IBC EX Series Installation & Operating Manual
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IBC EX Series Installation & Operating Manual

Commercial condensing boilers
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INSTALLATION &
OPERATING 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.
Commercial Condensing Boilers
EX 400
EX 500
EX 700
EX 850
WARNING

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Summary of Contents for IBC EX Series

  • Page 1 INSTALLATION & OPERATING MANUAL Commercial Condensing Boilers EX 400 EX 500 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 appliance 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 3.9 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 4.1 Controller 4.2 Controller interface 5.0 Before operating the boiler 5.1 Important pre-ignition checks...
  • Page 5 7.1.8 Water 7.1.9 Freeze protection 7.1.10 Boiler treatment 7.1.11 Relief valve - maintenance and testing 7.2 Replacing the fan, gas valve, and burner in EX 400 and EX 500 models 7.2.1 Replacing the fan on the EX 400 and EX 500 models 7.2.2 Replacing the gas valve in the EX 400 and EX 500 models 7.2.3 Replacing the burner in the EX 400 and 500 models 7.3 Replacing the fan, gas valve, and burner in EX 750 and EX 800 models...
  • Page 6 Section: Contents Appendices Wiring diagrams Installation & Commissioning Report Boiler parts diagram - EX 400 and EX 500 Boiler parts diagram - EX 700 and EX 850 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 appliance 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 Specifications EX 400 EX 500 EX 700 EX 850 CSA Input (natural gas or propane) - 40-399 50-500 70 - 700 85 - 850 CSA Input (natural gas or propane) - kW 11.7 - 117 14.6 - 146.5 20.5 - 205 24.9 - 249 CSA Output - MBH 824.5...

  • Page 10: Connection Specifications

    Section: Specifications Specifications EX 400 EX 500 EX 700 EX 850 Relief valve pressure (supplied) - psig* Approved installation altitude - ASL 0 - 12,000' 0-12,000' 0 - 12,000' 0-12,000' 170' 170' 120' 120' Maximum equivalent vent length each side (vent & air intake) (natural gas or propane) Air intake options: either direct vent or indoor supply...

  • Page 11: Cabinet Dimensions

    Cabinet dimensions Cabinet dimensions Figure 1 Frontal view - EX 400, EX 500 Figure 2 Back view - EX 400, EX 500 Figure 3 Top view - EX 400, EX 500...
  • Page 12 Section: Specifications Figure 4 Frontal view - EX 700, EX 850 Figure 5 Back view - EX 700, EX 850 Figure 6 Top view - EX 700, EX 850...

  • 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 7 Front internal view Figure 8 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-limited warranty on the EX series heat exchanger and a 2-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 appliance, it is important to review and observe the following checklist of precautions: Precautions Check □ Care must be taken to properly size the boiler for its intended use. Prolonged full fire run time, over-sizing or under-sizing, and incorrect flow rates through the boiler can lead to increased maintenance costs, equipment stress and premature failure.
  • Page 16 Section: Before installation Precautions Check □ 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 appliances 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 10 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 outdoors (see Vent termination clearance on page 30 for air intake piping requirements).

  • 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 3.5.4 Vent travel Warning Follow all installation instructions supplied by the pipe and fitting manufacturer. The actual vent travel allowance is reduced for fittings as shown in the following tables: Exhaust / Fittings EX 400, EX 500 EX 700, EX 850 4-inch rigid pipe 170 ft (max.) each side Not allowed...

  • Page 26: Venting Passage Through Ceiling And Floor

    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 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 15 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.
  • Page 30 Section: Installation Figure 16 Minimum clearances from vent/air inlet terminations (see legend on adjacent page) Canadian Description US Installations Installations Clearance above grade, veranda, porch, 1' (30 cm) 1' (30 cm) deck, or balcony Clearance to window or door that may be 4' (1.2 m) below or 3' (91 cm) opened...
  • Page 31 3.5.7 Sidewall vent termination Canadian Description US Installations Installations Clearance to unventilated soffit Clearance to outside corner 6' (1.83 m)* 6' (1.83 m)* Clearance to inside corner 6' (1.83 m) 6' (1.83 m)* Clearance to each side of center line 3' (91 cm) within a extended above meter/regulator assembly height 15' above the...
  • 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 19 Sidewall vent termination configuration option 1 Figure 20 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 Do not use bushing on EX 700 and EX 850 models Flue gas exhaust to outdoors Flue gas exhaust to outdoors (connection at rear of boiler) Combustion air from outdoors. "Direct Combustion air from outdoors. Use reducing Vent"...
  • 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 23 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 Intake / Fittings EX 400, EX 500 EX 700, EX 850 4-inch rigid pipe 170 ft max. each side Not allowed 6-inch rigid pipe 120 ft max. (See note below) 90° vent elbow allow 5 ft for each elbow 45°...

  • 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 24 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 Slide the union nut onto the elbow. The Attach the elbow and union nut firmly union nut must include an embedded O- to the boiler's outlet tube, making sure ring. Ensure that the O-ring seal is in that you rotate the elbow sideways. place on the heat exchanger's stainless steel outlet tube.

  • 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 To drain. Confirm slope. Slope the condensate hose and drain piping toward the drain and secure to prevent accidental dis-assembly. Danger The water in the condensate neutralizer can cause severe burns to the skin. Wear protective gloves and eye wear when servicing the condensate neutralizer. 3.8 Water Piping Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat...
  • 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

    Piping loads in parallel is also encouraged in systems that only have two loads, or when loads are operating simultaneously. 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 Caution Contact local water purveyors about the suitability of the supply for use in hydronic heating systems. If unsure about water quality, request testing and assessment (and treatment, if required) from a local water treatment expert. Alternatively, water or hydronic fluid of known quality can be brought to the site. 3.8.2 System piping System piping is connected to the boiler using 2½"...
  • Page 47 For further information and details, consult our Concept Drawings – which provide detail on specific single and multiple boiler applications “Piping”, “Wiring” and “Settings”. (available at www.ibcboiler.com or from your IBC Representative). Note The piping drawings in this manual are simple schematic guides to a successful installation.
  • Page 48 Section: Installation 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. Consult the IBC factory or the LWCO manufacturer for proper application of these devices.
  • Page 49 3.8.2 System piping Pressure relief valve (shipped with boiler): no isolation valve is permitted between the boiler and relief valve. Tridicator or external pressure and temperature gauge (shipped with boiler). 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.
  • 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 29 Boiler trim options - single boiler 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.
  • Page 51 3.8.2 System piping Heat migration: On secondary loops that extend vertically to a load that is above the primary loop, steps must be taken such as fabricating a thermal trap in the return piping - minimum 18" (46 cm) drop - to prevent thermal siphoning and heat migration to the load when there is no demand for heat to that loop.
  • Page 52 Section: Installation DHW indirect tank Air handler Check valves (may be integral to pumps - not shown) Figure 32 Two pump, two load - parallel piping concept...
  • Page 53 3.8.2 System piping 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 54 Section: Installation 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 55: Gas Piping

    3.9 Gas piping 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.

  • Page 56: Electrical Connections

    Section: Installation Maximum Gas Pipe Length (ft) Model 1¼" IPS 1½" IPS 2" IPS 2½" IPS EX 400 (Natural Gas) 150' 350' 1000' >2000' EX 400 (Propane) 400' 900' >2000' >2000' EX 500 (Natural Gas) 100' 200' 700' 1800' EX 500 (Propane) 250' 600' 2000'...

  • Page 57: Power Quality And Electrical Protection

    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 58 Section: Installation 3.10.2.1 Load pumps The 120VAC power supply to the load pumps (P/V1, P/V2, P/V3, and P/V4) is factory installed and connected to P/V-L and P/V-N for your convenience. If you use the P/V relay connections for zone valves, you need to remove and cap off the 120VAC connections at P/V-L and P/V-N. The 24VAC can then be applied using an external transformer to supply power to zone valves.
  • Page 59 3.10.2 120VAC line-voltage hook-up The boiler pump relay may require connection to a second electrical circuit (amperage greater than 4 amps). The boiler pump relay is rated for a maximum amperage load of ¾ horsepower. A disconnect switch should be installed to isolate the boiler pump and the boiler pump relay power supply.

  • Page 60: Other Wiring

    Thermister type with a resistance of 10,000 ohms at 77°F (25°C) and β = 3892. We do not recommend using 3rd party supplied sensors. Compatible water temperature sensors and outdoor sensors can be supplied by your IBC distributor. 3.10.4 Thermostat / sensor wiring Each of the four loads has dry contacts for thermostats as marked on the lower connector strip (e.g., "Therm 1").

  • Page 61: Thermostat Heat Anticipator

    3.10.5 Thermostat heat anticipator 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.
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  • 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: Controller 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.

  • 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 >...

  • Page 67: Boiler Operation

    6.0 Boiler operation Before operating the appliance, there are some important pre-igntion checks that need to be performed. For more information, see Before operating the boiler on page 63. To understand the boiler start-up process, see Sequence of Operation on page 122.

  • Page 68: Testing The Ignition Safety Shutoff

    Examine the rating plate of the boiler to ensure it is configured for the fuel you are using. If the boiler is configured for natural gas, but needs to be converted to propane, use the conversion kit (sold separately by IBC) to install the appropriate fitting(s) and adjust the gas valve accordingly. See Table 10 for the required conversion kit.

  • Page 69: Performing A Fuel Conversion

    Danger Operating any IBC boiler using a fuel other than the fuel listed on its rating plate is prohibited. Failure to follow the instructions on converting to alternate fuels can result in a fire or explosion, which may cause property damage, personal injury, or loss of life.
  • Page 70 Section: Boiler operation Low pressure switch Low fire adjustment Mixing device Figure 42 Gas valve and fan components - EX 400, 500 Mixing device Gas high pressure switch Three- (3) wire Molex plug Inlet gas pressure test port (location of) Gas low pressure switch Low fire adjustment (zero-offset) High fire adjustment (on the side)
  • Page 71 6.3.2 Performing a fuel conversion Shutoff valve Figure 43 Gas valve and fan components - EX 700, 850 The High Fire (gas-air ratio) adjustment screw will have to be adjusted to attain optimum combustion results whenever fuel conversion is undertaken, however, no mixture adjustment shall be performed unless done by a qualified technician using properly functioning and calibrated combustion analyzing equipment.
  • Page 72 Section: Boiler operation Figure 44 Fuel pipe assembly 5. Carefully lift off the fuel pipe assembly. Figure 45 Removing the orifice 6. Remove the orifice. 7. Retain the two O-rings in the elbows for reassembly. 8. Install the kit-supplied orifice. 9.
  • Page 73 6.3.2 Performing a fuel conversion 6.3.2.2 Performing a fuel conversion on EX 700 and EX 850 appliances 1. Turn off the power and shut off the gas supply at the external gas shut-off valve. 2. Remove the front door and top cover from the boiler. 3.

  • Page 74: Measuring The Inlet Gas Pressure

    Section: Boiler operation 11. Tune the gas valve. For instructions, see Adjusting the gas valve (EX 700, EX 850) on page 12. Check for gas leaks. 6.3.3 Measuring the inlet gas pressure To locate the inlet gas pressure test port on the EX 400 and the EX 500 models, see Figure 42 To locate the inlet gas pressure test port on the EX 700 and the EX 850 models, see Figure 43...
  • Page 75 6.3.3 Measuring the inlet gas pressure 6.3.3.2 Measuring the inlet gas pressure - EX 700 and EX 850 To perform a gas pressure test, you will need to use the inlet gas pressure test fitting (supplied with the boiler to transition from ⅛" BSP to barbed for connection to a manometer), a 3 mm Allen wrench, and a digital manometer.

  • Page 76: Adjusting The Gas Valve (Ex 400, Ex 500)

    6.3.4 Adjusting the gas valve (EX 400, EX 500) Danger Making adjustments to the IBC gas valve without a properly calibrated gas combustion analyzer and by persons who are not trained and experienced in its use is forbidden. Failure to use an analyzer can result in an immediate hazard.
  • Page 77 6.3.4 Adjusting the gas valve (EX 400, EX 500) 3. Set the heat-out value in manual mode to the minimum MBH for the boiler. To do this: a. Go to Main Menu > Diagnostics > Test Operation. b. Click inside the Fan Test: Heat Output box, and using the number pad, enter the minimum MBH.

  • Page 78: Adjusting The Gas Valve (Ex 700, Ex 850)

    6.3.5 Adjusting the gas valve (EX 700, EX 850) Danger Making adjustments to the IBC gas valve without a properly calibrated gas combustion analyzer and by persons who are not trained and experienced in its use is forbidden. Failure to use an analyzer can result in an immediate hazard.

  • Page 79: Resetting The Gas High / Low Pressure Switches

    6.3.6 Resetting the gas high / low pressure switches Allen wrench. Keep the fitting with the boiler for future use. 11. Turn on the gas supply shut off valve and test for gas leaks. 6.3.6 Resetting the gas high / low pressure switches The gas high and low pressure switches are used to verify that the gas pressure is within the operating range (see images below).
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  • Page 81: Service And Maintenance

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

  • Page 82: Venting

    Section: Service and maintenance 7.1.1 Venting Maintenance Required for Venting Frequency Check □ Monthly Check and replace filter as needed. For replacement instructions, see Replacing the air filter on page 102 □ Annually Have your local heating contractor inspect the appliance annually. □...

  • Page 83: Heat Exchanger

    7.1.4 Heat exchanger Maintenance Required for Burner Frequency Check □ Annually If the burner is operating improperly, remove and clean or replace. Use a analyzer to determine proper combustion. See Combustion test target ranges - CO2 / Maximum CO on page 75 for correct values.

  • Page 84: Touchscreen Boiler Controller

    Section: Service and maintenance 7.1.7 Touchscreen boiler controller Maintenance Required for Boiler Controller Frequency Check □ Annually Check that boiler operation is consistent with the steps in the Touchscreen Boiler Controller Manual. □ Annually Check that water temperature targets and setpoint is satisfactory and have not been adversely amended.

  • Page 85: 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. 7.1.10 Boiler treatment...

  • Page 86: Relief Valve - Maintenance And Testing

    Section: Service and maintenance Caution Installers should inquire of local water purveyors as to the suitability of their supply for use in hydronic heating systems. If water quality is questionable, a local water treatment expert must be consulted for testing, assessment and, if required, treatment. Alternatively, water or hydronic fluid of known quality can be brought to the site.

  • Page 87: Replacing The Fan, Gas Valve, And Burner In Ex 400 And Ex 500 Models

    7.2 Replacing the fan, gas valve, and burner in EX 400 and EX 500 models 7.2 Replacing the fan, gas valve, and burner in EX 400 and EX 500 models This section documents the following maintenance procedures for EX 400 and EX 500 models: Replacing the fan Replacing the gas valve Replacing the burner.

  • Page 88: Replacing The Fan On The Ex 400 And Ex 500 Models

    Section: Service and maintenance Low fire adjustment Mixing device Figure 51 Gas valve and fan components - EX 400, 500 7.2.1 Replacing the fan on the EX 400 and EX 500 models 1. Turn off the electric power and gas supply to the boiler. 2.

  • Page 89: Replacing The Gas Valve In The Ex 400 And Ex 500 Models

    7.2.2 Replacing the gas valve in the EX 400 and EX 500 models Figure 53 Location of screws securing mixing device to fan 8. Use a 7mm wrench to remove the four screws at the base of the fan (attaching the fan to the heat exchanger lid).
  • Page 90 Section: Service and maintenance Figure 54 Connector wires 5. Gently remove the silicone air pressure tube from the gas valve by gripping near its base, and put aside. Figure 55 Silicone air pressure tube 6. From the inlet side of the gas valve (see ‰on Figure 51 ), remove the four (4) screws using a 4mm Allen key, and put aside.
  • Page 91 7.2.2 Replacing the gas valve in the EX 400 and EX 500 models 7. Remove the screws from the outlet side of the gas valve (see Šon Figure 51 ) to separate the gas valve from the appliance. To do this, ensure that you support the bottom of the gas valve when you remove the bottom two (2) screws (see Figure 57 ) and then the top two (2) screws.

  • Page 92: Replacing The Burner In The Ex 400 And 500 Models

    7.2.3 Replacing the burner in the EX 400 and 500 models 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 93 7.2.3 Replacing the burner in the EX 400 and 500 models Figure 58 Fan connectors 4. Remove the Nylok nuts from the air intake clamp and gasket assembly. Figure 59 Air intake clamp and gasket assembly 5. When loose, slide off the clamp and gasket assembly, and put aside with screws and Nylok nuts for reassembly.
  • Page 94 Section: Service and maintenance Figure 61 Removal of clamp and gasket assembly 7. Remove the silicone tube. Figure 62 Removal of silicone tube 8. Disconnect the electrical connectors (see on above image). 9. Remove the four (4) bolts from the right side of the gas valve. 10.
  • Page 95 7.2.3 Replacing the burner in the EX 400 and 500 models Figure 64 Removing mixer assembly, gas line and gas valve 12. Remove the air intake tube. Figure 65 Removing air intake tube 13. Disconnect the ignitor electrical cable and green grounding wire. 14.
  • Page 96 Section: Service and maintenance Figure 66 Lifting heat exchanger lid with burner on underside 19. Carefully remove the 6 M8 bolts securing the burner to the heat exchanger lid. Tip: to gain better access to the burner, carefully unscrew the ignitor from the lid and place in a safe place.
  • Page 97 7.2.3 Replacing the burner in the EX 400 and 500 models Figure 68 Example of cross-tightening of screws 3. Reinstall the lid and burner components. 4. Reinstall the fan gasket and fan. Replace gasket if necessary. 5. Reconnect the ignitor electrical cable and green grounding wire. 6.

  • Page 98: Replacing The Fan, Gas Valve, And Burner In Ex 750 And Ex 800 Models

    Section: Service and maintenance 16. Turn on the electric power and gas supply to the boiler. 17. Reset the low pressure switch. For instructions, see Resetting the gas high / low pressure switches on page 18. Tune the gas valve. For instructions, see Adjusting the gas valve (EX 400, EX 500) on page 7.3 Replacing the fan, gas valve, and burner in EX 750 and EX 800 models...

  • Page 99: Replacing The Fan On The Ex 700 And Ex 850 Models

    7.3.1 Replacing the fan on the EX 700 and EX 850 models Inlet gas pressure test port Low pressure switch Low fire adjustment (zero-offset) High fire adjustment (on the side) Manifold gas pressure test port Shutoff valve Figure 70 Gas valve and fan components - EX 700, 850 7.3.1 Replacing the fan on the EX 700 and EX 850 models 1.

  • Page 100: Replacing The Gas Valve In Ex 700 And Ex 850 Models

    Section: Service and maintenance 7.3.2 Replacing the gas valve in EX 700 and EX 850 models Four (4) bolts connecting gas valve and mixing device. Keep gasket and bolts for re- assembly. Location of high gas pressure switch. Gas valve inlet: Four (4) bolts of the flange. Keep gasket and bolts for re-assembly. Low gas pressure switch.
  • Page 101 7.3.2 Replacing the gas valve in EX 700 and EX 850 models 3. Remove the front cover, and then remove the boiler's top panel by removing the four Torx head screws on the top panel of the boiler. A ladder or step may be required to have a clear vertical view of the work area. Do not attempt to reach from the front without a clear view, as damage to connectors, screws or refractory may occur.

  • Page 102: Replacing The Burner In The Ex 700 And Ex 850 Models

    7.3.3 Replacing the burner in the EX 700 and EX 850 models 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 103 7.3.3 Replacing the burner in the EX 700 and EX 850 models 4. Remove the two screws of the bracket supporting the gas valve on the inlet side (see Figure 72 5. Remove the Phillips head screw (see Figure 72 ) from the power connector plug, and pull off the electrical connector from the gas valve.

  • Page 104: Replacing The Air Filter

    Section: Service and maintenance 7.4 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 appliance, use a MERV 8 filter sized at 10" x 10"...

  • Page 105: Cleaning A Condensate Trap

    7.5 Cleaning a condensate trap 7.5 Cleaning a condensate trap Condensate traps should be checked annually, 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.
  • Page 106 Section: Service and maintenance Fill the condensate trap to the top with Clean and flush out the debris in the water. condensate trap base. Reinsert the condensate trap through Rotate the elbow, and tighten the union the metal plate. nut, so that elbow and condensate trap are secured.

  • Page 107: Troubleshooting

    8.0 Troubleshooting Often, you can identify a problem and solve it through basic checks: confirming the electrical power supply, gas flow and resetting the thermostat control. For troubleshooting, we recommend that you use the three-step approach illustrated below. Note The boilers are equipped with a blocked vent shutoff system, which closes the gas supply upon detection of an irregular venting condition.

  • Page 108: Electronic Components

    Section: Troubleshooting 8.2 Electronic components This section details the method for troubleshooting the non-standard electronic components on the boiler. 8.2.1 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 109: Fan

    8.2.2 Fan Resist. Resist. Temp. °F/°C Temp. °F/°C Ω – Ohm Ω – Ohm 75 / 24 10,501 175 / 79 1,281 80 / 27 9,299 180 / 82 1,172 85 / 29 8,250 185 / 85 1,073 90 / 35 7,334 190 / 88 95 / 35...

  • Page 110: Gas Pressure Switches

    “Low/High Gas Pressure”. 8.2.6 Safety and Ignition Module (SIM) The SIM is a safety control used in the EX series of boilers. It is certified to conform to the UL 60730-5-5 and ANSI Z21.20-2014 • CAN/CSA-C22.2 No. 60730-2-5-14 standards.
  • Page 111 8.2.6 Safety and Ignition Module (SIM) 8.2.6.1 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 startup checks and resetting...
  • Page 112 Section: Troubleshooting 8.2.6.3 Resetting the boiler after a LWCO lockout Before you reset the boiler, ensure that the boiler is pressurized and that the air has been removed. 1. On the touchscreen controller, tap the Home screen. 2. On the Main Menu, tap the Diagnostics button. 3.

  • Page 113: Troubleshooting Error Messages

    8.3 Troubleshooting error messages The system clears the errors, and resets the boiler. Testing the Hi-Limit cutoff temperature function 1. On the touchscreen controller, tap the Home screen. 2. On the Main Menu, tap the Diagnostics button. 3. Tap the SIM Module button. 4.

  • Page 114: Maximum Ignition Trials Error

    Section: Troubleshooting The text inside the bar will indicate the specific warning or alarm. If there is more than one alarm present the text will scroll slowly through all current alarm conditions. Besides the errors listed below, see also Miscellaneous touchscreen controller errors on page 114.

  • Page 115: Hi/Low Gas Pressure Switch Error

    8.3.3 Hi/Low gas pressure switch error 8.3.3 Hi/Low gas pressure switch error High/Low Gas Press Error Issue Diagnosis Error – High/Low Gas Press Inlet gas pressure has Measure the inlet gas risen above 15" w.c. or pressure. Then reset the has fallen below 3.5"...

  • Page 116: Miscellaneous Touchscreen Controller Errors

    Section: Troubleshooting 8.4 Miscellaneous touchscreen controller errors Miscellaneous errors Issue Diagnosis The sensor plug is not Check the P501 plug is fully engaged “ Loop/Indoor Sensor” engaged. in the back of the controller board. “Insufficient Air Flow” “Insufficient Water Pressure” “Unknown Error” The sensor plug is not Check the P501 plug is fully engaged engaged.

  • Page 117: Ignition Issues

    8.4.1 Ignition issues 8.4.1 Ignition issues Ignition issues Issue Diagnosis Noisy spark when igniting Ignition lead is not firmly Reconnect ignition lead. connected. Contaminants/moisture on Ensure probe is dry by re-running igniter probe/flame sensor. post-purge; otherwise, clean or replace igniter probe. Boiler rumbles when Fluctuating gas pressure/ Check CO...

  • Page 118: Temperature Issues

    Section: Troubleshooting 8.4.2 Temperature issues Temperature issues Issue Diagnosis Low heat Operating temperature too Increase temperature target. low. Increase temperature target. Priority parameters or load Review load configuration parameters. configuration improperly set appliance undersized. Refer to Load Calculation vs. Boiler Output.

  • Page 119: 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 High Limit / Boiler is in 1 hour safety Reset safety device and cycle boiler Low Water Cutoff won’t...

  • Page 120: Cycling Issues

    Section: Troubleshooting 8.4.4 Cycling issues Cycling issues Issue Diagnosis Rapid Improper values entered via Check load maximum temps are above target Cycling keypad. temps, by ½ of the selected boiler differential. Ensure boiler differential is OK (16 - 30 °F is generally adequate) Excess condensate in venting.
  • Page 121 Appendices Appendices Wiring diagrams Figure 73 Controller electrical diagram...
  • Page 122 Section: Appendices Figure 74 Internal wiring diagram - EX 400 and EX 500 models...
  • Page 123 Wiring diagrams Figure 75 Internal wiring diagram - EX 700 and EX 850 models...
  • Page 124 Section: Appendices Figure 76 Sequence of Operation...
  • Page 125 Installation & Commissioning Report 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.
  • Page 126 Intentionally left empty...
  • Page 127 Section: Boiler parts diagram - EX 400 and EX 500 Boiler parts diagram - EX 400 and EX 500 Item Replacement Kit Description Part Number Number Numbers Door 500-134 P-1209 Controller 500-044 P-242 Safety Ignition Module 500-105 P-270B Top panel 251-030 P-1227 Controller module chassis...
  • Page 128 Boiler parts diagram - EX 400 and EX 500...
  • Page 129 Section: Boiler parts diagram - EX 400 and EX 500 Item Number Description Part Number Replacement Kit Number 240-113 P-311 Fuel mixer 180-164 P-1235 NG EX 400 180-163 P-1236 LP EX 400 180-252 P-1237 NG EX 500 180-253 P-1238 LP EX 500 251-112 P-1235 Fuel orifice NG...
  • Page 130 Boiler parts diagram - EX 400 and EX 500 Item Number Description Part Number Replacement Kit Number Manual air vent 180-258 P-1219 Sight glass kit 500-117 P-107A Ignitor 240-153 P-1213 Ignitor cable 200-154 P-358 Item Replacement Part Description Part Number Number Number Low water cut-off probe...
  • Page 131 Section: Boiler parts diagram - EX 400 and EX 500 Boiler parts diagram - EX 700 and EX 850 Item Replacement Kit Description Part Number Number Numbers Door 500-134 P-1209 Controller 500-044 P-242 Safety Ignition Module 500-105 P-270B Top panel 251-030 P-1227 Controller module chassis...
  • Page 132 Boiler parts diagram - EX 700 and EX 850...
  • Page 133 Section: Boiler parts diagram - EX 400 and EX 500 Item Number Description Part Number Replacement Kit Number 240-156 P-1212 Fan gasket 255-126 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...
  • Page 134 Boiler parts diagram - EX 700 and EX 850 Item Number Description Part Number Replacement Kit Number (not shown) Item Replacement Part Description Part Number 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...
  • Page 135 Revision history R0 (October 2019) Initial release R1 (December 2019) Updated figure 36, and added new sections on measuring the inlet gas pressure and resetting the gas high/low pressure switches. R2 (February 2020) Introduction of the new EX 400 and EX 500 models. R3 (December 2020) Added fuel conversion instructions.
  • Page 136 856-735-5584 Toll Free: 1-844-HEAT-IBC/ 1-844-432-8422 www.ibcboiler.com Information in this document is subject to change without notice. IBC assumes no responsibility for changes made to the manual due to clerical errors, to regulation changes, or to product development. March, 2021 120-327E-R3 ©...

This manual is also suitable for:

Ex 400Ex 500Ex 700Ex 850

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