IBC SL 40-399 G3 Quick Start Manual
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- Installation and operating instructions manual (88 pages) ,
- Installation & operating manual (121 pages)
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SL 40-399 G3 - Fuel Conversion to
Propane (NG to LP) P-Kit 302B
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
1 x Mixing device O-ring Part # 150-073
1 x Gasket, gas valve coupler- IBC - Part # 255-035C1
4 x Screw, S S, M5 x10 - I BC - Part # 150-076
3 x Washer, Flat, SS, M4 - I BC - Part # 150-099
This conversion involves changing the mixing assembly. There is no propane orifice.
120-273 R4
3 x Screw, Zinc, M4x12 - I BC - Part # 150-164
1 x Rating Plate Fuel Overlay - Part # 080-242
1 x Gas Valve Conversion Label - P art # 080-107B
1 x Installer Identifier Label - Part # 080-244A1
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Summary of Contents for IBC SL 40-399 G3
- Page 1 SL 40-399 G3 - Fuel Conversion to Propane (NG to LP) P-Kit 302B 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...
- Page 2 Combustion Test Target Ranges 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. Figure 1 Gas valve and fan Fuel High Fire Low Fire Co Max PPM Range Target Range Target Natural Gas < 150 9.0 – 10.0 8.2 – 9.2...
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Page 3: Fuel Conversion Instructions
2. Use an Allen key to remove the h ex 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 b etween 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). SL 40-399 G3 - Convert to LP fuel (P-Kit 302B) - 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 a utomatically resets after 60 minutes, if no action is taken. To perform a combustion test and adjustment: 1. ...
- Page 5 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 SL 40-399 G3 - Convert to LP fuel (P-Kit 302B)
- Page 6 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.
- Page 7 Where to Place Conversion Labels on the Boiler SL 40-399 G3 - Convert to LP fuel (P-Kit 302B)