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Replacing the burner on the SL 40-399 G3

For reference, see

Figure 42

To remove the burner:

1. Turn off the electric power and gas supply to the boiler.

2. Ensure that the boiler cools down to the surrounding temperature.

Do not drain the boiler

unless freezing conditions are expected during this procedure.

3. Remove the cabinet door, and then remove the top cover/lid.

Warning

Wear a suitable protective mask to avoid ingesting particles from the refractory.

4. Note the colors and orientation of the electrical wires before disconnecting them from the gas

valve.

5. Remove the 4 bolts on the gas valve connector outlet

, and move the gas valve out of the

way. Retain the O-ring, or replace if worn.

6. Disconnect the electrical wires of the fan.

7. Remove the 4 nuts securing the fan to the heat exchanger lid.

8. Remove the fan and the fan gasket.

9. Remove the wires attached to the ignitor.

10. Remove the ignitor and gasket.

11. Loosen the lid fasteners located around the top edge of the heat exchanger, and swing the

bolts off the lid and let them hang down.

12. Remove the heat exchanger lid-burner assembly, and place upside down on a clean dry

surface.

13. Remove the heat exchanger lid gasket.

14. Wearing a mask and gloves, carefully remove the refractory. Inspect for damage and replace if

necessary.

15. When separating the burner from the heat exchanger lid, gradually loosen the mounting

screws in a criss-cross pattern.

16. Remove the burner gasket. Replace if damaged or worn.

7.3.3 Replacing the burner

Содержание SL Series

Страница 1: ...le vapors and liquids or other combustible materials in the vicinity of this or any other appliance If you smell gas Do not try to light any appliance Do not touch any electrical switch do not use any...

Страница 2: ...dness 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 tr...

Страница 3: ...mply 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 in...

Страница 4: ...e contained in component manufacturers manuals before installing starting up operating maintaining or servicing the appliance Warning Disconnect power supply before any wiring service is performed Fai...

Страница 5: ...3 3 Determining location of the appliance 16 Best installation conditions 17 3 4 Mounting the boiler 17 3 5 Connecting the vent and air intake pipes 18 3 6 Installation clearances 19 3 7 Exhaust venti...

Страница 6: ...ignition checks 63 Checklist for electrical conditions ducting and water connections 63 6 0 Boiler operation 65 6 1 Lighting and shutting down the boiler 65 6 2 Testing the ignition safety shutoff 66...

Страница 7: ...error 97 8 2 3 Low Water Cut off error 98 8 2 4 Aux Interlock 1 or 2 98 8 3 Miscellaneous touchscreen controller errors 98 8 3 1 Ignition issues 99 8 3 2 Temperature issues 101 8 3 3 Miscellaneous iss...

Страница 8: ...Intentionally left empty...

Страница 9: ...m water temp electronic hi limit 190 F 88 C 190 F 88 C Max T supply return electronic fence 40 F 40 F Max Water Temperature Lockout Limit 201 F 94 C 201 F 94 C Power use 120Vac 60Hz full fire less pum...

Страница 10: ...gs Fan Pre purge 15 seconds Trial for Ignition 4 seconds Flame Failure Response 0 8 second Table 1 Ignition stages timings Cabinet dimensions SL 26 260 G3 Figure 1 Front and side view SL 26 260 G3 6 S...

Страница 11: ...Figure 2 Top view SL 26 260 G3 Figure 3 Bottom view SL 26 260 G3 SL 40 399 G3 Figure 4 Front and side view SL 40 399 G3 7 SL 40 399 G3...

Страница 12: ...Figure 5 Top view SL 40 399 G3 Figure 6 Bottom view SL 40 399 G3 8 Section Specifications...

Страница 13: ...399 G3 A Flue Outlet 3 Schedule 40 4 Schedule 40 B Combustion Air Inlet 3 Schedule 40 4 Schedule 40 C Safety Relief Valve and Air Vent NPT F D LCD Display 2 x 4 E Water Outlet 1 NPT M F Water Inlet 1...

Страница 14: ...Intentionally left empty...

Страница 15: ...w pressure fully condensing units with a variable input range Approved as Category IV vented appliances the boilers use direct vent sealed combustion or indoor combustion air Figure 7 View from the fr...

Страница 16: ...defects in materials or workmanship and failures due to thermal shock In addition IBC offers a heat exchanger limited warranty with registration according to the following terms 0 10 years 100 coverag...

Страница 17: ...m interior dust sources Do not seal boiler case openings directly when firing allow for air circulation and ventilation in the immediate area Place the exhaust outlet 12 minimum above the down turned...

Страница 18: ...well away from all building air intakes including those of neighboring properties Caution Care must be taken to properly size the boiler for its intended use Prolonged full fire run time over sizing...

Страница 19: ...s ANSI ASME CSD 1 If there is any conflict follow the more stringent regulations Table 3 Code requirements by country 3 2 Removing an existing boiler When an existing boiler is removed from a common v...

Страница 20: ...ed and approved for indoor installation wall or rack mounting in areas such as an alcove basement or utility room These areas should have a surrounding temperature of 32 F 0 C to 122 F 50 C and less t...

Страница 21: ...ction Keep exhaust plumes well away from all building air intakes including those of neighboring properties Refer to Table 7 and Figure 15 in Sidewall vent termination on page 29 The minimum clearance...

Страница 22: ...he boiler to the wall with a minimum of two field supplied bolts 3 5 Connecting the vent and air intake pipes These appliances offer 3 or 4 inch connections that accept standard 3 or 4 inch PVC CPVC a...

Страница 23: ...ler s exhaust outlet and tighten clamp to ensure the venting connection is locked in place as shown above Manufacturers of stainless steel Type BH venting systems must submit their approved transition...

Страница 24: ...iler of 12 is required to provide clearance for the supplied condensation trap assembly More clearance will typically be required to accommodate associated water and gas piping 3 7 Exhaust venting and...

Страница 25: ...sate can cause corrosion of metal roofing components and other roofing materials Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate pH levels can...

Страница 26: ...s is prohibited Do not use ABS or any cellular core pipe for exhaust venting 3 7 4 Direct vent Direct vent is a two pipe system that draws combustion air air intake from outdoors and discharges exhaus...

Страница 27: ...debris Configure intake air openings so that rain or other forms of moisture cannot enter the air intake piping system Otherwise serious damage to the boiler may result Notes When installing air inta...

Страница 28: ...or to testing Coat all joints with an approved leak test solution just as you would joints in a gas line and make sure that there are no leaks We suggest attaching a tag on the vent line near the cond...

Страница 29: ...llow 3 ft for each elbow PP 87 90 elbows allow 8 ft for each elbow 3 inch Stainless Sidewall Terminal SST IBC P 257 Intake No additional allowance required Exhaust Allow 65 ft 3 inch CPVC to adapt to...

Страница 30: ...length of pipe allowed is 152 feet 200 6 x 8 48 152 For 4 inch flexible PP pipe up to 160 linear feet is allowed in vertical orientation 45 The equivalent length of 4 inch flexible PP pipe should be...

Страница 31: ...ern about rain infiltration rain will drain away through the condensate trap Optional bird screen may be placed in a termination fitting Leave unglued and hold in place with a short nipple This permit...

Страница 32: ...ose together using commonly available pipe flashing Similarly group the exhaust pipes and place the two separate groups of pipes at least 3 apart the closest intake and exhaust pipes must be 36 or mor...

Страница 33: ...fully Take action to avoid moisture entering building structures Serious structural damage may occur if adequate precautions and clearances are not considered These precautions apply to neighboring st...

Страница 34: ...ator within 3 ft 91 cm horizontally of the vertical center line of the regulator vent outlet to a maximum vertical distance of 15 ft 4 5 m J Clearance to non mechanical air supply inlet to building or...

Страница 35: ...16 and Figure 17 Use a 45 elbow on the exhaust termination to launch the plume up and off the sidewall for protection of wall A short piece of venting cut at 45 gives a horizontal termination protecte...

Страница 36: ...l penetration kits that do not maintain these minimum separations must not be used Improper installation will void the warranty Do not use proprietary InnoFlue or PolyPro PP terminals without specific...

Страница 37: ...Figure 18 Vent termination clearance stacked Figure 19 Vent termination clearances stacked side view Figure 20 Sidewall multi vent terminations stacked option 33 3 7 6 Sidewall vent termination...

Страница 38: ...proved for use with this appliance Install the SST to comply with the minimum vent clearances listed in Table 7 Install the SST with the vent and intake pipes horizontally beside each other or vertica...

Страница 39: ...orientation shown Ensure that the vent termination location does not exceed the allowed maximum equivalent vent length including the allowance for the SST Install multiple vent SST installations level...

Страница 40: ...t the venting must extend past the soffit by transitioning to vertical as shown in Figure 27 Figure 27 Sidewall vent termination transition to vertical to clear soffit This illustrates the scenario wh...

Страница 41: ...ined 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 a...

Страница 42: ...ge 15 The condensate trap must be installed on the drain connection at the base of the boiler The condensate drain must be piped to within 1 of a drain or connected to a condensate pump The drainage l...

Страница 43: ...lide the trap over the boiler drain outlet and then tighten the upper union nut 5 To reinstall the condensate retainer tilt the retainer to enable you to slide the two tabs under the chassis of the bo...

Страница 44: ...sate water line of the appliance Affix hose to drainage piping Factory supplied condensate trap Confirm slope Condensate hose and drain piping to slope toward drain and be secured to prevent accidenta...

Страница 45: ...e condensate neutralizer can cause severe burns to the skin Wear protective gloves and eye wear when servicing the condensate neutralizer Flue gas exhaust condensate and potentially rain water flow ba...

Страница 46: ...ischarge before the drain is necessary for proper maintenance in order to check the effectiveness of the neutralizing agent A simple pH test should be performed annually to ensure neutralizing agent i...

Страница 47: ...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 less than 125 mg l Iron is to be less than 0 3 mg l...

Страница 48: ...glycol solutions are formulated to inhibit corrosion in hydronic heating systems of mixed materials Improper mixtures and chemical additives may cause damage to ferrous and non ferrous components as...

Страница 49: ...ischarge line Is independently supported and securely anchored so as to avoid applied stress on the valve Is as short and straight as possible Terminates freely to atmosphere where any discharge will...

Страница 50: ...to the site 3 11 2 System piping Note The piping drawings in this manual are simple schematic guides to a successful installation For further information and details consult our concept drawings whic...

Страница 51: ...he highest temperature and lowest pressure on boiler outlet at expansion tank connection Expansion tank connection point of no pressure change should be on the suction side of the circulator with mini...

Страница 52: ...ation 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 de...

Страница 53: ...strictions between the fittings that would result in a pressure drop Heat Migration On secondary loops that extend vertically to a load that is above the primary loop steps must be taken such as fabri...

Страница 54: ...sure that the components are compatible For instance many air handlers have a thermostat connection that will energize an internal relay to operate the air handler circulator and its fan on a call for...

Страница 55: ...pply and return piping for each load This avoids thermal siphoning and reverse flow In order to ensure appropriate flow of water through the boiler in the case of high pressure drops or heating of a s...

Страница 56: ...uction side of the circulator with minimal pressure drop between Fill station with isolation valve closed or fill tank Supply piping to load 1 load 2 load 3 load 4 Return from loads Boiler primary pum...

Страница 57: ...w water cut off An internally mounted UL 353 Certified Low Water Cut Off LWCO is factory installed In some instances an external device may be required by local jurisdiction which may have specific in...

Страница 58: ...d Drain with cap Figure 37 Multiple boiler piping four staged boilers single load Supply to heating system Secondary loop sensor to master boiler Closely spaced tees are a maximum of four pipe diamete...

Страница 59: ...imum specification at all firing rates and will not exceed the boiler s maximum pressure rating when locked up with no load 3 12 1 Gas pressure The boilers require a minimum inlet gas supply pressure...

Страница 60: ...s supply during any pressure testing of the system at test pressures in excess of psig Dissipate test pressure prior to reconnecting The boiler and its gas piping must be leak tested before being plac...

Страница 61: ...ll the plug when done 3 13 2 120VAC line voltage hook up Line voltage wiring is done within the field wiring box see Wiring diagrams on page 105 Connect the boiler to the grid power using a separate f...

Страница 62: ...hrough the on board pump relays should not exceed 10 amps The control circuit board is protected using on board field replaceable fuses Each pump is fused with a separate 5 Amp fuse The Alarm contact...

Страница 63: ...ystems only 4 Wire individual load zone valves to their associated contacts on the secondary pump zone valve connector Do not confuse such load zone valves with similar valves used to segregate a sing...

Страница 64: ...Figure 40 Electric wiring connections 60 Section Installation...

Страница 65: ...imultaneous operation of two similar water temperature loads Programmable setback override schedule The control can manage or operate in a network of up to 4 IBC boilers without additional controller...

Страница 66: ...rate the touch controls Do not use a sharp or metallic object such as a screw driver as it could damage the touchscreen Prior to any interaction with the touchscreen the display shows the Home screen...

Страница 67: ...d before operating the appliance it is important to review the following checklist of precautions Checklist for electrical conditions ducting and water connections Checking electrical conditions Check...

Страница 68: ...p is flowing in the correct direction Checking venting connections Check All connections are pressure tested and leak free All vent pipe is sized correctly and joints are sealed Powering on the boiler...

Страница 69: ...ocess see Sequence of Operation on page 107 6 1 Lighting and shutting down the boiler Start up Checklist Check Followed lighting and shutting down procedure Tested the ignition safety shutoff function...

Страница 70: ...ler in operation shut off the gas control valve directly outside the boiler case 2 Ensure that the boiler has purged attempted to re light three times has shut off and the appropriate error informatio...

Страница 71: ...xample if the boiler is configured for natural gas but needs to be converted to propane use the conversion kit sold separately by IBC to install the appropriate fitting s and adjust the gas valve acco...

Страница 72: ...k that the gasket is in place between the gas valve and the Venturi mixing device 3 Connect the gas valve to the Venturi mixing device using the brass coupler nut 4 Place the conversion labels associa...

Страница 73: ...o use an analyzer can result in an immediate hazard To view illustrations of the gas valve and its components see Figure 41 and Figure 42 6 3 3 1 Measuring the inlet gas pressure To perform a gas pres...

Страница 74: ...start up procedure Pressure may drop up to 1 to 2 w c at high fire 5 To run the boiler at high fire you can set the heat out value in Test Operation mode to the maximum MBH for the boiler To do this o...

Страница 75: ...gas supply at the external gas shut off valve b Disconnect the manometer c Tighten the inlet pressure port screw with a Torx 15 screwdriver 13 Remove the analyzer probe and install the test port plug...

Страница 76: ...Intentionally left empty...

Страница 77: ...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 7 2 Maintenance checklist for heating contr...

Страница 78: ...in a hazardous condition 7 2 2 General boiler maintenance Boiler Component Maintenance Required Frequency Check Condensate trap Remove and clean annually see Cleaning the condensate trap on page 89 En...

Страница 79: ...lude airborne dust debris and volatiles With the burner removed examine the heat exchanger for signs of contamination and clean if necessary Annually Boiler Pump Check that the pump is on in normal op...

Страница 80: ...nd non ferrous components as well as non metallic wet components normally found in hydronic systems Ethylene glycol is toxic and may be prohibited for use by codes applicable to your installation loca...

Страница 81: ...ain and safely dispose of equipment discharge The relief valve manufacturer requires that under normal operating conditions a try lever test must be performed every two months Under severe service con...

Страница 82: ...pressurize your system we recommend using a system pressurization appliance such as an Axiom Industries model series Capture the discharged fluid in a container and recycle it by returning it to the s...

Страница 83: ...fire gas air adjustment Gas valve inlet compression coupling nut On Off switch Inlet gas pressure port Manifold pressure port not used Low fire offset pressure Fan gasket Figure 41 Gas valve and fan...

Страница 84: ...ressure adjustment Outlet pressure port not used Inlet gas pressure port High fire gas air adjustment Venturi mixing device Combustion fan Aluminum gas block gas inlet Figure 42 Gas valve and fan comp...

Страница 85: ...e fan and Venturi mixing device assembly and then the fan gasket 9 Separate the fan from the Venturi mixing device by removing the three screws Installing the new fan 1 Attach the Venturi mixing devic...

Страница 86: ...he screws and washers You should note the position of the Venturi mixing device on the fan before removing it 11 Examine the fan gasket and replace if necessary Installing the new fan 1 Attach the Ven...

Страница 87: ...sion coupling screw on the compression nut 9 Reattach the electrical wire to the gas valve 10 Open the gas supply and check for gas leaks 11 Tune the gas valve Replacing the gas valve on an SL 40 399...

Страница 88: ...k to the new gas valve ensuring that the O ring is in place If this O ring is lost it must be replaced with a factory supplied O ring Tighten by hand the 4 gas inlet block screws plus an extra turn in...

Страница 89: ...rs certified by NIOSH For the most current information NIOSH can be contacted at 1 800 356 4676 or on the web at www cdc gov niosh 2 Wear long sleeved loose fitting clothing gloves and eyes protection...

Страница 90: ...on a clean dry surface 11 Carefully remove the refractory Inspect for damage and replace if necessary 12 Remove the burner screws and then the burner To install the new burner 1 Inspect the burner ga...

Страница 91: ...he way Retain the O ring or replace if worn 6 Disconnect the electrical wires of the fan 7 Remove the 4 nuts securing the fan to the heat exchanger lid 8 Remove the fan and the fan gasket 9 Remove the...

Страница 92: ...Ensure that the lid gasket is in good condition and is in place and level 5 Reinstall the heat exchanger lid burner assembly 6 Replace the lid fasteners Evenly tighten the bolts in a criss cross patt...

Страница 93: ...ly will result in severe personal injury or death Condensate traps should be checked every year cleaned and refilled as necessary Before cleaning the condensate trap you must turn off the power to the...

Страница 94: ...e upper union nut and slide the condensate trap off the boiler drain outlet 3 Unscrew the union cap at the base of the trap and empty and flush the trap with water 4 Replace the union cap and gasket a...

Страница 95: ...boiler drain outlet and then tighten the upper union nut 6 To reinstall the condensate retainer tilt and slide the two retainer tabs under the chassis of the boiler and secure with the two wing nuts...

Страница 96: ...Intentionally left empty...

Страница 97: ...nvironment and compare with the value derived from the measurement of the resistance obtained by connecting a good quality test meter capable of measuring up to 5 000 k 5 000 000 at the controller end...

Страница 98: ...01 175 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 13 Temperature sensor resistance values 10K ohms 8 1 2 Fan Operating power is prov...

Страница 99: ...not fire Check the operation of the sensor by isolating the boiler from its system piping and close the system fill valve and then crack the pressure relief valve The pressure displayed should reflect...

Страница 100: ...LED 2 Burner on call State Rapid flash On Igniting LED 1 Flashing Electrode sparking LED 2 Burner on call state Off Flashing Lockout Possible errors An operating limit was exceeded A sequence failed...

Страница 101: ...n lead is secure at the control module and at the probe Manual gas shutoff is closed or gas line not fully purged Check for gas flow Open manual gas shutoff and reset boiler Gap between ignition probe...

Страница 102: ...jumper lead External safety is in an alarm state Inspect the external safety devices 8 3 Miscellaneous touchscreen controller errors Miscellaneous errors Issue Diagnosis Fix Loop Indoor Sensor Insuffi...

Страница 103: ...uck in service mode after software update If update fails or no updates applied Restarting returns the boiler to normal operation 8 3 1 Ignition issues Ignition issues Issue Diagnosis Fix Noisy spark...

Страница 104: ...be Defective Control Module Check ignition output from control module Boiler will not attempt to ignite Fan and or pump are off Display not illuminated No power to boiler Check line voltage Defective...

Страница 105: ...evel Defective thermostat Refer to manufacturer s instructions Obstruction in condensate drain Inspect and clean condensate drain Appliance cycling on operating safety controls Check operation with Oh...

Страница 106: ...is in 1 hour safety lockout For instructions on clearing errors see the V10 Touchscreen Controller manual DHW taking too long to heat Sensor may be under reading actual water temp Check sensor engagem...

Страница 107: ...required Confirm adequate pump size and temp rise in the heat exchanger Slow combustion air blower Check that CO2 level is within specification Dirty burner heat exchanger Check pressure drop Low wat...

Страница 108: ...Intentionally left empty...

Страница 109: ...105 Appendices Wiring diagrams V 10 Controller electrical diagram Figure 45 Controller electrical diagram...

Страница 110: ...Internal wiring diagram Figure 46 Internal wiring diagram 106 Section Appendices...

Страница 111: ...Sequence of operations Figure 47 Sequence of Operation 107 Sequence of operations...

Страница 112: ...duct 250 804 P 393 1 110 Intake duct 250 856 P 435 1 115 Safety Ignition Module 500 105 P 270B 1 Ignition cable only 200 154 P 358 1 120 Flue temperature sensor 240 132 P 361 1 125 Transformer 240 00...

Страница 113: ...Item Description Part ID Kit Quantity 200 Fan or 240 113 P 311 1 109 Boiler part diagrams SL 26 260 G3...

Страница 114: ...250 761 P 386 1 275 Pressure Switch Bracket 250 867 P 414 1 280 Air pressure switch blocked vent 240 138 P 337B 1 285 Pressure sensor silicone tube 190 308 P 382 1 288 Water Pipe Gasket 255 024 P 389...

Страница 115: ...Fuel Mixer LP 180 162 P 300 1 375 Mixer O Ring 150 073 P 389 1 380 Fan Gasket 250 322 P 389 1 390 Vessel High Limit Switch 240 030 P 9070 1 Wiring Harness 200 157 P 431 1 Boiler part diagrams SL 40 39...

Страница 116: ...P 270B 1 Ignition cable only 200 154 P 358 1 120 Air pressure switch blocked vent 240 138 P 337 1 125 Pressure switch Bracket 250 870 P 422 1 130 Vessel Temperature High Limit Switch 240 030 P 9070 1...

Страница 117: ...ive Fan 240 172 P 311 1 205 Mixer O Ring 150 073 P 387B 1 210 Fuel Mixer LP 500 114 P 302B 1 211 Fuel Mixer NG 500 113 P 303B 1 220 Gas Valve Coupler Gasket 250 035 P 330 1 225 O Ring 150 259 P 330 1...

Страница 118: ...ply Water Pipe 250 853 P 425 1 305 Tridicator 180 019 P 9014 1 310 Water Pipe Gasket 255 027 P 387B 1 311 Low Water Cutoff Probe 240 010 P 9061 1 315 Flue Gas Temperature Sensor 240 132 P 361 1 320 Pr...

Страница 119: ...stem Filled type concentration of any glycol chemicals used _________________________ Air purge completed Relief Valve correctly installed and piped Relief valve try lever test performed Condensate tr...

Страница 120: ...s the same function 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 a...

Страница 121: ...0277 T 856 877 0544 F 604 877 0295 F 856 735 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 responsibil...

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