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Carrier KGBPN4401VSP Installation Instructions Manual
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Carrier KGBPN4401VSP Installation Instructions Manual

Carrier KGBPN4401VSP Installation Instructions Manual

Gas conversion kit propane-to-natural for variable speed, condensing and non-condensing gas furnaces
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KGBPN4401VSP
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATION
WARNING
!
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
This conversion kit shall be installed by a qualified service
agency in accordance with the manufacturer's instructions
and all applicable codes and requirements of the authority
having jurisdiction. If the information in these instructions
is not followed exactly, a fire, explosion, or production of
carbon monoxide could result causing property damage,
personal injury, or loss of life. The qualified service agency
is responsible for the proper installation of this furnace with
this kit. The installation is not proper and complete until the
operation of the converted appliance is checked as specified
in the manufacturer's instructions supplied with the kit.
!
AVERTISSEMENT
LE FEU, L'EXPLOSION, CHOC ELECTRIQUE,
ET MONOXYDE DE CARBONE
EMPOISONNER
Cette trousse de conversion doit être installée par un servie
d'entretien qualifié, selon les instructions du fabricant et
selon toutes les exigences et tous les codes pertinents de
l'autorité compétente. Assurezvous de bien suivre les
instructions dans cette notice pour réduire au minimum le
risque d'incendie, d'explosion ou la production de
monoxyde de carbone pouvant causer des dommages
matériels, de blessure ou la mort. Le service d'entretien
qualifié est responsable de l'installation de cette trousse.
L'installation n'est pas adéquate ni complète tant que le bon
fonctionnement de l'appereil converti n'a pas été vérfié
selon les instructions du fabricant fornies avec la trousse.
Installing and servicing heating equipment can be hazardous due
to gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. Trained service

Installation Instructions

CERTIFIED
Gas Conversion Kit Propane---to---Natural for
Variable Speed, Condensing and
Non---Condensing Gas Furnaces
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
CAN/CSA- -B149.1 and .2. Wear safety glasses and work gloves.
Have a fire extinguisher available during start- -up, adjustment
steps, and service calls.
Recognize safety information. This is the safety- -alert symbol
. When you see this symbol on the furnace and in instructions
or manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION
and NOTE. The words DANGER, WARNING, and CAUTION
are used with the safety alert symbol. DANGER identifies the
most serious hazards which will result in severe personal injury or
death. WARNING signifies a hazard which could result in
personal injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or product
and property damage. NOTE is used to highlight suggestions
which will result in enhanced installation, reliability, or operation.
INTRODUCTION
WARNING
!
FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow instructions could result in personal injury,
death or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions, which
could result in personal injury or death. Consult your
distributor or branch for information or assistance. The
qualified
installer
or
factory- -authorized kits or accessories when servicing this
product.
WARNING
!
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD
Failure to follow this warning could result in personal
injury, death or property damage.
Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.
Codes
(NSCNGPIC),
agency
must
use
only

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Summary of Contents for Carrier KGBPN4401VSP

  • Page 1: Installation Instructions

    Gas Conversion Kit Propane---to---Natural for KGBPN4401VSP Variable Speed, Condensing and Non---Condensing Gas Furnaces Installation Instructions 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.

  • Page 2: Description And Usage

    This instruction covers the installation of gas conversion kit Part 2. Remove outer doors. No. KGBPN4401VSP to convert the following furnaces from 3. Disconnect power at external disconnect, fuse or circuit Propane gas usage to natural gas usage. See appropriate section breaker.
  • Page 3 HOT SURFACE IGNITER MANUAL RESET GAS BURNER ROLLOUT SWITCH FLAME SENSOR MANUAL RESET ROLLOUT SWITCH GAS VALVE MAIN LIMIT SWITCH (BEHIND GAS VALVE) OPERATING INSTRUCTIONS NOT SHOWN (LOCATED ON MAIN FURNACE DOOR, SEE OPERATING INSTRUCTIONS INSIDE DOOR FIGURE). INDUCER MOTOR ASSEMBLY ELECTRICAL JUNCTION BOX (IF REQUIRED,...
  • Page 4 Table 3 – Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate To be used with Modulating Furnaces EXCEPT 59MN7A060V21- -20 and 987MA60060V21 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
  • Page 5 Table 3 - - Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate (Continued) To be used with Modulating Furnaces EXCEPT 59MN7A060V21- -20 and 987MA60060V21 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE...
  • Page 6 Table 4 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate To Be Used with Modulating Furnaces 59MN7A060V21- -20 and 987MA60060V21 ONLY (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
  • Page 7 Table 4 - - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) To Be Used with Modulating Furnaces 59MN7A060V21- -20 and 987MA60060V21 ONLY (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE...
  • Page 8 Refer to Fig. 8 and 9. 1-1/4-in. (31.8) 2-1/2-in. (64.4) A11405 A11373 Fig. 6 - - Igniter Position - - Back View Fig. 8 - - Propane Jumper 2 − in. (50 mm) 3/8 − in. (9.6 mm) 3/16− in. (4.6 mm) A11502 3/32 −...
  • Page 9 Brass Street Tee Inlet Pressure Tap with Plug Black Iron Street 90 Pointing Low Gas Pressure Switch Brass Street Brass Street Tee Brass Nipple Low Gas Pressure Switch A11517 Inlet Pressure Tap with Fig. 11 - - LGPS for Casing Wider Than 14- -3/16 (360 mm) Brass Street 90 and Vent Does Not Pass Between Inducer and Burner Brass Hex Nipple...

  • Page 10: Check Inlet Gas Pressure

    CHECK INLET GAS PRESSURE CAUTION 24 VAC Outside Air Thermistor UNIT DAMAGE HAZARD HUM Output Failure to follow this caution may result in unit damage. (0.5 AMP SW3 Continuous Fan MAX) (CF) airflow setup DO NOT operate furnace more than one minute to check switches CF 1 through inlet gas pressure, as conversion is not complete at this time.

  • Page 11: Set Gas Input Rate

    5. Follow heat- -value line and specific- -gravity line to point AVERTISSEMENT of intersection to find orifice size and maximum and min- imum manifold pressure settings. RISQUE D’EXPLOSION ET D’INCENDIE Furnace gas input rate on rating plate is for installations at Le fait de ne pas suivre cet avertissement pourrait entraîner des altitudes up to 2000 ft.

  • Page 12: Label Application

    6. Turn furnace gas valve switch to ON position. If the temperature rise is too high or too low in Minimum Heat: 7. Turn Setup switch SW 1-2 to ON. 1. Remove jumpers from R and W/W1. 8. Verify Set-up switch SW 4-2 is turned OFF. 2.
  • Page 13 A13203 Fig. 15 - - Conversion Responsibility Label A13201 Fig. 16 - - Conversion Kit Rating Plate A13207 Fig. 17 - - Gas Control Conversion Label...

  • Page 14: Installation

    SECTION 2 WARNING Table 5 – Variable Speed Condensing Furnaces FIRE, EXPLOSION, ELECTRICAL SHOCK MODEL NUMBERS BEGINNING WITH: HAZARD 59TN6 986T Failure to follow this warning could result in personal 59TP6 926T injury, death or property damage. PG96V_T Gas supply MUST be shut off before disconnecting INSTALLATION electrical power and proceeding with conversion.
  • Page 15 MANIFOLD/ORIFICE/BURNER REMOVAL BURNER SUPT. ASSY IGNITER BRACKET, IGNITER CAUTION UNIT OPERATION HAZARD BURNER ASSY Failure to follow this caution may result in unit damage or improper operation. Label all wires prior to disconnection when servicing controls. FLAME ROLLOUT SWITCH PRUDENCE FLAME SENSOR (BELOW BURNER) A11403...
  • Page 16 Table 6 – Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64...
  • Page 17 Table 5 - - Orifice Size and Manifold Pressure (In.W.C.) for Gas Input Rate (Continued) TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62...
  • Page 18 WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death or property damage. Before installing, modifying, or servicing system, main 1-1/4-in. electrical disconnect switch must be in the OFF position and (31.8) 2-1/2-in.
  • Page 19 All 14 3/16-in (360 mm) Casings or Vent Passes Between wide casing, the switch may have been installed as follows. (See Fig 27.) Inducer Assembly and Burner Assembly 1. Remove low- -gas pressure switch, brass street 90_ elbow, If the vent pipe passes between the inducer and burner assembly, brass Hex nipple, brass Tee and brass nipple from the gas or the furnace is a 14 3/16-in.
  • Page 20 9. With a back-up wrench on the inlet boss of the gas valve, CHECK FURNACE AND MAKE ADJUSTMENTS finish tightening the gas pipe to the gas valve. WARNING 10. Turn gas on at electric switch on gas valve. CHECK INLET GAS PRESSURE FIRE AND EXPLOSION HAZARD CAUTION Failure to follow this warning could result in personal injury...
  • Page 21 Determine natural gas orifice size and manifold pressures for 17. Replace caps that conceal the gas valve regulator adjust- correct input at installed altitude by using Table 5. ment screws. 1. Obtain yearly heat- -value average (at installed altitude) for NOTE: When correct input is obtained, main burner flame local gas supply.
  • Page 22 A13203 Fig. 30 - - Conversion Responsibility Label A13204 Fig. 31 - - Conversion Kit Rating Plate A13207 Fig. 32 - - Gas Control Conversion Label...
  • Page 23 SECTION 3 WARNING Table 7 – Non- -condensing Furnaces FIRE, EXPLOSION, ELECTRICAL SHOCK MODEL NUMBERS BEGINNING WITH: HAZARD 58CTW 314AAV Failure to follow this warning could result in personal 58CVA 315AAV injury, death or property damage. 58CVX 315JAV PG8MVA PG8JVA Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.
  • Page 24 ORIFICE SELECTION/DERATE Clip, Harness Manifold Assy Sensor Flame CAUTION Burner Assy Burner Support Assy UNIT DAMAGE HAZARD Failure to follow this caution may result in unit damage. DO NOT re- -drill burner orifices. Improper drilling may Attach Green/Yellow result in burrs, out- -of- -round holes, etc. Obtain new orifices ground wire here if orifice size must be changed.
  • Page 25 Table 8 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Tabulated Data Based on 22,000 Btuh High- -Heat/14,500 Btuh for Low- -Heat per Burner, Derated 4 Percent for Each 1000 Ft. (305 M) Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG.
  • Page 26 Table 8 - - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con’t.) (Tabulated Data Based on 22,000 Btuh High- -Heat/14,500 Btuh for Low- -Heat per Burner, Derated 4 Percent for Each 1000 Ft. Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG.
  • Page 27 Table 9 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Tabulated Data Based on 21,000 Btuh High- -Heat/14,500 Btuh for Low- -Heat Per Burner, Derated 4 Percent for Each 1000 Ft. (305 M) Above Sea level) SPECIFIC GRAVITY OF NATURAL GAS AVG.
  • Page 28 Table 9 - - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con’t.) (Tabulated Data Based on 21,000 Btuh High- -Heat/14,500 Btuh for Low- -Heat Per Burner, Derated 4 Percent for Each 1000 Ft. (305 M) Above Sea level) SPECIFIC GRAVITY OF NATURAL GAS AVG.
  • Page 29 REMOVE MIXER SCREWS Each burner contains a mixer screw that must be removed. Refer to Fig. 37 for the mixer screw location. 1-7/8 (47.6 mm) 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.
  • Page 30 WARNING FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, death or property damage. Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion. WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION A05196 HAZARD Fig.
  • Page 31 NOTE: Use pipe dope approved for use with Propane gas. DO a. Trace one of the orange wires previously disconnected from the LGPS back to the NO terminals of the LPS. NOT use Teflon tape. b. Trace the other orange wire previously disconnected 3.
  • Page 32 NOTE: This kit is to be used only when inlet gas pressure is WARNING between 4.5-in. W.C. and 13.6-in. W.C. 1. Verify manometer is connected to inlet pressure tap on gas ELECTRICAL SHOCK, FIRE OR EXPLOSION valve. HAZARD 2. Turn on furnace power supply. Failure to follow this warning could result in personal 3.
  • Page 33 4. Turn on furnace power supply. 18. Remove jumper across R, W1, and W2 after high- -heat ad- justment to terminate call for heat. 5. Turn gas supply manual shutoff valve to ON position. 19. Turn setup switch SW1-2 on furnace control to OFF posi- 6.
  • Page 34 A13202 Fig. 47 - - Conversion Rating Plate Label A13207 Fig. 48 - - Gas Control Conversion Label A13208 Fig. 49 - - Gas Control Adjustment Label Edition Date: 08/13 Catalog No: AG ---KGBPNVSP---01 Copyright 2013 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.