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IBC VFC 15-150, Manual

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IBC VFC 15-150 Manual Download Page 22

INSTALLATION AND OPERATION INSTRUCTIONS

1-18

VFC 15-150 - VFC 45-225 MODULATING GAS BOILERS

Figure 19: Condensate trap drainage

Figure 20: Condensate neutralization tank

WARNING

If condensates are to be 

discharged into building 

drain piping materials that 

are subject to corrosion, a 

neutralization package must 

be used.

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 18: Condensate trap 

disassembly for cleaning

Summary of Contents for VFC 15-150

Page 1: ...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 build...

Page 2: ...Minimum gas supply pressure Natural Gas or Propane inch w c 3 3 3 3 Maximum gas supply pressure Natural Gas or Propane inch w c 14 14 14 14 Power use 120Vac 60Hz full fire Watts excluding pumps 57 158...

Page 3: ...S LEVELS 2 2 2 5 SEQUENCE OF OPERATION 2 4 2 6 OTHER OPERATING FEATURES 2 6 2 7 SET UP LOAD DEFINITION 2 10 3 0 STARTUP AND COMMISSIONING 3 1 3 1 LIGHTING AND SHUTTING DOWN THE BOILER 3 1 3 2 PRIOR TO...

Page 4: ...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 ster...

Page 5: ...Direct 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 fin...

Page 6: ...such as those released with the use of laundry detergents are also to be avoided For this reason the indoor air venting option using air surrounding the boiler should not be used in a laundry room Sim...

Page 7: ...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 betw...

Page 8: ...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 10 Installa...

Page 9: ...onnections Fittings are to be used to adapt to the appropriate diameter see Vent Travel below Exhaust venting is to be connected directly to the 2 NPT male threaded stainless steel fitting on the bott...

Page 10: ...mum exhaust venting length Note 1 Plus up to 30 15 150 or 60 45 225 equivalent in rigid PPs can be used Note 2 Unused intake travel cannot be added to the exhaust Unequal intake and exhaust piping is...

Page 11: ...instructions 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 man...

Page 12: ...elevation as the exhaust as shown lower down roof is OK To promote the projection of exhaust away from the building and from the intake pipe reduction of 3 pipe to 2 is permitted for a maximum lineal...

Page 13: ...apart Use same 24 minimum vertical separation as displayed above Alternately as long as the boilers are identical models intake and exhaust terminals can maintain a minimum of 12 of separation horizo...

Page 14: ...n 10 3 1m horizontally Clearance above paved sidewalk or paved driveway located on public property 7 2 2m Note Cannot terminate directly above a paved sidewalk or paved driveway that is located betwee...

Page 15: ...o 60 equivalent For the inlet air Schedule 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...

Page 16: ...efer 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 A...

Page 17: ...or 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 whe...

Page 18: ...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 19: ...stalled as follows For the 15 150 model must be 7 min in height see Figure 14 with the conventional vent kit parts supplied with the boiler approximately 15 clearance below the boiler is required For...

Page 20: ...Outlet A Insert one Trap Hook barb into the back mounting hole 2 Fill Trap with water and slide Trap Body D over Boiler Drain Outlet A Swing Trap Hook B around the Drain Outlet F connection threads I...

Page 21: ...cribed in the installation instructions above 1 5 4 Further installation details Condensate drain must be piped to within 1 of a drain or be connected to a condensate pump Drainage line must slope dow...

Page 22: ...ndensates are to be discharged into building drain piping materials that are subject to corrosion a neutralization package must be used CAUTION When a condensate neutralization package is installed th...

Page 23: ...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 system In build...

Page 24: ...7 at 14 gpm and 12 at 22 gpm so an inexpensive fractional horsepower pump is normally adequate Primary Secondary piping ensures adequate flow and de couples T issues boiler vs distribution Aim for a 2...

Page 25: ...o isolate the boiler loop from the system and pipe the system from the secondary side of the separator A variety of application drawings showing basic design options are available from the IBC web sit...

Page 26: ...C modulating series boilers offer unparalleled matching of heat generation to radiation The low minimum firing is better suited to low thermal loads presented in a typical multi zoned radiation system...

Page 27: ...simplify installation and operation of this preferred layout offsetting such costs For optimal performance place pumps on the supply side of secondary loops to facilitate air evacuation Use pumps with...

Page 28: ...licity of constant head and flow at the boiler with reduced flexibility in the handling of large temperature differentials Wiring loop the yellow white Primary Pump pair up to connect to the lowest pa...

Page 29: ...upport gas supply piping as per applicable codes The boiler must be disconnected or otherwise isolated from the gas supply during any pressure testing of the system at test pressures in excess of 1 2...

Page 30: ...r right backside of the controller board do not attempt to connect the primary pump to the Pump Zone Valve Terminal Block along the controller s right edge this is for the secondary pumps and or zone...

Page 31: ...auxiliary interlocks for external safety devices as may be required by some jurisdictions such as a low water cut off or a low gas pressure cut out for off grid propane A floor protecting aquastat ca...

Page 32: ...nticipator IBC Therm contacts draw no power so an anticipator setting for the thermostat is not applicable with the VFC modulating series boilers In the case of a single temperature heat load where zo...

Page 33: ...range 34 F to 185 F CONTROL The control unit provides overall management of boiler operations including 1 Power up set up boiler state machine standby heat call management etc 2 Burner pumps primary...

Page 34: ...Floor with Reset CIR Cast Iron Radiators w Reset BBd Baseboards w Reset AIR Air Handler w Reset StP Set Point DHW Domestic Hot Water Other information is accessible using a menu based system described...

Page 35: ...vs boiler supply A record of the service history is also available for onscreen access 2 4 3 Advanced Diagnostics Not an access level this field allows a view into detailed sensor readings and operati...

Page 36: ...ture is below the water temperature target or setpoint Heating Enabled The boiler is powered and there is a Call for Heat Heat is Required The boiler will start and enter the Heating Cycle unless it i...

Page 37: ...eating The heating cycle lasts until the Heating Enabled state ends for all loads or until water temperature exceeds the target temperature by of the supply differential for the last served load and t...

Page 38: ...tended purge followed by the error cycle of 5 minutes for all conditions other than Maximum Ignition Trials a modified Hard Error which locks out for 1 hour after 3 unsuccessful ignition attempts Foll...

Page 39: ...is generally better to avoid equal ratings Note the priority scale values do not need to add up to 100 they are relative only to each other 2 6 2 Load Pairing With software versions 3 10 0 and higher...

Page 40: ...ne 1 in the User screen To increase heat e g from 72 F to 73 move the Indoor value upward warmer from the level otherwise chosen This shifts the position of the reset curve will amend the boiler water...

Page 41: ...ck twice and returned twice each day The routine can be applied by specific day Mon Sun The automated setback feature cannot be applied to setpoint loads including DHW with simple aquastat control Thi...

Page 42: ...minals accessible through the slotted clearance hole Where the IBC controller senses a signal on the remote connections it automatically subordinates its internal throttle logic and adopts the externa...

Page 43: ...iven weather because a given current condition is relatively warmer than the designated coldest day Moving down the screen set the Design Supply Temperature the targeted temp for circulating water on...

Page 44: ...display Indoor Temp Open and there will be no effective indoor trim of the reset curve These lines do not require amendment at most installation sites The mapping feature allows reassignment of the s...

Page 45: ...1 6 2 Installation Rules page 1 20 for piping layouts and the Wiring Schematics on pages 6 7 and 6 8 Ensure that DHW aquastat or thermistor probe leads thermostat and pump or zone valve leads are conn...

Page 46: ...INSTALLATION AND OPERATION INSTRUCTIONS 2 14 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 47: ...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 48: ...evel The relevant valve adjustment screws have been factory sealed using Loctite thread lock compound which can be broken where required However no mixture adjustment shall be performed unless done by...

Page 49: ...tput in Configure Load x to control the output as needed 6 At the minimum firing rate adjust the zero offset screw see Figure 31 A to obtain 28 excess air It may be necessary to reduce the output in s...

Page 50: ...INSTALLATION AND OPERATION INSTRUCTIONS 3 4 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 51: ...sight glass Ensure flame is stable and without excessive fluttering Normal flame pattern is evenly distributed over the burner surface If burner is operating improperly remove and clean or replace Use...

Page 52: ...cursor to a load and push Enter to access This gives a profile of the boiler s duty cycle by throttle level see below The first screen below shows that this boiler a 15 150 has operated for 54 of tota...

Page 53: ...performed at the end of any non service period Test at or near maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of sediment and debri...

Page 54: ...ove 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 control over the range 15 150 MBH for VFC...

Page 55: ...emperature Signals controller to adjust output according to water temperature Installation see Diagram 6 1 1 for correct position Use 1 4 nutdriver to loosen ring clamp Install with back curve toward...

Page 56: ...INSTALLATION AND OPERATION INSTRUCTIONS 4 6 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 57: ...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 diagrams see Section...

Page 58: ...r 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 b...

Page 59: ...if disconnected Blue 35 VDC Negative power terminal Fan will only operate at max speed if disconnected Black Signal from controller Fan will only operate at max speed if disconnected White Fan tach 2...

Page 60: ...ssure If one or both remain fixed drain boiler and replace sensor s or dislodge any blocking debris from sensor inlet channel and reinsert To remove a red coloured 502 sensor it is necessary to releas...

Page 61: ...ter The control will lock out if the reading drops below 0 7 Microamps see Section 5 3 1 Control Module Maximum ignition trials error and Section 5 3 2 Ignition problems For conversion from Fenwal to...

Page 62: ...e a disconnect intake 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...

Page 63: ...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 unserviceable ign...

Page 64: ...probe Blown fuse 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 no...

Page 65: ...tem 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 9 0 nat gas 10 2 for propane Dirty burner...

Page 66: ...anger Poor gas air mixing Check CO2 level Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain Unit cycling on operating safety...

Page 67: ...3 5 Miscellaneous SYMPTOM DIAGNOSIS REMEDY Fumes and High Humidity Improperly installed condensate trap Refer to installation operation instructions Leak in vent piping Inspect using soap solution Flu...

Page 68: ...INSTALLATION AND OPERATION INSTRUCTIONS 5 12 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 69: ...DIAGRAMS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 0 DIAGRAMS 6 1 VFC 45 225 PARTS DIAGRAMS 6 2 VFC 15 150 PARTS DIAGRAMS 6 3 additional parts DIAGRAMS 6 4 WIRING DIAGRAMS 6 5 SEQUENCE OF OPERAT...

Page 70: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 2 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 1 VFC 45 225 PARTS DIAGRAM...

Page 71: ...ter Pressure 240 006 2 105 Enclosure 250 312 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...

Page 72: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 2 VFC 15 150 PARTS DIAGRAM...

Page 73: ...2 105 Enclosure 250 312 1 111 Gas Valve Mounting Bracket 250 314 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 Pan Head 150 01...

Page 74: ...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 75: ...6 7 DIAGRAMS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 4 WIRING DIAGRAMS Diagram 6 2 1 Pictorial wiring diagram ELECTRICAL NOTES AND SPECIFICATIONS...

Page 76: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 8 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS Diagram 6 2 2 Ladder wiring diagram...

Page 77: ...6 9 DIAGRAMS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS Diagram 6 2 3 Internal wiring diagram...

Page 78: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 10 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 5 SEQUENCE OF OPERATION Diagram 6 3 Sequence of operation diagram...

Page 79: ...ever test performed Condensate trap filled Condensate drain clear and free flowing Condensate Neutralization Yes No Ignition Safety Shutoff test completed Flame current reading High fire _______ A Low...

Page 80: ..._________________________________ Load Definition Load 2 _______________________________________________________________________ Load Configuration Load 2 _____________________________________________...

Page 81: ...NOTES...

Page 82: ...NOTES...

Page 83: ...ure is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE...

Page 84: ...IBC Technologies Inc 1445 Charles Street Vancouver BC Canada V5L 2S7 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 100E A R4 September 2012...

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