IBC Boilers VFC 15-150, VFC 45-225 Installation And Operating Instructions Manual

VFC 15-150, VFC 45-225

MODULATING GAS BOILERS

(Natural Gas or Propane)

WARNING: If the information in this manual is not followed exactly, a re or

explosion may result causing property damage, personal injury, or loss of life.

Do not store or use gasoline or other ammable vapours and liquids or other 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 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 re department.

Installation and service must be performed by a qualied installer, service

agency or the gas supplier.

This Manual is also available in French - contact IBC or visit our web site www.ibcboiler.com

INSTALLATION AND OPERATING INSTRUCTIONS

www.ibcboiler.com

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

SAFETY CONSIDERATIONS

WARNING

If the information in this manual is not followed

exactly, a re or explosion

may result causing property damage, personal injury, or loss of life.

Installation, start-up and servicing of IBC boilers must be done with due care and attention, and should only be performed by competent, qualied,

licensed and trained heating technicians.

Failure to read and comply with all instructions and applicable National and local codes may result in hazardous conditions that could result in property damage and injury to occupants which in extreme cases might result in death.

HAZARDS & PRECAUTIONS

DANGER

Points out an immediately hazardous situation which

must be avoided in order to prevent serious injury or

death.

CAUTION

WARNING

Points out a potentially hazardous situation which

must be avoided to prevent

serious injury or death.

NOTE

Points out a potentially hazardous situation which

must be avoided to prevent

possible moderate injury and/ or property damage

Points out installation, maintenance and operation details that will result in

enhanced efciency, longevity

and proper operation of your boiler.

BEST PRACTICES

Points out recommendations for better installation.

Supplied with the boiler - The IBC boiler is shipped with an accessory parts kit

consisting of the following items:

• 1 x Vent connection kit

• 1 x Condensate trap kit

• 1 x 30 psig pressure relief valve

• 1 x Outdoor temperature sensor

INSTALLATION AND OPERATION INSTRUCTIONS

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

SPECIFICATIONS

SPECIFICATION VFC 15-150 VFC 45-225

CSA Input (Natural Gas or Propane) - MBH

CSA Input (Natural Gas or Propane) - kW

CSA Output - MBH

CSA Output - kW

A.F.U.E. 95% 95%

Minimum gas supply pressure (Natural Gas or Propane) - inch w.c.

Maximum gas supply pressure (Natural Gas or Propane) - inch w.c.

Power use (120Vac/60Hz) @ full re - Watts (excluding pumps)

Weight (shipping) - lbs/Kg 165 / 75 168 / 76

Pressure vessel water content - USG/Litres 2.4 / 9 2.4 / 9

Maximum boiler ow rate - USgpm 16 25

Minimum boiler ow rate - USgpm 4 8

Maximum operating water pressure* - psig 80 80

Minimum water pressure - psig 8 8

Normal ue temperature @ 100°F boiler return water temperature - high re

15 - 150

4.4 - 44

14 - 139

4.1 - 41

57 167

100 to 105 °F

37.8 to 40.5°C

45 - 225

13 - 66

41 - 206

12 - 60

100 to 105 °F

37.8 to 40.5°C

Normal ue temperature @ 160°F boiler return water temperature - high re

Approved installation altitude - ASL 0 - 12,000’ 0 - 12,000’

Ambient temperature - Low (°F-°C) Ambient temperature - High (°F-°C)

Max. relative humidity (non-condensing) 90% 90%

Minimum water temp. 34°F / 1.1°C 34°F / 1.1°C

Maximum water temp. (electronic hi-limit) 190°F / 87.8°C 190°F / 87.8°C

Maximum water temp. (mechanical hi-limit) 200°F / 93.3°C 200°F / 93.3°C

Max. ΔT - supply/return (electronic fence) 40°F 40°F

Maximum equivalent vent length - 2”

Each side (Vent & Air Intake)) - 3”

(Natural Gas or Propane)

Air intake options: either direct vent or indoor

supply

* boilers are shipped with 30 psig pressure relief valve

160 to 165 °F

71.1 to 73.9°C

32°F / 0°C 122°F / 50°C

50’

120’

160 to 165 °F

71.1 to 73.9°C

32°F / 0°C 122°F / 50°C

N/A

240’

INSTALLATION AND OPERATION INSTRUCTIONS

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

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INSTALLATION AND OPERATION INSTRUCTIONS

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

CONTENTS

1.0 INSTALLATION....................................................1-1

1.1 GENERAL ...................................................1-1

1.2 CODE REQUIREMENTS ........................................1-2

1.3 LOCATION ...................................................1-2

1.4 EXHAUST VENTING AND AIR INTAKE.............................1-3

1.5 CONDENSATE REMOVAL......................................1-14

1.6 WATER PIPING ..............................................1-20

1.7 GAS PIPING.................................................1-26

1.8 ELECTRICAL CONNECTIONS ..................................1-27

2.0 IBC BOILER CONTROL.............................................2-1

2.1 GENERAL ...................................................2-1

2.2 CONTROL ...................................................2-1

2.3 CONTROL INTERFACE.........................................2-2

3.0 STARTUP 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 DESCRIPTION....................................4-4

4.3 GAINING ACCESS TO COMBUSTION CHAMBER, BURNER REMOVAL

INSTRUCTIONS; FAN AND GAS VALVE REMOVAL INSTRUCTIONS ....4-6

5.0 TROUBLESHOOTING ..............................................5-1

5.1 PRELIMINARY CHECKS ........................................5-1

5.2 ELECTRONIC COMPONENTS ...................................5-2

5.3 TROUBLESHOOTING GUIDE....................................5-6

6.0 DIAGRAMS.......................................................6-1

6.1 VFC 15-150 PARTS DIAGRAMS ..................................6-2

6.2 VFC 45-225 PARTS DIAGRAMS ..................................6-4

6.3 ADDITIONAL PARTS DIAGRAMS .................................6-6

6.4 WIRING DIAGRAMS ...........................................6-7

6.5 SEQUENCE OF OPERATIONS ...................................6-9

INSTALLATION AND OPERATION INSTRUCTIONS

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

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.

WARNING

Do not use this boiler if any part has been under water.

Immediately call a qualied service technician to inspect

the boiler and to replace any part of the control system and any gas control that has been under water.

CAUTION

Care must be taken to

properly size the boiler for its intended use. Prolonged

full re run time, over-

sizing or under-sizing,

and incorrect ow rates

through the boiler can lead to increased maintenance

costs, equipment stress and

premature failure.

WARNING

If the boiler can become

exposed to uid temperatures below 34°F (1°C), a method of protection to prevent freezing

of condensate should be

employed. Contact the factory

for further information.

The Installer must carefully read this manual to ensure that all installation details can be adhered to. Special attention is to be paid to clearances and access, vent travel and termination, gas supply, condensate removal and combustion air supply.

The Installer should do a pre-installation check the to ensure that the following precautions can be observed:

• The boiler should be installed in areas where the combustion air source is

not subject to chemical fouling or agricultural vapours. Exposure to corrosive

chemical fumes such as chlorinated and/or uorinated hydrocarbons can

reduce the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants,

aerosol propellants, dry-cleaning uids, de-greasers and paint-removers all

contain vapours which can form corrosive acid compounds when burned in a

gas ame. Airborne chlorides 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. 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 and/or dust.

• The boiler should be located where water leakage will not result in damage

to the area. If a location such as this cannot be found, a suitable drain pan should be installed under the appliance. The boiler is not to be installed above carpeting.

• At a new construction site, or during renovations, action must be taken to

protect the boiler from drywall dust or other construction related contaminants; combustion air should be drawn from a CLEAN source (e.g. outdoors) and the boiler should be isolated from interior dust sources. Do not seal boiler case

openings directly when ring - allow for air circulation and ventilation in the

immediate area.

• When the boiler is in 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 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 those of neighbouring properties.

• The exhaust outlet should be placed so as to reach 24” minimum above the

down-turned intake - to avoid exhaust re-ingestion.

• For sidewall venting options: Both the inlet and exhaust terminations should

normally be located on the same plane (side) of the building. The elevation of both pipes can be raised in “periscope style” after passing through the wall to gain required clearance above grade and snow level.

• If the indoor combustion air option is used, ensure combustion air openings to

the boiler room remain unblocked and free of obstructions.

• Examine the condensate outlet to ensure proper disposal of condensate will

occur during operation. If condensate will be discharged into copper or ferrous metal drains, ensure acid neutralization is employed.

• Ensure that the pressure relief valve will be installed with no valves or other

means of isolation between its inlet and the boiler. Make sure the relief valve outlet will be piped with unobstructed piping (minimum 3/4” diameter) to a safe discharge location.

INSTALLATION AND OPERATION INSTRUCTIONS

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

INSTALLATION1.0

1.1

GENERAL

VFC gas-red modulating boilers are low pressure, fully condensing units having

variable input ranges (a) 15 MBH (15,000 Btu/hr) to 150 MBH (15-150 model, 0 to 12,000’) and (b) 45 MBH to 225 MBH (45-225 model, 0 to 12,000’). The boilers are approved as “Category IV” vented appliances using either Direct Vent (sealed combustion) or indoor combustion air, providing a great degree of

installation exibility.

Figure 1 shows outer case dimensions and piping and electrical holes. Use this diagram to nd a suitable location for the boiler. See also Section 1.3 Location.

DESCRIPTION SIZE

A Water Outlet 1-1/4" NPT-M

B Water Inlet 1-1/4" NPT-M

C Gas Inlet 1/2" NPT-F

D Knock-outs (6) 1/2"

E Touch Screen Display 2-1/4” x 4”

F Exhaust Vent 4.0" Hole

G Combustion Air 4.0" Hole

Table 1: Connections

Figure 1a: Dimensions / Connections for VFC 15-150 Figure 1b: Dimensions / Connections for VFC 45-225

INSTALLATION

1-1

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

1.2

1.3

WARNING

Keep boiler area free and clear

of combustible materials,

gasoline, and other ammable vapours and liquids.

WARNING

Combustion air must not be

drawn from areas containing

corrosive air from swimming

pools or spas, including air directly next to outdoor pools and spas.

WARNING

The boiler shall not be exposed to water leaks from piping or components located overhead. This includes condensation

dropping from un-insulated

cold water lines overhead.

CODE REQUIREMENTS

The VFC 15-150 and VFC 45-225 boiler models were tested to and certied

under CSA 4.9-2014 / ANSI Z21.13-2014.

Installation must conform to local codes, or in the absence of these, with the latest editions of CAN/CGA B149.1 and the Canadian Electrical Code Part 1 CSA C22.2 No. 1.

In the US, installations must conform to the current National Fuel Gas Code ANSI Z223.1 and the National Electrical Code ANSI/NFPA 70. Where required by jurisdiction, installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. If there is any

conict, then the more stringent requirement will apply.

LOCATION

VFC-series boilers are designed and approved for indoor installation (wall or rack

mounting), with signicant exibility of location provided with the available venting

options. The boiler can be placed in an alcove, basement, closet or utility room. Surrounding ambient conditions shall be 0°C to 50°C and less than 90% relative

humidity.

Install the boiler in areas where the combustion air source is not subject to

chemical fouling or agricultural vapours. Exposure to corrosive chemical fumes such as chlorinated and/or uorinated hydrocarbons can reduce

the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants, aerosol

propellants, dry-cleaning uids, de-greasers and paint-removers all contain vapours which can form corrosive acid compounds when burned in a gas ame.

Airborne chlorides 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. 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 and/or dust.

Locate the boiler where water leakage will not result in damage to the area. If a location such as this cannot be found, a suitable drain pan should be installed under the appliance. The boiler is not to be installed above carpeting.

Boiler weight: 150 lbs / 68 kg without water. Use - as a minimum - 4 x #12 size 2" lag screws or 1/4" bolts (with metal mounting systems). Fasteners are to be attached to solid material capable of supporting the combined weight of the boiler and piping assembly components.

WARNING

Ensure the gas ignition system components are

protected from water (dripping, spraying, rain, etc.) during

appliance operation and when

servicing (pump replacement, condensate trap servicing, control replacement, etc.)

1-2

Other factors affecting potential mounting sites:

• Ensure minimum clearance requirements for combustible materials (see

• Minimum 24" clearance at the front and 10” above is recommended for

• At a new construction site, or during renovations, action must be taken

Table 2) are satised.

adequate servicing. Check local codes for additional access and service clearance requirements.

to protect the boiler from drywall dust or other construction related

contaminants; combustion air should be drawn from a CLEAN source (e.g. outdoors) and the boiler should be isolated from interior dust

INSTALLATION AND OPERATION INSTRUCTIONS

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

WARNING

Exposed water piping and associated components

(relief valves, circulators, etc.)

should not be in contact with

combustible materials. Check local codes for required clearances and/or provide adequate insulation.

1.4

sources. Do not seal boiler case openings directly when ring - allow for air circulation and ventilation in the immediate area.

DISTANCE FROM

SURFACE

Front 2" 24"

Rear 0" 0"

Left Side 0" 8" (for vent run)

Right Side 2" 18"

Top 6" 10"

Table 2 - Clearance from boiler cabinet

Distance below the boiler of up to 15" is required to provide clearance for the inlet and exhaust venting together with the required condensation trap. See page 1-15.

COMBUSTIBLE SURFACES

RECOMMENDED DISTANCE FOR SERVICE

EXHAUST VENTING AND AIR INTAKE

DANGER

Do not common vent the VFC

modulating series boilers with any other existing or new appliance.

WARNING

DO NOT MOUNT THIS BOILER TO HOLLOW WALL STRUCTURES - The

combined weight of the boiler, its water contents and associated piping

components can exceed 225

pounds. Fasteners must be rated for this strain, and must

be rmly anchored into solid

material that will support this weight.

Installers are to take all

necessary precautions

to avoid injury during the

installation of this boiler.

It is important to carefully plan the installation to ensure the appropriate

vent materials, travel and termination decisions are incorporated. Specic

attention is warranted to manage the impact of the steam plume normally experienced at the exhaust terminal of a condensing boiler. Generally,

intake and exhaust pipes should terminate at a rooftop or sterile wall location, to maximize customer satisfaction. Keep exhaust plumes well away from all building air intakes including those of neighbouring

properties.

All venting must be installed in accordance with the requirements of the jurisdiction having authority: in Canada, Part 8, Venting Systems of the B149.110 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 between the installation instructions below, 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 venting of the appliances remaining connected to it.

When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code, ANSI Z223.1 - latest edition. In Canada, use the B149.1-10 Installation Code.

At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

• Seal any unused opening in the common venting system.

• Visually inspect the venting system for proper size and horizontal pitch and

INSTALLATION

1-3

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

determine there is no blockage or restriction, leakage, corrosion and other

deciencies which could cause an unsafe condition.

• Insofar as is practical, close all building doors and windows and all doors

between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer

exhaust fan. Close replace dampers.

• Place in operation the appliance being inspected. Follow the lighting

instructions. Adjust thermostat so appliance will operate continuously.

• After it has been determined that each appliance remaining connected to the

common venting system properly vents when tested as outlined above, return

doors, windows, exhaust fans, replace dampers and any other gas-burning

appliance to their previous conditions of use.

• Any improper operation of the common venting 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 Installation Code and/or local codes.

WARNING

Venting, condensate

drainage, and combustion

air systems for all IBC

boilers must be installed in compliance with all applicable codes and the instructions of

their respective Installation Manuals.

Inspect nished vent and air

piping thoroughly to ensure all are airtight and comply

with the instructions provided and with all requirements of

applicable codes.

Failure to comply will result

in severe personal injury or

death.

WARNING

Covering non-metallic vent pipe and ttings with thermal

insulation shall be prohibited.

1.4.1 Applications

All VFC-series boilers are approved with alternative venting options: either 2-pipe

Direct Vent or single pipe /Indoor Air venting can be used offering exibility to meet the specic requirements of the installation. With the Direct Vent case,

combustion air is piped directly to the 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 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 upward using an existing - but otherwise unused - chimney as a vent raceway.

1.4.2 Exhaust Vent Material

EXHAUST VENT MATERIAL – CANADA

Use Polypropylene (PPs) or CPVC vent systems approved under ULC-S636 Standard for Type BH Gas Venting Systems, or stainless steel Type BH venting

systems. Permitted PPs materials comprise Single Wall Rigid pipe and ttings

and Flexible.

• ULC-S636 CPVC: 90°C (194°F)

• ULC-S636 PPs: 110°C (230°F)

In the standard conguration, VFC series boilers can supply water temperatures

up to 190°F, leaving stack temperatures above the 65°C (149°F) limit for ULC-S636 approved PVC.

For long vent runs with higher initial exhaust temperature, some jurisdictions may allow the use of mixed materials for economy: ULC-S636 approved CPVC for the initial run followed by ULC-S636 approved PVC to the termination (It is the responsibility of the Installer to conrm that local codes will allow this option). Ensure appropriate transition glue is used. The installer is responsible to ensure

1-4

INSTALLATION AND OPERATION INSTRUCTIONS

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

WARNING

Do not mix PPs venting

materials from different

Manufacturers.

These venting materials are

designed to be installed as part of a complete system.

Failure to comply may result

in severe personal injury or

death.

DANGER

Failure to install PPs adaptor with retainer clip could cause release of harmful exhaust gases into the heated space, potentially leading to injury or death.

that sufcient temperature loss is allowed for in the CPVC section to fall below

the limit for PVC, taking into account the highest possible ambient temperature in the area of vent travel (e.g. boiler room, attic and/or chase).

EXHAUST VENT MATERIAL – USA

IBC strongly recommends that only CPVC or PPs vent component systems approved under UL1738 (Standard for Venting Systems for Gas Burning

Appliances, Categories II, III and IV), ULC-S636 Standard for Type BH Gas Venting Systems, or stainless steel Type BH venting systems* are to be used,

but many local jurisdictions in the USA still allow the use of PVC (Sch. 40 ASTM

D1785 or D2665 and ttings) or CPVC (Sch. 40/ASTM F441 with Sch. 80 ttings).

Do not use ABS or any cellular core pipe for exhaust venting.

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in venting systems shall be prohibited.

The boiler offers 2" venting connections. 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 tting on the

bottom of the pressure vessel using:

• For CPVC (and in the USA only, PVC) systems a 2" CPVC (USA: 2” PVC

allowed) threaded adaptor or 90° elbow adaptor. A condensate trap formed

using the supplied ttings 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:

Figure 1c: PP Vent Adaptor Assembly

CENTROTHERM INNOFLUE™ M&G DURAVENT POLYPRO™

KIT# P-166A KIT# P-167A

2” Stainless Coupler (190-044) 2” Stainless Coupler (190-044)

2” Stainless Steel Adaptor (250-419) 2” Stainless Steel Adaptor (250-419)

Retainer Clip (180-050) Retainer Clip (180-051) x 2

PPs Transition Fitting (180-037) PPs Transition Fitting (180-040)

N/A PPs Condensate Trap Adaptor (180-060)

Condensate Trap and Hose (180-013) Condensate Trap and Hose (180-013)

Re-Usable Trap Strap (152-004) Re-Usable Trap Strap (152-004)

Table 3: Polypropylene Venk Kits

Combustion air piping is connected at the base of the boiler using a standard 2" PVC (ABS) coupler or elbow (see Section 1.4.7). For PPs intake piping, use standard PPs : 2”Sch 40 adaptor parts from the respective PPs manufacturers.

Venting shall be supported in accordance with applicable code.

*Manufacturers of stainless steel Type BH venting systems must submit their approved transition tting to IBC for evaluation and written approval.

INSTALLATION

1-5

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

1.4.3 Vent Travel

CPVC or PPs (Rigid Single Wall) piping is the standard venting option; with this, the VFC 15-150 boiler, for example, can be sited up to 50 equivalent feet from the vent termination using 2” or up to 120’ using 3”. The actual vent travel allowance is reduced for ttings in accordance with Table 4. – e.g. for an VFC 15-150 using 6 x 90º CPVC elbows, the maximum lineal measure of pipe allowed using 3” pipe is 72 feet (120’ – (6 x 8’ = 48) = 72’).

For 3” exible PPs, up to 60 actual lineal feet are allowed in a nominally vertical orientation (>45°). The equivalent length of 3” ex PPs shall be computed using

a multiple of 3:1, eg. 45’ x 3 = 135’ equivalent (for the VFC 45-225). With 45’ of 3”

ex, up to 105’ equivalent of 3” rigid PPs would still be allowed. 2” exible PPs is

not allowed.

EXHAUST PIPE SIZE MAXIMUM EQUIVALENT LENGTH

Sched.40; Rigid PPs

2" (15-150 only) 50' (each side)

3" (15-150) 120'

3" (45-225) 240'

90° vent elbow allow 8' equivalent

45° elbow allow 3’ equivalent

PPs 87-90° elbow allow 8’ equivalent

Flexible PPs

2” Flexible N/A

3” Flexible (VFC 15-150) 60’ (max) actual lineal x 1.5 = equivalent

3” Flexible (VFC 45-225) 60’ (max) actual lineal x 3 = equivalent

Table 4: Maximum exhaust venting length

Note: 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 foot (PPs vent: follow PPs manufacturer requirements) so condensate runs back towards the trap. Support should be provided for intake and vent piping, particularly so for horizontal runs (follow local code). Insulate exhaust piping where it passes through unheated spaces or underground, with appropriate pipe insulation to prevent freezing of condensates.

Certain installations of the VFC 15-150 model can employ the 2” vent options. We caution installers when using horizontal runs of 2” pipe. Reason: air friction from the

fast moving exhaust during long burner runs at high-re in a 2” pipe can overcome

gravity on 1/4” / foot vent slope – leaving a pool of condensate at the next upturned

elbow. Pooling can impair the achievement of full high-re rating plate performance

If the site requires a horizontal exit immediately below the boiler – bush out to 3" pipe in the downward vertical run immediately below the 2" threaded adaptor,

and elbow to horizontal before splicing in a eld sourced 3" reducing tee for mounting of the condensate trap; this will slow the exhaust velocity sufciently for

good drainage and reduce “spitting” at the vent termination. In this case, the 3" x 3/4" reducing tee would replace the 2" tee and 2" x 3/4" bushing supplied with the VFC 15-150 boiler.

1-6

INSTALLATION AND OPERATION INSTRUCTIONS

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

WARNING

Fill trap with water before

boiler is rst red to prevent

exhaust fumes from entering

room. Never operate the boiler unless the trap is lled

with water.

Fan control harness plug

Exhaust venting must slope down to the trap/drain with a pitch of at least 1/4" per foot (PPs vent: follow PPs manufacturer requirements for slope) so condensate runs towards the trap. Support should be provided for intake and vent piping, particularly so for horizontal runs (follow local code). Insulate exhaust piping where it passes through unheated spaces or underground, with appropriate pipe insulation to prevent freezing of condensates.

Figure 2a: Basic exhaust vent assembly

Figure 2b: Basic exhaust vent assembly

Ensure all venting components are clean of burrs/debris prior to assembly. Care is to be taken to avoid ingestion into the fan of PVC/ABS debris left in the combustion air piping.

Unplugging fan control harness plug will drive the fan into manual high speed operation for vent leak test

BEST PRACTICES

To reduce the possibility of expansion noise, allow a 1/4”

gap around the exhaust and

air intake piping.

All joints must be secured. For CPVC in Canada, use ULC-S636 approved CPVC solvent cement, in accordance with its manufacturer 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 manufacturer.

All vent connections must be liquid and pressure tight. Prior to ring 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 with the vent blocked,

using a soap/water solution. Installer must ll condensate trap prior to test.

Remove the fan control harness plug as illustrated in the photos, and then block the vent outlet so that the vent run will be under maximum fan pressure. Paint all joints with an approved leak test solution just as you would joints in a gas line, and make sure there are no leaks. Good practice would suggest that the installer attach a tag on the vent line near the condensate drain tee indicating the type of test, the date and the installer’s name.

INSTALLATION

1-7

WARNING

Condensate can cause corrosion of metal roong

components and other

roong materials. Check with the builder or roong

contractor to ensure that materials will be resistant to

acidic condensate. pH levels can be as low as 3.0

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, and ingress of moisture into building

structures is to be avoided.

Serious structural damage

may occur if adequate

precautions and clearances are not allowed for.

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

1.4.4 Venting Passage Through Ceiling and Floor

• Conrm material meets local codes including re stopping requirements.

•

Pipe clearances - no IBC requirements, but best practice allows a minimum 1/4” gap around pipes to prevent binding and expansion noise; follow local codes.

• All piping must be liquid and pressure tight.

1.4.5 Rooftop Vent Termination

Rooftop vents must terminate as follows:

• The exhaust pipe can terminate in an open vertical orientation without

concern about rain inltration; this will drain away through a properly congured condensate trap.

• If used, the intake air pipe is not typically drained, so it must be terminated

with a down-turned elbow (see Figure 3). The intake pipe does not need to penetrate the roof at the same 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 travel

of 3' (e.g. the nal 3') including 2 x 90° elbows on each side.

• Optional bird screen may be placed in a termination tting. 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 through a custom cap. Alternatively, place in the

closest proximity achievable using commonly available pipe ashing. Similarly

group the exhaust pipes and place the 2 separate groups of pipes at least 3' apart (the closest intake and exhaust pipes shall be 36" - or more - apart). Use the same 24" (minimum) vertical separation for all termination options. For alternate group terminations, contact the IBC Factory for written guidance.

• DO NOT exhaust vent into a common venting system.

These precautions are to be observed for neighbouring

structures as well as for the

structure the boiler(s) are

installed in.

Figure 3: Rooftop vent terminal congurations

1-8

INSTALLATION AND OPERATION INSTRUCTIONS

WARNING

It is extremely important to maintain at least the minimum

separation of exhaust vent

termination from boiler

intake air as illustrated in

Figures 3, 4 and 5. Failure to do so can result in a dangerous situation where exhaust gasses are reingested 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

maintain these minimum separations shall NOT be used. Improper installation

will void the warranty. Do

not use proprietary InnoFlue or PolyPro PPs sidewall

terminals without specic written approval from IBC.

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

1.4.6 Sidewall Vent Termination

Sidewall direct vent applications shall be vented as follows:

• Both the inlet and exhaust terminations should normally be located on the

same plane (side) of the building.

• The exhaust outlet is to be placed so as to reach 24" minimum above the

down-turned intake - to avoid exhaust re-ingestion.

• The elevation of both pipes can be raised in “periscope style” after passing

through the wall, then congured as in Figure 4, to gain required clearance.

• Use a 45° elbow on the exhaust termination to launch the plume up and off

the sidewall, for protection of wall.

• Bird screen of 1/4" stainless steel or plastic mesh is useful to guard against

foreign objects.

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 travel of 3' including

2 x 90° elbows on each side. This allows for smaller wall penetrations, with sufcient travel allowance to achieve the minimum exterior conguration as shown above.

Figure 5: Sidewall vent termination - multiple vent piping conguration

INSTALLATION

Figure 4: Sidewall vent termination - piping conguration

1-9

Figure 6: Vent terminal clearances

Figure 7: Prohibited installation

WARNING

In areas of high snowfall,

Users must be advised to check side wall vent and air intake terminations on

a regular basis to ensure

blockage does not occur.

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

For side venting of multiple boiler sets, group all intake terminals together with 4" to 8" lateral spacing, and similarly group the exhaust pipes. Place the 2 groups on the same plane of the building (e.g. north facing wall). Place the 2 groups of pipes at least 3' apart (the closest intake and exhaust pipes shall be 36" - or more – 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 horizontally from any exhaust or inlet termination of an adjacent boiler. For alternate group terminations, contact the IBC Factory for written guidance.

Vent terminal clearance minimums are as follows:

• Clearance above grade, veranda, porch, deck or balcony – 12" (0.3m), but

check local code also (anticipated snow levels may supersede).

• Clearance to openable window or door – 36" (0.91m) (USA – 12”)

• Vertical clearance to ventilated sot located above the terminal within a

horizontal distance of 2’ (0.61m) from the centreline of the terminal.

• 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.

• Clearance to service regulator vent outlet: - 3' (0.91m)

• Clearance to non-mechanical air supply inlet to building or the combustion air

intake to any other appliance: - 3' (0.91m) (USA – 12" (0.3m))

• Clearance to a mechanical air supply inlet: - 6’ (1.82m) (USA - 3’ (0.91m)

above if within 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 between two single family dwellings and serves both dwellings

• Clearance under veranda, porch, deck or balcony: - 12" (0.3m). NOTE:

Prohibited unless fully open on a minimum of two sides below the oor.

• Vents must be installed such that ue gas does not discharge towards

neighbor’s windows, or where personal injury or property damage can occur.

• It is important to ensure proper condensate management from vent

terminations. Condensate shall not be discharged in a manner that will cause

damage to external building nishes or components, or inltrate the building

envelope.

1-10

Figure 9: Vent terminal clearancesFigure 8: Vent terminal clearances

INSTALLATION AND OPERATION INSTRUCTIONS

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

WARNING

In addition to preventing

ingestion of chemical contaminants, care must

be taken to ensure air intake terminals are not

installed in locations where contamination might occur due to ingestion of particulate

foreign material (dust, dirt and debris).

WARNING

Intake air openings must be congured such that rain

or other forms of moisture

cannot enter the air intake piping system. Otherwise

serious damage to the boiler may result.

1.4.7 “Direct Vent” Combustion Air Intake Piping

There are two basic methods of supplying combustion air to an IBC boiler.

The direct vent option uses piping from the outside to supply combustion air directly to the boiler’s combustion air connection.

NOTE

Care must be taken when installing air intake piping to ensure that a “trap” is not

formed in the piping so as to allow a build-up of water, and

blockage of intake air.

Such blockage will result in a

boiler safety shut-down.

Figure 10: Direct vent - intake, exhaust and condensate removal system

INTAKE PIPE SIZE MAXIMUM EQUIVALENT LENGTH

Sched.40; Rigid PPs

2" (15-150 only) 50' (each side)

3" (15-150) 120'

3" (45-225) 240'

90° vent elbow allow 8' equivalent

45° elbow allow 3’ equivalent

PPs 87-90° elbow use 8’ equivalent

Air Intake Filter (Part #SC100A) allow 8' equivalent

Flexible PPs

2” Flexible N/A

3” Flexible (VFC 15-150) 60’ (max) actual lineal x 1.5 = equivalent

3” Flexible (VFC 45-225) 60’ (max) actual lineal x 3 = equivalent

Table 5: Maximum intake piping length

INSTALLATION

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: It is not permitted to add to the exhaust length by transfer of unused

intake allowance.

1-11

WARNING

When using Indoor

Air options, adequate

combustion air must be supplied to the boiler room

according to the requirements

of all applicable codes.

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

Combustion air piping is connected at the base of the boiler using a standard 2” PVC (ABS) coupler or elbow and run horizontally or vertically to the outdoors. Screen material can be placed at the inlet as appropriate for the environment (e.g. insects, dust).

For 3” piping, a 3”x 2” bushing is to be used in the inlet piping within 3 feet of the combustion air line clearance hole at the base of the boiler. Such 3’ interval of 2” pipe can be treated as 3” pipe without reference to its smaller diameter in calculation of the maximum allowable vent travel distance. All elbows and tees at the base of the boiler and at the termination must be included in the calculation.

Care must be taken to ensure adequate separation is maintained between the

air intake inlet and the vent terminal. Refer to the vent terminal conguration

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 Air” Combustion Air Intake Piping

An “Indoor Combustion Air installation”, as described herein, is one in which air for combustion is taken from the ambient air around the boiler.

Figure 11: Indoor air - intake, exhaust and condensate removal system

To support combustion, an ample air supply is required. This may require

direct openings in the boiler room to the outside. If the boiler is not in a room adjacent to an outside wall, air may be ducted from outside wall openings.

Provisions for combustion and ventilation air must be made as follows:

• in the USA, in accordance with the National Fuel Gas Code, ANSI Z223.1

• in Canada, in compliance with B149.1-10.

1-12

(latest edition), or applicable provisions of the local building codes

INSTALLATION AND OPERATION INSTRUCTIONS

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

1.4.9 Combustion Air Filtration

NOTE

Combustion fan blockages can occur when environmental particulate and

foreign matter contaminants

(leaves, dust, dandelion & cottonwood uff, etc) are drawn into the air intake. In

areas where this problem is suspected to be an issue,

our optional air intake lter

should be installed.

Filters should be checked

and cleaned or replaced on a regular schedule based on

the severity of the problem.

If combustion air contamination from ingested particulate matter may be a

concern in any installation, an optional air intake lter may be installed. IBC supplied air intake lters 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 Table 4.

Figure 12: Optional air intake lter IBC Part #SC100A - Filter element alone is IBC Part #180-103

Air intake lter IBC Part #SC100A

INSTALLATION

Figure 13: Direct vent - intake, exhaust and condensate removal system with optional air

intake lter (ltration may also be used on indoor air applications as required)

1.4.10 Closet Installations

For installations in a conned space (such as a closet), ventilation openings may

be needed through a door 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).

1-13

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

1.5

WARNING

Fill trap with water before

boiler is rst red to prevent

exhaust fumes from entering

room. Never operate the boiler unless the trap is lled

with water.

Failure to comply will result

in severe personal injury or

death.

WARNING

If condensates are to be discharged into building drain piping materials that are subject to corrosion, a

neutralization package must

be used.

CONDENSATE REMOVAL

IBC’s specied vent conguration promotes the safe drainage of moisture from the boiler and exhaust venting without owing liquids back through the heat exchanger

(as done by other condensing boilers). Reliable system operation requires (1) proper design and installation of exhaust venting to allow condensate to run back to the drain/trap; (2) proper trap depth to handle maximum potential pressure within the vent, and (3) acid neutralization as appropriate. To achieve these:

1. Allow for a 1/4” per foot slope back to the trap connection, with appropriate

hangers to maintain that gradient; do not use 2” pipe on horizontal runs - air

friction from the fast moving exhaust at high re in a 2” pipe can overcome gravity even with the specied slope, leaving a pool of condensate at the

next upturned elbow; do not transition between pipe diameters on horizontal vent runs – always place any reducing couplers in the vertical run)

2. Ensure a trap is established as described below.

3. When required, add (and maintain in good condition) a neutralization tank.

1.5.1 Condensate Trap

When installling the condensate trap, please take into 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 trap

• If necessary, the drain connection tee can be laid so the main axis is

horizontal; ensure the drain tee is as close as possible to the vent riser to avoid water bypass and pooling.

• Most installers prefer to run the combustion air intake pipe alongside the vent,

both to the left side of the boiler to keep the area right of the unit clear for system water piping.

• Use the supplied PVC unions for easy access for cleaning. Locate on the

vertical legs as per Figures 15 and 16. Earlier installations may have a single union at base of the trap (as shown in Figure 13).

• Condensate traps should be checked every 2 months, and cleaned and

relled as necessary.

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.

1-14

INSTALLATION AND OPERATION INSTRUCTIONS

Figure 15: Condensate trap

conguration (double union option

shown)

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

1.5.1.1 WITH SCHEDULE 40 PLASTIC VENTING SYSTEMS (E.G. ULC-S636 CPVC)

A condensate trap must be installed near the base of the boiler as shown in Figure

14. The trap is formed using PVC pipe, elbows and threaded union ttings.

disassembly for cleaning

Figure 14: Condensate trap conguration Figure 16: Condensate trap

NOTE: for CPVC vent systems, the connecting tee and bushing should be

formed using CPVC, transitioning to PVC in the wetted section of the trap, where

non-ULC-S636 materials are allowed as this section is not in contact with ue

products. The trap must be installed as follows:

• The trap depth must be 6” min. in height (see Figure 14); with the

conventional vent kit parts supplied with the boiler, approximately 15” clearance below the boiler is required.

• Use the supplied vent kit parts to establish the trap 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 transition kit is required; select the kit corresponding to the brand of PPs venting to be used at the installation site (see page 1-5). Note this kit is needed to make safe connection to the boiler’s 2” NPT-M threaded exhaust outlet and to provide for good drainage from both the boiler and from the external venting run. Ensure metal retaining clips are applied at each PPs joint in the system, including that

between PPs and the stainless steel coupler, immediately below the boiler ue

outlet. The condensate trap itself is to be installed at the drain outlet provided at

the bottom of the PPs transition tting, as shown in Figure 17.

INSTALLATION

1-15

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 #180-050)

1-16

INSTALLATION AND OPERATION INSTRUCTIONS

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

Figure 19: IBC Kit #P-167A for M&G Duravent PPs (with M&G Duravent clips – IBC #180-051)

Each manufacturer of PPs venting systems has its own unique design for their metal retaining clips. While they may look very similar, do not mix any such components between suppliers. IBC supplies these only within the respective parts kits. Installation steps:

1. With sealant material, attach the stainless coupler and adaptor onto the

boiler’s 2” NPT-M exhaust connection. Take care not to disturb the lower 1” of the stainless adaptor with your pipe wrench – that must be smooth for good sealing with the PPs Exhaust Adaptor.

2. Slide a retainer clip (with barb down) up the stainless adaptor, then move the

PPs Exhaust Adaptor into position. Engage the retainer clip.

Build the 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 using their retaining clips).

4. For the M&G Duravent system, next install their Condensate Trap Adaptor

(IBC #180-060) after sliding on the 2nd retaining clip supplied in kit P-167A (barb down).

5. The transition assembly is now ready for the trap itself:

Undo Drain Spout Compression Nut (E), remove Drain Hose (G) from Trap. Drain Outlet (F). Place Vacuum breaker cap (J) over the Vacuum breaker

opening and push rmly home. Remove Upper Compression Nut and

Washer (C) and slide over PPs Transition Fitting Drain Outlet (A).

Fill Trap with water, and slide Trap Body (D) over PPs Transition Fitting Drain

Outlet (A).

Attach Drain Hose (G) and tighten Drain Spout Compression Nut (E).

INSTALLATION

1-17

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

WARNING

The Trap Hook reusable retaining strap (IBC #152-

004) must be installed

as instructed and all trap

ttings must be tightened as instructed to prevent leakage of ue gasses.

Failure to comply may result

in severe personal injury or

death.

NOTE

It is the responsibility of

the installing and/or service Contractor to advise and

instruct the end User in how

to perform the Trap cleaning procedure, and to advise that the Trap be checked at least every two months and cleaned as required.

6. Conrm the Drain Spout Compression Nut (E) is secure by applying 10 lbs

of downward force on the trap body (D). Then apply IBC #152-004 Reusable Strap as shown in Figure 17 to prevent blow-off of the trap during any delayed ignition event. Ensure the Strap is seated well in the “V” formed between the main Trap Body (D) and its Trap Drain Outlet (F).

1.5.2 Condensate Trap Assembly - cleaning procedure

1. Turn off the power to the boiler and allow it to cool down.

2. Remove the trap for cleaning:

• for Schedule 40 CPVC/PVC systems, see Figure 16

• for PPs systems, see Figure 20

3. Flush the debris out.

4. Re-assemble trap components, re-ll trap, and rex trap. Ensure the

Reusable Retaining Strap 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.

• Drainage line must slope down to the drain at a pitch of 1/4” per foot so

condensate runs towards the drain.

• Condensate traps should be checked every 2 months, and cleaned and

relled as necessary.

Figure 20: Condensate trap disassembly for cleaning

1-18

Figure 21: Condensate trap drainage

INSTALLATION AND OPERATION INSTRUCTIONS

WARNING

If condensates 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, the pH of the

condensate discharge must be measured on a regular schedule to ensure the

neutralizing agent is active and effective.

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

DANGER

The water in the condensate

neutralizer can cause

severe burns to the skin.

Use extreme caution when

servicing the condensate neutralizer. Wear protective gloves and eyewear.

Figure 22: Condensate neutralization tank

INSTALLATION

1-19

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

1.6

WARNING

During operation, the relief

valve may discharge large

amounts of steam and/or hot

water. Therefore, to reduce

the potential for bodily injury and property damage,

a discharge line MUST be

installed that it:

1. is connected from the valve outlet with no intervening valve and directed downward to a safe point of discharge.

2. allows complete drainage of both the valve and the discharge line.

3. is independently supported and securely anchored so as to avoid applied stress on the valve.

4. is as short and straight as possible

5. terminates freely to atmosphere where any discharge will be clearly visible and is at no risk of freezing.

6. terminates with a plain end which is not threaded.

7. is constructed of a material suitable for exposure to temperatures of 375°F or greater.

8. is, over its entire length, of a pipe size equal to or greater than that of the valve outlet.

WATER PIPING

1.6.1 General Piping Issues

The VFC modulating series boilers are designed for use within a closed loop, forced circulation, low pressure system. A 30 psi pressure relief valve (3/4" NPT)

is supplied for eld installation in the ow supply line – see below. An optional 75

Psig relief valve can be used where required on closed loop systems within multilevel buildings. Relief valve discharge piping must terminate between 6" (15cm)

and 12” (30cm) above the oor using plain un-threaded end, or per local Code.

DO NOT CAP, PLUG OR OTHERWISE OBSTRUCT THE DISCHARGE PIPE OUTLET!

CAUTION

Installers should inquire of local water purveyors as to

the suitability of their supply for use in hydronic heating systems.

If water quality is questionable, a local water

treatment expert must be consulted for testing,

assessment and, if required,

treatment.

Alternatively, water or hydronic uid of known quality can be brought to the

site.

Figure 23: Boiler trim options

System piping is connected to the boiler using the 1-1/4" NPT-M threaded ttings.

Unions and gate or ball valves at the boilers supply and return water connections are recommended to simplify servicing. Un-insulated hot water pipes must be installed with a minimum 1/4" clearance from combustible materials.

Fluid ll is most often accomplished by using a boiler regulator & ll valve set at 12 psig or more, with appropriate backow prevention device as required by

local code. This is acceptable in areas where municipal water or well water has

been treated and ltered to remove excessive minerals and sediment, and water

chemistry is known to be suitable for closed loop hydronic systems. In areas where water quality is in question, or when chemical treatment or glycol is required, other options should be considered. Follow applicable Codes and good piping practice.

There are a number of boiler feed and pressurization devices on the market

today that may be a better choice than a raw water ll 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 uid and chemicals

back into the system. In buildings that may be unoccupied for long periods of

time, pressurization units are useful to prevent ood damage should leakage occur from any component in the system. An additional benet is that backow

prevention devices are not required when using these devices.

1-20

INSTALLATION AND OPERATION INSTRUCTIONS

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

Do not place any water connections overhead the boiler; leaks can damage the fan & controls. If needed, create a shield over the louvered top of the cover,

but allow clearance for airow and service access.

WARNING

Close ll valve after any

addition of water to the

system, to reduce risk of

water escapement.

NOTE

Full sized application drawings can be downloaded from our web site.

www.ibcboiler.com

NOTE

For best results, use a Primary: Secondary piping system, with a pumped boiler loop using 1-1/4" piping for the 15-150 and 1-1/2” for the 45-225. Heat exchanger head for both models is approx. 7' at 14 gpm, and 12’ at 22 gpm so an inexpensive fractional horsepower pump is normally adequate. Primary/

Secondary piping ensures adequate ow and de-couples Δ°T issues (boiler vs. distribution). Aim for a 20° to 30° F Δ°T across the heat exchanger at high re (there is a boiler protection throttle fence limiting the Δ°T to 40°F).

The boiler, when used

in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with

appropriate valves to prevent

the chilled medium from entering the boiler.

NOTE

The boiler piping system of

a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation

must be equipped with ow control valves or other automatic means to prevent gravity circulation of the

boiler water during the cooling cycle.

Figure 24: Basic Primary/Secondary piping concept

INSTALLATION

Figure 25: Important Primary/Secondary piping details

1-21

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

WARNING

Water quality has a signicant

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 through corrosion or fouling. Repeated or uncontrolled water

lls will increase the potential

for damage.

High levels of dissolved solids

or minerals may precipitate

out of the uid onto the hottest

part of the heat exchanger, impairing heat transfer and

resulting in overheating and premature failure. The amount

of solids that may form on the heat exchanger will depend on the degree of hardness and

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:

The VFC modulating series boilers are designed to supply up to four different heating loads with temperatures within the range 34°F to 185°F - to meet three separately piped loads. Use closely spaced tees to connect each pumped “load”

(e.g. DHW, baseboards or radiant oor) to the primary loop, or employ the use

of a hydraulic separator to 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 site at: www.ibcboiler.com

Figure 26: Primary/Secondary piping concept with hydraulic separator

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/l

Cu less than 0.1 mg/l

Conductivity is to be less than 400μS/cm (at 25°C)

Hardness is to be 7 Grains or

less

IMPORTANT: Ensure that these limits are acceptable for the other water-side components in the system.

1-22

Figure 27: Important Primary/Secondary piping details with hydraulic separator

Always ensure that loads sensitive to high temperatures are protected using means such as an aquastat (wired to the boiler’s auxiliary interlocks) or mixing

valve set for maximum limit (say 140°F) to protect radiant oors.

INSTALLATION AND OPERATION INSTRUCTIONS

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

PRESSURE VESSEL HEAD

Flow rate (gpm) 4 8 12 16 20

Head @ ow (ft wc) 0.7 2.5 5.0 8.3 12.3

NOTE

The Primary (boiler) pump

must be under the control of the boiler and wired to the correct yellow and white

wires labelled “Primary” in

the wiring box.

Failure to do so will result in a no heat condition as the boiler will interrupt start-up

with a “No Water Flow” error.

WARNING

Do not use automotive-type

ethylene or other types of

automotive glycol antifreeze,

or undiluted antifreeze of

any kind. This may result in severe boiler damage. It

is the responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials. Improper mixtures

and chemical additives may

cause damage to ferrous and non-ferrous components as well as non-metallic, wetted 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 nontoxic propylene glycol.

Table 6: Pressure Vessel Head

Ensure the pump is rated for the design circulating water temperatures; some pumps have a minimum water temperature rating above the low temperature potential of the

boiler. Following installation, conrm actual performance by measuring Δ°T (under high and low ow conditions) after establishing the correct ring rate.

We require waterow after burner shutdown to utilize legacy heat – this is signicant due to the mass of the heat exchanger (40 Kg) plus its 9L internal

water volume. Default software values 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 software will run the DHW pump for 5 minutes to place the legacy heat where it is useful – e.g. in the DHW tank. Any secondary pump can be set to run for 0 – 900 seconds in the heat purge mode. Guard against deadheading pumps when all zone valves are closed.

The primary pump must be under the control of the boiler, to allow the boiler’s

ow proving routine to run. The boiler control looks for ow/no ow during a

pump on / off check on each start up. Ensure that temporarily wired primary or

secondary pumps (e.g. wired externally during the system ll/purge phase) are

returned to the boiler’s control terminals. A “No Water Flow” error message will otherwise be experienced on start-up.

There are two water pressure sensors, located on the boiler’s supply and return water piping. These act to provide both low water pressure and low water level

cut-off protection and water ow measurement. Schematics for several piping

layouts are provided, and additional drawings are available at www.ibcboiler.com.

Installers shall conform the piping design to one of the provided congurations to simplify the control application, promote good loads-and- ows management.

The VFC modulating series boilers offer unparalleled matching of heat generation

to radiation. The low minimum ring is better suited to low thermal 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 benet through

use of a buffer tank to ensure a controlled supply temperature, and to prevent short cycling. Buffering should be added on the secondary piping of the relevant load, to avoid bulking up the thermal mass of the primary piping circuit (and potentially lengthen the duration of the transition from hot to cool loads).

Propylene glycol solution is commonly used in a closed loop where freeze protection is required. Its density is lower than that of water, resulting in

lower thermal performance at a given ow and pressure. As a rule of thumb,

a 50%:50% solution of propylene glycol and water will require an increased system circulation rate (gpm up 10%), and system head (up 20%) to provide performance equivalent to straight water.

VFC modulating series boilers can be connected directly to a oor of non-oxygen

barrier polybutylene material (PB tubing). For maintenance of warranty on such

systems, we require evidence of a thorough ushing of all loops, plus installation of a dirt separator or side stream lter. A separator/lter maintenance routine shall be carried out after the retrot, with lter clearing after the 1st day, 1st week, month and annually thereafter. Care is to be taken to avoid use of ferrous ttings

and pumps on PB tube systems.

INSTALLATION

1-23

NOTE

This piping drawings in this

manual are simple schematic guides to a successful

installation. There are many

necessary components not shown, and details such as thermal traps are left out so

the drawings have greater clarity. We require that

our boilers be installed by licensed and experienced trades people who are familiar with the applicable local and national codes. System design is to be completed by an experienced hydronic designer or Engineer. It is necessary to carefully read and follow these installation instructions along with the

application drawing that ts

your system.

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

1.6.2 Installation Rules

NOTE: The Boiler Trim element – common to each of the following systems

- includes the pressure relief, ll, expansion tank and air bleed elements. The

primary pump can be located on either the Supply or Return piping sections.

NOTE

VFC boilers are equipped

with a factory installed

pressure sensor-type Low Water Cut Off system. The

minimum operating system pressure allowable with this

is 4 psig. Check local codes if a Low Water Cutoff Device is required. If so, determine if this device meets the local

codes.

Figure 28: Basic Primary/Secondary, 3 load piping concept

Features of the preferred Primary / Secondary piping system:

1. Good circulating water ow through the boiler irrespective of load or radiation

system head

2. Allows exible ΔT° control in secondary loops

3. Adds to the system’s thermal buffering, to assist in handling small loads and

temperature transition.

This piping conguration 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, offsetting such costs.

For optimal performance, place pumps on the supply side of secondary loops to facilitate air evacuation. Use pumps with internal check valves to avoid ghost

ows and thermal siphoning.

The primary loop temperature may need to transition from a 180°F domestic water

heating load to a 100°F radiant oor requirement. The secondary pumps will swap

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

oor (most would enter 140°F); the oor pump would remain off, the boiler shut

down, leaving primary circulation on until the primary loop temperature drops into

the acceptable range for the oor. Temperature sensing is done using thermistors

at the boiler supply and return – no further sensors need to be installed.

1-24

INSTALLATION AND OPERATION INSTRUCTIONS

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

NOTE

Load Combining is now available to operate 2

compatible water temperature loads at the same time.

When using the sequential load feature of the IBC boiler,

attention must be paid to the operation of system components in order to ensure they are compatible.

Many air handlers (fan coils) for instance have a

thermostat connection that will energize an internal relay to operate the air handler circulator and its fan on

a call for heat. This may

result in operation of these components when other loads are running at a higher priority, resulting in cold air blowing, or robbing heat from another load.

The use of the multi-temperature modulating system is optimized when the need to shutdown the boiler is reduced or eliminated during the transitional period. System design enhancements: (a) keep a relatively low thermal mass in the primary loop, and (b) incorporate a 3-way mixing valve on the “cool” load piping.

If the installation involves small loads, as in typical zoned baseboard heating applications, use of a buffer tank is recommended. To aid in temperature transition from hot to cool loads, a 3-way mixing valve can be placed at the

entrance to the cool load (this will also provide oor protection). This will permit immediate circulation of mixed ow into the cool loop. See separate publication

Application Notes for more detail (available at www.ibcboiler.com or from your IBC Representative).

Always ensure that loads sensitive to high temperatures (e.g. radiant oor)

are protected using appropriate means such as a manual mixing valve, or an aquastat (set to130°F, for example) wired to the boiler’s auxiliary interlocks.

Some wiring alteration may

be required to divorce both

of these functions from

thermostat control in favour of more effective control from the IBC boiler.

NOTE

For information and details

regarding Multiple Boiler

application, consult our

Technical Notes - Multiple Boiler Systems. These notes

provide necessary detail on specic single and multiple boiler applications “Piping”, “Wiring” and “Settings”. (available at www.ibcboiler. com or from your IBC Representative).

Figure 29: Two pump, two load - parallel piping concept

Compared with the Primary/Secondary approach, the above design saves one

pump. Lost is the simplicity of constant head and ow at the boiler, with reduced exibility in the handling of large temperature differentials.

Check valves or thermal traps should be used to isolate both the supply and

return piping for each load - to avoid thermal siphoning and reverse ow.

To ensure adequate water ow 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 the ow rate might drop below minimum

requirements (4 gpm for the 15-150, 8 gpm for the 45-225).

For further information and details, consult our Application Notes – which provide

detail on specic single and multiple boiler applications “Piping”, “Wiring” and “Settings”. (available at www.ibcboiler.com or from your IBC Representative).

INSTALLATION

1-25

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

1.7

NOTE

Due to the precision of modern modulating boilers it is important to pay special attention to gas pressure regulation.

It is essential to check gas

supply pressure to each boiler with a manometer or

other high-quality precision measuring device. Pressure

should be monitored before

ring the boiler, when the regulator is in a “lockup” condition and during

operation, throughout the boiler’s full modulation range.

Pay special attention to

retrot situations where existing regulators may have an over-sized orice and/or

worn seats, causing pressure

“creep” and high lock up

pressures.

A high quality regulator will

maintain constant pressure

above the boiler’s minimum specication at all ring

rates, and will not exceed the boiler’s maximum pressure

rating when locked-up with no

load.

GAS PIPING

The boiler requires an inlet gas pressure of at least 3.0" w.c. for natural gas or propane. For either fuel, the inlet pressure shall be no greater than 14.0" w.c.

Conrm this pressure range is available with your local gas supplier.

The inlet gas connection of the boiler’s gas valve is 1/2" NPT (female).

Adequate gas supply piping shall be provided with no smaller than 1/2" Iron Pipe Size (IPS), in accordance with the following chart:

MODEL 1/2" IPS 3/4" IPS 1" IPS

VFC 15-150 (Natural Gas) 10 40 130

VFC 15-150 (Propane) 50 180 620

VFC 45-225 (Natural Gas) 5 20 60

VFC 45-225 (Propane) 25 90 290

Table 7: Maximum Pipe Length (ft)

Gas piping must have a sediment trap ahead of the boiler’s gas valve (see Figure

30). A manual shutoff valve must be located outside the boiler, in accordance with

local codes/standards. All threaded joints in gas piping should be made with an approved piping compound resistant to the action of natural gas/propane. Use proper hangers to support 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 psig. Dissipate test pressure prior to reconnecting. The boiler and its gas piping shall 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 (see

Figure 32). Note that manifold pressure varies slightly in accordance with ring

rates with the modulating series boilers, but will always be close to 0” w.c.

Figure 30: Typical gas piping

1-26

INSTALLATION AND OPERATION INSTRUCTIONS

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

Removing wiring box covers

1.8

ELECTRICAL CONNECTIONS

All Electrical wiring to the boiler (including grounding) must conform to local electrical codes and/or National Electrical Code, ANS/NFPA No. 70 – latest edition, or The Canadian Electrical Code, C22.1 - Part 1.

1.8.1 120VAC Line Voltage Hook-up

Line-voltage wiring is done within the eld-wiring box (refer to Figure 31). Connect the boiler to the grid power using a separate, fused circuit and on/ off switch within sight of the boiler. Use 14-gauge wire in BX cable or conduit properly anchored to the boiler case for mains supply and pump circuits.

Connect a 120 VAC / 15 amp supply to the “AC IN” tagged leads in the wiring box. The max. actual draw (with 4 typical residential size pumps) is less than 4 amps.

The 120 VAC power supply to the load pumps (P/V1, P/V2, P/V3, and P/V4) have been factory installed and connected to P/V-L and P/V-N for your convenience. If you are to use the P/V relay connections for zone valves then the 120 VAC connections at P/V-L and P/V-N will have to be removed and properly capped off. 24VAC can then be applied using an external transformer to supply power to zone valves. The upper 4 pairs of contacts on this green connector strip are then powered to manage up to 4 load pumps – the top pair for Load 1, the second pair for #2 etc. Once the controller is programmed for the respective loads, the boiler will manage all the loads without need of further relays (for loads up to 1/3 HP; for more – use a protective relay).

Line voltage leads for power supply, primary pump and VS output

Line voltage load pump terminals

CAUTION

The internal pump relays are

protected with 5 Amp fuses.

The maximum recommended

load on each fuse is 4 Amps

(80% of rating). The maximum combined pump load is 10

Amps. Isolation relays or

contactors MUST be used if the

loads exceed these maximums.

The primary pump is connected to the White/Yellow pair labeled Primary Pump. This lead is factory wired to the controller (and its 120 VAC supply) at the upper 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 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 primary pump is connected to the mains power).

Pumps can be switched on/off using the keypad, so there is no need for temporary pump wiring during system lling / air purging. If pumps are hard-wired to the panel during the system ll/purge phase, re-wire the

boiler pump to the Primary Pump leads inside the wiring box, to enable the

water ow proving routine to run.

In a new construction application- use a construction thermostat – or jumper with in-line on/off switch – for on/off management of the boiler. Do not just pull power from the unit, or its moisture management routine will be interrupted (fan turns at ultra low rpm for 90 minutes after burner shutdown).

Treat it like a computer, where you do not just pull the plug when done. If a “Low

Airow” error signal shows, check for (and remove) any water in the clear vinyl air

reference tubes. This has been seen occasionally at construction sites where the boiler has been repeatedly de-powered wet.

The combined current of all pumps connected through the on-board pump relays should not exceed 10 amps. The control circuit board is protected using on-board

eld replaceable fuses. Each pump is fused with a separate 5 Amp fuse. The

Alarm contact is fused with a 5 Amp fuse and the 24VAC boiler control circuit is protected with a 2 Amp fuse.

INSTALLATION

1-27

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

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.

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 oor) – 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 oor zone) to present a common thermostat signal to the controller. Ensure there are no disturbing inuences 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.

DANGER

Do not connect thermistor

sensors to “Therm” terminals. An overheating hazard can

result in serious personal injury and/or property damage.

NOTE

The IBC Touch-Screen

controller has the ability to connect to most power stealing thermostats. See the Wiring Diagram for details.

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 oor-protecting aquastat can use one of these, to cause a full boiler shutdown in the case of excess oor 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 efciency.

• 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 nal 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.

1-28

INSTALLATION AND OPERATION INSTRUCTIONS

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

1.8.6 Thermostat Heat Anticipator

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 zone valves are used to manage individual thermostatically controlled zones, each room thermostat’s heat anticipator should be adjusted to the current draw of its associated zone valve.

INSTALLATION

Figure 31: Electrical Wiring Connections (full page ladder diagram at back of this manual)

1-29

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

THIS PAGE INTENTIONALLY LEFT BLANK

1-30

INSTALLATION AND OPERATION INSTRUCTIONS

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

2.0

2.1

IBC BOILER CONTROLLER

GENERAL

This boiler is equipped with the V-10 Touch Screen controller. The controller

simplies the programing of the boiler while providing greater exibility. For more

detailed instructions, reference the Touch Screen Boiler Controller Manual.

The controller is equipped to provide:

• Control of up to 5 pumps – 1 boiler pump + 4 separate load pumps

• Outdoor Reset control

• Set Point temperature regulation

• Domestic Hot Water (DHW)

• External control via 0-10VDC or 4-20mA signaling

• Alarm dry contacts

• Load Combining – simultaneous operation of 2 similar water temperature

loads

• The control can manage and/or operate in a network of up to 24 IBC VFC or

SL boilers

Some of the new features available in the touch screen control include:

• Express Setup Menu for simple, quick programing

• Software updatable in the eld with a SD card or a USB stick

• Setup conguration 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 connectivity

• BACnet (with activation)

2.2

WARNING

No sharp or metallic object should be used on the touch screen as this will cause damage. Use only a Stylus or a

clean nger.”

BOILER SYSTEMS AND OPERATION

CONTROL

When the boiler is rst energized, the controller will go through a power up

sequence that will take approximately 90 seconds. During this time the controller is completing a self-diagnostic and loading all previous settings. In the event of a power interruption the boiler will automatically resume operation when power is restored with all the previously stored values. The controller provides overall management of the boiler operations including;

• Power-up, Self-diagnostics, easy Load parameter adjustments

• Burner operation, safety management systems, Call for Heat management

and Load Priority

• Real time boiler data

• Temperature and throttle operation

• Maintenance of operational and error service logs

• 2-way communication between other IBC boilers and controls

2-1

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

Operational and historical data may be accessed at any time using the System

Status and Load Proles sections of the control. Error logs are available in the

Diagnostics section and the controller is capable of recording any or all errors since original power-up complete with the date and time of the error.

2.3

CONTROL INTERFACE

The control interface is provided through a 2-1/4 x 4 inch, color Touch Screen

display. The Touch Screen responds to a light nger touch on the screen. You

can also use a stylus or similar device to operate the touch controls. Do not use a sharp or metallic object such as a screw driver to operate the control as it could damage the touch screen.

The controller display is divided into two areas, the screen active area and the boiler status bar. All screens have an active area consisting of the screen title bar at the top and 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 Home screen that includes 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 with be dimmed to save power.

The control will automatically return to the home screen if left unattended. The screens will step back one screen at a time in 10 minute increments if the touch screen has not been touched. The pop-up windows will also step back automatically in 2 minute intervals.

The boiler status bar indicates if the boiler is in a normal, warning or alarm state. When no warning or alarm state is present, the bar will be green and the time will be displayed inside the green area. The bar can also be yellow or red corresponding a warning or alarm state. Text inside the bar will indicate the

specic warning or alarm present. If more than one alarm is present the text

display will slowly change, rotating though whatever alarms that are present.

2-2

INSTALLATION AND OPERATION INSTRUCTIONS

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

STARTUP AND COMMISSIONING3.0

3.1 LIGHTING AND SHUTTING DOWN THE BOILER

STARTUP AND COMMISSIONING

3-1

3.2 PRIOR TO START-UP

Inlet gas supply pressure test port

WARNING

Fill trap with water before boiler

is rst red to prevent exhaust

fumes from entering room.

Never operate the boiler unless the trap is lled with water.

Failure to comply will result in

severe personal injury or death.

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

3.2.1 Pre-Ignition Checks

1. Ensure venting system is complete and seal tested. Conrm any common

venting system at the installation site is isolated and independent of the VFC boiler, that any holes left from removal of a previous boiler have been sealed,

and that any resizing of the old ue has been done. Fill condensation trap to

full neck height.

2. Check water piping system is fully ushed and charged, and that all air

has been discharged through loosened bleed caps. Note it is possible to switch all pumps on/off from the Touch Screen – without a call for heat. This greatly simplies system lling and air bleeding (go to Installer Setup, System Settings, Site Settings, change Manual Pump Purge to “ON”. When complete, return to Off, or this will automatically occur with a call for heat).

Use a minimum water pressure of 12 psig. And conrm pressure relief valve

is installed and safely drained.

3. Perform a nal check of electrical wiring.

4. Using a manometer, check to see that adequate gas pressure is present

at the inlet gas supply test port. Requirements are minimum 3” w.c and maximum 14” w.c.

3.3

Manifold pressure test port

DANGER

Making adjustments to the IBC gas valve without

a properly calibrated gas combustion analyzer and by persons who are not trained and experienced in its use is forbidden. Failure to use an analyzer can result in an immediate hazard.

3.2.2 Test Ignition Safety Shutoff

With the boiler in operation, test the ignition system safety shutoff device by shutting the gas control valve immediately outside the boiler case. Ensure boiler has shut off and the appropriate Error information is displayed on the Touch Screen. To restart boiler, reset power or press “Clear Errors” in the Advanced Diagnostics section.

COMMISSIONING

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 using Loctite thread-lock compound, which can be broken where required. However, no mixture adjustment shall be performed unless

done by a qualied technician using properly functioning combustion analyzing equipment.

The controller will automatically detect the installations altitude and make the appropriate adjustments to operate the boiler up to 4,500 feet in elevation without de-ration. The boiler will automatically de-rate at altitudes above 4,500 feet. Refer to the IBC Altitude tables for further information.

To verify the proper operation of the gas valve in the eld, the following procedure can be carried out by a qualied technician (see Figure 32).

1. Turn OFF gas supply to the boiler. With a small (1/8" or 3 mm) at

screwdriver, open the manifold pressure test port by turning its centre- screw 1 full turn counterclockwise. Attach a manometer between the manifold pressure test port and the reference line and turn on gas to the appliance. Static manometer reading should be ideally 7” w.c., for Natural Gas and 11” w.c. for Propane. Minimum and maximum static pressure should be between 5” and 14” w.c. Monitor pressure throughout the commissioning

3-2

INSTALLATION AND OPERATION INSTRUCTIONS

Zero-offset adjustment screw

Gas:Air ratio adjustment screw

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

procedure. Pressure may droop up to 1” to 2” w.c. at high re but under no

circumstances should it drop below 3” w.c. at the gas valve inlet test port.

2. Allow the boiler to ignite / run against a large load, to maintain high re

3. With the boiler at maximum output, use a 2 mm hex key to adjust the zero-

offset (see Figure 32, “A”) as required to achieve -0.2 to -0.3” wc. This adjustment should only be necessary if this screw has been tampered with.

4. With a combustion analyzer probe in the ue gas test port, turn the Gas:Air

Ratio Adjustment screw (see Figure 32, “B”) to achieve the appropriate Table

8 mixture target at High Fire. This screw offers very ne adjustment, and

may require several turns. NOTE: This screw has signicant backlash. When changing direction of turn, it may take up to a full turn before any change

is indicated on the analyzer reading. Clock the gas meter to conrm full

maximum rating plate input.

5. To conrm or adjust the minimum re level settings, Re-dene the load as

“Manual Control”. Use Heat Output in “Congure Load x” to control the output

as needed.

6. At the minimum ring rate, adjust the zero-offset screw (see Figure 32, “A”)

to obtain the target CO2 value. It may be necessary to reduce the output in stages if this adjustment has been tampered with.

7. Turn boiler off by removing the call for heat (use the Heat Load Conguration

screen to turn load to off if no other ready means available); turn OFF gas supply to boiler, then remove the manometer connections, and turn the centre-screw in the manifold pressure test port 1 full turn clockwise. Ensure fully closed, but not over-tightened. Restore gas and soap test for leaks.

MODEL HIGH FIRE LOW FIRE CO MAX PPM

RANGE TARGET RANGE TARGET

VFC 15-150 (Natural Gas) 8.9 to 9.5% CO

VFC 15-150 (Propane) 10.4 to 10.7% CO

VFC 45-225 (Natural Gas) 8.9 to 9.5% CO

VFC 45-225 (Propane) 10.4 to 10.7% CO

9.2% CO

10.6% CO

9.2% CO

10.6% CO

7.9 to 8.6% CO

9.0 to 9.8% CO

7.9 to 8.6% CO

9.0 to 9.8% CO

8.4% CO

9.6% CO

8.4% CO

9.6% CO

< 100

< 150

< 120

< 180

Table 8: Combustion test target ranges - CO2 / Maximum CO

Insertion of ue gas analyzer probeRemoval of ue gas test port plug

STARTUP AND COMMISSIONING

3-3

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

Figure 32: Gas Valve and Pressure Reference System

3-4

INSTALLATION AND OPERATION INSTRUCTIONS

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

3.4

WARNING

Check the rating plate of

the boiler to ensure it is

congured for the fuel you

are using. If the fuel is incorrect for the appliance,

a conversion kit must be ordered from IBC and the gas valve adjusted accordingly.

Failure to perform the

required fuel conversion can

result in an immediate hazard.

DANGER

Operating any IBC boiler

using a fuel other than the fuel listed on its rating plate is prohibited. If the information in this section related to

conversion to alternate

fuels is not followed exactly, a dangerous situation can

result, leading to re or

explosion, which may cause property damage, personal injury, or loss of life.

FUEL CONVERSION

The VFC Series modulating boiler is factory re-tested to operate with natural

gas, or propane as ordered. The rating plate will be marked to indicate which fuel the particular boiler has been set up with. Firing a boiler with a fuel other than what is listed on the rating plate is prohibited unless the following conversion

procedure is completed by a qualied technician.

Refer to the details in the boiler’s current Installation and Operation Manual, section 3.3 - “COMMISSIONING”.

The Low Fire (Zero-offset) valve and High Fire (Gas: Air) ratio adjustment will have to be adjusted to attain optimum combustion results whenever fuel conversion is undertaken however, no mixture adjustment shall be performed

unless done by a qualied technician using properly functioning and calibrated combustion analyzing equipment.

The following procedure can be carried out by a qualied technician:

1. Ensure you are installing the correct fuel conversion kit for your boiler.

Compare the boiler model number with the Kit# found in Table #9.

2. Ensure 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

Instruction document, Combustion Testing and Adjustment.

4. Place the conversion labels associated with the new fuel onto the boiler at

the positions indicated on page 4 of the applicable FUEL CONVERSION instruction sheet.

5. Carefully follow the “Prior to Start-Up “ - Section 3.2 and “Commissioning” -

Section 3.3 procedures on the preceding pages 3-2 and 3-3.

MODEL NUMBER NATURAL GAS TO

PROPANE

PROPANE TO NATURAL GAS

STARTUP AND COMMISSIONING

VFC 15-150 P-174 P-176

VFC 45-225 P-174 P-176

Table 9: Fuel Conversion Kits

3-5

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

THIS PAGE INTENTIONALLY LEFT BLANK

3-6

INSTALLATION AND OPERATION INSTRUCTIONS

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

4.0

4.1

CAUTION

The owner is responsible for

general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition.

CAUTION

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous operation.

WARNING

Fill trap with water before

boiler is rst red to prevent

exhaust fumes from entering

room. Never operate the boiler unless the trap is lled

with water.

Failure to comply will result

in severe personal injury or

death.

MAINTENANCE

BOILER MAINTENANCE

4.1.1 General Care

• Keep combustible materials and ammable liquids and vapours away from the

boiler.

• Keep vent terminals clear of obstructions (snow, dirt, etc.).

4.1.2 Inspection

Inspection of the boiler is to be performed annually by a qualied service

technician.

4.1.3 Venting

• Check vent terminals for and remove any obstructions (e.g. leaves, dust,

other debris).

• Check, and clean or replace intake air lters or screens as required.

• Check for holes or leaks in venting. Replace venting as needed.

• Examine for any signs of moisture caused by sweating intake air pipes;

insulate as required.

• Ensure proper resealing or reinstallation of venting on each servicing.

4.1.4 Condensate Traps

• Condensate trap must be examined every two months to see if cleaning is

necessary (refer to trap cleaning instructions, section 1.5.3 of this manual).

Ensure that trap has been re-lled completely before ring boiler.

• If condensate neutralization is used, check pH level of condensate discharge.

4.1.5 Burner

WARNING

Whenever the burner is removed for inspection or boiler servicing, the sealing gaskets must be examined

and replaced if damaged. Upon re-assembly, an

approved leak test solution

must be applied around the

burner ange sealing area to ensure there is no leakage of

combustible gas/air premix.

MAINTENANCE

• Annually, remove burner to inspect for extent of fouling (refer to burner

removal and reassembly instructions, section 4.3 of this manual). Blow clear

using compressed air. Evaluate the magnitude of clearing required, and establish a reasonable burner inspection schedule. Some boiler / locations may call for annual service, others showing clean burners will only need

attention every 2 – 5 years. Consider adding air ltration if burner requires

cleaning every year. In alternate years, visually inspect burner through sight

glass. Ensure ame is stable and without excessive uttering. Normal ame

pattern is evenly distributed over the burner surface.

• If burner is operating improperly, remove and clean or replace. Use a CO

analyzer to determine proper combustion. See Table 8 for correct values.

• When re-installing burner, ensure it is inserted so that the seam (that runs

along the length of the metal-bre surface) is placed as far away from the ignitor as possible (180° rotation arc away). Also conrm spark gap is 1/8". Conrm visually by removing viewport, turning gas supply OFF, and allowing

the boiler to run through an ignition cycle. Compare the spark length with the spark rod diameter, which is the same 1/8" (e.g. use the rod as a reference).

4-1

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

CAUTION

The heat exchanger has a

small amount of combustion chamber insulation

(refractory), which contains ceramic bers. When

exposed to extremely high temperatures, the ceramic

bers, which contain

crystalline silica, can be

converted into cristobalite

- which is classied as a

possible human carcinogen.

Care should be taken to 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:

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

Certied under 42 CFR 84” for selection and use of respirators certied by NIOSH. For the most current information, NIOSH can be contacted at 1-800356-4676 or on the web at www.cdc.gov/niosh.

2. Wear long sleeved, loose

tting 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.

4.1.6 Heat Exchanger

During burner inspection (with the burner removed), examine the heat exchanger tubes adjacent to the burner’s normal position. In areas of poor gas quality, there may be a buildup of black plaque (typically sulfur). Other fouling agents: airborne dust, debris and volatiles.

Refer to burner removal instructions in Section 4.3 for access to combustion chamber and heat exchanger. Note that the safety warning regarding burner

refractory on this page must be observed.

4.1.7 Pump

Check that the pump is on in normal operation and that the water Δ°T is reasonable for a given ring rate (e.g. 10°F between supply and return when ring at 75,000 Btu/hr. for a VFC 15-150 unit).

4.1.8 Gas Piping

Check for damage or leaks and repair as needed.

4.1.9 Control Module

• Check that boiler operation is consistent with the steps in the Touch Screen

Boiler Controller Manual.

• Check that water temperature targets and setpoint is satisfactory and have

not been adversely amended.

• Check the operating history using the boilers Logs menu and Error Logs

menu. The controller tracks the duty cycle of the boiler in each of the 4 loads separately. This information can be used to adjust the water temperatures of each load.

• If a problem exists with the control, consult troubleshooting guide.

4.1.10 Water

• Check water pressure and temperature. There should be no noticeable

change if boiler is functioning normally. Check for any noise in the system.

• Check water piping for damage or leaks and repair as needed.

• Check for 12-15 psig in normal operation, and look to ensure pressure does

not run up toward 30 psig at high temperature. If pressure rises sharply,

consider replacement of expansion tank. Check also for noise at high re,

which may signal water quality problems.

• Check water piping for damage or leaks and repair as needed.

• Water chemistry shall be of a quality generally accepted as suitable for

hydronic applications. See Section 1.6 for details.

• Ensure any direct “city ll” water connections are left in the closed position to

minimize exposure to leaks and ooding.

4.1.11 Freeze Protection

NIOSH stated rst aid:

• Eye contact - Irrigate and

wash immediately.

Check freeze protection. Use only antifreeze made specically for hydronic

systems. Inhibited propylene glycol is recommended. Antifreeze volume must be between 25-50% of the total volume of water in the system.

• Breathing - Provide fresh

air.

4-2

INSTALLATION AND OPERATION INSTRUCTIONS

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

WARNING

Do not use automotive-type

ethylene or other types of

automotive glycol antifreeze,

or undiluted antifreeze of

any kind. This may result in severe boiler damage. It is the

responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials. Improper mixtures and chemical

additives may cause damage

to ferrous and non-ferrous components as well as nonmetallic, wetted 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.

4.1.12 Boiler Treatment

• Check consistency of any boiler treatment used (e.g. Furnox™), for

appropriate mixture. Chemical inhibitors are consumed over time, lowering their density.

• Verify proper operation after servicing.

4.1.13 Relief Valve - Maintenance and Testing

The relief valve manufacturer requires that under normal operating conditions a “try lever test” must be performed every two months. Under severe service conditions, or if corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be 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 ush the valve seat free of sediment and debris. Then

release the lever and permit the valve to snap shut.

If the lever does not activate, or there is not evidence of discharge, discontinue

use of equipment immediately and contact a licensed contractor or qualied

service personnel.

If the relief valve does not completely seal, and uid continues to leak from the discharge pipe - perform the test again to try and ush any debris that may be

lodged in the valve. If repeated tries fail to stop the leakage, contact a licensed

contractor or qualied service personnel to replace the valve.

CAUTION

Installers should inquire of local water purveyors as to

the suitability of their supply for use in hydronic heating

systems. If water quality is questionable, a local water

treatment expert must be consulted for testing,

assessment and, if required, treatment. Alternatively, water or hydronic uid of known quality can be brought to the

site.

CAUTION

Before testing the relief valve, make certain the discharge

pipe is properly connected to

the valve outlet and arranged to

contain and safely dispose of

equipment discharge.

While performing a “try lever test”, a quantity of heat transfer uid will be discharged from the piping system and the system pressure will drop. This uid

must be replaced. It is highly recommended that a system pressurization unit, such as an Axiom Industries model MF200 be employed to rell and pressurize

your system. Capture the discharged uid in a container and recycle it by

returning it to the system feeder unit. This is particularly important when your system contains treatment chemicals or glycol solutions. If the system employs

plain water, the boiler auto ll valve must be turned on in order to recharge the lost uid.

MAINTENANCE

4-3

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

4.2

COMPONENT DESCRIPTION

A diagram of components and their placement can be found at the end of this manual. To obtain service parts, contact your installer, telephone IBC Technologies or visit our website at www.ibcboiler.com. The following list provides a summary description of major components:

4.2.1 Fan/Blower

PART#/TYPE: RG130 – IBC # 240-040 (VFC 15-150)

RG137 – IBC # 240-048 (VFC 45-225)

FUNCTION: Moves combustion air and ue gas products through the boiler

and venting.

INSTALLATION: Fan removal is done at the ange (4 x #10-32 x 7/8” hex head)

and the gas valve (3 x M4 x 30mm Phillips head self tapping screws accessible for the underside of the gas valve; 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 control over

the range — 15 - 150 MBH for VFC 15-150 or 45 – 225 MBH for VFC 45-225.

Air pressure sensor removal showing reference line connections

INSTALLATION: see Section 3.3 - Commissioning, for gas valve adjustments

4.2.3 Direct Spark Ignition Module

TYPE: Fenwal 240-004C

FUNCTION: microprocessor based spark generator and ame proving control

with 15 sec. pre-purge; 3 try before an auto re-setting 1 hour lockout.

INSTALLATION: (see Diagram 6.1-1 for correct position). Use IBC # 180-011

suppression cable as the ignition lead.

4.2.4 Differential Pressure Sensor

TYPE: Air Prove Switch (IBC # 240-003)

FUNCTION: precise measurement of combustion airow for operating control.

INSTALLATION: (see Figure 32 for correct connection of air reference lines).

4-4

INSTALLATION AND OPERATION INSTRUCTIONS

Main combustion components (clockwise from left) Burner, with ignitor and V clamp - Fan coupler

- Fan/Blower - Mixing plates &

housing - Gas valve

Combustion group assembly

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

4.2.5 Water Pressure Sensor

TYPE: Water Pressure (IBC # 240-006)

FUNCTION: water pressure and ow sensing.

INSTALLATION: (see Diagram 6.1-1, and Diagram 6.1-2).

4.2.6 High Limit

PART#/TYPE: IBC # 240-032 High Limit calibrated for 200°F, 15°F differential.

FUNCTION: Shuts boiler off when water temperature exceeds safety limit.

INSTALLATION: (see Diagram 6.1-1 for correct position). Mount with Honeywell

Tradeline #107408 Heat Conductive Compound between the base of the hi-limit switch and the mounting surface.

4.2.7 Transformer

PART#/TYPE: IBC # 240-008 Primary- 120 VAC; Sec.- 24 V AC; 40VA control

transformer.

FUNCTION: Provides 24 VAC for the control board, for (1) the control / safety

circuit, (2) relays for pump and zone valve control, plus (3) input to DC power converters for 5 V and 12 V circuits (NB not for use to power external zone valves).

INSTALLATION: (see Diagram 6.1-1 for correct position).

Control Module removal

4.2.8 Temperature Sensors

PART#/TYPE: IBC # 240-006 Thermistor; 10,000Ω with Beta = 3892

FUNCTION: Senses water temperature. Signals controller to adjust output

according to water temperature.

INSTALLATION: (see Diagram 6.1-1 for correct position).

4.2.9 Control Module

PART#/TYPE: IBC # 500-0044 Touch Screen boiler controller, V10.0

FUNCTION: (see Touch Screen Boiler Controller Manual for an explanation of

controller function).

INSTALLATION: (see Diagram 6.1-1 for correct position). The 4 screws on

the front panel corners secure the cover. To remove the unit from the mounting brackets, ensure all wires are removed from the connectors on the edge and back

of the control module. Place ngers on the board edge only when handling.

There is a 3V lithium battery (IBC # 240-024) for powering the permanent memory if AC power is not connected.

On-board eld replaceable fuses (IBC # 240-023) are 5A, slow blow, 5mm x

20mm, and must be replaced using these same specs.

Disconnecting Control Module plugs

MAINTENANCE

4-5

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

4.3

NOTE

The safety warning regarding

burner refractory on page

4-2 of this manual must be observed.

Burner Arm Bolts

Fan Screws

Gas Valve Bracket Screws

GAINING ACCESS TO COMBUSTION CHAMBER, BURNER REMOVAL INSTRUCTIONS; FAN AND GAS VALVE REMOVAL INSTRUCTIONS

The installer or service technician can select from three separate routes to gain access to the burner and heat exchanger:

1. The base method involves removal of the aluminum Fan Coupler (FC) while

leaving the fan and gas valve in-place:

a. Ensure boiler cools down to ambient temperature. Do not drain the boiler

unless freezing conditions are expected during this procedure.

b. Remove the front cover. No tools are required. A ladder or step may be

required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to connectors, screws or refractory may occur.

c. Ensuring the power and gas are shut off, disconnect the ignitor cable and

ground wire from the ignitor

d. Remove the two screws that secure the ignitor to the lid using a # 2

Phillips screwdriver. Carefully remove the ignitor by sliding it straight up.

e. Remove the ignitor gasket and place parts on a clean dry area. f.

Release the v-clamp, taking care to preserve its gasket for possible reuse.

g. For the VFC 15-150, remove the 4 x 6mm hex socket bolts at the FC:

Fan interface. Three of the 4 bolts are easily dealt with using a regular

6mm Allen key, while the upper (rear) fastener is in a conned space;

start turning with the wrench then complete the job using needle-nose

pliers and/or ngers. 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” wrench for the nuts.

Lift away the Fan Coupler.

h. Remove the burner, noting the alignment of the longitudinal seam of its

metal bre surface relative to the ignitor location (it should be 180° of arc

opposed).

Remove the burner: heat exchanger gasket, and protect for possible reuse.

j. Remove the 4 bolts that attach the heat exchanger lid to the heat

exchanger. A 17 mm open end wrench or socket will be required. Note alignment for reinstallation. Lift off lid.

k. Note alignment of the inner refractory disk, then carefully lift out and

place on a clean, dry disposable material (paper or plastic).

Using this technique leaves the fan, gas valve and associated electrical

connections exposed to water and/or debris from heat exchanger cleaning; take precaution by bagging these components.

2. The preferred option for experienced IBC service personnel – for combined

servicing of the HX and swirl plate – involves removal of the FC and fan together, done as follows:

a. Perform steps 1 (a) to (f) as listed in #1above. Disconnect the 2 power

connections to the fan within step 1(c).

b. Split the fan from the swirl plate/ intake air housing:

i. Remove the 3 Phillips screws which run vertically upwards from the

gas valve into the fan. The rear screw can be challenging - these bolts

can be identied by the spacers under the bolt heads. Best to use an

4-6

INSTALLATION AND OPERATION INSTRUCTIONS

Vellumoid paper gasket VFC15-150 O-Ring, VFC 45-225

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

angle-driver to reach past the gas valve, or a stubby Phillips screwdriver for enhanced working space.

ii. Three vinyl hoses do not need to be disconnected, but if that is chosen

ensure they are marked for reinstallation. Avoid placing pressure on the disk-shaped air pressure sensor, which can damage the sensor.

iii. Lift away the FC/ Fan assembly and stow safely.

c. Perform steps 1(h) to (k) as listed above, and protect the gas valve from

water and dirt.

Use this method if site conditions provide a risk of debris within the

combustion air (dirty environment with no combustion air ltration). This

offers open access for cleaning of the swirl plate, air intake housing and fan inlet. Take care to protect the air intake and gas valve components left in place.

3. A third option available is a variation of #2, but substituting disassembly of

gas inlet piping (e.g. at a union near the drop leg) in place of splitting the fan/ gas valve in situ. This eliminates having to deal blind with the back screw per 2(b)(i) above; rather it can be handled “face-on” on a work bench. For this option, at Step 1(c), also unplug the gas valve electrical connection by removing the 1/4” gas valve harness connector screw, mark and disconnect the vinyl hoses from the intake air housing and gas valve; after Step 1(f) remove the 4 small Phillips screws at the gas valve inlet. Block off the combustion air intake pipe to prevent debris from falling inside.

Figure 33: Gas Valve Detail

With either approach selected, leave undisturbed the outer refractory ring unless

there are signs of damage. If replacement is required, make specic 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 appropriate), and reinsert per

noted alignment. If the outer refractory ring requires replacement, rst perform a dry t test (including placement of the HX lid overtop with the HX: lid gasket properly positioned) to conrm positive engagement of lid to

refractory for a good thermal seal. Apply a thin layer of mouldable refractory to the water pipes and header to be covered then insert the new outer ring. Apply gentle pressure until the ring’s upper surface is level and approx 1/16” (1-1.5 mm) proud to the HX rim.

2. Inspect the HX: lid gasket: look for cracks, deterioration or signs of gas

bypass. Replace if necessary. Conrm it is in place and offers a positive

sealing surface.

3. Place the HX lid over the gasket, reconrming that 1/16” (1-1.5 mm) is

available for compression on bolt tightening. Install the 4 Lid-to-HX bolts; with a 17mm wrench or socket, tighten with light force until bolt starts to get tight,

then nal tighten with 1/2 to 1 extra turn.. Over-tightening will cause lid to warp and possible leakage of fumes or ames.

4. Inspect the lower burner-to-HX gasket. Look for cracks, deterioration or signs

of gas bypass. Install original or replace as necessary.

5. Insert the burner, ensuring the metal mesh seam is rotated away from the

ignitor location.

6. Move the Fan Coupler into place, then:

a. Under option 1 – replace the paper gasket after applying silicone to each

side; install the 4 small Phillips bolts at the Fan: FC interface

b. Under option 2 – install the 3 standard Phillips screws to reattach the Fan

and swirl plate to the gas valve

MAINTENANCE

4-7

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

c. For option 3 – install the 4 small Phillips screws through the gas valve

support bracket and into the gas valve adjacent to the gas inlet. The screws are to be loosely attached at this stage to allow easier alignment at step 7. After the v-clamp is tightened at step 7, these 4 screws at support bracket can be tightened. Reinstate all gas piping.

7. With the FC/ Fan / gas valve assembly secure, place a good v-clamp-to-

burner gasket over the top of the burner ange, spread the v-clamp to span

the HX-burner-gasket sandwich then draw the v-clamp nut tight by hand plus 2 turns by wrench. Do not over-tighten. Use a max. 5 ft/lbs torque.

8. Reconnect all fan and gas valve electric leads, vinyl hoses

9. Re-install ignitor, tightening its screws by hand, then an extra 1/2 turn.

10. Re-attach ignitor wire and ground wire to ignitor.

11. Open up the gas supply and check for possible leaks

12. Return electric power to the boiler and perform start up routine

13. If the outer refractory ring has been replaced at Step 1 above, using a Type J

or K thermocouple, check the upper areas of the HX and lid for temperature for good thermal sealing at the refractory-to-lid interface. Allow 20 mins. prior

running at high re before the test; max target is 110°C

14. Check for gas or fume leaks after 10 minutes of continuous operation.

Figure 34: Refactory Detail

FOR REMOVAL OF THE FAN AND/OR GAS VALVE

For removal of the fan and/or gas valve only, follow steps 1(a) to (f) above, then depending on the objective perform the following:

• Fan removal: use Option 2, the additional steps within 2(a) (b) and (c) above

• Gas valve: use Option 3

For any change-out of the fan: with a permanent marker or equivalent, make an alignment mark between the fan and swirl plate adapter and use a 6 mm hex (Allen) key or driver, remove the 3 screws that attach the gas valve/swirl plate assembly to the fan.

FOR RE-INSTALLATION OF FAN AND/OR GAS VALVE,

1. If the gas valve has been removed, reattach it to the swirl plate.

2. Re-attach gas valve and swirl plate assembly onto fan observing the

alignment marks made during disassembly.

3. Re-plug both upper and lower fan harness connectors.

4. Re-plug gas valve connector and tighten up retaining screw.

5. If a new gas valve is being installed, remove the protective cover from the

gas inlet now.

Vellumoid paper gasket

Aluminium Spacer

Vellumoid paper gasket

Figure 35a: VFC 15-150 Fan Detial Figure 35b: VFC 45-225 Fan Detail

4-8

INSTALLATION AND OPERATION INSTRUCTIONS

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

5.0

TROUBLESHOOTING

The troubleshooting section is divided into 3 sections:

5.1 Preliminary Checks

5.2 Electronic Components

5.3 Troubleshooting Guide

Often, a problem can be identied and solved through simple checks of the basics: conrming the electrical power supply, gas ow and resetting the

thermostat control. To extend the cover of such preliminary checks, the boiler’s control module offers a clear visual display of the status of the various control circuit components.

Should a problem remain unsolved after applying the preliminary checks, proceed to the detailed system review, using the Troubleshooting Guide. The Guide covers potential error conditions as grouped into the following categories:

5.3.1 Using Control Module Errors Displayed

5.3.2 Ignition Problems

5.3.3 Cycling Problems

5.3.4 Temperature Problems

5.3.5 Miscellaneous

5.1

Below each section is a list of Symptoms, Diagnoses, and Remedies.

Also provided with this manual are a number of diagrams (see Section 6.0) for use with troubleshooting including:

• Electrical Wiring Diagrams

• Sequence of Operations Flowchart

• Boiler Component Layout Diagrams

PRELIMINARY CHECKS

The rst step in troubleshooting this system should be a review of the Controller’s

Touch Screen. There are a number of diagnostic features incorporated in the software that evaluate system integrity, display error conditions and provide initial suggested remedial actions.

In addition to checking the display, the following list is a guideline for troubleshooting:

1. Conrm power to the boiler: check that control module display is on (e.g.

display is lit).

2. Check that boiler is not in a safety lockout.

3. Ensure wiring is clean and secure.

4. Check that gas is reaching the unit.

5. Conrm water system is properly charged to 12 psig and pump is

serviceable.

TROUBLESHOOTING

5-1

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

5.2

Return water temperature sensor

ELECTRONIC COMPONENTS

This section details the method for troubleshooting the non-standard electronic components on the boiler including the electronic differential air pressure sensor and the temperature sensors.

5.2.1 Temperature Sensors

The resistance of the temperature sensors varies inversely with temperature. To test, measure the temperature of the sensed environment 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. Locate the blue

2-wire leads coming from the thermistors, which are afxed to the boiler supply

and return piping to the right of the heat exchanger. 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 binding force, which can distort the internal

dielectric isolation. Use modest tension only when afxing sensor to pipe.

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE

°F °C Ω °F °C Ω

10KΩ sensors supplied with boiler

2 x Water temperature sensors - (L) 1 x Outdoor sensor - (R)

See Table #10 for resistance values

0 -18 85,362 100 38 5,828

5 -15 72,918 105 41 5,210

10 -12 62,465 11 0 43 4,665

15 -9 53,658 115 46 4,184

20 -7 42,218 120 49 3,760

25 -4 39,913 125 52 3,383

30 -1 34,558 130 54 3,050

35 2 29,996 135 57 2,754

40 4 26,099 140 60 2,490

45 7 22,763 145 63 2,255

50 10 19,900 150 66 2,045

55 13 17,436 155 68 1,857

60 16 15,311 160 71 1,689

65 18 13,474 165 74 1,538

70 21 11,883 170 77 1,403

75 24 10,501 175 79 1,281

80 27 9,299 180 82 1,172

Table 10: Temperature Sensor resistance values

5-2

85 29 8,250 185 85 1,073

90 32 7,334 190 88 983

95 35 6,532 195 91 903

INSTALLATION AND OPERATION INSTRUCTIONS

Control wire plug

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

5.2.2 Fan/Blower

Operating power is provided by means of a separate 120 VAC connector at the back of the fan (white/black/green). Control of the fan is provided via a four lead connector 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 the fan to go to high speed and trigger a “Blocked Vent Error” within 6 seconds if the boiler is operating.

LEAD COLOR FUNCTION TROUBLESHOOTING

Unplug to run fan full speed

Air pressure sensor mounting

Red

Blue

Black Signal from controller

White Fan tach. 2 pulses/rev (freq x 30=rpm)

Table 11: Fan Operation

35 VDC Positive power terminal

35 VDC Negative power terminal

Fan will only operate at max. speed if disconnected.

5.2.3 Differential Air Pressure Sensor

Do not blow into the ports of the sensor, this is not a switch and “does not click when closed”. Excessive pressure will damage the sensor thus requiring replacement. The sensor values are located in the advanced diagnostics section of the controller. In general, the Fan Pressure and the Required Pressure should be very close to each 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

• Improper grading of the Exhaust and/or Air Intake piping allowing condensate

to be trapped in the piping

• Re-Ingestion of ue gasses has caused the Swirlplate and/or Fan Impeller to

erode, becoming ineffective.

• Air Pressure Sensor tubing not correctly attached.

TROUBLESHOOTING

If the Differential Air Pressure Sensor replacement is required, ensure the replacement sensor is IBC part# 240-003 (and specically that it is not a similar- looking part marked for use only on the SL 28-160 model boiler). Use of any other differential air pressure sensor is forbidden.

5.2.4 Water Pressure Sensor

The water pressure sensor ensures there is adequate pressure in the heating system for safe operation. The pressure is displayed in PSI as the default. If the

system pressure should drop below 8PSI the ring rate of the boiler is reduced. If the pressure drops to 4PSI or lower, the boiler will not re.

Check operation of the sensor by isolating the boiler from its system piping,

closing the system ll valve then cracking the pressure relief valve; the pressure displayed should reect declining pressure. If it remains “xed”, drain boiler and

replace sensor, or dislodge any blocking debris from sensor inlet channel and reinsert.

5-3

Fenwal ignition module - Microamp

(μA) test points are shown at top

right corner of module (above red L.E.D.)

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

5.2.5 Hi-Limit Switch (water and vent)

Check resistance between leads. If resistance is very low, temperature should be acceptable. If resistance is very high, temperature should be out of bounds. A simple means of checking whether a high limit switch is open is by measuring the AC voltage across the device. If the reading is 24 VAC the switch is open. If a 0VAC reading is shown, it is closed. NEVER connect an ohm-meter or continuity checker across a live circuit.

5.2.6 Ignition Module

There are two approved ignition modules - Fenwal (grey) and Capable Controls (white). Each have a red LED lamp providing the following signals: Fenwal – 1

rapid ash on 1st entering Pre-purge, 3 rapid ashes upon Failure to Ignite After 3 Attempts; the Capable Controls module provides a single ash at the start of each Purge and Interpurge cycle, continuous rapid ashes during the 4 second spark

interval, solid illumination following successful ignition until burner shutdown, and a slow on/off cycle with a 3-try failure.

Flame current can be monitored on the Fenwal. Connect an electrical test

meter - set to read Microamps (symbol μA) to the two test pins at the top right of

the ignition module. Recycle the boiler so it enters another trial for ignition and

monitor the ame current reading. When the burner ignites, a steady reading of

2-7 Microamps should be measured by your meter. 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 the Capable Control, specify IBC part# 240-049 – that provides the module plus added wire lead and instructions.

5-4

INSTALLATION AND OPERATION INSTRUCTIONS

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

5.3 TROUBLESHOOTING GUIDE

5.3.1 Using Control Module Errors Displayed

SYMPTOM DIAGNOSIS REMEDY

AIRFLOW ERROR

Touch Screen Message:

Error – Low Air Flow

Low combustion airow; soft error; will retry in 5 minutes

WARNING

Never attempt to repair the control module (circuit board). If the control module is defective, replace it

immediately.

Check fan operation • Check lead is attached at fan.

• Cycle power off/on; listen for fan initialization. If no action, focus your attention on the fan itself.

Check for fouled

reference lines and air sensor

Check achieved fan

power

Water noise in vent.

Excess condensate in

venting.

• Check clear vinyl air reference lines below gas valve for any sign of water. After disconnecting from black sensor, blow clear. Check for exhaust re-ingestion, or repeated power interruptions .

• Ensure condensate trap is not blocked.

• Go to Advanced Diagnostics and check differential air pressure sensor (at rest and with fan on). See Section 5.2.3.

In Diagnostics, Fan Operation, during Prepurge, Fan Pressure (FP) should move close to Required Pressure (RP); if FP only 480 to 600 vs. RP of 1,000 to 1,200, then check for actual vent system blockage: (a) disconnect intake within boiler case; (b) open burner then fan/gas valve looking for debris.

• Check condensate trap for obstructions.

Remove obstructions and rell condensate

trap with water.

• Check vent length, size and conguration,

particularly re: horizontal 2" piping.

WATERFLOW ERROR

Touch Screen Message:

Error - No Water Flow

Low water ow – soft error; will

retry in 5 minutes

TROUBLESHOOTING

Check pressure

sensors

Check for proper

piping

Check primary pump If there is a valve on the primary loop, close it

Check for restriction

in water pipe

• Check wiring: water pressure sensors to controller.

• Check pressure sensors. See Section 5.2.4 – 2nd paragraph.

Refer to Section 1.6 Water Piping for recommended piping installation.

and listen for cavitation (evidence ow). If not,

go to Installer Setup; select pump purge “on” to run pumps without a heat call - check for heat

buildup at pump body (indicates no ow).

Check temperature differential across heat

exchanger at low –medium ring rate if possible.

Examine air strainer components for scale.

5-5

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

SYMPTOM DIAGNOSIS REMEDY

MAXIMUM IGNITION TRIALS ERROR

Touch Screen Message:

Error – Ignition Failure after 3

tries

Boiler has failed to ignite on 3 successive attempts. Boiler in lockout for 1 hour, then repeats 3-try seq. Consult service technician if error recurs.

No spark when

igniting. Igniter

Check that igniter lead is secure at the control module and at the probe.

probe/ame sensor

disconnected.

Manual gas shutoff is

closed or gas line not

Check for gas ow. Open manual gas shutoff

and reset boiler.

fully purged.

Gap between igniter probe and ground rod is too large or too small.

Adjust gap between igniter probe/ame sensor

and ground rod to a distance of 3/16" (turn off gas supply and remove viewport for best

visibility; use prole of 1/8" diameter ignitor rod

to gauge distance)

Spark, but no ignition. Check spark module is sending power to gas

valve – close gas supply, then disconnect (black) electric housing from face of gas valve, gently spread plastic tabs to open, and look for 24vac voltage between 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 unserviceable ignition

• Ensure pressure vessel is grounded.

• Check the igniter probe/ame sensor is

electrically isolated from the vessel, and its ceramic insulator is intact.

• Replace ignition lead

• Replace spark module

lead or spark module.

HI LIMIT ERROR

Touch Screen Message:

Error – Water High-Limit

Exceeded

Water temperature exceeds hilimit. Boiler in hard lockout. Will reset in 1 hour. Consult service technician.

VENT HI-LIMIT ERROR

Touch Screen Message:

Error - Vent High-Limit Exceeded *** Call for service!

Vent temperature has exceeded the vent limit switch. Boiler in lockout. Consult service technician.

Defective or

disconnected hi-limit switch.

• Check wiring to hi-limit switch and control module.

• Check hi-limit switch. See Section 5.2.5.

• Check wiring to ensure sensor is properly connected to control module.

• Check for evidence of any damage to vent system.

• Push manual reset button, maintain constant watch during boiler operation to evaluate vent temperature at maximum operating settings to ensure no unsafe condition exists,

e.g. max ue temp. within allowable limits for

exhaust pipe material used.

5-6

INSTALLATION AND OPERATION INSTRUCTIONS

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

SYMPTOM DIAGNOSIS REMEDY

TEMPERATURE SENSOR ERROR

Touch Screen Message:

Error - Max. In-Out Temp.

Exceed. -> Check water ow

Water temperature signal not within acceptable range.

Current outlet

temperature exceeds operating limit.

Defective or

disconnected temperature sensor.

• Check water ow.

• Check wiring to temperature sensor and

control module.

• Check temperature sensor. See Section

5.2.1.

Potential ow or sensor failure.

Consult service technician.

MISCELLANEOUS

Touch Screen Message:

• Check transformer; replace if damaged.

• Check circuit board for visible damage.

Blank – screen dark, but fan

running Indicative of powersurge damage to appliance

5.3.2 Ignition Problems

SYMPTOM DIAGNOSIS REMEDY

NOISY SPARK WHEN IGNITING

Ignition lead is not

rmly connected.

Reconnect ignition lead.

BOILER RUMBLES WHEN IGNITING.

BOILER WILL NOT ATTEMPT TO IGNITE. FAN AND PUMP ARE OPERATING NORMALLY.

BOILER WILL NOT ATTEMPT TO IGNITE. FAN AND / OR PUMP ARE OFF DISPLAY NOT ILLUMINATED

Contaminants/

moisture on igniter

Ensure probe is dry by re-running post-purge; otherwise, clean or replace igniter probe.

probe/ame sensor.

Fluctuating gas

Check CO2 level via analyzer.

pressure/ gas pressure too high/too low.

Check for proper

Check pressure with manometer during ignition.

piping.

No power to ignition control module.

Igniter probe/ame

• Check system wiring.

• Check air reference tubing.

Reconnect probe.

sensor disconnected.

Blown fuse in ignition

Check fuse. If blown, replace.

module.

Defective Control

Check ignition output from control module.

Module.

No power to boiler. Check line voltage .

Defective transformer. Check transformer. Reconnect or replace as

needed.

TROUBLESHOOTING

5-7

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

5.3.3 Cycling Problems

SYMPTOM DIAGNOSIS REMEDY

RAPID CYCLING Improper values

entered via keypad.

Excess Condensate in venting.

Obstruction in

condensate trap.

Improper vent length

or improper slope to

vent.

Incorrect settings or

defective thermostat.

Air in system or

marginal water ow.

Slow combustion air blower.

Dirty burner/heat exchanger.

Check load maximum temps are above target temps, by 1/2 of the selected boiler differential. Ensure boiler differential is OK (16-30°F is generally adequate)

Check venting slopes on horizontal runs. Look for sags.

Inspect and clean condensate trap.

Check venting. Compare vent length and diameter to Table 4: Maximum Venting.

Check operation. Refer to manufacturer’s instructions. Check setting with ammeter.

Bleed/purge system as required. Conrm

adequate pump size and temp rise in HX

Check that CO2 level is OK per Tabel 8.

Check pressure drop.

Insufcient water

Refer to recommended piping in Section 1.6

ow due to improper

piping.

Insufcient water ow

due to undersized

Check manufacturer’s rating charts/check temperature differential across heat exchanger.

pump.

Insufcient water ow

due to restrictions in

Check temperature differential across zone/heat exchanger.

water pipe.

Insufcient radiation. Check actual amount of radiation per zone and

refer to manufacturer’s rating tables.

Unit over-red. Clock gas meter/check gas pressure with

manometer/ check CO2 level.

Unit Oversized. Check load calculation vs. min. boiler output.

Improperly set or

Check operation with ohmmeter/voltmeter.

defective operating/

safety controls.

5-8

INSTALLATION AND OPERATION INSTRUCTIONS

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

5.3.4 Temperature Problems

SYMPTOM DIAGNOSIS REMEDY

INSUFFICIENT HEAT

Operating

Increase temperature target.

temperature too low.

Priority parameters

Review load conguration parameters.

or load conguration

improperly set up.

Unit undersized. Refer to Load Calculation vs. Boiler Output.

Air trapped within

Bleed system as required.

system.

Improper system

Refer to recommended piping in Section 1.6

piping.

System pump undersized.

Check pump manufacturer’s data/check temp differential across heat exchanger.

Poor gas/air mixing. Check CO2 level.

Defective thermostat. Refer to manufacturer’s instructions.

Obstruction in

Inspect and clean condensate drain.

condensate drain.

Unit cycling on

Check operation with Ohmmeter/Voltmeter.

operating/ safety controls.

TEMPERATURE EXCEEDS THERMOSTAT SETTING

ONE OR MORE ZONES DO NOT HEAT PROPERLY

System radiation undersized.

Incorrect anticipator

Check manufacturer’s rating tables for capacity per foot.

Check with Ammeter.

setting.

Thermostat not level. Check level.

Air trapped within

Vent system/zone as required.

zone(s) piping

Insufcient radiation/ excessive heat loss.

Insufcient ow rate

Check actual length of pipe using radiation / heat loss calculation.

Check temperature drop across zone.

to zone(s).

Defective zone valve/

Check operation per manufacturer’s instructions.

zone circulator.

TROUBLESHOOTING

5-9

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

5.3.5 Miscellaneous

SYMPTOM DIAGNOSIS REMEDY

FUMES AND HIGH HUMIDITY

Improperly installed

Refer to installation/operation instructions

condensate trap

Leak in vent piping Inspect using soap solution

BOILER STUCK ON INITIALIZE

TOUCH SCREEN MESSAGE:

Unknown Error

ERROR: WATER HIGH LIMIT / LOW WATER CUT-OFF WON’T CLEAR.

DHW TAKING TOO LONG TO HEAT.

BOILER OUTPUT NOT MODULATING UP TO MAXIMUM DESPITE TARGET NOT BEING REACHED.

Flue gas leak within

Visually inspect all mechanical connections

boiler

Fan board failure Replace fan.

Temperature sensor

input problem.

Test each temperature sensor for appropriate readings and replace defective temperature sensor.

Boiler is in 1 hour safety lockout.

Sensor may be underreading actual water temp.

Reset safety device and cycle boiler power off and on to reset error.

Check sensor engagement; note well is 15cm / almost 6 inches deep and sensor must be fully set to back. Check programmed settings boiler temp set too close to the required DHW temp

Possible ow issue: check for 35 or 40

degree F temperature

Conrm that primary pump is able to overcome

head loss of boiler and primary loop piping at the

required ow rate.

difference between boiler supply and return water temperatures

(evokes electronic fence).

PRIMARY PUMP RUNS DURING PARALLEL-PIPED DHW CALL.

Load denition as DHW. On Touch Screen Controllers set the boiler pump

to off in the Installer Set-up Menu.

5-10

INSTALLATION AND OPERATION INSTRUCTIONS

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 OPERATION

DIAGRAMS

6-1

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

6-2

INSTALLATION AND OPERATION INSTRUCTIONS

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

ITEM# DESCRIPTION PART# QTY

6 FAN, RG130 240-040 1

11 GASKET, FAN - FAN ADAPTER 250-310 1

15 FAN ADAPTER PLATE 180-023 1

20 SCREW, M4 x 10, FLAT HEAD,

EQUIPPED w/240-040

25 AIR INTAKE, BASE 180-017 1

30 SWIRL PLATE 180-020 1

35 AIR INTAKE, COVER 180-018 1

40 GAS VALVE 180-022 1

45 SPACER, #8, 1/8” THICK, 1/4”

150-092 3

O.D.

50 SCREW, M4 x 30, TAPPING,

EQUIPPED w/180-022

55 SCREW, #10-32 x 7/8”, HEX

150-110 4

HEAD

61 GASKET, FAN - FAN

250-311 1

COUPLER

70 NUT, #10-32, w/EXTERNAL

150-111 4

TOOTH WASHER

75 SWITCH, SNAP DISK,

240-030 1

MANUAL RESET, 230F

80 SWITCH, SNAP DISK, AUTO-

240-032 1

RESET, 203F

85 MOUNTING PLATE, SNAP

250-333 1

DISK

90 IGNITION MODULE

240-004C 1 (ALTERNATE CAPABLE CONTROLS 240-049)

95 SCREW, SHEET METAL, #8

150-021 2 x 3/4”

100 SENSOR, WATER PRESSURE 240-006 2

105 ENCLOSURE 250-312 1

111 GAS VALVE MOUNTING

250-314 1 BRACKET

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

150-014 6 HEAD

135 CHASSIS, CONTROLLER PCB 250-583 1

140 PCB, CONTROLLER V10.0 230-002 1

145 SPACER, MALE - FEMALE,

150-096 4 #6-32 x 3/4”

150 FRONT COVER,

250-591 1 CONTROLLER

155 PIPE CLAMP 150-039 3

160 2” ABS AIR INTAKE

ASSEMBLY

165 CLIP NUT, M10, 19mm

150-105 4 CENTER

170 HEAT EXCHANGER 170-009 1

ITEM# DESCRIPTION PART# QTY

175 REFRACTORY, OUTER 250-287 1

180 REFRACTORY, INNER 250-306 1

185 GASKET, HEAT EXCHANGER

250-328 1

LID

190 LID, HEAT EXCHANGER 250-284 1

195 SCREW, M10 x 55, HEX HEAD 150-106 4

200 WASHER, FENDER, M10 150-104 4

205 IGNITOR 240-002 1

210 GASKET, IGNITOR 250-050 1

215 SCREW, M4 x 10, PAN HEAD 150-013 4

220 SIGHT GLASS HOLDER 250-309 1

225 GASKET, SIGHT GLASS 250-060 2

230 SIGHT GLASS 250-059 1

235 GASKET, BURNER 250-308 2

240 BURNER 180-021 1

245 V-CLAMP 150-071 1

250 FAN COUPLER 250-280 1

270 FRONT COVER, VFC 150 250-313 1

Diagram 6.1-1 (Parts List)

Diagram 6.1-2: Door Assembly – VFC 15-150

DIAGRAMS

6-3

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

6-4

INSTALLATION AND OPERATION INSTRUCTIONS

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

ITEM# DESCRIPTION PART# QTY

5 FAN, NRG 137 240-048 1

10 O-RING 150-073 1

15 FAN ADAPTER PLATE 180-023 1

SCREW, M4x10 TAPPING,

FLAT HEAD, EQUIPPED w/FAN

25 AIR INTAKE, BASE 180-017 1

30 SWIRL PLATE 180-020 1

35 AIR INTAKE, COVER 180-018 1

40 GAS VALVE 180-022 1

45 SPACER, #8, 1/8” THICK, 1/4”

150-092 3 O.D.

50 SCREW, M4 x 30, TAPPING,

EQUIPPED w/GAS VALVE

55 SCREW #10-32 x 7/8” HEX

150-110 4 HEAD

60 GASKET, FAN - FAN

250-381 2 COUPLER

65 FAN COUPLER SPACER 250-370 1

70 NUT, #10-32, w/EXTERNAL

150-111 4 TOOTH WASHER

75 SWITCH, SNAP DISK,

240-030 1 MANUAL RESET, 230F

80 SWITCH, SNAP DISK, AUTO-

240-032 1 RESET, 203F

85 MOUNTING PLATE, SNAP

250-333 1 DISK

90 IGNITION MODULE

240-004C 1 (ALTERNATE CAPABLE CONTROLS 240-049)

95 SCREW, SHEET METAL, #8

150-021 2 x 3/4”

100 SENSOR, WATER PRESSURE 240-006 2

105 ENCLOSURE 250-312 1

110 MOUNTING BRACKET, GAS

250-316 1 VALV E

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 250-583 1

140 PCB, CONTROLLER V10.0 230-002 1

145 SPACER, MALE - FEMALE,

150-096 4 #6-32 x 3/4”

150 FRONT COVER,

250-591 1 CONTROLLER

155 PIPE CLAMP 150-039 3

160 2” ABS AIR INTAKE

ASSEMBLY

165 CLIP NUT, M10, 19mm

150-105 4 CENTER

170 HEAT EXCHANGER 170-009 1

ITEM# DESCRIPTION PART# QTY

175 REFRACTORY, OUTER 250-287 1

180 REFRACTORY, INNER 250-306 1

185 GASKET, HEAT EXCHANGER

250-328 1

LID

190 LID, HEAT EXCHANGER 250-284 1

195 SCREW, M10 x 55, HEX HEAD 150-106 4

200 WASHER, FENDER, M10 150-104 4

205 IGNITOR 240-002 1

210 GASKET, IGNITOR 250-050 1

215 SCREW, M4 x 10, PAN HEAD 150-013 4

220 SIGHT GLASS HOLDER 250-309 1

225 GASKET, SIGHT GLASS 250-060 2

230 SIGHT GLASS 250-059 1

235 GASKET, BURNER 250-308 2

240 BURNER 180-021 1

245 V-CLAMP 150-071 1

250 FAN COUPLER 250-280 1

280 FRONT COVER, VFC 225 250-315 1

Diagram 6.2-1 (Parts List)

Diagram 6.2-2: Door Assembly – VFC 45-225

DIAGRAMS

6-5

Diagram 6.3-1: Vent high limit

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

6.3 ADDITIONAL PARTS DIAGRAMS

51 TRAP/EXHAUST KIT

Diagram 6.3-2: Intake Air Filter (order separately)

Diagram 6.3-4: Accessory parts kit (shipped with boiler)

ITEM # DESCRIPTION PART #

47 Pressure Relief Valve 180-005

49 Outdoor Temperature Sensor 240-025

51(a) Trap/Exhaust Kit VFC15-150 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 Pressure Sensor Bushing 250-023

103 Intake Air Filter Element 180-103

104 Intake Air Filter Housing 180-104

PARTS BELOW - NOT SHOWN

68 Ignition Cable 210-001

69 Fuse Kit (10 pack) P-114

71 8 Position Terminal Block - Green 240-019

72 22 Position Terminal Block - Orange 240-020

73 DC to AC Fan Harness Conversion Kit 71-ACDC

74 Acid Neutralization Tank 180-029

102 Ignitor Kit w/Gasket P-142

Diagram 6.3-3: Water pressure sensor group

6-6

INSTALLATION AND OPERATION INSTRUCTIONS

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

6.4 WIRING DIAGRAMS

Diagram 6.4-1: Ladder wiring diagram

DIAGRAMS

6-7

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

Diagram 6.4-2: Internal wiring diagram

6-8

INSTALLATION AND OPERATION INSTRUCTIONS

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

6.5 SEQUENCE OF OPERATION

Diagram 6.5-1: Sequence of operation diagram

DIAGRAMS

6-9

INSTALLATION & COMMISSIONING REPORT

Boiler Details:

Model Number _____________________ Serial Number ______________________________________________

Date of Installation ______________ Address of installation __________________________________________

_____________________________________________________________________________________________

User contact information _______________________________________________________________________

Installer Information Company ___________________________________________________________________

Address ______________________________________________________________________________________

Phone/Fax/E mail ____________________________________________________________________________ __

Fuel Natural Gas Propane

Gas Supply Pressure (high re) _______ Inches w.c. Measured Rate of Input (high re) ____________ Btu/hr

Installation instructions have been followed and completed (Section 1 of Installation and Operating Instructions).

Check-out procedures have been followed and completed (Section 3 of Installation and Operating Instructions).

Leak testing completed gas piping venting system Fan and combustion components

System Cleaned and Flushed (type of cleaner used) ________________________________________________

System 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 lled

Ignition Safety Shutoff test completed. Flame current reading - High re _______ µA - Low re _______ µA

Owner advised and instructed in the safe operation and maintenance of the boiler and system.

Information regarding the unit and installation received and left with owner

Condensate drain clear and free owing Condensate Neutralization? Yes/No

Combustion Readings:

_____________ % O2 ______________ % CO ____________ ppm

Flue temperature _________ Return water temperature (measure simultaneously with ue temp.) _______________

Installers: send this completed sheet - Fax to 604 877 0295 - or - scan and Email to info@ibcboiler.com, and earn an extra year’s Parts Warranty coverage (User to submit corresponding Installation Record from User Guide).

Commissioning has been completed as listed on this report - Installer Signature _____________________________

INSTALLER SET-UP

Load Denition - Load #1 _______________________________________________________________________

Load Conguration - Load #1

_____________________________________________________________________________________________

Load Denition - Load #2 _______________________________________________________________________

Load Conguration - Load #2

_____________________________________________________________________________________________

Load Denition - Load #3 _______________________________________________________________________

Load Conguration - Load #3

_____________________________________________________________________________________________

Load Denition - Load #4 _______________________________________________________________________

Load Conguration - Load #4

_____________________________________________________________________________________________

SERVICE RECORD

DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE

NOTES

IMPORTANT

This Boiler is equipped with a feature that saves energy by reducing the boiler water

temperature as the heating load decreases. This feature 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 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 equipped with a tankless coil (not applicable to IBC’s VFC boilers).

US installers should contact IBC for any further information required.

REVISION HISTORY

R1 (SEPTEMBER 2005) Initial release

R2 (JULY 2007) Venting requirements (Canada) to ULC-S636; internal wiring diagram and warranty

details added

R3 (MARCH 2010) VFC 45-225-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 designation merged within base VFC 45-225 model

R5 (SEPTEMBER 2014) Disclosures updated to CSA 4.9-2014 / ANSI Z21.13-2014 Standard; Touch Screen Controller added

R6 (MAY 2015) Address update

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 Boilers VFC 15-150, VFC 45-225 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual