Instructions for High Altitude Installations Above 4500 FT.
WARNING
If installing Boiler sizes 080 OR 180, do not attempt to convert 080 for use with LP at altitudes above 2000 ft
(610 m). Also, do not attempt to convert 180 for use with LP gas at altitudes above 7800 ft (2377 m). Attempts
to do so may result in unreliable operation, property damage, personal injury, or loss of life due to carbon
monoxide (CO) poisoning.
These instructions apply only to altitudes from 4501 to 10200 ft. (1350 to 3109 m).
These instructions contain specic information to set up your Boiler to ensure proper operation.
WARNING
LP Conversions - Boiler setup from factory is congured for use with natural gas installed from 4501 to 10200
ft (1350 to 3109 m) above sea level only. For conversion to LP at altitudes from 4501 to 10200 ft (1350 to
3109 m), follow the “High Altitude Start-Up Instructions for LP” section in this supplement. This conversion
shall be performed by a qualied 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, explosion, or production of carbon monoxide may result causing
property damage, personal injury, or loss of life. Installation is not proper and complete until the operation of
the converted appliance is checked as specied in the manufacturer’s instructions supplied.
DANGER
These instructions include a procedure for adjusting the air-fuel mixture on this Boiler. This procedure
requires a combustion analyzer to measure the CO2 (or Oxygen) and Carbon Monoxide (CO) levels in ue
gas. Adjusting the air-fuel mixture without a proper combustion analyzer could result in unreliable Boiler
operation, personal injury, or death due to carbon monoxide poisoning.
WARNING
Asphyxiation Hazard. The outlet pressure for the gas valve has been factory set and requires no eld
adjustment. This setting is satisfactory for both natural gas and LP. Attempting to adjust the outlet pressure
may result in damage to the gas valve and cause property damage, personal injury, or loss of life due to
carbon monoxide (CO) poisoning.
WARNING
Failure to set up Boiler in accordance with these instructions could result in production of high amounts of
Carbon Monoxide which could result in death, serious injury, and/or reduced component life.
107284-01 - 9/16
1
High Altitude Start-up Instructions for Natural Gas
1. Install Boiler in accordance with the Installation, Operating and Service Instructions manual supplied with the Boiler. Follow
all instructions in Section XI (Start-up and Checkout) up through Step 14. Skip Step 10.
2. Verify the gas inlet pressure is between the ranges shown in Table 4 with all gas appliances (including the Boiler) both on
and off.
3. Perform a combustion test. Boilers are equipped with a screw cap in the vent adapter. Be sure to replace this cap when
combustion testing is complete. Check CO2 (or O2) and CO at both high and low re. The Boiler may be temporarily locked
into high or low re as follows:
a. From the home screen, press and hold both the LH and RH buttons for 3s. The screen will change to Diagnostic Mode
and show the ame signal (Figure 12.7 in the Installation, Operating and Service Instructions manual).
b. Press the RH (“Next”) button 5 times to advance to the high re (“HF”) screen.
c. To set the Boiler in low re from the high re screen, press the LH button 6 more times.
d. To return to automatic ring control from either the HF or LF screens, press the LH (“Done”) button. The Boiler will
return to automatic modulation from either screen after 15 minutes if no buttons are pressed.
e. At both high and low re, CO readings should be less than 200PPM air-free. Acceptable CO2 and O2 ranges are shown
in Table 3.
Adjust the throttle at high re if ue gases are not in range:
• To reduce the CO2 (increase the O2), turn throttle clockwise.
• To increase the CO2 (reduce the O2), turn throttle counter-clockwise.
Make adjustments in increments of 1/8 to 1/4 turn and allow Boiler at least a minute to respond to each adjustment before
making another. The CO level will be at its lowest somewhere in the CO2 range shown in Table 3. Consult factory if it is
not possible to reduce CO level below 200PPM air free within the range of CO2 shown for the fuel and altitude at which
the Boiler is being used. Final readings should be taken with all doors and covers in place.
4. Follow all instructions in Section XI (Start-up and Checkout) from Steps 17 to 20.
5. Apply the “High Altitude Installation Label for Canadian Installations” adjacent to the Rating Plate Label, if applicable.
This label is provided in the Instructions Packet supplied with the Boiler.
High Altitude Start-up Instructions for LP
1. Install Boiler in accordance with the Installation, Operating and Service Instructions manual supplied with the Boiler. Follow
all instructions in Section XI (Start-up and Checkout) up through Step 9.
2. Set the throttle to its preliminary setting for LP. To do this:
a. Turn the throttle (Figure 1) clockwise until it stops (several full turns).
b. Turn the throttle counter-clockwise the exact number of turns shown in Table 2.
3. Follow all instructions in Section XI (Start-up and Checkout) from Steps 11 through 14.
Note: If the Boiler does not light on the rst try for ignition, allow the Boiler to make at least four more attempts to light.
If the Boiler still does not light, turn the throttle counterclockwise in 1/8 increments, allowing the Boiler to make at least
four tries for ignition at each setting, until the Boiler lights.
4. Verify the gas inlet pressure is between the ranges shown in Table 4 with all gas appliances (including the converted Boiler)
both on and off.
5. Perform a combustion test. Boilers are equipped with a screw cap in the vent adapter. Be sure to replace this cap when
combustion testing is complete. Check CO2 (or O2) and CO at both high and low re. The Boiler may be temporarily locked
into high or low re as follows:
a. From the home screen, press and hold both the LH and RH buttons for 3 seconds. The screen will change to Diagnostic
Mode and show the ame signal (Figure 12.7 in the Installation, Operating and Service Instructions manual).
b. Press the RH (“Next”) button 5 times to advance to the high re (“HF”) screen.
c. To set the Boiler in low re from the high re screen, press the LH button 6 more times.
d. To return to automatic ring control from either the HF or LF screens, press the LH (“Done”) button. The Boiler will
return to automatic modulation from either screen after 15 minutes if no buttons are pressed.
2
e. Allow Boiler to operate for approximately 5 minutes before taking combustion readings. At both high and low re, CO
readings should be less than 200PPM air-free. Acceptable CO2 and O2 ranges are shown in Table 3.
Adjust the throttle at high re if ue gases are not in range:
• To reduce the CO2 (increase the O2), turn throttle clockwise.
• To increase the CO2 (reduce the O2), turn throttle counter-clockwise.
Make adjustments in increments of 1/8 to 1/4 turn and allow Boiler at least a minute to respond to each adjustment before
making another. The CO level will be at its lowest somewhere in the CO2 range shown in Table 3. Consult factory if it is
not possible to reduce CO level below 200PPM air free within the range of CO2 shown for the fuel and altitude at which
the Boiler is being used. Final readings should be taken with all doors and covers in place.
6. Cycle Boiler at least ve times at the nal throttle setting to ensure burner ignites without delay and without noise.
7. Follow all instructions in Section XI (Start-up and Check-out) from Steps 17 to 20.
8. A sheet of yellow labels is provided in the Instructions Packet supplied with the boiler for boilers converted from natural
to LP gas. Select the model from this sheet of labels and apply them as follows:
a. Apply the “Rating Plate Label” adjacent to the rating plate.
b. Apply the “Gas Valve Label” to a conspicuous area on the gas valve.
c. Apply the “Boiler Conversion Label” to a conspicuous surface on, or adjacent to, the outer boiler jacket. Fill in
the date of the conversion and the name and address of the company making the conversion with a permanent marker.
9. Apply the “High Altitude Installation Label for Canadian Installations” adjacent to the Rating Plate Label, if applicable.
This label is provided in the Instructions Packet supplied with the boiler.
Figure 1a: Gas Valve Detail (80MBH Thru 120MBH)
3
Figure 1b: Gas Valve Detail (150MBH, 180MBH)
Table 2: Starting Number of Throttle Turns For
Conversion To LP Gas
Boiler
Size
080
100 3
120 4
150 5-3/4
180 6-1/2
# Counterclockwise Turns
(From Fully Closed)
WARNING
Throttle adjustments shown in Table 2 are approximate. The nal throttle setting must be found using a
combustions 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. Leaving the Boiler in operation with a CO2 level
outside of the range shown in Table 3 could also result in injury or death from carbon monoxide poisoning,
even if the Boiler is operating at an air-free CO level below 200PPM during this adjustment procedure.
If the throttle is very far out of adjustment on the “rich” (counter-clockwise) side, the Boiler burner may
be running at 0% excess air or even with a air de ciency. Operating the Boiler in this condition may cause
property damage, personal injury or loss of life. Under these conditions, most combustion analyzers used
in the eld will show 0% O2 and a very high (over 1000PPM) CO. Combustion readings will also appear to
be unresponsive to throttle adjustment. If the Boiler appears to be operating under this condition, turn the
throttle screw clockwise until the ame lengthens signi cantly and is mostly blue. Then, slowly turn the
throttle counter-clockwise, using a combustion analyzer to achieve the required CO2 as described in these
instructions.
4
Table 3: Boiler Altitude Adjustments 4501 - 10200 Ft. (1350 - 3109 m)
Acceptable Combustion Readings Approximate Derate per 1000 Ft.
Boiler
Size
80
100
120
150
180
Fuel
NG 8.7-9.1 4.9-5.6 200 0.0% 3.1%
LP
NG 8.5-9.3 4.5-6.0 200 0.0% 3.1%
LP 9.9-10.2 5.4-5.8 200 0.9% 3.1%
NG 8.8-9.3 4.5-5.4 200 0.0% 3.1%
LP 9.9-10.2 5.4-5.9 200 0.5% 3.1%
NG 8.6-9.3 4.5-5.8 200 0.4% 3.1%
LP 9.8-10.3 5.2-6.0 200 1.2% 3.1%
NG 8.5-9.1 4.9-6.0 200 1.9% 3.1%
LP 9.9-10.2 5.4-5.8 200 2.4%
Measured
% CO
2
Measured
% O
2
Max CO
(PM Air-Free)
4501 - 7800 ft. *
(1350 - 2377 m)
* Derate is referenced from sea level.
** Derate is referenced from 7800 ft.
Example:
1) 150 Boiler Size using natural gas installed at 6000 ft.
Total derate = (0.4% x 6.0) = 2.4%
2) 150 Boiler Size using natural gas installed at 8800 ft.
Total derate = (0.4% x 7.8) + (3.1% x 1.0) = 6.22%
7801 - 10200 ft. **
(2377 - 3109 m)
Table 4: Acceptable Gas Inlet Pressure Range
Fuel
Nat. Gas 4.0-14.0
LP 11.0-14.0
Inlet Pressure (in w.c.)
4501 - 10200 Ft.
Table 5: High Altitude Specic Parameters
Boiler Size 080 100 120 150 180
PIM High Altitude Repair Kit Part Number 107394-01 107394-02 107394-03 107394-04 107394-05
Altitude 4501 - 10200 Ft.
Maximum Heat Rate (RPM) 6200 7500 7050 7300 7200
Minimum Heat Rate (RPM) 1800 2000 1800 2000 1900
Absolute Maximum Heat Rate (RPM) 7720 7680 7132 7300 7385
Minimum Light-off Rate (RPM) 3500 3500 3500 3500 3500
Maximum Light-off Rate (RPM) 4000 4000 4000 4000 4000
5
Loading...