IBC EX 850 User manual

120-331E2 |1
Note
Ifconvertingtonaturalgas,ordertheNaturalGasConversionPartskit(P-1202)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 850
Part # Description Quantity
150-001 O-Ring,126Nitrile 1
150-025 Wshr,Flat,Zn,1/4 4
150-159 M5FlatWasher 4
150-329 M8x14HexBolt 6
150-339 M8FlatWasher 6
150-354 M5x25HexBolt 4
150-373 HexBolt1/4-20x1.25L 4
150-376 O-ring 1
180-257 Mixer,PGT850,LP 1
080-286 Ratingplateoverlay 1
080-244 Installeridentifierlabel 1
080-107 Gasvalveconversionlabel 1
EX 850 - Fuel Conversion to Propane
(NG to LP) - P-1203

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
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EX 850 - Convert to LP fuel (P-Kit 1203) |3
Fuel conversion instructions
Thefollowingprocedure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,remove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).Carefullyseparatethetwoparts,removeandretaintheO-ringforre-assembly.
9. Removethepropanemixingdevice.
10. WheninstallingthenewnaturalgasmixingdeviceensurethattheO-ringisproperlyseatedinthe
grooveofthefan.
Caution
FailuretopositiontheO-ringasindicatedwillresultinagasleak,andaffectburner
operation.
11. Re-assembleinthereverseorderofstepsprovided.

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850 850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automaticallyresetsafter60minutes,ifnoactionistaken.
Combustion test target ranges
TheLowFire(zero-offset)valveadjustmentscrewonthegasvalvehasbeenfactoryset.See inFigure: Gas
Valve and Fan.
TheHighFire(gas-air)ratioadjustmentscrewonthegasvalvehasalsobeenfactoryset.See inFigure: Gas
Valve and Fan.Itwillhavetobeadjustedtoattainoptimumcombustionresultswheneverfuelconversionis
undertaken;however,nomixtureadjustmentshallbeperformedunlessdonebyaqualifiedtechnicianusing
properlyfunctioningandcalibratedcombustionanalyzingequipment.
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EX 850 - Convert to LP fuel (P-Kit 1203) |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.Note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 %
Range % Target %
NaturalGas
9.0-10.0 9.5
8.2-9.2 8.7
<150
Propane
10.3-11.3 10.8
9.3-10.3 9.8
<250
Table 2 Combustion test target ranges - CO2 / Maximum CO
1. Aftertheboilerislitandisathighfire,insertthecombustionanalyzertestprobeintothefluegastest
port.Thenadjustthehighfire(gas-airratio)adjustmentwithasmallslotscrewdriveraccordingtothe
Table for Combustion test target ranges - CO2 values.

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 - CO2.Usea
2.5mmAllenkey.Turncounter-clockwise(inthedirectionofthe'+'sign)toraisetoraisetheCO2%(to
richen).TurnclockwisetolowerCO2%.Startwith1/8ofaturnuntilyouseetheanalyzermeasurea
changethenonlymake1/16adjustments.If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toconfirmfullmaximumratingplateinput.Checkthemeasuredresults
withTable for Rated Input of a Converted Boiler.
5. Runtheboilertolowfire,andchecktheresultstoconfirmcorrectsettings.
6. Restoretheloadtothepreviousloadtype.Unlessyouchangedtheloadhighlimit,alltheprogrammed
settingswillberestoredandtheloadwilloperateasbefore.Confirmasmoothignitionsequence.
7. Turnoffthegassupplyattheexternalgasshut-offvalve.
8. Disconnectthepowertotheboiler.
9. Removetheanalyzerprobeandinstallthetestportplug.
10. Disconnectthemanometer.
11. Removetheadapterfittingandreinstallthetestportplug.Keep the fitting with the boiler for future
use.
12. Turnonthegassupplyshutoffvalveandtestforgasleaks.
13. Restorepowertotheboileraftertheconversioniscompleted.
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EX 850 - Convert to LP fuel (P-Kit 1203) |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.

Where to Place Conversion Labels on the Boiler

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