HTP EFTU-085 User manual

EFTUEFTU
NATURAL GAS TO PROPANE GASNATURAL GAS TO PROPANE GAS
CONVERSION INSTRUCTIONSCONVERSION INSTRUCTIONS
This conversion kit shall be installed by a qualied
service agency in accordance with the manufacturer’s
instructionsandallapplicablecodesand requirements
of the authority having jurisdiction. If the information
in these instructions is not followed exactly, a re,
an explosion or production of carbon monoxide
may result causing property damage, personal
injury or loss of life. The qualied 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, WHICH
NECESSITATES THE USE OF A CALIBRATED CO2/O2
AND CO COMBUSTION ANALYZER.
WARNING
272 Duchaine Blvd.
New Bedford, MA 02745
www.htproducts.com
lp-725 Rev. 000 Rel. 000 Date 6.1.20
Applicable Models:
EFTU- 085, 110, 150, 199,
110C, 150C, and 199C

2
General Safety Information
HTP boilers are factory set to operate
with Natural Gas. BEFORE OPERATING
WITH PROPANE the boiler must be
converted to Propane using this kit.
Use the procedures outlined in these
instructions to fully complete the
Natural Gas to LP conversion for
models 085, 110, 150, 199, 110C,
150C, and 199C.
Kit Contents:
- Natural to LP Conversion
Instructions nr. 1
- LP Conversion Label nr. 1
- LP-Mixer w. Diaphragm
(Table 1) nr. 1
- Gasket for gas pipe nr. 2
Model Polidoro code
(MIXER data plate) LP diaphragm Ø in (mm)
085, 110, and 110C
350_0944_02 6.4 mm
150 and 150C
350_0921_02
199 and 199C 350_0922_02 6.9 mm
Table 1 - LP Mixer and Gas Diaphragm
Data plate
LP diaphragm
If the kit contents do not match
those specied for your boiler
model (see Table 1), DO NOT
proceed with installing the LP-
Conversion Kit, and DO NOT
operate the boiler - contact HTP
for assistance.

3
General Safety Information
These instructions CANNOT be used
to convert HTP appliance models
not referenced in these instructions.
Contact HTP for the Natural Gas to
LP conversion kit and instructions
for other models.
Failure to apply these instructions
properly may result in dangerous
Carbon Monoxide levels, re or
explosion leading to property
damage, personal injury or death.
ATTENTION:
LIQUEFIED PETROLEUM (LP)
PROPANE
Liqueed Petroleum (LP)
propane gas is heavier than air;
therefore, it is imperative that
your boiler is not installed in a
pit or similar location that will
permit heavier than air gas to
collect.
Local Codes may require
appliances fueled with LP gas
be provided with an approved
means of removing unburned
gases from the room. Check your
local codes for this requirement.
WARNING

4
Part 1 Propane Conversion Procedure
1. Install LP-Mixer with
LP-Diaphragm
a. Check that the code of the air / gas
mixer and the diameter of the gas
diaphragm are those indicated for the
model of boiler to be converted – see
Table 1.
b. Turn the 120VAC power supply OFF to
the boiler.
c. Turn the gas supply OFF.
d. Remove the front cover from the unit.
LP - Gas diaphragm
Figure 1 - Remove the Silencer
Figure 2 - Remove the Gas Pipe
Figure 3 - Remove the NG-mixer
Figure 4 - Insert the LP-diaphragm
e. Remove the silencer.
f. Unscrew the two nuts and remove the
gas pipe.
g. Remove the three bolts securing the
NG-mixer to the blower and remove
the NG-Mixer.
i. Reassemble the gas pipe to the gas
valve and mixer.
ATTENTION!! Use the new rubber
gaskets provided with the kit.
j. Install the silencer.
NOTICE: 150/150C NG-mixers are
equipped with an NG Diaphragm
located on the mixer gas line inlet
(see Figure 4 for general diaphragm
location).
NOTICE: Save the NG-mixer (and NG
Diaphragm for 150/150C) in-case
the boiler needs to be converted
back to Natural Gas at a later date.
h. Secure the LP-Mixer (with LP
Diaphragm) to the blower in the same
position as the removed NG-Mixer,
reusing the bolts from the previous
step.
NOTICE: Verify the O-ring seal
between the mixer and blower is
correctly positioned and in good
condition before assembling.

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5
Part 1 Propane Conversion Procedure
1 32 4
1
2
4
4
2
1
2. Perform preliminary
adjustment on gas valve
throttle screw 4.
a. 085, 110, and 110C: Adjust throttle
screw 4 - counter-clockwise 0.5 turns.
b. 150, 199, 150C, and 199C: Adjust
throttle screw 4 - counter-clockwise 2
turns.
c. Turn the gas supply on and test for
gas leaks in all piping.
d. Perform gas line pressure test and
combustion calibration in accordance
with Parts 2 and 3.
NOTICE: 199 and 199C Models ONLY:
Adjust High and Low Fan Speeds
When converted to LP, the 199 and
199C models must have the High and
Low Fan Speeds adjusted from the
Natural Gas default values. Access
the Technical Menu and adjust
parameters 232, 233, and 234 in
accordance with Table 4 - Minimum
and Maximum Gas Flow, in this
document.
Figure 5 - Gas valve

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6
Part 2. Gas valve and burner setup
2. Gas Line pressure
The boiler gas valve is equipped with
a Line Pressure Test Port; see screw 1,
Figure 5.
Use the following procedure to measure
the gas line pressure to the boiler to
ensure it falls within the range given in
Table 2:
a. Turn the supply of gas to the boiler o.
b. Loosen screw 1 (Torx 10 - Line
Pressure Test Port). This port is
directly connected to the gas line
feeding the boiler. See screw 1, Figure
5.
c. Connect a gas pressure gauge to
the line pressure test port using
applicable tubing. Ensure both
ends of the tubing make a tight
connection.
d. Turn the gas supply to the boiler on
and check for gas leaks.
e. Observe the line pressure under static
conditions and compare it to Table 2.
The pressure will be greatest under
static conditions.
1. Operating Sequence
Prior to commencing the Gas Valve and
Burner Setup, perform the following
operating sequence check:
a. Turn the supply of gas to the boiler o.
b. Set the thermostat to the highest
setting.
c. Ensure the combustion fan pre-
purges for a short time prior to
activating the igniter.
d. Ensure the combustion fan post-
purges for at least 5 seconds prior to
reactivating the igniter.
e. Set the thermostat to the lowest
setting and continue with the Gas
Valve and Burner Setup procedure
outlined below.
Failure to perform the Gas Valve
and Burner Setup correctly may
result in incorrect operation,
component failure, property
damage, serious injury or death.
Table 2 - Line Pressure Parameters
Line Pressure
(inches w.c.)
Nominal Min. Max.
Natural 7 3.5 10.5
Propane 11 8 13
Failure to close the bleed screw
of the Line Pressure Test Port will
cause a severe leakage of gas,
resulting in a re or explosion
causing property damage, serious
injury or death.
f. Observe the line pressure with the
boiler running, while checking/
adjusting the CO2 at maximum and
minimum gas ow rate (see Part. 3).
Compare it to Table 2. The pressure will
be lowest during the maximum ow of gas.
g. Adjust the gas line pressure to ensure
the parameters in Table 2 are attained
under all conditions.
If possible, adjust the line pressure to
the “Nominal/Desired” value listed in
Table 2 while the unit is operating at the
maximum power.
Continue observing gas line pressure
until completing of necessary Checking/
Adjusting of the CO2(see Part 3), in case
adjustments need to be made.
h. Complete pressure testing. Remove
the tubing from the test port and then
return the bleed screw of the Line
Pressure Test Port to the closed position.
Check for gas leaks.
WARNING
DANGER
Thelinepressureisafunctionofthe
gas supply and is aected solely
by eld provided parameters
such as line size and regulator
settings. Under no circumstances
can the boiler gas valve inuence
or be used to adjust the gas line
pressure.
NOTICE

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7
Part 3. Checking/Adjusting the CO2 at max and min gas ow rate
It is very important that the
combustion system be set
within the recommended CO2/
CO measurements listed in
Table 3. Visually looking at the
burner does not determine
combustion quality. Failure to
measure combustion with a
calibrated combustion analyzer
and set the throttle within
the recommended CO2/CO
measurements could result
in property damage, severe
personal injury, or death.
1. Preparing the measuring equipment
Remove the ue test port plug as
illustrated, and insert a calibrated
combustion analyzer.
Make sure the analyzer is set to the
appropriate fuel.
It is required to use a calibrated
combustion analyzer to verify
nal adjustment according to
the combustion chart (Table 3).
Failure to do so could result in
serious personal injury or death.
Figure 6 - Combustion Test Port
Adjustments to the Gas valve may
only be made by a qualied gas
technician, while using a calibrated
combustion analyzer capable of
measuring CO2 and CO. Adjustments
may only be performed if the gas
line pressure is maintained above
minimum levels throughout the
duration of the test. See Table 3.
Failure to follow these instructions
may result in serious injury or death.
FAILURE TO PERFORM THE FLUE
GAS ANALYSIS AND ADJUSTMENT
AS DETAILED IN THIS SECTION
MAY RESULT IN ERRATIC AND
UNRELIABLE BURNER OPERATION,
LEADING TO REDUCED EFFICIENCY,
INCREASED FUEL CONSUMPTION,
REDUCED COMPONENT LIFE,
HEAT EXCHANGER COMBUSTION
DEPOSITS, AND GENERAL UNSAFE
OPERATION. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT
IN SERIOUS INJURY OR DEATH.
WARNING
WARNING
WARNING
WARNING
NOTICE

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8
Part 3. Checking/Adjusting the CO2 at max and min gas ow rate
2. Checking/Adjusting the CO2at
Maximum Gas Flow Rate (High Fan Speed)
Set the thermostat at the highest
possible setting or draw o the domestic
hot water at the maximum water ow
rate to create a demand for heat.
Note: For only Heating Boiler
Applications, open all thermostatic
valves present in the CH circuit.
Select the TEST Function by pressing and
holding the RESET button for 10 seconds.
WARNING! When the Test Function
is activated the temperature of the
water coming out of the boiler may be
more than 150°F.
and the icon will appear on
the display when Test Function is active.
The boiler will operate
at maximum heating
power.
Press the button
to operate the boiler at
maximum power.
The icon will display.
Wait 1 minute for the boiler to stabilize
before carrying out the combustion
analyses. Read the CO2value (%) and
compare it with the values given in the
table below:
Gas CO2
(%)
CO MAX
(ppm)
Natural 8.5 to 10 175
Propane 9.5 to 11 175
Table 3 - CO2 max-min
ATTENTION: The CO2 at minimum gas ow
must not be set higher than the CO2 reading
a maximum gas ow; it may be set lower by
as much as 1.0%, e.g., if CO2 at Max. = 9.5%,
then CO2 at Min. must = 8.5-9.5%.
0
ATTENTION!! Values must be obtained
with the front cover installed.
If the CO2reading diers from the
values given in the table, then adjust
the gas valve following the instructions
below. Otherwise move directly to next
operation.
Adjusting the Gas Valve at Maximum
Gas Flow
Adjust the gas valve by turning setting
screw 4clockwise to increase the CO2
level; counterclockwise to reduce the
CO2 level (1 turn adjusts the CO2 level by
approximately 0.3%). Wait 1 minute after
each change in setting for the CO2 value
to stabilize.
If the value
measured
corresponds to
the value given
in Table 3, max
adjustment
is complete.
Otherwise
continue the setting procedure.
ATTENTION!!
Test Function will automatically deactivate
after 30 minutes. Test Function can be
turned o manually by pressing the RESET
button.
3. Checking/Adjusting the CO2at
Minimum Gas Flow (Low Fan Speed)
With Test Function active, press the
button to operate the boiler at minimum
DHW power. The and icons will
display.
1 32 4
4
4
Figure 7 - Max CO2
Adjustment
Wait 1 minute for the boiler to stabilize
before carrying out the combustion
analyses.

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9
Part 3. Checking/Adjusting the CO2 at max and min gas ow rate
Carbon Monoxide - Never
leave the unit operating while
producing Carbon Monoxide (CO)
concentrations in excess of the
values indicated in Table 3. Failure
to follow this warning may result in
serious injury or death.
Table 4 Minimum and Maximum Gas Flow
Model
Minimum Gas Flow Maximum Gas Flow
P.233 (%) RPM MBH P.232 / 234 (%) RPM MBH
085 7 1504 8.5 78 6616 85
110 / 110C 11 1792 11.0 100 8200 110
150 / 150C 6 1432 15.0 91 7552 150
199 / 199C NG 4 1288 19.9 91 7552 199
LP 6 1432 93 7696
1. Canada: Altitudes between 2000-4500 ft, de-rate by 10%. Consult local authorities
for de-rating for altitudes above 4500ft.
2. USA: De-rate capacity by 4% for every 1000 ft above sea level, if altitude is above
2000 ft.
Adjusting the Gas Valve at Minimum
Gas Flow
Remove cap and adjust screw 2by
turning
counter-
clockwise to
reduce the
CO2level;
clockwise to
increase the
CO2level.
Wait 1 minute
after each adjustment for the CO2
value to stabilize.
WARNING! Minimum Gas Flow
Adjustment is very sensitive.
If the value measured corresponds to
the value given in Table 3 adjustment
is complete. Otherwise continue the
setting procedure.
Attention!! If the value of the
CO2at minimum power has been
changed, it is necessary to repeat
the adjusting at maximum gas ow.
1 32 4
2
2
Figure 8 - Min CO2
Adjustment
4. Ending Adjustment
1. Exit Test Mode by pressing RESET.
2. Turn down the thermostat and / or
stop the DHW draw-o. For Only
Heating Boiler applications reset all
thermostatic valves.
3. Reinstall the combustion test port.
See Figure 6.
4. Check for and repair any leaks of gas.
5. Reinstall the front cover.
If the CO2(%) reading at min gas ow
is greater than the CO2(%) reading at
max ow, or if it is less than the reading
at max ow by more than 1.0%, adjust
the gas valve following the instructions
below.
Otherwise move directly to next
operation.
WARNING

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10
Part 3. Checking/Adjusting the CO2 at max and min gas ow rate
5. Update rating plate
As the certied installer of the Natural
Gas to LP Conversion Kit, you must
indicate on the boiler that it has been
converted for use with Propane (LP) Gas:
a. Update Rating Plate Decal – Locate
the rating plate decal on the side of
the appliance. Using a regular ink pen,
check the box next to “Field converted
to Propane Gas” and ll in the date.
Press hard enough to permanently
mark the decal. See Figure 9.
FACTORY SET FOR NATURAL GAS
Field converted to Propane Gas
ADJUSTER A L’USINE POUR GAZ NATURAL
Convertie au propane sur place
Date: Date:
Gas Pressure [Pression du Gaz]
Maximum Inlet Gas Pressure [Pression maximale d’entrée du gaz]
Minimum Inlet Gas Pressure [Pression minimum d’entrée du gaz]
Manifold Pressure [Pression d’admission]
Natural [Naturel] Propane
10.5" wc [2.6 kPa]
3,5" wc [1 kPa]
0" wc [0 kPa] 0" wc [0 kPa]
8" wc [2 kPa]
13" wc [3.2 kPa]
October 22,2018
b. Conversion Decal - Fill out the
required information on the
Conversion Decal (included in this
kit) and ax it to the boiler cabinet
adjacent to the rating plate decal, in
a location where it can be easily seen.
See Figure 10.
Figure 9 - Update the Rating Plate Decal
Figure 10 - Conversion Decal
THIS CONTROL WAS CONVERTED FOR USE WITH PROPANE GAS
This appliance has been converted for use with Propane Gas, in accordance with the
instructions provided with the Natural to Propane Conversion Kit
by ______________________________________ , which accepts responsibility that
the conversion was performed properly.
Reference rating plate for Propane Input and Gas Pressure
420060882600
John Smith

11

272 Duchaine Blvd.
New Bedford, MA 02745
www.htproducts.com