IBC SFC-199, Installation And Operating Instructions Manual

Page 1: ...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...

Page 2: ...ly 1 x Pressure Relief valve NPT 30psi 1 x Outdoor Temperature Sensor IBC part P 732 1 x SFC Installation Operating Instructions 1 x SFC SFB Controller Manual 1 x Propane Conversion Kit P 844 WARNING...

Page 3: ...ing Pressure Domestic Hot Water Coil psig 150 Minimum water pressure psig 8 Approved installation altitude ASL 10 000 ft Ambient Temperature Low F C 32 0 Ambient Temperature High F C 122 50 Max relati...

Page 4: ...SI 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 death Th...

Page 5: ...1 18 1 5 4 Further Installation Details 1 18 1 6 Water Piping SPACE HEATING 1 20 1 6 1 General Piping Considerations 1 20 1 6 2 Basic Heating Piping Arrangements 1 24 1 7 Domestic Hot Water System 1 2...

Page 6: ...Exchanger 4 2 4 1 7 Pump 4 2 4 1 8 Gas Piping 4 2 4 1 9 Control Module 4 2 4 1 10 Water Heating System 4 2 4 1 11 Freeze Protection 4 2 4 1 12 Unit Treatment 4 3 4 1 13 Relief Valve Maintenance and T...

Page 7: ...h the correct temperature 5 8 5 4 3 Central heating system remains too warm 5 9 5 4 4 No domestic hot water DHW 5 9 5 4 5 Domestic hot tap water does not reach the correct temperature 5 9 5 4 6 Burner...

Page 8: ...including those of neighbouring properties Place the exhaust outlet so it to reaches 12 minimum above the down turned intake Avoid exhaust re ingestion For sidewall venting options Both the inlet and...

Page 9: ...s usage of 4000 m3 for natural gas or 1500 m3 for propane The units are approved as Category IV vented appliances using Direct Vent sealed combustion Figures 1a and 1b show outer case dimensions and p...

Page 10: ...S UNITS A Exhaust Outlet 3 Schedule 40 B Combustion Air 3 Schedule 40 C Cold Domestic Water Connection Male NPT D Hot Domestic Water Connection Male NPT E Heating Water Inlet Return Male NPT F Heating...

Page 11: ...o avoid airborne chlorides such as those released with the use of laundry detergents Avoid installing the unit where water leakage may damage the area for example above carpeting If a location such as...

Page 12: ...2 Wall mounting of unit 1 3 1 Mobile Home Installations Units installed in a mobile or manufactured home must conform to the local building codes WARNINGS Exposed water piping and associated component...

Page 13: ...s and Propane Installation Code CAN CSA B149 1 or applicable provisions of the local building codes IMPORTANT When an existing unit is removed from a common venting system the common venting system is...

Page 14: ...s and any other gas burning appliance to their previous conditions of use Correct any improper operation of the common venting system to ensure that the installation conforms to the National Fuel Gas...

Page 15: ...lent feet from the vent termination using 3 The actual vent travel allowance is reduced for fittings in accordance with Table 3 Example For the models listed above using 6 x 90 CPVC elbows the maximum...

Page 16: ...a bird screen of 1 4 stainless steel or plastic mesh e g IPEX System 636 drain grate for CPVC systems to guard against foreign objects Figure 4 Secure joints using appropriate solvent cement to bond t...

Page 17: ...nd hold in place with a short nipple to allow easy access for cleaning For roof top venting of multiple unit sets group all intake terminals together for a common penetration through a custom cap Alte...

Page 18: ...p Concentric Termination kits are approved for use with this unit For vertical roof top concentric terminations you must follow the installation instructions supplied with the venting material manufac...

Page 19: ...nation piping configuration Figure 9 Top view minimum distance of exhaust vent to inside and outside corners DIRECT VENT SIDE WALL TERMINATION KITS The Side Wall Termination kits approved for use with...

Page 20: ...ile termination kit Ipex 196985 3 PVC low profile termination kit Figure 10 Non Concentric kits Ipex 196984 2 PVC and 196985 3 PVC Figure 11a Horizontal Concentric Termination Two Kits Figure 11b Hori...

Page 21: ...allation of multiple Concentric Side Wall Termination kits On the same horizontal line not stacked With a minimum vertical separation of 12 center to center Refer to local code requirements or restric...

Page 22: ...ion air inlet to any other appliance 6 in 15 cm for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 6 in 15...

Page 23: ...8 2 8 3 or 8 4 of Natural Gas and Propane Installation Code CAN CSA B149 1 or applicable provisions of the local building codes Figure 16 Direct vent combustion air intake V V V V V V V V V X X F C B...

Page 24: ...VC CPVC ABS or PPs piping of any type Use the same diameter as vent piping Insert combustion air piping directly into the 3 female plastic fitting on the top of the unit and run it horizontally or ver...

Page 25: ...ondensate Trap The condensate trap cup must be installed on the drain connection at the base of the unit 1 5 2 Installing the Condensate Trap 1 Fill the condensate trap cup with water 2 Place the cond...

Page 26: ...and refill with water Inspect the trap and clean the interior portion of the trap attached to the unit 4 Re install the condensate trap cup and twist to the right 1 5 4 Further Installation Details Pi...

Page 27: ...corrosion you must use a neutralization package CAUTION When a condensate neutralization package is installed the pH of the condensate discharge must be measured on a regular schedule to ensure the ne...

Page 28: ...r is recommended for maximum flexibility in multi zone load applications Piping loads in parallel is only acceptable in systems where the minimum flow rate is guaranteed to be higher than the minimum...

Page 29: ...or closed loop hydronic systems When water quality is unknown or when chemical treatment or glycol is required you should consider other options Follow applicable Codes and good piping practice Other...

Page 30: ...ischarge 2 Allows complete drainage of both the valve and the discharge line 3 Is independently supported and securely anchored to avoid applied stress on the valve 4 Is as short and straight as possi...

Page 31: ...rs The installer designer must ensure that if the integral pump is used for the space heating emitters it is powerful enough for system distribution Avoid D where an external pump is placed in series...

Page 32: ...n the supply side of secondary loops to facilitate air evacuation Use pumps with internal check valves to avoid ghost flows and thermal siphoning The SFC series units are designed to be piped in a pri...

Page 33: ...types of automotive glycol antifreeze or undiluted antifreeze of any kind This may result in severe unit damage It is the responsibility of the Installer to ensure that glycol solutions are formulate...

Page 34: ...TER HEATERS SFC 199 Figure 27 Space heating piping concept with closely spaced tees on secondary loop Figure 26 Typical one temperature space heating piping concept with direct domestic hot water conc...

Page 35: ...rature space heating piping concept with domestic hot water concept drawing This drawing is only a simple schematic guide Figure 29 Air handler and direct domestic hot water parallel piping for low lo...

Page 36: ...LLATION AND OPERATION INSTRUCTIONS 1 28 SFC BOILER WATER HEATERS SFC 199 Figure 30 Air handler and direct domestic hot water primary secondary concept drawing This drawing is only a simple schematic g...

Page 37: ...anual before operating the relief valve The unit requires a pressure relief valve identified with the ASME V or HV symbol and set to relieve at or below 150psi of domestic water pressure and a minimum...

Page 38: ...68 gr gal Aluminum 0 05 to 0 2 mg L Chlorides 250 mg L Copper 1 0 mg L Iron 0 3 mg L Manganese 0 05 mg L Zinc 5 mg L Table 6 Domestic Water Quality Guidelines 1 7 2 Domestic Hot Water Piping The dome...

Page 39: ...essurized 1 2 or larger domestic cold water supply piping and the domestic hot water piping in the home The minimum domestic water pressure required is 40PSI and recommended to be 50PSI or higher Gene...

Page 40: ...static mixing valve may be installed on the direct domestic hot water piping connections at the unit or at the outlet of a domestic hot water storage tank if using the domestic hot water function Fail...

Page 41: ...st pressures equal to or greater than 1 2 psi 3 5 kPa Dissipate test pressure prior to reconnecting The gas valve is provided with pressure taps to measure gas pressure upstream supply pressure and do...

Page 42: ...t of the unit The unit is equipped with 3 x 1 2 electrical knock outs for control wiring located behind the power supply terminal strip The SFC series units include a factory installed and pre wired p...

Page 43: ...r supply If the unit is being used only as a direct domestic hot water unit an external low water cut off device is not required However if required we recommend using an electronic probe style device...

Page 44: ...rom a single zone heating system can be connected directly to the controller s X13 terminals 1 and 2 Do not apply power to the X13 terminal strip An outdoor sensor is not required for the unit to oper...

Page 45: ...1 37 INSTALLATION SFC BOILER WATER HEATERS SFC 199 Figure 39 Electrical Wiring Connections full page ladder diagram at back of this manual...

Page 46: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 38 SFC BOILER WATER HEATERS SFC 199 PAGE INTENTIONALLY LEFT EMPTY...

Page 47: ...nit pump operates for 10 seconds every 24 hours to prevent it from seizing The pump is energized 24 hours after the last call for heat and every 24 hours after that until the next call for heat The SF...

Page 48: ...or F Radiator Heating Indicator G Wrench Service Reset H Return Arrow Enter Save I Numerical Display Service Display Table 9 Controller Indicators and Touch Pad 2 3 INSTALLER INTERFACE 2 3 1 Turning A...

Page 49: ...er Menu code 15 a Master Installer Menu code 20 RF Menu code 30 See separate publication SFC controller manual for details Adjusting the Space Heating Water Temperature To access the main menu 1 Touch...

Page 50: ...Plus or Minus buttons 2 To alter this value touch the Plus or Minus buttons 4 To Save the changes touch the Return button Exit without saving the changes touch the area above the NOTE The domestic ho...

Page 51: ...s heat exchanger will not maintain its domestic hot water temperature between demands for hot water Comfort Mode ON The water heater s heat exchanger is maintained at the DHW temperature ECO Comfort...

Page 52: ...he unit and the indirect tank The pump to the optional junction box can be wired 2 6 SPACE HEATING 2 6 1 Overview The SFC series unit is designed to be installed in a primary secondary type piping sys...

Page 53: ...s still a call for heat or hot water the burner will turn off integral pump runs unless call is on demand DHW Service Display 1 6 After the call for heat is satisfied the unit s pump will operate for...

Page 54: ...INSTALLATION AND OPERATION INSTRUCTIONS 2 8 SFC BOILER WATER HEATERS SFC 199 PAGE INTENTIONALLY LEFT EMPTY...

Page 55: ...3 1 STARTUP AND COMMISSIONING SFC BOILER WATER HEATERS SFC 199 3 0 STARTUP COMMISSIONING 3 1 LIGHTING SHUTTING DOWN THE UNIT...

Page 56: ...yed on the main display screen To restart the unit press the Reset button 3 3 COMMISSIONING The SFC series units are factory calibrated to operate with natural gas at sea level High Fire adjustment is...

Page 57: ...to confirm full maximum rating plate input With a combustion analyzer probe in the flue gas test port check the measured results against Table 12 High Fire If the results are outside the permitted ran...

Page 58: ...e The following procedure must be carried out by a qualified technician 1 Ensure that the gas supply is turned off at the manual gas valve 2 Disconnect the electrical power 3 Disconnect the nut at the...

Page 59: ...power switch to the unit 2 Turn off the gas supply valve to the unit There is no need to drain the unit unless the unit will be exposed to freezing conditions while off 3 Remove the front door and al...

Page 60: ...s If necessary inspect and clean the gasket mating surface 2 Place the heat exchanger cover onto the heat exchanger and loosely install the 6mm Allen bolts removed in step 6 Tighten the 6mm hex bolts...

Page 61: ...1 of this manual Blow clear using compressed air Evaluate the magnitude of clearing required and establish a reasonable burner inspection schedule Some installations may call for annual service other...

Page 62: ...t run up toward 30 psig at high temperature If pressure rises sharply consider replacement of the expansion tank Check also for noise at high fire that may signal water quality problems Water chemistr...

Page 63: ...ressurize your system Capture the discharged fluid in a container and recycle it by returning it to the system feeder unit This is particularly important when your system contains treatment chemicals...

Page 64: ...f the removed fan is to be re installed ensure the fan and venturi are clean and dust free If the fan is being replaced move the venturi over to the new fan Note that the fit is tight 4 1 16 Fan and g...

Page 65: ...eating 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 solutions So...

Page 66: ...sensor as damage may result 12K temperature sensors are supplied with the unit See Table 15 for resistance values SENSOR TYPE PURPOSE LOCATION S0 NTC 12K Heat Exchanger Temperature Upper Left of Heat...

Page 67: ...rate When the water pressure is less than 4 5psi the unit restricts its firing rate If the pressure is less than 4psi then the unit will not fire at all To test the operation of the pressure sensor t...

Page 68: ...rn off the cold and hot water valves below the unit release the water pressure and then drain the domestic hot water circuit Leave the drain valves open 5 2 7 Domestic Hot Water Sensor The SFC Series...

Page 69: ...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 39 913 125 52 3 383 30 1 34 558 130 5...

Page 70: ...akage Check whether heating supply temperature sensor S1 is installed correctly Check for the correct operation of heating supply temperature sensor S1 Replace the heating supply temperature sensor S1...

Page 71: ...F014 Mounting fault sensor S0 Heat exchanger sensor S0 is not mounted correctly Mount the sensor correctly F016 Mounting fault S3 Domestic hot water sensor S3 is not mounted correctly Mount the senso...

Page 72: ...Yes Check the wiring according to the schematic Check Connector X13 5 4 2 Central heating does not reach the correct temperature POSSIBLE CAUSES ANALYSIS POSSIBLE SOLUTION Water pressure in the syste...

Page 73: ...stic hot water flow Domestic hot water sensor S3 is defective Yes No Replace the domestic hot water sensor S3 No electricity on the flow sensor 5V DC Yes Check the wiring according to the schematic CK...

Page 74: ...ompany Ignition distance is incorrect Yes No Replace the ignitor including the ignition cable Gas air control is not correctly adjusted Yes Check and or replace the ignition cable Replace the ignition...

Page 75: ...6 1 DIAGRAMS SFC BOILER WATER HEATERS SFC 199 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS...

Page 76: ...6 2 SFC BOILER WATER HEATERS SFC 199 6 1 PARTS DIAGRAMS Diagram 6 1 1 Unit assembly parts SFC 199 Series modulating unit Parts assembly For information on the contents of P kits visit the Technical I...

Page 77: ...asket 250 807 P kit 850 90 Front panel assembly 180 262 P 857 100 Burner 180 170 P 841 110 Burner gasket 250 808 4 x screws 150 344 Spring 150 241 O ring 150 343 120 Heat exchanger plate with refracto...

Page 78: ...NTC for 15 mm tube 240 117 P 852 260 Bypass valve with flow sensor turbine 240 121 P 851 270 Boiler pressure sensor 180 221 P 834 280 Supply temperature sensor 180 222 P 835 290 DHW supply temperature...

Page 79: ...6 5 DIAGRAMS SFC BOILER WATER HEATERS SFC 199 6 2 WIRING DIAGRAMS Diagram 6 2 1 Pictorial wiring diagram...

Page 80: ...3 of Installation and Operating Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner used ____________________________...

Page 81: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Page 82: ...me function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the unit s water temperature as the he...

Page 83: ...r revisions made R2 October 2019 Additions to the Specifications table and update of piping diagrams and parts list R3 March 2020 Updated images R4 August 2020 Updated Specifications table miscellaneo...

Page 84: ...M8 Toll Free 1 844 432 8422 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 313E R5 84114405 September 2020 IBC Technologies Inc 2020 IBC Technologies USA Inc 1702 Taylors Lane Cinnaminson NJ...