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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.If boiler can be installed at altitude, 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 Kit080-100 107873-01 or 108099-01120-150 107874-01 or 108100-01

180 107875-01 or 108101-01

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

Table 1: LP Conversion Kits

Required Tools/Equipment:• 10mmWrench(ColdBurnerDoor)• (2)AdjustableWrenches• TorxT-25(GasValvetoVenturi)• TorxT-30(VenturiAssemblytoBlower)• PhillipsHeadScrewdriver• CombustionAnalyzer

IncludedwiththisKit:• LPVenturi• Hardware• BlowerO-ring(BlowertoVenturi)• GasValveCoupling(VenturitoGasValve)• RatingPlateLabel• ServiceLabel

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When disconnecting flexible gas line;Place a backup wrench on this nut toprevent damage to the gas valve.

Flexible Gas LineConnection

Figure 2: Flexible Gas Line Disconnection

1. Disconnect power supply to boiler.2. Shut-off gas supply to boiler.3. Ifnotalreadydone,installtheboilerinaccordancewiththeInstallation,Operating,andServiceinstructions,following

allinstructionsinSectionXI“Start-upandCheck-out”uptoStep10.4. Disconnecttubetoairprovingswitch,anddisconnecttheendsofthesewireharnesses(Figure6):

a. AtGasValve b. atBlower c. AtIgnitor d. AtFlameSensor

For boilers having corrugated stainless steel tubing (CSST) gas connection inside boiler jacket, complete the following steps. Otherwise skip to Step 9:

5. Insidethejacket,useoneadjustablewrenchtoholdtheCSSTadapter.UsethesecondwrenchtoloosenanddisconnecttheCSSTflairnut(Figure2).

6. Removethe(4)10mmnutsthatattachthecoldburnerdoortotheheatexchanger.

7. Slidethecoldburnerdoorofftheheatexchangerstuds.Oncethedoorisclearofthestuds,theentiredoor/blower/gasvalve/gaspipeassemblycanbeliftedoutoftheboiler.

8. SkiptoStep17.

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For boiler having rigid steel gas connections inside boiler jacket only. Steps 9-12 Combi units only:9. Removeadditionalelectricalconnectionsatthetopofthecontrolboxassembly.10. Disconnectdisplayharnessatcontrol.11. DisconnectharnessconnectionatPCB.12. Removethe(3)screwsfromcontrolboxassemblyandremovecontrolboxassemblyfromboiler.

13. Iftheboilerinstallationmanualfollowed,a1/2"unionshouldbeinstalleddirectlyundertheboilerasshowninFigure3.Ifso,theblower/gasvalveassemblycanberemovedfromtheboilerwiththetophalfofthisunioninplace.Breakthisunionusinga"backupwrench"onthetop(male)halfoftheuniontoprotecttheboilergaspipingfromexcessivetorque.Note:Ifthereisnounionatthelocationshown,breakthegaslineattheclosestconvenientpointandremovethegaspipingattachedtotheboiler(whenre-assemblinginstalla1/2"unionasshowninFigure3).

14. Removethe(2)8-32screwsandnutsholdingthegaslinesealingplatetothebottomjacketpanel.15. Removethe(4)10mmnutsthatattachthecoldburnerdoortotheheatexchanger.16. Slidethecoldburnerdoorofftheheatexchangerstuds.Oncethedoorisclearofthestuds,theentiredoor/blower/gas

valve/gaspipeassemblycanbeliftedoutoftheboiler.

Figure 3: Blower/Gas Valve/Venturi Detail

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For all boilers (Figure 4):17.(onbench)Remove(2)screwsconnectinggasvalvetoventuriassembly.18.Remove(3)screwsconnectingventuriassemblytoblower.19.Replacenaturalgasventuriassemblywithpropane(LP)venturiassembly,ensuringO-ringbetweenblowerandventuri

assemblyisinplaceandarrowonventuripointsup.20.Secureventuriassemblytoblowerusing(3)screwsremovedinstep18.21.Ensurecouplingbetweenventuriassemblyandgasvalveisinplaceandsecureusing(2)screwsremovedinstep17.22.Reconnectcoldburnerdoortoheatexchangerusing(4)10mmnutsremovedinstep6orstep15.23.Reconnectgaspiping.24.Re-connecttubetoairprovingswitchandallelectricalconnections.25.Beforeattemptingtostarttheboiler,turnthethrottle(Figure6)clockwiseuntilitstops(severalturns).26.Turnthrottlecounter-clockwisetheexactnumberofturnsshowninTable5.

WARNINGThe throttle adjustments in Table 5 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.

Boiler Size # Counter-clockwise Turns (From Fully Closed)080 10100 10120 9150 10180 14

Table 5: Starting Number of Throttle Turns for Conversion to LP Gas

Figure 4: Gas Line Union

O-RING

VENTRURI ASSEMBLY

ARROW TO POINT UP

COUPLING

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GAS INLET

RECTIFIERMODULE

GAS OUTLET

TUBE TO AIRPROVING SWITCH

Figure 6: Gas Valve Detail

For boilers with touchscreen display only. Otherwise skip to step 28:27.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. For boiler with push button display only Otherwise skip to step 29:28.SelectLPconversionkits(PartNumbers:108099-01and108100-01)willincludeablueboiler"PIM"module.ThisPIM

isdesignedtoprogramtheboilercontrolwithspecificparametersrequiredforLPgas.Ifrequired,seestepsbelowtoinstallboilerPIM,otherwise,skiptostep29:

a. RemoveexistingboilerPIM.GentlypressthetabsatthetopandbottomofthePIMandpullstraightback (Figure7).ReplacewithPIMprovidedinkit.

b. PressandholdtheRHandDWNbuttonforapproximately3secondsuntil"rES"screen(showninFigure9) appears.

c. PressRHbuttontoconfirmthatyouwanttouploadthePIMdataontotheControl.Note:Ifyoureachthis screenbymistake,youcanescapewithoutuploadingthePIMbycyclingpowertotheboiler.

d. "rES"willflashduringtheuploadingprocess.Iftheuploadingprocessissuccessful,"rES"willstopflashing afterafewseconds.PressingLH("Done")atthispointwillreturntotheHomeScreen.

e. Ifthereisaproblem,anErrorcodewillappearonthescreen.PressingtheLH("Done")buttonwillreturnthe usertothehomescreenwithoutanychangesmade.Pressing"Next"willreturntheusertothe"rES"screenfor anotherattempt.

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Figure 9: Uploading PIM Data to Control

Figure 7: Removal of PIM

Figure 8: Home Screen

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29. Attempttostarttheboilerusingtheoperatinginstructionslocatedoninsideofboilerfrontdoor.Iftheboilerdoesnotlightonthefirsttryforignition,allowboilertomakeatleastfivemoreattemptstolight.Ifboilerstilldoesnotlight,turnthethrottlecounter-clockwisein1/8turnincrements,allowingtheboilertomakeatleavefivetriesforignitionateachsettinguntiltheboilerlights.

30. Aftertheburnerlights,forcetheburnertohighfirebyenteringtheAdjustMenu/DiagnosticModeandtheHighFireHoldasdescribedinSectionXI"Start-upandCheckout"ofI,O&SInstructions.Allowtheboilertooperateforapproximately5minutesbeforetakingcombustionreadings.Note:after10-15minutes,theboilerisautomaticallyreleasedfromhighfirehold.

31.Performacombustiontest,samplingflueproductsfromthetapinfrontoftheventadapter.32.Withburnerathighfire,adjustthrottleasneededtoobtainCO2(orO2)settingshowninTable10:• ToreduceCO2(increaseO2)turnthrottleclockwise.• ToincreaseCO2(reduceO2)turnthrottlecounter-clockwise.

Makeadjustmentsinincrementsof1/8and1/4turnsandallowtheboileratleastaminutetorespondtoeachadjustment

beforemakinganother.33. ForceburnertolowfirebyenteringtheAdjustMenu/DiagnosticModeandthenLowFireholdasdescribedinSection

XI"Start-upandCheckout".Allowtheboilertooperateforapproximately5minutesbeforetakingcombustionreadings.

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.

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.

34.Withburneratlowfire,offsetregulatorasneededtoobtainCO2(orO2)settingshowninTable10:• ToreduceCO2(increaseO2)turnoffsetregulatorcounter-clockwise.• ToincreaseCO2(reduceO2)turnoffsetregulatorclockwise. Makeadjustmentsinincrementsofnomorethan1/8turnandallowtheboileratleastaminutetorespondtoeach

adjustmentbeforemakinganother.

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35. Verifygasinletpressureisbetween11.0and14.0inchesw.c.withallgasappliances(includingconvertedboiler)both onandoff.

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

dateoftheconversionandthenameandaddressofthecompanymakingtheconversionwithapermanentmarker.37. AlabelwithacceptableLPcombustionreadingsisprovidedwiththeseinstructions.Affixthislabelinaconspicuous

locationontheboiler.38.RefertotheSectionXI"Start-upandCheckout"intheI,O,andSInstructionsandperformanychecksnotalready

completed.

Table 10: Acceptable Combustion Readings for LP Gas Operation

Acceptable %CO2 Combustion Readings for LP Gas (Propane)*

Boiler Model

Altitude 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 Target COAF readings must be less than 200 ppm.

080B

9.8-10.1 10.0

Not Permitted100B 9.6-9.9 9.9 9.4-9.7 9.7 9.4-9.7 9.7120B 9.4-9.7 9.7 9.8-10.1 10.1 Not Permitted150B 9.5-9.8 9.8 9.5-9.8 9.8 9.5-9.8 9.8180B Not Permitted180M Not Permitted 9.5-9.8 9.8 9.5-9.8 9.8 9.5-9.8 9.8

* 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)**

Boiler Model

Altitude 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 Target COAF readings must be less than 200 ppm.

080B

9.8-10.1 10.0

Not Permitted100B 5.9-6.3 5.9 6.2-6.6 6.2 6.2-6.6 6.2120B 6.2-6.6 6.2 5.6-6.0 5.6 Not Permitted150B 6.0-6.5 6.0 6.0-6.5 6.0 6.0-6.5 6.0180B Not Permitted180M Not Permitted 6.0-6.5 6.0 6.0-6.5 6.0 6.0-6.5 6.0

* 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.