NTI TRX085 User manual

For Qualified TechnicianFor Qualified Technician
Installation InstructionsInstallation Instructions
TRXTRX NATURAL TO PROPANENATURAL TO PROPANE
CONVERSION INSTRUCTIONSCONVERSION INSTRUCTIONS
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, WHICH NECESSITATES THE USE OF A CALIBRATED
CO2/O2AND CO COMBUSTION ANALYZER.
WARNING

2
Part 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
TRX085, TRX120,
TRX110C and TRX150C.
Kit Contents:
- Natural to LP Conversion Instructions nr. 1
- LP Conversion Label nr. 1
- LP-Mixer w. Diaphragm (Table 1) nr. 1
- Gasket for gas pipe nr. 2
Model Customer code
(MIXER data plate)
LP diaphragm
Ø in (mm)
TRX150CTRX150C
TRX120TRX120
400080007800
or
400080007801
6.0 mm
TRX110CTRX110C
400080007600
or
400080007801 5.5 mm
TRX085TRX085
400080022500
or
400080022501
Table 1 - LP Mixer and Gas diaphragm
Data plate
LP diaphragm
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.

3
Part 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
Carbon Monoxide levels, fire or
explosion leading to property
damage, personal injury or death.
ATTENTION:
LIQUEFIED PETROLEUM (LP)
PROPANE
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

4
Part 1 Propane Conversion Procedure
1. Install LP-Mixer with
LP-Diaphragm
a. Check that the code of the air / gas
mixer and the diameter of the gas
diaphragm are those indicated for the
model of boiler to be converted – see
Table 1.
b. Turn the 120VAC power supply OFF to
the boiler.
c. Turn the gas supply OFF.
d. Remove the front cover from the unit
and rotate the control box.
e. Unhook the electrical connection box.
Figure 1 - Removing Housing
Figure 2 - Rotate the Control box
Figure 3 - Unhook the Junction Box
Figure 4 - Unhook the Junction Box support
f. Unhook the junction box support from
the fan and silencer.

5
Part 1 Propane Conversion Procedure
LP - Gas diaphragm
Figure 6 - Remove the gas pipe
Gas diaphragm - Natural Gas
Figure 7 - Remove the NG-diaphragm
Figure 8 - Remove the NG-mixer
Figure 9 - Insert the LP-diaphragm
g. Remove the silencer.
Figure 5 - Remove the silencer
h. Unscrew the two nuts and remove the
gas pipe.
i. Remove the three bolts securing the
NG-mixer to the blower; remove the NG-
Mixer together with the NG Diaphragm.
Save these parts in-case the boiler
needs to be converted back to Natural
Gas at a later date.
j. Secure the LP-Mixer (with LP
Diaphragm) to the blower, reusing the
bolts from the previous step.
NOTICE: Verify the O-ring seal
between the mixer and blower is
correctly positioned and in good
condition before assembling.
K. Reassemble the gas pipe to the gas
valve and mixer.
ATTENTION!! Use the new rubber
gaskets provided with the kit.
l . Install the silencer and apply the
support bracket.
m. Hook the electrical connection box.

6
Part 1 Propane Conversion Procedure
4
2
1
2. Perform preliminary adjustment
on gas valve throttle screw 4.
a. TRX085 and TRX120 – Adjust throttle
screw 4 counter-clockwise 1.5 turns.
b. TRX110C and TRX150C – Adjust
throttle screw 4 counter-clockwise 3
turns.
c. Turn the gas supply on and test for gas
leaks in all piping.
d. Perform gas line pressure test and
combustion calibration in accordance
with Parts 2 and 3.
Figure 10 - Gas valve

7
Part 2. Gas valve and burner setup
2. Gas Line pressure
The boiler gas valve is equipped with a Line
Pressure Test Port; see Figure 10.
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. Turn the supply of gas to the boiler off.
b. Loosen screw 1 (Torx 10 - Line Pressure
Test Port). This port is directly connected
to the gas line feeding the boiler. See
Figure 10.
c. 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.
f. Observe the line pressure with the boiler
running, while checking/adjusting the
CO2 at maximum and minimum gas flow
rate (see Part. 3). Compare it to Table 2.
The pressure will be lowest during the
maximum flow of gas.
1. Operating Sequence
Prior to commencing the Gas Valve and
Burner Setup, perform the following
operating sequence check:
a. Turn the supply of gas to the boiler off.
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 Parameters
Line Pressure
(inches w.c.)
Nominal Min. Max.
Natural 7 3.5 10.5
Propane 11 8 13
Failure to close the bleed screw of
the Line Pressure Test Port will cause
a severe leakage of gas, resulting in
a fire or explosion causing property
damage, serious injury or death.
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 the
maximum DHW 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.
WARNING
DANGER
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.
NOTICE

8
Part 3. Checking/Adjusting the CO2
It is very important that the
combustion system be set within
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 flue test port plug as
illustrated, 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 11 - Combustion Test Port
Adjustments to the Gas valve may
only be made by a qualified gas
technician, while using a calibrated
combustion analyzer capable of
measuring CO2and 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.
WARNING
WARNING
WARNING
WARNING
NOTICE

9
Part 3. Checking/Adjusting the CO2
2. Checking/Adjusting the CO2at
MAXIMUM Gas Flow Rate
(High Fan Speed)
Set the thermostat at the highest possible
setting or draw off the domestic hot water
at the maximum water flow rate to create a
demand for heat.
Note: For only Heating Boiler Applications,
open all thermostatic valves present in the
CH circuit.
Select the TEST Function by pressing and
holding the RESET button for 10 seconds.
WARNING! When the Test Function is
activated the temperature of the water
coming out of the boiler may be more than
150°F.
and the icon will appear on the
display when Test Function is active.
The boiler will operate at maximum heating
power.
Press the button
to operate the boiler at
maximum power.
The icon will display.
Gas CO2
(%)
CO MAX
(ppm)
Natural 8.7 to 9.7 175
Propane 9.5 to 10.5 175
Table 3 - CO2 max-min
ATTENTION: The CO2at minimum gas
flow must not be set higher than the CO2
reading a maximum gas flow; it may be
set lower by as much as 0.3%, e.g., if CO2
at Max. = 9.2%, CO2at Min. = 8.9-9.2%
ATTENTION!! Values must be obtained
with the front cover installed.
If the CO2reading differs from the values
given in the table, then adjust the gas
valve following the instructions below.
Otherwise move directly to next operation.
ADJUSTING THE GAS VALVE AT MAXIMUM
GAS FLOW
Adjust the gas valve by turning setting
screw 4clockwise to increase the CO2level;
counterclockwise to reduce the CO2level (1
turn adjusts the CO2level by approximately
0.3%). Wait 1 minute after each change in
setting for the CO2value to stabilize.
If the value
measured
corresponds to the
value given in Table
3, max adjustment
is complete.
Otherwise continue
the setting
procedure.
ATTENTION!!
Test Function will automatically deactivate
after 30 minutes. Test Function can be
turned off manually by pressing the RESET
button.
3. Checking/Adjusting the CO2at
MINIMUM Gas Flow
(Low Fan Speed)
With Test Function active, press the
button to operate the boiler at minimum
DHW power. The and icons will
display.
4
Figure 12 - Max CO2
Adjustment
Wait 1 minute for the boiler to stabilize
before carrying out the combustion
analyses.
Wait 1 minute for the boiler to stabilize
before carrying out the combustion analyses.
Read the CO2value (%) and compare it with
the values given in the table below:

10
Part 3. Checking/Adjusting the CO2
Carbon 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 Minimum and Maximum Gas Flow
Model
Minimum Gas Flow CH Maximum Gas
Flow
DHW Maximum Gas
Flow
P.233
(%)
RPM MBH P.234
(%)
RPM MBH P.232
(%)
RPM MBH
TRX085 3 1216 9.4 61 5392 85 61 5392 85
TRX110C 3 1216 11.2 71 6112 106 77 6544 114
TRX120 2 1144 13.2 73 6256 120 73 6256 120
TRX150C 2 1144 13.2 73 6256 120 93 7696 150
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.
Adjusting the Gas Valve at Minimum
Gas Flow
Remove cap and adjust screw 2by
turning counter-
clockwise to
reduce the CO2
level; clockwise
to increase the
CO2level. Wait
1 minute after
each adjustment
for the CO2
value to stabilize.
WARNING! Minimum Gas Flow
Adjustment is very sensitive.
If the value measured corresponds to
the value given in Table 3 adjustment
is complete. Otherwise continue the
setting procedure.
ATTENTION!! If the value of the CO2at
minimum power has been changed,
it is necessary to repeat the adjusting
at maximum gas flow.
2
Figure 13 - Min CO2
Adjustment
4. Ending Adjustment
1. Exit Test Mode by pressing RESET.
2. Turn down the thermostat and / or stop
the DHW draw-off. For Only Heating
Boiler applications reset all thermostatic
valves.
3. Reinstall the combustion test port.
See Figure 11.
4. Check for and repair any leaks of gas.
5. Reinstall the front cover.
If the CO2(%) reading at min gas flow is
greater than the CO2(%) reading at max
flow, or if it is less than the reading at max
flow by more than 0.3%, adjust the gas
valve following the instructions below.
Otherwise move directly to next operation.
WARNING

11
Part 3. Checking/Adjusting the CO2
5. Update rating plate
As the certified installer of the Natural Gas
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
to Propane Gas” and fill in the date. Press
hard enough to permanently mark the
decal. See Figure 14.
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 Decal - Fill 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 15.
Figure 14 - Update the Rating Plate Decal
Figure 15 - Conversion Decal
THIS 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 Pressure
420060882600
John Smith

NTI Boilers Inc.
30 Stonegate Drive Saint John,
NB E2H 0A4 Canada
Technical Assistance: 1-800-688-2575
Website: www.ntiboilers.com
Fax: [phone]
Visit us online
420020189401