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IBC DC 33-160 User Manual

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INSTALLATION AND OPERATING INSTRUCTIONS
www.ibcboiler.com
DC Series Boilers / Water Heaters
DC 15-95, DC 15-96, DC 20-125, 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
suppliers 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

Table of Contents

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IBC DC 33-160 Specifications

General IconGeneral
BrandIBC
ModelDC 33-160
CategoryBoiler
LanguageEnglish

Summary

SAFETY CONSIDERATIONS

DANGER: Hazardous Situations

Identifies immediately hazardous situations to prevent serious injury or death.

WARNING: Potentially Hazardous Situations

Alerts to potentially hazardous situations to prevent serious injury or death.

CAUTION: Moderate Hazards

Points out potentially hazardous situations to prevent moderate injury or property damage.

NOTE: Installation and Operation Details

Provides details for enhanced efficiency, longevity, and proper operation.

BEST PRACTICES: Installation Recommendations

Offers recommendations for optimal installation procedures.

SPECIFICATIONS

WATER HEATER INSTALLATION GUIDELINES

Adjustable Temperature Setting

Details how to adjust the domestic hot water temperature settings.

INSTALLATION

General Installation Overview

Introduces the DC Series boilers/water heaters and their general installation aspects.

Code Requirements

Outlines the installation must conform to all applicable codes and standards.

Location Requirements

Specifies suitable locations and clearance requirements for installation.

EXHAUST VENTING AND AIR INTAKE

Venting Applications

Explains the applications of direct vent systems and combustion air requirements.

Exhaust Vent Material

Details approved materials for exhaust venting systems in Canada and USA.

Vent Travel and Equivalency

Defines vent travel allowances and equivalent lengths for various pipe sizes and fittings.

Venting Passage Through Ceiling and Floor

Provides guidelines for routing vent piping through building structures.

Rooftop Vent Termination

Details requirements for terminating exhaust and intake vents on a rooftop.

Sidewall Vent Termination

Outlines procedures for terminating exhaust and intake vents on building sidewalls.

Combustion Air Intake Piping

Details requirements for direct vent combustion air intake piping.

Indoor Air Combustion Air Intake

Discusses limitations on indoor air intake for combustion.

Closet Installations

Provides guidance for installing the unit in confined spaces like closets.

CONDENSATE REMOVAL

Condensate Trap Cleaning and Details

Explains the procedure for cleaning the condensate trap and further installation details.

WATER PIPING - SPACE HEATING

General Piping Considerations

Covers general aspects of water piping for space heating, including pump operation.

Relief Piping Installation

Details the requirements for installing the pressure relief valve and its discharge piping.

Boiler/Water Heater Trim Options

Illustrates basic options for boiler/water heater trim and piping configurations.

Basic Heating Piping Arrangements

Discusses primary/secondary piping benefits and installation rules, and pump air bleeding.

DOMESTIC HOT WATER SYSTEM

Domestic Hot Water System Operation

Explains the operation of the domestic hot water system, including modes and water quality considerations.

Domestic Hot Water Piping

Details the piping requirements for domestic hot water connections and system components.

GAS PIPING

ELECTRICAL CONNECTIONS

120VAC Line Voltage Hook-up

Provides instructions for connecting the unit to a 120VAC power supply.

Power Quality and Electrical Protection

Addresses the need for surge protectors and power conditioning equipment.

Zone Valve and Zone Pump Connections

Explains how to connect zone valves and pumps for system zoning.

Thermostat / Sensor Wiring

Details wiring connections for thermostats and sensors to the control module.

BOILER / WATER HEATER SYSTEMS AND OPERATION

General System Overview

Provides a general overview of the boiler/water heater's capabilities and features.

Control Panel and Interface

Describes the controller indicators, buttons, and basic operation.

Installer Interface and Settings

Covers the installer interface for appliance ON/OFF and basic settings.

Unit Settings and Programming

Explains how to set PSI/Fahrenheit or Bar/Celsius and access programming modes.

Tankless Domestic Hot Water Modes

Details the different operating modes for tankless domestic hot water generation.

Adding Domestic Hot Water Storage

Explains how to connect the unit to a domestic hot water storage tank.

Space Heating Operation

Describes how the unit provides heat for space heating, including outdoor reset.

Sequence of Operation

Details the operational sequence of the boiler/water heater for heating and hot water calls.

STARTUP AND COMMISSIONING

Lighting and Shutting Down the Boiler

Provides instructions for safely starting up and shutting down the boiler.

Prior to Start-Up Checks

Lists essential checks to perform before initial boiler startup.

Commissioning Procedures

Outlines the steps for commissioning the boiler, including fuel conversion checks.

Fuel Conversion

Details the procedure for converting the unit between natural gas and propane fuels.

Burner Access and Removal

Explains how to access the combustion chamber and remove the burner assembly.

MAINTENANCE

Boiler / Water Heater Maintenance Overview

Covers general care, inspection, venting, condensate traps, and burner maintenance.

Heat Exchanger Maintenance

Details inspection and cleaning procedures for the heat exchanger.

Pump, Gas Piping, and Control Module Checks

Outlines checks for the pump, gas piping, and control module during maintenance.

Water Heating System and Freeze Protection

Covers maintenance of the water heating system and freeze protection measures.

Boiler/Water Heater Treatment

Advises on the proper treatment of boiler water and chemical inhibitors.

Relief Valve Maintenance and Testing

Details the procedure for maintaining and testing the pressure relief valve.

Domestic Hot Water System Quality

Emphasizes the importance of domestic water quality for system longevity.

Fan and Gas Valve Removal/Re-assembly

Provides instructions for removing and re-assembling the fan and gas valve components.

TROUBLESHOOTING

Preliminary Checks

Guides users through initial checks to diagnose system issues.

Electronic Components Overview

Introduces troubleshooting for electronic components like sensors and the control module.

Warnings and Fault Codes

Lists common warning and fault codes displayed by the controller and their solutions.

Other Faults

Covers various other faults not classified under warnings or specific codes.

Temperature Sensors

Details the function, resistance values, and testing of various temperature sensors.

Fan/Blower and Thermostat Connections

Describes the fan operation and how to connect thermostats to the control.

Water Pressure Sensor (LWCO)

Explains the function of the water pressure sensor and its role as a low water cut-off.

Vent High-Limit Sensor

Details the vent high-limit sensor's function in ensuring safe shutdown.

Domestic Hot Water Flow and Temperature Sensors

Covers troubleshooting and replacement of DHW flow and temperature sensors.

DHW Tank Sensor

Details the DHW tank sensor and its resistance values for temperature control.

Warning Codes

Lists controller warning codes and possible solutions for troubleshooting.

Fault Codes

Lists controller fault codes and possible solutions for troubleshooting.

Burner Faults

Covers common burner faults like ignition failure, noisy ignition, and resonance.

Heating and Hot Water Faults

Addresses issues related to no space heating, desired temperature not reached, and no hot water.

Hot Water Temperature Faults

Details troubleshooting steps when hot water does not reach the desired temperature.

DIAGRAMS

Parts Diagrams

Refers to diagrams showing the assembly of boiler and water heater parts.

Wiring Diagrams

Refers to diagrams illustrating the electrical wiring connections for the unit.

DC 15-95 Parts Assembly

Provides a parts assembly diagram for the DC 15-95 model.

DC 15-96, 20-125, 33-160 Parts Assembly

Provides parts assembly diagrams for DC 15-96, 20-125, and 33-160 models.

Wiring Diagrams - Schematic and Ladder

Illustrates the schematic and ladder wiring diagrams for the DC series.

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