IBC VFC 15-150, Installation And Operating Instructions Manual

Page 1: ...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 th...

Page 2: ...items 1 x Vent connection kit 1 x Condensate trap kit 1 x 30 psig pressure relief valve 1 x Outdoor temperature sensor WARNING If the information in this manual is not followed exactly a fire or expl...

Page 3: ...80 Minimum water pressure psig 8 8 Normal flue temperature 100 F boiler return water temperature high fire 100 to 105 F 37 8 to 40 5 C 100 to 105 F 37 8 to 40 5 C Normal flue temperature 160 F boiler...

Page 4: ...INSTALLATION AND OPERATION INSTRUCTIONS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 5: ...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 5 4 0 MAINTENANCE 4 1 4 1 BOILER MAINTENANCE 4 1 4 2 COMPONENT...

Page 6: ...ing 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 corr...

Page 7: ...Vent sealed combustion or indoor combustion air providing a great degree of installation flexibility Figure 1 shows outer case dimensions and piping and electrical holes Use this diagram to find a su...

Page 8: ...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 an...

Page 9: ...elow and the code requirements the more stringent shall apply IMPORTANT When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper v...

Page 10: ...e boiler s air intake from outdoors see Section 1 4 for air intake piping requirements Using the indoor air alternative air for combustion is drawn from the indoor air surrounding the boiler Provided...

Page 11: ...lied fittings shall be considered part of the exhaust and installed near the base of the boiler see Figure 2 for PPs use IBC s VFC PPs transition kit as appropriate for the chosen PPs system CENTROTHE...

Page 12: ...Unused intake travel cannot be added to the exhaust Unequal intake and exhaust piping is allowed see Section 1 4 8 Exhaust venting must slope down towards the boiler with a pitch of at least 1 4 per...

Page 13: ...st be liquid and pressure tight Prior to firing 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 wit...

Page 14: ...g 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 th...

Page 15: ...ipe reduction of 3 pipe to 2 is permitted for a maximum lineal travel of 3 including 2 x 90 elbows on each side This allows for smaller wall penetrations with sufficient travel allowance to achieve th...

Page 16: ...ator assembly 3 0 91m within a height of 15 4 6m above the meter regulator Clearance to service regulator vent outlet 3 0 91m Clearance to non mechanical air supply inlet to building or the combustion...

Page 17: ...dule 40 PVC ABS or PPs piping of any type is permitted Use same diameter as Vent pipe allowing for up to 6 ft actual run of 2 before any required transition NOTE It is not permitted to add to the exha...

Page 18: ...fer to the vent terminal configuration drawings in the Vent Termination section above Support should be provided for intake piping particularly so for horizontal runs follow local code 1 4 8 Indoor Ai...

Page 19: ...wall to prevent excessive heat from building up inside the space The boiler shall not be exposed to ambient conditions above 122 F 50 C or below 32 F 0 C NOTE Combustion fan blockages can occur when...

Page 20: ...account the following Must be piped to within 1 of a drain or be connected to a condensate pump Drainage line must slope down to the drain at a pitch of 1 4 per foot so condensate runs towards the tra...

Page 21: ...rap in the location shown below Do not place the drain connection tee directly at the base of the boiler 1 5 1 2 WITH PPS VENTING SYSTEMS For connection to PPS venting systems an IBC VFC PPs transitio...

Page 22: ...LATION AND OPERATION INSTRUCTIONS 1 16 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS Figure 17 Condensate trap installation PPs Figure 18 IBC Kit P 166A for Centrotherm PPs with Centrotherm clips IBC 1...

Page 23: ...venting system upward from the PPs Exhaust Adaptor securing the venting in accordance with that supplier s installation instructions and local code e g to the wall and amongst all the system parts us...

Page 24: ...trap is applied to secure the trap against blow off on PPs systems 1 5 3 Further installation details Condensate drain must be piped to within 1 of a drain or be connected to a condensate pump Drainag...

Page 25: ...CAUTION When a condensate neutralization package is installed the pH of the condensate discharge must be measured on a regular schedule to ensure the neutralizing agent is active and effective Figure...

Page 26: ...fill from the mains When regular maintenance requires relief valve blow off the discharge may be directed back into the pressurization unit for recycling of boiler fluid and chemicals back into the s...

Page 27: ...re there is a boiler protection throttle fence limiting the T to 40 F WARNING Close fill valve after any addition of water to the system to reduce risk of water escapement NOTE Full sized application...

Page 28: ...r WARNING Water quality has a significant impact on the lifetime and performance of an IBC Boiler heat exchanger Improperly prepared water in a heating circuit may cause damage to the heat exchanger t...

Page 29: ...hermal loads presented in a typical multi zoned radiation system However where individual zones in a heating system have loads under 5 000 Btu hr the system will still benefit through use of a buffer...

Page 30: ...ap off on simultaneously provided the pre set maximum allowable temperature of the new load is not exceeded In the case of the typical maximum limit for a radiant floor most would enter 140 F the floo...

Page 31: ...reverse flow To ensure adequate water flow through the boiler under high head single zone space heating conditions a pressure activated bypass or other means of bypass must be used on any load where t...

Page 32: ...he gas supply during any pressure testing of the system at test pressures in excess of 1 2 psig Dissipate test pressure prior to reconnecting The boiler and its gas piping shall be leak tested before...

Page 33: ...Terminal Block along the controller s right edge this is for the secondary pumps and or zone valves only Connect the pump s Black wire to the Yellow of this pair switched Hot The White Yellow pair sh...

Page 34: ...e A floor protecting aquastat can use one of these to cause a full boiler shutdown in the case of excess floor temperature Contacts for indoor and outdoor temperatures sensors associated with Reset He...

Page 35: ...not applicable with the VFC modulating series boilers In the case of a single temperature heat load where zone valves are used to manage individual thermostatically controlled zones each room thermost...

Page 36: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 30 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 37: ...up configuration back up and cloning using SD card or USB stick Superior warning messages while setting up the control Advanced Error messages with visual display on the Home Screen Internet LAN conne...

Page 38: ...nd a boarder surrounding the active area At the bottom of the display there is space reserved for the boiler status bar Prior to any interaction with the touch screen the display will be showing the H...

Page 39: ...3 1 STARTUP AND COMMISSIONING VFC 15 150 VFC 45 225 MODULATING GAS BOILERS STARTUP AND COMMISSIONING 3 0 3 1 LIGHTING AND SHUTTING DOWN THE BOILER...

Page 40: ...calibrated to operate with natural gas or propane if so ordered at sea level The relevant valve adjustment screws have been factory sealed using Loctite thread lock compound which can be broken where...

Page 41: ...el settings Re define the load as Manual Control Use Heat Output in Configure Load x to control the output as needed 6 At the minimum firing rate adjust the zero offset screw see Figure 32 A to obtain...

Page 42: ...INSTALLATION AND OPERATION INSTRUCTIONS 3 4 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS Figure 32 Gas Valve and Pressure Reference System...

Page 43: ...e the fuel conversion instructions supplied with the fuel conversion kit are read understood and followed carefully 3 Carefully follow the procedures on page 3 of the relevant Fuel Conversion Instruct...

Page 44: ...INSTALLATION AND OPERATION INSTRUCTIONS 3 6 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 45: ...2 5 years Consider adding air filtration if burner requires cleaning every year In alternate years visually inspect burner through sight glass Ensure flame is stable and without excessive fluttering N...

Page 46: ...ses sharply consider replacement of expansion tank Check also for noise at high fire which may signal water quality problems Check water piping for damage or leaks and repair as needed Water chemistry...

Page 47: ...uid must be replaced It is highly recommended that a system pressurization unit such as an Axiom Industries model MF200 be employed to refill and pressurize your system Capture the discharged fluid in...

Page 48: ...alve for improved access mark and remove vinyl air reference tubes and black air pressure sensor 4 2 2 Gas Valve TYPE IBC 180 022 FUNCTION zero governor gas valve provides strict gas air mixture contr...

Page 49: ...rature Sensors PART TYPE IBC 240 006 Thermistor 10 000 with Beta 3892 FUNCTION Senses water temperature Signals controller to adjust output according to water temperature INSTALLATION see Diagram 6 1...

Page 50: ...dle nose pliers and or fingers This task is best done using a 9 tee handle hex key For the VFC 45 225 remove the 4 bolts and nuts at the FC Fan interface using a 5 16 wrench for the bolts and 3 8 wren...

Page 51: ...ecific precautions for silica dust management then pry up the material likely in several pieces Bag with care to seal off and dispose RE ASSEMBLY 1 Inspect the inner refractory disk replace as appropr...

Page 52: ...HX and lid for temperature for good thermal sealing at the refractory to lid interface Allow 20 mins prior running at high fire before the test max target is 110 C 14 Check for gas or fume leaks afte...

Page 53: ...ion Problems 5 3 3 Cycling Problems 5 3 4 Temperature Problems 5 3 5 Miscellaneous Below each section is a list of Symptoms Diagnoses and Remedies Also provided with this manual are a number of diagra...

Page 54: ...Disconnect the Molex connectors located approx 6 from the sensors Place multi meter probes into Molex socket Do not apply voltage to the sensor as damage may result Sensors are sensitive to excess bi...

Page 55: ...other while the boiler is in operation If the required pressure is higher than the actual pressure there are several possible causes Exhaust and or Air Intake piping installed longer that allowed Imp...

Page 56: ...rols module provides a single flash at the start of each Purge and Interpurge cycle continuous rapid flashes during the 4 second spark interval solid illumination following successful ignition until b...

Page 57: ...within boiler case b open burner then fan gas valve looking for debris Water noise in vent Excess condensate in venting Check condensate trap for obstructions Remove obstructions and refill condensate...

Page 58: ...tween blue and brown wires during an ignition cycle Replace module if no current detected Boiler ignites but shuts off at the end of the ignition trial Improperly grounded pressure vessel burner or un...

Page 59: ...use in ignition module Check fuse If blown replace Defective Control Module Check ignition output from control module BOILER WILL NOT ATTEMPT TO IGNITE FAN AND OR PUMP ARE OFF DISPLAY NOT ILLUMINATED...

Page 60: ...h ammeter Air in system or marginal water flow Bleed purge system as required Confirm adequate pump size and temp rise in HX Slow combustion air blower Check that CO2 level is OK per Tabel 8 Dirty bur...

Page 61: ...ck CO2 level Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain Unit cycling on operating safety controls Check operation with...

Page 62: ...s in 1 hour safety lockout Reset safety device and cycle boiler power off and on to reset error DHW TAKING TOO LONG TO HEAT Sensor may be under reading actual water temp Check sensor engagement note w...

Page 63: ...DIAGRAMS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 0 DIAGRAMS 6 1 VFC 15 150 PARTS DIAGRAMS 6 2 VFC 45 225 PARTS DIAGRAMS 6 3 ADDITIONAL PARTS DIAGRAMS 6 4 WIRING DIAGRAMS 6 5 SEQUENCE OF OPERAT...

Page 64: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 2 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 1 VFC 15 150 PARTS DIAGRAM Diagram 6 1 1 Boiler Assembly VFC 15 150...

Page 65: ...R INTAKE COVER 180 018 1 40 GAS VALVE 180 022 1 45 SPACER 8 1 8 THICK 1 4 O D 150 092 3 50 SCREW M4 x 30 TAPPING EQUIPPED w 180 022 3 55 SCREW 10 32 x 7 8 HEX HEAD 150 110 4 61 GASKET FAN FAN COUPLER...

Page 66: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 2 VFC 45 225 PARTS DIAGRAM Diagram 6 2 1 Boiler Assembly VFC 45 225...

Page 67: ...1 110 MOUNTING BRACKET GAS VALVE 250 316 1 115 SENSOR AIR PRESSURE 240 003 1 120 TRANSFORMER 240 008 1 125 SIDE COVER CONTROLLER 250 327 1 130 SCREW 6 32 x 3 8 150 014 6 135 CHASSIS CONTROLLER PCB 250...

Page 68: ...P 150 51 b Trap Exhaust Kit VFC45 225 P 151 66 Washer 10 External Tooth 150 085 67 Screw 10 32 x 1 2 150 084 75 Switch Snap disk Manual Reset 230F 240 030 100 Sensor Water Pressure 240 006 101 Pressu...

Page 69: ...6 7 DIAGRAMS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 4 WIRING DIAGRAMS Diagram 6 4 1 Ladder wiring diagram...

Page 70: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 8 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS Diagram 6 4 2 Internal wiring diagram...

Page 71: ...6 9 DIAGRAMS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 5 SEQUENCE OF OPERATION Diagram 6 5 1 Sequence of operation diagram...

Page 72: ...g Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner used ________________________________________________ System Fi...

Page 73: ...uration Load 2 _____________________________________________________________________________________________ Load Definition Load 3 ____________________________________________________________________...

Page 74: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Page 75: ...NOTES...

Page 76: ...NOTES...

Page 77: ...NOTES...

Page 78: ...RIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases...

Page 79: ...SL variant added with new NRG 137 fan warranty removed to separate document R4 SEPTEMBER 2012 Polypropylene venting detachable lid heat exchanger and US Energy Act disclosures added VFC 45 225 SL desi...

Page 80: ...IBC Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 100E A R6 May 2015 IBC Technologies Inc 2015...