Carrier KGAPN42011SP, Installation Instructions Manual

Page 1: ...lters 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 current edition of the National Fuel Gas Code NFGC NFPA No 54 ANSI Z223 1 In...

Page 2: ... 701 1 PARTS ASSY 42 323267 702 1 PARTS ASSY 43 323267 703 1 PARTS ASSY 44 323267 704 1 PARTS ASSY 45 338303 701 1 LABEL KIT 338303 702 1 LABEL KIT 319965 448 1 LABEL SHIPPING AG KGAPN1SP 01 1 INSTR GAS CVRSN LP TO NAT CA64AS001 1 PLUG PIPE SECTION 1 Table2 Condensing Furnaces MODEL NUMBERS BEGINNING WITH 59SP5A 59SC5A 59SC3A 59SC2A 925SA 915SA 913SA 912SA PG95SAS PG92XAS PG92SAS INSTALLATION 1 Se...

Page 3: ...ng is not acceptable Fig 2 Manifold Assembly Fig 1 Representative Furnace Drawing BURNER SUPq ASSY IGNITER BURNER ASSY SENSOR BELOW BURNER Fig 3 Burner Assembly ORIFICE SELECTION DERATE A11408 BRACKET IGNITER FLAME ROLLOUT SWITCH A11403 A11407 NIT 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 roun...

Page 4: ...ve sea level The Conversion Kit Rating Plate accounts for high altitude derate INSTALL ORIFICES 1 Install main burner orifices DO NOT use Teflon tape Fin ger tighten orifices at least one full turn to prevent cross threading then tighten with wrench 2 There are enough orifices in each kit for largest furnace Discard extra orifices NOTE DO NOT reinstall the manifold at this time REMOVE MIXER SCREWS...

Page 5: ... 3 2 42 3 3 42 3 4 825 43 3 6 43 3 7 43 3 8 42 3 2 850 44 3 8 43 3 5 43 3 6 43 3 7 875 44 3 6 44 3 7 43 3 4 43 3 5 900 44 3 4 44 3 5 44 3 7 44 3 8 925 44 3 2 44 3 4 44 3 5 44 3 6 950 44 3 1 44 3 2 44 3 3 44 3 4 750 42 3 3 42 3 4 42 3 5 42 3 6 775 43 3 7 43 3 8 42 3 3 42 3 4 800 43 3 5 43 3 6 43 3 7 43 3 8 825 44 3 8 43 3 4 43 3 5 43 3 6 850 44 3 5 44 3 7 44 3 8 43 3 4 875 44 3 3 44 3 5 44 3 6 44 3...

Page 6: ... DAMAGE HAZARD Failure to follow this caution may result in unit damage The G or J gas valve must be converted and pre adjusted before operating on natural gas The E valves must be pre adjusted before operating on natural gas If left this way sooting and corrosion will occur leading to early heat exchanger failure Al1253B ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning cou...

Page 7: ... corporels et ou la mort Ne jamais exanfiner pour les fuites de gaz avec une flamme vive Utilisez plut6t un savon fait specifiquement pour la d_tection des fuites de gaz pour verifier tousles connections Un incendie ou une explosion peut entrainer des dommages materiels des blessures ou la mort Casings Wider Than 14 3 16 in Vent Does Not Pass Between Inducer and Burner Assembly If the vent pipe do...

Page 8: ...UST be shut off before disconnecting electrical power and proceeding with conversion ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal iniury 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 Lock...

Page 9: ...h on the gas valve 2 Remove the 1 8 inch NPT plug from the outlet pressure tap on the gas valve 3 Connect a manometer to the outlet pressure tap on gas valve 4 Turn on furnace power supply 5 Turn gas supply manual shutoff valve to ON position 6 Turn furnace gas valve switch to ON position 7 Jumper R and W thermostat connections to call for heat See Fig 11 8 Check manifold orifices for gas leaks wh...

Page 10: ...EL 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 NOTE Furnace gas input rate on rating plate is for instaRations up to 2000 ft 610m above sea level In U S A the input rating for altitudes above 2000 ft 610m must be derated by 2 for each 1000 ft 305m...

Page 11: ...ting or OFF 2 Remove outer doors 3 Disconnect power at external disconnect fuse or circuit breaker 4 Turn off gas at external shut off or gas meter 5 Remove outer doors and set aside 6 Turn electric switch on gas valve to OFF FIRE EXPLOSION ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal iniury death or property damage Gas supply MUST be shut off before disconnectin...

Page 12: ... sure Switch LGPS located on the gas valve 3 Support the manifold and remove the 4 screws that secure the manifold assembly to the burner box and set aside 4 Note the location of the green yellow wire ground wire for re assembly later 5 Slide one piece burner assembly out of slots on sides of burner box 6 Remove the flame sensor from the burner assembly 7 Remove the orifices from the manifold and ...

Page 13: ...ly heat value average at installed altitude for local gas supply 2 Obtain yearly specific gravity average for local gas sup ply 3 Find installation altitude in Table 5 or 6 NOTE For Canada altitudes of 2000 to 4500 ft use U S A Altitudes of 2001 to 3000 ft in Table 5 or 6 4 Find closest natural gas heat value and specific gravity in Table 5 or 6 5 Follow heat value line and specific gravity line t...

Page 14: ...3 3 8 42 3 3 42 3 4 42 43 3 6 43 3 8 42 3 2 42 43 3 5 43 3 6 43 3 7 43 43 3 3 43 3 4 43 3 5 43 44 3 6 43 3 2 43 3 4 43 44 3 4 44 3 5 43 3 2 43 44 3 3 44 3 4 44 3 5 43 42 3 4 42 3 5 42 3 6 42 42 3 2 42 3 3 42 3 4 42 43 3 7 43 3 8 42 3 2 42 43 3 5 43 3 6 43 3 7 43 43 3 3 43 3 4 43 3 5 43 43 3 1 43 3 2 43 3 3 43 43 2 9 43 3 0 43 3 1 43 43 2 8 43 2 9 43 3 0 43 43 2 6 43 2 7 43 2 8 43 42 3 2 42 3 3 42 ...

Page 15: ...3 43 675 43 3 4 43 3 5 43 3 6 43 700 43 3 1 43 3 3 43 3 4 43 725 43 2 9 43 3 0 43 3 1 43 750 46 2 7 46 2 8 46 2 9 46 775 46 2 6 46 2 7 46 2 7 46 800 46 2 4 46 2 5 46 2 6 46 825 43 2 3 43 2 3 43 2 4 43 850 46 2 1 46 2 2 46 2 6 46 650 43 3 1 43 3 2 43 3 4 43 675 43 2 9 43 3 0 43 3 1 43 700 46 2 7 46 2 8 46 2 9 46 725 46 2 5 46 2 6 46 2 7 46 750 46 2 4 46 2 4 46 2 5 46 775 46 2 2 46 2 6 46 2 4 46 800...

Page 16: ... 43 2 6 43 2 5 43 2 4 43 3 3 43 3 1 43 2 9 43 2 7 43 2 6 43 2 4 43 2 3 43 2 2 SPECIFIC GRAVITY OF NATURAL GAS 0 80 0 82 Orifice Manifold No Pressure 42 3 3 43 3 8 43 3 6 43 3 4 43 3 3 44 3 6 44 3 4 44 3 2 45 3 7 42 3 2 43 3 7 43 3 5 43 3 3 43 3 1 43 2 9 43 2 8 43 2 6 43 2 5 43 3 7 43 3 4 43 3 2 43 3 0 43 2 9 43 2 7 43 2 6 43 2 4 43 3 4 43 3 2 43 3 0 43 2 8 43 2 7 43 2 5 43 2 4 43 2 2 Orifice Manif...

Page 17: ...6 46 775 46 2 0 46 2 1 46 2 2 46 800 48 6 6 48 6 7 46 2 0 46 825 48 3 3 48 6 5 48 6 6 48 625 46 2 7 46 2 7 46 2 8 46 650 46 2 5 46 2 5 46 2 6 46 675 46 2 6 46 2 4 46 2 4 46 700 46 2 1 46 2 2 46 2 6 46 725 48 6 7 46 2 0 46 2 1 46 750 48 6 5 48 6 6 48 6 7 46 600 46 2 4 46 2 5 46 2 6 46 625 43 2 3 43 2 3 43 2 4 43 650 46 2 1 46 2 2 46 2 2 46 675 48 3 6 48 3 8 46 2 1 46 700 48 6 4 48 6 5 48 6 6 48 725...

Page 18: ...sition Top View F W32 8 7 mm CELL PANEL _HOT SURFACE IGNITER ASSEMBLY IGNITER 7 8 22 2 mm BURNER _ _ IGNITER ASSEMBLY Fig 23 Silicon Carbide Igniters CONVERT GAS VALVE A93347 NIT DAMAGE HAZARD Failure to follow this caution may result in unit damage The G or J gas valve must be converted and pre adjusted before operating on natural gas The E valves must be pre adjusted before operating on natural ...

Page 19: ...E GULATO R SEAL CAP REGULATOR ADJUSTMENT _SCREW SPRING PROPANE WHITE 6 TURNS NATURAl_ SI_VER 10 TURNS GAS PRESSURE REGULATOR ADJUSTMENT PRESSURE TAP A01073 Fig 26 Single Solenoid Redundant Auto Gas Valve REMOVE LOW GAS PRESSURE SWITCH For E 1 2 1 8 NPT Manifold Pressure Tap Al1153 Fig 24 Single Stage Gas Valve and F valves see Fig 25 26 Be sure gas and electrical supplies to furnace are off Remove...

Page 20: ...niter 7 Connect the connector harness to gas valve 8 Rewire unit low pressure switch LPS as follows a Trace one of the orange wires previously disconnected from the LGPS back to the NO terminals of the LPS b Trace the other orange wire previously disconnected from the LGPS back to its splice connection with the yel low wire of the furnace wire harness Disconnect and dis card this orange wire and t...

Page 21: ...ze Determine natural gas orifice size and manifold pressure for correct input at installed altitude by using Table 5 or 6 NOTE All models in all positions except Low NOx models in downflow and horizontal positions use Table 5 22 000 Btuh per burner Low NOx models in downflow or horizontal positions must use Table 6 21 000 Btuh per burner See input listed on rating plate 1 Obtain yearly heat value ...

Page 22: ...GENCRATEUR D AIR CHAUD A TE CONVERTILE POUR JOUR NOIS AN NI_ E DE L ENSEIVlBLEN KGAPN42011SP PAR Nora et adresse de organisme qui a effectu6 la conversion qui accepte entri_re responsabRit_ de a conversion 338303 205 REV A _ Fig 28 Conversion Responsibility Label Al1537 CONVERSION KIT RATING PLATE CARRIER CORPORATION THiS APPLIANCE HAS BEEN CONVERTED TO USE NATURAL GAS FOR FUEL REFER TO KiT iNSTRU...