IBC EX700 Fuel Conversion To Natural Gas P Kit 1200 User Guide

: June 15, 2024
: IBC

Table of Contents

IBC EX700 Fuel Conversion To Natural Gas P Kit 1200
Product Specifications
Product Usage Instructions
FAQ
Included Kit
Product Overview
Fuel conversion instructions
Combustion testing and adjustments
- Testing and adjusting
Completing and affixing the conversion labels
Documents / Resources

IBC EX700 Fuel Conversion To Natural Gas P Kit 1200

Product Specifications

Product Name: EX 700 – Fuel Conversion to Natural Gas (LP to NG) P-Kit 1200
Conversion Type: Fuel conversion from propane to natural gas
Compatible Fuel Source: Natural gas
Compatible Appliance: Modulating boiler
Conversion Kit Included Parts:
- 1 x NG Mixer Assembly – IBC Part # 180-254
- 1 x O-ring gas valve coupler- IBC Part # 150-001
- 4 x Hex bolt M5 x25 IBC Part # 150-354
- 4 x Flat Washer, 0.562ID – IBC Part # 150-025
- 4 x M6 Flat Washer IBC Part # 150-159
- 6 x M8 Flat washer – IBC Part # 150-339
- 4 x Hex bolt M6 x 14 SS – IBC Part # 150-373
- 1 x Rating Plate Fuel Overlay – IBC Part # 080-285A
- 1 x Gas Valve Conversion Label – IBC Part # 080-107B
- 1 x Installer Identifier Label – IBC Part # 080-283A
- 6 x Hex bolt M8 x14 – IBC Part # 150-329
- 1 x O-ring EBM blower – IBC Part # 150-376

Product Usage Instructions

Step 1: Preparation

Before starting the fuel conversion, ensure that you have the Natural Gas Conversion kit and all the necessary parts mentioned in the specifications section.
Make sure to order the Propane Conversion Parts kit (IBC Part # P-1201) if you are converting to propane.
Verify that the fuel source at the site is natural gas and check the rating plate on the boiler to determine the current fuel source.

Step 2: Safety Precautions

Follow these safety precautions before performing the fuel conversion:

Read and understand all instructions and warnings provided in the user manual and the conversion kit.
Ensure that the conversion kit is installed by a qualified service agency in accordance with the manufacturer’s instructions and applicable codes.
Failure to follow the instructions exactly may result in fire, explosion, or carbon monoxide production, causing property damage, personal injury, or loss of life.

Step 3: Fuel Conversion

Turn off the power and shut off the gas supply at the external gas shut-off valve.
Remove the front door and top cover from the boiler.
Locate the gas inlet to the mixing device and remove the four (4) 5/16 hex bolts.
Carefully separate the two parts of the mixing device and remove the O-ring. Retain the O-ring for re-assembly.

Step 4: Installation

Install the NG Mixer Assembly (IBC Part # 180-254) included in the conversion kit.
Attach the O-ring gas valve coupler (IBC Part # 150-001) to the gas inlet of the mixing device.
Secure the NG Mixer Assembly and the gas valve coupler using the provided hex bolts and flat washers.

Step 5: Combustion Test and Labeling

Perform a combustion test to ensure proper functioning of the converted appliance.
Fill in the required information on the fuel conversion labels included in the kit.
Affix the fuel conversion labels to the boiler after the conversion is completed.

FAQ

FAQ (Frequently Asked Questions)

Q: Can I convert the fuel source from natural gas to propane using this kit?
- A: No, this kit is specifically designed for converting from propane to natural gas. If you want to convert from natural gas to propane, you need to order the Propane Conversion Parts kit (IBC Part # P-1201) separately.
Q: Who should install this conversion kit?
- A: This conversion kit should be installed by a qualified service agency in accordance with the manufacturer’s instructions and applicable codes. Improper installation may result in safety hazards and damage to the appliance.
Q: What should I do if I don’t have all the necessary parts mentioned in the specifications?
- A: Before starting the fuel conversion, ensure that you have all the necessary parts mentioned in the specifications section. If any parts are missing or damaged, contact your authorized IBC distributor to obtain the required parts.

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:

Perform a fuel conversion.
Perform a combustion test.
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 governors will ensure that the gas-air mixture is not affected at altitude.

Included Kit

Included with the conversion kit:

1 x NG Mixer Assembly – IBC Part # 180-254
1 x O-ring gas valve coupler- BC Part # 150-001
4 x Hex bolt M5 x25 IBC Part # 150-354
4 x Flat Washer, 0.562ID – IBC Part # 150-025
4 x M6 Flat Washer IBC Part # 150-159
6 x M8 Flat washer – BC Part # 150-339
4 x Hex bolt M6 x 14 SS – IBC Part # 150-373
1 x Rating Plate Fuel Overlay – IBC Part # 080-285A
1 x Gas Valve Conversion Label – IBC Part # 080-107B
1 x Installer Identifier Label – IBC Part # 080-283A
6 x Hex bolt M8 x14 – IBC Part # 150-329
1 x O-ring EBM blower – IBC Part # 150-376

This conversion involves changing the mixing assembly.

Product Overview

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

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:

Turn off the power and shut off the gas supply at the external gas shut-off valve.
Remove the front door and top cover from the boiler.
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 3 in image below).
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 4 on image above).
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.
Remove the propane mixing device.
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.
Re-assemble in the reverse order of steps provided.
Check for gas leaks.

Combustion testing and adjustments

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.

Table 1: Rated input of a converted boiler

Model Number

EX 700

High Fire Input

700 MBH

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 7 in Figure 1 . The High Fire (gas-air) ratio adjustment screw on the gas valve has also been factory set. See 6 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.

Testing and adjusting

Measuring the inlet gas pressure

Before performing a combustion test and adjustment, turn off the boiler’s external gas shut-off valve.
Remove the inlet gas pressure test port plug with a 3 mm Allen key. Note the fitting has BSP threads.
Use the supplied fitting to transition from 1/8″ BSP to barbed for connection to a manometer.
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.
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.
Before you change the load to manual control, note the load setting.
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

Performing a combustion test

Table 2: Combustion test target ranges – CO2 / Maximum CO

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%.
Set the heat-out value in manual mode to the minimum MBH for the boiler (see Table 1 ).
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.
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
Run the boiler to low fire, and check the results to confirm correct settings.
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.
Turn off the gas supply at the external gas shut-off valve.
Disconnect the power to the boiler.
Remove the analyzer probe and install the test port plug.
Disconnect the manometer.
Remove the adapter fitting and reinstall the test port plug. Keep the fitting with the boiler for future use.
Turn on the gas supply shut off valve and test for gas leaks.
Restore power to the boiler after the conversion is completed.

Completing and affixing the conversion labels

Fill in the conversion labels (included in the kit) associated with the new fuel type.
Place the conversion labels onto the boiler at the positions indicated on Where to place conversion labels on the boiler.

Clocking the meter (Natural Gas)

Turn off all other appliances and pilots.
Turn on the boiler and set the boiler to high fire.
Ensure the boiler has a large load to heat, so that the boiler will not shut off.
With a Stop-Watch, record the number of seconds for the smallest dial to make 1 full revolution.
CFH = (3600 x Dial Size) / Seconds.
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

Documents / Resources

| IBC EX700 Fuel Conversion To Natural Gas P Kit 1200 [pdf] User Guide
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