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Installation Manual - IBC Better Boilers

1. Control 120VAC Service Switch Module Terminal Strip by others LE e x2 W IN Power Igniter g 1 GL Supply e 5 2 M L External LY 3H BK 2 DHW Pump Gas Valve ek 12 3 G 1A Max BL 3 gt sil 2 BR 14 few 5 I BHK g Space Heating Circulator 5 n x x 1 5 3 9 x 2 2H BK 1 2 3 3H R 2 Blower Motor 5 5 5 4 4H 8L 4 5 0 0 915 4 gt gt 6 o o 5 S 9 2 2 ox mm gt o0 o a i GY gt H Room Thermostat yu I HI 2 2 2 with Dry Contacts yu BLH 7H Fe others R44 eH yu 5l 9H 5 Outdoor Sensor V 8 MOH n Aquastat or Y 18 al DHW Sensor cold closed Notes Original wire as supplied with the appliance must be replaced with type T wire or its equivalent The wiring for 120V field connections to the appliance shall have a minimum size of 14 AWG and a temperature rating of at least 194 F 90 C Wire Color Code Key 120V Wire Terminal Key BK Black L Incoming Supply L W White N Incoming Supply N G Green G Incoming Supply G BL Blue 1 Lp 1 max R Red 2 N O Orange 3 G V Violet Y Yellow 24V X4 Wire Terminal Key BR Brown X4 6 Thermostat GY Gray 4 7 Thermostat X4 8 Outdoor Sensor Wire Terminal Key X4 9 Outdoor Sensor 5 Factory Wiring X4 9 DHW Senso
2. INSERT TRAP HOOK INTO CABINET HOLE INSERT TRAP HOOK INTO SLOT ATTACH AND TIGHTEN DRAIN HOSE TO TRAP DRAIN OUTLET AND TIGHTEN HAND TIGHT Figure 18 Condensate trap installation It is the responsibility of the installing and or service Contractor to advise and instruct the end User in how to perform the Trap cleaning procedure and to advise that the Trap be checked at least every two months and cleaned as required INSTALLATION 1 5 3 Condensate Trap Assembly cleaning procedure 1 Turn off the power to the boiler and allow it to cool down Remove the trap from the boiler reverse the installation procedure above Remove the Trap Cleanout Assembly H from the Trap Body and clean and flush the debris out Re assemble trap components re fill trap and replace on boiler 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 per foot so condensate runs towards the drain Condensate traps should be checked every 2 months and cleaned and refilled as necessary Better Boilers 3 32 HOLE IN CAP Figure 19 Condensate trap disassembly for cleaning If condensates are to be discharged into building drain piping materials that are subject to corrosion a neutralization package
3. 31 G Pump 1A Max 1 Igniter Sensor 9 Space Heating Circulator Supply Sensor Space Heating Pressure Sensor Control Module HC series Ladder Wiring Diagram Control 120VAC Service Switch Module Terminal Strip by others x2 W INL Power Igniter S 1 mem Supply R 5 2H 8K MRE L External H 3H BK t 2 DHW Pump Gas Valve BK 121 Is 13 6 Max H3 gt HCR 9 141 lel w 5 D 7 o T BH eK 1 o Space Heating Circulator 5 im fe mi maia N X5 x3 E 1 tHW Eh DIIS m 2 2H BK 11 8 9 3 3H R 2 Blower Motor 5 9 5 5 4 4H BL 14 0 5 o o gt E w E a 5 45 c 3 a 2 X4 gt o o x X7 S 4 i GY gt 5 Room Thermostat yu E zISHT 777 7 with Dry Contacts ar ps 3 THT E by others Ba 8 am 5 9 Outdoor Sensor imo B Aquastat 7 11 oss quastat or Y H8 42 L 72 DHW Sensor o cold closed Notes Original wire as supplied with the appliance must be replaced with type T wire or its equivalent The wirin
4. Power conditioning equipment surge protectors APC or UPS devices may be required in areas where power quality is suspect Do not apply power to any connection point on the controllers terminal strips A potentially hazardous situation could occur which must be avoided to prevent possible serious injury or death The IBC control only recognizes a true dry contact closure as a call for heat Thermostats and other devices that use a Triac output cannot be used as a call for heat without the installation of an intervening relay with dry contacts to connect to the IBC terminal strip ELECTRICAL CONNECTIONS All Electrical wiring to the boiler including grounding must conform to local electrical codes and or National Electrical Code ANS NFPA No 70 latest edition or The Canadian Electrical Code C22 1 Part 1 If an external electrical source is utilized the boiler when installed must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 and or the Canadian Electrical Code Part I CSA C22 1 Electrical Code 1 8 1 120VAC Line Voltage Hook up Line voltage wiring is done within the field wiring box Refer to Section 6 2 Wiring Diagram on page 6 4 Connect the boiler to the grid power using separate fused circuit and on off switch within sight of the boiler Use 14
5. The boiler is equipped with a factory installed pump The pump is pre wired and will operate with any call for space heating and when heating an IBC indirect water heater The pump will not operate with a call for domestic hot water using the boiler s internal domestic hot water tankless coil The boiler pump will operate for 10 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 boiler is equipped with an electronic boiler controller which ignites the burner and continuously monitors the flame throughout each call for heat The control also displays the current operating conditions of the boiler and any error messages should a problem occur The boilers controller also provides frost protection When the boiler s heat exchanger becomes too low the burner switches on to keep the heat exchanger warm Please ensure that the condensate trap is protected from freezing The boiler must be installed indoors in a heated space A DANGER o Water temperature over 125 F 52 C can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded o See instruction manual before setting temperature at water heater o Feel water before bathing or showering o Temperature limiting valves a
6. Better Boilers HC Series Boilers HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 33 160 Natural Gas or Propane nm x WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapours and liquids 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 be performed by a qualified installer service agency or the gas supplier This Manual is also available in French contact IBC or visit our web site www ibcboiler com lt WO de ENERGY STAR o r 44 N 2 O Q 2 c lt 2 ef E a N lt C US www ibcboiler com Better Boilers If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life SAFETY CONSIDERATIONS Installation start up and servicing of IBC boilers must be done with due care and attention and should only be performed by competent quali
7. Ethylene glycol is toxic and may be prohibited for use by codes applicable to your installation location For environmental and toxicity reasons IBC recommends only using non toxic propylene glycol INSTALLATION HC SERIES BOILERS 1 6 2 Basic Heating Piping Arrangements PRIMARY SECONDARY PIPING BENEFITS AND INSTALLATION RULES 1 Good circulating water flow through the boiler irrespective of load or radiation System head 2 Allows flexible AT control in secondary loops 3 Adds to the system s thermal buffering to assist in handling small loads and temperature transition A Primary Secondary piping configuration requires an extra pump independant from any secondary load pumps The HC series modulating boiler includes the boiler Primary Pump installed inside the boiler cabinet and is pre wired The pumps volute is epoxy coated to allow compatibility with the non oxygen barrier tubing found in some older radiant heating systems For optimal performance place pumps on the supply side of secondary loops to facilitate air evacuation Use pumps with internal check valves to avoid ghost flows and thermal siphoning The HC series boilers are designed to be piped in a Primary Secondary piping arrangement In some cases the boiler can be piped in series with the heating load if the boilers pump is capable of providing the required flow and head the system requires For example a HC series boiler and an IBC Air Handler series
8. Figure 29a Air handler and direct domestic hot water concept drawing This drawing is only a simple schematic guide IBC HC Boiler Air Handler Thermostatic Tempering Valve Field Supplied Figure 29b Air handler and direct domestic hot water concept drawing This drawing is only a simple schematic guide INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers 1 7 This boiler model can burn either Natural gas or Propane A boiler configured for Propane can be converted to Natural gas with gas valve adjustments Refer to section 3 3 for further instruction If a boiler is to be converted from one fuel to another a conversion kit must be ordered prior to the conversion The conversion kit must be installed according to the detailed instructions supplied with the kit Failure to perform the required fuel conversion correctly can result in serious injury or death It is essential to check gas supply pressure to each boiler with a manometer or other high quality precision measuring device Pressure should be monitored before firing the boiler when the regulator is in a lock up condition and during operation throughout the boiler s full modulation range Pay special attention to retrofit situations where existing regulators may have an over sized orifice and or worn seats causing pressure creep and high lock up pressures OUTLET PRESSURE TEST PORT HIGH FIRE ADJUSTME
9. INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers Do not use automotive type ethylene or other types of automotive glycol antifreeze or undiluted antifreeze of any kind This may result in severe boiler damage It is the responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials Improper mixtures and chemical additives may cause damage to ferrous and non ferrous components as well as non metallic wetted components normally found in hydronic systems Ethylene glycol is toxic and may be prohibited for use by codes applicable to your installation location For environmental and toxicity reasons IBC recommends only using non toxic propylene glycol Installers should inquire of local water purveyors as to the suitability of their supply for use in hydronic heating systems If water quality is questionable a local water treatment expert must be consulted for testing assessment and if required treatment Alternatively water or hydronic fluid of known quality can be brought to the site Before testing the relief valve make certain the discharge pipe is properly connected to the valve outlet and arranged to contain and safely dispose of equipment discharge MAINTENANCE HC SERIES BOILERS 4 1 12 Boiler Treatment Check consistency of any boiler treatment used for appropriate mixture Chemical inhibitors a
10. Indirect Domestic Hot Water functions are available 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 The domestic hot water thermostat is adjusted it its lowest temperature position when shipped from the factory It s recommended to set the domestic hot water thermostat to 120 F 49 C as an initial setting and further adjust as required For energy efficient operation this setting should be set as low as practical for the consumer s needs BOILER SYSTEMS AND OPERATION HC SERIES BOILERS 2 3 2 PSI and Fahrenheit Bar and Celsius PSI and Fahrenheit are the default setting as shipped from the factory To change to Bar and Celsius simply press the 2 to toggle Fahrenheit and Celsius 2 3 3 Programing Mode There are 2 parameters available in the User Set Up Menu See 2 3 4 Table of Programmable Parameters The Controller has four levels User Menu Installer Menu code 15 a Master Installer Menu code 20 RF Menu code 30 future use USER MENU Adjusting the Space Heating Water Temperature To enter the User Menu simply hold down the Space Heating DHW Toggle 8 button for 2 seconds LED beside the will illuminate and the current maximum heating system water temperature will be displayed in the 4 digit display
11. This is repeated 4 times before a hard lock out occurs The Reset button it must be pressed to reset the controller and allow for another attempt 4 Once the burner is lit and flame has been proven the boiler operates as it is programmed Service Display 5 for Space Heating or 6 for Domestic Hot Water 5 Ifthe boiler reaches 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 pump will operate for an adjustable amount of time Service Display 0 7 Ifthe burner is on to maintain the heat exchanger temperature for DHW Comfort mode or for Freeze Protection mode Service Display 7 8 Ifthe burner is on for Frost Protection Service Display 9 MAIN SERVICE DESCRIPTION DISPLAY DISPLAY blank The boiler is OFF Press the On Off 5 button to turn on the boiler blank blank No Call for Heat Standby XXX 0 Boiler pump running pump post purge XXX Boiler water temperature reached target boiler pump is energized call for heat still present XXX 2 Self test When power is applied to the boiler the controller enters a self diagnostic mode for 5 seconds XXX 9 Fan Pre purge Inter purge and Post purge XXX 4 Trial for Ignition and Flame Proving XXX 5 Heating Space Heating XXX 6 Heating DHW XXX 7 Burner on for Comfort mode or Freeze Protection mode Table 8 Operating Display
12. loose fitting clothing gloves and eyes protection 3 Assure adequate ventilation 4 Wash with soap and water after contact 5 Wash potentially contaminated clothes separately from other laundry and rinse washing machine thoroughly 6 Discard used insulation in an air tight plastic bag NIOSH stated first aid e Eye contact Irrigate and wash immediately Breathing Provide fresh air HC SERIES BOILERS 4 1 6 Heat Exchanger During annual inspection with the heat exchanger cover removed examine the heat exchanger for signs of contamination and clean if necessary In areas of poor gas quality or contaminated combustion air there may be a buildup of black plaque typically sulfur Other fouling agents airborne dust debris and volatiles Clean the heat exchanger surface with a stiff plastic bristle brush only Refer to heat exchanger cover removal instructions in Section 3 5 1 for access to combustion chamber and heat exchanger Note that the safety warning regarding burner refractory on this page must be observed 4 1 7 Pump Check that the pump is on in normal space heating operation and that the water Delta T is reasonable for the heating application 4 1 8 Gas Piping Check for damage or leaks and repair as needed 4 1 9 Control Module e Check that boiler operation is consistent with the steps in Section 2 7 Sequence of Operation Check that water temperature targets and setpoint are satis
13. 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 Check that boiler is not in a safety lockout Ensure wiring is clean and secure Check that gas is reaching the unit Confirm water system is properly charged to 12 psig and pump is serviceable mem Better Boilers SUPPLY WATER TEMPERATURE SENSOR RETURN WATER TEMPERATURE SENSOR SN Return water temperature sensor TEMPERATURE F C RESISTANCE ELECTRONIC COMPONENTS This section details the method for troubleshooting the non standard electronic components on the boiler including the electronic water pressure sensor and the temperature sensors 5 2 1 Temperature Sensors The resistance of the temperature sensors varies inversely with temperature To test measure the temperature of the sensed environment and compare with the value derived from the measurement of the resistance obtained by connecting a good quality test meter capable of measuring up to 5 000 kQ 5 000 000Q at the controller end of the sensor lead To obtain a resistance 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 Pl
14. 170 023 HEAT EXCHANGER HC124 170 024 HEAT EXCHANGER HC160 250 687 GASKET H Ex FRONT PANEL HC50 DC HC84 250 688 GASKET H Ex FRONT PANEL DC HC106 250 689 GASKET H Ex FRONT PANEL DC HC124 160 180 114 BURNER 250 646 GASKET BURNER 250 627 GASKET FAN 180 122 ORIFICE FAN OUTLET DC HC84 ONLY 240 068 FAN 180 111 VENTURI 406 DC HC84 106 180 112 VENTURI 362 DC HC124 160 180 133 VENTURI 541 HC50 180 095 ORIFICE 505 NATURAL GAS DC HC84 106 180 096 ORIFICE 580 NATURAL GAS DC HC 124 160 180 119 ORIFICE 480 NATURAL GAS HC50 180 107 ORIFICE 650 PROPANE DC HC84 106 180 108 ORIFICE 725 PROPANE DC HC124 160 180 118 ORIFICE 330 PROPANE HC50 150 175 O RING 150 206 GASKET GAS VALVE INLET 180 097 GAS VALVE 240 069 GAS VALVE CABLE IGNITION MODULE 250 628 GAS LINE 250 634 GASKET PUMP 180 098 PUMP 250 631 RETURN PIPE 500 072 DOOR ASSEMBLY HC50 DC HC84 500 073 DOOR ASSEMBLY DC HC106 500 074 DOOR ASSEMBLY DC HC124 160 500 051 CONTROLLER ASSEMBLY DC HC84 106 124 500 053 CONTROLLER ASSEMBLY DC HC160 500 071 CONTROLLER ASSEMBLY HC50 190 123 CONDENSATE PIPE ASSEMBLY 190 124 SEAL COND PIPE TO BOTTOM PAN 180 100 BOTTOM PAN HEAT EXCHANGER 240 076 VENT HIGH LIMIT SWITCH 190 119 FITTING 1 2 NPT M 190 121 FITTING 1 NPT M 180 099 CONDENSATE TRAP SHORT 180 113 CONDENSATE TRAP LONG 250 638 CONDENSATE TRAP HOOK 240 072 WATER PRESSURE SENSOR 150 204 C CLIP WATER PRESSURE SENSOR 240 073 WATER TEMPERATURE SENSOR 150
15. Anticipated Snow Level USA Figure 7 Vertical Concentric Termination 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 The elevation of both pipes can be raised in periscope style after passing through the wall then configured as in Figure 8 to gain required clearance Better Boilers It is extremely important to maintain at least the minimum separation of exhaust vent termination from boiler intake air as illustrated in figures 5 8 and 13 Failure to do so can result in a dangerous situation where exhaust gasses are re ingested with combustion air Damage to the boiler can result from a failure to maintain these separations Improper installation will void the warranty In areas of high snowfall Users must be advised to check side wall vent and air intake terminations on a regular basis to ensure blockage does not occur HC SERIES BOILERS Use 45 elbow on the exhaust termination to launch the plume up and off the sidewall for protection of wall Bird screen of 1 4 stainless steel or plastic mesh eg IPEX System 636 drain grate for CPVC systems is
16. BOILERS 5 2 2 Fan Blower Operating power is provided by means of a separate 120 VAC connector at the upper right side of the fan white black green Control of the fan is provided via a four lead connector at the bottom of the fan 5 2 3 Thermostat Connections The boiler controller is designed to heat a single space heating load The load can consist of a single zone or several zones In either case the Call for Heat must be from a device providing a DRY CONTACT and connected to X4 6 and 4 7 The use of power robbing thermostats directly will cause the boiler to operate erratically If a power robbing thermostat is to be used it will have to be isolated through a relay 5 2 4 Water Pressure Sensor The water pressure is displayed in the main display when the pressure is low For example a system water pressure of 4 6psi would be displayed as 4 6P If the pressure is too low the controller will flash an error message in the main display by toggling between the actual pressure and LO Simply increase the system pressure to correct this error The water pressure in the heating system must be higher than 8psi for the boiler to reach maximum firing rate 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 1 Turn off the boiler at the controller by pressing the button current system p
17. Comfort and ECO Comfort Modes Section Reserved for the DC Series Boilers 2 5 ADDING DOMESTIC HOT WATER STORAGE 2 5 1 Tankless Domestic Hot Water with a Storage Tank Section Reserved for the DC Series Boilers BOILER SYSTEMS AND OPERATION Better Boilers 2 6 SPACE HEATING 2 6 1 Overview The HC series boiler is designed to be installed in a primary secondary type piping system The boiler comes complete with a factory installed boiler pump The pump is designed to circulate heating system water through the boiler s heat exchanger and primary 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 and offer an easy method of connecting the zoning system to the boiler Example piping and electrical drawing are available at www ibcboiler com The boiler supplies heat to the space using an Outdoor Reset Curve With an outdoor sensor installed the boiler will automatically adjust its space heating water temperature based on the parameters programmed into the boiler See Page 2 4 for parameter information If the Outdoor Sensor is not installed the boiler will use the temperature set
18. Remove the gas pressure manometer from the gas valve and close the test port Turn on the gas at the boilers gas shut off valve Ensure there are no gas leaks and reinstall the front cover Turn on the boiler by pressing the On Off button CO VALUE AT HIGH FIRE WITH THE FRONT COVER OPEN NATURAL GAS PROPANE value 10 1 11 5 Min value 9 196 9 8 CO VALUE AT LOW FIRE WITH THE FRONT COVER OPEN value value at value at Max 0 3 Min CO value 9 1 9 5 Table 10 CO Values and High and Low Fire Better Boilers 3 4 Operating any IBC boiler using a fuel other than the fuel listed on its rating plate is prohibited If the information in this section related to conversion to alternate fuels is not followed exactly a dangerous situation can result leading to fire or explosion which may cause property damage personal injury or loss of life PROPANE ORIFICE CHART ORIFICE SIZE MODEL NUMBER HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 33 160 NATURAL GAS ORIFICE CHART MODEL NUMBER HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 33 160 ORIFICE SIZE When converting a Natural Gas boiler to Propane the Back Flow Valve located above the outlet of the fan must be removed Failure to remove the Back Flow Valve when using Propane fuel may result in serious injury or death FUEL CONVERSION
19. To alter this value simply press the Plus or the Minus buttons Adjusting the Domestic Hot Water Temperature Press the Space Heating DHW Toggle 2 button a second time and the LED beside the 9 will illuminate and the current tankless domestic hot water temperature target is 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 it button Pressing the On Off 5 button will also exit the User Menu but will NOT save the changes INSTALLER MENU To enter the Installer Menu press and hold the Service gt and Reset Ur 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 a 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 Ur button Pressing the On Off button will also exit the Installer Menu but will NOT save the changes ADVANCED INSTALLER MENU To enter the Advanced Installer Menu press and hold the Service A and Reset 1 r buttons together until a 0 appears in the main display Press the Plus button repeatedly until 20 appears in the main display Press the Service y button to scroll through the parameters Press the Plus or Minus buttons to alter a parameters set
20. and Service Display Codes LIJ Better Boilers PAGE INTENTIONALLY LEFT BLANK 210 INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers HC SERIES BOILERS 3 0 STARTUP AND COMMISSIONING 3 1 LIGHTING AND SHUTTING DOWN THE BOILER FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot It is equipped with an ignition device which auto matically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the ap pliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from neighbor s phone Follow the gas suppli er s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to turn the gas control valve Never force using tools If the valve will not turn by hand don t try to repair it call a qualified service technician Force or attempt ed repair may result in a fire or explosion Do notuse this appliance if any part has been under water Immediately call a qualified ser vice technician to inspect the ap
21. boiler is shut down safely if the heat exchanger or the venting system becomes blocked The Vent Hi Limit is located at the bottom of the heat exchanger just to the left of the vent outlet and above the condensate tray For access remove the vent stack and the condensate tray 5 2 6 Domestic Hot Water Flow Sensor Section Reserved for the DC Series Boilers 5 2 7 Domestic Hot Water Sensor Section Reserved for the DC Series Boilers 5 2 8 Outdoor Sensor An Outdoor Sensor is supplied with each boiler The sensor should be mounted on the north side of the building away from any direct sunlight The sensor must also be kept away from any heat sources such as exhaust fan outlets dryer outlets mechanical room ventilation grills etc The Outdoor Sensor is a 12 sensor with resistance values as listed in Table 12 If the sensor is not connected to the boiler the boiler will operate at the Boiler Supply Temperature set in the User Set Up menu and operate as a Set Point load INSTALLATION AND OPERATION INSTRUCTIONS IT Better Boilers 5 2 9 DHW Tank Sensor The DC and HC Series boilers allow the use of a tank sensor for controlling the domestic hot water tank temperature IBC Indirect water heaters come with a 10 sensor An Aquastat may also be used If a field supplied domestic hot water sensor is used it must be a 10KO sensor matching the following table TEMPE
22. first fired to prevent exhaust fumes from entering room Never operate the boiler unless the trap is filled with water Failure to comply will result in severe personal injury or death Making adjustments to the IBC gas valve without a properly calibrated gas combustion analyzer and by persons who are not trained and experienced in its use is forbidden Failure to use an analyzer can result in an immediate hazard 3 3 PRIOR TO START UP 3 2 1 Pre Ignition Checks 1 Fill condensation trap Ensure venting system is complete and seal tested Confirm any common venting system at the installation site is isolated and independent of the HC boiler that any holes left from removal of a previous boiler have been sealed and that any resizing of the old flue has been done 2 Check water piping system is fully flushed and charged and that all air has been discharged through loosened bleed caps Use a minimum water pressure of 12 psig and confirm pressure relief valve is installed and safely drained Check to see that adequate gas pressure is present at the inlet gas supply test port With the boiler gas valve shut off open the test port using a small 1 8 or 3 mm flat screwdriver open the test port by turning its center screw 1 full turn counterclockwise Connect a manometer and open the gas control valve Requirements are minimum 5 w c and maximum 14 w c Check to ensure no gas leaks 4 Perform a final check of electric
23. in the User Set Up menu Boiler Supply Temperature to supply hot water to the space heating system INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers 2 1 The boiler is equipped with a Frost Protection feature This feature will operate the boiler pump and the burner to help protect the boiler from freezing If the boiler is in a hard lock out condition the burner will not operate however the boiler pump will operate IBC is not responsible for damages to the boiler and or related components nor property damages that may result from freezing conditions STARTUP AND COMMISSIONING SEQUENCE OF OPERATION The boiler will operate in a similar way for both a space heating and a domestic hot water call for heat When the boiler is powered up the controller enters a self diagnostic mode and displays 2 in the Service Display The Sequence of Operation is as follows 1 The boiler receives a call for heat from closing terminals X4 6 and X4 7 24 volts The boiler can also receive a call from Domestic Hot Water heating from the closing terminals X4 9 and X4 10 24 volts 12KQ sensor or aquastat 2 The boiler does a safety check and energizes the fan for a pre purge Service Display 3 3 Once the 5 second pre purge is compete the boiler enters a 5 second trial for ignition Service Display 4 If the boiler fails to ignite the boiler will compete a 5 second inter purge then another 5 second trial for ignition
24. must be used The water in the condensate neutralizer can cause severe burns to the skin Use extreme caution when servicing the condensate neutralizer Wear protective gloves and eyewear 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 HC SERIES BOILERS WARNING Risk of damage to appliance Ensure rainwater is prevented from entering air intake piping Condensate and rain water flow back Flue Gas Exhaust from venting system Condensate Drainage Free flow of condensate from venting systems and pressure vessel must be maintained at all times Trap and condensate drain piping must be accessible to allow regular inspection and cleaning HC Boiler WARNING Risk of damage to appliance All condensate discharge lines must be at a lower elevation than the condensate water line of the appliance Condensate Water Line Affix hose to drainage piping BL Factory supplied condensate trap Confirm slope Condensate hose and drain piping to slope toward drain be secured to prevent accidental disassembly Drain materials subject to corrosion must be protected by acid neutralization To Drain Figure 20 Condensate trap drainage MAINTENANCE DETAILS FOR NT 25 CONDENSATE NEUTRALIZATION TANK Refer to manufacturer s m
25. sets group all intake terminals together for a common penetration through a custom cap Alternatively place in the closest proximity achievable using commonly available pipe flashing Similarly group the exhaust pipes and place the 2 separate groups of pipes at least 3 apart the closest intake and exhaust pipes shall be 36 or more apart Use the same 24 minimum vertical separation for 2 pipe option For alternate group terminations contact the IBC Factory for written guidance DO NOT exhaust vent into a common venting system BIRD SCREEN RECOMMENDED FOR BOTH INLET AND EXHAUST PER LOCAL CODE 77272 Figure 5 Rooftop vent terminal configurations 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 taken to install the termination kit a minimum horizontal distance of 10 305cm away from any portion of the building and a minimum of 18 46cm above the roof line plus the anticipated snow line See Figure 6 and 7 on page 1 9 INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers INSTALLATION HC SERIES BOILERS 12 Minimum Clearance Figure 6 Vertical Concentric Termination Two Kits Minimum Clearances 18 Anticipated Snow Level Canada 12
26. should be running Replace the controller if 120V is not present when the pump should be running Burner not firing on space heating sensor S1 or S2 faulty Replace sensor S1 or S2 See fault code Burner does not ignite See burner does not ignite 5 4 6 Indoor Temperature Does Not Reach Desired Temperature POSSIBLE CAUSES Room thermostat setting incorrect SOLUTION 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 short circuit Water temperatures are set incorrectly Target water temperature is set higher than the maximum water temperature Pump not running correctly Pump setting is too low Variable speed pumps only Increase pump setting or replace the pump No circulation in the heating system Ensure the zone valves are open and there are no air blockages No heat transfer as a result of lime scale or fouling in the heat exchanger De scale or flush the heat exchanger on the space heating side 5 4 7 No Hot Water DHW this section is used with the DC Series Boilers only POSSIBLE CAUSES Flow sensor not functioning No voltage at the flow sensor 5V DC SOLUTION DHW flow lt 2 0 l min 5 GPM e Clean or replace
27. swimming pools or spas including air directly next to outdoor pools and spas The boiler shall not be exposed to water leaks from piping or components located overhead This includes condensation dropping from un insulated cold water lines overhead Ensure the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and when servicing pump replacement condensate trap servicing control replacement etc CODE REQUIREMENTS The HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 33 160 models were tested to and certified under CSA 4 9 2014 ANSI Z21 13 2014 The installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or Natural Gas and Propane Installation Code CAN CSA B149 1 The installation must also conform to the Canadian Electrical Code Part 1 CSA C22 2 No 1 and or the National Electrical Code ANSI NFPA 70 Where required by jurisdiction installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 If there is any conflict then the more stringent will apply LOCATION The HC series boilers are designed and approved for indoor installation wall with significant flexibility of location provided with the available venting options The boiler can be placed in an alcove basement cl
28. 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 hr or greater This boiler is equipped with a tankless coil not applicable to IBC s HC boilers US installers should contact IBC for any further information required REVISION HISTORY R1 JULY 2014 Initial release R2 SEPTEMBER 2014 New Model HC 13 50 Minor updates R3 MARCH 2015 Minor Updates Change DHW Tank Sensor to 10KO R4 AUGUST 2015 Address Update IBC Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 185 4 88397703 August 2015 IBC Technologies Inc 2015
29. the base of the boiler as shown in Figure 16 1 5 2 Condensate Trap Assembly Installation 1 Undo Drain Spout Compression Nut E remove Drain Hose G from Trap Drain Outlet F Place Vacuum breaker cap J over the Vacuum breaker opening and push firmly home Remove Upper Compression Nut and Washer C and slide over Boiler Drain Outlet A Insert one Trap Hook barb into the back mounting hole DRAIN SPOUT a COMPRESSION NI AND WASHER E VACUUM BREAKER CAP J P 6 9 Figure 16 Condensate Trap as shipped Figure 17 Condensate Trap disassembled UPPER COMPRESSION NUT AND WASHER C TRAP CLEANOUT ASSEMBLY NUT WASHER PLUG H 2 Fill Trap with water and slide Trap Body D over Boiler Drain Outlet A Swing Trap Hook B around the Drain Outlet F 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 C 3 Attach Drain Hose G and tighten Drain Spout Compression Nut E INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers V BOILER DRAIN OUTLET A HC SERIES BOILERS TRAP HOOK B e PULL THE TRAP DOWN TO SNUG IT TIGHT TO THE TRAP HOOK AND TIGHTEN THE TRAP NUT SLIDE TRAP OVER BOILER DRAIN OUTLET AND SWING THE TRAP HOOK OVER THE TRAP OUTLET SLIDE NUT AND WASHER OVER BOILER DRAIN OUTLET
30. valve harness plug from the gas valve Select the correct Fuel Conversion Kit for your boiler from Table 9 Disconnect the nut at the gas valve outlet top of the gas valve and remove the orifice and O ring 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 Restore gas supply by opening the gas control valve and using an approved leak detection solution soap test all joints Place the conversion labels associated with the new fuel onto the boiler at the positions indicated on the applicable conversion kit instruction sheet 9 Carefully follow the Prior to Start Up Section 3 2 and Commissioning Section 3 3 procedures on the preceeding pages 3 2 and 3 3 3 5 1 Gaining access to combustion chamber burner removal instructions DIS ASSEMBLY 1 Turn off the main power switch to the boiler 2 Turn off the gas supply valve to the boiler INSTALLATION AND OPERATION INSTRUCTIONS 19 Better Boilers A WARNING Fan Outlet Orifice 25mm must be installed in the DC puc de UT 23 84 model If the fan is being replaced the orifice must be reinstalled in the new M5 NUTS fan FAN GASKET FAN VENTURI ORIFICE AND O RING IGNITOR CABLE GAS VALVE O RING GAS VALVE CONNECTOR GAS LINE Figure 35 Blower and Gas Valve Assembly Figure 36 Orifice and O ring STARTUP AND COMMISSIONING Better B
31. 1 4 2 Exhaust Vent Material EXHAUST VENT MATERIAL CANADA Only CPVC or Polypropylene PPs vent component systems approved under ULC S636 Standard for Type BH Gas Venting Systems or stainless steel Type BH venting systems are to be used Permitted PPs materials comprise Single Wall Rigid pipe and fittings Ensure compliance with exhaust temperature limitations for the respective materials which typically are ULC S636 CPVC 90 C 194 F e 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 allow this option Ensure appropriate transition glue is used The installer is responsible to ensure that sufficient temperature loss is allowed for in the CPVC section to fall below the 65 C 149 F upper limit for PVC taking into account the highest possible ambient temperature in the area of vent travel e g boiler room attic and or chase EXHAUST VENT MATERIAL USA IBC recommends that only CPVC or PPs vent component systems approved under UL1738 Standard for Venting Sustens for Gas Burning Appliances Categories II Ill and IV ULC S636 Standard for Type BH Gas Venting Systems or stainless steel Type BH venting systems are to be used but many local jurisdictions in the USA s
32. 221 CLIP WATER TEMPERATURE SENSOR 250 632 SUPPLY PIPE 250 635 GASKET SUPPLY PIPE 250 673 EXHAUST DUCT INTERNAL HC50 DC HC84 250 674 EXHAUST DUCT INTERNAL DC HC106 250 675 EXHAUST DUCT INTERNAL DC HC124 160 250 636 EXHAUST DUCT 250 637 INTAKE DUCT A 2 m 2 2 2a 23 A 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 DIAGRAMS EIN 6 2 WIRING DIAGRAMS Better Boilers HC series Schematic Wiring Diagram 120 VAC Terminal Strip Service Switch Room Thermostat by others with Dry Contacts Outdoor Aquastat DHW by others Sensor Sensor ll External DHW 1 1 1 Igniter Space Heating Se Circulator Supply Sensor 721314 x2 Space Heating Pressure Sensor Control Module HC series Ladder Wiring Diagram
33. Boilers Venting condensate drainage and combustion air systems for all IBC boilers must be installed in compliance with all applicable codes and the instructions of their respective Installation Manuals Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes Failure to comply will result in severe personal injury or death It is not recommended to use concentric venting systems in climates where the outdoor design temperature is below 5 F 15 C Possible blockage of the flue outlet with freezing condensation due to the reduce flue gas temperatures Concentric vertical and horizontal terminations are approved as listed in this manual The minimum wall thickness for venting is 1 and the maximum wall thickness for venting is 14 HC SERIES BOILERS All venting must be installed in accordance with the requirements of the jurisdiction having authority in Canada Part 8 Venting Systems of the B149 1 10 Code and any other local building codes are to be followed In the USA the National Fuel Gas Code ANSI 223 1 latest edition prevails Where there is a discrepancy between the installation instructions below and the code requirements the more stringent shall apply Provisions for combustion and ventilation air in accordance with the section Air for Combustion and Ventilation of the National F
34. Chloride is to be less than 125 mg l e Iron is to be less than 0 3 mg l Culess than 0 1 mg l e Conductivity is to be less than 400p S cm at 25 C Hardness is to be 7 Grains or less IMPORTANT Ensure that these limits are acceptable for the other water side components in the system HC SERIES BOILERS a b fill station with isolation valve closed or fill tank b gt Closely Spaced Tees to avoid induced flow each set of tees should be installed in a straight length of pipe and a minimum of 6 pipe diameters from any elbow or other component that may create turbulent flow Tees should be as close together as possible maximum four pipe diameters apart and there should be no restrictions between the fittings that would result in a pressure drop Primary loop circulator built into P d boiler IBC HC Boiler Heat Migration on secondary loops that extend vertically to a load that that is above the primary loop steps must be taken such as fabricating thermal trap the piping minimum 18 46cm drop to prevent thermal siphoning and heat migration to the load when there is no demand for heat to that loop Alternatively use check valves on both supply and return of secondary piping VUDUTURU 8 T Figure 25 Basic Primary Secondary piping with closely spaced tees concept concept drawing This drawing is only a simple schematic guide We recommend water flow a
35. EQUIVALENT LENGTH Schedule 40 or PPs Allowances are for each side separately 2 35 3 120 2 or 3 90 Long Sweep Vent Elbow Allow 5 equivalent feet 2 or 3 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 35 actual feet Table 4 Maximum intake piping length INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers INSTALLATION HC SERIES BOILERS 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 stainless steel fitting on the top right side of the boiler and run horizontally or vertically to the outdoors Bird screen of 1 4 stainless steel or plastic mesh eg IPEX System 636 drain grate for CPVC systems is useful to guard against foreign objects 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 the HC series boilers 1 4 10 Closet Installations For installations in a c
36. F200 be employed to refill and pressurize 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 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 Section Reserved for the DC Series Boilers Better Boilers When servicing or replacing the fan the following parts must be moved from the old fan to the new fan Venturi e Back Flow Valve Fan Outlet Orifice HC 23 84 model only Failure to relocate these parts to the new fan may cause an immediately hazardous situation which must be avoided in order to prevent serious injury or death HC SERIES BOILERS 4 1 15 Fan and gas valve removal instructions Turn off the power and the gas supply to the boiler Remove the front cover and allow the boiler to cool down Disconnect the 2 electrical plugs attached to the fan Loosen the union nut at the top of the gas valve Carefully remove the Orifice and O ring and keep in a safe place for re installation later Ensure you protect the gas valve outlet from dust and debris 5 Remove the 2 hex nuts connecting the fan to the burner housing and carefully remove the fan You will find a gasket attached to the fan outlet as well as an internal check valve Keep these items in a sa
37. IES BOILERS 1 8 4 Thermostat Sensor Wiring A Thermostat from a single zone heating system can be connected directly to the controller s terminals X4 6 and X4 7 Do not apply power to the X4 terminal strip The Outdoor Sensor is not required for the boiler to operate If the outdoor sensor is not connected the boiler will assume that the outdoor temperature is 32 F 0 C and operate at a target water temperature 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 such as a dryer or exhaust fan outlet relief air or combustion air grill above a window or door or mounted directly under a deck or soffit overhang DHW Aquastat or 10KO sensor can be connected to the controller s terminals X4 9 and X4 10 Do not apply power to the X4 terminal strip INSTALLATION AND OPERATION INSTRUCTIONS LIJ Better Boilers HC series Schematic Wiring Diagram 120 VAC Service Switch Room Thermostat Terminal Strip by others with Dry Contacts Outdoor Aquastat DHW L seg P by others Sensor Sensor NH Power Gl Supply I 11220 Extemal DHW
38. MS 5 nes nya y b des beds 6 2 6 2 WIRING 8 6 4 INSTALLATION AND OPERATING INSTRUCTIONS LIJ Better Boilers The Installer must carefully read this manual to ensure that all installation details can be adhered to Special attention is to be paid to clearances and access vent travel and termination gas supply condensate removal and combustion air supply y DANGER The Installer should do a pre installation check the to ensure that the following precautions can be observed Should overheating occur e The boiler should be installed in areas where the combustion air source is or the gas supply fails to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the not subject to chemical fouling or agricultural vapours Exposure to corrosive chemical fumes such as chlorinated and or fluorinated hydrocarbons can reduce the life of a boiler Cleaners bleaches air fresheners refrigerants aerosol propellants dry cleaning fluids de greasers and paint removers all contain vapours which can form corrosive acid compounds when burned in a gas flame Airborne chlorides such as those released with the use of laundry appliance detergents are also to be avoided The boiler should be located where water leakage will not result in damage to the area If a location such as this cannot be found a suitable
39. NSTALLATION AND OPERATION INSTRUCTIONS Better Boilers Check the rating plate of the boiler to ensure it is configured for the fuel you are using If the fuel is incorrect for the appliance a conversion kit must be ordered from IBC and the gas valve adjusted accordingly Failure to perform the required fuel conversion can result in an immediate hazard OUTLET PRESSURE TEST PORT HIGH FIRE ADJUSTMENT LOW FIRE ADJUSTMENT INLET GAS SUPPLY PRESSURE TEST PORT Gas Valve Adjust FLUE GAS TEST PORT Flue gas test port plug STARTUP AND COMMISSIONING HC SERIES BOILERS The gas valve will automatically de rate the maximum input in accordance with the density altitude by approximately 2 per 1 000 above sea level The gas valve s zero governor will ensure that the gas air mixture is not be affected at altitude To verify the proper operation of the gas valve in the field the following procedure can be carried out by a qualified technician diagrams on this page 1 Turn off the boilers gas shut off valve With a small 1 8 or 3 mm flat screwdriver open the inlet gas supply pressure test port by turning its center screw 1 full turn counterclockwise Attach a manometer to the pressure test port and turn on gas to appliance Static manometer reading should be ideally 7 w c for Natural Gas and 11 w c for Propane Minimum and maximum static pressure should be between 7 and 14 w c Monitor pre
40. NT LOW FIRE ADJUSTMENT UU INLET GAS SUPPLY PRESSURE TEST PORT GAS PIPING The boiler should normally have an inlet gas pressure of at least 7 0 w c for natural gas and 11 w c for propane gas For either fuel the inlet pressure shall be no greater than 14 0 w c Confirm this pressure range is available with your local gas supplier The inlet gas connection of the boiler s gas valve is 1 2 NPT male Adequate gas supply piping shall be provided with no smaller than 1 2 Iron Pipe Size e g Iron Pipe Size IPS and using a 1 w c pressure drop in accordance with the following chart MODEL 1 2 IPS 3 4 IPS 1 IPS HC Series Natural Gas 20 70 200 HC Series Propane 50 200 600 Table 6 Maximum Pipe Length ft HC series 33 160 boiler Gas piping must have a sediment trap ahead of the boiler s gas valve see Figure 31 A manual shutoff valve must be located outside the boiler in accordance with local codes standards All threaded joints in gas piping should be made with an approved 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 being placed into opera
41. ON 2 1 24 GENERAL ia be E one EROR HR Re Eo 2 1 2 2 CONTROL reed redeo m esed Dod Ber asd eda 2 2 2 3 INSTALL ER INTERFACE 2 ca serer tekn tona cae e t ena ios 2 2 2 4 TANKLESS DOMESTIC WATER MODES 2 7 2 5 ADDING DOMESTIC HOT WATER 2 7 2 6 SPAGE HEATING 2c2cunccneavanack x eg 2 8 2 7 SEQUENCE OF 2 9 3 0 STARTUP AND COMMISSIONING 3 1 3 1 LIGHTING AND SHUTTING DOWN THE BOILER 3 1 3 2 PRIOR TO STARTUP s ese sok tract o er remo eod ac eae tera ena d 3 2 3 9 COMMISSIONING ecc iier Decano Ped aute due deret deas 3 2 34 FUEL CONVERSION 2 Ra etx decade HR baud ren CE de dara dd 3 4 40 MAINTENANCE 0 Pu ead ea Das ac o ERR S 4 1 4 1 BOILER MAINTENANQGE 2xae x eget d LER Ra 4 1 5 0 TROUBLESHOOTING xri prr mmn sme en 5 1 5 17 PRELIMINARY CHECKS naa tinpe eae aks ae ree a Ba ac das 5 1 5 2 ELECTRONIC 5 5 2 5 3 WARNINGS AND 8 5 5 5 4 OTHER FAULIS esc ae cin ec cui ex GR eee e aR a bis 5 7 6 0 8 6 1 6 1 PARTS DIAGRA
42. ON AND OPERATION INSTRUCTIONS Better Boilers SPECIFICATIONS SPECIFICATION CSA Input Natural Gas or Propane MBH HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 33 160 13 5 51 28 5 106 HC SERIES BOILERS CSA Input Natural Gas or Propane KW CSA Output MBH 3 95 14 94 12 4 45 4 8 4 31 0 CSA Output KW 3 64 13 3 A F U E 94 Min Gas Pressure Nat Gas Propane inch 5 W C Max Gas Pressure Nat Gas or Propane inch 14 14 14 w c Power 120Vac 60Hz Watts full fire with 126 126 128 internal pump Weight empty Ibs Kg Pressure Vessel water content USG Liters 85 39 85 39 85 39 0 37 1 4 0 37 1 4 0 37 1 4 Max boiler flow rate USgpm 9 10 Min boiler flow rate USgpm D Max Operating Pressure Space Heating Coil psig Approved installation altitude ASL 12 000 ft 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 32 0 Ambient Temperature High F C 122 50 122 50 122 50 122 50 122 50 Max relative humidity non condensing 90 90 90 90 90 15 20 15 20 15 20 15 20 15 20 water Temperature Space Heating F C 194 90 194 90 194 90 194 90 194 90 Max equivalent vent length 3 each side 120 120 120 120 120 Max equivalent vent length 2 each side 35 35 35 35 35 Natural Gas boilers require a Propane conversion kit see page 3 2 Table 9 to
43. OTING 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
44. RATION INSTRUCTIONS Better Boilers Close fill valve after any addition of water to the system to reduce risk of water escapement Application drawings can be downloaded from our web site www ibcboiler com The boiler when used in connection with a refrigeration system must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle Ensure the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and when servicing pump replacement condensate trap servicing control replacement etc INSTALLATION HC SERIES BOILERS Isolation valve between boiler and relief valve not permitted Microbubble air eliminators are best installed where the fluid is at highest temperature and lowest pressure Expansion tank connection point of no pressure change should be on the suction side of the circulator with minimal pressure drop between De fill station with isolation valve closed or fill tank Primary HC Boiler loop circulator buil
45. RATURE RESISTANCE TEMPERATURE RESISTANCE p AG Q F C Q 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 18 13 474 165 74 1 538 70 21 11 883 170 77 1 403 75 24 10 501 175 79 1 281 80 27 9 299 180 82 1 172 85 29 8 250 185 85 1 073 90 32 7 334 190 88 983 95 35 6 532 195 91 903 Temperature Sensor resistance values TROUBLESHOOTING 29 Better Boilers 5 3 WARNINGS AND FAULTS 5 3 1 Warning Codes During operation the controller can detect unusual situations and can take action to avoid damage to the heat exchanger or other unsafe operations During these situations the controller will limit the temperature and power output of the burner or temporarily disable operation entirely These warnings are shown flashing and visible on the main display and only displayed when an unusual reading is currently detected MAIN DISPLAY DISPLAY FAULT POSSIBLE SOLUTION Flue gas temperature approaching limit Supply water temperature too high Ambient temperature too high Check positioning of flue gas sensor Heat exchanger front panel loose check bolt torque Check heat exchanger for contamination or debris Replace flue gas temperature sen
46. RIES BOILERS POSSIBLE SOLUTION Air in heating system Bleed the system of any remaining air Check the positioning of S1 Check wiring for break Replace S1 Check the positioning of S2 Check wiring for break Replace S2 Sensor fault after self check Replace S1 and or S2 Temperature too high Air in system Bleed the system of any remaining air Pump not running check and or replace the pump Insufficient flow in installation radiators closed 51 and S2 interchanged No flame signal Check wiring harness Replace S1 or S2 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 Poor flame signal Condensate drain blocked Gas supply pressure too low or drooping under 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 Flame detection fault Replace ignition cable ignitor cap Replace ignition module Replace controller Incorrect fan speed Fan rubbing on casing Wiring between fan and casing Check wiring for poor wire contact Replace fan Replace controller Flue Gas Temperature Sensor Open Lockout Condition Inspect heat exchanger for fouling and clean as required C
47. The HC Series modulating boiler is factory fire tested to operate with natural gas The rating plate will be marked to indicate which fuel the particular boiler has been set up with Firing a boiler with a fuel other than what is listed on the rating plate is prohibited unless the following conversion procedure is completed by a qualified technician Refer to the preceeding section 3 3 COMMISSIONING The Low Fire Zero Offset valve adjustment cap on the gas valve has been factory set This cap must not be tampered with The Zero offset screw is not to be adjusted in the field Fuel conversion requires hardware adjustments Orifice Replacement as well as measurement and possible tuning of the gas air mixture Detailed instructions including parts and labeling are found in Fuel Conversion kits Refer to Table 9 for the correct kit number CO VALUE AT HIGH FIRE WITH THE FRONT COVER OPEN NATURAL GAS PROPANE Max CO value 10 1 11 5 Min CO value 9 196 9 8 CO VALUE AT LOW FIRE WITH THE FRONT COVER OPEN Max CO value value at Max Min CO value 9 196 Table 11 CO Values and High and Low Fire value at Max 0 396 9 596 The following procedure must be carried out by a qualified technician 1 Ensure the fuel conversion instructions supplied with the fuel conversion kit are read understood and followed carefully Ensure that the gas supply is turned off at the gas control valve Disconnect the gas
48. ace multi meter probes into sensor s male Molex connector socket Do not apply voltage to the sensor damage may result 12KQ Temperature Sensors supplied with boiler See Table 12 for resistance values SENSOR TYPE NTC 12 PURPOSE Supply Water Temperature LOCATION Upper Left of Heat Exchanger NTC 12KQ Return Water Temperature Lower Left of Heat Exchanger NTC 12KQ NTC 10KQ Domestic Hot Water Hot Water Tank DHW Supply Pipe External Water Heater NTC 12KQ Outdoor Sensor Outdoors North side NTC 12KQ Flue Gas Temperature Bottom of Heat Exchanger at Flue outlet Water Pressure Temperature and Pressure Sensors TEMPERATURE F C RESISTANCE F C TEMPERATURE Heating Supply Pipe RESISTANCE 5F 15C 25C 149F 65C 14F 10C 86F 30C 158F 70C 23F 5C 95F 35C 167F 75C 32F 0C 104F 40C 176F 80C 41F 5C 113F 45C 185F 85C 50F 10C 122F 50C 194F 90C 59F 15C 131F 55C 203F 95C 68F 20C 140F 60C 212F 100C Table 12 Temperature Sensor Resistance Values INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers FAN POWER FAN CONTROL PLUG Fan Power and Control Plugs SPACE HEATING WATER PRESSURE SENSOR Water Pressure Sensor TROUBLESHOOTING HC SERIES
49. aintenance instructions for other makes and models of condensate neutralization tanks WARNING Risk of injury Tank fluid can be highly acidic Do not use hands to stir material WARNING Risk of damage to appliance Neutralization tank inlet and discharge must be at a lower elevation than the condensate water line of the appliance NOTE Access to the discharge before the drain is necessary for proper maintenance in order to check the effectiveness of the neutralizing agent A simple pH test should be performed annually to ensure neutralizing agent is still effective If pH falls below 6 5 the neutralizing material should be replaced The agent limestone chips with a minimum calcium carbonate content of 85 can be purchased from a local supplier HC Boiler Condensate Water Line Unions for ease of maintenance ship with NT 25 1 FPT 1 FPT Commercial sized NT 25 neutralization tank shown see your plumbing wholesaler for residential sized models E Figure 21 Condensate neutralization tank INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers INSTALLATION 1 6 WATER PIPING SPACE HEATING 1 6 1 General Piping Considerations The HC series boilers include a factory installed integral Grundfos UPS 15 58 heating pump The pump is designed to provide adequate flow through the boiler and near boiler piping The pump is pre wired and factory set to speed 3 HC Boiler Heating Supply Heat
50. al wiring and provide power to the boiler to initialize operation 3 2 2 Test Ignition Safety Shutoff With the boiler in operation test the ignition system safety shutoff device by shutting the manual gas valve immediately outside the boiler case Ensure boiler has shut off and the appropriate 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 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 required however no mixture adjustment shall be performed unless done by a qualified technician using properly functioning and calibrated combustion analyzing equipment This boiler model can burn either Natural gas or Propane if equipped with the correct specified orifice Examine the rating plate of the boiler to ensure it is configured for the fuel you are using If the boiler is to be converted from Natural Gas to Propane or from Propane to Natural Gas a Fuel Conversion Kit must be installed The correct Fuel Conversion Kit part number can be found in Table 9 MODEL NUMBER NATURAL GAS PROPANE TO TO PROPANE NATURAL GAS HC 13 50 HC 23 84 HC 29 106 HC 33 124 HC 33 160 Table 9 Fuel Conversion Kits I
51. ance INSTALLATION HC SERIES BOILERS DISTANCE FROM RECOMMENDED DISTANCE COMBUSTIBLE FOR INSTALLATION AND SURFACES SERVICE Front 24 Rear 0 6 labels may be difficult to read with reduced clearance SURFACE Left Side 6 labels may be difficult to read with Right Side reduced clearance Top 24 Bottom 24 Table 2 Clearance from boiler cabinet A minimum distance below the boiler of 10 is required to provide clearance for the supplied condensation trap assembly More clearance will typically be required to accommodate associated water and gas piping MOUNT BRACKET TO WALL HOOK BOILER OVER TOP 1 4 FLAT WASHERS MINIMUM OF 2 SCREWS USE 1 4 x 2 1 2 LAG SCREWS WITH FLAT WASHERS INTO STUDS FOR METAL MOUNTING SYSTEM USE 1 4 BOLTS WITH FLAT WASHERS MINIMUM OF 2 SCREWS Figure 2 Wall mounting of boiler EXHAUST VENTING AND AIR INTAKE It is important to carefully plan the installation to ensure the appropriate vent materials travel and termination decisions are incorporated Specific attention is warranted to manage the impact of the steam plume normally experienced at the exhaust terminal of a condensing boiler Generally intake and exhaust pipes should terminate at a rooftop or sterile wall location to maximize customer satisfaction Keep exhaust plumes well away from all building air intakes including those of neighbouring properties Better
52. aterial exposed to outdoor weather follow the venting suppliers recommendations on UV protection Combustion air piping is inserted directly into the 3 female stainless steel fitting on the right see Section 1 4 7 Venting shall be supported in accordance with applicable code Manufacturers of stainless steel Type BH venting systems must submit their approved transition fitting to IBC for evaluation and written approval 1 4 3 Vent Travel CPVC or PPs Rigid Single Wall piping is the standard venting option with this the HC Series boilers for example 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 90 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 245 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 EXHAUST PIPE SIZE FITTINGS MAXIMUM EQUIVALENT LENGTH Schedule 40 CPVC or PPs Allowances are for each side separately 2 35 3 2 or 3 90 Long Sweep Vent Elbow 120 Allow 5 e
53. be ordered separately if converting a Natural Gas boiler to Propane Propane LP boilers require a Natural Gas conversion kit see page 3 2 Table 9 to be ordered separately if converting a Propane boiler to Natural Gas Min water Temperature Space Heating F C T boilers are shipped with 30 psig pressure relief valve INSTALLATION AND OPERATING INSTRUCTIONS Better Boilers HC SERIES BOILERS DANGER o Water temperature over 125 F 52 C can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering o Temperature limiting valves are available see manual WATER HEATER INSTALLATION GUIDELINES WARNING o This boiler must be installed in accordance with local codes if any if not follow the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 as applicable o Failure to correctly install and operate this appliance can result in severe personal injury or death o 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 Refer to the Boiler User s Manual before operating relief valve o The water heater i
54. ble of supporting the combined weight of the boiler and piping assembly components Other factors affecting potential mounting sites Ensure minimum clearance requirements for combustible materials see Table 2 are satisfied Minimum 24 clearance at the front and 10 above is recommended for adequate servicing Check local codes for additional access and service clearance requirements At a new construction site or during renovations action must be taken to protect the boiler from drywall dust or other construction related contaminants combustion air should be drawn from a CLEAN source e g outdoors and the boiler should be isolated from interior dust sources INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers Exposed water piping and associated components relief valves circulators etc should not be in contact with combustible materials Check local codes for required clearances and or provide adequate insulation DO NOT MOUNT THIS BOILER TO HOLLOW WALL STRUCTURES The combined weight of the boiler its water contents and associated piping components can exceed 150 pounds Fasteners must be rated for this strain and must be firmly anchored into solid material that will support this weight Installers are to take all necessary precautions to avoid injury during the installation of this boiler 1 4 Do not common vent the HC modulating series boilers with any other existing or new appli
55. c 1Amp Max enabled with a call for DHW Internal Boiler Pump is enabled with a call for Space Heating nternal Boiler Pump is disabled with a call for Tankless DHW External DHW Pump is enabled with a call for Tankless DHW 0 DHW Storage Tank Sensor or Aquastat DC Models Tankless DHW with a Storage Tank Only DHW must be turned on by pressing the Tap twice Bottom LED must be ON e Space Heating is disabled Aquastat or Sensor connected to X4 9 and X4 10 External Pump Terminals 4 5 6 120Vac 1Amp Max enabled with call for DHW e Internal Boiler Pump disabled Internal Boiler Pump is disabled with a call for Tankless DHW 0 Tankless DHW 1 Indirect DHW Tank Sensor or Aquastat 2 Space Heating DC Models Space Heating Indirect DHW Tank Tankless DHW e External Pump Terminals 4 5 6 120Vac 1Amp Max enabled with a call for DHW Internal Boiler Pump is enabled for both Space Heating and for Indirect DHW nternal Boiler Pump is disabled with a call for Tankless DHW 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 INSTALLATION AND OPERATION INSTRUCTIONS LIJ Better Boilers 2 4 TANKLESS DOMESTIC HOT WATER MODES 2 4 1 Tankless Domestic Hot Water Standard
56. can be installed together with out the use of an additional pump if the air handler is installed with in close proximity of the boiler and with properly sized supply and return piping Propylene Glycol mixtures of 2596 5096 are acceptable for use with in the boiler and piping system In general the use of propylene glycol will reduce the heating capacity of the heating system and increases the pump head required for 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 3 way mixing valve can be placed at the entrance to the cool load this will also provide floor protection This will permit immediate circulation of mixed flow into the cool loop See separate publication Application Notes for more detail available at www ibcboiler com or from your IBC Representative Always ensure that loads sensitive to high temperatures e g radiant floor are protected using appropriate means such as a manual mixing valve or an aquastat set to130 F for example wired in series with the boilers 120 VAC power supply or connect to the X4 6 and X4 7 terminals on the boilers controller Better Boilers The piping drawings in this manual are simple schematic guides to a successful installation There are many necessary components not shown and details such as thermal traps are left out so t
57. cts for each boiler 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 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 INSTALLATION AND OPERATION INSTRUCTIONS 29 Better Boilers External Controller or Relays operates space heating pumps and sends enable signal to boiler IBC HC Boiler Optional E Sep SB SiN Thermostatic g Valve n Se UU of Figure 27 Typical two temperature space heating piping concept with direct domestic hot water concept drawing This drawing is only a simple schematic guide External Controller or Relays operates load pumps and sends enable Priority Relay Box signal to boiler switched by boiler f cad Optional HC Series B lt Domestic Hot Water Cold Thermostatic Tempering Valve recommended 7 4 aN 2 Thermostatic Mixing Valve Figure 28 Typical two temperature space heating piping concept with indirect domestic hot water concept drawing This drawing is only a simple schematic guide INSTALLATION ELS LIJ Better Boilers IBC HC Boiler Air Handler
58. cycling when the heating temperature load is smaller than the min firing rate P Heat Exchanger Size Reference Model Dependent HC 13 50 HC 23 84 24 HC 29 106 30 HC 33 124 36 HC 33 160 36 PARAMETER 1 SETTINGS LOAD PRIORITY 0 HIGHEST 0 Tankless DHW 1 Space Heating PARAMETER NUMBER 1 DETAILED DESCRIPTION DC Models Both Space Heating and Tankless DHW Internal Boiler Pump is enabled with a call for Space Heating Internal Boiler Pump is disabled with a call for Tankless DHW 0 Indirect DHW Tank Sensor or Aquastat 1 Space Heating HC Models Space Heating and Indirect DHW Tank DHW must be turned on by pressing the Tap twice Bottom LED must be ON Aquastat or Sensor connected to X4 9 and X4 10 Internal Boiler Pump is enabled for both Space Heating and for DHW heating External Pump Terminals 4 5 6 120Vac 1Amp Max enabled with call for DHW 0 Tankless DHW 0 Space Heating 0 DHW Storage Tank Sensor or Aquastat 1 Space Heating DC Models Tankless DHW Only DHW only Space Heating Disabled Internal Pump disabled HC Models Space Heating Only Internal Boiler Pump is enabled with a call for Space Heating DC Models Space Heating and Tankless DHW with a Storage Tank DHW must be turned on by pressing the Tap twice Bottom LED must be ON Aquastat or Sensor connected to X4 9 and X4 10 e External Pump Terminals 4 5 6 120Va
59. drain pan WARNING should be installed under the appliance The boiler is not to be installed above Do not use this boiler if any carpeting part has been under water Atanew construction site or during renovations action must be taken to Immediately call a qualified protect the boiler from drywall dust or other construction related contaminants service technician to inspect combustion air should be drawn from a CLEAN source e g outdoors and the the boiler and to replace any boiler should be isolated from interior dust sources part of the control system and When the boiler is in operation the impact of the steam plume normally any gas control that has been experienced at the exhaust terminal of a condensing boiler should be under water assessed Generally intake and exhaust pipes should terminate at a rooftop or sterile wall location Boiler condensate is corrosive Protective measures must be taken to prevent corrosion damage to metal roofs or other metal A CAUTION building components in contact with the condensate Keep exhaust plumes well away from all building air intakes including those of neighbouring Care must be taken to properties properly size the boiler for its intended use Prolonged n sealed combustion applications the exhaust outlet should be placed so as full fire run time over to reach 24 minimum above the down turned intake to avoid exhaust re sizing or under sizing ingestion and incor
60. e all venting components are clean of burrs debris prior to assembly Care is to be taken to avoid ingestion into the fan of PVC ABS debris left in the combustion air piping All joints must be secured using appropriate solvent cement to bond the respective pipe material Canada CPVC cement approved under ULC S636 in accordance with its manufacturer instructions USA PVC ASTM D2564 or PVC ABS 02235 Use transition 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 the installer must test the exhaust joints under fan pressure with the vent blocked using a soap water solution Installer must fill condensate trap prior to test 1 4 4 Venting Passage Through Ceiling and Floor Confirm material meets local codes including fire stopping requirements Some local jurisdictions require a minimum initial length of pipe be exposed or accessible for inspection Pipe clearances no IBC requirements but best practice allows a minimum 1 4 open annulus around the pipe to prevent binding and expansion noise follow local codes All piping must be liquid and pressure tight Better Boi
61. ed 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 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 loosely install the 9 6mm hex bolts and lock washers removed in step 9 Tighten the 6mm hex bolts in a cross pattern as shown in diagram on this page 3 Connect the gas line to the gas valve ensuring the O ring is in place Tighten the gas valve nut Ensure the upper gas valve connection is tight Re connect the gas valve electrical connection 4 Re connect the electrical connections to the fan 5 Re install the flue pipe to the vent connector at the top of the boiler and to the condensate tray Tighten the nut clockwise about 1 4 turn Ensure the nut is properly engaged Hand tighten only Do Not Use any tools to tighten the flue pipe nut 6 Inspect the condensate trap for debris Remove and clean if necessary Fill the condensate trap with water 7 Turn on the gas supply valve to the boiler and inspect for gas leaks Use an approved leak detection solution soap test all j
62. er 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 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 ibcboiler com Better Boilers Water quality has a significant impact on the lifetime and performance of an IBC Boiler heat exchanger Improperly prepared water in a heating circuit may cause damage to the heat exchanger through corrosion or fouling Repeated or uncontrolled water fills will increase the potential for damage High levels of dissolved solids or minerals may precipitate out of the fluid onto the hottest part of the heat exchanger impairing heat transfer and resulting in overheating and premature failure The amount of solids that may form on the heat exchanger will depend on the degree of hardness and the total water volume in the system A high water volume system with a low hardness count may cause as much damage as a system with less volume and higher hardness so it is recommended to treat water so as to remove all dissolved solids Other water chemistry allowable limits are as follows Acidity pH is to be between 6 5 and 8 5
63. ers 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 burner surface e f burner is operating improperly remove and clean or replace Use CO analyzer to determine proper combustion See Table 11 for correct values 3 16 4 5MM Figure 37 Ignitor Gap 3 16 4 5mm Better Boilers The heat exchanger has a small amount of combustion chamber insulation refractory which contains ceramic fibers When exposed to extremely high temperatures the ceramic fibers which contain crystalline silica can be converted into cristobalite which is classified as a possible human carcinogen Care should be taken to avoid disturbing or damaging the refractory If damage occurs contact the factory for directions Avoid breathing and contact with skin and eyes and follow these precautions 1 For conditions of frequent use or heavy exposure respirator protection is required Refer to the NIOSH Guide to the Selection and Use of Particulate Respirators Certified under 42 CFR 84 for selection and use of respirators certified by NIOSH For the most current information NIOSH can be contacted at 1 800 356 4676 or on the web at www cdc gov niosh 2 Wear long sleeved
64. f 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 relieving capacity of 124 000 Btu hr with 3 4 NPT threads For safe operation of the water heater the relief valve must not be removed from its designated point of installation or plugged o For complete information refer to installation manual o Read and follow warnings and instructions CAUTION o Hotter water increases the risk of scald injury Before changing the temperature setting see instruction manual ADJUSTABLE TEMPERATURE SETTING o Press the n and hold for 2 seconds then press again When the LED is lit the Domestic Hot Water temperature can be set INSTALLATION AND OPERATION INSTRUCTIONS LIJ Better Boilers CONTENTS 1 0 1 1 14 GENERAL 0 at de edi od a 1 1 1 2 CODE REQUIREMENTS res Ree Senado tas Pod dus 1 2 1 3 LOCATION ict cera aes rh hor n RD Deo eue b S ad os 1 2 1 4 EXHAUST VENTING AND AIR 1 3 1 5 CONDENSATE REMOVAL memi a en sce kac 1 16 1 6 WATER PIPING SPACE HEATING 1 19 1 7 GAS PIPING ui enar et Rte gr reu doe he Rok a ee Rs eee 1 27 1 8 ELECTRICAL CONNECTIONS 1 1 28 2 0 BOILER SYSTEMS AND OPERATI
65. factory and have not been adversely amended e Check that the domestic hot water generation is performing as expected Fouling of the interior of the domestic heating coil can cause poor performance 4 1 10 Water Heating System Check water pressure and temperature There should be no noticeable change if boiler and system components are functioning normally Check for any noise in the system Check heating system water piping for damage or leaks and repair as needed e Check for 12 15 psig in normal operation and look to ensure pressure does not run up toward 30 psig at high temperature If pressure rises sharply consider replacement 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 control will operate the boiler to protect the boiler from freezing If the boiler and system components are subject to possible freezing condition then a freeze protection solution is recommended Check freeze protection Use only antifreeze made specifically for hydronic systems Inhibited propylene glycol is recommended Antifreeze concentration must be between 25 and 50 of the total volume of water in the system
66. fe place for re installation 6 If the removed fan is to be re installed ensure the fan and venture are clean and dust free A OND 4 1 16 Fan and gas valve re assembly instructions 1 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 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 gas valve inlet lower nut is tight 4 Connect the 2 electrical plugs to the fan 5 Restore gas supply to the boiler and test the gas valve inlet for gas leaks 6 Restore power to the boiler and create a call for heat or hot water 7 Check for leaks at the gas valve outlet and the connection between the fan and the burner housing 8 Install the cover to the boiler 9 Resetthe boiler to normal operation FAN GASKET EL RA ORIFICE PLATE INSTALLED 7 FOR DC HC 23 84 MODELS IGNITOR CABLE GAS VALVE CONNECTOR 22 GAS Figure 38 INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers 5 0 This boiler is equipped with a blocked vent shutoff system which closes the gas supply upon detection of an irregular venting condition TROUBLESHOOTING 9 1 TROUBLESHO
67. fied licensed and trained heating technicians Failure to read and comply with all instructions and applicable National and local codes may result in hazardous conditions that could result in property damage and injury to occupants which in extreme cases might result in death HAZARDS amp PRECAUTIONS Points out an immediately hazardous situation which must be avoided in order to prevent serious injury or death Points out a potentially hazardous situation which must be avoided to prevent possible moderate injury and or property damage A BEST PRACTICES Points out recommendations for better installation Points out a potentially hazardous situation which must be avoided to prevent serious injury or death Points out installation maintenance and operation details that will result in enhanced efficiency longevity and proper operation of your boiler Supplied with the boiler The IBC boiler is shipped with an accessory parts kit consisting of the following items e 1 Wall Mounting Bracket e 1x Condensate Assembly e 1 Pressure Relief valve 3 4NPT 30psi 1x Outdoor Temperature Sensor e 1x 3 4 x 1 2 x 3 4 Brass Tee e 1x Elbow 3 4 Brass Street 90 1x 3 4 x 1 3 8 close Brass Nipple e 1x 1 2 x 1 8 Brass Bushing e 1 x Automatic Air Vent e 4xLag Screws Hex Head Zn PI 1 4 x 2 1 2 and Washers 1xHC Installation amp Operating Instructions e 1xDC HC User Manual INSTALLATI
68. fter burner shutdown to utilize legacy heat this is significant due to the mass of the heat exchanger The boiler pump is under the control of the boiler to allow pump purge after burner shut down Default software values will run the boiler s pump for 1 minute after the burner shuts down Schematics for several piping layouts are provided herein and additional drawings are available at www ibcboiler com Installers shall conform the piping design to one of the provided configurations to simplify the control application promote good loads and flow management Propylene glycol solution is commonly used in a closed loop where freeze protection is required Its density is lower than that of water resulting in lower thermal performance at a given flow and pressure As a rule of thumb a 50 50 solution of propylene glycol and water will require an increased System circulation rate gpm up 10 and system head up 20 to provide performance equivalent to straight water The HC series modulating boilers offer exceptional matching of heat generation to radiation The low minimum firing is better suited to low thermal loads presented in a typical multi zoned radiation system However where individual zones in a heating system have loads under 10 000 Btu hr the system will still benefit through use of a buffer tank to ensure a controlled supply temperature and to prevent short cycling Buffering should be added on the secondary piping of the rele
69. g for 120V field connections to the appliance shall have a minimum size of 14 AWG and a temperature rating of at least 194 F 90 C Wire Color Code Key 120V Wire Terminal Key BK Black L Incoming Supply L W White N Incoming Supply N G Green G Incoming Supply G BL Blue 1 Lp 1A max R Red 2 N O Orange 3 G V Violet Y Yellow 24V X4 Wire Terminal Key BR Brown ee T mum 7 GV maray X4 8 Outdoor Sensor Wire Terminal Key X4 9 Outdoor Sensor Ss Factory Wiring X4 9 DHW Sensor Thermostat Field Wiring X4 10 DHW Sensor Thermostat 8 Figure 34 Electrical Wiring Connections full page ladder diagram at back of this manual INSTALLATION LIJ Better Boilers PAGE INTENTIONALLY LEFT BLANK INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers 2 0 2 1 BOILER SYSTEMS AND OPERATION BOILER SYSTEMS AND OPERATION GENERAL The HC series modulating condensing boilers are designed to heat both the indoor space and an indirect domestic hot water tank The boiler s unique heat exchanger design incorporates separate copper water ways for space heating and for domestic hot water generation The boiler s control is equipped to provide outdoor reset control for the space heating load and also can provide a set point water temperature for the space heating load Installing the outdoor sensor is optional but recommended for additional efficiency
70. gauge wire in BX cable or conduit properly anchored to the boiler case for mains supply and pump circuits The boiler is equipped with 3 x 1 2 electrical knock outs located behind the power supply terminal strip Connect the 120 VAC 15 amp power supply to the AC in connections located to the right side of the controller To access the terminal strip remove the boiler cover and slide open the controller drawer Ensure 120 VAC polarity is correct and that the boiler is properly grounded The HC Series boilers include a factory installed and pre wired pump The pump is intended to supply adequate flow for the boiler s primary heating circuit only The system heating pump will need to be switched through a separate relay or control box A second set of contacts is available to connect a DHW pump This pump will allow the connection of an indirect fired storage water heater to heating circuit to take full advantage of the boilers heating capacity The maximum amperage rating of the connected pump is 1 0 amps If the connected pump has a rating 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 connected to the boiler For an interlock designed for the sole purpose of pr
71. gs located on the bottom of the boilers Unions and gate or ball valves at the boilers supply and return water connections are recommended to simplify servicing Un insulated hot water pipes must be installed with a minimum 1 4 clearance from combustible materials Fluid fill is most often accomplished by using a boiler regulator amp fill valve set at 12 psig or more with appropriate backflow prevention device as required by local code This is acceptable in areas where municipal water or well water has been treated and filtered to remove excessive minerals and sediment and water chemistry is known to be suitable for closed loop hydronic systems In areas where water quality is in question or when chemical treatment or glycol is required other options should be considered Follow applicable Codes and good piping practice There are a number of boiler feed and pressurization devices on the market today that may be a better choice than a raw water fill from the mains When regular 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 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 are not required when using these devices INSTALLATION AND OPE
72. he boiler and system Information regarding the unit and installation received and left with owner Combustion Readings recommended but optional required for fuel conversion CO Flue temperature Return water temperature measure simultaneously with flue temp Installers send this completed sheet Fax to 604 877 0295 or scan and Email to info ibcboiler com and earn an extra year s Parts Warranty coverage User to submit corresponding Installation Record from User Guide Commissioning has been completed as listed on this report Installer Signature SERVICE RECORD LICENSED CONTRACTOR DESCRIPTION OF WORK DONE NOTES NOTES NOTES IMPORTANT This Boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy 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
73. he drawings have greater clarity We require that our boilers be installed by licensed and experienced trades people who are familiar with the applicable local and national codes System design is to be completed by an experienced hydronic designer or Engineer It is necessary to carefully read and follow these installation instructions along with the application drawing that fits your system HC SERIES BOILERS MULTIPLE BOILER PIPING BENEFITS AND INSTALLATION RULES Multiple IBC HC Series boilers can be installed in a single heating system to provide redundancy increased output and greater heating plant turn down capabilities Primary Secondary piping must be employed This approach provides constant head and flow at each boiler regardless of flow variations in the main building loop Ty v 1 x To building HC Boiler HC Boiler _2 Check valve Closely Spaced Tees From External 2 stage Controller ron building operates space heating pump and sends enable signals to boilers Figure 26 Multiple boiler piping concept concept drawing This drawing is only a simple schematic guide Each boiler will control its own pump turning it off or on when heat is required This approach saves electricity by reducing the pumping power required as load conditions are reduced A multiple boiler system can be controlled by installing an external boiler staging controller with dry conta
74. heck wiring Replace Sensor Flue Gas Temperature Sensor Short Lockout Condition Inspect heat exchanger for fouling and clean as required Check wiring Replace Sensor TROUBLESHOOTING Gas valve relay faulty Replace controller Better Boilers HC SERIES BOILERS 5 4 OTHER FAULTS 5 4 1 Burner Does Not Ignite POSSIBLE CAUSES Gas valve is closed SOLUTION Open gas valve Air in gas line Remove air form gas line Gas supply pressure too low Contact the gas supply company No ignition Replace ignition electrode No spark Ignition module on gas valve faulty Check the cabling Check the ignitor cap Replace the ignition module Gas air adjustment not correctly set Fan faulty Check adjustment See gas air adjustment Check the wiring Check the fuse 3 15A if necessary replace the fan Fan dirty Clean the fan Gas valve faulty 5 4 2 Burner Ignites Noisily POSSIBLE CAUSES Gas supply pressure too high Replace the gas valve Re adjust the gas valve see gas air adjustment SOLUTION 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 5 4 3 Burner Resonating POSSIBLE CAUSES Gas supply p
75. in 15 cm for appliances lt 10 000 Btuh 3 kW 12 in 30 cm for appliances gt 10 000 Btuh 3 kW and lt 100 000 Btuh 30 kW 36 in 91 cm for appliances lt 100 000 Btuh 30 kW 6 in 15 cm for appliances lt 10 000 Btuh 3 kW 9 in 23 cm for appliances gt 10 000 Btuh 3 kW and lt 50 000 Btuh 15 kW 12 in 30 cm for appliances gt 50 000 Btuh 15 kW C Clearance to window or door that may be opened D Clearance to permanently closed window INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers In addition to preventing ingestion of chemical contaminants care must be taken to ensure air intake terminals are not installed in locations where contamination might occur due to ingestion of particulate foreign material dust dirt and debris Intake air openings must be configured such that rain or other forms of moisture cannot enter the air intake piping system Otherwise serious damage to the boiler may result Care must be taken when installing air intake piping to ensure that a is not formed in the piping so as to allow a build up of water and blockage of intake air Such blockage will result in a boiler safety shut down HC SERIES BOILERS E Clearance to unventilated soffit Clearance to outside corner G Clearance to inside corner Clearance to each side of center line extended ab
76. ing Return Figure 22 Overview of piping options 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 and the boilers 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 Pressure drop delivery head flow graph 8 70 20 10 7 25 16 75 5 80 13 40 4 35 10 05 Pressure Drop psi ft WC 2 90 6 70 1 45 8 35 Dx DC 33 124 DC 33 160 DC 29 106 DC 23 84 Flow gpm Table 5 Better Boilers During operation the relief valve may discharge large amounts of steam and or hot water Therefore to reduce the potential for bodily injury and property damage a discharge line MUST be installed that it 1 is connected from the valve outlet with no intervening valve and directed downward to a safe point of discharge 2 allows complete drainage of both the valve and the discharge line 3 is independently supported and securely anchored so as to avoid applied stress on the valve 4 is as short and straight as possible 5 terminates freely to at
77. ion HC SERIES BOILERS EXHAUST VENT BANK 6 0 15m MIN EXHAUST VENT BANK 12 0 30m MIN FRESH AIR INTAKE BANK Figure 13 Sidewall vent termination multiple vent piping configuration CONCENTRIC SIDE WALL TERMINATION KITS Must be installed on the same horizontal line not stacked Must be installed with a min separation of 12 center to center Do not use Concentric Side Wall Termination Kits when the outdoor design temperature is below 5 F 15 The possible blockage of the combustion air intake increases when the outdoor temperature drops below this temperature The clearances recommended by the vent termination manufacture 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 e Duravent Polypro Z3PPS HK Horizontal Termination Kit Concentric e Centrotherm Innoflue ICWT242 2 termination 0224 2 transition to 2 pipe e Centrotherm Innoflue ICWT352 3 termination ICTC0335 3 transition to 2 pipe e 197009 3 CPVC e 196006 3 PVC USA only VENT TERMINAL CLEARANCE MINIMUMS ARE AS FOLLOWS A Clearance above grade veranda porch deck or balcony CANADIAN INSTALLATIONS 12 in 30 cm US INSTALLATIONS 12 in 30 cm B Clearance to window or door that may be opened 6
78. le gas air premix MAINTENANCE MAINTENANCE BOILER MAINTENANCE 4 1 1 General Care Keep combustible materials and flammable liquids and vapours away from the boiler Keep vent terminals clear of obstructions snow dirt etc 4 1 2 Inspection Inspection of the boiler is to be performed annually by a qualified service technician 4 1 3 Venting Check vent terminals for and remove any obstructions e g leaves dust other debris Check and clean or replace intake air filters or screens as required Check for holes or leaks in venting Replace venting as needed Examine for any signs of moisture caused by sweating intake air pipes insulate as required Ensure proper resealing or reinstallation of venting on each servicing 4 1 4 Condensate Traps Condensate trap must be examined every two months to see if cleaning is necessary refer to trap cleaning instructions section 1 5 3 of this manual Ensure that trap has been re filled completely before firing boiler f condensate neutralization is used check pH level of condensate discharge 4 1 5 Burner e Annually remove burner to inspect for extent of fouling refer to burner removal and reassembly instructions section 3 5 1 of this manual Blow clear using compressed air Evaluate the magnitude of clearing required and establish a reasonable burner inspection schedule Some boiler locations may call for annual service others showing clean burn
79. lers Condensate can cause corrosion of metal roofing components and other roofing materials Check with the builder or roofing contractor to ensure that materials will be resistant to acidic condensate pH levels can be as low as 3 0 Vent termination clearances in this section are code minimum or IBC recommended minimum requirements and may be inadequate for your installation Building envelope details must be examined carefully and ingress of moisture into building structures is to be avoided Serious structural damage may occur if adequate precautions and clearances are not allowed for These precautions are to be observed for neighbouring structures as well as for the structure the boiler s are installed in HC SERIES BOILERS 1 4 5 Rooftop Vent Termination DIRECT VENT TWO PIPE Rooftop vents must terminate as follows The exhaust pipe can terminate in an open vertical orientation without concern about rain infiltration rain will drain away through the condensate trap The intake air pipe is not typically drained so it must be terminated with a down turned elbow see Figure 5 The intake pipe does not need to penetrate the roof at the same elevation as the exhaust as shown lower down the roof is OK Optional bird screen may be placed in a termination fitting Leave unglued and hold in place with a short nipple This permits easy access for cleaning For roof top venting of multiple boiler
80. lly condensing units having variable input ranges see specification chart inside front cover The boilers are approved as Category IV vented appliances using Direct Vent sealed combustion Figure 1 shows outer case dimensions and piping and electrical holes Use this diagram to find a suitable location for the boiler See also Section 1 3 Location DESCRIPTION SERIES BOILERS Exhaust Outlet 3 Schedule 40 Combustion Air 3 Schedule 40 Heating Water Inlet Return 1 Male NPT Heating Water Outlet Supply 1 Male NPT Gas Inlet 1 2 Male NPT Condensate Outlet 3 4 Hose Knock out 3 1 2 HC 29 106 29 0 736 Table 1 Connections HC 33 124 31 3 796 HC 33 160 31 3 796 HEIGHT HC 13 50 26 6 676 HC 23 84 26 6 676 AIR SEPARATOR RELIEF VALVE CONNECTOR 2 6 65 84 214 4 7 120 HEIGHT G 1 2 NPT M E 1 NPT M E 5 9 149 10 9 277 FOR 160 MBH 19 8 502 SUPPLIED WITH 3 4 X 24 CONDENSATE FLEX HOSE 11 1 281 BOTTOM VIEW FRONT VIEW SIDE VIEW Figure 1a Dimensions Connections for HC Series Figure 1b Dimensions Connections for HC Series INSTALLATION Better Boilers 1 2 1 3 Keep boiler area free and clear of combustible materials gasoline and other flammable vapours and liquids Combustion air must not be drawn from areas containing corrosive air from
81. mosphere where any discharge will be clearly visible and is at no risk of freezing 6 terminates with a plain end which is not threaded 7 is constructed of a material suitable for exposure to temperatures of 375 F or greater 8 is over its entire length of a pipe size equal to or greater than that of the valve outlet DO NOT CAP PLUG OR OTHERWISE OBSTRUCT THE DISCHARGE PIPE OUTLET Installers should inquire of local water purveyors as to the suitability of their supply for use in hydronic heating systems If water quality is questionable a local water treatment expert must be consulted for testing assessment and if required treatment Alternatively water or hydronic fluid of known quality can be brought to the site HC SERIES BOILERS The HC series modulating boilers are designed for use within a closed loop forced circulation low pressure system A 30 PSI pressure relief valve 3 4 NPT is supplied for field installation at the boilers top connection point A Relief Valve and Air Vent Piping Kit is also included with each HC series boiler to aid in the proper installation of the relief valve and air vent Pressure Relief Valve Required shipped with boiler Important Shut off valves are not allowed between relief valve and boiler HC Boiler Heating Supply and Return Figure 23 Relief Piping System piping is connected to the boiler using the 1 NPT Male threaded fittin
82. n Outdoor Design Temp 14 F 10 C Range to 22 F 30 C to 55 F 13 C Summer Shut Down Temperature Internal Boiler Pump Post Purge 64 F 18 C 1 min Range 59 F 15 C to 86 F 30 C Pump and burner will not operate if the Outdoor Temperature is above this setting Range 0 min to 15 min External DHW Pump Post Purge 1 min Range 0 min to 15 min Indirect Tank Temperature if using a sensor Note Use only IBC 10KQ Sensor 140 F 60 C Fixed tank differential of 9 F 5 C below the set point must use an IBC 10KQ tank sensor 104 F 149 F 40 C 65 C Tankless DHW with Storage Tank offset temperature Boiler operates at the Tankless Domestic Hot Water Temperature setting plus this offset temperature to efficiently generate DHW 18 F 10 C 2 F 27 F 1 C 15 C Fixed tank differential of 9 F 5 C below the set point must use an IBC 10KQ tank sensor Boiler Water Supply Temp for heating Indirect DHW Tank 170 F 77 C Range 149 F 65 C to 194 F 90 C Comfort and ECO Comfort Mode Heat exchanger temperature maintained while in standby 110 F 43 C Range 0 or 104 F 149 F 40 C 65 C NOTE If set to 0 then the temperature will be the same as the temperature set for the Tankless DHW in the user menu NOTE The control displays codes that include upper and lower case letter and a combination with a
83. nnoflue ICWT352 3 termination ICTC0335 3 transition to 2 pipe e 197009 3 CPVC pex 196006 3 USA only INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers INSTALLATION HC SERIES BOILERS 12 Minimum Clearance 152 7 Minimum Clearances Canada 18 Anticipated Snow Level USA 12 Anticipated Snow Level Figure 9 Horizontal Concentric Termination Two Kits Minimum Clearances 18 Allowance for Snow Level Canada 12 Allowance for Snow Level USA Figure 10 Horizontal Concentric Termination Single Kit For side venting of multiple boiler sets group all intake terminals together with 4 minimum lateral spacing and similarly group the 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 inlet termination of an adjacent boiler For alternate group terminations contact the IBC Factory for written guidance Better Boilers Figure 11 IBC recommended minimum vent terminal clearance under ventilated soffit Figure 12 Prohibited installat
84. ntrol Fan RPM at Burner Start for Space Heating Model Dependent 0 Ignore a call for heat if the target temperature is less than E 1 Answer call for heat with a temperature equal to E 2 Answer a call for heat with a temperature equal to that set in the user menu Boiler Maximum Temperature 50 100 of High Fire HC 13 50 70 HC 23 84 70 HC 29 106 60 HC 33 124 50 HC 33 160 40 Range 40 75 Fan RPM at Burner Start for Tankless DHW Model Dependent 50 100 of High Fire DC 23 84 70 DC 29 106 60 DC 33 124 50 DC 33 160 40 Range 40 75 Max Fan Speed Adjustment Model Dependent HC 13 50 HC 23 84 HC 29 106 and HC 33 124 50 Range 40 50 HC 33 160 70 Range 65 75 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 If set to 0 Opentherm will control Eco Comfort Mode Occupied or Un Occupied 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 BOILER SYSTEMS AND OPERATION Better Boilers HC SERIES BOILERS Space Heating Delay after 2 min Range 0 15 min The boiler will remain off for X the boiler reaches the target min to help reduce short
85. oilers HC SERIES BOILERS 3 There is no need to drain the boiler s water unless the boiler will be subject to A NOTE freezing conditions while the boiler is off The safety warning regarding burner refractory on page 4 2 of this manual must be observed T 2 Be X CNN Y 2 0 is Es 2 SPAR AT 4 Remove the front cover and allow the boiler to cool 5 Disconnect the flue pipe from the condensate tray by rotating the nut counter clockwise about 1 4 turn Slide the flue pipe up and dis engage the bottom of the flue pipe from the condensate tray and slide down to remove 6 Unplug the electrical connector at the gas valve 7 Loosen both the lower gas valve connection nut NOTE There is an O ring in the lower gas connection and an O ring and orifice in the upper gas valve connection Place these in a safe location to be used for re assembly Cover the gas piping connections to prevent debris from entering the gas piping 8 CAUTION When removing the heat exchanger cover in step 9 be careful not to damage the burner and refractory material located on the opposite side of the heat exchanger cover Use caution when handling refractory materials See Caution on page 4 2 9 Remove all 9 6mm hex bolts and lock washers from the heat exchanger cover and carefully remove the front cover complete with the fan and the gas valve attach
86. oints 8 Ensure the boiler is full of water and purged of air if the boiler was drained during dis assembly step 3 9 Turn on the power to the boiler and create a call for heat or for domestic hot water 10 Inspect the gasket around the heat exchanger cover and flue pipe connections for leaks 11 Check flue gases for proper combustion See Section 3 3 Commissioning for proper adjustments 12 Re install the boiler cover and set the boiler into normal operation INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers 4 0 4 7 The owner is responsible for general care of the boiler Improper maintenance of the boiler may result in a hazardous condition Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Periodic inspection of Low Water Cut Off Device including flushing of float types is required if installed as an accessory to the boiler Fill trap with water before boiler is first fired to prevent exhaust fumes from entering room Never operate the boiler unless the trap is filled with water Failure to comply will result in severe personal injury or death Whenever the burner is removed for inspection or boiler servicing the sealing gaskets must be examined and replaced if damaged Upon re assembly an approved leak test solution must be applied around the burner flange sealing area to ensure there is no leakage of combustib
87. onfined space such as a closet ventilation openings may be needed through a door or wall to prevent excessive heat from building up inside the space The boiler shall not be exposed to ambient conditions above 122 F 50 C or below 32 F 0 Better Boilers 1 5 Fill trap with water before boiler is first fired to prevent exhaust fumes from entering room Never operate the boiler unless the trap is filled with water Failure to comply will result in severe personal injury or death The Trap Hook must be installed as instructed and all trap fittings must be tightened as instructed to prevent leakage of flue gasses Failure to comply may result in severe personal injury or death CONDENSATE REMOVAL IBC s specified vent configuration promotes the safe drainage of moisture from the boiler and exhaust venting without 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 and filled with water 3 When required add and maintain in good condition a neutralization tank 1 5 1 Condensate Trap A condensate trap must be installed on the drain connection at
88. oset or utility room Surrounding ambient conditions shall be 0 C to 50 C and less than 90 relative humidity Install the boiler in areas where the combustion air source is not subject to chemical fouling or agricultural vapours Exposure to corrosive chemical fumes such as chlorinated and or fluorinated hydrocarbons can reduce the life of a boiler Cleaners bleaches air fresheners refrigerants aerosol propellants dry cleaning fluids de greasers and paint removers all contain vapours which can form corrosive acid compounds when burned in a gas flame Airborne chlorides such as those released with the use of laundry detergents are also to be avoided For this reason the indoor air venting option using air surrounding the boiler should 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 installed under the appliance The boiler is not to be installed above carpeting Boiler Weight approximately 85 Ibs 39 kg For support fasteners use the supplied 4 x 1 4 x 2 1 2 long lag screws Installer to supply 1 4 bolts if metal mounting systems are used Fasteners are to be attached to solid material capa
89. otecting the heating circuit of the boiler the Auxiliary Safety interlocks can be wired in series with the Call for heat X4 6 and 4 7 Do not apply power to the X4 terminal strip The Auxiliary Safety interlocks must be a Dry Contact Space Outdoor DHW Open Therm Field Heating Sensor Sensor Space Heating F1 315A 1 Not Used 2 Line In 3 Line to Fan 4 Neutral In 5 Line to external DHW pump Max 1 0 6 Neutral to Fan 7 Neutral to Boiler Pump 8 Line to Boiler Pump X2 Not for Field Wiring 120V Factory wiring block Wiring Demand 12KO 10KQ Demand D ry Or Contact Aquastat X4 24V block Figure 32 X4 Terminal Strip for connection of the DHW Aquastat optional Thermostat or end switch s mandatory Outdoor Sensor optional INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers A hot water boiler installed above radiation level or as required by the Authority Having Jurisdiction must be provided with a low water cut off device at the time of boiler installation If a low water cut off is not factory installed instructions shall be provided for the installation and wiring of a low water cut off INSTALLATION HC SERIES BOILERS EXTERNAL LOW WATER CUT OFF DEVICE DC Series Boiler Only An external low water cut off device is not required if the boiler is only being used as a direct domestic hot water unit If an external low water cut off device is re
90. ove meter regulator assembly 3 ft 91 cm within a height 15 ft above the meter regulator assembly Clearance to service regulator vent outlet 3 ft 91 cm J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance K Clearance to a mechanical air supply inlet L Clearance above paved sidewalk or paved driveway located on public property 6 in 15 cm for appliances lt 10 000 Btuh 3 kW 12 in 30 cm for appliances gt 10 000 Btuh 3 kW and s 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 6 feet 1 83 m 7 ft 2 13 m t 6 in 15 cm for appliances lt 10 000 Btuh 3 kW 9 in 23 cm for appliances gt 10 000 Btuh 3 kW and s 50 000 Btuh 15 kW 12 in 30 cm for appliances gt 50 000 Btuh 15 kW 3 ft 91 cm above if within 10 ft 3 m horizontally M Clearance under veranda porch deck or balcony 12 in 30 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 n accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code T Avent 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 code
91. 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 INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers HC SERIES BOILERS Space Heating Delay min 0 min Range 0 15 min The Boiler will not respond to a Space Heating call for X min Space Heating Delay after 0 min Range 0 15 min The boiler will not respond heating DHW 20 ADVANCED INSTALLER MENU Maximum Power available for Space Heating 100 to a call for heat after the tankless DHW call for heat has ended for X min Parameter c value to 100 Max Pump Speed PWM Space Heating Only 100 For use only with a PWM style pump Terminal X4 5 Max DHW power Model Dependent DC 23 84 DC 29 106 and DC 33 124 100 DC 33 160 75 Burner Modulation Ramp up with a Space Heating Demand 0 OFF 12 ON 2 Open Therm control Min fan speed in Space Heating Model Dependent HC 13 50 HC 23 84 HC 29 106 and HC 33 124 28 HC 33 160 22 Min Pump Speed PWM Space Heating Only 40 Min Fan power during Tankless DHW Model Dependent Range 20 50 DC 23 84 DC 29 106 and DC 33 124 28 DC 33 160 22 Minimum Space Heating Temperature with an Open Therm heating demand 104 F 40 C 50 F 140 F 10 C 60 C Only for use with an Open Therm thermostat Open Therm or RF Space Heating Co
92. pliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label before doing anything Setthe thermostat to lowest setting Turn off all electric power to the appliance by selecting main power switch to OFF This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Locate manual gas shut off valve see pictures below and turn clockwise to CLOSE Waitfive 5 minutes to clear out any gas Then 1 CLOSE clockwise open N 2 clockwise smell for gas including near the floor If you smell gas STOP Follow step B in the safety information above on this label If you don t smell gas go to the next step Turn gas control valve to OPEN Turn on electric power to appliance by select ing main power switch to ON Set thermostat to desired setting If the appliance will not operate follow the in structions TO TURN OFF GAS APPLIANCE and call your service technician or gas supplier CLOSED OPEN CLOSED TO TURN OFF GAS APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance by selecting main power switch to OFF STARTUP AND COMMISSIONING 3 Turn gas control valve to CLOSE Better Boilers 2 2 Fill trap with water before boiler is
93. quired an electronic probe style device is recommended The low water cut off device must be installed in the boiler supply water piping with a tee connection at a level above the top of the boiler The low water cut off device must be wired in series with the 120Vac power supply so that when the device trips on a low water condition the power supply to the boiler is interrupted Low Water Cut Off device installed above Boiler Water Level amd fill station with isolation valve closed or fill tank IBC HC Boiler Figure 33 External Low Water Cut Off Device 1 8 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 8 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 will need to be installed externally Zone Valve end switches can be wired to together in parallel and connected to a fan center relay See Figure 34 Do not apply power to the X4 terminal strip Alternately the zone valves and thermostats can be connected to a zoning panel control system available from your local heating wholesaler Zone Pumps can be connected to the boiler with a zone pump control available from your local heating wholesaler Better Boilers HC SER
94. quivalent feet 2 or 3 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 Table 3 Maximum Exhaust Venting Length 35 actual feet Exhaust venting must slope down towards the boiler with a pitch of at least 1 4 per foot PPs vent follow PPs manufacturer requirements so condensate runs back towards the trap Support should be provided for intake and vent piping particularly so for horizontal runs follow local code INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers BEST PRACTICES To reduce the possibility of expansion noise allow a 1 4 open annulus around the exhaust and air intake piping INSTALLATION HC SERIES BOILERS x E Ey m US ENSURE PIPE AND FITTINGS ARE BEVELED FOR TROUBLE FREE INSERTION THROUGH EXHAUST AND INTAKE PIPE GASKETS WET GASKETS AND PIPE BEFORE INSERTION Figure 4 Exhaust piping is inserted directly into the 3 female stainless steel fitting on the top left side of the boiler and run horizontally or vertically to the outdoors Bird screen of 1 4 stainless steel or plastic mesh eg IPEX System 636 drain grate for CPVC systems is useful to guard against foreign objects Follow all installation instructions supplied by the pipe and fitting manufacturer Ensur
95. r Thermostat Field Wiring X4 10 DHW Sensor Thermostat Diagram 6 2 1 Pictorial wiring diagram INSTALLATION AND OPERATION INSTRUCTIONS INSTALLATION amp COMMISSIONING REPORT Boiler Details Model Number Serial Number Date of Installation Address of installation User contact information Installer Information Company Address Phone Fax E mail Fuel Natural Gas Propane Gas Supply Pressure high fire Inches w c Measured Rate of Input high fire Btu hr Installation instructions have been followed and completed Section 1 of Installation and Operating Instructions Check out procedures have been 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 installed and piped Relief valve try lever test performed Condensate trap filled Condensate drain clear and free flowing Condensate Neutralization Yes No Ignition Safety Shutoff test completed Flame current reading High fire pA Low fire pA Owner advised and instructed in the safe operation and maintenance of t
96. re available see manual Better Boilers 2 2 2 9 HC SERIES BOILERS CONTROL Power ON OFF Space Heating DHW Toggle Power Indicator Space Heating Minus Plus Fahrenheit Celsius Domestic Hot Water Main Display Fahrenheit and PSI Celsius and Bar Comfort ECO OFF Indicator Comfort ECO OFF Indicator Reset Button Service Display Flashes to indicate a fault Table 7 Controller Indicators and Buttons Domestic Hot Water Comfort Eco Service CN EE 6 1 2 3 4 5 6 7 8 9 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 o button When the boiler is ON the green LED above the On Off button will be on When the boiler is on and there is no call for heat or DHW the displays are blank If the boiler is being powered up after a power outage the boiler will return to heating as it was when the power was removed from the boiler INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers Some features of the control are not available with the HC Series boilers The Direct Domestic Hot Water functions are not available however the
97. re consumed over time lowering their density Verify proper operation after servicing 4 1 13 Relief Valve Maintenance and Testing The relief valve manufacturer requires that under normal operating conditions a lever test must be performed every two months Under severe service conditions or if corrosion and or deposits are noticed within the valve body testing must be performed more often A try lever test must also be performed at the end of any non service period Test at or near maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of sediment and debris Then release the lever and permit the valve to snap shut If the lever does not activate or there is not evidence of discharge discontinue use of equipment immediately and contact a licensed contractor or qualified service personnel If the relief valve does not completely seal and fluid continues to leak from the discharge pipe perform the test again to try and flush any debris that may be lodged in the valve If repeated tries fail to stop the leakage contact a licensed contractor or qualified service personnel to replace the valve While performing a try lever test a quantity of heat transfer fluid will be discharged from the piping system and the system pressure will drop This fluid must be replaced It is highly recommended that a system pressurization unit such as an Axiom Industries model M
98. rect flow rates For sidewall venting options Both the inlet and exhaust terminations should through the boiler can lead normally be located on the same plane side of the building The elevation of to increased maintenance both pipes can be raised in periscope style after passing through the wall to costs equipment stress and gain required clearance above grade and snow level premature failure Examine the condensate outlet to ensure proper disposal of condensate will occur during operation If condensates are to be discharged into building drain piping materials that are subject to corrosion a neutralization package must be used Ensure that the pressure relief valve will be installed with no valves or other means of isolation between its inlet and the boiler Make sure the relief valve outlet will be piped with unobstructed piping minimum 3 4 diameter to a safe discharge location nlocations where power supply quality varies or is unstable installation of surge protection and power conditioners up to and including battery back up uninterrupted power supply devices should be considered Ensure the domestic hot water demands are considered before purchasing the HC Series boiler The addition of a storage tank or an IBC Indirect Water Heater may be required in some cases INSTALLATION AND OPERATION INSTRUCTIONS 29 Better Boilers 1 0 INSTALLATION 1 1 GENERAL HC Series gas fired modulating boilers are low pressure fu
99. ressure too low Check the ignition spark gap Replace the ignitor Replace the ignition module on the gas valve SOLUTION Gas pressure regulator may be faulty Replace the regulator or contact the gas company Recirculation of combustion gasses Check combustion air supply and flue gas exhaust piping and terminations possible flue gas recirculation in the system Gas air adjustment not correctly set Check the setting see gas air adjustment 5 4 4 The Power is Reduced POSSIBLE CAUSES SOLUTION Al high rpm the power has fallen by more than e Check appliance and flue system for fouling 5 e Clean the appliance and flue system INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers 5 4 5 No Space Heating POSSIBLE CAUSES Room thermostat end switches or zone controller Outdoor sensor faulty No voltage 24V DC HC SERIES BOILERS SOLUTION Room thermostat must be a DRY CONTACT style thermostat Check the wiring Check and or Replace the thermostat end switches or zone controller Replace the outdoor sensor Check the wiring against the diagram Check the connector terminals X4 6 and X4 7 for 24V DC with thermostat wires disconnected Check the Fuse Replace the controller Internal Pump not running Check the power supply Check connector X2 7 and X2 8 for 120VAC while the pump should be running Replace faulty pump if 120VAC is present when the pump
100. ressure will be displayed 2 Isolate the space heating circuit and reduce the water pressure 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 from sensor inlet channel and reinsert 3 Ifthe pressure sensor is OK then simply refill the boiler and open the closed valves Ensure the system pressure is adequate for the heating system PRESSURE SENSOR REPLACEMENT Turn off the power to the boiler Isolate and drain the boiler Remove the Vent Stack Disconnect the electrical connection to the sensor Carefully remove the clip at the base of the sensor Twist the sensor as you are pulling to remove from the socket There may be some water leakage at this point Ensure the water does not spill into the controller 7 Push the new sensor into the socket while twisting slightly Careful not to damage the O ring 8 Reinstall the clip at the base of the sensor to ensure the sensor does not come out when the boiler is pressurized 9 Connect the electrical connector to the sensor 10 Reinstall the vent stack oop SP PS Better Boilers HC SERIES BOILERS 11 Restore water pressure to the boiler 12 Restore power to the boiler 5 2 5 Vent High Limit This sensor has been installed to ensure the
101. s and the requirements of the gas supplier INSIDE CORNER DETAIL JA 9 6 z VENT TERMINAL 0 AIR SUPPLY INLET NS AREA WHERE TERMINAL IS NOT PERMITTED Figure 14 Vent Terminal Clearance INSTALLATION Better Boilers HC SERIES BOILERS 1 4 7 Direct Vent Combustion Air Intake Piping The boiler must always be installed as a Direct Vent venting system with the combustion air piped directly from the outdoors to the boilers 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 Flue Gas Exhaust to Outdoors Combustion Air from Outdoors HC Boiler Direct Vent Installation Check air intake outside to make sure it is clear of obstructions Figure 15 Direct vent combustion air intake For 3 Flexible PPs up to 35 actual lineal feet are allowed in a nominally vertical orientation gt 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
102. sor Direct DHW Tank Error No flow Pump failed Replace pump detected when enabling the external DHW pump DHW piping loop air locked Bleed Air Flow Sensor Flow Restrictor blocked Remove and Clean Flow Sensor Faulty Replace S3 DHW Sensor Open Check wiring Replace Sensor S3 DHW Sensor Short Check wiring Replace Sensor S5 Outdoor Sensor Short Check wiring Replace Sensor No pressure sensor detected voltage 0 25V on orange sense wire CH is disabled E7 Pressure sensor out of range above 4 25Bar 47psi CH is disabled pressure P CH Pressure too low Bring the system back up to pressure Check pressure sensor Replace pressure sensor Polarity detection fault Switch the Line and Neutral wire on the power supply Check grounding Check for high potential on Neutral wire Replace controller INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers 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 the Reset itr button on the operating panel to restart the burner controller MAIN DISPLAY 10 11 12 13 14 20 21 22 23 24 DISPLAY FAULT Sensor fault S1 Supply Sensor upper left side of the heat exchanger Sensor fault S2 Return Sensor lower left side of the heat exchanger HC SE
103. ssure throughout the commissioning procedure Pressure may droop up to 1 to 2 w c at high fire Allow the boiler to ignite run against a large load to maintain high fire Enter the High Fire Manual Mode by pressing both the Service and Plus buttons together twice H will be showing in the service display NOTE Do not make any adjustments if an h is showing in the service display Allow the boiler to operate at High Fire for 3 minutes to stabilize The boiler will operate in manual mode for 10 minutes then switch back to the normal operating mode To extend manual mode operation press the Service and Plus together twice while the boiler is operating in manual mode to reset the timer for 10 more minutes 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 maximum rating plate input Check the measured results with Table 10 High Fire Switch the boiler to low fire by pressing both the Service gt button and Minus buttons at the same time The boiler will drop to low fire Compare the readings with Table 10 Low Fire Switch off the boiler by pressing the On Off o button Turn off the gas at the boiler gas shut off valve Remove the flue gas analyzer from the test port and reinstall the test port cap
104. t into Dirt Separator recommended Figure 24 Boiler trim basic options concept drawing This drawing is only a simple schematic guide Do not place any water connections overhead the boiler leaks can damage the fan and controls If needed create a shield over the top of the cover but allow clearance for airflow and service access For best results use a Primary Secondary piping system with a boiler loop using 1 1 1 4 for the HC 33 160 piping for the HC Series Boilers The boiler comes with the boiler primary pump installed in the boiler and will provide adequate flow for the boiler and primary loop piping only The minimum flow rate required through the heat exchanger is 2 USgpm with a maximum of 11 USgpm allowed Primary Secondary piping ensures adequate flow and de couples issues boiler vs distribution Aim for a 20 to 30 F A T across the heat exchanger at high fire The HC Series modulating boilers are designed to supply the heating load with temperatures within the range of 86 F to 194 F Use closely spaced tee s to connect each pumped space heating load to the primary loop As an option a hydraulic separator or buffer tank can be used to separate the heating loads from the boiler Always ensure that loads sensitive to high temperatures are protected using means such as a mixing valve set for maximum limit say 130 F to protect radiant floors or an aquastat wired to the boil
105. tem are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers Covering non metallic vent pipe and fittings with thermal insulation shall be prohibited INSTALLATION HC SERIES BOILERS Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI 2223 1 latest edition In Canada all installations must conform with the current CAN CGA B149 1 Installation Code and or local codes 1 4 1 Applications All HC Series boilers must be installed as a Direct Vent venting system combustion air must be piped in from the outdoors and connected directly to the boilers combustion air connection See section 1 4 7 for air intake piping requirements
106. the flow sensor Check the wiring according to the diagram Burner not firing on DHW S3 faulty Replace S3 Burner does not ignite TROUBLESHOOTING See burner does not ignite LIJ Better Boilers 5 4 8 Hot Water Does Not Reach Temperature this section is used with the DC Series Boilers only POSSIBLE CAUSES DHW flow to high SOLUTION Adjust the inlet assembly insert a flow restriction Temperature 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 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 lt 5 C INSTALLATION AND OPERATION INSTRUCTIONS LZ Better Boilers 6 0 DIAGRAMS 6 1 PARTS DIAGRAMS 6 2 WIRING DIAGRAMS DIAGRAMS L1 Better Boilers 6 1 PARTS DIAGRAMS HC Series Modulating Boiler Parts assembly Diagram 6 1 1 Boiler assembly parts INSTALLATION AND OPERATION INSTRUCTIONS 29 Better Boilers ITEM No PART No DESCRIPTION 10 240 067 IGNITOR 20 250 622 GASKET IGNITOR 30 250 623 VIEWPORT HOLDER 40 250 624 GASKET VIEWPORT HOLDER 50 250 625 GASKET VIEWPORT GLASS 60 250 626 VIEWPORT GLASS 170 020 HEAT EXCHANGER HC50 170 021 HEAT EXCHANGER HC84 170 022 HEAT EXCHANGER HC106
107. till allow the use of PVC Sch 40 ASTM D1785 or D2665 and fittings or CPVC Sch 40 ASTM F441 with Sch 80 fittings or CSA approved 3 stainless vent systems Better Boilers Do not mix venting materials from different Manufacturers These venting materials are designed to be installed as part of a complete system Failure to comply may result in severe personal injury or death SEE WARNING BELOW Fully insert the approved venting material into the boilers exhaust outlet and tighten clamp to ensure the venting connection is locked in place HC SERIES BOILERS Do not use ABS or any cellular core pipe for exhaust venting Use of cellular core PVC ASTM F891 cellular core CPVC or Radel amp polyphenolsulfone in venting systems shall be prohibited The boiler offers 3 venting connections Fittings are to be used to adapt to the appropriate diameter see Vent Travel below CPVC Exhaust Venting is to be inserted directly into the 3 female stainless steel fitting on left side of the boiler s top panel The clamp must be tightened to secure the pipe into the fitting If PPs materials are being used ensure the proper adapter is used to transition from the CPVC diameter to the PPs size diameter For PPs material use the 3 transition adaptor fitting Sch 40 to PPs offered by the respective PPs manufacturers Centrotherm InnoflueTM their part ISAA0303 or M amp G Dura Vent PolyPro 3PPS AD For PPs m
108. ting To exit from the Advanced Installer Menu and save the changes press the Reset it button Pressing the On Off button will also exit the Advanced Installer Menu but will NOT save the changes Better Boilers 2 3 4 Table of Programmable Parameters PARA METER USER SET UP DESCRIPTION Boiler Supply Temperature DEFAULT 180 F 82 C HC SERIES BOILERS RANGE OPTIONS 86 F 30 C to 194 F 90 C Tankless Domestic Hot Water Temperature 15 INSTALLER SET UP MENU System Type SEE CHART ON PAGE 2 6 FOR ADDITIONAL DETAILS 120 F 49 C DC series 0 HC series 3 104 F 40 C to 149 65 C DC 0 Both Space Heating and Tankless DHW HC 1 Space Heating and Indirect DHW Tank DHW must be turned on by pressing the Tap twice Bottom LED must be ON DC 2 Tankless DHW Only HC 3 Space Heating Only DC 4 Space Heating and Tankless DHW with a Storage Tank DHW must be turned on by pressing the Tap twice Bottom LED must be ON DC 5 Tankless DHW with a Storage Tank Only DHW must be turned on by pressing the Tap twice Bottom LED must be ON DC 6 Space Heating Indirect DHW Tank and Tankless DHW Min Heating Curve Supply Water Temp 90 F 32 C 50 F 10 C to 194 F 90 C Must be at least 18 F 10 C lower than Parameter 5 Max Heating Supply Water Temp 194 F 90 C Range 86 F 30 C to 194 F 90 C Mi
109. tion The boiler and 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 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 equal to or less than 1 2 psi 3 5 kPa The gas valve is provided with pressure taps to measure gas pressure upstream supply pressure and downstream manifold pressure of the gas valve see Figure 30 Note that manifold pressure varies slightly in accordance with firing rates with the modulating series boilers but will always be close to 0 w c INSTALL MANUAL MAIN SHUT OFF VALVE CHECK LOCAL CODE FOR HEIGHT REQUIREMENT UNION gt FULL SIZED SEDIMENT TRAP Figure 30 Gas Valve INSTALLATION Figure 31 Gas Piping Better Boilers 1 8 A NOTE Some features of the control are not available with the HC Series boilers The Direct Domestic Hot Water functions are not available however the Indirect Domestic Hot Water functions are available The IBC boiler like any modern appliance that contains electronic equipment must have a clean power supply and is susceptible to power surges and spikes lightning strikes and other forms of severe electrical noise
110. uel Gas Code ANSI 2223 1 NFPA 54 or Clause 8 2 8 3 or 8 4 of Natural Gas and Propane Installation Code CAN CSA 149 1 or applicable provisions of the local building codes Flue Gas Exhaust to Outdoors HC Boiler Figure 3 Basic exhaust vent assembly IMPORTANT When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper venting of the appliances remaining connected to it When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code ANSI Z223 1 latest edition Canada use the B149 1 Installation Code latest edition At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation e 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 windows and all doors between the space in which the appliances remaining connected to the common venting sys
111. useful to guard against foreign objects i U 6 EB 152mm 24 4 610mm BIRD MIN _ f SCREEN e Cy L v Uu j 12 12 12 J 305mm 305mm 305mm MIN MIN MIN v i y i i e 6 N M 152mm GRADE OR ANTICIPATED SNOW LEVEL MIN Figure 8 Sidewall vent termination piping configuration DIRECT VENT CONCENTRIC SIDE WALL TERMINATION The following Concentric Side Wall Termination Kits are approved for use with the DC series boilers and are subject to the following restrictions NOTE Some jurisdictions may not allow this type of side wall termination due to close proximity to the neighboring properties See Figure 9 and 10 on page 1 11 Do not use Concentric Side Wall Termination Kits when the outdoor design temperature is below 5 F 15 C The possible blockage of the combustion air intake 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 e Duravent Polypro 3PPS HK Horizontal Termination Kit Concentric e Centrotherm Innoflue ICWT242 2 termination ICTC0224 2 transition to 2 pipe e Centrotherm I
112. vant load to avoid bulking up the thermal mass of the primary piping circuit and potentially lengthen the duration of the transition from hot to cool loads HC modulating series boilers can be connected directly to a floor of non oxygen barrier polybutylene material PB tubing The internal boiler piping and connections are all non ferrous with the exception of the corrosion resistant epoxy coated cast iron pump For 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 carried out after the retrofit with filter clearing after the 1st day 1st week month and annually thereafter The installer must insure that all external piping components and pumps are non ferrous when connecting the boiler to a system with non oxygen barrier tubing INSTALLATION AND OPERATION INSTRUCTIONS Better Boilers Do not use automotive type ethylene or other types of automotive glycol antifreeze or undiluted antifreeze of any kind This may result in severe boiler damage It is the responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials Improper mixtures and chemical additives may cause damage to ferrous and non ferrous components as well as non metallic wetted components normally found in hydronic systems

Installation Manual - IBC Better Boilers

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