IBC HC 15-95 User manual

INSTALLATION AND OPERATING INSTRUCTIONS
www.ibcboiler.com
HC Series Boilers
HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 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 OPERATION INSTRUCTIONS
2
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
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
Supplied with the boiler - The IBC boiler is shipped with an accessory parts kit
consisting of the following items:
• 1 x Wall Mounting Bracket, IBC Part # 250-647
• 1 x Condensate Assembly
• 1 x Pressure Relief valve, 3/4NPT, 30psi
• 1 x Outdoor Temperature Sensor
• Air Vent and Relief Valve ttings
• 1 x Automatic Air Vent
• 4 x Lag Screws, Hex Head, Zn-Pl, 1/4 x 2-1/2 and Washers
• 1 x HC Installation & Operating Instructions
• 1 x DC/HC User Manual
• 1 x DC/HC Controller Manual
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.
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.
DANGER
Points out an immediately
hazardous situation which
must be avoided in order to
prevent serious injury or
death.
BEST PRACTICES
Points out recommendations
for better installation.

3
INSTALLATION AND OPERATING INSTRUCTIONS
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
SPECIFICATION HC 13-50 HC 15-95 HC 15-96 HC 20-125 HC 33-160
CSA Input (Natural Gas or
Propane) – MBH
13.5 - 51 15 - 95 15 - 96 20 - 125 33 - 160
CSA Input (Natural Gas or
Propane) – KW
3.95 - 14.94 4.4 - 27.8 4.4 - 28.1 5.6 - 36.6 9.7 - 46.9
CSA Output – MBH 12.4 - 45.4 14.4 - 85.5 14.5 - 85.9 18.6 - 110.8 30.4 - 140.0
CSA Output - KW 3.64 - 13.3 4.2 - 25.0 4.3 - 25.2 5.4 - 32.5 8.9 - 41.0
A.F.U.E 94% 95% 96% 95% 94%
Min Gas Pressure (Nat. Gas or
Propane) – inch w.c.
5555 5
Max Gas Pressure (Nat. Gas or
Propane) – inch w.c.
14 14 14 14 14
Power (120Vac/60Hz) - Watts @ full
re with internal pump
126 128 128 130 164
Weight (empty) – lbs/Kg 84 / 38 91 / 41 96 / 44 96 / 44 96 / 44
Pressure Vessel water content –
USG/Liters
0.37 / 1.4 0.37 / 1.4 0.5 / 1.9 0.5 / 1.9 0.5 / 1.9
Max boiler ow rate - USgpm 9 10 10 11 11
Min boiler ow rate - USgpm 2 2 2 3 3
Max Operating Pressure – Space
Heating Coil - psig
43.5 43.5 43.5 43.5 43.5
Approved installation altitude -
ASL
10,000 ft 10,000 ft 10,000 ft 10,000 ft 10,000 ft
Ambient Temperature – Low
(°F/°C)
32 / 0 32 / 0 32 / 0 32 / 0 32 / 0
Ambient Temperature – High
(°F/°C)
122 / 50 122 / 50 122 / 50 122 / 50 122 / 50
Max relative humidity (non-
condensing)
90% 90% 90% 90% 90%
Min water Temperature - Space
Heating (°F/°C)
50 / 10 50 / 10 50 / 10 50 / 10 50 / 10
Max water Temperature – Space
Heating (°F/°C)
194 / 90 194 / 90 194 / 90 194 / 90 194 / 90
Max equivalent vent length 3"
(each side)
120' 120’ 120' 120' 120'
Max equivalent vent length 2"
(each side)
35' 35’ 35' 35' 35'
* Natural Gas boilers require a Propane conversion kit (see page #3-2, Table 9) 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 9) to be ordered separately if converting a Propane boiler to Natural Gas.
† boilers are shipped with 30 psig pressure relief valve
SPECIFICATIONS

INSTALLATION AND OPERATION INSTRUCTIONS
4
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
PAGE INTENTIONALLY LEFT BLANK

5
INSTALLATION AND OPERATING INSTRUCTIONS
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
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 GAS PIPING.................................................1-27
1.8 ELECTRICAL CONNECTIONS ..................................1-28
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.......................2-4
2.5 ADDING DOMESTIC HOT WATER STORAGE.......................2-4
2.6 SPACE HEATING..............................................2-5
2.7 SEQUENCE OF OPERATION ....................................2-6
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 .......................................5-6
5.4 OTHER FAULTS...............................................5-8
6.0 DIAGRAMS.......................................................6-1
6.1 PARTS DIAGRAMS ............................................6-2
6.2 WIRING DIAGRAMS ...........................................6-6
CONTENTS

INSTALLATION AND OPERATION INSTRUCTIONS
6
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 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.
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.
• The exhaust outlet should be placed so as to reach 12" minimum above the
down-turned intake - to avoid exhaust re-ingestion.
• 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 HC Series boiler. The addition of a storage tank or an IBC Indirect Water
Heater may be required in some cases.
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.
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.
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.

1-1
INSTALLATION
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
INSTALLATION1.0
GENERAL
HC Series gas-red modulating boilers are low pressure, fully condensing units
having variable input ranges (see specication chart - page 3). 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 HC SERIES BOILERS
AExhaust Outlet 3" Schedule 40
BCombustion Air 3" Schedule 40
EHeating Water Inlet (Return) 1" Male NPT
FHeating Water Outlet (Supply) 1" Male NPT
GGas Inlet 1/2" Male NPT
HCondensate Outlet 3/4" Hose
IKnock-out (3) 1/2"
Table 1: Connections
1.1
Figure 1a: Dimensions / Connections for HC Series Figure 1b: Dimensions / Connections for HC Series
MODEL
NUMBER
HEIGHT
HC 13-50 26.6" [676]
HC 15-95 29.0" [736]
HC 15-96 31.3" [676]
HC 20-125 31.3" [796]
HC 33-160 31.3" [796]

INSTALLATION AND OPERATION INSTRUCTIONS
1-2
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
CODE REQUIREMENTS
The HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160 models were tested
to and certied under CSA 4.9 / ANSI Z21.13.
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 HC 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. 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 96 lbs / 44 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.
Other factors affecting potential mounting sites:
•Ensure minimum clearance requirements for combustible materials (see
Table 2) are satised.
•Minimum 24" clearance at the front and 10" above is recommended for
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.
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.
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.)

1-3
INSTALLATION
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
SURFACE
DISTANCE FROM
COMBUSTIBLE
SURFACES
RECOMMENDED DISTANCE
FOR INSTALLATION AND
SERVICE
Front 2" 24"
Rear 0" 0"
Left Side 1.5" 6" (labels may be difcult to read with
reduced clearance)
Right Side 4" 6" (labels may be difcult to read with
reduced clearance)
Top 2" 24"
Bottom 8" 24"
Table 2: Clearance from boiler cabinet
A minimum distance below the boiler of 11" is required to provide
clearance for the supplied condensation trap assembly. More clearance will
typically be required to accommodate associated water and gas piping.
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.
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.
1.4
DANGER
Do not common vent the HC
modulating series boilers
with any other existing or new
appliance.
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.
Installers are to take all
necessary precautions
to avoid injury during the
installation of this boiler.
Figure 2: Wall mounting of boiler

INSTALLATION AND OPERATION INSTRUCTIONS
1-4
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
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. 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.
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.
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.
Figure 3: Basic exhaust vent assembly
NOTE
The minimum wall thickness
for venting is 1” and the
maximum wall thickness for
venting is 14”.

1-5
INSTALLATION
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 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 HC 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
EXHAUST VENT MATERIAL – CANADA
Only PVC, CPVC, Polypropylene (PPs) or stainless steel* vent component
systems approved under ULC-S636 Standard for Type BH Gas Venting Systems
are to be used. Ensure compliance with exhaust temperature limitations for
the respective materials. The vent temperature is limited with the use of a ue
temperature sensor and software to ensure the maximum temperature of the
PVC venting material is not exceeded.
•ULC-S636 PVC
•ULC-S636 CPVC
•ULC-S636 PPs
EXHAUST VENT MATERIAL – USA
PVC, CPVC, and PPs materials are approved for use with this boiler in the USA.
The vent temperature is limited with the use of a ue temperature sensor and
software to ensure the maximum temperature of the PVC venting material is not
exceeded. PVC venting material shall be certied to Sch. 40 ASTM D1785 or
D2665. CPVC venting material shall be certied to Sch. 40 ASTM F441.
*Manufacturers of stainless steel Type BH venting systems must submit
their approved transition tting to IBC for evaluation and written approval.
WARNING
Covering non-metallic vent
pipe and ttings with thermal
insulation shall be prohibited.

INSTALLATION AND OPERATION INSTRUCTIONS
1-6
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
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 or PVC 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 Schedule 40 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.
1.4.3 Vent Travel
CPVC or PPs (Rigid Single Wall) piping is the standard venting option; with this,
the HC Series 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').
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 PVC, 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 (Max. 35) actual feet times 1.4
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).
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
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.
WARNING
Fully insert the approved
venting material into the
boilers exhaust outlet and
tighten clamp to ensure the
venting connection is locked
in place.

1-7
INSTALLATION
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
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.
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" gap around the pipe to prevent binding and expansion noise; follow local
codes.
•All piping must be liquid and pressure tight.
BEST PRACTICES
To reduce the possibility of
expansion noise, allow a 1/4"
gap around the exhaust and
air intake piping.
Figure 4

INSTALLATION AND OPERATION INSTRUCTIONS
1-8
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
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; lower down the roof is OK.
•The air intake pipe may terminate on the side wall of the building as long as
the air intake terminal is turned down and the side wall of the building is not
exposed to large wind loads i.e.: prevailing winds.
• 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 12" (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.
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.
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
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
Figure 5a: Rooftop exhaust venting
with sidewall combustion air.

1-9
INSTALLATION
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
Figure 6: Vertical Concentric Termination - Two Kits
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 12" minimum above the
down-turned intake - to avoid intake re-ingestion of exhaust gases.
•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.

INSTALLATION AND OPERATION INSTRUCTIONS
1-10
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
•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.
DIRECT VENT SIDE WALL TERMINATION KITS
The following Side Wall Termination Kits are approved for use with the HC 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 Figures 9a, 9b and 10 on page 1-11.
The installation instructions, clearances and wall thickness requirements of the
approved vent termination manufactures must be followed.
Approved Side Wall Termination Kits are listed as follows: (Alternate vent
termination kits must be submitted to IBC for approval prior to installation.)
• Ipex - #196984 – 2" PVC low prole termination kit (see Figure 10).
• Ipex - #196985 – 3" PVC low prole termination kit (see Figure 10).
Figure 8: Sidewall vent termination - piping conguration
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.
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.

1-11
INSTALLATION
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
Figure 9a: Horizontal Concentric Termination - Two Kits
Figure 9b: Horizontal Concentric Termination - Single Kit
For side venting of multiple boilers, group all intake terminals together with 6"
(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 12" (minimum) vertical separation (See (A) in
Figure 13). 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 (See (B) in Figure 13). For
alternate group terminations, contact the IBC Factory for written guidance.
Figure 10: Ipex #196984 2" PVC and #196985 3" PVC

INSTALLATION AND OPERATION INSTRUCTIONS
1-12
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
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
Use caution when installing Concentric Side Wall Termination Kits when the outdoor
design temperature is below 5°F / -15°C. Possible blockage of the combustion air
intake increases when the outdoor temperature drops below this temperature.
The clearances recommended by the vent termination manufacturer 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.)
• Centrotherm – Innoue #ICWT242 (2” termination) + ICTC0224 (2” concentric
transition to 2 pipe)
• Centrotherm – Innoue #ICWT352 (3” termination) + ICTC0335 (3” concentric
transition to 2 pipe)
•Duravent – Polypro #3PPS-HK – Horizontal Termination Kit – Concentric
•Ipex - # 197009 – 3" CPVC concentric termination kit
•Ipex - # 196006 – 3” PVC concentric termination kit
VENT TERMINAL CLEARANCE MINIMUMS ARE AS FOLLOWS:
CANADIAN
INSTALLATIONS1
US INSTALLATIONS2
A= Clearance above grade,
veranda, porch, deck, or
balcony
12 in (30 cm) 12 in (30 cm)
B= Clearance to window or
door that may be opened
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)
C= Clearance to window or
door that may be opened
* *
D= Clearance to
permanently closed window
* *
Figure 12: Prohibited installation
Figure 11: IBC recommended
minimum vent terminal clearance
under ventilated soft
Figure 13: Sidewall vent termination - multiple vent piping conguration

1-13
INSTALLATION
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 33-160
E= Clearance to
unventilated soft
* *
F= Clearance to outside
corner
*4 ft (1.22m) or local code,
whichever is stricter
* 4 ft (1.22m) or local code,
whichever is stricter
G= Clearance to inside
corner
* 4 ft (1.22m) or local code,
whichever is stricter
* 4 ft (1.22m) or local code,
whichever is stricter
H= Clearance to each side
of center line extended
above meter/regulator
assembly
3 ft (91 cm) within a height
15 ft above the meter/
regulator assembly
*
I= Clearance to service
regulator vent outlet
3 ft (91 cm) *
J= Clearance to
nonmechanical air supply
inlet to building or the
combustion air inlet to any
other appliance
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)
K= Clearance to a
mechanical air supply inlet
6 feet (1.83 m) 3 ft (91 cm) above if within
10 ft (3 m) horizontally
L= Clearance above paved
sidewalk or paved driveway
located on public property
7 ft (2.13 m) † *
M= Clearance under
veranda, porch deck, or
balcony
12 in (30 cm) ‡ *
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.
V
V
V
V
V
V
V
V
V
X
X
F
C
B
D
E
B
K
M
G
A
INSIDE
CORNER DETAIL
H
FIXED
CLOSED
OPERABLE
OPERABLE CLOSED
FIXED
B
J
A
B
B
B
V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED
I
L
Figure 14A: Vent Terminal Clearance

INSTALLATION AND OPERATION INSTRUCTIONS
1-14
HC SERIES BOILERS HC 13-50, HC 15-95, HC 15-96, HC 20-125, HC 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
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.
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.
Such blockage will result in a
boiler safety shut-down.
Figure 14B: Distance Inside / outside minimums