Pennco LP TO NATURAL GAS User Manual

CONVERSION INSTRUCTIONS

LP TO NATURAL GAS (SEA LEVEL TO 2000 FEET)

Cast Iron Gas Fired Water Boilers

15B, UH15B, BWB, GMGWB

For Forced Hot Water

!

WARNING

This conversion kit shall be installed by a qualied

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 re,

an explosion or production of carbon monoxide may
result causing property damage, personal injury or

loss of life. The qualied 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 specied in the

manufacturer’s instructions supplied with the kit.

Tools Required

Flat Head Screwdriver, 1/4” Nut Driver, 7/16” Open Ended
Wrench, 3/16” Allen Wrench, 18” Manometer (or dial

manometer)

Installation

1.

Turn off gas supply to the boiler.

!

WARNING

Electrical shock hazard. Turn OFF electrical power

supply at service panel before making electrical
connections. Failure to do so could result in death
or serious injury.

KIT CONTENTS

ITEM QTY.

Installation Instructions 1

Conversion Plate/Label 1

Pilot Orice - Spark 1

Pilot Orice - 24 Volt 1

Liquid Sealing Compound 1

Spring Kit 1

PILOT ORIFICES

MFG. PART NUMBER

Honeywell 390686-4*

*Use 390686-37 for Boilers Manufactured before July
2008 with Q381 Pilot.

Figure 1

BURNERS

GAS VALVE
KNOB

2.

Turn off all electrical to boiler.

3.

Remove front panel.

4.

Remove burner access door.

5.

Remove main gas burner tubes. See Figure 1.

6.

Remove main burner orices. See Figure 1.

7.

Install supplied natural gas main burner orices. See
table for orice size and quantities.

8.

Use 7/16” wrench, disconnect pilot tube from pilot. See
Figure 2.

9.

Remove pilot orice. See Figure 2.

10.

Install natural gas pilot orice. See Figure 2.

11.

Apply liquid sealing compound to threads of pilot
assembly tting.

12.

Attach pilot tube to pilot and securely tighten. See
Figure 2.

13.

Replace LP main burner tubes, if present, with natural

gas tubes. See Figure 3.

ORIFICES

Figure 2

Pilot

Pilot Orice

Pilot Tube

P/N 24004820, Rev. E [11/2014]

LP TO NATURAL GAS CONVERSION INSTRUCTIONS

-X

LP

ONLY

NAT/LP

14.

Remove the cover screw from gas valve pressure regu­lator. See Figure 4.

15.

Remove adjustment screw by turning counterclockwise

. See Figure 5.

16.

Remove red LP gas spring. See Figure 5.

NOTICE

Parts for steps 17, 18, 26, and 27 are located in the
Honeywell natural gas conversion kit HW#394588
(#VG00802) for VR8200, VR8204, VR8300 or
VR8304 gas valve or conversion kit HW#391936
(#VG00701) for VR8440 gas valve.

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use
any phone in your building.

• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.

• If you cannot reach your gas supplier, call the re
department.

17.

Insert stainless steel natural gas spring. See Figure 5.

18.

Install adjustment screw. Verify screw top is ush with

regulator top.

19.

Turn pressure regulator adjustment screw clockwise

eight (8) complete turns. This is starting point

for manifold pressure.

20.

Install manometer to pressure tap on outlet side of gas

valve. See Figure 4.

21.

Turn ON electric and gas supply.

NOTICE

Verify gas inlet pressure is between minimum of 5”
w.c. maximum of 14” w.c.

22.

Check for gas leaks around all gas connections using

commercially available soap solution specically made

for leak detection.

!

DANGER

Fire Hazard. Do not use matches, candles, open
ames, or other methods providing ignition source.

Failure to comply will result in death or serious
injury.

MAIN BURNER ORIFICES

INPUT
(Btuh)

45,000 3.1 1

70,000 2.8 2

96,000 3.2 2

120,000 2.9 3

145,000 3.2 3

170,000 2.9 4

175,000 3.0 4

195,000 3.2 4

245,000 3.2 5

295,000 3.2 6

Figure 3 - Burners

ORIFICE

(mm)

QTY.

23.

With boiler operating adjust manifold pressure to 3½”

water column by turning pressure regulator adjustment
screw.

24.

Turn OFF electric and gas supply.

25.

Remove manometer. Replace pressure tap cover screw
securely.

26.

Install silver natural gas regulator adjustment cover

screw with o-ring. See Figure 5.

27.

Mount conversion label on gas valve.

28.

Turn electric and gas supply ON.

29.

Cycle boiler to ensure proper operation and lighting.

30.

Replace front panel.

31.

Fill out and afx conversion plate adjacent to

rating plate. Complete this step to provide proper

identication for customer service or technical support

issues.

Figure 4 - Gas Valve

2

SEQUENCE OF OPERATION

Figure 5 - Gas Valve

Figure 6 - Burners, Gas Valve, & Manifold

• Thermostat actuates on call for heat, completing circuit
to control.

• Completed circuit to control activates circulator. Damper
will close end switch inside the damper. This will
complete circuit to ignition system and ignition takes
place.

• Power is interrupted between control system and
ignition system if boiler water temperature exceeds high
limit setting on boiler mounted high limit control. Power
remains off until boiler water temperature drops below
high limit setting. Circulator continues to operate under

this condition until thermostat is satised.

• Blocked ow of combustion products through boiler
venting system causes blocked vent safety switch to

shut main burner gas off. If boiler ueway becomes
blocked, ame rollout safety switch will shut main
burner gas off. See Figure 6. If either condition occurs,

do not attempt to place boiler back into operation.

Contact qualied service agency.

• Main burner ame should have well dened inner blue
mantel with lighter blue outer mantel. See Figure 7.

• Pilot ame should envelop ⅜ to ½ inch of tip of the pilot
thermocouple, ignition/sensing electrode or mercury

sensor. See Figure 8.

Figure 7 - Burner with Mantel

Checking Gas Input Rate To Boiler

• Adjust gas input to boiler by removing protective cap on
pressure regulator and turning screw clockwise to
increase input and counterclockwise to decrease
input.

• Set natural gas manifold pressure at approximately

3.5 inches water column. Manifold pressure is taken at
outlet side of gas valve.

• To check for proper ow of natural gas to boiler, divide
input rate shown on rating plate by heating value of gas
obtained from local gas company. This will determine
number of cubic feet of gas required per hour.

• With all other gas appliances off, determine ow of gas
through meter for two minutes and multiply by 30 to
get hourly rate. Make minor adjustments to gas input as
described above.

• Change burner orices if nal manifold pressure varies
more than plus or minus 0.3 inches water column from

specied pressure.

• Primary air adjustment is not necessary, therefore air

shutters are not furnished as standard equipment. Air

shutters are available on request where required by
local codes or conditions.

3

Figure 8 - Pilot

3/8” To 1/2”

In Flame

LP TO NATURAL GAS CONVERSION INSTRUCTIONS

Ignition

Electrode