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Installation Instructions

NOTE: 

Read the entire instruction manual before starting the 

installation.

A200203

NOTE: 

Read  the  entire  instruction  manual  before  starting  the

installation.

SAFETY CONSIDERATION

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-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. 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  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.

INTRODUCTION

AGAGC9PNS01B Gas Conversion Kit, Propane to Natural

Condensing (90%+) Furnaces

40,000 BTUH to 140,000 BTUH Models Only

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  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.

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.

WARNING

!

FIRE, EXPLOSION, ELECTRICAL SHOCK AND 

CARBON MONOXIDE POISONING HAZARD

Failure to follow instructions could result in personal injury, death or

property damage.

Improper installation, adjustment, alteration,  service, maintenance, or

use  can  cause  carbon  monoxide  poisoning,  explosion,  fire,  electrical

shock,  or  other  conditions,  which  could  result  in  personal  injury  or

death. Consult your distributor or branch for information or assistance.

The qualified installer or agency must use only factory-authorized kits

or accessories when servicing this product.

WARNING

!

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, death or

property damage.

Gas  supply  MUST  be  shut  off  before  disconnecting  electrical  power

and proceeding with conversion.

Summary of Contents for AGAGC9PNS01B

Page 1: ...o 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 pr...

Page 2: ...urn electric switch on gas valve to OFF A190014 Fig 1 Representative Furnace Drawing MANIFOLD ORIFICE BURNER REMOVAL NOTE Use a back up wrench on the gas valve to prevent the valve from rotating on the manifold or damaging the mounting to the burner box 1 Disconnect the gas pipe from gas valve and remove pipe from the furnace casing see Fig 1 2 Disconnect the connector harness from gas valve Disco...

Page 3: ...line to point of intersection to find orifice size and manifold pressure settings For Modulating Furnaces Follow Steps 1 and 2 above For Step 3 use Table 6 for all sizes 20 000 BTUH Max Heat 8 000 BTUH Min Heat per burner except 60 000 BTUH models in a 21 in wide cabinet Table 7 for 60 000 BTUH models in a 21 in wide cabinet 20 200 BTUH Max Heat 8 000 BTUH Min Heat per burner 1 For both tables fol...

Page 4: ...No High Low No High Low 900 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 42 3 4 1 4 0 925 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 42 3 2 1 4 0 950 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 975 44 3 7 1 6 44 3 8 1 6 43 3 4 1 5 43 3 6 1 5 to 1000 44 3 5 1 5 44 3 6 1 5 44 3 8 1 6 43 3 4 1 4 1025 44 3 3 1 4 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 2000 1050 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 610 1075 45 3 7 1 6 45 3 ...

Page 5: ... 3 3 0 50 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 2743 775 45 3 7 0 60 44 3 2 0 50 44 3 3 0 50 44 3 4 0 55 9001 600 42 3 3 0 55 42 3 4 0 55 42 3 6 0 55 42 3 7 0 60 2744 625 43 3 7 0 60 42 3 2 0 50 42 3 3 0 55 42 3 4 0 55 650 43 3 5 0 55 43 3 6 0 55 43 3 7 0 60 43 3 8 0 60 675 44 3 7 0 60 44 3 8 0 60 43 3 4 0 55 43 3 5 0 55 10000 700 44 3 4 0 55 44 3 5 0 55 44 3 7 0 60 44 3 8 0 60 3048 725 44 3 2 0 50 ...

Page 6: ...any time specifications and designs without notice and without obligations 6 SINGLE STAGE GAS VALVE A200248 A200249 Fig 5 Conversion Kit Rating Plate 40 000 BTUH to 140 000 BTUH ONLY Single Stage Furnace TWO STAGE GAS VALVE A200250 A200251 Fig 6 Conversion Kit Rating Plate 40 000 BTUH to 140 000 BTUH ONLY Two Stage Furnace ...

Page 7: ...o plug the hole in the burner when the mixer screws are removed A11460 Fig 8 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 9 Fig 10 A11405 Fig 9 Igniter Position Back V...

Page 8: ... or improper operation DO NOT use this kit if the gas valve has a green label 26 000 BTUH model on it The 26 000 BTUH model uses a different conversion kit available from your distributor CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in unit damage The gas valve must be converted and pre adjusted before operating on propane gas If not converted and pre adjusted sooting and c...

Page 9: ...r for the modulating gas valve is very small Needle nose pliers are required to remove the jumper from the valve If the jumper is not removed the valve will not operate properly on natural gas pressures 1 Locate the round LP GAS sticker on the top of the gas valve 2 Peel the sticker off and discard 3 Note the small square opening in the top of the gas valve 4 Note the two jumper pins inside the mo...

Page 10: ...ided in kit and install in the 1 8 in 3 mm tapped inlet pressure tap opening in the gas valve DO NOT over tighten Check for gas leaks after gas supply has been turned on A170142 Fig 19 LGPS for casing wider than 14 3 16 and vent does not pass between inducer and burner assembly INSTALL MANIFOLD 1 Refer to Fig 2 and Fig 3 2 Align the orifices in the manifold assembly with the support rings on the e...

Page 11: ...alve switch to OFF position 5 Turn gas supply manual shutoff valve to OFF position 6 Turn off furnace power supply 7 Remove manometer and on some models remove pressure tap fitting 8 On some models apply pipe dope sparingly to end of inlet gas pipe plug and install into unused end of 1 8 in 3 mm tee Use a small back up wrench on tee when tightening gas inlet pipe plug Or on some models tighten set...

Page 12: ...ARNESS CONNECTOR TRANSFORMER 24 VAC CONNECTIONS 3 AMP FUSE STATUS AND COMM LED LIGHTS SW1 SETUP SWITCHES AND BLOWER OFF DELAY MODEL PLUG CONNECTOR AIR CONDITIONING A C AIRFLOW SETUP SWITCHES COMMUNICATION CONNECTOR CONTINUOUS FAN CF AIRFLOW SETUP SWITCHES OUTDOOR AIR TEMP CONNECTOR HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX FLASH UPGRADE CONNECTOR FACTORY ONLY SW4 SETUP SWITCHES SOFTWARE VERSION PART ...

Page 13: ... to 2000 ft 610 M In the U S A the input rating for altitudes above 2000 ft 610M must be reduced by 2 percent for each 1000 ft 305 M above sea level In Canada the input rating must be derated by 5 percent for altitudes of 2000 ft 610 M to 4500 ft 1372 M above sea level The Conversion Kit Rating Plate accounts for high altitude derate SET GAS INPUT RATE A11461 Fig 24 Burner Flame Single Stage Gas V...

Page 14: ... opening Or on some models tighten set screw on manifold tower pressure tap with a 3 32 in hex wrench see Fig 6 20 Turn on furnace power supply 21 Set room thermostat to call for heat 22 Check pressure tap plug for gas leaks when main burners ignite 23 Check for correct burner flame 24 After making the required manifold pressure adjustments check and adjust the furnace temperature rise per the fur...

Page 15: ...ed on the furnace rating plate Determine air temperature rise as follows 1 Place thermometers in return and supply ducts as near furnace as possible Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings This practice is particularly important with straight run ducts 2 When thermometer readings stabilize subtract return air temperature from supply air temperat...

Page 16: ...oor of furnace Date name and address of organization making this conversion are required see Fig 26 2 Attach Conversion Rating Plate Label 346162 201 204 206 207 208 or 209 to outer door of furnace see Fig 5 Fig 6 or Fig 7 3 Attach Gas Control Conversion Label 346162 202 to gas valve Do not use 346162 203 which is similar CHECKOUT 1 Observe unit operation through two complete heating cycles 2 See ...

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