Shareddocs AGAGC9PNS01E Gas Conversion Kit

Installation Instructions

NOTE: Read the entire instruction manual before starting the installation.

SAFETY CONSIDERATION

WARNING
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.

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 current edition of the National Fuel Gas Code (NFGC) NFPA No. 54/ANSI Z223.1. In Canada, refer to the current edition of the National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC), CAN/CSA-B149.1 and .2. 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, CAUTION and 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 a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which may 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.

INTRODUCTION

WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow instructions could result in personal injury, death or property damage. Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions, which could result in personal injury or death. Consult your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized kits or accessories when servicing this product.

WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, death or property damage. Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.

WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, 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 out and tag switch with a suitable warning label. Verify proper operation after servicing.

CAUTION: UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage or improper operation. Do NOT use this kit with furnaces with an input of 26,000 BTUh; the unit will be severely over-fired. This could result in delayed ignition, sooting or premature heat exchanger failure. This instruction covers the installation of gas conversion kit to convert the following furnaces from propane gas usage to natural gas usage.

NOTE: See appropriate sections for your furnace type.

Table 1 – Kit Contents

QUANTITY	DESCRIPTION
2	REGULATOR SPRINGS
4	ORIFICES (BAG ASSEMBLIES)
1	LABELS 351332-201 through 351332-209
1	PLUG, PIPE
1	INSTRUCTIONS

SINGLE-STAGE GAS VALVE
Condensing Furnaces with 40,000 to 140,000 BTUh (not all models have 140,000 BTUh) gas input rates.

TWO-STAGE & MODULATING GAS VALVE
Condensing Furnaces with 40,000 through 120,000 BTUh gas input rates.

DESCRIPTION AND USAGE
This kit is designed for use in the furnaces listed in Table 2 or Table 3; see Table 1 for kit contents. To accommodate many different furnace models, more parts are shipped in the kit than will be needed to complete conversion. When installation is complete, discard extra parts.

SINGLE-STAGE CONDENSING FURNACES

Table 2 – Single Stage Model Numbers

Model Numbers Beginning with:
59S(P/C/E)	91(2/5/6)S	92(2/5/6)S
PG9(2/5)S	PG9(2/6)M	PG9(2/5)ESA
(F/G)9MXE	F9MES	(N/R)9MS
(N/R)95ESN	(N/R)92ESN	(N/R)96MS
(N/R)92MS	(N/R)96VS	WF(A/H/S)X

TWO-STAGE & MODULATING CONDENSING FURNACES

Table 3 – Two-Stage & Modulating Condensing Furnaces

Model Numbers Beginning with:
Two-Stage:		Modulating:
59T(N/P)	PG95X	59MN
98(6/7)T	(F/G)9M(V/XT)	987M
92(5/6/7)T	(F/G)9(6/7)(V/C)TN	(F/G)9MA
(G/P)G9(6/7)V	WF(S/J)T	(F/G/N)97CM

INSTALLATION

1. Set room thermostat to lowest setting or OFF.
2. Disconnect power at external disconnect, fuse or circuit breaker.
3. Turn off gas at external shut-off or gas meter.
4. Remove outer doors and set aside.
5. Turn electric switch on gas valve to OFF.

MANIFOLD/ORIFICE/BURNER REMOVAL

CAUTION: UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage or improper operation. Label all wires prior to disconnection when servicing controls.

NOTE: Use a back-up wrench on the gas valve to prevent the valve from rotating on the manifold or damaging the mounting to the burner box.

1. Disconnect the gas pipe from gas valve and remove pipe from the furnace casing (Fig. 1).
2. Disconnect the connector harness from gas valve Disconnect wires from Hot Surface Igniter (HSI) and Flame Sensor.
3. Support the manifold and remove the four (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 (Fig. 2).
5. Remove wires from both rollout switches (Fig. 3).
6. Slide one-piece burner assembly out of slots on sides of burner box (Fig. 3).
7. Remove the flame sensor from the burner assembly.
8. Remove the orifices from the manifold and discard.
9. Disconnect wires from Low Gas Pressure Switch. Re-attached these wires to the furnace pressure switch. Refer to furnace wiring diagram.

ORIFICE SELECTION/DERATE

CAUTION: UNIT 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-round holes, etc. Obtain new orifices if orifice size must be changed (Fig. 4).

For Single Stage and Two Stage Furnaces:
Determine natural gas orifice size and manifold pressure for correct input at installed altitude by using Table 4 for Single Stage furnaces and Table 5 for Two-Stage furnaces.

1. Obtain yearly heat−value average (at installed altitude) for local gas supply.
2. Obtain yearly specific−gravity average for local gas supply.
3. Find installation altitude in Table 4 or Table 5. For Canada altitudes of 2000 to 4500 ft., use U.S.A. Altitudes of 2001 to 3000 ft. in Table 4 or Table 5.
4. Find closest natural gas heat value and specific gravity in Table 4 or Table 5.
5. Follow heat−value line and specific−gravity line to point of intersection to find orifice size and manifold pressure settings.

For Modulating Furnaces:
Follow Steps 1 and 2 above.

For Step 3 use:
Table 6 for all sizes (20,000 BTUh/Max-Heat/8,000 BTUh Min-Heat per burner) except 60,000 BTUh models in a 21-in. wide cabinet. Table 7 for 60,000 BTUh models in a 21-in. wide cabinet. (20,200 BTUh Max-Heat/8,000 BTUh Min-Heat per burner)

1. For both tables, follow heat−value line and specific-gravity line to point of intersection to find orifice size and manifold pressure settings.

For all furnaces: Furnace gas input rate on furnace rating plate is for installations at altitudes up to 2000 ft. (610 M). In the U.S.A.; the input rating for altitudes above 2000 ft. (610 M) must be reduced by 2 percent for each 1000 ft. (305 M) above sea level. In Canada, the input rating must be derated by 5 percent for altitudes of 2000 ft. to 4500 ft. (610 M to 1372 M) above sea level. The Conversion Kit Rating Plate accounts for high altitude derate.

SINGLE-STAGE GAS VALVE

TWO-STAGE GAS VALVE

MODULATING GAS VALVE
Table 6 to be used with Modulating Furnaces EXCEPT the 60,000 BTUh INPUT IN 21-IN. WIDE CASING

MODULATING GAS VALVE (60,000 BTUh ONLY)
Table 7 to be used with Modulating Furnaces 60,000 BTUh INPUT IN 21-IN. WIDE CASING ONLY

SINGLE-STAGE GAS VALVE

TWO-STAGE GAS VALVE

MODULATING GAS VALVE

INSTALL ORIFICES

1. Install main burner orifices. Do not use PTFE thread-seal tape. Finger-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
NOTE: Each burner contains a mixer screw that must be removed. Refer to Fig. 8 for the mixer screw location.

1. Remove the mixer screws from the burners.
   NOTE: It is not necessary to plug the hole in the burner when the mixer screws are removed.

REINSTALL BURNER ASSEMBLY

To reinstall burner assembly:

1. Attach flame sensor to burner assembly.
2. Insert one-piece burner in slot on sides of burner box and slide burner back in place.
3. Reattach HSI wires to HSI.
4. Verify igniter to burner alignment, see Fig. 9 & Fig. 10.

Furnace gas input rate on furnace rating plate is for installations at altitudes up to 2000 ft. (610 M). In the U.S.A.; the input rating for altitudes above 2000 ft. (610 M) must be reduced by 4 percent for each 1000 ft. (305 M) above sea level. In Canada, the input rating must be derated by 10 percent for altitudes of 2000 ft. to 4500 ft. (610 M to 1372 M) above sea level. The Conversion Kit Rating Plate accounts for high altitude derate. 

CONVERT GAS VALVE

CAUTION: UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage or improper operation. DO NOT use this kit if the gas valve has a green label (26,000 BTUh model) on it. The 26,000 BTUh model uses a different conversion kit available from your distributor.

NOTE: Do not use this kit if the gas valve in Fig. 11 has a green label on top of the valve. The green label on the gas valve is a special low capacity gas valve. Refer to Specification Sheet for the correct conversion kit.

CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit damage The gas valve must be converted and pre-adjusted before operating on propane gas. If not converted and pre-adjusted, sooting and corrosion will occur leading to early heat exchanger failure.

WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, death or property damage. Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.

WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, 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 out and tag switch with a suitable warning label. Verify proper operation after servicing.

Single Stage Gas Valve

1. Refer to Fig. 5. Verify the gas valve has a white label with black lettering on top of the operator.
2. Be sure gas and electrical supplies to furnace are off.
3. Remove caps that conceal adjustment screws for the gas-valve regulators, see Fig. 11 or Fig. 12 and Fig. 13.
4. Remove the regulator adjustment screw.
5. Remove the propane gas regulator springs (white).
6. Install the natural gas regulator springs (silver).
7. Install the regulator adjustment screws.
8. Turn the adjusting screw clockwise (in) 8.5 full turns. This will increase the manifold pressure closer to the natural set point, see Fig. 11 or Fig. 12 and Fig. 13.
9. Do not install regulator seal caps at this time.
   NOTE: Remove the propane gas regulator spring (white) Install the natural gas regulator spring (silver)

Two Stage Gas Valve
Refer to Fig. 14, Fig. 15or Fig. 16.

1. Remove caps that conceal adjustment screws for high heat and low heat gas-valve regulators, see Fig. 14, Fig. 15, or Fig. 16.
2. Remove the high heat and low heat propane regulator adjustment screws.
3. Remove the high heat and low heat propane gas regulator springs (white).
4. Install the high heat and low heat natural gas regulator springs (silver).
5. Install the high heat and low heat regulator adjustment screws.
6. Turn high heat stage adjusting screw clockwise (in) 12 full turns. This will increase the manifold pressure closer to the natural set point.
7. Turn low heat stage adjusting screw clockwise (in) 9.5 full turns. This will increase the manifold pressure closer to the natural low heat set point.
8. Do not install regulator seal caps at this time.

Modulating Gas Valve
Refer to Fig. 17 through Fig. 21.

1. Locate the round “LP GAS” sticker on the top of the gas valve.
2. Peel the sticker off and discard.
3. Note the small square opening in the top of the gas valve.
4. Note the two jumper pins inside the modulating gas valve.
5. Use needle-nosed pliers to gasp the jumper by the tab on the end.
6. Remove the small black plastic propane jumper from the gas valve.
7. Cover the opening in the gas valve with the label marked “NAT GAS.”

NOTE: The Propane jumper for the modulating gas valve is very small. Needle-nose pliers are required to remove the jumper from the valve. If the jumper is not removed, the valve will not operate properly on natural gas pressures.

REMOVE LOW GAS PRESSURE SWITCH

NOTE: Remove the Low Gas Pressure Switch before installing the manifold on the burner assembly.
NOTE: There are two ways that the Low Gas Pressure Switch (LGPS) could have been installed during the original natural to Propane gas conversion.
All 14 3/16-in Casings or Vent Passed Between Inducer

Assembly and Burner Assembly
If the vent pipe passes between the inducer and burner assembly, or the furnace is a 14 3/16-in. wide casing. The switch is installed as shown in Fig. 22.

1. Remove low gas pressure switch, brass street 90_ elbow, brass hex nipple, brass tee and black iron street 90_ elbow from the gas valve inlet pressure tap, see Fig. 22.
   NOTE: Use pipe dope approved for use with Propane gas. DO NOT use PTFE thread-seal tape.
2. Apply pipe dope sparingly to the 1/8-in. (3 mm) 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.

WARNING: FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death, and/or property damage. 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 of life.

Casings Wider Than 14 3/16-in/Vent Does Not Pass Between Inducer and Burner Assembly
If the vent pipe does not pass between the inducer and burner assembly, or the furnace is wider than a 14 3/16-in. wide casing. The switch is installed as shown in Fig. 23.

1. Remove Low Gas Pressure Switch (LGPS), brass street tee, brass nipple and brass street 90° elbow from the gas valve inlet pressure tap, see Fig. 23.
   NOTE: Use pipe dope approved for use with Propane gas. DO NOT use PTFE thread-seal tape.
2. Apply pipe dope sparingly to the 1/8-in. (3 mm) NPT pipe plug (provided in kit) and install in the 1/8-in (3 mm) 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. Refer to Fig. 2 and Fig. 3.
2. Align the orifices in the manifold assembly with the support rings on the end of the burner.
3. Insert the orifices in the support rings of the burners. Manifold mounting tabs should fit flush against the burner box.
   NOTE: If manifold does not fit flush against the burner box, the burners are not fully seated forward. Remove the manifold and check burner positioning in the burner box assembly.
4. Attach the green/yellow wire and ground terminal to one of the manifold mounting screws, see Fig. 2.
5. Install the remaining manifold mounting screws.
6. Connect the wires to the flame sensor and hot surface igniter.
7. Connect the connector harness to gas valve.
   NOTE: Do not use PTFE thread-seal tape.
8. Insert the gas pipe through the grommet in the casing. Apply a thin layer of pipe dope to the threads of the pipe and thread the pipe by into the gas valve.
   NOTE: Use a back-up wrench on the gas valve to prevent the valve from rotating on the manifold or damaging the mounting to the burner box.
9. With a back-up wrench on the inlet boss of the gas valve, finish tightening the gas pipe to the gas valve.
10. Turn gas on at electric switch on gas valve.

CHECK INLET GAS PRESSURE

CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit damage. DO NOT operate furnace more than one minute to check inlet gas pressure, as conversion is not complete at this time.

NOTE: This kit is to be used only when inlet gas pressure is between 4.5-in. w.c. and 13.6-in. w.c.

1. On some models, remove 1/8-in. (3 mm) pipe plug from inlet pressure tap (see Fig. 22 and Fig. 23) and insert pressure tap. Or, on some models, loosen set screw on inlet tower pressure tap no more than one full turn with the 3/32-in. hex wrench, see Fig. 11 or Fig. 13.
2. Verify manometer is connected to inlet pressure tap on gas valve, see Fig. 11 or Fig. 13.
3. Turn on furnace power supply.
4. Turn gas supply manual shutoff valve to ON position.
5. Turn furnace gas valve switch to ON position.

WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, death or property damage. Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.

WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, 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 out and tag switch with a suitable warning label. Verify proper operation after servicing.

Single Stage Gas Valve

1. Jumper R-W thermostat connections on control.
2. When main burners ignite, confirm inlet gas pressure is between 4.5-in. w.c. and 13.6-in. w.c.
3. Remove jumper across R-W thermostat connections to terminate call for heat.
4. Turn furnace gas valve switch to OFF position.
5. Turn gas supply manual shutoff valve to OFF position.
6. Turn off furnace power supply.
7. Remove manometer and on some models remove pressure tap fitting.
8. On some models, apply pipe dope sparingly to end of inlet gas pipe plug and install into unused end of 1/8-in. (3 mm) tee. Use a small back-up wrench on tee when tightening gas inlet pipe plug. Or, on some models, tighten set screw on inlet tower pressure tap with a 3/32-in. hex wrench, see Fig. 11 or Fig. 13.

Two-Stage Gas Valve

CAUTION: ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, or death. Blower access door switch removes 115-V power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes. Do not tape or permanently allow the door switch to be bypassed. Temporarily depress the door switch with one hand while accessing the service buttons with your other hand. Do not touch uninsulated electrical components.

1. Enable two-stage thermostat on furnace control by:
   1. Furnace controls with DIP switches, turn SW1-2 on furnace control ON, see Fig. 26 thru Fig. 28.
   2. Furnace controls with 3 digit display, navigate to (Htt) and select (2st), see Fig. 24 and Fig. 25. See furnace installation manual for additional instructions.
2. Jumper R-W/W1 and R-W2 thermostat connections on control.
3. When main burners ignite, confirm inlet gas pressure is between 4.5-in. w.c. and 13.6-in. w.c.
4. Remove jumper across R-W/W1 and R-W2 thermostat connections to terminate call for heat.
5. Turn furnace gas valve switch to OFF position.
6. Turn gas supply manual shutoff valve to OFF position.
7. Turn off furnace power supply.
8. Remove manometer and on some models remove pressure tap fitting.
9. On some models, apply pipe dope sparingly to the end of inlet gas pipe plug and install into unused end of 1/8-in. (3 mm) tee. Use a small back-up wrench on tee when tightening gas inlet pipe plug. Or, on some models, tighten set screw on inlet tower pressure tap with a 3/32-in. hex wrench, see Fig. 14 or Fig. 16.

Fixed Speed Blower (FCT), Two-Stage Gas Valve

1. Turn Setup Switch SW1 (LHT or TT) on furnace control ON, see Fig. 29 and Fig. 30.
2. Jumper R-W/W1 and R-W2 thermostat connections on control.
3. When main burners ignite, confirm inlet gas pressure is between 4.5-in. w.c. and 13.6-in. w.c.
4. Remove jumper across R-W/W1 and R-W2 thermostat connections to terminate call for heat.
5. Turn furnace gas valve switch to OFF position.
6. Turn gas supply manual shutoff valve to OFF position.
7. Turn off furnace power supply.
8. Remove manometer and on some models remove pressure tap fitting.
9. On some models, apply pipe dope sparingly to the end of inlet gas pipe plug and install into unused end of 1/8-in. (3 mm) tee. Use a small back-up wrench on tee when tightening gas inlet pipe plug. Or, on some models, tighten set screw on inlet tower pressure tap no more than one full turn with a 3/32-in. hex wrench, see Fig. 14 or Fig. 16.

Modulating Gas Valve

CAUTION: ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, or death. Blower access door switch removes 115-V power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes. Do not tape or permanently allow the door switch to be bypassed. Temporarily depress the door switch with one hand while accessing the service buttons with your other hand. Do not touch uninsulated electrical components.

1. Enable two-stage thermostat on furnace control by:
   • Furnace controls with DIP switches, turn SW1-2 on furnace control ON, see Fig. 31 and Fig. 32.
   • Furnace controls with 3 digit display, navigate to (Htt) and select (2St-lHT). See furnace installation manual for additional instructions.
2. Jumper R-W/W1 and R-W2 thermostat connections on control.
3. When main burners ignite, confirm inlet gas pressure is between 4.5-in. w.c. and 13.6-in. w.c.
4. Remove jumper across R-W/W1 and R-W2 thermostat connections to terminate call for heat.
5. Turn furnace gas valve switch to OFF position.
6. Turn gas supply manual shutoff valve to OFF position.
7. Turn off furnace power supply.
8. Remove manometer and on some models remove pressure tap fitting.
9. On some models, apply pipe dope sparingly to the end of inlet gas pipe plug and install into unused end of 1/8-in. (3 mm) tee. Use a small back-up wrench on tee when tightening gas inlet pipe plug. Or, on some models, tighten set screw on inlet tower pressure tap with a 3/32-in. hex wrench, see Fig. 21.

CHECK FURNACE AND MAKE ADJUSTMENTS

WARNING: FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death, and/or property damage. 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 of life.

1. Be sure main gas and electric supplies to furnace are off.
2. On some models, remove 1/8-in. (3 mm) pipe plug from manifold pressure tap on the outlet end of gas valve and insert pressure tap. Or, on some models, loosen the set screw on manifold tower pressure tap no more than one full turn with the 3/32-in. hex wrench.
3. Attach manometer to manifold pressure tap on gas valve, see Fig. 11, Fig. 13, Fig. 14, Fig. 16, or Fig. 21.
4. Turn gas supply manual shutoff valve to ON position.
5. Turn furnace gas valve switch to ON position.
6. Check all threaded pipe connections for gas leaks.
7. Turn on furnace power supply.

GAS INPUT RATE INFORMATION
See furnace rating plates, see Fig. 5, Fig. 6, or Fig. 7, for input rate. The input rate for natural gas is determined by manifold pressure and orifice size. Modulating gas valve must be set for Maximum Heat first and then set for Minimum heat on Modulating furnaces. Two-Stage gas valve is recommended to adjust Low Heat first and then adjust High Heat on Two-Stage furnaces. Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). In the U.S.A.; the input rating for altitudes above 2000 ft. (610M) must be reduced by 2 percent for each 1000 ft. (305 M) above sea level. In Canada; the input rating must be derated by 5 percent for altitudes of 2000 ft. (610 M) to 4500 ft. (1372 M) above sea level. The Conversion Kit Rating Plate accounts for high altitude derate.

SET GAS INPUT RATE
Single Stage Gas Valve

1. Jumper R and W thermostat connections to call for heat, see Fig. 25.
2. Check manifold orifices for gas leaks when main burners ignite.
3. Adjust gas manifold pressure, see Table 4.
4. Remove cap that conceals gas valve regulator adjustment screw.
5. Turn adjusting screw counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure.
6. Replace gas valve regulator seal cap.
7. Verify manifold pressure is correct.
   NOTE: Gas valve regulator seal cap MUST be in place when checking input rate. When correct input is obtained, main burner flame should be clear blue, almost transparent, see Fig. 33. Be sure regulator seal cap is in place when finished.
8. Remove jumper across R and W thermostat connections to terminate call for heat.
9. Turn furnace gas valve control switch or control knob to OFF position.
10. Turn off furnace power supply.
11. Remove manometer and on some models remove pressure tap fitting.
12. On some models, apply pipe dope sparingly to end of 1/8-in. (3 mm) pipe plug and install in the manifold pressure tap opening. Or, on some models, tighten set screw on manifold tower pressure tap with a 3/32-in. hex wrench, see Fig. 5.
13. Turn furnace gas-valve switch to ON position.
14. Turn on furnace power supply.
15. Set room thermostat to call for heat.
16. Check pressure tap plug for gas leaks when main burners ignite.
17. Check for correct burner flame.
18. After making the required manifold pressure adjustments, check and adjust the furnace temperature rise per the furnace installation instructions.

Fixed-Speed Blower (FCT), Two-Stage Gas Valve

1. Verify SW1 (LHT or TT) on furnace control is turned “ON”. See Fig. 30.
2. Jumper R and W/W1 thermostat connections to call for heat.
3. Check manifold orifices for gas leaks when main burners ignite.
4. Adjust gas manifold pressure, see Table 5.
5. Remove caps that conceal adjustment screws for gas valve regulators, see Fig. 6.
6. Adjust low heat input rate manifold pressure.
7. Turn low heat adjusting screw counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.
8. When correct input is obtained, main burner flame should be clear blue, almost transparent, see Fig. 33.
9. Jumper R and W/W1 and W2 on control center thermostat connections. This keeps furnace locked in high heat operation.
10. Adjust high heat input rate manifold pressure.
11. Turn high heat adjusting screw counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.
12. Replace caps that conceal gas valve regulator adjustment screws.
13. When correct input is obtained, main burner flame should be clear blue, almost transparent, see Fig. 33.
14. Remove jumper across R, W1, and W2 after high heat adjustment to terminate call for heat.
15. Turn setup switch SW1 (TT) on furnace control to OFF position.
16. Turn furnace gas-valve switch to OFF position.
17. Turn off furnace power supply.
18. Remove manometer from the manifold pressure tap of the gas valve.
19. On some models, apply pipe dope sparingly to end of 1/8-in. (3 mm) pipe plug and install in the manifold pressure tap opening. Or, on some models, tighten set screw on manifold tower pressure tap with a 3/32-in. hex wrench, see Fig. 6.
20. Turn on furnace power supply.
21. Set room thermostat to call for heat.
22. Check pressure tap plug for gas leaks when main burners ignite.
23. Check for correct burner flame.
24. After making the required manifold pressure adjustments, check and adjust the furnace temperature rise per the furnace installation instructions.

Two-Stage Gas Valve

1. Enable two-stage thermostat on furnace control by:
   • Furnace controls with DIP switches, turn SW1-2 on furnace control ON.
   • Furnace controls with 3 digit display, navigate to (Htt) and select (2st). See furnace installation manual for additional instructions.
2. Jumper R and W/W1 thermostat connections to call for heat.
3. Check manifold orifices for gas leaks when main burners ignite.
4. Remove caps that conceal adjustment screws for gas valve regulators, see Fig. 6.
5. Adjust low-heat manifold pressure, see Fig. 6.
6. 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. 33.
7. Jumper R, W/W1 and W2 on control center thermostat connections. This keeps furnace locked in high-heat operation.
8. Adjust high-heat manifold pressure.
9. Turn high-heat adjusting screw counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.
10. Replace caps that conceal gas valve regulator adjustment screws.
    NOTE: When correct input is obtained, main burner flame should be clear blue, almost transparent, see Fig. 33.
11. Remove jumper across R, W1, and W2 after high-heat adjustment to terminate call for heat.
12. Return thermostat type setting back to desired setting based on your thermostat:
    • Furnace controls with DIP switches, turn SW1-2 on furnace control ON for a two-stage Thermostat, OFF for a single-stage thermostat, see Fig. 30.
    • Furnace controls with 3 digit display, navigate to (Htt) and select (2St) for a two-stage thermostat or select (1St) for a single-stage thermostat. See furnace installation manual for additional instructions.
13. Turn furnace gas valve switch to OFF position.
14. Turn off furnace power supply.
15. Remove manometer from the manifold pressure tap of the gas valve.
16. On some models, apply pipe dope sparingly to end of 1/8-in. (3 mm) pipe plug and install in the manifold pressure tap opening. Or, on some models, tighten set screw on manifold tower pressure tap with a 3/32-in. hex wrench, see Fig. 6.
17. Turn furnace gas valve switch to ON position.
18. Turn on furnace power supply.
19. Set room thermostat to call for heat.
20. Check pressure tap plug for gas leaks when main burners ignite.
21. Check for correct burner flame.
22. Observe unit operation through two complete heating cycles.
23. See Sequence of Operation in furnace Installation, Start-up, and Operating Instructions.
24. Set room thermostat to desired temperature.
25. After making the required manifold pressure adjustments, check and adjust the furnace temperature rise per the furnace installation instructions.

Modulating Gas Valve

CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in gas valve damage. DO NOT force the rotary adjustment switch on the modulating gas valve. DO NOT turn the rotary adjustment switch faster than one click per second when adjusting manifold pressure. Gas valve will be damaged if excessive force is used on the rotary switch.

For proper operation and long term reliability, the manifold pressure must be adjusted as specified on the conversion kit rating plate. The modulating furnace manifold pressure is set at two points. The first point is Maximum Heat. The second point is Minimum Heat. Do not adjust Intermediate Heat manifold pressure. Intermediate Heat manifold pressure can be checked as part of the temperature rise, but is not adjustable. Always adjust Maximum Heat first, then Minimum Heat.

NOTE: Use care when performing adjustments. Gas valve adjustment is performed by turning a rotary adjustment switch inside the gas valve with a small straight blade screwdriver. Excessive force can break or bend the rotary adjustment switch making it non-adjustable.

To adjust manifold pressure to obtain input rate for Maximum Heat:

1. Enable two-stage thermostat with low heat on furnace control by:
   • Furnace controls with DIP switches, turn SW1-2 ON and SW4-2 OFF at the furnace control.
   • Furnace controls with 3 digit display, navigate to (Htt) and select (2St-LHt). See furnace installation manual for additional instructions.
2. Jumper the R to W/W1 and W2 thermostat connections at the furnace control.
3. After the main burners ignite and the blower starts, confirm Maximum Heat manifold pressure is correct, based on the manifold pressure table on the Conversion Kit Rating Plate.
4. To adjust the Maximum Heat manifold pressure, Slowly turn the rotary adjustment switch counterclockwise to decrease manifold pressure or clockwise to increase manifold pressure.
5. Turn rotary adjustment switch no more than one click per second until you obtain the required manifold pressure. Main burner flame should be clear blue, almost transparent.

To adjust manifold pressure to obtain input rate for Minimum Heat:

1. Remove the jumper from W2 at the thermostat connections at the furnace control.
2. Wait until the burners and the blower transitions to Minimum Heat.
3. Verify the Minimum Heat manifold pressure is correct, based on the manifold pressure table on Conversion Kit Rating Plate.
4. To adjust the Minimum Heat manifold pressure, Slowly turn the rotary adjustment switch counterclockwise to decrease manifold pressure or clockwise to increase manifold pressure.
5. Turn rotary adjustment switch no more than one click per second until you obtain the required manifold pressure. This adjustment will not affect the previous Maximum Heat adjustment.
6. When correct input is obtained, remove jumpers across thermostat connections to terminate the call for heat. Wait until the blower off delay is completed.
7. Return thermostat type setting on furnace control back to desired setting based on your thermostat:
   • Furnace controls with DIP switches, set SW1-2 and SW4-2 at furnace control per the furnace installation manual.
   • Furnace controls with 3 digit display, navigate to (Htt) and select (1St) for a single-stage thermostat, (2St-LHt) for a two-stage thermostat running low heat, or (2St iHt) for a two-stage thermostat running intermediate heat. See furnace installation manual for additional instructions.
8. Turn gas supply manual shutoff valve to OFF position.
9. Turn off furnace power supply.
10. Remove manometer from the manifold pressure tap of the gas valve.
11. On some models, apply pipe dope sparingly to end of 1/8-in. (3 mm) pipe plug and install in the manifold pressure tap opening, see Fig. 7. Or, on some models, tighten set screw on manifold tower pressure tap with a 3/32-in. hex wrench, see Fig. 34)
12. Re-install plastic cap over rotary adjustment switch on the top of the gas valve
13. After making the required manifold pressure adjustments, check and adjust the furnace temperature rise at Minimum, Intermediate and Maximum heat per the furnace installation instructions.WARNING: FIRE HAZARD
    Failure to follow this warning could result in personal injury, death, and/or property damage. Manifold pressure trap set screw must be tightened or 1/8-in. (3 mm) NPT pipe plug must be installed to prevent gas leaks.
14. Turn furnace gas valve switch to ON position.
15. Turn on furnace power supply.
16. Set room thermostat to call for heat.
17. Check pressure tap plug for gas leaks when main burners ignite.
18. Check for correct burner flame.

LABEL APPLICATION

1. Fill in Conversion Responsibility Label 351332-205 and apply to Blower Access Door of furnace. Date, name, and address of organization making this conversion are required, see Fig. 35.
2. Attach Conversion Rating Plate Label 351332-201, -204, -206, -207, -208 or -209 to outer door of furnace, see Fig. 5, Fig. 6 or Fig. 7.
3. Attach Gas Control Conversion Label 351332-202 to gas valve. Do not use 351332-203, which is similar.

CHECKOUT

1. Observe unit operation through two complete heating cycles.
2. See Sequence of Operation in furnace Installation, Start-Up, and Operating Instructions.

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A Proud Member of the Carrier Family.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Documents / Resources

Shareddocs AGAGC9PNS01E Gas Conversion Kit [pdf] Installation Guide AGAGC9PNS01E Gas Conversion Kit, AGAGC9PNS01E, Gas Conversion Kit, Conversion Kit, Kit

References

• User Manual