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Gas Conversion Kit
Propane-to-Natural for
Variable-Speed and
2-Speed Furnaces
NOTE: Read the entire instruction manual before starting the installation.
This symbol → indicates a change since the last issue.
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. All other operations must be performed
by trained service personnel. 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 National Fuel Gas Codes NFPA No. 54-1996/ANSI Z223.1-1996
(NFGC). In Canada, refer to the National Standard of Canada Natural Gas and Propane Gases Installation Codes, CAN/CGA-B149.1 and .2-M95
(NSCNGPIC).
Wear safety glasses and work gloves. Have a fire extinguisher available during start-up operation, adjustment procedures, and service calls.
Recognize safety information. This is the safety-alert symbol
alert to the potential for personal injury.
Understand the signal word DANGER, WARNING, CAUTION, or 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
hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which would 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.
WARNING: 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 may result causing property
damage, personal injury, or loss of life. The qualified service agency performing this work
assumes responsibility for the proper conversion of this furnace with this kit.
In Canada, the conversion shall be carried out in accordance with the requirements of the
provincial authorities having jurisdiction and the National Standard of Canada Natural Gas
and Propane Installation Code (NSCNGPIC).
AVERTISSEMENT: Cet ensemble de conversion ne doit être installé que par le représen-
tant d'un organisme qualifié et conformément aux instructions du fabricant et à tous les
codes et exigences applicables de l'autorité compétente. Quiconque ne respecte pas à la
lettre les instructions dans le présent manuel risque de déclencher un incendie ou une
explosion entraînant des dommages matériels, des lésions corporelles ou la perte de vies
humaines. L'organisme qualifié qui effectue les travaux est responsable de la conversion
correcte de ce générateur d'air chaud à l'aide de cet ensemble.
This instruction covers the installation of gas conversion kit Part No. KGAPN20012SP to convert the following furnaces from propane gas usage
to natural gas usage. See the appropriate section for your furnace type.
Form: AG-GAPN-13
Installation Instructions
®
SAFETY CONSIDERATIONS
INTRODUCTION
Cancels: AG-GAPN-12
A PP R O VED
R
. When you see this symbol on the furnace and in instructions or manuals, be
Printed in U.S.A.
8-97
KGAPN20012SP
Catalog No. 63GA-PN0
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Summary of Contents for Carrier KGAPN20012SP
- Page 1 à l’aide de cet ensemble. INTRODUCTION This instruction covers the installation of gas conversion kit Part No. KGAPN20012SP to convert the following furnaces from propane gas usage to natural gas usage. See the appropriate section for your furnace type.
-
Page 2: Description And Usage
• Section 1—Models 58DXT, 58TMA, 58TUA, 58UHV, 58UXT, 58UXV, 330AAV, 330JAV, 331AAV, 331JAV, 333BAV, and 333JAV Induced-Combustion, Hot Surface Ignition, 2-Speed and Variable-Speed Non-Condensing Furnaces. The kit is designed for use in 040 through 140 size furnaces. • Section 2—Models 58MVP and 355MAV Multipoise, Hot Surface Ignition, Variable-Speed Condensing Furnaces. The kit is designed for use in 040 through 120 size furnaces. - Page 3 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.
- Page 4 In Canada, the input rating must be derated by 10 percent for altitudes of 2000 ft to 4500 ft above sea level. a. Obtain yearly heat value average (at installed altitude) for local gas supply. b. Obtain yearly specific gravity average for local gas supply. c.
- Page 5 Table 2—Upflow and Upflow/Horizontal, 2-Speed and Variable-Speed, Hot Surface Ignition, Non-Condensing Furnace Orifice Size and Manifold Pressure for Correct Input (Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner, Derated 4% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE...
- Page 6 Table 2—Upflow and Upflow/Horizontal, 2-Speed and Variable-Speed, Hot Surface Ignition, Non-Condensing Furnace Orifice Size and Manifold Pressure for Correct Input-Continued (Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner, Derated 4% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE...
- Page 7 Table 2—Upflow and Upflow/Horizontal, 2-Speed and Variable-Speed, Hot Surface Ignition, Non-Condensing Furnace Orifice Size and Manifold Pressure for Correct Input-Continued (Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner, Derated 4% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE...
- Page 8 Table 3—Downflow and Downflow/Horizontal, 2-Speed, Hot Surface Ignition, Non-Condensing Furnace Orifice Size and Manifold Pressure for Correct Input (Tabulated Data Based on 21,000 Btuh High Heat/13,500 Btuh Low Heat per Burner, Derated 4% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE...
- Page 9 Table 3—Downflow and Downflow/Horizontal, 2-Speed, Hot Surface Ignition, Non-Condensing Furnace Orifice Size and Manifold Pressure for Correct Input-Continued (Tabulated Data Based on 21,000 Btuh High Heat/13,500 Btuh Low Heat per Burner, Derated 4% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE...
- Page 10 Table 3—Downflow and Downflow/Horizontal, 2-Speed, Hot Surface Ignition, Non-Condensing Furnace Orifice Size and Manifold Pressure for Correct Input-Continued (Tabulated Data Based on 21,000 Btuh High Heat/13,500 Btuh Low Heat per Burner, Derated 4% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE...
- Page 11 11 32 13 32 " " BURNER CELL ON/OFF LOW-FIRE PANEL SWITCH ADJUSTMENT ALLEN SCREW (UNDER CAP) INLET HIGH-FIRE PRESSURE ADJUSTMENT SURFACE IGNITOR ALLEN SCREW ASSEMBLY (UNDER CAP) INSERT PLUG BUTTON FROM NATURAL GAS VALVE AFTER REMOVING IGNITOR PRESSURE TAP "...
- Page 12 → 10. Turn furnace gas valve control knob or electric switch to OFF position. 11. Turn gas supply manual shutoff valve to OFF position. 12. Turn off furnace power supply. 13. Remove manometer and reinstall gas valve inlet pressure tap plug. (See Fig. 4.) NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks.
- Page 13 EAC - ELECTRONIC AIR CLEANER (115-VAC 1 AMP MAX) 3-AMP FUSE LED - DIAGNOSTIC LIGHT 10 11 TWIN / TEST TERMINAL MASTER SLAVE HUM - HUMIDIFIER (24-VAC 0.5 AMP MAX) 24-VOLT THERMOSTAT TERMINALS BLOWER- HIGH HEAT HEAT (ADAPTIVE DELAY ONLY ALGORITHM) FURNACE AND BLOWER OFF DELAY...
- Page 14 3. Verify natural gas input rate by clocking gas meter. a. Calculate high-altitude adjustment (if required). UNITED STATES At installation altitudes above 2000 ft, this furnace has been approved for a 4 percent derate for each 1000 ft above sea level. See Table 4 for derate multiplier factor and example.
- Page 15 Table 5—Gas Rate (Cu Ft/Hr) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS FOR 1 FOR 1 REVOLUTION REVOLUTION Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft 1800 1636 1500 1385 1286 1200 1125 1059 1000 11.
- Page 16 PROCEDURE 6—LABEL APPLICATION NOTE: See Fig. 1 or 2 for label location. 1. Fill in Conversion Responsibility Label (321201-104) and apply inside furnace as shown. Date, name, and address of organization making this conversion are required. 2. Attach Furnace Conversion Rating Plate (323870-101) near existing furnace rating plates. 3.
- Page 17 SECTION 2—MODELS 58MVP AND 355MAV MULTIPOISE, HOT SURFACE IGNITION, VARIABLE-SPEED, CONDENSING FURNACES PROCEDURE 1—INSTALL MAIN BURNER ORIFICES NOTE: See Fig. 9 for component location in upflow furnaces. Re-orient component arrangement when furnace is installed in other positions. ON/OFF LOW-FIRE FURNACE SWITCH ADJUSTMENT RATING...
- Page 18 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.
- Page 19 Table 6—Multipoise, Hot Surface Ignition, Variable-Speed, Condensing Furnace Orifice Size and Manifold Pressure for Correct Input Rate Orifice Size and Manifold Pressure for Correct Input (Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner Derated 2% for each 1000 ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE...
- Page 20 Table 6—Multipoise, Hot Surface Ignition, Variable-Speed, Condensing Furnace Orifice Size and Manifold Pressure for Correct Input Rate Orifice Size and Manifold Pressure for Correct Input-Continued (Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner Derated 2% for each 1000 ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE...
- Page 21 Table 6—Multipoise, Hot Surface Ignition, Variable-Speed, Condensing Furnace Orifice Size and Manifold Pressure for Correct Input Rate Orifice Size and Manifold Pressure for Correct Input-Continued (Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner Derated 2% for each 1000 ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE...
- Page 22 NATURAL POSITION SHUTTER A96271 Fig. 12—Air Shutter in Natural Gas Usage (NAT) Position (060120 and 120-20 Size Units Only) NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape. → WARNING: Gas valve knob or electric switch MUST be facing forward or tilted upward. Failure to follow this warning could result in property damage or death.
- Page 23 COMBUSTION AIR INTAKE BOX SCREWS DIVERTER PLATE COMBUSTION AIR INTAKE BOX A95443 A96274 Fig. 13—Removing Combustion Air Intake Box Fig. 14—Removing Diverter Plate 13 32 " 11 32 " BURNER CELL PANEL BURNER BOX IGNITOR ASSEMBLY W2 COM W/ W1 Y/ Y2 R G HUM FLT (FAULT CODE RECALL) LOW HEAT ONLY...
- Page 24 11. Turn gas supply manual shutoff valve to OFF position. 12. Turn off furnace power supply. 13. Remove manometer and reinstall gas valve inlet pressure tap plug. (See Fig. 10.) NOTE: Use propane-gas-resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape. PROCEDURE 5—CHECK FURNACE OPERATION AND MAKE NECESSARY ADJUSTMENTS 1.
- Page 25 EXAMPLE: (Using Table 6 at 0—2000 ft altitude) Heating value = 1050 Btu/cu ft Specific gravity = 0.62 Therefore: Orifice No. 45 Manifold pressure: 3.6-in. wc for high heat 1.5-in. wc for low heat g. Check and verify burner orifice size in furnace. NEVER ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY. 2.
- Page 26 BURNER FLAME BURNER MANIFOLD A89020 Fig. 18—Burner Flame 3. Verify natural gas input rate by clocking gas meter. NOTE: Be sure all pressure tubing, combustion-air and vent pipes, and burner enclosure front are in place when checking input by clocking gas meter.
- Page 27 k. Multiply gas rate cu ft/hr by heating value (Btu/cu ft). l. Turn setup switch SW-2 to OFF position and jumper R and W2 thermostat connections. (See Fig. 16.) This keeps furnace locked in high-heat operation. Repeat items h through k for high-heat operation. EXAMPLE: (High-heat operation for all models at 0—2000 ft altitude) Furnace input from rating plate is 100,000 Btuh.
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Page 28: Service Training
SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials.