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IBC EBX Series Installation And Operation Manual Download Page 62

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Summary of Contents for EBX Series

Page 1: ...TALLATION OPERATING MANUAL WARNING Risk of electric shock If the information in this manual is not followed exactly a fire or electrocution 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 ...

Page 2: ...r 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 reduce dissolved solids to 30 ppm Other water chemistry allowable limits are as follows Acidity pH is to be between 6 6 and 8 5 Chloride is to be l...

Page 3: ... 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 flam...

Page 4: ...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...

Page 5: ...ents 19 6 2 Removing an existing gas boiler 19 6 3 Determining the location of the boiler 20 6 4 Mounting the boiler 20 6 5 Installation clearances 22 6 6 Closet installations 22 6 7 Water Piping 22 6 8 Boiler Pump 24 6 9 Propylene glycol usage 25 6 10 Relief Valve 26 6 10 1 Pressure Gauge 26 6 11 General piping best practices 27 6 12 Electrical connections 36 6 12 1 Power management quality and e...

Page 6: ... Service and maintenance 51 10 1 Maintenance checklist for homeowner 51 10 2 Replacing the elements 52 10 3 Replacing the pump 53 11 0 Troubleshooting 55 11 1 Electronic components 55 11 1 1 Temperature sensors 55 11 2 Troubleshooting error messages 57 11 2 1 Temperature issues 58 11 2 2 Miscellaneous issues 59 11 2 3 Cycling issues 59 Appendices 61 Wiring diagrams 61 Boiler parts diagram EBX seri...

Page 7: ...pper Wire Size 10 AWG 8 AWG 8 AWG 6 AWG Minimum Ambient temperature 32 F 0 C Max Ambient temperature 122 F 50 C Maximum relative humidity non condensing 90 Minimum water temp 34 F 1 C Maximum water temp electronic hi limit 190 F 88 C Max Water Temperature Lockout Limit 210 F 99 C Weight empty 29 lbs 13 2 kgs Minimum boiler flow rate 0 7 USgpm 2 6 Lpm 1 4 USgpm 5 3 Lpm 1 7 USgpm 6 4 Lpm 2 1 USgpm 8...

Page 8: ...oiler Figure 2 Side view EBX series Boiler Figure 3 Top view EBX series Boiler Figure 4 Bottom view EBX series Boiler Connection specifications The following table displays the required connection specifications 8 Section Specifications ...

Page 9: ...iption EBX series Boiler A Supply water outlet 3 4 NPT M B Return water inlet 3 4 NPT M C Supply power knock out Dual 3 4 and 1 D Control wiring knock out 1 2 Table 1 Connections 9 Connection specifications ...

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Page 11: ...11 Connection specifications ...

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Page 13: ...l applications IBC offers a 1 year warranty on the pump and the elements All other parts carry a 5 year warranty against defects in materials or workmanship and failures due to thermal shock For commercial applications IBC offers a 1 year warranty on all parts against defects in materials or workmanship and failures due to thermal shock To view the full warranty statement for the EBX series Boiler...

Page 14: ...4 3 Internal view 14 Section Introduction ...

Page 15: ... NPT Flow sensor inlet temperature sensor assembly Solid state relay modulation control block see below for alternate 3 speed pump Drain port High temperature limit switch manual reset Outlet temperature sensor Outlet piping connection 3 4 NPT Figure 5 Interior view Figure 6 Item 7 alternate modulation control block 15 4 3 Internal view ...

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Page 17: ...vers all contain vapors that can form corrosive acid compounds 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 pr...

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Page 19: ...iate tables in the National Fuel Gas Code ANSI Z223 1 latest edition In Canada follow the B149 1 Installation Code When removing an existing gas boiler the following checks must be carried out for each of the appliances still connected to the common exhaust system by operating them one at a time Seal any unused opening in the common venting system Visually inspect the venting system for proper siz...

Page 20: ... F 50 C and less than 90 relative humidity Warnings Keep the area around a boiler clear of combustible materials gasoline and other flammable vapors and liquids Ensure that a boiler is not exposed to water leaks from piping or components located overhead including condensation from uninsulated cold water lines overhead Ensure that combustible materials do not make contact with exposed water piping...

Page 21: ...ook the boiler tab located on back of boiler over the support bracket flange Ensure that the boiler tab is flush against the mounting bracket flange 3 Secure the lower part of the boiler to the wall with two field supplied bolts 4 Profile view of the lower mounting flange 21 6 4 Mounting the boiler ...

Page 22: ...allow access to elements Bottom 2 6 for drain and power supply access Table 3 Clearance distances for boiler mounting sites 6 6 Closet installations For installations in a confined space such as a closet ventilation openings may be needed through a door or wall to prevent excessive heat from building up inside the space The appliance must not be exposed to surrounding air above 122 F 50 C or below...

Page 23: ... 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 reduce dissolved solids to 30 ppm Other water chemistry allowable limits are as follows Acidity pH is to ...

Page 24: ...listed below according to the selected speed Table 4 EBX series pump available head 3 speeds water The installed pump is rated for the designed water temperature range some pumps have a minimum water temperature rating above the low temperature potential of the boiler 24 Section Installation ...

Page 25: ... the EB series boilers propylene glycol concentrations between 25 and 50 are permitted These boilers are designed for use within a closed loop forced circulation low pressure system A 30 psi pressure relief is supplied for field installation on the outlet piping Relief valve discharge piping must terminate between 6 15 cm and 12 30 cm above the floor or per local code Warning During operation the ...

Page 26: ...een its inlet and the boiler Make sure the relief valve outlet is piped with unobstructed piping minmum 3 4 diameter to a safe discharge location 6 10 1 Pressure Gauge The boiler does not include a water pressure sensor Field piping should always include a water pressure gauge or a tridicator 26 Section Installation ...

Page 27: ...l installation For further information and details consult our concept drawings which provide details on specific single and multiple boiler applications available in IBC s Technical portal There are many necessary components not shown and details such as thermal traps are left out so the drawings have greater clarity Our boilers must be installed by licensed and experienced heating professionals ...

Page 28: ...erature and lowest pressure on boiler outlet at expansion tank connection Expansion tank connection point of no pressure change there should be minimal pressure drop to circulator inlet in this case boiler inlet Fill station with isolation valve closed or fill tank Boiler primary pump is integral to boiler To from load Dirt separator recommended Figure 7 Boiler trim options single boiler 28 Sectio...

Page 29: ...he discharge may be directed back into the pressurization appliance for recycling of boiler fluid and chemicals back into the system In buildings that may be unoccupied for long periods of time pressurization appliances are useful to prevent flood damage should leakage occur from any component in the system An additional benefit is that backflow prevention devices are not required when using these...

Page 30: ...ond tee Heat Migration on secondary loops that extend vertically to a load that is above the primary loop steps must be taken such as fabricating a thermal trap in the return piping minimum 18 46cm drop to prevent thermal siphoning and heat migration to the load when there is no demand for heat to that loop Alternatively use check valves on both supply and return of secondary piping Figure 8 Prima...

Page 31: ...s heating calls The boilers can supply multiple heating loads with compatible supply temperature requirements Always ensure that loads sensitive to high temperatures are protected using means such as mixing valves 31 6 11 General piping best practices ...

Page 32: ...etween relief and boiler Pump integral to boiler must be verified capable of overcoming combined pressure drops of boiler system piping and air handler coil Dirt separator recommended where water quality is unknown Figure 10 One load direct piping concept 32 Section Installation ...

Page 33: ...alve Check valves Generously sized buffer tank connections hydraulically separate heat pump from loads Supply manifold Return manifold Figure 11 Heat pump boiler and backup EBX serving heat loads through a buffer tank 33 6 11 General piping best practices ...

Page 34: ...iler and relief valve Hydraulic separator Recommended expansion tank connection point Fill station with isolation valve closed or fill tank Supply piping to loads Returns to loads Figure 12 Primary Secondary multiboiler piping concept with hydraulic separator 34 Section Installation ...

Page 35: ...four pipe diameters apart with a minimum of eight pipe diameters of straight piping upstream of the first tee and a minimum of four pipe diameters of straight piping downstream of the second tee Supply to Heating System heat pump piping without buffer tank requires that every zone have a large thermal mass Return from Heating System see above Figure 13 Multiple boiler piping 35 6 11 General piping...

Page 36: ...g strikes and other forms of severe electrical noise Power conditioning equipment surge protectors may be required in areas where power quality is suspect In temporary or manual operation for example in new construction heating use a construction thermostat or jumper with an in line switch for on off management of the boiler Do not turn off the heat by removing power to the boiler as this interrup...

Page 37: ...s See section 3 8 for boiler pump curve chart 6 12 4 Thermostat wiring Thermostat type control wiring will go to the three terminals of the CN2 block these are labeled VAC24 R VAC24 W VAC24 C Closing a dry contact between terminals 1 and 2 VAC24 R W initiates a call for heat For a load with multiple zones e g thermostats controlling zone valves wiring the end switches of each zone valve in paralle...

Page 38: ...y some jurisdictions such as an external low water cutoff Contacts for outdoor temperature sensor associated with reset heating at CN6 terminals 5 6 A 10K ohm sensor for outdoor reset feature is sold separately as IBC part P 9067 Thermostat or zone valve endswitches parallel wired three shown RS485 connection for MODBus control see ibcboiler com for more details Jumper or to dry contact on externa...

Page 39: ...odule or field wiring a double pole relay as shown here Thermostat 24V Transformer Space heating pump 24V double pole relay can be DPDT shown or DPST Call for heat to boiler CN2 terminals 1 and 2 Figure 16 Load pump relay field wiring This wiring can be expanded to use multiple zone valves as shown here 39 6 12 6 Load pump wiring ...

Page 40: ...te for up to four zone valves Space heating pump 24V double pole relay can be DPDT shown or DPST Call for heat to boiler CN2 terminals 1 and 2 Figure 17 Load pump relay field wiring with zone valves Alternatively using a pressure activated load pump may make pump control unnecessary 40 Section Installation ...

Page 41: ...t energized the controller will go through a brief power up sequence During this time the controller is completing a self diagnostic and loading all previous settings In the event of a power interruption the boiler will automatically resume operation when power is restored with all the previously stored values The controller provides overall management of the boiler operations including Power up a...

Page 42: ... shows the current boiler status The control has three levels 1 Home Menu Status Ready Heating Circulating Warning or Error Target temperature Outlet temperature Inlet temperature Figure 19 Controller Home screen 2 Settings Menu Setpoint T range 68 F to190 F 20 C to 88 C default 120 F 48 9 C Outdoor Design T range 31 F to 59 F 35 C to 15 C default 10 F 12 2 C Heat Type Setpoint SET or Outdoor Rese...

Page 43: ...next higher level in 1 minute if no button has been touched If the controller is in an error state the Error Code and an explanatory text will be displayed If the controller has a warning to declare the screen will rotate between the Home Screen and the Warning s each displayed for 10 seconds Warnings do not prevent operation 7 2 1 Heat Types The EBX series controller can be programmed for either ...

Page 44: ... hottest water for the coldest weather When Heat Type is set to ODR the controller needs only two variables defined Setpoint T for the hottest water and Outdoor Design T for the local climate s winter temperature The graphs below sample four Outdoor Design Temperatures to show how the target temperature tracks building heat loss over a heating season For ODR mode an outdoor sensor is necessary IBC...

Page 45: ...7 2 1 3 Sample ODR Temperatures Imperial units Figure 21 Outdoor reset lines for sample Outdoor Design Temperatures and Setpoints in Imperial units 100 F 180 F 45 7 2 1 Heat Types ...

Page 46: ...7 2 1 4 Sample ODR Temperatures Metric units Figure 22 Outdoor reset lines for sample Outdoor Design Temperatures and Setpoints in Metric units 40 F 80 C 46 Section About the boiler controller ...

Page 47: ...nspect the boiler and to replace any part of the system that has been under water Checklist for electrical conditions and water connections Checking electrical conditions Check Check all line voltage electrical connections to ensure all connections are correct and tight Check thermostat connections Thermostat in a suitable location Checking piping connections Check All connections are pressure tes...

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Page 49: ... boiler Start up Checklist Check With the boiler power turned off check that all electrical connections are tight Check with a gauge that the system pressure is stable and appropriate for the application at all times it should be between 8 psi and 50 psi A pressure relief valve must be installed on the system A 30 psi relief valve is supplied Perform a thorough visual check for any leaks or signs ...

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Page 51: ...ecklist for homeowner Maintenance Required Frequency Check Inspect system for unusual noises Call your local heating contractor for service if needed As needed Keep combustible materials and flammable liquids and vapors away from the boiler As needed Inspection of the boiler is to be performed annually by a qualified service technician Annually Caution Label all wires prior to disconnection when s...

Page 52: ...Element hex heads Figure 24 Unscrew and lift out elements 1 Power off boiler and open cabinet door 2 Close the water isolation valves and drain the boiler 3 Remove and set aside the four screws of the cabinet lid Remove the cabinet lid 4 Label the element wires and disconnect them 5 Unscrew the elements from the heat exchanger and lift straight upwards to remove 6 Reassemble in reverse order 52 Se...

Page 53: ...Pull pump forward to disconnect wiring Figure 28 Remove bolts holding pump to bracket Re use bracket 1 Power off boiler and open cabinet door 2 Close the water isolation valves and drain the boiler 3 Remove the four screws to the pump bracket on the cabinet underside 53 10 3 Replacing the pump ...

Page 54: ...ent the pump from falling forward and pulling on its wiring harness 6 Disconnect the wiring harness 7 Remove the pump and bracket Inspect gaskets carefully or replace 8 Remove the bolts holding the pump to the bracket and transfer the bracket to the new pump 9 Reassemble in reverse order 54 Section Service and maintenance ...

Page 55: ...es and Fixes a See sections covering diagnoses and fixes including i Cycling ii Temperature iii Miscellaneous 11 1 Electronic components This section details the method for troubleshooting the non standard electronic components on the boiler 11 1 1 Temperature sensors The resistance of the temperature sensors varies inversely with temperature To test measure the temperature of the sensed environme...

Page 56: ...50 35 2 29 996 135 57 2 754 40 4 26 099 140 60 2 490 45 7 22 763 145 63 2 255 50 10 19 900 150 66 2 045 55 13 17 436 155 68 1 857 60 16 15 311 160 71 1 689 65 18 13 474 165 74 1 538 70 21 11 883 170 77 1 403 75 24 10 501 175 79 1 281 80 27 9 299 180 82 1 172 85 29 8 250 185 85 1 073 90 35 7 334 190 88 983 95 35 6 532 195 91 903 Table 5 Outdoor temperature sensor resistance values 10K ohms 56 Secti...

Page 57: ...ry contact may be tied into CN6 block terminals 3 4 labeled INTLCK A B A jumper must be installed if an external interlock is not required MODbus Error Displayed after successful MODbus communication has stopped for two continuous minutes Error can be cleared with a power cycle to boiler WARNING MESSAGES Warning Description Comment Low Water Flow Water flow below 0 5 gpm 1 9 lps Open Outdoor Senso...

Page 58: ...manufacturer s instructions Boiler cycling on operating safety controls Check operation with Ohmmeter Voltmeter System radiation undersized Check manufacturer s rating tables for capacity per foot Temperature exceeds mercury thermostat setting Incorrect anticipator setting Check with Ammeter Thermostat not level Check level One or more zones do not heat properly Air trapped within zone s piping Ve...

Page 59: ...ive thermostat Check operation Refer to manufacturer s instructions Check setting with ammeter Air in system or marginal water flow Bleed purge system as required Confirm temp rise in the heat exchanger Low water flow due to improper piping Review pressure drop of boiler piping Low water flow due to restrictions in water pipe Check temperature differential across zone heat exchanger Low radiation ...

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Page 61: ...61 Appendices Wiring diagrams Figure 29 EBX series Boilerinternal wiring diagram ...

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Page 64: ...1 1 30 Inlet Water Pipe with Flow Sensor Assembly P 1702 1 40 Water Temperature Sensor P 1703 2 50 Inlet Pipe plate assembly P 1704 1 60 Modulation control block Solid State Relay version or P 1705 1 60 Modulation control block Triac version P 1706 70 3 Speed 120V Pump not including bracket P 1707 1 80 Pump bracket P 1708 1 64 Section Boiler parts diagram EBX series Boiler ...

Page 65: ...0 Heating Elements 2kW EBX4K 240 P 1716 2 4kW EBX8K 240 P 1717 2 5kW EBX10K 240 P 1718 2 6kW EBX12K 240 P 1719 2 170 Cabinet lid P 1720 1 Hardware package o rings screws etc P 1721 Wiring harnesses sold as set not shown P 1722 Gasket pack P 1723 Optional Parts Description P kit replacement Outdoor Sensor P 9067 Air Vent Piping Kit P 195 External Tridicator P 9014 Boiler Stand P 267 Pressure Relief...

Page 66: ...it Breaker ____ Labeled Power supply wire gauge _____ Leak testing completed System Cleaned and Flushed type of cleaner used _________________________________ _ System Filled type concentration of any glycol chemicals used _______________________ __ Air purge completed Relief Valve correctly installed and piped Relief valve try lever test performed Owner advised and instructed in the safe operatio...

Page 67: ...n THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a tan...

Page 68: ...7 0277 T856 877 0544 F604 877 0295 F856 735 5584 Toll Free 1 844 HEAT IBC 1 844 432 8422 www ibcboiler com Information in this document is subject to change without notice IBC assumes no responsibility for changes made to the manual due to clerical errors to regulation changes or to product development December 08 2022 120 440E1 IBC Technologies Inc 2022 ...

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