Carrier KGANP5201VSP Instruction manual

Installation Instructions
personnel
must perform
all other
operations.
heating equipment,
observe precautions
and on labels attached to or shipped
safety precautions
Follow
NOTE:
Read
installation.
the entire
SAFETY
instruction
manual
before
starting
the
CONSIDERATION
codes.
In the United
the current
edition
(NFGC)
NFPA No. 54/ANSI
current edition of the National
and
Propane
CAN/CSA-BI49.1
Failure to follow
injury or death.
ELECTRICAL
POISONING
this warning
could
SHOCK,
HAZARD
result
AND
in personal
safety
/_.
When
you see this symbol
information.
or
manuals,
be
alert
follow
In Canada,
of Canada,
to
during
This
the
all safety
Fuel Gas Code
refer to the
Natural Gas
(NSCNGPIC),
and work gloves.
start-up,
adjustment
is the safety-alert
on the furnace
potential
symbol
and in instructions
for
personal
iniury.
are used with the safety alert symbol. DANGER
identifies
the
most serious hazards which will result in severe personal iniury or
death. WARNING
signifies
a hazard which could
result in
personal
practices
iniury
which
or death. CAUTION
may result in minor
doit 0tre install0e
par un servie
d'entretien
qualifiO, selon les instructions
du fabricant
selon routes les exigences
et tousles
codes pertinents
l'autoritO
compOtente.
Assurezvous
de bien suivre
et
de
les
instructions
dans cette notice pour rOduire au minimum
le
risque
d'incendie,
d'explosion
ou la production
de
monoxyde
de carbone
pouvant
causer
des dommages
mat0riels,
de blessure ou la mort. Le service d'entretien
qualifiO est responsable
de l'installation
de cette trousse.
L'installation
n'est pas adOquate ni complOte rant que le bon
fonctionnement
de l'appereil
converti
n'a pas Or0 vOrfiO
selon les instructions du fabricant fornies avec la trousse.
personnel
can perform
cleaning
and replacing
basic maintenance
functions
air filters. Trained
service
to identify unsafe
iniury or product
INTRODUCTION
ELECTRICAL
POISONING
instructions
damage.
SHOCK
HAZARD
AND
could result in personal
iniury,
Improper
installation,
adjustment,
alteration,
service,
maintenance,
or use can cause carbon monoxide
poisoning,
explosion,
fire, electrical shock, or other conditions,
which
could result in personal
iniury or death. Consult
your
distributor
or branch for information
or assistance.
The
qualified
installer
or
agency
factory-authorized
kits or accessories
product.
FIRE, EXPLOSION,
HAZARD
Installing and servicing heating equipment
can be hazardous
due
to gas and electrical components.
Only trained
and qualified
personnel should install, repair, or service heating equipment.
is used
personal
and property
damage. NOTE is used to highlight
suggestions
which will result in enhanced installation, reliability, or operation.
Failure to follow
death or property
LE FEU, L'EXPLOSION,
CHOC ELECTRIQUE,
ET MONOXYDE DE CARBONE
EMPOISONNER
Untrained
such as
Z223.1.
Standard
available
Recognize
FIRE,
EXPLOSION,
CARBON
MONOXIDE
de conversion
on
Understand
the signal words DANGER,
WARNING,
CAUTION
and NOTE. The words DANGER,
WARNING,
and CAUTION
This 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, explosion,
or production
of
carbon monoxide
could result causing
property
damage,
personal injury, or loss of life. The qualified service agency
is responsible for the proper installation
of this furnace with
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.
Cette trousse
States,
of the National
Installation
Codes
and .2. Wear safety glasses
Have a fire extinguisher
steps, and service calls.
FIRE,
EXPLOSION,
CARBON
MONOXIDE
working
that may apply.
all safety
codes including
When
in the literature, on tags,
with the unit, and other
ELECTRICAL
Failure to follow
this warning
iniury, death or property damage.
could
must
when
use
only
servicing this
SHOCK
result
in personal
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
Table
1 - KGANP5201VSP
COMPONENT
NUMBER
ELECTRICAL
SHOCK,FIRE OR EXPLOSION
HAZARD
Failure
to follow
this warning
could result in personal
iniury,
death or property
damage.
Before
installing,
modifying,
or servicing
system,
main
electrical disconnect switch must be in the OFF position and
install
a lockout
tag. There
may be more
than one
disconnect
switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
This instruction
covers
No. KGANP5201VSP
the installation
of gas conversion
kit Part
to convert the following
furnaces from
natural gas usage to propane
for your furnace type.
gas usage.
See appropriate
section
Section
1--59MN7
& 987M 4-Way Multipoise,
Hot Surface
Ignition, Modulating
Condensing
Furnaces.
This kit is designed
for use in furnaces with 60,000 through 120,000 Btuh gas input
rates.
Section
2--59TN6,
986T, & PG96V_T
4-Way
Surface Ignition, 2-Stage,
Variable-Speed
59TN6A
applies to 60,000
to 120,000
986TA
rates.
& PG96VAT
Section
3--58CVA,
PG8JVA
Surface
33.3-In.
Ignition,
applies
to 40,000
58CVX,
(846 mm)
2-Stage,
Multipoise,
to 120,000
315AAV,
315JAV,
Btuh gas input
PG8MVA,
with
42,000
AND USAGE
This kit is designed for use in the furnaces listed below. See Table
1 for kit contents.
To accommodate
many different
furnace
models, more parts
complete conversion.
parts.
are shipped in kit than will be needed to
When installation
is complete, discard extra
QTY
DESCRIPTION
616166-629
319965-445
320069-602
326269-701
326269-703
326269-704
326272-702
326751-702
367704-701
367704-702
367704-703
1
1
2
1
1
1
1
1
1
1
1
PCS
PCS
PCS
PCS
PCS
PCS
PCS
PCS
PCS
PCS
PCS
CARTON
LABEL, SHIPPING
TAPE
PARTS ASSY
PARTS ASSY
PARTS ASSY
PARTS ASSY
PARTS ASSY
LABEL KIT
LABEL KIT
LABEL KIT
367932-701
367932-702
337932-703
AG- KGANPVSP-XX
EF69ZWO02
EF39ZW026
1
1
1
1
1
2
PCS
PCS
PCS
PCS
PCS
PCS
BAG ASSY
BAG ASSY
BAG ASSY
INSTRUCTIONS
VALVE CVRSN KIT
VALVE CVRSN KIT
HKO2LBO08
W182X06- -04- -012
W182X26- -04- -018
W182X66- -04- -012
W182X66- -04- -018
W182Y66- - 11 - -006
1
1
2
1
1
1
PCS
PCS
PCS
PCS
PCS
PCS
SWITCH, PRESSURE
WIRE ASSY
WIRE ASSY
WIRE ASSY
WIRE ASSY
WIRE ASSY
W182Y66-11--014
W182Y66- -26- -016
1 PCS
1 PCS
&
High, Induced-Combustion,
HotVariable-Speed,
Non-Condensing
Furnaces.
This kit is designed
for use in furnaces
through 154,000 Btuh gas input rates.
DESCRIPTION
Hot
Condensing
Furnaces.
Btuh gas input rates.
Contents
SECTION
WIRE ASSY
WIRE ASSY
1
Table 2 - Condensing Furnaces
MODELNUMBERS BEGINNINGWITH:
59MN7
987M
INSTALLATION
1. Set room thermostat to lowest setting or "OFF".
2. Remove outer doors.
3. Disconnect
breaker.
power at external disconnect, fuse or circuit
4. Turn off gas at external shut-off or gas meter.
5. Remove outer doors and set aside.
6. Turn electric switch on gas valve to OFF.
HOTSURFACE
IGNITER
i
GASBURNER
MANUALRESET
ROLLOUT
SWITCH
i
/
ELECTRICALJUNCTION
BOX(
REPRESENTATIVE
DRAWING
ONLY,
SOME
MODELS
MAY
VARY
IN APPEARANCE
Al1408
Fig. 1 - Component
MANIFOLD/ORIFICE/BURNER
UNIT
OPERATION
wires
3. Support the manifold and remove the 4 screws that secure
the manifold assembly to the burner box and set aside.
4. Note the location of the green/yellow wire ground wire for
re-assembly later.
5. Slide one-piece burner assembly out of slots on sides of
burner box.
HAZARD
Failure to follow this caution
improper operation.
Label all
controls.
REMOVAL
prior
to
Location
may result in unit damage
disconnection
when
or
6. Remove the flame sensor from the burner assembly.
7. Remove the orifices from the manifold and discard.
servicing
Orifice
Manifold
©
/
/
di
D'EQUIPEMENT
D'OPERATION
Connect
ground wire here
Toute erreur de cfiblage peut _tre une source de danger et de
panne.
Lors des op6rations d'entretien des commandes,
tous les ills avant de les d6connecter.
Green/Yellow
Gas Valve
6tiqueter
Gas valve is parallel to manifold
NOTE:
Use a back-up
valve from rotating
the burner box.
wrench
on the gas valve
on the manifold
or damaging
1. Disconnect
the gas pipe from
from the furnace casing.
2. Disconnect
nect wires
Sensor.
the connector
from
Hot
gas valve
harness
Surface
to prevent
the mounting
and remove
from gas valve.
Igniter
(HSI)
and
the
to
pipe
Discon-
CLwithin + or - 3_
"
\
/
,/' /"
I>/- ,"
/'_
• Indicated
surfaces
to be 90 _+ or -2 _
Gas valve must be installed on
manifold with minimum engagement
6 threads. Cross threading is not
acceptable.
of
Flame
A11486
Fig. 2 - Modulating
Gas Valve with
Orifices
BURNER
SUPT
ASSY
IGNITER
Refer
BRACKET,
IGNITER
to conversion
main burner
/
gas input rate on furnace
altitudes
up to 2000 ft.
reduced
ASSY
_
FLAME
BURNER)
above
2000 ft. must be
5 percent
The Conversion
derate.
high
Kit
at
for each 1000 ft. above sea level.
In Canada, the input rating must be derated by
altitudes of 2000 ft. to 4500 ft. above sea level.
orifices
A11403
Assembly
Rating
Plate
accounts
for
for
altitude
SELECTION/DERATE
burner
orifices.
Do not
use
Teflon
tape.
orifices
at least one
full turn
to prevent
then tighten with wrench.
There are enough
in each kit for largest furnace.
NOTE:
DO NOT reinstall
INSTALL
ORIFICE
rating plate is for installations
the input rating for altitudes
by 2 percent
Install
main
Finger-tighten
cross-threading,
Fig. 3 - Burner
to determine
INSTALL ORIFICES
FLAM E SENSOR
(BELOW
337704-201
ROLLOUT
SWITCH
2_"'_
plate
Furnace
In the U.S.A.;
BURNER
kit rating
orifice size. (See Fig. 5.)
MIXER
NOTE:
There
Condensing
are
Discard
the manifold
extra orifices.
at this time.
SCREWS
2 sets
gas furnaces,
of
mixer
screws.
One
set
is for
the other set is for Non-condensing
gas
furnaces.
Use only the parts in the bag marked "REQUIRED
FOR
THE
CONVERSION
OF
CONDENSING
GAS
UNIT
DAMAGE
HAZARD
Failure
to follow
this caution
DO NOT re-drill
burner
result in burrs, out-of-round
FURNACES
may result in unit damage.
GAS"
See Fig. 6 to verify you have the correct set of mixer screws.
1. Locate the dimple
orifices. Improper drilling may
holes, etc. Obtain new orifices
if orifice size must be changed.
TO PROPANE
on each burner
not locate the dimple,
mixer screw.
(See Fig. 4.)
2. Drill a 7/64-in.
dimple.
venturi
tube. If you can-
refer to Fig. 7 for location
(2.8 ram)
hole (supplied
of the
in kit) in each
3. Install a mixer screw in each drilled
hole drilling
as
straight as possible. The screw head should be flush with
the top of the burner
venturi.
A96249
Fig. 4 - Burner
Orifice
CONVERSION
KiT
RATING
PLATE
-
CARRIER
CORP.
THiS APPLIANCE HAS BEEN CONVERTED TO USE PROPANE GAS FOR FUEL. REFER TO KIT iNSTRUCTiONS FOR CONVERSION
PROCEDURES. USE PARTS SUPPLIED BY CARRIER CORPORATION AND iNSTALLED BY QUALiFiED PERSONNEL.
SEE EXISTING RATING PLATE FOR APPLIANCE MODEL NO. AND iNPUT RATING.
NOTE:
Furnace gas input rate on rating plate is for installations
be derated
by 2% for each 1000 ft, (305m) above sea level
up to 2000 ft. (610m) above sea level
in Canada the input rating
KIT NO.: KGANP5201VSP
MODELS
0rificeNo.
59MN7A
987MA
Jn U,S,A, the input rating for altitudes
MAX
INT
MIN
OF iNSTALLATION
0
to 2000
2001 *
to 3000
3001
to 4000
1.25mm
1.25mm
1.25mm
11.0
5.8
2.2
11.0
515
2.1
11.0
5.5
2.1
above 2000 ft, (610m) must
by 5% for altitudes of 2000 ft, (610m) to 4500 ft, (1372m) above sea level,
FUEL USED: PROPANE GAS
ALTITUDE
APPLIANCE
must be derated
4001
to 5000
1.25mm
Manifold
11.0
5,5
2.1
iNLET PRESSURE (rain - max): 11.0- 13.6 in. wc
(FT. ABOVE
5001
to 6000
6001
to 7000
SEA LEVEL)
U.S.A.
*
7001
to 8000
8001
to 9000
9001
to 10000
1.25mm
1.25mm
1.25mm
1.25mm
1.25mm
Pressure
11.0
5,4
2.1
11.0
5.4
2.0
11.0
5.4
2.0
11.0
5.3
2.0
11.0
5.3
2.0
* For Canadian Installationsfrom 2000 to 4500 ft. (610m to 1373m) use U.S.A. column 2001 to 3000 ft. (611m to 914m).
337704-201 REV.B
A11295
Fig. 5 - Conversion
Kit Rating
Plate 337704-201
1337932-701]
2-in.
(50 mm)
CONTAINS:
DESCRIPTION
PART #
328456-402
QTY
BIT, DRILL
FAJ5812B
1
SCREW
7
3/16-
in.
(4.6 mm)
REQUIRED FOR CONVERSION OF
CONDENSING GAS FURNACE TO
PROPANE GAS.
_
/32 -in.,
(2.5 mm,
+1/32 -3/64-in.
+0.8-1.5)
A12392
Fig. 9 - Igniter
Position
- Side View
A11294
Fig. 6 - Gas Conversion
Kit
CONVERT
GAS VALVE
FIRE, EXPLOSION,
HAZARD
1.9"
ELECTRICAL
SHOCK
Failure to follow this warning could result in personal
iniury, death or property damage.
(48.76 mm)
Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.
J
Drill out with
7/64" drill bit
1.8"
(46.96
ram)
ii /
ELECTRICAL
HAZARD
\\\\
A11460
Fig. 7 - Mixer
REINSTALL
BURNER
Screw
Location
SHOCK,
FIRE
OR
EXPLOSION
Failure to follow this warning could result in personal
iniury, death or property damage.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position and
install a lockout tag. There may be more than one
disconnect switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
ASSEMBLY
To reinstall burner assembly:
1. Attach flame sensor to burner assembly.
2. Insert one-piece burner in slot on sides of burner box and
slide burner back in place.
3. Reattach HSI wires to HSI.
Refer to Fig. 10 and 11.
4. Verify igniter to burner alignment. See Fig. 8 and 9.
, ,Oo
II
I
A11373
Fig. 10 - Propane
-2-1/2-in.
(64.4)
A11405
Fig. 8 - Igniter
Position
- Top View
Jumper
1. Remove the 1/8-in. NPT pipe plug from the gas valve inlet
pressure tap.
NOTE: Use pipe dope approved for use with Propane Gas.
NOTE: Tighten all fittings and the Low Gas Pressure Switch
with a small wrench. Do not over-tighten, check for gas leaks
after gas supply has been turned on.
>
FIRE AND EXPLOSION
Failure to follow
and/or death.
A11375
Fig. 11 - Installing
NOTE:
The
very small.
Propane
jumper
Needle-nose
pliers
into the valve.
operate
1. Locate
Jumper
for the modulating
If the jumper
properly
Propane
are required
gas valve
to insert
is not installed,
is
"NAT.
GAS"
sticker
will not
explosion
may result
injury or loss of life,
causing
2. Apply
l/8-in,
on the top of the
2. Peel the sticker off and discard.
4. Note the 2 jumper
opening
in the top of the gas valve.
pins inside the modulating
the small black plastic
propane
pliers
3. Apply
l/8-in,
7. Insert the jumper
on the pins inside
8. Cover the opening
"LP GAS"
INSTALL
LOW
GAS
PRESSURE
Install the Low Gas Pressure
manifold
on the burner
Inducer
the Low
(360 mm) Casings
Assembly
and Burner
Gas Pressure
threads
installing
the
6. Apply
l/8-in,
Switch
Switch.
or Vent Passes
the inducer
or the furnace is a 14 3/16-in. (360
switch as follows (See Fig 12):
ram) wide
...................
2 /,,
casing,
in Fig 12. One opening
assembly,
install the
pipe dope sparingly
to the male threads of the
brass hex nipple. Install the hex nipple into the
of the elbow point away from you.
pipe dope sparingly
to the male threads of the
brass street elbow. Install the Low Gas Pressure
on the male
8. Check
turned
,/
Wider
all fittings
on.
Than
Inducer
burner
2. Remove
pressure
NOTE:
with
_
Brass Hex Nipple
A11367
for 14-3/16
Passes Between
(360 mm) Casing
Inducer
and Burner
or When
Assembly
of the street
Vent
for leaks
elbow.
Tighten
does
after
not pass between
casing,
has
been
Assembly
or the furnace
the l/8-in.
gas supply
(360 mm) / Vent Does Not
and Burner
assembly,
(360 ram) wide
Fig 13):
Fig. 12 - LGPS
threads
14 3/16-in.
1. If the vent pipe
"
with the
the open end of the brass street tee. Or if installation
is to
be completed
later, apply pipe dope to inlet pressure plug
from gas valve and install in open end of brass street tee.
Pass Between
90
be parallel
7. The remaining
opening on the brass street tee is the new
gas valve inlet pressure tap. Install manometer
fitting to
Casings
Brass Street
on the street tee should
should
switch at hex fitting at base of switch. Do not use switch
body to tighten switch. Do not over-tighten
switch.
Between
and burner
pipe dope sparingly
to the male threads of the
brass street tee. Install the male end of the street tee
5. Install the open end of the brass street elbow on the end of
the hex nipple. Tighten
the street elbow so the male
Assembly
If the vent pipe passes between
_';_l
4. Apply
l/8-in,
SWITCH
before
tap. Point the open end of the
open end of the brass street tee. See Fig 12. The hex nipple
should be parallel with the boss on the gas valve.
assembly.
There are 2 ways to mount
All 14 3/16-in.
by the tab on
the gas valve.
Switch
personal
you.
face you. The other opening
inlet of the gas valve.
from the
in the gas valve with the label marked
NOTE:
damage,
pipe dope sparingly
to the male threads of the
black iron street elbow. Install the street elbow into
as shown
gas valve.
jumper
to hold the jumper
property
the gas valve inlet pressure
envelope.
6. Use needle-nosed
the end.
injury
leaks with an open flame. Use a
soap solution made specifically
for
to check all connections.
A fire or
street elbow toward
3. Note the small square
could result in personal
NEVER
test for gas
commercially
available
the detection of leaks
gas valve.
5. Remove
this warning
the jumper
the valve
on propane.
the round
HAZARD
install
is wider
the inducer
and
than a 14 3/16-in.
the switch
as follows
(See
NPT pipe plug from the gas valve inlet
tap.
Use pipe dope approved
for use with Propane
Gas.
For larger
casing
when
Vent Pipe does
switch contacts
must point
used at Valve Inlet instead
not pass
across
toward the Cell Panel.
of Brass Street 90.
Brass
Street
Black
casing.
Iron
All Sizes
Street
90 can be
Tee
D'EQUIPEMENT
D'OPERATION
Toute erreur de cfiblage peut _tre une source de danger et de
panne.
Lors des op6rations d'entretien
des commandes,
6tiqueter
tousles/ills
avant de les d6connecter.
1. Disconnect orange wire from Low Pressure switch LPS on
inducer housing.
2. Connect the orange wire from the Low Pressure Switch to
the orange wire with the insulated male spade terminal.
3. Connect the orange wire from the Low Gas Pressure
Switch to the terminal on the Low Pressure Switch.
A11366
Fig. 13 - LGPS for Casing Wider Than 14-3/16
(360 mm)
and Vent Does Not Pass Between Inducer
and Burner
Assembly
INSTALL LOW GAS PRESSURE
SWITCH
WIRES
1. Locate the orange wire in the kit with an insulated
female spade terminal and an insulated
minal on the other end.
2. Connect
Pressure
the female
terminal
straight
to a terminal
straight
male
ter-
on the Low Gas
Switch.
3. Locate the orange wire in kit with an insulated straight female spade terminal and an insulated female flag terminal
on the other end.
4. Connect both straight female terminals of the orange
to the ternfinals on the Low Gas Pressure Switch.
INSTALL
wires
[]NIT DAMAGE HAZARD
Failure to follow this caution may result in unit damage.
DO NOT operate furnace more than one minute to check
inlet gas pressure, as conversion is not complete at this time.
MANIFOLD
1. Align the orifices in the manifold assembly
port rings on the end of the burner.
with the sup-
2. Insert the orifices in the support rings of the burners. Manifold mounting tabs should fit flush against the burner box
NOTE:
If manifold
burners
does not fit flush against
are not fully seated
check burner positioning
forward.
the burner box, the
Remove
the manifold
and
NOTE:
between
This kit is to be used only when
ll.0-in.
W.C. and 13.6-in. W.C.
1. Verify manometer
valve.
is connected
2. Turn on furnace
power
3. Turn gas supply
manual
inlet gas pressure
to inlet pressure
is
tap on gas
supply.
shutoff
valve to ON position.
in the burner box assembly.
3. Attach the green/yellow
wire and ground
of the manifold mounting screws.
4. Install the remaining
manifold
mounting
5. Connect
niter.
the wires to the flame
6. Connect
the connector
NOTE:
4. Route orange wires along wire harness. If possible, secure
with wire tie provided in kit.
CHECK INLET GAS PRESSURE
harness
Use only propane-resistant
sensor
terminal
to one
FIRE, EXPLOSION,
HAZARD
screws.
and hot surface
ELECTRICAL
SHOCK
igFailure to follow
this warning
iniury, death or property damage.
to gas valve
pipe dope. Do not use Teflon
tape.
could
result
in personal
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
7. Insert the gas pipe through the grommet in the casing. Apply a thin layer of pipe dope to the threads of the pipe and
thread the pipe into the gas valve.
NOTE:
Use a back-up
valve from rotating
the burner box.
8. With
finish
wrench
a back-up
tightening
or damaging
to prevent
the
the mounting
to
wrench on the inlet boss of the gas valve,
the gas pipe to the gas valve.
9. Turn gas on at electric
MODIFY
on the gas valve
on the manifold
PRESSURE
switch on gas valve.
SWITCH
ELECTRICAL
HAZARD
SHOCK,
FIRE
Failure to follow
this warning
iniury, death or property damage.
OR
could
EXPLOSION
result
in personal
Before
installing,
modifying,
or servicing
system,
main
electrical disconnect switch must be in the OFF position and
WIRING
install
a lockout
tag. There
may be more
than one
disconnect
switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
UNIT
OPERATION
HAZARD
Failure to follow this caution
improper operation.
Label all
controls.
wires
prior
to
may result in unit damage
disconnection
when
or
servicing
4. Turn furnace
gas valve switch
5. Turn Setup
Fig. 14).
Switch
6. Jumper
control.
R-W/WI
SWI-2
and R-W2
to ON position.
on
furnace
thermostat
control
ON (see
connections
on
SW4
Outside
RISQUE D'EXPLOSION
24 VAC
Air Thermistor_
HUM Output
(O.5 AMP
_[ SW4
_/F_ Crflntin u;_2pFan_
switches
CF 3
[]
CF 1 through
_I=_
O_
PL9
Communication
Connocton
ET D'INCENDIE
Le fait de ne pas suivre cet avertissement pourrait entrai'nerdes
dommages corporels et / ou la mort.
Ne jamais examiner pour les fuites de gaz avec une flamme
vive. Utilisez plut6t un savon fait specifiquement pour la
d_tection des fuites de gaz pour verifier tousles connections.
Un incendie ou une explosion peut entrainer des dommages
matdriels, des blessures ou la mort.
i
1. Be sure main gas and electric supplies to furnace are off.
2. Remove 1/8-in. (3 mm) pipe plug from manifold pressure
tap on downstream side of gas valve.
_t_
/_:21
_
W2
'1
Yt
DHUM
3. Attach manometer to manifold pressure tap on gas valve.
(see Fig. 15.)
4. Turn gas supply manual shutoff valve to ON position.
SW2
Setup Switches
1 thru 8
SWl,
5. Turn furnace gas valve switch to ON position.
6. Check all threaded pipe connections for gas leaks.
SW2 A/C Air Flow
Setup Switches
AC 1 through AC 3
7. Turn on furnace power supply.
ON/OFF Switch
Al1471
Fig. 14 - Furnace
MODULATING
/
Control
Min/Max
/
(Under
Heat
Adust
Cap)
7. When main burners ignite, confirm inlet gas pressure is
between 11.0-in. W.C. and 13.6-in. W.C.
8. Remove jumper across R-W/W1 and R-W2
connections to terminate call for heat.
thermostat
9. Turn furnace gas valve switch to OFF position.
10. Turn gas supply manual shutoff valve to OFF position.
11. Turn off furnace power supply.
12. Remove manometer.
Inlet
13. Apply pipe dope sparingly to end of inlet gas pipe plug
and install into unused end of 1/8 in. tee. Use a small
back-up wrench on tee when tightening gas inlet pipe
plug. (See Fig. 13.)
CHECK FURNACE
AND MAKE ADJUSTMENTS
_Manifold
Pressure
lap
A10496
Fig. 15 - Gas Valve
GAS INPUT
FIRE
AND EXPLOSION
RATE INFORMATION
HAZARD
The gas input rate for propane
Failure to follow this warning could result in personal iniury
and/or death.
NEVER test for gas
commercially available
the detection of leaks
explosion may result
injury or loss of life.
leaks with an open flame. Use a
soap solution made specifically for
to check all connections. A fire or
causing property damage, personal
is the same as for natural
gas. See
furnace rating plate on blower door for input rate. The input rate
for propane is determined
by manifold pressure and orifice size.
The gas valve
for Minimum
must be set for Maximum
Heat first and then set
heat on Modulating
furnaces.
Furnace gas input
rate on rating
plate is for installations
at altitudes
up to 2000
ft,
(610 M).
In the U.S.A., the input rating for altitudes above 2000 ft. (610M)
must be reduced by 2 percent for each 1000 ft, (305 M) above sea
level.
In Canada,
altitudes
level.
the input
of 2000
The Conversion
@rate,
rating
ft, (610
Kit
must
be derated
M) to 4500
Rating
Plate
by
ft, (1372
accounts
for
5 percent
for
M) above
sea
high
altitude
SET GAS INPUT
RATE
crease manifold
pressure
or clockwise
to increase
manifold
pressure.
12. Turn rotary
second
UNIT
DAMAGE
Failure to
damage.
adjustment
switch
until you obtain
follow
this
caution
may
result
in gas
manifold pressure. Gas valve will be damaged
force is used on the rotary switch.
/_r
valve
>
if excessive
_
Burnel
A11451
Fig. 17 - Modulating
Main burner
To adjust
Heat:
Al1461
Fig. 16 - Burner
pressure
plate.
operation
and
must be adjusted
long
term
as specified
reliability,
the
kit rating
10.5-in.
W.C. or more than 11-in. W.C. for propane
NOTE:
Use
adjustment
care
when
is performed
Heat manifold
perfornfing
pressure
by turning
a rotary
Gas
valve
adjustment
switch
it non-adjustable.
To adjust
Heat:
manifold
1. Make
pressure
to obtain
sure the gas supply
at the electric
input
is turned
3. Connect
valve.
a manometer
4. Turn on furnace
5. Turn gas supply
6. Turn furnace
from
to the outlet
power
the outlet
pressure
shutoff
gas valve switch
firm Maximum
on the manifold
ing Plate.
burners
ignite
to ON position.
OFF.
starts,
Heat manifold
pressure,
switch counterclockwise
or clockwise
switch
to Minim-
to increase
Slowly
to demanifold
no more than one click per
manifold
pressure,
5 nfinutes
before
allow
checking
the
furnace
Minimum
to
Heat
so that radiant heat does not affect readings. This
is particularly
important with straight-run
ducts.
2. When thermometer
readings
temperature
from supply-air
1. Remove
and the blower
transitions
1. Place thermometers
in return and supply ducts as near furnace as possible. Be sure thermometers
do not see heat ex-
at
con-
Slowly
to de-
stabilize, subtract return-air
temperature
to deternfine
air
rise.
the furnace
to run for at least
Temperature
If the temperature
connections
adjustment
the
checking
Heat manifold
pressure is correct, based
pressure table on the Conversion
Kit Rat-
11. To adjust the Maxinmm
turn the rotary adjustment
adjusting
3. Allow
valve to ON position.
SW 4-2 is turned
pressure
operate an additional
Temperature
rise.
temperature
9. Jumper the R to W/W1 and W2 thermostat
the furnace control board.
the main
tap on gas
SW 1-2 to ON.
8. Verify Set-up switch
After
changer
practice
pressure
supply.
manual
7. Turn Setup switch
10. After
and
switch on the gas valve.
2. Remove the 1/8 inch NPT plug
tap on the gas valve.
and the blower
connec-
Furnace must operate within ranges of temperature
rise specified
on the furnace rating plate. Deternfine
air temperature
rise as
follows:
rate for Maximum
off to the furnace
W2 at the thermostat
board control.
second until you obtain the required manifold
pressure.
This adjustment
will not affect the previous
Maximum
Heat adjustment.
gas.
adjustments.
transparent.
rate for Minimum
pressure.
less than
inside the gas valve with a small straight blade screwdriver.
Excessive force can break or bend the rotary adjustment
switch
making
crease manifold
5. Turn rotary
DO NOT set Maximum
input
4. To adjust the Minimum
Heat manifold
pressure,
turn the rotary adjustment
switch counterclockwise
Heat.
NOTE:
to obtain
3. Verify the Minimum
Heat manifold
pressure
is correct,
based on the manifold
pressure table on Conversion
Kit
Rating Plate.
not adjust
Intermediate
Heat manifold
pressure.
Heat manifold pressure can be checked as part of the
rise, but is not adjustable.
Always adjust Maximum
Heat first, then Minimum
be clear blue, almost
pressure
2. Wait until the burners
um Heat.
manifold
on the conversion
flame should
manifold
Gas Valve Adjustment
1. Remove
the jumper from
tions at the furnace control
Flame
The modulating
furnace manifold pressure is set at two points.
The first point is Maximum
Heat. The second point is Mininmm
Heat. Do
Intermediate
temperature
pressure.
ner Flame
__
proper
manifold
HAZARD
Do not force
the rotary
adjustment
switch
on the
modulating
gas valve. Do not turn the rotary adjustment
switch faster than one click per second
when adjusting
For
no more than one click per
the required
10 minutes
rise is too high or too low in Minimum
jumpers
before
Rise.
Heat:
from R and W/W1.
2. Wait until the blower
off delay is completed.
3. Turn 115 VAC power off.
4. Check
SW1-3.
the position
of Heat Rise Adjustment
Switch
When set to ON, airflow is raised 18% higher for
Minimum Heat and Intermediate
sition is OFF.
5. Turn 115 VAC power on.
6. Jumper
R to W/W1
and W2.
Heat. Factory
default
po-
7. After burners ignite and blower starts allow the furnace to
run for at least 10 minutes before checking Temperature
Rise.
Maximum
Heat Temperature
can result from low gas supply pressure. Switch opens at not less
than 6.5 in. W.C. and closes at not greater than 10.2 in. W.C.
This switch also prevents operation when the propane tank level
is low which can result in gas with a high concentration of
impurities, additives, and residues that have settled to the bottom
of the tank. Operation under these conditions can cause harm to
the heat exchanger system. This normally open switch closes
when gas is supplied to gas valve under normal operating
pressure. The closed switch completes control circuit. Should an
interruption or reduction in gas supply occur, the gas pressure at
switch drops below low gas pressure switch setting, and switch
opens. Any interruption in control circuit (in which low gas
pressure switch is wired) quickly closes gas valve and stops gas
flow to burners. When normal gas pressure is restored, the system
must be electrically reset to re-establish normal heating operation.
Rise
If the temperature rise is too high or too low in Maximum Heat:
1. Remove jumpers from R, Wl and W2.
2. Wait until the blower off delay is completed.
3. Turn 115 VAC power off.
4. Check the position of the Efficiency/Comfort
switch SWl-4. When set to OFF (Efficiency
flow is 10% higher for Minimum, 7.5% for
Heat, and 17.5% for Maximum Heat. Factory
tion is ON (Comfort Mode).
5. Turn 115 VAC power on.
Adjustment
Mode), airIntermediate
default posi-
Before leaving installation, observe unit operation through 2
complete heating cycles. During this time, turn gas supply to gas
valve off just long enough to completely extinguish burner flame,
then instantly restore full gas supply. To ensure proper low gas
pressure switch operation, observe that there is no gas supply to
burners until after hot surface igniter begins glowing.
LABEL
APPLICATION
6. Re-check Minimum Heat Temperature Rise.
7. Remove jumpers across thermostat connections to terminate the call for heat. Wait until the blower off delay is completed.
8. Turn gas supply manual shutoff valve to OFF position.
9. Turn off furnace power supply.
10. Remove manometer from the outlet pressure tap of the gas
valve.
1. Fill in Conversion
11. Apply pipe dope sparingly to 1/8-in. NPT plug and re-install outlet pressure tap on the gas valve.
12. Re-install plastic cap over rotary adjustment switch on the
top of the gas valve.
CHECK LOW GAS PRESSURE
SWITCH
The newly installed low gas pressure switch is a safety device
used to guard against adverse burner operating characteristics that
THiSFURNACEWAS CONVERTED
ON
TO PROPANEGAS
Responsibility
and
to out-
3. Attach Gas Control Conversion
valve. Do not use 337704-203,
to gas
Label 337704-202
which is similar.
CE GENC:RATEUR D'NR CHAUD A €:TI_
CONVERTiLE
POUR
(DAY-MONTH-YEAR)
(JOUR-MOIS-ANNI_E)
DE L'ENSEMBLE N°.: KGANP5201VSP
BY:
PAR:
of organization
which accepts the responsibility
been properly made.
337704-205
2. Attach Conversion
Rating Plate Label 337704-201
er door of furnace., see Fig. 5.
KiT NO.: KGANP5201VSP
(Name and address
Label
apply to Blower Access Door of furnace as shown. (See
Fig. 18. Date, name, and address of organization
making
this conversion
are required.
making this conversion),
that this conversion
has
(Nora
et adresse
qui accepte
de
|' entrii.=re
I'organisme
responsabilit6
qui
a effectu6
[a conversion),
de [a conversion,
337704-205 REV.B
Al1296
Fig. 18 - Conversion
Responsibility
10
Label
SECTION
2
Table 3 - Variable Speed Condensing Furnaces
MODEL NUMBERS BEGINNING WITH:
59TN6
986T
PG96V T
LE FEU, L'EXPLOSION,
CHOC
ET MONOXYDE
DE CARBONE
EMPOISONNER
Cette trousse de conversion doit _tre install_e par un servie
d'entretien qualifid, selon les instructions du fabricant et
selon toutes les exigences et tous les codes pertinents de
l'autorit_ comp_tente. Assurezvous de bien suivre les
instructions dans cette notice pour rdduire au minimum le
risque d'incendie,
d'explosion
ou la production
de
monoxyde de carbone pouvant causer des dommages
matdriels, de blessure ou la mort. Le service d'entretien
qualifid est responsable de l'installation de cette trousse.
L'installation n'est pas adequate ni complete tant que le bon
fonctionnement de l'appereil converti n'a pas _td v_rfid
selon les instructions du fabricant fornies avec la trousse.
INSTALLATION
FIRE,
EXPLOSION,
CARBON
MONOXIDE
ELECTRICAL
POISONING
SHOCK
HAZARD
ELECTRIQUE,
AND
Failure to follow instructions could result in personal injury,
death or property damage.
Improper
installation,
adjustment,
alteration,
service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions, which
could result in personal injury or death. Consult your
distributor or branch for information or assistance. The
qualified
installer
or
agency
must
use
only
factory-authorized kits or accessories when servicing this
product.
FIRE, EXPLOSION,
HAZARD
ELECTRICAL
SHOCK
Failure to follow this warning could result in personal
injury, death or property damage.
FIRE,
EXPLOSION,
CARBON
MONOXIDE
Failure to follow
injury or death.
ELECTRICAL
POISONING
this warning
SHOCK,
HAZARD
Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.
AND
could result in personal
This 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, explosion, or production of
carbon monoxide could result causing property damage,
personal injury, or loss of life. The qualified service agency
is responsible for the proper installation of this furnace with
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.
ELECTRICAL
HAZARD
SHOCK,
FIRE
OR
EXPLOSION
Failure to follow this warning could result in personal
injury, death or property damage.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position and
install a lockout tag. There may be more than one
disconnect switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
1. Set room thermostat to lowest setting or "OFF".
2. Remove outer doors.
3. Disconnect
breaker.
power at external disconnect, fuse or circuit
4. Turn off gas at external shut-off or gas meter.
5. Remove outer doors and set aside.
6. Turn electric switch on gas valve to OFF.
11
HOTSURFACE
GASBURNER
i
_GNITER
_
MANUALRESET
!
ROLLOUT
SW,TO,
]
t
i
Fig. 19 - Component
Location
FLAME
SENSOR
MANUAL
ROL
LOUT
SW_TCH
GAS
OPERATING
NOT
INSIDE
VALVE
_NSTRUCT
SHOWN
ONS
(LOCATED
MA_N
FURNACE
OPERAT
NG
DOOR
ON
DOOR,
NSTRUCTIONS
SEE
F_GURE)
ELEUTR_CAL
BOX
......
RESET
(F
JUNCTION
REQUIRED
LOCATION
MAY
BLOWER
SAFETY
VARY)
DOOR
SW_TCH
FURNACE
CONTROL
BOARD
RATNG
PLATE
(LOCATED
ON
NOT
SHOWN
BLOWER
DOOR)
A11408
MANIFOLD/ORIFICE/BURNER
UNIT
OPERATION
REMOVAL
Orifice
HAZARD
Connect
Failure to follow this caution may result in unit damage or
improper operation.
Label all wires prior to disconnection
controls,
ground
Green/Yellow
wire here
when servicing
_as valve is
......3
D'EQUIPMENT
-+-
D'OPERATION
Lors des op6rations
d'entretien
des commandes,
tous les fils avant de les d_connecter.
2. Disconnect
the connector
nect wires
Sensor.
3. Support
from
Hot
the manifold
the manifold
4. Note the location
re-assembly
from gas valve.
Igniter
and remove
assembly
of
A11407
Fig. 20 - Two-Stage
SUPT
ASSY
Gas Valve
IGNITER
pipe
BRACKET,
IGNITER
/
harness
Surface
and remove
surfaces
to be 9_ or -2
on
manifold with minimum engagement
6 threads. Cross threading is not
acceptable.
BURNER
gas valve
tndicated
÷U
Gas valve must be installed
6tiqueter
NOTE:
Use a back-up wrench on the gas valve to prevent the
valve from rotating on the manifold or damaging the mounting to
the burner box.
1. Disconnect
the gas pipe from
from the furnace casing.
,d_!
to the burner
(HSI)
the 4 screws
and
DisconFlame
BURNER
that secure
ASSY
box and set aside.
of the green/yellow
wire ground
wire for
later.
5. Slide one-piece
burner box.
burner
6. Remove
the flame
7. Remove
the orifices
assembly
out of slots on sides of
FLAME
ROLLOUT
SWITCH
sensor
from the burner
from the manifold
assembly.
_*V"_"_
F LAM E SENSOR
_1
(BELOW
and discard.
BURNER)
A11403
Fig. 21 - Burner
12
Assembly
ORIFICE
SELECTION/DERATE
In Canada,
altitudes
level.
the input
of 2000
The Conversion
derate.
[]NIT
DAMAGE
HAZARD
Failure
to follow
this caution
INSTALL
must
orifices. Improper drilling may
holes, etc. Obtain new orifices
if orifice size must be changed.
Kit
Plate
Rating
(See Fig. 22.)
main burner
orifices.
ORIFICE
There
Condensing
BURNER
ORIFICE
2 sets
gas furnaces,
FURNACES
Orifice
kit rating
plate
337704-206
Furnace
gas input rate on furnace
altitudes
up to 2000 ft. (610 M).
to determine
the input rating
for altitudes
by 2 percent
,f
rating plate is for installations
above
in each kit for largest
PROCEDURES,
SEE EXiSTiNG
HAS
BEEN
KiT
CONVERTED
at
ft. (610
RATING
TO USE
of
prevent
furnace.
set
is for
gas
mixer
screws.
One
GAS"
you have the correct
on each burner
not locate the dimple,
mixer screw.
(2.8 mm)
3. Install
screw
tube. If you can-
hole (supplied
in each
drilled
GAS
FOR
-
CARRIER
FUEL.
REFER
USE PARTS SUPPLIED
BY CARRIER
CORPORATION
AND iNSTALLED
RATING PLATE FOR APPLIANCE
MODEL
NO. AND iNPUT RATING.
of the
in kit) in each
hole
straight as possible. The screw head should
the top of the burner venturi.
PLATE
PROPANE
a mixer
set of mixer screws.
venturi
refer to Fig. 25 for location
2. Drill a 7/64-in.
dimple.
for each 1000 ft. (305 M) above
CONVERSION
THiS APPLIANCE
2000
tape. Finto
the other set is for Non-condensing
TO PROPANE
See Fig. 24 to verify
orifice size. (See Fig. 23.)
M) must be reduced
sea level.
altitude
SCREWS
are
1. Locate the dimple
In the U.S.A.;
sea
furnaces.
Use only the parts in the bag marked "REQUIRED
FOR
THE
CONVERSION
OF
CONDENSING
GAS
A96249
Fig. 22 - Burner
main burner
high
Do not use Teflon
BURNER
MIXER
NOTE:
to conversion
for
for
DO NOT reinstall the manifold at this time.
INSTALL
Refer
accounts
M) above
ger-tighten
orifices
at least one full turn
cross-threading,
then tighten with wrench.
NOTE:
f
by 5 percent
M to 1372
ORIFICES
2. There are enough orifices
Discard extra orifices.
"\
be derated
ft. (610
may result in unit damage.
1. Install
DO NOT re-drill
burner
result in burrs, out-of-round
rating
ft. to 4500
drilling
be flush
as
with
CORPORATION
TO KiT iNSTRUCTIONS
BY QUALIFIED
FOR
CONVERSION
PERSONNEL.
NOTE: Furnace gas input rate on rating plate is for installations up to 2000 ft. (610m) above sea level, in U.S.A. the input rating for altitudes above 2000 ft. (610m) must
be derated by 2% for each 1000 ft. (305m) above sea meveL mnCanada the input rating must be derated by 5% for altitudes of 2000 ft. (610m) to 4.500ft. (1372m) above sea meveL
KiT NO.: KGANP5201VSP
ALTITUDE
APPLIANCE
MODELS
59TN6A
986TA
PG96VAT
FUELUSED:
(SUPERSEDES: NONE)
0
to 2000
2001
*
to 3000
Orifice 1.25mm
No.
iHIGH
LOW
PROPANEGAS
OF iNSTALLATiON
3001
to 4000
4001
to 5000
NLETPRESSURE(min-max):
(FT. ABOVE
5001
to 6000
6001
to 7000
SEA LEVEL)
7001
to 8000
1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm
Manifold Pressure
U.S.A.
8001
to 9000
11.0-13.61n.wc
*
9001
to 1OOOO
1.25mm
1.25mm
11.o
]11.o
[ 11o
_11.o
5.8
5.5
5.5
5.5 I 11o
5.4 [ 11o
5.4 [ 11.o
5.4 [ 11o
5.3 [ 11.o
5.3
* For Canadian Installations from 2000 to 4500 ft. (610m to 1373m) use U.S.A. column 2001 to 3000 ft. (611m to 914m).
N
337704-206 REV. D
i'
Al1635
Fig. 23 - Conversion
Kit Rating
Plate
[337932=701j
PART #
CONTAINS:
DESCRIPTION
328456-402
BIT, DRILL
FAJ5812B
Drill out with
1.9"
(48.76 mm)
QTY
/64"drill bit
1
SCREW
7
t
REQUIRED FOR CONVERSION
CONDENSING
GAS FURNACE
PROPANE GAS.
1.8"
(46.96 ram)
OF
TO
\\\\\
Al1294
Fig. 24 - Gas Conversion
Al1460
Kit
Fig. 25 - Mixer
13
Screw
Location
REINSTALL
To reinstall
BURNER
burner
1. Attach
ASSEMBLY
assembly:
flame sensor
to burner
assembly.
ELECTRICAL
HAZARD
2. Insert one-piece
burner in slot on sides of burner box and
slide burner back in place.
3. Reattach
to burner
FIRE
Failure to follow
this warning
iniury, death or property damage.
HSI wires to HSI.
4. Verify igniter
SHOCK,
alignment.
See Fig. 26 and 27.
OR
could
EXPLOSION
result
in personal
Before
installing,
modifying,
or servicing
system,
main
electrical disconnect switch nmst be in the OFF position and
install
a lockout
tag. There
may be more
than one
disconnect
switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
1. Refer to Fig. 28.
II
!
2. Be sure gas and electrical
supplies
3. Remove
adjustment
caps that conceal
and low-heat
to furnace
are off.
screws for high-heat
stage gas valve regulators.
(See Fig. 28.)
(64.4)
Al1405
Fig. 26 - Igniter
Position
- Top View
4. Remove
screws.
the high-heat
and low-heat
regulator
adjustment
5. Remove
the high-heat
and low-heat
gas regulator
springs
(silver).
6. Install
springs
the high-heat
and low-heat
7. Install the high-heat
screws.
2-in.
(50 mm)
propane
gas regulator
(white).
and low-heat
regulator
adjustment
8. Turn high-heat
stage adjusting screw clockwise (in) 13.5
full turns. This will increase the manifold pressure closer
to the propane
high-heat
set point. (See Fig. 28.)
9. Turn low-heat
stage adjusting
screw clockwise
(in) 9.5
full turns. This will increase the manifold pressure closer
3/16-in.
to the propane
low-heat
set point. (See Fig. 28.)
(4.6 mm)
10. Do not install regulator
seal caps at this time.
'_
TWO-STAGE
A12392
Fig. 27 - Igniter
CONVERT
UNIT
Position
ON/OFF
- Side View
1/2"
GAS VALVE
DAMAGE
HAZARD
Regulator
"_<"_
_ %_@_-_9
_
_%
4: _
Regulator
..... Screw
Seal Cap
*
Ad ustment
Switch
NPT Inlet
1/8" NPT
Inlet
Pressure
Tap
Failure to follow this caution may result in unit damage
The G or J gas valve must be converted and pre-adjusted
before operating on propane gas. The E valves nmst be
pre-adjusted before operating on propane gas. If left this
way, sooting and corrosion will occur leading to early heat
exchanger failure.
1t8" NPT
Manifold
Pressure
Tap
A11472
Fig. 28 - Two-Stage
FIRE, EXPLOSION,
HAZARD
ELECTRICAL
Failure to follow
this warning
iniury, death or property damage.
could
INSTALL
SHOCK
result
in personal
LOW
GAS
PRESSURE
NOTE:
Install the Low Gas Pressure
manifold
on the burner
Gas valve
SWITCH
Switch
before
There are 2 ways to mount
the Low
Gas Pressure
All 14 3/16-in. (36t) ram) Casings or Vent Passes
Inducer
Assembly
and Burner
Assembly
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
14
installing
assembly.
Switch.
Between
the
(Iftheventpipepasses
between
theinducer
andburner
assembly,
orthefurnace
isa143/16-in.
(360ram)widecasing,
install
the
switch
asfollows
(See
Fig29.):
1.Remove
thel/8-in.NPTpipeplugfromthegasvalve
inlet
pressure
tap.
NOTE:Usepipedope
approved
forusewithPropane
Gas.
NOTE:Tighten
allfittingsandtheLowGasPressure
Switch
withasmallwrench.
Donotover-tighten,
check
forgasleaks
after
gassupply
has
been
turned
on.
2.Applypipedopesparingly
to themalethreads
of the
l/8-in,black
ironstreet
elbow.
Install
thestreet
elbow
into
thegasvalve
inletpressure
tap.Point
theopen
endofthe
street
elbow
toward
you.
3.Applypipedopesparingly
to themalethreads
of the
l/8-in,brass
street
tee.Install
themale
endofthestreet
tee
asshown
inFig29.Oneopening
onthestreet
teeshould
faceyou.Theotheropening
should
be)arallel
withthe
inletofthegasvalve.
4.Applypipedopesparingly
to themalethreads
of the
l/8-in,brass
hexnipple.
Installthehexnippleintothe
open
endofthebrass
street
tee.See
Fig29.Thehexnipple
should
beparallel
withtheboss
onthegasvalve.
5.Install
theopen
endofthebrass
street
elbow
ontheendof
thehexnipple.
Tighten
thestreet
elbowsothemale
threads
oftheelbow
pointaway
fromyou.
6.Applypipedopesparingly
to themalethreads
of the
l/8-in,brass
street
elbow.
InstalltheLowGasPressure
Switch
onthemalethreads
ofthestreet
elbow.
Tighten
switch
athexfittingatbase
ofswitch.
Donotuseswitch
bodytotighten
switch.
Donotover-tighten
switch.
7.Theremaining
opening
onthebrass
street
teeisthenew
gasvalveinletpressure
tap.Installmanometer
fittingto
theopen
endofthebrass
street
tee.Orif installation
isto
becompleted
later,
applypipedopetoinletpressure
plug
fromgasvalve
andinstall
inopen
endofbrass
street
tee.
8.Check
allfittingsforleaksaftergassupplyhasbeen
turned
on.
Casings
WiderThan143/16-in. (360 mm) / Vent Does Not
Pass Between
Inducer
1. If the vent pipe
burner
assembly,
(360 ram) wide
Fig 30.):
2. Remove
pressure
NOTE:
and Burner
does
the 1/8-in.
install
Inlet
Pressure
Tap with
Low Gas Pressure
the inducer
as follows
Street
Black
casing.
Iron
All Sizes
Street
90 can be
Tee
Plug
Switch/Q2i_
'"
Brass Nipple
A11366
sembly
INSTALL
LOW
GAS PRESSURE
SWITCH
WIRES
1. Locate the orange wire in the kit with an insulated
female spade terminal and an insulated
minal on the other end.
2. Connect
Pressure
the female
terminal
straight
to a terminal
straight
male
ter-
on the Low Gas
Switch.
3. Locate the orange wire in kit with an insulated straight female spade terminal and an insulated female flag terminal
on the other end.
4. Connect both straight female terminals of the orange
to the terminals on the Low Gas Pressure Switch.
INSTALL
wires
MANIFOLD
1. Align the orifices in the manifold assembly
port rings on the end of the burner.
with the sup-
2. Insert the orifices in the support rings of the burners. Manifold mounting
tabs should fit flush against the burner
box.
NOTE:
If manifold
burners
are not fully seated
does not fit flush against
check burner positioning
3. Attach
and
(See
forward.
the green/yellow
the manifold
wire and ground
mounting
and
terminal
to one
screws.
manifold
mounting
5. Connect
niter.
the wires to the flame
6. Connect
the connector
NOTE:
the burner box, the
Remove
in the burner box assembly.
4. Install the remaining
tap.
for use with Propane
across
Fig. 30 - LGPS for Casing Wider Than 14-3/16
(360 mm)
and Vent Does Not Pass Between Inducer
and Burner
As-
than a 14 3/16-in.
the switch
not pass
toward the Cell Panel.
of Brass Street 90.
Brass
NPT pipe plug from the gas valve inlet
Use pipe dope approved
Vent Pipe does
of the manifold
not pass between
is wider
when
switch contacts
must point
used at Valve Inlet instead
Assembly
or the furnace
casing,
For larger casing
harness
Use only propane-resistant
sensor
screws.
and hot surface
ig-
to gas valve.
pipe dope. Do not use Teflon
tape.
Gas.
7. Insert the gas pipe through the grommet in the casing. Apply a thin layer of pipe dope to the threads of the pipe and
thread the pipe into the gas valve.
NOTE:
Use a back-up
valve from rotating
the burner box.
8. With a back-up
finish
wrench
tightening
wrench
[]NIT
Brass Hex Nipple
Between
for 14-3/16
Inducer
Casing
and
or When
Burner
OPERATION
to prevent
the mounting
Vent Passes
switch on gas valve.
SWITCH
WIRING
HAZARD
Label all wires prior to disconnection
controls,
Assembly
15
the
to
on the inlet boss of the gas valve,
Failure to follow this caution may result in unit damage or
improper operation,
A11367
Fig. 29 - LGPS
PRESSURE
or damaging
the gas pipe to the gas valve.
9. Turn gas on at electric
MODIFY
on the gas valve
on the manifold
when servicing
6. Jumper
control.
D'EQUIPEMENT
R-W/W1
8. Remove jumper across
connections
to terminate
9. Turn furnace
manual
11. Turn off furnace
power
back-up
wrench
CHECK
FURNACE
NEVER
test
commercially
the detection
Failure to follow this caution may result in unit damage.
explosion
DO NOT operate furnace more than one minute to check
inlet gas pressure, as conversion is not complete at this time.
power
3. Turn gas supply
manual
to inlet pressure
injury
5. Turn Setup
Fig. 31).
Switch
SWI-2
to OFF position.
shutoff
valve to OFF position.
supply.
tee when
tightening
AND
tap on gas
RISQUE
valve to ON position.
furnace
control
pipe
this warning
for
gas
available
of leaks
may
HAZARD
result
leaks
could result in personal
iniury
with
Use
an open
flame.
a
soap solution made specifically
for
to check all connections.
A fire or
causing
property
damage,
personal
or loss of life.
D'EXPLOSION
ET D'INCENDIE
pourrait
entra_ner
des
Ne jamais examiner
pour les fuites de gaz avec une flamme
vive. Utilisez plut6t un savon fair specifiquement
pour la
d_tection des fuites de gaz pour verifier tous les connections.
Un incendie ou une explosion
peut entrainer des dommages
materiels, des blessures ou la mort.
to ON position.
on
gas inlet
ADJUSTMENTS
MAKE
Le fait de ne pas suivre cet avertissement
dommages
corporels et / ou la mort.
shutoff
gas valve switch
thermostat
is
supply.
4. Turn furnace
on
FIRE AND EXPLOSION
UNIT DAMAGE HAZARD
is connected
ON (see
SW4
Outside
24 VAC
HUM Output
(O.5AMP
Air Thermistor_
_I_ SW4
_F_
Crflnotiwn
U;_uSpFa
n_
switches
CF 3
CF 1 through
FIRE, EXPLOSION,
HAZARD
[]
Communication
ModelPlug ____
could
result
in personal
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
32
_-I[1 _'!_i
/_
/_:21
I_]_
_
W2
'1
Yt
DHUM
ELECTRICAL
HAZARD
SW2
Setup Switches
1 thru 8
ELECTRICALSHOCK
Failure to follow
this warning
iniury, death or property damage.
_I=_PL9
O_
Connect
on-SWl,
SHOCK,
FIRE
Failure to follow
this warning
iniury, death or property damage.
SW2 A/C Air Flow
Setup Switches
AC 1 through AC 3
could
OR
EXPLOSION
result
in personal
Before
installing,
modifying,
or servicing
system,
main
electrical disconnect switch must be in the OFF position and
install
a lockout
tag. There
may be more
than one
disconnect
switch. Lock out and tag switch with a suitaMe
warning label. Verify proper operation after servicing.
Al1471
Fig. 31 - Furnace
is
manometer.
Failure to follow
and/or death.
inlet gas pressure
gas pressure
plug. (See Fig. 13.)
4. Route orange wires along wire harness. If possible, secure
with wire tie provided in kit.
CHECK INLET GAS PRESSURE
This kit is to be used only when
ll.0-in.
W.C. and 13.6-in. W.C.
on
13. Apply pipe dope sparingly
to end of inlet gas pipe plug
and install into unused end of 1/8 in. tee. Use a small
3. Connect the orange wire from the Low Gas Pressure
Switch to the terminal on the Low Heat Pressure Switch.
2. Turn on furnace
connections
R-W/WI
and R-W2
call for heat.
gas valve switch
10. Turn gas supply
12. Remove
1. Disconnect orange wire from low-heat pressure switch
LPS on inducer housing.
2. Connect the orange wire from the Low Heat Pressure
Switch to the orange wire with the insulated male spade
terminal.
1. Verify manometer
valve.
thermostat
7. When main burners ignite, confirm inlet
between ll.0-in.
W.C. and 13.6-in. W.C.
D'OPERATION
Toute erreur de cfiblage peut _tre une source de danger et de
panne.
Lors des op6rations d'entretien des commandes, 6tiqueter
tous les ills avant de les d6connecter.
NOTE:
between
and R-W2
Control
16
1.Besure
main
gasandelectric
supplies
to furnace
are off.
2. Remove l/8-in. (3 ram) pipe plug from manifold
tap on downstream
side of gas valve.
3. Attach
manometer
to manifold
pressure
12. Remove
tap on gas valve.
14. Turn furnace
4. Turn gas supply
6. Check
manual
gas valve switch
all threaded
7. Turn on furnace
GAS
INPUT
shutoff
power
RATE
to ON position.
16. Remove
plug.
for gas leaks.
is determined
by manifold
pressure
and orifice size.
must be set for Maxinmm
Heat first and then set
for Minimum
rate on rating
heat on Modulating
furnaces.
Furnace gas input
plate is for installations
at altitudes up to 2000 ft.
21. Check
for correct burner
In Canada,
the input
of 2000
The Conversion
derate.
GAS
rating
ft. (610
Kit
Rating
INPUT
be derated
Plate
by
ft. (1372
accounts
5 percent
for
M) above
sea
for
high
R and W/W1
is turned
thermostat
manifold
4. Adjust
Rating
gas manifold
pressure.
Plate 337704-206.
orifices
input
be clear blue, almost
8. Jumper
R, W/WI
connections.
ation.
9. Adjust
The
Refer
NOTE:
should
When
to Conversion
for propane
is obtained,
main
furnace
Kit
caps that conceal
input
be clear blue, almost
through
2 complete
in furnace
heating
cycles.
Installation,
Start-
to desired
temperature.
newly
GAS
installed
PRESSURE
SWITCH
low gas pressure
switch
is a safety
device
switch
locked
(out) to
input rate.
pressure
center
for propane
gas valve
is obtained,
transparent
regulator
main
tank level
drops
below
low gas pressure
switch
setting,
and switch
valve off just long enough to completely
extinguish burner flame,
then instantly restore full gas supply. To ensure proper low gas
pressure switch operation,
observe that there is no gas supply
burners until after hot surface igniter begins glowing.
oper-
LABEL
gas.
name, and address
are required.
of organization
making
2. Attach Conversion
Rating Plate Label
Fig. 23, to Outer Door of furnace.
flame
(see Fig. 32).
3. Attach Gas Control Conversion
valve. Do not use 337704-203,
Burner Flame
to
APPLICATION
1. Fill in Conversion
Responsibility
Label 337704-205
apply to Blower Access Door of furnace as shown.
adjustment
burner
when the propane
Before leaving installation,
observe
unit operation
through
2
complete heating cycles. During this time, turn gas supply to gas
flame
thermostat
in high-heat
operation
opens. Any interruption
in control circuit (in which low gas
pressure switch is wired) quickly closes gas valve and stops gas
flow to burners. When normal gas pressure is restored, the system
must be electrically reset to re-establish
normal heating operation.
gas. See
burner
also prevents
pressure. The closed switch completes
control circuit. Should an
interruption
or reduction in gas supply occur, the gas pressure at
(see Fig. 32).
and W2 on control
manifold
correct
flame.
of the tank. Operation under these conditions
can cause harm to
the heat exchanger
system. This normally
open switch closes
when gas is supplied
to gas valve under normal
operating
burners
10. Turn high-heat
adjusting screw counterclockwise
(out) to
decrease input rate or clockwise (in) to increase input rate.
11. Replace
screws.
burners
is low which can result in gas with a high concentration
of
impurities,
additives, and residues that have settled to the bottom
screws for gas valve
pressure
transparent
This keeps
high-heat
LOW
This switch
to call for
7. Turn low-heat
adjusting screw counterclockwise
decrease input rate or clockwise (in) to increase
should
CHECK
"ON".
connections
adjustment
manifold
correct
to ON position.
25. After making the required manifold pressure adjustments,
check and adjust the furnace temperature
rise per the furnace installation
instructions.
altitude
for gas leaks when main
5. Remove caps that conceal
regulators. See Fig. 28.
When
tap
than 6.5 in. W.C. and closes at not greater than 10.2 in. W.C.
control
3. Check
ignite.
NOTE:
pressure
used to guard against adverse burner operating characteristics
that
can result from low gas supply pressure. Switch opens at not less
on furnace
6. Adjust low-heat
Fig. 28.
manifold
Instructions.
24. Set room thermostat
RATE
1. Verify SW1-2
2. Jumper
heat.
nmst
M) to 4500
to OFF position.
supply.
of Operation
up, and Operating
In the U.S.A., the input rating for altitudes above 2000 ft. (610M)
nmst be reduced by 2 percent for each 1000 ft. (305 M) above sea
level.
to OFF posi-
tap plug for gas leaks when main
unit operation
23. See Sequence
control
to call for heat.
pressure
(610 M).
SET
power
20. Check
ignite.
22. Observe
ad-
supply.
and re-install
19. Set room thermostat
is the same as for natural gas. See
door for input rate. The input rate
on furnace
gas valve switch
18. Turn on furnace
The gas valve
altitudes
level.
power
manometer
17. Turn furnace
INFORMATION
and W2 after high-heat
call for heat.
gas valve switch
15. Turn off furnace
supply.
The gas input rate for propane
furnace rating plate on blower
for propane
valve to ON position.
pipe connections
across R, Wl,
to terminate
13. Turn setup switch SWI-2
tion.
(see Fig. 28.)
5. Turn furnace
jumper
justment
pressure
and
Date,
this conversion
337704-206,
label 337704-202
which is similar.
see
to gas
CHECKOUT
Burner
1. Observe
unit operation
2. See Sequence
tion, Start-Up,
3. Set room thermostat
Al1461
Fig. 32 - Burner
Flame
17
through
2 complete
heating
of Operation operation
in furnace
and Operating Instructions.
to desired
temperature.
cycles.
Installa-
SECTION
3
Table 4 - Non-condensing
Furnaces
MODEL NUMBERS BEGINNING WITH:
58CVA
315AAV
58CVX
315JAV
PG8MVA
PG8JVA
FIRE, EXPLOSION,
HAZARD
Failure to follow
this warning
iniury, death or property damage.
SHOCK
could
result
in personal
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
INSTALLATION
FIRE,
EXPLOSION,
CARBON
MONOXIDE
Failure to follow
death or property
ELECTRICAL
ELECTRICAL
POISONING
instructions
damage.
SHOCK
HAZARD
AND
could result in personal
injury,
1. Set room thermostat to lowest setting or "OFF".
2. Remove outer doors.
3. Disconnect
breaker.
4. Turn off gas at external shut-off or gas meter.
5. Remove outer doors and set aside.
Improper
installation,
adjustment,
alteration,
service,
maintenance,
or use can cause carbon monoxide
poisoning,
explosion,
fire, electrical shock, or other conditions,
which
could result in personal
injury or death. Consult
your
distributor
or branch for information
or assistance.
The
qualified
installer
or
agency
factory-authorized
kits or accessories
product.
must
when
power at external disconnect, fuse or circuit
6. Turn electric switch on gas valve to OFF.
MANIFOLD/ORIFICE/BURNER
REMOVAL
use
only
servicing this
[]NIT
OPERATION
HAZARD
Failure to follow this caution may result in unit damage or
improper operation.
Label all wires prior to disconnection
controls.
FIRE,
EXPLOSION,
CARBON
MONOXIDE
Failure to follow
injury or death.
ELECTRICAL
POISONING
this warning
could
SHOCK,
HAZARD
result
when servicing
AND
in personal
This 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, explosion,
or production
of
carbon monoxide
could result causing
property
damage,
personal injury, or loss of life. The qualified service agency
is responsible for the proper installation
of this furnace with
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.
D'EQUIPEMENT
D'OPERATION
Toute erreur de cfiblage peut _tre une source de danger
et de
panne.
Lors des op6rations
d'entretien
des commandes,
tousles ills avant de les d_connecter.
6tiqueter
NOTE:
Use a back-up wrench on the gas valve to prevent the
valve from rotating on the manifold or damaging the mounting to
the burner box. See Fig. 33 and 34.
1. Disconnect
the gas pipe from
from the furnace casing.
2. Disconnect
the connector
nect wires
Sensor.
LE FEU, L'EXPLOSION, CHOC ELECTRIQUE,
ET MONOXYDE DE CARBONE
EMPOISONNER
3. Support
re-assembly
and remove
from gas valve.
Igniter
(HSI)
the 4 screws
to the burner
and
pipe
DisconFlame
that secure
box and set aside.
of the green/yellow
wire ground
wire for
later.
wires from both rollout
6. Slide one-piece
burner box.
18
harness
Surface
and remove
assembly
4. Note the location
5. Remove
Hot
the manifold
the manifold
Cette trousse de conversion
doit Otre installOe par un servie
d'entretien
qualifiO, selon les instructions
du fabricant et
selon routes les exigences
et tousles
codes pertinents
de
l'autoritO
compOtente.
Assurezvous
de bien suivre
les
instructions
dans cette notice pour rdduire au minimum
le
risque
d'incendie,
d'explosion
ou la production
de
monoxyde
de carbone
pouvant
causer
des dommages
matOriels, de blessure ou la mort. Le service d'entretien
qualifiO est responsable
de l'installation
de cette trousse.
L'installation
n'est pas adOquate ni complOte rant que le bon
fonctionnement
de l'appereil
converti
n'a pas OtO vOrfiO
selon les instructions du fabricant fornies avec la trousse.
from
gas valve
burner
7. Remove
the flame
8. Remove
the orifices
sensor
assembly
switches.
out of slots on sides of
from the burner
from the manifold
assembly.
and discard.
Clp,
3. Squeeze
Harness
the sides
of the device,
if necessary,
to remove
from the heat exchanger.
Burner
Assy
umer
/
Attach
4. Re-install
Support
Assy
screw in hole underneath
NOTE:
It is very
mounting
screw.
5. Repeat
IMPORTANT
heat exchanger
to reinstall
inlet.
the NOx
bracket
steps for each heat exchanger.
/
ORIFICE
SELECTION/DERATE
G reen/Yeilow
ground
wire
here
Bracket
Ignito_
Switch,
Temp
[]NIT DAMAGE
(2)
HAZARD
Failure to follow this caution may result in unit damage.
DO NOT re-drill burner orifices. Improper drilling may
result in burrs, out-of-round holes, etc. Obtain new orifices
if orifice size must be changed. (Fig. 36.)
Al1390
Fig. 33 - 80%
Burners
Gas Valve
\
\
Manifold
A96249
Fig. 36 - Burner
Orifice
Refer to conversion
kit rating plate 337704-204
main burner orifice size. (See Fig. 37.)
Attach
Orifice
j
ground
Green/Yellow
Furnace gas input rate on furnace
altitudes up to 2000 ft.
wire here
Screw
In the U.S.A.;
(2)
be reduced
the input
rating plate is for installations
rating for altitudes
by 2 percent
to determine
above
2000
at
ft. must
for each 1000 ft. above sea level.
Al1395
In Canada,
the input rating must be derated
altitudes of 2000 ft. to 4500 ft. above sea level.
Fig. 34 - 80% Manifold
NOx DEVICE
REMOVAL
[]NIT DAMAGE
Failure
to follow
The Conversion
derate.
Install
main
Finger-tighten
cross-threading,
HAZARD
this caution
orifices
may result in unit damage.
Furnace MUST have low NOx devices
operating furnace on propane gas.
removed
prior
1. Remove
secures
35.)
follow these additional
the screw underneath
the NOx
device
to
steps:
in the heat exchanger.
Plate
accounts
for
high
altitude
in each kit for largest furnace.
Discard
extra orifices.
INSTALL ORIFICES
Install
the heat exchanger
Rating
for
burner
orifices.
Do not
use
Teflon
tape.
orifices
at least one
full turn
to prevent
then tighten with wrench.
There are enough
main
burner
Finger-tighten
cross-threading,
For NOx device removal,
Kit
by 5 percent
orifices
orifices.
Do
in each kit for largest furnace.
inlet that
NOTE:
DO NOT reinstall
(See Fig.
INSTALL MIXER SCREWS
NOTE:
There
Condensing
not
use
Teflon
orifices
at least one
full turn
then tighten with wrench.
There
are
Discard
the manifold
2 sets
gas furnaces,
of
mixer
tape.
to prevent
are enough
extra orifices.
at this time.
set
is for
the other set is for Non-condensing
screws.
One
gas
furnaces.
Use only the parts in the bag marked "REQUIRED
FOR THE CONVERSION
OF NON-CONDENSING
GAS
FURNACES
TO PROPANE
See Fig. 38 to verify
you have the correct
1. Locate the dimple
on each burner
not locate the dimple,
mixer screw.
2. Drill a 7/64-in.
dimple.
A02195
set of mixer screws.
venturi
tube. If you can-
refer to Fig. 39 for location
(2.8 mm)
hole (supplied
of the
in kit) in each
3. Install a mixer screw in each drilled
hole drilling
as
straight as possible. The screw head should be flush with
Fig. 35 - NOx Device
2. Use a pair of needle nose pliers to remove
GAS"
the top of the burner
the NOx device.
19
venturi.
f
CONVERSION
KiT
RATING
PLATE
CARRIER
CORPORATION
THiS APPLIANCE HAS BEEN CONVERTED TO USE PROPANE GAS FOR FUEL, REFER TO KiT iNSTRUCTiONS FOR CONVERSION
PROCEDURES. USE PARTS SUPPLIED BY CARRIER CORPORATION AND iNSTALLED BY QUALiFiED PERSONNEL.
SEE EXiSTiNG RATING PLATE FOR APPLIANCE MODEL NO. AND iNPUT RATING.
NOTE: Furnace gas input rate on rating plate is for installations up to 2000 ft. (610m) above sea level
be derated
In U,S.A. the input rating for altitudes above 2000 ft, (610m) must
by 4% for each 1000 ft. (305m) above sea [eveL in Canada the input rating must be derated
by 10% for aRitudes
of 2000 ft. (610m) to 4500 ft. (1372m) above sea [eveL
KiT NO.: KGANP5201VSP
FUEL USED: PROPANEGAS
iNLET PRESSURE (rain - raax): 11.0- 13.6 in. wc
(SUPERSEDES:
KGANP4601ALL,
KGANP4101ALL,
KGANP4001ALL,
KGANP3001ALL,
KGANP2901ALL)
ALTITUDE
APPLIANCE
MODELS
Orifice
No,
58CVA,
58CVX
PG8JVA,
_.
OF INSTALLATION
0
to 2000
2001 *
to 3000
3001
to 4000
4001
to 5000
55
1.30mm
1.30ram i1.25mm
Manifold
(FT. ABOVE
SEA LEVEL)
5001
to 6000
6001
to 7000
1.25mm
1.25mm
U.S.A.
*
7001
to 8000
8001
to 9000
9001
to 10000
56
56
56
Pressure
I_
,o, o oleo[o olo l o11.o
I
PGSMVA
LOW
5.8
I
5.3
5.0
5.5
5.2
4.9
5.7
5.2
4.8
* For Canadian installations from 2000 to 4500 ft. (610ra to 1373ra) use U.S.A. column 2001 to 3000 ft. (611ra to 914ra).
337704-204REV.D
Al1636
Fig. 37 - Conversion
Kit Rating
Plate
1337932-7021
5/16"
PART
CONTAINS:
DESCRIPTmON
#
328456-401
BIT, DRILL
327593-401
7.9mm
QTY
1
SCREW
7
REQUIRED FOR CONVERSION OF
NON CONDENSING GAS FURNACE
TO PROPANE GAS.
A11397
Fig. 38 - Gas Conversion
Kit
A05025
\
Drill out with
5/64" drill bit.
i
Fig. 40 - Igniter
Position
BURNER
ASSEMBLY
REINSTALL
To reinstall
assembly:
1. Attach flame sensor
I
I
--_l
burner
- Side View
to burner
assembly.
2. Install HSI and bracket
to burner
3. Insert one-piece
in slot on sides of burner
burner
assembly.
slide burner back in place.
1-9/16"
1
4. Reattach
HSI wires to HSI.
39.7 ram
5. Verify igniter
A06432
Fig. 39 - Mixer
Screw
Location
Nitride
7. For Silicon
Carbide
8. Re-attach
2O
to burner
6. For Silicon
alignment.
igniters,
igniters,
Flame sensor
see Fig. 40 and 41.
see Fig. 42.
wire to Flame Sensor.
box and
f
1-7/8
(47.6 mm)
FIRE, EXPLOSION,
HAZARD
ELECTRICAL
Failure to follow
this warning
iniury, death or property damage.
SHOCK
could
result
in personal
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
A05026
Fig. 41 - Igniter
t¾2"
Position
,,,.4
- Top View
_-'/32"
.,1_|
ELECTRICAL
HAZARD
SHOCK,
FIRE
Failure to follow
this warning
iniury, death or property damage.
OR
could
EXPLOSION
result
in personal
Before
installing,
modifying,
or servicing
system,
main
electrical disconnect switch must be in the OFF position and
install
a lockout
tag. There
may be more
than one
disconnect
switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
NOTE:
SURFACE
iGNITER
ASSEMBLY
valve
For the 2-stage
replaced
Fig.
44),
replaced
they
2-stage
DO
with a Series J and Series G gas
MUST
and the gas valve
For older model
/
furnaces
(see Fig. 43), they
have
MUST
furnaces
NOT
to have
--
BURNER
3. Remove
both regulator
adjustment
screws.
4. Remove
both natural gas regulator
springs
adjustment
to the high-heat
For E valves
HAZARD
this caution
screws.
seal caps at this time,
see Fig 44.
1. Be sure gas and electrical
to follow
(silver).
(white).
set point,
9. Do not install regulator
Failure
springs
8. Turn high-heat
stage adjusting screw clockwise (inwards)
13.5 turns. This will increase the manifold pressure closer
GAS VALVE
DAMAGE
are turned OFF.
seal caps. (See Fig. 28.)
7. Turn low-heat
stage adjusting screw clockwise (inwards)
9.5 turns, This will increase the manifold pressure closer to
the low-heat
set point.
A93347
UNIT
supplies
both regulator
6. Install regulator
Fig. 42 - Silicon Carbide Igniters
CONVERT
springs
in the gas valve must
2. Remove
5. Install propane gas regulator
IGNITER
ASSEMBLY
the regulator
See Fig 28.
1. Be sure main gas and electrical
"_
springs
for propane applications.
For J and G valves
7/8.
22.2 mm
regulator
with a Series E gas valve (see
need
in the gas valve, but the regulators
be pre-adjusted
IGNITER
both
be pre-adjusted.
2. Remove
caps
and low-heat
may result in unit damage
supplies
that conceal
to furnace
adjustment
stage gas valve regulators.
are off.
screws
for high-
(See Fig. 44.)
3. Turn low-heat
stage adjusting screw (3/32-in.
[2 mm] hex
Allen screw) clockwise (in) 1 full turn. This will increase
the manifold
pressure closer to the propane low-heat
set
The G or J gas valve must be converted and pre-adjusted
before operating
on propane gas. The E valves must be
pre-adjusted
before operating
on propane gas. If left this
way, sooting and corrosion will occur leading to early heat
exchanger failure.
point.
4. Turn high-heat
stage adjusting screw (3/32-in.
[2 mm]
hex Allen screw) clockwise (in) 2 full turns. This will increase the manifold
pressure closer to the propane highheat set point.
5. Do not install regulator
21
seal caps at this time.
TWO-STAGE
9. With a back-up
finish
ON/OFF
Regulator
\\
\
INSTALL
Ir
LOW
on the inlet boss of the gas valve,
the gas pipe to the gas valve.
10. Turn gas on at electric
Seal Cap
Regulator Adjustment
1/2"NPT
wrench
tightening
GAS
switch on gas valve.
PRESSURE
SWITCH
ELECTRICAL
SHOCK
Regulator Seal Cap
ruder Cap
1/8" NPT Inlet
FIRE, EXPLOSION,
HAZARD
Pressure Tap
Failure to follow
this warning
iniury, death or property damage.
Outlet
could
result
in personal
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
1/8" NPT Manifold
Pressure Tap
Al1152
J
Fig. 43 - 2-Stage
or G Valve
SWITCH
ELECTRICAL
HAZARD
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
PRESSURE
FIRE
Failure to follow
this warning
iniury, death or property damage.
HIGH-HEAT
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
INLET
SHOCK,
OR
could
EXPLOSION
result
in personal
Before
installing,
modifying,
or servicing
system,
main
electrical disconnect switch must be in the OFF position and
install
a lockout
tag. There
may be more
than one
disconnect
switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
PLUG BUTTON
(2-STAG
E AND
_/
VARIABLE
SPEED,
NON CONDENSING
FURNACES ONLY)
NOTE:
3. Apply
2--in.
Fig. 44 - 2-Stage E Valve
1. Align the orifices in the manifold assembly
port rings on the end of the burner.
does not fit flush against
are not fully seated
check burner positioning
3. Attach
4. Apply
of the manifold
4. Install the remaining
5. Connect
forward.
Remove
manifold
terminal
mounting
6. Connect
niter.
the wires to the flame
7. Connect
the connector
NOTE:
the manifold
and
to one
8. Tighten
Use only propane-resistant
ig-
to gas valve.
pipe dope sparingly
switch finger
toward
10. The remaining
pipe dope. Do not use Teflon
11. Install manometer
the grommet
in the casing.
ply a thin layer of pipe dope to the threads
Ap-
Use a back-up
valve from rotating
the burner box.
wrench
on the gas valve
on the manifold
or damaging
in kit)
tight.
motor when complete.
on the brass
street tee is the new
tap.
fitting to the open end of the brass street
tee. Or if installation
is to be completed
later, apply pipe
dope to inlet pressure plug from gas valve and install in
of the pipe and
thread the pipe into the gas valve.
NOTE:
to male end of brass tee.
the inducer
opening
gas valve inlet pressure
tape.
8. Insert the gas pipe through
end of the l/8-in.
9. Use a small open-end wrench on base of pressure switch
for final tightening.
The contacts of the LGPS should be
pointing
harness
to opposite
7. Install propane low gas pressure switch (provided
on male end of the female x female x male tee.
screws.
and hot surface
sparingly
you.
6. Apply
switches.
sensor
pipe dope
5. Tighten tee finger tight. Use a small open-end wrench for
final tightening.
The male end of the tee should be facing
screws.
the wires to both rollout
(3 mm) tapped opening in gas
Tighten
fitting with a small
the brass coupling.
the burner box, the
wire and ground
mounting
are off.
(3 mm) x 2--in. (51 mm) brass coupling (provided in kit).
Install the female end of the female x female x male tee on
in the burner box assembly.
the green/yellow
to furnace
with the sup-
2. Insert the orifices in the support rings of the burners. Manifold mounting
tabs should fit flush against the burner
box.
burners
supplies
pipe dope sparingly to one end of 1/8-in. (3 mm) x
(51 mm) brass nipple (provided
in kit) and install
the doped end in 1/8-in.
valve inlet pressure-tap.
wrench.
MANIFOLD
If manifold
on all connections
tape.
2. Remove l/8-in. (3 mm) pipe plug from inlet pressure tap
on gas valve. DO NOT DISCARD
l/8-in. (3 mm) PLUG.
A01069
NOTE:
pipe dope
gas leaks. DO NOT use Teflon
1. Be sure main gas and electric
BURNER ENCLOSURE
REFERENCE PRESSURETAP(2-STAGE
AND VARIABLE-SPEED,
CONDENSING
FURNACES ONLY)
INSTALL
Use propane-gas-resistant
to prevent
MANIFOLD
PRESSURE
TAP
open end of brass street tee.
to prevent
the mounting
the
12. Check
turned
to
22
all fittings
on.
for leaks
after
gas supply
has
been
7. Connect
the orange wire from the Low Gas Pressure
Switch to the terminal on the Low Heat Pressure Switch.
FIREANDEXPLOSION
HAZARD
Failure
to follow this warning could result
8. Route
orange
wires along wire harness.
with wire tie provided
in personal
CHECK
injury
INLET
GAS
If possible,
secure
in kit.
PRESSURE
and/or death.
NEVER
test for gas
commercially
available
the detection of leaks
leaks with an open flame. Use a
soap solution made specifically
for
to check all connections.
A fire or
explosion
may result
injury or loss of life.
causing
property
damage,
SW4
personal
Outside
SW4
SW3 Continuous
(CF) airflow setup
switches CF 1 through
CF 3
_-_--_
RISQUE
D'EXPLOSION
[]
_I=_
O_
PL9
Communication
ET D'INCENDIE
Le fair de ne pas suivre cet avertissement
dommages
corporels et / ou la mort.
24 VAC
HUM Output
(O.5AMP
Air Thermi,'
pourrait
entra_ner
des
Connection
._<
Ne jamais examiner
pour les fuites de gaz avec une flamme
vive. Utilisez plut6t un savon fair specifiquement
pour la
d6tection des fuites de gaz pour verifier tousles
connections.
Un incendie ou une explosion
peut entrainer des dommages
mat6riels, des blessures ou la mort.
in
" P,7 ABeD
,
ModelPlug_
SW3
_
g__ _i_:_ _11_')11_,_11(\_11
SW2
_
/_21
W2
Yt
DHUM
Setup Switches SWl,
1 thru 8
SW2 A/C Air Flow
Setup Switches
AC 1 through AC 3
MODIFY PRESSURE SWITCH WIRING
Al1471
Fig. 45 - Furnace
UNIT
OPERATION
HAZARD
Failure to follow this caution
improper operation.
Label all
controls.
wires
Control
prior
to
may result in unit damage
disconnection
when
or
servicing
[]NIT DAMAGE HAZARD
Failure to follow this caution may result in unit damage.
DO NOT operate furnace more than one minute to check
inlet gas pressure, as conversion is not complete at this time.
D'EQUIPEMENT
D'OPERATION
Toute erreur de cfiblage peut _tre une source de danger
NOTE:
between
et de
panne.
Lors des op6rations
d'entretien
des commandes,
tousles fils avant de les d6connecter.
1. Verify manometer
valve.
6tiqueter
1. Locate the orange wire in the kit with an insulated straight
female spade terminal and an insulated
straight male terminal on the other end.
2. Connect
Pressure
the female
terminal
to a terminal
on the Low Gas
orange
LPS on inducer
6. Connect
wire
from
low-heat
pressure
the orange
wire
from
wire with
the
Low
Heat
the insulated
manual
shutoff
gas valve switch
5. Turn
Switch
Setup
is
tap on gas
supply.
4. Turn furnace
SWI-2
R-W/WI
valve to ON position.
to ON position.
on
and R-W2
8. Remove
jumper across
connections
to terminate
wires
9. Turn furnace
switch
Pressure
male
power
3. Turn gas supply
to inlet pressure
furnace
thermostat
7. When main burners ignite, confirm inlet
between ll.0-in.
W.C. and 13.6-in. W.C.
housing.
Switch to the orange
terminal.
2. Turn on furnace
6. Jumper
control.
3. Locate the orange wire in the kit with an insulated straight
female spade terminal and an insulated female flag terminal on the other end.
5. Disconnect
is connected
inlet gas pressure
control
ON (see
Fig. 45).
Switch.
4. Connect both straight female terminals of the orange
to the terminals on the Low Gas Pressure Switch.
This kit is to be used only when
ll.0-in.
W.C. and 13.6-in. W.C.
manual
11. Turn off furnace
power
12. Remove
spade
shutoff
on
gas pressure
R-W/WI
and R-W2
call for heat.
gas valve switch
10. Turn gas supply
connections
is
thermostat
to OFF position.
valve to OFF position.
supply.
manometer.
13. Apply pipe dope sparingly
to end of inlet gas pipe plug
and install into unused end of 1/8 in. tee. Use a small
23
back-up
wrench
onteewhentightening
gasinletpipe
plug.(See
Fig.46.)
ELECTRICAL
HAZARD
SHOCK,
FIRE
OR
EXPLOSION
2" Brass Nipple
/
Failure to follow
this warning
iniury, death or property damage.
Low Gas
Pressure Switch
1/8" NPT Pipe Plug ..................................
J
For inlet pressure tap
Fig. 46 - 80% Low
Gas Pressure
Be sure main gas and electric
1.
A11398
in personal
Switch
3.
Attach
4.
Turn gas supply
manometer
5. Turn furnace
6. Check
could result in personal
iniury
NEVER
test for gas
commercially
available
the detection of leaks
leaks with an open flame. Use a
soap solution made specifically
for
to check all connections.
A fire or
explosion
may result
iniury or loss of life.
causing
property
damage,
GAS
to manifold
manual
to furnace
INPUT
RATE
pressure
shutoff
gas valve switch
all threaded
7. Turn on furnace
HAZARD
this warning
supplies
are off.
2. Remove l/8-in. (3 ram) pipe plug from manifold
tap on downstream
side of gas valve.
CHECK FURNACE AND MAKE ADJUSTMENTS
Failure to follow
and/or death.
result
Before
installing,
modifying,
or servicing
system,
main
electrical disconnect switch nmst be in the OFF position and
install
a lockout
tag. There
may be more
than one
disconnect
switch. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
Female x Female x Male Tee
FIRE AND EXPLOSION
could
tap on gas valve.
valve to ON position.
to ON position.
pipe connections
power
pressure
for gas leaks.
supply.
INFORMATION
The gas input rate for propane is the same as for natural gas. See
furnace rating plate for input rate. The input rate for propane is
deternfined by manifold pressure and orifice size.
The gas valve nmst be set for Low Heat first and then set for High
Heat on 2-stage and variable-speed
furnaces. Furnace gas input
personal
rate on rating
plate is for installations
at altitudes
up to 2000
ft.
(610 M).
In the U.S.A.,
the input rating
M) must be reduced
sea level.
RISQUE
D'EXPLOSION
In Canada,
ET D'INCENDIE
Le fait de ne pas suivre cet avertissement
dommages
corporels et / ou la mort.
pourrait
entra_ner
altitudes
level.
des
The Conversion
derate.
Ne jamais exanfiner
pour les fuites de gaz avec une flamme
vive. Utilisez plut6t un savon fair specifiquement
pour la
d_tection des fuites de gaz pour verifier tousles
connections.
Un incendie ou une explosion
peut entrainer des dommages
materiels, des blessures ou la mort.
FIRE, EXPLOSION,
HAZARD
ELECTRICAL
Failure to follow
this warning
iniury, death or property damage.
could
rating
ft. (610
Kit
must
be derated
M) to 4500
Rating
above
2000
ft. (610
for each 1000 ft. (305 M) above
Plate
by 5 percent
ft. (1372
accounts
for
M) above
high
for
sea
altitude
SET GAS INPUT RATE
Burner
SHOCK
result
the input
of 2000
for altitudes
by 2 percent
Flame
___
Burner>
in personal
Al1461
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
Fig. 47 - Burner Flame
1. Verify SW1-2 on furnace control is turned "ON". See Fig.
45.
2. Jumper R and W/W1 thermostat connections
heat.
to call for
3. Check manifold orifices for gas leaks when main burners
ignite.
4. Adjust gas manifold pressure, (Refer to conversion kit rating plate 337704-204,
5. Remove caps that conceal adjustment screws for gas valve
regulators, (See Fig. 43.)
24
6. Adjust low-heat
Fig. 43.)
can result from low gas supply pressure. Switch opens at not less
than 6.5 in. W.C. and closes at not greater than 10.2 in. W.C.
This switch also prevents operation when the propane tank level
is low which can result in gas with a high concentration of
impurities, additives, and residues that have settled to the bottom
of the tank. Operation under these conditions can cause harm to
the heat exchanger system. This normally open switch closes
when gas is supplied to gas valve under normal operating
pressure. The closed switch completes control circuit. Should an
interruption or reduction in gas supply occur, the gas pressure at
switch drops below low gas pressure switch setting, and switch
opens. Any interruption in control circuit (in which low gas
pressure switch is wired) quickly closes gas valve and stops gas
flow to burners. When normal gas pressure is restored, the system
must be electrically reset to re-establish normal heating operation.
manifold pressure for propane gas. (See
7. Turn low-heat adjusting screw counterclockwise (out) to
decrease input rate or clockwise (in) to increase input rate.
NOTE:
When correct input is obtained, main burner flame
should be clear blue, almost transparent (see Fig. 47).
8. Jumper R, W/W1 and W2 on control center thermostat
connections. This keeps fltrnace locked in high-heat operation.
9. Adjust high-heat manifold pressure for propane gas.
10. Turn high-heat adjusting screw counterclockwise (out) to
decrease input rate or clockwise (in) to increase input rate.
11. Replace caps that conceal gas valve regulator adjustment
screws.
Before leaving installation, observe unit operation through 2
complete heating cycles. During this time, turn gas supply to gas
valve off just long enough to completely extinguish burner flame,
then instantly restore full gas supply. To ensure proper low gas
pressure switch operation, observe that there is no gas supply to
burners until after hot surface igniter begins glowing.
LABEL
APPLICATION
NOTE:
When correct input is obtained, main burner flame
should be clear blue, almost transparent. (See Fig. 47).
12. Remove jumper across R, Wl, and W2 after high-heat adjustment to terminate call for heat.
13. Turn setup switch SWl-2 on fltrnace control to OFF position.
14. Turn fltrnace gas valve switch to OFF position.
1. Fill in Conversion Responsibility Label 337704-204 and
apply to Blower Access Door of furnace as shown. Date,
name, and address of organization making this conversion
are required.
15. Turn off fltrnace power supply.
16. Remove manometer and re-install manifold pressure tap
plug.
17. Turn fltrnace gas valve switch to ON position.
18. Turn on fltrnace power supply.
19. Set room thermostat to call for heat.
2. Attach Conversion Rating Plate Label 337704-204
er door of furnace.
3. Apply Gas Control Conversion Label: For 2-stage J and
G gas valves, use Gas Control Conversion
Label
337780-202. (Do not use 337780-203, which is similar.)
For 2-stage E gas valve, use Gas Control Adjustment Label 337780-203. (Do not use 337780-202, which is similar.)
4. Replace control access door, blower access door and outer
door of furnace.
20. Check pressure tap plug for gas leaks when main burners
ignite.
21. Check for correct burner flame.
22. Observe unit operation through 2 complete heating cycles.
23. See Sequence of Operation in furnace Installation, StartUp, and Operating Instructions.
24. Set room thermostat to desired temperature.
CHECKOUT
25. After making the required manifold pressure adjustments,
check and adjust the furnace temperature rise per the furnace installation instructions,
CHECK
LOW
GAS
PRESSURE
1. Observe unit operation through 2 complete heating cycles.
2. See Sequence of Operation in furnace Installation, StartUp, and Operating Instructions.
SWITCH
3. Set room thermostat to desired temperature.
The newly installed low gas pressure switch is a safety device
used to guard against adverse burner operating characteristics that
THiSFURNACEWAS CONVERTED
ON
TO PROPANEGAS
CE GENERATEUR D'AiRCHAUD A i_T¢
CONVERTILE
POUR
(DAY-MONTH-YEAR)
(JOUR-MOIS-ANNEE)
KiT NO.: KGANP5201VSP
DE L'ENSEMBLE N°.: KGANP5201VSP
BY:
PAR:
(Name and address of organization
to out-
making this conversion),
which accepts the responsibRRy that this conversion
been properly made.
has
(Nora et adresse de ['organisme qui a effectu_, la conversion),
qui accepte
|' entri_re responsabRitO
de la conversion.
337704-205 REV.B
Al1296
Fig. 48 - Conversion
Rating
25
Plate Label
Copyright
2012 CAC / BDP •
Manufacturer
reserves
7310 W. Morris St. •
the right to change,
Indianapolis,
IN 46231
at any time, specification8
Edition
and design8
without
Date: 08/12
notice and without
26
Catalo_
obligations,
Replaces:
No: AG-KGANPVSP-04
AG KGANPVSP
03