IBC CX Series Manuale utente

INSTALLATION AND

OPERATING MANUAL

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.

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)

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.

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 reduce dissolved solids to the

minimum 10 ppm, and to no more than 30 ppm. Water chemistry allowable limits are as

follows:

TDS 0.6 to 1.75 grains/ gal (10 to 30 ppm)

Acidity pH is to be between 6.6 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 77°F (25°C)

Important: Ensure that these limits are acceptable for the other water-side components in

the system.

Shipped with the boiler:

1 x Wall mounting bracket, P-9092

1 x Condensate trap assembly

1 x 30 psig pressure relief valve, P-9009

1 x Outdoor temperature sensor, P-9067

6 x ¼" x 2 ½" Lag screws/w flat washers

Contents

Safety information 7

Manual safety markings 7

Important safety instructions 7

Known contaminants 9

Specifications 11

Cabinet dimensions 12

CX 150 dimensions 12

CX 199 dimensions 13

Connection specifications 14

1.0 Introduction 15

1.1 Standard features and benefits 15

1.2 Warranty 16

2.0 Before installation 17

3.0 Installation 19

3.1 Code requirements 19

3.2 Removing an existing boiler 19

3.3 Determining location of the appliance 20

3.3.1 Best installation conditions 21

3.4 Mounting the boiler 21

3.5 Connecting the vent and air intake pipes 23

3.6 Installation clearances 24

3.7 Exhaust venting and air intake 24

3.7.1 Venting code 25

3.7.2 Venting options 25

3.7.3 Exhaust vent material 25

3.7.4 Direct vent 26

3.7.5 Rooftop vent termination 30

3.7.6 Sidewall vent termination 32

3.7.7 Indoor air combustion air intake 40

3.7.8 Combustion air filtration system 41

3.8 Closet installations 42

3.9 Installing a condensate trap 42

3.10 Installing a condensate neutralizer 45

3.11 Water piping (space heating) 47

3.11.1 General piping best practices 50

3.11.2 System piping 50

3.12 Water piping (domestic hot water) 59

3.12.1 Domestic hot water system 59

3.12.2 Domestic hot water piping 61

3.13 Gas piping 64

3.13.1 Gas pressure 64

3.14 Electrical connections 65

3.14.1 Power management, quality and electrical protection 66

3.14.2 120VAC line-voltage hook-up 66

3.14.3 Other wiring 68

3.14.4 Thermostat / sensor wiring 68

3.14.5 Wiring zone valves in place of pumps 68

3.14.6 Thermostat heat anticipator 69

4.0 About the boiler controller 71

4.1 Controller 71

4.2 Control interface 72

5.0 Before operating the boiler 73

Important pre-ignition checks 73

Checklist for electrical conditions, ducting and water connections 73

6.0 Boiler operation 75

6.1 Lighting and shutting down the boiler 75

6.2 Testing the ignition safety shutoff 76

6.3 Commissioning 76

6.3.1 Checking a boiler's fuel source 77

6.3.2 Performing a fuel conversion 77

6.3.3 Adjusting the gas valve 78

6.3.4 Testing the LWCO function 82

6.3.5 Testing the Hi-Limit cutoff temperature function 83

7.0 Service and maintenance 85

7.1 Maintenance checklist for homeowner 85

Section: Contents

7.2 Maintenance checklist for heating contractor 85

7.2.1 Touchscreen boiler controller 86

7.2.2 General combi boiler maintenance 87

7.3 Replacing the fan, gas valve, and burner 90

7.3.1 Replacing the fan 91

7.3.2 Replacing the gas valve 92

7.3.3 Replacing the burner 94

7.4 Maintenance of the On-Demand DHW block 96

7.4.1 Cleaning the bypass check valve 97

7.4.2 Replacing the bypass actuator 97

7.4.3 Removing the flow sensor 97

7.4.4 Cleaning the water strainer / flow restrictor 97

7.5 Cleaning the sight glass 98

7.6 Cleaning the condensate trap 98

7.7 Ensure door in place 101

8.0 Troubleshooting 103

8.1 Electronic components 103

8.1.1 Temperature sensors 103

8.1.2 Fan 104

8.1.3 Water pressure sensor 104

8.1.4 DHWflow sensor 105

8.1.5 Safety and Ignition Module (SIM+) 105

8.2 Troubleshooting error messages 107

8.2.1 Maximum ignition trials error 108

8.2.2 Hi Limit cut-off temperature error 108

8.2.3 Low Water Cut-off error 108

8.2.4 Aux. Interlock 1 or 2 109

8.3 Miscellaneous touchscreen controller errors 109

8.3.1 Ignition issues 110

8.3.2 Temperature issues 111

8.3.3 Miscellaneous issues 112

8.3.4 Cycling issues 113

Appendices 114

Wiring diagrams 114

8.4 Exploded views of the CX150, CX199 appliance 117

Boiler part diagrams - CX 150, CX 199 118

Installation & Commissioning Report 122

Section: Contents

Safety information

Manual safety markings

Danger

Points out an immediate hazardous

situation that must be avoided to

prevent serious injury or death.

Warning

Points out a potential hazardous

situation that must be avoided to

prevent serious injury or death.

Caution

Points out a potential hazardous

situation that must be avoided to

prevent possible moderate injury

and/or property damage.

Note

Points out installation, maintenance and

operational notes to enhance efficiency,

longevity and proper operation of the

boiler.

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. Keep instructions near the air handling appliance for future reference.

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. If you smell gas vapors, do not try to operate any appliance - do

not touch any electrical switch or use any phone in the building. Immediately, call the

gas supplier from a phone located remotely. Follow the gas supplier’s instructions, or if

the supplier is unavailable, contact the fire department.

Warning

If the boiler is likely to be exposed to fluid temperatures below 34°F (1°C), use a method

to prevent freezing of condensate. Contact the factory for further information.

Warning

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.

Section: Safety information

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.

Read all instructions, including all those contained in component manufacturers’ manuals

before installing, starting up, operating, maintaining, or servicing the appliance.

Warning

Disconnect power supply before any wiring/service is performed. Failure to do so could

result in damage to appliance and/or electric shock.

Caution

The boiler must be installed so that electrical components are not exposed to water during

operation.

Known contaminants

Known Corrosive Contaminants to Avoid

Cements and glues Refrigerant leaks from cracks in coils

Paint or varnish removers Sodium chloride or potassium chloride used for

water softening

Adhesives used to fasten building products

and other similar products

Chemicals in perming solutions

Chlorinated waxes or cleaners Chlorofluorocarbon chemicals found in spray cans

Chlorine-based swimming pool chemicals Antistatic dryer sheets in clothes dryers

Hydrochloric acid or muriatic acid used in

household cleaning and stain removal

Chlorine-type bleaches, detergents, and cleaning

solvents found in household laundry rooms

Calcium chloride used for snow clearing

Known contaminants

Intentionally left empty

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