IBC VX Series Installation & Operating Manual
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IBC VX Series Installation & Operating Manual

Residential condensing boiler
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INSTALLATION &
OPERATING MANUAL
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 vapors and liquids or other combustible materials in
the vicinity of this or any other appliance.
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.
Residential Condensing Boiler
VX 110 (model # IBGFSW1-0110)
VX 150 (model # IBGFSW1-0150)
VX 199 (model # IBGFSW1-0199)
WARNING

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Summary of Contents for IBC VX Series

  • Page 1 INSTALLATION & OPERATING MANUAL Residential Condensing Boiler VX 110 (model # IBGFSW1-0110) VX 150 (model # IBGFSW1-0150) VX 199 (model # IBGFSW1-0199) 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 vapors and liquids or other combustible materials in the vicinity of this or any other appliance.
  • Page 2 Water quality Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage.

  • Page 3: Safety Information

    Important safety instructions Installation, start-up and servicing of IBC boilers must be performed by competent, qualified, licensed and trained heating technicians. Failure to read and comply with all instructions and applicable national and local codes may result in hazardous conditions that could result in property damage and injury to occupants, and in extreme cases to death.
  • Page 4 Section: Safety information Warning 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 that has been under water. Warning Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, or loss of life.

  • Page 5: Table Of Contents

    Contents Safety information Manual safety markings Important safety instructions Known contaminants Specifications Cabinet dimensions VX 110 dimensions VX 150 dimensions VX 199 dimensions Connection specifications 1.0 Introduction 1.1 Standard features and benefits 1.2 Warranty 2.0 Before installation 3.0 Installation 3.1 Code requirements 3.2 Removing an existing boiler 3.3 Determining location of the appliance 3.3.1 Best installation conditions...
  • Page 6 Section: Contents 3.9 Installing a condensate trap 3.10 Installing a condensate neutralizer 3.11 Water Piping 3.11.1 General piping best practices 3.11.2 System piping 3.12 Gas piping 3.12.1 Gas pressure 3.13 Electrical connections 3.13.1 Power management, quality and electrical protection 3.13.2 120VAC line-voltage hook-up 3.13.3 Other wiring 3.13.4 Zone valve hook-up 3.13.5 Thermostat / sensor wiring...
  • Page 7 7.2.2 General boiler maintenance 7.3 Replacing the fan, gas valve, and burner 7.3.1 Replacing the fan 7.3.2 Replacing the gas valve 7.3.3 Replacing the burner 7.4 Cleaning the sight glass 7.5 Cleaning the condensate trap 8.0 Troubleshooting 8.1 Electronic components 8.1.1 Temperature sensors 8.1.2 Fan 8.1.3 Water pressure sensor...

  • Page 8: Known Contaminants

    Intentionally left empty...

  • Page 9: Specifications

    Specifications Specification VX 110 VX 150 VX 199 CSA Input (Natural Gas or Propane) - 16.9-110 23-150 30.6-199 CSA Input (Natural Gas or Propane) - 5-32.2 6.7-44 8.8-58.3 CSA Output - MBH 16.2-101.5 22-138.5 29.2-183.7 CSA Output - kW 4.74-29.8 6.5-40.6 8.6-53.8 AFUE (to be confirmed)

  • Page 10: Cabinet Dimensions

    Section: Specifications Specification VX 110 VX 150 VX 199 Approved installation altitude - ASL 0 - 12,000' 0 - 12,000' 0 - 12,000' 2" 100' 3" 240' 170' 100' Maximum equivalent vent length each side (vent & air intake) (natural gas or propane) Air intake options: either direct vent or indoor supply Cabinet dimensions...

  • Page 11: Vx 150 Dimensions

    VX 150 dimensions Figure 3 Top view - VX 110 Figure 4 Bottom view - VX 110 VX 150 dimensions Figure 5 Frontal view - VX 150 Figure 6 Side view - VX 150...

  • Page 12: Vx 199 Dimensions

    Section: Specifications Figure 7 Top view - VX 150 Figure 8 Bottom view - VX 150 VX 199 dimensions Figure 9 Frontal view - VX 199 Figure 10 Side view - VX 199...

  • Page 13: Connection Specifications

    Connection specifications Figure 11 Top view - VX 199 Figure 12 Bottom view - VX 199 Connection specifications The following table displays the required connection specifications. Description VX 110 VX 150 VX 199 Flue Outlet 3" Schedule 40 or 3" PPs (80 mm) Combustion Air Inlet 3"...
  • Page 14 Intentionally left empty...

  • Page 15: Introduction

    1.0 Introduction Figure 13 View from the front 1.1 Standard features and benefits High thermal efficiency Compact Turn-down ratio 6.5 to 1 Cascade up to 4 appliances 4 load pump management 1 boiler pump management Easy-to-use touchscreen...

  • Page 16: Warranty

    Section: Introduction 1.2 Warranty For residential applications, IBC offers a 5-year warranty on all parts against defects in materials or workmanship and failures due to thermal shock. IBC offers a heat exchanger 15-year limited warranty with registration, according to the following...

  • Page 17: Before Installation

    2.0 Before installation Before installing the appliance, it is important to review and observe the following checklist of precautions: Precautions Check □ Care must be taken to properly size the boiler for its intended use. Prolonged full fire run time, over-sizing or under-sizing, and incorrect flow rates through the appliance can lead to increased maintenance costs, equipment stress and premature failure.
  • Page 18 Section: Before installation Precautions Check □ Ensure that the pressure relief valve is installed with no valves or other means of isolation between its inlet and the boiler. Make sure the relief valve outlet is piped with unobstructed piping (minimum ¾" diameter) to a safe discharge location.

  • Page 19: Installation

    3.0 Installation Refer to the Specifications section for dimensional drawings and connection specifications. Use these drawings to find a suitable location for the appliance. 3.1 Code requirements The appliances are tested and certified under CSA 4.9-2017 / ANSI Z21.13-2017. Below are the code requirements for every installation.

  • Page 20: Determining Location Of The Appliance

    Section: Installation Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

  • Page 21: Best Installation Conditions

    3.3.1 Best installation conditions 3.3.1 Best installation conditions Below are some factors to consider for best installation conditions: Install the boiler in areas where the combustion air source is not subject to chemical fouling or agricultural vapors. Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a boiler.
  • Page 22 Section: Installation Attach the support bracket (supplied) to the Hook the boiler tab (located on wall studs using the two ¼" x 2½" long lag back of boiler) over the support screws with flat washers. bracket flange. Ensure that the boiler tab is flush against Secure the lower part of the boiler the mounting bracket flange.

  • Page 23: Connecting The Vent And Air Intake Pipes

    3.5 Connecting the vent and air intake pipes 3.5 Connecting the vent and air intake pipes The appliance offers 3" connections that accept standard 3" PVC/CPVC and PPs pipe. Use available pipe-reducer fittings (not bushings) to adapt to smaller diameter pipe. Insert pipe directly into the 3" female fitting, and secure with the built-in clamp (see image below).

  • Page 24: Installation Clearances

    3.7 Exhaust venting and air intake Warning Venting, condensate drainage, and combustion air systems for all IBC boilers must be installed in compliance with all applicable codes and with instructions provided in the respective installation manuals.

  • Page 25: Venting Code

    3.7.1 Venting code These approved “Category IV” vented appliances offer flexible installations via direct vent (sealed combustion) or indoor combustion air. When planning a boiler's installation, consider the appropriate vent materials, travel and termination. 3.7.1 Venting code All venting must be installed in accordance with the requirements of the jurisdiction having authority: in Canada, Part 8, Venting Systems of the B149.1-10 Code and any other local building codes are to be followed.

  • Page 26: Direct Vent

    Section: Installation Exhaust vent material – U.S.A PVC, CPVC, PPs, or SS venting materials are approved for use with these boilers in most of the USA. Check local codes to determine if any materials are prohibited. The vent temperature is limited with the use of the flue temperature sensor and software to ensure that the maximum temperature of the PVC venting material is not exceeded.
  • Page 27 Check that material meets local codes including fire stopping requirements. Some local jurisdictions require a minimum initial length of pipe be exposed or accessible for inspection. Pipe clearances - no IBC requirements; follow local codes. All piping must be liquid and pressure tight.
  • Page 28 Check the local jurisdiction on the minimum initial length of pipe that should be exposed or accessible for inspection. Follow the local codes for pipe clearances - no IBC requirements. Ensure that piping is liquid and pressure tight. 3.7.4.1 Air intake and exhaust vent length allowance Warning Follow all installation instructions supplied by the piping and fitting manufacturer.
  • Page 29 3.7.4 Direct vent Intake/Exhaust VX 110 VX 150 VX 199 2-inch Stainless No allowance required Not permitted Not permitted Sidewall Terminal (P-256) 3-inch Stainless Allow 20 feet Sidewall Terminal - exhaust vent (P- 257) 3-inch Stainless No allowance required Sidewall Terminal - air intake (P-257) Flexible PPs 3-...

  • Page 30: Rooftop Vent Termination

    Section: Installation 3.7.5 Rooftop vent termination Warning Condensate can cause corrosion of metal roofing components and other roofing materials. Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate. pH levels can be as low as 3.0. a.
  • Page 31 3' apart (the closest intake and exhaust pipes must be 36", or more, apart). Use the same 12" (minimum) vertical separation for all termination options. For alternate group terminations, contact the IBC factory for written guidance.

  • Page 32: Sidewall Vent Termination

    3.7.6 Sidewall vent termination Caution Vent termination clearances in this section are code minimum, or IBC-recommended minimum requirements, and may be inadequate for your installation. Building envelope details must be examined carefully. Take action to avoid moisture entering building structures.
  • Page 33 3.7.6 Sidewall vent termination US Installations Canadian Description Installations Clearance above grade, veranda, porch, deck, 12 in (30 cm) 12 in (30 cm) or balcony Clearance to window or door that may be 6 in (15 cm) for 6 in (15 cm) for opened appliances ≤...
  • Page 34 Improper installation will void the warranty. Do not use proprietary InnoFlue or PolyPro PPs terminals without specific approval from IBC. In accordance with the current CAN/CSA-B149 Installation Codes.
  • Page 35 3.7.6 Sidewall vent termination Sidewall direct vent with separate vent and air pipes must be terminated as follows: Locate the intake air and exhaust vent terminations on the same plane (side) of the building. Place the exhaust vent termination, so that it reaches 12" minimum above the down-turned intake to avoid exhaust re-ingestion.
  • Page 36 Section: Installation Figure 22 Sidewall vent termination configuration option 1 Figure 23 Sidewall vent termination configuration option 2...
  • Page 37 Sidewall direct vent with stainless sidewall terminal must be terminated as follows: The Stainless Sidewall Terminal (SST) 2 inch (IBC kit P-256 ) or 3 inch (IBC kit P-257 ) are approved for use with this appliance.
  • Page 38 Section: Installation Figure 26 Pipes extend completely through the wall (Vertical orientation shown) Ensure that the vent termination location does not exceed the allowed maximum equivalent vent length, including the allowance for the SST. Install multiple vent SST installations level with one another and maintain at least the minimum separation distances shown below.

  • Page 39: Indoor Air Combustion Air Intake

    3.7.7 Indoor air combustion air intake Figure 29 Approved PVC Side Wall Termination configuration 3.7.7 Indoor air combustion air intake An “Indoor Combustion Air installation” can be described as air for combustion that is taken from the air surrounding the boiler. Warning When using indoor air options, supply adequate combustion air to the boiler room according to the requirements of all applicable codes.

  • Page 40: Combustion Air Filtration System

    If combustion air contamination from ingested particulate matter is a concern in any installation, an optional air intake filter may be installed. IBC-supplied air intake filters have a known pressure drop and fouling factor and should be used as a component of the combustion air system...

  • Page 41: Closet Installations

    The appliance must not be exposed to surrounding air above 122°F (50°C) or below 32°F (0°C). 3.9 Installing a condensate trap IBC’s specified vent configuration promotes the safe drainage of moisture from the boiler and exhaust venting without flowing liquids back through the heat exchanger (as done by some other condensing boilers).
  • Page 42 Section: Installation Place the vacuum breaker cap over the Fill the condensate trap with water. vacuum breaker opening and push firmly. Attach the drain hose and tighten the Slide the trap over the boiler drain outlet, drain compression nut (including washer). and tighten upper union nut.

  • Page 43: Installing A Condensate Neutralizer

    3.10 Installing a condensate neutralizer Ensure that the trap upper union nut is Check that all trap fittings have been secured by the outlet clip. hand-tightened to prevent leakage of flue gases. Do not use tools and over-torque. Check for leaks. 3.10 Installing a condensate neutralizer If discharging condensate into building drain piping materials that are subject to corrosion, use a neutralization package.
  • Page 44 Section: Installation Figure 32 Condensate neutralization tank Flue gas exhaust: condensate, and potentially rain water, flow back from the venting system. Air intake piping: Warning - Risk of damage to appliance. Ensure that rain water is prevented from entering. Condensate water line: Warning - Risk of damage to appliance. All condensate discharge lines, including neutralization tank inlet, must be at a lower elevation than the condensate water line of the appliance.

  • Page 45: Water Piping

    3.11 Water Piping Condensate neutralizer: Drain materials subject to corrosion must be protected by acid neutralization. Warning - Risk of injury. Tank fluid can be highly acidic. Do not use hands to stir material. Refer to the neutralization instructions of the manufacturer. Access to the discharge, before the drain, is necessary for proper maintenance in order to check the effectiveness of the neutralizing agent.
  • Page 46 Section: Installation Boiler Head Loss - VX 110 Flow rate (gpm) Head @ flow (ft) 0.18' 0.51' 0.99' 1.59' 2.49' 3.55' 4.75' Table 6 Boiler Head Loss Boiler Head Loss - VX 150 Flow rate (gpm) Head @ flow (ft) 0.42' 0.9' 1.52'...
  • Page 47 Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation location. For environmental and toxicity reasons, IBC recommends only using non-toxic propylene glycol.

  • Page 48: General Piping Best Practices

    The piping drawings in this manual are simple schematic guides to a successful installation. For further information and details, consult our concept drawings – which provide detail on specific single and multiple boiler applications (available in IBC's Technical portal). There are many necessary components not shown, and details such as thermal traps are left out so the drawings have greater clarity.
  • Page 49 3.11.2 System piping Pressure relief valve (shipped with the boiler): no isolation valve permitted between boiler and relief valve Microbubble air eliminators are best installed where the fluid is at the highest temperature and lowest pressure, on boiler outlet at expansion tank connection. Expansion tank connection (point of no pressure change) should be on the suction side of the circulator, with minimal pressure drop between.
  • Page 50 Section: Installation Fluid fill is most often accomplished by using a boiler regulator and fill valve set at 12 psig or more, with the appropriate backflow prevention device as required by local code. This is acceptable in areas where municipal water or well water has been treated and filtered to remove excessive minerals and sediment, and water chemistry is known to be suitable for closed loop hydronic systems.
  • Page 51 3.11.2 System piping Closely-spaced tees: Install tees with straight piping (min. pipe diameter lengths as per Table 9 ), with tees maximum 4 pipe diameters apart with no restrictions between fittings. Figure 34 Primary-secondary piping details with closely-spaced tees Figure 35 Primary-secondary piping with simultaneous heating calls...
  • Page 52 Section: Installation Figure 36 Two pump, two load - parallel piping concept...
  • Page 53 3.11.2 System piping Pressure relief valve (shipped with boiler): no isolation valve permitted between boiler and relief valve Hydraulic separator Expansion tank connection (point of no pressure change) should be on the suction side of the circulator, with minimal pressure drop between. Fill station with isolation valve closed, or fill tank Supply piping to loads Returns to loads...
  • Page 54 Section: Installation The boilers can supply multiple heating loads with compatible supply temperature requirements. Always ensure that loads sensitive to high temperatures are protected using means such as mixing valves. Supply to heating system. Secondary loop sensor (to master boiler). Closely-spaced tees are a maximum of four pipe diameters apart, with a minimum of eight pipe diameters of straight piping upstream of the first tee and a minimum of four pipe diameters of straight piping downstream of the second tee.

  • Page 55: Gas Piping

    3.12 Gas piping 3.12 Gas piping Note Due to the precision of modern modulating boilers it is important to pay special attention to gas pressure regulation. Important: Check gas supply pressure to each boiler with a manometer or other high- quality precision measuring device.

  • Page 56: Electrical Connections

    Section: Installation Gas piping must have a sediment trap ahead of the boiler’s gas valve. A manual shutoff valve must be located outside the boiler, in accordance with local codes or standards. All threaded joints in gas piping should be made with an approved piping compound resistant to the action of natural gas or propane.

  • Page 57: Power Management, Quality And Electrical Protection

    Note The IBC boiler (like any modern appliance that contains electronic equipment) must have a “clean” power supply, and is susceptible to power surges and spikes, lightning strikes and other forms of severe electrical “noise”. Power conditioning equipment (surge protectors, APC or UPS devices) may be required in areas where power quality is suspect.
  • Page 58 5 Amp fuse. The Alarm contact is fused with a 5 Amp fuse and the 24VAC boiler control circuit is protected with a 2 Amp fuse. The VS output leads are not commonly used except when providing a variable speed signal to the fan in an IBC air handler.

  • Page 59: Other Wiring

    DHW routine. One pair of contacts for remote secondary loop temperature control. One pair (marked BoilerNet) for network connection – this is used for connecting multiple IBC modulating appliances for autonomous staging.

  • Page 60: Thermostat / Sensor Wiring

    Consult the Controller manual for more detailed instructions. 3.13.6 Thermostat heat anticipator IBC “Therm” contacts draw no power, so an anticipator setting for the thermostat is not applicable with these appliances. In the case of a single temperature / heat load where zone valves are used to manage individual thermostatically controlled zones, each room thermostat’s heat anticipator...

  • Page 61: About The Boiler Controller

    Load Combining – simultaneous operation of two similar water temperature loads Programmable setback / override schedule The control can manage or operate in a network of up to 4 IBC boilers without additional controller.  Some of the new features available in the touchscreen control include:...

  • Page 62: Control Interface

    Real time boiler data Temperature and throttle operation Maintenance of operational and error service logs 2-way communication between other IBC boilers and controls Internet connection and communication Operational and historical data may be accessed from the Status menu > Load Status > Load Profiles and Load Statistics screens. Also in the Status menu, you can view error logs, including records of all errors since original power-up complete with the date and time of the error.

  • Page 63: Before Operating The Boiler

    5.0 Before operating the boiler Danger Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, do not try to operate any appliance - do not touch any electrical switch or use any phone in the building.
  • Page 64 Section: Before operating the boiler Checking piping connections Check □ Check that the water piping system is fully flushed and charged, and that all air has been discharged through loosened bleed caps. Note that it is possible to switch all pumps on/off from the touchscreen – without a call for heat.

  • Page 65: Boiler Operation

    6.0 Boiler operation Before operating the appliance, there are some important pre-igntion checks that need to be performed. For more information, see Before operating the boiler on page 59. To understand the boiler start-up process, see Sequence of Operation on page 99.

  • Page 66: Testing The Ignition Safety Shutoff

    Section: Boiler operation Start-up Checklist Check □ Performed gas pressure test by measuring the inlet gas pressure. □ Tested efficiency of the appliance and made necessary adjustments by Performing a combustion test and adjustment. □ Tested the low water cutoff function to check that the LWCO sensor is working. See Testing the LWCO function on page □...

  • Page 67: Checking A Boiler's Fuel Source

    6.3.1 Checking a boiler's fuel source Danger Operating any IBC appliance using a fuel other than the fuel listed on its rating plate is prohibited. Failure to follow the instructions on converting to alternate fuels can result in a fire or explosion, which may cause property damage, personal injury, or loss of life.

  • Page 68: Adjusting The Gas Valve

    6.3.3 Adjusting the gas valve Danger Making adjustments to the IBC gas valve without a properly calibrated gas combustion analyzer and by persons who are not trained and experienced in its use is forbidden. Failure to use an analyzer can result in an immediate hazard.
  • Page 69 6.3.3 Adjusting the gas valve Gas valve inlet Inlet gas pressure test port Manifold gas pressure test port Low fire adjustment (offset pressure)  Gas valve outlet Orifice O-ring Gas valve outlet pipe Fan inlet Fan plug...
  • Page 70 Section: Boiler operation High Fire Adjustment Gas valve support bracket Venturi insert clip Venturi insert Figure 42 Gas valve and fan components 6.3.3.1 Measuring the inlet gas pressure To perform a gas pressure test, you will need to use a Torx 15 screwdriver and a manometer. 1.
  • Page 71 6.3.3 Adjusting the gas valve 6.3.3.2 Performing a combustion test and adjustment The High Fire (gas-air ratio) adjustment screw will have to be adjusted to attain optimum combustion results whenever fuel conversion is undertaken, however, no mixture adjustment must be performed unless done by a qualified technician using properly functioning and calibrated combustion analyzing equipment.

  • Page 72: Testing The Lwco Function

    Section: Boiler operation 7. Check the results and confirm the correct settings when you return the boiler to high fire, and then to low fire. Note Clock the gas meter to confirm full maximum rating plate input. 8. To exit the Test Operation screen, select Back. 9.

  • Page 73: Testing The Hi-Limit Cutoff Temperature Function

    6.3.5 Testing the Hi-Limit cutoff temperature function 6.3.5 Testing the Hi-Limit cutoff temperature function The hi-limit temperature function monitors the maximum supply temperature set in the safety ignition module (SIM). If the water temperature exceeds the hi-limit temperature, the boiler goes into a lockout condition, requiring a manual reset.
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  • Page 75: Service And Maintenance

    7.0 Service and maintenance Inspection of the boiler is to be performed annually by a qualified service technician. Caution The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition. 7.1 Maintenance checklist for homeowner Maintenance Required Frequency...

  • Page 76: Touchscreen Boiler Controller

    Section: Service and maintenance 7.2.1 Touchscreen boiler controller Maintenance Required for Boiler Controller Frequency Check □ Annually Check that boiler operation is consistent with the steps in the Touchscreen Boiler Controller Manual. □ Annually Check that water temperature targets and setpoint is satisfactory and have not been adversely amended.
  • Page 77 7.2.2 General boiler maintenance Boiler Maintenance Required Frequency Check Component c. Reassemble. Visually inspect the burner through sight glass. Ensure the flame is stable, without excessive fluttering. Normal flame pattern is evenly distributed over the burner surface. □ Annually If the burner is operating improperly, remove and clean or replace.
  • Page 78 Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation location. For environmental and toxicity reasons, IBC recommends only using non-toxic propylene glycol. □ Water...
  • Page 79 7.2.2 General boiler maintenance Boiler Maintenance Required Frequency Check Component □ Annually Check the water pressure. Pressure should be stable when the boiler is firing and the water temperature is rising. If pressure rises sharply, consider replacement of expansion tank. □...

  • Page 80: Replacing The Fan, Gas Valve, And Burner

    Section: Service and maintenance Boiler Maintenance Required Frequency Check Component replaced. To refill and pressurize your system, we recommend using a system pressurization appliance such as an Axiom Industries model SF100 series. Capture the discharged fluid in a container and recycle it by returning it to the system feeder appliance.
  • Page 81 7.3 Replacing the fan, gas valve, and burner Gas valve inlet Inlet gas pressure test port Manifold gas pressure test port Low fire adjustment (offset pressure) - Do not adjust in the field Gas valve outlet Orifice O-ring Gas valve outlet tube Fan inlet...

  • Page 82: Replacing The Fan

    Section: Service and maintenance Fan plug Combustion Fan High Fire Adjustment Gas valve support bracket Venturi insert clip Venturi insert Figure 45 Gas valve and fan components 7.3.1 Replacing the fan 1. Turn off the electric power and gas supply to the boiler. 2.

  • Page 83: Replacing The Gas Valve

    7.3.2 Replacing the gas valve 16. Insert the gas valve outlet pipe and venturi clip. 17. Reinstall the components in reverse order. Upon reassembly, ensure that all O-rings and gaskets are correctly positioned. 18. Check for leaks at the gas valve outlet and at the connection point between the fan and the heat exchanger lid.

  • Page 84: Replacing The Burner

    Section: Service and maintenance 7.3.3 Replacing the burner Warning The IBC heat exchanger has a small amount of combustion chamber insulation (refractory), which contains ceramic fibers. When exposed to extremely high temperatures, the ceramic fibers that contain crystalline silica can be converted into cristobalite, classified as a possible human carcinogen.

  • Page 85: Cleaning The Sight Glass

    7.4 Cleaning the sight glass 6. Remove the electrical connection to the fan. 7. For instructions on removing the fan, see Replacing the fan on page 8. Remove the ignitor cables (green and red). 9. Remove the four (4) nuts securing the lid to the heat exchanger. The burner is attached to the underside of the heat exchanger lid.

  • Page 86: Cleaning The Condensate Trap

    Section: Service and maintenance 1. Turn off the electric power and gas supply to the boiler. 2. Remove the two screws holding the sight glass in place. 3. Remove the four components of the sight glass and wipe the glass clean. 4.
  • Page 87 7.5 Cleaning the condensate trap Condensate traps should be checked every year, cleaned and refilled as necessary. Before cleaning the condensate trap, you must turn off the power to the boiler, and allow it to cool down. Important: Installers or service contractors should ensure that the end user is instructed on cleaning and...
  • Page 88 Section: Service and maintenance Fill the condensate trap to the top with Slide the trap over the boiler drain outlet, water and replace the union cap and making sure it is secured by the clip, and gasket. tighten the upper union nut to ensure an airtight seal.

  • Page 89: Troubleshooting

    8.0 Troubleshooting This section includes various conditions as well as possible solutions. Often, a problem can be identified and solved through basic checks: confirming the electrical power supply, gas flow and resetting the thermostat control. Below are some common troubleshooting issues including fixes. 8.1 Electronic components This section details the method for troubleshooting the non-standard electronic components on the boiler.

  • Page 90: Fan

    Section: Troubleshooting Resist. Resist. Temp. °F/°C Temp. °F/°C Ω – Ohm Ω – Ohm 0 / -18 85,362 100 / 38 5,828 5 / -15 72,918 105 / 41 5,210 10 / -12 62,465 110 / 43 4,665 15 / -9 53,658 115 / 46 4,184...

  • Page 91: Safety And Ignition Module (Sim+)

    8.1.4 Safety and Ignition Module (SIM+) Check the operation of the sensor by isolating the boiler from its system piping, and close the system fill valve, and then crack the pressure relief valve. The pressure displayed should reflect declining pressure. If it remains “fixed”, drain the boiler and replace the sensor, or dislodge any blocking debris from the sensor inlet channel and reinsert.
  • Page 92 Section: Troubleshooting SIM Status Indicators Description, LED status LED 1 LED 2 State indication Heating Rapid flash Igniting Flashing Lockout Flash alternately with Flash alternately with Fail-safe Boiler requires a power cycle LED 2 LED 1 Table 13 SIM+ LED status Indicators 8.1.4.2 Resetting a boiler after a LWCO lockout A boiler in a lockout condition due to a LWCO error will need to be reset.

  • Page 93: Troubleshooting Error Messages

    8.2 Troubleshooting error messages 8.2 Troubleshooting error messages Warning Never attempt to repair the control module (circuit board). If the control module is defective, replace it immediately. Errors shown on the touchscreen controller are described below as well as diagnoses and fixes. The bottom line of the touchscreen displays the boiler's error status.

  • Page 94: Hi Limit Cut-Off Temperature Error

    Section: Troubleshooting 8.2.2 Hi Limit cut-off temperature error Hi Limit cutoff temperature Error Issue Diagnosis Error – Water High-Limit Water temperature exceeds Resetting a boiler after a Exceeded hi-limit. Boiler is in hard hi-limit temperature lockout on lockout mode. page 8.2.3 Low Water Cut-off error Low Water Cutoff Error Issue...

  • Page 95: Miscellaneous Touchscreen Controller Errors

    8.3 Miscellaneous touchscreen controller errors 8.3 Miscellaneous touchscreen controller errors Miscellaneous errors Issue Diagnosis The sensor Check the P501 plug is “ Loop/Indoor Sensor” plug is not fully engaged in the back of engaged. the controller board. “Insufficient Air Flow” “Insufficient Water Pressure” “Unknown Error”...

  • Page 96: Ignition Issues

    Section: Troubleshooting 8.3.1 Ignition issues Ignition issues Issue Diagnosis Noisy spark when igniting Ignition lead is not firmly Reconnect ignition lead. connected. Contaminants/moisture Ensure probe is dry by re-running on igniter probe/flame post-purge; otherwise, clean or sensor. replace igniter probe. Boiler rumbles when igniting.

  • Page 97: Temperature Issues

    8.3.2 Temperature issues 8.3.2 Temperature issues Temperature issues Issue Diagnosis Low heat Operating temperature too low. Increase temperature target. Increase temperature target. Priority parameters or load Review load configuration parameters. configuration improperly set up. appliance undersized. Refer to Load Calculation vs. Boiler Output. Air trapped within system.

  • Page 98: Miscellaneous Issues

    Replace the Power Robbing boiler. thermostat, isolate the thermostat with a relay or install a properly sized resistor (consult the thermostat manufacturer first then IBC for instructions). Error: Water Boiler is in 1-hour For instructions on clearing errors, see...

  • Page 99: Cycling Issues

    8.3.4 Cycling issues 8.3.4 Cycling issues Cycling issues Issue Diagnosis Rapid Improper values Check load maximum temps are above target temps, by ½ of the Cycling entered via keypad. selected boiler differential. Ensure boiler differential is OK (16 - 30 °F is generally adequate) Excess condensate Check venting slopes on horizontal runs.
  • Page 100 Intentionally left empty...

  • Page 101: Appendices

    Appendices Wiring diagrams Figure 48 Controller electrical diagram...
  • Page 102 Section: Appendices Figure 49 Internal wiring diagram...
  • Page 103 Appendices Figure 50 Sequence of Operation...

  • Page 104: Boiler Part Diagrams - Vx 110, Vx 150, Vx 199

    Section: Appendices Boiler part diagrams - VX 110, VX 150, VX 199 Item ID Description Part # P-kit # Top access cover - VX 110 251-168 P-1506 Top access cover - VX 150 251-184 P-1531 Top access cover - VX 199 251-194 P-1532 Exhaust duct...
  • Page 105 Boiler part diagrams - VX 110, VX 150, VX 199 Item ID Description Part # P-kit # Front door cover - VX 150 500-181 P-1533 Front door cover - VX 199 500-182 P-1534 Thumb screw 250-275 Terminal block cover 251-163 P-1509 V-10 touchscreen controller 500-103...
  • Page 106 Section: Appendices...
  • Page 107 Boiler part diagrams - VX 110, VX 150, VX 199 P-kit Item ID Description Part # replacement Quantity Gas valve 180-165 P-326 P-1501 Orifice NG 505 180-095 P-1500 Orifice LP 410 180-194 P-1503 Orifice NG 620 180-195 P-1502 Orifice LP 520 180-300 P-1505 Orifice NG 705...
  • Page 108 Section: Appendices P-kit Item ID Description Part # replacement Quantity Condensate trap 180-013 P-115 Water pressure sensor 240-180 P-1517 Heat exchanger - VX 110 170-119 P-1518 Heat exchanger - VX 150 170-121 P-1523 Heat exchanger - VX 199 170-123 P-1527 Burner 110 180-297 P-1519...

  • Page 109: Installation & Commissioning Report

    Installation & Commissioning Report Installation & Commissioning Report Model Number _____________________ Serial Number ________________________________ Date of Installation ________ Address of installation ____________________________________ User contact information __________________________________________________________ Installer Information (Company & Address)_____________________________________________ Phone/Fax/E-mail ________________________________________________________________ □ □ Fuel: Natural Gas Propane Gas Supply Pressure (high fire) ____ Inches w.c. Measured Rate of Input (high fire) _____Btu/hr □...
  • Page 110 This boiler is not used for any space heating. This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. This boiler is equipped with a tankless coil (not applicable to these boilers). US installers should contact IBC for any further information required.
  • Page 111 856-735-5584 Toll Free: 1-844-HEAT-IBC/ 1-844-432-8422 www.ibcboiler.com Information in this document is subject to change without notice. IBC assumes no responsibility for changes made to the manual due to clerical errors, to regulation changes, or to product development. April, 2021 120-347E1 ©...

This manual is also suitable for:

Vx 110Vx 150Vx 199Ibgfsw1-0110Ibgfsw1-0150Ibgfsw1-0199

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