IBC Boilers VFC 160 Installation And Operating Instructions Manual

IBC

IBC Technologies Inc. Vancouver, Canada

VFC Series Fixed Firing Gas Boiler Model VFC 160

INSTALLATION AND OPERATING INSTRUCTIONS

WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.

Do not store or use gasoline or other flammable vapours and liquids or other combustible materials in the vicinity of this or any other appliance.

Should overheating occur or the gas supply fail 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

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 fire department.

• Installation and service must be performed by a qualified installer, service

agency or the gas supplier.

VFCF160-v1.0

TABLE OF CONTENTS

1. INSTALLATION ...................... 3

1.1 GENERAL..........................................3

1.2 CODE REQUIREMENTS ................3

1.3 Location ..............................................4

1.4 Venting ................................................5

1.4.1 Applications................................5

1.4.2 Category IV Venting ................10

1.4.3 Closet Installations ...................10

1.5 Water Piping.....................................10

1.6 Gas Piping.........................................12

1.7 Electrical Connections .....................13

1.7.1 Mains Hook-up.........................13

1.7.2 Thermostat wiring.....................13

1.7.3 Thermostat Heat Anticipator ....14

2. STARTUP.............................. 15

2.1 PRIOR TO START-UP ...................16

2.1.1 Test Ignition System Safety

Shutoff Device.............................................16

2.4 CHECK BOILER INPUT .............. 17

2.5 SET OPERATOR LIMIT .............. 17

3. MAINTENANCE AND

TROUBLESHOOTING..................18

3.1 BOILER OPERATION .................. 18

3.1.1 Normal Operation .................... 18

3.1.2 Post-Purge Cycle ..................... 18

3.1.3 Boiler Safety System ............... 18

3.2 BOILER MAINTENANCE............ 19

3.2.1 General Care ............................ 19

3.2.2 Inspection................................. 19

3.3 COMPONENT DESCRIPTION.... 20

3.3.1 Pressure Switch........................ 20

3.3.2 Flow Switch............................. 20

3.3.3 Operator ................................... 20

3.3.4 Hi-Limit ................................... 20

3.3.5 Transformer ............................. 21

3.3.6 Gas Valve ................................ 21

3.3.7 Blower ..................................... 21

3.3.8 Ignition Control Module(ICM) 21

3.3.9 Igniter Probe/Flame Sensor ..... 21

3.3.10 DC Power /Enunciator Panel... 21

3.3.11 Detailed System Checks .......... 22

2.2 GAS VALVE ADJUSTMENT........16

2.3 BLOWER ADJUSTMENT .............17

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1. INSTALLATION

1.1 GENERAL

The VFC 160 boiler is a low pressure, fully condensing unit having a fixed firing rate input of 160 MBH (160,000 Btu/hr). The boiler is approved for either Direct Vent (sealed combustion) or Category IV (indoor air) applications, providing a great degree of installation flexibility.

The installer must clearly indicate the vent category for the installation on the rating plate using an indelible marker. See section 1.4 - Venting.

Figure 1. shows outer case dimensions and piping and electrical holes. Use this diagram to find a suitable location for the boiler. (see also Section 1.3 Location.)

22.5" [572mm]

12" [305mm]

Table 1 - Connections

Description Size

A water outlet 1” NPT

B water inlet 1” NPT

C gas ½” NPT

D electrical power 3/4”

E thermostat 3/4”

F pump 3/4”

G combustion air 4.0"

H exhaust vent 4.0"

1.2 CODE REQUIREMENTS

Gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13-2000.

Installation must conform to local codes,

or in the absence of these, with the latest editions of the National Fuel Gas Code

ANSI Z223.1 and the National Electrical Code ANSI/NFPA 70.

34" [864mm]

Where required by jurisdiction, installation must conform to the Standard for Controls and Safety

Instructions to put the boiler in operation are located on the inside surface of this cover panel.

FOR YOUR SAFETY

Do not store or use gasoline of other flammable vapors and liquids in the vicinity of this or any other appliance.

Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. If there is any

22.5" [572mm]

conflict in the above requirements, then the more stringent requirement will apply.

12" [305mm]

In Canada, installations must conform to the current CAN/CGA B149 and the

Canadian Electrical Code Part 1 CSA

Figure 1. Dimensions/Connections

C22.2 No. 1.

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1.3 Location

Keep boiler area free and clear of combustible materials, gasoline, and other flammable vapours and liquids.

The VFC-series boilers are designed and approved for wall or floor installation (on combustible flooring), with significant flexibility of location provided with the available venting options. The boiler can be placed in an alcove, basement, closet or utility room.

Care must be taken not install the boiler in areas where the combustion air source is subject to chemical fouling. Experience has shown that exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants, aerosol propellants, drycleaning fluids, de-greasers and paintremovers all contain vapours which can form corrosive acid compounds when burned in a gas flame. Airborne chorides such as those released with the use of laundry detergents are also to be avoided. For this reason, the Category IV (indoor air) venting option using air surrounding the boiler should not be used in a laundry room installation.

It is recommended that the boiler be located in an area 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.

In addition to the foregoing, other factors determining potential mounting sites:

• ensure minimum clearance

requirements for combustible materials(see Table 2) are satisfied

• 36” clearance at the front is

recommended for adequate servicing

• gas ignition system components

should be protected from water (dripping, spraying, rain, etc.)

• boiler should not be exposed to

water leaks from piping or components located overhead

• in a new construction installation,

particular action must be taken to protect the boiler from dust; combustion air should be drawn from a CLEAN source (e.g. outdoors) and the boiler must be isolated from interior dust sources. Do not seal boiler case openings directly - allow for air circulation and ventilation in the immediate area.

Table 2 - Clearance from Boiler Cabinet

Surface Distance

from

Combustible

Surfaces

Front 2” 24”

Rear 0” 0” L. Side 0” 12” R. Side 2” 18”

Top 10” 10”

Below the boiler, 12” is required to rovide clearance for the inlet and exhaust venting together with the required condensation trap. Legs are available as an accessory for floormounting of the boiler; the 14” legs provide the necessary clearance.

Recommended

Distance for

Service

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1.4 Venting

All venting must be installed in accordance with the requirements of the jurisdiction having authority: in the USA Part 7, Venting of Equipment of the National Fuel Gas Code, ANSI 223.1, latest edition, and any other local building codes are to be followed. In Canada, Part 7 - Venting Systems of the B149 Code 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.

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.

a) seal any unused opening in the

common venting system.

b) Visually inspect the venting system

for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

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 fireplace dampers.

d) Place in operation the appliance

being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

e) 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, fireplace dampers and any other gas-burning appliance to their previous conditions of use.

f) 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 Installation Code and/or local codes.

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 CAN/CGA - B149 Installation Code.

c) 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

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1.4.1 Applications

The VFC 160 boiler is approved with alternative venting options: either Direct Vent or Category IV venting can be used offering flexibility to meet the specific requirements of the installation. With the

Direct Vent case, combustion air is piped directly to the boiler’s air intake from outdoors. Using the Category IV alternative, air for combustion is drawn from the indoor air surrounding the boiler or drawn from ventilated attic or crawl spaces.

The VFC 160 is shipped with a high water temperature limit switch set for 200°F.

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 (see below).

All boilers are shipped with connectors permitting attachment of 2” intake piping.

It is a code requirement that the rating plate reflect the nature of the boiler vent configuration as installed. To facilitate such venting installation flexibility, VFC boilers are shipped with the rating plate unmarked. The installer shall indelibly mark the appropriate box on the rating plate to recognize the venting alternative chosen.

Exhaust venting is to be connected directly to the 2” NPT male threaded stainless steel fitting on the bottom of the pressure vessel using a 2” CPVC NPT x Socket fitting (female threaded adaptor or 90° elbow). A condensate trap of CPVC and PVC shall be spliced into the CPVC exhaust pipe at or near the base of the boiler (see Figure 2).

Combustion air piping is connected at the base of the boiler using a standard 2" PVC coupler or elbow. Screen material shall be placed at the inlet termination as appropriate for the environment (e.g. insects, dust).

1.4.1.2 Vent Travel

With the specified 2 1/2" or 3” piping (after 10' of 2" CPVC on the exhaust side), the boiler can be sited up to 90 equivalent feet from the vent termination. The actual vent travel is reduced for fittings in accordance with Table 3. - for example, using 5 x 90º long-sweep* ABS elbows, the maximum lineal measure is 65 feet.

Table 3 - Max. Venting Length

Pipe Size

( * = long sweep)

Max.

Equiv.Length

1.4.1.1 Intake/Exhaust Vent Material

The approved materials of construction: For the exhaust vent-

• 2" CPVC Sch. 40 or 80 pipe (per ASTM F441) and Sch. 40 or 80 fittings for the initial 10 lineal feet of travel

• 2 1/2" or 3" Sch 40 CPVC or PVC, or 3" ABS (Sch. 40/ASTM D2661 or F628) and fittings thereafter; For the inlet air - ABS and PVC (ASTM D1785 or D2665) are permitted.

See Vent Travel- below.

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3” (after 10' of 2") 90’ (incl 1st 10') 90° elbow(CPVC/PVC) Allow 8’ equiv. 45° elbow(CPVC/PVC) Allow 4’ equiv.

90° elbow*(ABS) Allow 5’ equiv. 45° elbow*(ABS) Allow 2.5’ equiv.

A 3” x 2” (or 2.5" x 2" as appropriate) 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. The 3’ interval (which is part of the 90’ max. travel distance) is allowed to

provide space for splicing in an optional 2” compatible air filter unit.

The junction between the initial 2" vent section (e.g. 10' of CPVC ), the vent line diameter is increased through use of a 3”- 2” (or 2.5" x 2") reducer. It shall be placed in a vertical section of the flue gas vent to avoid pooling of condensate.

Exhaust venting must slope back to the trap/drain with a pitch of at least ¼” per foot so condensate runs towards the trap. Support should be provided every 2 to 3 feet for each of the intake and vent piping. Insulate exhaust piping where it passes through unheated space with appropriate pipe insulation to prevent freezing of condensates.

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

straight 2" tee or a 2” x ½” x 2” reducing tee). The trap itself is formed using ½” CPVC pipe for the drop leg, with ½” PVC pipe, elbows and threaded union fittings. The trap must be installed as follows:

• Have 5” minimum neck depth

• Piped to within 3” of a drain or be

connected to a condensate pump

• Drainage line must slope down to the

drain at a pitch of ¼” per foot so condensate runs towards the trap

• IMPORTANT! Fill trap with

water before boiler is first fired to prevent exhaust fumes from entering room. Never operate the boiler unless the trap is filled with water.

• Trap should be checked every 6

months. Clean and refill as necessary.

All joints must be secured using CPVC, ABS or ABS/PVC solvent cement to bond the respective pipe material. Use solvent cement on the connector located at the CPVC/ABS junction (e.g. 10’ along the exhaust piping). Follow the cement manufacturer’s instructions closely when joining various components.

All vent connections must be liquid and pressure tight. Test exhaust venting connections, under fan pressure with vent blocked, using a soap/water solution prior to firing.

1.4.1.3 Condensate Trap

A condensate trap must be installed at the base of the boiler (or within 12” of the first 90° exhaust line elbow), as shown in Figures 2. (e.g. spliced into the 2” CPVC exhaust vent using a

¼" vertical per

horizontal foot

fill wit h wat er (CP VC D rop leg)

to drain or condensate trap

5" min.

Figure 2 -Condensation Trap Alternatives

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1.4.1.4 Venting Passage Through

Ceiling and Floor

12" min.

24" min.

The following instructions apply to 2”,

2.5" and 3” piping:

• pipe clearances - no specific

requirements - follow local codes

• piping must be supported in the

flooring

• all piping must be liquid and

pressure tight.

1.4.1.5 Rooftop Vent Termination

Vents must terminate as follows:

• 12” above grade and normal snow

line to vent terminal bottom

• DO NOT exhaust vent into a

common venting system (See Figures 3 & 4 for rooftop vent terminations)

exhaust vent with s creen

air intake 1 80° elbow

with screen face down

12"min.

12" min.

snow line

2" min.

10 ft. or less

2 ft. min.

2" min.

Figure 3. Vent Terminations through a Pitched Roof

1.4.1.6 Sidewall Vent Termination

Vents must terminate as follows:

• minimum 12” from any building

opening

36" min.

snow line

12" min.

2" min.

other than as listed, vents terminate in the sam e manner as in figure 3. above.

Figure 4. Vent Terminations Through a Flat Roof

• minimum 3’ above any forced air

intake located within 10’

• minimum 4’ horizontally from (and

in no case above or below unless 4’ horizontal distance is maintained), from electric or gas meters, regulators and relief equipment

• not to be located over public

walkway, in a confined space, or under any overhang or deck

• vents must be installed such that flue

gas does not discharge towards neighbor’s windows, or where personal injury or property damage can occur.

• For Direct Vent installations

employing sidewall vent terminations, both the inlet and exhaust terminations shall be located on the same plane (side) of the building, with the exhaust outlet placed above the inlet to avoid reingestion (later point not applicable to concentric vent termination).

(See Figures 5, 6 & 7 for side wall vent terminations)

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Figure 5. Side Wall Venting

vent tee sh ould be parallel to side wall. intake should be swung to parallel with side wall.

min. 12 " between

bottom of intake

and bottom of vent

MIN. 24" TO

ANY OVERHANG

MIN. 4’

HORIZONTAL

DISTANCE

FROM ANY

GAS OR

ELECTRICAL

METER

MIN 36" TO

INTAKE

MIN. 12"

installation below average snow level

4−3/8"

minimum

5−1/2"

12"

MIN. 12" TO ANY OPENING

SNOW LINE

12" m in. clearance

to any overhang

FIELD SUPPLIED PLASTIC STRAPPING MUST BE USED TO SECURE THE VENT TO THE STRUCTURE

24−1/2"

18−1/2"

12" min. above

average snow leve l

Figure 6. Side Wall Vent Terminations (Configuration 1)

2.5" or 3" PVC or 3" ABS

"−

2.5"/3" PVC or 3" ABS or CPVC

4"x4"x4" ABS/PVCTee(alt: 4x4x3 Tee with approp.bushing)

If 3" venting is used, the exhaust line must be reduced to 2½" immediately prior to entering the 4" termination tee to allow adequate intake clearance. Use a 3 x 2½"

Figure 7. Side Wall Vent Terminations (Configuration 2)

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1.4.2 Category IV Venting

A category IV venting system is one in which air for combustion is take from the ambient air around the boiler. Vent piping is run horizontally or vertically to the outdoors.

1.4.2.1 Ventilation and Air Supply

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 Section

5.3 Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 (latest edition), or applicable provisions of the local building codes; in Canada, in compliance with CAN 1.4.3.

The following lists are recommendations for buildings of energy-saving construction, fully caulked and weatherstripped:

• an opening to the outside, within 18”

of the floor, but no less than 6” off

the floor, should be provided in the

room. Each opening should be

covered in a grill, and have an area

of 1” per 1,000 BTUh for ALL

APPLIANCES in the area.

• Openings must not be closed or

reduced. Doors and windows used

for air supply must be locked open.

• Mechanical draft exhaust or supply

fans are not to be used in or near the

boiler area

• Boiler combustion and ventilation

airflow must not be obstructed

Category IV venting is installed in the same manner as for the exhaust side of Direct Vent installations.

1.4.3 Closet Installations

For installations in a confined space (such as a closet), ventilation openings must be provided through a door or wall to prevent excessive heat from building up inside the space.

Minimum requirements:

• one opening within 12” of the ceiling

(100 sq. in. opening)

• one opening within 12” of the floor

(100 sq. in. opening)

1.5 Water Piping

Follow applicable Codes and good piping practice. Any uninsulated hot water pipes must be installed with a minimum 1” clearance from combustible materials.

System piping is connected to the boiler using the 1” NPT female threaded fittings provided at the locations shown on page 10. Typical piping systems are shown in Figures 8,9, &10.

A 30 psi pressure relief valve (¾” NPT) is supplied for field installation in the flow supply line, in the manner shown in Figures 8,9, & 10. Relief valve discharge piping must terminate 6” above a drain using plain un-threaded end, or per local Code.

To avoid exposure to water damage, system piping and components are not to be located overhead the boiler.

Indoor combustion air must not expose the boiler to contamination - see Section

1.3 - Location, above. In other respects,

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(s)

stop & waste

(

)

backflow

or ball valve

boiler feedwater

preventer

Figure 8. Sample Piping Schematic (1)

cold supply

flow

check

system supply

hydronic flow check(s) o zone valves to prevent thermal circulation

contractor

supplied

system

circulator

air purger

diaphragm expansion tank

auto fill valve

12 psi min.

drain

air vent

12−18"

pressure relief valve

system supply piping

tee & boiler drain for system purging

ball valve

system return piping

#30

#15

Figure 910. Sample Piping Schematic (2)

note: wire aquastat or control contacts in series wit

parallel wired zone control end switches or pump relay

air

eliminator

diaphragm expansion

tank

pressure relief valve

contacts.

buffer/tempering tank

flow

check

additional zones

zones

aquastat

indirect

T&P

domestic

relief

water

heater

wire to zone valve end switches or relay contacts

hot

cold

Figure 10. Sample Piping Schematic (3)

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The VFC boiler is designed for supply water temperatures within the range 80°F to 180°F, with a 20°F rise. Water flow rates and pressure drop (head in ft. w.c.) associated with a 20°F maximum rise (∆°T) for the respective VFC models are as follows:

Table 4 - Flow Rate

Model Flow

(Usgpm)

VFC 160 16.0 12

Water flow rates must not be allowed to fall below 8 gpm in any possible operating condition (eg. Single zone in use).

To achieve system flow rates and temperatures within such limits, care must be taken to select the appropriate pump. Evaluate pressure drop across the system, including the above head values for the boiler itself. Ensure 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, confirm actual performance by measuring ∆°T (under high and low flow conditions) after establishing the correct firing rate (see Section 2.2 – Check Boiler Input).

VFC-series boilers are supplied with a integral low-water flow switch, which allows installation of the boiler above radiation level. The flow switch is calibrated to close with at 4.5 US gpm and open at 4.0 US gpm.

When installed in a low mass heating system such as an in-floor radiant application, the VFC-series boilers may benefit through use of a buffer tank to

Approx.

Head (ft. wc)

ensure a controlled supply temperature, and to prevent short cycling. It is highly recommended that a buffer tank be included in any heating system in which any single zone has radiative loading lower than 1/3rd of the minimum input of the boiler (i.e. at 160 000 BTU/hr, the boiler should be buffered if any single zone attached is below 55 000 Btu/hr).

Propylene glycol solution is commonly used in a water heating loop where freeze protection is required. Its density is lower than that of water, resulting in lower thermal performance at a given flow 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.

Whether required by local Codes or otherwise, it is recommended that piping systems include a suitable check valve, gate valve and feedwater regulator set at 12 psig. In the make-up water link with the city main. Use of unions and gate or ball valves at the boilers supply and return water connections is recommended to simplify servicing.

1.6 Gas Piping

The boiler requires an inlet gas pressure of at least 3.5” w.c. and no greater than

14.0” w.c. Confirm this pressure range is available with your local gas utility.

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:

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Table 5 - Max. Pipe Length (ft)

Model 1/2” IPS 3/4” IPS 1” IPS

VFC 160

8 35 120

Gas piping must have a sediment trap ahead of the boiler’s gas valve (see Figure 11.). 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 a piping compound resistant to the action of natural gas - do not use Teflon tape. Use proper hangers to support gas supply piping.

union

gas valve inside

install manual

main shutoff valve 5 ft. above floor when required by local code

full size sediment trap

Figure 11. Typical Gas Piping

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.

1.7 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.

1.7.1 Mains Hook-up

Line-voltage wiring is done within the field-wiring box. Referring to Wiring Diagram on page 26, connect the boiler to the mains power using a separate, fused circuit and a disconnect means within sight of the boiler. Use 14-gauge conductors in BX cable or conduit appropriately anchored to the boiler case for both mains supply and pump circuits. The transformer primary (black wire) is connected to the neutral and line (hot) wires. The red conductors for the pump contacts should be wired into the ungrounded leg of the pump circuit.

Note: The combined current of all pumps connected through the on-board pump relay (red conductors) should not exceed 10 amps.

1.7.2 Thermostat wiring

The Thermostat terminal block is located on the control module. The thermostat terminals should NOT be connected to any other power source and should only be connected to a room thermostat, isolated, zone valve end switches or circulator end switches. When using 3wire zone valves (non-isolated) the zone valve end contacts must be isolated from the thermostat terminals using an appropriate relay.

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1.7.3 Thermostat Heat Anticipator

When installed in a non-zoned system, the heat anticipator setting is dependant on the gas valve installed in the boiler:

Gas Valve Anticipator

Current

Setting

White-Rodgers 36E22 0.5 A White-Rodgers 36E36 0.5 A White-Rodgers 36F22 0.5 A White-Rodgers 36G22 0.3 A Honeywell VR8205A 0.7 A

For zoned systems, each room thermostat’s heat anticipator should be adjusted to the current draw of its associated zone valve.

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2. STARTUP

WARNING: If you do not follow these instructions exactly, a fire or

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

FOR YOUR SAFETY READ BEFORE OPERATING

A. This appliance does not have a pilot. It is equipped

with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any

phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas suppliers instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance by selecting main power switch to Off.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

Gas Inlet

• If you cannot reach your gas supplier, call the

fire department.

C. Use only your hand to turn the gas control knob.

Never use tools. If the knob will not turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

6. Turn gas control knob clockwise ¬ to Off.

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow B in the safety information above on this label. If you don’t smell gas, go to the next step.

8. Turn gas control knob counterclockwise « to On.

9. Replace front cover on appliance.

10. Turn on electric power to appliance by selecting main power switch to On.

Gas valve shown in ON position

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

5. Remove front cover from appliance.

TO TURN OFF GAS APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn of all electric power to the appliance by selecting main power switch to Off.

3. Remove front cover from appliance.

4. Turn gas control knob clockwise ¬ to Off.

5. Replace front cover on appliance

Also ensure items under the following caption 2.1 Prior to Start-up have been addressed.

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2.1 PRIOR TO START-UP

Ensure venting system is complete and seal tested. Confirm any common venting system at the installation site is isolated and independent of the VFC boiler and that any holes left from removal of a previous boiler have been sealed. Fill condensation trap to full 5” (min.) neck height. Check water piping system is fully charged, and that all air has been discharged through loosened bleed caps. Use a minimum operating water pressure of 12 psig. Perform a final check of electrical wiring.

2.1.1 Test Ignition System Safety Shutoff Device

With the boiler in operation, test the ignition system safety shutoff device by shutting the manual gas valve immediately outside the boiler case. Ensure boiler has shut off and error and gas valve lights are flashing. To restart boiler, reset power.

setting (using manual Fan Speed screw as shown in Figure 13) until pressure switch indicator illuminates

5. Open gas supply and start boiler

6. Raise thermostat to trigger call-for-

heat. Within 40s, gas valve will open and boiler will attempt to ignite

7. Once stable combustion has been

achieved, remove set screw on top of gas valve. Turn calibration screw on gas valve until pressure gauge reads

3.0” w.c. Ensure set screw has been returned to its original position.

2.2 GAS VALVE ADJUSTMENT

The gas valve is factory pre-set for proper gas/air mixing at mean sea-level pressure, however some adjustment may be required, e.g. for altitude.

To ensure gas input is set to the desired boiler output, set the gas valve using the method described in this section. A pressure measurement gauge (with

0.1”w.c. divisions) should be used as shown in Figure 13.

Table 6 - Gas Valve Adjustment

1. Ensure that vents are not obstructed

(see Troubleshooting Guide)

2. Set pressure measurement gauge to 0

3. Connect pressure measurement gauge

as shown in Figure 12

4. Increase blower speed from lowest

Figure 12. Gas Valve Adjustment

Ignition Module

Pump

Fan adjust

Pressure Switch

Power

Fan Speed

Fan

Operator

Flow Switch Vent Hi-Lim it W ater Hi-Lim it

180°F

80°F

Set Point

FXFR

Therm ostat

Figure 13. Fan Adjustment Screw

24 V

Call for Heat

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2.3 BLOWER ADJUSTMENT

To ensure a proper gas/air ratio, adjust the blower using the manometer as shown in

Figure 14.

Ignition Module

Pump

Fan adjust

Pressure Switch

Power

Fan Speed

Operator

Flow Switch Vent Hi-Limit Wa ter Hi-Limit

180°F

80°F

Set Point

Fan

FXFR

Therm osta t

24 V

Call for Heat

Figure 15. Fan Adjustment

2.4 CHECK BOILER INPUT

To ensure that the boiler input is correct, check the boiler input rate using the following procedure:

Figure 14. Blower Adjustment Connections

Table 7 - Blower Adjustment

1. Once again, ensure that vents are not

obstructed (see Troubleshooting Guide)

2. Connect manometer in the

configuration shown in Fig.14

3. Increase blower speed (using manual

Fan Speed screw as shown in Figure 15) until 1.20”wc differential is achieved

4. Open gas supply and start boiler

5. Raise thermostat to trigger call-for-heat.

Within 40s, gas valve will open and boiler will attempt to ignite

6. Once stable combustion has been

achieved, take CO2 sample at vent termination

7. Turn Fan adjust screw on enunciator

panel to vary fan speed (and airflow) until combustion analyzer reading of

9.2% CO2 is achieved

2.5 SET OPERATOR LIMIT

Adjust operator limit as temperature demands require.

Table 8 - Check Boiler Input

1. Start boiler

2. Ensure other gas appliances are not

using the supply gas

3. Observe the number of cubic feet used

by the boiler in 1 minute

4. Consult gas supplier for gas heating

value(typically 1000 BTU/cu. ft.)

5. Verify output by using the formula at

the end of this section

6. If fuel flow is too high or low, check

the orifice plate size. Adjust gas valve (per Section 2.2) as required to achieve Rating gas plate input; recheck flue gas composition at 9.2% CO2 if adjustment is made.

Boiler Input Formula

3600

INPUTHV

=×

time

time = seconds for 1 cu. ft. of

natural gas through meter

HV = heating value of gas as

provided by gas supplier

INPUT = gas input(in BTU/hr)

Table 9 - Operator Setting

Dial Colour "A" to "E" Temp. Range

Red 130°F - 170°F

Black 100°F - 140°F

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3. MAINTENANCE AND TROUBLESHOOTING

commanded to an ultra-lowflow mode for

3.1 BOILER OPERATION

3.1.1 Normal Operation

1. On power-up, the boiler exercises the

fan and pump by entering into a postpurge routine - see below.

up to 90 minutes to act as a vent-damper. The pump maintains normal circulation throughout the phase. This low intensity mode is a simple way of ensuring moisture does not migrate and re-condense around and above the burner area (e.g. fouling the igniter) during the off-cycle.

2. On a call for heat, the blower and

pump switch on.

3. After 20-40 seconds, the gas valve

opens and the igniter probe sparks. The ignition module will issue a spark to the burner for approximately 10 seconds. If no flame is present, the gas valve closes, and locks out until there is a new call for heat.

4. On successful ignition, the spark is

discontinued and the gas valve remains open.

5. If water or vent temperature conditions

exceed safe operating limits, or vent pressure falls below the calibrated value, the gas valve closes and the burner remains off until a safe condition exists. A post-purge cycle follows.

6. If the call for heat ends, the gas valve

closes and the boiler will enter a postpurge cycle.

The post-purge is immediately interrupted by a new call for heat, or return to safe condition of a tripped limit switch (in the case of a shutdown caused by an open hilimit). In such case the mode ends and the boiler enters an ignition cycle. The interrupt is deferred however, to allow a 2 minute low-flow interval prior to return to the ignition routine in the event of an opening of the control circuit at the air pressure switch; this is to allow for clearance of any excess buildup of condensates in the vent.

3.1.3 Boiler Safety System

There are 5 safety devices that can cause the boiler to shut down:

1. Outlet Water Limit: closes gas-valve

when outlet water exceeds 200°F.

2. Vent Hi-Limit: closes gas-valve when

vent temperature exceeds 230°F.

3. Pressure Switch: closes gas-valve

when air pressure drops below 0.9”wc.

3.1.2 Post-Purge Cycle

The post-purge cycle employs the variable speed fan to clear exhaust gases from the boiler and its venting, and the pump to utilize residual heat from the boiler vessel during cool-down. The fan and pump provide normal flow rates for an initial 10 second period; subsequently the fan is

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4. Flow Switch: Shuts boiler off if water

flow drops below US 4 gpm

5. Flame Presence: the ignition module

will lockout if no flame is detected during its 21 second trial period. Causes for this can be found in Section 4 - Troubleshooting Guide under Lockout.

3.2 BOILER MAINTENANCE

blockage exists, trap must be cleared and refilled.

The installer is responsible to ensure the owner aware of the importance of regular maintenance, and that improper maintenance may result in a hazardous condition.

Unless otherwise specified, boiler must be inspected at the beginning of each heating season by a qualified technician.

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

3.2.1 General Care

Keep combustible materials and flammable liquids and vapours away from the boiler.

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

3.2.2 Inspection

Burner

Visually inspect burner through sight glass. Ensure flame is stable and without excessive fluttering. Normal flame pattern is evenly distributed over the burner surface.

Annual inspection of the burner is not necessary. If operating improperly, remove burner and clean or replace.

Use a CO2 analyzer to determine proper combustion. CO2 level should be 9.2%.

Pump

Check that the pump is on in normal operation.

Heat Exchanger

In the unlikely event of boiler flue passage blockage, service to remedy situation must be performed only by an authorized IBC representative.

Annual inspection of the boiler to be performed by a qualified technician.

Venting

Check vent terminals and vent piping for and remove any obstructions.

Check for holes or leaks in venting.

Examine for any signs of moisture caused by sweating intake air pipes; insulate as required.

If any of these conditions exists, contact a qualified technician.

Air Filter

Replace or clean air filter annually.

Condensate Traps

Check condensate traps every 6 months for water seal and blockages. If a

Gas Piping

Check for damage or leaks and repair as needed.

Ignition Module/Igniter Probe

Check that boiler ignites 40s after a call for heat. Ensure that fan and pump are on when a call for heat occurs.

There should be no unusual crackling noise when igniting the boiler. If there is, consult Section 4 - Troubleshooting.

Enunciator

Check that the blower is on in normal operation, and pump remains on and blower operates at normal speed for 10 seconds then ultra-low speed (for 90 min. max.) after boiler shuts off.

Water

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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.

volume must not exceed 50% of the total volume of water in the system.

WARNING: Do not use Ethylene Glycol, automotive-type antifreeze, or undiluted antifreeze. This may result in severe boiler damage.

Freeze Protection

Use only antifreeze made specifically for hydronic systems. Inhibited propylene glycol is recommended. Antifreeze

3.3 COMPONENT DESCRIPTION

A diagram of components and their placement can be found at the end of this manual.

For a list of supplier for all components, contact IBC Technologies or visit our website at www.ibcboiler.com.

The following list provides a summary description of major components:

3.3.1 Pressure Switch

Part#/Type: #VFCF-P011-NO4 / Honeywell C6065D Differential Pressure Switch, calibrated to 0.88” (Alt: Micro Pneumatics 9300-0.88)

Function: used to confirm adequate flow of combustion air; shuts boiler off when intake air pressure differential drops below

0.9” at measurement point -

Verify proper operation after servicing.

Installation: Ensure that arrow points towards the pressure vessel; shift bar to “NO” position.

3.3.3 Operator

Part#/Type: #VFCF-P010-150 or -120 / High range (red face): calibrated for 150°F centerpoint, 20°F differential; low range (black face): 120°F centerpoint, 20°F diff.

Function: Switch closes/opens to enable/prevent boiler operation to provide desired water temperature range.

Installation: Mount with Honeywell Tradeline #107408 Heat Conductive Compound between the base of the operator and the surface of the tee. Set to desired operating temperature - see Section 3.5 - Set Operator Limit above.

Installation: see diagram at the end of the manual for correct installation.

3.3.2 Flow Switch

Part#/Type: #VFCX-P002 / ½" NPT paddle type brass/spst reed switch

Function: for confirmation of adequate circulating water flow; shuts boiler off when flowrate drops below US 4.0 gpm

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3.3.4 Hi-Limit

Part#/Type: #VFCX-HL200 / Therm-ODisc 37T_21, calibrated for 200°F, 15°F differential.

Function: Shuts boiler off when water temperature exceeds safety limit. Two hilimits are available depending on the desired maximum.

Installation: Mount with Honeywell Tradeline #107408 Heat Conductive

Compound between the base of the operator and the mounting surface.

3.3.5 Transformer

Part#/Type: #VFCX-P006 /Hammond DG2G control transformer; Alternate: Rex CS100AW/X Primary- 120VAC; Sec.- 24 VAC; 100VA

Function: Provides 24 VAC for (1) the control circuit and (2) AC to DC power converter, to drive the brushless DC fan

Installation: see wiring & ladder diagrams.

3.3.6 Gas Valve

Type: White-Rodgers 36E22 (alts: 36E36; 36F22 or 36G22) Fast-Opening Valve. Alternative: Honeywell VR8205A

Function: regulates and supplies gas for gas:air mixing; opens/closes on signal from the ignition control module.

Installation: see Section 2.2 Gas Valve Adjustment.

3.3.7 Blower

1. 30 second (approx.) prepurge on a call

for heat

2. opens gas valve

3. provides ignition spark (30,000 V open

circuit, which provides approx 8,000 V on a formed-arc basis) for a single trial-for-ignition period of 20 second. Checks for flame presence; locks out if no flame by end of ignition trial. See 4

- Troubleshooting, under Lockout.

4. discontinues spark if flame present

5. on loss of flame, a timed trial-for-

ignition is repeated (locks out if trialfor-ignition period ends before flame is re-established)

Installation: see wiring diagram.

3.3.9 Igniter Probe/Flame Sensor

Part#/Type: #VFCX-P004 / single probe of Kanthal A1 and Alumina ceramic.

Function: Transmits spark from ICM to burner for ignition, and sends electrical signal back to ICM for flame proving.

Installation: Set gap between burner and probe end must be between 3/16 - 1/4”.

Part#/Type: #VFCX-P005 / RG130/0800 24V DC blower

Function: Moves combustion air and flue gas products through the boiler and venting.

Installation: see Section 2.3 Blower Adjustment.

3.3.8 Ignition Control Module(ICM)

Type: #VFCF-M003 / Honeywell S87J1034 Direct Spark Ignition Control Module.

Function: Boiler ignition, flame proving and gas valve control.

On a call for heat, the S87J-1034 performs the following functions:

3.3.10 DC Power /Enunciator Panel

Ignition Module

Pump

Pressure Switch

Power

Fan Speed

Fan

Operator

Flow Switch Vent Hi-Limit Water Hi-Limit

180°F

80°F

Set Point

FXFR

Thermostat

24 V

Call for Heat

Figure 16. DC Power & Enunciator

Part#/Type: #VFCF-M002 / combination

dc power supply and wiring bus

Function: Provides DC power supply for fan operation and a PWM electronic signal for fan speed variation. Also acts as a

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connector bus for control circuit wiring. The integrity of the series control circuit is preserved in the FXFR module’s internal circuitry. Finally, the module comprises the circuitry supporting the optional Electronic Operator.

The Enunciator panel carries seven indicator lamps (LEDs) pertaining to the various control circuit components wired to the module. The LEDs provide a visual aid for locating open switches within the control circuit. on the boiler showing the states of the boiler:

1. power

2. airflow

3. water temperature operating range

(Operator)

4. water flow

5. vent temperature limit

6. water temperature limit

7. thermostat

The remaining indicators light up in series from right to left, beginning with the thermostat. If an indicator is off, all indicators to the left of it will be off. The first unlit indicator shows an open circuit at that point. If the boiler is heating, all indicators will be on.

Output of the fan may be adjusted during installation using the fan speed adjustment screw. This allows optimization of fan speed to minimize electrical consumption and noise for each installation. Fan adjustment should only be done by a qualified technician with appropriate equipment (incl. combustion analyzer) during installation or servicing.

The DC Power / Enunciator module circuitry also manages the Post-Purge cycle - see 3.1.2 Post-Purge Cycle above.

The power indicator light always remains on except when there is no power to the boiler.

3.3.11 Detailed System Checks

Should overheating occur or the gas supply fail 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.

Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water.

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4. Detailed Systems Troubleshooting

Cycling Problems

Symptom Diagnosis Remedy

Rapid Cycling

i) Gas valve clicks on and

off repeatedly when igniting.

ii) Water noise in exhaust

venting

no other symptoms

Obstruction in Intake/ Exhaust venting.

Excess Condensate in venting.

•

Obstruction in

condensate trap.

•

Improper vent length.

•

Improper slope to vent.

Incorrect anticipator setting or defective thermostat.

Air in system (check for flashing flowswitch lamp), of marginal water flow. Slow combustion air blower. Check that CO2 level is 9.2%. Dirty burner/heat exchanger. Check pressure drop. Insufficient water flow.

•

Improper piping.

•

Undersized pump.

•

Restriction in water

pipe.

Insufficient radiation. Check actual amount of

Unit overfired. Clock gas meter/check gas

Unit Oversized. Refer to Load Calculation vs.

Improperly set or defective operating/safety controls

Inspect vent terminals and tubing. Clear any obstructions.

Check venting angles

Inspect and clean condensate trap.

Check venting. Compare vent length and diameter to

Maximum Venting

Check operation. Refer to manufacturer’s instructions. Check setting with ammeter. Bleed/purge system as required. Confirm adequate pump size and temp rise in HX

Refer to recommended piping in

ection 1.5

S Check manufacturer’s rating charts/check temperature differential across heat exchanger. Check temperature differential across zone/heat exchanger.

radiation per zone and refer to manufacturer’s rating tables.

pressure with manometer/ check

level.

Boiler Output Check operation with Ohmmeter/Voltmeter

Table 3-

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Ignition Problems

Symptom Diagnosis Remedy

Noisy spark when igniting. Ignition lead is not firmly

connected. Contaminants/moisture on igniter probe/flame sensor.

Boiler rumbles when igniting. Poor gas/air mixture. Check CO2 in exhaust. Check

Fluctuating gas pressure/ gas pressure too high/too low.

Boiler will not attempt to ignite.

i) Fan and pump are

operating normally.

ii) Fan and pump are off

No lights on display

iii) Fan off and pump on

Boiler ignites but shuts off

within seconds

No power to ignition control module. Igniter probe/flame sensor disconnected. Blown fuse in ignition module. Defective Control Module.

No power to boiler Check line voltage Defective transformer. Check transformer.

Bad electrical grounding of vessel defeats flame rectification Loose or bad igniter cable

Reconnect ignition lead

Ensure probe is dry by rerunning post-purge; otherwise, clean or replace igniter probe.

mass airflow sensor. Check pressure with

manometer during ignition. Check mass airflow sensor.

Check system wiring. Check airswitch & air tubing. Reconnect probe.

Check fuse. If blown, replace. Check ignition output from control module.

Reconnect or replace as needed.

Confirm continuity between pressure vessel and ground terminal on Control Module. Check and replace as required

Miscellaneous

Symptom Diagnosis Remedy

Fumes and High Humidity Improperly installed

condensate trap Leak in CPVC/ABS/PVC vent piping Flue gas leak in heat exchanger

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Refer to installation/operation instructions Visually inspect using soap solution Visually inspect all mechanical connections

Temperature Problems

Symptom Diagnosis Remedy

Insufficient heat. Operating temp. too low

Unit undersized Refer to Load Calculation vs.

Air trapped within system Bleed system as required. Improper system piping Refer to recommended piping

System pump undersized Check pump manufacturer’s

Poor gas/air mixing Check CO2 level. Defective thermostat. Refer to manufacturer’s

Incorrect gas/air orifices. Refer to orifice sizing table Obstruction in condensate drain. Unit cycling on operating/ safety controls. System radiation

undersized Temperature exceeds thermostat setting

One or more zones do not heat properly.

Incorrect anticipator

setting

Thermostat not level. Check level.

Air trapped within

zone(s)

piping

Insufficient radiation/

excessive heat loss.

Insufficient flow rate to

zone(s).

Defective zone valve/

zone circulator.

Defective zone

thermostat.

Improper control wiring. Check wiring per

Improper/obstructed

baseboard radiation.

Operating limit set

improperly.

Boost setpoint per Section

2.3.1 above

Boiler Output

in Section 1.5.

data/check temp differential across heat exchanger.

instructions.

Inspect and clean condensate drain. Check operation with Ohmmeter/Voltmeter. Check manufacturer’s rating tables for capacity per foot. Check with Ammeter.

Vent system/zone as required.

Check actual length of pipe using radiation / heat loss calculation. Check temperature drop across zone. Check operation per manufacturer’s instructions. Check operation per manufacturer’s instructions.

manufacturer’s instructions. Check baseboard manufacturer’s instructions/ check at zone. Check limit setting/operation.

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pressure

switch

operator

+25V

(GND)

valve

+25V

gnd

(burner)

flow

switch

vent limit

water

limit

Ignition Module

Pump

pump

Pressure Switch

Power

Fan Speed

Operator

Flow Switch Vent Hi-Limit Water Hi-Limit

Set Point

Thermostat

FXFR

Call for Heat

rwbry

thermostat

pwm−V tac +v

blower

jb1

(control)

115V AC

24V AC

Wiring Diagram for IBC VFC 160 Boiler

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Component Layout Diagram

1. Igniter Probe/Flame Sensor

2. Blower

3. Tridicator

4. Water Hi-Limit

5. Operator

6. Gas Valve

7. Pressure Switch

8. Ignition Control Module (ICM)

9. Enunciator

10. Transformer

11. Flow Switch

12. Vent Hi-Limit

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Installation Checklist

Model#: Water Tank #:

Dealer Name: Serial#: Installation Date:

Heat Loss: BTUhr ft. of Radiation: # of Zones:

BTU/ft.: Total Radiation Output: BTUhr

Electrical Information

Thermostat: Anticipator Setting: Amps

Supply Voltage: Volts Combusti on Air Blower Amp Draw: Amps

Boiler Information

Type of Gas: Operating Gas Inlet Pressure: in. w.c.

reading: % Air Intake Orifice Size:

Air Pressure Differential Across Air Intake Orifice Plate: in. w.c.

Exhaust Vent Piping: in. ft.

Air Intake Piping: in. ft.

Temperature Rise Through Boiler

Space Heating: °F

Domestic Hot Water: °F Flue Gas Temp.: °F Operating Temp.: °F

Water Manifold Pipe Size

Supply: DHW Tank Aquastat Setting: °F Two-Way:

Return: Differential Setting: °F Three-W ay:

System Pump Model #: Additonal Pump Model #:

Expansion Tank Model #: Expansion Tank Size:

Type of Air Elimination

Spirovent Honeywell

Manual Air Bleed Manual

Pipe Size

perator Setting(A-E): Operating Pressure: psig

Pipe Size to DHW Tank: Valve Type to DHW Tank

Vent/Intake Piping

Water Pressure/Temperature

Water Piping

Actual Length # of 90 and 45 Elbows

Tridicator Gauge

System Bypass Type

None

Notes:

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Air Switch Reference Line Connections

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IBC Boilers VFC 160 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

See Vent Travel- below.