IBC Boilers EX 700, EX 850 Installation And Operating Manual

Installation and

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.

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.

Operating Manual

EX SERIES

Commercial Boilers

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.

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. The amount of solids that may form on the heat exchanger will depend on the degree of hardness and the total water volume in the system. A high water volume system with a low hardness count may cause as much damage as a system with less volume and higher hardness, so it is recommended to treat water so as to remove all dissolved solids. Other water chemistry allowable limits are as follows:

Acidity pH is to be between 6.6 and 8.5

Chloride is to be less than 125 mg/l

Iron is to be less than 0.3 mg/l

Cu less than 0.1 mg/l

Conductivity is to be less than 400μS/cm (at 77°F [25°C])

Hardness is to be 7 grains per gallon or less / 120 ppm or less

Important: Ensure that these limits are acceptable for the other water-side components in the system.

Shipped with the boiler:

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

Contents

Safety information 5

Manual safety markings 5

Important safety instructions 5

Known contaminants 6

Specifications 7

Connection specifications 8

Cabinet dimensions 9

1.0 Introduction 11

1.1 Standard features and benefits 12

1.2 Warranty 12

2.0 Before installation 13

3.0 Installation 15

3.1 Code requirements 15

3.2 Determining location of the unit 15

3.2.1 Factors to consider for best installation conditions 16

3.3 Unpacking a boiler 17

3.4 Installation clearances 18

3.5 Exhaust venting and air intake venting 18

3.5.1 Code 19

3.5.2 Applications 21

3.5.3 Exhaust vent material 21

3.5.4 Vent travel 22

3.5.5 Venting passage through ceiling and floor 24

3.5.6 Rooftop vent termination 25

3.5.7 Sidewall vent termination 27

3.5.8 Direct vent combustion air intake piping 32

3.5.9 Indoor air combustion air intake 35

3.5.10 Combustion air filtration system 36

3.6 Installing a condensate trap 37

3.7 Installing a condensate neutralizer 39

3.8 Water Piping 41

3.8.1 General piping best practices 43

3.8.2 System piping 44

3.9 Gas piping 54

3.9.1 Gas pressure 54

3.10 Electrical connections 55

3.10.1 Power quality and electrical protection 55

3.10.2 120VAC line-voltage hook-up 56

3.10.3 Other wiring 59

3.10.4 Thermostat / sensor wiring 59

3.10.5 Thermostat heat anticipator 60

4.0 About the boiler controller 61

4.1 Controller 61

4.2 Control interface 62

5.0 Before operating the boiler 63

5.1 Important pre-ignition checks 63

5.1.1 Checklist for electrical conditions, ducting and water connections 63

6.0 Service and maintenance 65

6.1 Maintenance checklists for manager of unit 65

6.2 Maintenance checklists for heating contractor 65

6.2.1 Venting 66

6.2.2 Condensate trap 66

6.2.3 Burner 66

6.2.4 Heat exchanger 67

6.2.5 Pump 67

6.2.6 Gas piping 67

6.2.7 Touchscreen boiler controller 67

6.2.8 Water 68

6.2.9 Freeze protection 69

Section: Contents

6.2.10 Boiler treatment 69

6.2.11 Relief valve - maintenance and testing 69

6.3 Replacing the fan, gas valve, and burner 70

6.3.1 Replacing the fan 71

6.3.2 Replacing the gas valve 72

6.3.3 Replacing the burner 74

6.4 Replacing the air filter 76

6.5 Cleaning a condensate trap 77

7.0 Troubleshooting 79

7.1 Preliminary checks 79

7.2 Electronic components 80

7.2.1 Temperature sensors 80

7.2.2 Fan 81

7.2.3 Air pressure sensor 81

7.2.4 Water pressure sensor 81

7.2.5 Gas pressure switches 82

7.2.6 Safety and Ignition Module (SIM) 82

7.3 Troubleshooting error messages 85

7.3.1 Touchscreen error messages 85

7.3.2 Maximum ignition trials error 86

7.3.3 Hi/Low gas pressure switch error 87

7.3.4 Hi Limit cut-off temperature error 87

7.3.5 Low Water Cut-off error 87

7.3.6 Aux. Interlock 1 or 2 88

7.4 Miscellaneous touchscreen controller errors 88

7.4.1 Ignition issues 89

7.4.2 Temperature issues 90

7.4.3 Miscellaneous issues 91

7.4.4 Cycling issues 92

Appendices 93

Wiring diagrams 93

Installation & Commissioning Report 96

Boiler parts diagram 97

Revision history 101

Section: Contents

Safety information

Danger

Points out an immediate hazardous

situation that must be avoided to

prevent serious injury or death.

Warning

Points out a potential hazardous situation that must be avoided to prevent serious injury or death.

Caution

Points out a potential hazardous situation that must be avoided to prevent possible moderate injury and/or property damage.

Note

Points out installation, maintenance and operational notes to enhance efficiency, longevity and proper operation of 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. Immediately, call the gas supplier from a phone

located remotely. Follow the gas supplier’s instructions, or if the supplier is unavailable, contact

the fire department.

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. Read all instructions, including all those contained in component manufacturers’ manuals before installing, starting up, operating, maintaining, or servicing the unit.

Manual safety markings

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. Keep instructions near the air handling unit for future reference.

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.

Known contaminants

Known Corrosive Contaminants to Avoid

Cements and glues

Paint or varnish removers

Adhesives used to fasten building products and other similar products

Chlorinated waxes or cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for snow and ice clearing

Sodium chloride or potassium chloride used for water softening

Refrigerant leaks from cracks in coils

Hydrochloric acid or muriatic acid used in household cleaning and stain removal

Chemicals in perming solutions

Chlorofluorocarbon chemicals found in spray cans

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Antistatic dryer sheets in clothes dryers

Section: Safety information

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 679 824.5

CSA Output - kW 199 241.6

Thermal Efficiency 97% 97%

Minimum gas supply pressure (Natural Gas or Propane) - inch w.c. 4 4

Maximum gas supply pressure (Natural Gas or Propane) - inch w.c. 14 14

Ambient temperature:

Low °F / °C

High °F / °C

32 / 0

122 / 50

32 / 0

122 / 50

Max. relative humidity (non-condensing) 90% 90%

Minimum water temp. °F / °C 34 / 1 34 / 1

Maximum water temp. (electronic hi-limit) °F / °C 190 / 88 190 / 88

Max. ΔT - supply/return (electronic fence) °F / °C 80 / 44 80 / 44

Max. Water Temperature Lockout Limit °F / °C 201 / 94 201 / 94

Power use (120Vac/60Hz) @ full fire - Watts (less pumps) 195 228

Weight (empty) - lbs/Kg Approx. 440 /

200

Approx. 520 /

236

Heating Surface Area - ft2/ m

84.6 / 7.86 99.88 / 9.28

Pressure vessel water content - USG/Liters 17.5 / 66.2 17.5 / 66.2

Maximum boiler flow rate - USgpm 100 100

Minimum boiler flow rate - USgpm 18 21

Maximum operating water pressure* - psig 160 160

Minimum water pressure - psig 8 8

Relief valve pressure (supplied) - psig* 50 50

Approved installation altitude - ASL 0 - 12,000' 0-12,000'

EX 700 EX 850

Maximum equivalent vent length Each side (Vent & Air Intake)) (Natural Gas or Propane)

Air intake options: either direct vent or indoor supply

120' 120'

*These alternative relief valves can be purchased: 30, 100, 125 and 150.

Flue Outlet 6" Schedule 40

Combustion Air Inlet 4" Schedule 40

Water Outlet 2½" NPT-M

Water Inlet 2½" NPT-M

Knock-outs (8) ½"

Gas Inlet 1" NPT-F

Condensate Outlet ¾" Hose

Section: Specifications

Table 1 Specifications

Connection specifications

The following table displays the required connection specifications for each model.

Table 2 Connections

Cabinet dimensions

Figure 1 Frontal view Figure 2 Top view

Figure 3 Back view

Cabinet dimensions

Section: Specifications

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

1.1 Standard features and benefits

Section: Introduction

High thermal efficiency

Built-in BACnet option

Turn-down ratio 10 to 1

Built-in 4-zone pump control

Multiple boilers: Up to 24 boilers can be connected without external controls

Maximum allowable ∆T=80 °F (44 °C)

50 psi relief valve (345 kPa)

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.

For more information and to obtain the EX series warranty form, go to ibcboiler.com.

2.0 Before installation

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.

□

Ensure you install the boiler where the combustion air source is not subject to chemical fouling or agricultural vapors.

Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a boiler. Cleaners, bleaches, air fresheners, refrigerants, aerosol propellants, drycleaning fluids, de-greasers and paint-removers all contain vapors that can form corrosive acid compounds when burned in a gas flame. Airborne chlorides such as those released with the use of laundry detergents are also to be avoided.

□

Locate the boiler where water leakage will not result in damage to the area.

If there is no suitable location, install a suitable drain pan under the boiler. Do not install above carpeting.

□

At a new construction site, or during renovations, protect the boiler from drywall dust or other construction related contaminants.

Draw combustion air from a clean source (e.g., outdoors) and isolate the boiler from interior dust sources. Do not seal boiler case openings directly when firing - allow for air circulation and ventilation in the immediate area.

□

Place the exhaust outlet 12" minimum above the down-turned intake to avoid exhaust re-ingestion.

□

For sidewall venting options, place the inlet and exhaust terminations on the same side of the building.

The elevation of both pipes can be raised in “periscope style” after passing through the wall to gain required clearance above grade and snow level.

□

If using the indoor combustion air option, ensure combustion air openings to the boiler room

remain unblocked and free of obstructions.

□

Examine the condensate outlet to ensure proper disposal of condensate will occur during

operation. If condensates are to be discharged into building drain piping materials that are subject

to corrosion, a neutralization package must be used.

□

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 (minimum 1" diameter) to a safe

□

Before installing the unit, it is important to review and observe the following checklist of precautions:

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.

□

When the boiler is in operation, assess the impact of the steam plume normally at the exhaust terminal of a condensing boiler.

Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location. Boiler condensate is corrosive. Protective measures must be taken to prevent corrosion damage to metal roofs or other metal building components in contact with the condensate. Keep exhaust plumes well away from all building air intakes including those of neighboring properties.

□

Caution

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.

Section: Before 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. Below are the code requirements for every installation.

Canada US

Conform to local codes, or in the absence of these, with the latest editions of CAN/CGA B149.1 and the Canadian Electrical Code Part 1 CSA C22.2 No. 1.

Where required by jurisdiction, installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

If there is any conflict, follow the more stringent regulations.

Table 3 Code requirements by country

Conform to the current National Fuel Gas Code ANSI Z223.1 and the National Electrical Code ANSI/NFPA

70.

Where required by jurisdiction, installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

If there is any conflict, follow the more stringent regulations.

3.2 Determining location of the unit

The boilers are designed and approved for indoor installation in areas such as an alcove, basement, or utility room. These areas should have a surrounding temperature of 32 °F (0°C) to 122 °F (50 °C) and less than 90% relative humidity.

Even though EX models are approved from installation on combustible floors, do not install them on carpet.

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.

Protect the gas ignition system components from water (dripping, spraying, rain, etc.)

during appliance operation and when servicing (pump replacement, condensate trap

servicing, control replacement, etc.).

Ensure that combustible materials do not make contact with exposed water piping

and associated components (relief valves, circulators, etc.). Check local codes for

required clearances and/or provide adequate insulation.

3.2.1 Factors to consider for best installation conditions

Section: Installation

Install the boiler in areas where the combustion air source is not subject to chemical fouling or

agricultural vapors. Exposure to corrosive chemical fumes such as chlorinated and/or

fluorinated hydrocarbons can reduce the life of a boiler. See list of Known contaminants on page

6. For this reason, do not use the indoor air venting option (using air surrounding the boiler) in a

laundry room. Similarly, ensure any direct vent air source is not near a clothes dryer exhaust

terminal. Avoid agricultural applications where the boiler and/or the intake air source are

affected by ammonia and/or dust.

Avoid installing a boiler where water leakage will cause damage; for example, above carpeting.

If unavoidable, install a suitable drain pan under the appliance.

Other factors to consider:

The minimum clearance requirements for combustible materials (see Table 4 ).

For adequate servicing, we recommend a minimum 30" clearance at the front and 12" above the

boiler. Check local codes for additional access and service clearance requirements.

At a new construction site, or during renovations:

Take action to protect the boiler from drywall dust or other construction related

contaminants

Ensure combustion air is drawn from a clean source (e.g., outdoors)

Isolate the boiler from interior dust sources. Do not seal boiler case openings directly when

firing - allow for air circulation and ventilation in the immediate area.

3.2.1.1 Anchoring the boiler

3.3 Unpacking a 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" Hex head bolts. Once the anchor brackets are removed they can be used to secure the boiler to the floor.

Figure 6 Boiler packaging dimensions (inches)

3.4 Installation clearances

Warning

Exposed water piping and associated components (relief valves, circulators, etc., should not

be in contact with combustible materials. Check local codes for required clearances and / or

provide adequate insulation.

EX 700, 850

Surface

Minimum distance from

combustible surfaces

Recommended clearance for

installation and service

Front 2" 30"

Rear flue connection 2" 24"

Left side 1" 2"

Right side 1" 4"

Top 6"

12"

(required for filter replacement)

Bottom 0 0

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.

Inspect finished vent and air piping thoroughly to ensure all are airtight, and comply with the instructions provided as well as with the requirements of applicable codes. Failure to comply will result in severe personal injury or death.

Section: Installation

Table 4 Clearance distances for boiler mounting sites

3.5 Exhaust venting and air intake venting

When planning a boiler's installation, consider the appropriate vent materials, travel and termination.

An important consideration is managing the impact of the steam plume normally at the exhaust terminal of a

Danger

Do not common vent EX series modulating boilers with any other existing or new appliance.

3.5.1 Code

condensing boiler. Generally, intake and exhaust pipes should terminate at a rooftop or sterile wall location to maximize customer satisfaction. Keep exhaust plumes well away from all building air intakes including those of neighboring properties.

Flue gas exhaust to outdoors

Figure 7 Flue gas venting

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. In the USA, the National Fuel Gas Code, ANSI 223.1, latest edition, prevails. Where there is a discrepancy between the installation instructions provided, and the code requirements, apply the more stringent.

Provisions for the combustion and air ventilation must be in accordance with the section “Air for Combustion and Ventilation” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Clause 8.2, 8.3 or

8.4 of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

3.5.1.1 Important considerations when removing an existing boiler:

Warning

Covering non-metallic vent pipe and fittings with thermal insulation is prohibited.

Section: Installation

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. In Canada, use the B149.1 Installation Code.

At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation:

Seal any unused opening in the common venting system.

Visually inspect the venting system for proper size and horizontal pitch. Determine that there is

no blockage or restriction, leakage, corrosion and other deficiencies that could cause an unsafe

condition.

(Where practical) Close all building doors and windows such as doors adjacent to appliances

remaining connected to the common venting system and other spaces of the building.

Turn on clothes dryers and any appliance not connected to the common venting system.

Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will

operate at maximum speed. Do not operate a summer exhaust fan.

Close fireplace dampers.

Place in operation the appliance being inspected.

Follow the lighting instructions.

Adjust the thermostat so that the appliance operates continuously.

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. In Canada, all

installations must conform with the current CAN/CGA - B149.1-10 Installation Code and/or local

codes.

3.5.2 Applications

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.

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. Using the indoor air alternative, air for combustion is drawn from the indoor air surrounding the boiler.

Provided the maximum overall vent length limit is not exceeded, the boiler may be vented through the wall, directly through the roof, or upward using an existing -- but otherwise unused - chimney as a vent raceway.

3.5.3 Exhaust vent material

Exhaust vent material – CANADA

Use PVC, CPVC, Polypropylene (PPs), or Stainless Steel (SS) vent component systems approved under ULC-S636 Standard for Type BH Gas Venting Systems, or stainless steel Type BH venting systems*. The vent temperature is limited by the boiler controller with the use of a flue temperature sensor to ensure the maximum temperature of the PVC venting material is not exceeded.

Exhaust vent material – USA

PVC, CPVC, PPs, or SS venting materials are approved for use with these boilers in most of the USA. Check local codes to determine if any materials are prohibited. The vent temperature is limited with the use of the flue temperature sensor and software to ensure that the maximum temperature of the PVC venting material is not exceeded. PVC venting material shall be certified to Sch. 40 ASTM D1785 or D2665. CPVC material shall be certified to Sch. 40/ASTM F441.

Exhaust vent material

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in venting systems is prohibited.

Do not use ABS or any cellular core pipe for exhaust venting.

The exhaust fitting has a 6" PVC (schedule 40) connection. Use fittings to adapt to either PPs or SS venting material. Insert exhaust venting directly into the 6" female stainless steel fitting, and secure with the built-in clamp (see Figure 8 ).

For PPs material, use the 6" transition / adaptor fitting (Sch 40 to PPs) offered by the respective PPs

Warning

Ensure that you lubricate the gasket with silicone grease before inserting the venting material. Fully insert the approved venting material into the boiler's exhaust outlet, and tighten clamp to ensure the venting connection is locked in place (as shown below).

Warning

Do not mix PPs venting materials from different manufacturers. These venting materials are designed to be installed as part of a complete system. Failure to comply may result in severe personal injury or death.

Section: Installation

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.

For SS material, use the 6" transition / adaptor fitting offered by the SS manufacturers M&G Dura Vent (# FSA-6PVCM-6FNSF [300538]) or Heat Fab (Saf-T-Vent) 9601PVC.

Figure 8 Securing the vent connection

Venting must be supported in accordance with the applicable code and instructions supplied by the manufacturers.

3.5.4 Vent travel

PVC/CPVC (Schedule 40), PPs (Rigid Single Wall), or SS approved piping are the standard venting options that can be sited up to 120 equivalent feet from the vent termination.

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:

EX 700, EX 850

Exhaust 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

For example, for an EX 850 using 6 x 90º CPVC vent elbows, the maximum lineal measure of pipe allowed is 90 feet (120' – (6 x 5' = 30) = 90').

Note

Unused intake travel cannot be added to the exhaust. Unequal intake and exhaust piping is allowed.

3.5.4 Vent travel

Table 5 Maximum Exhaust Venting Length for EX 700, 850

Exhaust venting must slope down towards the boiler with a pitch of at least 1/4" per foot (PP vent: follow PP manufacturer requirements for slope), so condensate runs back towards the trap. Support should be provided for intake and vent piping, particularly for horizontal runs (follow local code).

Figure 9 Pipe and fitting beveling

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.

Ensure all venting components are clear of burrs/debris prior to assembly. Clear plastic debris

Section: Installation

left in the combustion air piping to avoid intake into the fan.

Secure joints using appropriate solvent cement to bond the respective pipe material (Canada:

CPVC cement approved under ULC-S636, in accordance with its manufacturer instructions;

USA: PVC (ASTM D2564), or PVC/ABS (D2235) - Use transition glue anywhere that PVC and

CPVC are joined. Follow the cement manufacturer’s instructions closely when joining various

components. For PPs, connections shall be secured using approved retainer clips supplied by

the respective PPs manufacturer.

Check that vent connections are liquid and pressure tight. Prior to firing the boiler, and before

any of the venting run is concealed by the building construction, the installer must test the

exhaust joints under fan pressure with the vent blocked, using a soap and water solution .the

installer must fill the condensate trap prior to testing.

To drive the fan into manual high speed operation for vent leak testing, from the touchscreen controller Main Menu go to Diagnostics>Test Operation>Set Vent Test to On. Paint all joints with an approved leak test solution just as you would joints in a gas line, and make sure there are no leaks. We suggest attaching a tag on the vent line near the condensate drain tee with the type of test, the date and the installer’s name.

3.5.5 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.

3.5.6 Rooftop vent termination

Warning

Figure 10 Rooftop vent terminal

configurations

Figure 11 Rooftop vent termination with

sidewall combustion air

3.5.6 Rooftop vent termination

a. Rooftop vents must terminate as follows:

The exhaust pipe can terminate in an open vertical orientation without concern about rain

infiltration; rain will drain away through the condensate trap.

Optional bird screen may be placed in a termination fitting. Leave unglued, and hold in

place with a short nipple. This permits easy access for cleaning.

Do not exhaust vent into a common venting system.

b. For rooftop direct vent systems:

Rooftop, two pipe, direct vent configurations, including typical clearance requirements are shown below in the following images.

Vent screen retainer

Exhaust

Vent screen

Inlet

Flashing

Figure 12 Rooftop vent terminal vent screen and retainer

Best Practice: To reduce the possibility of expansion noise, allow a ¼" gap around the exhaust and air intake piping.

Section: Installation

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); lower down on the roof is acceptable.

For roof top venting of multiple boiler sets, group all intake terminals together for a common

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. These precautions apply to neighboring structures as well as to the structure the boiler(s) are installed in.

3.5.7 Sidewall vent termination

penetration through a custom cap. Alternatively, place close together using commonly

available pipe flashing. Similarly, group the exhaust pipes and place the two separate

groups of pipes at least 3' apart (the closest intake and exhaust pipes shall be 36", or more,

apart). Use the same 12" (minimum) vertical separation for all termination options. For

alternate group terminations, contact the IBC Factory for written guidance.

Roof top termination kits are approved for use with the boiler model. Installation of the

vertical roof top termination must follow the installation instructions supplied with the venting

material manufacturer. Care must be taken to install the termination kit a minimum horizontal

distance of 10' (305 cm) away from any portion of the building and a minimum of 2' (61 cm)

above the roof line plus the anticipated snow line.

3.5.7 Sidewall vent termination

Figure 13 Minimum clearances from vent/air inlet terminations (see legend on adjacent page)

Description US Installations

Canadian

Installations

A Clearance above grade, veranda, porch, deck, or

balcony

1' (30 cm) 1' (30 cm)

B Clearance to window or door that may be opened 4' (1.2 m) below or to

side of opening

3' (91 cm)

C Clearance to permanently closed window

Section: Installation

In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.

In accordance with the current CAN/ CSA-B149 Inst allation C odes.

Clearances in acc ordance wit h local installation codes and the requirements of the gas supplier.

Description US Installations

Canadian

Installations

D Vertical clearance to ventilated soffit located above

the terminal within a horizontal distance of 2' (61 cm)

from the center line of the terminal

5' (1.5 m) *

E Clearance to unventilated soffit * *

F Clearance to outside corner 6' (1.83 m)* 6' (1.83 m)*

G Clearance to inside corner 6' (1.83 m) 6' (1.83 m)*

H Clearance to each side of center line extended above

meter/regulator assembly

* 3' (91 cm) within a

height 15' above the

meter/ regulator

assembly

I Clearance to service regulator vent outlet * 6' (1.83 m)

J Clearance to non-mechanical air supply inlet to

building or the combustion air inlet to any other

appliance

4' (1.2 m) below or to

side of opening; 1'

(30 cm) above

opening

3' (91 cm)

K Clearance to mechanical air supply inlet * 6' (1.83 m)

L Do not terminate above paved sidewalk or paved

driveway

Slip hazard due to

frozen condensate

Slip hazard due to

frozen condensate

M Clearance under veranda, porch, deck or balcony * 12" (30 cm)

Warning

Important!: Maintain at least the minimum separation of exhaust vent termination from boiler

intake air as illustrated in Figure 14 , Figure 15 , Figure 16 and Figure 17 . Failure to do so can result in a dangerous situation where exhaust gasses are re-ingested with combustion air. Damage to the boiler can result from a failure to maintain these separations. Third party vent termination kits and concentric wall penetration kits that do not maintain these minimum separations shall not be used. Improper installation will void the warranty. Do not use proprietary InnoFlue or PolyPro PPs terminals without specific approval from IBC.

3.5.7 Sidewall vent termination

Table 6 Vent/air inlet termination clearances

In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.

In accordance with the current CAN/ CSA-B149 Inst allation C odes.

Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and t op of terminal, and underside of

veranda, porch, deck or balcony is greater than 1' (30 cm).

Sidewall direct vent with separate vent and air pipes shall be terminated as follows:

Caution

When the outdoor temperature drops below 5°F/-15°C, take care installing Concentric Side Wall Termination kits. Possible blockage of the combustion air intake can occur when the outdoor temperature drops below this temperature.

Figure 14 Vent termination clearance Figure 15 Vent termination clearances

Section: Installation

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.

(Optionally) Raise the elevation of both terminations in “periscope style” after passing through the

wall, then to gain the required clearance configure as shown in Figure 14 , Figure 15 , and Figure

16 .

Use a 45° elbow on the exhaust termination to launch the plume up and off the sidewall (for

protection of wall). A short piece of venting cut at 45° gives a horizontal termination protected from

wind loads (see Figure 14 , Figure 15 , and Figure 16 ).

Suggest use of a bird screen of ¼" stainless steel or plastic mesh (IPEX System 636 drain grate) to

guard against foreign objects.

Figure 16 Sidewall vent termination configuration option 1

3.5.7 Sidewall vent termination

Figure 17 Sidewall vent termination configuration option 2

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

Known Corrosive Contaminants to Avoid

Cements and glues

Paint or varnish removers

Adhesives used to fasten building products and other similar products

Chlorinated waxes or cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for snow and ice clearing

Sodium chloride or potassium chloride used for water softening

Refrigerant leaks from cracks in coils

Hydrochloric acid or muriatic acid used in household cleaning and stain removal

Chemicals in perming solutions

Chlorofluorocarbon chemicals found in spray cans

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Antistatic dryer sheets in clothes dryers

Section: Installation

The direct vent option uses piping from the outside to supply combustion air directly to the boiler’s combustion air connection. Combustion air piping - if used - is inserted directly into the 4" PVC-sized fitting, and increased immediately to 6".

At a new construction site, or during renovations, action must be taken to protect the boiler from drywall dust or other construction related contaminants; combustion air should be drawn from a clean source (e.g. outdoors) and the boiler should be isolated from interior dust sources. Do not seal boiler case openings directly when firing - allow for air circulation and ventilation in the immediate area.

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. Otherwise serious damage to the boiler may result.

Do not use

bushing

Flue gas exhaust to outdoors (connection at

rear of boiler)

Flue gas exhaust to outdoors

Combustion air from outdoors. "Direct Vent"

installation: check air intake outside is clear

of obstructions.

Combustion air from outdoors. Use reducing

coupling to transition from 4" connection to 6"

venting before first elbow.

Boiler supply

Boiler return

Figure 18 Direct vent combustion air intake Figure 19 Combustion air intake - side view

3.5.8 Direct vent combustion air intake piping

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. Such blockages will cause a

boiler safety shut-down.

Filters require checking and cleaning or replacing on a regular schedule based on

the severity of the problem.

Section: Installation

EX 700, EX 850

Note

Unused intake travel cannot be added to the exhaust. Unequal intake and exhaust piping is allowed.

Warning

When using indoor air options, supply adequate combustion air to the boiler room according to the requirements of all applicable codes.

3.5.9 Indoor air combustion air intake

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

For the inlet air – 6" Schedule 40 PVC, CPVC, ABS, PPs or SS piping of any type is permitted.

Ensure that adequate separation is maintained between the air intake inlet and the vent terminal. Refer to the vent terminal configuration drawings in the Vent Termination section above.

Use support for intake piping, particularly for horizontal runs (follow local codes).

3.5.9 Indoor air combustion air intake

An “Indoor Combustion Air installation” can be described as air for combustion that is taken from the air surrounding the boiler.

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

Section: Installation

To support combustion, an ample air supply is required. This may require direct openings in the boiler room to the outside. If the boiler is not in a room adjacent to an outside wall, air may be ducted from outside wall openings.

Provisions for combustion and ventilation air must be made as follows:

in the USA, in accordance with the National Fuel Gas Code, ANSI Z223.1 (latest edition), or

applicable provisions of the local building codes

in Canada, in compliance with B149.1 (latest edition).

3.5.10 Combustion air filtration system

A built-in combustion air filter system is supplied with the boiler, and is located at the top of the unit. The boilers use a 10" x 10" x 1" (MERV 8) filter.

End users will need to be instructed on how to maintain the filter in the boiler.

3.6 Installing a condensate trap

For instructions on how to replace the filter, see Replacing the air filter on

page 76.

Figure 22 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).

Reliable system operation requires:

1. Proper design and installation of exhaust

venting to allow condensate to run back to the

drain/trap.

Installing a condensate neutralizer on page 39.

2. Acid neutralization as appropriate.

To achieve these:

Allow a minimum ¼" per foot slope back to the

vent connection, with appropriate hangers to

maintain that gradient. For PPs venting, follow

the manufacturer's requirements. This will

ensure proper drainage and prevent

condensate from clogging.

Ensure the supplied trap is correctly installed

and filled with water.

When required, add (and maintain in good

condition) a neutralization tank. For information

on installing a condensate neutralizer, see

The condensate trap must be installed on the drain connection at the base of the boiler. The condensate

Slide the union nut onto the elbow. The union

nut must include an embedded O-ring. Ensure

that the O-ring seal is in place on the heat

exchanger's stainless steel outlet tube.

Attach the elbow and union nut firmly

to the boiler's outlet tube, making

sure that you rotate the elbow

sideways.

Fill the condensate trap with water and insert the trap into the hole of the metal plate.

Rotate the elbow, and tighten the union nut, so that the elbow and condensate trap are secured. Ensure the union nut O-ring is included. Check for leaks.

Section: Installation

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" per foot so condensate runs towards the drain.

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.

3.7 Installing a condensate neutralizer

Warning

After installing a condensate neutralization package, the pH of the condensate discharge must be measured on a regular schedule to ensure the neutralizing agent is active and effective.

Flue gas exhaust (connection at rear of boiler): condensate, and potentially rain water, flow back from

the venting system.

3.7 Installing a condensate neutralizer

If discharging condensate into building drain piping materials that are subject to corrosion, use a neutralization package.

Figure 23 Condensate neutralization tank

Air intake piping: Warning - Risk of damage to appliance. Ensure rain water is prevented from

entering.

Free flow of condensate from venting systems and the pressure vessel must be maintained at all

times. Trap and condensate drain piping must be accessible to allow regular inspection and cleaning.

Condensate water line: Warning - Risk of damage to appliance. All condensate discharge lines,

including neutralization tank inlet, must be at a lower elevation than the condensate water line of the

appliance.

Condensate neutralizer: Drain materials subject to corrosion must be protected by acid neutralization.

Warning - Risk of injury. Tank fluid can be highly acidic. Do not use hands to stir material. Refer to the

neutralization instructions of the manufacturer. Access to the discharge, before the drain, is necessary

for proper maintenance in order to check the effectiveness of the neutralizing agent. A simple pH test

should be performed annually to ensure neutralizing agent is still effective. If the pH falls below 6.5

the neutralizing material should be replaced. 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).

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.

Section: Installation

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.

Acidity pH is to be between 6.6 and 8.5

Chloride is to be less than 125 mg/l

Iron is to be less than 0.3 mg/l

Cu less than 0.1 mg/l

Conductivity is to be less than 400μS/cm (at 77°F [25°C])

Hardness is to be 7 grains per gallon or less / 120 ppm or less

Important: Ensure that these limits are acceptable for the other water-side components in the system.

Boiler Head Loss - EX 700, 850

Flow rate (gpm) 20 30 40 50 60 70 80 90 100

Head @ flow (ft) 2.6 2.9 3.2 3.7 4.2 4.8 5.5 6.4 7.2

3.8 Water Piping

Table 8 Boiler Head Loss - EX 700, 850

Ensure that the pump is rated for the design circulating water temperatures; some pumps have a minimum water temperature rating above the low temperature potential of the boiler. Following installation, confirm the actual performance by measuring Δ°T (under high and low flow conditions) after establishing the correct firing rate.

To use legacy heat, we recommend water flow after burner shutdown. This is significant due to the mass

Warning

Do not use automotive-type ethylene or other types of automotive glycol antifreeze, or undiluted antifreeze of any kind. This may result in severe boiler damage. Installers must ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials. Improper mixtures and chemical additives may cause damage to ferrous and non-ferrous components as well as non-metallic, wetted components, normally found in hydronic systems. 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.

Section: Installation

of the heat exchanger plus its internal water volume. Default load settings will run the boiler’s primary pump for up to 5 minutes (300 seconds) after burner shutdown. Secondary pumps can be set to run up to 15 minutes after burner shutdown (for the last calling load). As shipped, the default settings will run the Load pump for 5 minutes to place the legacy heat where it is useful. Any secondary pump can be set to run for 0 – 900 seconds in the heat purge mode. Guard against deadheading pumps when all zone valves are closed by setting the load Pump Post Purge (sec) to '0'.

The primary pump must be under the control of the boiler to allow pump purge after burner shut-down.

Installers must conform to the piping design configurations provided to simplify the control application, promote good loads and flow management.

Propylene glycol usage

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. Generally, a 50%:50% solution of propylene glycol and water requires an increased system circulation rate (gpm up 10%), and system head (up 20%) to provide performance equivalent to straight water.

These boilers are designed for use within a closed loop, forced circulation, low pressure system. A 50 psi pressure relief valve (¾" NPT inlet, 1" NPT outlet) is supplied for field installation in the relief valve fitting on top of the boiler. An optional relief valve, with a rating of up to 150 psi, can be used where required on closed loop systems. Relief valve discharge piping must terminate between 6" (15 cm) and 12" (30 cm) above the floor or per local code.

Warning

During operation, the relief valve may discharge large amounts of steam and/or hot water. To reduce the potential for bodily injury and property damage, install a discharge line that:

Is connected from the valve outlet with no intervening valve and directed downward to a

safe point of discharge.

Allows complete drainage of both the valve and the discharge line.

Is independently supported and securely anchored, so as to avoid applied stress on the

valve.

Is as short and straight as possible.

Terminates freely to atmosphere where any discharge will be clearly visible and is at no

risk of freezing. terminates with a plain end which is not threaded.

Is constructed of a material suitable for exposure to temperatures of 375° F or greater.

Is, over its entire length, of a pipe size equal to or greater than that of the valve outlet (1"

NPT).

Do not cap, plug or obstruct the discharge pipe outlet.

3.8.1 General piping best practices

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.

3.8.1 General piping best practices

Primary/secondary piping, or the use of a hydraulic separator (such as the Caleffi 549 SEP4™ 4-in-1 Magnetic Hydraulic Separators) is recommended for maximum flexibility in multi-load applications. 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.

3.8.2 System piping

Warning

Close the fill valve after any addition of water to the system, to reduce risk of water escapement.

Example: In these EX models, the minimum flow rate required through the heat exchanger is 18 or 21 gpm (depending on model) and a maximum of 100 gpm is allowed. Primary/Secondary piping ensures adequate flow and de-couples Δ°T issues (boiler vs. distribution). Aim for a 20° to 30° F Δ°T across the heat exchanger at high fire (there is a boiler protection throttle fence limiting the Δ°T to 80°F).

Section: Installation

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.

Fluid fill is most often accomplished by using a boiler regulator & fill valve set at 12 psig or more, with the appropriate backflow prevention device as 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. In areas where water quality is in question, or when chemical treatment or glycol is required, other options should be considered. Follow the applicable codes and good piping practice.

There are a number of boiler feed and pressurization devices on the market today that may be a better choice than a raw water fill from the mains. When regular maintenance requires relief valve blow-off, the discharge may be directed back into the pressurization unit for recycling of boiler fluid and chemicals back into the system. In buildings that may be unoccupied for long periods of time, pressurization units are useful to prevent flood damage should leakage occur from any component in the system. An additional benefit is that backflow prevention devices are not required when using these devices.

Do not place any water connections above the boiler; leaks can damage the fan and controls. If needed, create a shield over the top of the cover, but allow clearance for airflow and service access.

For best results, use a Primary/Secondary piping system, with a pumped boiler loop using 2½" piping. Refer to Table 8 for boiler head loss information.

Check valves or thermal traps should be used to isolate both the supply and return piping for each load

- to avoid thermal siphoning and reverse flow.

To ensure adequate water flow through the boiler under high-head / single zone space heating conditions, a pressure activated bypass or other means of bypass must be used on any load where the flow rate might drop below minimum requirements (18 or 21 gpm - depending on model).

For further information and details, consult our Concept Drawings – which provide detail on specific single

Note

The piping drawings in this manual are simple schematic guides to a successful installation. There are many necessary components not shown, and details such as thermal traps are left out so the drawings have greater clarity. We require that our boilers be installed by licensed and experienced trades people who are familiar with the applicable local and national codes. System design is to be completed by an experienced hydronic designer or Engineer. It is necessary to carefully read and follow these installation instructions along with the application drawing that fits your system.

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.

Pressure relief valve (ships with boiler): no isolation valve permitted between boiler and relief valve.

Tridicator / external pressure and temperature gauge (ships with boiler).

3.8.2 System piping

and multiple boiler applications “Piping”, “Wiring” and “Settings”. (available at www.ibcboiler.com or from your IBC Representative).

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.

To supply manifold

From return manifold

Optional flow switch: follow manufacturer’s instructions. Typical requirements include installing on a

horizontal run, with at least five (5) pipe diameters of straight piping both upstream and downstream

of flow switch, and ensuring proper paddle engagement for the piping size.

Integrated boiler drain

Figure 24 Trim for multiple boiler installations

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).

Section: Installation

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.

Return lines from loads.

Expansion tank connection (point of no pressure change)should be on the suction side of the

circulator.

Primary pump or boiler circulator into connection at rear of boiler.

Fill station with isolation valve closed, or fill tank.

Figure 25 Primary/Secondary piping concept with hydraulic separator

Pressure relief valve (field-supplied): no isolation valve is permitted between the boiler and relief

valve.

Tridicator or external pressure and temperature gauge (field-supplied).

Microbubble air eliminators are best installed where the fluid is at the highest temperature and

lowest pressure.

Expansion tank connection (point of no pressure change) should be on the suction side of the

circulator.

3.8.2 System piping

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

Section: Installation

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.

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. Alternatively, use check valves on both supply and return of secondary piping.

Figure 27 Important Primary/Secondary piping details with closely-spaced tees

3.8.2 System piping

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

Section: Installation

DHW indirect tank

Air handler

Check valves (may be integral to pumps - not shown)

3.8.2 System piping

Figure 29 Two pump, two load - parallel piping concept

The boilers can supply multiple heating loads with compatible supply temperature requirements.

Check valve (typical of each boiler - may be integral to pump).

Tridicator (shipped with boiler) typical of each boiler.

Pressure relief valve (shipped with boiler) 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.

Section: Installation

Always ensure that loads sensitive to high temperatures are protected using means such as mixing valves.

Figure 30 Multiple boiler 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.

Opt-out pump into rear side (opt-out boiler(s) only)

Opt-out load piping in reverse-return for balanced flows

Figure 31 Multiple boiler opt-out piping

3.8.2 System 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. 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" condition.

Pay special attention to retrofit situations where existing regulators may have an over-sized orifice and/or worn seats, causing pressure “creep” and high lock-up pressures.

A high quality regulator will maintain constant pressure above the boiler’s minimum specification at all firing rates, and will not exceed the boiler’s maximum pressure rating when locked-up with no load.

Section: Installation

3.9.1 Gas pressure

The boilers require a minimum inlet gas supply pressure of 4.0" w.c. for natural gas or propane during high fire operation. For either fuel, the inlet pressure shall be no greater than 14.0" w.c. Confirm this pressure range is available with your local gas supplier.

The inlet gas connection to the boiler is 1" NPT (female).

The high gas pressure switch setpoint is set at 14" wc and the low gas pressure setpoint is set at 3.5" wc. To locate the switches on the boiler, see EX 700, 850 - gas valve and fan components.

Adequate gas supply piping must be installed with no smaller than 1¼" Schedule 40 (e.g. Iron Pipe Size (IPS) and using a 1" w.c. pressure drop, in accordance with the following chart.

Maximum Gas Pipe Length (ft)

Model 1¼" IPS 1½" IPS 2" IPS 2½" IPS

EX 700 (Natural Gas) 50' 100' 350' 800'

EX 700 (Propane) 150' 300' 900' 2000'

EX 850 (Natural Gas) 40' 80' 250' 600'

EX 850 (Propane) 100' 200' 700' 1600'

Table 9 Maximum Gas Pipe Length (ft)

3.10 Electrical connections

Gas piping must have a sediment trap ahead of the boiler’s gas valve. A manual shutoff valve must be located outside the boiler, in accordance with local codes or standards. All threaded joints in gas piping should be made with an approved piping compound resistant to the action of natural gas or propane. Use proper hangers to support gas supply piping as per applicable codes.

The boiler must be disconnected or otherwise isolated from the gas supply during any pressure testing of the system at test pressures in excess of ½ psig. Dissipate test pressure prior to reconnecting. The boiler and its gas piping shall be leak tested before being placed into operation.

The gas valve is provided with pressure taps to measure gas pressure upstream (supply pressure) and downstream (manifold pressure) of the gas valve (see Figure 2 on page 1). Note that manifold pressure varies slightly in accordance with firing rates with the modulating series boilers, but will always be close to 0" wc. An adapter fitting is supplied with the boiler.

Figure 32 Typical gas piping

3.10 Electrical connections

All electrical wiring to the boiler (including grounding) must conform to local electrical codes and/or to the National Electrical Code, ANS/NFPA No. 70 – latest edition, or to the Canadian Electrical Code, C22.1 - Part 1.

3.10.1 Power quality and electrical protection

In areas of unreliable power, appropriate surge protectors and or power conditioning equipment should be installed in power supply wiring circuits.

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.

3.10.2 120VAC line-voltage hook-up

Caution

The on-board controller load pump relays are protected with 5 Amp fuses. The maximum recommended load on each fuse is 4 Amps (80% of rating). The maximum combined pump load is 10 Amps. Isolation relays or contactors must be used if the loads exceed these maximums.

Section: Installation

Line-voltage wiring is done within the field-wiring box (see Wiring diagrams on page 93). Connect the boiler to the grid power using a separate, fused circuit and on/off switch within sight of the boiler. Use 14gauge wire in BX cable or conduit properly anchored to the boiler case for mains supply and pump circuits.

Figure 33 Line voltage load pump terminals

Connect a 120VAC / 15 amp supply to the “AC IN” tagged leads in the wiring box.

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. The upper 4 pairs of contacts on the connector strip are then powered to manage up to 4 load pumps – the top pair for Load 1, the second pair for #2 etc. Once the controller is programmed for the respective loads, the boiler manages all the loads without need of further relays (for loads up to ⅓ HP; for more – use a protective relay).

3.10.2.2 Boiler pump

Power in - black wire.

To boiler - yellow wire.

3.10.2 120VAC line-voltage hook-up

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.

Figure 34 Electrical box with boiler pump relay - black and yellow wires

If the total boiler amperage drawn is less than 12 amps and the boiler pump is 120V, you can connect the black wire from the relay to the line voltage mains supplied to the boiler. For 120 volt boiler pumps, the black wire can be connected to the line voltage mains and the yellow wire connected to boiler pump. For 208/240 volt boiler pumps, the black wire can be one leg of the 208/240 voltage mains and the yellow wire connected to the boiler pump. 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.

Pumps can be switched on/off using the touchscreen controller, so there is no need for temporary pump

Section: Installation

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.

In a new construction application, use a construction thermostat, or jumper with an in-line on/off switch – for on/off management of the boiler. Do not just turn off power from the unit, or its moisture management routine will be interrupted (fan turns at ultra low rpm for 90 minutes after burner shutdown). Treat it like a computer, where you do not just pull the plug when done. If a "low airflow / check vent" error signal shows, check for (and remove) any water in the clear vinyl air reference tubes. This has been seen occasionally at construction sites where the boiler has been repeatedly de-powered wet.

The combined current of all load pumps connected through the on-board pump relays should not exceed 10 amps. The control circuit board is protected using on-board field replaceable fuses. Each pump is fused with a separate 5 Amp fuse. The Alarm contact is fused with a 5 Amp fuse and the 24VAC boiler control circuit is protected with a 2 Amp fuse.

3.10.2.3 Variable speed boiler pumps

Variable speed boiler pumps are for connecting and managing speed in pumps that accept 0-10VDC on 4-20 mA input signal.

Figure 35 Electrical box with new variable speed connection

3.10.3 Other wiring

Danger

Do not connect sensors to “Therm” terminals. Overheating components can result in serious

personal injury and/or property damage.

Note

Sensors connected to any sensor input contacts must be of the NTC 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.

3.10.3 Other wiring

Other optional low voltage connections to the control board include:

Two auxiliary Interlocks - for external safety devices as may be required by some jurisdictions, such

as an external low-water cutoff.

Contacts for indoor and outdoor temperatures sensors associated with reset heating. A 10K ohm

thermister (resistor dependent on temperature) for outdoor reset sensing is supplied with the boiler

for improved comfort and combustion efficiency.

One pair for a DHW tank sensor. Connect to "DHW S" (not the respective Therm. 1,2,3,4 location)

and the boiler automatically detects and calls a smart 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.

The bottom pair of contacts (labeled 'External Control') receives a 0-10VDC (default) or 4-20 mA

signal from an external boiler controller for direct throttle control. The boiler’s own sensors act as

high limits only. The user must enter maximum and minimum boiler supply temperatures.

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”). Gang lines from a multiple-zoned load (e.g., off the end-switches for each radiant floor zone) present a common thermostat signal to the controller. Ensure that there are no disturbing influences on the call-forheat lines - for example, that there are no coils to switch an air handler motor. Most power stealing thermostats can be connected directly to the Therm terminals. Consult the Controller manual for more detailed instructions.

3.10.5 Thermostat heat anticipator

Section: Installation

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.

Figure 36 Electric wiring connections

4.0 About the boiler controller

Note

Use only a stylus or a clean finger to interact with the touchscreen. Using sharp or metallic objects will cause damage.

This boiler is equipped with a touchscreen controller for programming the boiler. For detailed instructions on using the controller, see the Touchscreen Controller manual.

The controller is equipped to provide:

Control of up to 5 pumps – 1 boiler pump + 4 separate load pumps

Outdoor Reset control

Set Point temperature regulation

Domestic Hot Water (DHW)

External control via 0-10VDC or 4-20mA signaling

Manual control of firing rate for gas valve calibration

Alarm dry contacts

Zoning - simultaneous operation of up to four pumps

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:

Express Setup Menu for simple, quick programming

Portal connectivity for remote monitoring and programming

Superior warning messages while setting up the control

Advanced Error messages with visual display on the Home Screen

Internet/LAN connectivity

BACnet (with activation)

4.1 Controller

When the boiler is first energized, the controller will go through a power up sequence that will take approximately 90 seconds. During this time the controller is completing a self- diagnostic and loading all previous settings. In the event of a power interruption the boiler will automatically resume operation when power is restored with all the previously stored values. The controller provides overall management of the boiler operations including:

Power-up, self-diagnostics, easy Load parameter adjustments

Section: About the boiler controller

Burner operation, safety management systems, Call for Heat

management and Load Priority

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.

4.2 Control interface

The control interface is provided through a 2¼ x 4 inch, color touchscreen display. The touchscreen responds to a light finger touch on the screen. You can also use a stylus, pencil, or similar device to operate the touch controls. Do not use a sharp or metallic object such as a screw driver to operate the control as it could damage the touchscreen.

The controller display is divided into two areas, the screen active area and the boiler status bar. All screens have an active area consisting of the screen title bar at the top and a border surrounding the active area. At the bottom of the display there is space reserved for the boiler status bar.

Prior to any interaction with the touchscreen, the display shows the Home screen details of the current boiler status. If the controller has been left on the Home screen long enough (user adjustable, 10 minutes by default) the display will be dimmed to save power.

The control will automatically return to the home screen if left unattended. The screens will step back one screen at a time in 10 minute increments if the touchscreen has not been touched. The pop-up windows will also step back automatically in 2 minute intervals.

The boiler status bar indicates if the boiler is in a normal, warning or alarm state. When no warning or alarm state is present, the bar will be green and the time will be displayed inside the green area. The bar can also be yellow or red corresponding a warning or alarm state. Text inside the bar will indicate the specific warning or alarm present. If more than one alarm is present the text display will slowly change, rotating though whatever alarms that are present.

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. Immediately, call the gas supplier from a phone located remotely. Follow the gas supplier’s instructions, or if the supplier is unavailable, contact the fire department.

Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water.

Should overheating occur or the gas supply fails to shut off, do not turn off or disconnect the electrical supply to the pump. Instead shut off the gas supply at a location external to the appliance.

Checking electrical conditions Check

Check all line voltage electrical connections to ensure all connections are correct and tight.

□

Check thermostat connections.

□

Thermostat in a suitable location.

□

Checking piping connections Check

Ensure venting system is complete and seal tested.

Confirm any common venting system at the installation site is isolated and independent of the EX boiler.

Also confirm that any holes left from the removal of a previous boiler have been sealed, and that any resizing of the old flue has been done.

□

5.1 Important pre-ignition checks

Once installation of the unit is completed, and before operating the unit, it is important to review the following checklist of precautions:

5.1.1 Checklist for electrical conditions, ducting and water connections

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". When complete, return to "OFF", or this will automatically occur with a call for heat). Use a minimum water pressure of 12 psig. And confirm that the pressure relief valve is installed and safely drained.

□

Check to see that adequate gas pressure is present at the inlet gas supply test port.

Open the test port by turning its center-screw one full turn counterclockwise, using a small (1/8" or 3 mm) flat screwdriver.

Connect a manometer and open the gas control valve. Requirements are minimum 4" w.c and maximum 14" w.c.

Check that there are no gas leaks.

□

All connections are pressure tested and leak free.

□

All piping flushed to ensure all air is removed.

□

Check valve is installed and the external pump is flowing in the correct direction.

□

Checking ducting connections Check

All connections are pressure tested and leak free.

□

All duct work is sized correctly and joints are sealed.

□

All supply air dampers and registers are opened.

□

Powering on the boiler Check

Perform a final check of electrical wiring, and provide power to the boiler to initialize operation.

Warning

Fill the condensate trap with water before you first fire 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.

□

Section: Before operating the boiler

6.0 Service and maintenance

Caution

The owner is responsible for general care of the boiler. Improper maintenance of the boiler may result in a hazardous condition.

Maintenance Required for Venting Frequency Check

Check and replace filter as needed. Site conditions will determine how often the filter will need to be replaced. For replacement instructions, see Replacing the air filter on

page 76

As needed

□

Inspect system for unusual noises. Call your local heating contractor for service if

needed

As needed

□

Keep vent terminals clear of obstructions (snow, dirt, etc.). As needed

□

Inspection of the boiler is to be performed annually by a qualified service technician. Annually

□

Caution

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Maintenance Required Check

Remove any obstructions (e.g. leaves, dust, other debris) from vent terminals

□

Check and clean or replace intake air filters or screens as required.

□

Check for holes or leaks in venting. Replace venting as needed.

□

Examine for any signs of moisture caused by sweating intake air pipes; insulate as required.

□

Ensure proper resealing or re-installation of venting on each servicing.

□

Inspection of the boiler is to be performed annually by a qualified service technician.

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.

6.2 Maintenance checklists for heating contractor

6.2.1 Venting

Maintenance Required for Venting Frequency Check

Check and replace filter as needed. For replacement instructions, see Replacing

the air filter on page 76

Monthly

□

Have your local heating contractor inspect the unit annually.

Annually

□

Inspect system for unusual noises. Call your local heating contractor for service if

needed

As needed

□

Keep vent terminals clear of obstructions (snow, dirt, etc.). As needed

□

Inspection of the boiler is to be performed annually by a qualified service

technician.

Annually

□

Maintenance Required for Condensate Trap Frequency Check

Examine every two months to see if cleaning is necessary (see Maintaining a

condensate trap).

Ensure that the trap has been re-filled completely before firing boiler.

Bi-monthly

□

If condensate neutralization is used, check the pH level of condensate discharge.

Annually

□

Maintenance Required for Burner Frequency Check

Remove the burner to inspect for extent of fouling (see Replacing the burner on

page 74).

a. Wash the burner from outside with a domestic water pressure, and dry

using compressed air.

b. Evaluate the magnitude of clearing required, and establish a reasonable

burner inspection schedule. Some boiler / locations may call for annual

service, others showing clean burners will only need attention every 2 – 5

years.

c. Reassemble. Visually inspect the burner through sight glass. Ensure the

flame is stable, without excessive fluttering. Normal flame pattern is evenly

distributed over the burner surface.

Annually

□

Section: Service and maintenance

6.2.2 Condensate trap

6.2.3 Burner

Maintenance Required for Burner Frequency Check

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.

Annually

□

Warning

When removing the burner for inspection or boiler servicing, examine the sealing gaskets and replace if damaged. Upon re-assembly, test all sealing areas to ensure there is no leakage of combustible gas/air premix.

6.2.4 Heat exchanger

Maintenance Required for Heat Exchanger Frequency Check

In areas of poor gas quality, there may be a build-up of black plaque (typically sulfur). Other fouling agents include: airborne dust, debris and volatiles.

With the burner removed, examine the heat exchanger for signs of contamination and clean if necessary. Refer to instructions in Replacing the burner on page 74 for access to the combustion chamber and heat exchanger.

Annually

□

Maintenance Required for Pump Frequency Check

Check that the pump is on in normal operation and that the water Δ°T is reasonable for a given firing rate.

Annually

□

Maintenance Required for Gas Piping Frequency Check

Check for damage or leaks and repair as needed.

Annually

□

Maintenance Required for Boiler Controller Frequency Check

Check that boiler operation is consistent with the steps in the Touchscreen Boiler Controller Manual.

Annually

□

6.2.4 Heat exchanger

6.2.5 Pump

6.2.6 Gas piping

6.2.7 Touchscreen boiler controller

Maintenance Required for Boiler Controller Frequency Check

Check that water temperature targets and setpoint is satisfactory and have not been adversely amended.

Annually

□

Check the operating history using the boilers Logs menu and Error Logs menu.

The controller tracks the duty cycle of the boiler in each of the 4 loads separately. This information can be used to adjust the water temperatures of each load.

□

If a problem exists with the controller, consult the section Troubleshooting

on page 79.

6.2.8 Water

Checks for Water in the Boiler Frequency Check

Check water pressure and temperature.

There should be no noticeable change if boiler is functioning normally. Check for any noise in the system.

Annually

□

Check water piping for damage or leaks and repair as needed.

Annually

□

Check the water pressure. Pressure should be stable when the boiler is firing and the water temperature is rising.

If pressure rises sharply, consider replacement of expansion tank.

Annually

□

Check also for noise at high fire, which may signal water quality problems. Annually

□

Water chemistry shall be of a quality generally accepted as suitable for hydronic

applications.

Annually

□

Ensure any direct “city fill” water connections are left in the closed position to

minimize exposure to leaks and flooding.

Annually

□

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.

Section: Service and maintenance

6.2.9 Freeze protection

Maintenance to prevent freezing Frequency Check

Check the freeze protection. Use only antifreeze made specifically for hydronic systems. Inhibited propylene glycol is recommended. Antifreeze volume must be between 25% and 50% of the total volume of water in the system.

Annually

□

Warning

Do not use automotive-type ethylene or other types of automotive glycol antifreeze, or undiluted antifreeze of any kind. This may result in severe boiler damage. It is the responsibility of the Installer to ensure that glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials. Improper mixtures and chemical additives may cause damage to ferrous and non-ferrous components as well as non-metallic, wet components, normally found in hydronic systems. 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.

Maintenance for Boiler Treatment Frequency Check

Check consistency of any boiler treatment used, for appropriate mixture. Chemical inhibitors are consumed over time, lowering their density.

Annually

□

Verify proper operation after servicing.

Annually

□

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.

6.2.9 Freeze protection

6.2.10 Boiler treatment

6.2.11 Relief valve - maintenance and testing

The relief valve manufacturer requires that under normal operating conditions a “try lever test” must be performed every two months.

Under severe service conditions, or if corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be performed at the end of any non-service period.

Maintenance for Relief valve Frequency Check

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.

If the lever does not activate, or if there is no sign of discharge, discontinue use of equipment immediately and contact a licensed contractor or qualified service personnel.

If the relief valve does not completely seal, and fluid continues to leak from the discharge pipe - perform the test again to try and flush any debris that may be lodged in the valve. If repeated tries fail to stop the leakage, contact a licensed contractor or qualified service personnel to replace the valve.

While performing a “try lever test”, a quantity of heat transfer fluid will be discharged from the piping system and the system pressure will drop. This fluid must be replaced. To refill and pressurize your system, we recommend using a system pressurization unit such as an Axiom Industries model SF100 series. Capture the discharged fluid in a container and recycle it by returning it to the system feeder unit. This is particularly important when your system contains treatment chemicals or glycol solutions. If the system employs plain water, the boiler auto fill valve must be turned on in order to recharge the lost fluid.

Annually

□

6.3 Replacing the fan, gas valve, and burner

Section: Service and maintenance

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

6.3.1 Replacing the fan

Figure 37 EX 700, 850 - gas valve and fan components

1. Turn off the electric power and gas supply to the boiler.

2. Ensure the boiler cools down to the surrounding temperature. Do not drain the boiler unless

freezing conditions are expected during this procedure.

3. Remove the front cover, and then remove the boiler's top panel by removing the Torx 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.

4. Unplug both the upper and lower electrical connectors from the fan.

5. Position the harnesses out of the way of the heat exchanger lid.

Remove the four 5/16" hex head bolts that attach the gas valve to the mixing device. (See on

Figure 38 .) These bolts should be first loosened slightly in a cross sequence to prevent deformation

of the mating parts.

7. Carefully move aside the gas valve assembly, and retain the O-ring for re-installing.

8. Remove the four (4) ¼" hex bolts that connect the mixing device to the air filter box. The gasket

should remain attached to the air filter box.

9. Remove the four (4) hex bolts that attach the fan to the heat exchanger lid. An open-ended

Unscrew four (4) bolts to separate the gas valve from the mixing device. Keep gasket and bolts

for re-assembly.

Location of high gas pressure switch.

Gas valve inlet: Unscrew the four (4) bolts of the flange to separate gas valve from the gas

valve. Keep gasket and bolts for re-assembly.

Low gas pressure switch.

Section: Service and maintenance

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. Place the removed components in a clean,

dry area.

11. Note how the mixing device is positioned on the fan before removing it from the fan. Remove the

six (6) 6 mm screws to separate the mixing device from the fan.

12. Attach the mixing device to the new fan.

13. Re-install the components in reverse order of the steps above.

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

6.3.2 Replacing the gas valve

1. Turn off the electric power and gas supply to the boiler.

2. Ensure that the boiler cools down to the surrounding temperature. Do not drain the boiler unless

freezing conditions are expected during this procedure.

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.

4. 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.

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. (See lon Figure 38 .)

7. Unscrew the four (4) bolts of the flange to separate the gas valve outlet from the gas line. Keep gasket

and bolts for re-assembly. (See o on Figure 38 .)

8. Re-install the components in reverse order of the steps above.

9. Tune the gas valve. For instructions, see Adjusting the gas valve on page 1.

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.

Avoid disturbing or damaging the refractory. If damage occurs, contact the factory for directions.

Avoid breathing and contact with skin and eyes and follow these precautions:

1. For conditions of frequent use or heavy exposure, respirator protection is required.

Refer to the “NIOSH Guide to the Selection and Use of Particulate Respirators

Certified under 42 CFR 84” for selection and use of respirators certified by NIOSH.

For the most current information, NIOSH can be contacted at 1-800-356-4676 or on the web at www.cdc.gov/niosh.

2. Wear long sleeved, loose fitting clothing, gloves and eyes protection.

3. Assure adequate ventilation.

4. Wash with soap and water after contact.

5. Wash potentially contaminated clothes separately from other laundry and rinse

washing machine thoroughly.

6. Discard used insulation in an air tight plastic bag.

NIOSH stated first aid:

Eye contact - Irrigate and wash immediately.

Breathing - Provide fresh air.

Section: Service and maintenance

1. Turn off the electric power and gas supply to the boiler.

2. Ensure that the boiler cools down to the surrounding temperature. Do not drain the boiler unless

freezing conditions are expected during this procedure.

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.

4. 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.

5. Remove the screw and pull off the electrical connector from the gas valve, and disconnect the three-

Warning

After removing a burner, it is imperative that you perform a gap analysis on the ignitor.

6.3.3 Replacing the burner

(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. (See l on Figure 38 .)

7. Remove the four 5/16" hex head bolts that attach the gas valve assembly to the mixing device. (See

j on Figure 38 .) These bolts should be first loosened slightly in a cross sequence to prevent

deformation of the mating parts.

8. Carefully move aside the gas valve assembly, and retain the O-ring for re-installing.

9. Remove the four (4) ¼" hex bolts that connect the mixing device to the air filter box. The gasket should

remain attached to the air filter box.

10. Remove the four (4) 10 mm hex bolts that attach the fan to the heat exchanger lid. An open-ended

wrench or socket is required.

11. 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. Place the removed components in a clean, dry area

12. Unplug the ignitor from the lid and place in a safe place.

13. Loosen the eight (8) 5 mm Allen lid fasteners securing the lid to the heat exchanger. Mark the

orientation of the lid onto the heat exchanger with a marker.

14. Carefully lift up on the lid and remove. Be careful not to damage the refractory insulation. Place the lid

and burner assembly in a clean dry area.

15. Carefully loosen the burner cap screws and remove. Keep the cap screws for re-installation.

16. Separate the burner from lid. Replace the burner gasket upon re-installaion.

17. Re-install the components in reverse order of the steps above.

6.4 Replacing the air filter

Remove the two screws of the air filter lid, and

set aside.

Remove the air filter, and replace

with a new one.

Section: Service and maintenance

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".

6.5 Cleaning a condensate trap

Warning

If condensate neutralization is used, check the pH level of condensate discharge.

Never operate the boiler unless the trap is filled with water. Failure to comply will result in severe personal injury or death.

Unscrew the union nut.

Rotate the elbow sideways, so that you

can remove the condensate trap base.

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.

Clean and flush out the debris in the condensate

trap base.

Fill the condensate trap to the top

with water.

Reinsert the condensate trap through the metal

plate.

Rotate the elbow, and tighten the union

nut, so that elbow and condensate trap

are secured. Ensure the union nut O-ring

is included. Check for leaks.

Section: Service and maintenance

7.0 Troubleshooting

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.

Preliminary Troubleshooting Checks Check

Confirm power to the boiler: check that the touchscreen controller display is on (e.g., display is lit.

The touchscreen controller’s display will be fully functional in 90 seconds after power is restored

to the boiler.)

□

Check that the boiler is not in a safety lockout.

□

Ensure wiring is clean and secure.

□

Check that gas is reaching the unit.

□

Check the gas pressure switches.

□

Confirm that the water system is properly charged to 12 psi minimum, and that the pump is

serviceable.

□

This section includes various conditions as well as possible solutions related to the EX unit.

The troubleshooting section is divided into 3 sections:

Preliminary checks

Electronic components

Troubleshooting error messages

Often, a problem can be identified and solved through simple checks of the basics: confirming the electrical power supply, gas flow and resetting the thermostat control.

7.1 Preliminary checks

The first step in troubleshooting this system should be a review of the touchscreen controller. There are a number of diagnostic features incorporated in the software that evaluate system integrity, display error conditions and provide initial remedial actions.

In addition to checking the display, the following list is a guideline for troubleshooting:

7.2 Electronic components

Section: Troubleshooting

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 (5,000,000Ω) at the controller end of the sensor lead).

To obtain a resistance reading, remove power to the boiler. For the supply water, return water, and vent temperature sensors, remove the wire leads by disconnecting their respective Molex connectors. Place multi-meter probes into the sensor’s female Molex connector socket. Do not apply voltage to the sensor as damage may result.

The supply water and vent temperature sensors each contain two separate circuits. Test each pair. Both circuits must deliver accurate (although not necessarily identical) readings. Note that failures may occur only within certain temperature ranges.

Temp. °F/°C

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

20 / -7 42,218 120 / 49 3,760

25 / -4 39,913 125 / 52 3,383

30 / -1 34,558 130 / 54 3,050

35 / 2 29,996 135 / 57 2,754

40 / 4 26,099 140 / 60 2,490

45 / 7 22,763 145 / 63 2,255

50 / 10 19,900 150 / 66 2,045

55 / 13 17,436 155 / 68 1,857

60 / 16 15,311 160 / 71 1,689

Resist.

Ω – Ohm

Temp. °F/°C

Ω – Ohm

Resist.

65 / 18 13,474 165 / 74 1,538

Temp. °F/°C

7.2.2 Fan

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

90 / 35 7,334 190 / 88 983

95 / 35 6,532 195 / 91 903

Table 10 Temperature sensor resistance values - 10K ohms

Resist.

Ω – Ohm

Temp. °F/°C

Resist.

Ω – Ohm

7.2.2 Fan

Operating power is provided by means of a separate 120 VAC connector (white/black/green). Control of the fan is provided via a four-lead connector. This connector feeds a PWM control signal (black wire) from the controller and provides a tachometer signal (white wire) back from the fan. Unplugging the control connector will cause the fan to go to high speed and trigger a “Blocked Vent Error” within 6 seconds if the boiler is operating.

7.2.3 Air pressure sensor

The air pressure sensor monitors air flow in the venting system. If airflow through the combustion air intake or the exhaust vent becomes too restricted for safe operation, the boiler will stop firing, and display a "Fan Pressure Error". Also, to prevent avoidable Fan Pressure Errors, the system decreases the fan speed if the reading from the sensor nears the error threshold.

7.2.4 Water pressure sensor

The water pressure sensor ensures that there is adequate pressure in the heating system for safe operation. The pressure is displayed in PSI as the default. If the system pressure should drop below 8PSI the firing rate of the boiler is reduced. If the pressure drops to 4PSI or lower, the boiler will not fire.

Check the operation of the sensor by isolating the boiler from its system piping, and close the system fill valve, and then crack the pressure relief valve. The pressure displayed should reflect declining pressure. If it remains “fixed”, drain the boiler and replace the sensor, or dislodge any blocking debris from the sensor inlet channel and reinsert.

7.2.5 Gas pressure switches

Warning

Do not attempt to adjust the High or Low pressure switch.

Section: Troubleshooting

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" w.c.

The high gas pressure switch is pre-calibrated and will trip when the inlet gas pressure rises

above 15" w.c.

You must reset the low gas pressure switch after the gas to the boiler is connected and turned on. To “reset” either the low or high gas pressure switch, press on the clear plastic cover above the Red button.

If either the high or low gas pressure switch trips, the boiler controller will show a Red bar at the bottom of the screen and indicate “Low/High Gas Pressure”.

7.2.6 Safety and Ignition Module (SIM)

The SIM is a safety control used in EX. It is certified to conform to the UL 60730-5-5 and ANSI Z21.202014 • CAN/CSA-C22.2 No. 60730-2-5-14 standards.

The module controls the boiler’s gas valve, including:

Direct spark automatic ignition

Flame detection and current measurement

Supply water temperature sensing

Flue gas temperature sensing

Supply water maximum temperature shutdown

Flue gas maximum temperature shutdown

Low water cut-off.

The SIM continuously communicates with the boiler’s main controller reporting sensor readings and status. The sensor readings and error status, if any are displayed on the boiler controller’s screen.

7.2.6.1 Table showing LED operating status

7.2.6 Safety and Ignition Module (SIM)

Its two status LEDs indicate the operating status as shown in the table below.

SIM Status Indicators

LED 1 LED 2 State

Rapid flash Power up or resetting startup checks and initialization

Off Off Standby

Off On Pre-purge or inter-

purge

On On Heating

Rapid flash On Igniting

Off Flashing Lockout

Flash alternately with

LED 2

Table 11 SIM LED status Indicators

Flash alternately with

LED 1

Fail-safe Boiler requires a power cycle

Description, LED status

indication

LED 1 Off=flame or sparking

LED 2 = Burner-on call state

LED 1 Off=no flame or sparking

LED 2 = Burner-on call state

7.2.6.2 Low water cutoff function: reset and test

The low water cutoff (LWCO) function provides continuous protection against a low water incident.

If the SIM detects a low water incident, the boiler goes into a lockout condition. To clear the lockout condition in the controller, go to Diagnostics>Advanced Diagnostics>Clear Errors. To test the LWCO on the boiler, you can also manually place the boiler in a lockout condition.

7.2.6.3 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. Tap the Advanced Diagnostics button.

Section: Troubleshooting

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

Press and hold the LWCO Test button for 5 seconds (located on top of the electrical box).

A message on the screen indicates that the boiler is in lockout mode.

2. On the touchscreen controller, select the Reset button.

The message: "The SIM Module has been reset" is displayed.

3. Tap the Close button, and then tap the Back button until you return to the Home screen.

7.2.6.5 Water Temperature function: reset and test

The hi-limit temperature function monitors the hi-limit temperature set in the SIM. If the water temperature exceeds the hi-limit temperature, the boiler goes into a lockout condition (locks), requiring a manual reset. You can test the hi-limit cutoff temperature function on the boiler.

Resetting the boiler after a Hi-Limit 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. Tap the Advanced Diagnostics button.

4. Tap the Clear Errors button.

5. Tap the Yes button, and then tap OK.

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. Tap the Hi-Limit Test button.

Warning

Never attempt to repair the control module (circuit board). If the control module is defective, replace it immediately.

7.3 Troubleshooting error messages

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. Tap inside the Cut-Off Temp. box, and then tap a number value.

Tap the OK button.

The message: "Hi-Limit Detected" is displayed.

To reset the boiler, select the Reset button. The cutoff value reverts to normal upon reset.

The message: "The SIM module has been reset" is displayed.

8. Tap the Close button, and then tap the Back button until you return to the Home screen.

7.3 Troubleshooting error messages

Errors shown on the touchscreen controller are described below as well as diagnoses and fixes.

7.3.1 Touchscreen error messages

The bottom line of the touchscreen displays the boiler's error status. The following colors represent the boiler's operating status:

Green – Normal

Yellow – Warning

Red – Alarm

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 88.

7.3.2 Maximum ignition trials error

Maximum Ignition Trials Error

Issue Diagnosis Fix

Error – Ignition Failure after 3

tries boiler has failed to ignite

on 3 successive attempts.

Boiler is in lockout for 1 hour,

then repeats 3-try sequence.

Consult service technician if

error recurs.

No spark when igniting.

Ignition probe/flame

sensor disconnected.

Check that ignition lead is secure at the

control module and at the probe.

Manual gas shutoff is

closed or gas line not

fully purged.

Check for gas flow. Open manual gas

shutoff and reset boiler.

Gap between ignition

probe rods is too large

or too small.

Adjust ignition probe rod gap between ⅛

and 3/16th (3.2-4.7 mm).

Spark, but no ignition. Check spark module is sending power to

gas valve – close gas supply, then

disconnect (black) electric housing from

face of gas valve, gently spread plastic tabs

to open, and look for 24vac voltage during

an ignition cycle. Replace module if no

current detected

Boiler ignites, but shuts

off at the end of the

ignition trial. Improperly

grounded pressure

vessel/burner or

unserviceable ignition

lead or spark module.

Ensure the pressure vessel is grounded.

Check the ignition probe/flame sensor is

electrically isolated from the vessel, and its

ceramic insulator is intact. Replace ignition

lead Replace spark module.

Section: Troubleshooting

7.3.3 Hi/Low gas pressure switch error

High/Low Gas Press Error

Issue Diagnosis Fix

Error – High/Low Gas Press Inlet gas pressure has risen

above 15" w.c. or has fallen below

3.5" w.c.

7.3.4 Hi Limit cut-off temperature error

Hi Limit cutoff temperature Error

Issue Diagnosis Fix

Error – Water High-Limit

Exceeded

Water temperature exceeds hi-limit. Boiler is in hard

lockout mode.

7.3.5 Low Water Cut-off error

Measure the inlet gas pressure.

Reset the switch.

See Water

Temperature

function:

reset and

test on page

84.

Low Water Cutoff Error

Issue Diagnosis Fix

Error - Low Water Cutoff The Safety and Ignition module

has detected a low water

condition.

See Low water cutoff function:

reset and test à la page 83.

7.3.6 Aux. Interlock 1 or 2

Section: Troubleshooting

Issue Diagnosis Fix

Aux. Interlock 1 or 2

Interlock 1 or 2 terminals are

open.

Jumper lead is loose or

compromised.

External safety is in an alarm state. Inspect the external safety

Replace the jumper lead.

devices.

7.4 Miscellaneous touchscreen controller errors

Miscellaneous errors

Issue Diagnosis Fix

“Loop/Indoor Sensor”

“Insufficient Air Flow”

“Insufficient Water Pressure”

“Unknown Error” The sensor

The sensor

plug is not

engaged.

plug is not

engaged.

Check the P501 plug is fully

engaged in the back of the

controller board.

Check the P501 plug is fully

engaged in the back of the

controller board.

Error - Max. Inlet/Outlet Sensor Temp. Exceeded. ->

Check water flow Water temperature signal not within

acceptable range. Potential flow or sensor failure.

Consult service technician.

Temperature

sensor input

problem.

Current outlet

temperature

exceeds

operating

limit.

Defective or

disconnected

temperature

sensor.

Test each temperature

sensor for appropriate

readings and Replace

defective temperature

sensor.

Check water flow.

Check wiring to temperature sensor and control module.

Check temperature sensor.

Miscellaneous errors

7.4.1 Ignition issues

Issue Diagnosis Fix

Blank – screen dark, but fan running Indicative of

power-surge damage to appliance

Controller is stuck in "service" mode after software update.

If update fails

or no updates

applied.

7.4.1 Ignition issues

Ignition issues

Issue Diagnosis Fix

Noisy spark when igniting Ignition lead is not firmly

connected.

Contaminants/moisture

on igniter probe/flame

sensor.

Check transformer; replace if

damaged.Check circuit

board for visible damage.

Restarting returns the boiler

to normal operation.

Reconnect ignition lead.

Ensure probe is dry by re-running post-

purge; otherwise, clean or replace

igniter probe.

Boiler rumbles when igniting. Fluctuating gas pressure/

gas pressure too high/too

low.

Check for proper gas

piping

Boiler will not attempt to ignite. Fan

and pump are operating normally.

Boiler will not attempt to ignite. Fan

and / or pump are off Display not

illuminated

No power to ignition

control module.

Igniter probe/flame

sensor disconnected.

Defective Control Module. Check ignition output from control

No power to boiler. Check line voltage.

Defective transformer. Check transformer. Reconnect or

Check CO2level via analyzer.

Check pressure with manometer during

ignition.

Check system wiring.

Check air reference tubing.

Reconnect probe.

module.

replace as needed.

7.4.2 Temperature issues

Section: Troubleshooting

Issue Diagnosis Fix

Temperature issues

Low heat Operating temperature too low.

Increase temperature target.

Priority parameters or load

configuration improperly set up.

Unit undersized. Refer to Load Calculation vs. Boiler Output.

Air trapped within system. Bleed system as required.

Improper system piping. Refer to recommended piping guidelines for

System pump undersized. Check pump manufacturer’s data/check

Poor gas:air mixing. Check CO2level.

Defective thermostat. Refer to manufacturer’s instructions.

Obstruction in condensate drain. Inspect and clean condensate drain.

Unit cycling on operating/ safety

controls.

System radiation undersized. Check manufacturer’s rating tables for

Increase temperature target.

Review load configuration parameters.

the respective boiler model.

temp differential across heat exchanger.

Check operation with Ohmmeter/Voltmeter.

capacity per foot.

Temperature exceeds

thermostat setting

One or more zones

do not heat properly

Incorrect anticipator setting. Check with Ammeter.

Thermostat not level. Check level.

Air trapped within zone(s) piping Vent system/zone as required.

Low radiation/ excessive heat

loss.

Low flow rate to zone(s). Check temperature drop across zone.

Defective zone valve/ zone

circulator.

Check actual length of pipe using radiation /

heat loss calculation.

Check operation per manufacturer’s

instructions.

7.4.3 Miscellaneous issues

Miscellaneous issues

Issue Diagnosis Fix

Fumes and

High Humidity

Boiler stuck

on Initialize

‘Ghost’ call for

heat.

Error: Water

High Limit /

Low Water

Cutoff won’t

clear.

DHW taking

too long to

heat.

Improperly installed

condensate trap

Leak in vent piping Inspect using soap solution.

Flue gas leak within boiler Visually inspect all mechanical connections.

Fan board failure Replace fan.

Triac or ‘Power-robbing’

thermostat sending current

to boiler.

Boiler is in 1 hour safety

lockout.

Sensor may be under-

reading actual water temp.

Refer to installation/operation instructions.

Remove Therm. connections from boiler to confirm that stray

voltage, or current induced in thermostat wiring, is source of

nuisance signal. 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).

Reset safety device and cycle boiler power off and on to reset

error.

Check sensor engagement; note well is 15cm / almost 6

inches deep and sensor must be fully set to back. Check

programmed settings boiler temp set too close to the required

DHW temperature.

Boiler output

not

modulating up

to maximum

despite target

not being

reached.

Primary Pump

runs but load

pumps do not.

Possible flow issue: check

for 35 or 40 °F temperature

difference between boiler

supply and return water

temperatures (evokes

electronic fence).

Wiring not complete. Supply power to the PV/L and PV/N terminals from the

Confirm that primary pump is able to overcome head loss of

boiler and primary loop piping at the required flow rate.

incoming power supply to the boiler. (Factory wired on boilers

with a factory installed touchscreen controller)

7.4.4 Cycling issues

Section: Troubleshooting

Cycling issues

Issue Diagnosis Fix

Rapid

Cycling

Improper values entered via keypad. Check load maximum temps are above target

temps, by ½ of the selected boiler differential.

Ensure boiler differential is OK (16 - 30 °F is

generally adequate)

Excess condensate in venting. Check venting slopes on horizontal runs. Look for

sags.

Obstruction in condensate trap. Inspect and clean condensate trap.

Improper vent length or improper

slope to vent.

Incorrect settings or defective

thermostat.

Air in system or marginal water flow. Bleed/purge system as required. Confirm adequate

Slow combustion air blower. Check that CO2level is within specification.

Dirty burner/heat exchanger. Check pressure drop.

Low water flow due to improper

piping.

Check venting. Compare vent length and diameter.

Check operation. Refer to manufacturer’s

instructions. Check setting with ammeter.

pump size and temp rise in the heat exchanger.

Refer to recommended piping for the respective

boiler model.

Low water flow due to undersized

pump.

Low water flow due to restrictions in

water pipe.

Low radiation. Check actual amount of radiation per zone and refer

Unit over-fired. Clock gas meter/check gas pressure with

Unit Oversized. Check load calculation vs. minimum boiler output.

Improperly set or defective

operating/safety controls.

Check manufacturer’s rating charts/check

temperature differential across heat exchanger.

Check temperature differential across zone/heat

exchanger.

to manufacturer’s rating tables.

manometer/ check CO2level.

Check operation with ohmmeter/voltmeter.

Appendices

Wiring diagrams

Figure 39 Controller electrical diagram

Figure 40 Internal wiring diagram

Section: Appendices

Figure 41 Sequence of Operation

Wiring diagrams

Installation & Commissioning Report

Section: Appendices

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

□Leak testing completed □ Gas piping □ Venting system □ Fan □ combustion components □System Cleaned and Flushed (type of cleaner used) __________________________________ □System Filled (type/concentration of any glycol/chemicals used) _________________________ □Air purge completed □Relief Valve correctly installed and piped Relief valve “try lever” test performed □Condensate trap filled Condensate drain clear and free flowing Condensate Neutralization. □Ignition Safety Shutoff test completed. Flame current reading - High fire _____ µA - Low fire _____ µA □Owner advised and instructed in the safe operation and maintenance of the boiler and system. □Information regarding the unit and installation received and left with owner

Combustion Readings:

CO2_____________ % O2______________ % CO ____________ ppm

Flue temperature ___ Return water temperature (measure simultaneously with flue temp.) _____

Commissioning has been completed as listed on this report - Installer Signature _____________

Installers: send this completed sheet - Fax to 604 877 0295 - or - scan and Email to info@ibcboiler.com.

Boiler parts diagram

Item

Number

Description Part Number Replacement Kit Numbers

10 Door 500-134 P-1209

20 Controller 500-044 P-242

30 Safety Ignition Module 500-105 P-270

40 Top panel 251-030 P-1227

50 Controller module chassis 251-042 P-1228

60 Gas valve relay 240-165 P-1233

70 Boiler pump relay 240-165 P-1233

80 Transformer 240-008 P-9059

90 Air pressure sensor (behind

controller)

240-162 P-1210

100 Vessel high limit switch (behind

controller)

240-030 P-9070

Boiler parts diagram

Item

Number

Description Part Number Replacement Kit Numbers

Wiring harness (not shown) P-1232

Item Number Description Part Number Replacement Kit Number

150 Fan 240-156 P-1212

160 Fan gasket 255-126

Section: Appendices

IBC Boilers EX 700, EX 850 Installation And Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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

3.5.1 Code

3.5.2 Applications

3.5.3 Exhaust vent material

3.5.4 Vent travel

3.5.5 Venting passage through ceiling and floor

3.5.6 Rooftop vent termination

3.5.7 Sidewall vent termination

3.5.8 Direct vent combustion air intake piping

3.5.9 Indoor air combustion air intake

3.5.10 Combustion air filtration system

3.6 Installing a condensate trap

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

4.1 Controller

4.2 Control interface

5.0 Before operating the boiler

5.1 Important pre-ignition checks

5.1.1 Checklist for electrical conditions, ducting and water connections

6.0 Service and maintenance

6.1 Maintenance checklists for manager of unit

6.2 Maintenance checklists for heating contractor

6.2.1 Venting

6.2.2 Condensate trap

6.2.3 Burner

6.2.4 Heat exchanger

6.2.5 Pump

6.2.6 Gas piping

6.2.7 Touchscreen boiler controller

6.2.8 Water

6.2.9 Freeze protection

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

7.2.1 Temperature sensors

7.2.2 Fan

7.2.3 Air pressure sensor

7.2.4 Water pressure sensor

7.2.5 Gas pressure switches

7.2.6 Safety and Ignition Module (SIM)