IBC EX Series Installation instructions

INSTALLATION&
OPERATING MANUAL
Commercial Condensing Boilers
EX 400
EX 500
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])
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:
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

1
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 appliance 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 53
3.9.1 Gas pressure 53
3.10 Electrical connections 54
3.10.1 Power quality and electrical protection 55
3.10.2 120VAC line-voltage hook-up 55
3.10.3 Other wiring 58
3.10.4 Thermostat / sensor wiring 58
3.10.5 Thermostat heat anticipator 59
4.0 About the boiler controller 61
4.1 Controller 61
4.2 Controller 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 Boiler operation 65
6.1 Lighting and shutting down the boiler 65
6.2 Testing the ignition safety shutoff 66
6.3 Commissioning 66
6.3.1 Checking a boiler's fuel source 66
6.3.2 Performing a fuel conversion 67
6.3.3 Measuring the inlet gas pressure 72
6.3.4 Adjusting the gas valve (EX 400, EX 500) 74
6.3.5 Adjusting the gas valve (EX 700, EX 850) 76
6.3.6 Resetting the gas high / low pressure switches 77
7.0 Service and maintenance 79
7.1 Maintenance checklists for heating contractor 79
7.1.1 Venting 80
7.1.2 Condensate trap 80
7.1.3 Burner 80
7.1.4 Heat exchanger 81
7.1.5 Pump 81
7.1.6 Gas piping 81
7.1.7 Touchscreen boiler controller 82
2
Section: Contents

7.1.8 Water 82
7.1.9 Freeze protection 83
7.1.10 Boiler treatment 83
7.1.11 Relief valve - maintenance and testing 84
7.2 Replacing the fan, gas valve, and burner in EX 400 and EX 500 models 85
7.2.1 Replacing the fan on the EX 400 and EX 500 models 86
7.2.2 Replacing the gas valve in the EX 400 and EX 500 models 87
7.2.3 Replacing the burner in the EX 400 and 500 models 90
7.3 Replacing the fan, gas valve, and burner in EX 750 and EX 800 models 96
7.3.1 Replacing the fan on the EX 700 and EX 850 models 97
7.3.2 Replacing the gas valve in EX 700 and EX 850 models 98
7.3.3 Replacing the burner in the EX 700 and EX 850 models 100
7.4 Replacing the air filter 102
7.5 Cleaning a condensate trap 103
8.0 Troubleshooting 105
8.1 Preliminary checks 105
8.2 Electronic components 106
8.2.1 Temperature sensors 106
8.2.2 Fan 107
8.2.3 Air pressure sensor 107
8.2.4 Water pressure sensor 107
8.2.5 Gas pressure switches 108
8.2.6 Safety and Ignition Module (SIM) 108
8.3 Troubleshooting error messages 111
8.3.1 Touchscreen error messages 111
8.3.2 Maximum ignition trials error 112
8.3.3 Hi/Low gas pressure switch error 113
8.3.4 Hi Limit cut-off temperature error 113
8.3.5 Low Water Cut-off error 113
8.3.6 Aux. Interlock 1 or 2 113
8.4 Miscellaneous touchscreen controller errors 114
8.4.1 Ignition issues 115
8.4.2 Temperature issues 116
8.4.3 Miscellaneous issues 117
8.4.4 Cycling issues 118
3

Appendices 119
Wiring diagrams 119
Installation & Commissioning Report 123
Boiler parts diagram - EX 400 and EX 500 125
Boiler parts diagram - EX 700 and EX 850 129
Revision history 133
4
Section: Contents

5
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. 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 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 and ice
clearing
6
Section: Safety information

7
Specifications
Specifications EX 400 EX 500 EX 700 EX 850
CSA Input (natural gas or propane) -
MBH
40-399 50-500 70 - 700 85 - 850
CSA Input (natural gas or propane) - kW 11.7 - 117 14.6 - 146.5 20.5 - 205 24.9 - 249
CSA Output - MBH 388 485 679 824.5
CSA Output - kW 114 142 199 241.6
Thermal Efficiency 97.9 97.5 97.0 97.0
Minimum gas supply pressure (natural
gas or propane) - inch w.c.
4 4 4 4
Maximum gas supply pressure (natural
gas or propane) - inch w.c.
14 14 14 14
Ambient temperature:
Low °F / °C
High °F / °C
32 / 0
122 / 50
32 / 0
122 / 50
32 / 0
122 / 50
32 / 0
122 / 50
Max. relative humidity (non-condensing) 90% 90% 90% 90%
Minimum water temp. °F / °C 34 / 1 34 / 1 34 / 1 34 / 1
Maximum water temp. (electronic hi-
limit) °F / °C
190 / 88 190 / 88 190 / 88 190 / 88
Max. ΔT - supply/return (electronic
fence) °F / °C
80 / 44 80 / 44 80 / 44 80 / 44
Max. Water Temperature Lockout Limit
°F / °C
201 / 94 201 / 94 201 / 94 201 / 94
Power use (120Vac/60Hz) @ full fire -
Watts (less pumps)
150 210 195 228
Weight (empty) - lbs/Kg Approx. 414 /
188
Approx. 441 /
200
Approx. 486 /
220
Approx. 510 /
231
Heating surface area - ft2/ m255.3 / 5.14 72.9 / 6.77 84.6 / 7.86 99.88 / 9.28
Pressure vessel water content -
USG/Liters
13.5 / 51.1 12.4 / 46.9 17.5 / 66.3 16.4 / 62.0
Maximum boiler flow rate - USgpm 100 100 100 100
Minimum boiler flow rate - USgpm 10 12 18 21
Maximum operating water pressure* -
psig
160 160 160 160
Minimum water pressure - psig 8 8 8 8

Specifications EX 400 EX 500 EX 700 EX 850
Relief valve pressure (supplied) - psig* 50 50 50 50
Approved installation altitude - ASL 0 - 12,000' 0-12,000' 0 - 12,000' 0-12,000'
Maximum equivalent vent length each
side (vent & air intake) (natural gas or
propane)
Air intake options: either direct vent or
indoor supply
170' 170' 120' 120'
*These alternative relief valves can be purchased: 30, 100, 125 and 150.
Connection specifications
The following table displays the required connection specifications for each model.
EX 400, EX 500 EX 700, EX 850
Flue Outlet 4" Schedule 40 6" Schedule 40
Combustion Air Inlet 4" Schedule 40 4" Schedule 40 (See note
below)
Water Outlet 2" NPT-M 2½" NPT-M
Water Inlet 2" NPT-M 2½" NPT-M
Knock-outs (8) ½" ½"
Gas Inlet 1" NPT-F 1" NPT-F
Condensate Outlet ¾" Hose ¾" Hose
Table 1 Connections
Note
You must use a reducer to connect 6" vent piping to the 4" vent collar. See Figure 22 .
8
Section: Specifications

Cabinet dimensions
Figure 1 Frontal view - EX 400, EX 500 Figure 2 Back view - EX 400, EX 500
Figure 3 Top view - EX 400, EX 500
9
Cabinet dimensions

Figure 4 Frontal view - EX 700, EX 850 Figure 5 Back view - EX 700, EX 850
Figure 6 Top view - EX 700, EX 850
10
Section: Specifications

11
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 7 Front internal view
Figure 8 Back view of boiler

1.1 Standard features and benefits
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-limited warranty on the EX series heat exchanger and a 2-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.
12
Section: Introduction

13
2.0 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 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, dry-cleaning 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 discharge location.
□

Precautions Check
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.
14
Section: Before installation

15
3.0 Installation
The gas-fired modulating boilers are low pressure, fully condensing appliances 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.
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.
Table 2 Code requirements by country
3.2 Determining location of the appliance
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 for 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
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 3 ).
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 when renovating:
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.
16
Section: Installation

3.2.1.1 Anchoring the 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 9 Boiler packaging dimensions (inches)
17
3.3 Unpacking a boiler

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 400, EX 500, EX 700, EX 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
Table 3 Clearance distances for boiler mounting sites
3.5 Exhaust venting and air intake venting
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.
When planning a boiler's installation, consider the appropriate vent materials, travel and
termination.
18
Section: Installation