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SFC 15-99 / SFB 15-99 - Fuel
Conversion to Natural Gas - Kit P-805
Note
If converting from N atural Gas to Propane, order the Propane Conversion Parts Kit (IBC Part # P-804) from
your authorized IBC Distributor.
Use the Natural Gas conversion parts kit if the fuel source at the site uses Natural Gas and the unit has been set up t o
operate with Propane. Check the rating plate on the unit to see which fuel source the particular unit 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 unit 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 unit will automatically de-rate the maximum input at a rate of approximately 2% per 1,000' above 4,500'. The gas
valve's zero-governor will ensure that the gas-air mixture is not affected at altitude.
Included with the conversion kit:
1 x Orifice - marked 392 - IBC Part # 180-216
1 x O-ring - IBC Part # 150-175
1 x Rating Plate Fuel Overlay - IBC Part # 080-247
1 x Gas Valve Conversion Label - IBC Part # 080-107
1 x Installer Identifier Label - IBC Part # 080-245
120-243E-R1
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Summary of Contents for IBC INTERGAS Kit P-805
- Page 1 SFC 15-99 / SFB 15-99 - Fuel Conversion to Natural Gas - Kit P-805 Note If converting from N atural Gas to Propane, order the Propane Conversion Parts Kit (IBC Part # P-804) from your authorized IBC Distributor. Use the Natural Gas conversion parts kit if the fuel source at the site uses Natural Gas and the unit has been set up t o operate with Propane. Check the rating plate on the unit to see which fuel source the particular unit 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 unit 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.
- Page 2 Combustion Test Target Ranges Figure 1 Gas valve and fan The Low Fire (zero-offset) valve adjustment cap on the gas valve has been factory set. Do not adjust this screw in the field unless indicated i n these instructions. After converting the unit to natural gas, a combustion (CO ) reading must be taken by a qualified technician using properly functioning and calibrated combustion analyzing equipment and the results compared to the values in Table 1. Natural Gas High Fire with front cover open Low Fire with front cover open 10.1% Actual Value at High Fire Max. CO value 9.1% Min. CO value 9.1% Table 1 - CO values at High and Low Fire...
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Page 3: Fuel Conversion Instructions
Table 3 Natural Gas Orifice Chart To perform a fuel conversion: 1. Turn off the gas supply at the manual gas valve. 2. Disconnect the electrical power. 3. Disconnect the nut at the gas valve outlet (top of the gas valve), and remove the O-ring and orifice. 4. 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 then tighten the nut. 5. Restore the gas supply by opening the gas control valve. 6. Test for leaks by using an approved leak detection solution on all joints. 7. Power on the unit. Now, carefully follow the procedures on Combustion Testing and Adjustment. SFC 15-99 / SFB 15-99 - Fuel Conversion to Natural Gas - Kit P-805... - Page 4 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 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 SFC 15-99 / SFB 15-99 99 MBH Table 4 Rated input of a converted unit Normal ignition system sequence of operation: The unit's control, upon a call for heat or DHW, turns on the combustion fan for a 5-second pre-purge, then energizes the spark electrode and gas valve for a 5-second trial for ignition. If the burner does not light, the process is repeated until the burner lights and flame is detected. After 4 unsuccessful trials for ignition, the unit locks out and will need to be manually reset by pressing the Return Arrow button. To perform a combustion test and adjustment: 1. Turn off the boiler’s manual gas valve. 2. ...
- Page 5 8. Turn off the gas at the unit's manual gas v alve. 9. Remove the flue gas analyzer from the test port, and reinstall the test port cap. 10. Remove the gas pressure manometer from the gas valve, and fully close the test port. 11. Turn on the gas at the unit’s manual gas valve. 12. Ensure there are no gas leaks before reinstalling the front cover. 13. Turn on the unit by pressing the space above the dot. Next you must fill in the information and affix the included fuel conversion labels to the unit as indicated after the conversion is completed. 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 as indicated on the last page. SFC 15-99 / SFB 15-99 - Fuel Conversion to Natural Gas - Kit P-805...
- Page 6 Clocking the Meter (for Natural Gas only) 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.
- Page 7 Where to Place Conversion Labels on the Boiler SFC 15-99 / SFB 15-99 - Fuel Conversion to Natural Gas - Kit P-805...