IBC EBX Series User manual

Residential Electric Boiler
EBX4K-240 (model #IBEXSW1-004K)
EBX8K-240 (model #IBEXSW1-008K)
EBX10K-240 (model #IBEXSW1-010K)
EBX12K-240 (model #IBEXSW1-012K)
INSTALLATION &
OPERATINGMANUAL
WARNING
Risk of electric shock. If the information in this manual is not followed exactly, a fire or
electrocution may result causing property damage, personal injury, or loss of life.
Do not store or use gasoline or other flammable vapors and liquids or other combustible
materials in the vicinity of this or any other appliance.

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 reduce dissolved solids to 30 ppm.
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)
7 grains/ gal (120 ppm)
Important: Ensure that these limits are acceptable for the other water-side components in
the system.
Shipped with the boiler:
1 x Wall mounting bracket
1 x 30 psig pressure relief valve
2 x ¼" x 2 ½" Lag screws/w flat washers

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 appliance 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.
Warning
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 system that has been under
water.
3
Safety information

Warning
Improper installation, adjustment, alteration, service or maintenance can cause
property damage, personal injury, or loss of life. Read and understand the entire
manual before attempting installation, start-up, operation, or service. Installation and
service must be performed only by an experienced, skilled installer or service agency.
Failure to follow all instructions in the proper order can cause personal injury or death.
Read all instructions, including all those contained in component manufacturers’
manuals before installing, starting up, operating, maintaining, or servicing the
appliance.
Warning
Disconnect power supply before any wiring/service is performed. Failure to do so could
result in damage to appliance and/or electric shock.
Caution
The boiler must be installed so that electrical components are not exposed to water
during operation.
Known contaminants
Known Corrosive Contaminants to Avoid
Cements and glues Refrigerant leaks from cracks in coils
Paint or varnish removers Sodium chloride or potassium chloride used for
water softening
Adhesives used to fasten building products
and other similar products
Chemicals in perming solutions
Chlorinated waxes or cleaners Chlorofluorocarbon chemicals found in spray cans
Chlorine-based swimming pool chemicals Antistatic dryer sheets in clothes dryers
Hydrochloric acid or muriatic acid used in
household cleaning and stain removal
Chlorine-type bleaches, detergents, and cleaning
solvents found in household laundry rooms
Calcium chloride used for snow clearing
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Section: Safety information

5
Contents
Safety information 3
Manual safety markings 3
Important safety instructions 3
Known contaminants 4
Specifications 7
Cabinet dimensions 7
EBX-series dimensions 7
Connection specifications 8
4.0 Introduction 13
4.1 Standard features and benefits 13
4.2 Warranty 13
4.3 Internal view 14
5.0 Before installation 17
6.0 Installation 19
6.1 Code requirements 19
6.2 Removing an existing gas boiler 19
6.3 Determining the location of the boiler 20
6.4 Mounting the boiler 20
6.5 Installation clearances 22
6.6 Closet installations 22
6.7 Water Piping 22
6.8 Boiler Pump 24
6.9 Propylene glycol usage 25
6.10 Relief Valve 26
6.10.1 Pressure Gauge 26
6.11 General piping best practices 27
6.12 Electrical connections 36
6.12.1 Power management, quality and electrical protection 36
6.12.2 240VAC line-voltage hook-up 36
6.12.3 Boiler pump 37
6.12.4 Thermostat wiring 37
6.12.5 Other wiring 38
6.12.6 Load pump wiring 38

7.0 About the boiler controller 41
7.1 Controller 41
7.2 Control interface 42
7.2.1 Heat Types 43
8.0 Before operating the boiler 47
Checklist for electrical conditions and water connections 47
9.0 Boiler operation 49
9.1 Starting and shutting down the boiler 49
10.0 Service and maintenance 51
10.1 Maintenance checklist for homeowner 51
10.2 Replacing the elements 52
10.3 Replacing the pump 53
11.0 Troubleshooting 55
11.1 Electronic components 55
11.1.1 Temperature sensors 55
11.2 Troubleshooting error messages 57
11.2.1 Temperature issues 58
11.2.2 Miscellaneous issues 59
11.2.3 Cycling issues 59
Appendices 61
Wiring diagrams 61
Boiler parts diagram - EBX-series Boiler 64
Installation & Commissioning Report 66
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Section: Contents

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Specifications
Boiler Specification EBX4K-240 EBX8K-240 EBX10K-240 EBX12K-240
Power @ 240V 1.3 - 13.7 MBH
0.4 - 4.0 kW
2.7 - 27.3 MBH
0.8 - 8 kW
3.4- 34.1 MBH
1.0 - 10.0 kW
4.1 - 41.0 MBH
1.2 - 12.0 kW
Power @ 208V 1.0 - 10.2 MBH
0.3 - 3 kW
2.1 - 20.5 MBH
0.6 - 6.0 kW
2.6 - 25.6 MBH
0.8 - 7.5 kW
3.1 - 30.7 MBH
0.9 - 9.0 kW
Maximum Current Draw (with
pump) @ 240V
17.6 A 34.2 A 42.6 A 50.9 A
Maximum Current Draw (with
pump) @208V
15.4 A 30.0 A 37.1 A 44.3 A
Breaker Size 30 A 45 A 60 A 70 A
Copper Wire Size 10 AWG 8 AWG 8 AWG 6 AWG
Minimum Ambient temperature 32°F / 0°C
Max. Ambient temperature 122°F / 50°C
Maximum relative humidity
(non-condensing)
90%
Minimum water temp. 34°F / 1°C
Maximum water temp.
(electronic hi-limit)
190°F/ 88°C
Max. Water Temperature
Lockout Limit
210°F/ 99°C
Weight (empty) 29 lbs / 13.2 kgs
Minimum boiler flow rate 0.7 USgpm /
2.6 Lpm
1.4 USgpm /
5.3 Lpm
1.7 USgpm /
6.4 Lpm
2.1 USgpm /
8.0 Lpm
Maximum boiler flow rate 4.2 USgpm / x 16 Lpm
Maximum operating water
pressure*
50 psig / 345 kPa
Minimum water pressure 8 psig / 55 kPa
Element construction Titanium
*Boiler ships with a 30 psi Pressure Relief Valve
Cabinet dimensions
EBX-series dimensions

Figure 1 Frontal view - EBX-series Boiler Figure 2 Side view - EBX-series Boiler
Figure 3 Top view - EBX-series Boiler Figure 4 Bottom view - EBX-series Boiler
Connection specifications
The following table displays the required connection specifications.
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Section: Specifications

Description EBX-series Boiler
A Supply water outlet 3/4" NPT-M
B Return water inlet 3/4" NPT-M
C Supply power knock-out Dual 3/4" and 1"
D Control wiring knock-out 1/2"
Table 1 Connections
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Connection specifications

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Section: Specifications

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Connection specifications

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4.0 Introduction
4.1 Standard features and benefits
Compact
Modulating
Boiler pump built in
Easy set-up for Set-Point or Outdoor Reset heating
Flow-proving and high limit safeties built in
4.2 Warranty
For residential applications, IBC offers a 1-year warranty on the pump and the elements. All other
parts carry a 5-year warranty against defects in materials or workmanship and failures due to thermal
shock.
For commercial applications, IBC offers a 1-year warranty on all parts against defects in materials or
workmanship and failures due to thermal shock.
To view the full warranty statement for the EBX-series Boiler, go to ibcboiler.com.

4.3 Internal view
14
Section: Introduction

Incoming power wiring connections
Heating element (1 of 2)
Display screen / controller
Control wiring terminals
Return piping connection 3/4" NPT
Flow sensor / inlet temperature sensor assembly
Solid-state relay (modulation control block): see below for alternate
3-speed pump
Drain port
High temperature limit switch (manual reset)
Outlet temperature sensor
Outlet piping connection 3/4" NPT
Figure 5 Interior view
Figure 6 Item 7 alternate modulation control block
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4.3 Internal view

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5.0 Before installation
Before installing the appliance, it is important to review and observe the following checklist of
precautions:
Precautions Check
Care must be taken to properly size the boiler for its intended use. Prolonged full output
run time, over-sizing or under-sizing, and incorrect flow rates through the boiler can lead to
increased maintenance costs, equipment stress and premature failure.
□
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, dry-cleaning fluids, de-greasers and paint-removers all
contain vapors that can form corrosive acid compounds. 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. Do not seal boiler case openings directly when
operating - allow for air circulation and ventilation in the immediate area.
□
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 ¾" diameter) to a safe discharge location.
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6.0 Installation
Refer to the Specifications section for dimensional drawings and connection specifications. Use these
drawings to find a suitable location for the appliance.
6.1 Code requirements
The appliances are tested and certified under CSA22.2 No.165-17 and/or UL834 (5th edition). Below
are the code requirements for every installation.
Canada US
Conform to local codes, or in the absence of
these, with the latest editions of the Canadian
Electrical Code Part 1 CSA C22.2 No. 165-17.
Conform to the current National Electrical Code
ANSI/NFPA 70 and UL 834 (5th edition).
Table 2 Code requirements by country
6.2 Removing an existing gas boiler
When an existing gas boiler is removed from a common venting system, the common venting
system may 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, follow
the B149.1 Installation Code.
When removing an existing gas boiler, the following checks must be carried out for each of the
appliances still connected to the common exhaust system, by operating them one at a time:
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.
6.3 Determining the location of the boiler
The boilers are designed and approved for indoor installation (wall or rack mounting) 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.
Warnings
Keep the area around a boiler clear of combustible materials, gasoline, and
other flammable vapors and liquids.
Ensure that a boiler is not exposed to water leaks from piping or components
located overhead, including condensation from uninsulated cold water lines
overhead.
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.
6.4 Mounting the boiler
Warning
Do not mount the appliance to hollow wall structures - The combined weight of
the boiler, its water content and associated piping components can exceed 30
pounds (14 kg). Fasteners must be rated for this strain, and must be firmly anchored
into solid material that will support this weight. Installers must take necessary
precautions to avoid injury during the installation of this boiler.
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Section: Installation