NTI FTG 600 Manuale utente

Firetube Giant FTG 600-1400

NATURAL GAS TO LP CONVERSION INSTRUCTIONS:

Version Date: 2019-11-28

Kit Number: 85418-1

NTI boilers are factory equipped to operate with Natural Gas. BEFORE OPERATING WITH PROPANE the

boiler’s gas valve must be adjusted according to these instructions. Use the procedures outlined in these instructions to

fully complete the Natural Gas to LP conversion.

Kit Contents:

Natural Gas to LP Conversion Instructions (p/n 85445)

Natural Gas to LP Conversion Decal (p/n 85418)

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.

NTI # 85445

This conversion shall be performed 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 application of these instructions. The conversion 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.

1.0 Adjusting the Gas Valve

The FTG 600, FTG 800, FTG 1200 & FTG 1400 are converted from Natural to LP Gas by

adjusting the Throttle Screw located on the gas valve; unlike most LP conversions an LP

orifice is NOT used.

1. Locate the Throttle Screw on the gas valve, see Figure 1-1.

2. Turn the Throttle Screw all the way in (clockwise until it stops).

3. Turn the Throttle Screw counterclockwise (out) ½ of a turn (¾ of a turn for FTG 1400).

4. Proceed to Section 2.0, Gas Valve and Burner Setup, for instructions on how to test the Gas Line Pressure and

perform the Combustion Calibration.

Figure 1-1 Gas Valve Assembly

2.0 Gas Valve and Burner Setup

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

Prior to commencing the Gas Valve and Burner Setup, perform the following operating sequence check:

1. Turn the supply of gas to the boiler off.

2. Set the thermostat to the highest setting.

3. Ensure the combustion fan pre-purges for at least 30 seconds prior to activating the igniter.

4. Ensure the combustion fan post-purges for at least 60 seconds prior to reactivating the igniter.

5. Set the thermostat to the lowest setting and continue with the Gas Valve and Burner Setup procedure outlined

below.

Gas Valve

Throttle Screw –used to calibrate

combustion at max. modulation rate (use

3 mm hex wrench). Pre-set by turning

screw all the way in (clockwise) until it

stops, then turn out (counterclockwise) ½

a turn (3/4 of a turn for FTG 1400)

Line Pressure Test Port

(located on gas valve inlet

flange)

Venturi

Combustion Blower

Air Filter

Cap (remove to access the

Throttle Screw)

Low Gas Pres. Switch

(auto-reset)

High Gas Pres. Switch

(manual reset)

Offset Screw –used to set

combustion at min. modulation rate;

must remove cap first

(use T40 Torx wrench)

Combustion Calibration Procedure

To calibrate burner combustion, perform the following procedure using a calibrated combustion analyzer capable of

measuring CO2and CO from a Natural Gas or Propane burning appliance:

1. Set analyzer to the appropriate fuel (Propane).

2. Gas Line Pressure Test –monitor gas line pressure throughout all combustion tests and verify it is maintained

within tolerance. See Gas Line Pressure Test below.

3. Set Throttle Screw –operate burner to the maximum modulation rate (see Table 2-2); set combustion according

to Table 2-1 using the Throttle Screw; allow time for the analyzer readings to stabilize between adjustments –

record CO2value. See Throttle Screw Adjustment below.

4. Set Offset Screw –operate burner to the minimum modulation rate (see Table 2-2); using the Offset Screw, set

the CO2to 0.5-1.0% lower than the value obtained during the maximum modulation rate test (e.g. if CO2at Max

= 10%, then CO2at Min must = 9.0-9.5%). See Offset Screw Adjustment below.

Combustion Calibration is mandatory upon installation and during each annual service.

Failure to perform the Combustion Calibration in accordance with these instructions may

result in incorrect combustion leading to burner damage or excessive Carbon Monoxide

concentrations causing property damage, personal injury or death.

Carbon Monoxide - Never leave the unit operating while producing Carbon Monoxide (CO)

concentrations in excess of 175 ppm. Failure to follow this warning may result in serious

injury or death.

Throttle Screw Adjustment

The gas valve Throttle Screw (see Figure 1-1) is used to calibrate the CO2concentration with the burner operating at

or near the maximum modulation rate (see Table 2-2). Turning the Throttle Screw in (clockwise) decreases the CO2

concentration. Turning the Throttle Screw out (counterclockwise) increases the CO2 concentration. Typical

adjustment required is 0 - 1/8th of a turn in or out from the position established in Section 1.0 above.

NOTE: Calibration of the Throttle Screw should only be performed with the burner operating at or near the

maximum modulation rate (see Table 2-2).

Adjustments to the Throttle Screw may only be made by a qualified gas technician 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 2-1). Failure to follow these instructions may result in serious

injury or death.

Offset Screw Adjustment

The gas valve Offset Screw (see Figure 1-1) is used to calibrate the CO2offset at minimum modulation vs. maximum

modulation. Turning the Offset Screw in (clockwise) increases the CO2 concentration at minimum modulation rate.

Turning the Offset Screw out (counterclockwise) decreases the CO2 concentration at minimum modulation rate.

Typical adjustment required is 0 - 1/8th of a turn in or out from the factory setting.

NOTE: Calibration of the Offset Screw must only be performed with the burner operating at the minimum

modulation rate (see Table 2-2).

Adjustments to the Offset Screw may only be made by a qualified gas technician using a

calibrated combustion analyzer capable of measuring CO2and CO, and only with the burner

at the minimum modulation rate (see Table 2-2). Attempting to set the Offset Screw while the

burner is operating at a modulation rate other than the minimum will result in incorrect

combustion and may lead to burner damage or excessive CO.

Gas Line Pressure Test

The boiler gas valve is equipped with a line pressure test port; see Figure 1-1. Use the following procedure to

measure the gas line pressure to the boiler to ensure if falls within the range given in Table 2-1:

1. Turn the supply of gas to the boiler off.

2. Using a 3/16 in. hex wrench, remove the plug from the flange located at the inlet of the gas valve, identified as

Line Pressure Test Port in Figure 1-1. In place of the plug, install a 1/8 NPT x hose barb adapter, suitable for

connecting the tubing of the gas pressure manometer being used to measure gas line pressure.

3. Slide the gas pressure manometer tubing over the hose barb adapter installed in step 2; connect the other end of

the tubing to gas pressure manometer. Ensure both ends of the tubing make a tight connection.

4. Open the supply of gas to the boiler and check for gas leaks.

5. Observe the line pressure under static conditions and compare it to Table 2-1. The pressure will be greatest under

static conditions.

6. With all other gas appliances in the application running, operate the burner to the maximum firing rate (see Table

2-2) and compare the observed line pressure with Table 2-1. The pressure will be lowest during the maximum

flow of gas.

7. Adjust the gas line pressure to ensure the parameters in Table 2-1 are attained under all conditions (see NOTICE

below). If possible adjust the line pressure to the "Nominal/Desired" value listed in Table 2-1, while the unit is

operating at the maximum modulation rate, see Table 2-2.

8. Continue observing the gas line pressure until the completion of the combustion analyses, in case adjustments

need to be made.

9. Complete pressure testing, turn the gas supply off, and then reinstall the Line Pressure Test Port plug, applying

appropriate thread sealant to the threads prior to installing. Turn gas on and check for leaks.

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.

Failure to properly install the Line Pressure Test Port plug will cause a severe leakage of gas,

resulting in a fire or explosion causing property damage, serious injury or death.

Table 2-1 Line Pressure and Combustion Parameters

Gas

Line Pressure (inches w.c.)

CO2(%) 1

CO (ppm)

Max. 1

Nominal/Desired

Min.

Max.

Min.

Max.

Natural

10.5

8.3

9.3

175

Propane

9.6

10.6

175

Notes:

1Combustion values listed are for burner operation at maximum modulation rate; when tested at minimum modulation

rate the CO2must be 0.5-1.0% lower than CO2at maximum modulation rate.

Table 2-2 Minimum and Maximum Modulation and Input Rates

Model

Min. Modulation Rate (RPM)

Max. Modulation Rate (RPM)

Input Rate (MBH)

Min

Max 1

FTG 600

1150

5600

600

FTG 800

1150

7450

800

FTG 1200

1050

8100

120

1200

FTG 1400

1050

7800

140

1400

Notes:

1Canada: Altitudes between 2000-4500 ft, de-rate by 10%. Consult local authorities for de-rating for altitudes above 4500ft.

2Use Diagnostic Test, accessed from the Diagnostic menu of the display, to force max. and min. modulation rates; see

Appendix A –Controller and Touchscreen Display Instructions, Section 5 DIAGNOSTICS PAGE.

3.0 Labeling

As the certified installer of the LP Conversion Kit, you must indicate on the boiler that it has been converted for use

with Propane (LP) Gas:

1. 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; depress hard enough to permanently

etch the decal (see Figure 3-1).

2. 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, and in a location where it can be easily seen (see Figure 3-2).

Figure 3-1 Update the Rating Plate Decal

Figure 3-2 Conversion Decal

March 29, 2016

John Smith

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