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(NG to LP) - P-1201
Note
If converting t o natural gas, order the Natural Gas Conversion Parts kit (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.
Included with the Conversion Kit:
Part #
150-001
150-025
150-159
150-329
150-339
150-354
150-373
150-376
180-255
080-284
080-244
080-107
120-333E2
EX 700 - Fuel Conversion to Propane
Fuel Conversion Kit, NG to LP - EX 700
Description
O-Ring, 126 Nitrile
Wshr, Flat, Zn, 1/4
M5 Flat Washer
M8 x 14 Hex Bolt
M8 Flat Washer
M5 x 25 Hex Bolt
Hex Bolt 1/4-20 x 1.25L
O-ring
Mixer, PGT700, LP
Rating plate overlay
Installer identifier label
Gas valve conversion label
Quantity
1
4
4
6
6
4
4
1
1
1
1
1
| 1
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Table of Contents
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Summary of Contents for IBC P-1201
- Page 1 EX 700 - Fuel Conversion to Propane (NG to LP) - P-1201 Note If converting t o natural gas, order the Natural Gas Conversion Parts kit (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. Included with the Conversion Kit: Fuel Conversion Kit, NG to LP - EX 700...
- Page 2 This conversion involves changing the mixing assembly. There is no propane orifice. 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...
- Page 3 Fuel conversion instructions The following p rocedure 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. To perform a fuel conversion: 1. Turn off the gas supply at the gas shut-off valve. 2. Change the gas fuel source. 3. Disconnect the electrical power. 4. Remove the front door cover. 5. Remove the top panel of the appliance to access the gas valve. 6. Remove the four (4) 5/16" hex bolts from the gas inlet to the mixing device. Carefully separate the two parts, r emove and retain the O-ring for re-assembly. (See in image below). 7. 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). 8. Use a Hex key to remove the Six (6) 6 mm bolts connecting the mixing device to the fan. (See in image above). C arefully separate the two parts, r emove and retain the O-ring for re-assembly. 9. ...
- Page 4 12. Reinstall the top panel. 13. Restore the gas supply by opening the gas control valve and reconnect the electrical power. 14. When the boiler is running, use an approved leak detection solution to soap test all joints. 15. Perform a combustion test (see instructions below). 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. 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 (Status) > Clear Errors). The boiler a utomatically resets after 60 minutes, if no action is taken.
- Page 5 Testing and adjusting Measuring 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. N ote 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 fire CO max PPM Range % Target %...
- Page 6 Figure 2 Flue gas test port 2. Set the heat-out value in manual mode to the minimum MBH for the boiler (see Table for Rated Input of a Converted Boiler). 3. Low fire adjustment - adjust the low fire according to Table for Combustion test target ranges - CO . U se a 2.5 mm Allen key. Turn counter-clockwise (in the direction of the '+' sign) to raise to raise the CO % (to richen). Turn clockwise to lower CO %. Start with 1/8 of a turn until you see the analyzer measure a change then only make 1/16 adjustments. I f 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 t o confirm full maximum rating plate input. Check the measured results with Table for Rated Input of a Converted Boiler.
- Page 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 the last page. EX 700 - Convert to LP fuel (P-Kit 1201)
- Page 8 Where to place conversion labels on the boiler ...
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