Carrier KGANP5201VSP User manual

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. KGANP5201VSP to convert the following furnaces from

natural gas usage to propane 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.

59TN6A applies to 60,000 to 120,000 Btuh gas input rates.

986TA & PG96VAT 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

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

1 for kit contents. To accommodate many different furnace

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

complete conversion. When installation is complete, discard extra

parts.

Table 1 -KGANP5201VSP Contents

COMPONENT QTY DESCRIPTION

NUMBER

616166-629 1 PCS CARTON

319965-445 1 PCS LABEL, SHIPPING

320069-602 2 PCS TAPE

326269-701 1 PCS PARTS ASSY

326269-703 1 PCS PARTS ASSY

326269-704 1 PCS PARTS ASSY

326272-702 1 PCS PARTS ASSY

326751-702 1 PCS PARTS ASSY

367704-701 1 PCS LABEL KIT

367704-702 1 PCS LABEL KIT

367704-703 1 PCS LABEL KIT

367932-701 1 PCS BAG ASSY

367932-702 1 PCS BAG ASSY

337932-703 1 PCS BAG ASSY

AG- KGANPVSP-XX 1 PCS INSTRUCTIONS

EF69ZWO02 1 PCS VALVE CVRSN KIT

EF39ZW026 2 PCS VALVE CVRSN KIT

HKO2LBO08 1 PCS SWITCH, PRESSURE

W182X06- -04- -012 1 PCS WIRE ASSY

W182X26- -04- -018 2 PCS WIRE ASSY

W182X66- -04- -012 1 PCS WIRE ASSY

W182X66- -04- -018 1 PCS WIRE ASSY

W182Y66- - 11- -006 1 PCS WIRE ASSY

W182Y66-- 11--014 1 PCS WIRE ASSY

W182Y66- -26- -016 1 PCS WIRE ASSY

SECTION 1

Table 2 - Condensing Furnaces

MODELNUMBERS BEGINNINGWITH:

59MN7 987M

INSTALLATION

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

2. Remove outer doors.

3. Disconnect 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.

HOTSURFACE

IGNITER MANUALRESET

GASBURNER i ROLLOUT SWITCH

ELECTRICALJUNCTION

BOX(

REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY IN APPEARANCE

Fig. 1 - Component Location

Al1408

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'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 d6connecter.

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

Connect Green/Yellow

ground wire here

Gas Valve

Manifold

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.

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

nect wires from Hot Surface Igniter (HSI) and Flame

Sensor.

Gas valve is parallel to manifold " /

CLwithin + or - 3_ ,/' /"

/'_ I>/- ,"

Gas valve must be installed on

manifold with minimum engagement of

6 threads. Cross threading is not

acceptable.

\• Indicated surfaces

to be 90 _+ or -2 _

A11486

Fig. 2 - Modulating Gas Valve with Orifices

BURNER SUPT ASSY IGNITER

BURNER ASSY

2_"'_ FLAM E SENSOR

(BELOW BURNER)

Fig. 3 -Burner Assembly

ORIFICE SELECTION/DERATE

BRACKET, IGNITER

_ FLAME ROLLOUT

SWITCH

A11403

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.)

A96249

Fig. 4 - Burner Orifice

Refer to conversion kit rating plate 337704-201 to determine

main burner orifice size. (See Fig. 5.)

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

altitudes up to 2000 ft.

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

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

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

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

The Conversion Kit Rating Plate accounts for high altitude

derate.

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.

INSTALL MIXER SCREWS

NOTE: There are 2 sets of mixer screws. One set is for

Condensing gas furnaces, the other set is for Non-condensing gas

furnaces. Use only the parts in the bag marked "REQUIRED

FOR THE CONVERSION OF CONDENSING GAS

FURNACES TO PROPANE GAS"

See Fig. 6 to verify you have the correct set of mixer screws.

1. Locate the dimple on each burner venturi tube. If you can-

not locate the dimple, refer to Fig. 7 for location of the

mixer screw.

2. Drill a 7/64-in. (2.8 ram) hole (supplied in kit) in each

dimple.

3. Install a mixer screw in each drilled hole drilling as

straight as possible. The screw head should be flush with

the top of the burner venturi.

CONVERSION KiT RATING PLATE - CARRIER CORP.

THiS APPLIANCE HAS BEEN CONVERTED TO USE PROPANE GAS FOR FUEL. REFER TO KIT iNSTRUCTiONS FOR CONVERSION

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

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

NOTE: Furnace gas input rate on rating plate is for installations up to 2000 ft. (610m) above sea level Jn 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 by 5% for altitudes of 2000 ft, (610m) to 4500 ft, (1372m) above sea level,

KIT NO.: KGANP5201VSP FUELUSED: PROPANE GAS iNLET PRESSURE (rain - max): 11.0- 13.6 in.wc

ALTITUDE OF iNSTALLATION (FT. ABOVE SEA LEVEL) U.S.A. *

0 2001 *3001 4001 5001 6001 7001 8001 9001

to 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 to 9000 to 10000

0rificeNo. 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm

59MN7A Manifold Pressure

987MA MAX 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0

INT 5.8 515 5.5 5,5 5,4 5.4 5.4 5.3 5.3

MIN 2.2 2.1 2.1 2.1 2.1 2.0 2.0 2.0 2.0

APPLIANCE MODELS

* For Canadian Installationsfrom 2000 to 4500 ft. (610mto 1373m) useU.S.A. column 2001 to 3000 ft. (611mto 914m).

337704-201 REV.B

Fig. 5 - Conversion Kit Rating Plate 337704-201

A11295

1337932-701]

CONTAINS: QTY

PART # DESCRIPTION

328456-402 BIT, DRILL 1

FAJ5812B SCREW 7

REQUIRED FOR CONVERSION OF

CONDENSING GAS FURNACE TO

PROPANE GAS.

Fig. 6 -Gas Conversion Kit

A11294

2-in.

(50 mm)

3/16- in.

(4.6 mm)

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

(2.5 mm, +0.8-1.5)

A12392

Fig. 9 - Igniter Position - Side View

CONVERT GAS VALVE

1.9"

(48.76 mm)

1.8"

(46.96 ram)

Drill out with

J 7/64" drill bit

ii /

\\\\

A11460

Fig. 7 -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. 8 and 9.

, ,Oo

II I

-2-1/2-in.

(64.4)

Fig. 8 -Igniter Position -Top View

A11405

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.

Refer to Fig. 10 and 11.

Fig. 10 -Propane Jumper

A11373

A11375

Fig. 11 -Installing Propane Jumper

NOTE: The Propane jumper for the modulating gas valve is

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

into the valve. If the jumper is not installed, the valve will not

operate properly on propane.

1. Locate the round "NAT. 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. Note the 2 jumper pins inside the modulating gas valve.

5. Remove the small black plastic propane jumper from the

envelope.

6. Use needle-nosed pliers to hold the jumper by the tab on

the end.

7. Insert the jumper on the pins inside the gas valve.

8. Cover the opening in the gas valve with the label marked

"LP GAS"

INSTALL LOW GAS PRESSURE SWITCH

NOTE: Install the Low Gas Pressure Switch before installing the

manifold on the burner assembly.

There are 2 ways to mount the Low Gas Pressure Switch.

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, install the

switch as follows (See Fig 12):

_';_l ...................2/,, ,/

with

Brass Street 90 " _ Brass Hex Nipple

A11367

Fig. 12 -LGPS for 14-3/16 (360 mm) Casing or When Vent

Passes Between Inducer and Burner Assembly

1. Remove the 1/8-in. NPT pipe plug from the gas valve inlet

pressure tap.

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

NOTE: Tighten all fittings and the Low Gas Pressure Switch

with a small wrench. Do not over-tighten, check for gas leaks

after gas supply has been turned on.

FIRE AND EXPLOSION 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,

2. Apply pipe dope sparingly to the male threads of the

l/8-in, black iron street elbow. Install the street elbow into

the gas valve inlet pressure tap. Point the open end of the

street elbow toward you.

3. Apply pipe dope sparingly to the male threads of the

l/8-in, brass street tee. Install the male end of the street tee

as shown in Fig 12. One opening on the street tee should

face you. The other opening should be parallel with the

inlet of the gas valve.

4. Apply pipe dope sparingly to the male threads of the

l/8-in, brass hex nipple. Install the hex nipple into the

open end of the brass street tee. See Fig 12. The hex nipple

should be parallel with the boss on the gas valve.

5. Install the open end of the brass street elbow on the end of

the hex nipple. Tighten the street elbow so the male

threads of the elbow point away from you.

6. Apply pipe dope sparingly to the male threads of the

l/8-in, brass street elbow. Install the Low Gas Pressure

Switch on the male threads of the street elbow. Tighten

switch at hex fitting at base of switch. Do not use switch

body to tighten switch. Do not over-tighten switch.

7. The remaining opening on the brass street tee is the new

gas valve inlet pressure tap. Install manometer fitting to

the open end of the brass street tee. Or if installation is to

be completed later, apply pipe dope to inlet pressure plug

from gas valve and install in open end of brass street tee.

8. Check all fittings for leaks after gas supply has been

turned on.

Casings Wider Than 14 3/16-in. (360 mm) /Vent Does Not

Pass Between Inducer and Burner Assembly

1. 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, install the switch as follows (See

Fig 13):

2. Remove the l/8-in. NPT pipe plug from the gas valve inlet

pressure tap.

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

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

A11366

Fig. 13 -LGPS for Casing Wider Than 14-3/16 (360 mm)

and Vent Does Not Pass Between Inducer and Burner As-

sembly

INSTALL LOW GAS PRESSURE SWITCH WIRES

1. Locate the orange wire in the kit with an insulated straight

female spade terminal and an insulated straight male ter-

minal on the other end.

2. Connect the female terminal to a terminal on the Low Gas

Pressure Switch.

3. Locate the orange wire in kit with an insulated straight fe-

male spade terminal and an insulated female flag terminal

on the other end.

4. Connect both straight female terminals of the orange wires

to the ternfinals on the Low Gas Pressure Switch.

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

NOTE: Use only propane-resistant pipe dope. Do not use Teflon

tape.

7. 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.

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

finish tightening the gas pipe to the gas valve.

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

MODIFY PRESSURE SWITCH WIRING

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'EQUIPEMENT D'OPERATION

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

panne.

Lors des op6rations d'entretien des commandes, 6tiqueter

tousles/ills avant de les d6connecter.

1. Disconnect orange wire from Low Pressure switch LPS on

inducer housing.

2. Connect the orange wire from the Low Pressure Switch to

the orange wire with the insulated male spade terminal.

3. Connect the orange wire from the Low Gas Pressure

Switch to the terminal on the Low Pressure Switch.

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

with wire tie provided in kit.

CHECK INLET GAS PRESSURE

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

DO NOT operate furnace more than one minute to check

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

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

between ll.0-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

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.

4. Turn furnace gas valve switch to ON position.

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

Fig. 14).

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

control.

SW4

Outside Air Thermistor_

_/F_ Crflntin u;_2pFan_

switches CF 1 through

CF 3

Communication

_[ SW4

[]

_I=_ PL9

Connocton

24 VAC

HUM Output

(O.5 AMP

Setup Switches SWl,

1 thru 8

_t_ /_:21 _ W2 Yt DHUM

SW2

SW2 A/C Air Flow

Setup Switches

AC 1 through AC 3

Fig. 14 - Furnace Control

Al1471

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

between 11.0-in. W.C. and 13.6-in. W.C.

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

connections to terminate call for heat.

9. Turn furnace gas valve switch to OFF position.

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

11. Turn off furnace power supply.

12. Remove manometer.

13. Apply pipe dope sparingly to end of inlet gas pipe plug

and install into unused end of 1/8 in. tee. Use a small

back-up wrench on tee when tightening gas inlet pipe

plug. (See Fig. 13.)

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

injury or loss of life.

RISQUE D'EXPLOSION ET D'INCENDIE

Le fait de ne pas suivre cet avertissement pourraitentrai'nerdes

dommages corporels et /ou la mort.

Ne jamais examiner pour les fuites de gaz avec une flamme

vive. Utilisez plut6t un savon fait specifiquement pour la

d_tection des fuites de gaz pour verifier tousles connections.

Un incendie ou une explosion peut entrainer des dommages

matdriels, des blessures ou la mort.

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

2. Remove 1/8-in. (3 mm) pipe plug from manifold pressure

tap on downstream side of gas valve.

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

(see Fig. 15.)

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/OFF Switch MODULATING

Min/Max Heat Adust

/(Under Cap)

Inlet

_Manifold

Pressure lap

Fig. 15 - Gas Valve

A10496

GAS INPUT RATE INFORMATION

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

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

for propane is determined by manifold pressure and orifice size.

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

for Minimum heat on Modulating furnaces. Furnace gas input

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

(610 M).

In the U.S.A., the input rating for altitudes above 2000 ft. (610M)

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

level.

In Canada, 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

@rate,

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.

/_r ner Flame

__ _ Burnel

Al1461

Fig. 16 -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: DO NOT set Maximum Heat manifold pressure less than

10.5-in. W.C. or more than 11-in. W.C. for propane gas.

NOTE: Use care when perfornfing 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.

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 on the Conversion Kit Rat-

ing Plate.

11. To adjust the Maxinmm 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.

A11451

Fig. 17 -Modulating Gas Valve Adjustment

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 5 nfinutes before checking Minimum Heat

Temperature rise.

Furnace must operate within ranges of temperature rise specified

on the furnace rating plate. Deternfine 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 ex-

changer 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 deternfine 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

SW1-3. 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.

CHECK LOW GAS PRESSURE SWITCH

The newly installed low gas pressure switch is a safety device

used to guard against adverse burner operating characteristics that

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

than 6.5 in. W.C. and closes at not greater than 10.2 in. W.C.

This switch also prevents operation when the propane tank level

is low which can result in gas with a high concentration of

impurities, additives, and residues that have settled to the bottom

of the tank. Operation under these conditions can cause harm to

the heat exchanger system. This normally open switch closes

when gas is supplied to gas valve under normal operating

pressure. The closed switch completes control circuit. Should an

interruption or reduction in gas supply occur, the gas pressure at

switch drops below low gas pressure switch setting, and switch

opens. Any interruption in control circuit (in which low gas

pressure switch is wired) quickly closes gas valve and stops gas

flow to burners. When normal gas pressure is restored, the system

must be electrically reset to re-establish normal heating operation.

Before leaving installation, observe unit operation through 2

complete heating cycles. During this time, turn gas supply to gas

valve off just long enough to completely extinguish burner flame,

then instantly restore full gas supply. To ensure proper low gas

pressure switch operation, observe that there is no gas supply to

burners until after hot surface igniter begins glowing.

LABEL APPLICATION

1. Fill in Conversion Responsibility Label 337704-205 and

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

Fig. 18. Date, name, and address of organization making

this conversion are required.

2. Attach Conversion Rating Plate Label 337704-201 to out-

er door of furnace., see Fig. 5.

3. Attach Gas Control Conversion Label 337704-202 to gas

valve. Do not use 337704-203, which is similar.

THiSFURNACEWASCONVERTED

ON TO PROPANEGAS

(DAY-MONTH-YEAR)

KiT NO.: KGANP5201VSP

BY:

(Name and address of organization making this conversion),

which accepts the responsibility that this conversion has

been properly made.

CE GENC:RATEURD'NR CHAUD A €:TI_

CONVERTiLE POUR

(JOUR-MOIS-ANNI_E)

DE L'ENSEMBLE N°.: KGANP5201VSP

PAR:

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

qui accepte |' entrii.=re responsabilit6 de [a conversion,

337704-205 REV.B

Fig. 18 -Conversion Responsibility Label

Al1296

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