lp gas (propane) conversion instructions...table 10: acceptable combustion readings for lp gas...
TRANSCRIPT
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DANGERAsphyxiation Hazard. These instructions include a procedure for adjusting the air-fuel mixture on this boiler. Always use a combustion analyzer to measure the CO2 (or Oxygen) and Carbon Monoxide (CO) levels in flue gas. Adjusting the air-fuel mixture without a proper combustion analyzer will result in unreliable boiler operation, personal injury, or death due to carbon monoxide poisoning. Explosion Hazard, Electrical Shock Hazard, Burn Hazard. The gas supply shall be shut off prior to disconnecting the electrical power, before proceeding with the conversion.
WARNINGThis 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 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.These instructions are intended for use only with sizes listed in this document.Consult Appendix A in Installation, Operating and Service ( I, O & S) Instructions for installations above 2,000 ft. I, O & S Instructions are supplied with boiler and available on manufacturer's website.
LP Gas (Propane) Conversion Instructions
Size LP Conversion Kit Page085 107934-01 2-3110 107935-01 2-3155 107936-01 2-3205 107937-01 2-3270 107938-01 4320 108015-01* 5399 108015-02* 5
* Also used for LP Service kit
These instructions are included in LP conversion kits listed in Table 1:Table 1: LP Conversion Kits
Required Tools/Equipment:• 15/16"Wrench(FlareFitting)• 1-1/8"Wrench(GasFlexLine)• TorxT-25(GasValvetoVenturi)• TorxT-30(VenturiAssemblytoBlower)• PhillipsHeadScrewdriver• FlatHeadScrewdriver/5/16"NutDriver• 7mmHexHeadSocket(VenturiAssemblyto Blower320/399)• 1-7/16"Wrench(GasValveAdaptor320/399)• CombustionAnalyzer
Parts Included with This Kit:• LPVenturi• Hardware• BlowerO-ring• GasValveCoupling• RatingLabel• ServiceLabel
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When disconnecting flexible gasline, place backup wrench on thisnut to prevent damage to gas valve.
Connection
Flexible Gas Line
Figure 2: Backup Wrench Detail
To convert this boiler for use on LP gas, perform the following steps:1. Ifnotalreadydone,installtheboilerinaccordancewiththeInstallation,Operating,andServiceinstructions,following
allinstructionsinSectionXI“Start-upandCheck-out”uptoStep10.2. Disconnectpowersupplytoboiler3. Shutoffgassupplytoboiler
Steps 4 thru 12 for boiler sizes 85, 110, 155 and 205 (Figure 3)4.Disconnecttubetoairprovingswitchanddisconnectharnessfromrectifiermoduleongasvalve.(Figure8)5.Usewrenchandbackupwrenchtodisconnectflexiblegaspipefromgasvalveatflarefitting(Figure2).6. Remove(2)screwsconnectinggasvalvetoventuriassembly.(Figure3)7. Remove(3)screwsconnectingventuriassemblytoblower.(Figure3)8. Replacenaturalgasventuriassemblywithpropane(LP)venturiassembly,ensuringo-ringbetweenblowerandventuri
assemblyisinplaceandarrowonventuripointsup.(Figure3)9. Secureventuriassemblytoblowerusing(3)screwsremovedinstep7.10.Ensurecouplingbetweenventuriassemblyandgasvalveisinplaceandsecureusing(2)screwsremovedinstep6.11.Re-connectflexiblegaspipetogasvalve.12.Re-connecttubetoairprovingswitchandreconnectharnesstorectifiermoduleongasvalve.
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Figure 3: 085-205 Blower/Gas Valve/Venturi Detail
Venturi Assembly
O-Ring
Coupling
Arrow to Point up
PVC Attenuator Assembly(Used on Size 110 Installations
Above 2,000 ft. only)
Tighten Clamp
Steps 13 thru 14 for boiler size 110 installations above 2,000ft only (Figure 3 and 4)13.AttachPVCattenuatortoventuriassembly.(Figure3)14.Insertperforatedattenuatorintoventadaptor(Figure4)andskiptostep27.
Vent Adapter
Perforated Attenuator(Used on Size 110 LPInstallations Above 2,000 ft. only)
Figure 4: Vent Attenuator for 110 LP Installations above 2,000ft.
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Steps 15 thru 21 for boiler size 270 (Figure 5)15.Removeattenuatorfromventuriassembly,disconnecttubetoairprovingswitch,anddisconnectharnessfromrectifier
moduleongasvalve.(Figure9)16.Usewrenchandbackupwrenchtodisconnectflexiblegaspipefromgasvalveatflarefitting(Figure2).17.Remove(3)screwsconnectinggasvalvetoventuriassembly.(Figure5)18.Removegasketfromgasvalveoutlet,insertfactorysuppliedorificeintogrooveofgasketandreplace.(Figure5)19.Securegasvalvetoventuriassemblyusing(3)screwsremovedinstep17.20.Re-connectflexiblegaspipetogasvalve.21.Re-attachattenuatortoventuriassembly.Re-connecttubetoairprovingswitch,reconnectharnesstorectifiermoduleon
gasvalveandskiptostep27.
Figure 5: 270 Blower/Gas Valve/Venturi Detail
Gasket
VenturiAssembly
Orifice
PolypropyleneAttenuator
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Gasket
Arrow to point up
Venturi Assembly
Gas Valve Adapter
O-Ring
Figure 6: 320-399 Blower / Gas Valve / Venturi Detail
Steps 22 thru 26 for boiler sizes 320 and 399 (Figure 6)22.Loosenunionbetweengasvalveandventuriassembly23.Remove(3)screwsconnectingventuriassemblytoblower.24.Replacenaturalgasventuriassemblywithpropane(LP)venturiassembly,orreplacepropane(LP)venturiassembly,
ensuringo-ringbetweenblowerandventuriassemblyisinplaceandarrowonventuripointsup.25.Secureventuriassemblytoblowerusing(3)screwsremovedinstep23.26.Tightenunionbetweengasvalveandventuriassembly,andensuregasketisbetweengasvalveadaptorandventuri.Gas
valveisorientedasshowninFigure6.
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Main Flow Throttle
Outlet Tap
Tube to AirProving Switch
Gas Outlet
Servo Regulator(OFFSET Adjustment)
Gas Inlet
Inlet Tap
Rectifier Module
Figure 8: 085-205 Gas Valve Detail
Boiler Size
#Counter-clockwise Turns (From Fully Closed)
085 10.0110 10.0155 9.0205 14.0270 3.5320 4.0399 5.0
Table 7: Starting Number of Throttle Turns for Conversion to LP Gas
Outlet Tap
Tube to AirProving Switch
Main Flow Throttle
Servo Regulator(OFFSET Adjustment)
Gas Outlet
Rectifier Module
Inlet Tap
Gas Inlet
Figure 9: 270-399 Gas Valve Detail
27.Beforeattemptingtostarttheboiler,turnthethrottle(Figure8and9)clockwiseuntilitstops(severalfullturns).28.Turnthrottlecounter-clockwisetheexactnumberofturnsshowninTable7.
WARNINGThe throttle adjustments shown in Table 7 are approximate. The final throttle setting must be found using a combustion analyzer. Leaving the boiler in operation with a CO level in excess of 200PPM air-free could result in injury or death from carbon monoxide poisoning.
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WARNINGAll combustion performance numbers MUST be verified with a combustion analyzer. Failure to do so could result in substantial property damage, severe personal injury or death.
29. Selectthecorrectboilersize,altitude,andfuelusingthetouchscreendisplay. a. Checkboiler'sratinglabelforactualboilersize. b. Confirminstallationaltitude. c. Press"Adjust"buttonontheHomescreen. d. Press"Adjust"buttonontheAdjustModescreen. e. Press"Login"buttontoaccessPasswordscreen. f. Press5-digitdisplaytoopenakeypad.Enter the password "86"andpressthereturnarrowtoclosekeypad. Press"Save"button. g. Press"Adjust"buttontoenterAdjustmentMode. h. Press"ModulationSetup"menubutton. i. Press"Adjust"buttonafterreadingWarningscreen. j. Usethearrowbuttonstoselectthecorrectsize,altitude,andfuelofyourboiler.Pressthe(Checkwith Circle)buttontoenteryourselection. k. Press"Enter"buttonuntildisplaystopsblinking,pressnextandrepeatuntil"Completed"isdisplayed. l. PressXtoexit. m. Press"Confirm"toverifycorrectsize,altitude,andfuelisdisplayed.30. Attempttostarttheboilerusingtheoperatinginstructionslocatedoninsideofboilerfrontdoor.Iftheboilerdoesnot lightonthefirsttryforignition,allowboilertomakeatleastfourmoreattemptstolight.Ifboilerstilldoesnotlight, turnthethrottlecounter-clockwisein1/8turnincrements,allowingtheboilertomakeatleastfourtriesforignitionat eachsetting,untiltheboilerlights.31. Aftertheburnerlights,forcetheburnertohighfirebyenteringtheAdjustMenuandthenHighFireHoldasdescribed
inSectionXI"Start-upandCheckout"ofI,O&SInstructions.Allowtheboilertooperateforapproximately5minutesbeforetakingcombustionreadings.Note:after10minutes,theboilerisautomaticallyreleasedfromhighfirehold.
32. Performacombustiontest,samplingflueproductsfromthetapinfrontoftheventadaptor.33.Withburnerathighfire,adjustthrottleasneededtoobtainCO2(orO2)settingshowninTable10:• ToreduceCO2(increaseO2)turnthrottleclockwise.• ToincreaseCO2 (reduceO2)turnthrottlecounterclockwise.
Makeadjustmentsinincrementsof1/8and1/4turnsandallowtheboileratleastaminutetorespondtoeachadjustment
beforemakinganother.34. ForceburnertolowfirebyenteringtheAdjustMenuandthenLowFireholdasdescribedinSectionXI"Start-upand
Checkout".Allowtheboilertooperateforapproximately5minutesbeforetakingcombustionreadings.
35.Withburneratlowfire,adjustoffsetregulatorasneededtoobtainCO2(orO2)settingshowninTable10.• ToreduceCO2(increaseO2)turnoffsetregulatorcounter-clockwise.• ToincreaseCO2(reduceO2)turnoffsetregulatorclockwise.
Makeadjustmentsinincrementsnomorethan1/8turnsandallowtheboileratleastaminutetorespondtoeach adjustmentbeforemakinganother.
WARNINGAsphyxiation Hazard. Use combustion analyzer for all gas valve adjustments. Low fire offset screw is very sensitive. Adjust offset no more than 1/8 turn before checking combustion with analyzer. Maximum total offset adjustment ± 1 turn. Adjustments greater than ± 1 turn may damage regulator diaphragm. Failure to follow these instructions could result in death, serious injury or substantial property damage.
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37.AsheetofyellowlabelsisprovidedintheenvelopewiththeseinstructionsforboilersconvertedfromnaturaltoLPgas. Selecttherespectivefiringratefortheboilerbeingconvertedfromthissheetoflabelsandapplythemasfollows:• Applythe"RatingPlateLabel"adjacenttotheratingplate.• Applythe"GasValveLabel"toaconspicuousareaonthegasvalve.• Applythe"BoilerConversionLabel"toaconspicuoussurfaceon,oradjacentto,theouterboilerjacket.Fillinthe
dateoftheconversionandthenameandaddressofthecompanymakingtheconversionwithapermanentmarker.38.AlabelwithacceptableLPcombustionreadingsisprovidedwiththeseinstructions.Affixthislabelinaconspicuous
locationontheboiler.39.RefertotheSectionXI"Start-upandCheckout"intheI,O,andSInstructionsandperformanychecksnotalready
completed.
Table 10: Acceptable Combustion Readings for LP Gas (Propane) Operation
36. VerifygasinletpressureisbetweenvalueslistedinTable11withallgasappliances(includingconvertedboiler)bothon andoff.
Acceptable %CO2 Combustion Readings for LP Gas (Propane)
SizeAltitude
Max. CO Air Free0-2,000 ft 2,001-6,000 ft 6,001-7,800 ft 7,801-10,100 ft
Range Target Range Target Range Target Range Target85
10.5-11.2 11.0 10.2-10.5 10.510.3-10.6 10.6
10.3-10.5 10.5COAF
readings must be less than 200 ppm
11010.0-10.3 10.3
155
10.0-10.5 10.5
10.1-10.4 10.49.9-10.2 10.2
205 10.2-10.5 10.5 9.9-10.2 10.2270 9.8-10.0 10.0 9.7-9.9 9.9 9.5-9.7 9.7320 10.3-10.6 10.6
10.1-10.4 10.4 9.9-10.2 10.2399 9.9-10.2 10.2
*Low Fire Range and Target values are the same as High Fire above. Ensure low fire CO2 reading is less than or equal to high fire CO2 reading.
Acceptable %O2 Combustion Readings for LP Gas (Propane)
SizeAltitude
Max. CO Air Free0-2,000 ft 2,001-6,000 ft 6,001-7,800 ft 7,801-10,100 ft
Range Target Range Target Range Target Range Target85
5.0-3.9 4.2 5.4-5.0 5.05.2-4.8 4.8
5.3-5.0 5.0COAF
readings must be less than 200 ppm
1105.7-5.2 5.2
155
5.7-5.0 5.0
5.5-5.1 5.15.8-5.4 5.4
205 5.4-5.0 5.0 5.8-5.4 5.4270 6.0-5.7 5.7 6.1-5.8 5.8 6.5-6.1 6.1320 5.2-4.8 4.8
5.5-5.1 5.1 5.8-5.4 5.4399 5.8-5.4 5.4
**Low Fire Range and Target values are the same as High Fire above. Ensure low fire O2 reading is greater than or equal to high fire O2 reading.
Table 11: Minimum and Maximum Inlet PressureSize Min. (in. wc) Max. (in. wc)
85-399 8.0 14.0