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IBC Technologies Inc.

VFC 15-150 and VFC 45-225

TABLE OF CONTENTS

INSTALLATION ...................... 3

1.1

GENERAL..........................................3

1.2

CODE REQUIREMENTS ................4

1.3

Location...............................................4

1.4

Venting ................................................5

1.4.1

Applications 6

1.4.2

“Category IV” Venting..................13

1.4.3

Closet Installations ........................13

1.5

Water Piping.....................................14

1.5.1

General Piping Issues ....................14

1.5.2

Installation Rules:- ........................16

1.6

Gas Piping.........................................19

1.7

Electrical Connections .....................19

1.7.1

“110V” Hook-up ...........................19

1.7.2

Power Quality and Electrical
Protection .................................20

1.7.3

Zone Valve Hook-up.....................20

1.7.4

Thermostat / Sensor Wiring ..........21

1.7.5

Other wiring 21

1.7.6

Thermostat Heat Anticipator .........21

BOILER SYSTEMS AND

OPERATION................................. 22

2.1

GENERAL........................................22

2.2

CONTROL .......................................22

2.3

USER INTERFACE.........................22

2.3.1

Keypad Functions..........................22

2.3.2

LCD Display 22

2.4

ACCESS LEVELS ...........................23

2.4.1

User setup .................................24

2.4.2

Installer Setup................................24

2.4.3

Advanced Setup.............................24

2.4.4

Advanced Diagnostics...................24

2.4.5

Passwords .................................24

2.5

SEQUENCE OF OPERATION ......25

2.5.1

Standby .................................25

2.5.2

Purging .................................25

2.5.3

Ignition .................................25

2.5.4

Heating .................................26

2.5.5

Circulating .................................26

2.5.6

- Error Mode .................................27

2.6

OTHER OPERATING FEATURES .

........................................................... 27

2.6.1

Prioritization .................................27

2.6.2

Reset Heating ................................28

2.6.3

Variable Speed Pumping ...............29

2.6.4

Temperature Setback .....................30

2.6.5

Unoccupied Mode .........................30

2.6.6

Summer Shutdown ........................30

2.6.7

Remote / Slave Mode ....................30

2.7

SET UP & LOAD DEFINITION... 31

STARTUP & COMMISSIONING

3.1

PRIOR TO START-UP .................. 36

3.1.1

Test Ignition Safety Shutoff ..........36

3.2

GAS VALVE ADJUSTMENT ....... 36

MAINTENANCE AND

TROUBLESHOOTING..................38

4.1

BOILER MAINTENANCE............ 38

4.1.1

General Care .................................38

4.1.2

Inspection .................................38

4.2

COMPONENT DESCRIPTION.... 40

4.3

TROUBLESHOOTING GUIDE ... 42

4.3.1

Preliminary Checks .......................42

4.3.2

Troubleshooting Electronic
Components .................................42

4.3.3

Troubleshooting using the Control45

4.3.4

Detailed System Checks ................47

DIAGRAMS ...........................51

5.1

Parts Diagrams ................................ 52

5.2

Wiring Diagram .............................. 54

5.3

Sequence of Operations Flowchart 55

Содержание VFC 15-150

Страница 1: ...he vicinity of this or any other appliance 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...

Страница 2: ...p 24 2 4 4 Advanced Diagnostics 24 2 4 5 Passwords 24 2 5 SEQUENCE OF OPERATION 25 2 5 1 Standby 25 2 5 2 Purging 25 2 5 3 Ignition 25 2 5 4 Heating 26 2 5 5 Circulating 26 2 5 6 Error Mode 27 2 6 OTH...

Страница 3: ...viding a great degree of installation flexibility The installer must clearly indicate the vent category for the installation on the rating plate using an indelible marker See section 1 4 Venting Figur...

Страница 4: ...rocarbons can reduce the life of a boiler Cleaners bleaches air fresheners refrigerants aerosol propellants dry cleaning fluids de greasers and paint removers all contain vapours which can form corros...

Страница 5: ...between the installation instructions below and the code requirements the more stringent shall apply DO NOT COMMON VENT THE VFC MODULATING SERIES BOILERS WITH ANY OTHER EXISTING OR NEW APPLIANCE IMPOR...

Страница 6: ...from the indoor air surrounding the boiler Provided the maximum overall vent length limit is not exceeded the installer may choose to vent the boiler through the wall directly through the roof or upwa...

Страница 7: ...o 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 bottom of the pressure vessel...

Страница 8: ...as the for 2 option If the site requires a horizontal exit immediately below the boiler bush out to 2 or 3 pipe in the downward vertical run immediately below the 2 threaded adaptor and elbow to horiz...

Страница 9: ...ust 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 per foot so condensate runs towards the trap Use the supplied vent kit...

Страница 10: ...e 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 linea...

Страница 11: ...nless steel or plastic mesh is useful to guard against foreign objects Figure 4 Sidewall Vent Termination Piping Configuration To promote the projection of exhaust away from the building and from the...

Страница 12: ...corner see CSA B149 H Clearance to each side of centreline extended above meter regulator assembly 3 0 91m within a height of 15 4 6m above the meter regulator I Clearance to service regulator vent o...

Страница 13: ...t edition or applicable provisions of the local building codes in Canada in compliance with B149 The following lists are recommendations for buildings of energy saving construction fully caulked and w...

Страница 14: ...S piping ensures adequate flow and de couples T issues boiler vs distribution Aim for a 20 to 30 F T across the heat exchanger at high fire there is a boiler protection throttle fence limiting the T t...

Страница 15: ...dividual zones in a heating system have loads under 5 000 Btu hr the system will still benefit through use of a buffer tank to ensure a controlled supply temperature and to prevent short cycling Buffe...

Страница 16: ...ping configuration requires an extra pump The VFC modulating series boilers controller hosts wiring terminals and integral relays to simplify installation and operation of this preferred layout offset...

Страница 17: ...n from hot to cool loads a manually set 3 way mixing valve can be placed at the entrance to the cool load This will permit immediate circulation of mixed flow into the cool loop See separate publicati...

Страница 18: ...gher head pump at a higher cost An imbalance in the head between the loads may call for a balancing valve on the low head side Zone valves should be wired to the Pump Zone Valve Terminal Block Run 24...

Страница 19: ...er 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 psig Dissipate test pressure prior to reconnecting The bo...

Страница 20: ...load pumps in the normal way this will bring power to the pump control block Pumps can be switched on off using the keypad so there is no need for temporary pump wiring during system filling air purgi...

Страница 21: ...cting 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 Heating A 10K ohm...

Страница 22: ...gement of boiler operations including 1 power up set up boiler state machine standby heat call management etc 2 burner pumps primary external and or zone valve management 3 temperature and throttle op...

Страница 23: ...a menu based system described in the following sections 2 4 ACCESS LEVELS The controller provides for the display of further information via the Load Status Screen plus three levels of access for the...

Страница 24: ...arget vs boiler supply A record of the service history is also available for onscreen access 2 4 3 Advanced Setup This access level is set for the sole use of factory representatives and is permanentl...

Страница 25: ...e fan starts and automatically adjusts to a level suitable for ignition Ten seconds later the pump starts After a total of 15 seconds the ignition cycle begins Interpurge The boiler enters an interpur...

Страница 26: ...BH minimum input rating The following default differentials are automatically applied upon initial load characterization DHW and other SetPoint loads 20 F space heating with Outdoor Reset invoked 11 F...

Страница 27: ...ch of up to 3 loads over time Multiple heating loads with varying temperature targets are run sequentially as opposed to simultaneously with a mixing valve The objective is to serve each load at the m...

Страница 28: ...or a tekmar 070 or similar sensor is shipped with each boiler to be placed in an appropriate outdoor position The temperature management algorithm flexes the boiler supply temperature according to cha...

Страница 29: ...n procedure 2 6 3 Variable Speed Pumping One strategy to optimize combustion efficiency across the boiler s wide throttle range is to use a variable speed system primary pump This will better match wa...

Страница 30: ...d will drop both the circulating water and the indoor setpoint temperature parameters to 50 F Set Point controlled loads are not adjusted through this process to avoid the potential for boiler cycling...

Страница 31: ...and Differential temperature values 2 7 SET UP LOAD DEFINITION After the boiler is powered up the installer can use the keypad and display to characterize the application as follows 1 In the Standby m...

Страница 32: ...Mass Radiant Baseboard Air Handler etc An appropriate reset curve is called up through this procedure Reset loads carry a default value for Design Outdoor Temp of 10 F 23 C Raise or lower this as appr...

Страница 33: ...st be input they are not automatically assigned as done within some boiler controls Ensure the Maximum takes account of the construction and safety requirements of each application e g 140 F max for t...

Страница 34: ...as 29 as rounded to the nearest hundred 16 Two lines below Altitude adjustment is the field for amendment of the primary pump heat purge time To shorten the 5 minute post firing period reduce the 300...

Страница 35: ...an to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2...

Страница 36: ...GAS VALVE ADJUSTMENT The VFC modulating boilers are factory calibrated to operate with natural gas or propane if so ordered at sea level The relevant valve adjustment screws have been factory sealed u...

Страница 37: ...fire level 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 Fig 12 9 to o...

Страница 38: ...n if burner requires cleaning every year In alternate years visually inspect burner through sight glass Ensure flame is stable and without excessive fluttering Normal flame pattern is evenly distribut...

Страница 39: ...the bottom 10 of the throttle range e g between 15 000 to 27 500 Btu hr Where a load is heavily weighted to the lowest firing rate and the cycles day count is in excess of 96 day there may be insuffic...

Страница 40: ...dels Care should be taken to identify which fan type is needed Gas Valve Type 12 Dungs GB WND 055 D01 S22 Function zero governor gas valve provides strict gas air mixture control over the range 15 150...

Страница 41: ...to adjust output according to water temperature Installation use 1 4 nutdriver to loosen ring clamp Install with back curve toward pipe using Honeywell Tradeline 107408 Heat Conductive Compound and re...

Страница 42: ...a number of diagnostic features incorporated in the software that evaluate system integrity display error conditions and provide initial suggested remedial actions Section 2 6 6 Error Mode In additio...

Страница 43: ...ector at the front of the fan This connector feeds a PWM control signal black wire from the controller and provides a tachometer signal white wire back from the fan Unplugging the connector will cause...

Страница 44: ...of the boiler pump will determine the movement of valid sensor values in general inlet pressure will increase while the outlet will decrease when the pump starts Check operation of both sensors by iso...

Страница 45: ...ove close to Required Pressure RP if FP only 120 150 vs RP of 250 or 300 then check for actual vent system blockage a disconnect intake within boiler case b open burner then fan gas valve looking for...

Страница 46: ...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 ignition lead or spark m...

Страница 47: ...operation Refer to manufacturer s instructions Check setting with ammeter Air in system or marginal water flow Bleed purge system as required Confirm adequate pump size and temp rise in HX Slow combu...

Страница 48: ...nect probe Blown fuse in ignition module Check fuse If blown replace Defective Control Module Check ignition output from control module ii Fan and or pump are off Display not illuminated No power to b...

Страница 49: ...n condensate drain Unit cycling on operating safety controls Check operation with Ohmmeter Voltmeter System radiation undersized Check manufacturer s rating tables for capacity per foot Temperature ex...

Страница 50: ...IBC Technologies Inc 50 VFC 15 150 and VFC 45 225 Intentionally Blank...

Страница 51: ...IBC Technologies Inc 51 VFC 15 150 and VFC 45 225 5 DIAGRAMS See Following Pages 5 1 Parts Diagrams 5 2 Wiring Diagrams 5 3 Sequence of Operations Flowchart...

Страница 52: ...enwal 17 Diff Air Press Sensor 17 H401 18 8 Rob n Screw Fenwal 2 18 fas Fen 19 Control Corner Cover 19 CCC 20 6 32 x 0 375 screws 2 20 fas 632 3 8 21 24VAC Transformer 40 VA 21 transform 22 a No longe...

Страница 53: ...2 54A PVC 90 54 b Trap PVC elbw 90 2 54B PVC 90 55 a Trap pipe PVC x 2 2 55A PVC x 2 55 b Trap pipe PVC x 2 2 55B PVC x 2 56 a PVC union clean out 56A union 56 b PVC union clean out 56B union 57 a Tra...

Страница 54: ...IBC Technologies Inc 54 VFC 15 150 and VFC 45 225 5 2 Wiring Diagram Wiring Diagram for VFC 15 150 and VFC 45 225 Modulating Boilers...

Страница 55: ...IBC Technologies Inc 55 VFC 15 150 and VFC 45 225 5 3 Sequence of Operations Flowchart...

Страница 56: ...IBC Technologies Inc 56 VFC 15 150 and VFC 45 225 Intentionally Blank...

Страница 57: ...lures resulting from abuse accident negligence freezing or acts of God d Damage caused by hard water scale build up excessive oxygenation or external leakage 2 The Phase 2 Warranty excludes all of the...

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