Westinghouse High Altitude Pressure Switch Conversion Kit Installation Instruction

LP & HIGH ALTITUDE LP GAS CONVERSION KIT
FOR INSTALLATIONS IN THE UNITED STATES
Installation Instructions
For *G7 / *GC2 & GUH* / GDD* Series Furnaces & Appliances Using Honeywell Gas Valves
BEFORE THE CONVERSION
IMPORTANT: Please read all instructions before
converting the furnace. Pay attention to all safety
warnings and any other special notes highlighted in the
manual. Safety markings are used frequently throughout
this manual to designate a degree or level of seriousness
and should not be ignored. WARNING indicates a
potentially hazardous situation that if not avoided, could
result in personal injury or death. CAUTION indicates a
potentially hazardous situation that if not avoided, may
result in minor or moderate injury or property damage
DESCRIPTION
QTY
Honeywell Conversion Kit 396221
(to convert VR8205S2890 or VR8215S1289)
1
Honeywell Conversion Kit 396021
(to convert VR8205Q2381)
1
Honeywell Conversion Kit 50033841
(to convert VR9205Q1127)
1
#55 Drill Size Burner Orifice Kit
(contains (7) 661055)
1
This conversion kit is only to be used to convert natural
gas furnaces to LP/Propane gas in the United States.
For installations in Canada, the Canadian conversion kit
must be used.
#56 Drill Size Burner Orifice Kit
(contains (7) 661056)
1
#57 Drill Size Burner Orifice Kit
(contains (7) 661057)
1
Table 1 is a detailed listing of the components in the LP
gas conversion kit. Please check the contents of the
conversion kit with that of the parts listing, and familiarize
yourself with each component.
#59 Drill Size Burner Orifice Kit
(contains (3) 661059)
1
#60 Drill Size Burner Orifice Kit
(contains (3) 661060)
1
#61 Drill Size Burner Orifice Kit
(contains (3) 661061)
1
Conversion Warning Label
Conversion Information Label
Installation Instructions
1
1
1
IMPORTANT: When converting a low NOx furnace from
natural gas to LP/Propane gas, it is necessary to remove
the NOx Baffles from the furnace.
WARNING:
FIRE OR EXPLOSION HAZARD
• Failure to follow safety warnings exactly
could result in serious injury or property
damage.
• Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
• Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbors phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call
the fire department.
DO NOT DESTROY.
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
Table 1. LP Gas Conversion Kit
WARNING:
All gas piping must conform with local building
codes, or in the absence of local codes, with
the most recent edition of the National Fuel Gas
Code ANSI Z223.1. DO NOT attempt to modify,
or tap into existing gas lines yourself. Fire or
explosion may result causing property damage,
personal injury or loss of life. Failure to follow the
safety warnings exactly could result in serious
injury, death or property damage.
WARNING:
All electrical wiring must comply with the latest
edition of the National Electrical Code ANSI/
NFPA 70. Failure to follow these instructions
could result in possible damage to equipment,
serious personal injury, or death.
CONVERTING TO LP/PROPANE GAS AT
ALTITUDES BETWEEN ZERO & 10,000 FT.
Converting single stage valves to LP/Propane requires the
replacement of the burner orifices and/or the spring found
under the cap screw in the pressure regulator. Converting
2 - stage valves to LP/Propane requires the replacement
of the burner orifices and/or the stem/spring assembly in
the pressure regulator.
Table 2 (page 3), provides the manifold pressure for
altitudes above 2,000 feet.
WARNING:
Shut off the gas supply at the manual gas shutoff
valve, before disconnecting the electrical power.
A fire or explosion may result causing property
damage, personal injury or loss of life. Failure to
follow the safety warnings exactly could result
in serious injury, death or property damage.
6. Remove the wires from the terminals (3) of the gas
valve (6).
7. Remove the supply gas piping from the gas valve
inlet (5).
8. Carefully remove four screws (8) securing the gas
manifold assembly (7) to the burner assembly (9).
9. Set the screws (8) aside and remove the gas manifold
assembly (7) from the appliance.
10.Carefully remove the burner orifices (2) from the gas
manifold assembly (7).
11.Read the rating plate affixed to the appliance to
determine its rated input (Btu/hr) and the size of the
factory installed orifices.
IMPORTANT NOTE: Before installing an orifice, check
the side or face of the orifice for the drill number to
ensure that it is the appropriate size.
12.Install the appropriate LP/Propane gas burner orifices
(2) into the gas manifold assembly (7).
NOTE: To prevent cross threading, hand tighten the
orifices (2) into the gas manifold assembly (6) until
snug, then tighten with a wrench.
WARNING:
To avoid electric shock, personal injury, or death,
turn off the electric power at the disconnect
or the main service panel before making any
electrical connections.
WARNING:
The reduction of input rating necessary for high
altitude installation may only be accomplished
with factory supplied orifices. Do not attempt to
drill out orifices in the field. Improperly drilled
orifices may cause fire, explosion, carbon
monoxide poisoning, personal injury or death.
WARNING:
Do not use Teflon tape or pipe joint compound
on the orifice threads. The hole in the orifice
may become blocked and cause fire, explosion,
property damage, carbon monoxide poisoning,
personal injury, or death.
13.Reinstall the gas manifold assembly (7) to the burner
assembly (9) with the 4 screws (8), that were removed
earlier. NOTE: It is important that the center of the
orifices (2) are aligned with the center of the burners
(1).
14.Reconnect the gas piping to the gas valve inlet (5).
15.Reconnect the wires to the gas valve terminals (3).
5
Before You Convert the Gas Valve
1. Turn the thermostat OFF or to its lowest temperature
setting.
2. Verify the gas supply is shut OFF.
3. Verify the electrical power to the appliance is turned
OFF.
Removing The Burner Orifices
1. Set the thermostat to the OFF position, or its lowest
temperature setting.
2. Shut OFF the gas supply at the manual shutoff valve
located outside of the appliance.
3. Turn off all electrical power to the appliance.
4. Remove the door from the burner compartment.
5. Move the gas valve ON/OFF switch (4) to the OFF
position as shown in Figure 1. For VR8205Q2381 gas
valves, turn the knob to the OFF position.
2
1
6
2
4
3
7
9
8
Figure 1. Burner & Manifold Assembly
Table 2. Liquid Propane Conversion Chart
3
*G7TC / *GC2TC
*G7TL / *GC2TL
GUH95T*
*G7TA / *GC2TA
*G7TK / *GC2TK
*G7SC / *GC2SC
*G7SL / *GC2SL
*G7SD / *GC2SD
*G7SM / *GC2SM
GUH92A* GDD92A*
GUH95A / GDD95A*
*G7SA / *GC2SA
*G7SK / *GC2SK
GUH80A* / GDD80A*
FURNACE
MODEL
10.0
10.0
10.0
56
56
55
55
55
55
55
55
55
90,000
108,000
118,000
120,000
60,000
80,000
100,000
120,000
140,000
10.0
55
55
55
55
60,000
80,000
100,000
120,000
4.2
10.0
10.0
10.0
4.2
Low Fire
10.0
10.0
10.0
10.0
10.0
10.0
10.0
56
72,000
10.0
10.0
56
60
10.0
54,000
38,000 (SD)
10.0
56
56
126,000
56
108,000
38,000 (SC)
10.0
56
10.0
56
10.0
10.0
10.0
90,000
56
72,000
57
54,000
Low Fire
2,000 to 2,999 FT
3,000 to 4,999 FT
5,000 to 5,999 FT
6,000 to 7,999 FT
8,000 to 10,000 FT
55
55
55
55
55
55
55
55
55
55
55
56
56
56
56
60
56
56
56
56
56
56
57
3.8
9.0
9.0
9.0
9.0
3.8
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
55
55
55
55
55
55
55
55
55
55
55
56
56
56
56
60
56
56
56
56
56
56
57
3.6
8.5
8.5
8.5
8.5
3.6
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
56
56
56
56
56
56
56
56
56
56
56
57
57
57
57
61
57
57
57
57
57
57
59
4.2
10.0
10.0
10.0
10.0
4.2
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
8.5
10.0
10.0
10.0
10.0
10.0
10.0
10.0
56
56
56
56
56
56
56
56
56
56
56
57
57
57
57
61
57
57
57
57
57
57
59
3.8
9.0
9.0
9.0
9.0
3.8
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
8.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
56
56
56
56
56
56
56
56
56
56
56
57
57
57
57
61
57
57
57
57
57
57
59
3.6
8.5
8.5
8.5
8.5
3.6
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
7.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
ORIFICE MANIFOLD ORIFICE MANIFOLD ORIFICE MANIFOLD ORIFICE MANIFOLD ORIFICE MANIFOLD ORIFICE MANIFOLD
SIZE
PRESSURE
SIZE
PRESSURE
SIZE
PRESSURE
SIZE
PRESSURE
SIZE
PRESSURE
SIZE
PRESSURE
0 to 1,999 FT
45,000
INPUT
ALTITUDE ABOVE SEA LEVEL
Single Stage Honeywell Valves
2 - Stage Honeywell Valves
Models: VR8205S2890 or VR8215S1289
Model VR8205Q2381
IMPORTANT NOTE: When converting to LP/
Propane gas from natural gas, the black spring in
the gas valve must be replaced by the red spring
in the kit.
IMPORTANT NOTE: When converting to LP/
Propane gas from natural gas, the white stem/
spring assembly in the gas valve must be replaced
by the black stem/spring assembly in the kit.
1. Remove the cap screw from the gas valve as shown
in Figure 2.
1. Remove two screws (1) securing the pressure
regulator cover assembly (2) to the gas valve. See
Figure 4.
2. Remove the pressure regulator cover assembly (2)
from the gas valve.
3. Remove and discard the existing stem/spring
assembly (3) from the gas valve.
4. Install the replacement stem/spring assembly (3)
from the conversion kit.
5. Reinstall the pressure regulator cover assembly (2)
onto the gas valve.
6. Install the two screws (1) and tighten.
7. Affix the label from the conversion kit to the gas
valve
Cap screw
(VR8205S2890 shown)
2 Adjustment Screws
(beneath cap)
Figure 2. Cap Screw Removal
2. Remove and discard the plastic pressure regulator
adjustment screw from the gas valve. See Figure
3.
3. Remove the black colored spring from the gas valve.
4. Install the red spring from the conversion kit.
5. Install the new adjusting screw from the kit.
6. Check and adjust the regulator setting. See Gas
Adjusting Screw
2
1
3
Spring
(VR8205S2890 shown)
Figure 3. Pressure Regulator Spring &
Adjustment Screw Removal
Pressure Adjustment Section (page 5).
7. Reinstall the cap screw.
8. Affix the label from the conversion kit to the gas
valve.
Figure 4. Spring / Stem Assembly Removal
4
Gas Pressure Adjustment
Model VR9205Q1127
IMPORTANT NOTES:
• When converting to LP/Propane gas from natural
gas, the springs from gas valve must be replaced
by the larger springs from the kit.The LP/Propane
springs for both HIGH & LOW fire are the same
size, shape and color.
• Use only a Torx-25 or 3/16” flathead screwdriver
when removing adjustment screws or during
pressure adjustment.
1. Remove the HIGH fire cap screw. See Figure 5.
2. Remove and discard the HIGH fire adjustment screw
from the gas valve.
3. Remove the spring from the gas valve and discard.
4. Install a larger spring from the conversion kit.
5. Install a new adjusting screw from the kit.
Low Fire
Cap Screw
High Fire
Cap Screw
Measuring the Supply Gas Pressure
1. Turn OFF the gas supply at the manual valve located
on the outside of the unit.
2. Using a 3/16” Allen wrench, remove the plug from the
inlet pressure tap (INLET side of gas valve). See Figure
6.
3. Install an 1/8” NPT pipe thread fitting, that is compatible
with a Manometer or similar pressure gauge.
4. Connect the Manometer or pressure gauge to the Inlet
Pressure Tap.
5. Turn ON the main gas supply at the manual valve.
6. Check and adjust the incoming gas line pressure to
11.0-14.0 inches Water Column for LP/Propane gas.
7. Turn OFF the gas supply at the manual valve.
8. Disconnect the Manometer or pressure gauge.
9. Remove the NPT fitting and reinstall the INLET pressure
tap plug. Hand tighten the plug first to prevent crossthreading. Tighten with 3/16 Allen wrench.
Lighting & Adjustment of the Appliance
Low Fire
Adjustment Screw
High Fire
Adjustment Screw
Spring
WARNING:
Spring
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury or property damage.
Figure 5. Pressure Regulator Spring &
Adjustment Screw Removal
6. Repeat steps 1 - 5 for replacement of the LOW fire
spring and adjustment screw.
7. Check and adjust the regulator setting. See Gas
Pressure Adjustment Section.
8. Reinstall the cap screws on the HIGH and LOW
regulators. Plastic replacement cap screws are
provided in the conversion kit.
9. Affix the label from the conversion kit to the gas
valve.
Never test for gas leaks with an open flame. Use
a commercially available soap solution made
specifically for the detection of leaks to check
all connections. A fire or explosion may result
causing property damage, personal injury or
loss of life.
1. Turn ON the manual gas valve, located on the outside
of the unit to the ON position.
2. Check all gas connections for leaks with a soap and
water solution. If the solution bubbles there is a gas
leak which must be corrected.
3. Turn on the electrical power to the appliance.
4. Place the gas valve ON/OFF switch/knob to the ON
position. See Figure 6.
2-STAGE VALVES
SINGLE STAGE VALVES
Inlet
Pressure
Tap
Inlet
Pressure
Tap
ON/OFF
Knob
ON/OFF
Switch
Manifold
pressure
Tap
IN
ON/OFF
Switch
Model VR8215S1289
Manifold
Manifold
pressure
pressure
Tap
Tap
Model VR8205S2890
Inlet
Pressure
Tap
ON/OFF
Switch
ON
OFF
Manifold
pressure
Tap
Model VR8205Q2381
Model VR9205Q1127
Inlet
Pressure
Tap
Figure 6. Inlet & Manifold Pressure Tap Locations
5
5. Set the thermostat above room temperature to begin
the heating cycle of the furnace.
6. Check that the furnace ignites and operates properly.
Refer to the installation instructions provided with the
unit for the normal operating sequence.
7. After ignition, visually inspect the burner assembly to
ensure that the flame is drawn directly into the center of
the heat exchanger tube. In a properly adjusted burner
assembly, the flame color should be blue with some light
yellow streaks near the outer portions of the flame.
Note: The ignitor may not ignite the gas until all air is
bled from the gas line. If the ignition control locks out,
turn the thermostat to its lowest setting and wait one
minute then turn the thermostat above room temperature
and the ignitor will try again to ignite the main burners.
This process may have to be repeated several times
before the burners will ignite. After the burners are lit,
check all gas connections for leaks again with the soap
and water solution.
Measuring the Manifold Pressure
The manifold pressure must be measured by installing a
pressure gauge (Manometer, Magnehelic Meter, etc.) to
the outlet end of the gas valve as follows:
1. Turn off all electrical power to the appliance.
2. Shut OFF the gas supply at the manual shutoff valve
located outside of the appliance.
3. Using a 3/16” Allen wrench, remove the manifold
pressure tap plug located on the outlet side of the gas
valve. See Figure 6 (page 5).
4. Install an 1/8” NPT pipe thread fitting, that is compatible
with a Manometer or similar pressure gauge.
5. Connect the Manometer or pressure gauge to the
manifold pressure tap.
6. Set the room thermostat above room temperature to
start the furnace.
7. Allow the furnace to operate for 3 minutes and then
check the manifold pressure. Compare the measured
value with the value shown in Table 2 (page 3). If the
manifold pressure is not set to the appropriate pressure,
then it must be adjusted.
Adjusting the Manifold Pressure
NOTE: Adjustments must be made to both LOW & HIGH
fire settings when converting two-stage gas valves. Refer
to Table 2 for manifold pressures.
1. Single stage gas valve: Remove the cap screw from
the top of the gas valve regulator. See Figure 2 (page
4) for VR8205S2890 or VR8215S1289 models.
2-stage gas valve: For VR8205Q2381 models, remove
the plastic cap covering the adjustment screws (Figure
4 page 4). For VR9205Q1127 models, remove the cap
screw (Figure 5, page 5).
2. Using a screwdriver or Allen wrench (where appropriate),
slowly turn the adjustment screw till the appropriate
manifold pressure listed in Table 2 is achieved. See
6
Figure 2 for VR8205S2890 or VR8215S1289 models.
See Figure 4 for VR8205Q2381 models or Figure 5 for
VR9205Q1127 models.
NOTE: Turning the screw clockwise increases the
pressure, turning the screw counter-clockwise
decreases the pressure. To prevent the screw from
backing all the way out from the valve, turn the screw
slowly.
3. Replace and tighten the cap screw or the plastic cap
over the adjustment screw.
Removing the Manometer/Pressure Gauge
After the manifold pressure is properly adjusted, the
Manometer or pressure gauge must be removed from
the gas valve.
1. Turn the thermostat to its lowest setting.
2. Turn OFF the main gas supply to the unit at the manual
shut-off valve, which is located outside of the unit.
3. Turn OFF all of the electrical power supplies to the unit.
4. Remove the pressure gauge adapter from the gas valve
and replace it with the 1/8” NPT manifold pressure plug
that had been removed earlier. NOTE: Make sure the
plug is tight and not cross-threaded.
5. Turn ON the electrical power to the unit.
6. Turn ON the main gas supply to the unit at the manual
shut-off valve.
COMPLETING THE CONVERSION
WARNING:
Do not alter or remove the original rating plate
from the furnace.
1. Attach the following labels:
• The conversion warning label (P/N 703935) should
be affixed to the outside of the unit door.
• The conversion information label (P/N 703942)
should be affixed near the rating plate on the inside
of the control area.
• The gas valve conversion label should be affixed
on the gas valve.
NOTE: Each label should be prominently visible after
installation.
2. Reinstall the appliance door.
3. Run the appliance through 3 complete cycles to assure
proper operation.
7
The installer performing this work assumes all responsibility for this conversion. These instructions are primarily
intended to assist qualified individuals experienced in the proper installation of these components. Some local codes
require licensed installation/service personnel for this type of equipment. Safety should always be the deciding
factor when installing this product and using common sense plays an important role as well. Improper installation of
the components or failure to follow safety warnings could result in serious injury, death, or property damage. After
completing the installation, return these instructions to the Homeowner’s Package for owner-user’s future reference.
Specifications & illustrations subject to change without notice or incurring obligations (05/15).
O’Fallon, MO, © Nortek Global HVAC LLC 2015. All Rights Reserved.
709369A (Replaces 7093690)