Carrier KGAPN20012SP, Installation Instructions Manual

Page 1: ...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 explosio...

Page 2: ...UST be shut off before disconnecting electrical power and proceeding with conversion DESCRIPTION AND USAGE This kit is designed for use in the furnaces listed above See Table 1 for kit contents The conversion uses a White Rodgers 36E 2 stage gas valve More parts are shipped in kit than are needed to complete conversion Furnace models 58DXT 58UXT 58UXV 330JAV 331JAV and 333JAV that reside in South ...

Page 3: ...ALVE BURNER HOLD DOWN BRACKET CONVERSION RESPONSIBILITY LABEL CONVERSION RATING PLATE MANIFOLD BURNERS CLEARANCE LABEL FURNACE RATING PLATE Fig 3 Conversion Rating Plate Label Used for Natural Gas Non Condensing 2 Speed and Variable Speed Furnaces A97180 CONVERSION KIT RATING PLATE CARRIER CORP APPLIANCE MODELS 58MVP 355MAV 323870 101 REV B Max Inlet Gas Pressure Press Max D Admission De Gaz Manif...

Page 4: ...ur local distributor NOTE DO NOT reinstall main burners or burner hold down bracket at this time PROCEDURE 2 REPLACE AND CONVERT GAS VALVE SEE FIG 4 NOTE Discard labels and instructions packaged with White Rodgers gas valve All necessary information is provided in this instruction 1 Be sure gas and electrical supplies to furnace are off 2 Remove wires from gas valve Note location for reassembly 3 ...

Page 5: ... 43 3 7 1 6 43 3 8 1 6 Altitudes 800 44 3 6 1 5 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 2001 825 44 3 4 1 4 44 3 5 1 5 44 3 7 1 5 44 3 8 1 6 43 3 4 1 4 to 850 44 3 2 1 4 44 3 3 1 4 44 3 4 1 5 44 3 6 1 5 44 3 7 1 5 3000 875 45 3 7 1 6 45 3 8 1 6 44 3 2 1 4 44 3 4 1 4 44 3 5 1 5 or 900 45 3 5 1 5 45 3 6 1 5 45 3 7 1 6 45 3 8 1 6 44 3 3 1 4 Canada 925 45 3 3 1 4 45 3 4 1 4 45 3 5 1 5 45 3 6 1 5 4...

Page 6: ...3 7 1 6 45 3 8 1 6 44 3 3 1 4 44 3 4 1 4 750 45 3 4 1 4 45 3 5 1 5 45 3 6 1 5 45 3 7 1 6 45 3 8 1 6 775 45 3 2 1 3 45 3 3 1 4 45 3 4 1 4 45 3 5 1 5 45 3 6 1 5 5001 800 47 3 5 1 5 47 3 6 1 5 45 3 2 1 3 45 3 3 1 4 45 3 4 1 4 825 48 3 8 1 6 47 3 4 1 4 47 3 5 1 5 47 3 7 1 5 45 3 2 1 3 to 850 48 3 6 1 5 48 3 7 1 6 48 3 8 1 6 47 3 4 1 5 47 3 5 1 5 875 48 3 4 1 4 48 3 5 1 5 48 3 6 1 5 48 3 7 1 6 48 3 8 1...

Page 7: ...ld Pressure High Low Orifice No Manifold Pressure High Low U S A Only 600 45 3 4 1 4 45 3 5 1 5 45 3 6 1 5 45 3 7 1 6 45 3 8 1 6 625 47 3 7 1 6 45 3 2 1 4 45 3 3 1 4 45 3 4 1 4 45 3 5 1 5 8001 650 47 3 4 1 4 47 3 5 1 5 47 3 6 1 5 45 3 2 1 3 45 3 3 1 4 675 48 3 6 1 5 48 3 7 1 6 48 3 8 1 6 47 3 5 1 5 47 3 6 1 5 to 700 48 3 3 1 4 48 3 5 1 5 48 3 6 1 5 48 3 7 1 6 48 3 8 1 6 725 49 3 7 1 5 49 3 8 1 6 4...

Page 8: ... 1 4 42 3 5 1 4 Altitudes 800 43 3 5 1 4 43 3 6 1 5 43 3 7 1 5 42 3 2 1 3 42 3 3 1 3 2001 825 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 43 3 7 1 5 to 850 44 3 6 1 5 44 3 7 1 5 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 3000 875 44 3 4 1 4 44 3 5 1 4 44 3 6 1 5 44 3 7 1 5 44 3 8 1 6 or 900 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 44 3 5 1 4 44 3 6 1 5 Canada 925 46 3 8 1 6 45 3 8 1 6 44 3 2 1 3 44 3 3 1 4 44 3 4 1...

Page 9: ...44 3 5 1 4 44 3 6 1 5 44 3 7 1 5 750 45 3 7 1 5 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 44 3 5 1 4 775 46 3 6 1 5 46 3 8 1 6 45 3 7 1 5 44 3 2 1 3 44 3 3 1 4 5001 800 46 3 4 1 4 46 3 5 1 5 46 3 7 1 5 46 3 8 1 6 45 3 7 1 5 825 47 3 7 1 5 47 3 8 1 6 46 3 4 1 4 46 3 6 1 5 46 3 7 1 5 to 850 47 3 4 1 4 47 3 6 1 5 47 3 7 1 5 47 3 8 1 6 46 3 5 1 4 875 48 3 7 1 5 48 3 8 1 6 47 3 5 1 4 47 3 6 1 5 47 3 7 1 5 6000 ...

Page 10: ...ure High Low Orifice No Manifold Pressure High Low U S A Only 600 45 3 7 1 5 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 44 3 5 1 4 625 46 3 6 1 5 46 3 7 1 5 46 3 8 1 6 45 3 8 1 6 44 3 2 1 3 8001 650 47 3 8 1 6 46 3 4 1 4 46 3 5 1 5 46 3 7 1 5 46 3 8 1 6 675 47 3 5 1 4 47 3 6 1 5 47 3 7 1 5 47 3 8 1 6 46 3 5 1 4 to 700 48 3 7 1 5 48 3 8 1 6 47 3 5 1 4 47 3 6 1 5 47 3 7 1 5 725 48 3 4 1 4 48 3 6 1 5 48 3 7 1 ...

Page 11: ...6 in wc 1 Be sure main gas and electrical supplies to furnace are off 2 Remove 1 8 in pipe plug from inlet pressure tap on gas valve See Fig 4 3 Attach manometer to inlet pressure tap on gas valve See Fig 17 4 Turn on furnace power supply 5 Jumper R and W2 thermostat connections on control See Fig 6 This keeps furnace locked in high heat operation CAUTION DO NOT operate furnace more than 1 minute ...

Page 12: ...g Table 2 for models 58TUA UHV UXT UXV 330AAV JAV 333BAV JAV upflow and upflow horizontal or Table 3 for models 58DXT TMA 331JAV AAV downflow and downflow horizontal a Obtain yearly heat value average at installed altitude from local gas supplier b Obtain yearly specific gravity average from local gas supplier c Verify furnace model and select appropriate table Table 2 can only be used for upflow ...

Page 13: ...ange main burner orifices g Remove jumper across R and W W1 thermostat connections after low heat stage adjustments h Replace gas valve regulator adjustment screw caps i Turn setup switch SW 2 on control board to OFF position See Fig 6 and 7 Fig 6 Non Condensing Furnace Control Center 2 Speed Control Shown A93348 1 2 3 4 5 6 7 8 9 PR2 L2 COM PR1 L1 EAC 2 EAC 1 HI COOL HI GAS HEAT LO GAS HEAT PARK ...

Page 14: ...s 80 000 Btuh Btu heating input Btu cu ft X cu ft hr Heating value of gas 975 Btu cu ft Time for 1 revolution of 2 cu ft dial 88 sec Gas rate 82 cu ft hr from Table 5 Btu heating input 82 X 975 79 950 Btuh In this example the orifice size and manifold pressure adjustment is within 2 percent of the furnace input rate i Remove jumper across R and W2 thermostat connections and repeat items d through ...

Page 15: ...1 129 126 124 122 327 321 316 310 305 20 21 22 23 24 180 171 164 157 150 360 343 327 313 300 900 857 818 783 750 60 62 64 66 68 60 58 56 54 53 120 116 112 109 106 300 290 281 273 265 25 26 27 28 29 144 138 133 129 124 288 277 267 257 248 720 692 667 643 621 70 72 74 76 78 51 50 48 47 46 103 100 97 95 92 257 250 243 237 231 30 31 32 33 34 120 116 113 109 106 240 232 225 218 212 600 581 563 545 529 ...

Page 16: ...ace 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 Check for correct normal operating sequence of ignition system as described in the furnace Installation Instructions 4 Replace furnace control component access door 16 ...

Page 17: ... orifices from manifold 11 Determine natural gas orifice size for correct input at installed altitude by using Table 6 See also Fig 11 Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft In the U S A the input rating for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level In Canada the input rating must be derated by 5 percent fo...

Page 18: ...eed and Variable Speed Furnaces A97180 CONVERSION KIT RATING PLATE CARRIER CORP APPLIANCE MODELS 58MVP 355MAV 323870 101 REV B Max Inlet Gas Pressure Press Max D Admission De Gaz Manifold Pressure 13 6 3 386 4 5 1 121 0 2 000 ft 0 610 m 3 2 3 8 797 946 Refer to installation manual Respecter les instruction D Installation 2 5 4 10 58TMA 58DXT 331AAV 331JAV 58TUA 58UXT 58UHV 58UXV 330AAV 330JAV 333B...

Page 19: ...h Low Orifice No Manifold Pressure High Low U S A and Canada U S A 775 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 Altitudes 800 43 3 5 1 5 43 3 7 1 5 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 2001 825 44 3 8 1 6 43 3 4 1 5 43 3 6 1 5 43 3 7 1 5 43 3 8 1 6 to 850 44 3 6 1 5 44 3 7 1 6 44 3 8 1 6 43 3 5 1 5 43 3 6 1 5 3000 875 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 or 900 44 3 2 1...

Page 20: ...ssure High Low U S A Only 700 43 3 6 1 5 43 3 7 1 6 42 3 2 1 3 42 3 3 1 4 42 3 4 1 4 725 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 750 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 775 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 5001 800 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 825 45 3 6 1 5 45 3 7 1 6 44 3 2 1 4 44 3 3 1 4 44 3 4 1 4 to 850 45 3 4 1...

Page 21: ... High Low Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low U S A Only 600 43 3 8 1 6 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 625 43 3 5 1 5 43 3 6 1 5 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 8001 650 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 675 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 44 3 8 1...

Page 22: ...ched to orange wire from PL2 2 on control board b Disconnect and discard orange wire attached to NO terminal of low pressure switch LPS c Connect orange wire from PL2 2 on control board to NO terminal of low pressure switch LPS d Refer to wiring label on furnace to ensure proper location of wires 8 Reinstall gas supply pipe to gas valve using backup wrench on gas valve to prevent rotation and impr...

Page 23: ...at 10 Turn furnace gas valve control knob or electric switch to OFF position Fig 13 Removing Combustion Air Intake Box A95443 COMBUSTION AIR INTAKE BOX SCREWS COMBUSTION AIR INTAKE BOX Fig 14 Removing Diverter Plate A96274 DIVERTER PLATE Fig 15 Ignitor Position A93260 BURNER IGNITOR 13 32 11 32 7 8 C L C L IGNITOR ASSEMBLY IGNITOR ASSEMBLY CELL PANEL BURNER BURNER BOX Fig 16 Condensing Furnace Con...

Page 24: ...e gas input rate on rating plate is for installations at altitudes up to 2000 ft See also Fig 11 In the U S A the input rating for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level In Canada the input rating must be derated by 5 percent for altitudes of 2000 ft to 4500 ft above sea level Furnace input rate must be within 2 percent of input on furnace rating plat...

Page 25: ...and heat exchanger failures NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics d Turn setup switch SW 2 to OFF position after completing low heat adjustment e Jumper R and W2 thermostat connecti...

Page 26: ...urner enclosure front INSTALLED c Check that gas valve adjustment caps are in place for proper input to be clocked d Obtain average yearly heat value for local gas supply NOTE Be sure heating value of gas used for calculations is correct for your altitude Consult local gas utility for altitude adjustment of gas heating value e Check and verify orifice size in furnace NEVER ASSUME THE ORIFICE SIZE ...

Page 27: ... to terminate call for heat 5 Turn furnace gas valve control knob or electric switch to OFF position 6 Turn off furnace power supply 7 Remove manometer and reattach manifold pressure tap plug See Fig 10 and 17 8 Turn furnace gas valve control knob or electric switch to ON position 9 Turn on furnace power supply 10 Set room thermostat to call for heat 11 Check pressure tap plug for gas leaks when m...

Page 28: ...using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service T...