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7.3.3 Replacing the burner

Warning

The IBC heat exchanger has a small amount of combustion chamber insulation
(refractory), which contains ceramic fibers.

When exposed to extremely high temperatures, the ceramic fibers that contain crystalline
silica can be converted into cristobalite, classified as a possible human carcinogen.

Avoid disturbing or damaging the refractory. If damage occurs, contact the factory for
directions.

Avoid breathing and contact with skin and eyes and follow these precautions:

1. For conditions of frequent use or heavy exposure, respirator protection is required.

Refer to the “NIOSH Guide to the Selection and Use of Particulate Respirators
Certified under 42 CFR 84” for selection and use of respirators certified by
NIOSH.

For the most current information, 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 soap and water after contact.

5. Wash potentially contaminated clothes separately from other laundry and rinse

washing machine thoroughly.

6. Discard used insulation in an air tight plastic bag.

NIOSH stated first aid:

Eye contact - Irrigate and wash immediately.

Breathing - Provide fresh air.

1. Turn off the electric power and gas supply to the boiler.

2. Remove the front cover, and then remove the boiler's top panel by removing the four Torx

head screws on the top panel of the boiler.

Warning

Wear a suitable protective mask to avoid ingesting particles from the refractory.

3. Remove the electrical connection from the gas valve.

4. Undo the union nut at the gas valve outlet.

5. Carefully remove the O-ring and orifice for re-installation later.

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Section: Service and maintenance

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Содержание IBGFSW1-0110

Страница 1: ...e 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 electrical switch do not use any phone in your building Immediately call your gas supplier from a nearby phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire dep...

Страница 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 so as to remove all dissolved solids Other water chemistry allowable limits are as follows Acidity pH is to be between 6 6 and 8 5 Chloride is to be less than 125 mg l Iron is to be less than 0 3 mg ...

Страница 3: ...ult 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 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 at a location external to the appliance Danger...

Страница 4: ...or 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 installed so that electrical components are not exposed to water during operation Known contaminants Known Corrosive Contaminants to Avoid Cements and glues Refrigerant leaks from cracks in coils Pain...

Страница 5: ...de 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 intake pipes 19 3 6 Installation clearances 20 3 7 Exhaust venting and air intake 20 3 7 1 Venting code 21 3 7 2 Venting options 21 3 7 3 Exhaust vent material 21 3 7 4 Direct vent 22 3 7 5 Rooftop vent t...

Страница 6: ...ntroller 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 operation 61 6 1 Lighting and shutting down the boiler 61 6 2 Testing the ignition safety shutoff 62 6 3 Commissioning 62 6 3 1 Checking a boiler s fuel source 63 6 3 2 Performing a fuel conversion 63 6 3 ...

Страница 7: ...6 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 Low Water Cut off error 90 8 2 4 Aux Interlock 1 or 2 90 8 3 Miscellaneous touchscreen controller errors 91 8 3 1 Ignition issues 92 8 3 2 Temperature issues 93 8 3 3 Miscellaneous issues 94 8 3 4 Cyc...

Страница 8: ...Intentionally left empty ...

Страница 9: ...0 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 ΔT supply return electronic fence F C 40 22 2 40 22 2 40 22 2 Max water temperature lockout limit F C 201 94 201 94 201 94 Power use 120Vac 60Hz full fire Watts without pumps 90 79 90 Weight empty lbs Kg 67 30 4 7...

Страница 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 dimensions Figure 1 Frontal view VX 110 Figure 2 Side view VX 110 6 Section Specifications ...

Страница 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 ...

Страница 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 ...

Страница 13: ...connection 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 Supply Water Inlet hot water 1 NPT M E Condensate Outlet Hose F Gas Inlet NPT F Table 1 Connections 9 Connection specifications ...

Страница 14: ...Intentionally left empty ...

Страница 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 Easy to use touchscreen ...

Страница 16: ...he 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 year warranty on the heat exchanger and a 2 year warranty on all parts against defects in materials or workmanship and failures due to thermal shock To view the full warranty statement for the VX se...

Страница 17: ...ult 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 appliance from drywall dust or other construction related contaminants Draw combustion air from a clean source e g outdoors and isolate the boiler from interior dust sources Do not seal boiler case openi...

Страница 18: ...team 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 measures must be taken to prevent corrosion damage to metal roofs or other metal building components in contact with the condensate Keep exhaust plumes well away from all building air intakes including...

Страница 19: ...rs 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 venting system the common venting system may be too large for proper venting of the appliances that remain connected to it When resizing any portion of the common venting system use the minimum size a...

Страница 20: ...ned 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 than 90 relative humidity Danger Do not common vent appliances with other existing appliances or with a new appliance Warnings Keep the area around a boiler clear of combustible materials gasoline and...

Страница 21: ...eep 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 requirements for combustible materials see Table 3 For adequate servicing we recommend a minimum 24 clearance at the front and 6 above the boiler Check local codes for additional access and service clearanc...

Страница 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 part of the boiler to the wall with two field supplied bolts 18 Section Installation ...

Страница 23: ...n 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 further The pipe must be secured with the built in clamp Warning Ensure that you lubricate the gasket with silicone grease before inserting the venting material Fully insert the approved venting mat...

Страница 24: ...p 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 will typically be required to accommodate associated water and gas piping 3 7 Exhaust venting and air intake Warning Venting condensate drainage and combustion air systems for all IBC boilers must be...

Страница 25: ...ndoor 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 otherwise unused chimney as a vent raceway 3 7 3 Exhaust vent material Warnings Condensate can cause corrosion of metal roofing components and other roofing materials Check with the builder or roofing con...

Страница 26: ...rial 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 vent Direct vent is a two pipe system that draws combustion air air intake from outdoors and discharges exhaust gases to the outdoors Ensure that adequate separation is maintained between the air int...

Страница 27: ...ter 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 venting installation Exhaust venting must slope down towards the boiler with a pitch of at least per foot PP vent follow PP manufacturer requirements for slope so condensate runs back towards the tra...

Страница 28: ...sate 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 local jurisdiction on the minimum initial length of pipe that should be exposed or accessible for inspection Follow the local codes for pipe clearances no IBC requirements Ensure that piping is liquid a...

Страница 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 piping particularly for horizontal runs follow local code Example of equivalent length calculations for a VX 110 A VX 110 can be sited up to 100 feet actual vent length allowance from the vent terminat...

Страница 30: ...t 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 permits easy access for cleaning Do not exhaust vent into a common venting system b For rooftop direct vent systems Rooftop two pipe direct vent configurations including typical clearance requirements...

Страница 31: ...ion 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 Alternatively place close together using commonly available pipe flashing Similarly group the exhaust pipes and place the two separate groups of pipes at least 3 apart the closest intake and exhaust pipes must ...

Страница 32: ...mination 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 examined carefully Take action to avoid moisture entering building structures Serious structural damage may occur if adequate precautions and clearances are not considered These precautions apply to neigh...

Страница 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 within 3 ft 91 cm horizontally of the vertical center line of the regulator vent outlet to a maximum vertical distance of 15 ft 4 5 m 1In accordance with the current CAN CSA B149 Installation Codes 2If l...

Страница 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 are re ingested with combustion air Damage to the boiler can result from a failure to maintain these separations Third party vent termination kits and concentric wall penetration kits that do not maint...

Страница 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 protected from wind loads see Figure 20 Figure 21 and Figure 22 Recommend the use of a bird screen of stainless steel or plastic mesh IPEX System 636 drain grate to guard against foreign objects Caution Refe...

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

Страница 37: ...um 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 installed below the intake The vent cap must be installed with the openings directed up and down see Figure 25 and not side to side Figure 25 Allowed SST installation orientations The SST vent air connection...

Страница 38: ...nals 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 Caution Take care installing Concentric Side Wall Termination kits when the outdoor temperature drops below 5 F 15 C Possible blockage of the combustion air intake can occur when the outdoor tempera...

Страница 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 boiler room For indoor air installation check air intake and boiler room combustion air opening s to ensure they are clear of obstructions Figure 30 Indoor combustion air intake 35 3 7 7 Indoor air com...

Страница 40: ...ance 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 may be installed IBC supplied air intake filters have a known pressure drop and fouling factor and should be used as a component of the combustion air system according to the allowable intake length in...

Страница 41: ...e 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 death Ensure the supplied trap is correctly installed and filled with water When required add and maintain in good condition a neutralization tank For information on installing a condensate neutralizer...

Страница 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 tighten upper union nut 38 Section Installation ...

Страница 43: ...lding 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 on a regular schedule to ensure the neutralizing agent is active and effective Danger The water in the condensate neutralizer can cause severe burns to the skin Wear protective gloves and eye wear wh...

Страница 44: ...ntering 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 appliance Free flow of condensate from venting systems and the pressure vessel must be maintained at all times Trap and condensate drain piping must be accessible to allow regular inspection and clean...

Страница 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 water fills will increase the potential for damage High levels of dissolved solids or minerals may precipitate out of the fluid onto the hottest part of the heat exchanger impairing heat transfer an...

Страница 46: ...cy 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 for up to 5 minutes 300 seconds after burner shutdown Secondary pumps can be set to run up to 15 minutes after burner shutdown for the last calling load As shipped the default settings will run the...

Страница 47: ...e 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 valve fitting on top of the boiler Relief valve discharge piping must terminate between 6 15 cm and 12 30 cm above the floor or per local code Warning During operation the relief valve may discharge l...

Страница 48: ...t 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 which provide detail on specific single and multiple boiler applications available in IBC s Technical portal There are many necessary components not shown and details such as thermal traps are left out s...

Страница 49: ...perature 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 drop between Fill station with isolation valve closed or fill tank Boiler primary pump To from load Dirt separator recommended Figure 33 Boiler trim options single boiler 45 3 11 2 System piping ...

Страница 50: ...urization 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 these devices Do not place any water connections above the boiler to avoid damage to the fan and controls If needed create a shield over the top of the cover but allow clearance for airflow and service ac...

Страница 51: ...ameter 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 secondary piping with simultaneous heating calls 47 3 11 2 System piping ...

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

Страница 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 loads Returns to loads Boiler primary pump Figure 37 Primary Secondary piping concept with hydraulic separator 49 3 11 2 System piping ...

Страница 54: ...ng 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 upstream of the first tee and a minimum of four pipe diameters of straight piping downstream of the second tee Return from heating system Figure 38 Multiple boiler piping 50 Section Installation ...

Страница 55: ...ll 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 gas or propane during high fire operation For either fuel the inlet pressure shall be no greater than 14 0 w c Confirm this pressure range is available with your local gas supplier The inlet gas conne...

Страница 56: ...as 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 placed into operation The gas valve is provided with pressure taps to measure gas pressure upstream supply pressure and downstream manifold pressure of the gas valve Note that manifold pressure varies sl...

Страница 57: ...to 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 computer where you do not just pull the plug when done 3 13 2 120VAC line voltage hook up Line voltage wiring is done within the field wiring box see Wiring diagrams on page 97 Connect the boiler to the g...

Страница 58: ...he 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 the pump s Black wire to the Yellow of this pair switched Hot The White Yellow pair should be individually capped if the primary pump does not obtain its power from this pair e g if a variable speed pr...

Страница 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 maximum and minimum boiler supply temperatures Note Sensors connected to any sensor input contacts must be of the NTC Thermister type with a resistance of 10 000 ohms at 77 F 25 C and β 3892 We do not ...

Страница 60: ...ir 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 Therm contacts draw no power so an anticipator setting for the thermostat is not applicable with these appliances In the case of a single temperature heat load where zone valves are used to manage indiv...

Страница 61: ...simultaneous 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 Some of the new features available in the touchscreen control include Setup Menu for simple quick programming Portal connectivity for remote monitoring and programming Superior warning messages while...

Страница 62: ...ls 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 details of the current boiler status If the controller has been left on the Home screen long enough user adjustable 10 minutes by default the display dims to save power The control automatically ret...

Страница 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 of the appliance is completed and before operating the appliance it is important to review the following checklist of precautions 5 1 1 Checklist for electrical conditions ducting and water connectio...

Страница 64: ...let 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 and leak free All piping flushed to ensure all air is removed Check valve is installed and the external pump is flowing in the correct direction Checking venting connections Check All connections are p...

Страница 65: ...equence 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 lighting and shutting down procedure Tested the ignition safety shutoff function see Testing the ignition safety shutoff on page 62 Checked the appliance s fuel source and if necessary performed a fuel ...

Страница 66: ...iler 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 information is displayed on the controller 3 The error is displayed after testing the ignition safety shutoff 4 To restart the boiler reset the power or on the touchscreen controller tap Clear Errors Yes 6 3 C...

Страница 67: ...configured 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 the required conversion kit The touchscreen controller will automatically detect the installation s altitude and make the appropriate adjustments to operate the boiler up to 4 500 feet in elevation w...

Страница 68: ...d 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 combustion test see instructions below 14 When the boiler is running use an approved leak detection solution to soap test all joints 15 Place conversion labels associated with the new fuel onto the boiler...

Страница 69: ...inlet 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 the gas valve ...

Страница 70: ...sure 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 pressure Ensure that you have a load configured reset heating set point or DHW This load should be large enough to allow the boiler to operate at high fire for over 10 minutes The gas pressure for natural ...

Страница 71: ...st 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 screwdriver Turn the screwdriver clockwise no more than a maximum of one full rotation at a time to raise the CO2 to richen Turn counter clockwise no more than a maximum of one full rotation at a time t...

Страница 72: ...e 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 function The low water cutoff LWCO function provides continuous protection against low water in the boiler If the SIM detects low water the boiler enters a lockout state Perform the test to ensure that t...

Страница 73: ...perature 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 Supply Temp value is 180 F enter 170 F in the Cut Off Temp box 2 In the Cut Off Temp field enter a number value OK The message Hi Limit Detected is displayed 3 To reset the boiler select the Reset button ...

Страница 74: ...Intentionally left empty ...

Страница 75: ...t 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 disconnection when servicing controls Wiring errors can cause improper and dangerous operation Maintenance Required Check Remove any obstructions e g leaves dust other debris from vent terminals Check and c...

Страница 76: ...densate 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 used check the pH level of condensate discharge Annually Burner Warning When removing the burner for inspection or boiler servicing examine the sealing gaskets and replace if damaged Upon re assembly ...

Страница 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 Δ T is reasonable for a given firing rate Annually Gas Piping Check for damage or leaks and repair as needed Annually Boiler treatment Check consistency of any boiler treatment used for appropriate mixture Chemical inhibitors are consumed over time lowering ...

Страница 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 location For environmental and toxicity reasons IBC recommends only using non toxic propylene glycol Annually Water Caution Installers should inquire of local water purveyors as to the suitability of their ...

Страница 79: ...body 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 fully open for at least 5 seconds to flush the valve seat free of sediment and debris Then release the lever and allow the valve to snap shut If the lever does not activate or if there is no sign of ...

Страница 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 valve must be turned on in order to recharge the lost fluid 7 3 Replacing the fan gas valve and burner This section documents the following maintenance procedures Replacing the fan Replacing the gas v...

Страница 81: ...s 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 fan gas valve and burner ...

Страница 82: ...ews 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 valve outlet tube away from the gas valve 8 To remove the fan unscrew the two bolts at the base of the fan and retain with the washers and fan gasket 9 Carefully lift and remove the fan from the boi...

Страница 83: ...rews 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 valve bracket Retain the gasket 7 Push the flexible pipe to the side 8 To remove the gas valve undo the union nut at the gas valve outlet 9 Carefully remove the O ring and orifice for re installation...

Страница 84: ...formation 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 soap and water after contact 5 Wash potentially contaminated clothes separately from other laundry and rinse washing machine thoroughly 6 Discard used insulation in an air tight plastic bag NIOSH stated...

Страница 85: ...the 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 port and heat exchanger studs are aligned correctly 17 Reinstall the ignitor gasket and ignitor with two screws 18 Re install the lid with burner and gasket refractory assembly Ensure that you tighten ...

Страница 86: ...ide 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 condensate trap Warning If condensate neutralization is used check the pH level of condensate before and after neutralization to verify effectiveness and ensure that the discharge has neutral pH levels Nev...

Страница 87: ...llow 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 trap downwards to remove 2 Unscrew the condensate union cap at the base of the trap empty the water and flush the trap with water 83 7 5 Cleaning the condensate trap ...

Страница 88: ...he 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 Section Service and maintenance ...

Страница 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 kΩ 5 000 000Ω at the controller end of the sensor lead To obtain a resistance reading remove power to the boiler For the supply water return water and vent temperature sensors remove the wire leads by disconnecting their respective M...

Страница 90: ...180 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 provides electronic commutating power to the fan motor coilers determining the fan speed and power usage 8 1 3 Water pressure sensor The water pressure sensor ensures that there is adequate pressure in...

Страница 91: ...e 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 SIM continuously communicates with the boiler s main controller reporting sensor readings and status The sensor readings and error status if any are displayed on the boiler controller s screen 8 1 4 1...

Страница 92: ...nsure 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 after a hi limit temperature lockout A boiler in a lockout condition due to a hi limit temperature error will need to be reset 1 Go to Clear Errors Yes 2 Check that there is no air trapped in the sy...

Страница 93: ...agnosis 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 recurs No spark when igniting Ignition probe flame sensor disconnected Check that ignition lead is secure at the control module and at the probe Manual gas shutoff is closed or gas line not fully purged...

Страница 94: ...ow 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 88 8 2 4 Aux Interlock 1 or 2 Aux Interlock 1 or 2 Issue Diagnosis Fix Interlock 1 or 2 terminals are open Jumper lead is loose or compromised Replace the jumper lead External safety is in an a...

Страница 95: ...r 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 exceeds operating limit Check water flow Defective or disconnected temperature sensor Check wiring to temperature sensor and control module Check temperature sensor Blank screen dark but fan running Indi...

Страница 96: ...el 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 system wiring Check air reference tubing Igniter probe flame sensor disconnected Reconnect probe Defective Control Module Check ignition output from control module Boiler will not attempt to ignite ...

Страница 97: ...level 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 Ohmmeter Voltmeter System radiation undersized Check manufacturer s rating tables for capacity per foot Temperature exceeds thermostat setting Incorrect anticipator setting Check with Ammeter Thermosta...

Страница 98: ...ions 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 reading actual water temp Check sensor engagement note well is 15 cm almost 6 inches deep and sensor must be fully set to back Check programmed settings boiler temp set too close to the required DHW tem...

Страница 99: ...s 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 water flow due to improper piping Refer to recommended piping for the respective boiler model Low water flow due to undersized pump Check manufacturer s rating charts check temperature differential acro...

Страница 100: ...Intentionally left empty ...

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

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

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

Страница 104: ...1506 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 Safety Ignition Module plus SIM 500 078 P 271 1 6 Front door cover VX 110 500 180 P 1508 1 100 Section Appendices ...

Страница 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 9059 1 101 Boiler part diagrams VX 110 VX 150 VX 199 ...

Страница 106: ...102 Section Appendices ...

Страница 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 110 255 151 P 1513 1 Refractory and gasket VX 150 255 152 P 1525 1 Refractory and gasket VX 199 255 153 P 1529 1 120 Rollout switch 240 030 P 9070 1 130 Gasket supply return pipe union 251 122 P 1522 2 140 Su...

Страница 108: ...199 170 123 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 251 143 P 1520 1 280 Fan gasket 250 627 P 1520 1 290 Fan 240 114 P 1520 1 300 Inlet gas line union gasket 150 271 P 1522 2 310 Gas line 190 212 P 1521 1 Gasket pack P 1522 Sold only with the P 1517 not s...

Страница 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 filled Condensate drain clear and free flowing Condensate Neutralization Ignition Safety Shutoff test completed Flame current reading High fire _____ µA Low fire _____ µA Owner advised and instructed i...

Страница 110: ...es 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 as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is ...

Страница 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 responsibility for changes made to the manual due to clerical errors to regulation changes or to product development April 2021 120 347E1 IBC Technologies Inc 2021 ...

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