IBC HC 33-124, Installation And Operating Instructions Manual

Page 1: ...iquids 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 pho...

Page 2: ...damage personal injury or loss of life 1 x Wall Mounting Bracket 1 x Condensate Assembly 1 x Pressure Relief valve 3 4NPT 30psi 1 x Outdoor Temperature Sensor 1 x 3 4 x 1 2 x 3 4 Brass Tee 1 x Elbow 3...

Page 3: ...Max boiler flow rate USgpm 9 9 10 11 11 11 Min boiler flow rate USgpm 2 2 3 3 3 3 Max Operating Pressure Space Heating Coil psig 43 5 43 5 43 5 43 5 43 5 43 5 Approved installation altitude ASL 12 00...

Page 4: ...essure relief valve installed within 6 152mm of the DHW HOT outlet connection with the relief valve spindle installed in the vertical position The water heater if utilized requires a pressure relief v...

Page 5: ...GENERAL 2 1 2 2 CONTROL 2 2 2 3 INSTALLER INTERFACE 2 2 2 4 TANKLESS DOMESTIC HOT WATER MODES 2 7 2 5 ADDING DOMESTIC HOT WATER STORAGE 2 7 2 6 SPACE HEATING 2 8 2 7 SEQUENCE OF OPERATION 2 9 3 0 STAR...

Page 6: ...act with the condensate Keep exhaust plumes well away from all building air intakes including those of neighbouring properties In sealed combustion applications the exhaust outlet should be placed so...

Page 7: ...ng and electrical holes Use this diagram to find a suitable location for the boiler See also Section 1 3 Location DESCRIPTION HC SERIES BOILERS A Exhaust Outlet 3 Schedule 40 B Combustion Air 3 Schedu...

Page 8: ...e 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 a...

Page 9: ...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 satisfact...

Page 10: ...val 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...

Page 11: ...s are to be used Permitted PPs materials comprise Single Wall Rigid pipe and fittings Ensure compliance with exhaust temperature limitations for the respective materials which typically are ULC S636 C...

Page 12: ...an be vented up to 120 equivalent feet from the vent termination using 3 The actual vent travel allowance is reduced for fittings in accordance with Table 3 e g for the models listed above using 6 x 9...

Page 13: ...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 supplied...

Page 14: ...shall be 36 or more apart Use the same 24 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...

Page 15: ...dewall 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...

Page 16: ...learances and wall thickness requirements of the approved vent termination manufactures must be followed Approved Concentric Side Wall Termination Kits are listed as follows Alternate vent termination...

Page 17: ...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...

Page 18: ...oncentric Centrotherm Innoflue ICWT242 2 termination ICTC0224 2 transition to 2 pipe Centrotherm Innoflue ICWT352 3 termination ICTC0335 3 transition to 2 pipe Ipex 197009 3 CPVC Ipex 196006 3 PVC USA...

Page 19: ...e Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code A vent shall not terminate directly above a sidewalk or paved driveway that is located between two singl...

Page 20: ...of the local building codes For 3 Flexible PPs up to 35 actual lineal feet are allowed in a nominally vertical orientation 45 The equivalent length of 3 Flexible PPs shall be computed using a multiple...

Page 21: ...jects Care must be taken to ensure adequate separation is maintained between the air intake inlet and the vent terminal Refer to the vent terminal configuration drawings in the Vent Termination sectio...

Page 22: ...pout Compression Nut E remove Drain Hose G from Trap Drain Outlet F Place Vacuum breaker cap J over the Vacuum breaker opening and push firmly home Remove Upper Compression Nut and Washer C and slide...

Page 23: ...ed 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...

Page 24: ...re 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...

Page 25: ...ary piping 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 minim...

Page 26: ...ular maintenance 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 b...

Page 27: ...stat wired to the boiler s Heat Demand X4 6 and X4 7 terminals Ensure the pump is rated for the design circulating water temperatures some pumps have a minimum water temperature rating above the low t...

Page 28: ...or of non oxygen barrier polybutylene material PB tubing The internal boiler piping and connections are all non ferrous with the exception of the corrosion resistant epoxy coated cast iron pump For ma...

Page 29: ...50 are acceptable for use with in the boiler and piping system In general the use of propylene glycol will reduce the heating capacity of the heating system and increases the pump head required for a...

Page 30: ...your local heating wholesaler Check valves are to be used in each boilers piping to prevent reverse flow when the boiler is off For further information and details consult our Application Notes which...

Page 31: ...Typical two temperature space heating piping concept with direct domestic hot water concept drawing This drawing is only a simple schematic guide Figure 28 Typical two temperature space heating piping...

Page 32: ...23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 Figure 29a Air handler and direct domestic hot water concept drawing This drawing is only a simple schematic guide Figure 29b Air handler and direct domes...

Page 33: ...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 must be isolated from the gas supply piping system by closing disconne...

Page 34: ...t fired storage water heater to heating circuit to take full advantage of the boilers heating capacity The maximum amperage rating of the connected pump is 1 0 amps If the connected pump has a rating...

Page 35: ...ee connection at a level above the top of the boiler The low water cut off device must be wired in series with the 120Vac power supply so that when the device trips on a low water condition the power...

Page 36: ...our local heating wholesaler 1 8 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 apply power to t...

Page 37: ...1 31 INSTALLATION HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 Figure 34 Electrical Wiring Connections full page ladder diagram at back of this manual...

Page 38: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 32 HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 Figure 36 Suggested Field Wiring for Space Heating...

Page 39: ...1 33 INSTALLATION HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 Figure 37 Suggested Field Wiring for Space Heating...

Page 40: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 34 HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 PAGE INTENTIONALLY LEFT BLANK...

Page 41: ...en heating an IBC indirect water heater The pump will not operate with a call for domestic hot water using the boiler s internal domestic hot water tankless coil The boiler pump will operate for 10 se...

Page 42: ...ble 7 Controller Indicators and Buttons NOTE The control displays codes that include upper and lower case letter and a combination with a period after the letter Example C c c are all valid parameter...

Page 43: ...in display Press the Plus button repeatedly until 15 appears in the main display Press the Service button to scroll through the parameters Press the Plus or Minus buttons to alter a parameters setting...

Page 44: ...C Range to 22 F 30 C to 55 F 13 C 7 Summer Shut Down Temperature 64 F 18 C Range 59 F 15 C to 86 F 30 C Pump and burner will not operate if the Outdoor Temperature is above this setting 8 Internal Boi...

Page 45: ...HC 23 84 HC 29 106 and HC 33 124 28 HC 20 125 19 HC 33 160 22 E Minimum Space Heating Temperature with an Open Therm heating demand 104 F 40 C 50 F 140 F 10 C 60 C Only for use with an Open Therm the...

Page 46: ...Internal Pump disabled 3 0 Space Heating HC Models Space Heating Only Internal Boiler Pump is enabled with a call for Space Heating 4 0 DHW Storage Tank Sensor or Aquastat 1 Space Heating DC Models Sp...

Page 47: ...HC 33 160 TANKLESS DOMESTIC HOT WATER MODES 2 4 1 Tankless Domestic Hot Water Standard Comfort and ECO Comfort Modes Section Reserved for the DC Series Boilers ADDING DOMESTIC HOT WATER STORAGE 2 5 1...

Page 48: ...r pumps will require a separate control system or relays to operate the pumps Zoning of the space heating system can be accomplished many ways Several control packages are available from your local wh...

Page 49: ...get 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 pump will operate for an adjustable amount of time Service Display 0...

Page 50: ...INSTALLATION AND OPERATION INSTRUCTIONS 2 10 HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 PAGE INTENTIONALLY LEFT BLANK...

Page 51: ...3 1 STARTUP AND COMMISSIONING HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 STARTUP AND COMMISSIONING 3 0 3 1 LIGHTING AND SHUTTING DOWN THE BOILER...

Page 52: ...splayed on the Main Display screen To restart boiler reset power COMMISSIONING The HC Series modulating boilers are factory calibrated to operate with natural gas at sea level This cap must not be tam...

Page 53: ...peration press the Service and Plus together twice while the boiler is operating in manual mode to reset the timer for 10 more minutes 3 With a combustion analyzer probe in the flue gas test port turn...

Page 54: ...plug from the gas valve 4 Select the correct Fuel Conversion Kit for your boiler from Table 9 5 Disconnect the nut at the gas valve outlet top of the gas valve and remove the orifice and O ring 6 Inse...

Page 55: ...3 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 Figure 35 Blower and Gas Valve Assembly Figure 36 Orifice and O ring WARNING Fan Outlet Orifice 25mm must be installed in the DC 23 84 model If the fan is...

Page 56: ...way the gasket must be replaced 10 Place the heat exchanger cover in a safe location RE ASSEMBLY 1 Carefully inspect the gasket sealing the heat exchanger to the heat exchanger cover for damage hardn...

Page 57: ...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 Consider adding air filtration if burner...

Page 58: ...fire which may signal water quality problems Water chemistry shall be of a quality generally accepted as suitable for hydronic applications See Section 1 6 for details Ensure any direct city fill wat...

Page 59: ...highly recommended that a system pressurization unit such as an Axiom Industries model MF200 be employed to refill and pressurize your system Capture the discharged fluid in a container and recycle i...

Page 60: ...outlet of the fan housing The gasket has 2 locator pins to ensure the gasket does not move during installation 2 Place the check valve on the fan gasket and attach the fan to the burner housing and in...

Page 61: ...ing 5 4 6 Indoor Temperature 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 p...

Page 62: ...e Molex connector socket Do not apply voltage to the sensor damage may result 12K Temperature Sensors supplied with boiler See Table 12 for resistance values SENSOR TYPE PURPOSE LOCATION S1 NTC 12K Su...

Page 63: ...estrict its firing rate If the pressure is less than 4psi then the boiler will not fire at all TO TEST THE OPERATION OF THE PRESSURE SENSOR 1 Turn off the boiler at the controller by pressing the butt...

Page 64: ...he condensate tray 5 2 6 Domestic Hot Water Flow Sensor Section Reserved for the DC Series Boilers 5 2 7 Domestic Hot Water Sensor Section Reserved for the DC Series Boilers 5 2 8 Outdoor Sensor An Ou...

Page 65: ...lowing 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...

Page 66: ...f flue gas sensor Heat exchanger front panel loose check bolt torque Check heat exchanger for contamination or debris Replace flue gas temperature sensor E2 Direct DHW Tank Error No flow detected when...

Page 67: ...on radiators 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...

Page 68: ...LUTION 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 Ga...

Page 69: ...oes 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 CONTACT sty...

Page 70: ...IBLE CAUSES SOLUTION DHW flow to high Adjust the inlet assembly insert a flow restriction Temperature setting for water circuit too low Adjust the hot water circuit depending on the desired temperatur...

Page 71: ...6 1 DIAGRAMS HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS...

Page 72: ...ION AND OPERATION INSTRUCTIONS 6 2 HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 6 1 PARTS DIAGRAMS Diagram 6 1 1 Boiler assembly parts HC Series Modulating Boiler Parts...

Page 73: ...ERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 Diagram 6 1 2 Boiler assembly parts list refer to Diagram 6 1 1 on opposite page Some parts are available in Kits Please visit www ibcboil...

Page 74: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 20 125 HC 33 160 6 2 WIRING DIAGRAMS Diagram 6 2 1 Pictorial wiring diagram...

Page 75: ...completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner used ________________________________________________ System Filled type concentration of...

Page 76: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Page 77: ...NOTES...

Page 78: ...RIDE 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 temperature as the heating load decreases...

Page 79: ...R1 JULY 2014 Initial release R2 SEPTEMBER 2014 New Model HC 13 50 Minor updates R3 MARCH 2015 Minor Updates Change DHW Tank Sensor to 10K R4 AUGUST 2015 Address Update R5 OCTOBER 2015 Addition of new...

Page 80: ...IBC Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 185 A R5 88397705 October 2015 IBC Technologies Inc 2015...