IBC V-10 Manual 

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.

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

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 2 Section: Contents

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 3

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 4 Section: Contents

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

The diagram below shows the controller's four menu options and associated submenus: Figure 2 Map of the controller's menus and submenus 6 Section: Introduction and overview of the features in the V10 controller

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. 7 1.2 Who is the manual for?

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. 8 Section: Introduction and overview of the features in the V10 controller

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. 9 1.4.3 Status

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. 10 Section: Introduction and overview of the features in the V10 controller

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. 11 1.4.3 Status

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 12 Section: Introduction and overview of the features in the V10 controller

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 13 1.4.4 More

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. 14 Section: Introduction and overview of the features in the V10 controller

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. 15 1.4.4 More

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. 16 Section: Introduction and overview of the features in the V10 controller

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.

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. 18 Section: Operating concepts

Set Point heating, which relies on the temperature of the return water to fire or shut down. Figure 6 Potential heat loss from house Ensure that the outdoor sensor is appropriately located, typically on the north face of the building away from any heat source. If there is no signal from the outdoor sensor, the controller assigns a default 32 °F/0 °C value for the outdoor design temperature, and adopts the appropriate temperature target from the relevant reset curve. IBC's controller offers two reset heating methods for controlling the supply/outlet water temperature: 1. "Standard" reset heating (default) that uses a two-point reset heating ratio. 2. Advanced reset heating that uses a characteristic reset curve ratio. 2.2.1 Standard reset heating (default) Standard reset uses two points in the reset heating ratio to determine the outlet water temperature. The illustration below shows the relationship of the two points: The supply/outlet water temperature will rise linearly with a decrease in the outdoor temperature until the coldest expected temperature is reached, called the "Design Outdoor" temperature setting. The supply/outlet water temperature changes based on the straight line between the two points. 19 2.2.1 Standard reset heating (default)

To determine these two points, and for the system to accurately control the supply/outlet water supply, set the: Design Supply ° – defines the desired boiler outlet water temperature to occur on the coldest day for the building location. Corresponds to the Design Outdoor air temperature appropriate for the geographic location. Consult the ACCA manual J to calculate the Design Outdoor air temperature to perform heat loss calculations and to determine the heating loads of the home or building. High Limit° - defines the highest (maximum) water temperature allowed to prevent overheating, or damage to piping or flooring. Minimum Supply° - defines the minimum starting supply/outlet water temperature. Summer Shutdown°- defines the cut-off level for outdoor temperature that prevents further heating. The boiler ignores a call for heat. We recommend using "Setup" to program standard reset heating. For a list of standard reset heating settings, see Operational settings in the Setup menu: temperature ranges and defaults on page 30. Note Thermostats and zone valves - Typical room thermostats simply provide a call for heat. They do not control the circulating water temperature from the boiler. Adjustment of a room thermostat from 72 °F/22 °C to 86 °F/30 °C will make no difference to the delivered temperature if the floor slab has stabilized at the boiler temperature determined by the reset curve. 20 Section: Operating concepts

Advanced Reset heating offers greater control of air temperature in a building, and can be more accurate than standard reset heating. More parameter settings are available that allow the reset heating curve to extend down to much lower target supply water temperatures. This is useful for radiant heat emitters such as floors. Configure Advanced Reset via Advanced Setup >set up a load as Reset Heating> Choose an emitter > OK>Scroll down to Advanced Reset > tap Off > then On > Save. A list of all available settings for Advanced Reset appear. For a list of advanced setup settings, see Operational settings in the Advanced Setup menu: temperature ranges and defaults on page 32. Below is an illustration of how different emitters determine the characterized heating "curve" by delivering heat to an area at a different rate or amount as the outdoor temperature changes. Figure 8 Characterized heating curve in advanced reset heating Fin-tube baseboard IBC Air handler Cast iron radiator Low mass radiant floor High mass radiant floor 21 2.2.2 Advanced reset heating

heating, specify the following: Type of emitter - Once the emittter is selected the controller loads the factory defaults. Design Supply ° – the desired boiler outlet temperature to occur on the coldest day. Use this temperature when performing heat loss calculations. Design Outdoor ° – the coldest expected outdoor air temperature typically experienced at the installation site. Use this temperature when performing heat loss calculations. Design Indoor ° - the desired and comfortable temperature to be maintained in the space or building. Use this setting when performing heat loss calculations. The Indoor Setpoint °- the lowest supply target temperature corresponding to the Design Indoor temperature. Indoor Setpoint° can be set to the same temperature as the Design Indoor°. Adjust the setting up or down to increase or reduce heating and to "fine tune" for the most comfortable indoor temperature. Tip To increase heat, use the Indoor Setpoint° setting to adjust the water outlet temperature, not the Design Indoor temperature setting. Summer Shutdown - cut-off temperature level for further heating. We strongly recommend using this feature with a value 5 °F-10 °F/3 °C-6 °C below the Indoor Setpoint ° to avoid short cycling of the boiler during very low heating conditions. The controller must receive a valid signal from the outdoor sensor, supplied with the boiler, for Summer Shutdown to operate correctly. When defining the above settings, factor in space or building heat loss. See also Setting the supply differential in heating modes on page 29. 2.3 Set Point Set point refers to the temperature set in the controller, not to the temperature read from a room thermostat. Since the set point is measured at the temperature of water flowing (outlet) from the supply temperature to the boiler, and not from the air surrounding a wall thermostat, the boiler may shut down, thinking it has satisfied the set point while the required wall thermostat temperature may not have been met. 22 Section: Operating concepts

water temperature to maintain a steady and comfortable indoor temperature. Indoor temperature is compared with the preset operating range (set point target), and if the temperature deviates (as sensed by the room thermostat), the controller will bring the temperature back to the set point limits. For example, if the room temperature is 65°F and the set point target range is 70°F-80°F, then the controller will work to raise the room temperature back to within that set point range. Since set point regulates the target temperature based on the room thermostat, an outdoor sensor is not required. Figure 9 Controller compares set point target with indoor temperature To program the set point target range, set the: Boiler Supply° – desired or fixed supply/outlet water temperature. Maximum Supply° – the highest water temperature allowed to prevent overheating of the outlet water temperature. Check that this temperature takes into account the construction and safety requirements of each application (e.g., 140 °F/ 60°C maximum for in-slab radiant floor to avoid thermal stress). Supply Diff'l (differential) - Set the differential to prevent short cycling. The boiler will shut off when the boiler supply water temperature minus half its differential falls below the boiler Current Target°. The boiler will fire when the boiler supply water temperature plus its differential rises above the boiler Current Target°. See Setting the supply differential in heating modes on page 29. Summer shutdown° - The cut-off temperature level that prevents further heating. Boiler ignores a call for heat. 2.4 External Control You can place the control of a load under an external electronic controller (such as a building management or automation system). In external control mode, temperature management is controlled by the building management system (BMS), consisting of one or more control panels wired to various sensors and valves in a building. The BMS will determine the desired boiler set point for any given building occupancy parameters. 23 2.4 External Control

Set the boiler's maximum boiler supply and on/off differential temperatures. The boiler treats these as high limit switches. Burner On From - Use a thermostat or external control to control the supply of heat. For guidance on wiring, see External control on page 42. For setup instructions, see Setting up an external control load on page 53. 2.5 Zone Of Boiler zone control enables you to set different spaces in a building with particular temperatures. If you want different rooms or zones in a building to have the same temperature use the "Zone Of" mode. This mode syncs the temperature, so that the temperature load settings in one area match the "zone of" another area. These temperature load settings include matching load priority, target and differential temperatures. If two rooms or zones in a building have different temperatures, use the "load combining" strategy (see Combining loads on page 26). Note "Zone Of" is not available until one or more active loads have been set up in the system. Zoned loads can operate independently or simultaneously. You can use this method of zone control to maximize energy costs. For example, you can zone bedrooms that need lower room temperatures to match another area in the house that is set at a low temperature. For instructions on setting "Zone Of", see Syncing zones with "Zone Of" on page 51. 2.6 Setting load priority Boiler load is the total "work" performed by a boiler. IBC's controller uses a priority algorithm to coordinate or schedule the delivery of heat in multiple load systems. This type of planning strategy temporarily turns off one or more loads based on given conditions in the system. As an example, an intermittent heating load (e.g., space heating) is suspended until a call for a DHW load has been satisfied. Loads declared as DHW receive significant, but not absolute priority. Multiple heating loads of varying temperature targets run in sequence with the use of a mixing valve. Each load is serviced at the minimum possible temperature, as opposed to running hot then mixing down (with hardware). Consider Combining loads on page 26. 24 Section: Operating concepts

"low", "high" or "very high". There's more precision in Advanced Setup, where you can enter numeric values between 20 and 90 for a priority load. Note: The priority value has to be different for each load, but the priority scale values do not need to add up to 100 – they are relative only to each other. A higher numerical value means a higher priority. Consider priority values as minutes. The difference between two load priority values is the number of minutes the higher priority load will operate before switching back to the lower priority load. For example, if DHW has a priority of 86 and the Set Point load has a priority of 62, the DHW load will run for (86-62) 24 minutes before switching to the simultaneously calling Set Point load. Following the initial cycle, the competing loads will switch back and forth after a further 10-minute interval pending satisfaction of one or both loads. Figure 10 Default priority values by load type in Installer Settings Note Ensure that loads are set with a minimum of 15-minute differential between competing loads. Example: If baseboards (set up with Reset Heating as Load 3) are not providing the desired heat, you can bring on baseboard run time sooner by increasing the priority value relative to the other declared loads (e.g., changing the Load 3 preset value from 43 to 50 or reducing another load’s value). Temperature targets for the under-served load can also be raised, in this example. To cause repeated unequal run times; for example, constant 35 vs 5-minute runs, you need to integrate an external load removing relay or timer on one of the heat calls. Do not set each load to the top value, and avoid equal ratings. 25 2.6 Setting load priority

As a control strategy, load combining is used when two rooms or zones in a building have different temperatures. Running two loads at compatible temperature settings at the same time provides added efficiency and heating comfort. This feature allows two compatible loads to run simultaneously; that is, they are "combined" to service their loads at the same time. To set different rooms or zones in a building with the same temperature, see Syncing zones with "Zone Of" on page 51. The main principle for load combining is that the target temperature and the load’s minimum and maximum supply temperatures (+/- differential temperature) in the primary and secondary loads must overlap. With the boiler’s load priority scheme, load combining functions only while the primary load is the active load. Note that any system or load temperature limits will still be in effect. In load combining there are two modes: Basic mode and Full mode. Basic mode should cover most of the load combining applications. Use the full mode when the load is not using a mixing valve. Suppressing the higher temperature rather than overshooting the lower temperature may be required. Note For Reset Heating or External Control loads, the target temperature is dynamic. Therefore, it is possible that as outdoor and/or indoor temperatures change, reset and external control heating loads could switch in and out of compatible temperatures. For instructions on using the Load Combining feature, see Combining two loads to service two loads at the same time on page 55. 2.7.1 Basic mode load combining (default) - recommended Basic (simple) mode allows any two of the four loads to be combined together by setting a primary and secondary load. Parameter Default Minimum Maximum Primary Load Disabled Load 1 Load 4 Secondary Load Disabled Load 1 Load 4 The boiler supplies a target water temperature based on the highest water temperature required between both loads. 26 Section: Operating concepts

types call for heat, the boiler will supply 160 °F. If only the load for radiant floor is calling, the boiler will supply water temperature at 120 °F. 2.7.2 Full mode load combining In Full mode load combining, there are six default parameter settings: Parameter Default Minimum Maximum Primary Load Disabled Load 1 Load 4 Secondary Load Disabled Load 1 Load 4 Initial Delay 5 mins 2 mins 15 mins Off Delay 5 mins 2 mins 15 mins Retry Delay 10 mins 5 mins 60 mins Maximum Throttle % 75 % 50 % 90 % Primary Load - Highest temperature Set as the load that will control the boiler operation while Load Combining is active. This load must have a higher initial priority than the Secondary Load, and should have a higher water temperature requirement. Secondary Load - Lowest temperature Set to the load that will be serviced simultaneously, in combination with the Primary Load, if the conditions for Load Combining are met; that is, if the: - Supply temperature requirements for the Primary Load are being met; - Supply temperature is within the temperature range requirements of the Secondary Load and the boiler has the capacity to service the Secondary Load as determined by the Maximum Throttle % setting. Initial Delay The number of minutes after the Primary Load must initially be serviced before the boiler can add the Secondary load. Allow sufficient time for the Primary Load to stabilize before the boiler adds the Secondary load. Off Delay When the secondary load is added into combination service the supply temperature should fall briefly below the allowed temperature range for the Primary load. The Off Delay is the number of minutes after the loads have been initially combined that the loads will continue to be combined regardless of an under-temperature condition. Allow a long enough delay to allow the boiler to drive the supply temperature up within the Primary load’s 27 2.7.2 Full mode load combining

temperature condition persists after the Off Delay time. If the supply temperature exceeds the requirements for either the Primary or Secondary loads, the loads will no longer be combined. Retry Delay If the boiler removes the Secondary load from combined service because load combining conditions are not followed, the Retry Delay is the number of minutes the boiler waits before attempting to add the Secondary load back into combination service. Maximum Throttle % Maximum (percentage) of the boiler’s heat output below which load combining is allowed to begin. If set at Maximum Throttle 75% for example, the throttle needs to be operating at below 75% of the boiler's heat output before the Secondary load is added into combined service. The Maximum Throttle % has no effect once the loads have been combined. Table 3 Default parameter settings in full mode load combining Example of compatible load combining Primary Load 140 °F to 180 °F Secondary Load 150 °F to 170 °F Initial Delay: 5 mins Off Delay: 5 mins Retry Delay: 10 mins Maximum Throttle %: 75 % The boiler will wait a minimum of 5 minutes (initial delay) after it begins servicing the Primary load before adding the Secondary load. The supply temperature must be between 150 °F and 170 °F (the compatible temperature range for both loads), and the throttle is below 75%, before the secondary load is added. If the supply temperature rises above 170 °F, the load is dropped. If the supply temperature is/or drops below 150 °F after the 5-minute "Off Delay", the secondary load is also dropped. If the secondary load is dropped, the boiler waits a minimum of 10 minutes (Retry Delay) before attempting to add the Secondary load again. At this time, the supply temperature must be between 150 °F and 170 °F. 28 Section: Operating concepts

Primary Load 140 °F to 180 °F Secondary Load 120 °F to 140 °F Initial Delay: 5 mins Off Delay: 5 mins Retry Delay: 10 mins Maximum Throttle %: 75 % The secondary load temperature range of 120 °F to 140 °F is outside the range (does not overlap) with the Primary load's supply temperature range of 140 °F to 180 °F. Load combining will be ignored, and the loads sequentially serviced according to the system's priority rotation. "Not compatible" is displayed on the Load Combining screen. 2.8 Setting the supply differential in heating modes An on/off appliance, such as a boiler, must be operated with a differential to prevent short cycling. When the supply water temperature drops below the low limit of the differential, the appliance is turned on. The appliance continues to run until the temperature reaches the upper limit of the differential. If the differential is set too wide, there can be large temperature swings, and if the differential is too narrow, the appliance short cycles and operates inefficiently. To prevent short cycles and component wear- and-tear, and to maintain boiler efficiency, you should set a differential. Figure 11 Boiler turns on/off according to differential high and low limits A differential is based on a boiler’s target temperature. For example, a boiler that has a target temperature of 150°F will have a differential of 20° F (160° F being the half differential above the target temperature and 140° F being the half differential below the target temperature). The boiler will shut off when the supply water temperature is half the differential setting below the target temperature. It will open when the supply water temperature is half the differential setting above the boiler target. 29 2.8 Setting the supply differential in heating modes

half its supply temperature differential to ensure the maximum supply takes account of the construction and safety requirements of each application (e.g., 140 °F/60 °C maximum for typical in-slab radiant floor to avoid thermal stress). Ensure the range between the boiler supply and maximum supply temperatures is greater than one half of the Supply Diff'l°. Suggested Supply Diff'l° settings: High mass radiant - 20 °F/11 °C. Example: For radiant floor - Design Supply° is 125 °F, Maximum Supply° is 140 °F, and Supply Diff'l° is 20 °F (half of which is 10 °F) works well. For DHW, there is only one differential setting below the target temperature. For example, if the target temperature for the DHW is 135 °F, the differential below the target temperature will be 125 °F. 2.9 Operational settings in the Setup menu: temperature ranges and defaults Operational settings in the Setup Menu Mode Setting Description Temp. Range Default DHW Tank Setpoint° Target temperature of DHW 95 °F-160 °F 140 °F Boiler Supply° Target outlet water temperature 95 °F-185 °F 170 °F Maximum Supply° Temperature limit to prevent overheating of outlet water temperature 41 °F-190 °F 190 °F Priority Priority of the DHW load against other loads Very Low- Very High Very High Pump Post Purge Time (seconds) the pump will operate after satisfying call for DHW 0-900 seconds 180 secs Boiler Pump See Boiler Pump on page 87. On-Off On 30 Section: Operating concepts

Mode Setting Description Temp. Range Default Reset Heating Emitter Enter the device type used to emit heat: high mass radiant system, low mass radiant system, air handler, cast radiator, or baseboard. high mass radiant system Design Supply° Desired boiler outlet temperature on the coldest day 95 °F-185 °F 125 °F Maximum supply° Maximum water temperature limit to prevent overheating 41 °F-190 °F 140 °F Minimum Supply° Starting outlet water temperature 70 °F-147 °F 80 °F Design outdoor -76 °F-86 °F 14 °F Priority Priority of the Reset Heating load against other loads Very Low- Very High Low Pump post Purge Time (seconds) the pump will operate after satisfying call for heat 0-900 seconds 0 Summer Shutdown° Cut-off level for outdoor temperature that prevents further heating 32 °F-122 °F 65 °F Setpoint Boiler Supply° Desired or target outlet water temperature 59 °F-185 °F 130 °F Maximum Supply° Temperature limit to prevent overheating of outlet water 41 °F-190 °F 145 °F Summer Shutdown° Cut-off temperature level that prevents further heating. 32 °F-122 °F 65 °F Priority Priority of the Set Point load against other loads Very Low- Very High High Pump Post Purge Time (seconds) the pump will operate after satisfying call for heat 0-900 seconds 0 Ext. Control Burner On From Type of control used to control boiler supply of heat. Thermostat or Ext. Control Thermostat Max. Control° (9.5VDC) Temperature limit per maximum voltage sent to the controller 32 °F-185 °F 160 °F 31 2.9 Operational settings in the Setup menu: temperature ranges and defaults

Mode Setting Description Temp. Range Default Min. Control° (2.1VDC) Lowest temperature per minimum voltage sent to the controller 32 °F-185 °F 100 °F Maximum supply Maximum limit to prevent overheating 41 °F-190 °F 180 °F Failsafe enable (if no signal boiler comes on - prevent no heat occurring and ext. controller failure Enabled or Disabled Disabled Failsafe setpoint 86 °F-185 °F 86 °F Priority Priority of the call for heat by external control against other loads Very Low - Very High High Pump Post Purge Time (seconds) the pump will operate after satisfying call for heat from external control 0-900 seconds 300 secs Table 4 Temperature ranges and defaults in declared loads - Setup 2.10 Operational settings in the Advanced Setup menu: temperature ranges and defaults Operational settings in the Advanced Setup Menu Mode Setting Description Temp. Range Default Reset Heating Current Target° 95 °F-185 °F 130 °F Emitter Type of heating device used to transfer heat in a building (radiant, air handler, cast radiator, baseboard) Boiler Pump See Boiler Pump on page 87. On-Off On Design Supply° Desired boiler outlet temperature on the coldest day 50 °F-190 °F 125 °F Design Outdoor° Coldest expected outdoor temperature typically experienced at the installation site. Set the Design Outdoor Air temperature correctly for the geographic location; consult a local IBC wholesaler or the heat loss calculation documentation used in the design of the heating system. -76 °F-86 °F 14 °F 32 Section: Operating concepts

Mode Setting Description Temp. Range Default Summer Shutdown° Cut-off level for outdoor temperature that stops further heating 32 °F-122 °F 65 °F Maximum Supply° Highest supply water temperature 70 °F-147 °F 70 °F Minimum Supply° Lowest supply water temperature 70 °F-147 °F 70 °F Supply Diff'l Boiler will shut off at half differential setting when supply water temperature is half the differential setting below the boiler Current Target° and fire when the supply water temperature is half half the differential setting above the boiler Current Target° 3 °F-62 °F 20 °F Ramp Speed See Ramp Speed on page 91. 1-10 3 Priority See Priority on page 90. 20-90 28 Pump Purge See Pump Post Purge (sec) on page 90. 0-900 seconds 0 Indoor From° See Indoor ° From on page 89. Indoor / Sec. Loop Indoor Outdoor From° See Outdoor ° From on page 90. Outdoor, Sec. Loop, DHW Outdoor Water From° See Water° From on page 92. Outlet, Sec. Loop, DHW Burner On From Type of control used to control boiler supply of heat. Thermostat or Ext. Control Thermostat Advanced Reset Current Target° 95 °F-185 °F 130 °F (When Advanced Reset check box is checked) Emitter Type of heating device used to transfer heat in a building (radiant, air handler, cast radiator, baseboard) Boiler Pump See Boiler Pump on page 87. On-Off On Design Supply° Desired boiler outlet temperature on the coldest day 50 °F-190 °F 125 °F 33 2.10 Operational settings in the Advanced Setup menu: temperature ranges and defaults

Mode Setting Description Temp. Range Default Design Outdoor° Coldest expected outdoor temperature typically experienced at the installation site. Set the Design Outdoor Air temperature correctly for the geographic location; consult a local IBC wholesaler or the heat loss calculation documentation used in the design of the heating system. -76 °F-86 °F 14 °F Design Indoor° This setting only becomes available when the Advanced Reset check box is checked. The indoor air temperature used that factors in the heat loss calculations for the heating space. 41 °F-95 °F 72 °F Indoor Setpoint° This setting only becomes available when the Advanced Reset check box is checked. 41 °F-95 °F 75 °F Summer Shutdown° Cut-off level for outdoor temperature that stops further heating 32 °F-122 °F 65 °F Maximum Supply° Highest supply water temperature 70 °F-147 °F 70 °F Minimum Supply° Lowest supply water temperature 70 °F-147 °F 70 °F Supply Diff'l Boiler will shut off at half differential setting when supply water temperature is half the differential setting below the boiler Current Target° and fire when the supply water temperature is half half the differential setting above the boiler Current Target° 3 °F-62 °F 20 °F Ramp Speed See Ramp Speed on page 91. 1-10 3 Priority See Priority on page 90. Very Low- Very High Low Pump Purge See Pump Post Purge (sec) on page 90. 0-900 seconds 0 Indoor From° See Indoor ° From on page 89. Indoor / Sec. Loop Indoor Outdoor From° See Outdoor ° From on page 90. Outdoor, Sec. Loop, DHW 34 Section: Operating concepts

Mode Setting Description Temp. Range Default Water From° See Water° From on page 92. Outlet, Sec. Loop, DHW Burner On From Type of control used to control boiler supply of heat. Thermostat or Ext. Control Thermostat Setpoint Boiler Pump See Boiler Pump on page 87. On-Off On Boiler Supply° Target outlet water temperature 59 °F-185 °F 130 °F Maximum Supply° Temperature limit to prevent overheating of outlet water 41 °F-190 °F 145 °F Supply Diff'l Boiler will shut off at half differential setting when supply water temperature is half the differential setting below the boiler target temperature and fire when the supply water temperature is half the differential setting above the boiler target 3 °F-62 °F 20 °F Summer Shutdown° Cut-off level for further heating. 32 °F-122 °F 65 °F Ramp Speed See Ramp Speed on page 91. 1-10 7 Priority See Priority on page 90. 20-90 62 Pump Post Purge (sec) See Pump Post Purge (sec) on page 90. 0-900 seconds 0 Water° From See Water° From on page 92. Outlet, Sec. Loop, DHW Burner On From Type of control used to control boiler supply of heat. Thermostat or Ext. Control Thermostat 35 2.10 Operational settings in the Advanced Setup menu: temperature ranges and defaults

Mode Setting Description Temp. Range Default DHW Boiler Pump See Boiler Pump on page 87. On-Off On Boiler Supply° Target temperature for the outlet 95 °F-185 °F 170 °F Maximum Supply° Limit to prevent overheating of supply water 41 °F-190 °F 190 °F Supply diff. Boiler will shut off when the supply water temperature is half the differential setting below the boiler target temperature and fire when the supply water temperature is half the differential setting above the boiler target 3 °F-62 °F 20 °F Tank Setpoint° Target temperature of DHW 95 °F-160 °F 140 °F Tank diff. 3 °F-62 °F 10 °F Ramp Speed See Ramp Speed on page 91. 1-10 7 Priority Priority of the DHW load against other loads 20-90 87 Pump Post Purge See Pump Post Purge (sec) on page 90. 0-900 seconds 180 secs Water° From See Water° From on page 92. Outlet, Sec. Loop, DHW Outlet Tank° From Sec. Loop, DHW DHW 36 Section: Operating concepts

Mode Setting Description Temp. Range Default Ext. Control Boiler Pump See Boiler Pump on page 87. On-Off On Burner On From Type of control used to control boiler supply of heat. Thermostat or Ext. Control Thermostat Max. Control° (9.5VDC) Temperature limit per maximum voltage sent to controller. 32°F-185°F 160°F Min. Control° (2.1VDC) Lowest temperature per minimum voltage sent to controller. 32 °F-185 °F 100 °F Maximum Supply° Limit to prevent overheating of supply/outlet water 41°F-190°F 190°F Supply Diff'l Boiler will shut off at half differential setting when supply water temperature is half the differential setting below the boiler target temperature and fire when the supply water temperature is half the differential setting above the boiler target 3 °F-62 °F 20 °F Ramp Speed See Ramp Speed on page 91. 1-10 7 Priority Priority of the call for heat by external control against other loads 20-90 65 Pump Post Purge See Pump Post Purge (sec) on page 90. 0-900 seconds 300 secs Fail Safe Enable See Enable Failsafe SP on page 88. Enabled / Disabled Disabled Water° From See Water° From on page 92. Outlet, Sec. Loop, DHW Water° From Table 5 Temperature ranges and defaults in declared loads - Advanced Setup 37 2.10 Operational settings in the Advanced Setup menu: temperature ranges and defaults

For reference, you can find wiring diagrams for the respective boiler in the Appendices on page 93. This section includes the following topics: Boiler pump Thermostats Load pumps or valves Sensors Alarm contacts External control Multiple boilers: wiring and networking Wiring checklist Note For a boiler to fire, it needs an "enabler" across the load such as a zone valve end switch, thermostat switch, or jumper. Figure 12 Controller's wiring strip 3.1 Boiler pump For VX boilers, wire the boiler pump to its boiler pump harness lead. The image below shows the boiler pump leads (yellow and white wires) located in the wiring box behind the controller.

Field wiring box with yellow and white wires for primary pump - VX series 3.2 Thermostats The controller is compatible with most common thermostats including simple single contact types (for example, a mercury switch) as well as most power-stealing-type thermostats. The standard connection for common thermostats provides a simple contact closure for the boiler (see the electrical diagrams in the Appendices on page 93). For example, Therm 1 will activate Pump 1, Therm 2 will activate Pump 2, etc (see Figure 12 ) . The Therm. 24Vac (TB2 terminal 5) provides 24 volts AC to all thermostats (up to four). This connects to the "R" terminal on the thermostat. Each individual thermostat’s "W" terminal connects separately to one of the controller input terminals: Therm. 1 (TB2: 5-6); to activate load one, close 5-6, Therm. 2 (TB2: 5-7); to activate load 2, close 5-7, Therm. 3 (TB2: 5-8); to activate load 3, close 5-8, or Therm. 4 (TB2: 5-9); to activate load 4, close 5-9. Power stealing thermostats take a small amount of current from the 24VAC to operate their internal electronics. To complete the 24VAC circuit required to operate power stealing thermostats, the controller includes an internal 2740 ohm resistor from the thermostat input to ground. This internal resistor limits the power available to the thermostat and for some models additional power is required for proper operation. Thermostats that require this extra amount of power (for example the Honeywell T8775) will have a resistor available from the manufacturer capable of supplying the required power. Connect the power resistor from the thermostat’s input terminal to the Therm. GND (TB2-10) terminal. Note Some thermostats, for example those with WiFi circuits, may require their own 24V power source. 40 Section: Wiring

Note that TB1: 9-10 P/V power is prewired with 120VAC. You can wire up to four load pumps to the load pump terminal labeled P/V1 (Pump/Valve1), P/V2, P/V3, and P/V4 (see Figure 12 ). The top pair PV/V1 - 1 L(live) and 2 N(neutral) is reserved for Load 1, the second pair PV/V2 - 3 L and 4 N is reserved for Load 2 etc. Figure 14 Load pump terminal The factory has pre-wired the terminal to use a 120VAC power supply, but it can be configured for other voltage uses in the field. Note that the total loads running should not exceed 10 amps. Note that any pump being directly switched by an IBC control board must draw less than 4 amps. 3.4 Sensors Use a thermister (10K ohm type 2 sensor) wired to any of the following sensors at TB2: Outdoor Sensor - 11 and 12 terminals Indoor Sensor - 13 and 14 terminals 2nd Loop Sensor - 15 and 16 terminals DHW sensor - You can use two methods for wiring DHW on a boiler controller: Aquastat: Set up a call for heat for DHW by using an aquastat that is wired to a Therm 1, 2, 3, or 4 connection (see Figure 12 ). DHW sensor: Use a DHW thermister (10K ohm type-2 sensor) to connect to the "DHW Sensor" 17 and 18 terminal connections (see Figure 12 ). With this method, the Therm connection corresponding to the DHW pump is not used. 41 3.3 Load pumps or valves

The controller provides a relay dry contact connection to indicate the boiler’s alarm state externally. This can be used, for example, to connect to an external alarm panel or an indicator light. The terminals on TB3 (see Figure 12 ) supply the wiring connection. To access the TB3 connection, disconnect electrical power to the boiler, and remove the controller front cover. The alarm contacts will normally be open indicating that there is no alarm present. The contacts are closed when an alarm state is present and boiler operation has been disabled. This corresponds to when the boiler status bar on the display is red. The error that was detected creating the alarm state is recorded in the Error Log and displayed on the boiler status bar. Figure 15 Location of alarm contacts on front of controller 3.6 External control Connections are provided at TB2 Ext. Cont. to receive a 0-10VDC or 4-20 mA signal for throttle management (see Figure 12 ). The default configuration is 0-10VDC (JPA01A installed). Note Always disconnect electrical power to the boiler before removing the circuit board cover. Figure 16 Relocating jumper 42 Section: Wiring

1. Remove the electrical box corner cover and the circuit board cover to access the jumpers on the lower-right corner of the control circuit board. 2. Use needle-nose pliers to place the plastic jumper tabs. 3. Reinstall the cover, and then restore power to the boiler. 3.7 Multiple boilers: wiring and networking Caution Controllers must be powered off during boiler network wiring. Network wiring should not run parallel to any nearby line voltage wiring. Networking multiple IBC modulating condensing boilers at a plant site offers tangible energy savings. Networked boilers produce exceptional "turn down" capability to match any building load demands. IBC boiler networks are designed for single load applications and certain two-load systems. Three- or four-load sequences (typically for residential scenarios) are generally not suitable for larger multi-boiler applications. You can connect up to 4 IBC boilers in the VX series and up to 24 IBC boilers in the SL G3 series and EX series to operate as a single heating plant. Other benefits of networking multiple boilers include: System redundancy. Removing a single boiler off-line for servicing without affecting the operation of the other boilers on the network. “Opting out” a single boiler from the heating load when called upon for DHW by an individual indirect storage water heater. 3.7.1 Methods for networking a group of boilers The methods that can be used for networking a group of boilers include: 1. (Recommended method) An Ethernet switch device. 2. BoilerNet two-wire CAN-bus daisy chain cabling. 3. Standard crossover cable for a simple 2-boiler network. A straight through ethernet cable will fail. If this method is used, it will not be possible to connect to IBC's V10 portal, which allows remote access to boilers. Warning Disconnect the electrical power to the boiler before removing the circuit board cover. 43 3.7 Multiple boilers: wiring and networking

If you build a network that is not connected to the internet, you can still assign manual IP addresses to each boiler, that is, assign fixed IP addresses. For example, if using the simple 2- boiler networking method, you will need to assign manual IP addresses to both boilers. For instructions, see Assigning fixed IP addresses to boilers on a network using a switch not connected to the internet on page 59. 3.7.3 Ethernet switch device (recommended) Networking switch devices, purchased from any office supply or computer store, contain multiple ports that enable you to connect multiple boilers via a network (Ethernet) cable. Use a parallel Cat 5 cable with the switch device. The cable plugs into each boiler’s Ethernet jack located at the back of the controller (see Controller Board Layout on page 93). 3.7.4 BoilerNet two-wire CAN bus daisy chain cabling Warning Always power the boilers down prior to working on or installing the two-wire CAN bus. Failure to do so will destroy the network chips on all the boiler control boards on the network. Note The CAN bus method is suitable for small networks consisting of 2-3 boilers. The boilers are configured in a daisy chain networked for communication and control via a proprietary network called BoilerNet. Use polarity-sensitive twisted 2-wire leads (CAN bus standard) to join one boiler to the next (to a maximum of 24 boilers). Connection is made between the “Boiler Net” terminals near the base of the TB2 terminal strip. Wiring between boilers needs to be a sequential “daisy chain” approach (see Figure 17 ). 44 Section: Wiring

communicates between boilers. The wire type and installation must comply with CAN bus standards such as ISO 11898 and/or SAE J2284. Cable Polarity-sensitive twisted 2-wire leads (CAN bus standard) to join one boiler to the next (to a maximum of 24 boilers). Connection made between the "Boiler Net" terminals #19 and #20 (see Figure 12 ). Specifications for the cable: 24 AWG shielded twisted pair 9 twists / ft Capacitance 12.5pF/ft (cond./cond.) Resistance 25.5 ohms/1000 ft Network Wiring Power down all boilers prior to connecting or disconnecting. The "Boiler Net +" and "Boiler Net –" are polarity sensitive and must not be crossed. Network wiring must only be installed in a "Daisy Chain" arrangement where network wiring goes from the first boiler to the second to the third to the fourth, and so on. If using shielded pair wire, ensure the shielding is only grounded at one end of the "Daisy Chain". If the shielding is grounded in multiple locations (i.e. at each boiler or at the first and last boiler,) the shielding becomes ineffective and in some cases increases the electromagnetic interference affecting the communication signal. The termination jumper (JA02) needs to be removed from the boiler controller boards that are NOT the first or last boiler in the BoilerNet chain. For example, in a two-boiler network, JA02 must be left installed in both controls, and in a three-boiler network, the JA02 must be removed on the middle boiler only. Terminators Terminators must be removed from the middle boilers, and the wire polarity must be correct at all the boilers. Table 6 CAN bus setup requirements 45 3.7.4 BoilerNet two-wire CAN bus daisy chain cabling

When three or more boilers are networked, removal of a circuit board jumper is necessary (as illustrated below). Note on the illustration that you must not remove the jumpers from the boilers on both ends of the networked boiler system. Caution Failure to remove the required jumpers may cause network instability. Figure 17 Circuit board jumper removal To remove jumpers: 1. Turn off power to the boilers. 2. Remove the control board covers from each intermediate (non-terminating) boiler in the array. 3. Locate the jumper clips at the bottom right of the circuit board. There are two of them. The jumper for configuring multi-boiler operation is the JA02 shown in the drawing below. 4. Pull this jumper clip straight away from the two pins on the circuit board, and store it somewhere safe in case it might be needed in the future. Common practice is to place it so that it hangs onto the bottom pin only. 5. Replace the control board covers, and restore power to the boilers. Figure 18 Jumper A02 46 Section: Wiring

The following provides useful checks to confirm that wiring is successful. Checklist for Wiring Check Ensure the appropriate loads are set to "Off" or to an appropriate load type. □ Ensure the pumps cycle on or off as expected. □ Check for poor connection or voltage problems from flickering screens or intermittent calls for heat. □ An Ethernet cable is installed if requiring Internet for connection to the IBC V10 portal. □ Ensure the DHW sensor is fully immersed in the well to prevent tank overheating. □ Verify the sensor to control the DHW is fully engaged in terminal 17 and 18 (DHW). □ If three or more boilers are networked using CAN bus, ensure that you have removed appropriate jumpers from the center boilers. For instructions, see Removing jumpers when networking three or more boilers on page 46. □ 47 3.8 Wiring checklist

IBC boiler networks are designed for single-load applications and certain two-load systems. A three- or four-load sequential management strategy, popular on single boiler residential systems, does not typically scale up to larger multi-boiler applications. Large systems imply significant thermal masses that generally cannot change temperature quickly. The IBC controller can control up to four load pumps that are zoned for the same temperature. However, for multiple-temperature applications, you should use external mixing valves or injection control for cooler demands, or IBC’s "Opt-out" strategy (for a description of the "opt out" feature, see Domestic hot water (DHW) on page 17). Note For multi-boiler systems, you must configure the boiler network configuration before setting loads. For instructions, see Configuring multiple boiler systems on page 57. 1. Leave loads in subordinate boilers set to Off (see Opt-out section for exceptions). 2. Set up and configure heat loads on the master boiler only. Use the Advanced Setup menu to specify: A set temperature (Setpoint) or The reset heating curve. The boiler will supply the "Design Supply Temperature" on the coldest days of the year (as defined by the "Design Outdoor Temperature" appropriate to your area; contact your heating wholesaler or contact IBC if unsure of this value). The target temperature will change according to the outdoor sensor inputs. IBC's controller is programmed with default settings and parameters typical of standard installation conditions. You can use one of two methods for setting up loads: Setup (recommended method) is a quick method for setting all the necessary parameters for most single-boiler installations. Advanced Setup is recommended for the advanced installer. For instructions, see Setting loads using Advanced Setup on page 52. 4.1 Configuring loads using Setup (recommended) As the boiler controller is equipped to automatically detect altitude this value will be set for you (see > System Settings > Site Settings > Altitude). Note Zone Of is not available as an option until you have programmed a load with one of the other control modes.

The "Select a load" menu screen appears displaying four possible loads. All loads are set to "Off" to allow the system to be programmed to correspond to the installation’s specific wiring connections. To configure a load: 1. Tap . If the boiler has never been programmed, all loads will be set to "Off". For example, if Load 1 is piped and wired (Load 1 = P/V1 & Therm.1) to heat a load type, select "Load 1 - Off" button. 2. On the Select a load screen select a load (Load 1-4) > Select a control mode (e.g., Setpoint) > OK. To change the control mode, select the Change... button. Note Zone Of is not available as an option until you have programmed a load with one of the other control modes. If selecting: Setpoint, DHW or Ext. Control, a settings screen is populated with pre- programmed values appropriate for typical residential applications. To change a value: Choose a setting > Using the number pad, enter a new value > select OK. The temperature setting range is shown on the number pad popup. For information on recommended settings, see Operating concepts on page 17. Reset Heating > Choose an emitter type (e.g., H-Mass Radiant) > OK. The Reset Heating screen is populated with default settings. Ensure that these settings will work for the intended application, and change them if necessary. For information on recommended settings, see Reset heating on page 18. Note that an outdoor sensor must be installed for Reset Heating. 50 Section: Settings loads

4. Repeat steps for other loads connected to the boiler. Date and time in the boiler are factory set. If the boiler is connected to the internet, date and time will be updated automatically. If the boiler is not connected to the internet, you can manually change the date and time (see Changing and updating date and time on page 76). Setting the clock is necessary for boilers connected to the IBC V10 portal and for setting overrides. 5. (optional) To change units (Imperial or Metric) on the boiler, go to > User Settings > Units > Choose preferred units > Save. Note After defining the loads, perform a manual pump purge to ensure air is purged. Go to > System Settings > Site Settings > Set Manual Pump Purge to "On" > Save. 4.1.2 Syncing zones with "Zone Of" To use the Zone Of control mode, you must have an active load set up. If you want to duplicate or synchronize the configuration (load type and settings) of another active load, you can use "Zone Of". Let’s say that Load 1 is already configured as a Setpoint load, and you want Load 3 to have the same properties and settings as Load 1. To synchronize the zone of Load 3 to match the zone of Load 1 (in our example, Setpoint): 1. Tap to display the Select a load screen. 2. Tap Load 3 > choose Zone Of. 3. Tap Load 1 Setpoint > Save. Load 3 is now synchronized with the same configuration as Load 1. 4.1.3 Changing an assigned control mode on a load type If you are modifying a control mode on a load type and its settings, we recommend that you change the control mode before you change any setting values to prevent changes from being lost. 1. To change a control mode, tap > choose the load you wish to change. 2. If selecting: a. DHW, Setpoint, or Ext. Control, tap Change... > Save. b. Reset Heating > choose an emitter > OK > Save. 51 4.1.2 Syncing zones with "Zone Of"

load with> Save. 4.1.4 Removing an assigned control mode from a load 1. To change a control mode, go to > choose the load you wish to change: 2. Choose a control mode (e.g., Reset Heating) > Tap Change... > Off > OK. 4.1.5 Changing settings in a load After programming a controller, you can change the current settings of one or more loads. Note You can adjust the Outdoor design temperature in the Advanced Setup menu. 1. To change one or more settings in a load, tap to display the Select a load screen. 2. Select a setting highlighted in blue > enter a new value/option > Save. 4.2 Setting loads using Advanced Setup The Advanced Setup menu provides more options for the experienced installer. For a list of operational settings in this menu, see Operational settings in the Advanced Setup menu: temperature ranges and defaults on page 32. 1. Go to > Advanced Setup. If the boiler has never been programmed, all loads will be set to "Off". 2. On the Select a load screen, choose a load (Load 1-4) > Choose a control mode (e.g., Reset Heating) > OK. To change the control mode, select the Change... button. Once a control mode is assigned, all the load’s parameters can be edited individually. Note "Zone Of" is not available as an option until you have programmed a load with one of the other control modes. 52 Section: Settings loads

values appropriately selected for typical residential applications. To change a default value: Choose a setting > Using the number pad, enter a new value > select OK. For information on recommended settings, see Operating concepts on page 17. Reset Heating, choose an emitter type, and then OK. The Reset Heating screen is populated with default settings. Check the pre-programmed values carefully to ensure that they will work for the intended application. Change the settings, if necessary. For information on recommended settings, see Reset heating on page 18. 3. Once all values are set as desired, tap Save. 4. Repeat steps for other loads connected to the boiler. Note To reset the controller's configuration to factory settings, see Resetting configured settings to factory defaults on page 75. To set up an IBC air handler to communicate the indoor and outdoor temperatures to enable the boiler to control 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. Note After defining the loads, perform a manual pump purge to ensure air is purged. Go to > System Settings > Site Settings > Set Manual Pump Purge to "On" > Save. 4.3 Setting up an external control load To set up external control (BMS) to manage a desired boiler set point: 1. Go to > Advanced Setup. If the boiler has never been programmed, all loads will be set to "Off". 2. On the Select a load screen, choose Ext. Control > OK. The settings screen is populated with pre-programmed values appropriately selected for typical residential applications. 3. In the Burner on from field, choose either Thermostat or Ext. Control. If set as "Thermostat" (dry-contact enabled), the boiler will wait for a call for heat from the thermostat terminal associated with the load, and then look at the Ext. Cont. terminals for the target water temperature signal. 53 4.3 Setting up an external control load

call for heat. If the voltage at the Ext. Cont. terminals is below 2.1VDC there is no call for heat. If the voltage is at or above 2.1VDC, then there is a call for heat. 4. In the Minimum control field, set the minimum supply set point temperature from the BMS. 5. In the Maximum control field, set the maximum supply temperature for the BMS (e.g., 182°F). Voltage 2.1VDC. 6. In the Maximum (boiler) supply field, enter the high limit for the BMS (e.g., maximum 190°F) Voltage 9.5VDC. 7. In the Water from field, for a: Single boiler, choose Outlet > OK. Multiboiler network, choose Sec. Loop > OK. Buffer tank, choose DHW > OK. 8. Save. 4.4 Setting up external control to control water temperature in a single boiler or in each boiler wired on a network The following procedure documents setup required when the external control is modulating the boiler output only for a single boiler operation, or in a multiboiler system where system input from the BMS is wired to each boiler. An IBC network cannot be used. To set up external control: 1. Go to > Advanced Setup. If the boiler has never been programmed, all loads will be set to "Off". 2. On the Select a load screen, choose Ext. Control > OK. The settings screen is populated with pre-programmed values appropriately selected for typical residential applications. 3. To change a default value: Choose a setting > Using the number pad, enter a new value > OK. > Save. 4. To enter the firing rate, tap Installer Options > enter the default password 1445 > OK >System Options > Enter the required minimum and maximum firing rate in the Minimum Output and Maximum Output fields > OK > Save. 54 Section: Settings loads

time To enable the boiler to service two loads at the same time, you can combine loads using the controller's basic mode or full mode. We recommend using the basic mode, which is the system default. For information on "Full Mode", see Full mode load combining on page 27. Load combining operates by this criteria: The "primary" load is set at the highest temperature. That both loads are set to operate within the same target temperature range (overlap of temperature). That the "secondary" load is configured with a lower initial priority than the "primary" load (we recommend a priority difference of at least 15). If the secondary load’s running priority becomes higher than the primary load, then it is serviced in the normal priority rotation, just as if the load were not combined. The primary load will be dropped, and the secondary load will be serviced in the normal priority rotation. The steps described below illustrate a typical-load combination setup of DHW with reset heating, using basic mode. In Setup, Load 1 is programmed as domestic hot water (DHW) and load 2 is programmed as reset heating. Because DHW will have the highest temperature load, it will be set up as the primary load. For examples of compatible and incompatible load settings, see Example of compatible load combining on page 28. 4.5.1 Combining loads using "basic mode" To combine two loads using " basic mode" : 1. Go to > Advanced Setup > Load Combining. The "Basic Mode" box is checked by default. 2. In the Primary Load field, tap Disabled > select the load type that will control boiler operation (while load combining is active), in our example Load 1- DHW> OK. 3. In the Secondary Load field, tap Disabled > select the load type for the secondary load, in our example, Load 2 - Reset Heating > OK. A message appears reminding users that a mixing valve must be used in basic mode. 4. Tap Yes to confirm that a mixing valve has been installed >Save. 55 4.5 Combining two loads to service two loads at the same time

To combine two loads using " full mode" : 1. Go to > Advanced Setup > Load Combining. The "Basic Mode" box is checked by default. . 2. Uncheck the "Basic Mode" box. More parameters appear on the screen (may need to scroll down): Initial Delay, Off Delay, Retry Delay, and Maximum Throttle. Initial Delay Amount of time (minutes) between when the primary load is being serviced and the secondary load is brought on to be serviced. For example, 5 equals 5 minutes. Off Delay Sets a delay between loads to prevent loads from coming off-on. Default is 5 minutes. Retry Delay The system was unable to bring on a load because of a conflict with set rules. Indicates the amount of time (default is 10 minutes) before the system will attempt to service the secondary load. Maximum Throttle% If say the throttle is set at 75% (default) and the boiler is already running over 75% of it full fire the secondary load will not be allowed to be serviced at the same time. Once the boiler is running below 75% of its capacity, the secondary load will be serviced. 3. In the Primary Load field, tap Disabled > select the load type that will control boiler operation (while load combining is active), in our example Load 1- DHW> OK. 4. In the Secondary Load field, tap Disabled > select the load type for the secondary load, in our example, Load 2 - Reset Heating > OK. 5. To change the Initial Delay default, tap 5 > from the number pad, pick a number > OK. 6. To change the Off Delay default, tap 5 > from the number pad, pick a number > OK. 7. To change the Retry Delay default, tap 10 > from the number pad, pick a number > OK. 8. To change the Maximum Throttle %, tap 75% > from the number pad, pick a number > OK 9. Tap Save to save the changes. 10. Check the Boiler Status screen. If the field indicates that it is out of temperature range, you may need to adjust the temperature of one of the loads. 56 Section: Settings loads

When configuring a network of boilers, you can assign a boiler as the "master" boiler, so that it can control the other "subordinate" boilers on the network. This enables all heating loads to be set up via the master boiler. Some of the advanced features include the ability to assign a secondary master boiler as a backup if communication from the "primary" master is disrupted. Another safety feature provides the ability to configure a setpoint/supply differential to maintain a set temperature in subordinate boilers in case communication with the master boiler is disrupted. For more information on the advanced settings for multi-boilers, scan the adjacent QR code. 5.1 Checklist for configuring multiple boilers Checklist for Multi-boiler Setup Check Master boiler is configured (see "Configuring a master boiler" below). □ Subordinate boilers are configured (see Configuring a subordinate boiler on page 58). □ All subordinate boilers have a unique ID. □ Master boiler designated and all boilers shown on the network (see Confirming network programming was successful on page 59). □ A secondary loop sensor is wired to the master boiler controller (see TB2: 15-16 at Figure 12 ) and the heat load is mapped to the secondary loop sensor (Water From° set to Sec. Loop). □ 5.2 Configuring a master boiler You can assign a boiler among a group of boilers as the "master" boiler. When you configure a boiler as the master boiler, it receives all sensor and dry contact call-for-heat signals, manages the secondary pumps, and coordinates the firing of all boilers in the group. To assign a boiler in a network as the master (lead) boiler: 1. Go to > Advanced Setup > Multiboiler. Note Each boiler requires a unique Boiler ID within the range of 1-24 (0=offline). 2. In the Boiler ID field, tap 0 > On the number pad select 1 > OK to set the default value from 0 to 1. Note that the master can be assigned an ID between 1 and 24.

"No"). After assigning a master, the screen populates with these fields: Staging delay, Rotation, Fixed Lead, Firing Order, Add Level (%), Drop Level (%), Opt Out box Types, boilers Online, Boilers Available, Boilers Firing. The Master Redundancy field is used to assign a secondary master should the master boiler fail. For more information, click the QR code above. 4. (If desired) In the Staging Delay field, tap 8 (default staging delay in minutes), and on the number pad, set the minimum delay time before the next boiler comes on line (must be at minimum equal to time for closed-loop water to complete one full circuit of system. For large mass systems, allow for two or more loop times). Rotation is turned to "On" to balance the run time on each of the boilers. When Fixed Lead is turned to "On", the master boiler will always be the first to answer a call for heat. If left to "Off", the boiler on the network with the least run time will be the first respond to a call for heat. Note that when Rotation is set to "On", Fixed Lead is treated as "Off". 5. (If desired) In the Rotation field, tap Off > On. This gives each boiler similar run times. There is a 48-hour maximum allowable run time difference between boilers. If prompted to restart, tap Cancel, and go back to the > Advanced Setup > Multiboiler. 6. (Applicable if Fixed Lead is set to "On" and Rotation is set to "Off) To promote more balanced run times, in the Firing Order field > tap > First On / first Off > First on / last off > OK. "First On / Last Off" allows for wider turndown ratios when a smaller model boiler is chosen as a master of larger model boilers. Tip: A quick way to check that the system is calling each boiler as configured, change the "Staging Delay" to one minute. 7. Tap Save. The text "Master" should display in the Status bar. 5.3 Configuring a subordinate boiler Each subordinate boiler requires a unique ID and the “Master Boiler” option must be set to “No”. Subordinate boilers that will be controlled by the master boiler require some basic configuration. To configure a subordinate boiler: 1. Go to > Advanced Setup > Multiboiler. 2. In the Boiler ID field, tap 0 > On the number pad select a unique ID number (e.g. 2, 3 etc. - "1" is typically reserved for the master boiler, but it can be assigned any number 1-24). 3. Ensure that Master is set to No > Save. 58 Section: Configuring multiple boiler systems

the QR code at the beginning of this section. 5.4 Confirming network programming was successful After assigning boiler IDs, the controller prompts you to restart. You can check that the master boiler is now the designated master. To check that the master boiler is the designated master: 1. Go to > Advanced Setup > Multiboiler. Alternatively, go to > Network Information. 2. Scroll down to Boilers Online. The "Boilers Online" field should show the number of boilers networked. "Boilers available" means the number of boilers available for the master to call upon. For example, there may be three boilers online ready to answer a call for heat, but when there is a call for DHW only 2 boilers will be available. 5.5 Confirming number of boilers available and firing on the network To check available boilers that are online/ firing on a network, go to > Network Information > To view all available/unavailable boilers and their network IDs, see Net. Boilers. 5.6 Assigning fixed IP addresses to boilers on a network using a switch not connected to the internet If you are connecting boilers on a network via a switch that is not connected to the internet, you will need to manually assign IP addresses to each boiler; for example, in a 2-boiler network. 1. Go to > Network Settings. 2. In the TCP/IP field, select Manual. 3. In the IP Address field, tap the IP address value, and on the number pad, enter an IP address > OK. Most home routers will accept 192.168.0.1-254 or 192.168.1.1-254. If there is a possibility that the network of boilers could have internet connectivity in the future, we recommend using 192.268.20.1-254 to avoid IP address conflicts. 59 5.4 Confirming network programming was successful

> Save. 5.7 Using the master to control a group of IBC boilers with 5-button-type controllers via a BACnet gateway 1. Go to > Network Settings. 2. Scroll down and check the CANbus Master check box > Save. 5.8 Setting up an IBC air handler to send data to an IBC boiler to control its reset heating curve The boiler determines a water setpoint target to send to the air handler. The air handler uses the water temperature to run at a particular speed or output. If you have an IBC air handler connected to one or more IBC boilers, you can set up the air handler to transmit data such as the indoor and outdoor temperatures to enable the boiler to control its reset heating curve. The IBC air handler will transmit these temperatures to any boiler connected to the local area network. To set up data communication between an IBC air handler and IBC boiler to establish the reset heating curve in the boiler, go to > Network Settings > (Scroll down) Check the AHU Comm. Enabled check box > Save. It may take a couple of minutes for data transmission to complete. 60 Section: Configuring multiple boiler systems

thermostat switch, or jumper. When a boiler is first energized, the controller runs through a power-up sequence that takes approximately one minute. During this time, the controller completes a self-diagnostic, and loads all previous settings. When power is restored after a power interruption, the boiler automatically resumes operation with all the previously stored values. If commissioning a boiler with a new (replacement controller), see Programming a replacement touchscreen controller on page 78. 6.1 Start-up checklist Start-up Checklist Check Measured the inlet gas pressure. Refer to the boiler's Installation and Operating Instructions manual. □ Tested the flue gas (combustion test). Refer to the boiler's Installation and Operating Instructions manual. □ Tested the ignition system safety shutoff device. For instructions, see Testing the ignition safety shutoff on page 62. □ Tested the Hi Limit cutoff temperature functionality to ensure the sensor is working. For instructions, see Testing the Hi-limit temperature function on page 62. □ Tested the low water cutoff functionality to ensure that the sensor is working. For instructions, see Testing the low water cutoff (LWCO) function on page 62. □ Tested the pressure relief valve. For instructions, refer to the Installation and Operating Instructions manual "Service and maintenance: Relief valve" section. □ Checked that the exhaust pipe clamp is tight and secure (no leaking flue into the room). Refer to the Installation and Operating Instructions manual "Installation: Exhaust vent material" section. □ Tested the flow by observing the supply and return delta temperature. □ Verified that the correct pump is activated by the corresponding call for heat. □

To test the ignition system safety shutoff device: 1. With the boiler in operation, shut off the gas control valve directly outside the boiler case. 2. Ensure that the boiler has shut off and the appropriate error information is displayed on the controller. 3. To restart the boiler, reset the power or on the touchscreen controller, tap >Clear Errors > Yes. 6.3 Testing the Hi-limit 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. To test the Hi-limit function: 1. Go to > SIM Menu > Hi-Limit Test > Read the instructions. You will need to enter a cutoff temperature below the actual supply temperature value currently displayed. For example, if the Supply Temp. value is 180°F, enter 170°F in the Cut Off Temp. box. 2. Tap inside the Cut-Off Temp. box, and then tap a number value > OK. The message: "Hi-Limit Detected" is displayed. 3. To reset the boiler, select the Reset button. The cutoff value reverts to normal upon reset. The message: "The SIM module has been reset" is displayed. 4. Tap Close. 6.4 Testing the low water cutoff (LWCO) function The LWCO function provides continuous protection against a low water incident. If the SIM detects low water in the boiler it enters a lockout condition. Here, you will need to reset the boiler. To test the LWCO on the boiler, you can also manually place the boiler in a lockout condition. 62 Section: Start-up

1. Press and hold the LWCO Test button for 5 seconds (located on top of the electrical box). A message on the screen indicates that the boiler is in lockout mode. 2. Go to > SIM Menu > LWCO Test > Read the instructions. 3. On the touchscreen controller, select the Reset button. The message: "The SIM Module has been reset" is displayed. 4. Tap the Close button. 63 6.4 Testing the low water cutoff (LWCO) function

At a site, you can set up internet access to enable you to monitor and control one or more boilers remotely through IBC’s V10 Portal. Figure 19 Benefits of gaining remote access to boilers via the IBC V10 portal To set up remote access to boilers via the V10 portal, you must connect a boiler’s controller to an IP network (see instructions below). Then you can register a boiler for the V10 portal. For steps on how to register for access to the V10 portal, scan the adjacent QR code. 7.1 Connecting a boiler’s controller to an IP network The boiler must be properly connected to an IP network to enable web browser capability. You can do this by using a router to connect the boiler’s local area network to the internet. The connection for the boiler’s controller to an IP network is through the Ethernet jack located at the back of the controller appliance (see Appendices on page 93). The controller supports standard 100 Base T data rates over typical CAT5 or CAT6 wiring. Note Remote access via the Internet typically requires that the router have its port forwarding settings configured to forward port 80 to the boiler’s local IP address. When connecting to the boiler within the local area network, the boiler’s IP address will be the same as listed on the controller’s Network Information screen.

1. Installing an Ethernet cable that connects from the boiler (RJ 45 Ethernet Jack) to the router. 2. Purchasing and installing a wireless access point device connected to the Ethernet jack. The wireless access point device must be configured to operate in client mode (to enable the router to function as a wireless client). There are many wireless access point devices on the market such as the TP-LINK AV500 Nano Powerline Adapter Starter kit. The adapter plugs into an electrical wall socket, and connects to a router via an Ethernet cable. Once an IP network connection is established, using one of the above methods, the router automatically requests the IP address, Net Mask, Net Mask, and the default gateway as part of the TCP/IP protocol configuration settings. Warning Ensure the boiler controller is configured with a "local" network IP address, with access to the Internet through a properly configured and enabled firewall device. IBC Technologies Inc. does not approve connecting the boiler controller directly to the Internet using a "public" IP address, or connecting without a secure firewall device. On the controller's "Network Settings" screen ( > Network Settings), the TCP/IP group of parameters includes the basic settings required to connect to an IP network. By default DHCP is selected. When DHCP is activated the other four entries (IP address, the gateway, DNS server, and Net Mask) are not required, and their entry boxes are disabled. When assigning a boiler with a fixed IP address, tap "Manual" and manually enter the boiler’s IP Address, Net Mask, DNS Server address and Gateway address. 66 Section: Optional - Setup for Internet access

This section describes the ways in which you can perform an software update in a boiler. When you install software updates, the system checks if the boiler has the latest software version. If the system detects that the boiler requires more than one software release update, the system installs each software release update, from the oldest to the latest. To view the latest update in a boiler, on the controller, go to > Boiler Information > Software Release. Tip Consider updating a boiler with the latest software only if the new features are beneficial to the operation of the boiler. There are two methods for updating software in an IBC boiler: 1. Updating software in a boiler that has no internet access. 2. Updating software in a boiler connected to the internet. 8.1 Updating software in a boiler that has no internet access If the boiler has no internet access, updating software will involve the following three stages:

access At the boiler site, insert the USB flash drive into the boiler controller, and use the menu to complete the software update. When a software update is performed, the touchscreen controller is put into "service" mode. This prevents the system from servicing loads. 1. At the boiler, remove active calls for heat. The home screen should show a "Standby" status. 2. Carefully insert the USB stick or SD card into one of the ports on the left-hand side of the controller (see ). 3. On the controller screen, tap > System Settings > Software Update. 4. Select the appropriate device (SD-Card or USB). 5. If you do not get a response, select Cancel and try again. The controller checks if a software update is required. If required, the system prompts you for permission to proceed. 6. Select Yes>OK. 7. If you see a message "Could not mount flash device", select Cancel and try again. The controller automatically restarts after loading the update, and the process takes a few minutes. 8. To check that the controller has the latest software release, go to > Boiler Information > Software Release. You should perform a fan calibration after a software update. For instructions, see Calibrating the fan on page 71. 68 Section: Updating boiler controller software

This section describes other settings that heating professionals can use when operating, servicing, or troubleshooting a boiler. Testing the fan operation Testing the firing rate Calibrating the fan Performing a manual pump purge Limiting the minimum and maximum firing rate of the boiler Adjusting the space heating temperature Adjusting the domestic hot water temperature Checking the water flow in the boiler Setting Overrides Backing up and restoring a boilers' configuration and settings Restricting access to areas in a controller Switching a boiler to unoccupied "away" mode Resetting configured settings in a boiler to factory defaults Changing and updating date and time Changing default error lockout time periods Changing default units of measurement displayed on the controller's screens Setting the venting material Programming a replacement touchscreen controller 9.1 Testing the fan operation When a boiler is not heating, you can test its fan heat output. For all models (excluding the G3 models), the fan heat output MBtu value should match closely the heat output MBtu value. The test also includes the vent factor. A lower vent factor value indicates a shorter vent while a higher vent factor value indicates a longer vent. These values are useful for troubleshooting issues such as a blocked vent. To view the fan model, go to > Boiler Information > Fan Type. To test the fan’s heat output: 1. Go to > Test Operation. 2. In the Fan Test: Heat Out field, tap 0 MBtu, then enter a heat value between 0 and 260 > OK. Note that exiting the screen will stop the fan test.

> Boiler Status. 9.2 Testing the firing rate You can test the firing rate if the fan is not operating, or if there is a low error flow, low air flow, or low rpm error. Fuel High fire Low fire CO max PPM Range % Target % Range % Target % Natural Gas 9.0 - 10.0 9.5 8.2 - 9.2 8.7 <150 Propane 10.3 - 11.3 10.8 9.3 -10.3 9.8 < 250 Table 7 Combustion test target ranges - CO2 / Maximum CO 9.2.1 Testing the high fire 1. To run the boiler at high fire, you can set the heat-out value in manual mode to the maximum MBH for the boiler. To do this: Go to > Test Operation > Tap inside the Fan Test: Heat Output box, and using the number pad, enter the maximum MBH > OK . 2. When the boiler reaches high fire, insert the combustion analyzer test probe into the flue gas test port. Then verify that the CO2 reading is within the combustion test targets defined in the table below. Make necessary adjustments to the high fire on the gas valve, as necessary. 3. To exit the Test Operation screen, select Back. 9.2.2 Testing the low fire 1. To run he boiler at low fire, t the heat-out value in manual mode to the minimum MBH for the boiler. To do this: Go to > Test Operation > Tap the Fan Test: Heat Out box, and using the number pad, enter the minimum MBH > OK. 2. Adjust the low fire according to the table below using a Torx 15 screwdriver. Turn the screwdriver clockwise to raise the CO2% (to richen). Turn counter-clockwise to lower CO2%. Start with ⅛ of a turn until you see the analyzer measure a change then only make 1/16 adjustments. If changing direction on this adjustment you may notice a significant backlash. 3. To exit the Test Operation screen, select Back. 70 Section: Other operating procedures

After replacing a fan or performing a software update, fan calibration is required. 1. Remove all calls for heat by pulling out the entire TB2 terminal block (see Figure 12 ). 2. Go to > System Settings > Restart Boiler. 3. Tap Yes to "Restart the boiler". 4. Tap Yes to "Run the Fan Pressure Calibration on restart?". A red bar appears across the bottom of the display and the boiler turns off, then restarts. During calibration the status will display Offline. When the status returns to Standby, calibration is complete. 5. Restore the calls for heat by reinserting TB2 terminal block. 6. Open the manual gas valve, and restore power to the boiler. 7. Check for leaks at the gas valve outlet and at the connection between the fan and heat exchanger lid. 8. Confirm normal operation and install the cover to the boiler. 9.4 Performing a manual pump purge After installing a boiler, you will need to perform a manual pump purge to ensure that air is fully removed from the piping circuit. 1. After defining loads, go to > System Settings > Site Settings > In the Manual Pump Purge field, set to "On" . The manual pump purge runs until it is turned off, or when there is a call for heat. 2. To shut off the manual pump purge, tap "On" to toggle to "Off". 9.5 Limiting the minimum and maximum firing rate of the boiler If a boiler is oversized for the specific installation, you can lower the maximum firing output. Or, if a boiler is not able to stay operational at its lowest btu due to a high wind environment, you can raise the minimum firing rate output. To adjust the minimum or maximum firing range on a boiler: 1. Go to > Installer Options > On the number pad, enter the default password 1445 > OK. 71 9.3 Calibrating the fan

and enter a higher minimum output (e.g., if the minimum output is currently 10, enter 15) > OK > Save. 3. (If applicable) Tap the number value in the Maximum Output field and enter a lower maximum output (e.g., if the maximum output is currently 85, enter 80) > OK > Save. 9.6 Adjusting the space heating temperature Ensure that a reset heating or set point load is set up in the controller. See Settings loads on page 49. To adjust the space heating temperature in: A Reset Heating load, go to > Advanced Setup > Select the Reset Heating load > tap Design supply temperature number value (default 125° F) > On the number pad choose a value between 50° F and 190° F > OK > Save. A Set Point load, go to > Advanced Setup > Select the Set Point load > tap Boiler Supply temperature value > On the number pad, choose a value between 59° F and 185° F > OK > Save.The load pump must provide adequate water flow if the boiler pump is set to OFF. 9.7 Adjusting the domestic hot water temperature To adjust the domestic hot water temperature, go to > Advanced Setup > Select the DHW Tank setpoint temperature value > On the number pad, choose a number > OK > Save. 9.8 Checking the water flow in the boiler To check the water flow in the boiler, go to > Boiler Status > Flow Rate. Refer to the Specifications table in the Installation and Operation instructions manual for the required flow rate. 9.9 Setting overrides Note Date and time must be set in the boiler for overrides to work. For instructions, see Changing and updating date and time on page 76. 72 Section: Other operating procedures

set up overrides in the system so that domestic hot water is set up to heat the water to 140° C at night to kill bacteria in the water. Alternatively, home owners may want to set up a DHW override so that the water is extra hot for the morning. To set up a temperature override for a DHW load: 1. Go to > User Settings > Overrides. Each load can have two automated (override) programs for each day of the week: Prog 1 and Prog 2. Each program includes one override temperature that can be applied during two separate programmable time periods, for example, in the morning and in the evening. 2. Tap the Edit button for the DHW load (the system is programmed to heat the DHW to 125 ° C). 3. Tap either Prog 1 or Prog 2 next to a day of the week, for example Monday. Each period is defined by a start and an end time in 24-hour clock format. If the programmed times overlap, Prog 1 will supersede Prog 2. 4. Tap the DHW Tank Setpoint value > On the number pad, enter a temperature value, for example, 140° C > OK. 5. In the Start Time 1 field, tap 0:00 > Enter the hour and minutes, using the 24- hour format (e.g., 01:00) > OK > OK to confirm. 6. In the End Timefield, tap 0:00 > Enter the hour and minutes, using the 24- hour format (e.g., 04:00) > OK > OK to confirm. 7. Tap the Save button to save the settings in the selected program. 8. (Optional) Repeat steps 3-7 to configure program settings for the other days of the week. 9. When you have finished entering the necessary settings for the required program(s), tap the Back button. Temperature Override programming can be enabled or disabled for each load independently, without affecting the temperature and time settings for each day of the week. 10. Tap the Enable box next to a load with a temperature override, so that it has a check mark in the box. 11. Tap the Save button, and then tap the Back button to return to the Overrides screen. 12. Now, when you want to set the override, check the Enable box next to the DHW load that has the override set up > Save. Based on the programmed settings above, the system begin heating the DHW at 01:00 am to 140° C, and will end at 04:00 am, and revert to heating the DHW at 125° C. This will continue every Monday during the night until you uncheck the "Enable" box. 73 9.9 Setting overrides

and settings You can back up/restore a boiler’s complete controller configuration and settings to or from a USB memory stick or SD-card that you can then load onto other boilers. This saves time when setting up multiple boilers that will have the same configuration and settings. 9.10.1 Backing up a boiler's configuration and settings 1. Go to > System Settings > Backup and Restore. 2. Choose This Boiler or Boiler Model: "This Boiler" creates or loads a copy of the configuration for the specific single boiler. "Boiler Model" creates or loads a copy/clone of the configuration. Creating a standard boiler configuration allows for quick loading of settings into another boiler of the same model. 3. Insert an SD card or USB Flash into one of the ports on the left-hand side of the controller. 4. Select the device (SD card or USB Flash). 5. Select Backup to save the boiler's configuration and settings to the chosen device. 9.10.2 Loading boiler configuration and settings from a device onto another boiler To load the configuration and settings backed up on a device to another boiler: 1. Go to > System Settings > Backup and Restore. 2. Choose This Boiler or Boiler Model: "This Boiler" creates or loads a copy of the configuration for the specific single boiler. "Boiler Model" creates or loads a copy/clone of the configuration. Creating a standard boiler configuration allows for quick loading of settings into another boiler of the same model. 3. Insert the device containing the boiler configuration and settings into one of the ports on the left-hand side of the controller. 4. Select the device (SD card or USB Flash). 5. Select Restore to save the configuration and settings from the USB stick to the chosen boiler. 74 Section: Other operating procedures

In the controller, you can restrict access to the boiler controls by enabling password access. When you enable password protection, you are provided with an installer default password and a user default password. These passwords cannot be changed. The installer password enables the heating professional to access all options in the boiler. You can give the homeowner the user default password, so that they can access User Settings. To turn on password protection: 1. Go to > Installer Options > User Lock. 2. Select On.The screen displays: User Password: 4321 and Installer Password: 1445. 3. Tap Save to enable password access. When password protection is activated, the Installer password will be required to access the four loads on the "Setup" menu, the "Advanced Setup", "System Settings", "Network Settings", and "Test Operation" screens. The User password will be required on "User Settings" (under ). The 'Security' password is permanent until it is turned "Off". 9.12 Switching a boiler to unoccupied "away" mode You can reduce energy consumption by switching the boiler to "unoccupied" mode during holidays or other away periods. In unoccupied mode, the: DHW load is turned off. The circulating water temperature of a Reset Heating load is lowered by reducing the Indoor Setpoint° to 50°F / 10°C. Setpoint controlled loads are not adjusted through this process to avoid the potential for boiler cycling as there is no linkage with the relevant thermostat. To turn on unoccupied mode, go to > User Settings > Remove the check mark from the Occupied check box > Save. To remove unoccupied mode, go to > User Settings > Check the Occupied check box > Save. 9.13 Resetting configured settings to factory defaults You can use the factory default reset function when the boiler gets into an error for unknown reason or the error cannot be cleared. Or you simply want to reset all boiler settings to default. 75 9.11 Restricting access to areas in a controller

1. Go to > System Settings > Reset Factory Defaults. 2. If you are certain that you want to reset all settings, and lose all configured (customized) settings in the controller, select Yes. The controller will take approximately two minutes to reset to factory defaults. 9.14 Changing and updating date and time The boiler is delivered factory-preset with date and time. Once the boiler is connected to the internet, you can set up data and time to update automatically (e.g., for daylight savings). Setting the date and time in a boiler is necessary for programming overrides and for boilers connected to the IBC V10 portal. You can also manually change the factory default time (e.g., different time zone). 9.14.1 Setting up date and time to update automatically in a boiler connected to the Internet If the boiler is connected to the Internet or to a computer (e.g., a server set up on an internal network that acts as the NTP time source), you can set up date and time to update its internal clock automatically from an Internet time service. 1. Go to > User Settings > Date & Time. 2. Select the NTP Server option. When NTP server is selected, the time in the controller synchronizes daily with the NTP server. 3. In the Time field, tap the time (blue link) > On the Enter Time popup, and set the time in hours and minutes (using the 24-hour format) > OK. 4. In the Date field, tap the date > On the Enter Date popup, enter the year/month/date > Save. 5. In the Time Zone field, tap the zone > On the Time Zone popup, select your time zone > OK. 6. Tap Save. 9.14.2 Changing the default date and time in a boiler not connected to the Internet If the boiler is not connected to the internet, there will be times when you need to manually set/reset a boiler’s date and time. For example, if the boiler has been shutoff, or if there has been a daylight saving time change. 76 Section: Other operating procedures

1. Go to > User Settings > Date & Time. 2. Ensure that the Internal option (default) is selected. "Internal" refers to an internal clock used for time keeping. 3. Set the Date & Time boxes, using the number pad. 4. (If required), tap the Time Zone field, and select an option. 5. Tap Save. 9.15 Changing default error lockout time periods You can change the default lockout periods in mutes for major errors, interlock errors, minor errors and warnings. 1. Go to > Installer Options > On the number pad, enter the default password 1445. 2. Tap System Options > In one of the Error Lockout fields, tap the number value, and on the number pad choose a value in the range indicated > OK > Save. 9.16 Changing default units of measurement displayed on the controller's screens You can set the controller to display imperial or metric units of measurement. Go to > User Settings > Units > Tap the desired unit(s) > Save. 9.17 Setting the venting material The default setting for venting material in the controller is PVC. Other options include CPVC and PP. Caution If you change the venting setting, you are solely liable and responsible for selecting the correct venting type. To select a different venting type: 1. Go to the > System Settings > Site Settings. 2. Scroll down to the Venting Material field, and select PVC.A popup is displayed indicating Installer responsibility for selecting the correct venting type. 3. Carefully choose an option, then tap OK > Save. 77 9.15 Changing default error lockout time periods

controller After powering up a replacement touchscreen controller, you need to enter the correct boiler number details. You can find the correct model number on the boiler’s rating plate. 1. On the touchscreen controller, tap the Boiler Model box, and from the dropdown list, carefully select the correct boiler model number. Note Important: This is the only chance to enter the correct model number. If you save an incorrect model number the board will be unusable, and you will have to buy another controller. 2. Tap the Save button. Note Do not select the “Start” button to run the Self Test. This is for IBC staff use only. 3. Select "Setup" to set up the loads configured in the old boiler. 4. Check that the boiler has registered the thermostat connections correctly along with the correct load types and settings. 5. Check that all pumps operate according to the previous controller. 6. Check the temperature sensor and pressure sensor readings. 78 Section: Other operating procedures

information on the types of errors, see Clear Errors on page 12. Note that disconnected wires or defective sensors may be the cause of the error. Always check connections and wiring first. Warning Do not attempt to repair the control module (circuit board). If the control module is defective, replace it immediately. 10.1 Viewing errors If one ore more errors are displaying on the status bar, you can view more details by going to the Error Logs screen. 1. Go to > Error Logs button. Alternatively, go to > Error Logs. 2. Tap an error log, and then tap the Details... button. The Error log displays all the errors present at the time of the error event such as minor errors, major errors, and system faults. Each error type is displayed as a dropdown that you can select to view the types of errors; for example, selecting the "View minor errors dropdown may display "SIM: See SIM Status" as a message. Tip Once the errors have been resolved, it is not necessary to wait for the lockout period to end. See "Clearing Errors" below. 10.2 Clearing errors When you clear an error, the system clears any error states and forces the controller to reassess the boiler’s error status and to determine if any error state is still present. To clear the error(s), go to > Clear Errors > Yes. 10.3 List of touchscreen controller error messages In the table below, we've included a list of error messages that you may encounter on a controller as well as diagnostic steps to help you troubleshoot.

Troubleshooting Ign. Trials Exceeded Touch Screen Message: Error – Ignition Failure after 3 tries Boiler has failed to ignite on 3 successive attempts. Boiler in lockout for one hour, then repeats 3-try seq. Consult service technician if error recurs. No spark when igniting. Ignitor probe/flame sensor disconnected, dirty, or old. Check that ignitor lead is secure at the control module and at the probe. Burner is dirty from construction dust. Insufficient gas pressure to the boiler. Manual gas shutoff is closed or gas line not fully purged. Check for gas flow. Open manual gas shutoff and reset boiler. Gap between ignitor probe rods is too large or too small. While the boiler is operating, wiggle the gas valve connector on the SIM module. If the boiler stops and starts, you have a poor connection between the gas valve connector and the SIM module. Adjust ignitor probe rod gap between 1/8th and 3/16th (3.2-4.7mm). Spark, but no ignition. Check spark module is sending power to gas valve – close gas supply, then disconnect (black) electric housing from face of gas valve, gently spread plastic tabs to open, and look for 24VAC voltage during an ignition cycle. With the gas valve cable connected, during an ignition attempt, back probe the blue/brown wires and look for 24VAC. Replace module if no current is detected. Boiler ignites, but shuts off at the end of the ignition trial. Improperly grounded pressure 80 Section: Troubleshooting

Troubleshooting vessel/ burner or unserviceable ignition lead or spark module. Ensure the pressure vessel is grounded. Check the igniter probe/flame sensor is electrically isolated from the vessel, and its ceramic insulator is intact. Replace ignition lead Replace spark module Vent Pressure Check the flame signal. If the flame signal is strong then the error may be caused by the Pressure Switch opening. Temp. Probe Error Other message that may display simultaneously: Water High Limit or Vent High Limit. Check the temperature probe and connection. Check the wiring connection of the SIM module connector. Low Water Cutoff See Resetting a boiler after a LWCO lockout on page 85. If the error persists, perform a manual reset: > Clear Errors > Yes. Roll Out Switch Vent High Limit The heat exchanger lid gasket may be damaged or the nuts may not be tightened properly. 1. Check the connections to the Upper Vessel High Limit switch (Roll Out switch) at the back of the heat exchanger. 2. If the switch has been tripped, reset it. 81 10.0 Troubleshooting

Troubleshooting Low Air Flow Other message that may display simultaneously: Flame Sig/Vent Blk. Check the flame signal at low fire. If the flame signal is low then: Check the low fire tuning. See the table for Low Fire in the Commissioning section for each boiler model. Check the condition of the ignitor (e.g., bent, damaged or contaminated). Check that the vent is clear of blockages. Check that the gas valve is functioning properly. Check that the fan is functioning properly. Other messages that may display simultaneously: Check SIM status and Check Ignition Module. No/Low Water Flow Reverse flow error Check that the pumps are operating correctly. Install pump so it provides flow in the correct direction. Water High Limit Check that the supply water temperature sensor is connected and working properly. Check wiring on the SIM module. If this is satisfactory, check that the water pumps are working properly. See Resetting a boiler after a hi-limit temperature lockout on page 86. Vent High Limit Other message that may display simultaneously: Temp. Probe Error Check the vent temperature sensor is connected and working properly. Check the wiring connection of the SIM module connector. If this is satisfactory, check that the water pumps are working properly. 82 Section: Troubleshooting

Troubleshooting Inlet Pres. Sensor Check that the Inlet Pressure Sensor is connected properly. It may need replacing. Check the connector on the back of the circuit board. Other message that may display: Inlet Pres. Sensor. Ignition Module Other message that may display simultaneously: Low Module Current. 1. Check the gas flow. Open the manual gas shutoff, if necessary. 2. See Resetting a boiler after a SIM module ignition lockout on page 85. See About Status indicators on page 11. Low Water Pressure Check for a plugged or dirty water sensor part. Max deltaT Exceeded This may be a temporary condition that may clear automatically. Check the Specifications table for the boiler to ensure the maximum ΔT is not exceeded. The water flow in the pumps may be too low. Check that the water pumps are functioning properly. Check the Specifications table that the flow is higher than the minimum boiler flow rate. Other message that may display simultaneously: No/Low Water Flow. Failed primary boiler pump. Blown primary pump fuse on the main control board. 83 10.0 Troubleshooting

Troubleshooting Output Limited (warning) - indicates that the boiler is limiting/reducing water temperature and/or vent temperature output. Warning may appear if: The Inlet/Outlet water temperature differential exceeds the maximum allowed. The inlet water temperature is very close to the max. outlet water temperature. The vent temperature is too high. If the warning persists, the status bar will display a "Max deltaT Exceeded" alarm or "Vent High Limit" alarm. GV / Ign Module Gas valve or Ignition Module (depending on software) Check the ignition or the SIM module. Check that the gas valve and gas valve cable are functioning properly. Interlock 1 Open / Interlock 2 Open Jumper lead is loose or compromised. Replace the jumper lead. External safety is in an alarm state. External safety wired to Interlock has tripped or malfunctioned. Inspect the external safety devices. High/Low Press (Only EX models) Indicates that the gas pressure entering the boiler is too high or too low. Reset the gas pressure switch. Other errors: “ Loop/Indoor Sensor” “Insufficient Air Flow” “Insufficient Water Pressure” “Unknown Error” The sensor plug is not engaged. Check the P501 plug is fully engaged in the back of the controller board (see Controller Board Layout on page 93). 84 Section: Troubleshooting

You may need to back up an error log onto a USB stick to send to IBC's Technical Support team for troubleshooting. 1. To back up an error log, go to > Error Logs > Select an error log (link) > Export > Insert the SD card or USB stick into the side of the controller > Yes. 2. After the data is copied, remove the device from the controller > Close. 10.5 Deleting or clearing an error log Deleting will delete all entries in an error log. Go to > Error Logs > Choose an error log (link) > Delete all > Yes to clear all entries in the error log. 10.6 Resetting a boiler after a SIM module ignition lockout If you are at the boiler when the boiler is locked out due to an ignition error, you can use the Module Reset function to avoid having to wait the 5-minute lockout period. For example, use Module Reset to clear the "Check SIM Module" error displayed on SL G3 models. Go to > SIM Menu> Module Reset > The message "The SIM module has been reset" is displayed > Close. 10.7 Resetting a boiler after a LWCO lockout A boiler that has been placed in a lockout condition due to a LWCO error will need to be reset in the controller's SIM module. 1. Go to > Clear Errors > Yes. 2. Check that there is enough water in the system. 3. To reset the SIM Module, go to > SIM Menu> LWCO Test > Reset > Yes. 4. Run the boiler to ensure that the error has been cleared. 85 10.4 Backing up (exporting) error logs

> SIM Menu> LWCO Test > Run the test to check if the low water cutoff sensor is opening. 10.8 Resetting a boiler after a hi-limit temperature lockout A boiler that has been placed in a lockout condition due to a hi-limit temperature error will need to be reset in the controller's SIM module. 1. Go to > Clear Errors > Yes. 2. Check that there is no air trapped in the system. 3. To reset the SIM Module, go to > SIM Menu> Hi-Limit Test > Reset > Yes. 4. Run the boiler to ensure that the error has been cleared. 5. If the error persists, perform a hi-limit test. Go to > SIM Menu> Hi-Limit Test > Run the test to see if the hi-limit switch is opening. You can also perform this test for gasket blowouts. 86 Section: Troubleshooting

Term Definition Add Level (%) Sets the relative ouput level at which an idle boiler fires up. This is a percent of the maximum firing rate of the lead boiler – on a 40-399 G3, for instance, a value of 60 would correspond to an output of 399 x 60/100 = 239. Note that this value must be at least 10 higher than the Drop Level (%), which will be adjusted to satisfy this if Add Level (%) is changed. Aquastat Control Device used in hydronic heating systems for controlling water temperature. Typically used to manage domestic hot water temperature in an indirect water heater. BACnet A Data Communication Protocol for Building Automation and Control Networks - A protocol that provides information about a boiler’s heating, ventilating, and air conditioning control (HVAC), lighting control, access control, and fire detection. Boiler Pump Enables you to shut off the Boiler Pump (primary loop pump) while a load is running. The load pump must be piped (series piping) to ensure adequate flow through the boiler without needing the Boiler Pump to provide flow through the heat exchanger. When you set the Boiler Pump to "Off" a warning message appears as a reminder. If the load is a radiant floor, we strongly recommend using primary or secondary piping and leaving the Boiler Pump set to "On". Boiler Pump Purge Time (Site Settings) Adjustable independently of the four load pumps. Many installations use a primary (boiler) loop. We recommend that the boiler pump operate for 3 – 5 minutes after all calls for heat have been satisfied. Boiler Turndown A ratio that compares the full maximum boiler heat output (high fire) to the minimum level of heat output (low fire). Call for Heat A call for heat could be: The thermostat is indicating that room temperature is below the thermostat setting. An Aquastat calling for DHW. The tank sensor calling for DHW. Classic-DDC control Involves separate dry-contact calls and throttle control signals to each boiler from external DDC. (Not generally recommended.) Cycles Running tally of the number of calls for heat that a load has received in the last 24 hours. Fewer cycles per day = better efficiency. Delta T Difference between the supply water temperature and the return water temperature. Drop Level (%) Sets the relative output level at which a firing boiler will be shut down as a percent of the maximum firing rate of the master boiler. Note that this value must be at least 10 lower than Add Level (%), which will be adjusted to satisfy this when Drop Level (%) is changed. DSP Daylight Standard Pacific - time zone update. 87 11.0 Definition of terms

is set to External Control. If this feature is active and the External Control voltage drops below 0.25Vdc, the boiler automatically turns on the Boiler Pump (if set to "ON"), the load pump, and operates the boiler to the Fail Safe Set Point temperature. This temperature set point is adjustable. Failsafe SP Differential The supply differential used by the subordinate boiler while in Failsafe SP mode. If the supply temperature exceeds Failsafe SP + (Failsafe SP Differential) / 2, then the boiler will enter Circulating until the supply temperature decreases to Failsafe SP – (Failsafe SP Differential) / 2, at which point it will reignite and enter heating again. Failsafe SP Delay (min) The delay in minutes of lost communication with the master, and the subordinate boiler entering Failsafe SP mode. Failsafe Setpoint SP When set to On, provides the ability to maintain a setpoint temperature in subordinate boilers if communication with the master is lost. Only available on subordinate boilers, it enables default setpoint operation. If a boiler receives no communication from a master boiler for a period of time (how long?), it will fire at the preset setpoint/differential until communication resumes. Firing Order Firing Order determines which boiler is shut down first. If FirstOn/FirstOff is selected, the first boiler fired up will be shutdown first. If FirstOn/LastOff is selected, then the most recently fired boiler will be shutdown first. Fixed Lead A boiler that is always the first to fire up. Appears as a field if Master, Primary Master, or Secondary Master are set to "On". If Fixed Lead is set to "On", then the active master will always attempt to fire first, before any other boilers. Otherwise, the boiler with the lowest burner on time will attempt to fire first. Fully autonomous mode Designation of a master boiler that will receive all sensor and dry contact call-for-heat signals, manage the secondary pump(s) and, via BoilerNet connection, coordinate firing of all subordinate boilers. This fully autonomous approach uses IBC’s internal heat regulation and boiler management software. Group Add Level (%) Similar to Add Level (%) for master boilers, this is the relative output level at which the Group Opt Out Lead will bring another boiler on to service the Group Opt Out load. Note that this value must be at least 10 higher than Group Drop Level (%), which adjusts to satisfy this if Group Add Level (%) is changed. Group Drop Level (%) Similar to Drop Level (%) for master boilers, this is the relative output level at which the Group Opt Out Lead will shut down a boiler that is currently servicing the Group Opt Out load. Note that this value must be at least 10 lower than Group Add Level (%), which adjusts to satisfy this if Group Drop Level (%) is changed. Group Opt Out Lead This boiler is the Group Opt Out lead, and is the first to fire when a call for heat is received on the Group Opt Out load. Makes the remaining Group Opt Out fields visible. Group Staging Delay (min) Similar to Staging Delay (min) for master boilers, this value determines the number of minutes between boilers being fired up or shut down by the Group Opt Out Lead. 88 Section: Definition of terms

temperature decreases. Heating Enabled The boiler is powered and there is a Call for Heat, Heat is Required. The boiler will start and enter the Heating Cycle unless it is in an error mode. Heat pump Uses electricity to draw heat out of a building in the summer (to cool the space) and heat from the outside air to indoors in the winter time (to warm the space). Heat Required Temperature sensors on the boiler indicate that water temperature is below the water temperature target or setpoint. Indoor ° From If an indoor temperature sensor is being used, the sensor will normally be connected to the TB2 Indoor Sensor terminals on the controller board. Alternatively the TB2 2nd Loop Sensor input terminals can be wired to the indoor temperature sensor. If using TB2 2nd Loop Sensor, you must configure the Indoor ° From setting as Sec. Loop. Use for shop or warehouse, but not for residential properties. HVAC Heating, ventilation and air conditioning system. Master Rotation Rotates the role of active master between any boilers configured as Primary or Secondary Masters on the network. This feature confirms that master redundancy is functioning properly. The time between master rotations is 24 hours. The active master will not attempt to pass the role of active master to a master currently in an Error or Circulating state, or to a Secondary Master currently servicing an opt out load. n/c Not connected NTP Server Network Time Protocol Opt out A term used by IBC to describe a boiler that "opts out"or becomes unavailable to a network to satisfy a request. Typically, opt out boilers are used and dedicated to service DHW. 89 11.0 Definition of terms

Load 1-4 The Opt Out Type for each load dictates how the load is handled by the multi-boiler algorithm. None: Only for boilers configured as a master. This load is serviced by the entire multi-boiler network (the master will not opt out to service the load, but will use all boilers to service it). Single: A subordinate boiler will opt out of the main multi-boiler network to service a load. Master boilers with a load configured as Single will opt out to service that load, but will continue to control the subordinates and run the highest priority multi-boiler load. Group: The boiler will opt out of the main multi-boiler network to service this load if commanded by the Group Opt Out Lead. Mainly for DHW purposes, it allows a subset of the main multi-boiler network to be configured to opt out from the main network load as needed to service the DHW load. Note: The same load (1-4) must be configured as Group Opt Out on each boiler in the group. For example, if Load 2 is configured as Group Opt Out on Boiler #1, and you want #2 and #3 to also be part of the opt out group, then Load 2 must be configured as Group Opt Out on boilers #2 and #3 as well. One boiler must be chosen as the Group Opt Out Lead – this is the only boiler that needs a physical call for heat (such as a thermostat) wired into the controller on the Group load. Only one opt out group is permitted per network. Once one load is configured as Group, it must be set back to Single or None before a different load can be configured as Group. Outdoor ° From The Default setting is Outdoor. If an outdoor temperature sensor is being used the sensor will normally be connected to the TB2 Outdoor Sensor terminals on the controller board. Alternatively the TB2 2nd Loop Sensor or the DHW Sensor input terminals can be wired to the outdoor temperature sensor. To support these alternate wiring options the "Outdoor ° From" setting must be set to Sec. Loop or DHW to correspond with the wiring. Priority A load has a priority value between 20 and 90. Note: The Priority Value has to be different for each load. A higher numerical value means a higher priority. Consider these values as minutes. The difference between two load priority values is the number of minutes the higher priority load will be allowed to operate before switching back to the lower priority load. For example, if DHW has a priority of 80 and the Set Point load has a priority of 50, the DHW load will operate for (80-50) 30 minutes while the Set Point load is temporarily turned off. Pump Post Purge (sec) How long a load pump operates after the call for heat has ended. Each load pump can 90 Section: Definition of terms

heat left-over in the heat exchanger and nearby boiler piping after the burner has turned off and pumps it into the load. A good example of this is the indirect water heater DHW load. After the tank has reached its target temperature, the boiler shuts down, but allows the load pump to operate for a period of time to transfer heat that is stored in the boiler’s heat exchanger into the hot water tank. You can adjust this feature in seconds from 0 to 900 (15 min). If the load has zone valves that close off the flow to the load as the boiler shuts down, this can be set to 0 sec. You can set each load independently to provide maximum flexibility. Ramp Speed How fast the boiler tries to raise the water temperature flowing through the heat emitters. With a fin tube baseboard radiator, you may want the water temperature to rise quickly to provide heat as quickly as possible. This type of heat emitter has very little mass, so it can heat up quickly. When the call for heat is removed, it cools down quickly. Generally this requires a higher (faster) ramp speed. A radiant floor, on the other hand, has significant mass, and therefore takes a long time to heat up. When the call for heat is removed, the floor is still warm and continues to add heat to the space for a significant period of time. If the indoor temperature overshoots the desired indoor temperature, we recommend reducing the Ramp Speed value. Generally this requires a lower (slower) ramp speed. You can manually set the Ramp Speed by choosing a value from 1 to 10. A setting of 1 will raise the water temperature very slowly and 10 will raise the water temperature very quickly. Rotation Rotation monitors the boilers on the network for a difference of more than 48 hours in burner on time. If a boiler is currently firing, which has 48 hours or more of burner on time than a currently idle boiler, the active master will tell the idle boiler to fire up. Once the master detects that the rotated in boiler is in Heating mode, and has finished its post ignition hold, it will tell the rotated out boiler to shut down. If the rotated in boiler is in Error, Circulating, or does not complete its post ignition hold within 2 minutes, the rotation will be declared a failure and the rotated out boiler will continue firing as before. Rotation balances the amount of time each boiler spends firing. If a run time difference of more than 48 hours is detected between the currently firing boiler with the most run time and the idle boiler with the least run time, the running boiler will be shut down and the idle boiler will be fired up. Semi- autonomous mode Involves a remote analogue signal to the master boiler’s External Control terminals. This signal corresponds to a target set-point temperature, with the range scaled according to the programmed min-max temperatures. IBC’s multi-boiler heat regulation algorithm still determines which boiler fires, throttle levels etc., but to an externally determined operating temperature. Call-for-heat to the Master can be conveyed via a 2.1+ VDC signal on the External Control terminal, or via a dry contact boiler enable with the 0-10VDC input for target temperature. Short Cycling A boiler’s burner turns on and off frequently. This leads to shorter component life, reduced efficiency, and higher emissions. A cycle on/off time typically should be 10 minutes or longer. 91 11.0 Definition of terms

is, the length of time before the next boiler is brought online once the current firing boiler has passed its add boiler firing rate level. It must be at minimum equal to time for closed-loop water to complete one full circuit of system. For large mass systems, allow for two or more loop times. Water° From The Default setting is Outlet. When set to Outlet, the controller determines the supply water temperature from the outlet temperature sensor on the boiler. Alternatively the 2nd Loop Sensor or the DHW Sensor input terminals can be wired to a water temperature sensor. To support these alternate wiring options the Water ° From setting must be set to Sec. Loop on DHW to correspond with the wiring. Multi-boiler: Most have an external sensor mounted on the building supply water. 92 Section: Definition of terms

diagram, and sequence of operation. Controller Board Layout Figure 20 Front and back of controller 93 Appendices

Figure 21 VX series - internal diagram 94 Section: Appendices

Figure 23 VX series - Sequence of Operation 96 Section: Appendices

domestic hot water temperature 72 space heating temperature 72 Advanced Setup menu 15 setting loads 52 temperature ranges and defaults 32 AHU Comm. Enabled 60 air purge 71 B Backing up or restoring boiler configuration and settings 74 backlight 14 BACnet 5-button controllers on network 60 Boiler Information 9 C calibrate touchscreen 16 CANBus Master 60 characterized heating "curve" 21 Checking water flow 72 clean the screen 14 Clear errors about error states 12 Combining loads setting two loads using full mode 56 D Date & Time 14 setting 76 DHW about 17 adjusting 72 opt-out boilers on network 17 priority load 17 differential 29 Domestic hot water (DHW) 17 E Engineer options 16 Error Clear errors 79 list of controller error messages 79 major 11 97 minor 11 SIM Status 12 states 12 system faults 12 Error logs 11 backing up (exporting) 85 deleting/clearing entries 85 Ethernet switch device 44 External Control 23 control single boiler water temperature 54 setting 53 wiring 42 F factory defaults resetting to 75 fan calibration 71 fan operation testing 69 firing rate adjusting 71 testing 70 fixed IP addresses, assigning 59

Internet access connecting boiler to IP network 65 setup 65 Internet connectivity 44 L Licensing BACnet 15 Load combining about 26 basic mode 26 combining two loads 55 example compatible load 28 full mode 27 incompatible load combining 29 setting two loads in basic mode 55 load priority setting 24 Load Status 9 lockout resetting hi-limit temperature 86 resetting low water cutoff 85 resetting SIM module ignition 85 LWCO error resetting after lockout 85 M manual pump purge 71 More menu about 13 multi-boiler setup 57 multiboiler assigning fixed IP addresses 59 Multiboiler advanced settings 57 checking programming 59 checklist for setup 57 configuring master boiler 57 configuring subordinate boilers 58 confirming boilers available in network 59 wiring 43 N Network information 13 Network Settings 16 O Overrides 14 setting 72 P password installer password 75 setting password protection 75 user password 75 Power up sequence & operating states/cycles 7 R replacement touchscreen controller, programming 78 Reset factory defaults 16 Reset heating about 18 advanced mode 21 characterized heating curve settings 22 standard mode 19 Reset heating curve sending air handler data to IBC boiler to control reset heating curve 60 Restart boiler 16 S Sensors and channels 12 sequence of operation 7 Set Point about 22 programming target range 23