Carrier KGBPN42011SP Installation Instructions Manual
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Carrier KGBPN42011SP Installation Instructions Manual

Carrier KGBPN42011SP Installation Instructions Manual

Gas conversion kit propane-to-natural for 1 stage condensing (90%+) and non-condensing gas furnaces
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KGBPN42011SP
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
Gas Conversion Kit Propane---to---Natural for
Installation Instructions
CERTIFIED
1 Stage Condensing (90%+) 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 KGBPN42011SP

  • Page 1 Gas Conversion Kit Propane---to---Natural for 1 Stage Condensing (90%+) and KGBPN42011SP 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 breaker. No. KGBPN42011SP to convert the following furnaces from 4. Turn off gas at external shut- -off or gas meter. Propane gas usage to natural gas usage. See appropriate section 5.
  • 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 ORIFICE SELECTION/DERATE NOTE: It is not necessary to plug the hole in the burner when the mixer screws are removed. CAUTION UNIT DAMAGE HAZARD Location of mixer screw Failure to follow this caution may result in unit damage. that must be removed 1.9”...
  • Page 5 Table 3 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice Manifold Orifice...
  • Page 6 Table 3 - - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (cont.) SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice...
  • Page 7 Regulator Seal Cap AVERTISSEMENT Regulator Adjustment Screw RISQUE D’EXPLOSION ET D’INCENDIE SINGLE-STAGE Cet avertissement peut entraîner de la mort, des blessures et/ou Regulator Spring ON/OFF Switch des dégâts matériels. Propane - White 8.5 turns Natural Gas - Silver 8.5 turns 1/2”...

  • Page 8: Check Inlet Gas Pressure

    b. Trace the other orange wire previously disconnected 7. Remove jumper across R- -W thermostat connections to from the LGPS back to its splice connection with the yel- terminate call for heat. low wire of the furnace wire harness. Disconnect and dis- 8.

  • Page 9: Set Gas Input Rate

    Furnace gas input rate on rating plate is for installations at 15. Turn furnace gas valve control switch or control knob to altitudes up to 2000 ft. (610 M). OFF position. In the U.S.A.; the input rating for altitudes above 2000 ft. 16.

  • Page 10: Label Application

    LABEL APPLICATION 3. Apply Gas Control Conversion Label to gas valve: For single- -stage gas valve apply label 339851- -202 to gas 1. Fill in Conversion Responsibility Label 339851- -205 and valve. (DO NOT use 339851- -203, which is similar) apply to blower door of furnace as shown.

  • Page 11: Installation

    SECTION 2 WARNING Table 4 – Non- -condensing Furnaces FIRE, EXPLOSION, ELECTRICAL SHOCK 58DL 58PH 58ST 310A 310J 311A HAZARD 311J 313A 313J PG8MA PG8JA PG8ME Failure to follow this warning could result in personal PG8JE injury, death or property damage. INSTALLATION Gas supply MUST be shut off before disconnecting WARNING...
  • Page 12 2. Disconnect the connector harness from gas valve Discon- Clip, Harness Manifold Assy Sensor Flame nect wires from Hot Surface Igniter (HSI) and Flame Sensor. Disconnect the two wires from the Low Gas Pres- Burner Assy sure Switch (LGPS) located on the gas valve. 3.
  • Page 13 ORIFICE SELECTION/DERATE CAUTION 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. 19.) BURNER ORIFICE BURNER...
  • Page 14 Table 5 – Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Tabulated data based on 22,000 Btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level) SPECIFIC GRAVITY OF NATURAL GAS AVG. GAS 0.58 0.60 0.62...
  • Page 15 Table 5–Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) (Tabulated data based on 22,000 Btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level) SPECIFIC GRAVITY OF NATURAL GAS AVG. GAS ALTITUDE RANGE 0.58 0.60...
  • Page 16 Table 6 – Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level) SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG.
  • Page 17 Table 6—Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) (Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level) AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0.58...
  • Page 18 REINSTALL BURNER ASSEMBLY To reinstall burner assembly: 1. Attach flame sensor to burner assembly. 2. Install HSI and bracket to burner assembly. 3. Insert one-piece burner in slot on sides of burner box and slide burner back in place. 4. Reattach HSI wires to HSI. 5.
  • Page 19 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 electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one disconnect switch.
  • Page 20 1. Be sure main gas and electric supplies to furnace are off. 4. Attach the green/yellow wire and ground terminal to one of the manifold mounting screws. 2. Remove Low Gas Pressure Switch, brass tee and 2- -in. brass nipple from the gas valve inlet pressure tap. (See Fig. 5.
  • Page 21 CHECK FURNACE AND MAKE ADJUSTMENTS GAS INPUT RATE INFORMATION See furnace rating plate for input rate. The input rate for natural WARNING gas is determined by manifold pressure and orifice size. Determine natural gas orifice size and manifold pressure for correct input at installed altitude by using Table 5 or 6.
  • Page 22 NOTE: Gas valve regulator seal cap MUST be in place when CHECKOUT checking input rate. 1. Observe unit operation through 2 complete heating cycles. 12. When correct input is obtained,main burner flame should 2. See Sequence of Operation in furnace Installation, Start- - be clear blue, almost transparent.

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