Installation Instructions

Transcription

1 KGAPN4701AAA Gas Conversion Kit Propane --- to --- Natural ECM X Stage and Single --- Stage 90% Condensing Gas Furnaces Installation Instructions CERTIFIED C E D E S R T I G N TABLE OF CONTENTS PAGE Safety Considerations... 1 Introduction... 2 Description and Usage... 2 Install Main Burner Orifices... 2 Remove Diverter Plate (Two Stage Models Only)... 3 Convert Main Gas Valve... 8 Convert Two -Stage Gas Valve... 8 Convert Single-Stage Gas Valve... 8 Remove Low Gas Pressure Switch... 9 Reinstall Manifold Assembly... 9 Modify Pressure Switch Wiring... 9 Two -Stage Furnaces... 9 Single-Stage Furnace Connect Manometer to Inlet Pressure Tap Check Inlet Gas Pressure Two -Stage Furnaces Single-Stage Furnace Connect Manometer to Manifold Pressure Tap Gas Input Rate Information Set Gas Input Rate / Adjust Manifold Pressure Two -Stage Furnaces Single-Stage Furnace Check Meter to Verify Input Rate Label Application NOTE: Read the entire instruction manual before starting the installation. I F I E D SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. Trained service personnel must perform all other operations. When working on heating equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit, and other safety precautions that may apply. Follow all safety codes. In the United States, follow all safety codes including the current edition of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z In Canada, refer to the National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC), CAN/CGA -B149.1 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 injury. Understand the signal words DANGER, WARNING, CAUTION and NOTE. These words are used with the safety -alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.! WARNING FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death. This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a fire, explosion, or production of carbon monoxide may result causing property damage, personal injury, or loss of life. The qualified service agency is responsible for the proper installation of this furnace with this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer s instructions supplied with the kit. 1

2 Table 1 Kit Contents DESCRIPTION PART NO. QUANTITY Main Burner Orifice #45 LH32DB205 7 Main Burner Orifice #44 LH32DB200 7 Main Burner Orifice #43 LH32DB202 7 Main Burner Orifice #42 LH32DB207 7 Wire Tie HY76TB125 1 Conversion Rating Plate Label 2---Stage Condensing Furnaces Conversion Rating Plate Label 1---Stage Condensing Furnaces Conversion Responsibility Label Gas Control Conversion Label (converted) Installation Instructions IIK--- KGAPN Regulator Spring Kit (Silver Natural) for White-Rodgers 36J Valve EF39ZW037 2! AVERTISSEMENT LE FEU, L EXPLOSION, CHOC ELECTRIQUE, ET MONOXYDE DE CARBONE EMPOISONNER Cette trousse de conversion doit être installée par un servie d entretien qualifié, selon les instructions du fabricant et selon toutes les exigences et tous les codes pertinents de l autorité compétente. Assurezvous de bien suivre les instructions dans cette notice pour réduire au minimum le risque d incendie, d explosion ou la production de monoxyde de carbone pouvant causer des dommages matériels, de blessure ou la mort. Le service d entretien qualifié est responsable de l installation de cette trousse. L installation n est pas adéquate ni complète tant que le bon fonctionnement de l appereil converti n a pas été vérfié selon les instructions du fabricant fornies avec la trousse. BURNER ENCLOSURE MANIFOLD BURNER ENCLOSURE REFERENCE PRESSURE TUBE GAS VALVE CONTROL INTRODUCTION This instruction covers the installation of gas conversion kit Part No. KGAPN4701AAA to convert the following furnaces from propane gas usage to natural gas usage. Two Stage Models: 58MEC, 353BAV, PG9MXA 4 -way multipoise, hot surface ignition, two -stage condensing furnaces. This kit is designed for use in furnaces with 60,000 through 120,000 Btuh gas input rates. Single-Stage Models: 58MEB and 353AAV 4 -way multipoise, hot surface ignition, single-stage condensing furnaces. This kit is designed for use in furnaces with 40,000 through 120,000 Btuh gas input rates. DESCRIPTION AND USAGE This kit is designed for use in the furnaces listed above. See Table 1 for kit contents. To accommodate different furnace models at different altitudes, more parts are shipped in kit than will be needed to complete the conversion. When installation is complete, discard extra parts. Step 1 Install Main Burner Orifices NOTE: See Fig. 1 for component location in upflow orientation. Reorient component arrangement when furnace is installed in other positions.! Fig. 1 - Component Location CAUTION A01081 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.! PRUDENCE D EQUIPEMENT D OPERATION Toute erreur de câblage peut être une source de danger et de panne. Lors des opérations d entretien des commandes, étiqueter tous les fils avant de les déconnecter. 2

3 1. Turn off furnace gas and electrical supplies. 2. Remove main furnace door. 3. Turn furnace gas valve switch to OFF position. 4. Remove burner enclosure front. (See Fig. 1.) 5. Remove gas supply pipe from gas valve. 6. Remove wires from gas valve. Note location for reassembly. 7. Remove burner-box pressure tube from gas-valve burner enclosure; reference pressure -tap fitting. (See Fig. 1.) 8. Unplug hot surface igniter from harness. 9. Remove igniter leads from slot in manifold grommet. 10. Remove screws that secure manifold to burner box and remove manifold, orifices, and gas valve as one assembly. 11. Remove and discard orifices from manifold. Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). In the USA, 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. (610 M) to 4500 ft. (1372 M) above sea level. 12. Determine main burner orifice size. a. Obtain yearly average gas heat content value (at installed altitude) for local gas supply. b. Obtain yearly average gas specific gravity (at installed altitude) for local gas supply. c. Verify the installation altitude of the furnace. NOTE: For Canadian altitudes of 2000 to 4500 ft. (610 to 1372 M) use USA altitudes of 2001 to 3000 ft. (610 to 914 M) in Tables 2 or 3. d. Verify correct manifold pressure table for the furnace model being converted. (a.)for 2 -Stage models, see Table 2. (b.)for 1 -Stage models, see Table Find the closest natural gas heat value and specific gravity in Table 2 or Table 3 depending on the type of furnace. Follow across the gas heat content line and down the specific gravity line to a point where they intersect. 14. Use Table 2 to determine the orifice size and low heat and high heat manifold pressure setting for 2 stage models. Use Table 3 to determine the orifice size and manifold pressure setting for single -stage models. EXAMPLE: (Using Table 2 at ft. (610 M) altitude) Heat value Btu/cu ft. Specific gravity = 0.62 Therefore: Orifice No. 45 is required. 15. Install main burner orifices. Do not use Teflon tape. Finger - tighten orifices at least one full turn to prevent cross threading, and then tighten with wrench. There are enough orifices in each kit for the largest furnace. Discard extra orifices. 16. Do not re -install the manifold assembly at this time.! BURNER ORIFICE Fig. 2 - Burner Orifice CAUTION BURNER ORIFICE A96249 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. 2.) Step 2 Remove Diverter Plate (Two-Stage Models Only) 1. Remove diverter plate from air intake box as follows: 2. Remove front two screws on combustion air intake box. (See Fig. 3.) 3. Remove combustion air intake box. Remove diverter plate and discard. (See Fig. 4.) 4. Re-install combustion air intake box. 5. Replace two screws to ensure diverter plate is properly installed. (See Fig. 4.) 3

4 Table 2 Orifice Size* and Manifold Pressure for Gas Input Rate A

5 Table 2 - Orifice Size* and Manifold Pressure for Gas Input Rate (Continued) A08216A 5

6 Table 3 Orifice Size* and Manifold Pressure for Gas Input Rate A

7 Table 3 - Orifice Size* and Manifold Pressure for Gas Input Rate (Continued) A08215A COMBUSTION AIR INTAKE BOX SCREWS PROP NAT COMBUSTION AIR INTAKE Fig. 3 - Removing Combustion Air Intake Box COMBUSTION AIR INTAKE BOX A

8 PROP NAT PROP NAT COMBUSTION AIR INTAKE COMBUSTION AIR INTAKE DIVERTER PLATE PART NO Fig. 4 - Removing Diverter Plate A06695 REGULATOR SEAL CAP ON/OFF SWITCH REGULATOR ADJUSTMENT SCREW REGULATOR SPRING (PROPANE - WHITE, 8.5 TURNS NATURAL - SILVER, 8.5 TURNS) BURNER ENCLOSURE REFERENCE PRESSURE TAP INLET PRESSURE TAP GAS PRESSURE REGULATOR ADJUSTMENT MANIFOLD PRESSURE TAP Fig. 5 - Convert Two -Stage Gas Valve A05196 Fig. 6 - Convert Single-Stage Gas Valve A05193 Step 3 Convert Main Gas Valve NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape. NOTE: DO NOT reinstall burner enclosure front at this time. NOTE: The two regulator springs included in the kit are identical and can be used in either high or low fire regulator or the main regulator of the single -stage furnace. NOTE: The gas valve used on the 2 -stage furnaces MUST have both regulator springs replaced and the gas valve MUST be pre-adjusted. NOTE: The gas valve used on the single -stage furnaces MUST have the regulator spring replaced and the gas valve MUST be pre-adjusted. Pre-adjustment of the regulator springs are necessary to ensure proper initial main burner ignition and to prevent flashback on ignition. Refer to Step 3a for Two -Stage gas valves or Step 3b for Single-Stage gas valves. Step 3a Convert Two Stage Gas Valve (See Fig. 5.) 1. Be sure main gas and electrical supplies are turned OFF. 2. Remove both regulator seal caps and set aside. 3. Remove both regulator adjustment screws. 4. Remove both propane gas regulator springs (white). 5. Install propane gas regulator springs (silver).! WARNING ELECTRIC SHOCK, FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death, equipment damage, and/or property damage. Turn OFF gas supply at manual gas valve before turning OFF electric power supply and starting conversion. Turn OFF electric power supply at disconnect switch or service panel before starting conversion. Tag and lockout shutoff(s) with appropriate device warning labels. There may be more than one disconnect. 6. Install regulator adjustment screws. a. Pre-adjust the High Fire regulator by turning the adjustment screw in 12 turns. b. Pre-adjust the Low fire regulator by turning the adjustment screw in 9.5 turns. 7. Do not re -install manifold assembly at this time. Step 3b Single -Stage Gas Valve (See Fig. 6.) 1. Be sure main gas and electrical supplies are turned OFF. 2. Remove regulator seal cap and set aside. 3. Remove regulator adjustment screws. 8

9 Fig. 7 - LGPS Fittings as Installed A Remove propane gas regulator spring (white). 5. Install propane gas regulator spring (silver). 6. Install regulator adjustment screw. a. Pre-adjust regulator by turning the adjustment screw in 8.5 turns. 7. Do not re -install manifold assembly at this time. Step 4 Remove Low Gas Pressure Switch (LGPS) NOTE: The manifold should have been removed in previous steps above. NOTE: Use propane gas-resistant pipe dope on all connections to prevent gas leaks. DO NOT use Teflon tape. 1. Be sure main gas and electric supplies to furnace are off.! WARNING ELECTRIC SHOCK, FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death, equipment damage, and/or property damage. Turn OFF gas supply at manual gas valve before turning OFF electric power supply and starting conversion. Turn OFF electric power supply at disconnect switch or service panel before starting conversion. Tag and lockout shutoff(s) with appropriate device warning labels. There may be more than one disconnect. 2. Remove wires from Low Gas Pressure Switch (LGPS) 3. Remove 1/8 -in. (3 mm) pipe plug from brass tee. (See Fig. 7. ) DO NOT DISCARD 1/8 -in. (3 mm) PLUG. 4. Remove 1/8 -in. (3 mm) brass tee and nipple from black iron street elbow attached to gas valve and discard. 5. Remove 1/8 -in. (3mm) black iron street elbow from gas valve and discard 6. Connect a manometer fitting to the open end of the tee installed in the inlet pressure tap of the gas valve. (See Fig. 5 or 6). NOTE: Install 1/8 -in. (3 mm) pipe plug in inlet pressure tap if gas supply is not available at the time of conversion. IGNITER WIRES MUST BE PLACED IN THIS SLOT Fig. 8 - Igniter Wire Placement Step 5 Re -install Manifold Assembly A Reinstall manifold assembly in burner box. Ensure manifold seal grommet is installed properly and burners fit over orifices. 2. Reinsert the igniter wires in the slot in the manifold grommet, dressing the wires to ensure there is no tension on the igniter itself. (See Fig. 8.) 3. Reconnect hot surface igniter to wiring harness. 4. Reconnect wires to gas valve. Refer to furnace wiring schematic for proper wire location. 5. Reinstall burner box pressure tube to gas-valve regulator fitting. 6. Reinstall burner box pressure tube to intake air box. NOTE: Use propane gas-resistant pipe dope on all connections to prevent gas leaks. DO NOT use Teflon tape. 7. Apply pipe dope sparingly to end of inlet gas pipe and reconnect gas supply pipe to gas valve using backup wrench on gas valve to prevent rotation and improper orientation. Step 6 Modify Pressure Switch Wiring (Refer to furnace wiring diagram) NOTE: For Two -Stage furnaces, follow Step 6a, 1 thru 4 below. NOTE: For Single -Stage furnaces, proceed to Step 6b, 1 thru 3 below. Step 6a Modify Two-Stage Pressure Switch Wiring (Refer to furnace wiring diagram) 1. Disconnect the orange wire that connected the N.O. terminal of the low gas pressure switch (LGPS) to the low - heat pressure switch (LPS) on inducer housing and discard. 2. Connect the orange wire removed from the C terminal of the low gas pressure switch (LGPS) to the low -heat pressure switch (LPS) on inducer housing. 3. Route orange wire along wire harness. If possible, secure with wire tie provided in kit. 9

10 Step 6b Modify Single -Stage Pressure Switch Wiring (Refer to furnace wiring diagram) 1. Disconnect the orange wire connected between the Low Gas Pressure Switch (LGPS) and the pressure switch located on the inducer housing and discard. 2. Connect the yellow wire previously connected to the Low Gas Pressure Switch (LGPS) to the pressure switch located on the inducer housing. Step 7 Connect Manometer to Inlet Pressure Tap NOTE: This kit is to be used only when inlet gas pressure is between 4.5 -in. w.c. and in. w.c.! CAUTION 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. 1. Connect a manometer to the fitting previously installed on the inlet pressure tap on gas valve. (See Fig. 9.) 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. Check all threaded pipe connections for gas leaks. Step 8 Check Inlet Gas Pressure NOTE: For Two -Stage furnaces with HK42FZ028 board, turn the LHT DIP switch on furnace control to ON (See Fig. 10.) Follow Steps 8a, 1 thru 9 below. NOTE: For Single -Stage furnaces, follow steps 8b, 1 thru 8 below. Step 8a Check Inlet Gas Pressure, Two-Stage Furnaces: 1. Turn LHT DIP switch on furnace control to ON to lock the furnace in high fire (See Fig. 10.) 2. Jumper R -W/W1 and R -W2 thermostat connections on control. 3. When main burners ignite, confirm inlet gas pressure is between 4.5 -in. w.c. and in. w.c. (See Fig. 9.) 4. Remove jumper across R to W or R -W/W1 and R -W2 thermostat connections to terminate call for heat. 5. Turn furnace gas valve switch to OFF position. 6. Turn gas supply manual shutoff valve to OFF position. 7. Turn off furnace power supply. 8. Remove manometer. 9. Apply pipe dope sparingly to end of 1/8 -in. (3 mm) inlet gas pipe plug and install in inlet pressure tap of gas valve. (See Fig. 5.) Step 8b Check Inlet Gas Pressure, Single -Stage Furnaces: 1. Jumper across thermostat connections R to W (See Fig. 11.) 2. When main burners ignite, confirm inlet gas pressure is between 11.5 in. w.c. and 13.6 in. w.c. 3. Remove jumper across R to W thermostat connections to terminate call for heat. 4. Turn gas valve switch to OFF position. 5. Turn gas supply manual shutoff valve to OFF position. 6. Turn off furnace power supply. 7. Remove manometer. 8. Apply pipe dope sparingly to end of 1/8 -in. (3 mm) inlet gas pipe plug and install in inlet pressure tap of gas valve. (See Fig. 6.) Step 9 Connect Manometer to Manifold Pressure Tap 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. 5, 6 and 14.) 4. Turn gas supply manual shutoff valve to ON position. 5. Turn furnace gas valve switch to ON position. 6. Check all threaded pipe connections for gas leaks. 7. Turn on furnace power supply. Fig. 9 - Inlet Gas Pressure Check A

11 1 SET UP SWITCHES LOW HEAT ONLY AND BLOWER OFF-DELAY TWINNING AND/OR COMPONENT TEST TERMINAL ACRDJ - AIR CONDITIONING RELAY DISABLE JUMPER 24-V THERMOSTAT TERMINALS W2 Y DHUM G COM W/W1 Y/Y2 R 24V LHT OFF DLY TEST / TWIN HUM ON OFF PLT HUMIDIFIER TERMINAL (24 VAC 0.5 AMPS MAX) TRANSFORMER 24 VAC CONNECTIONS 3-AMP FUSE LED OPERATION & DIAGNOSTIC LIGHT FUSE 3-AMP SEC-2 COM SEC-1 24VAC PL1 PL1-LOW VOLTAGE MAIN HARNESS CONNECTOR BLOWER SPEED TERMINALS COM HI HT COOL LO HT 24V MTR TAPS 1 SPARE 2 SPARE 1 EAC VAC (L2) NEUTRAL CONNECTIONS L2 EAC-1 L1 BL-1 PR-1 IDR PL2 HSIR IDM HSI HI LO IHI/LOR 115 VAC LINE (L1) CONNECTION 115 VAC BLOWER POWER (BL1) CONNECTION PL2 - HOT SURFACE IGNITER/INDUCER MOTOR CONNECTION Fig Two -Stage Furnace Control A08344 BLOWER OFF-DELAY 24-V THERMOSTAT TERMINALS TWINNING AND/OR COMPONENT TEST TERMINAL HUMIDIFIER TERMINAL (24-VAC 0.5 AMP. MAX) 3-AMP FUSE LED OPERATION & DIAGNOSTIC LIGHT BLOWER SPEED SELECTION TERMINALS HEAT COOL FAN SPARE 2 SPARE VAC (L2) NEUTRAL CONNECTIONS EAC-1 TERMINAL (115-VAC 1.0 AMP. MAX.) 115-VAC (L1) NEUTRAL CONNECTIONS TRANSFORMER 24-VAC CONNECTIONS PL1-LOW VOLTAGE DRAIN HARNESS CONNECTOR PL2-HOT SURFACE IGNITER & INDUCER MOTOR CONNECTOR Fig Single-Stage Furnace Control A

12 A09609 Fig Conversion Rating Plates A09610 Table 4 Altitude Derate Multiplier for USA ALTITUDE FT (M) PERCENT OF DERATE DERATE MULTIPLIER FACTOR* ( ) ( ) ( ) ( ) ) ( ) ) ( ) ,000 ( ) * Derate multiplier factor is based on midpoint altitude for altitude range. Step 10 Gas Input Rate Information The gas input rate for natural gas is the same as for propane gas. See furnace rating plate (see Fig. 12.) for input rate. The input rate for natural gas is determined by manifold pressure and orifice size. The gas-valve regulator must be set for low heat first and then set for high heat on 2 -stage and variable -speed furnaces. Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). In the USA, 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. See Table 4 for derate multiplier factor and example. 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 by an authorized Gas Conversion Station or Dealer. 12

13 BURNER FLAME BURNER! WARNING 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. MANIFOLD Fig Burner Flame GAS VALVE PRESSURE SWITCH(ES) (LOCATION WILL VARY DEPENDING ON MODEL) MANOMETER Fig Checking Manifold Pressure A05219 BURNER ENCLOSURE (REMOVE COVER WHEN CHECKING PRESSURE) A01070 Step 11 Set Gas Input Rate/Adjust Manifold Pressure For Two -Stage furnaces, follow Step 11a, 1 thru 18 below. For Single -Stage furnaces, follow Step 11b, 1 thru 17 below. Step 11a Set Gas Input Rate/Adjust Manifold Pressure - Two Stage Furnaces NOTE: Manifold pressure MUST always be measured with burner box cover removed. 1. Verify manometer is connected to manifold pressure tap on gas valve. (See Fig. 14.) 2. Jumper R and W/W1 thermostat connections to call for heat. 3. Check manifold orifices for gas leaks when main burners ignite. 4. Adjust gas manifold pressure. (See Fig. 5.) a. Remove caps that conceal adjustment screws for gas valve regulators. b. Adjust low -heat input rate manifold pressure for natural gas. c. Turn low -heat regulator adjusting screw counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate. (See Table 2.) d. Main burner flame should be clear blue, almost transparent. (See Fig. 13.) 5. Jumper R, W/W1 and W2 on control center thermostat connections. This keeps furnace locked in high -heat operation. a. Adjust high -heat input rate manifold pressure for natural gas. b. Turn high -heat regulator adjusting screw counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate. c. Remove jumper across R, W1, and W2 after high -heat adjustment to terminate call for heat. d. Replace caps that conceal gas -valve regulator adjustment screws. e. Main burner flame should be clear blue, almost transparent. (See Fig. 13.) 6. Turn setup switch LHT to OFF position. 7. Turn furnace gas-valve switch to OFF position. 8. Turn off furnace power supply. 9. Remove manometer and adapter fitting for manometer. 10. Apply pipe dope sparingly to 1/8 -in. (3 mm) pipe plug from manifold pressure tap and install the plug in the gas valve. 11. Reinstall burner enclosure front. 12. Turn furnace gas-valve switch to ON position. 13. Turn on furnace power supply. 14. Set room thermostat to call for heat. 15. Check pressure tap plug for gas leaks when main burners ignite. 16. Check for correct burner flame. 17. Observe unit operation through two complete heating cycles. See sequence of operation in furnace Installation, Start-Up, and Operating Instructions. 18. Set room thermostat to desired temperature. 13

14 Table 5 Gas Rate (Cu. Ft. / Hr.) SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 REVOLU- FOR 1 REVOLU- TION 1CuFt 2CuFt 5CuFt TION 1CuFt 2CuFt 5CuFt Step 11b Set Gas Input Rate/Adjust Manifold Pressure - Single -Stage Furnaces NOTE: Manifold pressure MUST always be measured with burner box cover removed. 1. Verify manometer is connected to outlet pressure tap on gas valve. (See Fig. 14.) 2. Jumper R and W thermostat connections to call for heat. (See Fig. 11.) 3. Check manifold orifices for gas leaks when main burners ignite.! WARNING 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. 4. Adjust gas manifold pressure. a. Remove burner enclosure cover and gas valve regulator seal cap that conceal adjustment screw. (See Fig. 6.) b. Turn adjusting screw counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure. (See Table 3.) c. Replace gas valve regulator seal cap. d. Verify manifold pressure is correct. NOTE: Gas valve regulator seal cap MUST be in place when checking input rate. e. When correctinput isobtained, main burner flameshould be clear blue, almost transparent. (See Fig. 13.) Be sure regulator seal cap is in place when finished. 5. Remove jumper across R and W thermostat connections to terminate call for heat. 6. Turn furnace gas valve control switch or control knob to OFF position. 7. Turn off furnace power supply. 8. Remove manometer and adapter fitting. 14

15 9. Apply pipe dope sparingly to 1/8 -in. (3 mm) pipe plug from manifold pressure tap and install the plug in the gas valve. 10. Reinstall burner enclosure front. 11. Turn furnace gas-valve switch to ON position. 12. Turn on furnace power supply. 13. Set room thermostat to call for heat. 14. Check pressure tap plug for gas leaks when main burners ignite.! WARNING GAS CONTROL CONVERSION LABEL FURNACE RATING PLATE RESPONSIBILITY LABEL BURNER ENCLOSURE GAS VALVE 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. 15. Check for correct burner flame. 16. Observe unit operation through two complete heating cycles. See sequence of operation in furnace Installation, Start- Up, and Operating Instructions. 17. Re -check all threaded pipe connections for gas leaks. 18. Set room thermostat to desired temperature. Step 12 Check Meter To Verify Gas Input Rate 1. Turn off all other gas appliances and pilots. 2. Start furnace and let operate for 3 minutes. 3. Measure time (in sec) for gas meter test dial to complete one revolution. 4. Refer to Table 5 for cu. ft. of gas per hr. 5. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft) using natural gas heating value from local gas utility/supplier. NOTE: Measured gas input must be within +/-2 percent of that stated on furnace rating plate when installed at sea level or derated per that stated above when installed at higher altitudes. Step 13 Label Application 1. Fill in Conversion Responsibility Label 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 appropriate Conversion Rating Plate Label , (See Fig. 12.) 3. Apply Gas Control Conversion Label Reinstall main furnace door. Step 14 Troubleshooting FURNACE CONVERSION RATING PLATE Fig Label Application CONTROL A

16 Copyright 2009 CAC / BDP S 7310 W. Morris St. S Indianapolis, IN Printed in U.S.A. Edition Date: 10/09 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 16 Catalog No: IIK---KGAPN Replaces: New