Nortek GC2 User manual

LP & HIGH ALTITUDE LP GAS CONVERSION KIT FOR INSTALLATIONS IN CANADA

BEFORE THE CONVERSION

IMPORTANT: Please read all instructions before

converting the furnace. Pay attention to all safety warnings

and any other special notes highlighted in the manual. Safety

markings are used frequently throughout this manual to

designate a degree or level of seriousness and should not

be ignored. WARNING indicates a potentially hazardous

situation that if not avoided, could result in personal injury

or death.

This conversion kit is only to be used to convert natural

gas furnaces to LP/Propane gas in the United States. For

installations in Canada, the Canadian conversion kit must

be used.

Table 1 is a detailed listing of the components in the LP gas

conversion kit. Please check the contents of the conversion

kit with that of the parts listing, and familiarize yourself with

each component.

Use caution when servicing or removing components from

the appliance. Personal injury can occur from sharp metal

edges present in all sheet metal constructed equipment.

IMPORTANT: When converting a low NOx furnace from

natural gas to LP/Propane gas, it is necessary to remove

the NOx Bafﬂes from the furnace.

For *G7 / *GC2 & GUH* / GDD* Series Furnaces & Appliances Using Honeywell Gas Valves

INSTALLATION INSTRUCTIONS

WARNING AVERTISSEMENT

FIRE OR EXPLOSION HAZARD

• Failuretofollowsafetywarningsexactlycould

result in serious injury or property damage.

• Installation and service must be performed

by a qualiﬁed installer, service agency or the

gas supplier.

• Do not store or use gasoline or other

ﬂammable vapors and liquids in the vicinity

of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

use any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a

neighbors phone. Follow the gas suppliers

instructions.

• If you cannot reach your gas supplier, call

the ﬁre department.

RISQUE D’INCENDIE OU D’EXPLOSION

• Le non-respect des avertissements de sécurité

pourrait entraîner des blessures graves ou des

dommages matériels.

• L’installation et l’entretien doivent être effectués

paruninstallateurqualiﬁé,unorganismedeservice

ou le fournisseur de gaz.

• Ne pas entreposer ni utiliser de l’essence ni

d’autresvapeurs ou liquidesinﬂammables dans le

voisinage de cet appareil, ni de tout autre appareil.

QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

• Ne tenter d’allumer aucun appareil.

• Ne toucher à aucun interrupteur électrique;

n’utiliser aucun téléphone dans le bâtiment.

• Évacuer l’immeuble immédiatement.

• Appeler immédiatement le fournisseur de gaz en

employant le téléphone d’un voisin. Respecter les

instructions du fournisseur de gaz.

• Si personne ne répond, appeler le service des

incendies.

DO NOT DESTROY. PLEASE READ CAREFULLY &

KEEP IN A SAFE PLACE FOR FUTURE REFERENCE. NE PAS DÉTRUIRE. VEUILLEZ LIRE ATTENTIVEMENT ET

CONSERVER EN UN LIEU SÛR POUR RÉFÉRENCE ULTÉRIEURE.

Table 1. LP Gas Conversion Kit

DESCRIPTION QTY

Honeywell Conversion Kit 396221

(to convert VR8205S2890 or VR8215S1289) 1

Honeywell Conversion Kit 396021

(to convert VR8205Q2381) 1

Honeywell Conversion Kit 50033841

(to convert VR9205Q1127) 1

#55 Drill Size Burner Oriﬁce Kit

(contains (7) 661055) 1

#56 Drill Size Burner Oriﬁce Kit

(contains (7) 661056) 1

#57 Drill Size Burner Oriﬁce Kit

(contains (7) 661057) 1

#59 Drill Size Burner Oriﬁce Kit

(contains (3) 661059) 1

#60 Drill Size Burner Oriﬁce Kit

(contains (3) 661060) 1

Conversion Warning Label 1

Conversion Information Label 1

Installation Instructions 1

Before You Convert the Gas Valve

1. Turn the thermostat OFF or to its lowest temperature

setting.

2. Verify the gas supply is shut OFF.

3. Verify the electrical power to the appliance is turned OFF.

Removing The Burner Oriﬁces

1. Set the thermostat to the OFF position, or its lowest

temperature setting.

2. Shut OFF the gas supply at the manual shutoff valve

located outside of the appliance.

3. Turn off all electrical power to the appliance.

4. Remove the door from the burner compartment.

5. Move the gas valve ON/OFF switch to the OFF position

as shown in Figure 1. For For VR8205Q2381 gas valves,

turn the knob to the OFF position.

6. Remove the wires from the terminals of the gas valve.

7. Remove the supply gas piping from the gas valve inlet.

8. Carefully remove four screws securing the gas manifold

assembly to the burner assembly.

9. Set the screws aside and remove the gas manifold assembly

from the appliance.

10.Carefully remove the burner oriﬁces from the gas manifold

assembly.

11.Read the rating plate afﬁxed to the appliance to determine

its rated input (Btu/hr) and the size of the factory installed

oriﬁces.

IMPORTANT NOTE:

Before installing an oriﬁce, check the side or face of

the oriﬁce for the drill number to ensure that it is the

appropriate size.

WARNING:

Do not use Teﬂon tape or pipe joint compound

on the oriﬁce threads. The hole in the oriﬁce

may become blocked and cause ﬁre, explosion,

property damage, carbon monoxide poisoning,

personal injury, or death.

12.Install the appropriate LP/Propane gas burner oriﬁces

into the gas manifold assembly.

NOTE: To prevent cross threading, hand tighten the

oriﬁces into the gas manifold assembly until snug, then

tighten with a wrench.

13.Reinstall the gas manifold assembly to the burner

assembly with the 4 screws, that were removed earlier.

NOTE: It is important that the center of the oriﬁces are

aligned with the center of the burners.

14.Reconnect the gas piping to the gas valve inlet.

15.Reconnect the wires to the gas valve terminals.

WARNING:

All gas piping must conform with local building

codes, or in the absence of local codes, with

the most recent edition of the natural gas and

propanecode CAN/CGAB149.1. DONOT attempt

to modify, or tap into existing gas lines yourself.

Fire or explosion may result causing property

damage, personal injury or loss of life. Failure to

follow the safety warnings exactly could result in

serious injury, death or property damage.

WARNING:

All electrical wiring must comply with the latest

editionof the CanadianElectrical Code CGA2.17.

Failuretofollow theseinstructionscould resultin

possibledamage toequipment, seriouspersonal

injury, or death.

CONVERTING TO LP/PROPANE GAS AT

ALTITUDES BETWEEN ZERO & 4,500 FT.

Converting single - stage valves to LP/Propane requires the

replacement of the burner oriﬁces and/or the spring found

under the cap screw in the pressure regulator. Converting

two - stage valves to LP/Propane requires the replacement

of the burner oriﬁces and/or the stem/spring assembly in the

pressure regulator.

Table 2 (page 3), provides the manifold pressure for altitudes

above 2,000 feet.

WARNING:

Shut off the gas supply at the manual gas shutoff

valve,before disconnecting theelectrical power.

A ﬁre or explosion may result causing property

damage, personal injury or loss of life. Failure to

follow the safety warnings exactly could result in

serious injury, death or property damage.

WARNING:

Toavoid electric shock,personal injury,or death,

turnoff theelectric poweratthe disconnector the

main service panel before making any electrical

connections.

WARNING:

The reduction of input rating necessary for high

altitude installation may only be accomplished

with factory supplied oriﬁces. Do not attempt to

drill out oriﬁces in the ﬁeld. Improperly drilled

orifices may cause fire, explosion, carbon

monoxide poisoning, personal injury or death.

FURNACE

MODEL

INPUT

(BTUH)

LP ORIFICE SIZE

FOR ALTITUDES

BETWEEN 0 - 4,500 FT.

MANIFOLD PRESSURE

*G7SA / *GC2SA

*G7SK / *GC2SK

GUH80A* / GDD80A*

45,000 57

0 to 1,999 ft.

10.0 in. w.c.

2,000 to 4,500 ft

8.5 in. w.c.

54,000 56

72,000 56

90,000 56

108,000 56

126,000 56

*G7SC / *GC2SC

*G7SL / *GC2SL

*G7SD / *GC2SD

*G7SM / *GC2SM

GUH92A* GDD92A*

GUH95A / GDD95A*

38,000 (SC) 56

0 to 1,999 ft.

10.0 in. w.c.

2,000 to 4,500 ft.

8.5 in. w.c.

38,000 (SD) 60

54,000 56

72,000 56

90,000 56

108,000 56

118,000 55

120,000 55

*G7TA / *GC2TA

*G7TK / *GC2TK

60,000 55

0 to 1,999 ft.

10.0 in. w.c. for High

4.2 in. w.c. for Low

2,000 to 4,500 ft.

8.5 in. w.c. for High

3.8 in. w.c. for Low

80,000 55

100,000 55

120,000 55

140,000 55

*G7TC / *GC2TC

*G7TL / *GC2TL

GUH95T*

60,000 55

0 to 1,999 ft.

10.0 in. w.c. for High

4.2 in. w.c. for Low

2,000 to 4,500 ft.

8.5 in. w.c. for High

3.8 in. w.c. for Low

80,000 55

100,000 55

120,000 55

*G7TE / *GC2TE

*G7TN / *GC2TN

GUV96T*

60,000 55

0 to 1,999 ft.

10.0 in. w.c. for High

4.2 in. w.c. for Low

2,000 to 4,500 ft.

8.5 in. w.c. for High

3.8 in. w.c. for Low

80,000 55

100,000 55

115,000 55

Table 2. Liquid Propane Conversion Chart

Figure 1. Burner & Manifold Assembly

Terminals

Orifices

ON/OFF

Switch

Gas Valve

Inlet

Manifold

Assembly

Screws (x4)

Burner

Assembly Burners

2 - Stage Honeywell Valves

Model VR8205Q2381

IMPORTANT NOTE:

When converting to LP/Propane gas from natural gas,

the white stem/spring assembly in the gas valve must be

replaced by the black stem/spring assembly in the kit.

1. Remove two screws securing the pressure regulator cover

assembly to the gas valve. Do not discard the screws.

See Figure 4.

2. Remove the pressure regulator cover assembly from the

gas valve.

3. Remove and discard the existing stem/spring assembly

from the gas valve.

4. Install the replacement stem/spring assembly from the

conversion kit.

5. Reinstall the pressure regulator cover assembly onto the

gas valve.

6. Install the two screws and tighten.

7. Afﬁx the label from the conversion kit to the gas valve.

Single Stage Honeywell Valves

Models: VR8205S2890 or VR8215S1289

IMPORTANT NOTE:

When converting to LP/Propane gas from natural gas,

the black spring in the gas valve must be replaced by

the red spring in the kit.

1. Remove the cap screw from the gas valve as shown in

Figure 2.

Figure 3. Pressure Regulator Spring &

Adjustment Screw Removal

Spring

Adjusting Screw

(VR8205S2890 shown)

Screws (x2)

Regulator Co

ver

Assembly

Spring / Stem

Assembly

2 Adjustment Screws

(beneath cap)

Figure 4. Spring / Stem Assembly Removal

Figure 2. Cap Screw Removal

Cap screw

(VR8205S2890 sho

wn)

2. Remove and discard the plastic pressure regulator

adjustment screw from the gas valve. See Figure 3.

3. Remove the black colored spring from the gas valve.

4. Install the red spring from the conversion kit.

5. Install the new adjusting screw from the kit.

6. Check and adjust the regulator setting. See Gas Pressure

Adjustment Section (page 5).

7. Reinstall the cap screw.

8. Afﬁx the label from the conversion kit to the gas valve.

Lighting & Adjustment of the Appliance

WARNING:

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could

result in serious injury or property damage.

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.

AVERTISSEMENT :

RISQUE D’INDENDIE OU D’EXPLOSION

Le non-respect des avertissements de sécurité

pourrait entraîner des blessures graves, la mort ou

des dommages matériels.

Ne jamais utiliser une ﬂamme nue pour vériﬁer la

présencedefuitesde gaz.Pourlavériﬁcationdetous

les joints, utiliser plutôt une solution savonneuse

commerciale fabriquée spéciﬁquement pour la

détection des fuites de gaz. Un incendie ou une

explosion peut entraîner des dommages matériels,

des blessures ou la mort.

1. Turn ON the manual gas valve, located on the outside of

the unit to the ON position.

2. Check all gas connections for leaks with a soap and water

solution. If the solution bubbles there is a gas leak which

must be corrected.

3. Turn on the electrical power to the appliance.

4. Place the gas valve ON/OFF switch/knob to the ON position.

See Figure 6.

5. Set the thermostat above room temperature to begin the

heating cycle of the furnace.

6. Check that the furnace ignites and operates properly. Refer

to the installation instructions provided with the unit for the

normal operating sequence.

7. After ignition, visually inspect the burner assembly to

ensure that the ﬂame is drawn directly into the center of

the heat exchanger tube. In a properly adjusted burner

assembly, the ﬂame color should be blue with some light

yellow streaks near the outer portions of the ﬂame.

NOTE: The ignitor may not ignite the gas until all air is bled

from the gas line. If the ignition control locks out, turn the

thermostat to its lowest setting and wait one minute then

turn the thermostat above room temperature and the ignitor

will try again to ignite the main burners. This process may

have to be repeated several times before the burners will

ignite. After the burners are lit, check all gas connections

for leaks again with the soap and water solution.

High Fire

Cap Screw

High Fire

Adjustment Scr

Low Fire

Cap Screw

Low Fire

Adjustment Scr

Spring

Figure 5. Pressure Regulator Spring &

Adjustment Screw Removal

Model VR9205Q1127

IMPORTANT NOTES:

• When converting to LP/Propane gas from natural gas,

the springs from gas valve must be replaced by the

larger springs from the kit. The LP/Propane springs

for both HIGH & LOW ﬁre are the same size, shape

and color.

• Use only a Torx-25 or 3/16” ﬂathead screwdriver when

removing adjustment screws or during pressure

adjustment.

1. Remove the HIGH ﬁre cap screw. See Figure 5.

2. Remove and discard the HIGH ﬁre adjustment screw from

the gas valve.

3. Remove the spring from the gas valve and discard.

4. Install a larger spring from the conversion kit.

5. Install a new adjusting screw from the kit.

6. Repeat steps 1 - 5 for replacement of the LOW ﬁre spring

and adjustment screw.

7. Check and adjust the regulator setting. See Gas Pressure

Adjustment Section.

8. Reinstall the cap screws on the HIGH and LOW regulators.

Plastic replacement cap screws are provided in the

conversion kit.

9. Afﬁx the label from the conversion kit to the gas valve.

GAS PRESSURE ADJUSTMENT

Measuring the Supply Gas Pressure

1. Turn OFF the gas supply at the manual valve located on

the outside of the unit.

2. Using a 3/16“ Allen wrench, remove the plug from the

inlet pressure tap (INLET side of gas valve). See Figure

6 (page 6).

3. Install an 1/8” NPT pipe thread ﬁtting, which is compatible

with a Manometer or similar pressure gauge.

4. Connect the Manometer or pressure gauge to the Inlet

Pressure Tap.

5. Turn ON the main gas supply at the manual valve.

6. Check and adjust the incoming gas line pressure to 11.0-

14.0 inches Water Column for LP/Propane gas.

7. Turn OFF the gas supply at the manual valve.

8. Disconnect the Manometer or pressure gauge.

9. Remove the NPT ﬁtting and reinstall the INLET pressure

tap plug. Hand tighten the plug ﬁrst to prevent cross-

threading. Tighten with 3/16” Allen wrench.

Removing the Manometer/Pressure Gauge

After the manifold pressure is properly adjusted, the

Manometer or pressure gauge must be removed from the

gas valve.

1. Turn the thermostat to its lowest setting.

2. Turn OFF the main gas supply to the unit at the manual

shut-off valve, which is located outside of the unit.

3. Turn OFF all of the electrical power supplies to the unit.

4. Remove the pressure gauge adapter from the gas valve

and replace it with the 1/8” NPT manifold pressure plug

that had been removed earlier. NOTE: Make sure the plug

is tight and not cross-threaded.

5. Turn ON the electrical power to the unit.

6. Turn ON the main gas supply to the unit at the manual

shut-off valve.

COMPLETING THE CONVERSION

WARNING:

Do not alter or remove the original rating plate

from the furnace.

1. Attach the following labels:

• The conversion warning label (P/N 703935) should be

afﬁxed to the outside of the unit door.

• The conversion information label (P/N 703942) should be

afﬁxed near the rating plate on the inside of the control

area.

• The gas valve conversion label should be afﬁxed on the

gas valve..

NOTE: Each label should be prominently visible after

installation.

2. Reinstall the appliance door.

3. Run the appliance through 3 complete cycles to assure

proper operation.

Measuring the Manifold Pressure

The manifold pressure must be measured by installing a

pressure gauge (Manometer, Magnehelic Meter, etc.) to the

outlet end of the gas valve as follows:

1. Shut OFF the gas supply at the manual shutoff valve

located outside of the appliance.

2. Turn off all electrical power to the appliance.

3. Using a 3/16” Allen wrench, remove the manifold pressure

tap plug located on the outlet side of the gas valve. See

Figure 6.

4. Install an 1/8” NPT pipe thread ﬁtting, that is compatible

with a Manometer or similar pressure gauge.

5. Connect the Manometer or pressure gauge to the manifold

pressure tap.

6. Set the room thermostat above room temperature to start

the furnace.

7. Allow the furnace to operate for 3 minutes and then check

the manifold pressure. Compare the measured value

with the value shown in Table 2 (page 3). If the manifold

pressure is not set to the appropriate pressure, then it

must be adjusted.

Adjusting the Manifold Pressure

NOTE: Adjustments must be made to both LOW & HIGH

ﬁre settings when converting two-stage gas valves. High ﬁre

must be adjusted ﬁrst and then low ﬁre. The Low ﬁre will be

afffected if not adjusted in this order. Refer to Table 2 for

manifold pressures.

1. Single stage gas valve: Remove the cap screw from the

top of the gas valve regulator. See Figure 2 (page 4) for

VR8205S2890 or VR8215S1289 models.

2-stage gas valve: For VR8205Q2381 models, remove

the plastic cap covering the adjustment screws (Figure

4 page 4). For VR9205Q1127 models, remove the cap

screw (Figure 5, page 5).

2. Using a screwdriver or Allen wrench (where appropriate),

slowly turn the adjustment screw till the appropriate manifold

pressure listed in Table 2 is achieved. See Figure 2 for

VR8205S2890 or VR8215S1289 models. See Figure 4

for VR8205Q2381 models or Figure 5 for VR9205Q11127

models.

NOTE: Turning the screw clockwise increases the

pressure, turning the screw counter-clockwise decreases

the pressure. To prevent the screw from backing all the

way out from the valve, turn the screw slowly.

3. Replace and tighten the cap screw or the plastic cap over

the adjustment screw.

Figure 6. Inlet & Manifold Pressure Tap Locations

OFF

Inlet

Pressure

Ta p

Inlet

Pressure

Ta pInlet

Pressure

Ta p

SINGLE STAGE VA LVES

Manifold

pressure

Ta p

Manifold

pressure

Ta p

Manifold

pressure

Ta p

Manifold

pressure

Ta p

2-STAGE VALVES

Model VR8215S1289

Inlet

Pressure

Ta p

Model VR8205S2890 Model VR8205Q2381 Model VR9205Q1127

ON/OFF

Switch

ON/OFF

Switch

ON/OFF

Knob

ON/OFF

Switch

The installer performing this work assumes all responsibility for this conversion. These instructions are primarily intended to assist qualiﬁed

individuals experienced in the proper installation of these components. Some local codes require licensed installation/service personnel for this

type of equipment. Safety should always be the deciding factor when installing this product and using common sense plays an important role as

well. Improper installation of the components or failure to follow safety warnings could result in serious injury, death, or property damage. After

completing the installation, return these instructions to the Homeowner’s Package for owner-user’s future reference.

Speciﬁcations & illustrations subject to change without notice or incurring obligations (09/17).

709370B

(Replaces 709370A)

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