IBC VX Series Istruzioni per l'installazione

Residential Condensing Boiler

VX 110 (model # IBGFSW1-0110)

VX 150 (model # IBGFSW1-0150)

VX 199 (model # IBGFSW1-0199)

INSTALLATION &

OPERATINGMANUAL

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.

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.

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.

High levels of dissolved solids or minerals may precipitate out of the fluid onto the hottest part

of the heat exchanger, impairing heat transfer and resulting in overheating and premature

failure. The amount of solids that may form on the heat exchanger will depend on the degree of

hardness and the total water volume in the system. A high water volume system with a low

hardness count may cause as much damage as a system with less volume and higher

hardness, so it is recommended to treat water so as to remove all dissolved solids. Other water

chemistry allowable limits are as follows:

Acidity pH is to be between 6.6 and 8.5

Chloride is to be less than 125 mg/l

Iron is to be less than 0.3 mg/l

Cu less than 0.1 mg/l

Conductivity is to be less than 400μS/cm (at 77°F [25°C])

7 grains/ gal (120 ppm)

Important: Ensure that these limits are acceptable for the other water-side components in the

system.

Shipped with the boiler:

1 x Wall mounting bracket

1 x Condensate trap assembly

1 x 30 psig pressure relief valve

1 x Outdoor temperature sensor

2 x ¼" x 2 ½" Lag screws/w flat washers

1 x Propane fuel conversion kit

Safety information

Manual safety markings

Danger

Points out an immediate hazardous

situation that must be avoided to

prevent serious injury or death.

Warning

Points out a potential hazardous

situation that must be avoided to

prevent serious injury or death.

Caution

Points out a potential hazardous

situation that must be avoided to

prevent possible moderate injury

and/or property damage.

Note

Points out installation, maintenance and

operational notes to enhance efficiency,

longevity and proper operation of the

boiler.

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. Keep instructions near the air handling appliance for future reference.

Danger

Should overheating occur or the gas supply fails to shut off, do not turn off or disconnect the

electrical supply to the pump. Instead shut off the gas supply at a location external to the

appliance.

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. Immediately, call the gas supplier from

a phone located remotely. Follow the gas supplier’s instructions, or if the supplier is

unavailable, contact the fire department.

Warning

If the boiler is likely to be exposed to fluid temperatures below 34°F (1°C), use a method to

prevent freezing of condensate. Contact the factory for further 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. Read and understand the entire manual before

attempting installation, start-up, operation, or service. Installation and service must be

performed only by an experienced, skilled installer or service agency.

Failure to follow all instructions in the proper order can cause personal injury or death.

Read all instructions, including all those contained in component manufacturers’ manuals

before installing, starting up, operating, maintaining, or servicing the appliance.

Warning

Disconnect power supply before any wiring/service is performed. Failure to do so could

result in damage to appliance and/or electric shock.

Caution

The boiler must be installed so that electrical components are not exposed to water during

operation.

Known contaminants

Known Corrosive Contaminants to Avoid

Cements and glues Refrigerant leaks from cracks in coils

Paint or varnish removers Sodium chloride or potassium chloride used for

water softening

Adhesives used to fasten building products

and other similar products

Chemicals in perming solutions

Chlorinated waxes or cleaners Chlorofluorocarbon chemicals found in spray cans

Chlorine-based swimming pool chemicals Antistatic dryer sheets in clothes dryers

Hydrochloric acid or muriatic acid used in

household cleaning and stain removal

Chlorine-type bleaches, detergents, and cleaning

solvents found in household laundry rooms

Calcium chloride used for snow and ice

clearing

Section: Safety information

Contents

Safety information 3

Manual safety markings 3

Important safety instructions 3

Known contaminants 4

Specifications 5

Cabinet dimensions 6

VX 110 dimensions 6

VX 150 dimensions 7

VX 199 dimensions 8

Connection specifications 9

1.0 Introduction 11

1.1 Standard features and benefits 11

1.2 Warranty 12

2.0 Before installation 13

3.0 Installation 15

3.1 Code requirements 15

3.2 Removing an existing boiler 15

3.3 Determining location of the appliance 16

3.3.1 Best installation conditions 17

3.4 Mounting the boiler 17

3.5 Connecting the vent and air intake pipes 19

3.6 Installation clearances 20

3.7 Exhaust venting and air intake 20

3.7.1 Venting code 21

3.7.2 Venting options 21

3.7.3 Exhaust vent material 21

3.7.4 Direct vent 22

3.7.5 Rooftop vent termination 26

3.7.6 Sidewall vent termination 28

3.7.7 Indoor air combustion air intake 35

3.7.8 Combustion air filtration system 36

3.8 Closet installations 37

3.9 Installing a condensate trap 37

3.10 Installing a condensate neutralizer 39

3.11 Water Piping 41

3.11.1 General piping best practices 44

3.11.2 System piping 44

3.12 Gas piping 51

3.12.1 Gas pressure 51

3.13 Electrical connections 52

3.13.1 Power management, quality and electrical protection 53

3.13.2 120VAC line-voltage hook-up 53

3.13.3 Other wiring 55

3.13.4 Zone valve hook-up 55

3.13.5 Thermostat / sensor wiring 56

3.13.6 Thermostat heat anticipator 56

4.0 About the boiler controller 57

4.1 Controller 57

4.2 Control interface 58

5.0 Before operating the boiler 59

5.1 Important pre-ignition checks 59

5.1.1 Checklist for electrical conditions, ducting and water connections 59

6.0 Boiler operation 61

6.1 Lighting and shutting down the boiler 61

6.2 Testing the ignition safety shutoff 62

6.3 Commissioning 62

6.3.1 Checking a boiler's fuel source 63

6.3.2 Performing a fuel conversion 63

6.3.3 Adjusting the gas valve 64

6.3.4 Testing the LWCO function 68

6.3.5 Testing the Hi-Limit cutoff temperature function 69

7.0 Service and maintenance 71

7.1 Maintenance checklist for homeowner 71

7.2 Maintenance checklist for heating contractor 71

7.2.1 Touchscreen boiler controller 72

Section: Contents

7.2.2 General boiler maintenance 72

7.3 Replacing the fan, gas valve, and burner 76

7.3.1 Replacing the fan 78

7.3.2 Replacing the gas valve 79

7.3.3 Replacing the burner 80

7.4 Cleaning the sight glass 81

7.5 Cleaning the condensate trap 82

8.0 Troubleshooting 85

8.1 Electronic components 85

8.1.1 Temperature sensors 85

8.1.2 Fan 86

8.1.3 Water pressure sensor 86

8.1.4 Safety and Ignition Module (SIM+) 87

8.2 Troubleshooting error messages 89

8.2.1 Maximum ignition trials error 89

8.2.2 Hi Limit cut-off temperature error 90

8.2.3 Low Water Cut-off error 90

8.2.4 Aux. Interlock 1 or 2 90

8.3 Miscellaneous touchscreen controller errors 91

8.3.1 Ignition issues 92

8.3.2 Temperature issues 93

8.3.3 Miscellaneous issues 94

8.3.4 Cycling issues 95

Appendices 97

Wiring diagrams 97

Boiler part diagrams - VX 110, VX 150, VX 199 100

Installation & Commissioning Report 105

Intentionally left empty

Specifications

Specification VX 110 VX 150 VX 199

CSA Input (Natural Gas or Propane) -

MBH

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) 95% 95% 95%

Minimum gas supply pressure (natural

gas or propane) - inch w.c.

4 4 4

Maximum gas supply pressure (natural

gas or propane) - inch w.c.

14 14 14

Ambient temperature:

Low °F / °C /

High °F / °C

32°F / 0°C

122°F / 50°C

32°F / 0°C

122°F / 50°C

32°F / 0°C

122°F / 50°C

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

Minimum water temp. °F / °C 34 / 1 34 / 1 34 / 1

Maximum water temp. (electronic hi-

limit) °F / °C

190 / 88 190 / 88 190 / 88

Max. ΔT - supply/return (electronic

fence) °F / °C

40 / 22.2 40 / 22.2 40 / 22.2

Max. water temperature lockout limit °F

/ °C

201 / 94 201 / 94 201 / 94

Power use (120Vac/60Hz) @ full fire -

Watts (without pumps)

90 79 90

Weight (empty) - lbs/Kg 67 / 30.4 78 / 35.4 88 / 39.9

Pressure vessel water content -

USG/Liters

1.88 / 7.12 2.79 / 10.56 3.51 / 13.29

Maximum boiler flow rate - USgpm 14 19 25

Minimum boiler flow rate - USgpm 2 3 4

Maximum operating water pressure* -

psig

50 50 50

Minimum water pressure - psig 8 8 8

Relief valve pressure (supplied) - psig 30 30 30

Specification VX 110 VX 150 VX 199

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

Maximum equivalent vent length each

side (vent & air intake) (natural gas or

propane) Air intake options: either direct

vent or indoor supply

100'

240'

50'

170'

N/A

100'

Cabinet dimensions

VX 110 dimensions

Figure 1 Frontal view - VX 110 Figure 2 Side view - VX 110

Section: Specifications

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