Carrier PG9YAA User manual

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KGANP45011HW
Installation Instructions
NATURAL GAS TO PROPANE
CONVERSION KIT
PG9YAA
SAFETY REQUIREMENTS
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 service personnel can perform basic maintenance
functions such as cleaning and replacing air filters. All other
operations must be performed by trained service personnel. When
working on heating equipment, observe precautions in the
literature, on tags, and on labels attached to or shipped with the
furnace and other safety precautions that may apply.
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) ANSI
Z223.1--2006/NFPA 54--2006. In Canada, refer to the National
Standard of Canada Natural Gas and Propane Installation Code
(NSCNGPIC) CAN/CGA--B149.1 and .2--M--05.
Wear safety glasses and work gloves. Have 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 instruction
manuals be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, or CAUTION.
These words are used with the safety--alert symbol. DANGER
identifies the most serious hazards, those that will result in severe
personal injury or death. WARNING signifies a hazard that could
result in personal injury or death. CAUTION is used to identify
unsafe practices that may result in minor personal injury or product
and property damage. Note is used to highlight suggestions that
will result in enhanced installation, reliability, or operation.
This conversion kit shall be installed by a qualified service agency.
Please read these instructions completely before attempting
installation. Consult gas supplier and tables in National Fuel Gas
Code NFPA 54/ANSI Z223.1, 2006 or latest edition. In Canada,
the National Standard CAN/CGA B149--1 and B149--2--05.
Parts List
Description Part # Qty.
Burner Orifice #55 1011354 5
Honeywell Conv. Kit #396221 1172953 1
Switch, Low Pressure (LGPS) 1008801 1
Fitting Assy. 1009775 1
Wire Assy. 1173071 1
Label, Field Conversion 1009678 1
Label, Propane Conversion 333681---101 1
Label, Derate 2505235 1
Instructions IIKKGANP4501---001 1
Orifices for High Altitude Conversion
(Refer to Table 1 -- for required orifice)
Description Part # Qty.
Burner Orifice #56 1011355 5
CERTIFIED
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FIRE, EXPLOSION, ELECTRIC SHOCK, AND
CARBON MONOXIDE HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
This conversion kit shall be installed by a qualified service
technician in accordance with the Manufacturer’s instructions
and all applicable codes and requirements of the authority
having jurisdiction. The qualified service agency is
responsible for the proper installation of 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.
!WARNING
General Information
This kit is for conversion of furnaces equipped with Honeywell
VR8205S Series 2--stage gas valves certified for use with Natural
Gas (and so marked) to units functionally the same as the certified
furnace for use with Propane Gas. Before the furnace can be
operated with Propane Gas, the Propane low pressure switch must
be installed. A gas valve conversion kit must be installed and main
burner orifices must be replaced with properly sized orifices.
The orifices provided in this kit are stamped to indicate the size
(twist drill number) and are sized for commercially pure propane
gas ONLY. Do NOT use them with butane or a mixture of butane
and propane gas. The parts list specifies the size orifices supplied in
the kit. Compare the size marking on the orifices with the sizes as
listed in the parts list. Make sure you have the correct main burner
orifices.
Extreme care is used to assure that this kit contains the proper
orifices. Oversized orifices could result in hazardous conditions,
especially if the venting is inadequate. For that reason, we
recommend that the installer check the size of the orifice with a
new twist drill of the correct size. This procedure assures that the
orifices provided are the correct size.
Installation
ELECTRIC SHOCK, FIRE, AND EXPLOSION
HAZARD
Failure to follow this warning could result in death, personal
injury, property damage and/or equipment damage.
Turn OFF gas supply at manual gas valve before turning OFF
electric power supply and starting conversion.
Turn OFF electric power supply at disconnect switch or
service panel before starting conversion.
!WARNING
Disassembly
A07838
Fig. 1 -- Disassembly
Refer to Fig. 1 and the following steps.
1. After disconnecting power and gas supply to the furnace,
remove the access door, exposing gas valve and burner
compartment.
2. Disconnect gas line from gas valve so manifold assembly
can be removed.
3. Disconnect wiring at gas valve. Be sure to note the proper
location of any and all electrical wiring disconnected.
4. Remove the screws holding the manifold and gas valve to
the manifold supports. Do not discard any screws.
5. Carefully remove the manifold assembly.
Main Burner Orifices
1. Remove the Natural gas burner orifices from the manifold
assembly and replace them with the appropriate Propane
(silver) orifices furnished in the conversion kit (Fig. 2),
unless converting a high altitude unit, then see Table 1 for
appropriate orifices.
A07839
Fig. 2 -- Remove Orifices
2. Tighten the orifices so they are seated and gas tight about
1--1/8″(28.6 mm) from the face of the orifice to the back of
the manifold pipe (Fig. 3). Make sure orifice is installed
straight so that it forms a right angle (90°) to the manifold.

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MANIFOLD PRESSURE AND ORIFICE SIZE FOR HIGH ALTITUDE APPLICATIONS
PROPANE GAS MANIFOLD PRESSURE (IN WC)
MEAN ELEVATION FEET ABOVE SEA LEVEL
HEATING VALUE AT
ALTITUDE BTU/CU. FT. 0 to 2000 2001 to 3000 3001 to 3999 4001 to 5000 5001 to 6000 6001 to 7000 7001 to 8000
2500 10.0 10.0 9.0 10.0 9.4 8.5 10
Orifice Size #55 #55 #55 #56 #56 #56 #56
NOTE: Propane data is based on 1.53 specific gravity. For fuels with different specific gravity consult the National Fuel Gas Code
ANSI Z223.1---2002/NFPA 54--- 2006 or National Standard of Canada, Natural Gas and Propane Installation Code CSA B149.1---05.
NOTE: Unshaded orifice size box indicates factory shipped size.
NOTE:In the USA, the input rating for altitudes above 2000′must be reduced by 4% for each 1000′abovesealevel(seeTable1)
In Canada, the input rating for altitudes above 2000′must be reduced by 10% for altitudes of 2000′to 4500′above sea level. Use the 2001 to 3000 column
Tabl e 1.
Table 1 – Manifold Pressure and Orifice Size
29.3
Measure from face of orifice
to the back side of the
manifold.
1.11
″
=(28.2mm)
1.21
″
=(30.8mm)
+1.5 mm
-1.1 mm
A07840
Fig. 3 -- Changing Orifices
High Altitude Installation
Gas input rate on furnace rating plate is for installation at altitudes
up to 2,000′(610 M). The #55 burner orifices supplied in this kit
are sized for propane gas at full rate only, for use between 0--2000′
(0 to 610 M) elevation. Do not use them above 2000’(610 M)
(except when noted by Table 1). Orifices for conversion at high
altitude are included in this kit.
In the USA, the input rating for altitudes above 2000′(610 M)
must be de--rated by 4% for each 1000′(305 M) above sea level
(see Table 1).
In Canada, the input rating for altitudes above 2000′(610 M) must
be reduced by 10% for altitudes of 2000′(610 M) to 4500′(1372
M) above sea level. Use the 2001 to 3000 (610 M to 914 M)
column in Table 1.
21/16(52.4)
5/16(8) 1/4(6.4)
A07735
Fig. 4 -- Igniter Location
Gas Valve Conversion
Conversion of Honeywell VR8205Q Gas Valve using Natural Gas
Conversion Kit #396221.
1. Remove the cap screw and pressure regulator adjusting
screw. (See Fig. 5 & Fig. 6)
2. Remove the existing regulator spring from the regulator
housing.
3. Insert the replacement spring (red color) contained in this
kit into the regulator housing.
4. Install the pressure regulator adjusting screw and give it el-
even (11) full clockwise turns. This will set the manifold
pressure close to required setting for normal operation.
5. Replace the regulator cap screw.
6. Attach the Yellow Attention Label contained in the kit to
the Gas Valve where it can be readily seen.
Regulator Adjustment
Under Cap
Inlet
Pressure
Tap
1
/
8
NPT
INLET
OUTLET
Outlet
Pressure
Tap
1
/
8
NPT
IN
OFF ON
HONEYWELL
A07843
Fig. 5 -- Typical Gas Control Valve
Spring
Pressure Reg. Adjust
Screw
Color
Code
Propane
Gas
Natural
Gas
Pressure
Regulator
Adjusting
Screw
Black Black
Spring Red Stainless
Steel
A07844
Fig. 6 -- Honeywell Gas Valve VR8205S

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Use elbows and 1
″
close nipple to connect valve
to piping when using right side gas pipe entry.
Alternative
installation
Right Side Entry
Manual shut- off
valve
Drip Leg
&Union#
1
″
close
nipple
# Union should be outside cabinet except when
clearances disallow, then it may be installed
inside the cabinet .
Manual shut- off valve MUST be upstream of dripleg, union, and
furnace.
Left Side Entry
LP Low Pressure
Switch Detail
A07842
Fig. 7 -- Typical Gas Piping and Adding Propane Low Pressure Switch
Propane Low Pressure Switch (Required)
1. Using pipe joint compound that is resistant to Propane gas,
tighten the fitting assembly into the inlet side of the gas
valve. (Fig. 7).Position fitting assembly as shown.
2. Screw the Propane pressure switch into the bushing. Use
pipe dope on connection. Tighten securely.
NOTE: Do not block inlet port of pressure switch with pipe dope.
Switch will not operate if inlet port is blocked.
3. Remove one yellow wire from the pressure switch.
Connect this wire to the male terminal of the insulated
yellow wire in the wire harness provided.
4. Connect the other yellow wire in the harness to the open
termination on the air pressure switch.
5. Connect the other end of the wire harness to the two
terminals on the Propane low pressure switch.
NOTE: Propane low pressure switch is factory set to open if
Propane gas supply pressure falls below 6 in w.c.
NOTE: See Furnace Wiring Label to confirm wiring.
Reassembly
Reassemble all parts in reverse order as removed. Attach Propane
Conversion Label next to the furnace rating plate or to the front
exterior of the furnace.
SManifold Assembly -- Be sure to engage the main burner
orifices in the proper openings in the burners.
SVerify the igniter is in the correct location. (See Fig. 4).
STesting for leaks -- After reassembly, turn the gas on and check
all joints for gas leaks using a soapy solution. All leaks must be
repaired immediately.
Gas Pressure
SRefer to the furnace rating plate for the approved gas input
ratings.
SGas input to burners MUST NOT exceed the rated input shown
on rating plate.
SDo NOT allow minimum gas supply pressure to vary
downward. Doing so will decrease input to furnace. Refer to
Table 2 for gas supply and manifold pressures.
Gas Pressures
Gas
Type
Supply Pressure
Manifold
Pressure
Recom-
mended Max. Min.
Propane 11″
(2.7kPa)
14″
(3.5kPa)
11″
(2.7kPa)
10″*
(2.5kPa)
*SEE TABLE 1
Important Notes
•With Propane gas, the rated input is obtained when
the BTU content is 2,500 BTU per cubic foot and
manifold pressure set at 10 in wc.
•If Propane gas has a different BTU content,orifices
MUST be changed by licensed Propane installer.
•Measured input can NOT exceed rated input.
•Any major change in gas flow requires changing
burner orifice size.
Table2–GasPressures(inwc)

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Start--up and Check--out
1. Remove the plug from the Inlet Pressure Tap on gas valve
and install a manometer. (Fig. 5)
2. Open manual gas line valve to unit. Check for gas leaks
and correct as necessary. Check supply pressure, 11 in wc
recommended, (11 in wc minimum, 14 in wc maximum).
If not within these limitations DO NOT OPERATE
FURNACE, contact gas supplier.
3. Close manual gas line valve to unit, remove manometer and
replace inlet pressure tap plug.
Gas Valve Adjustments
1. With the gas valve switch in the OFF position, remove the
pressure tap plug from the outlet end of the valve, and con-
nect a “U” tube manometer to the pressure port (See Fig. 5).
2. Turn the gas valve switch to the ON position and restore
electrical power to unit. Cycle the main burner on and off
several times to stabilize the pressure regulator diaphragm.
This MUST be done before an accurate pressure reading
can be obtained.
3. With the main burner on, read the manometer. For appro-
priate reading, see Table 1. Turn pressure regulator adjust-
ing screw clockwise to increase or counterclockwise to de-
crease manifold pressure. Burner Input must not exceed
nameplate rating. Refer to Section “Checking Input Rate”.
4. Turn gas valve to OFF. Remove the manometer and replace
the pressure tap plug and pressure regulator cap screw.
5. Start the main burners and check pressure tap plug for gas
leaks.
6. With gas valve on, observe furnace through two or more
complete cycles to be sure all controls are operating.
Checking Input Rate
*High Altitude Input Rate =
Nameplate Sea Level Input Rate x (Multiplier)
Elevation High Altitude Multiplier
Propane Gas*
0′- 2000′
(0 -- 610 M) 1.00
2001′- 3000′
(610 -- 914 M) 0.90
3001′- 4000′
(914 -- 1219 M) 0.86
4001′- 5000′
(1219 -- 1524 M) 0.82
5001′- 6000′
(1524 -- 1829 M) 0.78
6001′- 7000′
(1829 -- 2134 M) 0.74
7001′- 8000′
(2134 -- 2438 M) 0.70
* Ba s e d o n m i d --- r a n g e o f e l e v a t io n .
Table 3 – Input Rate Multiplier
Main Burner Flame Check
Check for the following: (See Fig. 8)
SStable and blue flames. Dust may cause orange tips or wisps of
yellow, but flames MUST NOT have solid, yellow tips.
SFlames extending directly from burner into heat exchanger.
SFlames do NOT touch sides of heat exchanger.
If any problems with main burner flames are noted, it may be
necessary to adjust gas pressures or check for drafts.
Burner Face
A07734
Fig. 8 -- Main Burner
High Altitude Derated Unit Label
The derated label supplied with the conversion kit must be
completed and affixed to the furnace near the rating plate. Fill in
the manifold pressure, orifice size and revised input rate.
Refer to Table 1 provided to determine the manifold pressure and
proper orifice part numbers.
Verify System Operation
Upon completion of all conversion procedures, perform the
following steps to attach the appropriate labels and verify the
system operation.
1. Locate the Propane Gas Conversion Label next to the
furnace rating plate.
2. Fill out and attach the Field Conversion Label to the front
exterior of the furnace.
3. Turn the thermostat to its lowest temperature setting or to
OFF if equipped with a System Select Switch.
4. Turn the gas switch to ON.
5. Reinstall all access panels.
6. Turn ON all electrical power to the unit.
7. Set the thermostat to the desired temperature and the System
Select Switch to HEAT.
8. Observe unit operation through two (2) complete heating
cycles. See “Sequence of Operation” in furnace intallation
instructions.

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Copyright 2007 CAC / BDP D7310 W. Morris St. DIndianapolis, IN 46231 Printed in U.S.A. Edition Date: 09/07
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
Catalog No: IIKKGANP4501---001
Replaces: NEW