IBC DC 15-95 Installation And Operating Instructions Manual Download Page 26

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INSTALLATION AND OPERATION INSTRUCTIONS

1-20

DC SERIES BOILERS / WATER HEATERS

DC 15-95, DC 15-96, DC 20-125, DC 33-160

WATER PIPING - SPACE HEATING

1.6.1 General Piping Considerations

The DC series boilers / water heaters include a factory installed, integral

Grundfos UP 15/58 heating pump. The pump is designed to provide adequate

flow through the boiler / water heater and near boiler / water heater piping. The

pump is pre wired.

Primary/secondary 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 minimum flow rate is

guaranteed to be higher than the minimum for the boiler / water heater and the

boilers / water heaters pump is adequate to provide the required flow rate and

pump head for the system.
There are some important details to consider however, and this section of the

Installation and Operating Manual will walk you through them so you can enjoy a

trouble-free installation.

1.6

Figure 22: Overview of piping options

Table 5: Boiler side pump curve

Summary of Contents for DC 15-95

Page 1: ...uids 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 fire department Installation and service ...

Page 2: ...elief 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 Instructions 1 x DC HC User Manual 1 x DC HC Controller Manual WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or...

Page 3: ...perating 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 Temperature High F C 122 50 122 50 122 50 122 50 Max relative humidity non condensing 90 90 90 90 Min water Temperature Space Heating F C 50 10 50 10 50 10 50 10 Max water Temperature Space Heating F C 194 ...

Page 4: ...FPA 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 heater if utilized shall have a pressure relief valve installed within 6 152mm of the DHW HOT outlet connection Refer to the Boiler User s Manual before operating relief valve The water heater if utilize...

Page 5: ...ER 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 2 7 SEQUENCE OF OPERATION 2 6 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 3 4 FUEL CONVERSION 3 4 4 0 MAINTENANCE ...

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 reach 12 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 th...

Page 7: ...iagram 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 Cold Domestic Water Connection 3 4 Male NPT D Hot Domestic Water Connection 3 4 Male NPT E Heating Water Inlet Return 1 Male NPT F Heating Water Outlet Supply 1 Male NPT G Gas Inlet 1 2 Male NPT H Co...

Page 8: ...a 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 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 water heater is not to be installed ...

Page 9: ...ume 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 Exposed water piping and associated components relief valves circulators etc should not be in...

Page 10: ...ed 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 deficie...

Page 11: ...cted 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 Polypropylene PPs or stainless steel vent component systems approved under ULC S636 Standard for Type BH Gas Venting Systems are to be used Ensure compliance with exhaust temperature limitations for the resp...

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 90º CPVC long sweep elbows the maximum lineal measure of pipe allowed using 3 pipe is 90 feet 120 6 x 5 30 90 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 multi...

Page 13: ...glue 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 by the respective PPs manufacturer All vent connections must be liquid and pressure tight Prior to firing the boiler and before any of the venting run is concealed by the building construction th...

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 ROOF TOP TERMINATION Roof Top Concentric Termination Kits are approved for use with this boiler water heater model The installation of the vertical roof top concentric termination must follow the inst...

Page 15: ...wall 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 12 minimum above the down turned intake to avoid intake re ingestion of exhaust gases The elevation of both pipes can be raised in periscope style after passing through the wall then conf...

Page 16: ...uirements 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 prior to installation Ipex 196984 2 PVC low profile termination kit see Figure 10 Ipex 196985 3 PVC low profile termination kit see Figure 10 Figure 8 Sidewall vent termination piping configuration W...

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 See A in Figure 13 Alternately as long as the boilers water heaters are identical models intake and exhaust terminals can maintain a minimum of 12 of separation horizontally from any exhaust or inle...

Page 18: ...rior 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 Polypro 3PPS HK Horizontal Termination Kit Concentric Ipex 197009 3 CPVC concentric termination kit Ipex 196006 3 PVC concentric termination kit VENT TERMINAL CLEARANCE MINIMUMS ARE AS FOLLOWS The v...

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 feet 1 83 m 3 ft 91 cm above if within 10 ft 3 m horizontally L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13 m M Clearance under veranda porch deck or balcony...

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 Clause 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 V V V V V V V V V X X F C B D E B K M G A INSIDE CORNER DETAIL H ...

Page 21: ...90 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 Maximum intake piping length For the inlet air Schedule 40 PVC CPVC ABS or PPs piping of any type is permitted Use same diameter as Vent pipe Combustion air piping is inserted directly into the 3 female s...

Page 22: ...flowing 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 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...

Page 23: ...arb 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 Hook barb into the front hole Pull the trap slightly downward to seat it against the hook and tighten Upper Compression nut 3 Attach Drain Hose and tighten Drain Spout Compression Nut NOTE It is the res...

Page 24: ...ve 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 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...

Page 25: ...rrosion 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 19 Condensate trap disassembly for cleaning DANGER The water in the condensate neutralizer can cause severe burns to the skin Use extreme caution when ser...

Page 26: ...ng 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 rate is guaranteed to be higher than the minimum for the boiler water heater and the boilers water heaters pump is adequate to provide the required flow rate and pump head for the system There are som...

Page 27: ...intenance 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 unoccupied for long periods of time pressurization units are useful to prevent flood damage should leakage occur from any component in the system An additional benefit is that backflow prevention devices a...

Page 28: ...sign 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 measuring Δ T under high and low flow conditions after establishing the correct firing rate A variety of application drawings showing basic design options are available from the IBC web site at www...

Page 29: ...n 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 For maintenance of warranty on such systems we require evidence of a thorough flushing of all loops plus installation of a dirt separator or side stream filter A separator filter maintenance routine sh...

Page 30: ...return 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 heating system and increases the pump head required for adequate boiler water heater flow If the installation involves small loads as in typical zoned baseboard heating applications use of a buffer ...

Page 31: ...er 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 reverse flow when the boiler is off Figure 26 Multiple boiler water heater piping concept concept drawing This drawing is only a simple schematic guide NOTE The piping drawings in this manual are simple...

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 guide Figure 26a Closely spaced tees on secondary piping concept drawing ...

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

Page 34: ...ode 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 death The water heater if utilized shall have a pressure relief valve installed within 6 152mm of the DHW HOT outlet connection Refer to the Boiler User s Manual before operating relief valve The water ...

Page 35: ...r 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 quality must always be considered when installing the boiler water heater Treating hard water and adjusting the pH to 6 5 and 8 5 is strongly recommended As a reference Table 6 represents some of the d...

Page 36: ...low 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 space heating portion of the heat exchanger and not using the Domestic Hot Water portion of the heat exchanger then the mixing valve and the Temperature and Pressure Relief valve need not be install...

Page 37: ...GPM 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 heater or at the outlet of a domestic hot water storage tank if the domestic hot water function is used Failure to install the thermostatic mixing valve may result in a hazardous situation which can ca...

Page 38: ...its 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 must be isolated from the gas supply piping system by closing disconnecting and capping its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures ...

Page 39: ...dvantage 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 is required to protect the boiler water heater s controller A field supplied external safety device can be connected to the boiler water heater by connecting the safety device in series with the boil...

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 the boiler water heater The probe type 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 supply to the boi...

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 apply power to the X4 terminal strip The Outdoor Sensor is not required for the boiler water heater to operate If the outdoor sensor is not connected the boiler water heater will operate at the designat...

Page 42: ...INSTALLATION 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 manual ...

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: ...ON 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 applications only ...

Page 45: ...om 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 in several ways The DC series boiler water heater can be used as a tankless water heater with or without a storage tank and also with an IBC indirect water heater The boiler water heater is equipped ...

Page 46: ...er 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 for details INSTALLER INTERFACE 2 3 1 Appliance ON OFF The boiler water heater can be switched on and off with the On Off button When the boiler water heater is ON the green LED above the On Off button...

Page 47: ...displayed 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 button will also exit the User Menu but will NOT save the changes The Controller has four levels User Menu Installer Menu code 15 a Master Installer Menu code 20 RF Menu code 30 future use See separate...

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 Comfort Eco button ADDING DOMESTIC HOT WATER STORAGE 2 5 1 Tankless Domestic Hot Water with a Storage Tank The DC series boiler water heater has the ability to connect a domestic hot water storage tank...

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 accomplished many ways Several control packages are available from your local wholesaler and offer an easy method of connecting the zoning system to the boiler water heater Example piping and electrical draw...

Page 50: ...es 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 time Service Display 0 7 If the burner is on to maintain the heat exchanger temperature for DHW Comfort mode or for Freeze Protection mode Service Display 7 8 If the burner is on for Frost Protection...

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 natural gas at sea level The Low Fire Zero Offset screw is not to be adjusted in the field The High fire Gas Air Ratio Adjustment screw may have to be adjusted to attain optimum combustion results if...

Page 53: ...or more than 2 seconds while in the Service Mode will display the Flame Current in DC microamps Expect approximately 9 8μA at High Fire 6 5μA or higher at Low Fire 3 With a combustion analyzer probe in the flue gas test port turn the High Fire Gas Air Ratio Adjustment screw see diagrams on this page to achieve results This screw offers very fine adjustment and may require several turns Clockwise r...

Page 54: ...an 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 carefully 3 Ensure that the gas supply is turned off at the gas control valve 4 Disconnect the gas valve harness plug from the gas valve 5 Disconnect the nut at the gas valve outlet top of the gas val...

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 serious injury or death 3 5 1 Gaining access to combustion chamber burner removal instructions DIS ASSEMBLY 1 Turn off the main power switch to the boiler water heater 2 Turn off the gas supply valv...

Page 56: ...e 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 Place the heat exchanger cover onto the heat exchanger and loosely install the 9 or 11 6mm hex bolts and lock washers removed in step 9 Tighten the 6mm hex bolts in a cross pattern as shown in diagr...

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 the burner surface If burner is operating improperly remove and clean or replace Use a CO2 analyzer to determine proper combustion See Table 11 page 3 3 for correct values 4 1 CAUTION Label all wire...

Page 58: ...cement 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 Section 1 6 for details Ensure any direct city fill water connections are left in the closed position to minimize exposure to leaks and flooding 4 1 11 Freeze Protection The boilers water heaters contro...

Page 59: ...tions 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 is very important to the longevity of the boiler water heater The recommended pH of the domestic water is between 6 5 and 8 5 The internal domestic water heat exchanger tubing and the flow sensor is...

Page 60: ...ove 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 Attach the fan to the burner housing and install the 2 hex nuts Tighten the 2 hex nuts with a wrench 4 Insert the Orifice and O ring between the gas valve outlet and the gas line to the fan Tighten t...

Page 61: ...rature 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 manual are a number of diagrams see Section 6 0 for use with troubleshooting including Electrical Wiring Diagrams Boiler Water Heater Component Layout Diagrams PRELIMINARY CHECKS The first step in trouble...

Page 62: ...le Molex connector socket Do not apply voltage to the sensor damage may result 12KΩ Temperature Sensors supplied with boiler water heater See Table 14 for resistance values SENSOR TYPE PURPOSE LOCATION S1 NTC 12KΩ Supply Water Temperature Upper Left of Heat Exchanger S2 NTC 12KΩ Return Water Temperature Lower Left of Heat Exchanger S3 NTC 12KΩ Domestic Hot Water DHW Supply Pipe S4 NTC 10KΩ Hot Wat...

Page 63: ...essure 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 SENSOR TYPE LWCO 1 Turn off the boiler water heater at the controller by pressing the button The current system pressure will be displayed 2 Isolate the space heating circuit and reduce the water pressu...

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 clockwise Take care not to drain the water onto any of the electrical components Clean or replace the flow sensor as required and reassemble in reverse order 5 2 7 Domestic Hot Water Sensor The DC Serie...

Page 65: ...ing table TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE F C Ω F C Ω 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 54 3 050 35 2 29 996 135 57 2 754 40 4 26 099 140 60 2 490 45 7 22 763 145 63 2 255 50 10 19 900 150 66 2 045 55 13 17 436 155 68 1 857 60 16 15 311 160 71 1 689 65 ...

Page 66: ...orque 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 piping loop air locked Bleed Air Flow Sensor Flow Restrictor blocked Remove and Clean Flow Sensor Faulty Replace E3 S3 DHW Sensor Open Check wiring HC boiler defined as DC Replace Sensor E4 S3 DHW Senso...

Page 67: ...s 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 or incorrect ignition gap Condensate drain blocked Check grounding of all parts 5 Poor flame signal Condensate drain blocked Gas supply pressure too low or drooping under load Check ignitor and igniti...

Page 68: ...TION 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 air adjustment not correctly set Check the setting See gas air adjustment Weak spark Check the ignition spark gap Replace the ignitor Replace the ignition module on the gas valve 5 4 3 Burner Resonati...

Page 69: ...Temperature 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 CONTACT style thermostat Water temperature is too low Increase the space heating water temperature See Table of Programmable Parameters in DC HC Controller Manual Check outdoor sensor and wiring for...

Page 70: ...ature 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 temperatures are set incorrectly Target water temperature is set higher than the maximum water temperature No heat transfer as a result of lime scale or fouling in the heat exchanger DHW side Descale...

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: ...OPERATION 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 Heater Parts Assembly ...

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 1 235 180 134 FLOW RESTRICTOR DC 124 125 160 1 180 135 FLOW RESTRICTOR DC 106 180 140 FLOW RESTRICTOR DC 84 240 240 071 WATER FLOW SENSOR 1 250 250 631 RETURN PIPE 1 260 180 098 PUMP 1 270 500 073 DOOR AS...

Page 74: ...PERATION 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 Heaters Parts Assembly ...

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 LINE LOWER 1 210 240 070 DHW TEMPERATURE SENSOR 1 220 250 629 SUPPLY PIPE DHW 1 230 250 630 RETURN PIPE DHW 1 235 180 134 FLOW RESTRICTOR DC 124 125 160 1 180 135 FLOW RESTRICTOR DC 106 180 140 FLOW RE...

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 used ________________________________________________ System Filled type concentration of any glycol chemicals used _______________________________________ Air purge completed Relief Valve correctly in...

Page 78: ...NOTES ...

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

Page 80: ...IDE 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 decreases This boiler water heater is not used for any space heating This boiler water heater is part of a modular or multiple boiler water heater system having a total input of 300 000 BTU hr or gr...

Page 81: ...UARY 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 Sensor Type LWCO language R9 JUNE 2017 Separation of Controller Manual Minor Updates R10 MAY 2018 Added information related to new models DC 15 95 and DC 15 96 Removed references to discontinued model...

Page 82: ...BC 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 2018 ...

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