IBC EX 700 User manual

120-334E-R1 |1
Note
Ifconvertingtopropane,orderthePropaneConversionPartskit(IBCPart#P-1201)fromyourauthorizedIBC
distributor.
UsetheNaturalGasConversionkitifthefuelsourceatthesiteusesnaturalgasandthemodulatingboilerhasbeenset
up(factoryfire-tested)tooperatewithpropane.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.
Theboilerwillautomaticallyde-ratethemaximuminputatarateofapproximately2%per1,000'above4,500'.Thegas
valveszerogovernorwillensurethatthegas-airmixtureisnotaffectedataltitude.
Includedwiththeconversionkit:
1xNGMixerAssembly-IBCPart#180-254 4xHexboltM6x14SS-IBCPart#150-373
1xO-ringgasvalvecoupler-IBCPart#150-001 1xRatingPlateFuelOverlay-IBCPart#080-285A
4xHexboltM5x25IBCPart#150-354 1xGasValveConversionLabel-IBCPart#080-107B
4xFlatWasher,0.562ID-IBCPart#150-025 1xInstallerIdentifierLabel-IBCPart#080-283A
4xM6FlatWasherIBCPart#150-159 6xHexboltM8x14-IBCPart#150-329
6xM8Flatwasher-IBCPart#150-339 1xO-ringEBMblower-IBCPart#150-376
Thisconversioninvolveschangingthemixingassembly.
EX 700 - Fuel Conversion to Natural Gas
(LP to NG) P-Kit 1200

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 700 - Convert to NG fuel (P-Kit 1200) |3
Fuel conversion instructions
Thefollowingproceduremustbecarriedoutbyaqualifiedtechnician.Inthisprocedure,youwillreplacethecurrent
propanefuelmixerwiththenewnaturalgasfuelmixer.
Caution
Beforeyoudisconnecttheelectricalpower,youmustshutoffthegassupply.
To perform a fuel conversion:
1. Turnoffthepowerandshutoffthegassupplyattheexternalgasshut-offvalve.
2. Removethefrontdoorandtopcoverfromtheboiler.
3. 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).
4. 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).
5. UseanAllenkeytoremovetheSix(6)6mmscrews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.
6. Removethepropanemixingdevice.
7. 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.
8. Re-assembleinthereverseorderofstepsprovided.
9. Checkforgasleaks.
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700 700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(Diagnostics>
AdvancedDiagnostics>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 1 .
TheHighFire(gas-air)ratioadjustmentscrewonthegasvalvehasalsobeenfactoryset.See inFigure 1 .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 700 - Convert to NG fuel (P-Kit 1200) |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1/8"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counter-clockwise¾to1fullturnto
increasethefuel(enrichen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Table 2 values.This
adjustmentscrewisverysensitiveandwillonlyneedverysmalladjustmentstofinetunethegasvalve(1/16of
aturnatatimeonly).Turncounter-clockwise(inthedirectionofthe'+'sign)toraisetheCO2%(torichen).Turn
clockwisetolowerCO2%.

Figure2Flue gas test port
2. Settheheat-outvalueinmanualmodetotheminimumMBHfortheboiler(seeTable 1 ).
3. Lowfireadjustment-adjustthelowfireaccordingtoTable 2 .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 1
.
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 700 - Convert to NG fuel (P-Kit 1200) |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Where to place conversion labels on
the boiler on page 8.
Clocking the meter (Natural Gas)
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.

Where to place conversion labels on the boiler

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