Fuel Conversion - IBC DC Series Installation And Operating Instructions Manual

DANGER
Operating any IBC boiler /
water heater using a fuel
other than the fuel listed on
its rating plate is prohibited. If
the information in this section
related to conversion to
alternate fuels is not followed
exactly, a dangerous situation
can result, leading to fire or
explosion, which may cause
property damage, personal
injury, or loss of life.
PROPANE ORIFICE CHART
MODEL ORIFICE
NUMBER SIZE
DC 15-95 392
DC 15-96 392
DC 20-125 460
DC 33-160 580
NATURAL GAS ORIFICE
CHART
MODEL ORIFICE
NUMBER SIZE
DC 15-95 505
DC 15-96 505
DC 20-125 550
DC 33-160 725
3-4
DC SERIES BOILERS / WATER HEATERS DC 15-95, DC 15-96, DC 20-125, DC 33-160
3.4

FUEL CONVERSION

The DC Series modulating boiler / water heater is factory fire-tested to operate
with natural gas. The rating plate will be marked to indicate which fuel the
particular boiler / water heater has been set up with. Firing a boiler / water heater
with a fuel other than what is listed on the rating plate is prohibited unless the
following conversion procedure is completed by a qualified technician.
Refer to the preceeding section 3.3 - COMMISSIONING. The Low Fire (Zero
Offset) valve adjustment cap on the gas valve has been factory set. This cap
must not be tampered with. The Zero-offset screw is not to be adjusted in
the field.
Fuel conversion requires hardware adjustments (Orifice Replacement) as well as
measurement and possible tuning of the gas :air mixture. Detailed instructions
including parts and labeling are found in Fuel Conversion kits: Refer to Table 10
for the correct kit number.
CO VALUE (%) AT HIGH FIRE WITH THE FRONT COVER OPEN
2
Max. CO value
2
Min. CO value
2
CO VALUE (%) AT LOW FIRE WITH THE FRONT COVER OPEN
2
Max. CO value
2
Min. CO value
2
Table 12: CO Values and High and Low Fire
2
The following procedure must be carried out by a qualified technician.
Select the correct Fuel Conversion Kit for your boiler / water heater from
1.
Table 10.
Ensure the fuel conversion instructions supplied with the fuel conversion kit
2.
are read, understood and followed carefully.
3. Ensure that the gas supply is turned off at the gas control valve.
Disconnect the gas valve harness plug from the gas valve.
4.
Disconnect the nut at the gas valve outlet (top of the gas valve) and remove
5.
the orifice and O-ring.
6. Insert the correct orifice into the O-ring and re-install into the nut at the gas
valve outlet (top of the gas valve) and tighten the nut.
Restore gas supply by opening the gas control valve, and using an approved
7.
leak detection solution, soap test all joints.
Place the conversion labels associated with the new fuel onto the boiler
8.
/ water heater at the positions indicated on the applicable conversion kit
instruction sheet.
Carefully follow the "Prior to Start-Up" – Section 3.2 and "Commissioning" –
9.
Section 3.3 procedures on the preceeding pages 3-2 and 3-3.
NATURAL GAS
10.1%
9.1%
= value at High
9.1%
INSTALLATION AND OPERATION INSTRUCTIONS
PROPANE
11.5%
9.8%
= value at High – 0.3%
9.5%