HANG16, HALP13, HAPS30, HAPS31
HIGH ALTITUDE CONVERSION KIT(S)
INSTALLATION INSTRUCTIONS
Description
This kit contains the appropriate burner orifices, and/or pressure switch for the application of 90% furnaces in installations above their maximum (as shipped) rated altitudes. These kits are not applicable in Canada. Kits apply as shown in the table below.
"Standard" and "High Altitude" Kits
0 - 7,000 Feet (Standard Altitude)
UPFLOW |
Natural Gas Orifices |
Propane Gas Orifices |
|
Pressure Switch |
|
|
|||
|
|
|
|
|
|
No Change |
LPM-06 |
|
No Change |
|
|
7,001 - 11,000 Feet |
|
|
|
Natural Gas Orifices |
Propane Gas Orifices |
|
Pressure Switch |
|
|
|
|
|
|
HANG16 |
HALP13 |
|
HAPS30 |
|
|
|||
COUNTERFLOW |
"Standard" and "High Altitude" Kits |
|||
0 - 7,000 Feet (Standard Altitude) |
|
|||
|
|
|||
|
Natural Gas Orifices |
Propane Gas Orifices |
|
Pressure Switch |
|
|
|
|
|
|
No Change |
LPM-06 |
|
No Change |
|
|
7,001 - 11,000 Feet |
|
|
|
Natural Gas Orifices |
Propane Gas Orifices |
|
Pressure Switch |
|
|
|
|
|
|
HANG16 |
HALP13 |
|
HAPS31 |
Table 1
Above an altitude of 7,000 feet, a derating of the appliance must be followed since the CFM moved by the induced draft blower remains almost constant while the pounds of oxygen in that air is reduced as altitude increases. If this procedure is not followed and the fuel input is not reduced the resulting combustion can be inefficient, incomplete, or possibly cause premature heat exchanger failure due to excessive temperature rise. The burner orifices in the high altitude kits have been selected as a result of agency certified testing at high altitude and will provide the appropriate derating (Table 2).
Orifice selection is based on non-derated gas [at standard conditions of 29.92 in Hg and 60°F—approximately 1,000 Btu/ ft3 for natural gas and 2,500 Btu/ft3 for propane]. NOTE:
“Point of use” Btu content will be less due to decreased atmospheric pressure. If the Btu content of your gas supply has been artificially changed to account for altitude, contact your gas supplier for orifice sizing.
Altitude (ft) |
Natural Gas |
Propane |
|
Derate |
Gas Derate |
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|||
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|
|
|
7,001 - 11,000 |
24 + 2% |
33 + 2% |
|
|
|
|
|
|
|
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Table 2
Do not derate by adjusting the manifold pressure to a lower pressure setting than specified on the furnace nameplate. A lower air density in combination with a lower manifold pressure at the burner orifice will prevent the orifice from aspirating the proper amount of air into the burner required for complete combustion.
In addition to using smaller orifices to reduce the fuel input, a different pressure switch must be used above the maximum (as shipped) rated altitude. A high altitude pressure switch is necessary as a result of the reduction in air density and is required regardless of the Btu content of the fuel used.
Altitude (ft.) |
Burner Orifice Size |
||
Natural |
Propane |
||
|
|||
0 - 7,000 |
#43 |
#55 |
|
|
|
|
|
7,001 - 11,000 |
#44 |
#56 |
|
|
|
|
|
Table 3
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION
ATTENTION INSTALLING PERSONNEL
As a professional installer you have an obligation to know the product better than the customer. This includes all safety precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual.
Pay special attention to all safety warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation.
Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use.
Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety practices...follow them.
The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is a direct conflict between existing practices and the content of this manual,
the precautions listed here take precedence.
IO-686A
September 2013
CONTENTS |
|
Important Information .......................................................... |
2 |
HANG16 and HALP13 |
|
Orifice Installation HANG16 and HALP13 .................... |
3 |
Gas Manifold Removal ............................................ |
3 |
Burner Orifice Replacement .................................... |
3 |
Gas Manifold Re-Installation ................................... |
3 |
HANG16 |
|
Adjustments and Checks ............................................ |
3 |
Orifice Leak Check ................................................. |
3 |
Line Pressure Check .............................................. |
3 |
Manifold Pressure Check ........................................ |
4 |
Unit Operations Check ................................................ |
4 |
Check Normal Operating Sequence |
|
of Ignition System ............................................. |
4 |
Verify Gas Input Rates ............................................ |
4 |
Inspect Burner Flame ............................................. |
5 |
Check & Adjust Unit |
|
Temperture Rise ............................................... |
5 |
HALP13 |
|
Propane Gas Unit Kit Installation ................................ |
5 |
Low Pressure LP Kit Accessory Installation ................ |
5 |
Adjustments and Checks ............................................ |
5 |
Orifice Leak Check ................................................. |
5 |
Line Pressure Check .............................................. |
6 |
Manifold Pressure Check ........................................ |
6 |
Unit Operation Checks ................................................ |
6 |
Check Normal Operating Sequence |
|
of Ignition System ............................................. |
6 |
Verify Gas Input Rates ............................................ |
6 |
Inspect Burner Flame ............................................. |
6 |
Check & Adjust Unit |
|
Temperture Rise ............................................... |
6 |
Label Attachment ................................................... |
6 |
HAPS 30 and HAPS31 |
|
Pressure Switch Removal/Replacement ...................... |
7 |
IMPORTANT INFORMATION
Contact a local propane gas supplier about installing a gas detecting warning device.
NOTE: To ensure proper operation, install, operate and maintain the unit in accordance with these installation instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149.1 Installation Codes.
HANG16 and HALP13
The conversion from “standard altitude” orifices (as shipped from the factory) to “high altitude” orifices requires:
•Removing gas manifold
•Replacing burner orifices
•Reinstalling gas manifold
Before proceeding, shut OFF gas supply at manual shut-off and turn off power to the unit.
2
ORIFICE INSTALLATION - HANG16 AND HALP13 GAS MANIFOLD REMOVAL
1.Shut OFF gas supply at manual shutoff and turn OFF power to the unit.
2.Disconnect wiring from the gas valve.
3.Where necessary, cut wire ties securing wiring to manifold.
4.Remove the screws securing the gas manifold and valve to the burner bracket. Separate gas manifold and valve from burner bracket.
Burner |
Burner Bracket |
Manifold
3.Refer to the following sections detailing Adjustments and Checks for natural gas (HANG16) or Propane Spring Change for propane gas (HALP13).
ADJUSTMENTS AND CHECKS - HANG16
The following adjustments and checks are a required part of this ocnversion. Adjustment and checks include:
•Leak checking orifices
•Checking and adjusting line and manifold gas pressures
•Verfying proper unit operation (input rate, operational sequence, burner flame, temperature rise, etc.)
Before proceeding, shut OFF gas supply at manual shut-off and turn off power to the unit.
ORIFICELEAKCHECK
Gas Valve
Ground wire
Figure 1
Gas Manifold Removal (Upflow shown, counterflow similar)
BURNERORIFICEREPLACEMENT
1.Remove standard altitude natural gas orifices from gas manifold using a box end wrench.
2.Install high altitude gas orifices supplied in the high altitude kit. Tighten orifices with a box-end wrench; do not use a socket wrench as it could damage the orifices; do not cross-thread or overtighten. Refer to Tables 1 and 2 for the appropriate high altitude kit and orifice size. Orifice usage depends on an installation’s gas usage (natural or propane) and altitude.
GAS MANIFOLD RE-INSTALLATION
1.Reinstall gas manifold and valve. Make certain that the orifices are inserted in each burner and that each burner remains properly seated in the burner bracket.
(NOTE: Secure green burner assembly ground wire with manifold screw).
2.Reconnect wiring to gas valve. Secure wiring to manifold using wire ties provided.
Leak check burner orifice threads using a soap solution.
LINEPRESSURECHECK
1.Shut OFF gas at the manual gas shutoff valve and turn OFF power to the unit.
2.Connect a calibrated water manometer or appropriate gas pressure gauge at either the gas valve inlet pressure tap or gas piping drip leg.
3.Turn ON the power and gas, put the unit into heating cycle and turn on all other gas consuming appliances.
4.Measure the gas supply pressure with the burners firing. The inlet gas pressure for natural gas should be between 5.0 and 10.0 inches W.C. If supply pressure differs from required, make necessary adjustments to pressure regulator(s), gas piping, etc.
3
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