IBC EX Series Manuel utilisateur

Installation and

Operating Manual

EX SERIES

Commercial Boilers

EX 700

EX 850

WARNING

If the information in this manual is not followed exactly, a fire or explosion may result causing

property damage, personal injury, or loss of life.

Do not store or use gasoline or other flammable vapors and liquids or other combustible

materials in the vicinity of this or any other appliance.

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.

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

Manual safety markings

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.

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.

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.

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/ m284.6 / 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.

Table 1 Specifications

Connection specifications

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

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

Table 2 Connections

Section: Specifications

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