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IBC EX Series User Manual
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Revisi
on
hi
s
tor
y
R
0
(O
c
tob
er
20
19
)
Initial
re
le
a
se
R
1
(Dece
mb
er
20
19
)
Upd
ated
f
ig
ur
e
3
6
,
an
d
a
d
de
d
ne
w
s
e
c
t
io
ns
on
me
asur
ing
t
h
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ess
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re
a
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e
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in
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e
ga
s
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ig
h
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r
ess
u
r
e
s
w
itc
he
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.
R
2
(F
e
b
ru
ar
y
2
0
20
)
I
n
t
r
o
du
c
t
io
n
of
the
ne
w
EX
40
0
an
d
EX
5
0
0
mod
els.
R
3
(Dece
mb
er
20
20
)
Ad
d
ed
f
u
e
l
c
on
v
e
rsion
inst
r
uct
io
ns.
134
136
Table of Contents
Default Chapter
3
Table of Contents
3
Safety Information
7
Manual Safety Markings
7
Important Safety Instructions
7
Known Contaminants
8
Specifications
9
Connection Specifications
10
Cabinet Dimensions
11
1 Introduction
13
Standard Features and Benefits
14
Warranty
14
2 Before Installation
15
3 Installation
17
Code Requirements
17
Determining Location of the Appliance
17
Factors to Consider for Best Installation Conditions
18
Unpacking a Boiler
19
Installation Clearances
20
Exhaust Venting and Air Intake Venting
20
Code
21
Applications
23
Exhaust Vent Material
23
Vent Travel
24
Venting Passage through Ceiling and Floor
26
Rooftop Vent Termination
27
Sidewall Vent Termination
29
Direct Vent Combustion Air Intake Piping
34
Indoor Air Combustion Air Intake
37
Combustion Air Filtration System
38
Installing a Condensate Trap
39
Installing a Condensate Neutralizer
41
Water Piping
43
General Piping Best Practices
45
System Piping
46
Gas Piping
55
Gas Pressure
55
Electrical Connections
56
Power Quality and Electrical Protection
57
120VAC Line-Voltage Hook-Up
57
Other Wiring
60
Thermostat / Sensor Wiring
60
Thermostat Heat Anticipator
61
4 About the Boiler Controller
63
Controller
63
Controller Interface
64
5 Before Operating the Boiler
65
Important Pre-Ignition Checks
65
Checklist for Electrical Conditions, Ducting and Water Connections
65
6 Boiler Operation
67
Lighting and Shutting down the Boiler
67
Testing the Ignition Safety Shutoff
68
Commissioning
68
Checking a Boiler's Fuel Source
68
Performing a Fuel Conversion
69
Measuring the Inlet Gas Pressure
74
Adjusting the Gas Valve (EX 400, EX 500)
76
Adjusting the Gas Valve (EX 700, EX 850)
78
Resetting the Gas High / Low Pressure Switches
79
7 Service and Maintenance
81
Maintenance Checklists for Heating Contractor
81
Venting
82
Condensate Trap
82
Burner
82
Heat Exchanger
83
Pump
83
Gas Piping
83
Touchscreen Boiler Controller
84
Water
84
Freeze Protection
85
Boiler Treatment
85
Relief Valve - Maintenance and Testing
86
Replacing the Fan, Gas Valve, and Burner in EX 400 and EX 500 Models
87
Replacing the Fan on the EX 400 and EX 500 Models
88
Replacing the Gas Valve in the EX 400 and EX 500 Models
89
Replacing the Burner in the EX 400 and 500 Models
92
Replacing the Fan, Gas Valve, and Burner in EX 750 and EX 800 Models
98
Replacing the Fan on the EX 700 and EX 850 Models
99
Replacing the Gas Valve in EX 700 and EX 850 Models
100
Replacing the Burner in the EX 700 and EX 850 Models
102
Replacing the Air Filter
104
Cleaning a Condensate Trap
105
8 Troubleshooting
107
Preliminary Checks
107
Electronic Components
108
Temperature Sensors
108
Fan
109
Air Pressure Sensor
109
Water Pressure Sensor
109
Gas Pressure Switches
110
Safety and Ignition Module (SIM)
110
Troubleshooting Error Messages
113
Touchscreen Error Messages
113
Maximum Ignition Trials Error
114
Hi/Low Gas Pressure Switch Error
115
Hi Limit Cut-Off Temperature Error
115
Low Water Cut-Off Error
115
Aux. Interlock 1 or
115
Miscellaneous Touchscreen Controller Errors
116
Ignition Issues
117
Temperature Issues
118
Miscellaneous Issues
119
Cycling Issues
120
Other manuals for IBC EX Series
Installation And Operating Manual
104 pages
Quick Reference Installation Guide
2 pages
4
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IBC EX Series Specifications
General
Brand
IBC
Model
EX Series
Category
Boiler
Language
English
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