IBC TECHNOLOGIES INDIRECT-FIRED WATER HEATERS
MODELS - IBC 30, IBC 40, IBC 40L, IBC 50, IBC 60, IBC 60L, IBC 80, IBC 115
HIGH OUTPUT MODELS - IBC 80-HO, IBC 80-HO-C, IBC 115-HO, IBC 115-HO-C
FOR SINGLE WATER HEATER INSTALLATIONS
For service or repairs to the water heater, call your heating contractor. Your water heater has
been manufactured to provide years of service. In order to insure proper service, the following
information is provided to assist in enabling the installation, operation, and maintenance of this
water heater. When the installation is completed, keep this manual with the water heater.
INSTALLATION AND OPERATING INSTRUCTIONS
www.ibcboiler.com
IBC INDIRECT WATER HEATERS - ALL MODELS
HAZARDS &
PRECAUTIONS
DANGER
Points out an immediately
hazardous situation which
must be avoided in order
to prevent serious injury or
death.
WARNING
Points out a potentially
hazardous situation which
must be avoided to prevent
serious injury or death.
CAUTION
Points out a potentially
hazardous situation which
must be avoided to prevent
possible moderate injury and/
or property damage
NOTE
Points out installation,
maintenance and operation
details that will result in
enhanced efciency, longevity
and proper operation of your
boiler.
IMPORTANT SAFETY INSTRUCTIONS
WARNING
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.
When using electrical appliances, basic safety precautions to reduce
the risk of re, electric shock, or injury to persons should be followed,
including:
READ ALL INSTRUCTIONS BEFORE USING THIS WATER HEATER.
1. Water heaters equipped with electric backup must be grounded. Connect only to properly grounded outlet. See “GROUNDING INSTRUCTIONS” found in Section IV.
2. Install or locate this water heater only in accordance with the provided
installation instructions
3. Use this water heater only for its intended use as described in this
manual.
4. Do not use an extension cord with electric back-up water heaters. If no
receptacle is available adjacent to the water heater, contact a qualied
electrician to have one properly installed.
5. As with any appliance, close supervision is necessary when used by
children.
6. Do not operate this water heater if it is not working properly, or if it has
been damaged or dropped.
7. Installation, start-up and servicing of IBC Indirect Water Heaters must
be done with due care and attention, and should only be performed
by competent, qualied, licensed and trained plumbing and heating
technicians. Contact nearest authorized service facility for examination,
repair, or adjustment.
1) - General Information
This equipment shall be installed in accordance with those installation regulations
required in the area where the installation is to be made. These regulations shall
be carefully followed in all cases. Authorities having jurisdiction shall be consulted
before the installations are made.
All wiring on water heaters shall be in accordance with the National Electrical
Code and/or local regulations.
2
SAVE THESE INSTRUCTIONS
IMPORTANT INFORMATION – READ CAREFULLY
NOTE
INSTALLATION AND OPERATION INSTRUCTIONS
IBC INDIRECT WATER HEATERS - ALL MODELS
Table of Contents:
1. General Information and
Specications
2. Pre-Installation
3. Piping
4. Electrical
5. Operation
6. Maintenance
7. Troubleshooting
8. Schematics
9. Water Heater Selection
Data
NOTE
The instructions in this
manual focus almost entirely
on installations where the
IBC water heater is used in
conjunction with a compatible
IBC Boiler. It is necessary
for the Installer and Designer
to read the IBC Boiler
manuals and application
notes, to ensure that nished
installations will operate in
harmony and deliver optimal
energy savings and efciency.
IBC water heaters are
compatible with most other
boiler makes, and can be
an excellent choice, but
Installers and Designers must
tailor their designs to the
specic control, operational
and installation requirements
of any alternate Boiler.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause
property damage, personal injury, or loss of life. Read and understand the entire
manual before attempting installation, start-up, operation, or service. Installation
and service must be performed only by an experienced, skilled installer or service
agency.
This water heater contains very hot water under high pressure. Do not unscrew
any pipe ttings or attempt to disconnect any components of this water heater
without positively assuring that the water is cool and has no pressure. Always
wear protective clothing and equipment when installing, starting up or servicing
this water heater to prevent scalding injuries. Do not rely on the pressure and
temperature gauges to determine the temperature and pressure of the water
heater. This water heater contains components that become very hot when the
boiler is operating. Do not touch any components unless they are cool.
Failure to follow all instructions in the proper order can cause personal injury
or death. Read all instructions, including all those contained in component
manufacturers’ manuals before installing, starting up, operating, maintaining, or
servicing the water heater.
CAUTION
To reduce the risk of excessive pressures and temperatures in this water heater,
install temperature and pressure protective equipment required by local codes
but no less than a combination temperature relief valve certied by a nationally
recognized testing laboratory that maintains periodic inspection of production of
listed equipment or materials, as meeting the requirements for Relief Valves and
Automatic Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22-latest
edition. This valve must be marked with a maximum set pressure not to exceed
the marked working pressure of the water heater. Install the valve into an opening
provide and marked for this purpose in the water heater, and orient it or provide
tubing so that any discharge from the valve will exit only within 6 inches above, or
at any distance below, the structural oor, and cannot contact any live electrical
part. The discharge opening must not be blocked or reduced in size under any
circumstances.
The heat transfer medium must be water or other non-toxic uid having a toxicity
rating or class of 1, as listed in clinical Toxicology of Commercial Products, latest
edition.
The pressure of the heat transfer medium must be limited to the maximum of 30
or 75 psig (depending on IBC boiler model) by its approved pressure relief valve.
CAUTION
Installation, start-up and
servicing of IBC boilers and
Water Heaters must be done
with due care and attention,
and should only be performed
by competent, qualied,
licensed and trained heating
technicians.
INSTALLATION AND OPERATION INSTRUCTIONS
DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity
of this or any other appliance.
If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch
any electrical switch or use any phone in the building. Immediately, call the gas
supplier from a remote located phone. Follow the gas supplier’s instructions or if
the supplier is unavailable, contact the re department.
3
IBC INDIRECT WATER HEATERS - ALL MODELS
3/4" NPT
8.0
Storage Coil Piping Connections-N.P.T. Max. Approx
Model Volume Heating Dimensions Domestic Boiler Working Shipping
Surface (inches) Water Water Pressure Wt.-Lbs.
(Gals.) Sq. Ft. Ht. Dia. In/Out In/Out (psi)
IBC 30 30 7.0 34.0 23.5 3/4 1 150 85
IBC 40 40 7.5 44.0 23.5 3/4 1 150 100
IBC 40L 42 7.1 36.0 28.0 3/4 1 150 100
IBC 50 50 8.0 54.0 23.5 3/4 1 150 110
IBC 60 60 8.3 62.0 23.5 3/4 1 150 125
IBC 60L 60 7.5 46.0 28.0 3/4 1 150 120
IBC 80 80 8.0 56.0 28.0 1 1 150 140
IBC 115 115 8.9 74.0 28.0 1 1 150 175
IBC 80-C 80 8.0 56.0 28.0 1 150 140
IBC 115-C 115 8.9 74.0 28.0 1 150 175
High Output Units IBC 80-HO and IBC 115-HO
1 1/2
1 1/2
IBC 80-HO 80 13.4 56.0 28.0 1 1 150 155
IBC 115-HO 115 14.4
IBC 80-HO-C
IBC 115-HO-C
80 13.4
115 14.4
74.0 28.0 1 1 150 190
56.0 28.0 1 1/2 1 1/4 150 155
74.0 28.0 1 1/2 1 1/4 150 190
Table 1: Dimensions and Capacities
SENSOR
WELL
-C UNITS
8.0
DRAIN
HOT OUTLET
T+P VALVE
DOM. COLD INLET
SENSOR
WELL
DRAIN
STANDARD UNITS
BOILER RETURN
8.0
BOILER SUPPLY
Figure 1: Standard Unit - Dimensions and
Connections
RECIRC. PORT
1 1/2" NPT
HOT OUTLET
1 1/4" NPT
BOILER SUPPLY
1 1/2" NPT
DOM. COLD INLET
9.5
Figure 2: C Series Unit - Dimensions and
Connections
Max. First Continuous Boiler Min. Boiler Pressure
Model Hour Rating Rating Output Water Flow Drop
Gal./Hr. @ Gal./Hr. @ Required Through Coil Through Coil
140 F 115 F 140 F 115 F (BTU/Hr.) Gal./Min. (Ft.Water)
IBC 30 168 223 144 200 125,600 14.0 5.3
IBC 40 185 244 154 213 134,200 14.0 5.7
IBC 40L 168 223 144 200 125,600 14.0 5.3
IBC 50 201 265 163 226 129,900 14.0 6.0
IBC 60 218 286 172 240 151,000 14.0 6.2
IBC 60L 200 260 154 213 134,100 14.0 5.7
IBC 80 229 293 167 231 145,600 14.0 6.0
IBC 115 274 347 186 258 162,400 14.0 6.6
IBC 80-C
IBC 115-C
229 293 167 231 145,600 14.0 6.0
274 347 186 258 162,400 14.0 6.6
High Output Units 80-HO and 115-HO
IBC 80-HO
IBC 115-HO
IBC 80-HO-C
IBC 115-HO-C
332 436 270 374 235,600 14.0 9.9
378 488 289 400 251,700 14.0 10.5
351 462 289 400 251,700 21.0 15.8
387 501 298 413 259,800 21.0 16.7
Note: All Ratings are based on 180 degree F boiler water supply and 50 degree F cold Water inlet.
For 160 degree F boiler water supply multiply by ratings by 0.86
In the interest of continuous improvement, specifications are subject to change without notice.
Table 2: Ratings - Also refer to Section 9, Tables 6 and 7 for more detail about extended capacities and temperatures
8.0
T+P VALVE
1 1/4" NPT
BOILER RETURN
4
INSTALLATION AND OPERATION INSTRUCTIONS
IBC INDIRECT WATER HEATERS - ALL MODELS
Supplied with this Water Heater:
The IBC Water Heater is shipped
with the following items:
1 x 210°F x 150 psig T & P relief
valve
1 x IBC 10KΩ Temperature sensor
Installation Instructions
Warranty Sheet
NOTE
If this water heater is to be
installed with a different
make of boiler than IBC, the
sensor supplied will not be
compatible. The temperature
well in the IBC water heater
is designed to accept a
number of different aquastat
thermostats which can be
ordered separately. Contact
your IBC Distributor to order
an alternate temperature
controller.
2) - Pre-Installation Considerations
Inspect shipment carefully for signs of damage. All equipment is carefully
inspected and packed. IBC’s responsibility ceases upon delivery of the water
heater to the carrier in good condition. Any claims for damage or shortage, must
be led immediately against the carrier by the consignee. No claims for variances
or shortages will be allowed by the Manufacturer, unless they are presented
within sixty days after receipt of the equipment.
Installation must conform to the requirements of the authority having jurisdiction.
In the absence of such requirements, it must conform to the National Plumbing
Code and the National Electrical Code ANSI/NFPA No. 70, current edition.
IMPORTANT CONSIDERATIONS BEFORE INSTALLATION
1. Water heater sizing
Choose the water heater model based on the expected water usage for the given
site. The average residence with one shower or more will require a Model 40
or larger. The Model 30 should only be considered for residences with minimal
water demand, or for commercial applications without showers.
Factors that increase water demand dramatically include high ow shower
heads, hot tubs, and the use of more than one shower at a time. Increase the
tank size if these factors are present. Carefully review the IBC Water Heater
specications contained herein, and consult ASHRAE sizing guides and other
reliable references.
Dimensions, weights, ratings, and capacities are outlined in Tables 1 and 2.
NOTE
There are a number of
jurisdictional issues that may
prevent this water heater
from being accepted by local
Inspection Authorities. Issues
such as double-wall heat
exchanger requirements,
local or State registration
requirements, may cause an
installation to be rejected.
It is essential that the Installer
check with local Ofcials
to ensure acceptance of
this equipment prior to the
installation.
IBC will not accept liability
for any of these situations,
although we will assist in any
way we can, in order to help
gain acceptance.
2. Boiler sizing
The water heater will provide the rated performance only if it is used with a
boiler with a heating capacity of at least as much as the capacity ratings in Table
2. If the boiler has less capacity, the water heating output will be reduced. To
determine performance with other boiler outputs, refer to the expanded capacity
tables #6 and #7 in Section 9 of this manual.
3. Circulator sizing
Refer to Table 2 and table 5 for the ow through the water heater coil and the
pressure drop at minimum ow. Calculate the pressure drop across all piping and
ttings connected to the water heater zone. Be sure to include all zone valves,
check valves, and shut-off valves. It is recommended that the water heater zone
be piped with 1” pipe around the entire loop on typical residential sites.
A. System Zone Control
The water heater must be installed as a separate zone from the space heating
system. The water heating zone’s piping and circulator must be sized for the
minimum ow rate with all the zones in use and a maximum ow with only the
water heater in use. This is the reason that the best method of zone control is
with circulators.
The three most common systems are:
1. Zone Circulators - The space heating zones use a circulator for each zone,
and the water heater is controlled with an additional circulator. See Section 8,
Mechanical Drawings #1, #2 and #3.
2. Hybrid System- The space heating zones use zone valves for each zone,
and the water heater is controlled with an additional circulator. See Section 8,
Mechanical Drawing #5.
INSTALLATION AND OPERATION INSTRUCTIONS
5
IBC INDIRECT WATER HEATERS - ALL MODELS
CAUTION
To avoid water damage from
leaks, a drain pan should
be installed under the water
heater unless it is installed in
a location where leaks will not
cause property damage - see
Drawing # 6.
If the discharge from a T&P
relief valve cannot be directed
into a drain or to an area
where water damage will not
occur, a drain pan capable
of draining away the full,
continuous discharge ow
of the relief valve should be
installed.
WARNING
During operation, the T&P
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 atmosphere
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.
3. Zone Valves – The space heating zones use zone valves for each zone, and
the water heater is controlled with an additional zone valve. Select a valve
with a low pressure drop, and adequate pipe size to assure minimum ow.
See Section 8, Mechanical Drawing #4.
B. Priority or Non-Priority for Hot Water
Option 1 – Priority. The demand for space heating is interrupted until the hot
water demand is satised. This option provides the maximum delivery of hot water. IBC boilers are easily congured to operate the Hot Water as a priority load.
Priority is recommended when:
1. The boiler output is less than 100,000 Btu per hour, or
2. The boiler output required to satisfy the hot water demand is more than 50%
of the boiler output needed to satisfy the space heating demand, or
3. When an interruption in space heating can be tolerated during long domestic
hot water draws.
The preferred strategy when using an IBC boiler is to use a load circulator for
domestic hot water and the IBC controller to switch the circulator on and off using
the IBC control logic and sequential priority hardware. In most cases the delay
in space heating will not be noticed because of the rapid recovery of the water
heater. Certain water heater malfunctions, such as a failed sensor or circulator,
might delay space heating temporarily until the IBC controller internal logic takes
over and operates all loads equally until the malfunction is corrected.
Option 2 – Non-Priority. The boiler output is divided between space heating
and water heating. Heating of domestic hot water can be reduced during simultaneous space and water heating demands. The maximum amount of reduction
depends on the boiler output, the number of space heating zones calling, the
space heating target water temperature, and the amount of boiler water ow split
between the space heating and zones and the water heater zone. Most IBC boilers are now shipped with “Load Pairing” software that can provide DHW priority
with simultaneous space heating allowed during moderate heating demands.
C. Locating the water heater.
The water heater should be located in an area where water leakage from the tank
or connections will not result in damage to areas adjacent to the water heater or
to lower oors of the structure. When such a location can not be avoided, a suitable drain pan must be installed under the water heater, and the drain pan must
be connected to a drain.
The water heater should be installed as close to the boiler as is practical for easy
access for service. The unit is designed for installation on combustible ooring
and in alcoves, closets, etc.
SURFACE
Front 1" 30"
DISTANCE FROM
COMBUSTIBLES
FOR SERVICE
DO NOT CAP, PLUG OR OTHERWISE
OBSTRUCT THE DISCHARGE PIPE
OUTLET!
Table 3: Clearances from heater jacket
6
Rear, Right and Left Sides 1" 3"
Top 6” 6”
Bottom 0" 0”
INSTALLATION AND OPERATION INSTRUCTIONS
IBC INDIRECT WATER HEATERS - ALL MODELS
WARNING
There are a number of
conditions, including
improper control settings,
which could result in elevated
tank temperatures from
ANY type of water heater.
An overheating hazard can
result, potentially causing
serious personal injury and/or
property damage.
IBC Highly recommends
as a minimum precaution,
the installation of a point of
source ASSE 1017 approved
thermostatic mixing valve on
the outlet of the water heater.
Local jurisdictions may
require more comprehensive
protective measures
depending on the place of
installation (ie. schools,
nursing homes, etc.). Check
with local Authorities for
direction.
CAUTION
When removing any fuel
burning appliance from a
common venting system, the
opening must be properly
sealed off and; if there are
remaining appliances still
using the common venting
system, the vent must be
examined to ensure that it is
not over-sized as a result of
having removed the old water
heater.
D. Additional recommended components
1. Shut-off valves. Allows the isolation of the water heater from the boiler
system during service.
2. Unions. Allows for easy locating or removal.
3. Vacuum breaker. Protects the water heater from collapse if a hot tank is
valved off to service other components in the system.
4. Thermal expansion tank. If the water heater is installed in a closed water
supply system, such as a system having a back ow preventer in the cold
water supply line, the installation of a thermal expansion tank is required.
5. Refer to drawing #6 in this manual for suggested external components.
E. Removing the Existing Domestic Water Heating System
If the IBC water heater is being installed in an older hydronic system that does
not use an IBC boiler:
• External Tankless Heater - Disconnect all lines to the boiler and plug the
boiler ttings. Disconnect the external heater from the boiler piping, and the
domestic piping systems.
• Internal Tankless Heaters - Disconnect the domestic piping. Do not plug the
cold water or the hot water ttings in the internal tankless coil. Leave the coil
in the boiler with the cold and hot water ttings open to prevent pressure
build-up in the coil.
If the IBC water heater is being installed to replace an electric or direct red
gas or oil water heater: Disconnect the water piping and either strip back to
the nearest main line and cap off, or re-use for the new tank, whichever is
appropriate.
• Electric Water Heater - Disconnect the electrical supply wiring and remove
back to the breaker panel or terminate in an approved junction box. Work
must conform to all applicable electrical codes.
• Direct Fired Gas Water Heater - Disconnect the gas supply line to the heater,
strip back to the nearest mains piping and cap off. Remove vent connector
back to the common venting system and seal off or abandon as applicable.
Work must conform to all applicable codes.
• Direct Fired Oil Water Heater - Disconnect the oil supply line to the heater,
strip back to the tank or nearest mains piping and cap off. If oil heating
system is to be abandoned completely, ensure proper removal and disposal
of old oil tank and remaining fuel oil. Remove vent connector back to the
common venting system and seal off or abandon as applicable. Work must
conform to all applicable codes.
CAUTION
Do not operate the IBC water
heaters in areas where the
Ph is above 8.0 or below
6.0, and/or with chloride
concentrations greater than
80 parts per million (ppm).
IBC’s standard warranty does
not cover problems caused
by improper water Ph or
excessive levels of chlorides.
INSTALLATION AND OPERATION INSTRUCTIONS
F. Water Quality
Improper water quality will reduce the expected life of the water heater. Hard
water, sediment, high or low Ph, and high levels of chlorides in the domestic
water should be avoided. Sediment and hard water will eventually coat the
heating coil inside the water heater and reduce the rate of hot water production
and may, eventually cause a failure. High or low Ph and/or high chloride
concentrations will cause corrosion and eventually failure. A lter is strongly
recommended where sediment is present in the water. A water softening system
is recommended for areas with hard water.
In an area where the water quality is not known, a water quality test should be
performed.
7
IBC INDIRECT WATER HEATERS - ALL MODELS
NOTE
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
uid of known quality can be
brought to the site.
WARNING
Do not use automotive-type
ethylene or other types of
automotive glycol antifreeze,
or undiluted antifreeze
of any kind on the boiler
water side of the system.
This may result in severe
boiler or tank 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.
3) - Piping
A. Domestic water piping - See Section 8, Mechanical Drawing # 6
1. Drain the domestic water system.
• Shut off the cold water supply at the main shutoff valve.
• Open one or more faucets to relieve the pressure. Open the system drain,
leaving the faucets open.
2. Position the water heater in the nal location.
3. Connect the cold water supply piping.
• Install piping onto cold inlet connection -
• Connect to cold water supply connection using the following suggested
components where applicable: A union, a heat trap, a shut-off valve, an
expansion tank, a back ow preventer, a vacuum breaker and a lter
(recommended to prevent sediment buildup).
4. Connect the domestic hot water piping.
• Install piping on to hot water supply connection using a union, a heat trap,
and a shut-off valve.
• Pipe the relief valve discharge so that the discharge from the valve will exit
only within 6 inches above, or at any distance below, the structural oor, and
cannot contact any live electrical part. The discharge opening must not be
blocked or reduced in size under any circumstances.
5. Fill the water heater tank.
• Open all faucets to allow air to purge from the tank and piping. Remove
screens on faucets.
• Open the domestic hot water shut-off valve.
• Slowly open the cold water inlet shut-off valve.
• Purge all of the air from the domestic water system. Allow water to run so the
tank is completely purged of any debris. Run the water long enough so that it
runs clear and to change at least one tank volume change past full. Close all
faucets. Reinstall all of the screens in the faucets.
• Check the system for leaks. Repair as required.
B. Boiler water piping. See Figures in Section 8.
1. Determine where the boiler, the space heating, and the water heater
connections should be made based on the type of piping system that is either
in place, or is to be installed for a new hydronic system installation. See
Schematic drawings in Section 8 for direction.
2. It is recommended that minimum size 1” pipe be used on the water heater
zone to ensure adequate ow, larger sizes (80 and 115 models) min 1 1/4”.
Ethylene glycol is toxic, and
Zone Circulator System
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, and nontoxic boiler water additives of
any kind.
8
For space heating systems that use Zone Circulators only; refer to Mechanical
Drawings #1, #2 and #3 in Section 8 of this manual. The water heater connection
labeled “BOILER SUPPLY” should be piped to the boiler supply piping after
the air purger and before the space heating takeoffs - for primary/secondary
systems, see Mechanical Drawing #1 - parallel piping, see Mechanical drawings
#2 and #3. Mount the water heater circulator as close as is practicable to the
water heater, and make sure the ow arrow points toward the water heater. The
use of shut-off valves is recommended for future service convenience.
INSTALLATION AND OPERATION INSTRUCTIONS
IBC INDIRECT WATER HEATERS - ALL MODELS
NOTE
The piping drawings in
Section 8 of 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 the
drawings have greater clarity.
We require that our boilers
and tanks 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.
The application drawing(s)
shown in this manual are only
part of the nished design.
It is absolutely neccessary
to carefully read and follow
these installation instructions,
and just as importantly, the
installation instructions or the
boiler model you are using
with this water heater.
DANGER
DO NOT connect thermistor
sensors to “Therm” terminals
on the IBC control board.
An overheating hazard can
result, potentially causing
serious personal injury and/or
property damage.
WARNING
The Thermistor temperature
sensor supplied with the IBC
water heater is unlikely to be
compatible with other makes
of boiler or controls, and its
use may create a hazardous
condition. DO NOT USE THE
IBC SENSOR WITH OTHER
APPLIANCE MAKES.
The water heater connection labeled “BOILER RETURN” should be piped to the
boiler return piping as close to the boiler as possible and after any ow control or
check valves in the space heating return piping. The use of a union and a shut-off
valve is recommended. The use of a check valve is required to prevent back ow
through the water heater during operation of the space heating system.
Zone Valve System
It is recommended that minimum size 1” pipe and 1” full-port zone valves with a
high CV be used on the water heater zone to ensure adequate ow.
For a space heating system that uses Zone Valves only, see Section 8,
Mechanical Drawing #4. Some important details for Hybrid Systems - see Section
8, Mechanical Drawing #5. The water heater connection labeled “BOILER
SUPPLY” should be piped to the boiler supply piping after the air purger and
before the space heating circulator. Installing the check valve, as illustrated in
the drawing is necessary to prevent reverse ow from the heating system back
through the water heater. Mount the water heater circulator as close as possible
to the water heater, and make sure the ow arrow points toward the water heater.
The use of a shut-off valve is recommended for future service convenience.
The water heater connection labeled “BOILER RETURN” should be piped to the
boiler return piping as close to the boiler as possible and after any ow control or
check valves in the space heating return piping. The use of a union and a shut-off
valve is recommended. The use of a check valve is required to prevent back ow
through the water heater during operation of the space heating system.
4) - Electrical
1. Install electric wiring and grounding in accordance with the National Electrical
code and local regulations.
2. All water heaters are supplied with a temperature sensor that connects to
the IBC control board “DWH S” terminals with standard 2-wire, 18 gauge
thermostat wire. For other boiler makes, an aquastat thermostat is required.
3. Refer to Mechanical Drawings #1, #2 and #3 for separate circulator wiring.
4. Refer to schematics #4, #5 for zone valve wiring.
5. Reference should be made to the Installation Manual for the boiler as well.
Temperature Sensor
The Temperature Sensor supplied with the IBC Water Heater is an NTC
Thermistor type with a resistance of 10,000 ohms at 25°C and β = 3892. IBC
does not recommend using 3rd party supplied sensors. Compatible water
temperature sensors are readily available from your IBC distributor.
The resistance of the temperature sensor 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 kΩ (5,000,000Ω) at the
controller end of the sensor lead).
To obtain a resistance reading, remove power to the boiler. The sensor leads
must be disconnected from the terminal strip while taking the reading. Do not grip
the sensor leads in your hands or place them on or against a conductive surface
or the reading will be compromised. Place multi-meter probes onto the bare wire
ends of the leads and obtain the reading. Compare the reading to the actual
sensor temperature and the resistance value listed for that temperature in Table 4
(below). Do not apply voltage to the sensor (damage may result).
INSTALLATION AND OPERATION INSTRUCTIONS
9
IBC INDIRECT WATER HEATERS - ALL MODELS
WARNING
IBC water heaters are
supplied with a 10kΩ
thermistor sensor to be
inserted into the temperature
well of the tank, and secured
with a retainer clip or cap.
The thermistor must be solidy
afxed so as to prevent it
from falling out or being
pulled out. If the sensor
is pulled out of the well, a
continuous call for hot water
will be generated, resulting in
elevated tank temperatures
and risk of scalding.
NOTE
When programming the IBC
DHW load in the Congure
Load Menu, there are three
critical settings that will result
in satisfactory operation.
DHW Supply Set Point
The temperature to which the
boiler heats the water that it
sends into the Water heater coil.
Must be at least 20°F higher
than the DHW Tank Set Point
temperature.
DHW Tank Set Point
The temperature the end
user gets from the faucet.
Recommended to be no higher
than 120°F to prevent scalding.
Maximum Supply Temp
The highest DHW Supply Set
Point temperature the boiler will
allow. Should be at least 20°F
higher than the DHW Supply
Set Point temperature.
Supply Diff’l Temp
The variance the control allows
in the DHW Supply Set Point.
Trial setting of 20°F. Set higher
to reduce short-cycling around
the DHW Supply Set Point.
Tank Diff’l Temp
The variance the control allows
in the DHW Tank Set Point. Trial
setting of 10°F. Set lower for
tighter Tank temperature control.
TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE
°F °C Ω °F °C Ω
30 -1 34,558 115 46 4,184
35 2 29,996 120 49 3,760
40 4 26,099 125 52 3,383
45 7 22,763 130 54 3,050
50 10 19,900 135 57 2,754
55 13 17,436 140 60 2,490
60 16 15,311 145 63 2,255
65 18 13,474 150 66 2,045
70 21 11,883 155 68 1,857
75 24 10,501 160 71 1,689
80 27 9,299 165 74 1,538
85 29 8,250 170 77 1,403
90 32 7,334 175 79 1,281
95 35 6,532 180 82 1,172
100 38 5,828 185 85 1,073
105 41 5,210 190 88 983
110 43 4,665 195 91 903
Table 4: Temperature Sensor resistance values
5) - Operation
Startup
After the water heater has been plumbed and wired, and the boiler water piping
is purged of air, the water heater is ready to be started.
1. Follow the boiler installation instructions to place the boiler in operation.
2. In the “Installer Setup Menu”, go to “Heat Load Conguration” and “Dene
Load 1” as DHW. Move to “Congure Load 1” and enter the appropriate
values for the system you are working with.
3. When the actual tank temperature is below the DHW “Tank Set Point”
temperature, the boiler will turn on the DHW pump or valve and re up its
burner. It will then throttle up in order to raise the boiler water temperature to
the “DHW Supply Set Point” temperature. As the tank heats, the boiler will
throttle down, and when the tank temperature reaches Set Point, the boiler
will shut off (if there are no other loads calling for heat) and turn off the DHW
pumps and/or valves.
4. If the boiler switches over to satisfy other heating loads, and the tank
temperature falls below the Tank Set Point temperature, it will return to DHW
operation if the DHW Priority setting is higher than the other heating loads.
Temperature Adjustment
The tank sensor controls the maximum water temperature in the water heater. If
it is set too high, the resulting hot water can cause painful scalding with possible
serious and permanent injury. The temperature at which this occurs varies with
a person’s age, and the length of time in contact with the hot water. The slower
response time of infants, older, or handicapped people increases the hazard for
them.
10
INSTALLATION AND OPERATION INSTRUCTIONS
IBC INDIRECT WATER HEATERS - ALL MODELS
CAUTION
As a precaution:
After the water heater
has reached its setpoint
temperature, the installer
should locate a faucet that
is unprotected by an overtemperature device.
Turn the faucet on full, and
allow it to run long enought to
ensure the water and piping
have been heated up to the
discharge temperature of the
tank.
Using an accurate
thermometer, test the water
temperature to ensure it is
withing plus or minus 10°F of
the setpoint. If there is more
deviation, the cause should
be determined and corrective
measures taken.
It is recommended that the thermostat be set for the lowest possible temperature
that satises your needs. This will also provide you with the lowest energy
consumption and cost.
Check the water temperature at a hot water faucet soon after the tank thermostat
has satised, and the circulator and the boiler have turned off. Adjust as needed.
Lowering the thermostat setting will not have an immediate effect on the water
temperature because the stored water will have to be used and the thermostat
must go through the cycle of heating cold water and satisfying at the new, lower
temperature. Additional temperature checks should follow the completion of a
heating cycle. Further adjustments may be required after you have used the
water heater.
6) - Maintenance
The water heater is intended to provide many years of reliable service.
Components, such as sensors and relief valves, may be subject to failures that
require service. Depending on the quality of the water supply, sediment and/or
scale may coat the heating coil in the tank and reduce hot water recovery rate.
Failure to use the correct procedures or parts can result in unsafe operation.
The owner should arrange to have the following inspections and simple
maintenance procedures done at the suggested frequencies.
1. Boiler and Domestic Water Piping (Annual)
Check all piping for signs of leakage at the joints, unions and shut-off valves.
Repair as required.
2. Temperature and Pressure Relief Valve (Annual)
3. Sediment (Annual except where harsh water quality may require more
frequent service)
Depending on water conditions, a varying amount of sediment may collect
in the tank. Levels requiring service are indicated by a small temperature
difference between the boiler supply and return lines, and a reduced recovery
rate. Repeated ushing usually clears such material. As a preventive
measure, water should be drawn from the drain valve until it runs clear and
the installation of a water lter should be considered.
4. Scale (Annual)
Hard water may cause scale buildup on the outside of the heating coil
inside the tank. A water softener will help prevent this problem. Symptoms
are identical to sediment buildup. If repeated ushing does not resolve the
problem, chemical cleaning may be required. Proceed as follows:
Chemical cleaning of the heating coil:
1. To avoid water damage, shut off the cold water supply to the water heater.
2. Make a note of the DHW temperature control setting on the IBC control,
and turn off the power to the boiler and water heater.
3. Relieve the water pressure in the tank by opening a hot water faucet. This
will reduce the risk of scalding.
4. Remove the relief valve from the water heater.
5. Drain the water heater until the water is at a level equal to 3” above the
thermostat well. This level will cover the coil and the thermostat.
INSTALLATION AND OPERATION INSTRUCTIONS
11
IBC INDIRECT WATER HEATERS - ALL MODELS
6. Using a funnel, pour one gallon of commercial ice maker cleaning solution
into the tank through the relief valve opening. Follow the instructions,
cautions, and warnings supplied with the cleaning solution.
7. Turn on the power to the boiler and water heater, program the IBC control
to its highest DHW temp. setting, and allow the boiler to heat the water until
the control is satised. If the boiler control is not satised after 45 minutes
of operation, program the IBC DHW control setting to its lowest temp.
8. Allow the heated solution to set in the tank 30 minutes.
9. Drain the tank completely using ttings and hoses, as required, to reach a
drain.
10. Fill the water heater tank with fresh, cold, water and drain it completely.
Repeat lling and draining at least three (3) times to ush all of the
cleaning solution from the tank.
11. Reinstall the relief valve and the drain piping.
12. Open the cold water supply and ll the tank with water. Purge the air from
the tank and the piping by opening the cold and hot water faucets in the
house.
13. Return the IBC DHW control setting to the temperature noted in Step 2.
7) - Troubleshooting
SYMPTOM DIAGNOSIS REMEDY
WATER AT FAUCETS TOO
HOT
WATER AT FAUCETS TOO
COOL
IBC boiler DHW
temperature setting
too high
DHW temperature
sensor problems
giving false reading to
IBC Control
IBC boiler DHW
temperature setting
too low
IBC boiler DHW
Maximum Supply
Temp. setting too low
• Reduce the DHW Tank Set Point
• Sensor has fallen from well
• Sensor giving incorrect resistance reading
• sensor connected to Therm terminals
• improper 3rd party sensor installed in well
•
• Increase the DHW Tank Set Point
• Make sure the Maximum Supply Temp.
temperature in the Congure Load Menu
instead of DHW S terminals
temperature in the Congure Load Menu
setting is at least 10°F higher than the DHW
Supply Setpoint PLUS 1/2 of the Supply
Diff’l Temp setting.
12
INSTALLATION AND OPERATION INSTRUCTIONS
IBC INDIRECT WATER HEATERS - ALL MODELS
SYMPTOM DIAGNOSIS REMEDY
NO HOT WATER AT
FAUCETS
Boiler does not
operate
Water Heater
Circulator does not
operate
Water heater zone
valve does not open
• Ensure boiler power is on
• Ensure the boiler is programed for DHW and
the water temperatures are set properly
• Check the tank temperature on the IBC
screen, Open or Short + sensor or wiring
issue
• Follow steps for Boiler does not operate
• Ensure the boiler green terminal strip has
power (120V) to the lower 2 terminals P/VL
and P/VN
• Check wiring connections at the circulator
• Measure voltage at the circulator during a
call for heat, should see 120VAC +/- 12VAC
• If power is at the circulator and connections
are correct, replace circulator
• Follow steps for Boiler does not operate
• Check for 24VAC at the zone valve while
there is a call for heat, if correct voltage is
available and connections are good, replace
the zone valve.
Tank sensor open,
short, or mis-wired
• If the zone valve is connected to the P/V
terminals on the IBC boiler, ensure 24VAC
has been applied to the P/VL and P/
VN terminals on the bottom of the green
terminal strip and in the Installer Menu the
Load Control has been set to Valve
• Ensure the tank sensor is connected to the
correct terminals and the wires are properly
attached to the terminal strip and the sensor
is properly attached to the wiring at the tank
• Disconnect the sensor wires from the
terminal strip and measure the resistance in
Ohm’s across the 2 sensor wires. Compare
this value to the chart and the actual tank
temperature. Repeat this test for the sensor
only and compare the results. Check/
replace the wire from the boiler to the sensor
or replace the sensor
INSTALLATION AND OPERATION INSTRUCTIONS
13
IBC INDIRECT WATER HEATERS - ALL MODELS
ELECTRICAL LADDER DIAGRAM
3 Load Primary/Secondary with Pumps - Refer to Mechanical Drawing #1
Valid for all IBC Boilers except the SL 80-399 - refer to SL 80-399 I&O Manual
IBC
CB
Input to ProcessorInput to Processor
DO NOT connect ANYTHING to these terminals
Auxiliary Interlock
Fan Coil Thermostat
Radiant Thermostat
Interlock 1
Therm. 1
Interlock 2
Therm. 2
Therm. 3
Outdoor S.
Indoor S.
2nd Loop S.
DHW S.
Boiler Net +
Ext. Cont. –
G
120VacL N
IBC Control Board
Boiler Pump
(P1)
CB-1
Yellow
White
CB-2
CB-3
CB-4
P/ V Power - L
P/ V Power - N
P/ V3 - N
P/ V3 - L
P/ V1 - N
P/ V1 - L
P/ V2 - N
P/ V2 - L
IBC
CB
Domestic Hot Water Sensor
Supplied with IBC Water Heater
Interlock 1
Interlock 2
Therm. 1
Therm. 2
Therm. 3
Outdoor S.
Indoor S.
2nd Loop S.
DHW S.
Boiler Net –
Ext. Cont. +
White
Green
Black
Fuse - 5A
Fuse - 5A
Fuse - 5A
Fuse - 5A
G1
DHW
Pump
(P2)
Fan Coil
Pump
(P3)
Radiant
Pump
(P4)
G2
G3
G4
G5
G6
G7
G8
O1
O2
O3
O4
O5
O6
O7
O8
O9
O10
O11
O12
O13
O14
O15
O16
O17
O18
O19
O20
O21
O22
Auxiliary Interlock
Outdoor Sensor
Supplied with IBC Boiler
8) - Schematics
NOTE
Full sized and more detailed
application drawings can be
downloaded from our web
site.
www.ibcboiler.com
NOTE
When using the sequential
load feature of the IBC boiler,
attention must be paid to
the operation of system
components in order to
ensure they are compatible.
Many air handlers (fan
coils) for instance have a
thermostat connection that
will energize an internal relay
to operate the air handler
circulator and its fan on
a call for heat. This may
result in operation of these
components when other
loads are running at a higher
priority, resulting in cold air
blowing, or robbing heat from
another load.
14
Some wiring alteration may
be required to divorce both
of these functions from
thermostat control in favour
of more effective control from
the IBC boiler.
Outdoor Sensor
IBC
BOILER
IBC
Thermostat
Mechanical
Domestic Hot Water Sensor
Boiler Pump
Radiant
DHW Pump
(P2)
(P1)
LOW TEMP RADIANT
DHW
Fan Coil
Pump
(P3)
Fan Coil
Thermostat
Radiant
Pump
(P4)
FAN COIL
Drawing #1
3 Load Primary / Secondary Piping/w Pumps
INSTALLATION AND OPERATION INSTRUCTIONS
IBC INDIRECT WATER HEATERS - ALL MODELS
ELECTRICAL LADDER DIAGRAM
2 Load Parallel Piping/w Pumps - Refer to Mechanical Drawings #2 & #3
Valid for all IBC Boilers except the SL 80-399 - refer to SL 80-399 I&O Manual
IBC
CB
Input to ProcessorInput to Processor
DO NOT connect ANYTHING to these terminals
Auxiliary Interlock
Fan Coil Thermostat
Interlock 1
Therm. 1
Interlock 2
Therm. 2
Therm. 3
Outdoor S.
Indoor S.
2nd Loop S.
DHW S.
Boiler Net +
Ext. Cont. –
G
120VacL N
IBC Control Board
CB-1
Yellow
White
CB-2
CB-3
CB-4
P/ V Power - L
P/ V Power - N
P/ V3 - N
P/ V3 - L
P/ V1 - N
P/ V1 - L
P/ V2 - N
P/ V2 - L
IBC
CB
Domestic Hot Water Sensor
Supplied with IBC Water Heater
Interlock 1
Interlock 2
Therm. 1
Therm. 2
Therm. 3
Outdoor S.
Indoor S.
2nd Loop S.
DHW S.
Boiler Net –
Ext. Cont. +
White
Green
Black
Fuse - 5A
Fuse - 5A
Fuse - 5A
Fuse - 5A
G1
DHW
Pump
(P1)
Fan Coil
Pump
(P2)
G2
G3
G4
G5
G6
G7
G8
O1
O2
O3
O4
O5
O6
O7
O8
O9
O10
O11
O12
O13
O14
O15
O16
O17
O18
O19
O20
O21
O22
Auxiliary Interlock
Outdoor Sensor
Supplied with IBC Boiler
LN
Outdoor Sensor
IBC
BOILER
IBC
DHW Pump
(P1)
Fan Coil Pump
(P2)
Domestic Hot Water Sensor
Fan Coil Thermostat
DHW
FAN COIL
Mechanical Drawing #3, immediately below,
is only applicable to the IBC model SL 20-115
Mechanical Drawing #2
2 Load Parallel Piping/w Pumps
NOTE
IBC VFC Series boilers
have been designed to take
advantages of the many
benets of primary/secondary
piping. These models have a
software routine that utilizes
the boiler pump contacts on
start-up in order to prove
ow. The sketch below details
a wiring modication that
must be made when using
parallel pumping with IBC
VFC model Boilers.
On a VFC Model boiler, locate the
Black
IBC Control Board
Yellow and White pair of wires in the
wiring box behind the IBC Control.
Connect the Yellow wire to the “P/V
Power L” terminal second from the
bottom on the Green terminal plug.
Connect the White wire to the bottom
terminal labelled “P/V Power N”. This
will satisfy the boiler’s ow proving
routine when either zone starts up.
INSTALLATION AND OPERATION INSTRUCTIONS
ELECTRICAL LADDER DIAGRAM DETAIL
CB-1
CB-2
CB-3
CB-4
VFC Series Boiler Wiring for Parallel Piping
Valid for IBC VFC 15-150 and VFC 45-225 Model Boilers
120Vac
IBC
CB
Fuse - 5A
Fuse - 5A
Fuse - 5A
Fuse - 5A
P/V1 - L
P/V1 - N
P/V2 - L
P/V2 - N
P/V3 - L
P/V3 - N
P/V Power - L
P/V Power - N
Green
White
White
Yellow
G1
G2
G3
G4
G5
G6
G7
G8
G
DHW
Pump
(P1)
Heating
Pump
(P2)
Connect Yellow and
White Primary Pump
wires to the bottom
two terminals on the
Green Terminal Strip
Mechanical
Drawing #3
DHW Pump
(P1)
Outdoor Sensor
IBC
SL 20-115
BOILER
Fan Coil Pump
(P2)
Fan Coil Thermostat
DHW
Domestic Hot Water Sensor
IBC
2 Load Parallel - 2 Side Piping - SL 20-115 & Pumps Only
FAN COIL
15
IBC INDIRECT WATER HEATERS - ALL MODELS
NOTE
When using zone valves in a
multi-zone heating system,
careful consideration must
be taken to ensure that ow
rates do not decrease below
the boiler’s rated minimum
ow requirement. Bypass
arrangements (pressure
activated bypass, three way
valves, etc.) may be required
to ensure adequate ow
under low load conditions.
L
R
120 Vac
24 Vac
Transformer
N
C
Black
IBC Control Board
CONNECT ANY 120Vac LOADS
IS WIRED UP FOR 24Vac, DO NOT
WHEN THE GREEN TERMINAL BLOCK
CB
IBC
Input to ProcessorInput to Processor
CB-1
CB-2
CB-3
CB-4
Outdoor Sensor
IBC
IBC
CB
DHW Zone Valve
IBC
BOILER
(ZV1)
Boiler
Pump
(P1)
Domestic Hot Water Sensor
Fan Coil Thermostat
Fan Coil
Zone Valve
(ZV2)
ZV
ZV
DHW
FAN COIL
Mechanical Drawing #4
2 Load Parallel Piping/w Zone Valves
ELECTRICAL LADDER DIAGRAM
2 Load Parallel Piping/w 24 Vac Zone Valves
Valid for all IBC Boilers except the SL 80-399 - refer to SL 80-399 I&O Manual
120VacL N
Fuse - 5A
Fuse - 5A
P/ V1 - R
P/ V1 - C
Fuse - 5A
P/ V2 - R
P/ V2 - C
Fuse - 5A
P/ V3 - R
P/ V3 - C
P/ V Power - R
P/ V Power - C
Therm. 1
Therm. 1
Therm. 2
Therm. 2
Therm. 3
Therm. 3
Indoor S.
Indoor S.
DHW S.
DHW S.
O1
O2
O3
O4
O5
O6
O7
O8
O9
O10
O11
O13
O17
O19
O20
O21
O22
Interlock 1
Interlock 1
Interlock 2
Interlock 2
Outdoor S.
Outdoor S.
2nd Loop S.
2nd Loop S.
Boiler Net +
Boiler Net –
Ext. Cont. –
Ext. Cont. +
Refer to Mechanical Drawing #4
Green
White
White
Yellow
G1
G2
G3
G4
G5
G6
G7
G8
Auxiliary Interlock
Auxiliary Interlock
DO NOT connect ANYTHING
to these terminals
O12
O14
O15
O16
O18
White
G
Boiler Pump
(P1)
DHW Zone
Valve
(ZV1)
Fan Coil
Zone Valve
(ZV2)
Fan Coil Thermostat
Outdoor Sensor
Supplied with IBC Boiler
Domestic Hot Water Sensor
Supplied with IBC Water Heater
16
INSTALLATION AND OPERATION INSTRUCTIONS
IBC INDIRECT WATER HEATERS - ALL MODELS
ELECTRICAL LADDER DIAGRAM
“Hybrid” Zoning System - 2 Temp Parallel Piping/w DHW Pump and
Baseboard System Zone Valves - Refer to Mechanical Drawing #5
Valid for all IBC Boilers except the SL 80-399 - refer to SL 80-399 I&O Manual
IBC
CB
Input to ProcessorInput to Processor
Interlock 1
Therm. 1
Interlock 2
Therm. 2
Therm. 3
Outdoor S.
Indoor S.
2nd Loop S.
DHW S.
Boiler Net +
Ext. Cont. –
G
120VacL N
IBC Control Board
CB-1
Yellow
White
CB-2
CB-3
CB-4
P/ V Power - L
P/ V Power - N
P/ V3 - N
P/ V3 - L
P/ V1 - N
P/ V1 - L
P/ V2 - N
P/ V2 - L
IBC
CB
Domestic Hot Water Sensor
Supplied with IBC Water Heater
Interlock 1
Interlock 2
Therm. 1
Therm. 2
Therm. 3
Outdoor S.
Indoor S.
2nd Loop S.
DHW S.
Boiler Net –
Ext. Cont. +
White
Green
Black
Fuse - 5A
Fuse - 5A
Fuse - 5A
Fuse - 5A
G1
DHW
Pump
(P1)
Baseboard
Pump
(P2)
G2
G3
G4
G5
G6
G7
G8
O1
O2
O3
O4
O5
O6
O7
O8
O9
O10
O11
O12
O13
O14
O15
O16
O17
O18
O19
O20
O21
O22
Outdoor Sensor
Supplied with IBC Boiler
DO NOT connect
ANYTHING
to these terminals
Transformer
120 Vac
24 Vac
R
C
N
L
(ZV1)
(ZV2)
(ZV3)
BB Zone 1
Thermostat
BB Zone 2
Thermostat
BB Zone 3
Thermostat
LN
Outdoor Sensor
IBC
BOILER
IBC
Mechanical
Drawing #5
NOTE
“Hybrid” Zoning System
IBC VFC Series boilers
have been designed to take
advantages of the many
benets of primary/secondary
piping. These models have a
software routine that utilizes
the boiler pump contacts on
start-up in order to prove
ow. The sketch below details
a wiring modication that
must be made when using
parallel pumping with IBC
VFC model Boilers.
On a VFC Model boiler, locate the
Yellow and White pair of wires in the
wiring box behind the IBC Control.
Connect the Yellow wire to the “P/V
Power L” terminal second from the
bottom on the Green terminal plug.
Connect the White wire to the bottom
terminal labelled “P/V Power N”. This
will satisfy the boiler’s ow proving
routine when either zone starts up.
INSTALLATION AND OPERATION INSTRUCTIONS
IBC Control Board
Black
CB-1
CB-2
CB-3
CB-4
IBC
CB
Fuse - 5A
Fuse - 5A
Fuse - 5A
Fuse - 5A
ELECTRICAL LADDER DIAGRAM DETAIL
VFC Series Boiler Wiring for Parallel Piping
Valid for IBC VFC 15-150 and VFC 45-225 Model Boilers
120Vac
Green
White
White
Yellow
G1
P/V1 - L
G2
P/V1 - N
G3
P/V2 - L
G4
P/V2 - N
G5
P/V3 - L
G6
P/V3 - N
G7
P/V Power - L
G8
P/V Power - N
G
DHW
Pump
(P1)
Heating
Pump
(P2)
Connect Yellow and
White Primary Pump
wires to the bottom
two terminals on the
Green Terminal Strip
2 Temp Parallel Piping/w DHW Pump
and Baseboard system Zone Valves
Ganged end-switch dry contact closure
DHW Pump
(P1)
Domestic Hot
Water Sensor
Baseboard
Pump
(P2)
BB Zone 1
Valve (ZV1)
ZV
BB Zone 2
Valve (ZV2)
ZV
BB Zone 3
Valve (ZV3)
DHW
BB Zone 1
Thermostat
BB Zone 1
Thermostat
BB Zone 1
Thermostat
Zone Val ve end-switch
Zone Val ve end-switch
Zone Val ve end-switch
ZV
17
IBC INDIRECT WATER HEATERS - ALL MODELS
115-HO-C 5.6 6.6 10.5 16.7 48.8 14.4
Boiler Flow (gpm)
Head ( ft. of water)
Coils
IBC Technologies Indirect Water Heater, Pressure Drop vs. Boiler Flow
Mechanical Drawing #6
FRESH
WATER
FROM
MAINS
WHOLE
HOUSE SHUT
OFF VALV E
BACKFLOW
PREVENTER
Wherever
required by
local code
PRESSURE
REDUCING
where mains
pressure may
VALV E
Required
exceed
component
pressure
ratings
MAINTENANCE
SHUT OFF
VALV E
contaminates
are present in
WHOLE
HOUSE
WATER
FILTER
Required
where
the water
supply
Domestic Water Piping
Not all components in this drawing may be required by code in
your jurisdiction, but the external components shown here are
all highly recommended by IBC Technologies. At the very
minimum - IBC requires installation of a Vacuum Breaker in the
position shown, with no shut off valves between the device and
the tank. IMPORTANT NOTE: All external components shown
are field supplied.
IBC supplies the Tank, which includes the Factory installed
Temperature Well, Drain Valve, and Temperature & Pressure
Relief Valve. An IBC Temperature Sensor is shipped loose with
the tank to be inserted into the Temperature Well and wired to
the IBC Boiler Control Board on Terminals labelled “DHW S”.
MAINTENANCE
SHUT OFF
VALV E
POTABLE
EXPANSION
TANK
Required
where
backflow
check
valves are
installed
PIPE TO DRAIN
COLD WATER TO
HOUSE
COLD WATER
SHUT OFF
VALV E
Always
required
RELIEF VALVE
DISCHARGE
PIPE
DHW
TANK
SHUT
OFF
VALV E
Always required
when tank can be
isolated by shut
off valves (as is
recommended
by IBC)
VACUUM
BREAKER
UNIONS
DRAIN PAN
DHW
DHW
TO
TANK
HOUSE
SHUT
OFF
VALV E
T & P RELIEF
VALV E
(FACTORY
INSTALLED)
TEMPERATURE
SENSOR WELL
(FACTORY
INSTALLED)
DRAIN VALV E
(FACTORY
INSTALLED)
Drain Pan is
required where
water leakage
might cause
damage to the
structure
9) - Water Heater Selection Data
Model 10 12 14 21 Length Area
30 2.9 3.4 5.3 - 23.6 7.0
40 3.0 3.6 5.7 - 25.4 7.5
40 LOW 2.9 3.4 5.3 - 23.6 7.0
50 3.3 4.0 6.0 - 27.1 8.0
60 3.3 4.0 6.2 - 28.3 8.3
60 LOW 3.1 3.6 5.7 - 25.4 7.5
80 3.3 3.8 6.0 - 27.1 8.0
115 3.5 4.2 6.6 - 30.3 8.9
80-HO 5.2 6.4 9.9 - 45.5 13.4
115-HO 5.6 6.6 10.5 - 48.8 14.4
80-HO-C 5.2 6.4 9.9 15.8 45.5 13.4
Table 5: Pressure drop through coil vs. ow
18
(ft.) (sq. ft.)
INSTALLATION AND OPERATION INSTRUCTIONS
IBC INDIRECT WATER HEATERS - ALL MODELS
250,000 362 473 290 401 412 531 309 428
(GAL/HR)
(GAL/HR)
(GAL/HR)
(GAL/HR)
RATING
RATING
RATING
RATING
(GAL/HR)
Boiler flow = 21 gpm
Boiler flow = 21 gpm
1st HOUR
CONTINUOUS
1st HOUR
CONTINUOUS
1st HOUR
CONTINUOUS
(GAL/HR)
(GAL/HR)
High Output Units - 80-HO and 115-HO - 21 gpm boiler flow
80-HO High Output
115-HO High Output
(GAL/HR)
(GAL/HR)
(GAL/HR)
RATING
RATING
RATING
RATING
RATING
RATING
1st HOUR
CONTINUOUS
60 LOW
80 and 80-C
115 and 115-C
Boiler flow = 14 gpm
Boiler flow = 14 gpm
Boiler flow = 14 gpm
1st HOUR
CONTINUOUS
RATING
RATING
(GAL/HR)
(GAL/HR)
(GAL/HR)
(GAL/HR)
(GAL/HR)
(GAL/HR)
RATING
RATING
RATING
RATING
Boiler flow = 14 gpm
Boiler flow = 14 gpm
Boiler flow = 14 gpm
1st HOUR
CONTINUOUS
1st HOUR
CONTINUOUS
1st HOUR
CONTINUOUS
180 deg. F Boiler Supply
30 and 40LOW
40
60
IBR Rating Condition
Water Heater capacities and performance at 180°F supply water temperature from boiler
MODEL
BOILER
OUTPUT
(BTU/HR)
50,000 94 119 67 92 103 128 67 92 121 146 67 92
60,000 107 138 80 111 116 147 80 111 134 165 80 111
80,000 134 174 107 147 143 183 107 147 161 201 107 147
100,000 160 212 133 185 169 220 133 184 187 238 133 184
120,000 171 227 144 200 190 250 154 214 214 275 160 221
140,000 171 227 144 200 190 250 154 214 227 293 173 239
160,000 171 227 144 200 190 250 154 214 227 293 173 239
MODEL
BOILER
OUTPUT
(BTU/HR)
50,000 121 146 67 92 139 164 67 92 170 195 67 92
60,000 134 165 80 111 152 183 80 111 183 214 80 111
80,000 161 201 107 147 179 219 107 147 210 250 107 147
100,000 187 238 133 184 205 256 133 184 236 287 133 184
120,000 208 268 154 214 232 293 160 221 263 324 160 221
140,000 208 268 154 214 239 303 167 231 289 360 186 257
160,000 208 268 154 214 239 303 167 231 289 360 186 257
140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F
140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F
MODEL
BOILER
OUTPUT
(BTU/HR)
50,000 139 164 67 92 170 195 67 92
60,000 152 183 80 111 183 214 80 111
80,000 179 219 107 147 210 250 107 147
100,000 205 256 133 184 236 287 133 184
120,000 232 293 160 221 263 324 160 221
140,000 258 330 186 258 289 361 186 258
160,000 285 368 213 296 316 398 213 295
180,000 312 405 240 333 343 435 240 332
200,000 339 442 267 370 370 473 267 370
220,000 343 473 271 401 396 509 293 406
240,000 362 473 290 401 412 531 309 428
140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F
Table 6: Output ratings at 180°F boiler supply
INSTALLATION AND OPERATION INSTRUCTIONS
19
IBC INDIRECT WATER HEATERS - ALL MODELS
250,000 304 393 232 321 341 446 238 343
(GAL/HR)
(GAL/HR)
(GAL/HR)
(GAL/HR)
RATING
RATING
RATING
RATING
(GAL/HR)
Boiler flow = 21 gpm
Boiler flow = 21 gpm
1st HOUR
CONTINUOUS
1st HOUR
CONTINUOUS
1st HOUR
CONTINUOUS
(GAL/HR)
(GAL/HR)
High Output Units - 80-HO and 115-HO - 21 gpm boiler flow
80-HO High Output
115-HO High Output
(GAL/HR)
(GAL/HR)
(GAL/HR)
RATING
RATING
RATING
RATING
RATING
RATING
1st HOUR
CONTINUOUS
60 LOW
80 and 80-C
115 and 115-C
Boiler flow = 14 gpm
Boiler flow = 14 gpm
Boiler flow = 14 gpm
1st HOUR
CONTINUOUS
RATING
RATING
(GAL/HR)
(GAL/HR)
(GAL/HR)
(GAL/HR)
(GAL/HR)
(GAL/HR)
RATING
RATING
RATING
RATING
Boiler flow = 14 gpm
Boiler flow = 14 gpm
Boiler flow = 14 gpm
1st HOUR
CONTINUOUS
1st HOUR
CONTINUOUS
1st HOUR
CONTINUOUS
160 deg. F Boiler Supply
30 and 40LOW
40
60
IBR Rating Condition
Water Heater capacities and performance at 160°F supply water temperature from boiler
MODEL
BOILER
OUTPUT
(BTU/HR)
50,000 94 119 67 92 103 128 67 92 121 146 67 92
60,000 107 138 80 111 116 147 80 111 134 165 80 111
80,000 134 174 107 147 143 183 107 147 161 201 107 147
100,000 144 188 117 161 160 208 124 172 187 238 133 184
120,000 144 188 117 161 160 208 124 172 187 238 133 184
140,000 144 188 117 161 160 208 124 172 187 238 133 184
160,000 144 188 117 161 160 208 124 172 187 238 133 184
MODEL
BOILER
OUTPUT
(BTU/HR)
50,000 121 146 67 92 139 164 67 92 170 195 67 92
60,000 134 165 80 111 152 183 80 111 183 214 80 111
80,000 161 201 107 147 179 219 107 147 210 250 107 147
100,000 178 213 124 159 205 256 133 184 236 287 133 184
120,000 178 213 124 159 205 257 133 185 252 310 149 207
140,000 178 213 124 159 205 257 133 185 252 310 149 207
160,000 178 213 124 159 205 257 133 185 252 310 149 207
140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F
140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F
MODEL
BOILER
OUTPUT
(BTU/HR)
50,000 139 164 67 92 170 195 67 92
60,000 152 183 80 111 183 214 80 111
80,000 179 219 107 147 210 250 107 147
100,000 205 256 133 184 236 287 133 184
120,000 232 293 160 221 263 324 160 221
140,000 258 330 186 258 289 361 186 258
160,000 285 368 213 296 316 398 213 295
180,000 304 393 232 321 341 436 238 333
200,000 304 393 232 321 341 446 238 343
220,000 304 393 232 321 341 446 238 343
240,000 304 393 232 321 341 446 238 343
140 F 115 F 140 F 115 F 140 F 115 F 140 F 115 F
Table 7: Output ratings at 160°F boiler supply
20
INSTALLATION AND OPERATION INSTRUCTIONS
Notes
IBC INDIRECT WATER HEATERS - ALL MODELS
Service Record
DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE
INSTALLATION AND OPERATION INSTRUCTIONS
21
IBC INDIRECT WATER HEATERS - ALL MODELS
22
IBC Technologies Inc.
1445 Charles Street,
Vancouver, BC
Canada V5L 2S7
Tel: 604.877.0277
Fax: 604.877.0295
www.ibcboiler.com
120-158A R1
INSTALLATION AND OPERATION INSTRUCTIONS
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