IBC Technologies SL 30-175 User manual

INSTALLATION AND OPERATING INSTRUCTIONS
www.ibcboiler.com
SL 30-175, SL 45-260
MODULATING GAS BOILERS
(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 30-175, SL 45-260 MODULATING GAS BOILERS
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
property 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.
SPECIFICATION SL 30-175 SL 45-260
CSA Input (Natural Gas or Propane) - MBH
CSA Input (Natural Gas or Propane) - kW
CSA Output - MBH
CSA Output - kW
30 - 175
8.8 - 51.3
29 - 161
8.4 - 47.2
45 - 260
13.2 - 76.2
43.2 - 239
12.7 - 70.0
AFUE 96.1% 96.1%
Minimum gas supply pressure (Nat. Gas or
Propane) - inch w.c.
5 5
Maximum gas supply pressure (Nat. Gas or
Propane) - inch w.c.
14 14
Power use (120Vac/60Hz) @ full re - Watts 91 (less pumps) 127 (less pumps)
Weight (empty) - lbs/Kg 151 / 69 162 / 74
Pressure vessel water content - USG/Litres 5 / 19 5 / 19
Maximum boiler ow rate - USgpm 25 25
Minimum boiler ow rate - USgpm 6 6
Maximum operating water pressure* - psig 30 30
Minimum water pressure - psig 8 8
Installation altitude - ASL 0 - 8,000’ 0 - 8,000’
Ambient temperature - Low (°F-°C)
Ambient temperature - High (°F-°C)
32°F / 0°C
122°F / 50°C
32°F / 0°C
122°F / 50°C
Max. relative humidity (non-condensing) 90% 90%
Minimum water temp. 34°F / 1°C 34°F / 1°C
Maximum water temp. (electronic hi-limit) 185°F / 85°C 185°F / 85°C
Maximum water temp. (mechanical hi-limit) 200°F / 93°C 200°F / 93°C
Max. ΔT - supply/return (electronic fence) 35°F / 19°C 35°F / 19°C
Maximum equivalent vent length (Each side,
Vent & Air Intake - Natural Gas or Propane)
3” Vent option
4” Vent option
200’
200’
200’
200’
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
•1 x Natural Gas to Propane conversion Kit - IBC Part #168A (SL 30-175)
•1 x Natural Gas to Propane conversion Kit - IBC Part #170A (SL 45-260)

INSTALLATION AND OPERATION INSTRUCTIONS
SL 30-175, SL 45-260 MODULATING GAS BOILERS
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....................................5-6
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 30-175, SL 45-260 MODULATING GAS BOILERS
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
CAUTION
Care must be taken to
properly size the boiler for
its intended use. Prolonged
full re run time, over-
sizing or under-sizing,
and incorrect ow rates
through the boiler can lead
to increased maintenance
costs, equipment stress and
premature failure.

1-1
INSTALLATION
SL 30-175, SL 45-260 MODULATING GAS BOILERS
INSTALLATION1.0
GENERAL
SL30-175andSL45-260gas-redmodulatingboilersarelowpressure,fully
condensing units having a variable input range from 30 MBH to 175 MBH, and
45 MBH to 260 MBH respectively (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.
Table 1: Connections
1.1
Figure 1: Dimensions / Connections
ITEM SIZE
AExhaust Vent 3” Schedule 40 vent pipe
BCombustion Air 3” Schedule 40 intake pipe
CRelief Valve and
Air Vent 3/4" NPT-F
DLCD Display 2 3/4” x 1 1/2”
EWater Outlet 1-1/2” NPT-M
FWater Inlet 1-1/2” NPT-M
GKnock-outs (6) 1/2”
HGas Inlet 3/4” NPT-F

INSTALLATION AND OPERATION INSTRUCTIONS
1-2
SL 30-175, SL 45-260 MODULATING GAS BOILERS
CODE REQUIREMENTS
TheSL30-175andSL45-260boilerswere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. 160 lbs/72 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 30-175, SL 45-260 MODULATING GAS BOILERS
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.
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 weight
of the boiler alone is 160
pounds. The combined
weight of the boiler, its water
contents and associated
piping components can
exceed 250 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.
SURFACE DISTANCE FROM
COMBUSTIBLES FOR SERVICE
Front 2" 24"
Rear 0" 0"
Left Side 1" 0" - (to non-combustibles)
Right Side 1" 4” for electric and gas if required
Top 2” 12”
Bottom 0" 12" trap/service clearance
Table 2: Clearances from boiler cabinet
Figure 2: Wall mounting of boiler

INSTALLATION AND OPERATION INSTRUCTIONS
1-4
SL 30-175, SL 45-260 MODULATING GAS BOILERS
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,
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
FLUE GAS
EXHAUST TO
OUTDOORS
IBC
SL 30-175
SL 45-260
BOILER
IBC

1-5
INSTALLATION
SL 30-175, SL 45-260 MODULATING GAS BOILERS
•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
Use CPVC or Polypropylene (PPs) vent component systems approved under
ULC-S636 Standard for Type BH Gas Venting Systems, or stainless steel Type
BH venting systems*. Permitted PPs materials comprise Single Wall Rigid pipe
andttingsandFlexible. Ensure compliance with exhaust temperature limitations
for the respective materials, which typically are:
• ULC-S636 CPVC: 90°C (194°F)
• ULC-S636 PPs:- 110°C (230°F)
Inthestandardconguration,SLseriesboilerscansupplywatertemperaturesup
to 185°F, leaving stack temperatures above the 65°C (149°F) limit for ULC-S636
approved PVC.
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
ULC-S636 approved 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 65°C (149°F ) upper 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 PPs or CPVC 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. - BUT - Many local
jurisdictions in the USA, still allow the use of PVC (ULC-S636 or Sch. 40 ASTM
D1785orD2665andttings)orCPVC(ULC-S636orSch.40/ASTMF441with
Sch.80ttings).IfPVCistobeused,youshalluseaminimumof10linealfeet
of CPVC, and then transition to PVC using approved transition glue. The installer
shall ensure that vent temperatures in the PVC section cannot exceed 140°F.
Never use ABS or any cellular core pipe for exhaust venting.

INSTALLATION AND OPERATION INSTRUCTIONS
1-6
SL 30-175, SL 45-260 MODULATING GAS BOILERS
The boiler offers 3" 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leftmost3"femalestainlesssteelttingonthetop,rightsideof
the boiler (see Figure 3).
ForPPsmaterial,usethe3"transition/adaptortting(Sch40toPPs)offeredby
the respective PPs manufacturers Centrotherm / InnoueTM (their part # ISAA0303)
or M&G Dura Vent / PolyProTM (#3PPs-AD). For PPs material exposed to outdoor
weather: follow the venting supplier’s recommendations on UV protection.
Combustion air piping - if used - is inserted directly into the 3" 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
3" PPs (Rigid Single Wall) or CPVC ULC-S636 approved piping is the standard
venting option; with this, the SL 30-175 and SL 45-260 boilers can be sited up to
200 equivalent feet from the vent termination. The actual vent travel allowance
isreducedforttingsinaccordancewithTable 3. – e.g. using 6 x 90º CPVC
vent elbows, the maximum lineal measure of pipe allowed is 152 feet (200' – (6
x 8' = 48) = 152'). Both models are also approved with the same materials of 4”
diameter, to the same 200’ equivalent length.
Flexible PPs: both the SL 30-175 and SL 45-260 models are approved with up
to 160 actual lineal feet of 4” Flex PPs in a nominally vertical orientation (>45°).
The equivalent length of 4” Flex shall be computed using a multiple of 1.2:1. The
200’ maximum equivalent limit applies; e.g. 80’ x 1.2 = 96’ equivalent (with such
use of 80’ of 4” Flex, up to 104’ equivalent of 4” Rigid PPS would still be allowed).
The SL 30-175 can be installed using 3” Flex to the same 160’ (actual lineal),
200’ max equivalent and 1.2:1 multiple. On the SL 45-260, 3” Flex is limited to
60’ actual feet maximum, consuming the full 200’ equivalent allowance (for an
effective multiple of 3.33:1).
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"
(PPs vent: follow PPs manufacturer requirements for slope) per foot so condensate
EXHAUST & AIR
INTAKE PIPE SIZE
MAXIMUM EQUIVALENT
LENGTH
3" CPVC / Rigid PPs (both models) 200' (each side)
4” CPVC / Rigid PPs (both models) 200’ (each side)
90° Long sweep elbow allow 5’ equivalent
90° Vent elbow allow 8’ equivalent
45° Elbow allow 3’ equivalent
PPs 87°-90° Elbow allow 8’ equivalent
3” PPs Flexible (SL 30-175) 160’ actual; 1.2:1 multiple; 200’ max equiv.
3” PPs Flexible (SL 45-260) 60’ actual; 3.33:1 multiple; 200’ max equiv.
4” PPs Flexible (both models) 160’ actual; 1.2:1 multiple; 200’ max equiv.
WARNING
Do not mix PPs venting
materials from different
Manufacturers.
These venting materials are
designed to be installed as
part of a complete system.
Failure to comply may result
in severe personal injury or
death.

1-7
INSTALLATION
SL 30-175, SL 45-260 MODULATING GAS BOILERS
runs back towards the trap. Support should be provided for intake and vent piping,
particularly so for horizontal runs (follow local code). You may have to insulate
exhaust piping where it passes through unheated spaces or underground, with
appropriate pipe insulation to prevent freezing of condensates. Contact Factory for
details.
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. For CPVC in Canada, use ULC-S636 approved CPVC
solvent cement, in accordance with its manufacturer instructions. Follow the
cement manufacturer’s instructions closely when joining various components. For
PPs, connections shall be secured using approved retainer clips supplied by the
respective PPs manufacturer.
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.
1.4.4 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.
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.
Fan control harness plug
Unplugging fan control harness plug
will drive the fan into manual high
speed operation for vent leak test
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
Figure 4: Rooftop vent terminal congurations

INSTALLATION AND OPERATION INSTRUCTIONS
1-8
SL 30-175, SL 45-260 MODULATING GAS BOILERS
• 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.
For alternate group terminations, contact the IBC Factory for written guidance.
•DO NOT exhaust vent into a common venting system.
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.
WARNING
It is extremely important
to maintain at least the
minimum separation of
exhaust vent termination
from boiler intake air as
illustrated in Figures 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. Do
not use proprietary InnoFlue
or PolyPro PPs terminals
available without specic
approval from IBC.
Figure 6: Sidewall vent termination - indoor combustion air applications
Figure 5: Sidewall vent termination - direct vent applications

1-9
INSTALLATION
SL 30-175, SL 45-260 MODULATING GAS BOILERS
•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.
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 between common terminations, and similarly group the
exhaust pipes the same. 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. Alternately, as long as the boilers are identical models - intake
and exhaust terminals can maintain a minimum of 12” of separation horizontally
from any exhaust or inlet termination of an adjacent boiler. For alternate group
terminations, contact the IBC Factory for written guidance.
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)
•Clearance above paved sidewalk or paved driveway located on public
property: - 7' (2.2m) Note: Cannot terminate directly above a paved sidewalk
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 30-175, SL 45-260 MODULATING GAS BOILERS
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 series boilers to avoid
damage to the structure. Note: Prohibited unless fully open on a minimum of
two sides below the oor.
• 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 30-175, SL 45-260 MODULATING GAS BOILERS
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.
For the inlet air – 3" or 4” Schedule 40 PVC, CPVC, ABS, or PPs piping of any
type is permitted. It is expected that the inlet air be the same size as the exhaust.
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 3” 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
COMBUSTION
AIR FROM
OUTDOORS
“DIRECT VENT”
INSTALLATION
CHECK AIR INTAKE
OUTSIDE TO MAKE
SURE IT IS CLEAR OF
OBSTRUCTIONS
FLUE GAS
EXHAUST TO
OUTDOORS
IBC
SL 30-175
SL 45-260
BOILER
IBC
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.
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.
EXHAUST & AIR
INTAKE PIPE SIZE
MAXIMUM EQUIVALENT
LENGTH
3” Schedule 40 / Rigid PPs (both models) 200' (each side)
4” Schedule 40 / Rigid PPs (both models) 200’ (each side)
90° Long sweep elbow allow 5’ equivalent
90° Vent elbow allow 8’ equivalent
45° Elbow allow 3’ equivalent
PPs 87°-90° Elbow allow 8’ equivalent
3” PPs Flexible (SL 30-175) 160’ actual; 1.2:1 multiple; 200’ max equiv.
3” PPs Flexible (SL 45-260) 60’ actual; 3.33:1 multiple; 200’ max equiv.
4” PPs Flexible (both models) 160’ actual; 1.2:1 multiple; 200’ max equiv.
Table 4: Exhaust and air intake pipe size

INSTALLATION AND OPERATION INSTRUCTIONS
1-12
SL 30-175, SL 45-260 MODULATING GAS BOILERS
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 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 45-260 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 these boilers without IBC’s written approval.
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
COMBUSTION
AIR FROM
BOILER ROOM
INDOOR AIR
INSTALLATION
CHECK AIR INTAKE
OUTSIDE TO MAKE
SURE IT IS CLEAR OF
OBSTRUCTIONS
FLUE GAS
EXHAUST TO
OUTDOORS
IBC
SL 30-175
SL 45-260
BOILER
IBC

1-13
INSTALLATION
SL 30-175, SL 45-260 MODULATING GAS BOILERS
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.
1.5.2 Condensate Trap Assembly - Installation
1. Undo Drain Spout Compression Nut (E), remove Drain Hose (G) from Trap
Drain Outlet (F). Place Vacuum breaker cap (J) over the Vacuum breaker
openingandpushrmlyhome.RemoveUpperCompressionNutandWasher
(C) and slide over Boiler Drain Outlet (A). Insert one Trap Hook barb into the
back mounting hole.
2. Fill Trap with water, and slide Trap
Body (D) over Boiler Drain Outlet
(A). Swing Trap Hook (B) around the
Drain Outlet (F) connection threads.
Insert remaining Trap Hook barb into
the front hole. Pull the trap slightly downward to seat it against the hook and
tighten Upper Compression nut (C).
3. Attach Drain Hose (G) and tighten Drain Spout Compression Nut (E).
1.5
Figure 16: Condensate trap
installation
WARNING
The Trap Hook must be
installed as instructed and all
trap ttings must be tightened
as instructed to prevent
leakage of ue gasses.
Failure to comply may result
in severe personal injury or
death.
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.
Condensate Trap as shipped
Condensate Trap, disassembled

INSTALLATION AND OPERATION INSTRUCTIONS
1-14
SL 30-175, SL 45-260 MODULATING GAS BOILERS
1.5.3 Condensate Trap
Assembly - cleaning
procedure
1. Turn off the power to the boiler
and allow it to cool down.
2. Remove the trap from the boiler
(reverse the installation procedure
above).
3. Remove the Trap Cleanout
Assembly (H), from the Trap Body
andcleanandushthedebrisout.
4. Re-assembletrapcomponents,re-lltrap,andreplaceonboilerasdescribed
in the 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.
NOTE
It is the responsibility of
the installing and/or service
Contractor to advise and
instruct the end User in how
to perform the Trap cleaning
procedure, and to advise
that the Trap be checked at
least every two months and
cleaned as required.

1-15
INSTALLATION
SL 30-175, SL 45-260 MODULATING GAS BOILERS
Figure 19: Condensate neutralization tank
Figure 18: Condensate trap drainage
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 17: Condensate trap
disassembly for cleaning
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.
FLUE GAS
EXHAUST
CONDENSATE AND
RAIN WATER
FLOWS BACK FROM
VENTING SYSTEM
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
IBC
SL 30-175
SL 45-260
BOILER
IBC
WARNING - “Risk
of damage to
appliance”
Ensure rainwater
is prevented from
entering air intake
piping.
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.
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.
FLUE GAS
EXHAUST
CONDENSATE AND
RAIN WATER
FLOWS BACK FROM
VENTING SYSTEM
IBC
SL 30-175
SL 45-260
BOILER
IBC

INSTALLATION AND OPERATION INSTRUCTIONS
1-16
SL 30-175, SL 45-260 MODULATING GAS BOILERS
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.An
automatic air vent is also required - as illustrated - to remove air from the top of
the pressure vessel. 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
CAUTION
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:
1. is connected from the valve outlet
with no intervening valve and
directed downward to a safe point of
discharge.
2. allows complete drainage of both the
valve and the discharge line.
3. is independently supported and
securely anchored so as to avoid
applied stress on the valve.
4. is as short and straight as possible
5. terminates freely to atmosphere
where any discharge will be clearly
visible and is at no risk of freezing.
6. terminates with a plain end which is
not threaded.
7. is constructed of a material suitable
for exposure to temperatures of
375°F or greater.
8. is, over its entire length, of a pipe size
equal to or greater than that of the
valve outlet.
DO NOT CAP, PLUG OR OTHERWISE
OBSTRUCT THE DISCHARGE PIPE
OUTLET!
1.6
PRIMARY/BOILER
CIRCULATOR
TO/FROM
LOAD TWO
TO/FROM LOAD ONE
TO/FROM LOAD THREE
FLOW
DIRECTION
FILL AND
EXPANSION
POINT
AIR
ELIMINATOR
“Y”
STRAINER
WITH
DRAIN
SHUT OFF
VALVE
SHUT OFF
VALVE
DIRT
SEPARATOR
WITH DRAIN
OR
IBC
SL 30-175
SL 45-260
BOILER
IBC
GLYCOL FEEDER & SYSTEM
PRESSURIZATION UNIT
OR
EXPANSION
TANK
FRESH
WATER
SUPPLY
SHUT
OFF
VALVE
BACKFLOW
PREVENTER
PRESSURE
REDUCING
VALVE
IMPORTANT NOTE: NONE OF THE
EXTERNAL DEVICES SHOWN ON
THIS DRAWING ARE SUPPLIED BY
IBC AS STANDARD EQUIPMENT
EXCEPT FOR THE PRESSURE
RELIEF VALVE. THE OTHER
DEVICES CAN BE PROVIDED BY
YOUR IBC DISTRIBUTOR OR BY
SPECIAL ORDER FROM IBC
SINGLE BOILER
TRIM OPTIONS