CARRIER Controls And HVAC Accessories Manual L0801202

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Installation Instructions

NOTE: Read the entire instruction manual before starting the

installation.

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due

to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions

such as cleaning and replacing air filters. Trained service

personnel must perform all other operations. When working on

heating equipment, observe precautions in the literature, on tags,

and on labels attached to or shipped with the unit, and other

safety precautions that may apply.

Follow all safety codes. In the United States. follow all safety

codes including the National Fuel Gas Code (NFGC) NFPA No.

54-2006/ANSI Z223.1-2006. In Canada, refer to the National

Standard of Canada, Natural Gas and Propane Installation Codes

(NSCNGPIC), CAN/CGA-B149.1 and .2-M05.

Wear safety glasses and work gloves. Have a fire extinguisher

available during start-up, adjustment steps, and service calls.

Recognize safety information. This is the safety-alert symbol

/_. When you see this symbol on the furnace and in

instructions or manuals, be alert to the potential for personal

injury.

Understand the signal words DANGER, WARNING. CAUTION

and NOTE. The words DANGER, WARNING, and CAUTION

are used with the safety-alert symbol. DANGER identifies the

most serious hazards which will result in severe personal injury or

death. WARNING signifies a hazard which could result in

personal injury or death. CAUTION is used to identify unsafe

practices which may result in minor personal injury or product

and property damage. NOTE is used to highlight suggestions

which will result in enhanced installation, reliability, or operation.

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

injury or death.

This conversion kit shall be installed by a qualified service

agency in accordance with the manufacturer's instructions

and all applicable codes and requirements of the authority

having jurisdiction. If the information in these instructions

is not followed exactly, a fire, explosion, or production of

carbon monoxide may result causing property damage,

personal injury, or loss of life. The qualified service agency

is responsible for the proper installation of this furnace with

this kit. The installation is not proper and complete until the

operation of the converted appliance is checked as specified

in the manufacturer's instructions supplied with the kit.

INTRODUCTION

This instruction covers the installation of gas conversion kit Part

No. KGANP4301STM to convert the following furnaces from

natural gas usage to propane gas usage:

Models 58MVC and 355CAV 4-Way Multipoise. Hot Surface

Ignition, Variable-Speed. Step-Modulating, Condensing

Furnaces. This kit is designed for use in furnaces with 60,000

through 120,000 Btuh gas input rates.

This kit is designed for use in the furnaces listed above. The gas

valve will be a White-Rodgers.

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning 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 nmst use only

factory-authorized kits or accessories when servicing this

product.

Table1- Kit Contents

DESCRIPTION PART NO. QUANTITY

Main Burner Orifice (Drill Size 1.25 mm) LH32DB209 7

Screw, Spoiler DO NOT USE 327593-401 7

Diverter Plate 323184-301 1

Low Gas Pressure Switch (Propane) (LGPS) HK02LB008 1

Nipple CA52JZ103 1

90 ° Street Elbow (1/8 in.) CA15RA001 1

Male X Female X Female Tee (1/8 in.) CA21JZ001 1

Splice Connector (1/4 in. Male, Both Ends) 66175D55 1

Splice Connector (3/16 in. Male, Both Ends) HY89SC047 1

Orange Wire Assembly (18 in.) W182X23 04 018 2

Wire Tie HY76TB125 1

Conversion Rating Plate Label Condensing Furnaces 333583-201 1

Conversion Responsibility Label 333583-203 1

Gas Control Conversion Label (adjusted) 333583-202 1

Installation Instructions IIKKGANP4301STMO01 1

Regulator Spring Kit (White Propane-EF39W023) for White- 92-0659 2

Rodgers 36J Valve

DESCRIPTION AND USAGE

This kit is designed for use in the furnaces listed above. See Table

1 for kit contents. To accommodate many different furnace

models, more parts are shipped in kit than will be needed to

complete conversion. When installation is complete, discard extra

parts.

INSTALLATION

DIRECT VENT, VARIABLE-SPEED, 4-WAY

MULTIPOISE, STEP-MODULATING CONDENSING

FURNACES

VARIABLE SPEED MODELS

58MVC (Multipoise) 355CAV (Multipoise)

Step 1-- Install Main Burner Orifices

NOTE: See Fig. 2 for component location in UPFLOW

orientation. Reorient component arrangement when furnace is

installed in other positions.

A96249

Fig. 1 - Burner Orifice

FIRE, EXPLOSION, ELECTRICAL SHOCK

HAZARD

Failure to follow this warning could result in personal

injury, death or property damage.

Gas supply MUST be shut off before disconnecting

electrical power and proceeding with conversion.

1. Turn off furnace gas and electrical supplies.

2. Remove main furnace door.

3. Turn furnace gas valve switch to OFF position.

4. Remove burner enclosure front.

5. Remove gas supply pipe from gas valve.

6. Remove wires from gas valve. Note location for reas-

sembly.

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage or

improper operation.

Label all wires prior to disconnection when servicing

controls.

7. Remove burner-box pressure tube from gas valve burner

enclosure; reference pressure-tap fitting. (See Fig. 2).

8. Remove screws that secure manifold to burner box and re-

move manifold, orifices, and gas valve train as one as-

sembly.

9. Remove and discard orifices from manifold.

10. Refer to conversion kit rating plate 333583-201 to deter-

mine main burner orifice size. (See Fig. 3.)

Furnace gas input rate on furnace rating plate is for installations at

altitudes up to 2000 ft. In the U.S.A.; the input rating for altitudes

above 2000 ft. must be reduced by 2 percent for each 1000 ft.

above sea level.

In Canada, the input rating must be derated by 5 percent for

altitudes of 2000 ft. to 4500 ft. above sea level.

The Conversion Kit Rating Plate accounts for high altitude

derate.

11. Install main burner orifices. Do not use Teflon tape. Fin-

ger-tighten orifices at least one full turn to prevent cross-

threading, then tighten with wrench. There are enough ori-

fices in each kit for largest furnace. Discard extra orifices.

BURNER

D'4CLOSURE

MANIFOLD

THROTTLING

VALVE

BURNERENCLOSURE

REFFERENCETUBE

GAS VALVE

CONTORL

AO6692

Fig. 2 - Multipoise Variable Speed Condensing Furnace

Component Location

NOTE: DO NOT reinstall the manifold, orifices, gas-valve

assembly, and burner enclosure front at this time.

UNIT DAMAGE 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. (See Fig. 1.)

Step 2 -- Reposition Air Shutter

Remove two screws holding air shutter in natural gas usage

(NAT) position.

1. Reposition air shutter to propane gas usage (PROP) posi-

tion. (See Fig. 4). Screws will now be located in the shut-

ter next to the PROP stamp.

NOTE: Air opening above burners will now be partially

obstructed by air shutter.

Step 3 -- Install Diverter Plate

1. Install diverter plate (provided in kit) above combustion

air intake box as follows:

a. Remove front two screws on combustion air intake box.

(See Fig. 5.)

b. Remove combustion air intake box and set aside.

c. Install diverter plate Part Number 323184-301 provided

in kit. (See Fig. 6.)

d. Reinstall combustion air intake box and replace two

screws to ensure diverter plate is properly installed. (See

Fig. 5.)

/CONVERSION KIT RATING PLATE - CARRIER CORE

T_L_ APPUARCE HAS B_EN CONVERTED TO USE PEOPARE GA_ FOR FUEL REFER TO KiT _MSTRUCT_N_ FOR

CONVERt;lOB PROCEO_REE, USE PART5 SUPPLIED BY CARBIER CORPORATION AND [NETALLBB BY _JALFIEB PERSONNEL,

R;ED EXIR;TING EATING PLATE FOR; APPt3ANCE MODEL N0. AND iNPUT P,ATNG_

KT fi0KG#_P_Z_I_ F%L U_E0:PROPANEGAS N_T PRESSU,__ - ram::I - 3_ _ _'_

ALTITUDE OF INBTALLATION {FT, ABOVE S_A LEVEL) U,B.A, *

APPLIANC_ NOD_L8 0 2001 _ 3001 4001 5001 0001 7001 8001 _001

_0 2000 tO,3000 tO 4000 IO 5000 _o 6000 tO _OO0 tO 8000 I0 9000 _0 10000

58MVC, 355CAM Orifice No. %25mm !.25mm 1,25mm 1,25mm 1,25mm 1,25mm 1.25mm !.25mm 1,25mm

M_fld #ross

High 1%0 /1!.0 /!1.0 ¢11,0 /11.0 i11.0 /11.0 f11.0 /110 /

M_ 5.8 /5.5 /5.5 /5=5 _ 5.4 /5.4 /B=4 _ 5=3 /5.3

Low 2.2 2.! 2_1 2.1 2.1 2.0 2.0 2.0 2.13

ForCanadianinstalhtions from 2000to 4,500ft. useLI,R;J',.column200"tte 3000ft, :,'_33583,.20t REVA

Fig. 3 - Conversion Kit Rating Plate

A07831

GAS

POSITION PROP

o NAT

Fig. 4- Air Shutter in Propane Gas Usage (PROP) Position

A96264

A06693

Fig. 5- Removing Combustion Air Intake Box Fig. 6-Installing Diverter Plate

A06695

Fig. 7 - Igniter to Burner

A06_6

Fig. 8 - Position of Igniter to Burner

A06697

Step 4-- Install Manifold Assembly

1. Reinstall manifold, orifice, and gas-valve assembly in

burner box. Ensure manifold seal grommet is installed

properly and burners fit over orifices. Verify Igniter to

Burner alignment. See Fig. 7 and 8.

2. Reconnect wires to gas valve. Refer to furnace wiring

schematic for proper wire location.

3. Reinstall burner box pressure tube to gas-valve regulator

fitting.

NOTE: DO NOT reinstall burner enclosure front at this time.

INLET

PRESSURE

ON/OFF

NIGH HEAT

(UNDER CAP)

BURNER

ENCLOSURE

REFFERENCE

TAP

MEDIUM NEAT

ADJUSTMENT

(UNDERCAP) LOW HEAT /

ADJUSTMENT ...............

(UNDERCAP) MANIFOLD

PRESSURE

TAP

A07280

Fig. 9 -Redundant Automatic Gas Valve with Throttling

Valve

Step 5 -- Replace Regulator Springs and Pre-adjust

Gas Valve

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage

The gas valve must be pre-adjusted before operating on

propane gas. If left non-modified, sooting and corrosion

will occur leading to early heat exchanger failure.

1. Be sure gas and electrical supplies to furnace are off.

2. Remove caps that conceal adjustment screws for high-,

medium-, and low-heat stage gas-valve regulators. (See

Fig. 9.)

3. Remove the high-heat and medium-heat regulator adjust-

ment screws.

4. Remove the high-heat and medium-heat gas regulator

springs (silver).

5. Install the high-heat and medium heat propane gas regu-

lator springs (white).

6. Install the high-heat and medium-heat regulator adjust-

ment screws.

7. 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. 9.)

8. Turn medium-heat stage adjusting screw clockwise (in)

9.5 full turns. This will increase the manifold pressure

closer to the propane medium-heat set point. (See Fig. 9.)

_8" brass male coupling

brass female x female x

male tee for installing LGPS

Fig. 10 - Gas Valve Inlet Pressure tap

A05155

Manomete__

connection _ _

Fig. 11 -LGPS Installed

A05191

9. Turn low-heat stage adjusting screw (flat blade screw-

driver screw) clockwise (in) the number of turns shown in

Table 2. This will increase the manifold pressure closer to

the propane low-heat set point. (See Fig. 9.)

10. Do not install regulator seal caps at this time.

Table 2 -Low Stage Pie-Adjustment

Model Number of Turns

042060 /060-14 1%

042080 /080-14 2 Vz

060080 /080-20 2 _/z

060100 /100-20 3

060120 /120-20 3 _/_

Step 6 -- Install Low Gas Pressure Switch (LGPS)

NOTE: Use propane-gas resistant pipe dope on all connections

to prevent gas leaks. DO NOT use Teflon tape.

1. Be sure main gas and electric supplies to furnace are off.

2. Remove 1/8-in. pipe plug from inlet pressure tap on gas

valve. (See Fig. 9.) DO NOT DISCARD PLUG!

3. Apply pipe dope sparingly to the ends of 1/8 in. brass

male coupling (provided in kit) and install it in 1/8 in.

tapped opening in gas valve inlet pressure-tap. Tighten

fitting with a small wrench. (See Fig. 10.)

4. Attach the female end of the female x female x male brass

tee (provided in kit). Tighten fitting with a small wrench

so the male portion of the tee points out from the furnace.

(See Fig. 10.)

5. Apply pipe dope sparingly to male end of brass tee. Install

propane low gas pressure switch (provided in kit) on

nipple. After switch has been finger tightened, use small

wrench on base of pressure switch for final tightening.

When pressure switch is tight, switch terminals should

point as shown in Fig. 11 relative to gs valve and clear

control compartment access door.

6. Apply pipe dope sparingly to end of inlet gas pipe and

connect gas supply pipe to gas valve using backup wrench

on gas valve to prevent rotation and improper orientation.

7. Connect a manometer to the open end of the tee installed

in the gas valve. (See Fig. 11.)

Step 7-- Check Inlet Gas Pressure

NOTE: This kit is to be used only when inlet gas pressure is

between 11.0-in. wc and 13.6-in. wc.

1. Veri_, manometer is connected to inlet pressure tap on gas

valve.

UNIT 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.

GAS VALVE

-2_4

2. Turn on furnace power supply.

3. Turn gas supply manual shutoff valve to ON position.

4. Turn furnace gas valve switch to ON position.

5. Turn Setup Switch SW4-2 on furnace control ON (see

Fig. 13)

6. Jumper R-W/W1 and R-W2 thermostat connections on

control.

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 thermostat

connections to terminate call for heat.

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.

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. 11)

MANOMETER

BURNER ENCLOSURE

THROTTLING VALVE

PRESSURE

SWITCHES

Fig. 12 -Checking Line Pressure

A06701

USERINTERFACE CONTINUOUSFAN SW4 SETU_

ORADVANCEO (OF)AI_LOW SWITCHES

PRODUCT SETUPSWITCHES OAT

MODEL PLUG MONFTO_ CONNECTOR

_LOWER O_ - " OAJ

DELAY

(A/C) AIR FlOW

SFUP SW_TCHES _'

115VAC (_2)NEUTRAL

CONNECTIONS

PEt LOWVOLTAGEMAFN _ EXAMPLE:

HARNESSCONNECTOR

soFrwAfl_ pART DATE

VERSION NUMBER COD_

NUM_

VOLTA_ CONNECTIONS

Fig. 13 - Furnace Control

HUMIDIFIER

TEflM_NAL(2_VAC

0,5 AMPMA×,

CONDmONING

RELAYD_SABLE

JUMPE_

CONNECTOR

(FACTORY

ONLY)

\ PL3 ECMB_OWE_

HARNESS

N_ONNECTO_

NUMBER

PL2 HOTSURFACE

_GNITE__INOUCER

MOTORCONNECTOR

A07422

Step 8 -- Pressure Switch Wiring (refer to furnace

wiring diagram)

1. Disconnect orange wire from low-heat pressure switch

LPS on inducer housing.

2. Connect uninsulated terminal of one orange wire (pro-

vided in kit) to splice connector. Connect other end to C

terminal on low gas pressure switch LGPS. Connect the

other end of the splice connector to the orange wire dis-

connected in Step 1.

3. Connect insulated terminal of second orange wire (pro-

vided in kit) to N.O. terminal on low gas pressure switch

LGPS. Connect other end to pressure switch LPS located

on inducer housing.

4. Route orange wires along wire harness. If possible, secure

with wire tie provided in kit.

Step 9 -- Check Furnace Operation and Make

Necessary Adjustments

1. Be sure main gas and electric supplies to furnace are off.

2. Remove 1/8-in. pipe plug from manifold pressure tap on

throttling valve. (See Fig. 9.)

3. Attach manometer to manifold pressure tap on throttling

valve (See Fig. 14.)

4. Turn gas supply manual shutoff valve to ON position.

5. Turn furnace gas valve switch to ON position.

6. Check all threaded pipe connections for gas leaks.

7. Turn on furnace power supply.

Step 10 -- Gas Input Rate Information

The gas-input rate for propane is the same as for natural gas. See

furnace rating plate (Fig. 16) for input rate. The input rate for

propane is determined by manifold pressure and orifice size (See

Fig. 3.) The gas-valve regulator must be set for high heat first,

then medium heat and then set for low heat.

NOTE: Manifold pressure MUST always be measured with the

burner enclosure front REMOVED. (See Fig. 2.) Furnace gas

input rate on rating plate is for installations at altitudes up to 2000

ft.

In the U.S.A.. the input rating for altitudes above 2000 ft. must be

reduced by 2 percent for each 1000 ft. above sea level.

In Canada, the input rating must be derated by 5 percent for

altitudes of 2000 ft. to 4500 ft. above sea level.

The Conversion Kit Rating Plate accounts for high altitude

derate.

Step 11 -- Set Gas Input Rate

BURNER ENCLOSURE

(REMOVE COVBR WHEN

CHECKING PRESSURE}

GAS VALVE

THROTTLING VALVE

MANOMETER

AD06702

Fig. 14 - Adjusting Manifold Pressure (Manifold Attachment)

1. Setup switch SW4-2 on control center should already be

in the ON position. If not, put setup switch SW4-2 in the

ON position. (See Fig. 13.) This keeps furnace locked in

medium-heat operation.

2. Jumper R and W/W1 and R to W2 thermostat connections

on furnace control. (See Fig. 13.) This keeps furnace

locked in high-heat operation.

3. Turn high-heat adjusting screw (3/32 hex Allen wrench)

counterclockwise (out) to decrease manifold pressure or

clockwise (in) to increase manifold pressure.

4. Remove jumper across R to W/W2.

5. Wait one minute then turn medium-heat adjusting screw

(3/32) hex Allen wrench) counterclockwise (out) to de-

crease manifold pressure or clockwise (in) to increase

manifnld pressure.

6. Remove jumper across R to W/W1.

7. Wait for blower off-delay to finish then reset 115-v power

to furnace.

8. Move setup switch SW4-2 to OFF position.

9. Jumper R to W/W1 thermostat connections on control to

start furnace.

10. Wait for the blower to turn ON then check low-heat mani-

fold pressure. Remove the low-heat adjustment cap (See

Fig. 9) and turn the low-heat adjusting screw clockwise

(in) to decrease manifold pressure or counterclockwise

(out) to increase manifold pressure. You will only have 15

minutes to make and adjustment. If you need more time

then move setup switch (SW1-2 on control center to ON

position (See Fig. 13.)

11. When correct manifold pressures are obtained, replace

caps that conceal gas valve adjustment screws. Min burn-

er flame should be clear blue. almost transparent. (See

Fig. 15.)

12. Remove jumper across R to W/W1. If necessary move

setup switch SW1-2 to the OFF position.

13. Turn furnace gas valve control switch or control knob to

OFF position.

14. Turn off furnace power supply.

15. Remove manometer and reattach manifold pressure tap

plug to the throttling valve. (See Fig. 9.)

16. Reinstall burner enclosure front.

17. Turn furnace gas valve switch to ON position.

18. Turn on furnace power supply.

19. Set room thermostat to call for heat.

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.

See Sequence of Operation in furnace Supplemental In-

structions.

23. Set room thermostat to desired temperature.

Step 12 -- Check Low Gas Pressure Switch Operation

The newly installed low gas pressure switch is a safety device

used to guard against adverse burner operating characteristics that

can result from low gas supply pressure. Switch opens at not less

than 6.5 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.

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.

BURNER FLAME

BURNER

MANIFOLD

Fig. 15 - Burner Flame

A89020

Step 13 -- Label Application

1. Fill in Conversion Responsibility Label 333583-203 and

apply to Blower Access Door of furnace as shown. (See

Fig. 16.) Date. name. and address of organization making

this conversion are required.

2. Attach Conversion Rating Plate Label 333583-201, see

Fig. 16 to Outer Door of furnace.

3. Apply Gas Control Conversion Label to gas valve: Apply

label 333583-203 to gas valve.

4. Reinstall main furnace door.

GASCONTROL

LABEL

RATING

PLATE

LABEL

FURNACECONVERSION

RATINGPLATE

BURNER

ENCLOSURE

-GASVALVE

CONTROL

A01025

Fig. 16 -Condensing Furnace Label Location

Manufacturer rese_'es the tight to change, at any time. specifications and designs without notice and without obllgatlolls.

Catalo_ No: IIKKGANP4301STM001

Rep_aoes: New

CARRIER Controls And HVAC Accessories Manual L0801202

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