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IBC HC Series, Installation And Operating Instructions Manual

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IBC HC Series Installation And Operating Instructions Manual Download Page 66

INSTALLATION AND OPERATION INSTRUCTIONS

5-10

HC SERIES BOILERS  

HC 13-50, HC 23-84, HC 29-106, HC 20-125, HC 33-160

5.4.8 Hot Water Does Not Reach Temperature (this section is used with the DC 

Series Boilers only)

POSSIBLE CAUSES

SOLUTION

DHW flow too high.

Adjust the inlet assembly, insert a flow restrictor.

Temperature 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. 

No heat transfer as a result of lime scale or 
fouling in the heat exchanger DHW side.

Descale or flush the exchanger DHW side.

Cold water temperature <5°C.

Summary of Contents for HC Series

Page 1: ...s 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...

Page 2: ...ief 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 HC Installation Operating Inst...

Page 3: ...low rate USgpm 9 9 10 11 11 Min boiler flow rate USgpm 2 2 3 3 3 Max Operating Pressure Space Heating Coil psig 43 5 43 5 43 5 43 5 43 5 Approved installation altitude ASL 12 000 ft 12 000 ft 12 000 f...

Page 4: ...INSTALLATION AND OPERATION INSTRUCTIONS 4 HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 20 125 HC 33 160 PAGE INTENTIONALLY LEFT BLANK...

Page 5: ...AL 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 A...

Page 6: ...ents 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...

Page 7: ...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 Schedule...

Page 8: ...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 lea...

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 K...

Page 10: ...f 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 to th...

Page 11: ...tly to the boilers 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 or Polypropylene PPs vent compo...

Page 12: ...ented 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 90 CPVC...

Page 13: ...ere 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 th...

Page 14: ...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 ROO...

Page 15: ...l 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...

Page 16: ...requirements 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 appro...

Page 17: ...he same plane of the building e g north facing wall Place the 2 groups of pipes at least 3 apart the closest intake and exhaust pipes shall be 36 or more apart Use same 12 minimum vertical separation...

Page 18: ...otherm 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 19600...

Page 19: ...tallation 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 single fam...

Page 20: ...lding 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...

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 abo...

Page 22: ...18 1 5 2 Condensate Trap Assembly Installation 1 Undo Drain Spout Compression Nut remove Drain Hose from Trap Drain Outlet Remove Upper Compression Nut and Washer and slide over Boiler Drain Outlet A...

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 d...

Page 24: ...ensate 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...

Page 25: ...se 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 gua...

Page 26: ...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 be uno...

Page 27: ...mperatures some pumps have a minimum water temperature rating above the low temperature potential of the boiler Following installation confirm actual performance by measuring T under high and low flow...

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 mainten...

Page 29: ...together without the use of an additional pump if the air handler is installed within close proximity of the boiler and with properly sized supply and return piping see figure 29a Propylene Glycol mix...

Page 30: ...an external boiler staging controller with dry contacts for each boiler These controllers are available from your local heating wholesaler Check valves are to be used in each boilers piping to preven...

Page 31: ...13 50 HC 23 84 HC 29 106 HC 20 125 HC 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...

Page 32: ...rallel piping 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 schemat...

Page 33: ...hutoff 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 must be isolated from the gas s...

Page 34: ...d 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 higher...

Page 35: ...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 boiler is interrupted NOTE A hot water boiler installed a...

Page 36: ...control available from your 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...

Page 37: ...1 31 INSTALLATION HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 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 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 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 20 125 HC 33 160 PAGE INTENTIONALLY LEFT BLANK...

Page 41: ...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 boiler is e...

Page 42: ...odes 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 corr...

Page 43: ...To alter this value simply press the Plus or the Minus buttons Adjusting the Domestic Hot Water Temperature Press the Space Heating DHW Toggle button a second time and the LED beside the will illumina...

Page 44: ...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 45: ...e 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 met...

Page 46: ...rget 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...

Page 47: ...3 1 STARTUP AND COMMISSIONING HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 20 125 HC 33 160 STARTUP AND COMMISSIONING 3 0 3 1 LIGHTING AND SHUTTING DOWN THE BOILER...

Page 48: ...Error information is displayed 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...

Page 49: ...s Pressing and holding for more than 2 seconds while in the Service Mode will display the Flame Current in DC microamps Expect approximately 9 8 A at High Fire 8 7 A at Low 3 With a combustion analyze...

Page 50: ...tructions 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 f...

Page 51: ...utlet 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 When converting a Natural Gas boiler to Propane the Back...

Page 52: ...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 hardness c...

Page 53: ...ble 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...

Page 54: ...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 co...

Page 55: ...ly 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 it by...

Page 56: ...enturi 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 t...

Page 57: ...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 provid...

Page 58: ...olex 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 Suppl...

Page 59: ...When the water pressure less than 8psi the boiler will restrict 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 TYP...

Page 60: ...ndensate 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 Outdoor...

Page 61: ...e 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 39 913 125 52...

Page 62: ...l 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 enabling the external DHW pump Pump failed...

Page 63: ...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 incor...

Page 64: ...N 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...

Page 65: ...sired 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 Wa...

Page 66: ...TION DHW flow too high Adjust the inlet assembly insert a flow restrictor Temperature setting for water circuit too low Adjust the hot water circuit depending on the desired temperature and system con...

Page 67: ...6 1 DIAGRAMS HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 20 125 HC 33 160 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS...

Page 68: ...ALLATION AND OPERATION INSTRUCTIONS 6 2 HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 20 125 HC 33 160 6 1 PARTS DIAGRAMS Diagram 6 1 1 Boiler assembly parts HC Series Modulating Boiler Parts assem...

Page 69: ...ORIFICE 725 NATURAL GAS DC HC 160 180 118 ORIFICE 330 PROPANE DC HC 50 180 095 ORIFICE 505 PROPANE DC HC 84 106 180 143 ORIFICE 460 PROPANE HC 125 180 096 ORIFICE 580 PROPANE DC HC 160 150 150 175 ORI...

Page 70: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 HC SERIES BOILERS HC 13 50 HC 23 84 HC 29 106 HC 20 125 HC 33 160 6 2 WIRING DIAGRAMS Diagram 6 2 1 Pictorial wiring diagram...

Page 71: ...followed and completed Section 3 of Installation and Operating Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner u...

Page 72: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Page 73: ...NOTES...

Page 74: ...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 75: ...CTOBER 2015 Addition of new model HC 20 125 R6 FEBRUARY 2016 Updated Parameters and Orifice tables R7 JULY 2016 New Propane Back Flow Flapper Revision to Exhaust Vent Material USA R8 FEBRUARY 2017 Del...

Page 76: ...C Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Toll Free 1 844 432 8422 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 185 A R9 88397709 June 2017 IBC Technologies Inc 201...

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