IBC IWT 65 (01) PDF Document

The IBC IWT 65 has the following specifications: Max. Operating Pressure of 150 psi, a height of 54.5 inches (138.4 cm), and a maximum diameter of 24.5 inches (62.2 cm). It has a gross tank volume of 66 USG (250 Liters) and a net tank volume of 63.9 USG (242 Liters). The weight is 145 lbs (65.8 kg) and the shipping weight is 170 lbs (77 kg). The domestic connection size is 3/4 inch M. The first hour delivery is 349 Gal/Hr and the continuous draw is 259 Gal/Hr, based on 180 degree F boiler supply, 135 degree DHW, and 58 degree F entering cold water. The boiler output required is 180,000 Btu/Hr, with a minimum flow rate of 14 GPM. The heating coil pressure drop is 7.5 Ft. Hd. and the coil heat transfer area is 11.3 Ft2 (1.05 m2).

The pressure drop in feet of head for the IBC IWT 65 is 4.4 at 10 gpm, and 7.5 at 14 gpm.

The recovery rates for the IBC IWT 65 at 135 degrees F are as follows:

Table: Recovery rates for IBC IWT 65

Boiler Output (BTU/Hr): 50,000 | Boiler Flow = 14 gpm / 160 degrees F 1st Hour Rating (Gal/Hr): 116 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 60 | Boiler Flow – 14 gpm / 180 degrees F 1st Hour Rating (Gal/Hr): 134 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 78

Boiler Output (BTU/Hr): 60,000 | Boiler Flow = 14 gpm / 160 degrees F 1st Hour Rating (Gal/Hr): 128 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 72 | Boiler Flow – 14 gpm / 180 degrees F 1st Hour Rating (Gal/Hr): 149 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 93

Boiler Output (BTU/Hr): 80,000 | Boiler Flow = 14 gpm / 160 degrees F 1st Hour Rating (Gal/Hr): 151 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 96 | Boiler Flow – 14 gpm / 180 degrees F 1st Hour Rating (Gal/Hr): 179 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 124

Boiler Output (BTU/Hr): 100,000 | Boiler Flow = 14 gpm / 160 degrees F 1st Hour Rating (Gal/Hr): 174 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 120 | Boiler Flow – 14 gpm / 180 degrees F 1st Hour Rating (Gal/Hr): 209 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 156

Boiler Output (BTU/Hr): 120,000 | Boiler Flow = 14 gpm / 160 degrees F 1st Hour Rating (Gal/Hr): 198 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 144 | Boiler Flow – 14 gpm / 180 degrees F 1st Hour Rating (Gal/Hr): 239 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 187

Boiler Output (BTU/Hr): 140,000 | Boiler Flow = 14 gpm / 160 degrees F 1st Hour Rating (Gal/Hr): 221 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 168 | Boiler Flow – 14 gpm / 180 degrees F 1st Hour Rating (Gal/Hr): 269 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 218

Boiler Output (BTU/Hr): 160,000 | Boiler Flow = 14 gpm / 160 degrees F 1st Hour Rating (Gal/Hr): 244 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 192 | Boiler Flow – 14 gpm / 180 degrees F 1st Hour Rating (Gal/Hr): 300 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 249

Boiler Output (BTU/Hr): 180,000 | Boiler Flow = 14 gpm / 160 degrees F 1st Hour Rating (Gal/Hr): 252 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 199 | Boiler Flow – 14 gpm / 180 degrees F 1st Hour Rating (Gal/Hr): 309 | Continuous rating (Gal/Hr) 58 degrees F entering cold water: 259

The CSA rating is 105,000 Btu/hr and the recommended relief valve is a Watts 3/4 inch LF100XL or XL8, or equivalent.

The installation checklist includes:

Water heater sizing: Choose the model based on expected water usage. An average residence with one shower or more will require a Model 40 or larger. Factors like high flow shower heads, hot tubs, and multiple showers at once require larger sizes.

Boiler sizing: The IBC IWT 65 will provide rated performance only if used with a boiler with a heating capacity of at least as much as the capacity ratings listed in the specifications.

Circulator sizing: Refer to the specifications for flow through the IBC IWT 65 coil and pressure drop at minimum flow. Calculate the pressure drop across all piping and fittings connected to the water heater zone, including zone valves, check valves, and shut-off valves.

The clearances from the heater jacket are:

Front: 1 inch distance from combustibles, 24 inches for service.

Rear, Right and Left Sides: 1 inch distance from combustibles, 1 inch for service.

Top: 1 inch distance from combustibles, 1 inch for service.

Bottom: 0 inch distance from combustibles, 0 inch for service.

To pipe the domestic water system for the IBC IWT 65, follow these steps:

1. Drain the domestic water system by shutting off the cold water supply at the main shutoff valve, opening one or more faucets to relieve pressure, and opening the system drain.

2. Install piping onto the cold inlet connection using a union, a heat trap, a shut-off valve, a drain valve, an expansion tank, a back flow preventer, and a vacuum breaker where applicable.

3. Connect the domestic hot water piping to the hot water supply connection using a union, a heat trap, and a shut-off valve.

4. Pipe the relief valve discharge to exit within 6 inches above a suitable drain. Do not block or reduce the size of the discharge opening.

5. Fill the water heater tank by opening all faucets to purge air (remove screens first), opening the domestic hot water shut-off valve, slowly opening the cold water inlet shut-off valve, purging all air from the system, and allowing water to run until it is clear and has changed at least one tank volume past full.

6. Close all faucets, reinstall screens, and check the system for leaks.

The following maintenance is required for the IBC IWT 65:

Boiler and Domestic Water Piping: Check all piping annually for signs of leakage at joints, unions, and shut-off valves. Repair as required.

Temperature and pressure relief valve: Check annually for leaks or corrosion.

Sediment: Depending on water conditions, sediment may collect in the tank. Check annually, more frequently in hard water areas. Indications include a small temperature difference between boiler supply and return lines and reduced recovery rate. Repeated flushing typically clears this. Draw water from the drain valve until it runs clear.

Scale: Hard water may cause scale buildup on the outside of the heating coil inside the tank. Check annually. If repeated flushing does not resolve the problem, chemical cleaning may be required.

To flush the IBC IWT 65 tank:

1. Shut off the cold water supply.

2. Note the DHW temperature control setting, and turn off power to the boiler and water heater.

3. Reduce water pressure in the tank by opening a hot water faucet.

4. Remove the relief valve.

5. Drain 1/3 of the water heater so the tank is two-thirds full, ensuring the water level covers the coil and thermostat well.

6. Using a funnel, pour one gallon of commercial ice maker cleaning solution into the tank through the relief valve opening. Follow instructions provided with the cleaning solution.

7. Turn on power to the boiler and water heater.

8. Program the control to its highest DHW temperature setting, and allow the boiler to heat until the control is satisfied.

9. If the control is not satisfied after 45 minutes, program the control to its lowest temperature.

10. Allow the solution to set in the tank for 30 minutes.

11. Drain the tank completely using fittings and hoses to reach a drain.

To refill the IBC IWT 65:

1. Fill the tank with fresh, cold water and drain it completely.

2. Refill and drain at least three times to flush all cleaning solution.

3. Reinstall the relief valve and drain piping.

4. Open the cold water supply and fill the tank.

5. Purge air from the tank and piping by opening cold and hot water faucets.

6. Return the DHW control setting to the original temperature.

If there is no hot water at the faucets when using the IBC IWT 65, check the following:

Boiler does not operate: Ensure boiler power is on. Ensure the boiler is programmed for DHW and the temperatures are set properly. Check the tank temperature on the screen; if it shows “Open” or “Short,” there is a sensor or wiring issue.

Water Heater Circulator does not operate: Follow the steps for “Boiler does not operate.” Ensure the pump relay is closed and supplying power to the pump. Ensure the zone valve is open and the end switch is closed calling for heat. Check wiring connections at the circulator. Measure voltage at the circulator during a call for heat; it should be 120VAC. If power is at the circulator and connections are correct, replace the circulator.

Water heater zone valve does not open: Follow steps for “Boiler does not operate.” Check for 24VAC at the zone valve while there is a call for heat; if correct voltage is available and connections are good, replace the zone valve.

Tank sensor open, short, or mis-wired: Ensure the tank sensor is connected to the correct terminals and the wires are properly attached to the terminal strip and the sensor is properly attached to the wiring at the tank. Disconnect the sensor wires from the terminal strip and measure the resistance in Ohms across the 2 sensor wires. Compare this value to the resistance table and the actual tank temperature. Check/replace the wire from the boiler to the sensor or replace the sensor.

If the water at the faucets is too cool when using the IBC IWT 65, increase the DHW Tank Set Point temperature.

If the water at the faucets is too hot when using the IBC IWT 65, first reduce the DHW Tank Set Point temperature. Also check the following:

Boiler Maximum Supply Temp. setting too low: Make sure the Maximum Supply Temp. setting is at least 10 degrees F higher than the DHW Supply Setpoint PLUS 1/2 of the Supply Diff’l Temp setting.

DHW temperature sensor giving false reading: Ensure the sensor is fully inserted into the well. Check if the sensor is giving an incorrect resistance reading. Ensure the sensor is connected to the correct terminals, not the wrong ones. Verify that no improper 3rd party sensor is installed in the well.