IBC DC Series, Installation And Operating Instructions Manual

Page 1: ...ids 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...

Page 2: ...lief valve 3 4NPT 30psi 1 x Outdoor Temperature Sensor Air Vent and Relief Valve fittings 1 x Automatic Air Vent 4 x Lag Screws Hex Head Zn Pl 1 4 x 2 1 2 and Washers 1 x DC Installation Operating Ins...

Page 3: ...erating Pressure Domestic Hot Water Coil psig 150 150 150 150 Approved installation altitude ASL 10 000 ft 10 000 ft 10 000 ft 10 000 ft Ambient Temperature Low F C 32 0 32 0 32 0 32 0 Ambient Tempera...

Page 4: ...PA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 as applicable Failure to correctly install and operate this appliance can result in severe personal injury or death The water heat...

Page 5: ...R HEATER SYSTEMS AND OPERATION 2 1 2 1 GENERAL 2 1 2 2 CONTROL 2 2 2 3 INSTALLER INTERFACE 2 2 2 4 TANKLESS DOMESTIC HOT WATER MODES 2 4 2 5 ADDING DOMESTIC HOT WATER STORAGE 2 4 2 6 SPACE HEATING 2 5...

Page 6: ...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 r...

Page 7: ...agram to find a suitable location for the boiler water heater See also Section 1 3 Location DESCRIPTION DC SERIES BOILERS WATER HEATERS A Exhaust Outlet 3 Schedule 40 B Combustion Air 3 Schedule 40 C...

Page 8: ...clothes dryer exhaust terminal Avoid agricultural applications where the boiler water heater and or the intake air source are affected by ammonia and or dust Locate the boiler water heater where wate...

Page 9: ...me 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...

Page 10: ...d 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 unu...

Page 11: ...ted directly to the boilers water heaters combustion air connection See section 1 4 7 for air intake piping requirements 1 4 2 Exhaust Vent Material EXHAUST VENT MATERIAL CANADA Only PVC CPVC Polyprop...

Page 12: ...ctual vent travel allowance is reduced for fittings in accordance with Table 3 e g for the models listed above using 6 x 90 CPVC long sweep elbows the maximum lineal measure of pipe allowed using 3 pi...

Page 13: ...lue anywhere that PVC and CPVC are joined Follow the cement manufacturer s instructions closely when joining various components For PPs connections shall be secured using approved retainer clips suppl...

Page 14: ...12 minimum vertical separation for 2 pipe option For alternate group terminations contact the IBC Factory for written guidance DO NOT exhaust vent into a common venting system DIRECT VENT CONCENTRIC R...

Page 15: ...all 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...

Page 16: ...irements of the approved vent termination manufactures must be followed Approved Side Wall Termination Kits are listed as follows Alternate vent termination kits must be submitted to IBC for approval...

Page 17: ...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 12 minimum vertical separation...

Page 18: ...ior to installation Centrotherm Innoflue ICWT242 2 termination ICTC0224 2 concentric transition to 2 pipe Centrotherm Innoflue ICWT352 3 termination ICTC0335 3 concentric transition to 2 pipe Duravent...

Page 19: ...6 in 15 cm for appliances 10 000 Btuh 3 kW 9 in 23 cm for appliances 10 000 Btuh 3 kW and 50 000 Btuh 15 kW 12 in 30 cm for appliances 50 000 Btuh 15 kW K Clearance to a mechanical air supply inlet 6...

Page 20: ...heaters combustion air connection Provisions for combustion and ventilation air in accordance with the section Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or C...

Page 21: ...0 Short Sweep Vent Elbow Allow 8 equivalent feet 2 or 3 45 Vent Elbow Allow 3 equivalent feet PPS PPs 87 90 Elbow Allow 8 equivalent feet Flex PPS 3 PPs Flex Max 35 actual feet times 1 4 Table 4 Maxim...

Page 22: ...lowing liquids back through the heat exchanger Reliable system operation requires 1 proper design and installation of exhaust venting to allow condensate to run back to the drain trap 2 acid neutraliz...

Page 23: ...rb into the back mounting hole 2 Fill Trap with water and slide Trap Body over Boiler Water Heater Drain Outlet A Swing Trap Hook B around the Drain Outlet connection threads Insert remaining Trap Hoo...

Page 24: ...e the Trap Cleanout Assembly from the Trap Body and clean and flush the debris out 4 Re assemble trap components re fill trap and replace on boiler water heater as described in the installation instru...

Page 25: ...rosion 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 neutr...

Page 26: ...g or the use of a buffer tank hydraulic separator is recommended for maximum flexibility in multi zone load applications Piping loads in parallel is only acceptable in systems where the minimum flow r...

Page 27: ...ntenance requires relief valve blow off the discharge may be directed back into the pressurization unit for recycling of boiler fluid and chemicals back into the system In buildings that may be unoccu...

Page 28: ...gn circulating water temperatures some pumps have a minimum water temperature rating above the low temperature potential of the boiler water heater Following installation confirm actual performance by...

Page 29: ...oxygen barrier polybutylene material PB tubing The internal boiler water heater piping and connections are all non ferrous with the exception of the corrosion resistant epoxy coated cast iron pump Fo...

Page 30: ...eturn piping see Figure 29a Propylene Glycol mixtures of 25 50 are acceptable for use within the boiler and piping system In general the use of propylene glycol will reduce the heating capacity of the...

Page 31: ...r staging controller with dry contacts for each boiler water heater These controllers are available from your local heating wholesaler Check valves are to be used in each boilers piping to prevent rev...

Page 32: ...HEATERS DC 15 95 DC 15 96 DC 20 125 DC 33 160 Figure 27 Typical two temperature space heating piping concept with direct domestic hot water concept drawing This drawing is only a simple schematic guid...

Page 33: ...loss heat emitter concept drawing This drawing is only a simple schematic guide Figure 29b Air handler and direct domestic hot water primary secondary concept drawing This drawing is only a simple sch...

Page 34: ...de ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 as applicable Failure to correctly install and operate this appliance can result in severe personal injury or dea...

Page 35: ...heater will respond to an open faucet just as if it was in the Standard Mode While the DC Series boiler water heater is less susceptible to lime scale build up than other units on the market water qu...

Page 36: ...ow temperature heating system like a radiant floor at temperatures at or below 120 F 49 C then the thermostatic mixing valve may not be needed If the boiler water heater installation is only using the...

Page 37: ...PM DC 15 96 2 4 GPM DC 20 125 3 2 GPM DC 33 160 3 2 GPM CAUTION The field supplied thermostatic mixing valve may be installed on the direct domestic hot water piping connections at the boiler water he...

Page 38: ...ts individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psi 3 5 kPa The boiler water heater mus...

Page 39: ...vantage of the boiler water heater s heating capacity The maximum amperage rating of the connected pump is 1 0 amps If the connected pump has a rating higher than 1 0 amps an external isolation relay...

Page 40: ...electronic probe style device is recommended The probe type low water cut off device must be installed in the boiler water heater supply water piping with a tee connection at a level above the top of...

Page 41: ...ailable from your local heating wholesaler 1 9 4 Thermostat Sensor Wiring A Thermostat from a single zone heating system can be connected directly to the controller s terminals X4 6 and X4 7 Do not ap...

Page 42: ...NSTALLATION AND OPERATION INSTRUCTIONS 1 36 DC SERIES BOILERS WATER HEATERS DC 15 95 DC 15 96 DC 20 125 DC 33 160 Figure 35 Electrical Wiring Connections full page ladder diagram at back of this manua...

Page 43: ...1 37 BOILER SYSTEMS AND OPERATION DC SERIES BOILERS WATER HEATERS DC 15 95 DC 15 96 DC 20 125 DC 33 160 Figure 36 Suggested Field Wiring for Space Heating...

Page 44: ...N AND OPERATION INSTRUCTIONS 1 38 DC SERIES BOILERS WATER HEATERS DC 15 95 DC 15 96 DC 20 125 DC 33 160 Figure 37 Suggested Field Wiring for Space Heating and priority DHW for indirect DHW tank applic...

Page 45: ...m seizing The pump will be energized 24 hours after the last call for heat and every 24 hours after that until the next call for heat The DC series boiler water heater can generate domestic hot water...

Page 46: ...r and a combination with a period after the letter Example C c c are all valid parameter codes When adjusting settings double check that you are in the correct parameter See DC HC Controller Manual fo...

Page 47: ...isplayed in the Main Display To alter this value simply press the Plus or Minus buttons Saving the Changes To exit from the User Menu and save the changes press the Reset button Pressing the On Off bu...

Page 48: ...learning when the domestic hot water is used During the low use periods the boiler water heater s heat exchanger is allowed to cool To toggle between the 3 modes simply press the Domestic Hot Water Co...

Page 49: ...of the space heating water through the heating system The building pump or pumps will require a separate control system or relays to operate the pumps Zoning of the space heating system can be accompl...

Page 50: ...its target temperature and there is still a call for heat or hot water Service Display 1 6 After the call for heat is satisfied the boiler water heater pump will operate for an adjustable amount of t...

Page 51: ...3 1 STARTUP AND COMMISSIONING DC SERIES BOILERS WATER HEATERS DC 15 95 DC 15 96 DC 20 125 DC 33 160 STARTUP AND COMMISSIONING 3 0 3 1 LIGHTING AND SHUTTING DOWN THE BOILER...

Page 52: ...appropriate Error information is displayed on the Main Display screen To restart boiler reset power COMMISSIONING The DC Series modulating boilers water heaters are factory calibrated to operate with...

Page 53: ...r more than 2 seconds while in the Service Mode will display the Flame Current in DC microamps Expect approximately 9 8 A at High Fire 6 5 A or higher at Low Fire 3 With a combustion analyzer probe in...

Page 54: ...n 1 Select the correct Fuel Conversion Kit for your boiler water heater from Table 10 2 Ensure the fuel conversion instructions supplied with the fuel conversion kit are read understood and followed c...

Page 55: ...Flapper must be replaced with the black Propane Back Flow Flapper if not already installed see instructions in fuel conversion kit Failure to use the Propane Flapper may result in damage to the boiler...

Page 56: ...heat exchanger to the heat exchanger cover for damage hardness cracks and or discoloration If damaged in any way the gasket must be replaced Inspect and clean if necessary the mating gasket surface 2...

Page 57: ...removal and reassembly instructions section 3 5 1 of this manual Blow clear using compressed air Ensure flame is stable and without excessive fluttering Normal flame pattern is evenly distributed over...

Page 58: ...ement of expansion tank Check also for noise at high fire which may signal water quality problems Water chemistry shall be of a quality generally accepted as suitable for hydronic applications See Sec...

Page 59: ...ions If the system employs plain water the boiler water heater auto fill valve must be turned on in order to recharge the lost fluid 4 1 14 Domestic Hot Water System Quality of the domestic cold water...

Page 60: ...ve the venturi to the new fan Note that the fit is tight 2 Place the fan gasket on the outlet of the fan housing The gasket has 2 locator pins to ensure the gasket does not move during installation 3...

Page 61: ...ature Does Not Reach Desired Temperature 5 4 7 No Hot Water DHW 5 4 8 Hot Water Does Not Reach Temperature Below each section is a list of Symptoms Diagnoses and Remedies Also provided with this manua...

Page 62: ...s male Molex connector socket Do not apply voltage to the sensor damage may result 12K Temperature Sensors supplied with boiler water heater See Table 14 for resistance values SENSOR TYPE PURPOSE LOC...

Page 63: ...ssure less than 8psi the boiler water heater will restrict its firing rate If the pressure is less than 4psi then the boiler water heater will not fire at all TO TEST THE OPERATION OF THE PRESSURE SEN...

Page 64: ...the boiler release the water pressure and drain the domestic hot water circuit Leave the drain valves open Disconnect the Molex connector at the sensor Remove the sensor by turning the nut counter cl...

Page 65: ...wing table TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE F C F C 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 20 7 42 218 120 49 3 760 25 4 39 9...

Page 66: ...rque Check heat exchanger for contamination or debris Replace flue gas temperature sensor E2 Direct DHW Tank Error No flow detected when enabling the external DHW pump Pump failed Replace pump DHW pip...

Page 67: ...closed 2 S1 and S2 interchanged Check wiring harness Replace S1 or S2 4 No flame signal Gas valve closed Gas supply pressure too low or drooping under load Gas valve or ignition unit not powered No o...

Page 68: ...ION Gas supply pressure too high Gas pressure regulator may be faulty Replace the regulator or contact the gas company Incorrect ignition gap Replace the ignitor Check the ignitor gap 3 16 4 5mm Gas a...

Page 69: ...emperature Does Not Reach Desired Temperature POSSIBLE CAUSES SOLUTION Room thermostat setting incorrect Check the setting and if necessary adjust Set heat anticipator to 0 1A Thermostat must be a DRY...

Page 70: ...ture setting for water circuit too low Adjust the hot water circuit depending on the desired temperature and system configuration See Table of Programmable Parameters in DC HC Controller Manual Water...

Page 71: ...6 1 DIAGRAMS DC SERIES BOILERS WATER HEATERS DC 15 95 DC 15 96 DC 20 125 DC 33 160 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS...

Page 72: ...PERATION INSTRUCTIONS 6 2 DC SERIES BOILERS WATER HEATERS DC 15 95 DC 15 96 DC 20 125 DC 33 160 6 1 PARTS DIAGRAMS Diagram 6 1 1 Boiler water heater assembly parts DC 15 95 Modulating Boiler Water Hea...

Page 73: ...1 180 180 097 GAS VALVE 1 190 240 069 GAS VALVE CABLE INGITION MODULE 1 200 250 628 GAS LINE LOWER 1 210 240 070 DHW TEMPERTURE SENSOR 1 220 250 629 SUPPLY PIPE DHW 1 230 250 630 RETURN PIPE DHW 1 235...

Page 74: ...ERATION INSTRUCTIONS 6 4 DC SERIES BOILERS WATER HEATERS DC 15 95 DC 15 96 DC 20 125 DC 33 160 Diagram 6 2 1 Boiler water heater assembly parts DC 15 96 20 125 and 33 160 Modulating Boilers Water Heat...

Page 75: ...125 180 096 ORIFICE 580 PROPANE DC HC 160 170 150 175 O RING FOR ORIFICE 1 175 150 206 GASKET GAS VALVE INLET 1 180 180 097 GAS VALVE 1 190 240 069 GAS VALVE CABLE INGITION MODULE 1 200 250 628 GAS LI...

Page 76: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 6 DC SERIES BOILERS WATER HEATERS DC 15 95 DC 15 96 DC 20 125 DC 33 160 6 2 WIRING DIAGRAMS Diagram 6 2 1 Pictorial wiring diagram...

Page 77: ...followed and completed Section 3 of Installation and Operating Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner u...

Page 78: ...NOTES...

Page 79: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Page 80: ...DE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water heater water temperature as the heating load...

Page 81: ...RY 2016 Updated Parameters R7 JULY 2016 New Propane Back Flow Flapper Revision to Exhaust Vent Material USA R8 FEBRUARY 2017 Deletion of old model DC 33 124 Approval of PVC exhaust venting Pressure Se...

Page 82: ...C Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Toll Free 1 844 432 8422 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 183 A R10 88396710 May 2018 IBC Technologies Inc 201...