IBC Boilers DC 23-84, DC 29-106, DC 33-124, DC 33-160 Installation And Operating Instructions Manual

DC Series Combi Boilers

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

(Natural Gas or Propane)

WARNING: If the information in this manual is not followed exactly, a re or

explosion may result causing property damage, personal injury, or loss of life.

Do not store or use gasoline or other ammable 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 re department.

Installation and service must be performed by a qualied installer, service

agency or the gas supplier.

This Manual is also available in French - contact IBC or visit our web site www.ibcboiler.com

INSTALLATION AND OPERATING INSTRUCTIONS

www.ibcboiler.com

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

If the information in this manual is not followed

exactly, a re 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ed,

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 & 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 efciency, longevity

and proper operation of your boiler.

BEST PRACTICES

Points out recommendations for better installation.

Supplied with the boiler - The IBC boiler is shipped with an accessory parts kit

consisting of the following items:

• 1 x Wall Mounting Bracket

• 1 x Condensate Assembly

• 1 x Pressure Relief valve, 3/4NPT,

30psi

• 1 x Outdoor Temperature Sensor

• 1 x 3/4” x 1/2” x 3/4” Brass Tee

• 1 x Elbow, 3/4” Brass Street, 90

• 1 x 3/4” x 1-3/8” close Brass

Nipple

• 1 x Automatic Air Vent

• 1 x Tridicator, 1/4”NPT

• 1 x 1” x 1” x 1/4” Brass Tee

• 4 x Lag Screws, Hex Head, Zn-Pl,

1/4 x 2-1/2 and Washers

• 1 x Thermostatic mixing valve

• 1 x DC Installation & Operating

Instructions

• 1 x DC/HC User Manual

• 1 x 1/2” x 1/8” Brass Bushing

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

SPECIFICATIONS

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

CSA Input (Natural Gas or Propane) – MBH 23 – 84 28.5 – 106 33 – 124 33 – 160

CSA Input (Natural Gas or Propane) – KW 6.7 – 24.9 8.4 – 31.0 9.7 – 36.3 9.7 – 46.9

CSA Output – MBH 21 – 79 26 – 99 31 – 115 30 – 149

CSA Output - KW 6.3 – 23.0 7.8 – 28.9 9.0 – 33.8 9.0 – 43.6

DHW - CSA Input (Natural Gas or Propane) - MBH 23 - 84 28.5 - 106 33 - 124 33 - 124

DHW - CSA Input (Natural Gas or Propane) - KW 6.7 - 24.9 8.4 - 31.0 9.7 - 36.3 9.7 - 36.3

A.F.U.E 94% 94% 94% 94%

Min Gas Pressure (Nat. Gas or Propane) – inch w.c. 5 5 5 5

Max Gas Pressure (Nat. Gas or Propane) – inch w.c. 14 14 14 14

Power (120Vac/60Hz) - Watts @ full re with internal pump 126 128 130 164

Weight (empty) – lbs/Kg 85 / 39 85 / 39 85 / 39 85 / 39

Pressure Vessel water content – USG/Liters 0.37/1.4 0.37/1.4 0.5/1.9 0.5/1.9

Max boiler ow rate - USgpm 9 10 11 11

Min boiler ow rate - USgpm 2 3 3 3

Max Operating Pressure – Space Heating Coil - psig 43.5 43.5 43.5 43.5

Max Operating Pressure – Domestic Hot Water Coil - psig 150 150 150 150

Approved installation altitude - ASL 12,000 ft 12,000 ft 12,000 ft 12,000 ft

Ambient Temperature – Low (°F/°C) 32/0 32/0 32/0 32/0

Ambient Temperature – High (°F/°C) 122/50 122/50 122/50 122/50

Max relative humidity (non-condensing) 90% 90% 90% 90%

Min water Temperature - Space Heating (°F/°C) 15/20 15/20 15/20 15/20

Max water Temperature – Space Heating (°F/°C) 194/90 194/90 194/90 194/90

Min water Temperature – Domestic Hot Water (°F/°C) 104/40 104/40 104/40 104/40

Max water Temperature – Domestic Hot Water (°F/°C) 149/65 149/65 149/65 149/65

Min ow rate to activate DHW heating - USgpm 0.5 0.5 0.5 0.5

Max ow rate DHW heating - USgpm 2.6 3.3 4.0 4.0

Max equivalent vent length 3" (each side) 120' 120' 120' 120'

Max equivalent vent length 2" (each side) 35' 35' 35' 35'

* Natural Gas boilers require a Propane conversion kit (see page #3-2, Table 10) to 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 10) to be ordered separately if converting a Propane boiler to Natural Gas.

† boilers are shipped with 30 psig pressure relief valve

INSTALLATION AND OPERATING INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WATER HEATER INSTALLATION GUIDELINES

WARNING

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.

Failure to correctly install and operate this appliance can result in severe personal injury or death.

The water heater, if utilized, shall have a pressure relief valve installed within 6” [152mm] of the DHW HOT outlet connection with the relief valve spindle installed in the vertical position.

Refer to the Boiler User’s Manual before operating relief valve. The water heater, if utilized, requires a pressure relief valve identiﬁed with the ASME V or HV

symbol and set to relieve at or below 150psi of domestic water pressure and a minimum 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.

For complete information refer to installation manual. Read and follow warnings and instructions.

CAUTION

Hotter water increases the risk of scald injury. Before changing the temperature setting, see instruction manual.

ADJUSTABLE TEMPERATURE SETTING

Press the 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

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

CONTENTS

1.0 INSTALLATION....................................................1-1

1.1 GENERAL ...................................................1-1

1.2 CODE REQUIREMENTS........................................1-2

1.3 LOCATION ...................................................1-2

1.4 EXHAUST VENTING AND AIR INTAKE.............................1-3

1.5 CONDENSATE REMOVAL......................................1-16

1.6 WATER PIPING - SPACE HEATING ..............................1-19

1.7 DOMESTIC HOT WATER SYSTEM...............................1-26

1.8 GAS PIPING.................................................1-30

1.9 ELECTRICAL CONNECTIONS ..................................1-31

2.0 BOILER SYSTEMS AND OPERATION .................................2-1

2.1 GENERAL ...................................................2-1

2.2 CONTROL ...................................................2-2

2.3 INSTALLER INTERFACE ........................................2-2

2.4 TANKLESS DOMESTIC HOT WATER MODES.......................2-7

2.5 ADDING DOMESTIC HOT WATER STORAGE.......................2-7

2.6 SPACE HEATING..............................................2-8

2.7 SEQUENCE OF OPERATION ....................................2-9

3.0 STARTUP AND COMMISSIONING ....................................3-1

3.1 LIGHTING AND SHUTTING DOWN THE BOILER ....................3-1

3.2 PRIOR TO START-UP ..........................................3-2

3.3 COMMISSIONING .............................................3-2

3.4 FUEL CONVERSION ...........................................3-4

4.0 MAINTENANCE ...................................................4-1

4.1 BOILER MAINTENANCE........................................4-1

5.0 TROUBLESHOOTING ..............................................5-1

5.1 PRELIMINARY CHECKS ........................................5-1

5.2 ELECTRONIC COMPONENTS ...................................5-2

5.3 WARNINGS AND FAULTS .......................................5-5

5.4 OTHER FAULTS...............................................5-7

6.0 DIAGRAMS.......................................................6-1

6.1 PARTS DIAGRAMS ............................................6-2

6.2 WIRING DIAGRAMS ...........................................6-4

INSTALLATION AND OPERATING INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

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.

DANGER

Should overheating occur

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 appliance

WARNING

Do not use this boiler if any part has been under water.

Immediately call a qualied service technician to inspect

the boiler and to replace any part of the control system and any gas control that has been under water.

CAUTION

Care must be taken to

properly size the boiler for its intended use. Prolonged

full re run time, over-

sizing or under-sizing,

and incorrect ow rates

through the boiler can lead to increased maintenance

costs, equipment stress and

premature failure.

The Installer should do a pre-installation check the to ensure that the following precautions can be observed:

• The boiler should be installed 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 uorinated hydrocarbons can

reduce the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants,

aerosol propellants, dry-cleaning uids, de-greasers and paint-removers all

contain vapours which can form corrosive acid compounds when burned in a

gas ame. Airborne chlorides such as those released with the use of laundry

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 drain pan should be installed under the appliance. The boiler is not to be installed above carpeting.

• 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.

• When the boiler is in operation, the impact of the steam plume normally

experienced at the exhaust terminal of a condensing boiler should be 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 building components in contact with the condensate. Keep exhaust plumes well away from all building air intakes including those of neighbouring properties.

• In sealed combustion applications, the exhaust outlet should be placed so as

to reach 24" minimum above the down-turned intake - to avoid exhaust reingestion.

• For sidewall venting options: Both the inlet and exhaust terminations should

normally be located on the same plane (side) of the building. The elevation of both pipes can be raised in “periscope style” after passing through the wall to gain required clearance above grade and snow level.

• 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.

• In locations 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 DC Series Combi boiler. The addition of a storage tank or an IBC Indirect Water Heater may be required in some cases.

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

INSTALLATION1.0

MODEL NUMBER

DC 23-84 26.6” [676]

DC 29-106 29.0” [736]

DC 33-124 31.3” [796]

DC 33-160 31.3” [796]

HEIGHT

1.1

GENERAL

DC Series gas-red modulating combi boilers are low pressure, fully condensing

units having variable input ranges (see specication 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 nd a suitable location for the boiler. See also Section 1.3 Location.

DESCRIPTION DC SERIES COMBI BOILERS

A Exhaust Outlet 3" Schedule 40

B Combustion Air 3" Schedule 40

Cold Domestic Water Connection

D Hot Domestic Water Connection 3/4" Male NPT

E Heating Water Inlet (Return) 1" Male NPT

F Heating Water Outlet (Supply) 1" Male NPT

G Gas Inlet 1/2" Male NPT

H Condensate Outlet 3/4" Hose

I Knock-out (3) 1/2"

Table 1: Connections

3/4" Male NPT

Figure 1a: Dimensions / Connections for DC Series Figure 1b: Dimensions / Connections for DC Series

INSTALLATION

1-1

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

1.2

1.3

WARNING

Keep boiler area free and clear

of combustible materials,

gasoline, and other ammable vapours and liquids.

WARNING

Combustion air must not be

drawn from areas containing

corrosive air from swimming

pools or spas, including air directly next to outdoor pools and spas.

WARNING

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.

CODE REQUIREMENTS

The DC 23-84, DC 29-106, DC 33-124, DC 33-160 models were tested to and

certied under CSA 4.9-2014 / ANSI Z21.13-2014 and Water Heater CSA 4.3-

2013 / ANSI Z21.10.3.

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 conict, then the more stringent will apply.

LOCATION

The DC series boilers are designed and approved for indoor installation

(wall), with signicant exibility of location provided with the available venting

options. The boiler can be placed in an alcove, basement, closet 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 uorinated hydrocarbons can reduce

the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants, aerosol

propellants, dry-cleaning uids, de-greasers and paint-removers all contain vapours which can form corrosive acid compounds when burned in a gas ame.

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 lbs / 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 capable of supporting the combined weight of the boiler and piping assembly components.

WARNING

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.)

1-2

Other factors affecting potential mounting sites:

• Ensure minimum clearance requirements for combustible materials (see

• Minimum 24" clearance at the front and 10" above is recommended for

•

Table 2) are satised.

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

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

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.

WARNING

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 rmly anchored into solid

material that will support this weight.

DISTANCE FROM

SURFACE

Front 2" 24"

Rear 0" 0"

Left Side 1.5"

Right Side 4"

Top 2" 24"

Bottom 8" 24"

Table 2: Clearance from boiler cabinet

COMBUSTIBLE SURFACES

RECOMMENDED DISTANCE FOR INSTALLATION AND SERVICE

6" (labels may be difcult to read with

reduced clearance)

6" (labels may be difcult to read with

reduced clearance)

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.

Installers are to take all

necessary precautions

to avoid injury during the

installation of this boiler.

1.4

DANGER

Do not common vent the DC

modulating series boilers with any other existing or new appliance.

INSTALLATION

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. Specic

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.

1-3

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

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 nished 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.

All venting must be installed in accordance with the requirements of the jurisdiction having authority: in Canada, Part 8, Venting Systems of the B149.110 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 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.

NOTE

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 ue outlet with freezing

condensation due to the

reduce ue gas temperatures. Concentric vertical and

horizontal terminations are

approved as listed in this

manual.

NOTE

The minimum wall thickness for venting is 1” and the maximum wall thickness for venting is 14”.

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. In 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.

• 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

deciencies 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 system 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 replace dampers.

1-4

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

• Place in operation the appliance being inspected. Follow the lighting

instructions. Adjust thermostat so appliance will operate continuously.

• 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, replace 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 Z223.1 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 DC Series boilers must be installed as a Direct Vent venting system. The 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.

1.4.2 Exhaust Vent Material

WARNING

Covering non-metallic vent pipe and ttings with thermal

insulation shall be prohibited.

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 ttings. Ensure compliance with exhaust temperature

limitations for the respective materials, which typically are:

• ULC-S636 CPVC: 90°C (194°F)

• ULC-S636 PPs:- 110°C (230°F)

For long vent runs with higher initial exhaust temperature, some jurisdictions may allow the use of mixed materials for economy: CPVC for the initial run followed by ULC-S636 approved PVC to the termination (It is the responsibility of the Installer

to conrm that local codes will allow this option). Ensure appropriate transition glue is used. The installer is responsible to ensure that sufcient 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 strongly recommends that only CPVC or PPs vent component systems approved under UL1738 (Standard for Venting Sustens for Gas Burning

Appliances, Categories II, III 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 still allow the use of PVC (Sch. 40 ASTM

D1785 or D2665 and ttings) or CPVC (Sch. 40/ASTM F441 with Sch. 80 ttings); or CSA approved 3" stainless vent systems. If PVC is to be used, you

shall use a minimum of 10 lineal feet of CPVC, and then transition to PVC using approved transition glue. The installer shall ensure that vent temperatures in the PVC section cannot exceed 140°F.

INSTALLATION

1-5

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

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.

Do not use ABS or any cellular core pipe for exhaust venting.

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (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 tting on left side of the boiler’s top panel. The clamp must be tightened to secure the pipe into the tting. 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 tting (Sch 40 to PPs) offered

by the respective PPs manufacturers Centrotherm / InnoueTM (their part # ISAA0303) or M&G Dura Vent /PolyPro (#3PPS-AD). For PPs material exposed to

outdoor weather, follow the venting suppliers’ recommendations on UV protection.

Combustion air piping is inserted directly into the 3" female stainless steel tting

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 tting 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 DC 23-84, DC 29-106, DC 33-124, DC 33-160 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 ttings in accordance with Table 3. – e.g. for the models listed above using 6 x 90º CPVC long sweep elbows, the maximum lineal measure of pipe allowed using 3" pipe is 90 feet (120' – (6 x 5' = 30) = 90').

WARNING

Fully insert the approved venting material into the

boilers exhaust outlet and tighten clamp to ensure the

venting connection is locked

in place.

For 3" Flexible PPs, up to 35 actual lineal feet are allowed in a nominally vertical orientation (>45°). The equivalent length of 3" Flexible PPs shall be computed using a multiple of 1.4:1, e.g. 35' x 1.4 = 49' equivalent. The balance of the venting allowance is still available for use with rigid PPs piping material. 2" Flexible PPs is not allowed.

EXHAUST PIPE SIZE/FITTINGS MAXIMUM EQUIVALENT LENGTH

Schedule 40 CPVC 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 3: Maximum Exhaust Venting Length

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).

1-6

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

Figure 4

Exhaust piping is inserted directly into the 3" female stainless steel tting 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.

BEST PRACTICES

To reduce the possibility of

expansion noise, allow a 1/4"

open annulus around the

exhaust and air intake piping.

Follow all installation instructions supplied by the pipe and tting

manufacturer.

Ensure 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 (D2235) - 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 ring 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 ll condensate trap prior to test.

1.4.4 Venting Passage Through Ceiling and Floor

• Conrm material meets local codes including re 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.

INSTALLATION

1-7

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

Condensate can cause corrosion of metal roong

components and other

roong materials. Check with the builder or roong

contractor to ensure that materials will be resistant to

acidic condensate. pH levels can be as low as 3.0

CAUTION

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 inltration; 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 tting. Leave unglued,

and hold in place with a short nipple. This permits easy access for cleaning.

• For roof top venting of multiple boiler 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 ashing. 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.

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.

Figure 5: Rooftop vent terminal congurations

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.

1-8

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

Figure 6: Vertical Concentric Termination - Two Kits

INSTALLATION

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.

1-9

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

It is extremely important to maintain at least the minimum

separation of exhaust vent termination from boiler intake air as illustrated in gures 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.

• The elevation of both pipes can be raised in “periscope style” after passing

through the wall, then congured as in Figure 8, to gain required clearance.

• Use a 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 useful to guard against foreign objects.

WARNING

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.

Figure 8: Sidewall vent termination - piping conguration

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.)

• Duravent – Polypro #3PPS-HK – Horizontal Termination Kit – Concentric

• Centrotherm – Innoue #ICWT242 (2" termination) + ICTC0224 (2" transition

to 2 pipe)

• Centrotherm – Innoue #ICWT352 (3" termination) + ICTC0335 (3" transition

to 2 pipe)

• Ipex - # 197009 – 3” CPVC

1-10

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

Figure 9: Horizontal Concentric Termination - Two Kits

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.

INSTALLATION

1-11

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

Figure 13: Sidewall vent termination - multiple vent piping conguration

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

Figure 11: IBC recommended minimum vent terminal clearance under ventilated soft

Figure 12: Prohibited installation

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.)

• Duravent – Polypro #3PPS-HK – Horizontal Termination Kit – Concentric

• Centrotherm – Innoue #ICWT242 (2” termination) + ICTC0224 (2” transition

to 2 pipe)

• Centrotherm – Innoue #ICWT352 (3” termination) + ICTC0335 (3” transition

to 2 pipe)

• Ipex - # 197009 – 3” CPVC

VENT TERMINAL CLEARANCE MINIMUMS ARE AS FOLLOWS:

A= Clearance above grade, veranda, porch, deck, or balcony

B= Clearance to window or door that may be opened

C= Clearance to window or door that may be opened

D= Clearance to permanently closed window

E= Clearance to

unventilated soft

CANADIAN INSTALLATIONS1

12 in (30 cm) 12 in (30 cm)

6 in (15 cm) for appliances

≤ 10,000 Btuh (3 kW), 12

in (30 cm) for appliances >

10,000 Btuh (3 kW) and ≤

100,000 Btuh (30 kW), 36 in (91 cm) for appliances

≤100,000 Btuh (30 kW)

* *

US INSTALLATIONS

6 in (15 cm) for appliances

≤ 10,000 Btuh (3 kW), 9 in

(23 cm) for appliances >

10,000 Btuh (3 kW) and ≤

50,000 Btuh (15 kW), 12 in (30 cm) for appliances > 50,000 Btuh (15 kW)

1-12

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

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).

WARNING

Intake air openings must be congured such that rain

or other forms of moisture

cannot enter the air intake piping system. Otherwise

serious damage to the boiler may result.

NOTE

Care must be taken when installing air intake piping to ensure that a “trap” is not

formed in the piping so as to allow a build-up of water, and

blockage of intake air.

F= Clearance to outside

* *

corner

G= Clearance to inside

* *

corner

H= Clearance to each side of center line extended above meter/regulator

3 ft (91 cm) within a height 15 ft above the meter/ regulator assembly

assembly

I= Clearance to service

3 ft (91 cm) *

regulator vent outlet

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

6 in (15 cm) for appliances

≤ 10,000 Btuh (3 kW), 12

in (30 cm) for appliances >

10,000 Btuh (3 kW) and ≤

100,000 Btuh (30 kW), 36 in (91 cm) for appliances

≤100,000 Btuh (30 kW)

6 in (15 cm) for appliances

≤ 10,000 Btuh (3 kW), 9 in

(23 cm) for appliances >

10,000 Btuh (3 kW) and ≤

50,000 Btuh (15 kW), 12 in (30 cm) for appliances > 50,000 Btuh (15 kW)

6 feet (1.83 m) 3 ft (91 cm) above if within

10 ft (3 m) horizontally

7 ft (2.13 m) † * sidewalk or paved driveway located on public property

M= Clearance under

12 in (30 cm) ‡ * veranda, porch deck, or balcony

1 In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code

2 In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single 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 oor.

* Clearance in accordance with local installation codes and the requirements of the gas supplier.

Such blockage will result in a

boiler safety shut-down.

V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED

Figure 14: Vent Terminal Clearance

INSIDE

CORNER DETAIL

FIXED

CLOSED

OPERABLE

FIXED

CLOSED

INSTALLATION

1-13

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

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.

Figure 15: Direct vent combustion air intake

INTAKE PIPE SIZE/FITTINGS MAXIMUM EQUIVALENT LENGTH

Schedule 40 CPVC 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.

1-14

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

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

tting 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 conguration

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 DC series boilers.

1.4.10 Closet Installations

For installations in a conned 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°C).

INSTALLATION

1-15

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

1.5

WARNING

Fill trap with water before

boiler is rst red to prevent

exhaust fumes from entering

room. Never operate the boiler unless the trap is lled

with water.

Failure to comply will result

in severe personal injury or

death.

CONDENSATE REMOVAL

IBC’s specied vent conguration promotes the safe drainage of moisture from the boiler and exhaust venting without owing 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 lled 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 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 rmly 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.

WARNING

The Trap Hook must be

installed as instructed and all

trap ttings must be tightened as instructed to prevent leakage of ue gasses.

Failure to comply may result

in severe personal injury or

death.

1-16

Figure 16: Condensate Trap as shipped

2. Fill Trap with water, and slide Trap Body (D) over Boiler Drain Outlet (A).

3. Attach Drain Hose (G) and tighten Drain Spout Compression Nut (E).

Figure 17: Condensate Trap, disassembled

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).

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

Figure 18: Condensate trap installation

NOTE

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.

1.5.3 Condensate Trap Assembly - cleaning procedure

1. Turn off the power to the boiler and allow it to cool down.

2. Remove the trap from the boiler (reverse the installation procedure above).

3. Remove the Trap Cleanout Assembly (H), from the Trap Body and clean and

ush the debris out.

4. Re-assemble trap components, re-ll 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

relled as necessary.

INSTALLATION

1-17

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

Figure 19: Condensate trap disassembly for cleaning

WARNING

If condensates are to be discharged into building drain piping materials that are subject to corrosion, a neutralization

package must be used.

DANGER

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.

CAUTION

When a condensate

neutralization package is installed, the pH of the

condensate discharge must be measured on a regular schedule to ensure the

neutralizing agent is active and effective.

Figure 20: Condensate trap drainage

Figure 21: Condensate neutralization tank

1-18

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

1.6

WATER PIPING - SPACE HEATING

1.6.1 General Piping Considerations

The DC series boilers include a factory installed, integral Grundfos UPS 15/58

heating pump. The pump is designed to provide adequate ow through the boiler

and near boiler piping. The pump is pre wired and factory set to speed #3.

Figure 22: Overview of piping options

Primary/secondary piping or the use of a buffer tank / hydraulic separator is

recommended for maximum exibility in multi zone/load applications. Piping loads in parallel is only acceptable in systems where the minimum ow rate is

guaranteed to be higher than the minimum for the boiler and the boilers pump is

adequate to provide the required ow 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.

INSTALLATION

Table 5

1-19

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

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.

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.

DO NOT CAP, PLUG OR OTHERWISE OBSTRUCT THE DISCHARGE PIPE OUTLET!

CAUTION

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.

The DC 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 eld installation at the boilers top connection point. A Relief Valve and Air Vent Piping Kit is also included with each DC series boiler to aid in the proper installation of the relief valve and air vent.

Figure 23: Relief Piping

System piping is connected to the boiler using the 1" NPT Male threaded ttings

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. Uninsulated hot water pipes must be installed with a minimum 1/4" clearance from combustible materials.

Fluid ll is most often accomplished by using a boiler regulator & ll valve set at 12 psig or more, with appropriate backow prevention device as required

by local code. This is acceptable in areas where municipal water or well water

has been treated and ltered 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 ll 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 uid and chemicals

back into the system. In buildings that may be unoccupied for long periods of

time, pressurization units are useful to prevent ood damage should leakage occur from any component in the system. An additional benet is that backow

prevention devices are not required when using these devices.

1-20

INSTALLATION AND OPERATION INSTRUCTIONS

WARNING

Close ll valve after any

addition of water to the

system, to reduce risk of

water escapement.

NOTE

Application drawings can be downloaded from our web site.

www.ibcboiler.com

NOTE

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.

NOTE

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 ow control valves or other automatic means to prevent gravity circulation of the

boiler water during the cooling cycle.

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

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 airow and service access.

For best results, use a Primary: Secondary piping system, with a boiler loop using 1" (1-1/4" for the DC 33-160) piping for the DC Series Boilers. The boiler comes with the boiler (primary) pump installed in the boiler and will provide

adequate ow for the boiler and primary loop piping only.

The minimum ow rate required through the heat exchanger is 2 USgpm with a

maximum of 11 USgpm allowed. Primary/Secondary piping ensures adequate

ow and de-couples Δ°T issues (boiler vs. distribution). Aim for a 20° to 30° F Δ°T across the heat exchanger at high re.

The DC 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.

WARNING

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

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 oors, or an aquastat (wired to the boiler’s Heat Demand X4.6 and X4.7

terminals).

Ensure the pump is rated for the design circulating water temperatures; some pumps have a minimum water temperature rating above the low temperature

potential of the boiler. Following installation, conrm actual performance by measuring Δ°T (under high and low ow conditions) after establishing the correct ring rate.

A variety of application drawings showing basic design options are available from the IBC web site at www.ibcboiler.com

1-21

WARNING

Water quality has a signicant

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 lls will increase the

potential for damage.

High levels of dissolved

solids or minerals may

precipitate out of the uid

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

• Chloride is to be less than

125 mg/l

• Iron is to be less than 0.3

mg/l

• Cu less than 0.1 mg/l

• Conductivity is to be less

than 400μS/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.

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

Figure 25: Basic Primary/Secondary piping with closely-spaced tees concept – concept drawing. This drawing is only a simple schematic guide.

We recommend water ow after burner shutdown to utilize legacy heat – this is signicant 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 congurations to simplify the control application, promote good loads and ow 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 ow 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 DC series modulating boilers offer exceptional matching of heat generation

to radiation. The low minimum ring 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

benet 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 relevant 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).

DC modulating series boilers can be connected directly to a oor 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 ushing of all loops, plus installation of a dirt separator or side stream lter. A separator/lter maintenance routine shall be carried out after the retrot, with lter 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.

1-22

INSTALLATION AND OPERATION INSTRUCTIONS

WARNING

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 nontoxic propylene glycol.

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

1.6.2 Basic Heating Piping Arrangements

PRIMARY / SECONDARY PIPING - BENEFITS AND INSTALLATION RULES

1. Good circulating water ow through the boiler irrespective of load or radiation

system head

2. Allows exible ΔT° 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 conguration requires an extra pump, independant

from any secondary load pumps. The DC 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

ows and thermal siphoning.

The DC 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 ow and head the

system requires. For example a DC series boiler and an IBC Air Handler series 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 25% - 50% 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 ow.

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 oor protection). This will permit immediate circulation of mixed ow 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 oor)

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.

INSTALLATION

1-23

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

NOTE

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

the 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 ts

your system.

MULTIPLE BOILER PIPING - BENEFITS AND INSTALLATION RULES

Multiple IBC DC 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 ow at each boiler, regardless of ow variations in

the main building loop.

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 contacts 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 ow when

the boiler is off.

For further information and details, consult our Application Notes – which provide

detail on specic single and multiple boiler applications “Piping”, “Wiring” and “Settings”. (available at www.ibcboiler.com or from your IBC Representative).

1-24

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

Figure 27: Typical two temperature space heating piping concept with direct domestic hot water – concept drawing. This drawing is only a simple schematic guide.

INSTALLATION

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

1-25

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

1.7

Figure 29: Air handler and direct domestic hot water – concept drawing. This drawing is only a simple schematic guide.

DOMESTIC HOT WATER SYSTEM

WATER HEATER INSTALLATION GUIDELINES

WARNING

Failure to correctly install and operate this appliance can result in severe personal injury or death.

The water heater, if utilized, shall have a pressure relief valve installed within 6” [152mm] of the DHW HOT outlet connection with the relief valve spindle installed in the vertical position.

Refer to the Boiler User’s Manual before operating relief valve. The water heater, if utilized, requires a pressure relief valve identiﬁed with the ASME V or HV

For complete information refer to installation manual. Read and follow warnings and instructions.

CAUTION

Hotter water increases the risk of scald injury. Before changing the temperature setting, see instruction manual.

ADJUSTABLE TEMPERATURE SETTING

1-26

Press the 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

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

A potentially hazardous situation, which can cause serious injury or death, can exist if the un-used domestic water connections are capped off. The unused domestic water connections are meant to be left open if not used to allow for the air in the coil to expand and contract as the boiler is in operation.

WARNING

Bacteria growth can develop in domestic hot water tanks and

indirect water heaters if the minimum water temperature is

not set high enough to prevent

its growth.

WARNING

HOT WATER CAN SCALD!

Water Temperatures 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.

• Never leave then unattended in

or near the shower, bathtub or

sink.

• Never allow small children to

use a not water faucet or draw their own bath.

To avoid any potential scald hazard or if codes require specic

water temperatures at the hot water faucet, the installer must:

• Install the factory supplied

thermostatic mixing valve at

this appliance and ensure it is

working properly.

AND

• Set the thermostatic mixing

valve to the lowest temperature which satises your hot water

needs.

TO AVOID INJURY:

• Feel and adjust water

temperature before bathing or showering.

•

Water drained from the system

drain valve may be extremely

hot.

• Make sure all connections are

tight.

• Direct water ow away from

any person.

1.7.1 Domestic Hot Water System

The DC series boilers have an independent piping circuit for efciently generating Domestic Hot Water. When a faucet is opened to draw hot water, water ow is detected with a ow sensor and the DC Series boiler res up to begin generating domestic hot water. Due to the unique design of the boiler’s heat exchanger, the boiler can re with either no water in the alternate space heating circuit or without ow of water if pressurized with the heating system water.

The cast aluminum heat exchanger has two separate copper water passage-

way’s encased into the aluminum heat transfer block. Each copper passage-way

is completely isolated from the other to eliminate cross contamination in the event of a leak. This heat exchanger complies with the double wall heat exchanger requirements in many regional jurisdictions.

The unique design of the cast aluminum heat exchanger acts as a heat buffer, eliminating the cold sandwich effect when turning on and off the water repeatedly. The domestic hot water operation can be set to operate in 3 different ways.

• Standard Mode: The boiler responds to a call for domestic hot water when a

faucet is opened. After the faucet is closed the boiler shuts down and waits for a call for the faucet to open.

• Comfort Mode: After the faucet is closed the boiler will maintain the

programmed domestic hot water temperature so that the next time the faucet is opened, hot water is delivered to the faucet immediately without the “Cold Water Sandwich” effect.

• Eco Comfort Mode: As above, the boiler will maintain the programmed

domestic hot water temperature but based on a learned pattern, the boiler will allow the water to cool. For example during the night, the boiler will see

no ow of domestic hot water therefore will allow the boiler to cool down each

night. If hot water is required at night, the boiler will respond to an open faucet just as if it was in the Standard Mode.

While the DC Series boiler is less susceptible to lime scale build-up than other units on the market, water quality must always be considered when installing the boiler. Treating hard water and adjusting the pH to 6.5 and 7.5 is strongly recommended. As a reference Table 6 represents some of the drinking water guidelines published by the US EPA. Consult a water treatment advisor in your area to assess your local needs. Proper water treatment will aid in the longevity

of the boiler and ensure maximum efciencies.

DESCRIPTION MAX MIN

Water Pressure 150 psi 40 psi

Programmable water temperature 149°F (65°C) 104°F (40°C)

Minimum Flow Rate to Activate DHW Sensor N/A 0.5 GPM

Acceptable pH range 7.5 pH 6.5 pH

Chloride 250 mg/L

Iron 0.3mg/L

Total Dissolved Solids 500mg/L

Total Hardness 7 grains

Table 6: Water Quality

NOTE

See Domestic Hot Water Warnings on page 1-26.

INSTALLATION

1-27

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

This boiler model can burn either Natural gas or Propane.

A boiler congured 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.

NOTE

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

ring the boiler, when the regulator is in a “lockup” condition and during

operation, throughout the boiler’s full modulation range.

Pay special attention to

retrot situations where existing regulators may have an over-sized orice and/or

worn seats, causing pressure

“creep” and high lock up

pressures.

1.7.2 – Domestic Hot Water Piping

The domestic water piping connections are located at the bottom of the boiler, see Figure 30, Page 1-29. The connections are 3/4" male NPT threads. The cold water inlet is on the right side and the hot water outlet is on the left side.

A Temperature and Pressure Relief valve with a maximum pressure setting of 150PSI and rated for a minimum capacity of less than the rated input of the boiler (NOT Supplied with the boiler) must be installed on the domestic hot water outlet piping within 6" of the boiler. The temperature and pressure relief valve must be

installed between the boiler’s outlet and any isolation valve so as to ensure the

temperature and pressure relief valve cannot be isolated by closing a valve. A valve kit designed for this purpose is recommended to reduce installation time and reduce the space required.

The DC Series boiler is supplied with a 3-way thermostatic domestic hot water tempering valve. This valve must be installed to eliminate extremely high outlet water temperatures when the boiler is switching from high temperature heating loads to supply domestic hot water. See Figure 30.

If the boiler installation is only using the space heating portion of the heat exchanger and not using the Domestic Hot Water portion of the heat exchanger, then the mixing valve and the Temperature and Pressure Relief valve need not be installed.

Do not cap off the hot and cold piping connections if they are not being used.

The DC Series boilers can be connected to the pressurized 1/2" or larger domestic cold water supply piping and the domestic hot water piping in the home. The minimum domestic water pressure required is 40PSI and recommended to be 50PSI or higher. Generating domestic hot water with a water pressure lower than 40PSI will reduce the amount of hot water generated and will increase the risk of scaling in the heat exchanger.

The domestic water piping must be installed with isolation valves and ushing

taps installed on both the cold and hot domestic connections.

Thermal expansion of the water in the domestic hot water piping and boiler can cause excessive pressures to build in the piping system. This can cause the temperature and pressure relief valve to discharge on a regular basis. This condition must be prevented with the installation of a properly sized and installed domestic water expansion tank or other device designed for the purpose.

1-28

INSTALLATION AND OPERATION INSTRUCTIONS

Thermostatic Mixing Valve

DANGER

The factory supplied

thermostatic mixing valve

must be installed on the direct domestic hot water piping connections at the boiler or at the outlet of a domestic

hot water storage tank if the

domestic hot water function is used. Failure to install the

thermostatic mixing valve

may result in a hazardous situation which can cause serious injury or death.

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

DOMESTIC HOT WATER DELIVERY

@ 70°F / 39°C temperature rise

DC 23-84 2.0 GPM

DC 29-106 2.5 GPM

DC 33-124 3.0 GPM

DC 33-160 3.0 GPM

INSTALLATION

Figure 30: Tankless DHW Piping Options – concept drawing. This drawing is only a simple schematic guide.

1-29

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

1.8

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. Conrm 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

DC Series (Natural Gas) 20' 70' 200'

DC Series (Propane) 50' 200' 600'

Table 7: Maximum Pipe Length (ft) – DC series 33-160 boiler

Gas piping must have a sediment trap ahead of the boiler’s gas valve (see Figure

32). 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 operation.

• 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 31). Note that manifold pressure varies slightly in accordance with ring

rates with the modulating series boilers, but will always be close to 0" w.c.

Figure 32: Gas PipingFigure 31: Gas Valve

1-30

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

1.9

NOTE

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”. Power conditioning equipment (surge protectors, APC or UPS devices) may be required in areas where power quality is

suspect.

WARNING

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.

NOTE

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.

NOTE

A hot water boiler installed

above radiation level or as required by the Authority Having Jurisdiction, must be provided with a low water cutoff 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.

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.

1.9.1 120VAC Line Voltage Hook-up

Line-voltage wiring is done within the eld-wiring box. (Refer to Section

6.2.Wiring Diagram on page 6-4). Connect the boiler to the grid power using a

separate, fused circuit and on/off switch within sight of the boiler. Use 14-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 DC Series boilers include a factory installed and pre-wired pump. The pump

is intended to supply adequate ow 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 red storage water heater to heating circuit

to take full advantage of the boilers heating capacity. The maximum amperage rating of the connected pump is 2.3 amps. If the connected pump has a rating higher than 1.0 amps, an external isolation relay is required to protect the boilers controller.

A eld 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 protecting the heating circuit of the boiler, the Auxiliary Safety interlocks can be wired in series with the Call for heat (X4.6 and X4.7). Do not apply power to the X4 terminal strip. The Auxiliary Safety interlocks must be a Dry Contact.

4 5 6 7 8 9 10 11 12

Figure 33: X4 Terminal Strip for connection of the DHW Aquastat (optional), Thermostat or end switch’s (mandatory), Outdoor Sensor (optional)

X4 (24 V = )

0,1A

12kOhm

25°C

12kOhm

25°C

(cold closed)

24 V =

120 V~

F1(3,15 AT)

X2 ( 120 V ~)

120 V ~, 60 Hz

BOILER SYSTEMS AND OPERATION

1-31

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

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 required, 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.

Figure 34: External Low Water Cut Off Device

1.9.2 Power Quality and Electrical Protection

In areas of unreliable power, appropriate surge protectors and or power conditioning equipment should be installed to protect the boiler.

1.9.3 Zone Valve and Zone Pump Connections

Zoning can be accomplished with either zone pumps or zone valves. In either case the controls and relays that may be required to accomplish this 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 35. 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.

1-32

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

1.9.4 Thermostat / Sensor Wiring

A Thermostat from a single zone heating system can be connected directly to the

controller’s terminals X4.6 and X4.7. Do not apply power to the X4 terminal strip.

The Outdoor Sensor is not required for the boiler 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 soft overhang.

DHW Aquastat or 12KΩ sensor can be connected to the controller’s terminals

X4.9 and X4.10. Do not apply power to the X4 terminal strip.

INSTALLATION

1-33

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

Figure 35: Electrical Wiring Connections (full page ladder diagram at back of this manual)

1-34

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

2.0

2.1

BOILER SYSTEMS AND OPERATION

GENERAL

The DC series modulating condensing boilers are designed to heat both your

indoor space and your domestic hot water. 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 efciency.

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 DC series boiler can be used as a tankless water heater with or without a storage tank and also with an IBC indirect water heater.

The boiler is equipped with an electronic boiler controller, which ignites the

burner and continuously monitors the ame 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.

BOILER SYSTEMS AND OPERATION

2-1

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

2.2

CONTROL

Power Indicator

Space Heating

Domestic Hot Water

Main Display

Fahrenheit and PSI

Celsius and Bar

Comfort / ECO / OFF - Indicator

Service Display

Flashes to indicate a fault

Power - ON / OFF

Space Heating / DHW Toggle

Minus

Plus

Fahrenheit/Celsius

Domestic Hot Water Comfort / Eco

Service

Reset Button

Table 8: Controller Indicators and Buttons

NOTE: The control displays codes that include upper and lower case letter

and a combination with a period after the letter. Example: C, c., c are all valid parameter codes. When adjusting settings, double check that you are in the correct parameter.

2.3

INSTALLER INTERFACE

2.3.1 Appliance ON/OFF

The boiler can be switched on and off with the On/Off button. When the boiler is “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.

2-2

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

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 to toggle Fahrenheit and Celsius.

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.

NOTE

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 efcient operation,

this setting should be set as low as practical for the consumer’s needs.

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 button for 2 seconds. The LED beside the will illuminate and the current maximum heating system water temperature will be displayed in the 4 digit display. To alter this value simply press the Plus + or the Minus - buttons.

Adjusting the Domestic Hot Water Temperature

Press the Space Heating /DHW Toggle button a second time and the LED beside the will 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 button. Pressing the On/Off 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 buttons together until a “0” appears in the main display. Press the Plus + button repeatedly until “15” appears in the main display.

and Reset

BOILER SYSTEMS AND OPERATION

Press the Service button to scroll through the parameters.

Press the Plus + or Minus - buttons to alter a parameters setting.

To exit from the Installer Menu and save the changes press the Reset button. Pressing the On/Off button 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

and Reset

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 button to scroll through the parameters.

Press the Plus + or Minus - buttons to alter a parameters setting.

To exit from the Advanced Installer Menu and save the changes press the Reset

button. Pressing the On/Off button will also exit the Advanced Installer

Menu but will NOT save the changes.

2-3

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

2.3.4 Table of Programmable Parameters

PARA-METER DESCRIPTION DEFAULT RANGE / OPTIONS

USER SET UP

Boiler Supply Temperature 180°F (82°C) 86°F (30°C) to 194°F (90°C)

Tankless Domestic Hot Water Temperature

15 - INSTALLER SET UP MENU

1 System Type

(SEE CHART BELOW FOR ADDITIONAL DETAILS)

3 Maximum Power available for

Space Heating

5 Min Heating Curve Supply Water

Temp

5. Max Heating Supply Water Temp 194°F (90°C) Range 86°F (30°C) to 194°F (90°C)

6 Min Outdoor Design Temp 14°F (-10°C) Range to -22°F (-30°C) to 55°F (13°C)

7 Summer Shut Down Temperature 64°F (18°C) Range 59°F (15°C) to 86°F(30°C)

8 Internal Boiler Pump Post Purge 1 min Range 0 min to 15 min

9 External DHW Pump Post Purge 1 min Range 0 min to 15 min

C Burner Modulation (Ramp up)

with a Space Heating Demand

E Minimum Space Heating

Temperature with an Open Therm heating demand

E. Open Therm or RF Space Heating

Control

F Fan RPM at Burner Start for

Space Heating

120°F (49°C) 104°F (40°C) to 149°F (65°C)

DC series = 0 HC series = 3

100% Parameter “c” value to 100%

90F (32°C) 50°F (20°C) to 194°F (90°C)

1 0 = OFF

104°F (40°C) 50°F – 140°F (10°C – 60°C)

1 0 = Ignore a call for heat if the target temperature

Model Dependent 50-100% of High Fire

DC - 0 – Both Space Heating and Tankless DHW HC - 1 – Space Heating and Indirect DHW Tank DC - 2 – Tankless DHW Only HC - 3 – Space Heating Only DC - 4 – Space Heating and Tankless DHW with

a Storage Tank DC - 5 – Tankless DHW with a Storage Tank Only DC – 6 – Space Heating, Indirect DHW Tank and

Tankless DHW

Must be at least 18°F (10°C) lower than Parameter “5.”

Pump will run but the burner will not re if

Outdoor Temperature is above this setting

1 = ON 2 = Open Therm control

Only for use with an Open Therm thermostat

is less than “E” 1 = Answer a 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”

DC 23-84 = 70 DC 29-106 = 60 DC 33-124 = 50 DC 33-160 = 40 (Range = 40-75)

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.

2-4

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

F. 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)

h Max Fan Speed Adjustment Model Dependent DC 23-84, DC 29-106 and DC 33-124 = 50

Range 40-50 DC 33-160 = 70 Range 65-75

L Indirect Tank Temperature if using

a sensor. Note: Use only IBC

12KΩ Sensor

140°F (60°C) Fixed tank differential

of 9°F (5°C) below

104°F - 149°F (40°C – 65°C)

the set-point, must

use an IBC 12KΩ

tank sensor

L. Tankless DHW with Storage

Tank offset temperature (Boiler operates at the Tankless Domestic Hot Water Temperature setting

18°F (10°C) 9°F – 27°F (5°C – 15°C)

Fixed tank differential of 9°F (5°C) below the set-

point, must use an IBC 12KΩ tank sensor.

plus this offset temperature to

efciently generate DHW)

n Boiler Water Supply Temp for

170°F (77°C) Range 140°F (60°C) to 194°F (90°C)

heating Indirect DHW Tank

n. Comfort and ECO Comfort Mode:

Heat exchanger temperature maintained while in standby

110°F (43°C) Range 0 or 104°F – 140°F (40°C – 60°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.

O. Space Heating Delay (min) 0 min Range 0 – 15 min: The Boiler will not respond to

a Space Heating call for X min.

o Space Heating Delay after

heating DHW

0 min Range 0 – 15 min: The boiler will not respond

to a call for heat after the tankless DHW call for heat has ended for X min.

o. DHW ECO mode Learning Days 3 days Range 1 to 10: Number of days the ECO mode

uses to learn the Tankless DHW usage habits. Rolling counter.

P Space Heating Delay after

the boiler reaches the target temperature

5 min Range 0 – 15 min: The boiler will remain off for X

min to help reduce short cycling when the heating

load is smaller than the min ring rate.

P. Heat Exchanger Size Reference Model Dependent DC 23-84 = 24

DC 29-106 = 30 DC 33-124 = 36 DC 33-160 = 36

20 - ADVANCED INSTALLER MENU

3. Max Pump Speed (PWM) Space Heating Only

100% For use only with a PWM style pump (Terminal

X4.5)

4 Max DHW power Model Dependent DC 23-84, DC 29-106 and DC 33-124 = 100

DC 33-160 = 75

c Min fan speed in Space Heating Model Dependent DC 23-84, DC 29-106 and DC 33-124 = 28%

DC 33-160 = 22%

c. Min Pump Speed (PWM) Space Heating Only 40%

d 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

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

2-5

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

PARAMETER 1 SETTINGS

0 0 = Tankless DHW

LOAD PRIORITY: 0 = HIGHEST

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

1 0 = Indirect DHW Tank Sensor

or Aquastat 1 = Space Heating

HC Models – Space Heating and Indirect DHW Tank

• 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 a

call for DHW

2 0 = Tankless DHW DC Models – Tankless DHW Only

• DHW only, Space Heating Disabled

• Internal Pump disabled

3 0 = Space Heating HC Models – Space Heating Only

• Internal Boiler Pump is enabled with a call for Space Heating

4 0 = DHW Storage Tank Sensor

or Aquastat 1 = Space Heating

DC Models – Space Heating and Tankless DHW with a Storage Tank

• Aquastat or Sensor connected to X4.9 and X4.10

• External Pump Terminals 4,5,6 (120Vac - 1Amp Max) enabled with a

call for DHW

• Internal Boiler Pump is enabled with a call for Space Heating

• Internal Boiler Pump is disabled with a call for Tankless DHW

• External DHW Pump is enabled with a call for Tankless DHW

5 0 = DHW Storage Tank Sensor

or Aquastat

DC Models – Tankless DHW with a Storage Tank Only

• Space Heating is disabled

• Aquastat or Sensor connected to X4.9 and X4.10

• External Pump Terminals 4,5,6 (120Vac - 1Amp Max) enabled with a

call for DHW

• Internal Boiler Pump disabled

• Internal Boiler Pump is disabled with a call for Tankless DHW

6 0 = Tankless DHW

1 = Indirect DHW Tank Sensor or Aquastat

2 = Space Heating

DC Models – Space Heating, Indirect DHW Tank and Tankless DHW

• 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

• Internal 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.

2-6

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

2.4

TANKLESS DOMESTIC HOT WATER MODES

2.4.1 Tankless Domestic Hot Water - Standard, Comfort and ECO Comfort Modes

Standard Mode (both LEDs are off): The boiler’s heat exchanger will not

maintain its domestic hot water temperature between demands for hot water.

(This the most energy efcient mode but will result in the “Cold Water Sandwich

Effect”.) The boiler will respond to a call for domestic hot water as a priority over

the space heating demand. When the domestic hot water demand is satised the

boiler will return to the space heating load if the load is still calling.

Comfort Mode (the top LED is on): The boiler’s heat exchanger will maintain

the pre-programmed temperature set in parameter n. or as set for the Tankless

hot water temperature. (This is the least efcient mode but does offer the

most consistent hot water delivery temperatures). This temperature will be the minimum temperature of the heat exchanger at all times unless the boiler is heating a low temperature load.

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

2.5

To toggle between the 3 modes simply press the Domestic Hot Water Comfort / Eco button.

ADDING DOMESTIC HOT WATER STORAGE

2.5.1 Tankless Domestic Hot Water with a Storage Tank

The DC series boiler has the ability to connect a domestic hot water storage tank to the boiler to prove larger volumes of domestic hot water during peak demands.

The storage tank will be piped to the boiler’s domestic hot and cold water piping

connections (see Figure #30 on Page 1-29). A bronze or stainless steel pump

must be installed to circulate water from the storage tank through the boiler’s

domestic hot water coil. The pump and the tank aquastat can be wired directly to

the boiler’s control for ease of installation.

Alternately, the pump and aquastat can be wired together without connecting to

the boiler. When the pump is energized, the ow of water through the domestic hot water coil in the boiler will be sensed by the ow sensor and activates the

boiler. The boiler will switch off its internal pump and operate at its programmed water temperature set in parameter [1].

BOILER SYSTEMS AND OPERATION

2-7

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

The correct 12KΩ temperature sensor (or aquastat) must be

used to operate the indirect water heater properly. If the incorrect sensor is used the domestic hot water may

overheat causing serious

injury or death.

2.6

2.5.2 Domestic Hot Water with an IBC Indirect Water Heater

The DC series boiler can be connected to an IBC indirect water heater. Connect

the IBC indirect water heater’s boiler supply and boiler return connections to the boiler’s primary loop (see Figure #28, Page 1-25). Properly sized piping must be

installed. A properly sized pump must also be installed between the boiler and the IBC indirect water heater. The IBC indirect water heater is shipped with a water temperature sensor designed to be used with the SL or VFC series boilers only. The correct DC series temperature sensor is available from your local IBC wholesaler or you can use an aquastat.

SPACE HEATING

2.6.1 Overview

The DC 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 there is no outdoor sensor installed the boiler will assume the outdoor temperature is 32°F (0°C). The boiler will supply a water temperature based on the outdoor reset curve and an outdoor temperature of 32°F (0°C).

2-8

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

2.7

NOTE

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.

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 internal ow sensor, X4.9 and X4.10 (24 volts) (12KΩ 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. This is repeated 4 times before a hard lock out occurs. The Reset button must be pressed to reset the controller and allow for another attempt.

4. Once the burner is lit and ame has been proven the boiler operates as it is

programmed (Service Display = 5 for Space Heating or 6 for Domestic Hot Water)

5. If the 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 satised, the boiler pump will operate for an

adjustable amount of time (Service Display = 0)

7. If the burner is on to maintain the heat exchanger temperature for DHW

Comfort mode or for Freeze Protection mode (Service Display = 7)

8. If the burner is on for Frost Protection (Service Display = 9)

MAIN

DISPLAY

(blank) - The boiler is OFF. Press the On/Off button to turn

(blank) (blank) No Call for Heat - Standby

XXX 0 Boiler pump running – pump post purge

XXX 1 Boiler water temperature reached target – boiler pump is

XXX 2 Self-test – When power is applied to the boiler the

XXX 3 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 9: Operating Display and Service Display Codes.

SERVICE DISPLAY

DESCRIPTION

on the boiler

energized, call for heat still present

controller enters a self diagnostic mode for 5 seconds

STARTUP AND COMMISSIONING

2-9

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

PAGE INTENTIONALLY LEFT BLANK

2-10

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

STARTUP AND COMMISSIONING3.0

3.1 LIGHTING AND SHUTTING DOWN THE BOILER

STARTUP AND COMMISSIONING

3-1

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

3.2 PRIOR TO START-UP

DANGER

Fill trap with water before

boiler is rst red to prevent

exhaust fumes from entering

room. Never operate the boiler unless the trap is lled

with water.

Failure to comply will result

in severe personal injury or

death.

DANGER

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.

3.2.1 Pre-Ignition Checks

1. Fill condensation trap. Ensure venting system is complete and seal tested.

Conrm any common venting system at the installation site is isolated and

independent of the DC boiler, that any holes left from removal of a previous

boiler have been sealed, and that any resizing of the old ue has been done.

Check water piping system is fully ushed and charged, and that all air has

been discharged through loosened bleed caps. Use a minimum water pressure

of 12 psig and conrm pressure relief valve is installed and safely drained.

3. 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) at 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 nal check of electrical 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.

3.3

COMMISSIONING

The DC Series modulating boilers are factory calibrated to operate with natural gas at sea level. This cap must not be tampered with. The Low Fire (Zero

Offset) screw is not to be adjusted in the eld. The High re (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 qualied technician using properly functioning and calibrated combustion analyzing equipment.

This boiler model can burn either Natural gas or Propane if equipped

with the correct specied orice. Examine the rating plate of the boiler to ensure it is congured 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 10.

MODEL NUMBER NATURAL GAS

TO PROPANE

DC 23-84 P-700 P-701

DC 29-106 P-700 P-701

DC 33-124 P-702 P-703

DC 33-160 P-702 P-703

Table 10: Fuel Conversion Kit’s

PROPANE TO NATURAL GAS

3-2

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

Check the rating plate of

the boiler to ensure it is

congured 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.

Gas Valve Adjust

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 eld, the following procedure can be carried out by a qualied technician (diagrams on this page).

1. Turn off the boilers gas shut off valve. With a small (1/8" or 3 mm) at

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 pressure throughout the commissioning procedure. Pressure may droop up

to 1" to 2" w.c. at high re.

2. Allow the boiler to ignite / run against a large load, to maintain high re. 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.)

3. With a combustion analyzer probe in the ue gas test port, turn the High Fire

(Gas : Air Ratio Adjustment) screw (see diagrams on this page) to achieve results This screw offers very ne adjustment, and may require several turns.

NOTE: Clock the gas meter to conrm full maximum rating plate input. Check

the measured results with Table 11 - High Fire.

4. Switch the boiler to low re by pressing both the Service button and

Minus - buttons at the same time. The boiler will drop to low re. Compare the readings with Table 11 - Low Fire.

5. Switch off the boiler by pressing the On/Off button. Turn off the gas at

the boiler gas shut off valve. Remove the ue gas analyzer from the test port

and reinstall the test port cap. 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.

Flue gas test port plug

STARTUP AND COMMISSIONING

CO2 VALUE (%) AT HIGH FIRE WITH THE FRONT COVER OPEN

NATURAL GAS PROPANE

Max. CO2 value 10.1% 11.5%

Min. CO2 value 9.1% 9.8%

CO2 VALUE (%) AT LOW FIRE WITH THE FRONT COVER OPEN

Max. CO2 value = value at Max = value at Max – 0.3%

Min. CO2 value 9.1% 9.5%

Table 11: CO2 Values and High and Low Fire

3-3

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

3.4

DANGER

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 re or

explosion, which may cause property damage, personal injury, or loss of life.

PROPANE ORIFICE CHART

MODEL NUMBER

DC 23-84 505

DC 29-106 505

DC 33-124 580

DC 33-160 580

ORIFICE SIZE

FUEL CONVERSION

The DC Series modulating boiler is factory re-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

qualied 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 eld.

Fuel conversion requires hardware adjustments (Orice 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 10

for the correct kit number.

CO2 VALUE (%) AT HIGH FIRE WITH THE FRONT COVER OPEN

NATURAL GAS PROPANE

Max. CO2 value 10.1% 11.5%

Min. CO2 value 9.1% 9.8%

CO2 VALUE (%) AT LOW FIRE WITH THE FRONT COVER OPEN

Max. CO2 value = value at Max = value at Max – 0.3%

Min. CO2 value 9.1% 9.5%

Table 12: CO2 Values and High and Low Fire

The following procedure must be carried out by a qualied technician.

NATURAL GAS ORIFICE CHART

MODEL NUMBER

DC 23-84 650

DC 29-106 650

DC 33-124 725

DC 33-160 725

ORIFICE SIZE

WARNING

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.

1. Ensure the fuel conversion instructions supplied with the fuel conversion kit

are read, understood and followed carefully.

2. Ensure that the gas supply is turned off at the gas control valve.

3. Disconnect the gas valve harness plug from the gas valve.

4. Select the correct Fuel Conversion Kit for your boiler from Table 10.

5. Disconnect the nut at the gas valve outlet (top of the gas valve) and remove

the orice and O-ring.

6. Insert the correct orice into the O-ring and re-install into the nut at the gas

valve outlet (top of the gas valve) and tighten the nut.

7. Restore gas supply by opening the gas control valve, and using an approved

leak detection solution, soap test all joints.

8. 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.

3-4

INSTALLATION AND OPERATION INSTRUCTIONS

WARNING

Fan Outlet Orice (25mm) must be installed in the DC 23-84 model. If the fan is being replaced the orice

must be reinstalled in the new fan.

WARNING

Each DC series boiler is equipped with a Back Flow Valve installed at the outlet of the fan. Inspect the Back Flow Valve annually.

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

STARTUP AND COMMISSIONING

Figure 36: Blower and Gas Valve Assembly

Figure 37: Orice and O-ring

3-5

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

NOTE

The safety warning regarding burner refractory on page

4-2 of this manual must be observed.

3. There is no need to drain the boiler’s water unless the boiler will be subject to

freezing conditions while the boiler is off.

4. Remove the front cover and allow the boiler to cool.

5. Disconnect the ue pipe from the condensate tray by rotating the nut

counter-clockwise about 1/4 turn. Slide the ue pipe up and dis-engage the bottom of the ue 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 orice 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 attached. 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. Reconnect the gas valve electrical connection.

4. Re-connect the electrical connections to the fan.

5. Re-install the ue 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 ue

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 joints.

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 ue pipe

connections for leaks.

11. Check ue 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.

3-6

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

4.0

4.1

CAUTION

The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition.

CAUTION

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous operation.

CAUTION

Periodic inspection of

Low Water Cut-Off Device including ushing of oat types is required, if installed

as an accessory to the boiler.

WARNING

MAINTENANCE

BOILER MAINTENANCE

4.1.1 General Care

•

Keep combustible materials and ammable 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 qualied 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 lters 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-lled completely before ring boiler.

• If condensate neutralization is used, check pH level of condensate discharge.

Fill trap with water before

boiler is rst red to prevent

exhaust fumes from entering

room. Never operate the boiler unless the trap is lled

with water.

Failure to comply will result in

severe personal injury or death.

WARNING

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 ange sealing area to ensure there is no leakage of

combustible gas/air premix.

MAINTENANCE

4.1.5 Burner

• 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 burners will only need

attention every 2 – 5 years. Consider adding air ltration if burner requires

cleaning every year. In alternate years, visually inspect burner through sight

glass. Ensure ame is stable and without excessive uttering. Normal ame

pattern is evenly distributed over the burner surface.

• If burner is operating improperly, remove and clean or replace. Use a CO

analyzer to determine proper combustion. See Table 11 for correct values.

Figure 38: Ignitor Gap - 3/16” / 4.5mm

4-1

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

CAUTION

The heat exchanger has a small amount of combustion

chamber insulation (refractory), which contains ceramic bers.

When exposed to extremely high temperatures, the ceramic

bers, which contain crystalline silica, can be converted

into cristobalite - which is

classied 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

Certied under 42 CFR 84" for selection and use of respirators certied 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, loose tting 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 rst aid:

• Eye contact - Irrigate and

wash immediately.

• Breathing - Provide fresh

air.

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. The pump installed in the boiler is a 3 speed pump and is factory set to speed 3.

4.1.8 Gas Piping

Check for damage or leaks and repair as needed.

4.1.9 Control Module

• Check that boiler operation is consistent with the steps in Section 2.7

Sequence of Operation.

• Check that water temperature targets and setpoint are satisfactory and have

not been adversely amended.

• 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.

• 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 re,

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 ll” water connections are left in the closed position to

minimize exposure to leaks and ooding.

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 specically 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.

4-2

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

WARNING

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

location. For environmental and toxicity reasons, IBC

recommends only using nontoxic propylene glycol.

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.

CAUTION

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.

4.1.12 Boiler Treatment

• Check consistency of any boiler treatment used, for appropriate mixture.

Chemical inhibitors are 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 “try 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 ush 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 qualied

service personnel.

If the relief valve does not completely seal, and uid continues to leak from the discharge pipe - perform the test again to try and ush any debris that may be

lodged in the valve. If repeated tries fail to stop the leakage, contact a licensed

contractor or qualied service personnel to replace the valve.

While performing a “try lever test”, a quantity of heat transfer uid will be discharged from the piping system and the system pressure will drop. This uid

must be replaced. It is highly recommended that a system pressurization unit, such as an Axiom Industries model MF200 be employed to rell and pressurize

your system. Capture the discharged uid 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 ll valve must be turned on in order to recharge the lost uid.

4.1.14 Domestic Hot Water System

Quality of the domestic cold water is very important to the longevity of the boiler. The recommended pH of the domestic water is between 6.5 and 8.5. The internal

domestic water heat exchanger tubing and the ow sensor is subject to fouling if

exposed to hard water (over 7 grains of hardness) or has a TDS of 500mg/L or higher. See Table 13.

DESCRIPTION MAX MIN

Water Pressure 150 psi 40 psi

Programmable water temperature 149°F (65°C) 104°F (40°C)

Minimum Flow Rate to Activate DHW Sensor N/A 0.5 GPM

Acceptable pH range 7.5 pH 6.5 pH

Chloride 250 mg/L

Iron 0.3mg/L

Total Dissolved Solids 500mg/L

Total Hardness 7 grains

Table 13: Domestic Water Quality Guidelines

MAINTENANCE

4-3

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

DANGER

When servicing or replacing

the fan the following parts

must be moved from the old

fan to the new fan.

• Venturi

• Back Flow Valve

• Fan Outlet Orice

(DC 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.

4.1.15 Fan and gas valve removal instructions

1. Turn off the power and the gas supply to the boiler

2. Remove the front cover and allow the boiler to cool down

3. Disconnect the 2 electrical plugs attached to the fan

4. Loosen the union nut at the top of the gas valve. Carefully remove the Orice

and O-ring and keep in a safe place for re-installation later. Ensure you protect the gas valve outlet from dust and debris.

Remove the 2 hex nuts connecting the fan to the burner housing and carefully

remove the fan. You will nd a gasket attached to the fan outlet as well as an

internal check valve. Keep these items in a safe place for re-installation.

6. If the removed fan is to be re-installed, ensure the fan and venture are clean

and dust free.

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 Orice 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. Reset the boiler to normal operation.

Figure 39

4-4

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

5.0

NOTE

This boiler is equipped with a blocked vent shutoff system,

which closes the gas supply upon detection of an irregular

venting condition.

TROUBLESHOOTING

The troubleshooting section is divided into 4 sections:

5.1 Preliminary Checks

5.2 Electronic Components

5.3 Warnings and Faults

5.4 Other Faults

Often, a problem can be identied and solved through simple checks of the basics: conrming the electrical power supply, gas ow 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

5.1

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 rst step in troubleshooting this system should be a review of the Controller’s

display screen. There are a number of diagnostic features incorporated in the software that evaluate system integrity, display error conditions and provide initial suggested remedial actions.

In addition to checking the display, the following list is a guideline for troubleshooting:

1. Conrm power to the boiler: check that control module display is on (e.g.

display is lit).

2. Check that boiler is not in a safety lockout.

3. Ensure wiring is clean and secure.

4. Check that gas is reaching the unit.

Conrm water system is properly charged to 12 psig and pump is serviceable.

TROUBLESHOOTING

5-1

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

5.2

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 kΩ (5,000,000Ω) 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. Place multi-meter probes into sensor’s male

Molex connector socket. Do not apply voltage to the sensor (damage may result).

12KΩ Temperature Sensors supplied with boiler. See Table 14 for resistance values.

Return water temperature sensor

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE

F / C Ω - ohm F / C Ω - ohm F / C Ω - ohm

5F / -15C 76,020 77F / 25C 12,000 149F / 65C 2,752

14F / -10C 58,880 86F / 30C 9,805 158F / 70C 2,337

23F / -5C 45,950 95F / 35C 8,055 167F / 75C 1,994

32F / 0C 36,130 104F / 40C 6,653 176F / 80C 1,707

41F / 5C 28,600 113F / 45C 5,522 185F / 85C 1,467

50F / 10C 22,800 122F / 50C 4,609 194F / 90C 1,266

59F / 15C 18,300 131F / 55C 3,863 203F / 95C 1,096

68F / 20C 14,770 140F / 60C 3,253 212F / 100C 952

Table 14: Temperature Sensor Resistance Values

5-2

INSTALLATION AND OPERATION INSTRUCTIONS

Fan Power and Control Plugs

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

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 X4.7. 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 ash an error message in the main display

by toggling between the actual pressure and LO. Simply increase the system pressure to correct this error.

Domestic Water Flow Sensor

TO TEST THE OPERATION OF THE PRESSURE SENSOR

1. Turn off the boiler at the controller by pressing the button. The current

system pressure will be displayed.

2. Isolate the space heating circuit and reduce the water pressure. The

displayed water pressure should drop as the system water is being removed (expansion tank isolated). If the pressure is remaining steady then the

pressure sensor may be block or faulty. If it remains “xed”, drain boiler and

replace sensor, or dislodge any blocking debris from sensor inlet channel and reinsert.

3. If the pressure sensor is OK then simply rell the boiler and open the closed

valves. Ensure the system pressure is adequate for the heating system.

PRESSURE SENSOR REPLACEMENT

1. Turn off the power to the boiler.

2. Isolate and drain the boiler.

3. Remove the Vent Stack.

4. Disconnect the electrical connection to the sensor.

5. Carefully remove the clip at the base of the sensor.

6. 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.

11. Restore water pressure to the boiler.

12. Restore power to the boiler.

Water Pressure Sensor

TROUBLESHOOTING

5-3

DHW Temperature Sensor

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

5.2.5 Vent High-Limit

This sensor has been installed to ensure the 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

The DC series boilers are equipped with a ow sensor to measure water ow through the domestic hot water circuit in the boiler. The minimum ow required to

activate the boiler is 0.5 GPM or 2 L/min.

• To service or replace the Water Flow Sensor:

• Disconnect power to the boiler

•

Turn off the Cold and Hot water valves below the boiler, release the water pressure and drain the domestic hot water circuit. Leave the drain valves open.

• Disconnect the Molex connector at the sensor

• Remove the sensor by turning the nut counter clock wise. Take care not to

drain the water onto any of the electrical components.

• Clean or replace the ow sensor as required and reassemble in reverse order.

5.2.7 Domestic Hot Water Sensor

The DC Series boilers are equipped with a domestic hot water temperature sensor. The sensor is located on the hot water outlet pipe and is just behind the boilers condensate tray. For access, remove the vent stack and the condensate tray.

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 12KΩ sensor with resistance values as listed in Table

14. 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.

5-4

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

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 ashing and visible on the main display, and only displayed when an unusual reading is

currently detected.

MAIN DISPLAY DISPLAY FAULT POSSIBLE SOLUTION

E1 Flue gas temperature approaching limit

[pressure] P CH Pressure too low

POLE Polarity detection fault

• Supply water temperature too high

• Ambient temperature too high

• Check positioning of ue gas sensor

• Heat exchanger front panel loose, check bolt torque

• Check heat exchanger for contamination or debris

• Replace ue gas temperature sensor

• Bring the system back up to pressure

• Check pressure sensor

• Replace pressure sensor

• Switch the Line and Neutral wire on the power supply

• Check grounding

• Check for high potential on Neutral wire

• Replace controller

5.3.2 Fault codes

If the fault LED is ashing, 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 button on the operating panel to restart the burner controller.

MAIN DISPLAY DISPLAY FAULT POSSIBLE SOLUTION

10, 11, 12, 13, 14 Sensor fault S1

Supply Sensor (upper left side of the heat exchanger)

20, 21, 22, 23, 24 Sensor fault S2

Return Sensor (lower left side of the heat exchanger)

0 Sensor fault after self check Replace S1 and/or S2

1 Temperature too high

2 S1 and S2 interchanged

• 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

• Air in system. Bleed the system of any remaining air

• Pump not running, check and/or replace the pump

• Insufcient ow in installation, radiators closed

• Check wiring harness

• Replace S1 or S2

TROUBLESHOOTING

5-5

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

4 No ame signal

• Gas valve closed

• Gas supply pressure too low or drooping under load

• Gas valve or ignition unit not powered

• No or incorrect ignition gap

• Condensate drain blocked

• Check grounding of all parts

5 Poor ame 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 ue gas exhaust piping and

terminations, possible ue gas recirculation in the system

6 Flame detection fault

Replace ignition cable + ignitor

cap

8 Incorrect fan speed

• Replace ignition module

• Replace controller

• Fan rubbing on casing

• Wiring between fan and casing

• Check wiring for poor wire contact

• Replace fan

• Replace controller

27 Short in outdoor sensor

• Check wiring to outdoor sensor

• Replace outdoor sensor

29,30 Gas valve relay faulty Replace controller

5-6

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

5.4 OTHER FAULTS

5.4.1 Burner Does Not Ignite

POSSIBLE CAUSES SOLUTION

Gas valve is closed. 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. Check adjustment. See gas/air adjustment.

Fan faulty. Check the wiring. Check the fuse (3.15A), if necessary, replace the fan.

Fan dirty. Clean the fan.

Gas valve faulty. Replace the gas valve. Re-adjust the gas valve, see gas/air adjustment

5.4.2 Burner Ignites Noisily

POSSIBLE CAUSES SOLUTION

Gas supply pressure too high. Gas pressure regulator may be faulty. Replace the regulator or contact the

gas company.

Incorrect ignition gap.

• Replace the ignitor.

• Check the ignitor gap (3/16” / 4.5mm).

Gas/air adjustment not correctly set. Check the setting. See gas/air adjustment.

Weak spark.

• Check the ignition spark gap.

• Replace the ignitor.

• Replace the ignition module on the gas valve.

5.4.3 Burner Resonating

POSSIBLE CAUSES SOLUTION

Gas supply pressure too low. Gas pressure regulator may be faulty. Replace the regulator or contact the

gas company.

Recirculation of combustion gasses. Check combustion air supply and ue gas exhaust piping and terminations,

possible ue 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

At high rpm the power has fallen by more than 5%.

TROUBLESHOOTING

• Check appliance and ue system for fouling.

• Clean the appliance and ue system

5-7

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

5.4.5 No Space Heating

POSSIBLE CAUSES SOLUTION

Room thermostat (end switches or zone controller) / Outdoor sensor faulty.

No voltage (24V DC).

Internal Pump not running.

Burner not ring on space heating: sensor S1 or

S2 faulty.

Burner does not ignite. See burner does not ignite.

• 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.

• 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 should be

running.

• Replace the controller if 120V is not present when the pump should be

running.

Replace sensor S1 or S2. See fault code.

5.4.6 Indoor Temperature Does Not Reach Desired Temperature

POSSIBLE CAUSES SOLUTION

Room thermostat setting incorrect. Check the setting and if necessary adjust: Set heat anticipator to 0.1A.

Thermostat must be a DRY CONTACT style thermostat

Water temperature is too low. Increase the space heating water temperature. See 2.3.Table of

Programmable Parameters. Check outdoor sensor and wiring for shortcircuit.

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.

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.

Increase pump setting, or replace the pump.

De-scale or ush the heat exchanger on the space heating side.

5.4.7 No Hot Water (DHW)

POSSIBLE CAUSES SOLUTION

Flow sensor not functioning.

No voltage at the ow sensor (5V DC). Check the wiring according to the diagram.

Burner not ring on DHW: S3 faulty. Replace S3.

Burner does not ignite. See burner does not ignite.

• DHW ow < 2.0 l/min – .5 GPM.

• Clean or replace the ow sensor.

5-8

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

5.4.8 Hot Water Does Not Reach Temperature

POSSIBLE CAUSES SOLUTION

DHW ow to high. Adjust the inlet assembly, insert a ow restriction.

Temperature setting for water circuit too low. Adjust the hot water circuit, depending on the desired temperature and

system conguration. See 2.3.4 Table of Programmable Parameters

Water temperatures are set incorrectly Target water temperature is set higher than the maximum water

temperature.

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

Cold water temperature <5°C.

Descale or ush the exchanger DHW side.

TROUBLESHOOTING

5-9

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

PAGE INTENTIONALLY LEFT BLANK

5-10

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

6.0

DIAGRAMS

6.1 - PARTS DIAGRAMS

6.2 - WIRING DIAGRAMS

DIAGRAMS

6-1

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

6.1 PARTS DIAGRAMS

DC Series Modulating Boiler - Parts assembly

Diagram 6.1-1: Boiler assembly parts

6-2

INSTALLATION AND OPERATION INSTRUCTIONS

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

DIAGRAMS

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.

6-3

DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160

6.2 WIRING DIAGRAMS

Diagram 6.2-1: Pictorial wiring diagram

6-4

INSTALLATION AND OPERATION INSTRUCTIONS

INSTALLATION & 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 re) _______ Inches w.c. Measured Rate of Input (high re) ____________ 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 lled Condensate drain clear and free owing Condensate Neutralization? Yes/No

Ignition Safety Shutoff test completed. Flame current reading - High re _______ µA - Low re _______ µA

Owner advised and instructed in the safe operation and maintenance of the boiler and system.

Information regarding the unit and installation received and left with owner

Combustion Readings - recommended, but optional (required for fuel conversion):

_____________ % O2 ______________ % CO ____________ ppm

Flue temperature _________ Return water temperature (measure simultaneously with ue 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

DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE

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 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.

US installers should contact IBC for any further information required.

REVISION HISTORY

R1 (JULY 2014) Initial release

R2 (SEPTEMBER 2014) Minor updates

IBC Technologies Inc.

1445 Charles Street, Vancouver, BC Canada V5L 2S7

Tel: 604.877.0277 Fax: 604.877.0295

www.ibcboiler.com

120-183-A-R2 883967

September 2014

IBC Boilers DC 23-84, DC 29-106, DC 33-124, DC 33-160 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual