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

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Page Count: 34

Installation Instructions

NOTE: Read the entire instruction manual before starting the

installation.

SAFETY CONSIDERATION

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

injury or death.

This conversion kit shall be installed by a qualified service

agency in accordance with the manufacturer's instructions

and all applicable codes and requirements of the authority

having jurisdiction. If the information in these instructions

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

carbon monoxide 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.

LE FEU, L'EXPLOSION, CHOC ELECTRIQUE,

ET MONOXYDE DE CARBONE

EMPOISONNER

Cette trousse de conversion doit 0tre install0e par un servie

d'entretien qualifiO, selon les instructions du fabricant et

selon routes les exigences et tousles codes pertinents de

l'autoritO compOtente. Assurezvous de bien suivre les

instructions dans cette notice pour 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.

Installing and servicing heating equipment can be hazardous due

to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions

such as cleaning and replacing air filters. Trained service

personnel must perform all other operations. When working on

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

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

safety precautions that may apply.

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

codes including the current edition of the National Fuel Gas Code

(NFGC) NFPA No. 54/ANSI Z223.1. In Canada, refer to the

current edition of the National Standard of Canada, Natural Gas

and Propane Installation Codes (NSCNGPIC),

CAN/CSA-BI49.1 and .2. Wear safety glasses and work gloves.

Have a fire extinguisher available during start-up, adjustment

steps, and service calls.

Recognize safety information. This is the safety-alert symbol

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

or manuals, be alert to the potential for personal iniury.

Understand the signal words DANGER, WARNING, CAUTION

and NOTE. The words DANGER, WARNING, and CAUTION

are used with the safety alert symbol. DANGER identifies the

most serious hazards which will result in severe personal iniury or

death. WARNING signifies a hazard which could result in

personal iniury or death. CAUTION is used to identify unsafe

practices which may result in minor personal iniury or product

and property damage. NOTE is used to highlight suggestions

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

INTRODUCTION

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow instructions could result in personal iniury,

death or property damage.

Improper installation, adjustment, alteration, service,

maintenance, or use can cause carbon monoxide poisoning,

explosion, fire, electrical shock, or other conditions, which

could result in personal iniury or death. Consult your

distributor or branch for information or assistance. The

qualified installer or agency must use only

factory-authorized kits or accessories when servicing this

product.

FIRE, EXPLOSION, ELECTRICAL SHOCK

HAZARD

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.

ELECTRICALSHOCK,FIREOR EXPLOSION

HAZARD

Failureto 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 the installation of gas conversion kit Part

No. KGAPN4401VSP to convert the following furnaces from

Propane gas usage to natural gas usage. See appropriate section

for your furnace type.

Section 1--59MN7 & 987M 4-Way Multipoise, Hot Surface

Ignition, Modulating Condensing Furnaces. This kit is designed

for use in furnaces with 60,000 through 120,000 Btuh gas input

rates.

Section 2--59TN6, 986T, PG96V_T, 4-Way Multipoise, Hot

Surface Ignition, 2-Stage, Variable-Speed Condensing Furnaces.

59TN6 applies to 60,000 to 120,000 Btuh gas input rates. 986T

and PG96V_T applies to 40,000 to 120,000 Btuh gas input rates.

Section 3--58CVA, 58CVX, 315AAV, 315JAV, PG8MVA,

PG8JVA, 33.3-In.(846 mm) High, Induced-Combustion, Hot-

Surface Ignition, 2-Stage, Variable-Speed, Non-Condensing

Furnaces. This kit is designed for use in furnaces with 42,000

through 154,000 Btuh gas input rates.

DESCRIPTION AND USAGE

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 conversion. When installation is complete,

discard extra parts.

Table I- KGAPN4401VSP Contents

COMPONENT QTY DESCRIPTION

NUMBER

319965-450 1 PCS LABEL, SHIPPING

323267-701 1 PCS PARTS ASSY #42

323267-702 1 PCS PARTS ASSY #43

323267-703 1 PCS PARTS ASSY #44

323267-704 1 PCS PARTS ASSY #45

338305-701 1 PCS LABEL KIT

338305-702 1 PCS LABEL KIT

338305-703 1 PCS LABEL KIT

338305-704 1 PCS LABEL KIT

CA64ASO01 1 PCS PLUG, PIPE

AG- KGAPNVSP-XX 1 PCS INSTRUCTIONS

EF39ZW037 2 PCS VALVE CVRSN KIT

SECTION 1

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 power at external disconnect, fuse or circuit

breaker.

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

[]NIT OPERATION HAZARD

Failure to follow this caution may result in unit damage or

improper operation.

Label all wires prior to disconnection when servicing

controls.

D'EQUIPEMENT D'OPERATION

Toute erreur de cfiblage peut _tre une source de danger et de

panne.

Lors des opOrations d'entretien des commandes, Otiqueter

tous les ills avant de les dOconnecter.

NOTE: Use a back-up wrench on the gas valve to prevent the

valve from rotating on the manifold or damaging the mounting to

the burner box.

1. Disconnect the gas pipe from gas valve and remove pipe

from the furnace casing. See Fig. 1.

2. Disconnect the connector harness from gas valve. Discon-

nect wires from Hot Surface Igniter (HSI) and Flame

Sensor. Disconnect the two wires from the low gas pres-

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.

4. Note the location of the green/yellow wire ground wire for

re-assembly later. See Fig. 2.

5. Slide one-piece burner assembly out of slots on sides of

burner box.

6. Remove the flame sensor from the burner assembly. See

Fig. 3.

7. Remove the orifices from the manifold and discard.

/CAPAC]TO_

POWERCHOKE

REPRESENTATIVE DRAW]N G ONLY, SOME MODELS MAY VARY IN APPEARANCE

Fig. 1 -Component Location

Al1408

Orifice

Manifold ORIFICE SELECTION/DERATE

Connect Green/Yellow

ground wire here

J

Gas Valve

/

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

DO NOT re-drill burner orifices. Improper drilling may

result in burrs, out-of-round holes, etc. Obtain new orifices

if orifice size must be changed. (See Fig. 4.)

Gas valve is parallel to manifold ,'_ :/

CLwithin + or - 3 j

Gas valve must be installed on

manifold with minimum engagement of

6 threads, Cross threading is not

acceptaMe.

Fig. 2- Modulating Gas Valve with Orifices

Al1486

BURNER SUP]: ASSY

BURNER_SY

_"""_ FLA M E SENSOR

(BELOW BURNER)

IGNITER

TER

_ F_IMEHROLLOUT

Al1403

Fig. 3 - Burner Assembly

A96249

Fig. 4 - Burner Orifice

Deternfine natural gas orifice size and manifold pressures for

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 average (at installed altitude) for

local gas supply.

2. Obtain yearly specific-gravity average for local gas sup-

ply.

3. Find installation altitude in Table 3 or Table 4, depending

on Nrnace gas input rate.

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 3 or Table 4, depending on Nrnace gas input rate.

4. Find closest natural gas heat value and specific gravity in

Table 3 or Table 4, depending on Nrnace gas input rate.

5. Follow heat-value line and specific-gravity line to point

of intersection to find orifice size and maximum and nfin-

imum 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 FURNACE

(TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT /8,000 BTUH MIN-HEAT PER BURNER,

DERATED 2%H000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

RANGE HEAT VALUE 0.58 0.60 0.62 0.64

ft(m)

AT ALTITUDE Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press

No. Max/Min No. Max/Min No. Max/Min No. Max/Min

900 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55

113

C

113

L)

c

113

u')

0

(o)

to

2000

(610)

U.S.A.

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

1050 44 3.2 /0.50 44 3.3 /0.55 44 3.4/0.55 44 3.5 /0.55

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

800 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55 42 3.7 /0.60

113

C

C

113

2001 (611)

to

3000 (914)

Canada

2001 (611)

to

825 43 3.8 /0.60 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55

850 43 3.6 /0.60 43 3.7 /0.60 42 3.2 /0.50 42 3.3 /0.55

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

925 44 3.5 /0.55 44 3.6 /0.60 44 3.8 /0.60 43 3.4 /0.55

950 44 3.3 /0.55 44 3.4/0.55 44 3.6 /0.55 44 3.7 /0.60

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

c

O

3001

(915)

to

4000

800 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55

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

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

u')

4001

(1220)

to

5000

775 43 3.7 /0.60 43 3.8 /0.60 42 3.3 /0.50 42 3.4 /0.55

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

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

c

O

5001

(1525)

to

6000

750 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55

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

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 46 3.7 /0.60 46 3.8 /0.60 45 3.8 /0.60 _ 3.2 /0.50

675 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.60 42 3.8 /0.60

6001

--_ (1830)

_ to

7000

700 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55

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

775 44 3.6 /0.60 44 3.7 /0.60 43 3.4 /0.55 43 3.5 /0.55

800 44 3.4/0.55 44 3.5 /0.55 44 3.6 /0.60 44 3.7 /0.60

(2133) 825 44

850 46

3.2 /0.50 44 3.3 /0.55 44 3.4/0.55 44 3.5 /0.55

38/060 42._ 38/060 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 FURNACE

(TABULATED DATA BASED ON 20,000 BTUH MAX.HEAT /8,000 BTUH MIN-HEAT PER BURNER,

DERATED 2°/o/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE

RANGE

ft (m)

7001

--_ (2134)

0

_ to

D 8000

(2438)

8001

= (2439)

0

_ to

9000

9001

-->' (2744)

O

_ to

D10000

_ 725 44 3.2 /0.50

* Orifice numbers shown in BOLD are factory-installed.

AVG. GAS

HEAT VALUE 0.58

AT ALTITUDE Orifice Mnfid Press Orifice

(Btu/cu ft) No, Max/Min No,

650 42 3.4 /0.55 42

675 43 3.8 /0.60 42

700 43 3.5 /0.55 43

725 44 3.8 /0.60 43

750 44 3.5 /0.55 44

775 44 3.3 /0.55 44

800 45 3.8 /0.60 44

825 46 3.7 /0.60 46

625 42 3.4 /0.55 42

650 43 3.8 /0.60 42

675 43 3.5 /0.55 43

700 44 3.7 /0.60 43

725 44 3.5 /0.55 44

750 44 3.3 /0.50 44

775 45 3.7 /0.60 44

600 42 3.3 /0.55 42

625 43 3.7 /0.60 42

650 43 3.5 /0.55 43

675 44 3.7 /0.60 44

700 44 3.4/0.55 44

4_4_

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Mnfld Press Orifice Mnfld Press Orifice

Max/Min No, Max/Min No,

3.5 /0.55 42 3.6 /0.60 42

3.2 /0.50 42 3.3 /0.55 42

3.7 /0.60 43 3.8 /0.60 42

3.4 /0.55 43 3.5 /0.55 43

3.7 /0.60 44 3.8 /0.60 43

3.4 /0.55 44 3.5 /0.55 44

3.2 /0.50 44 3.3 /0.55 44

3.8 /0.60 45 3.8 /0.60 44

3.5 /0.55 42 3.6 /0.55 42

3.2 /0.50 42 3.3 /0.55 42

3.6 /0.60 43 3.7 /0.60 42

3.4 /0.55 43 3.5 /0.55 43

3.6 /0.60 44 3.7 /0.60 44

3.4 /0.55 44 3.5 /0.55 44

3.2 /0.50 44 3.3 /0.50 44

3.4 /0.55 42 3.6 /0.55 42

3.2 /0.50 42 3.3 /0.55 42

3.6 /0.55 43 3.7 /0.60 43

3.8 /0.60 43 3.4 /0.55 43

3.5 /0.55 44 3.7 /0.60 44

3.3 /0.55 44 3.4 /0.55 44

0.64

Mnfid Press

Max/Min

3.7 /0.60

3.4 /0.55

3.2 /0.50

3.6 /0.60

3.4 /0.55

3.7 /0.60

3.4 /0.55

3.2 /0.50

3.7 /0.60

3.4 /0.55

3.2 /0.50

3.6 /0.55

3.8 /0.60

3.6 /0.55

3.4 /0.55

3.7 /0.60

3.4 /0.55

3.8 /0.60

3.5 /0.55

3.8 /0.60

3.5 /0.55

Al1251B

Table 4 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

To Be Used with Modulating Furnaces 59MN7A060V21-20 and 987MA60060V21 ONLY

(TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT /8,000 BTUH MIN-HEAT PER BURNER,

DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

RANGE HEAT VALUE 0.58 0.60 0.62 0.64

AT ALTITUDE Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press

ft (m) _ No. Max/Min No. Max/Min No. Max/Min No. Max/Min

900 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55

0925 43 3.7 /0.55 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.50

(0) 950 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60

t..

o 975 44 3.8/0.60 43 3.4/0.55 43 3.5/0.55 43 3.6/0.55

to 1000 44 3.6/0.55 44 3.7/0.60 44 3.8/0.60 43 3.5/0.55

<' 1025 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55 44 3.8 /0.60

2000 1050 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55

(610) 1075 45 3.8 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55

1100 46 3.8 /0.60 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50

U.S.A. 800 42 3.4/0.55 42 3.5/0.55 42 3.7/0.55 42 3.8/0.60

2001 (611) 825 42 3.2/0.50 42 3.3/0.50 42 3.4/0.55 42 3.6/0.55

to 850 43 3.7/0.60 43 3.8/0.60 42 3.2/0.50 42 3.3/0.55

t..

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

_. Canada 925 44 3.6/0.55 44 3.7/0.60 44 3.8/0.60 43 3.4/0.55

2001 (611) 950 44 3.4/0.55 44 3.5/0.55 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 3.6/0.55

__ 1000 45 3.7/0.60 44 3.2/0.50 44 3.3/0.50 44 3.4/0.55

775 42 3.4/0.55 42 3.5/0.55 42 3.6/0.55 42 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

O 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 45 3.8/0.60 44 3.2/0.50 44 3.4/0.55 44 3.5/0.55

750 42 3.3/0.50 42 3.4/0.55 42 3.6/0.55 42 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

t..

O 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 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55 44 3.6 /0.55

925 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55

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

t..

O 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 46 3.8 /0.60 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50

675 42 3.5 /0.55 42 3.6 /0.55 42 3.7 /0.60 42 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

t..

O 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 44 3.2 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55

850 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55

Al1621A

Table 4 -Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued)

To Be Used with Modulating Furnaces 59MN7A060V21-20 and 987MA60060V21 ONLY

(TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT /8,000 BTUH MIN-HEAT PER BURNER,

DERATED 2°/o/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE

RANGE

ft (m)

7001

--_ (2134)

O

to

8000

(2438)

8001

=(2439)

O

to

9000

AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

HEAT VALUE 0.58 0.60 0.62

AT ALTITUDE Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press

No. Max/Min No. Max/Min No. Max/Min

650 42 3.4 /0.55 42 3.6 /0.55 42 3.7 /0.60

675 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55

700 43 3.6 /0.55 43 3.7 /0.60 42 3.2 /0.50

725 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55

750 44 3,6 /0.55 44 3,7 /0.60 43 3.4 /0.55

775 44 3,4/0,55 44 3,5 /0,55 44 3,6 /0.55

800 44 3.2 /0.50 44 3.3 /0.50 44 3,4 /0,55

825 46 3.8 /0.60 45 3.7 /0.60 44 3,2 /0,50

625 42 3.4 /0.55 42 3.5 /0.55 42 3.7 /0.55

650 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55

675 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60

700 44 3,8 /0.60 43 3.4 /0.55 43 3.6 /0.55

725 44 3,6 /0,55 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

45 3.8 /0.60 44 3,2 /0,50 44 3,3 /0,50

42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55

43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55

43 3.5 /0.55 43 3.6 /0.55 43 3.8 /0.60

44 3,8 /0,60 43 3.4 /0.55 43 3.5 /0.55

44 3,5 /0,55 44 3,6 /0,55 44 3,7 /0,60

3,5 /0.55

__ 775

9001 600

(2744) 625

O 650

to 675

10000 700

_ 725 4.._.L43.3/0.50 4_..&4 3.4/0.5_ 4.....£_4

*Orifice numbers shown in BOLD are factory-installed.

0,64

Orifice Mnfld Press

No. Max/Min

42 3.8 /0.60

42 3.5 /0.55

42 3.3 /0.50

43 3.7 /0.60

43 3.5 /0.55

44 3,7 /0,60

44 3,5 /0,55

44 3,3 /0,50

42 3.8 /0.60

42 3.5 /0.55

42 3.2 /0.50

43 3.7 /0.55

43 3.4 /0.55

44 3,7 /0,55

44 3,4 /0,55

42 3.8 /0.60

42 3.5 /0.55

42 3.2 /0.50

43 3.6 /0.55

44 3,8 /0,60

44 3.6 /0,55

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) l

must be reduced by 2 percent for each 1000 ft. (305 M) above sea /

level. 1.9"

In Canada, the input rating must be derated by 5 percent for (48.76mm)

altitudes of 2000 ft. to 4500 ft. (610 to 1372 M) above sea level. /

The Conversion Kit Rating Plate accounts for high altitude

derate.

INSTALL ORIFICES l

18"

(46.96 mm)

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. There are enough

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

NOTE: DO NOT reinstall the manifold at this time.

REMOVE MIXER SCREWS FROM BURNERS

NOTE: Each burner contains a mixer screw that must be

removed. Refer to Fig. 5 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 when

the mixer screws are removed.

Al1621B

(\11

Location of mixer screw

..._hat must be removed

\\\\

Al1501

Fig. 5 - Mixer Screw Location

REINSTALL BURNER ASSEMBLY

To reinstall burner assembly:

1. Attach flame sensor to burner assembly.

2. Insert one-piece burner in slot on sides of burner box and

slide burner back in place.

3. Reattach HSI wires to HSI.

4. Verify igniter to burner alignment. See Fig. 6 and 7.

ql !

(64.4)

Fig. 6 - Igniter Position - Back View

Al1405

Refer to Fig. 8 and 9.

Fig. 8-Propane Jumper

Al1373

2- iiq.

(50 mm)

3/16- in.

(4.6 mm)

A12392

Fig. 7 -Igniter Position - Side View

CONVERT GAS VALVE

FIRE, EXPLOSION, ELECTRICAL SHOCK

HAZARD

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.

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 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.

Fig. 9- Removing Propane Jumper

Al1502

NOTE: The Propane jumper for the modulating gas valve is

very small. Needle-nose pliers are required to remove the jumper

from the gas valve,

1. Locate the round "LP GAS" sticker on the top of the gas

valve.

2. Peel the sticker off and discard.

3, Note the small square opening in the top of the gas valve.

4, Remove the small black plastic Propane jumper from the

gas valve.

5, Cover the opening in the gas valve with the label marked

"NAT GAS"

REMOVE LOW GAS 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

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 Hex Nipple

A11367

Fig. 10 -LGPS for 14-3/16 (360 mm) Casing or When Vent

Passes Between Inducer and Burner Assembly

NOTE: Use pipe dope approved for use with Propane gas.

2. Apply pipe dope sparingly to the l/8-in. NPT pipe plug

(provided in kit) and install in the l/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.

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury

and/or death.

NEVER test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for

the detection of leaks to check all connections. A fire or

explosion may result causing property damage, personal

injury or loss of life.

RISQUE D'EXPLOSION ET D'INCENDIE

Le fair de ne pas suivre cet avertissement pourrait entra*ner des

dommages corporels et /ou la mort.

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.

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.)

Brass Street

Low Gas Pressure Switch Brass Nipple

Al1517

Fig. 11 -LGPS for Casing Wider Than 14-3/16 (360 mm)

and Vent Does Not Pass Between Inducer and Burner

Assembly

1. Remove low gas pressure switch, brass street 90 ° elbow,

brass Hex nipple, brass Tee and brass nipple from the gas

valve inlet pressure tap. (See Fig 11.)

NOTE: Use pipe dope approved for use with Propane gas.

2. Apply pipe dope sparingly to the l/8-in. NPT pipe plug

(provided in kit) and install in the l/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.

INSTALL MANIFOLD

1. Align the orifices in the manifold assembly with the sup-

port rings on the end of the burner.

2. Insert the orifices in the support rings of the burners. Man-

ifold mounting tabs should fit flush against the burner box

NOTE: If manifold does not fit flush against the burner box, the

burners are not fully seated forward. Remove the manifold and

check burner positioning in the burner box assembly.

3. Attach the green/yellow wire and ground terminal to one

of the manifold mounting screws.

4. Install the remaining manifold mounting screws.

5. Connect the wires to the flame sensor and hot surface ig-

niter.

6. Connect the connector harness to gas valve.

7. Rewire unit low pressure switch (LPS) as follows:

a. Trace one of the orange wires previously disconnected

from the LGPS back to the NO terminals of the LPS.

b. Trace the other orange wire previously disconnected

from the LGPS back to its splice connection with the yel-

low wire of the furnace wire harness. Disconnect and dis-

card this orange wire and the splice connection.

c. Connect the yellow wire of the furnace wire harness (see

"b" above) to the NO terminal of the LPS.

d. Refer to the furnace wiring diagram to ensure proper loca-

tion of wires.

NOTE: Use only Propane-resistant pipe dope, DO NOT use

Teflon tape.

8. Insert the gas pipe through the grommet in the casing. Ap-

ply 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 wrench on the gas valve to prevent the

valve from rotating on the manifold or damaging the mounting to

the burner box.

9. With a back-up wrench on the inlet boss of the gas valve,

finish tightening the gas pipe to the gas valve.

10. Turn gas on at electric switch on gas valve.

CHECK INLET GAS PRESSURE

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

DO NOT operate furnace more than one minute to check

inlet gas pressure, as conversion is not complete at this time.

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.

2. Turn on furnace power supply.

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

FIRE, EXPLOSION, ELECTRICAL SHOCK

HAZARD

Failure to follow this warning could result in personal

injury, death or property damage.

Gas supply MUST be shut off before disconnecting

electrical power and proceeding with conversion.

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow this warning could result in personal

injury, death or property damage.

Before installing, modifying, or servicing system, main

electrical disconnect switch must be in the OFF position and

install a lockout tag. There may be more than one

disconnect switch. Lock out and tag switch with a suitaMe

warning label. Verify proper operation after servicing.

SW4

Outside Air Thermi,'

SW3 Continuous

(CF) airflow setup

switches CF 1 through

CF 3 _---_

Communication

24 VAC

HUM Output

(O.5AMP

}H

Fig. 12 -Furnace Control

Al1471

7. When main burners ignite, confirm inlet gas pressure is

between 4.5-in. W.C. and 13.6-in. W.C.

8. Remove jumper across R-W/WI and R-W2 thermostat

connections to terminate call for heat.

9. Turn furnace gas valve switch to OFF position.

10. Turn gas supply manual shutoff valve to OFF position.

11. Turn off furnace power supply.

12. Remove manometer.

13. Apply pipe dope sparingly to the l/8-in. NPT pipe plug

and install in the l/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

4. Turn furnace gas valve switch to ON position.

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.

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury

and/or death.

NEVER test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for

the detection of leaks to check all connections. A fire or

explosion may result causing property damage, personal

iniury or loss of life.

10

RISQUE D'EXPLOSION ET D'INCENDIE

Le fait de ne pas suivre cet avertissement pourrait entra_ner des

dommages corporels et /ou la mort.

Ne jamais examiner pour les fuites de gaz avec une flamme

vive. Utilisez plut6t un savon fait specifiquement pour la

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.

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

2. Remove l/8-in. NPT pipe plug from manifold pressure tap

on downstream side of gas valve.

3. Attach manometer to manifold pressure tap on gas valve.

(see Fig. 13.)

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

5. Turn furnace gas valve switch to ON position.

6. Check all threaded pipe connections for gas leaks.

7. Turn on furnace power supply.

ON/OFFSwitch MODULATING

/

Min/Max Heat Adust

5. Follow heat-value line and specific-gravity line to point

of intersection to find orifice size and maximum and min-

imum 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. (610M)

must be reduced by 2 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.

The Conversion Kit Rating Plate accounts for high altitude

derate.

SET GAS INPUT RATE

UNIT DAMAGE HAZARD

Failure to follow this caution may result in gas valve

damage.

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.

Turn screw 1 click per

) second to adjust rate,

Inlet _ Clockwise toincrease

Pressure Ta rate, counter clockwise

/2" NPT Outlet

Manifold

Pressure Tap

Fig. 13 -Gas Valve

Al1513

GAS INPUT RATE INFORMATION

See furnace rating plate on blower door for input rate. The input

rate for natural gas is determined by manifold pressure and orifice

size.

The gas valve must be set for Maxinmm Heat first and then set

for Minimum Heat on Modulating furnaces.

Determine natural gas orifice size and manifold pressures for

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 average (at installed altitude) for

local gas supply.

2. Obtain yearly specific-gravity average for local gas sup-

ply.

3. Find installation altitude in Table 3 or Table 4, depending

on furnace gas input rate.

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 3 or Table 4, depending on furnace 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.

Burner Flame

Burne_

Al1461

Fig. 14 - Burner Flame

For proper operation and long term reliability, the manifold

pressure must be adjusted as specified on the conversion kit rating

plate.

The modulating furnace manifold pressure is set at two points.

The first point is Maximum Heat. The second point is Mininmm

Heat. DO NOT adjust Intermediate Heat manifold pressure.

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.

NOTE: Use care when performing adjustments. Gas valve

adjustment is performed by turning a rotary adjustment switch

inside the gas valve with a small straight blade screwdriver.

Excessive force can break or bend the rotary adjustment switch

making it non-adjustable.

To adjust manifold pressure to obtain input rate for Maximum

Heat:

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 to the outlet pressure tap on gas

valve.

4. Turn on furnace power supply.

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

11

6. Turn furnace gas valve switch to ON position.

7. Turn Setup switch SW 1-2 to ON.

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.

10. After the main burners ignite and the blower starts, con-

firm 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 de-

crease 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.

Main burner flame should be clear blue, almost transparent.

To adjust manifold pressure to obtain input rate for Minimum

Heat:

1. Remove the jumper from W2 at the thermostat connec-

tions at the furnace control board control.

2. Wait until the burners and the blower transitions to Minim-

um Heat.

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 de-

crease 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 5minutes before checking Minimum Heat

Temperature rise.

Furnace must operate within ranges of temperature rise specified

on the furnace rating plate. Determine air temperature rise as

follows:

1. Place thermometers in return and supply ducts as near fur-

nace 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.

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.

If the temperature rise is too high or too low in Minimum Heat:

1. Remove jumpers from R and W/W1.

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 po-

sition is OFF.

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 Heat Temperature Rise

If the temperature rise is too high or too low in Maximum Heat:

1. Remove jumpers from R, Wl and W2.

2. Wait until the blower off delay is completed.

3. Turn 115 VAC power off.

4. Check the position of the Efficiency/Comfort Adjustment

switch SWl-4. When set to OFF (Efficiency Mode), air-

flow is 10% higher for Minimum, 7.5% for Intermediate

Heat, and 17.5% for Maximum Heat. Factory default posi-

tion is ON (Comfort Mode).

5. Turn 115 VAC power on.

6. Re-check Minimum Heat Temperature Rise.

7. Remove jumpers across thermostat connections to termin-

ate the call for heat. Wait until the blower off delay is com-

pleted.

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-in-

stall outlet pressure tap on the gas valve.

12. Re-install plastic cap over rotary adjustment switch on the

top of the gas valve.

LABEL APPLICATION

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 out-

er 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.

12

THiSFURNACEWAS CONVERTED

ON TO NATURALGAS

(DAY-MONTH-YEAR)

KiT NO.: KGAPN4401VSP

BY:

(Name and address of organization making this conversion),

which accepts the responsibility that this conversion has

been properly made.

CEG#NERATEURD'A[RCHAUDA _:TI_

CONVERTILE POUR

(JOUR-MOIS-ANNEE)

DE L'ENSEIVlBLEN°,: KGAPN4401VSP

PAR:

(Nora et adresse de I'organisrae qui a effectu_ Ja conversion),

qui accepte J' entri6re responsabiJit6 de Ja conversion.

338305-205 REV. A _'t._.

Fig. 15 - Conversion Responsibility Label

Al1504

CONVERSION KiT RATING PLATE -CARRIER CORPORATION

THiS APPLIANCE HAS BEEN CONVERTED TO USE NATURAL GAS FOR FUEL. REFER TO KiT iNSTRUCTiONS FOR CONVERSION

PROCEDURES. USE PARTS SUPPLIED BY CARRIER CORPORATION AND iNSTALLED BY QUALiFiED PERSONNEL.

SEE EXiSTiNG RATING PLATE FOR APPLIANCE MODEL NO. AND iNPUT RATING.

NOTE; Furnace gas input rate on rating plate is for instaJJationsup 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 (SUPERSEDES: NONE)

USA CANADA

APPLIANCE O/oDERATE % DERATE

MODELS PER FOR

1000 FT. 2000-4500 FT.

59MN7A 2% 5%

987MA

FUEL USED: NATURAL GAS

NATURAL GAS PRESSURE iN. W.C. (PO C.E.) P[ PA

Max. Inlet Gas Pressure

(Press. Max. D'Admission De Gaz) 13.6

Min. Inlet Gas Pressure

(Press, NJn, D'AdmJssion De Gaz) 4.5 1,121

(For Purpose of input Adjustment) (Pour L'Adjustment D'Entree)

ALTITUDE High Heat 3.2 -3.8

Manifold 0-2,000 ft. 797 - 946

Pressure (0 - 610 m) LOW Heat 1.4 - 1.8 349 - 448

Pression 2,000 - 10,000 ft. Refer to installation Manual

Tubu[ure (610 - 3050 ra) Respecter es nstructon D3nsta[[ation

338305-201 REV, A,

This control has been converted for use with natural gas. ]

Cette commande a et6 r6gl6e pour emploi avec le gaz _._ J

naturel. 338305-202 REV.A

This control has been adjusted for use with propane gas. I_,_ "}

Ce eoontrSle a et_ r6gl6e pour foneSonner au gaz propane, _/

330305-203 REV. A )

Fig. 16 - Conversion Kit Rating Plate

Al1503

13

SECTION 2

Table 5- Variable Speed Condensing Furnaces

MODEL NUMBERS BEGINNING WITH:

59TN6 986T

PG96V T

INSTALLATION

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow instructions could result in personal injury,

death or property damage.

Improper installation, adjustment, alteration, service,

maintenance, or use can cause carbon monoxide poisoning,

explosion, fire, electrical shock, or other conditions, which

could result in personal injury or death. Consult your

distributor or branch for information or assistance. The

qualified installer or agency nmst use only

factory-authorized kits or accessories when servicing this

product.

FIRE, EXPLOSION, ELECTRICAL SHOCK

HAZARD

Failure to follow this warning could result in personal

injury, death or property damage.

Gas supply MUST be shut off before disconnecting

electrical power and proceeding with conversion.

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

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.

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

injury or death.

This conversion kit shall be installed by a qualified service

agency in accordance with the manufacturer's instructions

and all applicable codes and requirements of the authority

having jurisdiction. If the information in these instructions

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

carbon monoxide 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.

LE FEU, L'EXPLOSION, CHOC ELECTRIQUE,

ET MONOXYDE DE CARBONE

EMPOISONNER

Cette trousse de conversion doit _tre install_e par un servie

d'entretien qualifid, selon les instructions du fabricant et

selon toutes les exigences et tous les codes pertinents de

l'autorit_ comp_tente. Assurezvous de bien suivre les

instructions dans cette notice pour rdduire au 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.

1. Set room thermostat to lowest setting or "OFF".

2. Remove outer doors.

3. Disconnect power at external disconnect, fuse or circuit

breaker.

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.

FLAME

SENSOR ¸¸¸

MANUALRESET

ROLLOUTSW_TCH

GASVA_E

OPERATINGFNSTRUCT_ONS

NOTSHOWS(LOCATEDOS

MA_NFURNACEDOOR,SEE

OPERATINGFNSTRUCT_OSS

FNS_DEDOORFFGURE)

ELECTRICALJUSCT_ON

BOX (_F REQH_RED ....

LOCATION MAY VARY)

8LOWERDOOR.....

SAFETY SWFTC H

FURSACE

CONTROL

BOARD

RAT_NGPLATENOTSHOWS

(LOCATEDOSBLOWERDOOR)

©

BLOWERAND

q MOTOR

f CAPAC_TOR_

REPRESENTATIVEDRAWINGOSLYSOMEMODELSMAYVARY_NAPPEARANCE

Fig. 17 -Component Location

A11408

14

MANIFOLD/ORIFICE/BURNER REMOVAL

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage or

improper operation.

Label all wires prior to disconnection when servicing

controls.

D'EQUIPMENT D'OPERATION

Lors des op6rations d'entretien des commandes, 6tiqueter

tousles ills avant de les d@onnecter.

BURNER SUPZ ASSY IGNITER

BURNER ASSY

_"'_ FLAM E SENSOR

(BELOW BURNER)

Fig. 19 - Burner Assembly

ORIFICE SELECTION/DERATE

BRACKET, IGNITER

/

FLAME ROLLOUT

SWITCH

Al1403

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. 18 and 19.

1. Disconnect the gas pipe from gas valve and remove pipe

from the furnace casing.

2. Disconnect the connector harness from gas valve. Discon-

nect wires from Hot Surface Igniter (HSI) and Flame

Sensor. Disconnect the two wires from the low gas pres-

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.

4. Note the location of the green/yellow wire ground wire for

re-assembly later.

5. Slide one-piece burner assembly out of slots on sides of

burner box.

6. Remove the flame sensor from the burner assembly.

7. Remove the orifices from the manifold and discard.

Orifice

d ¢ /

Connect Green/Yellow

ground wire here

Manifold S

Gas Valve

Gas valve must be installed on

manifold with minimum engagement of

6 threads. Cross threading is not

acceptable.

/

_lndicated sur[aces

!to be 90'+ or -2'

Fig. 18 - 2 Stage Gas Valve

Al1407

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

DO NOT re-drill burner orifices. Improper drilling may

result in burrs, out-of-round holes, etc. Obtain new orifices

if orifice size must be changed. (See Fig. 20.)

A96249

Fig. 20 - Burner Orifice

Deternfine natural gas orifice size and manifold pressures for

correct input at installed altitude by using Table 5.

1. Obtain yearly heat-value average (at installed altitude) for

local gas supply.

2. Obtain yearly specific-gravity average for local gas sup-

ply.

3. Find installation altitude in Table 5.

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.

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 mani-

fold pressure settings.

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 2%/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE AVG. GAS

RANGE HEAT VALUE 0.58 0.60

AT ALTITUDE Orifice Mnfld Press Orifice Mnfld Press

ft (m) _ No. Hi, h/Low No. Hi,h/Low

900 43 3.8 /1.6 42 3.2 /1.4

0925 43 3.6 /1.5 43 3.7 /1.6

(0) 950 43 3.4 /1.4 43 3.5 /1.5

c

o975 44 3.7 /1.6 44 3.8 /1.6

to 1000 44 3.5 /1.5 44 3.6 /1.5

<. 1025 44 3.3 /1.4 44 3.5 /1.5

u) 2000 1050 44 3.2 /1.3 44 3.3 /1.4

(610) 1075 45 3.7 /1.6 45 3.8 /1.6

1100 46 3.7 /1.6 46 3.8 /1.6

U.S.A. 800 42 3.4 /1.4 42 3.5 /1.5

2001 (611) 825 43 3.8 /1.6 42 3.3 /1.4

to 850 43 3.6 /1.5 43 3.7 /1.6

c

3000 (914) 875 43 3.4 /1.4 43 3.5 /1.5

900 44 3.7 /1.6 44 3.8 /1.6

Canada 925 44 3.5 /1.5 44 3.6 /1.5

u_ 2001 (611) 950 44 3.3 /1.4 44 3.4 /1.5

to 975 44 3.2 /1.3 44 3.3 /1.4

__ 1000 46 3.8 /1.6 45 3.8 /1.6

775 42 3.3 /1.4 42 3.4 /1.4

3001 800 43 3.8 /1.6 42 3.2 /1.4

--_ (915) 825 43 3.6 /1.5 43 3.7 /1.6

c

O 850 44 3.8 /1.6 43 3.5 /1.5

to 875 44 3.6 /1.5 44 3.7 /1.6

4000 900 44 3.4 /1.4 44 3.5 /1.5

(1219) 925 44 3.2 /1.4 44 3.4 /1.4

950 45 3.7 /1.6 44 3.2 /1.3

750 42 3.3 /1.4 42 3.4 /1.4

4001 775 43 3.7 /1.6 43 3.8 /1.6

--_ (1220) 800 43 3.5 /1.5 43 3.6 /1.5

c

O 825 44 3.8 /1.6 43 3.4 /1.4

to 850 44 3.5 /1.5 44 3.7 /1.5

5000 875 44 3.3 /1.4 44 3.5 /1.5

(1524) 900 44 3.2 /1.3 44 3.3 /1.4

925 46 3.8 /1.6 45 3.7 /1.6

725 42 3.2 /1.4 42 3.3 /1.4

5001 750 43 3.7 /1.5 43 3.8 /1.6

--_ (1525) 775 43 3.4 /1.4 43 3.5 /1.5

c

O 800 44 3.7 /1.6 44 3.8 /1.6

to 825 44 3.5 /1.5 44 3.6 /1.5

6000 850 44 3.3 /1.4 44 3.4 /1.4

(1829) 875 45 3.7 /1.6 44 3.2 /1.3

900 46 3.7 /1.6 46 3.8 /1.6

675 42 3.4 /1.4 42 3.5 /1.5

6001 700 42 3.2 /1.3 42 3.3 /1.4

--_ (1830) 725 43 3.6 /1.5 43 3.7 /1.6

c

O750 43 3.4 /1.4 43 3.5 /1.5

<" to 775 44 3.6 /1.5 44 3.7 /1.6

u) 7000 800 44 3.4 /1.4 44 3.5 /1.5

(2133) 825 44 3.2 /1.3 44 3.3 /1.4

850 46 3.8 /1.6 45 3.8 /1.6

SPECIFIC GRAVITY OF NATURAL GAS

0.62

Orifice Mnfld Press

No.

42 3.3 /1.4

43 3.8 /1.6

43 3.6 /1.5

43 3.4 /1.5

44 3.8 /1.6

44 3.6 /1.5

44 3.4 /1.4

44 3.3 /1.4

45 3.8 /1.6

42 3.6 /1.5

42 3.4 /1.4

42 3.2 /1.3

43 3.7 /1.5

43 3.5 /1.5

44 3.8 /1.6

44 3.6 /1.5

44 3.4 /1.4

44 3.2 /1.4

42 3.5 /1.5

42 3.3 /1.4

43 3.8 /1.6

43 3.6 /1.5

43 3.4 /1.4

44 3.7 /1.5

44 3.5 /1.5

44 3.3 /1.4

42 3.5 /1.5

42 3.3 /1.4

43 3.7 /1.6

43 3.5 /1.5

44 3.8 /1.6

44 3.6 /1.5

44 3.4 /1.4

44 3.2 /1.4

42 3.4 /1.5

42 3.2 /1.4

43 3.7 /1.5

43 3.4 /1.5

44 3.7 /1.6

44 3.5 /1.5

44 3.3 /1.4

45 3.8 /1.6

42 3.6 /1.5

42 3.4 /1.4

43 3.8 /1.6

43 3.6 /1.5

43 3.4 /1.4

44 3.6 /1.5

44 3.4 /1.4

44 3.2 /1.4

0.64

Orifice Mnfld Press

No. Hi_htLow

42 3.4 /1.4

42 3.2 /1.4

43 3.7 /1.6

43 3.6 /1.5

43 3.4 /1.4

44 3.7 /1.6

44 3.5 /1.5

44 3.4 /1.4

44 3.2 /1.4

42 3.7 /1.6

42 3.5 /1.5

42 3.3 /1.4

43 3.8 /1.6

43 3.6 /1.5

43 3.4 /1.4

44 3.7 /1.6

44 3.5 /1.5

44 3.3 /1.4

42 3.6 /1.5

42 3.4 /1.4

42 3.2 /1.4

43 3.7 /1.6

43 3.5 /1.5

44 3.8 /1.6

44 3.6 /1.5

44 3.4 /1.4

42 3.6 /1.5

42 3.4 /1.4

43 3.8 /1.6

43 3.6 /1.5

43 3.4 /1.4

44 3.7 /1.6

44 3.5 /1.5

44 3.3 /1.4

42 3.5 /1.5

42 3.3 /1.4

43 3.8 /1.6

43 3.5 /1.5

44 3.8 /1.6

44 3.6 /1.5

44 3.4 /1.4

44 3.2 /1.4

42 3.8 /1.6

42 3.5 /1.5

42 3.3 /1.4

43 3.7 /1.6

43 3.5 /1.5

44 3.7 /1.6

44 3.5 /1.5

44 3.3 /1.4

Al1252A

ld

Table 5 - Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate (Continued)

TWO-STAGE FURNACE

(TABULATED 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 0.58

AT ALTITUDE Orifice Mnfld Press

ft (m) _ No_,, ,,,,,_h/Low

650

7001 675

--_ (2134) 700

O 725

<' to 750

8000 775

(2438) 800

825

625

8001 650

c(2439) 675

O

<.' to 700

_. 725

9000 750

__ 775

9001 600

--_ (2744) 625

O 650

<' to 675

10000 700

* Orifice numbers shown in BOLD are factory-installed.

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice Mnfld Press Orifice Mnfld Press

No. Hi,h/Low No. Hi,h/Low

42 3.4 /1.4 42 3.5 /1.5 42 3.6 /1.5

43 3.8 /1.6 42 3.2 /1.4 42 3.3 /1.4

43 3.5 /1.5 43 3.7 /1.5 43 3.8 /1.6

44 3.8 /1.6 43 3.4 /1.4 43 3.5 /1.5

44 3.5 /1.5 44 3.7 /1.5 44 3.8 /1.6

44 3.3 /1.4 44 3.4 /1.4 44 3.5 /1.5

45 3.8 /1.6 44 3.2 /1.4 44 3.3 /1.4

46 3.7 /1.6 46 3.8 /1.6 45 3.8 /1.6

42 3.4 /1.4 42 3.5 /1.5 42 3.6 /1.5

43 3.8 /1.6 42 3.2 /1.4 42 3.3 /1.4

43 3.5 /1.5 43 3.6 /1.5 43 3.7 /1.6

44 3.7 /1.6 43 3.4 /1.4 43 3.5 /1.5

44 3.5 /1.5 44 3.6 /1.5 44 3.7 /1.6

44 3.3 /1.4 44 3.4 /1.4 44 3.5 /1.5

45 3.7 /1.6 44 3,2 /1,3 44 3,3 /1,4

42 3.3 /1.4 42 3.4 /1.5 42 3.6 /1.5

43 3.7 /1.6 42 3.2 /1.3 42 3.3 /1.4

43 3.5 /1.5 43 3.6 /1.5 43 3.7 /1.6

44 3.7 /1.6 44 3.8 /1.6 43 3.4 /1.4

44 3.4 /1.4 44 3.5 /1.5 44 3.7 /1.5

3.4 /1.4

0.64

Orifice Mnfld Press

No. Hi2h/Low

42 3.7 /1.6

42 3.4 /1.5

42 3.2 /1.4

43 3.6 /1.5

43 3.4 /1.4

44 3.7 /1.5

44 3.4 /1.4

44 3.2 /1.4

42 3.7 /1.6

42 3.4 /1.4

42 3.2 /1.3

43 3.6 /1.5

44 3.8 /1.6

44 3.6 /1.5

44 3.4 /1.4

42 3.7 /1.6

42 3.4 /1.4

43 3.8 /1.6

43 3.5 /1.5

44 3.8 /1.6

44 3.5 /1.5

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 for altitudes above 2000 ft. (610

M) must be reduced by 2 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. to 4500 ft. (610 M to 1372 M) above sea

level.

The Conversion Kit Rating Plate accounts for high altitude

derate.

INSTALL ORIFICES

1. Install main burner orifices. DO NOT use Teflon tape. Fin-

ger-tighten orifices at least one full turn to prevent

cross-threading, then tighten with wrench.

2. There are enough orifices in each kit for largest furnace.

Discard extra orifices.

NOTE: DO NOT reinstall the manifold at this time.

REMOVE MIXER SCREWS FROM THE BURN-

ERS

Each burner contains a mixer screw that must be removed. Refer

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 when

the mixer screws are removed.

Al1252B

1.9"

(48.76 mm)

t

1.8"

(46.96 mm)

(\11

Location of mixer screw

..._hat must be removed

\\\\

Al1501

Fig. 21 - Mixer Screw Location

REINSTALL BURNER ASSEMBLY

To reinstall burner assembly:

1. Attach flame sensor to burner assembly.

2. Insert one-piece burner in slot on sides of burner box and

slide burner back in place.

3. Reattach HSI wires to HSI.

4. Verify igniter to burner alignment. See Fig. 22 and 23.

17

ql !

(64.4)

Fig. 22 -Igniter Position - Back View

Al1405

2- irl.

(50 mm)

3/16- in.

(4.6 mm)

r3/32 -in., +1/32 -3/64-in.

(2.5 mm, +0.8 -1.5)

A12392

Fig. 23 -Igniter Position - Side View

CONVERT GAS VALVE

[]NIT 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.

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow this warning could result in personal

injury, death or property damage.

Before installing, modifying, or servicing system, main

electrical disconnect switch must be in the OFF position and

install a lockout tag. There may be more than one

disconnect switch. Lock out and tag switch with a suitable

warning label. Verify proper operation after servicing.

1. Refer to Fig. 24.

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

3. Remove caps that conceal adjustment screws for high-heat

and low-heat stage gas valve regulators. (See Fig. 24.)

4. Remove the high-heat and low-heat regulator adjustment

screws.

5. Remove the high-heat and low-heat Propane gas regulat-

or springs (white).

6. Install the high-heat and low-heat natural gas regulator

springs (silver).

7. Install the high-heat and low-heat regulator adjustment

screws.

8. Turn high-heat stage adjusting screw clockwise (in) 12

full turns. This will increase the manifold pressure closer

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

to the Propane low-heat set point. (See Fig. 24.)

10. DO NOT install regulator seal caps at this time.

') "_ Regulator Seal Cap

TWO-STAGE _ _@_ 9 *

_ _= Regulator Ad ustment

1-: _ ..... Screw

ON/OFF Switch

1/2" NPT Inlet

1/8" NPT Inlet

Pressure Tap

FIRE, EXPLOSION, ELECTRICAL SHOCK

HAZARD

Failure to follow this warning could result in personal

injury, death or property damage.

Gas supply MUST be shut off before disconnecting

electrical power and proceeding with conversion.

1t8" NPT Manifold

Pressure Tap

Fig. 24 - 2 Stage Gas valve

Al1472

REMOVE LOW GAS 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.

18

All143/16-in (360 mm) Casings or Vent Passes Between

Inducer Assembly and Burner Assembly

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 25.)

Brass Hex Nipple

A11367

Fig. 25 - LGPS for 14-3/16-in. (360 mm) Casing or When

Vent Passes Between Inducer and Burner Assembly

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 25.)

NOTE: Use pipe dope approved for use with Propane gas. DO

NOT use Teflon tape.

2. Apply pipe dope sparingly to the l/8-in. NPT pipe plug

(provided in kit) and install in the l/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.

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury

and/or death.

NEVER test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for

the detection of leaks to check all connections. A fire or

explosion may result causing property damage, personal

injury or loss of life,

RISQUE D'EXPLOSION ET D'INCENDIE

Le fait de ne pas suivre cet avertissement pourrait entra_ner des

dommages corporels et /ou la mort.

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 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 260

1. Remove low-gas pressure switch, brass street 90 ° elbow,

brass Hex nipple, brass Tee and brass nipple from the gas

valve inlet pressure tap. (See Fig 26.)

NOTE: Use pipe dope approved for use with Propane gas. DO

NOT use Teflon tape.

2. Apply pipe dope sparingly to the l/8-in. NPT pipe plug

(provided in kit) and install in the l/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.

For larger casing when Vent Pipe does not pass across casing. All Sizes

switch contacts must point toward the Cell Panel. Black Iron Street 90 can be

used at Valve Inlet instead of Brass Street 90.

Brass Street Tee

Inlet Pressure Tap with Plug " "

Low Gas Pressure Switch \2i_ ; Brass Nipple

Brass Street

A11366

Fig. 26 - LGPS for Casing Wider Than 14-3/16 and Vent

Does Not Pass Between Inducer and Burner Assembly

INSTALL MANIFOLD

1. Align the orifices in the manifold assembly with the sup-

port rings on the end of the burner.

2. Insert the orifices in the support rings of the burners. Man-

ifold mounting tabs should fit flush against the burner

box.

NOTE: If manifold does not fit flush against the burner box, the

burners are not fully seated forward. Remove the manifold and

check burner positioning in the burner box assembly.

3. Attach the green/yellow wire and ground terminal to one

of the manifold mounting screws.

4. Install the remaining manifold mounting screws.

5. Connect the wires to the flame sensor and hot surface ig-

niter.

6. Connect the connector harness to gas valve.

7. Rewire unit low pressure switch (LPS) as follows:

a. Trace one of the orange wires previously disconnected

from the LGPS back to the NO terminals of the LPS.

b. Trace the other orange wire previously disconnected

from the LGPS back to its splice connection with the yel-

low wire of the furnace wire harness. Disconnect and dis-

card this orange wire and the splice connection.

c. Connect the yellow wire of the furnace wire harness (see

"b" above) to the NO terminal of the LPS.

d. Refer to the furnace wiring diagram ensure proper loca-

tion of wires.

NOTE: Use only Propane-resistant pipe dope, DO NOT use

Teflon tape.

8. Insert the gas pipe through the grommet in the casing. Ap-

ply 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 wrench on the gas valve to prevent the

valve from rotating on the manifold or damaging the mounting to

the burner box.

19

9. Withaback-upwrenchonthe inlet boss of the gas valve,

finish tightening the gas pipe to the gas valve.

10. Turn gas on at electric switch on gas valve.

CHECK INLET GAS PRESSURE

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

DO NOT operate furnace more than one minute to check

inlet gas pressure, as conversion is not complete at this time.

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.

2. Turn on furnace power supply.

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

4. Turn furnace gas valve switch to ON position.

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

Fig. 27).

SW4

Outside Air Thermistor_

_F_ CrflnotiwnU;_uSpFan_

switches CF 1 through

CF 3 "_

Communication

SW4

[]

_I=_ PLB

O_

Connecton--

24 VAC

HUM Output

(O.5AMP

i

Setup Switches SWl,

1 thru 8

[_ SW3

Model Plug _ _-N _!:i _]_

Z"_ /_:21 _ W2 Yt DHUM

SW2

I

SW2 A/C Air Flow

Setup Switches

AC 1 through AC 3

Fig. 27 -Furnace Control

Al1471

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

control.

7. When main burners ignite, confirm inlet gas pressure is

between 4.5-in. W.C. and 13.6-in. W.C.

8. Remove jumper across R-W/WI and R-W2 thermostat

connections to terminate call for heat.

9. Turn furnace gas valve switch to OFF position.

10. Turn gas supply manual shutoff valve to OFF position.

11. Turn off furnace power supply.

12. Remove manometer.

13. Apply pipe dope sparingly to the l/8-in. NPT pipe plug

and install in the l/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

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury

and/or death.

NEVER test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for

the detection of leaks to check all connections. A fire or

explosion may result causing property damage, personal

iniury or loss of life.

RISQUE D'EXPLOSION ET D'INCENDIE

Le fair de ne pas suivre cet avertissement pourrait entra_ner des

dommages corporels et /ou la mort.

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.

FIRE, EXPLOSION, ELECTRICAL SHOCK

HAZARD

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.

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 suitaMe

warning label. Verify proper operation after servicing.

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

2. Remove l/8-in. NPT pipe plug from manifold pressure tap

on downstream side of gas valve.

3. Attach manometer to manih_ld pressure tap on gas valve.

(See Fig. 24.)

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

5. Turn furnace gas valve switch to ON position.

6. Check all threaded pipe connections for gas leaks.

7. Turn on furnace power supply.

GAS INPUT RATE INFORMATION

See furnace rating plate on blower door for input rate. The input

rate for natural gas is determined by manifold pressure and orifice

size.

20

Deternfinenaturalgasorificesizeandmanifoldpressuresfor

correctinputatinstalledaltitudebyusingTable5.

1.Obtainyearlyheat-valueaverage(atinstalledaltitude)for

localgassupply.

2.Obtainyearlyspecific-gravityaverageforlocalgassup-

ply.

3.FindinstallationaltitudeinTable5.

NOTE:ForCanadaaltitudesof2000to4500ft.(610to1372

M),useU.S.A.Altitudesof2001to3000ft.(610to914M)in

Table5.

Furnacegasinputrateonratingplateisfor installationsat

altitudesupto2000ft.(610M).

IntheU.S.A.,theinputratingforaltitudesabove2000ft.(610M)

mustbereducedby2percentforeach1000ft.(305M)abovesea

level.

In Canada,theinputratingmustbederatedby5percentfor

altitudesof 2000ft.(610M)to4500ft. (1372M)abovesea

level.

TheConversionKit RatingPlateaccountsfor highaltitude

derate.

SETGASINPUTRATE

1.Makesurethegassupplyisturnedofftothefurnaceand

attheelectricswitchonthegasvalve.

2.Removethe1/8inchNPTplugfromtheoutletpressure

taponthegasvalve.

3.Connectamanometertotheoutletpressuretapongas

valve.

4.Turnonfurnacepowersupply.

5.TurngassupplymanualshutoffvalvetoONposition.

6.TurnfurnacegasvalveswitchtoONposition.

7.VerifySWI-2onfurnacecontrolisturned"ON".

8.JumperRandW/WIthermostatconnectionstocallfor

heat.

9.Checkmanifoldorificesforgasleakswhenmainburners

ignite.

10.Adjustgasmanifoldpressure.RefertoTable5.

11.Removecapsthatconcealtheadjustmentscrewsforgas

valveregulators.SeeFig.24.

12.Adjustlow-heatmanifoldpressurefornaturalgas.See

Fig.24.

13.Turnlow-heatadjustingscrewcounterclockwise(out)to

decreaseinputrateorclockwise(in)toincreaseinputrate.

NOTE:Whencorrectinputis obtained,mainburnerflame

shouldbeclearblue,almosttransparent(seeFig.28).

14.JumperR,W/WIandW2oncontrolcenterthermostat

connections.Thiskeepsfurnacelockedinhigh-heatoper-

ation.

15.Adjusthigh-heatmanifoldpressurefornaturalgas.

16.Turnhigh-heatadjustingscrewcounterclockwise(out)to

decreaseinputrateorclockwise(in)toincreaseinputrate.

17.Replacecapsthatconcealthegasvalveregulatoradjust-

mentscrews.

NOTE:Whencorrectinputis obtained,mainburnerflame

shouldbeclearblue,almosttransparent(seeFig.28).

Burner Flame

_/_ Burner

Al1461

Fig. 28 - Burner Flame

18. Remove jumper across R, Wl, and W2 after high-heat ad-

justment to ternfinate call for heat.

19. Turn setup switch SWI-2 on furnace control to OFF posi-

tion.

20. Turn furnace gas valve switch to OFF position.

21. Turn off furnace power supply.

22. Remove manometer and re-install manifold pressure tap

plug.

23. Turn furnace gas valve switch to ON position.

24. Turn on furnace power supply.

25. Set room thermostat to call for heat.

26. Check pressure tap plug for gas leaks when main burners

ignite.

27. Check for correct burner flame.

28. After making the required manifold pressure adjustments,

check and adjust the furnace temperature rise per the fur-

nace installation instructions.

LABEL 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 338305-206, see

Fig. 30, to Outer Door of furnace.

3. Attach Gas Control Conversion label 338305-207 to gas

valve. DO NOT use 338305-208, which is sinfilar.

CHECKOUT

1. Observe unit operation through 2 complete heating cycles.

2. See Sequence of Operation operation in furnace Installa-

tion, Start-Up, and Operating Instructions.

3. Set room thermostat to desired temperature.

21

THiSFURNACEWAS CONVERTED

ON TO NATURALGAS

(DAY-MONTH-YEAR)

KiT NO.: KGAPN4401VSP

BY:

(Name and address of organization making this conversion),

which accepts the responsibility that this conversion has

been properly made.

CEGI_NI_RATEURD'AIRCHAUDA ETI_

CONVERTILE POUR

(JOUR-MOIS-ANNEE)

DE L'ENSEIVlBLEN°,: KGAPN4401VSP

PAR:

(Nora et adresse de I'organisme qui a effectu6 la conversion),

qui accepte |' entri6re responsabilit6 de la conversion.

338305-210 REV.A _.j

Fig. 29 - Conversion Responsibility Label

Al1505

CONVERSION KiT RATING PLATE CARRIER CORPORATION

THiS APPLIANCE HAS BEEN CONVERTED TO USE NATURAL GAS FOR FUEL, REFER TO KiT iNSTRUCTiONS FOR CONVERSION

PROCEDURES, USE PARTS SUPPLIED BY CARRIER CORPORATION AND iNSTALLED BY QUALiFiED PERSONNEL,

SEE EXISTING RATING PLATE FOR APPLIANCE MODEL NO, AND iNPUT RATING,

NOTE: Furnacegas inputrate on rating plate is for installationsup to 2000ft. (6t0m) above sea level in U.S.A.the input rating for altitudesabove2000ft. (610m)must

be deratedby 2%for each 1000ft. (305m)abovesea level, inCanadathe inputrating must be derated(per chart below) for altitudesof 2000ft. (610m)to 4500 ft. (1372m)

above sea level

KITNO,: KGAPN4401VSP (SUPERSEDES:NONE)

USA CANADA

APPLIANCE % BERATE %BERATE

MODELS PER FOR

1000 FT. 2000=4500FT.

2% 5%

59TN6A

986TA

PG96VAT

NATURAL GAS PRESSURE

Max. InletGas Pressure

(Press. Max. D'Admission De Gaz)

Min. inletGas Pressure

(Press. Min. D'Admission De Gaz)

(For Purpose of input Adjustment)

ALTITUDE

FUEL USED: NATURAL GAS

iN. W.C. (PO C.E.) PA

13.6 3,386

4.5 1,121

(Pour L'Adjustment D'Entree)

Manifold 0=2,000 ft. High Heat 3.2 - 3.8 /797 - 946 _1_1_.

Pressure (0 - 610 m) Low Heat 1.4 - 1.8 [ 349 - 448

Pression 2,000 - 10,000 ft. Refer to Installation Manual

Tubulure (610 - 3050 m) Respecter les instruction D'lnstallation

_. 338305-206 REV.B

Al1633

Fig. 30 - Conversion Kit Rating Plate

22

SECTION 3

Table 7-Non-condensing Furnaces

MODEL NUMBERS BEGINNING WITH:

58CVA 315AAV

58CVX 315JAV

PG8MVA PG8JVA

INSTALLATION

FIRE, EXPLOSION, ELECTRICAL SHOCK

HAZARD

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.

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow instructions could result in personal injury,

death or property damage.

Improper installation, adjustment, alteration, service,

maintenance, or use can cause carbon monoxide poisoning,

explosion, fire, electrical shock, or other conditions, which

could result in personal injury or death. Consult your

distributor or branch for information or assistance. The

qualified installer or agency must use only

factory-authorized kits or accessories when servicing this

product.

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

injury or death.

This conversion kit shall be installed by a qualified service

agency in accordance with the manufacturer's instructions

and all applicable codes and requirements of the authority

having jurisdiction. If the information in these instructions

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

carbon monoxide 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.

LE FEU, L'EXPLOSION, CHOC ELECTRIQUE,

ET MONOXYDE DE CARBONE

EMPOISONNER

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.

1. Set room thermostat to lowest setting or "OFF".

2. Remove outer doors.

3. Disconnect power at external disconnect, fuse or circuit

breaker.

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

[]NIT OPERATION HAZARD

Failure to follow this caution may result in unit damage or

improper operation.

Label all wires prior to disconnection when servicing

controls.

D'EQUIPEMENT D'OPERATION

Toute erreur de cfiblage peut _tre une source de danger et de

panne.

Lors des op6rations d'entretien des commandes, 6tiqueter

tous les ills avant de les d_connecter.

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 gas valve and remove pipe

from the furnace casing.

2. Disconnect the connector harness from gas valve. Discon-

nect wires from Hot Surface Igniter (HSI) and Flame

Sensor. Disconnect the two wires from the low gas pres-

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.

4. Note the location of the green/yellow wire ground wire for

re-assembly later.

5. Slide one-piece burner assembly out of slots on sides of

burner box.

6. Remove the flame sensor from the burner assembly.

7. Remove the orifices from the manifold and discard.

23

Bracket Ignito_

Fig. 31 -80% Burners

Gas Valve

\\

Manifold

Clp, Harness

Burner Assy

urner Support Assy

4_4P

Switch, Temp (2)

Al1390

Orifice (_/ .z¢p_ Attach Green/Yellow

J j ground wire here

@

Screw (2)

A11395

Fig. 32 -80% Manifold

NOx DEVICE INSTALLATION (when required)

The following models must have NOx baffles installed (58CVX

and 315JAV). NOx baffles are not included in this kit and must

be ordered separately or reused if retained from original

conversion to Propane.

For NOx device installation, follow these additional steps:

1. Remove the screw underneath the heat exchanger inlet that

secures the NOx device in the heat exchanger. (See Fig.

33.)

A02195

Fig. 33 -NOx Device

2. Use a pair of needle nose pliers to install the NOx device.

3. Squeeze the sides of the device, if necessary, to install in

the heat exchanger.

4. Re-install screw in hole underneath heat exchanger inlet.

NOTE: It is very IMPORTANT to reinstall the NOx bracket

mounting screw.

5. Repeat steps for each heat exchanger.

ORIFICE SELECTION/DERATE

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

DO NOT re-drill burner orifices. Improper drilling may

result in burrs, out-of-round holes, etc. Obtain new orifices

if orifice size must be changed. (Fig. 34.)

A96249

Fig. 34 - Burner Orifice

Determine natural gas orifice size and manifold pressures for

correct input at installed altitude by using Table 7 or 8.

NOTE: All models in all positions except Low NOx models in

downflow and horizontal positions use Table 7 (22,000 Btuh per

burner). Low NOx models in downflow or horizontal positions

must use Table 8 (21,000 Btuh per burner). See input listed on

rating plate.

1. Obtain yearly heat-value average (at installed altitude) for

local gas supply.

2. Obtain yearly specific-gravity average for local gas sup-

ply.

3. Find installation altitude in Table 7 or 8.

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 7 or 8.

4. Find closest natural gas heat value and specific gravity in

Table 7 or 8.

5. Follow heat-value line and specific-gravity line to point

of intersection to find orifice size and high and low mani-

fold pressure settings.

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 for altitudes above 2000 ft.(610

M) must be reduced by 2 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. to 4500 ft. (610 to 1372 M) above sea level.

The Conversion Kit Rating Plate accounts for high altitude

derate.

INSTALL ORIFICES

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. There are enough

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

NOTE: DO NOT reinstall the manifold at this time.

24

Table8- Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated Data Based on 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea Level)

ALTITUDE RANGE

FT. (M)

0 to

USA 2000

(0 to 610)

ALTITUDE RANGE

FT. (M)

2001 to

USA 3000 (610

to 914)

ALTITUDE RANGE

FT. (a)

3001 to

4000

USA (914 to

1219)

ALTITUDE RANGE

FT. (M)

4001 to

5000

USA (1219 to

1524)

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

900

925

950

975

1000

1025

1050

1075

1100

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

800

825

850

875

900

925

950

975

1000

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

775

800

825

850

875

900

925

950

AVG, GAS

HEAT VALUE

(BTUH/CU FT.)

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

750

775

800

825

850

875

900

925

Orifice number 43 are factory installed

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

High/Low High/Low

42 3.5/1.5 42 3.6/1.6

42 3.3/1.4 42 3.4/1.5

43 3.8/1.7 42 3.3/1.4

43 3.6/1.6 43 3.8/1.6

43 3.5/1.5 43 3.6/1.6

43 3.3/1.4 43 3.4/1.5

44 3.6/1.6 43 3.2/1.4

44 3.4/1.5 44 3.5/1.5

44 3.3/1.4 44 3.4/1.5

0.58

Orifice Manifold

No. Pressure

High/Low

42 3.4/1.5

42 3.2/1.4

43 3.7/1.6

43 3.5/1.5

43 3.3/1.4

44 3.5/1.5

44 3.4/1.5

44 3.2/1.4

45 3.7/1.6

0.58

Orifice Manifold

No. Pressure

High/Low

42 3.2/1.4

43 3.6/1.6

43 3.4/1.5

43 3.2/1.4

44 3.5/1.5

44 3.3/1.4

45 3.8/1.6

46 3.8/1.6

0.62 0.64

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

High/Low High/Low

42 3.7/1.6 41 3.5/1.5

42 3.5/1.5 42 3.7/1.6

42 3.4/1.5 42 3.5/1.5

42 3.2/1.4 42 3.3/1.4

43 3.7/1.6 43 3.8/1.7

43 3.5/1.5 43 3.6/1.6

43 3.4/1.5 43 3.5/1.5

43 3.2/1.4 43 3.3/1.4

44 3.5/1.5 43 3.2/1.4

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold

Orifice Manifold Orifice Pressure Orifice

Pressure

No. High/Low No. High/Low No.

42 3.5/1.5 42 3.6/1.6 42

42 3.3/1.4 42 3.4/1.5 42

43 3.8/1.6 42 3.2/1.4 42

43 3.6/1.6 43 3.7/1.6 43

43 3.4/1.5 43 3.5/1.5 43

43 3.2/1.4 43 3.3/1.4 43

44 3.5/1.5 44 3.6/1.6 43

44 3.3/1.4 44 3.4/1.5 44

45 3.8/1.7 44 3.2/1.4 44

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Manifold

Orifice Manifold Orifice Pressure

Pressure

No. High/Low No. High/Low

42 3.3/1.4 42 3.4/1.5

43 3.8/1.6 42 3.2/1.4

43 3.5/1.5 43 3.7/1.6

43 3.3/1.4 43 3.4/1.5

44 3.6/1.6 43 3.3/1.4

44 3.4/1.5 44 3.5/1.5

44 3.2/1.4 44 3.3/1.5

45 3.7/1.6 45 3.8/1.7

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

42

42

43

43

43

43

44

44

0.64

Manifold

Pressure

High/Low

3.7/1.6

3.5/1.5

3.3/1.4

3.8/1.7

3.6/1.6

3.4/1.5

3.2/1.4

3.5/1.5

3.4/1.5

0.64

Manifold

Pressure

High/Low

3.5/1.5

3.3/1.4

3.8/1.6

3.6/1.5

3.4/1.5

3.2/1.4

3.4/1.5

3.3/1.4

0.58 0.60 0.62 0.64

Manifold Manifold

Orifice Manifold Orifice Manifold Orifice Pressure Orifice

Pressure Pressure Pressure

No. High/Low No. High/Low No. High/Low No. High/Low

43 3.6/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

43 3.4/1.5 43 3.5/1.5 43 3.6/1.6 43 3.8/1.6

43 3.2/1.4 43 3.3/1.4 43 3.4/1.5 43 3.5/1.5

44 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

45 3.7/1.6 45 3.8/1.7 44 3.3/1.4 44 3.4/1.5

46 3.7/1.6 46 3.8/1.7 45 3.7/1.6 44 3.2/1.4

46 3.5/1.5 46 3.6/1.6 46 3.7/1.6 46 3.8/1.7

25

Table 8 -Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con't.)

(Tabulated Data Based on 22,000 Btuh High-Heat/14,500 Btuh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.

Above Sea Level)

ALTITUDE

RANGE

FT. (M)

5001 to

6000

USA (1524

to

1829)

ALTITUDE

RANGE

6001 to

7000

USA (1829

to

2134)

ALTITUDE

RANGE

7001 to

8000

USA (2134

to

2438)

ALTITUDE

RANGE

8001 to

9000

USA (2438

to

2743)

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

725

750

775

800

825

850

875

900

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

675

700

725

750

775

800

825

850

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

650

675

700

725

750

775

800

825

AVG, GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

625

650

675

700

725

750

775

600

9001to 625

10,000 650

USA 2743to 675

3048) 700

725

Orifice number43arefactoryinstalled

0.58

Manifold Manifold

Orifice Orifice

Pressure Pressure

No. No.

High/Low High/Low

43 3.4/1.5 43 3.5/1.5

43 3.2/1.4 43 3.3/1.4

44 3.4/1.5 44 3.5/1.5

44 3.2/1.4 44 3.3/1.4

46 3.8/1.7 45 3.8/1.6

46 3.6/1.6 46 3.7/1.6

47 3.8/1.7 46 3.5/1.5

47 3.6/1.6 47 3.8/1.6

0.58

Manifold

Orifice Pressure

No. High/Low

43 3.4/1.5 43 3.5/1.5

44 3.6/1.6 43 3.3/1.4

44 3.4/1.5 44 3.5/1.5

45 3.8/1.7 44 3.3/1.4

46 3.7/1.6 45 3.7/1.6

46 3.5/1.5 46 3.6/1.6

47 3.7/1.6 46 3.4/1.5

47 3.5/1.5 47 3.6/1.6

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

SPECIFIC GRAVITY OF

0.60

Manifold

Orifice Pressure

No. High/Low

0.58

Manifold

Orifice Pressure

No. High/Low

44 3.6/1.6 43 3.2/1.4

44 3.3/1.5 44 3.5/1.5

45 3.8/1.6 44 3.2/1.4

46 3.7/1.6 46 3.8/1.7

46 3.4/1.5 46 3.6/1.5

47 3.6/1.6 47 3.8/1.6

47 3.4/1.5 47 3.5/1.5

48 3.7/1.6 48 3.8/1.6

SPECIFIC GRAVITY OF

0.60

Manifold

Orifice Pressure

No. High/Low

0.58

Manifold

Orifice Pressure

No. High/Low

44 3.3/1.5 44 3.5/1.5

45 3.7/1.6 44 3.2/1.4

46 3.6/1.6 46 3.8/1.6

47 3.8/1.7 46 3.5/1.5

47 3.6/1.6 47 3.7/1.6

48 3.8/1.7 47 3.5/1.5

48 3.6/1.5 48 3.7/1.6

45 3.7/1.6 45 3.8/1.7

46 3.6/1.6 46 3.7/1.6

47 3.8/1.6 46 3.4/1.5

47 3.5/1.5 47 3.6/1.6

48 3.7/1.6 48 3.8/1.7

48 3.5/1.5 48 3.6/1.6

SPECIFIC GRAVITY OF

0.60

Manifold

Orifice Pressure

No. High/Low

Manifold

Orifice Pressure

No. High/Low

43 3.6/1.6

43 3.4/1.5

43 3.2/1.4

44 3.4/1.5

44 3.2/1.4

45 3.8/1.7

45 3.5/1.5

45 3.4/1.5

NATURAL GAS

0.62

Manifold

Orifice Pressure

No. High/Low

43 3.6/1.6

43 3.4/1.5

44 3.6/1.6

44 3.4/1.5

45 3.8/1.7

46 3.8/1.6

46 3.5/1.5

47 3.8/1.6

NATURAL GAS

0,62

Manifold

Orifice Pressure

No. High/Low

43 3.4/1.5

44 3.6/1.6

44 3.3/1.4

45 3.7/1.6

46 3.7/1.6

46 3.4/1.5

47 3.7/1.6

47 3.4/1.5

NATURAL GAS

0,62

Manifold

Orifice Pressure

No. High/Low

44 3.6/1.6

44 3.3/1.4

45 3.7/1.6

46 3.6/1.6

47 3.8/1.7

47 3.6/1.6

48 3.8/1.7

44 3.3/1.4

46 3.8/1.7

46 3.6/1.5

47 3.7/1.6

47 3.5/1.5

48 3.7/1.6

Orifice

No.

43

43

43

44

44

45

46

46

Orifice

No.

43

43

43

44

44

45

46

46

Orifice

No.

43

43

44

44

46

46

47

47

Orifice

No.

43

44

45

46

46

47

47

44

45

46

46

47

48

0.64

Manifold

Pressure

High/Low

3.7/1.6

3.5/1.5

3.3/1.4

3.5/1.5

3.3/1.4

3.8/1.6

3.7/1.6

3.5/1.5

0.64

Manifold

Pressure

High/Low

3.7/1.6

3.5/1.5

3.2/1.4

3.5/1.5

3.2/1.4

3.7/1.6

3.6/1.6

3.4/1.5

0.64

Manifold

Pressure

High/Low

3.5/1.5

3.2/1.4

3.4/1.5

3.2/1.4

3.8/1.6

3.6/1.5

3.8/1.6

3.6/1.5

0.64

Manifold

Pressure

High/Low

3.2/1.4

3.4/1.5

3.8/1.7

3.7/1.6

3.5/1.5

3.7/1.6

3.5/1.5

3.4/1.5

3.8/1.6

3.7/1.6

3.4/1.5

3.6/1.6

3.8/1.7

2d

Table 9 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated Data Based on 21,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea level)

ALTITUDE RANGE

FT. (M)

0 to

USA 2000

(0 to 610)

ALTITUDE RANGE

FT. (M)

2001 to

USA 3000 (610

to 914)

ALTITUDE RANGE

FT. (M)

3001 to

USA 4000 (914

to 1219)

ALTITUDE RANGE

FT. (M)

4001 to

5000

USA (1219 to

1524)

AVG, GAS

HEAT VALUE

(BTUH/CU

FT.)

900

925

950

975

1000

1025

1050

1075

1100

AVG, GAS

HEAT VALUE

(BTUH/CU

FT.)

800

825

850

875

900

925

950

975

1000

AVG. GAS

HEAT VALUE

(BTUH/CU

FT.)

775

800

825

850

875

900

925

950

AVG, GAS

HEAT VALUE

(BTUH/CU

FT.)

750

775

800

825

850

875

900

925

Orifice number 43 are factory installed

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Manifold

Manifold Manifold Manifold

Orifice Orifice Orifice Orifice Pressure

Pressure Pressure Pressure

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

43 3.7/1.8 43 3.8/1.8 42 3.2/1.5 42 3.3/1.6

43 3.5/1.7 43 3.6/1.7 43 3.7/1.8 43 3.8/1.8

43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 43 3.7/1.7

44 3.6/1.7 43 3.3/1.6 43 3.4/1.6 43 3.5/1.7

44 3.4/1.6 44 3.6/1.7 43 3.2/1.5 43 3.3/1.6

44 3.3/1.6 44 3.4/1.6 44 3.5/1.7 43 3.2/1.5

45 3.8/1.8 44 3.2/1.5 44 3.3/1.6 44 3.4/1.6

46 3.8/1.8 45 3.7/1.8 44 3.2/1.5 44 3.3/1.6

SPECIFIC GRAVITY OF NATURAL GAS

0,58 0,60 0,62 0,64

Manifold

Manifold Manifold Manifold

Orifice Orifice Orifice Pressure Orifice

Pressure Pressure Pressure

No. High/Low No. High/Low No. High/Low No. High/Low

43 3.8/1.8 42 3.2/1.5 42 3.3/1.6 42 3.4/1.6

43 3.5/1.7 43 3.7/1.7 43 3.8/1.8 42 3.2/1.5

43 3.3/1.6 43 3.5/1.6 43 3.6/1.7 43 3.7/1.8

43 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

44 3.2/1.5 44 3.3/1.6 44 3.5/1.6 44 3.6/1.7

45 3.7/1.8 45 3.8/1.8 44 3.3/1.6 44 3.4/1.6

46 3.7/1.8 46 3.8/1.8 45 3.8/1.8 44 3.2/1.5

46 3.5/1.7 46 3.6/1.7 46 3.8/1.8 45 3.7/1.8

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64

Manifold Manifold Manifold Manifold

Orifice Orifice Orifice Orifice

Pressure Pressure Pressure Pressure

No. No. No. No.

High/Low High/Low High/Low High/Low

43 3.5/1.7 43 3.7/1.7 43 3.8/1.8 42 3.2/1.5

43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 43 3.7/1.7

44 3.6/1.7 43 3.2/1.5 43 3.3/1.6 43 3.4/1.6

44 3.4/1.6 44 3.5/1.7 44 3.6/1.7 43 3.2/1.5

45 3.8/1.8 44 3.3/1.6 44 3.4/1.6 44 3.5/1.7

46 3.8/1.8 45 3.8/1.8 44 3.2/1.5 44 3.3/1.6

46 3.6/1.7 46 3.7/1.8 45 3.7/1.8 45 3.8/1.8

46 3.4/1.6 46 3.5/1.7 46 3.7/1.7 46 3.8/1.8

SPECIFIC GRAVITY OF NATURAL GAS

0,58 0,60 0,62 0,64

Manifold Manifold Manifold Manifold

Orifice Orifice Orifice Orifice

Pressure Pressure Pressure Pressure

No. No. No. No.

High/Low High/Low High/Low High/Low

43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 43 3.6/1.7

44 3.6/1.7 43 3.2/1.5 43 3.3/1.6 43 3.4/1.6

44 3.3/1.6 44 3.4/1.6 44 3.6/1.7 43 3.2/1.5

45 3.8/1.8 44 3.2/1.5 44 3.4/1.6 44 3.5/1.6

46 3.8/1.8 45 3.7/1.8 45 3.8/1.8 44 3.3/1.6

46 3.5/1.7 46 3.7/1.7 46 3.8/1.8 45 3.7/1.8

47 3.8/1.8 46 3.5/1.7 46 3.6/1.7 46 3.7/1.8

47 3.6/1.7 47 3.7/1.8 47 3.8/1.8 46 3.5/1.7

27

Table 9 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con't.)

(Tabulated Data Based on 21,000 Btuh High-Heat/14,500 Btuh for Low-Heat Per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea level)

ALTITUDE RANGE

FT. (M)

5001 to

6000

USA (1524 to

1829)

ALTITUDE RANGE

FT. (M)

6001 to

7000

USA (1829 to

2134)

ALTITUDE RANGE

FT. (M)

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU

FT.)

725

750

775

800

825

850

875

900

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU

FT.)

675

700

725

750

775

800

825

850

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU

FT.)

650

675

7001 to 700

8000 725

USA (2164 to 750

2468) 775

800

825

AVG, GAS

HEAT VALUE

ALTITUDE RANGE AT ALTITUDE

FT. (M) (BTUH/CU

FT.)

625

650

8001 to 675

USA 9000 700

(2468 to

2746) 725

750

775

600

9001 to 625

10,000 650

USA (2746 to 675

3048) 700

725

Orifice number 43 are factory installed

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60

Manifold Manifold

Orifice Pressure Orifice Pressure

No. High/Low No. High/Low

44 3.5/1.7 46 3.2/1.5

44 3.6/1.6 44 3.4/1.6

45 3.7/1.8 44 3.2/1.5

46 3.7/1.8 46 3.8/1.8

46 3.5/1.7 46 3.6/1.7

47 3.7/1.8 47 3.8/1.8

47 3.5/1.7 47 3.6/1.7

48 3.8/1.8 47 3.4/1.6

SPECIFIC GRAVITY OF

0.58 0.60

Manifold Manifold

Orifice Pressure Orifice Pressure

No. High/Low No. High/Low

44 3.5/1.7 43 3.2/1.5

44 3.3/1.6 44 3.4/1.6

45 6.7/1.8 45 6.8/1.8

46 3.6/1.7 46 3.8/1.8

46 3.4/1.6 46 3.5/1.7

47 3.6/1.7 47 3.8/1.8

47 3.4/1.6 47 3.5/1.7

48 3.7/1.7 48 3.8/1.8

SPECIFIC GRAVITY OF

0.58 0.60

Manifold Manifold

Orifice Orifice

Pressure Pressure

No. No.

High/Low High/Low

44 3.3/1.6 44 3.4/1.6

45 6.7/1.8 45 6.8/1.8

46 3.6/1.7 46 3.7/1.8

47 3.8/1.8 46 3.5/1.7

47 6.5/1.7 47 6.7/1.8

48 3.8/1.8 47 3.4/1.6

48 3.6/1.7 48 3.7/1.8

48 3.3/1.6 48 3.5/1.6

SPECIFIC GRAVITY OF

0.58 0.60

Manifold Manifold

Orifice Orifice

Pressure Pressure

No. No.

High/Low High/Low

45 6.7/1.8 45 6.8/1.8

46 3.6/1.7 46 3.7/1.8

47 3.8/1.8 46 3.4/1.6

47 3.5/1.7 47 3.6/1.7

48 3.7/1.8 48 3.8/1.8

48 3.5/1.7 48 3.6/1.7

49 3.8/1.8 48 3.4/1.6

46 3.6/1.7 46 3.7/1.8

47 3.7/1.8 47 3.8/1.8

47 3.4/1.6 47 3.6/1.7

48 3.6/1.7 48 3.8/1.8

48 3.4/1.6 48 3.5/1.7

49 3.7/1.8 49 3.8/1.8

0.62 0.64

Manifold

Manifold

Orifice Orifice Pressure

Pressure

No. High/Low No. High/Low

43 3.3/1.6 43 3.4/1.6

44 3.5/1.7 46 3.2/1.5

44 3.3/1.6 44 3.4/1.6

45 6.8/1.8 44 6.2/1.5

46 3.7/1.8 46 3.8/1.8

46 3.5/1.7 46 3.6/1.7

47 3.7/1.8 46 3.4/1.6

47 6.5/1.7 47 6.7/1.7

NATURAL GAS

0,62 0.64

Manifold Manifold

Orifice Orifice

Pressure Pressure

No. No.

High/Low High/Low

43 3.3/1.6 43 3.4/1.6

44 3.5/1.7 46 3.2/1.5

44 3.3/1.6 44 3.4/1.6

45 6.7/1.8 45 6.8/1.8

46 3.6/1.7 46 3.8/1.8

46 3.4/1.6 46 3.5/1.7

47 3.6/1.7 47 3.8/1.8

47 3.4/1.6 47 3.5/1.7

NATURAL GAS

0,62 0.64

Manifold

Manifold

Orifice Orifice Pressure

Pressure

No. High/Low No. High/Low

44 3.5/1.7 46 3.2/1.5

44 3.3/1.6 44 3.4/1.6

46 3.8/1.8 45 3.8/1.8

46 3.6/1.7 46 3.7/1.8

47 3.8/1.8 46 3.5/1.6

47 3.6/1.7 47 3.7/1.7

48 3.8/1.8 47 3.4/1.6

48 3.6/1.7 48 3.7/1.8

NATURAL GAS

0,62 0.64

Manifold Manifold

Orifice Orifice

Pressure Pressure

No. No.

High/Low High/Low

44 3.3/1.6 44 3.4/1.6

46 3.8/1.8 45 3.8/1.8

46 3.5/1.7 46 3.7/1.7

47 3.7/1.8 46 3.4/1.6

47 3.5/1.7 47 3.6/1.7

48 3.7/1.8 48 3.8/1.8

48 3.5/1.7 48 3.6/1.7

46 3.8/1.8 45 3.7/1.8

46 3.5/1.7 46 3.6/1.7

47 3.7/1.8 47 3.8/1.8

47 3.4/1.6 47 3.5/1.7

48 3.6/1.7 48 3.7/1.8

48 3.4/1.6 48 3.5/1.7

28

REMOVE MIXER SCREWS

Each burner contains a mixer screw that must be removed. Refer

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 when

the mixer screws are removed.

i

I

--_[ 1-9/16"

1

39.7 mm

Location of mixer screw

that must be removed

Fig. 35 - Mixer Screw Location

Al1511

Fig. 36 -Igniter Position - Side View

5/16"

7.9ram

A05025

REINSTALL BURNER ASSEMBLY

To reinstall burner assembly:

1. Attach flame sensor to burner assembly.

2. Install HSI and bracket to burner assembly.

3. Insert one-piece burner in slot on sides of burner box and

slide burner back in place.

4. Reattach HSI wires to HSI.

5. Verify igniter to burner alignment.

6. For Silicon Nitride igniters, see Fig. 36 and 37.

7. For Silicon Carbide igniters, see Fig. 38.

8. Re-attach Flame Sensor wire to Flame Sensor.

f

1-7/8

O (47'imm)

A05026

Fig. 37 -Igniter Position -Top View

/

_,_11/32 ,,

8.7 mm

f CELL

PANEL

_HOT

SURFACE

IGNITER

ASSEMBLY

{ IGNITER

7/8,,

22.2 mm

BURNER

IGNITER

ASSEMBLY

Fig. 38 -Silicon Carbide Igniters

CONVERT GAS VALVE

A93347

[]NIT 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.

29

FIRE,EXPLOSION,ELECTRICALSHOCK

HAZARD

Failureto 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.

TWO-STAGE

ON/OFF Switch f ...... _:::_-_

,,

1/2' NPT inlet

1/8" NPT Inlet

Pressure Tap

,Regulator Seal Cap

Regulator Adjustment

Regulator Seal Cap

under Cap

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.

NOTE: For the 2-stage furnaces with a Series J and Series G gas

valve (see Fig. 39), they MUST have both regulator springs

replaced and the gas valve MUST be pre-adjusted.

For older model 2-stage furnaces with aSeries E gas valve (see

Fig. 40), they DO NOT need to have the regulator springs

replaced in the gas valve, but the regulators in the gas valve must

be pre-adjusted for natural applications.

For J and G valves See Fig 39.

1. Be sure main gas and electrical supplies are turned OFF.

2. Remove both regulator seal caps. (See Fig. 39.)

3. Remove both regulator adjustment screws.

4. Remove both Propane gas regulator springs (white).

5. Install natural gas regulator springs (silver).

6. Install regulator adjustment screws.

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 seal caps at this time,

For E valves see Fig 40.

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

2. Remove caps that conceal adjustment screws for high-

and low-heat stage gas valve regulators. (See Fig. 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 nat-

ural low-heat set point.

4. Turn high-heat stage adjusting screw (3/32-in. [2 mm]

hex Allen screw) counter clockwise (outwards) 2 full

turns. This will decrease the manifold pressure closer to

the natural high-heat set point.

5. DO NOT install regulator seal caps at this time.

NPT Outlet

1/8" NPT Manifold

Pressure Tap

Al1152

Fig. 39 - 2-Stage J or G Valve

LOW-HEAT

ADJUSTMENT

ALLEN SCREW

(UNDER CAP)

-- HIGH-HEAT

ADJUSTMENT

ALLEN SCREW

(UNDER CAP)

PLUG BUTTON

(2-STAG E AND

t/ VARIABLE SPEED,

NON CONDENSING

FURNACES ONLY)

MANIFOLD

PRESSURE

TAP

BURNER ENCLOSURE "_/

REFERENCE PRESSURE TAP(2-STAGE

AND VARIABLE-SPEED, CONDENSING

FURNACES ONLY)

A01069

Fig. 40 - 2-Stage E Valve

REMOVE LOW GAS PRESSURE SWITCH

FIRE, EXPLOSION, ELECTRICAL SHOCK

HAZARD

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.

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.

30

1.Besuremaingasandelectricsuppliesto 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 approved for use with Propane gas. DO

NOT use Teflon tape.

3. Apply pipe dope sparingly to the l/8-in. NPT pipe plug

(provided in kit) and install in the l/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.

2" Brass Nipple

Low Gas

Pressure Switch

Female x Female x Male Tee

1/8" NPT Pipe Plug /

For inlet pressure tap

Fig. 41 -80% Low Gas Pressure Switch

Al1398

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury

and/or death.

NEVER test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for

the detection of leaks to check all connections. A fire or

explosion may result causing property damage, personal

injury or loss of life,

RISQUE D'EXPLOSION ET D'INCENDIE

Le fair de ne pas suivre cet avertissement pourrait entra*ner des

dommages corporels et /ou la mort.

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.

INSTALL MANIFOLD

1. Align the orifices in the manifold assembly with the sup-

port rings on the end of the burner.

2. Insert the orifices in the support rings of the burners. Man-

ifold mounting tabs should fit flush against the burner

box.

NOTE: If manifold does not fit flush against the burner box, the

burners are not fully seated forward. Remove the manifold and

check burner positioning in the burner box assembly.

3. Attach the green/yellow wire and ground terminal to one

of the manifold mounting screws.

4. Install the remaining manifold mounting screws.

5. Connect the wires to both rollout switches.

6. Connect the wires to the flame sensor and hot surface ig-

niter.

7. Connect the connector harness to gas valve.

8. Rewire unit low pressure switch (LPS) as follows:

a. Trace one of the orange wires previously disconnected

from the LGPS back to the NO terminals of the LPS.

b. Trace the other orange wire previously disconnected

from the LGPS back to its splice connection with the yel-

low wire of the furnace wire harness. Disconnect and dis-

card this orange wire and the splice connection.

c. Connect the yellow wire of the furnace wire harness (see

"b" above) to the NO terminal of the LPS.

d. Refer to the furnace wiring diagram ensure proper loca-

tion of wires.

NOTE: Use only Propane-resistant pipe dope. DO NOT use

Teflon tape.

9. Insert the gas pipe through the grommet in the casing. Ap-

ply 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 wrench on the gas valve to prevent the

valve from rotating on the manifold or damaging the mounting to

the burner box.

10. With a back-up wrench on the inlet boss of the gas valve,

finish tightening the gas pipe to the gas valve.

11. Turn gas on at electric switch on gas valve.

CHECK INLET GAS PRESSURE

SW4

Outside Air Thermi,'

SW3 Continuous

(CF) airflow setup

switches CF 1 through

CF 3 '-_

Communication

24 VAC

HUM Output

(O.5AMP

in

SW4

[]

<_I=_ PL9

O_

._ol [_ SW3

Mode, P,ug_ _-N _i_,:_ __

/,_ /_Zl _ W2 Yt DHUM

SW2

Setup Switches SWl,

1 thru 8

SW2 A/C Air Flow

Setup Switches

AC 1 through AC 3

Fig. 42 - Furnace Control

Al1471

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

DO NOT operate furnace more than one minute to check

inlet gas pressure, as conversion is not complete at this time.

31

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.

2. Turn on furnace power supply.

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

4. Turn furnace gas valve switch to ON position.

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

Fig. 42).

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

control.

7. When main burners ignite, confirm inlet gas pressure is

between 4.5-in. W.C. and 13.6-in. W.C.

8. Remove jumper across R-W/W1 and R-W2 thermostat

connections to terminate call for heat.

9. Turn furnace gas valve switch to OFF position.

10. Turn gas supply manual shutoff valve to OFF position.

11. Turn off furnace power supply.

12. Remove manometer.

13. Apply pipe dope sparingly to 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

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury

and/or death.

NEVER test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for

the detection of leaks to check all connections. A fire or

explosion may result causing property damage, personal

injury or loss of life.

RISQUE D'EXPLOSION ET D'INCENDIE

Le fait de ne pas suivre cet avertissement pourrait entrai'nerdes

dommages corporels et /ou la mort.

Ne jamais examiner pour les fuites de gaz avec une flamme

vive. Utilisez plut6t un savon fait specifiquement pour la

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, ELECTRICAL SHOCK

HAZARD

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.

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 suitaMe

warning label. Verify proper operation after servicing.

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

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

tap on downstream side of gas valve,

3. Attach manometer to manifold pressure tap on gas valve,

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

5. Turn furnace gas valve switch to ON position,

6. Check all threaded pipe connections for gas leaks,

7. Turn on furnace power supply,

GAS INPUT RATE 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 for

correct input at installed altitude by using Table 7 or 8.

NOTE: All models in all positions except Low NOx models in

downflow and horizontal positions use Table 7 (22,000 Btuh per

burner). Low NOx models in downflow or horizontal positions

must use Table 8 (21,000 Btuh per burner). See input listed on

rating plate.

1. Obtain yearly heat-value average (at installed altitude) for

local gas supply.

2. Obtain yearly specific-gravity average for local gas sup-

ply.

3. Find installation altitude in Table 7 or 8.

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 7 or 8.

4. Find closest natural gas heat value and specific gravity in

TaMe 7 or 8.

5. Follow heat-value line and specific-gravity line to point

of intersection to find orifice size and high and low mani-

fold 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 5percent for

altitudes of 2000 ft. (610 M) to 4500 ft. (1372 M) above sea

level.

The Conversion Kit Rating Plate accounts for high altitude

derate.

SET GAS INPUT 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 to the outlet pressure tap on gas

valve.

32

4.Turnonfurnacepowersupply.

5.TurngassupplymanualshutoffvalvetoONposition.

6.TurnfurnacegasvalveswitchtoONposition.

7.VerifySWI-2onfurnacecontrolisturned"ON".SeeFig.

42.

8.JumperRandW/WIthermostatconnectionstocallfor

heat.

9.Checkmanifoldorificesforgasleakswhenmainburners

ignite.

10.Adjustgasmanifoldpressure.(RefertoTable7or8.)

11.Removecapsthatconcealadjustmentscrewsforgasvalve

regulators.(SeeFig.39.)

12.Adjustlow-heatmanifoldpressurefornaturalgas.(See

Fig.39.)

13.Turnlow-heatadjustingscrewcounterclockwise(out)to

decreaseinputrateorclockwise(in)toincreaseinputrate.

NOTE:Whencorrectinputis obtained,mainburnerflame

shouldbeclearblue,almosttransparent(seeFig.43).

14.JumperR,W/WIandW2oncontrolcenterthermostat

connections.Thiskeepsfurnacelockedinhigh-heatoper-

ation.

15.Adjusthigh-heatmanifoldpressurefornaturalgas.

16.Turnhigh-heatadjustingscrewcounterclockwise(out)to

decreaseinputrateorclockwise(in)toincreaseinputrate.

17.Replacecapsthatconcealthegasvalveregulatoradjust-

mentscrews.

NOTE:Whencorrectinputis obtained,mainburnerflame

shouldbeclearblue,almosttransparent.(SeeFig.43).

Burner Flame

Burner

Fig. 43 -Burner Flame

Al1461

18. Remove jumper across R, Wl, and W2 after high-heat ad-

justment to terminate call for heat.

19. Turn setup switch SWI-2 on furnace control to OFF posi-

tion.

20. Turn furnace gas valve switch to OFF position.

21. Turn off furnace power supply.

22. Remove manometer and re-install manifold pressure tap

plug.

23. Turn furnace gas valve switch to ON position.

24. Turn on furnace power supply.

25. Set room thermostat to call for heat.

26. Check pressure tap plug for gas leaks when main burners

ignite.

27. Check for correct burner flame.

28. After making the required manifold pressure adjustments,

check and adjust the furnace temperature rise per the fur-

nace 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. See Fig. 44.

2. Attach Conversion Rating Plate Label 38305-204 to outer

door of furnace. See Fig. 45.

3. Apply Gas Control Conversion Label: For 2-stage J and

G gas valves, use Gas Control Conversion Label

338305-202. (DO NOT use 338305-203, which is simil-

ar.) For 2-stage E gas valve, use Gas Control Adjustment

Label 338305-203. (DO NOT use 338305-202, which is

similar.)

4. Replace control access door, blower access door and outer

door of furnace.

CHECKOUT

1. Observe unit operation through 2complete heating cycles.

2. See Sequence of Operation in fltrnace Installation, Start-

Up, and Operating Instructions.

3. Set room thermostat to desired temperature.

THIS FURNACE WAS CONVERTED

ON TO NATURAL GAS

(DAY-MONTH-YEAR)

KIT NO.: KGAPN4401VSP

BY:

(Name and address of organization making this conversion),

which accepts the responsibility that this conversion has

been properly made.

CE GI_NI_RATEUR D'AIR CHAUD A #TI_

CONVERTILE POUR

(JOUR-MOIS-ANNI_E)

DE L'ENSEIBLE N°.:KGAPN440IVSP

PAR:

(Nora et adresse de ['organisme qui a effectu6 la conversion),

qui accepte |' entri6re responsabilit6 de [a conversion,

338305-205 REV.A

Fig. 44 - Conversion Responsibility Label

Al1504

33

CONVERSION KiT RATING PLATE CARRIER CORPORATION

THiS APPLIANCE HAS BEEN CONVERTED TO USE NATURAL GAS FOR FUEL. REFER TO KiT iNSTRUCTiONS FOR CONVERSION

PROCEDURES. USE PARTS SUPPLIED BY CARRIER CORPORATION AND iNSTALLED BY QUALiFiED PERSONNEL.

SEE EXiSTiNG RATING PLATE FOR APPLIANCE MODEL NO. AND iNPUT RATING.

NOTE: Furnace gas inputrate on ratingplate is for installationsupto 2000ft. (610m)above sea level, inU.S.A.the inputratingfor altitudesabove 2000ft. (610m) must

be derated by 4%for each 1000ft. (305m)above sea level, in Canadathe input ratingmustbe derated (per chartbelow) for altitudesof 2000ft. (610m)to 4500ft. (1372m)

above sea level.

(SUPERSEDES: KGAPN3501ALL, KGAPN3401ALL, KGAPN1601ALL,

KIT NO.: KGAPN4401VSP KGAPN21012SP, KGAPN2201ALL, KGAPN3301ALL, KGAPN3901ALL)

USA CANADA NATURAL GAS PRESSURE

APPLIANCE %DERATE %DERATE Max. Inlet Gas Pressure

MODELS PER FOR (Press. Max. D'Admission De Gaz)

1000 FT. 20004500 FT. Min. Inlet Gas Pressure

4% 10% (Press. Min. D'Admissi0n De Gaz)

(For Purpose of Input Adjustment)

ALTITUDE

FUEL USED: NATURAL GAS

IN. W.C. (PO C.E.) PA

13.6 3,386

4.5 1,121

(Pour L'Adjustment D'Entree)

58CVA, 58CVX

315AAV, 315JAV,

PG8JVA,PG8MVA Manifold 0-2,000 ft. High Heat 3.2 =3.8 /797 =946 1,1,1,1,_',

Pressure (0-610m) Low Heat 1.4 = 1.8 ] 349 = 448

Pression 2,000 = 10,000 ft. Refer to Installation Manual

Tubulure (610 = 3050 m) Respecter les instruction D'lnstallation

_. 338305-204 REV. B

Al1634

Fig. 45 - Conversion Rating Plate Label

Copyright 2012 CAC /BDP •7310 W. Morris St. • Indianapolis. IN 46231 Edition Date:08/12

Manufacturer reserve8 the rightto change, at anytime, specification8 and design8 without notice and without obligations.

34

Catalo_l No: AG-KGAPNVSP-O4

Replaces: AG KGAPNVSP 03