Carrier PG8JEA Instruction Manual download pdf

KGANP4601ALL

Installation Instructions

Gas Conversion Kit Natural ---to---Propane for

Non---Condensing 80 % and

Condensing 90 % F urnaces

Fixed Capacity , 2---Stage, V ariable Speed

TABLE OF CONTENTS

Safety Considerations 1..............................

Introduction 2......................................

Description and Usage 2..............................

Induced Combustion, Single-- Stage, Non-- Condensing

Furnaces 2.................................

Induced Combustion, Two-- Stage and Variable Speed, Non--

Condensing Furnaces 10......................

Direct--Vent, Multipoise, Single--Stage Condensing

Furnaces 15................................

Direct/Non--Direct Vent,Two--Stage and Variable--Speed Multi-

poise and Dedicated Upflow Condensing

Furnaces 22...............................

NOTE: Read the entire instruction manual before starting the

installation.

SAFETY CONSIDERATIONS

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 National Fuel Gas Code (NFGC) NFPA

54--2006/ANSI Z223.1 --2006. In Canada, refer to the National

Standard of Canada, Natural Gas and Propane Installation Codes

(NSCNGPIC), CAN/CGA--B149.1 and .2--M05.

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, and

CAUTION. These words 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 ma y 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.

CERTIFIED

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.

WARNING

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.

AVERTISSEMENT

1 2 3 4 5 6 ... 29 30

Summary of Contents

Page 1 - Installation Instructions

1KGANP4601ALLInstallation InstructionsGas Conversion Kit Natural ---to---Propane forNon---Condensing 80 % andCondensing 90 % F urnacesFixed Capacity ,

Page 2 - Spoiler Screws

10FactoryClearanceLabelApply ConversionResponsibility Labelon exterior of doorFactory InformationLabelBlower DoorRating Plate onexterior of doorExisti

Page 3

11Gas input rate on furnace rating plate is for installations ataltitudes up to 2000 ft. (609 M).In the U.S.A., the input rating for altitudes above 2

Page 4

12A93347Fig. 25 -- Igniter to Burnerb. Install HSI and bracket to burner assembly.c. Insert one--piece burner in slot on sides of burner box andslide

Page 5

13ManometerconnectionA05191Fig. 29 -- LGPS Installed9. Do not install regulator seal caps at this time.10. Go to Step 3.For Fig.271. Be sure gas and e

Page 6

14FIRE AND EXPLOSION HAZARDFailure to follow this warning could result in personal injuryand/or death.NEVER test for gas leaks with an open flame. Use

Page 7

15A08099Fig. 32 -- Conversion Kit Rating Plate 334263-- 20414. Observe unit operation through two complete heatingcycles. See sequence of operation in

Page 8

16D’EQUIPMENT D’OPERATIONLors des opérations d’entretien des commandes, étiquetertous les fils avant de les déconnecter. Toute erreur decâblage peut ê

Page 9

17A93347Fig. 37 -- Position of Silicon Carbide IgniterStep 2 — Convert and Pre--Adjust Gas ValveNOTE: There are three variations of single stage gas v

Page 10 - PRUDENCE

18REGULATOR SEAL CAPREGULATORADJUSTMENTSCREWREGULATOR SPRING(PROPANE - WHITE, 8.5 TURNSNATURAL - SILVER, 8.5 TURNS)GAS PRESSURE REGULATOR ADJUSTMENTMA

Page 11 - KGANP4601ALL

19BLWNUETRALSTATUS CODE LEDSEC-2 SEC-1EAC-2 L2FUSE 3-AMP0.5 AMP@24VACHUMTEST/TWIN G Com W Y R24V120 18090 150BLOWER OF

Page 12

2INTRODUCTIONThis instruction covers the installation of gas conversion kit PartNo. KGANP4601ALL to convert the following furnaces fromnatural gas usa

Page 13

20765432101234567BURNER ENCLOSURE(REMOVE COVER WHEN CHECKING PRESSURE)GAS VALVEPRESSURESWITCH(ES)(LOCATION WILL VARYDEPENDING ON MODEL)MANOMETERA01070

Page 14 - AVERTISSEMENT

21Step 5 — Pressure Switch Wiring (Refer to furnacewiring diagram)1. Disconnect yellow wire from pressure switch (PRS) onfurnace inducer housing. Atta

Page 15 - FURNACES

22Step 9 — Check Low Gas Pressure Switch OperationThe newly installed low gas pressure switch is a safety deviceused to guard against adverse burner o

Page 16

23In Canada, the input rating must be derated by 5 percent foraltitudes of 2000 ft. (609 M) to 4500 ft. (1372 M) above sealevel.The Conversion Kit Rat

Page 17

24PROPANEGASPOSITIONAIRSHUTTERA96264Fig. 52 -- Air Shutter In Propane Gas Usage (PROP) PositionCOMBUSTION AIRINTAKE BOX SCREWSCOMBUSTIONAIR INTAKE BOX

Page 18 - All Furnaces

25DIVERTER PLATEPART NO. 323184-301A95450Fig. 55 -- Installing Diverter PlateBURNERIGNITOR1332"1132"78" (22 mm)IGNITERASSEMBLYIGNITERAS

Page 19

262-5/32˝(55 mm)A04181A05075Fig. 57 -- Position of Igniter to BurnerStep 4 — Install Manifold Assembly, All Furnaces1. Reinstall manifold, orifice, an

Page 20

27A05196Fig. 58 -- Series G and J Gas ValveONOFFON/OFFSWITCHINLETPRESSURETA PBURNER ENCLOSUREREFERENCE PRESSURE TAP(2-STAGEAND VARIABLE-SPEED, CONDENS

Page 21

2812345678 9PR2L2COMPR1L1EAC-2EAC-1HI-COOLHI-GAS-HEATLO-GAS-HEATPARK3FU1SEC-1SEC-2112345678910 11 12MASTER SLAVETWINTESTLEDGRY/Y2W/W1COM24 VW21ONOFF12

Page 22

29Model PlugSet up Switches SW1, 1 thru 8A/C & Constant Air FlowSwitchesStatus Code LightFuse, 3 Amp24 VAC OutputNeutral Leads and EAC 2 (Neutra

Page 23 - S Re--install burners

3Table 1 – Kit ContentsDESCRIPTION PART NO. QUANTITYMain Burner Orifice (Drill Size 1.30 mm) LH32DB210 7Main Burner Orifice (Drill Size 1.25 mm) LH32D

Page 24

30BURNER FLAMEBURNERMANIFOLDA89020Fig. 67 -- Burner Flamec. Remove jumper across R, W1, and W2 after high--heatadjustment to terminate call for heat.

Page 25

4A03059Fig. 2 -- Component LocationA06432Fig. 3 -- Location of Dimple for Spoiler ScrewNOTE: Models 310JAV, 311JAV, 313JAV, 58STX, 58DLX,58PHX, PG8JAA

Page 26

51-7/8(47.6 mm)A05026Fig. 6 -- Igniter to BurnerA93347Fig. 7 -- Igniter to Burner18. Secure manifold to left side of burner box, verifying thatgreen g

Page 27

6REGULATOR SEAL CAPREGULATORADJUSTMENTSCREWREGULATOR SPRING(PROPANE - WHITE, 8.5 TURNSNATURAL - SILVER, 8.5 TURNS)GAS PRESSURE REGULATOR ADJUSTMENTMAN

Page 28 - Necessary Adjustments

7BLWNUETRALSTATUS CODE LEDSEC-2 SEC-1EAC-2 L2FUSE 3-AMP0.5 AMP@24VACHUMTEST/TWIN G Com W Y R24V120 18090 150BLOWER OFF

Page 29

8BLWNUETRALSTATUS CODE LEDSEC-2 SEC-1EAC-2 L2FUSE 3-AMP0.5 AMP@24VACHUMTEST/TWINY1 DHUM G COM W/W1 Y/Y2 R24VPLT120 18090 150BLO

Page 30 - MANIFOLD

9A08098Fig. 16 -- Conversion Kit Rating Plate -- 334263-- 207NOTE: Use propane-- gas--resistant pipe dope to prevent gasleaks. DO NOT use Teflon tape.