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