IBC SFC-99 User manual

120-243E1 |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appliancehas
beensetuptooperatewithPropane.Checktheratingplateontheappliancetoseewhichfuelsourcethe
particularappliance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appliance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appliance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:
Fuel Conversion Kit, LP to NG - SFC 99, SFB 99
Part # Description Quantity
180-216 LPorifice#392 1
150-175 OrificeO-ring19x2 1
080-303 Ratingplateoverlay 1
080-107 Gasvalveconversionlabel 1
080-245 InstallerIdentificationlabel 1
SFC 99 / SFB 99 - Fuel Conversion to
Natural Gas - P-805

Combustion Test Target Ranges
Figure: 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appliance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 99 / SFB 99 - Fuel Conversion to Natural Gas - 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appliance.
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 appliance
Normalignitionsystemsequenceofoperation:
Theappliance'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appliance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appliancetohighfiremanually,createalargeDHWdemandfortheappliancetoheat.:
Allowtheappliance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applianceentershighfire.
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SFC 99 / SFB 99 - Fuel Conversion to Natural Gas - P-805 |5
Note:AllowtheappliancetooperateatHighFirefor3minutestostabilize.(Theappliance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appliance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appliancetolowfirebypressingtheServicebuttonandMinusbuttonatthesametime.The
appliance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appliancebypressingthespaceabovethedot.
8. Turnoffthegasattheappliance'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appliance’smanualgasvalve.
12. Ensuretherearenogasleaksbeforereinstallingthefrontcover.
13. Turnontheappliancebypressingthespaceabovethedot.
Nextyoumustfillintheinformationandaffixtheincludedfuelconversionlabelstotheappliance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 99 / SFB 99 - Fuel Conversion to Natural Gas - P-805 |7
Where to Place Conversion Labels on the Boiler
