NTI FTVN Series COMPASS Floor Mount Boilers Instruction Manual

NTI FTVN Series COMPASS Floor Mount Boilers

Specifications

• Product Name: FTSVeriNes ii
• Model Compatibility: FTVN Series II Models FTVN085 / FTVN110 / FTVN150 / FTVN199 / FTVN110C / FTVN150C / FTVN199C, COMPASS Floor  Mount Models NC085 / NC110 / NC110C / NC150 / NC150C / NC199 / NC199C
• Conversion Type: Natural Gas to Propane
• Conversion Kit Contents: Natural to LP Conversion Instructions, LP Conversion Label, LP-Mixer with Diaphragm, Gasket for gas pipe

FAQs

Q: What should I do if the kit contents do not match those specified for my boiler model?

A: If the kit contents do not match, do not proceed with installing the LP- conversion kit, and do not operate the boiler. Contact NTI for assistance.

Q: Why is it important to check local codes when installing a boiler fueled with LP gas?

A: LP propane gas is heavier than air, so it is important to ensure proper ventilation and installation according to local codes to prevent any safety hazards.

WARNING
This conversion kit shall be installed by a qualified installer, service agency, or gas supplier 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 installer, service agency, or gas supplier 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/O2 AND CO COMBUSTION ANALYZER.

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 formodels:

• – FTVN Series II
  • 085, 110, 150, 199, 110C,
  • 150C and 199C.
• – COMPASS Floor Mount
  • NC085, NC110, NC110C, NC150,
  • NC150C, NC199 and NC199C.

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| Polidoro code (MIXER data plate)| Conversion Kit No.| LP diaphragm Ø
---|---|---|---
085, 110, and 110C| 350_0944_03| 560001000300|

6.4 mm

150 and 150C| 350_0921_03| 560001000400
199 and 199C| 350_0922_03| 560001000500| 6.9 mm
Table 1 – LP Mixer and Gas diaphragm

WARNING

These instructions CANNOT be used to convert NTI appliance models not referenced in these instructions. Contact NTI for the Natural Gas t  LP conversion kit and instructions fo other models. Failure to apply these instructions properly may result in dangerous Carbon Monoxide levels, fire explosions 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
Breathing Hazard – Carbon Monoxide Gas

• Do not operate the heater if flood flood-damaged.
• install vent system in accordance with local codes and manufacturers installation instructions.
• Do not obstruct heater air intake or exhaust. Support all vent piping pe manufacturers installation instructions.
• Do not place chemical vapor-emitting products near the unit.
• According to NFPA 720, carbon monoxide detectors should be installed outside each sleeping area.
• Never operate the heater unless it is vented to the outdoors.
• Analyze the entire vent system to make sure that condensate will not become trapped in a section of the vent pipe and therefore reduce the open cross-sectional area of the vent. Breathing carbon monoxide can cause brain damage or death. Always read and understand the instruction manual.

Installation and Preset Procedure

Install LP-Mixer with LP-Diaphragm

• Check that the code of the air / gas mixer and the diameter of the gas diaphragm are those indicated for the model of the boiler to be converted – see Table 1.
• Turn the 120VAC power supply OFF to the boiler.
• Turn the gas supply OFF.
• Remove the front cover from the unit.
• Remove the silencer.
• Unscrew the two nuts and remove the gas pipe.
• Remove the three bolts securing th NG-mixer to the blower and remove the NG-Mixer.

NOTICE

• 150/150C NG-MIXERS ARE EQUIPPED WITH AN NG DIAPHRAGM LOCATED ON THE MIXER GAS LINE INLET (SEE FIGURE 4 FOR GENERAL DIAPHRAGM LOCATION). SAVE THE NG-MIXER (AND NG DIAPHRAGM FOR 150/150C) IN-CASE THE BOILER NEEDS TO BE CONVERTED BACK TO NATURAL GAS AT A LATER DATE.
• Secure the LP-Mixer (with LP Diaphragm) to the blower in the same position as the removed NG-Mixer, 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.
• Reassemble the gas pipe to the gas valve and mixer

ATTENTION!! USE THE NEW RUBBER GASKETS PROVIDED WITH THE KIT.

• Install the silencer.

Perform preliminary adjustment on gas valve throttle screw 4.

• 085, 110, and 110C: Adjust throttle screw 4 – counter-clockwise 0.5 turns.
• 150, 199, 150C, and 199C: Adjust throttle screw 4 – counter-clockwise 2 turns.
• Turn the gas supply on and test for gas leaks in all piping.
• Perform gas line pressure test and combustion calibration in accordance with Parts 2 and 3.

NOTICE

• 199 and 199C Models ONLY: WHEN CONVERTING TO LP THE MAX DHW/CH (FAN) PERCENTAGE PARAMETERS (2.3.2 & 2.3.4) MUST BE ADJUSTED FROM 82% TO 84%, AND THE MIN (FAN) PERCENTAGE PARAMETER (2.3.3) MUST BE ADJUSTED FROM 4% TO 6%. PARAMETERS ARE ADJUSTED FROM THE TECH MENU – COMPLETE MENU.

Operation Sequence and Gas Line Pressure Check

WARNING

Failure to perform the Gas Valve and Burner Setup correctly may result in incorrect operation, component failure, property damage, serious injury or death.

Operating Sequence

• Operating Sequence Prior to commencing the Combustion Check and Calibration, perform the following operating sequence check:
  • Turn the supply of gas to the boiler off.
  • Set the thermostat to the highest setting.
  • Ensure the combustion fan prepurges for a short time prior to activating the igniter.
  • Ensure the combustion fan postpurges for at least 5 seconds prior to reactivating the igniter.
  • Set the thermostat to the lowest setting and continue with the Gas Valve and Burner Setup procedure outlined below.

2. Gas Line pressure

• The boiler gas valve is equipped with a Line Pressure Test Port; see screw 1, Figure 5. Use the following procedure to measure the gas line pressure to the boiler to ensure it falls within the range given in Table 2:
• Turn the supply of gas to the boiler off.
  • Loosen screw 1 (Torx 10 – Line Pressure Test Port). This port is directly connected to the gas line feeding the boiler. See screw 1, Figure 5.
  • Connect a gas pressure gauge to the line pressure test port using applicable tubing. Ensure both ends of the tubing make a tight connection.
  • Turn the gas supply to the boiler on and check for gas leaks.
  • Observe the line pressure under static conditions and compare it to Table 2. The pressure will be greatest under static conditions.
  • 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.
  • 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 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.
  • 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.

Table 2 – Line Pressure Parameters

DANGER

• 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.

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.

WARNING

• Adjustments to the Gas valve may only be made by a qualified gas 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.

WARNING

• 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.

Preparing the measuring equipment

• Remove the flue test port plug as illustrated, and insert a calibrated combustion analyzer.

NOTICE

• Make sure the analyzer is set to the appropriate fuel.

WARNING

• 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.

WARNING

• 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.

Combustion Check and Calibration

Checking/Adjusting the CO2 at Max Power (100%)

• 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. Enable Burner Test, access the Main Menu by pressing the Menu button. Turn the dial to select Test Mode and press ENTER. Press ENTER to activate the Burner Test. Turn the dial to select MAX Power and press ENTER. The boiler turns on and ramps to Max Power (100%). (see Note BURNER TEST)
• Wait 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:

Power

| Max Power (100%)| Min Power (10%)
CO 2 (%)| 9.7-11%| 9.5-10.8%
CO PPM| <175| <175
Gas Pressure| 8-13” WC
Table 3 – Combustion Settings
NOTICE: the CO2 at Min Power must be set lower than the CO2 at Max Power by 0.2-1.0% Example: If CO2 at Max Power = 10.2%, then the CO2 at Min Power must = 9.5-10%

WARNING

WARNING! When the Burner Test Function is activated the temperature of the water coming out of the boiler may exceed 179°F.

ATTENTION!! VALUES MUST BE OBTAINED WITH THE FRONT COVER INSTALLED.
If the CO2 reading differs from the values given in the table, then adjust the gas valve following the instructions below. Otherwise move directly to next operation.

3. Checking/Adjusting the CO2 at Min Power (10%)

From the Burner Test screen, turn the dial to select MIN POWER and press ENTER to operate the boiler at minimum power.

• Wait 1 minute for the boiler to stabilize before carrying out the combustion analyses. If the CO2 (%) reading at Min Power is outside the range indicated in Table 3, adjust the gas valve following the instructions in Figure 8. Otherwise proceed  directly to step 4.
  • NOTE: Min Power calibration must be performed after Max Power calibration. COMPASS & FTVN Series II – Natural to Propane conversion instructions
  • NOTE: The CO2 reading at Min Power must be set lower than the CO2 reading at Max Power by 0.2-1.0%

10 %

| 8.5| ****

100%

| 85
110 / 110C| 11.0| 110
150 / 150C| 15.0| 150
199 / 199C| 19.9| 199
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.

Table 4 – Gas Input at Min and Max Power

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 6.
4. Check for and repair any leaks of gas.
5. Reinstall the front cover.

WARNING

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.

WARNING

• Breathing Hazard – Carbon Monoxide Gas
• Do not operate the heater if flood damaged.
• Install vent system in accordance with local codes and manufacturers installation instructions.
• Do not obstruct heater air intake or exhaust. Support all vent piping per the manufacturer’s installation instructions.
• Do not place chemical vapor-emitting products near unit.
• According to NFPA 720, carbon monoxide detectors should be installed outside each sleeping area.
• Never operate the heater unless it is vented to the outdoors.
• Analyze the entire vent system to make sure that condensate will not become trapped in a section of the vent pipe and therefore reduce the open cross-sectional area of the vent. Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual.

1 . 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:

• 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 9.m
• 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 10.
• COMPASS & FTVN Series II – Natural to Propane conversion instructions

CONTACT INFORMATION

• NTI Boilers Inc.
• 30 Stonegate Drive Saint John,
• NB E2H 0A4 Canada
• Technical Assistance: 1-800-688-2575
• Website: www.ntiboilers.com
• Fax: 1-506-432-1135

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