IBC EX Series Istruzioni per l'installazione

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

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

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

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

Section: Contents

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

Section: Safety information

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 .

Section: Specifications

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