Bryant 310JAV Installation, start-up, operating, and service and Instruction manual

Installation Instructions
Gas Conversion Kit Natural-to-Propane for
All Condensing Furnaces, 2-Stage 80%
Variable Speed, 2-Stage Non-Condensing
and Fixed Capacity 80% Furnaces
KGANP3001ALL
CERTIFIED
NOTE: Read the entire instruction manual before starting the installation.
This symbol → indicates a change since the last issue.
SAFETY CONSIDERATIONS
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.
Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. Trained service personnel must perform
all other operations. When working on heating equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with
the unit, and other safety precautions that may apply.
Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No. 54-2002/ANSI
Z223.1-2002. In Canada, refer to the National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC), CAN/CGA-B149.1
and .2-M00.
Wear safety glasses and work gloves. Have a fire extinguisher available during Start-up, Adjustment steps, and service calls.
. When you see this symbol on the furnace and in instructions or manuals, be
Recognize safety information. This is the safety-alert symbol
alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION, and NOTE. The words DANGER, WARNING, and CAUTION are used with
the safety-alert symbol. DANGER identifies the most serious hazards, which will result in severe personal injury or death. WARNING signifies
hazards, which could result in personal injury or death. CAUTION is used to identify unsafe practices, which may result in minor personal injury,
or product and property damage. NOTE is used to highlight suggestions, which will result in enhanced installation, reliability, or operation.
WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD
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 may 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.
AVERTISSEMENT: LE FEU, L’EXPLOSION, CHOC ELECTRIQUE ,ET MONOXYDE DE CARBONE EMPOISONNER
Cette trousse de conversion ne doit être installée que par le représentant d’un organisme qualifié et conformément aux instructions
du fabricant et à tous les codes et exigences pertinents de l’autorité compétente. Les instructions du présent guide doivent être suivies
afin de réduire au minimum au risque d’incendie ou d’explosion de dommange matériels, de blessure ou de mort. L’organisme qualifié
responsable de l’installation adéquate de cette trousse. L’installation n’est pas adéquate ni complète tant que le bon fonctionnement
de l’appereil converti n’a pas été vérfié selon les instructions du fabricant fornies avec la trousse.
INTRODUCTION
→ This instruction covers the installation of gas conversion kit Part No. KGANP3001ALL to convert the following furnaces from natural gas usage
to propane gas usage. See appropriate section for your furnace type.
• Section 1- (Page 3) Models 58STA, 58STX, 58DLA, 58DLX, 310AAV, 310JAV, 311AAV, 311JAV, PG8MAA, PG8JAA, 58CTA, 58CTX,
58CVA, 58CVX, 312AAV, 312JAV, 315AAV, 315JAV 33.3-inch high, Induced-Combustion, Hot-Surface Ignition, Single Stage, 2-Stage and
Variable Speed Non-Condensing 4-Way Multipoise Furnaces with 42,000 through 154,000 Btuh gas input rates.
Form:
AG-GANP-31
Cancels:
AG-GANP-30
Printed in U.S.A.
5-04
Catalog No.
63GA-NP11
→ Table 1—Kit Contents
DESCRIPTION
Main Burner Orifice (Drill Size 1.30mm)
Main Burner Orifice (Drill Size 1.25mm)
Main Burner Orifice (Drill Size No. 54)
Main Burner Orifice (Drill Size No. 55)
Main Burner Orifice (Drill Size No. 56)
Screw, Spoiler
Diverter Plate
Low Gas Pressure Switch (Propane) (LGPS)
Nipple
90° Street Elbow (1/8 in.)
Male x Female x Female Tee (1/8 in.)
Splice Connector (1/4 in. Male, Both Ends)
Splice Connector (3/16 in. Male, Both Ends)
Orange Wire Assembly (18 in.)
Orange Wire Assembly (12 in.)
Yellow Wire Assembly (6 in.)
Yellow Wire Assembly (14 in.)
Yellow Wire Assembly (16 in.)
Wire Tie
Conversion Rating Plate Label—Condensing Furnaces
Conversion Rating Plate Label—Non-Condensing Furnaces
Conversion Rating Plate Label—Non-Condensing Furnaces
Conversion Rating Plate Label—Non-Condensing Furnaces
Conversion Responsibility Label
Gas Control Conversion Label (adjusted)
Gas Control Conversion Label (converted)
Installation Instructions
Regulator Spring Kit (White—Propane-EF39ZW023) for
White-Rodgers 36C, 36E, 36F and 36G Valve
Drill Bit
PART NO.
LH32DB210
LH32DB209
LH32DB203
LH32DB201
LH32DB206
327593-401
323184-301
HK02LB008
CA52JZ103
CA15RA001
CA21JZ001
66175D55
HY89SC047
W182X23- -04- -018
W182X66- -04- -012
W182Y66- -11- -006
W182Y66- -11- -014
W182Y66- -23- -016
HY76TB125
327697-201
327697-204
327697-206
327697-204
327697-205
327697-202
327697-203
AG-GANP-31
QUANTITY
7
7
7
7
7
7
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
92-0659
2
328456-401
1
•
Section 2- (Page 12) Models 58WAV, 58PAV, 58ZAV, 58RAV, 395CAV, 383KAV, 376CAV, 373LAV, 393AAV, 58YAV, PG8UAA,
PG8DAA, 58DXT, 58TMA, 58TUA, 58UHV, 58UXT, 58UXV, 330AAV, 330JAV, 331AAV, 331JAV, 333BAV, and 333JAV 40-inch high,
Induced-Combustion, Hot-Surface Ignition, Single Stage, 2-Stage and Variable-Speed, Non-Condensing Furnaces. This kit is designed for use
in furnaces with 40,000 through 154,000 Btuh gas input rates.
• Section 3- (Page 19) Models 58MCA, 58MSA, 58MXA, 340MAV, 345MAV, 350MAV, 490AAV, and PG9MAA, 58MVP, 58MTA,
355MAV, and 352MAV, 4-Way Multipoise, Hot Surface Ignition, Condensing Furnaces. This kit is designed for use in furnaces with 40,000
through 140,000 Btuh gas input rates.
→ This kit is designed for use in the furnaces listed above. The gas valve will be a White-Rodgers 36E, 36F or 36G series gas valve with either an
electric control switch or a manual control knob.
IMPORTANT: This kit can replace conversion kit KGANP25012SP for furnaces listed in Sections 2 and 3, as specified on unit rating plate, when
gas valve is replaced with Two-Stage Gas Valve P/N EF33CW198 (White-Rodgers 36E55). Replacement gas valve is available through RCD.
WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD
Failure to follow instructions could result in serious 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.
→
WARNING: FIRE, EXPLOSION, ELECTRICAL HAZARD
Failure to follow this warning could result in serious injury, death or property damage.
Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.
DESCRIPTION AND USAGE
This kit is designed for use in the furnaces listed above. See Table 1 for kit contents. To accommodate many different furnace models, more parts
are shipped in kit than will be needed to complete conversion. When installation is complete, discard extra parts.
—2—
INSTALLATION
SECTION 1- INDUCED-COMBUSTION, HOT-SURFACE IGNITION, SINGLE-STAGE, TWO-STAGE AND VARIABLE-SPEED,
33.3-INCH HIGH, NON-CONDENSING FURNACES
58STA
58DLA
58STX
58DLX
SINGLE STAGE MODELS
310AAV
PG8MAA
311AAV
PG8JAA
310JAV
311JAV
2-STAGE MODELS
58CTA
312AAV
58CTX
312JAV
VARIABLE SPEED MODELS
58CVA
315AAV
58CVX
315JAV
PROCEDURE 1—INSTALL MAIN BURNER ORIFICES AND BURNER SPOILER SCREWS
NOTE: See Fig. 2 for component location in UPFLOW orientation. Reorient component arrangement when furnace is installed in other positions.
→
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in excessive burner noise and misdirection of burner flames. This may result in flame
impingement of the burners and the heat exchangers, causing failures.
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. (See Fig. 1.)
BURNER
ORIFICE
BURNER
ORIFICE
A96249
Fig. 1—Burner Orifice
1. Turn off furnace gas and electrical supplies.
2. Remove outer door.
3. Turn furnace gas valve switch to OFF position.
4. If furnace is oriented in a manner that the vent connector interferes with burner removal, remove vent connector from vent elbow inside
the furnace. Support the remaining vent connector with temporary metal wire or straps to prevent damage to the remaining portions of the
vent connector.
5. Remove gas supply pipe from gas valve (if installed).
Disconnect wires from gas valve.
CAUTION: UNIT OPERATION HAZARD
Wiring errors may cause improper and dangerous operation. Label all wires prior to disconnection when servicing controls.
ATTENTION: D’EQUIPEMENT DANGER D’OPERATION
Toute erreur de câblage peut être une source de danger et de panne. Lors des opérations d’entretien des commandes, étiqueter tous
les fils avant de les déconnecter
6. Remove the 2 screws on the left side that secure the manifold to the burner box.
7. Swing out manifold from burners then pull manifold out of right side of burner box. (See Fig. 2.)
8. Remove and discard orifices from manifold.
9. Refer to conversion kit rating plate 327697-204 to determine main burner orifice size. (See Fig. 10.)
Gas input rate on furnace rating plate is for installations at altitudes up to 2000 ft. In the U.S.A., the input rating for altitudes above 2000 ft must
be reduced by 4 percent for each 1000 ft above sea level.
In Canada, the input rating must be derated by 10 percent for altitudes of 2000 ft to 4500 ft above sea level.
The Conversion Kit Rating Plate accounts for high altitude derate.
10. Install main burner orifices. Do not use Teflon tape. Finger-tighten orifices at least 1 full turn to prevent cross-threading, then tighten with
wrench. There are enough orifices in each kit for largest furnace. Discard extra orifices.
—3—
INDUCER MOTOR
ASSEMBLY
VENT ELBOW
MAIN LIMIT SWITCH
(BEHIND GAS VALVE)
PRESSURE
SWITCH
DRAFT
SAFEGUARD
SWITCH
FLUE
COLLECTOR
BOX
GAS MANIFOLD
GAS VALVE
GAS BURNER
MANUAL RESET
LIMIT SWITCHES
FLAME SENSOR
HOT SURFACE
IGNITER
BLOWER DOOR
SAFETY SWITCH
BLOWER AND
MOTOR
CONTROL
RATING PLATE
NOT SHOWN
(LOCATED ON
BLOWER DOOR)
A03059
Fig. 2—Component Location
11. To install burner spoiler screws, follow the following steps:
a. Disconnect Hot Surface Igniter (HSI) wires from HSI.
b. Disconnect Flame Sensor wire from Flame Sensor.
c. Slide one-piece burner assembly out of slots on sides of burner box.
d. Remove the Hot Surface Igniter (HSI) and bracket from the burner assembly.
e. Remove the flame sensor from the burner assembly.
f. Locate the dimple on each burner venturi tube.
g. Drill a 5/64″ hole in each dimple with drill bit provided with spoiler screws.
h. Install a spoiler screw in each drilled hole as straight as possible.
NOTE: Models 58CTX, 58CVX, 58DLX, 58STX, 310JAV, 311JAV, 312JAV, 315JAV and PG8JAA are supplied with NOx emissions-reduction
devices necessary for use with Natural Gas in NOx emissions-regulated areas.
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in premature unit failure.
Furnace models 58CTX, 58CVX, 58DLX, 58STX, 310JAV, 311JAV, 312JAV, 315JAV and PG8JAA MUST have low NOx devices
removed prior to operating furnace on propane gas.
12. For NOx device removal, follow the following additional steps:
a. Remove the screw underneath the heat exchanger inlet that secures the NOX device in the heat exchanger (See Fig. 5.)
b. Use a pair of needle nose pliers to remove the NOx device. Squeeze the sides of the device if necessary to remove from the heat
exchanger.
Drill out with
5/64” drill bit.
A03110
Fig. 3—Location of Dimple for Spoiler Screw
—4—
SPOILER SCREW
BURNER
A03234
Fig. 4—Location of Spoiler Screw
c. Re-install screw in hole underneath heat exchanger inlet.
NOTE: It is very IMPORTANT to re-install the NOx bracket mounting screw.
d. Repeat steps ″a″ thru ″c″ for each heat exchanger.
13. Re-install burner assembly by:
a. Attach flame sensor to burner assembly.
b. Install HSI and bracket to burner assembly.
c. Insert one-piece burner in slot on sides of burner box and slide burner back in place.
d. Re-attach HSI wires to HSI. Verify Igniter to Burner alignment. (See Fig. 29.)
e. Re-attach Flame sensor wire to Flame Sensor.
14. Reinstall manifold by inserting right end of manifold into opening in right side of burner box.
15. Swing manifold into burner assembly and insert orifices into openings on burners.
16. Verify that orifices are fully inserted into burners and burners are fully seated in burner box.
17. Secure manifold to left side of burner box, verifying that green ground wire is reattached to burner box.
18. Reconnect wires to gas valve per the wiring diagram supplied with the unit.
NOTE: Failure to attach ground wire to gas manifold on burner box will result in loss of flame signal resulting in a no heat condition.
NOTE: Use propane-gas resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.
PROCEDURE 2—CONVERTING AND ADJUSTING SINGLE STAGE AND 2-STAGE GAS VALVE
A. Convert Single Stage Gas Valve
NOTE: The following furnaces must have the regulator spring replaced in the gas valve:
58STA
58DLA
58STX
58DLX
310AAV
311AAV
310JAV
311JAV
1. Be sure main gas and electrical supplies are off.
2. Remove regulator seal cap. (See Fig. 6A or 6B.)
3. Remove adjustment screw and natural gas regulator spring (silver).
4. Install propane gas regulator spring (white) in gas valve.
→
5. Turn regulator adjustment screw in 6 turns for Fig. 6A and 8.5 turns for Fig. 6B.
NOTE: DO NOT reinstall regulator seal cap at this time.
—5—
PG8MAA
PG8JAA
A02195
Fig. 5—NOx Device Location
REGULATOR
SEAL CAP
ON AND
OFF SWITCH
REGULATOR
SEAL CAP
REGULATOR
ADJUSTMENT
SCREW
REGULATOR
ADJUSTMENT
SCREW
ON/OFF SWITCH
REGULATOR SPRING
(PROPANE – WHITE, 6 TURNS
NATURAL – SILVER, 10 TURNS)
REGULATOR SPRING
(PROPANE - WHITE, 8.5 TURNS
NATURAL - SILVER, 8.5 TURNS)
GAS PRESSURE
REGULATOR
ADJUSTMENT
INLET
PRESSURE TAP
GAS PRESSURE
REGULATOR
ADJUSTMENT
INLET
PRESSURE TAP
MANIFOLD
PRESSURE TAP
MANIFOLD
PRESSURE TAP
Fig. 6A—Single-Stage Gas Valve
A01073
→ Fig. 6B—Single-Stage Gas Valve
A04112
B. Pre-Adjust 2-Stage Gas Valve
→ NOTE: The following furnaces with Fig. 6D type valves, DO NOT need to have the regulator spring replaced in the gas valve, but the valve
MUST be pre-adjusted for propane applications. The following furnaces with Fig. 6C type valves must have both springs replaced and the valve
MUST be pre-adjusted:
58CTA
58CTX
312AAV
312JAV
58CVA
58CVX
315AAV
315JAV
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in excess underfire and flashback.
The gas valve must be pre-adjusted before operating on propane gas. If left this way sooting and corrosion will occur leading to early
heat exchanger failure.
→ FOR FIG. 6C
1. Be sure gas and electrical supplies to furnace are off.
2. Remove caps that conceal adjustment screws for high- and low-heat stage gas-valve regulators. (See Fig. 6C.)
3. Turn low-heat stage adjusting screw clockwise (in) 9.5 turns. This will increase the manifold pressure closer to the propane low-heat set
point.
4. Turn high-heat stage adjusting screw clockwise (in) 13.5 turns. This will increase the manifold pressure closer to the propane high-heat
set point. Replace caps that conceal gas-valve regulator adjustment screws. Go to Procedure 3.
FOR FIG. 6D
1. Be sure gas and electrical supplies to furnace are off.
2. Remove caps that conceal adjustment screws for high- and low-heat stage gas-valve regulators. (See Fig. 6C.)
3. Turn low-heat stage adjusting screw (3/32-in. hex allen wrench) clockwise (in) 1 full turn. This will increase the manifold pressure closer
to the propane low-heat set point.
—6—
REGULATOR COVER SCREW
PLASTIC ADJUST SCREW
ON/OFF SWITCH
REGULATOR SPRING
HIGH STAGE GAS
PRESSURE REGULATOR
ADJUSTMENT
(PROPANE–WHITE, 13.5 TURNS
NATURAL–SILVER,12 TURNS)
LOW STAGE
GAS PRESSURE
REGULATOR ADJUSTMENT
(PROPANE–WHITE, 9.5 TURNS
INLET
PRESSURE TAP
NATURAL–SILVER,9.5 TURNS)
MANIFOLD
PRESSURE TAP
A04048
→ Fig. 6C—Two-Stage Gas Valve
ON/OFF
SWITCH
INLET
PRESSURE
TAP
FF
LOW-HEAT
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
HIGH-HEAT
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
O
ON
PLUG BUTTON
(2-STAGE AND
VARIABLE–SPEED,
NON–CONDENSING
FURNACES ONLY)
MANIFOLD
PRESSURE
TAP
BURNER ENCLOSURE
REFERENCE PRESSURE TAP(2-STAGE
AND VARIABLE-SPEED, CONDENSING
FURNACES ONLY)
A01069
Fig. 6D—Two-Stage Gas Valve
4. Turn high-heat stage adjusting screw (3/32-in. hex allen wrench) clockwise (in) 2 fulll turns. This will increase the manifold pressure
closer to the propane high-heat set point. Replace caps that conceal gas-valve regulator adjustment screws. Go to Procedure 3.
PROCEDURE 3—INSTALL LOW GAS PRESSURE SWITCH (LGPS)
NOTE: The inlet gas pipe must be disconnected from valve so pressure switch can be installed.
NOTE: Use propane-gas-resistant pipe dope on all connections to prevent gas leaks. DO NOT use Teflon tape.
1. Be sure main gas and electric supplies to furnace are off.
2. Remove 1/8-in. pipe plug from inlet pressure tap on gas valve. (See Fig. 6A, 6B or 6C, 6D and Fig. 7A and 7B.) DO NOT DISCARD 1/8″
PLUG.
3. Apply pipe dope sparingly to one end of 1/8″ brass male coupling (provided in kit) and install the doped end in 1/8-in. tapped opening in
gas valve inlet pressure-tap. Tighten fitting with a small open-end wrench. (See Fig. 7A and 7B.)
4. Apply pipe dope sparingly to opposite end of the 1/8″ brass coupling (provided in kit). Install the female end of the female x female x male
tee on the brass coupling. Tighten coupling finger tight. Use a small open-end wrench for final tightening.
5. Apply pipe dope sparingly to male end of brass tee. Install propane low gas pressure switch (provided in kit) on male end of the female
x female x male tee. Tighten switch finger tight. Use a small open-end wrench on base of pressure switch for final tightening.
6. Connect a manometer to the open end of the tee installed in the gas valve. (See Fig. 7A and 7B.)
7. Apply pipe dope sparingly to end of inlet gas pipe and reconnect pipe to gas valve.
—7—
1/8” brass coupling
Brass tee . . . install LPGS
A02198
Fig. 7A—Gas Valve Inlet Pressure Trap
A02211
Fig. 7B—LGPS Installed
PROCEDURE 4—CHECK INLET GAS PRESSURE
NOTE: This kit is to be used only when inlet gas pressure is between 11.0-in. w.c. and 13.6-in. w.c.
→ Verify manometer is connected to the open end of the brass tee installed in the gas valve. (See Fig. 7A and 7B.)
→
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in flame rollout, overheating the heat exchangers, etc. and reduce unit life.
DO NOT operate furnace more than 1 minute to check inlet gas pressure, as conversion is not complete at this time.
For Two-Stage furnaces, perform the following on the control board:
Turn LHT switch on furnace control to ON (See. Fig. 8C.)
For Variable Speed furnaces, perform the following on the control board:
Turn Setup Switch SW1-2 on furnace control ON (See Fig. 8D.)
1. Turn on furnace power supply.
2. Turn gas supply manual shutoff valve to ON position.
3. Turn furnace gas valve switch to ON position.
4. Jumper R-W thermostat connections on the Single Stage furnace control (See Fig. 8A or 8B.) or
Jumper R-W/W1 and R-W2 thermostat connections on the 2-Stage and Variable Speed furnace control (See Fig. 8C or 8D.) The two-stage
algorithm must be removed to force furnace to high heat operation.
5. When main burners ignite, confirm inlet gas pressure is between 11.0-in. w.c. and 3.6-in. w.c.
6. Remove jumper across thermostat connections to terminate call for heat.
7. Turn furnace gas valve switch to OFF position.
8. Turn gas supply manual shutoff valve to OFF position.
9. Turn off furnace power supply.
10. Remove manometer.
11. Apply pipe dope sparingly to end of inlet gas pipe plug and install in unused end of 1/8″ tee. Use a small back-up wrench on tee when
tightening gas inlet pipe plug. (See Fig. 7A or 7B.)
PROCEDURE 5—MODIFY PRESSURE SWITCH WIRING (REFER TO FURNACE WIRING DIAGRAM)
A.
Single Stage
1. Disconnect yellow wire from the N.O. contact of the pressure switch PRS and connect it to the N.O. terminal on the low gas pressure switch,
LGPS.
2. Connect the insulated straight terminal of the 16-in. yellow wire (provided in kit) to the C terminal on the low gas pressure switch, LGPS.
3. Connect insulated flag terminal of 16-in. yellow wire to the N.O. terminal to pressure switch PRS.
—8—
4. Route yellow wires along wire harness. Secure with wire tie provided in kit. Go to Procedure 6.
B.
2-Stage and Variable Speed
1. Disconnect yellow wire from the N.O. contact of the low-heat pressure switch LPS and connect it to the N.O. terminal on the low gas
pressure switch, LGPS.
2. Connect insulated straight terminal of 16-in. yellow wire (provided in kit) to C terminal on low gas pressure switch LGPS.
3. Connect insulated flag terminal of 16-in. yellow wire to N.O. terminal to low pressure switch LPS.
4. Route yellow wires along wire harness. Secure with wire tie provided in kit. Go to Procedure 6.
PROCEDURE 6—CHECK FURNACE OPERATION AND MAKE NECESSARY ADJUSTMENTS
1. Be sure main gas and electric supplies to furnace are off.
2. Remove 1/8-in. pipe plug from manifold pressure tap on downstream side of gas valve. (See Fig. 6A or 6B.)
3. Attach manometer to manifold pressure tap on gas valve.
NOTE: The 1/8 inch NPT street ell included in the kit may be attached to the gas valve manifold pressure tap or a field supplied 90 degree 1/8
inch NPT barbed fitting may be simplify manometer connection to gas valve when vent connector passes inside furnace casing. (See Fig 9.) The
street ell may be left in place on gas valve when plug from manifold pressure tap in installed in street ell.
4. Turn gas supply manual shutoff valve to ON position.
5. Turn furnace gas valve switch to ON position.
6. Check all threaded pipe connections for gas leaks.
7. Turn on furnace power supply.
WARNING: FIRE, EXPLOSION, INJURY OR DEATH HAZARD
Failure to follow this warning could result in fire, explosion, personal injury, or death.
NEVER use matches, candles, flame, or other sources of ignition to check for gas leakage. Use a soap-and-water solution to check
for leaks.
PROCEDURE 7—SET GAS INPUT RATE
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 determined by
manifold pressure and orifice size. On two-stage furnace models, the gas-valve regulator must be set for high heat and set for low heat. (See kit
rating plate 327697-204 Rev. B, Fig. 10.)
Gas input rate on furnace rating plate is for installations at altitudes up to 2000 ft. In the U.S.A., the input rating for altitudes above 2000 ft must
be reduced by 4 percent for each 1000 ft above sea level.
In Canada, the input rating must be derated by 10 percent for altitudes of 2000 ft to 4500 ft above sea level.
The Conversion Kit Rating Plate accounts for high altitude derate.
A.
Single Stage Furnaces
1. Jumper R and W thermostat connections to call for heat. (See Fig. 8A or 8B.)
2. Check manifold orifices for gas leaks when main burners ignite.
3. Adjust gas manifold pressure.
NOTE: Gas valve regulator seal cap MUST be in place when checking input rate.
a. Turn adjusting screw counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure. (See Fig. 6A
or 6B.)
NOTE: Gas valve regulator seal cap MUST be in place when checking input rate.
b. When correct input is obtained, main burner flame should be clear blue, almost transparent. Be sure regulator seal cap is in place when
finished.
4. Remove jumper across R and W thermostat connections to terminate call for heat.
5. Turn furnace gas valve control switch or control knob to OFF position.
6. Turn off furnace power supply.
7. Remove manometer and replace manifold pressure tap plug. (See Fig. 6A or 6B.)
NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.
8. Turn furnace gas valve control switch or control knob to ON position.
9. Turn on furnace power supply.
10. Set room thermostat to call for heat.
11. Check manifold pressure tap plug for gas leaks when main burners ignite.
12. Observe unit operation through 2 complete heating cycles. See sequence of operation in furnace Installation, Start-up and Operating
Instructions.
—9—
TWINNING AND/OR
COMPONENT TEST
TERMINAL
BLOWER OFF-DELAY
SETUP SWITCHES
LOW-HEAT ONLY AND
BLOWER OFF-DELAY
TWINNING AND/OR
COMPONENT TEST
TERMINAL
ACRDJ - AIR CONDITIONING
RELAY DISABLE JUMPER
J2 JUMPER
LED
SEC-2
PL1
PL3
NEUTRAL-L2
PL3
OD E
1
BHI/LOR
IDM
PR-1
HSI
HI LO
PL2 - HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
115-VAC (L1) LINE
VOLTAGE CONNECTION
COOL
SPARE-2
BLOWER SPEED
SELECTION TERMINALS
IHI/LOR
EAC-1
PL2
SPARE-2
SPARE-1
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
L1
1-AMP@115 VAC
COOL
SPARE-1
1
PL2-HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
HSIR
1
115 VAC (L1) LINE
VOLTAGE CONNECTION
BLWR
IDR
PL2
SPARE-1
SPARE-2
LO HEAT
L1
PR-1
BHT/CLR
HI HEAT
HEAT
HI HEAT
LO HEAT
1-AMP@
EAC-1 115VAC
1
BLW
115-VAC (L2) NEUTRAL
CONNECTIONS
SPARE-1 SPARE-2
BLOWER SPEED
SELECTION TERMINALS
SEC-1
EAC-2
COOL
COOL
HEAT
STAT
US C
LED OPERATION &
DIAGNOSTIC LIGHT
PL1-LOW VOLTAGE MAIN
HARNESS CONNECTOR
PL1 - LOW VOLTAGE MAIN
HARNESS CONNECTOR
FUSE 3-AMP
3-AMP FUSE
L2
1
115-VAC(L2)NEUTRAL
CONNECTIONS
EAC-2
PLT
LED OPERATION &
DIAGNOSTIC LIGHT
SEC-2 SEC-1
TRANSFORMER 24-VAC
CONNECTIONS
0.5-AMP024 VAC
R
NUETRAL BLW
STATUS CODE LED
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
FUSE 3-AMP
HUM
PLT
R
0.5 AMP@24VAC
3-AMP FUSE
TEST/TWIN
ACRDJ
PLT
Y
HUM
1 2 3
W
TRANSFORMER 24-VAC
CONNECTIONS
ON
Com
24V
24-V-THERMOSTAT
TERMINALS
TEST/TWIN
OFF
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
G
24-V THERMOSTAT
TERMINALS
LHT
OFF
DLY
Y1 DHUM G COM WW1 Y/Y2
24V
120 180
J2
90 150
W2
BLOWER OFF-DELAY
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
Fig. 8A—Standard
Single Stage Control
TWINNING AND/OR
A02100
A02017
Fig. 8C—Two Stage Control
115 VAC Output to
HSI & Inducer
COMPONENT TEST
TERMINAL
BLOWER OFF-DELAY
ECM Motor harness
Connector
DHUM
120 180
90 150
Y1
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
VS HSI HI LO
BLOWER OFF-DELAY
Future Use
G
PL3
SW4
OAT
PL9
SPARE-2
FAN
Com W/W1 Y/Y2
24V
R
STATUS
CODE
EAC-1
NEUTRAL-L2
Neutral Leads and
EAC 2 (Neutral)
EAC-2
LEDS
1-AMP@
EAC-1 115VAC
PR-1
L1
HEAT
FAN
SPARE-1 SPARE-2
SPARE-1
PL1
COMM
SW-1
PL4
COOL
Model Plug
SW3
CF
W2 Y1 DHUM G
BLOWER SPEED
SELECTION TERMINALS
12 Pin Inline
Connector
FUSE 3-AMP
PL7
HUM
PL1-LOW VOLTAGE MAIN
HARNESS CONNECTOR
A B C D
COOL
HEAT
L1
L2
1
115-VAC(L2)NEUTRAL
CONNECTIONS
EAC-2
PLT
LED OPERATION &
DIAGNOSTIC LIGHT
SEC-2 SEC-1
SEC-2 SEC-1
NUETRAL BLW
STATUS CODE LED
24 VAC Hum Output
(0.5 AMP MAX)
ACRDJ Jumper
FUSE 3-AMP
ACRDJ
R
HUM
0.5 AMP@24VAC
3-AMP FUSE
PL2
115 VAC EAC Input
(1.0 AMP MAX)
1-AMP@115 VAC
TEST/TWIN
TRANSFORMER 24-VAC
CONNECTIONS
PLT
COM W/W1 Y/Y2
24V
24-V THERMOSTAT
TERMINALS
115 VAC Input
Transformer
Primary & 120
VAC to ECM
Motor
PL2
SW2
AC
1
115 VAC (L1) LINE
VOLTAGE CONNECTION
Set up Switches SW1, 1
thru 8
PL2-HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
24 VAC Output
A/C & Constant Air Flow
Switches
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
Fuse, 3 Amp
Status Code Light
A02142
Fig. 8D—Variable Speed Control
Fig. 8B—Deluxe Single Stage Control
A02018
A02197
Fig. 9—Plug Removed from Gas Valve
Street Ell Installed and Plug Reinstalled in Ell
13. Set room thermostat to desired temperature.
B.
Set Two-Stage or Variable Speed Gas Input Rate
For Two-Stage furnaces, perform the following on the control board:
1. Make sure LHT switch on furnace control to ON. (See Fig. 8C.)
2. Jumper R and W/W1 thermostat connection on furnace control.
3. Check manifold orifices for gas leaks when main burners ignite. Go to Procedure 4.
For Variable Speed furnaces, perform the following on the control board:
1. Make sure Setup Switch SW1-2 on furnace control ON. (See Fig. 8D.)
—10—
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 up to 2000 ft above sea level. In U.S.A. the input rating for altitudes above 2000 ft must
be derated by 4% for each 1000 ft above sea level. In Canada the input rating must be derated by 10% for altitudes of 2000 ft to 4500 ft above sea level.
KIT NO. KGANP3001ALL (SUPERSEDES: KGANP2701LPS, KGANP2801F80, KGANP2901ALL)
FUEL USED: PROPANE GAS
INLET PRESSURE (min - max): 11.0 - 13.6 in. wc
ALTITUDE OF INSTALLATION (FT. ABOVE SEA LEVEL) U.S.A. *
APPLIANCE MODELS
310AAV, 310JAV, 311AAV,
311JAV, 58STA, 58STX,
58DLA, 58DLX, PG8MAA,
PG8JAA
312AAV, 312JAV, 315AAV,
315JAV, 58CTA, 58CTX,
58CVA, 58CVX,
0
2001 * 3001
4001
5001
6001
7001
8001
9001
to 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 to 9000 to 10000
Orifice No.
Mnfld Press
55
11.0
1.30mm
11.0
1.30mm
10.5
1.25mm
11.0
1.25mm
11.0
1.25mm
10.5
Orifice No.
55
1.30mm 1.30mm 1.25mm 1.25mm 1.25mm
Mnfld Press
11.0 /
11.0 /
10.5 /
11.0 /
11.0 /
10.5 /
High / Low
5.8
5.3
5.0
5.5
5.2
4.9
* For Canadian Installations from 2000 to 4500 ft use U.S.A. column 2001 to 3000 ft.
56
11.0
56
11.0
56
10.5
56
11.0 /
5.7
56
11.0 /
5.2
56
10.5 /
4.8
327697-204 REV. B
A04118
→ Fig. 10—Conversion Kit Rating Plate
2. Jumper R and W/W1 thermostat connection on furnace control.
3. Check manifold orifices for gas leaks when main burners ignite. Go to Procedure 4.
4. Adjust gas manifold pressure.
a. Remove caps that conceal adjustment screws for gas-valve regulators. (See Fig. 6C and 6D.)
b. Jumper R, W/W1 thermostat connections on control. (See Fig. 8C or 8D.) Adjust low-heat input rate manifold pressure for propane gas.
(See kit rating plate 327697-204 Rev. B, Fig. 10.) (Note: Gas valve should already have been pre-adjusted, from prior steps for two-stage
gas valve). Turn low-heat adjusting screw counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.
c. Jumper R, W/W1 and W2 thermostat connections on control. This keeps furnace in high-heat.
d. Adjust high-heat input rate manifold pressure for propane gas. (See kit rating plate 327697-204 Rev. B, Fig. 10.) Turn high-heat adjusting
screw.
e. Counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.
f. Main burner flame should be clear blue, almost transparent.
g. Remove jumper across R, W/W1 and W2 after high-heat adjustment.
h. Replace caps that conceal gas-valve-regulator adjustment screws.
5. Turn setup switch LHT (two-stage) or SW-2 (variable speed) switch to OFF position.
6. Turn furnace gas valve switch to OFF.
7. Turn off furnace power supply.
8. Remove manometer and replace manifold pressure tap plug. (See Fig. 6C and 6D.)
NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.
9. Turn on furnace power supply.
10. Turn furnace gas valve switch to ON position.
11. Set room thermostat to call for heat.
12. Check pressure tap plug for gas leaks when main burners ignite.
13. When correct input is obtained, main burner flame should be clear blue, almost transparent. (See Fig. 28.)
14. Observe unit operation through 2 complete heating cycles. See sequence of operation in furnace Installation, Start-Up, and Operating
Instructions.
15. Set room thermostat to desired temperature.
PROCEDURE 8—CHECK LOW GAS PRESSURE SWITCH OPERATION
The newly installed low gas pressure switch is a safety device used to guard against adverse burner operating characteristics that can result from
low gas supply pressure. Switch opens at not less than 6.5″w.c. and closes at not greater than 10.2″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.
—11—
Blower Door
Outer
door
Apply Conversion
Responsibility Label
on exterior of door
Factory
Clearance
Label
Factory Information
Label
Rating Plate on
exterior of door
Existing Warning Label
A02203
Fig. 11—Label Application
When normal gas pressure is restored, the system must be electrically reset to re-establish normal heating operation.
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.
PROCEDURE 9—LABEL APPLICATION
1. Fill in Conversion Responsibility Label (327697-205) and apply to Blower Access Door of furnace as shown. (See Fig. 11.) Date, name,
and address of organization making this conversion are required.
2. Attach Conversion Rating Plate Label (327697-204 Rev. B, Fig. 10.) to Outer Door of furnace.
→
→
3. Apply Gas Control Conversion Label to gas valve:
a. For single-stage gas valve apply label 327697-203 to gas valve. (Do not use 327697-202, which is similar)
b. For two-stage gas valve that was converted by replacing the regulator springs (Fig. 6C) apply label 327697-203.
c. For two-stage gas valve that was adjusted (Fig. 6D) apply label 327697-202.
4. Check for correct normal operating sequence of the ignition system as described in furnace Installation, Start-Up, and Operating
Instructions.
5. Replace control access door.
—12—
INSTALLATION
SECTION 2- INDUCED-COMBUSTION, HOT-SURFACE IGNITION, SINGLE STAGE, TWO-STAGE AND VARIABLE-SPEED,
40-INCH NON-CONDENSING FURNACES MODELS
58PAV
58WAV
58RAV
58ZAV
SINGLE-STAGE MODELS
383KAV
PG8UAA
395CAV
PG8DAA
373LAV
393AAV
376CAV
58YAV
TWO-STAGE MODELS
58TUA
330AAV
58TMA
331AAV
58UXT
330JAV
58DXT
331JAV
VARIABLE SPEED MODELS
58UHV
333BAV
58UXV
333JAV
PROCEDURE 1—INSTALL MAIN BURNER ORIFICES
NOTE: See Fig. 12A or 12B for component location.
1. Turn off furnace gas and electrical supplies.
2. Remove control access door.
3. Turn furnace gas valve switch to OFF position.
4. Remove gas supply pipe from gas valve (if installed).
CAUTION: UNIT OPERATION HAZARD
Label all wires prior to disconnection when servicing controls. Wiring errors will cause improper and dangerous operation.
ATTENTION: D’EQUIPEMENT DANGER D’OPERATION
Toute erreur de câblage peut être une source de danger et de panne. Lors des opérations d’entretien des commandes, étiqueter tous
les fils avant de les déconnecter.
5. Remove wires from gas valve. Note location for reassembly.
6. Remove wires from flame sensor and flame rollout safety switch(es).
7. Disconnect harness from hot surface igniter.
8. Remove the 4 screws that secure the gas manifold to the burner assembly. Note the location of the green ground wire attached to the
manifold for reassembly.
9. Remove the manifold.
NOTE: Models 58DXT, 58UXT, 58UXV, 330JAV, 331JAV and 333JAV are supplied with NOX emissions-reduction devices necessary for use
with Natural Gas in NOx emissions-regulated areas.
For 58UXT, 58DXT, 58UHV, 330JAV, 331JAV and 333BAV, remove NOX emissions-reducing device as follows: Using needle nose pliers,
remove coil from bracket on each heat exchanger cell inlet plate. (See Fig. 13.)
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in premature unit failure.
Furnace models 58DXT, 58UXT, 58UXV, 330JAV, 331JAV, and 333JAV, must have low NOx coils removed prior to operating furnace
on propane gas.
10. Remove and discard orifices from manifold.
11. Refer to conversion kit rating plate 327697-206 (Single Stage, See Fig. 14) or 327697-207 (Two Stage, See Fig. 15.) to determine main
burner orifice size.
Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. In the U.S.A., the input rating for altitudes above 2000 ft must
be reduced by 4 percent for each 1000 ft above sea level.
In Canada, the input rating must be derated by 10 percent for altitudes of 2000 ft to 4500 ft above sea level.
The Conversion Kit Rating Plate accounts for high altitude derate.
12. Install main burner orifices. Do not use Teflon tape. Finger-tighten orifices at least 1 full turn to prevent cross threading and then tighten
with wrench. There are enough orifices in each kit for largest furnace. Discard extra orifices. Orifices of other sizes must be field supplied
and are available through your local distributor.
13. For units equipped with NOx devices, NOx coil must be removed. (See Fig. 13.)
→
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in excessive burner noise and misdirection of burner flames. This may result in flame
impingement of the burners and the heat exchangers, causing failures.
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. (See Fig. 1.)
—13—
BLOWER
COMPARTMENT
DOOR
CONVERSION
RATING
PLATE
GAS CONTROL
CONVERSION
LABEL
GAS VALVE
CONVERSION
RATING
PLATE
GAS CONTROL
CONVERSION
LABEL
BURNER
HOLD–DOWN
BRACKET
GAS VALVE
BURNERS
BURNER
HOLD–DOWN
BRACKET
BURNERS
FURNACE
RATING
PLATE
MANIFOLD
FURNACE
RATING
PLATE
BLOWER
COMPARTMENT
DOOR
CLEARANCE
LABEL
CLEARANCE
LABEL
MANIFOLD
CONVERSION
RESPONSIBILITY
LABEL
CONVERSION
RESPONSIBILITY
LABEL
Fig. 12A—Downflow and Downflow/Horizontal,
Standing Pilot, Fixed Speed, Non-Condensing
Furnace Component and Conversion Label
Fig. 12B—Upflow and Upflow/Horizontal,
Standing Pilot, Fixed Speed, Non-Condensing
Furnace Component and Conversion Label
A95459
AS SHIPPED
A95460
COIL REMOVAL
A95171
Fig. 13—Removal of Low NOx
14. Reinstall manifold with 4 screws removed in Procedure 8. Burners should be checked for proper alignment of the burner crossover slot.
Verify green ground wire is attached to burner manifold
NOTE: Failure to attach ground wire to gas manifold on burner box will result in loss of flame signal resulting in a no heat condition.
15. Reconnect wires to flame sensor and flame rollout safety switch(es). See the furnace wiring label to ensure proper location of wires.
16. Reconnect igniter wire connector. Verify Igniter to Burner alignment. (See Fig. 30.)
17. Reconnect wires to gas valve. See wiring label on furnace to ensure proper location of wires.
18. Reconnect gas supply pipe to gas valve using backup wrench on gas valve to prevent rotation and improper orientation.
NOTE: Use propane-gas resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.
PROCEDURE 2—CONVERT OR PRE-ADJUST GAS VALVE
A.
Convert Single-Stage Gas Valve
The following furnaces must have the regulator spring replaced in the gas valve:
58PAV
58WAV
58RAV
58ZAV
383KAV
395CAV
373LAV
376CAV
1. Be sure main gas and electrical supplies are off.
2. Remove regulator seal cap. (See Fig. 16A.)
—14—
PG8UAA
PG8DAA
393AAV
58YAV
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 up to 2000 ft above sea level. In U.S.A. the input rating for altitudes above 2000 ft must
be derated by 4% for each 1000 ft above sea level. In Canada the input rating must be derated by 10% for altitudes of 2000 ft to 4500 ft above sea level.
KIT NO. KGANP3001ALL (SUPERSEDES: KGANP2701LPS, KGANP2801F80, KGANP2901ALL) FUEL USED: PROPANE GAS
ALTITUDE OF INSTALLATION (FT. ABOVE SEA LEVEL) U.S.A. *
APPLIANCE MODELS
373LAV, 376CAV, 58RAV,
58ZAV, PG8DAA
383KAV, 393AAV, 395CAV,
58PAV, 58WAV, 58YAV,
PG8UAA
INLET PRESSURE
(min - max): 11.0 - 13.6 in. wc
0
2001 *
3001
4001
5001
6001
7001
8001
to 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 to 9000
Orifice No.
Mnfld Press
54
11.0
Orifice No.
Mnfld Press
54
10.0
55
11.0
55
11.0
55
10.5
55
10.0
55
10.5
1.25mm
11.0
55
10.0
1.25mm
11.0
1.25mm
11.0
1.25mm
10.5
1.25mm
10.5
1.25mm
10.0
* For Canadian Installations from 2000 to 4500 ft use U.S.A. column 2001 to 3000 ft.
1.25mm
10.0
56
11.0
to
9001
10000
56
11.0
56
10.0
327697-206 REV. B
A04119
→ Fig. 14—Conversion Kit Rating Plate–Single Stage Units
CONVERSION KIT RATING PLATE - CARRIER CORP.
THIS APPLIANCE HAS BEEN CONVERTED TO USE PROPANE GAS FOR FUEL. REFER
PROCEDURES. USE PARTS SUPPLIED BY CARRIER CORPORATION AND INSTALLED BY
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 above sea level. In U.S.A.
be derated by 4% for each 1000 ft above sea level. In Canada the input rating must be derated by 10%
TO KIT INSTRUCTIONS FOR CONVERSION
QUALIFIED PERSONNEL. SEE
the input rating for altitudes above 2000 ft must
for altitudes of 2000 ft to 4500 ft above sea level.
INLET PRESSURE
FUEL USED: PROPANE GAS
KIT NO. KGANP3001ALL (SUPERSEDES: KGANP2701LPS, KGANP2801F80, KGANP2901ALL)
(min - max): 11.0 - 13.6 in. wc
ALTITUDE OF INSTALLATION (FT. ABOVE SEA LEVEL) U.S.A. *
APPLIANCE MODELS
0
2001 * 3001
4001
5001
6001
7001
8001
9001
to 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 to 9000 to 10000
Orifice No.
55
55
1.25mm 1.25mm 1.25mm
56
56
56
57
331AAV, 331JAV,
Mnfld Press
11.0 /
10.0 /
11.0 /
11.0 /
10.0 /
11.0 /
11.0 /
10.0 /
11.0 /
58DXT, 58TMA
4.7
4.2
4.7
4.5
4.2
4.9
4.6
4.2
5.3
High / Low
Orifice No.
55
1.25mm 1.25mm 1.25mm
56
56
56
57
57
330AAV, 330JAV, 333BAV,
333JAV, 58TUA, 58UHV,
Mnfld Press
10.0 /
11.0 /
10.5 /
10.0 /
11.0 /
11.0 /
10.0 /
11.0 /
11.0 /
58UXT, 58UXV
4.3
4.6
4.4
4.2
4.9
4.5
4.2
5.3
4.9
High / Low
* For Canadian Installations from 2000 to 4500 ft use U.S.A. column 2001 to 3000 ft.
327697-207 REV. B
A04120
→ Fig. 15—Conversion Kit Rating Plate–Two Stage Units
3. Remove adjustment screw and natural gas regulator spring (silver).
4. Install propane gas regulator spring (white) in gas valve.
5. Turn regulator adjustment screw in 6 turns.
NOTE: DO NOT reinstall regulator seal cap at this time.
B. Pre-Adjust Two-Stage Gas Valve
The following furnaces DO NOT need have the regulator spring replaced in the gas valve. The valve MUST be pre-adjusted for propane
applications:
58TUA
58TMA
58UXT
58DXT
330AAV
331AAV
330JAV
331JAV
58UHV
58UXV
333BAV
333JAV
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in excess underfire and flashback.
The gas valve must be pre-adjusted before operating on propane gas. If left this way, sooting and corrosion will occur leading to early
heat exchanger failure.
—15—
REGULATOR
SEAL CAP
ON AND
OFF SWITCH
ON/OFF
SWITCH
REGULATOR
ADJUSTMENT
SCREW
INLET
PRESSURE
TAP
REGULATOR SPRING
(PROPANE – WHITE, 6 TURNS
NATURAL – SILVER, 10 TURNS)
FF
O
ON
GAS PRESSURE
REGULATOR
ADJUSTMENT
INLET
PRESSURE TAP
LOW-HEAT
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
HIGH-HEAT
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
PLUG BUTTON
(2-STAGE AND
VARIABLE–SPEED,
NON–CONDENSING
FURNACES ONLY)
MANIFOLD
PRESSURE
TAP
BURNER ENCLOSURE
REFERENCE PRESSURE TAP(2-STAGE
AND VARIABLE-SPEED, CONDENSING
FURNACES ONLY)
MANIFOLD
PRESSURE TAP
Fig. 16A—Single Stage Gas Valve
A01073
Fig. 16B—Two-Stage Gas Valve
A01069
1. Be sure gas and electrical supplies to furnace are off.
2. Remove caps that conceal adjustment screws for high-and low-heat stage gas valve regulators. (See Fig. 16B.)
3. Turn low-heat stage adjusting screw (3/32-in. hex allen wrench) clockwise (in) 1 full turn. This will increase the manifold pressure closer
to the propane low-heat set point.
4. Turn high-heat stage adjusting screw (3/32-in. hex allen wrench) clockwise (in) 2 full turns. This will increase the manifold pressure closer
to the propane high-heat set point.
5. Replace caps that conceal gas valve regulator adjustment screws.
PROCEDURE 3—INSTALL LOW GAS PRESSURE SWITCH (LGPS)
NOTE: Use propane-gas-resistant pipe dope on all connections to prevent gas leaks. DO NOT use Teflon tape.
1. Be sure main gas and electric supplies to furnace are off.
2. Remove 1/8-in. pipe plug from inlet pressure tap on gas valve. (See Fig. 16A and 16B.) DO NOT DISCARD 1/8″ PLUG.
3. Apply pipe dope sparingly to one end of 1/8″ brass male coupling (provided in kit) and install the doped end in 1/8-in. tapped opening in
gas valve inlet pressure-tap. Tighten fitting with a small open-end wrench. (See Fig. 7A.)
4. Apply pipe dope sparingly to opposite end of the 1/8″ brass coupling (provided in kit). Install the female end of the female x female x male
tee on the brass coupling. Tighten coupling finger tight. Use a small open-end wrench for final tightening.
5. Apply pipe dope sparingly to male end of brass tee. Install propane low gas pressure switch (provided in kit) on male end of the female
x female x male tee. Tighten switch finger tight. Use a small open-end wrench on base of pressure switch for final tightening. When pressure
switch is tight, switch terminals should point as shown in Fig. 7B relative to gas valve and clear control compartment access door.
6. Connect a manometer to the open end of the tee installed in the gas valve. (See Fig. 7A.)
PROCEDURE 4—CHECK INLET GAS PRESSURE
NOTE: This kit is to be used only when inlet gas pressure is between 11.0-in. w.c. and 13.6-in. wc.
1. Verify manometer is connected to inlet pressure tap on gas valve. (See Fig. 7A.)
→
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in flame rollout, overheating the heat exchangers, etc. and reduce unit life.
DO NOT operate furnace more than 1 minute to check inlet gas pressure, as conversion is not complete at this time.
2. Turn on furnace power supply.
3. Turn gas supply manual shutoff valve to ON position.
4. Turn furnace gas valve switch to ON position.
5. Jumper thermostat connections:
a. Single Stage furnace control-jumper R-W thermostat connections
b. Two-Stage and Variable Speed furnace control-jumper R-W/W1 and R-W2 thermostat connections
6. When main burners ignite, confirm inlet gas pressure is between 11.0-in. w.c. and 13.6-in. w.c.
7. Remove jumper across R to W or R-W/W1 and R-W2 thermostat connections to terminate call for heat.
8. Turn furnace gas valve switch to OFF position.
—16—
9. Turn gas supply manual shutoff valve to OFF position.
10. Turn off furnace power supply.
11. Remove manometer.
12. Apply pipe dope sparingly to end of inlet gas pipe plug and install in unused end of 1/8″ tee. Use a small back-up wrench on tee when
tightening gas inlet pipe plug. (See Fig. 7A.)
PROCEDURE 5—MODIFY PRESSURE SWITCH WIRING
A.
Single Stage Pressure Switch Wiring
1. Disconnect yellow wire from the N.O. contact of the pressure switch PRS on the inducer housing and connect it to the N.O. terminal on
the low gas pressure switch, LGPS.
2. Connect the insulated straight terminal of the 16-in. yellow wire (provided in kit) to the C terminal on the low gas pressure switch, LGPS.
3. Connect insulated flag terminal of 16-in. yellow wire to the N.O. terminal to pressure switch PRS located on inducer housing.
4. Route yellow wires along wire harness.
5. Secure with wire tie provided in kit. Go to Procedure 6.
B.
Two-Stage and Variable Speed Pressure Switch Wiring
1. Disconnect yellow wire from low-heat pressure switch LPS on inducer housing. Add 3/16-in. splice connector to this wire.
2. Connect uninsulated terminal of 6-in. yellow wire (provided in kit) to splice connector. Connect other end to C terminal on low gas pressure
switch LGPS.
3. Connect insulated terminal of 14-in. yellow wire (provided in kit) to NO terminal on low gas pressure switch LGPS. Connect other end to
pressure switch LPS located on inducer housing.
4. Route yellow wires along wire harness. Secure with wire tie provided in kit. Go to Procedure 6.
PROCEDURE 6—CHECK FURNACE OPERATION AND MAKE NECESSARY ADJUSTMENTS
1. Be sure main gas and electric supplies to furnace are off.
2. Remove 1/8-in. pipe plug from manifold pressure tap on downstream side of gas valve. (Fig. 16A or 16B.)
3. Attach manometer to manifold pressure tap on gas valve. (See Fig. 16A.)
4. Turn gas supply manual shutoff valve to ON position.
5. Turn furnace gas valve switch to ON position.
6. Check all threaded pipe connections for gas leaks.
7. Turn on furnace power supply.
WARNING: FIRE, EXPLOSION, INJURY OR DEATH HAZARD
Failure to follow this warning could result in fire, explosion, personal injury, or death.
NEVER use matches, candles, flame, or other sources of ignition to check for gas leakage. Use a soap-and-water solution to check
for leaks.
PROCEDURE 7—SET GAS INPUT RATE
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 determined by
manifold pressure and orifice size. Refer to the appropriate Conversion Kit Rating Plate.
Gas input rate on furnace rating plate is for installations at altitudes up to 2000 ft. In the U.S.A., the input rating for altitudes above 2000 ft must
be reduced by 4 percent for each 1000 ft above sea level.
In Canada, the input rating must be derated by 10 percent for altitudes of 2000 ft to 4500 ft above sea level.
The Conversion Kit Rating Plate accounts for the high altitude derate.
A.
Single Stage Furnaces
1. Jumper R and W thermostat connections to call for heat.
2. Check manifold orifices for gas leaks when main burners ignite.
3. Adjust gas manifold pressure. Turn adjusting screw counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase
manifold pressure. Refer to Conversion Kit Rating Plate #327697-206 (Single-Stage).
NOTE: Gas valve regulator seal cap MUST be in place when checking input rate.
4. When correct input is obtained, main burner flame should be clear blue, almost transparent (See Fig. 28.) Be sure regulator seal cap is in
place when finished.
5. Remove jumper across R and W thermostat connections to terminate call for heat.
6. Turn furnace gas valve control switch or control knob to OFF position.
7. Turn off furnace power supply.
—17—
EAC - ELECTRONIC
AIR CLEANER
(115-VAC 1 AMP MAX)
PARK
FU1
3
EAC-1
EAC-2
SEC-2
SEC-1
HI-GAS
-HEAT
10 11
2
1
OFF
LED DIAGNOSTIC
LIGHT
12
7
8
4
5
6
1
2
3
9
LED
MASTER SLAVE
1
W2 COM W/W1 Y/Y2 R
24 V
G HUM
1
TWIN
TEST
3
3-AMP
FUSE
LO-GAS
-HEAT
3
L2
6
2
COM
5
1
HI-COOL
4
PR2
9
L1
8
PR1
7
4
ON
TWIN / TEST
TERMINAL
HUM HUMIDIFIER
(24-VAC 0.5
AMP MAX)
24-VOLT
THERMOSTAT
TERMINALS
BLOWEROFF
DELAY
1 2 3 4
OFF
ON
FURNACE AND
BLOWER OFF DELAY
SETUP SWITCHES
LOW
HEAT
(ADAPTIVE
ALGORITHM)
HIGH
HEAT
ONLY
A96402
Fig. 17B—Setup Switches on Furnace Control for 2-Stage
Condensing Furnace and 2-Stage/Variable Speed
Non-Condensing Furnaces (Factory Settings Shown)
A93348
Fig. 17A—Furnace Control for 2-Stage
Condensing Furnace and 2-Stage/Variable-Speed
Non-Condensing Furnaces
8. Remove manometer and replace manifold pressure tap plug.
NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.
9. Turn furnace gas valve control switch or control knob to ON position.
10. Turn on furnace power supply.
11. Set room thermostat to call for heat.
12. Check manifold pressure tap plug for gas leaks when main burners ignite.
13. Observe unit operation through 2 complete heating cycles. See sequence of operation in furnace Installation, Start-up and Operating
Instructions.
14. Set room thermostat to desired temperature. Go to Procedure 8.
B.
Two-Stage and Variable Speed Furnaces
1. Turn switch #2 (low heat) on furnace control to ON (See. Fig. 17A and 17B.)
2. Jumper R and W/W1 thermostat connection on furnace control.
3. Check manifold orifices for gas leaks when main burners ignite.
4. Adjust gas manifold pressure. Refer to Conversion Kit Rating Plate #327697-207 (Two-Stage).
a. Remove caps that conceal adjustment screws for gas-valve regulators. (See Fig. 16B.)
b. Adjust low-heat input rate manifold pressure for propane gas. (See kit rating plate 327697-207, see Fig. 15) Turn low-heat adjusting
screw (5/64 hex allen wrench) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.
c. Jumper R and W2 thermostat connections on control. This keeps furnace in high-heat.
d. Adjust high-heat input rate manifold pressure for propane gas. (See kit rating plate 327697-207) Turn high-heat adjusting screw (5/64
hex allen wrench) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.
e. Remove jumper across R and W2 after high-heat adjustment.
f. Replace caps that conceal gas-valve-regulator adjustment screws
5. Remove jumper across R, W1 and W2 thermostat connections to terminate call for heat.
6. Turn setup switch to SW-2 to OFF position.
7. Turn furnace gas valve switch to OFF.
8. Turn off furnace power supply.
9. Remove manometer and replace manifold pressure tap plug.
NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.
10. Turn on furnace power supply.
11. Turn furnace gas valve switch to ON position.
12. Set room thermostat to call for heat.
—18—
13. Check pressure tap plug for gas leaks when main burners ignite.
14. When correct input is obtained, main burner flame should be clear blue, almost transparent. (See Fig. 28.)
15. Observe unit operation through 2 complete heating cycles. See sequence of operation in furnace Installation, Start-Up, and Operating
Instructions.
16. Set room thermostat to desired temperature. Go to Procedure 8.
PROCEDURE 8—CHECK LOW GAS PRESSURE SWITCH OPERATION
The newly installed low gas pressure switch is a safety device used to guard against adverse burner operating characteristics that can result from
low gas supply pressure. Switch opens at not less than 6.5″w.c. and closes at no greater than 10.2″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 reestablish normal heating operation. 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.
PROCEDURE 9—LABEL APPLICATION (SEE FIG. 12A AND 12B)
1. Fill in Conversion Responsibility Label (327697-205) and apply to inside of furnace as shown. Date, name, and address of organization
making this conversion are required.
2. Attach Conversion Rating Plate Label # 327697-206 (Single-Stage) or #327697-207 (Two-Stage) near existing furnace rating plate.
3. Apply Gas Control Conversion Label:
a. For single-stage gas valve apply label 327697-203 to gas valve. (Do not use 327697-202, which is similar)
b. For two-stage gas valve apply label 327697-202 to gas valve. (Do not use 327697-203, which is similar)
—19—
INSTALLATION
SECTION 3- DIRECT-VENT, MULTIPOISE, HOT-SURFACE IGNITION, SINGLE-STAGE, TWO-STAGE AND VARIABLE-SPEED
CONDENSING FURNACES
58MXA
58MCA
58MSA
SINGLE STAGE MODELS
350MAV
PG9MAA
340MAV
490AAV
345MAV
TWO-STAGE MODELS
58MTA
352MAV
VARIABLE SPEED MODELS
58MVP
355MAV
PROCEDURE 1—INSTALL MAIN BURNER ORIFICES
NOTE: See Fig. 26 or 27 for component location in upflow orientation. Reorient component arrangement when furnace is installed in other
positions.
1. Turn off furnace gas and electrical supplies.
2. Remove main furnace door.
3. Turn furnace gas valve switch to OFF position.
4. Remove burner enclosure front.
5. Remove gas supply pipe from gas valve.
6. Remove wires from gas valve. Note location for reassembly.
CAUTION: UNIT OPERATION HAZARD
Wiring errors will cause improper and dangerous operation. Label all wires prior to disconnection when servicing controls.
ATTENTION: D’EQUIPEMENT DANGER D’OPERATION
Toute erreur de câblage peut être une source de danger et de panne. Lors des opérations d’entretien des commandes, étiqueter tous
les fils avant de les déconnecter.
7. Remove burner-box pressure tube from gas-valve burner enclosure; reference pressure-tap fitting. (See Fig. 27.)
8. Remove screws that secure manifold to burner box and remove manifold, orifices, and gas valve as 1 assembly.
9. Remove and discard orifices from manifold.
10. Refer to conversion kit rating plate #327697-201 to determine main burner orifice size. (See Fig. 25.)
Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. In the U.S.A., the input rating for altitudes above 2000 ft must
be reduced by 2 percent for each 1000 ft above sea level.
In Canada, the input rating must be derated by 5 percent for altitudes of 2000 ft to 4500 ft above sea level.
The Conversion Kit Rating Plate accounts for high altitude derate.
11. Install main burner orifices. Do not use Teflon tape. Finger-tighten orifices at least 1 full turn to prevent cross threading, and then tighten
with wrench. There are enough orifices in each kit for the largest furnace. Discard extra orifices.
CAUTION: UNIT DAMAGE HAZARD
to follow this caution may result in excessive burner noise and misdirection of burner flames. This may result in flame
impingement of the burners and the heat exchangers, causing failures.
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. (See Fig. 1.)
→ Failure
NOTE: DO NOT reinstall the manifold, orifices, gas-valve assembly, and burner enclosure front at this time.
PROCEDURE 2—REPOSITION AIR SHUTTER (VARIABLE SPEED 355MAV060120 AND 58MVP120-20 ONLY)
1. Remove 2 screws holding air shutter in natural gas usage (NAT) position.
2. Reposition air shutter to propane gas usage (PROP) position. (See Fig. 18.) Screws will now be located in the shutter next to the PROP
stamp.
NOTE: Air opening above burners will now be partially obstructed by air shutter.
PROCEDURE 3—INSTALL DIVERTER PLATE (TWO-STAGE AND VARIABLE SPEED CONDENSING FURNACES ONLY)
Install diverter plate (provided in kit) above combustion air intake box as follows:
1. Remove front 2 screws on combustion air intake box. (See Fig. 19.)
2. Remove combustion air intake box and set aside. (See Fig. 19.)
3. If air diffuser has a solid center, remove center section of air diffuser.
a. Remove burners.
—20—
PROPANE
GAS
POSITION
AIR
SHUTTER
A96264
Fig. 18—Air Shutter in Propane Gas Usage (PROP) Position
(355MAV060120 and 58MVP120-20 Units Only)
b. Remove center solid portion of air diffuser. (See Fig. 20.) Use tin snips to cut center portion of air diffuser. Do not overly distort air
diffuser. The air diffuser is Tog-L-Locked to burner box.
c. Replace burners.
COMBUSTION AIR
INTAKE BOX SCREWS
COMBUSTION
AIR INTAKE BOX
A95443
Fig. 19—Removing Combustion Air Intake Box
CUT OUT
CENTER
AIR
DIFFUSER
A95449
Fig. 20—Removing Center Section of Air Diffuser
4. Install diverter plate Part No. 323184-301 provided in kit. (See Fig. 21.)
5. Reinstall combustion air intake box and replace 2 screws to ensure diverter plate is properly installed. (See Fig. 19.)
—21—
DIVERTER PLATE
PART NO. 323184-301
A95450
Fig. 21—Installing Diverter Plate
PROCEDURE 4—INSTALL MANIFOLD ASSEMBLY, ALL FURNACES
1. Reinstall manifold, orifice, and gas-valve assembly in burner box. Ensure manifold seal grommet is installed properly and burners fit over
orifices. Verify Igniter to Burner alignment (See Fig. 31.)
2. Reconnect wires to gas valve. Refer to furnace wiring schematic for proper wire location.
3. Reinstall burner box pressure tube to gas-valve regulator fitting.
4. Apply pipe dope sparingly to end of inlet gas pipe and reconnect gas supply pipe to gas valve using backup wrench on gas valve to prevent
rotation and improper orientation.
NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.
NOTE: DO NOT reinstall burner enclosure front at this time.
PROCEDURE 5—PRE-ADJUST GAS VALVE
A. Convert and Pre-Adjust Single Stage Gas Valve
NOTE: The following furnaces MUST have the regulator spring replaced in the gas valve
58MCA
58MXA
58MSA
340MAV
350MAV
345MAV
PG9MAA
1. Be sure main gas and electrical supplies are off.
2. Remove regulator seal cap. (See Fig. 22A and 22B.)
3. Remove adjustment screw and natural gas regulator spring (silver).
4. Install propane gas regulator spring (white) in gas valve.
→ 5. Turn regulator adjustment screw in 6 turns for Fig. 22A and 8.5 turns for Fig. 22B.
NOTE: DO NOT reinstall regulator seal cap at this time.
B. Pre-Adjust 2-Stage and Variable Speed Gas Valve
→ NOTE: The following furnaces with Fig. D type valves DO NOT need have the regulator spring replaced in the gas valve, but the valve MUST
be pre-adjusted for propane applications. The following furnaces with Fig. 22C type valve MUST have both springs replaced another valve must
be pre-adjusted:
58MTA
352MAV
58MVP
355MAV
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in excess underfire and flashback.
The gas valve must be pre-adjusted before operating on propane gas. If left this way sooting and corrosion will occur leading to early
heat exchanger failure.
—22—
REGULATOR
SEAL CAP
REGULATOR
SEAL CAP
REGULATOR
ADJUSTMENT
SCREW
ON AND
OFF SWITCH
REGULATOR
ADJUSTMENT
SCREW
ON/OFF SWITCH
REGULATOR SPRING
(PROPANE – WHITE, 6 TURNS
NATURAL – SILVER, 10 TURNS)
REGULATOR SPRING
(PROPANE - WHITE, 8.5 TURNS
NATURAL - SILVER, 8.5 TURNS)
GAS PRESSURE
REGULATOR
ADJUSTMENT
INLET
PRESSURE TAP
GAS PRESSURE
REGULATOR
ADJUSTMENT
INLET
PRESSURE TAP
MANIFOLD
PRESSURE TAP
MANIFOLD
PRESSURE TAP
Fig. 22A—Single Stage Gas Valve
A01073
→ Fig. 22B—Single Stage Gas Valve
A04112
REGULATOR COVER SCREW
PLASTIC ADJUST SCREW
ON/OFF SWITCH
REGULATOR SPRING
HIGH STAGE GAS
PRESSURE REGULATOR
ADJUSTMENT
(PROPANE–WHITE, 13.5 TURNS
NATURAL–SILVER,12 TURNS)
LOW STAGE
GAS PRESSURE
REGULATOR ADJUSTMENT
(PROPANE–WHITE, 9.5 TURNS
INLET
PRESSURE TAP
NATURAL–SILVER,9.5 TURNS)
MANIFOLD
PRESSURE TAP
→ Fig. 22C—Two Stage Gas Valve
A04048
→ FOR FIG. 22C
1. Be sure gas and electrical supplies to furnace are off.
2. Remove caps that conceal adjustment screws for high-and low-heat stage gas valve regulators. (See Fig. 22C.)
3. Turn low-heat stage adjusting screw clockwise (in) 9.5 turns. This will increase the manifold pressure closer to the propane low-heat set
point.
4. Turn high-heat stage adjusting screw clockwise (in) 13.5 turns. This will increase the manifold pressure closer to the propane high-heat
set point.
5. Replace caps that conceal gas valve regulator adjustment screws.
FOR FIG. 22D
1. Be sure gas and electrical supplies to furnace are off.
2. Remove caps that conceal adjustment screws for high-and low-heat stage gas valve regulators. (See Fig. 22D.)
3. Turn low-heat stage adjusting screw (3/32-in. hex allen wrench) clockwise (in) 1 full turn. This will increase the manifold pressure closer
to the propane low-heat set point.
4. Turn high-heat stage adjusting screw (3/32-in. hex allen wrench) clockwise (in) 2 full turns. This will increase the manifold pressure closer
to the propane high-heat set point.
5. Replace caps that conceal gas valve regulator adjustment screws.
PROCEDURE 6—INSTALL LOW GAS PRESSURE SWITCH (LGPS), ALL FURNACES
NOTE: The inlet gas pipe must be disconnected from valve so pressure switch can be installed.
NOTE: Use propane-gas-resistant pipe dope on all connections to prevent gas leaks. DO NOT use Teflon tape.
1. Be sure main gas and electric supplies to furnace are off.
—23—
ON/OFF
SWITCH
INLET
PRESSURE
TAP
FF
O
ON
LOW-HEAT
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
HIGH-HEAT
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
PLUG BUTTON
(2-STAGE AND
VARIABLE–SPEED,
NON–CONDENSING
FURNACES ONLY)
MANIFOLD
PRESSURE
TAP
BURNER ENCLOSURE
REFERENCE PRESSURE TAP(2-STAGE
AND VARIABLE-SPEED, CONDENSING
FURNACES ONLY)
A01069
Fig. 22D—Two-Stage Gas Valve
2. Remove 1/8-in. pipe plug from inlet pressure tap on gas valve. (See Fig. 22A, 22B, 22C, or 22D.) DO NOT DISCARD PLUG!
3. Apply pipe dope sparingly to the ends of the 1/8″ brass male coupling (provided in kit) and install it in 1/8-in. tapped opening in gas valve
inlet pressure-tap. Tighten fitting with a small wrench.
4. Attach the female end of the female x female x male brass tee (provided in kit). Tighten fitting with a small wrench so the male portion
of the tee points out from the furnace.
5. Apply pipe dope sparingly to male end of bras tee. Install propane low gas pressure switch (provided in kit) on nipple. After switch has
been finger tightened, use small wrench on base of pressure switch for final tightening. When pressure switch is tight, switch terminals
should point as shown in Fig. 22A, 22B, 22C, or 22D relative to gas valve and clear control compartment access door.
6. Connect a manometer to the open end of the tee installed in the gas valve.
PROCEDURE 7—CHECK INLET GAS PRESSURE
NOTE: This kit is to be used only when inlet gas pressure is between 11.0-in. wc and 13.6-in. wc.
1. Verify manometer is connected to inlet pressure tap on gas valve.
→
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in flame rollout, overheating the heat exchangers, etc. and reduce unit life.
DO NOT operate furnace more than 1 minute to check inlet gas pressure, as conversion is not complete at this time.
2. Turn on furnace power supply.
3. Turn gas supply manual shutoff valve to ON position.
4. Turn furnace gas valve switch to ON position.
5. For single stage models, jumper R to W.
6. For two-stage and variable speed models, perform the following steps to force furnace control board to high-heat operation.
For Two-Stage furnaces with HK42FZ017 board, perform the following on the control board:
–Turn LHT switch on furnace control to ON (See Fig. 8C.)
For Two-Stage furnaces with HK42FZ010 or HK42FZ015 boards, perform the following on the control board:
–Turn switch #2 on furnace control board to ON. (See Fig. 17A and 17B.)
For Variable Speed furnaces using HK42FZ012 control boards, perform the following on the control board:
–Turn Setup Switch SW1-2 on furnace control ON. (See Fig. 23.)
For Variable Speed furnaces using HK42FZ022 control boards, perform the following on the control board:
–Turn Setup Switch SW1-2 on furnace control ON. (See Fig. 8D.)
7. Jumper R-W/W1 and R-W2 thermostat connections on control.
8. When main burners ignite, confirm inlet gas pressure is between 11.0-in. w.c. and 13.6-in. w.c.
9. Remove jumper across R to W or R-W/W1 and R-W2 thermostat connections to terminate call for heat.
10. Turn furnace gas valve switch to OFF position.
—24—
P4
P1
P3
W2 COM W/W1 Y/Y2 R
24V
G HUM
ON
FLT (FAULT CODE RECALL)
1
LOW HEAT ONLY
2
BPH (BYPASS HUMIDIFIER)
3
EMERGENCY HEAT
4
5
6
HEATING BLOWER
OFF TIME DELAY
7
8
MZ (MULTI ZONE)
COMPONENT TEST
A94299
Fig. 23—Variable Speed Condensing Furnace Control Board
11. Turn gas supply manual shutoff valve to OFF position.
12. Turn off furnace power supply.
13. Remove manometer.
14. Apply pipe dope sparingly to end of inlet gas pipe plug and install in unused end of 1/8″ tee. Use a small back-up wrench on tee when
tightening gas inlet pipe plug. (See Fig. 7A.)
PROCEDURE 8—MODIFY PRESSURE SWITCH WIRING
A. Modify Single Stage Pressure Switch Wiring
(Refer to furnace wiring diagram)
1. Disconnect yellow wire from pressure switch (PRS) on furnace inducer housing. Attach wire to C terminal on low gas pressure switch
(LGPS).
2. Connect insulated terminal of 16-in. yellow wire (provided in kit) to NO terminal on low gas pressure switch (LGPS). Connect other (flag
style insulated) end to the C terminal on furnace pressure switch (PRS) located on inducer housing.
3. Route wires along wire harness. Secure with wire tie provided in kit. Go to Procedure 9.
B. Modify 2-Stage and Variable Speed Pressure Switch Wiring
(Refer to furnace wiring diagram)
1. Disconnect orange wire from low-heat pressure switch LPS on inducer housing.
2. Connect un-insulated terminal of 1 orange wire (provided in kit) to splice connector. Connect other end to C terminal on low gas pressure
switch LGPS.
3. Connect insulated terminal of second orange wire (provided in kit) to NO terminal on low gas pressure switch LGPS. Connect other end
to pressure switch LPS located on inducer housing.
4. Route orange wires along wire harness. If possible, secure with wire tie provided in kit. Go to Procedure 9.
PROCEDURE 9—CHECK FURNACE OPERATION AND MAKE NECESSARY ADJUSTMENTS
1. Be sure main gas and electric supplies to furnace are off.
2. Remove 1/8-in. pipe plug from manifold pressure tap on downstream side of gas valve. (See Fig. 22A, 22B, 22C, or 22D.)
3. Attach manometer to manifold pressure tap on gas valve. (See Fig. 24.)
4. Turn gas supply manual shutoff valve to ON position.
5. Turn furnace gas valve switch to ON position.
6. Check all threaded pipe connections for gas leaks.
—25—
BURNER ENCLOSURE
(REMOVE COVER WHEN
CHECKING PRESSURE)
GAS VALVE
PRESSURE
SWITCH(ES)
(LOCATION WILL VARY
DEPENDING ON MODEL)
MANOMETER
7
6
5
4
3
2
1
0
1
2
3
4
5
6
7
A01070
Fig. 24—Adjusting Manifold Pressure (Manifold Attachment)
7. Turn on furnace power supply.
WARNING: FIRE, EXPLOSION, INJURY OR DEATH HAZARD
Failure to follow this warning could result in fire, explosion, personal injury, or death.
NEVER use matches, candles, flame, or other sources of ignition to check for gas leakage. Use a soap-and-water solution to check
for gas leaks.
PROCEDURE 10—SET GAS INPUT RATE INFORMATION
The gas input rate for propane is the same as for natural gas. See furnace rating plate (See Fig. 25.) for input rate. The input rate for propane is
determined by manifold pressure and orifice size. The gas-valve regulator must be set for low heat first and then set for high heat on 2-Stage and
Variable Speed furnaces. The gas valve regulator must also be adjusted on Single Stage furnaces.
NOTE: Manifold pressure must always be measured with the burner enclosure front removed. (See Fig. 27.) Furnace gas input rate on rating plate
is for installations at altitudes up to 2000 ft.
In the U.S.A., the input rating for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level.
In Canada, the input rating must be derated by 5 percent for altitudes of 2000 ft to 4500 ft above sea level.
The Conversion Kit Rating Plate accounts for high altitude derate.
A.
Set Gas Input Rate on Single Stage Furnaces
1. Jumper R and W thermostat connections to call for heat. (See Fig. 8A or 8B.)
2. Check manifold orifices for gas leaks when main burners ignite.
3. Adjust gas manifold pressure.
a. Remove burner box cover (See Fig. 27) and gas valve regulator seal cap that conceal adjustment screw. (See Fig. 22A or 22B.)
NOTE: Manifold pressure MUST always be measured with burner box cover removed.
b. Turn adjusting screw counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure.
NOTE: Gas valve regulator seal cap MUST be in place when checking input rate.
c. When correct input is obtained, main burner flame should be clear blue, almost transparent. (See Fig. 28.) Be sure regulator seal cap is
in place when finished.
4. Remove jumper across R and W thermostat connections to terminate call for heat.
5. Turn furnace gas valve control switch or control knob to OFF position.
6. Turn off furnace power supply.
7. Remove manometer and replace manifold pressure tap plug. (See Fig. 22A, 22B, 22C, or 22D.)
NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.
8. Reinstall burner box cover.
9. Turn furnace gas valve control switch or control knob to ON position.
10. Turn on furnace power supply.
11. Set room thermostat to call for heat.
12. Check manifold pressure tap plug for gas leaks when main burners ignite.
—26—
CONVERSION KIT RATING PLATE - CARRIER CORP.
THIS APPLIANCE HAS BEEN CONVERTED TO USE PROPANE GAS FOR FUEL. REFER
PROCEDURES. USE PARTS SUPPLIED BY CARRIER CORPORATION AND INSTALLED BY
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 above sea level. In U.S.A.
be derated by 2% for each 1000 ft above sea level. In Canada the input rating must be derated by 5%
TO KIT INSTRUCTIONS FOR CONVERSION
QUALIFIED PERSONNEL.
the input rating for altitudes above 2000 ft must
for altitudes of 2000 ft to 4500 ft above sea level.
KIT NO. KGANP3001ALL (SUPERSEDES: KGANP2701LPS, KGANP2801F80, KGANP2901ALL) FUEL USED: PROPANE GAS
INLET PRESSURE (min - max): 11.0 - 13.6 in. wc
ALTITUDE OF INSTALLATION (FT. ABOVE SEA LEVEL) U.S.A. *
APPLIANCE MODELS
340MAV, 345MAV, 350MAV,
490AAV, 58MCA, 58MSA,
58MXA, PG9MAA
(All model sizes EXCEPT 140)
340MAV, 350MAV, 490AAV,
58MXA, 58MCA, PG9MAA
(140 Model Size ONLY)
0
to 2000
2001 *
to 3000
3001
to 4000
4001
to 5000
5001
to 6000
6001
to 7000
7001
to 8000
8001
to 9000
9001
to 10000
Orifice No.
Mnfld Press
55
10.0
55
10.0
55
10.0
55
10.0
1.25mm
11.0
1.25mm
11.0
1.25mm
11.0
1.25mm
11.0
1.25mm
11.0
Orifice No.
54
54
54
54
54
54
54
54
54
Mnfld Press
11.0
10.5
10.5
10.0
10.0
10.0
10.0
10.0
Orifice No. 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm
352MAV, 355MAV,
Mnfld Press 11.0 /
11.0 /
11.0 /
11.0 /
11.0 /
11.0 /
58MTA, 58MVP
High / Low
5.4
5.1
5.1
5.1
5.0
5.0
* For Canadian Installations from 2000 to 4500 ft use U.S.A. column 2001 to 3000 ft.
10.0
1.25mm
11.0 /
5.0
1.25mm 1.25mm
11.0 /
11.0 /
4.9
4.9
327697-201 REV. B
A04121
→ Fig. 25—Conversion Kit Rating Plate
13. Observe unit operation through 2 complete heating cycles. See sequence of operation in furnace Installation, Start-up and Operating
Instructions.
14. Set room thermostat to desired temperature.
B. Set Gas Input Rate on Two-Stage and Variable Speed Furnaces
Furnace control boards should have already been set up to respond to individual W1 and W2 signals (see Procedure 7, No. 6). Additional
information can be found in furnace installation instructions.
1. Jumper R and W/W1 thermostat connections to call for heat.
2. Check manifold orifices for gas leaks when main burners ignite.
3. Adjust gas manifold pressure.
a. Remove caps that conceal adjustment screws for gas valve regulators. (See Fig. 22C or 22D.)
b. Adjust low-heat input rate manifold pressure for propane gas. (See kit rating plate #327697-201 Rev. B)
c. Turn low-heat adjusting screw counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.
d. Main burner flame should be clear blue, almost transparent. (See Fig. 28.)
4. Jumper R and W2 on control center thermostat connections. This keeps furnace locked in high-heat operation.
a. Adjust high-heat input rate manifold pressure for propane gas. (See kit rating plate #327697-201 Rev. B)
b. Turn high-heat adjusting screw (5/64 hex allen wrench) counterclockwise (out) to decrease input rate or clockwise (in) to increase input
rate.
c. Remove jumper across R, W1, and W2 after high-heat adjustment to terminate call for heat.
d. Replace caps that conceal gas-valve regulator adjustment screws. (See Fig. 22C or 22D.)
e. Main burner flame should be clear blue, almost transparent. (See Fig. 28.)
5. Turn setup switch LHT or SW-2 on control center to OFF position.
6.
7.
8.
9.
Turn furnace gas-valve switch to OFF position.
Turn off furnace power supply.
Remove manometer and reattach manifold pressure tap plug.
Reinstall burner enclosure front.
10. Turn furnace gas-valve switch to ON position.
11.
12.
13.
14.
Turn on furnace power supply.
Set room thermostat to call for heat.
Check pressure tap plug for gas leaks when main burners ignite.
Check for correct burner flame.
15. Observe unit operation through 2 complete heating cycles. See sequence of operation in furnace Installation, Start-Up, and Operating
Instructions.
16. Set room thermostat to desired temperature.
PROCEDURE 11—CHECK LOW GAS PRESSURE SWITCH OPERATION
The newly installed low gas pressure switch is a safety device used to guard against adverse burner operating characteristics that can result from
low gas supply pressure. Switch opens at not less than 6.5″ w.c. and closes at not greater than 10.2″ w.c.
—27—
GAS CONTROL
CONVERSION
LABEL
FURNACE
RATING
PLATE
BURNER
ENCLOSURE
RESPONSIBILITY
LABEL
GAS VALVE
CONTROL
FURNACE CONVERSION
RATING PLATE
A01025
Fig. 26—Condensing Furnace Label Location
BURNER
ENCLOSURE
MANIFOLD
BURNER
ENCLOSURE
REFERENCE
PRESSURE TUBE
GAS VALVE
CONTROL
A01081
Fig. 27—Multipoise, Hot-Surface Ignition, Fixed-Speed,
Condensing Furnace Component Location (Upflow Orientaion Shown)
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.
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.
PROCEDURE 12—LABEL APPLICATION
See Fig. 26 for label location.
1. Fill in Conversion Responsibility Label (327697-205) and apply to blower access panel as shown. Date, name, and address of organization
making this conversion are required.
2. Attach Conversion Rating Plate Label (327697-201 Rev. B, See Fig. 25.) on blower shelf as shown.
—28—
;;;;
BURNER FLAME
BURNER
MANIFOLD
A89020
Fig. 28—Burner Flame
9/32”
11/32”
7/8”
A02150
Fig. 29A—Position of Igniter to Burner (Section 1)
A02150
Fig. 29B—Picture of Igniter to Burner (Section 1)
→
→
3. Apply Gas Conversion Label.
a. For Single Stage Furnaces, apply label 327697-203 to burner box cover as shown. (Do not use 327697-202 which is similar)
b. For two-stage gas valve that was converted by replacing the regulator spring (Fig. 22C) apply label 327697-203.
c. For two-stage gas valve that was adjusted (Fig. 22D) apply label 327697-202.
4. Reinstall main furnace door.
—29—
11 32"
13 32"
BURNER
CELL
PANEL
HOT
SURFACE
IGNITOR
ASSEMBLY
C
L
7 8"
IGNITOR
C
L
BURNER
IGNITOR
ASSEMBLY
A93347
Fig. 30—Position of Igniter to Burner (Section 2)
13 32"
11 32"
BURNER
CELL
PANEL
BURNER BOX
IGNITOR
ASSEMBLY
C
L
IGNITOR
C
L
BURNER
7 8"
IGNITOR
ASSEMBLY
A93260
Fig. 31—Position of Ignitor to Burner (Section 3)
—30—
—31—
© 2004 CAC/BDP
7310 W. Morris St., Indianapolis, IN 46231
agganp31 —32—
Catalog No. 63GA-NP11