Installation Manual - IBC Better Boilers
Contents
1. Component Layout Diagram 9o c4 Ow UN cE US 9 10 11 12 13 14 Pressure Vessel Heat Exchanger Igniter Probe Flame Sensor Fan Blower Tridicator Hi Limit Switch Outlet Temperature Sensor Modulating Gas Valve MEG Modulating Boiler Control Module not shown under controller Mass Airflow Sensor not shown under controller Airflow Homogenizer 120V 24V Transformer Oxygen Sensor Inlet Temperature Sensor Water Flow Switch IBC Technologies Inc 33 VFC Modulating Boilers Model Dealer Name Heat Loss BTU ft Installation Checklist Serial ft of Radiation Water Tank Installation Date of Zones Total Radiation Output Electrical Information Thermostat Supply Voltage Boiler Information Anticipator Setting Combustion Air Blower Amp Draw Type of Gas CO reading Air Pressure Differential Across Air Intake Orifice Plate Operating Gas Inlet Pressure Air Intake Orifice Size in w c Vent Intake Piping Pipe Size Exhaust Vent Piping Air Intake Piping Actual Length of 90 and 45 Elbows Water Pressure Temperature Temperature Rise Through Boiler Space Heating Domestic Hot Water Operator Setting A E Flue Gas Temp Tridicator Gauge Operating Pressure Operating Temp Water Piping Water Manifold Pipe Size Supply Return Pipe2. N 12 TO ANY MIN 4 HORIZONTAL DISTANCE 42 FROM GAS OR MON ELECTRICAL METER 36 INTA ae a IN I2 N SNOW LINE Figure 5 Side Wall Venting INSTALLATION BELOW AVERAGE SNOW LI L VENT TEE SHOULD BE PARALLEL TO SIDE WALL 12 MIN CLEARANCE INTAKE SHOULD BE SWUNG TO PARALLEL 4 3 8 TO ANY OVERHANG WITH SIDE WALL MiNIMUM FIELD SUPPLIED PLASTIC MIN 12 BETWEEN STRAPPING MUST BE USED BOTTOM OF INTAKE SECURE THE VENT TO AND BOTTOM OF VENT 5 1 2 THE STRUCTURE 4 24 2 8 1 2 12 MIN ABOVE AVERAGE SNOW LEVEL Figure 6 Side Wall Vent Terminations Configuration 1 1 Pos 2 OR 3 ABS 2 2 5 3 PVC Hp p LX 5 OR amp X2V2 REDUCING BUSHINGS AS REQUIRED N i N 2 oR 5 ABS OR 2 2 5 OR 5 CPVC PVC 5 5 2 ABS PVC TEE ALT 4 4 TEE If 3 venting is used the exhaust line must be 1 MEN 8 reduced to 2 2 immediately prior to entering the 4 termination tee to allow adequate intake clearance Use a 3 x 2 2 reducer and 4 2 bushing Figure 7 Side Wall Vent Terminations Configura
3. Waterflow Error Water circ flashing Error and boiler operating lamps on Defective or disconnected flow Low water flow vent limit not exceeded e Check wiring to flow switch and control module switch e Check flow switch as explained in Section 4 3 2 4 Troubleshooting Electrical Components Improper piping e Refer to Section 1 4 Water Piping for recommended piping installation Undersized pump e Check manufacturer s rating charts e Check temperature differential across heat exchanger Restriction in water pipe e Check temperature differential across zone heat exchanger IBC Technologies Inc 26 VFC Modulating Boilers Hi Limit Error Temperature lamp flashing Water temperature exceeds hi limit Error lamp on Boiler in lockout Defective or disconnected hi limit switch Check wiring to hi limit switch and control module e Check hi limit switch as explained in Section 4 3 2 5 Troubleshooting Electrical Components e Check flow switch and connections Ensure flow switch connection on control module has not been bypassed e Check for obstructions in water pipe Low water flow not detected by the flow switch Maximum Ignition Trials Error Gas valve lamp flashing Boiler has failed to ignite on 3 successive attempts Error lamp on Boiler in lockout No spark when igniting e Check that igniter lead is secure at the control Igniter probe flame sensor m
4. Modulating Boilers BOILER FEEDWATER Figure 8 Sample Piping Schematic 1 SYSTEM RETURN PIPING Figure 9 Sample Piping Schematic 2 NOTE WIRE AQUASTAT CTS IN SERIES WIT PARALLEL WIRED ZONE HES OR PUMP RELAY i ELIMINATOR S WIRE TO ZONE Figure 10 Sample Piping Schematic 3 IBC Technologies Inc 11 Modulating Boilers 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 A T for the respective VFC models are as follows Table 4 Flow Rate Model Flow USgpm Approx Head ft wc 35 90 9 0 5 VFC 50 130 13 0 10 VFC 35 100LP 10 0 6 5 VFC 45 130LP 13 0 10 Water flow rates must not be allowed to fall below 6 gpm 35 90 amp 35 100LP series 5 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 measurin
5. 2 2 6 Error Mode The controller continually checks sensors to see that they are operating within normal parameters If sensors indicate the boiler is operating outside it limits it will declare an error condition 2 types of error conditions can occur Soft Errors result when an abnormal condition exists which does not present an immediate safety hazard The boiler enters an extended interpurge and a 5 IBC Technologies Inc 16 minute error cycle Following the interpurge the fan and pump are stopped until the end of the error cycle Normal operation then resumes Hard Errors result when a condition exists that may be a safety hazard The boiler enters an extended prepurge then the fan and pump are stopped The boiler is in a lockout and must be checked and restarted by a service technician A soft error can be identified when the error light and the boiler operating light are on at the same time If the boiler operating light is not on while the error light is on the boiler is in a hard error Table 7 lists the hard and soft errors and their causes Note that other problems such as disconnected wires or defective sensors may be the cause of the error Always check connections and wiring first Section 3 6 3 Troubleshooting With the Control Module provides a detailed troubleshooting list for each error condition Modulating Boilers HardErrors Description Hi Limit water temp ha
6. Description Size Af watrowlt B water intet 1 NPT 1 NPT 2 NPT electrical power 3 4 E thermostat combustion air 40 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 CSA 4 9 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 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 conflict in the above requirements then the more stringent requirement will apply In Canada installations must conform to the current CAN CGA B149 and the Canadian Electrical Code Part 1 CSA C22 2 No 1 VFC Modulating Boilers 1 3 Location e ensure minimum clearance requirements for combustible Keep boiler area free and materials see Table 2 are satisfied clear of combustible e 36 clearance at the front is materials gasoline and other recommended for adequate servicing flammable vapours and e gas ignition system components liquids should be protected from water dripping spraying rain etc VFC series boilers are designed and e boiler should not be exposed to approved for wall or flo
7. Data may be downloaded at any time successful ignitions in its lifetime from the controller by connecting the optional IBC communications cable between the optical link and a microcomputer Data includes the following e Ignition counter e Average water temperature e Average output e Gas usage meter e Error log Average Water Temperature The control module tracks the water temperature averaged over the lifetime of the boiler Average Output The control module tracks boiler output averaged over the lifetime of the boiler Gas Usage Meter The control module tracks the amount of gas used in its lifetime Further information about the communications interface can be found in the user manual for that product Error Log IBC Technologies Inc 14 Modulating Boilers The error log contains the last 3 errors detected by the controller 2 1 2 Glossary of Terms This glossary briefly defines some terms used in the control module functions Call for Heat The thermostat indicates that room temperature is below the thermostat setting A Call for Heat AND a Heat Required signal are needed to start the boiler and are defined as Heating Enabled Heat Required Temperature sensors on the boiler indicate that water temperature is below the water temperature setpoint A Call for Heat AND a Heat Required signal are needed to start the boiler and are defined as Heating Enabled Heating Enabled The bo
8. PVC debris left in the combustion air piping joints must be secured using CPVC PVC or ABS PVC solvent cement to bond the respective pipe material Use solvent cement on the connector located at the CPVC ABS or PVC junction e g 10 along the exhaust piping Follow the cement manufacturer s instructions closely when joining various components 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 PVC exhaust vent using a straight 2 tee or a 2 x 5 x 2 reducing tee The trap itself is formed using PVC pipe for the drop leg with PVC pipe IBC Technologies Inc elbows and threaded union fittings The trap must be installed as follows e Must be 5 min in height see Fig 2 e Must be piped to within 3 ofa drain or be connected to a condensate pump using 2 PVC e Drainage line must slope down to the drain at a pitch of 4 per foot so condensate runs towards the trap e 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 e Trap should be checked every 6 months Clean and
9. 2 4 Oxygen 22 4 2 5 Flow Switch ectares 22 42 67 cesta eats Bane 22 4 2 7 A Transforme h 22 4 2 8 Temperature 23 4 29 Control 23 4 3 TROUBLESHOOTING GUIDE 23 4 3 1 Preliminary Checks 23 4 3 2 Troubleshooting Electronic Components eerte eterne 24 4 3 3 Troubleshooting With the Control Module issu ene 25 4 3 4 Detailed System Checks 28 Modulating Boilers 1 INSTALLATION 1 1 GENERAL modulating boilers are low pressure fully condensing units having a variable inputs ranging from 35 MBH 35 000 Btu hr to 130 MBH The boilers are 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 Ls 22 5 572mm 12 305mm A 3 D E F 22 5 572mm 12 305mm N H Figure 1 Dimensions Connections IBC Technologies Inc Table 1 Connections
10. 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 IBC Technologies Inc 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 Note that manifold pressures vary in accordance with firing rate with the modulating series boilers Table 6 Manifold Pressures Model Fuel Type Range Natural Gas Units 0 5 3 5 w c ER cre 1 2 10 0 w c Propane Units 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 32 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
11. 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 water pressure of 12 psig Perform a final check of electrical wiring 3 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 3 2 ADJUSTMENT FOR ALTITUDE VFC Modulating Boilers are factory assembled to operate with natural gas at sea level As altitude increases the orifice plate between the gas valve elbow and the mixing tube see Figure 13 Gas Assembly must be changed as described in Table 9 Orifice Plate Sizing To ensure the correct orifice is in place adjust the thermostat to maximum setting and water temperature setpoint to its minimum setting Allow the boiler to reach a steady state then check the boiler input using the following formula Boiler Input Formula 3600 time x HV BTU ft INPUT time seconds for 1 cu ft of gas through meter HV heating value of gas as provided by gas supplier INPUT gas input in BTU hr Figure 13 Gas Assembly Table 9 Orifice Plate Identification
12. 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 VFC Modulating Boilers Tod 1 7 3 Thermostat Heat Anticipator The Thermostat terminal block is located When installed in a non zoned system on the control module The thermostat the heat anticipator setting is dependant terminals should NOT be connected to on the gas valve installed in the boiler any other power source and should only be connected to a room thermostat Gas Valve Anticipator isolated zone valve end switches or Current circulator end switches When using 3 Settina wire zone valves non isolated the zone White Rodgers 36E27 valve end contacts must be isolated from For zoned systems each room the d terminals using an thermostat s heat anticipator should be appropriate retay adjusted to the current draw of its associated zone valve 2 Boiler Systems and Operation 2 1 ELECTRONIC CONTROL MODULE The electronic control module governs 2 1 1 Logged Data ignition and flame safeguards throttle management and mixture and temperature control Additionally it provides a user interface and performs data and error logging functions All data is permanently logged in the controller and cannot be altered except on replacement of the controller Ignition Counter The control module tracks the number of
13. vent length Check venting Compare vent e Improper slope to vent length and diameter to Table 3 Maximum Venting no other symptoms Incorrect anticipator setting Check operation Refer to or defective thermostat manufacturer s instructions Check setting with ammeter Air in system check for Bleed purge system as required flashing flowswitch lamp Confirm adequate pump size of marginal water flow and temp rise in HX Slow combustion air blower Check that CO level is OK 9 2 nat gas 10 4 for propane Insufficient water flow e Improper piping Refer to recommended piping in Section 1 5 e Undersized pump Check manufacturer s rating charts check temperature differential across heat exchanger e Restriction in water Check temperature differential pipe across zone heat exchanger Insufficient radiation Check actual amount of radiation per zone and refer to manufacturer s rating tables Unit overfired Clock gas meter check gas pressure with manometer check CO level Boiler Output operating safety controls Ohmmeter Voltmeter IBC Technologies Inc 28 Modulating Boilers Ignition Problems Symptom 0 Diagnosis Remedy 1 Noisy spark when igniting Ignition lead is not firmly Reconnect ignition lead connected Contaminants moisture Ensure probe is dry by re on igniter probe flame running post purge sensor otherwise clean or replace igniter probe Boiler rumbles when
14. 2 2 6 Error Mode In addition to checking the display the following list is a guideline for troubleshooting 1 Confirm power to the boiler check that control module display is on 2 Check that boiler is not in a safety lockout Check that control module display is illuminated IBC Technologies Inc 23 Modulating Boilers 3 Ensure wiring is clean and secure 4 Check that manual gas valve and boiler gas valve are open 5 Confirm water systems is properly charged to 12 psig and pump is serviceable 4 3 2 Troubleshooting Electronic Components This section details the method for troubleshooting the non standard electronic components on the boiler including the mass airflow sensor and the temperature sensors 4 3 2 1 Mass Airflow Sensor If the mass airflow sensor is suspected of defect remove the sensor and connector and send both to IBC for testing 4 3 2 2 Temperature Sensor The resistance of the temperature sensors varies inversely with temperature Connect an Ohmmeter to the sensors as shown in Figure 14 Resistance should be between 3 5kO and 5 3 kO Resistance should decrease with an increase in temperature Temperature Probe P 93 threaded plug format Ohmmeter Approximately 5 3kQ at room temperature 3 5kQ at 100 F Figure 14 Ohmmeter Check of Temperature Sensors IBC Technologies Inc 24 Modulating Boilers 4 3 2 3 Fan Blower Fan sp
15. IBC Technologies Inc Vancouver Canada VFC Modulating Gas Boilers Model VFC 35 90 natural gas Model VFC 50 130 natural gas Model VFC 35 100LP propane e Model VFC 45 130LP propane 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 Listed VFCM MANv2 0 TABLE OF CONTENTS 1 INSTALLATION 3 1 1 GENERAL 3 1 2 CODE REQUIREMENTS 3 1 3 LOCATION PR 4 1 4 4 1 4 4 5 1 4 0 Category
16. IV 10 1 4 3 Closet Installations 10 1 5 Water Piping eere 10 1 6 Gas Piping eere 12 1 7 Electrical Connections 13 1 7 1 Mains 13 1 7 2 Thermostat wiring sssssss 14 1 7 3 Thermostat Heat Anticipator 14 2 BOILER SYSTEMS AND 14 2 1 ELECTRONIC CONTROL MODULE esee toe aene anno 14 2 1 1 Logged Data 14 2 1 2 Glossary of 15 2 2 SEQUENCE OF OPERATION 15 Standby tutto 15 2 2 2 Purging sea ainne 15 2 233 15 2 2 4 Heating 16 225 Circulating sonet 16 2 2 6 Error Mode see 16 IBC Technologies Inc 2 3 USER INTERFACE 17 2 3 1 Keypad 17 2 3 2 Indicator 18 3 STARTUP 19 3 1 PRIOR TO START UP 20 3 2 ADJUSTMENT FOR ALTITUDE 20 4 MAINTENANCE AND TROUBLESHOOTING 21 4 1 BOILER MAINTENANCE 21 4 1 1 General Care 21 4 1 2 Inspections idee Meee 21 4 2 COMPONENT DESCRIPTION 22 AZI Fan BloWer zo 22 42 2 Gas Valve isis sss sias 22 4 2 3 Mass Airflow 22 4
17. OSTAT Figure 12 Display The numeric display labeled TEMPERATURE indicates the current water temperature in F or C toggle between units by pressing and holding both keys simultaneously Pressing either button individually displays the setpoint temperature The left hand column labeled HEAT provides an illuminated display of the output level of the boiler The indicators light up sequentially from bottom to top as output increases The 8 indicators in the right hand column labeled STATUS display various conditions of the boiler These indicators are described in Table 8 Status Indicators IBC Technologies Inc Table 8 Status Indicators Flashing Boiler is waiting for a call for heat Off Boiler is firing or preparing to fire On Thermostat indicates more heat is needed Off Call for heat has ended On Boiler is in any mode except standby or a soft error exists Off Boiler is in standby or lockout On The error indicator lights when a hard or soft error exists See section 2 2 6 Errors In most cases one of the 4 indicators below will also be flashing when an error exists On Boiler is on and temp sensors are functioning normally On Pump is running Flashing pump is on but no water flow detected On Fan 1 Flashing fan is moving less air than normal AIRFLOW On Boiler heating Flashing gas valve is open but no flame detected GAS VALVE P
18. Pump off 9 Heating Enabled Prepurge Cycle Ignition Cycle Heating Cycle Gas valve Fan starts at 9pens More heat N Less heat N 1 ignition level pee required required 1 Spark for 3 Y A ay so Raise output Lower output Spark iode t and flame Y Pump starts sensing begins Y e Heating disabled OR j 10 aa E T delay Flame Y Y detected i Postpurge Cycle Interpurge Cycle 3 ignition trials T output set Close gas valve Y purge speed Fan and pump Y continue operating System 10 second Lockout delay 25 second delay Fan output set to min speed Set 90 min timer 1 Heat not required Pump off Y 1 Actual water temp 8 F lt N setpoint temperature AND heating required Sequence of Operation Flowchart for VFC Modulating Series Boilers IBC Technologies Inc 31 VFC Modulating Boilers 15 60Hz WEMA CABLE SOLD K 2 WRE 120 24 TRANSFORMER THERMOSTAT dd WIRE LEGEND Letter Symbols TERMINAL A USILL RY O WUT Pr IH TERLOCKS SCREW amp REEH FACTORY WIRING omue R RED FIELD WIRMG Y YELLow H Line Line FLOW VENT Group H SvaTcH Leer mer Wiring Diagram for VFC Modulating Series Boilers IBC Technologies Inc 32 Modulating Boilers
19. Size to DHW Tank DHW Tank Aquastat Setting Differential Setting Valve Type to DHW Tank Two Way Three Way System Pump Model Additonal Pump Model Expansion Tank Model Type of Air Elimination Spirovent Manual Air Bleed Notes IBC Technologies Inc 234 Expansion Tank Size System Bypass Type Honeywell Manual None VFC Modulating Boilers
20. Sizing 0 001 following D Model Altitude 0 1 500 1 501 3 000 3 001 4 500 VFC 35 90 M A005 090SL D208 M A005 090A1 D212 M A005 090A2 D215 VFC 50 130 M A006 130SL D250 M A006 130A1 D255 M A006 130A2 D259 VFC 35 100LP M A009 100SL D139 M A009 100A1 D142 M A009 100A2 D144 VFC 45 130LP M A008 130SL D159 IBC Technologies Inc M A008 130A1 D162 20 M A008 130A2 D164 VFC Modulating Boilers 4 MAINTENANCE AND TROUBLESHOOTING 4 1 BOILER MAINTENANCE The owner is responsible for general care of the boiler Improper maintenance of the boiler may result in a hazardous condition 4 1 1 General Care Keep combustible materials and flammable liquids and vapours away from the boiler Keep vent terminals clear of obstructions snow dirt etc For a list of suppliers for all components contact IBC Technologies or visit our website at www ibcboiler com CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation 4 1 2 Inspection Inspection of the boiler to be performed annually by a qualified service technician Venting Check vent terminals for and remove any obstructions 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 Air Filter Replace or clean ai
21. ck level Defective thermostat Refer to manufacturer s instructions Incorrect gas air orifices Refer to orifice sizing table Obstruction in condensate Inspect and clean condensate safety controls Ohmmeter Voltmeter Check manufacturer s rating undersized tables for capacity per foot Temperature exceeds thermostat Incorrect anticipator Check with Ammeter setting setting One or more zones do notheat Air trapped within Vent system zone as required properly zone s piping Insufficient radiation Check actual length of pipe excessive heat loss using radiation heat loss calculation zone s across zone Check operation per zone circulator manufacturer s instructions One or more zones do not heat Check operation per properly thermostat manufacturer s instructions manufacturer s instructions Improper obstructed Check baseboard baseboard radiation manufacturer s instructions check at zone Operating limit set Check limit setting operation improperly IBC Technologies Inc 30 Modulating Boilers Heating Enabled Occurs with for heat heat is required x Standby Cycle Heat required Heat is required as long as the controller senses requirement to raise or maintain the current water temperature ll for heat The room temperature is below th A Y Eae eius solic complete
22. ee eS i 60 2 For the exhaust vent 2 or 3 2 Sch 40 or 80 pipe ASTM F441 and Sch 40 or 80 fittings for the initial 10 lineal feet of travel 2 212 or 3 Sch 40 CPVC or PVC ASTM D1785 or D2665 alternatively 2 or 3 ABS Sch 40 ASTM D2661 or F628 and fittings thereafter For the inlet air 2 2 2 or 3 PVC or 2 and 3 ABS are permitted If the 277 or 3 piping alternative is selected a 3 x2 or 2 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 Such 3 interval which is part of the 90 max travel IBC Technologies Inc Modulating Boilers distance is allowed to provide space for splicing in the optional 2 compatible air filter unit On the exhaust side a 3 x 2 or 2 4 2 reducer must be placed in a vertical section of the flue gas vent to avoid pooling of condensate Exhaust venting must slope down to the trap drain with a pitch of at least 4 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 Care is to be taken to avoid ingestion into the fan of CPVC ABS
23. eed is adjusted using a signal from the control module Four leads are attached between the fan and the controller The red and blue leads supply power to the fan and the fan will not operate if these connections are lost The black lead carries the signal from the controller to the fan If this connection is lost the fan will operate at maximum speed The white lead is unused This connection will not alter the operation of the fan Table 10 Fan Operation Lead Color Function Troubleshooting Red 28Vdc Positive power Fan will not function if terminal disconnected Blue 28Vdc Negative power Fan will not function if terminal disconnected Black Signal from controller Fan will only operate at max speed if disconnected White Not used No effect on fan operation 4 3 2 4 Flow Switch Check resistance between flow switch leads If resistance is very low there should be water flow If resistance is very high flow rate should be 4 0 USGPM 4 3 2 5 Hi Limit Switch Check resistance between leads If resistance is very low temperature should be acceptable If resistance is very high temperature should be out of bounds 4 3 3 Troubleshooting With the Control Module Note Never attempt to repair the control module If the control module is defective replace it immediately Airflow Error Water circ lamp flashing Error and Boiler Operating lamps on Low Airflow Boiler unable to ignite e Check v
24. enting for obstructions and remove Partially blocked vent Water noise in vent e Check condensate trap for obstructions Remove Excess condensate in venting obstructions and refill condensate trap with water e Check vent length and size Compare with Table 3 Maximum Venting Length IBC Technologies Inc 25 VFC Modulating Boilers Mass Flow Error Airflow flashing Error and boiler Signal from mass airflow sensor is not being detected or is giving an Operating lamps on abnormal reading Defective or disconnected e Check wiring to mass airflow sensor and control mass airflow sensor module e Check mass airflow sensor as explained in Section 3 6 2 Troubleshooting Electrical Components e Check all wiring between fan and control module Replace leads if necessary If leads are intact replace fan or control module as necessary e Check fan as explained in Section 4 3 2 3 Troubleshooting Electrical Components Fan speed input to fan disconnected or fan is defective Temperature Sensor Error Temperature lamp flashing Error and Boiler Water temperature exceeds operating temperature Operating lamps on Current outlet temperature exceeds operating limit Defective or disconnected temperature sensor Check water flow e Check wiring to temperature sensor and control module e Check temperature sensor as explained in Section 4 3 2 2 Troubleshooting Electrical Components
25. front cover from appliance Set the thermostat to lowest setting Turn gas control knob clockwise to Off Turn off all electric power to the appliance by selecting main power switch to Off 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 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn gas control knob counterclockwise lt to On Replace front cover on appliance Turn on electric power to appliance by selecting main power switch to On Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier 1 Setthe 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 3 1 Prior to Start up have been addressed IBC Technologies Inc 19 Modulating Boilers 3 1 PRIOR TO START UP Ensure venting system is complete and seal tested Confirm any common venting system at the installation site 1 isolated and independent of the VFC
26. g A 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 IBC Technologies Inc 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 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 35 000 BTU hr the boiler should be buffered if any single zone attached is below 12 000 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 regulato
27. ignal any time during this cycle the postpurge ends and a prepurge begins otherwise the boiler will enter standby mode 2 2 3 Ignition After the prepurge the gas valve opens for 5 5 seconds For the first 3 seconds a spark is delivered to the burner For the remaining 2 5 seconds the probe is in a flame sensing mode and the gas valve is kept open Modulating Boilers If no flame is detected at the end of the trial the interpurge cycle is repeated If ignition fails 3 times successively the boiler locks out and must be reset by shutting the main power switch off and back on A qualified technician should be consulted to establish and remedy If ignition is successful the output of the boiler decreases immediately to minimum and the heating cycle begins 2 2 4 Heating The heating cycle lasts until the boiler operating signal ends or until water temperature exceeds the setpoint temperature by 8 F at minimum output At the end of the heating cycle the boiler enters a postpurge During the heating cycle boiler output changes to meet heating demands Water temperature is regulated about the setpoint to 3 F 2 2 5 Circulating This cycle operates when water temperature exceeds setpoint by 8 F at minimum output and call for heat is still present After entering a postpurge the pump remains on until water temperature is 8 F below setpoint temperature or the boiler operating light is off has ended
28. igniting Poor gas air mixture Check in exhaust Check mass airflow sensor Fluctuating gas pressure Check pressure with gas pressure too high too manometer during ignition low Check mass airflow sensor i Fan and pump are No power to ignition operating normally control module Check airswitch amp air tubing Igniter probe flame sensor disconnected Blown fuse in ignition module If blown replace Defective Control Check ignition output from Module control module No lights on display No power to boiler Check line voltage Defective transformer Check transformer Reconnect or replace as needed Boiler ignites but shuts off Bad electrical grounding Confirm continuity between within seconds of vessel defeats flame pressure vessel and ground rectification terminal on Control Module Loose or bad igniter Check and replace as required cable Symptom condensate trap instructions vent piping solution Flue gas leak in heat exchanger mechanical connections IBC Technologies Inc 29 Modulating Boilers Temperature Problems Symptom Diagnosis Remedy Insufficient heat Boost setpoint per Section 2 3 1 above Boiler Output Air trapped within system Bleed system as required Improper system piping Refer to recommended piping in Section 1 5 System pump undersized Check pump manufacturer s data check temp differential across heat exchanger Poor gas air mixing Che
29. iler is powered and there is a Call for Heat and Heat is Required If the boiler is in an error mode the boiler will not start 2 2 SEQUENCE OF OPERATION The control module has 5 cycles during normal operation as well as an error mode for problem detection Standby cycle Purging Ignition cycle Heating cycle Circulating cycle Error mode Quan e pac Each state is explained below A flow chart for the sequence of operation can be found in the back of the manual IBC Technologies Inc 2 2 1 Standby Waiting for a boiler operating signal The boiler is off during this time 2 2 2 Purging Prepurge On a boiler operating signal the boiler automatically enters a prepurge cycle The fan starts and automatically adjusts to a level suitable for ignition Twenty seconds later the pump starts Aftera total of 30 seconds the ignition cycle begins Interpurge The boiler enters an interpurge cycle if ignition is unsuccessful The fan and pump continue to run and ignition 15 delayed by an additional 25 seconds Postpurge The fan remains on for 10 seconds and then reduces airflow to an ultra low flow mode for 90 minutes unless pre empted The pump remains on for 5 minutes after the heating cycle ends If the heating cycle ends as a result of water temperature exceeding setpoint by 8 F the postpurge will continue as normal but the boiler will enter the circulating mode If there is a boiler operating s
30. l 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 fo 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 7223 1 latest edition In Canada use the CAN CGA B149 Installation Code 1 4 1 Applications VFC series boilers are 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 Modulating Boilers 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 standard VFC boiler 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 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 boi
31. lene glycol is recommended Antifreeze 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 4 2 1 Fan Blower Part Type VFCX P005 RG130 0800 24 blower Function Moves combustion air and flue gas products through the boiler and venting Installation The fan must be removed at the flange and step washers 4 2 2 Gas Valve Type White Rodgers 36E27 201B nat gas or 36E27 202B propane Modulating Electronic Governor MEG Valve Function regulates and supplies gas for gas air mixing based on a signal from the control module Installation see Section 3 1 Gas Valve Adjustment 4 2 3 Mass Airflow Sensor Part Type VFCM P009 Function Measures combustion airflow Installation The mass airflow sensor fits between the intake pipe and the mixing tube connected with 2 flexible couples IBC Technologies Inc 22 volume must not exceed 50 of the total volume of water in the system Verify proper operation after servicing 4 2 4 Oxygen Sensor Part Type VFCM P008 Potentio metric Oxygen Sensor Function Senses combustion quality and signals controller for fine tuning of fan gas valve Installation Replace every 5 years Remove with 3 8 wrench A
32. ler 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 1 4 1 1 Intake Exhaust Vent Material The approved materials of construction 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 as appropriate for the environment e g insects dust 1 4 1 2 Vent Travel Using the standard 2 piping the boiler can be sited up to 60 equivalent feet from the vent termination The actual vent travel is reduced for fittings in accordance with Table 3 for example using 5 x 90 ABS long sweep elbows the maximum lineal measure is 35 feet Direct vent installations requiring longer travel can be satisfied using 25 or 3 intake and vent piping the latter subject to an initial 10 of 2 CPVC which is included in the limit for 2 2 or 3 pipe Table 3 Max Venting Length Max Equiv Length
33. ning IBC Technologies Inc m 12 MIN 24 MIN 0 7 d SNOW LINE 12 MIN _ 416 2 MIN E MANNER AS IN FIGURE 5 ABOVE OTHER THAN AS LISTED VENTS TERMINATE IN THE SAM Figure 4 Vent Terminations Through a Flat Roof e minimum 3 above any forced air intake located within 10 e 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 e not to be located over public walkway in a confined space or under any overhang or deck e vents must be installed such that flue gas does not discharge towards neighbor s windows or where personal injury or property damage can occur e 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 re ingestion See Figures 5 6 amp 7 for side wall vent terminations VFC Modulating Boilers
34. odule and at the probe disconnected e Open manual gas shutoff and reset boiler Manual gas shutoff is closed e Adjust gap between igniter probe flame sensor and Gap between igniter probe and burner to a distance of 3 16 burner is too large Boiler ignites but shuts off at e Ensure pressure vessel is grounded the end of the ignition trial Improperly grounded pressure vessel burner Loose or defective igniter e Check ignition cable Ensure lead ends are secured cable to the control module and the igniter probe e Check the igniter probe flame sensor is electrically isolated from the vessel and its ceramic insulator is uncracked Cracked ceramic will ground out the current Ensure vessel is electrically grounded to facilitate flame rectification Vent Hi Limit Error Error lamp on Vent temperature has exceeded the vent limit switch Boiler in lockout Low water flow and flow switch signal has not been detected e Check wiring to flow switch and control module e Check that flow switch has not been bypassed or short circuited IBC Technologies Inc 27 Modulating Boilers 4 3 4 Detailed System Checks Detailed Systems Troubleshooting Symptom Diagnosis Remedy 1 RapidCycling _____ O i Gas valve clicks on and Obstruction in Intake Inspect vent terminals and off repeatedly when Exhaust venting tubing Clear any obstructions igniting venting venting condensate trap trap e Improper
35. on 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 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 any appliance not connected to the common venting system Turn on IBC Technologies Inc 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 Fue
36. or installation water leaks from piping or on combustible flooring with components located overhead significant flexibility of location e inanew construction installation provided with the available venting particular action must be taken to options The boiler can be placed in an protect the boiler from dust alcove basement closet or utility room combustion air should be drawn from a CLEAN source e g 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 dry cleaning fluids de greasers and paint removers all contain vapours which can form corrosive acid compounds when burned in a gas flame Airborne chorides outdoors and the boiler should 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 Distance Recommended from Distance for Combustible Service Surfaces such as those released with the use of Front 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 Below the boile
37. pply gas tape to threaded joint 4 2 5 Flow Switch Part Type VFCX P002 gt 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 Installation Ensure that arrow points towards the pressure vessel shift bar to NO position 4 2 6 Hi Limit Part Type VFCX HL200 Therm O Disc 37T_21 calibrated for 200 F 15 F differential Function Shuts boiler off when water temperature exceeds safety limit Installation 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 VFCX P006 Hammond DG2G control transformer Alternate Rex Manufacturing CS100AW X Primary 120 VAC Sec 24 VAc 100 VFC Modulating Boilers 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 amp ladder diagrams 4 2 8 Temperature Sensors Part Type VFCM P007 2 used Function Senses water temperature Signals controller to adjust output according to water temperature Installation use 3 8 wrench to remove and tighten 4 3 TROUBLESHOOTING GUIDE The troubleshooting section is divided into 2 sections e Preliminary checks e Detailed systems review Often a problem can be identified and solved through simple check
38. r 12 is required to provide clearance for the inlet and exhaust venting together with the required condensation trap Legs are available as an accessory for floor mounting of the boiler the 14 legs provide the necessary clearance It is recommended that the boiler be located in an area where water leakage will not result in damage to the area Ifa 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 1 4 Ventin factors determining potential mountin ids EP yx venting must be installed in accordance with the requirements of the IBC Technologies Inc 4 Modulating Boilers 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 comm
39. r filter annually Condensate Traps Check condensate traps every 6 months for water seal and blockages If a blockage exists trap must be cleared and refilled IBC Technologies Inc 21 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 CO analyzer to determine proper combustion CO level should be 9 2 for natural gas 10 4 propane Pump Check that the pump is on in normal operation Gas Piping Check for damage or leaks and repair as needed Control Module Check that boiler operation is consistent with the steps in section 2 2 Sequence of Operation Check that water temperature setpoint is satisfactory If a problem exists with the control module consult troubleshooting guide 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 Freeze Protection WARNING Do not use Ethylene Glycol automotive type antifreeze or undiluted antifreeze This may result in severe boiler damage Modulating Boilers Use only antifreeze made specifically for hydronic systems Inhibited propy
40. r 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 4 0 w c for natural gas and 10 5 w c for propane For either fuel the inlet pressure shall be no greater than 14 0 w c Confirm this pressure range is available with your local gas supplier Modulating Boilers 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 Table 5 Max Pipe Length ft Model 1 2 IPS_ 3 4 IPS 1 IPS 35 90 20 100 350 VFC 50 130 10 50 175 VFC 35 100LP 50 200 600 VFC 45 130LP 30 125 400 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 INSTALL MANUAL MAIN SHUTOFF VALVE 5 FT ABOVE FLOOR WHEN REQUIRED BY LOCAL CODE UNION FULL SIZE SEDIMENT TRAP GAS VALVE INSIDE Figure 11 Typical Gas Piping
41. refill as necessary RISE 1 4 PER FT FILL WITH WATER DRAIN OR CONDENSATE PUMP N VERTICAL PER o HORIZONTAL FOOT Lr T FILL WITH WATER i 5 j TO DRAIN OR CONDENSATE TRAP Figure 2 Condensate Trap Alternatives Modulating Boilers 1 4 1 4 Venting Passage Through Ceiling and Floor The following instructions apply to 2 2 and 3 piping e pipe clearances no specific requirements follow local codes e piping must be supported in the flooring e all piping must be liquid and pressure tight 1 4 1 5 Rooftop Vent Termination Vents must terminate as follows e 12 above grade and normal snow line to vent terminal bottom e DO NOT exhaust vent into a common venting system See Figures 3 amp 4 for rooftop vent terminations EXHAUST VENT WITH SCREEN AIR INTAKE 180 ELBOW WITH SCREEN FACE DOWN MIN AN 10 FT OR LESS Ta FT MIN FY MIN 2 12 SNOW LINE 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 ope
42. rovided there is power to the unit VFC Modulating Boilers 3 STARTUP DEN FOR YOUR SAFETY READ BEFORE OPERATING E WARNING If you do not follow these instructions exactly a fire explosion may result causing property damage personal injury or loss of life 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 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 If you cannot reach your gas supplier call the fire department 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 WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance 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 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 e STOP Read the safety information above on this label Remove
43. s exceeded limit of water temp switch Table 7 Soft and Hard Errors SoftErrors Description Temp Probe Error e measured temp exceeds max input temp or WATER less than min input temp e temp sensor defective or disconnected WATER TEMP Max Ignition e boiler has failed Trials 3 successive ignition trials BOILER OPERATING GAS VALVE airflow is below blocked vent threshold Defective or disconnected mass flow sensor Defective or disconnected fan Vent Hi Limit e vent temperature has exceeded limit of vent temp switch BOILER OPERATING 2 3 USER INTERFACE 2 3 1 Keypad Functions The keypad allows the user to change the setpoint or operating mode of the boiler Low Flow low water flow and vent limit not exceeded The boiler defaults to its normal operating mode during power up To change the setpoint temperature press and hold the key in the desired direction until the setpoint is reached The most recent setpoint is retained in BOILER OPERATING the controller even if power is interrupted IBC Technologies Inc 17 VFC Modulating Boilers 2 3 2 Indicator Lights HEAT TEMPERATURE status OF C 5 N 10 O STANDBY CALL FOR HEAT BOILER OPERATING ERROR WATER TEMP WATER DIRE AIRFLOW y 7 7 2 GAS VALVE SA Qe 4 2 07 THERM
44. s of the basics confirming the electrical power supply gas flow 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 4 3 1 Preliminary Checks 4 2 9 Control Module Part Type 001 Function See Section 2 for an explanation of controller function Installation 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 control module Remove the controller from the brackets by removing the thumbscrews on the left and the screws on the right potential error conditions as grouped into the following categories e Ignition e Cycling e Temperature Below each section is a list of Symptoms Diagnoses and Remedies Also provided with this manual are 4 diagrams for use with troubleshooting including e electrical wiring diagram e sequence of operations flowchart e boiler component layout diagram e troubleshooting flowchart The first step in troubleshooting this system should be to observe the control module display The right hand column of indicators display error conditions and sources of error as described in Section
45. tion 2 IBC Technologies Inc 9 Modulating Boilers 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 7223 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 weather stripped e anopening 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 1 000 BTUh for ALL APPLIANCES in the area e Openings must not be closed or reduced Doors and windows used for air supply must be locked open e Mechanical draft exhaust or supply fans are not to be used in or near the boiler area e Boiler combustion and ventilation airflow must not be obs
46. tructed IBC Technologies Inc 10 Indoor combustion air must not expose the boiler to contamination see Section 1 3 Location above In other respects Category IV venting is installed in the same manner as for the exhaust side of Direct Vent installations except that there is 2 2 extended travel vent option in the Category IV configuration 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 e one opening within 12 of the ceiling 100 sq in opening e 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 amp 10 30 psi pressure relief valve is supplied for field installation in the flow supply line in the manner shown in Figures 8 9 amp 10 Relief valve discharge piping must terminate 6 above a drain using plain un threaded end or per local Code To avoid water damage system piping and components are not to be located overhead the boiler
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