fuel conversion notes - ibcboiler.com · ex700-converttolpfuel(p-kit1201) |7 completing and...
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120-333E-R1 | 1
Note
If converting to natural gas, order the Natural Gas Conversion Parts kit (IBC Part # P-1200) from your authorized IBC distributor.
Use the Propane Gas Conversion 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 - IBC Part # 180-255 4 x Hex bolt M6 x 14 SS Hex Bolt - IBC Part # 150-373
1 x O-ring gas valve coupler- IBC Part # 150-001 1 x Rating Plate Fuel Overlay - IBC Part # 080-284A
4 x Hex bolt M5 x 25 IBC Part # 150-354 1 x Gas Valve Conversion Label - IBC Part # 080-107B
4 x Flat Washer, 0.562ID - IBC Part # 150-025 1 x Installer Identifier Label - IBC Part # 080-282A
4 x M6 Flat Washer - IBC Part # 150-159 6 x Hex bolt M8 x14 - IBC Part # 150-329
6 x M8 Flat washer - IBC Part # 150-339 1 x O-ring EBM blower - IBC Part # 150-376
This conversion involves changing the mixing assembly. There is no propane orifice.
EX 700 - Fuel Conversion to Propane (NG to LP) P-Kit 1201
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Figure 1 Gas valve and fan
Fan
Mixing device
Gas high pressure switch
Inlet gas pressure test port (location of)
Gas low pressure switch
Low fire adjustment (zero-offset)
High fire adjustment(on the side)
Shutoff valve
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EX700 - Convert to LP fuel (P-Kit 1201) | 3
Fuel conversion instructions
The following procedure must be carried out by a qualified technician. In this procedure, you will replace the current natural gas fuel mixer with the new propane fuel mixer.
Caution
Before you disconnect the electrical power, you must shut off the gas supply.
To perform a fuel conversion:
1. Turn off the power and shut off the gas supply at the external gas shut-off valve.
2. Remove the front door and top cover from the boiler.
3. Remove the four (4) 5/16" hex bolts from the gas inlet to the mixing device. Carefully separate the two parts,
remove and retain the O-ring for re-assembly. (See on image below).
4. Remove the four (4) ¼" hex bolts that connect the mixing device to the air filter box. The gasket should remain
attached to the air filter box. (See on image above).
5. Use an Allen key to remove the Six (6) 6 mm screws connecting the mixing device to the fan. (See on image
above). Carefully separate the two parts, remove and retain the O-ring for re-assembly.
6. Remove the natural gas mixing device.
7. When Installing the propane mixing device ensure that the O-ring is properly seated in the groove of the fan.
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Caution
Failure to position the O-ring as indicated will result in a gas leak, and affect burner operation.
8. Re-assemble in the reverse order of steps provided.
9. Check for gas leaks.
Combustion testing and adjustment
DangerA 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
EX 700 700 MBH
Table 1 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.
Combustion test target ranges
The Low Fire (zero-offset) valve adjustment screw on the gas valve has been factory set. See on Figure 1 .
The High Fire (gas-air) ratio adjustment screw on the gas valve has also been factory set. See on Figure 1 . It will have to be adjusted to attain optimum combustion results whenever fuel conversion is undertaken; however, no mixture adjustment shall be performed unless done by a qualified technician using properly functioning and calibrated combustion analyzing equipment.
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EX700 - Convert to LP fuel (P-Kit 1201) | 5
Testing and adjustingMeasuring the inlet gas pressure
1. Before performing a combustion test and adjustment, turn off the boiler’s external gas shut-off valve.
2. Remove the inlet gas pressure test port plug with a 3 mm Allen key. Note the fitting has BSP threads.
3. Use the supplied fitting to transition from ⅛" BSP to barbed for connection to a manometer.
4. 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.
5. Before firing the boiler, turn the high fire (gas-air ratio) adjustment screw clockwise ¾ to 1 full turn to decrease the fuel (leaning the mixture) before firing up the boiler.
6. Before you change the load to manual control, note the load setting.
7. 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.
Performing a combustion test
Fuel High Fire Low FireCO 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 2 Combustion test target ranges - CO2 / Maximum CO %
1. After the boiler is lit and is at high fire, insert the combustion analyzer test probe into the flue gas test port. Then adjust the high fire (gas-air ratio) adjustment with a small slot screwdriver according to Table 2 values. This adjustment screw is very sensitive and will only need very small adjustments to fine tune the gas valve (1/16 of a turn at a time only). Turn counter-clockwise (in the direction of the '+' sign) to raise the CO2% (to richen). Turn clockwise to lower CO2%.
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Figure 2 Flue gas test port
2. Set the heat-out value in manual mode to the minimum MBH for the boiler (see Table 1 ).
3. Low fire adjustment - adjust the low fire according to Table 2 . Use a 2.5 mm Allen key. Turn counter-clockwise (in the direction of the '+' sign) to raise to raise the CO2% (to richen). Turn clockwise to lower CO2%. Start with 1/8 of a turn until you see the analyzer measure a change then only make 1/16 adjustments. If changing direction on this adjustment you will notice a significant backlash (requirement for 1/8 turns until you see the analyzer measure a change.
4. Run the boiler to high fire, and check the results to confirm correct settings.
Note
Clock the gas meter to confirm full maximum rating plate input. Check the measured results with Table 1 .
5. Run the boiler to low fire, and check the results to confirm correct settings.
6. Restore the load to the previous load type. Unless you changed the load high limit, all the programmed settings will be restored and the load will operate as before. Confirm a smooth ignition sequence.
7. Turn off the gas supply at the external gas shut-off valve.
8. Disconnect the power to the boiler.
9. Remove the analyzer probe and install the test port plug.
10. Disconnect the manometer.
11. Remove the adapter fitting and reinstall the test port plug. Keep the fitting with the boiler for future use.
12. Turn on the gas supply shut off valve and test for gas leaks.
13. Restore power to the boiler after the conversion is completed.
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EX700 - Convert to LP fuel (P-Kit 1201) | 7
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 8.
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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Where to place conversion labels on the boiler
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