REZNOR LDAP Gas Conversion Kit

Product Information

Gas Conversion Kit for LDAP Downflow Unit Heaters

The Gas Conversion Kit is intended for use with Model LDAP Downflow Unit Heaters fitted with either a single-stage gas valve (unit sizes 400, 800, and 1200) or a two-stage gas valve (unit size 400). The kit can convert the heater from natural gas to propane or from propane to natural gas. It is important to have the complete heater model when converting fuels, and the identifying model number can be found on the heater rating plate. The rating plate identifies only original equipment, so it is also necessary to compare the label on the gas valve with the description listed.

The Gas Conversion Kit contains various components such as Spring kits, Tape Conversion, Elevation adjustment labels, Burner Orifice, and Gas Valve. The kit component selection depends on the type of conversion required and unit size of the heater being serviced.

Important Safety Information

Before installing or servicing this kit, it is important to read and understand all instructions and warnings included in the user manual. Failure to follow the instructions may result in personal injury or damage to the equipment. The warnings used are:

• DANGER: Designates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
• CAUTION: Designates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Product Usage Instructions

1. Verify that the Gas Conversion Kit is correct for the size of the heater being serviced (refer to Table 1 or Table 2).
2. Turn off the gas supply and electrical power to the unit before starting the conversion process.
3. Remove the front cover of the heater and locate the gas valve.
4. Disconnect the gas valve from the unit and remove it from the heater.
5. Install the new gas valve provided in the kit by following the instructions included in the kit.
6. Replace the burner orifices with the new ones provided in the kit (refer to Table 1 or Table 2 for the correct size).
7. Replace any other components as instructed in the kit if required.
8. Reconnect the gas valve to the unit and secure it in place.
9. Reconnect the electrical power to the unit.
10. Turn on the gas supply and test the unit to ensure that it is operating correctly.

Note: It is recommended to have a qualified technician perform the installation of this kit to ensure proper and safe installation.

GENERAL INFORMATION

These gas conversion kits are for model LDAP downflow unit heaters equipped with either a single-stage gas valve (unit sizes 400, 800, and 1200) or a two- stage gas valve (unit size 400).

Model Identification
When converting fuels, it is necessary to have the complete heater model. The identifying model number can be found on the heater rating plate. The rating plate identifies only original equipment so also compare the label on the gas valve with the description listed.

Important Safety Information

• Refer to the installation manual provided with the heater for important safety information.
• Pay attention to all dangers, warnings, cautions, and notes highlighted in this manual. Safety markings should not be ignored and are used frequently throughout to designate a degree or level of seriousness

DANGER

• All gas conversion must be done by a qualified service person in accordance with these instructions and in compliance with all codes and requirements.
• The gas burner in this gas-fired equipment is designed to provide safe complete combustion. However, if the installation does not permit the burner to receive the proper supply of combustion air, complete combustion may not occur. The result is incomplete combustion, which produces carbon monoxide, a poisonous gas that can cause death.
• Safe operation of indirect-fired gas burning equipment requires a properly-operating vent system that vents all flue products to the outside atmosphere. Failure to provide proper venting will result in a health hazard that could cause serious personal injury or death.
• For all heater installations, always comply with the combustion air requirements in the installation codes and instructions. Downflow unit heaters installed in a confined space must be supplied with air for combustion as required by code and in the heater installation manual. Combustion air at the burner should be regulated only by manufacturer-provided equipment. Never restrict or otherwise alter the supply of combustion air to any heater. Maintain the vent or vent/combustion air system in structurally sound and proper operating condition.
• Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death. Read the installation, operation and maintenance instructions thoroughly before installing or servicing this equipment.
• The conversion kit is to be selected and installed by a qualified service person in accordance with these instructions and in compliance with all codes and requirements of authorities having jurisdiction. Failure to follow instructions could result in death, serious injury, and/or property damage. The qualified agency performing this work assumes responsibility for this conversion.

Heater Component Locations
Heater component locations are shown in Figure 1.

CONVERSION KIT SELECTION

Ensure that conversion kit is correct for unit size of heater being serviced and that all parts are included. Refer to Table 1 for a list of natural gas to propane conversion kit components. Refer to Table 2 for a list of propane to natural

Table 1. Natural Gas to Propane Conversion Kit Components

Component

|

Description

| Gas Valve (Honeywell Model No.)
Two-stage (VR8305N4297)| Single-stage (VR8305K4241)
Unit Size
400| 400| 800| 1200
Kit PN
208879| 208877| 208894| 208895
Component PN
Spring kit| #396021 for two-stage valve| 197207| —

393691 for single-stage valve VR8105, VR8205, or VR8305| —| 98720

Tape| Conversion| 64391
Disk| Propane| 37752
Elevation adjustment label| For installation elevations >2000 feet (>610 meters)| 197062
Burner orifice | 5.88 mm| 196905
Quantity is one (1) for unit size 400, two (2) for unit size 800, or three (3) for unit size 1200.
Table 2. Propane to Natural Gas Conversion Kit Components

Component

|

Description

| Gas Valve (Honeywell Model No.)
Two-stage (VR8305N4289)| Single-stage (VR8305K4258)
Unit Size
400| 400| 800| 1200
Kit PN
208880| 208878| 208896| 208897
Component PN
Spring kit| #396025 for two-stage valve| 197208| —

394588 for single-stage valve VR8105, VR8205, or VR8305| —| 98721

Tape| Conversion| 64391
Disk| Natural gas| 1401
Elevation adjustment label| For installation elevations >2000 feet (>610 meters)| 197062
Burner orifice | 9.60 mm| 196897
Quantity is one (1) for unit size 400, two (2) for unit size 800, or three (3) for unit size 1200.

INSTALLATION

Install the conversion kit in accordance with the following steps. Ensure that the kit is correct for the size of the heater being serviced (refer to Table 1 or Table 2).

1. Remove gas supply and electrical power:

   • a. Turn OFF gas supply at shutoff valve outside of heater.
   • b. Turn OFF electrical power.
   • c. Open control access panel.

2. Install regulator spring kit:
   WARNING
   Regulator spring kits are not interchangeable. Each kit must be used only in the model and type of gas valve for which the kit is designated. Verify compatibility before installing the regulator spring kit.

   • a. Select regulator spring kit that corresponds with gas valve on heater.
   • b. Install regulator spring kit in accordance with gas valve manufacturer’s instructions (included with regulator spring kit).
     CAUTION
     After a new regulator spring kit is installed, it is necessary to adjust the spring by adjusting the manifold pressure. This adjustment can be made only after the heater is in operation (refer to step 7).

3. Replace burner orifice:
   CAUTION
   When removing or replacing a burner orifice, use two wrenches and take care not to damage the venturi tube and/or the bracket.

   • a. Carefully remove existing burner orifice (see Figure 1).

   • b. Select replacement burner orifice in accordance with Table 1 or Table 2.
     WARNING
     Do not attempt to drill burner orifice. Use factory-supplied orifice only.

   • c. Install replacement burner orifice (see Figure 1).

4. For installations at elevations >6,000 feet (>1,830 meters), replace pressure switch in accordance with Pressure Switch Replacement section in installation/operation/maintenance manual provided with unit.
   CAUTION
   If the heater will be operated at an elevation >6,000 feet (>1,830 meters), a high-elevation pressure switch (option DJ20) must be installed. Contact your distributor (refer to replacement parts manual) to select the factory- authorized replacement part.

5. Restore electrical power and gas supply:

   • a. Turn ON electrical power.
   • b. Turn ON gas supply and relight heater, following instructions on heater.

6. Perform leak test:

   • a. Check all connections for gas leaks using commercial leak-detecting fluid or rich soap and water solution. Leaks are indicated by presence of bubbles.

   • b. If leak is detected, tighten connection. If leak cannot be stopped by tightening connection, replace part(s).
     NOTES:

   • Conversion of a unit using these kits does not alter the input rate. Refer to the rating plate on the heater for the input rate and other appropriate information.

   • If adjusted for high-elevation operation, the input rate will be affected.

   • The high-elevation adjustment label is not used on units operated at elevations of ≤2,000 feet (≤610 meters).

7. Adjust manifold (outlet) gas pressure in accordance with Measure and Adjust Manifold (Outlet) Gas Pressure section in installation/operation/maintenance manual provided with unit.

8. Close control access panel.

Specifications and illustrations subject to change without notice or incurring obligations.
Latest version of this manual is available at www.reznorhvac.com.
©2022 Nortek Global HVAC LLC, O’Fallon, MO. All rights reserved.
LDAP-GC (01-22) 208881-AAGENCYPROCESSSTART

References

• Reznor HVAC

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