Important: If converting from Propane to Natural Gas - order the Natural Gas Conversion Parts Kit (IBC Part # P-307) 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 firetested) 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. With 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 respective 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 (IBC Part # P-306): 1 x Orifice - Marked 505 - IBC Part # 180-095 1 x O-ring - IBC Part # 150-175 1 x Rating Plate Fuel Overlay - IBC Part # 080-248 1 x Gas Valve Conversion Label - IBC Part # 080-107B 1 x Installer Identifier Label - IBC Part # 080-244 1 x Instruction Sheet - IBC Part # 1
Figure 1: Gas Valve and Pressure Reference System 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. Consult factory IBC 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 shall be performed unless done by a qualified technician using properly functioning and calibrated combustion analyzing equipment. FUEL HIGH FIRE LOW FIRE CO 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 Note: Low Fire CO 2 should be at least 0.5% lower than High Fire CO 2 Table 1: Combustion Test Target Range CO 2 2
PROPANE ORIFICE CHART MODEL NUMBER SL 20-160 G3 505 ORIFICE SIZE Fuel Conversion Instructions The following procedure must be carried out by a qualified technician. CAUTION Before you disconnect the electrical power, you must shut off the gas supply. 1. Turn off the gas supply at the gas shut-off valve. 2. Disconnect the electrical power. 3. Undo the union nut at the top of the gas valve outlet, and remove the O-ring and orifice. 4. Place the fuel-appropriate orifice into the O-ring, and re-install into the union nut at the gas valve outlet, and then tighten the nut. 5. Restore the gas supply by opening the gas control valve. 6. When the boiler is running, use an approved leak detection solution to soap test all joints.. Now, carefully follow the procedures on Page 4 on the combustion test and the appropriate setting. 3
MODEL NUMBER HIGH FIRE INPUT NATURAL GAS OR PROPANE SL 20-160 G3 160 MBH Table 2: Rated input of a converted boiler 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. 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. 1. Turn off the boiler s gas shut-off valve. 2. With a small (1/8 or 3 mm) flat screwdriver, open the inlet gas supply pressure test port by turning its center-screw 1 full turn counterclockwise. 3. 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. 4. Before you change the load to manual control, note the load setting. 5. 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. 6. With a combustion analyzer probe in the flue gas test port, check the flue gas reading and adjust the gas:air ratio screw to bring the flue gas to within the parameters indicated in Table 1. 7. Adjust slowly (clockwise) the High Fire (Gas : Air Ratio Adjustment) screw to obtain the correct CO 2 value (see Table 1). 4
8. Make tiny adjustments (may require several turns). Turning the High Fire (Gas : Air Ratio Adjustment) screw clockwise will lean out the flame. NOTE: Clock the gas meter (see instructions on Page 6) to confirm full maximum rating plate input. Check the measured results with Table 2 - High Fire. 9. Set the heat-out value in manual mode to the minimum MBH for the boiler (see Table 1). 10. While the boiler is at Low Fire, compare the combustion reading against the readings in Table 2. The reading should be within the range listed. 11. Restore the load to the previous load type. All the programmed settings will be restored and the load will operate as before. Confirm a smooth ignition sequence. 12. Turn off the gas supply at the gas shut-off valve. 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. 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 page 7 of this document. 5
SL 20-160 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 6
SL 20-160 NOTE The Installer must fill in the information and affix the included fuel conversion labels to the boiler in the positions indicated after the conversion is completed 7