IBC VX Series Installation instructions

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

3
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
4
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
1

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
2
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
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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) -
kW
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'
2"
3"
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
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Section: Specifications

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
7
VX 150 dimensions

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
8
Section: 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
A Flue Outlet 3" Schedule 40 or 3" PPs (80 mm)
B Combustion Air Inlet 3" Schedule 40 or 3" PPs (80 mm)
C Return water outlet (tepid
water)
1" NPT-M
D Supply Water Inlet (hot
water)
1" NPT-M
E Condensate Outlet ¾" Hose
F Gas Inlet ½" NPT-F
Table 1 Connections
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Connection specifications

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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

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
terms:
0-10 years (100% coverage)
11-15 years (25% coverage).
IBC offers a limited heat exchanger warranty with no registration of 0-5 years (100% coverage).
For commercial applications, IBC offers a 5-year warranty on the heat exchanger and a 2-year
warranty on all parts against defects in materials or workmanship and failures due to thermal shock.
To view the full warranty statement for the VX series, go to ibcboiler.com.
12
Section: Introduction

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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.
□
Ensure you install the appliance 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. Cleaners, bleaches, air fresheners, refrigerants, aerosol
propellants, dry-cleaning fluids, de-greasers and paint-removers all contain vapors that can
form corrosive acid compounds when burned in a gas flame. Airborne chlorides such as
those released with the use of laundry detergents are also to be avoided.
□
Locate the appliance where water leakage will not result in damage to the area.
If there is no suitable location, install a suitable drain pan under the boiler. Do not install
above carpeting.
□
At a new construction site, or during renovations, protect the appliance from drywall dust or
other construction related contaminants.
Draw combustion air from a clean source (e.g., outdoors) and isolate the boiler from interior
dust sources. Do not seal boiler case openings directly when firing - allow for air circulation
and ventilation in the immediate area.
□
Place the exhaust outlet 12" minimum above the down-turned intake to avoid exhaust re-
ingestion.
□
For sidewall venting options, place the inlet and exhaust terminations on the same side of
the building.
The elevation of both pipes can be raised in “periscope style” after passing through the wall
to gain required clearance above grade and snow level.
□
If using the indoor combustion air option, ensure combustion air openings to the boiler room
remain unblocked and free of obstructions.
□
Examine the condensate outlet to ensure proper disposal of condensate will occur during
operation. If condensates are to be discharged into building drain piping materials that are
subject to corrosion, a neutralization package must be used.
□

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.
□
If the appliance is likely to be exposed to fluid temperatures below 34° F (1° C), a method of
protection to prevent freezing of condensate should be employed. Contact the factory for
further information.
□
When the appliance is in operation, assess the impact of the steam plume normally at the
exhaust terminal of a condensing boiler.
Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location.
Boiler condensate is corrosive. Protective measures must be taken to prevent corrosion
damage to metal roofs or other metal building components in contact with the condensate.
Keep exhaust plumes well away from all building air intakes including those of neighboring
properties.
□
Caution
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 boiler can lead to
increased maintenance costs, equipment stress and premature failure.
14
Section: Before installation

15
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.
Canada US
Conform to local codes, or in the absence of
these, with the latest editions of CAN/CGA
B149.1 and the Canadian Electrical Code Part 1
CSA C22.2 No. 1.
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, follow the more stringent
regulations.
Conform to the current National Fuel Gas Code
ANSI Z223.1 and the National Electrical Code
ANSI/NFPA 70.
Where required by jurisdiction, installation must
conform to the Standard for Controls and Safety
Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
If there is any conflict, follow the more stringent
regulations.
Table 2 Code requirements by country
3.2 Removing an existing boiler
When an existing boiler is removed from a common venting system, the common venting system
may be too large for proper venting of the appliances that remain connected to it. When resizing any
portion of the common venting system, use the minimum size according to the appropriate tables in
the National Fuel Gas Code, ANSI Z223.1 - latest edition. In Canada, follow the B149.1 Installation
Code.
When removing an existing boiler, the following checks must be carried out for each of the appliances
still connected to the common exhaust system, by operating them one at a time:
Seal any unused opening in the common venting system.
Visually inspect the venting system for proper size and horizontal pitch. Determine that there
is no blockage or restriction, leakage, corrosion and other deficiencies that could cause an
unsafe condition.
(Where practical) Close all building doors and windows such as doors adjacent to appliances
remaining connected to the common venting system and other spaces of the building.

Turn on clothes dryers and any appliance not connected to the common venting
system.
Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a summer exhaust fan.
Close fireplace dampers.
Place in operation the appliance being inspected.
Follow the lighting instructions.
Adjust the thermostat so that the appliance operates continuously.
After determining 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 condition.
Any improper operation of the common venting system should be corrected, so the
installation conforms with the National Fuel Gas Code, ANSI Z223.1 - latest edition. In
Canada, all installations must conform with the current CAN/CGA - B149.1-10 Installation
Code and/or local codes.
3.3 Determining location of the appliance
The boilers are designed and approved for indoor installation (wall or rack mounting) in areas such
as an alcove, basement, or utility room. These areas should have a surrounding temperature of 32
°F (0°C) to 122 °F (50 °C) and less than 90% relative humidity.
Danger
Do not common vent appliances with other existing appliances or with a new appliance.
Warnings
Keep the area around a boiler clear of combustible materials, gasoline, and other
flammable vapors and liquids.
Ensure combustion air is not drawn from areas containing corrosive air such as
swimming pools or spas, including air directly next to outdoor pools and spas.
Ensure that a boiler is not exposed to water leaks from piping or components
located overhead, including condensation from uninsulated cold water lines
overhead.
Protect the gas ignition system components from water (dripping, spraying, rain,
etc.) during appliance operation and when servicing (pump replacement,
condensate trap servicing, control replacement, etc.).
Ensure that combustible materials do not make contact with exposed water
piping and associated components (relief valves, circulators, etc.). Check local
codes for required clearances and/or provide adequate insulation.
16
Section: Installation