Carrier KGANP5201VSP Installation Instructions Manual

Gas convection kit natural-to-propane for variable speed, condensing and non-condensing gas furnace

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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.

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Summary of Contents for Carrier KGANP5201VSP

  • Page 1 Installation Instructions personnel must perform all other operations. When working 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...
  • Page 2 Table 1 - KGANP5201VSP Contents COMPONENT DESCRIPTION NUMBER ELECTRICAL S HOCK, F IRE OR EXPLOSION 616166-629 1 PCS CARTON HAZARD 319965-445 1 PCS LABEL, SHIPPING 320069-602 2 PCS TAPE Failure t o follow this warning could result in personal 326269-701...
  • Page 3 HOTSURFACE IGNITER MANUALRESET GASBURNER ROLLOUT SWITCH ELECTRICALJUNCTION BOX( REPRESENTATIVE DRAWING ONLY, SOME MODELS VARY IN APPEARANCE Al1408 Fig. 1 - Component Location MANIFOLD/ORIFICE/BURNER REMOVAL 3. Support the manifold and remove the 4 screws that secure the manifold assembly to the burner box and set aside. 4.
  • Page 4 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.
  • Page 5: Burner Assembly

    1337932-701] 2-in. (50 mm) CONTAINS: PART # DESCRIPTION 328456-402 BIT, DRILL FAJ5812B SCREW 3/16- (4.6 mm) REQUIRED FOR CONVERSION CONDENSING GAS FURNACE TO PROPANE GAS. /32 -in., +1/32 -3/64-in. (2.5 mm, +0.8-1.5) A12392 Fig. 9 - Igniter Position - Side View A11294 Fig.
  • Page 6: Fire And Explosion

    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.
  • Page 7: Inlet Gas Pressure

    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 Brass Street D'EQUIPEMENT D'OPERATION Toute erreur de cfiblage peut _tre une source de danger et de panne.
  • Page 8 RISQUE D'EXPLOSION ET D'INCENDIE 24 VAC Le fait de ne pas suivre cet avertissement pourrait entrai'nerdes Outside Air Thermistor_ HUM Output dommages corporels et / ou la mort. (O.5 AMP _[ SW4 Ne jamais examiner pour les fuites de gaz avec une flamme _/F_ Crflntin u;_2pFan_ vive.
  • Page 9 SET GAS INPUT RATE 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. UNIT DAMAGE HAZARD Failure to follow this caution result in gas valve...
  • Page 10: Label Application

    THiSFURNACEWAS CONVERTED CE GENC:RATEUR D'NR CHAUD A €:TI_ TO PROPANEGAS CONVERTiLE POUR (DAY-MONTH-YEAR) (JOUR-MOIS-ANNI_E) KiT NO.: KGANP5201VSP DE L'ENSEMBLE N°.: KGANP5201VSP PAR: (Name and address of organization making this conversion), (Nora et adresse I'organisme a effectu6 [a conversion),...
  • Page 11 SECTION Table 3 - Variable Speed Condensing Furnaces LE FEU, L'EXPLOSION, CHOC ELECTRIQUE, MODEL NUMBERS BEGINNING WITH: ET MONOXYDE DE CARBONE 59TN6 986T EMPOISONNER PG96V T Cette trousse de conversion doit _tre install_e par un servie INSTALLATION d'entretien qualifid, selon les instructions du fabricant et selon toutes les exigences et tous les codes pertinents de l'autorit_...
  • Page 12 HOTSURFACE _GNITER GASBURNER MANUALRESET ROLLOUT SW,TO, FLAME SENSOR ..MANUAL RESET LOUT SW_TCH VALVE OPERATING _NSTRUCT SHOWN (LOCATED MA_N FURNACE DOOR, OPERAT NSTRUCTIONS INSIDE DOOR F_GURE) ELEUTR_CAL JUNCTION REQUIRED LOCATION VARY) BLOWER DOOR SAFETY SW_TCH FURNACE CONTROL BOARD RATNG PLATE SHOWN (LOCATED BLOWER...
  • Page 13 2% for each 1000 ft. (305m) above sea meveL mnCanada the input rating must be derated by 5% for altitudes of 2000 ft. (610m) to 4.500ft. (1372m) above sea meveL FUELUSED: PROPANEGAS NLETPRESSURE(min-max): 11.0-13.61n.wc KiT NO.: KGANP5201VSP (SUPERSEDES: NONE) ALTITUDE OF iNSTALLATiON (FT. ABOVE SEA LEVEL) U.S.A.
  • Page 14: Gas Valve

    REINSTALL BURNER ASSEMBLY To reinstall burner assembly: 1. Attach flame sensor to burner assembly. ELECTRICAL SHOCK, FIRE EXPLOSION 2. Insert one-piece burner in slot on sides of burner box and HAZARD slide burner back in place. Failure to follow this warning could result in personal...
  • Page 15 (Ifthe vent pipe passes between the inducer and burner assembly, For larger casing when Vent Pipe does not pass across casing. All Sizes orthe furnace isa143/16-in. (360 ram) wide casing, install the switch contacts must point toward the Cell Panel. Black Iron Street...
  • Page 16 6. Jumper R-W/W1 and R-W2 thermostat connections control. 7. When main burners ignite, confirm inlet gas pressure D'EQUIPEMENT D'OPERATION between ll.0-in. W.C. and 13.6-in. W.C. 8. Remove jumper across R-W/WI and R-W2 thermostat Toute erreur de cfiblage peut _tre une source de danger et de connections to terminate call for heat.
  • Page 17 1.Be sure m ain g as and electric supplies to furnace are off. 12. Remove jumper across R, Wl, and W2 after high-heat justment to terminate call for heat. 2. Remove l/8-in. (3 ram) pipe plug from manifold pressure tap on downstream side of gas valve.
  • Page 18 SECTION Table 4 - Non-condensing Furnaces FIRE, EXPLOSION, ELECTRICAL SHOCK MODEL NUMBERS BEGINNING WITH: HAZARD 58CVA 315AAV 58CVX 315JAV Failure to follow this warning could result in personal iniury, death or property damage. PG8MVA PG8JVA supply MUST shut before disconnecting INSTALLATION electrical power...
  • Page 19 3. Squeeze the sides of the device, if necessary, to remove Clp, Harness from the heat exchanger. Burner Assy 4. Re-install screw in hole underneath heat exchanger inlet. NOTE: It is very IMPORTANT to reinstall the NOx bracket mounting screw. umer Support Assy...
  • Page 20 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.
  • Page 21 1-7/8 (47.6 mm) FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal iniury, death or property damage. supply MUST shut before disconnecting electrical power and proceeding with conversion. A05026 Fig. 41 - Igniter Position - Top View t¾2"...
  • Page 22 TWO-STAGE 9. With a back-up wrench on the inlet boss of the gas valve, finish tightening the gas pipe to the gas valve. ON/OFF 10. Turn gas on at electric switch on gas valve. Regulator Seal Cap INSTALL PRESSURE SWITCH Regulator Adjustment 1/2"NPT Regulator...
  • Page 23: Fire And Explosion Hazard

    7. Connect orange wire from Gas Pressure Switch to the terminal on the Low Heat Pressure Switch. 8. Route orange wires along wire harness. If possible, secure FIRE AND EXPLOSION HAZARD with wire tie provided in kit. Failure CHECK INLET PRESSURE to follow this warning...
  • Page 24: Set Gas Input Rate

    back-up w rench ontee when tightening gas inletpipe plug. (See F ig. 4 6.) ELECTRICAL SHOCK, FIRE EXPLOSION HAZARD 2" Brass Nipple Failure to follow this warning could result in personal Low Gas iniury, death or property damage. Pressure Switch Before installing, modifying,...
  • Page 25 TO PROPANEGAS CONVERTILE POUR (DAY-MONTH-YEAR) (JOUR-MOIS-ANNEE) KiT NO.: KGANP5201VSP DE L'ENSEMBLE N°.: KGANP5201VSP PAR: (Name and address of organization making this conversion), (Nora et adresse de ['organisme qui a effectu_, la conversion), which accepts the responsibRRy that this conversion qui accepte |' entri_re responsabRitO de la conversion.
  • Page 26 Copyright 2012 CAC / BDP • 7310 W. Morris St. • Indianapolis, IN 46231 Edition Date: 08/12 Catalo_ No: AG-KGANPVSP-04 Replaces: AG KGANPVSP Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,...

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