Carrier KGBPN42011SP User manual

1
KGBPN42011SP
Installation Instructions
Gas Conversion Kit Propane-to-Natural for
1 Stage Condensing (90%+) and
Non-Condensing Gas Furnaces
40,000 BTUH to 140,000 BTUH Only
CERTIFIED
Read the entire instruction manual before starting the installation.
SAFETY CONSIDERATION
!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.
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
!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.

2
!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
flame roll−out, sooting or premature heat exchanger failure.
This instruction covers the installation of gas conversion to
convert the following furnaces from Propane gas usage to natural
gas usage. See appropriate section for your furnace type.
Section 1 −Models 59SC2, 59SP2, 59SC5, 59SE5, 59SP5,
912S, 915S, 922S, 925S, and PG92S are 4−Way Multipoise, Hot
Surface Ignition, Condensing Furnaces with 40,000 to 120,000
btuh gas input rates. Models 59SC5, 915S, and PG95S are
4−Way Multipoise, Hot Surface Ignition, Condensing Furnaces
with 40,000 to 140,000 btuh gas input rates.
Section 2 −Models 58DL, 58PH, 58ST, 310A, 310J, 311A, 311J,
313A, 313J, PG8MA, PG8JA, PG8ME, and PG8JE 33.3−Inch
High, Induced−Combustion, Hot−Surface Ignition, Single−Stage,
Non−Condensing 4−Way Multipoise Furnaces with 42,000 to
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 in Table 2 and Table 4. 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 NAHD00901NG Contents
COMPONENT
NUMBER QTY DESCRIPTION
EF39ZW037 1VALVE CVRSN KIT W/R SPRING 920935
323267-701 1PARTS ASSY #42
323267-702 1PARTS ASSY #43
323267-703 1PARTS ASSY #44
323267-704 1PARTS ASSY #45
339851-701 1LABEL KIT
339851-702 1LABEL KIT
319965-448 1 LABEL,SHIPPING
AG-KGBPN1SP-XX 1INSTR GAS CVRSN LP TO NAT
CA64AS001 1PLUG, PIPE
SECTION 1
CONDENSING FURNACES
Table 2 MODEL NUMBERS BEGINNING WITH:
59SC2 59SC5 59SE5 59SP2 59SP5
912S 915S 922S 925S
PG92S PG95S
* Except 26,000 BTUH models.
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.
MANIFOLD/ORIFICE/BURNER
REMOVAL
!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.
!PRUDENCE
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.
Figure 1 Representative Furnace Drawing
REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY IN APPEARANCE. A170154
RATING PLATE NOT SHOWN
(LOCATED ON BLOWER DOOR)
GAS VALVE
MAIN LIMIT SWITCH
(BEHIND GAS VALVE)
REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY IN APPEARANCE.
ELECTRICAL JUNCTION
BOX (IF REQUIRED,
LOCATION MAY VARY)
MEDIA CABINET
OPERATING INSTRUCTIONS
NOT SHOWN (LOCATED ON
MAIN FURNACE DOOR, SEE
OPERATING INSTRUCTIONS
INSIDE DOOR FIGURE).
FURNACE
CONTROL
BOARD
MANUAL RESET
ROLLOUT SWITCH
FLAME
SENSOR
MANUAL RESET
ROLLOUT SWITCH
GAS BURNER
HOT SURFACE
IGNITER
INDUCER MOTOR
ASSEMBLY
BLOWER AND
MOTOR
CAPACITOR/
POWER CHOKE
(IF USED)
BLOWER DOOR
SAFETY SWITCH
1. Disconnect the gas pipe from gas valve and remove pipe
from the furnace casing. See Figure 1.
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. See Figure 2 and Figure 3.

3
2. Disconnect the connector harness from gas valve.
Disconnect wires from Hot Surface Igniter (HSI) and Flame
Sensor. Disconnect the two wires from the Low Gas
Pressure Switch (LGPS) located on the gas valve.
3. Support the manifold and remove the four (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 Figure 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
Figure 3.
7. Remove the orifices from the manifold and discard.
Figure 2 Manifold Assembly
Orifice
Connect Green/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
Figure 3 Burner Assembly
FLAME SENSOR
(BELOW BURNER)
FLAME ROLLOUT
SWITCH
BRACKET, IGNITER
IGNITER
BURNER SUPT. ASSY
BURNER ASSY
A11403
ORIFICE SELECTION/DERATE
!CAUTION
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 Figure 4)
Figure 4 Burner Orifice
BURNER
ORIFICE BURNER
ORIFICE
A96249
Determine natural gas orifice size and manifold pressure for
correct input at installed altitude by using Table 3.
1. Obtain yearly heat−value average (at installed altitude) for
local gas supply.
2. Obtain yearly specific−gravity average for local gas supply.
3. Find installation altitude in Table 3.
For Canada altitudes of 2000 to 4500 ft., use U.S.A. Altitudes of
2001 to 3000 ft. in Table 3.
4. Find closest natural gas heat value and specific gravity in
Table 3.
5. Follow heat−value line and specific−gravity line to point of
intersection to find orifice size and manifold pressure
settings.
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 ft. (610 M)
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. to 4500 ft. (610 M to 1372 M) above sea
level.
The Conversion Kit Rating Plate accounts for high altitude
derate.
INSTALL ORIFICES
1. Install main burner orifices. DO NOT use Teflon tape.
Finger−tighten orifices at least one full turn to prevent
cross−threading, then tighten with wrench.
2. There are enough orifices in each kit for largest furnace.
Discard extra orifices.
DO NOT reinstall the manifold at this time.
REMOVE MIXER SCREWS FROM THE
BURNERS
Each burner contains a mixer screw that must be removed. Refer
to Figure 5 for the mixer screw location.
1. Remove the mixer screws from the burners.
It is not necessary to plug the hole in the burner when the mixer
screws are removed.
Figure 5 Mixer Screw Location
A11501
1.9”
(48.76 mm)
1.8”
(46.96 mm)
Location of mixer screw
that must be removed
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 Figure 6 &
Figure 7.

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Table 3 Orifice Size and Manifold Pressure (in.w.c.) for Gas Input Rate
SAGLARUTANFOYTIVARGCIFICEPSSAG.GVA
HEATVALUE0.580.600.620.64
AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold
(Btu/cu ft) No. Pressure No. Pressure No. Pressure No. Pressure
900 43 3.8 42 3.2 42 3.3 42 3.4
092543 3.6 43 3.7 43 3.8 42 3.2
(0) 950 43 3.4 43 3.5 43 3.6 43 3.7
975 44 3.7 44 3.8 43 3.4 43 3.6
to 1000 44 3.5 44 3.6 44 3.8 43 3.4
1025 44 3.3 44 3.5 44 3.6 44 3.7
2000 1050 44 3.2 44 3.3 44 3.4 44 3.5
(610) 1075 45 3.7 45 3.8 44 3.3 44 3.4
1100 46 3.7 46 3.8 45 3.8 44 3.2
U.S.A. 800 42 3.4 42 3.5 42 3.6 42 3.7
2001 (611) 825 43 3.8 42 3.3 42 3.4 42 3.5
to 850 43 3.6 43 3.7 42 3.2 42 3.3
3000 (914) 875 43 3.4 43 3.5 43 3.7 43 3.8
900 44 3.7 44 3.8 43 3.5 43 3.6
Canada 925 44 3.5 44 3.6 44 3.8 43 3.4
2001 (611) 950 44 3.3 44 3.4 44 3.6 44 3.7
to 975 44 3.2 44 3.3 44 3.4 44 3.5
4500 (1372) 1000 44 3.0 44 3.1 44 3.2 44 3.3
775 42 3.3 42 3.4 42 3.5 42 3.6
3001 800 43 3.8 42 3.2 42 3.3 42 3.4
(915) 825 43 3.6 43 3.7 43 3.8 42 3.2
850 44 3.8 43 3.5 43 3.6 43 3.7
875 44 3.6 44 3.7 43 3.4 43 3.5
4000 900 44 3.4 44 3.5 44 3.7 44 3.8
(1219) 925 44 3.2 44 3.4 44 3.5 44 3.6
950 44 3.1 44 3.2 44 3.3 44 3.4
750 42 3.3 42 3.4 42 3.5 42 3.6
4001 775 43 3.7 43 3.8 42 3.3 42 3.4
(1220) 800 43 3.5 43 3.6 43 3.7 43 3.8
825 44 3.8 43 3.4 43 3.5 43 3.6
850 44 3.5 44 3.7 44 3.8 43 3.4
5000 875 44 3.3 44 3.5 44 3.6 44 3.7
(1524) 900 44 3.2 44 3.3 44 3.4 44 3.5
925 44 3.0 44 3.1 44 3.2 44 3.3
725 42 3.2 42 3.3 42 3.4 42 3.5
5001 750 43 3.7 43 3.8 42 3.2 42 3.3
(1525) 775 43 3.4 43 3.5 43 3.7 43 3.8
800 44 3.7 44 3.8 43 3.4 43 3.5
825 44 3.5 44 3.6 44 3.7 44 3.8
6000 850 44 3.3 44 3.4 44 3.5 44 3.6
(1829) 875 44 3.1 44 3.2 44 3.3 44 3.4
900 44 2.9 44 3.0 44 3.1 44 3.2
675 42 3.4 42 3.5 42 3.6 42 3.8
6001 700 42 3.2 42 3.3 42 3.4 42 3.5
(1830) 725 43 3.6 43 3.7 43 3.8 42 3.3
750 43 3.4 43 3.5 43 3.6 43 3.7
775 44 3.6 44 3.7 43 3.4 43 3.5
7000 800 44 3.4 44 3.5 44 3.6 44 3.7
(2133) 825 44 3.2 44 3.3 44 3.4 44 3.5
850 44 3.0 44 3.1 44 3.2 44 3.3
to
to
to
to
ALTITUDE
RANGE
ft (m)
U.S.A. and Canada
SINGLE-STAGE FURNACE
(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL)
U.S.A. Only
U.S.A. Only
U.S.A. Only U.S.A. Only U.S.A. and Canada
A11253A

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Table 3 Orifice Size and Manifold Pressure (in.w.c.) for Gas Input Rate (cont.)
SAGLARUTANFOYTIVARGCIFICEPSSAG.GVA
HEATVALUE0.580.600.620.64
AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold
(Btu/cu ft) No. Pressure No. Pressure No. Pressure No. Pressure
ALTITUDE
RANGE
ft (m)
SINGLE-STAGE FURNACE
(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL)
650 42 3.4 42 3.5 42 3.6 42 3.7
7001 675 43 3.8 42 3.2 42 3.3 42 3.4
(2134) 700 43 3.5 43 3.7 43 3.8 42 3.2
725 44 3.8 43 3.4 43 3.5 43 3.6
750 44 3.5 44 3.7 44 3.8 43 3.4
8000 775 44 3.3 44 3.4 44 3.5 44 3.7
(2438) 800 44 3.1 44 3.2 44 3.3 44 3.4
825 44 2.9 44 3.0 44 3.1 44 3.2
625 42 3.4 42 3.5 42 3.6 42 3.7
8001 650 43 3.8 42 3.2 42 3.3 42 3.4
(2439) 675 43 3.5 43 3.6 43 3.7 42 3.2
700 44 3.7 43 3.4 43 3.5 43 3.6
725 44 3.5 44 3.6 44 3.7 44 3.8
9000 750 44 3.3 44 3.4 44 3.5 44 3.6
(2743) 775 44 3.0 44 3.2 44 3.3 44 3.4
9001 600 42 3.3 42 3.4 42 3.6 42 3.7
(2744) 625 43 3.7 42 3.2 42 3.3 42 3.4
650 43 3.5 43 3.6 43 3.7 43 3.8
675 44 3.7 44 3.8 43 3.4 43 3.5
10000 700 44 3.4 44 3.5 44 3.7 44 3.8
(3048) 725 44 3.2 44 3.3 44 3.4 44 3.5
* Orifice numbers shown in BOLD are factory-installed.
to
to
to
U.S.A. Only U.S.A. OnlyU.S.A. Only
A11253B
Figure 6 Igniter Position −Back View
A11405
2-1/2-in.
(64.4)
1-1/4-in.
(31.8)
Figure 7 Igniter Position −Side View
A12392
2−in.
(2.5 mm
3/8 −in.
3/16−in.
, +0.8 -1.5)
(50 mm)
(9.6 mm)
(4.6 mm)
3/32−in., +1/32 -3/64-in.
CONVERT GAS VALVE
!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 corrosion will occur leading to early heat
exchanger failure.
!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.
Do not use this kit if the gas valve in Figure 8 has a green label
on top of the valve. The green label on the gas valve is a special
low capacity gas valve. Refer to Specification Sheet for the
correct conversion kit.

6
!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.
Figure 8 Gas Valve (Single Stage) without Tower
Pressure Ports and Green Label
A13048
ON/OFF Switch
Regulator Seal Cap
Regulator Adjustment
Regulator Seal Cap under Cap
1/2”NPT Outlet
1/8”NPT Manifold
Pressure Tap
1/8”NPT Inlet
Pressure Tap
1/2”NPT Inlet
SINGLE-STAGE
Regulator Spring
Propane - White 8.5 turns
Natural Gas - Silver 8.5 turns
Regulator Adjustment
Screw
Regulator Seal Cap
Remove the propane regulator spring (white)
Install the natural gas regulator spring (silver)
Figure 8 (cont) −Gas Valve (Single Stage) with
Tower Pressure Ports and without the Green Label
ON/OFF SWITCH
1/8” NPT INLET
PRESSURE TAP
REGULATOR SEAL CAP
(REGULATOR ADJ.
UNDER CAP)
1/2” NPT
OUTLET
MANIFOLD PRESSURE TAP
SET SCREW: 3/32” HEX HEAD
ACCEPTS 5/16” HOSE CONNECTION
OUTP
INP
VENT
1/2” NPT
INLET
INLET PRESSURE
TAP SET SCREW:
3/32” HEX HEAD
ACCEPTS 5/16”
HOSE CONNECTION
Representative drawing only, some models may vary in appearance.
1/8” NPT
INLET PRESSURE TAP
1/2” NPT
INLET 1/2” NPT
OUTLET
Representative drawing only, some models may vary in appearance.
A170118
A170133
1. Refer to Figure 8.
2. Be sure gas and electrical supplies to furnace are off.
3. Remove cap that conceals the adjustment screw for the
gas−valve regulator. (See Figure 8)
4. Remove the regulator adjustment screw.
5. Remove the Propane regulator spring (white).
6. Install the natural gas regulator spring (silver).
7. Install the regulator adjustment screw.
8. Turn the adjusting screw clockwise (in) 8.5 full turns. This
will increase the manifold pressure closer to the natural
gas set point. (See Figure 8)
9. DO NOT install regulator seal cap at this time.
REMOVE LOW GAS PRESSURE
SWITCH
There are two ways that the Low Gas Pressure Switch (LGPS)
could have been installed during the original natural to Propane
gas conversion.
All 14 3/16-in Casings or Vent Passed Between Inducer
Assembly and Burner Assembly
If the vent pipe passes between the inducer and burner
assembly, or the furnace is a 14 3/16-in. wide casing. The switch
may be installed as shown in Figure 9.
1. Remove low gas pressure switch, brass street 90_elbow,
brass Hex nipple, brass tee and black iron street 90_
elbow from the gas valve inlet pressure tap. (See Figure 9)
Use pipe dope approved for use with Propane gas. DO NOT use
Teflon tape.
2. Apply pipe dope sparingly to the 1/8−in. (3 mm) 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.
Figure 9
LGPS for 14−3/16 Casing or when vent
passes between inducer and burner
assembly
Brass Street Tee
Brass Hex Nipple
Brass Street 90
Low Gas Pressure Switch
Black Iron Street 90 Pointing
Inlet Pressure Tap with Plug
A170141
(Optional inlet pressure
tap on some models)
!WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow 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.

7
!AVERTISSEMENT
RISQUE D’EXPLOSION ET D’INCENDIE
Le fait de ne pas suivre cet avertissement pourrait entraîner
des dommages corporels et / ou la mort.
Ne jamais examiner pour les fuites de gaz avec une flamme
vive. Utilisez plutôt un savon fait specifiquement pour la
détection des fuites de gaz pour verifier tous les connections.
Un incendie ou une explosion peut entrainer des dommages
matériels, des blessures ou la mort.
Casings Wider Than 14 3/16-in/Vent Does Not Pass Between
Inducer and Burner Assembly
If the vent pipe does not pass between the inducer and burner
assembly, or the furnace is wider than a 14 3/16-in. wide casing.
The switch maybe installed as shown in Figure 10.
1. Remove Low Gas Pressure Switch (LGPS), brass street
tee, brass nipple and brass street 90_elbow from the gas
valve inlet pressure tap. See Figure 10.
Use pipe dope approved for use with Propane gas. DO NOT use
Teflon tape.
2. Apply pipe dope sparingly to the 1/8−in. (3 mm) NPT pipe
plug (provided 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.
Figure 10
LGPS for casing wider than 14−3/16 and
vent does not pass between inducer and
burner assembly.
Brass Street 90
Brass Nipple
Low Gas Pressure Switch
Inlet Pressure Tap
Brass Street Tee
with plug
A170142
(Optional inlet
pressure
tap on some
models)
INSTALL MANIFOLD
1. Align the orifices in the manifold assembly with the support
rings on the end of the burner.
2. Insert the orifices in the support rings of the burners.
Manifold mounting tabs should fit flush against the burner
box.
If manifold does not fit flush against the burner box, the burners
are not fully seated forward. Remove the manifold and check
burner positioning in the burner box assembly.
3. Attach the green/yellow wire and ground terminal to one of
the manifold mounting screws. See Figure 2.
4. Install the remaining manifold mounting screws.
5. Connect the wires to the flame sensor and hot surface
igniter.
6. Connect the connector harness to gas valve.
7. Rewire unit low pressure switch (LPS) as follows:
a. Trace one of the orange wires previously disconnected
from the LGPS back to the NO terminals of the LPS.
b. Trace the other orange wire previously disconnected
from the LGPS back to its splice connection with the
yellow wire of the furnace wire harness. Disconnect
and discard this orange wire and the splice connection.
c. Connect the yellow wire of the furnace wire harness
(see “b” above) to the NO terminal of the LPS.
d. Refer to the furnace wiring diagram to ensure proper
location of wires.
Use only Propane-resistant pipe dope. DO NOT use Teflon tape.
8. Insert the gas pipe through the grommet in the casing.
Apply a thin layer of pipe dope to the threads of the pipe
and thread the pipe by into the gas valve.
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.
9. With a back-up wrench on the inlet boss of the gas valve,
finish tightening the gas pipe to the gas valve.
10. Turn gas on at electric switch on gas valve.
CHECK INLET GAS PRESSURE
!CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit damage.
DO NOT operate furnace more than one minute to check inlet
gas pressure, as conversion is not complete at this time.
This kit is to be used only when inlet gas pressure is between
4.5−in. w.c. and 13.6−in. w.c..
1. On some models, remove 1/8-in. (3 mm) pipe plug from
pressure tap on the inlet end of gas valve and insert
pressure tap. Or, on some models, loosen set screw on
inlet tower pressure tap no more than one full turn with the
3/32−in. hex wrench.
2. Verify manometer is connected to inlet pressure tap on gas
valve. (See Figure 8)
3. Turn on furnace power supply.
4. Turn gas supply manual shutoff valve to ON position.
!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.
!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.
5. Turn furnace gas valve switch to ON position.
6. Jumper R−W thermostat connections on control.
7. When main burners ignite, confirm inlet gas pressure is
between 4.5−in. w.c. and 13.6−in. w.c.
8. Remove jumper across R−W thermostat connections to
terminate call for heat.
9. Turn furnace gas valve switch to OFF position.

8
10. Turn gas supply manual shutoff valve to OFF position.
11. Turn off furnace power supply.
12. Remove manometer and on some models remove
pressure tap fitting.
13. On some models, apply pipe dope sparingly to the end of
inlet gas pipe plug and install into the unused end of
1/8−in. (3 mm) tee. Or, on some models, tighten set screw
on inlet tower pressure tap with a 3/32−in. hex wrench.
See Figure 8.
CHECK FURNACE AND MAKE
ADJUSTMENTS
!WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
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.
!AVERTISSEMENT
RISQUE D’EXPLOSION ET D’INCENDIE
Le non-respect des avertissements de sécurité pourrait
d’entraîner des blessures graves, la mort ou des dommages
matériels.
Ne jamais utiliser une flamme nue por vérifier la présence des
fuites de gaz. Pour la vérification de tous les joints, utiliser
plutôt une solution savonneuse commerciale fabriquée
spécifiquement pur la détection des fuites de gaz. Un incendie
ou une explosion peut entraîner des dommages matériels, des
blessures ou la mort.
1. Be sure main gas and electric supplies to furnace are off.
2. On some models, remove 1/8-in. (3 mm) NPT pipe plug
from manifold pressure tap on outlet end of gas valve. Or,
on some models, loosen set screw on manifold tower
pressure tap no more than one full turn with a 3/32−in. hex
wrench.
3. Attach manometer to manifold pressure tap on gas valve.
(See Figure 8)
4. Turn gas supply manual shutoff valve to ON position.
5. Turn furnace gas valve switch to ON position.
GAS INPUT RATE INFORMATION
See furnace rating plate on blower door for input rate. The input
rate for natural gas is determined by manifold pressure and
orifice size.
Determine natural gas orifice size and manifold pressure for
correct input at installed altitude by using Table 3.
1. Obtain yearly heat−value average (at installed altitude) for
local gas supply.
2. Obtain yearly specific−gravity average for local gas supply.
3. Find installation altitude in Table 3.
For Canada altitudes of 2000 to 4500 ft., use U.S.A. Altitudes of
2001 to 3000 ft. in Table 3.
4. Find closest natural gas heat value and specific gravity in
Table 3.
5. Follow heat−value line and specific−gravity line to point of
intersection to find orifice size and manifold pressure
setting.
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. (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
!WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow 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.
!AVERTISSEMENT
RISQUE D’EXPLOSION ET D’INCENDIE
Le fait de ne pas suivre cet avertissement pourrait entraîner
des dommages corporels et / ou la mort.
Ne jamais examiner pour les fuites de gaz avec une flamme
vive. Utilisez plutôt un savon fait specifiquement pour la
détection des fuites de gaz pour verifier tous les connections.
Un incendie ou une explosion peut entrainer des dommages
matériels, des blessures ou la mort.
1. Jumper R and W thermostat connections to call for heat.
(See Figure 13)
2. Check manifold orifices for gas leaks when main burners
ignite.
3. Adjust gas manifold pressure. Refer to Table 3.
4. Remove cap that conceals the gas valve regulator
adjustment screw.
5. Turn adjusting screw counterclockwise (out) to decrease
manifold pressure or clockwise (in) to increase manifold
pressure.
6. Replace gas valve regulator seal cap.
7. Verify manifold pressure is correct. Refer to Table 3.
Figure 11 Burner Flame
Burner Flame
Burner
Manifold
A11461
Gas valve regulator seal cap MUST be in place when checking
input rate. When correct input is obtained, main burner flame
should be clear blue, almost transparent (See Figure 11). Be
sure regulator seal cap is in place when finished.
8. Remove jumper across R and W thermostat connections
to terminate call for heat.
9. Turn furnace gas valve control switch or control knob to
OFF position.

9
10. Turn off furnace power supply.
11. Remove manometer and on some models remove
pressure tap fitting.
12. On some models, apply pipe dope sparingly to the end of
1/8−in. (3 mm) pipe plug and install in the manifold
pressure tap opening. Or, on some models, tighten set
screw on manifold tower pressure tap with a 3/32−in. hex
wrench. See Figure 8.
13. Turn furnace gas−valve switch to ON position.
14. Turn on furnace power supply.
15. Set room thermostat to call for heat.
16. Check pressure tap plug for gas leaks when main burners
ignite.
17. Check for correct burner flame.
18. After making the required manifold pressure adjustments,
check and adjust the furnace temperature rise per the
furnace installation instructions.
Figure 12 Conversion Rating Plate Label
A13070
LABEL APPLICATION
1. Fill in Conversion Responsibility Label 339851−205 and
apply over Propane Conversion Responsibility Label Date,
name, and address of organization making this conversion
are required. See Figure 26.
2. Apply Conversion Rating Plate Label 339851−201 over
Propane Conversion Rating Plate Label. See Figure 12.
3. Apply Gas Control Conversion Label over Propane label
on gas valve: For single−stage gas valve apply label
339851−202 to gas valve. (DO NOT use 339851−203,
which is similar) Check for correct normal operating
sequence of the ignition system as described in furnace
Service and Technical Support Manual.
CHECKOUT
1. Observe unit operation through two complete heating
cycles.
2. See Sequence of Operation in furnace Installation,
Start−Up, and Operating Instructions.
3. Set room thermostat to desired temperature.

10
Figure 13 Example of Single Stage Furnace Control for PSC Blower Motor
A11391
Representative drawing only, some models may vary in appearance.
TWINNING AND/OR
COMPONENT TEST
TERMINAL
PL1− LOW VOLTAGE MAIN
HARNESS CONNECTOR
TRANSFORMER 24VAC
CONNECTIONS
EAC TERMINAL
(115 VAC 1.0 AMP MAX.)
SEC-2
115−VAC (L2)
NEUTRAL
CONNECTIONS
24−V THERMOSTAT
TERMINALS
HUMIDIFIER TERMINAL
(24−VAC 0.5 AMP MAX)
3−AMP FUSE
LED
OPERATION &
DIAGNOSTIC
LIGHT
SEC-1
BLOWER SPEED
SELECTION TERMINALS
BL−1 PR-1
COM
HEAT
COOL
FAN
SPARE2
SPARE1
Y1 DHUM
BLOWER OFF-DELAY
120 180
90 150
24V MTR TAPS
115 VAC (L1)
INPUT
L1 IND
PL-2 HOT SURFACE
IGNITOR (HSI) &
INDUCER MOTOR
(IND) CONNECTOR
HUM
EAC-1
HSI
PL-2
PL1
EAC-2
Com 24V
L2
SECTION 2
NON−CONDENSING FURNACES
Table 4 MODEL NUMBERS BEGINNING WITH:
58DL 58PH58ST 310A310J311A
311J313A313JPG8MAPG8JA PG8ME
PG8JE
INSTALLATION
!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, 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.

11
!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 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.
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.
!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.
!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.
MANIFOLD/ORIFICE/BURNER
REMOVAL
!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.
!PRUDENCE
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.
Figure 14 80% Burner
A
ttach Green/Yellow
ground wire here
Manifold Assy Sensor Flame
Clip, Harness
Burner Assy
Burner Support Assy
Switch, Temp (2)
Ignitor
Bracket Ignitor
A11390
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. See Figure 14 & Figure 15.
1. Disconnect the gas pipe from gas valve and remove pipe
from the furnace casing. See Figure 16.
2. Disconnect the connector harness from gas valve
Disconnect wires from Hot Surface Igniter (HSI) and Flame
Sensor. Disconnect the two wires from the Low Gas
Pressure Switch (LGPS) located on the gas valve.
3. Support the manifold and remove the four (4) screws that
secure the manifold assembly to the burner box and set
aside.
Figure 15 80% Manifold
Gas Valve
Screw (2)
Attach Green/Yellow
ground wire here
Orifice
Manifold
A11395
4. Note the location of the green/yellow wire ground wire for
re-assembly later.
5. Remove wires from both rollout switches.
6. Slide one−piece burner assembly out of slots on sides of
burner box.
7. Remove the flame sensor from the burner assembly.
8. Remove the orifices from the manifold and discard.

12
NOx DEVICE INSTALLATION (when
required)
The following models must have NOx baffles installed (58PHX,
58PHY, 58DLX, 58STX, 313JAV, 313JBV, 311JAV, 310JAV,
PG8JEA, PG8JEB, and PG8JAA). NOx baffles are not included
in this kit and must be ordered separately or reused if retained
from original conversion to Propane.
For NOx device installation, follow these additional steps:
Figure 16 Representative Furnace Drawing
A03069
Representative drawing only, some models may vary in appearance.
9. Use a pair of needle nose pliers to install the NOx device.
10. Squeeze the sides of the device, if necessary, to install in
the heat exchanger.
11. Re-install screw in hole underneath heat exchanger inlet.
It is very IMPORTANT to reinstall the NOx bracket mounting
screw. (See Figure 17)
12. Repeat steps for each heat exchanger.
Figure 17 NOx Device Installation
A02195
ORIFICE SELECTION/DERATE
!CAUTION
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 Figure 18)
Figure 18 Burner Orifice
BURNER
ORIFICE BURNER
ORIFICE
A96249
Determine natural gas orifice size and manifold pressure for
correct input at installed altitude by using Table 5 or Table 6.
All models in all positions except Low NOx models in downflow
and horizontal positions use Table 5 (22,000 Btuh per burner).
Low NOx models in downflow or horizontal positions must use
Table 6 (21,000 Btuh per burner). See input listed on rating plate.
Use Table 5 (22,000 Btuh per burner) for models 58DLA, 58PHA,
58PHB, 58STA, 310AAV, 311AAV, 313AAV, 313ABV, PG8MAA,
and PG8MEA.
Use Table 6 (21,000 Btuh per burner) for Low NOx models
58DLX, 58PHX, 58PHY, 58STX, 310JAV, 311JAV, 313JAV,
313JBV, PG8JAA, PG8JEA, and PG8JEB.
1. Obtain yearly heat−value average (at installed altitude) for
local gas supply.
2. Obtain yearly specific−gravity average for local gas supply.
3. Find installation altitude in Table 5 or Table 6.
For Canada altitudes of 2000 to 4500 ft., use U.S.A. Altitudes of
2001 to 3000 ft. in Table 5 or Table 6.
4. Find closest natural gas heat value and specific gravity in
Table 5 or Table 6.
5. Follow heat−value line and specific−gravity line to point of
intersection to find orifice size and manifold pressure
setting.
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 ft. (610 M)
must be reduced by 4 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. to 4500 ft. (610 M to 1372 M) above sea
level.
The Conversion Kit Rating Plate accounts for high altitude
derate.
INSTALL ORIFICES
1. Install main burner orifices. DO NOT use Teflon tape.
Finger-tighten orifices at least one full turn to prevent
cross-threading, then tighten with wrench.
2. There are enough orifices in each kit for largest furnace.
Discard extra orifices.
DO NOT reinstall the manifold at this time.

13
Figure 19 Conversion Kit Rating Plate Label
A13071
Table 5 Orifice Size* and Manifold Pressure (in. w.c.) for Gas Input Rate
(Tabulated data based on 22,000 Btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)
ALTITUDE RANGE
FT. (M)
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT.)
SPECIFIC GRAVITY OF NATURAL GAS
0.58 0.60 0.62 0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
U.S.A. 0 to 2000
(0 to 610)
900 42 3.5 42 3.6 42 3.7 41 3.5
925 42 3.3 42 3.4 42 3.5 42 3.7
950 43 3.8 42 3.3 42 3.4 42 3.5
975 43 3.6 43 3.8 42 3.2 42 3.3
1000 43 3.5 43 3.6 43 3.7 43 3.8
1025 43 3.3 43 3.4 43 3.5 43 3.6
1050 44 3.6 43 3.2 43 3.4 43 3.5
1075 44 3.4 44 3.5 43 3.2 43 3.3
1100 44 3.3 44 3.4 44 3.5 43 3.2
U.S.A.
2001 to
3000 (610
to 914)
800 42 3.4 42 3.5 42 3.6 42 3.7
825 42 3.2 42 3.3 42 3.4 42 3.5
850 43 3.7 43 3.8 42 3.2 42 3.3
875 43 3.5 43 3.6 43 3.7 43 3.8
900 43 3.3 43 3.4 43 3.5 43 3.6
925 43 3.1 43 3.2 43 3.3 43 3.4
950 43 2.9 43 3.0 43 3.1 43 3.2
975 43 2.8 43 2.9 43 3.0 43 3.1
1000 43 2.6 43 2.7 43 2.8 43 2.9
U.S.A.
3001 to
4000
(914 to
1219)
775 42 3.2 42 3.3 42 3.4 42 3.5
800 43 3.6 43 3.8 42 3.2 42 3.3
825 43 3.4 43 3.5 43 3.7 43 3.8
850 43 3.2 43 3.3 43 3.4 43 3.6
875 43 3.0 43 3.1 43 3.3 43 3.4
900 43 2.9 43 3.0 43 3.1 43 3.2
925 43 2.7 43 2.8 43 2.9 43 3.0
950 43 2.6 43 2.7 43 2.8 43 2.8
U.S.A.
4001 to
5000
(1219 to
1524)
750 43 3.6 43 3.8 42 3.2 42 3.3
775 43 3.4 43 3.5 43 3.6 43 3.8
800 43 3.2 43 3.3 43 3.4 43 3.5
825 43 3.0 43 3.1 43 3.2 43 3.3
850 43 2.8 43 2.9 43 3.0 43 3.1
875 43 2.7 43 2.8 43 2.9 43 2.9
900 43 2.5 43 2.6 43 2.7 43 2.8
925 43 2.4 43 2.5 43 2.6 43 2.6
* Orifice number 43 is factory installed.

14
Table 5 Orifice Size* and Manifold Pressure (in. w.c.) for Gas Input Rate (Continued)
(Tabulated data based on 22,000 Btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)
ALTITUDE RANGE
FT. (M)
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT.)
SPECIFIC GRAVITY OF NATURAL GAS
0.58 0.60 0.62 0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
U.S.A.
5001 to
6000
(1524 to
1829)
725 43 3.4 43 3.5 43 3.6 43 3.7
750 43 3.2 43 3.3 43 3.4 43 3.5
775 43 3.0 43 3.1 43 3.2 43 3.3
800 43 2.8 43 2.9 43 3.0 43 3.1
825 43 2.6 43 2.7 43 2.8 43 2.9
850 43 2.5 43 2.5 43 2.6 43 2.7
875 43 2.3 43 2.4 43 2.5 43 2.6
900 43 2.2 43 2.3 43 2.3 43 2.4
U.S.A.
6001 to
7000
(1829 to
2134)
675 43 3.4 43 3.5 43 3.6 43 3.7
700 43 3.1 43 3.3 43 3.4 43 3.5
725 43 2.9 43 3.0 43 3.1 43 3.2
750 43 2.7 43 2.8 43 2.9 43 3.0
775 43 2.6 43 2.7 43 2.7 43 2.8
800 43 2.4 43 2.5 43 2.6 43 2.7
825 43 2.3 43 2.3 43 2.4 43 2.5
850 43 2.1 43 2.2 43 2.3 43 2.4
U.S.A.
7001 to
8000
(2134 to
2438)
650 43 3.1 43 3.2 43 3.4 43 3.5
675 43 2.9 43 3.0 43 3.1 43 3.2
700 43 2.7 43 2.8 43 2.9 43 3.0
725 43 2.5 43 2.6 43 2.7 43 2.8
750 43 2.4 43 2.4 43 2.5 43 2.6
775 43 2.2 43 2.3 43 2.4 43 2.4
800 43 2.1 43 2.1 43 2.2 43 2.3
825 48 3.7 43 2.0 43 2.1 43 2.2
U.S.A.
8001 to
9000
(2438 to
2743)
625 43 2.9 43 3.0 43 3.1 43 3.2
650 43 2.7 43 2.8 43 2.9 43 3.0
675 43 2.5 43 2.6 43 2.7 43 2.8
700 43 2.3 43 2.4 43 2.5 43 2.6
725 43 2.2 43 2.2 43 2.3 43 2.4
750 43 2.0 43 2.1 43 2.2 43 2.2
U.S.A.
9001 to
10,000
(2743 to
3048)
600 43 2.7 43 2.8 43 2.9 43 3.0
625 43 2.5 43 2.6 43 2.6 43 2.7
650 43 2.3 43 2.4 43 2.4 43 2.5
675 43 2.1 43 2.2 43 2.3 43 2.3
700 48 3.7 43 2.0 43 2.1 43 2.2
725 48 3.5 48 3.6 48 3.7 43 2.0
775 48 3.6 48 3.7 43 2.0 43 2.1
* Orifice number 43 is factory installed.

15
Table 6 Orifice Size* and Manifold Pressure (in. w.c.) for Gas Input Rate
(Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)
ALTITUDE RANGE
FT. (M)
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT.)
SPECIFIC GRAVITY OF NATURAL GAS
0.58 0.60 0.62 0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
U.S.A. 0 to 2000
(0 to 610)
900 42 3.2 42 3.3 42 3.4 42 3.5
925 43 3.7 43 3.8 42 3.2 42 3.3
950 43 3.5 43 3.6 43 3.7 43 3.8
975 43 3.3 43 3.4 43 3.5 43 3.7
1000 44 3.6 43 3.3 43 3.4 43 3.5
1025 44 3.4 44 3.6 43 3.2 43 3.3
1050 44 3.3 44 3.4 44 3.5 43 3.2
1075 45 3.8 44 3.2 44 3.3 44 3.4
1100 46 3.8 45 3.7 44 3.2 44 3.3
U.S.A.
2001 to
3000 (610
to 914)
800 43 3.8 42 3.2 42 3.3 42 3.4
825 43 3.5 43 3.7 43 3.8 42 3.2
850 43 3.3 43 3.5 43 3.6 43 3.7
875 43 3.2 43 3.3 43 3.4 43 3.5
900 43 3.0 43 3.1 43 3.2 43 3.3
925 43 2.8 43 2.9 43 3.0 43 3.1
950 43 2.7 43 2.8 43 2.9 43 2.9
975 43 2.5 43 2.6 43 2.7 43 2.8
1000 43 2.4 43 2.5 43 2.6 43 2.7
U.S.A.
3001 to
4000
(914 to
1219)
775 43 3.5 43 3.7 43 3.8 42 3.2
800 43 3.3 43 3.4 43 3.5 43 3.7
825 43 3.1 43 3.2 43 3.3 43 3.4
850 43 2.9 43 3.0 43 3.1 43 3.2
875 43 2.8 43 2.9 43 3.0 43 3.1
900 43 2.6 43 2.7 43 2.8 43 2.9
925 43 2.5 43 2.6 43 2.7 43 2.7
950 43 2.4 43 2.4 43 2.5 43 2.6
U.S.A.
4001 to
5000
(1219 to
1524)
750 43 3.3 43 3.4 43 3.5 43 3.6
775 43 3.1 43 3.2 43 3.3 43 3.4
800 43 2.9 43 3.0 43 3.1 43 3.2
825 43 2.7 43 2.8 43 2.9 43 3.0
850 43 2.6 43 2.7 43 2.8 43 2.8
875 43 2.4 43 2.5 43 2.6 43 2.7
900 43 2.3 43 2.4 43 2.5 43 2.5
925 43 2.2 43 2.2 43 2.3 43 2.4
U.S.A.
5001 to
6000
(1524 to
1829)
725 43 3.1 43 3.2 43 3.3 43 3.4
750 43 2.9 43 3.0 43 3.1 43 3.2
775 43 2.7 43 2.8 43 2.9 43 3.0
800 43 2.5 43 2.6 43 2.7 43 2.8
825 43 2.4 43 2.5 43 2.5 43 2.6
850 43 2.2 43 2.3 43 2.4 43 2.5
875 43 2.1 43 2.2 43 2.3 43 2.3
900 43 2.0 43 2.1 43 2.1 43 2.2
* Orifice number 43 is factory installed.

16
Table 6 Orifice Size* and Manifold Pressure (in. w.c.) for Gas Input Rate (Continued)
(Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level)
ALTITUDE RANGE
FT. (M)
AVG. GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT.)
SPECIFIC GRAVITY OF NATURAL GAS
0.58 0.60 0.62 0.64
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
U.S.A.
6001 to
7000
(1829 to
2134)
675 43 3.1 43 3.2 43 3.3 43 3.4
700 43 2.9 43 3.0 43 3.1 43 3.2
725 43 2.7 43 2.8 43 2.9 43 2.9
750 43 2.5 43 2.6 43 2.7 43 2.8
775 43 2.3 43 2.4 43 2.5 43 2.6
800 43 2.2 43 2.3 43 2.3 43 2.4
825 43 2.1 43 2.1 43 2.2 43 2.3
850 48 3.7 43 2.0 43 2.1 43 2.1
U.S.A.
7001 to
8000
(2134 to
2438)
650 43 2.9 43 3.0 43 3.1 43 3.2
675 43 2.7 43 2.7 43 2.8 43 2.9
700 43 2.5 43 2.6 43 2.6 43 2.7
725 43 2.3 43 2.4 43 2.5 43 2.5
750 43 2.1 43 2.2 43 2.3 43 2.4
775 43 2.0 43 2.1 43 2.2 43 2.2
800 48 3.6 48 3.7 43 2.0 43 2.1
825 48 3.3 48 3.5 48 3.6 48 3.7
U.S.A.
8001 to
9000
(2438 to
2743)
625 43 2.7 43 2.7 43 2.8 43 2.9
650 43 2.5 43 2.5 43 2.6 43 2.7
675 43 2.3 43 2.4 43 2.4 43 2.5
700 43 2.1 43 2.2 43 2.3 43 2.3
725 48 3.7 43 2.0 43 2.1 43 2.2
750 48 3.5 48 3.6 48 3.7 43 2.0
U.S.A.
9001 to
10,000
(2743 to
3048)
600 43 2.4 43 2.5 43 2.6 43 2.7
625 43 2.3 43 2.3 43 2.4 43 2.5
650 43 2.1 43 2.2 43 2.2 43 2.3
675 48 3.6 48 3.8 43 2.1 43 2.1
700 48 3.4 48 3.5 48 3.6 48 3.7
725 49 3.7 49 3.8 48 3.4 48 3.5
775 49 3.8 48 3.4 48 3.5 48 3.6
* Orifice number 43 is factory installed.
REMOVE MIXER SCREWS
Each burner contains a mixer screw that must be removed. Refer
to Figure 20 for the mixer screw location.
1. Remove the mixer screws from the burners.
It is not necessary to plug the hole in the burner when the mixer
screws are removed.
Figure 20 Mixer Screw Location
Location of mixer screw
that must be removed
A11501
REINSTALL BURNER ASSEMBLY
To reinstall burner assembly:
1. Attach flame sensor to burner assembly.
2. Install HSI and bracket to burner assembly.
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 Figure 21 and Figure 22.
7. For Silicon Carbide igniters, see Figure 23.
8. Reattach Flame sensor wire to Flame Sensor.

17
Figure 21 Igniter Position −Side View
9/32”
7.1mm
5/16”
7.9mm
A05025
Figure 22 Igniter Position −Top View
1-7/8
(47.6 mm)
A05026
Figure 23 Silicon Carbide Igniters
A93347
CONVERT GAS VALVE
!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 corrosion will occur leading to early heat
exchanger failure.
!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.
!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.
For J and G valves See Figure 24.
1. Be sure gas and electrical supplies to furnace are off.
2. Remove cap that conceals the adjustment screw for the
gas valve regulator. (See Figure 24)
3. Remove the regulator adjustment screw.
4. Remove the Propane gas regulator spring (white).
5. Install the natural gas regulator spring (silver).
6. Install the regulator adjustment screw.
7. Turn the adjusting screw clockwise (in) 8.5 full turns. This
will increase the manifold pressure closer to the natural
gas set point. (See Figure 24)
8. DO NOT install regulator seal cap at this time.
For E and F valves see Figure 24.
1. Be sure gas and electrical supplies to furnace are off.
2. Remove cap that conceals the adjustment screw for the
gas valve regulator. (See Figure 24)
3. Remove the regulator adjustment screw.
4. Remove the Propane gas regulator spring (white).
5. Install the natural gas regulator spring (silver).
6. Install the regulator adjustment screw.
7. Turn the adjusting screw clockwise (in) 10 full turns. This
will increase the manifold pressure closer to the natural
gas setpoint. (See Figure 24)
8. DO NOT install regulator seal cap at this time.

18
Figure 24 Single Stage Gas Valve
A13048
ON/OFF Switch
Regulator Seal Cap
Regulator Adjustment
Regulator Seal Cap under Cap
1/2”NPT Outlet
1/8”NPT Manifold
Pressure Tap
1/8”NPT Inlet
Pressure Tap
1/2”NPT Inlet
SINGLE-STAGE
Regulator Spring
Propane - White 8.5 turns
Natural Gas - Silver 8.5 turns
Regulator Adjustment
Screw
Regulator Seal Cap
Remove the propane regulator spring (white)
Install the natural gas regulator spring (silver)
A05071
Redundant Auto Gas Valve
A01073
Single−Solenoid Redundant Auto Gas Valve
REGULATOR SPRING
(PROPANE – WHITE, 6 TURNS
NATURAL – SILVER, 10 TURNS)
REGULATOR
ADJUSTMENT
SCREW
REGULATOR
SEAL CAP
GAS PRESSURE
REGULATOR
ADJUSTMENT
INLET
PRESSURE TAP
ON AND
OFF SWITCH
MANIFOLD
PRESSURE TAP
REMOVE LOW GAS PRESSURE
SWITCH
!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.
!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.
1. Be sure main gas and electric supplies to furnace are off.
2. Remove Low Gas Pressure Switch, brass tee and 2−in.
brass nipple from the gas valve inlet pressure tap. (See
Figure 25)
Use pipe dope approved for use with Propane gas. DO NOT use
Teflon tape.
3. Apply pipe dope sparingly to the 1/8−in. (3 mm) NPT pipe
plug (provided 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.
!WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
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.
!AVERTISSEMENT
RISQUE D’EXPLOSION ET D’INCENDIE
Le non-respect des avertissements de sécurité pourrait
d’entraîner des blessures graves, la mort ou des dommages
matériels.
Ne jamais utiliser une flamme nue por vérifier la présence des
fuites de gaz. Pour la vérification de tous les joints, utiliser
plutôt une solution savonneuse commerciale fabriquée
spécifiquement pur la détection des fuites de gaz. Un incendie
ou une explosion peut entraîner des dommages matériels, des
blessures ou la mort.

19
Figure 25 80% Low Gas Pressure Switch
L13F014
2” Brass Nipple
Low Gas
Pressure Switch
Female x Female x Male Tee
1/8” NPT Pipe Plug
For inlet pressure tap
Re−install pipe
plug after removal
INSTALL MANIFOLD
1. Refer to Figure 14 and Figure 15.
2. Align the orifices in the manifold assembly with the support
rings on the end of the burner.
3. Insert the orifices in the support rings of the burners.
Manifold mounting tabs should fit flush against the burner
box.
If manifold does not fit flush against the burner box, the burners
are not fully seated forward. Remove the manifold and check
burner positioning in the burner box assembly.
4. Attach the green/yellow wire and ground terminal to one of
the manifold mounting screws.
5. Install the remaining manifold mounting screws.
6. Connect the wires to the flame sensor and hot surface
igniter.
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 the NO terminals of the LPS.
b. Trace the other orange wire previously disconnected
from the LGPS back to its splice connection with the
yellow wire of the furnace wire harness. Disconnect
and discard this orange wire and the splice connection.
c. Connect the yellow wire of the furnace wire harness
(see “b” above) to the NO terminal of the LPS.
d. Refer to the furnace wiring diagram to ensure proper
location of wires.
Use only Propane-resistant pipe dope. DO NOT use Teflon tape.
9. Insert the gas pipe through the grommet in the casing.
Apply a thin layer of pipe dope to the threads of the pipe
and thread the pipe by into the gas valve.
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.
10. With a back-up wrench on the inlet boss of the gas valve,
finish tightening the gas pipe to the gas valve.
11. Turn gas on at electric switch on gas valve.
CHECK INLET GAS PRESSURE
!CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit damage.
DO NOT operate furnace more than one minute to check inlet
gas pressure, as conversion is not complete at this time.
This kit is to be used only when inlet gas pressure is between
4.5−in. w.c. and 13.6−in. w.c.
1. Verify manometer is connected to inlet pressure tap on gas
valve.
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. Jumper R−W thermostat connections on control.
6. When main burners ignite, confirm inlet gas pressure is
between 4.5−in. w.c. and 13.6−in. w.c.
7. Remove jumper across R−W thermostat connections to
terminate call for heat.
8. Turn furnace gas valve switch to OFF position.
9. Turn gas supply manual shutoff valve to OFF position.
10. Turn off furnace power supply.
11. Remove manometer.
12. Apply pipe dope sparingly to the 1/8 in. (3 mm) NPT pipe
plug 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.
CHECK FURNACE AND MAKE
ADJUSTMENTS
!WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow 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.
!AVERTISSEMENT
RISQUE D’EXPLOSION ET D’INCENDIE
Le fait de ne pas suivre cet avertissement pourrait entraîner
des dommages corporels et / ou la mort.
Ne jamais examiner pour les fuites de gaz avec une flamme
vive. Utilisez plutôt un savon fait specifiquement pour la
détection des fuites de gaz pour verifier tous les connections.
Un incendie ou une explosion peut entrainer des dommages
matériels, des blessures ou la mort.
!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.
!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.
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 valve.
3. Attach manometer to manifold pressure tap on gas valve.
See Figure 24.
4. Turn gas supply manual shutoff valve to ON position.

20
5. Turn furnace gas valve switch to ON position.
6. Check all threaded pipe connections for gas leaks.
7. Turn on furnace power supply.
GAS INPUT RATE INFORMATION
See furnace rating plate for input rate. The input rate for natural
gas is determined by manifold pressure and orifice size.
Determine natural gas orifice size and manifold pressure for
correct input at installed altitude by using Table 5 or Table 6.
All models in all positions except Low NOx models in downflow
and horizontal positions use Table 5 (22,000 Btuh per burner).
Low NOx models in downflow or horizontal positions must use
Table 6 (21,000 Btuh per burner). See input listed on rating plate.
1. Obtain yearly heat−value average (at installed altitude) for
local gas supply.
2. Obtain yearly specific−gravity average for local gas supply.
3. Find installation altitude in Table 5 or Table 6.
For Canada altitudes of 2000 to 4500 ft., use U.S.A. Altitudes of
2001 to 3000 ft. in Table 5 or Table 6.
4. Find closest natural gas heat value and specific gravity in
Table 5 or Table 6.
5. Follow heat−value line and specific−gravity line to point of
intersection to find orifice size and manifold pressure
setting.
The gas valve must be set for Low Heat first and then set for
High heat on two−stage and variable−speed furnaces. 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. (610M)
must be reduced by 4 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
1. Make sure the gas supply is turned off to the furnace and
at the electric switch on the gas valve.
2. Remove the 1/8 in. (3 mm) NPT plug from the outlet
pressure tap on the gas valve.
3. Connect a manometer to the outlet pressure tap on gas
valve.
4. Turn on furnace power supply.
5. Turn gas supply manual shutoff valve to ON position.
6. Turn furnace gas valve switch to ON position.
7. Jumper R and W thermostat connections to call for heat.
(See Figure 13)
8. Check manifold orifices for gas leaks when main burners
ignite.
9. Adjust gas manifold pressure. Refer to Table 5 or Table 6.
10. Remove cap that conceals the adjustment screw for the
gas valve regulator.
11. Turn adjusting screw counterclockwise (outwards) to
decrease manifold pressure or clockwise (inwards) to
increase manifold pressure.
Gas valve regulator seal cap MUST be in place when checking
input rate.
12. When correct input is obtained,main burner flame should
be clear blue, almost transparent. Be sure regulator seal
cap is in place when finished. See Figure 11.
13. Remove jumper across R and W thermostat connections
to terminate call for heat.
14. Turn furnace gas valve control switch or control knob to
OFF position.
15. Turn off furnace power supply.
16. Remove manometer and replace manifold pressure tap
plug.
Use Propane gas resistant pipe dope to prevent gas leaks. DO
NOT use Teflon tape.
17. Turn furnace gas valve control switch or control knob to
ON position.
18. Turn on furnace power supply. Set room thermostat to call
for heat.
19. Check manifold pressure tap plug for gas leaks when main
burners ignite.
CHECKOUT
1. Observe unit operation through two complete heating
cycles.
2. See Sequence of Operation in furnace Installation, Start−
up and Operating Instructions.
3. Set room thermostat to desired temperature.
After making the required manifold pressure adjustments, check
and adjust the furnace temperature rise per the furnace
installation instructions.
LABEL APPLICATION
1. Fill in Conversion Responsibility Label 339851−205 and
apply over Propane Conversion Responsibility Label.
Date, name, and address of organization making this
conversion are required. See Figure 26.
2. Apply Conversion Rating Plate Label 339851−204 over
Propane Conversion Rating Plate Label. See Figure 19.
3. Apply Gas Control Conversion Label over Propane Label
339851−202 to gas valve. (DO NOT use 339851−203,
which is similar.)
Figure 26 Conversion Responsibility Label
Copyright 2017 CAC / BDP D7310 W. Morris St. DIndianapolis, IN 46231
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
Catalog No: AG-KGBPN1SP-04
Replaces: AG−KGBPN1SP−03
Edition Date: 08/17