Carrier KGANP5201VSP User manual

Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATION
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.
LE FEU, L'EXPLOSION, CHOC ELECTRIQUE,
ET MONOXYDE DE CARBONE
EMPOISONNER
Cette trousse de conversion doit 0tre install0e par un servie
d'entretien qualifiO, selon les instructions du fabricant et
selon routes les exigences et tousles codes pertinents de
l'autoritO compOtente. Assurezvous de bien suivre les
instructions dans cette notice pour rOduire au minimum le
risque d'incendie, d'explosion ou la production de
monoxyde de carbone pouvant causer des dommages
mat0riels, de blessure ou la mort. Le service d'entretien
qualifiO est responsable de l'installation de cette trousse.
L'installation n'est pas adOquate ni complOte rant que le bon
fonctionnement de l'appereil converti n'a pas Or0 vOrfiO
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-BI49.1 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 iniury.
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 iniury or
death. WARNING signifies a hazard which could result in
personal iniury or death. CAUTION is used to identify unsafe
practices which may result in minor personal iniury or product
and property damage. NOTE is used to highlight suggestions
which will result in enhanced installation, reliability, or operation.
INTRODUCTION
FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow instructions could result in personal iniury,
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 iniury 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.
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD
Failure to follow this warning could result in personal
iniury, death or property damage.
Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.

ELECTRICALSHOCK,FIREOR EXPLOSION
HAZARD
Failureto follow this warning could result in personal
iniury, 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.
This instruction covers the installation of gas conversion kit Part
No. KGANP5201VSP to convert the following furnaces from
natural gas usage to propane 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, 986T, & PG96V_T 4-Way Multipoise, Hot
Surface Ignition, 2-Stage, Variable-Speed Condensing Furnaces.
59TN6A applies to 60,000 to 120,000 Btuh gas input rates.
986TA & PG96VAT applies to 40,000 to 120,000 Btuh gas input
rates.
Section 3--58CVA, 58CVX, 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
This kit is designed for use in the furnaces listed below. See Table
1 for kit contents. To accommodate many different furnace
models, more parts are shipped in kit than will be needed to
complete conversion. When installation is complete, discard extra
parts.
Table 1 -KGANP5201VSP Contents
COMPONENT QTY DESCRIPTION
NUMBER
616166-629 1 PCS CARTON
319965-445 1 PCS LABEL, SHIPPING
320069-602 2 PCS TAPE
326269-701 1 PCS PARTS ASSY
326269-703 1 PCS PARTS ASSY
326269-704 1 PCS PARTS ASSY
326272-702 1 PCS PARTS ASSY
326751-702 1 PCS PARTS ASSY
367704-701 1 PCS LABEL KIT
367704-702 1 PCS LABEL KIT
367704-703 1 PCS LABEL KIT
367932-701 1 PCS BAG ASSY
367932-702 1 PCS BAG ASSY
337932-703 1 PCS BAG ASSY
AG- KGANPVSP-XX 1 PCS INSTRUCTIONS
EF69ZWO02 1 PCS VALVE CVRSN KIT
EF39ZW026 2 PCS VALVE CVRSN KIT
HKO2LBO08 1 PCS SWITCH, PRESSURE
W182X06- -04- -012 1 PCS WIRE ASSY
W182X26- -04- -018 2 PCS WIRE ASSY
W182X66- -04- -012 1 PCS WIRE ASSY
W182X66- -04- -018 1 PCS WIRE ASSY
W182Y66- - 11- -006 1 PCS WIRE ASSY
W182Y66-- 11--014 1 PCS WIRE ASSY
W182Y66- -26- -016 1 PCS WIRE ASSY
SECTION 1
Table 2 - Condensing Furnaces
MODELNUMBERS BEGINNINGWITH:
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.

HOTSURFACE
IGNITER MANUALRESET
GASBURNER i ROLLOUT SWITCH
i/
ELECTRICALJUNCTION
BOX(
REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY IN APPEARANCE
Fig. 1 - Component Location
Al1408
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.
D'EQUIPEMENT D'OPERATION
Toute erreur de cfiblage peut _tre une source de danger et de
panne.
Lors des op6rations d'entretien des commandes, 6tiqueter
tous les ills avant de les d6connecter.
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.
5. Slide one-piece burner assembly out of slots on sides of
burner box.
6. Remove the flame sensor from the burner assembly.
7. Remove the orifices from the manifold and discard.
Orifice
/
di
Connect Green/Yellow
ground wire here
Gas Valve
Manifold
©
/
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.
2. Disconnect the connector harness from gas valve. Discon-
nect wires from Hot Surface Igniter (HSI) and Flame
Sensor.
Gas valve is parallel to manifold " /
CLwithin + or - 3_ ,/' /"
/'_ I>/- ,"
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 _
A11486
Fig. 2 - Modulating Gas Valve with Orifices

BURNER SUPT ASSY IGNITER
BURNER ASSY
2_"'_ FLAM E SENSOR
(BELOW BURNER)
Fig. 3 -Burner Assembly
ORIFICE SELECTION/DERATE
BRACKET, IGNITER
/
_ FLAME ROLLOUT
SWITCH
A11403
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.)
A96249
Fig. 4 - Burner Orifice
Refer to conversion kit rating plate 337704-201 to determine
main burner orifice size. (See Fig. 5.)
Furnace gas input rate on furnace rating plate is for installations at
altitudes up to 2000 ft.
In the U.S.A.; the input rating for altitudes above 2000 ft. must be
reduced by 2 percent for each 1000 ft. above sea level.
In Canada, the input rating must be derated by 5 percent for
altitudes of 2000 ft. to 4500 ft. above sea level.
The Conversion Kit Rating Plate accounts for high altitude
derate.
INSTALL ORIFICES
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. There are enough
orifices in each kit for largest furnace. Discard extra orifices.
NOTE: DO NOT reinstall the manifold at this time.
INSTALL MIXER SCREWS
NOTE: There are 2 sets of mixer screws. One set is for
Condensing gas furnaces, the other set is for Non-condensing gas
furnaces. Use only the parts in the bag marked "REQUIRED
FOR THE CONVERSION OF CONDENSING GAS
FURNACES TO PROPANE GAS"
See Fig. 6 to verify you have the correct set of mixer screws.
1. Locate the dimple on each burner venturi tube. If you can-
not locate the dimple, refer to Fig. 7 for location of the
mixer screw.
2. Drill a 7/64-in. (2.8 ram) hole (supplied in kit) in each
dimple.
3. Install a mixer screw in each drilled hole drilling as
straight as possible. The screw head should be flush with
the top of the burner venturi.
CONVERSION KiT RATING PLATE - CARRIER CORP.
THiS APPLIANCE HAS BEEN CONVERTED TO USE PROPANE GAS FOR FUEL. REFER TO KIT iNSTRUCTiONS FOR CONVERSION
PROCEDURES. USE PARTS SUPPLIED BY CARRIER CORPORATION AND iNSTALLED BY QUALiFiED PERSONNEL.
SEE EXISTING RATING PLATE FOR APPLIANCE MODEL NO. AND iNPUT RATING.
NOTE: Furnace gas input rate on rating plate is for installations up to 2000 ft. (610m) above sea level Jn U,S,A, the input rating for altitudes above 2000 ft, (610m) must
be derated by 2% for each 1000 ft, (305m) above sea level in Canada the input rating must be derated by 5% for altitudes of 2000 ft, (610m) to 4500 ft, (1372m) above sea level,
KIT NO.: KGANP5201VSP FUELUSED: PROPANE GAS iNLET PRESSURE (rain - max): 11.0- 13.6 in.wc
ALTITUDE OF iNSTALLATION (FT. ABOVE SEA LEVEL) U.S.A. *
0 2001 *3001 4001 5001 6001 7001 8001 9001
to 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 to 9000 to 10000
0rificeNo. 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm 1.25mm
59MN7A Manifold Pressure
987MA MAX 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0
INT 5.8 515 5.5 5,5 5,4 5.4 5.4 5.3 5.3
MIN 2.2 2.1 2.1 2.1 2.1 2.0 2.0 2.0 2.0
APPLIANCE MODELS
* For Canadian Installationsfrom 2000 to 4500 ft. (610mto 1373m) useU.S.A. column 2001 to 3000 ft. (611mto 914m).
337704-201 REV.B
Fig. 5 - Conversion Kit Rating Plate 337704-201
A11295

1337932-701]
CONTAINS: QTY
PART # DESCRIPTION
328456-402 BIT, DRILL 1
FAJ5812B SCREW 7
REQUIRED FOR CONVERSION OF
CONDENSING GAS FURNACE TO
PROPANE GAS.
Fig. 6 -Gas Conversion Kit
A11294
2-in.
(50 mm)
3/16- in.
(4.6 mm)
_/32 -in., +1/32 -3/64-in.
(2.5 mm, +0.8-1.5)
A12392
Fig. 9 - Igniter Position - Side View
CONVERT GAS VALVE
1.9"
(48.76 mm)
1.8"
(46.96 ram)
Drill out with
J 7/64" drill bit
ii /
\\\\
A11460
Fig. 7 -Mixer Screw Location
REINSTALL BURNER ASSEMBLY
To reinstall burner assembly:
1. Attach flame sensor to burner assembly.
2. Insert one-piece burner in slot on sides of burner box and
slide burner back in place.
3. Reattach HSI wires to HSI.
4. Verify igniter to burner alignment. See Fig. 8 and 9.
, ,Oo
II I
-2-1/2-in.
(64.4)
Fig. 8 -Igniter Position -Top View
A11405
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD
Failure to follow this warning could result in personal
iniury, death or property damage.
Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow this warning could result in personal
iniury, 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.
Refer to Fig. 10 and 11.
Fig. 10 -Propane Jumper
A11373

>
A11375
Fig. 11 -Installing Propane Jumper
NOTE: The Propane jumper for the modulating gas valve is
very small. Needle-nose pliers are required to insert the jumper
into the valve. If the jumper is not installed, the valve will not
operate properly on propane.
1. Locate the round "NAT. GAS" sticker on the top of the
gas valve.
2. Peel the sticker off and discard.
3. Note the small square opening in the top of the gas valve.
4. Note the 2 jumper pins inside the modulating gas valve.
5. Remove the small black plastic propane jumper from the
envelope.
6. Use needle-nosed pliers to hold the jumper by the tab on
the end.
7. Insert the jumper on the pins inside the gas valve.
8. Cover the opening in the gas valve with the label marked
"LP GAS"
INSTALL LOW GAS PRESSURE SWITCH
NOTE: Install the Low Gas Pressure Switch before installing the
manifold on the burner assembly.
There are 2 ways to mount the Low Gas Pressure Switch.
All 14 3/16-in. (360 mm) Casings or Vent Passes 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. (360 ram) wide casing, install the
switch as follows (See Fig 12):
_';_l ...................2/,, ,/
with
Brass Street 90 " _ Brass Hex Nipple
A11367
Fig. 12 -LGPS for 14-3/16 (360 mm) Casing or When Vent
Passes Between Inducer and Burner Assembly
1. Remove the 1/8-in. NPT pipe plug from the gas valve inlet
pressure tap.
NOTE: Use pipe dope approved for use with Propane Gas.
NOTE: Tighten all fittings and the Low Gas Pressure Switch
with a small wrench. Do not over-tighten, check for gas leaks
after gas supply has been turned on.
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,
2. Apply pipe dope sparingly to the male threads of the
l/8-in, black iron street elbow. Install the street elbow into
the gas valve inlet pressure tap. Point the open end of the
street elbow toward you.
3. Apply pipe dope sparingly to the male threads of the
l/8-in, brass street tee. Install the male end of the street tee
as shown in Fig 12. One opening on the street tee should
face you. The other opening should be parallel with the
inlet of the gas valve.
4. Apply pipe dope sparingly to the male threads of the
l/8-in, brass hex nipple. Install the hex nipple into the
open end of the brass street tee. See Fig 12. The hex nipple
should be parallel with the boss on the gas valve.
5. Install the open end of the brass street elbow on the end of
the hex nipple. Tighten the street elbow so the male
threads of the elbow point away from you.
6. Apply pipe dope sparingly to the male threads of the
l/8-in, brass street elbow. Install the Low Gas Pressure
Switch on the male threads of the street elbow. Tighten
switch at hex fitting at base of switch. Do not use switch
body to tighten switch. Do not over-tighten switch.
7. The remaining opening on the brass street tee is the new
gas valve inlet pressure tap. Install manometer fitting to
the open end of the brass street tee. Or if installation is to
be completed later, apply pipe dope to inlet pressure plug
from gas valve and install in open end of brass street tee.
8. Check all fittings for leaks after gas supply has been
turned on.
Casings Wider Than 14 3/16-in. (360 mm) /Vent Does Not
Pass Between Inducer and Burner Assembly
1. If the vent pipe does not pass between the inducer and
burner assembly, or the furnace is wider than a 14 3/16-in.
(360 ram) wide casing, install the switch as follows (See
Fig 13):
2. Remove the l/8-in. NPT pipe plug from the gas valve inlet
pressure tap.
NOTE: Use pipe dope approved for use with Propane Gas.

For larger casing when Vent Pipe does not pass across casing. All Sizes
switch contacts must point toward the Cell Panel. Black Iron Street 90 can be
used at Valve Inlet instead of Brass Street 90.
Brass Street Tee
A11366
Fig. 13 -LGPS for Casing Wider Than 14-3/16 (360 mm)
and Vent Does Not Pass Between Inducer and Burner As-
sembly
INSTALL LOW GAS PRESSURE SWITCH WIRES
1. Locate the orange wire in the kit with an insulated straight
female spade terminal and an insulated straight male ter-
minal on the other end.
2. Connect the female terminal to a terminal on the Low Gas
Pressure Switch.
3. Locate the orange wire in kit with an insulated straight fe-
male spade terminal and an insulated female flag terminal
on the other end.
4. Connect both straight female terminals of the orange wires
to the ternfinals on the Low Gas Pressure Switch.
INSTALL MANIFOLD
1. Align the orifices in the manifold assembly with the sup-
port rings on the end of the burner.
2. Insert the orifices in the support rings of the burners. Man-
ifold mounting tabs should fit flush against the burner box
NOTE: 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.
4. Install the remaining manifold mounting screws.
5. Connect the wires to the flame sensor and hot surface ig-
niter.
6. Connect the connector harness to gas valve
NOTE: Use only propane-resistant pipe dope. Do not use Teflon
tape.
7. Insert the gas pipe through the grommet in the casing. Ap-
ply a thin layer of pipe dope to the threads of the pipe and
thread the pipe into the gas valve.
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.
8. With a back-up wrench on the inlet boss of the gas valve,
finish tightening the gas pipe to the gas valve.
9. Turn gas on at electric switch on gas valve.
MODIFY PRESSURE SWITCH WIRING
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.
D'EQUIPEMENT D'OPERATION
Toute erreur de cfiblage peut _tre une source de danger et de
panne.
Lors des op6rations d'entretien des commandes, 6tiqueter
tousles/ills avant de les d6connecter.
1. Disconnect orange wire from Low Pressure switch LPS on
inducer housing.
2. Connect the orange wire from the Low Pressure Switch to
the orange wire with the insulated male spade terminal.
3. Connect the orange wire from the Low Gas Pressure
Switch to the terminal on the Low Pressure Switch.
4. Route orange wires along wire harness. If possible, secure
with wire tie provided in kit.
CHECK INLET GAS PRESSURE
[]NIT 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.
NOTE: This kit is to be used only when inlet gas pressure is
between ll.0-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.
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD
Failure to follow this warning could result in personal
iniury, death or property damage.
Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow this warning could result in personal
iniury, 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.
4. Turn furnace gas valve switch to ON position.
5. Turn Setup Switch SWI-2 on furnace control ON (see
Fig. 14).
6. Jumper R-W/WI and R-W2 thermostat connections on
control.

SW4
Outside Air Thermistor_
_/F_ Crflntin u;_2pFan_
switches CF 1 through
CF 3
Communication
_[ SW4
[]
_I=_ PL9
O_
Connocton
24 VAC
HUM Output
(O.5 AMP
i
Setup Switches SWl,
1 thru 8
_t_ /_:21 _ W2 Yt DHUM
SW2
'1
SW2 A/C Air Flow
Setup Switches
AC 1 through AC 3
Fig. 14 - Furnace Control
Al1471
7. When main burners ignite, confirm inlet gas pressure is
between 11.0-in. W.C. and 13.6-in. W.C.
8. Remove jumper across R-W/W1 and R-W2 thermostat
connections to terminate call for heat.
9. Turn furnace gas valve switch to OFF position.
10. Turn gas supply manual shutoff valve to OFF position.
11. Turn off furnace power supply.
12. Remove manometer.
13. Apply pipe dope sparingly to end of inlet gas pipe plug
and install into unused end of 1/8 in. tee. Use a small
back-up wrench on tee when tightening gas inlet pipe
plug. (See Fig. 13.)
CHECK FURNACE AND MAKE ADJUSTMENTS
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal iniury
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.
RISQUE D'EXPLOSION ET D'INCENDIE
Le fait de ne pas suivre cet avertissement pourraitentrai'nerdes
dommages corporels et /ou la mort.
Ne jamais examiner pour les fuites de gaz avec une flamme
vive. Utilisez plut6t un savon fait specifiquement pour la
d_tection des fuites de gaz pour verifier tousles connections.
Un incendie ou une explosion peut entrainer des dommages
matdriels, des blessures ou la mort.
1. Be sure main gas and electric supplies to furnace are off.
2. Remove 1/8-in. (3 mm) pipe plug from manifold pressure
tap on downstream side of gas valve.
3. Attach manometer to manifold pressure tap on gas valve.
(see Fig. 15.)
4. Turn gas supply manual shutoff valve to ON position.
5. Turn furnace gas valve switch to ON position.
6. Check all threaded pipe connections for gas leaks.
7. Turn on furnace power supply.
ON/OFF Switch MODULATING
/
Min/Max Heat Adust
/(Under Cap)
Inlet
_Manifold
Pressure lap
Fig. 15 - Gas Valve
A10496
GAS INPUT RATE INFORMATION
The gas input rate for propane is the same as for natural gas. See
furnace rating plate on blower door for input rate. The input rate
for propane is determined by manifold pressure and orifice size.
The gas valve must be set for Maximum Heat first and then set
for Minimum heat on Modulating 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 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
@rate,

SET GAS INPUT RATE
UNIT DAMAGE HAZARD
Failure to follow this caution may result in gas valve
damage.
Do not force the rotary adjustment switch on the
modulating gas valve. Do not turn the rotary adjustment
switch faster than one click per second when adjusting
manifold pressure. Gas valve will be damaged if excessive
force is used on the rotary switch.
/_r ner Flame
__ _ Burnel
Al1461
Fig. 16 -Burner Flame
For proper operation and long term reliability, the manifold
pressure must be adjusted as specified on the conversion kit rating
plate.
The modulating furnace manifold pressure is set at two points.
The first point is Maximum Heat. The second point is Mininmm
Heat. Do not adjust Intermediate Heat manifold pressure.
Intermediate Heat manifold pressure can be checked as part of the
temperature rise, but is not adjustable. Always adjust Maximum
Heat first, then Minimum Heat.
NOTE: DO NOT set Maximum Heat manifold pressure less than
10.5-in. W.C. or more than 11-in. W.C. for propane gas.
NOTE: Use care when perfornfing adjustments. Gas valve
adjustment is performed by turning a rotary adjustment switch
inside the gas valve with a small straight blade screwdriver.
Excessive force can break or bend the rotary adjustment switch
making it non-adjustable.
To adjust manifold pressure to obtain input rate for Maximum
Heat:
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 inch 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. Turn Setup switch SW 1-2 to ON.
8. Verify Set-up switch SW 4-2 is turned OFF.
9. Jumper the R to W/W1 and W2 thermostat connections at
the furnace control board.
10. After the main burners ignite and the blower starts, con-
firm Maximum Heat manifold pressure is correct, based
on the manifold pressure table on the Conversion Kit Rat-
ing Plate.
11. To adjust the Maxinmm Heat manifold pressure, Slowly
turn the rotary adjustment switch counterclockwise to de-
crease manifold pressure or clockwise to increase manifold
pressure.
12. Turn rotary adjustment switch no more than one click per
second until you obtain the required manifold pressure.
>
A11451
Fig. 17 -Modulating Gas Valve Adjustment
Main burner flame should be clear blue, almost transparent.
To adjust manifold pressure to obtain input rate for Minimum
Heat:
1. Remove the jumper from W2 at the thermostat connec-
tions at the furnace control board control.
2. Wait until the burners and the blower transitions to Minim-
um Heat.
3. Verify the Minimum Heat manifold pressure is correct,
based on the manifold pressure table on Conversion Kit
Rating Plate.
4. To adjust the Minimum Heat manifold pressure, Slowly
turn the rotary adjustment switch counterclockwise to de-
crease manifold pressure or clockwise to increase manifold
pressure.
5. Turn rotary adjustment switch no more than one click per
second until you obtain the required manifold pressure.
This adjustment will not affect the previous Maximum
Heat adjustment.
After adjusting the manifold pressure, allow the furnace to
operate an additional 5 nfinutes before checking Minimum Heat
Temperature rise.
Furnace must operate within ranges of temperature rise specified
on the furnace rating plate. Deternfine air temperature rise as
follows:
1. Place thermometers in return and supply ducts as near fur-
nace as possible. Be sure thermometers do not see heat ex-
changer so that radiant heat does not affect readings. This
practice is particularly important with straight-run ducts.
2. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to deternfine 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 power off.
4. Check the position of Heat Rise Adjustment Switch
SW1-3. When set to ON, airflow is raised 18% higher for
Minimum Heat and Intermediate Heat. Factory default po-
sition is OFF.
5. Turn 115 VAC power on.
6. Jumper R to W/W1 and W2.

7. After burners ignite and blower starts allow the furnace to
run for at least 10 minutes before checking Temperature
Rise.
Maximum Heat Temperature Rise
If the temperature rise is too high or too low in Maximum Heat:
1. Remove jumpers from R, Wl and W2.
2. Wait until the blower off delay is completed.
3. Turn 115 VAC power off.
4. Check the position of the Efficiency/Comfort Adjustment
switch SWl-4. When set to OFF (Efficiency Mode), air-
flow is 10% higher for Minimum, 7.5% for Intermediate
Heat, and 17.5% for Maximum Heat. Factory default posi-
tion is ON (Comfort Mode).
5. Turn 115 VAC power on.
6. Re-check Minimum Heat Temperature Rise.
7. Remove jumpers across thermostat connections to termin-
ate the call for heat. Wait until the blower off delay is com-
pleted.
8. Turn gas supply manual shutoff valve to OFF position.
9. Turn off furnace power supply.
10. Remove manometer from the outlet pressure tap of the gas
valve.
11. Apply pipe dope sparingly to 1/8-in. NPT plug and re-in-
stall outlet pressure tap on the gas valve.
12. Re-install plastic cap over rotary adjustment switch on the
top of the gas valve.
CHECK LOW GAS PRESSURE SWITCH
The newly installed low gas pressure switch is a safety device
used to guard against adverse burner operating characteristics that
can result from low gas supply pressure. Switch opens at not less
than 6.5 in. W.C. and closes at not greater than 10.2 in. W.C.
This switch also prevents operation when the propane tank level
is low which can result in gas with a high concentration of
impurities, additives, and residues that have settled to the bottom
of the tank. Operation under these conditions can cause harm to
the heat exchanger system. This normally open switch closes
when gas is supplied to gas valve under normal operating
pressure. The closed switch completes control circuit. Should an
interruption or reduction in gas supply occur, the gas pressure at
switch drops below low gas pressure switch setting, and switch
opens. Any interruption in control circuit (in which low gas
pressure switch is wired) quickly closes gas valve and stops gas
flow to burners. When normal gas pressure is restored, the system
must be electrically reset to re-establish normal heating operation.
Before leaving installation, observe unit operation through 2
complete heating cycles. During this time, turn gas supply to gas
valve off just long enough to completely extinguish burner flame,
then instantly restore full gas supply. To ensure proper low gas
pressure switch operation, observe that there is no gas supply to
burners until after hot surface igniter begins glowing.
LABEL APPLICATION
1. Fill in Conversion Responsibility Label 337704-205 and
apply to Blower Access Door of furnace as shown. (See
Fig. 18. Date, name, and address of organization making
this conversion are required.
2. Attach Conversion Rating Plate Label 337704-201 to out-
er door of furnace., see Fig. 5.
3. Attach Gas Control Conversion Label 337704-202 to gas
valve. Do not use 337704-203, which is similar.
THiSFURNACEWASCONVERTED
ON TO PROPANEGAS
(DAY-MONTH-YEAR)
KiT NO.: KGANP5201VSP
BY:
(Name and address of organization making this conversion),
which accepts the responsibility that this conversion has
been properly made.
CE GENC:RATEURD'NR CHAUD A €:TI_
CONVERTiLE POUR
(JOUR-MOIS-ANNI_E)
DE L'ENSEMBLE N°.: KGANP5201VSP
PAR:
(Nora et adresse de I'organisme qui a effectu6 [a conversion),
qui accepte |' entrii.=re responsabilit6 de [a conversion,
337704-205 REV.B
Fig. 18 -Conversion Responsibility Label
Al1296
10