Carrier 58CVA110 10020 User Manual FURNACE Manuals And Guides 1209611L
User Manual: Carrier 58CVA110---10020 58CVA110---10020 CARRIER FURNACE - Manuals and Guides View the owners manual for your CARRIER FURNACE #58CVA11010020. Home:Heating & Cooling Parts:Carrier Parts:Carrier FURNACE Manual
Open the PDF directly: View PDF 
.
Page Count: 34
| Download | |
| Open PDF In Browser | View PDF |
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.
SECTION
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. KGAPN4401VSP
the installation
of gas conversion
kit Part
to convert the following
furnaces from
Propane gas usage to natural
for your furnace type.
gas usage.
See appropriate
2--59TN6,
Surface
59TN6
and PG96V_T
Section
986T,
Ignition, 2-Stage,
applies to 60,000
applies
3--58CVA,
PG96V_T,
4-Way
Table 2 - Condensing Furnaces
MODEL NUMBERS BEGINNING WITH:
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.
MANIFOLD/ORIFICE/BURNER
REMOVAL
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
1
Multipoise,
Hot
Variable-Speed
Condensing
Furnaces.
to 120,000 Btuh gas input rates. 986T
to 40,000
to 120,000
Btuh gas input rates.
58CVX,
315AAV,
315JAV,
[]NIT
OPERATION
HAZARD
Failure to follow this caution may result in unit damage or
improper operation.
Label all wires prior to disconnection
controls.
when servicing
PG8MVA,
PG8JVA, 33.3-In.(846
mm) High, Induced-Combustion,
HotSurface
Ignition,
2-Stage,
Variable-Speed,
Non-Condensing
Furnaces.
This kit is designed
for use in furnaces with 42,000
through
154,000
D'EQUIPEMENT
Btuh gas input rates.
DESCRIPTION
AND
D'OPERATION
Toute erreur de cfiblage peut _tre une source de danger
USAGE
et de
panne.
See Table 1 for kit contents. This kit is designed for use in the
furnaces listed in Tables 2, 4 and 6. To accommodate
many
different furnace models, more parts are shipped in kit than will
be needed to complete
discard extra parts.
conversion.
When
319965-450
323267-701
323267-702
323267-703
323267-704
338305-701
338305-702
338305-703
338305-704
CA64ASO01
AG- KGAPNVSP-XX
EF39ZW037
QTY
1
1
1
1
1
1
1
1
1
PCS
PCS
PCS
PCS
PCS
PCS
PCS
PCS
PCS
Otiqueter
is complete,
NOTE:
Table I - KGAPN4401VSP
COMPONENT
NUMBER
installation
Lors des opOrations d'entretien
des commandes,
tous les ills avant de les dOconnecter.
Contents
DESCRIPTION
LABEL, SHIPPING
PARTS ASSY #42
PARTS ASSY #43
PARTS ASSY #44
PARTS ASSY #45
LABEL KIT
LABEL KIT
LABEL KIT
LABEL KIT
1 PCS
1 PCS
PLUG, PIPE
INSTRUCTIONS
2 PCS
VALVE CVRSN KIT
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 gas valve
from the furnace casing. See Fig. 1.
2. Disconnect
the connector
harness
to prevent
the mounting
and remove
from gas valve.
the
to
pipe
Discon-
nect wires from Hot Surface Igniter (HSI) and Flame
Sensor. Disconnect
the two wires from the low gas pressure switch (LGPS)
located
on the gas valve.
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
re-assembly
later. See Fig. 2.
5. Slide one-piece
burner box.
burner
6. Remove
Fig. 3.
the flame
7. Remove
the orifices
assembly
sensor
from
wire ground
wire for
out of slots on sides of
the burner
from the manifold
assembly.
and discard.
See
/
CAPAC]TO_
POWERCHOKE
REPRESENTATIVE
DRAW]N G ONLY, SOME
MODELS
MAY VARY
IN APPEARANCE
Al1408
Fig. 1 - Component
Orifice
Location
ORIFICE
SELECTION/DERATE
Manifold
/
Connect
ground
Green/Yellow
wire
UNIT
DAMAGE
HAZARD
Failure
to follow
this caution
may result in unit damage.
here
DO NOT re-drill
burner
result in burrs, out-of-round
J
Gas Valve
orifices. Improper
drilling may
holes, etc. Obtain new orifices
if orifice size must be changed.
Gas valve is parallel
CLwithin + or - 3
Gas
valve
must
to manifold
be installed
(See Fig. 4.)
,'_ :/
j
on
manifold
with minimum
engagement
6 threads,
Cross threading
is not
acceptaMe.
of
A96249
Fig. 4 - Burner
Al1486
Fig. 2 - Modulating
Gas Valve with
Orifices
Deternfine
correct
BURNER
SUP]:
gas orifice
at installed
size
altitude
and
manifold
by using
Table
pressures
for
3 (for 20,000
Btuh/Max-Heat/8000
Btuh Min-Heat
per Burner) or Table
(For 20,200 Btuh Max Heat/8,000 Btuh Min-Heat
per Burner).
IGNITER
ASSY
natural
input
Orifice
1. Obtain yearly heat-value
local gas supply.
2. Obtain
TER
yearly
average
specific-gravity
(at installed
average
altitude)
4
for
for local gas sup-
ply.
BURNER_SY
3. Find installation
on Nrnace
NOTE:
_
_"""_
F_IMEHROLLOUT
For Canada
4. Find closest
altitudes
of 2000
natural
Al1403
Assembly
to 4500
gas heat value
Table 3 or Table 4, depending
BURNER)
Fig. 3 - Burner
in Table 3 or Table 4, depending
ft. (610
to 1372
M), use U.S.A. Altitudes of 2001 to 3000 ft. (610 to 914 M) in
Table 3 or Table 4, depending
on Nrnace gas input rate.
FLA M E SENSOR
(BELOW
altitude
gas input rate.
and specific
on Nrnace
gravity
in
gas input rate.
5. Follow heat-value
line and specific-gravity
line to point
of intersection
to find orifice size and maximum
and nfinimum manifold
pressure
settings.
Table 3 - Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate
To be used with Modulating Furnaces EXCEPT 59MNTA060V21-20 and 987MA60060V21
MODULATING
(TABULATED
DATA
BASED
ON 20,000
DERATED
ALTITUDE
AVG.
RANGE
ft(m)
113
C
C
113
c
Orifice
Mnfld Press
GRAVITY
OF NATURAL
0.60
Orifice
Mnfld Press
GAS
0.62
Orifice
Mnfld
0.64
Press
Orifice
Mnfld
Press
900
No.
42
Max/Min
3.2 /0.50
No.
42
Max/Min
3.3 /0.55
No.
42
Max/Min
3.4 /0.55
925
43
3.6 /0.55
43
3.7 /0.60
43
3.8 /0.60
42
3.2 /0.50
950
43
3.4 /0.55
43
3.5 /0.55
43
3.6 /0.60
43
3.7 /0.60
975
44
3.7 /0.60
44
3.8 /0.60
43
3.4 /0.55
43
3.6 /0.55
1000
44
3.5 /0.55
44
3.6 /0.60
44
3.8 /0.60
43
3.4 /0.55
1025
44
3.3 /0.55
44
3.5 /0.55
44
3.6 /0.55
44
3.7 /0.60
2000
1050
44
3.2 /0.50
44
3.3 /0.55
44
3.4/0.55
44
3.5 /0.55
(610)
1075
45
3.7 /0.60
45
3.8 /0.60
44
3.3 /0.50
44
3.4/0.55
1100
46
3.7 /0.60
46
3.8 /0.60
45
3.8 /0.60
44
3.2 /0.50
U.S.A.
800
42
3.4 /0.55
42
3.5 /0.55
42
3.6 /0.55
42
3.7 /0.60
2001 (611)
825
43
3.8 /0.60
42
3.3 /0.50
42
3.4 /0.55
42
3.5 /0.55
to
850
43
3.6 /0.60
43
3.7 /0.60
42
3.2 /0.50
42
3.3 /0.55
3000 (914)
875
43
3.4 /0.55
43
3.5 /0.55
43
3.7 /0.60
43
3.8 /0.60
900
44
3.7 /0.60
44
3.8 /0.60
43
3.5 /0.55
43
3.6 /0.55
Canada
925
44
3.5 /0.55
44
3.6 /0.60
44
3.8 /0.60
43
3.4 /0.55
2001 (611)
950
44
3.3 /0.55
44
3.4/0.55
44
3.6 /0.55
44
3.7 /0.60
to
975
44
3.2 /0.50
44
3.3 /0.50
44
3.4/0.55
44
3.5 /0.55
4500 (1372)
1000
46
3.8 /0.60
45
3.8 /0.60
44
3.2 /0.50
44
3.3 /0.55
775
42
3.3 /0.55
42
3.4 /0.55
42
3.5 /0.55
42
3.6 /0.60
3001
800
43
3.8 /0.60
42
3.2 /0.50
42
3.3 /0.55
42
3.4 /0.55
(915)
825
43
3.6 /0.55
43
3.7 /0.60
43
3.8 /0.60
42
3.2 /0.50
850
44
3.8 /0.60
43
3.5 /0.55
43
3.6 /0.55
43
3.7 /0.60
875
44
3.6 /0.60
44
3.7 /0.60
43
3.4 /0.55
43
3.5 /0.55
4000
900
44
3.4/0.55
44
3.5 /0.55
44
3.7 /0.60
44
3.8 /0.60
(1219)
925
44
3.2 /0.50
44
3.4/0.55
44
3.5 /0.55
44
3.6 /0.55
950
45
3.7 /0.60
44
3.2 /0.50
44
3.3 /0.55
44
3.4/0.55
750
42
3.3 /0.50
42
3.4 /0.55
42
3.5 /0.55
42
3.6 /0.55
4001
775
43
3.7 /0.60
43
3.8 /0.60
42
3.3 /0.50
42
3.4 /0.55
(1220)
800
43
3.5 /0.55
43
3.6 /0.60
43
3.7 /0.60
43
3.8 /0.60
825
44
3.8 /0.60
43
3.4 /0.55
43
3.5 /0.55
43
3.6 /0.60
850
44
3.5 /0.55
44
3.7 /0.60
44
3.8 /0.60
43
3.4 /0.55
5000
875
44
3.3 /0.55
44
3.5 /0.55
44
3.6 /0.55
44
3.7 /0.60
(1524)
900
44
3.2 /0.50
44
3.3 /0.50
44
3.4/0.55
44
3.5 /0.55
925
46
3.8 /0.60
45
3.7 /0.60
44
3.2 /0.50
44
3.3 /0.55
725
42
3.2 /0.50
42
3.3 /0.55
42
3.4 /0.55
42
3.5 /0.55
5001
750
43
3.7 /0.60
43
3.8 /0.60
42
3.2 /0.50
42
3.3 /0.55
(1525)
775
43
3.4 /0.55
43
3.5 /0.55
43
3.7 /0.60
43
3.8 /0.60
800
44
3.7 /0.60
44
3.8 /0.60
43
3.4 /0.55
43
3.5 /0.55
825
44
3.5 /0.55
44
3.6 /0.55
44
3.7 /0.60
44
3.8 /0.60
6000
850
44
3.3 /0.50
44
3.4/0.55
44
3.5 /0.55
44
3.6 /0.60
(1829)
875
45
3.7 /0.60
44
3.2 /0.50
44
3.3 /0.55
44
3.4/0.55
900
675
46
42
3.7 /0.60
3.4 /0.55
46
42
3.8 /0.60
3.5 /0.55
45
42
3.8 /0.60
3.6 /0.60
42
3.2 /0.50
3.8 /0.60
6001
700
42
3.2 /0.50
42
3.3 /0.50
42
3.4 /0.55
42
3.5 /0.55
(1830)
725
43
3.6 /0.60
43
3.7 /0.60
43
3.8 /0.60
42
3.3 /0.50
750
43
3.4 /0.55
43
3.5 /0.55
43
3.6 /0.55
43
3.7 /0.60
to
775
44
3.6 /0.60
44
3.7 /0.60
43
3.4 /0.55
43
3.5 /0.55
7000
800
44
3.4/0.55
44
3.5 /0.55
44
3.6 /0.60
44
3.7 /0.60
(2133)
825
44
3.2 /0.50
44
3.3 /0.55
44
3.4/0.55
44
3.5 /0.55
850
46
38/060
42._ 38/060
(o)
to
O
to
to
u')
c
SPECIFIC
0.58
PER BURNER,
SEA LEVEL)
Max/Min
3.8 /0.60
L)
u')
/ 8,000 BTUH MIN-HEAT
FT (305M) ABOVE
No.
43
0
c
113
2%H000
FURNACE
MAX-HEAT
GAS
HEAT VALUE
AT ALTITUDE
113
C
113
BTUH
O
to
--_
_
32/o.5o
_
33/o.5
Al1251A
Table 3 - Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate (Continued)
To be used with Modulating Furnaces EXCEPT 59MN7A060V21-20
and 987MA60060V21
MODULATING
(TABULATED
DATA
DERATED
ALTITUDE
SPECIFIC
HEAT VALUE
AT ALTITUDE
ft (m)
(Btu/cu
ft)
/ 8,000 BTUH MIN-HEAT
2°/o/1000 FT (305M) ABOVE
AVG. GAS
RANGE
FURNACE
BASED ON 20,000 BTUH MAX.HEAT
0.58
Orifice
Mnfid Press
PER BURNER,
SEA LEVEL)
GRAVITY
OF NATURAL
0.60
GAS
0.62
0.64
Orifice
Mnfld Press
Orifice
Mnfld Press
Orifice
Mnfid Press
No,
Max/Min
No,
Max/Min
No,
Max/Min
No,
Max/Min
650
42
3.4 /0.55
42
3.5 /0.55
42
3.6 /0.60
42
3.7 /0.60
7001
675
43
3.8 /0.60
42
3.2 /0.50
42
3.3 /0.55
42
3.4 /0.55
--_
0
(2134)
700
43
3.5 /0.55
43
3.7 /0.60
43
3.8 /0.60
42
3.2 /0.50
725
44
3.8 /0.60
43
3.4 /0.55
43
3.5 /0.55
43
3.6 /0.60
_
to
750
44
3.5 /0.55
44
3.7 /0.60
44
3.8 /0.60
43
3.4 /0.55
D
8000
775
44
3.3 /0.55
44
3.4 /0.55
44
3.5 /0.55
44
3.7 /0.60
800
45
3.8 /0.60
44
3.2 /0.50
44
3.3 /0.55
44
3.4 /0.55
825
46
3.7 /0.60
46
3.8 /0.60
45
3.8 /0.60
44
3.2 /0.50
625
42
3.4 /0.55
42
3.5 /0.55
42
3.6 /0.55
42
3.7 /0.60
8001
650
43
3.8 /0.60
42
3.2 /0.50
42
3.3 /0.55
42
3.4 /0.55
(2439)
675
43
3.5 /0.55
43
3.6 /0.60
43
3.7 /0.60
42
3.2 /0.50
43
3.5 /0.55
43
3.6 /0.55
(2438)
0=
_
700
44
3.7 /0.60
43
3.4 /0.55
725
44
3.5 /0.55
44
3.6 /0.60
44
3.7 /0.60
44
3.8 /0.60
750
44
3.3 /0.50
44
3.4 /0.55
44
3.5 /0.55
44
3.6 /0.55
775
45
3.7 /0.60
44
3.2 /0.50
44
3.3 /0.50
44
3.4 /0.55
9001
600
42
3.3 /0.55
42
3.4 /0.55
42
3.6 /0.55
42
3.7 /0.60
(2744)
625
43
3.7 /0.60
42
3.2 /0.50
42
3.3 /0.55
42
3.4 /0.55
650
43
3.5 /0.55
43
3.6 /0.55
43
3.7 /0.60
43
3.8 /0.60
to
9000
-->'
O
_
to
675
44
3.7 /0.60
44
3.8 /0.60
43
3.4 /0.55
43
3.5 /0.55
D
10000
700
44
3.4/0.55
44
3.5 /0.55
44
3.7 /0.60
44
3.8 /0.60
725
44
3.2 /0.50
4_4_
3.3 /0.55
44
3.4 /0.55
44
3.5 /0.55
_
* Orifice numbers
shown in BOLD are factory-installed.
Al1251B
Table
4 - Orifice
Size and Manifold
To Be Used with Modulating
(TABULATED
Furnaces
Pressure
(In. W.C.) for Gas Input
59MN7A060V21-20
DATA BASED ON 20,200 BTUH MAX-HEAT
Rate
and 987MA60060V21
ONLY
/ 8,000 BTUH MIN-HEAT PER BURNER,
DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL)
ALTITUDE
AVG. GAS
RANGE
HEAT VALUE
AT ALTITUDE
Orifice
Mnfld Press
Orifice
900
No.
42
Max/Min
3.2 /0.50
No.
42
Max/Min
3.3 /0.50
No.
42
0
925
43
3.7 /0.55
43
3.8 /0.60
(0)
950
43
3.5 /0.55
43
3.6 /0.55
975
44
3.8/0.60
43
to
1000
44
3.6/0.55
2000
1025
1050
44
44
(610)
1075
1100
_
<'
_.
.-_
t..
t..
Max/Min
3.4 /0.55
No.
42
Max/Min
3.5 /0.55
42
3.2 /0.50
42
3.3 /0.50
43
3.7 /0.60
43
3.8 /0.60
3.4/0.55
43
3.5/0.55
43
3.6/0.55
44
3.7/0.60
44
3.8/0.60
43
3.5/0.55
3.4 /0.55
3.3 /0.50
44
44
3.5 /0.55
3.4 /0.55
44
44
3.6 /0.55
3.5 /0.55
44
44
3.8 /0.60
3.6 /0.55
45
46
3.8 /0.60
3.8 /0.60
44
45
3.2 /0.50
3.7 /0.60
44
44
3.3 /0.50
3.2 /0.50
44
44
3.4 /0.55
3.3 /0.50
42
3.4/0.55
42
3.5/0.55
42
3.7/0.55
42
3.8/0.60
825
850
42
43
3.2/0.50
3.7/0.60
42
43
3.3/0.50
3.8/0.60
42
42
3.4/0.55
3.2/0.50
42
42
3.6/0.55
3.3/0.55
3000 (914)
875
43
3.5/0.55
43
3.6/0.55
43
3.7/0.60
43
3.8/0.60
900
44
3.8/0.60
43
3.4/0.55
43
3.5/0.55
43
3.6/0.55
925
950
975
44
44
44
3.6/0.55
3.4/0.55
3.2/0.50
44
44
44
3.7/0.60
3.5/0.55
3.3/0.50
44
44
44
3.8/0.60
3.6/0.55
3.4/0.55
43
44
44
3.4/0.55
3.7/0.60
3.6/0.55
1000
775
45
42
3.7/0.60
3.4/0.55
44
42
3.2/0.50
3.5/0.55
44
42
3.3/0.50
3.6/0.55
44
42
3.4/0.55
3.7/0.60
3001
800
42
3.2/0.50
42
3.3/0.50
42
3.4/0.55
42
3.5/0.55
(915)
825
43
3.6/0.55
43
3.7/0.60
42
3.2/0.50
42
3.3/0.50
850
43
3.4/0.55
43
3.5/0.55
43
3.6/0.55
43
3.8/0.60
to
875
44
3.7/0.60
44
3.8/0.60
43
3.4/0.55
43
3.6/0.55
4000
900
44
3.5/0.55
44
3.6/0.55
44
3.7/0.60
43
3.4/0.55
(1219)
925
44
3.3/0.50
44
3.4/0.55
44
3.5/0.55
44
3.6/0.55
950
750
45
42
3.8/0.60
3.3/0.50
44
42
3.2/0.50
3.4/0.55
44
42
3.4/0.55
3.6/0.55
44
42
3.5/0.55
3.7/0.55
4001
775
43
3.8/0.60
42
3.2/0.50
42
3.3/0.50
42
3.4/0.55
(1220)
800
43
3.6/0.55
43
3.7/0.60
43
3.8/0.60
42
3.2/0.50
825
44
3.8/0.60
43
3.5/0.55
43
3.6/0.55
43
3.7/0.60
to
850
44
3.6 /0.55
44
3.7 /0.60
43
3.4 /0.55
43
3.5 /0.55
5000
875
44
3.4 /0.55
44
3.5 /0.55
44
3.6 /0.55
44
3.8 /0.60
(1524)
900
925
44
45
3.2 /0.50
3.7 /0.60
44
44
3.3 /0.50
3.2 /0.50
44
44
3.4 /0.55
3.3 /0.50
44
44
3.6 /0.55
3.4 /0.55
Canada
2001 (611)
to
725
42
3.3 /0.50
42
3.4 /0.55
42
3.5 /0.55
42
3.6 /0.55
5001
750
43
3.7 /0.60
42
3.2 /0.50
42
3.3 /0.50
42
3.4 /0.55
(1525)
775
43
3.5 /0.55
43
3.6 /0.55
43
3.7 /0.60
42
3.2 /0.50
800
44
3.8/0.60
43
3.4/0.55
43
3.5/0.55
43
3.6/0.55
to
825
44
3.5/0.55
44
3.7/0.55
44
3.8/0.60
43
3.4/0.55
6000
850
44
3.3 /0.50
44
3.4 /0.55
44
3.6 /0.55
44
3.7 /0.60
(1829)
875
45
3.8 /0.60
44
3.3 /0.50
44
3.4 /0.55
44
3.5 /0.55
900
675
46
42
3.8 /0.60
3.5 /0.55
45
42
3.7 /0.60
3.6 /0.55
44
42
3.2 /0.50
3.7 /0.60
44
42
3.3 /0.50
3.8 /0.60
6001
700
42
3.2 /0.50
42
3.3 /0.50
42
3.5 /0.55
42
3.6 /0.55
(1830)
725
43
3.7 /0.60
43
3.8 /0.60
42
3.2 /0.50
42
3.3 /0.50
750
43
3.4/0.55
43
3.5/0.55
43
3.7/0.55
43
3.8/0.60
to
775
44
3.7 /0.60
44
3.8 /0.60
43
3.4 /0.55
43
3.5 /0.55
7000
800
44
3.5 /0.55
44
3.6 /0.55
44
3.7 /0.60
44
3.8 /0.60
(2133)
825
850
44
45
3.2 /0.50
3.7 /0.60
44
44
3.4 /0.55
3.2 /0.50
44
44
3.5 /0.55
3.3 /0.50
44
44
3.6 /0.55
3.4 /0.55
O
.-_
Mnfld Press
800
O
t..
0.64
Orifice
U.S.A.
O
_'
Mnfld Press
2001 (611)
to
__
.-_
GAS
0.62
Mnfld Press
o
t..
0.60
Orifice
ft (m)
t..
SPECIFIC GRAVITY OF NATURAL
0.58
O
Al1621A
Table
4 - Orifice
Size and Manifold
To Be Used with Modulating
(TABULATED
Pressure
Furnaces
(In. W.C.) for Gas Input
59MN7A060V21-20
DATA BASED ON 20,200 BTUH MAX-HEAT
Rate (Continued)
and 987MA60060V21
ONLY
/ 8,000 BTUH MIN-HEAT PER BURNER,
DERATED 2°/o/1000 FT (305M) ABOVE SEA LEVEL)
ALTITUDE
AVG. GAS
RANGE
HEAT VALUE
SPECIFIC GRAVITY OF NATURAL GAS
AT ALTITUDE
0.58
Orifice
=
O
Orifice
0.62
Mnfld Press
Orifice
0,64
Mnfld Press
Orifice
Mnfld Press
Max/Min
No.
Max/Min
No.
Max/Min
No.
Max/Min
No.
650
42
3.4 /0.55
42
3.6 /0.55
42
3.7 /0.60
42
3.8 /0.60
7001
675
42
3.2 /0.50
42
3.3 /0.50
42
3.4 /0.55
42
3.5 /0.55
(2134)
700
43
3.6 /0.55
43
3.7 /0.60
42
3.2 /0.50
42
3.3 /0.50
725
43
3.4 /0.55
43
3.5 /0.55
43
3.6 /0.55
43
3.7 /0.60
to
750
44
3,6 /0.55
44
3,7 /0.60
43
3.4 /0.55
43
3.5 /0.55
8000
775
44
3,4/0,55
44
3,5 /0,55
44
3,6 /0.55
44
3,7 /0,60
(2438)
800
44
3.2 /0.50
44
3.3 /0.50
44
3,4 /0,55
44
3,5 /0,55
825
46
3.8 /0.60
45
3.7 /0.60
44
3,2 /0,50
44
3,3 /0,50
625
42
3.4 /0.55
42
3.5 /0.55
42
3.7 /0.55
42
3.8 /0.60
8001
650
42
3.2 /0.50
42
3.3 /0.50
42
3.4 /0.55
42
3.5 /0.55
(2439)
675
43
3.6 /0.55
43
3.7 /0.60
43
3.8 /0.60
42
3.2 /0.50
to
700
44
3,8 /0.60
43
3.4 /0.55
43
3.6 /0.55
43
3.7 /0.55
725
44
3,6 /0,55
44
3,7 /0.60
44
3,8 /0,60
43
3.4 /0.55
750
44
3.3 /0.50
44
3,4 /0,55
44
3,5 /0,55
44
3,7 /0,55
775
600
45
3.8 /0.60
44
3,2 /0,50
44
3,3 /0,50
44
3,4 /0,55
42
3.4 /0.55
42
3.5 /0.55
42
3.6 /0.55
42
3.8 /0.60
625
43
3.8 /0.60
42
3.2 /0.50
42
3.3 /0.55
42
3.5 /0.55
650
43
3.5 /0.55
43
3.6 /0.55
43
3.8 /0.60
42
3.2 /0.50
to
675
44
3,8 /0,60
43
3.4 /0.55
43
3.5 /0.55
43
3.6 /0.55
10000
700
44
3,5 /0,55
44
3,6 /0,55
44
3,7 /0,60
44
3,8 /0,60
3,5 /0.55
4.....£_4
44
3.6 /0,55
ft (m)
--_
O
0.60
Mnfld Press
9000
__
9001
(2744)
O
_
725
4.._.L43.3/0.50
4_..&4 3.4/0.5_
* Orifice numbers shown in BOLD are factory-installed.
Al1621B
Furnace
gas input rate on furnace
rating plate is for installations
at
altitudes up to 2000 ft. (610 M).
A
In the U.S.A.; the input rating for altitudes above 2000 fl.(610 M)
must be reduced by 2 percent for each 1000 ft. (305 M) above sea
level.
In Canada,
altitudes
the input
rating
must
be derated
by
5 percent
of 2000 ft. to 4500 ft. (610 to 1372 M) above
The Conversion
derate.
Kit
Rating
Plate
accounts
for
for
l
/
1.9"
(48.76mm)
sea level.
high
/
altitude
INSTALL ORIFICES
Install
main
Finger-tighten
burner
orifices.
DO NOT
use Teflon
tape.
orifices
at least one
full turn
to prevent
cross-threading,
then tighten with wrench.
orifices in each kit for largest furnace. Discard
NOTE:
REMOVE
DO NOT reinstall
MIXER
the manifold
mm)
( \11
at this time.
SCREWS
FROM
contains
a mixer
BURNERS
Each
removed.
Refer to Fig. 5 for the mixer screw location.
the mixer screws
18"
(46.96
There are enough
extra orifices.
NOTE:
1. Remove
burner
Location of mixer screw
..._hat must be removed
l
screw
that
\\\\
must
be
Al1501
Fig. 5 - Mixer
Screw
Location
from the burners.
NOTE:
It is not necessary to plug the hole in the burner
the mixer screws are removed.
when
REINSTALL
To reinstall
BURNER
burner
1. Attach
ASSEMBLY
assembly:
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.
4. Verify igniter
to burner
alignment.
See Fig. 6 and 7.
Refer to Fig. 8 and 9.
ql
!
(64.4)
Al1405
Fig. 6 - Igniter
Position
Al1373
- Back View
Fig. 8 - Propane
Jumper
2- iiq.
(50 mm)
3/16- in.
(4.6 mm)
Al1502
Fig. 9 - Removing
A12392
Fig. 7 - Igniter
Position
- Side View
NOTE:
The
very small.
Propane
jumper
Needle-nose
Propane
Jumper
for the modulating
pliers are required
gas valve
to remove
is
the jumper
from the gas valve,
CONVERT GAS VALVE
1. Locate
valve.
the round
"LP
GAS"
sticker
on the top of the gas
2. Peel the sticker off and discard.
FIRE, EXPLOSION,
HAZARD
ELECTRICAL
SHOCK
3, Note the small square
4, Remove
opening
the small black plastic
in the top of the gas valve.
Propane
jumper
from the
gas valve.
Failure to follow this warning could result in personal
iniury, death or property damage.
Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.
5, Cover
"NAT
REMOVE
the opening
GAS"
LOW
GAS
in the gas valve with the label marked
PRESSURE
SWITCH
NOTE:
There are 2 ways that the Low Gas Pressure Switch
(LGPS) could have been installed during the original natural to
Propane gas conversion.
All 14 3/16-in. (360 mm) Casings or Vent Passes Between
Inducer Assembly and Burner Assembly
ELECTRICAL
HAZARD
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 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.
If the vent pipe passes between the inducer and burner assembly,
or the furnace is a 14 3/16-in. (360 ram) wide casing, the switch
may have been installed as follows. (See Fig 10.)
1. Remove low gas pressure switch, brass street 90 ° elbow,
brass Hex nipple, brass tee and black iron street 90 ° elbow
from the gas valve inlet pressure tap. (See Fig 10.)
Brass Street Tee
Inlet Pressure Tap
with Plug
Brass Street
Brass Nipple
Low Gas Pressure Switch
Al1517
Fig. 11 - LGPS for Casing Wider Than 14-3/16
and Vent Does Not Pass Between Inducer
and
Brass Hex Nipple
Assembly
A11367
Fig. 10 - LGPS
Passes
NOTE:
for 14-3/16
Between
(360 mm) Casing
Inducer
Use pipe dope approved
2. Apply
pipe dope
sparingly
and Burner
or When
Vent
1. Remove low gas pressure switch, brass street 90 ° elbow,
brass Hex nipple, brass Tee and brass nipple from the gas
Assembly
for use with Propane
to the l/8-in.
valve inlet pressure
gas.
NPT pipe plug
(provided
in kit) and install in the l/8-in,
tapped inletpressure tap opening in the gas valve. DO NOT overtighten. Check for gas leaks after gas supply has been
turned on.
NOTE:
2. Apply
pipe dope
Failure to follow
and/or death.
HAZARD
this warning
could result in personal
injury
explosion
may result
injury or loss of life.
causing
property
the orifices
in the manifold
2. Insert the orifices
damage,
personal
in the support
tabs should
NOTE:
If manifold
assembly
with the sup-
burners
are not fully seated
check burner positioning
3. Attach
6. Connect
pourrait
7. Rewire
entra*ner
des
forward.
Remove
and
manifold
the connector
harness
unit low pressure
terminal
to one
screws.
mounting
the wires to the flame
sensor
screws.
and hot surface
ig-
to gas valve.
switch (LPS)
as follows:
disconnected
of the LPS.
b. Trace the other orange wire previously
disconnected
from the LGPS back to its splice connection with the yellow wire of the furnace wire harness. Disconnect and discard this orange
c. Connect
wire and the splice connection.
the yellow wire of the furnace
"b" above) to the NO terminal
Casings Wider Than 14 3/16-in. (360 mm)/Vent Does Not
Pass Between Inducer and Burner Assembly
If the vent pipe does not pass between the inducer and burner
assembly, or the furnace is wider than a 14 3/16-in. (360 ram)
wide casing, the switch may have been installed as follows. (See
Fig 11.)
the manifold
a. Trace one of the orange wires previously
from the LGPS back to the NO terminals
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.
box
the burner box, the
wire and ground
mounting
4. Install the remaining
ET D'INCENDIE
Man-
in the burner box assembly.
the green/yellow
5. Connect
niter.
rings of the burners.
fit flush against the burner
does not fit flush against
of the manifold
Le fair de ne pas suivre cet avertissement
dommages
corporels et / ou la mort.
gas.
NPT pipe plug
MANIFOLD
ifold mounting
leaks with an open flame. Use a
soap solution made specifically
for
to check all connections.
A fire or
D'EXPLOSION
to the l/8-in.
port rings on the end of the burner.
NEVER
test for gas
commercially
available
the detection of leaks
RISQUE
for use with Propane
sparingly
(provided
in kit) and install in the l/8-in,
tapped inletpressure tap opening in the gas valve. DO NOT overtighten. Check for gas leaks after gas supply has been
turned on.
1. Align
AND EXPLOSION
tap. (See Fig 11.)
Use pipe dope approved
INSTALL
FIRE
(360 mm)
Burner
d. Refer to the furnace wiring diagram
tion of wires.
NOTE:
Use
only
Propane-resistant
wire harness
(see
of the LPS.
to ensure proper loca-
pipe dope,
DO NOT
use
Teflon tape.
8. 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.
9. With a back-up
finish
wrench
on the gas valve
on the manifold
tightening
wrench
or damaging
to prevent
the mounting
to
on the inlet boss of the gas valve,
the gas pipe to the gas valve.
10. Turn gas on at electric
the
switch on gas valve.
CHECK INLET GAS PRESSURE
SW4
UNIT
DAMAGE
Failure
to follow
Outside
HAZARD
SW3 Continuous
(CF) airflow setup
switches CF 1 through
CF 3
_---_
this caution may result in unit damage.
DO NOT operate
inlet gas pressure,
24 VAC
HUM Output
(O.5AMP
Air Thermi,'
furnace more than one minute to check
as conversion is not complete at this time.
Communication
NOTE:
between
This kit is to be used only when
4.5-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
FIRE, EXPLOSION,
HAZARD
inlet gas pressure
to inlet pressure
}H
is
tap on gas
supply.
shutoff
valve to ON position.
ELECTRICAL
Failure to follow
this warning
injury, death or property damage.
could
SHOCK
result
in personal
Al1471
Fig. 12 - Furnace
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
7. When main burners ignite, confirm inlet
between 4.5-in. W.C. and 13.6-in. W.C.
8. Remove jumper across
connections
to terminate
9. Turn furnace
ELECTRICAL
HAZARD
SHOCK,
FIRE
Failure to follow
this warning
injury, death or property damage.
could
OR
EXPLOSION
result
Control
manual
11. Turn off furnace
power
12. Remove
in personal
R-W/WI
and R-W2
call for heat.
gas valve switch
10. Turn gas supply
gas pressure
is
thermostat
to OFF position.
shutoff
valve to OFF position.
supply.
manometer.
13. Apply pipe dope sparingly to the l/8-in.
NPT pipe plug
and install in the l/8-in, tapped inlet-pressure
tap opening
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
in the gas valve. DO NOT over-tighten.
leaks after gas supply has been turned on.
disconnect
switch. Lock out and tag switch with a suitaMe
warning label. Verify proper operation after servicing.
CHECK
FURNACE
AND
MAKE
Check
for gas
ADJUSTMENTS
4. Turn furnace gas valve switch to ON position.
FIRE
5. Turn Setup Switch SW1-2 on furnace control ON (see
Fig. 12).
6. Jumper R-W/W1 and R-W2 thermostat connections on
control.
AND EXPLOSION
Failure to follow
and/or death.
10
HAZARD
this warning
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,
personal
5. Follow heat-value
line and specific-gravity
line to point
of intersection
to find orifice size and maximum
and minimum manifold
RISQUE
D'EXPLOSION
ET D'INCENDIE
Le fait de ne pas suivre cet avertissement pourrait entra_ner des
dommages corporels et / ou la mort.
altitudes
up to 2000 ft. (610 M).
Ne jamais examiner pour les fuites de gaz avec une flamme
vive. Utilisez plut6t un savon fait specifiquement pour la
d6tection des fuites de gaz pour verifier tous les connections.
Un incendie ou une explosion peut entrainer des dommages
mat6riels, des blessures ou la mort.
In Canada,
2. Remove l/8-in.
on downstream
3. Attach
supplies
to furnace
NPT pipe plug from manifold
side of gas valve.
manometer
to manifold
pressure
on
rating
plate
is for
installations
at
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.
altitudes
level.
the input
of 2000
rating
ft. (610
The Conversion
derate.
are off.
pressure
rate
settings.
gas
1. Be sure main gas and electric
input
pressure
Furnace
Kit
must
be derated
M) to 4500
Rating
Plate
by
ft. (1372
accounts
5 percent
for
M) above
sea
for
high
altitude
SET GAS INPUT RATE
tap
tap on gas valve.
(see Fig. 13.)
4. Turn gas supply
5. Turn furnace
6. Check
manual
shutoff
gas valve switch
all threaded
7. Turn on furnace
pipe connections
power
ON/OFFSwitch
valve to ON position.
UNIT
to ON position.
DAMAGE
HAZARD
Failure to follow this caution may result in gas valve
damage.
for gas leaks.
supply.
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
manifold pressure. Gas valve will be damaged if excessive
force is used on the rotary switch.
MODULATING
/
Min/Max Heat Adust
Burner
Flame
Turn screw 1 click per
) second to adjust rate,
Inlet _
Pressure Ta
Clockwise toincrease
rate, counter clockwise
Burne_
/2" NPT Outlet
Manifold
Al1461
Pressure Tap
Fig. 14 - Burner
Flame
Al1513
Fig. 13 - Gas Valve
For proper
operation
and long term reliability,
the
pressure must be adjusted as specified on the conversion
GAS INPUT RATE INFORMATION
See furnace
rating plate on blower
rate for natural
size.
gas is determined
plate.
door for input rate. The input
by manifold
pressure
The modulating
and orifice
natural
gas orifice
size
and
manifold
pressures
2. Obtain
ply.
yearly
average
(at installed
altitude)
for
NOTE:
average
inside
for
For Canada
M), use U.S.A.
altitudes
Altitudes
of 2000
of 2001
Table 3 or Table 4, depending
to 4500
to 3000
on furnace
ft. (610
force
pressure
is set at two points.
when
valve
performing
adjustments.
by turning
with
can break
a small
or bend
Gas
a rotary
adjustment
straight
blade
the rotary
valve
switch
screwdriver.
adjustment
switch
it non-adjustable.
To adjust
Heat:
for local gas sup-
care
is performed
the gas
Excessive
manifold
pressure
to obtain
input
rate for Maximum
1. Make sure the gas supply is turned off to the furnace
at the electric switch on the gas valve.
3. Find installation
altitude in Table 3 or Table 4, depending
on furnace gas input rate.
NOTE:
Use
adjustment
making
specific-gravity
manifold
Intermediate
Heat manifold pressure can be checked as part of the
temperature
rise, but is not adjustable.
Always adjust Maximum
Heat first, then Minimum Heat.
correct input at installed altitude by using Table 3 (for 20,000
Btuh/Max-Heat/8000
Btuh Min-Heat
per Burner) or Table 4
(For 20,200 Btuh Max Heat/8,000 Btuh Min-Heat
per Burner).
1. Obtain yearly heat-value
local gas supply.
furnace
The first point is Maximum
Heat. The second point is Mininmm
Heat. DO NOT
adjust Intermediate
Heat manifold
pressure.
The gas valve must be set for Maxinmm
Heat first and then set
for Minimum
Heat on Modulating
furnaces.
Determine
manifold
kit rating
2. Remove the 1/8 inch NPT plug
tap on the gas valve.
to 1372
ft. (610 to 914 M) in
3. Connect
valve.
gas input rate.
4. Find closest natural gas heat value and specific gravity in
Table 3 or Table 4, depending on furnace gas input rate.
11
a manometer
4. Turn on furnace
power
5. Turn gas supply
manual
from
to the outlet
the outlet
pressure
pressure
tap on gas
supply.
shutoff
and
valve to ON position.
6. Turn furnace gas valve switch to ON position.
If the temperature rise is too high or too low in Minimum Heat:
7. Turn Setup switch SW 1-2 to ON.
1. Remove jumpers from R and W/W1.
8. Verify Set-up switch SW 4-2 is turned OFF.
9. Jumper the R to W/W1 and W2 thermostat connections at
the furnace control board.
2. Wait until the blower off delay is completed.
3. Turn 115 VAC power off.
4. Check the position of Heat Rise Adjustment Switch
SWl-3. When set to ON, airflow is raised 18% higher for
Minimum Heat and Intermediate Heat. Factory default position is OFF.
10. After the main burners ignite and the blower starts, confirm Maximum Heat manifold pressure is correct, based
on the manifold pressure table. (See Fig. 3.)
11. To adjust the Maximum Heat manifold pressure, slowly
turn the rotary adjustment switch counterclockwise to decrease manifold pressure or clockwise to increase manifold
pressure.
12. Turn rotary adjustment switch no more than one click per
second until you obtain the required manifold pressure.
5. Turn 115 VAC power on.
6. Jumper R to W/W1 and W2.
7. After burners ignite and blower starts allow the furnace to
run for at least 10 minutes before checking Temperature
Rise.
Maximum
Main burner flame should be clear blue, almost transparent.
Heat Temperature
Rise
If the temperature rise is too high or too low in Maximum Heat:
1. Remove jumpers from R, Wl and W2.
To adjust manifold pressure to obtain input rate for Minimum
Heat:
2. Wait until the blower off delay is completed.
1. Remove the jumper from W2 at the thermostat connections at the furnace control board control.
2. Wait until the burners and the blower transitions to Minimum Heat.
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.
6. Re-check Minimum Heat Temperature Rise.
3. Verify the Minimum Heat manifold pressure is correct,
based on the manifold pressure table on Conversion Kit
Rating Plate.
4. To adjust the Minimum Heat manifold pressure, Slowly
turn the rotary adjustment switch counterclockwise to decrease manifold pressure or clockwise to increase manifold
pressure.
5. Turn rotary adjustment switch no more than one click per
second until you obtain the required manifold pressure.
This adjustment will not affect the previous Maximum
Heat adjustment.
After adjusting the manifold pressure, allow the furnace to
operate an additional 5 minutes before checking Minimum Heat
Temperature rise.
Adjustment
Mode), airIntermediate
default posi-
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.
11. Apply pipe dope sparingly to 1/8-in. NPT plug and re-install outlet pressure tap on the gas valve.
Furnace must operate within ranges of temperature rise specified
on the furnace rating plate. Determine air temperature rise as
follows:
12. Re-install plastic cap over rotary adjustment switch on the
top of the gas valve.
LABEL
APPLICATION
1. Place thermometers in return and supply ducts as near furnace as possible. Be sure thermometers DO NOT see heat
exchanger so that radiant heat does not affect readings.
This practice is particularly important with straight-run
ducts.
1. Fill in Conversion Responsibility Label 338305-205 and
apply to Blower Access Door of furnace as shown. (See
Fig. 15.) Date, name, and address of organization making
this conversion are required.
2. Attach Conversion Rating Plate Label 338305-201 to outer door of furnace, see Fig. 16.
3. Attach Gas Control Conversion Label 338305-202 to gas
valve. DO NOT use 338305-203, which is similar.
2. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine air
temperature rise.
3. Allow the furnace to run for at least 10 minutes before
checking Temperature Rise.
12
CE G#NERATEURD'A[RCHAUDA _:TI_
CONVERTILE
POUR
THiSFURNACEWAS CONVERTED
ON
TO NATURALGAS
(DAY-MONTH-YEAR)
(JOUR-MOIS-ANNEE)
KiT NO.: KGAPN4401VSP
DE L'ENSEIVlBLEN°,: KGAPN4401VSP
BY:
PAR:
(Name and address of organization making this conversion),
which accepts the responsibility that this conversion has
(Nora
been properly made.
qui accepte
et adresse
de
I'organisrae
J' entri6re
qui a effectu_
responsabiJit6
Ja conversion),
de Ja conversion.
338305-205
REV. A
_'t._.
Al1504
Fig. 15 - Conversion
CONVERSION
KiT
RATING
Responsibility
Label
PLATE - CARRIER
THiS APPLIANCE
HAS BEEN
CONVERTED
TO USE NATURAL
GAS FOR FUEL.
REFER
PROCEDURES.
USE PARTS
SUPPLIED
BY CARRIER
CORPORATION
AND iNSTALLED
SEE EXiSTiNG
RATING
PLATE FOR APPLIANCE
MODEL
NO. AND iNPUT
RATING.
CORPORATION
TO KiT iNSTRUCTiONS
FOR
BY QUALiFiED
PERSONNEL.
CONVERSION
NOTE; Furnace gas input rate on rating plate is for instaJJations up to 2000 ft. (010m) above sea [eveJ. 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 level In Canada the input rating must be derated (per chart below) for altitudes of 2000 ft. (010m) to 4500 ft. (1372m)
above sea Jevel.
IT NO,:
KGAPN4401VSP
APPLIANCE
MODELS
59MN7A
987MA
(SUPERSEDES:
USA
O/oDERATE
PER
1000 FT.
2%
NONE)
FUEL
NATURAL
CANADA
% DERATE
FOR
GAS PRESSURE
Max. Inlet Gas Pressure
(Press. Max. D'Admission De Gaz)
Min. Inlet Gas Pressure
2000-4500 FT.
(For
Purpose
of input
ALTITUDE
0-2,000
Pressure
Pression
(0 - 610 m)
2,000
- 10,000
Tubu[ure
(610
- 3050
(Pour
High
ft.
ft.
ra)
NATURAL
C.E.)
4.5
Adjustment)
Manifold
(PO
GAS
P[
PA
13.6
(Press, NJn, D'AdmJssion De Gaz)
5%
USED:
iN. W.C.
1,121
L'Adjustment
Heat
3.2
-
3.8
D'Entree)
797
-
946
LOW Heat
Refer
1.4
- 1.8
to installation
349
Manual
-
448
Respecter
es
D3nsta[[ation
nstructon
338305-201
This control has been adjusted for use with propane gas.
Cette
commande
a et6converted
r6gl6e pour
avec
le gaz
This control
has been
for emploi
use with
natural
gas.
naturel.
338305-202 REV.A
_._
J
]
REV, A,
I_,_
Ce eoontrSle a et_ r6gl6e pour foneSonner au gaz propane,
_/
330305-203 REV. A
"}
)
Al1503
Fig. 16 - Conversion
Kit Rating
13
Plate
SECTION
2
Table 5 - Variable Speed Condensing Furnaces
MODEL NUMBERS BEGINNING WITH:
59TN6
FIRE, EXPLOSION,
HAZARD
986T
PG96V T
ELECTRICAL
SHOCK
Failure to follow this warning could result in personal
injury, death or property damage.
INSTALLATION
Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.
FIRE,
EXPLOSION,
CARBON
MONOXIDE
ELECTRICAL
POISONING
SHOCK
HAZARD
AND
Failure to follow instructions could result in personal injury,
death or property damage.
ELECTRICAL
HAZARD
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.
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 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. Set room thermostat to lowest setting or "OFF".
2. Remove outer doors.
FIRE,
EXPLOSION,
CARBON
MONOXIDE
Failure to follow
injury or death.
ELECTRICAL
POISONING
this warning
SHOCK,
HAZARD
3. Disconnect
breaker.
AND
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.
could result in personal
6. Turn electric switch on gas valve to OFF.
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.
FLAME
SENSOR ¸¸¸
MANUALRESET
ROLLOUTSW_TCH
GASVA_E
OPERATINGFNSTRUCT_ONS
NOTSHOWS(LOCATEDOS
MA_NFURNACEDOOR,SEE
OPERATINGFNSTRUCT_OSS
FNS_DE
DOORFFGURE)
ELECTRICAL
JUSCT_ON
BOX
(_F
REQH_RED
LOCATION
MAY
....
VARY)
8LOWERDOOR.....
SAFETY
LE FEU, L'EXPLOSION,
CHOC
ET MONOXYDE
DE CARBONE
EMPOISONNER
SWFTC
H
ELECTRIQUE,
©
BLOWERAND
q MOTOR
FURSACE
CONTROL
BOARD
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 n_ininmm 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.
f
CAPAC_TOR_
RAT_NGPLATENOT
SHOWS
(LOCATEDOSBLOWERDOOR)
REPRESENTATIVE
DRAWING
OSLYSOMEMODELSMAYVARY_NAPPEARANCE
A11408
Fig. 17 - Component
14
Location
MANIFOLD/ORIFICE/BURNER
BURNER
REMOVAL
SUPZ
ASSY
IGNITER
BRACKET,
IGNITER
/
UNIT
OPERATION
HAZARD
BURNER
Failure to follow this caution
improper operation.
Label all
controls.
wires
prior
to
may result in unit damage
disconnection
when
ASSY
or
servicing
FLAME
ROLLOUT
SWITCH
_"'_
FLAM E SENSOR
(BELOW
BURNER)
Al1403
D'EQUIPMENT
D'OPERATION
Fig. 19 - Burner
Lors des op6rations
d'entretien
des commandes,
tousles ills avant de les d@onnecter.
Assembly
6tiqueter
ORIFICE
SELECTION/DERATE
NOTE:
Use a back-up wrench on the gas valve to prevent the
valve from rotating on the manifold or damaging the mounting to
[]NIT
the burner box. See Fig. 18 and 19.
1. Disconnect
the gas pipe from
from the furnace casing.
2. Disconnect
nect wires
Sensor.
gas valve
and remove
Disconnect
the two wires from
located
HAZARD
Failure to follow this caution may result in unit damage.
pipe
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. 20.)
the connector harness from gas valve. Disconfrom Hot Surface Igniter (HSI) and Flame
sure switch (LGPS)
DAMAGE
the low gas pres-
on the gas valve.
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
re-assembly
later.
5. Slide one-piece
burner box.
burner
6. Remove
the flame
7. Remove
the orifices
sensor
assembly
wire ground
wire for
out of slots on sides of
from the burner
from the manifold
assembly.
A96249
Fig. 20 - Burner
and discard.
Orifice
Orifice
Deternfine natural gas orifice size and manifold pressures for
correct input at installed altitude by using Table 5.
d¢
Connect
/
Manifold
1. Obtain yearly heat-value average (at installed altitude) for
local gas supply.
2. Obtain yearly specific-gravity average for local gas supply.
3. Find installation altitude in Table 5.
S
Green/Yellow
ground wire here
NOTE: For Canada altitudes of 2000 to 4500 ft. (610 to 1372
M), use U.S.A. Altitudes of 2001 to 3000 ft. (610 to 914 M) in
Table 5.
Gas Valve
4. Find closest natural gas heat value and specific gravity in
Table 5.
/
5. Follow heat-value line and specific-gravity line to point
of intersection to find orifice size and high and low manifold pressure settings.
_lndicated
sur[aces
!to
Gas
valve
manifold
6 threads.
must
with
be installed
minimum
Cross
threading
be 90'+
or -2'
on
engagement
of
is not
acceptable.
Al1407
Fig. 18 - 2 Stage Gas Valve
15
Table 6 - Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate
TWO-STAGE
FURNACE
(TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER,
DERATED
ALTITUDE
RANGE
OF NATURAL
0.60
Orifice
Mnfld Press
Orifice
900
No.
43
Hi, h/Low
3.8 / 1.6
No.
42
Hi,h/Low
3.2 / 1.4
No.
42
0
925
43
3.6 / 1.5
43
3.7 / 1.6
(0)
950
43
3.4 / 1.4
43
3.5 / 1.5
975
44
3.7 / 1.6
44
to
1000
44
3.5 / 1.5
2000
1025
1050
44
44
(610)
1075
_
GAS
0.62
Mnfld Press
Mnfld Press
0.64
Orifice
Mnfld Press
3.3 / 1.4
No.
42
Hi_htLow
3.4 / 1.4
43
3.8 / 1.6
42
3.2 / 1.4
43
3.6 / 1.5
43
3.7 / 1.6
3.8 / 1.6
43
3.4 / 1.5
43
3.6 / 1.5
44
3.6 / 1.5
44
3.8 / 1.6
43
3.4 / 1.4
3.3 / 1.4
3.2 / 1.3
44
44
3.5 / 1.5
3.3 / 1.4
44
3.6 / 1.5
44
3.7 / 1.6
44
3.4 / 1.4
44
3.5 / 1.5
45
3.7 / 1.6
45
3.8 / 1.6
44
3.3 / 1.4
44
3.4 / 1.4
1100
46
3.7 / 1.6
46
3.8 / 1.6
45
3.8 / 1.6
44
3.2 / 1.4
U.S.A.
800
42
3.4 / 1.4
42
3.5 / 1.5
42
3.6 / 1.5
42
3.7 / 1.6
2001 (611)
825
43
3.8 / 1.6
42
3.3 / 1.4
42
3.4 / 1.4
42
3.5 / 1.5
to
850
43
3.6 / 1.5
43
3.7 / 1.6
42
3.2 / 1.3
42
3.3 / 1.4
3000 (914)
875
43
3.4 / 1.4
43
3.5 / 1.5
43
3.7 / 1.5
43
3.8 / 1.6
900
44
3.7 / 1.6
44
3.8 / 1.6
43
3.5 / 1.5
43
3.6 / 1.5
44
3.8 / 1.6
43
3.4 / 1.4
44
3.6 / 1.5
44
3.7 / 1.6
o
c
0.58
SEA LEVEL)
GRAVITY
Orifice
ft (m)
<.
u)
FT (305M) ABOVE
SPECIFIC
HEAT VALUE
AT ALTITUDE
c
2%/1000
AVG. GAS
Canada
2001 (611)
925
950
44
44
3.5 / 1.5
3.3 / 1.4
44
44
3.6 / 1.5
3.4 / 1.5
to
975
44
3.2 / 1.3
44
3.3 / 1.4
44
3.4 / 1.4
44
3.5 / 1.5
1000
775
46
42
3.8 / 1.6
3.3 / 1.4
45
42
3.8 / 1.6
3.4 / 1.4
44
3.2 / 1.4
44
3.3 / 1.4
42
3.5 / 1.5
42
3.6 / 1.5
3001
800
43
3.8 / 1.6
42
3.2 / 1.4
42
3.3 / 1.4
42
3.4 / 1.4
(915)
825
43
3.6 / 1.5
43
3.7 / 1.6
43
3.8 / 1.6
42
3.2 / 1.4
850
44
3.8 / 1.6
43
3.5 / 1.5
43
3.6 / 1.5
43
3.7 / 1.6
to
875
44
3.6 / 1.5
44
3.7 / 1.6
43
3.4 / 1.4
43
3.5 / 1.5
4000
900
44
3.4 / 1.4
44
3.5 / 1.5
44
3.7 / 1.5
44
3.8 / 1.6
(1219)
925
44
3.2 / 1.4
44
3.4 / 1.4
44
3.5 / 1.5
44
3.6 / 1.5
950
45
3.7 / 1.6
44
3.2 / 1.3
44
3.3 / 1.4
44
3.4 / 1.4
750
42
3.3 / 1.4
42
3.4 / 1.4
42
3.5 / 1.5
42
3.6 / 1.5
4001
775
43
3.7 / 1.6
43
3.8 / 1.6
42
3.3 / 1.4
42
3.4 / 1.4
(1220)
800
43
3.5 / 1.5
43
3.6 / 1.5
43
3.7 / 1.6
43
3.8 / 1.6
825
44
3.8 / 1.6
43
3.4 / 1.4
43
3.5 / 1.5
43
3.6 / 1.5
to
850
44
3.5 / 1.5
44
3.7 / 1.5
44
3.8 / 1.6
43
3.4 / 1.4
5000
875
44
3.3 / 1.4
44
3.5 / 1.5
44
3.6 / 1.5
44
3.7 / 1.6
(1524)
900
44
3.2 / 1.3
44
3.3 / 1.4
44
3.4 / 1.4
44
3.5 / 1.5
925
46
3.8 / 1.6
45
3.7 / 1.6
44
3.2 / 1.4
44
3.3 / 1.4
725
42
3.2 / 1.4
42
3.3 / 1.4
42
3.4 / 1.5
42
3.5 / 1.5
5001
750
43
3.7 / 1.5
43
3.8 / 1.6
42
3.2 / 1.4
42
3.3 / 1.4
(1525)
775
43
3.4 / 1.4
43
3.5 / 1.5
43
3.7 / 1.5
43
3.8 / 1.6
800
44
3.7 / 1.6
44
3.8 / 1.6
43
3.4 / 1.5
43
3.5 / 1.5
to
825
44
3.5 / 1.5
44
3.6 / 1.5
44
3.7 / 1.6
44
3.8 / 1.6
6000
850
44
3.3 / 1.4
44
3.4 / 1.4
44
3.5 / 1.5
44
3.6 / 1.5
(1829)
875
45
3.7 / 1.6
44
3.2 / 1.3
44
3.3 / 1.4
44
3.4 / 1.4
900
46
3.7 / 1.6
46
3.8 / 1.6
45
3.8 / 1.6
44
3.2 / 1.4
675
42
3.4 / 1.4
42
3.5 / 1.5
42
3.6 / 1.5
42
3.8 / 1.6
6001
700
42
3.2 / 1.3
42
3.3 / 1.4
42
3.4 / 1.4
42
3.5 / 1.5
--_
c
O
(1830)
725
43
3.6 / 1.5
43
3.7 / 1.6
43
3.8 / 1.6
42
3.3 / 1.4
750
43
3.4 / 1.4
43
3.5 / 1.5
43
3.6 / 1.5
43
3.7 / 1.6
<"
u)
to
775
44
3.6 / 1.5
44
3.7 / 1.6
43
3.4 / 1.4
43
3.5 / 1.5
7000
800
44
3.4 / 1.4
44
3.5 / 1.5
44
3.6 / 1.5
44
3.7 / 1.6
3.4 / 1.4
44
3.5 / 1.5
3.2 / 1.4
44
3.3 / 1.4
u_
__
--_
c
O
--_
c
O
--_
c
O
(2133)
825
44
3.2 / 1.3
44
3.3 / 1.4
44
850
46
3.8 / 1.6
45
3.8 / 1.6
44
Al1252A
ld
Table
5 - Orifice
Size and Manifold
Pressure
TWO-STAGE
(TABULATED
(In.W.C.)
for Gas Input
Rate (Continued)
FURNACE
DATA BASED ON 20,000 BTUH HIGH-HEAT/13,000
BTUH LOW-HEAT
PER BURNER,
DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL)
ALTITUDE
AVG. GAS
RANGE
HEAT VALUE
SPECIFIC GRAVITY OF NATURAL
0.58
AT ALTITUDE
--_
Orifice
Mnfld Press
Orifice
Mnfld Press
650
No_,, ,,,,,_h/Low
42
3.4 / 1.4
No.
42
Hi,h/Low
3.5 / 1.5
No.
42
Hi,h/Low
3.6 / 1.5
No.
42
Hi2h/Low
3.7 / 1.6
7001
675
43
3.8 / 1.6
42
3.2 / 1.4
42
3.3 / 1.4
42
3.4 / 1.5
(2134)
700
43
3.5 / 1.5
43
3.7 / 1.5
43
3.8 / 1.6
42
3.2 / 1.4
725
44
3.8 / 1.6
43
3.4 / 1.4
43
3.5 / 1.5
43
3.6 / 1.5
to
750
44
3.5 / 1.5
44
3.7 / 1.5
44
3.8 / 1.6
43
3.4 / 1.4
8000
775
44
3.3 / 1.4
44
3.4 / 1.4
44
3.5 / 1.5
44
3.7 / 1.5
(2438)
800
825
45
3.8 / 1.6
44
3.2 / 1.4
44
3.3 / 1.4
44
3.4 / 1.4
46
3.7 / 1.6
46
3.8 / 1.6
45
3.8 / 1.6
44
3.2 / 1.4
625
42
3.4 / 1.4
42
3.5 / 1.5
42
3.6 / 1.5
42
3.7 / 1.6
8001
650
43
3.8 / 1.6
42
3.2 / 1.4
42
3.3 / 1.4
42
3.4 / 1.4
(2439)
675
43
3.5 / 1.5
43
3.6 / 1.5
43
3.7 / 1.6
42
3.2 / 1.3
44
3.7 / 1.6
43
3.4 / 1.4
43
3.5 / 1.5
43
3.6 / 1.5
44
3.5 / 1.5
44
3.6 / 1.5
44
3.7 / 1.6
44
3.8 / 1.6
750
44
3.3 / 1.4
44
3.4 / 1.4
44
3.5 / 1.5
44
3.6 / 1.5
3.7 / 1.6
44
3,2 / 1,3
44
3,3 / 1,4
44
3.4 / 1.4
9001
775
600
45
42
3.3 / 1.4
42
3.4 / 1.5
42
3.6 / 1.5
42
3.7 / 1.6
(2744)
625
43
3.7 / 1.6
42
3.2 / 1.3
42
3.3 / 1.4
42
3.4 / 1.4
650
43
3.5 / 1.5
43
3.6 / 1.5
43
3.7 / 1.6
43
3.8 / 1.6
to
675
44
3.7 / 1.6
44
3.8 / 1.6
43
3.4 / 1.4
43
3.5 / 1.5
10000
700
44
3.4 / 1.4
44
3.5 / 1.5
44
3.7 / 1.5
44
3.8 / 1.6
3.4 / 1.4
44
3.5 / 1.5
O
<'
c
O
<.'
_.
to
700
725
9000
__
--_
0.64
Mnfld Press
_
O
<'
Mnfld Press
GAS
0.62
Orifice
ft (m)
Orifice
0.60
* Orifice numbers shown in BOLD are factory-installed.
Al1252B
Furnace
gas input rate on furnace
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.
In Canada,
altitudes
level.
The Conversion
derate.
INSTALL
above 2000
ft. (610
for each 1000 ft. (305 M) above
1.9"
the input
of 2000
for altitudes
by 2 percent
rating
must
be derated
ft. to 4500
ft. (610
Kit
Plate
Rating
by 5 percent
M to 1372
accounts
M) above
for
high
for
(48.76
t
altitude
ORIFICES
2. There are enough orifices
Discard extra orifices.
DO NOT reinstall
REMOVE
MIXER
Location of mixer screw
..._hat must be removed
1.8"
1. Install main burner orifices. DO NOT use Teflon tape. Finger-tighten
orifices
at least one full turn to prevent
cross-threading,
then tighten with wrench.
NOTE:
mm)
sea
in each kit for largest
mm)
( \11
furnace.
\\\\
the manifold
SCREWS
(46.96
at this time.
FROM
THE
Al1501
BURN-
Fig. 21 - Mixer
Screw
Location
ERS
Each burner
contains
a mixer screw that must be removed.
REINSTALL
Refer
To reinstall
to Fig. 21 for the mixer screw location
1. Remove
the mixer screws
from the burners.
NOTE:
It is not necessary to plug the hole in the burner
the mixer screws are removed.
BURNER ASSEMBLY
burner
assembly:
1. Attach flame sensor
2. Insert one-piece
when
to burner
burner
assembly.
in slot on sides of burner box and
slide burner back in place.
3. Reattach
HSI wires to HSI.
4. Verify igniter to burner alignment. See Fig. 22 and 23.
17
ELECTRICAL
HAZARD
ql
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.
(64.4)
Position
FIRE
Failure to follow
this warning
injury, death or property damage.
!
Fig. 22 - Igniter
SHOCK,
- Back View
Al1405
1. Refer to Fig. 24.
2. Be sure gas and electrical
supplies
3. Remove
adjustment
caps that conceal
and low-heat
2- irl.
(50 mm)
regulator
adjustment
5. Remove
the high-heat
and low-heat
Propane
gas regulat-
(white).
the high-heat
and low-heat
natural
and low-heat
regulator
to the natural high-heat
set point. (See Fig. 24.)
9. Turn low-heat
stage adjusting
screw clockwise
(in) 95
full turns. This will increase the manifold pressure closer
- Side View
to the Propane
low-heat
set point. (See Fig. 24.)
10. DO NOT install regulator
CONVERT GAS VALVE
seal caps at this time.
')
TWO-STAGE
ON/OFF
DAMAGE
HAZARD
Failure
to follow
this caution
1/2"
"_
_ _@_
9
_
_=
1-: _
Regulator
Regulator
..... Screw
Seal Cap
*
Ad ustment
Switch
NPT Inlet
may result in unit damage
The G or J gas valve must be converted and pre-adjusted
before operating
on natural
gas. The E valves must be
pre-adjusted
before operating
on natural gas. If left this
way, sooting and corrosion will occur leading to early heat
exchanger failure.
FIRE, EXPLOSION,
HAZARD
adjustment
8. Turn high-heat
stage adjusting screw clockwise
(in) 12
full turns. This will increase the manifold pressure closer
A12392
[]NIT
gas regulator
(silver).
7. Install the high-heat
screws.
r3/32
-in., +0.8
+1/32 -1.5)
-3/64-in.
(2.5 mm,
Position
(See Fig. 24.)
and low-heat
springs
Fig. 23 - Igniter
stage gas valve regulators.
the high-heat
6. Install
(4.6 mm)
are off.
screws for high-heat
4. Remove
screws.
or springs
3/16- in.
to furnace
ELECTRICAL
Failure to follow
this warning
injury, death or property damage.
could
1/8" NPT
Inlet
Pressure
Tap
SHOCK
result
1t8" NPT
Manifold
Pressure
Tap
Al1472
in personal
Fig. 24 - 2 Stage
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
Gas valve
REMOVE LOW GAS PRESSURE SWITCH
NOTE:
18
There
are 2 ways
(LGPS)
could
have been
Propane
gas conversion.
that the Low
installed
during
Gas Pressure
the original
Switch
Natural
to
All143/16-in
Inducer
(360 mm)
Assembly
Casings
and Burner
or Vent Passes Between
wide casing,
Fig 260
Assembly
1. Remove
If the vent pipe passes between the inducer and burner assembly,
or the furnace is a 14 3/16-in. (360 ram) wide casing, the switch
may have been installed
as follows.
the switch may have been installed
low-gas
pressure
brass Hex nipple,
NOTE:
Use pipe dope
(See
brass street 90 ° elbow,
brass Tee and brass nipple
valve inlet pressure
(See Fig 25.)
switch,
as follows.
from
the gas
tap. (See Fig 26.)
approved
for use with Propane
sparingly
to the l/8-in.
gas. DO
NOT use Teflon tape.
2. Apply
pipe dope
NPT pipe plug
(provided
in kit) and install in the l/8-in,
tapped inletpressure tap opening in the gas valve. DO NOT overtighten. Check for gas leaks after gas supply has been
turned on.
For larger casing
when
Vent Pipe does
switch contacts
must point
used at Valve Inlet instead
Brass
Inlet
Pressure
Tap with
not pass
across
toward the Cell Panel.
of Brass Street 90.
Street
Plug
casing.
Black
Iron
All Sizes
Street
90 can be
Tee
"
"
Brass Hex Nipple
A11367
Brass
Fig. 25 - LGPS
for 14-3/16-in.
Vent Passes
Between
(360 mm) Casing
Inducer
and Burner
Street
or When
Low Gas
Assembly
Pressure
Switch
\2i_
;
Brass
Nipple
A11366
1. Remove low-gas
brass Hex nipple,
pressure switch, brass street 90 ° elbow,
brass tee and black iron street 90 ° elbow
from the gas valve inlet pressure
NOTE:
Use pipe dope
Fig. 26 - LGPS
for Casing
Does Not Pass Between
Wider
Than
Inducer
14-3/16
and Burner
and Vent
Assembly
tap. (See Fig 25.)
approved
for use with Propane
sparingly
to the l/8-in.
gas. DO
INSTALL
MANIFOLD
NOT use Teflon tape.
2. Apply
pipe dope
(provided
in kit) and install in the l/8-in,
tapped
pressure tap opening in the gas valve. DO NOT
tighten. Check
turned on.
for gas leaks
after gas
1. Align the orifices in the manifold assembly
port rings on the end of the burner.
NPT pipe plug
supply
inletover-
2. Insert the orifices
ifold
box.
has been
mounting
in the support
tabs should
NOTE:
If manifold
burners
are not fully seated
does not fit flush against
check burner positioning
FIRE AND EXPLOSION
Failure to follow
and/or death.
against
could result in personal
injury
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,
the manifold
manifold
mounting
5. Connect
niter.
the wires to the flame
6. Connect
the connector
7. Rewire
and
in the burner box assembly.
4. Install the remaining
personal
Man-
the burner
the burner box, the
Remove
3. Attach the green/yellow
wire and ground
of the manifold mounting screws.
HAZARD
this warning
rings of the burners.
fit flush
forward.
with the sup-
harness
unit low pressure
sensor
terminal
to one
screws.
and hot surface
ig-
to gas valve.
switch (LPS)
as follows:
a. Trace one of the orange wires previously
from the LGPS back to the NO terminals
disconnected
of the LPS.
b. Trace the other orange wire previously
disconnected
from the LGPS back to its splice connection with the yellow wire of the furnace wire harness. Disconnect and disRISQUE
D'EXPLOSION
card this orange
ET D'INCENDIE
Le fait de ne pas suivre cet avertissement
dommages
corporels et / ou la mort.
pourrait
entra_ner
c. Connect
des
"b" above) to the NO terminal
d. Refer to the furnace
tion of wires.
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 tousles
connections.
Un incendie ou une explosion
peut entrainer des dommages
materiels, des blessures ou la mort.
Casings
Wider Than
Pass Between
Inducer
If the vent pipe
assembly,
14 3/16-in.
does
is wider
the inducer
than a 14 3/16-in.
only
Propane-resistant
(see
diagram
ensure
pipe dope,
proper loca-
DO NOT
use
8. 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.
and burner
(360
Use
wiring
wire harness
of the LPS.
Teflon tape.
Assembly
not pass between
or the furnace
NOTE:
(360 mm) / Vent Does Not
and Burner
wire and the splice connection.
the yellow wire of the furnace
ram)
19
wrench
on the gas valve
on the manifold
or damaging
to prevent
the mounting
the
to
9. Withaback-up
wrench
onthe
finish
tightening
10. Turn gas on at electric
CHECK
INLET
CHECK FURNACE
inlet boss of the gas valve,
GAS
switch on gas valve.
PRESSURE
FIRE
AND EXPLOSION
Failure to follow
and/or death.
UNIT
DAMAGE
HAZARD
Failure
to follow
this caution
DO NOT operate
inlet gas pressure,
NOTE:
between
may result in unit damage.
furnace more than one minute to check
as conversion is not complete at this time.
This kit is to be used only when
4.5-in. W.C. and 13.6-in. W.C.
1. Verify manometer
valve.
is connected
inlet gas pressure
to inlet pressure
3. Turn gas supply
power
manual
HAZARD
this warning
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,
personal
is
tap on gas
RISQUE
2. Turn on furnace
D'EXPLOSION
ET D'INCENDIE
supply.
shutoff
4. Turn furnace
gas valve switch
5. Turn
Switch
Setup
AND MAKE ADJUSTMENTS
the gas pipe to the gas valve.
SWI-2
Le fair de ne pas suivre cet avertissement
dommages
corporels et / ou la mort.
valve to ON position.
to ON position.
on
furnace
control
pourrait
entra_ner
des
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.
ON (see
Fig. 27).
SW4
Outside
24 VAC
HUM Output
(O.5AMP
Air Thermistor_
SW4
_F_
Crflnotiwn
U;_uSpFa
n_
switches
CF 3
[]
CF 1 through
"_
FIRE, EXPLOSION,
HAZARD
_I=_
O_
Failure to follow
this warning
iniury, death or property damage.
Connect
on--
[_
could
result
in personal
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
i
_-N _!:i
Z"_
SHOCK
PLB
Communication
Model Plug _
ELECTRICAL
SW3
_]_
/_:21
_
I
W2
Yt
DHUM
SW2
Setup Switches
1 thru 8
SWl,
ELECTRICAL
HAZARD
SW2 A/C Air Flow
R-W/W1
and R-W2
Control
thermostat
7. When main burners ignite, confirm inlet
between 4.5-in. W.C. and 13.6-in. W.C.
8. Remove jumper across
connections
to terminate
9. Turn furnace
manual
11. Turn off furnace
power
12. Remove
shutoff
on
gas pressure
R-W/WI
and R-W2
call for heat.
gas valve switch
10. Turn gas supply
connections
is
2. Remove l/8-in.
on downstream
thermostat
3. Attach
EXPLOSION
result
in personal
supplies
to furnace
NPT pipe plug from manifold
side of gas valve.
manometer
to manih_ld
pressure
are off.
pressure
tap
tap on gas valve.
(See Fig. 24.)
valve to OFF position.
4. Turn gas supply
supply.
5. Turn furnace
manometer.
6. Check
13. Apply pipe dope sparingly to the l/8-in.
NPT pipe plug
and install in the l/8-in, tapped inlet-pressure
tap opening
Check
could
1. Be sure main gas and electric
to OFF position.
in the gas valve. DO NOT over-tighten.
leaks after gas supply has been turned on.
OR
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
6. Jumper
control.
FIRE
Failure to follow
this warning
iniury, death or property damage.
Setup Switches
AC 1 through AC 3
Fig. 27 - Furnace
SHOCK,
all threaded
7. Turn on furnace
GAS
manual
INPUT
shutoff
gas valve switch
RATE
valve to ON position.
to ON position.
pipe connections
power
for gas leaks.
supply.
INFORMATION
for gas
See furnace
rating plate on blower
rate for natural
size.
20
gas is determined
door for input rate. The input
by manifold
pressure
and orifice
Deternfine
natural
gasorificesizeandmanifold
pressures
for
correct
inputatinstalled
altitude
byusing
Table
5.
1.Obtain
yearly
heat-value
average
(atinstalled
altitude)
for
localgassupply.
2.Obtain
yearly
specific-gravity
average
forlocalgassupply.
3.Findinstallation
altitude
inTable
5.
NOTE:ForCanada
altitudes
of2000to4500ft.(610to1372
M),useU.S.A.
Altitudes
of2001to3000ft.(610to914M)in
Table
5.
Furnace
gasinputrateonratingplateis for installations
at
altitudes
upto2000
ft.(610M).
IntheU.S.A.,
theinputrating
foraltitudes
above
2000ft.(610M)
must
bereduced
by2percent
foreach
1000
ft.(305M)above
sea
level.
In Canada,
theinputratingmustbederated
by 5 percent
for
altitudes
of 2000ft.(610M)to4500ft. (1372M)above
sea
level.
TheConversion
Kit RatingPlateaccounts
for highaltitude
derate.
SETGASINPUTRATE
1.Make
surethegassupply
isturned
offtothefurnace
and
attheelectric
switch
onthegasvalve.
2.Remove
the1/8inchNPTplugfromtheoutlet
pressure
taponthegasvalve.
3.Connect
a manometer
totheoutletpressure
tapongas
valve.
4.Turnonfurnace
power
supply.
5.Turngassupply
manual
shutoff
valve
toONposition.
6.Turnfurnace
gasvalve
switch
toONposition.
7.VerifySWI-2
onfurnace
control
isturned
"ON".
8.Jumper
R andW/WIthermostat
connections
tocallfor
heat.
9.Check
manifold
orifices
forgasleaks
when
mainburners
ignite.
10.Adjust
gasmanifold
pressure.
Refer
toTable
5.
11.Remove
caps
thatconceal
theadjustment
screws
forgas
valve
regulators.
See
Fig.24.
12.Adjustlow-heat
manifold
pressure
fornatural
gas.See
Fig.24.
13.Turnlow-heat
adjusting
screw
counterclockwise
(out)to
decrease
inputrateorclockwise
(in)toincrease
input
rate.
NOTE:Whencorrect
inputis obtained,
mainburner
flame
should
beclear
blue,
almost
transparent
(see
Fig.28).
14.Jumper
R,W/WIandW2oncontrol
center
thermostat
connections.
Thiskeeps
furnace
locked
inhigh-heat
operation.
15.Adjust
high-heat
manifold
pressure
fornatural
gas.
16.Turnhigh-heat
adjusting
screw
counterclockwise
(out)to
decrease
inputrateorclockwise
(in)toincrease
input
rate.
17.Replace
caps
thatconceal
thegasvalveregulator
adjustment
screws.
NOTE:Whencorrect
inputis obtained,
mainburner
flame
should
beclear
blue,
almost
transparent
(see
Fig.28).
Burner
Flame
_/_
Burner
Al1461
Fig. 28 - Burner Flame
18. Remove
justment
jumper
across R, Wl,
to ternfinate
19. Turn setup switch SWI-2
tion.
20. Turn furnace
power
manometer
23. Turn furnace
power
control
to OFF posi-
to OFF position.
and re-install
25. Set room thermostat
manifold
pressure
tap
to ON position.
supply.
to call for heat.
26. Check
ignite.
pressure
27. Check
for correct burner
tap plug for gas leaks when main
burners
flame.
the required
manifold
check and adjust the furnace
nace installation
instructions.
LABEL
ad-
supply.
gas valve switch
24. Turn on furnace
28. After making
on furnace
gas valve switch
21. Turn off furnace
22. Remove
plug.
and W2 after high-heat
call for heat.
pressure
temperature
adjustments,
rise per the fur-
APPLICATION
1. Fill in Conversion
Responsibility
Label
338305-210
and
apply to Blower Access Door of furnace as shown. (See
Fig. 29.) Date, name, and address of organization
making
this conversion
are required.
2. Attach Conversion
Rating Plate Label
Fig. 30, to Outer Door of furnace.
3. Attach Gas Control Conversion
valve. DO NOT use 338305-208,
338305-206,
label 338305-207
which is sinfilar.
see
to gas
CHECKOUT
1. Observe
unit operation
2. See Sequence
tion, Start-Up,
3. Set room thermostat
21
through
2 complete
heating
of Operation operation
in furnace
and Operating Instructions.
to desired
temperature.
cycles.
Installa-
CE GI_NI_RATEUR
D'AIRCHAUDA ETI_
CONVERTILE
POUR
THiSFURNACEWAS CONVERTED
ON
TO NATURALGAS
(DAY-MONTH-YEAR)
(JOUR-MOIS-ANNEE)
KiT NO.: KGAPN4401VSP
DE L'ENSEIVlBLEN°,: KGAPN4401VSP
BY:
PAR:
(Name and address of organization making this conversion),
which accepts the responsibility that this conversion has
(Nora et adresse de I'organisme qui a effectu6 la conversion),
been properly made.
qui accepte |' entri6re
responsabilit6
de la conversion.
338305-210 REV.A _.j
Al1505
Fig. 29 - Conversion
CONVERSION
KiT
RATING
Responsibility
PLATE
Label
CARRIER
THiS APPLIANCE
HAS BEEN CONVERTED
TO USE NATURAL GAS FOR FUEL, REFER
PROCEDURES,
USE PARTS SUPPLIED BY CARRIER CORPORATION
AND iNSTALLED
SEE EXISTING RATING PLATE FOR APPLIANCE
MODEL NO, AND iNPUT RATING,
CORPORATION
TO KiT iNSTRUCTiONS
FOR CONVERSION
BY QUALiFiED
PERSONNEL,
NOTE: Furnacegas inputrate on rating plate is for installationsup to 2000 ft. (6t0m) above sea level in U.S.A.the input rating for altitudesabove 2000 ft. (610m) must
be deratedby 2%for each 1000 ft. (305m) above sea level, in Canadathe inputrating must be derated(per chart below) for altitudesof 2000 ft. (610m)to 4500 ft. (1372m)
above sea level
KITNO,:
KGAPN4401VSP
APPLIANCE
MODELS
59TN6A
986TA
PG96VAT
(SUPERSEDES:NONE)
USA
% BERATE
PER
1000 FT.
2%
CANADA
% BERATE
FOR
2000=4500FT.
5%
FUEL USED:
NATURAL GAS PRESSURE
Max. Inlet Gas Pressure
(Press. Max. D'Admission De Gaz)
Min. inlet Gas Pressure
(Press. Min. D'Admission De Gaz)
(For
Purpose
iN. W.C. (PO
1 3.6
0=2,000 ft.
(0 - 610 m)
Pression
Tubulure
2,000 - 10,000 ft.
(610 - 3050 m)
(Pour
High Heat
Low Heat
1,121
L'Adjustment
3.2
1.4
-
3.8
1.8
Refer to Installation
Respecter
les instruction
_.
PA
3,386
4.5
of input Adjustment)
ALTITUDE
Manifold
Pressure
NATURAL GAS
C.E.)
D'Entree)
/ 797
[ 349
- 946
- 448
_1_1_.
Manual
D'lnstallation
338305-206 REV.B
Al1633
Fig. 30 - Conversion
Kit Rating
22
Plate
SECTION
3
Table 7 - 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,
tous les 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. 31 and 32.
1. Disconnect
the gas pipe from
from the furnace casing.
2. Disconnect
the connector
gas valve
harness
and remove
from gas valve.
pipe
Discon-
nect wires from Hot Surface Igniter (HSI) and Flame
Sensor. Disconnect
the two wires from the low gas pres-
LE FEU, L'EXPLOSION, CHOC ELECTRIQUE,
ET MONOXYDE DE CARBONE
EMPOISONNER
sure switch (LGPS)
located
on the gas valve.
3. Support the manifold and remove the 4 screws that secure
the manifold assembly to the burner box and set aside.
Cette trousse de conversion
doit Otre installOe par un servie
d'entretien
qualifiO, selon les instructions
du fabricant et
selon routes les exigences
et tous les 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.
4. Note the location of the green/yellow
re-assembly
later.
5. Slide one-piece
burner box.
23
burner
6. Remove
the flame
7. Remove
the orifices
sensor
assembly
wire ground
wire for
out of slots on sides of
from the burner
from the manifold
assembly.
and discard.
Clp,
ORIFICE
Harness
Burner
SELECTION/DERATE
Assy
urner
Support
UNIT
DAMAGE
Failure
to follow
HAZARD
Assy
this caution
DO NOT re-drill
burner
result in burrs, out-of-round
if orifice size must be changed.
4_4P
Bracket
may result in unit damage.
orifices. Improper
drilling may
holes, etc. Obtain new orifices
(Fig. 34.)
Ignito_
Switch,
Temp
(2)
Al1390
Fig. 31 - 80%
A96249
Burners
Fig. 34 - Burner
Gas Valve
Determine
\
\
natural
correct input
NOTE:
Manifold
gas orifice
at installed
All models
size
altitude
Orifice
and
manifold
pressures
for
by using Table 7 or 8.
in all positions
except
Low
NOx models
in
downflow
and horizontal
positions use Table 7 (22,000
burner). Low NOx models in downflow
or horizontal
Btuh per
positions
must use Table
listed on
8 (21,000
Btuh
per burner).
See input
rating plate.
1. Obtain
(_/
Orifice
.z¢p_
j
J
2. Obtain
@
(2)
Fig. 32 - 80%
models
NOTE:
Manifold
INSTALLATION
The following
(when
must have NOx baffles
For NOx device installation,
required)
installed
follow these additional
the screw underneath
secures
33.)
the NOx
(58CVX
(at installed
altitude)
for
average
for local gas sup-
device
in the heat exchanger.
Altitudes
of 2000
of 2001
to 4500
to 3000
gas heat value
ft. (610
to 1372
ft. (610 to 914 M) in
and specific
gravity
in
5. Follow heat-value
line and specific-gravity
line to point
of intersection
to find orifice size and high and low mani-
steps:
the heat exchanger
altitude in Table 7 or 8.
altitudes
4. Find closest natural
Table 7 or 8.
fold pressure
settings.
inlet that
Furnace
gas input rate on furnace
(See Fig.
altitudes
up to 2000 ft. (610 M).
rating plate is for installations
at
In the U.S.A.; the input rating for altitudes above 2000 ft.(610
M) must be reduced by 2 percent for each 1000 ft. (305 M) above
sea level.
In Canada,
altitudes
the input
INSTALL
Fig. 33 - NOx Device
4. Re-install
nose pliers to install the NOx device.
screw in hole underneath
NOTE:
It is very
mounting
screw.
NOTE:
if necessary,
IMPORTANT
to install in
heat exchanger
to reinstall
the NOx
Kit
Rating
Plate
be derated
inlet.
bracket
steps for each heat exchanger.
24
by 5 percent
for
to 1372 M) above sea level.
accounts
burner
orifices.
DO NOT
orifices
at least one
full
cross-threading,
then tighten with wrench.
orifices in each kit for largest furnace. Discard
A02195
3. Squeeze the sides of the device,
the heat exchanger.
must
for
high
altitude
ORIFICES
Install
main
Finger-tighten
2. Use a pair of needle
rating
of 2000 ft. to 4500 ft. (610
The Conversion
derate.
5. Repeat
average
specific-gravity
For Canada
M), use U.S.A.
Table 7 or 8.
and 315JAV). NOx baffles are not included in this kit and must
be ordered
separately
or reused
if retained
from original
conversion to Propane.
1. Remove
yearly
3. Find installation
A11395
DEVICE
heat-value
ply.
Screw
NOx
yearly
local gas supply.
Attach Green/Yellow
ground wire here
DO NOT reinstall
the manifold
use Teflon
tape.
turn
to prevent
There are enough
extra orifices.
at this time.
Table
8(Tabulated
Data Based
on 22,000
Orifice
Btuh
Size and Manifold
High-Heat/14,500
Pressure
(In. W.C.) for Gas Input
Btuh for Low-Heat
(305 M) Above
per Burner,
Rate
Derated
4 Percent
for Each 1000 Ft.
Sea Level)
SPECIFIC GRAVITY OF NATURAL GAS
ALTITUDE RANGE
FT. (M)
USA
0 to
2000
(0 to 610)
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
0.58
Orifice
No.
0.60
Manifold
Pressure
High/Low
Orifice
No.
0.62
Manifold
Pressure
High/Low
Orifice
No.
0.64
Manifold
Pressure
High/Low
Orifice
No.
Manifold
Pressure
High/Low
900
42
3.5/1.5
42
3.6/1.6
42
3.7/1.6
41
3.5/1.5
925
42
3.3/1.4
42
3.4/1.5
42
3.5/1.5
42
3.7/1.6
950
43
3.8/1.7
42
3.3/1.4
42
3.4/1.5
42
3.5/1.5
975
43
3.6/1.6
43
3.8/1.6
42
3.2/1.4
42
3.3/1.4
1000
43
3.5/1.5
43
3.6/1.6
43
3.7/1.6
43
3.8/1.7
1025
43
3.3/1.4
43
3.4/1.5
43
3.5/1.5
43
3.6/1.6
1050
44
3.6/1.6
43
3.2/1.4
43
3.4/1.5
43
3.5/1.5
1075
44
3.4/1.5
44
3.5/1.5
43
3.2/1.4
43
3.3/1.4
1100
44
3.3/1.4
44
3.4/1.5
44
3.5/1.5
43
3.2/1.4
SPECIFIC GRAVITY OF NATURAL GAS
ALTITUDE RANGE
FT. (M)
2001 to
USA
3000 (610
to 914)
ALTITUDE RANGE
FT. (a)
USA
3001 to
4000
(914 to
1219)
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
0.58
Orifice
No.
0.60
Manifold
Pressure
High/Low
USA
4001 to
5000
(1219 to
1524)
No.
Manifold
Pressure
High/Low
0.64
Manifold
Pressure
No.
High/Low
No.
Manifold
Pressure
High/Low
Orifice
Orifice
800
42
3.4/1.5
42
3.5/1.5
42
3.6/1.6
42
3.7/1.6
825
42
3.2/1.4
42
3.3/1.4
42
3.4/1.5
42
3.5/1.5
850
43
3.7/1.6
43
3.8/1.6
42
3.2/1.4
42
3.3/1.4
875
43
3.5/1.5
43
3.6/1.6
43
3.7/1.6
43
3.8/1.7
900
43
3.3/1.4
43
3.4/1.5
43
3.5/1.5
43
3.6/1.6
925
44
3.5/1.5
43
3.2/1.4
43
3.3/1.4
43
3.4/1.5
950
44
3.4/1.5
44
3.5/1.5
44
3.6/1.6
43
3.2/1.4
975
44
3.2/1.4
44
3.3/1.4
44
3.4/1.5
44
3.5/1.5
1000
45
3.7/1.6
45
SPECIFIC
3.8/1.7
GRAVITY
3.2/1.4
GAS
44
3.4/1.5
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
0.58
Orifice
No.
44
OF NATURAL
0.60
Manifold
Pressure
High/Low
Orifice
No.
0.62
Manifold
Pressure
High/Low
No.
42
3.2/1.4
42
3.3/1.4
42
800
43
3.6/1.6
43
3.8/1.6
42
825
43
3.4/1.5
43
3.5/1.5
850
43
3.2/1.4
43
875
44
3.5/1.5
900
44
925
950
High/Low
Manifold
Pressure
Orifice
No.
High/Low
3.4/1.5
42
3.5/1.5
3.2/1.4
42
3.3/1.4
43
3.7/1.6
43
3.8/1.6
3.3/1.4
43
3.4/1.5
43
3.6/1.5
44
3.6/1.6
43
3.3/1.4
43
3.4/1.5
3.3/1.4
44
3.4/1.5
44
3.5/1.5
43
3.2/1.4
45
3.8/1.6
44
3.2/1.4
44
3.3/1.5
44
3.4/1.5
46
3.8/1.6
45
3.7/1.6
45
3.8/1.7
44
3.3/1.4
SPECIFIC GRAVITY OF NATURAL GAS
0.58
AVG. GAS
HEAT VALUE
(BTUH/CU FT.)
0.64
Manifold
Pressure
Orifice
775
AVG, GAS
HEAT VALUE
(BTUH/CU
FT.)
ALTITUDE RANGE
FT. (M)
Orifice
0.62
0.60
0.62
0.64
No.
High/Low
No.
Manifold
Pressure
High/Low
3.8/1.6
42
3.2/1.4
42
3.3/1.4
3.5/1.5
43
3.6/1.6
43
3.8/1.6
43
3.3/1.4
43
3.4/1.5
43
3.5/1.5
3.4/1.5
44
3.6/1.5
43
3.2/1.4
43
3.3/1.4
44
3.2/1.4
44
3.4/1.5
44
3.5/1.5
44
3.6/1.6
875
45
3.7/1.6
45
3.8/1.7
44
3.3/1.4
44
3.4/1.5
900
46
3.7/1.6
46
3.8/1.7
45
3.7/1.6
44
3.2/1.4
925
46
3.5/1.5
46
3.6/1.6
46
3.7/1.6
46
3.8/1.7
Orifice
No.
Manifold
Pressure
High/Low
750
43
775
43
800
Orifice
No.
Manifold
Pressure
High/Low
3.6/1.6
43
3.4/1.5
43
43
3.2/1.4
825
44
850
Orifice number 43 are factory installed
25
Orifice
Manifold
Pressure
Orifice
Table
(Tabulated
Data Based
8 - Orifice
on 22,000
Btuh
Size and Manifold
Pressure
High-Heat/14,500
Btuh for Low-Heat
Above
ALTITUDE
RANGE
FT. (M)
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
Manifold
Pressure
Manifold
Pressure
Orifice
No.
No.
3.4/1.5
43
3.5/1.5
43
43
3.2/1.4
43
3.3/1.4
43
5001 to
6000
775
44
3.4/1.5
44
3.5/1.5
800
(1524
to
44
3.2/1.4
44
825
46
3.8/1.7
850
46
875
900
for Each 1000 Ft.
High/Low
0.64
Manifold
Pressure
Orifice
No.
High/Low
3.6/1.6
3.7/1.6
3.4/1.5
43
3.5/1.5
43
3.2/1.4
43
3.3/1.4
3.3/1.4
44
3.4/1.5
44
3.5/1.5
45
3.8/1.6
44
3.2/1.4
44
3.3/1.4
3.6/1.6
46
3.7/1.6
45
3.8/1.7
45
3.8/1.6
47
3.8/1.7
46
3.5/1.5
45
3.5/1.5
46
3.7/1.6
47
3.6/1.6
47
3.8/1.6
45
3.4/1.5
46
3.5/1.5
SPECIFIC GRAVITY OF NATURAL
0.60
0.62
0.58
Manifold
Pressure
Orifice
No.
Orifice
Manifold
Pressure
No.
High/Low
0.64
Manifold
Pressure
Manifold
Pressure
High/Low
Orifice
No.
3.7/1.6
Orifice
No.
GAS
High/Low
675
43
3.4/1.5
43
3.5/1.5
43
3.6/1.6
43
700
44
3.6/1.6
43
3.3/1.4
43
3.4/1.5
43
3.5/1.5
6001 to
7000
725
44
3.4/1.5
44
3.5/1.5
44
3.6/1.6
43
3.2/1.4
750
3.8/1.7
44
3.3/1.4
44
3.4/1.5
44
(1829
to
45
3.5/1.5
775
46
3.7/1.6
45
3.7/1.6
45
3.8/1.7
44
3.2/1.4
800
46
3.5/1.5
46
3.6/1.6
46
3.8/1.6
45
3.7/1.6
825
47
3.7/1.6
46
3.4/1.5
46
3.5/1.5
46
3.6/1.6
850
47
3.5/1.5
47
3.6/1.6
47
3.8/1.6
46
3.4/1.5
2134)
ALTITUDE
RANGE
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
SPECIFIC GRAVITY OF NATURAL
0.60
0,62
0.58
Manifold
Pressure
Orifice
No.
High/Low
Orifice
Manifold
Pressure
No.
High/Low
GAS
0.64
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
High/Low
High/Low
650
44
3.6/1.6
43
3.2/1.4
43
3.4/1.5
43
3.5/1.5
675
44
3.3/1.5
44
3.5/1.5
44
3.6/1.6
43
3.2/1.4
7001 to
8000
700
45
3.8/1.6
44
3.2/1.4
44
3.3/1.4
44
3.4/1.5
725
3.7/1.6
46
3.8/1.7
45
3.7/1.6
44
(2134
to
46
3.2/1.4
750
46
3.4/1.5
46
3.6/1.5
46
3.7/1.6
46
3.8/1.6
775
47
3.6/1.6
47
3.8/1.6
46
3.4/1.5
46
3.6/1.5
800
47
3.4/1.5
47
3.5/1.5
47
3.7/1.6
47
3.8/1.6
825
48
3.7/1.6
48
3.8/1.6
47
3.4/1.5
47
3.6/1.5
2438)
ALTITUDE
RANGE
AVG, GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
SPECIFIC GRAVITY OF NATURAL
0.60
0,62
0.58
Orifice
No.
Manifold
Pressure
High/Low
USA
4 Percent
43
High/Low
USA
High/Low
43
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU FT.)
(Con't.)
Manifold
Pressure
Orifice
750
ALTITUDE
RANGE
USA
Derated
725
1829)
USA
Rate
per Burner,
Sea Level)
High/Low
USA
for Gas Input
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.58
Orifice
No.
(In. W.C.)
Orifice
Manifold
Pressure
No.
High/Low
Orifice
No.
GAS
0.64
Manifold
Pressure
Orifice
No.
High/Low
625
44
3.3/1.5
44
3.5/1.5
44
8001 to
9000
650
45
3.7/1.6
44
3.2/1.4
44
675
46
3.6/1.6
46
3.8/1.6
(2438
to
700
47
3.8/1.7
46
725
47
3.6/1.6
2743)
750
48
775
Manifold
Pressure
High/Low
3.6/1.6
43
3.2/1.4
3.3/1.4
44
3.4/1.5
45
3.7/1.6
45
3.8/1.7
3.5/1.5
46
3.6/1.6
46
3.7/1.6
47
3.7/1.6
47
3.8/1.7
46
3.5/1.5
3.8/1.7
47
3.5/1.5
47
3.6/1.6
47
3.7/1.6
48
3.6/1.5
48
3.7/1.6
48
3.8/1.7
47
3.5/1.5
600
45
3.7/1.6
45
3.8/1.7
44
3.3/1.4
44
3.4/1.5
9001to
625
46
3.6/1.6
46
3.7/1.6
46
3.8/1.7
45
3.8/1.6
10,000
2743to
650
675
47
3.8/1.6
46
3.4/1.5
46
3.6/1.5
46
3.7/1.6
47
3.5/1.5
47
3.6/1.6
47
3.7/1.6
46
3.4/1.5
3048)
700
48
3.7/1.6
48
3.8/1.7
47
3.5/1.5
47
3.6/1.6
725
48
3.5/1.5
48
3.6/1.6
48
3.7/1.6
48
3.8/1.7
Orifice number43arefactoryinstalled
2d
Table
(Tabulated
Data Based
9 - Orifice
on 21,000
Size and Manifold
Btuh High-Heat/14,500
Pressure
Btuh
(In. W.C.)
for Low-Heat
(305 M) Above
ALTITUDE RANGE
FT. (M)
USA
0 to
2000
(0 to 610)
0.58
Manifold
Pressure
FT. (M)
USA
3000
(610
to 914)
ALTITUDE RANGE
FT. (M)
3001 to
USA
4000 (914
to 1219)
FT. (M)
USA
Manifold
Pressure
Orifice
Manifold
Pressure
Orifice
No.
High/Low
No.
High/Low
No.
High/Low
No.
High/Low
42
3.2/1.5
42
3.3/1.6
42
3.4/1.6
42
3.5/1.7
925
43
3.7/1.8
43
3.8/1.8
42
3.2/1.5
42
3.3/1.6
950
43
3.5/1.7
43
3.6/1.7
43
3.7/1.8
43
3.8/1.8
975
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
43
3.7/1.7
1000
44
3.6/1.7
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
1025
44
3.4/1.6
44
3.6/1.7
43
3.2/1.5
43
3.3/1.6
1050
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
43
3.2/1.5
1075
45
3.8/1.8
44
3.2/1.5
44
3.3/1.6
44
3.4/1.6
1100
46
3.8/1.8
45
3.7/1.8
44
3.2/1.5
44
3.3/1.6
AVG, GAS
HEAT VALUE
0,58
GRAVITY
OF NATURAL
0,60
No.
Manifold
Pressure
High/Low
800
43
825
43
850
GAS
0,62
No.
Manifold
Pressure
High/Low
3.8/1.8
42
3.5/1.7
43
43
3.3/1.6
875
43
900
0,64
Manifold
No.
High/Low
No.
Manifold
Pressure
High/Low
3.2/1.5
42
3.3/1.6
42
3.4/1.6
3.7/1.7
43
3.8/1.8
42
3.2/1.5
43
3.5/1.6
43
3.6/1.7
43
3.7/1.8
3.2/1.5
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
44
3.4/1.6
44
3.5/1.7
43
3.2/1.5
43
3.3/1.6
925
44
3.2/1.5
44
3.3/1.6
44
3.5/1.6
44
3.6/1.7
950
45
3.7/1.8
45
3.8/1.8
44
3.3/1.6
44
3.4/1.6
975
46
3.7/1.8
46
3.8/1.8
45
3.8/1.8
44
3.2/1.5
1000
46
3.5/1.7
46
3.6/1.7
46
3.8/1.8
45
3.7/1.8
AVG. GAS
HEAT VALUE
(BTUH/CU
FT.)
Orifice
Orifice
SPECIFIC
0.58
Orifice
High/Low
Orifice
GAS
0.62
Manifold
Pressure
Orifice
No.
Pressure
OF NATURAL
0.60
Manifold
Pressure
Orifice
No.
GRAVITY
0.64
Manifold
Pressure
Orifice
No.
High/Low
Manifold
Pressure
Orifice
No.
High/Low
High/Low
775
43
3.5/1.7
43
3.7/1.7
43
3.8/1.8
42
3.2/1.5
800
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
43
3.7/1.7
825
44
3.6/1.7
43
3.2/1.5
43
3.3/1.6
43
3.4/1.6
850
44
3.4/1.6
44
3.5/1.7
44
3.6/1.7
43
3.2/1.5
875
45
3.8/1.8
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
900
46
3.8/1.8
45
3.8/1.8
44
3.2/1.5
44
3.3/1.6
925
46
3.6/1.7
46
3.7/1.8
45
3.7/1.8
45
3.8/1.8
950
46
3.4/1.6
46
3.5/1.7
46
3.7/1.7
46
3.8/1.8
SPECIFIC
ALTITUDE RANGE
0.64
900
(BTUH/CU
FT.)
2001 to
for Each 1000 Ft.
0.62
Manifold
Pressure
Orifice
SPECIFIC
ALTITUDE RANGE
4 Percent
GRAVITY OF NATURAL GAS
0.60
Orifice
Rate
Derated
Sea level)
SPECIFIC
AVG, GAS
HEAT VALUE
(BTUH/CU
FT.)
for Gas Input
Per Burner,
AVG, GAS
HEAT VALUE
(BTUH/CU
FT.)
0,58
Orifice
No.
GRAVITY
OF NATURAL
0,60
Manifold
Pressure
Orifice
No.
High/Low
GAS
0,62
Manifold
Pressure
Orifice
No.
High/Low
0,64
Manifold
Pressure
Orifice
No.
High/Low
Manifold
Pressure
High/Low
750
43
3.3/1.6
43
3.4/1.6
43
3.5/1.7
43
3.6/1.7
775
44
3.6/1.7
43
3.2/1.5
43
3.3/1.6
43
3.4/1.6
4001 to
800
44
3.3/1.6
44
3.4/1.6
44
3.6/1.7
43
3.2/1.5
5000
825
45
3.8/1.8
44
3.2/1.5
44
3.4/1.6
44
3.5/1.6
(1219 to
1524)
850
46
3.8/1.8
45
3.7/1.8
45
3.8/1.8
44
3.3/1.6
875
46
3.5/1.7
46
3.7/1.7
46
3.8/1.8
45
3.7/1.8
900
47
3.8/1.8
46
3.5/1.7
46
3.6/1.7
46
3.7/1.8
925
47
3.6/1.7
47
3.7/1.8
47
3.8/1.8
46
3.5/1.7
Orifice number 43 are factory installed
27
Table
(Tabulated
Data Based
9 - Orifice
on 21,000
Size and Manifold
Btuh High-Heat/14,500
Pressure
(In. W.C.)
(305 M) Above
ALTITUDE RANGE
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.58
0.64
High/Low
No.
High/Low
No.
High/Low
No.
High/Low
725
44
3.5/1.7
46
3.2/1.5
43
3.3/1.6
43
3.4/1.6
750
44
3.6/1.6
44
3.4/1.6
44
3.5/1.7
46
3.2/1.5
5001 to
775
45
3.7/1.8
44
3.2/1.5
44
3.3/1.6
44
3.4/1.6
6000
800
46
3.7/1.8
46
3.8/1.8
45
6.8/1.8
44
6.2/1.5
(1524 to
1829)
825
46
3.5/1.7
46
3.6/1.7
46
3.7/1.8
46
3.8/1.8
850
47
3.7/1.8
47
3.8/1.8
46
3.5/1.7
46
3.6/1.7
875
47
3.5/1.7
47
3.6/1.7
47
3.7/1.8
46
3.4/1.6
900
48
3.8/1.8
47
3.4/1.6
47
6.5/1.7
47
6.7/1.7
(BTUH/CU
FT.)
SPECIFIC
AVG. GAS
HEAT VALUE
AT ALTITUDE
0.58
GRAVITY
Manifold
Pressure
Orifice
OF NATURAL
0.60
Manifold
Pressure
Orifice
GAS
0,62
0.64
Orifice
Manifold
Pressure
No.
High/Low
No.
675
44
3.5/1.7
43
3.2/1.5
43
3.3/1.6
43
3.4/1.6
700
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
46
3.2/1.5
6001 to
725
45
6.7/1.8
45
6.8/1.8
44
3.3/1.6
44
3.4/1.6
7000
750
46
3.6/1.7
46
3.8/1.8
45
6.7/1.8
45
6.8/1.8
(1829 to
2134)
775
46
3.4/1.6
46
3.5/1.7
46
3.6/1.7
46
3.8/1.8
800
47
3.6/1.7
47
3.8/1.8
46
3.4/1.6
46
3.5/1.7
825
47
3.4/1.6
47
3.5/1.7
47
3.6/1.7
47
3.8/1.8
850
48
3.7/1.7
48
3.8/1.8
47
3.4/1.6
47
3.5/1.7
(BTUH/CU
FT.)
0.58
GRAVITY
OF NATURAL
High/Low
GAS
0,62
0.64
Manifold
Pressure
Orifice
Manifold
Pressure
Orifice
Manifold
Pressure
High/Low
No.
High/Low
No.
High/Low
Orifice
No.
High/Low
Manifold
Pressure
Orifice
No.
High/Low
0.60
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
High/Low
SPECIFIC
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU
FT.)
Manifold
Pressure
Orifice
650
44
3.3/1.6
44
3.4/1.6
44
3.5/1.7
46
3.2/1.5
675
45
6.7/1.8
45
6.8/1.8
44
3.3/1.6
44
3.4/1.6
7001 to
700
46
3.6/1.7
46
3.7/1.8
46
3.8/1.8
45
3.8/1.8
8000
725
47
3.8/1.8
46
3.5/1.7
46
3.6/1.7
46
3.7/1.8
(2164 to
2468)
750
775
47
6.5/1.7
47
6.7/1.8
47
3.8/1.8
46
3.5/1.6
48
3.8/1.8
47
3.4/1.6
47
3.6/1.7
47
3.7/1.7
800
48
3.6/1.7
48
3.7/1.8
48
3.8/1.8
47
3.4/1.6
825
48
3.3/1.6
48
3.5/1.6
48
3.6/1.7
48
3.7/1.8
RANGE
FT. (M)
AVG, GAS
HEAT VALUE
AT ALTITUDE
(BTUH/CU
FT.)
USA
for Each 1000 Ft.
No.
FT. (M)
USA
4 Percent
Sea level)
Orifice
ALTITUDE RANGE
ALTITUDE
(Con't.)
Orifice
FT. (M)
USA
Derated
Manifold
Pressure
ALTITUDE RANGE
USA
Rate
Per Burner,
Manifold
Pressure
FT. (M)
USA
AVG. GAS
HEAT VALUE
AT ALTITUDE
for Gas Input
Btuh for Low-Heat
SPECIFIC
0.58
Orifice
No.
GRAVITY
OF NATURAL
0.60
Manifold
Pressure
Orifice
No.
High/Low
GAS
0,62
Manifold
Pressure
Orifice
No.
High/Low
0.64
Manifold
Pressure
Orifice
No.
High/Low
Manifold
Pressure
High/Low
625
45
6.7/1.8
45
6.8/1.8
44
3.3/1.6
44
3.4/1.6
650
46
3.6/1.7
46
3.7/1.8
46
3.8/1.8
45
3.8/1.8
8001 to
675
47
3.8/1.8
46
3.4/1.6
46
3.5/1.7
46
3.7/1.7
9000
(2468 to
2746)
700
47
3.5/1.7
47
3.6/1.7
47
3.7/1.8
46
3.4/1.6
48
3.7/1.8
48
3.8/1.8
47
3.5/1.7
47
3.6/1.7
48
3.5/1.7
48
3.6/1.7
48
3.7/1.8
48
3.8/1.8
775
49
3.8/1.8
48
3.4/1.6
48
3.5/1.7
48
3.6/1.7
600
46
3.6/1.7
46
3.7/1.8
46
3.8/1.8
45
3.7/1.8
9001 to
625
47
3.7/1.8
47
3.8/1.8
46
3.5/1.7
46
3.6/1.7
10,000
650
47
3.4/1.6
47
3.6/1.7
47
3.7/1.8
47
3.8/1.8
675
700
48
3.6/1.7
48
3.8/1.8
47
3.4/1.6
47
3.5/1.7
48
3.4/1.6
48
3.5/1.7
48
3.6/1.7
48
3.7/1.8
725
49
3.7/1.8
49
3.8/1.8
48
3.4/1.6
48
3.5/1.7
(2746 to
3048)
725
750
Orifice number 43 are factory installed
28
REMOVE
MIXER SCREWS
Each burner
contains
a mixer screw that must be removed.
f
Refer
1-7/8
to Fig. 35 for the mixer screw location.
1. Remove
the mixer screws
from the burners.
NOTE:
It is not necessary to plug the hole in the burner
the mixer screws are removed.
when
O
(47'imm)
Location of mixer screw
that must be removed
i
A05026
Fig. 37 - Igniter
Position
- Top View
I
_,_11/32
,,
8.7 mm
1-9/16"
--_[
1
39.7 mm
f
Al1511
Fig. 35 - Mixer
Screw
CELL
PANEL
Location
_HOT
SURFACE
IGNITER
ASSEMBLY
5/16"
7.9ram
/
{
IGNITER
7/8,,
22.2 mm
BURNER
IGNITER
ASSEMBLY
A05025
Fig. 36 - Igniter
Position
BURNER
ASSEMBLY
REINSTALL
To reinstall
burner
1. Attach
flame sensor
CONVERT
to burner
assembly.
box and
HSI wires to HSI.
5. Verify igniter
6. For Silicon
7. For Silicon
GAS VALVE
assembly.
to burner
3. Insert one-piece burner in slot on sides of burner
slide burner back in place.
8. Re-attach
Fig. 38 - Silicon Carbide Igniters
assembly:
2. Install HSI and bracket
4. Reattach
A93347
- Side View
to burner
Nitride
Carbide
Flame
igniters,
see Fig. 36 and 37.
see Fig. 38.
Sensor wire to Flame
DAMAGE
HAZARD
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 natural
gas. The E valves must be
pre-adjusted
before operating
on natural gas. If left this
way, sooting and corrosion will occur leading to early heat
exchanger failure.
alignment.
igniters,
[]NIT
Sensor.
29
TWO-STAGE
ON/OFF
FIRE,EXPLOSION,
ELECTRICAL
SHOCK
HAZARD
Failure
to follow
this warning
could result in personal
iniury,
death or property
Switch f
,,
......
_:::_-_
, Regulator
Seal Cap
Regulator
Regulator
1/2' NPT inlet
Adjustment
Seal Cap
under Cap
damage.
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
1/8" NPT Inlet
Pressure
Tap
NPT Outlet
ELECTRICAL
HAZARD
SHOCK,
FIRE
OR
EXPLOSION
1/8" NPT Manifold
Pressure
Failure to follow
this warning
iniury, death or property damage.
could
result
Al1152
Fig. 39 - 2-Stage
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:
For the 2-stage
furnaces
2-stage
Fig.
DO
40),
replaced
they
furnaces
NOT
need
with
for natural
For J and G valves
LOW-HEAT
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
--
(UNDER CAP)
ALLEN SCREW
springs
the regulator
springs
PLUG BUTTON
(2-STAG
E AND
applications.
supplies
MANIFOLD
PRESSURE
TAP
are turned OFF.
BURNER
2. Remove
both regulator
seal caps. (See Fig. 39.)
3. Remove
both regulator
adjustment
4. Remove
both Propane gas regulator
5. Install natural
6. Install regulator
VARIABLE
SPEED,
NON CONDENSING
FURNACES ONLY)
t/
in the gas valve must
See Fig 39.
1. Be sure main gas and electrical
HIGH-HEAT
ADJUSTMENT
a Series E gas valve (see
to have
in the gas valve, but the regulators
be pre-adjusted
J or G Valve
with a Series J and Series G gas
valve (see Fig. 39), they MUST have both regulator
replaced and the gas valve MUST be pre-adjusted.
For older model
Tap
in personal
gas regulator
springs
adjustment
screws.
screws.
springs
ENCLOSURE
"_/
REFERENCE PRESSURE TAP(2-STAGE
AND VARIABLE-SPEED,
CONDENSING
FURNACES
ONLY)
(white).
A01069
(silver).
Fig. 40 - 2-Stage
REMOVE
E Valve
LOW GAS PRESSURE SWITCH
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.
8. Turn high-heat
stage adjusting screw clockwise (inwards)
12 turns. This will increase the manifold pressure closer to
the high-heat
set point.
9. DO NOT install regulator
For E valves
FIRE, EXPLOSION,
HAZARD
Failure to follow
this warning
iniury, death or property damage.
supplies
Gas supply
MUST
be shut off before
disconnecting
electrical power and proceeding with conversion.
2. Remove
caps
and low-heat
that conceal
to furnace
adjustment
stage gas valve regulators.
are off.
screws
could
SHOCK
seal caps at this time,
see Fig 40.
1. Be sure gas and electrical
ELECTRICAL
result
in personal
for high-
(See Fig. 40.)
3. Turn low-heat
stage adjusting screw (3/32-in.
[2 mm] hex
Allen screw) counter clockwise
(outwards)
1 full turn.
This will decrease the manifold pressure closer to the natural low-heat
set point.
4. Turn high-heat
stage adjusting screw
hex Allen screw) counter
clockwise
turns. This will decrease the manifold
the natural
high-heat
ELECTRICAL
HAZARD
(3/32-in.
[2 mm]
(outwards)
2 full
pressure closer to
FIRE
Failure to follow
this warning
iniury, death or property damage.
set point.
5. DO NOT install regulator
SHOCK,
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 suitable
warning label. Verify proper operation after servicing.
seal caps at this time.
30
1.Besure
main
gasandelectric
supplies
to furnace
are off.
2. Remove low-gas
pressure switch, brass street 90 ° elbow
and 2-in. brass nipple from the gas valve inlet pressure
tap. (See Fig. 41.)
NOTE:
Use pipe dope
6. Connect
niter.
the wires to the flame
7. Connect
the connector
8. Rewire
approved
for use with Propane
sparingly
to the l/8-in.
gas. DO
pipe dope
harness
unit low pressure
and hot surface
NPT pipe plug
ig-
to gas valve.
switch (LPS)
as follows:
a. Trace one of the orange wires previously
from the LGPS back to the NO terminals
NOT use Teflon tape.
3. Apply
sensor
disconnected
of the LPS.
b. Trace the other orange wire previously
disconnected
from the LGPS back to its splice connection with the yellow wire of the furnace wire harness. Disconnect and dis-
(provided
in kit) and install in the l/8-in,
tapped inlet
pressure tap opening in the gas valve. DO NOT overtighten. Check for gas leaks after gas supply has been
turned on.
card this orange
c. Connect
wire and the splice connection.
the yellow wire of the furnace
"b" above) to the NO terminal
d. Refer to the furnace
tion of wires.
2" Brass Nipple
Low Gas
NOTE:
Pressure
Teflon tape.
Switch
Use
only
wiring
diagram
Propane-resistant
wire harness
(see
of the LPS.
ensure
pipe dope.
proper loca-
DO NOT
use
9. 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.
Female x Female x Male Tee
NOTE:
1/8" NPT Pipe Plug
For inlet pressure tap
/
41
- 80%
Low
Gas
Pressure
wrench
Switch
11. Turn gas on at electric
CHECK
FIRE
AND EXPLOSION
Failure to follow
and/or death.
NEVER
test
commercially
the detection
explosion
injury
gas
leaks
available
of leaks
may
with
causing
to prevent
the mounting
the
to
GAS
switch on gas valve.
PRESSURE
injury
an open
flame.
Use
a
property
damage,
SW4
(CF) airflow setup
switches CF 1 through
CF 3
'-_
personal
or loss of life,
24 VAC
HUM Output
(O.5AMP
Air Thermi,'
SW3 Continuous
soap solution made specifically
for
to check all connections.
A fire or
result
or damaging
SW4
could result in personal
Outside
for
INLET
HAZARD
this warning
on the gas valve
on the manifold
10. With a back-up wrench on the inlet boss of the gas valve,
finish tightening the gas pipe to the gas valve.
Al1398
Fig.
Use a back-up
valve from rotating
the burner box.
[]
<_I=_
O_
PL9
Communication
in
._ol
RISQUE
D'EXPLOSION
Mode, P,ug_
ET D'INCENDIE
Le fair de ne pas suivre cet avertissement
dommages
corporels et / ou la mort.
pourrait
entra*ner
[_
SW3
_-N _i_,:_ __
des
/,_
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 tous les connections.
Un incendie ou une explosion
peut entrainer des dommages
mat6riels, des blessures ou la mort.
/_Zl
SW2
_
W2
Yt
DHUM
Setup Switches SWl,
1 thru 8
SW2 A/C Air Flow
Setup Switches
AC 1 through AC 3
Al1471
Fig. 42 - Furnace
INSTALL
Control
MANIFOLD
1. Align
the orifices
in the manifold
assembly
with the sup-
port rings on the end of the burner.
2. Insert the orifices
ifold
box.
mounting
in the support
tabs should
NOTE:
If manifold
burners
are not fully seated
does not fit flush against
check burner positioning
3. Attach
against
Man-
the burner
the burner box, the
Remove
the manifold
mounting
wire and ground
terminal
to one
screws.
manifold
mounting
the wires to both rollout
UNIT
DAMAGE
HAZARD
Failure
to follow
this caution
DO NOT operate
inlet gas pressure,
and
in the burner box assembly.
4. Install the remaining
5. Connect
forward.
the green/yellow
of the manifold
rings of the burners.
fit flush
screws.
switches.
31
may result in unit damage.
furnace more than one minute to check
as conversion is not complete at this time.
NOTE: This kit is to be used only when inlet gas pressure is
between 4.5-in. W.C. and 13.6-in. W.C.
1. Verify manometer is connected to inlet pressure tap on gas
valve.
ELECTRICAL
HAZARD
2. Turn on furnace power supply.
3. Turn gas supply manual shutoff valve to ON position.
6. Jumper R-W/W1
control.
OR
EXPLOSION
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.
on furnace control ON (see
and R-W2 thermostat connections
FIRE
Failure to follow this warning could result in personal
iniury, death or property damage.
4. Turn furnace gas valve switch to ON position.
5. Turn Setup Switch SWl-2
Fig. 42).
SHOCK,
on
7. When main burners ignite, confirm inlet gas pressure is
between 4.5-in. W.C. and 13.6-in. W.C.
1. Be sure main gas and electric
8. Remove jumper across R-W/W1 and R-W2 thermostat
connections to terminate call for heat.
2. Remove
1/8-in.
tap on downstream
9. Turn furnace gas valve switch to OFF position.
10. Turn gas supply manual shutoff valve to OFF position.
3. Attach
5. Turn furnace
6. Check
13. Apply pipe dope sparingly to the 1/8-in. NPT pipe plug
and install in the 1/8-in. tapped inlet-pressure tap opening
in the gas valve. DO NOT over-tighten. Check for gas
leaks after gas supply has been turned on.
CHECK FURNACE
AND MAKE ADJUSTMENTS
to manifold
manual
INPUT
manifold
are off.
pressure
tap on gas valve,
valve to ON position,
to ON position,
pipe connections
power
RATE
to furnace
from
pressure
shutoff
gas valve switch
all threaded
7. Turn on furnace
GAS
plug
side of gas valve,
manometer
4. Turn gas supply
11. Turn off furnace power supply.
12. Remove manometer.
supplies
NPT pipe
for gas leaks,
supply,
INFORMATION
See furnace rating plate for input rate. The input rate for natural
gas is determined by manifold pressure and orifice size.
Determine
natural gas orifice size and manifold
pressures
correct input at installed altitude by using Table 7 or 8.
NOTE:
FIRE
AND EXPLOSION
HAZARD
downflow
burner).
Failure to follow this warning could result in personal injury
and/or death.
NEVER test for gas
commercially available
the detection of leaks
explosion may result
injury or loss of life.
All models
Low
NOx
must use Table
rating plate.
leaks with an open flame. Use a
soap solution made specifically for
to check all connections. A fire or
causing property damage, personal
in all positions
and horizontal
models
8 (21,000
2. Obtain
ply.
yearly
NOTE:
For Canada
M), use U.S.A.
Table 7 or 8.
Low
NOx models
or horizontal
per burner).
average
specific-gravity
positions
See input
(at installed
average
in
Btuh per
listed on
altitude)
for
for local gas sup-
altitude in Table 7 or 8.
altitudes
Altitudes
of 2000
of 2001
to 4500
to 3000
ft. (610
to 1372
ft. (610 to 914 M) in
ET D'INCENDIE
Le fait de ne pas suivre cet avertissement pourrait entrai'nerdes
dommages corporels et / ou la mort.
4. Find closest natural gas heat value and specific gravity in
TaMe 7 or 8.
Ne jamais examiner pour les fuites de gaz avec une flamme
vive. Utilisez plut6t un savon fait 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.
FIRE, EXPLOSION,
HAZARD
except
use Table 7 (22,000
in downflow
Btuh
1. Obtain yearly heat-value
local gas supply.
3. Find installation
RISQUE D'EXPLOSION
positions
for
ELECTRICAL
5. Follow heat-value line and specific-gravity line to point
of intersection to find orifice size and high and low manifold pressure settings.
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. (610
M) must be reduced by 4 percent for each 1000 ft. (305 M) above
sea level.
In Canada, the input rating must be derated by 5 percent for
altitudes of 2000 ft. (610 M) to 4500 ft. (1372 M) above sea
level.
SHOCK
Failure to follow this warning could result in personal
iniury, death or property damage.
The Conversion
derate.
Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.
SET GAS INPUT
Kit Rating Plate accounts
for high altitude
RATE
1. Make sure the gas supply is turned off to the furnace and
at the electric switch on the gas valve.
2. Remove the 1/8 inch NPT plug from the outlet pressure
tap on the gas valve.
3. Connect a manometer
valve.
32
to the outlet pressure tap on gas
4.Turnonfurnace
power
supply.
5.Turngassupply
manual
shutoff
valve
toONposition.
6.Turnfurnace
gasvalve
switch
toONposition.
7.VerifySWI-2
onfurnace
control
isturned
"ON".See
Fig.
42.
8.Jumper
R andW/WIthermostat
connections
tocallfor
heat.
9.Check
manifold
orifices
forgasleaks
when
mainburners
ignite.
10.Adjust
gasmanifold
pressure.
(Refer
toTable
7or8.)
11.Remove
caps
thatconceal
adjustment
screws
forgasvalve
regulators.
(See
Fig.39.)
12.Adjustlow-heat
manifold
pressure
fornatural
gas.(See
Fig.39.)
13.Turnlow-heat
adjusting
screw
counterclockwise
(out)to
decrease
inputrateorclockwise
(in)toincrease
input
rate.
NOTE:Whencorrect
inputis obtained,
mainburner
flame
should
beclear
blue,
almost
transparent
(see
Fig.43).
14.Jumper
R,W/WIandW2oncontrol
center
thermostat
connections.
Thiskeeps
furnace
locked
inhigh-heat
operation.
15.Adjust
high-heat
manifold
pressure
fornatural
gas.
16.Turnhigh-heat
adjusting
screw
counterclockwise
(out)to
decrease
inputrateorclockwise
(in)toincrease
input
rate.
17.Replace
caps
thatconceal
thegasvalveregulator
adjustment
screws.
NOTE:Whencorrect
inputis obtained,
mainburner
flame
should
beclear
blue,
almost
transparent.
(See
Fig.43).
18. Remove
jumper
justment
across R, Wl,
to terminate
19. Turn setup switch SWI-2
tion.
20. Turn furnace
power
manometer
23. Turn furnace
on furnace
gas valve switch
21. Turn off furnace
22. Remove
plug.
and W2 after high-heat
power
to OFF posi-
to OFF position.
and re-install
25. Set room thermostat
control
supply.
gas valve switch
24. Turn on furnace
ad-
call for heat.
manifold
pressure
tap
to ON position.
supply.
to call for heat.
26. Check
ignite.
pressure
tap plug for gas leaks when main
27. Check
for correct burner
burners
flame.
28. After making the required manifold pressure adjustments,
check and adjust the furnace temperature
rise per the furnace installation
instructions.
LABEL
APPLICATION
1. Fill in Conversion
Responsibility
Label
338305-205
and
apply to Blower Access Door of furnace as shown. Date,
name, and address of organization
making this conversion
are required.
2. Attach
See Fig. 44.
Conversion
door of furnace.
3. Apply
G
Rating
Gas Control
gas
Plate Label 38305-204
to outer
See Fig. 45.
valves,
Conversion
use
Gas
Label:
Control
For 2-stage
Conversion
J and
Label
338305-202.
(DO NOT use 338305-203,
which is similar.) For 2-stage E gas valve, use Gas Control Adjustment
Label 338305-203.
similar.)
Burner Flame
4. Replace control
door of furnace.
Burner
(DO NOT use 338305-202,
access door, blower
which
is
access door and outer
CHECKOUT
1. Observe
unit operation
through 2 complete
2. See Sequence of Operation
in fltrnace
Up, and Operating Instructions.
3. Set room thermostat
to desired
heating
Installation,
cycles.
Start-
temperature.
Al1461
Fig. 43 - Burner
Flame
THIS FURNACE WAS CONVERTED
CE GI_NI_RATEUR D'AIR CHAUD
ON
CONVERTILE
TO NATURAL GAS
A #TI_
POUR
(DAY-MONTH-YEAR)
(JOUR-MOIS-ANNI_E)
KIT NO.: KGAPN4401VSP
DE L'ENSEIBLE
BY:
PAR:
N°.:KGAPN440IVSP
(Name and address of organization making this conversion),
which accepts the responsibility
that this conversion has
(Nora et adresse de ['organisme qui a effectu6
been properly made.
qui accepte
|' entri6re
responsabilit6
la conversion),
de [a conversion,
338305-205 REV.A
Al1504
Fig. 44 - Conversion
Responsibility
33
Label
CONVERSION
KiT
RATING
PLATE
CARRIER
THiS APPLIANCE
HAS BEEN CONVERTED
TO USE NATURAL GAS FOR FUEL. REFER
PROCEDURES.
USE PARTS SUPPLIED BY CARRIER CORPORATION
AND iNSTALLED
SEE EXiSTiNG RATING PLATE FOR APPLIANCE
MODEL NO. AND iNPUT RATING.
CORPORATION
TO KiT iNSTRUCTiONS
FOR CONVERSION
BY QUALiFiED
PERSONNEL.
NOTE: Furnace gas inputrate on ratingplate is for installationsup to 2000 ft. (610m)above sea level, in U.S.A.the inputratingfor altitudesabove 2000 ft. (610m) must
be derated by 4%for each 1000 ft. (305m) above sea level, in Canadathe input ratingmust be derated (per chartbelow) for altitudesof 2000 ft. (610m) to 4500 ft. (1372m)
above sea level.
(SUPERSEDES: KGAPN3501ALL, KGAPN3401ALL, KGAPN1601ALL,
FUEL USED: NATURAL GAS
KIT NO.: KGAPN4401VSP
KGAPN21012SP, KGAPN2201ALL, KGAPN3301ALL, KGAPN3901ALL)
APPLIANCE
MODELS
58CVA, 58CVX
315AAV, 315JAV,
PG8JVA,PG8MVA
USA
% DERATE
PER
1000 FT.
4%
CANADA
% DERATE
FOR
20004500 FT.
IN. W.C. (PO
NATURAL GAS PRESSURE
Max. Inlet Gas Pressure
(Press. Max. D'Admission De Gaz)
Min. Inlet Gas Pressure
10%
(For
(Press. Min. D'Admissi0n De Gaz)
Purpose
of Input Adjustment)
ALTITUDE
Manifold
Pressure
Pression
Tubulure
0-2,000
ft.
(Pour
High Heat
(0-610m)
2,000 = 10,000 ft.
(610 = 3050 m)
C.E.)
PA
13.6
3,386
4.5
1,121
L'Adjustment
3.2
D'Entree)
= 3.8
Low Heat
1.4 = 1.8
Refer to Installation
Respecter
les instruction
/ 797
= 946
1,1,1,1,_',
] 349 = 448
Manual
D'lnstallation
_.
338305-204 REV. B
Al1634
Fig. 45 - Conversion
Copyright 2012 CAC / BDP • 7310 W. Morris St. • Indianapolis. IN 46231
Rating
Plate Label
Edition Date: 08/12
Manufacturer reserve8 the right to change, at any time, specification8 and design8 without notice and without obligations.
34
Catalo_l
No:
AG-KGAPNVSP-O4
Replaces: AG KGAPNVSP 03
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.2 Linearized : No Page Count : 34 Page Layout : SinglePage Page Mode : UseNone Producer : Goby Monitor Application version 4, 0, 0, 13 Create Date : Sun Sep 30 18:55:28 2012 Author : Title : Subject :EXIF Metadata provided by EXIF.tools