PERMASTELL AG-KN018SNP-03 Gas Conversion Kit Instruction Manual

PERMASTELL
AG-KN018SNP-03 Gas Conversion Kit
instruction Manual A200203

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 that 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 that 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.
The 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 the system, the 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 the 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 a gas conversion kit to convert the following furnaces from natural gas usage to propane gas usage. See the appropriate section for your furnace type.

Table 1 – Kit Contents

SINGLE-STAGE NON-CONDENSING FURNACES
Induced-Combustion furnaces with 42,000 to 154,000 BTUh (not all models have all sizes) gas input rates and (a.) Single-Stage, 4-Way Multi poise, Hot Surface Ignition with PSC blower motor or (b.)
Single-Stage gas valve with Fixed-Speeds Constant Torque ECM (FCT) blower motor.
TWO-STAGE & VARIABLE NON-CONDENSING FURNACES
Induced-Combustion furnaces with 42,000 to 154,000 BTUh (not all models have all sizes a.) Modulating gas valve with Variable-Speed Constant Airflow ECM (VCA), b.) Two-Stage gas valve with Variable-Speed Constant Airflow ECM (VCA), or c.) Two-Stage gas valve with Variable-Speed Constant Torque ECM (VCT) blower motor.
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 kits than will be needed to complete conversion. When the installation is complete, discard extra parts.
SINGLE-STAGE NON-CONDENSING FURNACES

Table 2 – Model Numbers Beginning with:

TWO-STAGE & VARIABLE NON-CONDENSING FURNACES

Table 3 – Model Numbers Beginning with:

WET

INSTALLATION

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, 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.
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, death, or property damage.
The gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, death, or property damage.
The 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 the system, the 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 the switch with a suitable warning label. Verify proper operation after servicing.

1. Set room thermostat to lowest setting or “OFF”.
2. Disconnect power at an external disconnect, fuse, or circuit breaker.
3. Turn off gas at external shut-off or gas meter.
4. Remove outer doors and set them aside.
5. Turn the electric switch on the 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 backup wrench on the gas valve to prevent the valve from rotating on the manifold or damaging the mounting to the burner box. See Fig. 2 and Fig. 3.

1. Disconnect the gas pipe from the gas valve and remove the pipe from the furnace casing.
2. Disconnect the connector harness from the gas valve. Disconnect wires from Hot Surface Igniter (HSI) and Flame Sensor.
3. Support the manifold and remove the 4 screws that secure the manifold assembly to the burner box and set it aside.
4. Note the location of the green/yellow wire ground wire for re-assembly later.
5. Remove wires from both rollout switches.
6. Slide one-piece burner assembly out of slots on the sides of the burner box.
7. Remove the flame sensor from the burner assembly.
8. Remove the orifices from the manifold and discard them.

NOx DEVICE REMOVAL
CAUTION
UNIT DAMAGE HAZARD
For NOx device removal, follow these additional steps:

1. Remove the screw underneath the heat exchanger inlet that secures the NOx device in the heat exchanger. (See Fig. 4)
   Failure to follow this caution may result in unit damage.
   Furnace MUST have low NOx devices removed prior to operating furnace on propane gas.

2. Use a pair of needle nose pliers to remove the NOx device.

3. Squeeze the sides of the device, if necessary, to remove it from the heat exchanger.

4. Re-install screw in the hole underneath the heat exchanger inlet.
   NOTE: It is very IMPORTANT to reinstall the NOx bracket mounting screw.

5. Repeat steps for each heat exchanger.

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 the orifice size must be changed. (See Fig. 5)

Refer to conversion kit rating plate 348709-201 or 348709-204 to determine the main burner orifice size. (See Fig. 6)
The furnace gas input rate on the furnace 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 4 percent for each 1000 ft. above sea level.
In Canada, the input rating must be derated by 10 percent for altitudes of 2000 ft. to 4500 ft. above sea level.
The Conversion Kit Rating Plate accounts for high altitude derate.
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 a wrench. There are enough orifices in each kit for the largest furnace. Discard extra orifices.

CONVERSION KIT RATING PLATE THIS APPLIANCE HAS BEEN CONVERTED TO USE PROPANE GAS FOR FUEL. REFER TO KIT INSTRUCTIONS FOR CONVERSION PROCEDURES. USE PARTS SUPPLIED BY THE MANUFACTURER AND INSTALLED BY QUALIFIED PERSONNEL. SEE EXISTING RATING PLATE FOR APPLIANCE MODEL NO. AND INPUT RATING.
NOTE: Furnace gas input rate on the rating plate is for installations up to 2000 ft. (610m) above sea level. In the U.S.A. the input rating for altitudes above 2000 ft. (610m) must be derated by 4% for each 1000 ft. (305m) above sea level. In Canada, the input rating must be derated by 10% for altitudes of 2000 ft. (610m) to 4500 ft. (1372m) above sea level.
KIT NO.: AGAGCBNPSOIC (SUPERSEDES: KGBNP50011SP, KGANP51012SP, KGCNP5201VSP, NAHD00901LP, NAHB01001LP, AGAGC8NPSO1A, AGAGC8NPSO1B)
FUEL USED: PROPANE GAS INLET PRESSURE (min-max): 12.0 – 13.6 in. we

APPLIANCE
MODELS §| | ALTITUDE OF INSTALLATION (FT. ABOVE SEA LEVEL) U.S.A.
---|---|---
0
to 2000| 2001
to 3000| 3001
to 4000| 4001
to 5000| 5001
to 6000| 6001
to 7000| 7001
to 8000| 8001
to 9000| 9001
to 10000
58S(T/P/C/B), 58DL, 58PH, 31(0/1/3). 8(0/1/2)0S. 8(0/112)1S. PG8M(A/E). PG8J(A/E), PG80ES(AIL), PG80MS(A/L). (N/R)8MS, (F/G/N/R)8MX, N8OVS, (N/R)80ES(N/L) (N/R)80MS(NIL), WF(M/E)(R/L)| Orifice
No.| 55| 1.30mm| 1.30mm| 1.25mm| 1.25mm| 1.25mm| 56| 56| 56
Manifold Pressure
| 11.0| 11.0| 11.| 11.0| 11.0| 11.| 11.0| 11.0| 11.
| | | | | | | | |

• For Canadian Installations from 2000 to 4500 ft. (610m to 1373m) use the U.S.A. column 2001 to 3000 ft. (611m to 914m).
  § THIS KIT IS FOR 45K THROUGH 155K INPUT MODELS ONLY

TWO-STAGE GAS VALVE

CONVERSION KIT RATING PLATE

THIS APPLIANCE HAS BEEN CONVERTED TO USE PROPANE GAS FOR FUEL. REFER TO KIT INSTRUCTIONS FOR CONVERSION PROCEDURES. USE PARTS SUPPLIED BY THE MANUFACTURER AND INSTALLED BY QUALIFIED PERSONNEL. SEE EXISTING RATING PLATE FOR APPLIANCE MODEL NO. AND INPUT RATING. NOTE: Furnace gas input rate on the rating plate is for installations up to 2000 ft. (610m) above sea level. In the U.S.A. the input rating for altitudes above 2000 ft. (610m) must be derated by 4% for each 1000 ft. (305m) above sea level. In Canada, the input rating must be derated by 10% for altitudes of 2000 ft. (610m) to 4500 ft. (1372m) above sea level.
KIT NO.: AGAGC8NPSOIC (SUPERSEDES: KGBNP50011SP, KGANP51012SP, KGCNP5201VSP, NAHD00901LP, NAHB01001LP, AGAGC8NPSO1A, AGAGC8NPSO1B)
FUEL USED: PROPANE GAS INLET PRESSURE (min-max): 12.0 – 13.6 in. we

APPLIANCE MODELS §| | **ALTITUDE OF INSTALLATION (FT. ABOVE SEA LEVEL) U.S.A.

---|---|---
0
to 2000| 2001 *
to 3000| 3001
to 4000| 4001
to 5000| 5001
to 6000| 6001
to 7000| 7001
to 8000| 8001
to 9000| 9001
to 10000
58CV, 58CT, 58T(N/P),
31(2/4/5), 82(0/1)T, 88(0/1)T, PG8(M/J)V, PG80V, (F/G)8MT, (F/G)8MV, (F/G/N)80CTL, (F/G/N)80V, WFET| Orifice
No.| 55| 1.30mm| 1.30mm| 1.25mm| 1.25mm| 1.25mm| 56| 56| 56
Manifold Pressure
HIGH| 11.0| 11.0| 11.| 11.0| 11.0| 11.| 11.0| 11.0| 11.
LOW| 6.| 5.| 5.0| 6.| 5.| 5.| 6.| 5.| 5.

• For Canadian Installations from 2000 to 4500 ft. (610m to 1373m) use the U.S.A. column 2001 to 3000 ft. (611m to 914m).
  § THIS KIT IS FOR 45K THROUGH 155K INPUT MODELS ONLY

Fig. 6 – Conversion Kit Rating Plate

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 a wrench.

2. There are enough orifices in each kit for the largest furnace. Discard extra orifices.

NOTE: DO NOT reinstall the manifold at this time.

**INSTALL MIXER SCREWS

**

NOTE: There are two sets of mixer screws. One set is for Condensing gas furnaces, the other set is for Non-condensing gas furnaces. Use only the parts in the bag marked “REQUIRED FOR THE CONVERSION OF NON-CONDENSING GAS FURNACES TO PROPANE GAS” See Fig. 7 to verify you have the correct set of mixer screws.

1. Locate the dimple on each burner venturi tube. If you cannot locate the dimple, refer to Fig. 8 for the location of the mixer screw.
2. Drill a 5/64-in. (2.8 mm) hole (supplied in kit) in each dimple.
3. Install a mixer screw in each drilled hole drilling as straight as possible. The screw head should be flush with the top of the burner venturi.

1337932-7021

REQUIRED FOR CONVERSION OF NON-CONDENSING GAS FURNACE TO PROPANE GAS.

A11397
Fig. 7 – Gas Conversion Kit

REINSTALL BURNER ASSEMBLY
To reinstall burner assembly:

1. Attach flame sensor to the burner assembly.
2. Install HSI and bracket to the burner assembly.
3. Insert a one-piece burner in the slot on the sides of the burner box and slide the burner back in place.
4. Reattach HSI wires to HSI.
5. Verify igniter to burner alignment.
6. For Silicon Nitride igniters, see Fig. 9.
7.  Re-attach the Flame sensor wire to Flame Sensor.

CONVERT GAS VALVE

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.
The 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 the system, the 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 the switch with a suitable warning label. Verify proper operation after servicing.

Single Stage Gas Valve

1. Refer to Fig. 10.
2. Be sure gas and electrical supplies to the furnace are off.
3. Remove caps that conceal adjustment screws for the gas valve regulators. (See Fig. 10)
4. Remove the regulator adjustment screw.
5. Remove the regulator springs (silver).
6. Install the propane gas regulator springs (white).
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 propane set point. (See Fig. 10)
9. Do not install regulator seal caps at this time.

Gas Valve (Single Stage)

Redundant Auto Gas Valve

Two Stage Gas Valve
NOTE: For older model 2-stage furnaces with a Series E gas valve (see Fig. 11), 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 propane applications.

For E valves see Fig. 11.

1. Be sure gas and electrical supplies to the furnace are off.
2. Remove caps that conceal adjustment screws for high- and low-heat stage gas valve regulators. See Fig. 10.
3. Turn the low-heat stage adjusting screw (3/32-in. [2 mm] hex Allen screw) clockwise (in) 1 full turn. This will increase the manifold pressure closer to the propane low-heat set point.
4. Turn the high-heat stage adjusting screw (3/32-in. [2 mm] hex Allen screw) clockwise (in) 2 full turns. This will increase the manifold pressure closer to the propane high-heat set point.
5. Do not install regulator seal caps at this time.

For all other gas, valves see Fig. 11.

1. Be sure the main gas and electrical supplies are turned OFF.

2. Remove both regulator seal caps. (See Fig. 11)

3. Remove both regulator adjustment screws.

4. Remove both natural gas regulator springs (silver).

5. Install propane gas regulator springs (white).

6. Install regulator adjustment screws.

7. Turn low-heat stage adjusting screw clockwise (inwards) 9.5 turns.
   This will increase the manifold pressure closer to the low-heat set point.

8. Turn the high-heat stage adjusting screw clockwise (inwards) 13.5 turns. This will increase the manifold pressure closer to the high-heat set point.

9. Do not install regulator seal caps at this time.

NOTE: For the two-stage furnaces (see Fig. 11), they MUST have both regulator springs replaced and the gas valve MUST be pre-adjusted.

Two Stage E Valve

Two Stage Valve

INSTALL MANIFOLD

1. Align the orifices in the manifold assembly with the support rings on the end of the burner.

2. Insert the orifices in the support rings of the burners. Manifold mounting tabs should fit flush against the burner box.
   NOTE: If the 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.

3. Attach the green/yellow wire and ground terminal to one of the manifold mounting screws.

4. Install the remaining manifold mounting screws.

5. Connect the wires to the flame sensor and hot surface igniter.

6. Connect the wires to both rollout switches.

7. Connect the connector harness to the gas valve.
   NOTE: Use only propane-resistant pipe dope. 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 into the gas valve.
   NOTE: Use a backup 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 backup wrench on the inlet boss of the gas valve, finish tightening the gas pipe to the gas valve.

10. Turn the gas on at the electric switch on the gas valve.

INSTALL LOW GAS PRESSURE SWITCH

WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, death, or property damage.
The 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 the system, the 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 the switch with a suitable warning label. Verify proper operation after servicing.

NOTE: Use propane-resistant pipe dope on all connections to prevent gas leaks. DO NOT use PTFE thread-seal tape.

1. Be sure the main gas and electric supplies to the furnace are off.
2. Remove 1/8-in. (3 mm) pipe plug from inlet pressure taps on the gas valve. DO NOT DISCARD 1/8-in. (3 mm) PLUG.
3. Apply pipe dope sparingly to the 1/8-in. (3 mm) x 2-in. (50.8 mm) brass nipple and install the doped end in 1/8-in. (3 mm) tapped opening in gas valve inlet pressure-tap. Tighten fitting with a small wrench.
4. Apply pipe dope sparingly to the opposite end of the 1/8-in. (3 mm) x 2-in. (50.8 mm) brass coupling. Install the female end of the female x female x male tee on the brass coupling.
5. Tighten tee finger tight. Use a small open-end wrench for final tightening. The male end of the tee should be facing you.
6. Apply pipe dope sparingly to the end of the brass tee.
7. Install a propane low gas pressure switch on the male end of the female x female x male tee.
8. Tighten and switch fingers tight.
9. Use a small open-end wrench on the base of the pressure switch for final tightening. The contacts of the LGPS should be pointing toward the inducer motor when complete.
10. The remaining opening on the brass street tee is the new gas valve inlet pressure tap
11. Install manometer fitting to the open end of the brass street tee. Or if installation is to be completed later, apply pipe dope to the inlet pressure plug from the gas valve installed in the open end of the brass street tee.
12. Check all fittings for leaks after the gas supply has been turned on.

WARNING
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 in causing property damage, personal injury, or loss of life.

MODIFY PRESSURE SWITCH WIRING

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.

1. Locate the orange wire in the kit with an insulated straight female spade terminal and an insulated straight male terminal on the other end.
2. Connect the female terminal to a terminal on the Low Gas Pressure Switch.
3. Locate the orange wire in the kit with an insulated straight female spade terminal and an insulated female flag terminal on the other end.
4. Connect both straight female terminals of the orange wires to the terminals on the Low Gas Pressure Switch.
5. Disconnect an orange wire from low-heat pressure switch LPS on inducer housing.
6. Connect the orange wire from the Low Heat Pressure Switch to the orange wire with the insulated male spade terminal.
7. Connect the orange wire from the Low Gas Pressure Switch to the terminal on the Low Heat Pressure Switch.
8. Route orange wires along the wire harness. If possible, secure with wire tie provided in the kit.

Single Stage Gas Valve

Representative drawing only, some models may vary in appearanceRepresentative drawing only, some models may vary in appearance
Fig. 13 – Example of Single Stage Furnace Control

1. Jumper R-W thermostat connections on control.
2. When main burners ignite, confirm inlet gas pressure is between 12.0-in. w.c. and 13.6-in. w.c.
3. Remove the jumper across the R-W thermostat connections to terminate the call for heat.
4. Turn furnace gas valve switch to OFF position.
5. Turn the gas supply manual shutoff valve to the OFF position.
6. Turn off the furnace power supply.
7. Remove the manometer and on some models remove the pressure tap fitting.
8. Apply pipe dope sparingly to the end of the inlet gas pipe plug and install it into the unused end of 1/8-in. (3 mm) tee. Use a small backup wrench on the tee when tightening the gas inlet pipe plug. (See Fig. 10)

Two-Stage Gas Valve

1. Enable two-stage thermostat on control board by:
   a. For boards with DIP switches, turn SW1-2 on furnace control ON, see Fig.

2. b. For boards with 3 digit display, navigate to (Htt) and select (2nd), see Fig. 14. See furnace installation manual for additional instructions.

3. Jumper R-W/W1 and R-W2 thermostat connections on control.

4. When main burners ignite, confirm inlet gas pressure is between 12.0-in. w.c. and 13.6-in. w.c.

5. Remove the jumper across R-W/W1 and R-W2 thermostat connections to terminate the call for heat.

6. Turn furnace gas valve switch to OFF position.

7. Turn the gas supply manual shutoff valve to the OFF position.

8. Turn off the furnace power supply.

9. Remove the manometer and on some models remove the pressure tap fitting.

10. Apply pipe dope sparingly to the end of the inlet gas pipe plug and install it into the unused end of 1/8-in. (3 mm) tee. Use a small backup wrench on the tee when tightening the gas inlet pipe plug. (See Fig. 10)

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

A11470
Representative drawing only, some models may vary in appearance.
Fig. 15 – Example of PSC or Discrete Tap Two-Stage Furnace Control

1. Turn Setup Switch SW1 (LHT or TT) on furnace control ON (see Fig. 15).
2. Jumper R-W/W1 and R-W2 thermostat connections on control.
3. When main burners ignite, confirm inlet gas pressure is between 12.0-in. w.c. and 13.6-in. w.c.
4. Remove the jumper across R-W/W1 and R-W2 thermostat connections to terminate the call for heat.
5. Turn furnace gas valve switch to OFF position.
6. Turn the gas supply manual shutoff valve to the OFF position.
7. Turn off the furnace power supply.
8. Remove the manometer and on some models remove the pressure tap fitting.
9. Apply pipe dope sparingly to the end of the inlet gas pipe plug and install it into the unused end of 1/8-in. (3 mm) tee. Use a small backup wrench on the tee when tightening the gas inlet pipe plug. (See Fig. 10)

CHECK INLET GAS PRESSURE

CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit damage.
DO NOT operate the furnace for more than one minute to check inlet gas pressure, as the conversion is not complete at this time.
NOTE: This kit is to be used only when inlet gas pressure is between 12.0-in. w.c. and 13.6-in. w.c.

1. Verify manometer is connected to the inlet pressure tap on the gas valve.

2. Turn on the furnace power supply.

3. Turn the gas supply manual shutoff valve to the ON position.

4. Turn furnace gas valve switch to ON position.

5. Turn Setup Switch SW1-2 on furnace control ON (see Fig. 14).

6. For single-stage jumper R-W thermostat connections on control.
   For two-stage jumper R-W/W1 and R-W2 thermostat connections on control.

7. When main burners ignite, confirm inlet gas pressure is between 12.0-in. w.c. and 13.6-in. w.c.

8. For single-stage remove jumper R-W thermostat connections on control to terminate the call for heat.
   For two-stage remove jumper R-W/W1 and R-W2 thermostat connections on control to terminate the call for heat.

9. Turn furnace gas valve switch to OFF position.

10. Turn the gas supply manual shutoff valve to the OFF position.

11. Turn off the furnace power supply.

12.  Remove the manometer.

13.  Apply pipe dope sparingly to the end of the inlet gas pipe plug and install it into the unused end of 1/8-in. (3 mm) tee. Use a small backup wrench on the tee when tightening the gas inlet pipe plug. (See Fig. 16)

CHECK FURNACE AND MAKE ADJUSTMENTS

WARNING
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 in causing property damage, personal injury, or loss of life.
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, death, or property damage.
The 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 the system, the 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 the switch with a suitable warning label. Verify proper operation after servicing.

1. Be sure the main gas and electric supplies to the furnace are off.
2. Remove 1/8-in. (3 mm) pipe plug from manifold pressure tap on the downstream side of the gas valve.
3. Attach manometer to manifold pressure tap on the gas valve.
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 the furnace power supply.

GAS INPUT RATE INFORMATION
The gas input rate for propane is the same as for natural gas. See furnace rating plate for input rate. The input rate for propane is determined by manifold pressure and orifice size.
The gas valve must be set for Low Heat first and then set for High Heat on two-stage and variable-speed furnaces. The furnace gas input rate on the 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. (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. 13)

2. Check manifold orifices for gas leaks when main burners ignite.

3. Adjust gas manifold pressure. (Refer to conversion kit rating plate 348709-201.

4. Remove the cap that conceals the gas valve regulator adjustment screw.

5. Turn the adjusting screw counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure.

6. Replace the 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, the main burner flame should be clear blue, almost transparent (See Fig. 17). Be sure the regulator seal cap is in place when finished.

8. Remove the jumper across R and W thermostat connections to terminate the call for heat.

9. Turn the furnace gas valve control switch or control knob to the OFF position.

10. Turn off the furnace power supply.

11. Remove the manometer and on some models remove the pressure tap fitting.

12. Turn furnace gas-valve switch to ON position.

13.  Turn on the furnace power supply.

14. Set room thermostat to call for heat.

15. Check pressure tap plug for gas leaks when main burners ignite.

16. Check for the correct burner flame.

17. 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. 15)
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.
5. Remove caps that conceal adjustment screws for gas valve regulators. (See Fig. 10)
6. Adjust low heat input rate manifold pressure for propane gas.
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. 17)
9. Jumper R and W/W1 and W2 on control center thermostat connections. This keeps the furnace locked in high heat operation.
10. Adjust high heat input rate manifold pressure for propane gas.
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. 17)
14. Remove the jumper across R, W1, and W2 after high heat adjustment to terminate the call for heat.
15. Turn setup switches SW1 (TT) on furnace control to OFF position.
16. Turn furnace gas-valve switch to OFF position.
17. Turn off the furnace power supply.
18. Remove the manometer from the manifold pressure tap of the gas valve.
19. Turn on the furnace power supply.
20. Set room thermostat to call for heat.
21. Check pressure tap plug for gas leaks when main burners ignite.
22. Check for the correct burner flame.
23. 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 control board by:
   a. For boards with DIP switches, turn SW1-2 on furnace control ON.
   b. For boards with 3 digit display, navigate to (Htt) and select (2st). See the 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. Adjust gas manifold pressure. (Refer to conversion kit rating plate 348709-204.

5. Remove caps that conceal adjustment screws for gas valve regulators. (See Fig. 11)
   Adjust low-heat manifold pressure for propane gas. (See Fig. 11)

6. Turn the low-heat adjusting screw counterclockwise (out) to decrease the input rate or clockwise (in) to increase the input rate.
   NOTE: When correct input is obtained, main burner flame should be clear blue, almost transparent. (See Fig. 17).

7. Jumper R, W/W1, and W2 on control center thermostat connections.
   This keeps the furnace locked in high-heat operation.

8. Adjust high-heat manifold pressure for propane gas.

9. Turn the high-heat adjusting screw counterclockwise (out) to decrease the input rate or clockwise (in) to increase the 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. 17)

11. Remove the jumper across R, W1, and W2 after high-heat adjustment to terminate the call for heat.

12. Return thermostat type setting back to it’s desired to set based on your thermostat:
    a. For boards with DIP switches, turn SW1-2 on furnace control ON for a two- stage Thermostat, OFF for a single-stage
    Thermostat, see Fig. 22.
    b. For boards with 3 digit display, navigate to ( ) and select ( ) for a two- stage thermostat or select ( ) for a single-stage thermostat. See the furnace installation manual for additional instructions.

13. Turn furnace gas valve switch to OFF position.

14. Turn off the furnace power supply.

15. Remove the manometer and re-install the manifold pressure tap plug.

16. Turn furnace gas valve switch to ON position.

17. Turn on the furnace power supply.

18.  Set room thermostat to call for heat.

19. Check pressure tap plug for gas leaks when main burners ignite.

20. Check for the correct burner flame.

21. Observe unit operation through two complete heating cycles.

22. See Sequence of Operation in furnace Installation, Start-Up, and Operating Instructions.

23. Set room thermostat to the desired temperature.
    After making the required manifold pressure adjustments, check and adjust the furnace temperature rise per the furnace installation instructions.
    

CHECK LOW GAS PRESSURE SWITCH
The newly installed low gas pressure switch is a safety device used to guard against adverse burner operating characteristics that can result from low gas supply pressure. The switch opens at not less than 6.5 in. w.c.
and closes at not greater than 10.2 in. w.c.

This switch also prevents operation when the propane tank level is low which can result in gas with a high concentration of impurities, additives, and residues that have settled to the bottom of the tank. Operation under these conditions can cause harm to the heat exchanger system. This normally open switch closes when gas is supplied to the gas valve under normal operating pressure. The closed switch completes the control circuit. Should an interruption or reduction in gas supply occur, the gas pressure at the switch drops below the low gas pressure switch setting, and the switch opens. Any interruption in the control circuit (in which the low gas pressure switch is wired) quickly closes the gas valve and stops gas flow to the burners. When normal gas pressure is restored, the system must be electrically reset to re- establish normal heating operation.
Before leaving the installation, observe a unit operation through two complete heating cycles. During this time, turn the gas supply to the gas valve off just long enough to completely extinguish the burner flame, then instantly restore the full gas supply. To ensure proper low gas pressure switch operation, observe that there is no gas supply to burners until after the hot surface igniter begins glowing.

LABEL APPLICATION

1. Fill in Conversion Responsibility Label 348709-205 and apply it to the Blower Access Door of the furnace. The date, name, and address of the organization making this conversion are required. (See Fig. 18)
2. Attach Conversion Rating Plate Label 348709-201 or 348709-204 to the outer door of the furnace. (See Fig. 6)
3. Apply Gas Control Conversion Label: Use Gas Control Conversion Label 348709-202 (See Fig. 19) Do not use 348709-203 which is similar.
4. Replace the control access door, blower access door, and outer door of the furnace.

CHECKOUT

1. Observe unit operation through two complete heating cycles.
2. See Sequence of Operation in furnace Installation, Start-Up, and Operating Instructions.
3. Set the room thermostat to the desired temperature.

THIS FURNACE WAS CONVERTED ONTO PROPANE GAS
(DAY-MONTH-YEAR) KIT NO.: AGAGC8NPSO1C
BY: ————–
(Name and address of organization making this conversion), which accepts the responsibility that this conversion has been properly made.

Fig. 18 – Gas Conversion Responsibility Label

This control has been converted for use with propane gas.| This control has been adjusted for use with propane gas.|
---|---|---
348709-202 REV.-| 348709-203 REV.-| 348709-205 REV.-

Fig. 19 – Gas Conversion Label
AGAGC8NPS01C
Gas Conversion Kit, Natural-to-Propane
Non-Condensing (80%) Furnace
45,000 BTUh to 155,000 BTUh Models Only
© 2022 Carrier. All rights reserved.
A Carrier Company
Catalog No: AG-KN018SNP-03
Replaces: AG-KN018SNP-02
The manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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