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INSTALLATION AND OPERATION INSTRUCTIONS

1-28

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

1.8.2 Power Quality and Electrical Protection

In areas of unreliable power, appropriate surge protectors and or power 

conditioning equipment should be installed in powers supply wiring circuits.

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. Disconnect the 120 Vac leads connected to PV-L/PV-N 

and cap off. 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 4 loads are provided as marked on the 

lower 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. Most power stealing 

thermostats can be connected directly to the Therm terminals. 

See Touch Screen 

Controller Manual section 2.1.1 for more detailed instructions.

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. 1,2,3,4 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. 

NOTE:

 Sensors connected to any sensor input contacts must be of NTC 

Thermister - type with a resistance of 10,000 ohms at 25°C and β = 3892. We do 

not recommend using 3rd party supplied sensors. Compatible water temperature 

sensors and outdoor sensors can be supplied by your IBC distributor.

NOTE

The IBC Touch-Screen 

controller has the ability 

to connect to most power 

stealing thermostats. See the 

Wiring Diagram for details.

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: ...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 building Immediately call your gas supplier from a nearby phone Follow th...

Страница 2: ...items 1 x Vent connection kit 1 x Condensate trap kit 1 x 30 psig pressure relief valve 1 x Outdoor temperature sensor WARNING If the information in this manual is not followed exactly a fire or expl...

Страница 3: ...80 Minimum water pressure psig 8 8 Normal flue temperature 100 F boiler return water temperature high fire 100 to 105 F 37 8 to 40 5 C 100 to 105 F 37 8 to 40 5 C Normal flue temperature 160 F boiler...

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

Страница 5: ...AND COMMISSIONING 3 1 3 1 LIGHTING AND SHUTTING DOWN THE BOILER 3 1 3 2 PRIOR TO START UP 3 2 3 3 COMMISSIONING 3 2 3 4 FUEL CONVERSION 3 5 4 0 MAINTENANCE 4 1 4 1 BOILER MAINTENANCE 4 1 4 2 COMPONENT...

Страница 6: ...ing boiler should be assessed 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 corr...

Страница 7: ...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 find a su...

Страница 8: ...Similarly ensure any direct vent air source is not adjacent to a clothes dryer exhaust terminal Avoid agricultural applications where the boiler and or the intake air source are affected by ammonia an...

Страница 9: ...elow and the code requirements the more stringent shall apply IMPORTANT When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper v...

Страница 10: ...e boiler s air intake from outdoors see Section 1 4 for air intake piping requirements Using the indoor air alternative air for combustion is drawn from the indoor air surrounding the boiler Provided...

Страница 11: ...lied fittings shall be considered part of the exhaust and installed near the base of the boiler see Figure 2 for PPs use IBC s VFC PPs transition kit as appropriate for the chosen PPs system CENTROTHE...

Страница 12: ...Unused intake travel cannot be added to the exhaust Unequal intake and exhaust piping is allowed see Section 1 4 8 Exhaust venting must slope down towards the boiler with a pitch of at least 1 4 per...

Страница 13: ...st be liquid and pressure tight Prior to firing the boiler and before any of the venting run is concealed by the building construction the installer must test the exhaust joints under fan pressure wit...

Страница 14: ...g Leave unglued and hold in place with a short nipple This permits easy access for cleaning For roof top venting of multiple boiler sets group all intake terminals together for a common penetration th...

Страница 15: ...ipe reduction of 3 pipe to 2 is permitted for a maximum lineal travel of 3 including 2 x 90 elbows on each side This allows for smaller wall penetrations with sufficient travel allowance to achieve th...

Страница 16: ...ator assembly 3 0 91m within a height of 15 4 6m above the meter regulator Clearance to service regulator vent outlet 3 0 91m Clearance to non mechanical air supply inlet to building or the combustion...

Страница 17: ...dule 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 It is not permitted to add to the exha...

Страница 18: ...fer 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 Ai...

Страница 19: ...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 when...

Страница 20: ...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 21: ...rap in the location shown below Do not place the drain connection tee directly at the base of the boiler 1 5 1 2 WITH PPS VENTING SYSTEMS For connection to PPS venting systems an IBC VFC PPs transitio...

Страница 22: ...LATION AND OPERATION INSTRUCTIONS 1 16 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS Figure 17 Condensate trap installation PPs Figure 18 IBC Kit P 166A for Centrotherm PPs with Centrotherm clips IBC 1...

Страница 23: ...venting system upward from the PPs Exhaust Adaptor securing the venting in accordance with that supplier s installation instructions and local code e g to the wall and amongst all the system parts us...

Страница 24: ...trap is applied to secure the trap against blow off on PPs systems 1 5 3 Further installation details Condensate drain must be piped to within 1 of a drain or be connected to a condensate pump Drainag...

Страница 25: ...CAUTION When a condensate neutralization package is installed the pH of the condensate discharge must be measured on a regular schedule to ensure the neutralizing agent is active and effective Figure...

Страница 26: ...fill from the 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 s...

Страница 27: ...re there is a boiler protection throttle fence limiting the T to 40 F WARNING Close fill valve after any addition of water to the system to reduce risk of water escapement NOTE Full sized application...

Страница 28: ...r WARNING Water quality has a significant impact on the lifetime and performance of an IBC Boiler heat exchanger Improperly prepared water in a heating circuit may cause damage to the heat exchanger t...

Страница 29: ...hermal loads presented in a typical multi zoned radiation system However where individual zones in a heating system have loads under 5 000 Btu hr the system will still benefit through use of a buffer...

Страница 30: ...ap off on simultaneously provided the pre set maximum allowable temperature of the new load is not exceeded In the case of the typical maximum limit for a radiant floor most would enter 140 F the floo...

Страница 31: ...reverse flow To ensure adequate water flow through the boiler under high head single zone space heating conditions a pressure activated bypass or other means of bypass must be used on any load where t...

Страница 32: ...he 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 boiler and its gas piping shall be leak tested before...

Страница 33: ...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 sh...

Страница 34: ...e 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 He...

Страница 35: ...not applicable with the VFC modulating series boilers In the case of a single temperature heat load where zone valves are used to manage individual thermostatically controlled zones each room thermost...

Страница 36: ...INSTALLATION AND OPERATION INSTRUCTIONS 1 30 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 37: ...up configuration back up and cloning using SD card or USB stick Superior warning messages while setting up the control Advanced Error messages with visual display on the Home Screen Internet LAN conne...

Страница 38: ...nd a boarder surrounding the active area At the bottom of the display there is space reserved for the boiler status bar Prior to any interaction with the touch screen the display will be showing the H...

Страница 39: ...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 40: ...calibrated to operate with natural gas or propane if so ordered at sea level The relevant valve adjustment screws have been factory sealed using Loctite thread lock compound which can be broken where...

Страница 41: ...el 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 Figure 32 A to obtain...

Страница 42: ...INSTALLATION AND OPERATION INSTRUCTIONS 3 4 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS Figure 32 Gas Valve and Pressure Reference System...

Страница 43: ...e the fuel conversion instructions supplied with the fuel conversion kit are read understood and followed carefully 3 Carefully follow the procedures on page 3 of the relevant Fuel Conversion Instruct...

Страница 44: ...INSTALLATION AND OPERATION INSTRUCTIONS 3 6 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 45: ...2 5 years Consider adding air filtration if burner requires cleaning every year In alternate years visually inspect burner through sight glass Ensure flame is stable and without excessive fluttering N...

Страница 46: ...ses sharply consider replacement of expansion tank Check also for noise at high fire which may signal water quality problems Check water piping for damage or leaks and repair as needed Water chemistry...

Страница 47: ...uid must be replaced It is highly recommended that a system pressurization unit such as an Axiom Industries model MF200 be employed to refill and pressurize your system Capture the discharged fluid in...

Страница 48: ...alve for improved access mark and remove 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 contr...

Страница 49: ...rature Sensors PART TYPE IBC 240 006 Thermistor 10 000 with Beta 3892 FUNCTION Senses water temperature Signals controller to adjust output according to water temperature INSTALLATION see Diagram 6 1...

Страница 50: ...dle nose pliers and or fingers This task is best done using a 9 tee handle hex key For the VFC 45 225 remove the 4 bolts and nuts at the FC Fan interface using a 5 16 wrench for the bolts and 3 8 wren...

Страница 51: ...ecific precautions for silica dust management then pry up the material likely in several pieces Bag with care to seal off and dispose RE ASSEMBLY 1 Inspect the inner refractory disk replace as appropr...

Страница 52: ...HX and lid for temperature for good thermal sealing at the refractory to lid interface Allow 20 mins prior running at high fire before the test max target is 110 C 14 Check for gas or fume leaks afte...

Страница 53: ...ion Problems 5 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 diagra...

Страница 54: ...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 bi...

Страница 55: ...other while the boiler is in operation If the required pressure is higher than the actual pressure there are several possible causes Exhaust and or Air Intake piping installed longer that allowed Imp...

Страница 56: ...rols module provides a single flash at the start of each Purge and Interpurge cycle continuous rapid flashes during the 4 second spark interval solid illumination following successful ignition until b...

Страница 57: ...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 and refill condensate...

Страница 58: ...tween blue and 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 un...

Страница 59: ...use 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 NOT ILLUMINATED...

Страница 60: ...h ammeter Air in system 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 per Tabel 8 Dirty bur...

Страница 61: ...ck CO2 level Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain Unit cycling on operating safety controls Check operation with...

Страница 62: ...s in 1 hour safety lockout Reset safety device and cycle boiler power off and on to reset error DHW TAKING TOO LONG TO HEAT Sensor may be under reading actual water temp Check sensor engagement note w...

Страница 63: ...DIAGRAMS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 0 DIAGRAMS 6 1 VFC 15 150 PARTS DIAGRAMS 6 2 VFC 45 225 PARTS DIAGRAMS 6 3 ADDITIONAL PARTS DIAGRAMS 6 4 WIRING DIAGRAMS 6 5 SEQUENCE OF OPERAT...

Страница 64: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 2 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 1 VFC 15 150 PARTS DIAGRAM Diagram 6 1 1 Boiler Assembly VFC 15 150...

Страница 65: ...R INTAKE COVER 180 018 1 40 GAS VALVE 180 022 1 45 SPACER 8 1 8 THICK 1 4 O D 150 092 3 50 SCREW M4 x 30 TAPPING EQUIPPED w 180 022 3 55 SCREW 10 32 x 7 8 HEX HEAD 150 110 4 61 GASKET FAN FAN COUPLER...

Страница 66: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 4 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 2 VFC 45 225 PARTS DIAGRAM Diagram 6 2 1 Boiler Assembly VFC 45 225...

Страница 67: ...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 3 8 150 014 6 135 CHASSIS CONTROLLER PCB 250...

Страница 68: ...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 69: ...6 7 DIAGRAMS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 4 WIRING DIAGRAMS Diagram 6 4 1 Ladder wiring diagram...

Страница 70: ...INSTALLATION AND OPERATION INSTRUCTIONS 6 8 VFC 15 150 VFC 45 225 MODULATING GAS BOILERS Diagram 6 4 2 Internal wiring diagram...

Страница 71: ...6 9 DIAGRAMS VFC 15 150 VFC 45 225 MODULATING GAS BOILERS 6 5 SEQUENCE OF OPERATION Diagram 6 5 1 Sequence of operation diagram...

Страница 72: ...g Instructions Leak testing completed gas piping venting system Fan and combustion components System Cleaned and Flushed type of cleaner used ________________________________________________ System Fi...

Страница 73: ...uration Load 2 _____________________________________________________________________________________________ Load Definition Load 3 ____________________________________________________________________...

Страница 74: ...SERVICE RECORD DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE...

Страница 75: ...NOTES...

Страница 76: ...NOTES...

Страница 77: ...NOTES...

Страница 78: ...RIDE 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...

Страница 79: ...SL variant added with new NRG 137 fan warranty removed to separate document R4 SEPTEMBER 2012 Polypropylene venting detachable lid heat exchanger and US Energy Act disclosures added VFC 45 225 SL desi...

Страница 80: ...IBC Technologies Inc 8015 North Fraser Way Burnaby BC Canada V5J 5M8 Tel 604 877 0277 Fax 604 877 0295 www ibcboiler com 120 100E A R6 May 2015 IBC Technologies Inc 2015...

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