IBC EBX Series Installation And Operation Manual
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IBC EBX Series Installation And Operation Manual

Residential electric boiler
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INSTALLATION &
OPERATING MANUAL
Risk of electric shock. If the information in this manual is not followed exactly, a fire or
electrocution 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.
Residential Electric Boiler
EBX4K-240 (model #IBEXSW1-004K)
EBX8K-240 (model #IBEXSW1-008K)
EBX10K-240 (model #IBEXSW1-010K)
EBX12K-240 (model #IBEXSW1-012K)
WARNING

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  • Page 1 INSTALLATION & OPERATING MANUAL Residential Electric Boiler EBX4K-240 (model #IBEXSW1-004K) EBX8K-240 (model #IBEXSW1-008K) EBX10K-240 (model #IBEXSW1-010K) EBX12K-240 (model #IBEXSW1-012K) WARNING Risk of electric shock. If the information in this manual is not followed exactly, a fire or electrocution 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 Water quality Warning Water quality has a significant impact on the lifetime and performance of a boiler's heat exchanger. Improperly prepared water in a heating circuit may cause damage to the heat exchanger through fouling or corrosion. Repeated or uncontrolled water fills will increase the potential for damage.

  • Page 3: 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 4: Known Contaminants

    Section: Safety information Warning Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, or loss of life. Read and understand the entire manual before attempting installation, start-up, operation, or service. Installation and service must be performed only by an experienced, skilled installer or service agency. Failure to follow all instructions in the proper order can cause personal injury or death.

  • Page 5: Table Of Contents

    Contents Safety information Manual safety markings Important safety instructions Known contaminants Specifications Cabinet dimensions EBX-series dimensions Connection specifications 4.0 Introduction 4.1 Standard features and benefits 4.2 Warranty 4.3 Internal view 5.0 Before installation 6.0 Installation 6.1 Code requirements 6.2 Removing an existing gas boiler 6.3 Determining the location of the boiler 6.4 Mounting the boiler 6.5 Installation clearances...
  • Page 6 Section: Contents 7.0 About the boiler controller 7.1 Controller 7.2 Control interface 7.2.1 Heat Types 8.0 Before operating the boiler Checklist for electrical conditions and water connections 9.0 Boiler operation 9.1 Starting and shutting down the boiler 10.0 Service and maintenance 10.1 Maintenance checklist for homeowner 10.2 Replacing the elements 10.3 Replacing the pump...

  • Page 7: Specifications

    Specifications Boiler Specification EBX4K-240 EBX8K-240 EBX10K-240 EBX12K-240 Power @ 240V 1.3 - 13.7 MBH 2.7 - 27.3 MBH 3.4- 34.1 MBH 4.1 - 41.0 MBH 0.4 - 4.0 kW 0.8 - 8 kW 1.0 - 10.0 kW 1.2 - 12.0 kW Power @ 208V 1.0 - 10.2 MBH 2.1 - 20.5 MBH...

  • Page 8: Connection Specifications

    Section: Specifications Figure 1 Frontal view - EBX-series Boiler Figure 2 Side view - EBX-series Boiler Figure 3 Top view - EBX-series Boiler Figure 4 Bottom view - EBX-series Boiler Connection specifications The following table displays the required connection specifications.
  • Page 9 Connection specifications Description EBX-series Boiler Supply water outlet 3/4" NPT-M Return water inlet 3/4" NPT-M Supply power knock-out Dual 3/4" and 1" Control wiring knock-out 1/2" Table 1 Connections...
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  • Page 11 Connection specifications...
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  • Page 13: Introduction

    Flow-proving and high limit safeties built in 4.2 Warranty For residential applications, IBC offers a 1-year warranty on the pump and the elements. All other parts carry a 5-year warranty against defects in materials or workmanship and failures due to thermal shock.

  • Page 14: Internal View

    Section: Introduction 4.3 Internal view...
  • Page 15 4.3 Internal view Incoming power wiring connections Heating element (1 of 2) Display screen / controller Control wiring terminals Return piping connection 3/4" NPT Flow sensor / inlet temperature sensor assembly Solid-state relay (modulation control block): see below for alternate 3-speed pump Drain port High temperature limit switch (manual reset)
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  • Page 17: Before Installation

    5.0 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 output 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.
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  • Page 19: Installation

    6.0 Installation Refer to the Specifications section for dimensional drawings and connection specifications. Use these drawings to find a suitable location for the appliance. 6.1 Code requirements The appliances are tested and certified under CSA22.2 No.165-17 and/or UL834 (5th edition). Below are the code requirements for every installation.

  • Page 20: Determining The Location Of The Boiler

    Section: Installation After determining that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition. Any improper operation of the common venting system should be corrected, so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 - latest edition.
  • Page 21 6.4 Mounting the boiler Attach the support bracket to the wall studs Hook the boiler tab (located on using two ¼" x 2½" long lag screws with back of boiler) over the support flat washers. bracket flange. Ensure that the boiler tab is flush against the mounting bracket flange.

  • Page 22: Installation Clearances

    The appliance must not be exposed to surrounding air above 122°F (50°C) or below 32°F (0°C). 6.7 Water Piping IBC recommends using unions on the inlet and outlet water connections. Unions simplify many service procedures, notably the cleaning of the inlet water strainer. See Installation on page 19below for other piping recommendations.
  • Page 23 6.7 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.

  • Page 24: Boiler Pump

    Section: Installation 6.8 Boiler Pump The factory-installed boiler pump can overcome the system head resistances listed below, according to the selected speed: Table 4 EBX-series pump available head, 3 speeds (water) The installed pump is rated for the designed water temperature range; some pumps have a minimum water temperature rating above the low temperature potential of the boiler.

  • Page 25: Propylene Glycol Usage

    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. Propylene glycol solution is commonly used in a closed loop where freeze protection is required. Its density is lower than that of water, resulting in lower thermal performance at a given flow and pressure.

  • Page 26: Relief Valve

    Section: Installation 6.10 Relief Valve Ensure that the pressure relief valve is installed with no valves or other means of isolation between its inlet and the boiler. Make sure the relief valve outlet is piped with unobstructed piping (minmum 3/4" diameter) to a safe discharge location.

  • Page 27: General Piping Best Practices

    The piping drawings in this manual are simple schematic guides to a successful installation. For further information and details, consult our concept drawings – which provide details on specific single and multiple boiler applications (available in IBC's Technical portal). There are many necessary components not shown, and details such as thermal traps are left out so the drawings have greater clarity.
  • Page 28 Section: Installation Pressure relief valve (shipped with the boiler): no isolation valve permitted between boiler and relief valve Water pressure gauge Microbubble air eliminators are best installed where the fluid is at the highest temperature and lowest pressure, on boiler outlet at expansion tank connection. Expansion tank connection (point of no pressure change);...
  • Page 29 6.11 General piping best practices Fluid fill is most often accomplished by using a boiler regulator and fill valve set at 12 psig or higher, with the backflow prevention device required by local code. This is acceptable in areas where municipal water or well water has been treated and filtered to remove excessive minerals and sediment, and water chemistry is known to be suitable for closed loop hydronic systems.
  • Page 30 Section: Installation Closely-spaced tees: Install tees a maximum of four pipe diameters apart with no restrictions between fittings, and with a minimum of eight pipe diameters of straight piping upstream of the first tee and a minimum of four pipe diameters of straight piping downstream of the second tee.
  • Page 31 6.11 General piping best practices Figure 9 Primary-secondary piping with simultaneous heating calls 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.
  • Page 32 Section: Installation Air handler with low head loss coil Pressure relief valve—no isolation valve between relief and boiler Pump integral to boiler must be verified capable of overcoming combined pressure drops of boiler, system piping, and air handler coil Dirt separator recommended where water quality is unknown Figure 10 One load direct piping concept...
  • Page 33 6.11 General piping best practices Heat Pump boiler (shown without integral pump) Relief valve Check valves Generously sized buffer tank connections hydraulically separate heat pump from loads Supply manifold Return manifold Figure 11 Heat pump boiler and backup EBX serving heat loads through a buffer tank...
  • Page 34 Section: Installation Pressure relief valve (shipped with boiler): no isolation valve permitted between boiler and relief valve Hydraulic separator Recommended expansion tank connection point Fill station with isolation valve closed, or fill tank Supply piping to loads Returns to loads Figure 12 Primary-Secondary multiboiler piping concept with hydraulic separator...
  • Page 35 6.11 General piping best practices Heat Pump boiler; system fluid circulates outdoors so typically requires glycol treatment. Electric boilers staged to supplement heat pump below system balance point. Check Valves Closely-spaced tees are a maximum of four pipe diameters apart, with a minimum of eight pipe diameters of straight piping upstream of the first tee and a minimum of four pipe diameters of straight piping downstream of the second tee.

  • Page 36: Electrical Connections

    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) may be required in areas where power quality is suspect.

  • Page 37: Boiler Pump

    6.12.3 Boiler pump Figure 14 Line voltage load pump terminals The Neutral connection is necessary for 120V operation of the boiler pump. 6.12.3 Boiler pump The boiler pump is factory installed and wired. It has three speeds to choose from. The installer may adjust the speed setting to best match the system requirements.

  • Page 38: Other Wiring

    Contacts for outdoor temperature sensor associated with reset heating at CN6 terminals 5 & 6. A 10K ohm sensor for outdoor reset feature is sold separately as IBC part P-9067. Thermostat, or zone valve endswitches parallel-wired (three shown) RS485 connection for MODBus control: see ibcboiler.com for more details...
  • Page 39 6.12.6 Load pump wiring The EBX-series does not control load pumps. IBC recommends for load pump control either its Sky 35 controller, a third-party pump module , or field-wiring a double-pole relay, as shown here: Thermostat 24V Transformer Space-heating pump...
  • Page 40 Section: Installation Thermostats Zone valves (four-wire type shown; 3-wire also applicable here) 40VA Transformer; typically adequate for up to four zone valves Space-heating pump 24V double pole relay: can be DPDT (shown) or DPST Call for heat to boiler CN2 terminals 1 and 2 Figure 17 Load pump relay field-wiring with zone valves Alternatively, using a pressure-activated load pump may make pump control unnecessary.

  • Page 41: About The Boiler Controller

    7.0 About the boiler controller Note Use a finger to interact with the controller buttons. The controller provides: Home Page display of the Target, Outlet and Inlet temperatures Status Page displaying Output power (in %) Set-Point temperature regulation Easy-to-set Outdoor Reset control Heat Enable from Thermostat Error Message Reporting Warning Message Reporting...

  • Page 42: Control Interface

    Section: About the boiler controller Figure 18 Controller screen and navigation buttons 7.2 Control interface The control interface is provided through four navigation buttons which respond to a light finger touch, and a display screen. Prior to any interaction with the control, the Home Page shows the current boiler status. The control has three levels: 1.

  • Page 43: Heat Types

    7.2.1 Heat Types Summer Shutdown range: 50°F to 104°F (10°C to 40°C) default: 65°F (18.3°C) Status is ON in ODR mode Post-Purge Time: pump will run set number of seconds after a call 3. Status Menu Outlet [Temperature] Inlet [Temperature] Outdoor [Temperature] Power % (current output) Faults and Warnings:  press Enter for code with plain language description.
  • Page 44 Outdoor Design Temperatures to show how the target temperature tracks building heat loss over a heating season. For ODR mode, an outdoor sensor is necessary (IBC part P-9067 sold separately). The sensor must be mounted on the North face of the building , unaffected by heat sources, and above the...
  • Page 45 7.2.1 Heat Types 7.2.1.3 Sample ODR Temperatures:  Imperial units Figure 21 Outdoor reset lines for sample Outdoor Design Temperatures and Setpoints in Imperial units 100°F- 180°F...
  • Page 46 Section: About the boiler controller 7.2.1.4 Sample ODR Temperatures:  Metric units Figure 22 Outdoor reset lines for sample Outdoor Design Temperatures and Setpoints in Metric units 40°F- 80°C...

  • Page 47: Before Operating The Boiler

    8.0 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.
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  • Page 49: Boiler Operation

    9.0 Boiler operation Before operating the appliance, there are some important checks that need to be performed. For more information, see Before operating the boiler on page 9.1 Starting and shutting down the boiler Start-up Checklist Check □ With the boiler power turned off, check that all electrical connections are tight. □...
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  • Page 51: Service And Maintenance

    10.0 Service and maintenance Inspection of the boiler is to be performed annually by a qualified service technician. Caution The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition. 10.1 Maintenance checklist for homeowner Maintenance Required Frequency...

  • Page 52: Replacing The Elements

    Section: Service and maintenance 10.2 Replacing the elements Heating elements come in sizes 2kW for the EBX4K-240, 4kW for the EBX8K-240, 5kW for the EBX10K-240, and 6kW for the EBX12K-240. The elements can be replaced only by models of identical wattage. Figure 23 Element hex heads Figure 24...

  • Page 53: Replacing The Pump

    10.3 Replacing the pump 10.3 Replacing the pump Figure 25 Remove bracket screws Figure 26 Undo pump unions Figure 27 Pull pump forward to disconnect wiring. Figure 28 Remove bolts holding pump to bracket. Re-use bracket. 1. Power off boiler and open cabinet door. 2.
  • Page 54 Section: Service and maintenance 4. Undo the two union nuts on the pump volute. 5. Slide the pump on its bracket forward enough to access the wiring box: prevent the pump from falling forward and pulling on its wiring harness. 6.

  • Page 55: Troubleshooting

    11.0 Troubleshooting This section includes various conditions as well as possible solutions. Often, a problem can be identified and solved through basic checks: confirming the electrical power supply and resetting the thermostat control. Below are some common troubleshooting issues including fixes. 1.
  • Page 56 Section: Troubleshooting Resist. Resist. Temp. °F/°C Temp. °F/°C Ω – Ohm Ω – Ohm 0 / -18 85,362 100 / 38 5,828 5 / -15 72,918 105 / 41 5,210 10 / -12 62,465 110 / 43 4,665 15 / -9 53,658 115 / 46 4,184...

  • Page 57: Troubleshooting Error Messages

    11.2 Troubleshooting error messages 11.2 Troubleshooting error messages ERROR MESSAGES Error Comment Over temperature limit Outlet Temperature ≥ 200°F (88°C); auto reset at 190°F (82°C) No flow Flow of 0 gpm for 1 min after pump is started Temp Sensor Inlet Inlet Negative Temperature Coefficient (NTC) sensor is open or closed Temp Sensor Outlet...

  • Page 58: Temperature Issues

    Section: Troubleshooting 11.2.1 Temperature issues Temperature issues Issue Diagnosis Low heat Operating temperature Increase temperature target. too low. Load configuration Review load configuration parameters. improperly set up. Boiler undersized. Refer to Load Calculation vs. Boiler Output. Air trapped within Bleed system as required. system.

  • Page 59: Miscellaneous Issues

    11.2.2 Miscellaneous issues 11.2.2 Miscellaneous issues Miscellaneous issues Issue Diagnosis ‘Ghost’ call Triac or ‘Power- Remove CN2 connections from boiler to confirm that stray for heat. robbing’ thermostat voltage, or current induced in thermostat wiring, is source sending current to of nuisance signal.
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  • Page 61: Appendices

    Appendices Wiring diagrams Figure 29 EBX-series Boilerinternal wiring diagram...
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  • Page 64: Boiler Parts Diagram - Ebx-Series Boiler

    Section: Boiler parts diagram - EBX-series Boiler Boiler parts diagram - EBX-series Boiler P-kit Item ID Description replacement Quantity Power / Pump Relay Board P-1700 Digital Controller Screen / Terminal Assembly P-1701 Inlet Water Pipe with Flow Sensor Assembly P-1702 P-1703 Water Temperature Sensor Inlet Pipe / plate assembly...
  • Page 65 Boiler parts diagram - EBX-series Boiler P-kit Item ID Description replacement Quantity Drain Pipe Assembly P-1709 Outlet Pipe Assembly P-1710 Manual Reset High Limit Switch P-1711 Heat Exchanger P-1712 Heat Exchanger Bracket P-1713 EBX 240V Transformer P-1714 Input Power Terminal Strip P-1715 Heating Elements 2kW (EBX4K-240)

  • Page 66: Installation & Commissioning Report

    Section: Boiler parts diagram - EBX-series Boiler Installation & Commissioning Report Model Number _____________________ Serial Number _______________________________ Date of Installation ________ Address of installation ___________________________________ User contact information _________________________________________________________ Installer Information (Company & Address)___________________________________________ Phone/Fax/E-mail ______________________________________________________________ □ Circuit Breaker # ____ Labeled? Power supply wire gauge _____ □...
  • Page 67 This boiler is not used for any space heating. This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. This boiler is equipped with a tankless coil (not applicable to these boilers). US installers should contact IBC for any further information required.
  • Page 68 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. December 08, 2022 120-440E1 ©...

This manual is also suitable for:

Ebx4k-240Ebx8k-240Ebx10k-240Ebx12k-240Ibexsw1-004kIbexsw1-008k ... Show all

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