 61

4.0 About the boiler controller 63

4.1 Controller 63

4.2 Control interface 64

5.0 Before operating the boiler 65

Important pre-ignition checks 65

Checklist for electrical conditions, ducting and water connections 65

6.0 Boiler operation 67

6.1 Lighting and shutting down the boiler 67

6.2 Testing the ignition safety shutoff 68

6.3 Commissioning 68

6.3.1 Checking a boiler's fuel source 69

6.3.2 Performing a fuel conversion 69

6.3.3 Adjusting the gas valve 70

7.0 Service and maintenance 75

7.1 Maintenance checklist for homeowner 75

7.2 Maintenance checklist for heating contractor 75

7.2.1 Touchscreen boiler controller 76

7.2.2 General boiler maintenance 76

7.3 Replacing the fan, gas valve, and burner 80

7.3.1 Replacing the fan on the SL 85, 115, 160 and 199 G3 boilers 82

7.3.2 Replacing the gas valve on the SL 85, 115, 160 and 199 G3 boilers 83

Section: Contents

7.3.3 Replacing the burner on the SL 85, 115, 160 and 199 G3 boilers 84

7.4 Cleaning the condensate trap 85

8.0 Troubleshooting 89

8.1 Electronic components 89

8.1.1 Temperature sensors 89

8.1.2 Fan 90

8.1.3 Water pressure sensor 90

8.1.4 Safety and Ignition Module (SIM+) 91

8.2 Troubleshooting error messages 92

8.2.1 Maximum ignition trials error 93

8.2.2 Hi Limit cut-off temperature error 94

8.2.3 Low Water Cut-off error 94

8.2.4 Aux. Interlock 1 or 2 94

8.3 Miscellaneous touchscreen controller errors 95

8.3.1 Ignition issues 96

8.3.2 Temperature issues 97

8.3.3 Miscellaneous issues 98

8.3.4 Cycling issues 99

Appendices 101

Wiring diagrams 101

V-10 Controller electrical diagram 101

Internal wiring diagram 102

Sequence of Operation 103

Exploded views of boiler parts 104

Installation & Commissioning Report 117

Intentionally left empty

Specifications

Boiler Specification SL 10-85 G3 SL 14-115 G3 SL20-160 G3 SL 30-199 G3

CSA Input (Natural Gas or

Propane) - MBH

CSA Input (Natural Gas or

Propane) - kW

CSA Output - MBH

CSA Output - kW

10.6 - 85

3.1 - 24.9

10.1 - 79

2.96 - 23.1

14 - 115

4.1 - 33.7

13.3 - 109

3.9 - 32

20 - 160

5.86 - 46.9

19 - 147

5.57 - 43.1

32 - 199

9.37 - 58.3

30 - 181.3

8.8 - 53.1

A.F.U.E 96% 95% 95% 95%

Minimum gas supply pressure

(Natural Gas or Propane) - inch

w.c.

4 4 4 4

Maximum gas supply pressure

(Natural Gas or Propane) - inch

w.c.

14 14 14 14

Power use (120Vac/60Hz) @ full

fire - Watts (less pumps)

54 72 82 100

Weight (empty) - lbs/Kg 85 / 39 85 / 39 102 / 46.3 152 / 69

Pressure vessel water content -

USG/Litres

2.47 / 9.35 2.47 / 9.35 1.72 / 6.51 5.09 / 19.3

Maximum boiler flow rate - USgpm 14 14 19 22

Minimum boiler flow rate - USgpm 2 2 4 6

Maximum operating water

pressure* - psig

30 30 30 30

Minimum water pressure - psig 8 8 8 8

Approved installation altitude - ASL 0 - 12,000’ 0 - 12,000’ 0 - 12,000’ 0 - 12,000’

Ambient temperature

Low °F / °C

High °F / °C

32°F / 0°C

122°F / 50°C

32°F / 0°C

122°F / 50°C

32°F / 0°C

122°F / 50°C

32°F / 0°C

122°F / 50°C

Max. relative humidity (non-

condensing)

90% 90% 90% 90%

Minimum water temp. 34°F / 1°C 34°F / 1°C 34°F / 1°C 34°F / 1°C

Maximum water temp. (electronic

hi-limit)

190°F / 88°C 190°F / 88°C 190°F / 88°C 190°F / 88°C

Max. Water Temperature Lockout 201°F / 94°C 201°F / 94°C 201°F / 94°C 201°F / 94°C

Boiler Specification SL 10-85 G3 SL 14-115 G3 SL20-160 G3 SL 30-199 G3

Limit

Max. ΔT - supply/return (electronic

fence)

40°F 40°F 40°F 40°F

Maximum equivalent vent length ,

each side (vent & air intake)

(Natural gas or propane)

Air intake options: either direct vent

or indoor supply

100’ (2")

240’ (3")

100’ (2")

240’ (3")

35’ (2")

170’ (3")

Not applicable

150’ (3")

* Boilers are shipped with a 30 psig pressure relief valve.

Cabinet dimensions

SL 10-85 G3, SL14-115 G3

Figure 1 : Front and side view - SL 10-85 G3, SL14-115 G3

Section: Specifications

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