Natural Gas to Propane Conversion Instructions

ManualsBrandsAirQuest ManualsCooling & Air Quality60,000 BTU 96% AFUE Two-Stage Multi-Positional Communicating Gas Furnace

AG--KC019SNP--02 9/19/2019

Specifications subject to change wi thout notice.

AGAGC9NPS01A

Installation Instructions

Gas Conver sion Kit

N a t u r a l --- t o --- P r o p a n e f o r

Conde nsing ( 90%+) F urnace s

40,000 BT UH to 140, 000 BTUH Models Only

CERTIFIED

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.

AVERTISSEMENT

LE FEU, L’EXPLOSION, CHOC ELECTRIQUE,

ET MONOXYDE DE CARBONE EMPOISONNER

Cette trousse de conversion doit être installée 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 qualifié est responsable de

l’installation de cette trousse. L’installation n’est pas adéquate

ni complète tant que le bon fonctionnement de l’appereil

converti n’a pas été vérfié selon les instructions du fabricant

fornies avec la trousse.

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 s afety--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 ma y 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

! W

RNING

FIRE, EXPLOSION, ELECTRICAL SHOC

ND 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.

! W

RNING

FIRE, EXPLOSION, ELECTRICAL SHOC

HAZARD

Failure to follow this warning could result in personal injury,

death or property damage.

Gas s upply MUST be shut off before disconnecting electrical

power and proceeding with conversion.

Summary of content (18 pages)

PAGE 1
AGAGC9NPS01A Gas Conversion Kit Natural---to---Propane for Condensing (90%+) Furnaces 40,000 BTUH to 140,000 BTUH Models Only Installation Instructions CERTIFIED 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.
PAGE 2
! DESCRIPTION AND USAGE 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.
PAGE 3
MANIFOLD/ORIFICE/BURNER REMOVAL ! Figure 3 Burner Assembly IGNITER BURNER SUPT. ASSY BRACKET, IGNITER CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in unit damage or improper operation. BURNER ASSY Label all wires prior to disconnection when servicing controls. ! PRUDENCE FLAME ROLLOUT SWITCH D’EQUIPEMENT D’OPERATION Toute erreur de câblage peut être une source de danger et de panne.
PAGE 4
Figure 5 Conversion Kit Rating Plate (40,000 BTUH to 140,000 BTUH ONLY) Single--Stage Gas Valve A190112 A190113 Two--Stage Gas Valve A190117 A190118 4 Specifications subject to change without notice.
PAGE 5
Modulating Gas Valve A190115 A190116 INSTALL ORIFICES Figure 6 Gas Conversion Kit 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. INSTALL MIXER SCREWS NOTE:“REQUIRED FOR THE CONVERSION OF CONDENSING GAS FURNACES TO PROPANE GAS” 1.
PAGE 6
Figure 7 CONVERT GAS VALVE Mixer Screw Location ! Drill out with 7/64” drill bit 1.9” (48.76 mm) 1.8” (46.96 mm) A11460 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 Figure 8 & Figure 9) Figure 8 UNIT OPERATION HAZARD Failure to follow this caution may result in unit damage or improper operation.
PAGE 7
Two Stage Gas Valve 9. Do not install regulator seal caps at this time. Figure 10 Refer to Figure 11. Gas Valve (Single Stage) Gas Valve (Two--Stage) Figure 11 If there is a GREEN LABEL on gas valve, ensure the correct conversion kit is ordered for the 26K BTUH models.
PAGE 8
6. Turn high heat stage adjusting screw clockwise (in) 13.5 full turns. This will increase the manifold pressure closer to the propane set point. 7. Turn low heat stage adjusting screw clockwise (in) 9.5 full turns. This will increase the manifold pressure closer to the propane low heat set point. 8. Do not install regulator seal caps at this time.
PAGE 9
INSTALL LOW GAS PRESSURE SWITCH NOTE:Install the Low Gas Pressure Switch before installing the manifold on the burner assembly. There are two ways to mount the Low Gas Pressure Switch. 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.
PAGE 10
9. 10. 11. 12. female threads face point to the male threads of the 2--in brass nipple. With a small back--up wrench on the brass street elbow, tighten the brass street tee with a small wrench until the fittings are tight and the male portion of the threads point away from you. Apply pipe dope sparingly to the male threads of the 1/8--in. brass street elbow. Install the Low Gas Pressure Switch on the male threads of the street elbow. Tighten switch at hex fitting at base of switch.
PAGE 11
screw on inlet tower pressure tap no more than one full turn with the 3/32--in. hex wrench. (see Figure 10) 2. Verify manometer is connected to inlet pressure tap on gas valve. (See Figure 10) 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 ! WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death or property damage.
PAGE 12
Variable Speed Blower, Two--Stage Gas Valve Figure 19 Example of Variable Speed Furnace Control for ECM (VCA) Blower Motor COMMUNICATION CONNECTOR MODEL PLUG CONNECTOR CONTINUOUS FAN (CF) AIRFLOW SETUP SWITCHES OUTDOOR AIR TEMP CONNECTOR SW4 SETUP SWITCHES SW1 SETUP SWITCHES AND BLOWER OFFDELAY AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCHES HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.
PAGE 13
Fixed Speed Blower (FCT), Two--Stage Gas Valve Figure 20 Example of Two--Stage Furnace Control SET UP SWITCHES THERMOSTAT TYPE (TT) AND HEAT OFF--DELAY TWINNING AND/OR COMPONENT TEST TERMINAL ON OFF W2 1 2 3 Y1 DHUM TT OFF DLY G COM 24V 24--V THERMOS TAT TERMINALS TEST / TWIN PLT W/W1 Y/Y2 HUM 24VAC HUMIDIFIER TERMINAL (24 VAC 0.
PAGE 14
Modulating Gas Valve Figure 21 Example of Modulating Furnace Control for ECM Blower Motor COMMUNICATION CONNECTOR MODEL PLUG CONNECTOR CONTINUOUS FAN (CF) AIRFLOW SETUP SWITCHES OUTDOOR AIR TEMP CONNECTOR SW4 SETUP SWITCHES PL8 - MODULATING GAS VALVE CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFFDELAY AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCHES HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.
PAGE 15
CHECK FURNACE AND MAKE ADJUSTMENTS ! SET GAS INPUT RATE Figure 22 WARNING Burner Flame Burner 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.
PAGE 16
8. When correct input is obtained, main burner flame should be clear blue, almost transparent. (See Figure 22) 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 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.
PAGE 17
6. 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 board control. 2. Wait until the burners and the blower transitions to Minimum Heat. 3.
PAGE 18
The closed switch completes control circuit. Should an interruption or reduction in gas supply occur, the gas pressure at switch drops below low gas pressure switch setting, and switch opens. Any interruption in control circuit (in which low gas pressure switch is wired) quickly closes gas valve and stops gas flow to burners. When normal gas pressure is restored, the system must be electrically reset to re--establish normal heating operation.