NTI TFTN285 User manual

NATURAL GAS TO PROPANE GAS
CONVERSION INSTRUCTIONS
service agency in accordance with the manufacturer's instructions and all applicable codes and requirements of the authority having jurisdiction. If the information an explosion or production of carbon monoxide may result causing property damage, personal 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.
WARNINGTFTN
Applicable Models:
TFTN285, TFTN340, and TFTN399

2Part 0. General Safety Information
NTI 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 TFTN285, 340, and 399.
Kit Contents:
nr. 1nr. 1
-Natural to LP ConversionInstructions -LP Conversion Label -LP-Orifice (Table 1)
ModelLP orifice markingsLP orifice Ø
TFTN285
LP / 285 / 5.25.2 mm
TFTN340
LP / 399 / 6.75TFTN3996.75 mmTable 1 – LP orificeTFTN285TFTN340-399If the kit contents do not match those specified for your boiler model (see Table 1), DO NOT proceed with installing the LP-Conversion Kit, and DO NOT operate the boiler - contact NTI for assistance.
NTI recommends installing the LP Conversion Kit before installing the boiler or connecting the gas line.Note:
nr. 1
Kit Part No.6498065264980653

3Part 0. General Safety Information
These instructions CANNOT be used
to convert NTI appliance models not
referenced in these instructions.
Contact NTI for the Natural Gas to
LP conversion kit and instructions
for other models.
Failure to apply these instructions
properly may result in dangerous
explosion leading to property
damage, personal injury or death.
ATTENTION:
Liquefied 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

4Part 1. Propane Conversion Procedure1.Install LP orificeFigure 1 – Removing the gas valve from a TFTN285a.Check that the markings on the LP orifice match those indicated for themodel of boiler to be converted – see Table 1.b.Turn the 120VAC power supply OFFto the boiler.c.Turn the gas supply OFF.d.Remove the front cover and top access panel from the unit.e.(TFTN285 only)Remove the right side panel.
f.Remove the electrical connector from the gas valve. g.Disconnect the gas line at the union fitting at the inlet to the gas valve.h.Disconnect the gas valve by removing the three screws securing it to the Venturi.i.Remove the rubber gasket located between the gas valve and Venturi and insert the LP orifice into the groove in the middle of the gasket; the orifice should fit securely.
h.d.e.i.

Figure 2 – Removing the gas valve from a TFTN340/399h.d.i.1.Install LP orifice (cont'd)
j. Seat gasket (w/orifice) into the outlet of the Gas Valve, and re-attach the Gas Valve to the Venturi and securely tighten the three screws.k.Reinstall the electrical connector onto the gas valve.l.Reconnect the gas line at the union fitting and tighten securely while supporting both sides of the fitting.m.Turn gas on and check for leaks. Proceed to Section 2.0 Gas Valve and Burner Setup.
5Part 1. Propane Conversion Procedure

6Part 2. Gas Valve and Burner Setup2. Gas Line pressureThe boiler gas valve is equipped with a Line Pressure Test Port; see screw 1, Figure 3. 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. b.c.Loosen screw 1 (Line Pressure Test Port). This port is directly connected to the gas line feeding the boiler. See screw 1, Figure 3.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 SequencePrior to commencing the Gas Valve and Burner Setup, perform the following operating sequence check:a. 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 ParametersLine Pressure (inches w.c.)NominalMin.Max.Natural73.510.5Propane 11813
Failure to close the bleed screw of the Line Pressure Test Port will cause a severe leakage of gas, causing property damage, serious injury or death.f.Observe the line pressure with the boiler running, while checking/adjusting the CO2 at Max Power and compare it to Table 2. The pressure will be lowest during the maximum flow 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 inTable 2 while the unit is operating at Max 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.
WARNINGDANGER
The line pressure is a function of the such as line size and regulator settings. Under no circumstances or be used to adjust the gas line pressure.
NOTICE

Figure 3 – Gas valve adjustment for TFTN285-399(1)7Part 2. Gas valve and burner setupLine PressureTest PortThrottle Screw (4) Used to calibrate combus-tion at Max Power (100%).Offset Screw (2) Used to set combustion at Min Power (10%). Use 2mm hex wrench.

8
It is very important that the combustion system be setwithin 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 Combustion Test Port plug / cap, as illustrated (Figures 4 & 5), 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 final adjustment according to the combustion chart (Table 3). Failure to do so could result in serious personal injury or death.Figure 4 – TFTN285 Combustion Test Port
Adjustments to the Gas valve may 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.
WARNINGWARNINGWARNINGWARNING NOTICE
Part 3. Checking/Adjusting the CO2 at Max and Min PowerFigure 5 – TFTN340-399 Combustion Test Port

9Wait 1 minute for the boiler to stabilize before carrying out the combustion analyses. Read the CO2 value (%) and compare it with the values given in the table below:GasCO2 (%) CO(ppm)NG8.9 – 10.0<175LP9.9 – 11.0<175
Table 3 – CO2 Max – Min
ATTENTION: The CO2 at Min Power must be set lower than the CO2 at Max Power by 0.4 – 0.8% (
e.g. if, using LP, the CO2 at Max Power = 10.3%, the CO2 at Min Power must be between 9.5 – 9.9%
).
ATTENTION!! Values must be obtained with the front cover installed.If the CO2values given in Table 3, adjust the gas valve following the instructions below. Otherwise move directly to the next operation.Figure 6 – Max PowerCO2 Adjustment
ATTENTION!! Test Function will automatically deactivate after 30 minutes. Test Function can be turned off manually by pressing the RESET button.
Wait 1 minute for the boiler to stabilize before carrying out the combustion analyses.
2. Checking/Adjusting the CO2 at Max Power
Set the thermostats at the highest possible setting to create a demand for heat. Select Max Power from the Test Mode – Burner Test screen, then wait for the Burner Power gauge to reach 100%.
3. Checking/Adjusting the CO2 at Min Power
Select Min Power from the Test Mode – Burner Test screen, then wait for the Burner Power gauge to reach 10%.
Part 3. Checking/Adjusting the CO2 at Max and Min PowerMax Power(100%)Min Power(10%)8.5 – 9.69.5 – 10.6
Adjusting the Gas Valve at Max Power
Adjust the gas valve by turning throttle screw (4) counterclockwise to increase the CO2 level; clockwise to reduce the CO2 level. Adjust in increments of 1/16th of a turn, waiting 1 minute after each adjustment.NOTE: when switching direction between clockwise and counter-clockwise, it may take a half to a full turn before a change in CO2 is realized.
When the measured value
corresponds
to the value givenin Table 3, Max
Power adjustment is complete.
(4)

10Carbon 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 - Gas Input at Min and Max Power
Model Min PowerMax Power
B u r n e r Power MBH MBH
TFTN285 28.5285TFTN340340TFTN399 39.9399
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.
Wait 1 minuteafter each adjustment for the CO2 value to stabilize. WARNING! Min Power adjustment
is very sensitive.
If the value measured corresponds to the value given in Table 3, Min Power adjustment is complete. Otherwise continue with the procedure.
Adjusting the Gas Valve at Min Power
Remove cap and adjust screw 2 by turning counter-clockwise to reduce the CO2 level; clockwise to increase it. Figure 7- Min PowerCO2 Adjustment
4. Ending Adjustment
1.Exit Test Mode by pressing the 'Press to Stop Test' button (located in the lower-left corner of the Burner Test screen).2.3.Turn down the thermostats and / or stop the DHW draw.Reinstall the Combustion Test Port plug (see Figures 4 & 5).4.Check for and repair any gas leaks.5.Reinstall the front cover.If the CO2 (%) reading at Min Power is not 0.4 – 0.8% lower than the CO2 (%) reading at Max Power, adjust the gas valve following the instructions below. Otherwise move directly to the next operation.WARNING
10%
B u r n e r Power
100%
Part3. Checking/Adjusting the CO2 at Max and Min Power(2)

115. Update rating plateGas 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 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 DecalFill out the required information on the Conversion Decal (included in this kit) and affix 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 DecalFigure 10 - Conversion DecalTHIS 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 Pressure420060882600John Smith
Part 3. Checking/Adjusting the CO2 at Max and Min Power

NTI Boilers Inc. 30 Stonegate Drive Saint John,
NB E2H 0A4 Canada
Technical Assistance: 1-800-688-2575
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Fax: [phone]
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