ACCESSORY KIT INSTALLATION INSTRUCTIONS HIGH ALTITUDE APPLICATION CONVERSION INSTRUCTION HIGH EFFICIENCY GAS FURNACES 1PS0306 / 1PS0307 / 1PS0308 / 1PS0309 / 1PS0901 / 1PS0902 / 1PS0903 FOR USE WITH MODELS: P*UR / G9T-UP / P*DH / G9T-DH / GF9 / GM9 / GY9 / XYF90 This conversion kit is to 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, an 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 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. The conversion of new certified central heating gas appliances must conform to directions outlined in this instruction. Installation must be made in accordance with American National Standard National Fuel Gas Code, ANSI Z223.1, NFPA- 54 latest edition, unless superseded by local codes. For Canadian installations, the conversion shall be carried out in accordance with the requirements of the Provincial authorities having jurisdiction and in accordance with the CAN/CGA B149.1 National Gas and Propane Installation Code. The manufacturer accepts no responsibility for malfunctions due to improper conversions. PROPANE AND HIGH ALTITUDE CONVERSION KITS It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed. Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use propane (LP) gas. Do not use this furnace with butane gas. Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat exchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death. High altitude and propane (LP) conversions are required in order for the appliance to satisfactory meet the application. An authorized distributor or dealer must make all gas conversions. In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion. The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed. Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames, causing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death. GENERAL This instruction is intended for the conversion of new equipment only, for operation at altitudes greater than 4,500 ft. above sea level. Follow the basic unit installation instruction for all other aspects of the installation. All units are equipped to operate up to 4,500 ft. above sea level without a high altitude kit. Installations above 2,000 ft. must be field derated as required by the National Fuel Gas Code, ANSI Z223.1 (latest edition), or in Canada, CAN/CGA B149.1 National Gas and Propane Installation Code and all other applicable local codes and utility requirements. This instruction provides the necessary information to select and install both the proper pressure switch and orifice for your specific application. Data is provided for both natural and propane (LP) gases. This high altitude pressure switch and accessory includes a special switch and other items as detailed below. TABLE 1: Common Parts Description Part Number Quantity Conversion Label 035-11635-000 1 Install. Instruction. 035-14447-001 1 Unitary Products Group
TABLE 2: Pressure Switch Accessory Kit Switch Part Number Pressure Setting 1PS0306 024-27633-00* 0.55 IWC 1PS0307 024-27635-00* 0.75 IWC 1PS0308 024-27636-00* 0.85 IWC 1PS0309 024-27637-00* 0.90 IWC 1PS0901 024-34561-00* 0.95/0.40 IWC 1PS0902 024-34560-00* 0.80/0.40 IWC 1PS0903 024-34577-00* 0.65/0.40 IWC * May be any numeral 0-9. PRESSURE SWITCH For installations below 4500 ft., refer to furnace installation instructions for applications which do not require a pressure switch change. For all other high altitude applications, a pressure switch change is required to provide safe and reliable operation. Table 3 indicates the correct pressure switch accessory for each unit model applied at two different altitude groupings. Do not adjust the original pressure switch to allow operation at high altitude. Unsafe operation will result. TABLE 3: High Altitude Pressure Switch Usage Input (MBH) ACCESSORY PART NUMBER P*UR / G9T-UP (Upflow) 40 1PS0309 60 1PS0307 80/1200 1PS0306 80/1600 1PS0307 100 1PS0306 120 1PS0307 140 1PS0307 P*DH / G9T-DH (Downflow/Horizontal) 40 1PS0309 60 1PS0307 80/1200 1PS0306 80/1600 1PS0307 100 1PS0306 120 1PS0307 GF9 / GM9 / GY9 / XYF90-U (Upflow) 60/80/120 1PS0309 100 1PS0307 GF9 / GM9 / GY9 / XYF90-N (Downflow/Horizontal) 60/100/120 1PS0901 80/1200 1PS0902 80/1600 1PS0903 The high altitude pressure switch should be changed by following this procedure. 1. Remove the burner access door. The gas supply shall be shut off prior to disconnecting the electrical power, before proceeding with the conversion. 2. Note the location of the wires on the pressure control and then disconnect them. Remove the hose from the pressure control. 3. Remove the screws securing the pressure control and remove it from the unit. Check that the new pressure control part number is correct for your application (Refer to Table 1). Install the new pressure control. 4. Replace the hose and wiring as originally connected. ORIFICE SIZE SELECTION A number of factors determine the correct orifice usage for your application. These factors include the original orifice sizing, BTU content of the gas and the altitude. The standard orifice used in the furnace is shown in Table 4 or 5. Find your unit and determine the standard orifice provided. For natural gas applications, contact your gas supplier for the actual BTU content (heating value) of the fuel provided at your altitude. Table 6 indicates various BTU content fuels. Use the BTU heating value that is nearest to your value. Read across the selected table from the standard orifice to the altitude for your application and then note the new orifice number. If your unit has a #45 orifice as standard and a heating gas value of 900 BTU/CU.FT., at an altitude of 7,000 feet a #47 orifice will provide the correct firing rate. For propane (LP) gas applications, Use Table 7 to select the proper high altitude orifice size. The furnace must first be converted to use propane (LP) through the use of the standard propane conversion kit accessory. After selecting the proper orifice size for your application, see Table 8 that indicates the part number for your required orifice number. The orifices may be obtained through your local Source 1 Parts Distribution Center. 2 Unitary Products Group
The high altitude orifices should be changed by the following procedure: 1. Carefully remove the wires from the gas valve and note their location so they may be properly replaced. Remove the burner box door. Remove the two screws that hold the manifold to the burner box and slide the manifold and orifices back out of the burners. 2. Remove the main burner orifices from the manifold and discard them. 3. Install the new main burner orifices in the manifold and tighten them. After installing a new orifice in each location, any leftover orifices may be discarded. 4. Reinstall the main burners in the assembly by reversing the removal process. TABLE 4: Standard Orifice Usage Input (MBH) Natural Orifice Propane Orifice Size Size Upflow Models 40 45 55 60 45 55 80 45 55 100 45 55 120 45 55 140 43 54 TABLE 5: Standard Orifice Usage Input (MBH) Natural Orifice Propane Orifice Size Size Downflow/Horizontal Models 40 45 55 60 45 55 80 45 55 100 45 55 120 45 55 TABLE 6: Altitude/ Heating Value Orifice Selection Heating Value (ManifolD Pressure 3.5" W.C.) 1200 BTU/CU Ft. 1100 BTU/CU.FT. 1000 BTU/CU.FT. 900 BTU/CU.FT. 800 BTU/CU.FT. Orifice Shipped With Unit TABLE 7: Altitude/Propane (LP) Gas Heating Value Orifice Selection Propane Gas Heating Value (Manifold Pressure 10.0 W.C.) 2516 BTU/CU FT. Recommended Orifice Altitude (Ft. Above Sea Level) 0 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 45 48 49 49 50 50 50 51 51 52 52 43 45 46 47 47 47 48 48 49 49 49 45 47 48 48 49 49 49 50 50 51 51 43 44 45 45 45 46 47 47 48 48 49 45 45 46 47 47 47 48 48 49 49 50 43 43 44 44 44 45 45 46 47 47 48 45 44 45 45 45 46 47 47 48 48 49 43 42 42 43 43 43 44 44 45 46 47 45 43 44 44 44 45 45 46 47 47 48 43 39 40 41 41 42 42 43 43 44 44 Propane Orifice @ Sea Level Recommended Orifice Altitude (Ft. Above Sea Level) 0 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 54 54 54 55 55 55 55 55 56 56 56 55 55 55 55 55 56 56 56 56 56 57 56 56 56 56 57 57 57 58 59 59 60 Unitary Products Group 3
TABLE 8: Orifice Part Numbers Burner Orifices Size # Source 1 Part Number 41 029-20423 - 041 42 029-20423 - 042 43 029-20423 - 043 44 029-20423 - 044 45 029-20423 - 045 46 029-20423 - 046 47 029-20423 - 047 48 029-20423 - 048 49 029-20423 - 049 50 029-20423 - 050 51 029-20423 - 051 52 029-20423 - 052 55 029-20423 - 055 56 029-20423 - 056 57 029-20423 - 057 58 029-20423 - 058 59 029-20423 - 059 60 029-20423 - 060 5. Install the high altitude conversion labels as described in the LABELS sections of this instruction. 6. Refer to the unit installation instructions to complete the installation before continuing with these procedures. TESTS AND ADJUSTMENTS The following tests must be performed at the time of conversion following completion of the installation. 4. Make sure unit electrical disconnect switch is in the OFF position. TABLE 9: Inlet Gas Pressure Range INLET GAS PRESSURE RANGE Propane (LP) Minimum 4.5 W.C. (1.12 kpa) 8.0 W.C. (1.99 kpa) Maximum 10.5 W.C. (2.61 kpa) 13.0 (3.24 kpa) W.C. IMPORTANT - The inlet gas pressure operating range table specifies what the minimum and maximum gas line presures must be for the furnace to operate safely. The gas line pressure MUST BE 7 W.C. (1.74 kpa) for 11 W.C. (2.74 kpa) for Propane (LP) Gas in order to obtain the BTU input specified on the rating plate and/or the nominal manifold pressure specified in these instructions and on the rating plate. 5. Set the room thermostat to call for heat. 6. Turn unit electrical disconnect switch to ON. The combustion blower should start and the hot surface igniter should start glowing. 7. After air has been purged from the gas supply line, ignition should occur. Shortly after ignition, the manifold and gas inlet pressures can be checked on the manometers. Main burner ignition may be delayed on the first ignition cycle due to air in the gas manifold. 8. Adjust manifold pressure to specifications shown above. This setting will result in an input which is properly derated for your altitude. Supply gas must be within the range shown above. If required, adjust the incoming regulator spring so that the pressure falls within the range. Make sure both gas and power supplies are shut off before proceeding. 1. Connect a manometer to the pressure tap on both the inlet and outlet side of the gas valve. Connect a power supply and a gas supply to the unit, if not already connected. Refer to unit installation instructions for proper procedure for connecting manometer to furnace. 2. Turn on the gas supply and bleed air from the gas supply lines at a point as close to the inlet or the gas valve as is practical. Make sure the space is free of gas before proceeding. 3. Turn the gas valve control switch to the ON position. The gas valve regulator cap must be in place to determine final gas pressure setting. 9. Observe several ignition cycles. All main burners must ignite without delayed ignition or burning at the orifices. If delayed ignition is observed, verify that the igniter is properly mounted (not loose or crooked on bracket, and that bracket screws are not loose). 10. If excessive yellow tipping, or excessive noise is observed during any phase of main burner operation, correct unit operation. 11. If burning at the orifices is observed during any phase of main burner operation change the orifice size to the next larger size and recheck the furnace input [BTU/H (kw)] using the input calculations in these instructions if you have a gas meter, and/or check the furnace operation making sure the unit is still operating with in the range specified on the rating plate. DO NOT ALLOW THE FURNACE TO CONTINUE OPERATAING WITH BURNING AT THE ORI- FICES. This is very dangerous condition that MUST BE RESOLVED. 4 Unitary Products Group
12. With the main burners ignited, check for gas leaks, especially in the following locations: gas valve inlet and outlet connections, manifold union in the burner compartment, and main burner orifices where they thread into the manifold. Repair any leaks found and recheck. Do not use an open flame or any source of ignition to check for leaks. 13. Operate the furnace for 15 minutes and measure the supply and return air temperatures. Verify that the temperature rise (supply air - return air rise) is within the allowable range. See the unit data plate for the minimum/maximum allowable temperature rise. If the measured rise is in excess of the maximum shown on the data plate, a higher blower speed must be selected. See the unit wiring diagram to make this change. 14. If a gas meter is available check the unit input using the calculations in this instruction. 15. During unit operation, the main burner appearance and igniter location should be as shown in Figure 1. BLUE CONE PORTION OF FLAME SHOULD ENTER HEAT EXCHANGER TUBE CALCULATING THE FURNACE INPUT (NATURAL GAS) NOTE: Front door of burner box must be secured when checking gas input. Burner orifices are sized to provide proper input rate using natural gas with a heating value of 1050 BTU/Ft 3. If the heating value of your gas is significantly different, it may be necessary to replace the orifices. For propane applications that do not have a gas meter you will have to replace the natural gas orifices and adjust the manifold pressure. The input rate can not be calculated without a gas meter. 1. Turn off all other gas appliances connected to the gas meter. 2. At the gas meter, measure the time (with a stop watch) it takes to use 2 cubic ft. (0.0566 m 3.) of gas. 3. Calculate the furnace input by using one of the following equations. LABELS 1. Remove label 035-11635-000 from the shipping box. Check the natural gas to Propane box. If in Canada, check the appropriate box for respective conversion station. NOTE: If the unit has been converted from natural gas to propane (LP), place the new label over the existing label and fill in the appropriate information. 2. Under "Rating After Conversion", write in the following: a. Orifice size, as stamped on the orifice b. Maximum inlet pressure c. Minimum inlet pressure d. Manifold pressure for both low and high inputs e. Input ratings, same as on the Rating Plate f. Outlet ratings, same as on the Rating Plate 3. Under "Changes After Conversion", write in the following: a. Kit number, located on the outside of the box FIGURE 1: Proper Burner Flame Appearance 16. With the main burners off, disconnect the manometers and replace the plugs. Check for gas leakage at the plugs. 17. Replace all access panels. b. Unit model number c. Stamp or write in the name of the organization making conversion, address, city, state, month and year. 4. Remove label backing and affix label adjacent to the Rating Plate. 5. On propane (LP) conversions, affix the corresponding gas valve label (provided in the conversion kit) to the valve. Unitary Products Group 5
In the USA use the following formula to calculate the furnace input. For natural gas multiply the heat content of the gas BTU/SCF (or Default 1030 BTU/SCF, times 2 cubic ft. of gas measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time (In seconds) it took to measure 2 cubic ft. of gas from the gas meter. The formula for US input calculation using a cubic foot gas meter: In Canada you will use the following formula to calculate the furnace input if you are using a cubic foot gas meter. For multiply the Heat content of the gas MJ/m 3 (or Default 39.2), times 2 cu. ft. of gas x 0.02831 to convert from cubic feet to cubic meters measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time it took to measure 2 cu.ft. of gas from the gas meter. The formula for metric input calculation using a cubic foot gas meter: For propane (LP) gas multiply the heat content of the gas BTU/ SCF (or Default 2500 BTU/SCF, times 1 cubic ft. of gas measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time (In seconds) it took to measure 1 cubic ft. of gas from the gas meter. BTU/f 3 x 2 cu.ft. x 0.960 x 3600 = BTUH/H BTU/f 3 x 2 cu.ft. x 0.960 x 3600 Seconds it took to measure the 2 cu.ft. of gas Seconds it took to measure the 2 cu.ft. of gas = BTUH/H NATURAL GAS INPUT CALCULATION PROPANE (LP) GAS INPUT CALCULATION 1030 x 2 x 0.960 x 3600 2500 x 1 x 0.960 x 3600 = 79,997.38 90.5 108 = 80,000.00 Propane Gas BTU/SCF 1030 BTU/SCF 2500 For Propane (LP) Gas multiply the Heat content of the gas MJ/ m 3 (or Default 93.14), times 1 cu. ft. of gas x 0.02831 to convert from cubic feet to cubic meters measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time it took to measure 1 cu.ft. of gas from the gas meter. MJ/m 3 x (2 cu.ft. x Conv) x 0.960 x 3600 = MJ/H x 0.2777 = kw x 3412.14 = BTUH/H Seconds it took to measure the 2 cu.ft. of gas NATURAL GAS INPUT CALCULATION 39.2 x 2 x 0.960 x 3600 = 84.76 x 0.2777 = 23.54 x 3412.14 = 80,312.62 90.5 BTU/SCF 1030 = 39.2 MJ/m 3 PROPANE (LP) GAS INPUT CALCULATION 93.15 x 1 x 0.960 x 3600 = 84.41 x 0.2777 = 23.45 x 3412.14 = 80,000.00 108 Propane Gas BTU/SCF 2500+93.15 MJ/m 3 In Canada use the following formula to calculate the furnace factor of 0.960; times 3600, then divided by the time it took to input if you are using a gas meter that measures cubic meters. measure 0.0566 m 3 of gas from the gas meter. For multiply the Heat content of the gas MJ/m 3 (or For Propane (LP) Gas multiply the Heat content of the gas MJ/ Default 39.2), times 0.0566 m 3 of gas measured at the gas m 3 (or Default 93.14), times 0.00283 m 3 of gas measured at the meter, times a barometric pressure and temperature correction gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time it took to measure 0.0283 cm of gas from the gas meter. The formula for metric input calculation using a cubic foot gas meter: MJ/m 3 x (2 cu.ft. x Conv) x 0.960 x 3600 = MJ/H x 0.2777 = kw x 3412.14 = BTUH/H Seconds it took to measure the 2 cu.ft. of gas NATURAL GAS INPUT CALCULATION 39.2 x 2 x 0.960 x 3600 = 84.76 x 0.2777 = 23.54 x 3412.14 = 80,312.62 90.5 BTU/SCF 1030 = 39.2 MJ/m 3 PROPANE (LP) GAS INPUT CALCULATION 93.15 x 1 x 0.960 x 3600 = 84.41 x 0.2777 = 23.45 x 3412.14 = 80,000.00 108 Propane Gas BTU/SCF 2500+93.15 MJ/m 3 6 Unitary Products Group
NOTES Unitary Products Group 7
Subject to change without notice. Printed in U.S.A. 035-14447-001 Rev. B (0404) Copyright by York International Corp. 2004. All rights reserved. Supersedes: 035-14447-001 Rev. A (0204) Unitary 5005 Norman Product York OK Group Drive 73069