IBC DC 23-84 Installation And Operating Instructions Manual Download | Manualshive

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5-1

TROUBLESHOOTING

DC SERIES COMBI BOILERS

DC 23-84, DC 29-106, DC 33-124, DC 33-160

5.0 TROUBLESHOOTING

The troubleshooting section is divided into 4 sections:

5.1 Preliminary Checks
5.2 Electronic Components
5.3 Warnings and Faults
5.4 Other Faults

Often, a problem can be identified and solved through simple checks of the basics:

confirming the electrical power supply, gas flow and resetting the thermostat

control. To extend the cover of such preliminary checks, the boiler’s control module

offers a clear visual display of the status of the various control circuit components.
Should a problem remain unsolved after applying the preliminary checks,

proceed to the detailed system review, using the Troubleshooting Guide. The

Guide covers potential error conditions as grouped into the following categories:

5.3.1 Warning Codes
5.3.2 Fault Codes
5.4.1 Burner does not Ignite
5.4.2 Burner Ignites Noisily
5.4.3 Burner Resonating
5.4.4 The Power is Reduced
5.4.5 No Space Heating
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 provided with this manual are a number of diagrams

(see Section 6.0)

for

use with troubleshooting including:

•

Electrical Wiring Diagrams

•

Boiler Component Layout Diagrams

PRELIMINARY CHECKS

The first step in troubleshooting this system should be a review of the Controller’s

display screen. There are a number of diagnostic features incorporated in the

software that evaluate system integrity, display error conditions and provide initial

suggested remedial actions.
In addition to checking the display, the following list is a guideline for troubleshooting:

1.

Confirm power to the boiler: check that control module display is on (e.g.

display is lit).

2.

Check that boiler is not in a safety lockout.

3.

Ensure wiring is clean and secure.

4.

Check that gas is reaching the unit.

5.

Confirm water system is properly charged to 12 psig and pump is serviceable.

5.1

NOTE

This boiler is equipped with a

blocked vent shutoff system,

which closes the gas supply

upon detection of an irregular

venting condition.

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Summary of Contents for DC 23-84

Page 1: ... 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 must...

Page 2: ...ll 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 4 Brass Street 90 1 x 3 4 x 1 3 8 close Brass Nipple 1 x 1 2 x 1 8 Brass Bushing 1 x Automatic Air Vent 1 x Tridicator 1 4 NPT 1 x 1 x 1 x 1 4 Brass Tee 4 x Lag Screws Hex Head Zn Pl 1 4 x 2 1 2 and Washers 1 x Thermostatic mixing valve 1 x DC ...

Page 3: ...43 5 43 5 43 5 43 5 Max Operating Pressure Domestic Hot Water Coil psig 150 150 150 150 Approved installation altitude ASL 12 000 ft 12 000 ft 12 000 ft 12 000 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 15 20 15 20 15 20 15 20 Max water Temperatu...

Page 4: ...e 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 valve identiﬁed with the ASME V or HV symbol and set to relieve at or below 150psi of domestic water pressure and a minimum For complete information refer to installation manual Read and follow warnings and...

Page 5: ...ION 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 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 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 4 1 4 1 BOILER MAINTENANCE 4...

Page 6: ...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 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 b...

Page 7: ...diagram to find a suitable location for the boiler See also Section 1 3 Location DESCRIPTION DC SERIES COMBI BOILERS 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 Condensate Outlet 3 4 ...

Page 8: ...d 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 installe...

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

Page 10: ...ther 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 deficiencies which could cause an unsafe condition Insofar as is practical close all building doors and window...

Page 11: ...mperature limitations for the respective materials which typically are ULC S636 CPVC 90 C 194 F ULC S636 PPs 110 C 230 F 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 confirm that local codes will...

Page 12: ...xample can 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 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 ...

Page 13: ...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 the installer must te...

Page 14: ...erminations 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 model The installation of the vertical roof top concentric termination must follow the installation instructions supplied with the venting material manufacturer Care must be t...

Page 15: ...on Single Kit 1 4 6 Sidewall Vent Termination DIRECT VENT TWO PIPE 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 intake re ingestion of exhaust gases ...

Page 16: ...e increases when the outdoor temperature drops below this temperature The installation instructions clearances 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 kits must be submitted to IBC for approval prior to installation Duravent Polypro 3PPS HK Horizont...

Page 17: ...he exhaust pipes 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...

Page 18: ...therm 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 VENT TERMINAL CLEARANCE MINIMUMS ARE AS FOLLOWS CANADIAN INSTALLATIONS1 US INSTALLATIONS2 A Clearance above grade veranda porch deck or balcony 12 in 30 cm 12 in 30 cm B Clearance to window or door that may be opened 6 in 15 cm for appli...

Page 19: ...n 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 single family dwellings and serves both dwellings Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor Clearance in accordance with local installation codes and the requiremen...

Page 20: ... 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 of 1 4 1 e g 35 x 1 4 49 equivalent The balance of the venting allowance is still available for use with rigid PPs piping material 2 Flexible PPs is not allowed INTAKE PIPE SIZE FITTINGS MAXIMUM EQUIVALENT...

Page 21: ... 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 section above Support should be provided for intake piping particularly so for horizontal runs follow local code 1 4 8 Indoor Air Combustion Air Intake Using Indoor Combustion Air is not approved for use with th...

Page 22: ...ompression 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 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 connectio...

Page 23: ... 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 refilled as necessary NOTE It is the responsibility of the insta...

Page 24: ...ject 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 19 Condensate trap disassembly for cleaning DANGER The water in the condensate neutralizer can cause severe burns to the skin Use extreme cautio...

Page 25: ...ping 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 and the boilers pump is adequate to provide the required flow rate and pump head for the system There are some important details to co...

Page 26: ...aintenance 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 ...

Page 27: ... 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 temperature potential of the boiler 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...

Page 28: ...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 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 shall be carr...

Page 29: ...re 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 adequate boiler flow If the installation involves small loads as in typical zoned baseboard heating applications use of a buffer tank is recommended To aid in temperature transition from hot to cool loads a...

Page 30: ...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 provide detail on specific single and multiple boiler applications Piping Wiring and Settings available at www ibcboiler com or from your IBC Representative Figure 26 Multiple boiler piping concept concept...

Page 31: ...al 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 concept with indirect domestic hot water concept drawing This drawing is only a simple schematic guide ...

Page 32: ... severe personal injury The water heater if utilized shall have a pressure 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 valve identiﬁed with the ASME V or HV symbol and set to relieve at or below 150psi of domestic water pressure and a minimum For compl...

Page 33: ... the DC Series boiler is less susceptible to lime scale build up than other units on the market water quality must always be considered when installing the boiler Treating hard water and adjusting the pH to 6 5 and 7 5 is strongly recommended As a reference Table 6 represents some of the drinking water guidelines published by the US EPA Consult a water treatment advisor in your area to assess your...

Page 34: ...estic 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 Generating domestic hot water with a water pressure lower than 40PSI will reduce the amount of hot water generated and will increase the risk of scaling in the heat exchanger The domestic water piping must be installed with isolati...

Page 35: ...temperature rise DC 23 84 2 0 GPM DC 29 106 2 5 GPM DC 33 124 3 0 GPM DC 33 160 3 0 GPM DANGER The factory supplied thermostatic mixing valve must be installed on the direct domestic hot water piping connections at the boiler 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 si...

Page 36: ...d piping compound resistant to the action of natural gas propane Use proper hangers to support gas supply piping as per applicable codes The boiler must be disconnected or otherwise isolated from the gas supply during any pressure testing of the system at test pressures in excess of 1 2 psig Dissipate test pressure prior to reconnecting The boiler and its gas piping shall be leak tested before bei...

Page 37: ...f the connected pump is 2 3 amps If the connected pump has a rating higher than 1 0 amps an external isolation relay is required to protect the boilers controller A field supplied external safety device can be connected to the boiler by connecting the safety device in series with the boilers 120 VAC power supply Ensure the external safety device is rated to accept 120 VAC and the total load connec...

Page 38: ...to the boiler is interrupted 1 9 2 Power Quality and Electrical Protection In areas of unreliable power appropriate surge protectors and or power conditioning equipment should be installed to protect the boiler 1 9 3 Zone Valve and Zone Pump Connections Zoning can be accomplished with either zone pumps or zone valves In either case the controls and relays that may be required to accomplish this wi...

Page 39: ...e calculated based on 32 F 0 C If outdoor reset functionality and the Summer Shut Down feature is required then the Outdoor Sensor must be connected to X4 8 and X4 9 The Outdoor Sensor is a 12K ohm thermistor type sensor The sensor should be installed on the exterior of the building on the north side The sensor should be installed so that it is not effected by any heat sources from the building su...

Page 40: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 34 DC SERIES COMBI BOILERS DC 23 84 DC 29 106 DC 33 124 DC 33 160 Figure 35 Electrical Wiring Connections full page ladder diagram at back of this manual ...

Page 41: ...for domestic hot water using the boiler s internal domestic hot water tankless coil The boiler pump will operate for 10 seconds every 24 hours to help prevent pump from 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 can generate domestic hot water in several ways The DC series boiler can be us...

Page 42: ... 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 codes When adjusting settings double check that you are in the correct parameter INSTALLER INTERFACE 2 3 1 Appliance ON OFF The boiler can be switched on and off with the On Off button When the boiler is O...

Page 43: ...nstaller Menu press and hold the Service and Reset buttons together until a 0 appears in the main 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 To exit from the Installer Menu and save the changes press the Reset button Pressing the On Off button w...

Page 44: ...Temp 14 F 10 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 will run but the burner will not fire if Outdoor Temperature is above this setting 8 Internal Boiler Pump Post Purge 1 min Range 0 min to 15 min 9 External DHW Pump Post Purge 1 min Range 0 min to 15 min C Burner Modulation Ramp up with a Space Heating Demand 1 0 OFF 1 ON 2 Ope...

Page 45: ...g Delay min 0 min Range 0 15 min The Boiler will not respond to a Space Heating call for X min o Space Heating Delay after heating DHW 0 min Range 0 15 min The boiler will not respond to a call for heat after the tankless DHW call for heat has ended for X min o DHW ECO mode Learning Days 3 days Range 1 to 10 Number of days the ECO mode uses to learn the Tankless DHW usage habits Rolling counter P ...

Page 46: ...ank Aquastat or Sensor connected to X4 9 and X4 10 External Pump Terminals 4 5 6 120Vac 1Amp Max enabled with a call for DHW Internal Boiler Pump is enabled with a call for Space Heating Internal Boiler Pump is disabled with a call for Tankless DHW External DHW Pump is enabled with a call for Tankless DHW 5 0 DHW Storage Tank Sensor or Aquastat DC Models Tankless DHW with a Storage Tank Only Space...

Page 47: ...on This mode operates like the Comfort Mode but has the added advantage of learning when the domestic hot water is used During the low use periods the boilers heat exchanger is allowed to cool This mode is the most practical of the three options 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 w...

Page 48: ...y loop piping only The building s distribution piping system requires a dedicated pump or pumps to provide circulation 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...

Page 49: ... 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 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 Service Display 9 MAIN DI...

Page 50: ...INSTALLATION AND OPERATION INSTRUCTIONS 2 10 DC SERIES COMBI BOILERS DC 23 84 DC 29 106 DC 33 124 DC 33 160 PAGE INTENTIONALLY LEFT BLANK ...

Page 51: ...3 1 STARTUP AND COMMISSIONING DC SERIES COMBI BOILERS DC 23 84 DC 29 106 DC 33 124 DC 33 160 STARTUP AND COMMISSIONING 3 0 3 1 LIGHTING AND SHUTTING DOWN THE BOILER ...

Page 52: ...formation is displayed on the Main Display screen To restart boiler reset power COMMISSIONING The DC Series modulating boilers are factory calibrated to operate with natural gas at sea level This cap must not be tampered with 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: ...ion 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 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 NOTE Clock the gas meter to confirm full maxi...

Page 54: ...he gas valve harness plug from the gas valve 4 Select the correct Fuel Conversion Kit for your boiler from Table 10 5 Disconnect the nut at the gas valve outlet top of the gas valve and remove the orifice and O ring 6 Insert the correct orifice into the O ring and re install into the nut at the gas valve outlet top of the gas valve and tighten the nut 7 Restore gas supply by opening the gas contro...

Page 55: ...e Assembly Figure 37 Orifice and O ring WARNING Fan Outlet Orifice 25mm must be installed in the DC 23 84 model If the fan is being replaced the orifice must be reinstalled in the new fan WARNING Each DC series boiler is equipped with a Back Flow Valve installed at the outlet of the fan Inspect the Back Flow Valve annually ...

Page 56: ...he 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 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 loosel...

Page 57: ...sonable 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 requires cleaning every year In alternate years visually inspect burner through sight glass Ensure flame is stable and without excessive fluttering Normal flame pattern is evenly distributed over the burn...

Page 58: ...n 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 control will operate the boiler to pro...

Page 59: ...emicals or glycol solutions If the system employs plain water the boiler 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 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 sub...

Page 60: ...t 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 install the 2 hex nuts Tighten the 2 hex nuts with a wrench 3 Insert the Orifice and O ring between the gas valve outlet and the gas line to the fan Tighten the gas valve union nut with a wrench Ensure the g...

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

Page 62: ...e reading remove power to the boiler For the supply water and return water temperature sensors remove the wire leads by disconnecting their respective Molex connectors Place multi meter probes into sensor s male Molex connector socket Do not apply voltage to the sensor damage may result 12KΩ Temperature Sensors supplied with boiler See Table 14 for resistance values 5 2 Return water temperature se...

Page 63: ...essing the button The current system pressure will be displayed 2 Isolate the space heating circuit and reduce the water pressure The displayed water pressure should drop as the system water is being removed expansion tank isolated If the pressure is remaining steady then the pressure sensor may be block or faulty If it remains fixed drain boiler and replace sensor or dislodge any blocking debris ...

Page 64: ...drain valves open Disconnect the Molex connector at the sensor Remove the sensor by turning the nut counter clock wise 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 Series boilers are equipped with a domestic hot water temperature sensor The sensor is located...

Page 65: ...or Replace pressure sensor POLE Polarity detection fault Switch the Line and Neutral wire on the power supply Check grounding Check for high potential on Neutral wire Replace controller 5 3 2 Fault codes If the fault LED is flashing the controller has detected a fault A fault code will be displayed on the main display Once the fault has been corrected the burner controller can be restarted Press t...

Page 66: ...r load Check ignitor and ignition cable Check gas valve adjustment Check grounding of all parts of the installation Check combustion air supply and flue gas exhaust piping and terminations possible flue gas recirculation in the system 6 Flame detection fault Replace ignition cable ignitor cap Replace ignition module Replace controller 8 Incorrect fan speed Fan rubbing on casing Wiring between fan ...

Page 67: ... 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 Resonating POSSIBLE CAU...

Page 68: ...ignite 5 4 6 Indoor 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 2 3 Table of Programmable Parameters Check outdoor sensor and wiring for sh...

Page 69: ... setting for water circuit too low Adjust the hot water circuit depending on the desired temperature and system configuration See 2 3 4 Table of Programmable Parameters 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 or flush the exchanger DH...

Page 70: ...INSTALLATION AND OPERATION INSTRUCTIONS 5 10 DC SERIES COMBI BOILERS DC 23 84 DC 29 106 DC 33 124 DC 33 160 PAGE INTENTIONALLY LEFT BLANK ...

Page 71: ...6 1 DIAGRAMS DC SERIES COMBI BOILERS DC 23 84 DC 29 106 DC 33 124 DC 33 160 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS ...

Page 72: ...NSTALLATION AND OPERATION INSTRUCTIONS 6 2 DC SERIES COMBI BOILERS DC 23 84 DC 29 106 DC 33 124 DC 33 160 6 1 PARTS DIAGRAMS Diagram 6 1 1 Boiler assembly parts DC Series Modulating Boiler Parts assembly ...

Page 73: ...ES COMBI BOILERS DC 23 84 DC 29 106 DC 33 124 DC 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 ibcboiler com for more information ...

Page 74: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 DC SERIES COMBI BOILERS DC 23 84 DC 29 106 DC 33 124 DC 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 any glycol chemicals used _______________________________________ Air purge completed Relief Valve correctly installed and piped Relief valve try lever test performed Condensate trap filled Condensate...

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

Page 77: ...NOTES ...

Page 78: ... management system that serves the same 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 boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU h...

Page 79: ......

Page 80: ...IBC Technologies Inc 1445 Charles Street Vancouver BC Canada V5L 2S7 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 183 A R2 883967 September 2014 IBC Technologies Inc 2014 ...

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