IBC SL 40-399 G3 User manual

120-273 R4 |1
Note
IfconvertingfromPropanetoNaturalGas,ordertheNaturalGasConversionPartsKit(IBCPart#P-303B)
fromyourauthorizedIBCDistributor.
UsethePropaneGasconversionpartskitifthefuelsourceatthesiteusesPropaneandthemodulatingboilerhasbeen
setup(factoryfire-tested)tooperatewithNaturalGas.Checktheratingplateontheboilertoseewhichfuelsourcethe
particularboilerhasbeensetupwith.
Usingthisconversionkit,aqualifiedtechnicianwillneedto:
1. Performafuelconversion.
2. Performacombustiontest.
3. Fillintheinformationrequiredonthefuelconversionlabels,andaffixthemtotheboileraftertheconversionis
completed.
Warning
This conversion kit shall be installed by a qualified service agency in
accordance with the manufacturer’s instructions and all applicable codes and
requirements of the authority having jurisdiction. If the information in these
instructions is not followed exactly, a fire, an explosion or production of
carbon monoxide may result causing property damage, personal injury or
loss of life.
The qualified service agency is responsible for the proper installation of this
kit. The installation is not proper and complete until the operation of the
converted appliance is checked as specified in the manufacturer’s
instructions supplied with the kit.
Theboilerwillautomaticallyde-ratethemaximuminputatarateofapproximately2%per1,000’above4,500’.Thegas
valveszerogovernorwillensurethatthegas:airmixtureisnotaffectedataltitude.
IncludedwiththeConversionKit:
1xLPMixerAssembly,399G3-Part#500-114 3xScrew,Zinc,M4x12-IBC-Part#150-164
1xMixingdeviceO-ringPart#150-073 1xRatingPlateFuelOverlay-Part#080-242
1xGasket,gasvalvecoupler-IBC-Part#255-035C1 1xGasValveConversionLabel-Part#080-107B
4xScrew,SS,M5x10-IBC-Part#150-076 1xInstallerIdentifierLabel-Part#080-244A1
3xWasher,Flat,SS,M4-IBC-Part#150-099 
Thisconversioninvolveschangingthemixingassembly.Thereisnopropaneorifice.
SL 40-399 G3 - Fuel Conversion to
Propane (NG to LP) P-Kit 302B

Combustion Test Target Ranges

Figure 1 Gas valve and fan
TheLowFire(Zero-offset)valveadjustment
caponthegasvalvehasbeenfactoryset.
Donottamperwithoradjustthisscrewinthe
field.Contactthefactoryforwritten
instructionsifconsideringfieldadjustmentof
theLowFire(zerooffset)adjustment.
TheHighFire(Gas:Air)ratioadjustment
screwisaslottedbrassscrewtotheleftof
thelongbrassprotrusiononthefrontofthe
gasvalve.Itwillhavetobeadjustedtoattain
optimumcombustionresultswheneverfuel
conversionisundertaken;however,no
mixtureadjustmentmustbeperformed
unlessdonebyaqualifiedtechnicianusing
properlyfunctioningandcalibrated
combustionanalyzingequipment.
Fuel High Fire Low Fire Co Max PPM
Range Target
Range Target
NaturalGas
9.0–10.0 9.5
8.2–9.2 8.7
<150
Propane
10.3–11.3 10.8
9.3–10.3 9.8
<250
Table 1 Combustion test target ranges - CO2 / Maximum CO
Note:LowFireCO2shouldbeatleast0.5%lowerthanHighFireCO2.
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SL 40-399 G3 - Convert to LP fuel (P-Kit 302B) |3
Fuel Conversion Instructions
Thefollowingprocedure-tobecarriedoutbyaqualifiedtechnician-describeshowtochangethefuelmixerontheSL
40-399G3.
Caution
Beforeyoudisconnecttheelectricalpower,youmustshutoffthegassupply.
Youcanviewavideoonchangingthefuelassemblymixerathttp://www.ibcboiler.com/TIPortal.
To perform a fuel conversion:
1. Ensurethatthegassupplyisturnedoffatthegasshut-offvalve.
2. UseanAllenkeytoremovethehexboltsthatboltthegasvalvetothegasvalveelbow.
3. Separatethegasvalvefromtheelbow,andremovetheO-ringandorifice(ifinstalled).YouwillneedtheO-ring
inStep8.
4. Notetheorientationandscrewpositions,andthenremovetheboltsandventurimixingdevicefromthefan.
5. Removetheventurimixingdevicefromthebaseofthefan.
6. EnsurethatthefanO-ringisnotdamaged,andisseatedinthegroove.
7. Attachthereplacementventurimixingdevicetothebaseofthefanusingthehexbolts.
8. Re-installtheO-ringbetweenthegasvalvebodyandtheventurimixingdeviceelbow.
Caution
FailuretopositiontheO-ringasindicatedwillresultinagasleak.
9. Repositionthegasvalve,andthenboltthegasvalvetotheventurimixingdeviceelbow.
10. Checkforgasleaks.
Now,carefullyfollowtheproceduresoncombustiontestingandthecorrectadjustment(seeCombustion testing and
adjustment on page 4).

Combustion testing and adjustment
Danger
Acombustiontestchecksthatthegasvalveisoperatingproperlyinthefield.Toperformacombustiontest,you
mustbeaqualified,trainedandlicensedgasfitter.
MakingadjustmentstotheIBCgasvalvewithoutaproperlycalibratedgascombustionanalyzerandbypeople
whoarenottrainedandexperiencedinitsuseisforbidden.Failuretouseananalyzercanresultinan
immediatehazard.
Model Number High Fire Input
SL40-399G3 399MBH
Table 2 Rated input of a converted boiler
Normalignitionsystemsequenceofoperation:
Theboilercontrol,uponacallforheatorDHW,turnsonthecombustionfanfora20-secondpre-purge,thenenergizesthe
sparkelectrodeandgasvalvefora4-secondtrialforignition.
Iftheburnerdoesnotlight,theprocessisrepeateduntiltheburnerlightsandflameisdetected.After3trialsforignition,the
boilerlocksoutandwillneedtobemanuallyresetbyclearingtheerroronthetouchscreencontroller(Diagnostics>
AdvancedDiagnostics>ClearErrors).Theboilerautomaticallyresetsafter60minutes,ifnoactionistaken.
To perform a combustion test and adjustment:
1. Turnofftheboiler’sgasshut-offvalve.
2. Withasmall(1/8"or3mm)flatscrewdriver,opentheinletgassupplypressuretestportbyturningitscenter-screw1
fullturncounterclockwise.
3. Attachamanometertotheinletpressuretestportandturnongastoappliance.
Staticmanometerreadingshouldbeideally7"w.c.forNaturalGasand11"w.c.forPropane.
Minimumandmaximumstaticpressureshouldbebetween5"and14"w.c.Monitorpressurethroughoutthe
commissioning(start-up)procedure.Pressuremaydropupto1"to2"w.c.athighfire.
4. Beforeyouchangetheloadtomanualcontrol,notetheloadsetting.
5. Settheloadtomanualcontrol,andsettheheat-outvaluetothemaximumMBHfortheboiler.Thisloadshouldbe
largeenoughtoallowtheboilertooperateathighfireforover10minutes.
6. Withacombustionanalyzerprobeinthefluegastestport,checkthefluegasreadingandadjustthegas:airratio
screwtobringthefluegastowithintheparametersindicatedinTable 1 .
7. Adjustslowly(clockwise)theHighFire(Gas:AirRatioAdjustment)screwtoobtainthecorrectCO2value(see
Table 1 ).
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SL 40-399 G3 - Convert to LP fuel (P-Kit 302B) |5
8. Maketinyadjustments(mayrequireseveralturns).TurningtheHighFire(Gas:AirRatioAdjustment)screw
clockwisewillleanouttheflame.
Note
Clockthegasmeter(seeinstructionsonPage6)toconfirmfullmaximumratingplateinput.Check
themeasuredresultswithTable 2 .
9. Settheheat-outvalueinmanualmodetotheminimumMBHfortheboiler(seeTable 1 ).
10. WhiletheboilerisatLowFire,comparethecombustionreadingagainstthereadinginTable 2 .Thereading
shouldbewithintherangelisted.
11. Restoretheloadtothepreviousloadtype.Alltheprogrammedsettingswillberestoredandtheloadwill
operateasbefore.Confirmasmoothignitionsequence.
12. Turnoffthegassupplyatthegasshut-offvalve.
13. Disconnectthepowertotheboiler.
14. Disconnectthemanometer.
15. Closethegassupplytestportscrewbyturningclockwise.
16. Turnonthegassupplyshutoffvalveandtestforgasleaks.
17. Restorepowertotheboiler.
Nextyoumustfillintheinformationandaffixtheincludedfuelconversionlabelstotheboilerinthepositionsindicated
aftertheconversioniscompleted.
Completing and Affixing the Conversion Labels
1. Fillintheconversionlabels(includedinthekit)associatedwiththenewfueltype.
2. PlacetheconversionlabelsontotheboileratthepositionsindicatedonWhere to Place Conversion Labels on
the Boiler on page 7.

Clocking the Meter (Natural Gas)
1. Turnoffallotherappliancesandpilots.
2. Turnontheboilerandsettheboilertohighfire.
3. Ensuretheboilerhasalargeloadtoheat,sothattheboilerwillnotshutoff.
4. WithaStop-Watch,recordthenumberofsecondsforthesmallestdialtomake1fullrevolution.
5. CFH=(3600xDialSize)/Seconds.
6. CFHx1000(checklocalBtucontent)=InputBtu’s.
Note
For2PSImetersmultiplyCFHx1.097
ForMetricmetersmultiplyCFHx35.3
For2PSImetricmetersmultiplyCFHx1.097x35.3
ForAltitudeabove4,500’deduct2%per1,000’ofaltitudefromtheInputBtu’s.
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SL 40-399 G3 - Convert to LP fuel (P-Kit 302B) |7
Where to Place Conversion Labels on the Boiler
