IBC INTERGAS Kit P-805 User manual

120-243E-R1 |1
Note
IfconvertingfromNatural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to
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
SFC 15-99 / SFB 15-99 - Fuel
Conversion to Natural Gas - Kit P-805

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intheseinstructions.
Afterconvertingtheunittonaturalgas,acombustion(CO2)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
Max.CO2value 10.1% ActualValueatHighFire
Min.CO2value 9.1% 9.1%
Table 1 - CO2 values at High and Low Fire
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SFC 15-99 / SFB 15-99 - Fuel Conversion to Natural Gas - Kit P-805 |3
Fuel Conversion Instructions
Thefollowingproceduremustbecarriedoutbyaqualifiedtechnician.
Model Number Orifice Size
SFC15-99/SFB15-99 392
Table 2 Natural Gas Orifice Chart
Alternative Natural Gas Orifices - Calorific values 750-
900 BTU/FT3
Model Number Orifice Size
SFC15-99/SFB15-99 426
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.

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. WithaTorx15screwdriver,opentheinletgassupplypressuretestportbyturningits
screw1fullturncounterclockwise.
3. Attachamanometertotheinletpressuretestportandturnongastoappliance.
Staticmanometerreadingshouldbeideally11"w.c.forPropane.
Minimumandmaximumstaticpressuremustbebetween5"and14"w.c.
Monitorpressurethroughoutthecommissioning(start-up)procedure.
Pressuremaydroopupto1"w.c.athighfire.
4. Tosettheunittohighfiremanually,createalargeDHWdemandfortheunittoheat.:
Allowtheunittoignite/runagainstalargeload,tomaintainhighfire.Tosetthehigh-firemanually,pressandhold
theServiceiconfortwoseconds.ThenwhileholdingtheServiceiconpressthePlusbuttontwice.“H”willshowin
theservicedisplayastheunitentershighfire.
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SFC 15-99 / SFB 15-99 - Fuel Conversion to Natural Gas - Kit P-805 |5
Note:AllowtheunittooperateatHighFirefor3minutestostabilize.(Theunitoperatesinmanualmodefor10
minutesthenswitchbacktothenormaloperatingmode.Toextendmanualmodeoperation,presstheService 
andPlusbuttonstogethertwicewhiletheunitisoperatinginmanualmodetoresetthetimerfor10more
minutes.)Donotmakeadjustmentsiftheservicedisplayshowsan“h”.
5. Clockthegasmeter(seeinstructionsClocking the Meter (for Natural Gas only) on page 6)toconfirmfull
maximumratingplateinput.
a. Withacombustionanalyzerprobeinthefluegastestport,checkthemeasuredresultsagainstTable 1 -
HighFire.
b. Iftheresultsareoutsidethepermittedrange,checktheinletpressure,andconfirmthatthecorrectorificeis
installed.
6. SwitchtheunittolowfirebypressingtheServicebuttonandMinusbuttonatthesametime.Theunitwilldropto
lowfire.“L”willshowintheservicedisplay.
a. ComparethereadingswithTable 1 -LowFire.Ifadjustmentisnecessary,removetheLowFire
AdjustmentcaptorevealaTorxheadscrew.
b. Maketinyadjustments,typicallylessthan1/8thofaturnatatime.Turnthescrewclockwisetoincrease
CO2andcounter-clockwisetoreduceCO2.Ifthetargetcannotbemet,evenafterahalfturn,contactthe
factory.
c. Whenfinished,replacetheLowFirecap,andleavethemanualmodebypressing+AND-
simultaneously.
7. Switchofftheunitbypressingthespaceabovethedot.
8. Turnoffthegasattheunit'smanualgasvalve.
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.

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.
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SFC 15-99 / SFB 15-99 - Fuel Conversion to Natural Gas - Kit P-805 |7
Where to Place Conversion Labels on the Boiler
