Carrier KGANP3001ALL Installation Instructions Manual Download Page 14

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14. Reinstall manifold with 4 screws removed in Procedure 8. Burners should be checked for proper alignment of the burner crossover slot.

Verify green ground wire is attached to burner manifold

NOTE:

Failure to attach ground wire to gas manifold on burner box will result in loss of flame signal resulting in a no heat condition.

15. Reconnect wires to flame sensor and flame rollout safety switch(es). See the furnace wiring label to ensure proper location of wires.

16. Reconnect igniter wire connector. Verify Igniter to Burner alignment. (See Fig. 30.)

17. Reconnect wires to gas valve. See wiring label on furnace to ensure proper location of wires.

18. Reconnect gas supply pipe to gas valve using backup wrench on gas valve to prevent rotation and improper orientation.

NOTE:

Use propane-gas resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.

PROCEDURE 2—CONVERT OR PRE-ADJUST GAS VALVE

Convert Single-Stage Gas Valve

The following furnaces must have the regulator spring replaced in the gas valve:

1. Be sure main gas and electrical supplies are off.

2. Remove regulator seal cap. (See Fig. 16A.)

CLEARANCE

LABEL

GAS CONTROL
CONVERSION
LABEL

CONVERSION

RESPONSIBILITY

LABEL

BURNERS

MANIFOLD

BURNER
HOLD–DOWN
BRACKET

GAS VALVE

BLOWER
COMPARTMENT
DOOR

CONVERSION

RATING

PLATE

FURNACE

RATING

PLATE

A95459

Fig. 12A—Downflow and Downflow/Horizontal,

Standing Pilot, Fixed Speed, Non-Condensing

Furnace Component and Conversion Label

GAS CONTROL
CONVERSION
LABEL

CONVERSION

RESPONSIBILITY

LABEL

BURNERS

MANIFOLD

CLEARANCE

LABEL

BURNER
HOLD–DOWN
BRACKET

GAS VALVE

BLOWER
COMPARTMENT
DOOR

CONVERSION

RATING

PLATE

FURNACE

RATING

PLATE

A95460

Fig. 12B—Upflow and Upflow/Horizontal,

Standing Pilot, Fixed Speed, Non-Condensing

Furnace Component and Conversion Label

Fig. 13—Removal of Low NO

A95171

AS SHIPPED

COIL REMOVAL

58PAV

383KAV

PG8UAA

58WAV

395CAV

PG8DAA

58RAV

373LAV

393AAV

58ZAV

376CAV

58YAV

—14—

Summary of Contents for KGANP3001ALL

Page 1: ...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 wit...

Page 2: ...RICAL HAZARD Failure to follow this warning could result in serious injury death or property damage Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion DESCRIPTION AND USAGE This kit is designed for use in the furnaces listed above See Table 1 for kit contents To accommodate many different furnace models more parts are shipped in kit than will be needed...

Page 3: ...mproper and dangerous operation Label all wires prior to disconnection when servicing controls ATTENTION D EQUIPEMENT DANGER 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 6 Remove the 2 screws on the left side that secure the manifold to the burner box 7 Swing out manifol...

Page 4: ...RD Failure to follow this caution may result in premature unit failure Furnace models 58CTX 58CVX 58DLX 58STX 310JAV 311JAV 312JAV 315JAV and PG8JAA MUST have low NOx devices removed prior to operating furnace on propane gas 12 For NOx device removal follow the following additional steps a Remove the screw underneath the heat exchanger inlet that secures the NOX device in the heat exchanger See Fi...

Page 5: ...x verifying that green ground wire is reattached to burner box 18 Reconnect wires to gas valve per the wiring diagram supplied with the unit NOTE Failure to attach ground wire to gas manifold on burner box will result in loss of flame signal resulting in a no heat condition NOTE Use propane gas resistant pipe dope to prevent gas leaks DO NOT use Teflon tape PROCEDURE 2 CONVERTING AND ADJUSTING SIN...

Page 6: ... stage adjusting screw clockwise in 13 5 turns This will increase the manifold pressure closer to the propane high heat set point Replace caps that conceal gas valve regulator adjustment screws Go to Procedure 3 FOR FIG 6D 1 Be sure gas and electrical supplies to furnace are off 2 Remove caps that conceal adjustment screws for high and low heat stage gas valve regulators See Fig 6C 3 Turn low heat...

Page 7: ... x female x male tee on the brass coupling Tighten coupling finger tight Use a small open end wrench for final tightening 5 Apply pipe dope sparingly to male end of brass tee Install propane low gas pressure switch provided in kit on male end of the female x female x male tee Tighten switch finger tight Use a small open end wrench on base of pressure switch for final tightening 6 Connect a manomet...

Page 8: ...tage and Variable Speed furnace control See Fig 8C or 8D The two stage algorithm must be removed to force furnace to high heat operation 5 When main burners ignite confirm inlet gas pressure is between 11 0 in w c and 3 6 in w c 6 Remove jumper across thermostat connections to terminate call for heat 7 Turn furnace gas valve switch to OFF position 8 Turn gas supply manual shutoff valve to OFF posi...

Page 9: ...or natural gas See furnace rating plate for input rate The input rate for propane is determined by manifold pressure and orifice size On two stage furnace models the gas valve regulator must be set for high heat and set for low heat See kit rating plate 327697 204 Rev B Fig 10 Gas input rate on furnace rating plate is for installations at altitudes up to 2000 ft In the U S A the input rating for a...

Page 10: ...TERMINAL 115 VAC 1 0 AMP MAX 115 VAC L1 LINE VOLTAGE CONNECTION PL2 HOT SURFACE IGNITER INDUCER MOTOR CONNECTOR PL1 LOW VOLTAGE MAIN HARNESS CONNECTOR TRANSFORMER 24 VAC CONNECTIONS HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX TWINNING AND OR COMPONENT TEST TERMINAL BLOWER OFF DELAY LHT OFF DLY ON OFF W2 BLW 24 V THERMOSTAT TERMINALS SETUP SWITCHES LOW HEAT ONLY AND BLOWER OFF DELAY TWINNING AND OR COMP...

Page 11: ...ating characteristics that can result from low gas supply pressure Switch opens at not less than 6 5 w c and closes at not greater than 10 2 w c This switch also prevents operation when the propane tank level is low which can result in gas with a high concentration of impurities additives and residues that have settled to the bottom of the tank Operation under these conditions can cause harm to th...

Page 12: ...anization making this conversion are required 2 Attach Conversion Rating Plate Label 327697 204 Rev B Fig 10 to Outer Door of furnace 3 Apply Gas Control Conversion Label to gas valve a For single stage gas valve apply label 327697 203 to gas valve Do not use 327697 202 which is similar b For two stage gas valve that was converted by replacing the regulator springs Fig 6C apply label 327697 203 c ...

Page 13: ...ay result in premature unit failure Furnace models 58DXT 58UXT 58UXV 330JAV 331JAV and 333JAV must have low NOx coils removed prior to operating furnace on propane gas 10 Remove and discard orifices from manifold 11 Refer to conversion kit rating plate 327697 206 Single Stage See Fig 14 or 327697 207 Two Stage See Fig 15 to determine main burner orifice size Furnace gas input rate on rating plate ...

Page 14: ...pe PROCEDURE 2 CONVERT OR PRE ADJUST GAS VALVE A Convert Single Stage Gas Valve The following furnaces must have the regulator spring replaced in the gas valve 1 Be sure main gas and electrical supplies are off 2 Remove regulator seal cap See Fig 16A CLEARANCE LABEL GAS CONTROL CONVERSION LABEL CONVERSION RESPONSIBILITY LABEL BURNERS MANIFOLD BURNER HOLD DOWN BRACKET GAS VALVE BLOWER COMPARTMENT D...

Page 15: ...LATE FOR APPLIANCE MODEL NO AND INPUT RATING NOTE Furnace gas input rate on rating plate is for installations up to 2000 ft above sea level In U S A the input rating for altitudes above 2000 ft must be derated by 4 for each 1000 ft above sea level In Canada the input rating must be derated by 10 for altitudes of 2000 ft to 4500 ft above sea level Fig 15 Conversion Kit Rating Plate Two Stage Units ...

Page 16: ... switch is tight switch terminals should point as shown in Fig 7B relative to gas valve and clear control compartment access door 6 Connect a manometer to the open end of the tee installed in the gas valve See Fig 7A PROCEDURE 4 CHECK INLET GAS PRESSURE NOTE This kit is to be used only when inlet gas pressure is between 11 0 in w c and 13 6 in wc 1 Verify manometer is connected to inlet pressure t...

Page 17: ...meter to manifold pressure tap on gas valve See Fig 16A 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 WARNING FIRE EXPLOSION INJURY OR DEATH HAZARD Failure to follow this warning could result in fire explosion personal injury or death NEVER use matches candles f...

Page 18: ...fold pressure for propane gas See kit rating plate 327697 207 Turn high heat adjusting screw 5 64 hex allen wrench counterclockwise out to decrease input rate or clockwise in to increase input rate e Remove jumper across R and W2 after high heat adjustment f Replace caps that conceal gas valve regulator adjustment screws 5 Remove jumper across R W1 and W2 thermostat connections to terminate call f...

Page 19: ...or reduction in gas supply occur the gas pressure at switch drops below low gas pressure switch setting and switch opens Any interruption in control circuit in which low gas pressure switch is wired quickly closes gas valve and stops gas flow to burners When normal gas pressure is restored the system must be electrically reset to reestablish normal heating operation Before leaving installation obs...

Page 20: ...ent for altitudes of 2000 ft to 4500 ft above sea level The Conversion Kit Rating Plate accounts for high altitude derate 11 Install main burner orifices Do not use Teflon tape Finger tighten orifices at least 1 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 CAUTION UNIT DAMAGE HAZARD Failure to...

Page 21: ... in kit See Fig 21 5 Reinstall combustion air intake box and replace 2 screws to ensure diverter plate is properly installed See Fig 19 Fig 18 Air Shutter in Propane Gas Usage PROP Position 355MAV060120 and 58MVP120 20 Units Only A96264 PROPANE GAS POSITION AIR SHUTTER Fig 19 Removing Combustion Air Intake Box A95443 COMBUSTION AIR INTAKE BOX SCREWS COMBUSTION AIR INTAKE BOX Fig 20 Removing Center...

Page 22: ...main gas and electrical supplies are off 2 Remove regulator seal cap See Fig 22A and 22B 3 Remove adjustment screw and natural gas regulator spring silver 4 Install propane gas regulator spring white in gas valve 5 Turn regulator adjustment screw in 6 turns for Fig 22A and 8 5 turns for Fig 22B NOTE DO NOT reinstall regulator seal cap at this time B Pre Adjust 2 Stage and Variable Speed Gas Valve ...

Page 23: ...ane high heat set point 5 Replace caps that conceal gas valve regulator adjustment screws PROCEDURE 6 INSTALL LOW GAS PRESSURE SWITCH LGPS ALL FURNACES NOTE The inlet gas pipe must be disconnected from valve so pressure switch can be installed 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 ...

Page 24: ... at this time 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 For single stage models jumper R to W 6 For two stage and variable speed models perform the following steps to force furnace control board to high heat operation For Two Stage furnaces with HK42FZ017 board perform the following on the control board Tur...

Page 25: ...ressure switch LPS on inducer housing 2 Connect un insulated terminal of 1 orange wire provided in kit to splice connector Connect other end to C terminal on low gas pressure switch LGPS 3 Connect insulated terminal of second orange wire provided in kit to NO terminal on low gas pressure switch LGPS Connect other end to pressure switch LPS located on inducer housing 4 Route orange wires along wire...

Page 26: ...call for heat See Fig 8A or 8B 2 Check manifold orifices for gas leaks when main burners ignite 3 Adjust gas manifold pressure a Remove burner box cover See Fig 27 and gas valve regulator seal cap that conceal adjustment screw See Fig 22A or 22B NOTE Manifold pressure MUST always be measured with burner box cover removed b Turn adjusting screw counterclockwise out to decrease manifold pressure or ...

Page 27: ...eaks when main burners ignite 14 Check for correct burner flame 15 Observe unit operation through 2 complete heating cycles See sequence of operation in furnace Installation Start Up and Operating Instructions 16 Set room thermostat to desired temperature PROCEDURE 11 CHECK LOW GAS PRESSURE SWITCH OPERATION The newly installed low gas pressure switch is a safety device used to guard against advers...

Page 28: ...unit operation through 2 complete heating cycles During this time turn gas supply to gas valve off just long enough to completely extinguish burner flame then instantly restore full gas supply To ensure proper low gas pressure switch operation observe that there is no gas supply to burners until after hot surface igniter begins glowing PROCEDURE 12 LABEL APPLICATION See Fig 26 for label location 1...

Page 29: ...e that was converted by replacing the regulator spring Fig 22C apply label 327697 203 c For two stage gas valve that was adjusted Fig 22D apply label 327697 202 4 Reinstall main furnace door Fig 28 Burner Flame A89020 BURNER FLAME BURNER MANIFOLD 7 8 A02150 Fig 29A Position of Igniter to Burner Section 1 9 32 11 32 A02150 Fig 29B Picture of Igniter to Burner Section 1 29 ...

Page 30: ...NER IGNITOR 11 32 7 8 C L C L IGNITOR ASSEMBLY CELL PANEL BURNER 13 32 HOT SURFACE IGNITOR ASSEMBLY Fig 31 Position of Ignitor to Burner Section 3 A93260 BURNER IGNITOR 13 32 11 32 7 8 C L C L IGNITOR ASSEMBLY IGNITOR ASSEMBLY CELL PANEL BURNER BURNER BOX 30 ...

Page 31: ... 31 ...

Page 32: ... 2004 CAC BDP 7310 W Morris St Indianapolis IN 46231 agganp31 32 Catalog No 63GA NP11 ...

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