IBC VX Series Installation & Operating Manual Download Page 104

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Boiler part diagrams - VX 110, VX 150, VX 199

Item ID

Description

Part #

P-kit #

Qty

Top access cover - VX 110

251-168

P-1506

Top access cover - VX 150

251-184

P-1531

Top access cover - VX 199

251-194

P-1532

Exhaust duct

251-142

P-1507

Intake duct

250-942

P-391

High limit temperature sensor

240-132

P-361

Safety Ignition Module plus (SIM+)

500-078

P-271

Front door cover - VX 110

500-180

P-1508

100

Section: Appendices

Summary of Contents for VX Series

Page 1: ...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 electr...

Page 2: ...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...

Page 3: ...lt 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 Danger Shou...

Page 4: ...r 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 i...

Page 5: ...e requirements 15 3 2 Removing an existing boiler 15 3 3 Determining location of the appliance 16 3 3 1 Best installation conditions 17 3 4 Mounting the boiler 17 3 5 Connecting the vent and air intak...

Page 6: ...troller 57 4 2 Control interface 58 5 0 Before operating the boiler 59 5 1 Important pre ignition checks 59 5 1 1 Checklist for electrical conditions ducting and water connections 59 6 0 Boiler operat...

Page 7: ...8 1 3 Water pressure sensor 86 8 1 4 Safety and Ignition Module SIM 87 8 2 Troubleshooting error messages 89 8 2 1 Maximum ignition trials error 89 8 2 2 Hi Limit cut off temperature error 90 8 2 3 L...

Page 8: ...Intentionally left empty...

Page 9: ...C 122 F 50 C 32 F 0 C 122 F 50 C Max relative humidity non condensing 90 90 90 Minimum water temp F C 34 1 34 1 34 1 Maximum water temp electronic hi limit F C 190 88 190 88 190 88 Max T supply retur...

Page 10: ...0 12 000 2 3 Maximum equivalent vent length each side vent air intake natural gas or propane Air intake options either direct vent or indoor supply 100 240 50 170 N A 100 Cabinet dimensions VX 110 dim...

Page 11: ...Figure 3 Top view VX 110 Figure 4 Bottom view VX 110 VX 150 dimensions Figure 5 Frontal view VX 150 Figure 6 Side view VX 150 7 VX 150 dimensions...

Page 12: ...Figure 7 Top view VX 150 Figure 8 Bottom view VX 150 VX 199 dimensions Figure 9 Frontal view VX 199 Figure 10 Side view VX 199 8 Section Specifications...

Page 13: ...onnection specifications Description VX 110 VX 150 VX 199 A Flue Outlet 3 Schedule 40 or 3 PPs 80 mm B Combustion Air Inlet 3 Schedule 40 or 3 PPs 80 mm C Return water outlet tepid water 1 NPT M D Sup...

Page 14: ...Intentionally left empty...

Page 15: ...Figure 13 View from the front 1 1 Standard features and benefits High thermal efficiency Compact Turn down ratio 6 5 to 1 Cascade up to 4 appliances 4 load pump management 1 boiler pump management Eas...

Page 16: ...e following terms 0 10 years 100 coverage 11 15 years 25 coverage IBC offers a limited heat exchanger warranty with no registration of 0 5 years 100 coverage For commercial applications IBC offers a 5...

Page 17: ...lt in damage to the area If there is no suitable location install a suitable drain pan under the boiler Do not install above carpeting At a new construction site or during renovations protect the appl...

Page 18: ...eam plume normally at the exhaust terminal of a condensing boiler Generally intake and exhaust pipes should terminate at a rooftop or sterile wall location Boiler condensate is corrosive Protective me...

Page 19: ...s ANSI ASME CSD 1 If there is any conflict follow the more stringent regulations Table 2 Code requirements by country 3 2 Removing an existing boiler When an existing boiler is removed from a common v...

Page 20: ...ed and approved for indoor installation wall or rack mounting in areas such as an alcove basement or utility room These areas should have a surrounding temperature of 32 F 0 C to 122 F 50 C and less t...

Page 21: ...ep exhaust plumes well away from all building air intakes including those of neighboring properties Refer to Table 5 and Figure 19 in Sidewall vent termination on page 28 The minimum clearance require...

Page 22: ...screws with flat washers 2 Hook the boiler tab located on back of boiler over the support bracket flange 3 Ensure that the boiler tab is flush against the mounting bracket flange 4 Secure the lower pa...

Page 23: ...Figure 14 Securing a pipe connection Combustion air piping if used is inserted directly into the 3 connector on the right side PPs pipe should be inserted firmly into the connector until it cannot go...

Page 24: ...and piping Table 3 Clearance distances for boiler mounting sites A minimum distance below the boiler of 12 is required to provide clearance for the supplied condensation trap assembly More clearance...

Page 25: ...door air surrounding the boiler Provided the maximum overall vent length limit is not exceeded the boiler may be vented through the wall directly through the roof or upward using an existing but other...

Page 26: ...ial general Use of cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenolsulfone in venting systems is prohibited Do not use ABS or any cellular core pipe for exhaust venting 3 7 4 Direct...

Page 27: ...er and blockage of intake air Such blockages will cause a boiler safety shut down Filters require checking and cleaning or replacing on a regular schedule based on the severity of the problem Exhaust...

Page 28: ...ate drain tee with the type of test the date and the installer s name Re venting passage through ceiling and floor Confirm material meets local codes including fire stopping requirements Check the loc...

Page 29: ...air intake pipe and maximum exhaust vent length Notes Unused intake travel cannot be added to the exhaust Unequal intake and exhaust piping is allowed Support should be provided for intake and vent pi...

Page 30: ...concern about rain infiltration rain will drain away through the condensate trap Optional bird screen may be placed in a termination fitting Leave unglued and hold in place with a short nipple This p...

Page 31: ...on noise allow a gap around the exhaust and air intake piping For roof top venting of multiple boiler sets group all intake terminals together for a common penetration through a custom cap Alternative...

Page 32: ...ination 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 exami...

Page 33: ...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 Above a regulator with...

Page 34: ...separation of exhaust vent termination from boiler intake air as illustrated in Figure 20 Figure 21 Figure 22 and Figure 23 Failure to do so can result in a dangerous situation where exhaust gasses ar...

Page 35: ...21 and Figure 22 Use a 45 elbow on the exhaust termination to launch the plume up and off the sidewall for protection of wall A short piece of venting cut at 45 gives a horizontal termination protecte...

Page 36: ...Figure 22 Sidewall vent termination configuration option 1 Figure 23 Sidewall vent termination configuration option 2 32 Section Installation...

Page 37: ...m vent clearances listed in Table 5 Install the SST with the vent and intake pipes horizontally beside each other or vertically with the vent pipe on top see Figure 25 The vent pipe cannot be installe...

Page 38: ...als shall not be stacked vertically Figure 27 Minimum separation for multiple vent installation vertical orientation Figure 28 Minimum separations for multiple vent installation horizontal orientation...

Page 39: ...boiler Warning When using indoor air options supply adequate combustion air to the boiler room according to the requirements of all applicable codes Flue gas exhaust to outdoors Combustion air from bo...

Page 40: ...nce with B149 1 latest edition 3 7 8 Combustion air filtration system If combustion air contamination from ingested particulate matter is a concern in any installation an optional air intake filter ma...

Page 41: ...initially firing the boiler to prevent exhaust fumes from entering the room Never operate the boiler unless the trap is filled with water Failure to comply will result in severe personal injury or de...

Page 42: ...breaker opening and push firmly 2 Fill the condensate trap with water 3 Attach the drain hose and tighten the drain compression nut including washer 4 Slide the trap over the boiler drain outlet and t...

Page 43: ...ding drain piping materials that are subject to corrosion use a neutralization package Caution After installing a condensate neutralization package the pH of the condensate discharge must be measured...

Page 44: ...tering Condensate water line Warning Risk of damage to appliance All condensate discharge lines including neutralization tank inlet must be at a lower elevation than the condensate water line of the a...

Page 45: ...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...

Page 46: ...heat we recommend water flow after burner shutdown There can be significant build up of energy due to the volume of heated water in the system Default load settings will run the boiler s primary pump...

Page 47: ...equivalent to straight water These boilers are designed for use within a closed loop forced circulation low pressure system A 30 psi pressure relief is supplied for field installation in the relief v...

Page 48: ...to the site 3 11 2 System piping Note The piping drawings in this manual are simple schematic guides to a successful installation For further information and details consult our concept drawings whic...

Page 49: ...erature and lowest pressure on boiler outlet at expansion tank connection Expansion tank connection point of no pressure change should be on the suction side of the circulator with minimal pressure dr...

Page 50: ...ssurization appliances are useful to prevent flood damage should leakage occur from any component in the system An additional benefit is that backflow prevention devices are not required when using th...

Page 51: ...meter lengths as per Table 9 with tees maximum 4 pipe diameters apart with no restrictions between fittings Figure 34 Primary secondary piping details with closely spaced tees Figure 35 Primary second...

Page 52: ...Figure 36 Two pump two load parallel piping concept 48 Section Installation...

Page 53: ...tank connection point of no pressure change should be on the suction side of the circulator with minimal pressure drop between Fill station with isolation valve closed or fill tank Supply piping to lo...

Page 54: ...g valves Supply to heating system Secondary loop sensor to master boiler Closely spaced tees are a maximum of four pipe diameters apart with a minimum of eight pipe diameters of straight piping upstre...

Page 55: ...l firing rates and will not exceed the boiler s maximum pressure rating when locked up with no load 3 12 1 Gas pressure The boilers require a minimum inlet gas supply pressure of 4 0 w c for natural g...

Page 56: ...s supply during any pressure testing of the system at test pressures in excess of psig Dissipate test pressure prior to reconnecting The boiler and its gas piping must be leak tested before being plac...

Page 57: ...o the boiler This will interrupt the moisture management routine fan turns at ultra low rpm for 90 minutes after burner shutdown resulting in serious damage to the boiler Treat the boiler like a compu...

Page 58: ...e 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 valves only Connect th...

Page 59: ...eled External Control receives a 0 10VDC default or 4 20 mA signal from an external boiler controller for direct throttle control The boiler s own sensors act as high limits only The user must enter m...

Page 60: ...r handler motor Most power stealing thermostats can be connected directly to the Therm terminals Consult the Controller manual for more detailed instructions 3 13 6 Thermostat heat anticipator IBC The...

Page 61: ...imultaneous operation of two similar water temperature loads Programmable setback override schedule The control can manage or operate in a network of up to 4 IBC boilers without additional controller...

Page 62: ...s Do not use a sharp or metallic object such as a screw driver to operate the control as it could damage the touchscreen Prior to any interaction with the touchscreen the display shows the Home screen...

Page 63: ...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 5 1 Important pre ignition checks Once installation...

Page 64: ...et gas pressure on page 66 Connect a manometer and open the gas control valve Requirements are minimum 4 w c and maximum 14 w c Check that there are no gas leaks All connections are pressure tested an...

Page 65: ...quence of Operation on page 99 If the sight glass viewport clouds up at start up see Cleaning the sight glass on page 81 6 1 Lighting and shutting down the boiler Start up Checklist Check Followed lig...

Page 66: ...ler in operation shut off the gas control valve directly outside the boiler case 2 Ensure that the boiler has purged attempted to re light three times has shut off and the appropriate error informatio...

Page 67: ...onfigured for natural gas but needs to be converted to propane use the conversion kit sold separately by IBC to install the appropriate fitting s and adjust the gas valve accordingly See Table 10 for...

Page 68: ...re install 10 Tighten the union nut at the gas valve outlet 11 Reinstall the top panel 12 Restore the gas supply by opening the gas control valve and reconnect the electrical power 13 Perform a combu...

Page 69: ...nlet Inlet gas pressure test port Manifold gas pressure test port Low fire adjustment offset pressure Gas valve outlet Orifice O ring Gas valve outlet pipe Fan inlet Fan plug Fan 65 6 3 3 Adjusting th...

Page 70: ...ure test port 3 Attach the manometer to the inlet gas pressure test port 4 To measure the inlet gas pressure switch on the gas supply 5 When the boiler is operating at high fire measure the gas pressu...

Page 71: ...t port Then verify that the CO2 reading is within the combustion test targets at Table 11 values Figure 44 Flue gas test port 4 Adjust the high fire according to values in Table 11 using a Torx 15 scr...

Page 72: ...CO max PPM Range Target Range Target Natural Gas 9 0 10 0 9 5 8 2 9 2 8 7 150 Propane 10 3 11 3 10 8 9 3 10 3 9 8 250 Table 11 Combustion test target ranges CO2 Maximum CO 6 3 4 Testing the LWCO func...

Page 73: ...erature function 1 Go to SIM Menu Hi Limit Test Read the instructions You will need to enter a cutoff temperature below the actual supply temperature value currently displayed For example if the Suppl...

Page 74: ...Intentionally left empty...

Page 75: ...etc As needed Inspection of the boiler is to be performed annually by a qualified service technician Annually 7 2 Maintenance checklist for heating contractor Caution Label all wires prior to disconn...

Page 76: ...ensate trap Remove and clean annually see Cleaning the condensate trap on page 82 Ensure that the trap has been re filled completely before firing the boiler Annually If condensate neutralization is u...

Page 77: ...anger for signs of contamination and clean if necessary Annually Boiler Pump Check that the pump is on in normal operation and that the water T is reasonable for a given firing rate Annually Gas Pipin...

Page 78: ...non ferrous components as well as non metallic wet components normally found in hydronic systems Ethylene glycol is toxic and may be prohibited for use by codes applicable to your installation locatio...

Page 79: ...ody testing must be performed more often A try lever test must also be performed at the end of any non service period Annually Test at or near the maximum operating pressure by holding the test lever...

Page 80: ...by returning it to the system feeder appliance This is particularly important when your system contains treatment chemicals or glycol solutions If the system employs plain water the boiler auto fill v...

Page 81: ...pressure test port Manifold gas pressure test port Low fire adjustment offset pressure Do not adjust in the field Gas valve outlet Orifice O ring Gas valve outlet tube Fan inlet 77 7 3 Replacing the...

Page 82: ...ws or refractory may occur 4 Undo the union nut at the gas valve outlet 5 Carefully remove the O ring and orifice for re installation later 6 Remove the electrical connection to the fan 7 Move the gas...

Page 83: ...ews or refractory may occur 4 Remove the electrical connection to the fan 5 Move the gas valve outlet tube away from the gas valve 6 Unscrew the top union nut of the flexible pipe attached to the gas...

Page 84: ...ormation NIOSH can be contacted at 1 800 356 4676 or on the web at www cdc gov niosh 2 Wear long sleeved loose fitting clothing gloves and eyes protection 3 Assure adequate ventilation 4 Wash with soa...

Page 85: ...he tightening sequence a few times as shown in the images below 16 Reinstall the refractory Carefully slide it over the burner all the way to the lid ensuring that the openings for the ignitor view po...

Page 86: ...de the refractory top mfollowed by the glass k and then the graphite gasket j Figure 47 Four components of the sight glass 6 Replace onto the lid and fasten with the two screws 7 5 Cleaning the conden...

Page 87: ...low it to cool down Important Installers or service contractors should ensure that the end user is instructed on cleaning and refilling the trap 1 Pull back the clip to release the trap and pull the t...

Page 88: ...e top with water and replace the union cap and gasket 4 Slide the trap over the boiler drain outlet making sure it is secured by the clip and tighten the upper union nut to ensure an airtight seal 84...

Page 89: ...nvironment and compare with the value derived from the measurement of the resistance obtained by connecting a good quality test meter capable of measuring up to 5 000 k 5 000 000 at the controller end...

Page 90: ...82 1 172 85 29 8 250 185 85 1 073 90 35 7 334 190 88 983 95 35 6 532 195 91 903 Table 12 Temperature sensor resistance values 10K ohms 8 1 2 Fan The fan is controlled via the SIM control The SIM prov...

Page 91: ...detection and current measurement Supply water temperature sensing Flue gas temperature sensing Supply water maximum temperature shutdown Flue gas maximum temperature shutdown Low water cut off The S...

Page 92: ...sure that the error has been cleared 5 If the error persists perform a LWCO test Go to SIM Menu Hi Limit Test Run the test to check if the low water cutoff sensor is opening 8 1 4 3 Resetting a boiler...

Page 93: ...gnosis Fix Error Ignition Failure after 3 tries boiler has failed to ignite on 3 successive attempts Boiler is in lockout for 1 hour then repeats 3 try sequence Consult service technician if error rec...

Page 94: ...w Water Cut off error Low Water Cutoff Error Issue Diagnosis Fix Error Low Water Cutoff The Safety and Ignition module has detected a low water condition See Resetting a boiler after a LWCO lockout on...

Page 95: ...Max Inlet Outlet Sensor Temp Exceeded Check water flow Water temperature signal not within acceptable range Potential flow or sensor failure Consult service technician Current outlet temperature exce...

Page 96: ...l via analyzer Check for proper gas piping Check pressure with manometer during ignition Boiler will not attempt to ignite Fan and pump are operating normally No power to ignition control module Check...

Page 97: ...evel Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain appliance cycling on operating safety controls Check operation with Oh...

Page 98: ...ons on clearing errors see Resetting a boiler after a hi limit temperature lockout on page 88 and Resetting a boiler after a LWCO lockout on page 88 DHW taking too long to heat Sensor may be under rea...

Page 99: ...required Confirm adequate pump size and temp rise in the heat exchanger Slow combustion air blower Check that CO2 level is within specification Dirty burner heat exchanger Check pressure drop Low wat...

Page 100: ...Intentionally left empty...

Page 101: ...97 Appendices Wiring diagrams Figure 48 Controller electrical diagram...

Page 102: ...Figure 49 Internal wiring diagram 98 Section Appendices...

Page 103: ...Figure 50 Sequence of Operation 99 Appendices...

Page 104: ...506 1 Top access cover VX 150 251 184 P 1531 1 Top access cover VX 199 251 194 P 1532 1 2 Exhaust duct 251 142 P 1507 1 3 Intake duct 250 942 P 391 1 4 High limit temperature sensor 240 132 P 361 1 5...

Page 105: ...VX 150 500 181 P 1533 1 Front door cover VX 199 500 182 P 1534 1 7 Thumb screw 250 275 2 8 Terminal block cover 251 163 P 1509 1 9 V 10 touchscreen controller 500 103 P 242 1 10 Transformer 240 008 P...

Page 106: ...102 Section Appendices...

Page 107: ...117 1 90 Sight glass and 2 screws 250 057 P 107 1 100 Heat exchanger lid 170 120 P 1512 1 Heat exchanger lid 170 122 P 1524 1 Heat exchanger lid 170 124 P 1528 1 110 Refractory and gasket VX 110 255 1...

Page 108: ...99 170 123 P 1527 1 250 Burner 110 180 297 P 1519 1 Burner 150 180 298 P 1526 1 Burner 199 180 299 P 1530 1 260 Burner gasket VX 110 255 034 1 Burner gasket VX 150 VX 199 255 141 1 270 Fan insert 251...

Page 109: ...Filled type concentration of any glycol chemicals used _________________________ Air purge completed Relief Valve correctly installed and piped Relief valve try lever test performed Condensate trap f...

Page 110: ...s the same function THIS OVERRIDE 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 a...

Page 111: ...877 0277 T 856 877 0544 F 604 877 0295 F 856 735 5584 Toll Free 1 844 HEAT IBC 1 844 432 8422 www ibcboiler com Information in this document is subject to change without notice IBC assumes no responsi...

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