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DANGERAsphyxiation Hazard. These instructions include a procedure for adjusting the air-fuel mixture on this boiler. Always use a combustion analyzer to measure the CO2 (or Oxygen) and Carbon Monoxide (CO) levels in flue gas. Adjusting the air-fuel mixture without a proper combustion analyzer will result in unreliable boiler operation, personal injury, or death due to carbon monoxide poisoning. Explosion Hazard, Electrical Shock Hazard, Burn Hazard. The gas supply shall be shut off prior to disconnecting the electrical power, before proceeding with the conversion.

WARNINGThis 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 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.These instructions are intended for use only with sizes listed in this document.Consult Appendix A in Installation, Operating and Service ( I, O & S) Instructions for installations above 2,000 ft. I, O & S Instructions are supplied with boiler and available on manufacturer's website.

LP Gas (Propane) Conversion Instructions

Size LP Conversion Kit Page085 107934-01 2-3110 107935-01 2-3155 107936-01 2-3205 107937-01 2-3270 107938-01 4320 108015-01* 5399 108015-02* 5

* Also used for LP Service kit

These instructions are included in LP conversion kits listed in Table 1:Table 1: LP Conversion Kits

Required Tools/Equipment:• 15/16"Wrench(FlareFitting)• 1-1/8"Wrench(GasFlexLine)• TorxT-25(GasValvetoVenturi)• TorxT-30(VenturiAssemblytoBlower)• PhillipsHeadScrewdriver• FlatHeadScrewdriver/5/16"NutDriver• 7mmHexHeadSocket(VenturiAssemblyto Blower320/399)• 1-7/16"Wrench(GasValveAdaptor320/399)• CombustionAnalyzer

Parts Included with This Kit:• LPVenturi• Hardware• BlowerO-ring• GasValveCoupling• RatingLabel• ServiceLabel

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When disconnecting flexible gasline, place backup wrench on thisnut to prevent damage to gas valve.

Connection

Flexible Gas Line

Figure 2: Backup Wrench Detail

To convert this boiler for use on LP gas, perform the following steps:1. Ifnotalreadydone,installtheboilerinaccordancewiththeInstallation,Operating,andServiceinstructions,following

allinstructionsinSectionXI“Start-upandCheck-out”uptoStep10.2. Disconnectpowersupplytoboiler3. Shutoffgassupplytoboiler

Steps 4 thru 12 for boiler sizes 85, 110, 155 and 205 (Figure 3)4.Disconnecttubetoairprovingswitchanddisconnectharnessfromrectifiermoduleongasvalve.(Figure8)5.Usewrenchandbackupwrenchtodisconnectflexiblegaspipefromgasvalveatflarefitting(Figure2).6. Remove(2)screwsconnectinggasvalvetoventuriassembly.(Figure3)7. Remove(3)screwsconnectingventuriassemblytoblower.(Figure3)8. Replacenaturalgasventuriassemblywithpropane(LP)venturiassembly,ensuringo-ringbetweenblowerandventuri

assemblyisinplaceandarrowonventuripointsup.(Figure3)9. Secureventuriassemblytoblowerusing(3)screwsremovedinstep7.10.Ensurecouplingbetweenventuriassemblyandgasvalveisinplaceandsecureusing(2)screwsremovedinstep6.11.Re-connectflexiblegaspipetogasvalve.12.Re-connecttubetoairprovingswitchandreconnectharnesstorectifiermoduleongasvalve.

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Figure 3: 085-205 Blower/Gas Valve/Venturi Detail

Venturi Assembly

O-Ring

Coupling

Arrow to Point up

PVC Attenuator Assembly(Used on Size 110 Installations

Above 2,000 ft. only)

Tighten Clamp

Steps 13 thru 14 for boiler size 110 installations above 2,000ft only (Figure 3 and 4)13.AttachPVCattenuatortoventuriassembly.(Figure3)14.Insertperforatedattenuatorintoventadaptor(Figure4)andskiptostep27.

Vent Adapter

Perforated Attenuator(Used on Size 110 LPInstallations Above 2,000 ft. only)

Figure 4: Vent Attenuator for 110 LP Installations above 2,000ft.

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Steps 15 thru 21 for boiler size 270 (Figure 5)15.Removeattenuatorfromventuriassembly,disconnecttubetoairprovingswitch,anddisconnectharnessfromrectifier

moduleongasvalve.(Figure9)16.Usewrenchandbackupwrenchtodisconnectflexiblegaspipefromgasvalveatflarefitting(Figure2).17.Remove(3)screwsconnectinggasvalvetoventuriassembly.(Figure5)18.Removegasketfromgasvalveoutlet,insertfactorysuppliedorificeintogrooveofgasketandreplace.(Figure5)19.Securegasvalvetoventuriassemblyusing(3)screwsremovedinstep17.20.Re-connectflexiblegaspipetogasvalve.21.Re-attachattenuatortoventuriassembly.Re-connecttubetoairprovingswitch,reconnectharnesstorectifiermoduleon

gasvalveandskiptostep27.

Figure 5: 270 Blower/Gas Valve/Venturi Detail

Gasket

VenturiAssembly

Orifice

PolypropyleneAttenuator

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Gasket

Arrow to point up

Venturi Assembly

Gas Valve Adapter

O-Ring

Figure 6: 320-399 Blower / Gas Valve / Venturi Detail

Steps 22 thru 26 for boiler sizes 320 and 399 (Figure 6)22.Loosenunionbetweengasvalveandventuriassembly23.Remove(3)screwsconnectingventuriassemblytoblower.24.Replacenaturalgasventuriassemblywithpropane(LP)venturiassembly,orreplacepropane(LP)venturiassembly,

ensuringo-ringbetweenblowerandventuriassemblyisinplaceandarrowonventuripointsup.25.Secureventuriassemblytoblowerusing(3)screwsremovedinstep23.26.Tightenunionbetweengasvalveandventuriassembly,andensuregasketisbetweengasvalveadaptorandventuri.Gas

valveisorientedasshowninFigure6.

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Main Flow Throttle

Outlet Tap

Tube to AirProving Switch

Gas Outlet

Servo Regulator(OFFSET Adjustment)

Gas Inlet

Inlet Tap

Rectifier Module

Figure 8: 085-205 Gas Valve Detail

Boiler Size

#Counter-clockwise Turns (From Fully Closed)

085 10.0110 10.0155 9.0205 14.0270 3.5320 4.0399 5.0

Table 7: Starting Number of Throttle Turns for Conversion to LP Gas

Outlet Tap

Tube to AirProving Switch

Main Flow Throttle

Servo Regulator(OFFSET Adjustment)

Gas Outlet

Rectifier Module

Inlet Tap

Gas Inlet

Figure 9: 270-399 Gas Valve Detail

27.Beforeattemptingtostarttheboiler,turnthethrottle(Figure8and9)clockwiseuntilitstops(severalfullturns).28.Turnthrottlecounter-clockwisetheexactnumberofturnsshowninTable7.

WARNINGThe throttle adjustments shown in Table 7 are approximate. The final throttle setting must be found using a combustion analyzer. Leaving the boiler in operation with a CO level in excess of 200PPM air-free could result in injury or death from carbon monoxide poisoning.

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WARNINGAll combustion performance numbers MUST be verified with a combustion analyzer. Failure to do so could result in substantial property damage, severe personal injury or death.

29. Selectthecorrectboilersize,altitude,andfuelusingthetouchscreendisplay. a. Checkboiler'sratinglabelforactualboilersize. b. Confirminstallationaltitude. c. Press"Adjust"buttonontheHomescreen. d. Press"Adjust"buttonontheAdjustModescreen. e. Press"Login"buttontoaccessPasswordscreen. f. Press5-digitdisplaytoopenakeypad.Enter the password "86"andpressthereturnarrowtoclosekeypad. Press"Save"button. g. Press"Adjust"buttontoenterAdjustmentMode. h. Press"ModulationSetup"menubutton. i. Press"Adjust"buttonafterreadingWarningscreen. j. Usethearrowbuttonstoselectthecorrectsize,altitude,andfuelofyourboiler.Pressthe(Checkwith Circle)buttontoenteryourselection. k. Press"Enter"buttonuntildisplaystopsblinking,pressnextandrepeatuntil"Completed"isdisplayed. l. PressXtoexit. m. Press"Confirm"toverifycorrectsize,altitude,andfuelisdisplayed.30. Attempttostarttheboilerusingtheoperatinginstructionslocatedoninsideofboilerfrontdoor.Iftheboilerdoesnot lightonthefirsttryforignition,allowboilertomakeatleastfourmoreattemptstolight.Ifboilerstilldoesnotlight, turnthethrottlecounter-clockwisein1/8turnincrements,allowingtheboilertomakeatleastfourtriesforignitionat eachsetting,untiltheboilerlights.31. Aftertheburnerlights,forcetheburnertohighfirebyenteringtheAdjustMenuandthenHighFireHoldasdescribed

inSectionXI"Start-upandCheckout"ofI,O&SInstructions.Allowtheboilertooperateforapproximately5minutesbeforetakingcombustionreadings.Note:after10minutes,theboilerisautomaticallyreleasedfromhighfirehold.

32. Performacombustiontest,samplingflueproductsfromthetapinfrontoftheventadaptor.33.Withburnerathighfire,adjustthrottleasneededtoobtainCO2(orO2)settingshowninTable10:• ToreduceCO2(increaseO2)turnthrottleclockwise.• ToincreaseCO2 (reduceO2)turnthrottlecounterclockwise.

Makeadjustmentsinincrementsof1/8and1/4turnsandallowtheboileratleastaminutetorespondtoeachadjustment

beforemakinganother.34. ForceburnertolowfirebyenteringtheAdjustMenuandthenLowFireholdasdescribedinSectionXI"Start-upand

Checkout".Allowtheboilertooperateforapproximately5minutesbeforetakingcombustionreadings.

35.Withburneratlowfire,adjustoffsetregulatorasneededtoobtainCO2(orO2)settingshowninTable10.• ToreduceCO2(increaseO2)turnoffsetregulatorcounter-clockwise.• ToincreaseCO2(reduceO2)turnoffsetregulatorclockwise.

Makeadjustmentsinincrementsnomorethan1/8turnsandallowtheboileratleastaminutetorespondtoeach adjustmentbeforemakinganother.

WARNINGAsphyxiation Hazard. Use combustion analyzer for all gas valve adjustments. Low fire offset screw is very sensitive. Adjust offset no more than 1/8 turn before checking combustion with analyzer. Maximum total offset adjustment ± 1 turn. Adjustments greater than ± 1 turn may damage regulator diaphragm. Failure to follow these instructions could result in death, serious injury or substantial property damage.

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37.AsheetofyellowlabelsisprovidedintheenvelopewiththeseinstructionsforboilersconvertedfromnaturaltoLPgas. Selecttherespectivefiringratefortheboilerbeingconvertedfromthissheetoflabelsandapplythemasfollows:• Applythe"RatingPlateLabel"adjacenttotheratingplate.• Applythe"GasValveLabel"toaconspicuousareaonthegasvalve.• Applythe"BoilerConversionLabel"toaconspicuoussurfaceon,oradjacentto,theouterboilerjacket.Fillinthe

dateoftheconversionandthenameandaddressofthecompanymakingtheconversionwithapermanentmarker.38.AlabelwithacceptableLPcombustionreadingsisprovidedwiththeseinstructions.Affixthislabelinaconspicuous

locationontheboiler.39.RefertotheSectionXI"Start-upandCheckout"intheI,O,andSInstructionsandperformanychecksnotalready

completed.

Table 10: Acceptable Combustion Readings for LP Gas (Propane) Operation

36. VerifygasinletpressureisbetweenvalueslistedinTable11withallgasappliances(includingconvertedboiler)bothon andoff.

Acceptable %CO2 Combustion Readings for LP Gas (Propane)

SizeAltitude

Max. CO Air Free0-2,000 ft 2,001-6,000 ft 6,001-7,800 ft 7,801-10,100 ft

Range Target Range Target Range Target Range Target85

10.5-11.2 11.0 10.2-10.5 10.510.3-10.6 10.6

10.3-10.5 10.5COAF

readings must be less than 200 ppm

11010.0-10.3 10.3

155

10.0-10.5 10.5

10.1-10.4 10.49.9-10.2 10.2

205 10.2-10.5 10.5 9.9-10.2 10.2270 9.8-10.0 10.0 9.7-9.9 9.9 9.5-9.7 9.7320 10.3-10.6 10.6

10.1-10.4 10.4 9.9-10.2 10.2399 9.9-10.2 10.2

*Low Fire Range and Target values are the same as High Fire above. Ensure low fire CO2 reading is less than or equal to high fire CO2 reading.

Acceptable %O2 Combustion Readings for LP Gas (Propane)

SizeAltitude

Max. CO Air Free0-2,000 ft 2,001-6,000 ft 6,001-7,800 ft 7,801-10,100 ft

Range Target Range Target Range Target Range Target85

5.0-3.9 4.2 5.4-5.0 5.05.2-4.8 4.8

5.3-5.0 5.0COAF

readings must be less than 200 ppm

1105.7-5.2 5.2

155

5.7-5.0 5.0

5.5-5.1 5.15.8-5.4 5.4

205 5.4-5.0 5.0 5.8-5.4 5.4270 6.0-5.7 5.7 6.1-5.8 5.8 6.5-6.1 6.1320 5.2-4.8 4.8

5.5-5.1 5.1 5.8-5.4 5.4399 5.8-5.4 5.4

**Low Fire Range and Target values are the same as High Fire above. Ensure low fire O2 reading is greater than or equal to high fire O2 reading.

Table 11: Minimum and Maximum Inlet PressureSize Min. (in. wc) Max. (in. wc)

85-399 8.0 14.0