HVAC Partners KGAPN43012SP, Installation Instructions Manual

Page 1: ...asic 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 current edit...

Page 2: ...e 2 35 in High Efficiency 2 Stage Condensing Furnaces MODEL NUMBERS BEGINNING WITH 59TP5 925T PG95X_T INSTALLATION 1 Set room thermostat to lowest setting 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 MANIFOLD ORIFICE BURNER ...

Page 3: ...URNACE CONTROL BOARD MANUAL RESET ROLLOUT SWITCH FLAME SENSOR MANUAL RESET ROLLOUT SWITCH GAS BURNER HOT SURFACE IGNITER INDUCER MOTOR ASSEMBLY BLOWER AND MOTOR CAPACITOR POWER CHOKE BLOWER DOOR SAFETY SWITCH A11408 Fig 1 Representative Furnace Drawing Orifice Connect Green Yellow ground wire here Manifold Gas Valve A11469 Fig 2 Manifold Assembly FLAME SENSOR BELOW BURNER FLAME ROLLOUT SWITCH BRAC...

Page 4: ...5 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 4000 900 44 3 4 1 4 44 3 5 1 5 44 3 7 1 5 44 3 8 1 6 1219 925 44 3 2 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 950 45 3 7 1 6 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 750 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 4001 775 43 3 7 1 6 43 3 8 1 6 42 3 3 1 4 42 3 4 1 4 1220 800 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 825 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 ...

Page 5: ...actory installed to to to U S A Only U S A Only U S A Only A11252B Determine natural gas orifice size and manifold pressures for correct input at installed altitude by using Table 3 1 Obtain yearly 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 3 NOTE For Canada altitudes of 2000 to ...

Page 6: ...fter servicing WARNING 1 Refer to Fig 8 2 Be sure gas and electrical supplies to furnace are off 3 Remove caps that conceal the adjustment screws for high heat and low heat gas valve regulators See Fig 8 4 Remove the high heat and low heat regulator adjustment screws 5 Remove the high heat and low heat Propane regulator springs white 6 Install the high heat and low heat natural gas regulator sprin...

Page 7: ...et Tee A11517 Fig 10 Alternate Low Gas Pressure Switch 17 1 2 in 445 mm and wider furnaces 2 Apply pipe dope sparingly to the 1 8 in NPT pipe plug provided in kit and install in the 1 8 in tapped inlet pressure tap opening in the gas valve DO NOT over tighten Check for gas leaks after gas supply has been turned on INSTALL MANIFOLD 1 Align the orifices in the manifold assembly with the sup port rin...

Page 8: ...n burners ignite confirm inlet gas pressure is between 4 5 in W C and 13 6 in W C 8 Remove jumper across R W W1 and R W2 thermostat connections to terminate call for heat 9 Turn furnace gas valve switch to OFF position 10 Turn gas supply manual shutoff valve to OFF position 11 Turn off furnace power supply 12 Remove manometer 13 Apply pipe dope sparingly to the 1 8 in NPT pipe plug and install in ...

Page 9: ... W W1 and W2 on control center thermostat connections This keeps furnace locked in high heat opera tion 15 Adjust high heat input rate manifold pressure for natural gas Refer to Table 3 16 Turn high heat adjusting screw counterclockwise out to decrease input rate or clockwise in to increase input rate 17 Replace caps that conceal the gas valve regulator adjust ment screws NOTE When correct input i...

Page 10: ...10 A11514 Fig 13 Conversion Responsibility Label A11515 Fig 14 Conversion Kit Rating Plate Label ...

Page 11: ... 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 q...

Page 12: ...t the connector harness from gas valve Discon nect wires from Hot Surface Igniter HSI and Flame Sensor Disconnect the two wires from the Low Gas Pres 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 piec...

Page 13: ...t listed on rating plate 1 Obtain yearly 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 ...

Page 14: ...14 Table 5 Orifice Size and Manifold Pressure In W C for Gas Input Rate A10184 ...

Page 15: ...15 Table 5 Orifice Size and Manifold Pressure In W C for Gas Input Rate cont A10184A ...

Page 16: ...16 Table 6 Orifice Size and Manifold Pressure In W C for Gas Input Rate A10185 ...

Page 17: ...ll 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 Verify igniter to burner alignment 6 For Silicon Nitride igniters see Fig 21 and 22 7 For Silicon Carbide igniters see Fig 23 8 Reattach Flame sensor wire to Flame Sensor 9 32 7 1mm 5 16 7 9mm A05025 Fig 21 Igniter Position Side View ...

Page 18: ...ries E gas valve they DO NOT need to have the regulator springs replaced in the gas valve but the regulators in the gas valve must be pre adjusted for natural applications For J and G valves see Fig 24 1 Be sure main gas and electrical supplies are turned OFF 2 Remove both regulator seal caps 3 Remove both regulator adjustment screws 4 Remove both Propane gas regulator springs white 5 Install the ...

Page 19: ...ighten Check for gas leaks after gas supply has been turned on FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury and or death NEVER test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss...

Page 20: ...nections on control 7 When main burners ignite confirm inlet gas pressure is between 4 5 in W C and 13 6 in W C 8 Remove jumper across R W W1 and R W2 thermostat connections to terminate call for heat 9 Turn furnace gas valve switch to OFF position 10 Turn gas supply manual shutoff valve to OFF position 11 Turn off furnace power supply 12 Remove manometer 13 Apply pipe dope sparingly to the 1 8 in...

Page 21: ... Table 5 or 6 11 Remove caps that conceal adjustment screws for gas valve regulators 12 Adjust low heat input rate manifold pressure for natural gas 13 Turn low heat adjusting screw counterclockwise out to decrease input rate or clockwise in to increase input rate NOTE When correct input is obtained main burner flame should be clear blue almost transparent See Fig 12 14 Jumper R W W1 and W2 on con...

Page 22: ...n Kit Rating Plate Copyright 2012 CAC BDP D 7310 W Morris St D Indianapolis IN 46231 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No AG KGAPN2SP 02 Replaces AG KGAPN2SP 01 Edition Date 08 12 ...