Nti Tftn500 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: TFTN500, TFTN600, TFTN725, and TFTN850

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 TFTN500, 600, 725, and 850.

If 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:

Kit Contents:Table 1 – LP-Mixer Identification

nr. 1nr. 1nr. 1-Natural to LP Conversion Instructions -LP Conversion Label -LP-Mixer (Table 1)

ModelPolidoro code(MIXER data plate)

TFTN500 - 600

350_1104_04

TFTN725 - 800

350_1017_05Kit Part No.6498074364980801

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-Mixera. Check that the code of the LP-Mixer is the one indicated for the model of

boiler to be converted – see Table 1.

b. Turn the 120 V AC power and gas supply off to the boiler.

c. Remove the front and top covers from the unit.

d. Remove the Natural Gas Mixer, Gas Outlet Manifold and Silencer Box as

an assembly from the boiler:

i. Remove the four 5 mm hex key head screws securing the Gas Outlet

Manifold to the Gas Valve.

ii. Remove the six 5 mm hex key head screws securing the Natural Gas

Mixer to the Fan.

e. Remove the Natural Gas Mixer from the assembly (keep gaskets and

hardware for reassembly):

i. Remove the four 4mm hex key head screws and 8 mm nuts securing

the Gas Outlet Manifold to the Natural Gas Mixer.

ii. Remove the four Philips head screws securing the Silencer Box to the

Natural Gas Mixer.

f. Assemble the Gas Outlet Manifold and Silencer Box to the applicable

LP-Mixer (Table 1), reusing the original hardware. Verify that the gaskets

are correctly positioned and in good condition.

g. Install the LP-Mixer, Gas Outlet Manifold and Silencer Box assembly into

the boiler, reusing the original hardware. Verify that the O-rings located

at the gas valve and fan are correctly positioned and in good condition.

h. Turn the gas valve Throttle Screw clockwise (in) 1 turn – see Figure 1.

i. Turn the gas supply on and check for leaks in all gas piping, including the

inlet connection to the gas valve, using a soap and water mixture.

j. Proceed to Part 2: Gas Valve and Burner Setup.

Fan

Throttle Screw

Turn in (clockwise) 1 turn;

then proceed with Gas Valve

and Burner Setup.

Mixer

Silencer Box

Gas Outlet Manifold

Gas Valve 5Part 1 Propane Conversion ProcedureFigure 1 – Mixer Replacement and Throttle Screw Pre-set

Figure 2 – Gas valve adjustment for TFTN500-8506Part 2. Gas valve and Burner SetupOffset Screw – Used to set combustion at Min Power (10%). Low Gas Pressure Switch GML (front)Factory-set to close at 3 in. w.c.High Gas Pressure Switch GMH (rear)Factory-set to open at 20 in. w.c.Throttle Screw – Used to calibrate combustion at Max Power (100%)Line Pressure Test Port (bleed screw)Manifold Pressure Test Port (bleed screw)

7Part 2. Gas Valve and Burner Setupc.2. Gas Line pressureThe boiler gas valve is equipped with a Line Pressure Test Port; see Figure 2. 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. T

urn the supply of gas to the boiler OFF.

Open the bleed screw of the Line Pressure Test Port approx. 1-1/2 turns. This port is directly connected to the gas line feeding the boiler (see Fig. 2).

Connect a gas pressure gauge to the line pressure test port using applicable tubing (e.g. 1/4" ID). 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 (100%) 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 in Table 2 while the unit is operating at Max Power (100%). Continue observing gas line pressure until the completion of the Checking/Adjusting of the CO2 (see Part 3), in case adjustments need to be made.

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 NOTICE

The line pressure is a function of the gas supply and is affected solely by field provided parameters such as line size and regulator settings. Under no circumstances can the boiler gas valve influence or be used to adjust the gas line pressure.

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.

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.

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 Power

1. Preparing the measuring equipment

Make sure that the combustion test probe is well-sealed at its point of entry into the flue pipe. The presence of fresh air can alter the measurement, invalidating the combustion adjustment process.

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)NG8.0 – 10.0<175LP10.0 – 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 0.5 – 1.0% (

e.g. if, using LP, the CO2 at Max Power = 10.3%, the CO2 at Min Power must be between 9.5 – 9.8%

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 3 – Max Power CO2 Adjustment

ATTENTION!! Test Function will automatically deactivate after 30 minutes. Test Function can be turned off manually by pressing the RESET button.

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%)7.5 – 9.59.5 – 10.5

Adjusting the Gas Valve at Max Power

Adjust the gas valve by turning throttle screw 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.When the measured value corresponds to the value given in Table 3, Max Power adjustment is complete. Figure 2 – Burner Test screen (Max Power)Figure 4 – Burner Test screen (Min Power)Wait 1 minute for the boiler to stabilize before carrying out the combustion analyses.

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

ModelMin PowerMax Power

B u r n e r P ower

MBHMBHTFTN60060060TFTN72573TFTN85085

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.

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

Adjust Offset Screw by turning counter-clockwise to reduce the CO2 level; clockwise to increase it.Wait 1 minute after each adjustment for the CO2 value to stabilize.Figure 5 – Min Power CO2 Adjustment4. Ending Adjustment1.2.3.Exit Test Mode by pressing the 'Press to Stop Test' button (located in the lower-left corner of the Burner Test screen). Turn down the thermostats and / or stop the DHW draw.Check for and repair any gas leaks.4.Reinstall the front cover.If the CO2 (%) reading at Min Power is not 0.5 – 1.0% lower than the CO2 (%) reading at Max Power, adjust the gas valve following the instructions below. Otherwise move directly to the next operation.WARNING10%

B u r n e r P ower

100%TFTN50050050725850

Part 3.

Checking/Adjusting the CO2 at Max and Min Power

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 6.

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 22,2018b.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 7.Figure 6 – Update the Rating Plate DecalFigure 7 – 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