Carrier KGAPN4401VSP 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. KGAPN4401VSP to convert the following furnaces from
Propane gas usage to natural gas usage. See appropriate section
for your furnace type.
Section 1--59MN7A & 987MA 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--59TN6A & 986TA 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 applies to 40,000 to 120,000 Btuh gas input rates.
Section 3--58CVA, 58CVX, 315AAV, 315JAV, 33.3-In. High,
Induced-Combustion, Hot-Surface Ignition, 2-Stage,
Variable-Speed, Non-Condensing Furnaces. This kit is designed
for use in furnaces with 42,000 through 154,000 Btuh gas input
rates.
DESCRIPTION AND USAGE
See Table 1 for kit contents. This kit is designed for use in the
furnaces listed in Tables 2, 4 and 6. 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 I - KGAPN4401VSP Contents
COMPONENT QTY DESCRIPTION
NUMBER
319965-450 1 PCS LABEL, SHIPPING
323267-701 1 PCS PARTS ASSY #42
323267-702 1 PCS PARTS ASSY #43
323267-703 1 PCS PARTS ASSY #44
323267-704 1 PCS PARTS ASSY #45
338305-701 1 PCS LABEL KIT
338305-702 1 PCS LABEL KIT
338305-703 1 PCS LABEL KIT
338305-704 1 PCS LABEL KIT
CA64ASO01 1 PCS PLUG, PIPE
AG- KGAPNVSP-01 1 PCS INSTRUCTIONS
EF39ZW037 2 PCS VALVE CVRSN KIT
SECTION 1
Table 2 - Condensing Furnaces
MODEL NUMBERS BEGINNING WITH:
59MN7A 987MA
INSTALLATION
1. Set room thermostat to lowest setting or "OFF".
2. Remove outer doors.
3. Disconnect power at external disconnect, fuse or circuit
breaker.
4. Turn off gas at external shut-off or gas meter.
5. Remove outer doors and set aside.
6. Turn electric switch on gas valve to OFF.
MANIFOLD/ORIFICE/BURNER REMOVAL
[]NIT 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 opOrations d'entretien des commandes, Otiqueter
tousles ills avant de les dOconnecter.
NOTE: Use a back-up wrench on the gas valve to prevent the
valve from rotating on the manifold or damaging the mounting to
the burner box.
1. Disconnect the gas pipe from gas valve and remove pipe
from the furnace casing. See Fig. 1.
2. Disconnect the connector harness from gas valve. Discon-
nect wires from Hot Surface Igniter (HSI) and Flame
Sensor. Disconnect the two wires from the low gas pres-
sure switch (LGPS) located on the gas valve.
3. Support the manifold and remove the 4 screws that secure
the manifold assembly to the burner box and set aside.
4. Note the location of the green/yellow wire ground wire for
re-assembly later. See Fig. 2.
5. Slide one-piece burner assembly out of slots on sides of
burner box.
6. Remove the flame sensor from the burner assembly. See
Fig. 3.
7. Remove the orifices from the manifold and discard.

HOTSURFACE
IGNITER MANUALRESET
GASBURNER i ROLLOUT SWITCH
i/
ELECTRICALJUNCTION
BOX(
Orifice
Connect Green/Yellow
ground wire here
J
Gas Valve
Manifold
REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY ]N APPEARANCE
Fig. 1 -Component Location
ORIFICE SELECTION/DERATE
/
[]NIT 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.)
Al1408
Gas valve is parallel to manifold ,'_:/
CLwithin + or - 3 j
Gas valve must be installed on
manifold with minimum engagement of
6 threads• Cross threading is not
acceptaMe.
Fig. 2 -Modulating Gas Valve with Orifices
Al1486
BURNER SUPT ASSY
BURNER_SY
'_"" FLA ME SENSOR
(BELOW BURNER)
IGNITER
TER
_ F_IME2OLLOU T
Al1403
Fig. 3 -Burner Assembly
A96249
Fig. 4 -Burner Orifice
Deternfine natural gas orifice size and manifold pressures 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 sup-
ply.
3. Find installation altitude in Table 3.
NOTE: 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 maximum and nfin-
imum manifold pressure settings.

Table 3- Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate
MODULATING FURNACE
(TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT /8,000 BTUH MIN-HEAT PER BURNER,
DERATED 2%H000 FT (305M) ABOVE SEA LEVEL)
ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS
RANGE HEAT VALUE 0.58 0.60 0.62 0.64
ft(m)
AT ALTITUDE Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press
No. Max/Min No. Max/Min No. Max/Min No. Max/Min
900 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55
r-
r-
o_
0
(o)
to
2000
(610)
925 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50
950 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.60 43 3.7 /0.60
975 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55 43 3.6 /0.55
1000 44 3.5 /0.55 44 3.6 /0.60 44 3.8 /0.60 43 3.4 /0.55
1025 44 3.3 /0.55 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60
1050 44 3.2 /0.50 44 3.3 /0.55 44 3.4/0.55 44 3.5 /0.55
1075 45 3.7 /0.60 45 3.8 /0.60 44 3.3 /0.50 44 3.4/0.55
1100 46 3.7 /0.60 46 3.8 /0.60 45 3.8 /0.60 44 3.2 /0.50
U.S.A. 800 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55 42 3.7 /0.60
r-
r-
2001 (611)
to
3000 (914)
Canada
2001 (611)
to
825 43 3.8 /0.60 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55
850 43 3.6 /0.60 43 3.7 /0.60 42 3.2 /0.50 42 3.3 /0.55
875 43 3.4 /0.55 43 3.5 /0.55 43 3.7 /0.60 43 3.8 /0.60
900 44 3.7 /0.60 44 3.8 /0.60 43 3.5 /0.55 43 3.6 /0.55
925 44 3.5 /0.55 44 3.6 /0.60 44 3.8 /0.60 43 3.4 /0.55
950 44 3.3 /0.55 44 3.4/0.55 44 3.6 /0.55 44 3.7 /0.60
975 44 3.2 /0.50 44 3.3 /0.50 44 3.4/0.55 44 3.5 /0.55
4500 (1372) 1000 46 3.8 /0.60 45 3.8 /0.60 44 3.2 /0.50 44 3.3 /0.55
775 42 3.3 /0.55 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.60
t-
O
3001
(915)
to
4000
800 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55
825 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50
850 44 3.8 /0.60 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60
875 44 3.6 /0.60 44 3.7 /0.60 43 3.4 /0.55 43 3.5 /0.55
900 44 3.4/0.55 44 3.5 /0.55 44 3.7 /0.60 44 3.8 /0.60
(1219) 925 44 3.2 /0.50 44 3.4/0.55 44 3.5 /0.55 44 3.6 /0.55
950 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.55 44 3.4/0.55
750 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55
o_
4001
(1220)
to
5000
775 43 3.7 /0.60 43 3.8 /0.60 42 3.3 /0.50 42 3.4 /0.55
800 43 3.5 /0.55 43 3.6 /0.60 43 3.7 /0.60 43 3.8 /0.60
825 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.60
850 44 3.5 /0.55 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55
875 44 3.3 /0.55 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60
(1524) 900 44 3.2 /0.50 44 3.3 /0.50 44 3.4/0.55 44 3.5 /0.55
925 46 3.8 /0.60 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.55
725 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55 42 3.5 /0.55
t-
O
5001
(1525)
to
6000
750 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55
775 43 3.4 /0.55 43 3.5 /0.55 43 3.7 /0.60 43 3.8 /0.60
800 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55
825 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60 44 3.8 /0.60
850 44 3.3 /0.50 44 3.4/0.55 44 3.5 /0.55 44 3.6 /0.60
(1829) 875 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.55 44 3.4/0.55
900 46 3.7 /0.60 46 3.8 /0.60 45 3.8 /0.60 4=.._4 3.2 /0.50
675 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.60 42 3.8 /0.60
6001
--_ (1830)
_ to
7000
700 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55
725 43 3.6 /0.60 43 3.7 /0.60 43 3.8 /0.60 42 3.3 /0.50
750 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60
775 44 3.6 /0.60 44 3.7 /0.60 43 3.4 /0.55 43 3.5 /0.55
800 44 3.4/0.55 44 3.5 /0.55 44 3.6 /0.60 44 3.7 /0.60
(2133) 825 44
850 46
3.2 /0.50 44 3.3 /0.55 44 3.4/0.55 44 3.5 /0.55
38/060 42._ 38/060 32/o.5o 33/o.5
Al1251A

Table 3 - Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate (Continued)
MODULATING FURNACE
(TABULATED DATA BASED ON 20,000 BTUH MAX.HEAT /8,000 BTUH MIN-HEAT PER BURNER,
DERATED 2°/o/1000 FT (305M) ABOVE SEA LEVEL)
ALTITUDE AVG. GAS
RANGE HEAT VALUE
AT ALTITUDE
ft (m) (Btu/cu if)
65O
7001 675
-->' (2134) 700
O 725
to 750
8000 775
(2438) 800
825
625
8001 650
>,
= (2439) 675
O
to 700
725
9000 750
__ 775
9001 600
SPECIFIC GRAVITY OF NATURAL GAS
0.58 0.60 0.62 0.64
Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press
No, Max/Min No, Max/Min No, Max/Min No, Max/Min
42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.60 42 3.7 /0.60
43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55
43 3.5 /0.55 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50
44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.60
44 3.5 /0.55 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55
44 3.3 /0.55 44 3.4 /0.55 44 3.5 /0.55 44 3.7 /0.60
45 3.8 /0.60 44 3.2 /0.50 44 3.3 /0.55 44 3.4 /0.55
46 3.7 /0.60 46 3.8 /0.60 45 3.8 /0.60 44 3.2 /0.50
42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55 42 3.7 /0.60
43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55
43 3.5 /0.55 43 3.6 /0.60 43 3.7 /0.60 42 3.2 /0.50
44 3.7 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55
44 3.5 /0.55 44 3.6 /0.60 44 3.7 /0.60 44 3.8 /0.60
44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55
45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55
42 3.3 /0.55 42 3.4 /0.55 42 3.6 /0.55 42 3.7 /0.60
-->' (2744) 625
O 650
_ to 875
10000 700
72. 5 44__ 3.2/0.50
* Orifice numbers shown in BOLD are factory-installed.
43 3.7 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55
43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60
44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55
44 3.4/0.55 44 3.5 /0.55 44 3.7 /0.60 44 3.8 /0.60
44__ 3.3/0.5 44 3.4/0.5 44 3.5/0.55
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 5percent 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.
REMOVE MIXER SCREWS FROM THE BURN-
ERS
NOTE: Each burner contains a mixer screw that must be
removed. Refer to Fig. 5 for the mixer screw location.
1. Remove the mixer screws from the burners.
NOTE: It is not necessary to plug the hole in the burner when
the mixer screws are removed.
Al1251B
1.9"
(48.76 mm)
t
1.8"
(46.96 mm) (\11
Location of mixer screw
..._hat must be removed
\\\\
A11501
Fig. 5 - 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. 6 and 7.
ql !
(64.4)
Fig. 6 - Igniter Position - Back View Al1405
Refer to Fig. 8 and 9.
Fig. 8-Propane Jumper
Al1373
Fig. 7 -Igniter Position - Side View
CONVERT GAS VALVE
Al1272
FIRE, EXPLOSION, ELECTRICALSHOCK
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 nmst 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.
Fig. 9- Removing Propane Jumper
A11502
NOTE: The Propane jumper for the modulating gas valve is
very small. Needle-nose pliers are required to remove the jumper
from the gas valve,
1. Locate the round "LP GAS" sticker on the top of the gas
valve.
2. Peel the sticker off and discard.
3, Note the small square opening in the top of the gas valve.
4, Remove the small black plastic Propane jumper from the
gas valve.
5, Cover the opening in the gas valve with the label marked
"NAT GAS"
REMOVE LOW GAS PRESSURE SWITCH
NOTE: There are 2 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 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. wide casing, the switch may have
been installed as follows. (See Fig 10.)
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 Fig 10.)

Brass Hex Nipple
A11367
Fig. 10 - LGPS for 14-3/16 Casing or When Vent Passes
Between Inducer and Burner Assembly
NOTE: Use pipe dope approved for use with Propane gas.
2. Apply pipe dope sparingly to the l/8-in. NPT pipe plug
(provided in kit) and install in the l/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.
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.
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 may have been installed as follows. (See Fig 11.)
Brass Street Tee
Inlet Pressure Tap
with Plug
NOTE: Use pipe dope approved for use with Propane gas.
2. Apply pipe dope sparingly to the l/8-in. NPT pipe plug
(provided in kit) and install in the l/8-in, tapped inlet-
pressure tap opening in the gas valve. DO NOT over-
tighten. Check for gas leaks after gas supply has been
turned on.
INSTALL MANIFOLD
1. Align the orifices in the 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.
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 yel-
low wire of the furnace wire harness. Disconnect and dis-
card 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 loca-
tion of wires.
NOTE: Use only Propane-resistant pipe dope, DO NOT use
Teflon tape.
8. 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.
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
Brass Street
Low Gas Pressure Switch Brass Nipple
Al1517
Fig. 11 -LgPS for Casing Wider Than 14-3/16 and Vent
Does Not Pass Between Inducer and Burner Assembly
1. Remove low gas pressure switch, brass street 90 ° elbow,
brass Hex nipple, brass Tee and brass nipple from the gas
valve inlet pressure tap. (See Fig 11.)
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.
NOTE: This kit is to be used only when inlet gas pressure is
between 4.5-in. wc 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,ELECTRICALSHOCK
HAZARD
Failureto 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
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.
4. Turn furnace gas valve switch to ON position.
5. Turn Setup Switch SW1-2 on furnace control ON (see
Fig. 12).
6. Jumper R-W/W1 and R-W2 thermostat connections on
control.
SW4
Outside Air Thermistor_
_ Cr_lntin U;_uSpFa n_
switches CF 1 through
CF 3
Communication
SW4
[]
_I=_ PLB
O_
connoc,on-
24 VAC
HUM Output
(O.5AMP
i
Setup Switches SWl,
1 thru 8
I_ SW3
Model Plug _ ___] _!:i [_]_
/,_ /_:21 _ W2 Yt DHUM
SW2
I
SW2 A/C Air Flow
Setup Switches
AC 1 through AC 3
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Fig. 12 -Furnace 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/WI 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 the 1/8-in. NPT pipe plug
and install in the l/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.
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
iniury or loss of life.
RISQUE D'EXPLOSION ET D'INCENDIE
Le fait de ne pas suivre cet avertissement pourrait entra_ner des
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
d6tection des fuites de gaz pour verifier tousles connections.
Un incendie ou une explosion peut entrainer des dommages
mat6riels, des blessures ou la mort.
1. Be sure main gas and electric supplies to furnace are off.
2. Remove l/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 Fig. 13.)
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/OFFSwitch MODULATING
[_Q_. Min/Max HeatAdust
/(Under Cap)
Inlet
PressureTa
Turn screw 1 click per
second to adjust rate.
Clockwise to increase
rate, counter clockwise
rate.
1/2"NPTOutlet
Manifold
PressureTap
Fig. 13 - Gas Valve
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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.

ThegasvalvemustbesetforMaxinmmHeatfirstandthen set
for Minimum Heat on Modulating furnaces.
Deternfine natural gas orifice size and manifold pressures for
correct input at installed altitude by using TaMe 3.
1. Obtain yearly heat-value average (at installed altitude) for
local gas supply.
2. Obtain yearly specific-gravity average for local gas sup-
ply.
3. Find installation altitude in TaMe 3.
NOTE: 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
TaMe 3.
5. Follow heat-value line and specific-gravity line to point
of intersection to find orifice size and maximum and nfin-
imum manifold pressure settings.
Furnace gas input rate on rating plate is for installations at
altitudes up to 2000 ft. (610 M).
In the U.S.A., the input rating for altitudes above 2000 ft. (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
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.
Burner Flame
Burner
Fig. 14 -Burner Flame
Al1461
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: 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/WI 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. (See Fig. 3.)
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.
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 thernmmeters DO NOT see heat
exchanger 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 nfinutes before
checking Temperature Rise.
If the temperature rise is too high or too low in Minimum Heat:
1. Remove jumpers from R and W/Wl.
2. Wait until the blower off delay is completed.

3.Turn115VACpoweroff.
4.Checkthepositionof HeatRiseAdjustmentSwitch
SWI-3.WhensettoON,airflowisraised18%higherfor
MinimumHeatandIntermediateHeat.Factorydefaultpo-
sitionisOFF.
5.Turn115VACpoweron.
6.JumperRtoW/WIandW2.
7.Afterburnersigniteandblowerstartsallowthefurnaceto
runforatleast10minutesbeforecheckingTemperature
Rise.
MaximumHeatTemperatureRise
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%j for Maximum Heat. Factory default pos-
ition 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 l/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.
LABEL APPLICATION
1. Fill in Conversion Responsibility Label 338305-205 and
apply to Blower Access Door of furnace as shown. (See
Fig. 15.) Date, name, and address of organization making
this conversion are required.
2. Attach Conversion Rating Plate Label 338305-201 to out-
er door of furnace, see Fig. 16.
3. Attach Gas Control Conversion Label 338305-202 to gas
valve. DO NOT use 338305-203, which is similar.
THiSFURNACEWASCONVERTED
ON TO NATURALGAS
(DAY-MONTH-YEAR)
KiT NO.: KGAPN4401VSP
BY:
(Name and address of organization making this conversion),
which accepts the responsibility that this conversion has
been properly made.
CEG#NERATEURD'AIRCHAUDA I_TI_
CONVERTILE POUR
(JOUR-bIOIS-ANNI_E)
DE L'ENSEIVlBLE N°.: KGAPN4401VSP
PAR:
(Nora et adresse de I'organisme qui a effectu6 la conversion),
qui accepte |' entri6re responsabilit6 de la conversion,
338305-205 REV. A
Fig. 15 - Conversion Responsibility Label
Al1504
CONVERSION KiT RATING PLATE - CARRIER CORPORATION
THIS APPLIANCE HAS BEEN CONVERTED TO USE NATURAL 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 In 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 (per chart below) for altitudes of 2000 ft, (610m) to 4500 ft. (1372m)
above sea level.
iT NO,: KGAPN4401VSP (SUPERSEDES: NONE)
USA CANADA
APPLIANCE % DERATE % DERATE
MODELS PER FOR
100O FT. 2000-4500 FT.
59MN7A 2% 5%
987MA
FUEL USED: NATURAL GAS
NATURAL GAS PRESSURE IN, W,C, (PO C.E,) P] PA
Max. Inlet Gas Pressure
(Press. Max. D'Admission De Gaz) 1 3.6
Min, Inlet Gas Pressure
(Press. Min. D'Admission De Gaz) 4,5 1,121
(For Purpose of input Adjustment) (Pour L'Adjustment D'Entree)
ALTITUDE High Heat 3,2 - 3.8
Manifold 0-2,000 ft. 797 - 946
Pressure (0 - 610 m) LOW Heat 1.4 - 1.8 349 - 448
Pression 2,000 - 10,000 ft. Refer to installation Manual
Tubulure (610 - 3050 m) Respecter es nstructon D']nsta]lation
338305-201 REV. A
This control has been converted far use with natural gas. )
Cette commande a et6 r6glee pour emploi avec le gaz _ J
naturel. 338305-202 REV.A
This control has been adjusted far use with propane gas. I_,_ "}
Ce eoontr61e a ete r6glee pour fonetionner au gaz propane, _,_|
330305-203 REV.A .)
Fig. 16 - Conversion Kit Rating Plate
Al1503
10