IBC V-10 User manual

V-10 TOUCHSCREEN
CONTROLLER MANUAL
VX SERIES

Handling the touchscreen
The touchscreen responds to a light finger touch on the screen. Use only a stylus or a clean
finger to interact with the touchscreen. Using sharp or metallic objects will cause damage.
If the touchscreen is:
Left unattended, the screens will step back one screen at a time in 10-minute intervals.
The pop-up windows will also step back automatically in 2-minute intervals.
Not activated for a user-defined period (10 minutes by default), the Home screen dims
to save power.
Controller's USB port
Be aware that the USB port is not designed to power user devices that require and draw high
amperage. Rather, it is designed for software updates and for downloading log error text files.
Powering such devices via the USB port may result in a blank controller screen, and thus
require a system reboot.
Power saving
The Backlight setting is a power saving feature. Use the slide bar to set the screen backlight
level (brightness). Also, you can program the screen to dim after a specified time of touchless
interaction.

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Contents
1.0 Overview of the controller 5
1.1 Controller's menu screens 6
1.2 Who is the manual for? 7
1.3 Power-up sequence and operational states/cycles 7
1.4 Getting to know the controller’s interface 8
1.4.1 Home 8
1.4.2 Setup 8
1.4.3 Status 9
1.4.4 More 13
2.0 Operating concepts 17
2.1 Domestic hot water (DHW) 17
2.1.1 DHW opt out in a multiple boiler network 17
2.2 Reset heating 18
2.2.1 Standard reset heating (default) 19
2.2.2 Advanced reset heating 21
2.3 Set Point 22
2.4 External Control 23
2.5 Zone Of 24
2.6 Setting load priority 24
2.7 Combining loads 26
2.7.1 Basic mode load combining (default) - recommended 26
2.7.2 Full mode load combining 27
2.8 Setting the supply differential in heating modes 29
2.9 Operational settings in the Setup menu: temperature ranges and defaults 30
2.10 Operational settings in the Advanced Setup menu: temperature ranges and defaults 32
3.0 Wiring 39
3.1 Boiler pump 39
3.2 Thermostats 40
3.3 Load pumps or valves 41
3.4 Sensors 41
3.5 Alarm contacts 42
3.6 External control 42
3.7 Multiple boilers: wiring and networking 43
3.7.1 Methods for networking a group of boilers 43

3.7.2 Internet connectivity 44
3.7.3 Ethernet switch device (recommended) 44
3.7.4 BoilerNet two-wire CAN bus daisy chain cabling 44
3.8 Wiring checklist 47
4.0 Settings loads 49
4.1 Configuring loads using Setup (recommended) 49
4.1.1 Configuring a load on a boiler 50
4.1.2 Syncing zones with "Zone Of" 51
4.1.3 Changing an assigned control mode on a load type 51
4.1.4 Removing an assigned control mode from a load 52
4.1.5 Changing settings in a load 52
4.2 Setting loads using Advanced Setup 52
4.3 Setting up an external control load 53
4.4 Setting up external control to control water temperature in a single boiler or in each
boiler wired on a network 54
4.5 Combining two loads to service two loads at the same time 55
4.5.1 Combining loads using "basic mode" 55
4.5.2 Combining loads using "full mode" 56
5.0 Configuring multiple boiler systems 57
5.1 Checklist for configuring multiple boilers 57
5.2 Configuring a master boiler 57
5.3 Configuring a subordinate boiler 58
5.4 Confirming network programming was successful 59
5.5 Confirming number of boilers available and firing on the network 59
5.6 Assigning fixed IP addresses to boilers on a network using a switch not connected
to the internet 59
5.7 Using the master to control a group of IBC boilers with 5-button-type controllers
via a BACnet gateway 60
5.8 Setting up an IBC air handler to send data to an IBC boiler to control its reset
heating curve 60
6.0 Start-up 61
6.1 Start-up checklist 61
6.2 Testing the ignition safety shutoff 62
6.3 Testing the Hi-limit temperature function 62
6.4 Testing the low water cutoff (LWCO) function 62
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Section: Contents

7.0 Optional - Setup for Internet access 65
7.1 Connecting a boiler’s controller to an IP network 65
8.0 Updating boiler controller software 67
8.1 Updating software in a boiler that has no internet access 67
8.2 Updating software in a boiler that has internet access 68
9.0 Other operating procedures 69
9.1 Testing the fan operation 69
9.2 Testing the firing rate 70
9.2.1 Testing the high fire 70
9.2.2 Testing the low fire 70
9.3 Calibrating the fan 71
9.4 Performing a manual pump purge 71
9.5 Limiting the minimum and maximum firing rate of the boiler 71
9.6 Adjusting the space heating temperature 72
9.7 Adjusting the domestic hot water temperature 72
9.8 Checking the water flow in the boiler 72
9.9 Setting overrides 72
9.10 Backing up and restoring a boiler's configuration and settings 74
9.10.1 Backing up a boiler's configuration and settings 74
9.10.2 Loading boiler configuration and settings from a device onto another boiler 74
9.11 Restricting access to areas in a controller 75
9.12 Switching a boiler to unoccupied "away" mode 75
9.13 Resetting configured settings to factory defaults 75
9.14 Changing and updating date and time 76
9.14.1 Setting up date and time to update automatically in a boiler connected to the
Internet 76
9.14.2 Changing the default date and time in a boiler not connected to the Internet 76
9.15 Changing default error lockout time periods 77
9.16 Changing default units of measurement displayed on the controller's screens 77
9.17 Setting the venting material 77
9.18 Programming a replacement touchscreen controller 78
10.0 Troubleshooting 79
10.1 Viewing errors 79
10.2 Clearing errors 79
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10.3 List of touchscreen controller error messages 79
10.4 Backing up (exporting) error logs 85
10.5 Deleting or clearing an error log 85
10.6 Resetting a boiler after a SIM module ignition lockout 85
10.7 Resetting a boiler after a LWCO lockout 85
10.8 Resetting a boiler after a hi-limit temperature lockout 86
11.0 Definition of terms 87
Appendices 93
Controller Board Layout 93
Internal wiring diagram VX series boilers 94
Wiring diagram - Opt Out DHW 95
Sequence of Operation - VX series boilers 96
Index 97
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Section: Contents

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1.0 Overview of the controller
The controller provides overall management of boiler operations such as self-diagnostics, easy load
parameter adjustments, burner operation, safety management systems, call for heat management and
load priority.
Figure 1 Touchscreen controller's features
* Not applicable to the VX series
** Networking of up to 4 boilers in the VX series

1.1 Controller's menu screens
The diagram below shows the controller's four menu options and associated submenus:
Figure 2 Map of the controller's menus and submenus
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Section: Introduction and overview of the features in the V10 controller

1.2 Who is the manual for?
While this manual is primarily written for heating professionals, some of the content may be useful for
building managers and homeowners; for example, information about setting overrides.
1.3 Power-up sequence and operational states/cycles
When a boiler is first energized, the controller runs through a power-up sequence that takes
approximately 90 seconds. During this time, the controller completes a self-diagnostic, then loads all
previous settings. When power is restored after a power interruption, the boiler automatically resumes
operation with all the previously stored values.
The controller has five states during normal operation as well as an error state for problem detection:
Figure 3 Stages of controller operation
For a detailed work flow and sequence of operation, see Sequence of Operation - VX series boilers on
page 96.
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1.2 Who is the manual for?

1.4 Getting to know the controller’s interface
The controller's main screen displays four menus: Home, Setup, Status, and More.
1.4.1 Home
The Home screen displays basic boiler status information such as a title bar
with boiler model number and boiler ID as well as its current operating state.
Other information shown includes the load currently being serviced (if any) and
a list of current operating values. The colored background on the status bar
represents different boiler states (see Status Bar Color on page 12).
If one or more errors occur in the boiler, an "Error Logs" button will display on
the Home screen. You can select the Error Logs button to view the current
error log. You can also view other logs to help detect recurring errors. Once you
have corrected the error(s), you need to clear the error(s) ( > Clear Errors).
This enables you to check for any unresolved errors still present in the system.
1.4.2 Setup
Tip
Our Setup feature is not only a quick way to configure a boiler, but is designed to cover
95% of operational requirements.
Setup walks you through a basic setup of the controller. You can configure a boiler’s parameters
using default values, including all the appropriate values to operate each load type under most
operating conditions. If you wish, you can change these default settings later. For instructions on
using Setup, see Configuring loads using Setup (recommended) on page 49.
In Setup, you can configure up to four loads with the following control modes:
DHW (domestic hot water)
Reset Heating
Set Point
Ext. Control
Zone of
When you select a control mode, the controller automatically loads the appropriate factory default
settings. For more information on control modes, see Operating concepts on page 17.
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Section: Introduction and overview of the features in the V10 controller

1.4.3 Status
The Status menu displays the following options that enable installers to identify problems:
Boiler Status
Boiler Information
Load Status
SIM Menu
Error Logs
Sensor and Channels
Clear errors
Network Information
1.4.3.1 Boiler Status
The Boiler Status screen lists key operational parameters and their current readings.
1.4.3.2 Boiler Information
Boiler Information lists basic information such as the controller software version and the boiler
model. You can also test fan operation here. For instructions, see Testing the fan operation on
page 69.
1.4.3.3 Load Status
Load Status displays a menu screen with six possible selections to display the current status
details for the four individual loads, operating load statistics, and operational load profiles (graphs)
for each load.
You can view:
Operational information on each load (loads 1-4).
A status screen that lists the run time statistics for the boiler including specifics for each
load.
A load profile screen that displays each load, showing a bar graph profile of the time the
boiler is firing at various throttle levels.
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1.4.3 Status

1.4.3.4 Safety and Ignition Module (SIM) Menu
The SIM reports sensor readings and information on the status bar. In the controller's SIM
menu, you can:
View Status - Provides an overview of the burner, gas valve, ignitor and venting.
Perform a Hi-Limit Test - Test the maximum supply cutoff temperature on the boiler. If
the SIM detects a high limit temperature, the boiler enters a lockout state. For
instructions, see Testing the Hi-limit temperature function on page 62.
Perform a Module Reset - Lockouts are typically 5 minutes, depending on the ignition
error. Use the Module Reset function to clear a lockout quickly. For instructions, see
Resetting a boiler after a SIM module ignition lockout on page 85.
Perform a LWCO Test - Test the low water cutoff to protect against low water in a boiler.
If the SIM detects low water, the boiler enters a lockout state. For instructions, see
Testing the low water cutoff (LWCO) function on page 62.
Figure 4 Comparing SIM modules
Note
The SIM+ module is installed in SL 85, 115, 160 and 199 G3 boilers as well as in the
VX boilers while the SIM module is installed in the SL 260 G3, SL 399 G3, and EX
series of boilers.
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Section: Introduction and overview of the features in the V10 controller

About Status indicators
The SIM’s two status LEDs indicate the operating status as shown in the table below.
LED 1 LED 2 State Description, LED status indication
Rapid Flash Rapid Flash Power up or
Resetting
Startup checks and initialization
Off Off Standby LED 1 Off = No Flame or Sparking
LED 2 = Burner-On Call state
Off On Pre-Purge
or Inter-
Purge
LED 1 Off = No Flame or Sparking
LED 2 = Burner-On Call state
On On Heating LED 1 On = Flame detected
LED 2 = Burner-On Call state
Rapid Flash On Igniting LED 1 flashing = Electrode Sparking
LED 2 = Burner-On Call state
Off Flashing Lockout An operating limit was exceeded or a sequence
failed or an external sensor fault was detected.
Flash
Alternately
with LED 2
Flash
Alternately
with LED 1
Fail-Safe A critical internal fault was detected. Fail Safe
requires a power cycle.
Table 1 LED status indicators
1.4.3.5 Error logs
The controller records all errors present at the time of an error event in a log.
These logs date back to the original power-up, organized by date, time,
classification, and type. For every error record, there is a "Details" button that
provides:
Minor errors. An abnormal condition exists that does not present an
immediate safety hazard.
Major errors. A condition exists that may be a safety hazard. The boiler
enters an extended purge then the fan and pump are stopped. The boiler
must be checked and restarted. Exception: The Ign. Trials Exceeded
error will time-out for one hour before the system attempts re-ignition.
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1.4.3 Status

System faults. Faults typically related to the touchscreen controller.
SIM Status. Operating SIM status errors. See About Status indicators on page 11.
On the Error Logs screen, you can:
View one or more errors. See Viewing errors on page 79.
Clear errors. See Clearing errors on page 79.
Save an error log to an SD card or USB stick. See Backing up (exporting) error logs on
page 85.
Delete or clear all entries in an error log. See Deleting or clearing an error log on page 85.
1.4.3.6 Sensors and Channels
This screen provides information screens on:
Sensors - The Sensors status screen displays the current active value for each of the
temperature and pressure (e.g., water flow rate, VS load duty cycle and the altitude)
sensors. If a:
Temperature sensor is not connected to the controller the text ‘n/c’ is displayed.
Pressure sensor is not connected to the controller, ‘0’ is displayed.
ATD Channels - (Analog to-Digital conversion) Lists the raw, unfiltered input values from
the analog inputs.
1.4.3.7 Clear Errors
Errors are triggered when a sensor detects that the boiler is operating outside its limits. If more
than one error/alarm is present, the status bar slowly rotates though the various alarm states.
Status Bar
Color Description
Green Normal state - boiler is operating within its limits.
Yellow Warning error - When the controller detects an error.
Red Alarm - Unresolved condition or error detected while the boiler is firing or
preparing to fire that results in the boiler shutting down and entering a lock-out
state. To change these error lockout periods, see Changing default error
lockout time periods on page 77.
For minor errors, the boiler will lock out for 5 minutes, and then attempt
to restart automatically.
For major errors, the boiler will lock out for 60 minutes after 3
unsuccessful ignition attempts, and then attempt to restart.
Table 2 Status bar background colors
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Section: Introduction and overview of the features in the V10 controller

Note that "System" errors do not typically result in a boiler lock-out state. If the controller detects a
single "system" error, it will typically continue operation, recording the event in the controller's error
log. For more serious "system" errors, or if many system errors occur within a short period of time
(about 10 seconds), the controller will treat the event as a major error, or will restart to try to clear
the problem.
Tip
Once the errors have been rectified, we recommend clearing errors using the "Clear
Errors" button on the Home screen because it is faster than a power cycle.
1.4.3.8 Network Information
The Network Information screen displays setup information related to:
Internet connectivity such a boiler's IP address and MAC address. For instructions on
connecting a boiler to the internet, see Optional - Setup for Internet access on page 65.
Internet data networks (BACnet) (not applicable for the VX series of boilers).
Multiboiler networking (Boiler ID, Master boiler, network ID, available boilers online in a
network, and network boilers that are firing).
1.4.4 More
When you select the More menu, you will be provided with options that enable you to configure the
boiler.
User Settings
Advanced Setup
Test Operation
System Settings
Network Settings
Installer Options
Engineer Options
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1.4.4 More

1.4.4.1 User Settings
This screen enables the user (installer, homeowner, site manager) to set or adjust:
Date & Time - Choose NTP Server or Internal. The controller must be
connected to the Internet for the NTP Server selection to work
properly. For instructions, see Changing and updating date and time
on page 76.
Overrides - Typically, temperature overrides for a load are used to
reduce temperatures during night-or-away hours to achieve fuel
savings. Conversely, you can use overrides to increase temperatures
for defined time periods in a day. This may be useful for certain
commercial applications where short-term high temperature DHW
service is desired. If using temperature overrides:
For Reset Heating loads, the Indoor Setpoint temperature setting is overridden for
the programmed time periods.
In setpoint loads, the Boiler Supply temperature setting is overridden.
In DHW loads, the DHW Tank Setpoint is overridden. The DHW Boiler Supply
temperature is also overridden to keep the difference between the Boiler Supply
and the DHW Tank Setpoint temperature the same when the override is in effect.
Note
The automated override feature will not work for DHW with simple
aquastat control where the DHW Tank Setpoint temperature has no
effect.
For instructions, see Setting overrides on page 72.
Backlight - Set the level of screen brightness to suit the lighting in the space. And to
save power, you can set the DIM time that controls how long the screen remains lit after
touch screen interaction.
Units - Configure which units of measurement (metric or imperial) are displayed in the
controller's screens (see Changing default units of measurement displayed on the
controller's screens on page 77).
Clean the Screen - Enables the touchscreen to be de-activated (will not respond to
touch) for 60 seconds while the screen is being cleaned. Care must be taken not to
scratch the screen while cleaning. Spray cleaning solution on a damp soft cloth, not
directly onto the screen.
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Section: Introduction and overview of the features in the V10 controller

1.4.4.2 Advanced Setup
Advanced Setup provides access to the full functionality of the system for the
advanced installer. Installers can access and configure the following:
Loads 1-4: Assign load types to up to four Loads. For instructions on
assigning one or more loads, see Settings loads on page 49.
Multiboiler: Set up a boiler to operate as part of a group of boilers (multi-
boilers) at a site. For instructions on how to set up multiple boilers, see
Configuring multiple boiler systems on page 57.
Load Combining: Set up two loads of compatible temperature to run
simultaneously. For information on this feature, see Combining loads on
page 26. For instructions on setting up two loads, see Combining two
loads to service two loads at the same time on page 55.
1.4.4.3 Test Operation
In the "Test Operation" screen, you can test the fan operation and check the venting for any
blockage or leakage. The "Fan Test Heat Out" entry box allows the fan to be activated
independently and set to speeds corresponding to the entered Heat Out value. You can use the
"Fan Test Heat Out" feature when a boiler is not heating. If the boiler is heating, you can check that
the heat output values correspond. For example, for all models (excluding the G3 models), the fan
heat output MBtu should be close to the heat output. For instructions, see Testing the fan operation
on page 69.
1.4.4.4 System Settings
The System Settings screen provides the following options:
Site Settings. Use to access generic boiler operating parameters that
are not specific to a load. Parameters include load control types (pumps
or control valves), boiler pump purge time, manual pump purge, and the
variable speed (VS) output control settings. For instructions, see
Performing a manual pump purge on page 71.
Licensing. Use to activate special add-on software packages such as
BACnet.
Backup and Restore. Use to back up or restore the boiler’s complete
controller configuration and settings to/from a USB memory stick or SD-
card inserted into the controller. For instructions, see Backing up and
restoring a boiler's configuration and settings on page 74.
Software Update. Use to update the controller’s software via an SD memory card, a USB
memory stick or via the Internet. For instructions, see Updating boiler controller software on
page 67.
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1.4.4 More

Restart Boiler. Use to initiate a full boiler controller restart that takes approximately two
minutes to complete. If you have replaced a fan or performed a software update, you can
calibrate the fan via this option. For instructions, see Calibrating the fan on page 71.
Reset Factory Defaults. Use to restore all operating parameters to factory default
settings. Settings that will not be reset include network, Date and Time, error logs and
operating history (see Resetting configured settings to factory defaults on page 75).
1.4.4.5 Network Settings
This screen is used for:
Assigning boiler IDs and other network setup to support multiboiler operation. Note that
you can also assign boiler IDs for master and subordinate boilers in the Advanced Setup
> Multiboiler screen (see Configuring multiple boiler systems on page 57).
Registering for access to the IBC V10 Internet Portal (see Optional - Setup for Internet
access on page 65).
Setting up a master boiler to control 5-button controllers via BACnet (see Using the
master to control a group of IBC boilers with 5-button-type controllers via a BACnet
gateway on page 60).
Enabling communication between a boiler and an air handler. Enables an air handler to
transmit the indoor and outdoor temperatures to an IBC boiler for controlling its reset
heating curve. See Setting up an IBC air handler to send data to an IBC boiler to control
its reset heating curve on page 60.
1.4.4.6 Installer Options
For the advanced installer, "Installer Options" (password protected) provides options to:
Perform troubleshooting adjustments in the field such as adjusting the
firing rate (see Limiting the minimum and maximum firing rate of the
boiler on page 71).
Calibrate the touchscreen. Over time the touch pad calibration can
drift slightly resulting in the touch locations being out of line with the
displayed touch points such as buttons or entry boxes. Touchpad
calibration resolves these alignment issues.
Enable user lock. Restricts access to areas in the controller with
password protection. See Restricting access to areas in a controller
on page 75.
1.4.4.7 Engineer Options
This option is password protected, reserved for IBC’s technical support staff for troubleshooting
boilers connected to the IBC V-10 portal.
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Section: Introduction and overview of the features in the V10 controller

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2.0 Operating concepts
This section contains important information about the control strategies used in the controller to deliver
space heating, domestic hot water (DHW), pool heating, garage heating, and snow-melting. Depending
on heating requirements, strategies will include the use of these control modes: DHW, Reset Heating,
Setpoint, Ext. Control, and Zone Of.
Other topics covered relate to multi-load systems that can have varying temperature loads: low
temperature loads and loads with high thermal mass. Topics include the controller's load priority, load
combining, and supply differentials - rules, logic, and settings used to provide added levels of protection.
All load settings come with factory defaults. You can change these defaults to suit the application and
heating requirements.
2.1 Domestic hot water (DHW)
In a single boiler, the system gives priority to servicing a call for DHW before switching to other loads
to service calls for heat (see Setting load priority on page 24). In two-sided piping, DHW mode operates
by simultaneously turning off the boiler pump and turning on the DHW boiler pump, diverting fluid flow
and heat production directly to the tank; the same applies to one-sided piping if all loads are 'off' on the
boiler loop, and "Boiler pump" is set to "On" in the DHW load.
Default settings for the DHW load are suitable for residential applications. It may be necessary to
change these settings to satisfy commercial requirements.
For information on wiring DHW, see Sensors on page 41.
2.1.1 DHW opt out in a multiple boiler network
Note
If a DDC system or other external control is used to operate individual boilers, the DHW opt-
out feature is unavailable.
When set as a dedicated DHW load, an indirect storage water heater can call up a boiler to "opt out" to
service DHW. In a multi-boiler network, one or more dedicated DHW boilers can be programmed to
"opt out" of the heating load, enabling the remaining boilers to continue heating uninterrupted. Multiple
DHW opt-out boilers can respond to a high demand in DHW in buildings with multiple bathrooms, for
example. If opt-out boilers are in the process of making DHW when the master boiler receives a
setpoint or heating call, other subordinate boilers on the network will switch to servicing that load.
DHW "opt-out" boilers cannot be configured as the master boiler without DHW operation disrupting the
boiler network. Opt-out loads are programmed on the opt-out subordinate boilers only. When an opt-out
load is active, the boiler is not available to the network, and will switch on the opt-out pump directly.

2.2 Reset heating
In a typical hot water heating system, a thermostat in a building signals a call for heat, causing the
boiler to circulate hot water to that space until the thermostat setting is reached. This can be
inefficient, requiring several burn on/off cycles, which may overshoot or undershoot the
requirement, due to heat loss and outdoor temperature variation. That is, the amount of heat lost in
a building changes according to the outdoor temperature. And the greater the difference between
the temperature inside and the temperature outside, the greater the heat loss.
Figure 5 Heat loss vs outdoor temperature
The controller's Reset Heating or outdoor reset mode is a way of balancing the heat lost in a
building with the heat supplied to the building. The Reset Heating mode uses a temperature
management algorithm to automatically adjust or "reset" the supply/outlet water temperature to
compensate for the differing rates of heat loss that a building experiences as the outdoor
temperature changes.
Note
Reset Heating mode requires the installation of an outdoor temperature sensor (supplied
with boiler).
The controller's default Set Point mode sets the boiler temperature to accommodate the estimated
coldest day of the year. However, the controller's Reset Heating mode will promote energy savings
by adjusting the higher setting down based on the outdoor temperature at any particular time of day.
When applied to IBC's condensing boilers, the Reset Heating mode enables efficiency benefits by
lowering the required circulating water temperature, so that cooler water returns to the boiler
(promoting more condensation). Its temperature control uses lower water heating temperatures for
outdoor temperatures above the coldest day expected.
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Section: Operating concepts