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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.

WARNING

This instruction covers the installation of gas conversion kit Part

No. KGBPN4401VSP to convert the following furnaces from
Propane gas usage to natural gas usage. See appropriate section

for your furnace type.

Section 1

—59MN7 & 987M 4-Way Multipoise, Hot Surface

Ignition, Modulating Condensing Furnaces. This kit is designed
for use in furnaces with 60,000 through 120,000 Btuh gas input

rates.

Section 2

—59TN6, 59TP6, 926T, 986T, PG96V_T, 4-Way

Multipoise, Hot Surface Ignition, 2--Stage, Variable--Speed

Condensing Furnaces. 59TN6 applies to 60,000 to 120,000 Btuh
gas input rates. 986T and PG96V_T applies to 40,000 to 120,000

Btuh gas input rates.

Section 3

—58CTW, 58CVA, 58CVX, 314AAV, 315AAV,

315JAV, PG8MVA, PG8JVA, 33.3--In.(846 mm) High,

Induced--Combustion,

Hot--

Surface

Ignition,

2-Stage,

Variable-Speed, Non-Condensing Furnaces. This kit is designed

for use in furnaces with 42,000 through 154,000 Btuh gas input

rates.

DESCRIPTION AND USAGE

See Table 1 for kit contents. This kit is designed for use in the

furnaces listed above. 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.

Table 1 – Kit Contents

QTY.

PART NUMBER

DESCRIPTION

EF39ZW037

VALVE CVRSN KIT - W/R SPRING

92-0659

323267-701

BAG ASSEMBLY Includes:

LH32DB207

ORIFICE - #42

323267-702

BAG ASSEMBLY Includes:

LH32DB202

ORIFICE - #43

323267-703

BAG ASSEMBLY Includes:

LH32DB200

ORIFICE - #44

323267-704

BAG ASSEMBLY Includes:

LH32DB205

ORIFICE - #45

340071-701

LABEL SHEET Includes:

340071-201

CONVERSION RATING PLATE

340071-202

GAS CONTROL CONVERSION LABEL

340071-203

GAS CONTROL ADJUSTMENT LABEL

340071-204

CONVERSION RATING PLATE

340071-205

CONVERSION RESPONSIBILITY LABEL

340071-702

LABEL SHEET Includes:

340071-206

CONVERSION RATING PLATE

340071-209

CONVERSION RATING PLATE

Kit Contents (Continued)

340071-703

LABEL SHEET Includes:

340071-211

CONVERSION RATING PLATE

340071-214

CONVERSION RATING PLATE

AG-KGBPN-

VSP-XX

INSTALLATION INSTRUCTIONS

SECTION 1

Table 2 – Condensing Furnaces

MODEL NUMBERS BEGINNING WITH:

59MN7

987M

INSTALLATION

1. Set room thermostat to lowest setting or “OFF”.
2. Remove outer doors.
3. Disconnect power at external disconnect, fuse or circuit

breaker.

4. Turn off gas at external shut-off or gas meter.
5. Remove outer doors and set aside.
6. Turn electric switch on gas valve to OFF.

MANIFOLD/ORIFICE/BURNER REMOVAL

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.

CAUTION

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.

PRUDENCE

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. Discon-

nect wires from Hot Surface Igniter (HSI) and Flame

Sensor. Disconnect the two wires from the low gas pres-
sure switch (LGPS) located on the gas valve.

3. Support the manifold and remove the 4 screws that secure

the manifold assembly to the burner box and set aside.

4. Note the location of the green/yellow wire ground wire for

re-assembly later. See Fig. 2.

5. Slide one--piece burner assembly out of slots on sides of

burner box.

6. Remove the flame sensor from the burner assembly. See

Fig. 3.

7. Remove the orifices from the manifold and discard.

Содержание KGBPN4401VSP

Страница 1: ... 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 ed...

Страница 2: ...5 ORIFICE 45 1 340071 701 LABEL SHEET Includes 1 340071 201 CONVERSION RATING PLATE 1 340071 202 GAS CONTROL CONVERSION LABEL 1 340071 203 GAS CONTROL ADJUSTMENT LABEL 1 340071 204 CONVERSION RATING PLATE 1 340071 205 CONVERSION RESPONSIBILITY LABEL 1 340071 702 LABEL SHEET Includes 1 340071 206 CONVERSION RATING PLATE 1 340071 209 CONVERSION RATING PLATE Kit Contents Continued 1 340071 703 LABEL ...

Страница 3: ...CE SELECTION DERATE 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 See Fig 4 CAUTION BURNER ORIFICE BURNER ORIFICE A96249 Fig 4 Burner Orifice Determine natural gas orifice size and manifold pressures for correct input at inst...

Страница 4: ...3 3 6 0 55 43 3 7 0 60 875 44 3 6 0 60 44 3 7 0 60 43 3 4 0 55 43 3 5 0 55 4000 900 44 3 4 0 55 44 3 5 0 55 44 3 7 0 60 44 3 8 0 60 1219 925 44 3 2 0 50 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 950 45 3 7 0 60 44 3 2 0 50 44 3 3 0 55 44 3 4 0 55 750 42 3 3 0 50 42 3 4 0 55 42 3 5 0 55 42 3 6 0 55 4001 775 43 3 7 0 60 43 3 8 0 60 42 3 3 0 50 42 3 4 0 55 1220 800 43 3 5 0 55 43 3 6 0 60 43 3 7 0 60 43 3 ...

Страница 5: ...5 8000 775 44 3 3 0 55 44 3 4 0 55 44 3 5 0 55 44 3 7 0 60 2438 800 45 3 8 0 60 44 3 2 0 50 44 3 3 0 55 44 3 4 0 55 825 46 3 7 0 60 46 3 8 0 60 45 3 8 0 60 44 3 2 0 50 625 42 3 4 0 55 42 3 5 0 55 42 3 6 0 55 42 3 7 0 60 8001 650 43 3 8 0 60 42 3 2 0 50 42 3 3 0 55 42 3 4 0 55 2439 675 43 3 5 0 55 43 3 6 0 60 43 3 7 0 60 42 3 2 0 50 700 44 3 7 0 60 43 3 4 0 55 43 3 5 0 55 43 3 6 0 55 725 44 3 5 0 5...

Страница 6: ... 5 0 55 43 3 6 0 55 43 3 8 0 60 875 44 3 7 0 60 44 3 8 0 60 43 3 4 0 55 43 3 6 0 55 4000 900 44 3 5 0 55 44 3 6 0 55 44 3 7 0 60 43 3 4 0 55 1219 925 44 3 3 0 50 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 950 45 3 8 0 60 44 3 2 0 50 44 3 4 0 55 44 3 5 0 55 750 42 3 3 0 50 42 3 4 0 55 42 3 6 0 55 42 3 7 0 55 4001 775 43 3 8 0 60 42 3 2 0 50 42 3 3 0 50 42 3 4 0 55 1220 800 43 3 6 0 55 43 3 7 0 60 43 3 8 0...

Страница 7: ...3 3 5 0 55 43 3 6 0 55 43 3 8 0 60 42 3 2 0 50 675 44 3 8 0 60 43 3 4 0 55 43 3 5 0 55 43 3 6 0 55 10000 700 44 3 5 0 55 44 3 6 0 55 44 3 7 0 60 44 3 8 0 60 3048 725 44 3 3 0 50 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 Orifice numbers shown in BOLD are factory installed U S A Only to U S A Only to U S A Only to A11621B Furnace gas input rate on furnace rating plate is for installations at altitudes up ...

Страница 8: ...pane Jumper A11502 Fig 9 Removing Propane Jumper NOTE The Propane jumper for the modulating gas valve is very small Needle nose pliers are required to remove the jumper from the gas valve 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 Remove the small black plastic Propane jumper from th...

Страница 9: ... Tee and brass nipple from the gas valve inlet pressure tap See Fig 11 NOTE Use pipe dope approved for use with Propane gas 2 Apply pipe dope sparingly to the 1 8 in NPT pipe plug provided in kit and install in the 1 8 in tapped inlet pressure tap opening in the gas valve DO NOT over tighten Check for gas leaks after gas supply has been turned on INSTALL MANIFOLD 1 Align the orifices in the manifo...

Страница 10: ... Turn Setup Switch SW1 2 on furnace control ON see Fig 12 6 Jumper R W W1 and R W2 thermostat connections on control Model Plug Setup Switches SW1 1 thru 8 SW2 A C Air Flow Setup Switches AC 1 through AC 3 OAT PL9 A B C D PL4 HUM PL7 W2 Y1 DHUM SW4 SW2 SW3 Communication Connection 24 VAC HUM Output 0 5 AMP MAX SW3 Continuous Fan CF airflow setup switches CF 1 through CF 3 Outside Air Thermistor SW...

Страница 11: ...ral gas heat value and specific gravity in Table 3 or Table 4 depending on furnace gas input rate 5 Follow heat value line and specific gravity line to point of intersection to find orifice size and maximum and min imum manifold pressure settings Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft 610 M In the U S A the input rating for altitudes above 2000 ft 61...

Страница 12: ...t with straight run ducts 2 When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise 3 Allow the furnace to run for at least 10 minutes before checking Temperature Rise If the temperature rise is too high or too low in Minimum Heat 1 Remove jumpers from R and W W1 2 Wait until the blower off delay is completed 3 Turn 115 VAC ...

Страница 13: ...13 A13203 Fig 15 Conversion Responsibility Label A13201 Fig 16 Conversion Kit Rating Plate A13207 Fig 17 Gas Control Conversion Label ...

Страница 14: ...vous 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 ...

Страница 15: ...reen Yellow ground wire here Manifold Gas Valve Gas valve must be installed on manifold with minimum engagement of 6 threads Cross threading is not acceptable Indicated surfaces to be 90 or 2 C L Gas valve is parallel to manifold within or 3 A11407 Fig 19 2 Stage Gas Valve FLAME SENSOR BELOW BURNER FLAME ROLLOUT SWITCH BRACKET IGNITER IGNITER BURNER SUPT ASSY BURNER ASSY A11403 Fig 20 Burner Assem...

Страница 16: ...75 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 4000 900 44 3 4 1 4 44 3 5 1 5 44 3 7 1 5 44 3 8 1 6 1219 925 44 3 2 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 950 45 3 7 1 6 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 750 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 4001 775 43 3 7 1 6 43 3 8 1 6 42 3 3 1 4 42 3 4 1 4 1220 800 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 825 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1...

Страница 17: ...6 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 10000 700 44 3 4 1 4 44 3 5 1 5 44 3 7 1 5 44 3 8 1 6 3048 725 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 Orifice numbers shown in BOLD are factory installed to to to U S A Only U S A Only U S A Only A11252B Furnace gas input rate on furnace rating plate is for installations at altitudes up to 2000 ft 610 M In the U S A the input rating for altitudes above 2000 ...

Страница 18: ... 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 WARNING 1 Refer to Fig 25 2 Be sure gas and electrical supplies to furnace are off 3 Remove caps that conceal adjustment screws for high heat and low heat stage gas valve regulators See Fig 25 4 Remove the high heat and low heat regul...

Страница 19: ...nipple from the gas valve inlet pressure tap See Fig 27 NOTE Use pipe dope approved for use with Propane gas DO NOT use Teflon tape 2 Apply pipe dope sparingly to the 1 8 in NPT pipe plug provided in kit and install in the 1 8 in tapped inlet pressure tap opening in the gas valve DO NOT over tighten Check for gas leaks after gas supply has been turned on Brass Street Brass Nipple For larger casing...

Страница 20: ...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 A fire or explosion may result causing property damage personal injury or loss of life WARNING RISQUE D EXPLOSION ET D INCENDIE Le fait de ne pas suivre cet avertissement pourrait entra...

Страница 21: ...t rate NOTE When correct input is obtained main burner flame should be clear blue almost transparent see Fig 29 14 Jumper R W W1 and W2 on control center thermostat connections This keeps furnace locked in high heat oper ation 15 Adjust high heat manifold pressure for natural gas 16 Turn high heat adjusting screw counterclockwise out to decrease input rate or clockwise in to increase input rate 17...

Страница 22: ...22 A13203 Fig 30 Conversion Responsibility Label A13204 Fig 31 Conversion Kit Rating Plate A13207 Fig 32 Gas Control Conversion Label ...

Страница 23: ...xplosion 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 AVERTISSEMENT FIRE EXPLOSION...

Страница 24: ...manifold pressures for correct input at installed altitude by using Table 7 or 8 NOTE All models in all positions except Low NOx models in downflow and horizontal positions use Table 7 22 000 Btuh per burner Low NOx models in downflow or horizontal positions must use Table 8 21 000 Btuh per burner See input listed on rating plate 1 Obtain yearly heat value average at installed altitude for local g...

Страница 25: ...1 5 43 3 5 1 5 43 3 6 1 6 925 44 3 5 1 5 43 3 2 1 4 43 3 3 1 4 43 3 4 1 5 950 44 3 4 1 5 44 3 5 1 5 44 3 6 1 6 43 3 2 1 4 975 44 3 2 1 4 44 3 3 1 4 44 3 4 1 5 44 3 5 1 5 1000 45 3 7 1 6 45 3 8 1 7 44 3 2 1 4 44 3 4 1 5 ALTITUDE RANGE FT M AVG GAS HEAT VALUE BTUH CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low Ori...

Страница 26: ... 1 6 850 47 3 5 1 5 47 3 6 1 6 47 3 8 1 6 46 3 4 1 5 ALTITUDE RANGE AVG GAS HEAT VALUE AT ALTITUDE BTUH CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low USA 7001 to 8000 2134 to 2438 650 44 3 6 1 6 43 3 2 1 4 43 3 4 1 5 43 3 5 1 5 675 44 3...

Страница 27: ...3 4 1 6 44 3 5 1 7 43 3 2 1 5 43 3 3 1 6 925 44 3 2 1 5 44 3 3 1 6 44 3 5 1 6 44 3 6 1 7 950 45 3 7 1 8 45 3 8 1 8 44 3 3 1 6 44 3 4 1 6 975 46 3 7 1 8 46 3 8 1 8 45 3 8 1 8 44 3 2 1 5 1000 46 3 5 1 7 46 3 6 1 7 46 3 8 1 8 45 3 7 1 8 ALTITUDE RANGE FT M AVG GAS HEAT VALUE BTUH CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 Orifice No Manifold Pressure High Low Orifice No Manifold Pressu...

Страница 28: ...8 1 8 850 48 3 7 1 7 48 3 8 1 8 47 3 4 1 6 47 3 5 1 7 ALTITUDE RANGE FT M AVG GAS HEAT VALUE AT ALTITUDE BTUH CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low USA 7001 to 8000 2134 to 2438 650 44 3 3 1 6 44 3 4 1 6 44 3 5 1 7 43 3 2 1 5 67...

Страница 29: ...sembly 3 Insert one piece burner in slot on sides of burner box and slide burner back in place 4 Reattach HSI wires to HSI 5 Verify igniter to burner alignment 6 For Silicon Nitride igniters see Fig 38 and 39 7 For Silicon Carbide igniters see Fig 40 8 Re attach Flame Sensor wire to Flame Sensor 1 7 8 47 6 mm A05026 Fig 39 Igniter Position Top View A93347 Fig 40 Silicon Carbide Igniters CONVERT GA...

Страница 30: ...s at this time For E valves see Fig 42 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 42 3 Turn low heat stage adjusting screw 3 32 in 2 mm hex Allen screw counter clockwise outwards 1 full turn This will decrease the manifold pressure closer to the nat ural low heat set point 4 Turn hig...

Страница 31: ...ow wire and ground terminal to one of the manifold mounting screws 4 Install the remaining manifold mounting screws 5 Connect the wires to both rollout switches 6 Connect the wires to the flame sensor and hot surface ig niter 7 Connect the connector harness to gas valve 8 Rewire unit low pressure switch LPS as follows a Trace one of the orange wires previously disconnected from the LGPS back to th...

Страница 32: ... 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 WARNING 1 Be sure main gas and electric supplies to furnace are off 2 Remove 1 8 in NPT pipe plug from manifold pressure tap on downstream side of gas valv...

Страница 33: ... high heat ad justment to terminate call for heat 19 Turn setup switch SW1 2 on furnace control to OFF posi tion 20 Turn furnace gas valve switch to OFF position 21 Turn off furnace power supply 22 Remove manometer and re install manifold pressure tap plug 23 Turn furnace gas valve switch to ON position 24 Turn on furnace power supply 25 Set room thermostat to call for heat 26 Check pressure tap p...

Страница 34: ...208 Fig 49 Gas Control Adjustment Label Copyright 2013 CAC BDP D 7310 W Morris St D Indianapolis IN 46231 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No AG KGBPNVSP 01 Replaces AG KGAPNVSP 04 Edition Date 08 13 ...

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