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1-27

BOILER SYSTEMS AND OPERATION

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

1.8.2 Power quality and Electrical Protection

The control board (for all models) is protected using in-line field replaceable

fuses of 5 amp (slow-blow). the control circuit board is further protected using

on-board factory repairable fusing.
the principal exposures to electrical damage:- (a) when wiring of pumps to the

boiler’s pump terminals, avoid screwdriver contact with the metal control cover;

(b) avoid water or solder spray onto fan motor circuitry.

1.8.3 Zone Valve Hook-up

if zone valves rather than pumps are used to manage multiple heating loads, then

24VaC for the zone valves should be provided to the power contacts on the Pump/

Zone Valve terminal Block. use a separate transformer – the 40Va unit inside the

wiring box is for internal systems only. the individual load/zone valves are then to

be wired to their associated contacts on the secondary pump/zone valve connector.

do not confuse such “load/zone valves” with similar valves used to segregate a

single load type (e.g. those used on a zoned radiant floor) – see next section.

1.8.4 Thermostat / Sensor Wiring

dry contacts for thermostats for each of 3 loads are provided as marked on the

lower / orange connector strip (e.g. “therm 1”). gang lines from a multiple-zoned

load (e.g. off the end-switches for each radiant floor zone) to present a common

thermostat signal to the controller. Ensure there are no disturbing influences

on the call-for-heat lines - e.g. no coils to switch an air handler motor. Where

these zone valves are of a non-isolated 3-wire configuration, the zone valve end

contacts must be isolated from the load’s controller thermostat terminal using an

appropriate relay. required input for enabling the iBC boiler is a dry / mechanical

contact; ensure that triac or other parasitically-powered units are not used.

1.8.5 Other Wiring

other optional low voltage connections to the control board include:

•

two 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 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 thermister for outdoor reset sensing is supplied with the

boiler, to encourage use of this temperature compensating space heating

technique for improved comfort and combustion efficiency.

•

one pair for a dHW tank sensor. Connect to “dHW s” (not the respective

therm. 1,2,3 location) and the boiler will automatically notice and go to a

smart dHW routine

•

one pair of contacts for remote secondary loop temperature control.

•

one pair (marked Boilernet) for network connection – this is used for

connecting multiple VFC modulating units for autonomous staging. see

separate

Technical Memo

for guidance.

•

A final pair of contacts, to receive 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. user must enter maximum and minimum boiler

supply temperatures.

Terminal Strip for:

• Thermostat/switch Inputs

• Sensor inputs

• Auxiliary Interlocks

• Network Wiring

• External Control Signal

NOTE

The IBC control only

recognizes a true dry contact

closure as a call for heat on

terminals “Therm. 1, Therm. 2

or Term. 3. Thermostats and

other devices that use a “Triac”

output cannot be used as a call

for heat without the installation

of an intervening relay with dry

contacts to connect to the IBC

terminal strip.

NOTE

The IBC boiler (like any

modern appliance that

contains electronic

equipment), must have a

“clean” power supply, and is

susceptible to power surges

and spikes, lightning strikes

and other forms of severe

electrical “noise”. Power

conditioning equipment

(surge protectors, APC or

UPS devices) may be required

in areas where power quality

is suspect.

DANGER

Do not connect thermistor

sensors to “Therm” terminals.

An overheating hazard can

result in serious personal

injury and/or property damage.

Содержание VFC 15-150

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

Страница 81: ...NOTES...

Страница 82: ...NOTES...

Страница 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...

Страница 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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