User Manual
Contents
1. Better Boilers DC Series Combi Boilers HC Series Boilers Natural Gas or Propane EAU 7 WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapours and liquids or other combustible materials in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a nearby phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier ec 2 lt r z E 44 O x x This Manual is also available in French contact IBC or visit our web site www ibcboiler com aD E Teu ENERGY STAR C US wwW ibchoiler com Better Boilers If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life DC HC SERIES BOILERS 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 qualified licensed and trained hea2. N A 7 5 pH 250 mg L 40 psi 104 F 40 C 0 5 GPM 6 5 pH Acceptable pH range Chloride Iron 0 3mg L Total Dissolved Solids 500mg L 7 grains Total Hardness Table 5 Domestic Water Quality Guidelines USER S INFORMATION MANUAL LIJ Better Boilers PAGE INTENTIONALLY LEFT BLANK USER S INFORMATION MANUAL 14 Better Boilers PARTS DIAGRAMS DC Series Modulating Boiler Parts assembly Diagram 1 Boiler assembly parts 9 USER S INFORMATION MANUAL LIJ Better Boilers ITEM No PART No DESCRIPTION 10 240 067 IGNITOR 20 250 622 GASKET IGNITOR 30 250 623 VIEWPORT HOLDER 40 250 624 GASKET VIEWPORT HOLDER 50 250 625 GASKET VIEWPORT GLASS 60 250 626 VIEWPORT GLASS 70 170 014 HEAT EXCHANGER 80 250 645 GASKET H Ex FRONT PANEL 90 180 114 BURNER 250 646 GASKET BURNER 250 627 GASKET 180 122 ORIFICE FAN OUTLET DC 23 84 ONLY 240 068 FAN 250 633 GASKET DHW WATER PIPE 250 634 GASKET PUMP 180 111 VENTURI 406 180 112 VENTURI 362 180 095 505 PROPANE 180 096 580 PROPANE 180 107 ORIFICE 650 NATURAL GAS 180 108 ORIFICE 725 NATURAL GAS 150 175 O RING 180 097 GAS VALVE 240 069 GAS VALVE CABLE IGNITION MODULE 250 628 GASLINE 240 070 DHW SENSOR 250 629 SUPPLY PIPE DHW 250 630 RETURN PIPE DHW 240 071 WATER FLOW SENSOR 250 631 RETURN PIPE 180 098 PUMP 500 050 DOO
3. hot water temperature set the valve to a higher number To achieve a lower domestic hot water temperature set the valve to a lower number Better Boilers DC HC SERIES BOILERS CONTROL C bar 5 Before adjusting the control settings read the control instructions carefully Power ON OFF Space Heating DHW Toggle Power Indicator Space Heating Minus Plus Fahrenheit Celsius Domestic Hot Water Main Display Fahrenheit and PSI Celsius and Bar Comfort ECO OFF Indicator Comfort ECO OFF Indicator Reset Button Service Display Flashes to indicate a fault Table 1 Controller Indicators and Buttons Domestic Hot Water Comfort Eco Service 1 2 3 4 5 6 7 8 9 NOTE The control displays codes that include upper and lower case letter and a combination with a period after the letter Example C c c are all valid parameter codes When adjusting settings double check that you are in the correct parameter USER INSTALLER INTERFACE 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 b
4. LIGHTING AND SHUTTING DOWN THE BOILER FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot It is equipped with an ignition device which auto matically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the ap pliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppli er s instructions f you cannot reach your gas supplier call the fire department C Use only your hand to turn the gas control valve Never force using tools If the valve will not turn by hand don t try to repair it call a qualified service technician Force or attempt ed repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified ser vice technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label before doing anything S
5. es aa a th els aus 20 LIJ Better Boilers PAGE INTENTIONALLY LEFT BLANK USER S INFORMATION MANUAL Better Boilers USER S INFORMATION MANUAL DC HC SERIES BOILERS DANGER Water temperature over 125 F 52 C can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available see manual 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 o Failure to correctly install and operate this appliance can result in severe personal injury or death o The water heater if utilized shall have a pressure relief valve installed within 6 152mm of the DHW HOT outlet connection with the relief valve spindle installed in the vertical position Refer to the Boiler User s Manual before operating relief valve o The water heater 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
6. HC SERIES BOILERS 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 Keep boiler area free and clear of combustible materials gasoline and other flammable vapours and liquids Combustion air must not be drawn from areas containing corrosive air from swimming pools or spas including air directly next to outdoor pools and spas The boiler shall not be exposed to water leaks from piping or components located overhead This includes condensation dropping from un insulated cold water lines overhead In areas of high snow fall users must check side wall exhaust vent and air intake terminations on a regular basis to ensure blockages do not occur Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water 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 The thermostatic mixing valve installed with the DC Series Combi Boiler is to protect the users from scalding from excessive hot water temperatures at the faucets The thermostatic mixing valves are user adjustable To achieve a higher domestic
7. Off button will also exit the User Menu but will NOT save the changes A Better Boilers TANKLESS DOMESTIC HOT WATER MODES DC SERIES BOILERS ONLY 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 efficient 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 satisfied 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 efficient 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 To toggle between the 3 modes simply press the Domest
8. R ASSEMBLY 500 051 CONTROLLER ASSEMBLY DC HC84 106 124 500 053 CONTROLLER ASSEMBLY DC HC160 190 124 CONDENSATE PIPE ASSEMBLY 190 125 SEAL COND PIPE TO BOTTOM PAN 180 100 BOTTOM PAN HEAT EXCHANGER 240 076 VENT HIGH LIMIT SWITCH 190 119 FITTING 1 2 NPT M 190 120 FITTING 3 4 NPT M 190 121 FITTING 1 NPT M 180 099 CONDENSATE TRAP SHORT 180 113 CONDENSATE TRAP LONG 250 638 _ CONDENSATE TRAP HOOK 240 072 WATER PRESSURE SENSOR 240 073 WATER TEMPERATURE SENSOR 250 632 SUPPLY PIPE 250 635 GASKET SUPPLY PIPE 190 122 EXHAUST DUCT INTERNAL 250 636 EXHAUST DUCT 250 637 INTAKE DUCT IN as se e e me ss zx ek fes e ST es IRS zx rs Diagram 2 Boiler assembly parts list refer to Diagram 1 on opposite page Some parts are available in Kits Please visit www ibcboiler com for more information USER S INFORMATION MANUAL LIJ Better Boilers HC Series Modulating Boiler Parts assembly Diagram 4 Boiler assembly parts USER S INFORMATION MANUAL LIJ Better Boilers ITEM No PART No DESCRIPTION 10 240 067 IGNITOR 20 250 622 GASKET IGNITOR 30 250 623 VIEWPORT HOLDER 40 250 624 GASKET VIEWPORT HOLDER 50 250 625 GASKET VIEWPORT GLASS 60 250 626 VIE
9. WPORT GLASS 70 170 014 HEAT EXCHANGER 80 250 645 GASKET H Ex FRONT PANEL 90 180 114 BURNER 250 627 GASKET BURNER 250 627 GASKET FAN 180 122 ORIFICE FAN OUTLET HC 23 84 ONLY 240 068 FAN 180 111 VENTURI 406 180 112 VENTURI 362 180 095 ORIFICE 505 NATURAL GAS 180 096 ORIFICE 580 NATURAL GAS 180 107 ORIFICE 650 PROPANE 180 108 ORIFICE 725 PROPANE 150 175 O RING 180 097 GAS VALVE 240 069 GAS VALVE CABLE IGNITION MODULE 250 628 GAS LINE 250 634 GASKET PUMP 180 098 PUMP 250 631 RETURN PIPE 500 050 DOOR ASSEMBLY 500 051 CONTROLLER ASSEMBLY DC HC84 106 124 500 053 CONTROLLER ASSEMBLY DC HC160 190 124 CONDENSATE PIPE ASSEMBLY 190 125 SEAL COND PIPE TO BOTTOM PAN 180 100 BOTTOM PAN HEAT EXCHANGER 240 076 VENT HIGH LIMIT SWITCH 190 119 FITTING 1 2 NPT M 190 121 FITTING 1 NPT M 180 099 CONDENSATE TRAP SHORT 180 113 CONDENSATE TRAP LONG 250 638 CONDENSATE TRAP HOOK 240 072 WATER PRESSURE SENSOR 240 073 WATER TEMPERATURE SENSOR 250 632 SUPPLY PIPE 250 635 GASKET SUPPLY PIPE 190 122 EXHAUST DUCT INTERNAL 250 636 EXHAUST DUCT 250 637 INTAKE DUCT 3 4 p 4 4 4 p p Dis Ni Diagram 5 Boiler assembly parts list refer to Diagram 4 on opposite page Some parts are available in Kits Please visit www ibcboiler com for more inform
10. ation USER S INFORMATION MANUAL LIJ Better Boilers SERVICE RECORD LICENSED CONTRACTOR DESCRIPTION OF WORK DONE USER S INFORMATION MANUAL EIJ Better Boilers NOTES USER S INFORMATION MANUAL LIJ Better Boilers The following message is relevant to users in the USA 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 not applicable to IBC s HC boilers US installers should contact IBC for any further information required USER S INFORMATION MANUAL LIJ Better Boilers REVISION HISTORY R1 JULY 2014 Initial release R2 SEPTEMBER 2014 Addition of the HC 13 50 R3 AUGUST 2015 Address Upda
11. away from any person Close fill valve after any addition of water to the system to reduce risk of water escapement Water quality has a significant impact on the lifetime and performance of an IBC Boiler heat exchanger Improperly prepared water in a heating circuit may cause damage to the heat exchanger through corrosion or fouling Repeated or uncontrolled water fills will increase the potential for damage High levels of dissolved solids or minerals may precipitate out of the fluid onto the hottest part of the heat exchanger impairing heat transfer and resulting in overheating and premature failure The amount of solids that may form on the heat exchanger will depend on the degree of hardness and the total water volume in the system A high water volume system with a low hardness count may cause as much damage as a system with less volume and higher hardness so it is recommended to treat water so as to remove all dissolved solids Other water chemistry allowable limits are as follows Acidity pH is to be between 6 5 and 8 5 Chloride is to be less than 125 mg l e Iron is to be less than 0 3 mg l Cu less than 0 1 mg l Conductivity is to be less than 400p S cm at 25 C Hardness is to be 7 Grains or less IMPORTANT Ensure that these limits are acceptable for the other water side components in the system USER S INFORMATION MANUAL Better Boilers USER S INFORMATION MANUAL DC
12. etthe thermostat to lowest setting Turn off all electric power to the appliance by selecting main power switch to OFF This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Locate manual gas shut off valve see pictures below and turn clockwise to CLOSE Wait five 5 minutes to clear out any gas Then EN CLOSE clockwise open D clockwise smell for gas including near the floor If you smell gas STOP Follow step in the safety information above on this label If you don t smell gas go to the next step Turn gas control valve to OPEN Turn on electric power to appliance by select ing main power switch to ON Set thermostat to desired setting If the appliance will not operate follow the in structions TO TURN OFF GAS APPLIANCE and call your service technician or gas supplier TO TURN OFF GAS APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance by selecting main power switch to OFF 3 Turn gas control valve to CLOSE USER S INFORMATION MANUAL Better Boilers Annual Maintenance must only be done by a qualified service technician USER S INFORMATION MANUAL MAINTENANCE Daily Maintenance Check the surrounding area inspect for water leaks in the general area around the boiler and boiler piping Check the system pressu
13. ic Hot Water Comfort Eco button Table of Programmable Parameters PARAMETER 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 120 F 49 C 104 F 40 C to 149 F 65 C Temperature Table 2 Programmable Parameters USER S INFORMATION MANUAL Better Boilers USER S INFORMATION MANUAL DC HC SERIES BOILERS OPERATING AND SERVICE DISPLAY CODES MAIN SERVICE DESCRIPTION DISPLAY DISPLAY blank The boiler is OFF Press the On Off 1 button to turn on the boiler 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 energized call for heat still present XXX 2 Self test When power is applied to the boiler the controller enters a self diagnostic mode for 5 seconds XXX 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 for Comfort mode Freeze Protection mode Table 4 Operating Display and Service Display Codes Figure 1 Boiler assembly parts To increase the water temperature turn the dial to a higher number To reduce the water temperature turn the dial to a lower number Better Boilers DC HC SERIES BOILERS
14. o your installation location For environmental and toxicity reasons IBC recommends only using non toxic propylene glycol Installers should inquire of local water purveyors as to the suitability of their supply for use in hydronic heating systems If water quality is questionable a local water treatment expert must be consulted for testing assessment and if required treatment Alternatively water or hydronic fluid of known quality can be brought to the site Before testing the relief valve make certain the discharge pipe is properly connected to the valve outlet and arranged to contain and safely dispose of equipment discharge DC HC SERIES BOILERS 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 try lever test must also be performed at the end of any non service period Test at or near maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of sediment and debris Then release the lever and permit the valve to snap shut If the lever does not activate or there is not evidence of discharge discontinue use of equipment immediately and contact a licensed contractor or qualified se
15. oiler USER S INFORMATION MANUAL Better Boilers The domestic hot water thermostat is adjusted it its lowest temperature position when shipped from the factory It s recommended to set the domestic hot water thermostat to 120 F 49 C as an initial setting and further adjust as required For energy efficient operation this setting should be set as low as practical for the consumer s needs USER S INFORMATION MANUAL DC HC SERIES BOILERS 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 e to toggle Fahrenheit and Celsius Programing Mode USER MENU Adjusting the Space Heating Water Temperature To enter the User Menu simply hold down the Space Heating DHW Toggle n 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 2 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 it button Pressing the On
16. re The heating system pressure should not exceed 25psi and not drop below 10psi in most applications If the pressure is outside this normal range or if the water pressure fluctuates more than 2 3psi contact your qualified service technician for service Check the area around the boiler and the air intake opening for obstructions and chemical contaminates Monthly Maintenance Check all the Daily Maintenance items For DC series boilers check the domestic hot water temperature at the faucet to ensure the temperature is not too hot If the temperature is too hot you can adjust the thermostatic mixing valve to a lower number adjust the water temperature with the boilers controller or adjust the water temperature at the hot water tank If these adjustments are not correcting the issue call your qualified service technician for service Check the pressure relief valve and discharge piping for signs of leakage or moisture If water or moisture is found contact your qualified service technician as soon as possible for service Check the condensate trap and outlet pipe The condensate trap shall be full of water The outlet hose may be connected to a condensate neutralizer if so check the pH of the water coming out of the neutralizer is above 6 0pH If the pH is below 6 0 then the neutralizer will need to be re charged or replaced Contact your qualified service technician for service Annual Maintenance The boiler must be inspected b
17. rvice personnel If the relief valve does not completely seal and fluid continues to leak from the discharge pipe perform the test again to try and flush any debris that may be lodged in the valve If repeated tries fail to stop the leakage contact a licensed contractor or qualified service personnel to replace the valve While performing a try lever test a quantity of heat transfer fluid will be discharged from the piping system and the system pressure will drop This fluid must be replaced It is highly recommended that a system pressurization unit such as an Axiom Industries model MF200 be employed to refill and pressurize your system Capture the discharged fluid in a container and recycle it by returning it to the system feeder unit This is particularly important when your system contains treatment chemicals or glycol solutions If the system employs plain water the boiler auto fill valve must be turned on in order to recharge the lost fluid Domestic Hot Water System Quality of the domestic cold water is very important to the longevity of the boiler The recommended pH of the domestic water is between 6 5 and 8 5 The internal domestic water heat exchanger tubing and the flow sensor is subject to fouling if exposed to hard water over 7 grains of hardness or has a TDS of 500mg L or higher See Table 5 DESCRIPTION Water Pressure 150 psi Programmable water temperature 149 F 65 C Minimum Flow Rate to Activate DHW Sensor
18. te USER S INFORMATION MANUAL IBC Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 184 A R3 88534702 August 2015 IBC Technologies Inc 2015
19. 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 o Hotter water increases the risk of scald injury Before changing the temperature setting see instruction manual ADJUSTABLE TEMPERATURE SETTING o Press the n and hold for 2 seconds then press again When the LED is lit the Domestic Hot Water temperature can be set Better Boilers DC HC SERIES BOILERS 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 specific 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 satisfies 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 flow
20. ting technicians Failure to read and comply with all instructions and applicable National and local codes may result in hazardous conditions that could result in property damage and injury to occupants which in extreme cases might result in death HAZARDS amp PRECAUTIONS Points out an immediately hazardous situation which must be avoided in order to prevent serious injury or death Points out a potentially hazardous situation which must be avoided to prevent possible moderate injury and or property damage BEST PRACTICES Points out recommendations for better installation Points out a potentially hazardous situation which must be avoided to prevent serious injury or death Points out installation maintenance and operation details that will result in enhanced efficiency longevity and proper operation of your boiler USER S INFORMATION MANUAL Better Boilers USER S INFORMATION MANUAL CONTENTS CONTROL eor iesus use owe ee a in du aie wa a ae Meee 8 USER INSTALLER INTERFACE 8 TANKLESS DOMESTIC HOT WATER MODES 10 OPERATING AND SERVICE DISPLAY CODES 11 LIGHTING AND SHUTTING DOWN THE BOILER 12 MAINTENANCE uere Ra eps bee kbs Oe erie eee 13 PARTS DIAGRAMS sehe Dae Ph UR RR d due dt hante bee 16 SERVICE RECORD Lupe aa ae Halen a ele aa
21. y your qualified service technician for the following Inspect the flue gas exhaust and air intake connections All connections should be tight and leak free Inspect flue gas exhaust piping combustion air piping and terminations Inspect the boilers interior and vacuum if required Check for water gas and condensate leaks in the boiler and around the boiler Check the condensate trap and clean if required Re fill the trap and re install the trap hook Check the water pressure expansion tank and pumps Check the electrical connections Check the ignition electrode and remove oxidation from the electrode Replace if necessary Check the gas valve and ignition cable Check the controller settings Check the burners flame Should be a quick and quiet ignition across the full burner If required clean the heat exchanger and the burner Better Boilers Do not use automotive type ethylene or other types of automotive glycol antifreeze or undiluted antifreeze of any kind This may result in severe boiler damage It is the responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials Improper mixtures and chemical additives may cause damage to ferrous and non ferrous components as well as non metallic wetted components normally found in hydronic systems Ethylene glycol is toxic and may be prohibited for use by codes applicable t
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