IBC EX Series User manual

EX Series Quick Reference Installation Guide
Boiler Mounting (Section 3.0 of the manual)
Venting (Sections 3.5)
Gas Supply (Section 3.9)
Follow the venng specicaons and informaon for the correct venng
material and venng length provided in the above secons of the
manual.
Ensure that sidewall conguraons have adequate vercal separaon,
and that exhaust plumes are well away from all building air intake vents.
Ensure that all venng material is sloped towards the boiler at
a minimum of ⅝″ per foot or at a slope required by the PP vent
manufacturer, whichever is greater.
Ensure that PPs venng is supported every 36″ (min).
On longer horizontal runs of PVC and CPVC, increase the grade to ⅜″ or
more.
Fully insert the approved venng material into the boiler’s exhaust
outlet, and ghten the clamp to ensure
the venng connecon is locked in
place.
Check that the venng is securely
aached to the exhaust ue of the
boiler by pulling on the venng.
Important: Use appropriate appliance adapters when using PPs
or stainless steel venng.
Condensate Trap (Section 3.6)
1. Fill the trap assembly with water.
2. Aach the trap to the drain elbow.
3. Tighten the union nut.
4. Check for leaks.
For gas delivery to the boiler, we recommend using hard piping
rather than exible piping. If you use exible piping, ensure that
the gas pipe size is appropriate for the maximum BTU input of
the boiler.
Minimum Gas Pressure 4" w.c.
Maximum Gas Pressure 14" w.c.
Size piping for sucient sustained gas delivery at sucient
pressure to the boiler.
Recommended Supply Pressure at Full Load
Natural Gas 7"
Propane 10"
• Ensure that there is a minimum of 6 feet of piping between
the boiler and gas regulators.
• Use a manometer to test that gas delivered to the boiler is
delivered at sucient pressure and that “lock up” does not
exceed the maximum pressure.
• If using a 5 psi to inches vented gas regulator, always oversize
the vent pipe to prevent hunng of the gas regulator when
boilers are ring at lower output levels.
In retrots with exisng copper gas pipes, clean and clear the
gas piping of any debris before connecng to the boiler. Failure
to do so can result in a blocked gas valve and inconsistent
performance.
Maximum Pipe
Length by Modell
1¼″
IPS
1 ½″
IPS 2″IPS 2 ½″ IPS
EX 400 (Natural Gas) 150’ 350’ 1000’ >2000’
EX 400 (Propane) 400’ 900’ >2000’ >2000’
EX 500 (Natural Gas) 100’ 200’ 700’ 1800’
EX 500 (Propane) 250’ 600’ 2000’ >2000’
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'
LWCO Errors
To clear LWCO errors caused by air:
1. Ensure that there is no air trapped in the boiler and
boiler piping.
2. On the touchscreen controller Main Menu, go to
Diagnoscs> Advanced Diagnoscs> Clear System
Errors> Yes> OK.
Ensure that the boiler’s anchor brackets are securely bolted to the
oor.
QS003 Quick Reference Installaon Guide - EX 400, 500, 700, EX 850
Important: Before turning o the boiler, make sure it is in
“Standby” mode.
Low Gas Pressure Errors (Section 6.3.5)
Every new install will require reseng the low gas pressure
switch. To do so, press on the red reset buon.
Important: Not applicable for construcon heang. Fouled fans,
burners, and ignitors are not covered under warranty.
Low gas
pressure
switch
High gas
pressure
switch
Maximum Exhaust Venng Lengths
Exhaust Pipe Size EX 400, EX 500 EX 700, EX 850
Sched.40; Rigid PPs
4" PVC/CPVC / Rigid PPs/SS 170' (each side) n/a
6" PVC/CPVC / Rigid PPs/SS n/a 120' (each side)
90° vent elbow allow 5' equivalent allow 5' equivalent
45° elbow allow 3' equivalent allow 3' equivalent
PPs 87-90° elbows use 5' equivalent use 5' equivalent

We recommend that you always use a primary/secondary piping
conguraon (see below for a basic conguraon).
In the case of hard water, use dislled or puried water. Glycol
systems require the use of propylene glycol. For large volume
systems, the opmum hardness is ≤2 grains.
Water Chemistry Allowable Limits
Acidity pH 6.6 - 8.5
Chloride < 125 mg/l
Iron < 0.5 mg/l
Copper <0.1 mg/l
Conducvity < 400μS/cm (at 25°C)
Water Hardness < 7 Grains
• Place an air separator at the highest point. These must be
installed above each boiler.
• Install the pressure relief valve in a vercal posion. Do not
use an isolaon valve between the boiler and relief valve.
• Support all piping with appropriate piping brackets.
• Plumb an appropriately sized expansion tank and make up
the water staon into a ng on the sucon side of the
circulator.
• Size boiler piping and pumps for the BTU output of the boiler.
For non-oxygen barrier piping systems, use a dirt separator and/
or a side stream lter. Ensure that the system is free of iron
components, and treat with an inhibitor.
Electrical (Section 3.10)
1. Connect the boiler to a dedicated (max.)15 Amp breaker.
2. Wire the AC to the black and white wires labeled in the
Field wiring box.
3. Ensure that the boiler is properly bonded (grounded).
4. Refer to the “Wiring Diagrams” secon in the Installaon
and Operang Instrucons manual (Fig 42) for more
informaon.
5. Wires labelled “Boiler Pump:” Wire power for the boiler
pump to the black wire, and the boiler pump “L” (hot)
connecon to the yellow wire.
6. Wire the respecve load pumps into the TB1 Terminal; for
example, PV 1, 2, 3, 4.
Electrical continued (Section 3.10)Water Piping (Section 3.8)
1. Wire thermostats or end switch dry contacts to Therm 24
Vac, and then connect the other wire to Therm 1, 2, 3, 4
corresponding to the load pump PV1, 2, 3, 4.
2. For a DHW load, wire either an Aquastat to the appropriate
Therm. connecon or a 10K Ω type II/B curve thermister to
the DHW Sensor connecon.
The boiler requires proper grounding, which conforms to all
electrical codes, ensuring proper ame reccaon.
• For mulple-boiler setups, use a secondary loop sensor wired to
the Master boiler.
• For zone valves or external peripherals, use external
transformers.
Note: If a load is dened as Reset Heang, the outdoor sensor
must be used for proper operaon.
Express Setup
1. On theV-10 Touchscreen controller, tap the Home (Standby)
screen>Main Menu>Express Setup.
2. Do the following:
a. Tap the Enter Design Outdoor Temperature box, and
enter a value.
b. Tap Set Clock to set the me and date.
c. Tap Save.
3. Select a load and then select the load type.
4. Accept the defaults, or change any of the sengs.
5. You can nd more substanal sengs in "Installer Sengs".
6. Tap the Save buon.
Manual Pump Purge
Aer the system is pressurized and you have dened loads,
perform a manual pump purge to ensure air is purged.
On the touchscreen controller, go to Main Menu> Installer
Sengs> System Sengs > Site Sengs>Set Manual Pump
Purge to "ON">OK>Save.
The manual pump purge runs unl it is turned o, or when there
is a call for heat.
Checklist
Treated water or Polypropylene glycol mixture in the pipes. □
Boiler system is pressured and ushed ≥ 8 psi. □
All gas connecons soap-tested for leaks and now leak free. □
Voltage supply to the boiler tested for voltage (nominal 120
Vac), polarity, and properly grounded.
□
The boiler requires a dry set of contacts in the Therm
connecons.
□
Boiler power turned on. □
Reset low gas pressure switch □
Use the “Express Setup” in the touchscreen controller to set
up the required loads. See above for instrucons.
□
Steps followed in the “6.3 Commissioning” secon of the
Installaon and Operang Instrucons manual.
□
Completed the Installaon & Commissioning Report in the
Installaon and Operang Instrucons manual - Combuson
Readings recorded.
CO2__________% O2 ________ % CO _______ppm
□
1. Pressure relief valve (shipped with boiler): no isolaon valve
permied between boiler and relief valve
2. Tridicator (shipped with boiler)
3. Microbubble air eliminators
4. Expansion tank connecon
5. Boiler Pump
6. Closely-spaced tees to/from Load 1
7. Closely spaced tees to/from Load 2
8. Fill staon
9. Dirt seperator recommended