IBC EX 850 Guide

User's Information 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 or less
Important: Ensure that these limits are acceptable for the other water-side components in the
system.

1
Contents
Safety information 3
Manual safety markings 3
Important safety instructions 3
Domestic hot water 6
Boiler operation 8
Lighting and shutting down the boiler 8
Service and maintenance 9
Maintenance checklists 9
Relief valve - maintenance and testing 11
Blocked vent safety system 11
Revision history 12

Intentionally left empty

3
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
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.
Warning
Keep boiler area free and clear of combustible materials, gasoline, and other flammable vapors
and liquids.
Warning
Combustion air must not be drawn from areas containing corrosive air from swimming pools or
spas, including air directly next to outdoor pools and spas.
Warning
The boiler must not be exposed to water leaks from piping or components located overhead. This
includes condensation dropping from un-insulated cold water lines overhead.

Warning
In areas of high snow fall, users must check side wall exhaust vent and air intake terminations
on a regular basis to ensure blockages do not occur.
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 control system and any gas
control that has been under water.
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
Close fill valve after any addition of water to the system, to reduce risk of water escapement.
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.
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Section: Contents

Caution
The heat exchanger has a small amount of combustion chamber insulation (refractory), which
contains ceramic fibers. When exposed to extremely high temperatures, the ceramic fibers, which
contain crystalline silica, can be converted into cristobalite - which is classified as a possible
human carcinogen.
Care should be taken to 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.
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
5
Safety information

Known Corrosive Contaminants to Avoid
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
Domestic hot water
Warning
HOT WATER CAN SCALD!
Water Temperatures over 125°F / 52°C can cause severe burns instantly or death from scalds.
Children, disabled, and elderly are at highest risk of being scalded.
Never leave then unattended in or near the shower, bathtub or sink.
Never allow small children to use a not water faucet or draw their own bath.
To avoid any potential scald hazard or if codes require specific water temperatures at the hot
water faucet, the installer must:
Install a thermostatic mixing valve at the outlet of the Domestic Hot Water Indirect
Water Heater outlet and ensure it is working properly.
AND
Set the thermostatic mixing valve to the lowest temperature which satisfies your hot
water needs.
To avoid injury:
Feel and adjust water temperature before bathing or showering.
Water drained from the system drain valve may be extremely hot.
Make sure all connections are tight.
Direct water flow away from any person.
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Section: Contents

Warning
Bacteria growth can develop in domestic hot water tanks and indirect water heaters if the
minimum water temperature is not set high enough to prevent its growth.
7
Domestic hot water

Boiler operation
Lighting and shutting down the boiler
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Section: Contents