IBC P-311B Guide

P-311B Fan Replacement Instructions -
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120-299E3 -August 23, 2023 - Released Document 1 of 5
SL399 G3, EX400/500
Warning
This replacement kit shall be installed by a qualified service agent in accordance with these
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 is checked as specified in these instructions.
Note
EX400/500 Firmware Update Version 2.00.3 effective September 2022.
IBCTechnologies is in the process of changing the EX400/500 fan from the current SITNG150 to
the EMB fan (VG145). This change in fan model requires that the firmware be updated with
version 2.00.3 or later to detect and utilize the proper fan curves.IBCTechnologies will be
temporarily supplying a USBstick loaded with firmware version 2.00.3 for fan kits to be installed in
EX 400/500 models.
Follow the procedure outlined in Installation of Software v 2.00.3 EX 400 EX 500 Models on page
4after the fan installation has been completed.

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When you purchase the kit from a wholesaler, you'll receive the following parts:
Fan Assembly - SL 40-399 G3, EX400, EX500
Part # Description Quantity
240-172 Fan, VG145 (EBM) 1
250-322 Heat Exchanger Gasket, Lid-fan 1
150-128 Nut, Hex M4 4
150-164 Screw, Zinc, M4 X 12 3
150-099 Washer, Flat, Stainless Steel, M4 3 3
150-073 O-ring, N70, Nitrile, 70 Mm X 3 Mm 1
900-012 Fan Detection Software USB V2.00.3 1
Note
A ladder or step may be required to have a clear vertical view of the work area.
Do not attempt to remove the assemblies without a clear view, as damage to the connectors or
screws may occur.
Fan removal
Preparing the Boiler for Servicing
1. Remove call(s) for heat.
2. Remove power to the boiler at a wall switch or a breaker.
3. Shut off gas supply to the boiler.
Do not drain the boiler unless freezing conditions are expected during this procedure.
4. Allow the boiler to cool down.

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5. Remove the front cover.
6. Remove the top service panel with a T-20 Torx screwdriver.
Removing the Fan Assembly - SL40-399 G3
1. Disconnect the two electrical connectors from the fan
(A).
2. Disconnect the female spade connections from the gas
valve (B).
3. Remove the 4 mm Allen bolts securing the gas valve
outlet to the 90 degree venturi mixer (C)adapter.
4. Separate the gas valve from the venturi mixer adapter.
Retain the O-ring for reinstallation.
5. Remove the four 7 mm hex nuts securing the fan to the
heat exchanger lid (D).
6. Remove the fan assembly, and set aside.
7. Remove the fan gasket (E)from the heat exchanger lid
and discard.
8. Remove and retain the 3 mm Allen bolts securing the
venturi mixer to the old fan.
Removing the Fan Assembly - EX400/500
1. Unplug the two fan wiring harnesses from the fan (A).
2. Disconnect the ignition cable and ground wire from the
ignitor , and wrap the loose wires around the ignition
module harness.
3. Remove the four 10 mm bolts that mount the fan to the
heat exchanger lid (D).
4. Push the air intake tube into the filter box to gain
clearance.
5. Disconnect the gas valve (B) electrical wires.
6. Remove the fan assembly.
7. Remove the fan gasket (E) from the heat exchanger lid
and discard.
8. Use a 3 mm Allen key to remove the three screws
connecting the mixing device (C) to the fan; keep these
for reinstallation. Remove and discard the fan O-ring that
is seated in the groove.

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Fan installation and Start Up
Fan Assembly and Installation
1. Install the venturi mixer onto the new fan with the provided screws and washers.
Warning
Ensure that the fan O-ring is seated in the groove of the fan when reassembling.
2. Install the new fan and fan gasket onto the heat exchanger lid.
3. Reinstall the fan assembly by following the removal steps backwards:
Note
SL40-399 models only:When reconnecting the female spade connections to the gas
valve, note the orientation of the wires. The blue wire connects to the upper connection,
and the brown wire connects to the lower connection.
a. from Removing the Fan Assembly - SL40-399 G3 on page 3 for the SL40-399 model, or
b. from Removing the Fan Assembly - EX400/500 on page 3 for the EX400/500 model.
Installation of Software v 2.00.3 EX 400 EX 500 Models
Note
Once you perform the software update, the boiler will calibrate the fan. You will hear the fan ramp
up and down several times during fan calibration. This will occur one time only.
1. At the boiler, remove active calls for heat. The home screen should show a "Standby" status.
2. Carefully insert the USB stick into one of the ports on the left-hand side of the controller.
3. On the controller, tap More >System Settings >Software Update.
4. Select the appropriate device (USB).
5. If you do not get a response, select Cancel and try again.
The controller checks if a software update is required. If required, the system prompts you for
permission to proceed.
6. Select Yes and OK.
7. If you see a message "Could not mount flash device", select Cancel and try again. The controller
automatically restarts after loading the update, and the process takes a few minutes.
Note
Do not remove the USB before the software update has finished as this will cause the
update to fail.

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8. To check that the controller has the latest software release, go to Status >Boiler Information.
When a software update is performed, the touchscreen controller is put into "service" mode. This prevents the
system from servicing loads.
Start Up
1. Turn on gas to the boiler.
2. Turn on power to the boiler.
3. Check connections for leaks during operation.
4. Reinstall the top service panel to the boiler cabinet.
5. Perform a combustion analysis, and test for proper operation.
6. Reinstall the front cover.