IBC EX Series Installation And Operating Manual
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IBC EX Series Installation And Operating Manual

Commercial boilers
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See also: User's Information Manual
If the information in this manual is not followed exactly, a fire or explosion may result causing
property damage, personal injury, or loss of life.
Do not store or use gasoline or other flammable vapors and liquids or other combustible
materials in the vicinity of this or any other appliance.
If you smell gas:
Do not try to light any appliance.
Do not touch any electrical switch; do not use any phone in your building.
Immediately call your gas supplier from a nearby phone. Follow the gas supplier's
instructions.
If you cannot reach your gas supplier, call the fire department. Installation and service must
be performed by a qualified installer, service agency or the gas supplier.
Installation and
Operating Manual
WARNING
EX SERIES
Commercial Boilers
EX 700
EX 850

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Summary of Contents for IBC EX Series

  • Page 1 Installation and Operating Manual EX SERIES Commercial Boilers EX 700 EX 850 WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance.
  • Page 2 4 x anchor brackets (installed on pallet) Condensate trap IBC # P-1221 Tridicator IBC # P-1234 Relief valve IBC # P-1205 2 x Inlet gas pressure test fittings, IBC part # 190-206 2 x spare air filters, IBC # P-381 Outdoor sensor, IBC part 240-025...

  • Page 3: Table Of Contents

    Contents Safety information Manual safety markings Important safety instructions Known contaminants Specifications Connection specifications Cabinet dimensions 1.0 Introduction 1.1 Standard features and benefits 1.2 Warranty 2.0 Before installation 3.0 Installation 3.1 Code requirements 3.2 Determining location of the unit 3.2.1 Factors to consider for best installation conditions 3.3 Unpacking a boiler 3.4 Installation clearances 3.5 Exhaust venting and air intake venting...
  • Page 4 Section: Contents 3.7 Installing a condensate neutralizer 3.8 Water Piping 3.8.1 General piping best practices 3.8.2 System piping 3.9 Gas piping 3.9.1 Gas pressure 3.10 Electrical connections 3.10.1 Power quality and electrical protection 3.10.2 120VAC line-voltage hook-up 3.10.3 Other wiring 3.10.4 Thermostat / sensor wiring 3.10.5 Thermostat heat anticipator 4.0 About the boiler controller...
  • Page 5 6.2.10 Boiler treatment 6.2.11 Relief valve - maintenance and testing 6.3 Replacing the fan, gas valve, and burner 6.3.1 Replacing the fan 6.3.2 Replacing the gas valve 6.3.3 Replacing the burner 6.4 Replacing the air filter 6.5 Cleaning a condensate trap 7.0 Troubleshooting 7.1 Preliminary checks 7.2 Electronic components...
  • Page 6 Section: Contents Installation & Commissioning Report Boiler parts diagram Revision history...

  • Page 7: Safety Information

    Important safety instructions Installation, start-up and servicing of IBC boilers must be performed by competent, qualified, licensed and trained heating technicians. Failure to read and comply with all instructions and applicable national and local codes may result in hazardous conditions that could result in property damage and injury to occupants, and in extreme cases to death.

  • Page 8: Known Contaminants

    Section: Safety information Warning Disconnect power supply before any wiring/service is performed. Failure to do so could result in damage to unit and/or electric shock. Caution The boiler must be installed so that electrical components are not exposed to water during operation.

  • Page 9: Specifications

    Specifications EX 700 EX 850 CSA Input (Natural Gas or Propane) - MBH 70 - 700 85 - 850 CSA Input (Natural Gas or Propane) - kW 20.5 - 205 24.9 - 249 CSA Output - MBH 824.5 CSA Output - kW 241.6 Thermal Efficiency Minimum gas supply pressure (Natural Gas or Propane) - inch w.c.

  • Page 10: Connection Specifications

    Section: Specifications EX 700 EX 850 120' 120' Maximum equivalent vent length Each side (Vent & Air Intake)) (Natural Gas or Propane) Air intake options: either direct vent or indoor supply *These alternative relief valves can be purchased: 30, 100, 125 and 150. Table 1 Specifications Connection specifications...

  • Page 11: Cabinet Dimensions

    Cabinet dimensions Cabinet dimensions Figure 1 Frontal view Figure 2 Top view Figure 3 Back view...
  • Page 12 Section: Specifications...

  • Page 13: Introduction

    1.0 Introduction IBC's range of large commercial boilers is the solution for large-scale projects such as apartment buildings, office buildings, big schools, hospitals, and hotels. Figure 4 Front internal view Figure 5 Back view of boiler...

  • Page 14: Standard Features And Benefits

    Boiler pump control up to ¾ H.P. 120V or 208/240V 1.2 Warranty IBC offers a 10-year warranty on the EX series heat exchanger and a 1-year warranty on all parts against defects in materials or workmanship and failures due to thermal shock.

  • Page 15: Before Installation

    2.0 Before installation Before installing the unit, it is important to review and observe the following checklist of precautions: Precautions Check □ Care must be taken to properly size the boiler for its intended use. Prolonged full fire run time, over-sizing or under-sizing, and incorrect flow rates through the boiler can lead to increased maintenance costs, equipment stress and premature failure.
  • Page 16 Section: Before installation Precautions Check discharge location. □ If the boiler is likely to be exposed to fluid temperatures below 34° F (1° C), a method of protection to prevent freezing of condensate should be employed. Contact the factory for further information. □...

  • Page 17: Installation

    3.0 Installation The gas-fired modulating boilers are low pressure, fully condensing units having a variable input range. Approved as “Category IV” vented appliances, the boilers use either Direct Vent (sealed combustion) or indoor combustion air, providing a great degree of installation flexibility. 3.1 Code requirements The boilers are tested and certified under CSA 4.9-2017 / ANSI Z21.13-2017.

  • Page 18: Factors To Consider For Best Installation Conditions

    Section: Installation Warnings Keep the area around a boiler clear of combustible materials, gasoline, and other flammable vapors and liquids. Ensure combustion air is not drawn from areas containing corrosive air such as swimming pools or spas, including air directly next to outdoor pools and spas. Ensure that a boiler is not exposed to water leaks from piping or components located overhead, including condensation from uninsulated cold water lines overhead.

  • Page 19: Unpacking A Boiler

    3.3 Unpacking a boiler 3.2.1.1 Anchoring the boiler Boiler weight – without water and any effect of system piping and components – is approximately 500 lbs / 225 kg. Use the brackets provided to secure the boiler to the floor. 3.3 Unpacking a boiler The boiler is shipped bolted to a pallet with four (4) anchor brackets and 3/8"...

  • Page 20: Installation Clearances

    Clearance distances for boiler mounting sites 3.5 Exhaust venting and air intake venting Warning Venting, condensate drainage, and combustion air systems for all IBC boilers must be installed in compliance with all applicable codes and with instructions provided in the respective installation manuals.

  • Page 21: Code

    Figure 7 Flue gas venting Danger Do not common vent EX series modulating boilers with any other existing or new appliance. 3.5.1 Code All venting must be installed in accordance with the requirements of the jurisdiction having authority: in Canada, Part 8, Venting Systems of the B149.1-10 Code and any other local building codes are to be followed.
  • Page 22 Section: Installation 3.5.1.1 Important considerations when removing an existing boiler: When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances that remain connected to it. When resizing any portion of the common venting system, use the minimum size according to the appropriate tables in the National Fuel Gas Code, ANSI Z223.1 - latest edition.

  • Page 23: Applications

    3.5.2 Applications 3.5.2 Applications All EX series boilers are approved with alternative venting options: either 2-pipe Direct Vent or Vent pipe with Indoor Air. With the Direct Vent case, combustion air is piped directly to the boiler’s air intake from...

  • Page 24: Vent Travel

    Section: Installation For PPs material, use the 6" transition / adaptor fitting (Sch 40 to PPs) offered by the respective PPs manufacturers Centrotherm / InnoflueTM (their part # ISAAL0606) or M&G Dura Vent / PolyProTM (# 6PPS-06PVCM-6PPF [10004281]), (# 4PPs-AD). For PPs material exposed to outdoor weather, follow the venting supplier’s recommendations on UV protection.
  • Page 25 Check that material meets local codes including fire stopping requirements. Some local jurisdictions require a minimum initial length of pipe be exposed or accessible for inspection. Pipe clearances - no IBC requirements; follow local codes. All piping must be liquid and pressure tight.

  • Page 26: Venting Passage Through Ceiling And Floor

    Confirm material meets local codes including fire stopping requirements. Check the local jurisdiction on the minimum initial length of pipe that should be exposed or accessible for inspection. Follow the local codes for pipe clearances - no IBC requirements. Ensure that piping is liquid and pressure tight.

  • Page 27: Rooftop Vent Termination

    3.5.6 Rooftop vent termination 3.5.6 Rooftop vent termination Warning Condensate can cause corrosion of metal roofing components and other roofing materials. Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate. pH levels can be as low as 3.0. a.
  • Page 28 Section: Installation Vent screen retainer Exhaust Vent screen Inlet Flashing Figure 12 Rooftop vent terminal vent screen and retainer The intake air pipe is not typically drained, so it must be terminated with a down-turned elbow as shown. The intake pipe does not need to penetrate the roof at the same elevation as the exhaust (as shown);...

  • Page 29: Sidewall Vent Termination

    3.5.7 Sidewall vent termination Caution Vent termination clearances in this section are code minimum, or IBC recommended minimum requirements, and may be inadequate for your installation. Building envelope details must be examined carefully. Take action to avoid moisture entering building structures. Serious structural damage may occur if adequate precautions and clearances are not allowed for.
  • Page 30 Section: Installation Figure 13 Minimum clearances from vent/air inlet terminations (see legend on adjacent page) Canadian Description US Installations Installations A Clearance above grade, veranda, porch, deck, or 1' (30 cm) 1' (30 cm) balcony B Clearance to window or door that may be opened 4' (1.2 m) below or to 3' (91 cm) side of opening...
  • Page 31 Improper installation will void the warranty. Do not use proprietary InnoFlue or PolyPro PPs terminals without specific approval from IBC. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.
  • Page 32 Section: Installation Sidewall direct vent with separate vent and air pipes shall be terminated as follows: Locate the intake air and exhaust vent terminations on the same plane (side) of the building. Place the exhaust vent termination, so that it reaches 12" minimum above the down-turned intake to avoid exhaust re-ingestion.
  • Page 33 3.5.7 Sidewall vent termination Figure 16 Sidewall vent termination configuration option 1 Figure 17 Sidewall vent termination configuration option 2...

  • Page 34: Direct Vent Combustion Air Intake Piping

    Section: Installation Warning In areas of high snowfall, users must be advised to check side wall vent and air intake terminations on a regular basis to ensure blockage does not occur. 3.5.8 Direct vent combustion air intake piping The direct vent option uses piping from the outside to supply combustion air directly to the boiler’s combustion air connection.
  • Page 35 3.5.8 Direct vent combustion air intake piping Warnings In addition to preventing ingestion of chemical contaminants, ensure air intake terminals are not installed in locations where contamination might occur due to ingestion of particulate foreign material (dust, dirt and debris). Configure intake air openings, so that rain or other forms of moisture cannot enter the air intake piping system.
  • Page 36 Section: Installation Combustion air from outdoors Flue gas exhaust to outdoors Boiler supply connection at rear of boiler Boiler return connection at rear of boiler Figure 20 Rear view - combustion air intake Notes When installing air intake piping, ensure that a “trap” is not formed in the piping causing a build-up of water and blockage of intake air.

  • Page 37: Indoor Air Combustion Air Intake

    3.5.9 Indoor air combustion air intake EX 700, EX 850 Intake Pipe Size Maximum Equivalent Length Sched.40; Rigid PPs 6" PVC/CPVC / Rigid PPs/SS 120' each side 90° vent elbow allow 5' equivalent 45° elbow allow 3' equivalent PPs 87-90° elbows use 5' equivalent Table 7 Maximum intake pipe venting length for EX 700, 850...

  • Page 38: Combustion Air Filtration System

    Section: Installation Flue gas exhaust to outdoors Combustion air from boiler room. For indoor air installation, check air intake and boiler room combustion air opening(s) to ensure they are clear of obstructions. Figure 21 Indoor combustion air intake To support combustion, an ample air supply is required. This may require direct openings in the boiler room to the outside.

  • Page 39: Installing A Condensate Trap

    Filter door - top view of boiler 3.6 Installing a condensate trap IBC’s specified vent configuration promotes the safe drainage of moisture from the boiler and exhaust venting without flowing liquids back through the heat exchanger (as done by some other condensing boilers).
  • Page 40 Section: Installation The condensate trap must be installed on the drain connection at the base of the boiler. The condensate drain must be piped to within 1" of a drain or connected to a condensate pump. The drainage line must slope down to the drain at a pitch of ¼"...

  • Page 41: Installing A Condensate Neutralizer

    3.7 Installing a condensate neutralizer Warning Fill the trap with water before initially firing the boiler to prevent exhaust fumes from entering the room. Never operate the boiler unless the trap is filled with water. Failure to comply will result in severe personal injury or death.
  • Page 42 The agent (limestone chips with a minimum calcium carbonate content of 85%) can be purchased from a local supplier. 1" FPT inlet and outlet. Unions for ease of maintenance (ships with shown model NT-25, IBC part 180- 048).

  • Page 43: Water Piping

    3.8 Water Piping 3.8 Water Piping Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage. High levels of dissolved solids or minerals may precipitate out of the fluid onto the hottest part of the heat exchanger, impairing heat transfer and resulting in overheating and premature failure.
  • Page 44 Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation location. For environmental and toxicity reasons, IBC recommends only using non-toxic propylene glycol.

  • Page 45: General Piping Best Practices

    The extremely low pressure drop through the heat exchanger of the EX series affords more flexible options unavailable in other designs.

  • Page 46: System Piping

    Section: Installation 3.8.2 System piping System piping is connected to the boiler using 2½" NPT-Male threaded fittings. To simplify servicing, we recommend using unions or flanged fittings, gate or ball valves at the boilers supply and return water connections. You must install un-insulated hot water pipes with a minimum ¼" clearance from combustible materials.
  • Page 47 Low water cut-off (LWCO): the IBC EX series comes factory-equipped with an internally mounted Certified Low Water Cut-Off. Sometimes an external device is required by local jurisdiction. These devices have specific installation requirements not illustrated here.
  • Page 48 Section: Installation Optional external water high limit (manual reset). The IBC EX series comes factory-equipped with an internally mounted manual reset mechanical water temperature high limit. It can be fitted with an external manual reset mechanical water temperature high limit if required by local jurisdiction.
  • Page 49 3.8.2 System piping Hydraulic separator (low-loss header) provides primary/secondary hydraulic separation, a microbubble air eliminator and a dirt separator. Air eliminator is installed at the most effective point, where the fluid is at the highest temperature and lowest pressure. Secondary pumps to multiple loads or zones. All receive identical temperatures. Note integrated check valves.
  • Page 50 Section: Installation Primary pump or boiler circulator. Closely-spaced tees to or from load 1. Closely-spaced tees to or from load 2. Fill station with isolation valve closed, or fill tank. Dirt separator recommended. Figure 26 Boiler trim options - single boiler...
  • Page 51 3.8.2 System piping Closely-spaced tees: To avoid induced flow, install each set of tees with straight piping a minimum of 8 pipe diameters upstream and 4 pipe diameters downstream. Avoid using elbow or other component that may create turbulent flow. Position tees as close together as possible (maximum 4 pipe diameters apart) and ensure that there are no restrictions between the fittings that would result in a pressure drop.
  • Page 52 Section: Installation DHW indirect tank Air handler Low temperature radiant protected by a mixing valve for simultaneous heating during higher temperature air handler operation. Boiler can return to lower supply temperature when radiant alone is operating. Figure 28 Primary/Secondary piping concept with simultaneous heating calls...
  • Page 53 3.8.2 System piping DHW indirect tank Air handler Check valves (may be integral to pumps - not shown) Figure 29 Two pump, two load - parallel piping concept...
  • Page 54 Section: Installation The boilers can supply multiple heating loads with compatible supply temperature requirements. Always ensure that loads sensitive to high temperatures are protected using means such as mixing valves. Check valve (typical of each boiler - may be integral to pump). Tridicator (shipped with boiler) typical of each boiler.
  • Page 55 3.8.2 System piping Pressure relief valve (shipped with boiler) typical of each boiler. Tridicator (shipped with boiler) typical of each boiler. Check valve (typical of each boiler) Boiler pump into rear connection (typical of each boiler) Low-loss header / hydraulic separator (shown) or closely-spaced tees 'bridge' to load piping Check valve for opt-out circuit.

  • Page 56: Gas Piping

    Section: Installation 3.9 Gas piping Note Due to the precision of modern modulating boilers it is important to pay special attention to gas pressure regulation. Important: Check gas supply pressure to each boiler with a manometer or other high-quality precision measuring device. Pressure should be monitored before firing the boiler, during operation throughout the boiler's full modulation range, and after the call when the regulator is in a "lock-up"...

  • Page 57: Electrical Connections

    3.10 Electrical connections Maximum Gas Pipe Length (ft) Model 1¼" IPS 1½" IPS 2" IPS 2½" IPS EX 700 (Natural Gas) 100' 350' 800' EX 700 (Propane) 150' 300' 900' 2000' EX 850 (Natural Gas) 250' 600' EX 850 (Propane) 100' 200' 700'...

  • Page 58: 120Vac Line-Voltage Hook-Up

    Section: Installation Note The IBC boiler (like any modern appliance that contains electronic equipment) must have a “clean” power supply, and is susceptible to power surges and spikes, lightning strikes and other forms of severe electrical “noise”. Power conditioning equipment (surge protectors, APC or UPS devices) may be required in areas where power quality is suspect.
  • Page 59 3.10.2 120VAC line-voltage hook-up 3.10.2.2 Boiler pump The boiler (primary) pump is powered by the yellow wire from the pair labeled "Boiler Pump". Wire the pump's neutral to the white wire labeled "AC In". Do not attempt to connect the boiler pump to the pump/zone valve terminal block along the controller’s right edge as this is reserved for the secondary pumps and/or zone valves only.
  • Page 60 Section: Installation Pumps can be switched on/off using the touchscreen controller, so there is no need for temporary pump wiring during system filling / air purging. If pumps are hard-wired to the panel during the system fill/purge phase, re-wire the boiler pump to the primary pump leads inside the wiring box so the primary pump purge function is active.

  • Page 61: Other Wiring

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

  • Page 62: Thermostat Heat Anticipator

    Section: Installation 3.10.5 Thermostat heat anticipator IBC “Therm” contacts draw no power, so an anticipator setting for the thermostat is not applicable with the EX modulating series boilers. For a heat load where zone valves are used to manage thermostatically controlled zones, each room's thermostat heat anticipator should be adjusted to the current draw of its associated zone valve.

  • Page 63: About The Boiler Controller

    Load Combining – simultaneous operation of two similar water temperature loads Programmable setback / override schedule The control can manage or operate in a network of up to 24 IBC boilers without additional controller.  Some of the new features available in the touchscreen control include:...

  • Page 64: Control Interface

    Real time boiler data Temperature and throttle operation Maintenance of operational and error service logs 2-way communication between other IBC boilers and controls Internet connection and communication Operational and historical data may be accessed at any time using the System Status and Load Profiles sections of the control. Error logs are available in the Diagnostics section and the controller is capable of recording any or all errors since original power-up complete with the date and time of the error.

  • Page 65: Before Operating The Boiler

    5.0 Before operating the boiler Danger Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, do not try to operate any appliance - do not touch any electrical switch or use any phone in the building.
  • Page 66 Section: Before operating the boiler Checking piping connections Check □ Check that the water piping system is fully flushed and charged, and that all air has been discharged through loosened bleed caps. Note it is possible to switch all pumps on/off from the touchscreen – without a call for heat. This simplifies system filling and air bleeding (go to Installer Setup, System Settings, Site Settings, change Manual Pump Purge to "ON".

  • Page 67: Service And Maintenance

    The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition. 6.1 Maintenance checklists for manager of unit Managers of EX series boilers should arrange follow-up inspections and simple maintenance procedures according to IBC's suggested servicing guidelines below. Maintenance Required for Venting Frequency Check □...

  • Page 68: Venting

    Section: Service and maintenance 6.2.1 Venting Maintenance Required for Venting Frequency Check □ Monthly Check and replace filter as needed. For replacement instructions, see Replacing the air filter on page 76 □ Annually Have your local heating contractor inspect the unit annually. □...

  • Page 69: Heat Exchanger

    6.2.4 Heat exchanger Maintenance Required for Burner Frequency Check □ Annually If the burner is operating improperly, remove and clean or replace. Use a CO analyzer to determine proper combustion. See Combustion test target ranges - CO2 / Maximum CO for correct values.

  • Page 70: Water

    Section: Service and maintenance Maintenance Required for Boiler Controller Frequency Check □ Annually Check that water temperature targets and setpoint is satisfactory and have not been adversely amended. □ Check the operating history using the boilers Logs menu and Error Logs menu.

  • Page 71: Freeze Protection

    Ethylene glycol is toxic, and may be prohibited for use by codes applicable to your installation location. For environmental and toxicity reasons, IBC recommends only using non-toxic propylene glycol.

  • Page 72: Replacing The Fan, Gas Valve, And Burner

    Section: Service and maintenance Maintenance for Relief valve Frequency Check □ Annually Test at or near the maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of sediment and debris. Then release the lever and allow the valve to snap shut.

  • Page 73: Replacing The Fan

    6.3.1 Replacing the fan Mixing device High pressure switch Inlet gas pressure test port (location of) Low pressure switch Low fire adjustment (zero-offset) High fire adjustment (on the side) Manifold gas pressure test port Shutoff valve Figure 37 EX 700, 850 - gas valve and fan components 6.3.1 Replacing the fan 1.

  • Page 74: Replacing The Gas Valve

    Section: Service and maintenance 9. Remove the four (4) hex bolts that attach the fan to the heat exchanger lid. An open-ended wrench or socket is required. 10. With the mixing device still attached, remove the fan by pulling straight up ensuring that no wires are caught and that the gas line remains in place.
  • Page 75 6.3.2 Replacing the gas valve Gas valve electrical connector Gas valve outlet: Unscrew the four (4) bolts of the flange to separate gas valve from the gas valve. Keep gasket and bolts for re-assembly. Figure 38 Accessing the gas valve - EX 700, 850 1.

  • Page 76: Replacing The Burner

    Section: Service and maintenance 6.3.3 Replacing the burner Warning The IBC heat exchanger has a small amount of combustion chamber insulation (refractory), which contains ceramic fibers. When exposed to extremely high temperatures, the ceramic fibers that contain crystalline silica can be converted into cristobalite, classified as a possible human carcinogen.
  • Page 77 6.3.3 Replacing the burner 5. Remove the screw and pull off the electrical connector from the gas valve, and disconnect the three- (3) wire Molex plug from the the gas pressure switches. 6. Unscrew the four (4) bolts of the flange to separate the gas valve inlet from the gas line. Keep gasket and bolts for re-assembly.

  • Page 78: Replacing The Air Filter

    Section: Service and maintenance 6.4 Replacing the air filter Two replacement filters are shipped with each boiler. The air filter should be inspected and/or replaced monthly. When replacing the air filter in the unit, use a MERV 8 filter sized at 10" x 10" x 1". Remove the two screws of the air filter lid, and Remove the air filter, and replace set aside.

  • Page 79: Cleaning A Condensate Trap

    6.5 Cleaning a condensate trap 6.5 Cleaning a condensate trap Condensate traps should be checked every two months, cleaned and refilled as necessary. Before cleaning the condensate trap, you must turn off the power to the boiler, and allow it to cool down. Important: Installers or service contractors should ensure that the end user is instructed on cleaning and refilling the trap.
  • Page 80 Section: Service and maintenance Clean and flush out the debris in the condensate Fill the condensate trap to the top trap base. with water. Reinsert the condensate trap through the metal Rotate the elbow, and tighten the union plate. nut, so that elbow and condensate trap are secured.

  • Page 81: Troubleshooting

    7.0 Troubleshooting This section includes various conditions as well as possible solutions related to the EX unit. Note The boilers are equipped with a blocked vent shutoff system, which closes the gas supply upon detection of an irregular venting condition. In such an event, the electronic controller automatically carries out a reset/ retry every 5 minutes.

  • Page 82: Electronic Components

    Section: Troubleshooting 7.2 Electronic components This section details the method for troubleshooting the non-standard electronic components on the boiler. 7.2.1 Temperature sensors The resistance of the temperature sensors varies inversely with temperature. To test, measure the temperature of the sensed environment and compare with the value derived from the measurement of the resistance (obtained by connecting a good quality test meter capable of measuring up to 5,000 kΩ...

  • Page 83: Fan

    7.2.2 Fan Resist. Resist. Temp. °F/°C Temp. °F/°C Ω – Ohm Ω – Ohm 70 / 21 11,883 170 / 77 1,403 75 / 24 10,501 175 / 79 1,281 80 / 27 9,299 180 / 82 1,172 85 / 29 8,250 185 / 85 1,073...

  • Page 84: Gas Pressure Switches

    7.2.5 Gas pressure switches The high and low gas pressure switches help protect the boiler from gas pressures outside of the acceptable range of operation. To view the location of the pressure switches on the EX series boilers, see Figure 38 The low gas pressure switch is pre-calibrated, and will trip when the inlet gas pressure falls below 3.5"...
  • Page 85 7.2.6 Safety and Ignition Module (SIM) 7.2.6.1 Table showing LED operating status Its two status LEDs indicate the operating status as shown in the table below. SIM Status Indicators Description, LED status LED 1 LED 2 State indication Rapid flash Power up or resetting startup checks and initialization Standby LED 1 Off=flame or sparking...
  • Page 86 Section: Troubleshooting 3. Tap the Advanced Diagnostics button. 4. Tap the Clear Errors button. 5. Tap the Yes radio button, and then tap OK. The system clears the errors, and resets the boiler. 7.2.6.4 Testing the LWCO function 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.

  • Page 87: Troubleshooting Error Messages

    7.3 Troubleshooting error messages 4. Tap the Hi-Limit Test button. You will need to enter a cutoff temperature below the Supply Temp. value currently displayed. For example, if the Supply Temp. value is 180°F, enter 170°F in the Cut Off Temp. box. 5.

  • Page 88: Maximum Ignition Trials Error

    Section: Troubleshooting 7.3.2 Maximum ignition trials error Maximum Ignition Trials Error Issue Diagnosis Error – Ignition Failure after 3 No spark when igniting. Check that ignition lead is secure at the tries boiler has failed to ignite Ignition probe/flame control module and at the probe. on 3 successive attempts.

  • Page 89: Hi/Low Gas Pressure Switch Error

    7.3.3 Hi/Low gas pressure switch error 7.3.3 Hi/Low gas pressure switch error High/Low Gas Press Error Issue Diagnosis Error – High/Low Gas Press Inlet gas pressure has risen Measure the inlet gas pressure. above 15" w.c. or has fallen below Reset the switch.

  • Page 90: Aux. Interlock 1 Or

    Section: Troubleshooting 7.3.6 Aux. Interlock 1 or 2 Aux. Interlock 1 or 2 Issue Diagnosis Interlock 1 or 2 terminals are Jumper lead is loose or Replace the jumper lead. open. compromised. External safety is in an alarm state. Inspect the external safety devices.

  • Page 91: Ignition Issues

    7.4.1 Ignition issues Miscellaneous errors Issue Diagnosis Blank – screen dark, but fan running Indicative of Check transformer; replace if power-surge damage to appliance damaged.Check circuit board for visible damage. If update fails Restarting returns the boiler Controller is stuck in "service" mode after software or no updates to normal operation.

  • Page 92: Temperature Issues

    Section: Troubleshooting 7.4.2 Temperature issues Temperature issues Issue Diagnosis Low heat Operating temperature too low. Increase temperature target. Increase temperature target. Priority parameters or load Review load configuration parameters. configuration improperly set up. Unit undersized. Refer to Load Calculation vs. Boiler Output. Air trapped within system.

  • Page 93: Miscellaneous Issues

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

  • Page 94: Cycling Issues

    Section: Troubleshooting 7.4.4 Cycling issues Cycling issues Issue Diagnosis Rapid Improper values entered via keypad. Check load maximum temps are above target Cycling temps, by ½ of the selected boiler differential. Ensure boiler differential is OK (16 - 30 °F is generally adequate) Excess condensate in venting.

  • Page 95: Appendices

    Appendices Appendices Wiring diagrams Figure 39 Controller electrical diagram...
  • Page 96 Section: Appendices Figure 40 Internal wiring diagram...
  • Page 97 Wiring diagrams Figure 41 Sequence of Operation...
  • Page 98 Section: Appendices Installation & Commissioning Report Boiler Details: Model Number _____________________ Serial Number ________________________________ Date of Installation ________ Address of installation ____________________________________ User contact information __________________________________________________________ Installer Information (Company & Address)_____________________________________________ Phone/Fax/E-mail ________________________________________________________________ □ □ Fuel: Natural Gas Propane Gas Supply Pressure (high fire) ____ Inches w.c. Measured Rate of Input (high fire) _____Btu/hr □...
  • Page 99 Boiler parts diagram Boiler parts diagram Item Description Part Number Replacement Kit Numbers Number Door 500-134 P-1209 Controller 500-044 P-242 Safety Ignition Module 500-105 P-270 Top panel 251-030 P-1227 Controller module chassis 251-042 P-1228 Gas valve relay 240-165 P-1233 Boiler pump relay 240-165 P-1233 Transformer...
  • Page 100 Section: Appendices Item Description Part Number Replacement Kit Numbers Number Wiring harness (not shown) P-1232 Item Number Description Part Number Replacement Kit Number 240-156 P-1212 Fan gasket 255-126...
  • Page 101 Boiler parts diagram Item Number Description Part Number Replacement Kit Number Fuel mixer 180-254 P-1200 NG EX 700 180-255 P-1201 LP EX 700 180-256 P-1202 NG EX 850 180-257 P-1203 LP EX 850 Air filter 500-136 P-1211 compartment Replacement air 180-126 P-381 filters...
  • Page 102 Section: Appendices Item Description Part Number Replacement Part Number Number Low water cut-off probe 240-143 P-9078 Supply Water temperature 240-159 P-1225 sensor Tridicator - field installed 180-283 P-1234 Relief valve - field installed 180-279 P-1205 Air pressure sensor 240-132 P-361 Return water temperature 240-160 P-1226...
  • Page 103 Revision history R0 (September 2019) Initial release R1 (December 2019) Measuring the inlet gas pressure, Resetting the High/Low pressure switches, new drawing (Fig. 23)
  • Page 104 IBC Technologies Inc. 8015 North Fraser Way Burnaby, BC Canada V5J 5M8 Tel: 604-877-0277 Fax: 604-877-0295 Toll Free: 1-844-432-8422 www.ibcboiler.com January, 2020 ©IBC Technologies Inc. 2020 120-327-R1...

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