IBC SL 20-160 G3 - User Manual

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.

IBC SL 20-160 G3 Specifications

General

Type	Condensing Boiler
Fuel Type	Natural Gas or Propane
AFUE	95%
Efficiency	95% AFUE
Water Connection Size	1 1/4"
Gas Connection Size	3/4"
Vent Connection Size	3"
Heating Capacity	20, 000 - 160, 000 BTU/hr
Dimensions	Varies by model
Weight	Varies by model

Summary

Introduction and Safety Overview

Critical Safety Warning: Gas Leaks

Immediate actions and precautions if gas is detected.

Manual Safety Markings and Instructions

Essential Safety Instructions

Key directives for safe operation and installation.

Additional Boiler Safety Precautions

Environmental and Operational Safety

Warnings about freezing, submersion, and electrical safety.

Boiler Specifications

Technical Performance Data

Details input, output, AFUE, pressure, and temperature limits.

Connection Specifications

Interface Port Details

Describes flue, combustion air, water, and gas connections.

Product Introduction and Features

Key System Features

Lists primary features like turn-down ratio and control capabilities.

Pre-Installation Requirements

Installation Site Precautions

General safety and operational considerations before installation.

Installation Guide

Regulatory Compliance and Codes

Installation standards based on national and local codes.

Installation Site Selection

Appliance Placement Guidelines

Recommended locations and environmental conditions for installation.

Site Safety Considerations

Critical advice for selecting a safe installation location.

Installation Best Practices

Optimizing Installation Environment

Boiler Mounting Procedures

Instructions for securely attaching the boiler to the wall.

Venting and Air Intake Systems

Venting System Setup

Boiler Cabinet Clearances

Venting Options and Materials

Direct Vent System Installation

Exhaust Venting Installation Details

Vent Length and Termination Allowances

Rooftop Vent Termination

Sidewall Vent Termination Requirements

Covers clearances and configurations for sidewall venting.

Sidewall Termination Clearances

Sidewall Direct Vent Termination

Condensate Management

Condensate Neutralizer Installation

Steps for installing a neutralization package for condensate.

Condensate Trap Installation and Drainage

Details on installing the condensate trap and piping.

System Piping

General Piping Best Practices

Pressure Relief Valve Installation

Instructions for installing and piping the relief valve.

Primary-Secondary Piping Configuration

Detailed explanation of primary-secondary piping.

Primary-Secondary Piping Details

Multiple Boiler Piping Configurations

Gas Piping Requirements

Gas Pressure Regulation Notes

Gas Pipe Sizing and Lengths

Electrical Connections

Power Quality and Protection

120 VAC Line-Voltage Hookup and Pumps

Wiring Diagram References

About the Boiler Controller

Controller Features and Capabilities

Before Operating the Boiler

Essential Pre-Ignition Checks

Essential checks before initial operation.

Final Piping and Venting Checks

Final checks on piping and venting systems.

Boiler Operation

Startup and Shutdown Procedures

Start-up Checklist Verification

Ignition Safety Shutoff Testing

Procedure to test the safety shutoff functionality.

Commissioning and Combustion Analysis

Steps for calibrating and testing combustion.

Performing a Fuel Conversion

Step-by-step guide for converting fuel types.

Gas Valve Adjustment Procedure

Safety warning and overview of gas valve adjustment.

Measuring Inlet Gas Pressure

Performing Combustion Test and Adjustment

Detailed steps for testing and adjusting combustion.

Combustion Test Target Ranges

Service and Maintenance

Heating Contractor Maintenance Tasks

General Boiler Component Maintenance

Relief Valve Maintenance and Testing

Replacing Boiler Components Overview

Introduction to replacing fan, gas valve, and burner.

Replacing the Fan Assembly

Step-by-step guide for fan replacement.

Replacing the Gas Valve

Step-by-step guide for gas valve replacement.

Replacing the Burner Assembly

Procedures for burner replacement, including safety precautions.

Cleaning the Condensate Trap

Troubleshooting Guide

Electronic Component Diagnostics

Troubleshooting temperature sensors and other electronic parts.

Hi Limit and Low Water Cutoff Errors

Diagnosing and resolving high limit and low water cutoff errors.

Miscellaneous Touchscreen Controller Errors

Ignition System Troubleshooting

Diagnosing and fixing issues related to ignition.

Temperature Related Issues

Miscellaneous Operational Issues

Cycling and Performance Issues

Appendices

Controller Electrical Diagram

Internal Boiler Wiring Diagram

Exploded View: SL 10-85;14-115 G3 Parts

Exploded View: SL 20-160 G3 Parts

Exploded View: SL 30-199 G3 Parts

Installation & Commissioning Report

Installer Commissioning Checklist

A form for documenting installation and commissioning.