IBC EX Series User manual

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

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 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
2
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
3

Installation & Commissioning Report 96
Boiler parts diagram 97
Revision history 101
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 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
6
Section: Safety information

7
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
8
Section: Specifications

Cabinet dimensions
Figure 1 Frontal view Figure 2 Top view
Figure 3 Back view
9
Cabinet dimensions

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 4 Front internal view
Figure 5 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 warranty on the EX series heat exchanger and a 1-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 unit, 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
□

Precautions Check
discharge location.
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 units 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 3 Code requirements by country
3.2 Determining location of the unit
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 from 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 4 ).
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 during renovations:
Take action to 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. Do not seal boiler case openings directly when
firing - allow for air circulation and ventilation in the immediate area.
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 6 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 700, 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 4 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