IBC CX Series Installation And Operating Manual
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IBC CX Series Installation And Operating Manual

Residential combi boiler
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INSTALLATION AND
OPERATING MANUAL
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 vapors and liquids or other combustible
materials in the vicinity of this or any other appliance.
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.
Residential Combi Boiler
CX 150 (model #ICGFSW1-0150)
CX 199 (model #ICGFSW1-0199)
WARNING

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  • Page 1 INSTALLATION AND OPERATING MANUAL Residential Combi Boiler CX 150 (model #ICGFSW1-0150) CX 199 (model #ICGFSW1-0199) 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 vapors and liquids or other combustible materials in the vicinity of this or any other appliance.
  • Page 2 Water quality Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage.

  • Page 3: Table Of Contents

    Contents Safety information Manual safety markings Important safety instructions Known contaminants Specifications Cabinet dimensions CX 150 dimensions CX 199 dimensions Connection specifications 1.0 Introduction 1.1 Standard features and benefits 1.2 Warranty 2.0 Before installation 3.0 Installation 3.1 Code requirements 3.2 Removing an existing boiler 3.3 Determining location of the appliance 3.3.1 Best installation conditions 3.4 Mounting the boiler...
  • Page 4 Section: Contents 3.10 Installing a condensate neutralizer 3.11 Water piping (space heating) 3.11.1 General piping best practices 3.11.2 System piping 3.12 Water piping (domestic hot water) 3.12.1 Domestic hot water system 3.12.2 Domestic hot water piping 3.13 Gas piping 3.13.1 Gas pressure 3.14 Electrical connections 3.14.1 Power management, quality and electrical protection 3.14.2 120VAC line-voltage hook-up...
  • Page 5 7.2 Maintenance checklist for heating contractor 7.2.1 Touchscreen boiler controller 7.2.2 General combi boiler maintenance 7.3 Replacing the fan, gas valve, and burner 7.3.1 Replacing the fan 7.3.2 Replacing the gas valve 7.3.3 Replacing the burner 7.4 Maintenance of the On-Demand DHW block 7.4.1 Cleaning the bypass check valve 7.4.2 Replacing the bypass actuator 7.4.3 Removing the flow sensor...
  • Page 6 Section: Contents Boiler part diagrams - CX 150, CX 199 Installation & Commissioning Report...

  • Page 7: Safety Information

    Important safety instructions Installation, start-up and servicing of IBC boilers must be performed by competent, qualified, 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, and in extreme cases to death.
  • Page 8 Section: Safety information 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. Danger Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

  • Page 9: Known Contaminants

    Known contaminants Warning Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, or loss of life. Read and understand the entire manual before attempting installation, start-up, operation, or service. Installation and service must be performed only by an experienced, skilled installer or service agency. Failure to follow all instructions in the proper order can cause personal injury or death.
  • Page 10 Intentionally left empty...

  • Page 11: Specifications

    Specifications Specification CX 150 CX 199 CSA Input (Natural Gas or Propane) 15 - 150 MBH 20 - 199 MBH CSA Input (Natural Gas or Propane) 4.4 - 44 kW 5.9 - 58.3 kW CSA Output 14.3 - 138.5 MBH 19.1 - 183.7 MBH CSA Output 4.2 - 40.6 kW...

  • Page 12: Cabinet Dimensions

    Section: Specifications Ignition Stages Timings Fan Pre-purge 15 seconds Trial for Ignition 4 seconds Flame Failure Response <0.8 second Domestic Hot Water Delivery @ 70°F / 39°C temperature rise CX 150 4.1 GPM CX 199 5.5 GPM Cabinet dimensions CX 150 dimensions Figure 1 Front and side view - CX 150...

  • Page 13: Cx 199 Dimensions

    CX 199 dimensions Figure 2 Top and bottom view - CX 150 CX 199 dimensions Figure 3 Front and side view - CX 199...

  • Page 14: Connection Specifications

    Section: Specifications Figure 4 Top and bottom view - CX 199 Connection specifications The following table displays the required connection specifications. Description CX 150 CX 199 Flue Outlet 3" Schedule 40 or 3" PP (80 3" Schedule 40 or 3" PP (80 Combustion Air Inlet 3"...

  • Page 15: Introduction

    1.0 Introduction Figure 5 View from the front 1.1 Standard features and benefits High thermal efficiency Coordinated Boiler and DHW circuits Compact Turn-down ratio 10 to 1 Cascade up to 4 appliances 4 load pump management Built-in boiler pump Easy-to-use touchscreen...

  • Page 16: Warranty

    0-10 years (100% coverage) 11-15 years (25% coverage). IBC offers a limited combustion heat exchanger warranty with no registration of 0-5 years (100% coverage). For commercial applications, IBC offers a 5-year warranty on the combustion heat exchanger (space heating) and a 2-year warranty on all parts (including the DHW heat exchanger), against...

  • Page 17: Before Installation

    2.0 Before installation Before installing the appliance, it is important to review and observe the following checklist of precautions: Precautions Check □ Care must be taken to properly size the boiler for its intended use. Prolonged full fire run time, over-sizing or under-sizing, and incorrect flow rates through the appliance can lead to increased maintenance costs, equipment stress and premature failure.
  • Page 18 Section: Before installation Precautions Check 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 neighboring properties. Caution Care must be taken to properly size the boiler for its intended use.

  • Page 19: Installation

    3.0 Installation Refer to the Specifications section for dimensional drawings and connection specifications. Use these drawings to find a suitable location for the appliance. 3.1 Code requirements The appliances are tested and certified under CSA 4.9 / ANSI Z21.13 (latest edition). Below are the code requirements for every installation.

  • Page 20: Determining Location Of The Appliance

    Section: Installation Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

  • Page 21: Best Installation Conditions

    3.3.1 Best installation conditions 3.3.1 Best installation conditions Below are some factors to consider for best installation conditions: Install the boiler in areas where the combustion air source is not subject to chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a boiler.
  • Page 22 Section: Installation Ensure that the boiler tab is flush against Secure the lower part of the boiler the mounting bracket flange. to the wall with two field-supplied ¼" bolts. Warning Do not mount the appliance to hollow wall structures - The combined weight of the boiler, its water content and associated piping components can exceed 113 pounds.

  • Page 23: Connecting The Vent And Air Intake Pipes

    3.5 Connecting the vent and air intake pipes 3.5 Connecting the vent and air intake pipes The appliance offers 3" connections that accept standard 3" PVC/CPVC and PP pipe. Use reducing fittings (not bushings) to adapt to smaller diameter pipe. Insert pipe directly into the 3" female fitting, and secure with the built-in clamp (see image below).

  • Page 24: Installation Clearances

    3.7 Exhaust venting and air intake Warning Venting, condensate drainage, and combustion air systems for all IBC boilers must be installed in compliance with all applicable codes and with instructions provided in the respective installation manuals.

  • Page 25: Venting Code

    3.7.1 Venting code When planning a boiler's installation, consider the appropriate vent materials, travel and termination. 3.7.1 Venting code All venting must be installed in accordance with the requirements of the jurisdiction having authority: in Canada, Part 8, Venting Systems of the B149.1-10 Code and any other local building codes are to be followed.

  • Page 26: Direct Vent

    Section: Installation Exhaust vent material - general Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in venting systems is prohibited. Do not use ABS or any cellular core pipe for exhaust venting. 3.7.4 Direct vent Direct vent is a two-pipe system that draws combustion air (air intake) from outdoors, and discharges exhaust gases to the outdoors.
  • Page 27 Check that material meets local codes including fire stopping requirements. Some local jurisdictions require a minimum initial length of pipe be exposed or accessible for inspection. Pipe clearances - no IBC requirements; follow local codes. All piping must be liquid and pressure tight.
  • Page 28 Check the local jurisdiction on the minimum initial length of pipe that should be exposed or accessible for inspection. Follow the local codes for pipe clearances - no IBC requirements. Ensure that piping is liquid and pressure tight. 3.7.4.1 Air intake and exhaust vent length allowance Warning Follow all installation instructions supplied by the piping and fitting manufacturer.
  • Page 29 3.7.4 Direct vent Intake/Exhaust CX 150 CX 199 256) 3-inch Stainless Allow 20 feet Sidewall Terminal - exhaust vent (P-257) 3-inch Stainless No allowance required Sidewall Terminal - air intake (P-257) Flexible PP 3-inch Limited to 45 feet Limited to 30 feet Flexible pipe maximums Flexible PP 3-inch...

  • Page 30: Rooftop Vent Termination

    Section: Installation 3.7.5 Rooftop vent termination Warning Condensate can cause corrosion of metal roofing components and other roofing materials. Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate. pH levels can be as low as 3.0. a.
  • Page 31 3' apart (the closest intake and exhaust pipes must be 36", or more, apart). Use the same 12" (minimum) vertical separation for all termination options. For alternate group terminations, contact the IBC factory for written guidance.

  • Page 32: Sidewall Vent Termination

    3.7.6 Sidewall vent termination Caution 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. Take action to avoid moisture entering building structures.
  • Page 33 3.7.6 Sidewall vent termination Vent terminal Air supply inlet Area where terminal is not permitted Figure 11 Minimum clearances from vent/air inlet terminations...
  • Page 34 Section: Installation Canadian Description US Installations Installations Clearance above grade, 12 in (30 cm) 12 in (30 cm) veranda, porch, deck, or balcony Clearance to window or 36 in (91 cm) for 12 in (30 cm) for door that may be opened appliances >100,000 Btuh appliances >...
  • Page 35 3.7.6 Sidewall vent termination Canadian Description US Installations Installations Clearance to mechanical 6 ft (1.83 m) 3 ft (91 cm) above if within air supply inlet 10 ft (3 m) horizontally Clearance above paved 7 ft (2.13 m) Vents cannot be located sidewalk or paved above public walkways or driveway...
  • Page 36 Third party vent termination kits and concentric wall penetration kits that do not maintain these minimum separations must not be used. Improper installation will void the warranty. Do not use proprietary InnoFlue or PolyPro PP terminals without specific approval from IBC. Figure 12 Vent termination clearance--horizontal...
  • Page 37 3.7.6 Sidewall vent termination Figure 14 Vent termination clearance--vertical Figure 15 Vent termination clearances--vertical alignment alignment, side view Figure 16 Sidewall vent termination configuration option 1...
  • Page 38 Sidewall vent termination configuration option 2 Sidewall direct vent with stainless sidewall terminal must be terminated as follows: The Stainless Sidewall Terminal (SST) three-inch (IBC kit P-257) is approved for use with these appliances when the equivalent length calculation (for exhaust) in the preceding table is used.
  • Page 39 3.7.6 Sidewall vent termination The SST vent/air connections fit Sched. 40 PVC/CPVC pipe. PP pipe cannot be used with the SST. The pipes must extend completely through the wall as shown below. The SST is an external fixture, and is not part of the sealed vent system that runs inside the building. Figure 19 Pipes extend completely through the wall (Vertical orientation shown) Ensure that the vent termination location does not exceed the allowed maximum...

  • Page 40: Indoor Air Combustion Air Intake

    Section: Installation Where an exhaust passes through a sidewall too close to a soffit, the venting must extend past the soffit by transitioning to vertical as shown below. Figure 23 Sidewall vent termination transition to vertical to clear soffit This illustrates the scenario where indoor air is used for combustion. Where combustion air is drawn from outdoors, combustion venting should also transition to vertical and terminations should observe the limitations shown for rooftop terminations.

  • Page 41: Combustion Air Filtration System

    If combustion air contamination from ingested particulate matter is a concern in any installation, an optional air intake filter may be installed. IBC-supplied air intake filters have a known pressure drop and fouling factor and should be used as a component of the combustion air system...

  • Page 42: Closet Installations

    The appliance must not be exposed to surrounding air above 122°F (50°C) or below 32°F (0°C). 3.9 Installing a condensate trap IBC’s specified vent configuration promotes the safe drainage of moisture from the boiler and exhaust venting without flowing liquids back through the heat exchanger (as done by some other...
  • Page 43 3.9 Installing a condensate trap Warning Fill the trap with water before initially firing the boiler to prevent exhaust fumes from entering the room. Never operate the boiler unless the trap is filled with water. Failure to comply will result in severe personal injury or death. Ensure the supplied trap is correctly installed and filled with water.
  • Page 44 Section: Installation Place the vacuum breaker cap over the Fill the condensate trap with water. vacuum breaker opening and push firmly. Attach the drain hose and tighten the Slide the trap over the boiler drain drain compression nut (including outlet, and tighten upper union nut. washer).

  • Page 45: Installing A Condensate Neutralizer

    3.10 Installing a condensate neutralizer Ensure that the trap upper union nut is Check that all trap fittings have been secured by the outlet clip. hand-tightened to prevent leakage of flue gases. Do not use tools and over- torque. Check for leaks. 3.10 Installing a condensate neutralizer If discharging condensate into building drain piping materials that are subject to corrosion, use a neutralization package.
  • Page 46 Section: Installation Figure 26 Condensate neutralization tank Flue gas exhaust: condensate, and potentially rain water, flow back from the venting system. Air intake piping: Warning - Risk of damage to appliance. Ensure that rain water is prevented from entering. Condensate water line: Warning - Risk of damage to appliance. All condensate discharge lines, including neutralization tank inlet, must be at a lower elevation than the condensate water line of the appliance.

  • Page 47: Water Piping (Space Heating)

    3.11 Water piping (space heating) Condensate neutralizer: Drain materials subject to corrosion must be protected by acid neutralization. Warning - Risk of injury. Tank fluid can be highly acidic. Do not use hands to stir material. Refer to the neutralization instructions of the manufacturer. Access to the discharge, before the drain, is necessary for proper maintenance in order to check the effectiveness of the neutralizing agent.
  • Page 48 Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation location. For environmental and toxicity reasons, IBC recommends only using non-toxic propylene glycol. Note Any glycol solution used in the system must be non-toxic due to the DHW heat exchanger.
  • Page 49 3.11 Water piping (space heating) system circulation rate (gpm up 10%), and system head (up 20%) to provide performance equivalent to straight water. These boilers are designed for use within a closed loop, forced circulation, low pressure system. A 30 psi pressure relief is supplied for field installation on the outlet piping. Relief valve discharge piping must terminate between 6"...

  • Page 50: General Piping Best Practices

    The piping drawings in this manual are simple schematic guides to a successful installation. For further information and details, consult our concept drawings – which provide detail on specific single and multiple boiler applications (available in IBC's Technical Information portal). There are many necessary components not shown, and details such as thermal traps are left out so the drawings have greater clarity.
  • Page 51 3.11.2 System piping Space heating supply Domestic hot water (DHW) Domestic cold water (DCW) Space heating return Figure 28 Piping connections Pressure relief valve (required) - shipped with boiler Important: Shut-off valves are not allowed between the relief valve and the boiler Space heating supply Figure 29...
  • Page 52 Section: Installation Isolation valve between boiler and relief valve not permitted Microbubble air eliminators are best installed where the fluid is at the highest temperature and lowest pressure Expansion tank connection (point of no pressure change) should be on the suction side of the circulator, with minimal pressure drop between.
  • Page 53 3.11.2 System piping 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 the applicable codes and good piping practice. Warning Close the fill valve after any addition of water to the system, to reduce risk of water escaping.
  • Page 54 Section: Installation Closely-spaced tees: Install tees with straight piping (min. pipe diameter lengths as Table 8 ), with tees maximum 4 pipe diameters apart with no restrictions between fittings. Heat migration: To prevent heat migration on secondary loops extending vertically to a load above the primary loop (especially where head loss is low): install check valves on both supply and return of secondary piping, or install a check valve in the supply piping and create a thermal trap in the return piping (min.
  • Page 55 3.11.2 System piping Domestic water Figure 32 Typical one-temperature space heating piping concept Outdoor sensor Optional isolation valves Thermostatic mixing valve for the lower-temperature emitter (required for simultaneous operation of two space-heating temperatures) Thermostatic tempering valve (if required by local code) Domestic water Figure 33 Typical two-temperature space heating piping concept...
  • Page 56 Section: Installation Figure 34 CX hydraulic separation The CX internal space heating pump can be hydraulically separated from the distribution pump by (A) closely-spaced tees, or by (B) a low-loss header, as shown in the figure above. Although best practice is to use primary/secondary piping, in a few cases (C) the internal pump will be adequate to provide flow through the building's heat emitters.
  • Page 57 3.11.2 System piping Air handler Closely-spaced tees Circulator sized for secondary piping only Figure 35 Air handler on primary loop and direct domestic water piping...
  • Page 58 Section: Installation Check valve (typical of each boiler) Closely-spaced tees Domestic water. Thermostatic tempering valve (if required by local code) From building To building Figure 36 Multiple boiler piping...

  • Page 59: Water Piping (Domestic Hot Water)

    3.12 Water piping (domestic hot water) 3.12 Water piping (domestic hot water) 3.12.1 Domestic hot water system These appliances have an independent piping circuit for efficiently generating domestic hot water. When a faucet is opened to draw hot water, water flow is detected with a flow sensor and the appliance fires up to begin generating domestic hot water.
  • Page 60 Section: Installation 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 them unattended in or near the shower, bathtub or sink. Never allow small children to use a not water faucet or draw their own bath.

  • Page 61: Domestic Hot Water Piping

    3.12.2 Domestic hot water piping Description Water pressure 40 psi 150 psi Minimum flow rate to activate DHW sensor 0.5 GPM Acceptable pH range 6.5 pH 8.5 pH Total dissolved solids 500 mg/L Total hardness 200 mg/L 11.68 gr/gal Aluminum 0.05 to 0.2 mg/L Chlorides 250 mg/L...
  • Page 62 Section: Installation If required by local code, you can install a field-supplied domestic hot water thermostatic mixing valve on the outlet of the appliance to prevent excessively hot water from reaching a faucet if the appliance is used in a high temperature heating system. Do not cap off the hot and cold piping connections if they are not being used.
  • Page 63 3.12.2 Domestic hot water piping Domestic hot water (DHW) on-demand application: DHW relief valve on outlet of water heater. An isolation valve is not allowed between the water heater and the relief valve Filter (optional) Figure 38 Tankless DHW Piping Options Caution The field supplied thermostatic mixing valve may be installed on the direct domestic hot water piping connections at the appliance or at the outlet of a domestic hot water...

  • Page 64: Gas Piping

    Section: Installation 3.13 Gas piping Note Due to the precision of modern modulating boilers it is important to pay special attention to gas pressure regulation. Important: Check gas supply pressure to each boiler with a manometer or other high- quality precision measuring device. Pressure should be monitored before firing the boiler, during operation throughout the boiler's full modulation range, and after the call when the regulator is in a "lock-up"...

  • Page 65: Electrical Connections

    3.14 Electrical connections Gas piping must have a sediment trap ahead of the boiler’s gas valve. A manual shutoff valve must be located outside the boiler, in accordance with local codes or standards. All threaded joints in gas piping should be made with an approved piping compound resistant to the action of natural gas or propane.

  • Page 66: Power Management, Quality And Electrical Protection

    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.
  • Page 67 24VAC boiler control circuit is protected with a two Amp fuse. VS Output leads are not commonly used, except when providing a boiler output signal to an external direct digital control (DDC), or a variable speed signal to a first-generation IBC air handler.

  • Page 68: Other Wiring

    10,000 ohms at 77°F (25°C) and β = 3892. We do not recommend using 3rd party supplied sensors. Compatible water temperature sensors and outdoor sensors can be supplied by your IBC distributor. 3.14.4 Thermostat / sensor wiring Each of the four loads has dry contacts for thermostats as marked on the lower connector strip (e.g., "Therm 1").

  • Page 69: Thermostat Heat Anticipator

    3. Wire individual load/zone valves to their associated contacts on the TB1 terminal strip 3.14.6 Thermostat heat anticipator IBC “Therm” contacts draw no power, so an anticipator setting for the thermostat is not applicable with these appliances. In the case of a single temperature / heat load where zone valves are used to manage individual thermostatically controlled zones, each room thermostat’s heat anticipator...
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  • Page 71: About The Boiler Controller

    Load Combining – simultaneous operation of two similar water temperature loads Programmable setback / override schedule The control can manage or operate in a network of up to 4 IBC CX boilers without additional controller.  Some of the new features available in the touchscreen control include:...

  • Page 72: Control Interface

    Real time boiler data Temperature and throttle operation Maintenance of operational and error service logs 2-way communication between other IBC boilers and controls Internet connection and communication Operational and historical data may be accessed from the Status menu > Load Status > Load Profiles and Load Statistics screens. Also in the Status menu, you can view error logs, including records of all errors since original power-up complete with the date and time of the error.

  • Page 73: Before Operating The Boiler

    5.0 Before operating the boiler Danger Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, do not try to operate any appliance - do not touch any electrical switch or use any phone in the building.
  • Page 74 Section: Before operating the boiler Checking piping connections Check □ Connect a manometer and open the gas control valve. Requirements are minimum 4" w.c and maximum 14" w.c. □ Check that there are no gas leaks. □ All connections are pressure tested and leak free. □...

  • Page 75: Boiler Operation

    6.0 Boiler operation Before operating the appliance, there are some important pre-igntion checks that need to be performed. For more information, see Before operating the boiler on page 73. To understand the boiler start-up process, see Sequence of Operation on page 116.

  • Page 76: Testing The Ignition Safety Shutoff

    Section: Boiler operation Start-up Checklist Check □ Tested efficiency of the appliance and made necessary adjustments by Performing a combustion test and adjustment. □ Tested the low water cutoff function to check that the LWCO sensor is working. See Testing the LWCO function on page □...

  • Page 77: Checking A Boiler's Fuel Source

    6.3.1 Checking a boiler's fuel source Danger Operating any IBC appliance using a fuel other than the fuel listed on its rating plate is prohibited. Failure to follow the instructions on converting to alternate fuels can result in a fire or explosion, which may cause property damage, personal injury, or loss of life.

  • Page 78: Adjusting The Gas Valve

    6.3.3 Adjusting the gas valve 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.
  • Page 79 6.3.3 Adjusting the gas valve Gas valve inlet Nut retainer Gasket Gas valve outlet pipe Inlet gas pressure test port Brass union nut Manifold gas pressure test port Gasket Low fire adjustment (offset pressure)  Mixer High Fire Adjustment Fan O-ring Gas valve Fan coupler O-ring...
  • Page 80 Section: Boiler operation 1. Shut off the gas supply. You will be measuring the inlet gas supply from the test port (see ). Do not perform a test from the manifold gas pressure test port. 2. On the gas valve, loosen the inlet gas pressure test port screw counter-clockwise. Location of inlet gas pressure test port 3.
  • Page 81 6.3.3 Adjusting the gas valve Figure 43 Flue gas test port 4. Adjust the high fire according to values in Table 10 using a Torx 15 screwdriver. Turn the screwdriver clockwise no more than a maximum of one full rotation at a time to raise the % (to richen).

  • Page 82: Testing The Lwco Function

    Section: Boiler operation CO max Fuel High fire Low fire Range % Target % Range % Target % Natural Gas <150 9.0 - 10.0 8.2 - 9.2 Propane < 250 10.3 - 11.3 10.8 9.3 -10.3 Table 10 Combustion test target ranges - CO / Maximum CO 6.3.4 Testing the LWCO function The low water cutoff (LWCO) function provides continuous protection against low water in the...

  • Page 83: Testing The Hi-Limit Cutoff Temperature Function

    6.3.5 Testing the Hi-Limit cutoff temperature function 6.3.5 Testing the Hi-Limit cutoff temperature function The hi-limit temperature function monitors the maximum supply temperature set in the safety ignition module (SIM). If the water temperature exceeds the hi-limit temperature, the boiler goes into a lockout condition, requiring a manual reset.
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  • Page 85: Service And Maintenance

    7.0 Service and maintenance Inspection of the boiler is to be performed annually by a qualified service technician. Caution The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition. 7.1 Maintenance checklist for homeowner Maintenance Required Frequency...

  • Page 86: Touchscreen Boiler Controller

    Section: Service and maintenance 7.2.1 Touchscreen boiler controller Maintenance Required for Boiler Controller Frequency Check □ Annually Check that boiler operation is consistent with the steps in the Touchscreen Boiler Controller Manual. □ Annually Check that water temperature targets and setpoint is satisfactory and have not been adversely amended.

  • Page 87: General Combi Boiler Maintenance

    7.2.2 General combi boiler maintenance 7.2.2 General combi boiler maintenance Component Maintenance Required Frequency Check □ Condensate Remove and clean annually (see Cleaning the condensate Annually trap trap on page 98). Ensure that the trap has been re-filled completely before firing the boiler. □...
  • Page 88 Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation location. For environmental and toxicity reasons, IBC recommends only using non-toxic propylene glycol.
  • Page 89 7.2.2 General combi boiler maintenance Component Maintenance Required Frequency Check □ Water 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.

  • Page 90: Replacing The Fan, Gas Valve, And Burner

    Section: Service and maintenance Component Maintenance Required Frequency Check □ Relief valve - Annually The relief valve manufacturer requires that under normal maintenance operating conditions a “try lever test” must be performed and testing 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.

  • Page 91: Replacing The Fan

    7.3.1 Replacing the fan Gas valve inlet Nut retainer Gasket Gas valve outlet pipe Inlet gas pressure test port Brass union nut Manifold gas pressure test port Gasket Low fire adjustment (offset pressure)  Mixer High Fire Adjustment Fan O-ring Gas valve Fan coupler O-ring Figure 44...

  • Page 92: Replacing The Gas Valve

    Section: Service and maintenance 1. Turn off the electric power and gas supply to the combi boiler. 2. Ensure the combi boiler cools down. Do not drain the combi boiler unless freezing conditions are expected during this procedure. 3. Remove the front cover, and then remove the four Torx 20 head screws on the top panel of the combi boiler.
  • Page 93 7.3.2 Replacing the gas valve A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to connectors, screws or refractory may occur.

  • Page 94: Replacing The Burner

    Section: Service and maintenance 7.3.3 Replacing the burner Warning The IBC heat exchanger has a small amount of combustion chamber insulation (refractory), which contains ceramic fibers. When exposed to extremely high temperatures, the ceramic fibers that contain crystalline silica can be converted into cristobalite, classified as a possible human carcinogen.
  • Page 95 7.3.3 Replacing the burner 4. Undo the union nut at the gas valve outlet. 5. Ensure that the O-ring and nut retainer are secured to the pipe. 6. Remove the fan/mixer/gas valve outlet pipe assembly. Tilt the fan to safely remove the assembly.

  • Page 96: Maintenance Of The On-Demand Dhw Block

    Section: Service and maintenance 7.4 Maintenance of the On-Demand DHW block The On-Demand DHW block is an assembly including the DHW flat-plate heat exchanger, the bypass valve with actuator, the primary pump, the four water external connection ports, two temperature sensors, the flow sensor, a boiler circuit drain port (not visible below--located behind boiler inlet connector), and the strainer / flow restrictor.

  • Page 97: Cleaning The Bypass Check Valve

    7.4.1 Cleaning the bypass check valve 7.4.1 Cleaning the bypass check valve 1. Turn off the electric power and gas supply to the combi boiler. 2. Isolate boiler circuit and drain. 3. Bypass circuit check valve access is by a bayonet plug on the left-hand side of the On-Demand DHW block (see inFigure 46 4.

  • Page 98: Cleaning The Sight Glass

    Section: Service and maintenance necessary. Reinstall in the same orientation, and lock bayonet port with a clockwise quarter-turn. 7.5 Cleaning the sight glass When a new combi boiler is first fired up, gases in the system can cloud up the viewport. If so, you will need to clean the sight glass to view the presence of a flame.
  • Page 99 7.6 Cleaning the condensate trap Condensate traps should be checked every year, cleaned and refilled as necessary. Before cleaning the condensate trap, you must turn off the power to the combi boiler, and allow it to cool down. Important: Installers or service contractors should ensure that the end user is instructed on cleaning and...
  • Page 100 Section: Service and maintenance Fill the condensate trap to the top with Slide the trap over the heat exchanger water and replace the union cap and drain outlet, making sure it is secured gasket. by the clip, and tighten the upper union nut to ensure an airtight seal.

  • Page 101: Ensure Door In Place

    7.7 Ensure door in place 7.7 Ensure door in place The boiler door must be in place during operation. Ensure door is in place after service.
  • Page 102 Intentionally left empty...

  • Page 103: Troubleshooting

    8.0 Troubleshooting This section includes various conditions as well as possible solutions. Often, a problem can be identified and solved through basic checks: confirming the electrical power supply, gas flow and resetting the thermostat control. Below are some common troubleshooting issues including fixes. 8.1 Electronic components This section details the method for troubleshooting the non-standard electronic components on the boiler.

  • Page 104: Fan

    Section: Troubleshooting Resist. Resist. Temp. °F/°C Temp. °F/°C Ω – Ohm Ω – Ohm 0 / -18 85,362 100 / 38 5,828 5 / -15 72,918 105 / 41 5,210 10 / -12 62,465 110 / 43 4,665 15 / -9 53,658 115 / 46 4,184...

  • Page 105: Dhw Flow Sensor

    8.1.4 DHW flow sensor Check the operation of the sensor by isolating the boiler from its system piping, and close the system fill valve, and then crack the pressure relief valve. The pressure displayed should reflect declining pressure. If it remains “fixed”, drain the boiler and replace the sensor, or dislodge any blocking debris from the sensor inlet channel and reinsert.
  • Page 106 Section: Troubleshooting SIM Status Indicators Description, LED status LED 1 LED 2 State indication Rapid flash Power up or startup checks and initialization resetting Standby LED 1 Off=flame or sparking LED 2 = Burner-on call state Pre-purge or LED 1 Off=no flame or sparking inter-purge LED 2 = Burner-on call state Heating...

  • Page 107: Troubleshooting Error Messages

    8.2 Troubleshooting error messages 5. If the error persists, perform a LWCO test. Go to > SIM Menu> Hi-Limit Test > Run the test to check if the low water cutoff sensor is opening. 8.1.5.3 Resetting a boiler after a hi-limit temperature lockout A boiler in a lockout condition due to a hi-limit temperature error will need to be reset.

  • Page 108: Maximum Ignition Trials Error

    Section: Troubleshooting 8.2.1 Maximum ignition trials error Maximum Ignition Trials Error Issue Diagnosis Error – Ignition No spark when igniting. Check that ignition lead is secure at the control Failure after 3 Ignition probe/flame module and at the probe. tries boiler has sensor disconnected.

  • Page 109: Aux. Interlock 1 Or

    8.2.4 Aux. Interlock 1 or 2 8.2.4 Aux. Interlock 1 or 2 Aux. Interlock 1 or 2 Issue Diagnosis Interlock 1 or 2 Jumper lead is loose Replace the jumper lead. terminals are open. or compromised. External safety is in an Inspect the external safety devices.

  • Page 110: Ignition Issues

    Section: Troubleshooting Miscellaneous errors Issue Diagnosis updates applied. operation. "service" mode after software update. 8.3.1 Ignition issues Ignition issues Issue Diagnosis Noisy spark Ignition lead is not firmly Reconnect ignition lead. when connected. igniting Contaminants/moisture Ensure probe is dry by re-running post-purge; on igniter probe/flame otherwise, clean or replace igniter probe.

  • Page 111: Temperature Issues

    8.3.2 Temperature issues 8.3.2 Temperature issues Temperature issues Issue Diagnosis Low heat Operating temperature Increase temperature target. too low. Increase temperature target. Priority parameters or Review load configuration parameters. load configuration improperly set up. appliance undersized. Refer to Load Calculation vs. Boiler Output. Air trapped within Bleed system as required.

  • Page 112: Miscellaneous Issues

    Replace the Power Robbing boiler. thermostat, isolate the thermostat with a relay or install a properly sized resistor (consult the thermostat manufacturer first then IBC for instructions). Error: Water Boiler is in 1-hour For instructions on clearing errors, see...

  • Page 113: Cycling Issues

    8.3.4 Cycling issues 8.3.4 Cycling issues Cycling issues Issue Diagnosis Rapid Improper values Check load maximum temps are above target temps, by ½ Cycling entered via keypad. of the selected boiler differential. Ensure boiler differential is OK (16 - 30 °F is generally adequate) Excess condensate in Check venting slopes on horizontal runs.

  • Page 114: Appendices

    Section: Troubleshooting Appendices Wiring diagrams Figure 48 Controller electrical diagram...
  • Page 115 Wiring diagrams Figure 49 Internal wiring diagram...
  • Page 116 Section: Troubleshooting Figure 50 Sequence of Operation...

  • Page 117: Exploded Views Of The Cx 150, Cx 199 Appliance

    8.4 Exploded views of the CX 150, CX 199 appliance 8.4 Exploded views of the CX 150, CX 199 appliance...
  • Page 118 Section: Troubleshooting Boiler part diagrams - CX 150, CX 199 Item Description P-kit # Top access cover - CX 150 Top access cover - CX 199 Exhaust duct Intake duct Temperature sensor P-361 Safety Ignition Module plus (SIM+) P-271B Front door cover - CX 150 Front door cover - CX 199 Thumb screw Terminal block cover...
  • Page 119 Boiler part diagrams - CX 150, CX 199...
  • Page 120 Section: Troubleshooting P-kit Item Description replacement Quantity Fan/fan coupler assembly P-1608 Polidoro mixer - CX 150 NG  P-1601 Polidoro mixer - CX 150 LP P-1600 Polidoro mixer - CX 199 NG  P-1603 Polidoro mixer - CX 199 LP P-1602 P-1522 Fan gasket Fan insert P-1520 Ignitor P-1511...
  • Page 121 Boiler part diagrams - CX 150, CX 199 P-kit Item Description replacement Quantity On-Demand DHW block (DHW heat exchanger block P-1606 and pump) Gas inlet, 3/4G to 1/2 NPT 27, 29 Inlet gas line union gasket P-1522 Flex gas line P-1610 Gas valve P-326B Gasket, gas valve outlet pipe to gas valve...
  • Page 122 Section: Troubleshooting Installation & Commissioning Report Model Number _____________________ Serial Number ___________________________ Date of Installation ________ Address of installation ____________________________ User contact information ______________________________________________________ Installer Information (Company & Address)____________________________________ Phone/Fax/E-mail ______________________________________________________________ □ □ Fuel: Natural Gas Propane Gas Supply Pressure (high fire) ____ Inches w.c. Measured Rate of Input (high fire) _____Btu/hr □...
  • Page 123 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 these boilers). US installers should contact IBC for any further information required.
  • Page 124 Toll Free: 1-844-HEAT-IBC / 1-844-432-8422 www.ibcboiler.com Information in this document is subject to change without notice. IBC assumes no responsibility for changes made to the manual due to clerical errors, to regulation changes, or to product development. April 24, 2023 120-415E1 ©...

This manual is also suitable for:

Cx 150Cx 199Icgfsw1-0150Icgfsw1-0199

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