Fuel Conversion - IBC DC 23-84 Installation And Operating Instructions Manual

DANGER
Operating any IBC boiler
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 23-84 505
DC 29-106 505
DC 33-124 580
DC 33-160 580
NATURAL GAS ORIFICE
CHART
MODEL ORIFICE
NUMBER SIZE
DC 23-84 650
DC 29-106 650
DC 33-124 725
DC 33-160 725
WARNING
When converting a Natural
Gas boiler to Propane, the
Back Flow Valve (located
above the outlet of the fan)
must be removed. Failure to
remove the Back Flow Valve
when using Propane fuel may
result in serious injury or
death.
3-4
DC SERIES COMBI BOILERS DC 23-84, DC 29-106, DC 33-124, DC 33-160
3.4

FUEL CONVERSION

The DC Series modulating boiler is factory fire-tested to operate with natural gas.
The rating plate will be marked to indicate which fuel the particular boiler has
been set up with. Firing a boiler 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.
Ensure the fuel conversion instructions supplied with the fuel conversion kit
1.
are read, understood and followed carefully.
Ensure that the gas supply is turned off at the gas control valve.
2.
3. Disconnect the gas valve harness plug from the gas valve.
4. Select the correct Fuel Conversion Kit for your boiler from Table 10.
5. Disconnect the nut at the gas valve outlet (top of the gas valve) and remove
the orifice and O-ring.
Insert the correct orifice into the O-ring and re-install into the nut at the gas
6.
valve outlet (top of the gas valve) and tighten the nut.
7. Restore gas supply by opening the gas control valve, and using an approved
leak detection solution, soap test all joints.
Place the conversion labels associated with the new fuel onto the boiler at
8.
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.
3.5.1 Gaining access to combustion chamber, burner
removal instructions
DIS-ASSEMBLY
Turn off the main power switch to the boiler.
1.
Turn off the gas supply valve to the boiler.
2.
NATURAL GAS
10.1%
9.1%
= value at Max
9.1%
INSTALLATION AND OPERATION INSTRUCTIONS
PROPANE
11.5%
9.8%
= value at Max – 0.3%
9.5%