background image

AGAGC9PNS01B Gas Conversion Kit, Propane to Natural: Installation Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

2

This instruction covers the installation of gas conversion kit to convert

the following furnaces from propane gas usage to natural gas usage. 
NOTE: See appropriate sections for your furnace type. 

Table 1 – Kit Contents

SINGLE-STAGE GAS VALVE

Condensing  Furnaces  with  40,000  to  140,000  BTUH  (not  all  models

have  140,000  BTUH)  gas  input  rates  and  a.)  Single-Stage,  4-Way

Multipoise,  Hot  Surface  Ignition  with  PSC  blower  motor  or  b.)

Single-Stage gas valve with Fixed-Speeds Constant Torque ECM (FCT)

blower motor. 

TWO-STAGE & MODULATING GAS VALVE

Condensing Furnaces with 40,000 through 120,000 BTUH gas input rate

and  a.)  Modulating  gas  valve  with  Variable-Speed  Constant  Airflow

ECM  (VCA),  b.)  Two-Stage  gas  valve  with  Variable-Speed  Constant

Airflow ECM (VCA), or  c.) Two-Stage gas valve with Variable-Speed

Constant Torque ECM (VCT) blower motor.

DESCRIPTION AND USAGE

This kit is designed for use in the furnaces listed in 

Table 2

 or 

Table 3

,

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.

SINGLE-STAGE CONDENSING FURNACES

Table 2 – Single Stage Model Numbers

*   Except 26,000 BTUH models.

TWO-STAGE & MODULATING CONDENSING 

FURNACES

Table 3 – Two-Stage & Modulating Model Numbers

INSTALLATION

1. Set room thermostat to lowest setting or “OFF”

2. Disconnect power at external disconnect, fuse or circuit breaker.

3. Turn off gas at external shut-off or gas meter.

4. Remove outer doors and set aside.

5. Turn 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 Disconnect wires

from Hot Surface Igniter (HSI) and Flame Sensor.

WARNING

!

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, 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.

CAUTION

!

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage or improper

operation.
Do NOT use this kit with furnaces with an input of 26,000 BTUH; the

unit will be severely over-fired. This could result in delayed ignition,

sooting or premature heat exchanger failure.

QUANTITY

DESCRIPTION

2

REGULATOR SPRINGS

4

ORIFICES (BAG ASSEMBLIES)

1

LABELS 346162-201 through 346162-209

1

PLUG, PIPE

1

INSTRUCTIONS

BEGINNING WITH:

59SP

59SC

912S

915S

922S

925S

926S

PG95S

PG95ES

PG92ES

(F/G)9MXE

(N/R)92ES

N96VSN

PG92S

R9MS

N9MS

WF(A/H/S)

(N/R)95ES

BEGINNING WITH:

59MN

59T(N/P)

PG96V

PG95X

987M

986T

925T

926T

(F/G)97C

(F/G)9MA

(F/G)9MV

(F/G)96V

(F/G)9MXT

(F/G)96C

CAUTION

!

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.

ATTENTION

!

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.

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 ...

Reviews: